EGYPTIAN NATURAL GAS COMPANY GASCO SECTION 1-DESIGN-NO_P7 LR 1.6 C&S PIPELINES CROSSINGSEGYPTIAN NATURAL GAS COMPANY GASCO C&S vocatrecuiation L.R. 1. SUBJECT PIPELINE CROSSINGS To define the standard to be used for pipeline crossings on the National Gas i Grid. ENGINEERING & DEVELOPMENT GEN, DIV.16.1 1.6.2 Road Al pipeline crossings will be unsleeved unless otherwise specified by the company. Impact protection measures such as cast in-situ or pre-cast concrete slabs shall be provided coupled with the placement. of a warning tape placed above and below such impact protection ‘The concrete slabs should be laid above the pipeline by a distance of SOcm, and laid in contact with each other to be as one unit in distributing the load, Backfiling, ‘must take place immediately after the pipe has been laid, and the trench clear of any ‘rocks, stones or siniar and the trench padded with a minimum of 20cm of sieved Above and around the pipe a:minimum of 20em sieved sand backfill, compacted around the pipe to provide protection from the remainder of the backfill. The backfill thoroughly compacted by wet tamping in 1Sem layers. Wall thickness. of the pipeline crossing on shall be 0.5in or using a design factor of 0.4 which ever is the greater, Rail All railway crossings shall include for externally coated H.S carbon steel sleeve in accordance with Egyptian Regulation, The cartier pipe shall include for a wall thickness of O Sins or using a design factor of 0.4 which ever is greater. Sleeve length to terminate at not less than 3 metres outside the rail boundary and with a diameter difference to the carrier pipe ofnot less than 10cm. For longer crossings the diameter difference may be extended to 15 - 20cm to avoid construction difficulties. Steel, sleeves shall have an electric resistance between pipe and sleeve of more than 100chm before being tied in. If a lower resistance is measured the carrier pipe shall be removed from the sleeve the insulation repaired and carrier pipe re- installed. With the prior installation of sleeve end seals it is ecommended that the annulus shall be filled between the support insulation spacers by a suitable material such as Bentonite cementitious fill which will provide a non-corrosive environment in the annulus and able to withstand extemal loadings, In practice great care will be necessary to ensure complete fling of the annulus by the cementitious fil. ‘The fill should not be relied upon to protect the carrier pipe from corrosion. However, corrosion can be controlled to a degree, provided an effective combination of the following is adhered to Cathodic Protection ‘Annular Fill Cartier pipe coating When any cementitious fil is used, it shall be free of all nitrates and calcium chloride. Page 21.6.3 Sleeved In the interest of effective Cathodic Protection to the pipeline the use of steel casings, should be avoided. Where casings have to be used the following options are available: a) Externally coated HS. (High Strength) Steel b) ‘Uncoated steel sleeves °) ‘Concrete (Reinforced) 4) High density Polyethylene ©) _-P.V.C Poly vinyl chloride) Design of casing shall ensure :~ a) by °° °) It is capable of withstanding external loads. Cartier pipe is easily installed, using suitable insulation spacers, such as fabricated galvanised steel 'P.V.C. coated with riser sections for ceentralising, Supports to be included at regular intervals and provision is rade especially atthe ends of ste! sleeves to avoid risk of contact between carrier and sleeve pipe. Support rings are spaced and based on the carrer pipe being filled with water, Possible additional forces caused by construction settlements at. the extremities which mark. a transition between two methods of installation. This. should be minimised by ensuring tha the cartier pipe shall have a firm bearing on the trench bottom for a distance of 8 metres from sleeve ends either by compaction ofthe trench bottom or alternatively the placement of sand filled bags under the pipe at | metre intervals. With the prior installation of sleeve end seals the annulus may be filled with ‘material for example Bentonite cement or other readily pumpable cementitious fill to give a non-corrosive environment coupled with the strength to withstand ‘extemal loadings imposed on the sleeve. Whichever material is used, itis essential to ensure that the grout should not have any significant change in volume when set. “The annulus is to be sealed as effectively as possible, or the casing filed with suitable material to minimise water circulation and therefore reduce oxygen supply to the minimum, Page 31.6.4 1.6.40 1.6.4 Above Ground Above ground pipeline crossings shall nt be used in situations where alternative ‘methods are possible. Self Supporting For self supporting crossings the design of the pipeline shall be spaced so as to prevent excessive deflection bending and shear stresses in the piping at the greatest load e.g, Hydraulic Test with special consideration given to pipeline sections where flange valves impose concentrated loads. Calculations shall be made to ensure that the sum of the longitudinal stresses due to ‘weight, pressure and sustained external loading does not exceed the maximum allowable stress. ‘Non-Self Supporting Where pipelines are required to cross obstacles such as e.g. Canals where the designed self support cannot be achieved, consideration shall be given to the use of pipe piles. In the case where pipe piles are not permitted an acceptable bridge arrangement will be used. ‘The design shall ensure thatthe stresses, mainly thermal and partially dynamic, on the structure are in harmony, and that the resulting pipeline stresses are minimised by ensuring maximum flexilty in the pipeline layout both in the approach and on the pipe piles or bridge. The pipe piles or bridge shall be designed to accommodate both the calculated weight of the pipeline and thermal movement together with its own structure arrangement, Page 4IMPACT PROTECTION ROAD 1-200 mm REINFORCED CONCRETE SLAP, CONCRETE TO BE GRADE c40 TO 85 8110,20mm AGGREGATE AND NOMINAL 50 mm SLUMP. REINFORCED WITH ONE LAYER OF A252 MESH FABRIC POSITIONED CENTRALLY IN SLAB.