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TABLE OF CONTENTS
1.0 BASIS OF UNIT PIPING.............................................................................................................................5

1.1 DESIGN CODES & STANDARDS ......................................................................................................5

2.0 PIPE WAYS / RACK PIPING........................................................................................................................7
3.0 COLUMN / VESSEL PIPING........................................................................................................................8

4.0 REACTOR PIPING ...........................................................................................................................9

5.0 EXCHANGER PIPING...............................................................................................................................10

6.0 AIR FIN COOLER PIPING ..............................................................................................................10

7.0 HEATER / FURNACE PIPING....................................................................................................................10
8.0 PUMP PIPING.........................................................................................................................................11
9.0 COMPRESSOR PIPING............................................................................................................................11

9.1 PIPING ARRANGMENT FOR CENTRIFUGAL COMPRESSOR ...........................................................12

9.2 PIPING ARRANGMENT FOR RECIPROCATING COMPRESSOR .......................................................12

10.0 REILEF / BLOWDOWN PIPING.............................................................................................................12
11.0 STEAM PIPING.....................................................................................................................................14
11.1 Indian Boiler Regulations (IBR)...............................................................................................................14
11.2 IBR requirements (in brief)..................................................................................................................14
12.0 STEAM HEADERS AND SUPPLY LINES...................................................................................................15
13.0 STEAM TRACING..................................................................................................................................15
14.0 STEAM JACKETING SYSTEM..................................................................................................................22
15.0 UTILITY STATIONS.................................................................................................................................24
16.0 FIRE FIGHTING......................................................................................................................................25

17.0 OFFSITE AND YARD PIPING ........................................................................................................25

18.0 TANK FARM PIPING...............................................................................................................................26
19.0 FLARE PIPING........................................................................................................................................26

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ANNEXURE I – TABLE OF BASIC SUPPORT SPAN

ANNEXURE II – ACCESSIBILTY FOR VALVES AND INSTRUMENTS
ANNEXURE III – VERTICAL AND HORIZHONTAL GUIDE SPACING
ANNEXURE IV – CLEARANCES

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1.0 BASIS OF UNIT PIPING

 P&IDs

 Equipment lists

 Equipment layout

 Equipment data sheet & setting plan

 Line list

 Instrument data sheet

 Structural & building drawings

 Topography of the plant

 Piping material specification

 Overall plot plan

The following objective shall be achieved during piping layout:

Proper access to all operating points including valves and for all orifice tapping points, instruments in particular
(refer Annexure-II).

Proper access to interrelated operating points for specific purpose and for maintenance.

Economic routing with minimum bends and flanges.

Flexibility to allow for thermal expansion and contraction.

Aesthetics.

1.1 DESIGN CODES & STANDARDS

The latest issue of the following major Codes and Standards shall be referred to as a part of the Piping Design
Basis. Other codes and standards not listed herein may also be used for any other design purpose.

Design, materials, equipment and related items in all systems (i.e. gas, oil, steam, water, air etc.) shall be in
accordance with the latest edition of ASME B 31.3 and ASME B 31.1, where provisions of these standards are
applicable.

American standards and recommended practices, along with other internationally recognized codes as
guidelines, shall be used for design activity.

Govt. / state / Local rules, regulation, OISD Standards and other industry practice shall be complied with and
shall govern the piping systems, in addition to this Piping Design Basis. Plant layout shall adhere to the
requirements of OISD-STD- 118 “Layout for Oil and gas Installation”.

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ASME B 31.3 Process Piping

ASME B 31.1 Power Piping

ASME Vol. VIII & IX ASME Boiler and Pressure Vessel Code
ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ASME B16.34 Valves – Flanged, Threaded, and welding End

ASME B16.47 Large Diameter Steel Flanges

ASME B1.20.1 Pipe threads, General Purpose, Inch

ASME B16.10 Dimensions of Ferrous Valves

Forged Steed Fittings, Socket welding and Threaded Metallic Gaskets for Pipe
ASME B16.11 Flanges – Ring Joints, Spiral Wound

ASME B16.20 and Jacketed

ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges

ASME B16.25 Buttwelding Ends

ASME B18.2.1 Square & Hexagonal Bolts & Screws (Inch Series)

ASME B18.2.2 Square & Hexagonal Nuts (Inch Series)

ASME B36.10 Welded and Seamless Wrought Steel Pipe

ASME B36.19M Stainless steel pipe

API 594 Wafer and Wafer-lug Check Valve

API 598 Valves inspection and testing

API 599 Metal Plug Valves – Flanged, Threaded and Welded Ends

API 600 Steel Gate Valves, Flanged or Buttwelding Ends

API 602 Compact CS gate valves flanged threaded, welded & extended body ends

API 607 Fire test for soft seated quarter turn valves

API 609 Lug and Wafer Type Butterfly valves

Spec. for steel check valves (flanged and butt-welding ends) for petroleum,
BS 1868 petrochemical and allied industries

Steel globe and globe stop and check valves (flanged and butt-welding ends) for
BS 1873 the petroleum petrochemical and allied industries

BS 5351 Steel ball valves for petroleum, petrochemical and allied industries

BS 5352 Steel wedge gate, globe and check valves, 50mm and smaller for petroleum,

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petrochemical and allied industries

Standard finishes for contact faces of pipe flanges and connected end flanges of
MSS-SP-6 valves and fittings

MSS-SP-25 Standard marking system for valves, fittings, flanges and unions

MSS SP43 Wrought Stainless-Steel Butt-Welding Fittings

MSS SP44 Steel Pipeline Flanges
MSS SP48 Steel Butt Welding Fittings (26" and larger)
MSS SP75 High Test Wrought Butt Weld Fittings
MSS SP83 Carbon Steel Pipe Unions, Socket Welding and Threaded

OISD-118 Layouts for Oil and Gas Installations

OISD-116 Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing Plants

Fire Protection facilities for Petroleum Depots and Terminals and Pipelines
OISD-117 Installations

OISD- 144 Liquified Petroleum Gas (LPG) Installation

OISD- 150 Design and Safety Requirements for LPG Mounded Storage facility

OISD-163 Safety of Control Room for Hydrocarbon Industry

OISD-164 Fireproofing of Steel Supporting Structures in Oil & Gas Industry
NFPA -58 Standard for the storage and handling of liquefied petroleum gases.

IS 1239 Steel Tubes, Tubulars and Other Wrought Steel Fittings - Specification

IS 3589 Steel Pipes for Water and Sewage

API 2218 Fireproofing Practices in Petroleum and Petrochemical Processing Plants

IBR Indian Boiler Regulation

2.0 PIPE WAYS / RACK PIPING

 Racks shall be designed to give the piping shortest possible run and to provide clear head rooms over
main walkways, secondary walkways and platforms.

 Predominantly process lines are to be kept at lower tier and, utility & hot process lines on upper tier.

 Generally, the top tier is to be kept for Electrical cable trays (if not provided in underground trench) and
Instrument cable ducts/trays. Cable tray laying to take care of necessary clearances for the fire proofing
of structure.

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

 Generally, the bigger size lines shall be kept nearer to the rack column.

 Minimum spacing between adjacent lines shall be decided based on O.D. of bigger size flange (minimum
rating 300# to be considered), O.D. of the smaller pipe, individual insulation thickness and additional 25
mm clearance. Even if flange is not appearing the min. spacing shall be based on above basis only.

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 Actual line spacing, especially at ‘L’ bend and loop locations, shall take care of thermal expansion /
thermal contraction / non-expansion of adjacent line. Non-expansion / thermal contraction may stop
the free expansion of the adjacent line at ‘L’ bend location.

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

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

 Process lines crossing units (within units or from unit to main pipe way) are normally provided with a
block valve, spectacle blind and drain valve. Block valves are to be grouped and locations of block valves
in vertical run of pipe are preferred. If the block valves located in an overhead pipe-way, staircase access
to a platform above the lines shall be provided.

 Stubs in sea water shall be from top of main header.

 Branches from main headers shall be preferably from top.

 For process lines, access shall be provided for all valves on the branch line.

 For utility lines, root valves on branch lines shall be accessible by temporary arrangements like portable

ladder, temporary scaffolding etc.

 Length/ height of HPVs (High Point Vent) / LPDs (Low Point Drains) and another instrument tapping shall

be as minimum as possible.

3.0 COLUMN / VESSEL PIPING

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

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

 Manholes shall be kept on the roadside of the column and shall be approachable from the platform.
Projection of platform shall be 1.0m up to 1.0m diameter column and 1.2m for column diameter >1m
beyond manhole. Care shall be taken to ensure that enough space is available for operation after
opening of manhole cover.

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

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

 Access platforms/ladders shall be provided along the column for valves and instruments.

 Minimum clear width of platform shall be 750mm.

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 For ease of operation and maintenance, column and vessels which are grouped together, shall have
their platforms at the same elevation and should be interconnected by walkways. However, each
column / vessel shall have an independent access also.

 Column / vessel platforms should be designed in such a way so that all the nozzles should be
approachable from platforms.

 Piping at columns/vessel nozzles shall be arranged so that blanks can be easily installed for hydro
testing.

 Unless specifically indicated in P&IDs control valves shall preferably be kept at grade.

 Piping intended for vacuum services shall be routed as short as possible with minimum bends and
flanged joints.

 Piping support cleats for safety valves shall be independent meant for safety valves only & shall be
designed considering impact loading during popping off.

 Utility Connection nozzles shall be from side/top.

4.0 REACTOR PIPING

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

 Platforms provided around reactors and for access to piping and valves shall generally be supported
from separate structure. However, the platform can be connected to vessel shell if welding is allowed
and clips are provided. Generally, reactor shell clips / clips are to be avoided.

 Reactor top piping shall be provided with break flanges and spectacle blind for ease in blinding and de
blinding and shall be as per P&ID.

 Piping connected to reactor top outlet nozzle shall be adequately supported from structure, considering
that this connection to man way will be dismantled during catalyst charging.

 Swing elbows type arrangement is preferred on the regeneration piping from reactor bottom as against
valves and bypasses. This eliminates stress problems to some extent since the used hot line and unused
cold line are not permanently interconnected as per P&ID.

 All valves provided on reactor hydrogen service lines be it inline, vent, drain and instrument valves shall
always be double blocked type as per P&ID.

 For reactor process piping where specification calls for ring joint flanges the piping shall be arranged to
allow for valve removal.

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

 Snuffing steam rings shall be provided around hydrogen service flanges size over 12".

5.0 EXCHANGER PIPING

 Exchanger piping shall not run in the path of built in or mobile handling facilities.

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 Wrench clearance shall be provided at exchanger flanges.

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

6.0 AIR FIN COOLER PIPING

 Air fin cooler bundles inlet piping shall be arranged in such a way that the flow distribution is equal for
all bundles to the maximum extent.

 For two phase services, piping arrangement shall be symmetrical and for other services, symmetric
arrangement shall be followed to the extent possible. If not possible, such cases shall be brought to the
notice of Authorized Representative.

 Flow transmitter requirement for such cases shall be decided on a case to case basis during detail
engineering phase.

 The piping inlet /outlet valves of air fin cooler bundles shall be accessible from platform.

 Air fin cooler inlet header and branches overhang shall be minimized.

 The tube bundle headers shall be allowed to have lateral movements equal to the thermal expansion of
the connected piping manifolds.

7.0 HEATER / FURNACE PIPING

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

 Burner valves shall be located close to the peepholes for operation so that adjustment can be made
while observing the flame from working level.

 Piping to burners shall be arranged so that there are no pockets & shall distribute equal and enough
quantity of oil/gas to all burners.

 Block valves for emergency, snuffing steam valve shall be located at the recommended distance from
the heater, preferably on the upwind side of the heater.

 Only flexible metallic SS (SS316/SS304) hoses shall be used for burner piping if required.

 Piping from various passes of heater outlet nozzles should preferably be symmetrical.

 Transfer line from heater to column shall be as short as possible, without pockets, free draining and with
minimum bends.

 No piping shall be routed in the tube withdrawal area. If unavoidable, break up flanges shall be provided
in the piping for removal of tubes.

8.0 PUMP PIPING

 Pump drives shall have clear access.

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 Pump suction piping shall be as short as possible and shall be arranged to avoid vapor pockets.

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

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

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

 Unless otherwise specified, T-type strainers shall be used on pump suction piping for sizes 2" and above.

 Y-type strainers shall be used for pump suction lines below 2”.

 All small-bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain).

 shall have break up flanges for removal of pumps.

 Piping shall be so arranged that the forces and moments imposed on the pump nozzle do not exceed the
allowable values as per the specification.

 Pump discharge should be preferably routed away from the pump rather than towards the motor side.

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

 Suction & discharge valves shall be located at operable height.

9.0 COMPRESSOR PIPING

 Suction lines shall be as short as possible. Suction piping shall have adequate flanged joints for ease of
erection and maintenance.

 Where the line between knockout drum and the compressor cannot be routed without pocket, low
point drain with a drain collection leg and auto drain trap arrangement shall be provided to remove
accumulation of liquid. The system should be approved by process.

 A minimum straight length of suction pipe shall be provided as per manufacturer's recommendation.

 Lube oil cooler space shall be provided in a way to facilitate tube bundle removal.

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

 Piping shall be designed so that forces and moments imposed on the compressor do not exceed the
manufacturer's recommendation.

 Low points in the discharge line from an air compressor shall be avoided because it is possible for lube
oil to be trapped and subsequently ignited. If low points are unavoidable, they shall be provided with
drain leg and auto drain trap arrangement.

 In case of reciprocating compressor, piping shall be suitably supported to avoid vibrations due to
pulsating flow. Unless requirements of no pockets are specified by the licensor, all the piping shall run at
500mm above grade level so that proper supports can be provided to minimize vibrations. Requirement

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of acoustic studies shall be addressed as per the project requirement. Finding from this study will be
implemented in the design.

 Reciprocating compressor piping shall be provided with independent supports from grade and shall not
be supported from compressor platform structure.

 All small-bore branches shall be checked for requirement of braced supports.

9.1 PIPING ARRANGMENT FOR CENTRIFUGAL COMPRESSOR

 Suction and discharge piping should preferably be routed at grade level to have a proper supporting.
 Check valve for the compressor shall be located as close as possible to the compressor to reduce surges.
It would be preferable to bunch valves in one area wherever possible with their hand wheels facing one
direction for ease of operation.
 Suction pipes which are too small for manual cleaning, shall be provided with a removable spool piece to
permit installation of a strainer at a convenient, accessible location. Piping from strainer to equipment
nozzle shall have a special note for clearing procedures.
 Lube and seal oil piping shall pass through the operating platform. Contaminated oil drain traps must be
located close to the compressor to have continuously sloped drain lines.

9.2 PIPING ARRANGMENT FOR RECIPROCATING COMPRESSOR

 Trenches, pits and similar gas traps should be avoided within compressor house.
 Compressor suction piping from K.O. Drum shall be independently supported. It is important to see that
this support is not provided from the compressor house steel work. Pulsation analysis should be carried
out to decide the routing of the line. Suction piping will subject to chemical cleaning as per the
procedure specified in standard specifications.
 It is very important to route all suction and discharge piping of the compressor as close to grade level as
practical to provide proper supports for the system. Concrete sleepers are preferred to steel supports.
Sleepers shall be spaced at varying distances (3000 mm max.) with no adjacent spans being equal,
enabling to dampen the vibration of the piping.

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