1. ABC Chemical Complex1 PIPELINE SPECIFICATIONS ABC Company ABC Chemical Complex Engineering Specifications

2. ABC Chemical Complex2 Scope Comparison u ASME/ANSI –Design –Materials –Construction –Assembly –Inspection –Testing –Operations –Maintenance –Safety u DOT 49CFR –Prescribes minimum safety requirements for pipeline facilities –Legal document enacted by Congress

3. ABC Chemical Complex3 Format Comparison u ASME/ANSI B31.4 –Scope & Definitions –Design –Materials –Dimensional Require. –Const., Weld, & Assb. –Inspection & Testing –O&M Procedures –Corrosion Control –Appendices u DOT 49CFR195 –A: General –B: Reporting Accidents –C: Design Requirement –D: Construction –E: Pressure Testing –F: O&M

4. ABC Chemical Complex4 Format Comparison: 31.8 vs 192 u ASME/ANSI B31.8 –Materials & Equipment –Welding –Pip Sys Comp & Fab –Design, Inst, and Test. –O&M Procedures –Corrosion Control –Miscellaneous –Offshore Gas Trans. –Appendices u DOT 49CFR192 –General –Materials –Pipe Design –Design of Pipeline Components –Welding of Steel –General Const. Req. –Req. for Corrosion Con –Test Requirements

5. ABC Chemical Complex5 Format Comparison: 31.8 vs 192 u See Previous Slide –Uprating –Operations –Maintenance

6. ABC Chemical Complex6 Engineering Specifications u Exceptions to Code Requirements – AS DEFINED: when Safety considerations in DOT 49CFR 192 or 195 demand tighter controls in ABC Engineering Specification than required in the governing design and construction Codes, i.e. ASME/ ANSI B31.4

7. ABC Chemical Complex7 Engineering Exceptions-Liquids u ABC Exceptions to ASME/ANSI B31.4 from DOT 49CFR195 Requirements –Subpart A »Definitions »Matter Incorporated by Reference u See “Finding Aids” in Appendix for DOT 49CFR »Compatibility necessary for transportation of hazardous liquids or carbon dioxide »Conversion to service »Responsibility of operator for compliance

8. ABC Chemical Complex8 Engineering Exceptions-Liquids –Subpart B, Reporting Accidents and Safety Related Conditions »Reporting Accidents and Safety Related Conditions u Reporting Accidents u Telephonic notice of certain accidents u Accident reports u Reporting safety-related conditions u Filing safety-related condition reports

9. ABC Chemical Complex9 Engineering Exceptions-Liquids –Subpart C, Design Requirements »Design Factor, Cold Expanded and Reheated Pipe u B31.4 –75% of the allowable stress as determined by para. 402.3.1(a), (b), or (c). [Maximum 0.72x0.75=0.54 u 195 –0.54 »195.120, Passage of Internal Inspection Devices u Not included in ASME/ANSI B31.4

10. ABC Chemical Complex10 Engineering Exceptions-Liquids –Subpart D, Construction »195.210, Pipeline Location u Minimum 12-inch cover within 50 feet of private dwelling or industrial building or place of public assembly. »195.234, Nondestructive Examination u 10% of all production welds for all stress levels. u 100% of all girth welds when installing used pipe. Minimum 90% in B31.4 u 100% for all tie in welds not hydrotested. Minimum 90% in B31.4

11. ABC Chemical Complex11 Engineering Exceptions-Liquids –Subpart D, Construction (Continued) »Cathodic Protection Systems u 31.4 & 195: Install with one year of commissioning u ABC: CP system to be commissioned with pipeline.

12. ABC Chemical Complex12 Engineering Exception-Liquids –Subpart E, Pressure Testing »General Requirements u Exclude –Interstate pipeline constructed before January 8, 1971 –Intrastate pipeline constructed before October 21, 1985

13. ABC Chemical Complex13 Engineering Exceptions-Liquids –Subpart F, Operations and Maintenance »195.406, Maximum Operating Pressure u Paragraph (a)(1)(i) refers to Appendix N, “Recommended Practice for Hydrostatic Testing of Pipelines in Place”, ASME/ANSI B31.8, Gas Transmission and Distribution Piping. Appendix N is generic for all pipelines and DOT required a reference in this paragraph to establish criteria for maximum operating pressure. u 80% of test pressure=0.8 x 1.25 = 1.00 = design pressure »195.424, Pipeline Movement u Reduce pressure to 50% MAOP.

14. ABC Chemical Complex14 Engineering Exceptions-Gas u ABC Exceptions to ASME/ANSI B31.4 Due to 49CFR192 Requirements –Subpart A, General »Definitions u Administrator u Class locations u Incorporation by reference u Conversion to service subject to this part u Rules of regulatory construction

15. ABC Chemical Complex15 Engineering Exceptions-Gas –Subpart B, Materials »Transportation of pipe. (192.65) u Pipe with an outer diameter to wall thickness ratio of 70 to 1 or more may not be used in a pipeline to be operated at a hoop stress of 20% or more of SMYS if the pipe is transported by railroad.

16. ABC Chemical Complex16 Engineering Exceptions-Gas –Subpart C, Pipe Design »Class Location and Design Factor u 1. 0.72 (Same as B31.4) u 2. 0.60 (Safety Factor Increased by 20% from 1) u 3. 0.50 (Safety Factor Increased by 44% from 1) u 4. 0.40 (Safety Factor Increased by 80% from 1) »Previous editions of ASME/ANSI B31.8 used the term, “Population Density Index” with Construction Types A, B, C, and D. The Location Classes 1, 2, 3, and 4 have replaced the above in the definition of design, construction, testing, and operating require- ments.

17. ABC Chemical Complex17 Engineering Exception-Gas –Subpart D, Design of Pipeline Components »192.145, Valves u Valves must be hydrotested at least 1.5 times the maximum service rating. »192.150, Passage of internal inspection devices u Each new pipeline must be designed for intelligent pigging. u Operators may petition for approval to not comply. »192.153, Components fabricated by welding u Orange-peel bull plugs and/or swages are prohibited on ABC pipelines. u Flat closures and fish tails may not be used on piping that either operates at 100 psig or above or is >3” in diameter.

18. ABC Chemical Complex18 Engineering Exceptions-Gas –Subpart E, Welding of Steel in Pipelines »192.233 - Miter Joints u Miter joints are permitted in certain cases for DOT gas pipelines. u ABC specifications prohibit these joints, because restrictions are too difficult to follow and enforce in construction and maintenance welding activities. »192.243, Nondestructive testing u B31.4 allows 40% weld inspection in Location Class 3 and 75% in Location Class 4. DOT requires 100% or at least 90% if impractical.

19. ABC Chemical Complex19 Engineering Exceptions-Gas –Subpart G, General Construction Requirements for Transmission Lines and Mains »192.315, Wrinkle Bends in steel pipe. u Wrinkle bends are allowed on steel pipe operating at a pressure that produces a hoop stress of less than 30% SMYS. u Wrinkle bends are prohibited on ABC pipelines.

20. ABC Chemical Complex20 Engineering Exceptions-Gas –Subpart J, Test Requirements »192.505 & 192.619 u For Location Class 3 which includes all ABC gas transmission pipelines, DOT requires a test pressure equal to 1.5 times the maximum operating pressure. u ASME/ANSI B31.8 requires a test pressure equal to 1.4 times the maximum operating pressure.