PIPING DESIGN INSTRUCTION

TOKYO JAPAN

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1. Purpose, Scope and Project Outline

1.1 Purpose and Scope

1.1.1 Purpose

This specification was prepared in order to standardize the philosophy regarding the layout of plantsand piping designed and constructed by TEC and to achieve rationalization, economizing and speeding upof the design work.

1.1.2 Scope

This specification applies to a particular Job. to be executed by TEC upon receipt of an order.

1.1.3 Notes

(1) All blank lines and check boxes in this specification shall be filled with data pertinent to therespective Job.

(2) In case of contradictions between this manual and Customer’s requests, applicable Laws andRegulations, climatic requirements this specification shall be changed accordingly.

(3) ??This specification only lists the most important and applicable sections of the various pipingspecifications of this company in order to keep its size within reasonable limits. Wherenecessary, references to said specifications shall be made in the text.

(4) This specification is prepared for general use; special requirements of the respective jobs shallbe added. Contradictions between this specification, TES and TEG specificaitons shall becontrolled on a Job level.

(5) If changes to TES or TEG specifications are deemed necessary, the respective request shall bemade to the Standard Preparation?? Commitee or the person-in-charge of the specific groupwithin the Job team. Where revisions of this specification are required, the respective requestshall be made to the person-in-charge of the specific group within the Job team.

1.2 Project Outline

1.2.1 Project Outline

(1) Project Name :

(2) Work Number :

(3) Plant Name :

(4) Customer (Abbr.) :

(5) Site (Country) :

(6) Consultant :

(7) Type of Contract : Turnkey Lumpsum Cost + Fee

FOB Supervising CIF

Others

(8) Scope of Contract : Basic Design Detail Design Procurement

Construction Operation Consulting

Others

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(9) Schedule : Issue Date Effective Date of Contract (Construction Period months)

L/S M/C

P/A

(10) Plant Structure

Unit Capacity Licenser Special Features

(11) Applicable Standards :

(12) Contract/Guarantee Conditions and Special Features

1.2.2 Summary of Scope of Work

(1) Scope of Work : (Circle the work items within the scope and mark with “ “ their range)

Work Range (Note 2)Work Item Process Utilities Off-Sites

FrontE Plan’g

DetailP

C/SCO

Comments :

Note: E : Engineering / P : Procurement / C : Construction / SC : Construction Supervision / O :Operation, Handing-Over

(2) Consultants(Note 3) : (Yes/No) Resident (Yes/No) Period of Stay [ months] Man-Months [ ]

(3) Customer’s Eng’rs (Note 3) : (Yes/No) Resident (Yes/No) Period of Stay [ months) Man-Months [ ]

(4) Eng’g Subcontracting : (Yes/No) Subcontrator : Domestic / Foreign [Country ]

Major Subcontracting Items : [ ]

(5) Overseas Procurement : (Yes/No) Major Countries of Procurement [ ]

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(6) Major Applicable Standards and Regulations : (related to Piping Design)

Domestic / Foreign (Circle Foreign Standards)1 4 72 5 83 6 9

(7) Government Approvals/Assitance : (Yes/No) Scope [ ]

(8) Witnessed Inspections : (Yes/No) Scope [ ]

Notes : 1. Fill in the respective data in the square brackets and circle the respective item shown in brackets. 2. Add ranges not specified in the blank cells, where required. 3. ???Include the respective resident person-in-charge.

(9) Engineering Scope (Detail)

PLOT PLAN TEC CUST OTHERSENGINEERING SPECIFICATIONS

H-100 TEC CUST OTHERSH-101 TEC CUST OTHERSH-103 TEC CUST OTHERSL-101 TEC CUST OTHERSOTHERS TEC CUST OTHERS

ROUTING DRAWINGS TEC CUST OTHERSPLANNING DRAWINGS TEC CUST OTHERSUNDERGROUND PIPING TEC CUST OTHERSABOVEGROUND PIPING TEC CUST OTHERSFIRE-FIGHTING PIPING TEC CUST OTHERSISOMETRIC DRAWINGS TEC CUST OTHERS(manual drawings or by computer “COMPIPE”)CIVIL INFORMATION TEC CUST OTHERSDETAIL CIVIL DESIGN TEC CUST OTHERSPIPE SUPPORTS TEC CUST OTHERSMATERIAL TAKE-OFF TEC CUST OTHERSPROCUREMENT TEC CUST OTHERS

DESIGN S/V DISPATCHED : (Yes/No) Period [ MM]CAD/CAE USE?? : (Yes/No) (3D CAD / 2D CAD)ASSIGNED SYSTEM : ?????????

Remarks :

1.3 Others

1.3.1 Execution Schedule

PROJECT OVERALL SCHEDULE (Data-????? ENGINEERING SCHEDULE ( Data: ?????

1.3.2 Special Items requested by the Customer, Licenser and Others

1.3.3 Battery Limit Conditions

Conn. Temperature (ºC) Pressure (KPaG)

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Size Spec. Max., Min.or Nor.

Des-ign

Max., Nor. Des-ign

123456

INCOMING 789

1011121314123456

OUTGOING 789

1011121314

2. Basic Design Conditions

2.1 Utility Conditions

(1) Imported Utilities

HP Steam MP Steam LP Steam Cooling Water Sea Water Potable Water Hot Water BFW Instrument Air Plant Air Nitrogen

(2) Tracing Media

HP Steam MP Steam LP Steam Hot Water Electric Power

2.2 Climatic Conditions

(1) Temperature

Max. Temperature : °C Min. Temperature : °C

Annual Ave. Temp. : °C

Design Temp. (Max): °C Design Temp. (Min): °C

(2) Humidity

Max. Relative Humidity : % Min. Relative Humidity : %

Annual Ave. : %

(3) Rain

Max. Rainfall : MM/Hr, MM/D Annual Ave. Rainfall : MM/D

Design : MM/Hr

(4) Snow

Max. Snowfall : MM Max. Weight Unit : N/M²

Design Weight Unit : N/M²

(5) Wind

Max. Wind Velocity : M/S Average (Month/Year) : M/S

Design : M/S Prevailing Wind Direction : →

Wind Pressure : Height 0 - M N/M²

M N/M²

M N/M²

2.3 Soil Condition

(1) Plant Datum :

Plant Site Elevation : M(=EL.0)

(2) Bearing Capacity : T/M²

(3) Ground Water Level: M

(4) Frost Depth : M

(5) Seismic Coefficient : __

(6) Ground/Soil Characteristics : (including all items to be considered for design)

(7) Topography : (including all items to be considered for design)

2.4 Design Standard

(1) Ambient Temperature for Thermal Stress Analysis : °C

(2) Piping Temperature for Thermal Stress Analysis Operation Temp. Design Temp.

(3) Amb. Temp. for Hot Insulation Thickness Calculation: °C

(4) Cold Insulation Thickness Calculation Basis : Rel. Humidity % Amb. Temp. °C

2.5 Others

(1) Process Experience : No Yes Job Name ( )

(2) Job Experience with Customer : No Yes Job Name ( )

(3) Job Experience with Licenser : No Yes Job Name ( )

(4) Job Experience with Consultant : No Yes Job Name ( )

(5) Similar Job Experience : No Yes Job Name ( )

Technical Measures or Cautions wich had to be observed in previous Job:

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3. Applicable Laws, Standards, Regulations, and related Specifications

The applicable Laws, Standards and Regulations shall be those specified in the Contract, where also theissue date shall be considered. What standards are to be applied to items not specified in the contract shallbe clarified with the Customer in advance.

3.1 Applicable Laws, Standards, Regulations and TES

ITEM LAWS, STANDARDS REMARKS

(1) Layout & Safety Design

(USA)

(Others)

(2) Piping Design

(3) Building Design

OSHA (Occupational Safety and Health Act) IRI (INDUSTRIAL RISK INSURERS) NFPA 30 NFPA 58 NFPA 59 API RP 500A API 2508 API 2510 Others

(1) Applied Laws and Standards ASME ANSI KHK JIS ASTM API JPI DIN BS MSS Others

(1) Applied Laws and Standards Others

TES : H-101H-103H-106H-107H-109H-112H-119EL-101O-301

3.2 Customer’s Engineering Specifications:

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3.3 Engineering Specifications, TEGs and Departmental Instructions related to Piping Design

NUMBER TITLE APPLICABLE PARA.

H-100

H-101

H-103

H-106

L-101

L-301

L-303

H-107

H-109

O-301

O-306

JL-101

PLANT LAYOUT

PIPING DESIGN

PIPING MATERIALS

MARKING OF PIPING MATERIALS

HOT/COLD INSULATION DESIGN

HOT INSULATION WORK

COLD INSULATION

STEAM TRACING

PIPING SUPPORTS

PAINTING

SHOP PAINTING

FIRE FIGHTING EQUIPMENT

(5.1),(5.2),(5,6),(5.7)

5.6, 5.7, 5.8(6.1), (8.2), 10.2

6.1

6.1

6.2

6.2

6.2

10.18

(11)

6.3

6.3

10.16

TEG1-1310-001

1-6225-102

1-1310-005

1-1314-101

1-1313-101

1-1313-102

1-1311-101

1-1312-101

1-1311-002

1-1311-003

1-1311-004

1-1316-007

GENERAL DRAFTING RULES

NUMBERING OF DRAWINGS

ASSIGNMENT OF DRAWING NUMBERS FORPLANNING AND PIPING DRAWINGS

“PIPE HANGING NO.1”PIPE HANGING MANUAL

PREPARATION OF PIPING ARRANGEMENTDRAWINGS

TYPE OF UNDERGROUND PIPING DRAWINGS

TYPE OF PLOT PLAN

TYPE OF PLANNING DRAWING

PLANT LAYOUT FOR CHEMICAL PLANT

DESIGN OF TANK YARDS BASED ON NFPACODE 30

SAFETY DESIGN GUIDEPIPING PLAN BASED ON LAWS

CATHODIC PROTECTION FORUNDERGROUND PIPING

4.2

4.2

4.2

4.2, 11.,

4.2

4.2, 10.4

4.2

4.2

5.,

5.5, 10.16

5.5

6.4

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NUMBER TITLE APPLICABLE PARA.

1-1319-010

1-1319-001

1-1313-004

1-1319-002

COUNTERMEASURES AGAINST STATICELECTRICITY OF PIPING

JOB COORDINATION BETWEEN PIPING ANDCIVIL DESIGN DISCIPLINES

RACK PIPING

JOB COORDINATION BETWEEN PIPING ANDINSTRUMENT DESIGN DISCIPLINES

6.5

7.2

7.5, 10.5

(8.),

TEG 1-1313-005

1-1313-007

1-1316-006

1-1313-003

1-1313-002

1-1316-005

TCM1-1313-003

TEG1-1313-010

1-1313-107

1-1313-105

1-1313-008

1-1313-009

1-1314-202

1-1314-203

1-1314-204

1-1314-205

1-1314-206

TCM1-1313-005

TOWER PIPING

PIPE SPACING

WALL THICKNESS CALCULATION OFUNDERGROUND PIPING

PUMP PIPING

PIPING DESIGN FOR COMPRESSORS ANDTURBINES

PREPARATION OF DETAIL DRAWINGS OFSPECIAL PIPING PARTS

CALCULATION BY COMPUTER OF REACTIONFORCE OF SAFETY VALVES ON PIPING

DESIGN OF COOLING DEVICES

PREPARATION OF HOOK-UP DRAWINGS

PREPARATION OF STEAM TRACINGDRAWINGS

PIPING VIBRATIONS

MAXIMUM PERMISSIBLE PIPE SPANS

“PIPING HANGING NO.2”STANDARD ATTACHMENTS

“PIPING HANGING NO.3” STANDARD FORM

“PIPING HANGING NO.4” DESIGN DATA

“PIPING HANGING NO.5” DETAIL DRAWINGS

“PIPING HANGING NO.6” STRENGTHCALCULATION DATA

CALCULATION BY COMPUTER OF SADDLESUPPORT SPAN FOR BIG PIPING SIZES

10.6, 8.,

10.1, 10.5,

10.4,

10.8

10.9

10.13

10.14

10.15

10.17

10.18

10.23

11.,

11.

11., 8.8

11., 8.8, 10.6.

11.

(11.)

(11.)

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(REFERENCE)

TEG1-1311-001

1-1319-006

1-1310-002

1-1310-003

1-1310-004

1-1310-006

1-1316-001

1-1316-002

1-1316-003

1-1316-100

1-1316-101

1-1316-102

1-1316-103

1-1316-104

1-1316-004

1-1316-202

1-1316-105

1-1319-004

1-1313-104

1-1313-103

1-1313-106

1-1315-001

SETTING OF PLOT PLAN ISSUE STAGE

SET-UP OF LINE REFERENCE BY COMPIPE

ISSUE MARK AND REVISION NUMBER OFDRAWINGS

USE OF ISSUE BLOCK AND ISSUE MARK INDRAWINGS

AFC ISSUE

ABBREVIATIONS FOR PIPING

DETERMINATION OF PIPING CLASS CODES

DETERMINATION OF VALVE NUMBERS

DETERMINATION OF FLANGE RATING

PREPARATION OF ENGINEERING SPECI-FICATION FOR PIPING MATERIAL (H-103)

SELECTION OF PIPING AND FITTINGS

SELECTION OF VALVES

SELECTION OF FLANGES AND BOLTS/NUTS

SELECTION OF GASKETS AND PACKINGS

MARKING CODE FOR SPECIAL PIPINGELEMENTS

USE OF PIPING MATERIAL LIST

SELECTION OF STEAM TRAPS

USE AND CONTROL OF PIPING DESIGNCONTROL SHEET

PREPARATION OF DRAWINGS FOR PIPINGENTERING/LEAVING BATTERY LIMIT

PREPARATION OF KEY PLAN

PREPARATION OF PIPING NOTES

PREPARATION OF ISOMETRIC DRAWINGS

(SPEC. FILE No.)

5/19

6/19

7/19

7/19

7/19

7/19

14/19

14/19

14/19

14/19

14/19

14/19

14/19

14/19

16/19

8/19

14/19

8/19

9/19

9/19

9/19

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DEPT. INST.

DG-05-07

DG-60-02

PM-62-01

DG-03-08

DG-01-05

GD-02-08

DG-04-02

DG-03-12

DG-03-14

DG-04-09

DG-03-09

DG-04-05

DG-04-06

DG-04-08

DG-04-12

DG-03-06

LAYOUT RULES BASED ON DOMESTIC LAWS

CHECK LIST FOR CATHODIC PROTECTION

SLIDING SUPPORTS FOR HOT/COLDINSULATED VERTICAL PIPING

DESIGN CALCULATIONS METHOD FOREXPANSION BELLOWS

COORDINATION BETWEEN PIPING ANDPROCESS DESIGN DISCIPLINES

STANDARD DESIGN OF PIPE EXPANSIONLOOPS

PIPING DESIGN FOR AIR COOLERS

EVALUATION BASIS FOR PERMISSIBLEPIPING VIBRATIONS AND VIBRATIONAMPLITUDE

PIPING DESIGN WITH SEISMIC FACTOR

PIPING SUPPORTS FOR PULSATING FLOWPIPING

SYMPATHETIC VIBRATIONS OF KARMANEDDIES FROM INJECTION NOZZLES

MEASURES AGAINST EXCESSIVE HIGHPRESSURE OF GATE/BALL VALVES

EVALUATION OF EXTERNAL LOADS ONFLANGES

PRESSURE INCREASE DUE TO LIQUIDEXPANSION

DESIGN STANDARD FOR PIPING STEAMPURGE

TEMPERATURE DISTRIBUTION AT FITTINGS

5.

6.4

6.2

(7.)

(10.3)

10.5, (10.22.),7.3, 7.5

10.7

(10.23.)

(10.23.)

10.23

10.24

10.24

10.24

10.24

10.24

(11.), 10.25

DEPT.INST.

DG-03-16

DG-04-10

DG-61-02

SPRING SUPPORT GRINNEL/NHKCOMPARISON LIST

PIPE SUPPORT DESIGN SYSTEM (IDOLL)

APPLICATION OF COSTDOWN CHECK LIST

(11.)

(11.)

(12.)

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11/26/1979 MEMO

12/20/1988 MEMO

12/29/1992 MEMO

P&I ISSUE STAGE OR SCREENING MEETINGCHECK LIST

DRAWING OF MAXIMUM PERMISSIBLENOZZLE MOMENTS AT THE PINT OFINSTALLATION

PREVENTION OF TOWER RESONANCES DUETO KARMAN VORTEX

SPLASH DEFLECTOR OF NOZZLES FORLEVEL GAGES

EXXON BASIC PRACTICE

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4. Others

4.1 Language and Units

(1) Language

Japanese English French German Russian Others

(2) Units

SI Units American

4.2 Drafting Requirements

4.2.1 Units/Measurements

(1) Units used : millimeters inches

(2) Piping size : millimeters inches

(2) Drawing scale

Site Plan 1/100 1/200 1/500 1/1000 1/2000Plot Plan 1/50 1/100 1/200 1/400Piping Dwg. 1/20 1/30 1/40 1/50 1/100

4.2.2 Line styles and lettering

As specified in para. 3.3 of “Drafting Manual” (TEG10005).

4.2.3 Numbering System

The assignment of more than one drawing, column, support number to the same part shall beeffectively prevented.

(1) Drawing numbers shall be determined according to TEG1-6225-102 (Preparation of Piping Drawings)and TEG1-1310-005 (Determination of Drawing Numbers:Piping Design Department?)

(2) The numbering convention for columns shall be from West to East as 1, 2, 3 .... and from North toSouth as A, B, C ..... The plant units moreover shall also be assigned numbers.

(3) For numbering of pipe supports TEG1-1314-101 “Pipe Hanging No. 1; Pipe Hanging Manual” shall bereferred to.

(4) Number assignment to special parts shall be made by P&I number and plant unit.

4.2.4 Related TEGs

The following specifications shall be referred to with regard to preparation of drawings:

TEG1-1303-101 Preparation of Piping DrawingsTEG1-1303-102 Preparation of Underground Piping DrawingsTEG1-1311-101 Preparation of Plot PlansTEG1-1312-101 Preparation of Planning Drawings

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4.2.3

(1) ALLOTMENT OF DRAWING NUMBERS

AREA/PLANT NAME DRAWING TITLE DRAWING NO. REMARKS

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4.2.3

(2) ALLOTMENT OF POLE NUMBERS

AREA/PLANT NAME STRUCTURE NAME DRAWING NO. REMARKS

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4.2.3

(3) ALLOTMENT OF SUPPORT NUMBERS

AREA/PLANT NAME DRAWING NO. REMARKS

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4.2.3

(4) ALLOTMENT OF SPECIAL PARTS NUMBERS

AREA/PLANT NAME SPECIAL PARTS NAME DRAWING NO. REMARKS

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5 - 1

5. Plant Layout

With regard to the plant layout there exist many TEGs and Instructions, a general summary of which isgiven below:

(1) Codes and Regulationsa) TEG1-1311-004 : Plant Layout based on “Philosophy of Safety in Design”b) TEG1-1131-003 : Major Design Points for Tankyards based on NFPA Code 30

(2) Referencea) TEG1-1311-002 : Plant Layout for Chemical Plants

5.1 Selection Criteria for Plant Sites

The selection criteria for construction site for petroleum refineries and petrochemical plants is as follows:

(a) Site : Sea level, topography (flat, hilly), reclaimed land, coastal or inland, size, soilcharacteristics, price, ground water level,

(b) Climate : Temperatures, wind directions, earthquakes, rain frequency, amount ofrainfall, frost depth

(c) Material Supply : local procurement, import(d) Water Supply : Water source (river, sea (desalination), quantity, quality, temperature, price,(e) Electric Power : Required energy, type of power (commercial / self-generation), price(f ) Available Transportation :

- Condition of transportation facilities and their convenience : Road, Railway, Sea- Means of transportation : Trucks, train, ship

(g) Product Distribution : Domestic, overseas, near, far(h) Labor : Domestic, foreign(i) Environment : Existing public facilities(j) Pollution Control : Difficiult/Easy requirements (waste water, noise, etc. ... to be checked)(k) State Regulations(l) Investment Analysis Result(m) Potential of future expansion of facilities

5 - 2

5.2 Plant Layout and Codes and Standards

The Codes and Standards as well as Customer Specifications to be observed for Plant Layout andEquipment Installation are specified in the Contract. Depending on the country in which plant facilities areexpanded, there will also be certain Codes and Standards to be observed even if they are not specified inthe Contract. For that reason a survey has to be carried out before the plant layout is determined. If Codesand Standards not specified in the Contract are applied, the layout shall be coordinated with the Customersuch that no problems will arise during detail design.

5.2.1 Applicable Codes and Standards

The Codes and Standards to be applied are as follows:

(a) Codes and Regulations Yes No(b) Standards Yes No(c) Customer Standards Yes No

5.2.2 Safety Distances and Safety Zones

(a) Between Plant Equipment and Battery Limit (b) Between Control Room and Process Plant 15M (c) Between Substation and Process Plant 15M (d) Between Compressor and other Process Equipment (e) Between Compressor and Fire Source (f ) Between Fire Source (furnace, incinerator etc.) and other Process Equipment (g) Flare Stack

(h) Storage Tank

Notes 1. Moreover, the recommended spacing issued by the Oil Insurance Association shall be referred toand coordinated with the Customer.

2. The philosophy of the hazardous zones shall be coordinated with the electrical engineeringdepartment and be considered in the plant layout.

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5.3 Overall Plant Layout

5.3.1 Area Classification

The plant shall be classified into the following areas from a viewpoint of fire fighting:

(a) Office Area (office, gatehouse, etc.)(b) Maintenance Area (maintenance shop, storehouse, etc.)(c) Utility Area (boiler, sewer, air conditioning equipment, etc.)(d) Process Area(e) Tank Area(f) Material Handling Area(g) Interconnecting Area (piperack, sleeper, cable trench, underground piping, rainy sewer, roads etc.)(h) Future Expansion Area(i) Others (waste water treatment, flare stack, etc.)

5.3.2 Other Plant Layout Considerations

(1) Basic items to be considered for plant layout(a) Safety(b) Operation (Access, Ease of Operation)(c) Maintenance (Access, Ease of Maintenance)(d) Economy(e) Construction (Ease of Construction)

5 - 4

(2) Major Items to be considered for the Layout of the Site Areas

CLASS AREA ITEM TO BE CONSIDEREDGeneral Material Handling, Storage, Production, Product Storage,

Coordination of Material and Shipping FlowOffice Location near Plant EntranceMaintenance (Maintenance Shop,Control Room, Warehouse, FireFighting Center, Laboratory)

Location near Plant Entrance

Econo- Utility Shortest possible utility distribution route in each areamical Process Layout according to process flowLayout Tank-yard Location near receiving/discharging pointbased Material Handling Location near Railway, Road, Port etc.on Flow Interconnection Piping Shortest possible functional connection between plant

areasFuture Expansion Location near Facilities to be expandedWaste Water Treatment Convenient location for collection of waste water from all

plant areasFlare Stack Location near the site border

Safety zone outside B.L. to prevent hazardsGeneral Securing acquisition of land

Measures against community noiseOffice Separation of Process Area and Tank-yard

Location of facilities processing toxic and flammablefluids downwind of plant

Maintenance Separation of Process Area and Tank-yardLocation of boilers and electrical facilities downwind offacilities processing inflammable fluids

Utility Location of cooling towers upwind of process area andaway from railway tracks, roads and other public facilities

Safety Process Location at safe distance from residential areas, officesand maintenance areas.Providing safety zones between plant areas

Tank-yard Location of feedstock and product tanks away fromprocess area

Material Handling Providing separate access from process and tankyardareas for hazardous materials and keeping safe distanceto residential areas

Interconnecting Provide roads permitting fire enginesFuture Expansion Potential for requested itemsWaster Water Treatment Separation from Process Area and TankyardsFlare Stack Location upwind of plant with a safety distance based on

the permissible heat intensity towards other facilitiesArea-wise layout with roads surrounding each areaConsidering future plan, if any

General Ease of construction, availability of temporary storageand material laydown areas at siteCondition of site groundMaterial receiving route

OfficeMaintenance Closeness of maintenance workshop and warehouse

Const- Process Arearuction, TankyardSafety Material Handling

InterconnectingFuture Expansion Material receiving route, overhead clearance and ease

of constructionWaste Water TreatmentFlare Stack

5 - 5

(2) Major Items to be considered for the Layout of the Site Areas (Cont’d)

CLASS AREA ITEM TO BE CONSIDEREDOffice Location outside of plant areaMaintenance Ease of access from all plant areas as well as from

outside of plantUtility Grouping of utility supply facilities

Opera- Process Block layout of process unitstion Tankyard Separation of feed and product tanks

Material Handling Separation of receiving and discharging facilities;smooth flow of transportation routes

InterconnectingWaste Water TreatmentFuture ExpansionFlare Stack

Note) The following cautions and regulations shall be considered for the size and layout of productionstorage facilities (Laws and Regulations for Petroleum Refineries and High Pressure Gas ControlLaws etc.):

- The area for production facilities shall not exceed 80,000 m², and for storage facilities it shall notexceed 90,000 m² (excluding setback area).

- Production facilities shall moreover be sub-divided into unit blocks which shall not be bigger than7,000 m² and be separated on all sides by roads with a width of at least 4 m.

- The total area of a group of units handling pressure gas shall not exceed 20,000 m².

(Calculation of area of a group of units)*) The borders of such areas shall not

bend into the it (i.e. >180° seeexample a. at left, example b. OK).

5 - 6

5.4 Unit and Equipment Layout

5.4.1 Items to be considered in the layout of units and equipment

Besides the aspects of safety, operation, maintenance, construction and economy as described in Para. 5.3.2(1) the following process related items shall be thoroughly checked:

(1) Items to be considered in the layout of units and equipment

CLASS AREA ITEM TO BE CONSIDEREDBlock Arranging all equipment groups within one process unit

according to the process flow.Economical

Process/Utility main header route Economical routing of Process/Utility main headers andpreventing crossing of the two (min. busy piping)???.

Pro- High-quality piping Minimizing piping of high-quality material (alloy, SS,etc.)

cess Critical lines of process Meeting process requirements and miniming pipinglength

FlowLayout

Underground piping main route Preventing crossing of pipes, shortest possible route ofbranches to/from process equipment.

Rack piping route Providing shortest and most simple layout of pipingroute.

Equipment handling toxic,inflammable fluids

Providing land to maintain safety zones (distance fromfire sources >15 m)???

Equipment with operational leaks(compressors, pumps, analyzersheds, etc.)

Providing sufficient safety distances and locatingdownwind from fire sources.

Atm. discharge (SV, Vents, etc.) dittoSafety Oily sewer ditto

HP gas equipment Locating away from inflammable and toxic fluid handlingequipment as well as from other facilities????

Fire sources (Heater, boiler, switch-room, flare stack, etc.

Locating upwind of inflammable fluid handlingequipment.

Storage tank for inflammable fluids Providing land to maintain safety zone and locating atlow plant level

Control room Locating at least one side of the building in a safe zone.Cooling tower Locating downwind of facility groupsBig equipment (high towers, heavyequipment)

Layout considering easy handling and installing ofequipment (availability/access for construction aids). ??

Const-ruction,Mainte-

Equipment requiring maintenance(heat exchangers, air coolers, pumps,compressors, heaters, turbines, etc.)

Considering maintenance access/space

nance Equipment requiring loading/unloading of catalyst, internals etc.

Providing access, sufficient space

Overall layout Laying the plant out on a square gridEquipment requiring frequentoperational control (compressor,heater, etc.)

Layout near control room

Oper-Emergency equipment (fire fightingequipment, emergency valve, etc.)

Locating away from hazardous equipment and near thecontrol room

ation Control room Layout with regard to easy main control and locatingnear process and utility facilities.

Ease of operational check Grouping of similar equipment considering minimizationof operator route.

Site area (total area)Others Ratio of equipment area

Road plan Layout on a square grid considering smooth vehicletraffic

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5.5 Tankyard Layout Plan

The Tankyard Layout Plan shall be determined after affirming that the distance towards other facilities,location of tankyard pumpstation, requirement of dike, capacity of dike, distance between tanks meet theapplicable codes and standards.Thereby the following TEG Standards shall also be referred to:

TEG1-1311-003 : “DESIGN OF TANK YARDS BASED ON NFPA CODE 30”TEG1-1311-004 : “SAFETY DESIGN GUIDE: PIPING PLAN”????Para. 5.10 : “Layout Standard based on Codes and Standards”

Note : The distance between tanks according to water sprinkling standard shall be 1.5 times the height of thetanks.

5.6 Roads, Routes and Clearances

5.6.1 Layout of plant roads

The road layout shall be done in consideration of the following:

(a) The plant site shall, as a rule, be divided into several rectangular blocks by plant roads.(b) All plant roads shall be designed as a big loop without dead end in such a way that every plant block is

accessible from two sides.(c) The plant roads shall be designed in consideration of fire engine traffic and smooth emergency work,

and the main access road shall be wide enough to permit two-way car traffic.(d) The plant roads should be connected to the public roads at least at two places.(e) ????

5.6.2 Major dimensions and overhead clearance of roads and routesBefore designing plant roads, the pertinent regulations for petroleum refineries as well as the localrequirements of the fire brigade regarding road width shall be checked and considered.

Table 5.6.2A Major dimensions and overhead clearance of roads and routes

Major Dimensions

Class UsePavingWidth

CornerRadius

ShoulderWidth

OverheadClearance

Note 1) Note 2)

Main AccessRoads

- Connecting Roadsbetween SITE andPublic road

6.0m 6.0m 1.5m 6.0m

- Plant Roads (6.1)- Plant Unit 4.0m 6.0m - 4.5m

Secondary Roads (4.88)Access - Maintenance 3.0m 6.0m - 3.5mRoads Roads (3.65)

- Operation and 0.8m - - 2.1mPlant Routes Inspection Roads (2.05)

- Rarely used Roads 0.6m - - 2.1m

Notes : 1)2) The figures in brackets are taken from EXXON BP3-7-4.

5 - 8

5.6.3 Basis for Operation Routes

The basis for operation routes is specified in Engineering Specification H-101, Attachment 2 (theAttachment 2 modified for the respective Job shall be used). Service routes shall be min. 600 mm andoperation routes min. 800 mm wide.

5.7 Access

5.7.1 Access

The basis for access is specified in Engineering Specification H-101, Attachment 1 (the Attachment 1modified for the respective Job shall be used).

5.7.2 Stairs and Ladders

(1) In the following cases is a stair required:(a) In case of a platform with a floor space of >50 m² and a height of >10 m above ground level (refer

to Fig. 5.7A).(b) In case that equipment requiring local operation such as sampling devices etc. are installed on such

a platform (criterion for determination: operation of at least once a day).(c) In case that the equipment installed on such platforms are important with regard to operation such

as reactors, boilers, etc. and also require operation in emergencies.(d) In case that frequently opened equipment for injection of chemicals and other materials are

installed on platforms or piperacks.(e) In case that the ascent/descent is an operation route used while carrying tools.(f) In places where frequent valve actuation is required during normal operation.(g) In case of platforms with a height of <1.0 m where ascent/descent by ladder is not suitable.

5 - 9

ATTACHMENT 1 ACCESS STANDARD

ACCESS TYPE

ACCESS POINTS(OVER 1.8m ABOVE GROUND ORPLATFORM)

ACCESSREQ’D

YES/NO

FIXEDFORM

PLAT- FIXEDLADDER

MOBILELADDEROR

REMARKS

STAIRACCESS

LADDERACCESS

STAND

(VALVES)

1. FREQUENTLY OPERATED VALVES

≥ 2B YES (3)

≤ 1-1/2 IN. YES (3)DRAINVENT

YES (1) TEMPORARYACCESS

2. RARELY USED VALVES

CHANGE-OVERVALVE FORSPAREEQUIP.

YES (3)(4)

OTHER YES (3) (4) (1)3. VALVES NOT REQ’D FOR OPERATION

NO FOR INSTAL-LATION ETC.

4. VALVES FOR QUICK OPERATION

YES (2) REQ’D BYOPERATION

5. REMOTE OPERA- TION VALVE

YES EMERGENCYVALVE

6. BATTERY LIMIT VALVE STATION

YES (3)

7. INSTRUMENT SOURCE VALVE

YES (1)

(OTHER PIPING ELEMENTS)1. SPECIAL PARTS MAINTANENCE

REQ’D BY YES (1)

2. SPECIAL PARTS MAINTENANCE

NOT REQ’D BY NO

3. BLIND FOR OPER-ATION

YES

FOR MAIN-TENANCE

YES (1)

4.SPRING SUPPORT NO

(INSTRUMENTS)1. PRESSURE GAUGE SENSOR NO SENSOR. INDICATOR YES2. THERMOMETER SENSOR NO THERMOWELL

INDICATOR YES

3. LEVEL GAUGE SENSOR YES FLOAT, DIS-PLACER ETC.

INDICATOR YES4. FLOW METER SENSOR YES (1)

INDICATOR YES (6)5. TRANSMITTER YES

YES (1)6. SAFETY VALVE YES (1)7. CONTROL VALVE YES

5 - 10

ACCESS TYPE

ACCESS POINTS(OVER 1.8m ABOVE GROUND ORPLATFORM)

ACCESSREQ’D

YES/NO

FIXEDFORM

PLAT- FIXEDLADDER

MOBILELADDEROR

REMARKS

STAIRACCESS

LADDERACCESS

STAND

(EQUIPMENT)

1. TOWER/VESSEL/TANK YESIF ACCES TOTOP PLAT-FORM REQ’D

2. COMPRESSOR/TURBINE YES IF LOCATED ONUPPER FLOOR

3. AIR COOLER YESACCESS TOHEADERBOX/MOTOR

4. COOLING TOWER YES ACCESS TOMOTORS

5. HEATER YESACCES TOBURNERS/PEEK HOLE

6. STACK YES ACCESS FORIGNITER

7. EQUIPMENT MANHOLE YES (1)8. EQUIPMENT HANDHOLE YES (1)9. EQUIPMENT NOZZLE NO

(OPERATION MONITORING DEVICES)1. SAMPLING POINTS (LOCAL) YES (5)2. FIRE HYDRANT, MONITOR (UPPER FLOOR) YES

Note (1) Portable ladders or platforms may be used to access equipment from the ground or from a fixed platform to access points not higher than 3.5 m.

(2) In general, objects shall be installed on ground. In case the objects shall be installed on fixed platformwhich height is over 1.5 m from ground, the access means should be applied stairs. In case the platformwhich heights is under 1.5 m from ground, access means can be used radder instead of stairs.

(3) In case the over 2B valves shall be installed position where can not operate from platform, valve mustbe installed a extension handle or used a extension valve or a chains operation valve.(4) The under 11/2B valves can be operated by fixed radder.

(5) In case the sampling point where site area is frequently used shall be installed over 1.5 m from groundon the fixed platform, the access means shall be applied to stairs.

(6) In case the volumetric flow meters (variable area flow meter, positive desplacement flow meter,magnetic flow meter, turbine meter, etc.) which is connecting by flange shall be installed fixed platform byradder access.

5 - 11

*) Normally we do not accept Building Standard Law, in case of accept, the height from ground is amaximum of 4.0 m.

(2) The following cases, more than two passages shall be installed.

(a) In case the horizontal walking distance is more than 20 m on the stand line, in general, refugepassage shall be installed besides main passage.

(b) A ladder should be installed a wark way on the pipe rack on the following basis.Process Plant Area : at a maximum of 60 m intervalsOffsite : at a maximum of 100 m intervals

(3) The following cases, a radder shall be installed.(a) In case the radder and plat form are not applicable to para 5.7.2.(1).(b) In case the refuge passage shall be required para 5.7.2.(2).(c) In general, a ascent and descent of platform which installed on instruments should be applied

radder.

Over 10.0m

Max.4.5m

*)

Fig 5.7-A Instale of stairs

5 - 12

(4) Standard for installation of safety gauges(a) Towers/Vessels/Tanks

Fig 5.7-B Standard for gauge installation of Towers/Vessels/Tanks

(b) Structures (refer to Fig 5.7-C)

Fig 5.7-C Standard for gauges installation of structures

5.7.3 Details of stair and style

(1) Details of stairThe following measures shows in the sample below, however, measures should be confirmed for civildesign department before design.

- Stair wide : minimum of 750 m/m- The middle landing : minimum of 1200 m/m- Tread : minimum of 240 m/m- Rise : minimum of 200 m/m (Stairs Slope 39.8°)

4.0munder

4.0mover

4.0mover

4.0munder

4.0mover

4.0munder

4.0munder

4.0mover4.0m

over

4.0mover

gauge

gauge

gauge

gauge

Not gauge

gauge

5 - 13

(2) Style of laddersAccording to the following figConfirm for Civil Design Department and Instrument Design Department before deisign.

(3) HandrailAccording to the following figConfirm for Civil Design Department and Instrument Design Department before design.

5.8 Foundation5.8.1 Heights of foundationFollowing to TES H-101 attachment (attach to attachement 4 that draw up by JOB)

5.8.2 Shape of foundationFoundation and ???shape (including shape of foundation, stand line and buildings etc.) shall be determinedafter confirmed to civil Design Departmenet.

5.9 Maintenance

5.9.1 Standard for installation of maintenance equipments

(a) When it is necessary to lift up a heavy equipment (more than 50 Kg) which can not to be lift up betweenthe two persons during maintenance or operating, crane shall be used.If the crane can not to be used, take the hoist, crane and removal lifter into consideration instead ofcrane. In case the crane shall be rarely used, take the bit or beam that can be used for lifting intoconsideration.

(b) In general, the heat transfer, air fin cooler, safety valve, valves, mechanical internal and rotating partsshall be maintained by crane, in case the crane shall not be used, take the as mentioned slinginstruments into consideration.???

(c) The loading and unloading or transportation of medicine and catalyst which are frequently used shouldbe used such a convenience transportation as permanent monorail, trolley, hoist, elevator, beltconveyer, etc.

(d) Performance of hoist and crane have to be enough to lift up a thing where the most heavily parts.

Max. 1200

5 - 14

(e) Ensure a proper space in order to move or put at temporary place or load a truck the things which arelifted up by hoist or crane.

5.9.2 Choose of lift up instruments

Table 5.9-A Choose of lift up instruments

1 12 11 2 2

12 1

2 1 21

2 11 1 2

11 2

2 11 2 2

1 2 21 2 1

1 2 211 2 21 2 2 21 21 2 21 2 2 21 2

1 21 2 2

1 2 2

Note 1) :

Note 2) :

6. Basic method of piping design

6.1 Piping material

The details of method for piping material are given in the Engineering Specification: H-103(Piping Material) and H-106 (Marking of Material).

(1) Piping materials shall be observed as follows:

JIS ASTM

(2) Piping measure (piping diameter, flange measure, measure between valve, fittingmeasure, etc.) shall be observed as follows:

Piping Diameter JIS ANSI

Flange between valve JIS JPI ANSI API MSS

Measure between valve JIS ANSI

JIS ANSI

Screw for tube PT NPT

(3) The valve and gear

Pressure class Gate valve Glove valve150 over 18 in over 12 in300 over 14 in over 10 in600 over 8 in over 8 in900 over 6 in over 6 in

1500 over 6 in over 4 in2500 over 6 in over 4 in

(4) In general, under 1 1/2 in size fitting should be applied socket weld type.

(5) Under 1 1/2 in size valve should be used socket weld type except for special parts.

(6) In general, over 2 in size valves should be used flanged type. Over 900 L in sizevalves should be used butt weld type.

(7) In general, the elbows should be used 1.5xD size elbow.In case the 1.0xD elbow may be used, however, they have to limit a using field afterconfirmed by basic design department.

(8) Instead of elbow, vent may can be used.- Under 1 1/2 in size line (bending diameter shall be applied 3D-5D)- The line which will be occurred a erosion by fluid- The line that the speed of running fluid is very high after vacuumed in valve, and

also shall be considered that the vibration will be occurred.

(9) The scope of miter have to be followed H-103.

(10) The scope of tea ?? have to be followed H-103.In case the engineering piping shall be arrested one after another, the supportingshould be investigated that is need or no based on ASME B31.3. In case the slopepicking is a minimum of 45°.

(11) The scope of reducer have to be followed H-103.In case of more than triple connection, trumpet piping of vibration piping. etc.

(12) Special items of other jobs are following as below. (high pressure gas recognition’sway of thinking etc.)

6.2 InsulationDesign of insulation and detail of execution are given in TEC Engineering Specificationas below.- L101 : Design of hot/cold insulation- L301 : Construction of hot insulation- L303 : Construction of cold insulation

(1) The scope of insulation shall be intended to P&ID, UFD and line schedule.

(2) The materials and thick of insulation should be followed TEC Engineering SpecificationL-101 (Design of Hot/Cold Insulation)

(3) Insulation codes on the P&ID, UFD and line schedule.

Class Code ItemH General heating

HO Insulation for stable operatingTS Insulation of steam trace installationTW Insulation of warm water trace installation

Hot Insulation TO Insulation of other heat mediumJS Insulation of steam jacket installationJW Insulation of warm water jacket installationE Insulation of electric trace installationW Insulation for winterizing (use the hot insulation material)C Common cold insulation

Cold Insulation CO Insulation for stable operatingJC Insulation of jacket by cold media installationA Anti-sweatP Personnel protection

Others M Requiring for Hot/Cold insulation on processS Insulation for sound protection

(4) Hot/Cold insulation of horizontal piping which need to ??? supporting, refer to thefollowing DEPT.INSTRUCTION:PM62-01 when designing. In case of not requiredfrom customer, it should be not applied. Note)

Note) In case of EXXON BP14-1-1, it should be installed.6.3 Painting

A detail of piping painting are following TEC Engineering Specification as below.- O301 : Painting Work- O306 : Shop Painting

(1) Confirm to painting work area, and enter a painting codes in line schedule(insert √ mark in ____ or numerical value in _____)

� The bare line that occurred a corrosion at carbon steel, low alloy cast steel,etc.(code :)� The bare line of stainless (code : )� Hot insulation line of carbon steel and low alloy cast steel under °C� Cold insulation line of carbon steel ad low alloy cast steel over °C� Hot insulation line of stainless under °C� Cold insulation line of stainless over °C

6.4 Cathodic protectionThe application of cathodic protection should be determined according to the area ofconstruction and the length of plant life, Vendor require, etc. on each job. Take the relativedatas are following as below.

- TEG1-1316-007 : Cathodic protection of underground facilities- DEPT.INSTRUCT : (DG)60-02 (check list of cathodic protection)

6.5 Grounding for static protectionThe grounding for static electricity protection should be confirmed to a Vendor require, aswell as they have to contact with electrical design department and basic design departmentabout detail method in advance. The following investigation and determine items as below,however, the details shall be referred to TEG1-1319-010 (Countermeasures Against StaticElectricity of Piping).

(1) The (dangerous place of Gas Steam) or (Dangerous place of Powder) where requiredto countermeasures against static electricity of piping shall be applied.

(2) The line which required to cathodic protection of piping shall be applied pipe rack andon he sliver, however, the following line can be omitted as below.- Conductivity fluid ( water, sulfuric acid, etc.)- Dry Gas (such a gas nitrogen, instrument air, hydrogen, methane, ethane, overheat

steam, etc., which gas have no possibility of reduce)

(3) Distance between protection shall be specified 30~50 m.

(4) Installation method of bounding Weld installation for piping Weld installation for piping shoe Installation for piping by

(5) Installation method of bounding Bounding of flange part Bounding of valve part

(6) A measure of rag and terminal plate shall be confirmed electrical design departmentbefore design.

6.6 Noise

6.6.1 The purpose of anti-noise

(1) The purpose of anti-noise are following as below.(a) For keeping a employee’s good health(b) For protecting the loose attention and keeping the safety of plant.(c) Protect from noise pollution around factory.

(2) Design of soundproofIn order to prevent a noise, take the following items into consideration when designing.(a) Choose the low noise of mechanical(b) Noisy mechanical instruments shall be installed where away from strict low are,

or shade of building. If circumstances require, the following measure shall berequired as below.

- Install to the silencer around source of noise- Roll up to the absorber around source of noise- Install to the acoustic board around source of noise- ????

Note) They have to contact with applied technical department about the specificationthat are considering with sound protect material of hot insulation and coldinsulation

6.6.2 The rule of noise(1) In case the Vendor is required, the designing shall be a value of within authorized by

Vendor.(2) In case the Vendor is no required, the designing shall be referred to the following the

table 6.6.2-A

Table 6.6.2-A Noise site ???

Location Time ofNoise

Vibration level ofmax. limit capacity

Operation and drop in atplace

2h/d or 19h/w 100dBA

Within buttery

The ordinarymaintenance shall berequired where gatewayor while operating

4h/d or 20/w 95dBA

limit The ordinarymaintenance shall berequired where operationplace or while operating

8h/d or 40h/w 90dBA

Control room, office - 55dBAOut of butterylimit, however,take intoconsideration atthe

(In case of only considerwith proper plant)

- 60dBA

borderline ofcomplex

(In case of consider allplant at the complex atonce)

- 65dBA

6.6.3 The source of noiseThe following table 6.6.3-A are shows a type of principal sorce of noise. The detail of sourceof noise shall be considered at job stage.

Table 6.6.3-A A type of the noise source

Class Source of noise (Note 1)Cycle

(Note 1)Noise energy

1 Pump Middle - High Medium2 Compressor High Large3 Fan ???? Middle Large

Rotating 4 Cooling Tower Low - Middle Medium1 or Sub 5 Air fin cooler Low - Middle Large

Chemical Stance 6 Vibration mil Middle - High LargeMachine 7 Others Middle - High Large

Vehicle 1 ST Turbine/Governor High LargePart 2 Motor/Gear box High Small

1 Vent/Silencer High MediumAir Dis- 2 Steam trap High Medium - Largecharge 3 Safety valve High Large

1 Control valve, vacuumvalve

High Large

2 Butter fly Middle - High Large2 Piping Piping

Parts3 Restriction orifice

(Note 2) (Note 3)Middle - High Medium

4 Ejector High Large5 Steam despair heater high Large1 Around rotating of noise

generationHigh Medium - Large

Piping 2 Around piping of noisegeneration

High Large

3 Fricative sound of highspeed liquid

High Medium

1 Fire place Low - Middle Medium - Large3 Combuster 2 Boiler Low - Middle Medium

3 Flare stack Low Large1 Transformer Low Small

4 Others 2 Vessel High Small3 Suction nozzle of air

compressorHigh Large

Note 1) The Cycle and energy of noise in the table are standard, therefore, it will be changedaccording to mechanical size in fact.

Note 2) In case the shock wave will be occurred, as well as the noise will be occurredNote 3) In case the cavitation will be occurred, as well as the noise will be occurred.

6.7 Design section of piping material

6.7.1 Relation between mechanical

(1) The connection by standard flange (following H-103)

(a) Connecting between single mechanical and piping

(b) Connecting between single mechanical and instrument

Single Mechanical

Single Mechanical

SingleMechanical

SingleMechanical

(2) ?????(a) ????

SingleMechanical

SingleMechanical

SingleMechanical

(b) ????

(c) ????

(d) ????????

(3) ?????

(4) Caution(a) The following coordination are principle, that is why, it shall be confirmed for

proper department.(b) Rotating and AL heat transfer shall be applied to low, however, in case the flange

and the big thickness of flange which are not given to H-103, they need toenough check,

(c) In case of weld coordination, they must be careful for in-out diameter, tolerance,????

(d) In case of connecting fellow the nozzle of mechanical directly, they need toconfirm bolt/Nat/gasket to proper department

SingleMechanical

SingleMechanical

SingleMechanical

6.7.2 Piping Material Division that determined by instrument department and piping designdepartment shall be observed.

6.7.3 Coordination with Vendor(1) To determine the coordination points, they have to contact with package Vendor in

advance.(2) In general??????(3) Investigating and confirming for thermal stress about anchor point and supporting

point, move olume etc. without fail.

6.7.4 Coordination with Instrument(1) To determine the coordination points, they have to contact with customer in advance.(2) In general, Piping coordination should be applied weld coordination, it must be careful

in-out-diameter, tolerance, shape of ???? etc. depend on the situation, it is necessaryto product special fitting.

(3) In case of connecting with mechanics which supply from customer, if the flange andpiping shall be used which are not be given in H-103.

(4) Investigate and confirm to anchor points, supporting points and removal volume forthermal stress without fail.

6.7.5 Coordination with construction buildingCoordination piping which connected for piping facilities of inside building shall be located far1.m from the center line of column for out wall, and the coordination place shall bedetermined which required to confirm for civil design department in advance.

7. Civil Information7.1 The preparation purposes and type of information

(1) PurposeThey have to prepare the plan drawing that included information of civil, building type,dimentions, loading etc., and sent in the plan drawing for civil design department. Civildesign departments have to detail design based on it drawing.

(2) Information type(a) Pipe rack

The shape, dimentions, height and loading, etc. such as an operation pipe stand onthe pipe rack shall be indicated.

(b) Pipe standThe shape, dimentions, height and location of equipment loading. etc. shall beindicated.

(c) Operation pipe stand (The valve and instrument, etc. shall be installed when cannot be operated from a plat form).The shape, dimentions, height and loading etc., shall be indicated.

(d) Compressor buildingThe shape, dimentions, height and loading etc., shall be indicated.

(e) Foundation, layout, height, shape and loading etc. shall be indicated.

(f) Pavement plan drawingPavement area and pavement material shall be indicated.

(g) Dike and pitThe shape, dimentions and location shall be indicated.

(h) Local foundationThe dimentions , location , height and loading shall be indicated.

(I) Insert plate and open nozzleThe dimentions and location shall be indicated.

7.2 Confirmation of design conditions

The items which determined COORDINATION MEETING NO. 1 PART 1 shall be confirmedbased on the TEG1-1319-001 [Job meeting between piping design department and civildesign department]Specially, the basic design (basic organization, basic shape etc.) data (typical drawings) shallbe confirmed. As well as the detail check items shall also be confirmed according to properTWC documents.

It should be determined that the items between piping design department and civil designdepartment in advance.

Item Piping design Civil design(1) Low and Regal application

or Standard

(2) Restriction items in acontract

(3) Special requirement ofcustomer, and basiccounterdimentions ofinterface

Item Piping design Civil design(4) Operation range of

interface

7.3 Classification of loading and method of calculation(1) Classification of loading

As the following loading should be considered in order to draw up the civil information(The loading shall be determined in advance which should be tended from piping designaccording to the construction calculation technique, and write down √ mark to )

Classification Factor

permanentload Static load

Static loadStatic loadStatic load

Static loadDynamic load

Static load

Static loadStatic loadDynamic loadStatic load

Static load

Static load

Dynamic load

- Piping • Weight of piping, fitting and valve • Weight of Hot/Cold insulation materials • Weight of internal fluid • Internal pressure of bellows and spring reaction

force • Heat elastic force and frictional reaction force • Vibrations (Pressure vibration of compressor,

vibration of vacuumed valve, vibration bykarman eddies)

-Equipment • Weight of equipment (tower, heat exchanger,

pump, compressor etc.) • Weight of contains • Weight of Hot/Cold insulation materials • Vibration of rotating • Heat elastic force and frictional reaction force

Weight of electrical and instrument cables

Loading will be occurred by the ground subsidence

Loading will be occurred by the edd and flow of thetide

temporaryload

Static loadDynamic loadDynamic load

Static loadDynamic loadDynamic loadDynamic loadStatic load

- Piping • Weight of pressure test fluid • Reaction force of sucking (safety valve, ??? etc. ) • Vibration (water shock action etc.)

- Loading will be occurred by the wind • Wind pressure • Vibration by karman eddies • Waving by wind Loading will be occurred by earthquake Loading will be occurred by snowfall or icering

- Equipment • Loading of test fluid • Loading while maintenance (Including when tube

pulling of heat exchanger)

(2) Calculation method of the loading(a) Weight calculation for pipings, valves hot insulation materials

(i) Fluid pipingLoading = Piping weight (note 1) + Hot (cold) insulation material weight +

Internal fluid weight (note 2)

(ii) Gas piping (under 8 in dimentions)Calculate shall be considered as full water. Loading weight should beaccordance with fluid piping of (i) items

(iii) Gas piping (over 10 in dimentions)Loading = Piping weight (note 1) + Hot (cold) insulation material weight

Note 1 : Including valve and instruments weight etc.Note 2 : Internal fluid weight shall be determined according to DENSITY which

indicated on Line Schedule.Note 3 : When the test fluid is water, the loading when full water shall be considered

as short terms loading.

(b) Frictional reaction force?????? (refer to Fig 7.3-A)

Ff

W

Fig 7.3-A Frictional reaction force

(c) The force will be occurred by installation of bellows(i) Main anchor

Directly tube fix point : In case of the piping facilities shall be installed frompressure case etc. to direct tube, ???????

Fm = Fp +Fe (7.3-2)Fp = A x P (7.3-3)Fe = K x X (7.3-4)

(ii) Main anchor in BendIn general, when installing the pipeline, this main anchor shall be installedfrequently. According to Fig 7.3-B, The Fb which act to Fm may be act onfrom a differential other direction, that is why, two directions that may becomposed shall be act on MAB.

Fb = 2Fm sin θ2 (7.3-5)

In case of the fluid is relative importance or swiftly stream, it needs to add tothe driving power which may be occurred by centrifugal force of the fluidmotion as the indicating expression 7.3-8.Fm = Fp + Fe +Fu (7.3-6)

Ff = µ X W (7.3-1)Ff = Frictional reaction force kg µ = Friction coefficient Iron and Iron 0.3 Iron and Teflon 0.05W = Vertical Loading Kg

Fu = 2 2A

gρυ

sin θ2 (7.3-6)

(iii) The immediate anchorIn case the expansion bellow shall be installed during two main fix points, themiddle fix point should be installed to proper position. Because if thefrictional reaction force of piping guide, difference the level of piping line,difference temperature, or as the other bellows??????The loading of anchor are sure based on the expression 7.3-8 that are beanticipated about a maximum.Fi = K x X = Fe (7.3-8)

Note : In case the frictional reaction force shall be add to the anchor, the Ffof (2)(b) as mentioned should be add to Fm and Fi as mentioned,

Calculation exampleThe calculation of driving power at each anchor when the Ex-3000 type 250A shallbe used to 10B-15 K Steam pipingP = 15 Kg/cm2 A = 785 cm2 K = 13.1 Kg/mm n = 6 x = 50 mm1) Immediate anchor from expression 7.3-8 Fi = 13.1 x 50 = 655 Kg2) Direct tube anchor from expression 7.3-2 Fm = (785x15) + (13.1 x 50) =

12430 Kg3) Anchor of 90° Bent tube

from expression 7.3-5 Fb = 2x12430x0.707 = 17576 Kg

Fb : Composition driving power is act to main anchor in bend KgFm : Driving power anchor of axis direction KgFi : Driving power is act to main anchor in bend KgFe : Spring reaction force of expansion bellow KgFp : Driving power by internal pressure of expansion bellow KgFu : Driving power of centrifugal force by fluid running speed. KgK : Ordinary spring number of bellows Kg/mmN : Number of bellows mountain ???X : Number of expansion mmA : Effective sectional area of bellows cm2

P :Operation internal pressure Kg/cmρ : Density of fluid g/cm3

ν :Running speed of fluid cm/secg : Acceleration of gravity 980 cm/sec2

θ : Vent angle of vent tube °

Fig 7.3-B Driving power and direction act to the main anchor and immediate anchor

(d) Loading caused by thermal expansionLoad caused by thermal expansion and contraction of piping. The calculationshould be based on the method of simple analysis, Dept inst 02-08 Standardmeasures against thermal expansion, CAESAR-II or ADL-PIPE. Note) Accordingto the EXXON BP3-7-1, in case the several anchor forces shall be specified??????

(e) Instruments and electric duct weight (refer to table 7.3-A)

Table 7.3-A Instruments and electric duct weightWidth x Height

(mm x mm)Weight(Kg/m)

Width x Height(mm x mm)

Weight(kg/m)

1500 x 500 515 600 x 300 1501400 x 400 480 500 x 300 1251200 x 400 350 400 x 200 751000 x 400 290 300 x 200 60800 x 300 190

Note 1 : Allowable duct span is 6000m (max.)Note 2 : As bellows data should be confirmed for electrical design department and

instrument design department without fail.

(f) Discharge reaction force of safety valve (refer to Fig 7.3-C)Calculation for discharge reaction force of air discharge type safety valve shall beapplied API RP520.

Fm :Fi :Fb :MA :IA :MAB :

Fs = 1

273W K T

K M( )( )

++

2731 (7.3-9)

Fs = REACTION FORCE KgW = MASS DISCHARGE Kg/HrK = SPECIFIC HEAT CP/CVM = MOL WEIGHT Kg/KmolT = TEMPERATURE AT GATE CIRCUMSTANCE °C

Fs

Fs

Fig 7.3-C Discharge reaction force of safety valve

(g) Equipment weightEquipment weight are given in ENGINEERING DRAWING or VENDORDRAWING that may be tendered from equipment design department. The weightof Equipment, contents and execution for pressure test shall be taken the weight oftest fluid and pipe stand into consideration for basic design.

(h) Wind loadingi) Standard for piping of high pressure gas (KHK S 0302-1978)

Wind pressure shall be act horizontal direction to piping or piping stand, andit shall be calculated according to as the following expression.

Fw = CqAFw : Wind pressure (Kgf)C : Wind pressure coefficient is specified 0.7 to individual well as it

specified 1.0 to pipe stand for several pipings arrangement, for theseveral pipings arrangement shall be specified according to as thefollowing table.

No. of piping 2 3 4 5 6 7 8 9 10 11 12 Over 13C 1.190 1.540 1.778 1.946 2.065 2.149 2.205 2.247 2.275 2.296 2.310 2.450

q : Pressure of average speed (kgf/m2). According to as the follows.However, it shall be specified more than 150Kgf/m2

Height of piping or pipe standard where the parts of under 16 m fromground are as follows:

q = 60 hIn case the parts is over 16m

q = 1204 hh : The height from ground (m)A : In case the piping or wind projected area of pipe stand?????

(ii) Earthquake loadinginteria force by earthquake vibration shall be calculated the weight of pipingor pipe stand (included contents weight) by design horizontal richter scale ordesign ?????????

(k) VibrationThe place where the possibility of occurring vibration such as a shock, pulsatingcurrent, vibration by compressor needs to enough strength to supporting andfoundation anticipating the supporting loading of twice weight by it weight.

7.4 Fire-proofing

(1) The construction area of Fire-proofing are difference depend on customers. They haveto confirm to the object of plant things and also the scope for civil design departmentbefore design.

(2) Application examples(a) Pipe rack

All pipe rack shall be installed fire-proofing. The area is specified until pillar of first???

Fig 7.4-A Fire-proofing example of pipe rack

(b) Steel StructureIn case there are process units which are operated inflammable liquid in the B.L, orthere are possibility of destroy important damage for unit , fire-proofing shall beinstalled. The application fire-proofing should be specified from foundation toupstairs. (refer to fig 7.4-B).

(c) Fire place supportingThe organizations of Fire place supporting are operating incombustible things.Except when there is only hydrocarbon gas, fire-proofing shall be installed. In casethe fire place that operated incombustible things or only hydrocarbon gas, fire-proofing shall be installed within 6 m from fire place that will be installed fire-proofing. The fire-proofing area are only vertical pillar from foundation to bottomof fire place except for the horizontal ??? (refer to fig 7.4-C).

Fig 7.4-C Example for fire-proofing of fire place supporting parts

(3) Structure of fire-proofing(a) Structure of Ferro concrete building.

The parts where needs to install fire-proofing shall be specified structure of ferroconcrete building.

(b) Structure of concrete fire-proofingThe parts of steel frame building where need to install fire-proofing shall beproofed concrete that depth of a minimum 50 mm. (refer to fig 7.4-D)

Fig 7.4-D structure of concrete proofing

(c) Structure of fire-proofing boardThe parts of steel frame building where need to install fire-proofing shall beinstalled fire-proofing board. (refer to fig 7.4-E).

Fig 7.4-E Structure of fire-proofing board

7.5 Pipe rackDetails plan for rack piping shall be given in the TEG1-1313-004 Rack Piping or para 10.5 ofthis instruction.

7.5.1 Draw up for loading dataThe way of tending for loading data shall be confirmed for civil design department aboutcalculation method in advance as simple as possible. As well as the loading of grider andjoist shall be clarified.

Example

girder joistAll bare lines Ο Ο

Under 2 ″ Hot/Cold insulation line Ο ΟOver 3 ″ Hot/Cold insulation line Ο -

(a) Load caused by thermal expansion of pipingThe calculation should be based on para 7.3(2)(b).(i) Main anchor force (refer to fig (A-1) of 7.5-A)

For each piping, indicate the position and load of main anchor.

(ii) Intermediate anchor force (refer to fig (A-3),(A-4) of 7.5-A)Indicate the load difference between the right and left side or 20% of the largerload of either side, whichever is a larger value.

(iii) Anchor force at corner parts (refer to fig (A-3), (A-4) of 7.5-A)

Indicate the axial load as well as the load of perpendicular to axis. The axial loadis derived in accordance with para 7.5(d)(ii) above.

(iv) The thermal reaction force of roupes are given in the DEPT. INSTRUCT.02-08:standard for absorption roupe design of thermal expansion.

(b) Frictional force (horizontal force) owing to the piping weight (Ff)(i) Frictional force to be used for loading data of the beam is the one that gives the

greatest bending moment to the beam, regardless of whether anchor point or slide.

(ii) Selection of loading dimentions.The dimentions of a frictional force (beam on the slide point) which occurred bypiping movement and a reaction force (beam on the anchor point) which occurredby it frictional force shall be applied to fig 7.5-B the load comparison for (simplebeams).

(iii) Example of the calculation of frictional force as below. (refer to fig 7.5-B)

Ff (Frictional force) = Total piping weight x Frictional coefficient (GeneralSteelmaterial

tefron0 3

0 05.

.)

Loading Loading of loadFf1=16.7Kgf/m x 8m x0.3 =40KgfFf2=11.2Kgf/m x 8m x0.3 =27KgfFf3= 9.2Kgf/m x 8m x 0.3 =22Kgf

1000/5000 = 20%1250/5000 = 25%1750/5000 = 35%

If a stop valve is used foropening/closing, apply theinstruction (A-1) above.

Fig 7.5-A Loading by thermal expansion

AnchorSlideSlide

Ff4= 6.3Kgf/m x 8m x 0.3 =15Kgf 2500/5000 = 50%

Fig 7.5-A Example for the calculation of frictional force

The loading dimentions shall be determined which are used fig 7.5-C load comparison figaccording to the loading of Ff1, Ff2, Ff3, Ff4 and loading layout. Ff1>Ff2=Ff3>Ff4, Ff2 and Ff3are same on the moment, as a results, Ff1 is biggest.

Beam at slide point: Indicate the position and value of Ff1 (frictional force by singlepiping weight)

Beam at Anchor point: Indicate the position and value of Fa (reaction force of Ff by singlepiping weight) = Ff1+Ff1’+.......

Fig 7.5-C Loading comparison fig (simple beam)

M : Moment (kg.m)P : PercentFf : load (Kgf)L : Span (m)L1, L2 : Distance between

R1 and R2(m)

L1 = P.LL2 = L.P.L

= L(1.P)

M Ff L LL

= . .1 2

The load location → %

(Using area)

Note 1: The load location is shown as the ratio (%) to the beam span (L).Note 2: To use the table, load location for each beam must be converted into percentage(%).Note 3: The moment remains the same on the same curve. (Ff2=Ff3)Note 4: The moment on the upper part of the curve is greater (Ff1>Ff2>Ff4)

(c) Reaction force owing to the internal pressure of expansion bellows. (refer to fir7.5-D).The calculation should be based on para 7.5(2)(c).

Fig 7.5-D The loading by expansion bellows

When expansion bellows (road type or sleeve type) are used, the same attentionshould be paid as para 7.5(1)(a) mentioned above. In particular, expansionbellows produce reaction force greater than that of expansion bends at mainanchor point or corner anchor point, so that the supporting structure must besuitably designed (with tie-bar, for example).

(d) Load caused by the piping vibration(i) This type of load is treated as dynamic load.(ii) This type of load is to be received by axial tension or compression of

members instead of the bending of members.

(e) Wind pressure load (horizontal force)(i) Indicated the cross-section of the piping concerned.(ii) Indicate the hot/cold insulation with a double circle. (the calculation is based

on the insulation thickness of 100mm)(iii) Indicate specially where the insulation thickness is more than 100mm.

(f) Loading data forms(i) Loading data should be shown in the following two types of drawing.

- Rack structure information drawing.(plan and section)- Vertical load information drawing (including dynamic load)

(ii) The following information should be included in the rack structureinformation drawing.- Location, dimentions and height of plat form.- Location where bracing are not allowed.- Location of ladder.- Horizontal load and local-concentrated load (location and magnitude,

elevation, direction and of each load) Data should be shown for each rack.(refer to fig 7.5-E and fig 7.5-F).

Example : Plan drawing Example : Verticaldrawing

Fig 7.5-A Example for load indication Fig 7.5-F Example for load indication

(iii) Vertical load information drawing.- Mainly long-term loading is shown in this drawing- Short-term loading when the pipe is full water for pressure test is treated as

concentrated loading if the pipe concerned is of more than 14 in.- Snow load (temporary load) should be indicated as necessary.- Dynamic load (vibrating pipe) should be indicated as necessary.- The following is the example of the drawing for vertical loading.

Fig 7.5-G Vertical load condition drawing.

7.5.2 Typical dimentions of pipe rack (reference)In case there are no requirement by customer and special condition, typical measureof pipe rack shall be chose from table 7.5-A.

Pipe spacing should be shown to scale and confirm toenough to the rack width

Table 7.5-A Typical measure of pipe rack

Items Typical dimentions RemarksWidth :B 6.0, 8.0, 10.0,

12.0(2 span of 6.0 x 2)Each jobs have to determineunder width 6.0m

Height :H1 EL 3.0, 3.5, 4.0, 4.5EL 5.0, 5.5, 6.0, 7.0, 8.0, 9.0

Height of pipe sleeper EL 0.3,0.6

Stair space :H2 1.0(Piping diameter under 6in)2.0(Piping diameter 8in~32in)3.0(In case the gateway isdownstairs)

Pillar space :L1 (3.0), 6.0(recommend), 9.0,(12.0)

( ) are uneconomical, not usefor as possible as

Joist :L23.0, 3.5, 4.0

It shall be determined take theelectrical, supporting span ofinstruments duct, orsupporting span of smalldiameter line intoconsideration.

7.5.3 Material quality of pipe rackIt needs to confirm which concrete structure or steel organization.

7.5.4 The shape of pipe rack (reference)It is preferable that few material and the method of buildings are simple andeconomical organization.

(i) Segment shape of interval beams direction.(refer to fig 7.5-H)

L2

H2

B1

B L1

Fig 7.5-H Segment shape of interval beams direction

- In general, t-type pipe rack shall be installed one step.- In general, two steps rack shall be installed except for very small plant.- Big plant should be a maximum of three steps rack.- Over rouged gantry type is economical compare with gantry type.

(ii) Typical shape for over gauged gantry type pipe rack. (refer to fig 7.5-1)

Fig 7.5-1 Typical shape for over gauged gantry type pipe rack

- In general, in case the over gauged gantry type, relation between width (b) andspan (b) = 3/5bm.

(iii) Shape of ???direction

- Normally the length of pipe rack are 60m, and it shall be devised by expansionjoint.

- The part where crossing pipe rack shall be installed expansion joint withoutconnect to beams of pipe rack that is directly crossing. (refer to fig 7.5-J)

- In general, ???direction span are a twice of joist intervals (3.0m, 3.5m, 4.0m).????

Fig 7.5-J Example for crossing part of pipe rack

(iv) Position of brace- In order to prevent steel material reduce and transformation pipe rack as

possible as brace shall be installed.- Vertical brace of ????friction shall be installed close at center part each point

where devised by expansion joint. When brases are required two point if thevertical force of ???direction are strong by thermal expansion, Installationposition shall be concentrated center part.

- Horizontal brace shall be installed to the anchor parts where may be occurreda reaction force or the vertical brace position by thermal expansion.

(v) The shape of brace- Vertical brace of longitudinal direction• A type of brace, the merit and demerit are following as below. (refer to fig 7.5-

K and Table 7.5-B)

(A) Brace Type (B) K-truss Type (C) Bracket Type

Fig 7.5-K Type of brace and layout

Under 6.0m

B

45°

Table 7.5-B Type of brace and merit and demerit

Type Merit DemeritBrace type 1) Brace are so pulling

material, that it enough todetail things. (2) Construction costs arecheap.

1) It is impossible to passunder the pipe stand.2) If brace is using forvibration things on the pipestand, brace may also bevibrated and ???

K truss type 1) It is possible to pass underthe pipe stand with a smalldamages.2) Transformation by reactionforce can be minimized.

1) The braces are socompressor material that itneed to hard strength???2) ???

Bracket type 1) It is possible to pass underthe pipe stand.2) ???

1) Comparing with otherthings, the result is a feweffect.

• In general, Pipe rack in the plant shall be installed k truss type, however, whenit is difficult to install it, it shall be installed bracket type. Example layout forbrace of K trass type are the following below. (refer to fig 7.5-L).

Fig 7.5-L Brace layout

• Under the interconnection pipe rack can not be used as passage, therefore,Brace of brace type shall be installed.

• In case of installing a two steps or three steps racks, the fig shows it need toinstall a brace upper steps. (refer to fig 7.5-M).

Fig 7.5-M Layout for Vertical brace of longitudinal direction when single beam

(D)(C)(B)(A)

(B)(A)

- Horizontal brace• Layout example for horizontal brace are following as below. (refer to fig 7.5-

N)

Fig 7.5-N Layout for horizontal brace

• When the horizontal force are operating to large longitudinal direction at theprotruding of Over gauged gantry type pipe rack,or when the layout of fig7.5-M is difficult to install, example for the installation of horizontal brace arefollowing as below. (refer to fig 7.5-O).

Fig 7.5-O ???

7.6 Pipe stand7.6.1 Installation of pipe stand, stair and ladder

Para 5.7 is indicating the installation standard

7.6.2 Determination of shape, dimentions and height

(a) To determine the shape and dimentions of pipe stand, take the equipmentdimentions, accessories, piping route, operation, inspection passage,maintenance area into consideration.

(b) To determine the height, the process requirements items should be enoughchecked including operation and inspection.

(c) To determine pipe stand organization, take the installation method of equipmentinto consideration.

(d) Equipment which required maintenance or (thermal exchanger, agitator) orinternals (catalyst, packing) changing shall be investigated installation ofoperation area, picking space and instruments for maintenance.

(e) In case the adjoining pipe stand, take as possible as together with one pipe standin order to operation well and economical merit into consideration.

(f) The range for handrail requirement are indicated

7.6.3 Materials and Structure(a) Confirm to concrete structure or steel structure in advance.(b) The method of ground brace, side brace, beam positions and flooring that may

be determined according to the result of detail design at Civil Design Departmentshall be confirmed to Civil Design Department in advance, as well as they haveto make a arrangement sufficiently based on the plan drawing of Piping DesignDepartment.

(A)4.8m ≤ B ≤ 9.0m

B ≤ 4.5m

(B)

7.6.4 Load and ????(a) Equipment are indicating installation position.(b) Mechanical and piping are indicating ????

7.7 Operation pipe standIn case the valve and instruments where can not be operated and confirmed from ground orplat form, there are two cases that shall be installed on the pipe rack or pipe stand, as well asinstalled on the ground independently.

(1) Stating items for civil information(a) Shape(b) Dimentions of each parts(c) Installation height and height from floor(d) Position and dimentions of concentrate load(e) Position and dimentions of ???(f) Installation position for radder or stair(g) Installation area for handrail(h) Install position

7.8 Compressor BuildingDetermination for shape of centrifugal compressor are following as below

From the past examples, there are three types in determining the type of building as below.The type of building shall be selected according to the consideration of whole position, forweather condition and environmental, customer requires. Each characteristic are followingtable 7.8-A

Table 7.8-A Characteristic of building type

Plan of parallel layout

(a) In case the many compressors, from a viewpoint of operation control, arrangement linelayout is easy to concentrate controlcompare with series layout.

(b) The building may be big and raising theconstruction cost . However, accessoriescan be installed for empty space andprotect from rain and snow. Therefore, thistype shall be applied at cold area wheremuch raining and snowing.

Plan of series layout

(a) In case a few compressor (under threecompressors), it way shall be applied andalso can be reduced of building.

(b) It is so economic that crane span is short.© It is easy to install a compressor, turbine

condenser and pull the tube.(d) It shall be applied at warm and few rain

areas because of the oil console and otheraccessories shall be mainly installed atoutside

Table 7.8-A Characteristic of building type (cont’d)

Plan of L-type layout

(a) This type is transformation of direct linelayout that required from total plot plan,and in order to compact the equipmentlayout of around building mainly.

(b) Two crased are required(c) Because of separated two drop out areas, it

is complicated to access by truck

(a) In case of not appointed from compressor maker or turbine maker, the height ofcarne shall be specified that can be resolved to casing.

(b) In general, floor level for operation maintenance shall be fitted the top ofcommon head. (refer to fig 7.8-A). If fitting the bottom line, The plan of civiloperation of foundation, piping of rub oil and seal oil and other accessories smalldiameter piping may be difficult planing.

Fig 7.8-A Floor level of building

Floor Level

Floor Level

Pitt

Over 300

(c) In general, floor level and shape of foundation for compressors are determinedaccording to compressor or turbine manufacture’s requirements, and furthermoredesigning and checking work should be made considering the following items.(refer to fig 7.8-B)

Fig 7.8-B Floor level of building

(i) Dimentions and installation height of condensers and turbines, and requiredNPSH for condensate pumps. (Net Positive Suction Head).

(ii) Space between a condenser and a turbine. Shapes of turbine outlet,condenser inlet nozzles, as well as their connection with pipings.(necessityof bellows)

(iii) Compressor height. Height of a straight part of the suction piping.(iv) Maintenance space for condensers and other equipment(v) Piping support space below compressors and turbines(vi) Locations of foundation columns for compressors (considering the relation

with nozzle positions, unnecessary charge in piping directions at the suctionside should be reduced).

(vii) Restrictions on height for lube oil and seal oil piping systems.

(d) Access means shall be applied stairs to compressor floor.

7.8.2 Cautions for determination of building(a) In plot plan, type of equipment and image dimentions shall be checked.Do not over look the modifying such as compressor existence, type of intercooler

(whether they are shell and tube type, air cooler type, other) etc. which mayhave a great influence on the shape of building.

(b) They have to check legal restrictions. Example: Regulations on oil-relatedand dangerous objects.

(c) Spacing where can not touch with the foundation of building pillar and thecompressor foundation shall be specified. (In order to prevent vibrationconvey from compressor foundation).

Condensate PumpCondenser

Compressor

SteamTurbine

(d) Compressor and turbine should be installed within a operation area of cranehook.

(e) To determine the mutual relation ship with pillar position, take the caring inturbine and condenser, maintenance and piping route into consideration. Insuch case, take care of the pillar span that may be restricted depend onmodule.

(f) Space of maintenance area shall be a minimum of 3 m or more than twiceof maximum casing width close to compressor or turbine. Determination ofthe floor load for maintenance area shall be calculated according to thecasing weight.

(g) Drop out area should be installed in order to carry and send in equipment.Space for drop out area shall be specified where casing can be handled atleast. The layout where can be used crane and also can be accessedvehicles.

(h) To determine the position for oil head tank and seal oil tank, take the oil linewhich may be required gravity flow into consideration. (Do not blockpassage).

(3) Detail of layout determination(a) An arrangement layout (refer to fig 7.8-C,D)

Fig 7.8-C Example for arrangement layout

Oil Head Tank

Drop out

PanelOilConsole PanelPanelPanel

CA

D

Fig 7.8-D The side layout of compressor building

Remark : Dimentions are determined by maker. (reference value)

Item Description Standard value (m)

h1

Mitsubishi Heavy industry ClarkKobe steel manufacture

Mitsui shipbuildingPIGNONE (Hitachi)

4.5 (4.0 - 5.0)5.0-

7.0

h2

Small CompressorMiddle CompressorLarge Compressor

4.05.07.0

??? load (t)20

Span (m)10 - 1617 - 26

2.52.6

h3 30 10 - 1617 - 26

2.72.8

40 10 - 1617 - 26

2.93.0

Min.4.0M

Min. 1.8M

OilLevel

Seal OilHead Tank

Panel

1FL

2FL

H

G

F

passage

Oil Trap

Condenser

Oil Console

h3

Table 7.8-B Example for parallel layoutItems Standard Article

Aequipment space

Minimum 6.0 m

The reasons for determination ofequipment interval space are following asbelow.(i) In case the steam turbine drive

compressor, condenser whichinstalled under foundation type shallbe ensured space of installation carryand pulling tube.

(ii) In case of install oil console, it shall beensured enough (minimum of 0.8 m)space for operation passage around it.

(iii) Main piping that is connected forequipment should be stick out of thebuilding through the equipmentinterval, therefore, space for thepiping installation should be ensured.

(iv) ????

BEquipment intervals

Minimum 4.0 m

The reasons for determination of spaceare following items as below.(i) Ensure the installation carry of

condenser for steam turbine and tubepulling area.

(ii) Center of equipment shall be installedat hang up available area of overhead crane.

CBuilding side space

Minimum 1.0 m

The reasons for determination of spaceare following items as below.(i) Ensure the enough space for

operation and maintenance passage.

DUp stair floor

Minimum 2.0 m(from building pillar inside to

equipment foundation)

The reasons for determination of spaceare following items as below.(i) spacing for the footing between

building pillar foundation andequipment foundation due to avoidtouch.

ESpace between

equipment and panel

Minimum 3.0 m(determine and check the casing

cover dimentions at each job)

The reasons for determination of spaceare following items as below.(i) Spacing for the operation, in front of

panel shall be a minimum of 2.0 mwidth.

(ii) Ensure the space for maintenancepassage which can be through bycrane. That is why, the minimum widthcan be pass the compressor casing bycrane, as well as it is possible to carry-in to the drop-out.

Items Standard Article

ESpace between

equipment and panel

Minimum 3.0 m

The reasons for determination of spaceare following items as below.(i) In front of panel shall be a minimum

of 2.0 m width take the operating intoconsideration.

(ii) Ensure the passage for maintenancepassage that can be through by crane.That is why, the minimum width canbe pass the compressor casing bycrane, as well as it is possible to carry-in to the drop-out.

Drop out

The reasons for determination of spaceare following items as below.(i) Ensure the enough space available

where can be arrived by over headcrane. In case of install two overhead crane, ensure the enough spacedue to use available where can bethrough both crane.

(ii) The drop out is connecting to the carentrance it can be carry-in to truckdirectly from crane.

(iii) Trucks can be passed sufficiently.

Oil Console Installation is closed tocompressor at first floor.

The reasons for determination of oilconsole are following items as below.(i) Oil console shall be installed where

can be transpoerted. In general, inthe case of stairwell, it should betransported from outside. In case theclosed type building, the instllationshall be hanged up by crane thenopening upstair`s floor.

(ii) Oil console area at upstair floor shallbe grayting proofed that can beopened from a view point ofmaintenance, the area shall not beinstalled such a interrept thingsinstrument panel or unremovablepipings etc. Pump, filter etc atconsole shall be installed where canbe hanged up easily by over headcrane.

Seal Oil Head Tank For use the buiding pillar andinstall as possible as close to

compressor

The reasons for determination of headtank layout are following items as below.(i) In the middle of building, it is the

cause of obstructing from cranerunning, the head tank shall beinstalled by using pillars. Therefore,small tank (under 2t) should beinstalled at inside of building, as wellas large tanks (more than 2t) are thecause of obstruction for crane running,from a view point of operation, itshould be installed at outside.

Items Standard ArticleThe reasons for determination ofinstallation height are following items as

Min. 6.0M

Min.4.0M

Dropout

2FL1FL

FInstllation height of

compressor

6.0 m

below.(i) Ensure the space for instllation of

condenser of steam turbine within thecompressor foundation. Installrelation between turbine andconsenser shall be provided frommaker`s data.

(ii) Returne of lube oil shall be collectedfrom the machine to tank of oilconsole by means of gravity flow.Reterning seal oil shall be collectedthrough traps at tank.In this case collecting piping is slopedfor gravity flow. Therefore, trapp andtank shall be installed lower thancompressor position enough.

GInstllation height of

crane

determine by jobs

The reasons for determination of craneinstallation height are following items asbelow.(i) It can be hang-up and hang-off the

largest parts of equipment (acausticcover of turbine, casing cover). Incase the piping ???

(ii) Take care of the height of installationof seal oil head tank. (this is notabsolute. ???

HOil Trap

Lower than draining of compressorand higher than oil tank

The reasons for determination of oil trapinstllation height are following as below.(i) Oil trap shall be received waste oil

from compressorby means of gravityflow, furthermore, it shal lbe installedlower than compressor and higherthan oil tank. (in case the streamfrom trap to oil tank shall be sendedby back pressure of compressor gas,it can be installed lower than trap).

(b) L type layout

Fig 7.8-E L type layout

Drop out

Drop out

Panel

Panel

Panel

Oil Head Tank

Oil Console

C

EA

D

C

E

Table 7.8-C L type layout

Items Standard Article

AMachine intervals Minimum 2.0 m

The reasons for determination of machineinterval are following as below.(i) From the view point of operation and

maintenance, machine intervals shallbe specified enough space aspassage.

(ii) Foundation footing of adjoiningmachine shall be space where can notbe touch with one another.

C?? Minimum 1.0 m

The reasons for determination of spaceare following as below.(i) From the view point of operation and

maintenance, machine intervals shallbe specified enough space aspassage.

DInterval between

machine and building

Minimum 1.0 m(dimentions of casing cover shall

be check at each jobs)

Same as parallel layout

EInterval between

machine and parel

Minimum 3.0 m(???)

Same as parallel layout

Drop out

Width : Over 3.0mHigh : Over 4.5m

Same as parallel layout

Oil console Same as parallel layout Same as parallel layoutSearl oil

Head TankSame as parallel layout Same as parallel layout

Installation height ofcompressor

Same as parallel layout Same as parallel layout

Installation hegiht ofcrane

Same as parallel layout Same as parallel layout

Oil Trap Same as parallel layout Same as parallel layout

Drop out

7.9 Layout and shape of foundation

7.9.1 Foundation layoutRegarding the equipment layout in plot plan, froundation layout drawing should bedraw up. It is complete shape that can not be designed foundation layout design atplot plan stage, it should be draw up the foundation layout plan drawing by pipingdesign department and send in cicil design department.

7.9.2 Foundation heightBasic foundation height is providing para 5.8. When selection the special height,piping design department have to indicate.

7.9.3 Foundation shapeConfirm to civil design department about basic foundation height (includingstructureof under ground beams) in advance.(a) Foundation shape and equipment dimentions shall be determined based on the

dimentions of base poot of equipment by civil design department.(b) Large gable of footing as a tall tower shall be intervened for adjoining foundation

of machine or pipe stand. If they can not design as total foundation, the positionof machine should be controlled. Confirm to civil design department whethermachine to be required control or not.

(c) In case the suction nozzles of pump may be standardized dimentions, they haveto draw up the foundation layout plan drawing and send in to civil designdepartment in order to clear the installation position of pump. (refer to fig 7.9-A)In case the several pumps are parallel on the foundation, determine thedimentions from anchor bolt or pump head to foundation as well as determinethe position of foundation. (refer to fig 7.9-B).

Fig 7.9-A Basic dimentions of pump foundation

Suction Nozzle

Pump Head

FoundationA

GF

E

CD

H

B

Note 1: Select for larger whether J or KNote 2: Foundation dimentions should be shaped a 50 mm units

Fig 7.9-B Relation between pump head or anchor box and foundation

7.10 Road and pavement plan7.10.1 Road plan

(a) Route plan shall be applied take the par 5.6. into consideration when drawing upthe plot plan.

(b) Investigation for the requirement of subroad for maintenance when planning.(c) Final determination for the road width, sholder, the method of road draining.

7.10.2 Pavement planPavement plan drawing shall be designed including the information and customerrequirement items that send from process design department or civil designdepartment.(a) Pavement area

- Requirement area for process- Requirement area for maintenance

(b) Pavement division- Concrete paving (Necessity of acid-proofing, alkali-proofing)- Gravel paving- Non pavement area

(c) Oily area plan- Area division by spill wall (Maximum area of one division)- Sloping and draining direction- Spill wall height (standard is 150 mm)

(d) Pavement strength- Indication for the area which required special pavement strength.

7.11 Breakwater and pit

7.11.1 Breakwater planRefer to the para 5.5 of when tank yard layout planing, the following operation shallbe applied as below.

(a) Proper tank that required for breakwater shall be picked up from the applicationlow and regal. as well as shall be calculated the necessity of capacity forbreakwater??.

Foundation LM16 150M20 150M24 150M30 200M36 200M42 200

J=50 End of head

Foundation

L=100

K=100Pump Head Anchor Box

L

(b) Confirm for civil design department to the structureand material of breakwater.The dimentions and height shall be determined according to the structureandnecessity of capacity.- Arc dike- Concrete dike

(c) In case the breakwater partition is require at the breakwater, the layout andheight shall be determined. Position for the stairs that frequently used at thebreakwater shall be determined.????

(d) Determine for the method of rain water draining and layout.(e) In case the piping through the breakwater, thay have to determine the position of

through area and connecting method to piping, sealing of through area.

7.11.2 Bit plan

(a) In a piping layout which may be required such as valve of underground piping orbit for instrument, catch basen of oily piping etc. shall be draw up the bit pipinglayout drawing.

(b) The bit piping drawing should be included the following items as below.(i) Installation place for bit(ii) Dimentions and Depth(iii) Position of step for ascent and descent(iv) Sealing of piping penetration and penetrationa.(v) Installation area for cover and handrail(vi) Position and load when required the insert plate and local foundation.

7.12 Local foundation(1) The layout plan for local foundation drawing should be draw up single foundation for all

piping support of ground and concrete floor when support designing of early stages.(2) Layout for plan for local foundation should be included the following items as below.

(i) Instllation place(ii) Direction (horizontal, vertical), dimentions and support height of laod(iii) The height of upper local foundation(iv) Type and dimentions

(3) Type (refer to fig 7.12-A)They have to contact with civil design department for the use of type and use of loadlimit.(i) Flash mount type : Use for low height support and large laod(ii) Insert plate type : Use for low height support and slide type support(iii) Hole in anchor type : Use for small load support and ????of support area.

(A) Flash mount type (B) Insert plate type (C) Hole in anchortype

Fig 7.12-A Type of local foundation

(4) Local foundation of adjoining machine shall be one setted with machine foundationwhere may be occured a big force for machine and a damage for operation of rotatingby sinking of unbalance foundation. (refer to fig 7.12-B)(i) Foundation of around rotating(ii) Foundation of around store tank

7.13 Insert plate and panetration7.13.1 Insert plate

(a) Support part of concrete building shall be buried insert plate in advance. Layoutplan for insert plate drawing shall be draw up when support designing earlystages.

(b) Layout plan for insert plate drawing shall be included the following items asbelow.(i) Installation place(ii) Direction and dimentions of load(iii) Type and dimentions.

(c) Type (refer to fig 7.13-A)(i) 100 , 200 , Special type

Selection the proper dimentions according to the dimentions of supportmaterial

(ii) Corener angle type:In case the flash mount information of insert plate is to be sent in beforewhen support designing, at corner of pillar and beams where to be guessefor support insatllation shall be buried.

Fig 7.12-A Example for foundation of pump around

FoundationFoundation

Fig 7.13-A Insert plate types

7.13.2 Penetrations(a) Penetration layout plan drawing of piping that penetrated floor and wall shall be

draw up when planning.(b) Penetration layout plan drawing shall be included the following items as below.

(i) Penetration place(ii) Penetration dimentions(iii) Instllation area of cover and hand rail ( when required)(iv) Seal of penetration (when required)

(c) Standard dimentions for penetration and the height of spill wall.

Fig 7.13-B Standard dimentions for penetration and the height of spill wall

200

100

(B) 200 Type

(A) 100 Type

L65 x 65 x 6

(C) Special Type

(E) Hole in Anchor Type

(D) Corner Angle Type

100mm

Spill Wall

About 50mm (note1)

Note 1 : In case of install the insulation or flange, todetermine, take it into consideration

Min.

8. Nozzle OrientationRegarding to the detail plan of the piping around tower and heat exchanger, TEG1-1313-005 Tower Piping and para 10.6 and 10.7 of this instruction shall be referred and to sincethe nozzle length, leg dimensions are specified in the Vessel Standard, the standard shallbe received and confirmed of them prior to start of the job.

8.1 Determination of Nozzle OrientationThe detail check items of nozzle orientations shall be confirmed using the proper TWC.

8.1.1 Nozzle Layout PlanThe layout plan of equipment nozzle shall be made in parallel with detail layout plan.To determine the nozzle layout plan, taking into consideration the tower, structure,functions of tank and heat exchanger. and the requirements from process and layout.The nozzle layout plan shall be forwarded to Piping Design Department for the detailplan. As the result of detail design, in same cases, the detail design can not bepreceded as the nozzle layout plan, then arrangements are required between bothdepartments. and ???

8.1.2 Items to be specified in Nozzle Layout Plan.In the drawing, the following items shall be included.(a) Nozzle Orientation(b) Height and area of plat form(c) Plat form penetration and loading position.(d) Location of ladders and steps.(e) Location of davits(f) Location of lifting lugs(g) Location of access hole and vent hole.(h) Location of name plate(i) Open and shaft of manhole cover(j) Height of skirt and legs (required confirmation of pump NPSH, Pump type etc.)(k) Installation level(l) Clip for pipe support(m) Especially, the orientation of equipment for miller shall be correctly prepared and

indicated.(n) Others, special mentions.

8.2 Installation for Ladders, Steps and Plat forms.

8.2.1 Standard Dimensions and Caring Loads(a) The standard dimensions of ladders and steps and plat forms shall be in

accordance with TEC STANDARD DRAWING. (refer to the para 5.7 of thisinstruction.)

(b) Caring loads(i) Standard for caring loads: 300 Kg/m2

(ii) In a cold districts, the snow load shall be considered in addition to thestandard caring load.

(iii) In case the special load for piping support and maintenance, these loadsshall be estimated separately from the standard load. The supportinglocation and size of load shall be communicated to Mechanical DesignDepartment or Civil Design Department.

8.2.2 Installation Criteria for Plat form and LadderRefer to the para 5.7 Access Criteria

8.2.3 Types and Sizes of Plat form(a) Plat form for general vertical equipment (refer to fig 8.2-D)

(i) The width of plat form shall be determined with consideration to manholesize, instrument take-out positions, etc.

Fig 8.2-Db Width of plat form

Fig 8.2-Dc Width of plat form

(b) Plat form for tower top(i) Select square type. In general, the effective space shall be 800 mm. (refer

to fig 8.2-E).

Width of plat form(B)

Remarks

600 Min. Not for used ingeneral.

8001000 Standard

1100 ~1500 Max. Determine thewidth the by 100mm pitch.

Fig 8.2-Da Width of plat form

Min.

Min.0.6m

(ii) In the case where the nozzles are penetrated the plat form for booting andfor setting main valve, longer nozzles than the standard shall be used.(Confirm to mechanical design department.) (refer to fig 8.2-F).

Fig 8.2-F Installation height of plat form top

(iii) The penetration size for nozzle that penetrated platform shall be either theflange diameter plus 100 mm or the insulation diameter plus 100 mm,whichever the larger. The penetration size for nozzle that does not gothrough the platform shall be the size that allows the uses of a spanner forflange bolting.

(iv) In case where the plat form is to be connected to the adjacent tower and tanketc., the connection shall not be of the rigid body, but cut apart (around 20mm) or of the flexible structure (connection by loose holes, etc.).

(c) Plat form for horizontal vesselsPlat form shall be installed at the shell top or the shell side. Plat form size andinstallation height shall be determined individually giving consideration eachoperation and inspection.

800 (Min. 600)

800 (Min. 600) Fig 8.2-E Width of Tower Top Plat form

Min. 25Min. 100 (Over 16B is

Min. 180m/m)

(d) Plat from for tank (refer to fig 8.2-G)

Cone Roof Circle Roof Spherical

Fig 7.9.2-G Plat form for Tank

(i) Selection of ladder and step

Height (HMO) MethodLess than 6 m Monkey ladder attached

safety gaugeover 6 m Spiral step

(ii) The plat form of the exceeding 10 m shall be installed a middle plat form(landing). Intervals of middle plat form shall be installed equally within 10 mspace.

(iii) The plat form on the roof and the queried rail shall be minimized.

(iv) In case the spiral step, nozzle shall be installed at the locations where can beprovided easy access and operation for checking level gauge or otherinstruments and for sampling. etc.

H

Middle Platform

Under 10m

8.2.4 Opening in the Plat form. (refer to fig 8.2-H).The opening size shall be as shown the following fig as below, and inserted inVESSEL INFORMATION DRAWINGS. For the instruments opening, TAG. NO. Shallalso be shown.

(a) Displacement type Level Gauge (b) Level Gauge

Fig 8.2-H Opening in plat form

8.2.5 Connection by Plat form

(a) In case more than two equipment in a line for each equipment a plat form isinstalled, the plat form height shall be made uniform as possible as for easyaccess.

(b) In case the plat form are made uniform height and make them to the common useplat form, that shall be structured as to be able to absorb heat expansiondifference between the tower and the pipe stands. (Connections by hinge to bedetach plat form with consideration for the horizontal movement by earthquake,etc.).

8.3 Accessories

8.3.1 Davit(a) Installation criteria

(i) When charged with packingIn case the packed tower, the lasting trolley beam may be installed, so the

exchange frequency of the packing, customer’s requirements shall beconfirmed.

(ii) Taking up and down of the internal and accessories.(iii) Taking up and down of the valve instruments etc.

(c) Piping

Max. 50m/m

250φ

(b) Operation of davit and the depository of the hung up-down. (refer to fig 8.3-A)Plat form for the hang up and down operation of davit should be installed.The temporary display for the internal or the packing shall be secured in the platform having a manhole.

Fig 8.3-A Installing location of davit

(c) Ensuring of Lift-up Space (refer to fig 8.3-B)The davit arms shall be apart 450 mm and over from the end of plat form not tobe interfered with the platform when hanging up and down.

Fig 8.3-B Ensuring of hanging-up space

8.3.2 Lifting LugsTo determine the installing position for lug, they have to contact with vessel engineerand civil engineer.

8.3.3 Access Holes and Vent Holes(a) Access holes

Access hole is the hole to access in the skirt and shall be provided at the locationto be easily approach. The install direction shall be unified in each area. In casethere are several holes, it shall be equally installed. Enough consideration shallbe paid to the interference with the anchor. Note)

Note) : In general, the height of access hole is 800 mm from the base. However,for high towers, it shall be 1000 mm.

(b) Vent holesVent hole is the hole for the air entrance and exit in the skirt, and no specialrequirements are specified for the location however, in case there are severalvent holes, it shall be equally distributed.

Temporary AreaDavit

Bad Good

Min. 450

8.3.4 Earth LugsEarth lugs shall be installed to the equipment apprehended of generation of staticelectricity and the equipment required for a lightning arrest based on BuildingStandard Low. The location of installation shall be determined by mechanical designdepartment or electrical design department.

(5) Name Plates(a) Name plate shall be attached on the load or passage side uniformly.(b) In general, the installation height shall be determined the following fig as below.

Fig 8.3-C Attaching position of name plate.

8.4 Nozzle Orientation for Distillatory Tower

8.4.1 Explanation of The Terms (refer to fig 8.4-A)

TRAY Shelf-Steps for instance, the TRAY in order to efficient contact andmixing of steam and liquid to separate composed materials bydistribution.

DECK A horizontal part of tray structure on which air and liquid are beingcontacted.

WEIR In general, installing on the upper side of deck to unify the liquid flow onthe deck. It is constituted of inlet weir and outlet weir.

DOWNCOMER Provided between deck and deck to guide the falling liquid from theupper side step at down comer, to separate accomplished bubbles and toflow the liquid to the down side step.

SEAL POT Liquid sink pat made by depressing the deck under DOWNCOMER.which act effectively when desired to make the step distance narrower.

DRAW-OFF POT When desired to extract liquid from middle tray, Liquid sink part havingenough depth to provide liquid extracting nozzle on the deck underDOWNCOMER effectively.

(Max. EL2000)(Max. EL2000)

PrinciplePrinciple

SEAL PAN A sort of receptacle to seal liquid under part of the lowestDOWNCOMER, and the overflowed liquid is stored in the tower bottompart.

DEFLECTOR A part of buffer plate which directly receive the liquid from inlet nozzle toreduce the liquid velocity.

Fig 8.4-A Name of parts in the distillatory tower

8.4.2 General Cautions for Determination of Nozzle Orientation(a) The position for installation nozzle shall be installed to head avoid the knuckle

part.(b) Not to install any valve within the skirt.(c) In general, nozzle position shall be in 5° unit.

8.4.3 Manhole(a) Access to manhole (refer to fig 8.4-B)

(i) Manholes should be generally located on the side of main access load.(ii) The width of plat form where installed manhole shall be minimum of 1000

mm, effective width of passage space shall be minimum of 600 mm.(iii) Ensuring the space for easy to pass from ladder to plat form.(iv) The area on which internal can be temporary deposited shall be taken into

account on the platform.

Fig 8.4-B Access to manhole

(b) Installation height of plat form (refer to fig 8.4-C)

Fig 8.4-C Installation height of plat form

(c) Opening and Shafting direction of manhole. (refer to fig 8.4-D)(i) Manhole cover shall be installed with the David (or hinge) on the location

where the cover can be opened by right hand.(ii) In case where a ladder is located closely near the David (hinge) and interfere

with opening and shafting the door and the passing, the David shall beinstalled the opposite side. (when the distance is over 1000 mm, the case isout of this scope).

Min. 1000Min.

passage

Top Manhole

Max.1500

500 - 1000(Principle 750)

Min.2100

Fig 8.4-D Open and shaft direction of manhole cover

(d) Relation between DOWNCOMER and manhole(i) Manhole shall be installed outside the DOWNCOMER area. However, when

the width of DOWNCOMER are is less than 300 mm, the manhole may beinstalled in the DOWNCOMER area.

- tower upper part (refer to fig 8.4-E)

Single Flow Double Flow All round

Fig 8.4-E Layout of tower upper part manhole

- tower middle part (refer to fig 8.4-F)

Min. 100° Open

David (or Hinge)

≤300

Good

Good

Good

BadBad

Good

Good

(A) (B)

Fig 8.4-F Layout of tower middle part manhole

- tower lower part (refer to fig 8.4-G)

* In case of Not Baffle Plate

Fig 8.4-G Layout of tower lower part manhole

(ii) Change for installing position of manholeThe change shall be made after contact with process department, payingattention to the following items.

BadBad

Bad

Bad Bad

Bad

BadBad

GoodGood

Good Good

Good Good

GoodGood

Single Flow

Single Flow

Double Flow

Double Flow

Bad Bad

Bad

Bad

Bad

Good

Good

GoodGood

* In case of Baffle Plate

- On setting manhole, when the relative location with the tray isunfavorable, the assigned engineer shall arrange the location by settingthe tray one step higher, after contact with mechanical design departmentengineer. Since the step difference at nozzle location is am larger, ingeneral, change for step difference shall be changed. (no change in thetower height) (Refer to fig 8.4-H).

Fig 8.4-H Change for installing position of manhole

- In case the manhole set at same level as the feed nozzle shall be movedto upper or lower step, the tower height become higher. (refer to fig 8.4-I)

Fig 8.4-I Change for manhole position set at the feed nozzle step

8.4.4 Reflux Nozzle(a) Pump return (to tower top) reflux

(i) In case the single flow tray, let the liquid flow to the opposite side to thedown flow (farthest position from the DOWNCOMER). (refer to fig 8.4-J).

Fig 8.4-J Position of reflux nozzle

Feed

Downcomer

(ii) Since the internal pipe can be bent as required , the restrictions orientationare small. (refer to fig 8.4-K).

Fig 8.4-K Position with nozzle utilizing internal piping

(iii) In case the double flow tray, let the liquid flow in the middle of side downflow tray. No special restriction is imposed to the orientation. (refer to fig 8.4-L).

Downcomer

(C) For Tower Diameter is 2400 and over

Fig 8.4-L Nozzle Layout for double flow tray

(iv) In case the width of inlet weir is narrower than that of close end pipe, longsized closed end piping shall be installed. (refer to fig 8.4-M).

(A) For Tower Diameter is less than 2400 mm

(B) For Tower Diameter is 2400 mm and over

Downcomer

Min.1.1/2d

Max. Dig. (3 x D/d°)D

equle

(b) Top circulation refluxTo be treated same as pump return reflux

(c) Intermediate Reflux (refer to fig 8.4-O)Returned liquid is usually flowed to the DOWNCOMER. In the orientation, careshall be given to the nozzle not to contact with DOWNCOMER.

(A) Single Flow (B) Double Flow

Fig 8.4-O Nozzle layout for intermediate reflux

Fig 8.4-M Installation for close end pipe

8.4.5 Feed Nozzle(a) The same method may be taken as the reflux nozzle. However, when the block

valve is installed, installation of plat form is to be considered.

(b) Feed to side stream strippers(i) The same method is taken as the trip reflux inlet.(ii) Since a seal loop is provided, sealing to piping is not required.

(c) Return of side stream strippers (refer to fig 8.4-P)

(A) Single Flow

Fig 8.4-P Nozzle layout of side stream stripper vapor

Fig 8.4-P1 Flow around side stream stopper

(B) Double Flow

Side Stream Stopper

Liquid Feed

Stripping Stream InletFeed to stripper

(d) Stripping stream (Steam or Gas) inlets to Tower or strippers.Stripping stream inlet shall be set 300 mm - 400 mm lower than bottom tray.

(e) Liquid FeedThe same method is taken as the pump return flux.

(f) Mixing of vapor and liquid (refer to fig 8.4-Q)

(A) Single Flow (B) double Flow

Fig 8.4-Q Nozzle Layout of mixing piping of vapour and liquid.

(c) Position of tower bottom part feed nozzle. (refer to fig 8.4-R)

(A) Single Flow (B) Double Flow (C) Double Flow (D) Triple FlowIn this case, twonozzles to berequired.

Fig 8.4-R Layout of tower bottom part feed nozzle

GoodGood

GoodGoodGood

GoodGood

Good

8.4.6 Draw-off Nozzle (refer to fig 8.4-S)(a) In case the single flow, Draw-off pan shall be installed to the opposite side of

DOWNCOMER to draining.(b) In case the double flow, draw-off pan shall be installed under the DOWNCOMER

or side down comer to draining. In case the large diameter tower the drainingfrom two locations, nozzles area installed symmetrically and the connectingpipings shall be installed symmetrically up to the junction point.

Fig 8.4-S Nozzle layout for draining

(A) Single flow

8.4.7 Around Reboilers(a) One through Reboilers (refer to fig 8.4-T).

(B) Double Flow

Fig. 8.4-T Reboilers Nozzle

To reboiler To reboiler

From reboiler

To reboiler

From reboiler

From reboilerFrom reboiler ( )

To reboiler

To reboiler

(A) Single Flow

(b) Circulation Reboilers (refer to fig 8.4-U)

(C) Double Flow (center DOWNCOMER)

Fig 8.4-C Layout of reboiler nozzle

To Reboiler ( )

To Reboiler

To Reboiler ( )

To Reboiler

From Reboiler

From Reboiler

(A) Single Flow

From Reboiler

From Reboiler

To ReboilerTo Reboiler

(B) Double Flow (Side Downcamer)

From ReboilerTo Reboiler ( )

To Reboiler

To Reboiler

From Reboiler

(c) As the special case, in case where the tower bottom is used for hold up. (Refer tofig 8.4-V)

Single Flow (when the products return to tower)

Fig 8.4-V Layout of reboiler nozzle

(d) Kettle type boilers (refer to fig 8.4-W)This type is different from other Reboilers, only the vapour returns to the towerand the products are taken-off from reboiler, The orientation may be determinedbased on the boiler pipings.

Fig 8.4-W Layout of reboiler nozzle

(e) Preferential Flow Reboilers (refer to fig 8.4-X)In this type, all the liquid from DOWNCOMER is circulated to the reboiler with apart of liquid pooled in the tower bottom. Regarding this type, the liquid level inthe tower bottom is affected by the elevation of reboiler.

(A) Single Flow

(B) Double Flow (side DOWNCOMER)

(C) Double Flow (center DOWNCOMER)

To ReboilerTo Reboiler

To Reboiler

To Reboiler

To Reboiler

To Reboiler

Return to Reboiler

Return to Reboiler

Return to Reboiler

Return to Reboiler

Return to Reboiler

Return to Reboiler

(B) Double Flow

Fig 8.4-X Layout of reboiler nozzle

(A) Single Flow

Return to Reboiler

Return to Reboiler

Return to Reboiler

Return to Reboiler

To Reboiler

To Reboiler

8.4.8 Change of Tray Direction (refer to fig 8.4-Y)To determine the tray direction, the tower upper part is of cross flow and the lowerpart is of double flow, the tray direction shall be 90° crossed.

(C) Change from single flow to double flow (Both ends inlet)

Fig 8.4-Y Change of Tray Direction

(A) Change from single flow to double flow (Center inlet)

(B) Change from single flow to double flow (Center inlet)

Down Pipe

8.4.9 Thermometer (refer to fig 8.4-Z)(a) To confirm whether temperature indicator is used to measure Liquid temperature

or Gas temperature.(b) When used to measure liquid temperature, the location where the thermowell

does not touch with internals is selected.

Fig 8.4-Z Layout of thermometer nozzle

(c) At the in front of T1 socket nozzle, minimum of 750 mm extraction space isrequired.

(d) Thermometer nozzle can be set upper or lower by distance of one step, therefore,when the location is unfavorable, the location of thermometer nozzle shall bechanged after consultation with Mechanical Engineer.

8.4.10 Local Pressure Indicator (refer to fig 8.4-AA)(a) Pressure indicator should be installed in the Gas Phase.(b) Pressure nozzle can be set upper and lower by distance of one step, therefore,

when the location is unforgivable, the location of thermometer nozzle shall bechanged after consolation with Mechanical Engineer.

Fig 8.4-AA Layout of local terminal pressure indicator

Dwoncamer Area

Dwoncamer Area

D

Under1900

About 1200

8.4.11 Gauge GlassIn order to reduce the influence of liquid wave, gauge glass shall not be installed thescope 60° from the flow direction by the flow in nozzle. Special care shall be given tothe liquid level controller. (Refer to fig 8.4-AB).

Fig 8.4-AB Installation position for gauge glass

(b) In case more than two glass gauges are required, they shall be arranged zig zagat left and right manner. In unforgivable case where the glasses can be installedone side only, the upward gauge glass shall be installed near the ladder. (Refer tofig 8.4-AC).

Fig 8.4-AC Layout along ladder

(c) In general, glasses shall not through the plat form. (In an unforgivable case, to beset at the location where the confirmation of liquid level is not disturbed.)

(d) Layout of cashing nozzle on the tower bottom part (refer to fig 8.4-AC)(i) When baffle plate is provided

(ii) When seal pan is provided, glasses shall be installed apart as far aspossible.

Fig 8.7-AD Layout for casing glass on the tower bottom part

(e) Gauge glass for high pressureFor gauge glass for high pressure, the installing suitable for the shape and theinstalling spaces shall be secured.

(f) Gauge glasses for low temperature(i) Gauge glass for low temperature should be determined for layout of nozzle

and ladder giving consideration to the non-frost board or the thickness ofinsulation. Install direction of non-frost board should be determined among A,B and C below, and communicated to instrument design department. (referto fig 8.4-AE)

Fig 8.4-AE Layout of gauge glass for low temperature.

A type : Ladder position is on either right side or left sideB type : Ladder position is on left sideC type : Ladder position is on right side

(ii) ??????

Baffle Plate

Sealpan

Left Right

“C” Type

“A” Type

“B” Type

Non-frost Board

BAD GOOD

Fig 8.4-AF Layout of gauge glass for low temperature along ladder

8.4.12 Level Controller(a) Control and checking of indicator and controller shall be done from ground or on

the platform. (refer to fig 8.4-AG.)

Fig 8.4-AG Layout of level controller

Non-frost board

Over 2100

MAX 450

8.4.13 Differential Pressure Gauges (∆P/CELL TYPE) liquid level gauge (refer to fig 8.4-AH)In general, this type shall be used when the liquid level difference is more than 2000m/m and over.

Fig 8.4-AH Layout of differential gauge type liquid level gauge

8.4.14 Differential Pressure Gauge (refer to fig 8.4-AI)(a) Differential pressure gauge for nozzle shall be minimized the bending of conduit

piping, and the length to the transmitter shall be installed as short as possible.(b) Transmitter should be installed platform where can be installed at upper the

nozzle for instruments that can be installed upper parts.????

Fig 8.4-AI Layout of differential pressure gauge

AT 600~1200 mm level, platform is required.

Nozzle diameter is generally 3/4 in,however, for some special equipment 1 innozzles may be used. (indicated P&ID).

For low temperature service, provideappx 2m pipings for heating.

About 1200

About 1200

8.4.15 ReboilerWhether set with tower body or install on the pipe rack shall be discussed anddetermined with mechanical engineer.

8.5 Nozzle Orientation for Vertical type tank

8.5.1 Determination of Nozzle Orientation for Vertical type Tank (refer to fig 8.5-A)(a) The liquid outlet nozzle shall be installed on the pump side, and the suction piping

shall be minimised. (However, the high temperature line shall have suitableflexibility space)

(b) The liquid inlet nozzle shall be installed apart from the outlet nozzle as far aspossible. (To make Gas and liquid separation better.)

(c) The gas outlet shall be installed at the location where the pipe lengths becomeshorter. (In general, at the pipe plug side, apart from liquid inlet nozzle)

(d) Nozzle of safety valve discharge shall be installed near relief header.(e) Level gauge and level controller shall be installed at the apart from the liquid inlet

nozzle where can be controlled the level controller watching the level gauge.(Level gauge and level controller shall be taken out to the same side.) (refer to fig8.5-B)

(f) To determine the position for the pressure gauge, vent and manhole, taking intoconsideration the operation pipe rack.

(g) Thermometer should be installed where they can measure the liquid temperature.(h) Drain nozzle should be installed on the opposite side of the liquid outlet nozzle.(i) Nozzle locations shall be put together not to make the pipe rack unnecessarily

large. Ladder shall be installed at the position where they can absorb to the liquidlevel gauge. (refer to fig 8.5-B).

Fig 8.5-A Nozzle orientation of horizontal tank

Fig 8.5-B Layout of LG and LIC

Instrument

Min 1100

Note)

Min 750

or

Note) To plan nozzles, flanges,valves and leg no tointerfere each other withconsideration to theelongation by heatexpansion.

Pump

8.6 Nozzle Orientation of Compressor Suction Drum(1) When the feed nozzle is plural, gas must be feed from a same direction. It causes of

blow out to mist of opposite side. (refer to fig 8.6-A)

Bad Good

Fig 8.6-A Feed nozzle orientation

8.7 Nozzle Orientation for Vertical Heat Exchanger.(1) According to the number of baffle, orientation is restricted. (refer to fig 8.7-A)

However, in case the whole quantity shall be condensed (generally, inlet and outlettemperature are same) the assigned engineer shall confirm the restriction with ProcessDepartment.

When Odd Number When Even Number

Fig 8.7-A Restriction of Nozzle orientation by Baffle

(2) In case the two passes, inlet nozzle of shell side and tube side shall be in the samedirection. (refer to fig 8.7-B.)

Fig 8.7-B Nozzle orientation of two pass

8.8 Determination of clip for Pipe Support

To plan the clip for pipe support, take the following items into consideration andcommunicate with Mechanical Design Department.(Also refer to para 11.4.2 of this instruction)

- The allowable load per one (set) of clip by any support method is Maximum 5000 Kg.

- The allowable load and the detail dimension by pipe support methods shall bereferred toTEG1-1314-203: Pipe Hanging No.3 (Standard Form) andTEG1-1314-204: Pipe Hanging No.4 (Design Data)

- In case the vessel design temperature is low, even if the piping is at normaltemperature, clips for low temperature shall be planned.

- Pay attention to the clip locations not to interfere with clips for plat form, and weld-line of vessel shell.

- Support number of clip shall be determined and assigned prior to the start of the job.

- In case the where the heavier load support than the plat form is to be applied, orwhere heavy loads article us to be temporarily deposited for maintenance, theconditions shall be reported to Mechanical Design Department.(The strength of plat form is 300 Kg/m2)

9. Other Information’s

9.1 Critical LineFor the critical line as written below, the critical line shall be confirmed on the planningdrawing or isometric drawing by Basic Design Department.- Line reflecting process requirements (seal line etc.)- Line of severe ∆P- Inlet line of safety valve- Line for cooling media system- Other line required by Basic Design Department.

9.2 Reboiler CirculationConfirming the result of tower and heat exchanger drawing and rating (circulation),assigned engineer shall plan and the relative position of reboiler and tower and thepiping, and perform thermal stress analysis, then finally confirm the Heat TransferDepartment (for horizontal reboiler) or Basic Design Department (for vertical reboiler).

9.3 External force and moment to Equipment NozzleEquipment such as tower, vessel, heat exchanger that received large external force andmoment shall be checked for the strength by Mechanical Design Department.

Note) External Force: The guide line of external force and moment are shown in the memo.(Issued by mechanical design department (on Sept.16 `79)

9.4 Draft of UFDAfter being confirmed of the liquid division and system by Basic Design Department,they shall arrange for header etc. and prepare to UFD draft.

9 Other Information

9.1 Critical LineObtain the confirmation of Basic Design on the following critical lines by submittingplanning drawings or isometric drawings:

- Lines (such as seal line) for which process demand is made- Lines with strict ∆P- Entrance line of safety valves- Line of refrigerant system- Other lines requested from Basic Design.

9.2 Reboiler, CirculationCheck against tower and heat exchanger drawings and the results of rating (circulation),work out plans for the relative positions of reboiler and tower and piping therefor,perform thermal stress analysis, and then obtain the final confirmation of Heat Transfer(horizontal reboiler) or Basic Design (vertical reboiler).

9.3 External Force and Moment Acting on Equipment NozzlesAs regards the nozzles of towers, vessels, heat exchangers, etc., which are exposed tolarge external force and moment, inform the fact to Equipment Design Division and askthem to perform strength check.Note : There is a memorandum (dated November 16, 1979) issued from Equipment

Design Division, specifying approximate standards on external force andmoment.

9.4 Manuscripts for UFDObtain the confirmation of Basic Design as to the classification of fluid and its system,make arrangements for headers, etc. and prepare manuscripts for UFD.

10 Piping Planning and Detailed Design

10.1 ROUTING STUDY

10.1.1 PurposeThe routing study is a work to be done in an early stage of PLANNING, and,shall be done, in regard to all objects to connect between facilities or between equipments. Atthis stage, there is no detailed reference materials, so, the routing must be determined,based on PRELIMINARY reference materials offered by each Dept. Department.When BASIC PLOT PLAN is to be worked up, it is required to make clear whether theassumed connecting routes and areas are adequate, and whetherthere is no problem as to the requirements by Customer and project, and as to accessibility,economy, etc.

10.1.2 Items to be studiedIt is required to make clear the design conditions for each object of study.

(1) Road(a) Width(b) Required-or-not of shoulder

(2) Pipe rack/sleeper(a) Pipe rack(b) Sleeper

(3) Piping(a) Underground piping(b) Overhead piping

(4) Electrical cable(a) Direct-buried(b) Trench(c) Rack(d) Duct

(5) Instrumentation cable(a) Direct-burial(b) Trench(c) Rack(d) Duct

(6) Rainwater sewage(a) Trench(b) Open channel(c) Culvert

10.1.3 Procedure of determining the routes

(1) Routing study (planning stage)(a) Determine the routes of piping, sewage, and electrical/instrumentation cables, based

on BASIC PLOT PLAN. (each related Dept.artment)

(b) Check to see whether the routes are reasonable, when each route was laid one uponanother on the plot plan. If any part was found to be unreasonable, make adjustmenton the route and on the plot plan. (Piping Design Dept.t.)

(2) Detailed design (detail-design stage)(a) Perform detailed design of each route. (each related Dept.artment)

(b) Work up UNDERGROUND COMMUNICATION DWG, and, make adjustment onbattery- relations of underground part of piping, rainwater sewage, electrical/instrumental trench, equipments foundation, etc. (Civil Design Dept.t.)

10.1.4 Routing study

(1) Routing study for road and pipe-rack/sleeper routesThe routing of road, pipe-rack/sleeper has been studied when BASIC PLOT PLAN wasworked up. So, this time, re-consider the process flow and the sizes of equipment, toreflect the results of routing study made by each Dept. Department, and, if anyadjustment was found to be necessary, make the adjustment.

(2) Routing study for piping routes(i) Determine the main route of piping, based on PRELIMINARY P&ID and UFD

(including watering flow diagram), having in consideration the requirements byprocess and Customer, and also, thermal stress analysis, economy, etc. At this time,make study on the route and width of rack/sleeper, and also, necessary-or-not ofsub-rack or operation platform.

(ii) Determine the grade of making of PIPING ROUTING STUDY DWG, such that thegrade be compatible with the actual execution-type of piping design.

* LASS 1 (in case where planning and detailed design are done in Japan)Indicate the main piping routes shown in P&ID and UFD.

* LASS 2 (in case where rutting study is made by TEC, and detailed design is made byengineering company of foreign country)Indicate the main piping routes shown in P&ID and UFD. Indicate the going-up/downof piping and the position of main valves.

(iii) Spacing between pipings shall be in accordance with TEG-1313-007 (PIPINGSPACING), where, TABLE-A shall be used, as a rule.

(iv) The routing study drawing is reflected in the work shown below.- Making of civil information drawing- Nozzle orientation- Making of planning drawing

(3) Routing study for electrical/instrumentation cable routesDetermine the cable routes, based on BASIC PLOT PLAN and on the data obtained fromInstrumentation Design Dept.t. and Electrical Design Dept..Determine the approximate width necessary for laying of cable, so that such data can bereferenced during the U/G planning and pipe-rack planning.

(4) Routing study for rainwater sewage routesDetermine, in Civil Design Dept.t., the rainwater sewage routes and the approximate sizeof sewer lines, so that such data can be reflected during the planning of undergroundpiping.

10.2 Arrangement of Valves and Instrumentation-instruments

10.2.1 Arrangement of valves and means of access

(1) Position of valve operation and means of accessThis shall be studied, in classifying the position of operation according to the purpose andsize of each valve. The means of access shall be in accordance with the Appendix 1 ofTechnical Specification H-101 (Appendix 1 made during JOB shall be attached.)

(2) Installation height and operation of valve

(a) Installation height of valve and installation height of chain wheel are shown in Fig.10.2.1-A and Fig. 10.2.1-B. In the figures, the installation height of valve has beenfixed based on the average height of grown-up male Americans (183 cm), so, whenJapanese are the object, the installation height must be lowered in accordance withthe average height of Japanese (167 cm).

(b) When the valve handle is placed lower than the operating floor, an extension of up to600-800 mm above the operating floor, shall be attached.

(c) There shall be open clearance of at least 50 mm or more, at the periphery of valvehandle.

(3) Prevention of miss-operation of valve(a) Valve which is operated in emergency and valve which is operated normally, shall

not be placed neighboring each other.(b) Preferably, valve which is frequently operated during normal operation and valve

which is normally not operated, shall be arranged, in such a way that they are notmixed each other as far as possible, so that miss-operation will be prevented.

(c) At any place from where valve is operated, the intensity of illumination necessary forthe operation shall be secured.

(4) Installation of valves Note: This is from EXXON BP3-7-4(a) In case of low temperature (-45°C, or lower) line, valve handle shall be as follows.

- Liquid line: horizontal or 45 upward- Gas line: horizontal

(b) Valve shall not be fixed to any vertical part of liquid line, as a rule.(c) Handle of C.S.O. valve shall not be directed upwardly. (in order to prevent fall-off of

internal piece)(d) There are some restrictions as to installation place of E.B.V (Emergency Shutdown

& Isolation Valve).

Standard height of valve operation (horizontal handle)

Fig. 10.2.1.-A

Range of danger to legProtrusion of valve stemprohibited (when there isno protection measures).

Range of danger to head.Protrusion of valve stemprohibited (when there isno protection measures).

Thirdrange

ofselec-tionThird

rangeof

selec-tion

Thirdrange

ofselec-tion

Firstrange ofSelec-tion

Firstrange ofSelec-tion

Firstrange ofSelec-tion

Secondrange ofselec-tion

Secondrange ofselec-tion

Secondrange ofselec-tion

Small-dia.valveonly

Small-dia.valveonly

The height measured atthe center of handle

Lowfrequency valve

Highfrequency valve

Emergencyoperationvalve

Chain shall not comechain operated passage

Chainope-ration

Portableladder 3.6mor less

Chainoperation(onlywhenpermitted)

The standardheight of the loweredge of the chain

Max height end ofhandle other than chainoperated

Standard height of valve operation (vertical handle)

Fig. 10.2.1-B

10.2.2 Arrangement of instrumentation-instruments and means of access(1) Means of access

The required-or-not of access during operation and during maintenance, and also thedegree of means of access, is different, Dept.ending upon the kind and installation-heightof each instrumentation-instrument. The means of access shall be in accordance withthe Appendix 1 of Technical Specification H-101. (Appendix 1 made during JOB shall beattached.)

(2) Arrangement of instrumentation-instrumentsArrangement shall be studied, so that access is possible, for the purpose ofmaintenance/inspection, even in case of instruments for which no means of access isneeded in Par. (1), by use of portable ladder, etc., and the place of installation shall beadequate from the view point of measurement by the instrument.

The heightmeasured at thecenter of handle

The heightmeasured at thecenter of handle

Head clearance shallbe secured wheninstalling valve abovethe access area.

Second range ofselection

Max. height of vertical handle.

First range ofselection

Extension handle

Handrail

Second rangeof Selection

Third range ofselection

First range of selectionSecond range of selection

(a) Temperature instrument shall be installed at places where fluid is flowing, and, whenthere is merging/branching, it shall be confirmed whether or not the installation placeof instrument, such as before merging, after merging, etc., is adequate.

(b) Pressure instrument can be installed at any place in the system, when there is onlysmall pressure drop in the piping, and therefore, (under such circumstances,) shallbe installed at places where access is convenient. When any pressure control valveis to be operated manually, a pressure instrument (of field-indication type) shall beinstalled near to the control valve.

(c) Level instrument (Field-indication type) shall be installed at places where theinstrument can be read from platform or ladder. When there is any liquid-levelcontrol valve (of manual operation), the level instrument shall preferably be installedat a place where the instrument can be read at the time when the control valve isoperated.

(d) Some kinds of flow instruments, such as orifice and turbine meter, require a certainlength of straight pipe, so, it is required to secure sufficient space. The requiredlength of straight pipe is different Dept.ending on the applied standard andmeasuring accuracy, so, it is required to confirm this before determining the routing.

(e) Safety valve shall be installed at places where maintenance/inspection for it can bedone from platform. In case where the discharge piping is to be connected to a flareline, etc., the arrangement shall be such that a routing which is free-draining can bemade.

(f) Control valve shall be installed at places where the control valve can be operatedfrom on-ground or from platform.

10.3 Items Required from the View Point of Process (to be made in each job)

10.3.1 Outline of the process (PFD of each job shall be attached.)

10.3.2 Requirements from the view point of processExplanation of items requiring attention on P&ID and UFD (concretely!)

10.3.3 Items to be confirmed on P&ID and UFD

(i) The time of confirmation and instructions for designAny part where occurrence of trouble is likely during the operation, caused by the designof piping, shall be picked up in advance, so that appropriate design can be made at thetime of planning and of detailed design. At the time of receiving P&ID and UFD and ofscreening meeting, confirmation shall be made on the corresponding ones of itemsshown in Table 10.3.3-A, and the design method in a concrete form, such as installationplace of pipings and valves, position and method of supporting, thermal stress, anti-vibration countermeasures, etc., shall be instructed to the designers, and also beconfirmed for the purpose of carrying them into effect.

(ii) Explanations of check list and of check items(a) Check list

Check items are shown in Table 10.3.3-A. Furthermore, confirmation shall be made, inreferring also to the memo issued by Jigyo Hombu (headquarters), P&I ISSUE STAGEand SCREENING MEETING CHECK LIST"

Table 10.3.3-A Check list

Item Parts to be checked Date Date Date Date Remarks1 Piping in general (1) Parts where two-phase flow is generated,

and the type of flow(2) Parts where flow velocity is more than the

standard flow velocity(3) Piping where condition of operation can

change(4) Piping where drain can accumulate (incl.

under abnormal condition)(5) Possibility of thermal shock(6) Piping of toxic fluid(7) Piping of explosive fluid(8) Piping requiring grounding for static-

electricity protection(9) Piping where stopping-up or solidification of

flow is likely (slurry, powder, etc.)(10) Possibility of stress corrosion (parts where

repetitive re-evaporation is anticipated,and crevis corrosion)

(11) Vacuum piping(12) Piping where pressure loss is critical(13) Piping requiring hydraulic head(14) Piping where biased non-uniform flow is

unfavorable(15) Piping where the flow is gravity-flow(16) Parts where generation of erosion is likely

2 Valves(emergencyvalve, controlvalve, butterflyvalve)

(1) Valve where up -/downstream differentialpressure is large (∆P=5kg/cm2, or more,and ∆P=50%, or more)

(2) Valve whose open/close speed is high(3) Valve where generation of flushing is

anticipated(4) Butterfly valve which is used for regulation

of flow(5) Valve where drain at upstream side is to be

considered(6) Emergency valve which requires heating at

all times(7) Low ∆P check valve

3 Vessels (1) Seal drum, or vessel where gas is injectedinto fluid

(2) Vessel requiring special consideration inregard to operation

(3) Vessel requiring special consideration inregard to maintenance

4 Compressors (1) Reciprocating type or turbo type5 Pumps (1) Pump whose NPSH-requirement is critical

(2) Pump of double-suction type6 Restriction

orifices(1) Confirmation of installation-position and

differential pressure7 Others (1) Thermosyphon type reboiler

(2) Piping where anti-freezing countermeasureis needed

Note 1: Enter the date of checking, and put marks to the items for which checking was completed.

(2) Explanation of check listHere, the content of each check item shown in Table 10.4.1-A, is explained. Item Parts to be checked

Item Parts to be checked

1 Piping in general (1) Parts where two-phase flow is generated, and the type of flowList up the parts where two-phase flow is generated, and check on thegeneration of SLUG FLOW, FLOTH FLOW, etc. Especially, at the timeof starting and during low-load operation, two-phase flow may begenerated, causing vibration.

(2) Parts where flow velocity is more than the standard flow velocityWhen flow velocity is high in a piping, vibration tends to be generated atelbow and tee. Especially, in case of thin-wall, large dia. pipe, bration ofradial direction may be generated, accompanied by a large noise.Especially, in case of minimum-flow bypass of compressor, pump etc.,the flow velocity may, in many cases, become very high, causinggeneration of vibration. As a rough standard of flow velocity, thefollowing shall be used.

Gas : flow velocity 20m/secLiquid : flow velocity 2m/sec

(3) Piping where condition of operation can changeBe sure, not to overlook the parts, where operating condition, such astemperature, pressure, etc., changes remarkably, due to repetitiveoperation, etc.

(4) Piping where drain can accumulateIn case of piping where drain is not generated during normal operationbut generated during abnormal operation; piping of vent line wheresteam purging is performed; piping of deadlocked line, such as the pipingbefore safety valve, which is cooled at all times, so that accumulation ofdrain can occur; a strong hammering may occur, when the valve is madeopen.

(5) Possibility of thermal shockIn case of high-temperature piping where low-temperature fluid mayabruptly flow in, due to the operating condition, etc., especially, in caseof thick-walled pipe, thermal-fatigue cracking, caused by temperaturedifference between inside and outside, may occur, so that attention isneeded (steam desuperheater, condensate line, etc.)

(6) Piping of toxic fluidConsider how to treat the waste liquid, or liquid leaked out from aroundpump, etc.

(7) Piping of explosive fluid(8) Piping requiring grounding for static-electricity protection(9) Piping where stopping-up or solidification of flow is likely (slurry, powder,

etc.)Consider necessary-or-not of steam-tracing, jacketing, for-cleaning hole,for-cleaning cutout of flange, etc.

(10) Possibility of stress corrosionIn case of high temperature piping where repetitive re-evaporation takesplace; piping where drain is generated, etc., consideration is required asto take-out direction and gradient of branch pipe, etc. Furthermore,there are cases where SR is required, such as the case of GV solution.

(11) Vacuum pipingAttention shall be paid to the strength of pipe and leakage at the part ofjoint.

(12) Piping where pressure loss is critical(13) Piping requiring hydraulic head(14) Piping where biased non-uniform flow is unfavorable.(15) Piping where the flow is gravity-flow

Provide appropriate size of piping and gradient for moving of liquid.(16) Consider countermeasure against occurrence of erosion, which is likely

at the downstream side of trap or pressure-reducing valve.

Item Parts to be checked

2 Valves (1) Valve where up -/downstream differential pressure is largeCheck on the up -/downstream differential pressure. If it is especiallylarge, vibration of piping can occur, caused by generation of variantpulsating pressure, so, consideration is required for method of supportingand also for the piping system of before and after the valve. In casewhere the pipe dia. was made smaller at before and after a control valve,cracking of welded part caused by supercooling due to adiabaticexpansion, and eddy motion of flow can occur, so, attention is needed.In case of piping for liquid, consideration shall be paid to cavitation.

(2) Valve whose open/close speed is highConsideration shall be paid to the possibility of hammering. Especially,in case of long piping, hammering is liable to occur, so, attention isneeded.

(3) Valve where generation of flushing is anticipatedEspecially, during low-load operation, flushing can occur, in many cases,causing generation of vibration, so, attention is needed.

(4) Butterfly valve which is used for regulation of flowDept.ending on the type and opening-degree of the valve, and affectedby vapor in the fluid, turbulent flow and cavitation can occur, causingvibration of the piping system.

(5) Valve where drain at upstream side is to be consideredAs a countermeasure, bypass or trap, for example, may be attached. Incase of high pressure, appropriate trap may not be available, so that itbecomes necessary to provide a bypass with R.O. leading to thedownstream side.

(6) Emergency valve which requires heating at all timesValve for emergency-discharge of high-temperature vapor shall beprovided with heating at all times. (This is because it is feared that thevalve seat may become loosened, caused by temperature difference.)

(7) Confirm countermeasure against erosion caused by high velocity at thedownstream side of trap or pressure-reducing valve (such as provision ofstraight pipe length, provision of bell-mouth, use of stainless steel asmaterial, etc.)

3 Vessels (1) Seal drum, or vessel where gas is injected into fluidVariation of pressure may occur, due to bubbling in the vessel, causingvibration of the piping.

(2) Vessel requiring special consideration in regard to operationFor example, vessel where frequent removal of piping is required, etc.

(3) Vessel requiring special consideration in regard of maintenance.For example, vessel which requires maintenance area, etc.

4 Compressors (1) Reciprocating type or turbo typeAppropriate consideration, Dept.ending on the type, shall be paid fromthe time of piping-planning.

5 Pumps (1) Pump whose NPSH-requirement is criticalPlanning shall be done, to have least number of bending.

(2) Pump of double-suction typeIf the shape of suction piping is awkward, cavitation-surging can occur,causing not only poor performance, but also generation of vibration.

6 Restriction orifice (1) Confirmation of installation-position and differential pressureCheck to see whether the number of orifices is adequate against the up-/downstream differential pressure. In case where the differential pressureis especially high, vibration can occur, caused by turbulent flow at thedownstream side, and also, cavitation-erosion can occur at the part ofelbow.

Item Parts to be checked

7 Others (1) Thermosyphon type reboilerIn case of this type of reboiler, the limitation of ∆P is especially critical.Furthermore, if there is a possibility of generating vibration caused bygeneration of two-phase flow, etc., consideration is needed, especially,from the time of planning. (∆P, thermal stress, vibration)

(2) Piping where anti-freezing countermeasure is to be consideredDraining devices, circulation piping at deadlocked part, steam-tracing,etc. shall be provided with appropriate countermeasures.

10.4 Underground Piping

10.4.1 Objects of burial laying

Objects of burial laying are different from job to job, so, it shall be confirmed before starting of design work.Especially, when electrical and/or instrumentation cables are to be buried for laying, the plant area requiredfor burial becomes broader, so that it is required to pay attention to the arrangement of equipment and piperack, and to any possible interference with underground piping.

Object On-ground Burial Trench Remarks(1) Water-related

(a) Cooling water(b) Drinking water(c) Sea water(d) Industrial water

(2) Fire-fighting-relatedNote 1)

(a) Fire-fighting foam(b) Fire-fighting water

(3) Sewer(a) Oily(b) Chemical(c) Non-oily

(storm water)

(4) Cable(a) Electrical(b) Instrumentation

(5) Sanitary

(6) Others

Note 1) Law/reg. in Japan:Oil ind. disaster prev. lawrequires to lay on ground.So, pay enogh attention.

10.4.2 Design of underground pipingAs to making of detailed piping planning drawing, refer to TEG1-1313-102, "How to make undergroundpiping drawing".(1) Order of priority from the view point of planning

Priority shall be given to the piping with gradient, such as main piping for cooling water, and, OILYSEWER, CHEMICAL SEWER, etc.

(2) Limitation for trench pipingWithin-unit trench piping shall be avoided, unless it is insulated piping, or is piping requiringinspection/maintenance during operation.

(3) Limitation on use of flanged jointsFlanged joint shall be avoided, unless it is for connection with valve or equipment/machinery.

(4) Minimum Depth of burial

(a) It shall be lower than the Depth of freezing.(b) At road-crossing part, the burial Depth of piping shall be min. 1200mm, at the top of piping. This

shall be 600mm, in case other than road-crossing part.(c) The Depth of burial shall be determined, in studying the wall thickness of pipe, method of

reinforcement, etc., taking into consideration the running and disposition of cranes duringconstruction and during operation. (Refer to TEG3015 : Thickness of underground steel pipe.)

(5) Spaces for underground piping (Refer to Fig. 10.4.2-A.)(In case of USSR job, this is not applied, because there is an applicable prescription which is from thatfor electrical facilities.)

Fig 10.4.2-A Space for underground piping

(6) Indication of elevation (Refer to Fig. 10.4.2-B and Fig. 10.4.2-C.)For underground piping, indication of TOP EL (TOP OF PIPE ELEVATION) shall be made, as a rule.

Fig 10.4.2-B Indication of elevation

In case where it is necessary to make indication of BOP.EL or INV.EL, such indication may be madeonly for that line or within that part.

Fig 10.4.2-C Indication of elevation

(7) Battery relations with above-ground piping (Refer to Fig. 10.4.2-D.)Because the work for underground piping is proceeded in advance, termination by cap shall be madeand kept until the time of connection with the above-ground piping, as a rule.

Cap or Plate

Fig 10.4.2-D Battery relations with above-ground piping

(8) Protection of underground pipeCheck to see the force of on-ground load effected to the pipe, within the area of road-crossing part,area for maintenance work, and area used for running and Dept. loyment of cranes during the time ofconstruction. And, if necessary, provide protection by means of wrapping with concrete or by use ofsleeves. (Refer to Fig. 10.4.2-E.)

Fig 10.4.2-E Protection of underground piping of road-crossing part

(9) Considerations in regard to thermal expansionThe thermal expansion of high-temperature underground line shall be limited to 40mm. The lines ofthis kind shall be re-filled with sand.

10.4.3 Cooling water piping(1) Attentions required from the view point of piping design

(a) Large-dia. pipes shall be laid, in an especially simple piping route, so that the amount of pipingmaterials be kept at a minimum.

(b) Drain pocket shall be avoided, as far as possible.(c) Manholes shall be installed for the purpose of inspection of the inside of piping. A rough standard

for its installation is as follows.(i) Where the size of main header is 24B or larger, the length already run is 200m or more, and,

there is a drain pocket.(ii) Where there is a block valve, such as the neighborhood of B.L.(iii) In case where the plant area is large, such as the case of ethylene plant, one shall be installed

within each area, the above i) and ii) being taken into consideration. (For example, one forQUENCH, one for COMP…)

It is to be desired 45°

Vent

Road

Sleeve

Support End-seal

(iv) Manhole shall be brought together with block valve of header, take-out for instrumentation,drain nozzle (this is explained later), etc. as far as possible, and be accommodated in the valvepit.

(v) Details of the manhole shall be as shown in Fig. 10.4.3-A.

Fig 10.4.3-A Manhole Details

(d) Drain nozzles shall be installed for the purpose of mud-sweeping of the inside of piping. A roughstandard for its installation is as follows.(i) Where the size of main header is 24B or larger, and there is a drain pocket. (the part of pocket

in case there is reducing, because of TOP FLAT in this case)(ii) Where accumulation of mud is anticipated, other than the above.(iii) Drain nozzle shall be brought together with block valve of header, take-out for instrumentation,

manhole, etc. as far as possible, and be accommodated in the valve pit.(iv) Details of the drain nozzle shall be as shown in Fig. 10.4.3-B. (Refer to JIS G 3451 for detailed

dimensions.)

Fig 10.4.3-B Drain Nozzle Details

10.4.4 Sewer pipingConfirm, in asking Basic Design Dept., the specification of sewer system. And, if necessary, thermal-stressanalysis shall be done.

(1) Kinds

Kind Application

OILY SEWER

(a) Drain from equipment of facility where the fluid is oil-related.(b) Drainage of rainwater from OILY PAVING AREA(c) Waste liquid at the time of decking of cracking furnace, etc.(d) Drainage from inside of OIL DIKE(e) Those designated in P&I

CHEMICALSEWER

(a) Drain from equipment where the fluid is chemical-related(b) Drainage of rainwater from CHEMICAL PAVING AREA.(c) Chemical waste water from CONTROL ROOM, LABORATORY,

ANALYZER(d) Those designated in P&I

NON-OILYSEWER

(STORM SEWER)

(a) Drain from equipment other than OILY/CHEMICAL-related(b) Drainage of rainwater in the plant other than OILY/CHEMICAL PAVING(c) Wasted water from drinking water used in BUILDING(d) Wasted water from fire-fighting water(e) Wasted water coming from neutralizer after neutralization

(2) Material

Kind Material (as a rule) Remarks

OILY SEWER(a) Carbon steel pipe + outside corrosion-preventative tape(b) For large dia. (16B or more) long distance line,concrete pipe shall be used, through discussions with CivilDesign Dept..

CHEMICAL SEWER

(a) Carbon steel pipe + outside corrosion-preventative tape(However, to be determined through sufficient study inregard to acid-resistance and alkali-resistance.)(b) Cast iron pipe(c) Porcelain pipe(d) PVC pipe

NON-OILY SEWER(STORM SEWER)

(a) Carbon steel pipe(b) Concrete pipe

(3) Making of FLOW SHEETSEWER flow sheet is, in many cases, not indicated in P&ID or U.F.D. So it is recommended to makethis, for the purpose of reciprocal transmission and confirmation of informations, construction work atsite, and operation.Piping Design Dept. shall obtain, from Basic Design Dept., the informations such as basic system andmaterial, etc., and, after studying the routing, make UFD-draft of SEWER. (The size, etc. shall bedecided on by Basic Design Dept. and Basic Design Dept.)

Fig 10.4.4-P

Fig 10.4.4-Q

Fig 10.4.4-R

FromAromaplant

FromAromaplant

(4) Design of OILY SEWER and CHEMICAL SEWER(a) These shall be, as a rule, of underground GRAVITY FLOW type. (Refer to Fig 10.4.4-A.)

The gradient for moving of water within the plant shall be, as a rule, 1/300 when planned. And, theflow velocity in the piping between each of the catch basins and manholes shall finally be checkedby Basic Design Dept. and Civil Design Dept..

Fig 10.4.4-A Gradient for moving of water

(b) Design flow rateThis shall be based on the rainwater + waste water from process. And, this shall be determined byCivil Design Dept. based on the reference materials, such as PROCESS DATA, rainfall, area ofPAVING AREA, coefficient of run-off, etc.

(c) Design flow velocityThe design flow velocity shall be 0.3--2.1m/sec.

(d) SIZING of MAIN SEWER LINE(i) This shall be determined by Civil Design Dept., based on the design flow rate and design flow

velocity.(ii) The minimum pipe dia. of MAIN LINE shall be 6B.

(e) Shape and extent of catchment AREA (Refer to Fig. 10.4.4-B.)(i) Catchment area shall be provided with concrete paving, and be surrounded by SPILL WALL.(ii) One catch basin shall be provided in each catchment area.(iii) Maximum extent of the catchment area shall be 400m2.

Note 1) In EXXON BP3-2-1, max. 280m2. However, if gravel area, 465m2.(iv) The gradient shall be 1/150 or more.

Note 2) In EXXON BP3-2-1, 1/100.(v) Dimensions of each part shall be in accordance with the figure below, as a rule.

Fig 10.4.4-B Shape and extent of catchment area

(f) Determination of paving areaPiping Design Dept. shall recieve, from Basic Design Dept., informations of the equipment requiringpaving, and, determine the dimension of paving area, based on considerations for maintenance ofthe equipment, disassembling of piping etc., and limitation of catchment area, etc.

(g) MAIN LINE shall be provided with CATCH BASIN, SUMP BOX, and MANHOLE PIT, at interval of25-30m, as a rule. OILY SEWER shall be of such type that it can be water-sealed, for preventionof spread of fire, when fire occurred. Note)

Catch-basin

Max. 22.5mMax. 22.5m

Over 1/150 note2)Over 1/150

(h) DRIP FUNNELThis shall be installed at places where direct draining from equipment or piping can be done, and beconnected to the NAIN LINE, CATCH BASIN, or SUMP BOX. The size of DRIP FUNNEL shall beas shown in Fig 10.4.4-C, Dept. ending on the size and number of the drainage line.

Fig 10.4.4-C DRIP FUNNEL Details (TYPE-I)

When it is in a building provided with FLOOR PAVING, or in a trench, etc., it shall be as shown in Fig.10.4.4-D.

Fig 10.4.4-D DRIP FUNNEL Details (TYPE-II)

(i) CLEAN-OUT (Refer to Fig. 10.4.4-E.)In case where a plurality of DRIP Funnels is to be used, SUB-HEADER shall be provided, and atthe end of it, a clean-out shall be installed. (Each of the DRIP Funnels is a clean-out, at the sametime, because the PERFORATED PLATE is removable.)

Note) In EXXON BP3.2.1,manhole for main lineshall be one for 90m,if it is 24” or smaller,and, one for 150m, ifit is 26” or larger.

And, manhole for drainarea shall be one for3700--5600m2.

Fig 10.4.4-E CLEAN-OUT Details

(j) In the case of CATCH BASIN or SUMP BOX where generation of flammable gas is liable, theconstruction of its cover shall be devised such that it is appropriate for gas-sealing, and the gasshall be exhausted, through a vent pipe, at a safe position.

(k) Kinds and purpose of pit(i) CATCH BASIN This is a kind of PIT which is installed in catchment area. (Refer to Fig. 10.4.4-

F.)- CATCH BASIN shall not be installed in the vicinity of stairway, ladder, or equipment.- Any two CATCH BASINs shall be connected each other directly. Note)

Maximum distance from drain-out point to CATCH BASIN shall be 22.5m. Note)However, the max. shall be 15m, when it is through open sewer.

Note) From EXXON BP3.2.1.

For-transport temporary polyethylene cap may beused.

Representative types

Fig 10.4.4-F CATCH BASIN Details

- Sleeve (Refer to Fig. 10.4.4-G.)

Pipe connection to pit shall be determined, Dept. ending on the method and time of theconstruction work, so, the scope of supply shall be made clear through discussions with CivilDesign Dept.. Here, it is assumed that a flanged sleeve is used, and its dimensions areshown in the following.

2”

Note) In EXXONBP3.2.1,150m/m

Fig 10.4.4-G Sleeve Details

(ii) SUMP BOX (Refer to Fig. 10.4.4-H.)This means intermediate pit which is installed when the distance between two CATCH BASINsor between CATCH BASIN and MANHOLE PIT is in excess of 25-30m.

Pipe Size (inch.) L4 3006 3008 300

10 30012 30014 30016 300

d (“) D (φ)2 1004 1806 2308 28010 370

d (“) D (φ)12 42014 48018 58020 63024 73028 820

1) Representative types

Fig 10.4.4-H SUMP BOX Details

* When there is no PAVING, the dimension “50” from PAVING shown in each type shallbe replaced by EL150. (This applies when GL=EL0.)

2) Sleeve shall be the same as that shown in the Paragraph of CATCH BASIN.

(iii) MANHOLE PIT (Refer to Fig. 10.4.4-I.)This means pit to be water-sealed by means of partition wall in the pit, for the purpose ofcleaning and inspection of long main piping. Therefore, as a standard of installation, it shall beinstalled in the vicinity of B.L. or in the part where UNIT or AREA changes.

1) Shape

Fig 10.4.4-I MAIN HOLE PIT Details

* When there is no PAVING, the dimension “50” from PAVING shown in each type shall bereplaced by EL150. (This applies when GL=EL0.)

2) Sleeve shall be the same as that shown in the Paragraph of CATCH BASIN.

(l) Details of cover for pit (Refer to Fig 10.4.4-J.)

A B800 900

1000 1000

A B C D E F800 630 700 760 950 10501000 830 900 960 1150 1250

Fig 10.4.4-J-1 Details of cover for pit

Fig 10.4.4-J-3 Details of cover for pit

A B C D800 760 940 6501000 960 1140 850

A B C D E800 760 950 1050 650

1000 960 1150 1250 850

Fig 10.4.4-J-2. Details of cover for pit

Detail “H”

(m) Drainage of the inside of dike (for oil or other liquid) (Refer to Fig 10.4.4-K, Fig 10.4.4-L.)

Fig 10.4.4-K Drainage of the inside dike

Fig 10.4.4-L Installation for drainage valves

(n) CATCH BASIN in area where fire is permitted, such as in area of heater, shall be kept DRY at alltimes, so that water will not be accumulated in the pit. (Refer to Fig. 10.4.4-M.)

Fig 10.4.4-M CATCH BASIN of fire permitted place

(o) When floor drainage is required within a STURUCTURE or a BUILDING of 2-stories or more, floordrainage pipe shall be provided, to be connected to the MAIN SEWER LINE. In this case,catchment FUNNEL shall be provided by Civil Design Dept., as a rule. (Have discussion with CivilDesign Dept..)

* To allow changeover between oily and non-oily.

Tank

Valve(Regularclosed)

To sewer

Dike

* In case of storage tank for ethylene, propylene,etc., it is all right to use for-non-oily valve only,because such liquid evaporates.

(p) SUMP BOX shall be provided at every turning point of MAIN LINE. And, the inlet and outlet LINEshall be oriented at 90° against the wall of pit.

(q) The turning angle of branch pipe shall be 45°, except for the starting point. Furthermore,consideration is required to have the burial-Depth of branch pipe as shallow as possible. (Refer toFig. 10.4.4-N.)

Fig 10.4.4-N Connecting of Branch Pipe

(5) Indication in the piping drawing(a) Symbols to be used in the piping drawing shall be as follows, and each of them shall be given a

peculiar number, within each area. (Refer to Fig 10.4.4-O.)

Fig 10.4.4-O Symbols for SEWER Piping Drawing

3-dimensional piping, because of thedifference between EVEN of SUB-HEADERand ELEV of MAIN LINE.

(b) Making of GENERAL DRAWINGIt is recommended to make GENERAL DRAWING, which may include, together with the above-said peculiar numbers, the type, size, and ELEV/direction of pit, details of covers, and also, DRIPFUNNEL, CLEAN-OUT, details of changeover-valve part of the dike, etc. (This shall be made, as arule, in case where there are many kinds and the plant becomes complicated.)

(6) Design of NON-OILY SEWER(a) NON-OILY SEWER (STORM, SANITARY, - etc.) shall be designed by Civil Design Dept..(b) Design flow rate shall be estimated based on the rainwater, and the sewer line shall be designed,

such that the maximum flow rate is attained with the Dept.th of 70%, as a standard.(c) Design flow velocity shall be 0.6-1.8m/sec, the flow being GRAVITY FLOW.(d) Sewer line may be made of underground pipe, U-shaped trough, concrete ditch, brick ditch, simply

dug out ditch, etc.(e) Position of installation may be periphery of road, periphery of roofed building, area where there is

NON-OILY drainage, etc.(f) Attentions required from the view point of piping design are as follows.

(i) Interference between NON-OILY SEWER and other underground piping (In case where rainfallis heavy, or where the length of drainage becomes long, the bottom of NON-OILY SEWER willbecome deep.

(ii) Discrimination between PAVING AREAs (Rainwater from OILY or CHEMICAL PAVING AREAshall not come into the NON-OILY SEWER.)

(iii) Convenience of traffic

10.4.5 Trench piping(1) Scope of application

(a) Piping so required from the view point of process (including drain piping of high temperature, etc.)(b) Fire-protection piping, such as for steam curtain, water curtain, etc.(c) Piping to be laid below ground level, which tends to become stopped up and requires cleaning of

the inside of pipe. (Example: Drain piping leading to a sump tank installed in an underground pit.)(2) Attentions required in regard to trench and trench piping

(a) For the sake of safety, the inside of trench may be filled with sand.(b) Upper-side cover may be CHECKERED PLATE or gracing. In some cases, cover is not provided.(c) Steam curtain and water curtain shall not be provided with cover, as a rule. However, if they are

obstructing the passages, they shall be provided partially with covers of light weight.(d) Clearance between trench and piping (Refer to Fig. 10.4.5-A.)

Fig 10.4.5-A Clearance between trench and piping

(e) Installation example of for-cleaning nozzle (Refer to Fig. 10.4.5-B.)

Fig 10.4.5-B Installation example of for-cleaning nozzle

(f) When the inside of trench is not filled with sand, drainage of the inside of trench shall be provided.

10.5 Pipe rack Piping

10.5.1 Layout plan of pipe rack

Pipe rack is concerned to other equipments or interval machines on the equipments, indeterming pipe rack layout, take the operation, maintenance, transportation of plant intoconsideration Furthermore, the rack structure (Gate type, Over hanged type, RC structure, SSstructure) shall be confirmed by Civil Design Department.

(1) General Items for Pipe rack layout(a) Interconnection pipe rack

-Piping between units are as short as possible.(b) Pipe rack at the plant area

-Position for through pipe rack shall be determined, it shall be installed withmachine along flow or same kind of machine as one group.

- Pipings between units are as short as possible ???- Installation and maintenance of equipments are easily performed.- Distance between racks to be caroused the passage access to these area

Fig 10.5.1-A Space between pipe racks

(2) Pipe rack width(a) To determine the pipe rack width, take the number of piping, pipe or flange size and

depth of insulation into consideration (Pipe space shall be refereed to TEG1-1313-007: Table A of PIPING SPACING).

(b) Effective height shall be ensured when required carry-in and out, operation andmaintenance of equipment.

(c) When arranging an air fin cooler (AFC) on top of a pipe rack, decision shall be made inconsideration of the leg width of AFC.

(3) Pipe rack high(a) The beam underside of pipe rack crossing a premises passage or the height of pipe

bottom (including heat insulating material) from the surface of passage shall be inaccordance with Paragraph 5.6.2. The height of passage and road surface shall bebased on the highest part of paved surface.

(b) The effective height necessary for bringing in and out of equipment, operation andmaintenance shall be secured.

- When an equipment is located under the rack, determine the minimum heightof rack by taking the operating space and piping arrangement around theequipment into consideration. When there is a plural number of heatexchangers, take the height of the highest heat exchanger for the basis.

Min. 20m Road

Fig. 10.5.1-B - Example of case of arranging heat exchanger under the rack

- Provide a level gap between the pipe rack running in East and West directionand that running in South and North so as to enable smooth arrangement ofpiping passing through the intersection.

(4) Pipe Rack Column Spacing (Pipeway direction)Determine the pipe rack column spacing by taking the following into consideration:(a) Deflection of piping (whether the plant is mainly composed of large bore piping or

small bore piping)(b) Size of equipment (such as pump and heat exchanger) installed under the pipe rack(c) In road crossing, the interference between the cutting of road corner and column

foundation.(d) Consider the ease of possibility, operation and maintenance beside piping

arrangement before determining the potion and form of braces.(e) Examine whether the columns of other frames and buildings, etc. could be commonly

used for the rack or not.

(5) Pipe Rack's Stage Interval(a) Determine the stage interval of pipe rack by taking the size of the clusters of pipe

placed on the rack and the branching method of the largest pipes into consideration.

(6) Utilization of Space under Pipe Rack, and RestrictionThe space under the pipe rack may be utilized by giving thought to the following points:(a) The space under the rack may be used for the installation of a row of pumps and

passage.(b) However, certain companies set limitation for the installation of heat oil pumps under

the rack.(c) Heat exchanger, etc. are laid out sometimes for the effective utilization of plant area.

Minimum of 300mm. When there is hot insulation orcold insulation, minimum of 100mm measured fromtheir outside. Take the elongation by thermalexpansion also into consideration.

(7) Example of pipe rack arrangement

Road

Road

Compressor house

Process equipment

(A) Dead end type yard piping

Control Room

Road

Road

Process equipment

(B) Straight line type yard piping

Control room

Road

(C ) L-type yard piping

Road

Road

Control Room

(D) T-type yard piping

Compressor House

Road

Control Room

(E) U-type yard piping

Control Room

Road

Road

Furnace

Compressor House

(G) Complicated yard piping for a large plant

Compressor House

Road

Furnace

Control Room

(F) L and T-type combination yard piping

10.5.2 GeneralFor detailed piping plan, refer to TEG1-1313-004. Piping inside and between units andthat connecting with tank yard shall be laid out on pipe racks, sleepers or under-ground.The piping to be laid out on sleepers or underground shall be determined afterconfirming the requirements of customers. The piping arranged on pipe rack shall beselected in accordance with the following standards:

(1) Connection inside and between units(a) Piping connecting equipment set apart for more than 6m(b) Utility header(c) Raw material and product piping(d) Blow down piping (flare piping, etc.)(e) Safety valve, control valve, block valve, etc. which are better if installed on pipe racks(f) Instruments and electricity duct (They are sometimes required to be buried

underground, so be careful). Separate instruments duct and electricity duct for morethan one meter.

(g) Corridor (for required places only)(2) Inside tank yard

(a) If space is available, sleeper piping shall be adopted in principle. However, adopttrench or rack for road crossing.

10.5.3 Piping Arrangement

(1) Place large size pipe (over 14 in) closest possible to columns so that the bending momenton horizontal beams of racks is minimized.

(2) In case of single rack, basically utility piping shall be arranged in the middle of rack, as wellas process piping shall be arranged at the top of rack. (refer to fig 10.5.3)

Fig 10.5.3-A Example for layout of single rack

(3) In case of two-tier rack, basically utility piping shall be arranged on the upper rack, as wellas process piping shall be arranged on the lower rack. However, large piping may bearranged on the upper rack in accordance with space. (refer to fig 10.5.3-B)

Instrument duct

Corridor

Large size pipe

Large size pipe Process Utility Process

Fig 10.5-3-B Example for layout of two-tier rack

(4) Table for piping arrangement

Pipings Upper Rack Lower RackEnd Middle End Middle

Blowdown (flare) piping ΟPiping for raw material receiving (12 in and larger) ΟPiping for raw material receiving (10 in and larger) Ο ΟPiping for product delivery (12 in and smaller) Ο

P Piping for product delivery (10 in and smaller) Ο ΟRO

Overhead piping for tower and drum or piping tobe connected at high position

Ο Ο

CE

Overhead piping for tower and drum that are to beconnected to pumps or heat exchangers

Ο Ο

SS

Pump discharge line Special∆

Ο Ο

Piping subjected to corrosion Ο ΟPiping connecting two equipments on ground Ο ΟPiping subjected to vibration Ο

CorrideInstrument

Duct MIN. 2100

Lower Rack : Basically Process piping

Upper Rack : Basically Utility piping

High/Low pressure steam pipingU condensate pipingT Boiler feed water piping Ο ΟI Piping for hose station (water, air, N2) Ο ΟL Plant air piping Ο ΟI Header piping for pump cooling water ΟT Fuel oil and gas piping Ο ΟY Instrument air piping ΟD Instrument duct Ο ΟU Electrical duct Ο ΟCT

When loop in required in the line

(5) Do not locate piping for corrosive fluid above cable ducts.

(6) Take proper measures against vibration if it is unforgivable to place discharge piping ofreciprocating compressors, pressure-reducing valves or large-size return water piping onthe racks.

(7) For piping at Buttery limit matching points, consult with the party concerned to clarify pipingarrangement, anchor points and the like.

(8) Provide a stage and plat form if valves on the rack require frequent operation ormaintenance. Ladder is to be used, as a rule, to elevate to the stage mentioned above.

(9) The end of utility header piping should be in accordance with blind flange, the largediameter shall be specified cap. (Refer to Fig. 10.5.3-C)

class Blind flange Cap type# 300 orunder

8 in andsmaller

10 in andlarger

# 600 6 in andsmaller

8 in andlarger

Fig 10.5.3-C Installation of Blind flange for flushing

Blind Flange Cap

Nozzle for Flushing 4”

(10) Expansion Loop made on a condensate line should be horizontal in order to preventwater hammering. When horizontal bending is impossible, employ the expansionloop shown below. (Refer to fig 10.5.3-D).

Fig 10.5.3-D Loop of condensate piping

(11) To obtain good piping appearance, expansion loops should be arranged in groupexcept for condensate piping. (refer to fig 10.5.3-E). Also the simple calculationaround loop are given in the DEPT.INSTRUCT02-08: Standard for Heat expansionabsorbed loop.

Place the line in order so that pipes with large diameters or expansion come on theouter side.

Fig 10.5.3E General piping loop

(12) For long sized piping, such as the yard piping and the pipe line, they shall bespecified vertical type loop.

(Exp. 2)

(Exp. 1)

θ : MAX. 30°

Vertical type loop

(13) Down pipe dimensions

Fig.10.5.3-F - Down pipe

(a) The dimensions of down pipe shall, in principle, be controlled by its center. Dependingon the method of support, however, it may be controlled by dimensions trued up on theexternal surface of pipe.

(b) The control dimensions shall, in principle, be 500mm. However, the case of large borepiping or where a distance (100mm) cannot be taken from insulated external wall tothe flange of beam and where the welding line of bare pipe falls on a beam shall beexcepted. Determine the dimensions by referring to Tables 10.5.4-A and B.

(14) Pipes for hazardous gas should be placed on the upper rack, and way from high-temperature pipes.

(15) Do not locate oxygen piping near to electrical ducts.

10.5.4 Installation height of piping (refer to fig 10.5.4-A and Table 10.5.4-C)

To determine the installation height of piping, taking the shoe, cradle and saddle height intoconsideration.

Shoe Cradle Saddle Note)

Note) Thin and large sized piping should be supported by saddles in order to reduce local stress.

Fig 10.5.4-A Installation height of piping

(Unify by areas)

(In principle)

(In principle)

Insulation

Exercise care that theshoe will not come closeto the welding line.

Insulation

(Rest-Type)

Table 10.5.4-C Insulation thickness and installation height of piping

Hot/Coldinsulation

Insulationthickness

Shoe, Cradle andSaddle height

Remarks

Hot25~75

80~125130~175180~225

100150200250

Installation height of infraction for personnelprotection shall be installed as same as barepiping installation.

Cold25~50

55~100105~150155~200

50100150200

Bare 100 Thin and large sized piping should besupported by saddle inorder to reduce localstress. Saddle require shall be ckecked inaccordance with allowable span list

10.5.5 Direction change for rack piping

Table 10.5.4-A Piping of minimum size (1/2)

(under 8 in )

SIZE (B) α1/2 336.93/4 336.91 336.9

11/2 317.82 298.83 260.74 222.66 146.48 70.2

SIZE (B) α1/2 441.93/4 441.91 441.9

11/2 422.82 403.83 365.74 327.66 251.48 175.2

Max. 125mm

Min. 20mm

(1) Piping layout for direction change part (refer to fig 10.5.5-A)

(10 in~24 in)

SIZE (B) L α10 500.0 127.712 500.0 77.114 500.0 19.416 750.0 218.618 750.0 167.820 750.0 117.022 750.0 66.224 750.0 15.4

SIZE (B) L α10 500.0 232.712 500.0 182.114 500.0 144.416 750.0 323.418 750.0 272.820 750.0 222.022 750.0 171.224 750.0 140.4

Max. 125mm

Min. 20mm

Table 10.5.4-B Piping of minimum size (2/2)

(26 in and over)

SIZE (B) L26 830.428 881.230 932.032 962.234 1033.636 1084.438 1135.240 1186.0

SIZE (B) L26 830.428 881.230 932.032 962.234 1033.636 1084.438 1135.240 1186.0

Min. 20mm

Max. 125mm

(A) Plane bending- Use for interconnection- Economical

(B) Solid bending- Applicable to complicated piping

arrangement- Be careful about overhang at corner

(provide intermediate beams)

Fig 10.5.5-A Piping Layout for change direction part

(2) Determination of double rack height between stages (refer to fig 10.5.5-B and Table 10.5.5-A)(i) In general, All step height are specified 1000 mm, 2000mm, 3000 mm.

Fig 10.5.5-B Determination of Double rack height between stages

(ii) Determination of height between stages shall be determined in accordance withchange direction of piping and branched pipe size.(Table 10.5.5-A : refer to pipe direction change size list)

(iii) Net height means the height between stages minus beams height.However, in order to minimize the height between stages, beams group of long elbowshall be arranged like a (a) of fig 10.5.5-B when contact with civil design department.

(a) 90° elbow + 90°elbow

SIZE h1 h hh3in 228.6 318.0 In case the4in 304.8 420.0 hot insulation6in 457.2 623.0 It shall be8in 609.6 826.0 added to the10in 762.0 1030.0 shoe height12in 914.4 1233.0 by two14in 1066.8 1423.016in 1219.2 1626.020in 1524.0 2032.024in 1828.8 2440.028in 2133.6 2845.030in 2286.0 3048.0

(b) 90° elbow + 45° elbow

SIZE h1 h hh3in 114.3 204.0 In case the4in 152.4 267.0 hot insulation6in 228.6 394.0 It shall be8in 304.8 521.0 added to the10in 380.9 650.0 shoe height12in 457.2 776.0 by two14in 533.4 890.016in 609.6 1016.020in 762.0 1270.024in 914.4 1524.028in 1066.8 1778.030in 1143.0 1905.0

Table 10.5.5-A Size list for direction change of piping

90° L.R. Elbow

90° L.R. Elbow

45° L.R. Elbow

(c) tea elbow + 90° elbow

SIZE h1 h hh6in 371.5 537.0 In case the8in 482.6 700.0 hot insulation10in 596.6 865.0 It shall be12in 711.2 1030.0 added to the14in 812.8 1170.0 shoe height16in 914.4 1321.0 by two20in 1143.0 1651.024in 1346.2 1956.028in 1587.5 2300.030in 1701.6 2464.032in 1816.1 2630.034in 1930.4 2794.036in 2044.7 2960.040in 2273.3 3290.0

(d) tea elbow +45° elbow

SIZE h1 h hh6in 168.0 334.0 In case the8in 215.0 432.0 hot insulation10in 264.2 532.0 It shall be12in 313.5 632.0 added to the14in 353.7 710.0 shoe height16in 394.1 801.0 by two20in 492.6 1001.024in 573.2 1183.028in 680.7 1392.030in 729.7 1492.032in 779.2 1592.034in 828.4 1692.036in 877.6 1793.040in 976.2 1993.0

90° L.R. Elbow 45° L.R. Elbow

TeeTee

10.5.6 Rack width(1) Pipe spacing on the rack are determined in accordance with TEG1-1313-007 PIPE

SPACING. Take full account of maintenance, hot/cold insulation and thermal expansion.

(2) In case special valves or instruments are installed, the space for operation andmaintenance of such valves or instruments should be taken into consideration in determingthe width of the rack.

(3) In case orifices are installed on the pipes, the direction of orifice taps should be taken intoconsideration.

(4) When there is a diagonal offtake, decision shall be made by referring to the table showingdiagonal offtake pipe spacing in TEG1-1313-007.

Fig.10.5.6-A - Directions of differential pressure off-take(From hook-up drawings prepared by Instrumentation Design)

Remarks : 1. In principle, B-2 type shall not be used for heating steam (to prevent stresscorrosion cracking).

2. B-1 and C-1 types shall as rule be as shown in the following figure:

Gas Steam Liquid

Picking up of orifice taps

(4) In general, take 5 to 15 % allowance of space. (plus future extension, if required)

(5) To determine a rack width, apply the following formula.

Fig 10.5.6-B Determination of rack width

B≥Bo +H + F

B0 ={(P1 + P2 +P3) +(Ce +Ci)} x (1 + α)Where:

B : Rack WidthBo : Calculated rack widthP1, P2, P3 : Space for pipes (in accordance with TEG-3007)Ce : Cable Duct (for electricity) widthCi : Cable Duct (for instrument) widthα : allowance; 0.05 to 0.15F : Space for future extensionH : Pillar size

Steam Header

Condenser

10.6. Piping around Tower and Tank

10.6.1 Cautions for arrangement

(1) Tower (self-supported tower)

(a) Space between towerSpaces between towers are minimum of 2.0 m at the surface. The following factorsshould be taken into in determining the space between tower. (Refer to Fig. 10.6-A)- Ensure the space consider with installation method.

- Investigate for problems for footing design of foundation in advance.- The gable of plat form shall be considered.- In order to prevent the danger of resonance by karman eddies, more than 50m

tower shall be confirmed for mechanical design department, and also itmeasures shall be determined.

(b) Structures and TowerDistance from a center of pillar of structure (or pipe rack) to tower shall not betouched with both foundations, the distance shall be specified around 1.5m. (Refer toFig. 10.6-A.) For installation height is required on process, it shall be specified therequire.

Fig 10.6-A Example for arrangement around tower.

(c) Access side and piping side (Refer to Fig. 10.6-B)- The surrounding of tower shall be divided into the access side which will take in

and out internals (tray and the like) using manhole and lower down cargo on to theground using the top davit, and into the piping side which will install piping aroundthe tower.

- Basically the access side shall be installed at road side, as well as the piping sideshall be installed structure side.

- Access side shall be ensured the space that required space for davit movementand hang-up operation and maintenance.

- Piping at piping side shall be ensured the space for operation around tower adladder space as possible as one group.

- Valves around tower at piping side shall be operated easily from plat form orladder.

Structures and Piperack

Tower

Rode

around

Min.

Fig 10.6-B Access side around tower at piping side

(2) Vertical Tank(a) Space between tank

- Space between vertical tank shall be a minimum of 1.2 m at tank surface.However, in case the vertical tank that not be attached footing, space can bereduce.

- Space between vertical tank at pipe stand shall be a minimum of 0.6m at tanksurface. However, in case of space to be used for carry-in and out operation, itshall be a minimum of 1.5 m at tank surface. (Refer to Fig. 10.6-C).

- The Fire Service provides guidance in Japan as regards the intervals of tankscoming under and applicable to No.20 tanks.

(b) Line up for vertical tankWhen more than two agitators shall be installed, center line shall be lined up at sameline. Due to carry-in and out for medicines, throw a thing, or installation of agitatorsand hang- up and off at maintenance, trolley beams should be installed according tothe process require (Refer to Fig. 10.6-C).

(c) Access side and piping sideAround agitators shall be distinct between access side and piping side consideringwith the medicine house, place for agitators axis, and motors as possible as clearly.(Refer to Fig. 10.6-C).

(d) Chemical injection nozzle and manhole heightThe height shall be specified around 0.8 m from installation floor. (Refer to Fig. 10.6-D)

(e) Maintenance space for around agitatorsAgitator motor or agitator axis shall be considered the space of hang-up (Refer toFig. 10.6-D)In case the long agitator axis, it shall be arranged such as divided etc. contact withmechanical design department.

Piperack and Structures Access Side Piping Side

Platform

Piping Side

Access Side

Piperack

andStructure

Manhole

Road

Fig 10.6-C Example for arrangement of agitators on the pipe rack

Fig 10.6-D Example for installation of agitators on the pipe rack

(3) Horizontal Tank(a) Space between tank

Space between horizontal tank shall be a minimum of 0.6m at tank surface. In caseof hot/cold insulation are installed, it shall be installed at surface of insulationmaterial.

Piping SideTrolley beams

Manhole

Access Side

Min.Chemical injection nozzle

Carry Exit

Hoist or Chain Block

Max.30°

Chemicalinjection nozzle

About0.8m

(b) Line-up for horizontal tankWhen more than two horizontal tanks are installed at same line, same size tanksshall be considered as group on the tangential line at access side or the center line ofsaddle must be arranged.

(c) Installation heightThe height of horizontal tanks shall be checked in accordance with accessories atupper side of tank and piping, and also they have to consider with position where notto be obstructed for each layout. If installation height have process requirement, itshall be specified.

(d) In case of installed on the pipe rack, large equipment’s shall be installed as possibleas close to pillar or girder.

10.6.2 Basic requirement for layout(1) Typical layout for around tower and vertical tank (Refer to Fig. 10.6-E).

Fig 10.6-E Typical layout for around tower and vertical tank

(2) Consideration items for maintenance(a) Changing for gob(b) Maintenance for Reboilers(c) load and unload of valves and tower accessories. (by pipe davit)

Ensure the space at ground

(3) Influence items for installation height(a) NPSH of pumps (NET POSITIVE SUCTION HEAD)(b) Thermosiphon of Reboilers(c) Gravity Flow Line(d) Combination of other tower at adjoining area and Reboilers(e) The pressure loss to control valve when liquid temperature is close to boiling point.

Access Area

Road

Piperack

10.6.3 Piping of tower and around vertical tankThe detail plans shall be referred giving in TEG1-1313-005 Tower Piping.(1) Overhead piping

(a) Route of overhead piping shall be determined at the beginning because ofimportance role at large diameter.

(b) In case the compressor suction piping, pay attention to the installation in order toprevent air pocket.

(c) Pay attention the calculation of thermal stress (temperature difference betweentower) and support (piping weight is heavy).

(d) When more than two compressors are installed stand in a low, piping shape shall bearranged to flowed equally. (Refer to Fig. 10.6-F).

Fig 10.6-F Overhead piping connecting to condenser

(2) Reflux pipingBeing usually small sized with low temperature and located on the top of tower, reflux pipingshould be designed to have sufficient flexibility.

(3) Feed piping(a) In consideration of thermal expansion difference between piping and tower, feed

piping should have sufficient flexibility. (Refer to Fig. 10.6-G)

Bad

Good Bad

Fig 10.6-G Layout of feed piping

(4) Draining piping from tower bottom(a) Nozzle height at tower bottom (Refer to Fig. 10.6-H)

Draining nozzle height at tower bottom shall be determined independently inaccordance with NPSH of pump and passage of operator (minimum 2100),connection object of piping. Nozzle heights shall be as possible as unified which canbe control.

In case of Skirt In case of LEG

Fig 10.6-H Nozzle height at tower bottom

(b) Bottom Draw-off pipe (Refer to Fig. 10.6-J)- Suction line distance of pump should be as short as possible to reduce the vent.- Draw-off piping of tower bottom should be simply arranged without pockets.- Pay attention enough the support position and the shape of piping in order to

prevent unreasonable force to pump by pump stretch.- When possible, the elevation and shape of bottom draw-off pipings should be

unform.- Make sure no pocket is generated by themal expansion during operation. Give the

piping a slope, if necessary.

Drain

Support Support

Drain

Fig 10.6-J Pump draining piping from tower bottom.

(c) Pressure loss of orifice for measure the flow (Refer to Fig. 10.6-K)In case the liquid which close to boiling point, if static head is small, it may beflashed and it can not count surely by pressure loss of orifice.

Fig 10.6-K Pressure loss of static head and orifice

(5) Reboiler piping(a) Reboiler outlet piping is critical loss that as possible as reduce the vent and distance.

In case the thermo siphon type reboilers, for the liquid circulation, pay attention tothe nozzle layout and installation height of mechanical may be limited.

(b) Generally, pipings around reboiler are large diameter, therefore, pay attention to thethermal stress and load for nozzle.

(6) Safety Valve Discharge Piping

StaticHead

Min. Orifice

Surface

Boiling Liquid

Highthof tower

(a) In the case of open-type discharge, the piping end should be located at least 3mabove the platform which comes within 8m radius of the discharge point.(?????)(Refer to Fig. 10.6-L).

Fig 10.6-L End discharge of air discharge safety valve

(b) The discharge piping should be free drain and , if necessary be sloped. Also, backpressure should be minimized.

(c) For safety valve maintenance, work should be feasible on platform. For the valve of4 in and larger, davit and crane should be available.

(d) Provide a 10mm-dia.weep hole at the low point of the discharge piping. In the caseof toxic or high temperature fluid, weep hole piping should be provided.

(e) Sufficient support should be provided against discharge reaction.

(f) For the maintenance of safety valve around tower, installation shall be arrangedeacy for maintenance, installation position where located unremoval position bythermal expansion.

(g) Though the safety valve around the tower is often installed at a location easy tomaintain on the overhead line, care is exercised to see the offtake point is taken at alocation where the shift due to thermal expansion is made minimal.

(7) Piping for samplingThe nozzles for sampling shall be installed near the platform as possible. ????? (Refer toFig. 10.6-M)

Radar

Sampling Pipe

Sampling Connection

Plat Form

Min.3m

Relief Valve

Weep Hole Pipe

Fig 10.6-M Example for the piping for sampling

(8) Horse station and other small-sized diameter piping(a) In determining of piping route, the piping for horse station and chemical injection,

PDI, fire piping shall be installed together as possible, and also the support and towercrip design shall be arranged easily.

(b) Horse stations should be installed at the end of platform where can not be interruptmanhole.

(c) Pay attention to the difference temperature between tower and piping, take intoconsideration of flexibility. (if necessary, rope may be installed under platform.)

(d) Be careful the moving of pipe davit at the top of tower.

(9) Other cautions(a) As a rule, valve should be connected directly to nozzle in order to prevent drain

pockets. (Refer to Fig. 10.6-N.)

(b)In determining pipe route, priority should be given to large sized piping and pipingcoming from upper nozzles. Lower nozzle pipings and small sized pipings aredetermined accordingly.

(c) Piping connecting two towers standing side by side or those connecting a tower and afixed equipment should be given flexibility in consideration of the sway of the towers.

(d) When a descending piping becomes horizontal it should be aligned with the elevationof the main rack piping. (Refer to Fig. 10.6-P).

Good Bad

Fig 10.6-P Connecting between equipment and pipe rack.

(e) When it is convenient to install an orifice flange to the vertical piping around thetower, consult Instrument Engineers taking the following points into account.- Cleaned liquid, dry gas, air : Vertical flow is allowed in both directions.- Steam, wet gas, wet air : Vertical flow is allowed. Downward direction is preferable.- Gas-liquid mixture : Vertical flow is allowed if the direction is upward.

(f) Piping connected to the equipment’s shall be arranged enough clearance where cannot be touched with equipment and support. (Refer to Fig. 10.6-Q) (TEG1-1314-104:Refer to the PIPING HANGING NO.4, DWG No.A3.952-1C~1F of DESIGNDATA).

Air Fin Cooler

Pipe Rack

Connectedto pimp

Connectedto pump

Fig 10.6-Q Cautions for insulation piping

(g) In general, standing piping shall be installed center line horizontally, if it isimpossible, it shall be installed in accordance with the following fig 10.6-R. RV shouldbe installed as close as possible to nozzle, as well as in the case of round piping,standing piping shall also be installed close to nozzle, support shall be installedhorizontally.

Flexibility

Min. Min.Min.

Fig 10.6-R Round of piping

(10) Flexibility of piping(a) Pipings and towers connected to the tower or vertical tank shall be choose proper

support type and position considering with thermal expansion of tank and piping.(Refer to Fig. 10.6-S).

Min.

Fig.10.6-S Precautions against thermal expansion and shrinkage of piping around tower

(b) Tower arranging in a low and the piping connected to the equipments shall bechecked the following procedure take into vibration by wind pressure, earthquake,thermal expansion, and heat transfer into consideration. (Refer to Fig. 10.6-T).

Care will have to beexercised for thermalexpansion for the typeof piping in whichsupply position ischanged by switchoverof valves by installingsupply nozzles atseveral places.

Avoid the installation of loop as far as possible.

Flexibility

Support

Support and route shall be planned bypaying attention to the difference in theelongation of tower and piping due to thedifference in temperature gradient insidethe tower and in the materials of towerand piping.

Support* Control valve and anchor support shall not beinstalled immediately below the vertical piping.

OK

OK

OK

OUT

OUT

OUT

(1)

(2) (3)

(4)

(5) (6)

(7)

(8)

CALCULATION OFAMOUNT OF SHIFT

1. Shift by externalforce (wind pressure,earthquake)

2. Shift by heat

PLANNING

1. Processrequirements

2. Support

3. Beauty of sight

STRENGTHCALCULATION

1. Computer

2. Guided cantilevermethod (manualcalculation)

Checkingthe strengthof nozzle

Check to seeif the processrequirementsare staisfied ornot.

Approval byplant owner(whennecessary)

US

E

Try to solve inconsultationwith Process.

CHANGE OF PLANNING

1. PIPING

2. BELLOWS

Fig 10.6-T Check procedures of flexibility

10.6.4 Support design of tower and around vertical tank(1) Installation of supporting for vessel crip

Support design that installed to equipment’s and the determination of nozzle orientationshould be done, and also vessel crip for supporting and information for nozzle orientationshall be send to equipment design department. Comparing with other support designschedule, it is earlier period in order to control the equipment process schedule.For the smoothly design, the using type of vessel crip and the depth of insulation shall bedetermined before design start.

10.7 Pipings around heat exchanger10.7.1 Shell and tube heat exchanger(1) Type of heat exchangersShell and tube heat exchangers shall be expressed the types in accordance with the combinationof alphabet 3 letters on the following fig 10.7-A. (According to the TEMA standard.)

Fig 10.7-A Shell and tube heat exchanger

(2) Cautions for piping configuration

(a) Valves around heat exchanger, operation space for instruments and the passage arefollowing as belows.- Intervals between heat exchangers shall be a minimum of 0.6 m on the surface of heat

exchangers. In case has hot/cold insulation, as well as the intervals shall be spacedon the surface of insulation (refer to fig 10.7-B)

- Intervals between heat exchangers shall be determined take the following factors intoconsideration.• Bolts of the body and channel flanges can be enough putted.• In case the stand-up piping is settled in the equipment, the construction space

(Specially, welding) shall be specified.• In the case of vertical type heat exchanger, take the enough space into

consideration when required the pipe rack for supporting and a plat form for access.• In case the several heat exchangers are lined up, take the passage for operation

which can be common used into consideration.

Fig 10.7-B Example for heat exchanger configuration

- Maintenance Space (refer to fig 10.7-B)- In case of pulling the tube bundle of heat exchanger, ensure the space of tube

bundle length + 1.5 m ~ 2.0 m as pulling space of tube bundle. As well as, theplace for tube bundle shall also be considered if required.

- Be careful a pulling area direction, if tube side is high pressure, shell side must bemoved and pull out when maintenance.

- In case the settled tube sheet type heat exchangers which required the tubecleaning, ensure the space 1.5 m ~ 2.5 m in front of tube side as operation area.

- In case the horizontal type heat exchangers are installed on the pipe rack, ensurethe space 0.9 m ~ 1.2 m between channel cover and ladder.

- Considering the space where can be pull the shell cover and channel cover andputted temporary when tube cleaning operation and pulling the tube bundle.

- In case the heat exchangers are installed in piles, they have to enough consider themaintenance of upper of heat exchanger and operation procedure.

- When it is difficult to used the crane when maintenance of heat exchanger, theyhave to prepare a trolley beam, a hoist or a davit for channel cover.

- Line up of heat exchangers (refer to fig 10.7-B)- Line up of heat exchanger shall be choose the following method of line up. In case

the many heat exchangers are lined up, channel nozzles and leg position shall beas arranged as possible. It is to beauty and simple the beams of structure.

- In order to good arrangement, the channel position at access side shall be lined-up.- Installation height of heat exchangers shall be determined in accordance with the

space between end of drain that the pipings are connected to nozzle at lower sideof heat exchanger or flange and floor, the space shall be a minimum of 150 mm.(refer to fig 10.7-C).

Floor

Min.150mm

Min.150mm

Min.150mm

Min.150mm

Fig 10.7-C Example for installation height of heat exchangers

(b) In case the heat exchangers are line-up, piping at cooling side and operation position ofvalve shall be arranged same sides.

(c) Channel cover and shell cover or tube bundle shall be arranged pipings where can beeasy removed.

(d) If there are heat exchangers in the building and pipe rack and install the trolley beam,The tube shall not be installed on the center line of heat exchangers. (Same as underpipe rack)

(e) The piping shall be as short as possible, and also avoid unnecessary rope and pocket.(f) The piping connecting to nozzle where away from settled side saddle of heat exchangers

are shall be installed the piping take the consider with heat expansion of heat exchanger.Normally the saddle shall be settled at channel side. (refer to fig 10.7-D).

Note)

Slide Side

Fig 10.7-D Settle and slide of heat exchanger saddles

(g) In general, the valve and blind shall be installed nozzles directly.

(h) In order to prevent a big force to the nozzle by piping weights or heat expansion, pipingform and support must be considered.

(i) When connecting piping in parallel with a plural number of heat exchangers, make theshape of piping after branching symmetrical and adopt the same dimensions so as not tocause drift current. In heat exchangers where products change from gas phase to liquidphase, see that confluence will be caused in the liquid phase part in order to keep flowbalance.

(j) Changing the taking out method of nozzleDetermined flow current direction and nozzle position can be changed when basic designconsidering with process requirement items according to the piping configuration andmaintenance. However, it is influence to the rating of heat exchangers, they have toenough contact with process design department and mechanical design departmentwithout fail.In general, the flow is as follows:

(i) Cool liquid flow is from down to up. Heat liquid flow is from up to down.(ii) Cool/heat flow must be specified couter current flow.(iii) In case the flow which through heat exchangers, or the non condensable gas that

has a multi-pass of tube side, shell side and tube side can be opposite the entrancegate.

(iv) In case the single pass of tube side, if shell side and tube side are changes at thesame time entrance gate can be opposite side.

(k) Change of nozzle type (refer to fig 10.7-E)

Fig 10.7-E Nozzle type of heat exchangers

(i) In general, (A) type shall be specified(ii) In case the large diameter, also (A) type is higher the installation height. If

installation height have be limited, (B) type must be specified.

Example- When the installation height must be unified to other heat exchangers- If installation height of heat exchangers are high-up structure also must be height

when install under the structures???- When heat exchanger shall be carried on the vertical vessel.- When heat exchanger shall be stacked exchanger.

(iii) Reservation of type shall be determined through the mechanical design departmentto vendor when first period of PIPING STUDY.- “a” dimension shall be determined by piping design department- “h” diminution shall be checked in accordance with Drain piping Type dimension

table of 10.21 drain and vent.

(3) Example for piping configuration around vertical heat exchangers. (refer to fig 10.7-F, 10.7-G, 10.7-J)

Note 1 :Adopt MAKE-UP dimensions in case of W.N. flange.Note 2 :A line's mesial point of tube side shall be taken on the shell side (so as not to

interfere with the removal of tube bundle).

Fig 10.7-F Example of piping around horizontal heat exchanger (Example 1)

No piping shall be passed rightabove a heat exchanger.(Especially on top of the channelcover as it will interfere withmaintenance).

No need to give any specialthought about operation.

Note 2)

Adopt a detachable typeof piping. (Consider bycases)

Flange for maintenance

No need to give any particular thoughtabout operation.

Min.

Note2)

Min. Min.

Vent

Min. 100

Note 1)

Fig 10.7-G Example of piping around horizontal heat exchanger (Example 2)- Operation of cooling water vent valve shall not needed special thinking.- If necessary, the flange for maintenance of hat exchanger shall be considered. As well

as support type shall be considered.

Fig.10.7-H - Example of piping around horizontal heat exchanger (Example 3)

Fig.10.7-J - Example of piping around horizontal heat exchanger (Example 4)

(4) Piping design around Reboilers(a) Cautions for piping configuration (refer to fig 10.7-K)

Overhead condenser

Since pressure reduction is causedin the vicinity of valve exit to result incavitation at times, bottominstallation will be better.

Adopt a symmetric linewhen there is no valve inthe line.

Bottom installation will be better.

Anticipate the installation of drain.

Flange for heatexchanger maintenance(Consider by cases)

Long elbow

Install a removablesupport. (Replacement ofblind and removal of pipe)

(i) The piping external form shall be simple in order to minimize the pressure drop ofcirculation piping. The determined piping external forms shall be checked thepressure drop and circulation by heat transfer department.

(ii) Boiler configuration and piping must be specified symmetric if there are standbyreboiler.

Fig.10.7-K - Arrangement of piping with standby reboiler

(b) The Vertical Reboiler and Tower (Refer to Fig. 10.7-L)- Vapor line of reboiler have to be installed as close as possible the tower according to

the heat expansion and efficiency.- The configuration of vertical reboiler should be installed at access side of tower

according to the maintenance of reboiler.

Into these directionswhen sliding the reboiler

Fig 10.7-L Example for configuration of vertical reboiler and tower

(c) thimble expansion absorption of reboiler piping(i) There are no standby reboiler

- Position of legs shall be determined that vessel elongation (∆L1) are equal toreboiler elongation (∆L2 +∆L3). (refer to fig 10.7-M)

Fig.10.7-M - Layout of reboiler piping

- Height relation between tower and reboiler shall be confirmed based on thermalstress analysis in accordance with leg installation position shall be determined bydata of basic design department and heat transfer design department.(According to the thermal stress analysis, in the case of out, spring may besupported.)

Pipe rack and structure

Piping Side

Access SideMake it asshort aspossible

Reboiler

Slide the reboiler.

Give flexibility to piping.

- In case of slide reboiler, pipe rack must be designed considering with frictionalreaction force of reboilers.

- In case of slide reboiler in order to absorb the piping dilatation, reboiler shall beslide sufficiently according to the heat expansion force for nozzle. (Use for TeflonSLIDING PLATE) (refer to fig 10.7-N).

Fig.10.7-N - Bolt holes for reboiler legs and frame

- Nozzle strength must be checked- Not required the reboiler movement (bolt hole is no needed the long hole). (refer to

fig 10.7-P).

Fig.10.7-P - Absorption of thermal expansion by piping

- In general, the method that heat expansion is absorbed by bellow shall not bespecified. (refer to fig 10.7-Q).

Use sliding plates

Direction of

Prepare bolt holes in slotin sliding direction

Bolt hole

I: Consider the amount of shift.d: Hole diameter of relevant

I: Consider the amount of shift.d: Hole diameter of relevant

Avoid thermal expansion in piping

Consider liner allowance (20mm)

Fig 10.7-Q - Example for use a bellows

- Comparing with tower diameter, if reboiler diameter is shorter than tower diameter,the support shall be picked up from the tower, and also reboiler shall be supported.(they have to contact with mechanical design department in advance).

(ii) STANDBY Reboiler (diverter operation)??? (refer to fig 10.7-K).- In order to equalize to reboiler dilatation (∆L2 + ∆L3) and vessel dilatation (∆L1),

leg position shall be determined while operating, reaction of piping and nozzleshall be checked while stop operating.

- Change the type of reboiler increase the flexibility of piping after discussed withmechanical design department ?????

(d) Precautions from the viewpoint of maintenance(i) Removal of reboiler head cover and pulling out of tube (Refer to Fig.10.7-R).

Fig. 10.7-R - Removal of head cover and pulling out of tube

(ii) Be careful about the position of valve and flange in the type of reboiler, for whichmaintenance is performed by suspending one unit during operation. (Make themremovable). (Refer to Fig.10.7-S).

Bellow (Not Use)

Cover removing area

Allow for lift up

Flange installation

Reboiler

Valve positionDepth of cut for flange

Fig. 10.7-S - Removal of bottom cover

(d) Check of thermal stress around reboiler(i) Calculation of reboiler elongation

- Installation temperature in accordance with Paragraph 2.4- Figure out the differential expansion of vessel and reboiler at the maximum

operating temperature, and check the stress.- Calculate the elongation of reboiler (fixed tube). (Refer to Fig.10.7-T).

Fig. 10.7-T - Calculation of reboiler elongation

L1 : Tube LengthL2 : Tube Sheet → Outlet Nozzle positionL3 : Tube Sheet → LEG positionTs : Shell side temperatureTt : Tube side temperatureAs : Shell sectional areaAt : Tube metal sectional areaα : Linear expansion coefficientTsi : Shell side inlet temperatureTso : Shell side outlet temperatureTti : Tube side inlet temperatureTxo : Tube side outlet temperature∆L1 : Elongation of L1∆L2 : Elongation of L2∆L3 : Elongation of L3∆L : Total elongation

( )∆L

L Ts As Tt AtAs At

11

=⋅ ⋅ + ⋅

+α

∆L Tto L2 2= ⋅ ⋅α

∆ ∆L LLL

3 131

=

∆L=∆L2+∆L3

TtTti Tto

=+

2

, TsTsi Tso

=+

2

(ii) Stress check of piping and nozzlePerform analysis by using ADL PIPE or CAESAR II.

10.7.2 Piping Design around Aluminum Heat Exchanger(1) Concept of Aluminum Heat Exchanger (Plate fin type heat exchanger)

(a) A heat exchanger composed of the combination of elements consisting of two flataluminum sheets and a corrugated fin brazed to them. Fluid will flow through the gap ofthe corrugated fin and heat exchange will be made through the fin and flat sheets. (Referto Fig.10.7-U).

Fig 10.7-U - Construction of aluminum heat exchanger

(b) Advantage(i) Very compact and lightweight as compared with tubular heat exchangers since heat

transfer area from several to ten times can be obtained with the same volume.(ii) Highly efficient in heat exchange and thermal loss is little.(iii) Being made of aluminum, cheap in price as low temperature material.(iv) Flow patterns are diverse.(v) Heat transfer performance can be maintained at a high level even when the flow

speed of fluid is small by contriving the shape of fin.(c) Disadvantage

(i) Cleaning is difficult, so that the use is limited to the case with no dirtiness or to thefluid cleaned by filter.

(ii) The component material is practically limited to aluminum.(d) Several heat exchangers are gathered under a shelter for retention and cold insulation.

For cold insulation, pearlite and the like are filled between the shelter and equipment andnitrogen is constantly purged for dehumidification. (Refer to Fig.10.7-V).

Sheet

Fin

Side Bar

Fig. 10.7-V - Arrangement of aluminum heat exchangers in a shelter

(2) Determination of Nozzle Orientation(a) In principle, all nozzles except those for instruments shall be installed on the rack side.

(Refer to Fig.10.7-W).

Fig. 10.7-W - Arrangement of nozzles of aluminum heat exchanger

When a connecting equipment is adjacent, it may be convenient at times from the pointsof piping arrangement, thermal stress and allowable load on nozzles if the nozzles werearranged on the opposite side of the rack. The change of nozzle direction is possible bythe manifold of heat exchangers, so consult with the manufacturer. (Refer to Fig.10.7-X).

Fig. 10.7-X - Replacement of nozzle of aluminum heat exchanger

(b) As rule, the platform and ladder shall be located on the access side. Thought shall begiven to secure access to the platform since strainers will be installed on each entrancenozzle of heat exchangers and access is required for additional tightening.

N2

Access area

Piping Rack

(3) Precaution for Piping Plan(a) Since the load permissible for nozzles is small as compared with carbon steel make,

obtain the confirmation of manufacturers on the permissible load and moment andexercise extra care for the design of support.

(b) Obtain the confirmation of manufacturers on the shift of nozzles since the permissibleload is small and the shift of nozzle is unexpectedly large.

(c) Install the clips for support in advance since no field welding will be done to avoidtroubles.

(d) Insulate the contact points of aluminum and steel materials to protect them fromgalvanic corrosion.

(e) Aluminum flange is soft, so protect it by inserting a washer.(f) Since aluminum flanges are generally thick, the bolts to be used will become specials(g) Use sheet gasket for flanges so as not to cause scratch on the flanges. (Check with H-

103).(h) Strainers are often installed on entrance nozzles, so that exercise care in pulling out the

elements.

10.7.3 Piping around Air Fin Cooler(1) Precaution for Layout

Determine the layout of air fin coolers by giving full consideration to the following items:(a) Consideration for maintenance

- As rule, air fin cools shall be so laid out to permit maintenance by use of crawlercranes.

- When installing air fin coolers on frames or pipe racks, adequate care shall begiven for the removal and installation of bundles, fans and driving units. In suchcase, bring the legs of air fin coolers fitted to the columns of pipe rack as much aspossible.

- A platform will be installed for an air fin cooler for its maintenance and operation.The method of access to the platform shall be fully examined.-

(b) Relationship with other Equipment- In the installation of air fin coolers, care shall be paid to assure that no air

interference will be caused by avoiding to install air fin coolers greatly different ininstallation height in a close proximity or avoiding a layout design in danger ofsucking smoke discharged from a heating furnace. Dimensions marked with * inthe Fig.10.7-Y shall be carefully examined before decision is made.

- It is desirable to avoid installation on top of high temperature objects like a heat oilpump and high temperature piping. When installation is unavoidable, a shieldingplate shall be installed between the both parties to assure not to accelerate theexpansion of fire should a fire breaks out on the side of a heat oil pump due to theleak of oil.When installing such a shielding plate, air suction area will be limited that much sothat it shall not be forgotten to present the fact to the vendor as a design condition.

(c) Piping around air Fin CoolersPiping support shall be taken from pipe rack or the column of air fin cooler shall beextended.

Air fin cooler on top of a pipe rack Air fin cooler on a frame Heating furnaceand high temperaturedevice

Fig. 10.7-Y - Examples of layout of air fin coolers and other equipment

(2) Precautions for PipingThe following points shall be emphasized in particular in the piping arrangement around airfin coolers:(a) When an air fin cooler consists of a plural number of tube bundles, piping arrangement

will have to be made in such way to assure uniform distribution of fluid to each tubebundle as far as possible. Distribution will become better in the order of (A), (B) and (C)which show typical shapes of manifold for uniform distribution of fluid. (Refer to Fig.10.7-Z).

Fig. 10.7-Z - Typical shapes of manifold

(b) Since the permissible value of force and moment acting on the nozzle is very smallbecause of the construction of air fin coolers, thorough examination shall be made ofsupport points and methods and the countermeasures against thermal expansion in thedesign of piping. If any excessive force or moment is applied, the tube bundle will bendbackward to cause troubles like the occurrence of leak in the connection with tubesheets.

(c) The force and moment permissible on nozzles shall be determined in accordance withthe followings:[ ] API STD 661 2nd EDITION (5.1.11)[ ] Values specified by vendorsNote : To be less than the double of APISTD661. Up to 2.5 times, however, decision

shall be made after informing to and consulting with Heat Transfer DesignDivision.

(d) As regards the precautions on clearance between the tube header and frame, etc.,reference shall be made to DEPT. INSTRUCTION 04-02.

10.8 Spacing between Pumps

10.8.1 Cautions on pump Layout

(1) Spacing between Pumps

- The space between pumps should be a minimum of 600 mm measured from outer surface ofpump foundations.

- Table 10.8-A below shows the standard spacing to be referred to in the preliminary pump layout ofplot plan.

TABLE 10.8-A DISTANCE BETWEEN PUMP CENTERS

SUCTION PIPESIZE

PUMP SIZE A

<2 NPS Small Pump(<20 KW) 1.2 m21/2~5 NPS Medium Pump(20~100 KW) 2.0 m6~14 NPS Large Pump(>100 KW) 2.7 m~3.0 m16~18 NPS Large Pump 4.0 m

(A: Distance between Pump Centers)

* In case of access routes, the effective width of the passage should be a minimum of 800 mmexcept for valves and pump consoles etc.

* Motor cables shall also be considered.

* Attention should also be paid to devices for mechanical seals (such as pots, etc.) as they tend toprotrude

- To determine pump spacing, the following shall be duly considered:

- Providing ample space for pump maintenance.

- Providing the required space to operate valves during pump operation.

- Determining the nozzle layout of pumps; in case of side nozzles, the space requirements shall beduly considered.

- In case of limited pipe space or small pumps, two pumps may be set on one foundation.

- In case that the driver is a turbine, the space for the installation of control valve shall be dulyconsidered.

Min. 600mm*

Min. 600mm*

Min.600mm

*

ValidWidth

- Spacing between lined up pump groups ???? (refer to Fig 10.8 -A)

Fig 10.8 -A Spacing between lined up pumps groups

(2) Pump Line-up

- For the line-up of pumps one of the following methods shall be selected:• The method of lining up pump discharge nozzles

This method is often used for lining up many centrifugal pumps as the appearance of them linedup with their piping aligned is quite aesthetic (refer to Fig. 10.8B).

Pump Side

Fig. 10.8-B Lining up of Discharge Lines of Pumps

• Line-up of Pump Side Foundation FacesThis method is used in case that a passage or common drain is provided in front of the pumps.

Pump Side

Motor Side

Fig. 10.8-C Line-up of Pump Side Foundation Faces

Way for Maintenance and Operation

Motor side

• Line-up of Motor Side (Driver Side) Foundation FacesThis method shall be used in case that a passage is provided at the motor side of pump. Thismethod should preferably be applied to the layout of pumps of the same size. It is alsoadvantageous in cases where electric cables are laid underground (refer to Fig. 10.8-D).

Pump Side

Motor Side

Fig. 10.8-D Line-up of Motor Side Foundation Faces

• In consideration of the piping layout and maintenance accessibility for vertical type pumps, thelineup should be based on the centerline of the pumps (refer to Fig. 10.8-E).

Fig. 10.8-E Line-up of Vertical Pumps

- In consideration of operation, passage and safety, pumps with similarly laid out suction lines (e.g.ground lines, vertical lines etc.) should be consolidated into a group.

- In case of large pumps, coordination with the Vendor’s is necessary with regard to specialrequirements for layout and safety inspection.

(3) Height of Pump FoundationIn case that there are many pumps lined up, the height of the pump foundations shall be fixed at auniform level (normally 300 mm) (refer to Fig. 10.8-F).

Floor

Fig. 10.8-F Philosophy of Alignment of Pump Foundation Heights

- For special pumps, the height of the foundation shall be determined based on the type of pumpand the piping installation height.

(4) Maintenance Space

- Overhead clearance of the piping of horizontal-type pumps shall be at least 2.5 m.- When determining the overhead clearance of vertical-type pumps the casing removal length shall be

considered.If the maintenance access by crane to a pump or motor is difficult, the space above it forremoving the pump or motor including a hoist beam and hoist, as well as sufficient access spacearound the unit for a maintenance truck shall be provided. However, as the type of maintenance isdifferent for various pumps, confirmation by the pump vendor is required.

10.8.2 Piping around Centrifugal Pumps

For Detail Piping Plan, refer to TEG1-1313-003 “Pump Piping”.

Note : If the pumps are installed under apiperack, sufficient maintenance spaceshall be considered. However if thereis interference with the rack piping thepumps shall be set up outside of thepiperack.

Usually300mm

(1) General notes on Piping Layout

Smooth pump operation is also affected by the piping design. In order to secure trouble freecontinuous operation the following shall be carefully considered when designing the piping:

(a) Cavitation

Cavitation is the cause of noise, vibration, erosion and hence inferior performance of pumps.

(b) External Forces and Moments on NozzleUndue load on pump nozzles may cause de-centering and hence abrasion of bearing or

vibration.

(c) Flow Deflection of Suction LineDeflection of flow in the suction line may cause unbalanced flow through the impeller and is the

source of noise, vibration, and hence inferior performance of pumps.

(d) Operation and MaintenanceEasy access to and space around pumps shall be provided to secure safe start-up, change-over

to spare unit, daily inspection, and maintenance.

(e) The piping around pumps may be laid out in various patterns; the arrangement therefore shall becoordinated at the beginning of the job.

(2) Notes on Suction Piping Layout

(a) Cavitation

If there are air pockets in the suction line, this air tends to expand and cause negative pressureduring operation, thus leading to inferior pump performance due to bigger frictionalresistance, formation of cavities, and pipe vibration.

(i) Suction piping should be as simple and short as possible so that pressure loss is minimized.Bends should be as wide as possible by using long radius elbows wherever possible. Ingeneral, short radius elbows should not be used (refer to Fig. 10.8-G)

Fig. 10.8-G Use of short elbows

Do not use short elbows. *)

*) Short elbows are liable to incur pressureloss by deflecting flow.

(ii) In case that a long suction pipe is used, a slope of 1/50~1/200 towards the pump shall beprovided (refer to Fig. 10.8-H).

Fig. 10.8-H Suction Line

(iii) Top-suction piping and the supports shall be designed to prevent air traps ( ) and pockets( ). Horizontal suction piping shall be designed to prevent air pockets by thermalexpansion of piping (refer to Fig. 10.8-J) .

Fig. 10.8-J Top-suction Piping Design

(iv) Suction piping from vacuum towers (refer to Fig. 10.8-K)

Fig. 10.8-K Suction Piping from Vacuum Towers

Good Bad

Slope Air pocket

Design the lines with slope toprevent drain accumulation or airpockets.

Suction lines fromvacuum towers shallhave a slope of min. 1/12towards the pump.

Over 1/12

(v) In case of change of suction pipe size, top-flat reducers shall be used to prevent air pockets(refer to Fig. 10.8-L).

Fig. 10.8-K Suction Piping with Reducer

(iv) Where the liquid level is higher than the pump suction, the suction pipe reducer shall bearranged as shown below (refer to Fig. 10.8-L).

Drain valve required

Fig. 10.8-L Suction Piping with Reducer

(Reference) If L<10D

Air pocket

Air pocket

Bad Bad

Good Good

Note)Note) See EXXON BP-3-3-2

* Do not use this arrangement except whenrequired by customer.(This method is used by Lummus, but notaccepted by ESSO)(This method is generally used by IDEMITSU)

(vii) Large gate valves shall preferably be installed sideways (refer to Fig. 10.8-N).

Fig. 10.8-N Arrangement of Large Gate Valves

(b) Minimum required length of straight pipe at suction nozzle

(i) End suction piping (refer to Fig 10.8 -P)

Over 2D

Fig 10.8-P End suction piping

(ii) Side suction piping (refer to 10.8-Q)

Fig 10.8 -Q Side suction piping

Air pocket area

Bad Good

- Big Size (12” 150#)- Support valve bonnet to

prevent bendingmoments

(a) Single suction Over 10D orinsertion of alaminar plate(2D or morefor singlesuction)

(b)Doublesuction

No special consideration isrequired for straight run ofpipe when the suction pipe isvertically set up or not. In the case of double suction pump, measures should be

taken against deflecting flow. Defecting flow will makeimpellers unbalanced, which causes a decrease in pumpcapacity as well as in the life of thrust bearings.

(iii) Top-suction piping (refer to Fig 10.8 -R)

(a) (b)

Fig 10.8-R Top suction piping

(c) Maintenance

(i) Suction piping shall be designed so that the impeller can be removed without moving thepump. (refer to Fig 10.8-S)

Fig 10.8 -S Removal of impellers

(d) Installation detail of suction piping and suction characteristics

As the velocity of a fluid at suction intake must be as low as possible in order to prevent suctionvortices, the suction piping should be as straight as possible and submerged into the fluid at asufficient depth to avoid air from being sucked in. The formation of a vortex around the suction lineallows air inflow, which in turn causes pump vibration and noise.

Single suction :Over 2D

Double suction :No specialconsiderationis required forstraight run ofpipe

Single suction : Over 2DDouble suction : Over 10D

Pump Pump

Consider to removal length ofimpellers (depending on the pumptype this may not be required;confirm with mechanical designdiscipline)

(i) Sucking in of air and local vortex (refer to Fig 10.8-S)

Fig 10.8 -S Sucking of air and local vortex

(ii) Detail of suction piping installation (refer to Fig 10.8-U)

Local vortexA local vortex occurs when water is sucked downfrom the surface in a spiral. It continually appearsand disappears. If the head point of vortexreaches the suction intake, air inflow into thepiping results.

Column vortexWith a column vortex, the water whileundulating, lowers and rotates fast around thesuction pipe, which results in a considerable airinflow.

(a) Local vortex (b) Column vortex

Waterway (improper)

Water way(acceptable)Waterway

(proper)

(a) (b)

Installation of bent suctionpiping

Installation of horizontalsuction piping

(c) (d)

ITEMBell Mouth Flare D 1.43 - 1.33dGap Bottom-Pipe C 1.5 - 1.0dSubmerged Depth S >1.5dGap Tank Side-Pipe B1 <1.5dGap Pipe-Pipe B2 >3d

Fig 10.8 -U Detail of suction piping installation

(iii) Layout of suction channel in water tank (refer to Fig 10.8-T)

(Bad) (Good)

Fig 10.8-V Suction channel in water tank

(iv) If water is recirculated to the water tank above the water level, there is a possibility that air isentrained with it that may be sucked in again. The end of the return line should therefore besubmerged below the suction water surface, and also be installed as far as possible away fromthe suction piping of pumps, or a baffle plate should be installed (refer to Fig 10.8 -W).

Note:• ???• If sludge accumulates on the pit bottom, thedimension C shall include a respective tolerance.• ???

Fig 10.8-W Layout of return piping

(e) Strainer

(i) Type of strainer

- Temporary strainer

During start-up operation, a temporary strainer should be mounted close to the pump suction in order toprotect the pump from dust, sand and pieces of iron that may enter the piping during construction.(conical types for suction pipes under 4 in. and T-type for suction pipes over 6 in. ???5in.???).

- Permanent strainerA permanent strainer should be used where the fluid contains foreign materials. Locations requiringthe installation of a permanent strainer are indicated in P&I flow diagram. (Y-types for suction pipesunder 3in., T-types for suction pipes over 4in. ????)

The above shall be the standard for the type of strainer, while details are indicated in P&ID and UFD.

(ii) Position for the installation of strainer (refer to Fig 10.8-X)

- Accessibility for maintenance and cleaning- Removability in connection with piping arrangement and supports

Return water

Pump

Detach

Note: If a foot valve is installed, pump damagecaused by back pressure (waterpressure) while the valves is open mustbe prevented.

Fig 10.8-X Position of strainer

(f) In case that several pumps are installed in line and operated simultaneously using a common suctionpipe, unstable pump operation due to air pockets and other negative effects may result. Pumps shouldtherefore be installed with their own suction pipe as much as possible. If common suction piping cannot beavoided, it should be designed for as low a flow velocity as possible by selecting a sufficiently big pipediameter and to prevent air pockets by measures such as maintaining the same pipe diameter up to the lastpump in line.

(3) Cautions on discharge piping layout

(a) The gate and check valves installed in discharge lines shall be located in the horizontal pipesection as close to the pump as possible (refer to Fig 10.8-Y).

Fig 10.8-Y Installation of gate and check valve

3”

4”

4”

6”

P&I Codes Types Examples

Parmanent

Temporary

MinimumNote: EXXON BP3-3-2 specifies instead of a

mini-flow line also a check valve with ahole in the disk.

(b) Installation of pressure gauge (refer to Fig 10.8-Z)

Single Double Triple

Fig 10.8 -Z Installation of pressure gauge

The pressure gauges shall be aligned for viewing as per above Figure.As a rule, pressure gauges shall be installed at the right side of the pumps. If there is not enoughspace above the pipe, the mounting boss for the PI shall be turned 45° towards the discharge valve(within the visible range).Pressure gauges shall be installed where they are visible from the discharge valve as well as theswitch box of pump.

(c) Draining of pump discharge pipingDrain nozzle shall be installed between pump discharge piping and check valve or check valve andblock valve. In case that a drain nozzle is installed at the check valve a short pipe shall beprovided????. In case of check valves smaller than 4in, 3/4in. nozzles can not be installed.????

(d) From the view point of maintenance, no piping shall be installed above pumps (this also includesthe motors).

(e) Air pockets in suction pipes cause piping and pump to vibrate and damage in the long run. Air ventsshall therefore be installed at a suitable location.

(4) Orientation of pump nozzles (reference)

The nozzle arrangement may be changed depending on the type of pump. Nozzle layout shall bedetermined in consideration of the height of suction nozzle, height of operation valve etc.. A change ofthe nozzle arrangement shall only be done after coordination with the mechanical design supervisor(refer to Table 10.8-B).

Table 10.8-B Layout of pump nozzles

(5) External forces on nozzle

(a) The pipe design shall be such that the thermal expansion of piping does not cause undue load onthe pumps. In case of standby pumps, according to the operation conditions check the pipingroutes by taking into account the temperature difference of piping.

(b) The piping configuration and support design shall be such as to preven undue load of piping andvalves on pumps.

SuctionnozzledirectionDischargenozzledirection

Configuration

RightRightRight

RightRightRight

LeftLeftLeft

LeftLeftLeft

Up UpUp

UpUpUp

SuctionNozzle

DischargeNozzle

(c) Standards for acceptable limits of external forces on pumps:

� API STD 610� Value specified by Vendor

(6) Auxiliary Pump Piping

(a) Types of auxiliary piping

There are the following auxiliary piping for pumps; depending on the pump, these support pipingsvary. In the final stage, when the vendor drawings are received, it necessary to revise the pipingdrawings accordingly. ????

- DRAIN- VENT- AUXILIARY PROCESS FLUID (VENT, DRAIN, BALANCE LINE, PRODUCT FLUSHING)- STEAM- COOLING WATER- INJECTION OF EXTERNAL LUBRICATING OIL

(b) Cooling water and drain piping (refer to Fig 10.8-AA)

Fig 10.8-AA Cooling water and drain piping

(7) Arrangement of piping

The types of piping layout shall be unified at the beginning of a Job based on the following pumpsuction and discharge piping patterns. Attention shall be paid to the fact that there will also be Vendordrawings drawn in a style other than the basic trigonometric style.

(In case of recalculation)

CW ReturnCW supply

Note)

Note)

Casing Drain

Drip Funnel

PT thread

PT thread

(In case of drain)

Though Mfg. STDgenerally specifiesscrew type, thisconnection shall beflanged.

Pump bed drain(materials to bedesigned by pipingdepartment)

Note : Cooling watersupply and returnline valves shall beseized by TEC (incase they areseized by maker,they shall beinstalled at alocation,considering pumpmaintenanceaccess and

(1) For slurry lines the dimensions should be minimized.(2) Reducers installed shall be Bottom Flat type.(3) When pump space for maintenance is needed, the down stream piping of strainer shall be removed.

Tank

Y-typestrainer

Pump

Min. 2xdMainte.

End suction (from Tank)< line size 3in. >

(1) For slurry lines the dimensions should be minimized.(2) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(3) Reducers installed shall be Bottom Flat type.(4) When pump space for maintenance is needed, the down stream piping of strainer shall be removed.(5) In case the space for maintenance is not required, strainer outlet shall be of butt weld type

End suction (from Tank)< line size 4in. and over>

Tank

Strainer

Pump

Min. 2 x dMainte.

Principlenot use.

(1) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(2) The strainer outlets shall be of butt weld type.(3) Reducers installed should be Bottom Flat type.(4) ????In case the both-side suction, it shall be installed 10xd size or rectifier boad. In case the one-sidesuction, should be a minimum of more than 2xd size.

Tank

Strainer

PumpSUC

Principle notuse

Side suction (from Tank)< line size 4B and over>

(1) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(2) The strainer outlets shall be of butt weld type.(3) Reducers installed should be Bottom Flat type.(4) ????In case the both-side suction, it shall be installed 10xd size or rectifier baod. In case the one-sidesuction, should be a minimum of more than 2xd size.

Side suction (from Tank)< large line size >

Tank

Strainer

PumpSVC

(1) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane. If the valve handle is not horizontal, the disk of gate valve will be prone toerosion?????(2) Reducers installed shall be Top Flat type.(3) In case the end type suction or one-side suction, it should be minimum of 2xd. But in case the both-sidesuction it shall be install 10xd size or rectifier board.?????(4) In case that space for pump maintenance is required, remove the downstream piping. However, if there is afoot valve, a flange shall be provided.(5) In order to prevent sucking wood etc., a screen shall be installed in the suction line.(6) There are two types of suction valves: gate valves (with trumpet piping) and foot valves.

End suction /Side suction (from pit)

Screen (5)

PumpSVC

Mainte.

Foot valve orGate valve

(1) For slurry lines the dimensions should be minimized.(2) Reducers installed should be Top Flat type.(3) In case that space for pump maintenance is required, remove the downstream piping.(4) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(5) It should be confirmed that drain mouth and the pump foundation do not interfere.

(a) Min. 2 x d

End suction (from Tower)< line size 3in. and below >

Tower

Y-type strainer

¾” Drain(a)

PumpSVC. Maint.

(1) Reducers installed should be Top Flat type.(2) In case that space for pump maintenance is required, remove the downstream piping.(3) It should be confirmed that drain mouth and the pump foundation do not interfere.

(a) Min. 2 x d

End suction (from Tower)< line size 3in. and below >

Tower

Y-type strainer

¾” Drain

PumpSVC.

(a)

Mainte.

(1) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(2) For slurry lines the dimensions should be minimized.(3) Reducers installed should be Top Flat type.(4) In case that space for pump maintenance is required, a flange shall be provided after the strainer andthe downstream piping be removed.(5) In case the space for maintenance is not required, strainer outlet shall be of butt weld type

Tower

Strainer

End suction (from Tower)< line size 4in. and over >

¾” drain

Min.2 x d

PumpMaint.

Principle notuse

(1) Reducers installed should be Top Flat type.(2) In case that space for pump maintenance is required, a flange shall be provided after the strainer andthe downstream piping be removed.(3) In case the space for maintenance is not required, strainer outlet shall be of butt weld type

Tower

End Suction ( from Tower)< line size 4in. and over >

Principlenot use

Strainer

¾”drain

Pump Min.2 x d

Mainte.

(1) In order to prevent air pockets, gas pockets (hot oil line etc.) at valve bonnet, the valve handle shall berotated to the horizontal plane.(2) For slurry lines the dimensions should be minimized.(3) Side suction shall be a minimum of 2Xd size, both-side suction shall be a minimum of 10xd size.????

Tower

Top suction (from Tower)< line size 4in. and over >

Strainer

Principle notuse

PumpSVC.

(1) Side suction shall be a minimum of 2xd size, both-side suction shall be a minimum of 10xd size.????

Tower

Top suction (from Tower)< line size 4in. and over >

Strainer

Principle notuse

PumpSVC.

(1) For slurry lines the dimensions should be minimized.(2) ??(3) The drain method shall be determined according to the respective job specifications.(4) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(5) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(6) Motor switch should be located away from the gate valve.

Top discharge

Pump

Local Swtich

Motor

(1) Install a piping between check valve and gate valve, because under 4in. line size can not be installed onvalve.????(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) Motor switch should be located away from the gate valve.

Top discharge

Pump

Local Switch

Motor

(1) Install a piping between check valve and gate valve, because under 4B line size can not be installed onvalve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) Motor switch should be located away from the gate valve.

Top discharge

Pump

Local Switch

Motor

(1) Install a piping between check valve and gate valve, because under 4B line size can not be installed onvalve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) To determine the piping route, confirm the installation side of motor switch and cable with the electricaldepartment, and decide on the location of the pipe supports.(6) For the space pumps required the gate valve handles etc. shall also be considered.

Top discharge

Pump

Local Switch

Motor Cable

Motor

(1) Install a piping between check valve and gate valve. Because under 4B line size can not be installed onvalve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) To determine the piping route, confirm the installation side of motor switch and cable with the electricaldepartment, and decide on the location of the pipe supports.

PumpLocal Switch

Motor Cable

Motor

(1) Install a piping between check valve and gate valve, because of under 4B size line can not be installedat valve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) To determine the piping route, confirm the installation side of motor switch and cable with the electricaldepartment, and decide on the location of the pipe supports.(6) Installation level of check and gate valves should be aligned with the center line of pump.

Pump

Motor Cable

Motor

Top Discharge(for high temperature and high pressure)

SwitchLocal

(1) Install a piping between check valve and gate valve, because of under 4B size line can not be installedat valve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers should be installed near the pumps.

*In general, reducers should not be installed in horizontal line, because the flow velocity becomes toofast and may cause trouble.

(5) To determine the piping route, confirm the installation side of motor switch and cable with the electricaldepartment, and decide on the location of the pipe supports.(6) Installation level of check and gate valves should be aligned with the center line of pump.

Top Discharge(for high temperature and high pressure)

Pump

Motor Cable

SwitchLocal

Motor

(1) Install a piping between check valve and gate valve, because of under 4B size line can not be installedat valve.???(2) The drain method shall be determined according to the respective job specifications.(3) Pressure gauges should be installed where they are visible from the operation point of the gate valve.(4) Reducers installed should be Bottom Flat type.

Side Discharge

Local SwitchPump

Motor

(1) Reducers installed should be Bottom Flat type.

Side Discharge

Local SwitchPump

Motor

BFW Pump SuctionFig 10.8-AB Piping layout of BFW Pumps

Strainer

Min.2 x d

Pump

Principle notuse

Turbine

(1) Reducers should be installed near the pumps(2) Reducers installed should be Bottom Flat type.(3) If possible, ARC valves should be installed as close to the pump as possible.

*In general, ARC valves have to be installed in horizontal lines, and require therefore the coordinationwith the Instrument Design Department.

(4) Mini flow by-pass and balancing lines tend to vibrate and should therefore be sufficiently supported.(5) Flanges shall be provided in the mini flow line in order to maintain the ARC valve.

BFW Pump DischargeFig 10.8-AC Piping layout of BFW Pumps

10.9 Piping Around Centrifugal Compressor And Turbine

10.9.1 Precautions required in regard to layout

(1) Space around compressorAround any compressor, there shall be secured a space for installation of auxiliaryequipment, a space for temporary storing parts during disassembling or inspection, and aspace to be used as passageway.The auxiliary equipment includes: pump, oil cooler, filter, tank, etc. constituting lube-oilsystem or seal-oil system of centrifugal compressor; knock-out drum, pulsation damper,intercooler, aftercooler, etc. of reciprocating compressor; and, condenser when steam turbineis used, etc., and the required space differs from compressor to compressor depending on itstype. So, it is required to confirm informations, if necessary, in asking the vendor.

(2) Spacing between compressors-When any two compressors are to be installed in parallel, the spacing shall be half the widthof the larger compressor, or more. However, it shall be min. 1.5m. (Refer to Fig. 10.9-A.)

Fig. 10.9-A Spacing between compressors

-When compressors are to be installed in rows, the spacing between rows shall be min. 1.5m.-In case of centrifugal compressors of small type, the spacing between them may bedetermined in the same way as in case of pumps. (In a rough standard, compressor of smallsize means those of 149kW or less.)

(3) Maintenance space-The space necessary for maintenance work is different depending on the manufacturer ofthe equipment. So, detailed informations shall be confirmed in asking the manufacturer.-When the centrifugal compressor is of barrel type (vertical split type), a space to be utilizedfor drawing-out of rotor shall be secured.-When any compressor is to be installed indoor or under a rack such that no mobile cranecan be used at the time of its maintenance, a hoist or an overhead crane shall be provided.-The overhead room above any compressor shall be determined, having in view theclearance for lifting-up of its parts.

(4) Others

(a) Installation position of local panel Local panel for compressor shall be installed within anarea wherein starting, stopping, increasing/decreasing of load (or changeover), etc. of thecompressor can be visually observed from the position of manipulation.

(b) The relation between the compressor proper or turbine proper and the oil unit, in regard tothe layout and height, shall be studied sufficiently, because there may be gravity-flow line,for instance. Moreover, study shall also be made on the arrangement of auxiliaryequipment, such as oil head- tank, etc.

10.9.2 Method of piping design (general)

Over W1/2 (Min. 1.5m)

Regarding detailed piping planning, refer also to TEG-1313-002 “Design standard for piping aroundcompressor/turbine”.

(1) Examples, as a standard, of rounding-about of pipingSome simple examples of how to determine the piping route and fixing point in order to haveless external force/moment effected to the compressor-nozzle or turbine-nozzle due to thepiping, are shown in the following.

(a) Method of determining the position of fixing point within horizontal plane.When, in Fig. 10.9-B, the nozzle at the part “A” moves in the direction of minus ∆X by theamount of ∆Xmm, the fixing point of the piping “B” shall be determined to have „Þ1 insuch a way that ∆X=?1.?

where,∆X : Amount of movement of nozzle in the direction of X-axis (mm)∆Z : Amount of movement of nozzle in the direction of Z-axis (mm)δ : Elongation of piping material (mm/m)

1 : Distance in the X-direction from “A” part of nozzle to “B” part of fixing point

2 : Distance from the center line of the compressor or turbine to the nozzle

Fig. 10.9-B Determination of fixing point within horizontal plane

(b) Method of determining the vertical-direction position of fixing point (Refer to Fig 10.9-C.)Also in regard to the vertical direction (direction right angle to the axis of the compressoror turbine), the method is the same as (a). However, when the nozzle is downwardlyextending, the movement shall be absorbed by the flexibility within horizontal plane,because, if the piping is turned back to the fixing point of the compressor or turbine, itwould come out above the floor.

Fixed point

Fixed point of in thedirection of X-axisPlane

Fixed point of in the direction of Z-axis

Fig 10.9-C Determination of vertical-direction position of fixing point

(2) Determination of actual piping route (planning)In Par,10.9-2(1), only the fundamental concept was explained. So, when determining actualrouting, attention shall also be paid to the followings.

(a) The routing shall be determined in the order beginning from the piping of highertemperature, larger diameter, and larger wall thickness (inlet and outlet piping ofcompressor and piping of turbine, at first).

(b) The position of cooler and separator may be determined, based on the general concept oflayout. However, if the result of study on the routing of the piping showed that it isunreasonable, the arrangement shall be altered at once, and then the route shall bedetermined.

(c) When reduction of the reaction force exerted to the nozzle cannot be attained bydetermination of arrangement, provision of fixing point, etc., or, when it is difficult orimpossible to provide fixing point, a loop may be provided. However, alteration of straight-part pipe length, alteration of the position of fixing point shall be made within the wholesystem, such that increase in the number of fittings (elbows) be avoided, as far aspossible

(d) When flexibility of piping cannot be attained within the large-diameter piping at the inletside of the compressor or the piping between the turbine and condenser, a bellows-typejoint shall be used. (Refer to Par. 10.9.2(6).)

(e) Also the method of routing of branch piping is the same as (a)-(c). It is required to checkon the effect brought about by branch pipings (minimum-flow bypass piping, piping tosafety valve, etc.), by means of thermal stress analysis.

(f) When there is a valve in the midway of piping, the position of the valve shall bedetermined, taking into consideration for various cases, such as changeover of running,warming-up running, etc. Attention is required especially for the installation position ofvalve on the steam piping around the turbine, and, the position and method of fixing ofminimum-flow bypass piping of the compressor.

(3) StrainerA strainer shall be provided at the suction piping, in order to avoid accidental damage ofimpeller due to sucking of foreign matter or drain, and a draining device shall be provided atthe lowest part of the suction piping or at the installation place of strainer. The drainingdevice shall be of the size of 3/4B(B: nominal dia.) or larger, and shall include, as required bythe actual situation, a drain trap (when under low pressure and frequent draining must bedone), or a set of double valves (when under high pressure of 100kgf/cm2 or more).

Moreover, the strainer shall be installed at a place near to the inlet nozzle, as a rule, forconvenience of maintenance. At the downstream side of the installation-position of strainer,no branch pipe, thermometer, etc. shall be installed. Standard installation methods are asshown in Fig. 10.9-D, where, Type A and Type B shall be used, as a rule.

Fig. 10.9-D Fixing of strainer

(4) Shape of inlet piping (Refer to Fig. 10.9-E.)

Type-A

Type-B

Type-C

* To be used for low pressure piping(flange of Class 300 or lower, as astandard. Actually used in ethyleneplant.)

* Re-alignment of compressor is notrequired even when the strainer wasremoved.

* Suitable for high pressure piping (flange of Class 300 orhigher, as a standard. Actually used in ammonia plant.)

* Re-alignment of compressor is not required even whenthe strainer was cleaned.

* In case of high pressure, the drain valve shall be a set ofdouble valves, when necessary.

* Strainer shall be fixed by welding.

TO COMP. NOZZLE

MIN. 6” HAND HOLE

- The piece A shall be a spool pipe with flanges. Not suitable for flanges ofClass 400 or higher.

- Re-alignment of compressor is required each time the strainer is removed.

Peace A

(a) At the upstream side of inlet nozzle of the compressor, a straight pipe part shall beprovided, as a rule, in order to avoid lopsided flow. The straight pipe part shall be of thediameter same as the nozzle, and of the length of 2D (D: nominal dia. of nozzle) or more(not including the length of reducer). In some cases, it shall be 2D or more, as required bymanufacturer.

(b) Elbows shall be of long elbow type.

(c) When tee is to be used in place of elbow, the length of straight pipe part shall be 6D ormore.

Fig 10.9-E Shape of inlet piping

(5) Minimum flow bypass pipingMinimum flow bypass piping shall be provided as a safety device, in order to protect thecompressor by preventing surging at the time of starting. (This is indicated in P&I.) Refer toFig. 10.9-F.

Fig 10.9-F Minimum flow bypass piping

When planning minimum flow bypass piping, attention shall be paid especially to the followings.

(a) Generally, vibration is apt to occur, because the pressure difference across the bypassvalve is large. Therefore, if, according to Fig. 10.23-A of Par. 10.23.3 Anti-vibrationdesign, there is any region where vibration can occur, the bypass valve shall be fixedfirmly, and, at its downstream side, a straight pipe part of 10D or more length shall beprovided.

Over 2D

SuctionDirection

(b) Adjustment of the anchor point for prevention of vibration, and also of the flexibility ofmain piping, shall be made. (Refer to Par. 10.9.2(1).)

(6) How to use flexible jointsWhen using flexible joints within the piping system around the compressor and turbine,attentions shall be paid to the followings.

(a) Generally, flexible joints are to be used for the reasons as follows.

(i) The space is too narrow, so that it is difficult to provide piping with desired flexibility.(ii) The reaction force is too large, so that there is a problem in regard to the strength of

equipment nozzle to be connected to, or,it is required to provide too large a foundationor structure.

(iii) When any mechanical vibration comes propagating through the piping.(iv) When it is more economical to use a flexible joint than to provide a loop within the

piping (in case of low pressure, large diameter pipe).

(b) Where flexible joints are to be usedIt is as shown in Table 10.9-A.

Table 10.9-A

Place where flexible joints is to be used Reason- Piping between discharge nozzle of turbine and condenser 10.9.2(a)(i), (ii), (iii)- Piping around low pressure stage of compressor 10.9.2(6)(iii), (iv)- Oil return piping 10.9.2(6)(I), (iii)- Piping between condenser and underground cooling water piping 10.9.2(6)(a)(i)

(c) Attention to be paid in regard to the use of flexible joint

(i) When a flexible joint without stay nor hinge is used, an axial force corresponding to theinternal pressure or vacuum (sect. area x pressure) is exerted to the jointing partbetween piping and flexible joint. Attention is required especially in case of large dia.piping or of high pressure piping.

(ii) Even when a bellows type joint with stay or hinge is used, in order to cancel the forcedue to the internal pressure or vacuum, a force, which is proportional to the springconstant of bellows and is corresponding to the compression (or tension) or bending ofthe bellows, is exerted to the piping.

(iii) For calculation on pressure and calculation on life of bellows, refer to ASME B31.3

(d) Examples of how to use flexible joint (Refer to Fig 10.9-G - 10.9-L.)

Fig 10.9-G One bellows type joint without stay is used

Note 1: Load due to pressure shall be considered. Attention shall be paid especially to the allowableforce exerted to the anchor part and to the turbine. [NEMA (National Electrical ManufacturersAssociation) NO. SM23 PART 8]

Note 2: The relation between the compression (tension) force corresponding to the spring constant ofbellows and the allowable external force (Refer to NEMA SM23 PART 8.)

Note 3: In case of vacuum pressure, the piping is pulled towards the bellows, so, restraining againsttension shall be considered.

Fig 10.9-H One bellows type joint with stay is used.

Note 1: Load due to pressure iscanceled by use of stay.

Note 2: The thermal expansion ofvertical direction shall beabsorbed by flexibility of thepiping and bending of thebellows.

Fig. 10.9-J Two bellows type joints with stay are used.

Fig. 10.9-K Two bellows type joints with stay are used.

Note 1: Load due to pressure is canceled by use of stay (pressure balancer).Note 2: The thermal expansion of horizontal and vertical direction shall be absorbed by compression

or tilting of the bellows.

Fig. 10.9-L Three bellows type joints with stay are used.

Note 1: Load due to pressure is canceled by use of hinge.Note 2: In an actual example, one condenser was used for cooling of exhaust from two turbines.

Note 1: Load due to pressure iscanceled by use of stay.

Note 2: The thermal expansion ofvertical direction ∆L shall beabsorbed by the bellows. Thethermal expansion of lowerhorizontal piping ∆L’ and theangle θ produced by thermalexpansion of the piping shallbe absorbed by tilting of thebellows part.

10.9.3 Requirements in regard to piping design

(1) Requirements in regard to the strength of compressor proper

(a) Prescriptions in regard to limitation of the external moment exerted to thecompressor/turbine are as follows. However, in some special cases, the values andformula may be indicated individually by manufacturer.

(i) Prescription in regard to compressor appears in API (American Petroleum Institute)STANDARD 617.

(ii) Prescription in regard to turbine appears in NEMA NO. SM23 PART 8.Remark: Allowable value in regard to compressor set forth by API is 1.85 times thevalue set forth by NEMA.

(b) Compressor/turbine proper and its for-installation bed have been given necessarytreatment, such as heat treatment, before shipment. So, it is prohibited, as a rule, to applyprocessing (such as welding, drilling, etc.) to them, or to put load of support on them.

(2) Requirements in regard to process and to running-operation

(a) Study on requirements for the installation position of valves, control valves, safety valves,instruments, etc. from the view point of process and running-operation. In particular, theposition of pressure gauge on the suction line shall be at the downstream side of suctionstrainer, and the position of thermometer shall be at the upstream side of suction strainer.

(b) Study on the pressure drop across the check valve, to be installed at the outlet side ofcompressor, on the extraction steam of turbine, etc. (Note 1), the installation position ofsuch check valve (Note 2), and the effect brought about by such check valve on theperformance of compressor or turbine.

Note 1: Indicated on the purchase specification of valves.Note 2: Requirement for prevention of occurrence of chattering at the valve, and for

prevention of reverse turning of the compressor.

(c) Study on the draining deviceThe draining device shall be considered, not only at the lowest pocket part of the piping,but also at any part where drain can accumulate when valve is closed. (Refer to Fig. 10.9-M.) In particular, consideration is required, such that, when the main inlet valve of turbineis operated, draining of the upstream side of the main inlet valve is assured, by means ofa drain trap installed there. Moreover, when any branch pipe is to be provided to motherpipe, the branch pipe shall be at the upper side of mother pipe, such that drain cannotenter the branch pipe.

Fig. 10.9-M Fixing of drain valveIn some cases of piping, drain can accumulate also within valve, i.e. at the bottom part of valve box.So it is necessary to provide draining device at that part of valve. (Refer to Fig. 10.9-N.)

Fig. 10.9-N Draining from valve proper

(d) Confirmation of the relation between the straight pipe length, at the up- and downstreamside of the orifice or Venture tube, and the accuracy of instrument.When the prescribed length of straight pipe cannot be observed, because of a reason inregard to the piping method, confirmation shall be made on the minimum required lengthof straight pipe, because the allowable error of any instrument is different, depending onits purpose of use.

(e) Items to be confirmed in each case of head tank or pressure type tank for lube oil or sealoil.

(i) Checking on the height of tank, and on the oil pressure.(ii) Checking on the pressure loss for each piping route and size.(iii) Whether or not a presence of pocket within piping is allowed.(iv) Whether or not a gradient is necessary.

(f) Confirmation of relation between the height of condenser vs. condensate pump (NPSH)and the piping size or piping route (bends, pockets, etc.).

(g) The degree of gradient of lube oil- and seal oil return line. (in API, 1/24)

(h) Whether or not the temperature control of lube oil- and seal oil is necessary. (In somecases, lagging or steam-tracing becomes necessary.)

Drain valve

Drain valve

Main header

Swing-type???? valve

Multi-plate ????valve

Draining

(i) Confirm whether there is any vacuum line, and check on the strength of vacuum line.Moreover, the number or flanges to be installed shall be kept at minimum, so that dangerof vacuum line caused by sucking of air be prevented.

(j) Confirmation of the take-out position for safety valve, installation position of safety valve,and exhausting position of safety valve.The pressure loss at the upstream side (in API, 3%), the piping size and piping route ofexhaust side, which can affect back pressure, as well as the thermal stress and exhaust-reaction force.

(k) Confirmation on yes/no of steam tracing for process piping.

(3) Requirements in regard to safety and security countermeasures

(a) Confirmation shall be made on the items prescribed in the inland or overseas laws orregulations enforced in the plant construction site (Fire Service Law, regulation ondangerous objects and environmental conservation, Ordinance on Industrial Safety andHealth, etc.).

(b) Separation between the oil-related equipment/piping, process gas piping (combustible,explosive), and steam piping.

(i) Separation within horizontal plane, by so designating the direction of nozzles of thecompressor/turbine oil console, for example.

(ii) Separation in vertical direction, between overlapping oil piping and steam piping(steam in upper side, oil in lower side), for example.

(c) When discharging or recovering the effluent of combustible, inflammable, explosive, or toxicfluid, attention shall be paid to the followings.

(i) When exhausting to atmosphere, confirmation of the necessary height of exhaustingpoint, necessary safety distance to neighboring equipment, and necessary distance inregard to the accessibility to such equipment (rate of atmospheric diffusion, distance toany air intake port, distance to the heat source of furnace, etc.).

(ii) When vent is led to flare through a closed system, or is exhausted to the atmosphere.

- Whether or not protection device against reverse-flow or back-fire (flame arrested) hasbeen provided.

- Whether or not provision for maintenance of equipment/piping has been made.(Provision of valve for isolation from other system at the time of maintenance.)

- Checking on whether there is any problem in regard to pressure-resistance caused byreverse flow from back pressure.

- Insertion of for-replacement fluid.(iii) The method of exhausting or recovering of drain, and countermeasures in regard to

preservation of safety (to use double valves, breather valve, blind flange, etc.).

(d) Countermeasures against leakage of compressed gas, oil vent, steam, etc.

(i) Prevention of accident caused by gas-leakage from the oil-film-seal, etc. of seal oilsystem (to provide piping system separately for exhausting only and for leakage only,for example).

(ii)Method of venting for prevention of accumulation-in-room of combustible or toxic gas(especially in case of compressor room of shut-up type).

(e) In order not to cause mis-operation, valves, switches, instruments, and instrument panelsshall be given distinctive colors, and shall be arranged properly, valves being arrangedseparately according to the type of valve, for example.

(f) Problems concerning noise

When necessary, because of Customers circumstances for example, special valve of low-noise type (such as drag valve, Mason-Neilan valve, etc.) shall be used. In general, noise-producing piping shall have application of noise insulation. (Refer to Fig. 10.9-P.) Itsspecification shall be confirmed in asking Application Technology Dep.

Fig. 10.9-P Example of noise insulation work for piping

(4) Requirements in regard to construction work, pressure test, flushing, alignment, andmaintenance

(a) At the time of piping design, the piping design shall be done after understanding andstudy on the construction work method, as follows.

(i) Destination between pre-fabrication and field-fabrication.(ii) Matters related to welding, such as method and kind of welding, method of fabricating

weld preparation, method of annealing, method and grade of inspection.

(b) Pressure test of piping system (hydrostatic and pneumatic tests)

(i) Confirm whether the test is to be hydrostatic or pneumatic. In case of hydrostatic test,provide vent at the higher part and draining device at the lower part, without fail.

(ii) In general, hydrostatic pressure test of the piping around compressor or turbine iscarried out without passing water through the compressor (or turbine). Therefore, blindflange shall be inserted at the piping side of the part connected to the compressor orturbine. If the piping does not have flexibility enough to have blind flange inserted, thepiping shall be removed and flanges shall be installed at proper positions such that thetes can be done. (Refer to Fig. 10.9-Q.)

Fig. 10.9-Q Consideration required at the time of flushing

??? Blanket Execution pipe

0.25t Aluminum jacket board

0.4t x 20w Aluminum band

(iii) The load at the time of hydrostatic test shall be considered when designing supportsand support-fixing parts.

(c) Flushing of piping

(i) Gas-, steam-, and oil piping shall undergo flushing, after completion of pipingconstruction work, for perfectly removing any foreign matters, welding residues, rust,and others from inside of piping. If the flushing is imperfect, foreign matter can comeinto a high-speed rotating machine, such as compressor, and turbine, so that therotating machine be seriously damaged, causing a big disaster. Sufficient discussionsshall be made in regard to the method of flushing and items to be given attention, withdepartments related to the construction work. And, also at the stage of design, careshall be taken to avoid such piping that can cause a trouble (for example, piping withpocket, refer to Fig. 10.9-R.). When the piping is desiged inevitably to have a pocket, aflange which allows connection of temporary piping for flushing, or a draining device,shall be attached to the end part of such pocket. When, in case of high-pressure, large-dia. piping, such installation of flange would cause large cost-up, a cap may be used insuch a way that the length of pocket is short, so that stagnation is prevented.Personnel’s in charge of work shall be thoroughly informed of the time, method, andexecution of welding of the cap.

Fig. 10.9-R Piping with pocket

(ii) Acid cleaning and oil flushing for oil piping- Oil is used for lubrication and cooling of high-speed rotating parts, for oil seals, andfor control system of turbine. Oil is used also in other delicate parts of compressor orturbine Therefore, oil shall not contain impurities nor rust. Consequently, oil pipingsystem, in general, shall undergo an acid cleaning and then a flushing by use of good-quality oil appropriate for the equipment concerned. After the cleaning, the used oilshall be replaced perfectly by the regular oil. (Refer to Fig. 10.9-S.)

Flange or draining (3/4” orlarger, the larger shall be thebetter.)

Shall be flanged device.If only blind plate or cap is to be used its welding doneafter flushing.

Min. Min.Min

Piping assembling work(have less number of welded part)

Welded workInert gas welding or acetylene gas welding

(Perferably, avoid use of socket joint, even for small-dia. pipe)

Disassembling of line(give marking)

Pressure Test

Acid Cleaning(dip in bath)

Wash

Steam cleaning

Air cleaning

Fixing(Temporary piping for inlet/outlet port)

Oil-circulation cleaning

Fill with oil for regular use

Connectcompressor

Fig. 10.9-S Flow from assembling to connection to compressor, of oil piping

Note 1: Oil line shall, as a rule, bemade of stainless steel, andall fittings shall be of B.W.type.

Note 2: After acid cleaning, havediscussions with ConstructionDept. in regard to the methodof oil flushing, and makedecision on whether or not thepiping must be divided by useof flanges.

-Example of standard bath tank for acid cleaning (Refer to Fig.10.9-T.)

Fig. 10.9-T Example of bath tank for acid cleaning

-Installation of strainer for oil flushing (Refer to Fig. 10.9-U.)

Fig. 10.9-U Installation of strainer for oil flushing

-There are two kinds of acid cleaning method.

Method 1 (Note 1) Pipe is washed in a tank filled with acid cleaning solution. In order toenable disassembled washing, the pipe is provided with flahges at acertain interval length, so that the pipe be divided into pieces of a certainlength.

Method 2 The piping is kept in connected condition, and acid cleaning solution is passedthrough it, by use of hose, etc. connected to it. This method does notrequire installation of flanges.

Note 1: The length of one piece divided for cleaning will be different depending on thediameter. grade, and shape of the piping. Furthermore, after each piece wasprovided with flanges, the cost goes up largely. So, attention shall be paid to themethod of dividing, especially in case of high grade piping.

Oil return pipe

To oil-tank (reserve) Strainer (short pipe isafter flashing)

To oil-tank (reserve)

Strainer(80 - 100 mesh SUS ???)

-Example of divided length (Refer to Fig. 10.9-V.)

Fig. 10.9-V Example of divided length

(d) Requirements in regard to maintenance

The space for maintenance of compressor proper and auxiliary equipment, which wassecured at the time of layout work, shall not be occupied by any piping. Moreover,consideration is required, such that the space necessary for maintenance, such as the spacein the direction of pulling steam coil out of oil tank housed in oil console, the space in theupward direction of vertical type pump, etc., is not occupied by any piping. Necessay flangesshall be provided on the piping, in consideration of removal of equipment. (Refer to Fig. 10.9-W.)

Fig. 10.9-W Installation of flanges for maintenance

Not only process piping, small-dia. pipings, such as lube oil/seal oil piping and gas piping,shall also be given attention in the same way.

(e) Attention required in regard to civil information

(i) The floor of compressors building and the foundation of compressor shall be separatedeach other, so that no vibration can be transmitted to the floor.

(ii) When oil unit, condenser, etc. installed under the floor are to be hanged up by a craneinstalled in the building, the floor shall be made removable. When any piping is to

Insert flange ????

Setting ?????

penetrate through the removable floor, the part of penetration shall be split into twoportions.

10.10 Piping Around Reciprocating Compressor

10.10.1 Precautions required in regard to layout

(1) Space around the compressorAround any compressor, there shall be secured a space for installation of auxiliaryequipment, a space for temporary storing parts during disassembling or inspection, and aspace to be used as passageway.The auxiliary equipment includes: pump, oil cooler, filter, tank, etc. constituting lube-oilsystem or seal-oil system of centrifugal compressor; knock-out drum, pulsation damper,intercooler, aftercooler, etc. of reciprocating compressor; and, condenser when steam turbineis used, etc., and the required space differs from compressor to compressor depending on itstype. So. it is required to confirm informations, if necessary, in asking the vendor.

(2) Spacing between compressors-When any two compressors are to be installed in parallel, the spacing shall be half the widthof the larger compressor, or more. However, it shall be min. 1.5m. (Refer to Fig. 10.10-A.)

Fig. 10.10-A Spacing between compressors

-When compressors are to be installed in rows, the spacing between rows shall be min. 1.5m.

-In case of centrifugal compressor of small type, the spacing between them may bedetermined in the same way as in case of pumps, (In a rough standard, compressor of smallsize means those of 149kW or less.)

(3) Maintenance spaceIn case of reciprocation compressor, a parts-pull-out space, of the length longer than the pull-out length of rod, piston, etc., shall be secured, such that the rod can be pulled out withoutremoving the cylinder. (Preferably, 1.0 - 1.5m shall be added to the pull-out length for rodand piston.) Moreover, if it is necessary to remove the cylinder, the space for its removalshall be considered. (Refer to Fig. 10.10-B.)Note) The space necessary for maintenance is different, depending upon the method ofmaintenance indicated by the manufacturer, so confirm any detailed information, in askingthe manufacturer.

W1 > W2

Over W1/2 (Min. 1.5m)

Fig. 10.10-B Example of maintenance space for reciprocating compressor of horizontal type

(4) Others

(a) Installation position of local panelThe local panel of compressor shall be installed within an area wherein starting, stopping,increasing/decreasing of load (or changeover), etc. of the compressor can be visuallyobserved from the position of manipulation.

(b) The relation between the compressor proper or turbine proper and the oil unit, in regard tothe layout and height, shall be studied sufficiently, because there may be gravity-flow line,for instance. Moreover, study shall also be made on the arrangement of auxiliaryequipment, such as oil head- tank, etc.

10.10.2 Requirements in regard to piping design

(1) General

(a) Because gas-fluid is to be handled, the piping shall be of free-draining type, such that nocondensate of the gas can accumulate in the piping. When a drain pocket is madeinevitably in the piping system, countermeasures shall be taken such that perfect drainingcan be done.

(b) Each line shall be planned to have minimum length. However, outlet piping of thecompressor, steam piping connected to the turbine (driver), etc. shall have flexibility suchthat there will be no problem due to thermal elongation/contraction.

(c) In order that changeover-operation of the compressor can be done easily, valves,instruments, etc. on the piping connected to the compressor shall be installed, in such away that changeover operation can be made easily.

(d) For the inlet and outlet piping of compressor, a vibration analysis of piping system shallbe made, so that planning of piping route and planning of support (supporting interval andshape of support) be made adequately, because such piping may cause vibration due topulsating flow of the fluid. Furthermore, piping route of such piping shall be such that it issmooth and has least number of bends. Note) In many cases, the manufacturer ofcompressor is requested to carry out the vibration analysis, after the piping route andsupports have been determined.

Rod, Piston etc., ???

(e) In order that countermeasures against vibration can be taken easily, it is preferable thatpiping supports are installed on-ground. Consequently, piping shall be arranged onsleepers, as far as possible.

(f) In case where any trench piping is to be made in the vicinity of the compressor, a studyshall be made to see whether any danger can be caused by accumulation of gas(especially propane gas, etc. which is heavier than the atmosphere) in the trench.

(g) The piping route shall be planned, in such a way that it does not obstruct the operationand maintenance of the compressor. When a platform for operation is provided, pipingshall be under the floor, so that broader space can be kept on the operating floor.

(h) When an overhead traveling crane has been provided, the arrangement of piping shall besuch that large-sized valves, strainers, and instruments (which are heavy) are accessibleby crane for the purpose of maintenance, as far as possible. (Pay attention to the workingrange of crane, and arrange the objects of maintenance.)

(2) Inlet piping

(a) The piping between the suction drum and the suction nozzle of compressor shall be,fundamentally, as short as possible, so that the pressure drop be kept at a minimun. But,that piping shall have a flexibility, because the allowable reaction force of the nozzle(which is indicated by manufacturer) is small.

(b) The piping between the suction drum and the suction nozzle of compressor shallpreferably be such that allows free draining and has gradient towards the side of suctiondrum. But, if any piping pocket is made as a result of adequately arranging operation-valves and piping supports, countermeasures shall be taken, such as provision of drainingdevice or heating by means of jacketed pipe or steam tracing, so that drain cannot enterthe compressors side.

(c) Valves on the suction line are those for manipulation in relation to the operation ofcompressor, such as starting and stopping, and therefore, shall preferably be arrangednear to the compressor, as far as possible. As a general rule, valves on the suction lineare installed, together with valves on the outlet line, on the platform for the compressor(on the ground near to the compressor, when there is no platform), for convenience oftheir manipulation. Moreover, the part where such valve is installed, will cause, due to itsown weight, a change in the load balance of piping system, so that the piping will tend togenerate vibration. So, as a countermeasure against vibration, such valves shall bepositioned as low as possible from the ground, such that the piping can be supported, atthe points before and behind the valve, easily from the ground.

(d) As a general rule as to strainers for the inlet piping of compressor, a strainer of fine mesh(in many cases, the screen mesh is indicated by the manufacturer) is used at the time ofinitial starting, and it is replaced by a strainer of coarser mesh (10 - 30 mesh), or isremoved at all, in many cases, after the time when the inside of pipe became clean (at thetime when put into normal running), such that the flow resistance become small. Thismeans that pulling-out/cleaning of the strainer screen is done frequently, until thecompressor is put into normal running. So, the strainer shall be installed at such place thatallows easy manipulation. Moreover, it shall preferably be fixed at a place near to thesuction nozzle of the compressor.

(3) Outlet piping

(a) In the same way as inlet piping, the outlet piping shall preferably be on-ground (onsleepers) piping, as a countermeasure against vibration, as far as its access is notobstructed. In having the piping on ground, supports, such as directional stops, can easilybe installed, especially for the purpose of mitigating the reaction force to the nozzle of thecompressor. Moreover, especially the bent parts and parts cocentratedly loaded by valve,

etc. of the piping tends to generate vibration. So, the piping arrangement shall be made,in anticipation of the space for installation of supports. When the piping is to be on piperacks, the piping can be supported easily from the beam of pipe rack, if it is arrangednearer to the column of higher rigidity. In order to make easy the countermeasures againstvibration, this line shall preferably be planned, such that it is along the same route asother likely-to-vibrate lines (to have grouping).

(b) Since the outlet piping gets hotter than the inlet piping, due to the heat of compression, itsarrangement shall be such that absorption of the thermal expansion is taken intoconsideration.

(c) As to the arrangement of valves on the outlet piping, the same as the arrangement ofvalves on the inlet piping shall fundamentally apply. One example of piping aroundcompressor is shown in Fig. 10.10-C.

Fig. 10.10-C Example of piping around compressor

Discharge Valve(Note)

Suction Valve

Note) Since the dischargevalve is, many cases (over100kg/cm2), of stairway anglevalve type, attention is neededto the piping arrangement.

Connected step???

Down

Dwon

This point of the pipingsystem the lowest point.

This part becomes the platform forinspection (platform and operation ofvalves, at the same time)

Suction Drum

Sleeper

Steam Trace

Pipe support

Compressor

Floor

(4) Other pipings

(a) Piping for oil unitIn many cases, the oil unit itself is completed on a skid and supplied by the manufacturer.Routing of the piping, such as water piping to the cooler and piping for steam tracing of oilpiping, shall be such that it does not obstruct the passageway.

(b) Vent pipingThe vent of combustible gas coming from the compressor proper shall be led to a safeplace, before it is exhausted. Especially when the vent gas from a compressor installedindoor is to be exhausted to atmosphere, it shall be led to a safe place outside of thebuilding, before it is exhausted.

10.10.3 Design of supports

As to the detailed design, refer to the instruction DG-04-09 “Piping support in regard to pulsating flow”.In order to avoid resonance due to pulsating flow, pay considerations to the support span and supportload explained in the following.

(1) Support span opposing out-of-surface vibration

Fig. 10.10-D Out-of-surface vibration

(2) Support span opposing in-surface vibration

Fig. 10.10-E In-surface vibration

Refer to Table 10.10-A Pitch span

Refer to Table 10.10-A Pitch span

Table 10.10-A Constant pitch span L

Pipe dia. Support span L(m) when frequency is 10HzWithout insulation With insulation

(inch) (mm) Water Air/Gas Water Air/Gas1/2 15 2.2 2.2 1.9 1.93/4 20 2.5 2.6 2.2 2.21 25 2.8 2.9 2.4 2.5

1 1/2 40 3.3 3.5 3.0 3.12 50 3.6 4.0 3.2 3.43 80 4.4 4.8 4.1 4.34 100 4.9 5.5 4.6 5.06 150 5.8 6.6 5.5 6.18 200 6.6 7.6 6.3 7.010 250 7.3 8.4 7.0 7.912 300 7.9 9.2 7.6 8.714 350 8.3 9.7 8.0 9.216 400 8.3 10.4 8.0 9.718 450 8.6 11.0 8.4 10.320 500 9.2 11.7 9.0 11.024 600 9.8 12.8 9.6 12.1

(3) Support span for opposing vibration having concentrated load (valve, vertical piping)Determine the rate of reduction β by use of Fig. 10.10-F, and make reduction of each of thein-surface and out-of-surface support span.

( )( )

α =concentrated mass or concentrated span length

L span mass or L span length

( )K

MIN=

+ι ι

ι ι1 2

1 2

,

Fig. 10.10-F Rate of span reduction when there is concentrated mass

(4) Support span at branch partDetermine the rate of reduction β by use of Fig. 10.10-G, and make reduction of the constantpitch span L.

(5) Support loadThe dynamic load, due to the impact caused by pulsating flow, is difficult to be determined,and, cannot be determined in any general manner. So, as a rough rule, the load shown belowshall be considered for supports. (The load due to pulsating flow shall be added to the loaddue to own weight, thermal extension, wind, etc.)

ConcentrateSpan

Vibrationdirection

Fig. 10.10-G Reduction coefficient for branch part*

* Both of the mother pipe and branch pipe shall be multiplied by this reduction coefficient.

That is, it shall be MAX (ι3, ι1+ι2) ≤ β1 x L

F1 = 1.5 Pm x ε x AWhere,

F1 = Axial force due to variation of pressure (kgf) {N}pm = Mean pressure (kgf/cm2) {N/cm2}

(Reductionrate)

Axial force due to variation ofpressure (F1)

ε = Rate of pressure variation

ε = 2PPm

A = Inside cross-sectional area of pipe (cm2) {cm2}

Fig. 10.10-H Axial force due to variation of pressure

(6) Planning of supports

Planning of supports shall be done adequately, taking into consideration the prevention ofresonance and the load due to pulsation flow. Piping supports around the compressor shallbe installed independently from the floor or building for the compressor, so that vibration willnot be transmitted to the floor or building. In order to have the piping fixed firmly, the pipingshall preferably be sleeper piping, and shall be fixed or guided, by U-band, shoe with guide,etc. (use of U-bolt shall be avoided). (Refer to Fig. 10.10-J.)

Use shaped steel in anticipation of band width.

Fig. 10.10-J Sleeper type piping support

When there is thermal extension/contraction, a type of fixed band may be used, in whichcushioning material, such as asbestos, rubber, etc., is inserted between the piping and U-band, so that the extension/contraction can be absorbed to a certain extent. Use of shock-absorbing damper shall be considered, when the amount of extension/contraction is large.

Use shaped steelin anticipation ofband width.

Common Sleeper(Shaped steel)

Pipe shore withGuide

Reinforce REB

Fig 10.10-K FIXED-BAND

Since the part of piping where there is bend or concentrated load of valve, etc., is liable togenerate vibration, supports shall be provided in the vicinity of such parts, as far as possible.Moreover, it is preferable, in regard to shock-absorbing, to have support span of randompitch rather than that of constant pitch. As the civil information, not only the static load, butalso the dynamic load shown in Par.(5) and frequency of the pulsating flow, shall be informedto Civil and Structural Dept., so that they will take care to avoid resonance of the structure,etc.

10.11 Piping Around Furnace

10.11.1 Attentions required in regard to layout.The layout around furnace shall be determined, the followings being taken into consideration.

- Because any furnace can become a source of ignition, it is preferable to have it to the windward.When there are a plurality of furnaces, they shall be within one and the same area.

- The layout shall be such that, when a fire occurred, the evacuation from there is easy, and theaccess by fire engine is also easy.

- In case of a furnace of horizontal tube type, a space, equivalent to the length of heating tubes, shallbe secured, at the side of drawing-out of the heating tubes, to be used at the time of construction orat the time of renewal of the heating tubes.

- Also in case of a furnace of vertical tube type, a space to allow the access by mobile crane, shall besecured, in anticipation of the assembling or renewal of tubes.

10.11.2 Items requiring attentions in general

(1) Any piping shall not be placed near to the passageway or any peep hole, in favor of the operation andinspection of the furnace.

(2) The piping arrangement shall be such that it allows easy maintenance work, in consideration of thenecessary spaces for removal of burners and drawing-out of heating tubes, of the furnace.

10.11.3 Transfer line

(1) The outlet piping of furnace is, because of high temperature, made of alloy steel, which is costly. So, itis required to have enough study on the flexibility of piping and to have a short piping route as far aspossible. Because the allowable force and allowable moment to be exerted on the connection nozzlesof the furnace are small, enough attentions are required for the study of flexibility of the piping and thedesign of supports.

(2) The allowable force and allowable moment to be exerted on the nozzles shall be in accordance with thefollowing.

API STD 560Values indicated by vendor

(3) Reference drawing for transfer line (Refer to Fig. 10.11-A.)

Fig. 10.11-A As-example arrangement of transfer line

10.11.4 Fuel piping *)(1) Fuel gas piping

(a) The fuel gas supply piping shall be such that any lopsided flow is prevented, and shall be branchedfrom the upper part of the supply header, so that any carry-over of drain can be prevented.

*) The relation between the burners, peep holes, and valves, in regard to the installationposition, may be different from coutomer to customer. So, it is required to determine it,in advance, in having discussions with Heat Transfer Dep.

(b) The piping connected to burner, shall have a provision of unions or of a flexible tube (see note)within the piping, in order to allow removal of the burner.

Note) According to EXXON BP3-4-1, use of flexible tube is prohibited.

(c) As-example arrangement of header for fuel gas piping of Isoflow type furnace. In one method ofarrangement, the header is installed, at the outside of the heater, on brackets extended from thelegs, and each branch piping from there is connected to the respective burner. In this arrangement,the conditions are satisfactory, although the valves for ignition are outside of the operators range ofvision, and, at the same time, the cost is not expensive. Each valve for ignition of burner is, as arule, not used for controlling, but is used in fully-open or fully-closed condition. Therefore, the factthat they are outside of the operators range of vision does not mean any large handicap. (Refer toFig. 10.11-B.)

Fig. 10.11-B As-example arrangement of fuel gas piping (A)

In another one method of arrangement, the header, which is also used as a drain pot, is installed atthe center of the area underside of the heater, and each piping from there is connected to therespective burner. This arrangement has an advantage that there is considerable space due to the

Transfer Line

Spring Hanger

Transfer Line Exchnager

installation of the header at the center, so that easy operation is allowed. But, on the other hand,the operator must be staying for long time, at the time of igniting or of extinguishing. (Refer to Fig.10.11-C.)

Fig. 10.11-C As-example arrangement of fuel gas piping (B)

In still another one method of arrangement, the header is installed at the outside of heater,extending along the heater at the level just above the peep holes, and each piping branched fromthere goes down vertically passing through the vicinity of observation door to be connected to therespective burner. This arrangement is very advantageous, in that the valves can be watchedsatisfactorily by the operator. However, the cost of material and of construction work becomesexpensive (see note). (Refer to Fig.,10.11-D.)

Fig. 10.11-D As-example arrangement of fuel gas piping (C)

(2) Fuel oil piping

(a) Supply piping for heavy-quality fuel oil coming from the tank shall be in the form of closed system,if necessary, so that the excess oil is always being circulated.

(b) The piping connected to burner, shall have a provision of unions or of a flexible tube within thepiping, in order to allow removal of the burner.

(c) As-example fuel-oil piping around burner.The regulation valves for fuel oil and atomizing steam shall be installed at a place where operatorcan manipulate them in peeping into the inspection hole. (Refer to Fig. 10.11-E.)

Fig. 10.11-E As-example piping arrangement for fuel oil

Gas Supply

Manifold drainControl Valve

Gas manifold

GasGas supply

Control valve

Header drain

Note) In EXXONBP3-4-1, thistype isrecommended.

Steam Header

Header

Burner

Fuel-oil Furnance

Pressuregauge

(3) Installation of block valve and regulation valve for fuel(a) The main-line block valves of the fuel-oil or fuel-gas piping shall be installed at a place, where, at

the time of emergency, immediate operation can be done, having distance of 15m or more from thefurnace. (However, this consideration is not needed in case of cracking furnace, where Em V isused.)

(b) The regulation valves for fuel oil, fuel gas, and atomizing steam, fed to the furnace, shall beinstalled in the way shown below.On-wall burning type furnace : In the vicinity of burner, where convenient watching on the peep

hole is allowed.On-floor burning type furnace : In the vicinity of burner.

10.11.5 Fire-fighting steam piping

(1) Snuffing steam piping shall be connected to the combustionroom, upper header box and lower header box, of the furnace.

(2) The main stop valve for steam piping shall be installed at a place on the ground, where the valve canget easy access and can be operated easily, having enough distance from the furnace.

(3) As-example piping arrangement for fire-fighting steam (Refer to Fig. 10.11-F.)

Fig. 10.11-F As-example piping arrangement for fire-fighting steam

Min. 15m

Upper snuffing

Lower snuffing

FurnaceHeader

Bottom snuffing Steam trap

Steam supply line

10.12 Piping of tank yard

10.12.1 Applicable laws/regulations, standards, etc.Before the starting of design, the applicable laws/regulations, standards, etc., to see whether there is anyarticle/clause which is to be heeded in carrying out the piping design.

10.12.2 Piping of tank yard(1) Piping outside of the dike

(a) The piping shall be on-pipe-rack or on-sleeper.(b) The height of the pipe rack shall be such that it does not obstruct any kind of activity for disaster

prevention.(c) As to the height of sleepers, there is no particular requirement.

(2) Piping within the dikeThe piping shall, as a rule, be on-sleeper, and its height shall be determined, after comprehensivelystudying the height of tank nozzle, height of pump nozzle, height of dike; and, the arrangement-order,branching, etc. of the piping.

(3) Design of piping around tanks(a) Piping zone within the inside of dike

As a rule, piping zone shall be established, in which the pump suction line located at the center andother piping at nearby are assembled and laid on one and the same sleeper. Therefore, when thereare many tanks, a plurality of piping zones will be installed. (Refer to Fig. 10.12-A.)

Fig. 10.12-A Piping zone within the inside of dike

(b) Pump suction line- The piping shall be such that the tank nozzle is at the highest, and there is no air pocket in the

pipe system. (Drain pocket is allowed.) (Refer to Fig. 10.12-B.)- If the pump suction line is too long, a vapor zone can be generated in the line, depending on

the atmospheric temperature. So, the countermeasures, such as to provide a vent pipe, shallbe determined, after having discussions with Basic Design Dept.

TankPump

Note)

Fig. 10.12-B Pump suction line

(c) Flexibility of piping and flexible tubeAs a countermeasure against any subsiding of the tank (subsiding due to fill-water test, unequalsubsiding, or subsiding due to earthquake), any deformation of nozzle at the time when the tank isfull of oil, and any thermal expansion due to temperature rise, the use of loop piping or use ofbellows or flexible tube can be considered. In general, a flexible tube shall be installed at the liquiddraw-out nozzle of any tank other than spherical tank (see Note 2). Moreover, in this case, theamount of subsiding shall be confirmed, through the discussions with Civil/structural Dept., beforethe piping is designed. (Refer to Fig. 10.12-C.)

Fig. 10.12-C Length of flexible tube

Unit : mmDia. Value of max. deviation right angle to the axis d

50 100 150 200 250 300 350 400ND Total length of flexible metallic hose, L40 500 600 700 800 900 1000 1100 120050 600 700 800 900 1000 1100 1200 130065 600 800 900 1000 1100 1200 1300 140080 700 800 1000 1100 1200 1300 1400 1500

100 700 900 1100 1200 1300 1400 1500 1600125 800 1000 1200 1300 1400 1500 1600 1800150 800 1100 1300 1500 1600 1700 1800 1900200 900 1200 1400 1500 1700 1800 1900 2100250 1000 1400 1500 1700 2000 2100 2200 2300300 1100 1400 1700 1900 2200 2300 2500 2600350 1200 1500 1800 2000 2200 2400 2600 2800400 1300 1600 2000 2200 2500 2700 2900 3200

Take care not to confuse the size of L with that of L', when placing order to manufacturer.

(d) Piping to be connected to tank nozzle(i) Main stop valve for tank shall be installed, to be connected directly to the nozzle, as a rule.(ii) Main stop valves for tanks, and changeover valves for headers, shall be assembled and

installed on an operation platform, which may be a bridge crossing over piping zone, at thesame time.

(iii) When the main stop valve for tank is of heavy weight, the nozzle shall be reinforced(discussions with Mechanical Design Dept. is needed), or the valve shall be supported, eitherby a part extending from the tank proper, or by a support, having foundation common with thatof the tank.

Note 1) In case of low-temperaturetank, consideration is required,to have the supports made oflow-temperature-resistantmaterial, to have the supportswrapped by concrete, etc.

Note 2) According to EXXON BP3-5-1,at least one elbow shall beprovided in between the tankand the dike.

(iv) In the area inside of dike, no underground piping shall be provided, excluding sewer lines.(Take care, especially when designing piping for fire-fighting/prevention.)

(v) Tank-drain shall be received by drip funnels, and be led, through an underground piping, to beconnected to the side-gutter or sump-box inside of the dike. (It shall not be led directly to theoutside of dike.)

(vi) Penetration through the dike shall not be made, as a rule. When a piping is to penetrate thedike, a countermeasure against leakage at the part of penetration shall be provided.

10.12.3 Sewer system As to the design of sewer system around tank yard, refer to Par. 10.4“Underground piping".

10.12.4 Fire-fighting/prevention system As to the design of fire-fighting/prevention system, refer to Par.10.18 Piping for fire-fighting/prevention.

10.13 Steam piping

10.13.1 General(1) All of the branchings from header shall be taken out from the upper side of the header.(2) One block valve shall be provided, for each branched piping from the header.(3) When steam is to be injected into any process fluid, a block valve and a check valve shall be provided

at a place near to the injection point.(4) Design shall be made, in regard to the thermal expansion of the piping, in referring to Par. 10.22.

10.13.2 Standards on installation of steam-draining devicesThe parts shown below shall be provided with draining piping, without fail. The type of it shall beunified, after having discussions with Basic Design Dept.

(1) Termination-part of header(2) Part having drain pot(3) When horizontal line is long, one per each 30 - 40m length.(4) The part upstream side of control valve (indicated on P&I).(5) The part upstream side of control valve or block valve which may become closed during operation.(6) In case of steam to be fed to any rotating machine (turbine), a bypass, for exhaust to atmosphere, shall

be provided at the downstream side of the block valve. (Refer to Fig. 10.13-A.)

Fig. 10.13-A As-example installation relationship of traps on steam line to turbine

10.13.3 Method of draining-out(1) Superheated steam line of 100kg/cm2 or over (Refer to Fig. 10.13-B.)

Fig. 10.13-B Draining-out from superheated steam line of 100kg/cm2 or over

TurbineTo Correct Header

Turbine To correct header

RemarkNote) When re-starting, be sure to drain-out

any condensate at the downstreamside of block valve, before the blockvalve is opened.(This is to preventcoming-in of condensate into theturbine.)

To vent stack???

(2) Saturated steam line(a) Lines whose main size is 3B or larger (Refer to Fig. 10.13-C.) Note)

Fig. 10.13-C Draining-out from saturated steam line (3” or larger).

(b) Lines whose main size is 2.1/2B or smaller (Refer to Fig. 10.13-D.)

Fig. 10.13-D Draining-out from saturated steam line (2 ½” or smaller)

10.13.4 Installation relationship of traps(1) To-atmosphere exhausting type A block valve and a bypass with a block valve shall be installed at the

upstream side of the trap. (Refer to Fig. 10.13-E.)

Fig. 10.13-E To-atmosphere exhausting type

(2) Recovery type(a) When recovery is made directly to a condensate header, a block valve and a bypass with a block

valve shall be installed, at both the upstream and downstream sides of the trap. (Refer to Fig.10.13-F.) (Moreover, as to the check valve at the downstream side, what is indicated on P$I shallbe observed.)

Note) This is applicable toheader pipe only. (Anytrap around control valveor line-trap at pocket partshall be installed, takenout through a boss of ¾”size.)

3”

¾”

3”

¾”¾”¾”B.F

¾” ¾”

Drain Assembling Drain

Fig. 10.13-F Recovery type

(b) When recovery is made to a subheader, a block valve and a bypass with a block valve shall beinstalled, at the upstream side only.

10.13.5 Steam drain piping(1) Steam line of 100kg/cm2 or over (Refer to Fig. 10.13-G.)

Desperheater

Fig. 10.13-G Steam drain piping of 100kg/cm2 or over

From upperCondensate header

or

or

Note) Steam trapsshall be fixedto thebranched line.

The route shall beof flowing gradientwithout verticalpart, as far aspossible.

Turbine

??? Drain (by 40m)

Vent Stack

(2) Other steam line (Refer to Fig. 10.13-H.)

Fig. 10.13-H Other steam drain piping

10.13.6 Vent stack(1) Installation standards

(a) Steam drain of 100kg/cm2 or over(b) Around turbine

* Turbine leak steam* Line traps

(c) When draining is done indoors (however, installation is not needed, if the drain piping is extendedto an outdoor place).

(d) Other places, where the installation is seemed to be necessary by reason of the condition ofcircumstances.

(2) Vent Stack Small (V.S.S) type(a) This type is for exhausting from a trap of low pressure steam or of middle pressure steam. (Refer to

Fig. 10.13-J.)

Fig. 10.13-J Vent stack for low- or middle pressure steam

Desuperheater

Note) Steam traps shall be fixedto the branched line, in anycase. When water vapor isemerging at around thefootage, When there is no(As to standards in regard tothe installation of badeffect. vent stacks, refer toPar. 10.13.6(1).

Ventstack

In case of ????

Guide support is necessary, when H is more than 5m.

12 x 6” Reducer

Drain 1 ½”

(b) This type is for exhausting of turbine-warming steam, or of high pressure steam. (Refer to Fig.10.13-K.)

Fig. 10.13-K Vent stack for warming steam and high pressure steam

10.13.7 Piping for desuperheater(1) Kinds of desuperheater

(a) Variable area type (Refer to Fig. 10.13-L.)

Fig. 10.13-L Variable area type

(b) Atomizing steam type (Refer to Fig. 10.13-M.)

Fig. 10.13-M Atomizing steam type

(2) As to the length of straight pipe, radius of bend, take-out position of taps for instrumentation, etc.,observe the P&I or instructions made by Instrument’s Design Dept. The values shown in the figurebelow are standard values.

Drain 1 ½”

Guide support is necessary, when H is more than 5m.

Note: As to details of thefoundation, orientation ofanchor bolts and of inletnozzle, etc., refer toTEG1-1316-005 “Makingof DETAIL DWG forSPECIAL PIPINGPARTS".

Water

Because its cost is expensive,this is used only for import steamwhere changes in the steambalance can occur.

SteamBecause its cost is notexpensive, this is used ingeneral cases. But this is notused, when there can bechanges in the steam balance.

Note 1) Piping shall be such that it is always sealed by water.Note 2) Check for any necessity of thermal sleeve.

Fig. 10.13-N Piping around desuperheater (atomizing steam type)

10.13.8 Piping for steam silencer (Refer to Fig. 10.13-P.)

Min. 15mNote 1)

Min.4xD

Direct part

Note 2)

Over 10m

Direct part

Min. 10 x D

Dangerous range(obstruction ofvision range,

personnel’s burninjury, etc..) Note) When the result of thermal stress

calculation shore that the nozzle neck isnot OK, a slide type nozzle can beadopted. In this case, ask themanufacturer for alternation of thenozzle type.The installation position and height ofthe silencer shall be the same as thesafety valve exhaust outlet.

Because accumulation drain is likely, the pipe shall beprovided with gradient.(Provide enough gradient, such that the calculatedelongation of pipe system can not cancel it.)

Pay attention to the vibration, whichway be caused by pressure reductionafter the reducing valve.(Countermeasures, such as supports,bell-mouth pipe, etc., shall beconsidered.)

Dangerous range

(obstruction of vision- burn injury, etc.)

Note) When the results of thermal stress calculation is that the nozzle neck is not OK, a

slide type nozzle can be adopted. In this case, ask the manufacturer for alteration of the

nozzle type.

range, personnel’s

The installation position of and height of the silencer shall be planned, piping in the same

manner as the case of exhausting shall have gradient. from safety valve.

Because accumulation drain is likely,

(Provide gradient, more than that caused by the which is likely elongation, be calculated.)

Pay attention to the vibration, which shall at the part further than the reducing valve.

(Countermeasures, such as supports, bell-mouth pipe, etc., shall be considered.)

Fig. 10.13-P Piping for steam silencer

10.13.9 Piping around steam drum (Refer to Fig. 10.13-Q.)

Note: For all of the pipings connected to the steam drum, the reaction force due to thermal stress shall becalculated, in order to check the strength of the nozzle.

Fig. 10.13-Q Piping around steam drum

Noise may be caused when testing safety valve

Vent piping (air-vent when pressure test isdone)

The drum proper do nothave any anchor, and cansliding both directions

Air is vented by this bypassvalve, for In no case providehydraulic pressure test.

Pay attention to thevibration of this line.

Pay attention vibrationdue to 2-phase(Stop it by DS.)

Pay attention to the vibration atthe time of start-up

The stage may be atone side only.

1 - 1.2m is needed, in order to enter tothe manhole

?????(Pay attention to the elongationfrom below.)

10.13.10 Piping for steam eject or (Refer to Fig. 10.13-R.)

Fig. 10.13-R Piping for steam ejector

10.13.11 Piping for steam trap (Refer to Fig 10.13-S)Especially in case of Lotus Z type trap, its surroundings requires some kind of countermeasureagainst erosion due to mist. So, it is necessary to have discussions with Basic Design Dept., oneach concrete item, before making any determination.

Ask Basic DesignDept. for checkingon the height, etc.(whether it is withinthe capacity of theejector.)

Steam trap(Lotus Z type)

Ejector

Drain

Steam(in some cases, air or water

Reducer

The suction line shall have the least numberof bends. (Straight pipe is preferable.)

Min. Min. 10xD

Steam trap(Lotus Z type)

Min.

Reducer

Drain

Remark

Note 1) A straight pipe length of 10 x Dshall be provided at thedownstream side of the trap, asa rule. However, if it is difficult,for the reason of the requiredspace, tee type may be used.

Note 2) The reducer at the downstreamside of the trap shall be at aplace directly near to the trap.Moreover, reducers to be usedshall be those of CON-type, inall cases.

Note 3) Drain shall be connected to thepipe after its expanding, in allcases.

Note 4) When tee type is to be used, itis preferably of stainless steel.

Fig. 10.13-S Piping for Steam Trap

10.14 Piping around Safety Valve10.14.1 GeneralThe purpose is to protect pressure vessels, actuated when pressure goes up over the levelset for safety valves. They are classified as follows by the type of fluid:(1) Safety valve : Air, gas including steam, vapor(2) Relief valve : Mainly liquid(3) Safety-relief valve: For both gas and liquid (hereinafter collectively called as safety

valves).

10.14.2 Piping at Entrance to Safety Valves(1) In principle, safety valves shall be laid out in such manner to assure the piping at their

entrance will be shortened (Refer to Fig.1 0.14-A). When installing the safety valve at anelevated spot for safety with the exit piping designed for atmospheric release, or wheninstalling it at a point higher than the flare header for the purpose of providing no pocketfor the exit piping which is to be connected to the flare system, determine the size ofpiping to assure that pressure drop of entrance piping will be w.thin the limitation asspecified in the table below

Safety Valve

i

i

i

—*

Ve&lII

Remarks): Take out from a point wherethe shift of mother pipe will beminimal.

,:c;w vicinity of

i i /

Vessel i - - Remarks)i &s!fY- -,,I Safety valve

Type of safety valves Pressure loss between equipment and safety valvesFor boiler Less than 0.6kg/cm2

For general purpose Less than 3°A of pressure set for safet y valves

(2)

(3)

Fig.1 0.14-A - Installation of tower head safety valves

The size of entrance piping of safety valves shall be greater than the size of flange onthe entrance side of safety valves. (Refer to Fig.1 0.14-B). For those entrance pipingwhich will unavoidably become long, ask Basic Design Division to check pressure loss:

4 z Flare headerz

/ ofJ )

Fig.1 0.14-B - Entrance piping of safety valve entrance piping ??

Install in such a way to assure the maintenance of safety valves and access to them:(a) Secure an adequate space for the removal of the body of safety valves.(b) Secure a space to allow the removal of spring adjusting cap and handle operation.

(Refer to Fig. 1O.14-C).

Lock M (Spaceto allow the use ofspanner)

-1- Adjusting apace

k~ ‘ ‘–-

Fig.1 0.14-C - Safety valve spring adjusting space

(c) Install a ladder or platform for locations where access is difficult. The means ofaccess shall be in accordance with Paragraph 5.7.

(d) The installation of maintenance tools shall be in accordance with Paragraph 5.9.

(4) Avoid to install at locations where turbulent flow or vortex is anticipated.(5) No branch pipe other than bypass pipe shall be taken off from the entrance piping of

safety valves. (Refer to Fig.1 0.14-0).

x

Fig.1 0.14-D - Taking off branch pipe from entrance piping

(6) Takeoff from safety valves shall be made from the vicinity of a fixed support point (apoint where vibration and thermal transfer are minimal) as far as possible. (Refer toFig.10.14-E).

( Set close as far as possible

Fig.1 O-14-E - Installation of safety valves

(7) Install safety valves taking the suppofls of valves and connected pipes intoconsideration.

(8) When taking off an entrance piping of safety valve by means of nozzle weld (squarejoint), install a reinforcing plate where necessary after checking delivery reaction. (Referto Fig,10.14-F).

.—. —.. . .

&-i .— -RF 20x t D 6+ hole

Fig.1 0.14-F - Reinforcement of safety valve nozzle neck

(9) For the stress check of the nozzle pad of entrance pipe and safety valve in considerationof the delivery reaction of safety valve, refer to TEG-3058.

10.14.3 Delivery Pipe of Safety Valve(1) General

(a) The size of delive~ pipe of safety valves shall be greater than that of flange on thedelivefy side of safety valves.

(b) Elbows to be used for delivery pipes shall be of long radius.(2) Atmospheric Release. .

(a)

(b)

(c)

The deiive~ height of vent line of safety valves for atmospheric release shall behigher for more than three meters from all platforms or rooftops which are locatedwithin a horizontal radius of 7.5m Note) from the outer edge of exit pipes. (Refer toFig.10.14-G).Note : Although TES H-1 01 and “RUHMAS ??” spec. specify the horizontal radius

to be 7.5m, the Kelogg spec. specifies it to be 12m in case of hydrocarbongas. Since the horizontal radius is an approximate standard only, the safetyof atmospheric release shall be confirmed when its quantity is large by takingconcentration and thermal radiation into consideration. As rule, no toxic fluidshall be released into atmosphere. EXXON BP 3-2-4 specifies the radius tobe 15m.

k 7500 4

Fig.1 0.14-G - Release end of safety valve

For relief valves designed to directly release harmful liquid into atmosphere, install adischarge pipe equipped with a protective device which will prevent the directdropping of such liquid onto the ground.Notch angle of release pipe (Refer to Fig.1 0.14-H).

\\’ //

IIi[

Use this type for general purposes.

$3 The use is limited to such cases where the direction of

D

I release is restricted. Thorough check the strength ofI nozzle and support as the direction of reaction will

change. As rule, do not use the type for high pressure ofmore than 100kg/cm2.

Fig.1 0.14-H - Notch angle of release pipe

(d) In principle, avoid gathering more than two release pipes of safety valves. Whensuch gathering is unavoidable, follow the instruction as shown in the figure below(Refer to Fig.10-14-J).

t

The sectional area of combining pipe shallbe greater than the sum total of the sectionalareas of individual pipes.

Fig.1 0.14-J - Gathering branch pipes

(3) Flare Svstem. .(a)

(b)

In principle, no pipe pocket shall be formed on delivery pipes and they shall beconnected to headers for drain. (Refer to Fig.1 0.14-K).

1W (Wet flare)

~’1~

1DF (Dry flare)

Vert.45° About S00

p

Fig.10.14-K - Connection to flare header

Measures such as the execution of steam trace and the installation of drain pot willbe necessary for those having the possibility of condensate accumulation whenpocket will be formed on the delive~ pipe from safety valves to wet flare headers.(Refer to Fig. 10.14-L). (Consult with Basic Design Division).

+?

--Vert.45” ,- 1 7I

I II

II

L?I n’Hor. 45°

:: l—–-.

A

L -A?

Fig.1 0.14-L - Countermeasure for cases where pocket is formed on delive~ pipe

(c)

(d)

The connection to header shall be made at a point close to the anchor of header.When it is impossible, adopt a flexible branch piping in consideration of the amountof shift of header.The header shall be connected as follows (Refer to Fig.1 0.14-M): Screw in the liquiddrain from the top of piping. For 26 and over, take an angle of 45° and for 1-1/26and under, 90°.

Vezt.45”)

( A q~w300 ~& Q

‘*E::’

,,4 $ 8to - 1

PlanUnder 1-1 /26

Fig.1 0.14-M - Connection to header

10.14.4 Example of Piping around Safety Valves(1) Steam Piping

(a) Details of Delivery Pipe (RefertoFig.10.14-N)

IvI Release pipe

I

( oref

Safety

(120Ketaam onlti T’

Y

than 3m from face.

Notel :

Note2 :

Note3 :

Note4 :

Separate the rafeasa pipa fmrnthe pan.Use the same material as theexit of safety valve for the pan.If a flaxfbiJii exists betweenthe safety valve and releasepipe, use the type mentioned inthe next paragraph instead ofthis *.Sinoe the support of releasepipe will have to be installed ona aide close to a frame and thelike, determine the dimensionsof pan after a careful check ofthe shift in installation point ofsafety valves.

Fig.1 0.14-N - Steam delivery pipe

Table 10.1 4-A - Dimensions of deiivefy pipesUnit: mm

,- 1 1 .-— ,4; 10B I

Dimensions tableA I B (PIPE) I C (PIPE) D E F G

2 l/2R 4R 10B I 200 350 300 1503B 220 370 300 1704B 6B 12B 250 410 350 2105B 8B 14B 300 450 400 2506B 8B 14B 350 480 400 2808B 10B 460+ 420 560 500 360

10B 12B 520+ 500 640 560 44012B 14B 610$ 580 720 650 520

(b) Points of support (RefertoFig.10.14-P)

PsnSafety valve -r

Salact one size smaller than the pipa.

Ml U. Install in such a way to permit sliding.

o(J

Fig.1 0.14-P - Points of support

(2) Piping for other than steam (Refer to Fig.10.14-Q)

(3)

/Donotcutoffaalant

I.k

\Morethan3rnfrwn

Check

Provide a drain hole only in case of kwwcuous gas and liquid, however.

Fig. 10.14-Q - Delivery piping for other than steam

Piping Connected to Flare HeaderAlthough the entrance line of safety valve always extends according to the temperatureof fluid handled, the exit line of the valves is usually exposed to normal temperature sothat the line extends only when the safety valve blows off. Therefore, both cases shall beexamined in thermal stress analysis.

. . . . .—. . . . . .

10.15 Piping around Measuring InstrumentsThe standards for piping around measuring instruments wili be prepared by InstrumentationDesign Division for each job. Conform to the “Piping design information”. (Attach those ofeach job).

Confirm for sure on the matters described below:

Type (SW, FUG type) and size of pressure gage root valve- Type, size and length of thermometers

Shape of the protecting tube of thermometersInstallation standards of thermometersType of orifice (flange tap, or pipe tap)Type of flow meters (orifice, annular bar, turbine meter, etc.)Straight pipe length of flow meters Note) (Confirm the concept in Padicular of jointcoefficient).

Standard face-to-face dimensions of level gagesSections responsible for drain and vent of level gages

Type of control valves (gage, butterfly, cam flex, etc.)

Classification of materials and works by responsible parties (Seethe enclosed“Classification table”).

Note: Specification is included in EXXON BP3-6-1 also. However, the number ofjoints and other details are not clear.

1A takeoff size and position

Parties responsible for steam trace of instrumentationParties responsible for analyzer gage (including the analyzer shed and its vicinity)

Instrumentation duct route and support intewals- Tie-in conditions for pressure difference gages (Flange or socket and butt joint)

- Type of desuperheaters, straight pipe length and other requirements

10.16 Piping for Fire Prevention and Extinguishing (In case of application of domestic lawsand regulations)

Confirm in advance since the master plan will be prepared by Basic Design Division (F/F).For details of fire prevention and extinguishing facilities, reference shall be made to thetechnical specifications, JL-1 01.

10.16.1 Applicable Laws and Regulations(1) SEKISAI-HO?? : Disaster prevention law at petroleum combinate and the likes(2) KOTORI-HO?? : High pressure gas control law(3) Fire Service Act : Fire service act

10.16.2 TypeS(1) Water fire extinguishing system

(a) Hydrant system(b) Water spray and deluge system(c) Sprinkler system(d)Water curtain (including steam curtain)

(2) Air Foam system(a) Outdoor air foam fire-hydrant system(b) Air foam chamber system

(3) C02 system

10.16.3 Water fire extinguishing system(1) Fire extinguishing piping

(a)

(b)

(c)

(d)

(e)

The fire extiriguishing piping in areas to which the SEKISAIHO is applicable shall beof aboveground piping. However, underground piping may be adopted if approved bythe head of relevant city, town or village when freezing is suspected in cold region.Underground piping will be acceptable when the Fire Service Actor KOTORI-HOonly are applicable. As for the burying depth, the top of piping at road crossingsection shall be -1200mm and -600mm in other areas.No firewater shall be used for permanent facilities for purposes other than fireextinguishing.Fire water main shall be aligned in a loop form along the outer periphe~ of plant.Block valves shall be installed on the fire main to enable to separate requiredsections. Note: (Refer to Fig. 10.16-A).

RoadNote: EXXON BP3-

2-2 specifiesthe valves tobe installed atthe rate ofone at themaximum of

t ) 300mdistance.

Fig.1 0.16-A - Example of fire extinguishing pipe network

Install a connection flange for fire extinguishing piping which is to be extended infuture.Fire hydrant and fire extinguishing piping shall be connected as follows: (Refer toFig.10.16-B).

.—

Fire hydrentB.v.

b~>.

%(Note 1) -1’

Note 1: Install valve bits in casewhere the piping is buriedunderground.

Note 2: Install fixed supports in theimmediate vicinity of firehydrants.

Fig.1 0.16-B - Tie-in of fire hydrant and fire extinguishing piping

(2) Fire hydrant system(a) Layout of fire hydrants

SEKISAI-HO: Fire hydrants shall be laid out at the rate less than 70m Note 3) asmeasured on the center line of road along road.KOTORI-HO and Fire Service Act: Fire hydrants shall be laid out in such mannerto enable to cover all equipment and buildings in a circle of 40m in radius.

Note 3 : At every 90m accotding to EXXON BP3-2-2.. No hydrant shall be installed in the vicinity of road mmers.

Install at one to two meters from the edge of road toward the plant side.Note 4 : According to EXXON BP3-2-2, the distance between fire hydrant

and fire engine shall be 7.5m at the most.(b) Hose hangarHose hangam shall be laid out within five meters on the right side of fire hydrants.

(3) Water spray and deluge systemObjects located at level lower than the ground sutface shall be covered by fire guns, andthose which cannot be covered shall be dealt with a fixed spray system. Obtain priorapproval or confirmation from government agencies or customers in the region.(a) Water spray and deluge system

The system shall be applicable to storage tanks of liquefied petroleum gas.(i) For spherical tanks, “top nozzle type deluge system” installed at the top to cover

all of the top half spherical surface and bottom spray system to cover the lowerhalf spherical surface shall be installed. (RefertoFig.10.16-C).

Q6x4

S%JI

6FF AIX

4 ‘L”’””” ~

Fig.10.16-C - Installation example of deluge and drencher of spherical tanks

(b)

(ii) For the freezing (double hulk) tank for storage of liquefied petroleum gas, “topnozzle type deluge” or “drencher system” shall be installed on its roof. “Drenchersystem” shall be installed on the tank shell. (Refer to Fig.1 0.16-D).

Firawater

1 1,

I 1IDeluge system

Note Use care to assurethat the use of waterwill not be obstructedby pipe, support, lug,platform leg, etc.

Drencher system

Fig.10.16-D - Installation of deluge and drencher on cone roof tank

Piping plan for deluge and drencher (Refer to Fig.1 0.16-E)(i)

(ii)

(iii)

(iv)

(v)(vi)

Install the drencher head at a position where the tank shall oan be fully coveredwith oooled water. Note)Install the distribution valve and main valve at locations outside the dyke andsafe. (Keep them away for more than 15m from the outside of tank).Install a strainer between the main valve and distribution header, and usegalvanized steel pipe for piping after the strainer.Adopt aboveground piping inside the oil dyke, and install drain valves fordrainage. The piping shall not pass through the dyke.Countermeasures shall be taken for freezing in cold region.An inclination shall be given for the piping around the tank to prevent theresidence of water.

1 1- \Jop.

~Js

Note In principle, routing shall bemade in such a way not toform any pocket. Installweep holes where pocket isunavoidable.

Fig.1 0.16-E - Example of piping around distribution valve

(4) Sprinkler system(a) Sprinkler system

The system shall be applied to warehouses, bagging area, office, etc.(b) Piping plan

(i) Install a strainer on piping. Use galvanized steel pipe after the strainer.

(5) Water and steam cutiain(a) Water and steam curtain Install water wttain to shut off heat and steam curtain to

dilute leaked gas.(b) Design the steam header paying attention to the pressure drop of steam quantity and

others. ??(c) Steam curtain piping plan

(i) Steam shall be provided from a medium pressure steam header afterconsultation with Basic Design Division.

(ii) When steam curtain header becomes long (more than 15m according to TEC),steam shall be provided from more than two points. (RefertoFig.10.16-F).

Steam supply pcdntT-’””- -1-

Fig.1 0.16-F - Steam supply

(iii) The control valve shall be of a manual type, and it shall be installed at a locationaccessible in case of gas leak.

(iv) Pitch of holes on steam curtain header (RefertoFig.10.16-G).

2.6mm + drill

Fig.1 0.16-G - Example of hole pitch on steam curtain header

(v) Install steam curtain header inside a trench as shown in the figure below; Note)(Refer to Fig. 1O.16-G)

,~, ~ , ‘ote)’”_.—I $Ww j ~/ 1 1, ,’1I

T Y T , -1- — .

Tj, 44 g , t

m Strainer IN ~ 4/

/ Drain hole Earth lug (more than one)

Drsin t- (5mm + in dia., Sm pitch)

Fig.10.16-H - Layout of steam curtain header

10.16.4 Air Foam System(1) Air Foam System

Use the air foam system for extinguishing fire of combustible liquid like naphtha andkerosene.(a) The air foam system consists of the following two systems:

(i) Outdoor foam fire hydrant, and(ii) Fixed air foam system for tanks (foam chamber).

(b) Install the air foam chamber for dangerous substance storage tanks with liquidsurface area exceeding 40m2 (tank diameter approximately 7.2m) or tank height ofmore than 6m, provided however that those storing high flash point dangeroussubstance (FPZ130”C) only at temperature below 10O”C shall be excluded. (Refer toFig.10.16-J).

More than

it L.LMore

1 If-. - ’

6rn=

I

than 4om2

Fig.1 0.16-J - Tanks requiring air foam chamber

(c) Install the chamber for cases other than the above mentioned where its necessity isapproved.

(d) The air foam system shall be so designed that foam liquid can be supplied to foamfire hydrants and air foam chambers from both concentrate solution tank and fireengines for chemical fire. (Refer to Fig.1 0.16-K).

-To foam fireY I

4 hydrant

i A

Firewater

-=i:l

To foamchamber

Note 1: Connection with fire engines forchemical fire (Install at a safe spot along

(Note 1)

main street and in the vicinity of aconcentrate solutiin tank).

Fig.1 0.16-K - System around concentrate solution tank

(e) Install foam fire hydrants in a way to cover dangerous substance of object in a circleof 40m in radius. Install the hydrants along oil retaining wall in tank yards at intervalsof every 70 meters.

(f) Dangerous substance within 15m in radius from the center of a foam fire hydrantshall be covered by other hydrant.

(2) Quantity of air foam chambers

Tank diameter CONE ROOF TANK FLOATING ROOF TANKLess than 13m 2 each 2 eachOver 13m and less than 19m 2 each 3 eachOver 19m and less than 24m 2 each 4 eachOver 24m and less than 35m 2 each 5 eachOver 35m and less than 42m 3 each 6 eachOver 42m and less than 46m 4 each 7 eachOver 46m and less than 53m 6 each 8 eachOver 53m and less tttan 60m 8 each 10 eachOver 60m and less than 67m 10 eachOver 67m and less than 73m 12 eachOver 73m and less than 79m 12 eachOver 79m and less than 85m 14 eachOver 85m and less than 90m 14 each

(3) Air foam piping plan (Refer to Fig.1 0.16-L)(a)

:;

(d)(e)

(9

(9)

Conform to the following when installing a plural number of foam chambers on asingle tank.(i) Lay out the foam chambers in a way to be uniform around the tank. And,(ii) Work out a piping plan to assure a uniform distribution from each foam chamber.Form solution piping needs not be laid out in a loop system piping.Form solution piping shall be laid out at a gradient to assure that all foam solution inthe pipe will be drained out (gradient 1/250), and a drain valve shall be installed at thelowest point. When the lowest point will have to be buried underground, install a pitfor the drain valve.install a strainer on the water supply line for the concentrate solution tank.Install the concentrate solution tank and manually operated control valve at theoutside of dyke.The block valves of line used for the hydrant of foam extinguishing system shall belaid out collectively as far as possible on the outside of oil dyke. They shall beinstalled, separated for more than 15m from the outside of tank.The concentrate solution tank shall be installed in the vicinity of the control room.

Foam chamber

ConcentrateI

[

Riser pipe eolutiin tank

.?J

Flexible hose.6

Strainer

Tank lf25Jo ( From fire-

% D ke $rqhting main

ANY%??w&

Fig.10.16-L - Air foam piping around tank

10.16.5 C02 SystemFire-fighting system of C02 will have to be installed at times for the switch room, controlroom, computer room, etc.

10.16.6 In case of NFPA CODEDesign shall be prepared in conformity to the requirements of NFPA CODE. An example ofNFPA CODE 30 is shown in TEG1 -1311-003 “Points of design of tank yard in conformity toNFPA 30”.

—

10.17 Sampling PipingFor the preparation of actual drawings, refertoTEG3108 “Preparation of HOOK-UP DWG”.

10.17.1 Cautions for layout of PiPin9(1)

(2)

(3)

(4)(5)

(6)

(7)

(8)

(9)

Sample takeoff points shail be ~rovided at easily accessible locations. The installationheight shall be at a level from 0.6 to LOm from the ground or platform. When installingon platforms, the principle shall be to sewre access by use of stairway.Sampling piping from the header to sample takeoff point shall be made as short aspossible.Sampling piping to be taken out from horizontal or inclined piping shall be taken outfrom the side of pipe unless otherwise specifically requested.Sample takeoff points shall be collectively installed at one location as far as possible.Sample takeoff points of combustible fluid shall be provided at locations away fromignition source.Install a sample cooler for the sampling of high temperature fluid. Note 1)

Note 1 : EXXON BP3-2-7 specifies the installation of cooler in case fluidtemperature exceeds 60”C.

For fluid containing substance which W-II increase viscosity at a low temperature,provide a means to clean the piping and cooler by steam or other medium.The size of drains and sampling piping except the following shall be the minimum of3/4B. The size of vent pipe shall be the minimum of 3/4B.(a) The sampling piping connected from equipment shall be sized the same as the

nozzle of equipment.(b) The minimum size for abrasive fluid or fluid becoming highly viscous at low

temperature shall be IB.Install the source valve in the vicinity of header and the operating valve in the vicinity ofsample takeoff point. Valve types are shown in P8JD and UFD.

(10) Provide a working space of about 0.5m x 0.5m in the vicinity of sample takeoff point.(11) Sampling of more than two fluid shall be done at a point 12xD away from their

confluence.Note 2 : From EXXON BP3-6-1.

10.17.2 Layout of analyzer shed(1) The analyzer shed shall be located at a position which will shoden sampling piping.

Consultation shall be held with Instrumentation Design Division as to the location,quantity and size.

(2) Show the location of analyzer shed on the plot plan, and have it reflected on pipingdesign.

10.17.3 Example of sampling piping around pump (Refer to Fig. 10.17-A).Takeoff point shall be provided at a location where fluid is always flowing. (However,the returning position can be selected on a residing section).Install a temporaiy valve in the immediate vicinity of mother pipe when takeoff point islocated at a high level. There will be no need to give any particular consideration to theoperational quality of such valve. (Dealing shall be possible with a tempora~ frame,etc.)

Temporary valve T

Tx

J x Sampling Cooler

@

T<

I/lJ

-1-1

5

C3

Fig.10.17-A - Example of sampling piping arour$l pump

- .—.,, -. . . . .

10.18 Steam Trace Piping- As a general practice, color the line necessary of tracing on a copy of piping diagram and

work out trace, manifold plans. Designing method, etc. will be briefly outlined in thefollowing. For the details, refer to the technical specifications, H-107. As regards thepreparation of actual drawings, refertoTEG1-131 3-105 “Preparation of steam tracingdrawings”.

10.18.1 Design Standards(1) Scope of Trace

The scope of application of steam trace to equipment, piping and line instruments isshown in P&lD and UFD.

(2) Purpose of TraceSteam trace is applied to equipment, piping and line instruments which require externalheating so as to assure that the freezing, solidification of internal fluid, increase inviscosity, separation caused under anticipated atmospheric temperature, or thecondensation of steam in corrosive gas will not hamper the normal operation andsuspension of plant.

(3) Steam and condensate for trace(a) Low pressure steam meeting with the following conditions will be used as the

heating source of trace system:Operating pressure : kg/cm2G ( MPaG)Operating temperature :

(b) The condensate generated shall, in principl~cbe recovered into the main pipe oflow pressure steam condensate under the following conditions:Operating pressure : kg/cm2G ( MPaG)Operating temperature : “ cNote 1 : When the main pipe of steam condensate does not exist in the vicinity of

condensate discharge point, condensate shall be discharged into asewer.

(4) Insulation ThicknessThe insulation thickness of piping to be traced shall be determined in accordance withthe following standards and the technical specification, L-1 01:(a) Pipe diametec External diameter of pipe to be traced(b) Temperature: Normal operating temperature of pipe to be traced

10.18.2 Steam Trace System(1) Outline of System and Terminology

(a) The terminology used in this design standards and the outline of system are shownin Fig.10.18-A.

(b) In the trace system, tracers characteristic and peculiar of things to be traced shallbe provided basically.Note 1 : Basically, piping, equipment and instruments shall be traced separately.

Provided, however, that sample piping, drain, vent and line instruments(pressure gage, control valve, safety valve, etc. installed on pipingsystem or equipment) shall be traced by the same tracer as used for thepiping system or equipment.

E

). . . . . . . . . . . .

(2) Steam Supply System(a) Steam Supply Header

(i) in PrinciPle, the SUPPIY of steam to trace system shall be made by the steamnetwork system inside the plant (hereinafter called the steam main pipe). Asubheader shall be installed, however, when the installation of a subheadersystem exclusively for steam trace (hereinafter called the subheader) isconsidered reasonable.

(ii) install a block valve to enable to take off the subheader upward from thesteam main pipe and make it as a separate and independent system from thesteam main pipe. The block valve shall be installed on a horizontal sectionnear the branching point of subheader.

(b) Steam Supply Nozzle (Tracer supply nozzle)(i) The nozzle for supplying steam to the tracer shall be taken out upward from

the steam main or subheader.(ii) When taking out the nozzle for supplying steam to the tracer from the steam

main or subheader, install a block valve in the vicinity of steam main orsubheader. The block valve shall be installed at a position easy to operationfor the purpose of opening and closing operation.

(c) Tracer Manifold(i) When more than three steam supply nozzles are required within a radius of

three meters, install a steam supply manifold (hereinafter called the tracermanifold) taking the following points into consideration:- Install a block valve on each tracer supply nozzle of the tracer manifold

for the purpose of opening and closing operation.- When branching off a steam supply pipe to be connected to the tracer

manifold (hereinafter called the tracer manifold supply pipe) from thesubheader, no block valve shall be installed between the subheader andtracer manifold.

- When branching off a steam supply pip to be connected to the tracermanifold from the steam main pipe, a block valve shall be installed in thevicinity of branching off point for the separation of system.

(ii) Except where otherwise specified, a plural number of steam supply nozzlesadjoining in vicinity shall be laid out on the same manifold in disregard oftheir objects (for piping, equipment or instruments) and the classification ofseason for use (throughout the year round, or for the use for prevention offreezing in winter season).

(3) Condensate Return System(a) As rule, the condensate return system shall be installed in accordance with the

same standards as applied to the steam supply system. (Refer to the paragraph,10.18.2(2)).

(b) When no condensate is recovered(i) Condensate return manifold (hereinafter called the condensate manifold) shall

not be installed.(ii) For the exit of steam trap, piping shall be done to the drainage ditch nearby.

10.18.3 Design Details(1) Steam Supply and Condensate Return Piping

(a) The subheader and tracer manifold supply pipe shall be designed similarly with thesteam main pipe.

(b) The subheader and condensate return pipe shall be designed similarly with thecondensate main pipe.

(c) Their piping shall be designed in a manner to minimize condensate pocket.(d) The size of tracer manifold supply pipe to be connected to manifold and of the

condensate manifold return pipe shall be 2 inches except where specificallyspecified in the drawings.

(e) A plural number of tracer manifold (2 inches) can be branched out from a tracermanifold supply pipe (2 inches). In this case, however, the total number of tracernozzles on each manifold as against the single tracer manifold supply pipe shall belimited as follows: (Refer to Table 10.18-A).

.—.— . . . . . . . .

Table 10.18-A - Number of tracer nozzles which can be branched out froma single tracer manifold supply pipe

~

Tracer size Total number of tracer nozzle max.

The limitation shall also be applicable to the condensate manifold return pipe.

(2) Manifold(a) Outline

Tracer manifold and condensate manifold shall conform to the following:(i)

(ii)

(iii)

(iv)

To unify the shape of steam supply and condensate return pipes, the manifoldshall conform to the standard shape as shown in Fig.10.18-B.In the designing stage, it shall be planned to install more than one sparenozzle for each manifold and cap-clamp their ends (no block valve). Thespare nozzles shall be installed on the upstream side in direction of steamsupply for tracer manifold and on the downstream side for condensatemanifold.The size of manifold shall be the same as the tracer manifold supply pipe andcondensate manifold return pipe (normally 2 inches).The size of steam supply nozzle and condensate return nozzle on manifoldsshall be 1/2 inch.

Note 1 : The quantity of nozzles on each manifold shall be 4 at the minimum and12 maximum.

11! 1!!!! !!!!~~!j!!!! !!!!1111814 !Illt vim

r l “ 2B , i“ w LJ

Support pint SW+& pint I

IType V#S I

7I II fhI

1/2s

2s ISUP@ point

1

SUPFA pdntII Type I-MD &in)

-1 II, ~ we

I 2s

support point suppat pointI Type I-MS I

Note 1: Definition of manifold type number

(Example)y/~(a) (b) (c)

Where,

(a) Nozzle directionV: VerticalH: Horizontal

(b) Nozzle quantity

(c) Drain nozzle on manifoldD: With drain nozzleS: No drain nozzle.

Note 2: The sketch shows the case of 12 nozzles. Even when the quantity ofnozzles is limited, no change shall be made, in principle, of drainnozzle position, support point and nozzle projection length.

Note 3: When using the spare nozzle on manifold for additional tracer, theend of the nozzle shall be cut off by about 50 millimeters and a blockvalve be installed.

Fig.10.18-B - Details of manifold

(b) ArrangementThe relationship between manifold arrangement and piping connected to it (tracermanifold supply pipe and condensate manifold return pipe) shall be as follows:(i) Tracer manifold

When tracer manifold is located above the steam main pipe or subheader(Refer to Fig.10.18-C).

Tracer supply pipe

1 J(

Sparen

P Sy*em separation valve

2“ 1-J

from steam main pipeT

} ~Steam main pipeor subheader

Fig.1 0.18-C - Arrangement of tracer manifold

Note 1 : In this case, no condensate will stay in the manifold because ofconstruction so that drain nozzle can be omitted from the manifold. Thisarrangement shall be use basically.

When tracer manifold is located below the steam main pipe or subheader(Refer to Fig.10.18-D).

Tracer supply pipeAr \

System separation valve from

m l ” “- ‘“”” ‘ “ ” ” ” ” ’-Steam main pipe

lJ-. .t~ Steam main p-ipe or..- —-. -

subheader4

PSystem separation valveFrom condensate main pipe

T

Connection from othercondensate manifold

c1T : Strainer built-in type steam trap

Fig.10.l 8-D - Arrangement of tracer manifold

(ii) Condensate manifold (Refer to Fig.1 0.18-E)

Tracer return System separation valveA condensate main pipef 3

1 ,+ ICondensate main pipe or

4subheader

L

n

a \2* c1

T : Strainer built-in type steam trap

~ Fig.1 0.18-E - Arrangement of condensate mariifold

(c) Drain nozzle of manifold(i) The drain nozzle on condensate manifold shall be equipped with a block valve,

and its end be capclamped.(ii) The drain nozzle on a tracer manifold located below steam main pipe or

subheader shall be provided with a steam trap. The drain pipe shall be .connected to the condensate main pipe or subheader through the condensatereturn pipe.

Note 1 : When no condensate main pipe exists in the vicinity of the manifold,condensate shall be discha~ed into an open sewer.

(3) Tracer(a) Size

Steam tracers shall, in principle, be made of carbon steel pipe and their nominaldiameter shall be 1/2 inch. However, for long distance piping (inter-connecting pipe,etc.) or large diameter piping and piping for tracing with diameter below 4 inches, orequipment having complicated external shape or line instruments, 3/4 inch pipe and$10 x $8 tube (external diameter x internal diameter) can be used.

(b) Number of tracersFor the retention of temperature of piping to be traced, the minimum number ofsteam tracers in parallel with the piping to be traced shall be as shown in the tableattached to the technical specification, H1 07.

—-...

Table 10.1 8.3-B - Minimum number of tracers

Table 1

STEAME 133°C (3at)INSULATION Annual total hours using calcium silicate: 6,000h (JIS A 9501 No. 2701)

Insulation thickness: 3/4in-l m: 25i 1 % in-3 in: 30T 4 iw12 in: 40t 14in-24 in: 50t

UmbuntTCIIIP.

m

20

0

-20

-40

~*- Tracsr PIPE SIZE (Mdmd Sk I

70I1 I 1 I 1 I I I

I 1 ,

I I I I I 1 1 I 1

fZZZZ2Z Single tracer ~ Triple tracer

@.%@’A&Yl, ., ,... Double tracer 1—1 Use large sized tracer ort h e r m o c e m e n t

..— —— .

Table 1O.18.3-B - Minimum number of tracers

Table 2

STEAME 147°C (4.5at)INSULATION Annual total hours using calcium silicate: 6,000h (JIS A 9501 No. 2701)

lnSLI[diOn thickness: ~wl in: 25t 1 % in-3 in: 3(IT 4 in-12 in: 40t 14in-24 in: SOt

,mbidTamp.

(w

20

0

-20

-40

Main- Tm=r PIPE SUE (in.)t4in9d .Temp. “-rc) W4 1 11/, 2 3 4 6 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4

10

30

60—

10

10

30—

50

70—

10

30—

60—

70

10—

30

60—

70

J 1 I t I I I 1 I t 1 I I

I I I 1 1 I 1 I

1 I I I I I I i

~ Single tracer ~ Triple tracer

~ Use large sized tracer orthermocement

*

Table 1O.18.3-B - Minimum number of tracers

Table 3

STEAME 170”C (8at)INSULATION Annual total hours using calcium silicate: 6,000h (JIS A 9501 No. 2701)

r

,mbHtTemp.

(%)

20

I

o

-20

-40

insulation thickness: 3/4in-l in: 2S 1 % in-3 in: 30T 4b12 in: 4ot 14in-24 in: Sot

Main. Tm=r PlPE6rzc(in.)● ind G*

kmp.(w anl lt&2a46810 111416]6~~24

~ Single tracer ~

Double tracer ~

Triple tracer

Use large sized tracer orthermocement

(c) Tracer lengthThe maximum allowable length of tracers from the tracer supply nozzle to steamtrap shall be as follows: (Refer to Table 10.18-B)

Table 10.1 8-B - Maximum allowable length of tracers

Note 1 : Even when 3/4 inch pipe is used for tracer, the steam supply nozzle on themanifold and condensate return nozzle shall be sized 1/2 inch, and thebore change to 3/4 inch shall be done at the vicinity of each nozzle. Whenusing $10 x+8 tube for tracer, the tracer supply nozzle and tracer returnnozzle shall be similarly sized at 1/2 inch. (Refer to Fig.1 0.18-F).

Pipe being traced,,I 1I II I

*10xa?8tracejubec1~~-~

(1/2x010)

Note 2 :

Note 3 :

AL~ Minimum‘/2’ %“

Minifoled

Fig.10.l 8-F - Connection of tracers and manifold

When a tracer has a branch, the branch length shall be included in thetracer length.When a tube tracer is used in part in a tracer system, size adjustment shallbe made by using a tube connector at an optional point in contact with theobject of tracing. The maximum allowable length in such case shall berestricted to an appropriate range.

(d) Position of tracerThe position of tracer as against the traced pipe shall be as shown in Fig.1 0.1 8-G.

— ..—. —-..

Sinale tracer Double tracer Trkde tracer

Horizontal Dic)inq

Vertical c)ic)inq

Fig.1 0.18-G - Position of tracers

(e) Pocket of tracer(i) Tracer pocket shall be minimal. No drain shall be provided even when a pocket

exists in a tracer.(ii) Tracer pocket shall not exceed the height of 2 meters. (Refer to Fig.10.1 8-H).

Pipe being traced

-----{IIIIII1IIII

L

II[

Fig.10.l 8-H - Height of tracer pocket

(f) Tracer piping(i)

(ii)

(iii)

(iv)

In principle, each tracer shall have individually a steam supply valve (startpoint) and a steam trap (terminal).When there is no pocket in a tracer and condensate can be discharged bynatural flow (including horizontal piping), it will be permissible to combine morethan two tracers into a single steam trap. In such case, the length of each tracershall be approximately the same and the total length of tracer shall not exceedthe specified value.The tracers of equipment, valve, line instruments, etc. shall be so arranged toassure that each element can be easily taken away.No elbow joint shall be used for tracers. Field bending shall be executed,instead. Tracers shall be bent in such way not to cause any excessive flatness.

.——... . -.,.. -— .. —- -——— .“

(The normal bending radius shall be from four to six times the nominal externaldiameter of tracem).

(g) LooP of tracersThermal expansion absorbing loops of tracers shall be provided on straight sectionsat an interval of every 24 meters. The direction change of tracers at the bend ofpiping, valve and flanged parts shall be regarded as loops. (Refer to Fig.10.1 8-J).

Q

-YIi

24 iii;“%---------- .

vql---------- . -.-,----- ---------- . - . -: .:------ .- .-.x:” :4 p-------- .-. +\

1J4in0f’m7rYi-24m-a— - - - - l Note 2:

t

30m according toEXXON BP3-9-2.From EXXON BP3-9-2.

Fig.1 0.18-J - Loop of tracers

(4) Spacer(a) Application

(i) For piping specially specified by a symbol peculiar to P&lD and UFD (thosehandling acidic and caustic fluid), 10mm-thick spacers shall be installedbetween tracers and traced piping for the prevention of overheating.

(ii) 10mm-thick spacers shall be applied for valves using nonmetallic sheet indanger of sustaining damage by heating.

(b) Pitch25mm wide spacers shall be installed at an interval of 300mm as shown in thefoIlowing drawing: (Refer to Fig.10.18-~.

Fixed fw.re or band]

-.

1 Omm

I

300mm

Fig.1 0.18-K - Installation of spacers

(5) Atmospheric Discharge of Condensate(a) When condensate is not recovered, piping shall be made for the exit of steam trap to

a drainage ditch (open ditch or trench).

— ——. . -. —---- —.. . . ..—. — . . .

Note 1 : No condensate shall be directly discharged to the sutiace of concretepaving. When no open ditch or trench exists in the vicinity of dischargepoint, a collecting pipe shall be installed from the discha~e point to adrainage ditch.

(b) When no open ditch exists in the vicinity of discharge point, an undergroundpenetrating type pipe ditch (gravel laid out) shall be installed at the discha~e point.

10.18.4 suPPOrt(1)

(2)

(3)

The steam supply and condensate return piping, manifold and tracer (excepting the partsin contact with traced objects) shall be properly supported in accordance with the suppedindication symbols as specified on “Steam trace piping hook-up drawings”. No shoe shallbe used for the support of these piping, manifold and tracers.No support symbols shall be shown on drawings for the tracer portion in contact withtraced objects. These tracers shall be fixed on traced objects at the interval ofapproximately one meter (approximately 300mm intewal when spacers are used), anddouble winding steel wire or single w“nding steel band shall be used. At the bend ofpiping, the intewal shall be properly shortened.When a special support becomes necessary, conform to the suppori method shown in thehook-up drawings or the design standards.

10.18.5 Materials(1) Steam Tracer Materials

(a) Steam tracer materials shall be basically to the same specifications as used for thematerials for steam main pipe and condensate main pipe. However, the connectionof tracers shall all be butt welded and the tracer nozzle takeoff patis (branches) frommanifold and the branches of tracer themselves shall be nozzle welded.

(b) When applying tube tracers, copper or stainless steel tube shall be used.(i) The specifications for tube and tube connector shall be as follows:

Copper materials: Seamless and normalized tube as specified in JIS H3300“Copper and copper alloy seamless tube”Stainless steel materials: Seamless and normalized tube of SUS304TP asspecified in JIS G3459 ‘Stainless steel pipe for piping”, or of equal or betterquality than SUS304LTP.

Note : Copper tubes shall be applied under the working pressure of10kgf/cm2G(l MPaG) or less and temperature below 200°C. Note 1) Note1: 260”C according to EXXON BP3-9-2.

(ii) Tube connectom shall be of bite type (flareless type), and materialspecifications shall be the same as the tube materials.

(2) Steam TrapSteam traps shall be of socket welded, strainer built-in thermodynamic type.Note 1: The thermodynamic type shall not be used when the back pressure of traps

exceeds 50°A of pressure on entrance side.(3) Binding Materials

(a) WireThe tying wire for the tracers used for carbon steel piping shall be to JIS G3532,SWM-G1, normalized and galvanized. And the wire diameter shall be +1 .2mm(S. W.G#18). For stainless steel piping and equipment, stainless steel wire, SUS304-W1, as specified in JIS G4309, shall be used. The wire diameter shall be similarly$1.2mm.

(b) BandWhen using steel band in place of wire, the band shall be galvanized steel asspecified in JIS G3313 or stainless steel make as specified in JIS G4307 withdimensions of 0.4mm thick and 13mm wide.

(4) SpacerSpacers shall be made of asbestos or glass cloth tape.

.—

10.18.6 Execution of Steam Trace System(1) Chamcteristic Number of Tracers (Refer to Fig.10.16-L)

(a) Chamcteristic numbers shall be given to the block valves used for opening andclosing opemtion of tmcer systems which are installed at steam supply nozzles andcondensate return nozzles to classify each tmcer.

(b) The assignment of numbers to block valves shall be done in accordance with thefollowing:

~ ~

(i) (ii) (iii) (iv) (i) (ii) (iii) (iv)

Where,(i) Abbreviation of purposes

SS: Steam supplyCR: Condensate return

(ii) Area code (to be defined by each Job)(iii) Manifold serial number(iv) Nozzle serial number (In case of manifold type only)

m m1 I ------------~

r - - - - - - - - - - - - - - ~-----=I I

: I I uT

I I I-. --q I I I *i ii i

F(Steam)

- 1 --------------- -------- 3.

iiii - - - -

SS-102 -2 -3 -4 -5 -’6

..4”

IIII

J F------

i i!

1t ~T.-.-.-.-.-.-. +-.-. -.:.-.qI

-: -5 -4 -3 -2~(Condensate)

o.

Fig.1 0.18-L- Example of number assignment to tracers

(c) The linkage information between steam supply nozzle and condensate return nozzleshall be in accordance with Table 1O.I8-C “Steam tmcer”.

——. .-— —. —.-

Table 10.1 8-C - Steam tracer(Tracer manifold standards)

Area: Sheet No. 1

Tracer Manifold Steam tracer Condensate ManifoldNo. Position Hook-up Nozzle No. Hook-up Being traced No. No. Position Hook-up Remarks

Piping Diagram No. Dwg. No. Dwg. No. Piping Diagram No. Dwg. No.

(2) Manifold(a) Except where othenvise specifically specified in job dowments, manifold shall be

manufactured in accxxdance with Fig.1 0.18-B by respective manifold type numbers.(b) Manifolds shall be installed in accordance with “steam trace piping hook-up

drawings” and “tracer manifold arrangement drawings”.(c) When arranging manifolds along the operation platform, their supports shall be

installed as rule in accordance with Fig.1 0.18-M.

Manifold.

Platform

Fig.1 0.18-M - Support on the side of platform

(3) Arrangement of tracers around manifold(a) The steam tracers around the manifold shall be executed as shown in the following

figure. (Refer to Fig.1 0.1 8-N).

. .—— -

. . . .

Taz9tshs(+AShorten as far as possible

3m

support

‘h~ml;ll~tias ‘ossib’eFig.1 0.18-N - Piping and support aroun

— . ..——— . . . . . . . .

(b) Steam tracers shall regathered asmuchas possible and besupportedas shown in the figure below: (Refer to Fig.1 0.18-P).

(Vertical tracer)I

I/

iii L50X50X6j

-iiiii

Side ViewIation

i

(Horizontal tracer)

M

II❑ \ InsulationIIII

+

Side View

collectively

,,, , ,/ *

i i i i i i

Plane

Fig.1 0.18-P - Details of manifold support

(4) Traced piping and tracer(a) Tracers in contact with traced pipe shall be fastened onto the traced pipe as shown

in Fig.10.18-Q:

Approx. 1 m Approx Approx. 0.3m Min. . 0.3m

p—l +-—+--+ 1+4+-., ,------ -------- ------ ----- ----

Wire or Band :

Tube FittingTube Fitting

(Without spacer) (VWh spacer)

Fig. 10.1 8-Q - Fastening tracers

. ..-— -

(b) Tracers around element parts having irregular shape, such as valves and Strainem,shall be fastened as shown in Fig.1 0.18-R:

Wire or band Wire or band Minimum Approx. lmFlange or tube fitting flange or tube fitting SpacerMinimum Approx. 0.3rn

/

bu ~. ~ .*.- == ‘inoAppr0x03mFlange-or A’PP~OX. 1 m //Tube Fitting Flange or

Tube Fitting ICover the outer circumference of tracerwith asbestos ribbon and fasten theribbon to the tracer by a single line ofwire.

(Without spacer) (With spacer)

Fig.1 0.18-R - Fastening tracer at irregular parts

(5) Tube ConnectionTube tracers shall be connected by using a bite type tube fitting as shown in Fig.1 0.1 8-T.The applicable parts of the tube fitting shall be indicated by the following symbols on the“steam trace hook-up drawings”. (Refer to Fig.1 0.18-S).

(a) Direct coupling union

(b) Branch union

(c) Connecting union with pipe

\pipe tube

\

Fig.1 0.18-S - Indication of fittings

.—. - . . -—— -----

Pipe - tube direct couplingconnector ~

I Branch union I

‘/2” x 10+ aloxalo Olox Olox OloWxlo+ mI ~loxdd tube

,$i$Ioxo?% Stainless tube

iJ*?* “..#* I

.— .

Pipe

symbolsMaterial *K 3~*

Stainless steel Ssu 04s SSU 06sCopper Csu 14s CSU 16S

Pipe - tube branch connector

#oxa?3 t u b e

/

\

— .if

I

I Materials I Symbols \

Pii3e I Materials

stainless steel SSU 04T Ssu 06Tlj$loxd8 Copper CSU 14T Csu 16T

a — .

h10X48 tube

#lox & tube

I Copper ! CSU llT I

—- . . ..- . .

Fig.1 0.18-T - Tube fittings

is shown in Fig.10.16-U through 10.16-Y.(6) Standad Arrangement of Tracers

The standard arrangement of tracers

.10.1 8-U Around Dinina... .- ----- ..-—. —Scope of trace Tracer arrangement

(1) Traced piping connected to equipmentnozzle

— —Start of tracirw from hiah Dosition

/

\\\

k>

)\\ I1 II1 1I I Steam supplyIi 1t1II

— I \\

\\ \ 1\\ I

\)IIItIII

(2) Traced piping bran~;ed out from header Steam Supply

‘. ‘ . \~,,~/0 \ \ I

.“ \ Ir

I I

k

\I -} I \I \I I \!I I1 It1 It I:II \4

g]

— . . . .—— ----

Srm-ua nf trae~ I Tracer arrangement----- -. ----- .. —— - —. ._. _. .._ . .(3) Trace of branch pipe only

\

Steam

N\

.-- ,.“ .“ :

.#.-..“..”fIIIIIII I1I I1I

II

:

(4) Branch of traced piping end

,.t II

tII

:.

1

:

i) Branch of traced piping Steam supply

r--- ~I - - -II

p‘.\- -

--

r - -IIII -9L. I

II1L

Fig.1 0.18-V- Around equipment nozzlescope of trace

(1) Nozzle trace inside skirt

r

.

FI

t,1,t ,8,

1!t: t----’IIII1IIII

J. .

/

Tracer arrangement

Venthole

\.

SteamSupply

r

FII --IIlL -- -

1I1

+

[

1IIIIL

—

Fig.10.18-W - Around line instruments and equipment

scope of trace(1) Pressure gage

(2) Rotor meter

Tracer arrangement

Visual

Visualdirection

J-

-)

.-. —----- ——

— .— -.— - . ----

. .- ..-4 -- —-1:-- -.-: ..4Plg.l U.l C$_A Aruunu SdIIIpIIIIy PUli IL

Scope of trace Tracer arrangement(1) -

Steam supply

/

1I

\ \ \ \ ●

II

I

‘1

I

(2)

. . . . . . . Steam

+

!t1IIrIIII Sampling coolerIII-t-

Fig.1 0.18-Y Around pump piping and pumpScope of trace

(1) Pump suction piping

(2) Pump delive~ piping

Tracer arrangement

Steam supply

?r“I

II

Steam supply

/

kSteam ~supply +

k’III

--- -—

scope of trace Tracer arrangement

Steam suDDly

——. . . .-. —.

Scope of trace Tracer arrangement

Take away point/

Flang

return /

Steam supply

Tee I Flange

Yv!!L.1I I

. . ..—

Scope of trace Tracer arrangement

Steam supply

i

. . ..-

1

bl

t }1

I

I1

(3) Pump

Pump bottom supporl(2ponts)

U-Bolt-

XL 50x SOX6I

10.19 Hose Station10.19.1 PurposeHose stations shall be established for the following purposes:(a) Air purge and nitrogen purge(b) Steaming of equipment and piping(c) Flashing of piping, filter element, etc., and(d) Cleaning of equipment and floor.

10.19.2 ObjectsGenerally, the station shall be established for the following equipment and piping as itsobiects. Scmafic objects will be indicated by Basic Design Division.(aj(b)(c)(d)(e)

Equipment and-piping handling combu~ble and toxic substancesEquipment and piping handling substances which tend to get dirty or clog upManhole of towerCrown and bottom of reactors, andCompressor.

10.19.3 Applicable FluidThe hose station w“ll supply three types of fluid of LP steam, plant air and water (four typesincluding nitrogen depending on cases). Depending on objects, supPly is required of a few ofsuch fluid. The details will be shown on UFD.

10.19.4 Specifications for Pipe Size and HoseThe specifications shall be as follows unless otherwise specifically requested by customers orthe necessity of process:(1) Size of pipe and hose: 3/4 inch(2) Length of hose : 20m(3) Type of hose : Select a necessary type according to the temperature of fluid,

pressure, and type of joint.(4) Supplied hose set : One set shall be supplied for two hose stations.

10.19.5 Cautions for Piping Arrangement(1) Arrangement of hose station piping and type

(a) Conform to Fig.10.l 9-A unless otherwise specifically specified for servicearrangement by customers,

..-— —..

11:!:111 li-i-il II :[ II

‘///;“’”,~,ptr””” “’A -, Dlisv2

Nitrogen (whenn—-v)

Nitrogen (whenr=’’’=v)

Air

Water

Steam

nlis i{4

Above-ground installation

*

0Ilsi{$El11s-[{2

Installation on platform

Fig.1 0.19-A - Arrangement of hose station

I

~!ii.-,-*- -s

piping

(b) When insulation is required of water and air lines also in a cold region, it will bedesirable to replace the arrangement of steam and water.

(c) When it is necessaiy for other service piping to establish as a station (for example,life air), obtain the confirmation of customers on the arrangement.

(2) Insulation of hose station piping and countermeasures against its freezing(a)

(b)

(c)

(d)

As a general practice: execute insulation for the steam piping only up to the blockvalve.When there is no fear of freezing, use generally by draining out condensate byslightly opening the root valve without installing any drain valve or steam trap beforethe block valve of steam piping.There is a method to prevent the freezing of water in a cold region by insulating thecomponent piping of station as a body by utilizing the diffusion heat of steam alongwith the discharge of condensate by installing a steam trap before the root valve. It isdesirable in this case for the prevention of freezing to change the arrangement ofsteam and water. However,, such change will make the piping for trap difficult so thatbe careful.It will be desirable in a cold region to limit the hose station nozzle of tower, etc. toone piece only and perform the connection and changeover of service on the ground.(To perform the separation of tower piping on the ground and leave the inside ofpiping always empty).

(3) Shape ofCoup~ng at End(a) Normally install a bamboo shoot type hose connector or quick coupling at the end of

hose station piping.(b) In a case using a quick coupling, certain customers request the prevention of misuse

by changing the type of connectors for nitrogen and air, so be prepared for that.(4) Position of Hose Station and Hose Rack

(a) The hose rack shall be installed in the vicinity of hose station.(b) The hose station shall be installed within 15m of an intended spot of its use.(c) Consider the supply of approximately 20m of rubber hose for each hose rack.(d) Details of hose rack. (Refer to Fig. 10.19-B).

.—-. .

16” PIPE

IOR 3..2t PLATE

I 400 —1

4

1

203

20

Note 1:

2 :

L60x60x6/

FIRLU WELD

Determine the installation point of hose rack afler havingdiscussion at the field.All joints shall be welded.

Fig.1 0.19-B - Details of hose rack

(5) Position of Block Valve(a)

(b)

(c)

The height of root valve of each hose station shall, in principle, be 1200mm from itsoperating surface.In the horizontal arrangement, the principle shall be to install the root valve at ahorizontal section.When installing on a platform in the horizontal arrangement, the support of eachpiping shall be taken from the end beam of the platform. In this case, the block valveshall be installed in the platform as rule. If the platform is narrow and thearrangement of hose station in that way will hamper passability, adjust the positionalrelationship between the support and block valve or consider the installation of blockvalve at the last transition point. (Consider the climatic conditions of Job as it is notdesirable from the viewpoint of countermeasure against freezing).

(6) Direction of Hose ConnectorThe direction of hose connector shall, as rule, be downward.

(7) Takeoff from Header (Refer to Fig.1 0.1 9-C)

Nitrogen Air, Water Steam

Note: Water can be take off upward from the header, considering the ease ofoperation of root valve.

Fig.1 0.19-C - Takeoff from header

(8) Example of piping around hose station (Refer to Fig.10.l 9-D)

Is3)

31

P

?’q

11

Main line (water )

1

1)

2)

3)4)

4Y.

Install valves on horizontal lines. (Close them up during winter season) or giveinsulation. (Be extra careful when countermeasures are required for freezing).Install a block valve for the hose station above the main line. During the w“nterseason, close the block valve for draining out.Install hose station valves above the main line on a horizontal line.Install a miniature trap on the hose station (steam line) below the main line fordraining out.

Fig.1 0.19-D - Example of piping around hose station

10.20 Eye Washer and Emergency Shower10.20.1 PurposeThe eye washer and the emergency shower shall be installed on following occasions.Specific objects shall be designated by the Basic Design Division.

(a) Cases where chemicals have to be frequently handled in person in the vicinity of anapparatus handling chemicals harmful to human body, and

(b) Cases where fluid handed by devices or apparatuses which require frequent internalinspection is harmful to human body or polluted.

10.20.2 Pints of Installation

(a) Places easily accessible(b) Places which could be reached within ten seconds from dangerous objects and within

30.5m (or 100 ft.) *1

*1 : Within 15m according to EXXON BP3.2.6

10.20.3 Shape of Eye Washer and Emergency ShowerShown below are the typical drawings of the eye washer and the shower : the shapes anddimensions shown here shall be taken as reference for planning purpose, and their detaileddesigns shall be in accordance with the maker drawings.

(1) Those in which the eye washer and the emergency shower are separate (as seen in theexample manufactured by Nikki). (Refer to Fig. 10.20.A)

Fig. 10.20.A - Eye washer and emergency shower

Drain port Water supplyport

Drain port

(A) Eye washer (B) Emergency shower

(2) Those in which the eye washer and the emergency shower are in one body.Which type to buy, monolithic or separate, shall be decided by jobs. (Refer to Fig. 10.20.B.)

(A) In case of using monolithic type (B) In case of buying separate type

Fig. 10.20.B - Monolithic type eye washer and emergency shower

10.20.4 Precautions for Piping Arrangement(1) The water for the eye washer and emergency shower shall be obtained from potable

water piping system.(2) The drain for the eye washer shall be piped to the nearby drainage ditch. It will be

desirable for the shower to be installed on a paved or gravel surface since the water willhave to be discharged without treatment.

(3) In a cold district, countermeasures shall be taken against freezing. Avoid traced linesystem, wrap insulating material around the piping and provide bypass and blow valve toprevent residence.

10.21 Drain and Vent10.21.1 Installation Standards(1) Installation of Drain and Vent(a) Those necessary for

operation- Specified by P&ID and

UFD.- Those required by the

shape of piping will bedesignated by the ProcessDesign Division.

- Closed system (Toxic orinflammable)

- Open system (Releasedinto air) (without danger)

(b) Those required inhydrostatic test

- Part of pipes subjected tohydrostatic test, at whichair pocket and drainpocket are to be formed(to effectively utilize drainand vent which arerequired for operation)(Note 1).

- Open system

Note 1 : Provide drains at all drain pockets and vent at air pockets of pipes larger than 21/2B.

(2) Drain and Vent Required for Operation(a) Vent

EntranceEntrance

Piping

Piping

Piping drain

Piping

Piping drain

(i) Vent for Tower and TankVents shall be provided at the highest points of towers and tanks. The vents aresometimes installed directly on devices and sometimes on connecting pipes. (Inthe latter cases, no valves or blind shall be placed between towers or tanks andpiping.) Which type to select, open vent or closed vent, shall be decided by thetypes of object fluid by the Process Design Division.

(ii) Vent for PumpAn air bleeder vent for starting shall be installed at a high point upstream of thegate valve of pump delivery line. Such installation will not be necessarilyrequired if a pump had a casing vent. Which type to select, open vent or closedvent, shall be decided by the types of object fluid by the Process DesignDivision.

(iii) Vent for Heart ExchangerThe necessity of vent installation and their positions shall be determined by thetype of heat exchangers. That is, if any air pockets is formed, an open vent shallbe adopted for the start of operation. Especially when possibility exists that non-condensable gas will remain inside a heat exchanger, the gas needs to beremoved during operation. It will become necessary, therefore, to install a closedvent depending on the type of fluid.

(iv) Vent for PipingA vent shall be installed at an air pocket of fluid line. The vent must always beinstalled when such air pockets is located upstream of a pump or control valve.The vent for hydrostatic test shall be an open vent and non valve needs to beinstalled.

(b) Drain(i) Drain for Tower and Tank

Install drains at the lowest points of towers and tanks. The drains are sometimesinstalled directly on devices and sometimes on piping. (In the latter cases, nonvalve or blind shall be placed between placed between towers or tanks andpiping.) Which type to select, open drain or closed drain, shall be decided by thetypes of fluid handled. Generally, both of closed drain and open drain are ofteninstalled on scoop tanks.

(ii) Drain for pumpIn order to drain out liquid remaining inside a pump, a drain is installed at a lowpoint downstream of the main gate valve of a pump’s suction line. Which type toselect, open drain or closed drain, shall be decided by the types of object fluidthe Process Design Division. It will be desirable to take measures to switch toopen drain even when installing closed drain. A casing drain (with valve or plug)is at times installed on a pump itself. On such an occasion, the installation of aseparate drain is omitted by regarding that as a drain.

Remarks : It will b necessary to install a bypass line and valve on a check valvefor the purpose of draining out liquid from a discharge line.

(iii) Drain for Heat ExchangerThe installation of drains and their positions shall be determined by the types ofheat exchanger.The drains shall, in principle, be installed for the discharge of remaining liquidpockets are formed. Which type to select, open drain or closed drain, shall bedecided by the type of object fluid.

(iv) Drain for PipingInstall drains at places with possibilities of pocket formation on liquid lines andof liquid condensation, The purpose is the same with other drains. Which type toselect, open or closed, shall be decided similarly with other drains.

(v) OthersAs for the drain for control valves, it shall be installed when installing blockvalves. Usually, an open drain shall be installed upstream of a control valve. Thedrain for a rotor meter shall be of an open type and be installed on its entranceside. As for the drain for strainers and filters, the open type shall be installed atthe lowest points.

Remarks : The drain is sometimes installed on the valve itself for the purpose ofreducing fittings.

(3) Drain and Vent Installing Points(a) Install drain valves at locations where discharged liquid is visible.(b) Install them at locations where no hindrance will be caused to passage or for access.(c) Install air blowoff drain and vent at locations where no harm will be given to human

body.(d) Height of drain from the surface of ground or floor (Refer to Fig. 10.21.A).

Note 1 : When heat insulation or cold insulation works are to be executed,the minimum height shall be 200mm irrespective of their thickness.

Fig. 10.21.A - Height from ground or floor surface

10.21.2 Size and Type of Drain and Vent(1) Size of Drain and Vent

(a) Size of Drain and Vent Required for OperationShown hereunder are general sizes of drains and vents required by the types ofdevices :(i) Tower and Tank

Generally, the sizes of vent and drain are determined by the magnitude of towerand tank diameters. The size, however, vary by respective licensers.

(ii) Heat ExchangerThe normal size is ¾ inches for both the vent and drain.

(iii) Pump and CompressorThe normal size is ¾ inches for both the vent and drain.

(iv) PipingThe normal size is ¾ inches for both the vent and drain. Sizes larger than oneinch are used at times for fluid or high viscosity fluid including solid.

(b) Sizes of Drain and Vent Required for Hydrostatic Test

Parent pipe size Drain VentGeneral Under ¾” Parent pipe size -(Those not specifically designated) Over ¾” - 2” Min. ¾” -

Over 2 ½” Min ¾”Piping for abrasive fluid and high ¾” ¾” -viscosity fluid at low temperature Over 1” Min. 1” Min. ¾”

(2) Type of Drain and VentThere are following types of vent and drain : Determine and unify the type in consultationwith the Basic Design Division Prior to the execution of each job.

Vent installing method Drain installing methodValves Valve

Valve + Cap Valves + CapValve + Blind Valve + Blind

Blind Plug

Min. 100mmMin. 150mm

Note1)

Note 1 : Double valves are adopted at times for high pressure line or slurry line.Note 2 : In the vent for hydrostatic test, plugs or blinds are used in principle

without installing any valve.Note 3 : Determine which to use, blind, cap or plug, after consideration of the

permissible leak of internal fluid. The decision will be affected by thetype of fluid (susceptibility to leak, danger in case of leak) and pressure.Blinds are often used for liquid which leak easily and is highlydangerous like hydrogen, or for liquid under a high pressure (900pounds and over for instance).

10.22 High Temperature and Low Temperature Pipings

10.22.1 Problem Caused by Thermal Expansion of PipingThermal expansion is caused to piping and devices which handle high or low temperaturefluids. A thorough consideration should be given to the effects of thermal expansion in thedesign of piping, connecting devices, supporting frame and supports. Problem caused bythermal expansion will be shown below- Destruction of piping and supporting device due to excessive stress or fatigue- Leak from joints- Harmful stress and deflection caused to piping and connecting devices due to an

excessive thrust and moment to piping- Touching of devices and piping to their neighboring objects due to thermal expansion

10.22.2 Precautions for Pipe Arrangement(1) In taking out branch pipes, let them have an adequate flexibility by giving a thought to

the amount of movement of the main pipe. (Refer to Fig. 10.22.A).

Fig. 10.22. A - Flexibility of Branch Pipe

(2) Take an adequate spacing to assure that devices and piping will not touch neighboringobjects due to thermal expansion. (Refer to Fig. 10.22.B). Take the elongation of thereactor body into full consideration since the platform is often handled as a separateframe in the vicinity especially around the reactor.

[7] Watch out for touching

Branch pipe

Fixed point

MovementDoes it have an adequate flexibility?

Fixed point

Main pipe

Fig. 10.22. B - Touching with neighboring objects due to thermal expansion

(3) As regards the insulated pipe to be placed on top of the support beam, determine theB.O.P. elevation of the pipe in consideration of the thickness of insulation. For therelationship between the thickness of insulation and elevation, refer to Paragraph 10.5.4(Refer to Fig. 10.22.C).

Fig. 10.22.C - B.O.P. of insulation thickness *

(4) Pipe arrangement in consideration of insulation thickness* (Refer to Fig. 10.22.D)

Watch out fortouching

Watchout fortouching

Fig. 10.22.D - Insulation and toughing with neighboring object

(5) Prevention of Excessive Distortion Locally Caused on Piping by Thermal Expansion(a) Places where high stress is caused on small diameter pipes when connected to large

- diameter or thick - walled pipes. (Refer to Fig. 10.22.E).

Fig. 10.22.E - An example of small - diameter pipes connected to large - diameter pipes

Watch out for touching

Watch out for touching

* Keep close watch on coldinsulation piping in particularsince dew condensation will becaused in case of any partiallack of such insulation.

Watch out fortouching

Watch out for touching

When no flexibility is given to small - diameter pipe asagainst the amount of thermal transfer from a large -diameter pipe.

Let it have a flexibility

(b) Places where diameter or wall thickness is locally reduced (Refer to Fig. 10.22. F).

Fig. 10.22.F - Example of local change in diameter or wall thickness

(c) Places where the majority of thermal expansion of piping must be absorbed by ashort offset section (Refer to Fig. 10.22.G).

Fig. 10.22.G - Example of absorbing thermal expansion by an offset section

(6) Install the pipe shoe at a location which will prevent it from falling from the rack beamdue to the thermal expansion of piping. (Shift the shoe installing position, or install abracket on the beam.)

Let it have a flexibility.

10.22.3 Absorption of Thermal Expansion(1) Method of Absorbing Thermal Expansion

Method Advantage Disadvantage Actual resultsUtilizing theflexibility of pipeitself (L.Z. vend,loop, etc.)

* High reliability forsafety

* Space is required for theinstallation of loop.

* Pressure loss increases

* Thermal expansion isabsorbed by use ofthe flexibility of pipesunless otherwisespecificallyrequested.

Expansion bellows(shaft line type)

* Being installed on astraight pipe, it doesnot require anyspacious place forinstallation.

* The support for fixingpoints and foundationbecome large because ofa large reaction due tointernal pressure.

* Guides will be required fora long piping to prevent itsbuckling.

* The method cannot beused for a high pressurepiping owing to its largereaction.

* It cannot be used for atype of liquid which willcause stress and corrosivecracks to the bellows.

* Places which will notallow the installationof bends, loops, etc.

* It has been adoptedin places requiringthe minimization ofpressure loss for thereason of process.

(Articulated type) * No spacious place isrequired.

* Used for piping, forwhich the shaft linetype bellows cannotbe adopted, forabsorption ofexpansion in thedirection at rightangle to the shaft.

* High cost* It cannot be used for a

type of liquid which willcause stress and corrosivecracks to the bellows.

Slip Joint * No spacious place isrequired.

* Applied to low pressureliquid only.

* Applied to a type of liquidwithout danger whenleaked.

* It is necessary to fastenboth ends of piping.

If has been adopted onspecial cases.

Swivel joint * No spacious place isrequired.

* Absorption ofexpansion in thedirection at rightangle to the shaft

* Impossible to absorbexpansion in the directionof shaft

* It has been adoptedon special cases.

Cold spring * Reaction decreasesat the fixed ends ofpiping. (Theamplitude ofgenerated stress willremain unchanged.)

* A High precision pipingwork will be required.

* It has been adoptedfor the pyrogenetic,high pressure, large -diameter piping ofpower generationplant.

(2) Absorption of Thermal Expansion by Utilizing the Flexibility of Piping(a) Utilization of Corner (Refer to Fig. 10.22.H).

Use the corner (L-bend) of piping, an important part having flexibility, for theabsorption of thermal expansion. In order to do so, install anchors and guides atlocations a little away from such corners.

Fig. 10.22. H - Utilization of Corners

(b) Method of Increasing Flexibility for Plane Piping (Refer to Fig. 10.22.J)The L-bend is the most economical method of absorbing thermal expansion with thesimplest form. When such absorption is impossible with the L-bend, add pipes atlocations far away form the line connecting endpoints.

Fig. 10.22.J - Method of Increasing Flexibility for Plane Piping

(c) Method of Increasing Flexibility for Three-dimensional Piping (Refer to Fig. 10.22.K).When a piping system is in lack of flexibility, it will be desirable to add pipes tolocations far away from the line connecting endpoints as a means of increasingflexibility.

No effect

Little effect

Great effect

Highcost,greateffect

Fig. 10.22.K - Method of Increasing Flexibility for three-dimensional Piping

10.22.4 Method of Reducing Force, Moment and Stress Generated by Thermal Expansion

(1) Give flexibility to piping. For details, refer to the Section, 10.22.3. (Refer to Fig. 10.22.L).

Fig. 10.22.L - Examples by Name of Piping

Piping system

Even if a loop is provided in the samebox, the flexibility is sometimesreduced.

Enlarge the box to increase the flexibility.However, it is not a very good methodthe illustration shows a case of extendingin the longitudinal direction.

The method to extend in the directionof breadth will be most effective. Thatis, the flexibility is increased with theaddition of pipes in locations far fromthe line connecting endpoints.

The method to extend in the direction ofheight will be more effective.

(2) Adoption of expansion bellows, slip joint, etc. For details, refer to the Section, 10.22.3.(Refer to Fig. 10.22.M).

Expansion bellows (shaft line type) or slip joint

Fig 10.22.M - Examples by means of Expansion Bellows, etc.

(3) Change in support points (Refer to Fig. 10.22.N).

Fig. 10.22.N - Change in Support Points

(4) Change in support types (Refer to Fig. 10.22.P).

Fig. 10.22.P - Change in Support Types

Expansion bellows (articulatedtype) or swivel joint

ShiftSupport

(5) Addition of support type (Refer to Fig. 10.22. Q).

Addition of support (In case of overhanging)

Fig. 10.22.Q - Addition of support

10.23 Vibrating PipingRefer also to TEG1.1313 “PIPING VIBRATION” which concerns with vibration.

10.23.1 Purpose of Countermeasures against VibrationTake measures against the vibration of devices and piping system to achieve the followingpurposes :

(1) To prevent the occurrence of an excessive stress by vibration(2) To prevent the decline in operation performance due to vibration(3) To secure environments to assure that workmen can engage in the operation of plant

without feeling any anxiety, and(4) To prevent vibration hazards.

10.23.2 Causes and Influence of Vibration(1) Piping in Need of Consideration for Countermeasures against Vibration

Shown below are the major sources and causes of vibration, for which attention shouldbe given in the design of piping :

Fluid Sources of vibration Causes of VibrationReciprocating pump Pressure pulsationRoots type pumpCentrifugal pump Surging (Note 1)

Fluid (gas-liquid mixing) Restriction orificeButterfly valve, gate valve Cavitation (Note 2)Centrifugal pumpGas-liquid mixed phase flow 2-phase flow (Note 3)OthersReciprocating compressor Pressure pulsationRoots type blower

Gas, steam Centrifugal compressor SurgingBlowerRestriction orifice Shock wave (Note 4)Pressure reducing valveSafety valve Discharge reactionSteam line Water hammerOthersWind Wind pressure, Karman

vortex street, vibration ofconstrained point

Earthquake Vibration of constrained pointOthers

Note 1 : Consider countermeasures to prevent vibration for a pump with the possibility ofsurge in test run.

Note 2 : It tends to be caused on a high speed liquid line.

Note 3 : For two-phase flow lines, there will be instructions from the Basic Design Division.

Note 4 : Shock wave will be generated when downstream pressure is less than a half (1/2) ofupstream pressure.

(2) Piping in Need of Paying Attention for ResonanceListed below are the major sources of vibration and the conditions for occurrence ofresonance, which are to be considered to avoid resonance in the design of piping :

Fluid Source of vibration Conditions for causing resonance

Liquid

Reciprocating pump - Resonance caused by coincidence of thefrequency of pressure pulsation and thecharacteristic frequency of liquid column (pipeline) (liquid column resonance)- Resonance caused by coincidence of thefrequency of pressure pulsation and thecharacteristic frequency of piping system

Roots type pumpRoots type flow meterThermometer well - Resonance caused by coincidence of the

frequency of Karman vortex street and thecharacteristic frequency of thermometer well

Gas, steamReciprocating compressor - (Gas column vibration) by coincidence of the

frequency of pressure pulsation and thecharacteristic frequency of gas column (pipeline)- Resonance caused by coincidence of thefrequency of pressure pulsation and thecharacteristic frequency of piping system

Roots type blowerThermometer well - Resonance caused by coincidence of the

frequency of Karman vortex street and thecharacteristic frequency of thermometer well

(3) Vibration of Devices, Caused by PipingThe following devices will vibrate if the piping were faulty so that particular attention willhave to be paid for the design of piping :

Devices Causes originating from piping Vibration of devicesCentrifugal pump Excessive nozzle reaction Vibration due to deviation in the centering of

shaft couplingMixing of air Vibration due to cavitationShortage of NPSH (includingdrift)

Centrifugalcompressor

Excessive nozzle reaction Vibration due to deviation in the centering ofshaft coupling

Turbine Excessive nozzle reaction Vibration due to deviation in the centering ofshaft coupling

Drain mixing Vibration due to unbalance in the axis ofrotation

10.23.3 Vibration - proof Design(1) Basic Concept of Vibration - proof Design

In order to prevent vibration, piping routes and piping supports will have to be designedby taking following items into consideration : Specifically, prior concrete consultation (P&Iscreening meeting, etc.) will have to be made with the Basic Design Division to decideupon the objects and countermeasures.(a) Aren’t there anything which could turn out to be the source of vibration ? (Consider

normal operation and start up.) Will it be impossible to remove the source ofvibration? Will it not be possible to exchange with one having less vibrating force ?

(b) Will it not be required to take a straight pipe length ?(c) Will it not be required to increase wall thickness ?(d) Isn’t the piping made in such a way to easily cause vibration ? Is the position of

support appropriate ?(e) Is the strength of support sufficient ?(f) Isn’t it possible to use vibration-proofing devices for places with severe thermal

stress?(g) Isn’t there any danger of resonance ?(h) Isn’t the piping arranged in such a way to vibrate devices ?

(2) Vibration-proof Design of Piping around Pressure Reducing Valve (In case of gas)(a) Vibration Generating Area (Refer to Fig. 10.23.A)

Refer to either one of the following figures as regards the size of piping anddifferential pressure, in which the vibration is expected to occur. (Note 1)

P1 : Pressure upstream of valveP2 : Pressure downstream of valve

(a) Weight of discharge (t/h) (b) Pipe size downstream of valve (inch)

Fig. 10.23.A - Vibration Generating Area in Pressure reducing Valve

(b) As against Piping in Areas, I and II(i) Confirm the followings with the Process Design Division while in the stage to

determine pipe sizes. (Note 2)- The flow velocity before the valve shall be less than 100ft/sec (33m/sec) if

the flow at full opening of valve were 1.1 times the maximum flow.- The flow velocity after the valve shall be less than 75% of sonic velocity

under the aforementioned conditions. (Refer to Fig. 10.23.B).

I Area most susceptible foroccurrence of vibration

II Area with possibility of occurrenceof vibration

III Area nearly free from vibration

(a) (b)

Fig. 10.23.B - Flow velocity before and after the valve

(ii) The straight pipe length from immediately behind the valve to the elbow shall bea minimum of 10 to 15D. (Note 3) (D : Pipe size downstream of the valve).

(iii) The pipe line shall be arranged as smooth as possible, and three-dimensionalpiping shall not be used in principle. (Refer to Fig. 10.23.C).

Good Good No Good No Good

Fig. 10.23.C - Shape of piping

(iv) Consider measure to strengthen takeoff parts (to increase wall thickness) likesmall-diameter takeoff tubes (pressure gage, drain, etc.) and to install stabilizers.(Refer to Fig. 10.23.D).

Fig. 10.23.D - Reinforcement of small -diameter branch pipes

(v) No screwed fitting shall be acceptable. All shall be of socket weld.(c) In Area I, furthermore (in addition to Paragraph (10.23.3(2) (b)))

(i) First, request the Basic Design Division to check if it is possible to reduce thepressure reducing ratio from P1/P2 to less than 2. (Note 4) (Restriction orifice,etc.)

(ii) Increase the thickness of downstream piping by more than 50% as compared to

Select pipe diameters toassure the velocity willbecome less than 75%

Pressure gage

Rib BossReinforcing plate

the thickness required by internal pressure. (Minimum of more than 10-15D).(iii) Use a bell mouth tube immediately after the valve. (Note 5) (Refer to Fig.

10.23.E).

Fig. 10.23.E - Shape of reducer after the valve

(iv) Use 5-6D bend for the bend after the valve.(v) Use care to assure easy reinforcement of support in future.

(Example : Constructing spare foundation, etc.)(vi) Use a 45° tee for a confluence pipe after the valve.

Note 1 : From OPC dataNote 2 : Recommendation of Lummus Corporation for charge gas compressor.Note 3 : It varies by flow velocity. This figure is currently under examination.Note 4 : As it will affect to the controllability of valve, pipe diameter, etc.,

consolation will have to be held with Project.Note 5 : When the flow velocity immediately after the valve is close to sonic

velocity, caution will have to be used on the other hand because of thedanger of occurrence of ultrasonic shock wave.

(d) As for Area III, compliance to Are II is desirable.(e) Qualitative explanation (in case of gas) (Refer to Fig. 10.23.F).

Fig. 10.23.F - Pressure change inside the valve

(i) Flow velocity in contraction will become sonic velocity if P2v<P2c (P2c=P1/2critical pressure) were materialized in the process of decline of gas pressureupstream of valve P1 to pressure inside valve P2v (normally P2v<P2).

(ii) In such a case, the following four items are conceivable as the causes ofoccurrence of vibration :- Occurrence of pressure wave due to the inertia of fluid in the process of fluid

pressure dropping from P2c to P2 (P2 : Pressure downstream of valve).- Occurrence of shock wave (or quasi-shock wave) as fluid velocity increases

to ultrasonic velocity due to the shape of valve and plug.- Turbulent motion and vortex motion caused by ordinary jet current- Occurrence of change in pressure due to vibration of valve stem (change in

Lessthan 7°

Pressure

Distance

(Conditions of pressure changeinside the valve)

opening) separate from those of fluid dynamics as mentioned aboveIf attention were paid to the magnitude of (P2c-P2v)G as a quantity directlyconcerning with the above four items, it will give an approximate yardstick toshow vibromotive force.

(3) Vibration-proof Design of Piping around Butterfly Valve(a) Piping Design

(i) When cavitation is caused on a liquid linePipes in which the occurrence of cavitation is anticipated should not be used inprinciple. When the use of such pipe is unavoidable, follow the procedures forvibration-proof design of around pressure reducing valve. (The recheck of valvesize will also be effective. Request Project to recheck.)

(ii) When no cavitation will occur on a liquid line- The straight pipe length from immediately after the valve to elbow shall be

preferably more than 10D.- Smoothen the pipe line downstream of valve as much as possible, and avoid

right-angle, three-dimensional bends as far as possible.

Note 1 : What has to b done not to cause cavitation will be to check cavitationcoefficient K blow the value of KC as obtained from the following figure:

Where,P1 : Pressure upstream of valveP2 : Pressure downstream of valvePS : Downstream side fluid steam pressure

Valve opening (degrees) Valve opening (degrees)

Fig. 10.23.G - Flow velocity after valve

The conceivable means to achieve the purpose will be to(1) Select valve type, or(2) Lower the valve fixing position to increase P1 against PS.

10.24 Others (Special Piping Design)(1) Wdh respect to the design around spray nozzle, countermeasures will be required

against resonance caused by Karman votiex street of fluid. For details, refer toDEPT. INSTRUCTION 03-09.

(2) With respect to high temperature and low temperature valves, there are valvesequipped with a balance hole for the prevention of abnormal pressure rise. At thestatt of Job, consult with Basic Design, obtain its confirmation and indicate surely thedirection of installation. As regards work exewtion, inform the precaution to beobserved at pressure test. For details, refer to DEPT. INSTRUCTION 04-05.

(3) When it becomes necessary to examine whether leak wi]l occur from hightemperature flange due to thermal expansion or not, refer to DEPT. INSTRUCTION04-06.

(4) When internal liquid is a fluid closed in by valves, etc., liquid expansion is caused byexternal heat and no safety valve is installed, it will be necessary to check thestrength against pressure rise due to liquid expansion. For details, refer to DEPT.INSTRUCTION 04-08.

(5) The designing method of line through which steam pu~e is performed shall bedetermined in accordance with DEPT. INSTRUCTION 04-12. Since steam purge isperformed at times by separating equipment nozzle, the method of purging shall beconfirmed and analyzed.

(6) As regards the drain piping of high heat fluid, reference shall be made to DEPT.INSTRUCTION.

10.25 Countermeasures against FreezingVarious countermeasures are available against freezing in cold regions, so have aprior consultation with Basic Design. Proposed countermeasures are enumeratedbelow- Circulation system (Connect the cooling water exit and entrance headers)- Completely drain out fluid from piping during winter season.- Give insulation.- Apply steam trace.- Minimize branch length. Note)

Branch out from right above.)Note : With respect to temperature drop in residence section, refer to

Dept.0306.

10.26 Rust Preventive MeasuresWith respect to rust preventive measures, customers, especially domestic customers,have their own ideas so that confirmation shall be obtained at the start of Job.Generally accepted measures are listed below for your reference:

- Support of bare pipe

● To install shoes (50mm height will do for small bore)● To insert a round bar between the pipe and support

P- - + 1 6 Note: From EXXON BP3-7-1.Around pole

● Lame bore saddle shall be welded all around.(Provide a degassing hole).

-assingho,e(withp,ug)- Trunnion

. Plate

&DegasSing,. -

hole (with plug)I ‘!

\L \

T< Degassing hole (withplug)

- Reinforcing pad

Dewatering forinsulation

i

Degassing hole

t (with plug)

Insulation E-~

“$. L

Insulation t.

IDewatering.>.

1$plate-----

/.:”%’ :: : ~. ..1/+

—----+: “,

.- x\

..- Dewatering plate

- All pipes in the trench shall be coated with waterproofing paint.

11. Design of Pipe Supports

11.1 Purpose and Applied Standards

11.1.1 PurposePipe supports shall be designed in accordance with the purpose and methods stipulated inASME B31.3 PARA. 321 “PIPE SUPPORTS”. Although the detailed design of pipe supportsis to be done in the last stage of piping design, it’s planning shall be performed from theearliest stage of piping layout planning by taking into account the position and type of thesesupports. The detailed design shall then be performed with the considerations made duringthe planning stage being duly incorporated.

Pipe supports shall be designed such that the piping and the supports themselves satisfy allof the requirements below:

(a) The stress in the piping dose not exceed the range permitted by the applied standards.(b) There will be no leak at any joint.(c) No excessive forces or moments are applied to any connected equipment (pump, turbine,

etc.,).(d) No excessive stress is generated at any support (or restrained part).(e) No resonance caused by forced or self-excited oscillation due to fluid flow will occur.(f) There is no restriction to thermal expansion/contraction of the piping.(g) There will be no possibility of the piping sliding off a support.(h) No excessive sagging will occur in piping requiring full drain-discharge.

11.1.2 Applied StandardsThere are two types of support design standards: those for pre-fabricated pipe shoes, andthose for shoes made of H-shaped steel. The Standards to be applied shall be confirmedindividually for each job, because the size of the attachments is different depending onwhether JIS or ANSI is applied for the outside diameter of piping.(Note : As to STANDARD ATTACHMENT, STANDARD SUPOORT, and TYPICALSUPPORT STANDARD FROM, the new STANDARD SUPPORT SHEET shall be used.)

TEC/TEG NO. TITLE J EH-108 Pipe Support O O

1-1314-101 Pipe Hanging No.1 Pipe Hanging Manual (PREFAB) O O1-1314-102 Pipe Hanging No.2 Standard Attachment (PREFAB) O O1-1314-103 Pipe Hanging No.3 Standard Form (PREFAB) O O1-1314-104 Pipe Hanging No.4 Design Data (PREFAB) O O1-1314-105 Pipe Hanging No.5 Detail DWG. (PREFAB) O O1-1314-106 Pipe Hanging No.6 Calculation for Strength (PREFAB) O O

A-406 Instruction for Support O O1-1314-201 Pipe Hanging No.1 Pipe Hanging Manual (H-TYPE) O O1-1314-202 Pipe Hanging No.2 Standard Attachment (H-TYPE)1-1314-203 Pipe Hanging No.3 Standard Form (H-TYPE)1-1314-204 Pipe Hanging No.4 Design Data (H-TYPE)1-1314-205 Pipe Hanging No.5 Detail DWG. (H-TYPE)1-1314-206 Pipe Hanging No.6 Calculation for Strength (H-TYPE)

A-304 Instruction for Pipe Support

11.2 Support Design

11.2.1 Design MethodThe design of supports shall be performed in accordance with the flow chart shown in Table11.2-A, as a rule. The time of issuing ??? drawing of informations, etc., in each stage shallbe decided, after sufficient coordination among all engineers in charge. Any change in theinformation made shall be information immediately to the assigned engineer.

11.2.2In the manuals related to the design of support there are forms and types for quantities.Therefore, the from type, and material to be used shall be coordinated at the beginning ofeach job, where the character of the job shall be considered.

- Unification of standard form to be used (AS-1,2,0 --, GS-1,2, --)- Unification of the size of members to be used (Unification of L,C,H, FB, etc.)- Unification of the material of members to be welded (Material of trunnion, of shoe, etc.,)- Unification of the size of trunnions (Combination with the size main pipe)- Unification of the type of foundations (Types of insert plate, fork anchor, anchor bolt, etc.,)

Table 11.2-A Flow Chart of Support Design

WORK STAGE WORK ITEM RESPONSIBILITY

ROUTING STUDY1. MAIN PIPE RACK INFORMATION a. Thermal stress / reaction force, etc. b. Brackets for heavy piping

2. MAJOR STRUCTURES

CIVIL ANDSTRUCTURALENGINEERING

DESIGN PLANNING

1. RACK INFORMATION

2. MAJOR FOUNDATIONS

3. SMALL STRUCTURES

4. MAJOR LOCAL FOUNDATIONS

(5. SPRING SUPPORT ORDER)

6. VESSEL CLIP INFORMATION

7. BRACKETS FOR FIRE-PROOFING

SUPPORT DESIGN

1. PIPING SUPPORT STANDARDS

2. INSUTRUMENT FOR PIPE SUPPORT

3. MARKING

4. DETAIL HANGING

5. SPRING HANGER LIST

6. LOCAL FOUNDATION

B/M VENDOREQUIPMENT DESIGN

CIVIL & STRUCTURALENG'G

B/M VENDOREQUIPMENT DESIGNCIVIL & STRUCTURALENG'G

PLANNER VENDOR

CIVIL ANDSTRUCTURALENGINEERING

11.3 Basic Support Design

11.3.1 Type of Support

(1) ANCHOR (A) “Anchor” means fixing of piping. There are various types suchremovable anchors like welded ones using shaped steel, shoes, etc..These are applied, for example, when movement of pipe is to beobstructed, when forces generated at a source are to be dissipatedinto the structure, or when any vibration is to be arrested, etc..

(2) GUIDE (G) “Guide” means a kind of device which helps to align the route ofpiping, by restraining it in the direction perpendicular to the axiswhile allowing free movement in the direction of the axis. This isused, for example, when the pipe is straight and long, as is in caseof piperack pipes, at the point of directional change of pipe.

(3) HANGER (H) “Hanger” means a kind of device that holds a pipe by verticallysupporting (hanging) the pipe load from above. This is used mainlywhen the elevation of pipe is too high for foundations, and whenadjustment of the piping is required.

(4) SPRING (S) “Spring” supports are used for piping in which large thermalexpansion occurs, for vertical piping around pump, etc.. They cansupport the load from the piping even if there is vertical movementat the support point.

(5) RESTING SUPPORT (R ) “resting Support” means a kind of device whose purpose is tosupport only the weight of piping at a beam or column. But, if suchbeam or column is to support an anchor or guide, this device shall betreated as an anchor or guide, rather than resting support.

(6) DIRECTIONAL STOP (D) “Directional Stop” is kind of device which obstructs movement in acertain direction in order to restrain the force that could be applied toconnected equipment or piping is restrained. It is used for partssubjected to thermal expansion or vibration.

11.3.2 Loads on SupportsAll loads introduced to a support as stipulated in Par. 7.3 shall be considered ; this includeslong-term and short-term loads.

11.3.3 Notes on the Design of Support

(1) Hot-insulated piping and all steam-traced piping shall be supported by steel shoes,regardless of the temperature. But, when any hot-insulated piping of 1 ½” or smaller indiameter is to be laid on a supporting structural member, it may be laid directly on such asupporting member, as shown in Fig. 11.3-A. This can be used especially in case of theanchors, guides, etc. of vertical piping, whereas this shall not be used for piping in hightemperature service (350°C)

Fig. 11.3-A An example of support for small hot-insulated piping

(2) Piping which is neither hot- nor cold-insulated, may be laid directly on supporting members.

(3) Cold-insulated piping shall be supported by means of heat-insulating members (cradles)with the cold-insulation material being cut off in part.

(4) The bottom of pipe (B.O.P) of a bare pipe, and the bottom of shoe or cradle, in case of hot-or cold-insulated pipe, shall come to the same elevation.

(5) Piping shall be supported such that it allows that equipment or valve to be removed formaintenance, and flanges to be separated for installation of blind plates.

(6) When piping with and operating temperature of 120°C or higher is to be laid on a surfaceof concrete, such piping shall be supported by means of steel shoes.

(7) Thin-walled, large-diameter lines shall be provided with saddles or reinforcing platesattached to it, so that the local stresses at the supporting part is alleviated.

(8) Piping to be connected to the nozzle of a compressor or turbine, shall be provided withsupports that allow easy alignment.

(9) Small-diameter lines may be supported by or hanged to large-diameter lines. However, themutual movement between such pipings shall be duly considered.

(10) The deflection of pipe-supporting beams shall be as follows.- Beams crossing with piping L/300 or smaller, and maximum 25mm- Beam parallel with piping L/500 or smaller, and maximum 25mm

11.3.4 Support Span

(1) Factors affecting determination of support span of pipingWhen determining the support span, the following items shall be studied, and the minimumspan resulting therefrom shall be adopted.(a) Deflection of the piping (max. 20mm)(b) Bending moment of the piping (Stress in the longitudinal direction of the piping shall

not exceed 1/2 of the allowable stress.)(c) Local stress of the piping (Local stress at the support part shall not exceed 1/2 of the

allowable stress. When such local stress is the determining factor for the supportspan, the span may be elongated by attaching a saddle.)

(2) Allowable support span

(a) Rough determination of spanWhen an approximate support span is to be obtained, it shall be in accordance withTable 11.3-A.

Table 11.3-A Approximate span

PIPE L : MAX SPAN (m)

MAX. SUPPORT SPAN SIZE WATER INSUL.(HORIZONTAL LINE) (IN.) WATER + INSUL THICK.

(mm)½ 4.0 2.7 H40¾ 4.4 3.2 H401 5.1 3.7

1½ 6.0 4.72 6.7 5.5 H50

2½ 8.0 6.83 8.5 7.5

3½ 9.0 7.74 9.5 8.35 10.4 9.3 H656 11.2 10.28 12.7 11.8

10 14.0 13.112 15.1 14.214 16.0 15.116 17.1 16.3

Note : Since this table only states approx. values, 18 18.2 17.5 H75refer to TEG1-1313-009 “maximum allowable 20 19.0 18.4Span for various Kinds of Pipes” for details. 24 20.8 20.2

(b) Determination of exact spanWhen the pipe span must be determined accurately, the material of the piping, wallthickness, content, insulation, etc. shall be taken into consideration in accordance withTEG1-1313-009???Important notice of using to TEG1-1313-009?????

(c) Support span regarding pipe deflection(i) Regarding horizontal pipe deflection (Refer to Fig.11.3-B)

Fig. 11.3-B Support span regarding horizontal pipe deflection

Within theallowable range

“L” shows ORDINARY SPAN in case of straight pipe

“L” shows ORDINARY SPAN in case of straight

Within theallowable range

(ii) Pipe deflection in 3 dimensions (Refer to Fig. 11.3-C)

Fig. 11.3-C Support span regarding pipe deflection in 3 dimensions

11.4 Design of Pipe Rack and Supports Around Equipment

11.4.1 Support of Pipe Rack Piping

(1) Spacing between supportsWhen preparing civil information, the span between girders and beams shall be determinedsuch that there will be no overhang of the piping on the rack. At the time of support design,the distance between additional supports for small-diameter piping such as shoes, cradles,or saddles, if necessary, shall be based on Para. 11.3.4 “Support Span”.

(2) Spacing between pipesThe distance between two or more pipes that are running in parallel will already bedetermined at the time of making the piping drawing. However, in the support design stagechecking shall be made by using Table 11.4.1-A, to see whether there is enough spacingfor pipes to which attachments are to be fixed.

“L” shows ORDINARY SPAN in case of straight pipe

Table 11.4.1-A Dimensions for providing attachments

A-11,12G-2, 3 A-15,16 G-11

(Hot Insul.) G-21 (Cold Insulated Pipe)

TYPE

U-BOLTFIXED BAND SHOE

(GUIDE)CRADLE(GUIDE)

PIPESIZE A A A

PIPESIZE(IN.)

INSUL.THICKN.

(mm)A

PIPESIZE(IN.)

INSUL.THICKN.

(mm)A

½ 35 80 50 125 50 225¾ 35 80 ½ 100 175 6 100 2751 40 85 80 150 225 150 325

1 ½ 45 90 80 50 130 50 2502 55 95 80 ½ 100 180 8 100 300

2 ½ 60 115 80 150 230 150 3503 70 120 140 50 130 50 275

3 ½ 75 135 140 1 100 180 10 100 3254 85 145 140 150 230 150 3755 100 160 140 1 ½ 50 140 50 3006 115 185 140 100 190 12 100 3508 145 210 165 150 240 150 40010 175 235 190 2 50 145 50 33512 205 265 190 100 195 14 100 38514 225 290 240 150 245 150 43516 250 240 2 ½ 50 155 50 36018 280 240 100 205 16 100 41020 305 290 150 255 150 46022 330 290 3 50 160 50 38524 360 100 210 18 100 435

150 260 150 48550 175 50 410100 225 20 100 460150 275 150 51050 210 50 460100 260 24 100 510150 310 150 560

(3) Support for bare pipe

(a) Fixing of anchor and guide

(i) When there is no loop nor expansion jointEven when the piping has no loop or expansion joint, such piping shall beprovided with anchors at intermediate points of each axis, so that there will be noconcentration of strain caused by improper fabrication. (Strain may beconcentrated at one point, caused by spatter, etc.) (Refer to Fig. 11.4.1-A.)

Even in case of normal temperature piping, there will be thermal expansion/contraction dueto change in atmospheric temperature. So, sufficient flexibility is required at the cornerportion.

Figure 11.4.1-1 Installation of Anchors and Guides

(ii) When there are loops or expansion jointsEven in case of bare pipes, anchors and guides shall be installed at the specifiedpositions, if there are loops or expansion joints. Anchors and guides shall beinstalled in the same manner as in the case of hot-insulated pipes described inPar. 11.4.1(4).

(b) Types of anchors and guides (Refer to Fig. 11.4.1-B.)

4” and smaller 5” and lager 4” and smaller 5” and larger

Figure 11.4.1-B Types of Anchors and Guides

(c) In case of bare pipes, it may be necessary to install shoes with regard to prevention ofcorrosion. This must therefore be determined beforehand in coordination with thecustomer, etc.

As thermal expansion/contraction due to atmospherictemperature changes will be present even in normal-temperature piping, sufficient flexibility is required atthe bend sections.

6” andsmaller,6m and over8” and over,10m and over

2” and smaller, 10 - 15 m2 ½” - 4”, 15 - 20 m5” and over, 20 - 25 m

(4) Supports for hot-insulated pipe

(a) Installation of Anchors and Guides (Refer to Fig. 11.4.1.C)

Fig. 17.4.1-C Determination of Anchors and Guides

The anchor spacing shall be 50m as a rule.Anchor points shall be determined in theplanning stage.

It is required that the expansion of pipe does not cause interference with other piping.(The expansion at pipe bends shall be assumed to be 40mm as a rule.) No guides shallbe installed between anchor points unless specified by design engineer.

To be determined in planning stage.Refer to Table 11.4.1-B for guide spacing.

These spacing shall be in accordance with Table 11.4.1-B

Table 11.4.1-B Determination of Anchor and Guide Spacing

Nominal Dia. L1(m) L2 (m)(inch) 10kg/cm2 20kg/cm2 30kg/cm2

2 0.2 3 2 22 ½ 0.25 4.5 3 2.5

3 0.3 6 4.5 44 0.4 9 6 5.55 0.5 9 7.5 76 0.6 10.5 7.5 78 0.8 13.5 10.5 9.5

10 1 18 13.5 1212 1.2 21 15 12.514 1.4 21 16.5 1316 1.6 24 18 14.718 1.8 25.5 19.5 16.520 2 27.5 21 17.522 2.2 30.5 21 1824 2.4 32 22.5 19.526 2.6 33.5 24 2028 2.8 35 25.5 2130 3 36.5 27.5 22.532 3.2 39.5 27.5 2334 3.4 39.5 29 24.536 3.6 41 30.5 25.538 3.8 42.5 30.5 2642 4.2 45.5 33.5 28.548 4.8 48.5 35 30.554 5.4 51.5 36.5 3260 6.0 54.5 39.5 33.566 6.6 57.5 42.5 36.572 7.2 61 44 37.5

Nominal Dia.(Inch.)

L3(m)

1 121 ½ 13.5

2 152½ 183 19.54 22.56 248 27

10 33.512 36.514 36.516 3818 4120 42.524 42.5

(b) Installation of shoesShoes shall be attached to the individual support parts of hot insulated piping.(i) Relation between insulation and shoe (Refer to Fig. 11.4.1-D.)

Fig. 11.4.1-D Relation between insulation and shoe

Expansion Joint

NominalNominal

Insulation Thickness Hup to 75mm 10mm76 - 125 mm 150mm126 - 175 mm 200 mm180 - 225 mm 250 mm

(ii) Kinds and proper use of shoes Note 1) (Refer to Fig. 11.4.1-E.)

Fig. 11.4.1-E Types of Shoes

(c) Types of anchors and guides (Refer to Fig. 11.4.1-F)

Over 8” Over 10” Under 1 ½” 2” - 8” Over 10” Under 8” Over 10”

Fig. 11.4.1-F Types of Anchors and Guides

(d) Supports at expansion loops (Refer to Fig. 11.4.1-G.)With regard to supporting the pipes, it is advantageous to provide the individualexpansion loops between the piperack beams as shown in the figures below. It isassumed here that all loops are to be supported and installed between the respectivepiperack beams.

Welded type shoe

Clamp-type Shoe

H-type Shoe

Saddle

Used widely ingeneral (8” &smaller)

Note 1) :As for proper use ofeach type with regardto material refer toTEG1-1314-102 “PIPEHANGING NO. 2 -STANDRDATTACHMENTS”

To be used for white gas pipe and wherewelding is difficult.- For thin-walled (3mm or smaller) stainless

and other type of steel pipe.- For resting of piping where stress relief is

required.

To be used as anchor and guide of restingsupports for 10” to 24” pipes.

To be used as anchor and guide of restingsupports for 16” - and large pipes Note 2).

Note 2) : Bare pipes of large diameter carryingliquids shall have saddles attached, forprevention of stress concentration.

Fig. 11.4.1-G Support at loop

(5) Supports for cold-insulated pipeOf cold-insulated pipes, those insulated for the purpose of shielding direct sunshine orpreventing moisture condensation shall be supported, having the insulation materialpartially cut away at the part of the supports depending on the type of shoe. Cold-insulatedpipes explained here are pipes carrying refrigerant, or pipes which are critical with regardto the process (normally, with operating temperatures of 0°C or less).

The part in contact with the support shall be treated to prevent heat transfer by providing acradle, so that the piping and atmosphere do not contact each other.???

(a) Relation between insulation and cradle (Refer to Fig. 1 1.4.1-H.)

Fig. 11.4.1-H Relation between insulation and cradle

(b) How to fix anchors and guidesThis shall be done in the same way as in case of hot-insulated pipe, described in Par.11.4.1(4)

Good

Bad

In case of large loop

In case of small loopFix to supportbeam

Support

In case of two or three loops are to be installedtogether, either of the above may be applied.

Insulation Material Thickness (mm) Cradle Height (mm)25 - 50 5055 - 100 100105 - 150 150155 - 200 200205 - 250 250

(c) Types of anchors and guides (Refer to Fig. 11.4.1-I.)

A-4 A-4 A-31 or A-32 G-21

2 ½” and under 3” and over , Anchor (For shock absorbing) Guide

Fig. 11.4.1-I Types of anchors and guides

(6) Support for large-diameter pipesHere, large-diameter pipes means those of 14' or larger in diameter. In case of hot-(andcold-) insulated pipes, shoes or cradles shall be used. Bare pipes may be simply laid on therack. But, it is required to check whether or not the contact part between the rack and pipeis safe in regard to local stress, and if not safe, saddle(s) shall be provided. The pipes towhich saddles must be attached are specified in TEG1-1313-009.

(a) Height of saddle (Refer to Fig. 11.4.1-J.)

Uniform 100mm in case of standard saddle. So, the pipe shall be raised from rack by 100mm, at thetime of determination of elevation.

Fig. 11.4.1-J Height of saddle

(b) Use of anchorsAnchors shall be used in the same way as the guides for bare pipes described in Par.11.4.3, while observing the proper spacing. In cases where oscillation is generated,such as in suction pipes of compressors, small anchors shall be installed in order toprevent resonance.

(c) Types of anchors and resting supports (Refer to Fig. 11.4 1-K.)

Anchor (For shock absorbing) Resting support

Fig. 11.4.1-K Types of anchors and resting supports

(7) Other considerations required in design of supports(a) Overhang (Refer to Fig. 11.4.1-L.)

Fig. 11.4.1-L Overhang at bends

(b) Reinforcement of beam (Refer to Fig. 11.4.1-M.)Beams are in general weaker against torsional moments, than against bendingmoments. If any large torsional moments are expected, the required structural designshall be made in coordination with the civil and structural engineers.

Note: Supporting shall be at 2 or more points, as far as possible.

Fig. 11.4.1-M Torsional moment and reinforcement of beam

11.4.2 Piping supports around vessels Torsional moment and reinforcement of beamPiping supports around vessels shall be planned before the general planning, in order thatchecking of the strength of vessel clips and vessel shell can be made. It is important, at thetime of planning, to arrange the piping especially in consideration of the support details.

(1) Limitation of loadSupporting loads of 5000 kg or more shall be divided such that the load at one point isreduced to below 5000 kg. The resting support for vertical piping to be supported at 2 ormore points shall be at a point nearest to the nozzle, while guides of springs supports shallbe used for the remaining points. When clip information must be given, the load data of thepart at spring support shall include the weight of spring hanger (whose hanging load isespecially large). (Refer to Fig. 11.4.2-A.)

Vertical load 9000kg

Resting support 5000kg (Note 1)

Load of this supporting part(spring supporting load + weight of spring proper) x 2 = 4500kg (assumed to be 250kg)

Spring support (supporting load 2000kg x 2 = 4000kg)

Guide

Example of load-dividing design

Fig. 11.4.2-A Supports for vertical type vessel and tower

Note 1: When the vertical load exceeds 5000kg, load-dividing shall be as follows.

(a) Vertical load W > 5000kgResting support part : 5000kgSpring support part : (W - 5000)kg

The resting support part shall bear 5000kg if possible, so that the supporting load ofspring hanger becomes smaller thus reducing the size (and cost) of spring hanger.

(2) Vessel clipVessel clips of appropriate type shall be selected, by referring to TEG1-1314-104. Theselected clips shall then be recorded in the Table of Vessel Clips for piping supports, whichshall be sent to the Equipment Design Department.

(a) Temperature conditions

(i) Outline of thermal insulation of clips Note 1)

In accordance with the design temperature conditions of the equipment, clips andsupports, as a rule, shall be thermally insulated in the way shown below.

6°C and higher Normally, not to be considered5°C - -45°C Asbestos sheet of t = 10mm-46°C and lower Wooden pillow or urethane block

(ii) Material classification of bolts/nuts to be used

351°C-575°C SNB/S45C6°C- 350°C SS41/SS475°C- -45°C SUS304/SUS304-46°C and lower SUS304/SUS304

(b) Mark number of supports Note 2)

2 1 0 8R V -

(a) Symbol to indicate kind of support

(d) Sequential number for each kind of support (to be allocated per each equipment)

(c) Area number in piping drawing

(b) Section classification number

Note 1) The type of clip shall be determined based on the designtemperature of vessel, and not on the design temperature ofthe piping to be supported.

Note 2) Allocation number shall be fixed at the start of job, so that itthere is enough time until issuance of clip information.

(3) Position of supports for tower-piping (Refer to Fig. 11.4.2-B)

Case 7 Case 2 Case 3 Case 4

Fig. 11.4.2-B Position of supports for tower-piping

MAX. SPACING GUIDEPIPE SIZE

(INCH)MAX. h

(m)PIPE SIZE

(INCH)MAX. h

(m)1 4 8 10

1 ½ 4.5 10 112 5.5 12 12

2 ½ 6 14 12.53 6.5 16 134 7.5 18 13.55 8 20 146 9 24 15

(4) Position of supports for tank-piping (Refer to Fig. 11.4.2-C.)

Fig. 11.4.2-C Position of supports for tank piping

MAX. SPACING GUIDEPIPE SIZE

(INCH)MAX. h

(m)PIPE SIZE

(INCH)MAX. h

(m)1 4 8 10

1 ½ 4.5 10 112 5.5 12 12

2 ½ 6 14 12.53 6.5 16 134 7.5 18 13.55 8 20 146 9 24 15

11.4.3 Piping supports around compressors and turbines

(1) GeneralThe purpose of the piping supports around compressors or turbines is not only to support the

piping itself, but also to restrain the piping such that the load, external forces and momentsproduced by the piping will not be introduced into the compressor or turbine. Thus, thequality of design, fabrication, and management of the piping supports will have animportant effect on the performance of the compressors or turbines. The design shalltherefore be performed by taking these aspects into consideration. The points to beconsidered in particular are as follows:

(a) The space around compressors or turbines is congested by piping and supports, sothat any change at the time of detailed design is very difficult and requiresconsiderable efforts. Therefore, it is necessary, that at the time of planning andtogether with the study of thermal expansion, the method of restraining, theinstallation possibilities and the type of the support-fixing parts shall be determined.This information shall then be informed to the Civil and Structural EngineeringDepartment.

(b) Supports shall be carefully designed in accordance with the conditions of restraintassumed in the calculation of thermal stress.

(c) The information given to the Civil and Structural Engineering Department shall beprecise and clear, so that mutual coordination is not impaired. The content of such

Note 1:The methods shown above can beapplied in general. Simpler methods,such as replacing RV with G type,may be applied if sufficientreinforcement has been made at theconnecting nozzle, or, the nozzle itselfis deemed to be resistant enoughagainst the bending momentsintroduced by the piping, and alsoagainst external forces caused byoscillation.

Note 1:The methods shown above can beapplied in general. Simpler methods,such as replacing RV with G type,may be applied if sufficientreinforcement has been made at theconnecting nozzle, or, the nozzle itselfis deemed to be resistant enoughagainst the bending momentsintroduced by the piping, and alsoagainst external forces caused byoscillation.

information shall include the load at the time of pressure test (loading data, shape ofinsert plate, allowable deflection at the support-fixing parts of structure or rack, etc.).

(d) The construction shall be such that it will not be affected by friction force (hanger type,use of Teflon).

(e) No moments due to proper weight of piping shall be introduced to the nozzle. Inordinary cases, springs do not absorb such moments. Therefore, it is difficult to makecorrection of horizontal deflection due to proper weight of the piping in the vicinity ofthe nozzles by spring supports.

Remark : The allowable deflection will be max. 20 mm, if the piping support span stipulated inTMG1-1313-009 “Maximum allowable span for various pipes" is applied. This does notmatch with the accuracy of piping around compressors or turbines. Therefore, the spanshall be determined to be about 1/2 - 1/3 of the standard value, as a rule, if TEG1-1313-009 is used as standard.

(i) Example of hanger-type spring application (Refer to Fig. 1.4.3-A.)

Compressoror turbine

Fig. 11.4.3-A Example of hanger-type spring application

(ii) Example of support-type spring application (Refer to Fig. 11.4.3-B.)

Compressor or turbine

Spring support

Fig. 11.4.3-B Example of support-type spring used to support from underside

(f) Supports in the vicinity of nozzles shall be of such construction type that they areadjustable in the X, Y, and Z axes. This allows adjustment of the piping in relation tothe nozzle at the time of alignment work.

(g) Supports which are of simple construction, permitting easy fabrication and installation,and providing for trouble-free operation shall be used. The guides “G-1”, ”G-2”, “G-3”,“G-11”, “G-21” shown in Fig. 11.4.3-C, shall not be used, as a rule.

Fig. 11.4.3-C Guides not to be used

(H) Supports of the whole system shall be balanced, so that no static load is introduced tothe nozzle.

(i) As to the forces and moments on the nozzle, there are requirement values set forth bythe respective maker. Therefore, such values shall be obtained at an early stage.

(2) Supporting by means of spring hanger

(a) As a rule, the weight of piping around compressors or turbines shall be supported bysprings, such that no effect of the weight, and also no effect of the deflection ofpiping, is introduced to the nozzles.

(b) Even when the temperature of the piping is normal, or near to normal, so that nospring support would be required from the viewpoint of thermal expansion of piping,

supporting of piping weight shall be made by means of spring supports up to abouttwo fixing points from the nozzle.

(c) Constant spring hangers are expensive, and require more space. So, variable springhangers shall be used, as a rule.

(d) The supporting point of spring supports may change due to thermal movement ofpipe, so that the supporting characteristics will change, affecting the load upon thenozzle. Since this is not taken into consideration at the time of thermal-stresscalculation, it is necessary to limit the variable load to such degree as is negligible.The variable load shall therefore ~e limited to 100 kg or smaller, as a rule, forsupports which are located away from nozzles. However, up to 2 supporting pointsfrom the nozzle, spring supports having a load-variation rate of about 5% shall beused. Springs in which the variable load is more than 100 kg, may be adjusted (bymeans of cold spring) immediately before start-up.

(f) Resting supports shall not be used, as a rule. If it is to be used, Teflon or graphitecoating shall be employed. The installation shall be limited to places where horizontalthermal displacement of the piping is small (1 - 2mm is tolerable), where there aredirectional stops (DS) or anchors along the piping between the nozzle and support,and where there is no effect caused by the friction force or off-center of the supports.(Refer to Fig. 11.4.3-D.)

Hanger type

Fig. 11.4.3-D Fixing of directional stop

(g) Spring hangers in the vicinity of nozzle

(i) Two-point hanging shall be employed, as a rule (Refer to Fig. 17.4.3-E.). If one-point hanging is employed, useless? moment(s) would be produced at the nozzle,so that the alignment work becomes difficult.

Good

Fig. 11.4.3-E Installation of spring hangers

(ii) The use of a support consisting of a combination of spring support and directionalstop for down pipes of compressors or turbines reduces the forces and momentsgenerated at the nozzle, and facilitates the alignment work. (Refer to Fig. 11.4.3-D.)

(h) At the time of spring-load calculation, small loads such as the weight of blind flangesfor handholes and of trunnions shall be taken into consideration.

moment

Bad

(3) Directional stop

(a) Definition of termDirectional stop (DS) means a kind of support which is installed at midway of thepiping for the purpose of providing restraint with regard to thermal stress. It includesthose supports that are able to carry the weight of piping at the same time, as asecondary function. Furthermore, as far as support marking is concerned, hydraulictype shock absorbers are treated as directional stop, being so classified. However, atthe time of thermal-stress calculation, it is normally not to be considered as restrainingcondition.

(b) The function and construction of directional stops shall essentially be the same as thecondition of restraint inputted at the time of thermal-stress calculation. Practically,rod/turnbuckle type shall be used. This type can almost always satisfy the functionrequired in regard to the analysis, and can furthermore be easily fabricated and fixed.

(b)

Fig. 1.4.3-F Shape of directional stop

When it is desired, in regard to the thermal stress analysis, to have free movement inthe directions of X and Y and restraint only in the direction of Z, at point “A” of thepiping in Fig. 11.4.3-F, turnbuckle type (Fig. a) shall be adopted, because in case ofguide type (Fig. b, c), restraining condition compatible with that assumed in thecalculation cannot be expected, due to friction force and error of fabrication. However,

Turnbuckle type

Restraining condition at point

X directionY direction

Z direction

X directionY directionZ direction

Guide Type

Plan view

Bad Side View

in case of turnbuckle type, thermal displacement in the direction of X or Y is so largethat, when the length “L” is short, reaction forces due to the tension of the rod willoccur in proportion to the amount of the thermal displacement. Therefore, large “L”values are preferable. In practice, it shall be L = 500 - 5000mm. The tensile stressgenerated in the rod in proportion to the amount of thermal expansion, and thereaction force against the piping shall be calculated by use of the formulae shownbelow.

Fig. 11.4.3-G

( )F EA S

LD K1 2

2 15=+

++

∆∆ ∆

ιι ι

ιι ι

.

( )F

EA S DK

EIS2

2 0 75 62 3=

++

+

+

∆∆ ∆

ιι ι ι

ιι ι ι

.

σιι= E

A∆

where:F1 : Reaction force when two points are ratable ends (kgf)F2 : Reaction force when only one point is fixed end (kgf)σ : Tensile stress of rod (kgf/mm2)E : Longitudinal modulus of elasticity (2.15 x 104) (kgf/mm2)A : Sectional area of rod (mm2)

∆ι : Elongation of rod (mm)

ι : Length of rod when fixed (mm)S : Distance of thermal displacement of pipe (mm)K : Rolling friction coefficient (0.01)D : Diameter of rod (mm)I : Geometrical moment of inertia (π/64 x D4) (mm4)

For details of the reaction force, refer to TCMl-1316-004 “Calculation of supporting force ofTENSION ROD by use of compute”.

(c) Attention required in the design of direction stopWhen constraining is required by use of directional stops, restraining of bothdirections shall be considered without fail, even if displacement or force is only in onedirection (either plus or minus), when calculation is concerned. Furthermore, checkingshall be made, to see whether or not the rigidity of the rod and rod-fixing part, in thedirection of intended restraint, is sufficient.

(i) Remarks about the direction of constraint (Refer to Fig. 1 1.4.3-H.)

Bad

Fig. 11.4.3-H Remarks on the direction of restraint

(ii) Remarks on fixing of rod type D.S. (Refer to Fig. 11.4.3-I.)

Fig. 11.4.3-I

When thin-walled large-diameter pipe is to be stopped, reinforcing ring shall be provided.NPS 14 - 16 and larger shall preferably be provided with reinforcing ring, as a rule.

(iii) Remarks on fixing of D.S. using trunion (Refer to Fig. 11.4.3-J.)- When directional stop is to be provided by use of trunion, attention shall be

paid to the elastic deformation of the trunion itself.

- When the trunion is long, reinforcing shall be made by fixing stays, or theelasticity of the trunion shall be taken into consideration at the time of thermal-stress calculation. Furthermore, in case where the length of the trunion is500mm or more, or where the position of the trunion is near to the nozzle ofcompressor, thermal stress analysis shall be made.

Restrained in only one direction. Frictionforce and fabrication error will be produced.

Restrained in only one direction.

Bad

Left and right not balance. In case ofthermal deflection, the piping is pulled tothe side of shorter length, and adjustmentis difficult.

Laterally upward pull. Upward force isexcreted.

Bad Bad

Provide stays

Fig. 11.4.3-J Fixing of stays

- When trunnion is fixed to thin-walled large diameter pipe (NPS 14 - 16) (Referto Fig. 11.4.3-K)

ReinforcingProvide attach plate, so that deformation is reduced as far as possible.

Fig. 11.4.3-K Fixing of reinforcing plate

- When trunnion is protruding from tnrnion (Refer to Fig. 11.4.3-L)

Spring support

Fig. 11.4.3-L Trunnion is fixed to trunnion

- When tensile force is large, sufficient reinforcement shall be made also fortnrnion.

ReinforcingProvide attach plate, so thatdeformation is reduced as far aspossible.

This construction shall not be used, as a rule,because twisting is produced and condition ofrestraining becomes complicated. Twisting isproduced, so that the direction of restraining willchange.

Fig. 17.4.3-M Reinforcement for trunnion

(d) Standardized example of detailed construction of turnbuckle (Refer to Fig. 11.4.3-N.)Diameter of the rod shall be 20mm when piping dia. is 8 in. or smaller, and 30mm forpiping dia. of 10 in. or larger. However, in case that the reaction force at the time ofrestraining or the load at the time of alignment is larger than 3 ton, the rigidity andstrength shall be checked, and if necessary, a trunnion of larger dia. shall be used.The thread for alignment/adjustment shall be fine thread.

Fig. 11.4.3 - N Details of turnbuckle

(e) Prevention of oscillation of piping

(i) For prevention of oscillation of piping, anchors, resting supports, and guides shallbe provided to the piping system, as a rule, under the condition that no excessivestress is introduced to the nozzles of equipment. If this method proves to beinsufficient, shock absorber(s) shall be used. Furthermore, attention shall be paidto the piping system around compressor and turbine, as there is a tendency to

Reinforcing

Clevix Bracket

Hanger Rod

Turnbuckle

Clevis Bolt

Lug Plate

Lock Nut

Lug Plate(pipe under 6” and)

Clevix Bracket(Pipe over 8” and)

The material anddimensions shall be asindicated in the StandardDrawing. Welded parts shallbe continuous fillet weld ofmin. 6mm throat thickness.

Direction of pin shall beat 90°C

excessive flexibility as a result of designer's preoccupation with preventingexternal forces/moments from being introduced to the nozzles. Especially, forpiping in which check valve is installed, shock-absorbing type supports shall beconsidered, so that the oscillation at the time of open/close of the valve will notact on the nozzle.

(ii) Method where turnbuckle hanger rod is usedThere are two cases: one where it is fixed, being introduced from the beginning asa restraining condition in the thermal-stress calculation, and, the other is the onebeing fixed in situ as a retrofit. In the latter case, attention shall be paid to thedirection of the movement due to thermal expansion of the fixing part. There is analternative similar to this type, where pipe is used instead of rod. (Refer to Fig.11.4.3-O.)

Direction of restraining

Fig. 11.4.3-O Example of shock absorber where pipe is used

(iii) Hydraulic type shock absorber, spring type shock absorberHydraulic type shock absorber does not restrain the elongation of piping due tothermal expansion, but functions as an anchor against high-velocity motion(oscillation due to pressure fluctuation within the piping, oscillation at the time ofexhausting from safety valve or pressure reducing valve, oscillation due toearthquake or wind, etc.). Spring type shock absorber has a function to raise thenatural frequency (rigidity) of the whole piping system, and as a result, a reactionforce in proportion to “thermal-expansion-displacement of the piping x stiffness ofshock absorber is effected to the piping. Spring type shock absorber isconsiderably cheaper than hydraulic type. Therefore, although it has someproblems such as maintenance, the use of spring type shock absorber isrecommended, as far as possible. As for fixing of shock absorber, Refer to Fig.11.4.3-P.

Pipe

Fig. 11.4.3-P Shock absorber installation method

(4) Resting support (R.S.) and hangerWhen a resting support is used, frictional counterforce is generated at the part contactingwith the piping. Ordinary methods used for reducing this frictional counterforce are shownbelow.

(a) To use slide plate at the contact-sliding partExplanation will be made based on the products of Nihon Pillar Ind. Fig. 7 I.4.3-Q (A)shows a W-shaped pad (welded to shoe) to which Pillarflon and base plate isadhesion-bonded. Fig. 11.4.3-Q(B) shows a W-shaped pad attached to a SUS plate.

Fig. 11.4.3-Q Example slide plate application

Features of Teflon-laying are shown below.

(i) Mechanical strengthThere are various products (W-shaped pads), each having characteristics owingto the strength and purpose of respective Teflon itself. It shall be confirmed byinquiring with the vendor.

(ii) Friction coefficient (25°C - 275°C) is about 0.04.

(iii) There are various products in accordance with the respective purpose.Coordination with the vendor (Nihon Pillar) shall be required.

(b) Carbon type support (Refer to Fig. 11.4.3-R.)

Slidesurface

Slidesurface

Shoe

W-type pad

Pillaflon

Shoe

W-type padSUS plate

Base plate (SS41)

(i) This can be used within a temperature range of 400°C - 600°C. (When exceeding600°C severe oxidation occurs).

(ii) Lubricating property is obtained when the carbon contact area is at least 17 - 18%.For applications, 25 -- 40% is recommended.

(iii) Contact-surface pressure shall be 50 kgf/cm2 or smaller.

Fig. 11.4.3-R Carbon type slide plate

(c) Hangers may be used, when method (a) and (b) cannot be adopted, such as in caseof high temperature piping. However, it shall not be used when there is thermaldeflection of the piping in vertical direction. Furthermore, when the amount ofdeflection is large, as it will be in the case of high temperature piping such as mainsteam pipes, consideration is required to provide long hangers, so that less piping liftdue to the inclination of hanger can be obtained. Generally, the displacement angle 8shall be 10° - 15° or smaller. The maximum displacement angle 8 shall be;8° orsmaller, when the movement of the hanger rod is restrained by clevis bracket (Referto Fig. 11.4.3-S). When the amount of displacement and with it the displacement inthe vertical direction is large, the hanger shall be installed obliquely in anticipation ofthe amount of displacement.

Fig. 11.4.3-S Displacement angle of hanger rod

(5) Strength of structure for support-fixingIt is preferable that the supports for piping around compressor or turbine be provided withtheir own structure/foundation for supporting. Practically, supporting is often provided fromthe foundation/structure of compressor, or column/beam of building/pipe-rack. Keep inmind to send timely and accurate information (information concerning the strength of fixingpart, such as loading data) to the Civil and Structural Department and structural designers,

Carbon-embedded plate

Slidesurface

Carbon-embeddedplate

The proper size of the plate shall be determinedwith regard to the size of shoe, amount ofdisplacement, contactsurface pressure. etc.

Clevis bracket

Fixing positionof hanger

Displacement

so that the original aim of having supports compatible to those as designed is attained.Below are explanations regarding the advance checking at the time of design.

(a) The support-fixing part shall have sufficient rigidity. Furthermore, as an information tobe sent to Civil and Structural Department; the allowable deflection of 1mm or lessshall be designated, together with the loading data. In practice, concrete structuresshall be used; when steel structure is to be used, bracing shall be added. (Refer toFig. 11.4.3-T)

Fig. 11.4.3-T Support

(b) When a support is to be fixed to concrete, insert plate and anchor bolts shall be used,as a rule. Fork anchors and Drive-it shall not be used.

(c) in general, it is sometimes difficult in regard to the schedule, to determine accurateloading data at the planning stage. In such cases, allowable values of supported load(for example, vertical load per one column of compressor foundation, (load per oneinsert plate) properly estimated from the view point of civil design and structuraldesign shall be determined, after coordination with Civil and Structural designerengineers, so that the piping route can be checked by thermal stress calculation, andthen adjustment by supports can be made.

(d) Insert plates shall be used when a support is to be fixed to concrete. Insert plates aredesigned in detail by the Civil and Structural Department based on information fromthe Piping Design Department, and be embedded into concrete structure, such ascompressor foundations, columns, beams, floors, walls, local foundations, etc. ofbuildings. Data concerning insert plates, such as loading data, material, shape,method of fabrication, location of embedding, and quantity, shall be put into order, sothat the work, such as detail design, procurement of material, fabrication, andembedding, be performed efficiently and accurately.

Provide bracingwithout fail

Designate allowable deflection

Provide bracing

11.4.4 Supports for piping around pump

(1) Attention required in design of supports

(a) Supports in which off-center of pump is taken into consideration

(i) Supporting shall be made, such that the proper weight of pipe or valve is notintroduced into the nozzle of pump. Note 1) (Refer to Fig. 11.4.4-A.)

Fig. 11.4.4-A Position of support for piping around pump

Note 1: Supporting shall be made in the vicinity of nozzle.

(ii) Suction and delivery shall be supported separately.

(iii) Supports installed in the vicinity of suction or discharge nozzles, shall be of aconstruction which allows fine adjustment, so that centering work can be doneeasily. (Refer to Fig. 11.4.4-B.)

Fig. 11.4.4-B Adjustable support

(b) Support to be installed in the vicinity of suction/discharge nozzleSupport to be fixed in the vicinity of suction/discharge shall be of such constructionthat the piping is removable and the pump can be disassembled.

(c) Consideration of maintenanceEven when no support is needed from the viewpoint of load at pump nozzle,support(s) shall be provided, if the support of piping is required at the time ofmaintenance.

Spring hanger orhanger support

Note 1) When calculation ofsupport balance withinwhole system is made,the nozzle shall not bedeemed as supportpoint.

(Note1)

Note1

Adjusting bolt

Insert Plate

Adjusting screw

(2) Supports for piping around pump (Refer to Fig 11 4.4-C.)

Fig. 11.4.4-C Example of support 1

Fig. 11.4.4-C Example of support 2

(a) Example of support type “PS-1” (Refer to Fig. 11.4.4-D.)

Fig. 11.4.4-D Details of PS-1

Note 1) PS-1 builds up an adjustable support, such that the piping can be adjusted with the center ofthe pump. In this case the part of the stanchion shown as shaded areas shall be fixed by thestrainer maker. Furthermore, when it is desired that the movement of X-direction is

T-type strainer T-type strainer

Jackpot(SUS)

Base plate Stanchion pipe

Stopper

(from + X direction)

restrained, stopper shall be fixed as shown in the figure at the right. When such stopper(DIRECTIONAL STOP) is to be used, the information of DS point as shown in the figurebelow shall be input without fail at the time of thermal-stress calculation (Refer to Fig. 11.4.4-E).

Fig. 11.4.4-E Method of thermal-stress input

(b) Example of support type “PS-2” (Refer to Fig. 11.4.4-F.)Because PS-2 has also a function to stop the swinging of piping, hanger rod shall notbe used, as a rule.

Bad

Fig. 11.4.4-F Details of PS-2

(c) Example of support type 'PS-4' (Refer to Fig. 11.4.4-H.)Although this place will not have so much effect on the alignment of the pump,consideration is needed to allow insertion of liner, so that the elevation of the pipingcan be adjusted to meet that of the adjustable support part.

Fig. 11.4.4-H Details of PS-4

(d) Example of support type 'PS-5' (Refer to Fig. 1 1.4.4-1.)

Trunnion

X directionY directionZ direction

Good

R-typeR-type

It is to be avoided to provide support in the place like this. In case where the pipingtemperature is normal temperature or higher, this shall be spring hanger. Furthermore, because oscillation is feared, a support which can also work as swing-stopper atthe same time, such as'PS-2', shall be added.

Fig. 11.4.4-I Details of PS-4

(e) Example of support type “PS-6” (Refer to Fig. 11.4.4-J.)Suction lines may produce oscillation caused by eddy of fluid. Generally, foot valve,strainer, etc. are installed at the suction port, and they too are in many casesanchored by bolts etc. at the bottom part of the pit. However, when the length of theriser pipe is long, it is necessary to provide a guide, PS-6.

Fig. 11.4.4-J Details of PS-5

(f) Example of support type “PS-7” (Refer to Fig. 11.4.4-K.)Concerning the support for discharge piping of pump, it is feared that water hammercaused by backward flow may affect the check valve when the pump has suddenlystopped. Generally, generation of such water hammer is prevented by having a checkvalve with damper, or by providing bypass for the check valve. When it is feared thatwater hammer is generated anyway, it is necessary to fix the check valve by a supportwhich has high rigidity. An example is shown below. Further more, the beamsupporting the valve, shall be installed after the valve installation such that it meetswith bolt holes of the valve.

Fig. 11.4.4-K Details of PS-7

Side viewPlan view

U-bolt orband

Water pumpCheck valve

Gate valve

(A)

(A) : Providesufficientrigidity

(g) Examples of support type “PS-8”,”PS-9” (Refer to Fig. 11.4,4-L.)PS-8 : In general, supports of this kind shall satisfy the two requirements of restricting

the displacement of the piping in the direction of X, and of controlling theupward movement of the piping caused by thermal expansion. Theconstruction of this support is the same as that used at around compressors.

PS-9 : This is a support which has the same function as PS-8. But, this supportgenerally restricts the movement of piping in the direction of X.

Attention shall be paid, so that this part does not contact with drain valve, etc. provided at theunderside of pipe.

When the amount of displacement of the support part is large, the distance L shall belong. Support column shall have sufficient strength, not only in the direction of theforce, but also in the direction perpendicular to that of the force.

Fig. 11.4.4-L Details of PS-8, PS-9

11.4.5 Support for exhaust piping of safety valveSafety valve with atmospheric vent shall have support in consideration of the reaction forceat the time of discharging. When the piping of primary side is short, support as shown in Fig.11.4.5-A can be thought of. In this case, although the reaction force of discharge side can beeasily calculated by use of computer, it is required to assume that twice the calculated valueis applied because this force is instantaneous, and is to be deemed an impulsive force.

(a) No excessive force shall be allowed to be introduced to the nozzle neck.

(b) An swing-stop support shall be provided at the exhaust-to-atmosphere end.

(c) When a support-fixing base member is to be welded to equipment, information to thiseffect shall be sent to the Equipment Design Department at the time of vessel clip design.

Trunnion Pipe

Section

Beam

Floor

PropAttention shall be paid, so that thispart does not contract with drainvalve, etc. provided at the undersideof pipe.

Fig. 11.4.5-A Support around safety valve of exhaust-to-atmosphere type

Calculation of the reaction force due to discharge can be done, according to API RP 520, asfollows.

( )( )F W

K TK M

=++

1273

2371

F : Reaction force (kgf)W : Discharge flow (kgf/hr)K : Specific heat ratio(cp/cv)M : Molecular weight (kg/kmol)T : Inlet temperature (°C)

11.4.6 Support for piping around pressure-reducing valve

(1) Attention required in design of supports

(a) Support shall be installed at the valve or its flange part. When on rack, the valve shallbe positioned at above a main rack-beam, and the main rack beam shall have bracing(or truss) to be supported from directly below, so that the force of vertical directioncaused by vibration of the valve is transmitted to the column by axial force of thebracing. (Supporting shall not made be ~y bending of beam.) Furthermore, the forcecaused by horizontal oscillation shall be stopped by horizontal bracing. (Refer to Fig.11.4.6-A.)

Bad Good

Fig. 11.4.6-A Support at the part of reducing valve

(b) Support shall be firm, and the distance between supports shall be short (to haverigidity of support). Furthermore, asbestos-wrapping shall be made.

(c) Bands shall be of flat steel (U-bolt shall not be used). Bolts shall be tightened bydouble nuts.

(d) There shall be no free ends (elbow part which is free to move), and the direction ofconstraint shall be carefully considered. (Refer to Fig. 11.4.6-B.)

Swing-stop supportFixing of support-fixing base-member shall be informed toVendor.

Fig. 11.4.6-B Support at free end part

(e) For branch pipes of small diameter (for pressure gauge, drain discharge, etc.),strength of the branching part shall be increased (increase thickness) and moreoverswing-stop shall be considered. (However, ribs shall not be used for piping which istemperature-related.) (Refer to Fig. 11.6-C.)

Fig. 11.4.6-C Take-out of small diameter pipe

11.5 Selection of Support Type

11.5.1 Attention required in selection

(1) Support type shall be selected from those stipulated in TEG1-1314-103, TEG 1-1314-203“PIPE HANGING MANUAL NO.3 STANDARD FORM”. Specific support design shall bedone only when standard type cannot be used.

(2) When support type for usage is to be restricted for each job, the selection shall be madebeforehand.

(3) Supports of the same piping shall be of the same type and material as far as the supportingcondition is the same even when the area is different, so that the design is unified. Forexample, they are all called resting support they may be of one-pillar type or two-pillar

Pressure gauge

SubBoss

Reinforcing Pad

type, from-above support type or from-below support type. They shall be unified as far aspossible.

11.6 Selection of Support Member and Material

11.6.1 Selection of support member

(1) Support members shall be selected by use of TEG1-1314-104, TEG1-1314-204 “PIPEHANGING MANUAL NO.4 DESIGN DATA”. Members shall be selected, each beingappropriate for respective load effected to the support.

(2) For each job, it shall be determined whether members and materials stipulated in JIS areto be used, or whether foreign standard are to be applied.

(3) Efforts shall be made to have members to be used, in small number of kinds as far aspossible, and those designated for each job shall be used.

11.6.2 Selection of support material

(1) Support members which are fixed and directly contacting with the piping shall be selectedproperly, in consideration of the material and/or temperature of the piping. Particularattention shall be paid to high temperature and low temperature service.

(2) Example of selection of support materials as a standard is shown in Table 11.6.2-A.

Bottom-mounted

Side-mounted

Top-mounted

Table 11.6.2-A Selection of support material

Piping materials Support Materials

Purpose Steel pipe (kind of steel)Standard

temperatureMembers directly welded or

contacting to pipingMembers not directly contacting to

pipingrange for use Pipe

materialsPlate

materials Bolt/Nut Pipematerials

Platematerials Bolt/Nut

STPL39 380AL-killed steel -40 - -10°C STPL380 SLA325A SUS304 SGP or

STGP SS400 SS400

For low temp. piping STPL46 4503.5 Ni steel -100- -40°C STPL450 SL3N275 SUS304 SGP or

STGP SS400 SS400

SUS304 - SUS347Each kind of stainless steel Under -10°C

SUS304 -SUS347

SUS304 -SUS347 SUS304 SGP or

STGP SS400 SS400

STPG, SGPCarbon steel -10 - 350°C

STPG,SGP SS400 SS400 SGP or

STGP SS400 SS400

STPTCarbon steel 350 - 450°C STPA SB410 S35C/S25C SGP or

STGP SS400 SS400

STPA12C-Mo steel 400 - 500°C STPA12 SCMV1 SNB7/S45C SGP or

STGP SS400 SS400

-40 - -10°CSTPA23

1 Cr-0.5 Mo steel 450 - 550°C STPA22 SCMV3 SNB7/S45C SGP orSTGP SS400 SS400

no problem of corrosion STPA231 ¼ Cr-0.5 Mo steel 525 - 575°C STPA23 SCMV3 SNB/S45C SGP or

STGP SS400 SS400

STPA242 ¼ Cr-1 Mo steel 550 - 600°C STPA23 SCMV4 SNB7/S45C SGP or

STGP SS400 SS400

SUS304 - 347Each kind of 18 Cr-8 Ni stainless

steel

600 - 800°CSUS304 -SUS347

SUS304 -SUS347

SUS304-SUS347

SGP orSTGP SS400 SS400

SUS309,310Stainless steel of higher class 800 - 1200°C STPA25 SUS309,

310SUS309,

310SGP orSTGP SS400 SS400

STPA255 Cr-0.5 Mo steel 200 - 600°C STPA26 SCMV4 SNB7/S45C SGP or

STGP SS400 SS400

For high temp. anti-sulfidation piping

STPA269 Cr-1 Mo steel 450 - 650°C

SUS304 -SUS347 SCMV4 SNB7/S45C SGP or

STGP SS400 SS400

SUS304 - 347Each kind of stainless steel 600 - 800°C

SUS304 -SUS347

SUS309,310

SUS304 -SUS347

SGP orSTGP SS400 SS400

For corrosion - resistantpiping

SUS304 - SUS347Each kind of stainless steel - SS400 SS400 SGP or

STGP SS400 SS400

When to be welded to piping, check the material.From TEG No. 3051

11.7 Spring Hanger and Shock Absorber Details

11.7.1 Spring hangers

(1) Variable hangersVariable hangers and variable supports have a spring contained in the casing as shownrespectively in Fig. 11.7.1-A. This support type is the most frequently used hanger for hightemperature piping systems.

Fig. 11.7.1-A Variable hanger

When a variable hanger is used, the internal spring expands and contracts in proportion tothe thermal expansion, and supporting load changes. Because this change in the load is noother than the resistance against the thermal expansion of the piping, it is thought that inorder to minimize this, a spring which is as soft as possible may be used. To show themagnitude of the resistance against the thermal expansion, load change rate β, which isdefined by the formula shown below, may be used.

βδ

=−

× = ×WH WC

WHKWH

100 100

where WH = Force of hanger in operationWC = Force of hanger during stoppageK = Stiffness of hangerδ = Pipe displacement at hanger

Because, strictly speaking, the amount of displacement δ will change with the stiffness ofthe hanger, it cannot be said that δ is proportional to K. But, generally, the smaller K is, thesmaller is δ.

The load change rate is used also for indication of performance of individual hangers. Insuch cases, the amount of displacement 6 in the above formula is assumed to be 25mm,as a standard value, and for WH the standard load of that hanger is adopted. Therefore:

β =×

×Spring Const

Std Load25

100%.

In case of variable hangers of Nihon Hatsujo, stiffness is set such that 6 of the aboveformula will become one of 3 kinds: 10.5, 21, or 42%, and it is recommended, in principle,to use rigid hangers when there is almost no thermal expansion, and to use variablehangers when there is much thermal expansion. But, there are cases in which, even thoughthe amount of displacement is near to zero, variable hangers rather than rigid hangers areintentionally used. This is because the actual supporting load cannot be read when rigidhangers are used. For example, it is not rare that a piping near to a nozzle which has littlereserve of strength is supported by a variable hanger.

(2) Design of variable hangerDetermination of use and installation-position of variable hanger supports are decided inthe planning stage. Based on the thermal stress, the amount of displacement andsupporting load calculated by use of computer (by ADL or CAESAR-II), the method of

installation, type (spring hanger type No.), etc. shall be determined; thereafter the springhanger schedule shall be prepared, and be used together with the installation drawing forplacing the orders. Hereunder, the selection of spring hanger type Nos. based on NihonHatsujo Co.'s catalogue is explained.

(3) Construction and material of variable hanger (Refer to Fig. 11.7.1 B, Table 11.7.1-A.)

Fig. 11.7.1-B Types of spring hanger

B type C type F type

H type S type T type

A type

Table 11.7.1-A

Part Description Material RemarksNo. JIS (SAE) ASTM (AISI)1 Upper Cover SS400 A362 Scale plate or Nameplate A1100P or -

SUS430 - Option3 Case SS400 A364 Rod SS400 A675 Gr.505 Turnbuckle S25C A575 Gr.10256 Present piece SS400 A367 Spring seat S25C A575 Gr. 1025 1 - 18

SS400 A36 19 - 23STKM A513 MT1020 19 - 2313A

8 Spring SWO-B A229 CL1 1 - 3SWOSM A229 CL1 4 - 8

SUP6 (AISI 9260) 9 - 11SUP9 (AISI 5155) 12 - 16

SUP11A (AISI 51B60) 17 - 21(SAE4161H) 22 & 23

9 Lower cover SS400 A3610 Ear SS400 A3611 Bolt/Nut SS400 A307 Gr. B 1 - 20

Pin SS400 A37 Gr. B 21 - 2312 Support SS400 A36 1 - 6

Beam SS400 A36 7 - 1813 Base Plate SS400 A3614 Washer SS400 A3615 Load column STPG37 A53 Gr. A Applicable16 Spring seat SS400 A36 only to S-type17 Load flange SS400 A3618 Load column STKM13A A53 MT102019 Intermediate spring seat SS400 A36 Applicable to20 Guide pipe SGP VS 120 - &

STPG370 A120 VS 160 - typeSTKM (Fig. omitted)

Preset piece

Variable hanger has a preset piece, shown in Fig. il.7.1-C(A) attached to it, so that presetting can bemade such that the internal spring be loaded to a predetermined value, and is sent to the site aftersuch presetting has been made. Preset piece is of such type that it is inserted into the ears of uppercover and spring seat of the hanger. There are two purposes of this preset piece. The first is tominimize the labor of load adjusting at the time of installation of the hanger, by having a setting equalto the as-installed load.

The second is to prevent deformation of the piping due to overload at the time of pressure test of thepiping. Therefore, preset piece shall not be removed until the pressure test of the piping is finished.When it is anticipated that locking of the hanger may becomes necessary after wards for a plannedinspection etc., the removed preset piece shall be put under custody rather than is to be wasted .

Universal locking apparatus

It is not necessarily easy to reattach the preset piece once it is removed. When frequent removing/re-attaching of the preset piece is necessary, it is convenient to use the universal locking apparatus asshown in Fig. 11.7.1-C(B). By tightening the lock nuts the hanger can be made rigid easily at any

position. This apparatus is, in the same manner as the preset piece, preset at the predetermined loadbefore shipping. The lock nuts shall not be loosened until the pressure test is finished. Hangersprovided with this locking apparatus are indicated by “L” added to the type No. of the hanger.(Example: VS30C-21L)

(A) Preset piece

Fig. 11.7.1-C Preset piece

(4) Purchase specification of variable hangerWhen placing an order of variable hangers, at least the 3 items shown below shall beindicated.

(a) Supporting load (when difference in the weight due to fluid in the pipe between thetime of normal temperature and the time of operation is large, indication to this effectshall be made.)

(b) The amount of displacement, when from the time of normal temperature to the time ofoperation (for example,”16mm upward” shall be indicated.). Note 1)

(c) Type of installation (Refer to Table 11.7.1-B.)Even in case that the hanger type No. is specified, (i) and (ii) shall be added, withoutfail. Items other than above to be considered at the time of placing the order, are asfollows:

(i) When F-type is to be ordered, the whole supporting load, supporting load per onehanger, and axis-to-axis distance between 2 hangers, shall be clearly indicated.

(ii) When requiring special specification, such as provision of universal lockingapparatus, indication to this effect shall be especially made.

(iii) The painting specification shall be indicated clearly.

Upper cover

Preset piece

Spring seat Lock nut(a)

Note 1) AS to the description ofthe amount ofdisplacement, that ofthe horizontal directionshall also be added.Especially, in case of“S” and “T” type, it shallbe indicated that guidesfor prevention oftottering must be fixed.

(a):Universal lockingapparatus

(B) Universal lockingapparatus

(5) Selection of variable hanger type number

(a) Selection of type No.

Example of how to indicate hanger type No.

VS 80 B - 2 0

SizeInstallation MethodSeries

Table 11.7.1 - B Symbols for indication of type number

Classification Symbol ExplanationSeries VS This means Variable Hanger

30, 60, 80, 120, 160 This indicates the load change rate and travel class.A, B, C, D, F, H, S,T

This indicates installation classification (Table B-3)

1 - 23 This indicates loading capacity classification.

Table 11.7.1-C Performance and features of each series

Series LoadChange

Travel Description

VS30 42% 30mm To be used when the amount of the vertical displacement of piping is small,i.e. about 10mm or smaller.

VS60 21% 60mm These are most frequently used because of both performance and costVS80 21% 80mmVS120 10.5% 120mm To be used when the amount of vertical displacement of piping isVS160 10.5% 160mm large, but use of constant hanger is not justified.

(6) Method of installation of variable hangerThe method of installation of variable hangers can be selected such, that it is inaccordance with the conditions of the place of installation and of surroundings, etc., byreferring to the classification regarding the method of installation, as shown in Table11.7.1-D, and the examples of installation and use. In general TYPE-A - TYPE-S, whichare of hanger type (type for hanging) are preferable, when the amount of displacement inthe horizontal direction is large. When T- TYPE which is of support type (type for passivesupport) is used, it is possible that the neck part of the spring support may be bent.Therefore, it is preferable, not to use this type. If there is a strong requirement for the useof this type, it is recommended to provide an antifriction material such as Teflon, in orderto have less friction force affecting the neck part, or to use a spring support of a type withreinforced neck part (Refer to Fig. 11.7.1- D). In addition to the above, there is a method asshown in Fig. 11.7.1-E, which is worth to be referred to.

Fig. 11.7.1-D T-type support provided with guide bar

Fig. 11.7.1-E Example of support coping with movement in horizontal direction

Slidingsurface

Guide pipe

Table 11.7.1-D Classification in regard to method of installation

TYPE Typical Form Description

A TYPE In this type, the upper cover of the hanger has a threaded part at which the rod isscrewed in. After the rod is screwed in, the upper nut shall be tightened and thenspot-welded without fail. When the length of rod is adjusted by turnbuckle afterinstallation of the hanger, the hanger proper may rotate and the nut may becomeloosened: So, attention is required. This is used, when the distance from the pipeto the supporting beam is large.

B TYPE The upper cover has a lug welded to it. This is used when the distance from thepiping to the supporting beam is short.

C TYPE The upper cover has two lugs welded to it. This is generally used when thedistance from the piping to the supporting beam is short. It can also be used, whenthe distance from the piping to the supporting beam is large, an eye rod beingused. In this case, in contrast to the A-type, there is no fear that the nut foradjusting the length becomes loosened. Therefore it is safe.

F TYPE In this type, two identical hangers are connected to each other by a support beam.The center-to-center distance of these two hangers is standard but can be varied ifnecessary. When selecting a hanger from the table of loading capacity, be sure totake ½ of the supporting load. However, when the piping is not at the center of thetwo hangers, it is necessary to calculate the load effected to each hanger, andaccordingly obtain a combination of hangers. This type is used when a hangercannot be installed between the upper supporting beam and the pipe.

H TYPE This is a type, where hanger is placed on a supporting beam, and the pipe is hungby rod. The length of the rod is adjusted by a turnbuckle. This used when thedistance from the pipe to the supporting beam is small.

S TYPE This is a type, where the hanger is placed on a supporting beam, and the pipe issupported by rod. The length of rod is adjusted by a screw of the load column atthe upper part of the hanger. This is used when the distance from the pipe to thesupporting beam is small.

T TYPE In this type, the pipe is supported from the underside, directly or via stanchion.When the amount of displacement in the horizontal direction is large, it isnecessary to use a slide plate such as Teflon, or rollers, at the same time.Adjustment of the height is done by rotating the load column.

(7) Supporting load of spring hangerCalculation of the supporting load and amount of displacement of each spring hanger,which must be controlled to be within the allowable limit at each nozzle of equipment,despite of the complexity of the piping system, is a severe task necessary in thedesign/analysis work. Especially, for piping system which is connected to nozzles ofcompressor, turbine, or of tower/tank made of high class material, sufficient study isrequired. Therefore, analysis is ordinarily performed by use of computer for such piping.Decision on the position and on the reaction forces affecting the nozzle is dependent on

the judgment of the design engineer in charge. Nevertheless, as for the optimumsupporting position of piping, the decision is made on a trial-and-error basis. If pipingdesign engineers can determine the appropriate supporting position in a comparativelyeasy manner, the number of trial-and-error by use of computer will be reduced, thusleading to reduction of cost. Hereunder, a simple graphic method to obtain the supportingload at each supporting point and the position of supporting point is shown.

ExamplePerform checking on the load-bearing at each support point of a steam pipe as shown inFig. 11.7.1-F, and balance them.

Fig. 11.7.1 - F

WEIGHT 12 in. SCH40 100 kg/m (75 mm INSULATION)6 in. SCH40 40 kg/m (65 mm INSULATION)12 in. VALVE 900 kg (WITH FLANGE)6 in. VALVE 250 kg (WITH FLANGE)12 in. FLANGE 120 kg (A COUPLE)6 in. FLANGE 40 kg (A COUPLE)

Assuming that the moment at point A is zero,

1.0 RP1” = 900 x 0.25 + 50 x 0.75 + 135 x 3.3RP1” = 225 + 37.5 445.5

= 708 kg

Although the weight of flange of part C is not included theoretically, result of calculation isapproximately correct.

For reference: Calculation when reaction at part A = 0

Around X-axis

Around Y-axis

11.7.2 Shock absorberAs a countermeasure against oscillation (caused by earthquake), hydraulic or mechanicalshock absorber (snubber), which alleviates and limits any rapid movement of the piping, shallbe used. Examples of shock absorber installation are shown below (when such shockabsorbers are to be used, sufficient consultation shall be made furthermore with the maker,and the optimum type shall be adopted.)

(1) Spring type shock absorberSBN-type spring-type shock absorber

Fig. 11.7.2.A

(2) Hydraulic shock absorber PT preset type

Fig. 11.7.2 - B

Don’t weld

Clevis

Inner pipe

Field weld

Pipe clampwith bracket

ClevisInner pipe

Field weld Field weld

Inner pipe

Field weld

Pipe clampfor spring-type shockabsorber

PT present type Clevis “A”

Connecting Pipe

Preset piece

Turnbuckle

Clevis “B”PC preset type Clevis “A”

Connecting Pipe

Preset piece

Turnbuckle

Clevis “B”

(3) Mechanical snubber

Fig. 11.7.2 - B

(4) Restrut

(Weld after adjustment of the length.)

Fig. 11.7.2-D

(5) Example of installation/use

Fig. 11.7.2-E

Mechanical sunubber proper

Stopper

Pin Pin

Cut at site

JOB NO. 1

COST DOWN CHECK LIST There is much meritThere is merit

∆ No merit DATE : x Cost up Prepared by :

<Contract form: >

No. Summary Adoption or Reason of Anticipated value Result Related Remarksrejection rejection Turnkey FOB Cost + Fee Other M/H (Hr) Cost (1,000yen) parts

1 Adoption of high frequency bend X *) ∆ *) It results in costincrease, consideringtransportation cost.

2 Adoption of long length pipe(RANJAKU ??)

∆

3 Adoption of CS pipe in low temperaturezone

∆

4 Change of 3.1/2Ni pipe to SUS ∆ ∆5 Adoption of SCH20,30 for C.S

materialsX *) X *) ∆ *) The seamless,

especially, will resultin cost increase.

6 Change of SLIP-ON flange to WN ∆7 Adoption of reducing flange ∆ ∆8 Adoption of reducing elbow ∆ ∆9 Adoption of miter bend ∆10 Adoption of trap with bypass X ∆11 Adoption of drain valve with boss and

short pipeX ∆

12 Adoption of manifold pipe for steamtrace

X ∆

13 Adoption of header pipe without balls X ∆14 Adoption of pipe with pump suction and

strainersX ∆

15 Adoption of nozzle with elbow ∆16 Adoption of B.W. nozzle ∆

JOB NO. 2

COST DOWN CHECK LIST There is much meritThere is merit

∆ No merit DATE : x Cost up Prepared by :

<Contract form: >

No. Summary Adoption or Reason of Anticipated value Result Related Remarksrejection rejection Turnkey FOB Cost + Fee Other M/H (Hr) Cost (1,000yen) parts

17 Shape of header pipe of heatexchanger

∆

X

∆

∆

18 Shape of pipe rack (front guard frameor gantry type)

∆

19 Combined use for rack and frame ∆20 Examination of equipment stacking ∆21 Shape of local foundation (Insert type

or backfilling type)

∆ ∆

Thickness up

Oarkanchor

Backfilling