CGA G-4.

4—2003
(EIGA Doc 13/02)

OXYGEN
PIPELINE SYSTEMS
FOURTH EDITION

COMPRESSED GAS ASSOCIATION, INC.

4221 Walney Road, 5th Floor
Chantilly, VA 20151
Phone: 703-788-2700
Fax: 703-961-1831
E-mail: cga@cganet.com
PAGE ii COMPRESSED GAS ASSOCIATION, INC. CGA G-4.4—2003
EIGA DOC13/02

PREFACE

As part of a program of harmonization of industry standards, the European Industrial Gases Association (EIGA)
and the Compressed Gas Association (CGA) formed an ad hoc task force with the goal of combining the sepa-
rate oxygen pipeline standards of each organization into one harmonized standard on oxygen pipelines. This
standard is intended as a joint EIGA/CGA international harmonized standard for the use and application of all
members of EIGA and CGA worldwide. The CGA edition is identical in technical content to the EIGA edition
except for regional regulatory requirements (noted), and it has minor changes in formatting and spelling.

PLEASE NOTE:

The information contained in this document was obtained from sources believed to be reliable and is based on
technical information and experience currently available from members of the Compressed Gas Association,
Inc. and others. However, the Association or its members, jointly or severally, make no guarantee of the results
and assume no liability or responsibility in connection with the information or suggestions herein contained.
Moreover, it should not be assumed that every acceptable commodity grade, test or safety procedure or
method, precaution, equipment or device is contained within, or that abnormal or unusual circumstances may
not warrant or suggest further requirements or additional procedure.

This document is subject to periodic review, and users are cautioned to obtain the latest edition. The Associa-
tion invites comments and suggestions for consideration. In connection with such review, any such comments
or suggestions will be fully reviewed by the Association after giving the party, upon request, a reasonable op-
portunity to be heard. Proposed changes may be submitted via the Internet at our web site, www.cganet.com.
This document should not be confused with Federal, state, provincial, or municipal specifications or regulations;
insurance requirements; or national safety codes. While the Association recommends reference to or use of
this document by government agencies and others, this document is purely voluntary and not binding.

A listing of all publications, audiovisual programs, safety and technical bulletins, and safety posters is available
via the Internet at our website at www.cganet.com. For more information contact CGA at Phone: 703-788-2700,
ext. 799. E-mail: customerservice@cganet.com.
Docket 99-90
Atmospheric Gases and Equipment Committee

NOTE—Appendices C, D, E, and F (Normative) are required.

NOTE—Appendices A, B, and G (Informative) are for information only.

FOURTH EDITION: 2003

© 2003 BY THE COMPRESSED GAS ASSOCIATION, INC. ALL RIGHTS RESERVED.
4221 WALNEY ROAD, 5TH FLOOR, CHANTILLY, VA 20151
Printed in U.S.A.
CGA G-4.4—2003 COMPRESSED GAS ASSOCIATION, INC. PAGE III
EIGA DOC 13/02

Contents Page

1 Introduction..................................................................................................................................................... 1

2 Scope and purpose ........................................................................................................................................ 1

3 Definitions....................................................................................................................................................... 2

4 Design philosophy .......................................................................................................................................... 4

4.1 General criteria .................................................................................................................................... 4
4.1.1 Causes of fire: Ignition mechanisms and kindling chain ....................................................... 4
4.1.2 Hazards analysis and risk assessment................................................................................. 5
4.1.3 General design precautions.................................................................................................. 6
4.2 Metallic materials, combustion resistant alloys, exemption pressure .................................................. 6
4.2.1 Flammability testing .............................................................................................................. 6
4.2.2 Velocity exemption pressures for standard purity oxygen .................................................... 7
4.2.3 Reduced purity oxygen-enriched atmospheres .................................................................... 7
4.2.4 Ultra high purity (UHP) oxygen atmospheres ....................................................................... 8
4.2.5 Very high pressure (VHP) oxygen applications .................................................................... 8
4.2.6 Temperature limitations ........................................................................................................9
4.3 Nonmetallic materials .......................................................................................................................... 9
4.3.1 Properties and risks .............................................................................................................. 9
4.3.2 Design practices and material selection ............................................................................. 10
4.4 Velocity and gas pressure criteria ..................................................................................................... 11
4.4.1 General ............................................................................................................................... 11
4.4.2 Impingement velocity curve and metallic material selection for piping and equipment ...... 11
4.4.3 Velocity limitations in nonimpingement sites ...................................................................... 12
4.5 Piping systems .................................................................................................................................. 13
4.5.1 Underground piping systems .............................................................................................. 13
4.5.2 Aboveground piping systems.............................................................................................. 14
4.5.3 Pipeline markers ................................................................................................................. 14
4.5.4 Cathodic protection............................................................................................................. 14
4.6 Siting, remote operation, use of barriers ........................................................................................... 14

5 Piping, valves, and equipment ..................................................................................................................... 15

5.1 General criteria .................................................................................................................................. 15
5.1.1 Material selection criteria ....................................................................................................15
5.2 Piping and fittings .............................................................................................................................. 15
5.2.1 Impingement sites............................................................................................................... 15
5.2.2 Nonimpingement sites ........................................................................................................ 16
5.2.3 Specific piping locations ..................................................................................................... 16
5.3 Valves................................................................................................................................................ 17
5.3.1 General ............................................................................................................................... 17
5.3.2 Valve functions ................................................................................................................... 18
5.3.3 Valve types ......................................................................................................................... 19
5.3.4 Valve seals and packing ..................................................................................................... 21
5.3.5 Other possible sources of ignition in valves........................................................................ 21
5.4 Equipment ......................................................................................................................................... 21
5.4.1 Conical strainers ................................................................................................................. 21
5.4.2 Filters .................................................................................................................................. 22
5.4.3 Flow-measuring devices ..................................................................................................... 23
5.4.4 Bursting disks ..................................................................................................................... 23
5.4.5 Insulating joints ................................................................................................................... 24
5.4.6 Flexible connections ...........................................................................................................24
5.4.7 Miscellaneous equipment items.......................................................................................... 25
5.4.8 Protection systems .............................................................................................................25
5.5 Lubricants .......................................................................................................................................... 25
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6 Cleaning ....................................................................................................................................................... 26
6.1 General requirements........................................................................................................................ 26
6.1.1 Cleaning strategy................................................................................................................ 26
6.1.2 Standard of cleanliness ...................................................................................................... 26
6.1.3 Cleaning methods...............................................................................................................26
6.1.4 Pipeline components .......................................................................................................... 27
6.1.5 Welding ............................................................................................................................... 27
6.1.6 Pressure testing.................................................................................................................. 27
6.1.7 Installation of pipeline equipment ....................................................................................... 27
6.2 Specification and manufacture of line pipe material .......................................................................... 28
6.2.1 General requirements ......................................................................................................... 28
6.2.2 Codes and standards.......................................................................................................... 28
6.2.3 Manufacturing process ....................................................................................................... 28
6.2.4 Heat treatment .................................................................................................................... 28
6.2.5 Hydrostatic test ................................................................................................................... 28
6.3 Pre-cleaned piping............................................................................................................................. 28
6.3.1 General ............................................................................................................................... 28
6.3.2 Pipe fabrication ................................................................................................................... 28
6.3.3 Pressure testing.................................................................................................................. 29
6.3.4 Internal surface finish.......................................................................................................... 29
6.3.5 Preparation for shipment .................................................................................................... 29
6.3.6 Maintaining cleanliness....................................................................................................... 29
6.3.7 Final cleaning...................................................................................................................... 30
6.3.8 Leak testing and blowout .................................................................................................... 30
6.4 Post-installation cleaning................................................................................................................... 30
6.4.1 General ............................................................................................................................... 30
6.4.2 Pressure testing.................................................................................................................. 31
6.4.3 Internal surface finish.......................................................................................................... 31
6.4.4 Maintaining cleanliness....................................................................................................... 31
6.4.5 Leak testing and blowout .................................................................................................... 31
6.5 Inspection .......................................................................................................................................... 31
6.5.1 Procedure ........................................................................................................................... 31
6.5.2 UVA light examination ........................................................................................................ 31
6.5.3 Acceptance criteria ............................................................................................................. 32
6.5.4 Remedial action .................................................................................................................. 32
6.5.5 Sealing, purging, and monitoring ........................................................................................ 32
6.6 Records ............................................................................................................................................. 32

7 Construction ................................................................................................................................................. 32
7.1 General criteria .................................................................................................................................. 32
7.2 Construction plan............................................................................................................................... 33
7.3 Pipe fabrication and welding.............................................................................................................. 33
7.3.1 General ............................................................................................................................... 33
7.3.2 Qualifications ...................................................................................................................... 33
7.3.3 Backing rings ...................................................................................................................... 33
7.3.4 Preparation for welding....................................................................................................... 34
7.3.5 Welding requirements for materials .................................................................................... 34
7.4 Assembly and installation .................................................................................................................. 34
7.4.1 Alignment ............................................................................................................................ 34
7.4.2 Flanged joints ..................................................................................................................... 34
7.4.3 Insulating joints ................................................................................................................... 35
7.4.4 Threaded joints ................................................................................................................... 35
7.4.5 Valves ................................................................................................................................. 35
7.4.6 Supports, guides, and anchors ........................................................................................... 36
7.5 Inspection and examination............................................................................................................... 36
7.6 Nondestructive testing ....................................................................................................................... 36
7.6.1 Pressure testing.................................................................................................................. 36
7.6.2 X-ray examination............................................................................................................... 37
7.7 Documentation .................................................................................................................................. 37
CGA G-4.4—2003 COMPRESSED GAS ASSOCIATION, INC. PAGE V
EIGA DOC 13/02

8 Design and construction of stations ............................................................................................................. 38

8.1 Function............................................................................................................................................. 38
8.2 Design brief ....................................................................................................................................... 38
8.2.1 Emergency shut-off valves ................................................................................................. 38
8.2.2 Isolation valves ................................................................................................................... 38
8.2.3 Filters and strainers ............................................................................................................ 38
8.2.4 Flowmeters ......................................................................................................................... 39
8.2.5 Flow and pressure control .................................................................................................. 39
8.2.6 Gas storage ........................................................................................................................ 39
8.2.7 Spill or vent control ............................................................................................................. 39
8.2.8 Pressure relief and vent valves........................................................................................... 39
8.2.9 Instruments ......................................................................................................................... 39
8.3 Standards and design codes ............................................................................................................. 40
8.4 Materials ............................................................................................................................................ 40
8.5 Barriers or screens ............................................................................................................................ 40
8.5.1 Barrier requirements criteria ............................................................................................... 40
8.5.2 Design criteria ..................................................................................................................... 40
8.5.3 Operational requirements ................................................................................................... 41
8.6 Location ............................................................................................................................................. 42
8.7 Earthing, grounding ........................................................................................................................... 43
8.8 Fabrication......................................................................................................................................... 43
8.9 Installation ......................................................................................................................................... 43
8.10 Testing............................................................................................................................................... 43
8.10.1 Post fabrication ................................................................................................................... 43
8.10.2 Post installation................................................................................................................... 43
8.11 Commissioning .................................................................................................................................. 43
8.11.1 Safety.................................................................................................................................. 44
8.11.2 Procedure ........................................................................................................................... 44
8.11.3 Filters .................................................................................................................................. 44
8.12 Operation........................................................................................................................................... 44

9 Operation, monitoring, and maintenance ..................................................................................................... 45

9.1 General safety instruction.................................................................................................................. 45
9.1.1 Personnel for operation and maintenance.......................................................................... 45
9.1.2 Operating isolation valves................................................................................................... 45
9.1.3 Welding and cutting work.................................................................................................... 46
9.1.4 Oxygen enrichment and deficiency..................................................................................... 46
9.1.5 Shutdown/startup of pipelines............................................................................................. 46
9.1.6 Venting and pressure relief................................................................................................. 47
9.1.7 Purging ............................................................................................................................... 47
9.1.8 Tools ................................................................................................................................... 47
9.2 Commissioning pipelines and stations .............................................................................................. 47
9.3 Operation and monitoring .................................................................................................................. 48
9.4 Information to third parties, work adjacent to pipelines, and update of documents........................... 48
9.4.1 General ............................................................................................................................... 48
9.4.2 Flow of information ............................................................................................................. 48
9.4.3 Summary of work................................................................................................................49
9.4.4 Records .............................................................................................................................. 49
9.4.5 Updating of pipeline drawings............................................................................................. 49
9.5 Specialized surveys........................................................................................................................... 49
9.6 Damage to the pipeline system ......................................................................................................... 49
9.6.1 Leakage .............................................................................................................................. 49
9.6.2 Revalidation ........................................................................................................................ 49

10 General protective measures ....................................................................................................................... 49

10.1 Emergency response plan................................................................................................................. 49
10.1.1 Liaison with public authorities and other consultees........................................................... 50
10.1.2 Description of pipeline system ............................................................................................ 50
10.1.3 Control centers ................................................................................................................... 50
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10.1.4 Notification of an incident....................................................................................................50

10.1.5 Alerting procedure .............................................................................................................. 50
10.1.6 Shutting down a pipeline..................................................................................................... 50
10.1.7 Emergency equipment........................................................................................................ 50
10.1.8 Remedial action .................................................................................................................. 50
10.1.9 Pipelines with cathodic protection....................................................................................... 51
10.1.10 Incident report form............................................................................................................. 51
10.1.11 Emergency exercises ......................................................................................................... 51
10.2 Power supplies and lightning strikes ................................................................................................. 51
10.3 Fire .................................................................................................................................................... 51
10.4 Oxygen deprivation hazards and precautions ................................................................................... 52
10.5 Accident and damage report ............................................................................................................. 52
10.6 Safety management system .............................................................................................................. 52
10.6.1 Notification to authorities and consultation on routing ........................................................ 52
10.6.2 Design and construction ..................................................................................................... 52
10.6.3 Shut-down systems ............................................................................................................ 53
10.6.4 Operations .......................................................................................................................... 53
10.6.5 Control of third party interference ....................................................................................... 53
10.6.6 Maintenance and inspection ............................................................................................... 53
10.6.7 Major accident prevention policies and safety management systems ................................ 54
10.6.8 Emergency planning ........................................................................................................... 54
10.6.9 Information to the public and interested parties.................................................................. 54
10.6.10 Land use planning ..............................................................................................................54
10.6.11 Accident reporting............................................................................................................... 54

Figures

Figure 1—Impingement velocity curve................................................................................................................ 12

Figure 2—Nonimpingement velocity curve ......................................................................................................... 13
Figure 3—Bypass installation.............................................................................................................................. 19

Appendices

Appendix A—Typical arrangements for pipelines systems (Informative)............................................................ 55

Appendix B—Description of promoted ignition combustion test method (Informative) ....................................... 56
Appendix C—Table of nominal alloy compositions and ranges (Normative) ...................................................... 58
Appendix D—Table of exemption pressures and minimum thicknesses (Normative) ........................................ 59
Appendix E—Table of safety distances (without barriers) for oxygen control and isolating/metering stations
(Normative) .................................................................................................................................................. 60
Appendix F—Example of preventive maintenance program (Normative) ........................................................... 61
Appendix G—References and bibliography (Informative)................................................................................... 63
CGA G-4.4—2003 COMPRESSED GAS ASSOCIATION, INC. PAGE 1
EIGA DOC 13/02

1 Introduction
This publication has been prepared by a group of specialists in oxygen pipeline systems, representing major
oxygen producers in various countries of Western Europe and North America and is based on the technical
information and experience currently available to the authors.

The industrial gases companies have engaged, through the Compressed Gas Association (CGA) and the Euro-
pean Industrial Gases Association (EIGA), in a process of developing harmonized safety practices and this
publication is one of them.

It must be recognized, however, that oxygen pipeline systems developed over 40 years in the various countries
of Western Europe and North America have shown good and comparable safety records, although national
practices show many differences in design and operations. Some national authorities have also introduced leg-
islation that is mandatory for the operators in those countries.

Thus, the information contained in this document applies only to future installations and not to existing installa-
tions or those in the project phase as of the date of this publication. Furthermore, to the extent that they exist,
national laws supersede the suggested practices listed in this publication. It should not be assumed that every
local standard, test, safety procedure, or method is contained in these recommendations or that abnormal or
unusual circumstances may not warrant additional requirements or procedures. The authors make no repre-
sentations or warranties on the information in or the completeness of this document and disclaim all warranties,
express or implied including, but not limited to, the warranty of merchantability and the warranty of fitness for a
particular use or purpose.

ISO units and corresponding Imperial units in parentheses are used in this document. Corresponding values
may be approximate.

2 Scope and purpose

The scope of this document is for metallic oxygen transmission and distribution piping systems, as shown in
Diagram 1 of Appendix A. It is limited to gaseous oxygen with a temperature range between –30 °C and 200 °C
(–22 °F and 400 °F), pressures up to 21 MPa (3000 psig) and a dew point of –30 °C (–22 °F) or lower depend-
ing on local conditions.

This document does not apply to the following processes:

• oxygen cylinder filling plants;

• medical oxygen piping installations;

• oxygen producing plants;

• oxygen compressor units;

• bulk oxygen facilities (liquid or high pressure gas) at the customer’s site up to the point where gas enters
the distribution systems; or

• piping on specialized equipment and machines such as scarfing, jet piercing, etc.

The purpose of this publication is to further the understanding of those engaged in the safe design, operation,
and maintenance of gaseous oxygen transmission and distribution systems. It is not intended to be a manda-
tory standard or code. It contains a summary of the current industrial practices. It is based upon the combined
knowledge, experience, and practices of the major oxygen producers in Western Europe and North America as
represented by their members on the EIGA/CGA ad hoc group on oxygen pipeline transportation systems.

Some of the practices represent conservative compromises and not all situations are described. The designer
is cautioned that this document is not a complete design handbook and does not do away with the need for
competent engineering judgment and interpretation. It is suggested that the user review any special problems
or concerns with his oxygen supplier who should be able to provide advice and guidance.