As 2885.1-2012 Design and Construction

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AS 2885.1—2012

Australian Standard

®

Pipelines—Gas and liquid petroleum

Part 1: Design and construction

AS 288

5.1—2

012

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This Australian Standard® was prepared by Committee ME-038, Petroleum Pipelines. It was approved on behalf of the Council of Standards Australia on 27 July 2012.

This Standard was published on 20 September 2012.

The following are represented on Committee ME-038: • APIA Research and Standards Committee • Australasian Corrosion Association

• Australian Chamber of Commerce and Industry • Australian Institute of Petroleum

• Australian Petroleum Production and Exploration Association • Australian Pipeline Industry Association

• Bureau of Steel Manufacturers of Australia • Department of Labour New Zealand

• Department for Manufacturing, Innovation, Trade, Resources and Energy (SA) • Department of Mines and Petroleum (WA)

• Department of Natural Resources and Mines (Qld) • Department of Resources (NT)

• Energy Networks Association • Energy Safe Victoria

• Gas Association of New Zealand

• NSW Department of Trade and Investment, Regional Infrastructure and Services • Petroleum Exploration and Production Association New Zealand

• Primary Industries and Resources SA • Welding Technology Institute of Australia

This Standard was issued in draft form for comment as DR AS 2885.1.

Standards Australia wishes to acknowledge the participation of the expert individuals that contributed to the development of this Standard through their representation on the Committee and through the public comment period.

Keeping Standards up-to-date

Australian Standards® are living documents that reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued.

Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments that may have been published since the Standard was published.

Detailed information about Australian Standards, drafts, amendments and new projects can be found by visiting www.standards.org.au

Standards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at [email protected], or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.

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AS 2885.1—2012

Australian Standard

®

Pipelines—Gas and liquid petroleum

Part 1: Design and construction

First published in part as part of AS CB28—1972. Revised and redesignated AS 1697—1975. AS 1958 first published 1976. AS 2018 first published 1977. Second edition AS 1697—1979. Third edition 1981. Second edition AS 1958—1981. Second edition AS 2018—1981.

AS 1958—1981 and parts of AS 1697—1981 and AS 2018—1981 revised, amalgamated and redesignated AS 2885—1987.

Parts of AS 1697—1981, AS 2018—1981 and AS 2885—1987 revised, amalgamated and redesignated in part as AS 2885.1—1997.

Second edition AS 2885.1—2007. Third edition AS 2885.1—2012.

COPYRIGHT

All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968. Published by SAI Global Limited under licence from Standards Australia Limited, GPO Box 476, Sydney, NSW 2001, Australia

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PREFACE

This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee ME-038, Petroleum Pipelines, to supersede AS 2885—2007, Pipeline—Gas and liquid petroleum.

After consultation with stakeholders in both countries, Standards Australia and Standards New Zealand decided to develop this Standard as an Australian Standard rather than an Australian/New Zealand Standard.

The objective of this Standard is to provide requirements for the design and construction of steel pipelines and associated piping and components that are used to transmit single-phase and multi-phase hydrocarbon fluids.

This Standard provides guidelines for use of pipe manufactured from certain non-steel or corrosion-resistant materials.

This Standard is part of a series that covers high pressure petroleum pipelines, as follows: AS

2885 Pipelines—Gas and liquid petroleum 2885.0 Part 0: General requirements

2885.1 Part 1: Design and construction (this Standard) 2885.2 Part 2: Welding

2885.3 Part 3: Operation and maintenance 2885.4 Part 4: Submarine pipelines AS/NZS

2885.5 Part 5: Field pressure testing

2012—Minor revision (harmonization with other parts)

This minor revision of AS 2885.1—2007 has been prepared to incorporate the revision/amendment to AS 2885.0, AS 2885.3 and AS 2885.5 to resolve inconsistencies between the Parts and update the referenced documents.

Significant changes to this edition include the following:

1 The requirements for specific items to be ‘approved’ have been deleted from this Standard unless the item is considered of sufficient importance to require specific approval of the licensee. AS 2885.0 requires approval of all documents by the authority designated by the Licensee, except those specifically nominated for approval by the Licensee, or so nominated in this Standard.

2 Draws attention to the need to properly specify line pipe, to the limits of some commonly used pipe, and a requirement is introduced to address these matters in the design basis.

3 Requirements for design of a pipeline for hydrostatic test developed for AS 2885.5 have been incorporated in this Standard.

4 Requirements for commissioning of a pipeline developed for AS 2885.3 have been incorporated in this Standard in recognition of the fact that commissioning is almost always a responsibility of the design and construction project and, after successful commissioning, the pipeline is handed over to operations in accordance with AS 2885.3.

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5 A new appendix (Appendix BB), addressing issues that need to be considered when applying this Standard to the design of pipelines transporting CO2, either pure or

anthropogenic, has been included. This appendix was prepared in response to an initiative of the Carbon Capture Taskforce of the Australian Government Department of Resources Energy and Tourism.

6 Changes have been made to achieve consistency between AS 2885.1, AS 2885.3 and AS 2885.5.

7 Section 11 has been revised to recognize the intent in the 2007 edition to transfer some requirements to the next revision of AS/NZS 2885.5.

8 Minor changes, the result of requests for clarification, have been included. Only minor clarifications have been addressed. Complicated clarifications have been reserved for the next revision of AS 2885.1.

9 Correction of an error in Equation S2(1). 2008 Amendment No. 1

Amendment No. 1 to AS 2885.1—2007 was prepared to correct errors in the 2007 revision and to clarify items identified as being potentially confusing. The amendment includes guidance on specifying fracture toughness when purchasing line pipe and includes a simplified calculation for energy release from leaks.

The requirements for the control of fracture initiation in components other than line pipe have been clarified.

2007 Revision

The comprehensive revision of AS 2885.1 is the result of extensive work by subcommittee ME-038-1 in response to a request from the industry that it consider increasing the design factor from 0.72 to 0.80. This request prompted a detailed review of each section and each clause of the Standard, resulting in the preparation of some 70 ‘issue papers’ that considered the underlying technical issues (in relation to an increased design factor) and recommended changes to the Standard. These issue papers were debated within the subcommittee and published on the Industry web site to allow consideration by the Industry. The results of these deliberations form the basis of this revision. The revision also reflects the results of a significant and ongoing industry funded research program undertaken by the Australian Pipeline Industry Association and its research contractors, and through its association with the Pipeline Research Council International and the European Pipeline Research Group.

This revision provides a basis for Industry to benefit through the application of an increased factor for pressure design (for new pipelines) and a structured basis for increasing the MAOP of a qualifying existing pipeline. These benefits are supported by robust requirements for safety, structural design, construction, testing and record keeping.

Significant changes in this revision include the following:

(a) A restructure of the sections of the document to separate pipeline general, pipeline, stations, and instrumentation and control.

(b) The incorporation of a section defining the minimum requirements for a pipeline whose maximum allowable operating pressure is proposed to be raised.

(c) Section 2 (Safety) has been rewritten, to reflect experience gained in the seven years since it was revised to provide a mandatory requirement for risk assessment. This revision provides more explicit guidance on the obligation to undertake safety assessments with the integrity required for compliance with this Standard. Material is provided in normative and informative appendices.

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(d) Section 3 (Materials and components) has been revised to better address the treatment of materials used in pipelines. It includes a requirement to de-rate the specified minimum yield stress of pipe designed for operation at temperatures of 65°C and higher. The use of fibreglass and corrosion resistant alloy pipe materials for pipelines constructed to this Standard is permitted and limited in this Section. A minimum toughness requirement for pipe DN 100 and larger has been introduced.

(e) Section 4 (Pipeline general) contains most of the material in the ‘Pipeline general’ section of the 1997 revision. The Section has been expanded to include the following: (i) A mandatory requirement for the design of a pipeline for the existing and

intended land use.

(ii) A revision of the requirements for effective pipeline marking including a change to require the marker sign to comply with a ‘danger sign’ in accordance with AS 1319, Safety signs for the occupational environment.

(iii) A plan for isolation of a pipeline.

(iv) Special requirements for pipelines constructed in locations where the consequence of failure by rupture is not acceptable. Provisions for compliance with these requirements for pipelines constructed to this edition, or to an earlier revision, of the Standard, in land where the location classification has changed to residential (or equal) is included.

(v) The location classification definitions are revised and additional sub-classes are defined.

(vi) The hydrostatic strength test pressure is redefined to address the situation where the pipe wall thickness exceeds the pressure design thickness, including corrosion allowance.

(vii) Provisions for low temperature excursions.

(viii) Calculation methods for critical defect length, energy release rate and radiation contour.

(f) The requirements for fracture control have been extensively revised to clarify the requirements and to reflect experience gained since 1997. Emphasis is placed on the use of the Battelle Two Curve model given the fact that most gas pipelines in Australia transport ‘rich’ gas.

(g) Section 5 (Pipeline design) has been revised to incorporate those provisions specific to pipeline in the 1997 revision. Significant changes to this Section include the following:

(i) The pipe wall thickness is required to be the greater of the pressure design thickness, and the thickness required for each other identified load condition. The thickness terms used in this Standard are clarified.

(ii) An equation for calculating the thickness required for external pressure is provided.

(iii) Recognizing the result of a comprehensive investigation, of its purpose and the impact of change, the design factor has been changed from 0.72 to 0.80, and the design factor for pipeline assemblies and pipelines on bridges has been changed from 0.60 to 0.67.

(iv) Requirements for stress and strain have been completely redrafted to clarify the requirements. The limits for each stress condition are tabulated and normative and informative appendices are provided incorporating the relevant equations. Reliability and limit state design methods are permitted for pipeline design and integrity analysis, using approved methods.

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(v) The requirements for a ‘prequalified’ design are included in a new clause. This is permitted for short pipelines DN 200 and smaller with a MAOP of 10.2 MPa or less.

(vi) The provisions for reduced cover for a pipeline constructed through ‘rock’ have been revised.

(vii) The method for calculating reinforcement of branch connections in AS 2885.1—1987 has been reinstated in full.

(h) Section 6 (Station design) incorporates the provisions of Clause 4.4 of the 1997 revision in relation to stations. The Section has been expanded to require the Design Basis for stations to be documented. Additional guidance is provided on treatment of lightning, together with some clarifying revisions to the text.

(i) Section 7 (Instrumentation and control design) incorporates the requirements of Clause 4.2 of the 1997 revision. The requirements for pipeline operation under 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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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 (t_P)

The wall thickness of pipe required to contain the design pressure, based on steel grade and design factor.

1.6.64 Wall thickness, required (t_W)

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(t_N)

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

Dm Average diameter mm

Dmax Greatest diameter mm

Dmin Smallest diameter mm

d Branch diameter mm

dW Depth of part through wall flaw mm

E Young’s modulus MPa

FD Design factor for pressure containment

FBucket Force exerted at a bucket, correlated against excavator mass kN

FMAX Maximum force exerted at bucket (most severe geometry) kN

FP Pressure factor for bends

FTP Test pressure factor

FTPE Equivalent test pressure factor

fo Ovality factor

G Sum of allowances mm

H Manufacturing tolerance mm

L Length of tooth at tip mm

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Symbol Description Unit KC In plane stress intensification factor (fracture initiation toughness) MPa/mm0.5

MT Folias factor

PC Collapse pressure MPa

PD Design pressure MPa

PEXT External pressure MPa

PL Pressure limit MPa

PM Measured pressure from hydrostatic test MPa

PTMAX Maximum strength test pressure MPa

PTMIN Minimum strength test pressure MPa

R Bend radius to the centreline of the pipe mm

rM Mean pipe radius mm

Rp Puncture resistance kN

RLi Number of runs of np pipe, each run having a length i

SDEV Standard deviation of toughness in all heat population

SEFF Effective stress (consistent with API RP 1102) MPa

SF Statistical factor

SFG Stress limit for girth weld fatigue (consistent with API RP 1102) MPa

SFL Stress limit for longitudinal weld fatigue (consistent with

API RP 1102)

MPa

Td Design minimum temperature for brittle fracture control °C

t Wall thickness mm

tP Wall thickness internal pressure design mm

tN Wall thickness—Nominal mm

tW Wall thickness—Required mm

W Width of tooth at tip mm

WOP Operating weight tonne

ΔSH Stress for longitudinal welds (consistent with API RP 1102) MPa

ΔSL Stress for girth welds (consistent with API RP 1102) MPa

σ Stress MPa

σc Combined equivalent stress MPa

σE Expansion stress MPa

σflow Flow stress = SMYS + 10 ksi for fracture control MPa

σH Hoop stress MPa

σL Longitudinal stress MPa

σO Occasional stress MPa

σSUS Sustained stress MPa

σU Ultimate tensile strength MPa

σW Bending stress MPa

σY Specified minimum yield strength (SMYS) MPa

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Symbol Description Unit

σYA Lowest yield strength estimated statistically from the population of

yield strength

MPa

ν Poisson’s ratio (stress and strain) 1.8 ABBREVIATIONS

Abbreviations Meaning Unit

AFV Allowable fluid variation L/24 h

ALARP As low as reasonably practicable

AS Australian Standard

CDL Critical defect length

CHAZOP Control hazard and operability

CRA Corrosion-resistant alloy

CW Continuously welded

DN Nominal diameter

DWTT Drop weight tear test

EIP External interference protection EIS Environmental impact statement EMP Environmental Management Plan EPRG European Pipeline Research Group ERW Electric resistance welded

FRP Fibre-reinforced plastic

GIS Geographic information system

HAZ Heat-affected zone

HAZAN Hazard analysis study HAZOP Hazard and operability study HAZID Hazard identification study HVPL High vapour pressure liquid JSA Job safety analysis

LPG Liquefied petroleum gas

MAOP Maximum allowable operating pressure MPa

MDR Manufacturer’s data report

MLV Main line valve

MOP Maximum operating pressure MPa

O&M Operation and maintenance

P&ID Piping and instrumentation diagram

PDR Public draft

PRCI Pipeline research council international

QC Quality control

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SAW Submerged arc welded

SCADA Supervisory control and data acquisition SCC Stress corrosion cracking

SIL Safety integrity level SLV Station limit valve

SMYS Specified minimum yield strength MPa

SMTS Specified minimum tensile strength MPa

XS Extra strong

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S E C T I O N 2 S A F E T Y

2.1 BASIS OF SECTION

Pipeline safety management shall be undertaken rigorously, shall apply controls to identified threats and shall reduce residual risk to an acceptable level through a safety management study, and a risk assessment of threats that are not controlled.

All threats to the integrity of the pipeline shall be identified and multiple independent controls shall be applied to each identified threat.

This Standard recognizes the hierarchy of effectiveness of controls: (a) Elimination.

(b) Physical controls. (c) Procedural controls. (d) Reduction.

(e) Mitigation.

Mandatory requirements are specified for control of external interference threats (which are known to be the most frequent events with the potential to create a failure).

Mandatory requirements are specified in high consequence areas for— (i) elimination of rupture; and

(ii) maximum energy release rate.

Where land use changes from a low consequence area to a high consequence area, this Standard applies mandatory requirements for maintaining the risk at an acceptable level. The safety management study shall include stations, pipeline facilities and control systems. The process safety of stations, pipeline facilities and control systems shall also be reviewed by HAZOP and, as appropriate, by other recognised safety study methods.

The safety management process involves two stages:

(A) Design and Safety Review in accordance with this Standard.

(B) Assessment of residual risks in accordance with AS/NZS ISO 31000.

The Licensee shall ensure that pipeline safety management activities are carried out by suitably qualified, trained and experienced personnel.

The safety management process and its outcomes shall be documented and approved.

Pipeline safety management shall be an ongoing process over the life of the pipeline. Safety controls require continuous management so that they remain effective. The outcomes of the safety management study shall be incorporated in the pipeline management system.

This Standard includes requirements for management of construction safety, electrical safety and environmental impacts.

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2.2 ADMINISTRATIVE REQUIREMENTS 2.2.1 Documentation

2.2.1.1 General

All aspects of the safety management process shall be documented with sufficient detail for independent or future users of the safety management study to make an informed assessment of the integrity of the process and its outcomes, including the identification of threats and the reasoning behind the assessment of the effectiveness of the control measures applied.

For new pipelines, or modifications to existing pipelines, the detailed design and the safety management study are undertaken as integrated iterative processes. The output of these processes is a design (generally shown on alignment sheets), and a safety management study document (generally recorded on a database).

2.2.1.2 Pipeline management system

Where threat control requires actions by the Licensee, the obligations of the Licensee shall be documented in the pipeline management system. The pipeline management system shall identify these actions including the implementation of specific risk management actions as an integral part of pipeline safety management.

NOTES:

1 Because the pipeline management system is prepared after the design phase safety management study, the safety management documentation should clearly summarize the obligations of the pipeline Licensee that arise in order to facilitate transfer of these requirements to the pipeline management system.

2 The detailed requirements for the incorporation of the safety management study are provided in AS 2885.3.

2.2.2 Implementation

All actions arising from the safety management study shall be implemented and the implementation documented. Where ongoing action is required, a reporting mechanism to demonstrate action shall be established, implemented and audited.

Safety management documentation shall be transferred from the design and construct phase of the project to the operating phase of the project in a form that enables safety management to be undertaken from the time that operation commences.

For new pipelines, all actions that are considered necessary for the safe pressurization of the pipeline shall be completed prior to the commencement of commissioning.

For existing pipelines the period for the implementation of each action shall be identified as part of the safety management documentation. The schedule for implementation shall be approved.

2.2.3 Safety management study validation

Each detailed safety management study shall be validated by a properly constituted workshop, which shall critically review each aspect of the safety management study.

The information requirements listed in Paragraph B3, Appendix B, shall be considered in the validation workshop.

NOTE: Guidance on assessment of the integrity of the safety management process is provided in Appendix H.

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2.2.4 Operational review

A safety management study shall be conducted as a result of any of the following triggers: (a) At intervals not exceeding five years.

(b) At any review for changed operating conditions. (c) At any review for extension of design life. (d) As may be required by AS 2885.3.

(e) At any other time that new or changed threats occur.

(f) At any time when there is a change in the state of knowledge affecting the safety of the pipeline.

Where a trigger point relates to a part of the pipeline (for example a change at a specific location or a specific safety aspect), the safety management study may be restricted to only that part which is changed.

An assessment of the implementation and effectiveness of all threat controls shall be made at each operational review.

2.3 SAFETY MANAGEMENT PROCESS 2.3.1 General

The pipeline safety management process consists of the following: (a) Threat identification.

(b) Application of physical, procedural and design measures to identified threats. (c) Review and control of failure threats.

(d) Assessment of residual risk from failure threats.

Figure 2.3.1 illustrates the pipeline safety management process. This section describes its detail and application.

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P r e l i m i n a r y d e s c r i p t i o n o f d e s i g n a n d o p e r a t i o n C o m m o n t h r e a t s / c o m m o n t h r e a t l o c a t i o n / s t a n d a r d d e s i g n L o c a t i o n a n a l y s i s T h r e a t i d e n t i f i c a t i o n N o n l o c a t i o n s p e c i f i c t h r e a t s I s t h r e a t c r e d i b l e? A p p l y ex te r n a l i n te r fe r e n c e p r o te c t i o n (w h e r e a p p l i c a b l e) A p p l y d e s i g n & p r o c e d u r e s Fa i l u r e p o s s i b l e? A p p l y f u r t h e r d e s i g n & /o r p r o c e d u r e s C a n f u r t h e r t h r e a t c o n t r o l s b e a p p l i e d? A S / N ZS I S O 310 0 0 R e s i d u a l t h r e a t s r i s k a s s e s s m e n t Fi n a l d e s i g n a n d p i p e l i n e m a n a g e m e n t sy s te m R i s k & d e s i g n a c c e p te d R i s k a c c e p t a b l e Th re a t id en ti fica ti on T h reat control R e s id u a l r is k a s s e s s m e n t N o N o Ye s N o Ye s Ye s Ye s N o

FIGURE 2.3.1 PIPELINE SAFETY MANAGEMENT PROCESS

2.3.2 Threats 2.3.2.1 General

The underlying principle of threat identification is that a threat exists at a location. Threats exist—

(a) at a specific location (e.g. excavation threat at a particular road crossing);

(b) at specific sections of a pipeline (e.g. farming; forestry; fault currents for sections with parallel power lines); or

(c) over the entire length of the pipeline (e.g. corrosion).

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The same safety management process applies to both location-specific and non-location-specific threats.

NOTE: Non-location-specific threats are often qualitatively different to location-specific threats (e.g. corrosion, versus external interference threats at a road crossing).

2.3.2.2 Location analysis

The pipeline route shall be analysed to divide it into safety management sections where the land use and population density are consistent.

A safety management section shall not contain more than one location class.

NOTE: Use of safety management sections facilitates the analysis of threats that apply over whole sections of the route (e.g. farming, forestry, urban development, etc.).

2.3.2.3 Threat identification

Threat identification shall be undertaken for the full length of the pipeline, including stations and pipeline facilities. The threats to be considered shall include, at least—

(a) external interference, (b) corrosion,

(c) natural events, (d) electrical effects,

(e) operations and maintenance activities, (f) construction defects,

(g) design defects, (h) material defects,

(i) intentional damage, and

(j) other threats such as seismic and blasting.

NOTE: Guidance on threats is given in Appendix C.

The threat identification shall consider all threats with the potential to damage the pipeline, cause of interruption to service, cause of release of fluid from the pipeline, or cause harm to pipeline operators, the public or the environment.

NOTE: Typical data sources used to conduct the threat identification include alignment survey data to determine basic geographical information; land user surveys in which land liaison officers gather information from land users on the specific activities carried out on the land, and obtain any other local knowledge; third-party spatial information (GIS type data) on earthquakes, drainage, water tables, soil stability, near-surface geology, environmental constraints, etc., and land planning information.

The threat identification shall generate sufficient information about each threat to allow external interference protection and engineering design to take place. For each identified threat, at least the following information shall be recorded:

(i) What is the threat to the pipeline?

(ii) Where does it occur? (the location of the threat) (iii) Who (or what) is responsible for the activity? (iv) What is done? (e.g. depth of excavation)

(v) When is it done? (e.g. frequency of the activity, time of the year)

(vi) What equipment is used? (if applicable, e.g. power of plant, characteristics of the excavator teeth, etc.).

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2.3.2.4 Threats to typical designs

The pipeline design process involves the development and application of typical designs to locations where there is a common range of design conditions and identified threats. Threats common to typical designs shall be documented. Each typical design shall be subjected to the safety management process in accordance with this Standard to demonstrate that the design provides effective control for the identified threats.

2.3.2.5 Other threats at typical design locations

Each location at which a typical design is applied shall be assessed to determine whether threats other than the threats common to that design exist at that location.

Where other threats are identified, effective controls shall be applied to each of these additional location specific threats.

2.3.2.6 Non-credible threats

Each threat identified as being non-credible shall be documented. The reason for it being declared non-credible shall also be documented. The validity of this decision shall be considered at each review of safety management study.

Non-credible threats do not require controls. 2.3.3 Controls

2.3.3.1 General

Effective controls for each credible threat shall be identified and applied using a systematic process.

Physical and procedural controls shall be applied to all credible external interference threats.

NOTE: Guidance on the criteria for effectiveness of procedural controls is given in Appendix E.

Design and/or procedures shall be applied to other threats.

Control is achieved by the application of multiple independent protective measures in accordance with this Standard.

Controls are considered effective when failure as a result of that threat has been removed for all practical purposes at that location.

Where controls are determined to be not effective for a particular threat, that threat shall be subject to failure analysis.

2.3.3.2 Control by external interference protection

The pipeline shall be protected from external interference by a combination of physical and procedural controls at the location of each identified threat. All reasonably practicable controls should be applied.

External interference protection shall be designed in accordance with Clause 5.5.

The physical controls applied shall be demonstrated to protect the pipeline from the specified threat. The procedural controls shall be demonstrated to be effective in contributing to reducing the frequency of the occurrence of that threat.

Where the minimum requirements of Clause 5.5 cannot be satisfied, other design and/or procedures shall be applied.

NOTE: Re-routing is an example of a design change decision that may be taken here if external interference protection is not sufficient.

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2.3.3.3 Control by design and/or procedures

Design and/or procedures shall be applied to threats other than external interference threats in accordance with this Standard:

(a) Materials shall be specified, qualified and inspected in accordance with Section 3. (b) Pipeline design shall be carried out in accordance with Section 4 and Section 5. (c) Protection against stress and strain shall be designed in accordance with Clause 5.7. (d) Operational controls shall be designed in accordance with Section 7.

(e) Corrosion and erosion protection for the full length of the pipeline shall be designed in accordance with Section 8. Guidance on design for environment related cracking is provided in Appendix P.

(f) Protection against construction related defects shall be in accordance with Section 10. (g) Induced voltage, lightning and fault current protection for sections of the pipeline

affected by these conditions shall be designed in accordance with AS 4853.

NOTE: Further guidance on design for a.c. electrical hazards is provided in Appendix R.

2.3.4 Failure analysis 2.3.4.1 General

Where controls may not prevent failure for a particular threat, the threat shall be analysed to determine the damage that it may cause to the pipeline.

Where the outcome is failure, the analysis shall determine the mode of failure and if applicable, the energy release rate at the point of failure, as inputs to the consequence analysis.

NOTE: Modes of failure include rupture as a running crack in brittle fracture mode, rupture as a ductile tear, hole, pinhole, crack, dent, and gouge, loss of wall thickness.

The analysis may conclude there is no immediate or delayed failure.

Appropriate management actions may be required to minimize non-failure consequences. 2.3.4.2 Treatment of failure threats

Where a failure event is identified additional controls to prevent failure shall be investigated and applied where practicable.

Any remaining failure events shall be subject to risk assessment in accordance with AS/NZS ISO 31000.

2.3.4.3 Documentation

The failure analysis for the specific threat shall document the following (as applicable): (a) The pipeline design features.

(b) The threat.

(c) The mode of failure.

(d) The physical dimensions of the failure. (e) The location of the failure.

(f) The nature of the escaping fluid.

(g) The energy release rate and the contour radius for a radiation intensity of 12.6 and 4.7 kW/m2.

(h) Environmental effects at the location (e.g. wind).

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(i) For fluids with potential to cause environmental damage, the volume release and other factors related to the spread of the fluid in the environment (e.g. oil and drainage systems).

NOTE: Some of this information may be addressed in a generic manner for a given set of pipeline parameters, and does not necessarily have to be documented against every threat analysed.

2.3.5 Risk assessment

Risk assessment of failures shall be undertaken in accordance with AS/NZS ISO 31000. Appendix F provides the requirements for qualitative risk assessment and it provides a risk matrix to be used in an AS/NZS ISO 31000 qualitative risk assessment.

There are circumstances where risk estimation using quantitative methods is required to enable comparison of alternative mitigation measures as a basis for demonstration of ALARP, and in some jurisdictions, to satisfy planning criteria.

2.3.6 Demonstration of fault tolerance

To demonstrate the fault tolerance of the pipeline design, a situation where failure of threat control measures leads to pipe damage or loss of containment shall be considered as a threat. The residual risk of such threats shall be assessed and treated in accordance with Appendix F.

NOTES:

1 Almost all pipeline incidents occur as a result of failure of control measures. Hence failure of threat controls is itself an important threat. The control failure threat(s) should be at a location where the consequences are most severe. It may be appropriate to address failures of different threat controls (e.g. external interference, corrosion) or different locations.

2 It is recommended that such threats are identified toward the end of the safety management review by which time sufficient knowledge of the threats and controls will have been developed to identify locations where fault tolerance is an essential part of the design.

2.4 STATIONS, PIPELINE FACILITIES AND PIPELINE CONTROL SYSTEMS 2.4.1 General

Stations and pipeline facilities involve processes that control or change the operating conditions of the fluid being transported. Such facilities are above-ground and contain operable components. Consequently, the threats and failure outcomes are normally different than those for a pipeline.

2.4.2 Safety assessments

The safety of facilities shall be assessed by the application of one or more of a number of recognized safety study methodologies. The most appropriate methodologies shall be used for each facility.

As a minimum—

(a) a hazard and operability (HAZOP) study shall be made to determine the process safety of each facility; and

(b) non-process threats shall be reviewed in accordance with the safety management process in this Standard.

NOTE: Other methodologies that should be considered include CHAZOP, SIL and numerical risk assessment.

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2.5 ENVIRONMENTAL MANAGEMENT

This Standard requires the threats to the environment from each part of the life cycle of the pipeline to be identified and control measures implemented so that risks to the environment are reduced to an acceptable level. Preference shall be given to ensuring environmental threats are managed by avoidance (route selection) and, where necessary, specific construction techniques.

The requirements of this Standard complement the requirements of regulatory authorities in assessment and management of environmental risk, and are intended to be used during planning construction and operational phases of a pipeline to ensure that—

(a) environmental management effort is concentrated on significant threats;

(b) environmental management methods are assessed holistically for their contribution to minimizing the impact to the environment; and

(c) there is a basis for assessing alternative construction and management methods to minimize the impact of the environment

Effective environmental impact assessment requires gathering basic environmental data and shall include consultation with key stakeholders at an early stage so that all relevant information required for all subsequent planning is available.

An environmental impact assessment shall be conducted in accordance with this Standard along the length of the pipeline route. The environmental impact assessment report shall form the basis of the environmental management plan.

An analysis of the impacts of construction techniques and design at sensitive locations shall be included in the environmental impact assessment.

Threat of damage to the environment from operational maintenance and abandonment activities shall be identified and control measures developed. The environmental management plan shall include procedures for protecting the environment from constructions, operation maintenance and abandonment activities. The environmental management plan shall address emergency situations.

NOTE: The APIA Code of Environmental Practice provides industry accepted guidance on management of the Environment through the Design, construction and Operational phase of a project.

The following data shall be obtained prior to conducting the environmental safety assessment:

(i) Basic environmental data (including cultural heritage and archaeological data). (ii) Stakeholder survey information.

(iii) Constructability/and safety constraints. (iv) Emergency response capabilities. (v) Legislative requirements.

NOTE: For guidance on the environmental management process, see Appendix I.

2.6 ELECTRICAL

A pipeline can be subject to significant voltages that can be hazardous to the pipeline itself, or to personnel who may come in contact with it.

High voltages can arise due to a variety of causes, such as earth potential rise in the vicinity of electrical earthing under fault conditions or due to voltages induced on the pipeline when faults occur on nearby parallel powerlines.

A pipeline in the vicinity of electricity supply powerlines or facilities shall be analysed to determine if controls are required to provide for electrical safety.

NOTE: General guidance on electrical safety is given in Appendix R.

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2.7 CONSTRUCTION AND COMMISSIONING 2.7.1 Construction safety

Construction of pipelines shall be carried out in a safe manner.

The safety of the public, construction personnel, adjacent property, equipment and the pipeline shall be maintained and not compromised.

A construction safety plan shall be prepared, reviewed by appropriate personnel, and approved. This review shall take the form of a construction safety plan workshop.

Specific construction safety requirements exist in each regulatory jurisdiction. The more stringent of the regulatory requirements and the requirements of this Section shall apply.

NOTES:

1 Review by appropriate personnel should include designers, construction personnel, OH&S personnel, environmentalists and/or the approval authority.

2 The construction safety plan detail should be consistent with the nature of the work being undertaken. It may be a component of an integrated construction safety system, a construction safety case (where the regulatory jurisdiction requires this), or a project or activity specific safety plan.

At least the following shall be addressed:

(a) Fire protection shall be provided and local bushfire and other fire regulations shall be observed.

(b) Where the public could be exposed to danger or where construction operations are such that there is the possibility that the pipeline could be damaged by vehicles or other mobile equipment, suitable physical and/or procedures measures shall be implemented.

(c) Where a power line is in close proximity to the route safe working practice shall be established.

(d) Where a pipeline is in close proximity to a power line, potential threats from induced voltage and induced or fault currents to personnel safety shall be assessed and appropriate measures taken to mitigate dangers to personnel and equipment.

NOTE: For guidance on measures that may be implemented, see Appendix R.

(e) Adequate danger and warning signs shall be installed in the vicinity of construction operations, to warn persons of dangers (including those from mobile equipment, radiographic process and the presence of excavations, overhead powerlines and overhead telephone lines).

(f) Unattended excavations in locations accessible to the public shall be suitably barricaded or fenced off and, where appropriate, traffic hazard warning lamps shall be operated during the hours of darkness.

(g) During the construction of submerged pipelines, suitable warnings shall be given. Signs and buoys shall be appropriately located to advise the public of any danger and to minimize any risk of damage to shipping. Where warnings to shipping are required by an authority controlling the waterway, the authority’s requirements for warnings should be ascertained and the authority advised of all movements of construction equipment.

(h) Provision of adequate measures to protect the public from hazards caused by welding. (i) Procedure to be followed for lifting pipes both from stockpile and into trench after

welding.

(j) Procedure for safe use and handling of chemicals and solvents.

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(k) Frequency and provision of safety talks (tool box meetings). (l) Accident reporting and investigation procedure.

(m) Appointment of safety supervisor and specification of duties. (n) Travel associated with attending the worksite.

(o) Statutory obligations. (p) Traffic management plan.

NOTE: APIA document Onshore Pipeline Projects, Construction Safety Guidelines provides guidance on construction safety for the Australian Pipeline Industry.

2.7.2 Testing safety

The construction safety plan shall address safety through all phases of testing of the pipeline during construction.

2.7.3 Commissioning safety

The commissioning plan shall consider the safety of the activities undertaken through all phases of commissioning and, where required, develop specific procedures to manage the safety during commissioning of the pipeline.

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S E C T I O N 3 M A T E R I A L S A N D C O M P O N E N T S

3.1 BASIS OF SECTION

Materials and components shall be fit for purpose for the conditions under which they are used, including construction. They shall have the pressure strength, ductility, fracture toughness, weldability, temperature rating, and design life specified by the engineering design.

The engineering design shall take into account the effect of all of the manufacturing and construction processes and service conditions on the properties of the materials.

3.2 QUALIFICATION OF MATERIALS AND COMPONENTS 3.2.1 General

Materials and components shall comply with one or more of the relevant requirements of this Clause. They shall be supplied with test certificates containing sufficient data to demonstrate compliance with this Standard, the engineering design, the relevant nominated Standard(s), and any supplementary specifications.

Where materials and components do not comply with nominated standards and have been qualified in accordance with this Clause, documentary evidence of that qualification shall be provided and approved.

3.2.2 Materials and components complying with nominated Standards

Where allowed by the engineering design, materials and components complying with one of the following nominated Standards may be used for appropriate applications as specified and as limited by this Standard without further qualification. Except as provided in Clause 3.4.3, they shall be used in accordance with the pressure/temperature rating contained in those Standards:

NOTES:

1 Nominated Standards for materials and components, especially line pipe specifications API Spec 5L and ISO 3183, contain multiple options that need to be specified by the purchaser, and for this reason, as well as the very common specification of supplementary requirements by pipeline designers, compliance with a nominated Standard will be necessary but insufficient.

2 A particular example where compliance with a nominated line pipe Standard will be insufficient for Australian pipelines arises from the fact that API Spec 5L and ISO 3183 do not require drop weight tear testing below DN 500, whereas AS 2885.1 requires control of brittle fracture by DWTT down to DN 300, and by alternative methods for smaller diameters. 3 Multiple examples have occurred in recent years of pipeline projects where materials certified

as complying with nominated Standards was found in audit and/or pressure testing not to comply, and so care should be exercised by line pipe purchasers to ensure that appropriate levels of inspection and quality assurance are implemented (see e.g. USA DOT PHMSA Advisory Bulletin ADB-09-01).

(a) Pipe—Carbon/carbon manganese steel pipe. API Spec 5L, ISO 3183, ASTM A106, ASTM A333, ASTM A671.

NOTES:

1 ASTM A106 specifies pipe for high temperature service and has no specific requirements for Charpy toughness. It is usually unsuitable for use in pipelines, stations and pipeline assemblies unless toughness properties are specified, and specific tests are made to confirm compliance.

As 2885.1-2012 Design and Construction

AS 2885.1—2012

Australian Standard

®

Pipelines—Gas and liquid petroleum

Part 1: Design and construction

AS 2885.1—2012

Australian Standard

®

Pipelines—Gas and liquid petroleum

Part 1: Design and construction

PREFACE

CONTENTS

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

S E C T I O N 2 S A F E T Y

S E C T I O N 3 M A T E R I A L S A N D C O M P O N E N T S