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HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY

DHT PROJECT

PART : III SECTION : A

TITLE : ENGINEERING DESIGN BASIS PIPING

DOCUMENT NO: 44LK-5100-00/L.02/002/A4

06.04.09

50

Revised as marked & Issued as Amendment no.1 Issued for FEED


Description

DRP

RMP

RMP/PVS

0
Rev No.

03.12.08
Issue Date

50
Pages

DRP
Prepared By

RMP
Checked By

RMP/PVS
Approved By

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 2 of 50

TABLE OF CONTENTS 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 4.0 ANNEXURES ANNEXURE A ANNEXURE B ANNEXURE C ANNEXURE D ANNEXURE E ANNEXURE F ANNEXURE G ACCESSIBILITY FOR VALVES & INSTRUMENTS CLEARANCES VERTICAL AND HORIZONTAL GUIDES SPACING TABLE OF BASIC SPAN TECHNICAL REQUIREMENTS OF PIPING MATERIAL GENERAL REQUIREMENT STANDARD DRAWINGS PURPOSE SCOPE GENERAL CRITERIA EQUIPMENT LAYOUT PIPING MODELING & GENERAL ARRANGEMENT OFFSITES AND YARD PIPING TANK FARM PIPING UNDERGROUND PIPING VENTS AND DRAINS FLEXIBILITY ANALYSIS & SUPPORTING FLARE PIPING MATERIALS AND SELECTION OF PIPES AND FITTINGS NDT REQUIREMENTS STRAINERS WELDING REFERENCED PUBLICATION

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 3 of 50

1.0

PURPOSE The purpose of this document is to establish a common understanding between PMC & LSTK Contractor on Piping Design Philosophies for DHT Project at HPCL, Mumbai Refinery.

2.0

SCOPE This Design Basis defines briefly the general guidelines for piping viz: preparation of equipment layout, piping arrangement, piping material specifications and local statutory / safety requirements. In case of any discrepancy or contradiction either in this Design Basis, or in Standard Drawings / Standard specifications, It is deemed mandatory to follow the requirements of the national / International design codes / standards, local statutory rules or OISD guide lines as applicable. The standard drawings provided in the BID are for reference and for conceptual understanding only and thus not exhaustive. Where ever necessary, either for the lack of information or non availability, LSTK shall prepare or develop the required specifications/standard drawings and use the same with prior approval of PMC

2.1

DEFINITION : OWNER - Hindustan Petroleum Corporation Limited, Mumbai Refinery. PMC LSTK - Jacobs Engineering India Pvt. Ltd. - Successful Bidder

3.0 3.1 3.1.1

GENERAL CRITERIA EQUIPMENT LAYOUT BASIS OF EQUIPMENT LAYOUT Equipment Layout shall be developed based on the following data: P&IDs Typical Equipment Layout Diesel Hydro treating Unit, by Process Licensor Indicative Equipment Layout by PMC Equipment Process Data Sheets. Wind direction. Overall Plot Plan Tie-in-Points for process & utilities with existing Plant.

3.1.2

DEVELOPMENT OF EQUIPMENT LAYOUT The following aspects shall be considered during development of Equipment Layout:

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 4 of 50

1. Process requirement i.e. proper interconnection between equipment as per P& IDs to achieve the intended process parameters. The indicative Equipment Layout by PMC only provides a suggested equipment layout that conforms to accepted good practice and incorporates the critical relationships between major equipment that affect process performance. 2. Economy of Piping material - Minimize the quantity of costly piping. 3. Erection & Construction requirement: Erection scheme and schedule of all equipment must be considered during equipment layout to have smooth erection mainly in case of tall columns, heavy equipments like thick walled reactors, approach road for cranes/ derrick for lifting the column or reactors and requirement of special foundation/pile etc. 4. Safety Requirements including fire fighting, and hazardous area classification, Access stairways in the platform/Technological structures. 5. Petroleum Rules, OISD Standard guidelines shall be followed. Fire fighting facility shall be as per TAC and OISD norms. Safety shower location shall be marked in equipment layout. The relevant standards are to be followed for preparation of hazardous area drawings.

6. Operation and Maintenance requirement as mentioned below: Overhead and side clearances for exchangers and pumps Provision of exchangers - tube bundle pulling area Horizontal and overhead clearances for easy movement of working personnel Crane approaches for air coolers / fired heaters Provision for catalyst loading / unloading facilities Provision for monorail for pumps and exchangers Provision for EOT / HOT crane for compressors Provision for operators cabin

7. Similar equipment grouping All columns, exchangers, pumps etc. shall be grouped together for convenience of maintenance and safety wherever feasible. 8. The technological structures should be interconnected for easy movement of operational personnel. 9. All areas requiring crane access in erection/maintenance of equipments, catalyst loading etc. shall be marked on the equipment layout. 10. U/G piping corridors for main headers should be marked in equipment layout for all underground piping. 11. Fire proofing requirements in pipe racks, structures & supporting equipments. 12. Eye wash & shower locations, Utilities stations.

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 5 of 50

3.1.3

PIPE RACK In general, equipment layout shall be prepared considering straight pipe rack, however other shapes like L/T/U/H/Z etc can also be considered based on area available. The total width of pipe rack shall include 30% extra space or 1.5m (min) for future modifications in unit at later stage at all levels/tiers. The width of the rack shall be 6m, 8m or 10m for single bay and 12M, 16M or 20M for double bay having 4 tiers maximum. For interconnecting pipes to different units, existing pipe racks to be expanded wherever possible considering foundation and column design. The spacing between pipe rack portals shall be taken as 6m in general. However it can be changed to suit intra units distances. Each bay between two passing columns shall have secondary structural members at a span of 3m to enable supporting of small bore lines. Pipe racks shall be fireproofed, as per OISD Codes with provision of insert plates in supporting auxiliaries. 1

Clearance beneath pipe rack shall be 4.5m minimum Road Clearance shall be 9m minimum for main road. Secondary road clearance shall be 5m. Dia. 20 rod above Sleeper/Pipe rack to be made of CS. Deleted. Corrosion wear pads shall be provided for all the lines at support locations.

3.1.4

REACTORS The reactor superstructure structural steel columns shall be placed in line and symmetrically so that piping routing is shorter, easier, and economical and the whole area looks aesthetically laid out. Maintenance access required near the reactor structure is mainly for catalyst loading and unloading. Stairway is provided for the reactor structure since the structure goes high and is frequently used by operators. Emergency escape ladder shall also be provided. Depending on the type of catalyst loading system i.e. fixed or mobile or as indicated in Process Licensors Package; make space allocation in the layout as required. The paved areas at grade will extend around catalyst unloading / loading areas Since reactors are heavily insulated, insulation to be shown on equipment layout drawing. Reactor shall have davits to handle top man way covers and its piping.

Jacobs
HPCL, Mumbai LSTK 44LK 5100
3.1.5 REBOILER Reboiler shall be located next to the tower they serve. The elevation of Reboiler shall be as given in the P&IDs. Horizontal thermo-siphon exchangers are located at a minimum elevation. Vertical thermo-siphon types are usually supported by the tower and are located on the backside to be accessible for maintenance. Large vertical types, which cannot be supported from the tower/ column, may require a separate supporting structure. As far as possible they shall not be mounted on springs to take care of differential expansion. No platform/ piping to obstruct removal of vertical Reboiler with the help of crane. Vertical Reboiler will require guides, where length/ diameter exceed 6.0 m. Reboiler piping shall be checked for pressure drop before finalization of the same. Clear crane access shall be provided for maintenance of unfired type re-boilers including piping elements like 3-way valve etc.

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 6 of 50

3.1.6

HORIZONTAL VESSELS The Horizontal vessels shall be laid perpendicular to pipe rack and dished end shall be placed minimum 4 m away from the pipe rack. The clearance between horizontal vessel shells shall be minimum 2m or 900 mm clear aisle whichever is higher. The aisle minimum 900mm/OISD as specified should be clear of any piping or instrument element (like LS, LG etc.) All the inter equipment distances shall be as per OISD std. High-pressure vessels shall be aligned with their dished ends facing away from the plant. The chemical vessels to be located close to the dosing pumps to the extend possible.

3.1.7

TOWERS AND VERTICAL VESSELS Towers and vertical vessels shall be arranged in a row with common centerline, decided by largest vessel, placing O.D of the equipment minimum 4m away from pipe rack. A minimum clearance of 3m shall be maintained between tower shells, but in any case, minimum 100mm horizontal gap shall be provided between platforms of adjacent towers. A minimum of 900mm clearance shall be provided between tower plinths. A davit is required to be provided to handle the heavy items (like relief valves, blinds, covers etc.) The davit shall be on the side of column/vessel away from pipe rack. The area at grade level to be kept clear for dropout. Efforts shall be made to provide interconnecting platforms at suitable levels for adjacent towers, considering thermal expansions of towers. All level switches, LG etc. including their isolation valves, shall be accessible from ladders / platforms. Chemical vessels shall be located close to the dosing point to the extent possible.

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 7 of 50

3.1.8

PUMPS Clearance between two adjacent pumps shall be such that clear 1000mm aisle is available. Wherever practicable, pumps shall be arranged in rows with the centerline of the discharge on a common line; in general pumps shall be kept outside the pipe rack only with motor facing opposite to equipment. All pumps not open to sky, with motor rating 75 KW and above, shall be provided with monorail under pipe rack / shed. Clearance between two adjacent pumps shall be such that clear 1000mm aisle is available. Pumps shall not be located within bunded (dyked) tank areas. Hydrocarbons process pumps shall not be installed beneath equipment containing flammable or combustible liquids other than unit pipe racks, unless special fireproofing and fire fighting precautions are taken, like water spray system. All process pumps handling class A fluid shall be provided with water sprinkle/spray system

3.1.9

EXCHANGERS In most of the cases floating head of exchangers shall be placed on a line 4 m away from pipe rack. Shell and tube type exchangers may have a removable shell cover with flanged head. Tube pulling or rod cleaning area must be allowed at the channel end. This shall be minimum tube bundle length + 1.5 m from the channel head. One number of tube bundle puller (common) to be considered in all the exchangers. Minimum clearance in between two horizontal exchangers shall be 2.0 m or 900 mm clear aisle whichever is higher. The minimum clear aisle specified between the exchangers i.e., 900mm, shall be clear from any piping element and instrument including probes of thermocouples. Likewise Heat Exchanger train should be suitably spaced such that shell / tube inlet/outlet piping do not foul with floating head covers. Monorails to be provided for tube bundle removal for all exchangers except for those, which are open sky. Davits to be provided for floating head cover for all exchanger. Elevation of exchangers shall be kept to minimum but shall be of sufficient height to allow drainage from low points of exchanger piping. Clear access shall be provided for the OWS and CBD valves of the exchangers. No piping element like CBD / OWS valves shall be located on grade directly below the channel cover and shell cover. The roof height of the technological structure shall be sufficient to allow erection of exchangers (including stack type) by crane. On technological structure- monorail with chain pulley block will be provided for exchanger bundle removal.

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 8 of 50

3.1.10

FIN FAN EXCHANGERS/ AIR FIN COOLERS Fin Fan Exchangers / Air Fin Coolers shall preferably be located over the main unit pipe rack. Suitable access for maintenance shall be provided. For air coolers located on technological structure/rack, pipe concrete blind floor shall be provided below the air coolers. Blind floor is generally not required if pumps handling hydrocarbons or equipment are not placed below them. Pumps handling hydrocarbon, shall not be placed below the air fin coolers. The width of the structure from where Air Fin Exchanger assembly is supported shall be about 2m more than the Air Fin Exchanger tube length so that supporting of piping manifold (inlet / outlet) can be done from the main member of pipe rack / technological structure, thus transferring the load to main structural members. Monorail shall be provided at one end of air cooler platform area for lowering the gearboxes. Following access shall be provided for air coolers mounted on pipe racks : Service platform to access the flanged inlet/outlet nozzles Plat forms to servicing the Fan, Drives, Gears etc. below to Air coolers. All platforms /walkways shall be supported from air cooler structure

Jacobs
HPCL, Mumbai LSTK 44LK 5100
3.1.11

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 9 of 50

FURNACES/FIRE HEATERS When the hydrocarbon being handled is above its auto-ignition temperature in process, equipment may be located close to the heater and adequate access for maintenance and adequate fire protection to be provided. This is done to reduce high hazard spreading within the plant Furnaces/Fire Heaters shall be located upwind or side wind of process units to blow any combustible leaks away from the open flame. They shall be located minimum 90 m away from tanks and 30m away from control room. Distances for equipments handling hydrocarbon from the heaters shall be strictly as per OISD norms. Vessels/ reactors/ columns directly connected to heater (if required as per P&ID) are exception. Heaters shall be arranged with centerline of the stacks on a common line in case of circular heater and wherever a common stack is furnished to cater more than one heater the stacks shall be located at the end or side, which is away from the unit. In case of individual box heater, the edge of the heaters on the rack side shall be matched. The stack height governed by the clearances from statutory authorities like Director General of Civil Aviation and Pollution Control Board or any other safety norms whichever is stringent. For maintenance, vertical tube heater must have access to permit a crane to remove and replace tubing. Horizontal tube heater must have horizontal free space equal to tube length plus crane parking space for tube pulling /maintenance/cleaning. In case of bottom floor fired heaters, there shall be adequate headroom clearance underneath furnace for removal of burners. In case of wall fired heater min 2m wide platform with escape route at each end is necessary. Pits and trenches are not permitted under heater or any fired equipment. Underground drain points and manhole covers shall be sealed within heater vicinity. Furnaces shall be provided with platforms for operation and for access as follows - For maintenance of soot blowers - For burner operation when inaccessible from grade. - For observation door, except that when the doors are located less than 3600mm, Above grade. Access shall be by ladder only When temporary platforms for header boxes containing removable plug fittings Are required, only the platform supports are to be provided. For analyzer and sample points etc

3.1.12

COMPRESSORS AND THEIR PRIME MOVERS Two major types of compressors are used in process plants. Centrifugal Compressors Reciprocating Compressors

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 10 of 50

Compressors shall be located to keep suction lines as short as possible. Drivers for compressor may be electric motor or steam turbines as per P&ID. The gas Compressors shall be located downwind side of furnace so that leaks are not blown towards the furnace. In general Compressors are kept under shed. When Compressors are kept under shed, sides are fully open for the low shed or partially closed from top for high shed to avoid accumulation of heavier gases in the shed. Layout of the compressor shall facilitate maintenance space for removal of motor, piston etc. In case of a turbine driven compressor, if exhaust steam is condensed, turbine and compressor are located at an elevated level and condenser is located below turbine. A major consideration in centrifugal compressor location is the lube and seal oil console. It must be accessible from a road, must be lower than the compressor to allow gravity drain of oil to the consoles oil tank. Intercoolers are placed near the compressor and are kept within the shed. Knockout pots and after coolers may be kept outside the shed but near compressor house. For compressors, one electrically operated traveling (EOT) crane to handle heaviest removable piece shall be provided for each compressor house. Maintenance bay for compressors shall be provided. Maintenance bay shall be accessible from road to facilitate unloading of load on to truck etc. For removal of exchangers located within building monorail arrangement shall be provided. The layout of compressor house shall take into consideration process licensors requirement as well as compressor manufacturers

3.1.13 3.1.13.1

CLEARANCE AND ACCESSIBILITY Crane Access & tube bundle pulling Equipment, structures shall be arranged to permit crane access to service air coolers, Compressors and exchangers. All exchanger tube bundles shall be "jacked out" against shell. A clear space for tube bundle removal shall be provided. Dropout bay/area may be considered for exchangers located at elevated structure. Provision for pulling and inserting of tube bundle to be provided. Monorail with chain-pulley shall be provided for all heat exchangers except on grade & open to sky For high-pressure exchangers, shell pulling on rails may be considered with prior approval of PMC / OWNER.

3.1.13.2

Access to Pumps Clear access of 3.8 m vertically and 4 m horizontally shall be provided centrally under main pipe ways for small mobile equipment to service pumps, wherever these are located under pipe rack. Pumps outside the rack shall be approachable by small cranes from under the pipe rack.

3.1.13.3

Access to lowering items to grade level (Lowering Area) Clear access shall be provided at grade on the access side for lowering external and internal fittings from tall elevated equipment by providing pipe davits.

Jacobs
HPCL, Mumbai LSTK 44LK 5100
3.1.13.4 3.1.13.4.1

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 11 of 50

Layout & access requirements for Platforms Ladders and Stairs For providing platform ladder & staircase following guidelines shall be followed: Two means of access shall be provided (i.e., two ladders or one ladder and one stair case) at any elevated platform, which serves three or more vessels and for battery limit valves / operating platform. Platforms, Ladders and stairways shall be the minimum, consistent with access and safety requirements. Stairways for tanks to be provided on upstream of predominant wind direction

3.1.13.4.2

Platform at elevated structure: Unless otherwise mentioned dual access (i.e. one staircase and one ladder) shall be provided for structure having length up to 22.65 m (75ft). For large elevated structure, if any part of platform has more than 22.65 m (75 ft) of travel, it shall have staircases on both sides. Also, based on height and levels of operating platform/technological structures, stairways shall be provided on both sides. Fire heaters located adjacent to one another shall have inter-connecting platform at various elevations. Fire heaters shall have minimum two stairways- access from grade level and will extend up to highest level of operating platform of the heaters. Air coolers shall have platforms with interconnected walkways provided to service valves ,Fan motors ,Instruments etc. Location at which normal monitoring (once a day or more) is required or where samples are taken shall be provided with stair access. Items that require occasional operating access including valves, spectacle blind and motor operated valves; heater stack sampling points shall be provided with ladder access. Columns and technological structure shall be interconnected by walkway. All nozzles of columns to be provided with ladder access. No ladder shall be more than 6m in one flight (Refer Annexure A for accessibility guidelines.)

3.1.13.5

Clearances Minimum clearances shall be as indicated in Annexure B.

3.2 3.2.1

PIPING MODELING AND GENERAL ARRANGEMENT BASIS OF 3D MODELING (ISBL)

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 12 of 50

Piping and Instrument Diagram, Inter connecting P&ID. Equipment layout Piping Specification and cats & specs Line list Instrument data sheet & vendor drgs The following objective shall be ascertained during piping modeling Proper access to all operating points including valves and instruments. (Refer Annexure A) Proper access to inter-related operating points for specific purpose. Economic routing with minimum bends and flanges Aesthetics

3.2.2 3.2.2.1

UNIT PIPING Basis of Piping Piping and Instrument Diagram Equipment Layout Equipment Data sheet and Setting plan Line list Instrument Data sheet Structural and Building drawings Topography of the plant Piping material specification Overall plot plan

Proper access to all operating points including valves /instruments and for maintenance purpose shall be considered during piping layout.

3.2.2.2

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. The entire Tie in points are to be clearly studied and identified so as to avoid any unnecessary crossing and jump over of pipes. 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 and Instrument cable trays.

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 13 of 50

Generally the hot lines and cold lines shall be kept apart in different groups on a tier. Generally the bigger and heavier size lines shall be kept nearer to the column. Spacing between adjacent lines shall be decided based on O.D. of bigger size flange (min 300# flange), O.D. of the smaller pipe, individual insulation thickness and additional 25 mm clearance, preferably. Wherever even if the flange is not appearing the min. spacing shall be based on above basis. 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 have to be located in an overhead pipe way, staircase access to a platform above the lines shall have to be provided. Provision of block valves, blinds etc. shall be as per Process Design Basis & P&IDs.

3.2.3 3.2.3.1

PIPING Design Pressure : The design pressure of each line is the maximum non-shock internal service pressure. This pressure corresponds with maximum of: 1.1 times the maximum operating pressure. Design pressure of equipment to which it is connected. The pressure setting of the relief valve that protects piping system. For liquid lines, static head between lowest point and safety valve also to be added. The pump shut-off pressure or a compressors maximum discharge pressure for system with no relief valves or 1.2 times differential pressure plus suction pressure for discharge lines. The static plus pressure head for system on the suction side of pumps. In cases where a pump discharge line includes a control valve, but no relief valve that portion of line from the pump through the control valve, including all valves in the control valve manifold; shall have the same design pressure as the pump shut-off pressure. All lines operating below atmospheric pressure shall be designed for full vacuum. Lines which normally do not operate in vacuum but vacuum can develop in abnormal condition shall also be designed for vacuum. All piping leaving Battery limit shall be designed for a closed valve outside the Battery Limit. Higher design pressure shall apply from the source to the last valve before entering equipment rated at a lower pressure. Process shall decide design pressure of pipe line.

Jacobs
HPCL, Mumbai LSTK 44LK 5100
3.2.3.2 Design Temperature The design temperature shall be maximum sustained fluid temperature in line. All the lines subjected to steam-out conditions shall be designed at 120 (process line data) or C as per process Design temperature of the line whichever is higher. The design temperature of piping may be the same as the design temperature of connecting upstream equipment if the difference between the operating temperature and design temperature is less than or equal to 20 C. If there is large difference between design and operating temperature, duration and frequency of process fluid attaining higher temperature shall be considered. For steam traced piping, design temperature shall be fluid temperature plus 20C or 10 C below steam saturation temperature whichever is higher. For low temperature (operating temperature is either lower than 0 C or lower than minimum ambient temperature) design temperature shall be minimum operating temperature of the fluid. Metal temperature resulting from emergency conditions like depressurization, operation errors etc. need to be taken care of. Process will decide all the design temperatures of pipeline.

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 14 of 50

3.2.3.3

Loads & Supports The piping system shall be designed to resist the efforts of loads imposed by the weight of the pipe, valves, fittings, insulation and fluid in the lines. When this fluid is air, gas or vapour, and the line is to be Hydrostatically tested, temporary support may be required. The additional loads imposed by wind shall be considered for large lines (18" and above). The wind pressure is spelled out elsewhere in bid document. The discharge of reciprocating compressors, pumps, HP safety valves and let down valves and other lines which are likely to pulsate and vibrate shall be properly designed and supported to avoid undue vibrations and forces/moments on piping, supports and connected equipment/machinery. Downstream of control valves, safety valves blowing to atmosphere which can attain some velocities shall be so designed to take care of the same and noise shall not exceed 88 dba at operating levels, by using diffusers, silencers etc. The stresses created by the imposed loads shall not exceed the allowable stress prescribed by the ANSI B 31.3 Code for pressure piping where applicable or the ASME boiler code and should also meet the requirements of IBR wherever applicable.

3.2.3.4

Corrosion Allowance The minimum corrosion allowance in general shall be as given below: Carbon Steel Alloy Steel Austenitic Steels Non-Ferrous Alloys 1.5 mm (1/16") 1.5 mm (1/16") 0.0 mm 0.0 mm

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 15 of 50

For corrosive services corrosion allowance for material shall be adequately designed to give a life of at least 20 years. Exception to these shall be only with PMC/owners approval.

3.2.4

COLUMN / VESSEL PIPING Piping from column shall drop or rise immediately upon leaving the nozzle and run parallel and 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 road side of the column and approachable from the platform. Projection of platform shall be 1.0m up to 1.0m diameter column and 1.2m for column diameter > 1m from column insulation surface Piping shall be supported from cleats welded on the vessel as far as possible. Proper guides at intervals shall be provided for long vertical lines. For ease of operation and maintenance, column and vessels, which are grouped together, shall have their platforms at the same elevation should be interconnected by walkways. However each Column/ Vessel shall have independent access also. Column/ Vessel platform should be designed in such a way so that all nozzles should be approachable from platforms. Piping support cleats shall be designed for safety valves considering impact loading during popping off. Complete platform all around shall be provided in case of columns, at all manhole locations. Maximum height of platform ladders shall be restricted to 6 meters. Davit shall be provided on top of all columns for handling safety valves, Top curves etc.

3.2.5.1

EXCHANGER PIPING Exchanger Piping shall not run in the way of built in or mobile handling facilities. Wrench clearance shall have to 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.

3.2.5.2

HEATER/FURNACE PIPING Arrange piping to permit burner removal by providing break up flanges in the piping. Burner valves shall be located close to peepholes for operation. Piping to Burners shall be arranged in such a way so as to give equal and sufficient quantity of oil/gas to all burners. Only flexible metallic SS (SS316/SS321) hoses shall be used for burner piping

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 16 of 50

Block valves for emergency, snuffing steam valve shall be located minimum 15 m away from the heater, preferably on the upwind side of the heater. 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 towards column 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. Nozzle forces and moments to be as per API 560 All furnaces if they are located in the same area should be inter connected with each other at different elevations. 3.2.6 PUMP PIPING Pump drives shall have clear access. Pump suction piping shall be as short as possible and shall be arranged with particular care to avoid vapor pockets. Reducers immediately connected to the pump suction shall be eccentric type 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 have to 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. When a suction vessel operates under vacuum, the vent connection of the pump has to be permanently connected to vapor space of the suction vessel to allow possible filling of the pump with liquid before it is started. T-type strainers are to be used for permanent as well as temporary to avoid disassembly of suction piping for strainer cleaning for sizes 2" and above. Y-type strainers are to be used for all sizes in steam services and for pump suction lines 1" and below All small-bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain) shall have provision for break up flanges for removal of pumps. Piping shall be so arranged that forces and moments imposed on the pump nozzle do not exceed the allowable values. Pump discharge should preferably be routed away from pump rather than towards the motor side. For top suction, pump elbow shall not be directly connected to suction flange. A straight piece of minimum 5 times the nozzle size shall have to be provided at the suction nozzle. Pump cooling water connection shall be taken from the top of the circulating cooling water header. PI (pressure gauge) connections shall be provided on upstream and downstream of valves in suction and discharge lines for all process pumps. 3.2.7 COMPRESSOR PIPING

Jacobs
HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 17 of 50

Suction lines shall be as short as possible Suction piping shall have adequate flanged joints for ease of erection and maintenance. All operating valves on main suction and discharge piping shall be lined on one side as far as possible. A minimum straight length of suction pipe is to be provided as per manufacturers recommendation. Piping shall be designed so that forces and moments imposed on the compressor do not exceed the manufactures recommendation. Compressor suction lines between the knockout drum and the compressor shall be as short as practicable & shall be without pockets. Where the line between knockout drum and the compressor cannot be routed without pocket, low point in compressor line shall be provided with drains to remove any possible accumulation of liquid, but after taking clearance from process licensor. 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 drains. Compressor suction and discharge shall have untied bellows. The bellows are to be supplied by compressor manufacturer as per design calculations and bellows selection done as per stress analysis. All the valves and spectacle blind in suction and discharge piping shall have operating and maintenance access.

3.2.7.1

Piping arrangement for Centrifugal Compressors Suction and discharge piping should preferably be routed at grade level to have a proper supporting of these lines. 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.

3.2.7.2

Piping arrangement for Reciprocating Compressors Trenches, pits and similar gas traps 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 JEs standard specifications. Also process licensors specifications/requirements shall be fulfilled.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 18 of 50

It is very important to route all suction and discharge piping of the compressor as close to grade level (min 500mm above grade) 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.

3.2.8

PIPING ARRANGEMENT FOR REACTORS 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 cleats are provided. Generally reactor shell clips / cleats are to be avoided. Reactor with top man way nozzle for catalyst charging is provided with a flanged elbow Nozzle on this man way to connect outlet piping. This flanged elbow nozzle is to facilitate spool removal during catalyst charging. Piping connected to reactor top outlet nozzle needs to be additionally supported from structure. (This support acts temporarily) since this connection to man way is 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. All valves provided on reactor hydrogen service lines be it inline, vent, drain and instrument valves shall always be double blocked type. Also snuffing steam rings shall be provided around hydrogen service flanges size over 12". For reactor process piping where spec. calls for ring joint flanges the piping shall be arranged so as 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.

3.2.9

RELIEF SYSTEM/ BLOW DOWN SYSTEM PIPING Relief of liquid and easily condensable hydrocarbons is to be discharged to closed blow down system. Wherever the inlet line size is higher than the safety valve inlet size, reducer shall be installed adjacent to inlet of safety valve. Relief valve discharging steam, air or other non-flammable vapor or gas directly to atmosphere shall be equipped with drain or suitably piped to prevent accumulation of liquid at valve point. Relief valve discharge piping to atmosphere shall be taken to safe location as per following.

Jacobs
HPCL, Mumbai LSTK 44LK 5100
3m 25 m 50 m -

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 19 of 50

Above top platform of column or structure within 6m radius for steam and 8m for hydrocarbon/ toxic discharge. Horizontally away from Reformer Or any fired equipment. Horizontally away from furnace, if more than 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. Reaction forces due to safety valve popping shall be ascertained in the connected piping. The effect of these forces on the piping supports and the anchors of the piping system shall be calculated to ascertain that the allowable limits at these locations are not exceeded. The supporting structure also shall be adequately designed so that when subjected to these System stresses in the inlet and outlet piping portions At safety valves also shall be kept within the allowable limits, inclusive of the distribution branching points in the inlet portion. These reactive forces shall not lead to any leakage at the flanged joints present in the system. To ascertain these necessary calculations at the flanged joints shall be performed.

3.2.10

STEAM PIPING Steam lines with conditions listed below fall in the scope of Indian Boiler Regulations (IBR). All lines falling under IBR purview must comply with IBR requirements. Lines having design pressure (maximum working pressure) 3.5 Kg/cm (g) & above Line sizes 10" inside diameter & above having design pressure 1.0 Kg/cm (g) & above Lines with pressure less than 1.0 Kg/cm2 (g) are exclusion. User of steam like steam tracing lines, jacket of the steam jacketed lines, steam heating coil within the equipment are excluded from IBR scope. All steam users where downstream piping is connected to IBR i.e. condensate flushed to generate IBR stream are covered under IBR Boiler feed water lines to steam generator, condensate lines to steam generator and flash drum as marked in P&ID shall be under purview of IBR. IBR Requirements (in brief) All materials used on lines falling under IBR must be accompanied with IBR Inspection Certificate, Leading Inspection authority viz. Lloyds or others are authorized inspection authorities for IBR outside India. Whereas for Indian supply only IBR is the inspection authority. IBR authority of state in which the system is being installed must also approve drawings like General Arrangement Drawings (GAD) and isometrics of lines falling under IBR. All welders used on fabrication of IBR system must possess IBR welding qualification certificate.
2 2

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 20 of 50

IBR system must be designed according to IBR regulations. IBR authority must approve all design calculations towards the same.

3.2.11

STEAM HEADER & SUPPLY LINES Steam header shall be located generally on the upper tier and at one end of the rack adjacent to columns. Branch lines from horizontal steam header, except condensate collection points, shall be connected to the top of the pipe header. Isolation valves if provided on the branch line shall preferably be provided on the horizontal run and outside the pipe rack. All branch lines shall be drainable. The Tapings on the headers shall have Gusset supports. Drip legs & steam traps shall be provided at all low points and dead ends of steam header. Drip legs at low points shall be close to down stream riser and shall be provided to suit bidirectional flows, if applicable. The first isolation valve on Drip leg (Boot leg) outlet shall be piston type glandless and butt welded type. All turbines on automatic control for start up shall be provided with a steam trap in the steam inlet line. All traps shall be provided with strainers if integral strainers are not provided. Steam traps discharging to atmosphere shall be connected to storm water drain/storm sewer. Expansion loops are to be provided to take care of the expansions within units. Line traps shall be thermodynamic type up to Class 600# & bimetallic for piping Class 900# & above. Double block Vents and drain valves shall be provided on high-pressure steam piping. Small size steam valves upto 1 inch NB to be piston type glandless valves. Wherever condensate is to be drained, proper condensate draining facility shall be provided. Discharge of steam traps should not be near the vicinity of any Process / utility lines. Proper drainage facility must be envisaged for the condensate drain.

3.2.12 3.2.12.1

Steam Tracing/Steam Jacketing Steam tracing system (If applicable)

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 21 of 50

Tracers for the individual lines shall be supplied from manifolds when there are two or more connections. Standard module for steam distribution and condensate collection manifolds with integral glandless piston valve and thermostatic steam trap shall be used. Balanced Pressure thermostatic steam trap with 40 mesh strainer to be used. Number of Mech. Mant. Point tracers shall be 4/8/12 and tracer size or depending upon the detail enggrequirement. 20% or minimum 2 nos tracer connections shall be kept spare for future use for both steam supply and condensate collection manifolds. All manifolds shall be installed in vertical position and manifold size shall be 1.5. For Steam tracing balanced pressure thermostatic steam trap with 40 mesh strainer to be used. Manifolds shall be provided with two spare blanked off connections. Maximum number of connections taken from a manifold is 12 including spares. Manifolds shall be accessible from grade or from a platform. Pockets in steam tracers shall be avoided as far as possible. Tracers shall be limited to the following run length upstream of traps.

Size of tracer (inch)

Length of tracer pipe (Meters) Steam operating pressure 20psig 50psig 38 100psig 46 150psig 53 200psig above 61 &

"

23

Tracers shall generally be of . Tracers shall be of CS steel seamless pipe and valves on the steam tracing circuit including steam station block valve shall be glandless piston valve. Size of the lead line to manifold shall be as follows: Number of connections 2 3 4-6 7-12 Size of Lead Line 1 1 2

The lead line to manifold, manifold up to the block valves of individual tracer shall be carbon steel of IBR quality. Tracer lines shall be provided with break up flanges for main line flange joints and valves. All tracers shall have individual steam traps before condensate manifolds. Condensate manifold including the last valve on individual tracer shall be of carbon steel. All steam traps discharging to a closed system shall have a block valves upstream and downstream of the trap. A bypass globe valve shall be installed around the trap. Check valve

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 22 of 50

shall be installed on the downstream of the steam trap near the condensate header in case discharging to a closed system. All steam tracer lines shall be welded as per approved Welding Specification followed by hydro test. All steam tracer lines up to 1-1/2 size shall be welded using GTAW welding process followed by hydro-test.

Number of tracers required on a line shall be as follows: Size of Line Up to 4 6 to 16 18 to 24 26 & above Number of Tracers 1 2 3 To calculate

3.2.12.2

Steam Jacketing System (If applicable) A Steam Jacketed pipe consists of a product line, which passes through the center of a larger diameter steam line. The normal size of the inner pipe (CORE) and outer pipe (JACKET) in inches shall be as per table below unless otherwise mentioned in project piping material specification (PMS) or P&ID. Core pipe will be of SS material only. Core pipe 1 1 2 3 4" 6" 8" 10" Jacket pipe 1 2 3 3 4 6" 8" 10" 12"

Distance between steam inlet and condensate outlet shall be similar to steam tracing system. Baffle plates, flanged joints or end caps shall be used to discontinue one feed length from the next. The size of steam feeder to jacket shall be generally " or as specified in job specification.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 23 of 50

Flanged jumpovers shall be used in case of Flanged joint. In case of discontinuous jacketing simple jumpovers shall be employed. The length of jacket shall be 4 to 5 meters or as mentioned in job specification. Intermediate partial baffles shall be provided if a separate branch portion is to be heated from the main line stream. Steam inlet to jacket shall generally be provided from top of the pipe in case of horizontal lines. The jumpovers and condensate outlets shall be from the bottom. In case of vertical lines steam inlet shall be done at the topmost points and condensate outlet shall be done from the lowest possible points. Two consecutive jumpovers shall be 180 deg apart. Each feed length shall be provided with individual trap before connecting to condensate recovery headers. Balanced pressure / bi-metallic type thermostatic steam traps shall be used in jacketing as well as steam tracing. To keep proper concentricity between core and jacket pipe internal guides (rods or flat bars) shall be provided at intervals depending on the size of the pipe. Wherever anchors are provided on jacket lines proper interconnection of jacket pipe and core pipe shall have to be provided with proper Jumpovers for steam. 3.2.13 UTILITY STATIONS Requisite number of Utility Stations shall be provided throughout the unit to cater for the utility requirement. Utility Stations shall have two connections (one for Plant Air, one for Service Water and one Low Pressure Steam each of 1") unless otherwise specified in P&ID. All connections shall be directed downward. All connections shall have globe valve for isolation purpose. All connections shall have ends flanged with threaded nipple for hose connections. Air and water lines shall have quick type hose connection and steam line shall have flanged type hose connection. Number of Utility Stations shall be such that all equipment shall be approachable from at least one Utility Station. The approach of Utility Station shall be considered 15m all around the station location. The Utility Stations shall generally be located adjacent to pipe-rack column. The Utility Stations shall also be provided on elevated structures, operating platforms of vertical equipments etc. Operating platforms having manholes must have a Utility Station. Spares required for utility stations are generally as described in mandatory spare list . 3.2.14 FIRE FIGHTING All Fire fighting facility shall be as per OISD / TAC- fire protection manual and shall conform to the scope of work, enclosed in the BID.

3.2.15

INSULATION AND PAINTING

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 24 of 50

For Insulation, Painting and Colour coding, Engineering Design Basis provided else where in the BID, shall be followed.

3.3

OFFSITE & YARD PIPING (If applicable) Battery limit integration to the main process block shall be through multi tier pipe rack and sleepers (either existing or new). Battery limits and tie-in points to be clearly marked and shall be routed economically and as to satisfy process requirements. In general, the pipes shall be laid at grade level on sleepers of concrete 450 mm high from grade level. Pipe sleepers shall have hard surfacing. Hard surfacing should be completed before start of pipe laying. Width of hard surfacing shall be about 1m more than the piping corridor. This extra hard surfacing shall be for the movement of operating personnel along the pipe corridor. At every 500 m approach to be provided from the road for hard surfacing area. Pipe rack/portals may be used depending upon requirement, if adequate space is not available for sleepers. Modification of existing sleepers shall be done if required. The exact level shall be decided during detail engineering depending on requirements. However, existing/modified pipe rack around Unit block shall be suitably used. Pipes at road crossing shall be under culverts in general. All process lines & steam lines if required to be routed below the road, the same shall be routed through culvert at the road crossing. Overhead pipe bridges may be used for areas where pipe racks are provided with minimum clearance as per Annexure B. Clearances between lines shall be minimum "C" as given below. C = (d0 + Df)/2 + 25 mm + Insulation thickness Where. d0 = outside diameter of smaller pipe (mm) Df = outside diameter of flange of bigger pipe (mm) Adequate clearances shall be provided for very long & high temperature lines to avoid clashing at the bends. Expansion loops for all lines shall generally be kept at the same location. Vents shall be provided on all high points and drains shall be provided at all low points. Drain valve shall be suitably located for ease of operation. Drain valves at sleeper piping shall be kept outside the sleeper way. If the same is not accessible and valves shall be put in horizontal only. At all such places where piping is extended to make drain valves accessible, 2 no. of stiffeners, irrespective of pipe rating shall be provided. Spacing of guides on each line on a pipe bay shall not exceed the value given in Annexure C.

3.4

TANK FARM PIPING ( If applicable)

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 25 of 50

The number of pipelines in the tank dyke shall be kept at minimum and shall be routed in the shortest practicable way to main pipe track outside the tank dyke, with adequate allowance for expansion. Within one tank dyke the piping connected to that tank shall only be routed. Manifolds shall be located outside the tank dyke and by the sides of the road, easily accessible by the walkway. Analysis shall be carried out to prevent damage to lines and tank connection caused by tank settlement. If exceptionally high settlement is expected "dressers coupling" or "flexible ball joint" may be provided. For flexibility analysis and supporting refer clause 3.8 Special consideration shall be given as regards to spacing of nozzles while installing special item like hammer blind, Motor Operated Valves etc. Tank connections to be done after tank hydro testing. 3.5 UNDERGROUND PIPING Services for underground piping. OWS CRW Sanitary sewer system.

All underground C.S .Pipes shall be painted/ coated as per painting/coating specification provided else where in the BID. All underground C.S pipes shall be provided with corrosion resistance protection as per the specification for coating & wrapping. 1. Surface preparation: Abrasive blast cleaning SA 2 followed by Tape primer (supplied by Tape manufacturer). 2. Poly Ethylene Tape (M/s.Denso) / PVC Tape (M//s. Rustech ) 3 mm thick tape coating 3. Holiday testing after tape coating Corrosion resistance protection given to underground C.S. pipes shall extend up to 500mm above/beyond grade on both sides To the extent possible, fire water header shall be laid above ground except around process area where it shall be laid underground .In case it is to be laid U/G, it shall be laid in RCC trenches covered with pre-cast RCC slabs in RCC paved area, whereas in unpaved area it shall be laid directly buried. All underground-buried firewater piping shall be externally protected from corrosion by wrapping & coating as per the specifications provided else where in the BID.

3.6

VENTS AND DRAINS

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 26 of 50

Process Licensors requirements are to be followed for the size and type of vents and drains and all shall be as per PIDs approved by PMC. All hydrocarbon drain & vents shall have valves with blind flanges at other end. Identification marks for location /visibility of drain points of off-site piping should be provided. All drain points should be approachable and clearly visible.

3.7

FLEXIBILITY ANALYSIS AND SUPPORTING Stress Design Basis provide else where in the BID, shall be referred.

3.8

FLARE PIPING Flare header shall be sloped towards flare knockout drum. Only horizontal loop shall be provided as per requirement to accommodate thermal expansion. The desired slope shall be ensured throughout including flat loop. Flare header shall be supported on shoe of height ranging from 100 mm to 300 mm. Proper thermal analysis temperature shall be established including the possibility of temperature gradient along the line before providing expansion loops. Flare piping to offsite shall be provided with guide support on all around the pipe to prevent it falling off from the flare trestles. Flare header valve stems shall be in vertical downward position. Valves in Flare Header shall be of Gate Type only.

3.9

MATERIALS AND SELECTION OF PIPES AND FITTINGS The PMS (Piping material specifications) provided by PMC are only for reference and indicative and thus may not be exhaustive. LSTK shall update PMS given in the BID and develop detailed piping material specifications (PMS) and Valve Data sheets (VMS), based on process Licensors piping specifications, basic material depending upon service conditions (temperature, pressure and corrosively etc.) as spelt in process package.

3.9.1

Pipe Wall thickness Calculation of pipe thickness and branch reinforcement shall be based on requirements of ASME B 31.3. /IBR as applicable. Proper corrosion allowance and mill tolerance shall be considered while selecting thickness. For carbon steel and low alloy steel pipes (expect for steam tracing piping) minimum pipe thickness shall be as follows: 'S160' up to 0.75"NB, 'XS' for 1 to 2 NB 'STD' for above 2NB.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 27 of 50

For Stainless Pipes minimum pipe thickness shall be: 80S up to 0.75 NB 40S for 1 to 2 NB 10S for above 2 NB The philosophy of minimum thickness/schedule is applicable for both seamless and welded pipes. The above-mentioned minimum thickness/schedule criterion is not applicable to category -D fluid where IS pipes or welded API 5L pipes are being used. All pipes (seamless & welded) shall have uniform negative wall thickness tolerance of 12.5% for wall thickness calculations purpose, except for pipes made out of plate material, where relevant ASTM code shall govern. For thickness exceeding minimum thickness/schedule criteria, schedule XS shall be selected for CS & AS classes (for 2" & above). Intermediate schedules between STD & XS shall be ignored. Similarly for SS classes (2" & above) S10, S20, S30 & 40S may be selected beyond minimum thickness/schedule criteria. If, the thickness exceeds XS in CS & AS classes and 40S in SS classes, only then, the thickness shall be calculated based on actual service conditions subject to a minimum of 80% class rating. Maximum 10% of corrosion allowance may be reduced in special cases, to optimize the pipe schedules. In general the pressure-temperature combination to calculate wall thickness shall be as follows:

Material C.S. (A 106 GR.B, API 5L GR.B, A672) LTCS (A333 GR 6) Low alloys 1.25%Cr-05%Mo 2.25%Cr-1.0%Mo 5%Cr.-0.5%Mo. S.S. (A312 TP304, TP304L, 316L, 347) OR (A358 TP304, 304L 316,316L, 321,347)

Class 150 300 600 900 1500&2500

Pipe Size Up to 24" Above 24" Up to 14" Above 14" Up to 8" Above 8" Up to 8" Above 8" Up to 4" Above 4"

Design condition Class condition Line condition (//) Class condition Line condition (//) Class condition Line condition (//) Class condition Line condition Class condition Line condition Class condition Line condition $ Class condition Line condition $ Class condition Line condition $ Class condition Line condition

150 300 600 900,1500

Up to 24" Above 24" Up to 14" Above 14" Up to 6" Above 6" Up to 4" Above 4"

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 28 of 50
Class condition Line condition Class condition Line condition Line condition

Up to 2" Above 2" Higher Alloys 150 Up to 6 Above 6" 300 -2500 All sizes // Only if the thickness/schedule as per class condition exceeds XS. $ Only if the thickness/schedule as per class condition exceeds 40S.

2500

For other than Category D classes D/t ratio shall be restricted to generally 100(Max), up to size of 48,D is nominal dia. andt is nominal thickness. For sizes 50and aboveD/t ratio shall be decided by job engineer. For Cat-D Classes, for above ground applications D/t ratio shall be taken, as 150, t is min. calculated thickness excluding corrosion and manufacturing tolerance.

Pipe size Pipe size shall normally be ", ", 1", 1", 2", 3", 4", 6", 8", 10", 12", 14", 16", 18", 20", 24", 26", 30", 36", 40", 44", 48", 52", 56", 60", 64", 72", 78", 80".

Pipe type Material CS & LTCS, AS (except for Category D fluids) SS (Process Lines) 1 SS (Non Process Lines) CS (Category D fluids) * Except for fire water and cooling water services, for which following shall apply:1. Up to 6 NB 2. 8 NB and above 3. Less than 3 NB Seamless Welded Carbon steel ( Higher schedule )

Size Up to 14

Type Seamless

10 and Above Up to 1" 2" & Above ALL

EFW Seamless Welded Welded *

4. 3 inch NB and above - Carbon Steel (Cement Lined)

3.9.2

Fittings Type of fittings shall be equivalent to pipe type.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 29 of 50

Thickness of fittings at ends to match pipe thickness for BW fittings SW fittings shall be 3000#, 6000#, and 9000# depending on the pipe thickness S80, S160 and above S160 respectively. Up to 600# all branch connections shall be as follows, unless specifically mentioned otherwise in PMS. Up to 1" NB 2" and above Half Coupling / Tee Tee/ Pipe to pipe reinforcement pad with / without

For branch connection above 600# rating equal tee/unequal tee shall be used for all sizes. Unequal tee may be replaced by weld-o-let up to branch size of 8".

Miters shall be used in Category D service above 6"NB. For other than category D fluids in 150#, 300# classes miters may be able to be permitted for sizes above 48" only. Miters to be designed as per ASME B 31.3.However use of miters shall be minimum.

3.9.3

Flanges: Flanges: Flanges shall be as follows: Class Size 150# Up to 1" Type SW RF Remarks If non-metallic gasket used.

300#, 600#

Up to 1" 2" & above 2" & above Up to 1"

WN RF WN RF/LJ FF SO RF SW RF

If metallic gasket used. For SS LJ FF + Stub ends If used in Category D service

2" & above WN RF 900#, 1500#, 2500# All WN RTJ All flange joints on piping system including flanges on equipment, manhole, etc shall be tightened using torque wrench/ hydraulic bolt tensioner depending upon service criticality.

3.9.4 3.9.5

Gaskets. Gaskets to be provided as per service condition as mentioned in PMS. Valves SW valves up to 1 inch up to 600# ANSI Class except ball and plug valves which shall be flanged for all sizes.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 30 of 50

Flanged cast valve above 1" 150#, 300#, 600# ANSI Class BW valves all sizes-900# ANSI Class & above No CI valves to be used. Over and above requirements, other technical requirement prescribed in Annexure E shall also be adhered to. 3.10 NON DESTRUCTIVE TESTING REQUIREMENTS Depending on the severity of application, extent of NDT shall be decided. As a rule, all hydrogen, oxygen, NACE and any other lethal service shall have 100% radiography on weld joints. Castings used in these services shall have 100% radiography. For high-pressure applications i.e. 600# upward 100% radiography on weld joints shall be employed. In 100% radiography classes any fillet welds employed shall have 100% MP in CS/AS classes and 100% DP in SS classes. Category D service shall have 2% radiography. Classes in 150# for normal hydrocarbon service shall be subjected to 10% radiography and SW/Fillet weld/attachment weld where radiography is not possible shall be 10% DP/MP tested. Classes in 300# for normal hydrocarbon service shall be subjected to 20% radiography and SW/ Fillet weld/attachment weld where radiography is not possible shall be 20% DP/MP tested. All AS pipes, fittings, flanges, valves & bolts shall undergo Positive Material Identification (100%) at site. All the PMI test at construction site shall be done as per standard.

3.11 3.11.1

STRAINERS Temporary Strainers: 1" & below for all services shall by Y-type 2" & above for steam service shall by Y-type 2" & above for other than steam services shall by T-type Permanent strainers Compressor suction, cold box inlet strainers shall be cone type with reinforced perforated sheet cage design 1" & above permanent strainer shall be as per process data sheet

3.11.2

3.12 3.12.1

WELDING Applicable codes and standards All welding work, equipment for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the following requirements of the latest edition of following accepted standards and procedures. Process piping ASME B 31.3 In addition, the following codes and specification referred in the code of fabrication shall be followed for the welding specifications, consumables, qualifications and non-destructive test procedures.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 31 of 50

Welding and Brazing qualifications ASME BPV Sec IX Non Destructive Test - ASME BPV Sec V Material specification: welding rods, electrodes, and filler metals ASME BPV Sec II part C The additional requirements mentioned in this specification, over and above those obligatory as per codes, shall be followed wherever specified. 3.12.2 3.12.2.1 Welding processes Welding of various materials shall be carried out using one or more of the following Shielded Metal Arc Welding process (SMAW) Gas Tungsten Arc Welding (GTAW) 3.12.2.2 Automatic and semi-automatic welding shall be employed only with the approval of the Owner. The welding procedure adopted and consumables used shall be specifically approved. All steam tracing line to be welded with TIG welding process and subjected to hydro test prior to commissioning. A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Owner. For additional details "welding specification for fabrication of piping / welding charts shall be referred. REFERENCED PUBLICATIONS The following latest codes and standards shall be followed unless otherwise specified. ASME SEC. I ASME SEC. VIII ASME B31.1 ASME B31.3 ASME B 31.8 ANSI/NEMA SM 23 API RP 520 API Std. 560 API Std. 610 API Std. 617 API Std. 618 API Std. 661 Rules for Construction of Power Boilers. Rules for Construction of Pressure Vessels. Power piping. Process piping. Guide for Gas Transmission and Piping distribution system Steam turbines for mechanical drive service. Sizing, selection and installation of Pressure relieving devices in Refineries. Fired heaters. Centrifugal pumps for Petroleum, Heavy-duty chemical and gas industry service. Centrifugal compressors for petroleum, chemical and gas industry service. Reciprocating Compressors Air cooled heat exchangers

3.12.2.3 3.12.2.4

3.12.2.5

4.0

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HPCL, Mumbai LSTK 44LK 5100
EJMA NACE MR-0175 NACE TM0177 NACE MR0284 IBR TAC OISD OISD 118 OISD 116 OISD 113 OISD 164 IS 5572 -

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 32 of 50

Expansion joints Manufacturers Association. Sulphide Stress cracking resistant metallic materials for oilfield equipment. Laboratory testing of metals for resistance to Sulphide Stress cracking in H2S Environments. Evaluation of pipeline and pressure vessel steel for resistance to Hydrogen Induced Cracking. Indian Boiler Regulations Tariff Advisory Committee. Oil Industry Safety Directorate. Layouts for oil and gas installation. Fire protection facilities for petroleum refineries and oil/gas processing plants. Classification of area for electrical installation at hydrocarbon and handling facilities. Fire proofing in Oil & Gas industry Classification of Hazardous area (other than mines) for electrical installation.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 33 of 50

ANNEXURE A Accessibility for valves and instruments Valves, instrument, equipment to be operated Centerline of item to be operated, located less than 3.6 m above grade, 2.75m above floor or platform or 1.8m above wing platform. Nil Fixed ladder Platform Platform Platform Fixed ladder Platform Portable ladder Platform note 1 Platform Fixed ladder if above 2.2 m Fixed ladder if above 2.2 m Platform Fixed ladder Platform Portable ladder/platform Platform Platform Platform Access required Portable ladder Portable ladder Portable ladder Centerline of item to be operated, located more than 3.6 m above grade, 2.75m above floor or platform or 1.8m above wing platform. Platform Fixed ladder Platform Platform Platform Fixed ladder Platform Platform Platform Platform Fixed ladder Fixed ladder Platform Platform Platform Platform Platform Platform Platform Platform Fixed ladder Portable ladder Portable ladder

Exchanger heads Oper. Valves 2" & smaller Oper. Valves 3" above Motor operated valves Control valves Relief valves 2" & smaller Relief valves 3" & above Block valves 2" & smaller Block valves 3" & above Battery limit valves Pressure instrument Temperature instrument Sample points Gauge glasses Level controllers Process blinds and spades 2" & above Process blinds and spades 3" & above Man ways / manholes Manholes / inspection holes Nozzles Vessel vents Line drains & vents Orifice flanges

Note: - 1. Centerline or 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.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 34 of 50

ANNEXURE B CLEARANCES Equipment, Structure, Platforms, Piping & its supports shall be arranged so as to provide the following clearances. A 1. 2. 3. 4. 5. B. 1. 2. 3. 4. 5. 6. 7 8 C 1. OVERHEAD CLERANCES Over rail roads, top of rail to bottom of any obstruction. Over plant roads for major mobile equipment Over grade & bottom of pipe (inside battery limit) Over walk-ways, pass-ways obstruction and inside building & platforms to nearest 9m 9m 4.5 m 2.2m 1.5 m

Over Exchangers at Grade, shell cover channel end. HORIZONTAL CLEARANCES Between Exchangers (Aisles between Piping). Around Pumps (Aisles between piping) Fired heaters to pumps handling flammable stock Fired heaters to other flammable containing equipment and closely associated with heaters. At driver end of pumps where truck/fork lifter access is required. At driver end of pumps where truck access is not required. At shell cover end of exchangers at grade, for access way Between shells of adjacent horizontal vessels EQUIPMENT SPACING Small size pumps (13.7 KW & Less)

0.9 m or 2m centre to centre whichever is higher 0.9 m 15 m 15 m 4m 1.8 m 1.3 m 2.0 m or 0.9m clear aisle whichever is higher

Mount on common foundations suitable centre to centre distance. 0.9m clears Aisle between associated piping. 0.9m clears Aisle between associated piping. 0.9m clears Aisle between associated piping.

2.

Middle size pumps (22.5 KW & Less)

3.

Large size pumps (Above 22.5 KW)

4.

Exchangers and other equipment on structures

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 35 of 50

D 1.

PLATFORMS TOWERS, VERTICAL & HORIZONTAL VESSELS i. ii. Iii iv. v. Distance of platform below centerline of manhole flange-side platform. Width of manhole platform from manhole cover to outside edge of platform Platform extension beyond centre line of manhole side platform. Distance of platform below under side of flange Head platform Width of Platform from three sides of manhole Head platform 0.9-1.05 m 1.0 m 1.0 m 1.75 m 0.75 m

2.

HORIZONTAL EXCHANGER i. Ii Iii Clearance in front channel or Bonnet flange. Heat exchanger space. tube bundle removal 1.3 m Bundle length + 1.5 m 0.1 m

Min. clearance from edge of flanges.

3.

VERTICAL EXCHANGER i. Distance of platform below top flange of channel on bonnet. 1.5 m

4.

FURNACES i. Ii Width of the platform at side of horizontal and vertical tube furnace. Width of the platform at ends of horizontal tube furnace. 2.0 m Min. 2.0 m Min.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 36 of 50

ANNEXURE C Vertical and Horizontal Guide Spacing

Pipe Size (Inch)

Guide Spacing in meters Vertical Horizontal 6 6 6 12 12 12 12 18 18 18 18 18 18 18

1 1 2 3 4 6 8 10 12 14 16,18 20 24 26 and above

6 6 6 8 8 8 8 12 12 12 12 16 16 16

Notes:

These spacing may be varied to suit column spacing of rack. The above spacing is for straight runs of pipe and does not include guides, which are used for control of thermal movements, as decided by stress group. The guide spacing given in the above table is indicative only.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 37 of 50

Pipe Size Inch

SCH. THK mm

PIPE-VAPOR INSULATION BASIC SPAN (L) m


Up to 175 C 176 to 345 C 446 C to 400 C

ANNEXURE D Table of Basic Span PIPE-LIQUIDINSULATION BASIC SPAN (L) m


Up to 175C 176C to 445C 346C to 400C

BARE PIPE EMPTY

BARE WATER FILLED

PIPE Pipe Size Inch

SPAN (L) m

Weigh t Kg/m

SPAN (L) m

Weight Kg/m

1 1 2 2 3 4 6 8 10 12 14 16 18 20 24 1 1 2 2 3 4 6 8 10 12 14 16 18 20 24 1 1 2 2 3 4 6 8 10 12 14 16 18 20 24

SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 SCH 40 3/8" w 3/8" w 3/8" w 3/8" w 3/8" w 3/8" w SCH 80 SCH 80 SCH 80 SCH 80 SCH 80 SCH 80 SCH 80 SCH 80 " w " w "w "w "w "w " w " w 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S

3.5 4.5 5.0 5.5 6.5 7.5 8.0 10.0 12.0 13.5 14.5 15.0 16.0 17.0 18.0 20.0 3.5 4.5 5.0 6.0 6.5 7.5 8.0 10.5 12.0 13.5 14.5 15.0 16.0 17.5 18.0 20.0 4.0 5.0 5.0 6.5 7.0 7.5 9.5 11.0 12.5 14.0 14.5 16.5 16.5 17.5 19.0

3.5 4.0 5.0 5.0 6.0 6.5 7.5 9.5 11. 13. 13. 14. 15. 16. 17. 19. 3.5 4.0 5.0 5.0 6.0 6.5 8.0 10. 11. 13. 13. 14. 15. 17. 17. 19. 3.5 4.5 4.5 5.5 6.0 7.0 9.0 10. 12. 13. 14. 14. 15. 16. 18.

2.5 3.0 4.5 4.5 5.0 5.5 6.5 8.5 10.0 12.0 13.0 13.5 14.5 15.0 16.0 17.5 2.5 3.0 4.5 4.5 5.5 6.0 7.0 9.0 10.5 12.0 13.0 13.5 15.0 16.0 17.0 18.5 3.0 3.5 3.5 4.5 5.0 6.0 8.0 10.0 11.0 12.0 13.0 14.0 14.5 15.5 17.0

3.5 4.5 5.0 5.0 6.0 6.5 7.5 9.0 10.0 11.5 12.0 12.0 13.0 13.5 14.0 14.5 3.5 4.5 5.0 5.5 6.0 6.5 7.5 9.5 10.5 11.5 12.5 13.0 13.5 14.5 15.0 16.0 4.0 4.5 4.5 5.5 6.0 6.5 8.0 9.5 10.5 11.0 11.5 12.0 12.5 13.0 14.0

3.0 3.5 4.5 4.5 5.5 6.0 7.0 8.0 10.0 10.5 11.5 12.0 12.5 13.0 13.5 14.5 3.0 3.5 4.5 5.0 6.0 6.5 7.5 9.0 10.0 11.5 12.0 12.5 13.0 14.0 14.5 15.0 3.0 4.0 4.0 5.0 5.5 6.0 7.5 9.5 10.0 11.0 11.0 11.5 12.5 13.0 13.5

2.0 3.0 3.5 3.5 4.5 5.0 6.0 7.5 9.0 10.5 11.0 11.5 12.0 12.0 12.5 13.0 2.0 3.0 4.0 4.0 5.0 6.0 6.5 8.5 10.0 10.5 11.5 12.0 13.0 13.5 14.0 15.0 2.5 3.0 3.0 4.5 5.0 6.0 7.5 8.5 9.5 10.0 11.0 11.5 11.5 12.0 12.5

4.5 5.0 6.0 6.5 7.5 8.0 9.0 10.5 12.0 14.0 15.0 16.0 17.0 18.0 19.0 21.0 4.5 5.0 6.0 6.0 7.5 8.0 9.0 10.5 12.0 14.0 15.0 16.0 17.0 18.0 19.0 21.0 4.5 5.5 6.0 7.0 7.5 8.0 10.0 11.5 13.0 14.5 15.5 16.5 17.5 18.5 20.5

1.68 2.52 4.0-8 5.47 8.7 11.35 16.2 28.3 42.84 60.74 74.40 82.5 94.5 106.5 118.5 142.5 2.20 3.25 5.45 7.53 11.49 15.37 22.47 42.90 65.10 82.20 98.13 108.1 124.2 140.2 157.0 188.2 2.08 3.12 3.94 5.26 6.45 8.34 13.82 19.94 27.83 36.00 41.18 47.33 53.18 68.50 94.37

4.0 4.5 5.0 5.5 6.5 6.5 7.5 9.0 10.0 11.5 12.0 12.5 13.0 13.5 14.0 15.0 4.0 4.5 5.0 6.0 6.5 7.0 8.0 9.5 11.0 12.0 13.0 13.5 14.0 14.5 15.0 16.0 4.0 5.0 5.5 6.0 6.0 7.0 8.5 10.0 11.0 11.5 11.5 12.5 13.0 13.0 14.0

2.04 3.07 5.4 7.65 11.79 16.15 24.45 46.7 75.22 111.9 147.5 172.05 213.15 258.3 307.5 418.2 2.49 3.72 6.60 9.45 14.25 19.66 29.94 59.85 94.8 130.69 168.64 194.4 240.0 286.64 341.8 458.44 2.7 4.57 6.63 8.85 11.91 17.67 34.54 55.5 83.4 114.6 132.6 172.2 212.1 264.5 376.8

1 1 2 2 3 4 6 8 10 12 14 16 18 20 24 1 1 2 2 3 4 6 8 10 12 14 16 18 20 24 1 1 2 2 3 4 6 8 10 12 14 16 18 20 24

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 38 of 50

ANNEXURE E TECHNICAL REQUIREMENTS OF PIPING MATERIAL 1.0 Ends Unless otherwise specified the ends shall be to the following standard: SW/SCRD BW FLANGED THREADING ASME B16.11 ASME B16.25 / B16.9 ASME B16.5 and ASME B16.47 SERIES B/API-605 ASME/ANSI B1.20.1 (NPT, Taper threads)

2.0

Face Finish This shall be to MSS-SP-6/ASME B46.1/ ASME B16.5. The interpretation shall be : Stock Finish Serrated Finish Smooth Finish/125 AARH Extra Smooth Finish /63 AARH 250-1000 in AARH 250-500 in AARH 125-250 in AARH 32-63 in AARH

3.0

Austenitic Stainless Steel All items/ parts shall be supplied in solution-annealed condition. Intergranular Corrosion (IGC) Test shall be conducted as per following: ASTM A262 Practice B with acceptance criteria of 60-mils/ year (max.) for casting. ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X magnification & microscopic structure to be observed from 250X magnification" for other than casting. For IGC test, two sets shall be drawn from each solution annealing lot: one set corresponding to highest carbon content and other set corresponding to the highest rating/ thickness. IGC test is a must for all stainless steel classes. For all items of stabilized SS grades, stabilizing heat treatment shall also be done. It shall be carried out subsequent to normal solution annealing. Soaking temperature and holding time shall be 900 Deg. C and 4 hours respectively.

4.0 4.1

Item specific notes: Pipes Double seam is allowed for sizes 36" and larger.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 39 of 50

Galvanized pipes shall be only Hot Dip galvanized To ASTM A53. Pipes greater than 10" spiral welded/ pipe shall be used weld seams to be kept in upper quadrant only. 4.2 Fittings All fittings shall be seamless in construction unless otherwise specified. For reducing BW fittings having different wall thickness at each end, the greater one shall be employed and the ends shall be matched to suit respective thickness. All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm, and the welds shall be ground smooth at least 25mm from the ends. For fittings made out of welded pipe, the pipe itself shall be of double welded type, manufactured with the addition or filler material and made employing automatic welding only. All welded fittings shall be normalized for CS, normalized & tempered for AS: and 100 % radiographed by X-ray for all welds made by fitting manufacturer as well as for welds on the parent material. Bevel ends of all BW fittings shall undergo 100 % MP/DP test. Those used in fire fighting facility should be marked Tell-tale hole to be tapped in all reinforcement pads. 4.3 Flanges For Ring Joint Flanges, Blinds and Spacers, the hardness shall be as follow: Flange Material (BHN) Carbon Steel 1 % Cr. To 5% Cr. Mo Type 304,316, 347, 321 Type 304 L, 316 L 120 150 180 140 Min. hardness of Groove

For RTJ flanges, blinds & spacers, the hardness of the groove shall be specified on the test report. Bore of weld neck flange shall correspond to the inside diameter of pipe for specified schedule/ thickness. Ends shall be beveled to suit the specified schedule/ thickness. All flange joints to be tightened with proper gaskets, bolts & nuts with skilled technician and box-up of flange joints to be documented.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 40 of 50

4.4

Valves Valves of Class 900# & above shall be pressure-seal type. Threaded and seal welded or welded bonnet may be employed up to sizes 1-1/2". All flanged valves (except forged) shall have flanges integral with the valve body. Yoke material shall be at least equal to body material. Forgings are acceptable in place of Castings but not vice-versa. No cast iron valves to be used in fire fighting or any other service except in drinking water service Valve castings/ forgings purchased from India or Indian Vendors shall be from Owner approved foundries/ forging shop.

4.5

Dimensions Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same is not covered under B16.10, the dimension shall be as per BS 2080/Manufacturers Std. Valve under cryogenic service (temp.below-45 shall be as per BS-6364 and shall be C) procured from pre-qualified vendor.

4.6

Operation Generally the valves are hand wheel or lever operated. However, suitable gear operator in enclosed gear box shall be provided for valves as follows;

TYPE OF VALVE Gate

ANSI CLASS 150 300 600 900 1500 2500 150 and 300 600 and over 150 300 all 150 and 300 600 900 1500 and 2500

SIZES 14" and larger 12" and larger 8" and larger 6" and larger 4" and larger 2" and larger 6" and larger Manufacturer's Std. 8" and larger 6" and larger 8" and larger 8" and larger 6" and larger 4" and larger 3" and larger

Ball Plug Butterfly Globe

Hand wheel diameter shall not exceed 750 mm and lever length shall not exceed 500 mm on each side. Effort to operate shall not exceed 35 kgf at hand wheel periphery. However, failing to meet the above requirement, vendor shall offer gear operation. Quarter-turn valves shall have "open" position indicators with limit stops.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 41 of 50

4.7

By pass A globe type valve (size as per ASME/ANSI B16.34) shall be provided as bypass for the following sizes of gate valves: Class 150 # 300 # 600 # 900 # 1500 # 2500 # For sizes 26" and above 16" and above 6" and above 4" and above 4" and above 3" and above

By-pass piping, fitting and valves shall be compatible material and design. Complete fillet welds for by-pass installation shall be DP/MP tested. NDT of by-pass valve shall be inline with main valve.

4.8

Radiography of cast valves Unless specified otherwise, the following valve castings shall undergo radiographic examination (for all materials): Class 150 # 300 # 600 # & ABOVE Size 26" & above 18" & above All Qty. 100 % (Except for Cat. D service) 100 % 100 %

For Hydrogen, Oxygen, NACE, Stress relieved, Caustic service, additional radiography requirements shall be as follows (Over & above the requirements covered under Para. above): 150 # 300 # Up to 24" Up to 16" 50 % 50 %

For CRYO/Low temperature classes, additional radiography requirements shall be as follows (Over & above the requirements covered under Para. A above): 150 # 300 # Up to 24" Up to 16" 20% 20%

For alloy steel, Stainless steel castings (not covered in Para B&C above) shall be additionally radiographed as follows: 150 # Up to 24" 10%

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HPCL, Mumbai LSTK 44LK 5100
300 #

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 42 of 50

Up to 16"

10%

Radiography procedure, areas of casting to be radiographed, and the acceptance criteria shall be as per ASME/ANSI B16.34. All casting in class 300 # & above shall be radiographic quality casting. This requirement to be ensured by sample radiography before proceeding with the actual production

4.9

Ball/plug/butterfly valves Each valve shall be supplied with a lever/wrench except for gear operated/ motor operated valves. Soft-seated Ball, Plug & Butterfly valves shall be supplied and antistatic devices. All Ball; Plug & Butterfly valves shall be fire safe to atmosphere. The ball of Ball Valves shall not protrude outside the end flanges. Ball valves shall be floating ball type/ trunion mounted type as per following: Plug valves, if used shall be of pressure balanced type Class Floating Ball Trunion Mounted

150 # 300 # 600 # & above

8" & below 4" & below 1 & below

10" & above 6" & above 2" & above

Use of soft-seated ball/plug/butterfly valves shall be suitably selected based on temperatures handled. Butterfly valve shall be suited for throttling application.

4.10

Strainer Allowable pressure drop shall be certified by vendor along with the offer. specifically, vendor shall furnish pressure drop calculations. If asked

All 2" & higher sized Y type strainer shall be provided with " threaded tap and solid threaded plug as drain connection. For less than 2", this shall be " size. Bottom flange of Y-type strainer shall not have tapped holes. Full length standard size studs shall be used for joining blind flanges For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be 100 % DP/MP checked. All the strainers shall be hydrostatically tested at twice the design pressure.

4.11

Traps

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 43 of 50

Vendor shall also furnish the performance curve indicating the capacity in mass/hour at various differential pressures across the trap. Parts subject to wear and tear shall be suitably hardened. Traps shall function in horizontal as well as in vertical installation. Traps shall have integral strainers. All traps shall be hydrostatically tested to twice the design pressure 4.12 Hoses Manufacturer shall guarantee suitability of hoses for the service and working conditions specified in the requisition, if the material is not specified in the Material Requisition for any particular service. All hoses shall be marked with service and working pressure at minimum two ends clearly. Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations. Complete Hose assembly shall be tested at two times the design pressure. Flexible hose of hydrogen reformer should be of SS316 or equivalent to resist chloride corrosion. Steam hoses shall be subject to steam resistant test.

4.13

Expansion Joints The applicable codes are ASME B 31.3 and EJMA (Expansion Joint Manufacturers Association). Bellows shall be formed from solution annealed sheet conforming to the latest ASTM Spec. Any longitudinal weld shall be 100 % radiographed. The finished longitudinal weld must be of the same thickness and same surface finish as the parent material. Circumferential welds are not permitted. Bellows are to be hydraulically or expansion (punched) formed. Rolled formed bellows are not acceptable. Noticeable punch or die marks resulting from expansion operation are not acceptable. No repairs of any kind are allowed on the bellows after forming. Deep scratches and dents are not acceptable. The out of roundness shall be limited to 3mm. This is the max. Deviation between the max. & min. diameter. The actual circumference of the welding end shall be maintained to 3 mm of the theoretical circumference. Apart from the usual requirements, the vendor shall also furnish: Design calculations to justify stiffness and fatigue life. Axial, lateral stiffness, angular stiffness, effective pressure thrust area. Installation maintenance manual

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 44 of 50

Bellows should be designed for 10,000 cycles (ANSI B31.3) minimum

4.14

Supporting & Spring Assemblies The material Design, Manufacture and Fabrication shall be generally as per MSS-SP58/MSS-SP-89 and/or BS 3974. Testing of springs shall be as per BS1726

4.15

Gaskets Filler for spiral wound gasket shall not have any color or dye. Full-face gaskets shall have boltholes punched out. Non-metallic ring gaskets as per ASME/ ANSI B 16.21 shall match flanges to ASME/ ANSI B16.5 up to 24" and ASME/ANSI B16.47 OR AWWA for sizes > 24" unless otherwise specified. Spiral wound gaskets as per ASME B16.20 shall match flanges to ASME/ANSI B16.5 up to 24" and ASME B16.47 series B for sizes > 24", unless otherwise specified. Inner and outer rings shall be considered for spiral wound gaskets based on under mention philosophy. CAF Gaskets shall not be used.

4.16

Outer Ring C.S. outer ring irrespective of temperature-spiral strip material (except subzero temperatures).

4.17

Inner Ring: Material of inner ring to be C.S. for C.S. classes & same as that of spiral strip material for other than C.S. classes. As per code ANSI B 16.20 26" & above for all classes. All sizes for vacuum classes, Cryo services and Hydrogen services. 2" & above for Hydrogen classes All sizes in H grades of S.S. SS347, SS321 classes. For all sizes for classes with temperature beyond 427 C. For piping class 900# and above

4.18

SPECIAL SERVICE REQUIREMENTS

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 45 of 50

Requirements given below shall be supplemented with detailed requirements included in the PIPING MATERIAL SPECIFICATION. 4.18.1 IBR IBR stands for Indian Boiler Regulation. For steam services, it is statutory obligation to meet IBR requirements. For items under IBR, composition restrictions, test reports, painting, etc. shall be as per IBRs stipulations. 4.18.2 NACE & Sour Service For items under this category, NACE MR01-75 shall be followed. Hardness shall be below BH No.200 for CS material. Carbon equivalent (CE) shall be limited to 0.43. 4.18.3 Impact tests Welded pipes and fittings used below ASME temp. 29 shall be impact tested as C per requirement of ASME B31.3. Impact test shall also be carried out as per process Licensors requirement in addition to ASME B31.3

4.19.0 4.19.1

SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE GENERAL Vendor quality plan shall include the special quality checks and inspection requirements for these services. For operating temperatures below 230 materials shall be of carbon steel to the C, appropriate specifications For operating temperatures of 230 and above, materials shall be selected on the C basis of Nelson Curves of API Publication No. 941 (Steels for hydrogen service at elevated temperatures and pressures in petroleum refineries and petrochemical plants). Impact test &normalizing of CS/AS materials shall be as mentioned in the code.

4.19.2 4.19.2.1

PIPE, FLANGES AND FITTINGS Method of manufacture All CS pipes, fittings and flanges having wall thickness 9.53mm and above, shall be normalized. Cold drawn pipes and fittings shall be normalized after the final cold draw pass for all thickness. In addition, fittings made from forgings shall have Carbon 0.35% max. And Silicon - 0.35% max. The normalizing heat treatment shall be a separate heating operation and not a part of hot forming operation. All Alloy Steel (Cr.-Mo) pipes, forgings and fittings shall be normalized and tempered. The normalizing and tempering shall be a separate heating operation and not a part of hot forming operation. The maximum room temperature tensile strength shall be 100,000 psi. In addition, details given by process licensors requirements shall be met.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 46 of 50

4.19.2.2

Post Weld Heat Treatment All carbon steel pipes and fittings having wall thickness 19 mm and above shall be post weld heat-treated. All alloy steel (cr-mo) pipes and fittings shall be post weld heat treated irrespective of type or thickness of weld. All austenitic stainless steel grades shall be solution annealed after welding.

4.19.2.3

Ferrite No. Test For all austenitic stainless steel, the weld deposit shall be checked for ferrite content. A ferrite No. (FN) not less than 3% and not more than 10% is required to avoid sigma phase embrittlement during heat treatment. FN shall be determined by Ferrite scope prior to post-to-post weld heat treatment.

4.19.2.4

Impact Test For all carbon steel and alloy steel pipes, flanges and fittings with the wall thickness over 19 mm, Carpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per heat treating batch. Impact test specimen shall be in complete heat-treated condition and in accordance with ASTM A370.impact energies at 0c shall be average greater than 27 J (20 ft-lb) per set of 3 specimens, with a minimum of 19J (15 ft-lb). If welding is used in manufacture, impact test of Heat Affected Zone (HAZ) and welds metal shall also be carried out. In addition top the details given process licensors shall be met.

4.19.2.5

Hardness For carbon steel pipes and fittings, hardness of weld and HAZ shall be limited to 200BHN(Max) For alloy pipes and fittings, hardness of weld and HAZ shall be limited to 225BHN(Max)

4.19.2.6

Radiography All girth welded joints (longitudinal and circumferential) shall be 100% radiographed in accordance with UW-51 of ASME section VIII Div-1 and ASME Section V

4.19.2.7

Valves All valves castings shall be radiographic quality.

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All cast valves flanges & bodies with flange rating of class 900 pr greater shall be examined in accordance with paragraphs 7.2 through 7.5of Appnedix-7 of ASME SECVIII DIV-1, regardless of casting quality factor.

4.20

INSPECTION & TESTING All items and their parts shall be subjected to all mandatory as well as supplementary (wherever specified) tests and checks called for in the respective codes/standards/data sheets). All critical service valves shall be hydro tested at site for leak test before installation. All facility for testing shall be arranged by contractor. The examining personnel shall have the requisite qualification and experience. Client and its authorized representative reserve the right to vet and suggest changes in vendors procedures. Vendors works and facilities shall be accessible to the Client/Representative at all reasonable times. Test reports for all mandatory as well as supplementary tests wherever specified shall be furnished. All items of low alloy and exotic material shall be subjected to positive material identification test before dispatch as well as at site before fabrication/ erection. Inspection and Testing shall be as per approved QAP.

4.20

MARKING All items shall be marked (stamped/etched) in accordance with the applicable code/standard/specification. In addition, the item code, if available, shall also be marked. For ease of identification, the color of painted strip (wherever required) shall be as per the applicable standard. Paint or ink for marking shall not contain any harmful metal or metal salts, which can cause corrosive, attack either ordinarily or in service. Special items/ smaller items shall have attached corrosion resistant tag providing salient features. For Color coding for all materials refer separate standard specification on color-coding. All materials including alloy steel pipes, fittings, flanges, Valves, Bolts and Nuts etc, shall maintain 100 % fool proof PMI with punch marked and proper color coding.

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 48 of 50

4.21

DISPATCH All items shall be dry, clean and free from moisture, dirt and loose foreign materials of all kinds. All items shall be protected from rust, corrosion, and mechanical damage during transportation, shipment and storage. Rust preventive on machined surfaces to be welded shall not be harmful to welding and shall be easily removable with a petroleum solvent. Ends shall be suitably protected, and the protectors shall be securely and tightly attached. Each variety and size of item shall be supplied in separate packaging marked with the purchase order no. item code (if available), and the salient specifications. Carbon steel, LTCS and low alloy steel valves shall be painted with one coat of inorganic zinc silicate primer.

ANNEXURE F

GENERAL REQUIREMENTS

1.0 2.0 3.0 4.0 5.0

The entire threaded high pressure/high temperature instrument Tapping and critical service tapping like hydrogen etc., should be seal welded. Vessel such as knock out drum for instrument air with auto drain to be provided at all battery limits. Identification or color coding on pipes, fittings, valves, fasteners, etc shall be as per IS: 5 (latest) for easy and clear identification of materials at site All the Austenitic stainless steel equipment/ piping passivation scheme/ facility shall be provided as per Process Licensor's specifications. All steam trap outlet inside process plant shall be connected to be connected to a common header with funnels and drained to suitable location to the same

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HPCL, Mumbai LSTK 44LK 5100 Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4 Part- III Section - A Sheet 49 of 50

ANNEXURE G STANDARD DRAWINGS (For Reference only) STD. DRGS. NO. 44LK-5100/L.02/0001 44LK-5100/L.02/0002 44LK-5100/L.02/0003 44LK-5100/L.02/0004 44LK-5100/L.02/0005 44LK-5100/L.02/0006 44LK-5100/L.02/0007 44LK-5100/L.02/0008 44LK-5100/L.02/0009 44LK-5100/L.02/0010 44LK-5100/L.02/0011 44LK-5100/L.02/0012 44LK-5100/L.02/0013 44LK-5100/L.02/0014 44LK-5100/L.02/0015 44LK-5100/L.02/0033 44LK-5100/L.02/0045 44LK-5100/L.02/0046 44LK-5100/L.02/0047 44LK-5100/L.02/0048 44LK-5100/L.02/0049 44LK-5100/L.02/0050 44LK-5100/L.02/0059 44LK-5100/L.02/0061 44LK-5100/L.02/0062 44LK-5100/L.02/0064 44LK-5100/L.02/0066 44LK-5100/L.02/0068 44LK-5100/L.02/0069 44LK-5100/L.02/0070 44LK-5100/L.02/0071 44LK-5100/L.02/0072 44LK-5100/L.02/0073 44LK-5100/L.02/0076 44LK-5100/L.02/0077 44LK-5100/L.02/0091 44LK-5100/L.02/0092 44LK-5100/L.02/0093 44LK-5100/L.02/0100 44LK-5100/L.02/0101 DESCRIPTION GENERAL PIPING ABBREVATION REPRESENTATION OF PIPING ON GENERAL ARRANGEMENT DRAWINGS PIPING SYMBOLS FOR GENERAL ARRANGEMENT DRAWINGS REPRESENTATION OF PIPING ON GENERAL ARRANGEMENT DRAWINGS VALVE SYMBOLS FOR PIPING G.A.'S REPRESENTATION OF PIPING ON GENERAL ARRANGEMENT DRAWINGS STANDARD SYMBOLS FOR ISOMETRIC PIPING DRAWINGS INSTRUMENT SYMBOLS FOR PIPING G.A.'S PIPING ORIENTATIONS DATA REQUIRED ON G.A.'S. MINIMUM PIPE SPACING BETWEEN BARE PIPE AND PIPE WITH FLANGES (STAGGERED) MINIMUM PIPE SPACING BETWEEN BARE PIPE AND BARE PIPE (WITHOUT FLANGES) METHOD OF CALCULATING PIPE SPACING WHEN SHEET 1 OR 2 CANNOT BE USED. PIPE SPACING TABLE FOR 300#, 600#, 900# & 1500# FLANGE RATINGS. PIPE SPACING TABLE FOR 300#, 600#, 900# & 1500# FLANGE RATINGS. PIPE SPACING TABLE FOR 300#, 600#, 900# & 1500# FLANGE RATINGS. DIMENSION FOR SLIP-ON FLANGES ON WELD ELBOWS PIPING DIMENSIONS VALVES-S.W./SCR'D/FLG'D,1.1/2" & BELOW PIPING DIMENSIONS VALVES 2" NB AND ABOVE PIPING DIMENSIONS VALVES 2" NB AND ABOVE DIMENSIONS OF BALL VALVES 1/4" TO 10" NB CONTROL VALVES CLEARANCE REQUIREMENTS CONTROL VALVE STATIONS MANIFOLD AND PIPING ARRANGEMENTS CARBON & STAINLESS STEEL 150# LARGE TONGUE MALE SPEC.BLIND, SPACER & SPADE FOR FEMALE ANSI B16.5 FLGS CARBON & STAINLESS STEEL 300# LARGE TONGUE SPEC. BLIND,SPACER & SPADE FOR LARGE GROOVE ANSI B16.5 FLGS CARBON, ALLOY & ST.STEEL:-300# R.T.J. FEMALE SPEC. BLIND, SPACER & SPADE FOR ANSI B16.5 FLANGES. CARBON & S.STEEL 600# LARGE TONGE SPEC.BLIND, SPACER & SPADE FOR LARGE GROOVE ANSI B 16.5 FLANGES. CARBON, ALLOY & ST.STEEL:-600# R.T.J. FEMALE SPEC. BLIND, SPACER & SPADE FOR ANSI B16.5 FLANGES. CARBON, ALLOY & ST.STEEL:-900# R.T.J. FEMALE SPEC. BLIND, SPACER & SPADE FOR ANSI B16.5 FLANGES. CARBON, ALLOY & ST.STEEL:-1500# R.T.J. FEMALE SPEC. BLIND, SPACER & SPADE FOR ANSI B16.5 FLANGES. TEMPORARY STRAINERS FOR RAISED FACE AND FULL FACE ANSI FLANGES TEMPORARY STRAINERS AND REPLACEMENT RINGS FOR ANSI FLANGES WITH RING TYPE FACE PIPE SLEEVE DETAILS FOR INSULATED LINES UNDER ROADS & DYKE WALLS PIPE SLEEVE DETAILS FOR INSULATED LINES UNDER ROADS & DYKE WALLS STANDARD DETAILS FOR SAMPLE POINTS. (S.P.) STANDARD SAMPLE COOLER FLANGED BRANCH CONNECTION DETAIL FOR C.S.MORTAR LINED PIPES BRANCH CONNECTION DETAIL FOR C.S.MORTAR LINED PIPES. DETAILS OF COLLAR FOR CEMENT MORTAR LINED PIPING STANDARD FOR STEAM TRAP ASSEMBLY STANDARD FOR STEAM TRAP ASSEMBLY

Jacobs
HPCL, Mumbai LSTK 44LK 5100
44LK-5100/L.02/0102 44LK-5100/L.02/0103 44LK-5100/L.02/0106 44LK-5100/L.02/0109 44LK-5100/L.02/0111 44LK-5100/L.02/0112 44LK-5100/L.02/0113 44LK-5100/L.02/0114 44LK-5100/L.02/0115 44LK-5100/L.02/0116 44LK-5100/L.02/0117 44LK-5100/L.02/0118 44LK-5100/L.02/0119 44LK-5100/L.02/0122 44LK-5100/L.02/0123 44LK-5100/L.02/0124 44LK-5100/L.02/0131 44LK-5100/L.02/0132 44LK-5100/L.02/0134 44LK-5100/L.02/0135

Piping Design Basis Doc NO : 44LK-5100-0/L.02/0002/A4

Part- III Section - A Sheet 50 of 50

STANDARD FOR STEAM TRAP ASSEMBLY STANDARD FOR STEAM TRAP ASSEMBLY JACK SCREWS FOR SPECTACLE BLINDS SPADES & SPACERS TO ANSI B165 TUNDISH FOR 1/2" - 8" NB PIPE DETAILS OF SINGLE HYDRANT DETAILS OF DOUBLE HYDRANT DETAILS OF WATER MONITOR DETAILS OF HOSE BOX VALVE CHAMBER MAXIMUM ALLOWABLE PIPE SPANS AND UNIT WEIGHTS MAXIMUM ALLOWABLE PIPE SPANS AND UNIT WEIGHTS MAXIMUM ALLOWABLE PIPE SPANS AND UNIT WEIGHTS MAXIMUM ALLOWABLE PIPE SPANS AND UNIT WEIGHTS STANDARD SPACING FOR PIPE RUNS NEAR COLUMNS, BELOW BEAMS AND SIZE OF FLOOR CUT-OUTS. STANDARD ARRANGEMENT OF SLEEPERS TYPICAL DETAILS OF UTILITY STATION UNDER GROUND PIPING SYSTEM TYPICAL SCHEME OWS SYSTEM ARRANGEMENT OF MANHOLES WITH GAS SEAL & FLAME TRAP UNDER GROUND PIPING SYSTEM DRAIN FUNNEL DETAILS UNDER GROUND PIPING SYSTEM CATCH BASIN DETAILS

Note -These standard drawings are included as the part of feed under index Standard Drawings

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