OISD-STD-141

First Edition April 1990

Amended Edition, September 2001
Revised Edition, September 2003

FOR RESTRICTED
CIRCULATION

DESIGN AND CONSTRUCTION REQUIREMENTS

FOR

CROSS COUNTRY HYDROCARBON PIPELINES

Prepared by

COMMITTEE ON
DESIGN AND INSPECTION OF
PIPELINES

OIL INDUSTRY SAFETY DIRECTORATE

7th FLOOR, “NEW DELHI HOUSE”
27, BARAKHAMBA ROAD
NEW DELHI -110001
 NOTE

OISD publications are prepared for use in the oil and gas
industry under Ministry of Petroleum & Natural Gas. These are
the property of Ministry of Petroleum & Chemicals and shall not
be reproduced or copied and loaned or exhibited to others without
written consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of the data contained in these documents. OISD
hereby expressly disclaims any liability or responsibility for loss or
damage resulting from their use.

These documents are intended to supplement rather than

replace their prevailing statutory requirements.
 FOREWARD

The Oil Industry in India is 100 years old. Due to various collaboration
agreements, a variety of international codes, standards and practices are in vogue.
Standardisation in design philosophies and operating and maintenance practices at a
national level was hardly in existence. This, coupled with feed back from some serious
accidents that occurred in the recent past in India and abroad, emphasised the need
for the industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the then Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by Oil Industry Safety Directorate (OISD) staffed
from within the industry in formulating and implementing a serious of self regulatory
measures aimed at removing obsolescence, standardising and upgrading the existing
standards to ensure safer operations. Accordingly OISD constituted a number of
Functional Committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.

The present standard on “Design and Construction Requirements for Cross

Country Hydrocarbon Pipelines” was prepared by the Functional Committee on
“Design and Inspection of Pipelines”. This standard is based on the accumulated
knowledge and experience of industry members and the various national and
international codes and practices. This standard is meant to be used as a supplement
and not as a replacement for existing codes and practices. It is hoped that the
provision of this standard if implemented objectively, may go a long way to improve the
safety and reduce accidents in the Oil and Gas Industry. Users are cautioned that
no standard can be a substitute for the judgement of responsible and experienced
engineer. Suggestions are invited from the users after it is put into practice to improve
the standard further. Suggestions for amendments to this standard should be
addressed to:-

The Coordinator,
Committee on Inspection of “Design and Inspection of Pipelines”,
Oil Industry Safety Directorate,
7th Floor, New Delhi House,
27-Barakhamba Road,
New Delhi-110 001.

This standard in no way supersedes the statutory regulations of Chief Controller

of Explosive (CCE), Factory Inspectorate or any other Statutory body which must be
followed as applicable.
 COMMITTEE
ON
DESIGN AND INSPECTION OF PIPELINES

( First Edition April 1990 )

-------------------------------------------------------------------------------------------------------
Name Organisation
-------------------------------------------------------------------------------------------------------

Leader
1. Sh.V.T. Karode Oil India Limited

2. Sh.R.A. Shanbhag ** Indian Oil Corporation Limited

Members
3. Sh.Rao Rudravajala Indian Oil Corporation Limited

4. Sh.S.K. Goyal Oil and Natural Gas Corporation Limited

5. Sh.C.N. Char Oil and Natural Gas Corporation Limited

6. Sh.E.M Bhumgara Hindustan Petroleum Corporation Limited

7. Sh.R.K. Mulla Hindustan Petroleum Corporation Limited

8. Sh.R.K. Dhadda Engineers India Limited

9. Sh.G.V.S. Saiprasad Gas Authority of India Limited

10. Sh.K.K. Dutta Oil India Limited

11. Sh.R.K. Baruah Oil India Limited

Member Coordinator
12. Sh.M. Bhandari Oil Industry Safety Directorate
-------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from the industry contributed in the preparation, review
and finalisation of this document.

** (Took over as Leader w.e.f June/89 on Shri Karode’s retirement from Oil India
Ltd).
 COMMITTEE
ON
DESIGN AND INSPECTION OF PIPELINES

( First Revision September 2003 )

-------------------------------------------------------------------------------------------------------
Name Organisation

Leader
1. Sh.A. Sengupta Indian Oil Corporation Limited

Members

2. Sh.G.S. Wankhede Bharat Petroleum Corporation Limited

3. Sh.KBS Negi Bharat Petroleum Corporation Limited

4. Sh.S.S.Patel GAIL India Limited

5. Sh.P.K.Pal Indian Oil Corporation Limited

6. Sh.C..K. Soman Kochi Refineries Limited

Member Coordinator
7. Sh.R.N.Mittal Oil Industry Safety Directorate
-------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from the industry contributed in the preparation, review
and finalisation of this document.
 DESIGN AND CONSTRUCTION REQUIREMENTS
FOR
CROSS COUNTRY HYDROCARBON PIPELINES

CONTENTS

Sl.No ITEM DESCRIPTION PAGE NO.

PART - I
1.0 INTRODUCTION 1

2.0 SCOPE 1

3.0 DEFINITIONS 1

4.0 DESIGN 1

4.1 Dynamic Effects 2

4.2 Weight Effects 2

4.3 Corrosion 2

4.4 Design of Components 2

4.5 Valves 2

4.6 Threaded Joints 2

4.7 Stress Values 2

4.8 Design of Pipe supporting Elements 2

5.0 MATERIALS 2

5.1 Steel 2

5.2 Materials for Sour Multiphase Service 3

6.0 DIMENSIONAL REQUIREMENTS 3

7.0 CONSTRUCTION, WELDING AND ASSEMBLY 3

7.1 Location 3

7.2 Handling, Hauling, Stringing and Storing 3

7.3 Ditching 4

7.4 Bends, Miters and Elbows 4

7.5 Installation of Pipe in the Ditch 4

7.6 Special Crossings 5

7.7 Pump Station, Tank Farm and Terminal 6

Construction
7.8 Storage and Working Tankage Storage 6

7.9 Pre-Operational Stresses 6

8.0 INSPECTION AND TESTING 6

8.1 Type and Extent of Examination Required 6

8.2 Testing 7

8.3 Commissioning 7

8.4 Record 7

9.0 OPERATION AND MAINTENANCE 7

PROCEDURES
10.0 CORROSION CONTROL 8

10.1 Protective Coating 8

10.2 Cathodic Protection System 8

10.3 Electrical Isolation 8

10.4 Temporary Cathodic Protection System 8

PART – II
11.0 DESIGN 11

12.0 PIPING SYSTEMS 11

13.0 MATERIALS AND EQUIPMENT 11

14.0 WELDING 12

15.0 PIPING SYSTEM COMPONENTS AND 12

FABRICATION DETAILS
15.1 Valves and Pressure Reducing Devices 12

15.2 Expansion and Flexibility 12

15.3 Combined Stress Calculations 13

15.4 Supports and Anchorage for Exposed Piping 15

15.5 Pre-Operational Stresses 15

16.0 DESIGN, INSTALLATION AND TESTING 15

16.1 General Provisions 15

16.2 Population Density Index 16

16.3 Corrosion Allowance 16

16.4 Cover Requirements for Pipelines 16

16.5 Clearance Between Pipelines or Mains and other 16
underground Structures
16.6 Casing, Requirements under Rail Roads, 16
Highways, Roads or Streets
16.8 Bends, Elbows and Miters in Steel Pipelines and 16
Mains
16.9 Miscellaneous Operations involved in the 17
Installation of Steel Pipelines and Mains
16.10 Water Crossings 17

16.11 Crossing of / or by Utilities 18

16.12 Testing after Construction 18

16.13 Control and limiting of Gas Pressure 20

16.14 Valves 20

16.15 Pipe Book 21

17.0 OPERATING AND MAINTENANCE 21

PROCEDURES
18.0 CORROSION CONTROL 21

18.1 Coating Requirements 21

18.2 Electrical Isolation 21

18.3 Electrical Connections and Monitoring Points 21

18.4 Electrical Interference 22

18.5 Existing Installations 22

18.6 Temporary Cathodic Protection System 22

18.7 Internal Corrosion Control 23

19.0 MISCELLANEOUS 23

20.0 REFERENCES 23
 DESIGN AND CONSTRUCTION REQUIREMENTS
FOR
CROSS COUNTRY HYDROCARBON PIPELINES
1.0 INTRODUCTION
Safety in petroleum installations and
pipelines comes through continuous
efforts at all stages and as such it can
be ensured by observing that
installations and pipelines are designed,
constructed and tested as per
recognised engineering standards and
they are periodically inspected and
maintained.
2.0 SCOPE
This standard outlines the minimum
requirements for design, materials,
construction, assembly, inspection,
testing, commissioning, operation,
maintenance and safety aspects of
cross country pipelines – onshore, (A)
transporting liquids such as crude oil,
condensate, natural gasoline, natural
gas liquids, and liquid petroleum
products (B) transporting Natural Gas,
between producer lease facilities, tank
farms, natural gas processing plants,
refineries, stations, terminals (marine,
truck and rail) and other delivery and
receiving points.
For convenience 'ASME/ANSI Code B
31.4 herein after is referred' as 'B 31.4'.
and 'ASME/ANSI Code B 31.8 herein
after is referred' as 'B 31.8'.
3.0 DEFINITIONS
a) MULTIPHASE FLUIDS
Multiphase fluids means oil, gas or
water in any combination produced
from one or more oil wells or
recombined oil well fluids that may have
been separated in passing through
treatment/processing facilities. For the
purpose of this standard, multiphase
fluids are considered to be low vapour
pressure fluids.
b) ON SHORE – LIQUID PIPELINES
Areas not covered by 'Offshore' as
defined in B 31.4 clause 400.2-
Definitions is defined as 'Onshore'. The
definitions of 'Offshore' as per B 31.4 is
reproduced hereunder for easy
reference:
‘Offshore - Areas beyond the line of
ordinary high water, along that portion
of the coast that is in direct contact with
the open seas and beyond the line
marking the seaward limit of inland
coastal waters’.
c) ON SHORE – GAS PIPELINES
Areas not covered by 'Offshore' as
defined in B 31.8 clause 803.17 is
defined as 'Onshore'. The definition of
'Offshore' as per B 31.8 is reproduced
hereunder for easy reference:
'Offshore-Areas beyond the line of
ordinary high water, along that portion
of the coast that is in direct contact with
the open seas and beyond the line
marking the seaward limit of inland
coastal waters.'
d) SHALL
The word 'Shall' is used to indicate that
the provision is mandatory.
e) SHOULD
The word 'Should' is used to indicate
that the provision is recommendatory as
sound engineering practices.
PART-I
LIQUID PETROLEUM
TRANSPORTATION SYSTEMS
4.0 DESIGN
Design of cross country pipelines –
onshore shall be as per ANSI/ASME
B31.4.
4.1 DYNAMIC EFFECTS
 Other Loadings Supports, Braces and Anchors

Unusual loadings such as those caused
by scour, erosion, soil movement and
slides, installation forces, vortex
shedding and other phenomena shall
also be considered and provided for in
accordance with sound engineering
practice.
4.2 WEIGHT EFFECTS
Live Loads
Weight of water during hydrostatic
testing shall also be considered while
designing.
4.8.1 Wherever non integral attachments,
such as pipe clamps and ring girders
are used, adequate precautions shall be
taken to prevent corrosion at or near
the contact points.
4.8.2 If a pipeline is designed to operate at
stress level of more than 50% of the
specified minimum yield strength of the
pipe, all connections welded to the pipe
shall be made to a separate cylindrical
member which completely encircles the
pipe, and this encircling member shall
be welded to the pipe by continuous
circumferential welds at both ends.

4.3 CORROSION 5.0 MATERIALS

Whenever internal or external corrosion 5.1 STEEL
is expected during the design life of the
pipeline, a suitable corrosion allowance 5.1.1 Carbon Equivalent shall be calculated
shall be made at the design stage. based on the formula given below:

4.4 DESIGN OF COMPONENTS CE = C + Mn + Cr+Mo+V + Ni+Cu

4.4.1 STRAIGHT PIPE
The least nominal wall thickness (tn) for
steel pipe, as indicated in B 31.4 clause
404.1.1 shall not be less than the
dimensions indicated in the
specifications for line pipe approved by
B 31.4. Further, pipe having a D/tn ratio
greater than 150 shall not be used,
where D = outside diameter of pipe.
6 5 15
Carbon Steels having a specified
carbon content in excess of 0.32% or a
carbon equivalent in excess of 0.65%
shall be preheated. API-1104 shall be
referred for guidance.
5.1.2 Additional test requirements shall be as
per Appendix-A of Part-I of this
standard for steel pipes manufactured
by Electric Resistance Welding and/or
Electric Induction welding.

4.5 VALVES 5.1.3 Mill Hydrostatic Testing of line pipe is

recommended as 90% of SMYS
Valves made of cast iron or ductile iron irrespective of grade of pipe material.
shall not be used. The pressure hold period should be 15
sec.
4.6 THREADED JOINTS
5.1.4 Ultrasonic testing for pipe skelp and
Threaded joints shall not be used in weld seam is 100%. Ultrasonic testing
cross country pipelines. for pipe ends is mandatory.

4.7 STRESS VALUES 5.2 MATERIALS FOR SOUR

MULTIPHASE SERVICE
Consideration shall be given to the use
of lower allowable design stress if there 5.2.1 Definition
is likelihood of repeated stress
changes giving rise to fatigue NACE Standard MR-OI-75 'Sulfide
conditions. Stress Corrosion Cracking Resistant
Metallic Materials for Oil Field
4.8 DESIGN OF PIPE Equipment defines limiting
SUPPORTING concentrations on hydrogen sulphide in
ELEMENTS the fluid transported' for it to be
considered as sour service.

Note: While past experience has
indicated this to be the accepted
minimum concentration at which
sulphide stress corrosion cracking may
occur, the presence of other
constituents in the phases making up
the multiphase fluid, such as carbon
dioxide in the gas and salt in the water
or larger amounts of free water or gas,
may cause problems to occur at lower
concentrations of hydrogen sulphide.
5.2.2 General
In addition to the applicable
requirements of B31.4 and this
standard, all materials used in sour
multiphase service shall meet the
following requirements.
a) Pipe, valve, fittings, flanges bolting
and other equipment exposed to or
which are necessary to contain sour
multiphase fluids may be susceptible to
stress corrosion cracking and hydrogen
induced stepwise cracking and thus due
consideration shall be given to material
selection in design.
b) Materials for sour multiphase service
shall conform to the requirements of
NACE Standard MR-01-75, 'Sulphide
Stress Corrosion Cracking Resistant
Metallic Material for Oil Field
Equipment'. Depending upon the
service and the materials involved, the
Sulphide Stress Corrosion Cracking
(SSCC) and Hydrogen Induced
Cracking (HIC) tests should be
conducted as per NACE standards
referred in Clause 20.0 of this
standard. The acceptance criteria shall
be based on current established
industry practice.
c) Pressure containing components
(excluding pipe) intended for sour
multiphase service shall be fully
identified with a permanent marking.
5.2.3 Pipes made of cast iron, ductile iron,
bronze and other copper based
materials shall not be used in sour
multiphase service.
6.0 DIMENSIONAL
REQUIREMENTS
All provisions of B 31.4 Chapter IV shall
apply.
7.0 CONSTRUCTION, WELDING
AND ASSEMBLY
7.1 LOCATION
The location of a new underground
pipeline, when running parallel to an
existing underground pipeline, should
be at a minimum clear distance of 5.0
metres from the existing underground
pipeline when heavy conventional
construction equipment is excepted to
be utilized. This distance may be
reduced after careful assessment of
construction methodologies so that it
does not result in unsafe conditions
during construction. In any case the
minimum clear distance shall not be
less than 3.0 metres. These areas shall
be distinctly identified on ground during
construction.
No pipeline should be located within
15.0 metres of any private dwelling or
any industrial building or place of public
assembly in which persons work,
congregate or assemble, unless it is
provided with at least 300 mm of cover
in addition to that provided in Table
7.3.3 of this standard.
7.2 HANDLING, HAULING, STRINGING
AND STORING
Pipe shall not be strung along the right
of way in rocky areas where blasting
may be required, until all blasting is
complete and the area cleared of all
debris. Material other than line pipe
shall not be strung on the right of way
but shall be transported to site for use
only at the time of installation.
7.3 DITCHING
7.3.1 The width of trench shall be such that a
minimum clear distance of 200mm for
trench in normal soil and 300mm for
trench in rock is maintained between
edge of pipe and the trench wall at the
bottom of trench.
7.3.2 Pipelines shall be buried below ground
level, unless construction above ground
is found to be desirable for exceptional
technical, economic or topographical
reasons.

7.3.3 Minimum cover for Buried Pipelines
The minimum cover shall be as per
table 7.3.3 given below.
TABLE 7.3.3
Minimum Cover for Buried Pipelines
________________________________
Location Minimum
Cover in
metre
________________________________
Industrial, Commercial 1.0 (2)
and Residential Areas
Stream, Canal and other 1.5 (4)
Minor water crossings
Drainage ditches at 1.0
Roadways and railroads
Rocky Areas 1.0 (2)
Uncased/Cased Road 1.2 (3)
Crossings
Railroad Crossings 1.4 (3)
Other Areas 1.0 (2)
(1) The above mentioned minimum
cover requirements shall be valid for all
class locations.
(2) Minimum depth of cover shall be
measured from the top of pipe coating
to the top of undisturbed surface of the
soil, or top of graded working strip,
whichever is lower. Fill material in
working strip shall not be considered to
add to the depth of cover.
(3) Cover shall be measured from the
top of road or top of rail, as the case
may be.
(4) In case of rivers/water bodies,
which are prone to scour and erosion,
adequate safe cover (minimum 1.5
metre) shall be provided below the
predicted scour profile expected during
the life time of the pipeline.
7.4 BENDS, MITERS AND ELBOWS
Bends made from pipe
7.4.1 The ends of each bent length shall be
straight and not involved any way in the
bending. The length of the straight
section shall permit easy jointing.
Tangents approximately 1 metre in
length shall be provided on both ends of
cold bends.
7.4.2 Pipes with longitudinal welds shall be
bent in such a way that weld lies in the
plane passing through neutral axis of
the bend which shall be installed
positioning the longitudinal weld in the
upper quadrants.
7.4.3 BENDS MADE FROM PIPE
The minimum radius of field cold bends
shall be as follows:
________________________________
Nominal Pipe Minimum Radius of
size In Bend in Pipe Diameter
________________________________
NPS 12 and smaller 21D
NPS 14 u/i 18 30D
NPS 20 and larger 40D
7.4.4 MITERED BENDS
A mitered bend is not permitted with the
exception of deflections upto 3 degrees
that are caused by misalignment.
7.5 INSTALLATION OF PIPE IN THE
DITCH
Before lowering operations are
commenced, particular attention shall
be paid to the suitability of the trench to
allow the pipeline to be lowered without
the coating being damaged and to give
a reasonably even support to the
pipeline.
When already coated pipes are being
lowered, a complete check of the pipe
coating and field joint coating shall be
carried out and all damages repaired.
Wherever pipeline is laid under tension
as a result of an assembly error (for
example incorrect positioning of bends,
either horizontal or vertical), the trench
shall be rectified or in exceptional cases
a new assembly shall be carried out so
that it fits the excavation and the laying
bed.
Care must be taken that during laying,
the deformation caused during the
raising of the pipe from the support
does not exceed the values for the
 minimum allowable radius of elastic
curvature, so as to keep the stresses in
the steel pipe and on the coating within
safe limits.
In laying parallel pipelines in the same
trench, the minimum clear distances
between the pipelines shall be 500 mm.
7.6 SPECIAL CROSSINGS
7.6.1 Water crossings
Special considerations shall be required
for submerged crossings which are
characterized by their perennial nature,
meandering course, steep and
potentially erodable banks, potentially
scouring bed, large erodable flood plain
and wide water course (high water mark
to high water mark) both during the
design and installation of such
crossings.
For river crossings such as those
described and established above the
following additional requirements are to
be considered.
a) Hydrological and geotechnical
surveys to establish the river bed and
water current profiles to predict the
behaviour of the river with respect to
change of course, scour of bed and
erosion of banks and to obtain all other
parameters related to design and
installation of such crossings.
b) The pipeline at such crossings
shall be installed with extra depth of
cover. The cover provided shall be
adequate to prevent exposure of the
pipeline for the entire design life of the
pipeline.
c) To ensure the stability of the
underwater pipeline, it may be
necessary to add weight to sink and
hold the pipeline in position.
d) A heavier wall thickness pipe
shall be provided for the river crossing
section.
e) A detailed stress analysis for the
pipe section for river crossings should
be carried out, taking into consideration
the effect of all loads during laying and
it shall be ensured that the stresses
remain within permissible limits in
accordance with B 31.4.
f) Whenever considered desirable,
the section of the pipeline
corresponding to the river crossing
should before installation be subjected
to hydrostatic pre-testing. However, the
complete pipeline corresponding to river
crossing shall be tested after
installation.
7.6.2 Crossing of or by Utilities
a) A minimum clearance of 300mm
shall be maintained at the point of
crossing and the utility or pipeline shall
be installed at a uniform depth for the
full width of the right of way. Where it
is not practicable to obtain the above
mentioned clearance, special design
and construction shall be used.
b) A clearance sufficiently large to
avoid electrical fault current interference
shall be maintained between the
pipeline and the grounding facilities of
electrical transmission lines.
c) Interference with, or from, other
systems through the application of
cathodic protection shall be dealt by
mutual action of the parties involved.
d) When laid parallel to, along or near
underground power and / or
communication cables, conductors or
conduit, underground pipes shall
maintain a vertical clearance of at least
300 mm. Where these clearances
cannot be maintained, extra precaution
shall be taken to ensure the maximum
possible clearance and to prevent
future contact. If pipelines and
communication and / or power utilities
share the same trench, the above
clearance shall be maintained with the
pipeline preferably at a lower level.
e) A minimum separation of 3.0 metre
should be maintained between pipeline
and transmission tower footings, ground
cables and counter poise. Regardless
of separation, consideration should
always be given to lightning fault current
protection of pipelines and safety of
personnel.
7.6.3 All crossings shall be made in such a
manner that the angle between the
centerline of the railway, highway, river,
 stream, canal or utility being crossed
and the centerline of the pipeline shall
be as close as possible to 90 degree
but in no case less than 45 degree .
7.7 PUMP STATION, TANK FARM AND
TERMINAL CONSTRUCTION
7.7.1 Location
Minimum distances from property lines
and road allowance limits to buildings
and equipment etc. shall meet the
requirements of OISD Standard 118
"Layouts for Oil and Gas Installations".
7.8 STORAGE AND WORKING TANKAGE
STORAGE
Underground Storage
Prior to design and construction of an
underground storage chamber, an
engineering and geological investigation
shall be carried out to determine the
feasibility of such a system at the
proposed site. Such chambers shall be
constructed and operated in
accordance with GPA Publication 8175,
Method for Underground Storage of
National Gas Liquids
7.9 PRE-OPERATIONAL STRESSES
It is desirable to limit stresses during
pre-operational manipulation of the pipe
so as to avoid damage that might impair
the operability of the line. The designer
shall ensure that pre-operational
stresses are controlled and that they
are non-injurious to the pipe.
Consideration shall be given to, but not
restricted to, the effect of the following
pre-operational loads:
a) Transportation and stockpiling of
the pipe;
b) Stringing, coating and wrapping,
and laying.;
c) Backfilling;
d) Loads imparted by construction
traffic;
e) Field bending;
f) hydrostatic test pressure loads
(particularly when the pipeline is
constructed as an above ground
installation or is buried in unstable
soils).
8.0 INSPECTION AND TESTING
8.1 TYPE AND EXTENT OF
EXAMINATION REQUIRED
Construction
8.1.1 Field pipeline coating shall be applied
on a properly prepared surface and
visually inspected during application.
Any cutting or removal of the coating
shall be promptly and carefully repaired.
8.1.2 Yard-coated pipe shall be examined
after field bending to ensure that the
quality of the coating has not been
impaired.
8.1.3 Additional precautions such as double
coating, rock shield, selected backfill,
and ditch padding shall be taken where
conditions are such that damage to the
pipe coating could occur.
8.1.4 If moisture is present on the surface of
the pipe, no coating materials shall be
applied.
8.1.5 Unless special procedures can be
taken, no coating shall be applied when
the ambient temperature might have a
detrimental effect on the coating either
during or after application.
8.2 TESTING
8.2.1 A gauging pig shall be passed through
the pipeline to prove the internal
diameter of the entire line. The gauging
plate shall have a diameter of 95% of
the internal diameter of the pipeline.
8.2.2 All sections which have been previously
hydrostatically tested viz. road/rail
crossings and river crossings shall be
retested alongwith the completed
mainline sections.
Water used for testing should be dozed
with suitable corrosion inhibitor, if
required.
8.2.3 Test Pressure
Hydrostatic Testing of Internal
Pressure Piping

The test pressure shall be decided as
per B31.4. The duration of hydrostatic
proof test shall be minimum 24 hours.
8.2.4 Acceptance of Test
The test is successful when the pipeline
has withstood the strength and leak
tests and during the test period there is
no observable drop in pressure that
cannot be accounted for by temperature
changes.
8.2.5 Termination of Testing
The pipeline shall be slowly
depressurized at a moderate and
constant rate. During dewatering, care
shall be taken to properly dispose the
discharging water in order to avoid
pollution, damages to fields under
cultivation and/or existing structures
and interference with the traffic.
8.2.6 Pre- tested Pipe
Pipe used for making repairs shall be
pre-tested to a pressure equal to or
greater than the original pipeline
strength test pressure.
8.2.7 Preservation of Pipeline
If the pipeline is to be preserved for a
specified duration before it can be
commissioned, the pipeline shall be
completely filled with water with
sufficient quantities of corrosion
inhibitors depending upon the quality of
water and the period of preservation
and at a suitable pressure.
8.3 COMMISSIONING
8.3.1 Commissioning shall consist of
displacing the hydrostatic test water
from the pipeline by pumping in the
liquid to be transported. Batching pigs
or spheres shall be used not only to
minimize mixing at the interface but
also to enable the progress of the
interface to be followed.
8.3.2 In cases where the water has to be
cleared from the pipeline before
commissioning because of possible
chemical or physical action between the
water and the liquid to be transported,
the pipeline shall be first drained and
then dried as thoroughly as possible.
After drying, the pipeline shall be filled
with the liquid. Care shall be taken to
clear pockets of water from valves and
fittings.
8.4 RECORD
Pipe Book
A pipe and welding book shall be
maintained for all projects. The purpose
of the pipe book shall be to indicate and
maintain as a permanent record the
exact position in the pipeline of each
pipe length and each pipeline material
like valves, scraper traps, bends,
flanges, and other fittings installed in
the project. Each item shall be
recorded by its identification number.
Location of each weld including weld
number, welder number, type of welding
and electrode, weld treatment and
details of equipment used for
radiography shall be recorded in the
pipe book.
9.0 OPERATION AND
MAINTENANCE PROCEDURES
All provisions of B 31.4-Chapter-VII and
OISD-STD-138 shall apply.
10.0 CORROSION CONTROL
10.1 PROTECTIVE COATING
a) Coatings shall electrically isolate
the external surface of the piping
system from the environment.
b) All joints, fittings, repairs and tie-ins
shall be coated with a material
compatible with the existing coating.
10.2 CATHODIC PROTECTION SYSTEM
a) Existing Bare Pipelines Systems
Investigation shall be made to
determine the extent or effect, of
corrosion on existing bare pipeline
systems. When these investigations
indicate that continuing corrosion will
create a hazard, corrosion control
measures or other remedial action shall
be undertaken.
b) Cathodically Protected Pipeline
Systems Temporarily Out of service
 B.1.
Cathodic Protection system shall be
maintained on any pipeline that is
temporarily out of service.

10.3 ELECTRICAL ISOLATION

Whereas such insulating devices are

installed, they shall be properly rated for
temperature, pressure, electrical
properties, and shall be resistant to the
commodity carried in the pipeline
systems.

10.4 TEMPORARY CATHODIC

PROTECTION SYSTEM

When considered necessary a

temporary cathodic protection system
with sacrificial anodes shall be installed
to ensure adequate protection of
pipeline from external corrosion from
the time the pipeline is laid in the trench
till the permanent cathodic protection
system is commissioned.
a) Selection of Mandrel
The reverse bend test shall be carried
out with a mandrel, whose radius(R),
width(A) shall be calculated for any
combination of diameter, wall thickness
and grade with the formula.

The temporary CP system shall A = 2R = 1.4 (D-t) t

preferably be installed simultaneously ------------- -t
keeping pace with the pipeline laying / e(D-2t)-1.4t
installation work and shall be monitored
periodically. where, D - Outside diameter of pipe
t - Wall thickness of pipe
10.5 Safety appliances shall be provided 1.4 - Peaking factor
against lightning, stray current inter- e - Strain
ference from foreign objects at HT
pipeline crossings. Minimum values of 'e' shall be as
follows:
----------------------------------------------------
APPENDIX - A Grade of Steel Min 'e' value
----------------------------------------------------
ADDITIONAL REQUIREMENTS FOR ASTM A53 B 0.1425
ELECTRIC RESISTANCE/ELECTRIC ASTM A 135 B 0.1425
INDUCTION WELDED LINE PIPE API 5L B 0.1425
API 5L X-42 0.1375
B.1 Reverse Bend Tests API 5L X-46 0.1325
API 5L X-52 0.1275
Reverse bend tests shall be performed API 5L X- 56 0.1175
on the pipe piece cut from the crop end API 5L X- 60 0.1125
from the front end of the first length and API 5L X- 65 0.1100
the back end of the last length API 5L X- 70 0.1025
produced from each coil. The API 5L X- 80 0.0900
specimen shall be 100mm to 115mm ----------------------------------------------------
long and shall be reverse bend tested in
accordance with procedure given below b) Procedure
and Figure
The mandrel is to be plugged into the
specimen, with the weld in contact with
mandrel, to such a depth that the angle
of engagement between mandrel and
0
specimen reaches 60 (see Fig. B1). If
the combination of diameter and wall
thickness of pipe, and radius of mandrel
is such that the angle of engagement
0
does not reach 60 , the mandrel shall
be plugged into the specimen until
opposite walls of the specimen meet.
c) Acceptance Criteria
A specimen which fractures completely
prior to the specified engagement of
mandrel and specimen, or which
reveals cracks and ruptures in the weld
or heat affected zone longer than 4mm,
shall be rejected. Cracks less than
6mm long at the edges of the specimen
shall not be cause for rejection.
B.2 Micrographic and Hardness
Examination
A test specimen shall be taken across
the longitudinal weld from one length of
finished pipe from each lot of maximum
50 lengths from the same heat
manufactured from the same process.
These specimens shall be polished and
etched for micro-examinations. The
examinations shall provide evidence
that heat treatment of weld zone is
adequate and there is no untempered
martensite left.
The Manufacturer shall make hardness
measurements on each specimen as
indicated in Fig. B.2 in accordance with
ASTM E-32. The maximum difference
in hardness between base material and
any reading taken in the heat affected
zone shall be less than 80 points
Vicker's HV10.
 PART-II

GAS TRANSPORTATION SYSTEMS

11.0 DESIGN a) The minimum design
temperature shall be taken as the
Design of cross country pipelines – lowest expected operating pipe or
onshore shall be as per ANSI/ASME metal temperature when the hoop
B31.8. stress exceeds 50 MPa (7000 psi),
having due regard to past recorded
temperature data and the minimum
12.0 PIPING SYSTEMS gas temperature that may occur. The
minimum design temperature shall
12.1 The Pipe wall thickness less than 6.4 take into account the effect of lower air
mm should not be used for cross or ground temperatures in the area.
country pipelines in the city limits.
b) The maximum design
12.2 Pipe diameter 4” and above shall be temperature shall be taken as the
used for cross country pipelines. highest expected operating pipe or
metal temperature, having due regard
12.3 All cross country pipelines shall be to past recorded temperature data and
piggable. the possibilities of higher temperatures
occurring.
13.0 MATERIALS AND
EQUIPMENT 13.3 MATERIAL SPECIFICATIONS

13.1 When the maximum design 13.3.1 Carbon Equivalent

temperature exceeds 120 deg.C (250
deg. F), particular attention shall be
given to the tensile properties of the
material to ensure that the derating for
temperature is adequate.
13.2 OPERATING CONDITIONS,
TEMPERATURE AND NOTCH
TOUGHNESS REQUIREMENTS
13.2.1 For steel pipes smaller than 2" NPS
and steel valves, fittings and flanges
smaller than 2" NPS, proven notch
toughness properties are not
mandatory.
13.2.2 For steel pipes and associated steel
components of size 2" NPS and larger,
Notch toughness values shall be
determined to provide protection
against fracture initiation and
propagation. Notch toughness valves
(minimum absorbed energy valves)
shall be specified based on the design
operating stress and the minimum
design temperature.
13.2.3 The minimum and maximum design
temperatures shall be determined as
follows:
Carbon Equivalent shall be calculated
based on the formula given below:
CE = C + Mn + Cr+Mo+V + Ni+Cu
6 5 15
Carbon Steels having a specified
carbon content in excess of 0.32% or
a carbon equivalent in excess of
0.65% shall be preheated. API-1104
shall be referred for guidance.
13.3.2 If steel pipe is intended to be heated
during fabrication and/or installation,
the effect of the time-temperature
relationship on the mechanical
properties of the pipe shall be
determined and taken into
consideration.
13.3.3 Additional test requirements shall be
specified as per Standards /
Guidelines mentioned in Appendix-A,
Part-I of this standard for steel pipes
manufactured by Electric Resistance
Welding and/or Electric Induction
Welding.
13.3.4 Mill Hydrostatic Testing of line pipe is
recommended as 90% of SMYS
irrespective of grade of pipe material.
 The pressure hold period should be 15
sec.
13.3.5 Ultrasonic testing for pipe skelp and
weld seam is 100%. Ultrasonic testing
for pipe ends is mandatory.
13.4 REQUIREMENTS FOR SOUR GAS
SERVICE
13.4.1 Definition
NACE standard MR-01-75 "Sulphide
Stress Corrosion Cracking Resistant
Metallic Material for Oil Field
Equipment" defines specific
conditions, which a gaseous
hydrocarbon shall be considered to be
sour.
Note: While the limiting conditions
defined in NACE standard MR-01-75
for considering gaseous hydrocarbons
as sour is the normally accepted
minimum concentration of hydrogen
sulphide at which material problems
occur, the presence of other
constituents in the gas stream, such
as CO2 and Salts in water, may cause
problems at lower concentrations of
hydrogen sulphide.
13.4.2 General
a) In addition to the applicable
requirements of B 31.8 and this
standard, all materials used in sour
gas service shall also meet the
following requirements.
b) Pipe, valves, fittings, flanges,
bolting and other equipment exposed
to or which are necessary to contain
sour gas may be susceptible to
Sulphide Stress corrosion cracking
and hydrogen induced step-wise
cracking and thus due consideration
shall be given to material selection in
design.
c) All materials used in sour gas
service shall conform to the material
requirements of NACE standard MR-
01-75, "Sulphide Stress Corrosion
Cracking Resistant Metallic Material
for Oil Field Equipment". Depending
upon the service and the materials
involved, the Sulphide Stress
Corrosion Cracking (SSCC) and
Hydrogen Induced Cracking (HIC)
tests should be conducted as per
NACE standards mentioned in Clause
20.0 of this standard. The acceptance
criteria shall be based on current
established industry practices.
d) Pressure containing components
(excluding pipes) intended for sour gas
service shall be fully identified with a
permanent marking.
e) Cast iron line pipe shall not be used
to convey sour gas.
14.0 WELDING
Carbon equivalent (CE) wherever
referred in this chapter, shall be
calculated based on the following
formula:
CE = C + Mn + Cr+Mo+V + Ni+Cu
6 5 15
Carbon Steels having a specified
carbon content in excess of 0.32% or
a carbon equivalent in excess of
0.65% shall be preheated. API-1104
shall be referred for guidance.
15.0 PIPING SYSTEM
COMPONENTS AND
FABRICATION DETAILS
15.1 VALVES AND PRESSURE
REDUCING DEVICES
Valves made of cast iron or ductile iron
shall not be used in gas piping
systems.
15.2 EXPANSION AND FLEXIBILITY
15.2.1 This section is applicable to both
above ground and buried piping and
covers all classes of materials
permitted by this standard. Formal
calculations shall be required where
reasonable doubt exists as to the
adequate flexibility of the piping.
Note : For the purpose of this
standard, 'unrestrained' means that
the pipe is able to strain along its
length, move laterally, or both. Pipe
that does not meet both of the above
requirements is referred to as
'restrained'. Typically, long straight
lengths of buried pipe and above
 ground pipe on closely spaced rigid
supports are classified as restrained, (a) Internal pressure;
whereas buried pipelines adjacent to
bends or unanchored end caps could (b) Thermal expansion and
be regarded as restrained or contraction;
unrestrained, depending on specific
circumstances. (c) Differential support movements;

15.2.2 EXPANSION AND FLEXIBILITY (d) Self-weight and gravity dead

loads;
a) Expansion calculations are
necessary for buried lines if significant (e) Static wind loads and static fluid
temperature changes are expected. loads.
Thermal expansion of buried lines may
cause movement at points where the ii) In addition to the requirements of
line terminates, changes in direction, Clause 15.3.2(i) above, consideration
or changes in size. Unless such shall be given, where applicable, to the
movements are restrained by suitable service conditions to which the pipe
anchors, the necessary flexibility shall and support system are to be
be provided. subjected. Consideration shall also be
given to, but not necessarily limited to
b) Means of providing Flexibility the effects of the following additional
loadings:
If expansion is not absorbed by direct
axial compression of the pipe, (a) Overburden loads;
flexibility shall be provided by the use
of bends, loops, or offsets or provision (b) Live loads;
shall be made to absorb thermal
strains by expansion joints or (c) Buoyancy;
couplings of the slip joint, ball joint, or
bellows type. If expansion joints are (d) Dynamic and seismic loads:
used, anchors or ties of sufficient Seismic load consideration for
strength and rigidity shall be installed earthquake prone areas should be
to provide for end forces due to fluid taken after proper seismic survey to
pressure and other causes. determine liquefaction factor of soil.
The pipeline cover will be decided
15.3 COMBINED STRESS considering the above factor.
CALCULATIONS
(e) Cyclic and vibratory loads
including the effect of Stress
15.3.1 General
Intensification. Factors on the fatigue
life of components;
In addition to satisfying the
requirements of clause 841 of B 31.8,
(f) Internal pressure fluctuations;
it may be necessary to calculate the
longitudinal, axial, and bending
(g) External hydrostatic pressure
stresses, the torsional stresses, the
(including collapse, wave loadings and
hoop stresses, the stress interactions
all significant fluid loads to which a
and the reactions at significant points
submerged line might be submitted);
in the system. In calculating these
stresses and reactions and the effects
(h) Geotechnical loads (including
of various loadings on the piping the
slides, differential settlement,
designer shall use established
loss of support, and thermal effect of
fundamental analysis methods.
the pipeline on soil properties).
15.3.2 Loading Considerations
15.3.3 Stress Values
i) Consideration shall be given to the
stresses and reactions caused by, but a) General
not necessarily limited to the following
loadings:-
There are fundamental differences in
loading conditions for the buried, or
similarly restrained positions of the
piping and the above ground portions
not subject to substantial axial
restraint. Therefore, different limits on
allowable longitudinal expansion
stresses are necessary.
b) Restrained Lines
The net longitudinal compressive
stress due to the combined effects of
temperature rise and fluid pressure
shall be computed from the equation:
SL = Ea (T2-T1) - v Sh
in which,
SL = The longitudinal compressive
stress, psi(MPa)
Sh = Hoop stress due to internal fluid
pressure, psi (MPa)
T1 = Temperature at time of
installation degrees F(degrees C)
T2 = Maximum or minimum
operating temperature degrees
F(degrees C)
E = Modulus of Elasticity of steel,
psi (MPa)
a = Linear coefficient of thermal
expansion, inch per inch per degree F
(mm per mm per degree C)
v = Poisson's ratio = 0.30 for steel
Note that the net longitudinal stress
becomes compressive for moderate
increases of T2 and that according to
the commonly used maximum shear
theory of failure, this compressive
stress adds directly to the hoop stress
to increase the equivalent tensile
stress available to cause yielding.
This equivalent tensile stress shall not
be allowed to exceed 90 per cent of
the specified minimum yield strength
of the pipe, calculated for nominal pipe
wall thickness. Beam bending
stresses shall be included in the
longitudinal stress for those portions of
the restrained line which are supposed
above ground.
c) Unrestrained Lines
Stresses due to expansion for those
portions on the piping without
substantial axial restrain shall be
combined in accordance with the
following equation:
2 2
SE = Sq. Root of (Sb + St )
Where,
SE = Stress due to expansion.
2 2
Sb = Sq. Root of{( i1 M1) + ( i0 M0) }/Z
=equivalent bending stress, psi
(MPa)
St = Mt/2Z = torsional stress, psi(MPa)
M1 = Bending moment in plane of
member (for members having
significant orientation, such as elbows
or tees, for the latter the moments in
the header and branch portions are to
be considered separately) in.lb. (N.m)
M0 = bending moment out of, or
transverse,to plane of member, in lb.
(N.m)
Mt = torsional moment, in lb. (N.m)
ii = stress intensification factor
under bending in plane of member (B
31.8 Appendix E)
io = stress intensification factor under
belonging out of, or transverse to,
plane of member (B 31.8 Appendix E)
Z = Section modulus of pipe,
3 3
inch (mm )
The maximum computed expansion
stress range, SE without regard for
fluid pressure stress, based on 100
per cent of the expansion, with
modulus of elasticity for the cold
condition, shall not exceed 0.72 times
the specified minimum yield strength
of the pipe.
The total of the following shall not
exceed the specified minimum yield
strength, S.
a) the combined stress due to
expansion, SE.
b) the longitudinal pressure stress.
 d) Loads imparted by construction
c) the longitudinal bending stress due traffic;
to external loads, such as weight of
pipe and contents, wind etc. e) Field bending;

The sum of the longitudinal stresses f) hydrostatic test pressure loads

due to pressure, weight, and other (particularly when the pipeline is
sustained external loadings shall not constructed as an above grade
exceed 0.75 time the allowable stress installation or is buried in unstable
in the hot condition. soils).

The sum of the longitudinal stresses 16.0 DESIGN, INSTALLATION

produced by pressure, live and dead
AND TESTING
loads, and those produced by
occasional loads, such as wind or
earthquake, shall not exceed 80 per 16.1 GENERAL PROVISIONS
cent of the specified minimum yield
strength of the pipe. It is not The selection of design for pipeline
necessary to consider wind and system shall be based on the following
earthquake as occurring concurrently. evaluation of the properties and
required flow rate of the fluid to be
Stresses due to test conditions are not transported, together with the
subject to the above limitations. It is environment in which the pipeline is to
not necessary to consider other be installed.
occasional loads, such as wind and
earthquake, as occurring concurrently a) Sweet or sour natural gas, single
with the live, dead and test loads or multiphase flow conditions, vapour
existing at the time of test. phase LPG.

15.4 SUPPORTS AND ANCHORAGE FOR b) Operating pressures and

EXPOSED PIPING temperatures.

Attachment of supports on Anchors c) Gathering system, transmission

system, distribution system, or service
Due consideration shall be given to the lines.
effect of such attachments on possible
fatigue failures and local stress d) Onshore or offshore pipeline.
concentrations.
16.2 POPULATION DENSITY INDEX
15.5 PRE-OPERATIONAL STRESSES
A Class 4 location ends 220 metre
It is desirable to limit stresses during from the nearest building with 4 or
pre-operational manipulation of the more stories above ground.
pipe so as to avoid damage that might
impair the operability of the line. The 16.3 CORROSION ALLOWANCE
designer shall ensure that pre-
operational stresses are controlled and Whenever internal or external
that they are non-injurious to the pipe. corrosion is expected during the
Consideration shall be given to, but not design life of the pipeline, a suitable
restricted to, the effect of the following corrosion allowance shall be made at
pre-operational loads: the design stage.

a) Transportation and stockpiling of

the pipe; 16.4 COVER REQUIREMENTS FOR
PIPELINES
b) Stringing, coating and wrapping,
and laying; Refer Table 7.3.3 for cover
requirements.
c) Backfilling;
16.5 CLEARANCE BETWEEN PIPELINES
OR MAINS AND OTHER
UNDERGROUND STRUCTURES
16.5.1 In laying parallel pipelines in the same
trench, the minimum clear distances
between the pipelines shall be 500
mm.
16.5.2 The location of a new underground
pipeline, when running parallel to an
existing underground pipeline should
be at a minimum clear distance of 5.0
metre from the existing underground
pipeline when heavy conventional
construction equipment is expected to
be utilized. This distance may be
reduced after a careful assessment of
construction methodologies, which do
not result in unsafe conditions during
construction. In any case the
minimum clear distance shall not be
less than 3.0 meter. These areas
shall be distinctly identified on ground
during construction.
No pipeline should be located within
15.0 metre of any private dwelling, or
any industrial building or a place of
public assembly in which persons
work, congregate or assemble, unless
it is provided with atleast 300 mm of
cover in addition to that provided in
clause 16.4 of this standard.
16.6 CASING, REQUIREMENTS UNDER
RAILROADS, HIGHWAYS, ROADS,
OR STREETS
Pipeline, casing pipe and vent pipes
shall be at least 1.2 metre away
(vertically) from aerial electrical wires
and shall be suitably insulated from
underground conduits carrying electric
wires on railway land.
16.7 Design and construction of
gas pipelines crossing Railroads,
Highways, Roads or Streets shall be
done in accordance with the provisions
of "Recommended Practice for Liquid
Petroleum Pipelines Crossing
Railroads and Highways" API RP 1102
and applicable clauses of B31.8 and
this standard.
16.8 BENDS, ELBOWS AND MITERS IN
STEEL PIPELINES AND MAINS
The minimum radius of field cold
bends shall be as follows:
_______________________________
Normal Pipe Minimum Radius of
Size (in) Bending in Pipe
Diameters
_______________________________
NPS 12 and smaller 21 D
NPS 14 u/i 18 30 D
NPS 20 and larger 40 D
_______________________________
16.8.1 The ends of each bent length shall be
straight and not involved anyway in the
bending. The length of the straight
section shall permit easy jointing.
Tangents approximately 1 metre in
length shall be provided on both ends
of cold bends. A field bend shall not
be made within two pipe diameters of
a field weld. Tangent lengths should
not be reduced in the field.
16.8.2 Pipes with longitudinal welds shall be
bent in such a way lies in the plane
passing through neutral axis of the
bend which shall be installed
positioning the longitudinal weld in the
upper quadrants.
16.8.3 A mitered bend is not permitted with
the exception of deflections upto 3
degrees that are caused by
misalignment.
16.8.4 Field-cut segments of elbows NPS 12"
and larger are not recommended.
16.9 MISCELLANEOUS OPERATIONS
INVOLVED IN THE INSTALLATION
OF STEEL PIPELINES AND MAINS
16.9.1 Handling, Hauling, and Stringing
Pipe shall not be strung on the Right-
of-Way in rocky areas where blasting
may be required, until all blasting is
complete and the area cleared of all
debris. Material other than line pipe
shall not be strung on the Right-of-way
but shall be transported to site for use
only at the time of installation.
16.9.2 Installation of Pipe in the Ditch
Pipelines shall be buried below ground
level, unless construction above
ground is found to be desirable for
 exceptional technical, economic or
topographical reasons.
Before lowering operations are
commenced, particular attention shall
be paid to the suitability of the trench
to allow the pipeline to be lowered
without the coating being damaged
and to give a reasonably even support
to the pipeline.
When already coated pipes are being
lowered, a complete check of the pipe
coating and field joint coating shall be
carried out and all damages repaired.
Wherever pipeline is laid under tension
as a result of an assembly error (for
example, incorrect positioning of
bends, either horizontal or vertical), the
trench shall be rectified or in
exceptional cases a new assembly
shall be carried out so that it fits the
excavation and the laying bed.
Care must be taken that the
deformation caused during the raising
of the pipe from the supports does not
exceed the valves for the minimum
allowable radius of elastic curvature,
so as to keep the stresses on the steel
pipe and on the coating within safe
limits.
The width of trench shall be such that
a minimum clear distance of 200mm
for trench in normal soil and 300mm
for trench in rock is maintained
between edge of pipe and the trench
wall at the bottom of trench.
16.10 WATER CROSSINGS
Special considerations shall be
required for submerged crossing by
pipelines of rivers which are
characterized by their perennial
nature, meandering course, steep and
potentially erodable banks, potentially
scouring bed, large erodable flood
plain and wide water course (high
water mark to high water mark) both
during the design and installation of
such crossings:
For river crossings such as those
described and established as above,
the following requirements are to be
considered:
(a) Hydrological and geotechnical
surveys to establish the river bed and
water current profiles, to predict the
behaviour of the river with respect to
change of course, scour of bed and
erosion of banks and to obtain all other
parameters related to design and
installation of such crossings.
(b) The pipeline at such crossings
shall be installed with extra depth of
cover. The cover provided shall be
adequate to prevent exposure of the
pipeline for the entire design life of the
pipeline.
(c) To ensure the stability of the
underwater pipeline, it may be
necessary to add weight to sink and
hold the pipeline in position.
(d) A heavier wall thickness pipe
shall be provided for a river crossing
section.
(e) A detailed stress analysis for
the pipe section for river crossings
should be necessary taking into
consideration the effect of all loads
during laying and it shall be ensured
that the stresses remain within
permissible limits in accordance with B
31.8 and this standard.
(f) Whenever considered
desirable, the section of the pipeline
corresponding to the river crossing
should, before installation, be
subjected to hydrostatic pretesting.
However, the complete pipeline
corresponding to river crossing shall
be tested after installation.
16.11 CROSSING OF / OR BY UTILITIES
16.11.1 A minimum clearance of 300mm shall
be maintained at the point of crossing
and the utility or pipeline shall be
installed at a uniform depth for the full
width of the right-of-way, provided that,
where it is not practicable to obtain the
above mentioned clearance, special
design and construction shall be used.
16.11.2 A clearance sufficiently large to avoid
electrical fault current interference
shall be maintained between the
pipeline and the grounding facilities of
electrical transmission lines.
16.11.3 Interference with, or from, other
systems through the application of
Cathodic Protection shall be dealt with
by mutual action of the parties
involved.
16.11.4 When laid parallel to along or near
underground power and/or
communication cables, conductors, or
conduit, underground pipes shall,
maintain a vertical clearance of at
least 300mm. Where these
clearances cannot be maintained,
extra precaution shall be taken to
ensure the maximum possible
clearance and to prevent future
contact. If pipelines and
communication and/or power utilities
share the same trench, the above
clearance shall be maintained with the
pipeline preferably at a lower level.
16.11.5 A minimum separation of 3.0 metre
should be maintained between pipeline
and transmission tower footings,
ground cables and counter poise.
Regardless of separation
consideration should always be given
to lightning fault current protection of
pipelines and safety of personnel.
16.11 6 All crossings shall be made in such a
manner that the angle between the
centreline of the railway, highway,
river, stream, canal or utility being
crossed and the centreline of the
pipeline shall be as close as possible
to 90 deg. but in no case less than 45
deg.
16.12 TESTING AFTER CONSTRUCTION
16.12.1 General Provisions
a) All Pipelines, mains, and service
lines shall be tested in place after
construction, except as provided for in
(b) below.
b) Tie-ins
For pipelines intended to operate at
hoop stresses of 30% or more of the
specified minimum yield strength
pretested pipe shall be used in tie-in
sections and for those sections where
in-place testing is not practicable.
16.12.2Test Required to Prove Strength of
Pipelines and Mains to Operate at
Hoop Stresses of 30% or More of
the Specified Minimum Yield
Strength of the Pipe:
a) All test assemblies used in testing
shall be fabricated and installed in
accordance with provisions of B 31.8
covering permanent assemblies and
fabrications.
For all buried and submerged piping,
the test pressure shall be maintained
for a period of 24 hours after
temperature stabilization and
stabilization of surges from
pressurizing operations. The test
pressure for above ground piping and
offshore platform piping shall be
maintained for a minimum period of 4
hours, during which time the piping
shall be inspected for leaks.
All sections, which have been
previously hydrostatically tested viz.
road/rail crossings and river crossings,
shall be retested along with the
completed mainline sections.
A guaging pig shall be passed through
the pipeline to prove the internal
diameter of the entire line, the guaging
plate having a diameter of 95% of the
internal diameter of the pipeline.
When water is used as the test
medium, inhibited water, i.e. water to
which suitable doses of corrosion
inhibitors are added depending upon
quality of water, shall be used.
b) Pipelines and mains located in
class 1 and class 2 location shall be
tested with air, gas or water to at least
1.25 times the maximum operating
pressure. Testing, wherever
practicable, shall be by means of
water rather than a gaseous medium.
Where a gaseous medium is used, the
test pressure shall not exceed 1.25
times the maximum operating
pressure. Sour gas shall not be used
as a test medium.
c) Compressor station, regulator
station and measuring station gas
piping, including the piping connecting
the station to valving employed for
isolating the station from the pipeline
and designed in accordance with
Type-C construction (Design factor =
 0.5) shall be tested to atleast class 3
location test requirements.
d) Where testing of offshore platform
gas piping and pipe riser cannot be
accomplished separately from the
main offshore pipeline, the piping
components shall be pretested to
atleast 1.4 times the maximum
operating pressure, provided that all
final welds are inspected in
accordance with the provisions of B
GENERAL NOTES:
mop = Maximum operating pressure (not
necessarily the maximum allowable
operating pressure)
dp = design pressure
tp = test pressure
This table brings out the relationship
between test pressures and maximum
allowable operating pressures
subsequent to the test. If an operating
company decides that the maximum
operating pressure will be less than
the design pressure, a corresponding
reduction in prescribed test pressure
may be made as indicated in the
pressure Test Prescribed, Minimum,
column. However, if this reduced test
pressure is used, the Maximum
operating pressure cannot later be
raised to design pressure without
retesting the line to the test pressure
prescribed in the Pressure Test
Prescribed.
31.8 and all such piping is retested
with the main offshore pipeline to class
1 location test requirements.
e) Test Requirements for Pipelines
and Mains to Operate at Hoop
Stresses of 30% or More of the
Specified Minimum Yield Strength of
the Pipe
f) In such cases an air test to 1.25
times the maximum operating
pressure shall be made and the
limitations on operating pressure
imposed by Table 16.12.2.5 of this
standard do not apply.
g) Records
The operating company shall maintain
in its file for the useful life of each
pipeline and main, records showing
the procedures used and the data
developed in establishing its maximum
allowable operating pressure.
The record shall contain at least the
following information:
i. Time and data of Test;
ii. Pipe Specifications of sections
under test;
 iii. Elevation profile and the location
of the test section and testing points,
if applicable;
iv. Testing medium used;
v. Test pressure at lowest elevation;
vi. Test duration;
vii. Pressure and temperature
recording charts, if applicable;
viii. Pressure-Volume chart,
applicable;
ix. Location of leaks or failures and
description of repair action taken.
h) Acceptance of Test
The test is successful when the
pipeline has withstood the strength
test, and during the test period there is
no observable drop in pressure that
cannot be accounted for by
temperature changes.
16.12.3 Termination of Testing
The pipeline shall be slowly
depressurized at a moderate and
constant rate. During dewatering, care
shall be taken to properly dispose the
discharging water in order to avoid
pollution, damages to fields under
cultivation and/or existing structures
and interference with the traffic.
16.12.4 Pre-tested Pipe
Pipe used for making repairs shall be
pre-tested to a pressure equal to or
greater than the original pipeline
strength test pressure.
16.12.5 Preservation of Pipeline
If the pipeline is to be preserved for a
specified duration before it can be
commissioned, the pipeline shall be
completely filled with water with
sufficient quantities of corrosion
inhibitors, depending upon the quality
of water and the period of
preservation, or with a non-flammable,
non-toxic gas and at a suitable
pressure.
16.13 CONTROL AND LIMITING OF GAS
PRESSURE
Maximum Allowable Operating
Pressure for Steel or Plastic Pipelines
or Mains Consistent with Table
16.12.2.5 of this standard shall be
adhered to.
16.14 VALVES
Notwithstanding the foregoing
provisions of this clause, sectionalizing
if block valves equipped with automatic
closing devices should be provided for
sour gas pipelines in order to minimize
the volume of hydrogen sulphide that
could be released in the event of a
pipeline failure.
16.15 PIPE BOOK
A pipe and welding book shall be
maintained for all projects. The
purpose of the pipe book shall be to
indicate and maintain as a permanent
record the exact position in the
pipeline of each pipe length and each
pipeline material like valves, scraper
traps, bends, and flanges and other
fittings installed in the project. Each
item shall be recorded by its
identification number. Location of
each weld including weld number,
welder number, type of welding and
electrode, weld treatment and the
details of used equipment for
radiography shall be recorded in the
pipe book.
17.0 OPERATING AND
MAINTENANCE
PROCEDURES
All provisions of B 31.8 Chapter V and OISD-
STD-138 shall apply.
18.0 CORROSION CONTROL
18.1 COATING REQUIREMENTS
Coatings shall:
a) Electrically isolate the external
surface of the pipeline system from the
environment;
 b) Have sufficient adhesion to
effectively resist underfilm migration of
moisture;
18.3.1
c) Be ductile to resist cracking;
d) Have a strength or otherwise be
protected to resist damage due to
normal handling (including concrete
coating application, or river weight
installation, where applicable) and soil
stress;
18.3 ELECTRICAL CONNECTIONS AND
MONITORING POINTS
Where a higher current carrying
capacity is required, a multistrand
conductor shall be used and the
strands shall be arranged into groups
no larger than No.6 AWG. Each group
shall be attached to pipe with a
separate charge. Attaching test leads
directly to the pipe by other methods of
brazing is prohibited.

e) Be compatible with cathodic 18.3.2 The following paragraph is added:

protection system.
18.2 ELECTRICAL ISOLATION
a) This clause shall not take
precedence over recognized electrical
safety practices and codes.
b) Where insulating devices are
installed to provide electrical isolation
of pipeline systems to facilitate the
application of corrosion control, they
shall be properly rated
temperature, pressure, and electrical
properties, and shall be resistant to the
commodities carried in the pipeline
systems. These devices shall not be
installed in enclosed areas where
combustible atmospheres are likely to
be present unless precautions are
taken to prevent arcing. (Refer Clause
18.4 of this standard)
c) Pipeline system shall be installed
so that the belowgrade or submerged
portions are not in electrical contact
with any casing, foreign piping
systems or other metallic structures.
This shall not preclude the use of
electrical bonds where necessary.
d) Provision shall be made to prevent
harmful galvanic action at below-grade
or submerged connections between
copper and steel piping.
Consideration should be given to:
i) Installing an insulated coupling or
insulating gasket set between the
copper and steel, or
ii) Protecting the piping with an
insulating coating material to provide a
spatial separation of not less than
0.5m between bare copper and steel.
When a thermit welding process is
used for electrical lead installation on
pressurized pipelines, precautions
shall be taken to avoid possible failure
of the pipeline during installation due
to loss of material strength at the
elevated welding temperatures. Where
a thermit welding process is not
deemed suitable. Consideration shall
be given to other methods of
installation.
for
18.4 ELECTRICAL INTERFERENCE
18.4.1 Fault Current Interference
Fault current interference shall be
taken into consideration.
NOTES:
a) Fault current resulting from
lighting or upset conditions of electrical
facilities could result in serious
damage to coating and pipe wall and
danger to personnel. These adverse
effects may occur where a pipeline is
close to the grounding facilities of
electrical transmission line structures,
sub-stations, generating stations or
other facilities that have high short
circuit current-carrying grounding
networks.
b) Where a buried pipeline system
is close to grounding facilities,
remedial measures may be necessary
to control the effect of these fault
currents in order to reduce the
resultant rise in potential gradient in
the earth near the pipeline system to
an acceptable level.
c) Safety appliances shall be
provided against lightning, stray
 current interference from foreign
objects at HT pipeline crossings.
18.4.2 Induced Potential Interference
Pipelines paralleling alternating current
electrical transmission lines are
subject to induced potentials as well
as the effects mentioned in Notes to
Clause 18.4.1 above.
a) When studies or tests show that
alternating current potentials will be or
are being induced on a buried pipeline
system, devices shall be installed to
reduce these potentials to a tolerable
level.
b) When such pipelines are under
construction, or when personnel are in
contact with the pipelines, special
precautions shall be taken to nullify the
possible effects of induced alternating
current potentials.
18.4.3 Safety Requirements
Following precautions shall be taken:
a) Employ blowdown connections
that will direct the gas away from the
electric conductors;
b) Install bonding across points
where the pipeline is to be separated
and maintain this connection while the
pipeline is separated;
c) Make a study in collaboration with
the electric company on the common
problems of personnel safety,
corrosion, electrical interference and
lighting problems.
18.5 EXISTING INSTALLATIONS
18.5.1 Existing Coated Pipeline Systems
Cathodic Protection shall be applied
and maintained on all existing coated
pipeline systems.
18.5.2 Existing Bare Pipeline Systems
Investigations shall be made to
determine the extent or effect of
corrosion on existing bare pipeline
systems. Where these investigations
indicate that continuing corrosion will
create a hazard, corrosion control
measures or other remedial action
shall be undertaken.
18.5.3 Cathodically Protected Pipeline
Systems Temporarily out of Service
Cathodic Protection systems shall be
maintained on any pipeline system
temporarily out of service.
18.6 TEMPORARY CATHODIC
PROTECTION SYSTEM
When considered necessary, a
temporary Cathodic Protection system
with sacrificial anodes shall be
installed to ensure adequate protection
of pipeline from external corrosion
from the time the pipeline is laid in the
trench till the permanent Cathodic
Protection system is commissioned.
The temporary cathodic protection
system shall preferably be installed
simultaneously keeping pace with the
pipeline laying/installation work and
shall be monitored periodically.
18.7 INTERNAL CORROSION CONTROL
18.7.1 Any gas whose water dew point is at all
times below the minimum pipeline
operating temperature is considered to
be non-corrosive, unless tests or
experience indicate otherwise.
18.7.2 Any gas whose water dew point
exceeds the minimum pipeline
operating temperature is considered to
be corrosive, unless tests or
experience indicate otherwise.
18.7.3 Any gas containing hydrogen sulphide
or carbon dioxide whose water dew
point exceeds the minimum pipeline
operating temperature is considered to
be corrosive, unless tests or
experience indicate otherwise.
18.7.4 Any gas containing hydrogen sulphide
or carbon dioxide whose water dew
point is maintained below the minimum
pipeline operating temperature by
dehydration, or is suitably inhibited, is
considered to be non-corrosive, unless
tests or experience indicate otherwise.
19.0 MISCELLANEOUS