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Revision 4.1
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Specification for BVS Design-Operation-Maintenance Revision 4.1
i Document Authorisation
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of
all revisions prior to these are held on file by the issuing department.
TABLE OF CONTENTS
1 INTRODUCTION
1.1 PURPOSE
The purpose of this document is to provide a common design basis for the piping within the
areas of a block valve station (BVS), for oil and gas transmission pipelines with a diameter
ranging from 4" (100mm) to 48" (1200mm). It also gives guidance on operation,
maintenance and inspection of Pipeline Block Valve Stations.
2 SCOPE
This document covers the basic requirements for the piping design within the areas of a
block valve station (BVS), for oil and gas transmission pipelines with a diameter ranging from
4" (100mm) to 48" (1200mm). It is written in the context of liquid, gas and multi-phase
hydrocarbon fluids, but may be applicable to other fluids and diameters greater than 48 inch.
The boundary of a block valve station is the fenced-in plot above a pipeline block valve. The
design of the block valve station is such that it can be used either in liquid or gas service.
The main purpose of a BVS is to provide a means of isolating a section of a pipeline to:
Emergency repair clamps can be installed on pinhole leaks provided that the remaining
pressure in the line is less than 700 kPa. This is a general guideline only. Should the
maximum hydrostatic head in a pipeline be lower than 700 kPa, there is thus no reason to
install a BVS for facilitating emergency repair.
Criteria for deciding whether block valve stations are required, their spacing and location
shall be based on a QRA study, in line with ASME B31.8 section 846.1.1.
- MOL/SOGL system does not have any leak monitoring system which can aid in
faster response time to leaks.
A BVS, including above ground pipework, shall be designed according to the same code as
the pipeline.
Wall thickness transitions shall meet the welding configuration requirements as specified in
1,2
the design codes ASME/ANSI B31.4 section 434.8.6, and B31.8 Appendix I .
1
NOTE: T D , the minimum thickness for design pressures, shall not be greater than 1.5t, where t is the nominal
wall thickness of the thinner pipe.
2
Pipes with a wall thickness less than 4.8 mm shall not be used.
The distance between welds for fittings and branch connections shall be at least one pipeline
diameter, but not less than 300 mm.
For pipelines designed with a factor of less than 0.6, the block valve stations shall be
designed with a factor equal to that of the pipeline.
This design factor shall be applied to the pipework within the boundaries of the fenced-in
block valve station plot.
2.2.2.1 PIPEWORK
2.2.2.1.1 Bypass Line
The minimum diameter of the bypass line should be sized in line with velocity limitations, as
mentioned in section 2.2.1.5. The design shall take due account of the following:
Oil lines:
A bypass line shall not be installed permanently for liquid lines as dead legs would occur.
The bypass can be made and stored onsite:
- Adequately protected externally: pipeline coating/ painting.
- Adequately protected internally: full coverage coating and hard cover dust caps
Pipe supports will be fabricated and kept on site, ready for installation.
- Sufficient gaskets and stud bolts are to be available in emergency stock.
The take off from the main line shall be via a vertical pipe with a flanged valve to prevent
stagnant water in contact with the pipe wall.
Gas lines
A bypass can be installed with the off take in the vertical position. The bypass valves should
be normally closed. Ensure that the bypass section is free water after hydrotesting.
2.2.2.2 VALVES
For toxic services, the block valve (2.2.2.2.1), and bypass valves (2.2.2.2.3) shall be welded
into the pipeline. For non-toxic services, the valves should have flanged ends in preference
to weld ends unless the elimination of potential leak paths is more important than
maintainability and replaceability. Consideration should be given to the difficulties with the
installation of raised face gaskets for larger flanged valves (raised faced gaskets are
specified for all pressure classes <ANSI class 1500).
When valves are flanged, bolts shall be tightened in a controlled manner using hydraulic bolt
tensioning equipment, as outlined in SP-2020.
Where valves are purchased with pup pieces attached by the valve manufacturer, then
attachments, e.g. weldolets for instruments shall either be installed by the valve manufacturer
before pressure testing of the valve assembly, or in the field on adjacent pipework. Welding
of attachments to the pup piece in the field is not permitted.
The throttle valve does not need to be a tight shut-off valve, but shall preferably be of a bi-
directional type to allow effective flow control in either directions shown in Figure 2. This
valve shall be flanged into the bypass line.
For liquid lines with an automated BVS and bypass permanently in place, a thermal relief
may be required, unless full flow relief valves are installed
For liquid lines with manual BVS, the bypass is not permanently installed so a thermal relief
is not required.
The relief valve capacity and setting shall comply with the pipeline design code (ASME/ANSI
B31.4 or B31.8) and DEP 80.45.10.10.
Branch connections shall be avoided where possible; where required, the connection should
be in the12 o’clock position.
In addition, pressure indicator connections shall be installed on both sides of the throttle
valve (gas lines).
2.2.2.4.4 Supports
Supports, wherever possible, shall be designed in accordance with GU-629 and they shall
be designed to carry the weight of the above ground section of the bypass line filled with
water.
The supports shall be electrically isolated from the above ground piping.
2.2.2.4.5 COATING
All components of the BVS installed above & below ground shall be coated in accordance
with SP-1246.
2.2.2.4.6 LAYOUT
The BVS shall be graded and fenced in accordance with SP-1279.
Under normal circumstances the bypass line shall be on the opposite side of the pipeline
from the ROW access road.
The BVS shall have at least two gates on opposite sides of the compound. One gate shall
be for light vehicle/truck access and the other to provide an alternative emergency escape
route for personnel.
Installation of fixed area lighting is not required unless there are special security situations.
On either side of the block valve and on the pipeline side of the bypass valves sufficient pipe
length shall be included for valve replacement by a hot tap stoppling operation. The length
required is the length of an equal split tee plus 200 mm.
For main line block valves installed in a valve pit, there shall be no extension for drain,
sealant lines etc from valve to above ground. At least 500 mm clearance from valve body to
pit bottom, shall be maintained in the pit. Valve pit shall be sized such that at least 1500 mm
clear space is available from mainline OD (outside diameter) to pit wall on either side of
pipeline. (i.e. pipeline is centered in the pit). Actuator (Hydraulic) and the two bypass valves
shall be above grade level penetrating thru the pit cover. For liquid lines, bypass spool shall
have at 6 o’clock and 12 o’clock positions two 2” connections with blind flange (without valve
– which shall be installed by Pipeline Maintenance team later when spool is to be installed).
2.2.2.4.7 LOCATION
A study shall be carried out for each individual pipeline to determine the location of each
BVS. This shall take into account:
The objective is to minimise the number of BVS on a pipeline, supported by risk analysis
based on ALARP approach. It should be noted that sometimes other considerations such as
public image or external stakeholder concerns may override a QRA decision.
Calculations shall be made to determine the minimum operating temperature in the bypass
line due to throttling. In case this temperature is below the minimum design temperature of
5°C, the material selection given below shall be reviewed to assure its suitability. It should
be noted that the ASME/ANSI B31.4 and B31.8 codes are limited to systems operating
above minus 29°C. Reference is made to DEP 30.10.02.31 for guidance and requirements
relating to materials in low temperature service. Although transmission pipelines are
excluded from its scope it may be relevant for some of the BVS components.
2.2.3.2 PIPE
The design lifetime for the bypass piping should equal the pipeline design life. Therefore,
material selection is critically important. Pipe with the same nominal diameter as the pipeline
shall be in accordance with the mainline linepipe specification DEP 31.40.20.37
For the bypass piping that is blinded, nitrogen purged and stored at site, however, carbon
steel is acceptable under the condition that a preservative coating must be applied to the
inside of the spool. Based on prior experience with stored piping it is expected that the
carbon steel piping will be internally flow coated, as this treatment gives excellent results.
2.2.3.3 VALVES
The importance of purchasing high quality valves for these BVS’s can hardly be overstated.
Therefore, it is recommended that the valve bodies along with the ball and trunion be
constructed as per SP-1201 using corrosion resistant alloys (CRA). The valve bodies shall be
carbon steel with a 3 mm (total thickness) welded overlay of alloy 625, laid down in two
passes, for the internal wetted parts. The trim for the valves shall be alloy 625. The valve
manufacturer shall submit a procedure detailing how it is proposed to apply CRA to all
openings in the valve body (drain, vent, sealant injection, etc.). Manual gear operators will
be sufficient, as per section 2.2.7 of SP 1201. The drain valves shall be solid alloy 625.
2.2.3.4 FLANGES
Flanges shall be procured in accordance with DEP 31.40.21.34 (Pipeline Flanges).
2.2.3.5 FITTINGS
The tees that connect the bypass lines with the main line shall be purchased in accordance
with DEP 31.40.21.30-Gen (Pipeline Fittings) and shall meet the sour service requirements
as per SP-2041.
2.2.4 OPERATION
A BVS will only be operated in case of:
- Emergency due to leak/rupture in an adjacent section
- Requirement to reroute flow to a parallel pipeline
- Depressurization of gas pipelines
- Draining for repairs.
2.2.5 MAINTENANCE/INSPECTION
For BVS maintenance procedure, please refer to PR-2120.
PDO Title
GU-629 Guideline for Application and Selection of Standard Pipe Supports
PR-2120 BVS maintenance procedure
SP-1200 Specification for the Procurement of Pipeline Check Valves
SP-1201 Specification for the Procurement of Pipeline Ball Valves
SP-1211 Onshore Pipeline Engineering
SP-1246 Painting and Coating Systems for Oil and Gas Facilities
SP-1279 Civil and Building Construction Specification
SP-2020 Specification for flange connections bolt torquing and tensioning
SP-2041 Specification for crack resistant materials in H2S containing
environments
SP-2061 Functional Technical Directorates - Technical Authority System
SIEP
DEP 30.10.02.31 Metallic Materials - Requirements for equipment for low temperature
service and for equipment containing liquefied gas or lethal substances
DEP 31.36.10.30 Hydraulic Systems for the operation of on/off valves in protective
functions.
DEP 31.38.01.15 EP Piping Classes
DEP 31.40.00.10 Pipeline Engineering
DEP 31.40.20.37 Linepipe for critical service
DEP 31.40.20.33 Line Pipe Induction Bends
DEP 31.40.21.30 Pipeline Fittings
DEP 70.08.10.11 Mechanical and electrical maintenance equipment and tools
DEP 80.45.10.10 Design of pressure relief, flare and vent systems.
International
ASME/ANSI B16.5 Pipe Flanges and Flanged Fittings
ASME/ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
ASME/ANSI B31.4 Liquid Transportation systems for Hydro carbons, Liquid Petroleum Gas,
Anhydrous Ammonia and Alcohols
ASME/ANSI B31.8 Gas Transmission and Distribution Piping Systems
ISO 3183 / API 5L Petroleum and natural gas industries - Steel pipe for pipeline
transportation systems / Specification for Line Pipe
API 6D Specification for Pipeline Valves (Steel Gate, Plug, Ball and Check
Valves)
ISO 31 Quantities and Units
ISO 1000 SI Units and Recommendations for the use of their multiples and of
certain other units
ISO 15590 part 1,2,3 Petroleum and Natural gas industries – Induction bends, fittings, and
Make sure this is the latest issue of this Specification. Refer to the wall chart GU-611 for the
last issue date.
Where this Specification refers to DEPs and International Standards, it refers to the issues
that were in-use when the author wrote this Specification. Exceptions are references to
specific issues. If you use DEPs or International Standards with this Procedure, make sure
you use the correct issues.
Where cross references to other parts of this Specification are made, the referenced section
number is shown in brackets.
This Specification shall not be changed without approval from the CFDH. Only the
Custodian, the Corporate Functional Discipline Head (CFDH) who owns this Specification,
can give approval for changes. The CFDH for this particular Specification is the Pipelines
CFDH, UEL. If you think the Specification is not correct, write your comments on a copy of
the User Comment Form. The form is the last page of this Specification. Send the copy with
your comments and personal details to DCS. This Specification will be updated once every
three years.
FIGURES
Figure 1 (a): Block Valve Station Layout for Liquid Pipelines
20 NC 20 NC
RV
RV
PI PG PG
Slope 1:50
NC
(typ)
2”-D 2”-D
20 NO 20 NO
”
Future piping modifications
for BVS automation
PG PG
NC
20 NC 20 NC
APPENDIX A
GLOSSARY OF TERMS, DEFINITIONS AND ABBREVIATIONS
A.1 LANGUAGE AND UNITS OF MEASUREMENT
You shall use the English language and the International System (SI) units of measurement in all
documents and drawings; refer to ISO 31 and ISO 1000. Where the SI unit is a conversion of a
manufactured dimension, the SI units shall be put after the original dimension in brackets. For
example, for linepipe where the manufactured dimensions are in inches, 2" (50mm) pipe.
The list that follows tells you the meaning of some words in all Procedures and Specifications:
A.3 ACRONYMS
The following abbreviations or acronyms are used:
UIPT2 (UEL)
Custodian of Document Date: