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TRUNKLINE SP XI - SPU PROJECT

JOB No: 001

PT. PERTAMINA EP – FIELD LIMAU

BASIS OF DESIGN - PIPELINE SYSTEM

DOCUMENT NUMBER: 001/2014-LMU-001

REV REV DESCRIPTION PREP’D CHK’D APP’D NOTE


A 00 ISSUED FOR INTERNAL REVIEW AS
B 00 ISSUED FOR CONSTRUCTION AS
TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU

BASIS OF DESIGN - PIPELINE SYSTEM

TABLE OF CONTENTS

Page
1.0 SCOPE............................................................................................................................................. 3
2.0 CODES, STANDARDS AND SPECIFICATIONS ........................................................................ 3
3.0 GENERAL REQUIREMENTS....................................................................................................... 3
4.0 SYSTEM DESCRIPTION .............................................................................................................. 3
5.0 DESIGN REQUIREMENTS........................................................................................................... 5
6.0 DESIGN DATA .............................................................................................................................. 7
7.0 DOCUMENTATION ...................................................................................................................... 9

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TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU

1.0 SCOPE
This document covers the Basis of Design for the Trunkline SP XI - SPU Project for the detailed
design of onshore pipelines.

2.0 CODES, STANDARDS AND SPECIFICATIONS


The requirements and recommendations of the latest revisions of the following listed codes,
standards and Specifications shall apply:
2.1 Codes
AGA On Bottom Stability Software
API RP 1102 Steel Pipelines Crossing Railroads and Highways
API Spec 5L Specification for Line Pipe
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASME B31.4 Liquid Petroleum Transportation Piping Systems
ASME B31.8 Gas Transmission and Distribution Piping Systems
2.2 Project Documents
003/2014-LMU-001 Pipeline Material Specification
004/2014-LMU-001 Pipeline Installation Specification
005/2014-LMU-001 Pipeline Protective Coatings Specification
006/2014-LMU-001 Cathodic Protection Pipeline Specification
007/2014-LMU-001 Pig Launcher-Receiver Pipeline Specification

3.0 GENERAL REQUIREMENTS


The purpose of this Basis of Design and its referenced codes, standards and Specifications is to
establish a minimum level of acceptable quality. Alternate standard designs of equal or superior
quality may be proposed, provided all exceptions are listed and written approval for all exceptions
is obtained from COMPANY.
In the case of conflict between documents, CONTRACTOR shall submit the discrepancy
immediately to COMPANY for final resolution.
The pipelines will be designed and constructed according to ASME B31.4.
Project specific design criteria shall be submitted to COMPANY for approval prior to the start of
detail engineering.

4.0 SYSTEM DESCRIPTION


4.1 Description
The pipeline system for the Trunkline SP XI - SPU Project comprises the following
components:
 8 inch tie-in from SP XI into the proposed SPU Trunkline Header Manifold and Pig
Reciever.
 8 inch tie-in from SP XI into the proposed SP XI Discharge Pump Header Manifold and
Pig Launcher.
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TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU
4.2 8 inch tie-in from SP XI into the proposed SPU Trunkline Header Manifold and Pig Reciever
The proposed line from SP XI into the proposed SPU Trunkline Header Manifold will
initially be used to supply crude oil to SPU. It is intended that as part of trunkline project will
be split into two sections. The first section will run from SP XI to SPU Header Manifold, and
will supply crude oil to SPU, replacing pipeline 6 inch existing for single line supply crude
oil from SP XI to SPU. The second section will run from trunkline to pig receiver in SPU,
and will transport liquids from SP XI to SPU for pipeline cleaning process.
The pipeline will be installed and tested by Contractor with a dummy flanged spool adjacent
in SPU Header Manifold and Pipeline in SPU Pig Reciever. The spool will be removed as
part of this Project to split the pipeline into two sections, and two points tie-ins will be
installed. One to tie-in the trunkline SP XI - SPU into the SPU header manifold section of
the pipeline, and the other to tie-in the Pig Reciever section in SPU.
The tie-ins shall be installed using the same line pipe. Pipeline wall thickness, coatings, and
concrete weightcoat will be the same as for existing pipeline. Spare 8 inch line pipe procured
via this project by COMPANY shall be responsible for pre-formed bends (if needed), flanges
and their fittings, and the associated coatings of the spools.
The tie-ins shall be routed to avoid possible conflicts with pipeline existing and pipeline of
Pig Reciever. The routing must also allow space for the proposed future pipeline tie-ins from
another gatehering stations.
The SP XI - SPU pipeline shall be isolated prior to the tie-in. A remote controlled
mechanical isolation plug or similar equipment approved by COMPANY shall be set into
position just past a removable spool.
After hydrotest and pre-commissioning, the liquids pipeline shall be left filled with treated
water ready for commissioning.
4.3 8 inch tie-in from SP XI into the proposed SP XI Pump Discharge Header Manifold and Pig
Launcher.
The proposed line from new trunkline into the proposed SP XI Pump Discharge Header
Manifold will initially be used to supply crude oil from SP XI. It is intended that as part of
trunkline project will be split into two sections. The first section will run from new trunkline
to SP XI Pump Discharge Header Manifold, and will supply crude oil from SP XI, replacing
pipeline 6 inch existing for single line supply crude oil from SP XI to SPU. The second
section will run from trunkline to Pig Launcher in SP XI, and will transport liquids from SP
XI to SPU for pipeline cleaning process.
The pipeline will be installed and tested by Contractor with a dummy flanged spool adjacent
in SP XI Pump Discharge Header Manifold and Pipeline in SP XI Pig Launcher. The spool
will be removed as part of this Project to split the pipeline into two sections, and two points
tie-ins will be installed. One to tie-in the trunkline SP XI - SPU into the SP XI Pump
Discharge Header Manifold section of the pipeline, and the other to tie-in the Pig Launcher
section in SP XI.
The tie-ins shall be installed using the same line pipe. Pipeline wall thickness, coatings, and
concrete weightcoat will be the same as for existing pipeline. Spare 8 inch line pipe procured
via this project by COMPANY shall be responsible for pre-formed bends (if needed), flanges
and their fittings, and the associated coatings of the spools.
The tie-ins shall be routed to avoid possible conflicts with pipeline existing and pipeline of
Pig Reciever. The routing must also allow space for the proposed future pipeline tie-ins from
another gatehering stations.

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TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU
The SP XI - SPU pipeline shall be isolated prior to the tie-in. A remote controlled
mechanical isolation plug or similar equipment approved by COMPANY shall be set into
position just past a removable spool.
After hydrotest and pre-commissioning, the liquids pipeline shall be left filled with treated
water ready for commissioning.
4.4 Pipeline Tie-in
In the absence of specific information from the pipeline operator, the following assumptions
have been made:
1. The pipeline operator from CONTRACTOR is responsible for the pipeline section
from the downstream outlet flange.
2. The pipeline operator from CONTRACTOR will install the tie-in into the existing
pipeline. The valves may be fitted either at the tie-in point or at the downstream
flange.
3. The pipeline operator from CONTRACTOR will be responsible for all costs
associated with providing the tie-in process.
4. COMPANY will operate the proposed pipeline system within the range 100 to 300
psi.
5. Both pipelines shall be rated to the same Maximum Allowable Operating Pressure
(MAOP) of 1,000 psig. The pipeline operator from CONTRACTOR and
COMPANY will ensure that the pipeline pressure protection devices on both
pipelines are set so that the pipeline pressure cannot exceed 110% of the MAOP (ie
1100 psig).

5.0 DESIGN REQUIREMENTS


5.1 Material
The pipelines shall be constructed from API 5L Grade B, with a 3 mm corrosion allowance
in accordance with Project Specification 003/2014-LMU-001.
5.2 Wall thickness
Wall thickness shall be designed to meet minimum requirements of:
(a) Hoop stress (in accordance with ASME 31.4),
(b) External buckling collapse (in accordance with ASME 31.4), and
(c) Propagation buckling (in accordance with ASME 31.4)
The nominal wall thickness shall be determined in accordance with API 5L specified wall
thickness.
The pipelines shall be constructed with a minimum wall thickness of 0.5 inches.
The tradeoff between the wall thickness and concrete coating thickness shall be considered
in design optimization.
5.3 On-Bottom Stability
The pipelines shall be analyzed to ensure that they are stable on the above of ground. The
concrete coating thickness and density shall be determined from this analysis.
The pipelines with minimum contents density shall be designed to withstand to 20 years
current conditions during operation.
For installation, empty pipelines shall be designed to withstand of 1 year current conditions.
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TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU
5.4 Vertical stability
Buried pipelines shall be subject to a vertical stability analysis during detailed design.
Onshore pipelines crossing swamp and paddy field area should be designed with appropriate
weight coat, ground anchors, geotextile mat, engineered backfill and / or other means to
prevent vertical movement.
5.5 Landfall Requirements
The pipeline must be buried to a depth of 2m to top of pipe up to the ground, or according to
government regulations.
5.6 Expansion
Expansion analysis of the onshore pipeline shall be performed in accordance with ASME
B31.4. Expansion loops shall be designed based on the expansion stresses determined from
the expansion analysis.
5.7 Free Spanning
For all temporary and permanent free spans subjected to combined wind and current loading,
a free span assessment shall be performed addressing the integrity with respect to buckling
and fatigue failure within the design life of the pipelines and supports. Short term fatigue
following installation and prior to freespan correction shall be considered. Fatigue during
installation in the event of an interruption to pipelay shall also be considered from the first
tensioner to a point beyond the touchdown point.
5.8 Coatings
The pipelines will be coated with asphalt enamel for corrosion protection in accordance with
Project Specification 005/2014-LMU-001.
5.9 Cathodic Protection
Zinc or other ground bed anodes shall be designed for the onshore pipeline section on the
land section in accordance with Project Specification 006/2014-LMU-001.
5.10 Bends
A minimum of 5D radius bends shall be used for pipeline tie-ins, onshore crossings.
5.11 Routing
The pipeline routing shall be planned with all tangent points, radius of curvatures, and
lengths shown on the detailed design Drawings.
5.12 Crossings
All pipe crossings shall be identified and designed in accordance with ASME 31.4.
Minimum separation taking into consideration short and long term pipeline and support
settlements.
Road crossings shall be designed in accordance with API RP 1102, with the separation
between the pipe and lowest point inside the road’s right of way clearly marked on the
Drawings.
5.13 Constructability
Designed pipelines and supports shall be subject to constructability analysis with respect to
combined external pressure, axial tension, and bending moment developing in the pipelines
and supports during construction and installation.
Constructability shall be analyzed in accordance with ASME B31.4.
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TRUNKLINE SP XI - SPU PROJECT
PT. PERTAMINA EP – FIELD LIMAU

6.0 DESIGN DATA


6.1 Design Life
The design life for the pipeline is 20 years.
6.2 Pipeline design pressure
Table 6.1
Pipeline Design Pressure

Parameter Unit 8 inch


Liquid
Design Pressure psi 340
Hydrotest Pressure psi 536

6.3 Pipeline mechanical design temperature


Table 6.2
Pipeline Mechanical Design Temperature

Parameter Unit 8 inch


Liquid
0
Mechanical Design F 140
Temperature (at support
inlet)
0
Hydrotest Temperature F 80

6.4 Contents density


Table 6.3
Contents Density

Parameter Unit 8 inch


Liquid
Maximum Contents lb/ft3 62.4
Density

6.5 Hydrodynamic coefficient


6.5.1 Hydrodynamic Coefficients for Pipeline Stability Design
Current Dominated Conditions (M>1)
 Drag Coefficient CD = 0.9
 Lift Coefficient CL = 0.9
 Inertia Coefficient CI = 3.29
Wind and Current Conditions (M<1)

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PT. PERTAMINA EP – FIELD LIMAU
 Drag Coefficient CD = 1.2
 Lift Coefficient CL = 1.5
 Inertia Coefficient CI = 3.29
6.5.2 Hydrodynamic Coefficients for Pipeline Spanning Design and Support Clamp
Spacing Design
The following numbers are hydrodynamics coefficients used for spanning design:
 Drag Coefficient CD = 1.2
 Inertia Coefficient CI = 3.29
6.6 Material Properties
6.6.1 Pipeline / Support Material Properties
The line pipe material properties are for the Trunkline SP XI - SPU Project is
presented in table below:

Table 6.5
Pipeline / Support Material Properties

Parameter Units Value


Grade API 5L grade X52
PSL2
SMYS psi 30,000
SMTS psi 60,000
Young Modulus, E psi 30 x 106
Poisson’s Ratio 0.3
3
Density lb/ft 490
Coefficient of Thermal / 0F 6.5 x 106
Expansion
Steel Potential volt -0.85

6.6.2 Pipeline / Support Coating Properties


Table 6.6
Pipeline / Support Coating Properties

Parameter Units Value


Support - Neoprene
Onshore Pipeline - Asphalt
Asphalt density lb/ft3 81

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PT. PERTAMINA EP – FIELD LIMAU

7.0 DOCUMENTATION
7.1 Design Report
A complete design report shall be prepared which includes the following as a minimum, plus
any other documentation required:
(1) Detail description of the analysis procedures
(2) Wall thickness calculations
(3) Calculations for on-bottom stability analysis
(4) Pipeline expansion analysis
(5) Crossing span analysis
(6) Constructability analysis
(7) Upheaval and lateral buckling
(8) Impact and dropped object analysis

7.2 Report Requirements


7.2.1 Explanation of calculations procedures, assumptions, and sources of data shall be
provided.
7.2.2 Pages shall be sequentially numbered within each section subdivision. A complete
table of contents shall be provided and included with each volume. Individual
volumes shall be clearly identified with titles and labels.
7.2.3 All calculations shall have the following:
(a) Printed name (not initials) and signature of person making the calculation
(b) Date
(c) Page number
(d) Project identification
(e) Subject identification.

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PT. PERTAMINA EP – FIELD LIMAU
7.2.4 The calculations shall be made in U.S. Customary Units (i.e. foot, inch, and
pound).
7.2.5 The calculations shall be archived by CONTRACTOR for the life of the facility,
and shall not be destroyed without prior written COMPANY approval.
7.3 Drawings
7.3.1 Drawing title blocks shall be agreed upon prior to start of drafting.
7.3.2 Drawings shall be to scale and in U.S. Customary Units with the exception of
Survey and positioning which shall be scale in SI units. Material and section
callouts shall be in accordance with American Institute of Steel Construction
(AISC).
7.3.3 Drawings shall be to the detail as defined by COMPANY.
7.3.4 A summary of the design criteria shall be shown on a general information and
index drawing.
7.3.5 During construction, as-built revisions shall be kept on a set of Construction
Drawing prints. At the completion of construction, the original drawings shall be
revised to "As-Built Drawings" and reissued to COMPANY.
7.3.6 Drawings shall be numbered in accordance with Field Limau Drawing Numbering
System.

7.4 Submission of Documents


7.4.1 Five copies of the design criteria shall be submitted for COMPANY approval prior
to beginning the design.
7.4.2 Three copies of the Construction Drawings shall be submitted for COMPANY
approval. COMPANY will return the Drawings within two weeks, either approved
or with exceptions noted. Drawings shall be approved by COMPANY prior to
beginning fabrication. COMPANY approval will be only for concept and contract
compliance. Such approval shall in no way relieve CONTRACTOR of his
responsibility per the Contract.
7.4.3 The documents shall be submitted in both electric and hard copy format at the end
of project.

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