1. Hazardous Liquid Pipelines
ABC Company
ABC Chemical Complex
Engineering Specification

2. Hazardous Liquid Pipelines
1.0 SCOPE
Covers the design, materials, fabrication, construction, inspection, testing, operations, maintenance, and safety aspects of hazardous liquid pipeline systems
Also covers the components including, but not limited to, pipe, relief devices, valves, fittings, flanges, bolting, gaskets, hangars, and supports.

3. Hazardous Liquid Pipelines
EXCLUSIONS
Auxiliary piping such as water, air, steam, lubricating oil, gas, and fuel
Pressure vessels, heat exchangers, pumps, meters, and other equipment not in scope
Petroleum refinery, natural gasoline, gas processing, ammonia, carbon dioxide processing, and bulk plant piping covered in the scope of ASME/ANSI B31.3, Plant Piping.

4. Hazardous Liquid Pipelines
Exclusions (Continued)
Gas transmission and distribution piping systems covered under ASME/ANSI B31.8
Piping at or below 15 psi
Piping above 15 psi if design temperature is below -20oF or above 250oF
Design and fabrication of proprietary items of equipment, apparatus, or equipment

5. Hazardous Liquid Pipelines
INTENT
Provide engineering specifications for safe construction, operation, maintenance, and inspection of ABC hazardous liquid pipelines
Shall meet or exceed the requirements in ASME/ANSI B31.4 and DOT 49CFR195
Not retroactive for existing pipelines which shall be inspected and tested to the Code used in original design and construction.

6. Hazardous Liquid Pipelines
3.0 PIPING SYSTEMS DEFINITIONS
General Terms (14)
Piping Systems (20)
Pressure Relief Stations and Regulators (3)
Valves (2)
Pipe and Piping Terms (2)
Dimensional Terms (3)
Mechanical Properties (5)
Steel Pipe (3)

7. Hazardous Liquid Pipelines
4.0 DESIGN, FABRICATION, OPERATION, AND TESTING TERMS
Uprating (1)
Pressure Terms (8)
Temperature Terms (3)
Stress Terms (5)

8. Hazardous Liquid Pipelines
5.0 MATERIALS AND EQUIPMENT
Acceptable Materials and Specifications
Marking
Material Specifications
Steel Pipe
Fittings
Transportation of Line Pipe
Conditions for Reuse of Line Pipe

9. Hazardous Liquid Pipelines
6.0 WELDING
Welding Terms
Preparation for Welding
Safe Practices in Cutting and Welding
Welding Processes and Filler Metal
Welding Qualifications
Qualification Records
Material Limitations
Welder Requalification Requirements
Qualification Records (WPS, PQR, Welder)

10. Hazardous Liquid Pipelines
7.0 Design Conditions
Provides a set of standards covering
Specifications for, and selection of, equipment and piping components
Acceptable methods of making branch connections
Provisions for temperature changes
Approved methods for support and anchorage of exposed and buried piping systems.

11. Hazardous Liquid Pipelines
Design Conditions (Continued)
Exclusions
Pipe Materials (Section 5)
Welding Procedures (Section 6)
Installation and Testing of Piping Systems
Special Engineering Stresses Not Specifically Covered in Specification
River crossings, inland coastal water areas, bridges, areas of heavy traffic, long self-supported spans, unstable ground, vibration, earthquake, thermal, etc.

12. Hazardous Liquid Pipelines
Allowable Stress Values
S = 0.72 x E x SMYS, psi (MPa)
where 0.72 = design factor
E = weld joint factor, normally 1
Allowable stress values shall be determined for
Used pipe or new/used pipe of unknown or ASTM 120 specifications
Pipe which is cold worked to meet SMYS and reheated to 600oF or higher shall be 75% of applicable stress value

13. Hazardous Liquid Pipelines
Allowable Stress Values (Continued)
In shear shall not exceed 45% SMYS
In bearing shall not exceed 90% SMYS
Structural supports and restraints shall not exceed 66% SMYS
Structural supports and restraints of unknown piping specifications shall be assigned an SMYS of 24,000 psi or less

14. Hazardous Liquid Pipelines
Limits of Calculated Stresses Due to Sustained Loads and Thermal Expansion
Internal Pressure Stresses
External Pressure Stresses
Allowable Expansion Stresses
Additive Longitudinal Stresses
Additive Circumferential Stresses Due to Occasional Loads

15. Hazardous Liquid Pipelines
Limits of Calculated Stresses Due to Occasional Loads
Operation
Sum of longitudinal stresses produced by pressure, live and dead loads, and occasional loads, i.e. wind and earthquake shall not exceed 80% SMYS
Test
Stress due to test conditions are not subject to above limitations

16. Hazardous Liquid Pipelines
Limitations on Design Pressure, P
Shall not exceed 85% of mill test pressure
Alternatively, shall not exceed 85% of field test pressure if mill tests are not available
Limitations on SMYS
Used pipe from Company stock with known specifications may be assigned full S value
An S value = 24,000 psi shall be assigned to pipe with unknown specifications

17. Hazardous Liquid Pipelines
Additional Requirements for Nominal Wall Thickness, t
Shall not be reduced to less than 90% of the design thickness under any circumstances
Allowances
Corrosion (Not required if corrosion controlled)
Threading and Grooving
Weld Joint Factors
Wall Thickness and Defect Tolerances

18. Hazardous Liquid Pipelines
Straight Pipe Under Internal Pressure
Design wall thickness of steel pipe shall be calculated by the following equation
t = PiD/2S
where Pi=internal design gage pressure
D=outside diameter of pipe, in.
S=applicable allowable stress value, psi

19. Hazardous Liquid Pipelines
Additional Pressure Design Considerations
Flanges, Reducers, Fittings, Elbows, Bends, and Intersections
Closures
Quick Opening Closures
Closure Fittings
Closure Heads
Fabricated Closures
Bolted Blind Flange Connections

20. Hazardous Liquid Pipelines
Expansion and Flexibility
Means of Providing Flexibility
Amount of Expansion
Properties
Coefficient of Thermal Expansion
(6.5x10-6in./in./oF)
Modulus of Elasticity (29x106 psi)
Poisson’s Ratio (0.3 for steel)

21. Hazardous Liquid Pipelines
Design of Pipe Supporting Elements
Combined Stress Calculations
Restrained Pipelines
Unrestrained Pipelines
Analysis
Basic Assumptions and Requirements

22. Hazardous Liquid Pipelines
8.0 CONSTRUCTION
Construction Specifications
Inspection Provisions
Right-of-Way
Handling, Hauling, Stringing, and Storing
Damage to Fabricated Items and Pipe
Ditching
Welding
Tie In

23. Hazardous Liquid Pipelines
CONSTRUCTION (Continued)
Installation of Pipe in Ditch
Backfilling
Hot Taps
Restoration of Right-of-Way and Cleanup
Special Crossings
Block and Isolating Valves
Mainline Valves
Scraper Traps

24. Hazardous Liquid Pipelines
CONSTRUCTION (Continued)
Line Markers
Corrosion Control
Pump Station, Tank Farm, and Terminal Construction
Storage and Working Tankage
Electrical Installations
Liquid Metering
Liquid Strainers and Filters

25. Hazardous Liquid Pipelines
9.0 INSPECTION
General
Shall assure compliance with material, construction, welding, assembly, and testing requirements of ABC Specifications, ASME/ANSI B31.4 and DOT 49CFR 195
Qualification of Inspectors
Inspection personnel shall be qualified by training and experience to the criteria in API 570

26. Hazardous Liquid Pipelines
Inspection Services
Right-of-way and grading
Ditching
Line up and pipe surface inspection
Welding
Coating
Cathodic protection
Tie-in and lowering
Backfilling & cleanup
Pressure testing
Station construction
River crossings
Electrical installation
Radiography
Corrosion control
external
internal

27. Hazardous Liquid Pipelines
Inspection Services
Backfilling & cleanup
Pressure testing
Station construction
River crossings
Electrical installation
Radiography
Corrosion control
external
internal

28. Hazardous Liquid Pipelines
Type and Extent of Examination Required
Visual
Material-mechanical damage
Permanent records: Location of pipe, wall thickness, type, specification, and manufacturer
Construction
Surface defects: before coating operation and during lowering-in and backfilling operations
Pipe swabbing operation

29. Hazardous Liquid Pipelines
Proper alignment and condition of weld joint surface before welding
Inspect stringer bead for cracks
Remove irregularities on weld cap to prevent coating damage
Inspect all repairs, changes, or replacements prior to backfilling operation
Inspect fit of pipe to ditch prior to backfilling
Inspect backfilling operations for quality and compaction of backfill, placement of material for erosion control, and possible coating damage

30. Hazardous Liquid Pipelines
Inspect cased crossings during installation to assure that the carrier pipe is supported, sealed, and insulated from the casing
Inspect piping components other than pipe to insure damage-free condition and proper installation

31. Hazardous Liquid Pipelines
Supplementary Types of Examination
Weld inspection and testing
Complete in accordance with ABC Specs and ASME/ANSI B31.4
Weld defect and repair
Coatings
Use ABC Specs and ASME/ANSI B31.4

32. Hazardous Liquid Pipelines
9.2 TESTING
Testing of Fabricated Items
Testing After New Construction
Systems or Parts of Systems
Testing Tie-Ins
Testing Controls and Protective Equipment
Hydrostatic Testing of Internal Pressure Piping
Hydrotest to 1.25 times the internal design pressure for at least four (4) hours
Use API 1110 for guidance in hydrostatic tests

33. Hazardous Liquid Pipelines
Treat hydrotest water with a bactericide and corrosion inhibitor
Relieve excess pressure during the test as required
Hydrotesting with gas or nonvolatile hydrocarbons is not permitted on ABC projects without written permission from Company management
Leak Testing
Reduce hydrotest pressure to design pressure and hold for an additional eight (8) hours

34. Hazardous Liquid Pipelines
Qualification Tests for Pipe
Visual Examination
Bending Properties
Determination of Wall Thickness
Determination of Weld Joint Factor
Weldability
Determination of Yield Strength
Minimum Yield Strength Value
Records

35. Hazardous Liquid Pipelines
10.0 Operation and Maintenance Plans and Procedures
Written detailed plans and training programs for employees
Plan for external and internal corrosion control
Written emergency plan
Plan for reviewing changes in conditions affecting the integrity and safety of the piping system.

36. Hazardous Liquid Pipelines
Liaison with local authorities and other pipeline operators to prevent excavation accidents.
Procedures to analyze all failures and accidents to determine the cause and prevent recurrence.
Record system to administer the plans and procedures.
Procedures for abandoning pipelines
Procedures to assure public safety in pipeline operation and maintenance

37. Hazardous Liquid Pipelines
Operation and maintenance of piping systems in conformance with ABC Specifications, ASME/ANSI B31.4, and DOT 49CFR195.
Plan and procedure modifications as required

38. Hazardous Liquid Pipelines
10.2 PIPELINE OPERATIONS AND MAINTENANCE
Operating Pressure
The internal design pressure and pressure rating for all components shall not be exceeded in steady state operations.
Pressure rise due to surges shall not exceed the internal design pressure at any point in the piping system by more than 10%.

39. Hazardous Liquid Pipelines
Requalification of a piping system is required if a higher operating pressure produces a hoop stress more than 20% SMYS. Requirements in paragraph 456, ASME/ANSI B31.4 shall be followed without exception.
Derating of a pipeline to a lower operating pressure in lieu of repair or replacement may be completed with the maximum operating pressure determined by paragraph , ABC Specification.
Codes in effect during original construction shall be consulted for allowable stress and design criteria.

40. Hazardous Liquid Pipelines
Communications
Markers
Right-of-Way Maintenance
Patrolling
Pipeline Repairs
Repairs shall be completed in accordance with ABC Specification, Repair of Pipelines.
Allowable pipeline repairs and repair methods are summarized in B31.4 and ABC specifications.

41. Hazardous Liquid Pipelines
Railroads and Highways Crossing Existing Pipelines
Use API 1102 to determine the total stress caused by internal pressure and external loads. If new external pipe loading exceeds 0.72SMYS, Company will install mechanical reinforcement, suitable protection, or increased pipe thickness.
Installation of uncased carrier pipe is preferred.

42. Hazardous Liquid Pipelines
10.3 PUMP STATION, TERMINAL, AND TANK FARM OPERATION AND MAINTENANCE
Pressure limiting devices, regulators, flow controllers, relief valves, and other safety devices shall be inspected annually to determine condition and functionality.
Inspect storage tanks in accordance with API 653.

43. Hazardous Liquid Pipelines
CORROSION CONTROL
EMERGENCY PLAN
RECORDS
Necessary operational data
Pipeline patrol records
Corrosion records as required by B31.4
Records for routine and/or unusual inspections
Pipeline repair records

44. Hazardous Liquid Pipelines
10.7 QUALIFYING A PIPING SYSTEM FOR A HIGHER OPERATING PRESSURE
Review initial design and previous testing
Determine present condition by leak surveys and other field inspections, examination of maintenance and corrosion control records, or other suitable means.
Complete necessary repairs, replacements, or alterations.

45. Hazardous Liquid Pipelines
Maximum steady state operating pressure may be increased after compliance with the previous slide and one of the following provisions:
If the condition of the pipeline is consistent with the design and hydrotesting has been completed to a test pressure equal to or higher than required for the new steady state operating pressure, the system is approved for the higher operating pressure.
The system is successfully hydrotested to a test pressure required for the higher operating pressure.

46. Hazardous Liquid Pipelines
10.8 Abandoning a Piping System
Disconnect all facilities to be abandoned from all transported sources, i.e., other pipelines, meter stations, control lines, and other equipment.
Purge all facilities to be abandoned to replace the transported liquid and vapor with an inert material.
Seal the ends of the piping system.

47. Hazardous Liquid Pipelines
11.0 CORROSION CONTROL
Scope
External Corrosion Control
Internal Corrosion Control
Pipelines in High Temperature Service
Stress Corrosion and Other Phenomena
Records