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NISCO
TARA TARH
Fluid Systems
Page 1 of 1
Page
Introduction
1.1
Scope of Standard
1.2
Piping Design
2.1
General
2.2
Pressure-Temperature Rating
2.3
2.4
15
3.1
15
3.2
17
3.3
18
3.4
21
3.5
Pressure Vessels
23
3.6
26
3.7
Blowers
28
3.8
Hydraulic Systems
29
3.9
Lube Systems
38
3.10
38
Table of Contents
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Fluid Systems
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1- Introduction
1.1- Scope of Standard
Scope of the present standard is to give the necessary criteria for design and selection of
materials and equipment for the fluid network to be installed in The Employer Plant taking into
account the operating and climatic conditions.
This standard covers:
x
Raw water
Treated water
Softened water
Demineralized water
Domestic water
Oxygen
Nitrogen
Argon
Compressed Air
Natural Gas
Waste water and systems for equipment and machinery include of:
Hydraulic Systems
The criteria shown shall be followed by the contractor for design and supply.
Any deviations shall be approved by the Employer.
API
ARI
ASHRAE
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ASME
ASTM
AWS
AWWA
BSI
DIN
EJMA
FM
ISO
NACE
NFPA
NIGC
NPC
UL
UNI
Page 2 of 38
All codes and standards referred to, shall be the latest edition of such documents unless
otherwise specified by the Employer.
Where special piping and equipment, not covered by these standards, is required, the Contractor
shall submit to the Employer, for approval, a description of the selected materials and design
criteria adopted.
The following regulations are to be used for performance testing of the related equipment:
EUROPUMP
HIS
PNEUROP
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2- Piping Design
2.1- General
Piping specifications are classified for the general selection of materials for the class of services.
The maximum design pressure and design temperature, together with the fluid in line, govern the
selection of size and material specifications. Deviation of material from class specifications may
occur due to specific design conditions. These deviations shall be permissible only if they are
equal or better than the individual class requirements. For piping inside the package unit, vendor
standard piping specification are applied.
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Section 2
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Where necessary, a bypass shall be provided for the isolating valve to facilitate the controlled
pressurization of down stream pipework containing sensitive equipment such as meters.
Upstream of all sensitive equipment such as control valves, regulating valves and meters, filters
of approved type shall be fitted. The filtration requirements will depend on the sensitivity of
equipment, upstream filtration, and pipe length.
Filter shall be rated to carry the maximum flow at the specified pressure drop, shall permit easy
access for cleaning or changing elements (without trapped particles entering the system), and
shall be fitted with all necessary purge, vent and drain connections.
All the gas piping shall form a continuous electrical conductor and shall be bonded to pipe
supports at intervals of not more than 20 meters. The pipe supports shall in turn be bonded to the
main grounding system where this is available near the supports, otherwise they shall be bonded
to an earth conductor directly buried along the run of the pipe or pipes.
Adequate provision shall be made to safely venting, purging, and draining the sections of pipe
work or equipment.
Vent points shall be located in positions which allow the elimination of air or gas from the
system.
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Design pressure for pipes and tubes shall be at least 1.33 times the working pressure. When
hoses are to be used, the hose shall be of two wire braid construction with permanently attached
fittings.
Hydraulic system piping shall be supported and securely fixed at regular intervals of not more
than:
x
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Pipe-work shall be supported and fixed immediately before and after bend or offset.
Pipe supports shall incorporate suitable vibration damping material and the supports assembly
shall in no way damage the pipe.
For installation see item 2.4, of this Standard.
The pipelines shall be anchored to the machinery or installed in special ducts and properly
supported. Where there is movement or vibration that could cause breakage of pipeline, hoses
shall be provided.
For installation see item 2.4, of this Standard.
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responsibility of the Contractor to determine the size of the pipes, piping components, and
relevant supports, anchors, and guides, by means of proper and detailed calculations that shall be
submitted to the Employer, if requested, When making these calculations, the Contractor must
take into account the weight of the piping, fluid, internal pressure, and thermal stresses, the
overload due to wind (and other weather conditions, if any), earthquake, internal fouling, the
weight of personnel and devices for erection and maintenance, weight of cleaning and/or testing
fluid. On the other hand, for underground piping, the calculations must include the overloads due
to the weight of the earth covering the pipes as well as loads due to traffic passing over the pipe.
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Where the depth of pipe is less than 600 mm, special consideration by the Supplier shall be taken
and the calculations shall be given to the Employer for approval.
Where the depth of pipe is more than 1800mm no special protection is required.
The culvert shall be laid true to line and grade with the bottom quadrant in contact with the
undisturbed trench bottom and without tamping.
Wherever possible the protecting culvert shall be extended beyond the end of the railroad ties or
roadway bed till a distance equal to the depth of the bottom of the pipe.
In cases where the extension of the protecting culvert will interfere with other structures, specific
drawings shall be performed showing the embodying and other protections.
If protection is made with concrete pipe, it shall be reinforced concrete culvert pipe.
The casing pipe should be at least two nominal pipe sizes larger than the service pipe.
Service pipe installed in a casing should be held clear of the casing pipe by property designed
supports, insulators or other devices, and installed so that no external load will be transmitted to
the service pipe.
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Where possible it shall be permitted to install electrical cable conduits on the pipe support steel
structures.
2.4.3.2- Supports
All the following supports and relevant accessories shall be provided by the Supplier; anchors,
hangers, rollers, clamps, guides, sway bracings, vibration dampeners, expansion joints, etc, for
aligning and controlling the piping movements.
Inside buildings, additional structural members shall be provided such as struts, purlins, etc.,
Between trusses or columns, if required, to support the piping.
The use of wood and wire for piping supports shall be limited to riggings and temporary supports
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during erection, and if used, these materials shall be replaced with proper permanent supports
before the lines are tested.
Vertical supports shall be spaced to prevent the pipe from being overstressed from the
combination of all loading effects.
Horizontal steel piping shall be supported at sufficiently close intervals to keep them in
alignment and to prevent sagging.
In any case, the maximum hanger spacing for standard and heavier pipe shall not be more than
indicated in the following table based on ANSI B 31.1. :
(inches)
Service
or Air Service
(ft)
(ft)
10
13
12
15
14
17
17
21
19
24
12
23
30
16
27
35
20
30
39
24
32
42
In case of pipes of sizes and schedules different from those listed in the above table, pipe
supports shall be spaced according to a proper calculation.
Piping systems shall be designed, fabricated and installed so as to have sufficient flexibility to
prevent thermal expansion or contraction from causing excessive bending moments at joints, or
undesirable forces or moments at points of connection to equipment at anchorage or at guide
points.
Flexibility shall be provided by changes of direction or by use of bends, loops or offsets.
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2.4.3.6- Vents
Plugged vents shall be provided at high points in all piping systems subject to hydrostatic tests.
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Manufacturer s catalogues
Pumps shall be designed so that accidental reverse rotation does not damage any components of
the pump and the design of the pump shall, as far as possible, provide hydraulic balance of
impeller, rotor and shaft.
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3.1.3- Design
3.1.3.1- Casing
Pump casing material shall be selected considering the fluid to be handled.
Pump casings shall be provided with valved vents and drains.
Pump casing shall be of such thickness to be suitable for the maximum discharge pressure with
maximum impeller size at pumping temperature and hydrostatic test pressure at ambient
temperature, with suitable corrosion allowance related to the fluid to be handeled.
3.1.3.2- Impeller
Impellers can be open or closed due to particular specification. They shall be in stainless steel,
gun metal or bronze. Other materials may be used depending on the service and with the
Employer approval.
3.1.3.3- Couplings
Couplings shall be generally of semi-flexible type, they shall be designed to connect shafts
which are misaligned either laterally or angularly.
The motor, side half-couplings shall be supplied by the pump manufacturer, but machined by the
electrical motor manufacturer, in agreement with the pump manufacturer.
3.1.3.4- Bearings
Ball bearings shall be used for inboard and outboard bearings. Ball bearings used in centrifugal
pumps shall normally be grease lubricated. For large shafts and heavy-duty pumps, roller
bearings shall be used.
The design of the bearings shall accommodate any residual axial imbalance that may occur.
3.1.3.5- Seals
Seals may be special asbestos rings or mechanical seals, according to the particular application
and to the Manufacturers practice.
All mechanical seal plates shall be carbon steel except:
x
Seal plates for alloy steel casing shall have corrosion resistance equal to casing.
Seal plates for carbon steel and nodular iron casing with specified corrosion allowance over
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3.1.3.7- Bedplates
All bedplates shall be common to pump and motor, made from cast iron or fabricated from wide
flanged, heavy section, mild steel joints, channels, or plates, stiffened with gussets at the point
of loading and machined all over the top and bottom pad surfaces.
Manufacturers catalogues
Pump rotation is to be clockwise looking from the driving end unless otherwise agreed by the
Employer.
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The pump shall be constructed of materials specifically chosen to resist deterioration by pitting,
erosion and corrosion.
3.3.3 - Structure
Up to 65C, the structure shall be in reinforced concrete and consist of a network of beams and
columns. Also, the deck where mechanical equipment is anchored shall be in reinforced
concrete.
Above 65C, the cooling tower shells shall be constructed of treated timber.
The design of the structure shall be such that all loads are evenly distributed to the foundation.
Loads used in the design shall allow for extreme site conditions.
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The structure shall be designed to ensure that its natural frequency is well clear of any frequency
or harmonic generated by the drive system or fans.
Tower basins shall be of concrete construction with concrete posts to support tower internals and
partition walls.
A fall in both directions shall be provided in the floor of the basin to allow complete drainage of
the basin for cleaning.
3.3.4- Packing
Packing shall preferably be of splash type, packed with asbestos cement, or red wood. Plastic
shall not be used where water temperature above 55C will be encountered.
The packings are placed inside the cooling tower designed in such way to create max contact
surface between air and water without any risk of clogging due to suspended solids in water, all
material will be designed to be resistant to chloride content of the water.
3.3.5- Cladding
Cladding can be waterproof covered bricks, reinforced concrete, or asbestos- cement, or other
approved material.
3.3.7- Fans
The type of fan shall be axial, statically and dynamically balanced at operation velocity.
Fans shall be of the multi-bladed, adjustable blades, in light, alloy covered with synthetic resin or
rubber that shall be specified by the Manufacturer.
The number of blades and speed of rotation shall be selected to avoid vibration and air pulsation.
Blades shall be locked to the hub in an approved manner.
The fan should have a low sound level and be able to operate continuously in hot, humid
atmosphere, without undue deterioration.
Automatic, variable pitch fans shall not be supplied.
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3.3.14- Bolts
Bolts shall be of stainless steel where necessary.
In all cold wells a level control, a temperature transmitter, pH meter, a conductivity meter
and Inhibitor analyzer (if necessary) shall be considered.
All the circuits shall be completed with a corrosion rack device for corrosion coupons.
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3.4.1- Plates
The plates shall be of the high number of heat transformer units.
3.4.2- Frame
The frame shall have one fixed end to which upper and lower carrying bars shall be attached.
The carrying bars shall be supported and held apart at the other and of the frame by a supporting
column.
The frames shall have extended nozzles mounted directly on the frame.
3.4.3- Gaskets
Unless otherwise specified, rubber gaskets shall be used.
3.4.4- Mounting
Unless otherwise specified exchanger shall be complete with support cradles for mounting on
concrete foundation, complete with stud bolts and washers.
3.4.6- Instrumentation
Inlet and outlet connections on the nozzles shall be provided with temperature and pressure
indicators.
3.4.7- Materials
Unless specified otherwise, plate heat exchangers shall be constructed from the following
materials:
x
Gasket- Rubber
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3.5.2- Design
3.5.2.1- Basic Allowable Design
The basic allowable stresses for pressure parts shall be the value established by the applicable
code.
The basic allowable stresses for non-pressure parts, except as modified below, shall be parts,
except as modified below, shall be 33 1/3% of the ultimate tensile strength, 66 2/3% of the yield
strength, or that producing a creep rate of 7% in 10,000 hours, whichever is lower.
(a) Welds attaching non-pressure parts to the pressure shell, and supports for important
internal equipment such as cyclones, grids, etc., shall be designed to the allowable stresses
for pressure parts.
(b) Anchor bolting shall be designed to a basic allowable stress of 1000 kg/cm2 based on the
net area of the thread unless a lower stress is specified by the codes.
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(b)
1
in, nominal pipe sizes may be used
2
for connections to piping with ANSI rating of 150 and 300 lb.
3.5.3- Construction
3.5.3.1- Nozzles
3.5.3.2- Bolting
Bolt holes in flanges shall straddle the vessel center lines unless otherwise approved by the
Employer.
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All vessels shall be provided with inspection and or access openings such that the inside of the
vessel may be visually inspected.
Vessels less than 1000mm inside diameter shall be provided with handholes, while vessels
greater than 1000mm inside diameter shall be provided with manholes.
Manholes shall be located in such a position as to facilitate access by personnel, Circular
manholes shall be a minimum of 600mm inside diameter and other manholes shall be a
minimum of 600 mm x 500 mm.
Circular handholes shall be a minimum of 125mm inside diameter and other handholes a
minimum of 125mm x 80mm.
Manholes located in the horizontal plane shall be fitted with hinges and balance weights,
Manholes located in the vertical plane shall be fitted with davits.
3.5.3.4- Internals
All internals spanning a chord or diameter of the vessel shall be provided with means for
allowing differential expansion between the part and the vessel shell.
Internal non-pressure piping for carbon steel vessels shall be fabricated from extra strong
seamless carbon steel pipe. All internals (fixed and removable) shall be supplied by the vessel
manufacturer unless approved otherwise by the Employer. Baffles or wear plates shall not be
welded directly to the shell (or head) but shall be bolted to support attachments which are welded
to the shell.
3.5.3.5- Welding
All welding shall be in accordance with the latest edition of the design code applicable to the
particular vessel. Only welders who are qualified in the accepted procedure shall be employed.
The size of welds for all internal attachments shall include the corrosion allowance.
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The selection and design of the type of tank to be used for a specified liquid will be based on the
design temperature and the absolute vapor pressure, toxicity, and corrosiveness, and the value of
stored liquid. Tanks suitable for the service conditions shall be provided in accordance with the
following table:
SELECTION OF TANKS
Type of Tank
Design Conditions
Construction
Liquid storage
Atmospheric
API 650
API 620
tanks
Water Storage
Atmospheric
Tanks
API 650
AWWA D100
Tank parts, accessories, and attachments which are furnished as a regular part of proprietary or
standardized equipment shall be in accordance the tank or equipment manufacturers or
recognized industry standards suitable for the design conditions.
When a code, rule, or regulation is specified, the design of tanks shall conform to such specified
requirements and to such portions of this specification as do not conflict.
3.6.2- Design
3.6.2.1- Design Conditions and Basic Allowable Stresses
Tanks and their supports shall be designed to resist the effects of combined loads within the
limits of stress specified herein. Wind and earthquake loads shall not be assumed to occur
simultaneously.
The basic allowable stresses for design or test conditions shall be of the values established by the
applicable code except as follows:
The allowable tensile stress for carbon steel threaded parts such as anchor bolts and rods, based
on the root area of the thread shall be 1000 kg/cm2 unless a lower stress is specified by code.
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In general, no allowance for corrosion beyond that inherent in the thickness of the material used
or that required by the applicable code shall be added to tank parts except that in a severely
corrosive service, a corrosion allowance as determined by the service shall be added to all
pressure parts and non-removable internal parts and all surfaces exposed to the contained
medium.
Parts or surfaces which are fabricated of, or surface protected with, corrosion resistant material
shall not require corrosion allowance.
When service conditions are such that it is not practicable to provide corrosion allowance by
added base metal, consideration shall be given to the use of special liners or coatings.
Atmospheric and low pressure tanks under 6m in height shall be provided with a ladder without
cage, and 6m and over in height with spiral stairways. Primary access to elevated water towers
and open tanks shall be by ladder only.
Atmospheric dome roof tanks shall be provided with walkways complete with handrail
extending to the center of the roof for maintenance of roof mounted accessories.
Pressure tanks shall be provided with platforms and ladders as required, for access to manholes,
relief valves, instruments, etc., requiring maintenance.
Ladders shall have safety cages when the ladders extend 6m above grade, and top rail hoops only
when ladders extend less than 6m above grade.
Hand railing shall be provided for all open sides of platforms, walkways, stairways, and near
ladder and stairway landings.
Horizontal tanks located above grade shall be supported on steel saddles or supporting towers
depending on the tank height. Vertical tanks may be supported by skirts, columns, or the bottom
of tanks.
Vertical tanks supported on skirts shall have the center lines of skirt and shell plates
approximately coincident.
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(a) When necessary (to maintain the calculated stresses within the allowable), skirts shall be
attached to the flanged portion of the head. The skirt shall be positioned so that the tank
girth seam can be inspected.
(b) All skirts shall have at least an 18 in, nominal diameter access opening.
Appurtenances and accessories shall be provided as per service requirement and design code.
All materials and fabrication shall be in accordance with the requirements of the applicable code.
Tanks shall be inspected and tested in with the applicable code.
3.7- Blowers
3.7.1- General
Rotary-lobe type blowers shall comply with the requirements of relevant sections of API 619,
and requirements hereunder mentioned as do not conflict. In case of any confliction the
Employer will decide which one should be complied with.
The straight two-lobe cyclonical rotor units shall be formed by a pair of mated contour rotors,
rotating in a casing with a suitable contoured internal surface.
The movement of the rotors shall be synchronized by two keyed gears on the shafts. The shaft
shall be pressure mounted on the rotors.
These blowers shall be used for high vacuum, low compression, with ratio of compression about
1.7, 3 and capacity upto 56,000 m3/hr.
For blower capacity upto 400 m3/hr, bearings shall be ball type, for higher capacities, roller
bearings shall be considered. No lubrication shall be made on the parts in contact with the
conveyed fluid,
in order to guarantee the complete absence of oil at the delivery, side.
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3.7.3- Drive
Unless otherwise specified, blowers shall be directly driven by means of electric motor coupled
with flexible coupling to driving shaft.
Connections shall be considered for pressure and temperature indicators on the suction and
delivery sides.
Units shall be complete with but not necessarily limited to the following:
x
air fitter
safety valve
foundation bolts
3.7.5- Material
This section of standard covers the hydraulic systems required for various units. The term
"hydraulic systems" referred herein generally covers the following: Hydraulic fluid reservoirs,
pumps, various kinds of valves, accumulators, hydraulic cylinders and pistons, oil heaters (if
any) and coolers, hydraulic motors, various accessories such as filters, strainers, hydraulic
pipework, fittings, flexible hose assemblies with end connections, Supports for equipment and
pipework, sealing devices, instruments for indicating, recording and integration of various
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parameters such as pressure, temperature, velocity etc. , control devices for manual and
automatic operation of the system, safety devices and alarms for abnormal operating conditions,
interlocks for sequencing and safe operation, and fluids.
3.8.2- General
The design and construction of the hydraulic systems shall be suitable in every way for the
service intended and shall be oriented towards maximising interchangeability of components and
minimising maintenance. Each system shall be complete in all respects including all accessories
essential for proper installation, operation and maintenance, irrespective of whether such systems
are specifically mentioned in contract document or not.
In hydraulic systems provided in the vicinity of open flames, high temperatures, molten metal,
etc, special care shall be taken to prevent breakout of fire in case of breakout of hydraulic
system.
3.8.3- Standards
The hydraulic systems shall be designed, manufactured, erected, tested and commissioned as per
the standards laid down in this section.
Any aspects not covered herein shall be as per the codes and practices adopted by German
standards (DIN), ISO, UNI or approved equivalent.
The design should ensure that the components of the hydraulic systems are compatible with the
hydraulic fluid selected at operating conditions in the plant and under ambient atmospheric
conditions.
In selecting the hydraulic fluids the operating temperature of the system shall be given careful
consideration.
Detailed specification of the hydraulic fluid for each system shall be furnished by Contractor,
wherever available equivalents produced locally shall be indicated.
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Each hydraulic circuit shall be designed to minimize surge pressure, Suitable accumulators of
adequate size shall be used to withstand maximum rate of surge pressure rise as well as the peak
surge pressure. All components shall be capable of withstanding the peak surge pressure.
Each hydraulic circuit shall be designed to minimize generation of heat in the system by
adequately sizing the pipework and valves and by reducing bends and restrictions but without
sacrificing the functional efficiency of the system.
Hydraulic fluid temperature shall be controlled so as not to exceed the Contractors
recommendations. Under continuous operation, the temperature of mineral oil at the pump inlet
shall not exceed 50C.
Each circuit shall be designed such that the load variations and changes in fluid temperature shall
not cause such variations in the operation of system.
Design of each circuit shall be such as to achieve quick response to functional needs, economic
operation of the system, and minimum maintenance. The circuit design shall also ensure safety
of the staff and of equipment actuated by the hydraulic system in case of emergencies such as
power failure, bursting of hose or pipe connections, opening of safety valves and other devices
etc.
The hydraulic system shall be designed taking into account the maximum pressure encountered.
Each circuit shall incorporate a reservoir of adequate capacity, pumping equipment, filters to
eliminate undesirable particulate contaminants, generously sized pipework, accessories and
hoses, adequate cooling system to cool the hydraulic fluid where required, accumulators, all
valves and all necessary audio-visual alarms, Unless otherwise specified hydraulic equipment
located in unattended areas, basements, etc, shall have remote control facilities to ensure safety
of the main equipment served.
The circuits shall incorporate necessary stand-by units, by-passes, isolation devices etc, to ensure
continuous operation of the systems even when some components are under maintenance,
cleaning or repair.
The circuit design shall incorporate necessary connections, valves and appurtenances to facilitate
testing, flushing, draining, and recommissioning the systems.
The system design shall incorporate necessary safety features to reduce the hazard of ignition of
hydraulic fluid at points of application and at locations around hot zones.
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Fluid sampling outlets with isolating valves shall be provided at suitable locations in the system.
Drain lines shall be independent of other return lines. Pilot return lines shall be independent of
power return lines.
Bleed points shall be provided to safely release air which would cause malfunction of the
system.
Power units shall be of integral construction. Power units and valve stations shall be provided
with adequate lifting facilities and be capable of being lifted safely and without distortion.
A drip tray shall be provided which shall have suitable means of draining and be at such a height
to allow drainage into a suitably sized container.
Piping shall not be used to support equipment. Where line mounted equipment is unavoidable,
the pipe shall be adequately supported either side of the item of equipment or the equipment
itself shall be adequately supported.
3.8.5- Equipment
3.8.5.1- Reservoirs
Reservoir shall have a working volume adequate to contain all the fluid that will return from the
system, maintain the fluid level within adequate working limits during operation and feed the
system for a minimum of 5 minutes, at the rated pumping capacity. For small systems, the
reservoir shall have a working volume to meet a minimum of 7.5 minutes, at the rated pumping
capacity.
The minimum fluid level shall be at least 100 mm above the upper most point of the suction
strainer.
The reservoir shall be designed and constructed to prevent entry of foreign matter, including
water and shall be separate and removable from the equipment base. Reservoirs shall be
fabricated from structural steel of adequate strength and thickness. Cast reservoirs shall not be
used.
All reservoirs shall have separate provisions for oil filling and air breathing. The filler hole shall
have a course strainer and be equipped with a cap permanently attached to the reservoir by
suitable means. Breather hole shall be protected by an air cleaner containing indicative type
silica-gel for moisture trapping. The air cleaner shall be of sufficient capacity to maintain
approximate atmospheric pressure even at maximum demands of the hydraulic system.
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An additional 50mm threaded connection Should be provided for an external filling line.
Reservoirs shall be designed for adequate heat dissipation by generous tank wall surfaces and so
installed as to allow unhindered air flow
over all surfaces.
Return fluid shall have peripherial flow along reservoir side wall from suitably bevelled cut pipe.
A suitable bent stem dial thermometer protected and mounted in a bulbwell shall be installed in
the reservoir with at least 100 mm immersion.
The bottom of the stand alone reservoir shall have a minimum clearance of 150 mm from the
floor.
The reservoir shall be equipped with a vertical glass type fluid level indicator.
Markings shall be provided to indicate high and low levels with pump running and where
necessary, high level with pump stopped.
Low level alarms shall be provided on each reservoir to sound an alarm for low level indication
and to shut down pumps at a lower level. High level alarms shall be provided where automatic
make-up is provided to shut down make-up pump.
Both the intake and return pipes shall be brought down below the minimum working fluid level
so as not to cause cavitation or aeration. Return pipe shall be located as far as possible away
from suction strainer for efficient and smooth suction.
Suitable tubing connection shall be made for seepage fluid return from glands and packings.
The outlet pipe end of this connection shall be kept above maximum fluid level in the reservoir
to facilitate free return of low pressure seepage fluid.
Suitable provision shall be made for efficient cleaning of reservoir. A suitable opening with
hinged cover shall be provided. Where possible the size of the opening shall be suitable for a
man to go into the tank.
An accessible means shall be provided to empty the reservoir without spillage. The reservoir
bottom shall be shaped to facilitate emptying and cleaning by providing about 4 per cent slope at
the bottom. The drain shall be piped out for further disposal.
3.8.5.2- Pumps
Pumps shall be designed to meet at least 125 per cent of system flow rates and 125 percent of
system operating pressures.
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Pump motors shall be adequate to operate the pump continuously at 125 per cent of the system
operating pressure without being overloaded. It shall be a high starting torque motor, if the
system requires starting with the pumps under load.
Unless otherwise specified pumps shall be provided with at least one stand-by unit for each
group of 2 or 3 pumps. The stand-by pumps shall be connected to the circuit and kept ready for
operation. Where only one operating pump is required, an identical stand-by pump shall be
provided.
Where possible, flooded suction shall be provided for the pumps. Direct coupled pumps shall be
securely mounted in a manner to assure alignment under normal operating conditions.
3.8.5.3- Valves
All valves shall be sized to meet the intended flow rates, with low pressure drops.
Lockable adjusting type valves shall be used to prevent change of adjustment caused by
equipment vibration and/or tampering, Where practical, directional valve of large capacity shall
be hydraulic pilot operated.
Valves shall not be mounted in reservoirs.
Suitable valve stands shall be used for mounting valves for the ease of operation and
maintenance.
Valves shall be kept above high fluid level of reservoir except where the functions of the valves
require them to be below the fluid level.
The operation of a valve shall not produce detrimental surges in the hydraulic system.
Solenoid operated valves shall be designed, constructed and installed to eliminate destructive
hammering of the solenoid or spool. Internal leakage shall be separately drained to reservoir or
to vented manifold to prevent blocking of plunger type controls.
Solenoid operated valves shall incorporate all features required by the service.
All hydraulic valves, accessories, and devices shall be plainly identified as to the function shown
on the diagram. Such identification shall be shown on a metal tag mounted adjacent to, and not
on, the component.
All valve porting shall be identified adjacent to ports by ISO thread designation.
All solenoids operating hydraulic equipment shall be identified. Each solenoid shall have the
same identification on both the electrical and hydraulic diagrams.
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Wherever cylinders, actuators, or motors may experience externally induced forces, the circuitry
shall include protective devices (such as suitable cushioning and relief valves) to prevent
detrimental pressures and component.
All valves shall have frame sizes, ports, connection etc, conforming to ISO or equivalent
standards.
3.8.5.4- Accumulators
The accumulator shall be sized to meet the functional needs and shall be designed according to
ASME section VIII pressure vessel code or approved equivalent.
Test certificate for accumulators shall be provided by Contractor.
Means shall be provided for safely relieving of the accumulator gas and liquid pressure before
the accumulator can be disassembled. Automatic bleed-off or shut-off when system is shut down
shall be provided. Suitable charging equipment for accumulator shall be provided along with the
accumulator.
Shock bottles shall be installed on all valve stands and anywhere else necessary for shock
elimination.
Hydraulic cylinders shall be designed to meet the working pressure of the system and tested to a
minimum of 150 per cent of the system operating pressure.
Cylinder bores with fitted pistons shall have a finish consistent with the type of service intended
and shall be free of porosity or other defects.
All cylinders bore shall be coated with hard chromium of appropriate thickness.
Cylinders shall be installed so that no side or radial load shall occur on piston rod or ram.
Cylinders shall be easily replaceable.
Cylinder body, heads and body flanges shall be of steel. Heads shall be bolted to cylinder body
flanges with heat treated, high strength steel bolts.
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Coolers shall be fitted external to the fluid reservoir and shall be incorporated in the hydraulic
circuit if normal operation of the system would raise the fluid temperature to over 50C. Cooling
medium shall preferably be water, and the water flow shall be thermostatically controlled.
Heaters shall be used if the viscosity of the hydraulic fluid in cold seasons would affect the pump
operation adversely. The heaters shall be of electrical type, having a heating intensity to prevent
cracking of the hydraulic fluid due to local overheating.
Electrical heaters shall be of cartridge type, suitable for mounting in reservoir and shall be
thermostatically controlled.
Heat exchangers shall be protected against excessive pressure or pressure surges by suitable
means.
Thermometers shall be provided for checking inlet and outlet temperatures of the hydraulic fluid.
All sealing devices shall be of suitable materials which will not be adversely effected by the
hydraulic fluid. Systems using phosphate ester, water glycol, invert emulsions or mineral oil,
shall be provided with viton seals, or approved equal.
Whenever possible, sealing devices shall be of the pressure sealing type.
Sealing devices for reciprocating or rotating shafts shall prevent all leakage, except that required
for lubrication of such devices, under all working conditions, without damaging shafts.
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Balanced piston type relief valves shall be provided on the discharge side of all positive
displacement pumps and over pressure protection shall be provided elsewhere in circuits where
damage to the equipment or hazards to personnel may result if design pressures are exceeded.
Check valves shall be provided on the discharge side of all pumps to prevent any back flow.
Hydraulic motor speeds shall be controlled by suitable pressure compensated flow control valve.
Sequence control shall be primarily governed by mechanically actuated limit switches, electronic
timers, sequence valve or any other position sensing device.
All pressure and volume controls shall be constructed so that they are not adjustable outside the
system safe working ranges. All pressure controls shall be marked to indicate minimum and
maximum pressures. A pressure gauge with shut-off valve shall be provided with each pressure
control valve. All relief valves shall be piped directly to the reservoir and not into a return line
with any back pressure.
The machinery and all connected equipment shall be brought to a safe stop upon failure of
electric power, control power, hydraulic power, or control components. The system shall remain
inoperative after restoration of service until the controls are reset.
If an unscheduled stop would result in an unsafe condition then the failure shall be announced by
audi-visual alarms and stand-by or stored power shall be provided that will permit a delayed or
gradual stop under manual or automatic control.
In the event of a failure in the controls, manual controls shall be provided that would permit
bringing the system to a safe operation or stop.
Where pumps are operating in parallel, manual valving which will permit removal of one pump
while the others are still in operation shall be provided downstream of the relief valve.
Where loss of working pressure on the discharge side of a pump or pumps may result in damage
to the equipment, in loss of accuracy, or in danger
of injury to personnel, means shall be provided to prevent operation under these conditions.
Electrically and pneumatically controlled hydraulic devices shall be applied in such a manner
that in the event of electrical or pneumatic circuit failure, there will be no damage to the
equipment or danger to personnel.
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When lube oil systems are provided, they shall be complete with, but not necessarily limited to
the following: tanks, pumps, water coolers, heaters, (where necessary), valves, instruments, (i. e.
pressure switches, temperature switches, etc.), piping, strainers, gauges, etc.
Wherever possible and practical, lubrication system shall be of the centralized type.
For the lubrication of gear speed reducers, splash lubrication may be sufficient in some cases.
When forced lubrication is required, the lubrication system shall be complete as indicated above.
Where there is a movement or vibration that could cause breakage of pipeline, hoses shall be
provided.
When grease systems are provided, they shall be complete with, but not necessarily limited to,
the following: pumps, fittings, tanks, etc.
The central pumping unit shall be a time-clock controlled automatic unit and hand operated unit.
Where there is a movement or vibration that could cause breakage of pipeline, hoses shall be
provided.
The system shall be installed and clamped in order to minimize exposure to mill damage and to
be adequately protected from shock and vibration.
All lubricating lines on each piece of equipment shall be brought to a common header station.
Equipment, ducting, diffusers, piping, controls, etc required for heating, ventilating and air
conditioning of spaces such as control rooms, switchgear rooms, transformer rooms (when
located in closed rooms), crane operator cabins, compressors rooms, emergency generator room,
shall be provided by the Contractor. Design, fabrication, inspection and testing of heating,
ventilating and air conditioning systems and components shall be accordance to ASHRAE
Standards and Handbooks.
Inside design conditions of spaces shall be as per equipment manufacturer's recommendations
and personnel comfort (when the space is permanently manned), which shall be established as
per ASHRAE recommendations.
Section 3
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