PIPELINE SPECIFICATIONS

ABC Company
ABC Chemical Complex
Engineering Specifications

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 Scope Comparison
 ASME/ANSI  DOT 49CFR
– Design – Prescribes minimum
– Materials safety requirements for
– Construction pipeline facilities
– Assembly
– Inspection – Legal document
– Testing enacted by Congress
– Operations
– Maintenance
– Safety

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 Format Comparison
 ASME/ANSI B31.4  DOT 49CFR195
– Scope & Definitions – A: General
– Design – B: Reporting Accidents
– Materials – C: Design Requirement
– Dimensional Require.
– D: Construction
– Const., Weld, & Assb.
– E: Pressure Testing
– Inspection & Testing
– O&M Procedures
– F: O&M
– Corrosion Control
– Appendices

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 Format Comparison: 31.8 vs 192
 ASME/ANSI B31.8
– Materials & Equipment
– Welding
– Pip Sys Comp & Fab
– Design, Inst, and Test.
– O&M Procedures
– Corrosion Control
– Miscellaneous
– Offshore Gas Trans.
– Appendices
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 DOT 49CFR192
– General
– Materials
– Pipe Design
– Design of Pipeline
Components
– Welding of Steel
– General Const. Req.
– Req. for Corrosion Con
– Test Requirements
4
 Format Comparison: 31.8 vs 192
 See Previous Slide – Uprating
– Operations
– Maintenance

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 Engineering Specifications
 Exceptions to Code Requirements
– AS DEFINED: when Safety considerations in
DOT 49CFR 192 or 195 demand tighter
controls in ABC Engineering Specification than
required in the governing design and
construction Codes, i.e. ASME/ ANSI B31.4

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 Engineering Exceptions-Liquids
 ABC Exceptions to ASME/ANSI B31.4
from DOT 49CFR195 Requirements
– Subpart A
» Definitions
» Matter Incorporated by Reference
 See “Finding Aids” in Appendix for DOT 49CFR
» Compatibility necessary for transportation of
hazardous liquids or carbon dioxide
» Conversion to service
» Responsibility of operator for compliance

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 Engineering Exceptions-Liquids
– Subpart B, Reporting Accidents and Safety
Related Conditions
» Reporting Accidents and Safety Related Conditions
 Reporting Accidents
 Telephonic notice of certain accidents
 Accident reports
 Reporting safety-related conditions
 Filing safety-related condition reports

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 Engineering Exceptions-Liquids
– Subpart C, Design Requirements
» Design Factor, Cold Expanded and Reheated Pipe
 B31.4
– 75% of the allowable stress as determined by para.
402.3.1(a), (b), or (c). [Maximum 0.72x0.75=0.54
 195
– 0.54
» 195.120, Passage of Internal Inspection Devices
 Not included in ASME/ANSI B31.4

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 Engineering Exceptions-Liquids
– Subpart D, Construction
» 195.210, Pipeline Location
 Minimum 12-inch cover within 50 feet of private dwelling
or industrial building or place of public assembly.
» 195.234, Nondestructive Examination
 10% of all production welds for all stress levels.
 100% of all girth welds when installing used pipe.
Minimum 90% in B31.4
 100% for all tie in welds not hydrotested.
Minimum 90% in B31.4

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 Engineering Exceptions-Liquids
– Subpart D, Construction (Continued)
» Cathodic Protection Systems
 31.4 & 195: Install with one year of commissioning
 ABC: CP system to be commissioned with pipeline.

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 Engineering Exception-Liquids
– Subpart E, Pressure Testing
» General Requirements
 Exclude
– Interstate pipeline constructed before January 8, 1971
– Intrastate pipeline constructed before October 21,
1985

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 Engineering Exceptions-Liquids
– Subpart F, Operations and Maintenance
» 195.406, Maximum Operating Pressure
 Paragraph (a)(1)(i) refers to Appendix N, “Recommended
Practice for Hydrostatic Testing of Pipelines in Place”,
ASME/ANSI B31.8, Gas Transmission and Distribution
Piping. Appendix N is generic for all pipelines and DOT
required a reference in this paragraph to establish criteria
for maximum operating pressure.
 80% of test pressure=0.8 x 1.25 = 1.00 = design pressure
» 195.424, Pipeline Movement
 Reduce pressure to 50% MAOP.

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 Engineering Exceptions-Gas
 ABC Exceptions to ASME/ANSI B31.4
Due to 49CFR192 Requirements
– Subpart A, General
» Definitions
 Administrator
 Class locations
 Incorporation by reference
 Conversion to service subject to this part
 Rules of regulatory construction

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 Engineering Exceptions-Gas
– Subpart B, Materials
» Transportation of pipe. (192.65)
 Pipe with an outer diameter to wall thickness ratio of 70 to
1 or more may not be used in a pipeline to be operated at a
hoop stress of 20% or more of SMYS if the pipe is
transported by railroad.

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 Engineering Exceptions-Gas
– Subpart C, Pipe Design
» Class Location and Design Factor
 1. 0.72 (Same as B31.4)
 2. 0.60 (Safety Factor Increased by 20% from 1)
 3. 0.50 (Safety Factor Increased by 44% from 1)
 4. 0.40 (Safety Factor Increased by 80% from 1)
» Previous editions of ASME/ANSI B31.8 used the term,
“Population Density Index” with Construction Types A,
B, C, and D. The Location Classes 1, 2, 3, and 4 have
replaced the above in the definition of design,
construction, testing, and operating require-ments.

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 Engineering Exception-Gas
– Subpart D, Design of Pipeline Components
» 192.145, Valves
 Valves must be hydrotested at least 1.5 times the maximum
service rating.
» 192.150, Passage of internal inspection devices
 Each new pipeline must be designed for intelligent pigging.
 Operators may petition for approval to not comply.
» 192.153, Components fabricated by welding
 Orange-peel bull plugs and/or swages are prohibited on ABC
pipelines.
 Flat closures and fish tails may not be used on piping that either
operates at 100 psig or above or is >3” in diameter.

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 Engineering Exceptions-Gas
– Subpart E, Welding of Steel in Pipelines
» 192.233 - Miter Joints
 Miter joints are permitted in certain cases for DOT gas
pipelines.
 ABC specifications prohibit these joints, because
restrictions are too difficult to follow and enforce in
construction and maintenance welding activities.
» 192.243, Nondestructive testing
 B31.4 allows 40% weld inspection in Location Class 3
and 75% in Location Class 4. DOT requires 100% or at
least 90% if impractical.

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 Engineering Exceptions-Gas
– Subpart G, General Construction Requirements
for Transmission Lines and Mains
» 192.315, Wrinkle Bends in steel pipe.
 Wrinkle bends are allowed on steel pipe operating at a
pressure that produces a hoop stress of less than 30%
SMYS.
 Wrinkle bends are prohibited on ABC pipelines.

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 Engineering Exceptions-Gas
– Subpart J, Test Requirements
» 192.505 & 192.619
 For Location Class 3 which includes all ABC gas
transmission pipelines, DOT requires a test pressure
equal to 1.5 times the maximum operating pressure.
 ASME/ANSI B31.8 requires a test pressure equal to 1.4
times the maximum operating pressure.

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