36 13:42 SAFETY REGULATIONS FOR LIQUID HYDROCARBON PIPELINES Le . se18s474013, PAGE.222PURPOSE OF REGULATION ARTICLEL ‘The purpose of this safety regulation isto set the essential engineering rules applicable to the construction and operation of pipelines (1) carrying liquid hydrocarbons with 2 flash point equal to a maximum of 100° C, except for the works excluded under Article 2, WORKS EXCLUDED FROM THIS REGULATION ARTICLE 2: ‘This regulation does not apply to pipelines or parts of pipelines whose pipe(s) are made of steel tubes at least 3.5 mm thick, when the maximum operating pressure P does not exceed 4 Keflem2, or the product of the maximum operating pressure P, expressed in Kgf/em’, and the outside diameter D of the tube, expressed in millimeters, does not exceed the following values for any of the products transported: = 2000 if the pipe or the section being considered occupies an area in Zone I according to the definition in Article 4, = 0 3000 if the pipe or the section being considered occupies an area in Zone II or II. LE part of a pipe is located in Zone I, the value of 2000 applies to the whole section containing this part. A section is a length of pipe contained between two flange joints, so that it can be isolated during testing. Catch piping for cil wells is also excluded from this regulation when it is joined by threaded sleeves. ‘The setting up and operation of liquid-hydrocarbon carrying facilities that are not subject to the provisions herein and do not require the specific prescriptions mentioned above must comply only with generally accepted engineering regulations. However, they may also be covered by specific prescriptions decreed by the Minister for Hydrocarbons, where applicable. (A pipeline is a structure composed of one or more pipes serving one or more terminals and may include one or more pumping stations, 1196 13843 sei8s47<013 PAGE.23DISCHARGE PRESSURE ARTICLES: ‘The maximum discharge pressure leaving a pumping station must not cause the pressure in pipes located downstream or in pipe accessories to exceed the range of maximum allowed operating pressures. ‘When the pipe is telescopi, in other words, when calculation of the nominal thickness of the different sections takes into account head loss, suitable devices are used to prevent the range of ‘maximum allowed operating pressures from being exceeded in sections located upstream of point along the pipe that was accidentally closed during pumping. RIPE PLACEMENT ARTICLE: Pipe placements are divided into three zones. ‘ZONE 1 includes: placements in urban areas, or areas near isolated residential sites oceupied by personnel at permanent stations or frequented by the public. ‘These placements are defined as being located: « less than 40 meters from a facility holding over 200 (two hundred) people or a non-oil or gas facility that poses a fire or explosion hazard. less than 15 meters from a residential building other than those described in the above paragraph. However, this limit may be shortencd to 10 m when the building in question is isolated, ic, located more than 200 m from any other inhabited site or from a site occupied by personnel at a permanent station. Inall instances, the national public domain shall be considered part of Zone I. It also includes the parts of pipeline located inside oil facilities. ‘ZONE Il includes: placements in rural zones, pasture land, farm land, forests, and the outskirts of towns. ‘ZONE ILincludes: placements in desert regions. Classifying of placements according to the three preceding zones is determined by the carrier in consultation with the relevant departments of the Ministry for Hydrocarbons. PPR 1°96 13:43 ssiesa7aei3 PAGE.@24CHAPTER TL FACTORY CONSTRUCTION OF TUBES METAL PROPERTIES AND STRESS LIMITS FOR TUBES AND ACCESSORIES QUALITY OF TUBE METAL ARTICLES: ‘The pipe is composed of welded or unwelded tubes, which are made of open-hearth steel, steel made in an electric oven, open converter steel, or mild steel of technically equivalent quality, particularly as concerns resistance to aging. ‘The sheet metal used in the manufacture of welded tubes must be of current commercial grade and specifically, not show any obvious plating on the edges or sections. The same is requixed of the strip steel or flat steel used to make tubes with spiral welding. ‘The metal must be easily weldable at the work site, taking into account the technique used. ‘Once all manufacturing operations have been completed on the tube components, length A measured on lengthwise samples according to the accepted standard must meet the following conditions: A> 18% if the tube component is intended to be laid in a Jocation in Zone | or located in an area affected by earth movements, as defined in Article 22 herein. A> 11% if the tube component is intended to be Inid in a location in Zone Il or lil and not located in an area affected by earth movements, In addition, the elastic limit E must not exceed the following values: 90% of breaking weight “R” for seamless steel tubes. 85% of breaking weight for rolled and welded sheet metal tubes, whether or not they are cold drawn. ‘The values for E 0.2 and R are regulated in Article 7. (1) The elastic limit E 0.2 discussed in this regulation is the quotient of the load in Kgf, which ‘causes an elongation of 0.2% of the initial length between reference points of the sample defined in Article 7, divided by the initial section in square millimeters of the portion calibrated. SPECIFICATIONS FOR WELDED TUBES ARTICLE 6: FPR 1 ‘56 33844 se1es274013 PAGE. 205Welded tubes are made in the factory of arched plate, strip steel, or rolled flats. They are butt- welded together by fusion or resistance following a generating line or spiral. Welding is followed by cold drawing by expansion or contraction when the manufacturer wants to raise the elastic limit, Welded tubes may be made by butt jointing two welded ferrules provided that the shorter of the two is at least 1.5 m long. The nominal coefficient “2” of factory-welded joints, meaning the ratio of the per-unit breaking weight of the assembled wait tothe nominal per-unit breaking weight of the metal in the finished tube, is specified in the accepted standard and must not be less than 0.6%, Verification of the coefficient is regulated by Article 11. STRESS LEVEL FOR TUBES ARTICLE7: \ The maximum allowed operating pressure for each tube is such thatthe coresponding transverse FER stress of the metal, expressed in Kgf/mm’ and calculated using the ratio given in Article 8, is limited tothe following values in relation to the elastic Limit E 0.2 and the per-uit breaking “eight R, also expressed in Kgffmm’: TE OD TR above-ground pipe PLACEMENT (underground or underground pipe | (except for above above-ground pipe) ground crossings in ‘the public domain covered in Art. 24c) Zone T 067 O47 0.44 Zone It 0.75 0.59 0.44 Zone Til 0,82 0.65 0.65 eS noe Elastic limit E 0.2 and per-unit breaking weight R for the metal of the finished tube are et the 43 “jrv usual temperature, These properties —E 0.2 and R—are measured on samples taken from finished tubes whose inital length is between markers Lo = 5.65 So, where So is the initial section of the portion calibrated. 2690 GS KEE “The above stress level limits may be increased by 10% in case of accidental dynamic excess pressure, particularly in case of a pressure surge. ‘TUBE DIMENSIONS ARTICLE 8: a) Thickness: The thickness “e” of the tube, its maximum outside diameter D, the pressure P of the fluid, and the transverse stress T of the metal are related by this equation: 1196 13ea se19se74013 PAGE. 206fFR PD e=— 2Tx where P and T on the one hand, and D and ¢ on the other, are expressed inthe same unix, which is a coefficient equal to 1 for unwelded tubes, or equal to the nominal joint coefficient “@” for factory welds defined in Article 6 for welded tubes. —_ “The thickness “e” of the tube is as provided in the specification, minus the manufacturing tolerance for thickness, and not including the weld reinforcement when the tubes are welded. Manufacturing tolerances for thicknesses are set by the accepted standard. For welded tubes, the inside weld reinforcement must not exceed 3 mm, and the inside padding, is removed from each end for a length of 80 mm. A slight indent for attachment must be made during grinding. “Any surface flaws in the tubes must not be deeper than an eighth of the thickness “e.” ») Diameter: Manufacturing tolerances for the outside diameter are set by the accepted standard, ‘Any localized indents in the wall of tube must not be deeper than 6 mm nor cover a range with the largest span exceeding half the diameter D. ¢) Deviation: The finished tubes must be sufficiently straight, Dimensions may be checked in accordance with the accepted standard. BEYELING TUBE ENDS ARTICLE 9: ‘Tubes with a maximurh thickness of 3 mm that are are welded and of 4 mm for torch-welded tubes can be straight-cut at the ends without a bevel. For all other tubes, the ends are beveled by machining or by machine oxyfuel cutting at an angle of 30-35° measured perpendicular to the tube’s axis, so that a root face with a beight of 0.8-2.4 mm is created at each end. If beveling reveals plating in the wall, the defective part of the tube must be thrown out. The straight cut or the root face must be even and the flat area created must be clearly perpendicular to the straight line joining the centers of the end sections. 1°96 1345 12195474013FPR ACCESSORIES ARTICLE 10: Gate valves, plug valves, and nonretum valves are made of steel, bronze, or a special material where operating conditions warrant it ‘The working pressure on valves and other accessories built into the pipeline shall be at least equal to the maximum expected working pressure defined above: It shall be guaranteed by the maker. CHAPTER I FACTORY TESTING OF TUBES AND ACCESSORIES ARTICLE 11: The carrier (1) determines the real coefficient a1 of the joint for welds made in the factory. It is defined as the ratio of the nominal per-unit breaking weight of the sample, discussed in the following paragraph, to the nominal per-unit breaking weight specified by the accepted standard for the metal of the finished tube. ‘The coefficient is determined by performing tensile tests, test A, on crosswise samples cut from. finished tubes so that the welding is in the middle of the sample. One sample is taken from every lot of: ~ 400 tubes, when the diameter D equals a maximum of 170 mm; ~ 200 tubes, when D falls between 170 and 320 mm; - 100 tubes, when D equals at least 320 mum, Tubes made up of two butt-jointed collars count as two. Test A is run according to the conditions defined in the accepted standard, ‘The lot is considered to have passed the test when al equals at least 1+a 2 (1) Under this regulation, the term “carrier” applies to any individual or company undertaking the construction or operation of a liquid hydrocarbon pipeline. ‘When these results are not obtained, the lot is refused if “a" equals 0.6, But if “a” is greater, the test is repeated on three more samples, with the final value for al being the value a2 which is the ‘smallest of those obtained on the four samples, 1°96 13:65 19185474013 PAGE. 2¢8FER If a2 is less than 0.8, the lot is refused. Tf a2 is at least equal to 0.8, the lot is accepted, Fer TET Test gilad a ert CG However, it can be used only in the portion of the pipe where the maximum allowable operating pressure and the transverse stress of the metal match the equation given in Article 8, where x is replaced by 2 a2-1. INSPECTION OF WELDING ON FACTORY-WELDED TUBES ARTICLE 12; . Welding done in the factory is inspected and repaired, as needed, by the tube manufacturer according to a technique that has been approved by an authorized expert or agency. The technique must be able to seveal any systematic defect that is likely to compromise the safety of the tubes in operation. ‘When the nominal coefficient “a” of the joint specified by the accepted standard equals at least 0.8, factory-welded tubes undergo an additional check. Cross samples are taken under the conditions defined in the second paragraph of Article 11 to check lengthwise or spiral welds, except for the proportion that is attached to a sample along five hundred meters of welded wes. When the outside diameter of welded tubes is a maxisrum of 150 mam, flaring tests (test B), are used to check the welding, or bend tests (test C) in other cases. Tensile tests (test D) are used to check circular welding on butt-jointed collars on lengthwise samples straddling the welding and taken at a rate of one sample for every two hundred butt jointings. However, sample-taking can be replaced by X-ray check (test E) of one percent of butt Joints. In this case, just one lengthwise semple is taken for a mecbanical test aimed at checking. that the right electrodes were used for the grade of steel in the (ubes, and to be sure that the ‘welding was done properly. ‘The method for taking samples, the definition of tests B, C, D, and E, and the required results ‘must comply with the provisions of the accepted standard. Welded tubes that are run through an expander or a rolling mill with decreasing passes also undergo a test to measure the shock breakage on beveled bars after artificial aging (test F). 1196 1345 18165474013 PAGE. 2@8Test F is done on transverse samples cut in the middle of the sheet metal in the area opposite the welding. Three samples are taken per tube and one tube out of every 400 tubes is cut. When the tube is thicker than 10 min, the thicksiess of the sample is reduced to 10 mm by planing the outside surface. Test F is defined in the accepted standard. It is intended to provide technical information. CTESTING TUBES ARTICLE 14; “The tube manufacturer carries out an in-plant hydraulic test under his supervision on each tube at a pressure set by the authorized expert or agency. The pressure must be such that the transverse stress t, calculated using the equation in Article 8, equals at least 60% of the elastic limit E 0.2 and no more than 90% of this limit, ‘The test lasts 15 seconds. ‘The authorized expert or agency will accept only those tubes that have passed the test without becoming obviously deformed or revealing any defect. However, if the manufacturer repairs a welding defect after the test, the autborized expert or agency may accept the tube if the size of the defect, the repair, the inspection, and any repeat of the test meet the technical specifications of the accepted standard. ACCESSORY TESTING ARTICLE 15: Elbows shaped in the factory from tubes that have been passed by the authorized expert or ‘agency according to the conditions defined in Article 14 are not tested by the manufacturer, All other elbows, extensions, reducing sleeves, and Ts undergo an in-plant hydraulic test, under the conditions described in Amticle 14 for tubes. Hydraulic pressure equaling at least 120% of the maximum expected operating pressure is applied to gate valves, plug valves, and nonretum valves in the factory. The test pressure may not, cause stress exceeding 90% of the metal’s elastic limit at any point, The valves are accepted by ‘the authorized expert or agency if they can withstand the test pressure for a sufficient period of time with no leaks or deformities. LABELING TUBES AND ACCESSORIES ARTICLE 16; FPR 1196 13:46 16185474013 PAGE.@10Tubes that have passed the test defined in Article 14, and the elbows made in the factory from tubes that have been passed by the authorized expert or agency according to the conditions defined in this article, shall bear one or more distinctive and indelible labels idestifying them in ‘compliance with the requirements of the accepted standard. The other accessories passed by the authorized expert or agency according to the conditions defined in the third paragraph of Article 15 also bear an indelible identifying label. EACTORY-TEST REPORTS ARTICLE 17; . ‘The carrier keeps on file the reports of the factory checks and tests described in Articles 11, 12, 13, 14, and 15, and the documents provided by the tube manufacturer confirming the quality and Properties of the steel as mentioned in Articles 5 and 7. A copy of the reports shall be given to the Minister for Hydrocarbons, CHAPTER Iv RULES .ON LAYING, DEVELOPING, AND MAINTAINING PIPELINES LAYING PIPE UNDERGROUND ARTICLE 18: The pipe is buried underground, except in certain special eases, particularly those mentioned in the last paragreph of point B and inthe first paragraph of point C, Article 25. tis nonmally ‘underground in the other sites of Zones I and II Every effort is made to seat the pipe perfectly at the bottom of the trench when itis being laid in the ground, and to ensure that, once itis laid, it will not be subject to abnormal strain, Covering height in Zone I, defined as the vertical distance from the surface of the ground to top of pipe, is at least 80 cm, Covering height in Zone II, defined as the vertical distance from the surface of the ground to top of pipe, is at least 80 cm if there are no local constraints, such as the practice of subsoiling, a thin arable layer, or the presence of a drainage system or absorption field. ‘When such constraints do exist, the covering height is set after consulting with the relevant government authorities, but no Jess than 40 cm and no more than 100 em, 10 FPR 1196 a3:45 ne18s474013 PAGE.O11BPR ‘When the lands crossed in Zone Il are cultivated intermittently, for example, depressions (sink holes) cultivated after rains, the pipe must be buried and the covering height is as indicated in the above paragraph. LAYING PIPE ABOVE GROUND ARTICLE 19; [In certain exceptional cases involving the public domain, and in particular in the cases described in the last paragraph of item B and the frst paragraph of item C, cle 25, in Zone I placements mecurtuences of any additional factors that might affect the pipe. In pariculs, he mae take into account stress due to temperature variations. The carricr must take al effective measures to account for vibrations emitted by pumping Stations inthe sections of pipelines located upstream and downstream of the stein cables, itis protected in order to avoid the wear and tear that may be caused by the operating conditions of these works or the results of operations. 1a particular, the minimum allowable distance between the closest generating lines of two neighboring works is as follows: 0.40 m for: + Nonmetal pipelines transporting noncombustible gases or liquids ¢ Telecommunications lines ¢ Metal pipelines transporting noncombustible gases ot liquids # Electric power cables 2.60 m for: i 4°96 13:47 seiesa7aa13 Pace. o12