14050642 100 PL DBM 0001_Pipeline Design Basis_Rev 1

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EFFLUENT WATER TREATMENT AND INJECTION

PLANT (NK)

Project No. EF/1761

Class 1

CONTRACT NO. 14050642 Page 1 of 54

PIPELINE DESIGN BASIS Rev 1

Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

PROJECT :Effluent Water Treatment And InjectionPlant (NK)

CONTRACT NO : 14050642

OWNER : KUWAIT OIL COMPANY

CONTRACTOR :Dodsal Engineering & Construction Pte.Ltd.

DOCUMENT NO. : 14050642-100-PL-DBM-0001

DOCUMENT REVISION STATUS : 1

DOCUMENT TYPE : E (Engineering Drawing/Document)

1 19.06.2016Re-Issued For Design

(Ref.14050642-KD-T-01011)SV AC PC

0 17.06.2015Issued For Design

(Ref.14050642-KD-T-00882)MD AC PC

B 02.06.2015Re-Issued For Approval

(Ref.14050642-KD-T-00172& 14050642-KD-T-00038)

SV AC PC

A 17.11.2014 Issued For Review / Approval PJ SV PC

Rev Date Description Prepared By Checked By

Approved

By




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

REVISION RECORD:

RevisionNo.

Reason for Revision Date

A Issued for Review / Approval 17.11.2014B Re-Issued for Approval 02.06.2015

0 Issued for Design 17.06.2015

1 Re-Issued for Design 19.06.2016




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

PAGE INDEX

Page Revision Page Revision

B C D 1 2 3 B C D 1 2 31 50 √

2 51 √ X 3 52 √

4 53 √

5 √ 546 √ 557 X 568 57

9 5810 √ 5911 √ 6012 6113 6214 6315 √ 6416 6517 √ 6618 √ X 671920 √ 21 √

22 √

23 √

24 √ X 25 √ X 26 √ X 27 √

28 √

29 √ X 30 √

31 √ X 32 √

33 √

34 √

35 √ X 36 √ X 37 √ X 38 √ X 39 √

40 √

41 √

42 √ X 43 X 44 √

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TABLE OF CONTENTS

1.

GENERAL ..................................................................................................................... 7

2.

OBJECTIVE ................................................................................................................... 7

3.

PROJECT DESCRIPTION ............................................................................................. 7

4.

SCOPE OF THIS DOCUMENT ...................................................................................... 8

5.

TERMINOLOGY ............................................................................................................ 9

5.1.

DEFINITIONS ..................................................................................................... 9

5.2.

ABBREVIATIONS ............................................................................................ 10

6.

DESIGN CODES, SPECIFICATIONS AND STANDARDS .......................................... 11

6.1.

INTERNATIONAL CODES AND STANDARDS ............................................... 11

6.2.

PROJECT REFERENCE SPECIFICATION / ADDENDUMS / DRAWINGS /

DOCUMENTS: ................................................................................................. 17

6.3.

ORDER OF DOCUMENT PRECEDENCE ........................................................ 20

7.

GENERAL DESIGN DATA .......................................................................................... 21

7.1.

BATTERY LIMIT .............................................................................................. 21

7.2.

UNITS OF MEASUREMENT ............................................................................ 21

7.3.

COORDINATE SYSTEM .................................................................................. 22

8.

SITE CONDITION & DESIGN DATA ........................................................................... 23

8.1.

SITE CONDITION / ENVIRONMENT DATA ..................................................... 23

8.2.

BASIC DESIGN DATA ..................................................................................... 23

8.3.

PIPELINE CATEGORIES ................................................................................. 24

8.4.

DESIGN LIFE SPAN ........................................................................................ 25

8.5.

PIPELINE TEMPERATURE & PRESSURE ..................................................... 26

8.6.

PIPELINE FLANGE RATING PHILOSOPHY ................................................... 26

9.

PIPELINE MATERIALS ............................................................................................... 27




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9.1.

GENERAL ........................................................................................................ 27

9.2.

LINE PIPE ........................................................................................................ 27

9.3.

CARBON STEEL PIPE DESIGN PROPERTIES .............................................. 28

9.4.

RTRP PIPE DESIGN PROPERTIES ................................................................ 29

9.5.

BRANCH CONNECTIONS ............................................................................... 29

9.6.

RTRP PIPE JOINTS ......................................................................................... 29

9.7.

MATERIAL CERTIFICATION ........................................................................... 30

10.

PIPELINE FITTINGS ................................................................................................... 30

10.1.

PIPELINE BENDS ............................................................................................ 30

10.1.1 GENERAL ........................................................................................................ 30

10.1.2 ELASTIC BENDS ............................................................................................. 31

10.1.3 COLD FIELD BENDS ....................................................................................... 32

10.1.4 HOT INDUCTION BENDS ................................................................................ 32

10.2. BARRED TEE .................................................................................................. 32

10.3.

INSULATING FLANGE JOINTS / INSULATION GASKET KIT........................ 32

10.4.

PIG LAUNCHER/RECEIVER ........................................................................... 32

10.5.

PIG SIGNALLERS ........................................................................................... 34

10.6.

PIPELINE ANCHORS ...................................................................................... 34

10.7.

FLANGES, BRANCH CONNECTIONS AND FITTINGS .................................. 34

10.8.

VALVES ........................................................................................................... 35

11.

PIPELINE ANCILLARIES ............................................................................................ 36

11.1.

PIPELINE TRACING ........................................................................................ 36

11.2.

PIPELINE MARKERS ...................................................................................... 36

11.3.

PIPELINE WARNING SIGNS ........................................................................... 36

12.

PIPELINE DESIGN CRITERIA .................................................................................... 37

12.1.

GENERAL ........................................................................................................ 37

12.2.

PIPELINE WALL THICKNESS CALCULATION .............................................. 37

12.3.

DESIGN FACTOR ............................................................................................ 38

12.4.

STRESS CALCULATION AT ROAD CROSSINGS ......................................... 38

12.5.

PIPELINE AT ABOVE GROUND / BELOW GROUND TRANSITION .............. 38




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12.6.

PIPELINE UPHEAVAL BUCKLING CHECK.................................................... 39

12.7.

ON-BOTTOM STABILITY OF PIPELINES IN WET AREAS ............................ 39

13.

PIPELINE ROUTING ................................................................................................... 40

13.1.

GENERAL APPROACH ................................................................................... 41

13.2.

ROUTE ALIGNMENT SHEET .......................................................................... 41

13.3.

TERRAIN AND INSTALLATION ...................................................................... 42

13.4.

SEPARATION DISTANCES AND EXCLUSION ZONES ................................. 43

13.5.

TOPOGRAPHICAL & GEOTECHNICAL DATA ............................................... 49

14.

DESIGN PHILOSOPHY AND PHYSICAL DATA ......................................................... 49

14.1.

PIGGING, HYDRO TESTING & INSPECTION ................................................. 49

14.2.

NON DESTRUCTIVE TESTING ....................................................................... 50

14.3.

PIPELINE DEWATERING AND DRYING ......................................................... 50

14.4.

FIRE AND SAFETY REGULATIONS ............................................................... 50

14.5.

SITE TIE-IN REQUIREMENTS ......................................................................... 50

14.6.

STRUCTURAL INTEGRITY: ............................................................................ 51

15.

WELDING REQUIREMENTS ....................................................................................... 51

16.

TESTING AND PRE-COMISSIONING ......................................................................... 52

17.

CORROSION PROTECTION ....................................................................................... 52

17.1.

CATHODIC PROTECTION .............................................................................. 52

17.2.

EXTERNAL CORROSION ............................................................................... 53

ATTACHMENT-1: PIPELINE SCHEMATIC DIAGRAM ............................................................. 54




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

1. GENERAL

Kuwait Oil Company (K.S.C), hereafter referred as COMPANY, as a major player of

global oil and gas sector has a long term strategy for the development of North Kuwait

(NK) Fields. North Kuwait Fields is located approximately 90kms from north of Kuwait

city.

The purpose of this project is to provide sufficient injection water to meet the

requirements of the north Kuwait well injectors.For this, an effluent water treatment and injection plant shall be built in a location between

the SABRIYAH and RAUDATAIN fields of north Kuwait having a treatment design

capacity of 1,045,000 BWPD with 550,000 BWPD for injection and balance 495,000

BWPD will be transferred to existing central processing injector facility (CIPF existing).

The plant shall receive a continuous supply of effluent water from existing Gathering

Centers GC-15, GC-23, GC-24, GC-25 and an intermittent supply of effluent water from

new GC-29, GC-30 and GC-31 (all routed from existing CIPF).

For this purpose, the COMPANY has entered into a contract with DODSAL

ENGINEERING & CONSTRUCTION PTE LIMITED, hereafter referred as

CONTRACTOR, for Engineering, Procurement, Construction and Related Activities,

with a Contract No. 14050642.

2. OBJECTIVE

The objective of this document is to define the relevant pipeline design data, general

philosophies, design criteria, methodology, relevant codes and standard and other

important considerations to be adopted for the detailed engineering of the pipelines

involved for New EWTIP project.

3. PROJECT DESCRIPTION

The purpose of this project is to provide sufficient injection water to meet the

requirements of the North Kuwait well injectors. To this end, the EW Treatment and

Injection Plant (NK) (EWTIP) will be located between the Sabriyah and Raudatain fields.

510 MBWPD EW injection facilities for injecting water into 51 no of wells (550

MBWPD Water Injection Pipelines Distribution System up to Manifolds). The EWTIP

1




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

treatment system is divided into two identical trains each designed to treat 522.5

MBWPD. The plant includes collection tanks that receive effluent water from:

• GC-15 (200 MBWPD normal; 220 MBWPD design)




• GC-29 (240 MBWPD design)



Collected effluent water from GCs is treated in the EW treatment facility to meet the

required quality specification for injection. Prior to injection, the treated water is stored in

the Treated Water Tanks. These tanks may also receive effluent water from GC-29, GC-

30 and GC-31 to maintain the required amount of injection water, should one of the

primary source GCs be shut down.

A portion of the treated effluent water is also to be transferred from the treatment plant to

the effluent water collection tank of the CIPF (EF/1071, Effluent Water Injection Plant,

Phase I). To minimize the size of the Treated Water Tanks and eliminate the need to

install new dedicated treated effluent water transfer pumps, this treated water is pumped

directly from the outlet of the new effluent water treatment plant upstream of the Treated

Water Tanks.

Inline Booster and High Pressure (HP) Injection Pumps are capable of maintaining a

minimum operating pressure of 255 barg (3700 psig) at the inlet of farthest injector

wellhead along with injection headers and injection lines to injection wells.

4. SCOPE OF THIS DOCUMENT

The scope of this document is to define the design criteria for the permanent works

relevant to this project like pipeline engineering design data, analysis methods and

design methods to be used for detail engineering of pipeline sections.

The CONTRACTOR shall design and install all pipelines as indicated on the P&ID’s

up to the interfaces and Tie-Ins to existing pipework. Refer to Drawing Number




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

14050642-0100-PL-DWG-0001: Schematic of Interconnecting Pipework for an overall

view of the Pipeline and Off-Sites Works.

The new Pipelines will connect and transport the various products between GC-15,

GC-23, GC-24, GC-25, GC-29, GC-30 and GC-31, Fuel Gas Headers, Recovered oil

headers, Brackish Water Header , Treated Water distribution header, Treated Water

Manifold, Wellhead Flow Lines, EWTIP, CIPF, B.S-131, B.S-132 & various tie-ins to

existing pipeline in North Kuwait. Refer to the Schematic & Layout represented in

Figure-1 shows the overall view of the Pipeline and Off-site works.

The pipelines are required for the following services:

Effluent Water

Treated Water

Fuel Gas

Recovered Oil

Brackish Water (Fire Water)

Injection Water.

5. TERMINOLOGY

For the purpose of this document, the words and abbreviations listed below shall have

the explanations as follows:

5.1. DEFINITIONS

COMPANY Kuwait Oil Company (K.S.C)

CONTRACTOREPC Contractor nominated to carry out the project,

Dodsal Engineering and Construction Pte Ltd.

PROJECT Works related to contract no: 14050642.

WORK Activities required to be completed by the CONTRACTOR

SHALL

The word “SHALL” is understood to be mandatory to

comply with the requirements.




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

SHOULDThe word “SHOULD” is understood to be strongly

recommended to comply with the requirements.

5.2. ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

BS British Standard

EWTIP Effluent Water & Treatment Injection Plant

CIPF Central Injection Pumping Facilities

B.S Booster Station

GC Gathering Centres

CA Corrosion Allowance

CP Cathodic Protection

DF Design Factor

KM Kilo meters

FEED Front End Engineering Design

FG Fuel Gas

ROW Right of Way

SMYS Specified Minimum Yield Strength

HSAW / SSAW Helical or Spiral Submerged Arc Weld

LSAW Longitudinal Submerged Arc Weld

LP Low Pressure

MBOPD Thousand U.S Barrels of Oil Per Day

MSS Manufacturers Standardization Society

NACE National Association of Corrosion Engineers

SMLS Seamless

TCP Temporary Cathodic Protection






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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

ASME B 16.21 Non-metallic Flat Gaskets for Pipe Flanges

ASME B 16.25 Butt-Welding Ends

ASME B 16.34 Valves – Flanged, Threaded and Welding End

ASME B16.47Large Diameter Steel Flanges NPS 26 through

NPS 60

ASME B 16.48 Line Blanks

ASME B 16.49Factory-made wrought Butt-welding induction

Bends for transportation & distribution system

ASME B 31.4Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids

ASME B 31.8Gas Transmissions and Distribution Piping

Systems

ASME B 31.3 Process Piping

ASME B 46.1 Surface texture

ASME

Section VIII - Boiler and Pressure Vessel Code

Section II Div. 1 Part A – Ferrous material

specifications

Section II Div. 1 Part D – Properties (Materials)

Section V – Non Destructive Examination

Section VIII Div. 1 - Pressure VesselsSection IX – Welding and brazing Qualifications

AMERICAN PETROLEUM INSTITUTE (API)

API 5L Specification for Line Pipe (45th Edition)

API 6D Specification for Pipeline Valves

API 6F Specification for Fire test for valves




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

API RP 1102

Recommended Practice for Liquid Petroleum

Pipelines Crossing Railroads and Highways (7th

Edition)

API STD 1104Standard for welding Pipelines and related

Facilities (20th Edition)

API RP 1109 Marking Liquid Petroleum Pipeline Facilities

API RP 1110 Recommended Practice for the Pressure Testing ofSteel Pipelines (5th Edition)

American Society for Testing and Materials (ASTM):

ASTM A 694 / M

Standard Specification for Carbon and Alloy Steel

Forgings for Pipe Flanges, Fittings, Valves and Parts

for High Pressure Transmission Service

ASTM E 94 Standard Guide for Radiographic Examination

ASTM E 165Standard Test Method for Liquid Penetrant

Examination

ASTM E 709 Standard Guide for Magnetic Particle Examination

ASTM E 747

Standard Practice for Design, Manufacture and

Material Grouping Classification of Wire Image

Quality Indicators (IQI) Used for Radiology

American Welding Society (AWS):

AWS A 2.4Standard Symbols for Welding, Brazing and

Non-Destructive Examination

AWS A 5.5 / M

Specification for Low Alloy Steel Electrodes for

Shielded Metal Arc Welding




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

British Standards (BS):

BS EN 558

Industrial Valves Face-to-Face and Centre-to-Face

Dimensions of Metal Valves for use in Flanged Piping

Systems

BS EN 1011

Welding Recommendations for Welding of Metallic

Materials Part 1: General Guidance for Arc WeldingPart 2: Arc Welding of Ferrite Steels

BS EN 1759Flanges and their Joints – Circular Flanges for

Pipes, Valves, Fittings and their Accessories

BS 3900

Methods of Tests for Paints: Part F 11: Determination

of Resistance to Cathodic Disbonding of Coatings for

use on Land Based Buried Structures

BS 5930 Code of Practice for Site Investigations

BS 6031 Code of Practice for Earthworks

BS EN ISO 6507 Metallic Materials – Vickers Hardness Test

BS PD 6513 Magnetic Particle Flaw Detection

BS 7361

Cathodic Protection Part 1 – Code of Practice for Land

and Marine Applications

BS PD 8010Code of Practice for Pipelines Part 1: Steel Pipelines

on Land

BS 8110 Structural Use of Concrete

BS EN ISO 17292Metal Ball Valves for Petroleum, Petrochemical

and Allied Industries




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

International Standards Organization (ISO):

ISO 15589

Petroleum and Natural Gas Industries – Cathodic

Protection of Pipeline Transportation Systems

Part 1: On-Land Pipelines.

Manufacturers Standardization Society of the Valve and Fittings Industry

(MSS):

MSS SP-6

Standard Finishes for Contact Faces of

Pipe Flanges Connecting Ends of Flanges of

Valves and Fittings

MSS SP-25Marking Systems for Valves, Fittings, Flanges and

Unions

MSS SP-44 Steel Pipe Flanges

MSS SP-53

Quality Standard for Steel Casting and Forging for

Valves, Flanges and Fittings and Other Piping

Components – Magnetic Particle Examination

Method

MSS SP-55

Quality Standard for Steel Castings for Valves,

Flanges and Fittings and Other Piping

Components – Visual Method for Evaluation of

Surface Irregularities

MSS SP-72Ball Valves with Flanged or Butt Welding Ends for

General Service

MSS SP-75Specification for High Test Wrought Butt Welding

Fittings

MSS SP-97

Integrally Reinforced Forged Branch Outlet

Fittings – Socket Welding, Threaded, and Butt-

welding Ends.




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

National Association of Corrosion Engineers International (NACE):

NACE MR 0175 /

ISO 15156

Petroleum and Natural Gas Industries -Materials for use

in H2S-containing environments in Oil and Gas

production: Parts 1 to 3 (2009 & its latest technical

circulars)

NACE SP 0177Mitigation of Alternating Current and Lightning Effects

on Metallic Structures and Corrosion Control Systems

NACE TM 0177

Laboratory Testing of Metals for Resistance to

Sulfide Stress Cracking and Stress Corrosion Cracking

in H2S Environments

NACE RP 0274 High Voltage Electrical Inspection of Pipeline Coatings

NACE TM 0284

Evaluation of Pipeline and Pressure Vessel Steels for

Resistance to Hydrogen-Induced Cracking

NACE SP 0286 Electrical Isolation of Catholically Protected Pipelines

NACE RP 0472

Methods and Controls to Prevent In-Service

Environmental Cracking of Carbon Steel Weldments in

Corrosive Petroleum Refining Environments.

NACE SP 0169Control of External Corrosion on Underground

submerged piping systems

NACE SP 0200 Steel Cased Pipeline Practices

NACE SP 0502Pipeline External Corrosion Direct Assessment

Methodology

NACE SP 0572Design, Installation, Operation and Maintenance of

Impressed current deep Anode Beds




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

6.2. PROJECT REFERENCE SPECIFICATION / ADDENDUMS / DRAWINGS /

DOCUMENTS:

KOC Specifications:

015-IH-1001 Rev.1 Pipeline Construction

015-IH-1002 Rev.1 Pipeline Design

015-IH-1004 Rev.1 Pipeline Pigging and Hydrostatic test

015-IH-1005 Rev.1 Pipeline Dewatering, drying and Purging

015-IH-1008 Rev.1 Pipeline Field Welding Non Sour

Service

015-IH-1009 Rev.1 Flow lines

015-LH-1002 Rev.1 Piping design

015-PH-1910 Rev.1 Cathodic Protection (CP) Transformer

Rectifier Units

015-SH-1006 Rev.1 Topographical Survey

015-WH-1001 Rev.0 Welding Procedure Approval and

Welding Quality Requirement

015-WH-1002 Rev.0 Field Welding Requirements including:

welding, Heat treatment and NDT of

piping

015-WH-1006 Rev.1 Cathodic Protection Design

Requirements

Document No. Description

KOC-L-002 Rev.3 RP for Protection of KOC Services

KOC-L-012 Rev.1 Cathodic Protection Material

KOC-L-015 Rev.2External Cathodic Protection of Underground

Steel Pipeline and Piping Networks

KOC-MP-005 Rev.1 Pipeline Pig Trap Systems

KOC-MP-010 Rev.1 Piping Material Classes






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EWTIP-20-PL-SPC-0002

Rev.1 ADDENDUM TO KOC SPECIFICATION:

PIPELINE DESIGN (015-IH-1002 REV1)


Rev.0 ADDENDUM TO KOC SPECIFICATION:

FLOWLINES (015-IH-1009 REV2)

EWTIP-20-PL-SPC-0004Rev.0

SPECIAL CRITERIA TO KOC STANDARD FOR

EXTERNAL COATING OF PIPELINES PART 4

FUSION BONDED EPOXY COATING (KOC-P-

004 PART4 REV2)


Rev.0 ADDENDUM TO KOC SPECIFICATION PIG

LAUNCHERS/RECEIVERS (015-IH-1006 REV1)


Rev.0


INTERNAL COATING OF PIPELINES (KOC-P-

005 REV1)


Rev.0


EXTERNAL COATING OF UNDERGROUND

PIPING/PIPELINES - HIGH BUILD EPOXY

COATING (KOC-P-004 PART8 REV1)


Rev.0

SPECIAL CRITERIA TO KOC RECOMMENDED

PRACTICE FOR THE PROTECTION OF KOC

SERVICES: CLEARANCE REQUIREMENTS

FOR BURIED PIPELINES, CABLES,

UNDERGROUND STRUCTURES, BUILDINGS

AND HOUSING PROJECTS (KOC-L-002 REV3)


Rev.0


EXTERNAL COATING OF UNDERGROUND

PIPING/PIPELINES - HIGH BUILD POLY-

URETHANE COATING (KOC-P-004 PART9

REV1)




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Rev.1

SPECIFICATION FOR HIGH DENSITY

POLYETHYLENE (HDPE) LINERS FOR

CARBON STEEL PIPELINES


Rev.1

SPECIFIC CRITERIA TO KOC STANDARD FOR

ELECTRIC WELDED PIPES (KOC-MP-017

REV1)


Rev.1 PIPELINE LEAK DETECTION SPECIFICATION


Rev.0

Special Criteria To Standard For Seamless Line

Pipe to API 5L ( KOC-MP-018 Rev.1)


Rev.0

Criteria To Standard For Submerged Arc Welded

(SAW) Pipe to API 5L ( KOC-MP-019 Rev.1)


Rev.0

ADDENDUM TO KOC SPECIFICATION:

PIPELINE PIGGING AND HYDROSTATIC TEST

(015-IH-1004 REV1)


Rev.0

ADDENDUM TO KOC SPECIFICATION

PIPELINE DEWATERING, DRYING AND

PURGING (015-IH-1005 REV1)


Rev.1

Project Specific Criteria to Material Specification

For Induction Bend (KOC-MS-002 Rev.1)


Rev.1

Addendum to Specification for Pipeline

Construction ( 015-IH-1001 Rev.1)


Rev.0

PROJECT SPECIFIC CRITERIA FOR KOC

RECOMMENDED PRACTICE FOR EXTERNAL

CATHODIC PROTECTION OF UNDERGROUND

STEEL PIPELINES & PIPING NETWORKS

6.3. ORDER OF DOCUMENT PRECEDENCE

In case of conflict on technical requirements, the most stringent requirements asdefined by the company shall apply as per clause no 1.2 and 3.3 of Appendix-F

of the contract.




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Doc. No. : 14050642-100-PL-DBM-0001 Date 19.06.2016

In case of conflict on codes, standards, company specifications, regulatoryrequirements, following order of precedence shall apply:

a. Regulatory Requirements

b. Addendum and project specific criteria to KOC specifications andstandards

c. KOC standards & Specifications

d. International Codes and Standards

Should there be an inconsistency, conflict or discrepancy between any of the

Standards, Specifications or Regulatory requirements, the most stringent and safest

requirement applicable to the project shall prevail to the extent of the inconsistency,

conflict or discrepancy. Any inconsistencies critical to the design shall be brought to

the attention of KOC for resolution.

7. GENERAL DESIGN DATA

7.1. BATTERY LIMIT

The design battery limit between pipeline and piping are the flanges at the

launcher / receiver and before first isolation valve on the bypass line near

barred tee & the code break between ASME B 31.3 and ASME B 31.8 / ASME

B31.4 as per P & ID.

7.2. UNITS OF MEASUREMENT

SI units shall be used for all calculations and on all drawings. For convenience,

data in imperial units may be included for reference.

Design Unit Standards(Note 1)

Item SI units Imperial Units

Oil Flow m /hr. bbl/d

Gas Flow MMm3/d MMscf/d

Density kg/m3 lbs./ft3

Pressure bar(a) or bar(g) psia or psig

Differential Pressure bar/mbar psi

Temperature °C °F




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Viscosity MPa cP

Kinematic Viscosity cSt cSt

Mass kg lbs

Pipe diameters, valve size,

instrument tubing (note 2) mm inch

Energy MJ Btu

Power kW hp

TimeSeconds, hours,

daysSeconds, hours, days

Piping (note 2), Structural,

Isometric, Site (Layouts,

Topographical etc.), and

Vendor Drawings

Metric English

Vessel Dimensions Metric English

Electrical Equipment Cabinets

& other equipment inside

control buildings

Metric English

Notes:

1. Standard conditions are defined as 14.696 psia and 60°F (1.01325

bar(a) and 15°C)

2. All piping and tubing to be SI sizes.

7.3. COORDINATE SYSTEM

The co-ordinate system to be used for mapping on the project shall be:

Projection : Universal Transverse Mercator

Zone : UTM 38R

Datum : World Geodetic System (WGS-84)






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Field maps showing injection well locations and pipeline routings used in

the FEED study.

Alignment sheets for produced water pipelines, injection water trunk

lines and the recovered oil pipelines.

Schematics of the high pressure pipelines used for hydraulic simulations

and materials quantity determination.

8.3. PIPELINE CATEGORIES

The pipeline categories shall comply with the requirements of KOC

specification:

Application of codes and Group Standards, which has been reproduced for

design purpose as in below table,

Table 8.1 : Pipeline Categories

S.No. Applicable Project Pipelines

Approx.

Length

(KM)

Product

type

Design

Code

1 20” RTRP Pipeline from GC-15 in CIPF to EWTIP 1.72Effluent

Water

ASME

B31.4


Water

ASME

B31.4


Water

ASME

B31.4


Water

ASME

B31.4

5 6” CS Pipeline from B.S-131 to EWTIP (2 nos.)17 (8.5

each)Fuel Gas

ASME

B31.8

620” CS HDPE lined Pipeline from EWTIP to

Sabriyah manifold distribution47.0

Injection

Water

ASME

B31.4

7

20” CS HDPE lined Pipeline from EWTIP to

Rudatain manifold distribution 16.4

Injection

Water

ASME

B31.4

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8.5. PIPELINE TEMPERATURE & PRESSURE

Table 8.2: Temperature and Pressure

Pipelines

Operating

Pressure

(barg)

Design

Pressure

(barg)

Operating

Temperature

(°C)*

Design

Temperature

UG / AG

(°C)

Distribution Lines 278 331 30-60 -3 / 93

Flow Lines 278 331 30-60 -3 / 93

Treated Water Return

Line to CIPF (existing

1071)

5.9 11 30-60 -3 / 93

Fuel Gas 25.5 46 30-60 -3 / 93

Effluent Water 4 15 30-60 -3 / 93

Oily Water 8.41 10.5 30-60 -3 / 93

Brackish Water 4.13 15 30-60 -3 / 93

8.6. PIPELINE FLANGE RATING PHILOSOPHY

For the selected material class, the flange rating shall be selected by applying

the chosen design pressure and temperature in the appropriate rating table in

the Piping Material specification and shall in accordance to ASME B 16.5 &

ASME 16.47.

Pipeline Flange Rating

Effluent water 150 #

Recovered Oil 300 #

Fuel Gas 300 #

Brackish Water 300 #

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manufacturer’s design.

For mechanical handling considerations and to avoid pipe damage during

construction the pipe diameter to wall thickness ratio should not exceed 96 in

general as per clause 403.2.5 of ASME B31.4.

All carbon steel pipes of API 5L X60 material shall be of SMLS construction up

to 20 inch.

Pipe material shall be Reinforced Thermosetting Resin Pipe (RTRP) for

Effluent Water, Treated water and Brackish Water and pipe shall bemanufactured by Dual Helical Filament Winding Process in accordance with

COMPANY standard for RTRP pipes and fittings: KOC-MP-011 Part 1.

9.3. CARBON STEEL PIPE DESIGN PROPERTIES

The properties shown in table below are to be used for calculations involving

carbon steel line pipe with reference to API 5L, 45th Edition.

Table 9.1: Pipeline Design Properties

Property Units Pipeline

Material API 5L, 45th

Edition All CS Pipelines in Table 8.1

Material grade L415 (X60) L245 (B)

Yield strength Min

SMYSMPa

415245

Yield strength Max MPa

565

450

Ultimate Tensile

StrengthMPa

520415

Density Kg/m3 7850

Young’s’ Modulus MPa 203000

Thermal Co-efficient

of Expansion mm / 11.7 x 10-6




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mm /C

Poisson’s Ratio 0.3

9.4. RTRP PIPE DESIGN PROPERTIES

The properties shown in table below shall be given to vendor for the RTRP Line

pipes with reference to ASTM D 2996

Table 9.2: Pipeline Design Properties

Property Units Resin Type

Epoxy ResinPolyester & Vinyl

Ester Resin

Tensile Strength 103 psi 4-13 6-13

Tensile Modulus 106 psi 0.35 0.3 – 0.64

Elongation at Break % 3-15 < 2

Flexural Strength 103 psi 13-21 8.5-23

Specific Gravity 1.11 – 1.40 1.1 – 1.46

9.5. BRANCH CONNECTIONS

For all pipeline pig trap nozzle fittings, the thickness shall be as per the

adjoining B31.3 piping class, however the material grade of the branch fitting

shall be the same as the pipeline.

9.6. RTRP PIPE JOINTS

The RTRP pipe joint methods shall be as follows:

Taper-Taper adhesive bonded pipes & fittings joints 1




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The RTRP piping shall be joined adopting most appropriate joining method(s)

based on design conditions, service fluid & pipe size.

The manufacturer shall suggest and recommend the most appropriate joining

method(s) to contractor based on KOC standards well ahead of the start of the

project for review & approval.

The jointing method shall be in accordance with CL.10. of KOC design

specification KOC-MP-011 part-2.

Flanged Joints shall be used at the transition points of RTRP pipes to Steelpipes.

9.7. MATERIAL CERTIFICATION

The specific requirements for documentation and certification of all materials

and equipment to be procured are included in the individual Project technical

Specifications or Material Requisition.

10. PIPELINE FITTINGS

The material used shall satisfy the requirements of NACE MR 0175 / ISO

15156 where applicable, pipeline fittings shall be ASTM, ANSI / ASME, API

and other international standards as applicable. Dimensional standards i.e.

tolerance, in general, shall be as per the relevant code.

The final material grade and wall thickness shall be confirmed. Factors to be

considered include ASME B31.4 / B31.8 requirements as applicable, KOC

specifications and contract specific requirements.

All butt welded fittings shall comply with ANSI B16.9.

RTRP fittings shall be in accordance with KOC standard for RTRP pipes and

fittings, KOC-MP-011 Part 1 and Part 2.

10.1. PIPELINE BENDS

10.1.1 GENERAL

The use of Cold Field bends and hot induction bends shall be avoided andwherever possible bends shall be formed by bending pipe with its elastic limits






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10.1.3 COLD FIELD BENDS

Cold field bends may be used at locations of horizontal or vertical changes in

direction. Miter or “lobster -back” bends shall not be used. Cold field bends shall

have a minimum bending radius of 40D, where D is the pipeline outside

diameter. Cold field bends shall be in accordance to Cl.9.2.1 of 15-IH-1002.

10.1.4 HOT INDUCTION BENDS

All bends shall be produced by induction bending. Bend radius shall be 5D

(where D is the pipe OD). All the bends shall be supplied with straight tangent

ends at least 500 mm in length. Induction Bends shall be manufactured in

accordance with COMPANY specification KOC-MS-002 and addendum

EWTIP-20-PL-SPC-0017. Hot bends shall be in accordance to Cl.9.2.3 of 15-

IH-1002.

10.2. BARRED TEE

Barred tees shall be installed in piggable lines where pipeline branch

connections of 25% and above of main pipeline diameter are required. Barred

tees shall be manufactured to a proven design that shall allow the smooth

passage of pigging tools without the risk of snagging or deflection. All barred

tees shall comply with the requirements of ASME B16.9/ MSS-SP-75 and also

to sour service conditions. Barred Tees shall be formed extruded outlet,

integral type and meeting the design code requirements of the existing header

pipe.

10.3. INSULATING FLANGE JOINTS / INSULATION GASKET KIT

Insulating flange joints shall be installed at each end of the pipeline to

electrically isolate the buried pipeline cathodic protection system from the

above ground station pipe work. All insulating flange joints shall be installed

above ground (not buried).

10.4. PIG LAUNCHER/RECEIVER

Pig launchers and receivers shall be designed for the same service conditions






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1004, rev.1 and EWTIP-20-PL-0015, rev.0.

10.5. PIG SIGNALLERS

Pig signallers shall be located on pig launchers / receiver facilities on pipeline

system to monitor the passage of pigs. Details of the required facilities shall be

as per relevant P&IDs. Pig signallers shall be bi-directional ultrasonic flanged

intrusive type with a trigger penetrating into the main bore of the pipe which will

be moved by the passing pig and a mechanical indicator mounted externally on

the pressure housing. They shall be mounted vertically on top of the pipe with

two x 2-in NB isolation ball valves to isolate the pig signaller from the pipeline.

Pig signaller isolation ball valves shall be full bore and end connections shall be

as per piping class. A portable jacking tool for removing the unit whilst the

pipeline is under pressure shall be provided.

10.6. PIPELINE ANCHORS

Full thrust anchors shall be installed at both ends of the various pipeline at the

transition where the pipeline changes from buried to above ground before the

permanent pig launcher/ receiver and as per the results of the Pipeline Stress

Analysis.

Calculations shall be performed to design the anchors, anchor flanges and

concrete blocks of reinforcement. Stress induced at the pipeline transition point

shall be calculated and verified for no failure.

10.7. FLANGES, BRANCH CONNECTIONS AND FITTINGS

Threaded connections (Pipe to pipe, fittings), slip-on flanges and miter

connections shall not be used in any part of the pipeline system. “Pup” pieces

shall not be less than 300mm length or one pipe diameter whichever is greater.

For mechanical strength reasons, there shall be no branch or instrument

connections smaller than DN 50 mm (2”) on the pipeline which are exposed to

service. Gaskets for flanged connections shall be as per project specification

for the relevant pressure class. The number of flanged connections in the








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12. PIPELINE DESIGN CRITERIA

12.1. GENERAL

The design criteria for the project are based on providing safe, environmentally

acceptable, low cost pipelines that are fit for their intended uses. All pipelines

and facilities shall be designed to the codes and standards identified in this

document and provide a 25-year service life.

Steel pipelines shall be designed in accordance with ASME B31.4 / B31.8 as

applicable. RTRP pipelines shall be designed in accordance with KOC

standard for RTRP pipes and fittings: KOC-MP-011, part 1 and Engineering

design and installation: KOC-MP-011 Part 2.

12.2. PIPELINE WALL THICKNESS CALCULATION

Pipeline Wall thicknesses are to be based on Pressure containment and

combined stresses plus corrosion allowance. The minimum selected wall

thickness shall be based on the following:

The OD/WT ratio maximum shall be ≤ 96 (land installation)

External interference by third parties is not considered to be criteria for

minimum pipe wall thickness as the pipeline shall be laid in designated pipeline

corridors. The minimum wall thickness consideration shall be 6.35mm.

The minimum thickness provided in FEED shall govern. The selected thickness

during detailed engineering shall be greater than or equal to FEED thickness

calculation.

Pipeline wall thickness shall be calculated as per ASME B 31.4 for hydrocarbon

liquid services and as per ASME B 31.8 for hydrocarbon gas services as

appropriate and pipeline stress shall be checked as per the code ASME B 31.8

& B 31.4

RTRP Pipeline wall thickness shall be per manufacturer standard based on

design pressure & temperature provided in Appendix-1 of this design basis.

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12.3. DESIGN FACTOR

Design factors to be used for calculating pipeline wall thickness shall be as

given in following Table 12.1.

Table 12.1: Design Factors

Fluid Design Factor

Effluent Water 0.72

Treated water 0.72

Fuel Gas 0.72 / 0.6 / 0.5

Distribution and Injection

Pipelines / Flow lines0.72

Brackish Water 0.72

Recovered Oil 0.72

12.4. STRESS CALCULATION AT ROAD CROSSINGS

Stresses in pipeline at road crossings shall be checked using methods

specified in API RP 1102, Steel Pipelines Crossing Railroads and Highways.

Stresses shall be checked for fully corroded pipeline, i.e., after deducting

corrosion allowance from the pipeline nominal wall thickness.

12.5. PIPELINE AT ABOVE GROUND / BELOW GROUND TRANSITION

The Pipeline shall be subject to movements due to thermal expansion at the

inlet / outlet of pig traps. This movement shall induce stresses in the pipeline

and the connected above-ground piping. In order to limit the stresses within

allowable limits, the pipeline movement at the above ground – below ground

transition shall be reduced, either by providing adequate flexibility in the

pipeline configuration at the approach to the scraper traps or by providing

suitably-sized anchor blocks.

The stress analysis shall be carried out and the pipeline movement shall be

reduced as per detailed specification for pipeline flexibility analysis (14050642-

100-PL-SPC-0001).

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13. PIPELINE ROUTING

A pipeline route survey shall be carried out prior to producing detailed route

alignment sheets which will include topographical, geotechnical and

underground investigation. The horizontal clearance between the pipelines

and the existing cable shall meet KOC-E-008 & KOC-L-002 requirements.

All pipelines installed in the new pipeline corridors will have 1 m berm constructed

from natural ground level for protection. The information included in the drawings,documents, specifications and alignment sheets must be reviewed fully to

appreciate the extent of the design parameters. All pipeline corridors depending

on the number of pipelines to be installed will have permanent six meter access

tracks constructed along each pipeline corridor to be used for pipeline

construction and also for permanent maintenance roads after construction

activities are completed. The location of permanent access tracks shall be shown

on the Pipeline Route Alignment sheets. No sectionalizing valves will be required

on any of the routes of the pipelines for intermediate isolation.

There are numerous rig track, gatch and asphalt road crossings, above and

below ground utilities to be crossed on all of the pipeline route corridors.

The minimum distance from the base of any power pylon shall be 20 meters as

per clause 11.4.2 of KOC-L-002. Where the pipeline runs parallel with a buried

power cable, the horizontal clearance between the pipeline and the existing cable

shall not be less than 3 meters. This shall be increased where there is a likelihood

of CP interference.

A Cathodic protection system shall be designed and installed on all steel buried

pipelines. A corrosion monitoring study shall also be carried out to review any

corrosion monitoring requirements on the various pipelines.

All carbon steel pipework will be externally coated along with the welded joints. All

carbon steel pipework will be welded to sour service conditions.

It is to be aware that there are other CONTRACTORS, working in the area along

with well drilling, road construction and other third party activities in North Kuwait.

Therefore interface is required with other CONTRACTORS to avoid any

disruption or impact to their work which would cause delay to their schedule.










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Mechanical Equipment operation

parallel to existing pipelines**- 5m**

Pipelines that run parallel with power

lines*- 20m*

Pipeline in the same trench as Fiber

Optic Cable- 0.5m

Pipeline or existing service and cable

buried crossings1.0 m -

*For distance between pipelines and overhead lines shall be as per

clause 11.4.3 of KOC-L-002.

**For protection of existing services during construction in accordance

with clause 17.0 of KOC-L-002.

# The distance can be further reduced upto 1m with manual excavation.

13.4.2. PIPELINE BURIAL DEPTH

Minimum cover for pipelines shall be generally 1 m from gradeelevation; however it shall be 1.2m under field roads as per clause

17.3.8 of KOC-L-002. Pipeline burial depth from ground surface to top

of pipe shall be as per table 13.2 below

Table 13.2 Pipeline Burial Depths

Location Minimum Cover

Normal Terrain and sand Dunes 1.0 m

Minor road / Track Crossing (Uncased) 1.2 m

Asphalt Road and Rig Track crossings(Cased) 1.2 m*

Sabkha crossings/ High Water table Areas

(Note1) 1.5 m

* Minimum cover from top of casing pipe.

Note 1: No high water table / Sabkha areas are identified in this project.

Note that the above indicated cover values are the minimum between

top of pipe and natural ground surface. In addition, pipelines shall have






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thickness shall meet the applicable Code requirements for road

crossing.

Sleeve pipe shall be sealed at each end with “Pull-On” type end seals to

prevent ingress of soil / water. Major Asphalt road crossings shall be

based on trenchless installation method using non-open cut techniques

like horizontal directional drilling, auger-boring, thrust-boring or micro-

tunneling techniques. But subject to approval by COMPANY, Open Cut

shall be carried out.

Crash Barriers shall be installed at all road crossings to protect the

installed pipeline and crossing vents from Third Party damage in

accordance with the drawings. All crossing methods shall be subject to

COMPANY approval. Pipeline safety shall be checked in accordance

with API 1102 – Steel Pipeline Crossing Railroads and Highways. all

road crossings shall be recorded during Topographic survey.

New pipelines shall be buried below existing pipelines with a minimum

clearance of 1.0m, unless otherwise agreed by the COMPANY.

All Major asphalt road crossings shall be made at an angle of 90

degree to the road Centre line by an approved ‘non-disruptive’ road

crossing method of carrier pipe without any casing if approved by

COMPANY. Specific crossing drawings shall be created for each major

crossing.

The minimum pipeline burial depth for the general route, road and track

crossings as given in table 13.2.

The following wheel loadings were taken into account in determining the stressesimposed on the carrier pipe / casing pipe at each crossing:

Asphalt Road / Highway / Track crossings: As per KOC specification 015-IH-

1002, 112kN per wheel at 900mm centers with maximum of four (4) wheels per

axle. Contact area per API RP 1102 is 0.093 square meters, giving surface

pressure = 1204 kN/m2.

Rig Track crossings: The total load of rig is 1100 KN and the maximum Tandem

axle wheel load is 550KN. The contact area, over which the wheel load isapplied, shall be taken as 0.403 square meters.

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CrossingMinimum Crossing

Angle

Existing pipelines and cables,

Unimproved roads, track & Asphalt roads

60° (note-1)

Overhead power lines 90° (note-2)

Notes: 1. Wherever it is not feasible to maintain minimum 60°, the

crossing angle between proposed pipeline and existing pipeline / cables

can be reduced up to minimum 30°.

2. Wherever underground pipeline crosses overhead power

transmission lines, it shall be preferably be at right angle (90°). In

unavoidable locations, the horizontal angle of intersection shall be

maintained within 70° to 110° to the overhead power line.

13.4.5. PIPELINE CROSSING DRAWINGS

Detailed crossing drawings shall be generated for major asphalt road

crossings based on confirmed alignment of pipelines as per topographic

and geotechnical survey findings shall be provided. The crossing

drawings shall include as a minimum:

The road / track / ROW / pipelines / utility / feature to be crossed

in relation to the pipeline.

Profile including bend information and depth of cover (if

applicable).

Plan, at a scale not greater than 1:500.

COMPANY requirements, including minimum clearances,

protection requirements, etc.

Cathodic Protection details.

Pipeline markers.

Line size, material grade and wall thickness.

Crossing co-ordinates. Proposed method of Construction / Installation

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13.4.6. PIPELINE PRESERVATION:

Pipeline preservation is not envisaged for this project. However, if

required, the pipeline preservation shall be carried out for Fuel Gas

Pipelines after construction, and hydro testing activities are completed.

The fuel gas carbon steel pipelines at the termination points of the

pipelines at the various installation boundary fences shall have welded

steel caps on the ends of the last pipe along with a 2 “ ball valve .Thepipelines shall be filled with nitrogen to a pressure of one barg and this

internal pipeline pressure shall be monitored to check that there is a

positive pressure in the pipeline until it is connected to the installation

facility pipeline. A temporary CP system must be installed and working

on the pipelines until a permanent CP system is designed and

commissioned. HDPE lined water injection pipelines, FBE lined

recovered oil pipelines and Pipelines constructed of RTRP do not

require nitrogen preservation.

13.5. TOPOGRAPHICAL & GEOTECHNICAL DATA

Topographic survey drawings, reports and geotechnical reports shall comply

with Project requirement as defined in scope of work for Topographical &

Geotechnical survey for Pipeline route corridor.

14. DESIGN PHILOSOPHY AND PHYSICAL DATA

14.1. PIGGING, HYDRO TESTING & INSPECTION

All carbon steel pipelines shall have a hydro test of 1.25 times the design

pressure in accordance with ASME B31.4 for water injection pipelines.

Fuel gas pipeline shall be hydro tested at 1.25 times the design pressure as

per table 841.3.2-1 ASME B31.8.

All RTRP pipelines shall have a hydro-test at 1.5 times the design pressure for

a period of 30 minutes as a strength test followed by a hydro-test at 1.33 times




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the design pressure for a period of 8 hours in accordance with KOC standards

for RTRP Pipes & Fittings: Engineering Design and Installation, KOC-MP-011

part 2 or as required by company.

The Water injection lines, Recovered Oil lines and Fuel Gas Lines shall be

designed as piggable. For details and the requirement of permanent or

temporary pig traps on the individual systems refer schematic drawing. Pipeline

pigging and hydrostatic testing shall be carried out in accordance with KOC

Standard 015-IH-1004 and associated Project Addendum EWTIP-20-PL-SPC-0015.

14.2. NON DESTRUCTIVE TESTING

In road crossing, populated areas, Tie-ins and weld repair locations, All butt

welds shall be subjected to 100% X-ray radiography or UT and all fillet welds

shall be 100% tested with liquid penetrant / wet magnetic particle crack

detection method in accordance with company specifications 015-IH-1008 and

015-WH-1002.

14.3. PIPELINE DEWATERING AND DRYING

Pipeline dewatering and drying shall be conducted in accordance with KOC

Standard 015-IH-1005 and associated Project Addendum EWTIP-20-PL-SPC-

0016.

14.4. FIRE AND SAFETY REGULATIONS

All relevant safety requirements of KOC’s Fire and Safety Regulations and

KOC’s HSE policy Shall be adhered to while performing the works within KOC

pig-trap areas and pipeline route.

14.5. SITE TIE-IN REQUIREMENTS

The associated pipeline facilities required at tie-in sites include other valves

and piping. These facilities, up to the code break locations identified on the

P&IDs, shall be designed in accordance with ASME B31.4.




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Positive isolation by spading / blinding shall be used for welded tie-ins. All tie-in

locations shall be identified and a tie-in schedule produced.

It shall be confirmed that the connecting piping is adequately protected from

overpressure of the pipeline.

Hot tapping shall be in accordance to KOC-MP-038: KOC recommended

practice for hot-tapping and plugging.

14.6. STRUCTURAL INTEGRITY:

The pipelines shall be checked for structural integrity taking into account the

anticipated stress conditions in the pipeline during installation, hydrostatic

testing and operation. As a minimum the following calculations/checks shall be

performed.

Internal pressure

Pipeline road and track crossing analysis in accordance with API 1102

Pipeline stress analysis

Pipeline flexibility and tie-in analysis for above ground pipe work

The stress analysis of the pipeline system shall be performed using the latest

version of Caesar II program and evaluated in accordance with the governing

code requirements. The stress analysis shall be carried out as per detailed

specification for pipeline flexibility analysis (14050642-100-PL-SPC-0001).

15. WELDING REQUIREMENTS

Welding shall be in accordance with API 1104: Welding of Pipelines and Related

Facilities, in conjunction with Project Specification EWTIP-20-PL-SPC-0002: Addendum

to KOC specification: Pipeline Design (015-IH-1002, rev.1), EWTIP-20-PL-SPC-0018:

Addendum to KOC specification for pipeline construction (015-IH-1001, rev.1).

It shall be in line with company standards 015-IH-1008, 015-IH-1001 and 015-IH-1002.

For sour service pipeline welding, a project specific welding specification is developed

and followed. Refer Document No: Weld key plan / Weld table: 14050642-700-QA-PRO-

0045.

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16. TESTING AND PRE-COMISSIONING

During the detail engineering phase of the project the optimum method of pipeline

testing and pre-commissioning shall be developed which shall take into account

method(s) of test water supply and disposal, dewatering, required level of dryness,

method of pipeline drying and introduction of product into the pipeline. Reference

shall be as per the Philosophy for cleaning, Gauging, Hydro testing, Dewatering,Drying and Purging of Flow lines/ Pipelines. The cleaning, gauging, testing, drying

and pre-commissioning activities shall be performed generally in accordance with the

above philosophy and Company specifications 015-IH-1004 and 015-IH-1005 with

Project Addendums EWTIP-20-PL-SPC-0015 and EWTIP-20-PL-SPC-0016.

17. CORROSION PROTECTION

17.1. CATHODIC PROTECTION

The underground pipelines shall be protected by the application of high-

integrity coating systems supplemented with impressed current cathodic

protection (ICCP). Temporary CP utilizing sacrificial anodes shall be used to

protect the pipelines during construction, and prior to commissioning of the

permanent ICCP systems. CONTRACTOR shall carry out a detailed corrosion

study to confirm the requirements for corrosion fittings, corrosion monitoring

sample pits and locations along the various pipelines. Reference shall be made

to company specification KOC-MP-035: Internal Corrosion Monitoring

Equipment for Facilities and Pipelines.

Insulating flange joints shall be provided at the location of underground to

aboveground transition of pipelines and wherever applicable as per clause 7.11

of KOC-L-015 for cathodically protected pipelines.

All carbon steel pipelines will be electrically isolated from pigging facilities by a

properly designed cathodic isolation device downstream of the bypass tee.

Pipeline/piping portions including valves and flanges in valve pits shall be

protected against corrosion to KOC standards and ensure integrity of cathodic




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protection system. All pipe supports shall ensure integrity of cathodic protection

system.

Cathodic protection shall be installed to provide the level of protection required

by the KOC standard KOC-L-015.

17.2. EXTERNAL CORROSION

17.2.1. COATING

The carbon steel pipes shall be externally coated with a shop applied

dual-layer fusion bonded epoxy corrosion coating as per company

specification KOC-P-004 part 4 rev.2 and field joint external coating for

girth welds, pipeline fitting and flanges shall be protected with fusion

bonded epoxy coating as per company specification KOC-P-004 part

7, rev.2.

Above ground installations shall be in accordance to Company

standard KOC-P-001.

Coating thickness DFT and other characteristics shall comply to Table-

1 and Table-3 of KOC-P-004 part 4 rev.2



Documents

14050642 100 PL DBM 0001_Pipeline Design Basis_Rev 1