KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

RTRP PIPES AND FITTINGS:

ENGINEERING DESIGN AND INSTALLATION

DOC. NO. KOC-MP-011: PART 2

STANDARDS TEAM 1

KUWAIT OIL COMPANY (K. S. C.)

DOC. NO. KOC-MP-0 7 7R, 2

STA NDAi RDS PUBLICA TION

Page 7 of 67

KOC RECOMMENDED PRACTEE

I REV. 7

FOR RTRP P/PES AND FITTfNGS:

ENGINEERING DES/GN AND

STANDARDS TEAM

KOC RECOMMENDED PRACTICE

FOR

R TRP PIPES AND F/TT/NGS:

ENGINEERING DESIGN AND

INSTAL LA TiON

(SUPERSEDES KOC-MP-021 Rcv.2)

ISSUING AUTHORITY:

STANDARDS TEAM

TABLE OF CONTENTS

FOREWORD

SCOPE

TERMINOLOGY 3. 7 Definitions 3.2 Abbreviations

REFERENCE STANDARDS, CODES AND SPECIFICA TIONS 4.7 C0nt.k ts 4.2 List of Standards and Codes

ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

R TRP PIPE: BASIC CHA RA C TER/S TICS 7. 7 General 7.2 Favorable Characteristics 7.3 Un fa vorab b Charasteris tics (Limitations}

DESIGN CONSIDERA TIONS 8.7 General 8.2 Design Considerations: Abo veground Piping 8.3 Design Co ndderations: Underground (Buried} Piping 8.4 Design Pressure 8.5 Design Temperature 8.6 Surge Pressure (Water Hammer) 8.7 Static Effects 8.8 Dynamic Effects 8.9 Vacuum Effects 8. 7 0 Chemical Compatibility

PIPE SIZING 9.7 General 9.2 Preliminary Pipe Sizing

PIPE AND FITTINGS JOINTS: REQUIREMENTS

Page No.

5

6

7

7 7 70

70 70 70

72

72

73 73 13 13

73 73 74 74 75 75 76 77 77 78 78

78 78 79

22

DOC. NU. KOC-MP-0 7 Iff.2 REV. 1

R TRP PIPING INSTALL A TION 7 7. i Aboveground Piping 7 7.2 Underground (Buried) Piping 7 7.3 RTRP Pipdine Crossing High way / Road

S TA TIC ELECTRICITY CHARGE ON RTRP PIPE

INSPECTION AND TESTING 73.7 Manufacturer's or Contractor's Responsibility 73.2 Inspection Requirements

H YDRO TES TING 74.7 Preparation for Test 7 4.2 Procedure for Hydrostatic Testing

TEST RECORDS

DISINFECTION OF POTABLE WA TER LINES AND MAINS

QUALITY ASSURANCE

DOCUMEIVTA TION 78.7 General 78.2 Deliverables 78.3 As-Built Records / Mechanical Dossier

APPENDIX- 7 - CHEMICAL RESISTANCE OF RTRP PIPE AND FITTINGS

APPENDIX-2 - SURGE PRESSURE: PREVENTION / CONTROL

A PPENDM-3 - S TA TIC ELECTRICITY CHARGE ON RTRP PIPE

APPENDIX--4 - TRENCH, PIPE LA YOUT AND TERMINOLOGY

A PPENDIX-5 - SAMPLE CA L CUL A TIONS

APPENDIX-6 - RTRP PIPES LAID IN A COMMON TRENCH, AND CROSSING EA CH 0 THER

APPENDIX- 7 - PLA CEMENT DETAILS OF THRUST / ANCHOR BLOCKS

ACKNOWLEDGEMENT

This document (Part 2) "KOC Recommended Practice for RTRP Pipes and Fittings: Engineering Design and lnstah tion " is intended to p r ov id e basic guidelines and minimum technical requirements for engineering design and installation of RTRP Pipe and Fittings to be used in KOC onshore facilities in Kuwait. The Part 1 document o f this RP covers the requirements o f RTRP (Epoxy, Polyester, and Vinyl ester resins) material for pipes and fittings.

This Recommended Practice (RP) has been approved by the Standards Team in consultation w i th the Standards Technical Committee (STC) for use throughout the corporate engineering and operational functions of Kuwait Oil Company, (K. S . C) . This RP sepersedes the KOC Standard for "Fik~g!ass (FRP) Pipe and Fittings" (KOC-MP-02 I), which has been withdrawn.

This RP sets out t o achieve the following objectives and benefits:

a) To recommend the basic technical specifications for Engineering Design and Installation o f RTRP Pipes and Fittings, that has applicability in KOC domestic and industrial facilities, and to help ensure a consistent and cost effective approach in i ts selection.

b) To cover the necessary aspects of engineering design, installation and construction o f piping systems so as to minimize the need for technical clarifications and disputes.

C) To provice technical guidance for engineering design of plastic piping system and development of project specifications.

Feedback, co.nments or suggestions, derived f rom the application o f this Recommended Practice at any stage of design, engineering, installation, operation and maintenance are encouraged, and be directed to:

The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P. 0. Box 9758, Ahmadi 61008 State o f Kuwait

Task Force Responsible for This Recommended Practice

The Standards Technical Committee (STC) entrusted the preparation o f this Recommendecl Practice to the Task Force No. TF-MP/O5, consisting of the following:

Mr. Mirza Mohsin Standards Team T. F. Leader/Author Tel. 61 371 Mr. Anwar Al-Sayer Utilities Team Member Tel. 66571 Mr. M . Shahid 0pns.Tech .Svcs. (E) Member Tel. 22326 Mr. Saleh Al-Harbi Safety Team Member Tel. 66296 Mr. Emad Al-Khaiyat Design Team Member Tel. 61 7 4 3

( DOC. NO. KOC-MP-0 1 1R.2 ( Page 6 o f 61 I REV. 7 7.0 -- SCOPE

1 . I This Recommended Practice (RP) specifies the minimum requirements for Engineering Design and Installation of RTRP Pipes and Fittings for onshore use in Kuwait Oil Company.

1.2 This RP specifies the basic guidelines for engineering design and installation of RTRP (Epoxy, Polyester, and Vinyl ester Resin) pipes and fittings for size 1 in. up to 66 in. nominal diameter intended for pressure piping for the foltowing:

a) Aboveground Piping System and / or

b) Underground (Buried) Piping System

for the transmission 1 distribution and / or disposal of:

i Potable Water (See vote-/) ii) Non-potable Water (See Note-2 o~rdNotc-3) iii) Plant Effluent Water (See~Vok-2) iv) Chemicals (Sce~ote-4) V) Liquid Hydrocarbons (Sour or Sweet) (&e,%'ote-j) vi) f mulsions (OilIWater) (See Note-5)

Bote-i : RTRPpipitig ifrterrdcdfcrr potubk water slrall be de.signcd us per A WWA C9SO. Notc-2: The water shall not contain chemicals to which RTRP k 1.011-r&btan&

(See Append&- I) vote-.?: Tlzis covers brackislr water, seawater, hard wa&r, alrd produced water as well, Note-4: Chemicals to which RTRP is resistrurt. (For guidance scc Appendk-l slruwirrg

clremical rcsbtarrce of RTRP pipe as per Fibergloss Pipe Harrdbolrk. Howeuer the Manufacturer shall co/rJlrm arrd/ur provide a detailed updated !is&

Note-5: Use of RTRP pbe for this service shall be subject to wrilterr approval by KOC and shall bc iw accordartcr willr the requirenrenls crflhis RP, ASME R31.3, AI'I ISLR, API ISHR, IS0 I4692 ulrd other relevarrt standards refcre~rced Irerein.

1.3 This RP is applicable for static operating pressure within 150 psig to 3500 psig, The KOC shall specify the pressure rating of the required RTRP pipes and fittings based upon the project requirements.

1.4 This RP covers RTRP pipes and fittings intended for continuous application at a temperature within -2gC (-20F) to + 11 O'C (230F). The operatingldesign temperature of the RTRP pipes and fittings shall depend upon the type of material (Epoxy, Polyester, or Vinyl ester) to be specified by KOC. SecCfause 1.6oftIrisRP.

1.5 This RP does not cover the transmissionldistribution of strong oxidizing agents, liquid hydrocarbons of aromatic type or of low molecular weight.

1.6 For "RTRP Pipe and Fittings: Materials", refer to KOC-MP-01 1 Part 1.

DOC. NO. ROC-MP-0 1 I&. 2 I Pag~ 7 of 6 1 I REV. 7 A PPLICA TION

The engineering design and installation of RTRP Pipes and Fittings should conform t o the requirements given in this Recommended Practice and other standards and codes referenced herein.

Any exception or deviation from this RP shall be brought t o the attention of KOC Controtling Team wi th merits and justifications for review 1 consideration and for necessary amendments by the Standards Team (if required).

Compliance wi th this RP does not of itself confer immunity from legal or statutory obligations.

TERMINOLOGY

Definitions --

For the purpose of this RP the following definitions shall apply:

Coupling

A sport heavy wall cylindrical f itt ing used t o join t w o pieces of same size pipe in a straight line. The coupling always has a female end that can 3e bell, threaded or a mechanical type for joining.

Elastic Modulus

The rate of change of strain (elongation) w i th the change in stress within the elastic limit of the RTRP pipe.

Embedment

The soil placed around the pipe that provides side support t o pipe.

Haunch Area

The area of embedment below the pipe and located between the bottom and the spring line of the pipe.

Hoop Stress

The tensile stress in the wall of RTRP pipe in the circumferential direction due t o internal pressure. The hoop stress could be calculated by using the I S 0 equation as given below:

S = P (D - t,) I 2 t,

Where: S = Hoop Stress, psi D = Average Reinforced Outside Diameter, in. P = Internal Pressure, psig tr = Minimum Reinforced Wall Thickness, in.

- - - - -

DOC. NO. KOC-MP-0 7 7R. 2 Page B of 67 -

REV. 7

Hydrostatic Design Basis (HDB)

The circumferential (Hoop) stress due to internal hydrostatic pressure in the pipe that wi l l fait the pipe when extrapolated t o 100,000 hours under continuously applied pressure as per ASTM D 2992 Procedure B.

Hydrostatic Design Pressure (HDP)

The estimated maximum internal hydrostatic pressure that can be applied continuously (ASTM D2992- Procedure 6) t o RTRP piping com.rronent w i th a high degree of certainty that failure o f the comgonent wil l not occur.

Hydrostatic Design Stress (HDS)

The estimated maximum tensile stress in the wall of the pipe in the hoop direction due t o internal hydrostatic pressure that can be applied continuously (ASTM D 2992-Procedure 6) w i th a high degree of certainty that failure of pipe will not occur. The HDS is established by multiplying the HDB by appropriate Service Design Factor.

Integral Joint

A joint configuration in which the female or male end connection forms an integral part of the pipe. A pipe length w i th integral joint wil l have one male end and one female end. Integral joints eliminate the need for couplings.

KOC Controlling Team

Any KOC Team authorized to initiate a request for procurement of material and/or equipment for KOC, or any KOC Team authorized t o manage/control/execute a LSTK project for KOC.

Long-Term Hydrostatic Pressure (LTHP)

The estimated internal pressure of the piping product that when applied statically will cause failure of the product after a specified number of hours as per ASTM D 2992 Procedure B.

Long-Term Hydrostatic Strength (LTHS)

The estimated tensile stress in the wall of the pipe in the hoop direction due to internal hydrostatic pressure that when applied statically will cause failure of the pipe after a specified number of hours as per ASTM D 2992 Procedure B.

Pressure Design Basis (PDB)

The internal pressure developed in the RTRP piping product in accordance wi th ASTM D 2992 Procedure B. When it is multiplied by the service design factor, the HDP is obtained.

Pressure Rating

The estimated maximum pressure that the medium in the pipe can exer: continuously wi th a high degree of certainty that failure of the pipe will not occur as per ASTM D2996.

Service Design Factor (SDF)

A number less than one that takes into consideration all the variables and degree of safety involved in a RTRP piping installation and is selected for the application on the basis of t w o general groups of concitions. The first group considers the manufacturing and testing varizbles (specifically, normal variations in material, manufacture, dimensions, good handling technique, and in evaluation procedure of this method). The second group considers the application or use (specifically, installation, environment, temperature hazard involved, life expectancy desired, and the degree of reliability selected) as per ASTM D2996.

(For the recommended values of Service Design Factor, refer t o Clause 8.1.3 of this RP).

Static Pressure Rating

The recommended constant pressure without significant changes at which RTRP pipe can operate continuously for long times without failure. The static pressure rating shall be in accordance with the requirements of ASTM D 2992 Procedure B.

The Surge Pressure is the pressure or shock wave generated in the pip i rg system as a result of sudden startingJstoppage of the liquid in the piping system. The surge pressure is sub-divided into the following t w o types:

DOC. NO. KOC-MP-0 7 1R. 2

a) Recurring Surne Pressure: Which occurs frequently and is inherent t o the operation o f the piping system such as sudden pump start- up or shutdown and sudden valve opening or closing.

Page 30 of 6 3

b) Occasional Surge Pressure: Which occurs as a result of power outage or system's component failure such as pump seize-up, valve-stem failure or pressure relief valve failure etc.

3.1 . I 7 Surge Pressure (Water Hammer)

Abbre via tions

AWWA HDB HDP HDS I S 0 KOC LTHP LTHS PC PR RTRP

American Water Works Association Hydrostatic Design Basis Hydrostatic Design Pressure Hydrostatic Design Stress International Organization for Standardization Kuwait Oil Company (K.S.C.) Long-Term Hydrostatic Pressure Long-Term Hydrostatic Strength Pressure Class Pressure Rating Glass-Fiber-Reinforced Thermosetting-Resin Pipe

REFERENCE STANDARDS, CODES AND SPECIFICA TIONS

In tl-e event of conflict between this RP and the standards and codes referenced herein, or other contractual or purchase requirements, the most stringent requirement shall apply. In case further clarifications are necessary, the subject shall be brought t o the attention of KOC Controiting Team for the resolution, review and J or amendments to be incorporated by the Standards Team (if required).

List of Standards and Codes

The latest edition of the following standards, codes and specifications shall apply:

4.2.1 Natimal / International Standards

DOC. NO. KOC-MP-O I I&. 2

API 15LR

Page 7 I of 61

API 15HR

API RPI 102

ASME I31 6.5

1 REV. 7

ASME 831.3

ASTM D257

ASTM D2996

ASTM D3839

ASTM D 4 l 6 l

ASTM F7 668

AWVVA C651

AWVVA C950

AWWA Manual M 45

Specification for Low Pressure Fiberglass Line Pipe and Fittings

Specification for High Pressure Fiberglass Line Pipe

Steel Pipelines Crossing Railroads and Highways

Pipe Flanges and Flanged Fittings NPS !4 Through NPS 2 4

Process Piping

Standard Test Methods for DC Resistance or Conductance of Insulating Material

Standard Terminology Relating to Plastics

Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for Fiberglass (Glass-Fiber- Reinforced Thermosetting-Resin) Pipe and Fittings

Standard Specification for Filament-Wound Fiberglass (Glass-Fiber-Reinforced Thermosetting- Resin Pipe)

Standard Guide for Underground Installation of Fiberglass (Glass-Fiber-Reinforced Thermosetting- Resin) Pipe

Standard Specification for Fiberglass (Glass-Fiber- Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastorneric Seats

Standard Terminology Relating to Plastic Piping Systems

Standard Guide for Construction Procedure for Buried Plastic Pipe

Standard for Disinfecting Water Mains

AWWA Standard for Fiberglass Pressure Pipe

Fiberglass Pipe Design

DOC. NO. KOC-MP-0 7 I P t . 2 Page 12 of 61 REV. 7

KOC Standards

KOC-G-002

KOC-G-007

KOC-L-002

Design and Construction of Glass-reinforced Plastics (GRP) Piping Systems for Individual Plants or Sites

Quality Management Systems - Requirements

Petroleum and Natural Gas Industries- Glass- Reinforced Plastics (GRP) Piping- Part 3: System Design

Petroleum and Natural Gas Industries- Glass- Reinforced Plastics (GRP) Piping- Part 4: Fabrication, Installation and Operation

KOC Standard for Hazardous Area Classification

KOC Standard for Basic Design Data

KOC Recommended Practice for the Protection of KOC Services: Clearance Requirements for Buried Pipelines & Piping, Cables, Underground Structures and Buildings

Additional / Supplementary References

Handbook Fiberglass Pipe Handbook

The environmental conditions in Kuwait are severe. Appropriate consideration should be given t o high levels o f solar radiation that occur during summer raising exposed metal black surface temperature t o o-ver 85OC (1 85OF).

Refer t o "KOC Standard for Basic Design Data" (KOC-G-007) that provides basic design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

The Contractor shall follow the necessary Material Safety Data Sheets and Health, Safety and Environment (HSE) Guidelines wi th a view to protect personnel and surrounding environment during any construction w0r.C.

The Contractor shall adhere to all relevant safety requirements of KOC Fire & Safety Regulations as well as KOC Health, Safety & Environment Management System (HSEMS) while performing the work within KOC premises.

RTRP PIPE: BASIC CHA RA CTERIS TICS

General

The RTRP pipe possesses several basic characteristics. Some of them are .'avorable and the others are unfavorable having limitations for the design, installation and operation of the piping systems.

These favorable and unfavorable characteristics, as given below should be considered in design to ensure an appropriate, safe and reliable RTRP piping system.

Favorable Characteristics

Unfavorable Characteristics (Limitations)

DOC. NO. KOC-MP-0 7 I P t . 2 Page 73 of 6 7

a) Operating Temperature limitations. b) Low strength as compared to carbon steel. C) Susceptibility to mechanical damage. d) Low modulus of elasticity. e) Fittings non-interchangeable from different manufacturers. f } Kinks due to excessive bending. g) Risk of permeationlattack by some fluids.

REV. 7

DESIGN CONSIDERA TIONS

The tensile strength, shear strength, modulus of elasticity, and other parameters determined by short-term tests methods shall not be used

Light weight. Ease of Installation. Low friction factor. Excellent toughness. Abrasion resistant. Low thermal and electrical conductivity. Non-conductor of electricity. Fungal, Bacterial and Rodent resistant. Not susceptible to galvanic or electrochemical corrosion Resistant to several acids, alkalis and corrosive fluids. Retains flexibility and ductility at low temperatures.

in the design of RTRP pressure piping systems that are intended for long-term static loading.

Appropriate Service Design Factor shall be applied for calculation / selection of the wall thickness (reinforced wall thickness) o f RTRP pipe andtor fitt ings.

The Service Design Factor for RTRP piping under static loading shall be between 0.50 to 0.60 and shall be recommended / determined and approved by KOC. Also see Clause 3.1 .I 5 of this RP.

Metallic valves and metallic flanges of appropriate type and size are permitted for use on RTRP piping. Such valves / flanges shall be directly supported to eliminate the stresses on RTRP piping. In case it is impractical, the RTRP pipe shall then be supported immediately adjacent t o the loads.

The Manufacturer shall carryout the surge analysis of the piping systzm and shall submit calculations and result to KOC for review and approval. Manufacturer shall ensure that the designed RTRP piping syst3m is capable to withstand the anticipated maximum surge pressure, Also see Clause 8.6 of this RP.

The Manufacturer shall carryout rigorous stress analysis of the RTRP piping system. Also see Clause I f .2.14 of this RP.

Desiqn Considerations: Aboveground Piwhy

The pipe support for the aboveground RTRP piping should be designed sucb that it shall be minimum 100 m m (4 in.) long or 1.5 times the diameter o f pipe being supported whichever is greater and embrace the pipe t o a minimum 120' circumferentially or as required by KOC.

The aboveground RTRP piping should be designed such that the pipe experience minimum stresses due t o thermal expansion.

Design Considerations: Underqround (Buried) Piping

The underground RTRP piping shall be designed so as to have a minLnum soil cover of 1.0 meter (3 .28 f t ) as measured from the natural ground level or final graded ground level t o the top of RTRP pipe or as required by KOC.

The underground (buried) RTRP piping system shall be designed t o withstand the maximum anticipated static loads due t o internal fluid pressure, soil load, weight o f pipe contents, adjacent heavy steel structure, heavy machine or heavy concrete building etc.

1 REV. 7 DOC. NO. KOC-MP-0 7 7Pt. 2 The underground RTRP pipeline shall not have any flanged joint. In case it is inevitable, a suitable pit (similar to a valve pit) t o facilitate maintenance shall be provided as illustrated in KOC-L-002.

Page 7t

All ive, dead and impact loads shall be considered when designing sleeve / casing for the RTRP pipe crossing under the highway / road. For design, size and installation procedure of sleeve / casing pipe refer t o API RP 1 1 0 2 and ASTM F1668. Also see Clause 11.3 of this RP.

A stainless steel strip (of suitable thickness and width) shall be wrapped spirally around the underground (buried) RTRP piping throughout in order t o facilitate detection of position or location when using metal detectors or as required by KOC. However care shall be taken that the metal strip does not interfere w i th the existing CP system (if any) in the proximity. The Manufacturer should also be consulted for appropriate advise.

For laying of RTRP pipe in the rocky terrain, refer to Clauses 1 1.2.1 0 (g), 11.2.10 (h} and 11.2.10 (i) of this RP.

For laying multiple RTRP pipes in a common trench, refer to Clause 11.2.12 (j), 11.2 .12 (k i), (k ii), (k iii) and 11.2.12 (I) of this RP.

Desiqn Pressure

The design pressure of each component in the RTRP piping system shall not be less than the pressure at the most severe condition o f coincident internal or external pressure at the expected temperature.

The most severe coincident pressure and temperature should be considered in determining the design conditions.

Occasional variations of pressure and/or temperature may occur in the piping system. Such variation should be given due consideration in sele:;ting design pressure and design temperature.

The RTRP piping shall be designed to have appropriate pressure relief system to protect the piping system from risk of collapse or damage.

The RTRP piping system if not protected by the pressure relief system shall be designed t o cover the highest pressure anticipated t o develop in the system.

Design Temperature

The design temperature of the RTRP piping system shall depend upon the type of RTRP pipe material (Epoxy, Polyester, or Vinyl ester)

specified/selected by KOC for the project, which in turn shall be governed by the KOC project requirements. (See CIrru?;e1.4)

The design temperature of each component in the RTRP piping system shal be considered as the temperature at which under the coincident pressure, the maximum design thickness or the component highest ratirg is established.

The design should take care of increase in the pressure due to the ther.mal expansion of the stagnant fluid within the piping system.

The RTRP piping system shall be designed based upon the maximum anticipated operating temperature.

Surqe Pressure (Water Hammer)

The RTRP piping system shall be designed to withstand maximum anticipated surge pressure arising as a result of rapid opening or closure of the valve or stopping or starting of a pump in an operating system. (See ~pperrdk-2 for detriils and Appendir-5for Sumple Calculations)

The maximum surge pressure (P,) shall be calculated as given below: Sourci.: A CVH'A 1l4urrual h445 mrd Fiberglass Pipe Nurrdbnok

ps = (a/g) x (SG / 2.3) x (Av), psig a = 12 / {(p/g) x [ I / K + d / E (t)l)"*, ft/sec Where : PS = Surge Pressure (above operating pressure), psig a = Surge Wave Velocity, ft/sec g = Gravitational Constant, 32.2 f t / s' SG = Specific Gravity of Fluid, dimensionless Av = Change in Flow Velocity, ft/sec p = Fluid Density, ibsl ft3 K = 8ulk ModuIus of Compressibility of Liquid, psi d = RTRP Pipe ID, in. E = Modulus of Elasticity of RTRP Pipe Wall, psi t = Pipe Reinforced Wall Thickness, in.

The pressure rating or pressure class of the RTRP pipe shall be equal to or greater than the cumulative maximum pressure in the RTRP piping systsm due to working pressure plus surge pressure divided by 1.4 as give7 below:

Where: PC = Pressure Rating / Class, psig PW = Maximum Working Pressure, psig P~ = Maximum Surge Pressure, psig

Static Effects

DOC. NO. KOC-MP-0 7 7Pt. 2

The RTRP piping shall be designed t o withstand all dead loads that include weight of piping and its components and the load of the soil cover, except when steel pipe as casinglsleeve is used.

Piping shall be designed t o cater for all the live loads such as weight of the fluid transported and weight of fluid used for testing.

b

P~ge 77 of 6 7

Piping shall be designed to withstand all effects, such as stress, strains and movements, that arise when thermal expansion and contraction of piping are restrained.

REV. 7

Dynamic Effects

The RTRP piping system shall be designed t o take into account all impact forces due t o internal or external conditions such as sudden change in f low rate, hydraulic shock, and solid slugging.

The effects of wind loading shall be taken into account for the RTRP piping system installed a t a height o f 9 m ( 3 0 ft .) or above from the ground level. (For Wind Data see clause 5.5 of KOC-G-007).

The piping shall be designed and constructed so as t o eliminate the excessive and harmful effects of vibration induced due t o fluid f low and wind effects etc.

The piping shall be designed, arranged and supported t o take care o f the reaction forces due to the discharge pressure o f the fluid.

The piping shall be designed to cater for the dynamic loads such as due t o heavy rotating equipment or heavy machinery situated in the vicinity, by using metal sleeve / casing or by other means as approved by K-OC.

The dynamic loads on RTRP piping may be eliminated or minimized by increasing the burial depth or by rerouting the piping or by providing a suitable metallic sleevelcasing or by other means as approved by KOC.

DOC. NO. KOC-MP-0 7 7Pt. 2 1 Page 18 of 6 7 REV. 7 Vacuum Effects

The piping system shall not be subjected to vacuum or external pressure unless it has been designed to withstand it. The piping system shall be designed to incorporate air-intake valve to break the anticipated vacuum liable to arise due to sudden change/drop in the piping elevation in the full flowing gravity line or otherwise.

The RTRP piping shall be used for the service of only those fluids to which it is generally resistant (compatible). The manufacturer should also be consulted for suitability of service.(see ~ ~ ~ e n d h - ~ )

The service temperature and level of concentration of the chemicals shall be carefully evaluated for compatibility before introducing into the RTR3 piping system. The manufacturer should also be consulted for suitz bility of the service. (SeeAppendk-I)

The RTRP piping system shall not be used to transport strong oxidizing agerts such as nitric acid, sulfuric acid, liquid chlorine and low molecular weight hydrocarbons as well as aromatic hydrocarbons such as benzene, toluene and xylene unless proven to be suitable by the Manufacturer and approved by KOC. (Also see Appendix-1)

The Manufacturer should be consulted to advise on the suitability of the RTRP pipe for the intended service.

Appropriate pipe sizing calculations should be carried out, based upon the project and operating requirements, to achieve a safe and reliable system with optimum performance. The following systematic procedure is recommended to achieve optimum RTRP pipe size:

a) Determine the pipe wall thickness to meet the project's pressure requirements.

b) If required, enhance the pipe thickness based on system's operating conditions such as pressure surges.

c) Evaluate the system's flow requirements to determine the appropriate pipe size.

-

DOC. NO. KOCMP-0 1 I P t . 2 I Page 19 of 6 1 I REV. 7 d) Verify the pipe's capability to perform or operate under intended

installation conditions.

e) Adjust the pipe wall thickness as required for external loads.

f) Assess the final pipe size and wall thickness to meet flow, pressure, and external load requirements.

Preliminarv P i ~ e Sizing

The pipe size calculations should be carried out in order to design a suitable and efficient RTRP piping system. The following equations may be used for pipe sizing and other design related calculations for the RTRP piping system. The Manufacturer may submit alternative design methods to KOC for review and approval. (See ~ppend ix - s fur satnpIc calcu:atio~rs)

Max mum Velocity for Water

Max-mum Velocity for Corrosive or Erosive Fluids

Where: v = fluid velocity, ftlsec p = fluid density, tbs/ft3

= 62.4 ibs I ft3for water.

Minimum RTRP Pipe Diameter for Water

Where: d = internal pipe diameter, in. Q = flow rate, gpm

SG = fluid specific gravity (water = I ) dimensionless

Minimum RTRP Pipe Diameter for Corrosive or Erosive Fluids

RTRP Pipe Diameter for Pressure Piping

RTR3 Pipe Diameter for Suction Piping

DOC. NO. KOC-MP-0 7 7Pt. 2

Aver-age Fluid Velocity and Flow Rate relation

REV. I

v = 0.409 {Q/& Where: v = fluid velocity, ftlsec

Q = flow rate, gpm d = internal pipe diameter, in.

J

Friction Loss Calculations

The equation given below should be used for friction loss calculation in liquid piping system with turbulent f{ow.

Where: h, = Friction loss, ft. C = Hazen-Williams roughness coef't = 150 for RTRP D = RTRP Pipe inside diameter (ID), in.

Simplified equation for Friction Loss Calculations

Where: d = internal pipe diameter, in. Q = flow rate, gpm C = Hazen-WiUiams roughness coefficient = 150

for RTRP

Pressure Drop and Head Loss Relationship

Where: Ap = Pressure Drop, psi H, = (h,/IOO)xL, ft. SG = Fluid Specific Gravity, dimensionless L = Line Length, ft.

Rey riolds Number Equation

This equation should be used to determine the Reynolds number and type of flow i.e. laminar or turbulent in the piping system as given be lo.^:

Re = D x v / p

Where: Re = Reynolds Number, dimensionless D = Pipe Inside Diameter, f t v = Fluid Velocity, ft/sec IJ - - Fluid's Kinematic Viscosity, ft2 /sec

DOC. NO. KOC-MP-0 f T B . 2 Page 21 of 6 7

The relationship between the flow type and the Reynolds number is as given below: The flow in the pipe is:

REV. 7

i) Laminar when Re 52100 ii) Transition when 2100

DOC. NO. KOC-MP-O I I P t . 2

TABLE I: FA CTOR "K" FOR RTRP FITTINGS

90Elbow, Standard --

--

45'Elbow, Standard

180' Return Bend Tee; Flow Straight Tee; Flow to Branch

Tee; Flow from Branch

Reducer; Single Size Reduction 8. I Reducer; Double Size Reduction I 3.3

Nore-.r: The Mam4acfrrrcr should dso be consulfcdjor ~ ( p d o ~ e d values of Jc~c~or "h"'

10.0 PIPE AND FITTIIVGS JOIN TS: REQUIREMEN TS

10.1 The RTRP piping shall be joined utilizing sound joining system that shall not permit leakage of the service fluid at the worst operating contlitions of pressure and temperature etc.

10.2 The RTRP piping may utilize any type of jointing method like threaded, mechanical key-lock, laminated, adhesive bonded, or flanged type joints. However the Manufacturer shall suggest the most appropriate joining method to KOC based upon the service and worst operating conditions at an early stage of the project for review and approval.

10.3 However in any case the joint shall not permit leakage of the service fluid under worst operating conditions. Moreover the KOC prefers to adopt the following sequence for joining the RTRP pipe and fittings. (Also See /Vole-2).

a) Threaded Joint; b Mechanical Key-Lock Joint; C) Laminated Joint; d) Adhesive Bonded Joint.

Notc-2: The Mwnrjachuer shall keep KOC abreast of any ndvancenrekrr, adopred by !he ~drrslty, irr rlre above joining rnerhod(s).

10.4 Threaded Joint:

The pipe and fittings shall be provided with malelfemale threaded ends and threads shall conform to standard threads as per API Spec 58.

The threaded joint(s) or end-connections shall meet the performance requirements of API 1 5LR andlor API I SHR.

Threads quality and finish etc. shall be as per the visual inspection limits outlined in APII 5LR, API15HR, IS01 4692-3 and 1 or the Manufacturer's specifications if approved by KOC.

The thread shall have full rounded thread root & crest as required by API Spec 5B. Flat thread roots and I or crests are not acceptable or as required by KOC.

When RTRP piping systems is intended for high pressure, the threaded joints shall conform to the requirements of API 15HR and, the piping shall be installed belowground (buried) or otherwise as required by KOC.

10.5 Mechanical Key-Lock Joint

a) The mechanical key-lock joint shall consist of a spigot end and a socket end with 0 or lip sealing ring and with a special hole to insert a locking strip.

b) The locking-key and rubber sealing rings used shall be of flexible material, suitable to the particular conditions of temperature, pressure, fluid service, and surrounding environment. The Manufacturer shall provide the specification and rating(s) o f the sealing material to KOC for review and approval.

10.6 Lam'nated Joint

a) RTRP pipes and fittings may be joined by laminations if required by KOC. However field joints of RTRP pipe by laminations should be as minimum as possible as there are possibilities of defects and imperfections.

b) Lamination of pipes for a pipe spool assembly prepared at a prefabrication shop or at Manufacturer's facility may be acceptable provided the Manufacturer ensures its leak free performance for the service and under worst operating conditions or as required by KOC.

C) The Manufacturer shall submit full details of the procedure for Laminated joint to KOC for review and approval.

DOC. NO. KOC-MP-0 1 IPt.2

d) Laminated joint(s) may be considered for field repair purposes, site modifications, tie-ins, and on-line attachments etc. Manufacturer should be consulted for providing appropriate advise and procedure to KOC for review and approval.

Page 24 of 6 1

e) The Manufacturer shall ensure that laminated joint used on RTRP piping shall not leak for the intended service and worst operating conditions.

I REV. 1

Adhesive Bonded Joint

The RTRP pipe(s) shall be of integral spigot and a socket (bell) end, or of spigot ends and a sleeve coupling when adhesive bonded joints are specified by KOC. Manufacturer shoutd also be consulted for appropriate advise.

Adhesive bonded joints on larger size RTRP pipe particularly on size 450 mm I18 in.) and over should not be used unless approved by KOC. Manufacturer should also be consulted for appropriate advise.

The adhesive bonded joints shall be constructed as per the Manufacturer's recommendations and such joints shall meet the performance requirements as per AP115 LR and 1 or AP115 HR.

The two component adhesive cement shall consist of resin and curing agent and shall be supplied in appropriate size containers to ensure correct ratio of resin-curing agent.

The Manufacturer shall provide complete instructions with the package which shall describe preparation of surfaces, mixing, jointing, safety, pot life and curing time. A t any time partial mixing of package contents shall not be allowed.

The adhesive cement shall be resistant to the fluid service or medium transported and shall be suitable for the worst operating temperature and pressures.

10.8 The unrestrained joints of RTRP piping shall be tested with a fixed-end- closure-condition and restrained-joints shall be tested with a free-end- closure condition.

The RTRP piping shall employ restrained type joining system so that the joints and piping can withstand both internal pressure (hoop stress) and longitudinal/tensile forces.

Adhesive bonded joints of RTRP piping shall be designed and constructed to withstand maximum separation forces anticipated to occur during worst operating conditions.

Flanged type joints in RTRP piping are acceptable wherever interfacing witt- metallic valve(s) and / or connection t o an equipment is required.

Fiberglass flanges used for joining RTRP piping shall be in accordance witt- ASME I31 6.5

The RTRP piping joints utilizing elastomeric rubber seal shall be in accordance with ASTM D4161 and shall meet the performance requirements as specified in ASTM D4161, API1 5LR, and API15HR.

For joining of the RTRP pipe only qualified joining procedure shall be employed.

Only experienced and qualified jointers shall be permitted for joining the RTRP piping system,

RTRP P/PIIVG /nrS TAL L A T/ON

A&veground Piping

The RTRP piping should not be installed aboveground unless appropriate precautions are taken to provide protection from excessive heat, mechanical damage, fire damage, and chemicals detrimental to RTRP.

The aboveground RTRP piping shall be provided with appropriate supports, anchors, and guides at suitable locations t o control or restrain the pipe movements due to thermal expansion / contraction or reac-:ions due t o operating conditions.

The aboveground RTRP piping shall be supported such that the maximum deflection at the mid span shall not exceed 6.35 mm (0.25 in.) at the design temperature and when the line is full of water or the service fluid whichever is of higher density or as required by KOC.

Metallic supports intended for the aboveground RTRP piping should be appr~priately coated or lined with non-metallic materials such as PTFE, Polyamide, Polyethylene or hard rubber so that the RTRP pipe is not damaged, scratched or eroded during thermal expansion/contraction.

The aboveground RTRP piping should not be used t o provide support to other nearby piping or components.

The small diameter aboveground RTRP pipe should be supported continuously in case the deflection at mid-span is higher than as specified in clause 11.1.3 of this RP or otherwise as required by KOC.

RTRP piping shall not be installed aboveground where the pipe wall temperature is anticipated to exceed the maximum temperature as specified i n Clause 8.5 of this RP.

RTRP piping shall not be directly connected to any vibration generating equipment or component t o avoid collapse of RTRP pipe due to fatigue. However in such situation install a steel pipe spool o f suitable length betvieen the pump and RTRP pipe to preclude / minimize the effects of anticipated vibration.

RTRP piping system terminating aboveground or outdoor shall be appropriately covered w i th shelter and / or encased in a suitable sleeve (Solid wall or corrugated plastidsteel pipe) such that i ts wall temperature does not exceed the maximum allowable limit. See Clause 8.5 3f this RP.

The piping passing through a concrete floor or masonry wall shall be protected by laying through a metallic pipe sleeve. In such situation the RTR3 pipe should be thoroughly wrapped and protected by a flexib\e long lasting and RTRP compatible material t o avoid the risk of abrasion resulting f rom the pipe movement due t o thermal expansion/contraction or other reasons.

Underground (Buried) Pi~ing

Trench Excavation

a) The Contractor shall adhere to the requirement of the KOC Fire & Safety Regulations chapter 1 8 "Excavations" besides meeting the requirements specified in this RP and the standards referenced herein while carrying-out trench excavation for underground piping,

b) For additional details of trench etc. refer t o Figure-1 t o Figure-3 of Appendix-4 o f this RP.

C) Proper attention shall be given when excavating the trench so that the sidewalls remain stable under all working conditions. If required and to avoid collapsing of the trench wall in the unstable soil, the trench walls shall be given a suitable slope to achieve the stability or as required by KOC.

The trench should not be left open for long time unnecessarily to avoid the risk of pedestrian safety and traffic disruption.

When the trench traverses a muddy or marshy terrain the sidewalls in addition to providing appropriate slope should be adequately and firmly supported by sheeting or shielding.

When supports such as trench sheeting, shoring or bracings are used, it should be ensured that the pipe support and the compacted soil around the pipe are maintained throughout the installation.

It should be ensured that the sheeting is sufficiently tight to prevent washing the soil out of the trench wall from behind the sheeting.

All sheeting used to preclude caving-in or sliding-in of the trench soil should be left in the place unless otherwise instructed by KOC or its authorized representative.

All sheeting left in-place shalt be cut-off at a height 0.5 meter or more above the top of the pipe.

The material of sheeting intended to remain in the trench should be such that it shall not corrode or degenerate.

All vertical and horizontal braces shall be left in place.

For addirional &toils on Trcnch Excavcrfion (Clause 11.2.1 of this RP), Beddirrg (C/ausel/.2.10 of rhis RP), and Embednrent Muterials (Clartse 11.2.1 lof rhir RP) refer r a ASTdVf 03539 ~d ASTM F1665.

The for:

width of the trench shall be sufficient to provide adequate room

Joining the RTRP pipe in the trench;

Laying of small-diameter RTRP pipe, from side-to-side along the bottom of the trench, when the effects of contraction/expansion are not otherwise accommodated;

Fiiling and compacting the haunch, side-fills, and embedment soil around the RTRP pipe in the trench.

The space between the pipe and trench wall must be wider than the corrpaction equipment used in the pipe zone to achieve the necessary corrpaction of haunching and embedment materials. (Also see Clause 11 -2.4 and Clause 11.2.1 2 of this RP)

DOC. NO. KOC-MP-0 I I P t . 2 Page 28 of 6 I 1 REV. 7 The trench width shall not be less than the pipe outside diameter plus 40C mm (1 6 in.) or the pipe outside diameter times 1.25, plus 300 mm (1 2 in.) whichever is greater as per the requirement of ASTM D3839.

When in the trench route area there is substantial ground water present, i t should be;

a) dewatered to attain and maintain the stability of native, in-situ or of imported backfill material;

b) maintain the water level below the pipe bedding by using appropriate sump pumps, well points, deep wells, geo-textiles etc. to remove and control the water in the trench;

C) curtail and control the water from flooding the trench before, during and after the pipe installation and until the embedment is complete!y installed and sufficient backfill has been placed in- place to prevent floatation of the RTRP pipe.

If the ground water accumulates in the trench because of high water table or other reasons, the water level shall be kept below the pipe invert level for safe and proper installation, by using deep well pumps or by other suitable means.

The pipeline at any point on its route shall not be given a sharp curvelbend that renders the pipeline to exceed the minimum recommended bend radius. The manufacturer should be consulted to provide the minimum recommended radius for RTRP piping.

When the RTRP pipe is warmer than the trench soil, a slightly longer pipe length should be used to compensate for the contraction of the pipe when it cools to ground temperature.

When ledge, rock, hardpan, cobbles, rubble, boulders, or stones larger than 38 mm (1.5 in.) are encountered in the trench bottom, excavate a minimum depth of 150 mm (6 in.) below the pipe bottom to get rid of Lnnecessary objects or as required by KOC. Also see Clause 11.2.10 (g) of this RP.

11.2.10 Bedding

a) For bedding and pipe details refer to Figure-I to Figure-3 of Appendix-4 of this RP.

b) For RTRP piping, the trench bedding shall be firm, stable and uniform to support the pipe over its entire length.

Blocks or slabs shall not be used to support the pipe or change its invert level or grade along the excavated trench bottom.

The trench bedding shall support the RTRP pipe entirely, evenly and f-rmly and it shall be free of ridges, hollows, and lumps.

The trench bedding should consist of free flowing material such as sand, or clay and should be free of stones, organic matter, and hard particles larger than 12 mm (0.5 in.).

Haunching shall be placed in uniform layers and firmly on both sides of pipe such that no voids or loose soil persist.

When rock or unyielding material is present in the trench bottom, tjie trench bottom shall be excavated (minimum) 150 mm (6 in.) deeper than designed, and a soil cushion (bedding) of minimum 150 mm (6 in.) thickness shall be laid below the bottom of the RTRP pipe to provide a firm, stable, and uniform bedding or as required by K.OC.

Eefore spreading the soil cushion on the rocky trench bottom, ensure that the trench bottom has no spiky or sharp projections. In such a case the sharp edges should be either cut or grinded or as required by KOC.

In such situations appropriate steps may be taken to protect the FTRP pipe from damage. The Manufacturer should also be consulted for necessary advise.

11.2.1 1 Embedment Materials

a) The RTRP pipe embedment material shall be adequately stable and sufficiently granular so that it is easily worked under the sides and bottom of the pipeline.

b) Embedment materials shall be free of refuse, degradable and organic materials. The particle size of the embedment materials in contact with the pipe shall not exceed 12 mm (0.5 in.) and the particle shalt not have sharp surfaces or edges.

c) The maximum particle size in the embedment zone of RTRP piping shalt be based on the pipe diameter and shall not be larger than as given in the Table-2 of this RP.

TABLE 2: MAXIMUM PEMISSIBLE PARTICLE SIZE FOR RTRP PIPE EMBEDMENT

DOC. NO. KOC-MP-0 7 3Pt . 2

Source: ASTM D 3839

r

Page 30 of 6 7 - I REV. I

1 1.2.1 2 Pipe Laying

For details refer to Figure-1 to Figure-3 of Appendix-4 of this RP.

The RTRP pipe shall be laid wi th moderate slack, to accommodate any anticipated contraction resulting from pipe cooling prior t o backfill.

The pipe shall be allowed to cool down to trench soil temperature before backfilling to help eliminate or reduce effects of contraction.

The pipe shall be allowed t o cool down t o temperature bearable t o hand before trimming when required to make rigid connections wi th equipment or pump t o avoid stresses in piping due to subsequent contraction.

The pipe shall not bend close to a fitting or valve. The minimum distance of bend from a fittings or valve shall be 10 times the nominal pipe diameter.

The RTRP piping shall be installed in such a way that shear or tensile stresses resulting from construction/installation, backfill, compaction or external loadings are either eliminated or minimized t o acceptable limits or as required by KOC.

Additional protection o f RTRP pipe shall be made when there is a risk o f pipe damage in cultivated / agricultural or similar areas due t o deep plowing.

DOC. NO. KOC-MP-0 9 I P t . 2 Page 3 1 of 6 3

Appropriate measures shall be taken to prevent ingress of dirt, debris, and foreign material(s) in the RTRP piping / pipeline. However i f any such material is suspected inside the line, that shall be completely removed before laying.

REV. 7

Sufficient clearance shall be maintained between RTRP pipe and other sources of heat to prevent the RTRP pipe skin temperature from exceeding the design limit specified in Clause 8.5 of this RP.

T w o or more RTRP pipes may be laid parallel t o each other in a common trench.

The minimum distance as given below shall be maintained, when t w o or more RTRP pipes are laid in a trench:

i) minimum distance shall be equal t o the average of the radii (outside) of the t w o adjacent pipes but shalt not be less than 1 0 0 m m (4 in); (See Figam-A of Appendh-6of r h k RP)

ii) the distance of extreme pipe f rom the trench wall shall not be less than as i f the pipe was installed as a single pipe in the trench as given in Clause 1 1.2.4 o f this RP;

iii) when mechanical compaction equipment is used, the minimum space between pipe and trench wall, or between t w o adjacent pipes shall not be less than the width o f the widest piece of compaction equipment used plus 1 5 0 m m (6 in.).

Compact the soil between and under the pipes (haunching) and between the pipe and the trench wall sufficiently and effectively t o achieve the required proctor density or as required by KOC.

The minimum distance between t w o RTRP pipeline crossing each other shall be equal to or greater than the average of the radii (outside) o f the t w o pipes but shall not be less than 1 5 0 m m (6 in .) . (See Figure-B of Appendir-6 of !his RP)

The Manufacturer should be consulted for appropriate advise for the minimum clearance required in the situations when the RTRP pipeline:

DOC. NO. KOC-IMP-0 ? 1fV. 2

i) is laid next to a steel pipeline (conveying hot product) in the same trench or crosses (over and under) a steel pipeline (conveying hot product);

ii) is in proximity of or crosses (over and under) an electric cable;

iii) crosses (over and under) an underground concrete slab, foundation and / or underground structure;

iv) when the above (i), (ii) and (iii) scenarios coexist.

11.2.1 3 Buoyancy Control of RTRP Piping

If Sabkha area(s) come across the RTRP pipeline route, the pipeline shall be restrained against float-out by using weight coating(s) or by anchor blocks or thrust blocks or by use of cohesive backfill or as required by KOC.

If the cohesive backfill is intended to be used to resist the floatation of pipeline, then the backfill soil properties like density, level of compaction and shear strength shall be determined by the Manufacturer to satisfy these requirements and the results shall be submitted to KOC for review and approval.

Calculations for alternative procedures intended for the buoyancy control shall be submitted by the Manufacturer to KOC for review and approval.

11.2.14 Flexibility Analysis and Requirements of Thrust / Anchor Blocks

a) The Manufacturer shall carryout calculations for flexibility / stress analysis of the RTRP piping and submit the results to KOC for review and approval well before the start of construction work showing locations and size of the thrust or anchor blocks required (if any) on the RTRP piping system.

b) The expansion in the RTRP piping system due to pressure and temperature shall be considered acceptable when the ends or the branch connections are not overstressed or the piping do not cause any soil disturbance. The Manufacturer shall provide the stress limits of the RTRP pipe for review and approval by KOC.

C) Thrust / Anchor blocks of appropriate size shall be provided if the restraint due to friction between soil and pipe is inadequate.

The Manufacturer shall provide permissible stress I expansion limits and other requirements to KOC for review and approval.

The stresses induced at the interface of RTRP pipework and thrustlanchor block shall be determined by the Manufacturer and submitted to KOC for review and approval. The location of all such thrustlanchor blocks shall be marked on the alignment sheetsldrawings.

The RTRP piping system that has gasket joints shall be appropriately restrained by thrust blocks in order to prevent the possible separation of the joints and to prevent the movement of the pipe.

The shape and dimensions of the thrust block shall be such that no point load is acting on the RTRP piping.

The anchor blocks shall be of appropriate size to hold back the upward thrust at the valve(s) or bends on the RTRP piping.

Anchor blocks shall be placed at appropriate intervals to support the weight of the uphill or ascending RTRP piping.

DOC. NO. KOC-MP-0 I 7Pt. 2 Page 33 of 6 I

Note- 7: For thrust block placement details, refer to Figure- l to Figure-8 of Appendix-7 of this RP,

Note-2: For anchor block placement details, refer to Figure-8 and Figure-9 of Appendix-7 of this RP.

1 1 . 2 . 1 5 Thrust 1 Anchor Blocks: Material of Construction

a) The Manufacturer shall submit details of material and construction of anchor and 1 or thrust blocks to KOC for review and approval.

b) The anchor and thrust blocks shall be of appropriate concrete having minimum 20 MPa (3000 psi) compressive strength and the slump test value shall be within 80-1 30 rnm (3-5 in.).

1 1 . 2 . 1 6 Superfluous or Extraneous Loads

The RTRP may be subjected to differential soil settlement when connected to a pump or vessel. The following precautions should be taken to minimize the excessive shear, bending and pullout forces;

a) appropriate care shall be taken during bedding and backfilling to provide firm and uniform support to the pipe.

b) a protective sleeve or shield shall be placed over the tapping I branch connection.

1 1.2.1 7 Trench Backfill

a) The initial backfill material should satisfy the requirements for embedment material as described in previous clauses. The initial backfill shall however cover the pipe by at least 100 mm (4 in.).

b) Ensure that the joints and fittings are clearly exposed until the hydrostatic pressure testing is complete and inspection is over.

c) The final backfill should consist of the native soil if suitable otherwise it shall be backfilled with borrowed material approved by KOC or its authorized representative. However, in any case the final backfill shall not include any hard stones, rocks or debris greater than 75 mm (3 in.).

d) Final backfill shall be placed and spread in uniform layers and compacted at least to 95% standard Proctor density or otherwise as required by KOC.

Washouts and Drainage

Whenever it is anticipated that soil erosion will occur due to surface water runoff, or due to underground water or wind, appropriate measures shall be taken to protect RTRP piping using drainage, barrier, wind breakers or other methods as recommended by the Manufacturer and approved by KOC.

RTRP Pipehe Crmsinq Hiqh wa y / Road

The RTRP pipeline crossing under the highway / road shall be protected by using a suitable sleeve / casing of steel t o avoid the risk of damage / colcapse of RTRP carrier pipe.

The sleeve / casing shall be suitable to carry a minimum design load of 53.4 kilonewtons (1 2000 pounds force) at a single axle as required by API 1102. Also see Clause 8.3.4 of this RP.

The sleeve / casings may be new or used line pipe, mill reject pipe, or other available steel tubular goods, including longitudinally split pipe.

The inside diameter of the sleeve / casing pipe should be sufficient enough to facilitate instaliation of the carrier pipe and to prevent transmission of external loads from the casing to the carrier pipe.

DOC. NO. KOCMP-01 IR.2 I Page 35 of 6 1 I REV. 7 - - - The sleeve / casing pipe should be at least two nominal pipe sizes larger than the carrier pipe.

The sleeve / casing should be free of internal obstructions, should be as straight as practicable, and should rest on a uniform and sound bedding for the entire length of the crossing.

The sleeve / casing pipe should extend a minimum of 0.6 meter (2 ft) beyond the toe of the slope or base grade, or 1.0 meter (3 f t) beyond the bottom of the drainage ditch, whichever is the greater as per API 1102.

The angle of intersection between pipeline crossings and the highwaylroad to be crossed, should be as near to 9 0 degrees as practicable. In no case it shall be less than 3 0 degrees.

RTRP Pipeline should not be designed, as far as possible, to cross the highwaydroad located in wet, watery or rocky terrain.

The minimum soil cover on the sleeve / casing pipe crossing under highwayslroad shall be as specified in API 1 1 02.

The sleeve / casing should be fitted with end seals at both ends to prevent / reduce the intrusion of water and fines from the surrounding soil. The seals should be of flexible material that will inhibit the formation of a waterway through the casing.

Installation of vent pipe(s) on the sleeve / casing pipe is not required unless otherwise required by KOC.

Appropriate care should be taken to avoid damage to RTRP carrier pipe when inserting / sliding into the sleeve / casing pipe.

Appropriate lubricants may be used to avoid rubbing / scratching of carr-er pipe when inserted into the sleeve / casing pipe. However care should be taken not to use those petroleum based lubricants which could damage the RTRP pipe or gaskets.

The bell of the RTRP pipe should not rest on the sleeve / casing pipe when the RTRP carrier piping comprise bell type joints. The Ma~ufacturer should be consulted for appropriate advise.

Care should be taken to avoid damage to the RTRP carrier pipe or joints when pushing or sliding into the metallic sleeve 1 casing. In such situations avoid exceeding the maximum push/pull force as recommended by the Manufacturer.

11.3.17 In order to avoid differential settlement of the soil at the ends of the sleeve / casing pipe, refer to the requirements of ASTM F1668 for the type of soil and level of compaction of embedment as well as consult the Manufacturer for advise.

1 1.3.1 8 To prevent the movement of RTRP carrier pipe within the sleeve / casing refer to ASTM F1668 or as required by KOC. The Manufacturer should also be consulted for appropriate advise.

S TA TIC ELECTRICITY CHARGE ON RTRP PIPE

-

Proper and adequate consideration shaU be given to the RTRP piping as it has great affinity to develop and retain the static charge on the s u rf a c e . (See Appemih-3)

REV. 7

The RTRP pipe intended to be installed in the hazardous area shall not have the affinity to develop the static charge. For Hazardous Area Classification see KOC-G-002.

The Manufacturer should be consulted to advise on static-charge-free RTRP pipe when intended to be installed in hazardous area.

The RTRP pipe shall be tested for the level of resistivity / conductivity in accordance with the requirements of ASTM D257 when intended for use in hazardous area.

IN_PECT/ON AND TESTING

Manufacturer's or Con tractor's Responsibitity

The Manufacturer or Contractor shall be responsible to carryout the inspection and testing of the ongoing work in a professional manner and shall also be fully responsible for:

a) providing appropriate quality materials, components and executing quality workmanship in accordance with the requirements of this RP and other standards / codes referenced herein such that it is completely acceptable to KOC;

b) preparing appropriate records of all inspection, examination / testing for KOC review, approvat / acceptance and record;

c) the hydrostatic testing of the RTRP piping systems as per Clause 14.0 of this RP.

- -

DOC. NO. KOC-MP-0 1 IR. 2 ( Page 37 of 6 1 REV. 7 Inspec tion Requirements

General

Prior to hydrostatic testing and / or commissioning and / or initial operation, all RTRP piping installations including all components and their workmanship shall be inspected and examined in accordance with the requirements of APII SLR, API1 SHR, this RP and the RTRP pipe and fittings Manufacturer's acceptance criteria approved by KOC. (The criteria shall be provided in advance by the Manufacturer to KOC for review and approval).

Inspection and Test Plan (ITP)

The Manufacturer shall list down in ITP all verifications, inspection and testing activities in sequence for the RTRP piping systems installation, construction and testing.

Pre-inspection Meeting (PIM)

The Manufacturer I Contractor shall organize PIM wi th KOC (After approval of time and date by KOC) before commencing the work on RTRP piping instaliation, construction and testing. During the PIM, the Manufacturer / Contractor and KOC shall review and finalize the mark- up crf the ITP, and confirm the requirements for witnessing (W), surveillance (S), monitoring (M), reviewing (R), of the ITP. Thereafter the approved quality plan shall be strictly adhered to by the Manufacturer I Contractor throughout the installation, construction, and inspection and testing of the RTRP piping system.

KOC however reserve the right of independent inspection of the material and workmanship at all times, to ensure conformance by the Manufacturer / Contractor to the KOC approved construction drawings/specification, requirements of this RP, as well as other standardslcodes referenced herein.

The hydrostatic pressure testing should be conducted to discover and subsequently fix the leak(s) or fault(s) in a newly constructed or modified RTRP pressure piping system(s) before commissioning the system for regular service. The hydrostatic leak test of the RTRP piping systam shall be conducted in accordance with the requirements of this RP.

DOC. NO. KOC-MP-0 7 7Pt.2 I Page 38 of 6 7 I REV, 7 11 -

Premrathn for Test Expose all Joints

All :oints, including bell & spigot, tapered, threaded, flanged and bonded shall be left exposed for inspection and examination during leak testing except those joints that have been previously tested.

Terrporary Supports

Pipirg system designed for vapor shall be provided additional temporary supports, if necessary, to support the weight of the test liquid.

Test Limits

Equipment as well as those piping sections that are not to be tested shal be either disconnected from the test piping or isolated by blinds or other means before the test starts. A valve may also be used for such purpose.

Cleaning the System

a) The piping system should be thoroughly cleaned and flushed to get-rid-of the dirt and debris to avoid damaging of valves, regulators and other such things.

b) The piping system to be tested shall be fitted with vents (at or near the highest) and drains (at or near the lowest) points respectively to help purge out air and drain the water.

Test Temperature

a) RTRP pipes are generally rated at 23OC (73.4OF). It is recommended that the test temperature be or close to this temperature.

b) The test-water temperature intended for the hydrostatic testing should not be below 5'C (41 '~) and above 35'C (95OF).

c) The Manufacturer shall be consulted in case the ambient or the water temperature is below 5 ' ~ (4I0F) or above 35OC (95 '~) .

d) Accurately calibrated temperature and pressure recorders and indicators shall be installed along the pipeline to be tested for manita ring and recording of the test-temperature and pressure.

DOC. NO. KOC-MP-0 7 I P t . 2 1 Page 39 of 6 7 REV. 7 e) Test Charts (as recorded during hydrostatic testing) shall be

provided to KOC for review, approval & record purposes and to ensure that the test was conducted within limits of the specified temperature, pressure and other requirements.

Test Pressure

The test pressure of the piping system shall be in accordance with the req~irements of Clause 14.2 of this RP.

When the piping system is tested at a pressure higher than the components(s) of lower pressure ratings, the component(s) or device(s) of lower pressure ratings shall be isolated or disconnected or removed from the piping system to avoid damage.

When lower pressure-rated components or devices cannot be removed or isolated from the test section, the maximum test pressure shall not exceed the pressure rating of the lowest pressure-rated component such as fittings of other plastic material or pressure relief devices etc. in the test section.

Do not resort to apply higher test pressure even if some components in the test section carry comparatively higher pressure-ratings.

Visible Leakage

When the test liquid is seen escaping i.e. dripping, spraying, streaming, flowing and so forth from the pipe, components, joints, connections, appurtenances and similar item of the test section, it shall be considered as "Visible Leakage".

Leakage Allowance

No leakage allowance shall be permitted for the RTRP piping.

Equipment required for Hydrostatic Testing

The following equipment such as caps, valves, blind flanges, manual or automatic air-release devices, pumps, pressure regulating devices, temperature and pressure recorders and indicators, as a minimum, should be available at site before the start of hydrostatic test.

a) Safety valve (s) with appropriate setting shall be installed on the piping system to avoid overpressure and pipe damage.

DOC. NO. KOC-MP-0 1 3Pr. 2 Page 40 of 6 1 I .- REV. I The end-closure(s) and other equipment(s1 intended for the test- section shall have equal or higher pressure-ratings than the test- pressure.

All air-release devices should be located at (or nearest to) the highest points along the test section.

Deteriorated or worn-out equipment(s) shall not be used for the hydrostatic testing.

Temperature and pressure recorders and indicators shoutd be installed on the initial, the middle and the fast portion of the test- section for continuous recording, controlling and monitoring.

Al l recorders and indicators should be calibrated t o a minimum accuracy of 22% of the full-scale. The recommended full-scale value of the indicators should not be more than twice of the test pressure.

14.1 .I 0 Precautions Before and During Hydrostatic Testing

Pressure testing may be hazardous and therefore it is extremely important t o adhere t o all necessary safety precautions at all t imes during the hydrotesting. All unconcerned personnel intending to observe or come close t o the piping system during testing shall be prohibited.

A formal risk assessment should be carried out prior to hydrostatic test. All supports, guides and anchors shall be i n place before the start of hydrostatic test.

Piping containing check valve(s) shall have the source of test pressure marked on downstream side.

All adhesive-bonded and laminated joints shall be fully cured prior to pressure testing.

Threaded connections and the bolts of flanged joints shall be tight t o the correct torque prior to testing.

Procedure for Hvdrostatic Testing!

1 The hydrostatic testing of RTRP piping system shall be carried out in accordance w i t h IS0 14692-4, BS 71 59 and this RP.

14.2.2 The Manufacturer / Contractor shall submit complete hydrostatic testing procedure i n advance t o KOC for review and approval.

The test liquid shall be water unless there is a possibility of adverse effects of water on subsequent service. In that case another suitable non-toxic liquid may be used.

The pipe-section intended for testing shall be slowly filled-in with water. Make sure that all air from the pipe section has been purged out through the vents as the water is filled in.

When filling the line with test water, two (2) soft foam pigs, one ahead of water and the other in the water shall be run in order to totally purge-out air from the test section.

The water filling velocity shall not exceed the capacity of the air- release devices to help discharge the entrapped air completely from the piping system.

The water filling velocity shall not exceed the design velocity of the piping system in order to prevent 1 minimize the generation of pressure surge(s).

The test-section, when completely filled with the test-water, shall be allowed to remain filled for a minimum six (6) and maximum twenty four (24) hours (depending on the test-section size) so as to reach to a common and homogeneous temperature.

After the system has attained uniform temperature, a strength-test shall be carried out at a pressure equal to '1.5 times the design pressure.

The system shall be upheld at the above test pressure (1.5 times the design pressure) for a minimum period of thirty (30) minutes or as required by KOC.

The rate of pressurization of the system shall not exceed 2 bar (29 psi) per minute.

The piping system should be checked thoroughly for any visible leakage during the strength-test.

Note: IJtest-pres.~tn.e cannot be omciitled, or Fit tokes on ~ilo-eo.wnab1 long time to reach the tist-pressure, tlrere m q be some fault(s) such as e,ucessive leokuge, entruppd uir, q e r r vnlve, or imdequacy of pressuring eqrriprnent. IJsuch fuult(i) exist, discontinue /he pressurizing and red r f i the faulf be fore continuing the fesf.

If the strength test is successful, the system should then be approved for a full hydrostatic leak detection test.

I -- 1 DOC. NO. KOC-MP-OI 1PI.Z [ Page 42 af 6 7 REV. I 14.2.14 The full hydrostatic test shall be carried out at a pressure equal to 1.33

times the design pressure.

14.2.1 5 The hydrostatic pressure shall be maintained for a period of minimum eight (8) hours during which no water shall be added to or removed from the piping system or as required by KOC.

14.2.16 During the test, the line pressure shall be recorded at every 30 minutes.

14.2.1 7 When the system shows a pressure drop, a step-test should be performed as follows:

a) The system shall be re-pressurized to 1.33 times design pressure and after each hour pressure should be recorded. This should continue for minimum 8 hours;

b) The quantity of water required to bring the system back to test- pressure should be recorded; '

C) If the quantity of water added each hour shows a decreasing trend, then the system should be considered as tight;

d) If the quantity of water added remains same or more in the subsequent hours, the system is not tight and should be checked for leakage after depressurization.

14.2.18 Pass (Acceptance) 1 Fail Criteria

a) If no visible leakage is observed in the test-section, or if the water added each hour shows a decreasing trend until no more water is required to be added, the test indicates as "Passed.

b} If the test-section fails then the fault should be located and subsequently the system should be depressurized for necessary repair or fixing.

C) After the necessary repair or fixing is done, the system shall be tested once again.

14.2.1 9 All temporary closures, gauges and supports etc used on the piping system for hydrostatic testing shall be removed when the test is over.

75.0 TEST RECORDS

The Contractor shall appropriately compile and submit to KOC for review and approval the "Test Records" covering all necessary

DOC. NO. KOC-MP-0 1 IPt. 2 I -

Page 43 of 6 3 REV. 7

infor-mation of the hydrostatic testing from beginning up to the completion of the test. The information may inciude but shall not be limited to the following:

Details of test liquid. Backflow prevention devices, if used. Weather conditions and ambient temperature at site during test. The test pressure. Type of gauges & recorders used in the test-section. Location of gauges & recorders in the test-section. Calibration record of gauges & recorders used. Record of test-pressure and temperature recorded during the test. Any adjustment made to the test-pressure. The duration of the test. Description of test section's length, elevations, and location. Description of test-section components. Description of any visible leak(s) or failure and the corrective actions taken. Name of the Contractor or Party conducting the test. The date and time when the test was conducted. Any other information deemed necessary.

D/SlNFECTION OF POTABLE WA TER LINES AND M A I M

The RTRP piping system and mains intended for potable water service shall have to be disinfected for bacteria and other organisms before commissioning.

The disinfection of piping and mains shall be done as per AWWA C 657.

The disinfecting solution, containing Chlorine, shall be applied to restore the free chlorine in the water to not less than 100 mg/L in compliance with AWWA C651.

The Chlorinated disinfection solution shall not be left for extended period in the RTRP piping system. The time period allowed for such solutions to reside in the RTRP piping is maximum 3 hours.

The solution shall be premixed with water before injection into the piping system.

At the end of the disinfection period, all lines shall be thoroughly flushed with clean water.

QUALITY ASSURANCE --

The Contractor shall operate a Quality Management System based on I S 0 9001 t o satisfy the requirements o f this RP. The Contractor shall demmstrate compliance by providing copy of the certificate from accredited bodies or i ts quality manual. Verification o f the Contractor's quality system is normally part o f the pre-qualification procedure and is therefore not detailed in the core text of this RP.

DOCUMENTA TION

General

All correspondence, instructions, data sheets, drawings, or any other writ ten information shall be in English language. In case of dual languages, one language shall be English.

Alf dimensions, units of measurement, physical constants etc. shall be in Si units unless otherwise specified. (Nominal bore pipe sizes t o be generally mentioned in inches).

All documents (text, data sheets, specifications etc.) shall be provided wi th electronic files in the approved and widely used software (MS Word, Excel, Auto Cad etc.) All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC.

Work Execution Plan. Pipe Route Survey Report. Pipe Route Map and Area Drawings. Alignment Drawings. Piping Layout, System Design and Calculations. System Hydraulic Calculations. Piping Stress Analysis. Surge Analysis. Supports Design and Details. ValvelFlanged Connection and Pit Drawings. Procedure t o Eliminate Accumulation of Static Charge on Pipe. Excavation Procedure. Trenching Methods and Details. Trench Dimensions: Drawings and Details. Trench Bedding: Preparation Procedure and Dimensions. Installation Procedures. Inspection and Test Procedures. Pipe Joining Procedure Specifications.

Pipe Joining Procedure Qualification. Qualified Joining Procedure. Qualified Pipe Jointers. Pipe Joints Record. Repair and Maintenance Procedures. Isometric Drawings of Tie-ins. Hydrostatic testing Procedure. Hydrostatic testing Test Records. Pre-Commissioning and Commissioning Procedure. Any other document required by KOC.

DOC. NO. KOC-MP-077Pt.2

78.3 As-Built Records / MechenicaI Dossier

I - - I Page 45 of 6 1 REV. 7 1

Individual dossier shall be compiled for each complete piping system. The minimum contents of the dossier shall be as follows:

Master and Volume Index. Certificates of Conformity applicable to installation /construction standard or practice together with the "as-built" data sheets. Concessions. Cross reference to vendor or sub-vendor certification dossiers containing certification of specification and properties of material (resin), pipe and fittings or any other item used in the system. Hydrostatic and leak test reports. Pre-erection pipe trench and bedding survey record. Settlement records. All design calculations. All documents/reports specified in this RP. Any other document or information required by KOC.

-- --- - 1 --- C - Les% Kc% stant than R, but still suitable for some conditions. (( 'n~nwlr Mnrli.lf;crrrr,t r) 1 --- - - ---- - ---- I( Y - Gcl~croll Writ Re\rit,ant. {c r w \ r r i r .\kmu,rhLr;wc.l

t I DESC [ i l l'TlON E POXY ; VINYLESTER POLYESTER

DOC. NO. KOC-MP-0 7 1Pt. 2 Page 47 of 61 -

SURGE PRESSURE: PREVENTION / CONTROL

Since the RTRP pipe is lightweight and also has relatively low bending modulus and modulus of elasticity, therefore the piping system would experience excessive and perilous movement whenever the surge pressure developed ir the system is of high intensity.

One of the best methods to avoid occurrence of such severe water hammers is to eliminate the cause of emanating of the water hammer i.e. quick closing of valves or sudden pump start-up. If this is not possible then the magnitude of the pressure peak should be curtailed by using accumulators and / or similar devices in the RTRP piping system.

In the RTRP pipe system, as with other piping materials, the peak pressure (due to surge) should not exceed the pressure rating of the piping system. Even after -:aking the suggested precautionary measures if the piping still undergoes excessive movements due to pressure surges, the piping should be appropriately and securely anchored at suitable points.

The calculatsd maximum surge pressure in the RTRP piping shall be added to the maximurn working or operating pressure to select appropriate pipe class.

STA T/C EL EC TR/C/TY CHARGE ON RTW P/PE

CA UTIONA R Z.' NOTE:

The static eiectricity charge is a Safety Hazard, particularly in hazardous areas where there is leaking gas or explosive atmosphere. RTRP pipe is a non- conductor of electricity and therefore the static electric charge developed on it remains in piace until some grounding device comes close enough to allow it to discharge. The ground wire installed on the pipe will only discharge static charge of thz small area. The most effective method to minimize the hazard of static electricity is to apply a film of water with 5% soap solution on the pipe surface to drain away the static charge. Also the pipe Manufacturer should be consulted fo i such requirement.

A PPENDIX-9

TRENCH, PIPE LA YOUT AND TERMNOLOG Y

DOC. NO. KOC-MP-0 I IPI. 2

150 TO 300 mrn (6 TO 12 in.)

PIPE ZONE

-

Page 49 of 6 7

100 TO 150 rnm (4 TO 6 in.)

REV. I

FOUNDATION (MAY NOT BE REQUlR

iVufc: The tremh wa1l.r rnny be sloped ouhvards us shown when approved by KUC'. The slope angle and slope deprh may vary as per the soil condifions.

FIGURE I: TRENCH CROSS SECTION SHOWING RTRP PIPE TERMINOLOGY (Source: ASTM 03839 and ASTM F 7668)

TRENCH, PIPE LA YOUT AND TERMINOLOGY

TRENCH WALL - / ( M A T E SOIL)

L SLOPED WILL (AS REQUIRED)

LTRENCH ~OTTOM (NATIVE SOIL) OR FOUNDATtON (AS REQUIRED)

FIGURE 2: ISOMETRIC VIEW OF FIGURE 7 APPENDIX-4sHQ WING UNDERGROWN& INSTALLA TION OF RTRP PIPE AND TERMINOLOGY

DOC. NO. KOC-MP-0 I 7Pt. 2 Page 5 7 of 6 7 I REV. I

APPENDIX-4 (Conrinuedj

TRENCH, PIPE LA YOUT AND TERMINOL OG Y

TOP OF PlPE 1

CROWN OF

SPRINGLINE

INVERT OF

PlPE

PlPE

RTRP PIPE TERM/NOL OG Y (Source: AS TM F 7 668)

I DOC. NO. KOC-MP-0 7 7Pt. 2 I Page 52 of 6 1 REV. 1

A PPEAfD/ X-5

SAMPLE CA L CULA T/ONS

A: Cuiculufion o f Pressure Drop ilr fire RTRP gipirrp system

Example: Determine the pressure drop in a 3500 f t long RTRP pipeline of inside diameter 12 inches. The line is supplying 2500 gpm of potable water (specific gravity 1.0).

,Yoiutio?z: (Source: AWWA Manual M45: Using US Customary Units)

Calculate the friction loss: Clause 9.2.1 (i)

= f42.7 x Q/(C) 63) 1.852

= [(42.7) x (2500) / (1 50) x (1 22")11~E52

= 1.062 f t / 100ft

Total head loss H, = (h, / 100) x Total pipe length

= (1 .O62/lOO) x (3500)

= 37.17 f t

Pressure drop Ap due to head loss: Clause 9.2. l; (j)

Ap = (H,) x (S.G) / 2.31

= (37.17) x (1 -0) / 2.31

Total pressure drop A p = 7 6.09 psi

A PPENDIX-5

SAMPLE CALCULA TIONS (Continued .... I

B: Cufcrrfrrinn of Diameter, Head Loss atrd Pressure Drop itr the RTRP pipinp .svstemn.

E Determine the diameter, head loss, and the pressure drop in a RTRP piping system transporting 1 100gpm of brackish water of specific gravit-4 1 .I 6 and kinematic viscosity = 0.00001 8 ft2/sec at temperature 95OF (35'C). Total length of pipeline is 4920 ft. with 1 0 standard 90' elbows, 6 standard 45' elbows, and one ( 1 ) 180' return bend. The pipelir~e is of uniform diameter throughout but undergoes 15.6 f t . change in elevation.

Data: Service Fluid Flow (Q) - - Specific Gravity (SG) - - Kinematic Viscosity (y) = Pipelir,e length (L) - - Standard Elbows 90' - - Standard Elbows 45' - - Return Bend 180' - - Differential efevation (A Z) =

Brackish water I 100 gpm 1.16 0.00001 8 ft2/sec at 95'F (35OC) 4920 f t 10 6 1 15.60 ft.

Soirrtu)~: (Source: AWWA Manual M 45-and Fiberglass Pbe Handbook: Using US Customary Units)

Service Fluid Density:

p = SG x 62.4 lbs/ft3

= 1 .16x62 .4 = 72.4 lbs/ft3

hlinimum pipe diameter: Clause 9.2.1 (c)

d = 0.73[(Q) 1 (sG)] ' .~ I

d = 5.47 in. therefore use:

Pipe Size 8 in. (ID=7.70 in. , OD=8.625 in.) See API 15LR

REV. 7 -

total - - H, + Hu (Note: H, = Az, see Data)

I-t total - - 95.97 + 15.60 = 11 1.57 ft.

A PPENDiXL5

SAMPLE CAL CUL A TWNS --

(Con linued.. . . J

Average Fluid Velocity: Clause 9.2.1 (g):

v = 0.409 (Q I d2)

v = 7.58 f t /sec

Reynolds number: Clause 9.2.1 (k)

Fie = D x v / p

= 0.642 x 7.58 / 0.000018

F., = 270353 (flow is turbulent) Friction Factor for turbulent flow: Clause 9.2.1 (1)

f, = [1 .8 l0g(%/7)] -~

f, = 0.014 (dimensionless)

Tota: head loss in Elbows (90" and 45") and Return bend: t K = 8.1 (Table-1)

Head Loss due to friction Clause 9.2.1 (1)

I-, = [f x L x (v)" 2 x (ID) x gl

Cumulative head loss after adding I K and rearranging the terms:

t = [I K + (f,) x (LIID)] x [v" 2gl H, = 95.97 ft.

Total Head Loss

Exunrrde: Determine the maximum surge pressure (water hammer) generated in the above given "8: Examp/er' due to sudden closure of the valve resulting in full instantaneous change in velocity of water equal to the flow velocity. Also check, the adequacy of the pressure rating or pressure class of the RTRP piping for the surge pressure computed. The RTRP pipe is of pressure rating or class 300 psi, pipe modulus of elasticity 3,000,000 psi, operating pressure 140 psi, and the bulk modulus of compressibility of water 300,000 psi.

DOC. NO. KOC-MP-0 7 7Pt. 2 Page 55 of 6 7

Data: Pipe ID (d) - - Pipe OD - - Pipe Wa!l Thickness (t) - - Pipe Modulus of Elasticity (E) - - Pipe P-essure Rating / Class (PC) = OperatinglWorking Pressure (Pw) = Bulk Mod. of Comp. of Water (K) = Brackish Water Density (p) - - Water Specific Gravity (SG) - - Fluid Average Velocity (v) - -

REV. I

7.7 in. 8.625 in. 0.463 in. 3,000,000 psi 300 psi 140 psig 300,000 psi 72.4 Ibs/ft3 1.16 7.58 ftlsec

1

-

SAMPLE CAL CULA T/ONS [Continued.. . . I

Pressure drop in the system due to head toss: Clause 9.2. I 0)

Ap = 56.02 psi

Result Summary;

Pipe Inside Diameter = 7.7 in. Total Head Loss = 11 1.57 ft. Total Pressure Drop = 56.02 psi

DOC. NO. KOC-MP-0 ? 7Pf. 2 Pzrge 56 of 6 7 1 REV. 7

SAMPLE CAL CULA TIONS (Continued.. . . I

Solution: -- (Source: AWWA Manual M45: Usinq US Customarv Units)

Surge Wave Velocity as per Clause 8.6.1

a = 1 2 / { ( p / g ) x ( I / K + d / E ~ t ) ) " ~ , f t / s e c

= 12 / ((72.4132.2) x (1 /3OOOOO + 7.7 / 3000000~0.463))""

a = 2686.9 ft/sec

Magnitude of surge pressure P, due to surge wave as per Clause 8.6.1

P, = (a/g) x (SG / 2.3) x (Av), psig

= (2686,9132.2) x (1 .I 6 / 2.3) x (7.58)

P, = 277.48psig

Check the adequacy of pressure ratings or pressure class (PC) of the RTRP pipe as per Clause 8.6.1

P~ 5 (Pi.,+ PSI / 1.4

300 2 (1 4 0 + 27 1.48) / 1.4

300 > 293.91 psig (Hence Pressure Rating or Pressure Class of the RTRP pipe is OK.)

Result: Design is satisfactory

DOC. NO. KOC-MP-0 7 7Pt. 2 Page 57 of 6 7 I REV. 7 APPENDIX*

RTRP PIPES LAID fN A COMMON TRENCH, AND CROSSfNG EACH OTHER

(IF REQUIRED) \ f R y , : -:. , . I.?;..; y ';;;,/;;+ ?~!-:cJ*y.;:.?'.-*~.~-i ;:.,,

11 DOC. NO. KOC-MP-0 1 1Pr. 2 [ Page 58 of 6 1 REV. 7 I A PPENDIX-2

PLACEMENT DETAILS OF THRUST/ ANCHOR BLOCKS

DESCRIPTION

TEE CROSS USED AS TEE OlRECTlON CHANGE, ELBOW REDUCER OR TAPER DIRECTION CHANGE. TEE USED AS ELBOW DIRECTION CHANGE, CROSS USED AS ELBOW DIRECTION CHANGE W E

DlRECTlON OF FLOW I-,

fisure- 1 to Fiqure-8: Placement Details of Thrust Blocks e u r c e : AS TM F 1668)

. APPEND/X-7 (Continued.. .)

PL ACEMEIVT DETAILS OF THRUST / ANCHOR BLOCKS

DESCRIPTION

9. VALVE ANCHOR 10. CHANGE IN DlRECTlON OF VERTICAL PIPING

Fiqure-9 and Fiqure- 70: Placement Details of Anchor Blocks {Source: A S TM F 7 668)

DOC. NO. KOC-IMP-OIlPI.2 Page 59 of 6 1 -

REV. 7

-

ACKNOWLEDGEMENT

This Recommended Practice has been approved by the Standards Technical Committee (STC) consisting of the following:

Mr. AIRedha Al-Haddad Mr. Mohamnad Emam Mr. S. Kumar Mr. Henry S. Hill Mrs. Amina Rajab Mr. Khalaf t-lamada Mr. N. Ramanathan Mr. Khalid Al-Ahmad Mr. Daniel Fino Mr. Ali H. Al-Failakawi Dr. Modistaba Araghi Mr. Abdul Aziz Akbar Mr. Moataz Khalaf

Standards Team Insp. & Corr. Team-S&E Standards Team Opns. Tech. Svcs. Team SK Design Team Design Team Major Projects-EFP Team Gen. Projects Team Utilities Team HSES Team Insp. & Corr. Team-N&W Project Mgmt. Team -NK Information System Team

Chairman Deputy Chairman Secretary/ Member Member Member Member Member Member Member Member Member Member Member

The draft of this Recommended Practice had been circulated to the KOC User Teams for review and the responses were received from the following: -

ENGINEERING GROUP MAJOR PROJECTS GROUP

Team Leader Gen. Projects Team Leader Maj. Project Support Team Leader Exp. Fac. Project

AHMADI SERVICES GROUP HSE GROUP

Team Leader Project Design Team Leader Utilities

Team Leader Safety Team Leader HSE Systems

OPERA TIONS GROUP {WK) OPERA T I O N GROUP lEKl Team Leader Opns. Tech. Svcs. Team Leader Igrod. Operations

Team Leader Opns. Tech. Svcs.

OPERA TIONS GROUP {SKI O