Professional Documents
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COMPLEX
Dual Feed Cracker Unit
ONGC Petro additions Limited & Associated Units EIL
SEZ, Dahej, Gujarat, India JOB NO. 6987
Page: 1 of 29
ENGINEERING SPECIFICATION
FOR
PIPING DESIGN
REVISION HISTORY
* Notes:
This page records all revisions on the specification.
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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
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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.
1.4 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.
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.
2.3 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.
2.5.2 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).
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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.
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3 DESIGN DETAILS
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.
3.5.1 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
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.
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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.
3.11 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.
Same as Control
Up to 4” Same as Gate Globe (1)
valve size
Line Size
One size smaller than
6" and larger Gate Globe (1)
control valve
Notes:
1. Use ball valves for plugging service.
2. For 10" and larger, gate valve shall be used as bypass valves.
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.
4.4.4 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.
4.5.5 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.
4.7.2 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.
4.10.2 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.
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(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.
(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.
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(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.
5.5.5 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.
5.8.4 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: