NIOEC-SP-50-50(0)

DOCUMENT CODE
PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. NO. OF PAGES: 16 DATE

NIOEC

000

EG

PL

SP

5050

A0

OCT., 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

NIOEC SPECIFICATION FOR

PIPELINE DESIGN CRITERIA

FIRST EDITION OCT., 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY, REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

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REV. PAGE

REVISION INDEX
REV. PAGE

REV. PAGE

REV. PAGE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

NOTES:
1) 2) 3) 4) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION. REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS. WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL DOCUMENT. NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET

5 4 3 2 1 0 OCT., 2005 M.R.HABIBZADEH G.R.KHOSHROO M.R.FARZAM M.A.A.SAJEDI

REV.

DATE

PREPARED

CHECKED 2

APPROVED

AUTHORIZED

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PAGE NO.

CONTENTS:
1. 2. 3. 4. 5. 6. 7. 8. 9.

SCOPE........................................................................................................................................4 REFERENCES ..........................................................................................................................4 UNITS.........................................................................................................................................4 DEFINITION OF PIPELINE ..................................................................................................5 PROCESS DESIGN ..................................................................................................................5 MECHANICAL DESIGN ........................................................................................................5 PIPELINE ANCHORS, SUPPORTS, GUIDES, SHOES, ETC. ..........................................9 PIPELINE ROUTE...................................................................................................................9 BURIED PIPELINES .............................................................................................................10

10. MAJOR RIVER CROSSINGS ..............................................................................................13 11. ROAD, RAILWAY AND PIPELINE CROSSINGS............................................................13 12. CATHODIC PROTECTION FACILITIES.........................................................................14 13. INTERNAL CORROSION ALLOWANCES ......................................................................16 14. CORROSION INHIBITION AND MONITORING ...........................................................16

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1.

SCOPE 1.1 This design criterion covers the general requirements to be implemented in the design of pipeline transportation systems for liquid hydrocarbons and other liquids. 1.2 Included in the scope are the following installations: - Tie-in connections at river & road crossing separators. - Pumping and / or scraper trap station. - Terminals - Any intermediate sectional and isolating valves and other installations directly associated with the pipelines, such as vent & drain valves. 1.3 The engineering and design requirements which have not been mentioned in this specification, shall be referred to NIOEC-SP-50-63.

2. REFERENCES Throughout this Specification the following dated and undated standards/ codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this Specification. For undated references, the latest edition of the referenced document (including any supplements and amendments) applies. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date, shall mutually be agreed upon by NIOEC and the Vendor/Contractor. API API 5L ASME (AMERICAN PETROLEUM INSTITUTE) Specification for Line Pipe (AMERICAN SOCIETY OF MECHANICAL ENGINEERS) Steel pipe flanges and flanged fittings Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B16.5 ASME B31.4 MSS

(MANUFACTURERS STANDARDIZATION SOCIETY) "Steel Pipeline Flanges" (NIOEC SPECIFICATIONS) NIOEC Specification for Units NIOEC Specification for Transportation Pipeline (Onshore) Pressure Testing NIOEC Specification for Pipeline Engineering NIOEC Specification for Cathodic Protection System NIOEC Specification for Insulation NIOEC Specification for Three Layers Polyethylene Coating System NIOEC Specification for Welding of Transportation Pipeline

MSS-SP-44 NIOEC-SP NIOEC-SP-00-10 NIOEC-SP-50-62 NIOEC-SP-50-63 NIOEC-SP-60-24 NIOEC-SP-80-01 NIOEC-SP-80-51 NIOEC-SP-90-51 3. UNITS

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International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless otherwise specified. 4. DEFINITION OF PIPELINE 4.1 Main oil trunk line defined as the piping, valves, and fittings between the main block valve on the pumping station outlet line and the main block valve on terminal inlet line, but excluding piping, valve, and fittings corresponding to main-line block valves and / or other intermediate station facilities piping. 5. PROCESS DESIGN 5.1 5.2 5.3 The effects of surge in main product pipeline shall be checked using an appropriate method of calculations. Hydraulic design of pipeline shall include summer and winter conditions. Velocity limitation and pressure drop calculations shall be in accordance with NIOEC-SP50-63.

6. MECHANICAL DESIGN 6.1 General 6.1.1 6.1.2 6.1.3 Facilities shall be provided on all pipelines to enable the lines to be pigged before commissioning and on "main oil lines" during operation. Adequate means of isolation must be provided to enable all sections of pipelines and associated piping to be hydrostatically tested. Vent and drain connections shall be provided where necessary for satisfactory commissioning and operation. NOTE Drain connection shall be seen only at on-plot piping. 6.1.4 Insulating joints shall be provided where necessary in cathodically protected lines and where the pipeline enters into the pumping stations, etc. Particularly to isolate unprotected installations from protected Installations. In lieu of insulating joint on small river overcrossings, the pipeline may be insulated from all supports and unprotected facilities.

6.2

Pipeline Wall Thickness 6.2.1 Liquid pipelines shall be designed to operate at maximum expected operating pressure in steady state conditions at a maximum hoop stress in the pipe wall of 72% of the specified minimum yield strength of the pipe steel, in accordance with ASME code B31.4. The calculated effects of transient surge due to sudden closure of valves or stoppage of pumps, etc., shall not increase the maximum hoop stress to more than 79.2% of the specified minimum yield strength of the pipe steel when operating at maximum pressures and flow rates. Pipeline wall thickness shall be sufficient to satisfy the above mentioned design conditions, subject to the pressure / temperature limitations given in ASME codes

6.2.2

6.2.3

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B31.4, taking into account the minimum thickness, required for satisfactory handling and construction. For example, consideration shall be given to increase wall thickness at river and/or major dry stream crossing, block valve site, etc. As a guide to the minimum pipe-wall thickness which may be safely employed to the allowable bending radius, it has been found that pipes of the following wall thicknesses and below will wrinkle. Pipe nominal diameter 6" 8" 10" 12" 16" 18" 24" 30" 36" 42" 48" 56" 6.2.4 pipe wall thickness 4.8 mm (0.188") 4.8 mm (0.188") 5.6 mm (0.219") 6.3 mm (0.250") 6.3 mm (0.250") 6.3 mm (0.250") 8.0 mm (0.312") 8.0 mm (0.312") 9.5 mm (0.375") 9.5 mm (0.375") 9.5 mm (0.375") 10.31 mm (0.406")

In calculating minimum wall thickness, consideration shall also be given to the effects of transient surge downstream of the initiating point.

6.3

Materials 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 Construction materials shall comply with the relevant ASME code B31.4. Whenever possible, NIOEC selected MESC items shall be used in preference to other materials or sizes. Fully welded construction shall be used where possible. All removable connections of 2" and larger shall be flanged. For connections 1 1/2" and smaller, socket welding fittings shall be used. Screwed joints shall be avoided wherever possible and their use limited to those joints which will be necessary to disconnect during service.

6.4

Line Pipe 6.4.1 6.4.2 Line pipe shall comply with last Ed. of API specifications 5L. Line pipe shall be seamless (SMLS), Submerged Arc Welded (SAW), Double Submerged Arc Welded (DSAW) high (Electron) Frequency Welded (EFW) or Electric Resistance Welded (ERW).

6.5

Valves 6.5.1 Wedge gate valves or reduced bore through conduit or ball valves may be used in piping which will not be pigged. Where reduced bore valves are used, the valve inlet and outlet passages shall be specified to match the pipe internal diameter. Where space considerations are important, use of "wafer" type check valves may be considered. Ball valves of size 10" and larger shall be trunnion mounted and be equipped with a secondary seal system to provide shut-off in the event of failure of the primary seal. Main line valves shall be welded into the pipeline. 6

6.5.2 6.5.3 6.5.4

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6.5.5

6.5.6

6.5.7

6.5.8 6.5.9

Where weld-end valves are fitted with hydraulic actuators and are employed in a cathodically protected pipeline, particular attention shall be given to electrical isolation of the actuator and/or stem riser from the valve in order to avoid leakage of cathodic protection current. Valves may be installed above ground at on-plot facilities, in concrete valve pits or may be buried for transmission pipeline. If buried, the valves shall be effectively coated with bitumen base mastic or an alternative insulating material. The rating of valves shall be sufficient to satisfy the maximum operating and test pressure of the pipeline, subject to the pressure / temperature limitations given in ASME codes B31.4. Valves to be employed for hot-tapping shall be selected with due regard to the capabilities of hot-tapping equipment available. Mainline valves will be spaced based on the followings : - At either sides of pumping station and/or incoming pipeline to terminal point. - At either sides of river crossings. - At max. 20 km interval within populated, industrial and/or city future development boundaries, up to 25 km for normal rout condition. - At some areas to facilitate maintenance activity and reduce excessive spillage during probable pipeline rupture. - At either sides of geologically hazardous area such as fault, land slide, salt dome, etc. - At either sides of very aggressive corrosive area. These valves will be locally operated to isolate sections of the pipelines for maintenance purposes or in the event of pipeline failure. At some special location as directed by NIOEC mainline valves with line break controls will be installed. All mainline valves will be full-opening to allow passage of scrapers pig during internal cleaning operations, normal operations, and also they must be equipped and /or designed with by-pass balance connection (minimum size 2").

NOTES At some specific location to be determined by the client, the abovementioned pipeline valves shall be equipped with automatic line break system. Recommendations for such specific locations are as follows: - At either sides of major river crossings (with through the year considerable water flow). - At either sides of geologically risked factor area. - At either sides of major city boundaries. 6.5.10 All valves and control valves specification shall be in accordance with the spec. mentioned in piping and instrumentation diagrams. 6.5.11 All pipeline valves shall be provided with double block and bleed or equivalent system. 6.5.12 Control valves shall be installed in horizontal pipe in a vertical plain. Manifold arrangement shall consider access, clearance, maintenance and removal of control valve without removing of stop valves. A valved drain shall be installed at the low point of control valve assemblies on upstream side of control valve body. Control valve manifold shall preferably be located within view of associated control room. 6.6 Fittings, Flanges, Gaskets, Branch Connections, Etc. 6.6.1 Fittings which will be welded to API 5L line pipe shall be specified as being compatible for welding to the particular grade considered. 7

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6.6.2 6.6.3 6.6.4

6.6.5 6.6.6 6.6.7

Butt welding fittings shall be used for all connections of 2" and larger in the pipelines. Pipes, fittings, and flanges shall be selected so that the component parts to be welded are the same inside bore diameter. For flow lines and high pressure lines, with rating above ASME class 900#, "Ring Type Joint" flanges to API shall be employed. All other pipelines shall incorporate "Raised Face" flanges. Flanges shall be of the "Welding Neck" type. Where applicable, flanges of size 1/2" to 24" shall be in accordance with ASME B16.5; MSS SP 44 flanges shall be used in size of 26" to 60". Except where insulated joints are required, gaskets shall be spiral wound, graphite filler type. Gaskets shall only be used for class 150# rating lines.

6.7

Pigging Facilities 6.7.1 All main oil and crude oil product lines shall be provided with suitable facilities to enable the lines to be pigged to ensure complete cleaning out of all foreign debris and sludge, before commissioning and if required during subsequent operation. Control system of pigging facilities shall be appropriately designed to provide automatic pigging operation in addition to the manually operation option. An electrical pig signaler shall be incorporated at an approximate distance of 1.0 km prior to any receiving trap. Pig receiving and lunching traps or spool pieces shall be installed at suitable locations to enable the required pigging and testing operations to be performed. In all cases, scraper traps will be installed at the inlet and outlet of each pumping station(s) and inlet of terminal facilities. Where branches are 40% or more of main line diameter, tees shall be employed and shall be fitted with scraper guide bars. Branches less than 40% of the main line size may be installed using approved weldolets if allowed by the respective design code. In product pipeline where a sphere pig is likely to be used, scraper guide bars must be used on all branches or consideration shall be given to the use of proprietary tees specially designed for the duty. The use of pig signalers or pigs with noise making devices shall be considered as methods of locating pigs in pipelines. Pigs signalers equipped with transmitters / receiver are preferred. Radioactive pig detectors are not recommended.

6.7.2

6.7.3

6.7.4

6.7.5

6.8

Vents and Drains 6.8.1 Vent and drain valves shall be 1" minimum for pipelines up to 12" , and 2" minimum for pipelines above 12" . These minimum sizes may however be increased as necessary to meet the special requirements of the client. Vent valves may be installed above ground, in concrete valve pits. After commissioning of buried lines, vent/drain valves apart form those in fenced areas, shall be blanked off, hand wheels removed, the valve assemblies completely protected with bitumen base mastic or similar coating. Pipeline markers inscribed "VENT" and/or "DRAIN" shall be installed adjacent to each valve's location. After commissioning of above ground lines, the vent valves or drain valves shall be blanked off and the handwheels securely locked in the closed position.

6.8.2 6.8.3

6.8.4

6.9

Welding Welding of carbon steel pipeline shall comply with NIOEC-SP-90-51.

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6.10 Hydrostatic Testing The pipeline and associated piping system shall be hydrostatically tested in accordance with NIOEC-SP-50-62. 6.11 Insulation 6.11.1 Lines requiring insulation shall be noted on flow diagrams. 6.11.2 Insulation type, material and thickness shall be noted by insulation spec. number (NIOEC-SP-80-01) on pipeline drawings. 6.12 Pipeline Flexibility 6.12.1 Thermal Stresses All pipelines must be designed generally for expansion / contraction under start-up and operating conditions without overstressing the pipes, valves, fittings and flanges. Stress due to thermal expansion / contraction must not exceed the allowable stress range defined by ASME piping codes.

7. PIPELINE ANCHORS, SUPPORTS, GUIDES, SHOES, ETC. 7.1 General All pipelines shall be adequately supported, guided, anchored or strutted whereby necessary so as to prevent undue vibration, deflection, or stress. Thermal expansion / contraction, dynamic effects (impact. wind, earthquake, and vibration) , and weight effects (live loads, dead loads , and test loads) shall be considered in the design so that stresses created by these combined loads shall comply to ASME piping codes. 7.2 Pipeline Over-Crossing - Proper location of pipeline supports, anchors, and guides shall be indicated on pipeline route drawing. Details shall be shown civil detail drawings. - Pipe supports if required, shall be wide enough to ensure pipeline does not fall of the supports during maximum expansion / contraction. - Where lines are insulated, the insulation shall be cut back to clear the support with allowance for expansion / contraction, and due to seismic effects. 8. PIPELINE ROUTE 8.1 General 8.1.1 An initial selection of possible pipeline routes corridor shall be made after an assessment of the following considerations : - Length of line - Terrain to be crossed - Avoidance of populated areas - Difficult sections, e.g. river crossings - Existing pipeline right-of-way - Other pertinent factors A site check of the selected pipeline route corridor shall be made before a route survey is carried out. This check shall be made before a final proposal is issued.

8.1.2

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8.2

Route Survey 8.2.1 The pipeline route shall be subjected to a survey by survey operation section after the selected route has been marked and agreed as being suitable. The scope of survey shall be determined or approved by the company. In certain sections, surveys of possible alternative routes may be necessary before the pipeline route is finalized. Each pipeline survey shall include a plan at a scale equal 1:10,000 and a profile with horizontal and vertical scales of 1:10,000 & 1:1000 respectively. Where the pipeline route passes through difficult section, e.g. river crossings, builtup areas, railway crossings, etc., additional plan and profile drawings shall be provided at enlarged scales. In certain areas full topographic surveys may also be required. The plan and profile drawings shall include details of the following features: - Any road crossings - Track crossings - Railway crossings - River crossings - Stream or gully crossings - Areas subject to flooding - Sand dune areas - Buried pipeline crossings - Surface pipeline crossings - Overhead electrical power lines within 500 meters of the proposed pipeline - Villages and built-up areas within 500 meters of the pipeline - Any factory or other installation within 500 meters of the pipeline which may present a hazard. The profile drawings shall show the natural ground elevation along the pipeline route, the elevation being expressed in meters above mean sea level. The profile drawings shall also indicate areas in which major excavation or elevated pipeline supports may be required.

8.2.2 8.2.3 8.2.4

8.2.5

8.2.6 8.2.7

8.3

RightOfWay 8.3.1 A rightofway is required for pipeline to enable the line to be constructed and to allow access for future pipeline maintenance.

9. BURIED PIPELINES 9.1 General 9.1.1 9.1.2 Cross-country pipeline may need to be buried for process reasons or in certain area where above ground lines would not be acceptable, e.g. populated areas. Buried pipelines shall be coated externally and cathodically protected against corrosion.

9.2

Trench Dimensions 9.2.1 The width of trench shall not be less than 500 mm wider than the pipeline diameter in all ground conditions including rock.

10

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9.2.2

The trench shall be sufficiently deep to provide 200 mm minimum soft padding around the pipeline and 900 mm minimum cover between the top of the pipe and mean graded level of the right-of-way. NOTE The 900 mm min. cover shall increase to 1500 mm in sandy area, the backfill in such case where there is the possibility of erosion by wind shall be reinforced by sand bags and/or rock fill at its top 20 cm layer at least. The depth of cover may be reduced to 600 mm in rocky ground under certain circumstances, (e.g. in isolated desert locations where vehicles would be unlikely to cross over the pipeline). In built-up areas, in cultivated areas, at dry water courses and also where vehicles are likely to cross the pipeline, it may be necessary to increase the minimum cover by increasing the depth of trench comprising the followings: Cultivated Area Depth : 120 cm + O.D of pipe (Minimum) Non-rocky Bed Dry Stream / Water Way crossing Except where noted on pertinent construction drawings: Depth : 170 cm + O.D of pipe (Minimum) Rocky Bed Dry Stream / Water Way Crossing Depth : 120 cm + O.D of pipe (Minimum) Major Road Crossing at any Soil Condition Except where noted on pertinent construction drawings: Depth : 200 cm + O.D of pipe (minimum) measured from lateral natural ground. Major River Crossing at any Soil Condition Except where noted on pertinent construction drawings: Depth : 320 cm + O.D of pipe (Minimum) measured from toll-way. Dirt Road / R.O.W Crossing Except where noted on pertinent construction drawing, while incorporating load bearing slab across the whole length of crossing. Depth : The same as corresponding terrain depth on either side of crossing. Existing Buried Pipeline / Duct / Cable Crossing Under Crossing Depth : Existing structure depth + O.D of under construction pipeline + 70 cm (minimum)

9.2.3

9.2.4

9.2.5

In addition to the minimum cover specified for the pipeline, the trench backfill shall be crowned to a min. height of 300 mm above the surrounding ground. However, crowning may be omitted in built-up and heavily cultivated areas where increased depth of cover is specified. Crowing shall always be omitted at dry water course and/or river crossings.

9.3

Corrosion Protection 9.3.1 External surface over the trench pipeline and the welded ends of shop coated line pipe in Buried pipelines shall be sandblasted to Swedish standard sa 2 1/2 to remove mill scale and primed irrespective the type of coating system selected for the 11

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pipeline. Such activities shall be accomplished prior to coating/ wrapping operation. The choice of coating system shall be based on an economic comparison between the coating types considering the capital, operating, and maintenance costs of the cathodic protection system. 9.3.2 9.3.3 9.3.4 External corrosion coating shall comply with NIOEC-SP-80-51. Cathodic protection by impressed current shall be applied to all along the buried pipelines as per NIOEC-SP-60-24. Consideration shall be given to the installation of sacrificial anodes and/or other forms of temporary cathodic protection system on short period when permanent cathodic protection system is not yet ready to operate.

9.4

Thermal Expansion 9.4.1 Pipelines which are buried at a depth or cover recommended herein, may be assumed to be fully restrained by the backfill and thermal expansion contained. Except for the last 500 m of pipeline ends which rise above ground or vice versa, which stress should be evaluated and analyzed and reported.

9.5

Pipeline Anchors 9.5.1 Pipeline anchor blocks are designed and/or constructed, incorporating standard manufactured forged flange which shall be installed at the end points of buried pipelines and at other locations where the pipeline rises above ground level for tie-on connections. Design procedure shall include the following parameters. - The minimum local soil shearing stress - The temperature difference between installation and operating temperature shall not be less than 70 c. - Hoop stress in the adjoining nipples imbedded by reinforce concrete block shall not increase 60% of SMYS of the line pipe. (subject to not disturbing pigging operation) - Depth of the pipeline at anchor block location shall not be less than 2.0 meter. - The distance between anchor block and point where pipeline rises above ground shall not exceed 40 times the diameter. - All section of pipeline as well as anchor flange which are imbedded in concrete anchor block shall be insulated with appropriate coating material. - Concrete pouring activity into the form-work shall be carried out continuously to avoid any cold lap. - Complete section of anchor flange including adjoining nipples shall hydrostatically pretested prior to tie-in welds and concrete pouring. Design procedure shall be stated. Where a buried pipeline passes through areas subject to seasonal inundation or passes under dry water courses, consideration shall be given to the need for concrete coating or the installation of anchors or anchor weight, or geotextile baskets. Continuous concrete, buoyancy, or geotextile baskets weights shall be designed on the basis of maintaining negative buoyancy. When calculating negative buoyancy the density of water logged backfill mud shall be taken into account. Particular attention must be paid to the special requirements in areas where ground conditions are poor, e.g. in marshy or sandy areas. The overall negative buoyancy coefficient including water logged mud, density and safety factor shall not be less than 1.3 kg/cm3.

9.5.2

9.5.3

12

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10. MAJOR RIVER CROSSINGS 10.1 General 10.1.1 In case of major river over crossing, elevated pipe supports shall be high enough to carry the line at least 1000 mm clear of maximum expected flood level (based on past 50 years data gathered). This clearance shall be increased if there is a likelihood of large floating objects being carried by flood waters. 10.1.2 Pipelines laid under the river bed shall be coated with reinforced type coating, and continuous concrete weight coated to give negative buoyancy sufficient to restrain the pipeline in position at all times during construction and subsequent operation. The concrete weight coating shall normally be designed to maintain pipeline stability in mud of specific gravity of 1.3, but the nature of the river bed shall be taken into account in each case. 10.1.3 Depth of cover of pipelines installed under the river bed shall be selected for the particular application to prevent damage to the pipeline when it is installed. Such depth for all river and / or major dry stream shall not be less than 3.0 meter measured from toll-way. 10.1.4 Isolating valves fitted with actuator shall be installed in fenced areas on either side of major river crossings. If installed in valve pits, the top of the pits shall be minimum 1 meter above maximum recorded high water level. 10.1.5 Insulating joints shall be installed adjacent to each river crossing isolating valve and the cathodic protection integrity shall be made by bonding across the insulating joints. Thus, if the coating is damaged at the river crossing, temporary means can be provided to protect the pipeline at crossing section without affecting the cathodic protection of the whole pipeline on its either side. 10.2 Geological Survey At Major Crossings 10.2.1 A survey shall be made in accordance with scope of work as determined or approved by NIOEC at each major river crossing between block valves. 10.2.2 The geological survey shall be include the following details: - Elevation of river banks. - Elevation of river bed at maximum intervals of 20 meters. - Water level at time of survey. - Maximum recorded high water level. - Minimum recorded low water level. - Current velocity at time of survey. - Maximum anticipated current velocity. - Details of any existing bridges, or other features within 100 meters upstream or downstream of the river crossing. 10.2.3 Soil strata and its geotechnical features shall also be required across the river crossing to determine the nature of the river bed. 11. ROAD, RAILWAY AND PIPELINE CROSSINGS 11.1 Railway Crossings Casings will be installed as required at points where the pipelines cross any railroad. Casings will generally be a larger pipe of thicker wall thickness. Seals will be installed at 13

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the ends of each casing to prevent moisture and rodents from entering. Insulators will be installed at regular intervals (max. 3meters interval) on the carrier pipe throughout the casing to prevent electrical shorting between the casing and the carrier pipe. Casing will be vented to atmosphere to prevent rupturing of the casing seals in the event of a carrier pipe leak. 11.1.1 Crossings of railways shall be made without interruption or railway traffic. 11.1.2 If the railway is on an embankment, the crossing shall preferably be made under an existing bridge. If this is not possible, the pipeline shall be laid in a thrust or auger bored casing pipe with concentric insulating supports. 11.1.3 If the railway is in a cutting, small diameter pipelines shall cross on a pipe bridge. The design of pipe bridge shall satisfy the requirements of the Railway Authority. Large diameter lines shall be treated similarly to 11.1.2 above. 11.2 Asphalt Road Crossings The pipeline wall thickness across the road and its boundary limits will be designed based on two standard sizes over the wall thickness of the line pipes adjacent to crossing. NOTES a. Details of proposed crossings of roads, railways and buried pipelines shall be submitted to the appropriate authority for Approval before construction commences. b. Details to be submitted shall include the followings: - Drawing(s) of proposed crossing. - Description of proposed construction method - Approximate date of construction c. Mechanical protection for the pipeline as mentioned in Para. 11.1 & 11.2 shall also be implemented for nearly future and/or under construction rail/asphalt road. d. Future expansion for the width of existing rail / asphalt road shall also be envisaged in the design dimension of the crossing. 11.3 Gravel Road Crossings 11.3.1 Crossing of secondary roads shall be made utilizing increased depth of cover as well as load bearing slab. 11.3.2 Crossings of highways and those public roads which can not be excavated by open trench shall be made using thrust bored crossings and pipe casings. 11.3.3 Suitable protection and warning objects shall be provided on both sides of the road to prevent damage to the pipeline by vehicles leaving the road. 11.3.4 If the roads (11.3.2) can be excavated by open trench the insitu concrete box culvert with removable constructed for road crossing, the depth cover shall be of top of culvert measured from natural ground shall be equal to general burial depth of pipeline plus 1 meter. 11.4 Pipeline Crossings 11.4.1 Where a buried pipeline is to cross an existing buried pipeline, the new line shall pass under the existing line with at least 800 mm clearance between lines. Warning plastic grating and/or concrete slab shall also be installed over the new line. 12. CATHODIC PROTECTION FACILITIES 12.1 General 14

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12.1.1 All buried pipelines shall be protected cathodically against external corrosion. As the pipeline is laid, cathodic protection test points are placed at every 1 km of pipeline route and every cased crossing, insulating joint, pipeline crossing, river crossing, and other strategic locations. For complete protection by due consideration to the sulfate reducing bacteria the pipeline potential shall be at least maintained at -0.95 volts referred to copper / copper sulfate reference electrode over the entire length of the pipeline. 12.1.2 Cathodic protection may be provided by impressed current or by sacrificial anodes or by a combination thereof. The cathodic protection station shall be installed at a max spacing of 40 km. 12.1.3 Impressed current systems shall be selected for long pipelines as such systems allow better potential control evenly current distribution and generally have financial advantages over sacrificial anode systems. 12.1.4 Design of a cathodic protection system shall be carried out after a soil resistivity measurements being taken at the following locations: - At every 500 meters along the pipeline route and at depths of 2 and 3 meters below ground level. - At ground bed locations and at depths of 2, 3, 5 and 10 meters below ground level. - At areas where low soil resistivities are expected, e.g. at river crossings and in marshy ground. 12.1.5 Account shall be taken of nearby buried pipelines, buried steel structures, overhead electrical power distribution lines and other sources of stray electrical currents which may affect the cathodic protection system. 12.1.6 The cathodic protection systems of parallel pipelines along the same right-of-way shall normally be integrated into one system. 12.1.7 Where pipelines cross each other, they shall be bonded together, if necessary through a resistance bond, to prevent interference between the systems. 12.2 Impressed Current Systems 12.2.1 Transformer/rectifiers shall whenever possible be supplied from a firm source of electrical power. Electrical supply form individual generating sets either by solar panel or fuel-engine shall also be envisaged for cathodic protection power requirement. 12.2.2 Each transformer/rectifier unit shall be of the double wound type, complete with an IP54 panel equipped with input isolating switch and fuses, an off-load means of adjusting the output voltage in steps of 0.5 volts approximately and an ammeter and voltmeter in the output, suitably scaled and protected by fuses. A voltage surge diverter, having a suitable breakdown voltage shall be connected between the positive and negative output terminals. The units shall be designed for continuous operation in the specified site conditions, and where units are installed out side, they shall be waterproofed, fitted with sun canopies and placed within fenced area. 12.2.3 Ground bed anodes shall be of the linseed oil impregnated graphite type for ground bed soil resistivity of 5000 ohm.cm and more and/or silicon cost iron for groundbed soil resistivity less than 5000 ohm.cm installed vertically and/or horizontally in the center of cylindrical pits and/or trench surrounded by coke breeze of an approved grade, to which some lime has been added. The resistivity of the mixture shall not exceed 50 ohm.cm when dry and 15 ohm.cm when wet. The coke breeze and lime backfill must be firmly tamped down around the anode. The upper section of the ground bed shall be filled with coarse gravel to facilitate the release of gas formed. 15

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NIOEC-SP-50-50(0)

12.2.4 Test points for potential and current measurement and bonding purposes, especially at pipeline crossings, shall be combined in the design of pipeline route marker posts. Various type of cathodic protection test posts are to be clearly identified in route & profile drawings (e.g. potential test point, bonding point, etc.). 12.3 Sacrificial Anode Systems 12.3.1 Sacrificial anode systems if being utilized shall be designed for a life greater than the design life of the pipeline. 12.3.2 Sacrificial anodes if being used for over the land pipelines shall be installed in pits not more than 5 meters apart from the pipeline. The anodes shall be prepacked in cotton bags containing a mixture of gypsum, bentonite, and sodium sulfate, and the bag itself shall be surrounded by coke breeze of an approved grade, to which some lime has been added. The resistivity of the mixture shall not exceed 55 ohm.cm when dry and 15 ohm.cm when wet. The coke breeze and lime backfill must be firmly tamped down around the anode bag. The upper section of the pit shall be filled with coarse gravel to facilitate the release of gas formed. 12.3.3 Sacrificial anodes may being used to supplement impressed current system for: - River under crossing - Marshy lands - Where long duration of power shout off or impressed current system commissioning is expected later than end of pipeline, construction. - Existing unprotected buried lines. - Hot spots. 12.3.4 Through route of pipeline the sacrificial anodes shall be connected to the pipelines combined with test point facilities and marker posts. 13. INTERNAL CORROSION ALLOWANCES 13.1 The calculated wall thicknesses require an internal corrosion allowance for pipelines handling corrosive fluids. In the cases of refined product pipelines kerosene may be somehow considered as a very mild corrosive agent. Therefore internal corrosion allowances need to be added to the calculated pipe wall thicknesses. The amount of this corrosion allowance shall be in accordance with ASME B31.4 or as directed by the client. 14. CORROSION INHIBITION AND MONITORING The inhibitor must be compatible with the expected environment, economical to use, and produce the required results. Corrosion inhibition package shall be provided at each pump station, and pipelines that contains following cases: The presence of corrosive ions such as hydrogen ions in kerosene along with moisture content may cause corrosion of pipeline interior surfaces. Also the presence of sulfate-reducing bacterial in water can contribute to internal corrosion. Sulfate reducing bacteria are almost always present in field produced water and contribute to internal corrosion by their ability to produce iron sulfide. Microbial corrosion is possible in a system which contains water and has temperatures below 150 F and at some time interval below 260 F. Bacterial corrosion essentially in systems of this type, is caused by contaminated hydrostatic test water and sulfate reducing bacteria from produced water. Therefore operation of the proposed pipeline system at 140 F yields the possibility of microbial corrosion.

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Rates of corrosion can be accurately determined only by field testing of the completed system. Simulated field usage tests could be run in the laboratory if representative samples were available. For accurate results, this requires proper simulation of field conditions which are difficult to achieve, since the actual corrosion kinetics of the system can not be duplicated. In any case, the corrosion inhibition system design shall include but not be limited to the followings: - Corrosion inhibitor mixing tanks (1+ one spare). - Corrosion inhibitor pumps (1+ one spare). - Appropriate type & size of flow meter. - Corrosion monitoring elements / device. - Automatic PH-meter.

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