EPCCOM FOR GAS PROCESSING PLANT

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 1 OF 24

HFY-CON/F&C0940-0964

PIPELINE DESIGN BASIS

0 Issued for Construction 12-Dec-2019

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 2 OF 24

REVISION DESCRIPTION SHEET

Rev. Page Para. Reason for Revision

Hold No. Page Para. Reason for Hold

 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 3 OF 24

CONTENT
1 INTRODUCTION ................................................................................................................... 4
1.1 SCOPE ............................................................................................................................. 4
1.2 PROJECT DESCRIPTION .................................................................................................... 4
1.3 DEFINITIONS..................................................................................................................... 5
1.4 ABBREVIATIONS ............................................................................................................... 5
1.5 LANGUAGE ....................................................................................................................... 6
1.6 UNITS OF MEASUREMENT ................................................................................................. 6
1.7 REFERENCE ..................................................................................................................... 6
1.8 ORDER OF PRECEDENCE .................................................................................................. 8
2 BASIC DATA ......................................................................................................................... 8
2.1 ENVIRONMENTAL DATA ..................................................................................................... 8
2.2 TOPOGRAPHY .................................................................................................................. 9
2.3 ENGINEERING GEOLOGY................................................................................................... 9
3 PIPELINE DESIGN .............................................................................................................. 10
3.1 DESIGN LIFE .................................................................................................................. 10
3.2 PIPELINE SCOPE AND PARAMETERS ................................................................................ 10
3.3 TIE-IN POINTS AND BATTERY LIMITS ................................................................................ 14
3.4 PIPELINE MATERIAL ........................................................................................................ 16
3.5 PIPELINE ROUTE LAYOUT ............................................................................................... 16
3.6 LOCATION CLASS AND DESIGN FACTOR .......................................................................... 17
3.7 PIPELINE COMPONENT AND AUXILIARIES ......................................................................... 18
3.8 PIPELINE MECHANICAL DESIGN ....................................................................................... 19
3.9 PIPELINE LAYING ............................................................................................................ 19
3.10 PIPELINE CROSSINGS ..................................................................................................... 20
3.11 PIPELINE WELDING AND NON-DESTRUCTIVE TESTING ...................................................... 21
3.12 PIPELINE PIGGING AND GAUGING .................................................................................... 21
3.13 PIPELINE PRESSURE TESTING AND DRYING ..................................................................... 22
3.14 PIPELINE CONSTRUCTION ............................................................................................... 22
4 FIBER OPTIC CABLES ...................................................................................................... 23
4.1 FOC BETWEEN GPP AND CPF2 .................................................................................... 23
4.2 FOC BETWEEN CPF1 AND CPF2 .................................................................................... 23
5 ANTI-CORROSION ............................................................................................................. 23
5.1 COATING ....................................................................................................................... 23
5.2 CATHODIC PROTECTION ................................................................................................. 23
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 4 OF 24

1 INTRODUCTION

1.1 Scope
This Design Basis concerns for pipelines in and out of GPP only.
1.2 Project Description
Halfaya Oil Field is situated in the southern part of Iraq, in the Missan Governorate, 35
km southeast of Amarah city. The field is a NW-SE trending anticlinal structure about 30
km long, 10 km wide, total area is about 288km2 .Location of Halfaya Oil Field is shown
in Figure 1.2.1.

Baghdad

AHDEB

Halfaya
Amarah

Basra
IRAQ

Figure 1.2.1 Location of Halfaya Oil Field

The Halfaya field was discovered in 1976. PetroChina (Halfaya) has completed FCP
(First Commercial Production) construction of Phase 1, in which CPF1 was constructed
with designed capacity of 70,000+ BOPD. Some facilities have been upgraded since
Y2012 to produce 100,000 BOPD as max. capacity.
Facilities have been constructed to achieve up to 200,000 BOPD of production in 2014,
by upgrading CPF1 and a new CPF2. Crude oil process in CPF2 has been optimized
according to the new reservoir data and CPF1 operational performance up to date.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 5 OF 24

Owner now plans to develop a new CPF3 with the capacity of 200,000BOPD, to achieve
total production capacity of 400,000BOPD. This will be the HALFAYA PROJECT
SURFACE FACILITY PHASE 3.
A Gas Processing Plant (GPP) is planned to be built in the fourth quarter of 2021 to treat
all the associated gas from Halfaya Oil Field CPFs. GPP will be built nearby CPF2 in
Halfaya Oil Field. Gas processing capacity of GPP is 300 MMSCFD and 26000 BPD of
condensate produced from all the CPFs.
At same time, Missan Oil Company (MOC) plan to gather the raw gas of Missan oil field,
Amarah oil field and Noor oil field, and transport to GPP to treatment in future. The total
capacity of three oilfield expected is 150MMSCFD. GPP expansion in future should be
considered.
1.3 Definitions

PROJECT EPCCOM FOR GAS PROCESSING PLANT

COMPANY(OWNER) Petro China International Iraq FZE Iraq Branch

EPC CONTRACTOR China Petroleum Engineering & Construction Corporation

(CPECC)

VENDOR/SUPPLIER Manufacturers/Suppliers of goods/equipment

SUB VENDOR Part of Manufacturers/Suppliers of goods/equipment Vendor

The word shall is used to indicate that a provision is mandatory.

The word should is used to indicate that a provision is not mandatory, but
recommended as good practice.
1.4 Abbreviations
Abbreviation Definition
GPP Gas Processing Plant
API American Petroleum Institute
BPD Barrels Per Day
CPF Central Processing Facilities
HP High Pressure
HPS Halfaya Pump Station
LP Low Pressure
MMSCFD Million Standard Cubic Feet per Day
ICCP Impressed current cathodic protection
IODF Intelligent Optical Distribution Frame
FOC Fiber Optic Cable
HDD Horizontal Directional Drilling
HDPE High Density Polyethylene
GRE Glassfiber Reinforcement Epoxy
UG Under Ground
AG Above Ground
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 6 OF 24

1.5 Language
English is the nominated language to be used on the project. Labels, nameplates, and
operator interfaces shall be in English. Safety instructions and warnings which to be
understood by non-operations staff shall also be in Chinese.
1.6 Units of Measurement
All technical data shall be presented in the International System of Units (SI) as defined
in the project document: Conceptual Design Report.
1.7 Reference
1.7.1 Project Specification, Documents and Drawings
Documents No. Documents Title
HFY-3800-5000-PPL-RPT-0001 Pipeline Mechanical Design Report
HFY-3800-5000-PPL-SCH-0001 Pipeline Schedule
HFY-3800-5000-PPL-DWG-0001 Overall Route Layout
Typical Drawing - Right of Way and Working Strip
HFY-3800-5000-PPL-DWG-0002
Dimensions
HFY-3800-5000-PPL-DWG-0003 Typical Drawing - Pipeline Trench Detail
HFY-3800-5000-PPL-DWG-0004 Typical Drawing - Underground Pipeline Crossing
HFY-3800-5000-PPL-DWG-0005 Typical Drawing - Underground Cable Crossing
HFY-3800-5000-PPL-DWG-0006 Typical Drawing - Road Excavation Crossing
HFY-3800-5000-PPL-DWG-0007 Typical Drawing - Road Casing Crossing
HFY-3800-5000-PPL-DWG-0008 Typical Drawing - Road Culvert Crossing
HFY-3800-5000-PPL-DWG-0009 Typical Drawing - River/Channel Excavation Crossing
HFY-3800-5000-PPL-DWG-0010 Typical Drawing - River/Channel/Road HDD Crossing
HFY-3800-5000-PPL-DWG-0011 Typical Drawing - Marker Post
HFY-3800-5000-PPL-DWG-0012 Typical Drawing - Warning Tape
HFY-3800-5000-PPL-DWG-0013 Typical Drawing - Security Defense Crossing
HFY-GEN-PPL-SPC-0001 Specification for Hydrostatic Testing
HFY-GEN-PPL-SPC-0017 Specification for Pipeline Construction
HFY-3800-0000-PIP-SPC-0004 Specification For Piping Materials
HFY-3800-0000-MAT-RPT-0001 Material Selection Report
Specification For BNS SAWL Piping and Pipeline Material
HFY-3800-0000-MAT-SPC-0002
In Sour Service
HFY-3800-0000-MAT-SPC-0007 Specification for GRE Piping Material
HFY-3800-0000-MAT-SPC-0008 Specification For HDPE Piping Material
HFY-3800-0000-MAT-SPC-0016 Specification For BM HFW Pipeline Material
HFY-3800-0000-MAT-SPC-0017 Specification For BM HFW Induction Bend Material
HFY-3800-0000-MAT-SPC-0018 Specification For BN Seamless Pipeline Material
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 7 OF 24

Documents No. Documents Title

HFY-3800-0000-MAT-SPC-0019
HFY-3800-0000-MAT-SPC-0020
HFY-3800-0000-MAT-SPC-0021
HFY-3800-0000-MAT-SPC-0022
HFY-3800-0000-MAT-SPC-0023
HFY-3800-0000-MAT-SPC-0024
HFY-3800-0000-MAT-SPC-0025
HFY-3800-0000-MAT-SPC-0026
HFY-3800-0000-MAT-SPC-0027
HFY-3800-0000-TEL-DB-0001
Specification For BN Seamless Induction Bend Material
Specification For BNS Seamless Pipeline Material In Sour
Service
Specification For BNS Seamless Induction Bend Material
In Sour Service
Specification For X52NS Seamless Pipeline Material In
Sour Service
Specification For X52NS Seamless Induction Bend
Material In Sour Service
Specification For X52NS SAWL Pipeline Material In Sour
Service
Specification For X52NS SAWL Induction Bend Material
In Sour Service
Specification For GRE Pipeline Material
Specification For Pipeline Welding
Telecommunication Design Basis

1.7.2 International Standards

Documents No. Documents Title
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B36.10 Welded and Seamless Wrought Steel Pipe
facory-made Wrought Steel Buttwelding Induction Bends
ASME B16.49
for Transportation and Distribution Systems
API SPEC 5L Specification for Line Pipe
API RP 1102 Steel Pipelines Crossing Railroads and Highways
API STD 1104 Welding of Pipelines and Related Facilities
API RP 1109 Marking Liquid Petroleum Pipeline Facilities
API RP 1110 Pressure Testing of Liquid Petroleum Pipelines
BS PD 8010 Steel Pipelines On Land
Petroleum and Natural Gas Industries –
NACE MR0175/ISO 15156 Materials for Use in H2S-containing Environments in Oil
and Gas Production
API SPEC 15HR Specification for High Pressure Fiberglass Line Pipe
API SPEC 15LE Specification for Polyethylene Line Pipe (PE)
Petroleum and Natural Gas Industries — Glass-reinforced
ISO 14692
Plastics (GRP) Piping
Plastics Piping System —Polyethylene(PE) Pipes amd
ISO 4427
Fittings for Water Supply
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 8 OF 24

1.8 Order of Precedence

The precedence applying for use of the Codes, Standards, Specifications and
Regulatory requirements for this Project is as follows:
 Local laws, standards and government regulations, as applicable
 Project Specification, Documents and Drawings as approved by Company
 International Engineering Standards and Practices
 Vendor Standards and Procedures
In the event of an inconsistency, conflict or discrepancy between any of these Codes,
Standards, Specifications and Regulatory Requirements, the most stringent and safest
requirement applicable to the Project shall prevail to the extent of the inconsistency,
conflict or discrepancy. However, in the event that compliance with any such Codes,
Standards, Specifications or Regulatory Requirements would result in contravention of
any applicable other Codes, Standards, Specifications or Regulatory Requirements,
Contractor shall promptly draw this matter to Company’s attention and shall follow
Company’s directions. Any inconsistencies critical to the design shall be brought to the
attention of the Company Engineering Manager for resolution.

2 BASIC DATA

2.1 Environmental Data

Table 2.1-1 Environmental Data
Item Unit Value
Altitude mASL 0.5~6 *
Atmospheric Pressure KPa 102
Max. Temp. ℃ 55
Dry Bulb Temp. ℃ 42.2 (GPSA 11-3b)
Max. Metal temp. by sun shine ℃ 80
Min. Temp. ℃ -2
Max. Speed Wind m/s 40
Prevailing Direction Wind (winter) NW-SE
Prevailing Direction Wind (summer) NW-SE
Max. Relative Humidity 80%
Min. Relative Humidity 25%
Rainfall mm/a 177.4
1-Hour Rainfall mm/h 41
15 in winter (1.2-1.6 m)
Temp. ℃
33.6 in summer (1m)
Seismic Zone 2B
Evaporation Rate mm/a 3054.4
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 9 OF 24

Notes:
1. Parts of the data above are from the Email Confirmation for climate data on Mar. 10th, 2010, Email-
Confirmation for climate data on June 30th, 2010. Dry Bulb Temp is referred to GPSA 11-3b. 1-hour rain
fall data is the maximum 1 hour rain fall in recent 10 years in Basra.
2. Parts of the data above are from site survey data of Phase 1, Phase 2.

2.2 Topography
The topography is flat and wide. The main cover along the pipelines is wheat, rice, date
palm, shrub and wild grass.

Figure 2.2-1 Typical Topography

2.3 Engineering Geology
The proposed routes for interconnection trunklines are investigated during FEED
engineering design. Preliminary survey result is described as follow based on the report
of HFY3-TRL-4GI-RP-00001_A Geotechnical Investigation Report For Condensate, Raw
Gas And Dry Gas Interconnection Trunklines.
2.3.1 Engineering Geology
The topography along the route is flat and wide, the groundwater table was variable
ranging from 1.0m to 3.2m below the existing ground surface. The vegetation are crops
and grass. the detail of layers as below:
① Fat clay, greyish brown～yellowish brown, hard to firm, dry, medium toughness,
medium dry strength, containing white shell debris, partly containing plant roots, partly
containing a small amount of silt. The geotechnical classification of soil and rock
engineering should be class II~class III.
②Fat clay, greyish cyan, firm to soft, moist, medium toughness, medium dry strength,
containing white shell debris, partly containing some organic matters and fine sand. The
geotechnical classification of soil and rock engineering should be class II.
2.3.2 Corrosivity Evaluation of Soil

Table 2.3-1 Subsoil Corrosivity for Metal Structure Estimated by Resistivity

Measuring Mean Value of Class of Corrosion
Depth(m) Resistivity(Ω.m) BS 7361-1:1991
1.0 2.88 Severely Corrosive
2.0 4.28 Severely Corrosive
3.0 7.33 Severely Corrosive
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 10 OF 24

2.3.3 Corrosivity Evaluation of Groundwater

Table 2.3-2 Groundwater Corrosivity for Concrete Structure Estimated by SO3
Class of Corrosion
SO3 Content (ppm)
UBC Code
6,526 Severe

Table 2.3-3 Groundwater Corrosivity for Concrete Structure Estimated by PH

PH Value Limit Value of Evaluation Class of Corrosion
6.9 5.0 Very Weak

Table 2.3-4 Groundwater Corrosivity for Metal Structure Estimated by Cl-

-
Cl Content (ppm) Limit Value of Evaluation Class of Corrosion
27,520 5,000 Very Severe

3 PIPELINE DESIGN

3.1 Design Life

Design life for pipelines is 20 years.
3.2 Pipeline Scope and Parameters
Pipelines under GPP Project are listed in the following table.
Table 3.2-1 Interconnection Trunklines
Sr. ITEM Unit Description Note
1 10” C5+ Condensate Interconnection Trunkline from GPP to HPS
Design Code - ASME B31.8
Design Pressure MPa 5.5
Operating Pressure MPa 1.3
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~61
Service - C5+ Condensate
Material - API 5L PSL2 BM HFW
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
Length km 10.8 approx.
2 4" HP Fuel Gas Interconnection Trunkline from GPP to CPF1
Design Code - ASME B31.8
Design Pressure MPa 4.5
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 11 OF 24

Sr. ITEM Unit Description Note

Operating Pressure MPa 3.4
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~50
Service - Dry gas
Material - API 5L PSL2 BN SMLS
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 1.5
Length km 10.4 approx.
24" Dry Gas Interconnection Trunkline from GPP to Armarh&Kahala
3
Power Plant
Design Code - ASME B31.8
Design Pressure MPa 4.7
Operating Pressure MPa 3.4
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~60
Service - Dry gas
Material - API 5L PSL2 X52NS SAWL
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
Length km 10.0 approx.
4 24" Raw Gas Interconnection Trunkline from CPF3 to GPP
Design Code - ASME B31.8
Design Pressure MPa 5.2
Operating Pressure MPa 4.7
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~65
Service - Raw gas
Material - API 5L PSL2 X52NS SAWL
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
Length km 10.0 approx.
5 8" Condensate Interconnection Trunkline from CPF1&CPF3 to GPP
Design Code - ASME B31.8
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 12 OF 24

Sr. ITEM Unit Description Note

Design Pressure MPa 4.5
Operating Pressure MPa 3.0
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~60
Service - Condensate
Material - API 5L PSL2 BNS SMLS
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
Length km 10.0 approx.
6 12" LP Fuel Gas Interconnection Trunkline from GPP to CPF1&CPF3
Design Code - ASME B31.8
Design Pressure MPa 2.5
Operating Pressure MPa 1.6
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~60
Service - dry gas
Material - API 5L PSL2 BM HFW
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 1.5
Length km 10.0 approx.

Table 3.2-2 Pipelines around GPP

Sr. ITEM Unit Description Note
1 16" Raw Gas Pipeline from CPF1 to GPP (CPF2-GPP part) Re-route
Design Code - ASME B31.8
Design Pressure MPa 4.7
Operating Pressure MPa 4.3
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~65
Service - Raw gas
Material - API 5L PSL2 X52NS SMLS
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 13 OF 24

Sr. ITEM Unit Description Note

Length km 1.5 approx.
2 12" HP Fuel Gas Pipeline from GPP to Power Plant
Design Code - ASME B31.8
Design Pressure MPa 4.5
Operating Pressure MPa 3.4
Design Temperature(Max/Min) °C 85/15
Operating Temperature °C 15~60
Service - Dry Gas
Material - API 5L PSL2 BN SMLS
Installation - UG
External Coating - 3LPP
Corrosion Allowance mm 3.0
Length km 1.4 approx.
3 24" Fresh Water Pipeline from CPF2 to GPP
Design Code - ASME B31.4/ISO 14692
Design Pressure MPa 3.0
Operating Pressure MPa 0.2
Design Temperature(Max/Min) °C 60/15
Operating Temperature °C 15~40
Service - Fresh water
Material - API 15LR GRE
Installation - UG
Length km 0.6 approx.
4 6" Waste Water Pipeline from GPP to CPF2
Design Code - ASME B31.4/ISO 14692
Design Pressure MPa 2.0
Operating Pressure MPa 1.0~1.5
Design Temperature(Max/Min) °C 60/15
Operating Temperature °C 15~40
Service - Waste water
Material - API 15LR GRE
Installation - UG
Length km 1.1 approx.
5 24" Waste Water Pipeline from GPP to Evaporation Pond
Design Code - ASME B31.4
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 14 OF 24

Sr. ITEM Unit Description Note

Design Pressure MPa 1.0
Operating Pressure MPa 0.25
Design Temperature(Max/Min) °C 60/15
Operating Temperature °C 15~40
Service - Waste water
Material - API 15LE HDPE (PE4710 )
Installation - UG
Length km 0.4 approx.
6 3" Sewage Pipeline from GPP to CPF2
Design Code - ASME B31.4
Design Pressure MPa 0.5
Operating Pressure MPa 0.2
Design Temperature(Max/Min) °C 60/15
Operating Temperature °C 15~40
Service - Sewage
Material - API 15LE HDPE (PE4710 )
Installation - UG
Length km 0.2

Note:
1. 12" HP Fuel Gas Pipeline from GPP to Power Plant includes two (2) branch pipelines, one (1)
for the existing power plant and the other reserved for future power plant.
2. 16" Raw Gas Pipeline from CPF1 to GPP (CPF2-GPP part) shall be upgraded based on Raw
Gas Trunkline (CPF2-CPF1) of Phase 2. Company shall shut down the Raw Gas Trunkline
(CPF2-CPF1) of Phase 2, Vent, pigging, purge the pipeline to meet requirements of work.
After completion of above work, Contactor shall cut the pipeline at tie-in point and weld new
pipeline to it and extend to GPP. The pipeline section from cut end to CPF2 shall be carefully
sealed and abandoned.
3.3 Tie-in Points and Battery Limits
Tie-in points indicate the interfaces between GPP Project and other projects.
Battery limits indicate the interfaces between pipeline design scope and piping design
scope under GPP Project as indicated in the PID drawings.
Before tie-in works, Company shall shut down the existing pipelines in service, venting,
pigging, and purging the pipelines to meet requirements of safety. After completion of
above work, Contactor shall conduct the tie-in works including but not limited to cutting,
welding, coating, inspection, and backfilling.
For more detail, please refer to the drawing of HFY3-3800-5000-PPL-DWG-0001 Overall
Route Layout and document of HFY-3800-5000-PPL-LST-0001 Pipeline Schedule.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 15 OF 24

3.3.1 Interconnection Trunklines

For 10” C5+ Condensate Interconnection Trunkline, the initial battery limit is 2m outside
of GPP brick wall. The terminal battery limit locates at 2m outside brick wall of HPS,
further section belong to piping design scope.
For 4" LP Fuel Gas Interconnection Trunkline, the initial battery limit is 2m outside of
GPP brick wall. The terminal tie-in point locates at approximate 7m off outside edge of
security defence of CPF1. A pre-buried pipeline section has been constructed by other
contractor to cross the security defence. GPP contractor shall take charge of tie-in work.
The pre-burried pipe shall be checked and tested to identify whether it can meet the
requirement of use. If test fail, Contractor shall report to Company, and take measures of
repairing or install new pipes based on approval of Company.
For 24" Dry Gas Interconnection Trunkline, the initial battery limit is 2m outside of GPP
brick wall. The terminal tie-in point locates at approximate 500m north of CPF1, to be
connected to a planned valve station. In case of the valve station being constructed later
than Dry Gas Interconnection Trunkline, GPP contractor shall dry and fill the pipeline
with nitrogen and seal it carefully after Mechanical Completion.
For 24" Raw Gas Interconnection Trunkline, the initial tie-in point locates at the existing
bend on Raw Gas interconnection Trunkline (CPF3-CPF1), approximate 500m north of
CPF1. The existing bend shall be changed to Barred Tee. GPP contractor shall take
charge of tie-in work. The terminal battery limit is 2m outside of GPP brick wall.
For 8" Condensate Interconnection Trunkline, the initial tie-in point locates at the
reserved barred tee, approximate 500m north of CPF1. GPP contractor shall take
charge of tie-in work. The terminal battery limit is 2m outside of GPP brick wall.
For 12" LP Fuel Gas Interconnection Trunkline, the initial battery limit is 2m outside of
GPP brick wall. The terminal tie-in point locates at approximate 500m north of CPF1, to
be connected to the reserved barred tee. GPP contractor shall take charge of tie-in work.
3.3.2 6" Waste Water Pipeline from GPP to CPF2
The battery limits are 2m outside of GPP/CPF2 brick wall.
3.3.3 16" Raw Gas Pipeline from CPF1 to GPP (CPF2-GPP part)
The initial tie-in point locates at the crossing point of existing raw gas interconnection
trunkline (CPF2-CPF1) with inside fence of CPF2, approximate 60m southwest of CPF2
brick wall. The pipeline section from tie-in point to CPF2 shall be sealed at both ends
and abandoned in-place.
3.3.4 12" HP Fuel Gas Pipeline from GPP to Power Plant
The initial battery limit is 2m outside of GPP brick wall. The terminal battery limit is 2m
outside of Power Plant brick wall. An additional branch line will be constructed and
sealed carefully for future power plant.
3.3.5 24" Fresh Water Pipeline from CPF2 to GPP
The initial tie-in point locates at the existing reserved valve, approximate 80m north of
CPF2 brick wall. The terminal battery limit is 2m outside of GPP brick wall.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 16 OF 24

3.3.6 24" Waste Water Pipeline from GPP to Evaporation Pond

The initial battery limit is 5m outside of GPP brick wall. The terminal battery limit is at the
edge of evaporation pond. No tie-in works.
3.3.7 3" Sewage Pipeline from GPP to CPF2
The initial battery limit is 5m outside of GPP brick wall. The sewage water will be drained
to a new built sewage tank which will be provided by COMPANY. the new sewage tank
is planned to be constructed next to existing sewage skid. The terminal tie-in point is
approximate 80m north of GPP brick wall.
3.4 Pipeline Material
For interconnection trunklines, material shall be the same as the existing pipelines or the
pipeline sections by other contractor.
For pipelines around GPP, material shall be the same as specified by piping material
specification.
Pipeline material has been detailed in Table 3.2-1 and Table 3.2-2 in section 3.1, for
more detail, please refer to the document HFY-3800-5000-PPL-RPT-0001 Pipeline
Mechanical Design Report, HFY-3800-0000-PIP-SPC-0004 Specification for Piping
Materials, and HFY-3800-0000-MAT-RPT-0001 Material Selection Report.
3.5 Pipeline Route Layout
The principal strategy to be considered in route layout are as follow:
 Arrange pipelines in the common corridor as practical
 Minimize route length
 Minimize crossing
 Facilitate construction
 Facilitate operation, maintenance and repairing purposes
Site visit shall be performed to verify the feasibility of proposed pipeline routes. Pipeline
routes shall be approved by Company in write for further design and construction
proposes.
A topographic and alignment survey shall be performed to develop detailed alignment
sheets. The alignment sheets, once completed, shall include all appropriate mechanical,
cathodic protection, and applicable operational data. The survey work will also support
the environmental assessment of the route. Permission to perform the survey work on
the corridors shall be obtained from appropriate owners prior to commencement.
For propsed routes, please refer to HFY3-3800-5000-PPL-DWG-0001 Overall Route
Layout.
The final route alignment sheets shall contain detailed information with respect to:
 Route layout
 Ground profile
 Topography
 Soil conditions / characteristics
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 17 OF 24

 Location of existing above ground and buried pipelines

 Location of existing power cables, overhead lines and other services
 Soil resistivity measurement for CP design
 Location of rig crossings
The final route alignment sheets shall also include all construction-related details of the
pipeline comprising of:
 Class location as per ASME B31.8
 Line pipe material, grade and wall thickness
 Pipeline OD
 Design factors
 Code break locations
 Surface/terrain details
 Track, asphalt road & rig road crossings
 Depth of burial
 Coating type
 Valves, fittings, hot induction bends, insulation joints etc.
 Type of construction
 Crossing location, type and reference drawing
 Cathodic protection installations
 Markers
3.6 Location Class and Design Factor
The location class along interconnection trunklines shall be class 2 as per ASME B31.8,
basic design factor shall be 0.6.
Design factors for various pipelines in different locations are tabulated as follow.
Table 3.6-1 Design Factors
Sr. Pipelines Design Factor
1 Condensate pipelines
Off Plot sections 0.6
On Plot setion up to 200m from outside fence 0.4
Minor road crossings without casing 0.4
Minor channel crossings 0.6
Main road and Main channel crossings 0.4
2 Gas Interconnection trunklines
Off Plot sections 0.6
On Plot setion up to 200m from outside fence 0.5
Minor road crossings without casing 0.5
Minor channel crossings 0.6
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 18 OF 24

Sr. Pipelines Design Factor

Main road and Main channel crossings 0.5
3 Gas pipelines around GPP 0.5

3.7 Pipeline Component and Auxiliaries

Following requirements 3.7.2 through 3.7.4 are applicable for carbon steel pipelines only.
Requirements such as construction specification, calculation and stress analysis for
GRE pipelines and HDPE pipelines shall be provided by vendor.
3.7.1 Line Pipe
Line pipe shall meet the requirements of project specifications listed in section 1.7.1.
3.7.2 Elastic Bending
The minimum radius of curvature shall be as per the report of HFY-3800-5000-PPL-
RPT-0001 Pipeline Mechanical Design Report.
3.7.3 Cold Bend
Considering the actual site condition of lack of bending machine, using cold bend
is impractical, hence cold bend will not be considerd for pipeline installation.
3.7.4 Hot Induction Bend & Elbow
Hot bend and elbow will be used in case of space limitation.
For trunklines , the hot induction bend shall be used. The radius of curvature shall be 6D.
For other pipelines, the elbows shall be used. The radius of curvature shall be 1.5D as
per HFY-3800-0000-PIP-SPC-0004 Specification For Piping Materials.
For 24” hot bend, at least 1m straight pipe shall be kept at each end, and 0.5m straight
pipe shall be kept for 16” hot bend and below diameters.
3.7.5 Anchor block
Anchor block shall be considered for the purpose of controlling the displacement of pig
traps, and to avoid overstress of pipeline. Whether an anchor block is needed shall be
checked and determined by corresponding stress report.
3.7.6 Culvert
New culverts shall be constructed and used for pipeline crossing of the security defense
of CPF2. Culvert locations are detailed in drawing of HFY-3800-5000-PPL-DWG-0001
Overall Route Layout and corresponding pipeline route plan and aligement sheets.
For more culvert detail, please refer to the drawing of HFY-3800-5000-CIV-DWG-0414
Concrete Culvert For Pipeline Crossing Flood Dam.
3.7.7 Marker Post
The location of buried pipelines shall be clearly identified by marker posts. Pipeline
marker posts should be installed at the following locations along pipeline.
 At point where pipeline changing direction horizontally, and the angle is more than
3°
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 19 OF 24

 At upstream side of each road and river crossing, at each pipeline and cable
crossing
 At one hundred meter interval
3.7.8 Warning Tape
Warning tape shall be set along the pipeline route. For GRE pipeline and HDPE
pipelines, warning tape shall be detectable.
3.8 Pipeline Mechanical design
Wall thickness calculation shall be performed and checked as per the ASME B31.8 and
ASME B31.4.
The amplification fator for hot bend according to ASME B16.49 shall be considered. Also,
the thickness thinning due to bending shall be considered too. Method from BS 8010
shall be used.
Hoop stress, axial stress, and equivalent stress shall be checked respectively. Ratio of
diameter to wall thickness shall be checked, value shall not exceed 100.
For pipeline section of crossing road without casing, stress check shall meet the
requirements of API RP1102.
In addition, pipeline strss analysis using CAESAR II sofaware should be conducted for
trunklines which are listed in table 3.2-1 and table 3.2-2.
For more detail, please refer to HFY-3800-5000-PPL-RPT-0001 Pipeline Mechanical
Design Report.
3.9 Pipeline Laying
3.9.1 Laying
The main pipelines shall be buried and shall not have buried flanged connections.The
pipelines shall be installed above the water table except at impractical locations (ie, road
crossings).
If rock areas are encountered and blasting is recommended by CONTRACTOR, special
permission will be required from COMPANY. Existing trees and plants shall not be
damaged or cut unless proper approval has been granted. Fencing shall be provided for
additional security and protection along both sides of the pipeline corridor as permitted
by the authorities. Fencing will not be necessary in areas deemed not to be beneficial by
COMPANY or it is against the acceptance of other parties.
A temporary 6m maintenance access track shall be provided alongside the entire
pipeline route in the construction duration.
For underground pipelines, the burial depth from ground surface to top of pipe shall not
be less 1.2m. Pipelines shall be buried in the same trench where applicable, the clear
distance shall be 0.6m.
3.9.2 Changing Direction
For carbon steel pipeline, elastic bending, hot bend and elbows shall be used to change
pipeline direction. The minimum length of straight pipe between two bends are tabulated
as follow.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 20 OF 24

Table 3.9-1 Hot Bend Angle

Item Elastic Bending Hot Bend
Elastic Bending 4m 3m
Hot Bend 2m
For GRE pipelines and HDPE pipelines, such requirements shall be provided by vendor.
3.10 Pipeline Crossings
All crossings shall meet the requirements of project specifications and typical drawings
listed in section 1.7.1. In addition, crossings shall also meet the requirements from whom
having jurisdiction of the obstacle to be crossed, and agreement in write shall be got
before construction.
3.10.1 Road Crossing
Road crossing shall follow the code of API RP 1102. Crossing angle should be 90°as
far as possible.
For minor road such as dirt road and sand road, open cut method should be preferred.
For main road such as highway, trenchless methods including boring, jacking casing,
and HDD method shall be preferred.
For more detail, please refer to following drawings:
HFY-3800-5000-PPL-DWG-0006 Typical Drawing - Road Excavation Crossing
HFY-3800-5000-PPL-DWG-0007 Typical Drawing - Road Casing Crossing
HFY-3800-5000-PPL-DWG-0008 Typical Drawing - Road Culvert Crossing
3.10.2 Channel and river Crossing
Channel and river crossing angle shall be 90°as far as possible.
For minor rivers, minor irrigation channels, and minor drain channels, open cut method
should be preferred.
For main rivers and main channels, which is source water for local, HDD method should
be preferred.
For more detail, please refer to following drawings:
HFY-3800-5000-PPL-DWG-0009 Typical Drawing - River/Channel Excavation Crossing
HFY-3800-5000-PPL-DWG-0010 Typical Drawing - River/Channel/Road HDD Crossing
3.10.3 Security Defence Crossing
The 10” C5+ condensate interconnection trunkline will cross the Security Defence of
CFP1 and GPP, the other interconnection trunklines, and 24" waste water pipeline will
cross the Security Defence of GPP.
To ensure that the flood protection dam(if any) in Security Defence will not be damaged
during pipeline construction, pipelines shall pass it on top of the dam in culvert. In case
of no existing culvert can be utilized, new culvert shall be constructed to satisfy this
requirement.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 21 OF 24

For more detail, please refer to HFY-3800-5000-PPL-DWG-0013 Typical Drawing -

Security Defense Crossing.
3.10.4 Other Crossings
The buried pipelines shall be laid below the existing obstacles.
The clear space between pipeline and existing pipeline is at least 0.3m.
The clear space between pipeline and existing cable is at least 0.5m. Necessary
protection measures will be taken to protect the cable as per the typical drawings.
For more detail, please refer to following drawings:
HFY-3800-5000-PPL-DWG-0004 Typical Drawing - Underground Pipeline Crossing
HFY-3800-5000-PPL-DWG-0005 Typical Drawing - Underground Cable Crossing
3.11 Pipeline Welding and Non-destructive Testing
Welding and NDT shall meet the requirements of HFY-3800-0000-MAT-SPC-0027
Specification For Pipeline Welding.
For pipelines carrying gas service, condensate service, seams of main crossings
sections, seams connecting bend and straight pipe and seams of gold weld shall be
100% radiography tested and 100% ultrasonic tested.
3.12 Pipeline Pigging and Gauging
Prior to commencement of hydrostatic testing, the carbon steel pipelines shall be pigged
to remove construction debris such as soil, welding rods, hand tools, etc and to clean the
line with temporary pig launcher and receiver facilities. Operational pigging shall be
accomplished until no any debris are found in the end of pipeline.
After pigging accepted by Company’s Representative, gauging for pipelines shall be
carried out by gauging pig equipped with a gauge plate. A written approval shall be
obtained from Company’s Representative regarding successful completion of gauging
pig run.
The pipelines shall be designed to accommodate scrapers on the pipelines for
construction, maintenance, operation, and inspection purposes. Interconncetion
Trunklins shall be designed with a minimum hot bend radius of 6D to accommodate
intelligent scrapers. A philosophy shall be provided that addresses the overall
requirements for running scrapers.
Pigging and gauging shall meet the requirements of HFY-GEN-PPL-SPC-0001
Specification for Hydrostatic Testing.
HDPE pipeline shall be tested to meet the requirements of API SPC 15LE.
Intelligent pigging shall be conducted three times:
 Immediately after commissioning
 One year from commissioning
 Before operation handover
Specifications for intelligent pigging shall be provided by special sub-contractor and send
to COMPANY fro approval.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 22 OF 24

3.13 Pipeline Pressure Testing and Drying

The hydrostatic test will be carried out only after the pigging and gauging operation is
accepted.
Hydrostatic test the pipeline system and prefabricated components to meet the
requirements of ASME B31.4/B31.8. Test medium shall be filtered and chemically treated
clean water; the hydrostatic test shall be carried out after backfilling.
After the acceptance of hydraulic testing, test water shall be drained. Plate pig or foam pig
shall be used. Dewatering shall be repeated until no free water found at the end.
For gas pipeline, drying operation shall be carefully executed after dewatering accepted as
soon as possible to ensure satisfactorily dried.
Drying and Nitrogen Filling in case of any of the followings:
1) The interval between mechanical completion and commission is more than two (2)
months;
2) No specific schedule of commissioning.
Pressure testing and drying shall meet the requirements of HFY-GEN-PPL-SPC-0001
Specification for Hydrostatic Testing.
3.14 Pipeline Construction
Construction shall meet the requirements of HFY-GEN-PPL-SPC-0017 Specification for
Pipeline Construction and the the typical drawings listed in section1.7.1.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 23 OF 24

4 FIBER OPTIC CABLES

4.1 FOC between GPP and CPF2

Fiber optic cables (6 pieces of 12-core) from GPP to CPF2 shall be buried directly with
raw gas pipeline (16" Raw Gas Pipeline from CPF2 to GPP, Tie-in to GPP, in Table 3.2-
2). The Fiber Optic Cable shall be laid from ODF in Lead-in room of CPF2 to the ODF in
Lead-in room of GPP.
4.2 FOC between CPF1 and CPF2
Fiber Optic Cable (1 piece of 36-core) from CPF1 to CPF2 shall be buried directly with
LP Fuel Gas Interconnection Trunkline (12" LP Fuel Gas Interconnection Trunkline from
GPP to CPF1&CPF3, in Table 3.2-1). The Fiber Optic Cable shall be laid from Optical
Distribution Frame(ODF) in CPF2 lead-in room to the tie-in point of LP Fuel Gas Pipeline
on the north of CPF1 and shall be connected with the reserved fiber optic cable in
WATER INTERCONNECTION TRUNKLINE project.
For above FOCs, Fiber pigtail, FOC fusion and systems testing work are in the scope of
this Project.
For detail, please refer to HFY-3800-5000-TEL-DB-0001 Telecommunication Design
Basis for Trunkline.

5 ANTI-CORROSION

5.1 Coating
The external coating for buried carbon steel pipeline shall be 3 layer PP, the field joint
coating shall be heat shrinkable tape (PP type), the repair coating shall use PP repair
tape and hot adhesive.
The external coating for hot bend pipes shall use double fusion bond epoxy (FBE) + PP
tape,FBE layer thickness shall be more than 800μm.
5.2 Cathodic Protection
The burried steel pipeline shall be protected by the ICCP system, and the cathodic
protection station will be installed in the GPP, the deep well anode groundbed shall be
considered.
5.2.1 Soil Resistivity
The soil resistivity shall be as 2.3.2.
5.2.2 Protection Criteria
The buried pipelines will be protected in accordance with NACE SP0169.
Pipelines-to-soil potential will be -0.85V or more negative vs. CSE reference electrode
(irrespective of IR drop), if the pipeline operating temperature less than 40°C.
Pipelines-to-soil potential will be -0.95V or more negative vs. CSE reference electrode
(irrespective of IR drop), if the pipeline operating temperature more than 40°C.
5.2.3 Protection Parameters
The 3LPP coating protection current density shall be 10μA/m2.
 PIPELINE DESIGN BASIS

DETAIL DESIGN DOC. NO.: HFY-3800-5000-PPL-DB-0001 REV.: 0 PAGE 24 OF 24

After cathodic protection energized, for 3 layers PP coated pipeline, the measured off-
potential value against a Cu/CuSO4 reference electrode of pipe shall be -850mV~-
1200mV (Vs. CSE, irrespective of IR drop).
5.2.4 ICCP System for Pipeline
The ICCP system for pipeline consist of TRU (transformer rectifier unit), deep well
ground bed anode, cables, negative junction box, test post, insolation joint and reference
electrodes etc.
The cathodic protection system detail information shall be as the HFY3-GEN-CP-SP-
00008.
5.2.5 ICCP Station
The ICCP station will be considered in GPP to protect pipeline.
5.2.6 Temporary Cathodic Protection
Mg Sacrificial Anode will be used as temporary cathodic protection measure for pipeline
before ICCP commissioning.