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SUMMER INTERNSHIP ON PIPING OF

PETROCHEMICAL PLANTS

Master of Technology
In
Pipeline Engineering
By

K. Navneeth Kumar
(R150214011)

Under Supervision of

Mr. Kaushik Mondal Mr. Om Prakash


Principal Engineer Head of the Department
Department of Piping Department of Piping
Technip, Noida. Technip, Noida.

DEPARTMENT OF MECHANICAL ENGINEERING


COLLEGE OF ENGINEERING STUDIES
UNIVERSITY OF PETROLEUM AND ENEGRY STUDIES
DEHRADUN – 248007.
CERTIFICATE

This is to certify that K. NAVNEETH KUMAR (R150214011), final year student of


Pipeline Engineering from Department of Mechanical Engineering, University of
Petroleum & Energy Studies, has done his summer training and project work in the
Department of Piping, Technip, Noida. The training has been duration of 2 months from 1st
June to 31st July 2015.

Mr. Kaushik Mondal Mr. Om Prakash


Principal Engineer Head of the Department
Department of Piping Department of Piping
Technip, Noida. Technip, Noida.

i
ACKNOWLEDGEMENTS

I would be very grateful and deeply gratitude to Mr. Adarsh Kumar Arya [Assistant
Professor (Senior Scale) – Pipeline Engineering] for his encouragement, moral support and
giving an opportunity to undergo training at Department of Piping, Technip, Noida.

I acknowledge my grateful thanks to Mr. Om Prakash [Head of the Department,


Department of Piping, Technip, Noida] who is a guide for this project. I am also thankful to
Mr. Kaushik Mondal [Principal Engineer, Dept. of Piping] for his guidance and mentorship
for me in completing my training and project at Dept. of Piping, Technip, Noida. I would also
like to extend my deepest gratitude to Mr. Nitin Kumar Jain, Mr. Manoj Hariharan and
Mr. Sutanu Nayak [Dept. of Piping, Technip, Noida] for training and guiding me in
completing my training and project. It was a treasurable learning experience and I augmented
my practical knowledge.

My sincere thanks to Mr. Ashok Kumar in enlightening about the basics and helping
throughout the training. I would be indebted to Mr. Ashwini for providing the necessary help
during the training. I would also be obliged to Mr. Satpathy for making as an internee/
trainee under my mentor. I will be ever obliged to the whole Dept. of Piping for supporting
me throughout the internship.

My deepest gratitude to Mr. Mukesh Chugh, for giving an opportunity to undergo


summer training and supporting me all the times in completing my project.

K. Navneeth Kumar
R150214011
M. Tech Pipeline Engineering

ii
CONTENTS

Page no.

CERTIFICATE i
ACKNOWLEDGEMENT ii
TABLE OF CONTENTS iii
LIST OF FIGURES vi
LIST OF TABLES viii
ABOUT TECHNIP ix
STATEMENT OF THE PROJECT xi

1. PIPING 01
1.1. PIPES 01
1.2. PIPE FITTINGS 04
1.2.1. ELBOWS 04
1.2.1.1. 90o ELBOWS 04
o
1.2.1.2. 45 ELBOWS 05
1.2.2. TEES 05
1.2.2.1. EQUAL TEE 06
1.2.2.2. REDUCING TEE 06
1.2.3. BRANCHES/ O-LETS 07
1.2.4. REDUCERS 08
1.2.5. WELD CAPS 09
1.2.6. COUPLINGS 10
1.3. FLANGES 10
1.3.1. WELD-NECK FLANGE 11
1.3.2. THREADED FLANGE 11
1.3.3. SOCKET WELD FLANGE 12
1.3.4. SLIP – ON FLANGE 12
1.3.5. LAP JOINT FLANGE 13
1.3.6. REDUCING FLANGE 13
1.3.7. BLIND FLANGE 14
1.3.8. ORIFICE FLANGE 14
1.4. BOLTS 15
1.5. GASKETS 16
1.6. VALVES 17
iii
1.6.1. GATE VALVE 17
1.6.2. GLOBE VALVE 18
1.6.3. ANGLE VALVE 19
1.6.4. CHECK VALVE 19
1.6.5. BALL VALVE 20
1.6.6. BUTTERFLY VALVE 20
1.6.7. RELIEF VALVE 21
1.6.8. CONTROL VALVE 22
1.6.9. VALVE OPERATORS 23
1.6.9.1. ACTUATORS 23

2. CODES & STANDARDS 26


2.1. API CODES 26
2.2. ASME CODES 27
2.3. ASTM STANDARDS 29
2.4. BRITISH STATNDARDS 29
2.5. ISO CODES 29
2.6. THICKNESS CALCULATION OF PIPE BASED ON ASME B31.3 30

3. PLOT PLANS AND EQUIPMENT LAYOUT DESIGN 32


3.1. EQUIPMENT LAYOUT 32
3.1.1. TANK FARM DESIGN 43
3.1.2. PIPE RACK DESIGN 44
3.2. PIPING GAD 48

4. EQUIPMENT DRAWINGS 53
4.1. MECHANICAL DRAWINGS 53
4.2. VENDOR DRAWINGS 54

5. LIVE PROJECT – SHELL FRANKLIN PE3 (064340C) 55


5.1. PROCESS DESCRIPTION 55
5.2. MODULARIZATION 57
5.3. PIPE MATERIAL SPECIFICATION (PMS) 59
5.4. SHELL DESIGN & ENGINEERING PRACTICES (DEP) 62

iv
5.4.1. PIPING – GENERAL REQUIREMENTS 62
5.4.2. PIPE SUPPORTS 67
5.4.3. THERMAL INSULATION 69
5.4.4. HUMAN FACTORS ENGINEERING – WORKSPACE DESIGN 72
5.4.5. HUMAN FACTORS ENGINEERING – VALVES 72
5.5. PIPING DESIGN STUDIES OF THE TREATOR 76
5.6. BASICS OF STRESS ANALYSIS OF PIPES 88

6. BIBLIOGRAPHY 90

ANNEXURES 91

v
List of Figures

Figure number Description Page number


1.1 Seamless Pipe 2
1.2 Butt-weld Pipe 2
1.3 Spiral-weld Pipe 3
1.4 Different types of pipe manufacturing 3
1.5 Pipe thickness 3
1.6 Different types of pipe joining 4
1.7 Pipe fittings 4
1.8 90o Elbow 5
o
1.9 45 Elbow 5
1.10 Tee – reducing 6
1.11 Tee – equal 6
1.12 Reinforcing pad 7
1.13 Welding saddle 7
1.14 Weldolet 8
1.15 Sockolet 8
1.16 Threadolet 8
1.17 Eccentric reducer 9
1.18 Concentric reducer 9
1.19 Weld cap 9
1.20 Coupling 10
1.21 Weld Neck flange 11
1.22 Threaded flange 12
1.23 Socket weld flange 12
1.24 Slip-on flange 13
1.25 Lap-joint flange 13
1.26 Reducing flange 14
1.27 Blind flange 14
1.28 Orifice flange 15
1.29 Bolts 15
1.30 Gasket 16
1.31 Spiral Wound gasket 16

vi
1.32 A Valve 17
1.33 Gate valve 18
1.34 Globe valve 18
1.35 Angle valve 19
1.36 Check valve 20
1.37 Ball valve 20
1.38 Butterfly valve 21
1.39 Relief valve 22
1.40 Control valve 22
3.1 Tank farm design and dyke volume 43
3.2 A typical figure showing a pipe rack configuration 45
3.3 A typical design of pipe rack 47
3.4 A typical piping GAD 48
3.5 Piping GAD 49
3.6 Piping GAD 50
3.7 Piping GAD 51
3.8 Piping GAD 52
4.1 A typical mechanical drawing of equipment 53
4.2 A typical vendor drawing of equipment 54
5.1 Flow diagram of process 56
5.2 Transportation chart 58
5.3 Plot plan of PE3 HDPE Slurry project 76
5.4 Area classification of PE3 HDPE Slurry project 77
5.5 PID of Treator 78
5.6 Line 1 MTO 79
5.7 Line 1 isometric 80
5.8 Line 2 MTO a 81
5.9 Line 2 MTO b 82
5.10 Line 2 isometric 83
5.11 Line 3 MTO 84
5.12 Line 3 isometric 85
5.13 Line 4 MTO 86
5.14 Line 4 isometric 87

vii
List of Tables
Table number Description Page number
1.1 Valve Selection Criteria 24
1.2 Valve Selection Criteria 25
3.1 Separation Distances 34
3.2 Separation Distances 36
3.3 Separation Distances 38
3.4 Separation Distances 39
3.5 Separation Distances 40
3.6 Separation Distances 41
3.7 Separation Distances 42
5.1 Pipe Material Specifications 60
5.2 Insulation Codes 70

viii
ABOUT TECHNIP

Department of Piping
TECHNIP, Noida

Technip S. A. is a company that carries out project management, engineering and


construction for the energy industry. Its headquarters are in the 16th Arrondissement of Paris.
It is primarily in the energy business and is active in three business segments, namely Subsea,
Offshore and Onshore. It has about 38,000 employees and operates in 48 countries and owns
a fleet of 21 vessels in operation with 6 under construction. The total revenues stood at more
than € 10.7 billion with the operating income of € 825 million at the end of 2014. It was
established in 1958 by IFP, Institut Français du Pétrole, (French Institute for Petroleum) as
Compagnie Française d’Etudes et de Construction Technip.

The Dept. of Piping, Technip, Noida works in co-ordination with Technip Lyon in
designing and delivering EPC contracts across the world. The Piping department has three
major segments to distribute the work among the employees.

Piping Department

Piping Stress analysis


Piping Layouts Piping Materials
and supports

 Piping Layouts: Design and preparation of plot plans and equipment layouts and
modelling of all lines per PIDs (Piping & Instrument Diagrams) and other piping
standards and relevant codes.
 Piping Materials: Design and preparation of piping material specifications/
carryout pipe thickness calculation, material take-off at different stages of project,
engineering for procurement of piping items.
 Piping Stress Analysis and Supports: Design and preparation of critical lines
and perform flexibility analysis and provide supports as per stress requirements.

ix
The Piping department interacts with Departments of Proposals, Process, Civil,
Electrical, Instrumentation, Mechanical, Combustion, Procurement and mainly HSE for
planning, reviewing, redesigning and implementing the ideas and views regarding a project
undertaken.

x
STATEMENT OF THE PROJECT/ WORK
The work being submitted is done by extensive studies on documents and no data is being
borrowed from any other source.

xi
PIPING

1.1. PIPES

1.2. PIPE FITTINGS

1.2.1. ELBOWS

1.2.2. TEES

1.2.3. BRANCHES/ O-LETS

1.2.4. REDUCERS

1.2.5. WELD CAPS

1.2.6. COUPLINGS

1.2.7. BLINDS AND SPACERS

1.3. FLANGES

1.4. GASKETS

1.5. VALVES

PIPES
Pipe is a term used to designate a hollow, tubular body used to transport any
commodity possessing flow characteristics such as those found in liquids, gases, vapours,
liquefied solids, and fine powders. A comprehensive list of the materials used to manufacture
pipe would be quite lengthy. Some of the materials include concrete, glass, lead, brass,
copper, plastic, aluminium, cast iron, carbon steel and steel alloys.

Each material has limitations that may make it inappropriate for a given application.
Carbon steel pipe can be manufactured using several different techniques, each of which
produces a pipe with certain characteristics. These characteristics include strength, wall
thickness, corrosion resistance, and temperature and pressure limitations. For example, pipes
having the same wall thickness but manufactured by different methods may vary in strength
and pressure limits. The manufacturing methods include seamless, butt-welded, and spiral-
welded pipe.

1
Seamless pipe is formed by piercing a solid, near-molten, steel rod, called a billet,
with a mandrel to produce a pipe that has no seams or joints. Figure below depicts the
manufacturing process of seamless pipe.

Fig 1.1: Seamless Pipe

Butt-welded pipe is formed by feeding hot steel plate through shapers that will roll it
into a hollow circular shape. Forcibly squeezing the two ends of the plate together will
produce a fused joint or seam. Figure below shows the steel plate as it begins the process of
forming butt-welded pipe.

Fig 1.2: Butt-weld Pipe

Least common of the three methods is spiral-welded pipe. Spiral-welded pipe is


formed by twisting strips of metal into a spiral shape, similar to a barber’s pole, then welding
where the edges join one another to form a seam. This type of pipe is restricted to piping
systems using low pressures due to its thin walls. Figure below shows spiral-welded pipe as it
appears before welding.

2
Fig 1.3: Spiral-weld Pipe

Fig 1.4: Different types of pipe manufacturing

Outside diameter (OD) and inside diameter (ID), as their names imply, refer to pipe by
their actual outside and inside measurements. Pipe 1/8” to 12” has an outside diameter greater
than its nominal pipe size, while pipe 14” and above has an outside diameter equal to its
nominal pipe size. Wall thickness is a term used to describe the thickness of the metal used to
make a pipe. Wall thickness is also commonly referred to as a pipe’s weight.

Commodities with ever-changing corrosive properties, high temperatures, and extreme


pressures have necessitated the development of numerous additional selections of wall
thicknesses for pipe. Now called schedules, these additional wall thicknesses allow a pipe to
be selected to meet the exact requirements needed for safe operation.

Fig 1.5: Pipe thickness


The following formula can be used to calculate a pipe’s inside diameter (ID):
ID = OD - (2 × Wall Thickness)

There are several methods for joining pipe together. The three methods we will focus
on are those most widely used in piping systems made of carbon steel, as shown in figure
below. They are butt-welded (BW), screwed (Scrd), and socket-weld (SW).
3
Fig 1.6: Different types of pipe joining

PIPE FITTINGS

Fittings are fabricated pieces of pipe that are used to make changes of direction
(elbow), branch from a main pipe (tee), or make a reduction in line size (reducer) (see figure
below). Because fittings are part of the piping system, they must match as closely as possible
in specification and rating to the pipe to which they are being attached. Fittings, like pipe, are
manufactured and classified according to their wall thickness.

Fig 1.7: Pipe fittings


90o Elbows
Of all the fittings, the elbow is the one most often used. Simply put, the elbow, or ell, is used
when a pipe changes direction. Elbows can turn up, turn down, turn left, right, or any angle in
between (see figure below). Ninety degree ells can be classified as one of the following:
 long-radius elbow

4
 short-radius elbow
 reducing elbow
 mitered elbow

Fig 1.8: 90o Elbow

45° Elbows
Another important fitting is the 45° elbow. This elbow is also used to make changes in
direction within the piping system. The obvious difference between the 90° and 45° elbows is
the angle formed by the turn. Because the 45° elbow is one-half of a 90° elbow, as shown in
figure below, it is obviously shorter.

Fig 1.9: 45° Elbow

Weld Tee
The name of this fitting comes from its resemblance to the letter T. It is a three-way
fitting used to make perpendicular connections to a pipe (see figure below). Lines that connect
5
to the main run of pipe are known as branches. The main run of pipe is often called the
header.

Fig 1.10: Tee - Reducing

Fig 1.11: Tee - Equal

Reinforcing pad
Resembling a metal washer that has been bent to conform to the curvature of the pipe,
the reinforcing pad is a ring cut from steel plate that has a hole in the centre equal to the
diameter of the branch connection. It is slipped onto the branch pipe then welded to both
branch and header.

6
Fig 1.12: Reinforcing pad

Welding saddle
A purchased reinforcing pad, the welding saddle has a short neck designed to give
additional support to the branch. Figure below shows representations of reinforcing pads and
saddles.

Fig 1.13: Welding saddle

O-lets
Purchased fittings, o-lets have one end shaped to the contour of the header and the
other end manufactured to accept the type of end connections being used on the branch.
Weldolets are manufactured for butt-weld fittings. Sockolets are made for socket-weld
fittings. And threadolets are available for screwed fittings. Figures below show the depiction
of the O-lets. Other o-lets are manufactured to be used to make connections at angles other
than 90°.

7
Fig 1.14: Weldolet

Fig 1.15: Sockolet

Fig 1.16: Threadolet

Reducers
When the piping designer wants to reduce the diameter of a straight run of pipe, a
reducing fitting must be used. Appropriately named, the reducer is available in two types,
Concentric—having a common centreline, Eccentric—having offset centrelines. The
concentric reducer maintains the same centreline at both the large and small ends of the
fitting. The eccentric reducer has offset centrelines that will maintain a flat side on the top or
the bottom of the fitting, depending on how the fitting is rolled prior to welding. The eccentric
reducer is used in pipe racks to maintain a constant bottom of pipe (BOP). Because pipe
supports within a pipe rack are of the same elevation, a pipe must have a consistent bottom of
pipe elevation so it can rest on each support throughout its entire length.

8
Fig 1.17: Eccentric Reducer

Fig 1.18: Concentric Reducer

Weld Cap
The last weld fitting is the weld cap. It is used to seal an open end of pipe. When
dimensioning the positional location of a weld cap on a drawing, indicate only the length of
the run of pipe. The cap will be welded to the end and need not be included in the length
dimension of the run of pipe.

Fig 1.19: Weld Cap


9
Coupling
Another type of fitting used to make branch connections is the coupling. Used
primarily for connecting small-bore screwed and socket-weld pipe to large-bore pipe headers,
the coupling is also used extensively where instrument connections are required. There are
two common methods used to make branch connections with couplings:
1. The coupling rests on the external surface of the pipe header and is welded
from the outside.
2. A hole is bored into the pipe header large enough to accept the OD of the
coupling. The coupling is inserted into the hole and is then welded.

Fig 1.20: Coupling

FLANGE
The flange is a ring-shaped device designed to be used as an alternative to welding or
threading various piping system components used throughout the piping system. Flanged
connections are used as an alternative to welding because they can be easily disassembled for
shipping, routine inspection, maintenance, or replacement. Flanged connections are preferred
over threaded connections because threading large bore pipe is not an economical or reliable
operation.

The flange is an important component of any piping system. Flanges are primarily
used where a connecting or dismantling joint is needed. These joints may include joining pipe
to fittings, valves, equipment, or any other integral component within the piping system. The
mating surface of a flange, nozzle, or valve is called the face. The face is usually machined to
create a smooth surface. This smooth surface will help assure a leak-proof seal when two
flanges are bolted together with a gasket sandwiched between. Although numerous types of
flange faces are produced, the most important are
 Flat face
 Raised face

10
 Ring-type joint
Flanges have been designed and developed to be used in a myriad of applications.
Each one has its own special characteristics, and should be carefully selected to meet specific
function requirements. The following flanges will be discussed in this chapter:
 Weld-Neck
 Threaded
 Socket weld
 Slip-on
 Lap-joint
 Reducing
 Blind
 Orifice

Weld Neck Flange


The weld neck flange shown in figure below is occasionally referred to as the “high-
hub” flange. It is designed to reduce high-stress concentrations at the base of the flange by
transferring stress to the adjoining pipe. Although expensive, the weld neck flange is the best-
designed butt weld flange available because of its inherent structural value and ease of
assembly.

Fig 1.21: Weld Neck Flange

Threaded Flange
The threaded flange depicted in figure below similar to the slip-on flange, but the bore
is threaded. Its principal value is that it can be assembled without welding. This feature makes
the threaded flange well-suited to extreme pressure services that operate at normal
atmospheric temperatures and in highly explosive areas where welding may create a hazard.

11
Fig 1.22: Threaded Flange

Socket Weld Flange


The socket weld flange shown in figure below is also similar to the slip-on flange. It
was originally developed for use on small diameter (½” through 4”) high-pressure piping
systems. Like socket weld fittings, pipe is inserted into the socket then welded. An internal
weld is often employed for added strength. By grinding the internal weld smooth, turbulence
and flow restriction are kept to a minimum.

Fig 1.23: Socket Weld Flange

Slip-on Flange
The slip-on flange shown in figure below has a low hub that allows the pipe to be
inserted into the flange prior to welding. Shorter in length than a weld neck flange, the slip-on
flange is used in areas where short tie-ins are necessary or space limitations necessitate its
use. Two significant disadvantages, however, are the requirements of two fillet welds, one
internal and one external, to provide sufficient strength and prevent leakage, as well as a life
span about one-third that of the weld neck flange. They are preferred over welding neck
flanges by many users because of their lower initial cost. significant disadvantages, however,
are the requirements of two fillet welds, one internal and one external, to provide sufficient
12
strength and prevent leakage, as well as a life span about one-third that of the weld neck
flange. They are preferred over welding neck flanges by many users because of their lower
initial cost.

Fig 1.24: Slip-on Flange

Lap-joint Flange
The lap-joint flange in figure below is primarily used on carbon or low alloy steel
piping systems. Attachment of the lap-joint flange to the piping system requires a lap-joint
stub end. The lap-joint flange and stub end assembly are used mainly in piping systems that
necessitate frequent dismantling for inspection or routine maintenance. It is also used in the
erection of large diameter or hard to adjust piping configurations because of its quick bolt
hole alignment. Figure below depicts the lap-joint flange.

Fig 1.25: Lap-joint Flange

Reducing Flange
Like the reducer fitting, the reducing flange in figure below is used to make a
reduction in the diameter of the pipe. A reducing flange is most frequently used in

13
installations with limited space. Crowded situations may necessitate the use of the reducing
flange because it has a shorter overall length when compared to a weld neck flange and
reducer-fitting configuration.

Fig 1.26: Reducing Flange

Blind Flange
The blind flange depicted in figure below serves a function similar to that of a plug or
cap. It is used to terminate the end of a piping system. The blind flange is basically a flange
that does not have a hub or a bored centre. Blind flanges have the face thickness of a flange, a
matching face type, and similar bolting pattern. Blind flanges can also be used to seal a nozzle
opening on a pressure vessel. Because it is bolted, the blind flange provides easy access to the
interior of a vessel or pipe, unlike a cap that is welded.

Fig 1.27: Blind Flange

Orifice Flange
Of the flanges discussed, the orifice flange (figure below) is the only one that actually
performs a function. The function of the orifice flange is to measure the rate of the flow of the
commodity through the piping system. Orifice flanges are easy to recognize because they
14
have a hole drilled through the face of the flange perpendicular to the pipe. The orifice flange
is a single component of the orifice flange union assembly. The orifice flange union is
composed of two orifice flanges, an orifice plate, bolts, nuts, jack screws, and two gaskets.

Fig 1.28: Orifice Flange

BOLTS
To complete any flanged assembly, two additional items are required: bolts and
gaskets. Bolts obviously hold mating flanges, nozzles, or valves together. The pressure rating
of a flange will determine the size, spacing, and number of bolts required. As the nominal
pipe size and pressure ratings change so will the diameter, spacing, and number of bolts. Bolt
hole arrangements may seem inconsequential, but, when one considers the fact that
components of a piping system may be fabricated in one country then shipped to another
country for assembly, bolt alignments become increasingly important. It is critical that
drawings convey the exact orientation of flanges to the fabricator. To assure that bolt holes on
flanges, nozzles, or valves align properly, holes are equally spaced around the flange. Bolts
are found in quantities of four, that is, 4, 8, 12, 16, etc. The following formula makes bolt hole
location and alignment quick and simple.

Fig 1.29: Bolts

15
GASKETS
The primary purpose of any flanged assembly is to connect piping systems in such a
manner as to produce a leak-free environment. Hazardous and combustible materials and
extreme pressures and temperatures require the utmost in safety precaution. Creating a leak-
proof seal between two connecting metal surfaces in an industrial setting is almost impossible.
Therefore, gaskets perform a vital function in plant safety. Using a gasket material softer than
two adjoining flanges is an excellent way to eliminate the possibility of a fluid escape.
Gaskets can be made of materials such as asbestos, rubber, neoprene, Teflon, lead, or copper.
When bolts are tightened and flange faces are drawn together, the gasket material will
conform to any imperfections in the flange faces to create a uniform seal. The three types of
gaskets that can be found in piping systems. They are full face, flat ring, and metal ring. Full
face gaskets are used on flat face flanges. Flat ring gaskets are used on raised face flanges.
Metal rings are used on ring-type joint flanges.

Fig 1.30: Gasket

Fig 1.31: Spiral Wound Gasket

16
VALVES
Valve is a device that controls the flow of a fluid. But today’s valves can control not
only the flow, but also the rate, the volume, the pressure, and the direction of a fluid within a
pipe. Valves are not limited to fluids. They can control liquids, gases, vapours, slurries, or dry
materials. Valves can turn on or off, regulate, modulate, or isolate. From the thinnest gas to
highly corrosive chemicals, from superheated steam to toxic gases, from abrasive slurries to
radioactive materials, valves can be designed to service them all. They can handle
temperatures from the cryogenic region to molten metal exceeding 1500°F, and valves can
contain pressures ranging from severe vacuum to 20,000 pounds per square inch.

Fig 1.32: A Valve

Gate Valves
The gate valve is the most frequently used valve in piping systems. It is a general
service valve that is used primarily for on-off, non-throttling applications. When fully opened,
the gate valve creates minimal obstruction to the flow. Gate valves control the commodity
flowing through the pipe with a flat, vertical wedge, or gate, that slides up or down as the
valve’s hand-wheel is turned. As the hand-wheel is rotated, the wedge will slide through the
valve body to block or release the flow. Designed to be either fully opened or closed, the gate
valve should not be operated in a partially opened/closed position. A partially opened gate
valve will hasten erosion caused by the commodity within the pipe and will ruin the valve seat
in a short period of time. Turbulence from the commodity will also cause the wedge to vibrate
creating a “chattering” noise when the valve is partially opened.

17
Fig 1.33: Gate Valve

Globe Valves
Globe valves are used primarily in situations where throttling of the commodity is
required. By simply rotating the hand-wheel, the rate at which the commodity flows through
the valve can be adjusted to any desired level. Having the valve seat parallel to the line of
flow is an important feature of the globe valve. This feature makes the globe valve efficient
when throttling commodities as well as yielding minimal disc and seat erosion. This
configuration, however, creates a large amount of resistance within the valve.

The design of the globe valve body forces the flow of the commodity to change
direction within the valve itself. This change in direction creates substantial pressure drop and
turbulence. The globe valve is therefore not recommended when flow resistance and pressure
drop are to be avoided.

Fig 1.34: Globe Valve

18
Angle Valves
The angle valve, like the globe valve, is used for throttling. As shown in figure below,
the flow entering the valve and the flow leaving the valve form a 90° angle. In the event a
pipe is making a 90° turn, the angle valve is used to eliminate the need for a 90° elbow and
additional fittings. Angle valves as well as globe valves are typically installed so a commodity
will flow in an upward direction through the valve body. This upward flow direction will keep
pressure under the disc seat. Pressure from below the seat promotes easier operation and
reduces the erosive action on the seat and disc.

Fig 1.35: Angle Valve

Check Valves
Check valves differ significantly from gate and globe valves. Check valves are
designed to prevent backflow. Backflow simply means flow that has reversed itself within a
pipe and begins to flow backwards. There are many designs of check valves, but the two most
common types are the swing check and the lift check. Check valves do not use hand-wheels to
control the flow of a commodity but instead use gravity and the pressure of the commodity to
operate the valve (see figure below).

The swing check valve is installed as a companion valve to the gate valve. As the
name implies, this valve has a swinging gate that is hinged at the top and opens as a
commodity flows through the valve. When the valve disc is in the open position, a clear flow
path is created through the valve. This clear path creates minimal turbulence and pressure
drop within the valve. Pressure must always be under the disc for the valve to function
properly. When flow reverses, the pressure and weight of the commodity against the disc will

19
force the disc against the seat, stopping all backflow. Check valves are often regarded as
safety or precautionary equipment.

Fig 1.36: Check Valve

Ball Valves
The ball valve is an inexpensive alternative to other valves. Ball valves use a metal
ball with a hole bored through the centre, sandwiched between two seats to control flow. Used
in many hydrocarbon process applications, ball valves are capable of throttling gases and
vapours and are especially useful for low flow situations. These valves are quick opening and
provide a very tight closure on hard to hold fluids (see figure below). Ball valves do not use a
hand-wheel but instead use a wrench to control the flow. A 90° turn of the wrench opens or
closes the valve. This simple design yields a non-sticking operation that produces minimal
pressure drop when the valve is in its full-open position.

Fig 1.37: Ball Valve

Butterfly Valve
The butterfly valve has a unique body style unlike the other valves. The butterfly uses
a circular plate or wafer operated by a wrench to control flow. A 90° turn of the wrench

20
moves the wafer from a fully open position to a fully closed position. The wafer remains in
the stream of flow and rotates around a shaft connected to the wrench. As the valve is being
closed, the wafer rotates to become perpendicular to the direction of flow and acts as a dam to
reduce or stop the flow. When the wrench is rotated back to the original position, the wafer
aligns itself with the direction of flow and allows the commodity to pass through the valve
(see figure below). Butterfly valves have minimal turbulence and pressure drop. They are
good for on-off and throttling service and perform well when controlling large flow amounts
of liquids and gases.

Fig 1.38: Butterfly Valve

Relief Valves
Relief valves are safety devices. Relief valves have a purpose quite different from the
previous valves. They are designed to release excessive pressure that builds up in equipment
and piping systems. To prevent major damage to equipment, and more importantly, injury to
workers, relief valves can release elevated pressures before they become extreme. Relief
valves use a steel spring as a means to automatically open when pressures reach unsafe levels.
These valves can be adjusted and regulated to pop off when internal pressures exceed
predetermined settings. Once internal pressures return to operational levels, the relief valve
closes.

21
Fig 1.39: Relief Valve

Control Valves
The control valve is an automated valve that can make precise adjustments to regulate
and monitor any commodity flowing through a piping system. The most common valve body
style used as a control valve is the globe valve. Although many other body styles are used, the
globe valve provides the most effective means to regulate and control flow. Control valves
use signals received from instruments positioned throughout the piping system to
automatically make adjustments that regulate the commodity within the pipe.

Though control valves can perform many functions, they are typically used to control
the flow of a commodity within a pipe or to limit its pressure. Control valves must be
arranged within a run of pipe so that they can be easily operated. To achieve this, control
valve manifolds are configured. Control valve manifolds make control valves readily
accessible to plant workers.

Fig 1.40: Control Valve


22
VALVE OPERATORS
A valve operator is a mechanism that causes a valve to perform its function. Operators
can be manual or automatic. Manual operators employ levers, gears, or wheels to facilitate
movement within a valve. In situations where the standard hand-wheel is insufficient to
operate the valve, gears are commonly used to enhance a hand-wheel’s effectiveness. Bevel,
spur, and worm gears supply the hand-wheel with a greater mechanical advantage to open,
close, or throttle the commodity within the pipe. If a valve is installed at a height that is out of
a worker’s reach, a chain operator is often used. The chain operator is a sprocket-like
attachment bolted to a valve’s hand-wheel. A looped chain is passed through the sprocket and
is hung down to a height that is accessible by a worker. This allows a worker to operate the
valve without the aid of a ladder or moveable scaffold.

Actuators
Automatic operators known as actuators use an external power supply to provide the
necessary force required to operate valves. Automatic actuators use hydraulic, pneumatic, or
electrical power as their source for operating valves. Hydraulic and pneumatic actuators use
fluid or air pressure, respectively, to operate valves needing linear or quarter-turn movements.
Electric actuators have motor drives that operate valves requiring multiple turn movements.
Automatic actuators are often provided on control valves that require frequent throttling or
those found in remote and inaccessible locations within a piping facility. Another common
application for automatic actuators is on control valves of large diameter pipe. These valves
are often so large that a worker simply cannot provide the torque required to operate the
valve. Also, in an effort to protect workers, control valves located in extremely toxic or
hostile environments are outfitted with automatic actuators. Additionally, in emergency
situations, valves that must be immediately shut down are operated automatically.

As of the work as a piping designer, pipes with all its fittings and valves are to be
remembered and data sheets are to be produced accordingly. Relief valves and Control valves,
although the name suggest as valve, it is handled by instrumentation designer as well as with
actuators.

23
Valves Selection Criteria

Table 1.1
Service Description of service Recommended valve
Control of fluids which may cause
Contamination contamination build-up, a valve with Ball/ Gate/ Globe/ Pinch
minimum obstruction to flow is needed
Control of flow at high pressures-selection of Ball/ Globe
a valve to be used in a high pressure
High pressure
application, particularly pneumatic, should be Poppet valves are used
approached with caution occasionally.
Ball/ Globe
High
Control of flow at high temperature
temperature Poppet valves are used
occasionally.
Control of flow with very low seat leakage in
Low leakage Ball/ Gate/ Globe/ Plug
the closed position
Ball/ Gate/ Globe/ Plug/
Shut-off Normal on-off control
Ball
Steam service Control of steam under pressure Ball/ Globe
Control the amount of flow by varying the
Throttling Globe/ Ball/ Gate
valve position

24
Table 1.2
Valve Type Mode of flow regulation Fluid
Solids in suspension
On-off Throttling Diverting Free of solids Sticky Sanitary
Non-abrasive Abrasive
Straight pattern Yes Yes Yes
Angle pattern Yes Yes Yes Special Special
Globe Oblique pattern Yes Yes Yes Special
Multi-port Yes Yes Yes
Piston Yes Yes Yes Yes
Conventional Yes Yes
Parallel
Conduit Yes Yes Yes Yes
Gate
Knife Yes Special Yes Yes Yes
With bottom cavity Yes Yes
Wedge Without bottom
Gate cavity (rubber Yes Moderate Yes Yes
seated)
Non – lubricated Yes Moderate Yes Yes Yes
Lubricated Yes Yes Yes Yes Yes Yes
Plug
Eccentric Yes Moderate Yes Yes Yes Yes
Lift Yes Yes Yes Yes Yes
Ball ---- Yes Moderate Yes Yes Yes
Butterfly ---- Yes Yes Special Yes Yes
Pinch ----- Yes Yes Yes Yes Yes Yes Yes
Weir Yes Yes Yes Yes Yes Yes
Diaphragm
Straight through Yes Moderate Yes Yes Yes Yes

25
CODES & STANDARDS
2.1. API CODES
2.2. ASME CODES
2.3. ASTM STANDARDS
2.4. BRITISH STATNDARDS
2.5. ISO CODES
2.6. THICKNESS CALCULATION OF PIPE BASED ON ASME B31.3

Every engineering lies on principles which guide and support the practice of engineering
for the assurance of quality and safety. These guidelines can be codes, standards and
principles accepted by the companies on basis of mutual understanding while initiating the
project.

API CODES/ STANDARDS


 Specification for line pipe API SPEC 5L
 Specification for Wellhead and Christmas tree equipment API SPEC 6A
 Technical report on capabilities of API flanges under combinations
of load API TR 6AF
 Technical report on capabilities of API integral flanges under combination
of loading - Phase II API TR AF2
 Specification for pipeline valves API SPEC 6D
 Recommended practice for repair and remanufacture of pipeline
Valves API RP 6DR
 Specification for fire test for valves API SPEC 6FA
 Pressure-relieving and depressurizing systems API STD 521
 Reconditioning of metallic gate, globe and check valves. API RP 621
 Check valves: Flanged, lug, wafer, and butt-welding API STD 594
 Metal plug valves - Flanged, threaded and welding ends API STD 599
 Steel gate valves-flanged and butt-welding ends, bolted bonnets API STD 600
 Steel gate, globe, and check valves for sizes NPS 4 (DN 100) and smaller
for the petroleum and natural gas industries API STD 602
 Corrosion-resistant, Bolted bonnet gate valves—Flanged and butt-welding
ends API STD 603
 Fire test for quarter-turn valves and valves equipped with non-metallic

26
Seats API STD 607
 Butterfly valves: double-flanged, lug- and wafer-type API STD 609
 Reciprocating compressors for petroleum, chemical and gas industry
services API STD 618
 Type testing of process valve packing for fugitive emissions API STD 622

ASME CODES/ STANDARDS


 Unified inch screw threads (UN and UNR thread form) ANSI/ASMEB1.1
 Rules for construction of power boilers ASME/BPVC SEC I
 Material specification of Ferrous metals ASME SEC II PART - A
 Rules for construction of power boilers ASME/BPVC SEC VIII-1
 Pipe threads, general purpose (inch) ASME B1.20.1
 Cast iron pipe, flanges and flanged fittings ASME B16.1
 Malleable iron threaded fittings ASME B16.3
 Cast iron threaded fittings ASME B16.4
 Pipe flanges and flanged fittings, NPS 1/2 through NPS 24 metric/inch
standard ASME B16.5
 Factory-made wrought butt-welding fittings ASME B16.9
 Face to face and End to end dimensions of valves ASME B16.10
 Forged fittings, socket-welding and threaded ASME B16.11
 Cast iron threaded drainage fittings ASME B16.12
 Ferrous pipe plugs, bushings and locknuts with pipe threads ASME B16.14
 Cast bronze threaded fittings ASME B16.15
 Cast copper alloy solder joint pressure fittings ASME B16.18
 Metallic gaskets for pipe flanges - ring-joint, spiral-wound and
jacketed ASME B16.20
 Non-metallic flat gaskets for pipe flanges ASME B16.21
 Wrought copper and copper alloy solder joint pressure fittings ASME B16.22
 Cast copper alloy solder joint pressure fittings for drain, waste
and vent ASME B16.23
 Cast copper alloy pipe flanges and flanged fittings
Classes 150, 300, 600, 900, 1500, and 2500 ASME B16.24
 Butt welding ends ASME B16.25
 Cast copper alloy fittings for flared copper tubes ASME B16.26
27
 Wrought steel butt-welding short radius elbows and returns ASME B16.28
 Wrought copper and wrought copper alloy solder joint fittings for
drain, waste and vent ASME B16.29
 Manually operated metallic gas valves for use in gas piping systems
up to 125 psig ASME B16.33
 Valves - Flanged, threaded, and welding end ASME B16.34
 Orifice flanges ASME B16.36
 Large metallic valves for gas distribution ASME B16.38
 Malleable iron threaded pipe unions ASME B16.39
 Manually operated thermoplastic valves ASME B16.40
 Ductile iron pipe flanges and flanged fittings, classes 150 and 300 ASME B16.42
 Manually operated metallic gas valves for use in house piping
systems ASME B16.44
 Cast iron fittings for sovent drainage systems ASME B16.45
 Large diameter steel flanges NPS 26 through NPS 60 metric/inch
standard ASME B16.47
 Steel line blanks ASME B16.48
 Factory made wrought steel butt-welding induction bends for
transportation and distribution systems ASME B16.49
 Power piping ASME B31.1
 Fuel gas piping ASME B31.2
 Process piping ASME B31.3
 Pipeline transportation systems for liquids and slurries ASME B31.4
 Refrigeration piping and heat transfer components ASME B31.5
 Gas transmission and distribution piping system ASME B31.8
 Building services piping ASME B31.9
 Slurry transportation piping systems ASME B31.11
 Hydrogen piping and pipelines ASME B31.12
 Welded and seamless wrought steel pipe ASME B36.10
 Stainless steel pipe ASME B36.19
 Performance test code on compressors and exhausters ASME PTC-10
 Thermo-wells performance test codes ASME PTC 19.3 TW

28
ASTM STANDARDS
 Standard specification for seamless carbon steel pipe for high
temperature service ASTM A106
 Standard specification for alloy-steel and stainless steel bolting for
high temperature or high pressure service and other special purpose
applications ASTM A193
 Standard specification for carbon and alloy steel nuts for bolts for high
pressure and high temperature service or both ASTM A194
 Standard specification for alloy steel and stainless steel bolting for low
temperature service ASTM A320
 Standard specification for high temperature bolting with expansion
coefficients comparable to austenitic stainless steels ASTM A453
 Standard specification for electric-fusion-welded steel pipe for high
pressure service at moderate temperatures ASTM A672
 Standard specification for electrodeposited coatings of zinc nickel
alloy deposits ASTM B841
 Standard specification for plastic-lined ferrous metal pipe, fittings
and flanges ASTM F1545
 Standards of the Expansion Joint Manufacturers
Association EJMA STANDARDS
 Petroleum and natural gas industries — Materials for use in
H2S-containing environments in oil and gas production NACE MR0175
 Steam turbines for mechanical drive service NEMA SM 23

BRITISH STANDARDS
 Specification for steel check valves (flanged and butt-welding ends) for
the petroleum, petrochemical and allied industries BS 1868
 Steel globe and globe stop and check valves (flanged and butt-welding ends)
for the petroleum, petrochemical and allied industries BS 1873
 Copper alloy globe, globe stop and check, check and gate valves BS 5154

INTERNATIONAL STANDARDS
 Pipe threads where pressure-tight joints are not made on the threads
Part 1: Dimensions, tolerances and designation ISO 228-1

29
 Petroleum and natural gas industries. Drilling and production equipment.
Wellhead and Christmas tree equipment ISO 10423
 Bolted bonnet steel gate valves for the petroleum, petrochemical and
allied industries ISO 10434
 Testing of valves – Fire type-testing requirements ISO 10497
 Petroleum and natural gas industries - Pipeline transportation
systems ISO 13623
 Petroleum and natural gas industries - design and installation of piping
systems on offshore production platforms ISO 13703
 Petroleum and natural gas industries - Pipeline transportation
systems- Pipeline valves ISO 14313
 Petroleum and natural gas industries - Materials for use in H2S
containing environments in oil and gas production ISO 15156
 Steel gate, globe and check valves for sizes DN 100 and smaller, for the
petroleum and natural gas industries ISO 15761
 Industrial valves - Measurement, test and qualification procedures for
fugitive emissions - Part 1: Classification system and qualification
procedures for type testing of valves ISO 15848-1
 Metal ball valves for petroleum, petrochemical and allied industries ISO 17292

Thickness Calculation of Pipe Based On ASME B31.3


The required thickness of straight sections of pipe shall be determined in accordance
with equation:
tm = t + c
The minimum thickness, T, for the pipe selected, considering manufacturer’s minus
tolerance, shall be not less than tm.
The following nomenclature is used in the equations for pressure design of straight
pipe:
 c = sum of the mechanical allowances (thread or groove depth) plus corrosion and
erosion allowances. For threaded components, the nominal thread depth (dimension h
of ASME B1.20.1 or equivalent) shall apply. For machined surfaces or grooves where
the tolerance is not specified, the tolerance shall be assumed to be 0.5 mm (0.02 in.) in
addition to the specified depth of the cut.

30
 D = outside diameter of pipe as listed in tables of standards or specifications or as
measured
 d = inside diameter of pipe. For pressure design calculation, the inside diameter of the
pipe is the maximum value allowable under the purchase specification.
 E = quality factor
 P = internal design gage pressure
 S = stress value for material
 T = pipe wall thickness (measured or minimum in accordance with the purchase
specification)
 t = pressure design thickness, as calculated in accordance for internal pressure or as
determined in accordance for external pressure
 tm = minimum required thickness, including mechanical, corrosion, and erosion
allowances
 W = weld joint strength reduction factor
 Y = coefficient from Table 3.1, valid for t < D/6 and for materials shown. The value of
Y may be interpolated for intermediate temperatures.
Table 3.1 Values of Coefficient Y for t < D/6
Temperature, °C (°F)
Materials ≤ 482 510 538 566 593 ≥ 621
(900 & Low) (950) (1,000) (1,050) (1,100) (1,150 & Up)
Ferritic steels 0.4 0.5 0.7 0.7 0.7 0.7
Austenitic steels 0.4 0.4 0.4 0.4 0.5 0.7
Other ductile metals 0.4 0.4 0.4 0.4 0.4 0.4
Cast iron 0.0 … … … … …
For t ≥ D/6,
𝒅 + 𝟐𝒄
𝒀=
𝑫 + 𝒅 + 𝟐𝒄
For t < D/6, the internal pressure design thickness for straight pipe shall be not less than that
calculated in accordance with either equation:
𝑷𝑫
𝒕=
𝟐𝑺𝑬𝑾 + 𝑷𝒀
or
𝑷(𝒅 + 𝟐𝒄)
𝒕=
𝟐(𝑺𝑬𝑾 − 𝑷(𝟏 − 𝒀))
For t ≥ D/6 or for P/SE > 0.385, calculation of pressure design thickness for straight pipe
requires special consideration of factors such as theory of failure, effects of fatigue, and
thermal stress.
31
PLOT PLANS AND EQUIPMENT LAYOUT DESIGN
3.1. EQUIPMENTS LAYOUT
3.1.1. TANK FARM DESIGN
3.1.2. PIPE RACK DESIGN
3.2. PIPING GAD

The equipment layout is based upon the Shell DEPs and local authoritative policies.
These include all the safety precautions taken in need while locating and installing the
equipment at appropriate place for the ease of access and maintenance issues.

DESIGN BASED ON OISD STD 118

Plant layout philosophy:


 Block layout as far as possible-layout arrangement-general route for raw materials
process units-tankage-storage and dispatch facilities.
 Area has to be divided into blocks and further sub-blocks.
 Primary traffic roads have to be installed outside hazardous areas. The roads between
the blocks installed as separators act as firebreaks in case of emergencies.
 Pedestrian pathways have to be marked along the primary traffic roads.
 An alternate access has to be provided for each facility other than the normal
approach.
 Road widths, gradient and turning radii along with junctions are to be designed on
basis of the largest fire-fighting vehicle available for unrestricted movement.
 Ignition source has to be outside the boundary wall of the installation.
 Two road approaches from highway/ major roads are to be designed such way that one
is for the access of employees and other for the product/ material movement.
 Flares, furnaces, heaters and dusty operations are to be oriented away from
hydrocarbon vapor based on wind flow (downwind).
 Space provisions are to be assessed for future expansions.

Layout identification: processing area, equipment layout in a unit, processing unit layout,
structural layout, piping layout and electrical layout.

32
Layout requirements:
 HSSE
o Segregation inside the facility fence.
o Segregation outside the facility fence.
o Toxics.
o Safety critical equipment.
o Hazardous area classification.
 Minimum separation distances
o 50 m (165 ft.) between process facilities containing pressurized liquids.
o 25 m (83 ft.) between process facilities containing gases.
o 100 m (330 ft.) between process facilities having a total hydrocarbon
containing equipment area in excess of 25000 m2 (272250 ft2).
o Roads away of 15 m from the units.
 Constructability
o Human factors engineering.
o Suitable access or construction equipment.
o Minimum workspace envelope for construction equipment.
o Areas for laydown, storage and temporary facilities.
o Material off-loading facilities.
o Safe SIMPOS.
o Traffic and pedestrian management.
o Severity and exclusion requirements.
o Desired construction strategy, sequence and schedule.
 Operability and maintainability
o Expansion.
o Ergonomics.
o Emergencies, escape and evacuation.
o Fire protection.
o Natural ventilation.
o Acoustic enclosures.

The tables below show the basic data to be remembered while designing the base layout based
on OISD – 118 (for India).

33
SEPARATION DISTANCES BETWEEN BLOCKS/FACILITIES TABLE – 3.1

S. No. From / To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 Process Units Note- Note-


30 30 30 60 90 45 45 60 45 30 60 60 30 90
1 3

2 Process Control Room (Note –2) Note- Note- Note- Note-


X 30 60 90 45 45 30 X 30 15 30 30
3 4 5 3

3 Storage Tanks Class-A Note- Note- Note- Note-


30 30 90 30 30 60 (90) 30 T3 60 30 50
4 6 6 6

4 Storage Tank Class-B Note Note- Note- Note-


30 30 90 30 30 60 (90) 30 T3 30 30 50
-5 6 6 6

5 Storage Tank Class-C Note- Note- Note-


30 30 30 90 30 30 60 (90) 30 T3 30 30 50
6 6 6
6 Pressurized Storage: LPG/ C4 & Lighter / H2 60 60 30 30 30 T7 90 30 T6 90 (90) 30 T7 45 30 60
7 Flare (Note-7) 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90

8 Bulk Loading POL (Rail /Road) Note- Note- Note-


45 45 30 30 30 30 90 60 30 T3 60 30 50
8 9 10

9 Bulk Loading LPG (Rail /Road) Note-


45 45 30 30 30 T6 90 T6 90 (90) T6 T6 60 30 50
9
10 Fire Station / First Aid Center 60 30 60 60 60 90 90 60 90 X 30 30 12 12 30 90

11 Boiler house / Process Unit Heaters (Note-11) Note- Note-


45 (90) (90) (90) (90) 90 30 (90) 30 X 15 50 30 30
3 12
12 Rail Spur 30 X 30 30 30 30 90 Note- T6 30 15 X 30 6 15 50

34
10

13 Boundary wall around installation 60 30 T3 T3 T3 T7 90 T3 T6 12 50 30 X 6 30 50


14 Service buildings 60 15 60 30 30 45 90 60 60 12 30 6 6 X 30 50
15 Cooling tower 30 30 30 30 30 30 90 30 30 30 30 15 30 30 X 15

16 API Separators / Oil sludge pit Note-


90 30 50 50 50 60 90 50 50 90 50 50 50 15 X
12
General Notes to Table – 3.1:
a) All distances are in meters. “T” indicates the table number to be referred. “X” means any distance suitable for constructional or operational
convenience.
b) All distances shall be measured between the nearest points on the perimeter of each facility except (i) In case of tank vehicle loading /
unloading area where the distance shall be from the center of nearest bay. (ii) The distances given in the brackets ( ) are from the shell of the
Heater / Boiler / Furnace / Still.
Specific notes to Table – 3.1:
Note-1: This shall be 36 meters considering the 6-meter wide road passing through the center. The edge of the road shall not be less than 15 meters
away from the edge of the unit.
Note-2: Type of construction shall be as per OISD-STD-163.
Note-3: Process control room to Process units / boiler house / heaters the minimum separation distance shall be 30 m. For a control room attached to
single process unit or a boiler or a heater, the minimum separation distance shall be 16 m. For Gas processing plants, it shall be minimum 30
meters irrespective of whether it is for one or more units.
Note-4: Shall be 60 m for non-blast construction and 30 m for blast resistant construction.
Note-5: Shall be 45 m for non-blast construction and 30 m for blast resistant construction.

35
Note-6: Separation distances between the nearest tanks located in two dykes shall be equivalent to the diameter of the larger tank or 30 m, whichever
is more. For distances within a dyke, it shall be as per Table – 3.3 and Table – 3.4
Note-7 The distances specified are for the elevated flare. For ground flare, these distances shall be 150 m. For Exploration and Production
installations, this shall be in line with Oil Mines Regulations.
Note-8 Separation distance between Tank truck gantry and wagon gantry shall be 50m.
Note-9 The separation distance shall be 50 m. However for LPG tank truck bulk loading to POL tank truck bulk loading it shall be 30 m.
Note-10 Separation distance between tank truck gantry and rail spur shall be 50 m.
Note-11: Boiler house or heater of a process unit is to be treated as a separate identity only for the consideration of surrounding blocks / facilities.
However, heater of a process unit remains an integral part of the process unit to which it is attached and in that case the inter equipment
distances should be in line with Table – 3.2.
Note-12: Centralized / common API separators, Corrugated Plate Interceptor (CPI), open oil separators shall be categorized under the same risk and
shall be located at a distance of 90 meters from heaters / boilers. However, if these are covered from the top and provided with adequate
venting to safe location, the minimum separation distance shall be 30 meter.
SEPARATION DISTANCES BETWEEN EQUIPMENT WITHIN PROCESS UNIT TABLE – 3.2

S. No. From / To 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 Fired Heater / Any fired equipment X 15 15 15 22 15 15 20 15 15 15 X 18 6 30 15
2 Reactors 15 2 2 6 8 7 15 7 7 4 3 15 5 3 15 3
3 Distillation column 15 2 3 4 7 5 15 5 5 2 3 15 3 3 15 3
4 Accumulators – Hydrocarbons 15 6 4 2 8 5 15 4 4 2 3 15 3 3 15 3
5 Compressors – Hydrocarbons 22 8 7 8 3 7 15 7 7 7 7 15 4 3 20 7
6 Hot oil pump 15 7 5 5 7 1 7 1 1 2 2 15 3 X 15 X
36
7 Fuel Oil / HCs day tank 15 15 15 15 15 7 T-5 15 15 15 15 15 15 X 15 15
8 Pumps for class- A & all above Auto-ignition temp 20 7 5 4 7 1 15 1 1 2 2 15 3 X 15 X
9 Pumps - for all other Hydrocarbons 15 7 5 4 7 1 15 1 1 2 2 15 3 X 15 X
10 Heat Exchangers 15 4 2 2 7 2 15 2 2 2 2 15 2 2 15 X
11 Air fin coolers for Hydrocarbons 15 3 3 3 7 2 15 2 2 2 X 15 2 X 15 2
12 Fired heater Local control panel X 15 15 15 15 15 15 15 15 15 15 X 10 X 15 5
13 Pressure vessels / Drums of Hydrocarbons 18 5 3 3 4 3 15 3 3 2 2 10 2 3 15 2
14 Main Pipe rack 6 3 3 3 3 X X X X 2 X X 3 X 15 X
15 Blow down facility – Drum, pump, vent stack 30 15 15 15 20 15 15 15 15 15 15 15 15 15 X 15
16 Structural main – Technological platforms 15 3 3 3 7 X 15 X X X 2 5 2 X 15 X
General notes to Table – 3.2:
a) All distances are face-to-face clear minimum distances in meters.
b) “X” indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements.
c) Distances specified in Table – 3.2 are the minimum recommended distances that the industry should adhere. These could be suitably
modified as required to suit space constraints and relevant engineering practices except the followings.
(i) Blow down facility (open pit type) / oil catcher shall be located at a distance not less than 30 m from fired heater / any fired
equipment. If the blow down drum is located underground / oil catcher is cover with vent to safe location, the minimum separation
distance shall be 15m.
(ii) Fuel Oil day tank shall be located at a distance of not less than 15m from equipment except those facilities such as heat exchanger,
pump connected directly with the Fuel Oil system.
d) Firewater hydrant / monitors shall be minimum 15 m away from the equipment that is to be protected.
37
e) Water spray deluge valve shall be minimum 15 m from equipment handling hydrocarbon.
f) Fuel gas knock out drum shall be located at a minimum separation distance of 15 m from the heater.
g) Separation distances specified in other OISD standards or elsewhere in this standard (other than Table – 3.2) shall be followed as
recommended.
SEPARATION DISTANCES BETWEEN TANK / OFFSITE FACILITIES - (For large installations) TABLE – 3.3
S. No. Tanks / Facility 1 2 3 4 5 6 7 8 9

1 Storage Tank for Petroleum Class A / Class B. T4 T4 15 15 15 15 8 15 0.5 d-min 20 m

2 Storage Tank for Petroleum Class C T4 X 15 X 8 X X X 0.5 d-min 20 m

3 Storage / Filling Shed for petroleum Class A or class B 15 15 X 8 15 15 8 15 15

4 Storage / Filling Shed for Petroleum Class C 15 X 8 X 8 X X X 10

5 Tank vehicle loading / Unloading for petroleum class A or class B 15 15 15 8 X X 8 15 20

6 Tank Vehicle loading / unloading for Class C 15 X 15 X X X X X 10

7 Flame proof Electric Motor 8 X 8 X 8 X X 8 X

8 Non flame proof electric Motor 15 X 15 X 15 X 8 X X

9 Boundary wall 0.5 D-Min 20


0.5 D-Min 20 m 15 10 20 10 X X X
m

38
SEPARATION DISTANCES BETWEEN STORAGE TANKS WITHIN A DYKE TABLE – 3.4
S. No. Item Between floating Roof Between fixed Roof Tanks Class Between Class C Petroleum
Tanks Class A & B A&B Storage tanks
1 All tanks with Diameter up to 50 (D + d) / 4 - Min 10 m (D + d) / 4 - Min 10 m (D + d) / 6 - Min 6 m
meters
2 Tanks with Diameter exceeding (D + d) / 4 (D + d) / 3 (D + d) / 4
50 meters.
General notes to Table – 3.3 and 3.4:
a) All distances are in meters.
b) “X” indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
c) D and d stands for diameter of larger and smaller tanks. Distances given are shell to shell in the same dyke
d) In Table – 3.3 all distances shall be measured between the nearest points on the perimeter of each facility except in the case of tank vehicle
loading/unloading area where the distance shall be measured from the center of each bay.
e) In Table – 3.4, Distances given are shell to shell in the same dyke.
f) For different combination of storage tanks, the stringent of the applicable formulae shall be considered for minimum separation distance.
g) The distance of storage tanks from boundary wall is applicable for;
(i) Floating roof tanks having protection for exposure
(ii) Tanks with weak roof-to-shell joint having approved foam or inerting system and the tank diameter not exceeding 50 meters.
h) For the facilities not covered in Table – 3.3, refer Table – 3.1.

39
SEPARATION DISTANCES BETWEEN TANKS/OFFSITE FACILITIES - (For small installations) TABLE – 3.5
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13

1 Storage Tank Class A 0.5D 0.5D 0.5D / 6.0 9 9 9 15 15 15 3 15 15 15


D
D
2 Storage Tank Class B 0.5D 0.5D 0.5D / 6.0 9 0.5D 0.5D 9 4.5 4.5 3 4.5 Min
Min 4.5
4.5
0.5D
0.5D / 0.5D
3 Storage Tank Class C 0.5D / 6.0 X 9 0.5D X 9 4.5 X X x Min
6.0 Min 3.0
3.0
Storage / Filling shed for petroleum 9 9 9 x 4.5 6 9 9 9 3 9 9 9
4
Class –A
Storage / Filling shed for petroleum 9 0.5D 0.5D 4.5 x 1.5 9 4.5 4.5 1.5 4.5 4.5 4.5
5
Class –B
Storage / Filling shed for petroleum 9 0.5D X 6 1.5 X 9 4.5 X X x 3 3
6
Class –C
Tank vehicle Loading / unloading 15 9 9 9 9 9 x 9 9 3 9 9 9
7
Class – A
Tank vehicle Loading / unloading 15 4.5 4.5 9 4.5 4.5 9 X 4.5 1.5 4.5 4.5 4.5
8
Class – B
Tank vehicle Loading / unloading 15 4.5 X 9 4.5 X 9 4.5 X X X 3 3
9
Class – C
10 Flame proof Electric motors 3 3 X 3 1.5 x 3 1.5 X X 3 X X
11 Non Flame proof Electric motors 15 4.5 X 9 4.5 x 9 4.5 X 3 X X X
D - Min 0.5D - Min
12 Office building, stores, amenities 15 9 4.5 3 9 4.5 3 X X X X
4.5 3.0
D - Min 0.5D - Min
13 Boundary wall 15 9 4.5 3 9 4.5 3 X X X X
4.5 3.0

40
General notes to Table – 3.5:
a) All distances are in meter and the table specifies the minimum requirement.
b) “X” indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
c) “D” indicates the diameter of the larger tank.
d) Distances given for the tanks are shell to shell in the same dyke.
e) Where alternate distances are specified (like 0.5 D / 6.0), the minimum thereof shall be used.
f) All distances shall be measured between the nearest points on the perimeter of each facility except in case of tank vehicle loading /unloading
area where the distance shall be from the center of each bay.
g) Pig launcher/receiver at liquid hydrocarbon handling pipeline installations should be located at least 5 m from boundary.
SEPARATION DISTANCES FOR LPG FACILITIES TABLE – 3.6

Sr no. FROM / TO 1 2 3 4 5 6 7 8

1 LPG Storage vessels Note-1 T7 30 30 50 30 15 60

2 Boundary wall / group of buildings not associated with LPG plant T7 X 30 30 50 30 30 X

3 Shed for filling and storage of LPG, Cold repair shed, Cylinder evacuation facilities 30 30 15 30 50 30 15 60

4 Tank Truck Loading / unloading gantry 30 30 30 30 50 50 30 60

5 Tank wagon gantry 50 50 50 50 50 50 30 60

6 Rail spur 30 30 30 50 50 50 30 60

7 Pump house / Compressor house (LPG) 15 30 15 30 30 30 X 60

8 Fire Water pump house 60 X 60 60 60 60 60 X

41
SEPARATION DISTANCES BETWEEN LPG STORAGE VESSELS AND BOUNDARY WALL/ GROUP OF BUILDINGS NOT
ASSOCIATED WITH LPG FACILITIES TABLE – 3.7
Capacity of Each vessel in Cum of water 10 – 20 21 - 40 41 – 350 351 - 450 451-750 751 - 3800

Distance in meters 15 20 30 40 60 90

General Notes to Table – 3.6 & Table – 3.7:


a) Table – 3.6 is applicable for total storage of above 100 Tonnes.
b) All distances are in meters
c) “X” indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
d) T7 indicates Table –7;
e) Distance of stabling line shall be as per Railway Standards.
Specific Notes to Table- 6;
Note – 1: The distance shall be 2 meters or 1/4 of the sum of the diameters of the adjacent vessels or half the diameter of the larger of the two adjacent
vessels in the same group whichever is greater.

42
Tank Farm Design
A small preview (figure below) of a tank farm with dyke distances design based on OISD
STD 118.

Fig 3.1: Tank farm design and dyke volume


43
Pipe Rack Design
Pipelines in the pipe rack are classified as process lines, relief-line headers and utility
headers.

 Process lines:
Process lines are those
o which interconnect nozzles on process equipment more than 20ft. apart (closer
process equipment can be directly interconnected with pipelines)
o product lines which run from vessels, exchangers, or more often from pumps
to the unit limits to storage or header arrangement outside the plant
o crude or other charge lines which enter the unit and usually run in the yard
before connecting to exchangers, furnaces or other process equipment e.g.,
holding drums or booster pumps.

 Relief-line headers:
Individual relief lines, blow down lines and flare lines should be self-draining from all
relief valve outlets to knock-out drum, flare stack or to a point at the plant limit. A
pocketed relief line system is more expensive, because usually an extra condensate pot
is required with instruments, valves and pumps. To eliminate pockets, some relief line
headers must be placed at higher elevation above the main yard usually on a tee
support on the extended pipe rack column. However, on some non-condensing gas
systems self-drainage is not so essential. Relief lines can be individual, some with
large diameters and occasionally high temperatures.

 Utility lines:
Utility lines in the pipe rack can be put in two groups
o Utility headers serving equipment in the whole plant. Such lines are: low and
high pressure steam lines, steam condensate, plant air and instrument air. If
required, cooling water supply and return and service water can be also
arranged on the pipe rack.
o Utility lines serving individually on or two equipment items or a group of
similar equipment (furnaces, compressors) in the plant. Such lines are: boiler
feed-water, smoothering steam, compressor staring air, various fuel oil lines,
lubricating oil, cooling oil, fuel gas, inert gas and chemical treating lines.

44
o Steam header should drain to the steam separator for more effective condensate
collection. Branch connections to steam headers usually connect to the top to
avoid condensate drainage to equipment.

 Instrument lines and Electrical cables:


Instrument lines and Electrical cables are often supported in the yard and extra space
should be provided for these facilities. The best instrument line arrangement
eliminates almost all elevation changes between the plant and the control room. This
can be easily achieved when instrument lines are supported outside the pipe rack
column on a suitable elevation.

Fig 3.2: A typical figure showing a pipe rack configuration

45
Steps to pipe rack piping:
 The step in the development of any pipe rack is the generation of a line-routing
diagram. A line routing diagram is a schematic representation of all process piping
systems drawn on a copy of pipe rack general arrangement drawing/ or on the unit plot
plan where the pipe rack runs in the middle of the process unit. Based on the
information available on the first issue of P & I diagrams/ Process flow diagrams i.e.
line size, line number, pipe material, operating temperature etc. the line routing is to
be completed.
 Once the routing diagram is completed, the development of rack width, structural
column spacing, road crossing span, number of levels and their elevations should be
started. Pipe rack column spacing shall be decided based on the economics of the pipe
span as well as the truss arrangement to accommodate double the span for road
crossing or avoiding underground obstructions. Pipe rack arrangement should be
developed to suit the specific plant requirements.
 The pipe rack width can now be worked out with atypical cross-section of the rack
with the levels. Normally, pipe rack carries process lines on the lower level or levels
and the utility lines on the top level. Instrument and electrical trays are integrated on
the utility level if space permits or on a separate level above the all pipe levels. Any
pipe rack design should provide provision for future growth to the extent of 25 to 30%
on the rack clear width. When flanges or flanged valves are required on two adjacent
lines, the flanges are to be staggered. Thermal expansion or contraction must be
accommodated by keeping sufficient clearance at the location where the movements
will occur. The clearance of the first line from the structural pipe rack column is to be
established based on the sizes furnished by the civil// structural engineers.
 After analyzing all the requirements and arrangements, the dimensions are to be
rounded-off to the next whole number. Based on the economics, the width and the
number levels e.g. two tier of 30 ft. wide or three tier of 20 ft. wide rack will be
considered. The gap between the tiers shall be decided on the basis of the largest
diameter pipeline and its branching. The difference between the bottom line of pipe in
the rack and the bottom of a branch as it leaves the rack shall be decided carefully, to
avoid any interference due to support, insulation, size of branch, etc. All branch line
from the main lines on pipe rack shall be taken aesthetically on a common top of steel.
 Regardless of service, heavy lines (very large diameter lines, large lines of liquid) are
placed over or near the pipe rack columns. Centrally loaded column and reduced
bending moment on the beam will result in a lighter structural design. Next to these
46
lines are placed all process lines and relief lines. Utility lines are in the center portion
of the yard.
 It is advantageous, from point of view of support, to group hot lines requiring
expansion loops. Loops elevated horizontally over the yard are the most common
adopted design, having the hottest and largest diameter line outside. Line guides, line
stops and anchor points are usually required along a hot line somewhere in the pipe
rack. Pipe expansion forces, at some of these points, will affect yard support design.
 Those process lines which interconnect equipment on the same side of the yard should
be near the edges of the yard bank. Lines which interconnect equipment located on
both sides of the yard should be closer to the utility lines and can be placed either side
of the yard. Position of product lines is influenced by their routing after leaving the
plant limit. Right (left) turning lines should be on the right (left) hand side of yard.
Utility lines serving individually one or two equipment items should be on the same
side of the yard as the equipment to which they connect.

Fig 3.3: A typical design of Pipe rack

47
Piping GAD
Piping GAD means “Piping General Arrangement Diagram”. It is an old
representation of pipeline routing done for estimating the pipe material, optimum valve
location and optimum location of process lines.

Fig 3.4: A typical piping GAD


The following tables show the symbols which are used in piping general arrangement
drawing.

48
Fig 3.5: Piping GAD
49
Fig 3.6: Piping GAD
50
Fig 3.7: Piping GAD
51
Fig 3.8: Piping GAD
52
EQUIPMENT DRAWINGS
4.1. MECHANICAL DRAWINGS
4.2. VENDOR DRAWINGS

Equipment drawings are made for realizing the equipment to actually exist. These
drawings are useful in knowing the orientation of nozzles which in through help the piping
designers to optimize the pipeline routing. These drawings also help the layout designers to
allocate the optimum space for equipment in the design. These drawings are drawn by
mechanical engineers.

Mechanical Drawings
Mechanical drawings are made mechanical engineers based on the data received from
process and instrumentation. These data are called “Process Data Sheets” in short PDS. From
PDS, the details of the equipment design viz., nozzle location and orientation, location of
valves if any, position of instrumentation materials, dimension of equipment and shape of
equipment.

Fig 4.1: A typical mechanical drawing of equipment

53
Vendor Drawings
When the mechanical drawings are sent to the vendors for idealization, the vendors
send a drawing in equivalent of what is available with them. These drawings would be more
realistic than mechanical drawings. The designers from both the teams decide whether the
changes are apt or not. The final drawing from the vendor then released for fabrication based
on the discussion and changes made.

Fig 4.2: A typical vendor drawing of equipment

54
LIVE PROJECT – SHELL FRANKLIN PE3 (064340C)
5.1. PROCESS DESCRIPTION
5.2. MODULARIZATION
5.3. PIPE MATERIAL SPECIFICATION (PMS)
5.4. SHELL DESIGN & ENGINEERING PRACTICES (DEP)
5.4.1. PIPING – GENERAL REQUIREMENTS
5.4.2. PIPE SUPPORTS
5.4.3. THERMAL INSULATION
5.4.4. HUMAN FACTORS ENGINEERING – WORKSPACE DESIGN
5.4.5. HUMAN FACTORS ENGINEERING – VALVES
5.5. PIPING DESIGN STUDIES OF THE TREATOR
5.6. BASICS OF STRESS ANALYSIS OF PIPES

PROCESS DESCRIPTION

Shell intends to develop a PE production facility along Ohio River in Monaco,


Pennsylvania with functional areas
i. ECU – Ethylene Cracker Unit
ii. PE 1 and PE 2 Gas phase PE Units
iii. PE 3 Slurry phase Unit
iv. Other units

The Shell-Franklin PE3 Slurry Polyethylene HDPE project, 064340C, is the current
project handling by Technip India. This project is an engineering project. The work
undertaken here is in the part of HDPE slurry unit. The official completion of project is 30%+
in 1½ years.

The HDPE slurry process is an innovative INNOVENETM S process where the


production of high density polyethylene (HDPE) is done through slurry at low temperatures
and pressures. The polymerization is done slurry loop reactor system; polymer growth in
suspension of inert light hydrocarbon liquid diluent with the mixtures of ethylene (monomer),
hydrogen and co-monomers in the presence of catalysts and co-catalysts. The process flow
diagram is depicted in to a flow chart as below.

55
Fig 5.1: Flow diagram of process
56
Where:
 LPSR – Low Pressure Solvent Recovery
 HPSR – High Pressure Solvent Recovery
 LSR – Low Hexene Solvent Recovery
 HSR – Hexene Rich Solvent Recovery
 TEAL – Tri-Ethyl Aluminium
 TEB – Tri-Ethyl Borane
 OSBL – Outside Battery Limit

MODULARIZATION

 No. of modules: 40
 Transport method: Deck Barge
 Setting plan: SPMT (Self Propelled Modular Transporter) and lift for some
 Estimated weights (totals):
o Pipe spool - 541 metric tonnes
o Steel - 4614 metric tonnes
o Equipment - 352 metric tonnes
Total - 5493 metric tonnes

Every part of the project is placed in modules which are easily identified by their tag
number. Some modules are pre-assembled from the vendors; process modules include
equipment; pipe racks and cable racks as separate modules. For each module, out to out
dimensions should not exceed height-40’-12.2 m, width-50’-15.2m, length-166’-50.6m and
weight-300 metric tonnes (maximum). The summary of the process of installation of
fabricated modules is shown below.

57
Fig 5.2: Transportation chart

58
PIPE MATERIAL SPECIFICATION (PMS)

For every material used in the project has its own material specification written by the
process team based upon their properties they exhibit. The material specification can change
from line to line, area to area and may be for module to module. It doesn’t mean that all the
materials used in the same area or module should have the same material specification.

The material specification is classified based on the pressure rating, steel grade used,
etc. The following description can used to understand how a PMS can be used to identify a
line and its location.

4”-PG101001-31011-3HH-2”
where:
 The first number is the pipe size
 The first two letters describes the process fluid
 The digit after the letters tells the location of the area
 The next two digits tells the unit or sub-unit
 The succeeding 3 digits describe the tag number/ sequence of the line
 The next digit is the pressure rating of the line (150#, 300#, 400#, 600#, 900#, 1500#
and 2500#)
 The following 2 digits tells the piping class (pipe grade)
 The number with 2 alphabet tells the insulation applied on the pipe
 The last digit depicts the insulation thickness applied on the pipe

The piping legends are described intensively in the annexures.

The following data, PMS is used in the project of “Modelling of Lines Carrying Process
Fluids from the Reactor”.

59
Table 5.1: Pipe Material Specification
Specification Part Grade Size
Pipe ASTM A106 – B NPS ½” – 12”
Blind Flange ASTM A105 NPS ½” – 48”
Weld-Neck Flange ASTM A105 NPS ½” – 48”
11011 – F1 Gasket Spiral Wound AISI 316 NPS ½” – 48”
Stud bolts with nuts ASTM A193 – B7/ A194 – 2H
90o Elbows (LR) ASTM A234 – WPB NPS ½” – 24”
Weldolet ASTM A105 NPS ½” – 48”
ASTM A312 – TP304 NPS ½” – 12”
Pipe
ASTM A358 – 304 NPS 14” – 48”
13095 - F31 90o Elbows (LR) ASTM A403 – WP304 NPS ½” – 12”
Branch Fitting (Plain) ASTM A182 – F304 NPS ½” – 1½”
Tee – reducing (BW) ASTM A403 – WP304 NPS ¾” – 24”
Pipe ASTM A333 – 6 NPS ½” – 16”
90o Elbows (5D) ASTM A420 – WPL6 NPS ½” – 16”

61141 – KS – F3 Tee – equal (BW) ASTM A420 – WPL6 NPS ½” – 16”


(consider same for Weldolet ASTM A350 – LF2 cl 1 NPS ½” – 16”
61015 – KS – F3) Blind Flange ASTM A350 – LF2 cl 1 NPS ½” – 16”
Weld-Neck Flange ASTM A350 – LF2 cl 1 NPS ½” – 16”
Gasket Spiral Wound AISI 316 NPS ½” – 16”
60
Stud bolts with nuts ASTM A320 – L7/ A194 - 4
Spectacle Blind ASTM A516 – 60/ 65/ 70 NPS ½” – 8”
Body: ASTM A350 – LF2 cl 1/ A352 – LCC
Ball valve Flanged Trunnion Full Bore NPS ½” – 16”
Trim: AISI 316, PTFE
ASTM A312 – TP304 (Seamless) NPS ½” – 12”
Pipe
ASTM A358 – 304 NPS 6” – 48”
Blind Flange ASTM A182 – F304 NPS ½” – 48”
Weld-Neck Flange ASTM A182 – F304 NPS ½” – 48”
Gasket Spiral Wound AISI 316, Graphite NPS ½” – 24”
Stud bolts with nuts ASTM A193 – B8 cl 2/ A194 - 8
Spectacle Blind ASTM A240 – TP304 NPS ½” – 12”
ASTM A403 – WP304 NPS ½” – 6”
90o Elbows (LR)
ASTM A403 – WP – Class S/ WX – 304 NPS 8” – 24”
63095 – F31
Branch (plain) ASTM A182 – F304 NPS ½” – 1½”
Tee – reducing (BW) ASTM A403 – WP304 NPS ¾” – 24”
ASTM A403 – WP304 NPS ¾” – 6”
Eccentric reducer (BW)
ASTM A403 – WP – Class S/ WX – 304 NPS 8” – 24”
Body: ASTM A182 – F316/ A351 – CF8M
Ball valve Flanged Float Reduced Bore NPS ½” – 2”
Trim: AISI 316, Stellite
Body: ASTM A182 – F316/ A351 – CF8M
Ball valve Flanged Trunnion Reduced Bore NPS 3” – 16”
Trim: AISI 316, Stellite
Body: ASTM A182 – F316/ A351 – CF8M
Check valve Flanged NPS ½” – 24”
Trim: AISI 316, Stellite
61
ASME B31.3: Process Piping
The design basis of piping systems for chemical and petroleum plants and refineries
processing chemicals and hydrocarbons, water and steam for utilization of materials. This
code contains rules for piping typically found in petroleum refineries; chemical,
pharmaceutical, textile, paper, semiconductor and cryogenic plants; and related processing
plants and terminals.

This code prescribes requirements for materials and components, design, fabrication,
assembly, erection, examination, inspection and testing of piping. This code applies to piping
for all fluids including:

 Raw, intermediate and finished chemicals.


 Petroleum products.
 Gas, steam air and water.
 Fluidized solids.
 Refrigerants.
 Cryogenic fluids.

Piping – General Requirements


The following pipe sizes shall be used:
 DN 15 (NPS ½)
 DN 20 (NPS ¾)
 DN 25 (NPS 1)
 DN 40(NPS 1 ½)
 DN 50 (NPS 2)
 DN 80 (NPS 3)
 DN 100 (NPS 4)
 DN 150 (NPS 6)
 DN 200 (NPS 8)
 DN 250 (NPS 10)
 DN 300 (NPS 12)
 DN 350 (NPS 14)
 DN 400 (NPS 16)
 DN 450 (NPS 18)
62
 DN 500 (NPS 20)
 DN 600 (NPS 24)

a) Due to their vulnerability to damage and their limited mechanical strength, sizes DN
15 (NPS ½) and DN 20 (NPS ¾) should not be used. Sizes DN 15 (NPS ½) and DN
20 (NPS 3/4) shall not be used for long-run piping.
b) Nominal pipe size in pipe tracks shall not be less than DN 50 (NPS 2)
c) Nominal pipe size in pipe racks shall not be less than DN 40 (NPS 1 ½)
d) Pipe sizes between those given in the piping classes shall not be used.

Unless economically justified otherwise, the range of pipe sizes above DN 600 (NPS
24) shall be restricted to the following, in order to avoid the purchase of many different sizes
of pipe and fittings:

 DN 750 (NPS 30)


 DN 900 (NPS 36)
 DN 1050 (NPS 42)
 DN 1200 (NPS 48)
 DN 1400 (NPS 56)
 DN 1600 (NPS 64)
 DN 1800 (NPS 72)
 DN 2000 (NPS 80)

After the basic pipe routes, number of valves, control valves, fittings, etc., have been
determined, the anticipated pressure drop for the preliminary pipe sizes shall be checked. A
calculation sheet for pumping data shall be prepared for each pump, showing calculations for
suction and discharge conditions, static head, static pressure, vapor pressure at pumping
temperature and minimum available NPSH (Net Positive Suction Head), including the
calculated pressure drop in equipment, pipes, valves, fittings and control valves.

Preliminary pipe sizing:


 Liquid piping systems –
 For water and other liquids (ISO 13703)
Velocity: 0.5 m/s to 5 m/s (1.6 ft/s to 16 ft/s)

63
Pressure:
Pump suction –
i. 0.034 bar/ 100 m to 0.083 bar/ 100 m (0.15 psi/ 100 ft to 0.37 psi/ 100
ft) with 15 oC (27 oF) of their boiling point
ii. 0.15 bar/ 100 m to 0.4 bar/ 100 m (0.66 psi/ 100 ft to 1.77 psi/ 100 ft)
for subcooled
Pump discharge –
i. 0.15 bar/ 100 m to 0.627 bar/ 100 m (0.66 psi/ 100 ft to 2.77 psi/ 100 ft)
 Gas piping systems
i. Air and other gases (non-corrosive/ non-erosive)
a. 10 to 20 m/s (33 to 66 ft/s)
b. ρυ2 < 20,000 kg/ m. s2 with maximum velocity of 60 m/s (200
ft/s)
ii. Saturated steam (dry): 15 to 30 m/s (50 to 100 ft/s)
iii. Supersaturated steam: 30 to 60 m/s (100 to 200 ft/s)
iv. Vacuum pipes: 10 to 100 m/s (33 to 330 ft/s)
 Drilling fluid piping system:
i. 0.8 m/s (3 ft/s) < velocity < 4 m/s (13 ft/s)
ii. Maximum pressure drop – 0.3 bar/ 100 m (13.3 psi/ 1000 ft)

Considerations:
The following should be considered in determining a suitable pipe size:
a. The allowable pressure drop.
b. Whether pressure surges could occur in the piping system.
c. Whether erosion could occur in the piping system.
d. Whether the piping system could be subjected to vibration.
e. Whether solids could settle out from the fluid (e.g., in slurry service).
f. The type of flow pattern in services where two-phase flow is possible (an intermittent
flow pattern shall be avoided).
g. The allowable temperature drop if the fluid is highly viscous.
h. The economic pipe diameter, considering the capital expenditure and operating
expenditure of the pumps, compressors and the piping system.
i. Mechanical strength
j. The required flow demand of the piping system or process (flow constraints)
k. Weight constraints
64
DESIGN CONDITIONS
A piping system shall be designed for the most severe conditions to which it may be
subjected. The following may determine the design conditions:
a. Steam-out pressure and temperature
b. Surge pressure
c. Pump shut-off pressure
d. Static pressure
e. Pressure drop
f. Vacuum caused by cooling and possible condensing of trapped medium
g. Steam/nitrogen purge pressure
h. Reactor regeneration temperature
i. Furnace decoking operation temperature
j. Settling pressure of compressor
k. Emergency depressurization
l. Killing condition of a well
m. Possibility of temperature rise due to stagnancy

Piping stress analysis


Piping systems shall be routed, supported, anchored or guided so that:
 Thermal expansion/contraction,
 Weight effects including the pipe contents,
 Insulation and any other superimposed loads,
 Pressure effects,
 Vibration or movements due to earthquakes and storms
will not result in stresses in the piping or loads on the connected equipment in excess of those
permitted by ASME B31.3 and the equipment design code, in order to prevent:
 Failure of piping components due to overstress;
 Leakage at joints;
 Excessive loads and moments on connected equipment, anchor points, flanged
connections, etc.

Piping stress analysis conditions:


 Temperature
o Upper Design Temperature

65
o Lower Design Temperature
o Maximum Operating Temperature
o Operating Temperature
o Transient Temperature
 Pressure
o Design Pressure
o Maximum Operating Pressure
o Operating Pressure
o Cyclic pressure conditions
 Other conditions
o Friction Effects
o Wind Loads
o Seismic Loads
o Snow Loads
o Sustained loads

Stress analysis critical line list


Pipe Stress Engineer shall identify and produce a formal listing of the critical lines to
be analyzed using formal computer analysis. The purpose of the analysis is to calculate the
thermal expansion/sustained or dynamic stresses, nozzle loads on the connected equipment
and determine the type of pipe supports required. The function of critical line list is to identify
those piping systems which require investigation by a pipe stress engineer. The critical line-
list lines to be computer analyzed shall include the following:
 Pipe size DN 80 to DN 200 (NPS 2 to NPS 8) with design temperature above
230 °C (450 °F)
 Pipe size DN 250 to DN 300 (NPS 10 to NPS 12) with design temperature
above 175 °C (350 °F)
 Pipe size DN 350 to DN 450 (NPS 14 to NPS 18) with design temperature
above 120 °C (250 °F)
 Pipe size DN 500 (NPS 20) and larger
 If pipe stress calculations require the approval of national or local authorities,
they shall be performed by methods approved by those authorities
 Process pipes connected to rotating equipment
 Pipes connected to air-cooled heat exchangers

66
 Pipes connected to pulsating equipment (reciprocating pumps or reciprocating
compressors)
 Pipes to and from boilers and heaters
 In cases where external movements, such as differential settlement of
equipment and/or supports could cause unacceptable stresses or reaction forces
 All pipe sizes in cyclic service (regeneration/batch process) resulting in a stress
range factor f<0.7 per ASME B31.3 Fig. 302.3.5
 Pipes where engineered items are required like spring supports, expansion
joints, snubbers, etc.
 All pipe sizes where subjected to slug flow or water hammer
 Pipes subjected to two-phase flow
 Flare pipes DN 100 (NPS 4) and larger
 Pipes of size DN 25 (NPS 1) and above subjected to relief loads
 Pipes in very toxic service with design temperatures above 200 °C (390 °F)
 Glass Reinforced Plastic piping
 Pipes subject to steam out
 Jacketed piping
 Cryogenic piping systems (below -46 °C (-50 °F))
 Pipes connected to Wellheads and X-mas trees
 Piping systems with hub clamp connectors or compact flanges
 Pipes along the derrick and the flare structure
 Piping associated with offshore platform bridges
 All glass-lined pipe or piping connected to glass-lined equipment

Pipe supports
Piping system should be supported, anchored or guided to prevent deflection, vibrations or
expansion/ contraction which could result in stresses in excess of those permitted by ASME
B31.3 in the piping or in-line connected equipment.
Specification for pipe supports-
 An index of the identification of the standard pipe supports
 Dimensional sketches of the standard pipe supports and/ or a reference to applied
standards
 A description of the pipe support identification numbering system
 Maximum allowable loading of the standard pipe supports
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 Materials of construction
 Surface protection

Location of pipe support:


Pipe supports shall be positioned on the piping system as follows:
 On pipe rather than valves flanges and fittings
 Base type tubular supports such as pipe dummies and trunnions may be attached to
elbows and tees, but only to the back of the fittings, not to the side which is the highly
stressed region
 On piping section which do not require frequent removal for disconnection for heat
exchangers tube bundle maintenance, decoking, regeneration, cleaning or isolation
 As close as possible to heavy components such as relief valves and isolation valves in
particular for high pressure rating and actuated valves for all pressure ratings
 At the positions where the vertical movements are minimal
 At the position close to flanged components (eg: valves), the disconnections of which
will bend down or deform or topple the connected piping system
 Location and selection of supports shall also minimize vibration in the line with the
requirements of overall span lengths and span lengths in the vicinity of vibration
sources such as valves and elbows
Pipe support material selection:
 For all welded type pipe supports shall be have pipe support component materials of
same grade as that of main pipe
 All clamped type pipe supports shall have component materials that are in contact with
the pipe of same basic grade as that of base pipe material
 All hanger type pipe supports shall have clamp support material with carbon steel
hanger rod attachment
 Polymeric material used in the construction of pipe supports shall be compatible with
the maximum/ minimum exposure temperatures
Pipe support types:
 Clamped
 Welded
 Hanger
 Sliding
 Pipe saddles and reinforcing pads
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 Spring
 Secondary steel
 Special

Thermal Insulation
The following criteria shall be used in both determining the need for and in designing
insulation systems, using good engineering practices:
 CUI and ESCC risks – where CUI (Corrosion Under Insulation) and ESCC
(External Stress Corrosion Cracking) risks are present, careful consideration
shall be given to the necessity of thermal insulation.
 Process reason – to minimize heat gain or heat loss for process reasons to
avoid process disruption or solidification. In such cases, insulation may be
combined with heat tracing.
 Economics – to minimize heat loss and reduce emissions. In hot service the
optimum economic insulation thickness shall be calculated according to the
"Minimum Total Cost Method". For a given thickness the total cost is the sum
of the cost of the investment and maintenance of the insulation system and the
cost of the energy lost through the insulation.
 Personnel burn protection – to protect personnel from heat or cold burns.
 Cold Service - Cold service insulation shall be installed to limit surface
condensation, icing, to conserve refrigeration (limit heat gain) or to limit boil
off. Surfaces that operate below the local ambient dew point for more than 5
percent of the time require insulation. The maximum heat gain in cold service
to conserve refrigeration shall be 25 W/m2 (8 Btu/hr/ft2). In some
circumstances boil-off is the dominant criteria e.g., liquefied gas spheres or
LNG tanks. For spheres, a separate calculation to determine insulation
thicknesses is required to meet the specified boil-off rate and the related
maximum heat gain.
 Acoustic reasons – to manage noise control. Acoustic insulation may be
combined with thermal insulation.
 Fire protection – to protect pipelines and equipment from heat radiation from
fires.

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 Winterizing – avoiding freezing of product in piping, instruments, and
equipment. Calculations for heat transfer shall be based on ISO 12241 or
ASTM C680.
All insulation shall be designed so that water ingress and capillary action is not
possible and that potential leaked product and water vapour or condensation can escape or
drain off. The design of the insulation systems shall take into account the optimum life cycle
costs, energy savings, process requirements and maintenance aspects, as well as present and
future equipment integrity implications due to corrosion under insulation (CUI) and external
stress corrosion cracking (ESCC).
Insulation shall not be applied to pipelines and equipment that has been designed to
emit heat or where cooling is required but areas where personnel burn risk is present
protective insulation or sheets shall be installed.
Valves, flanges, nozzles and pumps shall be insulated, except for in the following
circumstances:
 In hydrogen services, valves, flanges, nozzles and pump seals shall not be insulated.
 In systems containing hydrocarbons above their auto ignition temperature valves,
flanges, nozzles and pump seals shall not be insulated.
 Where calculations show that conductive heat loss is insignificant to the project.
Table 5.2 Insulation codes
TOW Temperature indication Process temperature CUI Category
All process temperatures
1 Cold or cryogenic Low Cold
< –5 ºC (25 °F)
Process temperatures
2 Ambient (+/-) between –5 ºC and 50 ºC Medium
(25 and 121 °F)
Process temperatures
3 Hot between 50 ºC and High
175 ºC (122 and 347 °F)
All process temperatures
4 Very hot Low Hot
> 175 ºC (347 °F)
Cycling or dual process
temperatures between –
5 Variable or cycling Extreme
20 ºC and 320 ºC ( -4 and
608 °F) (or lower)

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Primary
Insulation Description primary insulation function
Function
Acoustic (or noise control) insulation system: reducing/controlling noise in
A
piping, valves or equipment.
Cold insulation system Condensation control: mitigate condensation by
C
keeping surface temperature above the dew point of surrounding air.
Freeze protection (winterisation): minimizing energy required for heat
F tracing systems and/or extending the time to freezing in the event of system
failure.
Hot insulation system. Always energy conservation: minimizing unwanted
H heat loss/gain from piping and equipment, as well as preserving natural and
financial resources (reducing CO2)
N Not Required (e.g., piping/equipment only used for start-up or venting etc.)
Personnel protection: controlling surface temperatures to avoid contact burns
P
(hot or cold)
Fire safety: provide passive fire protection of critical products in piping
S
and/or equipment.
Temperature control: temperature control of processes or products, to avoid,
T
e.g., solidification or changing of viscosities.
V Insulation system for dual, cycling or variable operating temperatures
Secondary
Insulation Description secondary insulation function
Function
A Acoustic insulation system Class A
B Acoustic insulation system Class B
C Acoustic insulation system Class C
D Acoustic insulation system Class D
E Insulation system with electrical heat tracing
G Guards by means of metal screens for personnel protection
H Heat gain and energy conservation (including CO2 reduction)
I Insulation system for personnel protection
O Insulation system with hot oil heat tracing
S Insulation system with steam tracing

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W Avoiding condensation and water dripping of cold insulation systems
Avoiding condensation and water dripping of cold insulation systems and
X
reducing of heat gain.
“Blank” Function not required or unknown.

Human Factors Engineering – Workspace Design


 Minimum working volume – 1000 (width) * 1000 (depth) * 2100 (height) mm while
standing
 Minimum working volume – 1300 (width) * 1300 (depth) * 1300 (height) mm while
squatting
 Weight carried – 23 kg (1 person)
 Weight carried – 46 kg (2 persons)
 Weight carried – > 46 kg (crane lifting)
 Standing and control surfaces – 540 to 1770 mm with preference in 870 to 1160 mm
(height)
 Standing and displays – 1120 to 1730 mm with preference in 1390 to 1590 mm
(height)
 Squatting and control surfaces – 380 to 1190 mm with preference in 430 to 790 mm
(height)
 Squatting and displays – 530 to 1190 mm with preference in 670 to 940 mm (height)
 Walkways – minimum 600 mm
 Stairs – minimum width inside handrails 1220 mm with handrails height of minimum
910 mm
 Man ways:
o Access clearance – 1220 mm minimum
o Circular manways – up to 1500 mm for top entry DN 750 (NPS 30)
 Guard-rails: 610 mm above finished floor level (FFL)

Human Factors Engineering – Valves


Valves (including those on Vendor supplied skid-packaged units) shall be selected,
located and labelled, based on a Valve Criticality Analysis (VCA) so that they can be
identified, operated, maintained and inspected:
 with accessibility and visibility appropriate to their service;

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 without exposing operators to risk of injury or exposure to hazards.

A Valve Criticality Analysis (VCA) shall be conducted during the early define phase,
when the PEFS (P&IDs) first become available. This ensures that:
 the results can be factored into valve procurement and piping and layout design;
 space for physical access and other design requirements needed to identify,
operate, maintain and inspect valves can be integrated into layout drawings and 3D
models.

Valves shall be rated by criticality. The following three categories are recommended.
These criteria shall be reviewed and agreed upon prior to starting the analysis. The final
criteria shall balance ease of access for operations against maintenance access and project
costs. Risks to health and safety, including risk of human error, shall be kept as low as
reasonably practical.
Category 1 (C-1) valves:
Category 1 (C-1) valves include those essential to normal or emergency operations where
rapid and unencumbered access is essential. These are valves that meet any or all of the
following criteria:

a) Valves essential to production;


b) Valves essential to process safety or asset integrity;
c) Particularly large valves;
d) MOVs with high failure rates and which require rapid corrective action;
e) Valves being used in a service or under operating conditions where the failure rates
are not known or may be unreliable.
f) Valves where consequence of failure to obtain quick access would be serious (e.g.
process shutdown and/or damage to facilities or personnel);
g) Valves for which the expected routine operation, inspection and/or maintenance is
more frequent than once every 6 months.

Category 2 (C-2) valves:


Category 2 (C-2) valves are those that are not critical for normal or emergency operations but
are used during routine inspection or maintenance activities. These are valves that meet any or
all of the following criteria:

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a) Valves associated with equipment for which rapid intervention is unlikely to be
needed.
b) Valves with a low operating or inspection frequency (i.e. less than once every 6
months).

Category 3 (C-3) valves:


Category 3 valves are normally non-operating valves that are used or inspected in particular
circumstances on an infrequent or rare basis (e.g. hot tap valves, hydrostatic test vent, high
point vent or low point drain valves located in pipe rack) and are not used in HSSE critical
activities.

ACCESSIBILITY:
 Category 1 valves (C-1)
Permanent accessibility shall be provided at deck or ground level or via a permanent
standing elevated surface. If such access at ground or deck level is not practical,
access by stairs to the elevated platform is acceptable. Valve identification and status
shall be clearly visible to an approachable operator position i.e., on an adjacent
walkway, access platform, or in space around equipment that is intended for human
access.
 Category 2 Valves (C-2)
Category 2 valves may be located within the acceptable area, depending on their size
and the force needed to operate them. Where ground level access, or where deck level
access by stairs, is not justifiable, a vertical fixed ladder plus a small standing surface
shall be provided for access to C-2 valves. The use of auxiliary equipment to gain
access (e.g. mobile platforms, man lift, or scaffolding) for maintenance purposes may
be acceptable as long as it is indicated and allowed for in the design by preserving
sufficient space and access for personnel, tools, parts, and equipment. Identifying and
inspecting the status of C-2 valves may require the operator to enter space not
intended for human access, or to temporarily adopt an awkward posture provided
doing so does not induce human error or put the operator at risk of injury or exposure
to hazards.
 Category 3 valves (C-3)
Permanent accessibility to and visibility of C-3 valves is desirable but not essential.
No specific location requirements are imposed. The use of auxiliary equipment to gain
access (e.g. mobile platforms, personnel lift, and/or scaffolding) to C-3 valves shall be
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indicated and allowed for in the design. Portable ladders should not be used for
accessing C-3 valves. Any proposed exception(s) to this shall be subject to specific
review and approval.

 Valve to valve spacing in parallel lines – 75 mm minimum clearance (125 mm


minimum in cold service/ environments).
 Mounting heights of valves:
o Hand-wheel operated valves
 Valves with vertical stems – 150 to 1300 mm acceptable with 455 –
1300 mm preferred and 455 mm maximum clearance
 Valves with horizontal stems – 230 to 1830 mm acceptable with 610 to
1830 mm preferred with 455 mm maximum clearance and 610 mm
minimum for any obstruction
o Lever operated valves
 Valves with vertical stems – 760 to 1300 mm preferred height
 Valves with horizontal stems – 1905 mm maximum height and for
quarter up turn 150 to 760 mm preferred and for quarter down turn >
1300 mm.
Based on these all above criteria, the work entitled “PIPING DESIGN STUDIES OF THE
TREATOR” is done and picturized below.

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Fig 5.3: Plot plan of PE3 HDPE Slurry project
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Fig 5.4: Area classification of PE3 HDPE Slurry project
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Fig 5.5: Piping & Instrument Diagram of the Treator

78
Fig 5.6: Line 1 Material Take-off
79
Fig 5.7: Line 1 isometric diagram

80
Fig 5.8: Line 2 Material Take-off part a

81
Fig 5.9: Line 2 Material Take-off part b
82
Fig 5.10: Line 2 isometric diagram
83
Fig 5.11: Line 3 Material Take-off
84
Fig 5.12: Line 3 isometric diagram
85
Fig 5.13: Line 4 Material Take-off
86
Fig 5.14: Line 4 isometric diagram
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Basics of Stress Analysis of Pipes
All plant lines (> 2”) shall be submitted to stress analysis. All piping systems of size
2” and below do not require to be stress-analysed except for piping subjected to cyclic
conditions, slug or water hammer flow and relief flows. A study shall be performed to
determine the degree of criticality of piping systems and thus to establish the accuracy of the
calculation methods to be adopted for verifying piping system reliability and safety.

Flexibility verifications shall be performed by means of:


 Comprehensive method analysis using computerized systems in all cases considered
complex and critical for some piping connected to –
o Rotating machinery (pumps, turbines, compressors, air cooled heat exchangers,
etc.)
o Pulsating equipment (reciprocating equipment)
o Furnaces
o Boilers and heaters
 Formal analysis method (tables, graphics, and monographs) for recurrent and very
simple configuration as well as system configurations equivalent or similar to other
already verified.

CRITICAL LINE LIST


All critical lines shall be listed in the critical line list and shall include at least following
information:
 Line number
 Critical level (1, 2 or 3) based on pipe size, operating temperature and equipment
 Calculation note number
Single calculation report of each line shall become part of the project documentation. The
calculation report shall include at least following information:
 Software used with revision number. Input model native file name.
 Basic design data and conditions (always including the design condition), nature of
containing fluid, piping class and specification breaks, insulation type and thickness.
 Isometric layout of the complete piping system being analysed (with coordinates and
elevation of at least one reference point). Dimensions shall be shown from support to
support, support to branch or fitting to fitting. Location and size of reducers must be
specified.

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 Supports positions and types, location of fixed end of horizontal vessels and heat
exchangers.
 Anchors positions and displacements.

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BIBLIOGRAPHY

1. Hand written notes.

2. Shell DEP Documents

3. ASME and API Codes

4. Wikipedia

5. Pipe Drafting And Design, Second Edition, Roy A. Parisher & Robert A. Rhea

6. The ‘PIPING GUIDE’, Kenneth Williams

7. Process Plant Layout and Piping Design, Ed Bausbacher & Roger Hunt

8. Piping Handbook, Mohinder L. Nayyar

9. Images from Google and other sites

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ANNEXURES

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