Petroleum Development Oman L.L.C.

Onshore Pipeline Engineering

(SP-1211)
Document ID SP-1211

Document Type Specification

Security Restricted

Discipline Pipeline Engineering

Owner UIPT2 – Pipelines Corporate Functional Discipline Head

Issue Date Jul 2018

Revision 5.0

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval
system, or transmitted in any form by any means (electronic, mechanical, reprographic
recording or otherwise) without prior written consent of the owner.
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i Document Authorisation
Authorised For Issue
Document Authorisation

Document Owner Document Custodian Document Author

(CFDH)
Habsi, Badar UIPT2 Habsi, Badar UIPT2 Khalfay, Rayees UIPT2C
Date : 25-07-2018 12:00 Date : 25-07-2018 10:12 AM Date : 25-07-2018 8:45 AM
AM

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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.

Version No. Date Author Scope / Remarks

Version 5.0 Jul 2018 UIPT2 /UIPT2C  Updated definitions of fluid category
 Updated Table A1.4 - Health and Safety
Consequence Classification
 Updated flowline corridor requirements
 Added acceptable alternative materials
for small orders / stockist supplied items
 Added SHALL [PS] statements related
to PDO incidents
Version 4.2 Mar UEL  Updated based on FRD Engineering
2016 Standard Challenge Recommendations.
Version 4.1 Sep UEL  Star Chamber Committee
2015 recommendations implemented
Version 4.0 Nov UEL  Minimum thickness for GRP lines
2014 revised based on fluid category.
 Revised recommended spares.
 Added section on Stress analysis.
 Section updated on MAIP.
 Standard references updated and
obsolete standards /DEP deleted.

iii Related Business Processes

Code Business Process (EPBM 4.0)

iv Related Corporate Management System (CMS) Documents

The related CMS Documents can be retrieved from the Corporate Management Portal (CMS).

SP-1208 Pipeline Construction specification

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TABLE OF CONTENTS
i Document Authorisation ......................................................................................................... 3
ii Revision History ...................................................................................................................... 4
iii Related Business Processes .................................................................................................. 4
iv Related Corporate Management System (CMS) Documents ................................................ 4
1 INTRODUCTION .................................................................................................................... 8
1.1 Scope ................................................................................................................................ 8
1.2 Distribution, Intended Use and Regulatory Considerations.............................................. 8
1.3 Definitions ......................................................................................................................... 9
1.3.1 General Definitions .......................................................................................... 9
1.3.2 Specific Definitions .......................................................................................... 9
1.4 Abbreviations .................................................................................................................. 12
1.5 Cross-References ........................................................................................................... 13
2 APPLICATION OF CODES AND GROUP STANDARDS .................................................... 14
2.1 ASME Codes................................................................................................................... 14
2.2 Shell Group Standards .................................................................................................... 14
2.3 PDO Standards ............................................................................................................... 14
3 PIPELINE RISKS AND MANAGEMENT .............................................................................. 15
3.1 General ........................................................................................................................... 15
3.2 Risk Identification ............................................................................................................ 16
3.3 Risk Assessment ............................................................................................................ 16
3.4 Pipeline Classification ..................................................................................................... 17
3.5 Risk Control..................................................................................................................... 17
3.6 Recovery from Failures ................................................................................................... 18
4 DESIGN ................................................................................................................................ 18
4.1 General Considerations .................................................................................................. 18
4.1.1 Introduction.................................................................................................... 18
4.1.2 Specification and Design Code Break .......................................................... 18
4.1.3 Reviews ......................................................................................................... 19
4.1.4 Safety Risk Assessment ............................................................................... 19
4.1.5 Environmental Impact Assessment............................................................... 19
4.1.6 Hydraulic Design ........................................................................................... 20
4.1.7 Pipe Material Selection ................................................................................. 21
4.1.8 Operating Philosophy .................................................................................... 21
4.2 Pipeline Routing .............................................................................................................. 21
4.2.1 Introduction.................................................................................................... 21
4.2.2 Surveys ......................................................................................................... 21
4.2.3 Establishment of Location Classes for Onshore Pipelines ........................... 22

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4.2.4 Proximity to Occupied Buildings .................................................................... 22

4.2.5 Proximity to Other Facilities ........................................................................... 22
4.2.6 Special Routing Considerations .................................................................... 22
4.3 Pipeline Strength Considerations .................................................................................... 23
4.3.1 Design Factors (for hoop stress limitation of metallic pipelines) ................... 23
4.3.2 Design Factors for Hoop Stress Limitation of GRP/FCP Pipelines ............... 25
4.3.3 Steel Quality .................................................................................................. 25
4.3.4 Minimum Wall Thickness ............................................................................... 25
4.3.5 Equivalent Stresses (for restrained pipelines) .............................................. 26
4.3.6 Stress Analysis .............................................................................................. 27
4.3.7 Strain Based Design ...................................................................................... 27
4.3.8 Field bends .................................................................................................... 28
4.4 Crossings ........................................................................................................................ 28
4.5 Burial Philosophy / Pipeline Protection ........................................................................... 29
4.6 Stability ............................................................................................................................ 30
4.7 Corrosion Protection And Monitoring .............................................................................. 30
4.7.1 External Corrosion ......................................................................................... 30
4.7.2 Internal Corrosion .......................................................................................... 31
4.7.3 Corrosion Monitoring ..................................................................................... 32
4.8 Internal Flow Coatings .................................................................................................... 32
4.9 Provision For Pigging ...................................................................................................... 33
4.9.1 General .......................................................................................................... 33
4.9.2 Isolation ......................................................................................................... 33
4.9.3 Intelligent Pigs ............................................................................................... 34
4.10 Line Sectionalising And Emergency Shut Down Valves ............................... 34
4.10.1 General .......................................................................................................... 34
4.10.2 Sectionalising Block Valves........................................................................... 34
4.10.3 Emergency Shutdown Valves ....................................................................... 34
4.10.4 Valve Actuation.............................................................................................. 34
4.10.5 Leak Detection............................................................................................... 35
4.10.6 Blowdown ...................................................................................................... 35
4.11 Overpressure Protection ............................................................................... 35
4.11.1 Maximum Allowable Pipeline Pressures ....................................................... 35
4.11.2 Overpressurisation by the Upstream Facility ................................................ 36
4.11.3 Surge Pressures ............................................................................................ 36
4.11.4 Thermal Effects ............................................................................................. 37
4.12 Branch Connections And Fittings .................................................................. 37
4.13 Telecommunications ..................................................................................... 38
4.14 Records ......................................................................................................... 38
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5 MATERIAL PROCUREMENT .............................................................................................. 39

5.1 General ........................................................................................................................... 39
5.2 Re-Use Of Materials ....................................................................................................... 39
5.3 Spare Materials ............................................................................................................... 39
5.3.1 Metallic Linepipe ........................................................................................... 39
5.3.2 GRE Pipeline ................................................................................................. 39
5.3.3 Miscellaneous spares .................................................................................... 39
5.4 Linepipe Material ............................................................................................................. 40
5.5 Pipeline Components ...................................................................................................... 40
5.6 External Coatings ............................................................................................................ 41
5.7 Internal COATINGS ........................................................................................................ 41
5.8 Concrete Coating ............................................................................................................ 41
5.9 Records ........................................................................................................................... 41
6 CONSTRUCTION ................................................................................................................. 41
6.1 General ........................................................................................................................... 41
6.2 Construction Hydrotesting............................................................................................... 42
7 PRE-COMMISSIONING ....................................................................................................... 42
8 HAND-OVER DOCUMENTATION ....................................................................................... 42
9 REFERENCES ..................................................................................................................... 43
APPENDIX 1: Criticality Classification Of Pipelines And Flowlines ......................................... 47
A.1.1. General.......................................................................................................... 47
A.1.2. Susceptibility to Failure Classification ........................................................... 48
A.1.3. Failure Consequence Classification.............................................................. 51
APPENDIX 2: Building Proximity Distances ............................................................................ 53
APPENDIX 3: Pipeline Stresses .............................................................................................. 54
APPENDIX 4: Flowline Design ................................................................................................. 55
APPENDIX 5: Requirements for small orders (Off shelf purchases from stockists) ................ 61
APPENDIX 6: SHALL [PS] statement basis ............................................................................ 64
Figure 1 Diagrammatic Representation of Pipeline Scope Boundaries ................................... 68
Figure 2: Diagrammatic Representation Of Design Code Break ............................................. 69
Figure 3: PDO Pipeline Standards Hierarchy .......................................................................... 70
Figure 4: User Comments Form ............................................................................................... 70

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1 INTRODUCTION
1.1 Scope

This Specification (SP) gives minimum technical requirements and recommended

practices for the design, material procurement, construction and pre-commissioning of
onshore pipelines used for the transport of hydrocarbons and other fluids commonly
transported in PDO operations. For some fluids, in particular those of an unstable or
toxic nature, additional requirements not covered in this SP may be appropriate.
Technical requirements and recommended practices for operation and maintenance of
the pipelines are covered under a separate specification SP–1210 “Pipeline Integrity
Management”.
In this SP, a pipeline is defined as a system of pipes for the transportation of fluids in
the liquid or gaseous phase, or a combination of both phases, between (but excluding)
wellhead facilities, manifold stations, production plants, pressure boosting stations,
processing plants or storage facilities. A pipeline extends from pig trap to pig trap
(including the pig traps and associated pipework and valves), or, if no pig trap is fitted,
to the first on plot isolation valve within the onshore plant as applicable. This SP shall
be read in conjunction with ASME B31.4 and ASME B31.8 (as applicable).
Figure 1 provides a diagrammatic representation of pipeline scope boundaries.
This specification shall not be changed without approval from the Custodian, UIPT2
(CFDH Pipelines), who owns this specification. If you think any part of this specification
is not correct, write your comments on a copy of the User Comments Form. The form is
included as the last page of this specification. Send the copy with your comments and
personal details to UIPT2 (CFDH Pipelines)

1.2 Distribution, Intended Use and Regulatory Considerations

Unless otherwise authorised by PDO, the distribution of this SP is confined to PDO

operations and to Contractors nominated by them.
The SP is intended for use by all Functions in the Company that are involved in the
design, material procurement and construction of pipelines.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this SP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable as regards safety, environmental, economic and legal aspects. In all cases,
the Contractor shall inform the Company of any deviation from the requirements of this
SP which is considered necessary in order to comply with national and/or local
regulations. The Company may then negotiate with the Authorities concerned with the
object of obtaining agreement to follow this SP as closely as possible.
No liability shall be incurred by PDO for any cause arising from the authorised or
unauthorised use of this SP.

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1.3 Definitions
1.3.1 General Definitions

The Contractor is the party, which carries out all or part of the design, procurement,
construction, commissioning or management of a project or operation of a facility. The
Company may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party, which manufactures or supplies equipment or
services to perform the duties performed by the Contractor.
The Company is Petroleum Development Oman LLC. The Company will generally
specify the technical requirements and may nominate an agent or consultant authorised
to act for and on behalf of the Company.
shall identifies a requirement.
should identifies a recommendation.
SHALL [PS] identifies a process safety requirement (refer Appendix 6)
1.3.2 Specific Definitions

Assembly An arrangement of pipes and components such as a pig trap, a

block valve station.
Barred tee Tee-piece provided with bars across the internal bore of the branch
pipe to prevent entry of a pig.
Block valve Valve for interrupting the flow or to shut-in a section of a pipeline. A
block valve is normally either fully opened or fully closed.
Branch pipe Pipe connected to a pipeline of equal or larger diameter, using a
tee-piece.
Cold bend A bend made from linepipe at ambient temperature, normally on the
construction site, using a mechanical bending machine.
Commissioning An activity where the fluid to be transported is initially introduced
into a pipeline.
Consequence The result of an event in terms of human safety, damage to the
environment and economic impact.

Design Class Classification of facility as per SP-2199.

Design factor Ratio of the hoop stress created by the design pressure and the
The Design Pressure (DP) is the highest gauge pressure that, according to mechanical design codes,
SMYS of the pipeline material. a system or piece of equipment can be continually subjected to at or below the Upper Design
Temperature, and above the Lower Design Temperature. This pressure typically provides the basis
for relief valve set pressures, and actual operating conditions (OP, MOP) are below this pressure.
Design pressure As defined in DEP 01.00.01.30-Gen. The design temperature is used for the mechanical design (e.g., determination of minimum wall
thickness and other physical characteristics) of equipment and piping.
The design temperature is often referred to as the upper design temperature. This is the highest
Design temperature As defined in DEP 01.00.01.30-Gen.
temperature to which equipment is designed at the design pressure.

Emergency shutdown Valve for isolating a pipeline from a source or destination in case of
valve emergency situations.
FEED Engineering and design activities, following the conceptual design,
where a project is given further technical definition and where a job
specification can be drawn for the preparation of the tender
documents.

Refers to any liquid, gas or vapour, that is easily ignited as defined

Flammable fluid in Energy Institute (formerly Institute of Petroleum) Model Code of
Safe Practice Part 15
Flowline A pipeline transporting fluid hydrocarbons and/or other reservoir
fluids between a wellhead and a gathering (RMS or MSV) or
treatment facility or vice versa.
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Fluid A substance, which is transported through a pipeline in liquid or

gaseous phase, or a combination of these.
Header A section of pipe or pipeline collecting or distributing fluids from
several sources or destinations.
Hot bend A bend made under factory conditions by hot working billets, plates
or pipes.
Incidental pressure Pressure occurring in a pipeline with limited frequency and duration.
Pressures due to surges or heating of blocked-in static fluid are
considered incidental pressures, provided they are not regular
operating occurrences.
Injection line A pipeline transporting gas, water or other fluids for injection into a
well or a group of wells.
Inter-field Pipeline A pipeline between two processing facilities, transporting processed
hydrocarbon or other reservoir fluids.
Isolation valve Valve used to interrupt the flow or to isolate one section of a
pipeline from an adjacent section or a facility connected to the
pipeline. An Isolation valve is normally either opened or fully
closed. Isolation valve is also referred to as a block valve.
Line pack In a gas transmission system, the line pack is the volume of gas in
a pipeline above the minimum volume of gas necessary to provide
the pressure to facilitate the flow of gas through a pipeline to
achieve the required delivery rate and pressure. The line pack is
used to continue deliveries for some period following interruption of
supply upstream.
Liquid hold-up Quantity of liquids present in a two-phase pipeline.
Loading line A pipeline between a storage facility and a sales facility, e.g. a
single point mooring or product truck loading.
Maximum allowable The maximum pressure that is allowed to occur in a pipeline with a
incidental pressure limited frequency and duration, determined in accordance with
applicable design standard.
Maximum allowable The maximum pressure at which a pipeline is allowed to be
operating pressure operated under steady state process conditions, in accordance with
ASME B31.4/8.
Maximum operating As defined in DEP 01.00.01.30-Gen.
temperature
Minimum metal As defined in DEP 01.00.01.30-Gen.
temperature (MMT)
Off-plot A location outside designated plant boundaries.
Off-take line A pipeline transporting fluid from a larger pipeline.
On-plot A location inside designated plant boundaries.
Operating envelope A defined set of key parameters or parameter ranges which should
be adhered to during operation of the pipeline in order to prevent
loss of technical integrity.
Overpressure Valve intended to protect the pipeline against overpressure by
protection valve preventing pressure from a source building up in the pipeline.
Pig A device which can be propelled through a pipeline by fluid flow and
normally used for cleaning, batching, inspection or other activities.
Pig trap system An ancillary item of pipeline equipment, with associated pipework
and valves, for introducing a pig into a pipeline or removing a pig
from a pipeline.
Pipeline A system of pipes and other components used for the transportation
of fluids, between (but excluding) plants/facilities. A pipeline
extends from pig trap to pig trap (including the pig traps), or, if no
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pig trap is fitted, to the first off take isolation valve within the plant
boundaries or a more inward valve if so nominated.
Pipeline code An industry or national code written for the purpose of designing,
constructing and operating pipelines.
Pipeline leak An uncontrolled fluid release from a pipeline.
Plant An installation, such as well-head, processing facility, pressure
boosting station, storage tank, offshore platform, refinery, etc., with
defined boundaries and which is not normally accessible to the
public.
Pre-commissioning A series of activities, including cleaning and possibly drying,
executed to prepare the pipeline for commissioning.
Pressure equalisation Small bore bypass pipe with valves to allow equalisation of
line pressure across a larger valve, avoiding damage to the seats of the
larger valve or equipment on the depressurised side.
Pressure relief safety Valve for protecting a pipeline against overpressure by releasing
valve fluid from the pipeline.
Remote vent line A pipeline used for discharging light gaseous fluids to atmosphere
at a safe location.
Risk The product of the probability of an event occurring and the
consequences of the event when it has occurred.
Sour Service Exposure to oilfield environments that contain sufficient H2S to
cause cracking of materials by the mechanisms addressed by
ANSI/NACE MR0175/ISO 15156; Also refer SP-1190
Sectionalising block Main valve for sectionalising a pipeline, in order to limit the release
valve of line contents in case of pipeline leak or rupture.
Slug Catcher A device located at the downstream end of a two-phase pipeline, for
the primary separation of the liquid and gas phases, and the
temporary storage of liquids generated by pigging and transient flow
conditions. There are two types of slug catchers: the vessel type
and the finger type.
Specified minimum The level of stress which produces 0.5 percent total strain (API
yield stress (SMYS) definition). This stress is specified by the Company and guaranteed
by the Manufacturer/Supplier.
Sphere A spherical shape pig, used for batching, wax control, meter proving
and liquid hold-up removal in two-phase pipelines.
Sphere tee A jacketed tee-piece with a perforated inner pipe to prevent entry of
a sphere into the branch pipe.
Spurline A pipeline transporting fluid into a larger pipeline.
Stable fluid With reference to EP-95 0000, a stable fluid has an NFPA reactivity
grade number of zero.
Surface safety valve Valve, part of the well-head assembly, applied as isolation valve
between flowline and wellhead.
Surge pressure Pressure due to mass flow velocity changes, caused by operational
activities, e.g. valve closures, pump shut-down or start-up.
Technical integrity Technical integrity of a facility is achieved when, under specified
operating conditions, there is no foreseeable risk of failure
endangering safety of personnel, environment or asset value.
Test pressure The pressure at which the pipeline will be or has been tested for
strength.
Thermal pressure Pressure due to thermal effects on the fluid in the blocked-in
pipeline or blocked-in pipeline sections.
Toxic fluid The term "toxic" shall be understood to include the classification

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"very toxic – acute, chronic or environment", as defined in DEP

01.00.01.30-Gen.
Trunkline A main transmission pipeline connecting processing facilities and/or
pump stations to which spur lines and off take lines may be
connected.
Two-phase pipeline Pipeline transporting fluids where the liquid phases and the gas
phase are present at pipeline pressure and temperature conditions.
Two speed actuator An actuator that enables to reduce the valve closure speed over the
last 10% to 20% of the valve travel movement.

1.4 Abbreviations

ALARP As Low As Reasonably Practicable

AVME Approved Vendors of Materials and Equipment
BVS Block Valve Station
CCMS Certification and Completion Management System
CFDH Corporate Functional Discipline Head
CO2 Carbon Dioxide
CP Cathodic Protection
CS Carbon Steel
DCAF Discipline Controls and Assurance Framework
DN Diameter nominal
EIA Environmental Impact Assessment
EP Exploration and Production
ERW Electric Resistance Welding
ESD Emergency Shutdown
FBE Fusion Bonded Epoxy
FCP Flexible Composite pipe
FEED Front End Engineering Design
FRD Focussed Results Delivery
GOR Gas to Oil Ratio
GRE Glass Reinforced Epoxy
GRP Glass Reinforced Plastics
H2S Hydrogen Sulphide
HAZID Hazard Identification
HAZOP Hazard and Operability
HDPE High Density Polyethylene
HFW High Frequency Welded
HIC Hydrogen Induced Cracking
HIPPS High Integrity Pipeline Protection System (against overpressure)
ISO International Organization for Standardization
LCC Life Cycle Cost
LPG Liquefied Petroleum Gas
MAIP Maximum Allowable Incidental Pressure
MAOP Maximum Allowable Operating Pressure
MESC Materials and Equipment Standards and Code
MFL Magnetic Flux Leakage
MOL Main Oil Line
NFPA National Fire Protection Association
NGL Natural Gas Liquids
NPS Nominal Pipe Size
NPV Net Present Value
OD Outside Diameter
PE Polyethylene
PLEM Pipeline End Manifold
PQR Procedure Qualification Record
PSE Shell Product Safety and Environmental Conservation Committee
QRA Quantitative Risk Assessment
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RBA Risk Based Analysis

RBI Risk Based Inspection
RTP Reinforced Thermoplastic
SAP-PM System Application and Product – Plant Maintenance
SAW Submerged Arc Welding
SMYS Specified Minimum Yield Stress
SCC Stress Corrosion Cracking
SOGL South Oman Gas line
SOHIC Stress-Oriented Hydrogen Induced Cracking
SSC Sulphide Stress Cracking
TA Technical Authority
TGLR Total Gas to Liquids Ratio
UT Ultrasonic Testing
WPS Welding Procedure specification
1.5 Cross-References

Where cross-references to other parts of this SP are made, the referenced section
number is shown in brackets. Other documents referenced by this SP are listed in
Section 9 - References.

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2 APPLICATION OF CODES AND GROUP STANDARDS

2.1 ASME Codes

The fluid transported in the pipeline should be categorised in one of the following five
groups, depending on its hazard potential:
 Category A: Non-flammable water-based fluids. Example: water, (as
in water injection / disposal / supply lines).
 Category B: Flammable fluids that are liquids at ambient temperature and at
atmospheric pressure conditions. Example: stabilised
crude, oil (such as MOL).
 Category C: Flammable multiphase liquids. Example: unstabilised
crude (as in interfield headers / pipelines) and crude (as
in flowlines).
 Category D: Flammable multiphase fluid which are gases at ambient
temperature and atmospheric pressure conditions (such
as gas flowlines / pipelines, Gas lift network lines, export
natural gas lines, etc).
 Category E: Critical sour fluids as defined by SP-1190-1

Flammability, stability and toxicity are defined in section 1.3.2.

Pipelines carrying category A and B fluids shall be designed and constructed in
accordance with ASME B31.4 and the additional requirements of this SP.
Pipelines carrying category C, D and E fluids shall be designed and constructed in
accordance with ASME B31.8 and the additional requirements of this SP.
NOTE: Liquid petroleum gas and anhydrous ammonia, which are covered by ASME
B31.4, fall under category D. Pipelines transporting these products shall
therefore be designed to ASME B31.8.
2.2 Shell Group Standards

The Shell Group standards related to the design, material procurement, construction,
and pre-commissioning of pipeline systems are referenced in Section 9 - References.
2.3 PDO Standards

The PDO standards related to the design, material procurement, construction, and pre-
commissioning of pipeline systems are referenced in Section 9 - References.
The document hierarchy specified in this SP therein in Figure 3 shall be considered
during the concept to detailed design phase of any pipeline or flowline system. In
particular, the Project Engineer shall ensure that any technical, operational and
maintenance requirements for the pipeline specified in SP-1210, ‘Pipeline Integrity
Management’ are considered during the detailed design phase.
A detailed listing of currently applicable and compulsory pipeline engineering standards
can be found on PDO’s ‘Livelink’ or website. For topics, which are not specifically
covered in the PDO and Shell Group standards, the Contractor may utilise the external
standards referenced in ASME B31.4 and B31.8, after consultation with, and approval
by, the Company.

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3 PIPELINE RISKS AND MANAGEMENT

3.1 General

The risks associated with the pipeline, in terms of the safety of people, damage to the
environment, and loss of income, depends on the expected failure frequency and the
associated consequence, which is directly related to the type of fluids transported and
the sensitivity of locations of the pipeline. In this context, pipeline failures are defined as
loss of containment.
Risk is defined in Section 3.2. Failure causes within PDO are mainly internal corrosion,
external corrosion and third party damage. Failure consequences can be categorised in
terms of health and safety of personnel, environment, loss of asset and loss of revenue.
Integrity actions should reduce the failure risks by either reducing the failure frequency
or the failure consequences or both. Therefore a direct comparison of costs versus
benefits should be possible. Integrity management plans (and priority allocation) should
ideally be based on a quantitative risk ranking.
The methodology used in this document for the purposes of design of pipelines is based
on a classification of pipelines and flowlines in terms of pipeline’s susceptibility to failure
and consequences. This approach facilitates integrity assessments and appropriate
management focus throughout the life of the asset, starting with HAZID review, design
reviews, HAZOP review, IPF reviews, design quality audits etc, through construction
records, commissioning and the operations phase where different levels of corrosion
management and inspection requirements achieve the required level of integrity.
The risk management process described in the following sections shall be applied as
specified throughout the asset life cycle, i.e. to design, construction, operation and
abandonment.
The overall risk management process involves the following four steps, as per Hazard
Effect Management Process (HEMP):
1. Identify systematically the hazards and effects, which may affect and arise from
activities performed on pipelines or by pipeline systems on other facilities or the
environment. Hazards and effects shall be identified by using appropriate
HEMP Tools , such as, HAZID or EIA and/or by review & analysis of failure
statistics.

2. Assess the probability of occurrence and the severity of the consequences.

3. Control the risk through preventative or protective measures, which will reduce
the frequency and/or the consequences of failure.

4. Recover from residual risks through effective emergency response and pipeline
repair procedures and emergency management systems.

Notwithstanding the requirements of design codes and this SP, the factors, which are
critical to public safety and the protection of the environment should be analysed over
the entire life of the pipeline, including the abandonment phase. The risk shall be
reduced to As Low As Reasonably Practicable (ALARP) through a detail review of
Hazard Management Hierarchy, which is used to manage HSSE risks to ALARP, with
the definite objective of preventing leaks. The level of risk may change with time, and it
is likely to increase to some extent as the pipeline ages.
The methods by which these steps are to be completed are outlined in the following
sections of this specification.

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3.2 Risk Identification

The potential pipeline failures, causes and their consequences should be inventoried
and taken into account in the design and the operating philosophy. The most common
pipeline threats, which may lead to the loss of technical integrity, are given below.
 Internal corrosion, Sulphide Stress Cracking (SSC), hydrogen induced cracking
(HIC), Microbial Induced Corrosion (MIC).
 External corrosion and bi-carbonate stress corrosion cracking.
 Abrasion.
 Construction threat (e.g. pipe girth weld, fabrication weld, wrinkle bend or
buckle, stripped threads/broken pipe/ coupling)
 Third-party damage (e.g. third-party inflicted damage, vandalism).
 Incorrect Operations (e.g. Fatigue, Over-pressurization, Thermal expansion
forces)
 Geo-technical forces.
 Manufacturing defects (e.g. pipe seam and growth of material defects such as
inclusions, cracks)
 Equipment threat (e.g. gaskets and o-rings, control/relief, seal/pump packing)

Risks shall be identified and analysed through a systematic application of procedures

from conceptual through design and construction to operational and abandonment
phases as outlined in following sections.
3.3 Risk Assessment

The risk depends firstly on the expected frequency of failure, due to internal and
external corrosion, external loading (e.g. impacts, settlement differences, free spans),
material or construction defects, and operational mishaps. The frequency of failure is
difficult to assess and could be misleading because of lack of detailed and reliable
failure statistics and analysis for different kinds of pipelines in PDO. Alternatively,
susceptibility of a pipeline to failure can be assessed and related to risks, based on
material, service, operating conditions like pressure and temperature. The method to
assess pipeline susceptibility to failure is detailed in Appendix– 1 of this document.
Secondly, it depends on the consequences of the failure, based on the nature of the
fluid in terms of flammability, stability, toxicity and polluting effect, the location of the
pipeline in terms of ignition sources, population densities and proximity to occupied
buildings, and the prevailing climatic conditions. Failure consequences can be further
categorised in terms of health and safety of personnel, environment and economic
value (loss of asset and revenue). The method to assess consequence of failure is
detailed in Appendix – 1 of this document.
The economic risk associated with deferment of income, cost of repair, and other costs
such as liabilities to the public and clean-up costs, including the likely costs from fines
imposed by the authorities may be considered. The economic risk should be evaluated
for each phase of the pipeline operating life, and should be compatible with the overall
objectives of the Company. Past leak statistics of a particular operating area and crude
specification may be used to evaluate the likelihood and cost of failure of a particular
flowline/pipeline.
Risk assessment shall be carried out on all new pipelines at the conceptual design
stage and shall form the basis for material selection, inspection and corrosion control
strategy. The expected frequency of failure and the possible consequences may be
time-dependent and should be analysed over the entire life of the pipeline.
Risks related to pipeline integrity in the operational phase shall be regularly assessed
through a variety of pro-active operational methods (e.g. pigging and sampling) and
inspection methods (e.g. Intelligent pigging, corrosion measurement, visual monitoring)
detailed in SP-1210 ‘Pipeline Integrity Management’.

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3.4 Pipeline Classification

Pipeline criticality is related to the risks as detailed above and defined as the
combination of two parameters namely, susceptibility to failure and consequence of
failure.
All individual lines (including Pipelines, Headers and groups of Flowlines) shall be
classified into one of three “Pipeline Class” and hereafter referred to as “Class 1”,
“Class 2” and “Class 3”, according to perceived susceptibility and consequence of
failure based on the Risk Assessment Matrix below. Detailed guidance and the
methodology to classify pipelines are given in Appendix - 1.
The integrity requirements of the pipeline through design, operation, maintenance and
inspection phase shall be determined based on the criticality class of the pipeline. This
document (SP-1211) stipulates the methods and procedures to be followed in design
and engineering phase of the pipeline. Reference shall be made to SP-1210 that
covers detailed operations and maintenance activities required to assure an acceptable
state of pipelines and flowlines integrity during the operation phase of the pipeline.
Pipeline Criticality Class should not be confused with the location class defined in
ASME B31.8 and design class as defined in SP-2199.

3.5 Risk Control

Risks levels can be reduced by using lower design factors (e.g. higher wall thickness or
stronger steel), right material selection, rerouting, providing additional protection to the
pipeline, application of facilities to minimise any released fluid volumes, and controlled
methods of operation, maintenance and inspection.
Measures to control risk logically follow from the identification and assessment activities
outlined above. Typical risk control measures to be considered are as follows:
Design and Construction Phase:
 Application of detailed design and construction requirements specified in this
specification, SP-1208 and related documents.
 Selection of optimum corrosion control strategy through pipe material selection,
coating application, chemical inhibition and cathodic protection.
 Control of design and construction work through DCAF Framework as well as
PDO’s Technical Authority systems as described in SP-2061.
 Screening, pre-qualification and auditing of material suppliers, pipeline design
and construction contractors.
 Measures to minimise risk during installation and commissioning, e.g. adequate
water treatment, oxygen control and drying to prevent corrosion following
hydrotest.
 Selection of pipeline routing to minimise the probability of physical damage,
corrosion attack etc.
 In above ground sections, provision of adequate supports with wear plates,
including prevention of sand inundation and abrasion where appropriate.
 Development of a pipeline-specific corrosion management manual for all Class
1 Pipelines and flowlines.
 Development of a risk-based maintenance and inspection philosophy that
matches the parameters assumed in the basis for design.
 The risk of pipeline over-pressurisation shall be controlled by the pressure safe
guarding system in accordance to GU-437 and DEP80.45.10.11.
Operational Phase:
 Control of operating conditions close to design parameters immediately
following handover.
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 The risk for internal corrosion shall be controlled by corrosion mitigation

measures such as inhibition, routine pigging or a change in the operating mode.
 Regular condition monitoring and maintenance of the CP system should control
the risk of external corrosion.
 The risk of corrosion and impact damage should be controlled by application of
available technique and careful inspection and measurement against
established acceptance criteria (e.g. Inspection of external coatings against
current coating standards and the regular surveillance of pipeline Windrows and
Rights Of Way against SP-1208 requirements), ensuring appropriate actions
are scheduled for repair.
 The safety risk of pigging operations shall be controlled by regular maintenance
of the pigging facilities and use of a procedure for pigging operations PR-1082.
 The economic risk of pipeline blockage by pigs shall be controlled by a proper
selection of pig types. Pig selection shall be based on the type of cleaning or
other function required.
 A regular pigging programme based on evaluation of corrosion measurements
and the likelihood of pipeline blockage by wax or debris is required to clean
pipelines, which are not routinely pigged. This serves also to verify piggability of
the pipeline.
 The risk presented by unauthorised third party activities can be controlled by
regular Right of Way (ROW) inspections and visual/camera monitoring of
fenced areas.
3.6 Recovery from Failures

Recovery from pipeline failures shall be assured through the implementation of an

emergency response system, including preparation of an Emergency Response
Manual, qualified pipeline repair procedures and emergency material stocks.
Requirements and responsibilities for establishing and maintaining the Emergency
Response System are detailed in SP-1210.

4 DESIGN
4.1 General Considerations

4.1.1 Introduction

The metallic pipelines shall be designed in accordance with the relevant sections of
ASME B31.4/8, as appropriate, supplemented by this section. For GRP Pipelines, SP-
2092 and ISO-14692, shall apply in addition to the requirements of this Specification.
The control and safeguarding requirements as specified in GU-437 and
DEP80.45.10.11 shall also be met as a minimum.
The pipeline SHALL [PS] be designed taking into consideration the operating conditions
and requirements over its entire projected life cycle including final abandonment, i.e. the
maximum planned throughput and turn-down, the characteristics of the fluids to be
transported, the pressure and temperature requirements, the mode of operations, the
geographic location, and the environmental conditions.
4.1.2 Specification and Design Code Break

For the purpose of code break, it is assumed that the piping of the facilities to which the
pipeline/pig trap system is connected is designed in accordance with ASME B31.3. A
pipeline extends from pig trap to pig trap and includes the pig traps and associated pipe
work and valves or, if no pig trap is fitted, up to the first isolation valve/flange within the
plant boundary. The delineation between the pipeline and the facility is the specification
break between pipeline design code ASME B 31.4/8 and the station design code ASME
B 31.3. Where this is not the case e.g. at intermediate pig trap stations or where the pig

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trap ties into a slug catcher designed to ASME B31.8, the code break/delineation is not
applicable.
Two options - Option A and Option B of design code break between ASME B31.8/B31.4
and ASME B31.3 may be used, as shown in Figure 2. Option B is the recommended
option. The Company shall confirm acceptability of the selected code break location.
The entire pig trap system should be designed, constructed and tested according to the
same code as the pipeline.
In the case of GRP pipelines / flowlines, the code break ISO 14692 (GRP) / ASME
B31.3 (metallic piping) shall be at the GRP-Metallic interface flange located inside the
flange pit.
4.1.3 Reviews

For all new Class 1 pipelines, reviews as specified in CP-117 shall be performed and
documented to ensure that technical integrity is guaranteed from a design viewpoint.
These shall cover as a minimum:
 HAZID study during feasibility stage to provide a basis for hazard identification
during conceptual design.
 Conceptual design review concentrating on the hydraulic design, materials
selection, corrosion control strategy, inspection philosophy and pigging
facilities.
 HAZOP study during the front-end design stage, often as part of the facilities
HAZOP.
 Detail design review by senior Discipline and Operations members covering
isolating and safeguarding philosophies as well as overpressure protection
requirements.
The future asset holder and the custodian shall be involved in the design review,
HAZOP and policy decisions where deviating from this specification.
When existing pipeline systems are extended, e.g. by adding a new branch line, the
whole pipeline system shall be subject to a design review to ensure that
overpressurisation of the system from the new branch line is not possible.
4.1.4 Safety Risk Assessment

A formal quantitative risk assessment (QRA) shall be carried out on all critical pipelines
(i.e. location class 3 & 4 / fluid category E) and report approved by TA2 from Technical
safety discipline. The assessment should confirm that the selected design factors,
proximity distances to buildings and block valve spacing are adequate.
4.1.5 Environmental Impact Assessment

An environmental impact assessment (EIA) is a process for identifying the possible

impact of a project on the environment, for determining the significance of those
impacts, and for designing strategies and means to eliminate or minimise adverse
impacts.
An EIA should consider the interaction between the pipeline and the environment during
each stage of the pipeline life cycle. The characteristics of the environment may affect
pipeline design, construction method, reinstatement techniques, and operations
philosophy.
An EIA shall be carried out for all pipelines or groups of pipelines, which have not
received an environment permit issued under Oman Law RD 114-01. PDO’s
Environmental Advisor shall be consulted to establish whether an area is
environmentally sensitive or not.

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Environmental Impact Statements shall be prepared for all new and replacement
pipelines in line with GU-195 (Environmental Assessment Guidelines) and CP-117.
4.1.6 Hydraulic Design

In order to determine the possible range of operational parameters of the pipeline, a

hydraulic analysis shall be performed. For a given pipe size; fluid properties and flow
rate; the hydraulic analysis should provide the pressure and temperature profiles along
the pipeline for steady state and transient conditions. Possible changes in flowrates and
operational modes as per selected design class shall be considered for hydraulic
design.
The recommended application program for hydraulic sizing is PIPESIM (modified
version with added Shell routines). TLNET for single-phase liquids or TGNET for single-
phase gas may be used to assess the impact of new pipeline designs and tie-ins to the
existing pipeline systems. ‘OLGA’ shall be used for transient analysis of multiphase
pipelines.
The hydraulic analysis shall provide data to address: surge pressure during shut-down
of a liquid line, turn-down limitations and inhibition or insulation requirements to prevent
wax or hydrates deposition, effect of flow conditions on the efficiency of corrosion
inhibitors, liquid catching and slug control requirements at the downstream end of two
phase lines.
The normal range of flow velocities is 1 to 2 m/s in liquid lines, and 5 to 10 m/s in gas
lines. Continuous operations above 4 m/s for liquids and 20 m/s for gases should be
avoided, which may lead to erosion and vibration difficulties; lower units may apply to
fluids containing solid particles, where maximum velocities will be dictated by the
occurrence of erosive conditions.
NOTES:

1. Unlined carbon steel liquid lines containing a separate water phase, even in small
quantity (e.g. 1% water cut), should not be operated at velocities below 1 m/s. This is to
prevent water dropout, which may lead to a corrosive situation. Dry crude lines at export
specification are excluded from this requirement. At water-cuts higher than 20%, flow
velocity is no longer an issue as water wetting of the pipe wall will always occur, and
alternative means of corrosion mitigation shall be considered. However, a minimum
velocity of around 1 m/s is preferred for intelligent pigging operations.

2. If the minimum velocity cannot be achieved economically (e.g. high pumping station
costs), then a corrosion management strategy shall be developed based on expected
water drop-out in the line.
Hydraulic gradient diagram should be prepared for liquid lines. It is sometimes
advantageous to adjust the design pressure along the route, depending on the patterns
of the hydrostatic pressure and the friction pressure loss. Great care should be applied
in the definition of the various sections and associated design pressures to determine
whether, under any operations scenario, overpressurisation of one section is possible
by the adjacent sections.
When tying in new spurlines to existing pipeline systems, the whole pipeline system
shall be subject to hydraulic analysis for steady state and transient conditions and a
design review to ensure that overpressurisation of the system from spur lines or vice
versa is not possible.
For gas pipelines, sections of decreasing design pressure are not recommended in
general, because the slight cost benefit is unlikely to outweigh the lost advantage of line
packing and thus loss of system availability/flexibility.
Within the above limitations, carbon steel flowlines should be standardised where
possible to the stock sizes detailed in Appendix 4 of this specification.

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4.1.7 Pipe Material Selection

The selection of the pipeline material type is a fundamental issue to be decided at the
conceptual design stage of a pipeline project. Material selection and corrosion control
for surface operation shall be done in accordance with SP-2161 and SP-2156 (for non-
metallic).
For new developments or major modification projects, the Life Cycle Cost Analysis shall
be conducted using the principle of total development costs of facilities and pipelines
combined. (This is to allow for the alternative of lowering pressure upstream to provide
larger diameter low pressure GRP pipeline at lower life cycle cost than treatment
facilities with a high pressure low diameter carbon steel pipeline.)
4.1.8 Operating Philosophy

For the predicted life cycle conditions, the design shall take due account of operations,
inspection, maintenance, and start-up/shut-down requirements, as well as established
operating philosophy and practices, agreed in advance with the personnel responsible
for the operation and maintenance of the pipeline. These include manning levels for the
operation, integrity monitoring and maintenance of the pipeline system, the
requirements for telecommunications and remote operations, means of access to the
right of way, etc.
4.2 Pipeline Routing

4.2.1 Introduction

The selection of the route shall take full account of the associated risks (3.3),
particularly safety and environmental risks, the accessibility for maintenance and
inspection, as well as normal direct cost considerations.
4.2.2 Surveys

Detailed survey data should be available prior to carrying out detailed design. These
data include:
 Population and building densities for the establishment of location classes
(4.2.3), location of inhabited buildings, taking into account any future land
development plans, as advised by government authorities.

 Topographical data, location and class of wadis, location of sand dunes, and
roads including type and density of traffic.

 Records of any existing special features, which will need reinstatement after
construction is completed.

 Soil investigation for foundation design (burial and/or supports design),

subsidence areas (e.g. due to mining activities).

 Soil resistively for cathodic protection design.

 Environmental data (climatic, floods, earthquakes, landslides, currents at wadi

crossings, vegetation, fauna).

 Existing facilities and CP systems, which may influence pipeline design and
construction.

 Buried pipelines and cables

 Over head high voltage power lines

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Pipeline route survey shall be carried out as per technical specification SP-2179
4.2.3 Establishment of Location Classes for Onshore Pipelines

Based on the survey data, appropriate location classes shall be identified along the
pipeline route for pipelines transporting category C, D and E fluids, in accordance with
ASME B31.8 Article 840.2. There is no specific requirement for pipelines transporting
category A and B fluids, apart from access requirements during construction and for
maintenance and emergency services during operations.
ASME B31.8 Article 840.2.2 identifies 4 location classes, ranging from location class 1
(sparsely populated areas) to location class 4 (densely populated areas).
Since location classes are used for the determination the design factor (4.3.1), the route
selection should take due regard for the cost impact on pipeline sections in location
classes of higher category (e.g. class 3 and class 4).
4.2.4 Proximity to Occupied Buildings

In comparison to pipelines transporting category A and B fluids, pipelines transporting

category C, D, E fluids constitute potentially higher hazards to people nearby. There are
no provisions in ASME B31.8 to cover this, apart from the location classes defined in
(4.2.3) which only addresses population densities. For the purpose of initial routing,
Appendix 2 provides guidance for establishing minimum distances of pipelines from
occupied buildings depending on the type of the fluid, the pipeline diameter and its
maximum allowable operating pressure. Final routing should be established following
the pipeline safety assessment (4.1.4).
4.2.5 Proximity to Other Facilities

Separation requirements between the pipeline pig traps and other adjacent facilities
should be at least 15 meters. Pig trap systems should generally be located adjacent to
each other at a minimum distance of 10 meters, for ease of pigging operations.
4.2.6 Special Routing Considerations

Special considerations should be given when selecting a route for pipeline / flowline.
The route shall ensure it is safe for construction activities like trenching, material
handling, .etc.
All pipelines should have a permanent right of way with a width ranging from 4 m for
DN150 and below, to 10 m for DN600 and above (interpolate for in between sizes).
Additionally, all Class 1 pipelines shall have a permanent right of way with a width of 50
meters. The pipeline route should be centred on the right of way. Where two or more
pipelines are laid in parallel in the same corridor, the right of way corridor should be
enlarged by the space between the pipelines. In case the proposed ROW is crossing
any MOL / SOGL or Class 1 pipelines, refer to PR-1817 for details on restrictions on
third party or PDO activities and NOC requirements.
An access road with a minimum width of 5 meters shall be provided along one side of
the full length of all Class 1 pipelines. In the case of pipeline corridors, common access
road that can adequately support all the pipelines is sufficient.
Stress due to elastic radius of curvature shall be considered when evaluating equivalent
stresses. The equivalent stresses (including stress due to elastic radius) shall not
exceed the values given in Table 2. Hot or field cold bends shall be used when
equivalent stresses exceed the allowable limit.
When several pipelines are installed in the same trench, the clear separation between 2
adjacent pipelines shall be 0.5 m minimum. The minimum clear distance for pipelines
installed in a separate trench alongside an existing buried pipeline should range from 4
m for DN150 and below, to 7 m for DN900 and above (interpolate for in between sizes).

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The crossing of existing pipelines, cables, power lines, roads, railways and waterways
should be as close as practicable to 90 degrees angle but should not be less than 45
degrees.
The minimum horizontal separation distance and other mitigation measures required to
minimise hazards arising from induced voltage effects, when a proposed pipeline route
runs parallel to an overhead power line, shall be evaluated and reference shall be made
to SP-1128 and SP-1208. The effects of overhead powerline parallelism shall be
considered for all metallic pipelines as per section 4.7.1 of this specification.

In case of GRP pipelines standard angle elbows should be used for routing as per
manufacturer recommendations. Metallic cable OR detectable tape, for future detection
of GRP buried pipe shall be provided in congested areas and near station approaches
for a minimum length from station fence as decided by design consultant during site
visit depending on site conditions. However in case FOC with detectable marker tape, is
installed along the line in the same trench, then this cable need not be installed.

For new pipeline / flowline installations in existing corridors / congested areas, crossing
of lines SHALL [PS] be done in such a way that proper marking is done to provide easy
traceability of lines by maintenance team. This is to ensure that there will be no
incorrect identification of lines in future, when cutting / demolishing need arises.

4.3 Pipeline Strength Considerations

4.3.1 Design Factors (for hoop stress limitation of metallic pipelines)

The design factor applies to the minimal pipe wall thickness, excluding any corrosion
allowance.
The recommended design factors for the calculation of the minimal wall thickness are
given in Table 1, derived from ASME B31.8 Table 841.1.6-2, but expanded to include
ASME B31.4 pipelines.
NOTE: Table 1 provide recommended design factors for designs based on ASME
B31.4/8; they are not intended to replace the requirements included in National
codes, which may impose different design factors and/or hoop stress
calculations based on the minimum wall thickness (instead of nominal). These
tables however highlight the critical areas, and National requirements should be
assessed against the values provided. In any case, the Company should be
satisfied that the risk level at any point along the pipeline route remains within
acceptable limits (3.3).

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TABLE 1 DESIGN FACTORS FOR ONSHORE STEEL PIPELINES

FLUID CATEGORY A and B C, D and E
APPLICABLE CODE B31.4 B31.8
(Note 1)
LOCATION CLASSES 1 Div. 2 2 3 4
Pipelines 0.72 0.72 0.60 0.50 0.40

Crossings (Note 2 , 7)
Temporary crossings over existing 0.72 0.72 0.72 0.72 0.72
pipeline (used < 2 weeks)
Wadi type A, livestock 0.72 0.72 0.60 0.50 0.50

Private roads 0.60 0.60 0.60 0.50 0.40

Unimproved public roads 0.60 0.60 0.60 0.50 0.40
Roads, highways, streets, wadi (Type B 0.60 0.60 0.60 0.50 0.40
and C)
Rivers and beaches 0.60 0.60 0.60 0.50 0.40

Parallel encroachments
(Note 3)
Private roads 0.72 0.72 0.60 0.50 0.40
Unimproved public roads 0.72 0.60 0.60 0.50 0.40
Roads, highways, streets 0.72 0.60 0.60 0.50 0.40
Fabricated assemblies 0.60 0.60 0.60 0.50 0.40
(Note 4)

Pipelines on bridges 0.60 0.60 0.60 0.50 0.40

Near concentration of people 0.60 0.50 0.50 0.50 0.40
(Note 5)

Pipelines, within plant fences, block 0.60 0.60 0.60 0.50 0.40
valve stations and pig trap stations
(Note 6)
Above ground pipelines 0.72 0.72 0.60 0.50 0.40
NOTES

1: ASME B31.4 does not use design factors other than 0.72, which is considered inappropriate
at critical locations (e.g. crossings, within plant fences, near concentration of people), and for
fabricated assemblies. In these situations, modified design factors in line with ASME B31.8
location Class 1 Division 2 shall be used.

2: ASME B31.8 differentiates crossings with casings and without casings. Because of the poor
experience of cased crossings (i.e. annular corrosion), the same design factor is
recommended, whether a casing is used or not. Design factors for crossings of rivers, dunes
and beaches as well as temporary controlled crossings, not included in ASME B31.8, are
provided. Temporary crossings shall be monitored on a daily basis and windrow shall be
reinstated within one week of completion of the activity requiring a crossing.

3: Parallel encroachments are defined as those sections of a pipeline running parallel to existing
roads, at distance less than 50 metres.

4: Fabricated assemblies include pig traps, valve stations, headers, finger type slugcatchers, etc.

5: Concentrations of people are defined in ASME B31.8 Article 840.3.

6: This category, not specifically covered in ASME B31.8, is added for increased safety.
7: Reference is also made here to SP-2284 for assessment of vehicle loading over existing
lines.
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4.3.2 Design Factors for Hoop Stress Limitation of GRP/FCP Pipelines

GRP Pipeline design factors shall be determined as described in SP-2092.
Flexible composite pipes (FCP) SHALL [PS] be designed and installed in accordance
SP-2156 and SP-1208.
4.3.3 Steel Quality

The linepipe for pipeline construction should be as per section 5.4 of this specification.
Carbon steel Pipelines are commonly constructed with linepipe in steel grades L290 to
L450 as defined in ISO 3183. Gr. B
X-65 X-42
Lower grades such as L245 and higher grades may be appropriate in some cases.
Experience within PDO is presently limited up to and including L485 and problems have
been encountered in the industry for higher grades (hydrogen embrittlement caused by
cathodic protection, weldability, required tensile to yield ratio). Use of grades L555 and
above should at present be avoided. Appropriate derating factors, in accordance with
Table 841.1.8-1 of ASME B31.8, should be used for pipelines operating at high
temperatures.
NOTE: Table 841.1.8-1 applies to carbon steel materials (derating required above 121
°C).
Attention shall be given to the fracture toughness properties of pipe material for gas
pipelines to prevent the possibility of long running fractures. This is particularly critical
when low temperatures are possible, e.g. downstream of pressure reduction stations
and at exposed above ground locations, such as the throttle bypass valves at Block
Valve Stations.
The pipe body materials for pipelines carrying category C, D, E fluids SHALL [PS] be
capable of arresting running ductile shear failures. Running ductile shear failure
resistance is assessed by parent material Charpy testing.
4.3.4 Minimum Wall Thickness

The nominal pipe wall thickness including corrosion allowance shall not be less than
4.8 mm for all metallic and PE-lined pipelines. For MOL and SOGL pipelines, the
minimum wall thickness shall be 5.6 mm. For all GRP pipelines minimum thickness
(handling and impact resistance requirement) for category A fluids shall be as per SP-
2092 and 5.6 mm (including liner and top coat) for all other category fluids.
The diameter to wall thickness ratio should not exceed 96 for metallic pipelines, unless
it can be demonstrated that higher values are not detrimental to the handling, field
bending and other aspects relating to construction and in-situ integrity of the pipeline.
Collapse due to vacuum conditions shall be accounted for in the design of all pipelines,
also when vacuum conditions are not expected to occur in service.
Design pipe wall thickness may be custom ordered (i,e calculated thickness). However
Linepipe may be procured as per the standard thickness if commercially attractive
during procurement stage in consultation with Company.

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4.3.5 Equivalent Stresses (for restrained pipelines) Barlow's eq.

4.3.5.1 METALLIC PIPELINES
The wall thickness, initially derived from hoop stress considerations based on design
factors (Table 1), should be such that the longitudinal, shear, and equivalent stresses in
the pipe wall under functional and environmental loads do not exceed certain values.
This is covered in ASME B31.4 Article 402 and of ASME B31.8 Article 833. Because,
the requirements in these various articles differ from each other, it is recommended to
use a single approach for all pipelines as detailed below.
 The equivalent stress is defined as follows:
Seq = (Sh2 + SL 2- ShSL+ 3Ss2)1/2 (Von Mises equation)
Seq = equivalent stress
Sh = hoop stress (due to pressure)
SL = longitudinal stress (due to pressure, thermal expansion and bending)
Ss = combined shear stress (due to torque and shear force)
Formulae for Sh, SL and Ss can be found in Appendix 3.
 The equivalent stress shall not exceed the values given in Table 2.

The stress calculations for the operational phase shall be carried out with the nominal
wall thickness excluding the corrosion allowance.
Instead of an equivalent stress criterion as detailed above, a strain-based criterion may
be used if considered more appropriate (see 4.3.7).
TABLE 2 ALLOWABLE EQUIVALENT STRESS (PERCENT OF SPECIFIED
MINIMUM YIELD STRESS)
FUNCTIONAL PLUS ENVIRONMENTAL LOADS
Installation (Note 1) 90%

Road crossings 90%

Hydrostatic test (Note 1) 100%
Operation 90%

NOTE 1: For the installation and hydrostatic test conditions, the environmental loads may be
based on one-year return period.
A detailed stress analysis shall be carried using CAESAR II or Company approved
equivalent software to ensure that the induced stresses are within above allowable
limits during operation phases of the pipeline.
4.3.5.2 Non Metallic pipelines
The requirements given in the preceding paragraphs of this section were primarily
developed for the use of metallic pipe. Where non-metallic pipe such as GRP or FCP is
selected as the material of choice, relevant Company , Shell Group standards should
be used. The detailed design of such pipelines shall include a stress analysis of the
complete length of the pipeline using CAESAR II software and include provisions such
as thrust and/or anchor blocks where necessary to ensure that the pipeline is not
overstressed locally. In general it is preferred to design the pipeline with sufficient wall
thickness and large radius bends such that the use of thrust blocks or anchor blocks is
minimised / eliminated. Type of support / stops to be used shall be based on the
outcome of stress analysis which shall be carried out for complete GRP-metallic piping,
by Company approved manufacturers / consultants only. GRP pipelines shall be
designed in accordance with the requirements of this specification and additional

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requirements specified in SP-2092 and ISO 14692-3, and FCP pipeline SHALL [PS] be
designed and installed in accordance with the requirements of SP-2156 and SP-1208.
4.3.6 Stress Analysis

Detailed flexibility analysis shall be carried out during detail design for above ground (or
sections of) metallic pipelines, at design pressure and black bulb or design temperature
whichever is higher. For buried (or sections of) metallic pipelines, this analysis shall be
carried out at design pressure and maximum & minimum operating temperature. For
non metallic lines this analysis shall be carried out at design pressure and design
temperature. Hydrotest case shall also be run with test pressures as per SP-1212.
Metric system shall be used.

Installation temperature may be considered as 21° C. However for exotic materials like
DSS, the installation temperature may be higher in case the actual time of installation is
planned in summer, to optimise the thickness of pipeline.
Metallic lines shall comply with B31.4 / 31.8 codes as applicable. Soil modelling for
buried portion of the pipelines shall be done based on American Lifelines Alliance
guidelines on design of buried pipelines and geotechnical survey data should be used
during detailed design. For buried metallic lines, design consultant shall ensure that the
combined stresses in the stress report are based on Von Mises theory of failure. For
above ground / unrestrained metallic lines the acceptance criteria for allowable stress
shall be as per B31.4 / 31.8 codes. GRP lines shall comply with ISO14692.
Longitudinal stresses shall be computed considering both tensile and compressive
values of bending stresses.
Flange (metallic and non-metallic) leakage calculation shall be carried out based on
GU-706.

For high temperature buried pipelines (> 85° C) the thickness of the line should be
optimised by considering larger radius bends (than indicated in 4.3.8) in offplot areas
and higher cover depth as practical.
Pipeline design basis shall indicate details like load case combinations, soil modelling
input data,.etc, and shall be accepted by Pipeline TA2, prior to stress analysis. Dynamic
analysis in case required (Ref GU-706) shall also be identified in the Pipeline design
basis (including slug loads /surge loads / other dynamic conditions as applicable).
Permanent supports/clamps shall be used to support and restrain the pig traps. These
shall be designed to carry the weight of the pig trap system filled with water (or other
fluids if their density is greater than that of water) together with the weight of intelligent
pigs, if applicable. The supports under the pig trap barrel should normally be of the
sliding/clamp type to compensate for expansion of the unrestrained part of the pipeline.
Other supports may be fixed if design calculations indicate that sufficient flexibility is
incorporated in the pipework to compensate for any possible axial and transverse
movements.
Stress analysis reports shall be approved by Company Pipeline TA2 prior to start of
construction.
4.3.7 Strain Based Design

During pipeline construction, it is sometimes more appropriate to apply limitations to the

maximum allowable strain of the pipe wall rather than to a maximum allowable stress.
Examples during installation are field cold bending of onshore pipelines. When the
pipeline is plastically deformed, it shall be demonstrated that, after straining, the
pipeline material still complies with the required specifications; this is particularly
relevant to toughness, hardness and yield to tensile ratio properties. A maximum
permanent bending strain of 2 percent resulting from installation is acceptable in
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general. For pipelines in operation, the equivalent stress requirements (4.3.5) may lead
in some situations to very high wall thicknesses and a strain-based approach may be
used instead. This is particularly relevant to pipelines transporting hot products
4.3.8 Field bends

Pipes may be bent cold in the field to fit pipeline alignment and topographical
conditions. Field bends shall be made on bending machines, which provide sufficient
support to the pipe cross-section to prevent buckling or wrinkling of the pipe wall and to
maintain coating integrity.
In general, the minimum bending radii should not be less than:
- 25 D for pipe NPS of less than 8”

- 30 D for pipe NPS of 8” to 16”

- 40 D for pipe NPS of over 16”

However, cold field bends on the pipeline portion of the pig trap systems (swan neck
portion) should have minimum bending radius of 60D, where D is the pipeline diameter.
Refer also to section 4.9.3 for use hot bends in mainline designed for intelligent pigging.
The strain induced in a pipeline by bending it along a radius R is given by:
D

2R
where:  = Bending strain in outer fibre

D = Pipe outer diameter [m]

R = Bending radius [m]

Bend thinning calculations shall be performed. Recommended formula for calculating

bend thinning is as below.
bend thinning % = 50/(n+1)%
tb = (1-bend thinning) x t
where,
t= nominal thickness.
n= inner bend radius/pipe outer diameter.
tb = pipe wall thickness after bending.
In exceptions where severe space constraints exists, cold field bends may be made to
a shorter radius than shown above provided that, after bending, the permanent bending
strain is within 2%, the pipe ovality is not greater than 97.5%and the wall thickness is
not less than permitted by design. A field test bend shall be made to demonstrate that
the cold field bends with shorter radius than shown above are with smooth surface and
free from buckles, wrinkles, cracks, coating damages and other evidence of mechanical
damage.
Elastic bend radius shall be as per approved calculations or 500 x D whichever is more.
This value of elastic bend radius shall be indicated on the alignment sheets.
4.4 Crossings

The design of crossings depends in general on the installation method.

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Casings for the crossing of roads shall not be used for metallic pipelines, because of the
difficulty in providing the pipeline with adequate protection against external corrosion.
CS or HDPE casings should be used for non-metallic pipelines. Calculations shall be
approved prior to use of CS or HDPE casings. HDPE casings shall not be used at
crossing locations, where heavy loads such as rig movement is expected.
Trenchless crossings (e.g. horizontal directional drilling, micro-tunnelling) should be
used for long crossings and where constraints do not permit open trench solutions.
The recommended minimum covers at crossings are given in Table 3.
A minimum vertical separation of 0.5 m shall be kept between the pipeline and any
other buried structures, e.g. existing pipelines, cables, foundations, etc.
Detailed road crossing analyses shall be performed using API RP 1102 for new
crossings, taking into account all potential traffic loads (refer to SP-2284 for traffic
loads) or where unusually heavy traffic loading is foreseen at the road crossings of new
pipeline. The stress levels in pipeline at the crossing shall be within the allowable
equivalent stress for functional plus environmental loading noted in Table 2 of Para
4.3.5. Buried pipe tends to ovalize under the effects of earth and live loads. This ovality
shall be calculated with deflection lag factor of 1.0, as per section 4.2 of American
lifelines Allianz technical paper on “Guidelines for the design of buried steel pipe” and
shall be limited to 2.5%.
HDPE casing calculations should be done in accordance with “Plastics Pipe Institute
Hand Book” (www.plasticpipe.org)
Allowable loads per road crossing shall be fully documented and shall form part of the
handover documentation.

4.5 Burial Philosophy / Pipeline Protection

Onshore Class 1 pipelines, which are Class 1 by virtue of Health and Safety
considerations as specified in Appendix 1, shall be buried to protect them from
mechanical damage, fires and tampering. The recommended minimum covers are
given in Table 3, based on ASME B31.8 Article 841.1.11, but modified for increased
safety margins and vehicle loading at crossings. Class 1 pipelines (which are not class
1 by virtue of Health and Safety) may be installed aboveground if this can be shown to
reduce NPV life cycle costs. Class 2 and Class 3 pipelines may be installed above
ground. If the criticality classification of Gas lift lines permits aboveground installation,
then ALARP demonstration shall be performed and all risks shall be mitigated for above
ground installation. Gas flowlines from gas wells SHALL [PS] not be installed
aboveground.
In determining depth cover in agricultural areas, the depth of ploughing and of drain
systems shall be considered.
The location of buried pipelines shall be clearly identified by markers and windrows. In
areas where the risk of interference by mechanical excavators is high, a warning tape
should be installed in the trench above the pipeline to further lower the risk.
In areas where lines can be covered under blown sand, the supports of above ground
pipelines shall be of the goal post type to avoid external corrosion. Pipe supports should
be designed in accordance with GU-629, however, wear plates or reinforcement
sleeves shall only be attached to the line by means of friction clamps or circumferential
fillet welds. Longitudinal welding directly onto the linepipe shall not be allowed.
All GRP lines shall be buried.
Buried pipelines operating at high temperatures may be susceptible to upheaval
buckling caused by high compressive loads. Upheaval buckling can be prevented either
by expansion offsets regularly spaced along the pipeline, or a sufficient burial cover.

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The use of expansion bellows to accommodate thermal movement is not

recommended. Reference is made to DEP 31.40.10.16-Gen and OTC 6335/ K Peter’s
technical paper. Upheaval buckling calculations shall be performed for all buried lines
with design temperatures 85 deg C and above.

TABLE 3 RECOMMENDED MINIMUM COVER FOR ONSHORE PIPELINES

MINIMUM COVER (M) (Note 1)

LOCATION CLASS (as defined in IN NORMAL GROUND IN ROCK, REQUIRING
ASME B 31.8) BLASTING OR ROCK
CUTTING (note 4)

Location Class 1 0.6 0.50

Location Class 2 0.90 0.60
Location Class 3, 4 and Flood Plain 1.2 0.90
Public and private roads, Wadi, live 1.50 1.50
stock passage crossings

NOTES
1. The cover refers to the undisturbed ground level. Additional protection by way of minimum
750mm high Windrow shall be provided over the buried pipeline.

2. For pipelines transporting category A and B fluids, the minimum cover to the pipeline shall
meet the requirements of Location Class 1 above.

3. Shallow burial of Class 1 steel and GRP pipelines and flowlines may be considered in areas
of very hard rock. Shallow burial to a minimum depth of cover of 0.3 meter is acceptable
provided that it can be demonstrated by calculations that no risk of upheaval buckling exists
without any additional load protection. If upheaval buckling exists gabions or similar load
protection devices shall be installed along the full length of the pipeline as additional
protection where shallow burial has been accepted.. Gabions shall be designed as per
STD-2-4107-001 to cover the width of the trench and slabs shall be designed as per STD-
2-4106-01. Where shallow burial has been accepted, properly designed vehicle crossings
shall be provided at 2 km intervals.

4. Hard rock excavation is excavation that requires blasting or rock cutting (breaking).

4.6 Stability

All submerged sections of onshore pipelines in floodable areas, high water table areas,
wadi crossings, etc., should be stable under the combined action of hydrostatic and
hydrodynamic forces. The on-bottom stability can be achieved by increasing the pipe
wall thickness, by the application of concrete weight coating, by spaced anchor points,
by trenching, or by burial. Special considerations shall be given to pipelines installed in
weak soils (e.g. peat or soft sand, false fills), at dyke and sand dune crossings, etc. as
well as anchor and thrust block locations where differential settlements may lead to
pipeline loss of integrity.
4.7 Corrosion Protection And Monitoring
4.7.1 External Corrosion

All metallic buried pipelines including duplex material pipelines, shall be coated
externally by a suitable anti-corrosion coating, supplemented by cathodic protection (for
duplex steel pipelines, Company Materials and Corrosion department should be
consulted for specific recommendations and requirements on CP).

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Coatings for pipelines, such as fusion-bonded epoxy (FBE) and three-layer polyethylene (3LPE), generally provide excellent corrosion protection. In the
event that the coating is damaged or degraded and the bare steel substrate is exposed, the pipeline is still protected from corrosion by CP.
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To ensure that adequate cathodic protection can be demonstrated at all times, pipelines
shall be electrically isolated individually from the plants to which they are connected.
The design of cathodic protection systems for onshore pipelines shall be carried out in
accordance with Specification SP-1128.
For 132kV and above over head power line running parallel to the pipeline, if the
separation distance from the pipeline is less than 500m and the length of parallelism is
more than 0.5km, then mitigation study is required and mitigation measures shall be
implemented as per SP-1128.
For 33kV and below over head power line running parallel to the pipeline, if the
separation distance from the pipeline is less than 15m and the length of parallelism is
more than 0.5km, then mitigation study is required and mitigation measures shall be
implemented as per SP-1128.
A specialist CP Engineering Consultant shall execute the CP design and mitigation
measures. The PDO CFDHs for Electrical Engineering and Corrosion & Material should
also be consulted.
The sections of the pipeline that are externally insulated (either for thermal
requirements or fire protection) should be designed to prevent ingress of water in the
annulus between the pipeline and the insulation, and should be inspectable for external
corrosion.
Cathodic overprotection in terms of differential potential shall be avoided. Duplex
stainless steel and higher grade carbon steels (above L415) are particularly sensitive to
hydrogen embrittlement caused by excessive cathodic protection voltage.
The requirement of isolating joints SHALL [PS] be confirmed by M&C TA2. Where
permitted electrical isolation of pipelines from plants shall be done by isolation joints.
Isolating joints shall comply with requirements of SP-1236.
Short buried sections of above ground pipeline (e.g. road crossings, wadi crossing,
sections likely to be covered by blown sand), SHALL [PS] be externally protected by
using 3LPE /3LPP / wrap coat or company approved coating system as per SP-1246.
In the case that the pipeline is to be buried in highly corrosive soil and the installation of
the permanent cathodic protection system cannot be finalized before the pipeline is
buried (pipelines with long construction periods) or if specified by the Company, a
temporary cathodic protection system shall be installed. Such a system shall be
designed in the same way as a permanent cathodic protection system with the
exception that material quantities and quality shall be adequate to cover a lifetime equal
to the time of the pipeline construction until the expected commissioning of the
permanent cathodic protection system. Anode connections shall be constructed such
that they can easily be connected / disconnected during and/or after commissioning of
the permanent system.
4.7.2 Internal Corrosion

Corrosion Barriers and design requirements for internal corrosion shall be as per SP-
2161.
Polyethylene linings are susceptible to attack by aromatics, and to permeation of any
dissolved gas in the transported fluid. To prevent lining collapse when the pipeline is
depressurised, the permeated gas should be relieved from the annulus. PE Lining
systems shall comply with requirements of SP-2094. Spools and fittings used in PE
lined pipelines shall be rotolined for internal corrosion protection. Break away flanges
shall be provided to facilitate pulling of liners, as per PE liner vendor recommendations.
Break away flanges for buried lines shall be in flange pits.
Internal coatings for preventing corrosion shall only be applied if automatic joint coating
and holiday detection systems can guarantee a holiday-free application. Alternatively,

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use of internal joint sleeves (e.g. ‘thrukote sleeves’) may be considered if this does not
affect piggability and inspectability of the line.
Inhibitor injection and sampling points should be considered for corrosion mitigation and
monitoring. The requirement for inhibition shall be clearly stated and recognized during
material selection. This requirement is applicable for both piggable and non piggable
carbon steel pipelines.
Internal paint markings for individual pipe identification should not be used when
corrosive conditions will be present in service.
4.7.3 Corrosion Monitoring

For buried pipelines, the occurrence of coating damage is normally monitored by

cathodic protection measurements (refer to DEP 30.10.73.31-Gen.).Requirements for
corrosion monitoring for carbon steel pipelines shall be as per SP-2161. If the pipeline
is made of corrosion resistant material (e.g. duplex, GRP, clad steel), there is normally
no need to monitor for internal corrosion.
For carbon steel pipelines, the control of internal corrosion is normally by applying a
tight control on the process parameters (e.g. water dew point in gas transmission
systems, BS&W on crude systems, injection of corrosion inhibitor). The requirement
and type of corrosion monitoring system SHALL [PS] be confirmed by M & C TA2.
Where permitted - for buried lines, concrete pits should be installed to facilitate safe
access.. Installation of corrosion access fittings shall be done as per PR-1642. . The
location and number of pits should be determined in consultation with the Company
corrosion control support function.
Carbon steel lines laid above ground shall have access for inspection by MFL tools and
by UT. Supports should have a minimum elevation of 300 mm above grade level.
When corrosive conditions, which may lead to significant corrosion damage, are
present, either internally or externally, a complete inspection of the pipeline should be
carried out using intelligent pigging. Intelligent pigging should also be used when the
criticality of the pipeline is such that proof of continued integrity is required.
4.8 Internal Flow Coatings

Internal flow coatings, as per coating system specified in SP1246 may be used in the
following situations: to limit corrosion during transit, storage and construction, to
facilitate precommissioning, to reduce hydraulic friction losses, pig wear and the
formation of pyrophoric dust. It is highlighted that flow coating is NOT a corrosion
protection mechanism.
Pyrophoric dust (FeS) may be produced in pipelines, when the fluid contains H2S (even
in small quantities), under specific conditions. FeS will form when the fluid is in contact
with bare steel pipe over a sufficient period, and the water vapour content of the gas is
in excess of 60 percent of the content corresponding to the water dew point. FeS
creates operational problems, particularly at pressure reduction stations; it is a hazard
when it comes in contact with air, e.g. when it is recovered at a pig receiver (self
ignition). Finally, the dust can accumulate at isolating flanges and, since it is conductive,
render them ineffective. When pyrophoric dust is expected, internal flow coating of the
pipeline is strongly recommended (coating at the field welds, however, is not required).
The hydraulic studies conducted during the conceptual and FEED stages of a project
shall include an assessment of the economic benefits of use of flow coat. The resulting
reduction in friction pressure loss may suffice to reduce the line size and or allow
considerable savings in required compression power.

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4.9 Provision For Pigging

4.9.1 General

All pipelines, except short length spur lines shall be suitable to pass pigs, even if pig
traps are not permanently installed. Pigging should be used for the pre-commissioning,
commissioning and decommissioning of pipelines, cleaning and corrosion control
(removal of wax, debris and stagnant liquids, batch inhibition), the control of liquid hold-
up in gas lines, inspection with intelligent pigs, and pipeline repairs if required.
All Class 1 pipelines shall be designed to allow intelligent pigging, maintenance pigging,
except if they are constructed from non-metallic or corrosion resistant metallic materials
or PE lined pipelines. Guidelines and requirements for intelligent pigging are given in
SP-1210.
Class 1 pipelines made of corrosion resistant materials, non metallic and PE lined shall
have provision for maintenance pigging. This is required to allow pigging, to take place
efficiently, without having to drain large volumes of hydrocarbons. The provision for
pigging may consist of a pig trap or pig valves, or a barred tee and a full-bore valve with
a blind flange to which a pig trap can be connected. These lines may be provided with
removable spools, in lieu of these provisions, only in cases where it is feasible to install
temporary pigging facilities on removal of these spools, when required to facilitate
commissioning / decommissioning pigging. Any maintenance pigging activity in non-
metallic pipelines shall require approval from Material and Corrosion function. Special
attention should be paid to the requirement to maintain a minimum internal diameter
and bending radius for the whole length of the pipeline. Permanent pigging facilities
should be justified based on an analysis of pigging frequency and operational
constraints. The maximum acceptable distance between pigging stations should be
decided on the basis of anticipated pig wear and amount of collected solids, but should
normally not exceed 150 km.
The use of spheres should be limited to batch inhibition and to liquids removal in two-
phase lines. Spheres may be considered when automatic launching is envisaged, or for
pigging of branch lines, when the use of conventional pigs is not possible.
Permanent pig signallers (non-intrusive strap-on) should only be fitted when frequent
pigging operations are anticipated. (i.e. more frequent than once per Quarter).
Otherwise temporary non-intrusive strap-on pig signallers shall be used, when needed.
Ancillary equipment should be flush mounted and barred tees should be used on main
line sections of the pipeline. In the case of spheres, sphere tees should be used with
drainage provision to prevent collection of debris and liquids, which could cause
corrosive conditions in the sphere tee annulus.
The design of permanent pig trap systems shall be in accordance with DEP
31.40.10.13-Gen. Where temporary pig traps are to be used, the extent to which the
requirements and recommendations of DEP 31.40.10.13-Gen. are to be applied should
be agreed with Company.. Operational pigging requirements detailed in SP-1210 shall
be considered during the design of pig trap systems. When designing the temporary
pigging facilities due cognisance shall be given for the requirements of SP-1125 for
isolations. The end closure shall be in vertical plane, even when slope is provided on
the barrel.
4.9.2 Isolation

The isolation of the main stream and of the ancillary equipment on pig traps requires
careful choice of valve type and configuration to allow safe operation, maintenance and
repair without depressurising or decommissioning the pipeline. A double block and
bleed system, consisting of two separate isolation valves in series with a bleed point in
between to allow diversion to a safe location of any fluid leaking through either valve,
should be used as prescribed in SP-1125 “Isolation of Process equipment”.

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4.9.3 Intelligent Pigs

The following should be considered in the design of pipelines, based on the

requirements for intelligent pigging:
 The internal diameter variations of main line sections should be limited. This
may require the heavy wall sections of the pipeline (e.g. road or railway
crossings) to be specified based on the internal diameter, instead of the outside
diameter normally used.
 Where sections of different internal diameter are connected together, the
chamfer angle at the transition should not exceed 14 degrees, measured from
the axis of the pipe (i.e. a taper of 1:4).
 The main line valves shall be full bore.
 All main line bends should have a sufficient radius to allow passage of
intelligent pigs. Induction heated hot bends in the pipeline should be of the
following minimum radii.
o Pipeline below DN150: 7D to 10D
o Pipeline DN150 to DN 250: 5D
o Pipeline DN 300 and above: 3D

4.10 Line Sectionalising And Emergency Shut Down Valves

4.10.1 General

Requirements for the design of Block Valve Stations and associated piping including
valve selection requirements are given in Specification SP-1032.
4.10.2 Sectionalising Block Valves

The spacing of sectionalising block valves should consider limiting the pipeline contents
between adjacent valves.
Criteria for spacing and location of block valve stations shall be as per SP-1032 section
2.1 requirements.
Future tie-ins from other fields or tie-in of (partial) looplines should be considered in the
design, and selection of the location of block valve stations. BVS’s should preferably be
located on a local high spot with good access from public roads, and never in a Wadi or
low point.
4.10.3 Emergency Shutdown Valves

ESD valves should be located at each end of the pipeline, and on the incoming and
outgoing sections of any plant en route, such as compressor or pumping stations and
intermediate pig trap stations. The valves should be located close to the plant fences,
and they should preferably be welded into the main pipeline to minimise the number of
potential leak paths. (refer to DEP 31.40.10.13 and SP-1125 Isolation of Process
Equipment).
ESD valves shall not incorporate bypass arrangements as per SP-1243. Pressure
balancing, if required prior to valve opening, should be done using the operational
valves located immediately upstream or downstream of the ESD valve.
4.10.4 Valve Actuation

Three methods of operating block valves may be considered: locally, remotely

(preferred) and automatically (not preferred). The appropriate method shall be
determined from a study of the likely effects of a leak and acceptable release volumes,
based on the total time in which a leak can be detected, located and isolated. The
closure time of the valves shall not create surge pressures in excess of the pressure
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allowed by this specification, as applicable. The option of installing a two-speed

actuator may be considered to reduce valve closure speed over the last 10% to 20% of
the valve travel movement. However, the failure rate of these two speed actuators shall
be assessed and reliability confirmed before its use.
Automatic valves can be activated by detection of low pressure, increased flow, rate of
loss of pressure or a combination of these, or a signal from a leak detection system.
Low pressure detection shall not be used if the control system is designed to maintain
the pipeline pressure. Automatic valves shall be fail-safe to close.
Valve actuators & gearboxes should be adequately sized to operate valves without over
gearbox damage and shear pins should be fitted to valve stems to prevent gearbox /
actuator damage in event of high torques due to valve damage / debris in valve seats /
ball.
The process safeguarding system when an emergency shutdown condition occurs at
the plant or facility shall actuate the emergency shutdown valves.
4.10.5 Leak Detection

The requirements for and type of leak detection systems should be derived from an
evaluation of the criticality of the pipeline with regards to the consequence of a leak,
depending on the transported product, the potential amount released, the sensitivity of
the environment, the level of preparedness of emergency response system in place and
the location class, as defined in ASME B31.8. The requirements of DEP 31.40.60.11-
Gen. should apply.
4.10.6 Blowdown

Facilities for operational and emergency pipeline depressurisation shall be available at

one end of the pipeline and, for pipelines transporting category C and D (but not E )
fluids, which are gaseous at ambient temperature and pressure, and at each
sectionalising valve location. The capacity of the blowdown system should be such that
the pressure in the pipeline can be reduced as rapidly as practicable without requiring
that the material of the pipeline be exposed to temperatures below the design
temperature. The facilities for blow down shall be examined during the FEED design
review.
Cold vents shall be of sufficient height that the flammable envelope has disappeared
prior to reaching ground level. The fenced sterile area surrounding the vent shall be
sized such that the radiation levels from an ignited (accidentally) vent complies with the
requirements of DEP 80.45.10.10 “Pressure Relief, Emergency Depressurising, Flare
and Vent Systems”.
For category C, D & E fluids, the material specified for the blowdown system should be
compatible with the low temperatures encountered during blowdown.
4.11 Overpressure Protection

The risk of pipeline over pressurisation shall be controlled by pressure safe guarding
system in accordance to GU-437 and DEP80.45.10.11.
4.11.1 Maximum Allowable Pipeline Pressures

There are two governing levels of pressure in the safeguarding of pipelines against
overpressurisation: the Maximum Allowable Operating Pressure (MAOP), which shall
not be exceeded at any point along the pipeline during normal continuous operations,
and the Maximum Allowable Incidental Pressure (MAIP), which shall not be exceeded
at any point along the pipeline during upset conditions, i.e. conditions of limited
frequency and duration.
MAIP for metallic pipelines:

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The maximum allowable incidental pressure (MAIP) shall be 1.1 times MAOP for
Category A and B fluids. However for Pipelines with category C, D and E fluids, MAIP is
limited to a pressure which results in a hoop stress not exceeding 75 % of SMYS.

MAIP in GRP lines:

The maximum allowable incidental pressure (MAIP) for GRP lines shall not exceed the
design pressure of the pipeline.

4.11.2 Overpressurisation by the Upstream Facility

When the pressure immediately upstream of the pipeline is in excess of the evacuation
requirements, the pipeline may be designed to operate at lower pressures, in which
case a pressure control system shall be installed to limit the pipeline inlet pressure.
However, any type of pressure control system shall not be considered as an
overpressure protection system.
When, following failure of the pressure control system, the maximum pressure which
may be generated by the upstream facility is such that it results in pipeline pressures in
excess of MAIP, an overpressure protection system shall be fitted between the
upstream facility and the pipeline. Four methods can be considered as per SP-2283:
 Fully rated mechanical design
 Combination of Full flow relief and Safety Instrumented function
 Combination of Partial flow relief and Safety Instrumented function.
 Safety Instrumented functions as ultimate protection.
 Reference should also be made to DEP 32.80.10.10, DEP 80.36.00.30 and
DEP 80.45.10.11. In case of conflicting or ambiguous requirements, CFDH
pipelines (UIPT2) and CFDH control & automation ( UOA2) shall be consulted
to clarify and agree requirements.
4.11.3 Surge Pressures

Pressure surges in pipelines are created by a change in momentum of the moving

stream (e.g. resulting from valve closure). The occurrence of pressure surges should be
determined by transient pressure analysis, using a specialised simulation computer
program such as TLNet. OLGA should be used to analyse transient hydraulic behaviour
of multiphase pipelines.
Surge pressures are particularly critical for pipelines transporting liquid fluids, because
of the high density and lower compressibility compared to gaseous fluids. Although
damping of the pressure wave initiated at the point of blockage occurs as it travels
upstream, surge may in some cases result in the highest pipeline pressure at a location
well upstream of the point of origin. This may occur in particular for liquid pipelines in
hilly terrain.
The pipeline system shall be designed such that surge pressures cannot exceed MAIP
at any point along the pipeline, and will not trigger the system for overpressure
protection from the upstream facility if fitted.
Methods of preventing the generation of unacceptably high surge pressures include
valve closure speed reduction, use of two speed actuators or special fast-response
pressure relief systems installed to close to the point of surge initiation. Surge pressures
from closure of mainline valves at block valve stations can be avoided by installing in-
line relief valves or surge relief valve on the bypass line (refer to SP-1032).

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4.11.4 Thermal Effects

If a pipeline, or part of it, can be blocked-in while containing a medium with a low
compressibility (e.g. liquids), the effect of possible thermal expansion of the blocked-in
fluid volume on the internal pressure of the pipe section (e.g. due to solar heating)
should be investigated.
The pipeline system shall be designed such that pressures generated by thermal effects
cannot exceed MAIP at any point along the pipeline, and will not trigger the system for
overpressure protection from the upstream facility if fitted. When those pressures are
part of the routine operation of the pipeline, i.e. they occur a significant portion of the
time they shall not exceed MAOP.
Applying relief valves may affect the protection against overpressure due to thermal
effects. Except on assemblies which can be isolated such as pig trap systems and slug
catchers, an isolation valve may be installed between the pipeline and the relief valve
for maintenance purposes, provided that procedural controls are in place to ensure that
the isolation valve remains normally in the open position, and that the pipeline is not
required to be shut in while the relief valve is out of service.
Thermal relief valves located on above ground pipework between valves (e.g. Block
valve station pipework) may be routed back into the main pipeline (but not across ESD
valves).
4.12 Branch Connections And Fittings

Threaded connections (pipe to pipe, fittings), Positive Seal Coupling (PSC), slip-on
flanges and mitred connections shall not be used in any part of the pipeline system ,
except for 150# rated category A fluid Pipeline. The minimum length of pup pieces shall
be the larger of D or 500 mm. An exception to this is the fabrication of GRP
components where the fabrication of mitered bends is allowed, provided that the bends
are qualified as per SP-2092 and fabricated under factory controlled conditions as a
single fitting connected to straight pipe.
All branch connections (except for pressure relief systems, see 4.11) should be
provided with a valve to permit isolation of the branch from the pipeline.
For mechanical strength reasons, there shall be no branch or instrument connection
smaller than DN50 on pipelines except in case of PE liner vents (with ½” valves) which
shall be as below:
Upto and including 6” pipe - ½” size
From 8” to 12” pipe - 1” size
14” pipe and above - 2” size

For pipelines smaller than DN50, the branch connections should have the same
diameter as the pipeline. Weldolets larger than DN 100 shall not be used. Sockolets
shall not be used.

For flanges with a lower yield strength than the mainline pipe to which they are welded,
the pipe to flange transition design shall be confirmed to comply with the transition
requirements specified in ASME B31.4/B31.8.
Piping materials should conform to DEP 31.38.01.15-Gen. for EP applications, and to
DEP 31.38.01.12-Gen. for R & C applications.
Gaskets for flanged connections should conform to the following:
 Raised face spiral wound gaskets for flanges class 1500 and below

 Ring type joints for all flanges above class 1500.

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The number of flanged connections in pipeline systems should be minimised, i.e. tie-in
welds and welded mainline BVS and ESD valves are preferred. Flanged joint can be
buried for Category A fluids only, if the proposal on flange joint installation is approved
by Company. Special precautions shall be taken while tightening flanged joints.
Methods include use of conventional wrenches/spanners, hydraulic torquing and
hydraulic jack bolt tensioning. Selection of a particular method for flange tightening shall
depend on bolt size, system pressure rating, service and material of construction. UEC
group shall be consulted for use of appropriate method and procedures.
Branch connections to operating pipeline shall be made by hot tap technique as
detailed in DEP 31.38.60.10.
4.13 Telecommunications

For any pipeline system, telecommunications should be provided to assist in the

operational and maintenance activities (pipeline inspection, end to end communications
for pigging operations, emergency situations, etc.). Pipeline monitoring from a central
location and remote operations involving the use of reliable telecommunications such as
fibre optic cables should be considered for all pipelines transporting toxic fluids (i.e. fluid
E ).
4.14 Records
A comprehensive set of design documents shall be produced and retained for the life of
the pipeline. These documents should include all the design calculations and
assessments, which led to the technical choices during conception and design of the
pipeline. They shall form part of the hand-over documentation (Section 8).

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5 MATERIAL PROCUREMENT
5.1 General

All materials shall be procured from Manufacturers/Suppliers approved by the

Company, as specified in the latest AVME (Approved Vendors of Materials and
Equipment). The Company shall specify if, and to what extent, he intends to perform
surveillance inspection. This shall be in accordance with SP-2269.
5.2 Re-Use Of Materials

Materials from an abandoned pipeline may be used for a new project, provided that they
can be certified as fully complying with the specifications required for the new
application. Materials shall be inspected and tested to the level presently specified for
new materials, i.e. by visual, destructive and non-destructive means..
5.3 Spare Materials
5.3.1 Metallic Linepipe

Sufficient spare material should be ordered to cover for route deviations and possible
pipeline damage during construction, and the set-up of a material contingency stock for
pipeline emergencies during the operational phase. The quantity of spare materials
depends on the pipeline length, route deviations, test bends, location and the likelihood
of damage during transport, construction and operation. The following quantities are
provided for guidance. Any additional quantity to the below should be approved by
Company.
Route length Spare linepipe

Less than 100 m 12 m

100 m to 1 km 12m (min) < 5% < 50 m (max)

1 km to 10 km 50 m (min) < 3% < 250 m (max)

10 km to 200 km 250 m (min) < 1.5% < 1000 m (max)

above 200 km 0.5 percent of route length

For each pipe size, spare linepipe material for welding procedure/welder qualification
tests shall be ordered in consultation with welding engineers in addition to spares
mentioned above. The contingency stock of linepipe material should consist, for each
pipe size, of 60 m for onshore pipelines if required by Company.
Pipe information such as heat number and manufacturer shall be permanently marked
on the spare pipes for future references and tracking.
5.3.2 GRE Pipeline

Sparing philosophy for GRP linepipe and fittings should be as per the
recommendations of GRP manufacturer and shall be approved by Company
5.3.3 Miscellaneous spares

Procurement of additional spares for two years operation, should be considered, in

consultation with Company.

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5.4 Linepipe Material

Carbon steel linepipe shall be in accordance with the Shell DEP 31.40.20.37- for all
Class 1 Pipelines, which are amendments / supplements to ISO 3183-specifications.
For class 2 and 3 pipelines, linepipe should be procured as per ISO 3183, PSL 2. DSS
linepipes shall be in accordance with Shell DEP 31.40.20.34. The material
specifications for linepipe shall be approved by pipeline TA2 (ATA2) with inputs from
material TA2 (RTA2).
SMLS, HFW and SAW linepipes can be used for most services. For restrictions on use
of HFW pipes, please refer to SP- 2161. HFW pipes shall be manufactured in
accordance with SP-2272. For HFW pipes the D/t shall be restricted to 65.
GRP linepipe and fittings shall be procured in accordance with SP-2092, SP-2156 and
DEP 31.40.10.19-Gen and the purchase requisition shall be prepared by approved
design consultant and approved by Company Pipeline TA2, in consultation with Material
TA2.
FCP linepipe and fittings shall be procured in accordance with SP-2156 / DEP
31.40.10.20-Gen.
5.5 Pipeline Components
Fittings, flanges and special components installed in the pipeline shall be procured in
accordance with applicable company standards as indicated below.
COMPONENTS Applicable standard for criticality Applicable standard for criticality
class 1 pipelines (see notes below) class 2 & 3 pipelines (see notes below)
Pipeline Fittings DEP 31.40.21.30 International standard
(ISO 15590-2/ASME B
16.9/MSS SP-75)
Pipeline Flanges / DEP 31.40.21.34 International standard
Forged branch fittings (ISO 15590-3/ASME B
16.5/ASME B 16.47/MSS SP-
44/MSS-SP-97)
Pipeline Split Tees SP – 1199 SP – 1199
Induction bends DEP 31.40.20.33 International standard
(ISO 15590-1)
Pipeline Isolating Joints SP – 1236 SP – 1236

Pig trap systems DEP 31.40.10.13 DEP 31.40.10.13

Pipeline Check Valves SP – 1200 API 6D/ISO 14313
Pipeline Ball Valves SP – 1201/ API 6D/ISO SP – 1201/ API 6D/ISO 14313
14313 (Note-1) (Note-1)
Notes:
1. All mainline valves in pipelines upto first isolation valve shall be as per SP-1201,
except exclusions as mentioned in SP-1201 clause 2.1.
2. The material specifications shall be approved by pipeline TA2 (ATA2) with inputs
from material TA2 (RTA2).
3. For small orders / supply, of pipeline components (except linepipe) from stockist –
refer to Appendix 5 for alternative acceptable materials to above.
Components and fittings shall be compatible with the linepipe material in terms of
weldability and also conform to the bevel geometry constraints detailed in the pipeline
codes.

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For projects, with design temperature range of 5 to 82° C, pipes, fittings, flanges for
sizes 2” and below, are acceptable as per MESC / applicable equivalent piping class.
5.6 External Coatings

The following specifications shall apply for external corrosion protection coating of
linepipe:
 DEP 31.40.30.31-Gen. for polyethylene/polypropylene coating; For temperature
limitations, refer to ISO 21809-1, Table 1.

 DEP 31.40.30.32-Gen. for fusion bonded epoxy coating.

 DEP 31.40.30.37-Gen, external field joint and rehabilitation of coating systems

for line pipe

 SP-1246– Specification for Painting and Coating of Oil and Gas Production
Facilities

The external anticorrosion coating is as per material selection report and shall be
guided by the minimum / maximum operating fluid temperature, the terrain and soil
conditions and subsequent coatings (concrete weight coatings) and type of cathodic
protection systems planned.
5.7 Internal COATINGS

The following specifications apply:

 SP-2094 for PE liners in carbon steel pipelines and flowlines

 SP-2217 Specification of Internal FBE and Liquid Coating Systems.

5.8 Concrete Coating

The application of concrete coating for pipelines shall be carried out in accordance with
SP-1208.
5.9 Records

The material test certificates and equipment vendors' data (including

operating/maintenance instructions), shall be digitalised and to be included in the hand-
over documentation and shall be kept for the life of the pipeline.
Each individual pipe should be allocated an identification number at the pipe mill, and
the same number should be used for coating and construction records. For large
pipeline projects, a computer-based system for recording and tracking each individual
pipe joint from the pipe mill to the construction location should be considered.

6 CONSTRUCTION
6.1 General

Pipeline construction shall be performed in accordance with specification SP-1208, as

applicable and other relevant sections of the ASME Codes.
Construction activities close to existing facilities should be planned in coordination with
the Pipeline Operations.

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Field welding of carbon steel pipelines SHALL [PS] be performed and examined in
accordance with Specification SP-1177 for all Class 1 pipelines and as per SP-1174 for
Class 2 & 3 pipelines.

Welding / jointing qualifications, for both the procedure and the welders, should be
carried out under actual field conditions. Jointing of GRP pipelines shall be as per
manufacturer’s recommendation.
6.2 Construction Hydrotesting

All new pipelines shall be tested after construction and burial (if applicable) to prove the
strength and leak tightness, by means of a hydrostatic pressure test.
The hydrostatic pressure testing of metallic pipelines shall be as per SP-1212.
Hydrostatic pressure testing of non-metallic pipelines is covered in SP-1208.
Tie-in welds, i.e. welds, which are not subject to the hydrostatic pressure test, shall be
subjected to additional non-destructive testing (e.g. ultrasonic inspection).

7 PRE-COMMISSIONING
Pre-commissioning of pipelines shall be as per DEP31.40.50.30-Gen and SP-1208.

8 HAND-OVER DOCUMENTATION
The pipeline documentation should be structured in a manner such that all parties
involved with the operation, maintenance and inspection of the pipeline system have
ready access to all data required to control pipeline integrity.
Hand-over documentation shall comply with the requirements of SP-1131. Handover of
documents shall as a minimum include all required input data into CIMS - Corrosion
Inspection Management System and SAP. Asset registration of pipelines / flowlines
(including FCP flowlines) SHALL [PS] be in accordance with SP-2291.

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9 REFERENCES
In this SP, reference is made to the following publications, the hierarchy of which is
shown in Figures 3:
Note: Unless specifically designated by date, the latest edition of each publication shall
be used, together with any amendments/supplements/revisions thereto.

Title Number
Code of Practice
Maintenance and Integrity Management CP-114
Project Engineering CP-117
Health Safety and Environment Management System CP-122
Risk and Opportunity Management CP-131
Specification
Specification for the Design of Pipeline Block Valve SP-1032
Stations

Isolation of Process Equipment specification SP-1125

Specification for Cathodic Protection Design SP-1128
Specification for Handover and As-built documentation SP-1131
Specification for Welding of Class 2 & 3 Pipelines SP-1174
Specification for Welding of Class 1 Pipelines SP-1177

Design for sour service specification SP-1190

Procurement Specification for Pipeline Split Tees SP-1199
Procurement Specification for Pipeline Check Valves SP-1200
Procurement Specification for Pipeline Ball Valves SP-1201
Pipeline Construction Specification SP-1208
Pipeline Integrity Management SP-1210
Hydrostatic Pressure Testing of New Pipelines SP-1212
Pipeline Repairs SP-1235
Pipeline Isolating Joints SP-1236
Corporate Philosophy for Control & Automation SP-1243
Specification for painting and coating of oil and gas SP-1246
production facilities
Technical Authority System
Specification for Polyethylene Liners in Carbon Steel SP-2061
flowlines and pipelines

SP-2094
GRP specification - Part 1 SP-2092
Specification for use of non-metallic material SP-2156
Materials Selection & Corrosion Control for Surface SP-2161
Operating Process Facilities

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Title Number
Design Class Selection for Capital Projects SP-2199
Specification of Internal FBE and Liquid Coating Systems SP-2217
Specification for Quality Intervention for Provision of SP-2269
Products
Hot tap management specification SP-2276
Off-Plot Production Facilities Overpressure Safeguarding SP-2283
Design of Pipeline Road crossings SP-2284

Procedure
Pipeline Pigging Procedure PR-1082
Commissioning and start up PR-1159
Technical standards selection and challenge procedure PR-2194

Guideline
Environmental Assessment Guideline GU-195
Guidelines for The Protection Of Buried Sections Of GU-368
Surface Laid Pipelines/Flowlines
Guideline on SIL Assessments and Implementation GU-437
Guideline

Guidelines for Project Certification and Completion GU-623

Management System (CCMS) Users
Application & Selection of Standard Pipe Supports GU-629

Piping Stress Analysis Design Basis GU-706

SHELL STANDARDS
Global technical standards index DEP 00.00.05.05-Gen.

Definition of temperature, pressure and DEP 01.00.01.30-Gen

Toxicity levels
Cathodic protection design, installation, and DEP 30.10.73.10-Gen.
commissioning
Piping – General requirements DEP 31.38.01.11-Gen.
Piping Classes – refining and chemicals DEP 31.38.01.12-Gen.
Piping classes - exploration and production DEP 31.38.01.15-Gen.

Hot tapping on pipelines, piping and equipment DEP 31.38.60.10-Gen.

Design of pipeline pig trap systems DEP 31.40.10.13-Gen.

Upheaval buckling of pipelines DEP 31.40.10.16-Gen.

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Title Number

Line pipe induction bends (amendments / supplements to DEP 31.40.20.33-Gen.

ISO 15590 – 1)

Linepipe for critical service DEP 31.40.20.37-Gen.

(Amendments/supplements to ISO 3183)
Pipeline Fittings (amendments / supplements to ISO DEP 31.40.21.30-Gen.
15590-2)

Carbon and low alloy steel pipeline flanges for use in oil DEP 31.40.21.34-Gen.
and gas operations (amendments / supplements to ISO
15590-3)
Concrete coating of linepipe DEP 31.40.30.30-Gen.
External polyethylene and polypropylene coating for line DEP 31.40.30.31-Gen.
pipe
External fusion-bonded epoxy powder coating for line pipe DEP 31.40.30.32-Gen.

Pre-commissioning of pipelines DEP 31.40.50.30-Gen.

Pipeline leak detection DEP 31.40.60.11-Gen.

Safety Instrumented systems DEP 32.80.10.10-Gen

Selection of materials for life cycle performance DEP 39.01.10.11-Gen.

Pressure relief, emergency depressuring, flare and vent DEP 80.45.10.10-Gen.

systems

INTERNATIONAL STANDARDS
Petroleum and natural gas industries — Steel pipe for ISO 3183
pipeline transportation systems
Petroleum and natural gas industries – Glass reinforced ISO 14692
Plastic Piping (1-4 Parts)
Issued by:
International Organisation for Standardisation
1, Rue de Varembé
CH-1211 Geneva 20
Switzerland

AMERICAN STANDARDS
Pipeline transportation systems for liquid and slurries, ASME B31.4
Gas transmission and distribution piping systems, ASME B31.8

Recommended practice for liquid petroleum pipelines API RP 1102

crossing railroads and highways
Specification for Linepipe API Spec 5L
Issued by:
American Petroleum Institute
1220 L Street Northwest

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Title Number
Washington, DC 20005
USA.
Materials for use in H2S-containing environments in oil and NACE MR0175
gas production
Issued by:
National Association of Corrosion Engineers
P.O. Box 218340
Houston, TX 77218
USA

SOFTWARE
CAESAR II
Pipesim
HYSYS
OLGA
NATASHA
NATASHA PLUS
FRED
PIPE STUDIO
TGNET
TLNET
Pipe-RBI

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APPENDIX 1: CRITICALITY CLASSIFICATION OF PIPELINES

AND FLOWLINES
A.1.1. General
To maximise availability of pipeline, to reduce potential risk to safety, environment and
to achieve operational and maintenance excellence, it is necessary to assess criticality
of each pipeline to ensure technical integrity during development, design, construction,
operation and maintenance phase of the pipeline.
Criticality of a pipeline shall be assessed based on the risk matrix developed for safety
management within PDO and detailed in policy documents CP-122: Health Safety and
Environment Management system, CP-131: Risk Opportunity Management,
The Risk Assessment Matrix developed to derive “Pipeline Criticality Classes” is based
on the consideration of susceptibility to failure (mainly related to the perceived corrosion
rate) and the consequences of failure. All individual lines (including Pipelines, Headers
and Flowlines) shall be categorised into one of the three “Pipeline Criticality Classes”;
herein after referred to as “Class 1”, “Class 2” and “Class 3” respectively.
The susceptibility to failure is classified as follows:-
 N Not susceptible

 L Low susceptibility e.g. only under upset conditions

 M Susceptible under normal conditions

 H Very susceptible e.g. corrosion rate > 0.5 mm/yr

Consequence of failure is similarly classified as follows:-

 L Low consequence

 M Medium consequence

 H High consequence

 E Extreme consequence

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Table A1.1 outlines the Pipeline Criticality Classes resulting from the combination of
material’s susceptibility to failure and the consequences.
Table A1.1 – Pipeline Classification based on Risk Assessment Matrix
SUSCEPTIBILITY TO PIPELINE CRITICALITY CLASS
FAILURE

H Very susceptible to CLASS 2 CLASS 1 UNACCEPTA UNACCEPT

degradation BLE ABLE
SUSCEPTIBILTY CLASS

M Susceptible to CLASS 2 CLASS 1 CLASS 1 UNACCEPT

degradation under normal ABLE
conditions

L Susceptible to CLASS 3 CLASS 2 CLASS 1 CLASS 1

degradation under upset
conditions

N Not susceptible under any CLASS 3 CLASS 3 CLASS 2 CLASS 1

foreseen conditions

Economic value (USD) <100K 0.1 – 1 M 1 – 10 M > 10 M

CONSEQUENCE CATEGORY

Minor Injury Major Injury Permanent More than

total three
disability fatality
OR upto
three
Health and Safety fatalities

Minor Effect Localised Major Effect Massive

Environment Effect Effect

CONSEQUENCE CLASS L M H E

Notes:

1. Above Pipeline Criticality Class should not be confused with the location class
defined in ASME B31.8 and design class as defined in SP-2199..

2. Guidelines on selection of appropriate Susceptibility Class for different materials used in

pipeline construction and types of service are provided in section A1.2 of this Appendix –
1. The highest severity level among applicable failure modes shall be selected as
Susceptibility Class.

3. Guidelines on selection of appropriate Consequence Class on the grounds of Health &

Safety, Environmental and Economic Value are provided in section A1.3 of this Appendix -
1. Consequence Class shall be determined by the most severe risk among Consequence
Categories.
A.1.2. Susceptibility to Failure Classification
The following predominant failure modes that are relevant to PDO operations are
considered:
 Internal corrosion
 External corrosion
 Corrosion Cracking (SSC, SCC, HIC, SOHIC)
 Third party damage
 Mechanical/construction damage

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Susceptibility to these failure modes depends mainly on the pipeline material and the
service conditions namely, fluid type, pressure and temperature in the pipeline. A list of
indicative Susceptibility Classes for various materials and associated failure modes is
given in Tables A1.2 and A1.3.

Table A1.2 - Susceptibility to failure Classification for Various Materials

MATERIAL INTERNAL EXTERNAL CORROSION THIRD PARTY MECHANICAL &
CORROSION CORROSION CRACKING DAMAGE CONSTRUCTION
DAMAGE
C-steel, buried See Table A1.3 Class L for Class N for Class L or N Class L or N
pipelines with normal service.
new coatings and Class L for sour
operating at < service if
60°C. designed
Class N if accordingly
corrosion
allowance
provided.
Class M for
others
C-steel, above See Table A1.3 Class N if put on Class N for Class L or N Class L or N
ground sleepers and kept normal service
sand free.
Normally Class L

C-steel with PE Class N See C-steel above See C-steel above Class L or N Class L
liner
GRP Class N Class N Class N Class L Class L if T < 90°C
and water injection
service T< 20°C.
Class M for others
FCP Class N Class N Class L Class L Class L for T<60°C
Need to ensure
the fittings are
protected.
Duplex SS Class N Class L Class L Class L or N Class L

Note: The above failure classifications are to be further discussed and confirmed with UEC team.

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Table A1.3 - Susceptibility Classification for internal Corrosion for C-Steel in Various
Service Conditions
SERVICE TYPE SUSCEPTIBILITY CLASS (1)
Dry gas MOP > 20 bar Class L. Upset condition will be wet operation. Corrosion
mechanism is CO2 corrosion.
Class M under sour or acid conditions. Special corrosion
assessment shall be required.
MOP < 20 bar Class N. Corrosivity in upset conditions is low because of a low
CO2 partial pressure. Sour conditions require a special corrosion
assessment.
Dry & Stabilised Flow > 1.5 m/s Class N.
Condensate ( 1% water)
Flow < 1.5 m/s Class L. Corrosion prediction by HYDROCOR may reduce class to
N.
Wet separated gas MOP > 20 bar Class M. Corrosion mechanism is CO2 corrosion. Corrosion
prediction by HYDROCOR may reduce class to L. Continuous
inhibition may be required.
Class H under sour conditions. Special corrosion assessment shall
be required.
MOP < 20 bar Class L. Corrosion prediction by HYDROCOR may reduce class to
N. Sour conditions require a special corrosion assessment.
Wet condensate Class M. Corrosion mechanism is CO2 corrosion. Corrosion
prediction by HYDROCOR may reduce class to L. Continuous
inhibition may be required.
Multi-phase Flowlines & headers Class M. Corrosion prediction by HYDROCOR may reduce class
gas/condensate to L. Inhibition may be required.
Wet separated oil Flow < 1 m/s Class M depending on the corrosion control strategy. Corrosion
mechanisms are CO2, O2 and microbial. Chemical treatment may
reduce to class L. In some cases, class H if corrosion is not
controlled.
Flow > 1 m/s Class L if BS&W low. Otherwise class M. Chemical treatment may
impact on classification.
Multi-phase oil Flowlines & headers Class M. Corrosion mechanisms same as for wet separated oil.
May be reduced to class L for high liquid flow rates (> 1 m/s) and
low BS&W.
Water Class M or H depending on the corrosivity of the water. Consider
alternative material

NOTE (1) Corrosion susceptibility class may be lowered in case of a large corrosion allowance justified by a corrosion
assessment.

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A.1.3. Failure Consequence Classification

HEALTH AND SAFETY CONSEQUENCE

Health and Safety consequence of a failure is categorised based on the risks
associated with toxicity of the fluid and the pressure at which it is transported through
the pipeline. Table A1.4 provides guidelines to select consequence class on the basis of
health and safety consequences.
Table A1.4 - Health and Safety Consequence Classification

CLASS M CLASS H
System design Pressure Rating (ANSI CLASS)

1500#
(Increasing Pressure Hazard)

CLASS M
900#
CLASS L
CLASS H
CLASS E
600#
CLASS L

300#

CLASS N CLASS L CLASS M CLASS H

150#

Category A Category B Category C Category D Category E

System Fluid Category as defined in Section 2.1

(Increasing Fluid Hazard)

Table A1.5 - Health and Safety Consequence Classification Definition

CLASS POTENTIAL DESCRIPTION
IMPACT
N No/Slight injury No safety effect or slight injury or health effects (including first aid case and
medical treatment case) - Not affecting work performance or causing disability.
L Minor injury Minor injury or health effects (Lost Time Injury) – Affecting work performance,
such as restriction to activities (Restricted Work Case) or a need to take a few
days to fully recover (Lost Workday Case). Limited health effects, which are
reversible, e.g. skin irritation, food poisoning.

M Major injury Major injury or health effects (including Permanent Partial Disability) –
Affecting work performance in the longer term, such as a prolonged absence
from work. Irreversible health damages without loss of life, e.g. noise induced
hearing loss, chronic back injuries.
H Permanent total From an accident or occupational illness (poisoning, cancer).
disability OR upto
three fatalities
E More than three More than three fatalities - From an accident or occupational illness (poisoning,
fatality cancer).

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ENVIRONMENT CONSEQUENCE
Environmental consequence of a failure is categorised based on the risks associated
with possible level of damage that a failure can cause to the environment and
associated consequences. Table A1.6 provides guidelines to select consequence class
on the basis of environmental consequences. Advice of PDO’s head of corporate
environmental affairs MSE/2 should be sought to establish the environmental sensitivity
in which the pipeline is installed.
Table A1.6: Environmental Consequence Classification
CLASS POTENTIAL DESCRIPTION
IMPACT
N No/Slight effect Local environmental damage, within the fence and within systems.
Negligible financial consequences.

L Minor effect Contamination. Sufficiently large to damage the environment. No

permanent effect on the environment.
M Moderate effect Limited discharges of known toxicity affecting neighbourhood and
damaging the environment.
H Major effect Severe environmental damage. The company is required to take extensive
measures to restore the contaminated environment to its original state.
E Massive effect Persistent severe environmental damage or severe nuisance extending over a
large area. Loss of commercial, recreational use or nature conservancy
resulting in major financial consequences for the company.

ECONOMIC CONSEQUENCE
Economic consequences of a failure shall be loss of revenue (deferment cost), repair
cost and with or without loss of asset value (replacement cost). For simplicity the repair
cost may be neglected. Deferment cost may be calculated on the basis of loss of
production and duration of a deferment. Table A1.7 provides guidelines to select
consequence class on the basis of economic consequences. Relevant PDO policy
documents may be referred to arrive loss of economic value in case of a failure.

Table A1.7: Economic Consequence Classification

CLASS POTENTIAL DESCRIPTION
IMPACT
N No/Slight effect No disruption to operation, no operational upset or no damage to assets.
(total loss value less than US$ 1,0000)

L Minor effect Brief disruption, minor operational upset or minor damage to assets. (total
loss value between US$ 10000 and US$ 100,000)
M Moderate effect Partial shutdown, moderate operational upset or moderate damage to assets
(total loss value between US$100,000 and US$ 1M)

H Major effect Partial operation loss, major operational upset or major damage to assets
(total loss value between US$ 1M and US$ 10M)
E Massive effect Substantial or total loss of operations, damage causing major loss of
containment or damage to essential assets (total loss value in excess of US$
10M)

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APPENDIX 2: BUILDING PROXIMITY DISTANCES

This appendix does not replace the requirement to perform a quantitative risk analysis
(QRA) / Risk assessment. Adopting a QRA approach would typically reduce the building
proximity distance, recognizing the low probability of failure for pipelines. For the
purpose of initial pipeline routing/ guidance only, the following formulae provide the
minimum distances between the pipeline and normally occupied buildings:
Pipelines having a design factor not exceeding 0.72:

Pipelines having a design factor not exceeding 0.4:

d : distance in metres
D : pipeline diameter in mm; if the pipeline diameter is less than 150 mm (6 in), D
should be taken equal to 150 mm (6 in).
t : pipeline wall thickness in mm; if the wall thickness is less than 9.5 mm, t may
be taken equal to 9.5 mm. If the wall thickness is larger than 13.5 mm, t shall
be taken equal to 13.5 mm.
P : pipeline MAOP in bar (ga); for pipelines operating at less than 35 bar(g) (510
psig), P should be taken equal to 35 bar(g) (510 psig) .
Q : fluid factor, as provided in the table below
FLUID CATEGORY FLUID FACTOR
A and B Q = 0, i.e. there is no minimum distance
requirement except for access during construction and operations

C Q = 0.3 for all fluids

D, E Q = 0.5 for methane (Natural Gas)

Q = 0.8 for ethylene
Q = 1.0 for LPG
Q = 1.25 for NGL
Q = 0.45 for hydrogen
Q = 2.5 for ammonia

Fluids not specifically mentioned above should be given the fluid factor most closely
similar in hazard potential to those quoted.

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APPENDIX 3: PIPELINE STRESSES

(METALLIC PIPELINES)
There are three types of stresses to be considered in the calculation of the equivalent
stress: the hoop stress, the longitudinal stress and the combined shear stress.
Hoop stress:

Longitudinal stress:
Fully restrained pipeline:
SL =  (Sh) - E (T2 - T1)
Fully unrestrained pipeline:

Combined shear stress:

P = pipeline internal pressure,

D = pipeline diameter,
t = wall thickness,
 = Poisson's ratio,
E = modulus of elasticity,
 = linear coefficient of thermal expansion,
T1 = pipeline installation temperature,
T2 = pipeline design / operating temperature, (refer to section 4.3.6)
Mb = bending moment applied to the pipeline,
Z = pipe section modulus,
T = torque applied to the pipeline,
Fs = shear force applied to the pipeline,
A = pipe wall cross section area,
Note –Refer to section 4.3.5 and 4.3.6 for combined stress calculations and allowable
stresses criteria.

(NON-METALLIC PIPELINES)
For GRP pipelines, stress analysis shall be carried out in accordance with ISO 14692.

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APPENDIX 4: FLOWLINE DESIGN

A4.1 INTRODUCTION
This Appendix supplements the requirements in the main text of this SP. This Appendix
outlines additional design and material requirements and recommendations relevant to
flowlines, interfiled lines and pipelines carrying untreated hydrocarbons/reservoir fluids,
water and gas injection lines. Provisions of section A4.9 may be considered for general
application to all surface laid pipelines.
A4.2 OPERATING ENVELOPE
For carbon steel flowlines, the limiting operating conditions covered by this Appendix
are:
 Temperature: 5C to 82C
 Design Pressure: 100 kPag to 23,800 kPag
 Location Class: 1 (as defined in ASME Code B31.8)
The quoted design pressure for carbon steel flowlines is based on 82C max
temperature.
A4.3 CLIMATIC CONDITIONS
The climatic conditions in Oman should be as per SP 2200
A4.4 MECHANICAL STRENGTH
For various flowlines sizes, wall thickness values have been determined using the
Barlow formula (ref. ANSI B31.8 Codes) with a design factor of 0.72 to which corrosion
allowance is added as indicated in Table A4.1.
The Barlow formula assumes a metallic pipe. Carbon steel flowlines in PDO are
typically installed above ground and this imposes additional bending and thermal
(expansion) stresses not taken account of by the Barlow formula. To ensure that code
allowable stresses are not exceeded due to these additional stresses on flowlines, the
following requirements should apply to lines of 8 in. diameter and smaller, unless
otherwise specified by the Company:
 maximum distance between supports shall be 7 metres
 expansion loops shall be installed at maximum interval of 500 metres
Requirements for lines with a diameter in excess of 8” and all Class 1 flowlines shall be
individually assessed with formal stress analysis.
Road crossings of flowlines shall be analysed in accordance with Section 4.4 of the
main text of this SP.
Other strength requirements shall be as specified in Section 4.3 of the main text of this
SP.

A4.5 ROUTING
In line with Company philosophy to minimise land take, designated flowline corridors or
streets should be followed as much as possible when a new flowline is to be laid. In this
context, flowline town maps showing clearly designated flowline routes should be
developed for each field, and flowlines should be planned to follow these routes only.
Opportunities for inspectable bulklines and headers should always be explored.
In planning flowline route, access shall be provided for inspection / maintenance, and
flowline crossovers. Number of road crossings shall be minimised. Space should also
be provided for future flowlines. A minimum clearance of 250 mm is required between
adjacent flowlines to allow inspection by an external MFL tool.

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For GRP lines, a detailed route survey is required before detailed design.
For FCP lines, routing shall consider below requirements:.
 Topographical data, location and class of wadis, sand dunes, road
crossings including type and density of traffic
 Environmental impact (if any)
 Proximity to Occupied buildings / other pipeline corridors/ roads …etc
 Bend radius shall be based on manufacturer recommendations.
 Minimise crossings (road / wadi / pipelines…etc); Ensure crossing
design – similar to GRE lines.
 Optimise length
 Feasibility of FCP line Protection installation
 When FCP flowlines are routed in between existing lines of existing
corridors, no protection as per SP-1208 App E is required (except
markers provision), since protection is provided by the adjacent existing
pipelines / above ground flowlines on either side of the FCP line.
A4.6 OVERPRESSURE PROTECTION
The Company requires that flowlines should be fully rated, i.e. their design pressure
shall exceed the maximum pressure that can be produced on shut-in. If fully rating the
pipeline is not found to be ALARP appropriate partial relief system shall be implemented
to safeguard the system. Reference is be made to GU-437, DEP 32.80.10.10-Gen and
DEP 80.45.10.11.
A4.7 MATERIAL PROCUREMENT
Standard flowline and hook-up materials should be used where possible. Users are
encouraged to challenge the wall thickness requirements to optimise costs / availability.
Table A4.1 - Carbon Steel Flowlines
Size & Service Design ISO API Wall Corrosion Remarks
Pressure Pressure 3183 5L thickness Allowance
Rating Grade Grade (mm) included in
WT (mm)
3" – 600# Sour 9500 L290 X42 5.2 3
kPag
3'' - 900# Sour 13800 L360 X52 5.6 3
kPag
4'' - 600# Sour 9500 L360 X52 5.2 3 Also suitable for 900#
kPag with zero corrosion
allowance
4" - 900# Sour 13800 L360 X52 6.35 3 Also suitable for 1500#
kPag with zero corrosion
allowance
6" - 300# Sour 4750 L290 X42 5.2 3 Also suitable for 600#
kPag with zero corrosion
allowance
6" - 600# Sour 9500 L360 X52 6.35 3
kPag
6'' - 900# Sour 13800 L360 X52 7.92 3
kPag
6''- 1500# Sour 23800 L360 X52 7.92 0 To be PE Lined
kPag
8'' - 300# Sour 4750 L360 X52 5.2 3
kPag
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Linepipes should be procured in bulk to meet forecasted requirements for new wells
and for replacement of existing flowlines (or sections thereof) to maintain technical
integrity. For flowlines within design temperature range of 5 to 82° C, pipes, fittings,
flanges for sizes 2” and below, are acceptable as per MESC / applicable equivalent
piping class.
The minimum radius for cold bends shall be as prescribed in the main text of this SP. All
bends with a bend radius less than as prescribed should be factory made and procured
in accordance with DEP 31.40.20.33-Gen. as an induction heated or forged bends.
Minimum bend radius for factory made bends for different diameters of piggable
flowlines should be as prescribed in the main text of this SP.
Bends for carbon steel flowlines should be manufactured in a material grade and wall
thickness the same as the linepipe. Refer to section 4.3.8 for acceptable bend radii.
Materials other than carbon steels shall be procured in accordance with the relevant
Company and International standards.

A4.8 INSTALLATION
A4.8.1 General
This section expands some of the installation related requirements of the main text of
this SP where special provisions are necessary for flowlines and other surface laid
pipelines.
A4.8.2 Crossing of Pipelines, Roads and Service Lines
Flowlines and other above ground pipelines should remain on supports while crossing
existing buried pipelines. The pipeline windrow should be removed at the crossing point.
For flowlines longer than 2 km, provisions shall be made for camel and seismic vehicle
crossings at 2 km intervals.
Buried sections of pipelines crossing existing pipelines and other services should be
arranged with a ramp or standard road crossing so that access is retained at those
services. Where a flowline passes by an electricity pylon, access should be maintained
by the use of a ramp or standard road crossing.
To absorb expansion stresses at road crossings, it is recommended that carbon steel
lines follow the configuration that allows thermal (expansion) stresses to be channelled
into the loops on either side of the crossing rather than into the pipe crossing. By
providing an avenue for stress relief, thermal stresses, which can be a cause of leaks at
crossings, are properly absorbed by the loops.
As an alternative to the loop arrangement described above, carbon steel flowlines may
be sagged into crossings. Sagging flowlines into crossings does not relieve thermal
stresses, hence pipe movement may still occur and nevertheless it allows damaged
sections at crossings to be more easily clamped.
Use of low radius bends at crossings (except when used in a loop configuration) is not
advised as the gooseneck formed interferes with inspection and repair.
In developed / built-up areas (i.e. ASME B31.8 location Class 2 or above) where there
is increased risk to the flowline and to population, burial of flowlines is required as for
other Class 1 pipelines.
Where proper field layouts have been developed with designated flowline corridors,
open culverts serving as conduit for flowline street(s) should be considered at road
crossings. This will ensure that stresses from traffic loads are not transmitted to the
flowlines, soil cover acting as anchor does not restrain expansion, and access is
provided for inspection and maintenance at the crossings. Culverts should be designed

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taking into account future service requirements (e.g. heavier traffic and additional
flowlines).
Short buried sections of above ground pipeline (e.g. road crossings, wadi crossing,
sections likely to be covered by blown sand) SHALL [PS] be externally protected by
using 3LPE /3LPP / wrap coat or company approved coating system as per SP-1246.

A4.8.3 Flowline corridors

Flowline corridors shall be such that they shall permit maintenance activities. For urban
planning and new installations no more than eight flowlines shall be installed per
corridor, with lines spaced at minimum clearance of 250 mm from each other to allow
inspection by an external MFL tool. Adjacent flowline corridors shall be spaced 5 meter
apart.
A4.8.4 Supports
Above ground carbon steel flowlines shall be installed on supports, clear of the ground,
to protect the flowline from burial by wind-blown sand.
Standard pipe supports for different sizes and combinations of standard Company
flowlines are contained in GU-629. Modifications to these standard drawings are
permitted to suit local conditions but such modifications should be reviewed and
approved by CFDH civil engineering (custodian of the specification). It should be
ensured that supports do not interfere with the free expansion of the flowline..
Depth of burial below grade for support foundations should as a minimum be as
indicated in the standard support drawings to prevent washout by rain, and ensure
adequate resistance to overturning moments from thermal (expansion) and pressure
(end cap) stresses.
Standard sleeper-type supports to a minimum of 300 mm elevation above grade should
be used where there is a low risk of wind-blown sand, and at well pads. Goal post type
supports SHALL [PS] be installed from 550 mm to 1200 mm elevation above grade
depending on the risk of wind-blown sand in the area. Local requirements and
experience should guide the selection of support type and height of support.
GRP flowlines shall always be buried. Special attention should be paid to supporting
and anchoring where GRP is installed on supports on on-plot locations. GRP is
intolerant of vibrations and stresses induced (by thermal expansion, pressure surges,
etc.) at connections to fixed steel headers. Properly engineered anchors and supports
shall be designed and installed taking into account all possible operational stresses.

A4.8.5 Expansion Loops and Anchors

Expansion or contraction will occur when the temperature of the flowline material is
different from that at time of installation, or due to pressure and end-cap effects at
changes in direction.
Temperature changes may be due to the transported fluid or to changes in ambient
temperature. Due to wide variations in field ambient temperature, considerable thermal
expansion can occur in above ground carbon steel flowlines requiring special
considerations for their anchoring and flexibility.
An expansion loop is not required on the side of a road crossing where a mainline
expansion loop is located within 200 metres of the crossing.
To prevent preferential expansion in one direction, anchors should be provided to
ensure that each expansion loop absorbs only the thrust (caused by thermal expansion
or contraction) for which it has been designed. Anchors should be installed midway
between successive expansion loops, and in such other locations as may be required to
prevent pipe movement. Standard anchor drawings are contained in GU-629. It is
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important to locate the anchors in the correct place as tremendous stresses could be
set up in a flowline when its free expansion is completely restrained in the wrong
location. A minimum of one in four supports should be equipped with pipe guides to
prevent large lateral movement of the pipe and to channel expansion into expansion
loops.

A4.8.6 Hook-Up
Hook-up refers to the piping required to tie-in flowline to wellhead and to production
facilities. Hook-up piping is designed to ANSI B31.3 and the material specifications are
in accordance with DEP 31.38.01.15 (EP Piping Classes)
Buried Carbon steel flowlines should be electrically isolated from the wellhead and
station manifold piping by internally coated insulating spools. Internal coating of the
spools shall be in accordance with DEP SP 1128 .
A4.8.7 Hydrostatic Testing
New flowlines shall be subjected to strength and leak tightness test after construction.
The test procedure shall be in accordance with SP-1212 and SP-1208 (for GRP
flowlines).
A hydrostatic pressure test procedure outlining safety precautions, test equipment,
sources of water, test connection and vent points, filling and pressurising,
depressurising and emptying and other pertinent information (e.g. hydrotest date and
timing and nominated supervisory staff); shall be submitted for Company approval
ahead of hydrotest operations.
A4.9 Internal PE-Lining
Internal PE-lining of carbon steel flowlines may be undertaken:
 To take advantage of carbon steel to contain pressure and PE liner to prevent
internal corrosion in new water injection or production lines with no additional
corrosion allowance

 to arrest further internal corrosion in existing in-service carbon steel lines

 to rehabilitate an abandoned line for new service, where the parent pipe still
has adequate strength (wall thickness) to contain the new service MAOP

 to take advantage of the conduit provided by an abandoned line to install a low

pressure, stand-alone HDPE line.

Advice of the Materials and Corrosion Group should be sought on suitability of PE-lining
for given fluid and service conditions. Installation of PE liners shall be as per SP-2094.
A4.10 Commissioning and Handover
Commissioning commences when the flowline has been successfully hydro-tested,
hooked-up at both ends, and is ready for operational duty. Displacement of hydrotest
water by the well fluid particularly for liquid lines is the most common method of flowline
commissioning. For gas lines, it is usually necessary to develop specific commissioning
procedures taking account of the gas properties, and the producing and / or receiving
facilities.
If a metallic flowline is not planned to be put into service within one month after
hydrotest, it should be mothballed using water with appropriate dosage of corrosion
inhibitor and chemical treatment (biocide, oxygen scavenger) as specified in SP-1212.
The longer the period before a line becomes operational the greater the need for
chemical treatment. Where dewatering of a line is necessary in advance of the line

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being operational, an appropriate drying method that ensures that no residual water is
left in the line should be implemented.
Pre-commissioning activities shall include handover of pipeline / flowline drawings and
pertinent technical data to Operations. Asset registration of pipelines / flowlines
(including FCP flowlines) SHALL [PS] be in accordance with SP-2291. Handover
documents shall as a minimum include all required input data into CIMS - Corrosion
Inspection Management System and SAP.

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APPENDIX 5: Requirements for small orders (Off shelf purchases from

stockists)

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APPENDIX 6: SHALL [PS] statement basis

The reasons and risk ratings for SHALL [PS] requirements are summarised below.

PROCESS SAFETY TABLE

Risk Ranking: 5B
Case Description:
Numerous significant pipeline incidents have occurred in PDO causing injury, significant damage to the asset (including
production deferment) or environment and the reputation of the Operator. Examples of high profile pipeline incidents are:
1. FCP (LLRTP) incidents
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=264 (Thyfut-13 LLRTP Leak (24 Dec 2017)
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=269 (Runib NE 01 5" LLRTP Flow Line Leak (19th Dec 2017))
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=258 (Wadi Umairy LLRTP leak (7 Oct 2017))
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=184 (Sadad LLRTP Fire and MTC (5 Jun 2016))
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=183 (Wadi Umairy LLRTP crude leak (30 Apr 2016))
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=119 (Lekhwair G. Taliah LLRTP external damage (10 Nov 2014))
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=117 (Lekhwair L724 LLRTP external damage (15 Sep 2014))
2. Gas lift lines
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=235 (Lekhwair L-239 Gas Lift Line fire (26 Apr 17))
3. Isolation joint failures
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=241 (Y3DC Isolation Joint leaks (2 Jul 2017)
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=100
Haban Isolation Joint (IJ) leak (17 Oct 2015)
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=99
Saih Nahada Condensate Leak Isolation Joint (20 Jun 2015)
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=81
Saih Nihada-45 Isolation Joint Leak (7 Jan 2013)
4. Corrosion monitoring access fittings / coupons failures
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=129
MOL Corrosion Coupon failure & Spill (25 Feb 2016)
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=106
Kauther CPP 18" Condensate Line (29 Mar 2014)
5. Cold cutting fatality
 http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Lists/Incidents/Display-
Incident.aspx?ID=223
Cold Cutting Double Fatality Natih (28 Feb 1993)

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Risk RatingSeverity (0
through 5)
Number Section/Clause Process Safety Risk Likelihood (A through E)
P A E R
1 4.3.2, 4.3.5, 7.0, To avoid damage to FCP flowlines causing 4B 3A 3E
8.0 and A4.10 deferment and environmental impact.
2 4.7.1, 7.0, A4.8.2, To avoid sand blowing over the flowline / 3B 2D
A4.8.4 and A4.10 pipeline in sandy areas.
3 4.7.1 To avoid isolation joint failures 4B 3D 3C

4 4.7.3 To avoid corrosion monitoring access 5B 3B 4B 3B

fittings failures
5 4.2.6 / 4.5 To avoid fatalities during cold cutting of 4B
pipelines / flowlines / third party damage

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The Pipeline Engineering Shell DEP 31.40.00.10 is based on ISO 13623; PDO SP-1211 is
based on B31.4 and B31.8 and not DEP 31.40.00.10 / ISO 13623. However all the SHALL [PS]
statements from this DEP are captured in this SP-1211 and summarised below.
The reasons and risk ratings for SHALL [PS] requirements are summarised below.

PROCESS SAFETY TABLE

Risk Ranking: 5B
Case Description:
Numerous significant pipeline incidents have occurred causing multiple fatalities, injuries, significant damage to
the asset (including production deferment) or environment and the reputation of the Operator.
Examples of high profile pipeline incidents are:
Ghislenghien, Belgium (2004), gas pipeline ruptured, released gas ignited resulting in a fire causing significant
damage, 24 fatalities and over 120 injured persons.
http://www.iab-atex.nl/publicaties/database/Ghislenghien%20dossier.pdf
San Bruno, California, USA (2010), PG&E, 30” diameter natural gas transmission pipeline ruptured in a
residential area. The released natural gas ignited, resulting in a fire that destroyed 38 homes and damaged 70
resulting in 8 fatalities and many injuries.
http://www.ntsb.gov/investigations/summary/PAR1101.html
Marshall, Michigan, USA (2010), Enbridge, 30” diameter pipeline ruptured into a wetland, the total release was
estimated to be 843,444 gallons of crude oil. Cleanup efforts exceeding $767 million.
http://www.ntsb.gov/investigations/summary/PAR1201.html
Bellingham, Washington, USA (1999), Equilon (JV Shell/Texaco), ruptured 16” gasoline pipeline released about
237,000 gallons of gasoline into a creek, 3 fatalities and 8 injuries.
http://www.ntsb.gov/investigations/summary/PAR0202.html

Risk Rating
Severity (0 through 5)
Number Section/Clause Process Safety Risk Likelihood (A through E)

P A E R

1 4.1.1 To mitigate long term lifetime risks associated 5B 5B

with public safety and environmental damage.
See incidents listed in Case Description.
2 4.3.3 To avoid running ductile failures and mitigate 5B 5B 5B 5B
personnel and public safety risks. Small defects
can grow and rupture a (rich gas) pipeline over
significant length, not having specified the
toughness adequately, exposing people to
significant safety risk.
3 6.1 Maximum level of non-destructive testing to 5B 5B 5B 5B
mitigate the loss of containment risks associated
weld failure. Not all weld defects are picked up
performing only a hydrotest (and not inspecting
all welds using NDT). This potentially exposes
people to significant safety risk.

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FIGURES:
Figure 1 Diagrammatic Representation of Pipeline Scope Boundaries
Figure 2 Diagrammatic Representations of Design Code Breaks
Figure 3 PDO Pipeline Standards Hierarchy
Figure 4 User Comments Form

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FIGURE 1 DIAGRAMMATIC REPRESENTATION OF PIPELINE

SCOPE BOUNDARIES

Water/Gas Treatment
and Pump/Compressor Station
Water/Gas
Injection Lines
Oil/Gas/Water
Wells
Flowlines
Flowline Header
Pig Trap Facilities
Gathering Station
(Initial Treatment)
Gathering Line

Main Transmission Pipeline /

Treatment/Process
Trunkline
Facilities

Remote Vent Line

Spurline
Pressure Reduction
Station

Off take Line

Pump/Compressor
Station (w/bypass)

Liquid/gas Storage
Facilities (w/bypass)

Block Valve Station

KEY

Facility Plot

Facility not included

in Pipeline Scope
Main Transmission
Pipeline/Trunkline
Metering Facilities
Spur/Offtake
Pipeline

Gathering Line /
Slug Catcher
Flowline / Injection
(Only for 2 Phase
Line
Pipelines)

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FIGURE 2: DIAGRAMMATIC REPRESENTATION OF DESIGN

CODE BREAK

Note:
The first isolation valve on any branch from the mainline shall be as per SP-1201, except
exclusions as mentioned in SP-1201 clause 2.1.

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FIGURE 3: PDO PIPELINE STANDARDS HIERARCHY

HSE Protection Product Flow Asset Integrity Business Control Abandonment

CP-122 CP-117 CP-114 CP-115 CP-131

Onshore Pipeline Engineering Pipeline Operations & Maintenance P/L & F/L Abandonment
SP-1211 SP-1210

PL Design Procurement P/L Construction P/L Maintenance P/L Operations P/L F/L
Abandonment
SP-1032 SP-1199 SP-1097 SP-1195 PR-1074
SP-1125 SP-1200 SP-1131 SP-1235 PR-1082 SP-1012
SP-1128 SP-1201 SP-1174 SP-2276 PR-1146 PR-1071
SP-2092 SP-1236 SP-1177 SP-2285 PR-1164
SP-2094 SP-2034 SP-1208
SP-2156 SP-1212 PR-1010
SP-2161 SP-1246 PR-1011
SP-2284 PR-1159 PR-1180
PR-1817
GU-195 GU-368 PR-1994
GU-437 GU-623
GU-447 DEP31.40.20.33 GU-629 GU-379
GU-706 DEP31.40.20.34 GU-432
DEP31.40.20.37 DEP31.40.50.30
DEP31.40.21.30
DEP30.10.73.10
DEP31.38.01.11 DEP31.40.21.34
DEP31.38.60.10
DEP31.40.30.31
DEP31.38.01.12
DEP31.38.01.15 DEP31.40.30.32
DEP31.38.60.10 DEP31.40.30.35
DEP31.40.10.13

DEP31.40.10.16
DEP31.40.60.11
DEP32.80.10.10
DEP39.01.10.11
DEP80.45.10.11

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FIGURE 4: USER COMMENTS FORM

SP-1211 – Onshore Pipeline Engineering User Feedback Page

Any user who identifies an inaccuracy, error or ambiguity is requested to notify

the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:

Page Ref: Brief Description of Change Required and Reasons

To: UIPT2
Custodian of Document Date:

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