&se-00-l-sd 1001 engineering specification for piping design

ONGC Petro additions Limited SEZ, Dahej, Gujarat, India

DAHEJ PETROCHEMICAL

COMPLEX Dual Feed Cracker Unit

& Associated Units

EIL

JOB NO. 6987

Page: 1 of 29

ENGINEERING SPECIFICATION

FOR

PIPING DESIGN

04 09.09.2009 IFC (COMMENTS INCORPORATED) S.Yoo C.S.Park H.O.Lee 03 10.07.2009 For Construction S.Yoo C.S.Park H.O.Lee 02 10.04.2009 For Review S.Yoo C.S.Park H.O.Lee 01 23.03.2009 For Review S.Yoo C.S.Park H.O.Lee

Issue Date Reason for Issue / Remark Prepared Checked Approved

ENGINEERING DIVISION

Linde Proj. No.: Linde Project Code :

3110 A9NK DAHEJ

Samsung Proj. No.: Samsung Project Code :

SC 2252 OPaL DFCU & AU

Contract No / PO No.:

Item No.:

Contractor Doc. No.:

&SE-00-L-SD 1001 Company Doc. No.:

6987-LEPC1-SE-00-PP-SD 1001

Dahej Petrochemicals Complex DFCU & AU of 29

6987-LEPC1-SE-00-PP-SD 1001 ENGINEERING SPECIFICATION FOR PIPING DESIGN Issue: 04

REVISION HISTORY

REV DATE DESCRIPTION

02 2009.04.10 As per client technical clarification meeting

03 2009.07.10 As per Linde Specification and for detail design

04 2009.09.09 As per client comments

* Notes:

This page records all revisions on the specification.



Content: 1 GENERAL ........................................................................................................................... 5

1.1 Purpose ............................................................................................................................... 5

1.2 Scope .................................................................................................................................. 5

1.3 Codes and Standards.......................................................................................................... 5

1.4 Units .................................................................................................................................. 5

1.5 Symbols and Abbreviations................................................................................................. 5

1.6 Reference Specification ...................................................................................................... 5 2 DESIGN............................................................................................................................... 6

2.1 General................................................................................................................................ 6

2.2 Design Pressure and Temperature ..................................................................................... 6

2.3 Materials.............................................................................................................................. 6

2.4 Corrosion Allowance ........................................................................................................... 6

2.5 Piping General Arrangement............................................................................................... 6

2.6 Accessibility......................................................................................................................... 7

2.7 Access................................................................................................................................. 8 3 DESIGN DETAILS............................................................................................................. 14

3.1 Line and Connection Sizes................................................................................................ 14

3.2 Material Specification Changes......................................................................................... 14

3.3 Bends, Miters and Elbows................................................................................................. 14

3.4 Reducers ........................................................................................................................... 14

3.5 Branch Connections .......................................................................................................... 15

3.6 Flanges.............................................................................................................................. 15

3.7 Couplings .......................................................................................................................... 15

3.8 Valves................................................................................................................................ 15

3.9 End Closures..................................................................................................................... 16

3.10 Blanks and Spacer ............................................................................................................ 16

3.11 Strainers ............................................................................................................................ 16

3.12 By-Passes ......................................................................................................................... 16

3.13 Vents and Drains............................................................................................................... 17



4 GENERAL INSTALLATION REQUIREMENTS................................................................. 17

4.1 Provisions for Expansion and Flexibility ............................................................................ 17

4.2 Supports and Hangers ...................................................................................................... 18

4.3 Pipe Connections .............................................................................................................. 18

4.4 Valve Installations ............................................................................................................. 18

4.5 Pump Piping ...................................................................................................................... 19

4.6 Rack Piping ....................................................................................................................... 20

4.7 Tank and Vessel Piping..................................................................................................... 20

4.8 Exchanger Piping .............................................................................................................. 21

4.9 Compressor Piping............................................................................................................ 21

4.10 Furnance and Fired Heater Piping .................................................................................... 21 5 REQUIREMENTS for INDIVIDUAL PIPING SYSTEM ...................................................... 23

5.1 Process Piping Systems.................................................................................................... 23

5.2 Steam Piping Systems ...................................................................................................... 24

5.3 Water and Air Systems...................................................................................................... 26

5.4 Fire Protection Systems .................................................................................................... 26

5.5 Utility Services................................................................................................................... 26

5.6 Safety Shower and Eye Wash........................................................................................... 27

5.7 Drainage and Sewage Systems ........................................................................................ 27

5.8 Underground Piping .......................................................................................................... 27

5.9 Hydraulic Bolt Tensioning.................................................................................................. 29

5.10 Piping Tie Ins..................................................................................................................... 29

5.11 Drawing and Procedures................................................................................................... 29

5.12 Mandatory Spares ............................................................................................................. 29



1 GENERAL

1.1 Purpose

This specification covers general and detailed design requirements pertaining to the process

and utility piping systems which shall be included in the OPaL DFCU and AU.

1.2 Scope

This specification applies to all piping shown on the Piping and Instrument Diagram

(hereinafter referred to as P & ID) except auxiliary piping or piping systems which are part of

packages. Instrument piping shall be covered by this specification up to the first block valve.

1.3 Codes and Standards

The design, fabrication, inspection and tests of piping systems and components shall be

accomplished in accordance with the applicable codes and standards.

ASME B31.3 : Process Piping

ASME B31.1 : Power Piping

IBR (Indian Boiler Regulation)

OISD-118 : Layout for Oil and Gas Installations

1.4 Units

Unless otherwise specified, the international system of units (SI) shall be applied for

drawings and documents to be submitted. However, nominal sizes of piping and piping

components shall be in imperial system.

1.5 Symbols and Abbreviations

Symbols and abbreviations which are used in the P & ID, Engineering Specifications, Piping

Arrangement Drawings, Pipe Hanging Details, etc. shall be as defined in the drawings and

documents.

1.6 Reference and Specifications

References to be used in conjunction with this specification are:

(1) 6987-LEPC1-SE-00-PP-SD 1002 : Piping Material

(2) 6987-LEPC1-SE-00-PP-SD 1003 : Marking for Piping Material

(3) 6987-LEPC1-SE-00-PP-SD 1004 : Insulation

(4) 6987-LEPC1-SE-00-PP-SD 1005 : Painting &Coating Design and Work

(5) 6987-LEPC1-SE-00-PP-SD 1007 : Steam Tracing



(6) 6987-LEPC1-SE-00-PP-SD 1008 : Coating and Wrapping of Underground Steel Pipe

(7) 6987-LEPC1-SE-00-PP-SD 1009 : Standard and Special Pipe Support Details

(8) 6987-LEPC1-SE-00-PP-SD 1010 : Piping Flexibility Analysis

(9) 6987-LEPC1-SE-00-PP-SD 1011 : Fire Fighting

(10) 6987-LEPC1-AA-00-PS-PC 1022 : Safe Location Concept (DFCU&PGHU)

2 DESIGN

2.1 General The design of piping systems and components shall be generally in accordance with the

requirement of this specification, ASME B 31.3 "Process Piping", IBR and ASME B

31.1 ”Power Piping” unless otherwise specified. The plant shall be designed for design life

requirement of 25 years.

2.2 Design Pressure and Temperature

The design pressure and temperature shall be determined in consideration of start-up

conditions and other requirements for safety as well as normal operating conditions. The

design pressures and temperatures shall be as indicated in the Line List (6987-LEPC1-SE-

00-PP-LL 1001).

2.3 Materials

2.3.1 Ferrous, non-ferrous and non-metallic materials for individual piping system shall conform to

the requirements of ASTM

2.3.2 Alternative materials of other generally recognized standard specifications may be proposed

for Owner's written approval.

2.3.3 Environmental pollution, disruption and sanitation shall be considered in selection piping

materials.

2.4 Corrosion Allowance

Required corrosion allowances are provided in the piping material specification (6987-

LEPC1-SE-00-PP-SD 1002) and minimum corrosion allowance shall be in accordance with

the Process Design Basis Memorandum.

2.5 Piping General Arrangement 2.5.1 Piping shall be routed for the shortest possible run with the minimum number of fittings

consistent with provision for expansion and flexibility. Assembly, removal and support of

piping and equipment shall be taken into consideration.



2.5.2 All lines inside battery limits, except drain sewer lines and other special-use lines, shall be

run side by side on overhead pipe supports.

2.5.3 The main lines of fire water and sewer lines shall be generally laid underground.

2.5.4 Bottoms of hot and cold insulated lines, which are run on overhead supports, shall be

generally supported on steel shoes and cradles respectively. Pipes which rest directly onto

support steel and have operating temperatures of 150℃ and less shall be provided with a

wear pad to prevent corrosion problems.

2.5.5 Insulated lines shall be carried at a common elevation of bottom of shoes and cradles. The

lines, which run on overhead supports or in the rack shall generally change their elevation

when the direction changes. Lines carrying molten solids or service fluids of high viscosity,

or those lines so indicated on the applicable P & ID, shall be designed to have a continuous

slope and drain into a vessel.

2.6 Accessibility

2.6.1 Permanent Access

Where equipment, valves or instruments require operational control or normal maintenance

during plant operation, access shall be provided by means of grade access ways, elevated

platforms or permanent ladders. Where permanent access facilities are not provided with

owner agreement, as defined below, mobile platforms, temporary ladders or portable

scaffolding must be used.

2.6.2 Stairways

Stairways shall be provided as a primary means of access to main operating or service

levels in structures, buildings and on furnaces. Storage tanks shall also be provided with

stairways as a primary means of access, where levels are more than approximately 6000

mm high. Main operating or service levels shall be defined as those areas which require

plant personnel to be normally or intermittently present for substantial periods of time during

plant operation.

2.6.3 Ladders

Ladders shall be provided as a primary means of access to vessel platforms, auxiliary

service platforms in structures, and furnaces. Access from platform to ladder shall generally

be side step. Auxiliary service platforms shall be defined as those areas which, during plant

operation, do not require the presence of plant personnel other than for short periods.

2.6.4 Space on Elevated Platforms

Elevated platforms shall have adequate space for maintaining the equipment (see Table2).



2.7 Access

2.7.1 Mounting Level

All equipment (including pumps) and structural steel columns shall be mounted 300 mm (12")

minimum above high point of grade, paving or finished floor level. The high point of finished

floor level in buildings shall be 300mm (12") minimum above high point of grade or paving.

2.7.2 High Level Access

Equipment listed in Table 1, which requires operational control or normal maintenance during

plant operation, and which is located more than 4600 mm above grade or 2600 mm above

another platform shall be provided with the means of access specified subject to the

followings:

(1) Mobile platforms, temporary ladders and/or scaffolding shall be used for access to

equipment, valves, orifice and flowmeter and manholes when such items are located up

to 4600 mm above grade and outside the requirements of Table 1.

(2) Flanged nozzles and nozzles requiring initial tightening, metal temperature measuring

points on vessels, branch isolation valves at headers in any level of piperack, and orifice

flanges or other instrument connections in the lower piperack level shall not be provided

with permanent access.

(3) Groups of unit isolation valves at battery limits in elevated piperacks and grade

pipetracks shall be provided with permanent platform access.

(4) The maximum distance from the centerline of horizontally installed valve handwheels to

the operating level shall be 1800 mm. Install frequently operated block valves and critical

isolation valves with hand-wheel centered line no more than 1.5 m above working

surface.

(5) The use of chain operators and extension stems shall only be permitted with owner

review.

2.7.3 To permit access for the removal and/or maintenance of piping, a minimum side clearance of

25mm shall be provided between parallel lines, or between flange O.D. and pipe. Thermal

movements, the thickness of insulation, and the maximum diameter of flanges shall be

considered in determining side clearance. Space for the connection of instrument piping to

orifice flanges shall be provided.

2.7.4 Bottom of pipe elevation for up to 75mm insulation thickness shall be 500mm and for

insulation thickness more than 75mm, bottom of pipe shall be 600mm. The elevation of

bottom of elevation shall be maintained from grade or top of steel or any technical structure /

platform.



2.7.5 Valves/ Control Valves / PSVs on top of pipe rack

(1) Upto 14”, 150# : Pipe davits shall be used at every 35m. Walkway shall be provided to

move the trolley at the top of pipe rack for movement of valves to the davit.

(2) Beyond 14”: 100 ton crane access shall be ensured.

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Table 1 : Access Requirements

Type of Access Item Being Accessed

Temporary ladder, mobile

steps, temporary platform,

etc.

-Fig 8 blinds (any size without adjacent valves),Flow, pressure and

temperature instrumentation mounted in lines up to 4.6m BOP above

grade and up to 2.6m BOP above main structure platform levels

-Manhole and hand holes up to 3.75m above grade and 2.5m above

main structure platform levels

Permanent ladder with

cage

-Valves 1.1/2" and smaller

-Level gauges

-Temperature and pressure instrumentation above the elevations

stated previously

-Items that require occasional operating access including valves,

spectacle blind and motor operated valves, heater stack sampling

points.

-Man ways above grade on equipment.

Permanent platform with

item accessed from

platform edge (i.e. a

maximum of 500mm from

the platform edge and

1500mm above the

platform height).

-Valves 2" and larger

-Relief valves 3" inlet size and smaller

-Level controllers and switches

-Fig 8 blinds 3" and smaller

-Flow instrumentation above the elevations stated previously

-Sampling points

-Hand holes

-Steam distribution manifolds

Permanent platform with

item accessed from above

and in board of platform

-Relief valves 4" inlet size and larger

-Fig 8 blinds and blind spacers 4" and larger

-Motor operated valves

-Control valves

-Manholes above elevations stated previously

-Heat exchanger units

-Clean out points

-Catalyst loading flanges



Type of Access Item Being Accessed

Ladders and Stairs

For providing platform ladder & staircase following guidelines shall be

followed :

-Two means of access (i.e. two ladders or one ladder and one stair

case) shall be provided for any elevated platform, which serves three

or more vessels & for battery limit valves operating platforms.

-Platforms, ladders & stairways shall be consistent with access &

safety requirments.

-Stairway for tanks to be provided on upstream of predominant wind

direction.

(1) Platform at elevated structure:

-Dual access (i.e. one staircase and one ladder) shall be provided at

large elevated structure if any part of platform has more than 22.65m

(75ft) of travel.

-Fired heaters located adjacent to one another shall have inter-

connecting platforms at various elevations.

-Inter-connecting platforms between adjacent towers shall be provided,

wherever feasible, taking into consideration expansion of towers.

(2) Plaforms with stair access shall be provided only for:

-Location at which normal monitoring (once a day or more) is required

or where samples are taken.

-Location where vessels or equipment items have operator attention

such as compressors, heaters, boilers etc.

-Main pipe rack at battery limits

(3) Platforms with ladder access shall be provided for:

-Items that require occasional operating access including valves,

spectacle blind and motor operated valves, heater stack sampling

points.

-Man ways above grade on equipment.



Table 2 : Minimum Clearances in process plants

ITEM DESCRIPTION CLEARANCES

Width of primary and secondary roads, excluding

hard shoulder (where major maintenance vehicles

are expected to pass)

10000/6000

Headroom for primary roads (where major rigging

maintenance vehicles are expected to pass)

7000

Headroom over secondary roads 6000

Minimum inside edge turning radius for primary 15000

Minimum inside edge turning radius for secondary

roads

10000

Width for plant access roads 4000

Headroom for plant access roads 4500

Roads

Minimum inside edge turning radius for plant

access roads

6000

Railroads Headroom over through railroads (from top of rail) 6700

Headroom for main operating aisles / pedestrian

walkway

2700/2100

Width of stairway (treads) 800

Vertical rise of stairways (1 flight) 5000 max

Vertical rise of ladders (between platforms) 9000 max

Structural access

walkways and

maintenance

clearances

Width for main operating aisles / pedestrian

walkway

1000/750

Access required for vehicular equipment 4000 (Hor.) Access way under

piperacks Access required for potable (temporary) service

equipment

3000 (Ver.)

Clearance between piperack and vessel 4000

Clearance between vessels 3000

Vessels (Vertical and

Horizontal)

Heavy item (e.g. vessel internals, relief valves etc) are to be serviced by

davits or monorails. Davits are to be located on the side of the vessel

outboard of the piperack and drop-out areas to grade reserved.

Clear aisle between two adjacent pumps 900 Pump

All pumps of a rating more than or equal to 55kw shall be provided with a

monorail.



ITEM DESCRIPTION CLEARANCES

Pump Pumps shall be kept outside the pipe rack with pump discharge nozzle kept

at a distance of minimum 1 meter from pipe rack and motor towards rack and

also 4m horizontal clearance beneath the pipe rack shall be ensured while

placing the pump.

Distance of platform below manhole center 1050 max

750 preferred

Clearance in front of manhole 760

Vertical &

Horizontal

Vessel

Sheels Platform extension to side of manhole from

centerline of manhole. Nominal manhole diameter

Distance of platform below face of manhole

flange

175 to 200

1050(If special case)

Vessel

Top Head

Width of platform from three sides of the

manhole 760

Distance of platform below top flange of

channel or bonnet 1500 max

Vertical

Exchanger

Width of platform from three sides of flange 760

Width of the platform at side of horizontal and

vertical tube furnace

1000

Platform

Furnaces

Width of the platform at ends of horizontal tube

furnace 1000

NOTE Platform area around the manholes should be increased on packed vessels where the

manhole is used for filling or removing the vessel packing.



3 DESIGN DETAILS

3.1 Line and Connection Sizes

3.1.1 The outside diameter of pipe shall be as per ASME B36.10 except when necessary to match

equipment connections and required by the process licenser.Piping will be 1/2" normal

diameter minimum and with not less than 1/4 "bore.

3.1.2 In open system, minimum underground line size is 1-1/2" for steel and 4" for cast iron and

plastic lines. In closed system, minimum underground line size shall comply with P & ID.

3.2 Material Specification Changes

When a line is connected to another line of different material specification or pressure rating,

valve or flanges connecting these two lines shall be constructed with the higher material

specification or pressure rating between the two lines, unless otherwise indicated on the

applicable P & ID.

3.3 Bends, Miters and Elbows

3.3.1 Elbows shall be generally used to change the direction of piping. However, bends and miters

may be used in place of elbow with owner's prior approval.

3.3.2 The radius of bend shall be generally 5 times of nominal outside pipe diameter, unless

otherwise specified.

3.3.3 Pipes indicated below may be cold bend at site (if required).

(1) Carbon steel pipe -------------------------- 1" and smaller

3.3.4 Long radius elbows shall be generally used for piping of 2" over except where design

requirements dictate the use of short radius elbows.

3.3.5 Miter may be used for the following as per B31.3.

(1) Category D fluid service: 8" and larger

(2) Other than category D fluid service: Beyond 48" for process line can go for miter as per

B31.3,if not available in the market)

3.3.6 Single weld Miters are acceptable for manhole vent pipes.

3.4 Reducers

Reduction in line sizes shall be generally made by thread, butt weld or socket weld fittings.

Reducers shall be used in accordance with the Engineering Specification (6987-LEPC1-SE-

00-PP-SD 1002). Threaded reducers shall not be used on process lines.

3.5 Branch Connections



3.5.1 Branch connections shall be generally made by thread, butt weld or socket weld tees, half

couplings, welding outlet fittings or welded pipe-to-pipe connections. When welded pipe-to-

pipe connections are applied, unless the wall thickness of the pipe is sufficient to sustain the

pressure and the thermal stress, it is necessary to provide reinforcement. Welded pipe-to-

pipe connections shall be designed so that the angle of intersection between the branch and

the run is not less than 45°. Threaded connections shall not be used on process lines.

3.5.2 Selection of branch connection types shall be in accordance with the Engineering

Specification (6987-LEPC1-SE-00-PP-SD 1002).

3.6 Flanges

3.6.1 The use of flanges in the piping shall be limited to connections at the flanged equipment

(including instrument equipment) and valves.

Flanges shall also be provided in special cases.

(1) Where frequent dismantling of piping is required.

(2) Where dismantling of equipments such as compressors, reactors heads and heat

exchangers are required.

3.6.2 Where plastics, non-metallic, cast iron or lined piping system cannot be welded.

3.7 Couplings

Full coupling shall be generally used for joint of piping 1.5" and smaller in accordance with

the Engineering Specification (6987-LEPC1-SE-00-PP-SD 1002), Piping Materials and the

individual material class.

3.8 Valves

Cast Iron Flange Steel Flange

Class 125 Flat Face Class 150 Raised Face

Class 250 Flat Face Class 300 Raised Face

3.8.1 Valves, which type and number are shown on the applicable P & ID, shall be installed in the

suitable place to permit proper and safe operation of the unit. Valves shall be preferably

installed with their stems above their horizontal centerline. Double block and bleed valve

system shall be provided only where necessary to avoid product contamination or hazardous

condition, as shown on the P & ID.



3.8.2 Valves shall be generally gate valves. Globe valves shall be used when throttling is required.

Other types of valves are in accordance with the Engineering Specification (6987-LEPC1-

SE-00-PP-SD 1002).

3.8.3 Gear operator shall be provided for large valves requiring great torque for operation. Valves

requiring gear operator are in accordance with the Engineering Specification (6987-LEPC1-

SE-00-PP-SD 1002).

3.8.4 Orbit ball valves or Vanessa butterfly valves are to be used when tight shut off (TSO) is

required.

3.8.5 Wafer type butterfly valves are not to be used. Only flanged or lug type allowed with

separate bolting from each side.

3.9 End Closures

Welding caps, blind flanges and screwed caps shall be used as end closures. Screwed caps

shall not be used on process lines. The ends of all distribution headers are to be flanged /

capped (as per P & ID) with a low point drain at the end of each header.

3.10 Blanks and Spacer

Blanks and Spacer shall be provided to the extent as shown on the P & ID. Figure eight

blinds may be used in piping 8" and smaller. Line blinds with spacers to be provided for

greater than 8". Blinds larger than 8" are to be installed in horizontal piping to facilitate

removal, if possible.

3.11 Strainers

Temporary conical strainers or wire nets with proper space ring shall be provided in the

suction side of compressors for start-up operations. Permanent strainers (T-type or Y-type)

shall be installed in all pumps in accordance with the P & ID.

3.12 By-passes

Bypasses are provided only to the extent required for normal operation as shown in the P &

ID. In general, by-pass shall not be provided around equipment solely for serving as

replacement of the equipment while the unit is operating.

3.12.1 Control Valve Block Valve and By-Pass Valve Sizing

The following table may be used as a guide in sizing control valve block valves and the

control valve by-pass valve. In systems with a high pressure drop, if the control valve is two

or more sizes smaller than the line size, the block and by-pass valves may be of an

intermediate size.



<CONTROL VALVE BLOCK AND BY-PASS VALVES>

Control Valve Size

Block Valve Size

Block Valve Type By-Pass Size (2) By-Pass Type (2)

Up to 4” Gate Same as Control valve size Globe (1)

6" and larger

Same as Line Size

Gate One size smaller than control valve Globe (1)

Notes:

1. Use ball valves for plugging service.

2. For 10" and larger, gate valve shall be used as bypass valves.

3.13 Vents and Drains

3.13.1 Venting and draining shall be generally accomplished through the vessel and/or equipment

connections. Vessel vents and drains may be located at overhead or bottom of the piping

when valves or blinds are not located between vent or drain connections and vessels.

3.13.2 Pockets in piping system if unavoidable, shall be generally provided with 3/4" drains.

3.13.3 All drains and vents shall be provided with valves with caps and/or flanges, and those vents

for test purpose may be plugged with square head plug without valves. Exposed threads

shall be generally seal welded after hydro-test.

4 GENERAL INSTALLATION REQUIREMENTS

4.1 Provisions for Expansions and Flexibility

4.1.1 Provisions for thermal expansions shall be made in all lines in accordance with the

requirements of ASME B31.3, ASME B31.1 and additional requirements as follows:

(1) The basis of calculation for expansion requirements shall be the Design temperature

and/or other more severe temporary condition such as in start-up or steam-out.

(2) The lines which contain flammable or toxic service fluids and are flushed with steam-out,

shall also be provided with adequate flexibility. Dismantling of subjected lines prior steam

out may cause a hazardous situation due to spillage of flammable and/or toxic product.

4.1.2 Provisions for expansions shall be normally made with pipe loops. Bellows type or other

expansion joints may be only used where necessary under owner’s approval. When

expansion joints are applied, adequate guide for piping shall be provided to avoid

eccentricity of the centerline. Care shall be taken in use of horizontally installed bellows for

the possible creation of condensates.



4.1.3 All piping system shall be designed so that the loads and moments at the flanges of

mechanical equipment such as pumps and compressors shall not exceed the permissible

reactions for this equipment as specified by the applicable code or the vendors of equipment.

4.1.4 When excessive forces and moments occur, cold spring may be used. According to thermal

calculation results. Cold spring may be adopted to reduce forces and moments which acts

on equipment nozzle or structure. Special care should be taken to install cold spring for

rotating equipment piping.

4.1.5 As per the engineering practice, the maximum continuous operating temperature shall be

used for nozzle loads evaluation only for all rotating equipment. For stress evaluation of

piping connected to rotating equipment, design temperature shall be used.

4.2 Supports and Hangers

Supports and hangers shall be provided in accordance with pipe support specification 6987-

LEPC1-SE-00-PP-SD 1009: Pipe Support

4.3 Pipe Connections

4.3.1 Pipe connections are generally as follows:

(1) Connections in piping systems of 2” and above shall be butt welding.

(2) Connections in piping systems of less than 2” shall be socket welding or screwed

connections where permitted.

(3) Flanged connections shall be used at connections to vessels and equipment.

(4) Pipe connections shall be in accordance with the Project Engineering Specification 6987-

LEPC1-SE-00-PP-SD 1002 : Piping Materials

4.3.2 Threaded joints shall be generally assembled without seal weld unless otherwise indicated.

4.4 Valve Installations

4.4.1 Valves shall be preferably installed so that the valve hand wheel shall not be more than

1,800 mm above the pavement or platform levels and not obstructing walking aisle with

headroom of 2,100 mm.

4.4.2 Other valves, which are not frequently used and are not lower than 3,600 mm above the

operating level, shall be so installed that they can be reached from a portable ladder or an

operation stand.

4.4.3 Valves in trenches shall be provided with extended stems with hand wheel at 1,100 mm

above walkover platform.

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4.4.4 Valves at towers shall be located directly against or close to the tower nozzles, unless

physical interferences would prevent proper operation of the valves. Valves shall not be

located inside vessel skirts, unless otherwise specified.

4.4.5 All valve outlet ends, in all services which do not connect to a piping system, shall be

provided with a blind flange or screwed cap assembly, unless otherwise indicated on the P &

ID.

4.4.6 Manual operated valves, which are used in conjunction with locally mounted flow indicators,

etc., shall be placed at the same operating level and located where the instrument can be

readily observed.

4.4.7 Control and safety valves shall be installed above platform. For exemptions or special cases

a waiver from owner shall be obtained during detail design and/or model reviews.

4.4.8 For cryogenic service valves used in design temperature of between –50℃ and below, the

valve shall have an extended bonnet.

4.4.9 For cryogenic service valves shall not be installed in vertical lines.

4.4.10 Valves in horizontal lines shall be installed with stem in vertical position or at least 45˚

vertically from the horizontal centerline of the pipe except below:

(1) Inlet line block for safety valve

(2) Normal closed valve may require opening in an emergency or upset condition (for

example, by-pass valve for control valve system).

(3) Orifice tap valve

(4) Block valve for instrument items

(5) Flare system block valve

4.4.11 All valves in flare system to be installed with horizontal stem.

4.5 Pump Piping

4.5.1 Pump suction lines shall be designed to avoid traps and pockets. Horizontal suction lines

from towers shall be designed to avoid pockets resulting from thermal expansion of vertical

lines.

4.5.2 The discharge line from centrifugal or rotary pumps shall be provided with a check valve

between the pump and the block valve.

4.5.3 Suction and discharge lines of pump shall be drained through drain located at the low point

of the pump casing whenever possible.

4.5.4 Sealing oil system and cooling water piping for gland shall be furnished in accordance with

the pump vendor's recommendations.



4.5.5 Permanent (T-type or Y-type) strainers shall be provided for all pumps. The strainer open

area will be at least equal to 200% of the pipe cross sectional area.

4.5.6 A warm-up bypass will be provided as indicated on the P & ID. The bypass will have a globe

valve and will be installed around the pump discharge check valve. Drilled check valves can

only be used with written Owner permission.

4.5.7 Piping layout shall comply with the pump manufacturer's requirements for straight pipe run at

suction nozzles.

4.5.8 The reducers in the pump suction lines shall be eccentric and installed top flat to avoid

creating the air pocket.

4.5.9 Pump piping shall be designed to provide clearance for pump or driver removal.

4.5.10 Pump suction line dia should normally not be more than 2 std line sizes larger than nozzle

sizes to the extent possible.

4.5.11 Suction piping lengths shall be as short as possible. A straight section of minimum 3 times of

the line size shall have to be provided at the suction nozzle.

4.5.12 No monorail should normally be provided for pumps outside rack and sufficient space below

rack shall be available for pump maintenance.

4.5.13 Wherever practicable pumps shall be arranged in rows with the centre line of the discharge

nozzle varying between 1m to 3m from the rack column centerline. Pumps shall be kept

outside the pipe rack.

4.6 Rack Piping

4.6.1 When header block valves are used in utility lines, they should be installed in horizontal runs

at high points in the line so that the line drains in both directions from the valve. Any variation

from this statement could be determined during model review.

4.6.2 Hot lines on pipe racks shall be grouped and expansion loops shall be nested together. The

number of expansion loops shall be kept to a minimum.

4.6.3 The total width of pipe rack shall include 20% free space allowance for future expansion.

This 20% shall be of total width (including all tiers) of the pipe rack. But on each tier, free

space shall be complied with the following.

(1) For rack with rack width upto 6m : Minimum 750mm free space per tier

(2) For rack with rack width greater than 6m : Minimum 1000mm free space per tier

4.6.4 Cooling water lines 24" and below shall be routed above ground on piperack / sleeper.

4.7 Tank and Vessel Piping

4.7.1 The nozzle for level controlling instruments shall be preferably oriented within an angle not

exceeding 60˚ against the fluid inlet nozzle.



4.7.2 The permanent platform is to be provided for all the nozzles with a centerline of 5,000 mm or

higher above grade except where nozzle flanges are provided only for initial assembly.

4.7.3 The fluid inlet nozzle shall be located as far as possible from the fluid outlet nozzle.

4.7.4 Vibration caused by wind load or other dynamic effects on tower-overhead piping shall be

considered in the design.

4.7.5 Suitable expansion connections shall be provided in the piping between tanks and

equipment considering excessive stress on nozzle and differential settlement.

4.8 Exchanger Piping

4.8.1 Exchanger piping shall be designed to allow both the bonnet and channel ends to be free for

removal. Piping at exchangers shall be kept clear at channel section to allow for unbolting of

channel and tube removal.

4.8.2 Inlet and outlet piping for multi-pass exchangers or coolers shall be designed to be as

symmetrical as practicable in order for equal flow distribution. When individual pass flow

control is provided, this requirement is not required.

4.8.3 Use of Monorails for maintenance / removal of heat exchangers is not preferred unless there

is specific need for it (e.g between structures). And it is not required for heat exchangers on

the ground level and the top of the structure. Movable crane shall be used for maintenance

and removal for these items.

4.9 Compressor Piping

4.9.1 Compressor suction lines shall be provided with a suction filter which can completely remove

debris from the system.

4.9.2 Whenever possible, suction and discharge piping in the immediate vicinity of the compressor

shall be located at grade elevation, or below the elevated floor to minimize vibration.

4.9.3 Provision shall be made in the compressor piping to minimize stresses in the nozzle by

means of weight loaded hangers or their equivalent. The stress values shall be dependant

on vendor's recommendation.

4.9.4 Piping to compressors shall be so arranged that it will not interfere with the removal of parts

from or disassembly of the equipment.

4.9.5 Lube oil and/or seal oil returning piping shall be sloped back to the oil storage tank with a

minimum slope of 1/100.

4.10 Furnance and Fired Heater Piping

4.10.1 Furnaces are located at the periphery of the process area, to suit atmospheric conditions,

maintenance requirements (to service tubes & tube removal), and strict safety distance.



4.10.2 Furnaces should be grouped together in a common area. The minimum distance between

furnaces or furnaces and associated close coupled equipment is determined by erection,

operating, piping and maintenance requirements.

4.10.3 Furnaces should be located upstream of the prevailing wind to minimize the possibility of

flammable vapors passing into the area.

4.10.4 When locating furnaces, consideration must be given to the height of the furnace stack in

relation to adjacent towers or structures. The safety distance shall be provided as per Safe

Location Concept (6987-LEPC1-AA-00-PS-PC 1022).

4.10.5 Furnaces that are used for intermittent or start-up service can be located:

(1) A practical minimum distance from related process equipment they serve.

(2) A 7,500 mm minimum distance from non-related process equipment.

4.10.6 Furnaces or furnaces and associated close coupled equipment must be located minimum of

15,000 mm from other non-related equipment containing flammable fluids (except as noted

in paragraph 4.10.7).

4.10.7 Furnaces must be located at a minimum of 15,000 mm from:

(1) Air cooled heat exchangers containing flammable fluids

(2) Switch rooms

(3) Un-pressurized control houses

(4) Compressor and pump houses containing equipment in hydrocarbon service

(5) Remote valves

4.10.8 The process inlet enters the furnace through single or multiple connections. Generally, each

inlet line is furnished with controls which are located at the front end of the furnace, for ease

of operation. For multiple connections, each heater pass contains an identical number of

tubes with identical flow and heat transfer. So the means to divide flow equally among the

passes must be provided.

4.10.9 The product outlets connect to the transfer line, which is considered to be the most critical

line within the furnace arrangement. Usually of an expensive alloy and operating at a very

high temperature, the length of transfer line should be kept to a minimum to suit safety

distances, flexibility restraints, and de-coking requirements.

4.10.10 When certain feedstocks are used, transfer lines have a tendency to coke. In some services,

quench oil is injected into the transfer line to minimize coke formation. In transfer lines where

coking is expected, flanged fittings are specified to facilitate cleaning.



4.10.11 Fuel gas system shall be as follows:

(1) A condensate leg with a drain connection shall be provided at the low point of the

distribution header. The supply leads to the burners shall be taken from the top of the

distribution header. The branch line shall be connected to the distribution header in such

a manner as to give a balanced gas flow to each burner.

(2) A remotely located shut-off valve shall be installed in the gas supply main or in the branch

line to each furnace, positioned in an accessible location a minimum of 15,000 mm from

the furnace at grade.

(3) A valve located adjacent to the burner lighting post shall be installed in each burner lead

for manual adjustment of the fuel supply so that the operator can observe the flame while

operating the valve must be located.

5 REQUIREMENTS FOR INDIVIDUAL PIPING SYSTEM

5.1 Process Piping System

5.1.1 Sample connections shall be as follows:

(1) Sample connections and sample coolers shall be provided as indicated on the P & ID.

(2) The sample connections shall be generally located in vertical line. When pipe is in a

horizontal or inclined plane, the sample connection shall be located at the side or top of

the pipe.

5.1.2 Piping for pumping-out of towers and equipment shall be provided to the extent shown on

the P & ID and shall be adequate to permit normal operation and shutdown of the process

units. Such piping shall be a part of regular process piping of the unit and shall be designed

to be minimum.

5.1.3 Pressure relief valves shall be provided as follows:

(1) Pressure relief valves shall be provided to the extent shown on the P & ID.

(2) Pressure relief valves on process systems shall be connected to a flare or other disposal

systems, only when so indicated on the P & ID.

(3) Pressure relief valves shall be located at positions accessible from platform or grade.

(4) Pressure relief valves shall be installed in a vertical position and shall have a minimum of

pipe length between the protected line or equipment and the valve inlet. Where pressure

relief valves are positioned on the downstream of rotating equipments, for instance steam

turbine, it should be installed near the anchor point.



(5) The Safety distance on pressure relief valves, which are not connected to flare or other

disposal systems, shall be provided as per Safe Location Concept (6987-LEPC1-AA-00-

PS-PC 1022). A 12 mm minimum weep hole shall be provided at the low point of the

discharge piping when discharging to atmosphere.

(6) Pressure relief valves connected to flare lines shall be located higher than the flare

header, except where otherwise specified and agreed with owner.

(7) Outlet piping of pressure relief valves connected to a flare line shall be connected to the

top or side of a flare header so that the flow direction angle between the axes of the outlet

line and of the header is 45˚ . If the line size is 1.1/2" and smaller, 90˚ is allowed.

(8) Outlet piping of pressure relief valves including flare lines shall be designed to prevent

excessive stresses in the line resulting from large rapid temperature distribution.

(9) Flare header shall be sloped to the blow-down drum with a falling gradient.

(10) Block valves to flare systems to be mounted with horizontal stem.

5.2 Steam Piping Systems

5.2.1 Indian Boiler Regulations (IBR)

Steam lines with conditions listed below fall in the scope of IBR

(1) Lines having design pressure (maximum working pressure) above 3.5 Kg/cm2 (g)

(2) Line sizes above 10" inside diameter having design pressure 1.0 Kg/cm2(g) & above.

(3) Lines with pressure less than 1.0 Kg/cm2(g) are excluded.

(4) User of steam like steam tracing lines, jacket of the steam jacketted lines, steam heating

coil within the equipment are excluded from IBR scope.

(5) Boiler feed water lines to steam generator, condensate lines to steam generator and flash

drum as marked in P & ID shall be under purview of IBR

5.2.2 IBR Requirement (in brief)

(1) All materials used on lines falling under IBR must be accompanied with IBR Inspection

Certificate in original. In exceptional cases, clear & legible photocopy of the original

certificate duly countersigned and attested by local boiler inspector is acceptable.

Leading inspection authority viz. Lloyds, EIL & any other agency which are authorized

inspection authorities for IBR outside India. Whereas for Indian supply only IBR is the

inspection authority.

(2) Drawings like General Arrangement Drawings (GAD) and isometrics of lines falling under

IBR must also be approved by IBR authority of State in which the system is being

installed.



(3) All welders used on fabrication of IBR system must possess IBR welding qualification

certificate.

(4) IBR system must be designed to comply with IBR regulations as well as ASME B31.3. All

design calculations towards the same must be approved by IBR authority.

(5) IBR approval is obtained with requisite fees payable to Indian Boiler Board of the State

concerned.

5.2.3 Branch connection from steam headers shall be generally taken off from the top of the

header. Single block valves and/or check valves shall be provided to the extent shown on

the P & ID, and installed in horizontal run (condensate drains away from block valves),

adjacent to the headers. End of steam header should be provided with flange and blind

flange.

5.2.4 Steam and condensate lines shall not be buried.

5.2.5 Steam block valves in the branch lines, adjacent to the headers, shall generally be located in

horizontal position.

5.2.6 Steam safety valves shall be provided as follows:

(1) Steam safety valves shall be provided as shown on the P & ID.

(2) The safety distance shall be provided as per Safe Location Concept (6987-LEPC1-AA-

00-PS-PC 1022). A 12 mm minimum weep hole shall be provided at the low point of

discharge piping.

(3) Steam safety valves shall have generally a minimum length of piping between the

protected line or equipment and the valve inlet.

(4) Process steam connections to fired heaters, fractionating towers and any other process

equipment or lines shall be provided with a check valve and a block in series; the check

valve being located between the block valve and the injection point.

5.2.7 All steam lines shall be designed to avoid unnecessary pockets. Where pockets cannot be

avoided, steam traps or drain valves shall be provided. Traps shall be discharged to the next

lower pressure steam header, condensate header or other suitable locations unless

otherwise indicated on the applicable P & ID.

5.2.8 Steam Condensate

(1) Branch connection from condensate headers shall be generally taken off from the top of

the header unless. Single block valves and/or check valves shall be provided to the

extent shown on the P & ID, in branches, adjacent to the headers.

(2) Each drain on steam headers shall be provided with a condensate pot.

(3) Generally, collection and discharge of condensed water shall be carried out through steam

trap.



(4) When draining large steam consumers such as heaters, condensers, and re-boilers, level

controlled collection pots may be used.

(5) For closed condensate recovery system, the condensate collecting header shall be as

short as possible to the flash drum and they shall be planned with downward pipe route.

(6) Steam condensate headers subject to hydraulic shock shall be designed in consideration

of the following:

- Bolting and gaskets shall be made from materials capable of withstanding the effect

of hydraulic shock.

- Condensate headers shall be provided with slip expansion joints without corrugate

bellows type joints to prevent excessive expansion forces, when necessary.

(7) Standards for steam / condensate traps arrangement drawings to be issued.

5.3 Water and Air Systems

5.3.1 All process cooling water lines shall be installed so that equipment being cooled shall remain

full of water in the event of shut-down of the cooling water pumps.

5.3.2 Branch line from the header of the instrument air system shall be provided with single block

valve and check valve as indicated on the P & ID, and located at the top of the header.

5.3.3 Instrument air lines shall not be connected to process lines, service lines and other

equipment.

5.3.4 Instrument air shall not be used as plant air or service air in principle.

5.4 Fire Protection System

Fire water lines and hydrants shall be installed as indicated on the applicable P & ID.

5.5 Utility Services

5.5.1 Hose stations for steam, water, air and nitrogen (if required by process) shall be provided at

working platforms or grade locations and grouped together, as indicated on the P & ID.

Standards for utility stations arrangement drawing to be issued. Areas to be served with one

hose station shall be within reach of 15 m hose. For working platform upto 35m, air water

and steam lines shall be provided. But beyond 35m, only air and steam shall be provided.

5.5.2 Block valves and check valves are to be provided in individual branch headers to each utility

station.

5.5.3 Special fittings and different color hoses are to be provided for positive segregation from

other utilities according to existing plant standards.

5.5.4 Globe valves shall be used for air and water nitrogen and steam.



5.5.5 A hose rack to be provided for the four different hose types at each utility station except

those located on column platforms.

5.5.6 Provide spare connections on utility headers (nitrogen and LP steam) in areas needed for

preparing major equipment for maintenance.

5.6 Safety Shower and Eye Wash

5.6.1 Safety shower and eye wash unit will be provided within 15 m of where toxic, corrosive or

flammable liquids (C5+) are handled.

5.6.2 Supply piping to safety shower and eye wash units to be installed underground to maintain

the water temperature as low as possible during hot weather. Above ground piping to be

minimum and insulated.

5.6.3 A thermostat set at 40˚C to be provided at the inlet to the eye bath to limit water temperature.

5.7 Drainage and Sewage Systems

5.7.1 Drainage and sewage systems shall be supplied to the extent shown on the P & ID.

5.7.2 Equipment drains shall be collected to drip funnels.

5.7.3 Oily sewer systems shall be properly trapped and sealed at the manholes and sumps.

5.7.4 Oily sewer shall be drained separately from rain water and non-oily sewer.

5.7.5 OWS will convey waste water containing hydrocarbons from process area equipments such

as Pumps, Compressors, Exchangers, Vessels etc. and sent to oily water basin.

5.7.6 OWS from all process equipments drain shall be discharged into funnels and conveyed thru

slope to OWS header. Slope shall be calculated using Manning Formula. Material of

construction for pipe is CS (API 5L Gr.B) externally PE coated. These pipes are directly

buried. At every 30m sealed manholes are provided and vent from manhole is routed near

pipe rack columns and upto 3m above top rack.

5.8 Underground Piping

5.8.1 Underground piping shall be considered for drainage, sewage, firewater and cooling water

piping greater than 24" in diameter.

5.8.2 Underground piping can be direct buried, sleeved or run in engineered pipe trenches. The

criteria for access, inspection, and corrosion protection shall be considered carefully, before

deciding on the underground option to be adopted for the project.

5.8.3 Insulated lines and lines with significant thermal movement shall not be direct buried. At road

crossings buried piping shall be protected form road imposed loads using pipe sleeves.



5.8.4 Wherever underground pipes, cables, instrument lines cross a road, consideration shall be

given to combining them, with the spacing, and pass through a culvert instead of being direct

buried.

5.8.5 Cooling water supply and return line shall be provided as per PID. These lines are directly

buried. Material of construction for CWS/CWR is CS (API 5L Gr. B) externally PE coated.Flat

side down eccentric reducer shall be used.

5.8.6 Potable water will be supplied for safety shower and eye wash. It is directly buried (U/G).

Material of construction for potable water is Galv.(API 5L Gr. B) externally PE coated.

5.8.7 Slop system:

(1) Warm slop

- All warm slop line shall be installed in trenches and shall be steam traced.

- Slope shall be as per P&ID.

- Material of construction for pipe is CS (API 5L Gr.B).

- All warm slop line is connected to warm slop drum.

(2) Cold slop

- All cold slop line shall be installed in trenches.



- All cold slop line is connected to cold slop drum.

(3) Benzene slop

- All benzene slop line shall be installed in trenches.



- All benzene slop line is connected to benzene slop drum.

(4) Caustic slop

- All caustic slop line shall be installed in trenches.



- All caustic slop line is connected to caustic slop drum.

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5.9 Hydraulic Bolt Tensioning

Hydraulic bolt tensioning shall be applied for all joints where the bolt sizes match following

criteria.

Nominal Bolt Diameter Condition

50mm and over All joints

Class 600 and above 38mm and 50mm

Category ‘M’ fluid service

25mm and above Critical equipment nozzle such as compressor and

turbine, pump, blower where vibration is a possibility.

Consideration shall be given to space requirements for bolt tensioning equipment.

5.10 Piping Tie-Ins

All lines shall be terminated at the plot battery limit with isolation as per process package.

There are only two battery limits for this unit one in the north direction and the other in the

east direction as indicated in the plot plan attached with bid package. All lines at battery limit

shall be anchored as far as possible or otherwise forces and moments shall be provided by

other contractor at the interface.

5.11 Drawing and Procedures

All final as built drawings are to be submitted in latest Auto cad version. If the same is not

made available in Auto cad, the necessary software / system shall be supplied in order to

enable direct population of the same into company’s end user system with due integration.

5.12 Mandatory spares

Piping systems shall not be spared. However for pipe fittings including valves (less than and

equal to 10") 5% or minimum of 1 spare shall be provided as ware-house spares.

&se-00-l-sd 1001 engineering specification for piping design

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