SS 512 : 2005(ICS 23.040.01) 

SINGAPORE STANDARD

Code of practice for the design, construction and operation of pipeline service corridors

Published by

SS 512 : 2005 (ICS 23.040.01)

SINGAPORE STANDARD

Code of practice for the design, construction and operation of pipeline service corridors

ISBN 981-4154-06-7

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This Singapore Standard was approved by Chemical Standards Committee on behalf of the Standards Council of Singapore on 13 April 2005. First published, 2005. The Chemical Standards Committee appointed by the Standards Council consists of the following members: Name Capacity Chairman : Dr Peter Chan Ping Kwong Member, Standards Council

Deputy Chairman : Ms Lam Kit Wing Member, Standards Council

Secretary : Ms Ho Phuy Bee SPRING Singapore

Members : Dr Philip Adams Plastics and Rubber Institute of Singapore

Dr Fang Shu Nong Singapore Surface Finishing Society

Mr Terence Koh Singapore Chemical Industry Council

Mr Larry Ng Lye Hock Urban Redevelopment Authority

Ms Ong Kah Kee Singapore Manufacturers’ Federation

Ms Pamela Phua Singapore Paints Manufacturers' Association

Mr Pitt Kuan Wah National Archives of Singapore

Mr Tan Lay Thok Maritime and Port Authority of Singapore

Mr Tan Quee Hong National Environment Agency

Assoc Prof Teo Khay Chuan National Institute of Education

Dr Alastair Trigg Institute of Microelectronics (Singapore Surface Analysis Interest Group)

Mr Wang Hui Hua Singapore Chemical Industry Council

Co-opted Members : Mr Lim Eng Kiat Individual Capacity Mr Seah Khen Hee Individual Capacity The Working Group appointed by the Chemical Standards Committee to assist in the preparation of this standard comprises the following experts who contribute in their individual capacity:

Name Convenors : Prof Ching Chi Bun

Mr David Tan Tin Liung

Secretaries : Ms Ho Phuy Bee

Ms Jesline Lim

Members : Mr Ang Chee Pheng

Mr Aw Chin Leng

Mr Cao Wen

Mr Chua Swu Chun

Mr Charlie Goh

Mr Ismadi Mohamed

Mr S K Joshi

Mr Koh Chwee Tin

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Members : Mr Vincent Koh Liang Peng

Mr Kwa Soo Teck

Mr Lim Song Hau

Mr Loh Boon Chye

Mr Kuduva Nagaiar Kuppuraman Ravi

Major Ramanathan Sakhubai

Mr Tony Soh

Mr Singaravelu Sundaravel

Mr Teo Kwan Hai

Mr Tham Heng Mun

Mr Steven Thong

Dr Ti Hwei Chen

Mr Barnabas Wong Wai Kok

Mr Yau Tai Yin

Observers : Mr Devendra Borkar

Mr Cheong Wee Lee

Mr Muhammad Junaid

Mr K K Tan The experts of the Working Group are nominated/recommended by the following organisations: Air Products Singapore Pte Ltd Celanese Singapore Pte Ltd City Gas Pte Ltd Economic Development Board ExxonMobil Asia Pacific Pte Ltd Invista Singapore Pte Ltd JTC Corporation Maritime and Port Authority of Singapore Ministry of Manpower National Environment Agency National University of Singapore Oiltanking Odfjell Terminal Singapore Pte Ltd Petrochemical Corporation of Singapore Pte Ltd PowerGas Ltd Public Utilities Board (Water Department) Seraya Chemicals Singapore Pte Ltd Singapore Civil Defence Force Singapore Oxygen Air Liquide Pte Ltd Society of Loss Prevention in Oil, Chemical and Industry Processes, Singapore SUT Sakra Pte Ltd Vopak Terminals Singapore Pte Ltd

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Contents Page

Foreword 9

CLAUSES 1 Scope 10

2 Purpose 10

3 Normative references 10

4 Definitions 12

5 Conceptual activities 15

5.1 General 15

5.2 Survey and siting permissions 15

5.3 Ownership and operator responsibilities 17

5.4 Planning permission 17

6 Front end engineering design (FEED) 19

6.1 Basis for design 19

6.2 Design standards 19

6.3 Block diagram and piping and instrumentation diagram 21

6.4 Piping specification 23

6.5 Other written documentation 24

7 Detailed engineering design 24

7.1 Quality management plan 24

7.2 Hazard analysis/HAZOPS 26

7.3 Piping design 26

7.4 Pipeline supports design 29

7.5 Pipeline components 30

7.6 Piperack layout 33

7.7 Buried pipelines layout philosophy 35

7.8 Subsea pipeline layout philosophy 40

8 Corrosion protection 40

8.1 General 40

8.2 Internal corrosion 40

8.3 External corrosion of buried pipelines 40

8.4 Cathodic protection 41

8.5 Electrical isolation 41

9 Construction 43

9.1 General 43

9.2 Material quality control 43

9.3 Welding 44

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9.4 Qualification of welders 44

9.5 Inspection, examination and testing of welds 44

9.6 Bending of pipe 45

9.7 Repair of damaged pipe 46

9.8 Buried pipelines 46

9.9 Crossings 48

9.10 Subsea pipelines 48

9.11 Aboveground pipelines 49

9.12 Inspection control 49

10 Pre-commissioning and testing 50

10.1 General 50

10.2 Cleaning 51

10.3 Safety precautions during pressure testing 51

10.4 Hydraulic test procedure 52

10.5 Pneumatic test procedure 53

10.6 Test data recording 53

11 Handover and commissioning 53

11.1 General 53

11.2 In-service leak test 53

11.3 Commissioning of liquid pipelines 54

11.4 Commissioning of non-flammable permanent gas pipelines 54

11.5 Commissioning of flammable and toxic substances which are gases at ambient temperature 54

11.6 Deferred commissioning 55

11.7 Communications 55

12 Operations and maintenance 55

12.1 General 55

12.2 Basic requirements for maintenance and operations procedures 56

12.3 Operating instructions 56

12.4 Communication arrangements 56

12.5 Inspection and monitoring 57

12.6 Pipeline surveillance 57

12.7 Inspection surveys 58

12.8 Cathodic protection 58

12.9 Risk categories 59

12.10 Pipeline repairs 60

12.11 Pipeline modifications 61

12.12 Documentation control 61

13 Health, safety and environment (HSE) 62

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Page

13.1 General 62

13.2 Conceptual activities 62 13.3 Front end engineering design (FEED) 66

13.4 Detailed design 67

13.5 Construction 67

13.6 Radiography 70

13.7 Pre-commissioning and testing 71

13.8 Handover and commissioning 72

13.9 Operations and maintenance 73

13.10 Operating procedures 77

13.11 Maintenance procedures 77

13.12 Emergency preparedness 78

13.13 Decommissioning and removal 79

13.14 Pollution control 80

13.15 Leak containment 81

14 Documentation control and records 81

14.1 General 81

14.2 Document requirements 81

14.3 Document control 82

14.4 Records 82

14.5 Electronic forms 82

14.6 Drawings 82

ANNEXES A Examples of hazard register and qualitative risk matrix 84

B Guidelines for Quantitative Risk Assessment (QRA) study (for installations which store, transport or use hazardous substances) 86

C Conceptual health, safety and environmental evaluation for pipelines 94

D Construction safety management system – statutory requirements 96

E Code of practice on safety management system for the chemical industry 97

F Preparation of Emergency Response Plans (ERPs) to deal with accidents involving hazardous chemicals in hazardous installations 98

G Abbreviations 104

TABLES 1 Colour coding 36

2 Inspection control and documentation 50

3 Description of different class locations 57

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4 Maximum inspection intervals (based upon the ‘classes’ API 570) 58

5 Examples of pipeline inspection and monitoring methods 59 6 Records and documentation 83

FIGURES 1 Pipeline interfaces 16

2 Pipeline regulatory approval process 18

3 Typical standards 20

4 Typical block diagram 22

5 Example of piping specification 25

6 Examples of pipe shoes to prevent wear on pipe and corrosion due to water accumulation on piperack beam 27

7.1 Example of labeling with stickers directly on the pipeline 37

7.2 Example of pipeline labels 38

7.3 Example of label font size_________________________________________________ 39

8 Cathodic protection of buried pipeline using impressed currents __________________ 42

9 Typical configuration of a buried pipeline installation ___________________________ 46

10 Typical phases of a pipeline life cycle _____________ 63

11 Cold work permit and lockout/tagout sequence for pipleline maintenance _ ___________ 75

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Foreword

The companies on Jurong Island are and will be linked to one another via a network of pipelines, which will transverse a dedicated piece of land known as a ‘Pipeline Service Corridor’. These pipelines serve as a vital artery, supplying feedstock and products from one plant to another. Companies benefit from over-the-fence selling of products through this linked petroleum and petrochemical cluster concept. This linked cluster concept is vital for the success of Singapore as a chemicals hub.

However, in order for these pipelines to operate safely, it is necessary for consistent and appropriate standards to be set. The Working Group under the guidance of the then Singapore Productivity and Standards Board (PSB), now known as the Standards, Productivity and Innovation Board (SPRING Singapore), and comprising Jurong Island companies, National University of Singapore, government agencies and statutory boards, has developed the TR 6 : 2001 – Pipeline service corridors – Design, construction and operation of pipeline service corridors in Singapore (the first of its kind Technical Reference for pipeline service corridors).

The review of TR 6 : 2001 by the original Working Group was undertaken on 30 July 2003 subsequent to a two-year trial (pilot) implementation of the Technical Reference by the Working Group.

It is the responsibility of this Working Group to review and elevate TR 6 : 2001 to a Singapore Standard. This Singapore Standard is based on best industry practices and the appropriate existing internationally accepted codes and standards such as ASME already in use in Singapore. This Singapore Standard does not replace the need for appropriate experience and engineering judgement.

This standard represents the collaborative relationship and collective responsibility among the government agencies, statutory boards, companies, third party logistics companies and pipeline service corridor owners and operators to maintain and enhance the health, safety and environment on Jurong Island. The publication of this Singapore Standard is also a strong demonstration of the commitment by professionals in the chemical and supporting industries to set high standards for the continuing development of the chemical industry in Singapore.

Annex E specifies the safety management system for the purpose of ensuring the safety, and protecting the health and welfare of persons employed in the factory.

The list of abbreviations used in this standard are given in Annex G.

Attention is drawn to the possibility that some of the elements of this Singapore Standard may be the subject of patent rights. Enterprise Singapore shall not be held responsible for identifying any or all of such patent rights.

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Code of practice for the design, construction and operation of pipeline service corridors

1 Scope

This code of practice sets down the engineering and management system requirements in the design, construction and operation of pipeline service corridors in Singapore. This Code is applicable only for new piperacks/pipetracks in existing pipeline service corridors or new pipeline service corridors.

2 Purpose

To provide guidelines, building upon and referencing internationally accepted codes, to achieve consistent performance standards in the design, construction and safe operation of pipeline service corridors. These corridors will include pipelines for feedstock and finished products as well as utility services in Singapore.

3 Normative references

The following referenced documents are indispensable for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

API 570 Piping inspection code Inspection, repair, alteration, and rerating of in-service piping systems

API PUBL 581 Base resource document on risk-based inspection API RP 1102 Steel pipelines crossing railroads and highways API RP 2201 Safe hot tapping practices in the petroleum and petrochemical industries API RP 2220 Improving owner and contractor safety performance API RP 520 Sizing, selection and installation of pressure-relieving devices in refineries.

Part 1 : Sizing and selection Part 2 : Installation

API RP 521 Guide for pressure relieving and depressurising systems API RP 571 Damaged mechanisms affecting fixed equipment in the refining industry API RP 574 Inspection practices for piping system components API RP 580 Risk-based inspection API RP 750 Management of process hazards API RP STD 526 Flanged steel pressure relief valves API SPEC 15HR High pressure fiberglass line pipe API SPEC 15LE Polyethylene line pipe (PE) API SPEC 15LR Specification for low pressure fiberglass line pipe API SPEC 5L Specification for line pipe API SPEC 6A Specification for wellhead and Christmas tree equipment API SPEC 6D Specification for pipeline valves

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API STD 1104 Welding pipelines and related facilities ASME B16.20 Metallic gaskets for pipe flanges: Ring joint spiral wound and jacketed ASME B16.5 Pipe flanges and fittings ASME B16.9 Factory made wrought steel butt welding fittings ASME B31 Standards of pressure piping ASME B31.1 Power piping ASME B31.3 Process piping ASME B31.4 Pipeline transportation systems for liquid hydrocarbons and other liquids ASME B31.8 Gas transmission and distribution piping systems ASME Section I - IX Boiler and pressure vessel code ASME VIII Unfired pressure vessel applications ASTM D 2513 Standard specification for thermoplastic gas pressure pipe, tubing and

fittings ASTM D 2517 Standard specification for reinforced epoxy resin gas pressure pipe and

fittings BD 31 Buried concrete box type structures BD 37 Loads for highway bridge BS 381C Specification for colours for identification, coding and special purposes BS 4500 ISO limits and fits BS 8110 Structural use of concrete EN 12007-2 Gas supply systems – Gas pipelines for maximum operating pressure up

to and including 16 bar Part 2 : Specific functional recommendations for polyethylene (MOP up to

and including 10 bar) NACE Corrosion data survey – Metals section NACE RP-01-69 Control of external corrosion on underground or submerged metallic piping

systems NACE RP-01-77 Mitigation of alternating current and lightning effects on metallic structures

and corrosion control systems NACE RP-02-75 Application of organic coatings to the external surface of steel pipe for

underground service NACE RP-06-75 Control of external corrosion on offshore steel pipelines NFPA 11 Standard for low-, medium-, and high-expansion foam, 2002 edition (Next

edition in 2005) NFPA 15 Standard for water spray fixed systems for fire protection NFPA 24 Standard for the installation of private fire service mains and their

appurtenances, 2002 edition NFPA 600 Standard on Industrial fire brigades, 2000 edition NFPA 704 Standard for the identification of the fire hazards of materials for

emergency response, 2001 edition SS 286 Specification for caution labeling for hazardous substances SS CP 29 Code of practice for fire hydrant systems and hose reels