Pipes, F1tt1ngs, Valves and Plp1ng Layout, IPSS 1.

6w1th the act1ve par~icipation of the representatives of all the steel plants and associated organizations in the field was adopted in June 1998.

.,.;::
.-
-,--- ~".v
- CODE OF PRACTICE FOR'" - IPSS: 1-06-034 -91: .. _
'.
OXYGEN GAS PIPELINE

IPSS corresponding IS does not exist
~. FOREWORD
p.l This Inter Plant Standard prepared by the Standards committee on
. .2

(

1

Oxygen is distributed to consumers from a generation plant LOX storage and vaporizati.on plant or a cylinder discharge manifold by means of pipelines. Oxygen is a highly oxidizin99as which under

.certain conditions combines with almost all the elements giving'rise to a bri~k exothermic react ion. In view of the possibility of spontaneous combustion in oxygen piping systems, spec'ial precautions need to be taken in desigll, fabrication, erection, testing and commissioni.ng of oxygen pipelines.

SCOPE

Jnter Plant Standard stipulates engineering requirements for ~esign, construction and commissioning of oxygen "gas pipttlinef> 't carbon. steel or' non-ferrous metals or alloys {oJ." operation '~l!Sures upto 42 kg/cm2 (g) and temperature upto .5S~C. Th. · ••• nt. ar. cov.red after pressure r.gulation .yst ••..

In this St~rd. ~ever "ollygt'n pipeli~" is lIIe~tioned. the 5_ should be

.•. 'OO5trued •• ""'.rrine to "ollYllen II" pipet i~N only.

C[ASS ..... CA TION Of PIPELINES

~

~pending on ". the maximum operating pressures, oxygen gas pipelines

shan be categor h.d as follows:-

s;

~teg:ory I - fpr,operaUng pressure upto 16 kg/cm2

r" ----,-:

G.tegory II

~~"'~:~iaiD9

to~ operatiny pressure, al:?ove 16 upto 42 'Kgicm2

The three basic criteria that determine the design of pipes and components shall be,:

Gas velocity Pre •• ure 10 ....

Mechani.cal 8trengthof pipe (pressur., temperature and .tre •• )

.PAGS1/1'

t

IPSS: 1-0'-034-98

,2.2.2

For .ach lIection of the pip.lin.. the flow rate and~eql.lir.d pr •.•• ur. b.inq known t;he usual •• quence of seleetion shall' b. a~ follow.:

Th. diamet.r ot the pipeline .hall b. f ina~ized so that the required pressure is available at consurrie'r point with the maximulq flow ina qiven pipe run~ .It shall be s.lected by

,judg~nq fro~ .conomical velocity calculated sepllrat@ly for each pipeline.

Verification 9f velocity and possible adjustment of the diameter 80 as to observe velo~ity limits.

, .

select~on of thickness ot the pipeline bas.d on the desired resistance'to pressure.

selection of velocity

s.l.ctionof velocity in a particular section of a pipe de(-iends on , various factors like flow material. off the pipe, dust ahd, foreiqn ma.tt.r content etc. V"locity m.ans the 9'as ,velQcity in a given ceo •• section calculat;ed' under the conditions pt,', pressure temlJerdture anc(

flow.

It shall be calcullated as follows:-

=

1.31J <LT Z 02 p

Ve16city ot gas in m's

Flow in mJ/h under NTP conditions Gas t",.mperature ill It

Absol~teg.as pressure in bar

:: coefflfient of cOlDpressibility under flow ~ondition

= Interhal diameter of pipe ir. rr~

~:.

'"

i .4

Maximum Recommend~ velocities in.pipelines sh~ll be:

Category Category

I II

10 m/sec B m/sec

Velocity of oxygen in the pipeline depends on the maT:erial of the pipe selected and the pressure range tor which the pipel ine system i. designed. Although international standards and norms allow higher velocities of oxygen~ gas in pipeline, the velocities recommended by this code is limited to the values given above, considering pt'evailing qualities of workmanship and ~leanliness acnie'Jed.

),

"

.\ ,. LAYOUT OF PIPELINES .

3.1 Intershop oxygen pipelines (outdoor)

J .1.1 Oxygen pi,pework shall preferably be routed overhead, however, underground routing lJIay also be permitted, if the requirements so demand .

. 1.2 While routing overhead oxygen pipelines depending on the route through whl.ch they pass the minimum clearance (from surface to surface) from other structure shall be as per Table-l and the minimum clearance (in height) shall be as per Tabl.-2.

MINIMUM CLEARANCES OF OVERHEAD OJ:rOEN PIPELINES (surfac. to surfa.) (claus. ],.1.2)

TABLE-l

6.

7.

Structures

Clearance (m)

Remarks

Explosion Ha~ardous Shops

J

Railway Track.

To the near~st rail

J

Railway Bridges' Platform

J

Roads

1.S

1.5m upto the embattkment

High voltage transmis.ion lines

a)

par.\'lhtl to pipeline

10,

b)

croa8l.ng the pipeline.

upto 20 KV 35 - ISO KV 150 - 220 ltV

3 4 5

To the place of hot metal tapping and sourc. of open fire

10

(a) - for insulated LT cabl.

0.5

(b) - for bar. conductor LT

1

'.

1;:

IPSSa 1-o~-b34-98

MINIMUM CLEARANCB or OVBIUIUDS OXYOD PlftrLlOS Cia b .... v .. t) (e lau.. 3. 1. 2 )

s.Mo. Route Cl.arance Remar,ks
(m)
1. Roads 6.0 From the road surfac. to
the bottom of pipe or to the bottom of pipe support structure whichever is lower

2.

Pavement.

2.2

3

Non-electrified Railway Track

6.0

From tne top surface of the rail to the bottOm of the pipe or platform or heat shielrt,whichev'"r is lower

4

Electrified Railway ';" and Tram Track

'--t!-~

'~~~1Hot metal Track:

1'_0;":'

1.1

5

",{;:.' . .-j~,\'-'>-->;:;

:!t:.~,Y'~

Without heat shield With heat shield

10.0 6.0

J.1.~("i.~lin. shall be ,laid on the platforms" pillars, co Iumne alld 01\ t.h~:' r •• {,-;"extetnal walls of'the building using' the ~xternal bracket, .

-. ~:

'I\1 ..• ·1·>~~~~permitted to lay oxygen pipelineitiong with other pipel-il1es.:?~' ,~~n supportS',; k~eping a clear distance of 300 nun (both, veetiq,.:aL;

,<:.::V"\~,~. .~~d'~orizontaH~ ror' gaseous pipelines', r',fer IPSS: 1-~6-014-9S.· r '

.~-,:!>;,--->.-t;' .r: _-,;'(':1::' :'-~;-,-

:~:-Y;)~.~~P;;;i' ~~l!Cy"~~n . pipin<l", sh,Ul have electrical continuity ac r o s a." :a11 .

. <",,;:,', ¢hn T t~9ns anc;C .hail be effectively e,~thed at suitable iht~r';ai.

j';:,;r':,,'~i~n., . ib' tt\ey .... ~re in the ran'g_ of 1clo-150 mm). • ,.'

·;c~··(~,::-;~\ .. ,'::·:t~-,\~"·~:.,-A~~;t';:~:;\1_~~.,,~ ~", • ~

Wnen'9al:leouS oxygen pipeline crosses another pipeline af 300 mmana more diameter, the distance between them shall not be less than 150

rom and when the diameter is less than 300 mm, the distance should not b. l.ss than 100 mill.

3.1.7

The laying out of gaseous oxygen pipelines shall not be permitted in the following cases:

Along the walls of explosion hazardous building

Throu'Jh the ware houses of inflarr.rnable materials

With ~lectricdl wir~s and electrical cables.

"

------~-------

3.2.1

3.2·Undergz·oun.;! laying out 01 pipelines.

3.2.2

3.2.3

3.2.

3.2.5

:jnd._.z-tJl-' ... .illd l'lpE:!! J.I·~~ !:)",1: ~ rJac:k-ti::~d with !;(.Ji~ unjt.·:;::;

b", laid ill t ht! trellclw;> dl,d then spec ially pEH·mit.ted ot"~rwise by the

En',li 11*c"'-'" to p r o t, ... Ct. it'.F' i n s.t, t r o s t , casual s u r f a c e cunst r u c t, ion, shift,ili'; dUl:< to u n s t an l e s o i L, back-till damage to the external surface o{ the pip or' t1,.~ co e t Lriq, and ~bove ground loads such as vehicles or equipment moving over path .of pipeline. All buried oxygen pipelines ~hall have a minimum horizontal distance of 3 m from buildings and3.S m from centre line of railway tracks. A vertical distance of 1 m shall preferably be kept between burried oxygen lines and other underground piping cabling at crossings.

An earth cover of atleast 1.2 m shall be maiptained from the top of the pipe to t.he ground level in area. subject' to temporary load, and atleast 1 m in areas not subject to temporary loads.

In case of laying oxygen pipelines in open trench a depth of mLnLmum 1 m shall be maintained from the top of the pipe to the fi'ni"shed level of the road. In rocky soils, a clear distance of minimum 0.1 m shall be main~ained between the bottom of ·the pipe and lowest level of the trench. compacted sand shall be provided on the top and bottom of the pipe to afl extent of 0.2 m and 0.1 m respectively.

Piping shall b.eall ot WEdded construction applying a specif'icati'on and i n s pe c t i.on code su ch a s API 1104 (7). No mechanical joints ,shou'ld be installed unde r q r ou nd either buried .or in pits because of. possibility of leaks.

Cathodic prot.ection of the un,!··rground sections of the pipeline shall be provided in addition l. passive protection bycoat:ing and ng.This shall be as per APPENDIX-A.

ground portions of the pipeline systems shall be connected to ground portions through an electrically insu'lated joint to the underground cathodic protect,ion system. ~he insulation shall be,oxygen compatible.

pipes pas.inC} throuqh. wall., ceiling., fences and other res of .the tluUding. or constructions shall be encased in a

pipe ha\finq in.ide dia atleast SOmm more than that of oxygen The line. shall have no joints in the sections at such cro s. The gap between the oxygen pipe and the outer pipe shall be filled with non-intlanvnable material, but allOwing vertical and hori~ontal movements.

Inside shop layout

oxygen pipelines serving to the technological equipment inside or outside the shop are called the inside shop pipelines •

• 3.2 Inside the oxygen plants and the distribution compartments, the pipelines may be laid along the wall. or column. of the building ••

().Y9.npi~14n.s .. 18t"" consWller .hop shall be rout" as far .• ..,ay !~p~actic.~i.·:t'l''''.o~'''.r lines and process equip.n.nt contain.lng :t'lui~~ Whi~a,.i;'~tt:~J..'~~s 1n an oxygen environment. If loc&t~ in a #It!~rPipe~~51.C.!~~.~~.nical joints in the oxygen line shall not.:

IPsa: 1-0'~034-'.

3.3.4

be.l()o_~~d ·clo.e.to~.mechanic&l joint. 1ft oth.r fluid line. where ha&&lC'dous mixture. could be fo~med if .imultaneou. leak.ge or failure cceueeed , In plac •• of through w.lle, floorings, partition and other building .truccures oxygen pipelines .h.ll be efl.ca.ed. The run. of pipeline. within the cuinljJ shall be tree o.t joi.nts.

Sach run ot oxygen pipelin •• between the fixed .upport. shall be de.igned tor cOdlpens.tion ot thermal e.paa.10n. The compensation of th.rmal exp.n .• ion can be achieved eittMIx- by adopting a routing configur.t~n which 1 •• elf-flexible, or by u.ing U-loop. made frOM .eaml ••• pipe ..... umed e~ther horizont.lly or vertically.

3.1.5

The gate valves on the oxygen linea, whicb are situated in the open shall be a~least J m. away from pump housea and other building_ and equipment.

3.3.6 Necessary provi.sio.n shall be kept 'on oxygen' lines for purging by nitrog~rl for this ·put,pose.

1.4" Other Syste. de.igB cOD.iderat.ioB8

: 'ire break .ection. may be installed in the oxyg.n pipeline ~o Umi~ ·;·t~. propagation of combustion in a. steel .pipeline. Fite break i·.~ti()o8 may beint.roduced immadiatelY downstream at th';." main

~ifr, ..... . ,";"'" ,: «," ',' ' • ,J

,{.,\,cf,~1ation and thro!-tli;ng :valves wh.r .. ,.~he .. velocitia .. can be,lll9h.

J •• <:(~, fi,,_ break .ection will be eitheJ." 4.;:J.engt-h of copper pipe h.~ing ;.. rJh! ..... insid. 'diameter aa the main"SJ~~"'ith flanges ritt,ad ~:.th.

........ . <f'..... '.' '.'

. ~ tWo. ends which· is installed between th.,~.t .. l pip.s or copper in.ert.

made from copper sh.et/tube an¢fn •• rted inside the 8teel.P~pa of the valves. The copper In"J'.t tube shall ganeral1y' arge diameter steel pipeline ••

1.4.1

pipelines care shaH be taken 'to in,Btall i&olatio~ valvas ' sections of the pipeline.Apy pi~lin. compqnent which

y to cause a. change in the flow pattern like re~ucer I bend,

. "Y" connection,. orifice plate etc. snalJ be at. a diatance of fou~ diameters away from the valve.

als used ino~ygen piping.ystem ... fl~ll b. compatlb;Le with:.,

the t.mpera·t~re~ and pr ••• ur.~u •• ~~;within the system and ' .....

.. cleaned for·cucygen .ervice p-ito·J." to',;tbeir uae. Vi"l~tion. « requir'ements'are extremelyhazUc:loJ •. and .. can: lead. to a Recommended sp.cification for pip •• and other pipe fl..ttings

be as par Table-l

4.2 The metals most frequen~ly used in oxygen service shall be as follows:

i) CarbOD ste.ls - for delivery and distribution pipelines above or below ground and for the construction of pipe work fitt.ings.

ii) copper and its alloys - where resistance to oxi.dation and ignition are required and where the veloci.ties in the pipework are on t.ne higher side .

.:. ". ".."here gr4ila.te:r· mechanical strenrJth is " Io: ~lso facilitates ease of cleaning.

PAGE

,

IPSS: 1-06-034-~8

4.3 Valye~; in (jxyqeu IJlpifl"tJ systems shall befofisolatiCon. ?rocess;control and prf'5~;Ure reI iefpurposes ~nd shall be kept to a m i n rmum sine", t llf~:t t.iO(: t: .• ~ct.i1l1ical joints susceptible to leaks. Recommended speciflr:",~i(j:' uf ·/.d·:.~~; ~.i.itll be as per Table-4

4.4 Valves r. access(,ries used in the oxygen gas pipeline shall' be desi(_Jned to function :Nitt.out lubrication .. However, 'if a lubricant is necessary to permit assembly operations or the funct ioning of a component, it shall be selected from lubricants like graphite. molybdenum disulphate flourinated or non-flourinated sil:icons per-flourinated poly-ethers.

4.5 Lubricants used in actuators for valves on oxygen lines shall ~e suitable for oxygen service.

4.6 In case of a non-metallic being used for gaskets, valve seats, etc;c,"{;. care shall be taken to ensure that the material selected is dense, .~. non porous and free from surface or other defects. Compacted fibers'" and powders shall be excluded. These parts shall be securely enclosed with the minimum of play in solid metallic supports which are conductors of heats.

Plasti(" ~~ organic materials have a distinctly lower ignition r:,""'", than metallic materials and on ignition they eventually :'.1~: i c Le s and adjacent inetal particles to - the point of It is, therefore, good practice to use such. materials i.n ?r:1'.'::"!;!. possib!e quantities and only in intimate' conta~t with 114(; 1· .rts of greater mass and good conductivity to dissipate tlf;ilt. The use vf ths!$t;t materials in direct contact with o'xygen shall be limited to the following:

4.7

Seals and packingsin components and assemblies Oeformableelementfi(diaphragms) in regulating devices

Suggested product and their uses:

Properties

Uses .'

. P'1',,~ and FEP

Good 'antifrictlon Tendency to flow Tendency to sub.limate

Valve-seats Antifriction. bearings Antifriction. cO,atings Thrust washers'·· Thread .eala

Gland packings

PTFCE

Harder than PTFE Greater mechanical strength than PTFE and FEP

Valve .eats Bearing. Insulating seals Gland packing_

,lourinated Chloroflourinated ela,tomers (Viton)

Flexibi~lity Elasticity

O-ring .eals Diaphragms

and Chlo~fl~,inated r .. ins can bere~nforced with 914 •• , ceJ> .. i.c. ..tal, and alloy. in c>~r to improve .... , •• 11,"'041 p~opert1e •• • Suc" reinforCeMnt shaH not to ignitiolt.

oxide., aome of affect

IP88: 1-0'-034·"

o. •

~ABLS-3 RECOMMIXDBD ".~IFlCATJONOP PIPS. AND PIP8 FITrINOS (clau •• ··4.1)

s. No.

Item

Nominal dia. (IIIID)

5pecif ication

1.

Pipe

6 to 10

S •• 1111 ••• tub., deoxidiz.d non-ar •• nie copper or copper alloy. for both category I & II.

15 to 600

2. Pipe 40 and
below
50 and
above
l. Flanges 40 and
below 50 and above

4.

Gaskets All size

5.

Bolting All size

Studs Nuts

6. Bends 40 and
below and
upto 50
50 and
above
1. Filters 8.

Copper inserts

Carbon .• t.,l •• amle •• to A5TH A 106-1992 Grada B1AS3 Gr-,i':"~993, black with and. bfavell.d - for both category l'~ II.

Fqf);eQc c,rbon steel socket as per class 300 weld fittings - a, per ASTH A 105-1994 to ANSI B 16.11 for both category I & II.

FOJ"ged carbon st"l t;luttwelded fittings ~s per 'ANSI B '!l6.9 to ASTH A 234-1990. Grade WBP for category I & 'II.

Forged carbon steel, socket weld, raised face, class 300 for category,I & class 300 for category II to ANSI B 16.5 and ASTH A 10S-1994/cdrbon ~teel raised fae. slip on flanges to IS:6392-1i:i71 made fr~ platee to IS;2002-1992 Gr 2A with bore to Buit pipe O:D. -

Forged carbon steel, weld neck, raised fac~, class 300 for category 1 , class 600 for category II to ANSI 8 16.5 and A5TH A 10S-1994/carbon steel raised face slip on flanges to IS:6392-l971 madet'rom plates to IS;2002-1992 Gr 2A with bore to suit pipe 0.0.

Teflon (LOX grade) or paronite (oil free)

IS:1367 for category I

ASTH A 193-1994 Gr 87 ASTH A 194-1994 Gr 2H for category II.

Cold bend ( R • SD )

Forged c~rbon steel alternatively hot bend ( R • 50 )

Copper alloy/stainless steel body, copper alloy filtering element (for pipeline category-I)/glass cloth filtering element (for category-II), ends flanged

Hade ot copper tube/.heat., to bv located l.niida steel pipes downstream of obstruction (valves, etc), length 600 nun or SxDN (whichever is - more) as per working drawings.

PAGE 8/19

-,

IPSS: 1-06-034-98

TABLE-4 RECOMMENOEDSPECIFICATION OF VALVES (claus~4.:5 )

S.Mo.

Nominal dia (II1II)

Pipeline categorY-II

Item

Pipeline category-I

1 _ 1

Isolation valv~ 40 and below

50 .,a above

1.2

40 and below

Throttling

50 and above

1.3

All s izes

Non return

40 and below

50 and above

Note:

Class 800 8ronz~/stainl~ss ste~l ball/globe valv~, t~flon packing and seats with bronze/ 55 trim, ends flanged

Class 300 ball valve bronze/ stainless steel body and trim, teflon pack.ing, flanged ends to ANSI 816.5

Class 800 bronze, globe valve, teflon packing and seats with bronze/SS trim, ends' flanged

Class 300 bronze, globe valve, flanged ends to ANSI B16.5

Bronze/staint~ss steel valves' of swing/lift cheek type with soft seat to suit installation, flanged ends

Class 800 Bronze/stainless steel ball/globe valve wit~ teflon packing and. bronze/stainless· steel trim, flanged end

Class 300 ball valve, bronze/55 body and t,ri. teflon packing, flanged ends to ANSI B16.5 size provided with gear reducer

Class 800 bronze, globe valve, teflon packing and seats wi th bronze tddt,

Class 300 bronze globe valve, bronze trim, teflon

Class,800 bronze/stainless

Class 300 bronze/stainl~ss steel swing cheek valve with soft s~at bronz~/SS trim, teflon packing flanged ends to ANSI 816:5 working drawings

.) Steel .. ting flanges for flanlled copper valves/appurtences shall be flat taced with full face gaskets.

l) Rating and drilli", detail. of cOllpanion flanges for valves and fitting. shall match with those of valves and fit,tings.

PAGB 9/1t

s.

PREREQUISITES FOR PlPEUNI ERECFION

All general pipe., valves, fitting_, instrument. arid appurtenances to~ oxygen service _han ~ perta1ttecl for erection only aner physical inspection at installation slte .ad verlfylnCjJ the suppliers clocu.ents/certJ.ficate •. reCjJardJ.nCjJ .aU.deetory coepllance with the requirements for oxygen .ervice.. The important •• pect. to be checked are li.ted below:

All components of pipework .hal~ be checked .tandard at manufacture, dl.en.ional and .uitabill1y•

b) The accompanying document. and certificate. showing reaults of teata at manufacturers worka ahall be verified. Without 8uch 'certif icatea, the item shall not be used for oxygen

a)

for their material

service.

C) The packing. ahall be Checked to !insure that they are not damaged while in transport between place of manufacturer and site in.tallation.

d)

Pres!lnce of .<ireas. or oil. shall be cheCked in light on visible outer surfacea. Inside of pip •• or fittings may be checked by· passing a white lint free cotton. Alternatively the pipes and fittinga may be .ubjected to ultra-voilst ra.diation. Any presence of aU or grease on the surfae. will create fluorescence.

)

e) Presence. of seals shall be vi.ually checked. Presence of other foreign matters such aa fillings, scale flux, corrosion p r oduc t s , common dirt, wood and metal chips, ,threading compounde , sealers, tar, asphalt. moisture, paint, chalk, flushing compound etc shall also be checked.

f) It shall be ensured that all pipework are cleaned free of all foreign matter.

5.1 Cleaning by Ma~ufacturers

5.1.1

At the manufacturer's works, all pipes and fitting_ ahall be pickled, neutralized and phosphated as per ,IS.:3618 after completing shop tests. Then these shall be tightly sealed by plug. or blank flanges, packed with sachets of dry silica gel inside and tagged "pickled for oxygen services" before despatch.

Valves, regula'tors, filters etc shall be thoroughly cleaned and degreased, their ends sealed by plugs or blank flanges and packed in clean polythene bags and tagged "degreased for oXYgen service" before despatch. The method of degreasing shall be same as that described in clause S.3.3.

5.3

Cleaning at Erection Site

5.3.1

All pipes, valves, .fittings, etc after visual examination verification of documents mentioned in clauses 5.1 and 5.2 above, shall also be cleaned at site as described herein.

PAGE 10/19

1 J

!j

"

c

(

IPSS: 1;-06-034-"'98

:--..;.__--------------~::---------------,~,.''''''

"''0';';'

,,,,,...

5.3.2 In case the oxygen pipes and fittings delivered to site by manufacturers/stockists' are found to contain scale., rust, etc, they shall be subjected to cleaning, pickling, neutralizing and phosphating as per procedure given in APPENDIX-B. After this treatment they shall be dried in open air or by blowing dry air. The endashall then be kept sealed till degreasing commences.

5.3.3 Dageeasing

5.3.3.1 Before erection, all piping components shall be degreased thoroughly, using sol~ents such as trichloroethylene, carbon tetrachloride etc suitable for oxygen service. Patented procedures for vapour degreasing may also 'be adopted, subject to approval by Purchaser/Engineer.

5.3.3~2 The degreasing solvent quality shall be checked before using the same '~";t" for degreasing.

5.3.3.3 Before degre.sing, the pipe work shall be dried by blowing air.

5.3.3'.4 Then the outer surface of pipes shall be cleaned by wiping with cloth dipped in solvent and then dded in open air.

5.3.3.5 Inner surfaces of pipe shall be degreased by plugging one end, filling the pipe with solvent as per quantities given a~ Tabl. 5' and then plugging the otHer end. The pipe shall then be kept horizontally and rotated on its axis at least once every minute, this process shall continue for 15 minutes. After draining the solvent the pipe shall be blown with dry, oil free air or nitrogen of at least 94.0 percent purity at 60 08g C to 70 Deg c temperature for' about 5 minutes, or till the smell of solvent is completely elimina.ted. Alternatively, the drying may be done in open alrfor a mi.nim-Ilm"

period of 24 hours. "

TABLE-5

Mini .... Quantity of .olv.ntto b. u •• d for dagr.asing

(size of pipe in-~)

32

so

150

200 250

300

100

quantities Itr/m.

0.4

0.6

0.9

1.8 2.2

1.4

2.3

":'~'-':

5.3.3.6 If considered n.c •• sary after sit.inspaction, the valve., fittings

and instruments ahall also be degr.a.ed at .it. and dried in open air. The valve and fittings shall be di.assembl.d and kept in clo.ed containers containing the degreasing solvent tor 5 to 10 minutes. After removing the components the same shall be dried in open air till the solvent smell is eliminated. Degreasing of asbestos, gaskets and packing and packings shall be done in a suitable solvent for 2 to 3 minutes and then dried.

5.' All tools and appurtenances used for cleaning shall also be fr •• of, all oil, greas •• dirt etc. The •• shall al.o b. thoroughly clean.d, degreased in a .uitable solvent and dri.d before u •••

PAGB 11/1'

, , _ ... ,." ... " ... • t ... :!, .... : _

·_ .~ _.,_ ,h- _ _ -... ,_

1.5 AU," per.onn .. l involved .han follow .. high .tandard of persoQal cl .. nlin.... Th.y .u11 a.l.o take adequate .af.ty pr.caution. to avoid- inhaling .olv.ntvapoun ari.ing during deqr.a.l.ng. Th.y .hall us. clean gloves and gas mask ••

s.,

'Cleaned component. of pip.",ork ahaU be ",ell prot.cted from recontamination by proper packing and .toring_. Pipe. .ball. be .••• led with plastic .nd-cov.re. It i. rec~nded to plac. .mall .achet. of dry silica g.l In.id. the cl.aned and dagrea •• d pipe. by attaching the sachets by tape to ,the pl .. tic end ~~.. Small item •• hall be k.pt •• aled in polytben •• ha.t. All it .... hall be k.pt in cover.d .pace till i •• ua for _Faction. Suffic~ quantities of de.cant. shall b. kep~ in Fla~. of .torage, to prevent condensation of moisture on ferrous materi~l ••

•

S.7 Quantity of the degreaajn9, ~all ba checked by the following ~ethods:

a) Determination of the op content in the solvents removed from the components after controlled degreasing;degreasing quality may be considered sat'isfactory if oil content in the removed solvent does not exc'eed more by 20 mgtl of oil content in the solvent.

b) By wiping off the section of the cleaned surface by degreased ))

napkin from glass-clCith~ soaked' in the clean solvent and by subsequent determinatiori of oil content on this napkin.

c) Visual inspection of the open cleaned surface with the help of luminescent devices. Quality of degreaaing by water detergent solution of surfaces inaccessible for inspection And napkin wiping may be determined by random control degreasing with org<lnic solvents of a sample from every batch of simultaneously degreaaed items

6. ERECTION & MAINTENANCE OF GASEOUS OXYGEN PIPELINES

6.1 All erection work of oxygen gas pipeline. shall have to be closely supervised_and rigorously followed up to prevent unforeseen holdup which may result in deterioration in cleanliness of the pipework.

6.2 Part-s, accessories, materials and pipes used fOl: manufacture" erection and maintenance of t-he pipe lines, buildings and structures for pipelines shall meet the specifications of the project. Any changes from design shall b~ made only with the permission of design organization which worked out the project.

6.3 Materials, parts, units, accesso~ies and other equipment used for manufacture, erection and maintenance shall meet the required standard norms and technical conditions and shall have certificates of manufacturing plant.

6.4 Accessories shall have marking and distinguishing paint as per standards and norms, according to their use and materials. Steel slide valves, irrespective of their size shall have tag number on housing.

6.5 Pipelin~ assemblies and welding parts during assembly and welding shall be subjected to careful, one by one, control, the welded joints shall be controlled by physical methods. Openings ot accessories shall be closed by blanks or packings.

PAGE 12/19

,.

'. - ... J.t.'

"I

~f

:1

I

I I

(

(

IPSS: 1~06-034-98

6.6

While l ay i nq the p i pe lines through the walls, roofs and other s t r uc t u r'e s of bu Ll d i nqa s t.he pipelines shall be covered with sleeves. Portions of pipelin~s covered with sleeves shall not have joints. Gaps between pipelin~ and sleeve shall be sealed with asbestos or with other non-combustible materials.

6.7 Welding of pipeline

6.7.1

Electric arc welding shall be used for erection of pipelines. Welding shall be done by qualified welders. Low Hydrogen electrodes shall be used.

Backing ring. shall not be used for welding. Root run shall be made with Argon arc (TIG) welding.

Welding of each j~int sh,ll be carried out without breaks upto th~ completion of welding qualifying tests for welding, welding procedures and quality control etc shall be generally as per IS 2825:1969 'Code of Practice for Unfired Pressure Vessels'.

Radiographi~ examination of 100\ welds for oxygen pipelines with working pressure over 10 kg/cm2 shall be carried out. Interpretatio~ of radiographs shall be done by a competent agency.

For pipelines having working pressure 10 kg/cm2 (g) and below, 40 welds shall be tested by radiography. In case of failure of any welding joint found, 100\ radiography to be carried out.

For welding pipelines made of non-ferrous metals and its alloys, helium and argon shall be used. Putrity of Argon us.; for arc welding of copper pipelines shall not be less than 99.8\.

All defective welds shall be removed and redone and then will be subjected- to radiographic examination.

seque'nce of Inspection of pipework

Checking of quality of assembly for welding.

Control of t~chnology of welding.

6.9.1

6.9 Checking of welded joints 00 pipeline

Checking of alignment.

6.8.3

~.'.3

1.10

,.10.1 ,.10.2

6.7.2

6.7.3

6.7.4

6.7.5

6.7.6

6.7.7

During erection the systematic step by step procedure shall be followed.

External inspection ot welded joints.

Checking of the cont1nuity of the jointa.

All the joint. ahall be aubjected to the external inspection for the following defecta,

Cracks on the external surface of the joint.

Uneven surface in the welded zone.

6.8

6.8.1

6.8.2

PAG. 13/1'

IPS81 1-0.-034-'.

'.10.3 Th~o~gh hole ••

6.l0.tDepth and width at welded joint. tor ev.nne •••

7. TESTING OF ERECTED OXYGEN PIPELINE

" • .1 The t.ataof the pip.Un.a: .haU b. carried out .ft.r ... blowing them with oil tr.. and dry air or nitrogen which do not contain fatty material. or oil. Air c._n be con.id.red oil free if' the oil and grea.e content la' 1 ••• than o.OOSgm/Nal aad ia con.id.red dry if it. relative humidity i. le •• thanlO' •

7.2 Pipelines of all categories shall be t •• ted tor strength and t.ightness. The medium used for the pnewaatic testing on strength and tightness shall be pure to the extent possibla.

1.l The tasts shall be carried out under the direct supervision pf the pe-rson responsible 'for this job in strict accordance with the ru Le s and the project data.

1.t Strength-cu.-leakage teat

7.t.1

7.t.l

7.4.3

7.'.'

Pneumatic leak tightness test of the pipelines shall be carried out using oil free air ~r Nitrogen . Valve ~f tbe testing pressure shall be equal to 1.1 times the design pressure.

The welded seams of steel 'pipelines durinq inspection may be tapped with wooden . hammer of weight not more than 1.5 Kg. Pipeline .trom non-ferrous metals and alloys may be tapped with a wooden hammer of weight not more th'3n 0.8 Kg. It shall IIot be allowed to tap by hammering the pipelines made of the other aaterials.

Pneumatic test of the pipelines may be done on strength. and tightness. Pneumatic test of the pipeline on tightness (including the test with detection of pressure fall) is to be performed .only after the preliminary test on strength by any method.

Pressure shall be gradually raised to the test pressure and all joints checked by soap solution for leakage. The testing p~~ssure shall be held' for 30 minutes during which· joints shall be lightly tapped with a wooden ·hammer of 1.5 Kg weight. I f any leakage is detected, line shall be depressurised and defect rectified.

Leakage test for the' pipeline system sball be done at test pressure for a period of 12 liours. During this period, pressure and temperature readings shall be ta.ken at an interval of 1 hour. The gauges used shall be tested for their accuracy and shall ha\i~ minimum calibration of at least 0.1 Kg/cm2(g) and O.SoC.

Leakage shall be determined by the formula:

A

Where
A :a Quantity of air leakage in percent
PI = Pressure in pipeline at beginni~g of test (Kg/cm2a)
P2 :: Pressure in pipeline at the end of test (Kg/cm2 a)
Tl • Absolute temperature at beginning of test (OK)
T2 • Absolute temperature at the end of test (OK) The teat results shall be considered satisfactorly tested and acceptable if the leakage is less than 0.2\ per bour.

PAGE 14/19

(

IPSS: 1-06-034-98

After c.ompleting the testing, the line shall be kept under a pressure of atleast 1.0 kg/cm2 «(iO using Nitrogen, till pi'peline blowing/commissioning.

7.5 The pipelines which are under blowing shall be disconnected from the operating pipelines with the help of blanks which have special handles.

7.6 The final inspection of the pipelines shall be carried out under the working pressure and is combined with tests on tightness. In this case the tightnes~ of the welded seams, flange joints and packings shall be checked by leakage detecting device or by soap solution or by other solutions.

8. BLOWING AND COMMISSIONING OF PIPELINE

8.1 The blowing of the pipelines shall be carried out with dry, oqfree air or nitrogen (94' purity at velocity >20m/sec) which do not consist ot fatty material and oils for 30 min. The pressure of blowing gas may be low (close to atmospheric pressure).

8.2

The blo\ ... ing of the Oxygen pipelines shall be carried out for a period of atleast 8 hours ~ After finishing the 8 hour blowing, the board with sticked white paper shall be placed for 3-5 minutes at the end of the pipe to check for oil. However the duration of blowing depends on lenyth of pipeline, velocity of gas, amount of dust present etc. The oxygen pipeline is considered blown if there is no mark of dust or moisture coming out of the pipe.

8.3 If the testing doe. not give good results, the blowing shall be continued. Checking after each hour, the cleanliness wit~ the help of sheet of white paper..~~:

8.4 After completion of blowing with air/Nitrogen, the line shall be filled with Nitrogen, then oxygen shall be gradually introduced into the line and Nitrogen slowly exhausted through the bleeder. The purity of the exhaust gas haa to be checked until desired oxygen purity is reached. Then bleeder shall be closed.

8.5

If . there is any significant time gap between blowing w.ith· air/Nitrogen and cOlMlisaioning then the line shall be kept filleCit with Nitrogen at 1 Kg/cm2Cej).

,. SAFETY PROCEDURES

9.1 Some of the important safety procedures to be followed are given below. For general/specific requirements regarding safety procedures IPSS: 1-11-002-98 • Safety procedure for oxygen, nitrogen, Acetylene, fuel gase.- .hall al.o be followed.

A) The testing, cleaning and commissioning of Oxygen gas pipework .hall be carried out only in the pre.ence of,' and with the' permission and guidance of .enior Engineer and .taff of contractor, engineer and purchaser.

b) All first aid and fire fighting faciUties .hall be readily available during cleaning, te.ting and commi •• ioning of oxygen pipeli"es.

PAGB. 15/19

I'88a 1-0'-034-98

'"

NOTE:

10.

10.1

10.1.1

10.1. 2

10.1. 3

10.1. 4

10.1. 5

10.1. 6

10.1.1

10.1.8

c) -All arrangement. for cle.nin9~ te.ting and ·c,Ornm1 .. 10.11ng shall have the concurrence of ,the safety engineer.' The tira fighting officer or his authorL,aed reprasentativ'- .hall be present during cleaning. testing and commi •• ioning.

d) It L. prohibited to put tool. and materials on the pipeline.

a) During pneumatic tast.ing of pipeline. for tight.ne •• and strength pre.enca of unAuthorized people in the gua,rded zona (not nearer than 25 meters) i. prohibited.

f) On the container with carbon tetrachloride and other solvents there shall be the distinct label poison and dangerous and shall be kept awayfro~ the source of heat and fire.

g) Prolonged inha·latidn of vapours and contact of solvent with the skin shall be avoid.ed.

General safety rules for working at heights shall also be followed as per IPSS: 1-11-005 & 008 • Safety Procedure for Working at height by Contract.or·s workerM " .. ,Safety Procedure for Working at height by regular emp~oyee of plant/mines" respecively (under formulation)

HANDING AND TAKING On:R OF OXYGEN PIPELINES TO OPERATION DEPARTMENT

A proper protocol shall be drawn containing the compliance of the following points:

Certificat.es for welding works.

Rep~rts of inspection of internal cleaning of the pipelines.

Reports :)f t.ests of·accessories.

Reports of tests of pipelines on strength and tightness.

Log book d w~ldin9 works.

Lists of welders who took p~rt in welding works pointing numbers of their certificates and marks.

.»

Reports of cleaning, flushing and blowing of the pipelines (including accessories) .

Drawings of the pipelines, sketches explanatory notes.

PAGE 16/19

, : ~ ..

. ,

• s:

._ II !

., . . -

i

~

"

(

"

,!

c

IPsa: 1-06-034-98

APPENDIX-A (Ref.Cl.3.2.5)

{Based on IPSS:I-06-035 (under formulation)}

CATHODIC PROTEO-'ON .'OR UNDER GROU'ND PIPELINES

A-l Cathodic protection systems reverse the electro-chemical corrosive force by creating an external circuit between the pipeline to be protected and an auxiliary anode (sacrificial metal) buried in the ground at a predetermined distance from the pipe. Direct current applied to the circuit i8 discharged from the anode surface and the, travels througb the surrounding electrolyte to the pipe (cathode) surface.

A-2

Two (2) methods are available for generating a current of sufficient magnitude to guarantee protection. Inthe first method, sacrificial anode material such as malJD88ium or zinc i. used to create galvanic cell. The electrical potential generated by the cell causes current to flow from the anode to the pipe, returning to the anode through a simple connecting wire (refer Fig lA). This system is generally used ,where it i,. desirable to apply small amounts of current at a number of locations, most often on coated pipelines in lightly or moderately corrosive soils.

A-3

The second method of cu rr'e nt; generation is to energize the circuit with an external DC power supply, such as rectifier. This technique, commonly referred to as the ialpressed current method, uses relatively inert anodes (usually graphite or silicon. cast iron) connected ,to the positive terminal of a DC power supply, with the pipe connected to the negative terminal (refer Fig 18). This system is generally used where large amount of current 18 required at relatively few locations, and in many cas.:. it i. more economical t~n sacrificial anodes.

A-4 For, cathodic protection, ,a corrosion· survey including chemical-physical analy.i. of the 80il must be performed along the pipeline.

PAGB 17/1'

IPsal 1-06-034-9.

E

.. ,

SACRIFICIAL ANODE ( .... G 'OR ZINC)

FIG.-lA

CATHODIC PROTECTION - GALVANIC ANODE TYPE (iLt- A~p~ .... 4i}C 'I>,' Col A-~)

MEASURING --+I AND CONTROL SYSTEM

)

RECTIFIER

INERT Af.lODE( GRAPI 111£)

FIG.-~B

CATIIODIC PROTECTION -- RECTIFIER T'rPI:

----,----------------~--------

(Po..f· pt.t.e ... d,·x 'A' C L A- 3)

PAGE 18/19

,

, ,

(

IPSS: 1-06-034-98

APPENDIX-B

" PROCEDURE FOR PICKLING AND PHOSPHATING" (Ref. Cl. 5.3.2 )

8-1

GENERAl.

8-1.1

Pickl ing is a chemical process for removal of rust, scale and other coatings from pipes, fittings etc. This is normally done by subjecting the surface of the material to be treated in an aqueous solution of an acid. To prevent the acid from attacking the base rr..etal an £nhibit-or 1IIay be added. Pickling bares the metal of the surface treated which become highly acceptable to corrosion. This operation is, therefore, followed by an anti corrosion treatment which retards the corrosion of surface that have been pickled. Phosphating is .one such chemical process which deposits a thin protective layer on the Burface.

B-l.2

The procedure gi'lfen below is applicable for pickling and phosphat .• treatment of carbon steel pipes and components. The process require~ the pipes to be immersed in vats/baths of adequate dimensions to take full lengths of pipe. as supplied by the manufacturers/stockists. It also requires close supervision and avai,lability of a chemical testing laboratory to assure that proper control is exercised during the process. Arr.ang8lllents are also required for heating of the chemical solutions used for the treatment.

B-1 PROCEDURE

8-2.1 Pre-cleaning

B-2.1.1 The pipes and fittiGgs as supplied are cleaned to remove surface contamination. First a high pressure water wash is to be given on both the internal a~d external .urfaces. If the pipes as supplied contain excessiv. oil. grease or lacquer the same has to be firs~ removed by cleaning the surface with an approved chemical aolvent ~t: prepare the matedals for pickling. _j~'i~

B-2.2 pickling

8-2.2.1 Immerse each leogth of pipe in a solution of 18 to 20\. Hydraulic acid by volume haYing a inhibitor· of stannine low foam or equivalent for a duration of atleast 10 minutes and not more than 20 minutes.

8-2.2.2 Drain and wash in hot clean water.

8-2.3

Phosphating

B-2.3.1 Immerse the pickled pipes in the phosphating bath having solution with the following pacameters:

i) Concentration of Pyroband 847 x 30-35 points.

ii) Bath temperature (phosphate) 60-75 Deg C. The duration of the immersion shall be between 15 to 20 minutes.

B-2.3.2 Rinse the pipe. i. hot water bath maintained at 80 Deg C.

8-2.3.3 The phosphating procedure and coating weight per sq. metre shall gen.rally con fora to IS 3618&1966 ~Pho.ph.te treatment of Iron , St .. l for protect~nagalnst corrosion'.

B-2.3.4 It is recommended ~bat a production test coupon ie used with each batch dur~ng the phosphating process to ensure coating weight as per 15:3618.

PAGE 1'/19

•

j •

INTER PLANT STANDARDS- STEEL INDUSTRY

AMENDMENT NO.1 FEBRUARY 2001 TO

CODE OF PRACTICE FOR LAYING OF UNDERGROUND PIPELINES FOR WATER SERVICES, IPSS:1-06-035 (MAY 99)

ALTERATION

[Page-1, clause 2.1 (iijJ - Rewrite as under :

Ductile Iron - "For conveyance of raw and drinking water from distant place, ductile iron pipes are also used"

Clause 7.5 - TEST PRESSURE - Rewrite as under:

All water pipe work as erected shall be tested at 1.5 times the Maximum working pressure of the pipe work or the pressure to which the pipeline shall be subjected under surge condition, whichever is higher.

<,.,

Page 1/1

•

-

• I

'- .... ;