ISRAEL STANDARD SI 5664 PART 2 2 ‫ חלק‬5664 ‫תקן ישראלי ת"י‬

June 2006 ‫תמוז התשס"ו‬

ICS CODE: 75.060
75.200
79.140.75

NATURAL GAS TRANSMISSION PIPELINE SYSTEM:

ADDITIONAL REQUIREMENTS FOR STEEL PIPELINE
‫ דרישות נוספות לצנרת פלדה‬:‫מערכת הולכת גז טבעי‬

Combined edition

The Standards Institution of Israel

42 Chaim Levanon Street, 69977 Tel-Aviv, Tel. 03-6465154, Fax 03-6412762, www.sii.org.il
SI 5664 part 2 (Combined edition) (2006)

This Standard was prepared by a Committee of Experts, comprised of the following members:

Armand Coter, Yaron Daissy, Josef Jurborsky, Amichai Pessach, Samuel Tordjman, Yossi Zinger (chairman).

Also the following contributed to the preparation of the Standard:

- Ian Fordyce and Bernd J. Selig from abroad.
- Armand Abramovici, David Bashan, Jacob Dror, Rahamim Francis, Yair Rubinstein, Menashe Sarid, Gary
Schaffer, Jack Teboulle, Ilan Wise.

This Standard was approved by the Technical Committee TC 407 – Natural gas transmission:
Association of Engineers, Architects and Graduates
in Technological Sciences in Israel Amichai Pessach
Federation of Israeli Chambers of Commerce Yehuda Meitlis
Fire and Rescue Commission Sandra Moscovici
Histadrut Consumer Protection Authority Esra Levenberg (chairman)
Israel Electric Co. Zvi Eyal
Israel Natural Gas Lines Itsik Hanuni
Manufacturers Association of Israel Chaim Ferenc
Ministry of the Environment Jacob Dror
Ministry of the Interior Michal Eitan
Ministry of National Infrastructures Josef Jurborsky
The Israel Institute of Petroleum and Energy Jacob Adam
The Standards Institution of Israel / Industry Division Jacob Gal

Coordinators for the Standard preparation: Jacob Gal and Limor Argaman.
SI 5664 part 2 (Combined edition) (2006)

Notice of measure of compliance of Israeli Standards with foreign Standards or

documents
This Standard excluding the modifications and additions indicated, is identical to the unofficial
translation into the English language from November 2004 of the Dutch Standard
NEN 3650-2 – 2003.

Descriptors: gas pipelines, gas supply, natural gas, pipelines, steels

:‫מילות מפתח‬
‫ פלדות‬,‫ צנרת‬,‫ גז טבעי‬,‫ הספקת גז‬,‫צנרת גז‬

Updating the Standard

Israel Standards are reviewed periodically at least every five years, in order to adapt them to
scientific and technological developments. Users of Standards should ascertain that they are in
possession of the latest editions of the Standard including its Amendments.
A document appearing in the “Reshumot” (The Israeli Official Journal) as an Amendment may
be a separate Amendment, or an Amendment incorporated into the Standard.

Official Standard
Whether the document or parts of it are Official should be checked. An Official Standard or
Amendment (in whole or in part) takes effect 60 days following publication of the notice in the
“Reshumot”, unless the notice states otherwise for the effective date.

Standards Mark
A manufacturer of a product complying with the requirements of the
applicable Israel Standards is entitled, after being licensed by the
Standards Institution of Israel, to mark it with the Standards Mark:

Copyright
This Standard or any part of it may not be photocopied, copied or published by any means
whatsoever, without prior permission in writing of the Standards Institution of Israel. ©
 SI 5664 part 2 (Combined edition) (2006)

Introduction to the Israeli Standard

This Israel standard is the unofficial translation from November 2004 of the Dutch Standard NEN 3650-2 - 2003
approved in the English language as an Israel Standard with national deviations.
The national deviations are brought in this standard in a different font.

This Standard is part of a Standard series dealing with a natural gas transmission pipeline system, as follows:
SI 5664-1 - Natural gas transmission pipeline system – General
SI 5664-2 - Natural gas transmission pipeline system – Additional requirements for
steel pipeline

Foreword

SI 5664-2 is a part of standard series SI 5664. SI 5664-2 contains specific

requirements for a natural gas steel pipeline system. These requirements are in
addition to the general requirements set forth in SI 5664-1.
Appendixes A, B, C, D and F are the normative components of this standard. Appendix E
is an informative component of this standard.
Because the figures in this standard are in large part adopted from other standards,
the standards and editing rules for technical drawings have not been completely
followed, which can be seen from the editing and scripts of the figures. In the text
part of the standard, however, the correct manner of writing and printing is utilized.

Purpose of the Standard

The purpose of the Standard series is to obtain pipeline systems that are safe for
people, the environment and property, by specifying requirements for the design,
installation, operation and termination that will guarantees a durable, effective, and
efficient system.
This demands safety regulations. Deviation from the (fixed) regulations of this
standard is only possible, if approved by the authority having jurisdiction and
provides an equivalent or higher level of safety.

Interface EN and ISO standards

Application of the stipulations of this standard, including references to EN 1594:

2000 and ISO 13623: 2000 means that the pipeline system is also in compliance with the
stipulations of EN 1594: 2000 and ISO 13623: 2000.
Note: In case of contradiction between SI 5664 and any other standard mentioned
herein, the requirements of SI 5664 will prevail.

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SI 5664 part 2 (Combined edition) (2006)

Use of Standard

The people applying the standard shall be familiar with the subject and be in
possession of the relevant expertise.
The designer, builder or user of the pipeline system is reminded that this standard is
neither a design specification nor a handbook.

1 Subject and Scope

This section of the standard includes requirements for steel pipelines, which shall satisfy the requirements set forth in
SI 5664-1.

Figure 1 has been deleted and figure 2 has been modified and called Figure 1.

A schematic representation of which pipeline systems fall under the standard is depicted in Figure 1.

NOTE: Figure 1 is also found in SI 5664-1.

Informative note: F o r a p i p e l i n e s y s t e m d o w n s t r e a m o f t h e P R M S ( P r e s s u r e r e g u l a t i n g
and metering station) at the customer’s premises, see SI 4489 (ANSI/ASME B31.3
with modifications and additions) or ANSI/ASME B31.1 or NEN 2078. In any case, the
pressure safe control logic shall be compatible with SI 5664.

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 SI 5664 part 2 (Combined edition) (2006)

Figure 1 — Area of application of the standard

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SI 5664 part 2 (Combined edition) (2006)

2 Normative References

The following normative documents include provisions which, since they are referenced, are likewise provisions of this
standard. As this standard was printed, the cited versions were in force. All normative documents can however be
modified; it is therefore recommended that parties which make agreements on the basis of this Standard, try to apply
the most recent version of the standards documents cited below.

Israel Standards
SI 1340 - Carbon steel covered electrodes for shielded metal arc welding
SI 4489 - Process piping
SI 5664-1 – Natural gas transmission pipeline system – General
SI-ISO 9001: 2000 - Quality management systems – requirements
Israel Specification
SII 266 Part 5.2 - Steel pipes with protective coatings: External extruded
polyethylene coatings – three layer coating
International Standards
ISO 898-1: 1999 - Mechanical properties of fasteners made of carbon steel and alloy
steel – Part 1: Bolts, screws and studs.
ISO 898-2: 1992 - Mechanical properties of fasteners – Part 2: Nuts with
specified proof load values – Coarse threads
ISO 2566-1: 1999 - Steel – Conversion of elongation values – Part 1: Carbon and low
alloyed steels.
ISO 3183-1:1996 - Petroleum and natural gas industries – Steel pipe for pipelines – Technical delivery
conditions – Part 1: Pipes of requirement class A
ISO 3183-2:1996 - Petroleum and natural gas industries – Steel pipe for pipelines – Technical delivery
conditions – Part 2: Pipes of requirement class B
ISO 3183-3: 1999 - Petroleum and natural gas industries – Steel pipe for pipelines –
Technical delivery conditions – Part 3: Pipes of requirement
class C
ISO 3834-1: 1994 - Quality requirements for welding – Fusion welding of metallic
materials – part 1: Guidelines for selection and use
ISO 5817: 2003 Welding – Fusion-welded joints in steel, nickel, titanium and
their alloys (beam welding excluded) – Quality levels for
imperfections
ISO 7005-1:1992 - Metallic flanges – Part 1: Steel flanges
ISO 8501-1: 1998 - Pretreatment of steel for the application of paints and related
products – Visual evaluation of surface cleanliness– Part 1:
Pretreatment for rusting of uncoated steel and of steel following
removal of previous layers
ISO 9606-1: 1994 – Approval testing of welders – fusion welding – part 1: Steels.
+ A1: 1998
ISO 9692: 1992 - Metal arc welding with covered electrodes, gas shielded metal-arc
welding and gas welding joint preparations for steel
ISO 13623:2000 - Petroleum and natural gas industries – Pipeline transportation systems
ISO 14313 - Petroleum and natural gas industries – pipeline transportation
systems – pipeline valves

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 SI 5664 part 2 (Combined edition) (2006)

ISO 15589-1: 2003 - Petroleum and natural gas industries – Cathodic protection for
pipeline transportation systems – Part 1: On-land pipelines
ISO 15590-1: 2001 - Petroleum and natural gas industries – Induction bends, fittings
and flanges for pipeline transportation systems – Part 1:
Induction bends
ISO 15590-2: 2003 - Petroleum and natural gas industries – Induction bends, fittings
and flanges for pipeline transportation systems – Part 2:
Fittings
ISO 15614-1: 2004 - Specification and qualification of welding procedures for
metallic materials – Welding procedure test – part 1: Arc and gas
welding of steels and arc welding of nickel and nickel alloys
ISO 15741 - Paints and varnishes – Friction-reduction coatings for the interior of on- and offshore
pipelines for non-corrosive gases
ISO/IEC 17020: 1998 - General criteria for the operation of various types of bodies
performing inspections

European Standards

EN 288-9: 1999 - Specification and approval of welding procedures for metallic

materials. Welding procedure test for pipeline welding on land
and offshore site butt welding of transmission pipelines
EN 473: 2000 - Non-destructive testing - Qualification and certification of NDT
personnel - General principles
EN 1092-1: 2001 - Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated - Part 1: Steel flanges
EN 1591-1: 2001 - Flanges and their joints. Design rules for gasketed circular
flange connections - Part 1: Calculation method
ENV 1591-2: 2001 - Flanges and their joints. Design rules for gasketed circular
flange connections – Part 2: Gasket parameters
EN 1594: 2000 – Gas supply systems – Pipelines for maximum operating pressure
over 16 bar – functional requirements
EN 1708-1: 1999 - Welding. Basic weld joint details in steel - Pressurized
+ A1: 2003 components
EN 1991-2: 2003 – Eurocode 1: Actions on structures – Part 2: Traffic loads on
bridges
ENV 1993-1-1: 1995 - Eurocode 3: Design of steel structures – Part 1-1:General rules
and rules for buildings
EN 10021: 1993 - General technical delivery requirements for steel and iron
products
EN 10028-3: 2003 - Flat products made of steels for pressure purposes – Part 3:
Weldable fine grain steels, normalized
EN 10113-2: 1993 - Hot-rolled products of weldable fine-grained construction steel –
Part 2: Conditions of delivery for normally tempered / normalized
rolled types of steel
EN 10168: 2004 – Iron and steel products – Inspection documents – List of
information
EN 10204: 2004 - Metallic products– Types of inspection documents

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SI 5664 part 2 (Combined edition) (2006)

EN 10208-1: 1997 - Steel pipes for pipelines for flammable liquid substances —
Technica conditions of delivery – Part 1: Class A pipes
EN 10208-2: 1996 - Steel pipes for pipelines for flammable liquid substances —
Technical conditions of delivery – Part 2: Class B pipes
EN 10216-2: 2002 – Seamless steel tubes for pressure purposes — Technical
+ A1: 2004 delivery conditions – Part 2: Non-alloy and alloy steel tubes
with specified elevated temperature properties
EN 10217-2: 2002 – Welded Steel tubes for pressure purposes — Technical delivery
conditions – Part 2: Electric welded non-alloy and alloy steel
tubes with specified elevated temperature properties
EN 10217-5: 2002 – Welded steel tubes for pressure purposes – Technical delivery
conditions – Part 5: Submerged arc welded non-alloy and alloy
steel tubes with specified elevated temperature properties
EN 10222-2: 1999 – Steel forgings for pressure purposes – Part 2: Ferritic and
martensitic steels with specified elevated temperature properties
EN 10289: 2002 – Steel pipes and fittings for pipelines installed underground and
offshore – External coating comprised of layers of epoxy and
altered epoxy applied in a liquid form
EN 10290: 2002 – Steel tubes and fittings for onshore and offshore pipelines –
External liquid applied polyurethane and polyurethane-modified
coatings
prEN 10298: 2002 – Steel tubes and fittings for onshore and offshore pipelines –
Internal lining with cement mortar
EN 10301: 2003 – Steel tubes and fittings for on and offshore pipelines –
Internal coating for the reduction of friction for conveyance of
non corrosive gas
prEN 10309: 1999 – Steel tubes and fittings for onshore and offshore pipelines –
External epoxy powder coating
EN 10310: 2003 – Steel tubes and fittings for onshore and offshore pipelines –
Internal and external polyamide powder based coatings
EN 12007-3: 2000 – Gas supply systems – Pipelines for maximum operating pressure up
to and including 16 bar – Part 3: Specific functional
recommendations for steel
EN 12068: 1998 – Cathodic protection – External organic coatings for the corrosion
protection of buried or immersed steel pipelines used in
conjunction with cathodic protection – Tapes and shrinkable
materials
EN 12327: 2000 – Gas supply systems – Pressure testing, commissioning and
decommissioning procedures – Functional requirements
EN 12474: 2001 – Cathodic protection of submarine pipelines
EN 12560-1: 2001 – Flanges and their joints – Gaskets for class-designated flanges –
Part 1: Non-metallic flat gaskets with or without inserts
EN 12560-2: 2001 – Flanges and their joints – Gaskets for class–designated flanges –
Part 2: Spiral wound gaskets for use with steel flanges
EN 12560-3: 2001 – Flanges and their joints – Gaskets for class–designated flanges –
Part 3: Non-metallic PTFE envelope gaskets
EN 12560-4: 2001 - Flanges and their joints – Gaskets for class–designated flanges –
Part 4: Corrugated, flat or grooved metallic and filled metallic
gaskets for use with steel flanges

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 SI 5664 part 2 (Combined edition) (2006)

EN 12732: 2000 - Gas supply systems – Welding of steel pipework – Functional

requirements
EN 12954: 2001 - Cathodic protection of buried or immersed metalic structures –
General principles and applications of pipelines
EN 13480-3: 2002 - Metal industrial piping – Part 3: Design and calculation
CR 13642: 1999 - Flanges and their joints – Design rules for gasketed circular
flange connections – Background information
EN 13941: 2003 - Design and installation of preinsulated bonded pipe systems for
district heating
EN 50162: 2004 - Protection against corrosion by stray current from direct current
systems
National Standards
AD Specification Sheet - Calculations for alternating stress
S2:1995
ANSI/ASME B16.5-96 - Pipe Flanges and Flanged Fittings

ANSI/ASME B16.20-98 - Metallic Gaskets for Pipe Flanges – Ring Joint, Spiral-Wound, and Jacketed
ANSI/ASME B16.21-92 - Nonmetallic Flat Gaskets for Pipe Flanges
ANSI/ASME B 31.1: 2001 - Power piping
API RP 5L1 - Recommended Practice for Railroad Transportation of Line Pipe (Fifth Edition)
API RP 5LW - Recommended Practice for Transportation of Line Pipe on Barges and Marine Vessels
(Second Edition)
API SPEC 5L - Specification for Line Pipe Forty-Second Edition
ASME B&PVC 9
ASNT TC 1A: 2001 - Recommended practice, personnel qualification and certification
in nondestructive testing
ASTM A105/A105M-00 -`Standard Specification for Carbon Steel Forging for Piping Applications
ASTM A106-99e1 - Standard Specification for Seamless Carbon Steal Pipe for High-Temperature Service
ASTM A182/A182M-00c - Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings,
and Valves and Parts for High-Temperature Service
ASTM A193/A193M-00b - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-
Temperature Service
ASTM A194/A194M-00b - Standard Specification for Carbon and Alloy-Steel Nuts for Bolts for High-Pressure or
High-Temperature Service, or Both
ASTM A216/A216M-93 - Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-
Temperature Service
ASTM A234/A234M-00a - Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and High Temperature Service
ASTM A312/A312M-00c - Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes
ASTM A320/A320M-00b - Standard Specification for Alloy/Steel Bolting Materials for Low-Temperature Service
ASTM A333/A333M-99 - Standard Specifications for Seamless and Welded Steel Pipe for Low-Temperature
Service
ASTM A350/A350M-00c - Standard Specification for Carbon and Low-Alloy Steel Forging, Requiring Notch
Toughness Testing for Piping Components

7
SI 5664 part 2 (Combined edition) (2006)

ASTM A352/A352M-93 - Standard Specification for Steel Castings, Ferritic and Martensitic, for Pressure-
Containing Parts, Suitable for Low-Temperature Service
ASTM A420/A420M-00b - Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Low-Temperature Service
ASTM A487/A487M-93 - Standard Specification for Steel Castings Suitable for Pressure Service
BS 7910: 1999 - Guide on methods for assessing the acceptability on flaws in
+ A1: 2000 metallic structures
DIN 267-13, Edition: 1993-08 - Mechanical connection components – Technical conditions of delivery –Parts for screw
connections with special mechanical properties for use at temperatures from -200 °C to
+700 °C
DIN 2628:1975 - Welding neck flanges, Nominal pressure 250
DIN 2629:1975 - Welding neck flanges, Nominal pressure 320
DIN 2638:1975 - Welding neck flanges, Nominal pressure 160NEN 2078 - Requirements for
industrial gas installations
DNV-OS-F101:2000 - Submarine pipeline systems
MSS SP 44:1996 - Steel, pipeline flanges
MSS SP-75 - Specification for high test wrought butt welding fittings
NEN 2078 - Requirements for industrial gas installations
NEN 6770: 1997 - TGB 1990 – Steel structures – Basic requirements and basic rules
+ A1: 2001 for calculation of predominantly statically loaded structures
3 Terms and definitions

3.1 Safety

3.1.1
Group Risk (GR)
the yearly probability that a sizeable group of people will die in one occurrence as a result of some unusual event
relating to the pipeline.

3.1.2
Local Risk (PR)
the yearly probability that a person, continuously in a certain locality, will die as a result of some unusual event relating
to the pipeline

3.1.3
serviceability limit state
condition where the stated requirements are no longer satisfied in connection with the proper operation of the
construction

NOTE Examples of the serviceability limit state are the pipeline’s losing its rounded characteristic, the occurrence of annoying
vibrations or noise, leakage of substances which do not cause unacceptable damage.

3.1.4
ultimate limit state
condition where rupture or another form of failure in construction occurs because the maximum load bearing capacity is
exceeded

NOTE Examples of an ultimate limit state are the fracturing of the pipeline and/or leakage of substances which cause
unacceptable damage.

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 SI 5664 part 2 (Combined edition) (2006)

3.2 Engineering

3.2.1
yield strength
the highest or lowest limit of yielding (“yield strength”) can be understood as:

— the yield strength for 0.2 % permanent elasticity;

— the yield strength for 0.2 % disproportionate elasticity;

— the yield strength for 0.5 % total elasticity under load

NOTE 1 How the yield strength is defined and determined should be described in the material specifications.

NOTE 2 The specified minimum value of the yield strength (Re of Ra(θ)) is given in the material specifications. The calculation value
(Reb) is determined by dividing the specified minimum value by the material factor.

3.2.2
heat treatment
treatment whereby metal in a solid state is subjected to one or more temperature cycles

3.2.3
work piece
the pipe, the piece of pipe or (with local heat treatment) the area which is subjected to the heat treatment

NOTE A sample is considered to be a separate work piece, even when the heat treatment takes place together with the pipe, etc.

3.2.4
UO manufactured pipe
designation (sketch) of the method in which the pipeline is manufactured: a smooth plate is shaped into a “U” and then
made into a pipe

3.2.5
UOE manufactured pipe
same as UO manufactured pipe whereby the pipe is brought to the precise dimension by expansion

3.2.6
road
public structure for traffic and vehicles:

— primary road: road which forms a main connection for the passage of motor vehicle traffic throughout the nation
(primary road scheme);

— secondary road: road which forms a major connection for the passage of motor vehicle traffic regionally (secondary
road scheme);

— tertiary road: road which forms a major connection for the passage of intercity motor vehicle traffic;

— quaternary road: intercity road of lesser importance (such as agricultural roads and recreational roads);

— non plan -scheme road: for e.g. example, town and village roads usually used for mixed traffic between residential
areas and industrial areas. Also roads for the through going traffic, such as beltways, belong to this group

4 Symbols

4.1 Mechanical variables

A steel surface of the pipeline cross section mm2

De, Du external diameter of the pipe mm

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SI 5664 part 2 (Combined edition) (2006)

Dg average diameter of the pipe mm

Di internal diameter of the pipe mm
Do = De + 2 e external diameter, increased by the thickness of any possible coatings mm
d minimum wall thickness including manufacturing, corrosion and abrasion tolerances mm
dn chosen from a table of dimensions or applicable nominal wall thicknesses mm
d1 corrosion or abrasion additive mm
dmin minimum allowable wall thickness because of installation requirements (weld-ability, mm
manageability) dn > dmin
e thickness of the coatings (corrosion coating, concrete casing, possible marine mm
fouling)
l of lz moment of inertia with respect to the neutral line mm4
lp polar moment of inertia mm4
lw moment of inertia of the pipeline wall mm4/mm
lx moment of inertia with respect to a chosen line mm4
R bend radius mm
re external radius mm
rg average radius mm
ri internal radius mm
W section factor mm3
Ww section factor of the pipeline wall mm3/mm
z attenuation factor –

4.2 Material variables

E elasticity modulus of the pipeline material (20 °C) N/mm2

E(θ) elasticity modulus of the pipeline material at θ °C N/mm2
G sliding modulus N/mm2
Re specified minimum yield strength at 20 °C N/mm2
Re(a) actual measured yield strength N/mm2
Re(θ) Specified minimum yield strength at θ °C N/mm2
Reb value of Re of Re(θ) to be employed in the calculation N/mm2
Rm Specified minimum tensile strength at 20 °C N/mm2
Rm(a) actual measured tensile strength N/mm2
Rm(θ) guaranteed minimum value of the tensile strength at θ °C N/mm2
αg linear coefficient of expansion (averaged over the temperature incrase or decrease) mm/mm·K
ρ3 Specific weight per unit volume of the pipeline material kg/m3
ν Poisson’s ratio –
θ, θt temperature of the pipeline material °C

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 SI 5664 part 2 (Combined edition) (2006)

4.3 Processing variables

p internal overpressure MPa

pd design pressure (gauge pressure) MPa
pdv design pressure (gauge pressure) upstream of the pipeline system MPa
pinc internal overpressure (incidental) MPa
∆H difference in pressure MPa
v speed of flow of the medium m/s
K compression modulus of the medium N/m2
t temperature °C
dt, ∆t difference in temperature K
pv weight per unit volume of the medium kg/m3

4.4 Stress technical variables

σv resultant stress N/mm2

σx, σy, σz normal stress N/mm2
τ, τx, τy, τz shear stress N/mm2
σ 1 , σ2 , σ3 principal stresses N/mm2

4.5 Stochastic variables

α is the probabilistic coefficient of influence –

β is the reliability index –
µ is the average value of a stochastic variable –
σ is the standard deviation of a stochastic variable –
V is the coefficient of variation –
γM is the model factor –
γS Is the load factor –
γR is the material factor –

5 Abbreviations

LC Load combination
Global analyses (pipeline as a beam) Cross section analyses
E-E Elastic beam calculation – Elastic calculation

E-P Elastic beam calculation – Plastic calculation

P-P Plastic beam calculation – Plastic calculation

MAOP (MOP) Maximum Allowable Operating Pressure (MAOP according to ISO 13623); Maximum Operating
Pressure (MOP according to EN 1594). Both terms are equivalent

MIP Maximum allowable incidental pressure “Maximum Incidental Pressure”

6 Safety

6.1 General

The requirements for external (public) safety (safety of persons) with respect to the transport of natural gas are
presented in Chapter 6 of SI 5664-1. These requirements are fully applicable for steel natural gas
transmission pipeline systems.
The last sentence was deleted.

In this chapter, supplementary requirements are presented which are specific to on-shore steel pipelines.
Supplementary requirements for offshore pipelines are included in 11.2.

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SI 5664 part 2 (Combined edition) (2006)

6.2 Safety evaluation - External safety

The clause has been deleted.

6.3 Safety aspects in the development of a pipeline route and the design of the system

The following points shall be taken into consideration with steel pipelines:

— with regard to systems with operational temperatures that are higher that the installation temperature, the difference
in temperature shall be taken into consideration with the choice of route. A change in temperature (possibly
alternating) of the pipelines leads to expansion (whether hindered or not). Pipelines shall therefore be configured so
that stresses and deformations remain within allowable ranges;

— installation of the pipeline parallel to high voltage cables, railways, and tramways with electrical traction shall be
avoided or, if unavoidable, additional measures shall be undertaken to prevent detrimental effects from ground currents
and possible induction currents as per clause 6.4 . The last two sentences have been deleted.

6.4 Safety measures regarding Mutual influence of gas pipelines and (MV-HV-EHV) circuits

6.4.1 Terms and definitions

6.4.1.1 LV – Low voltage circuit (overhead lines and underground cables) /installation
a group of conductors and adjacent conductive structures for the distributrion
of electric energy with a nominal voltage of less than 1 kV AC and 1.5 kV DC.

6.4.1.2 MV – Medium voltage circuit (overhead lines and underground cables)

/installation
a group of conductors and adjacent conductive structures for the distributrion
of electric energy with a nominal voltage less than 52 kV AC.

6.4.1.3 HV – High voltage circuit (overhead lines and underground cables) /installation
a group of conductors and adjacent conductive structures for the transmissionn
of electric energy with a nominal voltage less than 245 kV AC (161 kV).

6.4.1.4 EHV – Extra high voltage circuit (overhead lines and underground cables)
/installation
a group of conductors and adjacent conductive structures for the transmissionn
of electric energy with a nominal voltage of more than 245 kV AC (400 kV).

6.4.2 Influence on pipelines by (MV-HV-EHV) circuits (see also Fig. 2A)

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 SI 5664 part 2 (Combined edition) (2006)

Figure 2A – Distance between pipe and electric installations

6.4.2.1 Close coordination between both MV-HV-EHV circuits and pipeline owners is
required.

6.4.2.2 The horizontal distance between the overhead phase conductor (without blowout)
and the pipeline shall be at least 15 m for Medium Voltage (MV) circuits, 25 m
for High voltage (HV) circuits, and 30 m for Extra High Voltage (EHV) circuits.

6.4.2.3 The abovementioned distances can be reduced if:

- close consultation and coordination between both MV-HV-EHV circuits and
pipeline owners is performed; and
- special calculations will be performed in order to avoid problems due to
induction currents and electricity interferences between the circuits and
pipelines.

6.4.2.4 The minimum distance between the pylon foundation and the pipeline shall be at
least 5 m for Medium Voltage circuits and 10 m for High and Extra High Voltage
circuits.

6.4.2.5 The abovementioned distances can be reduced if close consultation and

coordination between both MV-HV-EHV circuits and pipeline owners is performed.

6.4.2.6 The minimum distance between the earthing of pylon and the earthing of the
pipeline shall be at least 20 m.

6.4.2.7 To prevent ignitions of gas blow off, if relevant, the horizontal distance
between the pipeline blow off orifice (manual actuated vent), with diameter not
greater than 2", and the nearest insulator of the MV-HV-EHV circuits shall be
at least twice the vertical distance between them but not less than 35 m. In

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SI 5664 part 2 (Combined edition) (2006)

case of vent-stack greater than 2", a safety evaluation (QRA) shall be

performed.

6.4.2.8 The distance between the pipeline and MV-HV-EHV underground cables shall be at
least 1.5 m. This distance may be reduced to a minimum of 0.50 m if special
mechanical protection measures are taken to protect the electrical cable (i.e.
short sheet concrete partitions between the cables and the pipelines, cable
jackings or casings, pipelines and cables mounted in common corridors, etc.)

6.4.3 For other aspects about choice of route and pipeline alignment, refer to 8.1 of
SI 5664-1.

7 Structural Design – Strength analyses

7.1 General

The technical design of the pipeline shall minimally comply with the stipulations of 8.2 from SI 5664-1 and with the
supplementary requirements cited below.

SI 5664-1 gives a general description for reducing to an adequate level the probability of exceeding limit states.This
is further elaborated for structural design, along with the calculations required to verify the same.

Testing beforehand the wall thickness to be used in the calculations, with the stipulations of 7.2 and those in [1] and
[2], as per the information summarized in Appendix F.3.2.4, is recommended.

If a corrosion allowance is applied to the wall thickness, the influence of this on the strength calculation shall be
analyzed ( situation immediately after installation).

In doing the calculations, the selection of cross sections to be assessed shall take into account the most heavily loaded
points or pipeline sections.

NOTE In general, this involves the cross sections at bends and T-fittings, as well as cross sections in straight pipe
sections with the greatest bending moment (greatest curvature), the greatest support reactions, and/or greatest axial
forces (e.g., the axial compression force with “hot” pipelines).

7.2 Minimal nominal wall thickness

7.2.1 Minimal nominal wall thickness relative to handling during shipping and storage

The minimum nominal thickness of pipelines to meet requirements for handling (except
for cold bending) and transport, shall be equal to or greater than the dimensions given
in Table 1.

Table 1 - Wall thickness relative to handling during shipping and storage

Outside Diameter Nominal wall thickness

De dn
mm mm
219.1 4.5
273 4.8
323.9-406.4 5.2
508-599 5.6
610-914 6.4
965-1016 7.9
1067-1219 8.7
1321-1626 9.5
1727 11.9
1829-1930 12.7
2032 14.3

14
 SI 5664 part 2 (Combined edition) (2006)

7.2.2 Minimal nominal wall thickness relative to external force and corrosion

7.2.2.1 For pipes with nominal diameter up to 6", the minimum nominal wall thickness
shall be Sch. 80.

7.2.2.2 For pipes with nominal diameter 8" or more, 3 mm corrosion allowance shall be
applied. In any case, the nominal wall thickness shall be at least 9.52 mm
(3/8").

7.3 Wall thickness for T’s and other fittings

A separate wall thickness determination, relative to internal pressure, is required for Tees, fittings (elbows, adapters,
convex bottoms, etc.) and flanges. See EN 13480-3.

For Tees, or convex bottoms in gas pipelines with a maximum operating pressure greater than 16 bar, the calculation
method provided in EN 1594, Appendix L, or Appendix M may also be used.

7.4 Simplified calculation method

Based on the results of earlier research, for certain buried, drilled or jacked steel pipeline sections, it is sufficient
(except when assessing fatigue) to assess only the hoop stress from internal pressure. For various pipeline
configurations and crossings of less important public works, such research has been specified and grouped under the
so-called “simplified calculation method”. Appendix A deals with the simplified calculation method and the conditions
that have to be met.

If conditions do not allow the application of the simplified calculation method, an extensive strength calculation shall be
carried out in accordance with the stipulations of 7.5.2
The Note was deleted

7.5 Extensive strength calculation

7.5.1 General

If conditions do not allow for the application of the simplified calculation method , an extensive strength calculation shall
be carried out.

The representative values of loads, multiplied by the respective load factor γs given in, Table 2, shall be used in the
calculations.

7.5.2 Ultimate limit states

There is a distinction to be made between fundamental ultimate limit states and derived ultimate limit states.
Fundamental ultimate limit states are:

– tearing of a pipe wall;

– deformations;

– loss of equilibrium or stability of the pipeline or of the supporting structure;

– leakage from other causes then tearing of the pipe wall.

Checking these fundamental ultimate limit states can be done by checking the following derived ultimate limit states:

1) stresses: the limit state in which the calculated stress exceeds the calculation value for the resistance (of the pipe
material). When the stress limit state is exceeded, the pipe wall can tear open;

15
SI 5664 part 2 (Combined edition) (2006)

2) strain: the limit state in which the calculated strain exceeds the calculation value for the strain capacity . If this limit
state is exceeded, the pipeline wall can also tear open. When determining the calculation value for strain capacity, the
toughness of the pipe material shall be taken into account,as well as the factors influencing toughness, such as welds
and the associated welding imperfections;

3) deformation: the limit state manifested by excessive deformation of the pipeline cross-section, such as to much out
of roundness (ovalization), local buckling, flexural buckling, implosion and progressive plastic collapse. Even with such
deformation, there may not yet be a danger of a pipeline product spill, however locally, large strains may occur
exceeding the limit state of strain;

4) alternating yield: the limit state in which variations in the magnitude of load(s) cause strain variations in the steel to
such a degree that the steel becomes plastically deformed in more than one direction (+ and - );

5) fatigue: the limit state in which fatigue creates a rupture. This could be “high cycle” –fatigue or “low cycle” -fatigue.
”Low cycle” fatigue is sometimes also called, alternating yield;

6) resonance: the limit state in which the pipeline gets into its natural frequency (resonance), for example caused by
vortices past offshore pipelines in currents or by wind along above-ground pipelines, or by water hammer effects and
cavitation in specifically above-ground liquid pipelines;

7) displacements: the limit state in which the pipeline is subject to impermissible large displacements, (for example,
due to a longitudinal or cross current to an offshore pipeline on the sea bottom), and where the pipeline has no stable
position anymore;

8) dents and/or scratches: the limit state where local loads cause unacceptable damage to the pipeline wall, e.g.,
dents and/or scratches caused by excavation equipment.

9) leakage: the limit state in which leakage occurs, other than caused by tearing open of the pipewall (for example,
leaks caused by leaking couplings, corrosion, or damage by excavating equipment) giving rise to an unacceptable risk
to the environment or safety.

7.5.3 Serviceability limit states

Serviceability limit states to be taken into account are the following:

1) deformation: the limit state in which deformation is limiting the use of the pipeline. For example, the pipeline
shows to much out of roundness, so that pigs, measuring instruments and the like, can no longer pass through; the
development of large bending deformations and displacements (sea bottom), in so far no ultimate limit state has
yet been exceeded. Even minor folds which clearly do not threaten to violate a fundamental ultimate limit state,
could still make the pipeline unfit for use;

NOTE In general these kinds of large unacceptable deformations will occur in the plastic range (of the stress-
strain diagram). These are cases of excessive plastic deformation. However also situations can occur in which
excessive elastic deformations become a threat to safety.
Examples of this occur when moving parts which have some play (valves) are seized up, or when deformation
results, violating the tightness, due to the strain in non-prestressed bolts in flange connections.

2) vibrations and noise: the limit state in which vibrations might damage supporting structures and other contiguous
structures or people in the area. This can include the sound that is produced by the flow of the product to be
transported, compressors, etc.;

3) leakage: leakage other than that caused by rupture of the pipe wall, without causing unacceptable risk to the
environment or safety.

7.5.4 Loads and load combinations to be calculated

For the loads to be included in the calculations, see 8.2.7 of SI 5664-1.

16
 SI 5664 part 2 (Combined edition) (2006)

The load combinations to be assessed, and the load factors to be used in the same, are given in Table 2 (see also
8.2.8 of SI 5664-1).

In appendix D, Table D.1, more detailed information is given about the various load combinations.

7.5.5 Limit values and assessment

The results of the complete strength calculation for the relevant load combinations presented in Table 2, shall be tested
to their corresponding ultimate limit states and the associated limit values.

For the ultimate limit states presented in 7.5.2, the method of assessment and the limit values are given in appendix D.

As a serviceability limit state, the limit state of ovalization is especially important for the passing through of an
inspection apparatus. This also depends on the kind of inspection device used and differs per pipeline. As a rule of
thumb the allowable ovalization during operations can be kept on 5%.

NOTE In [16] a value of 6% is cited for the allowable deformation during operation .

7.5.6 Summary of limit states, load combinations and ultimate limit values

Table 3 gives an overview of the following:

- the limit states to be assessed

- the load combinations to include in the calculation

- possible calculation models

- limit values for every limit state.

17
SI 5664 part 2 (Combined edition) (2006)

Table 2 – Load combinations and load factors for ultimate limit states

a
Load factors for load combinations (LC)
Operational Phase

external pressure, external

static load, e.g., temperate

load and internal pressure

pressure and temperature
external load with internal

incidental load(other than

variable load (primarily
external load with zero

changes and pressure

only internal pressure,
Loads

operating pressure,
incidental pressure

internal pressure)
installation phase

internal pressure

difference

changes)
Load Combinations LC 1 LC 2 LC 3 LC 4 LC 5 LC 6 LC 7
Internal Pressure (Design Pressure) 1.25 - - - - 1.00
Internal Pressure (In combination with other loads) - 1.15 1.15 1.15 - -
Internal Pressure (Max. Incidental Pressure (MIP) 1.10 - - - - -
Temperature Differences 1.10 1.10 1.10 1.00
b
Soil Mechanical Parameters b b b
c
Forced Deformation 1.10 1.10 1.10 1.10
Traffic Load 1.35 1.35 1.35 1.10 0.50
Own Weight 1.10 1.10 1.10 1.10 1.10 1.00
Possible coatings 1.20 1.20 1.20 1.20 1.20 1.00
Weight Of fluid 1.10 1.10 1.10 1.10 1.10 1.00
d
Installation Load 1.10 1.10
External Water Pressure 1.10 1.10 1.10 1.10 1.10 1.00
Marine Growths (Offshore) 1.20 1.20 1.10 1.00
Current Load (Offshore) 1.10 1.20 1.20 1.10 1.10 1.00
a
If the load has a favorable influence on the limit state in question, it is not brought into the calculation, if it concerns a variable
load; when it is a permanent load, it is brought into the calculation with a load factor of 0.9.
b
For factors taking account for spatial variation of soil properties, and model factors to take into account when calculating soil
mechanical parameters, see Appendix B.4 of SI 5664-1.
c
Forced deformation can include the following: settling differences, uneven trench bottom, subsidence differences following
installation, deformation caused by impeded thermal expansion, deformation during horizontal directional drilling (HDD) and with
underwater steel pipe.
d
Examples of installation load are: load as a result of tensile forces on underwater pipelines, load during directional horizontal
drilling, pressure from pipe thrust jacking, and lifting forces from sidebooms, draglines and floating cranes.

18
 SI 5664 part 2 (Combined edition) (2006)

Table 3 – Overview limit states, load combinations and limit values

Load combination to be
assessed see Table 2

Material factors (γmi)

Possible calculation

Model factors (γMi)

Load factors (γgi,)
Limit states

Limit value
(resistance)
(reference article) models

Note’s
1,2,3,4
stresses (D.3.1) E-E Table 2 1,1 1,0 σv ≤ Re/γm
,5,6

including forced
stresses (D.3.1) 4,5 E-E Table 2 1,1 1,0 σv ≤ f(Re + Reθ)/γm
deformation
E-E;
Re ≤ 340 N/mm2 : ε ≤ 0,7 %
strain (D.3.2) 3,4,5 E-P Table 2 1,1 1,0
Re > 340 N/mm2 : ε ≤ 0,5 %
P-P
deformations (D.3.3):
E-E;
Use: ∆D ≤ 5 %
— ovalization (D.3.3.1) 1,3 E-P Table 2 1,1 1,0 ∆D ≤ 15 %
(recommended value)
P-P
2
dn ⎛ r' ⎞
ε cr = 0,25 − 0,0025 + 3000⎜⎜ ⎟ ⋅p⋅ p
⎟
E-E r' ⎝ Edn ⎠
— local buckling (D.3.3.2) 1,3,4 E-P Table 2 1,1 1,0
2
P-P dn ⎛ r' ⎞
ε cr = 0,10 + 3000⎜⎜ ⎟ ⋅p⋅ p
⎟
r' ⎝ Edn ⎠
E-E straight sections of hot
— buckling (D.3.3.3) γs ⋅N2
1,3,4,5 E-P Table 2 1,1 1,0 Q≥ f0 buried pipelines . See
P-P EI NEN 6770 (TGB Steel)
E-E
— implosion (D.3.3.4): 6 (offshore pipelines, deep drillings)
E-P

a) external pressure γ M ⋅ pc
1,3,6 1,05 1,45 0,93 γ g,p ⋅ pL ≤
(D.3.3.4.1) γ m,p

b) bending moment γ M ⋅ Mc
1,3,6 1,1 1,3 1,0 γ g,M ⋅ ML ≤
(D.3.3.4.2) γ m,M

n
ex. ⎛ ⎞
γ g,p ⋅ pL ⎜γ ⎟
c) external pressure + 1,05 1,25 g,M ⋅ M L
pres. +⎜ ⎟ ≤ γM
bending moment pc M
⎜ c ⎟
1,3,6 0,93 γ m,p ⎜ γ m,M ⎟
(D.3.3.4.3) ⎝ ⎠
ben- dn
1,55 1,15 n = 1 + 300
ding Dnom

⎡ 2⎤
Re (θ )
2
— progressive plastic failure E-E 1,1 3 ⎛ σy ⎞ R 3 ⎛σ ⎞
4 Table 2 εmax = α × ∆T ≤ ⎢ 1− ⎜⎜ ⎟ + e 0,9 − ⎜ y ⎟ ⎥
(D.3.3.5) E-P f1=0,95 ⎢ E 4 ⎝ Re (θ ) ⎟⎠ E 4 ⎜⎝ Re ⎟⎠ ⎥
⎢⎣ ⎥⎦

19
SI 5664 part 2 (Combined edition) (2006)

Table 3 (end)

Load combination to be
assessed see Table 2

Possible calculation

Material factors (γmi)

Model factors (γMi)

Limit states

Load factors (γgi,)

(reference article)

Limit value
models

Note’s
alternating yield (D.3.4) 5 E-E Table 2 1,1 1,0 σv ≤ f(Re + Reθ)/γm
1
fatigue (D.3.5): ∑ ni ≤
N i γ fat
a) elastic domain;
membrane-stress 5 1.0 high pressure pipelines
through internal pressure
5,15
γat= 10 ⎛R ⎞
a.1) seamless pipe 1,5 E-E ,, N = 5.3 × 10 3 ⎜⎜ m ⎟⎟
(γfat= 5) a ⎝ ∆σ ⎠
4,35
γfat= 10 ⎛R ⎞
a.2) welded pipe 1,5 E-E ,, N ≈ 700⎜ m ⎟
(γfat= 5) a ⎝ ∆σ ⎠
b) elastic and plastic 4
E-E ⎛ 5000 ⎞ elbows, T’s at high
domain; bending and 5
E-P
1,0 γfat= 10 N =⎜ ⎟
operating temperatures
peak stresses ⎝ ∆σ ⎠
system frequency
resonance/vortex shedding offshore
1,5 E Table 2 see[29] see[29] outside band of hammer
(D.3.6) pipelines
frequencies
large displacements(D.3.7) 1,5 E Table 2 see [29] see[29] See [29] See [29]
dents and/or scratches ‘Fitness for purpose’ calculations on the basis dents and/or scratches dimensions(see BS 7910)
a
If the actual operation is known with precision.

8 Construction Design – Miscellaneous

8.1 General

The remaining technical aspects of design which specifically cover steel as a pipeline material include:
- material requirements: the material specifications;
- requirements regarding connecting of pipeline elements: welding and flange connections;
- requirements regarding internal or external coating for protecting the material against corrosion and/or abrasion and
the application of cathodic protection in addition to the external coating.

8.2 Material specifications

The material specification requirements for pipeline components, as well as requirements related to approval of a
manufacturers production process for delivery of pipeline components according to specifications referred to in this
standard, have been stipulated in the model specifications in Appendix B.2.

20
 SI 5664 part 2 (Combined edition) (2006)

By pipeline components is meant: pipes, fittings, flanges, weldolets, split-Tees, repair shells, bolts and nuts.

For all materials that are to be used, the requirement applies that the steel shall be “fully killed”.

The pipe components shall have good weldability under field conditions.

8.2.1 Delivery, inspection and inspection documents

The general conditions for delivering steel and steel products in conformity with EN
10021: 1994 shall be applied.

In general, pipeline elements for use in gas pipeline systems shall be delivered with a
3.2 inspection report in accordance with EN 10204: 2004. At stations, pipeline elements
with diameter less than 10" can be delivered with a 3.1 inspection report in accordance
with EN 10204: 2004, althugh a 3.2 inspection report is preferred.

Bolts, nuts and gaskets shall be delivered with a 3.1 inspection report in accordance
with EN 10204: 2004.

An inspection report 3.2, means that approval has been granted by type A inspection –
independent certification institution – (in accordance with ISO/IEC 17020: 1998) that
is one of the following:

a) An inspection body, that is accredited (in accordance with ISO/IEC 17020: 1998) for
the relevant inspection procedures;
b) In the US: Inspection body that is widely recognized (like by the leading insurance
companies), for the relevant inspection procedures;
c) Authorized inspection agency for the relevant Standards;
d)Approved laboratory, according to the Israeli Standards Law.

An inspection report 3.1, means approval by the quality control department of the
factory which is accredited as a Type C inspection institution (in accordance with
ISO/IEC 17020: 1998).

Notes:
a) The inspection body will be qualified for the relevant Standards.
b) Lists of accredited institutions can be found on the internet.
c) All inspection institutions within the European Union should be acknowledged (non-
discrimination).
d) The certification of pipe components is in line with the Pressure Equipment Directive
(per member of the EU, there are lists of pressure equipment inspection institutions
available).
e) Station components (e.g., valves), when they are for pressures > 0.05 MPa, are under
the scope of the Pressure Equipment Directive, and shall be marked CE, or shall be
certified by the client’s inspectors.

8.2.2 (Line)Pipe

Examples of pipe specifications which satisfy the model specification, are specifications for welded and seamless pipe
with material in accordance with B.1, Table B.1, and the particulars of application given there.
Other steel grades than those mentioned in table B.1 can be used, provided their suitability can be demonstrated to the
user and/or an autonomous inspection body (see 8.2.1).

NOTE 1 It should be shown that steel to be used in H2S environments has sufficiently high resistance to rupture through high
stress in the presence of sulfides “Sulfide Stress Cracking,” and to rupture due to the presence of hydrogen “Hydrogen Induced
Cracking.”

NOTE 2 For information about corrosion resistant steel grades, see [30].

21
SI 5664 part 2 (Combined edition) (2006)

8.2.3 Induction bends

The same specifications as for pipe in 8.2.2, hold for induction bends. Induction bends shall moreover comply with
ISO 15590-1.

8.2.4 Fittings, flanges, bolts and nuts

8.2.4.1 General

Fittings shall comply with ISO 15590-2.

NOTE A standard is now in preparation for flanges [31].

8.2.4.2 Welded fittings

Welded fittings are subject to the same specifications as welded pipe in 8.2.2.

Manufacturing methods for welded fittings:

1) Tees, elbows (R < 3 De) or reducers made from a longitudinally welded pipe.
These fittings shall not be manufactured from pipe with a spiral weld seam.

2) Tees, elbows (R < 3 De) or reducers made from plate shells with at most two longitudinal welds, which shall be
placed diametrically opposite to each other.

Requirements for welded connection of fittings:

1) All weld filler material shall be approved by an accredited certification-institution, or:

2) the welding is carried out by a continuous electric resistance welding process and complies with the requirements
given in B.2.2 regarding welded fittings.

Repair of welded fittings:

a) Parent material
Exclusively repair by grinding
Plate or welded pipe which has been repaired by welding is not permitted for use in making welded fittings.

b) Welded seam
Repair by grinding.
Repair by welding shall be exclusively carried out before heat treatment and in accordance with a repair procedure
in consultation with the user.

If the dimensions deviate from those established in EN-, ISO-, ASTM-, API- or DIN-standards, stipulations shall be laid
down about verifying the dimensions and the relevant tolerances. Moreover, they shall minimally satisfy these
standards.

8.2.4.3 Seamless fittings

These fittings can be made in the following ways:

1) Tees, elbow (R < 3 De) or reducer made from seamless pipe;

2) Dished heads formed from steel plate.

In addition to the material specifications in 8.2.2, also seamless fittings which conform to the following specifications
and supplementary requirements, comply with the model specification ( refer to B.2).

22
 SI 5664 part 2 (Combined edition) (2006)

- ASTM A234/A234M Gr. WPB [a],[b];

- ASTM A420/A420M Gr. WPL6 [b];

In square brackets are the supplementary requirements to the specifications, described in 8.2.5.
Repair of fittings shall excusively be done by grinding.
Pipe which has been repaired by welding shall not be used to make fittings.

8.2.4.4 Forgings

Examples of specifications which, once the supplementary requirements are fulfilled, comply with the model
specification include:

– ASTM A 105/A 105M[a], [b];

– ASTM A 182;

– ASTM A216 M Gr. WCB/WCC [a], [b];

– ASTM A350/A350 M Gr. LF2 [b];

– ASTM A352 Gr. LCC [a], [b];

– ASTM A487 Gr. 1B/1C [a], [b];

– MSS-SP-75.

In square brackets are the supplementary requirements to the specifications, described in 8.2.5.

Material specifications for forgings not referred to in this standard, shall satisfy the requirements of the model
specification in accordance with B.2.2.

8.2.4.5 Cast fittings

Examples of specifications which, once the supplementary requirements are fulfilled, comply with the model
specification, include:

– ASTM A216/A216M-93;

– ASTM A216 Gr. WCB [a],[b];

– ASTM A216 Gr. WCC [a],[b];

– ASTM A352/A 4352M-93;

– ASTM A352 Gr. WCB [b];

– ASTM A352 Gr. WCC [b].

In square brackets are the supplementary requirements to the specifications described in 8.2.5.

8.2.4.6 Bolts and nuts

Examples of material specifications which, once the supplementary requirements are fulfilled, comply with the model
specifications are given in Table B.3.

23
SI 5664 part 2 (Combined edition) (2006)

8.2.5 Supplementary requirements to the specifications for pipe, fittings, flanges, bolts and nuts

8.2.5.1 Supplementary requirements relative to (Charpy V) notch-impact values [a]

For components that have a diameter greater than or equal to 150 mm, or bolts with a greater diameter than 25.4 mm
(1 inch) the following minimum values shall be met:

- for fittings and components made from steel with a specified minimum yield strength up to 360 N/mm2; average 27
Joule with the minimum individual value of 18.9 Joule;

- for fittings and components made from steel with a specified minimum yield strength above 360 N/mm2; average 40
Joule with the minimum individual value of 28 Joule.

The temperature θt at which the notch-impact test shall be carried out, depends upon the lowest possible material
temperature θc and the plate thickness dc, determined in accordance with B.1.3. The following formula holds:

θc = θmin + ∆θ1 + 15 K

where:

θmin is the lowest temperature to be brought into the formula, at normal operating conditions;

∆θ1 is the temperature change caused by pressure expansion (for example caused by failure of cryogenic lines).

8.2.5.2 Supplementary requirements relative to chemical analysis (cast analysis) [b]

For fittings and components made from steel with a specified minimum yield strength:

- up to 360 N/mm2 the following requirement holds: [Ceq] = maximum 0.45 (IIW-formula);

- above 360 N/mm2 the following requirement holds: [Ceq] = maximum 0.48 (IIW-formula);

Furthermore, the carbon content of the steel used shall not be more than 0.23%. The sulfur content shall lie below
0.030% and the phosphorus content below 0.035%. The sum of the sulfur and phosphorus content shall not amount to
more than 0.050% in accordance with the cast analysis.

If pipe material is being used as parent material for making fittings, then the mechanical and chemical values shall
satisfy the requirements for pipe material contained in this standard.

8.2.5.3 Ratio yield strength to tensile strength

The ratio of the yield strength to the tensile strength as measured from the tensile test of the base material of the pipe
shall not exceed 0.90.

8.2.5.4 Determination of notch-impact values of gas pipelines

As an alternative to using the values given in the tables of EN 10208-1 and EN 10208-2, it is also permitted to use
the following formulae to determine the notch-impact requirements for the pipe at 0 °C (average of three tests):

For pipe material with a yield point up to and including 450 N/mm2:

CV = 3,05 ⋅ 10 −4 ⋅ σ p1,5 ⋅ De0,5

For pipe material with a yield point up to and including 450 N/mm2

CV = 3,573 ⋅ 10 −5 σ p2 ⋅ (0,5 ⋅ De ⋅ d n )
13

24
 SI 5664 part 2 (Combined edition) (2006)

where

σp is the circumferential membrane stress as a result of the design pressure.

8.2.5.5 Take-off inspection

Mechanical testing shall take place in delivery condition. If mechanical properties are established by testing a piece of
test plate, then this test plate shall have undergone a heat treatment equivalent to that of the pipe segments. For
interest of checking mechanical properties pipeline segments can be grouped into identical groups. Identical groups
consist of materials, manufactured from the same cast of steel and being subject to the same heat treatment.

All pipes ready for shipping shall undergo complete and effective non-destructive testing.

NOTE: Pipe materials ordered in conformity with EN 10208-2, ISO 3183-2 and ISO 3183-3, are in compliance with the
requirement above.

8.2.5.6 Identifying markings

All pipe components shall be marked in such a way that inspection documents, components and casts can be related
to one another.

All pipe components shall be die stamped as follows:

- name or logo of the manufacturer;

- unique identification or series number;

- stamp of the inspection-institution;

- further identification that might be required on instructions of the client.

NOTE Pipe materials ordered in conformity with EN 10208-1, EN 10208-2, ISO 3183-2 and ISO 3183-3, are in compliance
with the requirement above.

For small items manufactured in a series (e.g., bolts and nuts), a mark, applied to the item may substitute for a 3.1.B
inspection report, provided all of the following conditions are satisfied:

- the stamp marks the article in an unambiguous way;

- the stamp shall be permanent and be indelibly applied to each article.

When a mark is used to substitute for an inspection document, then the inspection document reference stamps are no
longer necessary.

The stamping of bolts and nuts shall also comply with B.2.3.6.

8.2.6 Valves

8.2.6.1 Valves shall conform to the requirements of ISO 14313: 1999 (identical to API
6D: 1994).

8.2.6.2 Valves, including control valves, with minimum body welds, are preferred.

8.3 Connections

8.3.1 General

Connections between segments of a pipeline system can be realized by:

25
SI 5664 part 2 (Combined edition) (2006)

– welding: a butt weld between two segments makes a flexure resistant connection
equivalent in strength to the pipeline segment itself.

– mechanical connections: this includes "weld neck" flange connections only.

For more on welding, see 9.4.

8.3.2 Flange connections

Dimensions and boring patterns of all flanges shall comply with the relevant standards, and may only be applied,
relative to operating temperatures and concomitant permissible operating pressures, when in agreement with the
requirements cited in those standards. RTJ flange connections are preferred. Other flange types
can be used if suitable tightening procedures are applied.

– EN 1092-1, EN 1591-1, ENV 1591-2, EN 12560-1, -2, -3, -4;

– ISO 7005-1;

– ANSI/ASME B16-5 (for Iron and Steel);

– DIN 2686; DIN 2629; DIN 2638;

– MSS SP 44

Flanges which do not comply with the above-cited standards shall be calculated separately.

The calculation can be carried out in accordance with EN 1591-1:2001 (see also CR 13642:1999) or the
ANSI/ASME boiler and Pressure Vessel Code, Section VIII, Division 1, including the next supplement for forces from
connecting parts.

If an external axial force (Fe) and/or an external bending moment (Me) acts upon the flange connection, the force from
the adjoining cylindrical part (for example, the pipeline) on the flange connection shall be increased by:

Fe + 4 Me/Dg

where:

Dg is the diameter of the effective circumferential seal.

8.3.2.1 Bolts and nuts

Bolts and nuts shall comply with ISO 898-1 and ISO 898-2 or ANSI/ASME B 16.5 or an equivalent standard. The
nuts shall be so threaded upon the bolts or threaded ends that the thread protrudes beyond the nut. To prevent the
stripping of the internal thread, the quality of the nuts shall match the quality of the bolts.

The yield strength of the material of the nut may be lower than that of the bolts, but shall be at least 0.6 times the yield
strength of the bolt. Wherever vibrations may occur, the nuts shall be effectively held in place. For material
specifications, see 8.2.2.

8.3.2.2 Gaskets

Gasket material shall not be affected by the fluid to be transported and shall be capable of withstanding operating
temperature and pressure.

Gaskets shall be designed in coherence with the flange design. Gaskets which follow EN 1591-2,
ANSI/ASME B16.20, ANSI/ASME B16.21 can be applied.

26
 SI 5664 part 2 (Combined edition) (2006)

Gaskets which contain asbestos are not acceptable.

8.4 Coating

8.4.1 General

Internal corrosion of pipelines can result from the corrosiveness of- and abrasion by the fluid

Measures against internal corrosion can include the application of an internal coating, adding inhibitors to the product
or a combination of the two.

It is also possible to add a corrosion allowance tothe wall thickness, in case the processes and rates of corrosion are
known. Eventually a different material more resistant to corrosion than unalloyed or alloyed steel, may be selected,.

Internal linings, decreasing the friction between the pipeline wall and the fluid, may be applied to transport the fluid with
reduced loss of pressure.

Above-ground pipelines may be subject to external corrosion from the atmosphere. Protection against this can be
provided by an effective protective coating.

Underground pipelines may suffer external corrosion in moist soil by the formation of electro-chemical cells at the the
steel /soil interface, the presence of stray DC current in the soil or in the influence of high-voltage alternating current.

Protection against these possible causes of corrosion can be obtained by applying an external coating (passive
protection) and cathodic protection, including a managed grounding of stray currents (active protection).

8.4.2 Internal and external coatings

8.4.2.1 Internal coatings

Materials which can be factory-applied against internal corrosion are:

– mortar cement for steel pipe and fittings in accordance with prEN 10298:2002;

– epoxy resins with polyamide top layer (two layer system) as per EN 10310:2003;

– a line has been deleted.

– an internal coating with corrosion resistant steel (Clad steel).

Also applied, although to a lesser extent, PTFE, PUR and polyamides.

Tested and accepted methods of application shall be available for all materials. Untested and uncertified materials
shall not be used.

Internal finishing of girder welds after welding is necessary, unless additional inhibitors are used to further protect these
uncoated steel surfaces against corrosion.

For internal pipeline linings to lower frictional resistance for non-corrosive gases, the standards of EN 10301 or
ISO 15741 can be used.

The use of inhibitors

If corrosion inhibitors are used, this shall be taken into account when designing the pipeline. Equipment shall be
installed for detecting any corrosion process which may occur.

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SI 5664 part 2 (Combined edition) (2006)

The choice of inhibitor shall be such that there will be no adverse effects from its coming into contact with any segment
of the pipeline.

An adequate number of corrosion samples, or other means through which the corrosion process can be monitored,
shall be installed at appropriate locations, in such a way that they do not interfere with pigging operations .

8.4.2.2 External coating

8.4.2.2.1 External coating of above-ground pipelines

Above-ground pipelines can be protected against external corrosion by using a suitable coating system.

Any paint system to be used shall have adequate mechanical strength, adequate resistance to atmospheric influences,
and adequate resistance to ultraviolet radiation.

In selecting a coating system, the expected maximum temperature of the fluid shall be taken into account, as well as
any condensation that might form on the outside surface as a result of a relatively low fluid temperature.

8.4.2.2.2 External coating of underground pipelines

External coatings for underground application shall have good mechanical and electrical properties relative to the pipe
diameter, environment (soil type) and operation conditions. In selecting a coating system, the expected maximum
temperature of the fluid shall be taken into account.

The coating shall adhere well to the steel. A careful pre-treatment of the steel up to SA 2.5 according to EN-ISO 8501-
1 and the application of the coating under controlled conditions are essential in obtaining a good coating system.
The coating shall have adequate resistance against disbonding adjacent to areas of coating damage Therefore.
factory-applied coatings are preferred for all pipeline components,.

Criteria for mechanical and electrical properties, for adhesion and resistance against disbonding, and for temperature-
related applications, are given for various coatings in the following standards:

– SII 266 Part 5.2, triple-layer system with extruded polyethylene as a top layer;

– SII 266 Part 5.2, triple-layer system with extruded polypropylene as a top layer;

– SII 266 Part 5.2, single, double or triple-layer system with molten polyethylene as a top layer;

– A line has been deleted.

– EN 10289, coating system with epoxy or modified epoxy material;

– EN 10290, coating system with polyurethane or modified polyurethane material;

– prEN 10309, coating system with epoxy powder.

8.4.2.2.3 Coating applications in the field

Field application of coatings (such as when finishing girder welds) shall, as much as possible, occur under controlled
conditions.

For choice of materials and their application, see 9.5.

8.4.3 Cathodic protection

8.4.3.1 Pipelines

Damage to the coating can cause local corrosion of the pipeline.

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 SI 5664 part 2 (Combined edition) (2006)

This corrosion can be of a general nature, but there is also a risk of highly localized corrosion, (e.g., pit corrosion).
Therefore, in addition to applying the coating, it is generally necessary to employ cathodic protection (C.P.). Only in
exceptional cases, as defined in ISO 155819-1:2003, can C.P. be omitted.

Cathodic protection can be achieved by using sacrificial anodes or by impressed current. Design and installation of the
C.P. system for underground pipelines shall be in accordance with EN 12954 and/or ISO 15589-1:2003.

The C.P. system shall be in operation as soon as possible after the installation of the underground pipeline. If this is
not possible, the temporary use of sacrificial anodes is recommended, in particular in areas of aggressive soil
conditions.

In areas with stray currents in the soil or high voltage alternating current present, adequate measures shall be taken to
ensure the proper functioning of the cathodic protection system. In order to determine the mutual interference of
pipelines and high-voltage lines, and measures which can be taken, see clause 6.4.

Application of cathodic protection to pipeline systems can give rise to adverse effects on other underground metal
structures; similarly, the C.P. system may be adversely affected by third-party current sources. In the case of mutual
influence (interference) the procedures to be followed are described in EN 50162.

The cathodic protection of pipelines shall be continuously maintained, in accordance with the procedures described in
EN 12954.

8.4.3.2 Casing and cathodic protection

In the interests of effective cathodic protection the use of casing pipes at crossings shall be limited as much as
possible. Possible casing materials are steel, concrete, or plastic (HPE, PVC, GVK).

If steel casing is used, it should preferably be uncoated, and steps should be taken to prevent metallic contact between
the carrier pipe and the casing.

The ends of the casing shall be tightly sealed.

If an casing pipe of an isolating material is to be used, supplementary measures shall be taken to ensure cathodic
protection within the casing in orderto protect the fluid carrying pipeline. See 9.7 for a practical implementation of such
measures.

NOTE An uncoated steel pipeline casing does not interfere with the cathodic protection of the fluid carrying pipe . If the soil is too
aggressive, the casing can be coated externally and grounded. The uncoated inside of the casing then functions as an anode. The
protective current reaches the (steel) fluid carrying pipe ,via the grounding and the casing pipe.

8.5 Stations

8.5.1 Supports for above-ground pipelines

Supports and/or superstructure for pipelines shall not be welded directly to the pipeline if the hoop stress resulting from
the design pressure is higher than 0.5 Re. For such supports shells and/or brackets can be used which are put around
the pipeline and for example, fastened with bolts.

If the pipeline is to be anchored, the anchor force shall come to bear on the shell which grips the pipeline. In that case,
the shell can be welded to the pipeline with one single completely circumferential weld.

The note has been deleted.

8.5.2 Pipelines in stations

The minimum wall thickness of pipeline sections shall comply with the requirements of 7.2. The partia load factor
when calculating the load case of internal pressure only (load combination 2 in accordance with Table 2) is 1.5/1.1.

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SI 5664 part 2 (Combined edition) (2006)

9 Construction

9.1. General

In addition to the general construction acitivities, described in Chapter 9 of SI 5664-1, a number of specific
construction activities are required for the installation of a steel pipeline. These are described hereafter for on-shore
pipelines. Refer to Chapter 11 for offshore pipelines.

9.2 Transport and storage

In addition to the note in 9.4 of SI 5664 -1, the following points apply for steel pipelines:

— when using an electromagnet, take note of residual magnetism related to electrical welding;

— for transport see API RP 5L1 and API RP 5LW.

9.3 Bending of pipes

9.3.1 General

Changes in horizontal pipeline alignment and level differences in the vertical plane can be obtained by using elastically
or plastically bent bends.

In those cases where the pipeline cannot follow the changes along the route through elastic bending , cold-formed
bends (9.3.3) or hot-formed bends (9.3.4) are applied.

It is recommended to select the bending radius for smooth bends sufficiently large (R ≥ 3 D) to allow for pigging the
pipeline.

9.3.2 Elastic bends

The minimum allowable bend radius shall be specified in the structural design.

9.3.3 Cold-formed bends

The minimum allowable bend radius for cold field bending of bends,made from the pipe material (unalloyed or low-
alloyed steel), specified for the straight pipes, equals:

— 20 x D for pipes with a nominal diameter D of 200 mm or less;

— 30 x D for pipes with a nominal diameter D of 200 mm up to 400 mm;

— 40 x D for pipes with a nominal diameter D of 400 mm or more.

NOTE 1 Other dimensions may be applicable for high-alloyed types of steel.

The bending process shall not damage the pipe coating. If, after the cold-bending, small cracks occur in the pipe
coating, they shall be repaired. The difference between the maximum and minimum value of the outside diameter in
any cross-section of the bend shall not exceed 2.5 % of the pipe nominal outside diameter.

If wrinkling occurs , the allowable wrinkle depth amounts 0.01 times the distance between 2 successive peaks.

If necessary, a gauging plate made of soft metal can be pulled through the bend to check compliance with above
requirements. Other methods can be applied. The dimensions of the gauging plate are determined by the properties of
the pipe and allowable tolerances.

A bending test shall be conducted prior to commencement of the bending activities. The manufacturing procedures

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 SI 5664 part 2 (Combined edition) (2006)

shall form a part of an integral quality system according to SI-ISO 9001:2000.

When present, a longitudinal weld seam in the bend shall nearly coincide with the neutral axis of the bend during
bending.

No circumferential welds shall be present in the bending area . There shall be a straight length of pipe measuring at
least one pipe diameter on each end of the bend, with a minimum of 0.5 meter. If necessary, a mandrel can be used.

Spirally welded pipes may be cold formed.

The increase in hardness of the pipeline material as a result of the bending process shall not exceed 50 % of the
original hardness and the notch impact value shall satisfy the requirements from 8.2.5.1.

Certain fluids can give a lower limit (for example, the HIC-requirement).

NOTE 2 For diameters over 300 mm and for diameter / wall thickness ratios greater than 70:1, the use of a mandrel is
recommended.

9.3.4 Hot-formed bends

Hot-formed bends can be manufactured from straight pipes by means of inductive heating. No heat treatment is
necessary insofar as this method is applied with unalloyed or low-alloyed steel with [Mo] < 0.65 %. Hot-formed bends
shall be supplied in conformity with ISO 15590-1:2001.

If other methods are applied, heat treatment following the bending of the pipes is required.

NOTE If a hot-formed bend has to be made from line pipe, this should be specified to the pipe manufacturer at the time of
ordering so that they can take this into account when selectiing the (chemical) composition of the pipe material and the welding filler
material.
When making hot-formed bends in cold-formed (expanded) pipes or pipeline sections which have undergone heat treatment, due
account shall be taken of the possible change in material properties in comparison to the original pipe (also see 9.4.2).
It is recommended to determine per cast, diameter, wall thickness and bend radius, through mechanical testing, that the bends
comply with the applicable material specifications (Appendix B). It is customary that a representative bend or an (additional) section
of a bend of adequate length be manufactured during the production process and that 10% of the bends be tested.
The outside of the pipe may be (grit) blasted and can be protected against the formation of rust by an undercoat (“primer”).

9.3.5 Bends manufactured from half shells

Small radius bends can be manufactured through the welding of two half shells. These shells are manufactured from
material specified in EN 10113-2:1993.

9.3.6 Miter bends

Miter bends (also called segment or joint bends) are manufactured by cutting through a pipe at an angle, rotating one
section and welding the sections back together again.

This type of bend shall not be used.

9.4 (Field) weld connections, examination of welds and acceptance criteria

9.4.1 General

Weld connections in pipelines made of Iow-alloyed carbon steel in conformity with material groups 1 to 3, inclusive, of
ISO 15614-1:2004 shall be made according to EN 12732:2000 and the supplementary stipulations according to
C.1 and C.2.

NOTE For pipe material grades outside the scope of these material groups, agreements have to be made on a project-by-
project basis, given the specific properties of the materials (e.g. Duplex, X-80, 13Cr)

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SI 5664 part 2 (Combined edition) (2006)

For preparation of weld seams and construction details, refer to lSO 9692:1992 and EN 1708-1:1999+ A1:2003.

For weld connections in pre-manufactured insulated bonded pipe systems for the transport of hot water (district
heating), EN 13941:2003 is applicable .

9.4.2 Heat treatment

Following the welding of steel, heat treatment may be necessary.

Heat treatment of longitudinal welds shall take place according to the product standard or material standard. In case
those standards do not include requirements on this , the requirements according to C.3,.shall be followed.

9.4.3 Welding filler materials

All filler materials shall be approved by an independent inspection institution

(see 8.2.1).

9.4.4 Non-destructive testing and acceptance criteria

Non-destructive testing of welds (NDT) shall be done in accordance with EN 12732:2000 and the additional
requirements stated in C.1.2.

Guidelines for the determination of acceptance criteria for NDT techniques are presented in C.2.1.

For weld testing, conducted with TOFD (“Time Of Flight Diffraction”) techniques, the acceptance criteria is stated in
C.2.2.

9.5 Coating of field welds

9.5.1 Types of coating

Field coatings shall be applied, dependent on the type, according to the standards mentioned in 8.4.2.2.2, according to
the specifications of the coating supplier or the designer. Field applied coatings shall be compatible with the factory
coating and have sufficient overlap with it. The last three words hae been deleted.

For weld connections in pipeline sections which are constructed, using boring, jacking, or horizontal drilling
techniques, it is permissible, in addition to the relevant standards, that a fiberglass-reinforced epoxy coating or a
shrinkable sleeve specially developed for this purpose (fiberglass-reinforced heat shrinking coating) be applied. The
requirements of the supplier shall be satisfied for the application of this coating. The coating shall be able to resist the
shearing forces occurring during drilling or jacking. The functionality of the coating shall not be affected as a result of
the drilling or jacking.

For requirements with respect to the pre-treatment of the welded pipe sections and coating control, refer to the
standards mentioned in 8.4.2.2.2. For requirements with respect to wrapping tapes and heat shrinkable sleeves, refer
to EN 12068:1998.

NOTE The application of heat shrinkable sleeves for drilling is not advised because of the possibility of sliding (tearing) off.

9.5.2 Preparation

The sections that are to be coated, including the required overlap shall be dry and free of grease and dust/dirt and at a
temperature above the freezing point. Further preparations shall take place in conformity with the factory specifications
for relevant types of coating.

9.5.3 Application, control and repair

The application of the field coating shall be performed by qualified personnel who are thoroughly instructed and are
equipped with all tools, materials and equipment necessary to be able to perform their tasks properly. Repairs to and

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 SI 5664 part 2 (Combined edition) (2006)

replacements of damaged factory coating shall be performed according to the applicable standards (see 9.5.1).

Connection points for cathodic protection shall be protected with a coating that is compatible with the original coating.

The coating control (spark test) shall take place (once again) over the entire length of the pipe immediately after the
pipeline has been lifted from the temporary supports. If necessary, any damage shall be repaired. The repair coating
shall be compatible with the original coating and shall have comparable properties. Each repair shall be spark tested.

NOTE It is recommended that the coating be checked for density following the filling and compaction of the trench through an
aboveground coating integrity test.

9.5.4 Other

It is possible that a special pipeline coating has to be applied for additional resistance against external damage (e.g. in
rocky areas) or with a weight coating against buoyancy (e.g. in peat areas and marshes). This shall be specified in the
design.

A sentence has been deleted.

NOTE The design may also prescribe local measures against buoyancy such as: anchor rods with one auger blade, concrete
saddles, sandbags or clay-filled bags with or without geo-textile or an equivalent.

9.6 Trenchless techniques for steel pipelines

In principle, all trenchless technique ,discussed in Appendix G of NEN 3550-1:2003 can be utilized with steel pipelines.

A boring employed according to the “impact ramming” (PBT) technique (with a bare steel casing or with a fluid carrying
steel pipe coated with sintered PE) is not controllable. For pipelines with a small diameter, the risk arises that the
pipeline leaves the projected direction.

Horizontal directional drillings (HDD’s) are very feasible with steel pipelines.

9.7 Cathodically-protected pipeline in a casing

9.7.1 General

This paragraph applies to the insertion of steel pipelines into casings where the length of the material of the casing
forms an obstruction for the cathodic protection currents and as a consequence produces an additional risk.

9.7.2 Diameter casing

It is important to select a large (oversized) casing diameter whenconstructing a new crossing in order to ensure the
following:

— the simple insertion of the pipeline;

— adequate space for the subsequent application of anode ribbons;

— the subsidence and settlement differences between the casing and the fluid carrying pipeline can be better
absorbed;

— the replacement of an existing pipeline with a new one is simpler.

9.7.3 Insertion of the pipeline

9.7.3.1 General

The interior of the casing shall be cleaned before the fluid carrying pipeline is brought into position. The insertion of the
pipeline shall be done in such a way that the coating is not damaged and the thinsulators (spacers) are not moved.
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SI 5664 part 2 (Combined edition) (2006)

The casing end seals shall be positioned at the ends of the casing, immediately after the positioning of the fluid-
carrying pipeline.

9.7.3.2 Soil subsidence / soil settlements

When positioning the carrier pipe in the casing pipe, possible differences in settlement of the surrounding soil with
respect to the casing shall be taken into account. If a geotechnical investigation indicates that the casing will settle
more quickly than the surrounding soil, the pipeline shall be situated on the bottom of the casing pipe. In case it
appears that the casing will stay back with respect to the surrounding soil, the carrier pipe shall be situated against the
inner top side of the casing pipe (see figure 3).

9.7.3.3 Positioning of thinsulators (spacers)

The positioning of the thinsulators shall be done such that the carrier pipe remains free from the casing pipe
permanently. In order to absorb settlement of the surrounding soil it is advisable to place additional thinsulators at the
ends of the casing pipe.

The following aspects shall as well be taken into account when selecting the thinsulator type :

— electrically isolating (made entirely of plastic materials, without any metal components);

— absorption of the forces which occur during the insertion into the casing;

— weight of the fluid to be transported and pipe weight;

— diameter of the casing:

— type of pipeline coating,

9.7.3.4 Filling a casing with corrosion-inhibiting material

In order to minimize the risk of penetration of groundwater into a casing pipe, the annular space between the casing
and the pipeline shall be filled with material that will continuously protect the pipeline against corrosion over a long
period of time (see figure 3). If a casing is filled with corrosion-inhibiting material, it is no longer necessary to apply
anode ribbons in the casing. Before the corrosion-inhibiting material is applied, the casing pipe shall be free of water. It
shall be demonstrated through measurements and calculations that the filling of the (annular space by) corrosion-
inhibiting material is such that the pipeline is completely encased by the corrosion-inhibiting material..

pipeline
thinsulator

fill
casing

Figure 3 — Pipeline in casing with filling

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 SI 5664 part 2 (Combined edition) (2006)

9.7.3.5 Application of anode ribbons

Situations may occur where there is no possibility of applying corrosion-inhibiting material into the casing. In such
cases, the pipeline shall be protected with anode ribbons. When the steel (carrier) pipeline is being inserted it is
recommended to connect perforated auxiliary guide pipes (Ø 30 mm) to it, for easy insertion of new anode ribbons in
the future. (see figure 4). Plastic-coated steel cables (minimum Ø 2 mm) shall be placed in the auxiliary guide pipes.

The number of anode ribbons to be applied depends on:

— the pipe diameter:

— the length of the pipeline in the casing;

— the capacity of the anode ribbon;

— environmental conditions in the casing (acid degree of the groundwater in the annular space);

— ability of the rubber end-seals to remain waterproof, even with axial or radial movement of the fluid carrying pipe
relative to the casing pipe.

Perforated Anode ribbon in

auxiliary perforated
guide pipe guide pipe

Figure 4 — Pipeline in casing with additional guide pipes for anode ribbon

The guide pipes shall be mounted on the plastic thinsulators. In addition, the rubber end-seals shall be mounted free of
tension. This shall be installed in such a way that the soil load has as little influence as possible (S-form). The isolation
sleeve of the cathodic protection cable should not be removed to such an extent that the non-insulated cable sticks out
of the rubber seals.

9.8 Pressure testing

9.8.1 General

Pressure testing shall be conducted as indicated in 9.9 of SI 5664-1. In addition to

this, the requirements given in this chapter and up to 9.8.5 shall be met.

In the case of buried pipelines, testing is generally carried out after the pipeline
has been buried.

Some transport pipelines may be too long to permit testing of the entire pipeline. In
this case, the pipeline is tested in sections. The subsequent joints made between these
sections (girth welds, flanges) are not usually subjected to testing and the quality of
these joints is evaluated after visual and nondestructive examination.

Testing may take one of two forms, depending on whether it is possible to make a visual
examination during the test. Either:

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SI 5664 part 2 (Combined edition) (2006)

- no visual examination of the pipeline or pipeline section is possible during testing

(see 9.8.1.1); or
- visual inspection is possible throughout testing (see 9.8.1.2).

If the test reveals a leak or the presence of some other defect, this must be repaired.
After repair, the test must be repeated to demonstrate that the repair has been
effective.

The pipeline is approved if any pressure rises or falls occurring during the test can
be satisfactorily explained in terms of temperature variations, variations in air
pressure or other physical phenomena taking place during the test.

With regard to the equipment, joints and other ancillaries connected to the pipeline
section under test, the materials, dimensions and method of attachment must be capable
of withstanding the test pressure.

A test procedure and a test schedule must be drawn up for each test.

9.8.1.1 Testing of pipelines which do not permit full visual examination

Testing is generally carried out on the pipeline after the trench has been backfilled,
pipeline sections which are difficult or impossible to reach after installation
(sections constructed by directional horizontal drilling, prefabricated waterway
crossings, etc.) are also tested before installation.

The test procedure must cover the following aspects, as a minimum:

a) The pressure prevailing in the pipeline during temperature equalization,

stabilization, strength testing and tightness testing and the duration of these
tests:
- Temperature equalization
'temperature equalization' is understood as the equalization of the temperature of
the liquid in the pipeline and that of the soil surrounding the pipeline. Depending
on the difference in initial temperatures, the pipeline diameter and the insulation
applied to the pipeline may take several weeks. If the temperature equalization is
not possible, for example where the pipeline incorporates thermal insulation, this
must be taken into account in the procedure.

- Stabilization
'stabilization' is understood as the absorption by water of the air which is
present in the pipeline. A pressure in excess of around 50 bar is needed to ensure
that the water takes up all the air. Therefore, transport pipelines with a test
pressure below this value cannot be fully stabilized.
Stabilization is only possible if the tansport pipeline has no side branches and a
filler plug is used when filling the pipeline to reduce the volume of entrapped air
to a minimum.
- In the case of transport pipelines which do not satisfy these requirements, such as
those forming part of district heating systems, the welds are subjected to air
pressure or vacuum heating to check for tightness before the welds are coated and
before the strength test is carried out. The strength test is carried out after the
welds have been coated and the trench has been backfilled. Depending on the volume,
stabilization may take several days.
To monitor the pressure during the test, at least two pressure measuring devices
shall be installed, one at each end of the pipe.

b) The pressure gauge shall be with a measurement accuracy of at least 0.1% and read-out
accuracy of at least 0.05 bar.

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 SI 5664 part 2 (Combined edition) (2006)

9.8.1.2 Testing of pipelines which permit full visual examination

For transmission pipelines or part of, which permit full visual examination during
testing, the following requirements also apply:
a) The welds under test must not be covered with nonmetallic coatings, such as paint,
insulation, etc. either internally or externally.

b) The external surface of the welds under test must by dry, clean and grease-free.

c) The pipeline section under test must be vented, as far as possible, during filling.

d) The temperature of the test liquid must be at least 50 °C and at least 10 °C above
the minimum design temperature.

To monitor the pressure during the test, at least two pressure measuring devices shall
be installed, one at each end of the pipe.

9.8.2 Strength test

During the strength test a pressure pt ,,which shall be equal to the design pressure pd multiplied by Cp, is prevalent in
the pipeline (or a portion thereof). A higher value of pt is permissible, provided, the hoop stress σpt shall not exceed the
value Re. The duration of the strength test is 15 minutes.

The hoop stress shall be calculated according to the following formula:

σpt = pt · Dg / 2 · d

where:

σpt is the hoop or circumferential stress, in N/mm2;

pt is the test pressure, in MPa;

Dg is the average pipe diameter, in mm:

d is the minimum wall thickness after deducting mill tolerances and without corrosion or abrasion allowance, in
mm;

Re is the specified minimum yield strength, in N/mm2.

If the design temperature is higher than the ambient temperature, the strength test pressure changes as follows:

— with a design temperature of θ > 50 °C pt > Cp pd Re/Re(θ) is applicable;

The factor Cp in the equation above is dependent on the fluid carried. For natural gas pipelines Cp = 1.30 in accordance
with EN 1594:2000. The last sentence has been deleted.

NOTE 1 If Cp = 1.3 is also used for the other Group I pipelines, a MIP = 1.15 MAOP is allowable according to ISO 13623:2000
(6.7.3).

NOTE 2 ISO 13623:2000 specifies 1.1 MAOP and 8 hours for the tightness test and duration, respectively (6.7.3).

NOTE 3 For the above notes, MAOP is equal to pd.

9.8.3 Tightness test

After the strength test, the tightness test shall be conducted, which will last not less than 24 hours. For this test, it is
recommended to select a pressure equal to or greater than the design pressure. The pipeline can be approved
(considered leaktight) if changes in pressure can be explained from the recorded temperature measurements within

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SI 5664 part 2 (Combined edition) (2006)

acceptable limits, taking into account those points discussed in 9.8.1 such as stabilization and
temperature equalization.

For volumes smaller than 20 m3 or for sections which can be completely inspected visually, a shorter test period can be
selected.

9.8.4 Pre testing

Pipeline sections and components shall be pretested in following circumstances:

— if they cannot be tested following assembly in an existing installation;

— if they are to be installed near in an existing station that cannot be protected against possible consequences of a
rupture during the testing;

— if the consequences of a possible test failure justify testing prior to installation, such as in the case of a long sag
pipe or horizontal directional drilling.

9.8.5 Testing “tie-in” welds

Welds connecting tested pipeline sections to the pipeline system – so-called “tie-in welds” — are not tested by means
of the strength or tightness test and therefore require extra consideration and care during construction.

The location of the welds shall be chosen such that the welds are easily accessible from all directions.

Two different methods of non-destructive testing of welds shall be applied. Both methods shall demonstrate
satisfactory results for the weld. (Also see C.1 Ad. Chapter 11 supplement 3) in 11.7.)

9.8.6 Miscellaneous

The parts can be tested for strength with air or an inert gas. Furthermore, the entire unit can be tested for its tightness
following assembly with air or an inert gas at least at the design pressure. (The subject of this stipulation is not clear !! )

Those components or constructions from which it is demonstrated by means of material specifications, testing
documentation and/or calculations that they have sufficient strength to resist the applied test pressure do not need to
be retested for strength.

Machine directive for rotating components

In addition to the verification and inspection activities, described in 9.11 of SI 5664-1, a practical guideline is included
in Appendix J of SI 5664-1on how to comply with the current legislation and rules (such as the Machine directive) for
rotating components such as shut-off and actuator combinations, safety shut-offs, compressor and pump units, etc.

9.9 Completion

In addition to the stipulations of section 9.10 of SI 5664-1 the following standards can be taken into consideration for
commissioning and decommissioning activities:

— for natural gas pipelines EN 12327:2000;

A line has been deleted.

— for cathodic protection EN 12954:2001 or ISO 15589-1:2003.

38
 SI 5664 part 2 (Combined edition) (2006)

10 Operation and termination of operations

10.1 Corrosion management

Within the framework of integrity management presented in Chapter 10 of SI 5664-1, monitoring and management of
possible corrosion shall be included in the quality control cycle for steel pipelines.

NOTE In Chapter 9 of ISO 13623:2000 many aspects of corrosion management are discussed on a practical level.

10.2 Fitness (“fitness for purpose”)

Pipelines can be damaged by different causes. Examples are local damage from pitting corrosion and damage
resulting from excavation activities by third parties. The damage may not lead to pipeline leakage immediately, but
could also result in a dent in the pipeline wall, or in local reduction of wall thickness of the impacted bare wall as a
result of corrosion. An investigation shall be conducted as to whether it is necessary to correct the abnormality which
has occurred, respectively to establish whether the pipeline is still suited for its purpose (“fitness for purpose”). BS 7910
can be used during the investigation; [6] and [7] are informative as well.

NOTE The “fitness for purpose” assessment requires, in addition to knowledge of fracture mechanics, specific knowledge about
materials (brittle/ductile behavior, material lto fluid interaction at relevant temperatures, external interactions with soil or C.P. etc., as
well as knowledge of structural design). The determination of the extent and dimensions (of the damaged area) as well as the
evaluation is an inspection operation. These activities are often performed by an inspection institution referred to in 8.2.1, which is
competent for the specified operation(s) etc.

11 Offshore pipelines

11.1 General

This chapter gives, in addition to SI 5664-1, specific requirements for steel offshore pipelines.

11.2 Design

11.2.1 Structural design

11.2.1.1 Limit states

Research shall be conducted as to whether compressive stresses in the pipeline can give rise to:

— implosion as a result of external (hydrostatic) pressure (see E.3.3.4);

— local buckling resulting from a combination of compressive stresses in axial and circumferential direction;

— propagation of local buckling (see same);

— (upward) flexural buckling (upheaval buckling) with hot pipelines with no or little lateral support;

— flexural buckling (“global buckling”) as a result of bending and normal forces, especially with risers and free spans.

11.2.1.2 Cathodic protection

The design and the installation of the C.P. system of offshore pipelines shall be done according to EN 12474:2001.

11.3 Laying

11.3.1 Reel lay method

For pipelines that are installed with the reel lay (“reel barge”) method, it shall be demonstrated that the permanent
plastic strain in the pipeline material is less than or equal to 2 %. The demonstration can be performed according to
DNV-OS-F101:2000, clause E of section 9.
39
SI 5664 part 2 (Combined edition) (2006)

Appendix A
(normative)

Reduced analyses procedure

A.1 General

On the basis of results from earlier research, when making strength calculations for certain classified underground
steel pipeline sections it is sufficient (except for fatigue assessment) to test the hoop stress from internal pressure
according to the formula:

Reb
σ p = γ P ⋅ pd ⋅ Dg 2 ⋅ d ≤
γm

where:

σp is the hoop stress or circumferential stress caused by internal pressure in N/mm2;

γp is the (modified) partial factor applied to internal pressure according to Table A.1;

γm is the partial material factor from Table A.1;

pd is the design pressure, in MPa;

Dg is the average diameter, in mm;

d is the minimum wall thickness, in mm;

Reb is the limit value for stresses, in N/mm2.

The pipeline sections in question are classified into categories a) to e) inclusive:

a) 1) pipelines or pipelines laid in the open field or in pipeline corridors and laid in open trenches;

2) crossings of watercourses without flood defenses, less than 30 m wide and laid in open trenches (for the
purposes of calculation, these are regarded as field sections);

b) pipelines in the shoulder of secondary, tertiary, and quaternary roads and laid in open trenches;

c) pipeline crossings with tertiary, quaternary and uncategorized roads and laid in open trenches;

d) pipeline crossings with tertiary, quaternary and uncategorized roads and watercourses whose width is less than 30
m, without flood defenses, and the pipeline is installed by boring or jacking at the crossing, and open excavation in the
adjacent field sections;

e) railway crossings

If the reduced analyses procedure is to be allowed, these pipeline sections shall satisfy with a number of criteria. These
criteria are described in A.2.

A line has been deleted.

Figures illustrating the situations for the various categories of pipeline sections are included in A.3. How to incorporate
differences in construction subsidence is covered in Tables C.3 and C.5 of SI 5664-1.

40
 SI 5664 part 2 (Combined edition) (2006)

A.2 Criteria for applying the reduced analyses procedure

A.2.1 Category a) (fieldsection, watercourse)

Pipeline sections in (open) field or pipeline corridors (a1) and crossings with watercourses having a width of less than
30 m without flood defense (a2), and laid in open trenches.

The following criteria shall be complied with:

- The section shall be made of straight pipe or cold-formed field bends with a bend radius of R ≥ 40 D;

- De/d ratio(straight pipe):

2
Re = 480 N/mm → De/d ≤ 106;
Re = 415 N/mm2→ De/d ≤ 92;
Re = 360 N/mm2→ De/d ≤ 80;
2
Re = 240 N/mm → De/d ≤ 70;

- soil cover on top of the pipeline: between 0.8 m and 2.5 m.

- maximum difference in construction subsidence after installation:

see Table C.3 of SI 5664-1 (dry trench),
see Table C.5 of SI 5664-1 (underwater trench),
This difference in construction subsidence gradually goes from zero to a maximum value and back again to zero over
a distance of at least 2 x 20 m;

- the maximum difference between the installation temperature and the maximum, or minimum operating temperature
is not greater than 35 K. The total temperature range remains between –20 °C and + 50 °C with the stipulation that
the pipeline shall not be subject to frost heave;

- traffic load class: load model in conformity with “Fatigue Load Model 2, Lorry 4” from Table 4.6 of EN 1991-2:2003,
(see SI 5664-1, Figure C.17), multiplied by a factor of 0.5;

- there will be no crossings with potentially active fault planes or areas of mining subsidence;

- the expected settlement difference (e.g. due to lowering the water level of polders) shall not exceed 100 mm minus
the difference in construction subsidence after installation, as in Table C.3 of SI 5664-1;

- the minimum nominal wall thickness dn is 4.78 mm;

- γp to be applied according to Table A.1.

The criteria regarding soil cover and the traffic load class can be disregarded if it can be demonstrated that the total
2
intergranular stress at top level of the pipe (exclusive load factors) does not exceed 55 kN/m .

If vertical or horizontal factory-made bends with a small bend radius (R ≥ 3 D) are used, the following supplementary
requirements shall be complied with:

- the wall thickness of the bends shall be greater than for those used in adjacent field sections, and shall be calculated
using the so-called torus formula (see D.1.2 in SI 5664-1). If the bend is fabricated from material which has a
higher specified minimum yield strength, the bend shall have at least the same wall thickness as applied in the
adjacent field sections;

- maximum temperature difference for pipe with De ≤ 324 mm (12”) is 20 K, in case horizontal bends are used;

- the minimum center to center distance between two horizontal bends (R ≥ 3 D) is 2.0 m., unless the pipe diameter
De ≥ 457 mm (18”).

41
SI 5664 part 2 (Combined edition) (2006)

A.2.2 Category b) (road shoulder)

Pipe sections which are laid in open trench in the shoulder of secondary, tertiary and quaternary roads.

These shall satisfy the criteria for category a) (field sections), as well as:

- traffic load class: load model in conformity with “Fatigue Load Model 2, Lorry 4” from Table 4.6 of EN 1991-2:2003,
where the axle loads according to this load model,are divided, by the (incorporated) impact coefficient of 1.2 (see SI
5664-1, Figure C.17);

- apply γρ from Table A.1;

- settlement difference from c) (road crossing in open excavation).

The criteria related to soil cover and traffic load class can be disregarded if it can be demonstrated that the total
intergranular stress at top level of the pipe (exclusive load factors) does not exceed 65 kN/m2.

A.2.3 Category c) (crossing in open trenches)

Pipeline sections in crossings with tertiary, quaternary and uncategorized roads, and laid in open trenches.

These shall satisfy the criteria of category a) (field sections), except for of the stipulations regarding factory-bends, and
also:

- γρ is to be applied using Table A.1;

- there shall be no crossing of a dike (primary flood defence, secondary flood defence, inland flood defence and
enclosing dyke of a high-level-drainage-canal);

- for quaternary roads:Traffic load model in conformity with “Fatigue Load Model 2, Lorry 4” from Table 4.6 of EN
1991-2:2003 (see SI 5664-1, Figure C.17);

- for tertiary roads: Traffic load model in conformity with “Fatigue Load Model 3, from EN 1991-2:2003 (see
SI 5664-1, Figure C.17);

- for uncategorized roads: load model as in tertiary roads;

- the (rest-) settlement differences resulting from past embankments (roadbed, re-asphalting), and the embankments
from maintenance to be expected during the service life of the pipeline, as per information obtained from the road
administrator, shall not exceed 100 mm, sloping gradually over at least 2 x 20 m;

- the pipe wall thickness at the crossing shall be at least equal to the pipe wall thickness of the adjacent field sections,
regardless of possible differences in material quality.

The criteria related to soil cover and traffic load class can be disregarded, if it can be demonstrated that the total
2
intergranular stress at top level of the pipe (exclusive load factors) does not exceed 65 kN/m (for quaternary roads), or
2
85 kN/m (for tertiary and uncategorized roads).

A.2.4 Category d) (drilled crossings)

Pipeline sections crossing tertiary, quaternary and uncategorized roads and watercourses with a width less than 30 m
and without flood defenses, where the pipe is drilled or jacked, and the abutting field sections are laid in open trenches;

These shall satisfy the following criteria :

- settlement differences, as per A.2.3, shall not exceed 200 mm;

- only valid for straight pipe and cold-formed bends R ≥ 40 D;

42
 SI 5664 part 2 (Combined edition) (2006)

- γρ is to be applied using Table A.1;

- maximum construction subsidence difference after installation: see Table C.5 of SI 5664-1 (loosely compacted pit);

- no casing is to be used on the pipeline;

- there shall be compliance with the criteria of A.2.1, A.2.2 and A.2.3, except for the stipulations under A.2.1 regarding
factory-made bends.

If vertical factory-made bends with a small bend radius (R ≥ 3 D) are used in a jacking and/or receiving pit, the
following supplementary stipulations shall be complied with:

- the wall thickness of the bends with R = 3D shall be at least 10% greater than the wall thickness of the straight pipe in
the crossing, respectively 5.5% greater for R = 5D bends and 2.6% greater for R = 10D bends;

- De/d ratio(straight pipe in the crossing):

Re = 480 N/mm2→ De/d ≤ 81;
Re = 415 N/mm2→ De/d ≤ 70;
2
Re = 360 N/mm → De/d ≤ 61;
Re = 240 N/mm2→ De/d ≤ 57;

- vertical bends R ≥ 3 D shall be mounted at the back of the pit (see Figures A.5 and A.6) unless De ≥ 457 mm (18”). If
De ≤ 457 mm (18”) then bends R ≥ 40 D may also be mounted in the front of the pit, provided that the backfill of the pit
is well compacted;

- settlement differences as per A.2.3, shall not amount to more than 100 mm.

NOTE If the method described here for drilled or jacked crossings cannot be applied, a calculation method according to C.4.7.3 of
SI 5664-1is allowed.

A.2.5 Category e) (railway)

Pipeline sections crossing railroads

These shall satisfy the following criteria:

- maximum construction subsidence difference after installation; see Table C.5 of SI 5664-1 (well compacted pit);

- compliance with the boundary conditions a) through d), insofar as these are applicable for the chosen configuration
(straight pipe with field bends or straight pipe with factory-made bends);

- the pipeline is installed in a casing pipe;

- the diameter of the casing pipe shall be large enough to allow after installation, the fluid-carrying pipeline, including
spacers, to follow without obstruction a discontinuous construction subsidence difference of 10 cm;

- γρ is to be applied using Table A.1);

- the fluid-carrying pipeline shall be bedded over an angle of least 60º at the entry to and exit from the casing.

NOTE This can be done, for example, by mounting 3 spacers close together, and spiraled relative to one other, so that one is
always carrying on 2 ribs (or more as a result of the ovalization of both pipes).

43
SI 5664 part 2 (Combined edition) (2006)

Table A.1 – Partial factors reduced strength calculation

Partial Factor Partial

Category Pipelines in, or crossing with Internal Material
Pressure Factor
γρ γm
a) field sections and pipeline corridors
crossings with ditches, canals and natural waterways with a width of 1.39/1.1 1.1
less than 30 m, without water retaining structures and laid in open
excavation
b) in the shoulder of paved secondary, tertiary or quaternary roads (within
1.5/1.1 1.1
20 m from the edge of the pavement)
c) under the road surface of paved tertiary, quaternary and uncategorized
1.5/1.1 1.1
roads (open excavation)
d) drilled or jacked crossings of ditches, canals and natural watercourses
with a width smaller than 30 m without flood defences 1.82/1.1 1.1
drilled or jacked crossings with tertiary or quaternary roads
e) along or under railroads within 10 m from the outer rail, and in
1.82/1.1 1.1
crossings where the pipeline is encased in a casing.

In Table A.2, the application criteria of the reduced strength calculation for the various categories are tabulated.

44
 SI 5664 part 2 (Combined edition) (2006)

Table A.2 – Summary of application criteria for the reduced analyses procedure

a1 a2 b c d e
Category of Pipeline Section field water- shoul road boring railway
course der
straight pipe with:
- bends R ≥ 40 D + + + + ‫ا‬ +
- bends 3 D ≤ R ≤ 10 D + + + 0 ‫ا‬ ‫ا‬
installed:
- in open excavation x x x x - -
- crossing using drilling or jacking - - - - x x‫اا‬
soil cover between 0.8 m and 2.5 m x x x x x x
Traffic load class (max. soil + traffic load on top)III
- “Lorry 4”:1.2 *factor: 0.5XI (55 kN/m2) + + - - + -
- “Lorry 4”:1.2 *factor: 1.0XI (65 kN/m2) - - + + + -
- “Load Model 3” XII (85 kN/m2) - - - + + -
difference in construction subsidence over at least 2x20 m
- according to Table C.3 of SI 5664-1 + - + + - -
- according to Table C.5 of SI 5664-1 - + - - + +
IV
maximum difference in settlement in mm 100 100 100 200 200
IV
- for the case of 3 D ≤ R ≤ 10 D 100 100 - 100 100
maximum temperature difference in K 35 35 35 35 35 35
- for the case D ≤ 323 mm and 3 D ≤ R ≤ 10 D IX 20 - 20 - - -
dimensions of the pipeline
X X X
- wall thickness dn ≤ 4.78 mm x x x x x x
V
- De/ d ratio x x x x x x
- De/ d ratio VI - - - - xVII xVII
wall thickness increase increment in bends per VIII x x x x x x
design factor internal pressure 1.39 1.39 1.50 1.50 1.82 1.82
Legend: x = requirement; + = permissible; 0 = not permitted in a crossing; - = n.a.
I
Bends to be installed on the field side of the pit, unless De ≤ 457 mm.
II
With casing, bedding angle near the end of the casing greater than 60°, 100 mm clearance and well compacted pit
III
If it can be demonstrated that the soil- and traffic load does not exceed limit values given in brackets, the requirement
regarding soil cover and traffic load class can be waived.
IV
100 mm minus fv from Table C.3 in SI 5664-1.
V
Re = 480 N/mm2; De/d ≤ 106;
Re = 415 N/mm2; De/d ≤ 92;
Re = 360 N/mm2; De/d ≤ 80;
Re = 240 N/mm2; De/d ≤ 70;
VI
Re = 480 N/mm2; De/d ≤ 81;
Re = 415 N/mm2; De/d ≤ 70;
Re = 360 N/mm2; De/d ≤ 61;
Re = 240 N/mm2; De/d ≤ 57;
VII
If 3D ≤ R ≤ 10D bends are being used
VIII
R = 3D + 10%, R = 5D + 5.5%, R = 10D + 2.6% increment relative to the straight pipe in the crossing.
IX
When using 2 horizontal bends, the center-to-center distance between bends shall be 2.0 m or more.
X
dn crossing ≥ dn field section
XI
For traffic load model, in conformity with “Fatigue Load Model 2, lorry 4” from Table 4.6 of EN 1991-2:2003, Graphic I,
Figure C.17 from SI 5664-1.
XII
For traffic load model as per “Load model 3” (special transport) of EN 1991-2:2003, Graphic II, Figure C.17 from
SI 5664-1.

45
SI 5664 part 2 (Combined edition) (2006)

A.3 Figures for reduced strength calculation

These figures pertain to various categories of pipeline segments which are included in the reduced strength
calculation, drawn below (not to scale).

Legend:

fv is the maximum difference construction subsidence

∆ z is the maximum difference in settlement (words in parentheses have been deleted)

fv as per Table C.3 of SI 5664-1

∆ z = 100 mm – f v

Figure A.1 – Field section according to Category a1

fv as per Table C.3 of SI 5664-1

∆ z = 100 mm

Figure A.2 – Crossing watercourse as per Category a2

46
 SI 5664 part 2 (Combined edition) (2006)

fv as per Table C.3 of SI 5664-1

∆ z = 100 mm

Figure A.3 – shoulder of road as per Category b

fv as per Table C.3 of SI 5664-1

∆ z = 100 mm

Figure A.4 –Crossing of road as per Category c (words within the parentheses have been deleted)

fv as per Table C.5 of SI 5664-1: pit loosely compacted for category d),
pit well-compacted for category e),

∆ z = 200 mm for bends R ≥ 40 D,

∆ z = 100 mm for bends 3 D ≤ R ≤ 10 D

Figure A.5 Drilled, or jacked crossing of a road as per category d)

47
SI 5664 part 2 (Combined edition) (2006)

When applying D ≤ 457 mm and 3D ≤ R ≤ 10D

Figure A.6 – Alternative to Figure A.5

48
 SI 5664 part 2 (Combined edition) (2006)

Appendix B
(normative)

Material Specifications

B.1 Overview specifications and hot yield strengths

B.1.1 Introduction

The tables of this appendix are listing a number of material specifications which are in effect, in combination with with
any supplementary stipulations and particulars.

All of the materials shall only be used within the scope of application of the relevant specification or standard.

NOTE For example, materials corform EN 10208-1:1997 AND ISO 3183-1:1996 standards are, according to the foreword of
these standards, not meant to be used for transportation pipelines.

The tables also specify the hot yield strength (Re (θ) for a number of materials. However, if hot yield strengths are
specified in an EN- or ISO standard, referred to in this standard as a material specification, such values may be used
instead of the values from the tables of this appendix.

These tables are not exhaustive. In addition to the cited materials, there are still a great number of specific materials
(“specials”), having limited scopes of application. These materials shall comply with the model specifications of B.2.

Supplementary requirements relative to notch toughness testing are described in B.1.3.

If a material – according to a specification that is part of a national standard – is produced in another nation, it will not
necessarily comply with the specified hot yield strength. When in doubt, further data or supplementary proof may be
needed. This is true as well for specifications in regional or international standards (e.g., EN- or ISO standards) if the
country which produced the material has not accepted such standard as a national standard.

Note:
In order to meet the requirements of the Standard, when purchasing materials, the requisitioner
shall specify all the relevant requirements stated in this Standard. The supplier shall meet all
of the requirements stated in the purchase order and shall certify that he has met the purchase
order requirements. Stamping of materials shall be in accordance with the specified international
accepted standard only. No SI 5664 stammping is required.

B.1.2 Specifications and hot yield strength

B.1.2.1 Pipe (seamless and welded)

For hot yield strengths from Table B.1 and Table B.2 the following conditions shall be met:

a) for material thickness dn ≤ 35 mm, the values of Re (θ) from the tables can be used in the calculations, provided that
one hot yield strength test is carried out at 150°C for each cast and each thickness of material; the result of this test
shall be reported in the inspection certificate, and shall not be lower than the value in the table;

b) any higher value that might be found, shall not be brought into the calculation;

c) for material thickness 35 mm < dn ≤ 40 mm, other conditions being equal, the table values for Re (θ) shall be
lowered by 10 N/mm2;

d) if the hot yield strength test as per a) is not carried out, then Re (θ) shall be determined as follows:

Rm (720 − θ / oC )
Re (θ ) =
1400

49
SI 5664 part 2 (Combined edition) (2006)

NOTE The material specifications give the specified minimum yield strength (Re or Re (θ)). The calculation value of the yield
strength (Reb) is determined by dividing the specified minimum yield strenght by the material (resistance) factor.

50
 SI 5664 part 2 (Combined edition) (2006)

Table B.1 – Linepipe: EN-, ISO-, API-, ASTM- specifications and hot yield strength
2
Supplementary requirements Re (θ) [N/mm ]
Name and particulars for application θ [°C]
(dn ≤ 40 mm)
a b
Specification Material/ type of steel Material No. , ≤ 50°C 100°C 150°C 200°C
EN 10208-1 L210 1.0307 210 182 163
EN 10208-2 L245NB 1.0457 LT 245 208 187
ISO 3183-2 L290NB 1.0484 LT 290 255 235
L360NB 1.0582 LT 360 304 284
343
L415NB 1.8972 LT 415 363
235
L290MB 1.0429 LT 290 255
c 284
L360MB 1.0578 ,LT 360 304 343
c
L415MB 1.8973 ,LT 415 363 373 208
c
L450MB 1.8975 ,LT 450 402 392
c
L485MB 1.8977 ,LT 485 422
ISO 3183-3 L245NC
L290NC
L360NC
L290MC
L330MC
L415MC
L450MC
L485MC
f
EN 10216-2 P235GH 1.0345 225 198 187 170
f
EN 10217-2 P265GH 1.0425 225 226 213 192
f
EN 10217-5 16Mo3 1.5415 270 243 237 224
EN 10216-2 13CrMo45 1.7335 dn ≤ 40 mm 290 264 253 245
EN 10028-3 P355NH 1.0565 dn ≤ 35 mm 355 304 284 255
P355NL1 1.0566 dn ≤ 35 mm 355 217 199 182
API Spec. 5L PSL2 only Gr. A [a],[b] 207 182 163
Gr. B [a],[b] 241 208 187
Gr. X42 [a],[b] 289 255 235
Gr. X46 [a],[b] 317 275 255
Gr. X52 [a],[b] 358 304 284
c
Gr. X56 [a],[b] , [C] ≤ 0,23 % 386 333 314
c
Gr. X60 [a],[b] , [Ceq] ≤ 0,45 % 413 363 343
c
Gr. X65 [a],[b] , [Ceq] ≤ 0,45 % 448 402 373
c
Gr. X70 [a],[b] 482 422 392
c, d, e
ASTM A 106 Gr. B [a],[b] 241 215 198 182
d, e,
ASTM A 333M Gr. 6 LT, [C] ≤ 0,23 % 241 215 198 182
AISI 304
AISI 316
ASTM A 312M TP304 S30400 170 145 132 122
TP304L S30403 205 170 132 122
TP316L S31603 170 144 131 120
- S31254 300 235 215 195
VDTÜV 418 SAF 2205 X2 CrNiMoN 22 5 3 1.4462 450 360 335 310
S31803 450 360 335 310
a
The pipelines shall also be marked with the cast number.
b
Ratio between the yield strength and tensile strength (as given by the tensile test of the parent material) ≤ 0.90.
c
For the given materials, the actual (measured) yield strength Re (a) and the actual hot yield strength shall not exceed the guaranteed
2
minimum yield strength or the hot yield strength respectively with more then: for L360MB and L385M: 130 N/mm , for L415MB and
2 2 2 2
L450MB: 120 N/mm : for L485MB: 100 N/mm . For API material this is: for X52 and X56: 130 N/mm , for X60 and X65: 120 N/mm , for X70:
2.
100 N/mm The maximum allowable yield strength thus defined, is called Re (a, max).
d
Transverse notch impact test for dn > 20 mm.
e
Hot yield strength tested at 300 °C.
f
Can be applied for district heating pipelines per EN 13941:2003, supplementary diameter and wall thickness tolerances. Not applicable
for intrinsically dangerous substances per A.1.2.1 of SI 5664-1.
LT: Steel with specified notch-impact value at temperatures ≤ 0 °C;
[a] Supplementary requirement to notch impact value per 8.2.5.1.
[b] Supplementary requirement to chemical composition per 8.2.5.2

51
SI 5664 part 2 (Combined edition) (2006)

B.1.2.2 Flanges (Forgings)

Supplementary to 8.2.4.4, Table B.2 provides specifications with supplementary requirements, particulars regarding
application and hot yield strength.

Table B.2 – Flanges: Specifications and hot yield strengths

Re (θ) [N/mm ]
2
Supplementary requirements and
Name particulars for application θ [°C]
(dn ≤ 40 mm)
Specification Material/Type of steel ≤ 50 100 150 200
b
EN 10222-2 P245GH ⎫ Inspection
b
P280GH ⎬ per , LT
b
ASTM A 105M P305GH ⎭ batch , LT
a c
ASTM 350M [C] ≤ 0.23 % [a], [b], , 226 220 214
Gr. LF 2 [C] ≤ 0.23 % [b], LT 226 220 213
a
Heat treatment and mechanical testing is required for all dimensions.
b
≤ 300 °C. Application of non-standard flanges limited to pa DI ≤ 20,000 bar.mm.
c
The type with [C] ≤ 0.23 % in normal annealing condition is in conformity with C21, VdtÜV, Werkstoffblatt 399.
LT: Steel with specified notch-impact value at temperatures ≤ 0 °C.
[a] Supplementary requirement for notch impact value per 8.2.5.1.
[b] Supplementary requirement for chemical composition per 8.2.5.2.

The values for hot yield strengths from Table B.2 shall only be applied, when the following conditions are met:

a) for material thickness dn ≤ 100 mm, the values of Re (θ) from the table can be used into the calculation, provided if
θ > 100 °C, a hot yield strength test at 300 °C shall be carried out for each cast of the thickest semi-manufactured
goods; the results of this test shall be reported in the inspection certificate, and may not be lower than the value in
the table. Any higher result that might be found, shall not be brought into the calculation;

b) For material thicknesses 100 mm < dn ≤ 200 mm, other requirements being equal, the table values for Re (θ) shall
2
be lowered by 10 N/mm ;

c) for material thickness above 200 mm, the Re (θ) to be brought into the calculation shall be determined separately;

d) in case the hot yield strength test as per a) is not carried out, Re (θ) shall be calculated as follows:

Rm (720 − θ / oC )
Re (θ ) =
1400

B.1.2.3 Bolts and nuts

B.1.2.3.1 Specifications, required inspection certificate and hot yield strength test

Table B.3 states the (material) specifications with the supplementary requirements and particulars for application, and
with (for some specifications), the hot yield strength.

The values of Re (θ) can be brought into the calculation without further testing.

52
 SI 5664 part 2 (Combined edition) (2006)

Table B.3 - Bolts and nuts: Specifications, required inspection certificate and hot yield strength
2
Supplementary Requirement Required Re (θ) [N/mm ]
stipulations and inspection inspection θ [°C]
Name particulars for certificate bolts/ certificate for rod (dn ≤ 40 mm)
application nuts per material
EN 10204
b e
Specification Material/type , ≤50 100 150 200
of steel
f h
ISO 898-1 4.6-2 ,W m 3.2
f h
DIN 267 part 13 5.6 ,W m 3.2
f g
8.8 , 3.1 3.1
Bolts

c d a
ASTM A193
a
Gr. B7 , 3.2, 3.1, 3.2, 3.1 470 453 442
c d a
Gr.B7M , 3.2, 3.1, a 3.2, 3.1, 357 344 336
c d a
ASTM A 320 Gr.L7 , , LT 3.2, 3.1, a 3.2, 3.1,
c d a
Gr. L43 , , LT 3.2, 3.1, a 3.2, 3.1,
f h h
ISO 898-2 5-2 m m
f,g h h
DIN 267 part 13 8 m m
d
ASTM A 194 Gr.2
Nuts

3.1 3.1
d
Gr.2 H 3.1 3.1
Gr. 4 3.1 3.1
Gr. 7 3.1 3.1
a
An inspection certificate 3.1 is sufficient for standard bar bolts with D ≤ 51 mm.
b
Notch impact test and requirements per 8.2.5.1.
c
Checking surface faults for bolts with D > 51 mm.
d
At the end phase, products shall be checked for material changement.
e
Identifying markings as per Appendix B.2.3.6.
f
≤ M30, θ ≤ 300 °C: pa ≤ 4 MPa.
g
Application limited to connections with an internal diameter up to and including 500 mm.
h
No inspection certificates required, but identifying markings are, per B.2.3.6.
LT: Steel with the specified notch impact value at temperatures ≤ 0 °C.
W: Steel with specified mechanical properties at temperatures above room temperature.

The determination of the required inspection certificate 3.2, 3.1 or mark ‘m’ is based on Table B.4. An inspection
certificate of the bar stock material is required if the mechanical testing was carried out on the bar stock material and,
subsequently the bolts and nuts were made by machining only In all cases the bolts and nuts shall be supplied with the
required inspection certificate or mark.

If inspection certificate 3.2 or 3.1 is cited in Table B.3, then inspection certificate 3.1 will be accepted for bolts, nuts,
and bar stock material with D ≤ 51 mm.

Table B.4 – Required inspection certificate per EN 10204:1995 for bolts and nuts

Rod material for Bolts Nuts

Rm
Bolts Nuts
2
≤ 600 N/mm 3.2 ma ma ma
> 600 N/mm2 D ≤ 51 mm 3.2 3.1 3.1 3.1
D > 51 mm 3.2 3.2
a
No inspection certificate required, but identifying markings are required as per B.2.3.6

B.1.3 Notch ductility testing

Determining plate thickness dc

The determining plate thickness dc is derived from the thickness dn per construction drawing or dimension table.

a) for welding neck flanges, dc equals the greater of the two following values:

- dn of the welding end;

53
SI 5664 part 2 (Combined edition) (2006)

- 0.25 dn of the flange (plate) at the bolt circle.

b) for welded components of with unequal thickness, where (slope of) the taper does not exceed 1:4, dc shall be no
more than equal to the thickness on the weld side. (see figure B.1).

c) for welding, dc is equal to the greatest adjacent welding-edge thickness

d
c

d
c

Figure B.1 – Welded parts with different thickness

Sampling

The position and orientation of notch impact test samples of rolled steel for pipes, shall satisfy EN 10208-2:1996,
ISO 3183-2:1996 and ISO 3183-3:2000. Table B.5 states requirements for the other components.

Table B.5 Position and orientation for notch impact test samples
a
notch impact test samples
Component dn direction
mm site long. axis
plate, forged cylinders, spheres or ≤ 40 -
cones b
> 40 centerline ≤ 0.25 dn of the surface area transverse
other forgings ≤ 40 -
> 40 centerline ≤ 0.25 dn of the surface area -
cast fittings each - -
Bar (rod) material each Distance of center line at least 0.17 times from the -
diameter or the diagonal of the surface away
a
If not filled in: there is no requirement for position or orientation of the test sample.
b
Transverse: perpendicular to the direction of the last rolling, or to the direction of the maximum forging.

Test temperature

The test temperature for the notch impact test with Charpy-V test samples, if required according to the model
specification in B.2, shall comply with Figures B.2 – B.5 incl.

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 SI 5664 part 2 (Combined edition) (2006)

10 45
°C
dc = 40mm
0

-10 35

-20 30

-30 25
-40
20
-50
15
c -60
10
-70
5
-80

-90
-50 -40 -30 -20 -10 0 10 °C 20

t
Figure B.2 – Test temperature θt for the notch impact ductility test of ferritic material with Ni < 1.5% and R m ≤
450 N/mm2, where non-heat treated welds are present in or onto the pressurized section Extrapolation is not
permitted.

0
°C
-10

-20

-30

-40
dc = 50 mm – 70 mm
-50

-60
45
c 40
-70 35
30
25
-80
20
15
-90 10
5
-100

-110
-50 -40 -30 -20 -10 0 10 °C 20

t
Figure B.3 - Test temperature θt for the notch impact ductility test of ferritic material with Ni < 1.5% and Rm ≤
2
450 N/mm , where any weld present in or onto the pressurized section have been heat-treated. Extrapolation
is not permitted.

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SI 5664 part 2 (Combined edition) (2006)

45 m
10 40m
°C dc =
0
35
-10
30
-20
25
-30
20
-40
15
-50
10
c -60
5
-70

-80

-90
-50 -40 -30 -20 -10 0 10 °C 20

t
Figure B.4 – The test temperature θt for the notch impact ductility test of ferritic material with Ni < 1.5% and R m
> 450 N/mm2, where non-heat treated welds are present in or onto the pressurized section. Extrapolation is not
permitted.

0
°C
-10

-20

-30

-40 m
70m
50 -
-50 dc =
45
40
-60 35
30
c -70 25
20
15
-80 10
5
-90

-100

-110
-50 -40 -30 -20 -10 0 10 °C 20

Figure B.5 - The test temperature θt for the notch impact ductility test of ferritic material with Ni < 1.5% and R m
> 450 N/mm2, where any welds present in or onto the pressurized section have been heat-treated.
Extrapolation is not permitted.

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 SI 5664 part 2 (Combined edition) (2006)

B.2 Model specification and Order Specifications

B.2.1 Acceptance of a material specification

B.2.1.1 Requests

The following types of requests:

- request for acceptance of a material specification not cited in this standard, submitted by a manufacturer;

- acceptance of a material specification cited in this standard, submitted by a new manufacturer;

shall be directed to a for these services accredited inspection institution type A or B, as per ISO/IEC 17020:1998.

The following information shall be submitted along with the request:

- the complete material specifications including:

- characteristic designation;

- revision number and date;

- scope;

- (compliance ??);

- the results of the materials testing (for use by the inspection institution);

- the required inspection certificate.

NOTE In principle the only specifications which can be accepted, are those which comply with EN standards and/or ISO standards,
cited in this standard.

B.2.1.2 Material specifications

The material specifications shall always include the following elements:

Characteristic designation of the material

- the name or trade name of the pipe manufacturer (X);

- the number of the (European) standard and steel grade;

- the type of pipe (seamless S or welded pipe W);

- in case an inspection certificate is submitted, the type of certificate shall be specified (e.g., EN 10204:2004 3.2 or
3.1).

- the mark of the inspector or the inspection institution (Y);

- an identification number correlating the product delivered with its inspection certificate (Z).

EXAMPLE X EN 10208-1 L360GA S Y Z

Edition

The specification shall unambiguously indicate the revision, by issue date, revision number, etc.

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SI 5664 part 2 (Combined edition) (2006)

Scope

The specification shall include information about the dimensional range within which the specified material properties
are valid.

Dimensional tolerances

The specification shall stipulate the checking of dimensions, and the tolerances to be considered in case the
dimensions deviate from the relevant EN standards. Apart from that, these dimensions shall, as a minimum, comply
with these standards.

Chemical composition

The specification shall include requirements regarding chemical composition. The cast analysis shall be equivalent to
the ISO 3183 series . The end of the sentence has been deleted.

Steel manufacture.

The steel shall be fully killed. Unkilled steel is not acceptable.

Product manufacture

Heat treatment

Mechanical properties

- Yield strength; the specification shall state the minimum required yield strength at room temperature. “Yield strength”
means either the stress for 0.2 % permanent strain, the stress for 0.2% non-proportional strain, the stress for 0.5% of
the total elongation under load, as well as the upper or lower yield point. The specification shall clearly state the used
definition for the yield strength .

- Strain; the specification shall state the minimum required elongation at break of a tensile test bar, with a length of lo in
mm equal to 5.65 √A; this requirement shall fit with the type of steel considered, but shall amount to at least 18%, in
which A is the surface area of the perpendicular cross-section of the tensile test bar in mm2.

Scope and requirements of non-destructive testing

A specification is acceptable if it requires that all pipe ready for delivery be subjected to complete and effective non-
destructive testing (see also C.2); (for seamless pipe with a diameter less than 200 mm, this testing may be carried out
before hydrostatic testing).

Markings

The specification shall require that products ready for delivery be effectively marked with the casting number.

Checking for materials substitution

The specification shall require that alloyed steel, nickel and nickel alloys products ready for delivery, be duly tested for
materials substitution (e.g., by microscopic testing).

B.2.1.3 Materials Testing Results

The results of the materials testing shall minimally include the following:

1) (If mentioned in the model description) tensile strength, yield strength, elongation after fracture, and reduction of
cross-section at room temperature, and at temperatures at least 50 K higher than the specified maximum metal
temperature (if the material is to be used where metal temperatures will be > 50 °C);

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 SI 5664 part 2 (Combined edition) (2006)

NOTE If a tension test sample of another length is used, then the elongation measured after fracture shall be referred to a standard
measure of 5.65 √A, as per ISO 2566-1:1999.

2) notch impact toughness (transverse if so prescribed in Table B.5) at room temperature;

3) data about physical properties such as elasticity modulus, coefficient of expansion, heat conductivity coefficient, etc.
insofar as significant for the application;

4) (only if notch toughness test at temperatures < 20 °C are specified) sufficient data to be able to determine the
transition temperature of the notch toughness (longitudinal). The results shall relate to condition of the material that
is ready for delivery, and any condition it might be in following heat treatment which can occur during the processing
of the material;

5) (only if the weldability of the material is specified) the results of the notch-impact toughness- and hardness testing of
the fused weld metal and the heat-affected zone. Batches, whose chemical composition might have an – expected -
negative influence on the results, shall be used for welding tests;

6) data about the technological properties such as weldability, suitability for cold and hot forming, fracture sensitivity.

B.2.1.4 Required inspection certificate (for acceptance of a material specification)

General

The inspection certificates shall be prepared and validated certifying agreement with the requirements of this standard,
based on inspection and testing carried out by or under the supervision of an accredited inspection body cited in
B.2.1.1. For approval of a new material specification or a new manufacturer, an inspection certificate 3.1.A as per
EN 10204:2004 is required.

Content of the inspection certificate

The inspection certificate shall be prepared according to EN 10168. It shall include at least the following data:

1) information provided by the steel manufacturer:

- the steel preparation process;

- the chemical composition, with the results of the cast analysis for the specified elements;

2) information from the product manufacturer:

- the heat treatment undergone, including the temperature cycles that were run through, and the methods of cooling;

3) from a technical expert associated to the product manufacturer, being independent from the production departments
involved;

- the results of the materials substitution check (if applicable);

4) verified by the person issuing the inspection certificate;

- the nature, scope and results of the mechanical investigation;

- the results of visual inspection and the dimensions check;

5) a declaration that the shipment complies with the specification requirements cited in the inspection certificate. (E.g.,
EN 10208-2:1996 or equivalent ISO.)

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SI 5664 part 2 (Combined edition) (2006)

B.2.1.5 Supplementary stipulations for acceptance of a material specification (pipe)

Scope and requirements of mechanical testing:

Sampling

1) a specification can be accepted if the required mechanical testing relates to at least:

- 1% of the number of pipes, if De ≤ 500 mm;

- 2 % of the number of pipes, if De > 500 mm.

2) A batch means a quantity of pipes that comply with the following conditions:

- the same diameter and wall thickness;

- the same cast;

- the same steel quality;

- the same tunnel oven run or annealing furnace batch (if no heat treatment takes place);

- hot formed in the same way. If it appears from the temperature record that the temperature of a number of
annealing furnace batches do not differ from one another by more than 15 K, then these can be treated as a unit.

3) the testing shall take place on pipe that is ready for delivery.

4) a sample shall be taken from each pipe that is designated.

Required testing.

The scope and requirements of the mechanical testing are in conformity with ISO 3183 series. The end of the
sentence has been deleted.

Production

For cold formed steel, permanent strain shall not exceed 5 %.

With HFW welded pipe, the weld shall be subjected to heat treatment (when a pipe has been thermo-mechanically
treated, treat only the weld!).

Maximum wall thickness

For a plate thickness ≥ 40 mm, a post-welding heat treatment may be necessary, for application within the scope of this
standard.

B.2.2 Flanges (forgings), unalloyed and low-alloyed steel (model description for specifications)

B.2.2.1 Product manufacture

Acceptable forging methods are:

- forging by hammering or intermittent pressure forging;

- pressing;

- extrusion.

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 SI 5664 part 2 (Combined edition) (2006)

During the forging, the steel of the entire cross-section of the forging shall be re-formed.

B.2.2.2 Heat treatment

Depending on the type of steel, the material shall be delivered in a normalized or tempered
condition. This need not be adhered to if the material will undergo the required heat treatment afterwards.

B.2.2.3 Mechanical testing

Sampling

The number of samples per forging or batch of forgings , which shall be taken for mechanical testing, shall be at least:

1) for forgings with a mass > 3,500 kg and for hollow forgings with a length > 3 m:

- one sample from each end;

- for forgings where the diameter is greater than the length: two samples on the outer surface, diametrically
opposite at the greatest distance from each other;

2) for forgings with a mass > 1000 kg but ≤ 3500 kg, with the exception of hollow fittings with a length > 3 m:

- one sample from one end

- for forgings made by reducing the length of a bar : one sample from one location on the outside surface;

3) for forgings with a mass ≤ 1000 kg:

- one sample per batch of identical forgings which were made from the same melt and belong to the same annealing
oven batch, or to the same heat treatment sequence in a tunnel oven;

- one sample per batch of identical forgings which were made from one piece with a mass > 1000 kg, and were
separated only after the last heat treatment.

Heat treatment of the samples

The samples shall be selected in ready for delivery condition after the last heat treatment of the forging.
For closed hollow forgings, the required samples may be selected before the forging is closed.
In such case the test samples shall undergo the remaining heat treatment together with the forging from which they
were taken.
For material which is delivered without having undergone the required heat treatment, the samples shall be subjected
to the remaining heat treatment according to the specifications.

Test pieces

If the forging is a cylinder, sphere, cone or plate, or forms a part of such component, the test samples have to be taken
perpendicular to the greatest stress.(largest dimension?) For all other forgings, there is no preference regarding the
removal of the test pieces.

Position of samples:

- for a forging thicker than 40 mm. which is cylindrical, spherical, conical or a plate or a part of one of these, the
distance between the outer surface and the axis of the test piece shall be at least ¼ of the wall thickness of the
forging;

- in all other cases, the axis of the test piece shall be at least 12.5 mm away from the outer surface.

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SI 5664 part 2 (Combined edition) (2006)

The specification shall require for each sample the selection of the following test pieces:

- tensile test: a cylindrical tensile test piece;

- notch impact test piece: in those cases where a notch impact test is required, three Charpy-V notch impact test
pieces. The specification can also require DVM.

A notch impact test is required in the following cases:

a) for flanges, flat flange-covers, bars, bolts and nuts with wall thickness > 50 mm;

b) for other forgings;

- unalloyed steel with Rm ≤ 450 N/mm2 and wall thickness > 20 mm.
If the specification specifies notch impact values, this thickness limit is increased to 50 mm;

- other unalloyed and low-alloyed types of steel with wall thickness > 10 mm.

The selection of test pieces shall comply with Table B.5.

B.2.2.4 Non-destructive testing

The specification shall prescribe ultrasonic testing for each forging with dn > 100 mm.

B.2.2.5 Mechanical Properties Requirements

Tensile Strength

The specification shall give the minimum required and the maximum allowable tensile strength at room temperature.
The required minimum value shall not be less than 320 N/mm2 and the allowable difference between the two values
may not amount to more than:
2
- 140 N/mm for unalloyed steel;

- 150 N/mm2 for low-alloy steel.

Yield strength

The specification shall give the minimum required yield strength at room temperature.

Elongation

The specification shall give the minimal required elongation after fracture for a tensile test piece with a measured
length lo equal to 5 Do (Do is the diameter of the test piece) This value shall be at least:

- 16 % for unalloyed steel;

- 14 % for low-alloyed steel.

If a tensile test piece with a different length is used, then the measured elongation after fracture according to
ISO 2566-1:1999 shall be recalculated to the standard length 5 Do.

Notch impact value

The specification shall state the following requirements regarding the results of the notch impact test:
These requirements hold for notch impact test with Charpy-V test pieces:
2
- for unalloyed steel with Rm ≥ 450 N/mm ; average of three tests 27 J, minimum individual value 18.9 J;

62
 SI 5664 part 2 (Combined edition) (2006)

- for all other unalloyed and low-alloyed steels: average of three tests 31 J, minimum individual value 21.7 J.

B.2.2.6 Surface testing and tests for internal faults

The specification shall include stipulations for testing for surface- and internal faults, and what kinds of results are
required to meet the specifications.

B.2.2.7 Markings

Marks to be affixed

Each forging shall be marked with the following:

- a mark identifying the type of steel;

- a manufacturer’s mark: this shall be a specific mark and not a combination of standard characters;

- markings which makes it possible to correlate inspection certificates, forgings, and batches to one another;

- (if applicable) mark of the inspection body.

The marks shall be chosen such that confusion with other forgings is not possible.

Means of affixing

The stamp shall be affixed in a durable manner.

For flanges with De ≤ 61 mm, the marks may be duly applied on a sticker on the packaging.

B.2.3 Bolts and nuts (model description for specifications)

B.2.3.1 Manufacture of the product

The material, from which the bolts and nuts are manufactured, can be forged, rolled, or drawn.

Bolts and nuts can be manufactured by cold-forming, hot-forming, machining process, or by a combination of these.

Threading bolts by cold rolling does not require a follow-up heat treatment.

B.2.3.2 Heat treatment

Bolts and nuts shall be supplied in heat treated condition.

The heat treatment shall be appropriate for the type of steel and method of manufacture.

The heat treatment may be applied to the bar stock, or to the bolts and nuts, depending on the method of manufacture.

B.2.3.3 Scope of mechanical testing

Sampling

To be a batch, the bar stock, bolts and nuts shall comply with all the conditions below:

- the same dimensions;

- the same batch from the (s)melting oven;

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SI 5664 part 2 (Combined edition) (2006)

- the same annealing furnace charge, or the same heat treatment run in a tunnel oven.

The specification shall indicate how the homogeneity of the batch is established.

For material to be used for bolts and nuts, which do not have to undergo another heat treatment, two test samples per
batch, are required. If the starting material consists of bar stock, the two samples shall be selected from different bars.

If according to the inspection certificate, the rod material has undergone heat treatment, and has the required
mechanical properties, the nuts and bolts machined from it (including threading the bolts by rolling) require no further
testing.

For bolts and nuts which have not been tested in accordance with the above, one sample shall be taken per batch as
per Table B.6. In this table, 1 + n represents a unit sample of bolts, in which n is the number of bolts needed for the
required notch impact tests.

The samples shall be taken after the last heat treatment.

Table B.6 – Scope of the sample taking

Batch Size Sample Size

Bolts Nuts
≤ 800 1+n 7
801 ... 8000 2 (1+n) 14
8001 … 22000 3 (1 + n) 21
> 22000 5 (1 + n) 35
Test bars and test pieces

1) Bar material and bolts

The specification shall prescribe the method for selecting from each sample (or sample unit) the following test
pieces:

- tensile test piece

A cylindrical tensile test piece, of which the length lo and diameter Do satisfy lo = 5Do;

- notch impact test piece:

If a notch impact test is required, three Charpy-V- test pieces.

If the specification prescribes Charpy-U- test bars or DVM, these are also acceptable.

A notch impact test is required for ferritic steel with a diameter > 50 mm.

The test bars shall be taken in compliance with Table B.5

2) Nuts
For each nut to be tested, the specification shall prescribe the following tests:

- hardness test, unless the mechanical properties have been determined in some other way;

- proof load test with the load prescribed in the specification.

The following cases do not require a load test:

- test load > 350 kN;

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 SI 5664 part 2 (Combined edition) (2006)

- nut diameter > 39 mm, or 1.5 inches.

B.2.3.4 Requirements for mechanical properties

Tensile strength

The specification for the rod material for bolts shall state the minimally required and the maximally allowable tensile
strength at room temperature.

The required minimum values shall not be less than 400 N/mm2.

Yield strength

The specification for the bar stock or bolt material shall state the required yield strength at room temperature.

Strain

The specification for the bar stock or bolt material shall state the required strain after fracture, which shall be at least:

- 16% for Rm ≤ 600 N/mm2;

- 14% for Rm > 600 N/mm2.

Notch Impact values

The specification shall state the following requirements regarding the results of the notch impact testing:

- for all the unalloyed and low-alloy types of steel: average of three tests 27 J, lowest value minimum individual
18.9 J;

- for 1.5% to 9% Ni-steel: average of three tests 39 J; minimum individual, value 27.3 J.

Up to 70 mm thickness, a test temperature of 0 °C for a design temperature of –20 °C is sufficient.

Hardness

The specification for nuts shall state the minimally required and maximally permissible hardness at room temperature.

The required value shall match the type of steel.

Proof load

The specification for nuts shall demonstrate the minimum demands for load at room temperature. The required value
shall fit with the type of steel in question and the dimensions of the nut.

B.2.3.5 Surface testing

The specification shall include stipulations about the surface test, and about the resulting requirements. Such a check
shall be required for all steel bolts with a diameter > 51 mm with Rm ≤ 600 N/mm2.

B.2.3.6 Markings

Markings to be affixed.

The markings cited below shall be affixed to bolts, nuts and the rod material for manufacturing them:

- a mark identifying the type of steel;

- a manufacturer’s mark: this shall be a specific mark and not a combination of standard characters.

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SI 5664 part 2 (Combined edition) (2006)

And if Rm ≥ 600 N/mm2, on bolts with a diameter > 51 mm as well as on the rod material:

- markings which relate the inspection certificates, batches, and product to each another;

- (if applicable), mark of the inspection body.

The marks shall be chosen such that the bolts, nuts and rods cannot be mistaken for others.

Means of affixing.

The marks shall be affixed in a durable manner.

Stock bar material with a diameter of ≤ 26 mm shall have the marks duly made on a sticker and attached to the bundle
or package containing the bar material.

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 SI 5664 part 2 (Combined edition) (2006)

Appendix C
(Normative)

Welding and weld examination

C.1 Supplementary and/or deviating requirements in comparison to EN 12732:2000

C.1.1 General

EN 12732:2000 is applicable, together with the supplemental requirements to each chapter, paragraph or appendix
as specified in C.1.2.

C.1.2. Supplementary and/or deviating requirements to EN 12732:2000

In Chapter 4:

- Replace "If required by the pipeline operator, a quality system shall be applied to
the pipeline welding" by "A quality system shall be applied to pipeline welding".

- Replace EN 729 with ISO 3834 including all its parts, respectively.

- The quality requirements contained in "Table 2" are not "recommended" but normative.

- In table 2 after "according to EN 719:1994", add: or welding inspector according to

AWS (American Welding Society).

- In table 2 after "EN 473:2000" add or ASNT TC 1A:2001, level 2.

- In table 2 add after EN 288-3: or ISO 15614-1.

- In section 4.4: The last sentence is changed as follows: "All non-destructive

examination personnel shall be qualified for the duties they are to perform, in
accordance with EN 473:2000, level 2, or ASNT-TC-1A:2001: level; 2.

- In section 4.2, 4.3 and 4.4, replace "should" by "shall" (the requirements are a
normative).

In Chapter 5:

- At the end of the first sentence, add:... the following, or equivalent as approved
by the pipeline owner.

- In welding consumable list: Shielded metal arc welding: add "...or SI 1340".

- In the paragraph beginning with: "Batch testing...", replace the two first sentences
with: Filler materials shall be tested and approved by a type A inspection body (see
8.2.1). The certificate shall be in accordance with EN 10204: 2004, type 3.2.

- Table 3 is normative.

In Chapter 8:

- 8.2; the scope of the non-destructive examination (radiographic and ultrasonic

examination) for circumferential welds:

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SI 5664 part 2 (Combined edition) (2006)

- NDE shall be carried out on all circumferential welds over the complete
circumference.

- 8.3, paragraph 4: delete "if not otherwise agreed by the pipeline operator". And
at the end: "...EN 45001:1997 or SI-ISO 17025".

- add new paragraph after paragraph 4;

An X-ray shall be used.
Gamma radiation may be used on circumferential pipe welds if the use of an
X-ray is not possible for technical reasons, under the pipeline owner's approval and
in full compliance with the Standard's requirements.

- 8.5; paragraph 4; the ultrasonic examination only refers to ultrasonic pulse-echo

examination method.

100% of all circumferential welds shall be examined by NDE methods.

In Chapter 11:

- 11.2, replace EN 287-1 with ISO 9606-1. add: or ASME B&PVC 9.

- 11.4 add: The welding procedures and consumables shall be such that they provide low
hydrogen weld metal.

- 11.4.1; 2nd paragraph, Replace: "For grades L 485 and L 555 ..... and the use of
Table 3 is recommended" by "For grades L 485 and L 555 ..... and Table 3 shall be
used".

- 11.4.4; in addition to the documented requirements, two all-weld-metal tensile tests

shall be carried out for weld connections of the above pipelines DN 500 mm. The
results of every test rod shall fulfill the requirements in Table C.2 for tensile
strength, in the perpendicular direction to the weld (Rm⊥), and in a parallel
direction (RmII) to the weld.

- 11.5.3 (Repair of weld defects): 2nd paragraph, replace "pipeline operator" with
"the relevant authority".

- 11.6 EN 288-3 shall be deleted. The sentence shall be: "...Welds shall be tested in
accordance with EN 288-9."

Table C.2 - Additional requirements for weld connections of pipelines

Specification of base material Requirement melt down material

2
Re ≤ 320 N/mm Rm⊥andR
 mII ≥ Rm, base material
2
Re ≥ 320 N/mm Rm⊥andRmII ≥ 1.1 x Rm, base material
ReII ≥ 1.13 x Re, base material

- 11.7; Paragraph 1, 2 and 4 have been cancelled. As a supplement the following is applicable:

1) Circumferential welding of field sections.

For materials with a high yield strength (steel grade equivalent to L 480 or higher) and with a nominal wall
thickness ≥ 6 mm, half-mechanized TOFD examinations are recommended.

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 SI 5664 part 2 (Combined edition) (2006)

The TOFD images shall be coherent. For wall thicknesses > 10 mm, the TOFD examination shall be extended
with pulse-echo inspections. Circumferential welds in the base material L 480 or higher (or equivalent), welded
with cellulose electrodes, shall be examined with TOFD and pulse-echo techniques, irrespective of the pipeline
length.

The zone height shall, after deduction of 10 % of the wall thickness, amount to 3 mm or 4 mm. The acceptance
criteria for TOFD examinations, documented in C.2.2, are applicable.

2) Other circumferential welds

For other cases, whereby a radiographic examination of the circumferential welds is carried out, Tier 1 in Table
G.2.1 and Table G.2.2 are applicable for the acceptance of welding defects.

3) Welds that are not pressure tested for strength.

In supplement to Paragraph 3 of Chapter 11.7, of EN 12732:2000, it is applicable that for weld connections in
(Quality) category D, with material groups 2 and 3 of ISO 15614-1:2004, and with a wall thickness of more
than 8 mm, a second and different type of volumetric NDE examination shall take place.

4) Manual ultrasonic pulse-echo examination.

A manual pulse-echo examination is permitted as a supplement to radiographic or TOFD examinations. Table

G.3 is applicable for those weld imperfections that are detected.

5) Combined installation of pipelines in category D.

The requirements under 1) shall be applied to circumferential welds in pipeline sections, which are installed in
combination with other pipelines in one trench, regardless of the length.

6) Acceptance criteria for NDE

For the selection of acceptance criteria for welding defects with non-destructive examinations is referred to
C.2.

NOTE Pipe material of a high strength, such as L 485, is more sensitive to the occurrence of welding defects than lower
quality steel in a TM implementation. The use of inspection techniques with a higher "probability of detection", such as
TOFD, for transport pipelines can increase the reliability of welded connections. These inspection techniques should be
taken into account for critical welds showing severe consequences in case of failure. Examples are crossings, pipesections
to be pulled through bore holes and welds subject to addition al stresses from deformation restrictions.

In Chapter 12:

- Chapter 12 is normative.

In the appendixes:

- Appendix A is normative.

- A.2; Summary c is only applicable for welders that shall create tie-in welds in a trench. The welder's certificate
shall be amended with the certifying identification "T" (Tie-in welding). The specified dimensions are not applicable
for automated welding. A clearance of 40 cm, between the pipebottom and the trench bottom, remains applicable
for all welders qualifications for manual welding.

- A.3; If one single qualification weld is carried out, then the approval range for plates, respectively the pipe wall
thickness. shall be in conformity with Table C.3

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SI 5664 part 2 (Combined edition) (2006)

Table C.3 - Approval range for plate

Thickness d1 of the Applicable range for

welding sample wall thickness d
Welding process
mm mm
Arc welding with coated < 12 0.75 d1 ≤ d ≤ 2 d1
electrodes
≥ 12 >9
Arc welding with other electrodes all 0.75 d1 ≤ d ≤ 2 d1

Furthermore, Table C.4 is applicable for pipes.

Table C.4 - Approval range for pipes

Outside diameter De of the Applicable range for

welding sample outside diameter De
Welding process
mm mm
< 80 < 80
Arc welding 80 ≤ De ≤ 500 80 ≤ De ≤ 500
≥ 500 ≥ 325

- Appendix B is in informative.

- Appendix C is a normative.

- Appendix D is informative.

- Appendix E is informative.

- Appendix F is informative.

- Appendix G is normative. See also C.2.1.

- Appendix H is informative.

In Chapter 6:

- 6.7: First paragraph, delete: "unless otherwise agreed by the pipeline owner".

C.2 NDE acceptance criteria

C.2.1 Acceptance criteria

Acceptance criteria shall be in accordance with ISO 5817.

Defects acceptance level shall be according to Table 1 – Quality level B.

Clauses C.2.1.1 and C.2.1.2 have been deleted.

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C.2.2 Acceptance criteria TOFD

C.2.2.1 Acceptance criteria of relevant indications

NOTE See [10] for background information over the development of acceptance criteria on defects in transport pipelines.

All relevant indications shall be evaluated in accordance with Table C.5. If wall thicknesses differ, then the lowest wall
thickness shall be decisive .

Table C.5 - Maximum allowable length and depth of defects, in mm.

Nominal wall Maximum permitted length (lmax) and height (h) of defects,
thickness dn mm
mm Exposed defects Enclosed defects
Imax h3 Imax h2
6.0 < dn ≤ 9.0 2d 1.5 4d 2.0
9.0 < dn ≤ 15.0 2d 2.0 4d 3.0
15.0 < dn ≤ 27.0 2d 2.5 4d 4.0

Fault indications are acceptable if:

- the height is ≤ 1 mm for exposed defects, up to a length of ½ D and up to a maximum of 300 mm;

- the height is ≤ 1 mm for enclosed defects, regardless of the length;

- 1 mm < h ≤ h2 and I ≤ Imax for enclosed defects;

- 1 mm < h ≤ h3 and I ≤ Imax for exposed defects.

With the values for h2, h3 and Imax as given in the table.

A group of fault indications, for which the individual indications are acceptable, is only acceptable if all of the following
conditions are fulfilled:

1) the distance between the successive indications, paralle to the weld direction, is greater than the length of the
average length of the indications;

2) if the distance between two successive indications, in the direction of the thickness of the weld, is greater than the
height of the highest indication;

3) if the sum of the lengths of the individual indications is ≤ 7 x d, measured over any length of ½ D, up to a maximum
distance of 300 mm from the weld.

Indications that do not fulfill the above-mentioned conditions 1 and 2 shall be treated as one single indication. The
defect dimensions “h” and “I” shall then be measured under inclusion of the distance between the indications, and
Table C.5 shall be utilized for the evaluation.

C.2.2.2 Single diffraction signals

Whenever single diffraction signals are visible in a TOFD scan, then the maximum number of acceptable and relevant
indications shall not exceed the values from Table C.6 for each edge zone over a length of ½ D and up to a maximum
distance of 300 mm.

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SI 5664 part 2 (Combined edition) (2006)

Table C.6 - Maximum permitted number of single diffraction signals per edge zone of ¼ D

Nominal wall thickness dn Maximum allowable number of single diffraction

signals per edge zone of ¼ D
mm
6 < dn ≤ 9 20
9 < dn ≤ 15 30
15 < dn ≤ 27 40

C.3 Post –weld heat treatment

C.3.1 Scope

The data in Table C.3 is applicable for field welding in pipes, which are made of alloyed or unalloyed steel, in
conformity with section 9.4 (this is not applicable for components manufactured in a factory).

For each heat treatment, which may or may not be required according to C.3.2, the provisions of C.3.3 are applicable.
Incorrectly executed heat treatments can have a negative influence.

Symbols and units

Du outside diameter mm

dd wall thickness; according to the design drawing or size table mm

with regard to C.3.3, this is the greatest thickness of the welding edge.

Ceq carbon equivalent %

Re specified minimum yield strength, at 20 °C N/mm2

r bending radius mm

te cooling time s(h)

tn residence period s(h)

ϕ (angle at the center) °

θ temperature (in general) °C

qm metal temperature °C

qn temperature at the point of measurement n °C

[Symbol for chemical element] is the maximum content in % of the corresponding element, as shown by the specified
cast analysis.

{ } around the symbol for a magnitude indicates that the numerical value (expressed in the above-mentioned unit) is
meant; temperature differences are indicated in Kelvin (K).

C.3.2 Classification of materials with regard to heat treatment after welding

The following group classification is used (Table C.7):

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Table C.7 - Group classification of materials for post-weld heat treatment

a
Group Steel type
1 Steel with a specified minimum yield strength Re ≤ 360 N/mm2 and with a chemical composition that
does not exceed the following values in %: [C] = 0.24, [Si] = 0.60, [Mn] = 1.70, [Mo] = 0.70, [S] = 0.045,
[P] = 0.045, and each other element separate = 0.3, all other elements together = 0.8.
2 Normally annealed/normalized or thermo-mechanically rolled fine-grained steel with a specified
minimum yield strength of Re > 360 N/mm2
3 Quenched and tempered steel, and precipitation hardened steel, with the exception of corrosion
resistant steel
4 Ferritic and Martin-processed corrosion resistant steel with 10.5% ≤ [Cr] ≤ 30%
5 Austenitic corrosion resistant steel
6 Austenitic ferritic corrosion resistant steel (duplex)
a
For the groups 1,2 and 3, no heat treatment is required after welding. For the remaining groups 4, 5 and 6, the principal shall
specify whether a post-weld heat treatment is required. If the welding thickness is greater than 40 mm, then a post-weld heat
treatment is required for all groups.

C.3.3 Type and scope of post-weld heat treatment

If a heat treatment can adversely affect the properties of the coating or the protective layer, measures can be taken to
prevent or to repair these damages.

From case to case a decision shall be made, whether the corresponding welding works shall be subjected once more
to a heat treatment.

If required according to C3.2., and after all welding on a certain work piece have been completed, the welds shall be
subjected to a heat treatment according to the requirements of the material specification.

If such requirements are incomplete or missing, then the following conditions shall be met:

- if the temperature is not specified, then 600 °C will be taken for the materials (no fine-grained steel);

- if the allowable emperature deviations are not specified, then a tolerance of +20 K or -20 K will be used instead;

- if the residence time is not specified then a value of 120 {dd} s shall be applied, with a minimum of 1800 s (0.5 h);
the residence time need not be more than 7200 s (2 h). The application of arbitrarily long residence periods can
have a negative influence and shall preferably be avoided;

- If the cooling rate is not specified, it shal not exceed the smallest value of 2/{dd} K/s and 0.08 K/s. However,the
cooling rate needs not to be less than 0.015 K/s.

NOTE For cases in which a heat treatment is not foreseen, or in which a deviation from these regulations can lead to a more
effective heat treatment procedure, special regulations may be established. Such special regulations should not only be approved by
the accredited expert, but also by the manufacturer of the material, the pipe manufacturer, the designer and the operator.

C.3.4 Realization

The realization shall conform both to the following requirements and to the material specification.

If the material has to be tempered, then eventual hot forming may be considered part of the required heat treatment, if
the final temperature reached during hot forming lies within the temperature range that is indicated in the material
specification for hardening.

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C.3.4.1 Equivalent standards of post-weld heat treatment

Two workpieces are viewed as having been subjected to an equivalent post-weld heat treatment, if, in addition to the
requirements that are applicable to each of these workpieces, the requirements of C.3.4.1.1 and C.3.4.1.2 are also
fulfilled.

The method used for heat treatment of the two workpieces need not therefore be the same. This is relevant for
example, in case of a separate heat treatment of test pieces and samples.

C.3.4.1.1 Determination of allowable distribution range

The temperature-time diagram for the residence- and cooling period for one of the two workpieces is used to plot the
distribution range according to Figure C.1 and the related instructions.

Figure C.1 - Distribution range in the temperature-time diagram for residence and cooling periods

Permissible temperature distribution range, according to C.3.3: θ max - θ min

Actual lingering period tn

Cooling period to 400 °C (at point recording most rapid cooling) tmin

Cooling period to 400 °C (at point recording slowest cooling) tcmax

C.3.4.1.2 Assessment value

The temperature-time diagrams for the residence- and cooling periods of the other workpieces shall lie entirelywithin
the distribution range that has been determined in the previous paragraph.

C.3.4.2 Heat treatment in a furnace

In case of a heat treatment in a furnace, the following aspects shall be taken into account:

- The workpiece shall not be heated through a direct contact with flames;

- (for pipes with De ≤ 170 mm). The heat treatment process shall be monitored; the annealing report shall show that
the workpiece has been subjected to the required heat treatment;

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 SI 5664 part 2 (Combined edition) (2006)

- (for pipes with De > 170 mm). The heat treatment process shall be continuously recorded in a temperature-time
diagram, by means of an automatic recording device. This diagram shall show that the required heat treatment
have been effectuated at all measuring points ..

- (post-weld heat treatment). The workpiece shall remain in the furnace during cooling, until the temperature of all
parts with dd > 20 mm has declined to 400 °C. After this, the workpiece may be removed from the oven for further
cooling in standing air.

- (post-weld heat treatment). During cooling to 400 °C, the temperature gradient shall not exceed the following
values:

- in the axial direction: 100 K/m;

- in circumferential direction: 40 K/m;

- number and location of the temperature sensors shall be such that the recorded temperature is representative for
the temperature gradient in the entire workpiece. The following minimum number of measuring points is required:

- 1 for samples;

- 2 for pipes with De ≤ 170 mm;

- 3 in all other cases

- the temperature sensors shall be in contact with the workpiece;

- the temperature sensors shall be calibrated.

C.3.4.3 Local heat treatment

Stress-free annealing or tempering may be used as a local heat treatment, if all requirements of C.3.4.3.1 and also all
requirements of C.3.4.3.2 and C.3.4.3.3 are satisfied.

C.3.4.3.1 General

The zone to be heated (workpiece) shall satisfy one of the following descriptions, as illustrated in Figure C.2:

- bend;

- branch or T-piece

- a circular ring, which is a part of one of the following surfaces:

- a circular cylinder;

- a circular cone, with a half top angle < 30 °;

- a spherical segment, bounded by a central angle: 120 ° ≤ ϕ ≤ 240 °

This is also fulfilled, if the ring lies within a spherical element and both of the cut-off sphere segments fulfill
this requirement. The thus described spherical segment shows a tangent cone at the edge, with a half top
angle ≤ 30°;
- a transition area between two of the above-mentioned surfaces, with or without a torus, or a torus-shaped
ring.

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SI 5664 part 2 (Combined edition) (2006)

C.3.4.3.2 Inductive annealing or resistance annealing

The heat treatment process shall be continuously and automatically recorded in a temperature-time diagram. This
diagram shall show that the required heat treatment procedure has been fulfilled at all the measuring points. The
temperature registration may be discontinued, after the temperature has declined to ≤ 400 °C at all measuring points.

In the following cases, the temperature-time diagram does not have to be submitted to the accredited inspection
institution and it will be sufficient to supply an annealing report:

- (for all materials) De ≤ 170 mm;

- (for unalloyed or low-alloy content steel with [Cr] ≤ 1.5% and [Mo] ≤ 0.65%) De ≤ 325 mm and also dd ≤ 25 mm.

The required number of temperature measuring points shall be at least:

- 1 if De ≤ 170 mm and dd ≤ 70 mm;

- 2 if 170 mm < De ≤ 460 mm and dd ≤ 25 mm;

- 4 in all other cases.

If the zone to be heated includes changes in cross-section, additional measuring points are required. In these cases, a
programme shall be defined in advance for the execution of the heat treatment procedure.

- the temperature sensors shall be distributed evenly over the zone to be heated.

- (if dd ≤ 70 mm). The temperature profile recorded by additional measuring points shall demonstrate that the
required procedure for heat treatment has been fulfilled both on the internal and external surfaces of the
workpiece. These extra measuring points are not required if the heat treatment of a sample, which can be
regarded as an equivalent to the workpiece in accordance with C.3.4.1, demonstrates that during the cooling
process to 400° C the temperature gradient over the wall remains at ≤ 50 K.

- the temperature sensors shall be in contact with the workpiece.

- the temperature sensors shall be calibrated.

- the pipe shall be insulated over the entire zone to be heated, and over a length of at least 3.5 De × d d on
both sides thereof.

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Figure C.2 - Zones to be locally heated

C.3.4.3.3 Annealing with ring-type burners

- [Cr] < 2.5% and/or [Mo] < 1.2%;

- Du < 800 mm and dd ≤ 32 mm;

- The zone to be heated does not contain any transitions in cross-section and only includes circumferential welds;

- The treatment is carried out by an annealing technician holding a valid certificate of competence with regard to
annealing skills

- The progress of the heat treatment shall be monitored; and the annealing report shall state that the corresponding
workpiece has been subjected to the required heat treatment. The annealing report shall document the name of
the person carrying out the annealing process, as well as the observed residence period and the highest and
lowest temperature recorded during that period.

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C.3.5 Critical thickness

The thickness dc is to be deduced for each component from it’s dimensions and can be decisive for the need to carry
out post-weld heat treatment.

The following is not taken into account, in the determination of dc:

- overfill of welds, and additional fillet weld or mitres, applied over a weld (see Figure C.3);

- the thickness of the pipe plates, flanges and flat walls, except as stated belowl;

- the thickness of forged branches;

- the thickness of welded in rings around apertures.

The critical thickness dc is equal to the greatest value of:

- the weld thickness. For double-sided welds with less than full penetration this is the combined thickness of the two
sections of the weld. For a fillet weld this is the throat thickness (“a-measure”).

- (only for flanges, with fillet welds between the flange and the pipe or wall) two times the thickness dd of the wall or
pipe welded to the flange;

- the thickness dd of any component directly connected next to the weld. If at a butt weld, in cylinders, spheres,
heads or cones (but not in a branched pipe), the connected component is merged into a greater thickness at a
gradient than 14° (= 1:4) then this greater thickness is taken into account;

- (only for apertures with an flat reinforcing ring inside and outside) 0.5 times the combined thickness of the wall and
both reinforcing rings;

- (only for apertures) the thickness dd of the connecting part of a set-on branch directly abutting to the weld;

- (only for tube plates, flanges and flat walls, including full-penetration welds) the thickness dd of the pipe plates,
flange or flat wall. In this case, welds and weld preparations on pipe plates are not taken into consideration.
-

Figure C.3: Determining critical thickness

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Appendix D
(normative)

Complete Analysis procedure

D.1 Load combinations

The ultimate limit states that shall be tested are documented for each load combination (LC) in Table D.1, including the
motivation for the choice of the LC and the calculations that shall be carried out, for the benefit of a complete strength
calculation.

Table D.1: Calculations to be carried out for each load combination

LC 1: Construction phase for pipelines and stations

Limit states to be Stresses, strains, deformations
assessed
Motivation It shall be shown that the loads that occur in the construction phase do not lead to any
damages on the pipeline. The loads that occur during that phase are generally quite
different from those in the definition phase.
NOTE Since this concerns a temporary situation, and since the consequences of exceeding a
limit state will on the whole be limited, it is justified to use lower load factors than during the
operational phase.
Calculations to be Static beam and cross-section calculation, depending on the loads that occur.
carried out
LC 2: Internal pressure only
Limit states to be Stresses
assessed
Motivation The calculation for internal pressure only is often decisive for the final wall thickness.
NOTE In the assessment of the fundamental ultimate limit state of rupture, caused by excessive
internal pressure, other loads do not have to be taken into account in the case of buried pipelines,
provided the following conditions are fulfilled:
- ductile material behavior of the pipe wall;
- limitation of the occurring bending deformations, that is limitation of the occurring settlement
differences;
- primarily static loads, therefore no danger of fatigue.
These conditions are verified in the other load combinations.
Calculations to be A calculation according to the "boiler formula" is sufficient:
carried out γ p ⋅ pd ⋅ Dg
σp =
2⋅d
γp is the partial load factor for internal pressure, see Table 2.
LC 3: External loads, with internal pressure zero
Limit states to be Stresses, strains, deformations
assessed
Motivation In the case of external loads, such as soil loads and settlement differences, the situation
with the lowest internal pressure is often decisive for the magnitude of the occurring
stresses and deformations, such as ovalization and the occurrence of local buckling.
Occurring strain shall of course be verified.
Calculations to be Static global analyses (beam analyses, including pipe-soil interaction)(s) and cross-
carried out section analyses.
See continuation

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Table D.1 (continued)

LC 4: External loads with internal pressure and (maximum) temperature fluctuations

Limit states to be Stresses, strains, deformations
assessed
Motivation In a plasticity calculation and in case of (high) internal pressure, the resistance against
bending deformations (the plastic moment Mp) declines. This means that in case of
occurring settlement differences, the bending deformations will be larger than in the case
LC 3, and with that the strains will also be larger than in LC 3.
Temperature fluctuations, like settlement differences, contribute to bending deformations
(in bends), as well as axial forces and displacements.
NOTE Deformations, such as ovalization and local buckling, will not be decisive in case of
minor temperature fluctuations. In the case of pipelines, with a high operating temperature, large
local deformations can however occur in bends, as well as large normal forces in long and straight
pipeline sections, which make assessments for flexural buckling and local buckling necessary.
Calculations to be Static global (beam) analyses(s) and cross-section analyses.
carried out
LC 5: Cyclic, largely static, loads, (temperature fluctuations, pressure fluctuations)in combination with other loads
Limit states to be Stresses, strains, fatigue. In the corresponding cases, an assessment shall also be
assessed made on stepwise plastic deformation (ratcheting).
Motivation Fluctuations in operating pressure and operating temperature,will introduce variations in
stresses and strains.. This can lead to fatigue damage (cracks).
NOTE 1 A differentiation can be made between load cycles with corresponding strain
fluctuations within the elastic range, and load cycles with strain fluctuations, leading to local yield
with each cycle
NOTE 2: Traffic loads too,can, in principle, introduce stress fluctuations. The "stress wrinkle"
that can occur as a consequence of this, will usually be limited in the case of high-pressure
pipelines and not lead to fatigue damages. This may be a point of attention in the case of low-
pressure pipelines with limited soil cover, and in case the pipeline system is supported on piles.
Calculations to be These concerns the strain variations, as a consequence of load fluctuations.
carried out Calculations models, which can determine the strain history as a function of the load
history, are therefore to be recommended, especially when plastic deformation occurs.
The resulting strain fluctuations shall be assessed in a fatigue calculation that shall be
carried out, Common fatigue analyses however frequently introduce a (fictive) elastic
stress variation obtained from strain based fatigue tests (see D.3.5).
NOTE 1: In the case of elastic material behavior, use can be made of the superposition principle,
whereby two situations are compared with one another, namely one with a low value for the
temperature and one with a high value for the temperature. The difference gives an estimate of the
occurring strain fluctuation. This result is less precise, to the extent that the response of the
pipeline is less linear (geometrically and physically).
NOTE 2: Large strain variations are likely to occur, above all in and near T-pieces and bends.
LC 6: External pressure, external loads and internal pressure zero
Limit states to be Stresses, strains, deformations (implosion, local buckling, flexural buckling), large
assessed displacements
See continuation

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Table D.1 (end)

Motivation External pressure can cause collapse in deeply buried pipelines (for instance at
crossings), or in pipe-in-pipe systems with a pressurized annular space, and in the case
of offshore pipelines. Especially during the installation of offshore pipelines, critical load
combinations of external pressure, bending moment and normal forces may occur.
Calculations to be The calculations to be performed follow from the above described physical phenomena
carried out and load situations. The relevant limit states shall be assessed
LC 7: Incidental and special loads
Limit states to be Leakage, resonance, large displacements, fatigue, local supports
assessed
Motivation Resonance can result from water and air flows along respectively offshore pipelines and
above ground pipelines.. Resonance can also occur through pumps and water hammer.
Resonance can lead to uncontrolled stress and strain variations, as well as occurrence
of damages through fatigue.
NOTE: Offshore pipelines may be buried or not. Buried pipelines can as a result from
erosion (sea currents). subsequently come to lie on or above the seabed In the case of freely
suspended pipelines (present from the time of construction or as a consequence of erosion) it shall
be assessed whether there is a danger of resonance (for instance caused by vortex shedding) and
of large strains, local buckling and similar hazards.
Large displacements (unstable positioning) can occur in offshore pipelines due to
currents, and for instance in above ground pipelines, due to insufficient anchoring. In
case of unstable positioning, uncontrolled deformations can occur, which may lead to, for
nstance, exceeding a fundamental limit state, such as rupture.
Damages to the pipewall can occur through dents and scratches, caused by excavation
tools, passing fishing gear, etc. In due time, these can lead to pipeline rupture.
Calculations to be Suitable calculations shall be carried out for incidental and special loads.
carried out NOTE 1: In case of scratches or dents, caused to the pipewall by excavating machines etc.,
the wall thickness and toughness of material (and of course the shape and the dimensions of the
excavator bucket (tooth)), as well as the power that the excavating machine can exert, are of
crucial importance. Strictly seen one can speak of an incidental load here, and such a load cannot
(yet) be included in the common strength analyses models. If, in the relevant cases, the scratch
dimensions are known, then a "fitness for purpose" approach can be applied on the basis of BS
7910.
NOTE 2: BS 7910 does not give any information for an assessment of dents. To a certain
extent, this concerns a serviceability limit state, in which the opinion of the pipeline manager is
decisive. However , internal pressure variations may cause additional stresses in a circumferential
direction, which may possibly influence the result of the fatigue calculation. Also see [17].

D.2 Calculation models

D.2.1 Schematization

D.2.1.1 Geometry

See Chapter 8 of SI 5664-1 and the related appendices. The pipeline (beam) elements and the spring elements for
the soil shall be selected such that the behavior of the pipeline can be modelled with adequate accuracy.

D.2.1.2 Material properties

The values for material variables that are documented in Table D.2, such as the yield strength, tensile strength,
transverse contraction coefficient, maximum strain, the development of the stress-strain-diagram etc., are always
calculation values, unless indicated to the contrary. Calculation values are generally the characteristic values, which
are divided by a corresponding material factor γm (see Table D.2).

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Table D.2: Material factors γm

Material variable Material factor

(characteristic values) γm
Yield strength 1.1
Rupture strength 1.1
E modulus 1.0
Transverse contraction coefficient 1.0

The stress-strain diagram that shall be applied is dependent on the calculation model that is used. The diagram in
Figure D.1a) is applicable to a calculation in accordance with the elasticity theory, and Figure D.1b) for a calculation
according to the plasticity theory. The diagram in Figure D.1c) may also be used.

NOTE Other schematizations may also be used, such as for instance that of Ramberg-Osgood, under the condition these lead to
the same safety, at a minimum.

Figure D.1 - Schematization of the stress-strain diagram for calculations.

Variables mentioned in figure are:

fy:d is the calculation value for the yield strength (fy:d = Re/γm);

ft:d is the calculation value for the tensile strength (ft:d = Rm/γm);

Ed is the calculation value of the elasticity modulus;

εy:d is the calculation value for the strain, on reaching the yield strength. (strain at yield)

D.2.2 Calculation models under static load

For carrying out calculations, the following calculation models can be used.

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D.2.2.1 Elasticity theory for beam calculation - elasticity theory for cross-section calculation (E-E)

A beam calculation is carried out, whereby the pipeline is reduced to a system of linear elastic beam elements. The soil
is modelled to a system of soil springs (physically linear or physically non-linear).

Subsequently a cross-section calculation is carried out, whereby:

- the material behavior can be assumed to be physically linear or physically non-linear (elastic or elastic-plastic
material behavior);

- either geometrically linear behaviour or geometrically non-linear behavior (taking into account, the influence of
occurring deformations on the load distribution, or the inclusion of second order phenomena, such as
"rerounding") is assumed;

- the stiffness ratio between the pipe cross-section and the surrounding soil is taken into account.

The results (forces acting on the cross-section and stresses, deformations such as curvature from bending and
ovalization) shall be checked against the relevant limit states in D.3.

D.2.2.2 Elasticity theory for beam calculation - plasticity theory for cross-section calculation (E-P)

A beam calculation is carried out, whereby the pipeline is schematized with linear elastic beam elements. The soil is
schematized with soil springs (physically linear or physically non-linear).

The result of these calculations are forces acting on the cross-section, such as bending moments, transverse forces,
normal forces, soil loads resulting from overhead burdens and soil support reactions.

Subsequently, a set of interaction formulas used for verifying, whether the pipe cross-section is able to carry the forces
that act on it. A check is also made, whether the bending moments that are a result of the beam calculation fulfill the
boundary conditions for the application of the elasticity theory. See [23] and Attachment E.

NOTE If the series of interaction formulas and also the conditions of E.5.2 are met, then the verification of the limit state "stresses"
is also fulfilled (since, in the derivation of the interaction formulas, one of the boundary conditions states that the stresses shall not
be higher than the yield stress).

A cross-section calculation shall be carried out for verifying the ovalization limit state.

The results of the various calculations, in the form of deformations such as curvature from bending and ovalization,
shall be checked against the relevant limit states in D.3.

D.2.2.3 Plasticity theory for beam calculation - plasticity theory for cross-section calculation (P-P)

A beam calculation is carried out, whereby the pipeline is schematized with linear beam elements, which can describe
the non-linear behavior. The soil is schematized with soil springs (physically linear or physically non-linear).

The result of these calculations are forces acting on the cross-section, such as bending moments, transverse forces,
normal forces, soil loads due to overhead burdens and through soil support reactions.

Subsequently, a series of interaction formulas [23] for straight pipeline sections (see Attachment E) are used to verify
that the pipe cross-section is capable of handling the forces that act on it.

NOTE A check that the bending moment of the beam calculation fulfills the conditions that shall be met is discounted in the
calculation, in accordance with the plasticity theory. The limit state "stresses" is automatically met.

The necessary calculations, for checking that the other limit states are met, shall be carried out, such as a cross-
section calculation for the verification of the ovalization limit state, and a calculation of the strains, for a check of the
limit state "strains". In [20], [21] and [23], descriptions and formulas have been included for the determination of
ovalization.

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SI 5664 part 2 (Combined edition) (2006)

The results of the various calculations, in the form of deformations such as curvature from bending and ovalization,
shall be checked against the relevant limit states in D.3.

D.2.2.4 Integrated calculation for pipeline – soil interaction

Finite element models, schematizing both the behavior of the pipeline and that of the surrounding soil in one single
model, will be used for generating calculations, which should provide resulting values for stresses, strains and
deformations that are "ready for assessment".

NOTE 1: A distinction is usually made between a beam model and a ring (cross section) model in the computer programs, presently
available for calculation of elastic or plastic pipeline behaviour. In the beam calculation, the pipeline is modelled with beam elements
in two or three dimensions, in order tp calculate the normal forces, the transverse forces, torsional moments and longitudinal
bending moments, resulting from the various loads that influence the pipeline. The entire cross-section of a pipe element is
subsequently looked at in detail with a ring calculation, including the active of forces and bending moments in axial direction as well
as the loads and reactions in circumferential direction. Subsequently the stresses and strains as well as a resultant stress are
determined in a number of points along the cross sectional circumference.

NOTE 2: Validated models, which conform to the above, are not yet available at the time of publication of this standard.

D.2.3 Calculation models for cyclic loads

In this, a distinction can be made between models that are based on superposition and models that follow the load
history.

D.2.3.1 Superposition

Strictly seen, calculation models based on superposition may only be applied in cases of geometrical and physically
linear behavior, that is, in cases where the elasticity theory is applied, whereby effects of a secondary order do not
have to be taken into account. If these conditions are not met, then their use is nevertheless permitted by this standard,
under the condition that the scope of the geometrical and physical linear behavior remains within certain predefined
(still to be defined) limits.

The following calculation models may be used:

- Elasticity theory for beam calculation - Elasticity theory for cross-section calculation (E-E);

- Elasticity theory for beam calculation - Plasticity theory for cross-section calculation (E-P).

NOTE An example of superposition is the check of alternating yield under fluctuating internal pressure, whereby the stress
fluctuation is determined through the differences in the calculated stresses, which are arrived at through a calculation with low
internal pressure and with high internal pressure. If the second calculation model is used, including the application of the plasticity
theory for the cross-sectional calculation, then the conditions of geometrical and physically linear behavior are not met.

D.2.3.2 Load history

For the application of this, a computer program is required, which can include the load history over time in the
calculation.

NOTE Such computer programs are available, but they are only used to a limited extent.

D.3 Limit states and corresponding assessments

D.3.1 Limit state “stress”

The possibilities for checking this limit state depend on the model selected for calculating the response of the pipeline.
Two assess methods are available, namely assessment on the basis of cross-sectional forces and assessment on the
basis of resultant stresses:

a) Assessing on the basis of cross-sectional forces;

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 SI 5664 part 2 (Combined edition) (2006)

In this, use is made of the interaction formulas, which are documented in Attachment E. This assessment method
may be used for all calculation models.

b) Assessment on the basis of a resultant stress σv.

This assessment method is only used for the following calculation model:

- Elasticity theory for beam calculation - Elasticity theory for cross-section calculation (E-E).

This assessment method is described in detail below.

After the beam and cross-sectional calculations have been prepared, under application of the calculation values of the
loads, the calculated stresses in the representative points of the representative cross-sections shall be combined
After the determination respectively of the axial and the tangential stresses, in relevant points along the circumference
of pipeline cross-sections with the heaviest load, these stresses shall be combined into the equivalent stress σv. The
equivalent stress σv is a parameter, which characterizes the stress condition at a certain point.

The equivalent stress can be calculated both with the minimum distortion energy hypothesis (Von Mises), or with the
shear-stress hypothesis (Tresca):

- According to the “minimum distortion energy” hypothesis, the resultant stress is:

σv = (σ 2
x + σ y2 + σ z2 − σ x σ y − σ z σ x − σ y σ z + 3τ x2 + 3τ y2 + 3τ z2 )
In the analyses a plane (bi-axial) stress condition may generally be assumed, instead of a three-axial one, if the
third principal stress is relatively small in absolute terms (for example, the radial internal pressure component for
(thin-walled) pipeline components, without fittings, T-pieces etc.).

The following formula then applies for a plane stress condition:

σv = (σ 2
x + σ y2 − σ x σ y + 3τ 2 )
- The following applies in accordance with the shear-stress hypothesis (Tresca):

σv = σmax - σmin

where:

σmax is the maximum principal stress in 1 of the three directions;

σmin is the minimum principal stress in 1 of the other two directions.

NOTE In the determination of the values for the limit state of stresses in Table D.2, the possible redistribution of stresses, due to
the plastic deformation capacity of steel, and the self-limiting character of certain loads, such as temperature, have been taken into
account. As an alternative, a assessment in accordance with the fully elasticity analyses of section 6.4.1 and 6.4.2 of ISO
13623:2000 can be carried out.

In case of alternating loads, the relevant pipe elements shall also be assessed for fatigue.

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SI 5664 part 2 (Combined edition) (2006)

Table D.2: Assessment stress limit states and alternating yield, in calculations according to the calculating
model: E-E

Load combination Resultant stresses limit stress

from load
combination
LC 2 → σp ≤ Re(θ) / γm
a a a
LC 3 ; (LC 3 + LC 2) σv: pm 1.1 x Re / γm
LC 3, LC 4 σv 0.85 x (Re + Re(θ))/γm
a
This assessment concerns situations, in which the pipeline is loaded primarily as a
supporting beam and the occurring stresses are largely membrane stresses, for
instance a pipeline section on piles with circumferential stresses through internal
pressure and longitudinal bending stresses through beam-behavior..

D.3.2 Limit state “strain”

The calculation value of the strain (total strain under load) shall not amount to more than 0.50%, if no more detailed
information is available. In case it, is demonstrated for a specific material in combination with specific requirements
regarding the welding and the welding process, that the corresponding pipe material including welds have a greater
strain capacity than 0.5%, then this greater capacity may be utilized.

For steel types with Re ≤ 360 N/mm2 and within the framework of this standard, a calculation value for strain of 0.7%
can be applied.

NOTE The value of 0.5% was established in the middle of the 1980 s, when plastic calculation was introduced. The strain capacity
of the plate material is actually much larger, and the welds, including the imperfections in it, are the limiting factor. In Table C.2, a
new requirement with regard to "overmatching" of the welding material has been included. A check of the strain capacity of “old”
pipelines appears to show a strain capacity in the order of several %. Strains of up to 2.5% appeared to ’be possible for welded steel
pipelines, during the installation of offshore pipelines with the "reel" method. In [16], a maximum strain of 0.75% is specified, in
combination with a material factor of 1 or 0.7, if no further information is available. A limitation of the Re/Rm ratio is also important in
this instance. For steel types with a high yield strength, a higher safety margin should be applied.

D.3.3 Limit state deformations

Ovalization, local buckling, flexural buckling, implosion and progressive plastic failure shall be checked with the limit
state for deformations.

D.3.3.1 Ovalization

Ultimate limit state

The limit value for the smallest diameter of the ovalized cross-section is 0.85 D, or D’> 0.85 D (see Figure D.2).
’ ’
NOTE In tests carried out by Spangler, it appears that at D < 0.80 D there is a risk of colapse. Here D = 0.85D is indicated as
the value for the smallest permissible diameter.

Serviceability limit state

The limit value for ovalizationmay also be affectedby the deformation capacity of the corrosion coating or insulation, or
requirements related to efficient operations, such as the possibility of the passage of measuring and detection
equipment ("intelligent pigs"). The allowable ovalization is dependent on the equipment that shall pass through the
pipeline.

NOTE 1 For the benefit of passing of such equipment through the pipeline, the ovality is generally set at not more than 5%.
Requirements of the operator of the pipeline may influence this limit, as long as the limit value for instability of the cross-section is
not exceeded.

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 SI 5664 part 2 (Combined edition) (2006)

NOTE 2 When assessming serviceability limit states, a lower reliability index and, with that, lower partial factors are in
principle applicable. The practical difference with the partial factors presented in this standard for the ultimate limit states is however
rather small, which is why the latter factors are recommended for use.

D.3.3.2 Local buckling

With regard to deformations through local buckling, the following limit values are applicable for pipelines where
p = pi - pu > - 0.2 MPa (most pipelines on land):

1) Compressive strain under bending and normal force:

The limit valueεcr for compressive strain in the longitudinal direction is:

2
r' d ⎛ r' ⎞
— where 2 ≤ 120 : ε cr = 0,25 n − 0,0025 + 3000⎜⎜ ⎟⎟ ⋅ p ⋅ p
dn r' ⎝ Ed n ⎠

2
r' d ⎛ r' ⎞
— where 2 > 120 : ε cr = 0,10 n + 3000⎜⎜ ⎟⎟ ⋅ p ⋅ p
dn r' ⎝ Ed n ⎠

2) Torsional deformation:

The limit values for torsion θcr is:

2
dn d n 3000 ⎛ r ' ⎞
θ cr = 0,66 + ⎜ ⎟ ⋅ pd ⋅ pd
(r ')2 r' r ' ⎜⎝ Ed n ⎟⎠

The limit value for εcompression and θtorsion is given by:

1.5 2
⎛ ε compression ⎞ ⎛θ ⎞
⎜ ⎟ + ⎜⎜ torsion ⎟ ≤1
⎜ ε cr ⎟ ⎟
⎝ ⎠ ⎝ θ cr ⎠

The critical radius r’, which shall be used in the above-mentioned formulas, is given by:

r ' = r (1 − 3 w r )

where:

r’ is the critical radius;

r is the radius of the pipeline without load;

w is the change in the radius, at the area of the occurring compressive strain or torsional deformation (see Figure
D.2).

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SI 5664 part 2 (Combined edition) (2006)

D D’

Figure D.2 - Change in cross-section

NOTE 1 Whether local buckling occurs or not is largely dependent on the radius of the curvature of the pipe wall, at the
location of the compressed fibers, or where the torsional deformations occur. By bending, or by soil loads, the cross-section
becomes oval. Comparing the the formulas for the limit values, using r’ = r, with test results on pipes loaded by bending and normal
forces, shows that these formulas provide safe values.
Tests carried out show that if r’ is used when soil loads are acting, the influence of greater ovalization can be taken into account.

NOTE 2 If D t < 55 an assessment on local buckling can generally be omitted

D.3.3.3 Flexural Buckling

Flexural buckling of the pipeline

Criteria for a determination of the critical buckling stress shall be derived from NEN 6770:1997/A1:2001 (Dutch TGB
standard Steel).

If εcr is less than εe = Re/E, in the case of compressive strain from bending and normal forces, then, for the
determination of the critical buckling stress, one shall proceed from material with a fictitious yield stress of R’e = εe×E.
The buckling curvature, which shall be used with R’e < Re is givenin Figure D.3.

Figure D.3 - Buckling curvature

NOTE 1 Fexural buckling and local buckling may interact, resulting in collapse at a lower load than the lowest value
indicated by the local buckling and buckling criteria, if these were considered in isolation. This effect is allowed for by selecting the
buckling curve B in Figure D.3 (that is a material with Re = R’e) instead of the buckling curve A, where R’e is smaller than Re.
The hatched area in Figure D.3 represents the effect for interaction between flexural buckling and local buckling.

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 SI 5664 part 2 (Combined edition) (2006)

NOTE 2 In practice, the flexural buckling of pipelines is especially a problem with high-temperature underground pipelines.
This problem can be prevented by setting requirements with regard to the maximum excavation length, or on the desirable minimum
lateral or vertical soil load, for instance by using formulas of the following type:

γs ×N2
Q≥ f0
EI

where:

Q is the required lateral force (ultimate horizontal bearing capacity or passive soil load) per unit of length (N/mm1);

N is the calculated axial compression force (calculation value) in the pipe;

fo is the initial eccentricity of the pipe (as a beam), for instance fo = Io / 200, with a minimum of 10 mm;

EI is the bending stiffness of the pipe;

Io is the initial buckling length: l o =

EI
N

γs is the safety factor for stability, (for instance γs = 1.25)

NOTE 3 γs can be seen as the product of a spatial variation factor and a calculation model factor, analogous to SI 5664-1,
Table B.3, but with the introduction of a larger length effect. This concerns the average available lateral soil load over the initial
buckling length. In relevant cases it is recommended to calibrate this factor to the actual circumstances.

D.3.3.4 Implosion

In case of omnidirectional external pressure, possible implosion (radial instability) shall be checked for the following
load cases:

1) external pressure only ;

2) bending moments only ;

3) combination of external pressure and bending moments.

The utilized symbols are:

Dnom is the nominal diameter of the pipe;

Dmax is the largest diameter of the ovalized pipe cross-section;

Dmin is the smallest diameter of the ovalized pipe cross-section

Mc is the characteristic bending moment for local buckling;

ML is the maximum allowable bending moment for local buckling;

pc is the omnidirectional external pressure, whereby the pipe collapses through implosion;

pe is the omnidirectional external pressure, whereby the pipe collapses elastically;

pp is the omnidirectional external pressure, whereby the pipe collapses plastically;

pL is the maximum allowable omnidirectional external pressure on the pipe;

εo is the initial ovalization of the pipe.

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SI 5664 part 2 (Combined edition) (2006)

D.3.3.4.1 External pressure only

If only external (gauge) pressure is acting on the pipeline as a load, then the collapse pressure pc causing implosion
(radial instability) can be determined with the formula:

(p c ( )
− p e ) p c2 − pp2 = p c p e pp 2δ 0
Dnom
dn
where:

2Re d n
pp =
Dnom
3
2E ⎛ d n ⎞
pe = ⎜ ⎟
1 − ν 2 ⎜⎝ Dnom ⎟
⎠
Dmax − Dmin
δ0 =
Dmax + Dmin

The value for Re in the formula for pp shall be reduced by 15% for pipes produced according to the UOE manufacturing
process, and with 7.5% for pipes produced according to the UO manufacturing process.

Under application of the load factor (γg,p), the material factor (γm,p) and a modeling factor (γm) from Table 3 for this load
combination, it shall be valid that:

γ M ⋅ pc
γ g,p ⋅ pL ≤
γ m,p

D.3.3.4.2 Bending moment only

If only a bending moment is acting on the pipeline, the characteristic bending moment Mc, initiating local buckling, can
be taken equal to to the fully plastic bending moment of the pipeline cross-section:

2
M c = Dnom d nRe

Under application of the load factor (γg.M), material factor (γm.M) and modeling factor (γm) from Table 3 for this load
combination, it shall be valid that:

γ M ⋅ Mc
γ g,M ⋅ ML ≤
γ m,M

D.3.3.4.3 Combination of external pressure and bending moment

If combinations of loads can occur, then, in addition to the separate assessments of the external pressure and the
bending moment as given in D.3.3.4.1 and D.3.3.4.2 the assessment below shall also be carried out.

Under application of the load factor, material factor and modeling factor from Table 3 for this load combination, it shall
be valid that:

n
⎛ ⎞
γ g,p ⋅ pL ⎜ γ g,M ⋅ ML ⎟
+⎜ ⎟ ≤ γM
pc ⎜ Mc ⎟
γ m,p ⎜⎝ γ m,M ⎟
⎠

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 SI 5664 part 2 (Combined edition) (2006)

where:

dn
: n = 1 + 300
Dnom

NOTE 1 For background information is referred to DNV-OS-F101, [9] and [32].

NOTE 2 The corresponding load factors, material factors and modeling factors are derived in [9], for D/d ratios that vary
between 20 and 50. Further research may show whether the applied models are also applicable to larger D/d ratios.

D.3.3.5 Progressive plastic collapse

Progressivel plastic deformation with each load cycle leading to excessive deformation or failure.

NOTE 1 A characteristic of this limit state is that the stress, required to satisfy the state of equilibrium and which is of
constant magnitude, is relatively high. The stress, resulting from satisfying continuously the deformation (angular rotation) conditions
is, ,moreover, of a such substantial magnitude that, with every stress cycle , aggregated with the forementioned equilibrium
stresses, a plastic strain occurs in one direction. After only a few cycles, failure can already occur. On the basis of [8], assessment
of this limit state is important for an axially restrained pipe section, in which a high circumferential tensile membrane stress from
internal pressure occurs in combination with a high axial membrane compressive stress (for instance from restricted thermal
expansion).

The limit value is not exceeded if the following relationship is fulfilled:

⎡ ⎤
R (θ )
2 2
3 ⎛ σy ⎞ R 3 ⎛σ ⎞
ε max = α × ∆T ≤ ⎢ e 1 − ⎜⎜ ⎟ + e 0,9 − ⎜ y ⎟ ⎥
⎢ E 4 ⎝ Re (θ ) ⎠
⎟ E 4 ⎜⎝ Re ⎟⎠ ⎥
⎣⎢ ⎦⎥

NOTE 2 The partial factors that shall be applied to temperature and internal pressure (acting in combination) shall conform
to Table 2.

NOTE 3 In case of a ’restrained’ section of a hot buried pipeline, for the given load combination and with the fulfillment of
the above-mentioned requirements, the Von Mises criterion for alternating yield is also met.

D.3.4 Limit state with alternating yield

D.3.4.1 Background

If, through variations in the size of the loads, the strain in the steel varies to such an extent that plastic deformations
occur in the steel in more than 1 direction (+ and -), alternating yield occurs.

The number of cycles, which are needed to reach crack initiation, is dependant on the magnitude of the strains that
occur during yielding.
Relative to crack formation through strain variations in the elastic range, the number of cycles needed to cause
cracking is lower with alternating yield.
Characteristic in this is the loop in the stress-strain diagram of the material at that point (see Figure D.4).

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SI 5664 part 2 (Combined edition) (2006)

Figure D.4 - Stress-strain diagram during alternating yield

The limit state for alternating yield aims to limit the maximum strain and strain variations from cyclic loads, to ensure
that at a certain point of the structure plastic yield can only occur one time, and that during the following load cycle the
strain fluctuations stay within the elastic range.

The limit value for alternating yield is dictated by the condition that the stress fluctuations shall fit within the yield ellipse
of Figure D.5 (maximum distortion energy hypothesis by Huber, Hencky and Von Mises).

Figure D.5: Yield ellipse

NOTE 1 The deformations are elastic, as long as the stress points are within the yield envelope. Trough variation of the
pressure and/or temperature, after imposing a certain bending and/or axial deformation a point on the circumference of the yield
ellipse can be reached at the first cycle. This generally leads to some redistribution of stresses, accompanied with yielding. One time
yielding is considered acceptable, as long as the limit state for strain is fulfilled. Everything has to develop elastically after the first
cycle of load and during subsequent cycles, that is the stress ranges (such as OA - CB in Figure D.5) should be within the ellipse. If
this is not the case, then alternating yield occurs.
In a majority of the assessment cases it is possible to easily examine which stresses are or are not relevant, and a plane stress
condition will apply.

The shear-stress hypothesis may also be applied to assess alternating yield. It shall be shown that half of the variance
of the greatest difference between each pair of the three principal stresses during a load cycle is less than .

D.3.4.2 Procedure for assessing straight pipelines and bends

In principle, separate calculations shall be carried out for the load combinations LC 3 up to and including LC 5 of table
D.1. In the calculation, the load factors from Table 2 shall be applied.

The representative range of stresses or strains, between the different stress conditions, shall be determined.

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 SI 5664 part 2 (Combined edition) (2006)

NOTE 1 In general, in the case of pipelines under high-pressure and with substantial temperature fluctuations, the
difference between the load combinations LC 4 and LC 5 will be representative.

NOTE 2 The maximum variations of the resultant stresses, from operationally varying load components (pressure and
temperature) are considered. It is to be checked whether the design pressure and the design temperature will occur in combination
with one another, or whether the maximum operating temperature can only occur in combination with a lower operating pressure
than the design pressure.

NOTE 3 The pressure and/or temperature changes can also be varied through the simulation of time steps. During a load
cycle, the maximum difference between the stresses or strains is determined.

D.3.4.3 Generally applicable procedure

If it is not clear, whether the principal stress shows a change in direction direction during load fluctuations, then the
generally applicable procedure described below, shall be followed:

1) Calculate the stresses σx, σy and ι for each stress condition;

2) Select a (representative) stress condition as a reference condition (with the subscript i ), which is the extreme
stress condition during the load cycle. In some cases it is necessary to select different stress conditions as a
reference condition, so as to be able to determine the representative stress range or strain range;

3) Calculate the difference between the stresses σx, σy and ι of a stress condition with the reference condition, during
a load cycle;

4) Calculate the principal stresses for these stress ranges;

5) Determine the differences between each pair of the principal stresses;

6) Determine the representative difference (absolute value) between each pair of the principal stresses.

If necessary, repeat the above procedure (steps 2) up to and including step 6)) for finding the representative reference
condition.

The limit value for assessment for alternating yield is Re + Re(θ ).

D.3.4.4 Simplified procedure, if primary stresses do not change direction

If the principal stresses do not or only barely fluctuate in direction during load fluctuations, then the following
procedure, which is only applicable to a limited extent, may be followed:

1) Determine the principal stresses σx, σy and ι for each stress condition;

2) Determine the differences between each pair of the three principal stresses for each stress condition;

3) Determine the absolute value of representative stress range, during the load cycle.

The limit value for assessment for alternating yield is Re + Re(θ ).

D.3.4.5 Stress ellipse for straight field sections

Assessment for alternating yield in a straight pipeline section (no bend) may also be carried out with the help of the
Von Mises stress ellipse. The limit value for alternating yield is determined through the condition that the stress
fluctuations shall fit within the yield ellipse of Figure D.5 (distortion energy hypothesis by Huber, Hencky and Von
Mises).

NOTE The yield ellipse cannot be applied for assessing alternating yield of bends, since the stress condition can fluctuate in an
axial and a tangential direction due to fluctuations in the load. As a consequence the stress condition is no longer clearly defined in
case of yield.

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SI 5664 part 2 (Combined edition) (2006)

One can also apply the shear-stress hypothesis for alternating yield, that is, the limit value is Re/γm for half of the
variation of the greatest difference between each pair of the three principal stresses, during a load cycle.

D.3.4.6 Simplified assessments for bends

By applying the shear-stress hypothesis (Mohr, Tresca), a simplified assessment for bends has also been defined. The
basic assumption in this is in that the representative stress range is found by applying all loads in one go. The limit
value for assessment for alternating yield is Re + Re(θ), if the representative stress range is defined as the difference
between the principal stresses.

D.3.5 Limit state fatigue

D.3.5.1 Assessment procedure

Table D.3 lists the step-by-step measures that shall be carried out. (Also see ENV 1993-1-1:1995, Chapter 9
additional words have been deleted).

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 SI 5664 part 2 (Combined edition) (2006)

Table D.3 - Methodology for fatigue analysis

Step Explanation Reference

Identity the construction details to be straight pipe, bends, T-pieces, reducers, etc.
assessed.
Identity the loads that shall be taken pressure and temperature fluctuations; 8.2.7 from
into account. traffic load. SI 5664-1
perform globa l(beam) analyses. calculate the forces and moments on the cross- SI 5664-1and
section. 7.4 and 7.5
carrie out cross-section analyses calculate the forces and moments acting on the pipe
wall.
establish stress history and design calculate the stress range. D4
stressrange spectrumfor the relevant determine the principal stresses, calculated according
details and locations. to the elasticity theory, proceeding from linear elastic
material behavior (both in the elastic and in the plastic
range).
determine the peak stresses (hot-spot stresses) in the
representative components of the structure, by
analytical methods (stress intensification factors) or
finite element analysis.
determine the equivalent (reference) stresses (von
Mises or Tresca).
the spectrum of load cycles during the operating life of
the pipeline shall be translated by way of a suitable
determine the design 'stress range' method (the words in parentheses have
spectrum. been deleted) into a few full-load cycles.

Identify fatigue strength data. select a σ-N curve for the relevant construction detail D.3.5.2.2 and
m D.3.5.2.3
⎛k⎞
σ = k × N −1 m ;N = ⎜ ⎟
⎝σ ⎠
Identify fatigue endurance (number of ni 1 D.3.5.3
full load cycles) for the design 'stress ∑ ≤
Ni γ fat
range'

D.3.5.2 Limit value for fatigue

D.3.5.2.1 General

The fatigue strength of specific construction parts is expressed in σ-N curves, each of which is applicable for classified
construction details.

σ-N curves are determined through tests on representative pipe components, or through stress or (in the plastic range)
strain-oriented fatigue tests, under laboratory circumstances.

The fatigue strength (σ-N) curves are defined by using the equation:

m
⎛k⎞
σ = k × N −1 m ;N = ⎜ ⎟
⎝σ ⎠

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SI 5664 part 2 (Combined edition) (2006)

D.3.5.2.2 Limit values (σ-N-curve) for fatigue caused by variations in membrane stress
by internal pressure

In those pipes, which are primarily loaded by internal pressure, (for instance high-pressure gas and oil pipelines with
operating temperatures ≤ 50° C), the stress cycles, from internal pressure variations resulting from operations, are
often decisive when assessing the risk of fatigue damages. The resulting stress distribution is an elastic membrane
stress evenly distributed over the entire pipe wall. For such transport pipeline systems, a fatigue analysis shall be
carried out and assessed on the basis of the ∆σ-N curves according to Figure D.6 and Figure D.7:

Figure D.6 - ∆σ-N lines for seamless pipelines, and for pipelines in which the direction of the stresses is
2
parallel to the direction of the weld (∆σ and Rm in N/mm )

In the range between 5.103 and 2.106 cycles the curve of fig D.6 is approximated by [see14],:

5,15
⎛R ⎞
N = 5.3 × 10 3 ⎜⎜ m ⎟⎟
⎝ ∆σ ⎠

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 SI 5664 part 2 (Combined edition) (2006)

Figure D.7 - ∆σ-N lines for submerged arc welded steel pipes
2
(∆σ and Rm in N/mm )

In the range between 5.103 and 2.106 load cycles, the curve of fig D.7 is approximated by [see 14],:

4,35
⎛R ⎞
N ≈ 700⎜ m ⎟
⎝ ∆σ ⎠

NOTE 1 In case of high frequency induction welded (HFW) pipelines it is recommended not to use figure D.6 for, but rather
to use the curves that are provided in Figure D.7, for pipelines welded with longitudinal seams.

The value of ∆σ is calculated according to load combination 2 (‘hoop stress formula'), under application of a partial
load factor γp = 1.0.

The number of load cycles that are calculated according to the chart shall be divided by a safety factor (model and
material factor) γM.fat = 10.

NOTE 2 The ∆σ-N curves according to Figure D.6 and D.7 are based on field tests that were carried out in the '70s on
straight pipes. These curves have included the influence of standard surface defects, welding imperfections and form deviations in
manufacturing. The influence of corrosive surroundings has not been included. The curves furthermore do not take into account the
influence of the mean stress level on the operating life. Recent full scale field tests, by the European Pipeline Research Group
carried out on pipe sections manufactured according to up to date production methods, indicate that a correction for the influence of
the mean stress level may possibly be necessary [see 13], especially for spirally welded pipes and induction (HFW) welded pipes.
For HFW welded pipes it is recommended to utilize the chart for submerged arc pipes welded. Both the Gerber and the Goodman
models can be taken into consideration for this correction. Both models are described in [13].

D.3.5.2.3 Limit values (σ-N-curve) for fatigue caused by local stress as result of temperature and pressure
cycles

Fatigue due to local stresses, or by temperature or pressure cycles, is primarily important for the assessment of local
stress peaks in such components as bends, T-pieces, reducers, etc., whereby deformation-oriented loads, such as
temperature, play an important role. Arithmetically, such stresses can exceed the yield strength.

For steel grades that are documented in this standard, one can proceed from the factors: k = 5000 N/mm2 and m = 4.
This results in the curve according to Figure D.8. This curve is also based on the AD (Arbeitsgemeinschaft
Druckbehälter = German Pressure Container Association) data sheet S2:1995, and it also includes fatigue by local

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SI 5664 part 2 (Combined edition) (2006)

variation of plastic strains. Continuity from the elastic to the plastic range is achieved by expressing the strain, as
measured in the plastic range, into a pseudo- elastic 'stress range', for instance through σ = E ε.

The stress amplitude is recorded in a vertical direction in Figure D.8 (pseudo-elastic).

104

103

∆σ
N/mm2

102
102 103 104 105
N (number of cycles)
Figure D.8 - ∆σ-N curve

NOTE 1 The curve , used in the above figure for the design fatigue strength, is based on the AD data sheet S2:1995 and
[14], is estimated to lie at approximately three times the standard deviation of log N under the average curve, which was obtained
through "curve-fitting" from the original test results for welded test rods. The probability of having a fatigue material strength under
the curve values then amounts to approx. 0.1%. The values in the plastic range have been obtained through extrapolation from data
in the elastic range.

NOTE 2 Reduction factors for a butt weld, mill scale imperfections and temperatures of up to approx. 140 °C have been
included in the calculation of the curve. The effect of the electro-chemical surroundings has not been included in the curve.

NOTE 3 If other σ-N-curves are used, which are based on strain-oriented fatigue tests (for instance uni-axial tests on
polished test rods), then reduction factors for surface defects and welded details shall be applied, as well as a suitable theorem for
calculating the fictitious elastic stress and relating this to the plastic strain.

NOTE 4 The method with fictitious elastic stresses, as it has been covered here, is valid when the area in which plastic
strain occurs is relatively small with regard to the total cross-section. If large parts of the cross-section are subject to plastic
deformation, then the implicitly applied relationship between calculated elastic stresses and the occurring strain is no longer
guaranteed.

NOTE 5 Stress intensication factors, according to SI 5664-1, should be taken into account in determining the fictitious
elastic stresses in a curve.

NOTE 6 The influence of the fluid that is to be transported on the design fatigue curve should be examined.

NOTE 7 Reference is made to EN 13480-3:2002 for more information about fatigue calculations with regard to steel
constructions.

NOTE 8 The use of steel, with a higher yield strength, only leads to a marginal improvement of the fatigue endurance .

NOTE 9 For fatigue assessment of stress variations from internal pressure. fatigue curves, different from the curve in
Figure D.8, were used in the past These curves formed the basis for a simplified fatigue calculation, according to D.3.5.4.

The material and modeling factors are discounted, by dividing the calculated number of permissible cycles according to
the σ-N-curve by γm.fat (see Table 3).

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 SI 5664 part 2 (Combined edition) (2006)

D.3.5.3 Fatigue damage from changing stress intervals

To assess fatigue damage from variable stress intervals, the concept of "cumulative damages", as formulated by
Palmgren-Miner is used:

1
∑ ni ≤
N i γ fat

where:

ni is the number of cycles for each stress range σi

m
⎛k ⎞
Ni is the maximum number of cycles with a stress range σi, Ni = ⎜⎜ ⎟⎟
⎝σi ⎠

D.3.5.4 Simplified fatigue analyses

If it can be shown that the number of cycles (N) from temperature and pressure fluctuations, resulting in a variation in
the calculated stresses (calculation value) that is greater than 0.5 Re (but less than Re), conform to:

4,25
⎧ 60 ⎫
N ≤ 10 7 ⎨ ⎬ (Re in N/mm2)
R
⎩ e⎭
then no detailed fatigue analyses is required.

If this condition is not fulfilled, then a complete fatigue analysis shall be carried out.

D.3.5.5 Fatigue through traffic load

For possible fatigue through traffic loads, at crossings of pipelines with roads, reference is made to clause 6.5 SI
5664-1.

D.3.6 Limit state for resonance and "vortex shedding" / excessive lateral movements

NOTE These movements occur, whenever the impact frequencies of for instance wind, waves or currents, correspond with the
natural frequency of the corresponding pipeline section. The impact frequencies can, amongst others, be a consequence of
turbulences of the internal or external (liquid) currents ("vortex shedding"), acoustic vibrations, or a source of vibration located in the
neighborhood of the pipeline, for instance a machine.

No limit values for such vibrations are directly available. The designapproach is to prevent vibrations from resonance
and "vortex shedding".
The natural frequency of the pipeline system is assessed against a range of impact frequencies. An amplification of
these frequencies can be avoided by designing the pipeline system in such a way that the natural frequency of the
pipeline remains outside the range of impact frequencies (also see F.2.2.4 of SI 5664-1).

D.3.7 Limit state: displacements (stable position)

Inadmissibly large displacements in comparison to the desired position

The most unfavorable combination of simultaneously active horizontal and vertical loads acting on the pipeline shall be
taken into account.

The pipeline shall be supported, anchored or buried such, that no displacements will occur under all possible
conditions, with the exception of allowable displacements from pressure, temperature, expected settlements, and
possible effects due to self-burial.

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SI 5664 part 2 (Combined edition) (2006)

If a offshore pipeline is not buried, covered or anchored, then the dead weight of the pipeline, both empty, filled with
product or filled with a testing medium and own weight of the pipeline, shall be such that a stable horizontal and vertical
positioning in the construction phase is guaranteed.

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 SI 5664 part 2 (Combined edition) (2006)

Appendix E
(informational)

Application of the theory of plasticity

E.1 Introduction

After the yield strength has been reached, deformations in steel pipelines can still increase considerably before
collapse occurs. In addition, the load bearing capacity (strength) is frequently considerably greater than the load at
reaching yield strength.

The behavior (stress strain relationship) of the pipeline until the yield strength is reached can be described with the
elasticity theory. Formulae (calculation models) for this are given in manuals as well as in this standard.

A proper description of the behavior after yield occurs is only possible with the application of the theory of plasticity in
which the non-linear behavior of steel, namely yielding, has been taken into account. The available formulae
(calculation models) for the application of the theory of plasticity are complicated and more consuming than the ‘elastic’
models.

Calculation models are presented in [23] and in [19], among others, for the calculation of the elastic and plastic
behavior until collapse. A summary of these calculation models is presented in [18].

A series of interaction formulae has been included in this appendix in order to assess the limit state of stresses in the
plastic area in straight pipes. For the calculation of the deformations which occur such as bending and ovalization, and
for the calculation of the strains, simplified formulae for approximation have been provided. For more precise
calculations and for the calculation of bends, please see [20], [21], [22], [23] and [18].

Demarcation of the area where the theory of elasticity can be applied in beam calculations can be found in E.2 and E.3
(calculation model E-P, see D.2.2.2). The calculation procedure to be followed, is reported in E.4.

Interaction formulae with which the different variables, which determine the behavior of straight pipelines,as a beam
can be calculated, are included in E.5.

NOTE All forces and stresses in this appendix are calculation values, i.e. prior to calculation, the loads were multiplied with the
partial load factors according to table 2.

E.2 Load bearing capacity of the pipeline as a beam

The mechanism of yield in a longitudinal direction is generally representative for the determination of the load bearing
capacity for bending in a longitudinal direction. The load bearing capacity and the bending-stiffness of a pipe which is
loaded by a bending moment in a longitudinal direction, however, change under the influence of the other loads (soil
load, internal pressure, etc.). The influence of these other loads shall be taken into consideration when performing the
global(beam)analyses

Appearing in figure E.1 are:

Mp the (full) plastic bending moment when the pipeline is loaded only by bending in a longitudinal direction;

Me the elastic bending moment at which the yield strength is reached in the ultimate fiber;

Mm the maximum absorbable bending moment in case the pipeline is also loaded by other loads;

M*e the elastic bending moment in combination with other loads at which the yield strength is reached in the
ultimate fiber;

Ce the curvature of the pipe as a beam when the yield strength is reached in the ultimate fiber;

C*e the curvature of the pipe as a beam in combination with other loads, atwhich the yield strength is reached in
the ultimate fiber.

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SI 5664 part 2 (Combined edition) (2006)

without any other loads

with other loads

Figure E.1 — The influence of soil loads and other loads on the moment-curvature diagram in the
elastic-plastic area

Before reaching Me, the behavior is elastic. Afterwards, a gradual plastification of the cross-section occurs (elastic-
plastic behavior) until the entire cross-section is yielding and Mp is reached. As a result of the soil loads present, which
cause the ovalization of the pipe’s cross-section, , Me, Ce, and Mp however transform into Me*, Ce* and Mm,
respectively, and the situation in figure E.2 arises:

Deformation capability curvature

Figure E.2 — Moment-curvature diagram of the pipeline with different loads

E.3 Demarcation of the elastic area

If the results from analyses of the pipeline as a beam, according to the theory of elasticity (calculation model E-P) are
used, Me is used as the limit value for the calculated bending moment:

Straight pipelines:

Me π
M e* = ⋅ M m ≈ ⋅ M m ≈ π ⋅ rg2 ⋅ d n ⋅ σ e∗
Mp 4

The corresponding curvature is:

Me* ε y Mm
Ce* = = 2
EI D Mp

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 SI 5664 part 2 (Combined edition) (2006)

Bends:

π
M e* −bend = M m−bend
4

The corresponding curvature is:

M e −bend ε y Mm
Ce* −bend = =2 ⋅ k bend
EI bend D Mp

Here, Mm is the maximum bending moment that the pipe cross-section can transmit, see figure E.2. For the
determination of Mm, Mp, Mm-bend and k-bend, please refer to the interaction formulae in E.3 and [19], [21], [23] and [24].

If these conditions are satisfied and likewise the series of interaction formulae in E.3 (and the conditions in the
references [19], [20], [21], [22] and [23]) are satisfied, then it is also demonstrated that the limit state “stresses” has not
been exceeded (as, the requirement that the stresses cannot be higher than the yield strength is one of the conditions
in the derivation of the interaction formulae).

E.4 Calculation procedure

A ‘best guess” of the load bearing capacity on bending moment and torsional moment shall be made, providing “input”
for the beam calculation. This load bearing capacity is, as is shown in figure E.1 and E.2, influenced by the other loads.
For this reason, a provisional calculation of the cross-section is first conducted in order to determine this load bearing
capacity for the relevant cross-sections. The result of this cross-section calculation is the ovalization which shall be
imported into the formulae for bending stiffness.

Calculation model E-P:

After the beam-calculation has been performed, the stresses and deformations in the representative cross-sections are
calculated with the help of the interaction formulae from E.3. If the ovalization introduced into the beam-calculation (∆D
=2a) deviates more than 0.02D from the final calculated value, the calculations shall be repeated with a better initial
estimate of the ovalization.

Calculation model P-P:

If the results of the beam-calculation show that the resulting calculated soil loads, normal forces and shear forces are
deviating too much from the initially introduced values, the calculations shall be repeated.

NOTE A difference of 10 % between the introduced and the resullting calculated forces in the plastic range (load bearing
capacity, soil loads, Np, Dp) will still produce acceptable small deviations in the size of the load bearing capacity on bending and
torsion.

E.5 Interaction formulae for straight pipelines

E.5.1 General

A moment curvature-diagram is given in figure E.2 for a straight pipe which, aside from bending, is also loaded by other
loads such as direct soil load Qd, indirect soil load Qi, normal force F, shear force V, torsion moment Mt and pressure p
(p is the difference between the internal pressure pi, and the external pressure pu).

The maximum absorbable bending moment (Mm) for a straight pipe loaded with a combination of bending moment,
torsion moment, normal force, shear force, internal pressure, external pressure and soil load, can be calculated with
the interaction formulae from E.5.2 and E.5.3. The strains that occur are calculated according to E.5.4.

NOTE 1 For the derivation and background of the series of interaction formulae that follow, refer to [18], [10], [20] and [23].

NOTE 2 In general, the influence of the shear force and the normal force on Mm is relatively small. Soil loads and the pressure p
have the major influence.

NOTE 3 Performing the necessary calculations manually is very laborious. Use can be made of dedicated computer programs

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SI 5664 part 2 (Combined edition) (2006)

E.5.2 Interaction formulae for a straight pipe

The following formula is applicable for the cross-section being considered:

1 .7
M ⎛ N ⎞
+⎜ ⎟ ≤1
M pdtr ⎜⎝ Npdtr ⎟
⎠

where:

M is the bending moment occurring (calculation value) in the given load situation, in Nmm;

2
N is the effective normal force occurring (calculation value), N = F − pπ rg , in N;

where:

F is the normal force which comes from the beam-calculation, in N;

rg is the average radius, rg = (Du − d n ) / 2 , in mm;

p is the internal or external pressure (the pressure difference), whereby internal pressure shall be indicated
with a positive sign and external pressure shall be indicated with a negative sign, in N/mm2;

Mpdtr is the maximum absorbable bending moment if there is no normal force N acting on the relevant cross-section,
but other loads such as internal pressure, shear force, torsion moment, soil loads etc.are in effect, in Nmm;

2
⎛ V Mt ⎞
M pdtr = M pr 1− ⎜ + ⎟
⎜ Vpr M tpr ⎟
⎝ ⎠

Npdtr is the maximum absorbable effective normal force if there is no bending moment M acting on the relevant
cross-section, but other loads such as internal pressure, shear force, torsion moment, soil loads etc. are in
effect, in N;

2
⎛V Mt ⎞
Npdtr = Npr 1− ⎜ + ⎟
⎜ Vpr M tpr ⎟
⎝ ⎠
where:

Mpr is the absorbable plastic bending moment (pipe as beam) for a straight pipe, taking into account the
influences of the ovalization of the cross-section, the internal pressure repectively external pressure, and
the soil loads (directly and indirectly transmitted overhead loads Qd and Ql), in Nmm;

Mt is the torsion moment in the considered cross-section (beam effect), in Nmm;

Mtpr is the absorbable plastic torsion moment for a straight pipe, taking into account the influences of the
ovalization of the cross-section, the internal pressure respectively external pressure, and the soil loads
(directly and indirectly transmitted overhead loads Qd and Qi), in Nmm;

V is the shear force in the considered cross-section (pipe as a beam), in N;

Vpr is the absorbable shear force, taking in account the influences of the ovalization of the cross-section, the
internal pressure with respect to external pressure, and the soil loads (directly and indirectly transmitted
overhead loads Qd and Qi), in N;
Npr is the absorbable normal force, taking in account the influences of the ovalization of the cross-section, the

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 SI 5664 part 2 (Combined edition) (2006)

internal pressure with respect to external pressure, and the soil loads (direct and indirect transmitted
overhead loads Qd and Qi), in N;

Mpr = g h Mp

Mtpr = g Mtp

Npr = g Np

Vpr = g Vp

where:

Mp is the plastic bending moment (pipe as beam) for a straight pipe, in Nmm;

Mtp is the plastic torsion moment for a straight pipe, in Nmm;

Np is the normal force at yield for a straight pipe, in N;

Vp is the shear force at yield for a straight pipe, in N;

g is a factor used to count for the influence of the arising forces and moments in the pipe wall in
circumferential direction;

h is a factor used to count for the influence of the ovalization of the pipe on the absorbable plastic
bending moment;

a is the ovalization of the pipe cross-section in the bending plane (a is half of the change in the diameter
∆D), in mm (for the calculation of a, see E.5.3);
2
M p = 4 rg d n R eb
2 2
M tp = π rg d n Reb
3
Np = 2 π rg d n Reb

4
Vp = rg d n Reb
3

2 a
h = 1−
3 rg

c1 c2
g = +
6 3

2
⎛ ny ⎞ m
c1 = 4 − 3⎜ ⎟ −2 3 y
⎜ np ⎟ mp
⎝ ⎠

2
⎛ ny ⎞
c 2 = 4 − 3⎜ ⎟
⎜ np ⎟
⎝ ⎠

where:

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SI 5664 part 2 (Combined edition) (2006)

ny is the force occurring in the pipe wall per unit of plate width as a result of soil load (nyq), the
curvature of the pipe as a beam (nyk) and the difference between the internal and the external
pressure (nyp), in N/mm;

my is the bending moment occurring in the pipe wall in circumferential direction, per unit of plate width
as a result of soil load (myq), the curvature of the pipe as a beam (myk) and the difference between
internal and external pressure (myp), in Nmm/mm;

np is the force at yield in the pipe wall per unit of plate width, in N/mm;

mp is the plastic bending moment in the pipe wall in circumferential direction, per unit of plate width, in
Nmm/mm;

n y = n yq + n yk + n yp

m y = m yq + m yk + m yp

np = d n ⋅ Reb

2
mp = 0.25 ⋅ d n ⋅ Reb

with:
n yq = 0.25 Qd + 0.125 Qi
Mm C
n yk = 0.20
rg

n yp = p rg

m yq = m yqd + m yqi

⎛ ⎛ α β ⎞⎞
m yqd = 0.25 Qd rg ⎜⎜1 − 0.25⎜ sin + sin ⎟ ⎟⎟f0
⎝ ⎝ 2 2 ⎠⎠

⎛ γ⎞
m yqi = 0.25 Qi rg ⎜ 0.5 − 0.25 sin ⎟f0
⎝ 2⎠

a
f0 = 1+
rg

m yk = 0.071⋅ M m ⋅ C ⋅ f0

m yp = − p ⋅ rg ⋅ a

where:

Qd is the directly transmitted overhead load, in N/mm;

Qi is the indirectly transmitted overhead load, in N/mm;

C is the curvature of the pipe as a beam, in mm-1;

α is the load angle for directly transmitted overhead load;

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 SI 5664 part 2 (Combined edition) (2006)

β is the angle of support;

γ is the angle of load for indirectly transmitted overhead load (γ may be considered to be equal to α
= 180°).

E.5.3 Calculation of the ovalization

The ovalization a is primarily caused by the soil loads. In addition to this, the bending in longitudinal direction is also a
contributing factor. The internal pressure produces a reduction of the ovalization (“rerounding”). The ovalization a is the
result of an elastic component ael and a plastic component apl.

a = ael + apl

NOTE In deviation from the rest of this standard in this appendix , the notation a is used for the vertical deflection of the pipe
cross-section (the ovalization) , instead of δ or δy. This is done in order to guarantee conformity with the background literature ([20],
[21] and [23]).

a) Elastic range

ael = agd-el + aqi-el + ac-el

where:

aqd-eI is the ovalization caused by the directly transmitted soil load, including rerounding;

aqi-el is the ovalization caused by the indirectly transmitted soil load, including rerounding;

ac-el is the ovalization caused by curvature from Bending Moment including rerounding;

3
Qd ⋅ rg 3a
aqd−el = 0.5 k yd (1 + ) ⋅ frr
EI w rg

3
Qi ⋅ rg 3a
aqi−el = 0.5 k yi (1 + ) ⋅ frr
EI w rg
5
rg 3a
ac − el = C 2 2
(1 + ) ⋅ frr
dn rg

where:

kyd is the ovalization (deflection) coefficient dependent on the way in which the direct soil loads affect
the cross-section, see SI 5664-1. table D.1;

kyi is the ovalization (deflection) coefficient dependent on the way in which the indirect soil loads are
acting on the cross-section, see SI 5664-1, table D.2;

frr is the rerounding factor;

2
EIw is the bending stiffness of the pipe wall per unit of plate width, in Nmm /mm;

3
E dn
EI w =
12 (1 − ν 2 )

For the rerounding factor frr, please consult D.3.1 from SI 5664-1.

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SI 5664 part 2 (Combined edition) (2006)

M M
C= =
EI E ⋅ π rg3d n

The abovementioned formulae for aqd-el and aqd-pi can be used till the maximum circumferential bending moment in
the pipe wall where myq has become equal to mp is reached. The formula for ac-el is applicable up to reaching Ce

b) Plastic range

⎛ 3a ⎞
(
apl = aqd−pl + aqi−pl + ac −pl ⋅ ⎜1 +
⎜ r
⎟
⎟
)
⎝ g ⎠

where:

aqd-pI is the ovalization caused by the direct soil load, including rerounding (plastic);

aqi-pl is the ovalization caused by the indirect soil load, including rerounding (plastic);

ac-pl is the ovalization caused by curvature, including rerounding (plastic).

In general, the soil loads will not be that large to cause ovalizations exceeding the elastic range. In those cases , aqd-pI
and aqd-pi will be equal to 0. In other cases, a non-linear cross-sectional analyses shall be conducted to determine the
total of a resulting from the soil load. See [19], [20] and [23] for this purpose.

The following approximation formula may be used for ac-pl in case a more precise calculation is not necessary.

3
rg
ac −pl = −2 ⋅ψ ⋅ (C − Ce* )
dn

with:
2
⎛ 0.5 × c 2 ⎞
ψ = 1 − ⎜⎜ ⎟⎟
⎝ g ⎠

NOTE Because c2 and g are dependent on, among others, curvature and ovalization, iteration will be necessary.

E.5.4 Calculation of the strains

E.5.4.1 In longitudinal direction

ε x = ε xC + ε xN
with:

ε xC = ± C × rg
N
ε xN =
AE
where:

A is the cross-sectional area on which the normal force is acting, in mm2.

E.5.4.2 In circumferential direction

The following approximation formulae may be used for the maximum circumferenial strain εy-max if a more precise
calculation is not necessary.

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 SI 5664 part 2 (Combined edition) (2006)

a) Elastic range

The following formula applies in the elastic (εy-el ≥ εyield = Reb /E )range:

k max d n p ⋅ rg
ε y −max = ε y −el = ± ⋅ 2 ⋅a +
k yd rg E ⋅ dn
where:

kmax is the maximum value for the moment coefficient when calculating the circumferential bending
moments from soil loads (in general, this will be kbottom), see SI 5664-1, tables D.1 and D.2;

kyd is the ovalization coefficient dependent on the manner in which the direct soil loads are acting on the
cross-section, see SI 5664-1, table D.1.

The ovalization corresponding with εyield is named ayield.

b) Plastic range

The following formula applies in the plastic area:

2
⎛ a ⎞ p ⋅ rg
ε y −max = ε y −pl = ±⎜ ⎟ ⋅ ε yield +
⎜ ayield ⎟ E ⋅ dn
⎝ ⎠

E.6 Moment-curvature diagram

The following formula applies for the elastic range of the moment-curvature diagram (see figures E.1 and E.2):
⎛ a′ ⎞
Elred = Eπ rg dn ⎜1 − 1.5 ⎟
3
M = Elred ⋅ C with ⎜
⎝ rg ⎟⎠
In this equation, a’ is the ovalization when Ce* is reached.

The following formula applies for the moment-curvature diagram in the plastic range:
⎛ φ ⎞ ⎛ a⎞ C*
M = Mm 0.5⎜⎜ + cosφ ⎟⎟ ⋅ ⎜1 − 1.5 ⎟ with φ = arcsin e
⎝ sinφ ⎠ ⎜⎝ rg ⎟⎠ C

E.7 Interaction formulae for bends

There are two mechanisms that can determine the magnitude of the load bearing capacity on bending moment in
bends. These mechanisms are:

a) the occurrence of plastic hinges along the circumference of the cross section. This mechanism will become all the
more representative the more the bends are curved (small bend radius), the lower the internal pressure is, the
greater the soil loads are, and, moreover , are giving rise to an ovalization that has the same direction as the
ovalization from longitudinal bending;

b) the occurrence of yielding in a longitudinal direction. This mechanism will become all the more governing the less
the bends are curved (greater bend radius), at higher internal pressure, the greater the soil loads are and
moreover are giving rise to ovalization contrary to the ovalization produced by longitudinal bending. This
mechanism matches with the behavior dealt with in E.5.2 in the case of straight pipes.

For calculation methods and interaction formulae for bends, refer to [19], [21], [22], [23], [24] and [25]. Due to the
physically and geometrically non-linear character of the interactions, manual calculations are not really possible.
Therefore,finite element computer program is generally necessary to deal with both non-linear phenomena.

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SI 5664 part 2 (Combined edition) (2006)

Appendix F
(informativel)

Public Safety

F.1 Assessing local and group risk

F.1.1 Purple book

A “Quantitative Risk Assessment”, (abbreviated: QRA) shall be performed for natural gas
station.

A “Quantitative Risk Assessment”, (abbreviated: QRA) shall be performed for natural gas
pipelines in case the safety distances as stipulated in Table F.6 are not maintained.

CPR 18E “Guidelines for QRA” (the “Purple book”) [3] shall be used in order to complete the QRA. The text from F.2 is
a translation into Dutch of 3.5 “Pipeline transport” from section 2 ‘Transport’ of the CPR 18E. In case of discrepancies,
CPR 18E shall prevail.

The results of a QRA are iso risk contour lines of local (individual) risk(PR), presented in the form of a graph, and
graphics from which the group risks (GR) emerges. For evaluation of the results of the calculation of PR and GR, see
F.2.5.

F.1.2 VROM circulars

The text from F.3 is a summary from the Circular “Safety zones along high pressure natural gas transportation
pipelines “[1], from the Circular “Safety zones along transportation pipelines for category K1, K2 and K3 flammable
liquids” [2] and from Assistance regarding external safety in the transport of dangerous substances [28]. The text from
these circulars and the safety distances stated in these circulars have been determined and compiled under the aegis
of the ministry of VROM , The safety distances are summarized in table F.4 and table F.6 of this standard.

The distances are valid as long as the Dutch government does not issue an amendment through a new Circular.
Please consult the original documents for the correct application of the current regulations.

NOTE 1 Establishing the safety distances under regulation and their enforcement is primarily the task of the government.

NOTE 2 At the time of the first edition of this standard, a revision of CPR 18E and of the abovementioned circulars were in
preparation. (A few points under discussion are included under F.4). As soon as the results of the revision have been made
available, a revised version of appendix F will be included in this standard.

F.2 QRA according to CPR 18E

F.2.1 General

CPR 18E contains a description of a detailed external safety evaluation (“Quantitative Risk Assessment”, abbreviated:
QRA) for hazardous substances that are transported via underground pipelines. Indicated in CPR 18E are those events
where a quantity of substance escapes (“Loss of Containment Events”, abbreviated: LOC’s) which shall be included in
the QRA, as well as the respective frequencies of failure and the various events (and the probability thereof) which can
arise following the release of the substances. No detailed description is provided on medeling the types of discharge,
dispersion, exposure and injury, or the wayin which the results are calculated and reproduced,. Only the differences
with the modeling of stationary installations is explained (see section 1 “Establishments” of CPR 18E for this).

The data which are necessary to perform for a QRA are:

— a description of the transportation system (diameter, location of the safety (check) valves);

— a description of the transport stream (fluid, flow);

— a description of the sources of ignition;

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 SI 5664 part 2 (Combined edition) (2006)

— properties of the hazardous substance to be transported;

— classification of the area in the vincinity of the pipeline route;

— meteorological data;

— population density in the vicinity of the pipeline route.

F.2.2 Leakage or rupture of pipeline or “Loss of Containment Events”

Two types of LOC’s (“Loss of Containment Events”) can occur with underground pipelines:

— leakage from a 20 mm hole in the pipeline;

— rupture of the pipeline.

F.2.3 Frequencies, probabilities and results of incidents with leakage

The frequency of LOC is given per kilometer per year. Table F.1 shows the LOC frequency for the different types of
underground pipelines.

Table F.1 — LOC frequencies for the various types of pipelines

Type of pipeline LOC frequency (1/km year)

pipeline in a “pipeline corridor” 7.0 x 10-5
pipeline not in a 6.1 x 10-4
"pipeline corridor"
The last line has been deleted

NOTE 1 What is meant by a pipeline in a “pipeline corridor” is a pipeline which is a part of a group of pipelines ,located in a route
that has been specially designated and designed for pipelines. The LOC frequencies are lower because extra safety measures have
been included.

NOTE 2 Other frequencies can also be used for specific pipelines, for example, in case extra safety measures are included to lower
the probability of a LOC. (This has been applied, for example, to a chlorine pipeline in the” Rotterdam Harbour” area).

NOTE 3 Discussions regarding failure frequencies were still ongoing between pipeline operators and the government at the time of
issuing of this standard. The results of these discussions may be included in a revision of CPR 18E. [11] provides an inventory of the
available failure casuistics in Europe and the U.S.A. over the period of 1970-1998.

Table F.2 provides the probability of a leakage of a rupture given an LOC.

Table F.2 — Probability of a leakage or rupture in case of LOC

Type of pipeline Probability of leakage Probability of rupture

pipeline in a “pipe 0.9 0.1
corridor”
all other pipelines 0.75 0.25

The dangerous events which can occur following an LOC are:

— exposure to toxic substances;

— flares;

— fireballs;

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SI 5664 part 2 (Combined edition) (2006)

— pool fire;

— flash fires;

— explosions.

The probability of instant ignition following a LOC are presented in table F.3.

Table F.3 — Probabilities of immediately ignition following an LOC

Type of liquid Probability of instant ignition

Leakage Rupture
flammable gas 0.04 0.09
liquid flammable gas 0.14 0.30

The probability of delayed ignition is maximum: (1 minus probability of immediate ignition) because there is a possibility
that no ignition will occur.

NOTE 4 A higher probability of instant ignition shall be taken into account with hydrogen, because of the very low minimal energy
needed for ignition.

F.2.4 Modelling of discharge, dispersion, exposure and fatal injury

After the LOCs have been determined, the discharge is calculated. When doing this, a distinction shall be made
between a leakage and a rupture.

F.2.4.1 Leakage

If the LOC is not immediately noticed and the valves are not immediately closed, the leakage is considered to be a
continuous source from which a discharge lasting 30 minutes occurs.

If the valves are closed, the following is applicable:

— gas: the discharge will continue until the pressure in the pipeline is equal to the atmospheric pressure;

— liquid: due to expansion of the liquid the discharge will continue until the vapor pressure in the pipeline is equal to
the atmospheric pressure. If the pipeline does not run horizontally, consideration shall be made with a discharge ,
caused by gravity;

— gas compressed to a liquid: a two-phase discharge occurs.

NOTE A comparison of the flow going into the pipeline versus that leaving the pipeline gives an indication of the leak flow and the
possibility for the operator to notice the leakage.

F.2.4.2 Pipeline rupture

With a pipeline rupture the calculated discharge shall be doubled, because of discharge from both sides. Furthermore,
the discharge shall be increased by the pump discharge, until the pump is stopped or the valves are closed. In the
case of liquid transport pipelines, running through accidented terrain, gravity shall also be taken into consideration.

Starting points used and important related aspects are :

1) a check shall be made whether the pump speed increases as a result of the drop in pressure ,caused by the
rupture of the pipeline;

2) no consideration is made for crater formation and the location of the hole (direction of discharge), because
insufficient reliable data available for this are not i trustworthy;

3) the pool has a maximum dimension of 3000 m2 and is 0.1 m deep;

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 SI 5664 part 2 (Combined edition) (2006)

4) with the rupture of a ethene pipeline, the discharge is dependent on the temperature of the air and the soil: this is
because of the critical temperature of ethene. For leakage, there is hardly any difference in risk between a
discharge of gas or a two-phase discharge.

5) the evaporation factor for soil is equal to 1800 W/K.s1/2;

6) the meteorological data that are used in a QRA shall come from a weather station that is representative for the
transport route being considered. If applicable, data from different weather stations shall be used for the different
sections of the pipeline;

7) a representative value shall be used for the aerodynamic length of roughness z0 of the terrain along the transport
route (see 4.6.2 from section 1 of [3]). If applicable, different values shall be used for the different sections of the
pipeline. Standard value z0 = 1.0 m;

8) when modelling the dispersion of the gas cloud, no chemical processes or dry or wet deposition processes need to
be taken into consideration;

9) exposure and injury shall be modeled in conformity to chapter 5 in section 1 of [3];

10) An inventory shall be made of the presence of population along a transport route conform 5.3 in section 1 of [3].

After the size of the discharge has been determined, the modeling can be continued in the same manner as for
stationary installations.

F.2.5 Calculation and reproduction of the results

The results of a QRA are presented as iso-risk contour lines for local risk and graphs from which the group risk
emerges. Group risk shall be calculated and reproduced per kilometer of the respective transport route.
E
NOTE Chapter 6 of CPR 18 provides a description of a frequently applied methodology for the calculation of risk and how the
results can be reproduced graphically. The following aspects regarding this are important:

— the size of the grid should be sufficiently small in order to obtain sufficiently precise calculation results;

— in order to obtain consistent iso-risk lines, the accident locations should be situated at regular distances from each other and
accident locations which lie outside of the regions of the pipeline route that is being considered should also be taken into
consideration. There should also be an adequate number of accident locations so that the risk contour does not change
substantially if the number of locations increases;

— The beginning and the end of the section of a pipeline route that is considered for calculation of group risk, can be chosen .
previously and arbitrarily. However, the sections should be chosen in such a way that the maximum group risk will be
calculated

F.3 Safety zones for natural gas pipelines

F.3.1 General

In deciding upon an acceptable route, the determination of the iso-risk contour lines
for the local (individual) risk(PR) , by means of a QRA, can be omitted for natural gas
transport pipelines if compliance with Tables F.5 and F.7 are met.
With regard to group risk (GR), rules of thumb have been developed for natural gas
transport, through which a quick insight can be obtained if more detailed GR research
is necessary. See F.3.3.

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SI 5664 part 2 (Combined edition) (2006)

F.3.2 Local risk

F.3.2.1 Safety zoning

In the determination of an acceptable route from the viewpoint of local risk, the
following terms are employed:

a) Survey distance

Distance measured from the core of the pipeline (for stations, the edge of the
station) within which the location classification shall be determined on both sides
of the pipeline (for stations, the edge of the station). For land planning purposes,
unless otherwise agreed upon by the authorities, the area classification shall be
determined by surveying a strip whose width is determined in the statutory
regulations.

b) Building proximity distance

The shorter horizontal distance between the core of the pipeline (for stations, the
edge of the station) and the outer edge of a building intended for human occupancy,
buildings of considerable infrastructure value such as computer centers, telephone
exchanges, or buildings containing air traffic control equipment, or special objects
which shall be taken into consideration.

c) Location classification

The classification of an area based on the density of buildings intended for human
occupancy, the presence of special objects and the use of the area.

F.3.2.2 Objects determining the location classification

The design of gas pipelines must consider the factors and consequence of failure
due to the presence and activities of people along the pipeline route where
damage is likely to be more prevalent in locations with larger concentrations of
human occupancy. To address this, the route of pipelines must be given a location
classification based on population occupancy which in turn will limit the design
of the pipeline to the appropriate design factor .
The area class will comply with the following table – Area classification.

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 SI 5664 part 2 (Combined edition) (2006)

Area classification
Area class Description
1 Any 0.5 km. section along the pipeline that has 3 or fewer buildings
See note c intended for human occupancy.
It may include farmland, agricultural structures and storage
facilities.
2 Any 0.5 km section along the pipeline having more than 3 but fewer than 8
buildings intended for human occupancy.
It may include public assembly facilities such as open-air markets,
sports facilities, permanent houses of worship and other public and
industrial buildings not included in classes 3 and 4, that
accommodate less than 50 people at one time.
3 Areas intended for continued occupation for part of the year, such as
camping sites.
Areas occupied for short periods by large groups of people for part of
the day, such as playgrounds, allotments, sports fields or open-air
swimming pools.
Groups of adjacent dwellings where the shortest distance between the
dwellings do not generally exceed 10m.
Industrial areas and engineering facilities.
Area where there is frequent excavation work including quarries.
Main or secondary road with heavy traffic.
Areas in the close vicinity to several pipelines, cables etc.
4 • Buildings of more than three stories
• Residential homes for the elderly and nursing homes\ including
hospitals and sanatoria.
• Schools and commercial centers.
• Hotels , office buildings and facilities accommodating more than
50 people.
• Buildings of considerable infrastructure value such as computer
centers, telephone exchanges, or buildings containing air traffic
control equipment.
• Buildings, which present an increased risk due to secondary
effects such as above ground installations or aboveground storage
tanks (>5m3) for flammable, explosive and or toxic materials.
Notes a. The area classification shall be determined by surveying any
500 m long strip with a width of the assessment distance, (see SI
5664-2 Table F.4).
b. Each separate dwelling unit in a multiple dwelling building is to
be counted as separate building.
c. For wall thickness calculations, the design factor associated
with area class 1 shall not be used.

Remark: Once a section is defined based on the occupation density, the distance
of the beginning and the end of such a section to the outermost dwelling shall
be the minimal survey distance, given below.

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SI 5664 part 2 (Combined edition) (2006)

F.3.2.3 Survey distances

Table F4 —Summary survey distances (in m)
Nominal diameter Natural gas transport pipelines
operational pressure in MPa
inch mm 2-5 5-8 8-11
2 50 20 20 20
4 100 20 20 25
6 150 20 25 30
8 200 20 30 40
10 250 25 35 45
12 300 30 40 50
14 350 35 50 60
16 400 40 55 70
18 450 45 60 75
24 600 60 80 95
30 750 75 95 120
36 900 90 115 140
42 1050 105 130 160
48 1200 120 150 180

Note: For land planning purposes, refer to statutory regulations.

F.3.2.4 Wall thickness
The minimum wall thickness of the pipeline to be used is dependent on the
location classification. Because the wall thickness of the pipeline is calculated
in the structural design, however, the wall thickness calculated, using the
method described below shall always be taken as mandatory minimal wall thickness.
The pipe’s wall thickness shall also conform to the requirements of chapter 7.2.
The hoop stress and the wall thickness shall be calculated with the following
formula:

σ p = p ⋅ Dg / 2 ⋅ d and shall be assessed by: σ p ≤ Re / f d

where:

σp is the tensile circumferential hoop stress, in N/mm2;

p is the design pressure, in N/mm2;
Dg is the average pipeline diameter, in mm;
d is the minimum wall thickness after subtraction of manufacturing tolerance
and without any corrosion or abrasion allowances, in mm;
Re is the specified minimum yield strength, in N/mm2;
fd is the wall thickness factor (see table F.5).

The representative values for design pressure and yield strength shall be used in the
calculation, without applying a load factor or a resistance factor.

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 SI 5664 part 2 (Combined edition) (2006)

Table F.5 — Wall thickness factor

Location classification 1 2 3 4

pipelines in a “pipe 1 0.72 1 0.72 1 0.65 1 0.65

corridor” (1.39) (1.39) (1.54) (1.54)

1 0.72 1 0.65 1 0.55 1 0.45

all other pipelines
(1.39) (1.54) (1.82) (2.22)

NOTE The factor determines the minimum pipe wall thickness and provides a greater wall
thickness in case of higher location-classification (more densely populated areas).
F.3.2.5 Building proximity distances
Table F.6 sets forth the building proximity distances for transmission pipelines.

Table F.6 — Summary of building proximity distances (in m)

Natural gas transport pipelines

Nominal diameter
with operating pressure in MPa
inch mm 2-5 5-8 8-11
2 50 4 5 5
4 100 4 5 7
6 150 4 5 7
8 200 7 8 10
10 250 9 10 14
12 300 14 17 20
14 350 17 20 25
16 400 20 20 25
18 450 c 20 25
24 600 c 25 25
30 750 c 30 35
36 900 c 35 45
42 1050 c 45 55
48 1200 c 50 60
Distance to be determined in consultations between
c
the parties involved in a project.

F.3.2.6 Requirements related to the reduction of building proximity distances

F.3.2.6.1 General
The routing of a new pipeline or planning changes in the vicinity of an existing
pipeline can cause conflicts with the system of area classification.
In this case, the adoption of supplementary measures may be considered. The
object of these measures is to link risk-reduction techniques more specifically
to the needs of the area classification system. This is discussed in greater
detail below for transmission pipelines conveying (non-toxic) natural gas.

F.3.2.6.2 Measures
Measure 1) is mandatory.

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SI 5664 part 2 (Combined edition) (2006)

1) Increasing the design factor for wall thickness allowance (see table F.5)
for natural gas pipelines by reducing the reciprocal value by 0,1;
The measures which may be considered include:
2a) Providing additional protection over the pipeline, for example in the form
of concrete slabs;
2b) Providing additional protection on both sides of the pipeline, for example
with sheet piling;
2c) Providing depth of cover of at least 2 m and marking the pipeline on the
surface.
At least one additional measure chosen from 2a), 2b) or 2c) must be chosen for
pipelines with a diameter of 300 mm and larger.

F.3.2.7 Effect of additional measures

The proximity distance for natural gas pipelines can be halved provided the above
conditions are met.

F.3.2.8 Reduced wall thickness allowance for natural gas pipelines

For existing pipelines only, if one or more of the measures referred to under 2a,
b or c is adopted, a reduced design factor for wall thickness (Table F.5) may be
applied. This factor is the factor for the area classification one level lower
than the area classification for which the pipeline is designed (with a minimum
of 1/0.65).

F.3.3 Group risk

F.3.3.1 Rules of thumb for natural gas transport

In order to judge whether the requirements for group risk have been satisfied, a supplementary assessment shall be
conducted for natural gas transport pipelines. For this purpose, rules of thumb can be used through which (quick)
insight can be obtained with regard to the group risk into the actual risks and the possibilities for spatial development.

The rules of thumb indicate the lower limits with regard to the group risk. If a rule of thumb indicates that, given the size
of the pipeline (mass of the gas), the risk assesment criteria cannot be exceeded, additional assessment of the group
risk is not necessary. If the rule of thumb indicates that exceeding the requirements is possible, then an additional
assessment shall be conducted with the risk pattern (see F.3.3.2).

Rule of thumb 1: whenever there are residential buildings and/or special objects within the minimum building
proximity distance (see table F.6), the risk pattern shall be applied.

Rule of thumb 2: if all of the requirements in table F.7 are satisfied, the risk pattern shall be applied.

Table F.7 — Rule of thumb 2 for natural gas transport pipeline

Requirements
Parameter buildings at buildings at
one side(of both sides
the pipeline
diameter in inches > 42 > 24
population density per ha (determined up
> 120 > 60
to a max. of 175 m of the pipeline)
distance from buildings to pipeline, in m < 100 < 100

F.3.3.2 Risk pattern

Risk pattern is a simple aide for calculation to quantify risks in a more detailed fashion. If, on the basis of the rules of
thumb such as are given under F.3.3.1, it appears that there is potentially an unacceptable risk present, the risk pattern

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 SI 5664 part 2 (Combined edition) (2006)

shall be applied.

NOTE 1 An accepted risk pattern is the IPO risk pattern. This risk pattern was developed under the authority of the ministries of
VROM and of V&W, the IPO and the Netherlands Railroads, and is also known by the name of IPO Risk Calculation Methodology
(IPORBM). The program can be consulted in the provinces and the regional offices of the Ministry of Waterways and Public Works.

The input for the risk pattern is made up by the transport stream and data on the number of people present along the
route. The surrounding area is mapped in order to calculate the group risk. A characteristic of the group risk is that the
presence of persons close to the axis of transport weighs much more heavily on the calculation results than persons at
a greater distance. In theory, the group risk is influenced by all persons present withinin the greatest possible effect
area (“worst case scenario”); the size of that area is determined by the 1 % limit of lethality. When using the Risk
Pattern, special attention shall be paid to the inventory of persons present close to the pipeline (up to a distance of
approximately 300 meters), whereas at greater distances the estimates may be rougher.

If additional constructive measures are taken to lower the probability of damages, this can be conducted through a
correction on the standard failure frequency (see F.2.3). Whenever the results of the risk pattern indicate that the
requirements for the group risk have been exceeded or parameter(s) for the case to be calculated deviate strongly from
the standard parameter(s) in the risk pattern, a specific risk analysis (QRA) is necessary (see F.2).

NOTE 2 A specific risk analysis is an extensive risk analysis whereby a quantitative calculation of the risk tied to a particular area
and the group risk is made in a manner that is as realistic as possible. A QRA is frequently very detailed and contains many starting
points and assumptions. When drafting a QRA it is furthermore recommend to conduct interviews with all parties in advance
regarding the calculation models, level of detail, the scenarios to be used for calculations and the starting points that are to be
utilized.

F.4 Measures for limiting the probability of failure

Measures for limiting the probability of failure for steel pipelines are given below. The measures are also dealt with in
table 2 of SI 5664-1. Additionally, various measures are also applicable for other pipeline materials.
The degree to which the probability of failure is limited by the respective measures shall be established in consultation
with appropriate authorities.

NOTE One of the most important causes of pipeline failure (if not the most important at the current state of the art of pipeline
engineering, excluding internal corrosion resulting from the medium) results from external mechanical damage caused by
excavation work by third parties. Effective measures for limiting failure rates of the pipeline shall therefore in particular be oriented
towards the prevention of these mechanical damages.

Applicable measures for limiting the probability of failure are:

— increased wall thickness;

— a barrier above the pipeline, for example, concrete plates or slabs ( tyles);

— an additional barrier on each side of the pipeline, for example, a short sheet piling or buried curb stones or
concrete piles laid at grade level;

— laying the pipeline deeper with identification tape placed above it. Please consult [4] and [5] for the effects of laying
a pipeline deeper;

— the application of an extra soil cover which will prevent damage from agricultural activities (deep plowing,
drainage), whether or not in combination with additional pipeline markings placed aboveground;

— the application of a casing pipe;

— additional controls, monitoring and inspection during the construction phase;

— the application of an external corrosion resistant cover with a high mechanical strength (for example, sintered
polythene has a higher resistance against mechanical damage than asphaltic bitumen or epoxy paint);

— a stringent system for reporting and permits;

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SI 5664 part 2 (Combined edition) (2006)

— KLIC reporting; prior to the excavation work there is the possibility of entering into contact with the KLIC (Cable
and Pipeline Information Center), where it is known who operates the pipelines and cables in the affected area.
The pipeline operators supply information on the exact location of the pipeline or cable.

— “tough” (high notch toughness) material;

— crack arrestors (limiting the propagation of cracks), especially in crossings with important public works.

For additional information concerning measures for limiting risk for transport pipelines, refer to [4], [5], [11] and [12].

NOTE In [4] and [5], reductions of the probability of failure were reported for a few (combinations of) constructive measures based
on field tests with excavating machines.

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SI 5664 part 2 (Combined edition) (2006)

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predominantly static loaded constructions

[40] NEN-EN 10083-1:1997, Special steel — Part 1: Technical conditions of delivery for special steel (containing
amendment sheet A1: 1996)

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[41] NEN-EN 10246-7:1996, Non-destructive research of steel pipes — Part 7: Automated ultrasound research over
the entire circumference of seamless and welded (with the exception of puddle-welded) steel pipes for the
demonstration of imperfections in a longitudinal direction

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[44] DIN 30673:1986,

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