You are on page 1of 32

DOC.

NO:

PIPING DESIGN BASIS

REV: SHEET:

1 of 32

DESIGN BASIS REPORT FOR PIPING

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

2 of 32

REVISION STATUS SHEET

REV. A

DETAILS / DESCRIPTION Preliminary issue for comments

DATE 24 07 - 01

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

3 of 32

PIPING DESIGN BASIS


1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE CODES & STANDARDS DESIGN CRITERIA MATERIALS VALVING GENERAL THERMAL INSULATION PAINTING PROCESS DESIGN CRITETIA FOR PIPING

ANNEXURE - A ANNEXURE - B ANNEXURE - C ANNEXURE - D

PIPING MATERIAL SELECTION MATERIAL SELECTION CHART VALVE DATA SHEETS SCHEDULE OF THICKNESS FOR THERMAL INSULATION DESIGN PROCEDURES FOR PIPE SUPPORTS STRESS ANALYSIS DESIGN CRITERIA MAJOR REQUIREMENTS OF IBR ACCESSIBILITY REQUIREMENTS OF VALVES & INSTRUMENTS RECOMMENDED VELOCITY RANGE FOR VARIOUS FLUIDS

ANNEXURE - E ANNEXURE - F ANNEXURE - G ANNEXURE - H

ANNEXURE - I

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

4 of 32

1.0 1.1

SCOPE: This specification describes the basis for the overall design of steam, water & utility piping of the power plant. It is intended to establish designs confirming to codes and accepted practices currently applicable to piping systems.

2.0 2.1

CODES & STANDARDS: The main design codes and standards, which shall be considered as minimum requirements are listed below. Latest version of these shall be followed. ANSI / ASME B31.1 ANSI B16.5 ANSI B16.9 Power Piping Steel Pipe Flanges and Flanged Fitting Factory - made wrought steel butt-welding Fitting Face-to-Face & End-to-End Dimensions of Ferrous Valves Forged Steel Fittings, Socket Welding and Threaded Valves - Flanged and butt-welding ends Ring Joint gaskets and grooves for Steel pipe Flanges Butt Welding Ends Welded and seamless wrought steel pipe Stainless Steel Pipe Non Metallic Flat Gaskets for Pipes Flanges Square and Hexagonal Bolts Square and Hexagonal Bolts Spectacle Blind for Sizes up to 24 Expansion Joints

ANSI B16.10

ANSI B16.11

ANSI B16.34 ANSI B16.20

ANSI B16.25 ANSI B36.10 ANSI B36.19 ANSI B16. 21 ANSI B 18.2.1 ANSI B 18.2.2 API 590 EJMA

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

5 of 32

API 594 API 598 API 601 API 602 API 609 AWWA C 504 BS 5146 BS 5155 BS 5351 BS 5352 MSS SP 6 MSS SP 25

Wafer type Check Valves Valve Inspection Test Metallic Gaskets for Piping Compact Carbon Steel Gate Valves Butterfly Valve 150 Psig Rubber Seated Butterfly Valves Inspection and Testing of Steel Valves Cast iron & Carbon Steel Butterfly Valves Steel Ball Valves Forged Steel Globe & Check Valves Standard finishes for contact surfaces Standard marking system for Valves, Fittings & Flanges Wrought Stainless Steel Butt welded Fittings IS-1239 (I) Steel Fittings Seamless or Electrically welded steel pipes for Water, Gas, & Sewage (168.3 to 2032 mm Outside diameter) Pipe Hanger & Supports Materials Design & Manufacture -

MSS SP 43

Mild Steel Tubes IS-1239 (II) IS-3589

MSS-SP-58

In addition to the above the following specifications shall form part of this project. Technical Specification for Hot Insulation Technical specification for Shop & Field Painting

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

6 of 32

Piping Material Specification Valve Material Specification Fabrication and Erection of Piping Inspection, Flushing, & Testing of Piping Pre commissioning & chemical cleaning Non- Destructive examination

2.2

Boiler Code Piping: a) 1995 ASME boiler and pressure vessel code Sec. I and Sec. VIII apply to certain integral portions of steam, feed water and blow-off piping associated with boilers and steam generating equipment, as defined by that code. b) Certain portions of external piping shall meet the requirements of ANSI B31.1, (1992) Power Piping Code, as defined by that code. c) Steam and Feed water piping coming under the purview of the Indian Boiler Regulations shall be designed in accordance with that code. Annexure-G lays down the major requirements of Indian Boiler Regulations. Nevertheless, requirements spelt out in respective ASME / ANSI codes shall be adhered to, as a minimum.

3.0 3.1 3.1.1

DESIGN CRITERIA: Operating Conditions: Design conditions of pressure and temperature will be the most severe conditions expected to co-exist under long-term operating conditions. These usual operations include all functions such as throttling, blowing and bypassing likely to be used for operation and control. Temporary Conditions: Usual operating conditions do not include more severe temporary conditions, such as those abnormal operations like turbine over speed / over pressure conditions, as long as the duration and parameters do not exceed the values defined in the respective codes.

3.1.2

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

7 of 32

3.2

Design Temperature: Design temperature is the most severe sustained fluid temperature, subject to conditions of section 3.1 above. Design temperature will be usually the maximum fluid temperature.

3.3

Design Pressure: The Design pressure of piping shall be the most severe condition of internal or external fluid pressure, subject to conditions of Section 3.1 above arrived at in conjunction with the following considerations. Design pressure of the equipment to which it is connected. Set pressure of safety valve which protects the system.

However, Piping systems operating under vacuum / likely to be operated under vacuum shall be designed for full vacuum, also. 3.4 Design Life: Piping system shall be designed for 7000 cycle based on the plant life of 30 years, such that it operates without replacement and with normal maintenance, and shall withstand the fluctuations in operating parameters and cycling, normally expected. 3.5 Piping Flexibility: All piping must be designed for thermal expansion under start-up, operating and shut down conditions such that the actual stresses shall be well within the allowable limits of the pipe material and the forces / moments on the equipment shall be within the limits defined by the equipment supplier. Provisions for expansion or contraction shall normally be made with bends, offsets and expansion loops. Expansion joints may be used on large diameter piping, relief systems or where they are acceptable process wise and economically justified. Stress analysis shall be done for piping meeting the conditions specified in the stress analysis design criteria attached as Annexure-F. 3.6 Piping Supports: All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipment & piping and leakage at joints. Piping at valves and equipment such as heat exchangers and pumps, requiring periodic maintenance, shall be supported in such a way so that the piping can be detached with a minimum temporary supports.
REV.NO A DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

8 of 32

The Design and Selection of supports shall be based on Design procedures for pipe supports attached as Annexure-E. 4.0 4.1 MATERIALS: Piping Material Selection: Piping material selection attached as Annexure-A includes line service, pipe material, type of construction and ANSI Rating. Piping Material Selection for this project is attached as Annexure-A. The basis for material selection is as per Material Selection Chart attached as Annexure - B. 4.2 4.2.1 Corrosion Allowance: Unless otherwise specified in piping material specification, minimum corrosion allowance, as shown below, shall be provided for all non-IBR piping systems. Carbon Steel Ferritic Alloys Austenitic Steel Non - Ferrous 4.2.2 4.3 4.3.1 1.5mm 1.5mm 0mm 0mm

For IBR piping, refer to the requirements under the IBR regulations. Wall Thickness and Reinforcement: Reinforcement requirement for nozzles / stubs or other welded branch connections shall be as per Section 104.3 of ANSI B31.1 and shall additionally meet the requirements of IBR for piping systems under the purview of IBR. Line and Connection Size: Minimum line size shall be 1 for long runs in the offsite area. Exceptions are there for instrument piping, which may be minimum 1/4. Vents and Drains shall be 3/4 min. Pipe sizes 1-1/4, 2-1/2 and all other odd sizes such as 5 and 7 shall not be used unless required to match the connections to Mechanical equipment.

4.4

4.5 4.5.1

Bends & Mitres: Long radius welding elbows shall be used for changes in direction of piping. For steam and feed water piping coming under the purview of the Indian Boiler Regulation bend radii shall be as per that regulations. Short radius bends shall only be used where space does not permit the use of long radius elbows and bends.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

9 of 32

4.5.2

Welded mitre bends, with a maximum included angle of 22.5 per segment, may be used in utility piping systems, for sizes NB 350 and over, where the pressure and temperature does not exceed 10 kg/cm2 and 120C respectively. In other services & Higher-pressure conditions, the welded mitre bends may be used, provided they meet process requirements.

5.0 5.1 5.1.1

VALVING: Valves: Design, fabrication and testing of valves shall generally conform to ANSI B16.34 (1981). Butterfly valves shall conform to AWWA C504. All valves requiring attention during normal operation shall be accessible either from grade, platform or Ladders. All valves shall be suitable for installation in horizontal as well as vertical pipeline. All globe valves shall be capable of being closed against the design pressure. Where globe valve has been specified for regulation purpose, the disc shall be tapered plug type and suitable for controlling throughout its lift. All gate and globe valves shall have bonnet back seating arrangement to facilitate easy replacement of packing with the valves in service. All gate, globe and check valves shall be designed for reconditioning seating surfaces and replacement of stem and disc without removing the valve body from the line. Manual gear operators shall be provided to open / close the valve against the maximum differential pressure across the valve such that the effort required to operate does not exceed 25 kgf. However, unless otherwise stated in P&ID, geared operators shall be provided as below: Gate and Globe valves ANSI #150 ANSI #300 Ball valves ANSI #150 ANSI #300 ANSI #150 with size 12 & larger with size 8 & larger with size 8 & larger with size 6 & larger with size 8 & larger

5.1.2

5.1.3 5.1.4

5.1.5

5.1.6

5.1.7

5.1.8

Butterfly valves

All gate and globe valves of size 50 mm and below in vacuum services shall have extra deep gland packing without any provision for water gland sealing.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

10 of 32

5.1.9

All gate and globe valves of size 80 mm NB and above in vacuum services shall have adequately deep gland packing and shall be equipped with lantern rings to admit pressurised water for gland sealing.

5.1.10 Integral bypass valves shall be provided for all gate valves as classified below. Size and location of bypass valve shall be as per MSS-SP-45. a) Under pressure class of 600 lbs and above, where the sizes are 100 mm NB and above Under pressure class of 300 lbs and 400 lbs where the sizes are 250 mm NB and above.

b)

5.1.11 Valve Data Sheets attached as Annexure - C gives a basis of valve selection for the different systems 5.1.12 Valved drains, vents shall be installed at low and high points in piping systems, if required for operation, maintenance or for draining purposes. 5.1.13 Drains & vents required purely for hydraulic or pneumatic test purposes are to be shown on the isometric drawings and added to the P&IDS by the Piping erection contractor. To collect samples for laboratory analysis, dedicated sample connections are required; sample points shall not be located in dead ends of piping.

6.0 6.1

GENERAL: General Layout Requirements: Pipes of sizes 80 mm NPS and above shall be shop fabricated as per the drawings and pipes of sizes 50 mm NPS and below shall, in general, be field routed.

6.2

Accessibility: For accessibility requirement of Valves & Instruments for the plant refer Annexure-H of this specification.

6.3 6.3.1

Pipe Routing: All Piping entering and leaving a plot area shall be grouped together as far as practicable. Inside plot piping shall be routed on overhead pipe bridges wherever possible. Piping with Instrument connections shall be routed to ensure accessibility, if necessary Platforms / Walkways shall be provided.
DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

6.3.2

REV.NO A

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

11 of 32

6.3.3

Fire fighting water lines, if installed above ground shall not run along pipe bridges and pipe racks but as practical along roads. The elevations of overhead piping shall be as specified by the site requirements but never be less than 6.8 M over Railroads / Railways 6.0 M over Main roads 6.0 M for crane access 4.0 M for truck access 3.0 M for fork lift truck access 2.2 M over Walkways inside buildings and Platforms.

6.3.4

6.3.5

The minimum horizontal clearance shall be 0.75 M for access ways and walkways, however the minimum clearance shall be 0.9 M for frequently used main passages. Buried Piping shall be considered for Drainage or Sewerage. Fire water lines.

6.3.6

6.3.7

Buried piping shall have a minimum cover of soil: - Fire water lines (main) - Road crossings for lines 24 & smaller - 0.9 M - 0.6 M

6.3.8

The load on the pipes should be equalized for lines crossings railroads / railways and traffic roads by means of pipe sleeves or a culvert. The pipes shall be kept centrally in the sleeves by distance pieces welded to the pipe or fixed to the sheeting if the line is insulated. As far as practical, piping shall run at the different elevations designated for northsouth and east-west banks and shall change elevation at change in direction.

6.3.9

6.3.10 Sleeves or holes through walls, floors of buildings shall have a size permitting the passage of a flange of the relevant pipe size to facilitate the installation of fabricated piping and to permit insulation work. 6.4 Relief System / Blow down system Piping: Relief valve discharging steam, air directly to atmosphere shall be equipped with drain or suitably piped to prevent accumulation of liquid at valve outlet. Relief valve discharge piping shall be taken to safe location as per following

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

12 of 32

3 M above top platform of column or structure 25 M horizontally away from Boiler. 50 M horizontally away from Boiler, if more than more one-relief system of different set pressures is discharging into one common riser of vent stack.

Inlet and outlet piping of pressure relief valve shall be adequately supported to take care of the thrust induced by the relief valve during popping.

6.5

Offsite and Yard Piping: In general, the Pipes shall be laid at grade level on sleepers at 300mm higher from grade level. Pipes at crossing of roads shall be by pipe-way bridges in general. Pipes sleeves may be considered where one or two pipes are to cross the road.

6.6

Expansion and Contraction: Piping systems shall have sufficiently flexibility to allow for thermal expansion and contraction so as to prevent Failure of piping components owing to over stress leakage at joints. Excessive thrusts and moments on connected equipment anchor points etc. Forces on equipment connection nozzles, in case where the forces exceed normal conservative values.

Loops and offsets shall provide for flexibility in piping systems, especially for noxious or hazardous fluids, Expansion joints shall be considered when limited space will not give sufficient flexibility. Expansion joints shall be used only with adequate guided and anchors. Loops and offsets shall be used in preference to bellow type expansion joints wherever possible. Bellow type joints shall not be subjected to torsional loads. Horizontal piping expansion loops on pipe bridges shall have vertical offset to stay clear of adjacent piping and any thermally expanded piping shall be anchored at the plot limit. Calculations shall establish stresses, forces and moments. Pipe stress / flexibility analysis shall be executed with program: CEASAR II from COADE

7.0 7.1

THERMAL INSULATION: Thermal insulation shall be provided for all piping and equipment with surface operating temperatures of 60C or above for one or more of the following reasons:

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

13 of 32

a) b) c) 7.2

Conserve heat Maintain temperature for process control Provide for personnel protection.

Design basis for selecting insulation thickness shall be as below: Ambient Temperature Cladding Temperature Wind Velocity Emissivity of Cladding Hot Surface Temperature : : : : : 40C 60C (max) 0.5 m / sec. 0.15 Fluid Design Temperature

7.3

Insulation material for hot insulation shall be as below: i) For sizes (including insulation thickness) up to 350 mm, Rock wool preformed pipe sections of density 144 kg/m3 conforming to IS: 9842 For sizes 400 mm and above: In order to meet the sizes above 400mm, (Including insulation thickness) lightly resin bonded mattress confirming to ASTM C547 class III shall be applied in addition to the Rock wool preformed pipe sections. The physical requirement of bulk density and chloride content, thermal conductivity and PH value of the material shall be as follows: Bulk Density : 140 kg / cubic. Meters Chloride content : 20 PPM Thermal conductivity: 0.43 m W/cm deg. C for mean temp 50 deg. C 0.52 m W/cm deg. C for mean temp 100 deg. C 0.62 m W/cm deg. C for mean temp 150 deg. C 0.68 m W/cm deg. C for mean temp 200 deg. C 0.80 m W/cm deg. C for mean temp 250 deg. C 0.90 m W/cm deg. C for mean temp 300 deg. C

ii)

iii)

7.4

Aluminum cladding shall be used as a weather protection over insulation unless otherwise specified and shall conform to ASTM - B - 209 - 1060 Temper H-14. Schedule of thickness for Thermal Insulation is attached as Annexure - D. PAINTING: Painting of pipe work shall be as per the painting specification. The procedures for painting of insulated and non-insulated pipes, the colour codes, the method of painting, etc. shall comply with the guidelines specified in the painting specification.

7.5 8.0 8.1

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

14 of 32

9.0 9.1

PROCESS DESIGN CRITERIA FOR PIPING General: The complete CPP piping shall mainly consist of following systems; viz. Boiler feed pump suction piping, boiler feed pump discharge piping, boiler feed pump recirculating piping, main steam piping, auxiliary steam piping, extraction steam piping, condensate piping, Raw Water piping, DM Plant piping, fire water piping, boiler blow down, vents, drains, etc. and low pressure utility piping.

9.2

Boiler Feed Pump Suction Piping: A common suction line from deaerator/ feed water storage tank shall be provided with branching off lines to individual boiler feed pumps. The common suction line of BFPs shall be designed for rated flow of the operating BFPs + minimum recirculation flow of the standby BFP and the branch off line shall be designed for the rated flow of the pump.

9.3

Boiler Feed Pump Discharge Piping: The discharge of boiler feed pumps shall be connected to the common discharge header. From the discharge header feed water piping shall be routed to the steam generator through, hp heater and feed water control stations. The feed water control station shall have 1 x 100% and 1 x 40% control valves having flexibility in operating the Boiler at varying load conditions. Feed water required for super heater attemperation of the steam generators and other desuperheaters for auxiliary steam in the power plant shall be tapped from the discharge headers of BFPs.

9.4

Boiler Feed Pump Recirculation Piping: Separate recirculation line for each boiler feed pump shall be provided from the non-return-cum modulating recirulation valves (Automatic Recirculation Valves) with necessary isolation valves and pressure break down orifices and shall be connected to the deaerator. Though the pressure reduction is achieved mainly through the recirculation valve, the upstream of the pressure break down orifice located near deaerator shall be kept 3 to 4 kg/cm2 above the deaerator pressure so as to avoid flashing of water in the recirculation line thereby avoiding water hammer and vibrations in the recirculation lines.

9.5

Main Steam Piping, Auxiliary Steam Piping and Extraction Steam Piping: The main steam lines constitute the most important piping in a power plant and the main steam piping from the boiler is connected to the turbine with adequate expansion loop(s) to take care of the thermal expansions & to obtain adequate flexibility so as not to exceed allowable reactions on boiler & turbine connections.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

15 of 32

Three separate extraction piping will be provided from the turbine to the H.P. Heater, Deaerator and L.P. Heater to supply the steam. In order to meet the transient condition, separate tap off will be provided from the main steam line to the Deaerator extraction line through the Desuper Heater. Another tap off will be provided in the main steam line to meet the steam requirement of turbine gland steam ejector system. Desuperheater spray requirement for auxiliary steam Desuperheaters and superheater attemperators will be met by tap offs from the feed water pump discharge header. On all pressure part tapping joints, 2 root valves shall be provided in series. 9.6 Condensate Pump Suction Piping: The common suction line from condenser hot well shall be connected to individual condensate extraction pumps through branch lines and expansion joints. The piping shall be sized for the maximum flow to the condenser under various modes of plant operation. 9.7 Condensate Pump Discharge Piping: The discharge from the condensate pumps shall be connected and fed to the deaerator through ejector, gland steam condenser, drain cooler and L.P heater. A tapping shall be provided for supplying spray water to turbine exhaust hood to control the temperature. At the condensate outlet of GSC a minimum recirculation line shall be taken and this will be directly connected to condenser to control the level of the condenser. 9.8 Boiler Blow Down, Vents, Drains Etc. Blow down piping shall connect the drains from boiler drum, super heaters, bottom ring headers, etc. with the blow down tank. Pressure breakdown orifices shall be provided before the blow down tank nozzle. Some high-pressure steam line drains from different piping and equipment are connected to flash tank while others shall be let off to the plant drains. 9.9 Low Pressure Utility Piping: The low-pressure utility piping shall cover the following services.

1. 2. 3. 4. 5. 6. 7. 8.
REV.NO A

Make-up water Instrument air Service air D.M.water Fuel oil-HSD Service and potable water Cooling water Auxiliary cooling water
DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

16 of 32

9. Raw water
9.9.1 Make up Water Piping: Makeup water for the power plant shall be supplied from raw water reservoir. From the raw water reservoir, raw water shall be pumped for cooling tower make up, the DM plant requirement, air-conditioning ventilation system and service/drinking water.

9.9.2

Instrument Air: The instrument air shall be supplied through pipes from the common compressor house located in the power plant. The header shall be run throughout the power plant to meet all instrument requirements. Tapping for control valves in the deaerator area, feed water control station etc., and for other instruments shall be made from the header at all the nearest points.

9.9.3

Service Air: The service air shall be supplied from the compressor house through service air pipes. The header shall be routed through out the power plant. Tappings shall be made from this header for various plant locations in Boiler area. STG building, coal handling plant area as per the distribution list given in Compressed Air DBR.

9.9.4

DM Water: The DM water piping from DM plant to the DM water storage tank and from the storage tank to deaereator and other areas of requirement such as initial filling for condenser hot well, H.P. and L.P. Dosing system will be routed through suitably sized pipeline.

9.9.5

HSD: Fuel oil pipeline shall be routed from the storage tank to boiler through transfer pumps.

9.9.6

Potable Water: Potable water pipe lines shall be routed separately throughout the power plant. The material of potable water pipe shall be carbon steel conforming to IS: 1239 black and galvanized.

9.9.7

Cooling Water: The cooling water system shall be supplying cooling water to the condensers of the steam turbine generators of the power plant.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

17 of 32

The common supply header and return header shall be buried along the T.G. building for the turbine condenser. The buried piping shall be provided with suitable external coating and wrapping. Motor operated butterfly valves shall be installed at the discharge of each CW pump. Gear operated butterfly isolation valves shall be installed on the return header at the cooling tower inlet. CW pump suction piping shall have rubber expansion bellows. The butterfly valves shall conform to API 609 or AWWA C504 standards and flanged type and shall be of cast steel body and disc with nitrile rubber seating. 9.9.8. Auxiliary Cooling Water: The auxiliary cooling water header shall be routed along with the main cooling water piping. From the header branch lines for lube oil coolers, generator air coolers, ash handling system compressors and plant air compressor and sample coolers etc. The return piping shall be routed to cooling tower inlet header. The material of construction shall be same as that of cooling water piping. All piping to the coolers shall be provided with isolation valves of gate type at inlet and globe valve, at outlet.

9.9.9.

Raw Water: Raw water piping shall be routed from the existing raw water Reservoir (UMI) to the proposed CPP raw water reservoir. The Raw water piping shall be buried at 1.5 m below the ground. The material of piping shall be carbon steel as per IS: 3589 ERW pipes. The buried piping shall be provided with suitable external coating and wrapping.

9.10

Fire Water Piping: Firewater piping shall involve piping for the fire hydrant system and high velocity water spray systems. Fire hydrant piping shall be routed from the fire water pumps to various hydrant valve locations, the yard piping mainly being buried piping with suitable wrapping and coating. The hydrant piping shall be ring main type (close loop system) so that leakage/breakage at one location would not render the total system non-operational. Suitable isolation valves, drains connected at all low points shall be provided.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

18 of 32

9.11

Optimum Line Sizing: Following parameters for each service have been considered to arrive at optimum line size: a) Type of fluid, its properties under design condition. b) Design flow rate c) Recommended velocity d) Pressure at source and receiver ie., available pressure drop through the lines including fittings, valves and specialities such as strainers, flow elements etc. For pumps, in addition to friction losses, static head is also considered while estimating total pressure head required. Annexure - I, gives the recommended velocity range, for various fluids.

REV.NO A

DATE

ANNEXURE - A DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

19 of 32

PIPING MATERIAL SELECTION System Design Design Flange / Temperat Pressure Valve ure C BAR(a) Rating(AN SI)
500 157.5 202.7 330.5 145.5 202.0 116.2 66.89 2.13 6.2 18.52 6.0 125.2 8.3 900 150 150 300 150 900 150

Pipe Material

Construction

LIVE STEAM LP EXTRACTION STEAM IP EXTRACTION STEAM HP EXTRACTION STEAM BOILER FEED WATER PUMP SUCTION BOILER FEED WATER PUMP DISCHARGE CONDENSATE PUMP DISCHARGE (AFTER LEVEL CONTROL STATION) LP HEATER DRAIN HP HEATER DRAIN (BEFORE C.V STATION) HP HEATER DRAIN (AFTER C.V STATION) DEAERATOR OVERFLOW & BLOW LINES TO DRAIN MANIFOLD COOLING WATER SUPPLY COOLING WATER DISCHARGE INSTRUMENT AIR

ASTM- A335 SEAMLESS Gr.P22 ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B ASTM-A106 SEAMLESS Gr.B IS: 1239 IS: 3589 IS: 1239 IS: 3589 IS: 1239 GALV IS: 3589 GALV IS: 1239 ERW ERW ERW ERW ERW ERW

119.4 155.1 155.1 145.5

2.0 17.5 13.0 6.0

150 300 150 150 300/150 150 150 150

330.5/202.7, 18.52/6.20, 151.5 2.13 50 50 50 5 5 10

SERVICE AIR DEMINERALISED WATER RAW WATER POTABLE WATER

50 50 50 50

10 14 4.8 4.8

150 150 150 150

ERW

ASTM-A312, SEAMLESS TP-304 IS: 1239 IS: 3589 IS: 1239 GALV IS: 3589 GALV ERW ERW ERW ERW

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

20 of 32

ANNEXURE - B MATERIAL SELECTION CHART MATERIAL CARBON CONTENT % DESIGN TEMPERATURE C SEAMLESS PIPES ASTM A106 Gr.B ASTM A335 Gr.P1 ASTM A335 Gr.P11 ASTM A335 Gr.P22 ASTM A312 Gr.TP304 ASTM A312 Gr.TP304L WELDED PIPES ASTM A672 Gr.B60 API 5L Gr.B (ERW ; E = 0.85) ASTM A312 Gr.TP304 ASTM A312 Gr.TP304L FITTINGS ASTM A234 Gr.WPB ASTM A234 Gr.WP1 ASTM A234 Gr.WP11 ASTM A234 Gr.WP22 ASTM A403 Gr.WP304 ASTM A403 Gr.WP304L FORGINGS ASTM A105 ASTM A182 Gr.F1 ASTM A182 Gr.F11 Cl.1 ASTM A182 Gr.F22 Cl.1 ASTM A182 Gr.F304 ASTM A182 Gr.F304L 0.35 Max. 0.28 Max. 0.10 - 0.20 0.15 Max. 0.08 Max. 0.035 Max. 427 468 570 600 -200 to 500 -200 to 500 0.30 Max. 0.10 - 0.20 0.15 Max. 0.15 Max. 0.08 Max. 0.035 Max. 427 468 570 600 -200 to 500 -200 to 500 0.30 Max. 0.20 Max. 0.08 Max. 0.035 Max. -46 to 300 230 -200 to 500 -200 to 500 0.30 Max. 0.10 - 0.20 0.15 Max. 0.15 Max. 0.08 Max. 0.035 Max. 427 468 570 600 -200 to 500 -200 to 500

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

21 of 32

MATERIAL

CARBON CONTENT %

DESIGN TEMPERATURE C

CASTINGS ASTM A216 Gr.WCB ASTM A217 Gr.WC1 ASTM A217 Gr.WC6 ASTM A217 Gr.WC9 ASTM A351 Gr.CF8 BOLTS ASTM A193 Gr.B7 ASTM A193 Gr.B16 NUTS ASTM A194 Gr.2H ASTM A194 Gr.7 PLATES ASTM A515 Gr.60 ASTM A516 Gr.60 ASTM A387 Gr.11 Cl.1 ASTM A387 Gr.22 Cl.1 ASTM A240 Gr.304 ASTM A240 Gr.304L 0.30 Max. 0.30 Max. 0.10 -0.20 0.15 Max. 0.08 Max. 0.035 Max. 450 -46 to 300 570 600 -200 to 500 -200 to 500 0.4 Min. 0.37 - 0.49 427 566 0.37 - 0.49 0.36 - 0.44 427 566 0.30 Max. 0.25 Max. 0.20 Max. 0.18 Max. 0.08 Max. 427 468 570 600 -105 to 538

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

22 of 32

ANNEXURE - C VALVE DATA SHEETS SL. NO. 1 SYSTEM SIZE TYPE OF END ANSI MATERIAL VALVES CONNECITON RATING OF HOUSING BW BW SW SW BW BW SW SW BW BW SW SW BW SW BW BW SW BW BW BW SW SW BW BW SW SW 150# 150# 800# 800# 300# 300# 800# 800# 600# 600# 800# 800# 150# 800# 900# 900# 1500# 150# 150# 150# 800# 800# 150# 150# 800# 800# A216 Gr.WCB A216 Gr.WCB A105 A105 A216 Gr.WCB A216 Gr.WCB A105 A105 A216 Gr.WCB A216 Gr.WCB A105 A105 A216 Gr.WCB A105 A216 Gr.WCB A216 Gr.WCB A105 A216 Gr.WCB A216 Gr.WCB A216 Gr.WCB A105 A105 A216 Gr.WCB A216 Gr.WCB A105 A105

LP EXTRACTION Above 50 NB Gate Valve STEAM Check Valve 50 NB & Below Gate Valve Globe Valve IP EXTRACTION Above 50 NB Gate Valve STEAM Check Valve 50 NB & Below Gate Valve Globe Valve HP EXTRACTION STEAM Above 50 NB Gate Valve

Check Valve 50 NB & Below Gate Valve Globe Valve Above 50 NB Gate Valve 50 NB & Below Globe Valve Gate Valve Check Valve 50 NB & Below Globe Valve Gate Valve Check Valve Globe Valve 50 NB & Below Gate Valve Globe Valve Gate Valve

BFP SUCTION

BFP DISCHARGE Above 50 NB

CONDENSATE WATER

Above 50 NB

LP HEATER DRAIN

Above 50 NB

Globe Valve 50 NB & Below Gate Valve Globe Valve

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

23 of 32

VALVE DATA SHEETS

SL. NO. 8

SYSTEM

SIZE

TYPE OF END ANSI MATERIAL VALVES CONNECITON RATING OF HOUSING Gate Valve Globe Valve Gate Valve Globe Valve BW BW SW SW FL FL 300# 300# 800# 800# 150# 800# A216 Gr.WCB A216 Gr.WCB A105 A105 A216 Gr.WCB A105

HP HEATER DRAIN

Above 50 NB

50 NB & Below

COOLING WATER

Above 50 NB 50 NB & Below

Butterfly Valve Globe Valve

10 DEMINERALISED Above 50 NB WATER 50 NB & Below

Diaphragm Valve Globe Valve

FL SW

150# 150#

A351 Gr.CF8 A182 Gr.F304

11 CHEMICAL DOSING

Below 50 NB Ball valve

SW

150#

Polyethylene

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

24 of 32

ANNEXURE - D SCHEDULE OF THICKNESS FOR THERMAL INSULATION

TEMP. C Pipe Dia 15 mm (1/2) 20 mm (3/4) 25 mm (1) 32 mm (1 ) 40 mm (1 ) 50 mm (2) 65 mm (2 ) 80 mm (3) 100 mm (4) 125 mm (5) 150 mm (6) 200 mm (8) 250 mm (10) 300 mm (12) 350 mm (14) 400 mm (16) 450 mm (18") 500 mm (20") 550 mm (22") 600 mm (24)

Up to 100

101 to 150 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25

151 to 200 25 30 30 30 30 30 35 35 35 35 35 40 40 40 40 40 40 40 40 40

25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25

201 251 301 351 to to to to 250 300 350 400 Insulation Thickness (mm) 35 45 50 60 35 40 40 40 45 45 45 50 50 50 50 55 55 55 55 55 55 55 55 45 45 50 50 55 55 60 60 65 65 65 70 70 70 75 75 75 75 75 55 60 60 60 65 70 70 75 75 80 85 85 90 90 90 90 95 95 95 65 70 70 75 80 80 85 90 90 95 100 105 105 110 110 110 115 115 115

401 to 450 70 75 80 85 85 90 95 100 105 110 115 120 125 125 130 130 135 135 135 140

451 to 500 85 90 90 95 100 105 110 115 120 125 130 140 145 150 150 155 155 160 160 165

501 to 550 95 100 105 110 115 120 125 130 140 145 150 160 165 170 175 180 180 185 185 190

ANNEXURE - E
REV.NO A DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

25 of 32

DESIGN PROCEDURES FOR PIPE SUPPORTS

The design loads for hangers & supports shall include the weight of pipe, the weight of insulation and the weight of medium transported or the medium used for testing, whichever is heavier. All components of hanger or support assembly shall be designed for the above design load and the self-weight of hanger/support assembly. Design and manufacture of hanger components including springs shall generally confirm to MSS - SP58, MSS-SP69 and MSS-SP89. The materials used in the construction of hangers, supports and accessories shall be the most suitable for the service intended. Material of lugs and welded attachment to pipes and pipe clamps shall be compatible with parent pipe. However, welded pipe attachments shall be minimised. The hangers shall be provided with suitable linkages to permit swing. The angle of inclination shall not exceed 4 from the vertical plane. The diameter of hanger rods for piping, 50mm NPS and smaller, shall not be less than 10mm. Bolted pipe clamps, used with rod hangers, for pipe 50 mm NPS and smaller, shall have a minimum thickness of 6mm. Springs, for spring hangers, shall be of helical compression type and shall be provided with means to prevent misalignment, buckling and eccentric loading and with stops to prevent excessive travel. Where variable spring hangers are specified, the units selected shall have support variation of not more than 25% through its total travel range. Constant spring hangers shall be specified where pipe thermal vertical movements exceed 40 mm. Constant support hangers shall have a field load adjustment range of +10% of the operating load specified. The total travel of the unit selected shall be the calculated travel of plus 20% to take care of possible discrepancies. Constant support hangers shall have support variation of not more than 6% throughout the total travel range. All rigid / spring hangers shall provide a means of vertical adjustment after erection.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

26 of 32

The threads on threaded parts such as hanger rods, nuts and turnbuckles shall conform to applicable codes for the coarse-thread series with a medium class fit or equivalent. All anchors shall be designed for rigid fastening to the structure either directly or through a bracket. Anchors and guides shall be capable of withstanding the moments and forces imposed by thermal expansion. Pipe supports shall be designed such that a minimum amount of heat will be transferred to the structure. Stainless steel shim plates are required between stainless steel pipe and carbon steel supports. The maximum allowable deflection of supports due to the design loads in the direction of the restraints shall be 3mm. Shear lugs shall be provided for friction type clamped support on riser pipes. Friction type clamped supports shall not be normally used on a vertical riser for critical systems. The hanger shall be offset 1/2 of the thermal movement in cold position if swing angle of the rod is in excess of 5 degrees, but not exceeding 10 degrees. Suitable locking devices shall be used at all threaded connections of the hanger assembly. Each half assembly of a riser support shall be capable of supporting the entire load. Overall rod length shall not be greater than 6m without proper evaluation. Rigid Restraints:

Restraints fabricated out of structural steel shall have a clearance of 1.5mm in direction of the restrained movement except in the downward direction. Anchors shall only be used where full constraint of piping against three deflections and three rotations are required. Dependence on friction straps or bolted joints shall be avoided, to the extent possible, especially in pipes, where design temperature exceeds 120.

ANNEXURE - F
REV.NO A DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

27 of 32

STRESS ANALYSIS DESIGN CRITERIA General: This criteria is established for piping flexibility analysis to be performed during piping design work for the plant.

Application code & Specification : Stress analysis of piping systems shall be performed in compliance with ANSI B31.1

Temperature : Installation temperature = 30 C Design temperature : Design temperature is the most severe sustained fluid temperature subject to conditions of section 3.1 above.

Computer Software : The computer pipe stress analysis shall be carried out using CAESAR - II ver. 3.24 computer software. Basis for computer pipe stress analysis : Detail pipe stress analysis shall be required for the following : Pipe Diameter (mm) (in) 80 100 150 200 250 300 350 400 450 500 & above 3 4 6 8 10 12 14 16 18 20 Design Temperature Carbon steel (deg. C) Austenitic Steel (deg. C) & Ferritic alloys > 440 > 390 > 300 > 260 > 260 > 200 > 230 > 160 > 190 > 130 > 160 > 120 > 140 > 100 > 130 > 90 > 120 > 80 > 100 > 80

All following piping connected to reciprocating / rotary equipments. (i) Pipe diameters of 80mm to 200mm with design temp. greater than 60 (ii) Pipe diameter 250 mm & larger

Steam lines connected to turbine. Feed water pump suction and discharge lines. ANNEXURE - G
DATE DESCRIPTION Issued for Approval PREPD CHKD APPD

REV.NO A

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

28 of 32

MAJOR REQUIREMENTS OF IBR

Vessels (Reg. 2 (c) of IBR): Any closed vessel exceeding 22.75 litres (five gallons) in capacity, which is used exclusively for generating steam under pressure and include any mounting or other fittings attached to such vessels, which is wholly or partly under pressure when steam is shut off.

Piping: Steam Pipe (Reg. 2 (k) of IBR): Any pipe through which steam passes if 1. Steam pressure exceeds 3.5 kg/cm2 above atmosphere, OR 2. Pipe size exceeds 254 mm internal dia.

Note: Following are not under IBR Steam Tracing Heating coils or Tubes of Tanks, heat exchangers Feed Pipe (Reg. 2 (k) of IBR): Any pipe or connected fitting wholly or partly under pressure through which feedwater passes directly to a boiler.

Material Certificates: 1. Any item part of steam piping i.e. pipes, valves, fittings, traps, safety valves must have material certificates, countersigned by the local boiler inspector. 2. For imported items - certificates issued by an authority empowered by the Central Boilers Board (as listed in the Appendix C of IBR) or under the Law in force in a foreign country in respect of boilers manufactured in that country may be accepted.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

29 of 32

Drawings: 1. Prior to fabrication of any items i.e. Boiler, fabricated pipe work which are coming under the purview of the boiler drawings shall be submitted before construction to the Chief Boiler Inspector of the State where the plants / equipment / Pipe line will be installed. 2. The Chief Inspector shall after examination of the drawings and particulars shall inform the proposers whether he is satisfied with the design and fitness of the parts for the intended pressure and if not, what modification is necessary therein with respect to design, material etc.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

30 of 32

ANNEXURE - H ACCESSIBILITY REQUIREMENTS FOR VALVES & INSTRUMENTS Valves, Instrument, Centreline of item to be operated, Equipment to be operated located less than 3.6m above grade, 2.75m above floor or platform or 1.8m above wing platform Exchanger heads Nil Operating valves 2 & Fixed ladder ll Operating valves 3 & above Platform Motor operated valve Platform Control valves Platform Relief valves 2 & smaller Fixed ladder Relief valves 3 & above Platform Block valves 2 & smaller Portable ladder Block valve 3 & above Platform (Note-1) Battery limit valves Platform Pressure instrument Fixed ladder if above 2.2m h i h ladder if above 2.2m Temperature instrument Fixed h i h Sample points Platform Gauge glasses Level controllers Man ways / Manholes Hand holes / Inspection h l Nozzles Vessel vents Line drains & vents Orifice flanges Fixed ladder Platform Platform Platform No access reqd. (Note-2) Portable ladder Portable ladder Portable ladder Centreline of item to be operated, located more than 3.6m above grade, 2.75m above floor or platform or 1.8m above wing platform Platform Fixed ladder Platform Platform Platform Fixed Ladder Platform Portable ladder Platform (Note-1) Platform Fixed ladder Fixed ladder Platform Fixed ladder Platform Platform Platform No access reqd. Fixed ladder Portable ladder Portable ladder

Note:

1)

Center line of Block valves located above 2.0 meter from the operating floor which are required for normal operation shall be provided with portable platform or chain for operation of valves.

2) Temporary arrangement for access should be feasible.

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

31 of 32

ANNEXURE - I RECOMMENDED VELOCITY RANGE FOR VARIOUS FLUIDS A. STEAM Pipe Size Average velocity in meter/second Below 50 NB 15-20 15-25 20-30 20-35 20-35 50 to 100 NB 20-35 20-35 25-40 30-45 30-50 100 NB & up 25-45 30-50 30-50 35-55 40-60

1.Saturated steam up to 7.0 kg/cm2 (g) 2.Saturated steam over 7.0 kg/cm2 (g) 3.Superheated steam up to 7.0 kg/cm2(g) 4.Superheated steam from 7.1 to 3.5 kg/cm2 (g) 5 Superheated steam from 35.1 to 70 kg/cm2 (g) 6. Superheated steam from 70 kg/cm2 (g) 7.Turbine by pass steam 8.Exhaust steamline atmosphere 9.Vacuum lines from the line to

20-35 200 20

30-50 For all For all

45-70 Line sizes Line sizes

60

For all

Line sizes

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD

DOC.NO:

PIPING DESIGN BASIS

REV: SHEET:

32 of 32

B.

Water Average Velocity Meter / second Firewater lines Feed water suction lines Feed water discharge lines Auxiliary cooling water (suction) Auxiliary cooling water (discharge) Condensate delivery lines Condensate suction lines Main cooling water lines (discharge) Main cooling water lines (suction) Viscous fuel oil Gases 0.6. to 0.9 1.0 to 2.5 2.5 to 5.0 0.6 to 1.5 0.9 to 2.5 0.9 to 2.2 0.4 to 0.7 0.9 to 2.5 0.6 to 1.2 0.6 to 0.9 25 to 30

C.

Oil and gas lines Average Velocity Meter/second Lubricating oil and fuel oil suction Lines (depending on viscosity) 0.5

Fuel oil supply lines (pre-heated)

3.0

REV.NO A

DATE

DESCRIPTION Issued for Approval

PREPD

CHKD

APPD