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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number
0 15-IH-1002
Pipeline Design

1 23 MAY 9 4 ISSUED AS KOC ENG. GROUP SPEC.

0 26 FEB 9 4 ISSUED FOR INVITATION TO BID EM

Rev Date Revision BY Chkd Section PE Client

 Specification Number Rev Date Sheet

01 5-IH-1002 1 23-5-94 2 0 f 15

CONTENTS

1.0 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.0 STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.0 TECHNICAL REQUIREMENTS .............................. 6

4.1 Route Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Pipeline Area Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Alignment Sheets .................................. 6

5.0 PIPELINE WALL THICKNESS ............................... 6

6.0 PIPELINE LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6.2 Functional Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6 . 3 Hydrotest Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 . 4 Road Crossings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.5 Onshore Buoyancy Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7.0 EXPANSIONCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1 Frictional Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2 Burial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3 Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
7 . 4 Transition Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

8.0 CORROSION PROTECTION ................................9

9.0 ANCILLARY FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0
9.1 Scraper Launchers/Receivers . . . . . . . . . . . . . . . . . . . . . . . . . 1 0
9.2 Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0
9 . 3 Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 . 4 Pipeline crossing Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.5 Support Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 . 6 Steelwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

10.0 CALCULATIONS AND USE OF COMPUTERS . . . . . . . . . . . . . . . . . . . 11

APPENDIX 1: PIPELINE DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . 12

 Specification Number Rev Date Sheet
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01 5-IH-1002 1 23-5-94 3 of 15

1.0 SCOPE

1.1 This specification covers the detail design requirements for the pipelines
and the related ancillary facilities required for the pipeline systems for
installation at the Facility in Kuwait.

1.2 The design of the pipelines shall fully comply with all relevant
contractual requirements specified in the Scope of Work and Technical
Specification of the Contract.

2.0 STANDARD SPECIFICATIONS

2.1 The pipelines and related ancillary facilities shall conform in design,
materials and performance, except where otherwise specified, with the
current issue and amendments of the following prevailing on effective
date of Contract:

2. I.
I International Standards

ASME Section IX Welding and Brazing Qualification

ASME Section Vlll Boiler and Pressure Vessel Code

ASME 81.20.1 Pipe Threads

ASME 81 6.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-made Wrought Steel Buttwelding Fittings

ASME B16.25 Buttwelding Ends

ASME 831.3 Chemical Plant and Petroleum Refinery Piping

ASME 831.8 Gas Transmission and Distribution Piping Systems

ASME B31.4 Liquid Petroleum Piping Systems

ASME 836.10 Welded and Seamless Wrought Steel Pipe

ASME 836.19 Stainless Steel Pipe

ASME 846.1 Surface Texture

API 5L Specification for Line Pipes

API 6A Specification for Valves and Wellhead Equipment

API 6D Specification for Pipeline Valves (Gate, Plug, Ball

and Check Valves)
 API 6FA Fire Testing of Valves

API 5 9 4 Wafer-type Check Valves

API 598 Valve lnspection and Test

API 600 Steel Gate Valves ---- Flanged and Butt Welding
Ends

API 602 Compact Steel Gate Valves

API 609 Lug and Wafer-type Butterfly Valves

API RP 1110 Pressure Testing of Liquid Petroleum Pipelines

API RP 11 0 2 Pipeline Road Crossing

API RP 1104 Pipeline Welding

ASTM Specifications for Ferrous Piping Materials

MSS-SP-25 Standard Marking System for Valves, Fittings,

Flanges and Unions

MSS-SP-44 Steel Pipeline Flanges

MSS-SP-75 High Test Fittings

2.1.2 British Standards

BS 1868 Steel Check Valves

BS 1873 Steel Globe Valves

BS 3 9 7 4 Part 1 Pipe Hangers, Sliders and Roller-type Supports

BS 5146 Specification for lnspection and Test of Steel

Valves for the Petroleum, Petro-Chemical and
Allied lndustries

Steel Ball Valves for the Petroleum, Petro-

Chemical and Allied lndustries

Specification for Steel Wedge Gate, Globe and

Check Valves 5 0 m m and Smaller for the
Petroleum, Petro-Chemical and Allied lndustries

Specification for Use of Structural Steel in Building

 Specification Number Rev Date Sheet
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0 15-IH-1002 1 23-5-94 5 0 f 15

BS 5950 Structural Use of Steelwork in building

2.1.3 Engineering Group Specifications

Basic Design Criteria

International Codes and Standards

Pipeline Construction

Pipeline Design

Pipeline Pigging and Hydrostatic Test

Pipeline Dewatering and Drying

Pig Launchers/Receivers

Field Welding

External Coating of Line Pipe with Coal Tar Enamel

Induction Bends

Field Joint Coating

Shop and Field Painting

Cathodic Protection Design Requirements

Line Pipe Materials (Spiral Pipe), Submerged-Arc

Welding (SAW)

2.2 Compliance with this specification shall not relieve the Contractor of its
responsibility t o supply equipment suited t o meet the specified service
conditions and applicable requirements.

2.3 Where conflicts exist between this specification and other Drawings,
standards, codes or specifications, the most stringent shall be applied.

3.0 SERVICE CONDITIONS

3.1 The pipelines shall be suitable for continuous operation at a desert

location under high ambient temperatures and humidity. The
atmosphere at the Facility is generally dusty and corrosive and may
contain traces of hydrogen sulphide.
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01 5-IH-1002 1 23-5-94 6 o f 15

3.2 The pipelines shall in all respects be suitable for continuous operation in
service conditions stated in the Engineering Group Specification entitled
"Basic Design Criteria" (Number 0 1 5-AH-1001).

3.3 The basic and environmental data t o be used in the design is given in
the Engineering Group Specification entitled "Basic Design Criteria"
(Number 0 1 5-AH-1001 ).

3.4 The operational characteristics of the pipeline systems are summarised

in Appendix 1, Pipeline Data Sheet.

4.0 TECHNICAL REQUIREMENTS

Route Selection

The pipelines shall be routed on the basis of the shortest route which
causes the least amount of interference with the existing facilities. The
preliminary pipeline routes for the Facility have been selected on this
basis and are as shown in the relevant Drawings contained in Exhibit F
of the Contract documents.

Pi~elineArea Classificationg

The area classifications of the gas pipelines shall be calculated based on

ASME 831.8 requirements for Design Class 1 and Construction Type A.

Alignment Sheets

4.3.1 Pipeline alignment sheets shall be produced for all cross-country

pipelines. Alignment sheets shall be laid out in the format with
strip mapslprofiles t o a horizontal scale of 1 :5000 and a vertical
scale of 1:250.

4.3.2 Alignment sheets shall be marked up with the pipeline chainage

starting at the upstream end of the pipeline. The start point shall
be defined on the alignment sheets.

5.0 PIPELINE WALL THICKNESS

Pipeline wall thicknesses shall be calculated in accordance with the

requirements of the ASME B31.8 and 831.4 codes, as applicable. In addition,
the rules for limitation of longitudinal and combined stresses contained in
ASME B31.4 shall be applied t o pipelines designed t o ASME 831.8. The
minimum corrosion allowance shall be taken as 'I, in. (3.12 mm). The
minimum pipeline wall thickness shall be as per Appendix 1 and Project
Drawings.
6.0 PIPELINE LOADS

6.1 Introduction

6.1 .I To analyze the pipeline systems, the following loads shall be

taken into consideration as a minimum:

Internal pressure.

Functional loads comprising the effects of temperature and

pressure and of the frictional resistance between the pipeline
and the soils.

Live loads representing the weight of the transported fluids.

Loads caused by motor vehicle traffic at road crossings.

Environmental loads taking into account the thermal effects on

piping exposed to the sun.

Hydrotest loads.

Soil loads.

External loads.

Hydrodynamic loads caused by changes in water table levels.

6.2 Functional Loads

6.2.1 Functional loads occur due to the normal operation of the pipeline
system. The following shall be considered as minimum effects:

a. Temperature

The temperature differential to be used when calculating

temperature-induced loadings and expansion in the buried
section of the system shall be evaluated for both the
maximum inlet temperature minus the minimum tie-in
temperature and the maximum tie-in temperature minus the
blowdown temperature.
b. Pressure

The pressure to be used when calculating pressure-induced

loadings shall be the maximum pipeline design pressure.
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QKOC Errgldng Gnurp

SpeMcahn 01 5-IH-1002 1 23-5-94 8 o f 15

c. Friction

Pipeline expansion movements arising from temperature and

pressure effects will be reduced by pipelinelsoil friction. These
effects shall be calculated and allowances made t o reduce
anchor loads where applicable.

d. Creep

The potential for creep shall be calculated and allowances

made for the extent t o which creep can occur. Methods shall
be proposed t o minimise or eliminate this problem.

Hvdrotest Loads

Calculations of any hydrotest induced loads and the proposed method

t o cater for them shall be developed. Allowances shall be made within
the design for increased anchor loads due t o hydrotest pressures.

Road Crossinag

The live, dead and impact loadings at all road crossings shall be
calculated as outlined in API RP 1 102. Wheel loadings shall be 1 1 2 kN
per wheel at 900-mm centres with a maximum of four wheels per axle.

Onshore Buovancv Control

6.5.1 If sabkha areas are found along the pipeline routes, pipelines shall
be restrained against float-out by weight coating or the use of
cohesive backfill. Calculations shall be made t o demonstrate the
adequacy of the chosen techniques.

6.5.2 If float-out resistance by cohesive backfill is proposed, the backfill

properties shall be tested and compared with the required
properties of density, compaction and shear strength.

7.0 EXPANSION CONTROL

7.1 Frictional Restraint

7.1.1 Expansion of buried pipelines due t o pressure and temperature

effects shall be restrained to acceptable limits. The restraint shall
be provided by friction between soil and pipe and/or by the use
of anchors of the full thrust or drag type.

7.1.2 Expansion shall be considered acceptable when it does not

overstress end or branch connection pipework or cause any
external soil disturbance or pipeline coating damage. Pipeline end
expansion shall be limited t o 5 0 mm maximum at the above- t o
 Specification Number Rev Date Sheet

015-IH-1002 1 23-5-94 9 0 f 15

belowground transition. In calculating maximum allowable

expansion, both the short-term expansion immediately after
startup and the long term friction relaxation shall be considered.

7.1.3 Friction between the pipe and the soil restrains expansion so that
at a certain distance from the point where the pipeline comes
above-ground, the pipe is fully restrained. The pipeline systems
covered by this specification shall be designed t o be fully
restrained as defined in the applicable codes. Pipeline end
expansion, anchor loads, the buckling loads and all other related
loadings shall be calculated. The potential damage t o the coating
and appurtenances shall also be evaluated.

I 7.2 Burial

The minimum depth of cover shall be 1.0 m as measured from the final
graded ground level t o the top of pipe. The depth of cover required t o
fully restrain the pipeline systems including cold field bends, elastic
bends and preformed or factory bends shall be calculated. The analysis
shall take into account soil overburden, internal angle of friction, soils
passive wedge and the water table. The top of pipe depth of burial shall
be shown on the pipeline alignment sheets.

I 7.3 Anchors

7.3.1 Pipeline anchors shall be required at locations t o be identified by

the Contractor t o satisfy the conditions of a fully restrained
pipeline system. Rigorous calculations shall be made t o prove the
design for the anchors, anchor flanges, concrete and
reinforcement. The stresses induced at the pipelinelanchor
interface shall be determined.

7.3.2 The locations of all anchors shall be marked on the alignment

sheets.

7.4 Transition Points

The Contractor shall calculate the pipe stress at the aboveground1

belowground transition point and determine if the soils will move or
cause ratcheting.

I 8.0 CORROSION PROTECTION

8.1 Details of installed cathodic protection facilities shall be marked on the

alignment sheets.

8.2 Buried pipework shall be externally coated with a factory-applied coal tar
enamel system or polyken with fusible inner wrap system. Field joints
shall be coated by heat-shrink sleeves or polyken with fusible inner wrap
 Specification Number Rev Date Sheet
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01 5-IH-1002 1 23-5-94 10 of 15
SpeMWon

system. All coating systems shall be in accordance with Engineering

Group Specification entitled "External Coating of Linepipe with Coal Tar
Enamel" (Number 015-IH-1010).

9.0 ANCILLARY FACILITIES

9.1.1 Pipelines shall be suitable for running scraper pigs for testing, and
precommissioningoperations, as well as future intelligent pigging.

9.1.2 Wherever practicable, the pipeline shall be routed a minimum of

5 m from any cable or 25 m between the base of any pylon and
the pipeline trench and should cross the cable at an angle as close
as practicable to 90°. Cable and pipeline crossing shall be as per
Company Standard 381113, Part 1.

9.1.3 The Contractor shall provide detailed calculations to show that

any induced voltagelcurrents will not be hazardous to personnel
or livestock.

9.2 Bends

I 9.2.1 Preform Bends

The minimum allowable radius for preform bends (field cold

bending machine bends) shall be as recommended by the bending
machine manufacturer for the pipe diameter, material grade and
wall thickness to be used but shall not be less than 40 times the
nominal diameter.

9.2.2 Elastic Bends

Wherever possible, changes in direction shall be made using

elastic bends. The minimum elastic bend radius shall be
calculated based on the maximum permissible combined stress.
Bending stresses due to elastic bending shall be considered to be
additive to maximum thermal longitudinal stresses.

9.2.3 Factory-Made Bends

Factory-made bends (induction bends) shall be specified in

accordance with the Engineering Group Specification entitled
"Induction Bends" (Number 015-IH-1011). The minimum bend
radius shall be 5D. Where 5D bends are specified, particular
attention shall be paid to pipeline restraint against expansion and
soil loading at the bend. Bends made from longitudinally welded
pipe shall have the weld located at the neutral axis with a
tolerance of + 5 degrees.
 Specification Number Rev Date Sheet
E.q~/&w Group
01 5-IH-1002 1 23-5-94 11 of 15
SpaMmbn

9.3 Isolation

9.3.1 Aboveground portions in a pipeline, which has buried sections

with impressed current cathodic protection, shall be electrically
isolated from the supports using an approved insulating material.

9.3.2 The amount of current leakage through support structure shall be

considered when establishing the need for insulation.

9.4 Pioeline Crossina Points

9.4.1 Facilities shall be provided to cross the pipelines at all track

crossings and road crossings.

9.4.2 Crash barriers shall be installed at road crossings to protect the

pipelines.

9.5 a ~ o o r Foundation
t

9.5.1 Supports for aboveground pipework shall be designed with

foundations that will resist all imposed dynamic and static loads.

9.5.2 The footings of the supports shall be designed such that the
potential for movement following either wind or water erosion of
the soil is minimised.

9.6 Steelwork

9.6.1 Support steelwork shall be designed to ensure smooth transition

of the load from the pipe to the concrete foundations by means
of stiffened flanges or approved equal.

9.6.2 The concrete shall not be overstressed by bearing or other

transferred load.

10.0 CALCULATIONS AND USE OF COMPUTERS

10.1 All pipeline installation calculations made to support the design

shall be presented to the Company for review. Calculations
presented shall be neatly drafted and easily understandable.
Where reference is made to codes and technical papers, etc.,
copies of the relevant pages shall be appended to the calculation.
All calculations shall identify the person who performed the
calculation and the person who checked it.

10.2 Where computer programmes are used to perform calculations, a

user guide and validation report shall be presented for review with
the calculation.
 Specification Number Rev Date Sheet
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01 5-IH-1002 1 23-5-94 12 of 15
SpeMkwbn

APPENDIX 1: Pipeline Data Sheet 1 of 4

Pipeline Length (Approx.) - For Information Only of 4

Length
Crude Oil Transmission Line Network One No. 20" spur line from GC-5
to manifold Burgan-1 (G)
One No. 12" spur line from new
GC-12 t o manifold Burgan-1 (G)
One 20" tie-in from GC-14 t o
existing line
Low Pressure Gas Transmission Network One No. 18" gas line GC-5 t o
manifold "Sand"
One No. 18" gas line from
manifold "S7" t o manifold "S6"
One 20" tie-in from GC-12 t o
existing line
One 20" tie-in from GC-5 t o
existing 20" gas line
One 20" tie-in from GC-14 t o
existing line
High Pressure Gas Transmission Network One 12" tie-in from GC-5 t o
existing line
One 12" tie-in from GC-12 t o
existing line
One 12" tie-in from GC-14 t o
existing line
Fuel Gas System One 4 " tie-in from GC-5 t o
existing line
One 4" tie-in from GC-12 t o
existing line
One 4 " tie-in from GC-14 t o
existing line
Brackish Water GC's t o RingIMain

-
 APPENDIX 1 2 of 4

Category I Requirement
Material 1 API 5L Grade B I
Nominal Diameter 20" NPS, 18" NPS, 12" NPS and 4" NPS
Wall Thickness For all pipe size 9.5 mm
Corrosion Coating
Operating and Design Pressure MAOP Design Pressure
20" NPS Spur Line 400 psi 500 psi
12" NPS Spur Line 400 psi 500 psi
20" NPS Crude Oil Tie-in 400 psi 500 psi
18" NPS Low Pressure Gas Line 60 psi 75 psi
20" NPS Low Pressure Gas Tie-ins
12" NPS High Pressure Tie-ins
60 psi
300 psi
75 psi
350 psi
I
4" NPS Fuel Gas Tie-ins 460 psi I 500 psi
Flange Rating
Crude Lines ASME Class 300 I
Fuel Gas ASME Class 300 I
HP Gas Lines ASME Class 300
--
I
-
LP Gas Lines
- -
ASME Class 150
Hydrotest Pressure ASME B.31.8 125% of MAOP or 90%
SMYS
Minimum Cover 1.0 m (top of pipe)
Minimum Bending Radius Induction Bend 5D
Field Bend - Minimum Radius 40D
 Specification Number Rev Date Sheet

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015-IH-1002 1 23-5-94 140f 15

APPENDIX 1
GC-29 AND 30

- NetworkISystem Length
Crude Oil Transmission Line Network One 1 2 " crude oil line from GC30 t o
manif old.
One 1 0 " crude oil line from GC29 t o
manifold.
One 1 6 " from manifold t o existing
- line.
Condensate Transmission Network One 6 " condensate line GC30 t o
manifold.
One 4" condensate line from GC29
t o manifold.
One 6 " condensate line from
- manifold t o existing line.
High Pressure Gas Transmission One 1 0 " from GC30 t o manifold.
Network
One 8" from GC29 t o manifold.
One 1 0 " from manifold t o existing
- line.
Fuel Gas System One 6 " from existing line t o
manifold.
One 6 " from manifold t o GC30.

- One 6 " from manifold t o GC29.

N43-0159
 APPENDIX 1 4 of 4

I Category I Requirement I
Material API 5L Grade B
Nominal Diameter 16" NPS, 10" NPS, 8" NPS (spiral pipe)
6" NPS and 4" NPS (seamless)
Wall Thickness For all pipe size 9.5 mm
Corrosion Coating
-
- -- - -
Polvolefin
- -

Operating and Design Pressure MAOP Design Pressure

1Ow, 12" 16" NPS Crude Oil Lines 450 psi 500 psi
8", 10" HP Gas 930 psi 950 psi
6", 4 " Condensate 1230 psi 75 psi
6" NPS Fuel Gas psi 400 psi
Flange Rating
Crude Lines ASME Class 300
Fuel Gas ASME Class 300

, HP Gas Lines , ASME Class 400

I Condensate I ASMEClass 600 --

Hydrotest Pressure ASME 8.31.8 125% of MAOP or 90%

SMYS
Minimum Cover 1.0 m (top of pipe)
Minimum Bending Radius Induction Bend 5D

[ Field Bend - Minimum Radius I 40D I