Canadian Standards Association Oil and gas pipeline systems. Technical Committee on Petroleum and Natural Gas Industry Pipeline Systems and Materials

Transcription

1 Canadian Standards Association Oil and gas pipeline systems Contents Technical Committee on Petroleum and Natural Gas Industry Pipeline Systems and Materials Executive Committee on Petroleum and Natural Gas Industry Pipeline Systems and Materials xxi xxv Subcommittee on Aluminum Pipeline Systems xxvi Subcommittee on Construction xxvii Subcommittee on Design xxix Subcommittee on Distribution xxxi Editorial Subcommittee xxxiii Subcommittee on Materials xxxiv Subcommittee on Offshore Pipelines xxxvi Subcommittee on Operations and Systems Integrity xxxvii Subcommittee on Production xxxix Taskforce on Safety and Loss Management Systems xl Preface xli 1 Scope 1 2 Reference publications 5 3 Definitions 19 4 Design General Design conditions General Temperature Sustained force and wind loading Other loading and dynamic effects Design criteria General Class location assessment areas Class location designations Class location end boundaries Pressure design for steel pipe General Pressure design for steel pipe Design factor (F) Pressure design for steel pipe Location factor (L) Pressure design for steel pipe Joint factor (J) Pressure design for steel pipe Temperature factor (T) Pressure design for steel pipe Allowances Pressure design for steel pipe Wall thickness 40 June 2007 iii

2 Z Canadian Standards Association Pressure design for components General Pressure design for components Closures Pressure design for components Elbows Pressure design for components Tees and crosses Pressure design for components Branch connections Pressure design for components Integrally reinforced extruded outlet headers Pressure design for components Welded branch connections Pressure design for components Reinforcement of single openings Pressure design for components Reinforcement of multiple openings Valve location and spacing Selection and limitation of piping joints Buttwelded joints Threaded joints Sleeve, coupled, mechanical interference fit, and other patented joints Additional requirements for mechanical interference fit joints Flexibility and stress analysis General stress design Applicability Stress design of restrained and unrestrained portions of pipeline systems Discontinuity stresses Supplemental stress design Hoop stress Steel properties Flexibility and stress analysis Stress design for restrained portions of pipeline systems Combined hoop and longitudinal stresses Combined stresses for restrained spans Anchors and restraints Flexibility and stress analysis Stress design for unrestrained portions of pipeline systems Flexibility and stress analysis Loads on pipe-supporting elements General Supports and braces Flexibility and stress analysis Design of pipe-supporting elements Cover and clearance Crossings General Crossings of utilities Crossings of roads and railways Crossings of water Requirements for pipelines in proximity to electrical transmission lines and associated facilities General Effects on pipelines in proximity to high-voltage DC lines Safety requirements Design of compressor stations over 750 kw and pump stations over 375 kw General Design of compressor stations over 750 kw Design of pump stations over 375 kw Liquid storage in oil pipeline pump stations, tank farms, and terminals Aboveground tanks over 4000 L Aboveground tanks of 4000 L or less Underground tanks Pressure spheres, bullets, and ancillary vessels Pipe-type storage vessels Gas storage in pipe-type and bottle-type holders General Aboveground installations 73 iv June 2007

3 Canadian Standards Association Oil and gas pipeline systems Underground installations Vaults Structural design Location Vault ventilation Drainage and waterproofing Pressure control and overpressure protection of piping General General design requirements for systems for pressure control and overpressure protection Additional design requirements for pressure-relieving installations Additional overpressure-protection requirements for compressor and pump stations Instrument, control, and sampling piping Leak detection capability Odorization Requirements for pipelines installed by horizontal directional drilling 78 5 Materials Qualification of materials Steel materials and gaskets Design temperatures Steel materials Notch toughness requirements Steel pipe Notch toughness requirements Steel components Steel pipe Steel components General Steel components Flanges Bolting Gaskets Steel components Fittings Other materials Aluminum piping Polyethylene pipe and fittings Cast iron components Copper and copper-based alloys Stainless steels Reinforced composite pipe and fittings Nonferrous flanges Other alloys and composites External protective pipe coatings Oilfield water service Cement-mortar linings Reuse of materials Records of materials 91 6 Installation General Activities on pipeline rights-of-way Clearing, grading, and ground disturbances Pipe and components handling Bends and elbows in steel piping Alignment and welding Protective coatings Ditching and lowering-in Backfilling Internal cleaning 94 June 2007 v

4 Z Canadian Standards Association Clean-up and restoration Installation of crossings Crossing records Horizontal directional drilling (HDD) Pipe surface requirements applicable to steel piping Pipe manufacturing defects detected during installation inspection Field repair of gouges and grooves Dents Patching repair Removal of cracks in circumferential butt welds and in fillet welds Electrical test leads on pipeline systems Inspection Precautions to avoid the explosion of gas-air mixtures and uncontrolled fires during installation 97 7 Joining General Arc and gas welding General Arc and gas welding Joint configurations Butt welds Fillet welds Arc and gas welding Welding equipment Arc and gas welding Materials Pipe and components Filler metals and fluxes Shielding gases Arc and gas welding Qualification of welding procedure specifications General Company approval Records Welding procedure specifications Essential changes for qualification of welding procedure specifications Arc and gas welding Testing for qualification of welding procedure specifications and qualification of welders Welding of test joints Testing of butt welds General Testing of butt welds Tension test Testing of butt welds Nick-break test Testing of butt welds Root-bend and face-bend tests Testing of butt welds Side-bend test Testing of fillet welds and branch connection welds Root-break test Testing of fillet welds and branch connection welds Macrosection test Testing of fillet welds and branch connection welds Tension test Additional testing of partial-penetration butt welds Arc and gas welding Qualification of welders General Qualification range Special qualification Butt welds Visual inspection Qualification of welders by visual and nondestructive inspection Retests Records of qualified welders Arc and gas welding Production welding General 127 vi June 2007

5 Canadian Standards Association Oil and gas pipeline systems Alignment and root gap Grounding Use of line-up clamps Butt welds Relative movement Bevelled ends Weather conditions Clearance Cleaning between beads Position welding Roll welding Identification of welds Seal welding Fillet welds Preheating, interpass temperature control, controlled cooling, and stress relieving Stress relieving Arc and gas welding Inspection and testing of production welds General Visual inspection Mandatory nondestructive inspection Nondestructive inspection Destructive testing Disposition of defective welds Arc and gas welding Standards of acceptability for nondestructive inspection General Weld crown Incomplete penetration of the root bead Incomplete fusion Internal concavity Undercut Incomplete fusion due to cold lap Lack of cross-penetration Elongated slag inclusions Hollow bead Burn-through areas Isolated slag inclusions Spherical porosity Wormhole porosity Cracks and arc burns Unequal leg length Fillet welds Accumulation of imperfections Weld conditions limiting radiographic interpretation Arc and gas welding Repair of welds containing repairable defects Partial-penetration butt welds Authorization for repairs Repair procedures Removal of arc burns in weld areas Removal of cracks in circumferential butt welds and in fillet welds Inspection of repairs Arc and gas welding Materials and equipment for radiographic inspection General Radiographic procedure Radiation sources Imaging media Screens 145 June 2007 vii

6 Z Canadian Standards Association Image quality indicators Comparator shims Arc and gas welding Production of radiographs Radiation source location Geometric relationship Size of radiation field Location of image quality indicators Radiographic image identification markers Processing of radiographic images Radiation protection Radiographers Retention of radiographic records Arc and gas welding Ultrasonic inspection of circumferential butt welds in piping Methods Terminology General Equipment and supplies General Equipment and supplies Additional requirements for mechanized inspection systems Qualification of ultrasonic inspectors Calibration Inspection procedure for production welds Inspection procedure for production welds Additional requirements for mechanized inspection Standards of acceptability for ultrasonic inspection Ultrasonic inspection reports and records Welding Explosion General Qualification of welding procedure specifications Qualification of welders Production welding Mechanical interference fit joints General Qualification of joining procedure specifications Qualification of operators Inspection procedures Pressure testing General Strength and leak tests for piping intended to be operated at pressures greater than 700 kpa Strength and leak tests for piping intended to be operated at pressures of 700 kpa or less Pressure-test mediums for piping intended to be operated at pressures greater than 700 kpa Pressure-test mediums for piping intended to be operated at pressures of 700 kpa or less Minimum strength and leak test pressures for piping intended to be operated at pressures greater than 700 kpa Minimum strength and leak test pressures for piping intended to be operated at pressures of 700 kpa or less Maximum strength test pressures Maximum leak test pressures Duration of tests Leaks and ruptures Leaks Ruptures Investigations Gaseous-medium testing of crossings 162 viii June 2007

7 Canadian Standards Association Oil and gas pipeline systems 8.13 Testing of fabricated items Tie-ins Testing after installation Inspection Maximum operating pressures Piping intended to be operated at pressures greater than 700 kpa Piping intended to be operated at pressures of 700 kpa or less Pressure-test measurements and records General Piping intended to be operated at pressures greater than 700 kpa Piping intended to be operated at pressures of 700 kpa or less Safety during pressure tests Disposal of pressure-test mediums Test-head assemblies Testing procedures and techniques Corrosion control General Selection of external protective coatings for buried or submerged piping Application and inspection of external protective coatings for buried or submerged piping Storage, handling, transportation, and installation of coated pipe and components Cathodic protection Design and installation Electrical isolation Electrical interference Direct current Alternating current and lightning Corrosion-control test stations Operation and maintenance of impressed current and sacrificial cathodic protection systems Internal corrosion control General Mitigation Monitoring Corrosion-control records Operating, maintenance, and upgrading General Safety and loss management system Operating and maintenance procedures General Pipeline emergencies Failure investigations Communication facilities Environmental effects Leak detection for liquid hydrocarbon pipeline systems Leak detection for gas pipeline systems Leak detection for oilfield water pipeline systems Pipeline identification Signs at stations and other facilities Ground disturbance Records General Pipeline systems Pipeline emergency records Leaks and breaks 184 June 2007 ix

8 Z Canadian Standards Association Pressure-test records Safety Training programs Employee information Supervisor responsibility Hazards Security Work sites Firefighting and special equipment In-service pipelines Smoking and open flames Additional precautions for pipeline systems transporting high-vapour-pressure hydrocarbons Fluids containing H 2 S Carbon dioxide pipelines Right-of-way inspection and maintenance Pipeline patrolling Vegetation control Exposed facilities Crossings Operation and maintenance of facilities and equipment Compressor and pump stations Aboveground tanks and pressure vessels Underground storage Pipe-type and bottle-type gas holders and pipe-type storage vessels Pressure-control, pressure-limiting, and pressure-relieving systems Valves Vaults Change of class location and crossings of existing pipelines Change of class location Crossings of existing pipelines Evaluation of imperfections General Corrosion imperfections in pipe Gouges, grooves, and arc burns in pipe Dents in pipe Pipe body surface cracks Weld imperfections in field circumferential welds Weld imperfections in mill seam welds and mill circumferential welds Permanent repair methods General Grinding repairs Piping replacements Repair sleeves Defect removal by hot tapping Direct deposition welding Temporary repair methods General Fibreglass sleeves Maintenance welding General In-service piping In-service piping Fillet welding and branch connection welding on liquid-filled piping or flowing-gas piping and direct deposition welds on flowing-gas piping In-service piping Face-bend testing of fillet welds and branch connection welds 208 x June 2007

9 Canadian Standards Association Oil and gas pipeline systems In-service piping Macroexamination and hardness testing of fillet welds and branch connection welds In-service piping Qualification of welding procedure specifications and welders for direct deposition welds In-service piping Nondestructive inspection of fillet welds and direct deposition welds Pipeline hot taps General Pipe preparation Welding and hot tapping considerations Integrity of pipeline systems General Integrity of existing pipeline systems Change in service fluid Upgrading to a higher maximum operating pressure Pressure testing existing piping Engineering assessments Odorization Deactivation and reactivation of piping Deactivation of piping Reactivation of piping Abandonment of piping Offshore steel pipelines Applicability Design General Design information Pipeline route Route survey and data acquisition Pipeline operating conditions Design and load conditions Functional loads Environmental loads General Wind forces Hydrodynamic loads General Wave-induced and current-induced hydrodynamic loads Loads due to ice conditions and regional ice features Seismic activity Loads arising from marine growth Indirect environmental loads Accidental loads Design analysis Design for mechanical strength Design criteria for installation Design criteria for pressure testing Design criteria for operation Determination of stresses Pipe wall thickness specification Strain-based design Strain-based design criteria Design for thermal expansion Design for on-bottom stability Design for fatigue life Design for free spans, anchoring, and supports 236 June 2007 xi

10 Z Canadian Standards Association Design for shore approaches Design for components Design for crossings Pipeline components and fabrication details General Supports, braces, anchors, and buckle arresters Mechanical connectors Welded branch connections and reinforcements Reducers Weight-coating Thermal insulation Pipeline pressure control Leak detection Emergency shutdown valve Materials General Pipe Fittings, flanges, and valves Installation General Transportation, handling, and storage of materials Ancillary equipment and specialty items Installation procedures Installation inspection Repair of pipe and components prior to installation Repair of pipelines after installation As-built surveys Commissioning Welding General Qualification of welding procedures Testing of welded joints Pipe butt welds Production welding Underwater welding Mechanical connectors Pressure testing General Testing of mechanical connector assemblies Test pressure Pressure-test medium Safety during pressure tests Pressure-test records Corrosion-control General External corrosion-control Protective coatings External corrosion-control Cathodic protection systems Internal corrosion-control Maintenance of cathodic protection systems Records Operating and maintenance General Manual of operating procedures Contingency manual Communication systems 249 xii June 2007

11 Canadian Standards Association Oil and gas pipeline systems Inspection and patrolling of pipelines Leak detection Valves Control and safety devices Safety Repair of pipelines Records Pipeline deactivation and reactivation Gas distribution systems General Applicability Gas containing hydrogen sulphide Design Steel piping Polyethylene piping Design pressure Polyethylene piping Design limitations Polyethylene piping Design pressure of components Other metallic piping materials Other nonmetallic piping and tubing Cover and clearance Pipelines within road and railway rights-of-way Limitations on operating pressure General Limitations on operating pressure Piping within customers buildings Pressure control and overpressure protection Distribution system valves General Distribution system valves Valve location and spacing Distribution system valves Service shutoffs Customers meters and service regulators Distribution systems within buildings Liquefied petroleum gas (LPG) pipeline systems Materials Steel pipe, tubing, and components Polyethylene pipe, tubing, and components Cast iron pipe and valves Continuous length reinforced thermoplastic pipe and fittings Installation General Steel piping Polyethylene piping General Polyethylene piping Inspection and handling Polyethylene piping Direct burial Polyethylene piping Insertion in casing Polyethylene piping Bends and branches Cast iron piping Copper piping Installation of service lines Drainage Installation of service lines into or under buildings Installation of service lines Additional installation requirements for polyethylene service lines Trenchless installations Joining General Steel pipe joints and connections Essential changes for qualification of welding procedure specifications 268 June 2007 xiii

12 Z Canadian Standards Association Steel pipe joints and connections Qualification of welders Steel pipe joints and connections Inspection of field welds Steel pipe joints and connections Inspection of tie-in welds Steel pipe joints and connections Steel pipe joints within buildings Polyethylene pipe joints and connections General Polyethylene pipe joints and connections Joining by heat fusion Polyethylene pipe joints and connections Joining by electrofusion Polyethylene pipe joints and connections Joining by mechanical methods Cast iron pipe joints Joints in copper pipe and tubing Service line connections Pressure testing Piping in distribution systems intended to be operated at pressures in excess of 700 kpa Piping within customers buildings Polyethylene piping Test-head assemblies Corrosion-control Steel piping Cast iron piping Copper piping Visual inspection Operating, maintenance, and upgrading Marking of piping Distribution system maintenance Pressure recording for distribution systems Valve maintenance Pressure-control, pressure-limiting, and pressure-relieving devices Repair procedures for steel distribution pipeline systems Maintenance welding Additional maintenance and repair requirements for polyethylene piping Squeezing of polyethylene pipe for pressure-control purposes Maintenance and repair requirements for polyethylene piping and polyvinyl chloride piping and tubing Static electricity dissipation Pressure upgrading of distribution piping Operating and maintenance procedures for cast iron piping Integrity of pipeline systems Pipeline emergencies Ground disturbances Reinforced composite, thermoplastic-lined, and polyethylene pipelines Reinforced composite pipelines General Design Materials Installation Joining Pressure testing Operation Pipeline repairs Thermoplastic-lined pipelines General Design Materials 291 xiv June 2007

13 Canadian Standards Association Oil and gas pipeline systems Installation Joining liners Flange connections Pressure testing Operation and maintenance Polyethylene pipelines for gas gathering, multiphase, LVP, and oilfield water services General Design Materials Installation Joining Heat fusion joining inspection and test plan Pressure testing Operation and maintenance Oilfield steam distribution pipelines General Design General Straight pipe under internal pressure Pipe bends Limits of calculated stresses due to sustained loads and displacement strains Expansion, flexibility, and support Corrosion and erosion allowances Wall thickness tolerance Materials General Material testing Pipe Fittings other than bends Flanges Valves Transition pieces Pipe bends General Pipe bends Qualification and production Piping supports Joining Pressure testing General Aboveground pipelines Underground pipelines Corrosion-control Commissioning and operation Aluminum piping General Applicability Design Pressure design for aluminum pipe Pressure design for components Piping joints Aluminum properties Uncased railway crossings 315 June 2007 xv

14 Z Canadian Standards Association Effects on pipelines in proximity to low-voltage alternating current lines and associated facilities Materials Design temperatures Notch toughness Aluminum pipe and components Installation of aluminum piping Bends and elbows Attachment of test leads Storage and handling of aluminum pipe and fittings during installation Ambient temperature Burial of coiled aluminum pipe by ploughing Plain dents Joining General Arc welding High energy joining General High energy joining Qualification of joining procedure specifications High energy joining Qualification of personnel High energy joining Inspection and testing of high energy joints for qualification of joining procedure specifications and personnel High energy joining Production welding High energy joining Inspection and testing of high energy joints Mechanical interference fit joints Pressure testing Corrosion control Test lead attachment Installation of cathodic protection systems Corrosive medium Operating, maintenance, and upgrading Evaluation of imperfections and repair of piping containing defects Maintenance welding Pipeline hot taps Sour service General Material properties Exposure to iron sulphides Location factor Sectionalizing valves Nondestructive inspection Integrity management Construction Operating and maintenance Records Sour service pipelines General Sour service Specific definition Design Location factor for steel pipe Design parameters Design information Design considerations Stress design 325 xvi June 2007

15 Canadian Standards Association Oil and gas pipeline systems Anchors and restraints Sectionalizing valves Partial-penetration welds Threaded joints Mechanical interference fit joints Pipe-type and bottle-type holders and pipe-type storage vessels Materials Environmental cracking Material provisions Marking Nonferrous materials Construction Deviations Records Inspection plan Joining Carbon equivalent Change in carbon equivalent Butt welds of unequal thickness Weld hardness requirements Deposited weld metal composition limitations Alignment Preheat Mandatory nondestructive inspection Standards of acceptability for nondestructive inspection Backwelding Welding Explosion Corrosion and corrosion-control Supplemental mitigation requirements Mitigation and monitoring program Start-up corrosion mitigation Design and sizing of pigs Operation and maintenance Procedures Records Repair methods Hydrogen charging Direct deposition welding Change management process Changes in service conditions Pipeline integrity management program Composite-reinforced non-sour service steel pipelines General Applicability Specific definitions Design Stress distribution Maximum operating pressure Design pressure External pressures and loadings Stress limits Design temperature Engineering assessment 333 June 2007 xvii

16 Z Canadian Standards Association 17.5 Materials and manufacture Steel pipe Fibre-reinforced composite Composite-reinforced steel pipe manufacture Installation Field bending Damage Crossings Joining General Joint reinforcement Transitions to steel pipe Qualification of joining procedure specifications Pressure testing Corrosion control Operation and maintenance 337 Annexes A (informative) Safety and loss management system 340 B (informative) Guidelines for risk assessment of pipelines 348 C (informative) Limit states design 356 D (informative) Guidelines for in-line inspection of piping for corrosion imperfections 385 E (informative) Recommended practice for liquid hydrocarbon pipeline system leak detection 388 F (informative) Slurry pipeline systems 393 G (informative) Precautions to avoid explosions of gas-air mixtures 396 H (informative) Pipeline risk dictionary 398 I (informative) Oilfield steam distribution pipelines Alternate provisions 428 J (informative) Recommended practice for determining the acceptability of imperfections in fusion welds using engineering critical assessment 432 K (informative) Standards of acceptability for circumferential pipe butt welds based upon fracture mechanics principles 434 L (informative) Alternate or supplementary test methods for coating property and characteristics evaluation 448 M (informative) Gas distribution system integrity management guidelines 450 N (informative) Guidelines for pipeline integrity management programs 458 O (informative) Reliability-based design and assessment of onshore non-sour natural gas transmission pipelines 468 Tables 4.1 Class location designations Location factor for steel pipe Joint factor for steel pipe Temperature factor for steel pipe Least nominal wall thickness for steel carrier pipe Design of welded branch connections Valve spacing, km Flexibility and stress intensification factors Cover and clearance Least nominal wall thickness for steel casing pipe in cased crossings and carrier pipe in uncased crossings Maximum pipe diameter to wall thickness (D/t) ratio for uncased railway crossings Pipe body notch toughness for steel pipe Pipe threshold stress values Limitations for pipe and components 84 xviii June 2007

17 Canadian Standards Association Oil and gas pipeline systems 5.4 Cement-mortar lining thickness tolerances Equivalent ASME S-1 group numbers for welding procedures for piping materials Compliance factor (F) Carbon equivalent formula Essential changes for qualification of welding procedure specifications Type and number of test specimens for butt welds Number of root-break or macrosection test specimens for fillet welds and branch connection welds Outside crown height Maximum acceptable amount of spherical porosity Image quality indicator selection criteria for X-ray radiography Image quality indicator selection criteria for gamma radiography Test requirements for steel piping intended to be operated at pressures greater than 700 kpa Selection of external coating systems Limitations on acceptable permanent repair methods Number of face-bend test specimens Number of test specimens for qualification of procedures and welders for direct deposition welding Design factors Temperature factor for polyethylene pipe and tubing Cover and clearance Essential changes for qualification of welding procedure specifications Leak test pressure within buildings Reinforced composite pipes Material classification and minimum property values Service fluid factor (F) Design temperature factor (T) Minimum nominal wall thickness of threaded pipe nipples Circumferential joint factor Temperature factor Alloy factor Linear coefficient of thermal expansion and modulus of elasticity Limitations for acceptable pipe and components Minimum bend radius Visual acceptance criteria for fibre-reinforced composite Damage severity and repair guidelines for fibre-reinforced composite 339 Figures 1.1 Scope diagram Oil industry pipeline systems Scope diagram Gas industry pipeline systems Class location end boundaries, determined by dwelling-unit density Integrally reinforced extruded outlet headers Details for openings with complete encirclement types of reinforcement Reinforcement of branch connections End preparations and acceptable combinations of end preparations Buttwelding details between items having unequal thickness Fillet weld details Welding details of opening with localized type of reinforcement Welding details for branch-to-run pipe connection Location of test specimens for butt welds Tension test specimen Nick-break test specimen Root-bend or face-bend test specimen Side-bend test specimen 117 June 2007 xix

18 Z Canadian Standards Association 7.11 Permissible dimensions for slag inclusions in the fracture surfaces of nick-break test specimens Jig for guided-bend tests Location of root-break or macrosection test specimens for fillet welds and branch connection welds Root-break or macrosection test specimens Incomplete penetration of the root bead Incomplete fusion Internal concavity Comparator shim Incomplete fusion due to cold lap Lack of cross-penetration Hollow bead Spherical porosity Method of deriving the longitudinal length of corrosion Location of test specimens Face-bend test specimen Test specimens for direct deposition welding Scope diagram Subsea completion to platform and platform to shore (typical arrangement) Landward jetty system and offshore loading/unloading system (typical arrangement) Artificial island (typical arrangement) Single-point mooring system (typical arrangement) Scope diagram Typical reinforced composite to steel transition Typical flange configuration for pipe liner 291 xx June 2007