Piping-Design_Basis Rev 1

8/3/2019 Piping-Design_Basis Rev 1

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HINDUSTAN PETROLEUM CORPORATION LIMITEDMUMBAI REFINERY

DHT PROJECT

PART : III

SECTION : A

TITLE : ENGINEERING DESIGN BASIS

PIPING

DOCUMENT NO: 44LK-5100-00/L.02/002/A4

1 06.04.09 50 Revised as marked &Issued as Amendment

no.1

DRP RMP RMP/PVS

0 03.12.08 50 Issued for FEED DRP RMP RMP/PVS

Rev No. Issue Date Pages Description PreparedByChecked

ByApproved

By


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JacobsHPCL, Mumbai Piping Design Basis Part- IIILSTK Doc NO : 44LK-5100-0/L.02/0002/A4 Section - A44LK 5100 Sheet 2 of 50

TABLE OF CONTENTS1.0 PURPOSE

2.0 SCOPE

3.0 GENERAL CRITERIA

3.1 EQUIPMENT LAYOUT

3.2 PIPING MODELING & GENERAL ARRANGEMENT

3.3 OFFSITES AND YARD PIPING

3.4 TANK FARM PIPING

3.5 UNDERGROUND PIPING

3.6 VENTS AND DRAINS

3.7 FLEXIBILITY ANALYSIS & SUPPORTING

3.8 FLARE PIPING

3.9 MATERIALS AND SELECTION OF PIPES AND FITTINGS

3.10 NDT REQUIREMENTS

3.11 STRAINERS

3.12 WELDING

4.0 REFERENCED PUBLICATION

ANNEXURES

ANNEXURE A ACCESSIBILITY FOR VALVES & INSTRUMENTS

ANNEXURE B CLEARANCES

ANNEXURE C VERTICAL AND HORIZONTAL GUIDES SPACING

ANNEXURE D TABLE OF BASIC SPAN

ANNEXURE E TECHNICAL REQUIREMENTS OF PIPING MATERIAL

ANNEXURE F GENERAL REQUIREMENT

ANNEXURE G STANDARD DRAWINGS


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1.0 PURPOSE

The purpose of this document is to establish a common understanding between PMC & LSTKContractor on Piping Design Philosophies for DHT Project at HPCL, Mumbai Refinery.

2.0 SCOPE

This Design Basis defines briefly the general guidelines for piping viz: preparation of equipmentlayout, piping arrangement, piping material specifications and local statutory / safetyrequirements. In case of any discrepancy or contradiction either in this Design Basis, or inStandard Drawings / Standard specifications, It is deemed mandatory to follow therequirements of the national / International design codes / standards, local statutory rules orOISD guide lines as applicable. The standard drawings provided in the BID are for referenceand for conceptual understanding only and thus not exhaustive. Where ever necessary, eitherfor the lack of information or non availability, LSTK shall prepare or develop the requiredspecifications/standard drawings and use the same with prior approval of PMC

2.1 DEFINITION :

OWNER - Hindustan Petroleum Corporation Limited, Mumbai Refinery.

PMC - Jacobs Engineering India Pvt. Ltd.

LSTK - Successful Bidder

3.0 GENERAL CRITERIA

3.1 EQUIPMENT LAYOUT

3.1.1 BASIS OF EQUIPMENT LAYOUT

Equipment Layout shall be developed based on the following data:

P&IDs

Typical Equipment Layout Diesel Hydro treating Unit, by Process Licensor

Indicative Equipment Layout by PMC

Equipment Process Data Sheets.

Wind direction.

Overall Plot Plan

Tie-in-Points for process & utilities with existing Plant.

3.1.2 DEVELOPMENT OF EQUIPMENT LAYOUT

The following aspects shall be considered during development of Equipment Layout:


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1. Process requirement i.e. proper interconnection between equipment as per P& IDs toachieve the intended process parameters. The indicative Equipment Layout by PMC onlyprovides a suggested equipment layout that conforms to accepted good practice and

incorporates the critical relationships between major equipment that affect processperformance.

2. Economy of Piping material - Minimize the quantity of costly piping.

3. Erection & Construction requirement: -

Erection scheme and schedule of all equipment must be considered during equipment layoutto have smooth erection mainly in case of tall columns, heavy equipments like thick walledreactors, approach road for cranes/ derrick for lifting the column or reactors and requirementof special foundation/pile etc.

4. Safety Requirements including fire fighting, and hazardous area classification, Accessstairways in the platform/Technological structures.

5. Petroleum Rules, OISD Standard guidelines shall be followed. Fire fighting facility shallbe as per TAC and OISD norms. Safety shower location shall be marked in equipmentlayout. The relevant standards are to be followed for preparation of hazardous areadrawings.

6. Operation and Maintenance requirement as mentioned below:

Overhead and side clearances for exchangers and pumps

Provision of exchangers - tube bundle pulling area

Horizontal and overhead clearances for easy movement of working personnel

Crane approaches for air coolers / fired heaters

Provision for catalyst loading / unloading facilities

Provision for monorail for pumps and exchangers

Provision for EOT / HOT crane for compressors

Provision for operators cabin

7. Similar equipment grouping All columns, exchangers, pumps etc. shall be grouped togetherfor convenience of maintenance and safety wherever feasible.

8. The technological structures should be interconnected for easy movement of operationalpersonnel.

9. All areas requiring crane access in erection/maintenance of equipments, catalyst loading etc.shall be marked on the equipment layout.

10. U/G piping corridors for main headers should be marked in equipment layout for allunderground piping.

11. Fire proofing requirements in pipe racks, structures & supporting equipments.

12. Eye wash & shower locations, Utilities stations.


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3.1.3 PIPE RACK

In general, equipment layout shall be prepared considering straight pipe rack, however othershapes like L/T/U/H/Z etc can also be considered based on area available.

The total width of pipe rack shall include 30% extra space or 1.5m (min) for future modificationsin unit at later stage at all levels/tiers.

The width of the rack shall be 6m, 8m or 10m for single bay and 12M, 16M or 20M for doublebay having 4 tiers maximum. For interconnecting pipes to different units, existing pipe racks tobe expanded wherever possible considering foundation and column design. The spacingbetween pipe rack portals shall be taken as 6m in general. However it can be changed to suitintra units distances.

Each bay between two passing columns shall have secondary structural members at a span of3m to enable supporting of small bore lines.

Pipe racks shall be fireproofed, as per OISD Codes with provision of insert plates in supportingauxiliaries.

- Clearance beneath pipe rack shall be 4.5m minimum

- Road Clearance shall be 9m minimum for main road. Secondary road clearance shall be5m.

- Dia. 20 rod above Sleeper/Pipe rack to be made of CS.

- Deleted.

- Corrosion wear pads shall be provided for all the lines at support locations.

3.1.4 REACTORS

The reactor superstructure structural steel columns shall be placed in line and symmetrically sothat piping routing is shorter, easier, and economical and the whole area looks aesthetically laidout.

Maintenance access required near the reactor structure is mainly for catalyst loading andunloading.Stairway is provided for the reactor structure since the structure goes high and is frequentlyused by operators. Emergency escape ladder shall also be provided.

Depending on the type of catalyst loading system i.e. fixed or mobile or as indicated in Process

Licensors Package; make space allocation in the layout as required. The paved areas at gradewill extend around catalyst unloading / loading areas

Since reactors are heavily insulated, insulation to be shown on equipment layout drawing.Reactor shall have davits to handle top man way covers and its piping.


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3.1.5 REBOILER

Reboiler shall be located next to the tower they serve. The elevation of Reboiler shall be asgiven in the P&IDs. Horizontal thermo-siphon exchangers are located at a minimumelevation. Vertical thermo-siphon types are usually supported by the tower and are locatedon the backside to be accessible for maintenance. Large vertical types, which cannot besupported from the tower/ column, may require a separate supporting structure. As far aspossible they shall not be mounted on springs to take care of differential expansion. Noplatform/ piping to obstruct removal of vertical Reboiler with the help of crane. VerticalReboiler will require guides, where length/ diameter exceed 6.0 m. Reboiler piping shall bechecked for pressure drop before finalization of the same. Clear crane access shall beprovided for maintenance of unfired type re-boilers including piping elements like 3-way valveetc.

3.1.6 HORIZONTAL VESSELS

The Horizontal vessels shall be laid perpendicular to pipe rack and dished end shall be placedminimum 4 m away from the pipe rack. The clearance between horizontal vessel shells shall beminimum 2m or 900 mm clear aisle whichever is higher. The aisle minimum 900mm/OISD asspecified should be clear of any piping or instrument element (like LS, LG etc.) All the interequipment distances shall be as per OISD std.

High-pressure vessels shall be aligned with their dished ends facing away from the plant.

The chemical vessels to be located close to the dosing pumps to the extend possible.

3.1.7 TOWERS AND VERTICAL VESSELS

Towers and vertical vessels shall be arranged in a row with common centerline, decided bylargest vessel, placing O.D of the equipment minimum 4m away from pipe rack. A minimumclearance of 3m shall be maintained between tower shells, but in any case, minimum 100mmhorizontal gap shall be provided between platforms of adjacent towers. A minimum of 900mmclearance shall be provided between tower plinths.

A davit is required to be provided to handle the heavy items (like relief valves, blinds, coversetc.) The davit shall be on the side of column/vessel away from pipe rack.

The area at grade level to be kept clear for dropout.

Efforts shall be made to provide interconnecting platforms at suitable levels for adjacent

towers, considering thermal expansions of towers. All level switches, LG etc. including theirisolation valves, shall be accessible from ladders / platforms.

Chemical vessels shall be located close to the dosing point to the extent possible.


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PUMPS

Clearance between two adjacent pumps shall be such that clear 1000mm aisle is available.Wherever practicable, pumps shall be arranged in rows with the centerline of the discharge ona common line; in general pumps shall be kept outside the pipe rack only with motor facingopposite to equipment.

3.1.8

All pumps not open to sky, with motor rating 75 KW and above, shall be provided with monorailunder pipe rack / shed. Clearance between two adjacent pumps shall be such that clear1000mm aisle is available.

Pumps shall not be located within bunded (dyked) tank areas. Hydrocarbons process pumpsshall not be installed beneath equipment containing flammable or combustible liquids other thanunit pipe racks, unless special fireproofing and fire fighting precautions are taken, like waterspray system.

All process pumps handling class A fluid shall be provided with water sprinkle/spray system

3.1.9 EXCHANGERS

In most of the cases floating head of exchangers shall be placed on a line 4 m away frompipe rack. Shell and tube type exchangers may have a removable shell cover with flangedhead. Tube pulling or rod cleaning area must be allowed at the channel end. This shall beminimum tube bundle length + 1.5 m from the channel head.

One number of tube bundle puller (common) to be considered in all the exchangers.

Minimum clearance in between two horizontal exchangers shall be 2.0 m or 900 mm clearaisle whichever is higher. The minimum clear aisle specified between the exchangers i.e.,

900mm, shall be clear from any piping element and instrument including probes ofthermocouples.

Likewise Heat Exchanger train should be suitably spaced such that shell / tube inlet/outletpiping do not foul with floating head covers.

Monorails to be provided for tube bundle removal for all exchangers except for those, whichare open sky. Davits to be provided for floating head cover for all exchanger.

Elevation of exchangers shall be kept to minimum but shall be of sufficient height to allowdrainage from low points of exchanger piping. Clear access shall be provided for the OWS andCBD valves of the exchangers. No piping element like CBD / OWS valves shall be located ongrade directly below the channel cover and shell cover.

The roof height of the technological structure shall be sufficient to allow erection of exchangers(including stack type) by crane. On technological structure- monorail with chain pulley block willbe provided for exchanger bundle removal.


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3.1.10 FIN FAN EXCHANGERS/ AIR FIN COOLERS

Fin Fan Exchangers / Air Fin Coolers shall preferably be located over the main unit pipe rack.Suitable access for maintenance shall be provided. For air coolers located on technologicalstructure/rack, pipe concrete blind floor shall be provided below the air coolers. Blind floor isgenerally not required if pumps handling hydrocarbons or equipment are not placed belowthem. Pumps handling hydrocarbon, shall not be placed below the air fin coolers.

The width of the structure from where Air Fin Exchanger assembly is supported shall be about2m more than the Air Fin Exchanger tube length so that supporting of piping manifold (inlet / outlet) can be done from the main member of pipe rack / technological structure, thustransferring the load to main structural members. Monorail shall be provided at one end of aircooler platform area for lowering the gearboxes.

Following access shall be provided for air coolers mounted on pipe racks :

- Service platform to access the flanged inlet/outlet nozzles

- Plat forms to servicing the Fan, Drives, Gears etc. below to Air coolers.

- All platforms /walkways shall be supported from air cooler structure


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3.1.11 FURNACES/FIRE HEATERS

When the hydrocarbon being handled is above its auto-ignition temperature in process,equipment may be located close to the heater and adequate access for maintenance andadequate fire protection to be provided. This is done to reduce high hazard spreading within theplant

Furnaces/Fire Heaters shall be located upwind or side wind of process units to blow anycombustible leaks away from the open flame. They shall be located minimum 90 m away fromtanks and 30m away from control room. Distances for equipments handling hydrocarbon fromthe heaters shall be strictly as per OISD norms. Vessels/ reactors/ columns directly connectedto heater (if required as per P&ID) are exception. Heaters shall be arranged with centerline ofthe stacks on a common line in case of circular heater and wherever a common stack isfurnished to cater more than one heater the stacks shall be located at the end or side, which isaway from the unit. In case of individual box heater, the edge of the heaters on the rack sideshall be matched.

The stack height governed by the clearances from statutory authorities like Director General ofCivil Aviation and Pollution Control Board or any other safety norms whichever is stringent. Formaintenance, vertical tube heater must have access to permit a crane to remove and replacetubing. Horizontal tube heater must have horizontal free space equal to tube length plus craneparking space for tube pulling /maintenance/cleaning. In case of bottom floor fired heaters,there shall be adequate headroom clearance underneath furnace for removal of burners. Incase of wall fired heater min 2m wide platform with escape route at each end is necessary.

Pits and trenches are not permitted under heater or any fired equipment. Underground drainpoints and manhole covers shall be sealed within heater vicinity.

Furnaces shall be provided with platforms for operation and for access as follows

- For maintenance of soot blowers- For burner operation when inaccessible from grade.

- For observation door, except that when the doors are located less than 3600mm,

Above grade. Access shall be by ladder only

- When temporary platforms for header boxes containing removable plug fittings

Are required, only the platform supports are to be provided.

- For analyzer and sample points etc

3.1.12 COMPRESSORS AND THEIR PRIME MOVERS

Two major types of compressors are used in process plants.

Centrifugal Compressors

Reciprocating Compressors


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Compressors shall be located to keep suction lines as short as possible. Drivers forcompressor may be electric motor or steam turbines as per P&ID. The gas Compressors shallbe located downwind side of furnace so that leaks are not blown towards the furnace.

In general Compressors are kept under shed. When Compressors are kept under shed, sidesare fully open for the low shed or partially closed from top for high shed to avoid accumulationof heavier gases in the shed. Layout of the compressor shall facilitate maintenance space forremoval of motor, piston etc.

In case of a turbine driven compressor, if exhaust steam is condensed, turbine and compressorare located at an elevated level and condenser is located below turbine. A major considerationin centrifugal compressor location is the lube and seal oil console. It must be accessible from aroad, must be lower than the compressor to allow gravity drain of oil to the consoles oil tank.

Intercoolers are placed near the compressor and are kept within the shed. Knockout pots andafter coolers may be kept outside the shed but near compressor house.

For compressors, one electrically operated traveling (EOT) crane to handle heaviest removablepiece shall be provided for each compressor house. Maintenance bay for compressors shall beprovided. Maintenance bay shall be accessible from road to facilitate unloading of load on totruck etc. For removal of exchangers located within building monorail arrangement shall beprovided.

The layout of compressor house shall take into consideration process licensors requirement aswell as compressor manufacturers

3.1.13 CLEARANCE AND ACCESSIBILITY

3.1.13.1 Crane Access & tube bundle pulling

Equipment, structures shall be arranged to permit crane access to service air coolers,Compressors and exchangers.

All exchanger tube bundles shall be "jacked out" against shell. A clear space for tube bundleremoval shall be provided. Dropout bay/area may be considered for exchangers located atelevated structure. Provision for pulling and inserting of tube bundle to be provided. Monorailwith chain-pulley shall be provided for all heat exchangers except on grade & open to sky

For high-pressure exchangers, shell pulling on rails may be considered with prior approval ofPMC / OWNER.

3.1.13.2 Access to Pumps

Clear access of 3.8 m vertically and 4 m horizontally shall be provided centrally under main

pipe ways for small mobile equipment to service pumps, wherever these are located under piperack. Pumps outside the rack shall be approachable by small cranes from under the pipe rack.

3.1.13.3 Access to lowering items to grade level (Lowering Area)

Clear access shall be provided at grade on the access side for lowering external and internalfittings from tall elevated equipment by providing pipe davits.


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3.1.13.4 Layout & access requirements for Platforms Ladders and Stairs

3.1.13.4.1 For providing platform ladder & staircase following guidelines shall be followed:

Two means of access shall be provided (i.e., two ladders or one ladder and one staircase) at any elevated platform, which serves three or more vessels and for battery limitvalves / operating platform.

Platforms, Ladders and stairways shall be the minimum, consistent with access andsafety requirements.

Stairways for tanks to be provided on upstream of predominant wind direction

3.1.13.4.2 Platform at elevated structure:

Unless otherwise mentioned dual access (i.e. one staircase and one ladder) shall beprovided for structure having length up to 22.65 m (75ft). For large elevated structure,if any part of platform has more than 22.65 m (75 ft) of travel, it shall have staircases onboth sides. Also, based on height and levels of operating platform/technologicalstructures, stairways shall be provided on both sides.

Fire heaters located adjacent to one another shall have inter-connecting platform atvarious elevations. Fire heaters shall have minimum two stairways- access from gradelevel and will extend up to highest level of operating platform of the heaters.

Air coolers shall have platforms with interconnected walkways provided to servicevalves ,Fan motors ,Instruments etc.

Location at which normal monitoring (once a day or more) is required or wheresamples are taken shall be provided with stair access.

Items that require occasional operating access including valves, spectacle blind andmotor operated valves; heater stack sampling points shall be provided with ladderaccess.

Columns and technological structure shall be interconnected by walkway.

All nozzles of columns to be provided with ladder access.

No ladder shall be more than 6m in one flight

(Refer Annexure A for accessibility guidelines.)

3.1.13.5 Clearances

Minimum clearances shall be as indicated in Annexure B.

3.2 PIPING MODELING AND GENERAL ARRANGEMENT

3.2.1 BASIS OF 3D MODELING (ISBL)


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Piping and Instrument Diagram, Inter connecting P&ID.

Equipment layout

Piping Specification and cats & specsLine list

Instrument data sheet & vendor drgs

The following objective shall be ascertained during piping modeling

Proper access to all operating points including valves and instruments.

(Refer Annexure A)

Proper access to inter-related operating points for specific purpose.

Economic routing with minimum bends and flanges

Aesthetics

3.2.2 UNIT PIPING

3.2.2.1 Basis of Piping

Piping and Instrument Diagram

Equipment Layout

Equipment Data sheet and Setting plan

Line list

Instrument Data sheet

Structural and Building drawings

Topography of the plant

Piping material specification

Overall plot plan

Proper access to all operating points including valves /instruments and for maintenancepurpose shall be considered during piping layout.

3.2.2.2 Pipe ways/Rack piping

Racks shall be designed to give the piping shortest possible run and to provide clear headrooms over main walkways, secondary walkways and platforms. The entire Tie in points areto be clearly studied and identified so as to avoid any unnecessary crossing and jump overof pipes.

Predominantly process lines are to be kept at lower tier and utility & hot process lines onupper tier.

Generally the top tier is to be kept for Electrical and Instrument cable trays.


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Generally the hot lines and cold lines shall be kept apart in different groups on a tier.

Generally the bigger and heavier size lines shall be kept nearer to the column.

Spacing between adjacent lines shall be decided based on O.D. of bigger size flange (min300# flange), O.D. of the smaller pipe, individual insulation thickness and additional 25 mmclearance, preferably. Wherever even if the flange is not appearing the min. spacing shallbe based on above basis.

Anchors on the racks are to be provided on the anchor bay if the concept of anchor bay isadopted. Otherwise anchors shall be distributed over two to three consecutive bays.

Anchors shall be provided within unit on all hot lines leaving the unit.

Process lines crossing units (within units or from unit to main pipe way) are normallyprovided with a block valve, spectacle blind and drain valve. Block valves are to begrouped and locations of block valves in vertical run of pipe are preferred. If the blockvalves have to be located in an overhead pipe way, staircase access to a platform abovethe lines shall have to be provided. Provision of block valves, blinds etc. shall be as perProcess Design Basis & P&IDs.

3.2.3 PIPING

3.2.3.1 Design Pressure :

The design pressure of each line is the maximum non-shock internal service pressure. Thispressure corresponds with maximum of: 1.1 times the maximum operating pressure.

Design pressure of equipment to which it is connected.

The pressure setting of the relief valve that protects piping system. For liquid lines, static

head between lowest point and safety valve also to be added.The pump shut-off pressure or a compressors maximum discharge pressure for systemwith no relief valves or 1.2 times differential pressure plus suction pressure for dischargelines.

The static plus pressure head for system on the suction side of pumps.

In cases where a pump discharge line includes a control valve, but no relief valve thatportion of line from the pump through the control valve, including all valves in the controlvalve manifold; shall have the same design pressure as the pump shut-off pressure.

All lines operating below atmospheric pressure shall be designed for full vacuum. Lineswhich normally do not operate in vacuum but vacuum can develop in abnormal condition

shall also be designed for vacuum.All piping leaving Battery limit shall be designed for a closed valve outside the Battery Limit.

Higher design pressure shall apply from the source to the last valve before enteringequipment rated at a lower pressure.

Process shall decide design pressure of pipe line.


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3.2.3.2 Design Temperature

The design temperature shall be maximum sustained fluid temperature in line.

All the lines subjected to steam-out conditions shall be designed at 120C (process line data) oras per process Design temperature of the line whichever is higher.

The design temperature of piping may be the same as the design temperature of connectingupstream equipment if the difference between the operating temperature and designtemperature is less than or equal to 20C.

If there is large difference between design and operating temperature, duration and frequencyof process fluid attaining higher temperature shall be considered.

For steam traced piping, design temperature shall be fluid temperature plus 20C or 10Cbelow steam saturation temperature whichever is higher.

For low temperature (operating temperature is either lower than 0 C or lower than minimum

ambient temperature) design temperature shall be minimum operating temperature of the fluid.Metal temperature resulting from emergency conditions like depressurization, operation errorsetc. need to be taken care of.

Process will decide all the design temperatures of pipeline.

3.2.3.3 Loads & Supports

The piping system shall be designed to resist the efforts of loads imposed by the weight of thepipe, valves, fittings, insulation and fluid in the lines. When this fluid is air, gas or vapour, andthe line is to be Hydrostatically tested, temporary support may be required.

The additional loads imposed by wind shall be considered for large lines (18" and above). The

wind pressure is spelled out elsewhere in bid document. The discharge of reciprocatingcompressors, pumps, HP safety valves and let down valves and other lines which are likely topulsate and vibrate shall be properly designed and supported to avoid undue vibrations andforces/moments on piping, supports and connected equipment/machinery.

Downstream of control valves, safety valves blowing to atmosphere which can attain somevelocities shall be so designed to take care of the same and noise shall not exceed 88 dba atoperating levels, by using diffusers, silencers etc.

The stresses created by the imposed loads shall not exceed the allowable stress prescribed bythe ANSI B 31.3 Code for pressure piping where applicable or the ASME boiler code andshould also meet the requirements of IBR wherever applicable.

3.2.3.4 Corrosion Allowance

The minimum corrosion allowance in general shall be as given below:

Carbon Steel 1.5 mm (1/16")

Alloy Steel 1.5 mm (1/16")

Austenitic Steels 0.0 mm

Non-Ferrous Alloys 0.0 mm


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For corrosive services corrosion allowance for material shall be adequately designed to give alife of at least 20 years.

Exception to these shall be only with PMC/owners approval.

3.2.4 COLUMN / VESSEL PIPING

Piping from column shall drop or rise immediately upon leaving the nozzle and run paralleland close as practicable to vessel. Reboiler outlet piping shall be as short as possible withminimum bends.

Piping shall be grouped as far as possible for the ease of supports and shall run on the rackside of the column.

Manholes shall be kept on the road side of the column and approachable from the platform.

Projection of platform shall be 1.0m up to 1.0m diameter column and 1.2m for columndiameter > 1m from column insulation surface

Piping shall be supported from cleats welded on the vessel as far as possible.

Proper guides at intervals shall be provided for long vertical lines.

For ease of operation and maintenance, column and vessels, which are grouped together,shall have their platforms at the same elevation should be interconnected by walkways.However each Column/ Vessel shall have independent access also. Column/ Vesselplatform should be designed in such a way so that all nozzles should be approachable fromplatforms.

Piping support cleats shall be designed for safety valves considering impact loading during

popping off.Complete platform all around shall be provided in case of columns, at all manhole locations.

Maximum height of platform ladders shall be restricted to 6 meters.

Davit shall be provided on top of all columns for handling safety valves, Top curves etc.

3.2.5.1 EXCHANGER PIPING

Exchanger Piping shall not run in the way of built in or mobile handling facilities.

Wrench clearance shall have to be provided at exchanger flanges.

Piping shall be arranged so that they do not hinder removal of shell end and channel coverand withdrawal of tube bundle.

3.2.5.2 HEATER/FURNACE PIPING

Arrange piping to permit burner removal by providing break up flanges in the piping.

Burner valves shall be located close to peepholes for operation.

Piping to Burners shall be arranged in such a way so as to give equal and sufficient quantityof oil/gas to all burners.Only flexible metallic SS (SS316/SS321) hoses shall be used for burner piping


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Block valves for emergency, snuffing steam valve shall be located minimum 15 m away fromthe heater, preferably on the upwind side of the heater.Piping from various passes of heater outlet nozzles should preferably be symmetrical.Transfer line from heater to column shall be as short as possible, without pockets, freedraining towards column and with minimum bends.No piping shall be routed in the tube withdrawal area. If unavoidable, break up flanges shallbe provided in the piping for removal.Nozzle forces and moments to be as per API 560

All furnaces if they are located in the same area should be inter connected with each other atdifferent elevations.

3.2.6 PUMP PIPING

Pump drives shall have clear access.

Pump suction piping shall be as short as possible and shall be arranged with particular careto avoid vapor pockets.

Reducers immediately connected to the pump suction shall be eccentric type flat side up toavoid the accumulation of gas pocket.

For end suction pumps elbows shall not be directly connected to the suction flange. Astraight piece minimum 3 times the line size shall have to be provided at the suction nozzle.

Pump discharge check valve if installed in vertical lines shall be fitted with a drainconnection as close as possible downstream of the valve.

When a suction vessel operates under vacuum, the vent connection of the pump has to bepermanently connected to vapor space of the suction vessel to allow possible filling of thepump with liquid before it is started.

T-type strainers are to be used for permanent as well as temporary to avoid disassembly ofsuction piping for strainer cleaning for sizes 2" and above.

Y-type strainers are to be used for all sizes in steam services and for pump suction lines1" and below

All small-bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain)shall have provision for break up flanges for removal of pumps.

Piping shall be so arranged that forces and moments imposed on the pump nozzle do notexceed the allowable values.

Pump discharge should preferably be routed away from pump rather than towards themotor side.

For top suction, pump elbow shall not be directly connected to suction flange. A straightpiece of minimum 5 times the nozzle size shall have to be provided at the suction nozzle.

Pump cooling water connection shall be taken from the top of the circulating cooling waterheader.

PI (pressure gauge) connections shall be provided on upstream and downstream of valvesin suction and discharge lines for all process pumps.

3.2.7 COMPRESSOR PIPING


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Suction lines shall be as short as possible

Suction piping shall have adequate flanged joints for ease of erection and maintenance.

All operating valves on main suction and discharge piping shall be lined on one side as faras possible.

A minimum straight length of suction pipe is to be provided as per manufacturersrecommendation.

Piping shall be designed so that forces and moments imposed on the compressor do notexceed the manufactures recommendation.

Compressor suction lines between the knockout drum and the compressor shall be as shortas practicable & shall be without pockets.

Where the line between knockout drum and the compressor cannot be routed withoutpocket, low point in compressor line shall be provided with drains to remove any possible

accumulation of liquid, but after taking clearance from process licensor.Low points in the discharge line from an air compressor shall be avoided because it ispossible for lube oil to be trapped and subsequently ignited. If low points are unavoidable,they shall be provided with drains.

Compressor suction and discharge shall have untied bellows. The bellows are to besupplied by compressor manufacturer as per design calculations and bellows selectiondone as per stress analysis.

All the valves and spectacle blind in suction and discharge piping shall have operating andmaintenance access.

3.2.7.1 Piping arrangement for Centrifugal Compressors

Suction and discharge piping should preferably be routed at grade level to have a propersupporting of these lines.

Check valve for the compressor shall be located as close as possible to the compressor toreduce surges.

It would be preferable to bunch valves in one area wherever possible with their hand wheelsfacing one direction for ease of operation.

Suction pipes which are too small for manual cleaning, shall be provided with a removablespool piece to permit installation of a strainer at a convenient, accessible location. Pipingfrom strainer to equipment nozzle shall have a special note for clearing procedures.

3.2.7.2 Piping arrangement for Reciprocating Compressors

Trenches, pits and similar gas traps be avoided within compressor house.

Compressor suction piping from K.O. Drum shall be independently supported. It is importantto see that this support is not provided from the compressor house steel work. Pulsationanalysis should be carried out to decide the routing of the line.

Suction piping will subject to chemical cleaning as per the procedure specified in JEsstandard specifications. Also process licensors specifications/requirements shall be fulfilled.


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It is very important to route all suction and discharge piping of the compressor as close tograde level (min 500mm above grade) as practical to provide proper supports for thesystem. Concrete sleepers are preferred to steel supports. Sleepers shall be spaced at

varying distances (3000 mm max.) with no adjacent spans being equal, enabling to dampenthe vibration of the piping.

3.2.8 PIPING ARRANGEMENT FOR REACTORS

All reactor piping shall be clear of the access areas of loading / unloading of catalyst

Platforms provided around reactors and for access to piping and valves shall generally besupported from separate structure. However the platform can be connected to vessel shell ifwelding is allowed and cleats are provided. Generally reactor shell clips / cleats are to beavoided.

Reactor with top man way nozzle for catalyst charging is provided with a flanged elbowNozzle on this man way to connect outlet piping. This flanged elbow nozzle is to facilitatespool removal during catalyst charging.

Piping connected to reactor top outlet nozzle needs to be additionally supported fromstructure. (This support acts temporarily) since this connection to man way is dismantledduring catalyst charging.

Swing elbows type arrangement is preferred on the regeneration piping from reactor bottomas against valves and bypasses. This eliminates stress problems to some extent since theused hot line and unused cold line are not permanently interconnected.

All valves provided on reactor hydrogen service lines be it inline, vent, drain and instrumentvalves shall always be double blocked type. Also snuffing steam rings shall be provided

around hydrogen service flanges size over 12".For reactor process piping where spec. calls for ring joint flanges the piping shall bearranged so as to allow for valve removal.

The catalyst unloading / dump nozzle elevation of reactor bottom is to be decided based onthe provision of a catalyst shaker / vibrator equipment to be bolted onto this unloadingnozzle.

3.2.9 RELIEF SYSTEM/ BLOW DOWN SYSTEM PIPING

Relief of liquid and easily condensable hydrocarbons is to be discharged to closed blowdown system.

Wherever the inlet line size is higher than the safety valve inlet size, reducer shall beinstalled adjacent to inlet of safety valve.

Relief valve discharging steam, air or other non-flammable vapor or gas directly toatmosphere shall be equipped with drain or suitably piped to prevent accumulation of liquidat valve point.

Relief valve discharge piping to atmosphere shall be taken to safe location as per following.


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3 m - Above top platform of column or structure within 6m radius for steam and 8mfor hydrocarbon/ toxic discharge.

25 m - Horizontally away from Reformer Or any fired equipment.

50 m - Horizontally away from furnace, if more than one relief system of different setpressures is discharging into one common riser of vent stack.

Inlet and outlet piping of pressure relief valve shall be adequately supported to take care ofthe thrust induced by the relief valve during popping.

Reaction forces due to safety valve popping shall be ascertained in the connected piping.The effect of these forces on the piping supports and the anchors of the piping system shallbe calculated to ascertain that the allowable limits at these locations are not exceeded. Thesupporting structure also shall be adequately designed so that when subjected to theseSystem stresses in the inlet and outlet piping portions

At safety valves also shall be kept within the allowable limits, inclusive of the distributionbranching points in the inlet portion. These reactive forces shall not lead to any leakage atthe flanged joints present in the system. To ascertain these necessary calculations at theflanged joints shall be performed.

3.2.10 STEAM PIPING

Steam lines with conditions listed below fall in the scope of Indian Boiler Regulations (IBR). Alllines falling under IBR purview must comply with IBR requirements.

Lines having design pressure (maximum working pressure) 3.5 Kg/cm 2 (g) & above

Line sizes 10" inside diameter & above having design pressure 1.0 Kg/cm2

(g) & aboveLines with pressure less than 1.0 Kg/cm 2 (g) are exclusion.

User of steam like steam tracing lines, jacket of the steam jacketed lines, steam heating coilwithin the equipment are excluded from IBR scope.

All steam users where downstream piping is connected to IBR i.e. condensate flushed togenerate IBR stream are covered under IBR

Boiler feed water lines to steam generator, condensate lines to steam generator and flashdrum as marked in P&ID shall be under purview of IBR.

IBR Requirements (in brief)

All materials used on lines falling under IBR must be accompanied with IBR InspectionCertificate, Leading Inspection authority viz. Lloyds or others are authorized inspectionauthorities for IBR outside India. Whereas for Indian supply only IBR is the inspectionauthority.

IBR authority of state in which the system is being installed must also approve drawings likeGeneral Arrangement Drawings (GAD) and isometrics of lines falling under IBR.

All welders used on fabrication of IBR system must possess IBR welding qualificationcertificate.


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IBR system must be designed according to IBR regulations. IBR authority must approve alldesign calculations towards the same.

3.2.11 STEAM HEADER & SUPPLY LINES

Steam header shall be located generally on the upper tier and at one end of the rackadjacent to columns.

Branch lines from horizontal steam header, except condensate collection points, shall beconnected to the top of the pipe header.

Isolation valves if provided on the branch line shall preferably be provided on the horizontalrun and outside the pipe rack.

All branch lines shall be drainable.

The Tapings on the headers shall have Gusset supports.

Drip legs & steam traps shall be provided at all low points and dead ends of steam header.Drip legs at low points shall be close to down stream riser and shall be provided to suit bi-directional flows, if applicable.

The first isolation valve on Drip leg (Boot leg) outlet shall be piston type glandless and buttwelded type.

All turbines on automatic control for start up shall be provided with a steam trap in thesteam inlet line.

All traps shall be provided with strainers if integral strainers are not provided.Steam traps discharging to atmosphere shall be connected to storm water drain/stormsewer.

Expansion loops are to be provided to take care of the expansions within units.

Line traps shall be thermodynamic type up to Class 600# & bimetallic for piping Class 900#& above.

Double block Vents and drain valves shall be provided on high-pressure steam piping.

Small size steam valves upto 1 inch NB to be piston type glandless valves.

Wherever condensate is to be drained, proper condensate draining facility shall be

provided.Discharge of steam traps should not be near the vicinity of any Process / utility lines. Properdrainage facility must be envisaged for the condensate drain.

3.2.12 Steam Tracing/Steam Jacketing

3.2.12.1 Steam tracing system (If applicable)


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Tracers for the individual lines shall be supplied from manifolds when there are two or moreconnections. Standard module for steam distribution and condensate collection manifoldswith integral glandless piston valve and thermostatic steam trap shall be used. Balanced

Pressure thermostatic steam trap with 40 mesh strainer to be used. Number of Mech. Mant.Point tracers shall be 4/8/12 and tracer size or depending upon the detail engg-requirement. 20% or minimum 2 nos tracer connections shall be kept spare for future usefor both steam supply and condensate collection manifolds. All manifolds shall be installedin vertical position and manifold size shall be 1.5.

For Steam tracing balanced pressure thermostatic steam trap with 40 mesh strainer to beused.

Manifolds shall be provided with two spare blanked off connections.

Maximum number of connections taken from a manifold is 12 including spares.

Manifolds shall be accessible from grade or from a platform.

Pockets in steam tracers shall be avoided as far as possible.

Tracers shall be limited to the following run length upstream of traps.

Size of tracer(inch)

Length of tracer pipe (Meters)

Steam operating pressure

20psig 50psig 100psig 150psig 200psig &above

" 23 38 46 53 61

Tracers shall generally be of . Tracers shall be of CS steel seamless pipe and valves on thesteam tracing circuit including steam station block valve shall be glandless piston valve.

Size of the lead line to manifold shall be as follows:

Number of connections Size of Lead Line

2

3 1

4-6 1

7-12 2

The lead line to manifold, manifold up to the block valves of individual tracer shall be carbonsteel of IBR quality.

Tracer lines shall be provided with break up flanges for main line flange joints and valves.

All tracers shall have individual steam traps before condensate manifolds. Condensatemanifold including the last valve on individual tracer shall be of carbon steel.

All steam traps discharging to a closed system shall have a block valves upstream anddownstream of the trap. A bypass globe valve shall be installed around the trap. Check valve


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shall be installed on the downstream of the steam trap near the condensate header in casedischarging to a closed system.

All steam tracer lines shall be welded as per approved Welding Specification followed by hydrotest.

All steam tracer lines up to 1-1/2 size shall be welded using GTAW welding process followedby hydro-test.

Number of tracers required on a line shall be as follows:

Size of Line Number of Tracers

Up to 4 1

6 to 16 2

18 to 24 326 & above To calculate

3.2.12.2 Steam Jacketing System (If applicable)

A Steam Jacketed pipe consists of a product line, which passes through the center of a largerdiameter steam line.

The normal size of the inner pipe (CORE) and outer pipe (JACKET) in inches shall be as pertable below unless otherwise mentioned in project piping material specification (PMS) or P&ID.

Core pipe will be of SS material only.

Core pipe Jacket pipe

1

1 2

1 3

2 3

3 4

4" 6"

6" 8"

8" 10"

10" 12"

Distance between steam inlet and condensate outlet shall be similar to steam tracing system.Baffle plates, flanged joints or end caps shall be used to discontinue one feed length from thenext. The size of steam feeder to jacket shall be generally " or as specified in jobspecification.


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Flanged jumpovers shall be used in case of Flanged joint. In case of discontinuous jacketingsimple jumpovers shall be employed. The length of jacket shall be 4 to 5 meters or asmentioned in job specification.

Intermediate partial baffles shall be provided if a separate branch portion is to be heated fromthe main line stream.

Steam inlet to jacket shall generally be provided from top of the pipe in case of horizontal lines.The jumpovers and condensate outlets shall be from the bottom.

In case of vertical lines steam inlet shall be done at the topmost points and condensate outletshall be done from the lowest possible points. Two consecutive jumpovers shall be 180 degapart.

Each feed length shall be provided with individual trap before connecting to condensaterecovery headers.

Balanced pressure / bi-metallic type thermostatic steam traps shall be used in jacketing as wellas steam tracing.

To keep proper concentricity between core and jacket pipe internal guides (rods or flat bars)shall be provided at intervals depending on the size of the pipe.

Wherever anchors are provided on jacket lines proper interconnection of jacket pipe and corepipe shall have to be provided with proper Jumpovers for steam.

3.2.13 UTILITY STATIONS

Requisite number of Utility Stations shall be provided throughout the unit to cater for the utilityrequirement. Utility Stations shall have two connections (one for Plant Air, one for ServiceWater and one Low Pressure Steam each of 1") unless otherwise specified in P&ID. Allconnections shall be directed downward. All connections shall have globe valve for isolationpurpose. All connections shall have ends flanged with threaded nipple for hose connections. Airand water lines shall have quick type hose connection and steam line shall have flanged typehose connection.

Number of Utility Stations shall be such that all equipment shall be approachable from at leastone Utility Station. The approach of Utility Station shall be considered 15m all around thestation location.

The Utility Stations shall generally be located adjacent to pipe-rack column. The Utility Stationsshall also be provided on elevated structures, operating platforms of vertical equipments etc.Operating platforms having manholes must have a Utility Station.

Spares required for utility stations are generally as described in mandatory spare list .

3.2.14 FIRE FIGHTING

All Fire fighting facility shall be as per OISD / TAC- fire protection manual and shall conform tothe scope of work, enclosed in the BID.

3.2.15 INSULATION AND PAINTING


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For Insulation, Painting and Colour coding, Engineering Design Basis provided else where inthe BID, shall be followed.

3.3 OFFSITE & YARD PIPING (If applicable)

Battery limit integration to the main process block shall be through multi tier pipe rack andsleepers (either existing or new). Battery limits and tie-in points to be clearly marked and shallbe routed economically and as to satisfy process requirements.

In general, the pipes shall be laid at grade level on sleepers of concrete 450 mm high fromgrade level. Pipe sleepers shall have hard surfacing. Hard surfacing should be completedbefore start of pipe laying. Width of hard surfacing shall be about 1m more than the pipingcorridor. This extra hard surfacing shall be for the movement of operating personnel along thepipe corridor. At every 500 m approach to be provided from the road for hard surfacing area.Pipe rack/portals may be used depending upon requirement, if adequate space is not available

for sleepers. Modification of existing sleepers shall be done if required. The exact level shall bedecided during detail engineering depending on requirements.

However, existing/modified pipe rack around Unit block shall be suitably used.

Pipes at road crossing shall be under culverts in general. All process lines & steam lines ifrequired to be routed below the road, the same shall be routed through culvert at the roadcrossing.

Overhead pipe bridges may be used for areas where pipe racks are provided with minimumclearance as per Annexure B.

Clearances between lines shall be minimum "C" as given below.

C = (d 0 + Df)/2 + 25 mm + Insulation thickness

Where. d 0 = outside diameter of smaller pipe (mm)

Df = outside diameter of flange of bigger pipe (mm)

Adequate clearances shall be provided for very long & high temperature lines to avoid clashingat the bends.

Expansion loops for all lines shall generally be kept at the same location.

Vents shall be provided on all high points and drains shall be provided at all low points.

Drain valve shall be suitably located for ease of operation. Drain valves at sleeper piping shallbe kept outside the sleeper way. If the same is not accessible and valves shall be put inhorizontal only. At all such places where piping is extended to make drain valves accessible, 2

no. of stiffeners, irrespective of pipe rating shall be provided.Spacing of guides on each line on a pipe bay shall not exceed the value given in Annexure C.

3.4 TANK FARM PIPING ( If applicable)


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The number of pipelines in the tank dyke shall be kept at minimum and shall be routed in theshortest practicable way to main pipe track outside the tank dyke, with adequate allowance forexpansion. Within one tank dyke the piping connected to that tank shall only be routed.

Manifolds shall be located outside the tank dyke and by the sides of the road, easily accessibleby the walkway.

Analysis shall be carried out to prevent damage to lines and tank connection caused by tanksettlement.

If exceptionally high settlement is expected "dressers coupling" or "flexible ball joint" may beprovided.

For flexibility analysis and supporting refer clause 3.8

Special consideration shall be given as regards to spacing of nozzles while installing specialitem like hammer blind, Motor Operated Valves etc.

Tank connections to be done after tank hydro testing.3.5 UNDERGROUND PIPING

Services for underground piping .

OWS

CRW

Sanitary sewer system.

All underground C.S .Pipes shall be painted/ coated as per painting/coating specificationprovided else where in the BID.

All underground C.S pipes shall be provided with corrosion resistance protection as per thespecification for coating & wrapping.

1. Surface preparation: Abrasive blast cleaning SA 2 followed by Tape primer(supplied by Tape manufacturer).

2. Poly Ethylene Tape (M/s.Denso) / PVC Tape (M//s. Rustech ) 3 mm thick tapecoating

3. Holiday testing after tape coating

Corrosion resistance protection given to underground C.S. pipes shall extend up to 500mmabove/beyond grade on both sides

To the extent possible, fire water header shall be laid above ground except around process

area where it shall be laid underground .In case it is to be laid U/G, it shall be laid in RCCtrenches covered with pre-cast RCC slabs in RCC paved area, whereas in unpaved area itshall be laid directly buried.

All underground-buried firewater piping shall be externally protected from corrosion bywrapping & coating as per the specifications provided else where in the BID.

3.6 VENTS AND DRAINS


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Process Licensors requirements are to be followed for the size and type of vents and drainsand all shall be as per PIDs approved by PMC. All hydrocarbon drain & vents shall have valveswith blind flanges at other end.

Identification marks for location /visibility of drain points of off-site piping should be provided. Alldrain points should be approachable and clearly visible.

3.7 FLEXIBILITY ANALYSIS AND SUPPORTING

Stress Design Basis provide else where in the BID, shall be referred.

3.8 FLARE PIPING

Flare header shall be sloped towards flare knockout drum. Only horizontal loop shall beprovided as per requirement to accommodate thermal expansion. The desired slope shall beensured throughout including flat loop. Flare header shall be supported on shoe of heightranging from 100 mm to 300 mm.Proper thermal analysis temperature shall be established including the possibility oftemperature gradient along the line before providing expansion loops.Flare piping to offsite shall be provided with guide support on all around the pipe to prevent itfalling off from the flare trestles.Flare header valve stems shall be in vertical downward position.

Valves in Flare Header shall be of Gate Type only.

3.9 MATERIALS AND SELECTION OF PIPES AND FITTINGS

The PMS (Piping material specifications) provided by PMC are only for reference andindicative and thus may not be exhaustive. LSTK shall update PMS given in the BID anddevelop detailed piping material specifications (PMS) and Valve Data sheets (VMS), based

on process Licensors piping specifications, basic material depending upon service conditions(temperature, pressure and corrosively etc.) as spelt in process package.

3.9.1 PipeWall thicknessCalculation of pipe thickness and branch reinforcement shall be based on requirements ofASME B 31.3. /IBR as applicable. Proper corrosion allowance and mill tolerance shall beconsidered while selecting thickness.

For carbon steel and low alloy steel pipes (expect for steam tracing piping) minimum pipethickness shall be as follows:

'S160' up to 0.75"NB,'XS' for 1 to 2 NB

'STD' for above 2NB.


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For Stainless Pipes minimum pipe thickness shall be: -

80S up to 0.75 NB

40S for 1 to 2 NB10S for above 2 NB

The philosophy of minimum thickness/schedule is applicable for both seamless and weldedpipes.

The above-mentioned minimum thickness/schedule criterion is not applicable to category -Dfluid where IS pipes or welded API 5L pipes are being used.

All pipes (seamless & welded) shall have uniform negative wall thickness tolerance of 12.5% forwall thickness calculations purpose, except for pipes made out of plate material, where relevantASTM code shall govern.

For thickness exceeding minimum thickness/schedule criteria, schedule XS shall be selected

for CS & AS classes (for 2" & above). Intermediate schedules between STD & XS shall beignored. Similarly for SS classes (2" & above) S10, S20, S30 & 40S may be selected beyondminimum thickness/schedule criteria.

If, the thickness exceeds XS in CS & AS classes and 40S in SS classes, only then, thethickness shall be calculated based on actual service conditions subject to a minimum of 80%class rating. Maximum 10% of corrosion allowance may be reduced in special cases, tooptimize the pipe schedules.

In general the pressure-temperature combination to calculate wall thickness shall be as follows:

Material Class Pipe Size Design condition

150 Up to 24" Class conditionAbove 24" Line condition (//)



900 Up to 8" Class conditionAbove 8" Line condition

1500&2500 Up to 4" Class condition

C.S.

(A 106 GR.B, API 5LGR.B, A672)

LTCS

(A333 GR 6)

Low alloys

1.25%Cr-05%Mo

2.25%Cr-1.0%Mo

5%Cr.-0.5%Mo.Above 4" Line condition

150 Up to 24" Class conditionAbove 24" Line condition $



900,1500 Up to 4" Class condition

S.S. (A312 TP304,TP304L, 316L, 347)

OR

(A358 TP304, 304L

316,316L, 321,347)

Above 4" Line condition


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2500 Up to 2" Class conditionAbove 2" Line condition

150 Up to 6 Class condition

Above 6" Line condition

Higher Alloys

300 -2500 All sizes Line condition // Only if the thickness/schedule as per class condition exceeds XS.

$ Only if the thickness/schedule as per class condition exceeds 40S.

For other than Category D classes D/t ratio shall be restricted to generally 100(Max), up to sizeof 48,D is nominal dia. andt is nominal thickness. For sizes 50and aboveD/t ratio shall bedecided by job engineer. For Cat-D Classes, for above ground applications D/t ratio shall betaken, as 150, t is min. calculated thickness excluding corrosion and manufacturing tolerance.

Pipe size

Pipe size shall normally be ", ", 1", 1", 2", 3", 4", 6", 8", 10", 12", 14", 16", 18", 20", 24",26", 30", 36", 40", 44", 48", 52", 56", 60", 64", 72", 78", 80".

Pipe typeMaterial Size Type

Up to 14 SeamlessCS & LTCS, AS (except for Category Dfluids)

10 and Above EFWSS (Process Lines)

Up to 1" SeamlessSS (Non Process Lines)2" & Above Welded

CS (Category D fluids)

* Except for fire water and cooling waterservices, for which following shall apply:-

1. Up to 6 NB - Seamless

2. 8 NB and above - Welded

3. Less than 3 NB - Carbon steel

( Higher schedule )4. 3 inch NB and above - Carbon Steel

(Cement Lined)

ALL Welded *

3.9.2 Fittings

Type of fittings shall be equivalent to pipe type.


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Thickness of fittings at ends to match pipe thickness for BW fittings

SW fittings shall be 3000#, 6000#, and 9000# depending on the pipe thickness S80, S160 andabove S160 respectively.

Up to 600# all branch connections shall be as follows, unless specifically mentioned otherwisein PMS.

Up to 1" NB Half Coupling / Tee

2" and above Tee/ Pipe to pipe with / withoutreinforcement pad

For branch connection above 600# rating equal tee/unequal tee shall be used for all sizes.Unequal tee may be replaced by weld-o-let up to branch size of 8".

Miters shall be used in Category D service above 6"NB. For other than category D fluids in

150#, 300# classes miters may be able to be permitted for sizes above 48" only. Miters to bedesigned as per ASME B 31.3.However use of miters shall be minimum.

3.9.3 Flanges:

Flanges:

Flanges shall be as follows:Class Size Type Remarks

Up to 1" SW RF If non-metallic gasket used.

Up to 1" WN RF If metallic gasket used.2" & above WN RF/LJ FF For SS LJ FF + Stub ends

150#

2" & above SO RF If used in Category D service300#, 600# Up to 1" SW RF

2" & above WN RF900#, 1500#, 2500# All WN RTJAll flange joints on piping system including flanges on equipment, manhole, etc shall betightened using torque wrench/ hydraulic bolt tensioner depending upon service criticality.

3.9.4 Gaskets.Gaskets to be provided as per service condition as mentioned in PMS.

3.9.5 Valves

SW valves up to 1 inch up to 600# ANSI Class except ball and plug valves which shallbe flanged for all sizes.


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Flanged cast valve above 1" 150#, 300#, 600# ANSI Class

BW valves all sizes-900# ANSI Class & above

No CI valves to be used.Over and above requirements, other technical requirement prescribed in Annexure E shallalso be adhered to.

3.10 NON DESTRUCTIVE TESTING REQUIREMENTS

Depending on the severity of application, extent of NDT shall be decided. As a rule, allhydrogen, oxygen, NACE and any other lethal service shall have 100% radiography on weld

joints. Castings used in these services shall have 100% radiography. For high-pressureapplications i.e. 600# upward 100% radiography on weld joints shall be employed. In 100%radiography classes any fillet welds employed shall have 100% MP in CS/AS classes and100% DP in SS classes. Category D service shall have 2% radiography. Classes in 150#for normal hydrocarbon service shall be subjected to 10% radiography and SW/Filletweld/attachment weld where radiography is not possible shall be 10% DP/MP tested.Classes in 300# for normal hydrocarbon service shall be subjected to 20% radiography andSW/ Fillet weld/attachment weld where radiography is not possible shall be 20% DP/MPtested.

All AS pipes, fittings, flanges, valves & bolts shall undergo Positive Material Identification(100%) at site. All the PMI test at construction site shall be done as per standard.

3.11 STRAINERS

3.11.1 Temporary Strainers:

1" & below for all services shall by Y-type2" & above for steam service shall by Y-type2" & above for other than steam services shall by T-type

3.11.2 Permanent strainers

Compressor suction, cold box inlet strainers shall be cone type with reinforced perforatedsheet cage design

1" & above permanent strainer shall be as per process data sheet

3.12 WELDING

3.12.1 Applicable codes and standards

All welding work, equipment for welding, heat treatment, other auxiliary functions and thewelding personnel shall meet the following requirements of the latest edition of followingaccepted standards and procedures.

Process piping ASME B 31.3

In addition, the following codes and specification referred in the code of fabrication shall befollowed for the welding specifications, consumables, qualifications and non-destructive testprocedures.


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Welding and Brazing qualifications ASME BPV Sec IXNon Destructive Test - ASME BPV Sec VMaterial specification: welding rods, electrodes, and filler metals ASME BPV Sec II part

The additional requirements mentioned in this specification, over and above those obligatoryas per codes, shall be followed wherever specified.

3.12.2 Welding processes

3.12.2.1 Welding of various materials shall be carried out using one or more of the following

Shielded Metal Arc Welding process (SMAW)

Gas Tungsten Arc Welding (GTAW)

3.12.2.2 Automatic and semi-automatic welding shall be employed only with the approval of theOwner. The welding procedure adopted and consumables used shall be specificallyapproved.

3.12.2.3 All steam tracing line to be welded with TIG welding process and subjected to hydro testprior to commissioning.

3.12.2.4 A combination of different welding processes could be employed for a particular joint onlyafter duly qualifying the welding procedure to be adopted and obtaining the approval ofOwner.

3.12.2.5 For additional details "welding specification for fabrication of piping / welding charts shall bereferred.

4.0 REFERENCED PUBLICATIONS

The following latest codes and standards shall be followed unless otherwise specified.

ASME SEC. I - Rules for Construction of Power Boilers.

ASME SEC.VIII

- Rules for Construction of Pressure Vessels.

ASME B31.1 - Power piping.

ASME B31.3 - Process piping.

ASME B 31.8 - Guide for Gas Transmission and Piping distribution system

ANSI/NEMASM 23

- Steam turbines for mechanical drive service.

API RP 520 - Sizing, selection and installation of Pressure relieving devices inRefineries.

API Std. 560 - Fired heaters.API Std. 610 - Centrifugal pumps for Petroleum, Heavy-duty chemical and gas

industry service.

API Std. 617 - Centrifugal compressors for petroleum, chemical and gas industryservice.

API Std. 618 - Reciprocating Compressors

API Std. 661 - Air cooled heat exchangers


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EJMA - Expansion joints Manufacturers Association.

NACEMR-0175

- Sulphide Stress cracking resistant metallic materials for oilfieldequipment.

NACETM-0177

- Laboratory testing of metals for resistance to Sulphide Stresscracking in H 2S Environments.

NACEMR-0284

- Evaluation of pipeline and pressure vessel steel for resistance toHydrogen Induced Cracking.

IBR - Indian Boiler Regulations

TAC - Tariff Advisory Committee.

OISD - Oil Industry Safety Directorate.

OISD 118 - Layouts for oil and gas installation.

OISD 116 - Fire protection facilities for petroleum refineries and oil/gasprocessing plants.

OISD 113 - Classification of area for electrical installation at hydrocarbon andhandling facilities.

OISD 164 - Fire proofing in Oil & Gas industry

IS 5572 - Classification of Hazardous area (other than mines) for electricalinstallation.


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ANNEXURE A

Accessibility for valves and instruments

Valves, instrument, equipment tobe operated Centerline of item to be operated,located less than 3.6 m abovegrade, 2.75m above floor orplatform or 1.8m above wingplatform.

Centerline of item to beoperated, located more than3.6 m above grade, 2.75mabove floor or platform or1.8m above wing platform.

Exchanger heads Nil Platform

Oper. Valves 2" & smaller Fixed ladder Fixed ladder

Oper. Valves 3" above Platform Platform

Motor operated valves Platform Platform

Control valves Platform Platform

Relief valves 2" & smaller Fixed ladder Fixed ladder

Relief valves 3" & above Platform Platform

Block valves 2" & smaller Portable ladder Platform

Block valves 3" & above Platform note 1 Platform

Battery limit valves Platform Platform

Pressure instrument Fixed ladder if above 2.2 m Fixed ladder

Temperature instrument Fixed ladder if above 2.2 m Fixed ladder

Sample points Platform Platform

Gauge glasses Fixed ladder Platform

Level controllers Platform Platform

Process blinds and spades 2" &above

Portable ladder/platform Platform

Process blinds and spades 3" &above

Platform Platform

Man ways / manholes Platform Platform

Manholes / inspection holes Platform Platform

Nozzles Access required PlatformVessel vents Portable ladder Fixed ladder

Line drains & vents Portable ladder Portable ladder

Orifice flanges Portable ladder Portable ladder

Note: - 1. Centerline or block valves located above 2.0 meter from the operating floor, which arerequired for normal operation, shall be provided with portable platform or chain for operation of valves.


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ANNEXURE B

CLEARANCES

Equipment, Structure, Platforms, Piping & its supports shall be arranged so as to provide the followingclearances.

A OVERHEAD CLERANCES

1. Over rail roads, top of rail to bottom of any obstruction. 9 m

2. Over plant roads for major mobile equipment 9 m

3. Over grade & bottom of pipe (inside battery limit) 4.5 m

4. Over walk-ways, pass-ways & platforms to nearestobstruction and inside building

2.2m

5. Over Exchangers at Grade, shell cover channel end. 1.5 m

B. HORIZONTAL CLEARANCES

1. Between Exchangers (Aisles between Piping). 0.9 m or 2m centre to centrewhichever is higher

2. Around Pumps (Aisles between piping) 0.9 m

3. Fired heaters to pumps handling flammable stock 15 m

4. Fired heaters to other flammable containing equipment andclosely associated with heaters.

15 m

5. At driver end of pumps where truck/fork lifter access isrequired.

4 m

6. At driver end of pumps where truck access is not required. 1.8 m

7 At shell cover end of exchangers at grade, for access way 1.3 m

8 Between shells of adjacent horizontal vessels 2.0 m or 0.9m clear aislewhichever is higher

C EQUIPMENT SPACING

1. Small size pumps

(13.7 KW & Less)

Mount on commonfoundations suitable centre tocentre distance.

2. Middle size pumps

(22.5 KW & Less)

0.9m clears Aisle between

associated piping.

3. Large size pumps

(Above 22.5 KW)

0.9m clears Aisle betweenassociated piping.

4. Exchangers and other equipment on structures 0.9m clears Aisle betweenassociated piping.


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D PLATFORMS

1. TOWERS, VERTICAL & HORIZONTAL VESSELSi. Distance of platform below centerline of

manhole flange-side platform.0.9-1.05 m

ii. Width of manhole platform from manholecover to outside edge of platform

1.0 m

Iii Platform extension beyond centre line ofmanhole side platform.

1.0 m

iv. Distance of platform below under side offlange Head platform

1.75 m

v. Width of Platform from three sides ofmanhole Head platform

0.75 m

2. HORIZONTAL EXCHANGER

i. Clearance in front channel or Bonnetflange.

1.3 m

Ii Heat exchanger tube bundle removalspace.

Bundle length + 1.5 m

Iii Min. clearance from edge of flanges. 0.1 m

3. VERTICAL EXCHANGER

i. Distance of platform below top flange ofchannel on bonnet.

1.5 m

4. FURNACES

i. Width of the platform at side of horizontaland vertical tube furnace.

2.0 m Min.

Ii Width of the platform at ends of horizontaltube furnace.

2.0 m Min.


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ANNEXURE C

Vertical and Horizontal Guide Spacing

Pipe Size (Inch) Guide Spacing in meters

Vertical Horizontal

1 6 6

1 6 6

2 6 6

3 8 12

4 8 126 8 12

8 8 12

10 12 18

12 12 18

14 12 18

16,18 12 18

20 16 18

24 16 1826 and above 16 18

Notes:

These spacing may be varied to suit column spacing of rack. The above spacing is for straight runs ofpipe and does not include guides, which are used for control of thermal movements, as decided bystress group.

The guide spacing given in the above table is indicative only.


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ANNEXURE DTable of Basic Span

PIPE-VAPORINSULATION

PIPE-LIQUID-INSULATION

BARE PIPEEMPTY

BARE PIPEWATERFILLED

BASIC SPAN (L)m

BASIC SPAN (L) m

PipeSizeInch

SCH.THK mm

Up to175C

176 to345C

446 C to400 C

Up to175 C

176 Cto445 C

346 Cto400 C

SPAN(L) m

WeightKg/m

SPAN(L) m

WeightKg/m

PipeSizeInch

SCH 40 3.5 3.5 2.5 3.5 3.0 2.0 4.5 1.68 4.0 2.04 1 SCH 40 4.5 4.0 3.0 4.5 3.5 3.0 5.0 2.52 4.5 3.07 11 SCH 40 5.0 5.0 4.5 5.0 4.5 3.5 6.0 4.0-8 5.0 5.4 12 SCH 40 5.5 5.0 4.5 5.0 4.5 3.5 6.5 5.47 5.5 7.65 22 SCH 40 6.5 6.0 5.0 6.0 5.5 4.5 7.5 8.7 6.5 11.79 23 SCH 40 7.5 6.5 5.5 6.5 6.0 5.0 8.0 11.35 6.5 16.15 34 SCH 40 8.0 7.5 6.5 7.5 7.0 6.0 9.0 16.2 7.5 24.45 4

6 SCH 40 10.0 9.5 8.5 9.0 8.0 7.5 10.5 28.3 9.0 46.7 68 SCH 40 12.0 11. 10.0 10.0 10.0 9.0 12.0 42.84 10.0 75.22 810 SCH 40 13.5 13. 12.0 11.5 10.5 10.5 14.0 60.74 11.5 111.9 1012 3/8" w 14.5 13. 13.0 12.0 11.5 11.0 15.0 74.40 12.0 147.5 1214 3/8" w 15.0 14. 13.5 12.0 12.0 11.5 16.0 82.5 12.5 172.05 1416 3/8" w 16.0 15. 14.5 13.0 12.5 12.0 17.0 94.5 13.0 213.15 1618 3/8" w 17.0 16. 15.0 13.5 13.0 12.0 18.0 106.5 13.5 258.3 1820 3/8" w 18.0 17. 16.0 14.0 13.5 12.5 19.0 118.5 14.0 307.5 2024 3/8" w 20.0 19. 17.5 14.5 14.5 13.0 21.0 142.5 15.0 418.2 24 SCH 80 3.5 3.5 2.5 3.5 3.0 2.0 4.5 2.20 4.0 2.49 1 SCH 80 4.5 4.0 3.0 4.5 3.5 3.0 5.0 3.25 4.5 3.72 11 SCH 80 5.0 5.0 4.5 5.0 4.5 4.0 6.0 5.45 5.0 6.60 12 SCH 80 6.0 5.0 4.5 5.5 5.0 4.0 6.0 7.53 6.0 9.45 22 SCH 80 6.5 6.0 5.5 6.0 6.0 5.0 7.5 11.49 6.5 14.25 23 SCH 80 7.5 6.5 6.0 6.5 6.5 6.0 8.0 15.37 7.0 19.66 3

4 SCH 80 8.0 8.0 7.0 7.5 7.5 6.5 9.0 22.47 8.0 29.94 46 SCH 80 10.5 10. 9.0 9.5 9.0 8.5 10.5 42.90 9.5 59.85 68 " w 12.0 11. 10.5 10.5 10.0 10.0 12.0 65.10 11.0 94.8 810 " w 13.5 13. 12.0 11.5 11.5 10.5 14.0 82.20 12.0 130.69 1012 "w 14.5 13. 13.0 12.5 12.0 11.5 15.0 98.13 13.0 168.64 1214 "w 15.0 14. 13.5 13.0 12.5 12.0 16.0 108.1 13.5 194.4 1416 "w 16.0 15. 15.0 13.5 13.0 13.0 17.0 124.2 14.0 240.0 1618 "w 17.5 17. 16.0 14.5 14.0 13.5 18.0 140.2 14.5 286.64 1820 " w 18.0 17. 17.0 15.0 14.5 14.0 19.0 157.0 15.0 341.8 2024 " w 20.0 19. 18.5 16.0 15.0 15.0 21.0 188.2 16.0 458.44 241 10S 4.0 3.5 3.0 4.0 3.0 2.5 4.5 2.08 4.0 2.7 11 10S 5.0 4.5 3.5 4.5 4.0 3.0 5.5 3.12 5.0 4.57 12 10S 5.0 4.5 3.5 4.5 4.0 3.0 6.0 3.94 5.5 6.63 22 10S 6.5 5.5 4.5 5.5 5.0 4.5 7.0 5.26 6.0 8.85 23 10S 7.0 6.0 5.0 6.0 5.5 5.0 7.5 6.45 6.0 11.91 3

4 10S 7.5 7.0 6.0 6.5 6.0 6.0 8.0 8.34 7.0 17.67 46 10S 9.5 9.0 8.0 8.0 7.5 7.5 10.0 13.82 8.5 34.54 68 10S 11.0 10. 10.0 9.5 9.5 8.5 11.5 19.94 10.0 55.5 810 10S 12.5 12. 11.0 10.5 10.0 9.5 13.0 27.83 11.0 83.4 1012 10S 14.0 13. 12.0 11.0 11.0 10.0 14.5 36.00 11.5 114.6 1214 10S 14.5 14. 13.0 11.5 11.0 11.0 15.5 41.18 11.5 132.6 1416 10S 16.5 14. 14.0 12.0 11.5 11.5 16.5 47.33 12.5 172.2 1618 10S 16.5 15. 14.5 12.5 12.5 11.5 17.5 53.18 13.0 212.1 1820 10S 17.5 16. 15.5 13.0 13.0 12.0 18.5 68.50 13.0 264.5 2024 10S 19.0 18. 17.0 14.0 13.5 12.5 20.5 94.37 14.0 376.8 24


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ANNEXURE E

TECHNICAL REQUIREMENTS OF PIPING MATERIAL

1.0 Ends

Unless otherwise specified the ends shall be to the following standard:

SW/SCRD ASME B16.11

BW ASME B16.25 / B16.9

FLANGED ASME B16.5 and ASME B16.47 SERIES B/API-605

THREADING ASME/ANSI B1.20.1 (NPT, Taper threads)

2.0 Face Finish

This shall be to MSS-SP-6/ASME B46.1/ ASME B16.5. The interpretation shall be :

Stock Finish 250-1000 in AARH

Serrated Finish 250-500 in AARH

Smooth Finish/125 AARH 125-250 in AARH

Extra Smooth Finish /63 AARH 32-63 in AARH

3.0 Austenitic Stainless Steel

All items/ parts shall be supplied in solution-annealed condition.

Intergranular Corrosion (IGC) Test shall be conducted as per following:

ASTM A262 Practice B with acceptance criteria of 60-mils/ year (max.) for casting.

ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20Xmagnification & microscopic structure to be observed from 250X magnification" for otherthan casting.

For IGC test, two sets shall be drawn from each solution annealing lot: one setcorresponding to highest carbon content and other set corresponding to the highestrating/ thickness.

IGC test is a must for all stainless steel classes.

For all items of stabilized SS grades, stabilizing heat treatment shall also be done. It shallbe carried out subsequent to normal solution annealing. Soaking temperature and holdingtime shall be 900 Deg. C and 4 hours respectively.

4.0 Item specific notes:

4.1 Pipes

Double seam is allowed for sizes 36" and larger.


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Galvanized pipes shall be only Hot Dip galvanized To ASTM A53.

Pipes greater than 10" spiral welded/ pipe shall be used weld seams to be kept in upperquadrant only.

4.2 Fittings

All fittings shall be seamless in construction unless otherwise specified.

For reducing BW fittings having different wall thickness at each end, the greater one shallbe employed and the ends shall be matched to suit respective thickness.

All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6mm, and the welds shall be ground smooth at least 25mm from the ends.

For fittings made out of welded pipe, the pipe itself shall be of double welded type,manufactured with the addition or filler material and made employing automatic weldingonly.

All welded fittings shall be normalized for CS, normalized & tempered for AS: and 100 %radiographed by X-ray for all welds made by fitting manufacturer as well as for welds onthe parent material.

Bevel ends of all BW fittings shall undergo 100 % MP/DP test. Those used in fire fightingfacility should be marked

Tell-tale hole to be tapped in all reinforcement pads.

4.3 Flanges

For Ring Joint Flanges, Blinds and Spacers, the hardness shall be as follow:

Flange Material Min. hardness of Groove

(BHN)Carbon Steel 120

1 % Cr. To 5% Cr. Mo 150

Type 304,316, 347, 321 180

Type 304 L, 316 L 140

For RTJ flanges, blinds & spacers, the hardness of the groove shall be specified on thetest report.

Bore of weld neck flange shall correspond to the inside diameter of pipe for specified

schedule/ thickness. Ends shall be beveled to suit the specified schedule/ thickness.

All flange joints to be tightened with proper gaskets, bolts & nuts with skilled technicianand box-up of flange joints to be documented.


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4.4 Valves

Valves of Class 900# & above shall be pressure-seal type. Threaded and seal welded orwelded bonnet may be employed up to sizes 1-1/2".

All flanged valves (except forged) shall have flanges integral with the valve body.

Yoke material shall be at least equal to body material.

Forgings are acceptable in place of Castings but not vice-versa.

No cast iron valves to be used in fire fighting or any other service except in drinking waterservice

Valve castings/ forgings purchased from India or Indian Vendors shall be from Ownerapproved foundries/ forging shop.

4.5 Dimensions

Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same isnot covered under B16.10, the dimension shall be as per BS 2080/Manufacturers Std.Valve under cryogenic service (temp.below-45C) shall be as per BS-6364 and shall beprocured from pre-qualified vendor.

4.6 Operation

Generally the valves are hand wheel or lever operated. However, suitable gear operatorin enclosed gear box shall be provided for valves as follows;

TYPE OF VALVE ANSI CLASS SIZES

Gate 150300600900

15002500

14" and larger12" and larger8" and larger6" and larger4" and larger2" and larger

Ball 150 and 300600 and over

6" and largerManufacturer's Std.

Plug 150300

8" and larger6" and larger

Butterfly all 8" and larger

Globe 150 and 300600900

1500 and 2500

8" and larger6" and larger4" and larger3" and larger

Hand wheel diameter shall not exceed 750 mm and lever length shall not exceed 500 mmon each side. Effort to operate shall not exceed 35 kgf at hand wheel periphery.However, failing to meet the above requirement, vendor shall offer gear operation.

Quarter-turn valves shall have "open" position indicators with limit stops.


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4.7 By pass

A globe type valve (size as per ASME/ANSI B16.34) shall be provided as bypass for thefollowing sizes of gate valves:

Class For sizes

150 # 26" and above

300 # 16" and above

600 # 6" and above

900 # 4" and above

1500 # 4" and above

2500 # 3" and above

By-pass piping, fitting and valves shall be compatible material and design. Complete filletwelds for by-pass installation shall be DP/MP tested. NDT of by-pass valve shall be inlinewith main valve.

4.8 Radiography of cast valves

Unless specified otherwise, the following valve castings shall undergo radiographicexamination (for all materials):

Class Size Qty.

150 # 26" & above 100 % (Except for Cat. Dservice)

300 # 18" & above 100 %

600 # & ABOVE All 100 %

For Hydrogen, Oxygen, NACE, Stress relieved, Caustic service, addit

Piping-Design_Basis Rev 1

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