transient conditions and a tolerance specification for pressure controls on pipelines intended to be operated at MAOP are addressed.
(j) Section 8 (Corrosion mitigation) incorporates the requirements of Section 5 of the 1997 revision. The Section incorporates clarifying revisions.
(k) Section 9 (Upgrade of MAOP) is a new Section that sets down the minimum process, including activities required, to demonstrate the fitness of a pipeline designed and operated at one pressure as suitable for approval for operation at a higher pressure.
The Section establishes a structured methodology for demonstrating the pipeline fitness and, once approved, for commissioning the pipeline at the new pressure. The maximum pressure is limited to the hydrostatic strength test pressure divided by the equivalent test pressure factor.
(l) Section 10 (Construction) incorporates Section 6 of the 1997 Standard. The requirements for construction survey are clarified, and a minimum accuracy for as-constructed survey is incorporated. Since padding and backfilling are two activities that impact on the pipeline integrity, this revision incorporates additional requirements for these activities reflecting outcomes from APIA research on backfilling.
(m) Section 11 (Inspection and testing) has been revised to align it with the requirements of AS 2885.5. It specifies strength test endpoint requirements for pipelines with a pressure design factor of 0.80, and references APIA research and associated software designed to enable the analysis of the pipe in a proposed (and constructed) test section to be analysed to determine the presence and location of pipe that may be exposed to excessive strain at the intended strength test pressure.
(n) Section 12 (Documentation). Obligations on the developer of a new pipeline to document the design and construction, and to transfer this information to the pipeline operator, are clarified and expanded.
(o) Each appendix in the 1997 revision of the Standard has been critically reviewed and revised, as appropriate. New appendices are provided reflecting the findings of APIA research, clarification of concepts in the Standard, and providing detailed calculation methods.
(p) Resistance to penetration calculation methods and design requirements provided.
In addition to the items identified above, there are a great many changes of lesser significance incorporated in the document to the extent that users should consider it as a familiar but new Standard.
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An informative Appendix, which provides guidance on the design, construction and testing of fibreglass pipelines, is included.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be requirements of the Standard.
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CONTENTS
Page SECTION 1 SCOPE AND GENERAL
1.1 SCOPE ... 11
1.2 APPROVAL ... 11
1.3 APPLICATION ... 11
1.4 RETROSPECTIVE APPLICATION ... 12
1.5 REFERENCED DOCUMENTS ... 12
1.6 DEFINITIONS ... 12
1.7 SYMBOLS AND UNITS ... 17
1.8 ABBREVIATIONS ... 19
SECTION 2 SAFETY 2.1 BASIS OF SECTION ... 21
2.2 ADMINISTRATIVE REQUIREMENTS ... 22
2.3 SAFETY MANAGEMENT PROCESS ... 23
2.4 STATIONS, PIPELINE FACILITIES AND PIPELINE CONTROL SYSTEMS ... 28
2.5 ENVIRONMENTAL MANAGEMENT ... 29
2.6 ELECTRICAL ... 29
2.7 CONSTRUCTION AND COMMISSIONING ... 30
SECTION 3 MATERIALS AND COMPONENTS 3.1 BASIS OF SECTION ... 32
3.2 QUALIFICATION OF MATERIALS AND COMPONENTS ... 32
3.3 REQUIREMENTS FOR COMPONENTS TO BE WELDED ... 35
3.4 ADDITIONAL MECHANICAL PROPERTY REQUIREMENTS ... 36
3.5 REQUIREMENTS FOR TEMPERATURE-AFFECTED ITEMS ... 37
3.6 MATERIALS TRACEABILITY AND RECORDS ... 38
3.7 RECORDS ... 38
SECTION 4 DESIGN—GENERAL 4.1 BASIS OF SECTION ... 39
4.2 ROUTE ... 40
4.3 CLASSIFICATION OF LOCATIONS ... 42
4.4 PIPELINE MARKING ... 44
4.5 SYSTEM DESIGN ... 47
4.6 ISOLATION ... 51
4.7 SPECIAL PROVISIONS FOR HIGH CONSEQUENCE AREAS ... 53
4.8 FRACTURE CONTROL ... 55
4.9 LOW TEMPERATURE EXCURSIONS ... 63
4.10 ENERGY DISCHARGE RATE ... 64
4.11 RESISTANCE TO PENETRATION ... 65
SECTION 5 PIPELINE DESIGN 5.1 BASIS OF SECTION ... 67
5.2 DESIGN PRESSURE ... 67
5.3 DESIGN TEMPERATURES ... 68
5.4 WALL THICKNESS ... 68
5.5 EXTERNAL INTERFERENCE PROTECTION... 72
5.6 PREQUALIFIED PIPELINE DESIGN ... 79
5.7 STRESS AND STRAIN... 81
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5.8 SPECIAL CONSTRUCTION ... 86
5.9 PIPELINES ASSEMBLIES ... 95
5.10 JOINTING ... 97
5.11 SUPPORTS AND ANCHORS ... 98
5.12 HYDROSTATIC TESTING DESIGN ... 100
SECTION 6 STATION DESIGN 6.1 BASIS OF SECTION ... 106
6.2 DESIGN ... 106
6.3 STATION PIPEWORK ... 110
6.4 STATION EQUIPMENT ... 111
6.5 STRUCTURES ... 112
SECTION 7 INSTRUMENTATION AND CONTROL DESIGN 7.1 BASIS OF SECTION ... 115
7.2 CONTROL AND MANAGEMENT OF PIPELINE SYSTEM ... 115
7.3 FLUID PROPERTY LIMITS ... 117
7.4 SCADA—SUPERVISORY CONTROL AND DATA ACQUISITIONS SYSTEM ... 118
7.5 COMMUNICATION ... 118
7.6 CONTROL FACILITIES ... 118
SECTION 8 MITIGATION OF CORROSION 8.1 BASIS OF SECTION ... 119
8.2 PERSONNEL ... 119
8.3 RATE OF DEGRADATION ... 119
8.4 CORROSION MITIGATION METHODS ... 120
8.5 CORROSION ALLOWANCE ... 121
8.6 CORROSION MONITORING ... 121
8.7 INTERNAL CORROSION MITIGATION METHODS ... 122
8.8 EXTERNAL CORROSION MITIGATION METHODS ... 123
8.9 EXTERNAL ANTI-CORROSION COATING ... 126
8.10 INTERNAL LINING ... 127
SECTION 9 UPGRADE OF MAOP 9.1 BASIS OF SECTION ... 128
10.9 COVERING SLABS, BOX CULVERTS, CASINGS AND TUNNELS ... 139
10.10 SYSTEM CONTROLS ... 139
10.11 ATTACHMENT OF ELECTRICAL CONDUCTORS ... 139
10.12 LOCATION ... 140
10.13 CLEARING AND GRADING ... 140
10.14 TRENCH CONSTRUCTION ... 141
10.15 INSTALLATION OF A PIPE IN A TRENCH ... 141
10.16 PLOUGHING-IN AND DIRECTIONALLY DRILLED PIPELINES ... 143
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10.17 SUBMERGED CROSSINGS ... 143
10.18 REINSTATEMENT ... 143
10.19 TESTING OF COATING INTEGRITY OF BURIED PIPELINES ... 144
10.20 CLEANING AND GAUGING PIPELINES ... 144
10.21 ELECTRICAL EQUIPMENT INSTALLED IN HAZARDOUS AREAS ... 144
SECTION 11 INSPECTIONS AND TESTING 11.1 BASIS OF SECTION ... 145
11.2 INSPECTION AND TEST PLAN AND PROCEDURES ... 145
11.3 PERSONNEL ... 145
12.4 DESIGN AND CONSTRUCTION RECORDS ... 151
12.5 SAFETY MANAGEMENT STUDY REVIEW ... 151
12.6 TRAINING ... 151
12.7 SAFETY TAG SYSTEM ... 151
12.8 PRE-COMMISISONING ... 152
12.9 COMMISSIONING AND TESTING... 153
12.10 PERFORMANCE TEST ... 157
12.11 HANDOVER ... 157
12.12 DELAYED COMMENCEMENT OF OPERATION ... 158
SECTION 13 DOCUMENTATION
D DESIGN CONSIDERATIONS FOR EXTERNAL INTERFERENCE PROTECTION ... 177
E EFFECTIVENESS OF PROCEDURAL CONTROLS FOR THE PREVENTION OF EXTERNAL INTERFERENCE DAMAGE TO PIPELINES ... 180
F QUALITATIVE RISK ASSESSMENT ... 187
G ALARP ... 191
H INTEGRITY OF THE SAFETY MANAGEMENT PROCESS ... 193
I ENVIRONMENTAL MANAGEMENT ... 201
J PREFERRED METHOD FOR TENSILE TESTING OF WELDED LINE PIPE DURING MANUFACTURE ... 203
K FRACTURE TOUGHNESS TEST METHODS... 204
L FRACTURE CONTROL PLAN FOR STEEL PIPELINES ... 206
M CALCULATION OF RESISTANCE TO PENETRATION ... 215
N FATIGUE ... 220
O FACTORS AFFECTING CORROSION ... 223
P ENVIRONMENT-RELATED CRACKING ... 226
Q INFORMATION FOR CATHODIC PROTECTION ... 233 R MITIGATION OF EFFECTS FROM HIGH VOLTAGE ELECTRICAL
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S PROCEDURE QUALIFICATION FOR COLD FIELD BENDS ... 244
T GUIDELINES FOR THE TENSIONING OF BOLTS IN THE FLANGED JOINTS OF PIPING SYSTEMS ... 249
U STRESS TYPES AND DEFINITIONS ... 264
V EXTERNAL LOADS ... 271
W COMBINED EQUIVALENT STRESS ... 275
X PIPE STRESS ANALYSIS ... 285
Y RADIATION CONTOUR ... 290
Z REINFORCEMENT OF WELDED BRANCH CONNECTIONS ... 295
AA FIBREGLASS PIPE—MANUFACTURE, DESIGN AND CONSTRUCTION CONSIDERATIONS ... 301
BB GUIDELINES FOR PIPELINES FOR THE TRANSPORT OF CO2 ... 313
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STANDARDS AUSTRALIA
Australian Standard
Pipelines—Gas and liquid petroleum Part 1: Design and construction
S E C T I O N 1 S C O P E A N D G E N E R A L 1.1 SCOPE
This Standard specifies requirements for design and construction of carbon and carbon-manganese steel pipelines and associated piping and components that are used to transmit single-phase and multi phase hydrocarbon fluids, such as natural and manufactured gas, liquefied petroleum gas, natural gasoline, crude oil, natural gas liquids and liquid petroleum products.
The principles are expressed in practical rules and guidelines for use by competent persons.
AS 2885.0 sets out the fundamental principles on which AS 2885 series of Standards is based. These fundamental principles and the practical rules and guidelines set out in AS 2885.1, AS 2885.2, AS 2885.3 and AS 2885.5 are the basis on which an engineering assessment is to be made where these Standards do not provide detailed requirements appropriate to a specific item.
NOTE: AS 2885.4 for offshore submarine pipeline systems is a standalone document.
1.2 APPROVAL
Each document prepared for a pipeline in accordance with this Standard shall be approved as required by AS 2885.0.
Documents nominated in this Standard as requiring approval shall be approved by the Licensee and not delegated. All other documents shall be approved in accordance with the Licensee’s approval matrix.
1.3 APPLICATION
Where this Standard imposes requirements, which add to or override the requirements of a nominated Standard or code, the additional requirements, that are explicitly stated in this Standard shall be met.
Where approved, this Standard may also be used for design and construction of pipelines made with corrosion-resistant alloy steels, fibreglass and other composite materials. Where this Standard is used for pipelines fabricated from these materials, appropriate requirements shall be established to replace the provisions of this Standard in relation to nominated Standards for materials (Section 3), fracture control (Clause 4.8), stress and strain (Clause 5.7) and corrosion (Section 8) and the provisions of AS 2885.2 in relation to welding and non-destructive examination. For composite material, appropriate requirements shall be established to replace the hydrostatic strength test endpoint provisions of AS 2885.5.
As provided in AS 2885.0, where approved, this Standard may be used for the design and construction of pipelines to transport fluids that are predominantly CO2 and for other fluids including slurries. Where this Standard is applied to fluids other than gas and liquid petroleum, a gap analysis shall be conducted to identify the differences between the
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proposed fluid and those of gas and liquid petroleum, and appropriate requirements shall be established to address those differences.
NOTE: Appendix BB provides guidance for the design of CO2 pipelines using this Standard.
1.4 RETROSPECTIVE APPLICATION Retrospectivity is governed by AS 2885.0.
This revision (AS 2885.1—2012) does not introduce additional changes that are intended to apply retrospectively.
AS 2885.1—2007 introduced changes that reflect matters of public safety in high consequence areas and which are intended to apply retrospectively.
Each existing pipeline shall be assessed against the requirements of Clauses 4.7.2 and 4.7.3.
Where the existing pipeline does not comply with either Clause, mitigation shall be applied in accordance with Clause 4.7.4 regardless of whether or not there has been a land use change.
1.5 REFERENCED DOCUMENTS
The documents referred to in this Standard are listed in Appendix A.
1.6 DEFINITIONS
For the purpose of this Standard, the definitions given in AS 1929, AS 2812, AS 2832.1 and those below, apply.
1.6.1 Accessory
A component of a pipeline other than a pipe, valve or fitting, but including a relief device, pressure-containing item, hanger, support and every other item necessary to make the pipeline operable, whether or not such items are specified by the Standard.
1.6.2 Approved and approval
Approved by the Licensee or the Licensee’s delegate, and includes obtaining the approval of the relevant regulatory authority where this is legally required. Approval requires a conscious act and is given in writing.
NOTE: See AS 2885.0 for more information on approval and approved.
1.6.3 As low as reasonably practicable (ALARP)
ALARP means the cost of further risk reduction measures is grossly disproportionate to the benefit gained from the reduced risk that would result.
NOTE: Guidance on demonstration of ALARP and grossly disproportionate is given in Appendix G.
1.6.4 Buckle
An irregularity in the surface of a pipe caused by a compressive stress.
1.6.5 Casing
A conduit through which a pipeline passes, to protect the pipeline from excessive external loads or to facilitate the installation or removal of that section of the pipeline.
1.6.6 Collapse
A permanent cross-sectional change to the shape of a pipe (normally caused by instability, resulting from combinations of bending, axial loads and external pressure).
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1.6.7 Commissioning
The process of verifying the operational and safety functions of a pipeline and the introduction of the process fluid prior to handover for operation.
1.6.8 Common threats
Threats that occur at similar locations along the pipeline and which can therefore be treated by a standard design solution for that location type (e.g. road crossings).
1.6.9 Competent person
A person who has acquired through training, qualification, and experience, or a combination of these, the knowledge and skills that enable the person to safely and effectively perform the task required.
1.6.10 Component
Any part of a pipeline other than the pipe.
1.6.11 Construction
Activities required to fabricate, construct and test a pipeline, and to restore the right of way of a pipeline.
1.6.12 Control piping
Ancillary piping used to interconnect control or instrument devices or testing or proving equipment.
1.6.13 Critical defect length
The length of a through wall axial flaw that, if exceeded, will grow rapidly and result in pipeline rupture. When the defect is smaller than this length, the pipeline will leak. A critical defect length also exists for part through wall flaws.
1.6.14 Defect
A discontinuity or imperfection of sufficient magnitude to warrant rejection on the basis of the requirements of this Standard.
1.6.15 Dent
A depression in the surface of the pipe, caused by mechanical damage, that produces a visible irregularity in the curvature of the pipe wall without reducing the wall thickness (as opposed to a scratch or gouge, which reduces the pipe wall thickness).
1.6.16 Failure
The occurrence of one or more of the following conditions:
(a) Any loss of containment.
(b) Supply is restricted.
(c) MAOP is reduced.
(d) Immediate repair is required in order to maintain safe operation.
NOTE: It is emphasized that failure is not restricted to loss of containment.
1.6.17 Fitting
A component, including the associated flanges, bolts and gaskets used to join pipes, to change the direction or diameter of a pipeline, to provide a branch, or to terminate a pipeline.
1.6.18 Fluid
Any liquid, vapour, gas or mixture of any of these.
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1.6.19 Gas
Any hydrocarbon gas or mixture of gases, possibly in combination with liquid petroleum, condensates or water.
1.6.20 Heat
Material produced from a single batch of steel processed in the final steel-making furnace at the steel plant.
1.6.21 High consequence area
A location where pipeline failure can be expected to result in multiple fatalities or significant environmental damage.
1.6.22 High vapour pressure liquid (HVPL)
A liquid or dense phase fluid that releases significant quantities of vapour when its pressure is reduced from pipeline pressure to atmospheric (e.g. LP gas).
1.6.23 Hoop stress
Circumferential stress in a pipe or cylindrical pressure-containing component arising from internal pressure.
1.6.24 Hot tap
A connection made to an operating pipeline.
1.6.25 Inspector
A person appointed by the Licensee to carry out inspections required by this Standard.
1.6.26 Leak test
A pressure test that determines whether a pipeline is free from leaks.
1.6.27 Licensee
The organization responsible for the design, construction, testing, inspection, operation and maintenance of pipelines and facilities within the scope of this Standard. The Licensee is generally the organization named in the pipeline licence issued by the Regulatory Authority.
1.6.28 Location class
The classification of an area according to its general geographic and demographic characteristics, reflecting both the threats to the pipeline from the land usage and the consequences for the population should the pipeline suffer a loss of containment.
1.6.29 Manufacturer’s data report (MDR)
A document that consolidates all materials, testing, fabrication and installation data to comply with traceability requirements of this Standard.
1.6.30 May
Indicates the existence of an option (see also ‘shall’ and ‘should’).
1.6.31 Mechanical interference-fit joint
A joint for pipe, involving a controlled plastic deformation and subsequent or concurrent mating of pipe ends.
1.6.32 Nominated Standard
A Standard referred to in Clause 3.2.2.
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1.6.33 Non-credible threat
A threat for which the frequency of occurrence is so low that it does not exist for any practical purpose at that location.
NOTE: The credibility or otherwise of a threat is a characteristic of the threat itself and is assessed independently of any protective measures that may be applied to mitigate it. A non-credible threat is not the same as a non-credible threat that has been controlled.
1.6.34 Non-location specific threat
Threats that can occur anywhere along the pipeline (e.g. corrosion).
1.6.35 Petroleum
Any hydrocarbon or mixture of hydrocarbons in a gaseous or liquid state and which may contain hydrogen sulfide, nitrogen, helium and carbon dioxide.
1.6.36 Pig (pipeline inspection gauge)
A device inserted in a pipeline for operation or inspection, and transported through it by the flow of the product in the pipeline.
1.6.37 Pig trap (scraper trap)
A pipeline assembly to enable a pig to be inserted into or removed from an operating pipeline.
1.6.38 Pipeline design engineer
The person responsible for the design of the pipeline.
1.6.39 Pipework, mainline
Those parts of a pipeline between stations, including pipeline assemblies.
1.6.40 Pipework, station
Those parts of a pipeline within a station that begin and end where the pipe material specification changes to or from the mainline pipework.
1.6.41 Piping
An assembly of pipes, valves and fittings associated with a pipeline.
1.6.42 Pretest (also known as ‘Pretested’)
A pressure test of pipe, pipeline assembly or a component that is undertaken separately from the pipeline and is not retested after installation (e.g. spare pipe, isolation valve assemblies.)
1.6.43 Preliminary test
A test that is undertaken on pipe that will be subsequently exposed to the strength test pressure of the mainline pipe.
NOTE: The purpose of the test is to eliminate the risk of failure of the pipe during the strength test.
1.6.44 Pressure, design
The pressure nominated in the Design Basis for the purpose of performing calculations on the mechanical and process design of the pipeline.
1.6.45 Pressure, maximum allowable operating (MAOP)
The maximum pressure at which a pipeline or section of a pipeline may be operated, following hydrostatic testing in accordance with this Standard or after an MAOP review performed in accordance with AS 2885.3.
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1.6.46 Pressure, maximum operating (MOP)
The operating pressure limit (lower than the MAOP) imposed by the Licensee from time to time for pipeline safety or process reasons.
1.6.47 Pressure strength
The maximum pressure measured at the point of highest elevation in a test section.
NOTE: Pressure strength for a pipeline or a section of a pipeline is the minimum of the strength test pressures of the test sections comprising the pipeline or the section of the pipeline.
1.6.48 Propagating fracture
A fracture that is not arrested within the length of pipe in which the fracture initiated.
1.6.49 Proprietary item
An item made or marketed by a company having the legal right to manufacture and sell it.
1.6.50 Protection measures, procedural
Measures for protection of a pipeline that minimize the likelihood of human activities with potential to damage the pipeline.
1.6.51 Protection measures, physical
Measures for protection of a pipeline that prevent external interference from causing failure, either by physically preventing contact with the pipe or by providing adequate resistance to penetration in the pipe itself.
1.6.52 Regulatory authority
An authority with legislative powers relating to petroleum pipelines covered by the scope of this Standard.
1.6.53 Rupture
Failure of the pipe such that the cylinder has opened to a size equivalent to its diameter.
1.6.54 Safety management study or process
The process that identifies threats to the pipeline system and applies controls to them, and (if necessary) undertakes assessment and treatment of any risks to ensure that residual risk is reduced to an acceptable level.
1.6.55 Shall
Indicates that a requirement is mandatory (see also ‘may’ and ‘should’).
1.6.56 Should
Indicates a recommendation (see also ‘may’ and ‘shall’).
1.6.57 Sour service
Piping normally conveying crude oil or natural gas containing hydrogen sulfide together with an aqueous liquid phase in a concentration that may affect materials.
1.6.58 Specified minimum yield stress (SMYS)
The minimum yield stress for a pipe material that is specified in the manufacturing standard with which the pipe or fittings used in the pipeline complies.
1.6.59 Strength test
That part of the pressure test procedure that establishes the pressure strength of the test section.
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1.6.60 Supervising test engineer
The person responsible for the detailed planning, execution and assessment of the test.
1.6.61 Telescoped pipeline
A pipeline that is made up of more than one diameter or MAOP, tested as a single unit.
1.6.62 Threat
Any activity or condition that can adversely affect the pipeline if not adequately controlled.
1.6.63 Wall thickness, design pressure (tP)
The wall thickness of pipe required to contain the design pressure, based on steel grade and design factor.
1.6.64 Wall thickness, required (tW)
The greatest of the wall thicknesses required to meet the various design requirements nominated in Clause 5.4.2.
1.6.65 Wall thickness, nominal(tN)
The wall thickness nominated for pipe manufacture or certified on supplied pipe.
1.7 SYMBOLS AND UNITS NOTES:
1 Unless otherwise noted, pressure and calculations involving pressure are based on gauge pressures.
2 Symbols defined and used in appendices are not listed in this table.
Symbol Description Unit
AC Fracture area of the Charpy V-notch specimen mm2
CDL Critical defect length mm
CVN Upper shelf Charpy V-notch energy (Full size equivalent) J c Half of the length of an axial through wall flaw mm D Nominal outside diameter = Pipe diameter = Pipeline diameter mm
CVN Upper shelf Charpy V-notch energy (Full size equivalent) J c Half of the length of an axial through wall flaw mm D Nominal outside diameter = Pipe diameter = Pipeline diameter mm