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, .? . . PIPING DESIGN INSTRUCTION . . TOYO ENGINEERING CORPORATION TOKYO JAPAN

TOYO - Piping Design Instruction.pdf

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.

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PIPING DESIGN INSTRUCTION

.

. TOYO ENGINEERING CORPORATION TOKYO JAPAN

2. PLANNING

1. Plant layout 8

1.1 Plant area 1.2 Safe distance 1.3 Distance

1.4 Overhead clear ante 1.5 Design of tank yard 1.6 Height of foundation top and floor 1.7 Road

8 9 9 9

10 10 10

2. Installation of platform, stairs and ladder 11

2.1 Installation sf sructure 11

2.2 bstaliatioti of ladder .13 2.3 Installation of platform and ladder 15 2.4 Staira, ladder and handrail 16 2.5 Live load for platform 16

3. Nozzle orientation 17

3.1 Type and size of platform 3.2 Limitation on platform installation

(1) Manhole (2) Level control (3) Gauge glass (41 AP/CELL type liquid level instrument (5) Temperature instrument

.17 1% 1% 19 19 22

22

.

(6) Opening in platform

(7) Installation of davit ai the top of tower

23

24 3.3 Consideration on nozzle orientation 25

3.3,1 Nomenclature 25 3.3.2 Considerations required for tower nozzle orientation 27 3.3.3 Considerations for orientation in other vessels and

heat exchangers 34

34486 Contents -2 -

3. PIPING

1. Manuals relat ed d to piping design

1.1 Relation between this design instruction and other manuals 1.2 Related manuals

2. Draftxing rule

2.1 Unit and scale 2.2 Lines to be used

2.3 Indication of pipes (Double line)

3. Piping materials

3.1 'Pipe , 3.1.1 Equation to determine the thickness of steel pipe A

(KI3K.S 0302) i

3.1.2 Pipes requiring postweld heat treatment (PWHT) 3.1.3 Pipe eelection criteria

3.2 Valve 3.2.1 Gear operated valve

3.2.2 Special valve 3.2.3 Valve material

3.3 Pitting 3.3.1 Bend 3.3.2 Blitre bend 3.3.3 Reducer 3.3.4 Tee 3.3.5 Standard application of fitting 3.3.6 Comparison of material between JIS and ASTM

3.4 Flange

4. Scope of work for piping materials

4.1 Scope of work at equipment nozzle 4.2 Matching with instrument 4.3 Uatching with vendor's piping 4.4 Matching with customer's equipment and piping

37

37

37

38

38

38

39

39

39

39

39

40

41

41

41

41

41

41

42

43

44

45

45

45

46

46

50

50

50

3448G Contents -3 -

5. Insulation

5 .l General

5.2 Hot insulation 5.3 Cold insulation 5.4 Personnel protection 5.5 Fire proofing 5.6 poise protection

6. Noise and vibration 54

6.1 poise 6.1.1 General 6.1.2 Noise level limitation 6.1.3 Sources of noise

6.2 Vibration 6.2.1 General 6.2.2 Vibration of piping

7. Cathodic protection and grounding for static electricity protection 59

7.1 Cathodic protection 59

7.2 Grounding for static electricity protection 61

8. Piping design detail 63

8.1 Piping around tower and vertical tank 8.1.1 Layout

8.1.2 Nozzle orientation 8.1.3 Piping around tower

8.2 Piping around heat exchanger 8.2.1 Type of heat exchanger 8.2.2 Considerations required for arrangement and piping 8.2.3 Example of piping around horizontal heat exchanger 8.2.4 Piping around reboiltr 8.2.5 Piping around Al-heat exchanger 8.2.6 Piping around air cooler

8.3 Piping around rotating machine 8.3.1 Piping around pump 8.3.2 Piping around turbine 8.3.3 Piping around compressor

51

51 51 51 52 52 53

54 54

54 56

57 57

58

63 63 64 64 69 69 70 72 73

77 81 81 81 95 96

3448G Contents -4 -

8.10 Drain and Vent 144 8.11 Utility piping 146

8.11.1 Hose station 146 8.11.2 Eye washer and shower 148 8.11.3 Ejector piping 149

8.11.4 Cooling water piping for pump, turbine etc. 149 8.12 Sample connection and analyzer 149

(1) Installation criteria 149

(2) Type of valve 150 8.13 Tank yard piping 150

8.13.1 Regulations and safe distance 150 8.13.2 Tank yard piping 150

i.13.3 Drains-ge -system 153 8.13.4 Fire~ext&guishing system 153 :

8.14 Underground piping 153 8.14.1 Lines to be installed underground 153 8.14.2 Design 153 8.14.3 Cooling water piping 155 8.14.4 Sewer piping 164 8.114.5 Trench piping 178

8.15 Firefighting piping (when regulations in Japan are applied.) 179 0.15.1 Type of rystems 179 8.15.2 Water extinguishing system 179 8.15.3 Air-foam system 184 8.15.4 CO2 extinguishing system 186

8.15.5 Cases where WFPA CODE is applied 186

3448G Contents -6 -

4. PIPE SUPPORi

1. General

1.1 Purpose 1.2 Scope of application 1.3 Related manuals and manuals for reference

2. Support design

2.1 Procedurcof support design

2.2 Standard of support design 2.3 Allowable stress and safety factor

3. Supports for rack piping

3.1 3.2 3.3 3.4

3.5 3.6 3.7 3.8

3.9 3.10

Support span Pipe spacing Supports for bare pipe Supports for hot-insulated pipe Supports for cold-insulated pipe Supports for large-dia. pipe Other considerations required in design of supports Use of anti-friction agent Supporting to cope with vibration Absorption of thermal expansion 3.10.1 Model plan 3.10.2 l&en U-loops are used 3.10.3 When bellows-type expansion joints are used

3.10.4 When Yarway’s gun-packed expansion joint is used 3.10.5 Dissipation of heat 3.i0.6 Pressure loss

4. Supports for piping around vessels 207

4.1 Limitation of load 207

4.2 Supports for discharge pipe of safety valve 208

4.3 Vessel clips 208

4.3.1 Supporting of tank piping 209

4.3.2 Supporting of tower piping 210

187 187

188

188 188 190

192

191 191 191 192

195 195 196 200 200 202 202 203 203 204 204 205

3448G Contents -7 -

5. Supports for piping around compressor and turbine 211

5.1 General 211 5.2 .Manuals for reference 211 5.3 Piping provided with sxapnsion joint 211

5.4 Piping supports to be used in general 212 5.4.1 Slliding supports 212 5.4.2 Spring support 212 5.4.3 Thermal-expansion-direction restraining device 213

(Directional, stopper) 5.4.4 Directional stopper of free-in-one-direction type 214 5.4.5 Pipe hanger 215 5.4.6 Vibration atopper for piping 215

..:- : .:- ,I.. 6. Supports for piping arc&d pump .219

6.1 Manuals for reference . 219 6.2 Piping around pump and location of supports .220

7. Spring hanger 230

7.1 Variable hanger 230 7.2 Design of variable hanger 231 7.3 Construction and material of variable hangers 231

7.4 Specification for placing order of variable hangers 233

7.5 Selection of variable hanger's type No. 234 7.6 Supporting load of spring hanger 237

3448G Contents -8 -

5. Supports for piping around compressor and turbine 211

5.1 General

5.2 .Manuals for reference 5.3 Piping provided with exapnsion joint 5.4 Piping supports to be used in general

5.4.1 Slliding supports 5.4.2 Spring support 5.4.3 Thermal-expansion-direction restraining device

(Directional, stopper) 5.4.4 Directional stopper of free-in-one-direction type 5.4.5 Pipe hanger 5.4.6 Vibration stopper for piping

_: . . .- .:.

6. Supports for piping~around pump

6.1 Manuals for reference .

6.2 Piping around pump and location of supports

7. Spring hanger

7.1 Variable hanger 7.2 Design of variable hanger 7.3 Construction and mater ial of variable hangers

7.4 Specification for placing order of variable hangers 7.5 Selection of variable hanger's type No.

7.6 Supporting load of spring hanger

211 211 211 212 212 212 213

214' 215 215

-219

219 .220

230

230

231 231 233 234 237

34486 Contents -8 -

1. GENERAL

1.1 Intent and scope

(1) Intent

This design instruction is intended to standardize vays of equipment layout and piping design of the plant to be designed or constructed by TEC, in order to obtain correct , economical and quick plant design.

(2) Scope

This design instruction applies to all TEC jobs.

(3) Notes:

a. Blanks in this instruction should be filled out and selections made at the time of job.

b.. If conflict, due to customer's requirements, weather conditions etc., arises between the requirements of this instruction, this instruction should be revised and then used so as to meet them.

c. Where there are conflicts between this instruction and otherj TEM or TES etc., such conflicts should be solved by assigned Job Engineers and if revisidn of other TEM, TES is necessary, contact Standard Engineer and Section Chief. Whenever revision of this instruction is required, contact Section Chief.

d. Where applicable codes, customer's requirements etc. are in contradiction to this instruction, the formers should govern.

1.2 Outline of project

(1) Name of client :

a. Main Contractor :

b. End user :

(2) Name of project : I

(3) Type of contract q ENGINEERING n F.0.B D TURN-KEY q SUPERVISING tl COST PLDS FEE iJ LDMPSUM PRICE q UNIT PRICE 0 OTHERS

(4) Scope of engineering

PROCESS FLOW DIAGRAM c! TEC P&I E TEC PLOT PLAN q TEC

UNDERGROUND PIPING ABOVEGROUND PIPING FIRE-FIGHTING PIPING

f3 TEC 2 TEC c! TEC

CIVIL INFORMATION DETAIL CIVIL DESIGN

q TEC DTEC

113 CUST 0 CUST 0 CDST

a CUST 0 CUST q CDST

0 CUST 17 CUST

0 OTHER 3 OTHER ;3 OTHER

C OTHER 3 OTHER 0 OTHER

3 OTHER q OTHER

3402G -l-

1.3 Outline of plant

(5)

Licenser :

Production capacity :

Contract money :

Unit included in the plant

I I

Site of plant :

1.4 Climatic conditions

1.4.1 Ambient temperature

maximum :

minimum :

yearly average :

design max. :

design min. :

OC

OC

OC

OC (for equipment design)

'C (for equipment disign)

3402G -2-

1.4.3

1.4.4

1..

1.4.5

Humidity

max. relative humidity : 0

min. relative humidity : 0

year average humidity : %

design relative humidity : % (for cold insulation design)

Rainfall

max. rainfall :

yearly average :

design rainfall :

Snowfall

xun/hr, mm/day

m#W

m/hr

max. snowfall : mm

max. snowfall weight : kg/m2 design snow load : kg/m2

Direction and speed of wind

max. wind speed : m/s

average (monthly,yearly) : m/s design wind speed : m/s direction of prevailing wind : ;;

wind load : heignt 0 --., m kg/m2

i m kg/m2

- m kg/m2

N

W

f-B

t E

$ .‘..

1.5 Topograph)tic conditions

1.5.1 Datum plane of plant : Ground level of plant :

1.5.2 Rearing capacity of soil :

1.5.3 Groundwater level :

1.5.4 Max. freezing depth :

1.5.5 Seismic coefficient :

m (=EL.OI

ton/m2

1.5.6 Characteristic of soil : (including considerations to design)

1.5.7 Characteristic contour of Land : (including considerations to design)

1.6 Applicable regulations, codes and standards A(

Applicak.he regulations , codes and Etandards should be as indicated in the contract documents. Hake sure that the regulations, codes and standards applied are in what year's editions. If regulations, codes and standards other than indicated in the,contract are used, the names of such regulations, codes and standards and the reasons why they are used should be clearly stated.

1.6.1 Customer’s requirements

34026 -3-

1.6.2 Regulations , codes.and standards

Regulations codes and standaerds Items ] Remarks

L)LAYOOT and SAFETY

(USSR)

(DDR)

i (OTHERS) !

0 Law for conditions of plant site 0 Petroleum Kombinat and Other's Hazard

TEM: 2002

Prevention Law : TES: H-101

0 Fire Service Law H-117

0 High Pressure Gas Control Law JL-101

Cl HIT1 ordinance on High Pressure Gas Control Cl MIT1 Ordinance on Liquefied Petroleum Gas

Control D MIT1 Ordinance on High Pressure Gas Control:

i Concerning Kombinat and Others

D Industrial Safety and Health Law i 5 Law for mining industry ; Cl Law for gas industry i CIOthers .

,a OSHA WCCDPATIONAL SAFETY AND HEALTH ADMINISTRATION)

' 0 OIA (OIL INSURANCE ASSOCXATION) ; 0 NFPA i q API RPSOOA

(RECOMMENDED PRACTICE FOR CLASSIFICATION OF AREAS FOR ELECTRICAL INSTALLATION IN PETROLEUM REFINERIES)

R OTHERS

3 (SNIP) ll.H.l-* "

P O=W -0 (1

Standard for building Regulation for electrical.

(GOST)-12.1.004-" " equipment

n CODE AND REGDRATION AS To SAFETY TECHNIQUE installation

AND INDUSTRIAL SANITATION FOR FIRE ACCIDENT OF CHEMICAL AND PETRCCREHICAL PLAN OTHERS

._'

0 ASAO U%TROCHEMICAL LARCDR REGULATION)

: D ASA0 (GENERAL FIRE PROTECTION AND FIRE PROTECTION REGULATION)

! DOTHERS

Regulation for safety and heath Fire Service Law

.I

34026 -4-

1

Items Regulations codes and standaerds Remarks

2)PIPING CJ Codes and standareds as applied in item(l) TES: H-101 0 ANSI H-103 DKHK H-106 0 JIS H-107

1 D ASTM H-109 j z1 API H-110 j 0 JPI L-101 I Cl DIN 10 BS I 0 MSS i G OTHERS

3)BUILDING Z Codes and standards as applied in item(l) STRUCTURAL Cl Building Standards Law of Japan DESIGN DOTHERS

1.6.3 Index to piping design of the contract. (in Japanese and English)

. .._

34026 -5

1.7 Battery limit conditions

FLUID CONN SIZE

1

2

3,

4

IN- COMING ]

-

! I 1 T i I I 1

I !

I t

7 I

SPEC. Temperature ("C) Pressure (KG/CM=) I

MAX.OR Design MAX. MIN. NOR. NOR. Design !

1

i I 1 !

i

i i

3402G -6-

1.8 Utility conditions

Followings are utility lines commonly used. Be aware that Fluids each having the same name may have different specs respectively (different design conditions). When detail checking, use the design conditions given in the line schedules.

-. .'...., . .

FLUID SPEC. TEMP.(V) PRFSS.(KG/CM2G) I

MAX. MIN. MAX. MIN. i 1. SH (H.P STEAM) I

2. SM (M.P STEAM)

3. SD 84.P STEAM)

! ! I i i

! I I

4. SL (L.P STEAM) I ! 1

, I

5:CH (H.P COND.) I I i t 6

6. CM (M.P COND.) I ! I I I

I 7. CL (L.P COND.) ! i *

'8. INSTRUMENT AIR I ! I i I

1 9. PLANT AIR ! ! I

i ,

;

I i I

110 NITROGEN 1

L i i . i i i

I i

; I

; ; 11. COOLING WATER (IN) 1 1

i i 12. COOLING WATER (OUT) 1. I

i i

/

i i 13. SEA WATER (IN)

j 1 / i

1 .I.. _. i !14. SEA (OUT) i .i ! i 15. 1

1

I 1 .

-f -':- I 1 I I ‘ :l,. . ,.. i I t t i i I

117. I b I i

.f _.... j..! I 18. .. I

19. I i 20. i.

1.9 Customer's requirements

3402G -7-

2. PLANNING

Plant layout

1.1 Plant area

1.1.1 General 0

In most cases, shapes and sizes of plant areas are given by ers advance. However, the following items should always be considered as

;ic rules when developing a plot plan.

(1) The plant area should be small as far as safety, operation, maintenance and construction requirements will permit. This results in considerable saving in cost of piping materials and power equipment.

(2) To layout equipment into a slender area is liable to cause difficulty in obtaining piping flexibility, which increases piping cost due to additional loops and bellows. It is

:. recommended that a ratio 'of long side to short side of plant area be 1:1~1.5:1 based on past experiences.

(3) Plant areas should be prepared so as to obtain a neat layout in having minimum changes in direction of main racks and roads which are backbones of the plant.

1.1.2 Layout of main equipment

To have layout of equipment in a sequence to suit the process flow is le best rule from the view points.of economy and pressure drops. But, safety rd construction requirements dictate more or less modifications of this rule. be followings are main items of such modifications.

(1) Fired heaters (boilers, reformers, heaters etc.) should be located up wind from other equipment handling flammable liquids or gases, and should be grouped together in one area as far as possible to allow centralized control for safety.

(2) Equipment such as pumps and compressor handling flammable liquids or gases, which could easily leak out of the equipment, should be located minimum 15 meters ‘away from fired heaters. (Conforming to Regulations for explosion preventions) For other equipment containing flammable gases minimum 8 meters. (Conforming to MIT1 Ordinance on Bigh Pressure Gas Control 12-3)

(3) Vessels taller than the discharge point of fired heater stack or silencer discharging hot gases or steam should not be located within SO meter radius of the discharge point to prevent the vessel from exposing to hot winds.

(4) Towers more than 30 meters heigh should initially be reviewed I- from the installation point of view and located close to the route through which towers are moved into place.

(5) Large electrical equipment (switch room, motor, large sized switch), if installed within hazardous area, will cause considerable cost increase due to the explosion-protected construction.

1402G -8-

. . :.. i

i

(6) Control room and switch room should be located near the center of the plant and provided with exit on either one side of the room to allow easy access to and from boundary limits. Equipment or piping containing flammable substance should not be located within 15 meters from these rooms. (To keep the room outside Of hazardous areas.) MIT1 Ordinance on High Pressure Gas Control Concerning Kombinat-9 also dictates to have safe distance of 7.5 to 15 meters depending on the degree of hazard for the above case.

(7) Insides of buildings housing ccanpressors handling flammable gases are classified as a hazardous area, including areas 3 meter wide around the buildings of closed type and 15 meter wide around the buildings of open type. All electrical equipment within these areas should be of explosion-protected construction.

(8) Equipment handling poisonous substance should be completely enclosed by a dike to enable collection and recovery of the spillage. Related equipment should be grouped together for this purpose.

(9) Equipment cknected to underground lines such as cooling water or chemical sewer should be properly grouped so as to minimize the length and direction changes of underground pipes which reduces not only piping cost but also the possibility of interfer

P ce with

other cables and foundations.

1.2 Safe distance

Safe distances should conform to THM 2002 (Plant Layout).

1.3 Distance

1.3.1 Between control room, switch room and furnace

1.3.2 Plant equipment for combustible liquid and furnaces (except piping)

1.3.3 Equipment and equipment

1.3.4 Indoor (outdoor) passage

Passage between equipment and other facilities or piping

1.4 Overhead clearance

1.4.1 Plant roads and trucking areas inside process

1.4.2 Normal overhead for maintenance equipment inside'battery limits

1.4.3 Normal overhead inside battery limits

l-4.4 Above platform and walkway

1.4.5 Inside building

15m

MIN. 8m

MIN. 0.9m

MIN. 0.6m

4.5m

3.5m

2.lm (MIN. 1.8m)

2.lm (MIN. 1.8m)

2.lm

3402G -9-

i Design

1.5.1

of tank yard

When Japanese codes are applied;

1.5.2

Conform to attached *

When NFPA is appli&d; '.

Conform to attached " r

6 Height

1.6.1

of foundation top and floor

Height of foundation top

a.

b.

C.

d.

e.

f.

g- h.

1.

j. k.

Pavement of concrete

Pavement of gravel

Cable pit (top of 00Wr)

J-JF .

Compressor and other .rotating machine

Heat exchanger (horizontal type)

Other equipment-tower.s, tan&, etc.

Pipe rack, structure, outdoor stairway

Cone roof tank

Valve pit (top of cover)

Pipe sleepers

1.6.2 Floor height of building

a. First floor of control room and gwitch rocm

D. First floor of compressor house and other equipment house

c. Foundation of structure

1.7 Road

1.7.1 Side and overhead clearance

a) Access road

I=

12000

EL.+ MAX.150 M/M

EL.+ MAX. 50 M/M

EL.+ 100 M/M

EL.+ MIN.300 M/M

EL.+ MIN.300 M/M

EL.+ MIN.600 M/M

EL.+ MN.200 M/M

EL.+ MIN.200 M/M

EL.+ MIN.300 N/M

EL.+ MIN.200 M/M e

EL.+ MIN.250 M/M

EL.+ 600 M/M (CONTROL ROOM)

EL.+ 1000 M/M (SWITCH ROOM)

EL.+ MIN.300 M/M

EL.+ MAX.150 M/M

““/““““““““’ A z

,‘L,“,

Pavement \ ..

: :

I . :

. . .

. : . . . I . . ’ :

: _,/

_,‘-

/--/

:.

‘. . 3402G -lO-

b)Plant road-type 1 .

Pavement \

c),Plant road-type ?

.1.7.2 Turning radius at road junction Fd gradient _.. -

Gradient 12/100 and less

I- F--

2. Installation of platform, stairs and ladder

2.1 Installation of Structure

(1) Structures may be of concrete or steel, but steel should be used unless otherwize specified by customers.

(2) Structures mounted with valves or equipment requiring maintenance such as removal of heat exchanger channel covers, should be provided with stairs or ladders.

3402G -ll-

(3) Selection of stairs or ladder

a. Use stairs in the following cases;

1) When top platform of structure is 10 meters and more above the grade.

2) Top platform is less than 10 meters above the grade but platform area is 50 m2 and more.

3) Platforms mounted with instruments such as level gauge, Sampling etc. requiring patrol by operators at least once a day.

4) Platforms mounted with critical equipment such as reactors or boilers requiring emergency operation.

5) Platforms mounted with equipment such as filters requiring frequent opening of the covers.

6) Platforms'mounted with equi.pment requiring frequent replace Of internally packed material..

b. Ladder should be used in the following cases. J

1) Platforms other than mentioned above.

2)

3)

In addition to the above mentioned stairs, an escape ladder should be provided at closed end of more than 15 meter long blindalley, if any.

Sub-ladder should be provided on the side opposite to the stairs when the platform area is more than 50 m2.

3402G -12-

4) Platforms should have minimum clear width of 800 mm for maintenance, inspection and operation, but additional space is required to facilitate removal of exchanger channel covers and internals, as shown in the drawing below.

Sub-ladder A, . *

5 c Use sub-ladder where P.F. area is more than 5Om2 it.. (If ladder height exceeds 10 meters, use

'J- staggered type with intermediate platform.)

Min.800

Min.450

Min.800

Use sub-ladder where P.F. area is more than (If ladder height exceeds 10 meters, use staggered type with intermediate platform.)

f \ Poarforms should not be required on this side if no

operation floor is needed.

5) Main stairs and ladders should be located to permit ready access for operators.

2.2 Installation of ladder

(1) Tower

a. Ladders should generally be staggered with each ladder's length not more than 10 meters.

5om 2 .

3402G -13-

‘.

b. If the length of ladder exceeds 10 meters, intermediate platform should be provided. Not to be use&as far as possible.

intermediate platform

(2) Pipe rack .,

.. a. Main.pipe 'racks mounted with walkways should have ladders at approximatel$ :i?very SO mtftrs 6% the 'i&k length.

b. Pipe racks ladder.

or sub-racks without walkway should not

(3) Installation of safety cage

a. Tower

Ladder without cage

Caoe

.

generally

-‘T’i..

require

3402G -14-

Cage

b. Structure

0 4 Not requ i

i-l,,,,

V ' provided

1 /////////////////////////////7//////////////~f

.ired when ample 2FL under the ladder.

2.3 Installation of platform and ladder

(1) Platforms should be provided for the following items, when such items are located 3.6 meters or more above the grade (2.1 meters or more for instruments at vessels) or 1.8 meters or more above other platforms. . .

. . . .- a. $tems requiring surrounding platform underneath

,Qbj,ect \

,’ 11

2)

3)

4)

5) 8 figured blind flanges.

Control valves of all size$.

Safety valves IS and more at towers or vertical vessels.

Manholes in towers or vertical vessels.

Display type level gauges at towers and tanks.

b. Items which require side platform only

1)

2)

3)

4) .

5)

6)

mV, AW and other valves IB and more requiring manual operation.

Safety valves 3B and smaller at towers and vertical vessels.

Manholes and others in horizontal vessels or heat exchangers requiring manual operaton and inspection.

Sampling equipment.

Valves frequently operated.

Places in the proximity of BL, or places where valves are grouped together.

3402G -15-

(2)

(3)

(41 Platforms and ladders should not be required for the followings.

a.

b.

Hozale flanges at towers and tanks.

Temperature instruments measuring vessel metal temperatures.

C. Temperature or pressure instrument connections in the pipe (without instrument nor block valve).

a.

c.

Ladder should be provided for the following items, when such items are located 3.6 meters or more above the grade (2.1 meters and more for instruments at vessels) or 1.8 meters or more above other platforms.

1) All check valves at towers and tanks.

2) Valves 3B and smaller at towers and

tanks requiring manual operation.

3) Gauge glasses. (Platforms should be provided if gauge glass requires frequent inspection and maintenance.)

4)

5)

6)

7)

Pressure, temperature instruments at towers and tanks.

Inspection cocks.

Bandholes. (When packed material need not be replaced.)

Sampling valves.

Only a stand or portable ladder is required for manholes, valves, instruments etc. requiring manual operation, when they are located at less than 3.6 meters above the grade (less than 2.1 meters for instrument at vessels).

Spring hangers.

Orifices (when accessible with a portable ladder or temporary platform).

2.4 Stairs, ladder and handrail

StairS, ladders and handrails should conform to TEC ST'D DWG..

2.5 Live load for platform

(1) Unless otherwize specified, platforms should be designed for the live load of 200 kg/m2.

(2) Snow loads should be considered in case of cold district, aside from the above(l).

(3) Loads by pipe supports, heat exchanger channel covers, catalyst loading and other maintenance works will be given in The Loading Data aside from the above(l).

3402G -16-

3. Nozzle Orientation

3.1 Type and size of platform

(1)

(2) Top platform for towers and tanks

a. Top platforms for towers and tanks should be of square type with the standard side clearance of 800 mm.

Platforms for ordinary vertical equipment

Width B of 1) min.600 2) 800 1

3) 1000 4) 1lOON )

max.1500;

platform Not to be used as far as possible. To be used as a standard With 100 mm increment

b. Vessel nozzles, which are normally in standard length, may be extended through the top platform to facilitate tightening flange bolts or installing block valves. (Consult Hechanical Engineer.)

Reinforcement ribs =e. required for extended nozzles.

c. Openings should,,be made to allow tightening flange bolts using a spanner if the-nozzles are not extended through platforms.

d. Platforms should not be connected regidly to neighkx$ing vessels, but should he provided with a clearance approximately 20 mm or connected with slotted bolt-holes to allow for expansion.

(3) Platform for horizontal vessel

Platforms should be provided on the top or side of horizontal vessels lDounted with manholes or instruments requiring operation, inspection etc., if they are located 2.1 meters and more above the grade. (3.6 meters and more if no instrument is mounted.)

340x -17-

I

a.

b.

d.

Platform for tank

Selection of ladders and stairs

Height (Dm) Selection

Less than 6 meters Ladder with safety cage 6 meters and more Spiral stairs

In 4 termediate platforms should be installed at a uniform interval of height 10 meters or less.

Platforms and handrails for tank roofs should be minimum required.

For spiral stairs, careful study should be made to assure that level gauges, sampling connections and other instruments are accessible for operators to handle them.

Cone foof Dome roof

3.2 Limitation on platform installation

(1) Manhole

Top manhole g s-l i r*

500 (750

Intermediate platform .

10m

. .

Spherical

-loo0 is stand

i 8 ‘4 m . 5 4.x

1. Minimum effective side clearance of 500 should be provided for passages.

2. Manhole davits (or hinges) should generally be designed to allow right-hand opening.

3402G -18-

3. Menhole davits (or hinges) should be located away from down ladders (left-hand opening) unless a distance down ladder to manhole is sufficient (1,000 as a standard) to provide a passage.

--_ . .-_ (2) Level control

H>

H silo00

A irk00 (Provide clearance removing internal

r- 4 I-- I I1

I-- 1. I .I A-

(3) Gauge glass

a. Multiple level ladder.

Manually operated from ladder. H> 1000 I

\

100 mm

A distance allowing manual operation from ladder.

Ladder fo be provided from upper platform

gauges should be arranged to stagger on both sides Of

=402G -19-

I . ,_ i : - . . :

b. If two level gauges are arranged on one side, upper level gauge should be closer to the ladder.

Max. 1000 Reading of level from ladder

c. In'general, level gauges should not penetrate platform. (If this is impracticable, level gauges may penetrate it to allow for reading liquid level.)

d. Relation to feed nozzle

LIC should take precedence wer LG.

60° Do not instrall LG within this \ segment unless deflector is used.

Install LG within this range

34026 -2O-

e. Level gauge in low temperature service

on of

Ins;a$on of

Handle of Gauge Valve and Drain Valve 7

f>

Use *A* type when ladder is located on the left or right side of level gauge.

Use "B" type when ladder is located on the left side of level gauge.

Use "C" type when ladder is located on the right side of level gauge.

Wultiplc level gauges should be'installed as follows;

late with I

I the other one. Valve handle projecting into safety cage.

f. When baffle plate is installed in the bottom

Be aware of liquid level difference between both sides of the baffle plate.

Baffle Plate

34026 -21-

g. Level gauges should be located away from seal pan as far as possible.

Away as far as possible

h. Level gauge for high pressure service

Level gauges for high pressure should be installed to suit their actual sizes and provided with ample space for maintenence.

(4) aP/CELL type liquid level instrument

(In general,AP/CELL type is used where the range of measurement exceeds 2000 mm.)

Nozzle sixes are generally 3/4'. But, special equipment may require 1”. (as indicated in P&I)

Platform is required 600-1200 below the *nstrument.

This pipe should be horizontal.

Consider a space for instrument box.

Provide pipe of apprO~iXiately two

meters length to heat pipe in low temperature service.

(5) Temperature instrument

a. Check to ascertain whether liquid or vapor temperature.

b. When liquid temperature is measured, pay attention to downcomer sizes and insertion length. (In general, liquid tempetarure is measured.)

+ 97 I I - Or

34026 -22-

c. Length of temperature instrument

d. Type of temperature instruments should be determined concurrently with nozzle orientation study, considering clearances for the instrument removal.

Clearance for removal

l All nozzle heights are 150 mm regardless of insulation thickness.

Not@s) If temperature instrument interferes with vessel internals;

1) Install it in tangential direction.

2) If instrument interferes despite of tangential installation, use a special length instrument. (Consult Instrument Engineer)

e. In many cases, temperature instruments can be removed to an immediately upper or lower tray. Consult Process engineer if insertion difficulty arises.

(6) Opening in platform :.

Opening dimensions should be as shown below and should appear in the information DWG. TAG numbers should also appear for instrument openings.

a)Displacement type b)M

3402G -23-

c)Piping

::

(7) Installation of Davit at The Top of Tower

a. Drop area

Davits are used for lifting vessel internals when loading. An ample space for dropping and loading vessel internals should be provided on the platforms.

:Pipe davit Dropping area fir

Not good good Davits may be operated either from upper or lower platform.

b. Side clearance for lifting

Consult Process Engineer if special sized platform is required to obtain extended working area. In this case, the arm length should be determined to provide side clearance of min. 450 mm.

3402G -24-

3.3 Consideration on nozzle orientation

3.3.1 Nomenclature

TRAY : Trays, a large munber of equally spaced circular platesin vertical vessel, are devices on which efficient mixing of'p.por and liquid is performed when product separation is required by using distillation.

DECK : Deck, a part of tray, is a horizontal plate on which vapor liquid mixing is performed.

WEIR : Weir is mounted on the deck to maintain an even flow of the liquid on the plate.

DOWNCOMER : Downcomer.is mounted between the decks allowing the liquid to flow down'to.the deck below, while separating vapor upward.

SEAL POT : Seal pot is a pot provided in the deck underneath the downcomer to effectively reduce deck-to-deck distances.

DRAW-OFF POT : Draw off pot, used when draw off from intermediate deck is required, is a pot provided in the deck underneath the downcomer. It provides sufficient depth for liquid collection and installation of draw-off nozzle.

SEAL PAW : Seal pan is a pan located underneath the lowest downcomer to seal liquid from upper deck. Overflowed liquid from the seal pan is received by the bottom of tower.

DRFLRCTOR : Deflector is a baffle plate installed against inlet nozzle to prevent liquid with high velocity from entering directly into the vessel.

340x -25-

. Double flow Single flow

Center downcomer area m2 \ Downcomer area m2

Side downcomer area m2 \A

2 ir to shell distance'& .e.. . . I I 3 aowncomer wiazn at top m/m

1 I

weir

=t

Width of pot m/m

Outlet weir

Downcomer Area under downcome

1 Downcomer bottom to tray inlet in/m

Side View

340X -26-

.: :;

3.3.2

(1)

Considerations required for tower nozzle orientation

In case of top feed

a. Locate feed nozzle to feed inside of inlet weir.

Deflector

Approximately l/lOD or 10 to 150 of cross sectional area.

4-P

Single flow

Do not'locate nozzle here.

Open end tee Ll

Double flow YInlet weir

D=d+one size up

.Internal detail

b. If the above orientation, which is a standard, is impracticable, feed nozzles may be oriented in any directions by using internal

Double flow * Dimension A does not require

straight length.

3102G -27-

c. For internal piping, the elbow and .&ee may be of special type.

2

It i i

Min.

%

d. When the width of inlet weir is smaller than that of open end tee, closed end pipe with slotted holes should be used.

.be extended..

. D In this case, pay attention to manbole posltlon.

(2) In case of intermediate stage feed.

a. Vapor feed

Single flow Double flow

3402G -28-

b. Liquid feed

Slot$ed holes'

Single flow

Double flow . . .

c. Draw off nozzle

(3) Bottom feed nozzle

Single

CJ iD- g&d

t-l I

good Double

go* Double

:. ,:

good good

good Sd * Triple

* In this case, two feed nozzles are required.

3402G -29-

(4) Manhole ..

a. Top manhole

Pay attention to downcomer areas. But, manhole may be located in any direction, when the downcomer width in radial direction is 300 mm or smaller.

good

Single Double

In case, width of downcomen is 3OOmn or larger.

b. Manhole in the interm6diate stage

1) Single flow

c300

T

fB

t

In any direction

1n case, width of downcomer is 300mm or smaller.

_ Manhole may be located heke when downamer is 3OOmm of smaller.

2) Double flow

Two manholes are required, when

Not N Not god 9 good

Not good

Two nkhdles

Not good

One manhble

:.

3402G -3O-

2) When baffle plate is provided.

~~d~~~~~o~d

Single flow Double flow

(5) Types of tray to reduce the size of large tower

a. Reduction of height

L

1 t- 1 P

c/ :.

r-- I I- 1

.:

.‘..

b. Reduction of diameter

.:

- \ Increasing bubbling

area by reducing downcomer area.

3402G -32-

c. Reduction of both height and diameter

a) and b) are combined.

Note : Check carefully for interference of downcomer when determining feed nozzle and manhole orientation. *

Care should be taken not to have internal pipe in contact with the pot which sometimes is iot shown in ENG'G DNG. .

(6) Relation to rcboiler

a. Arrangement of reboiler

1)

Single flow

Best arrangement

Double~flow

An altern&v~ arrangement

.

34026 -33-' CProvided with impingement

baffle

2) When the amount of liquid is small , arrangement as shown below may be used. In this case, attention should be paid to the location of reboiler return nozzle.

Center line of reboiler return pipe should have same elevation with the top of baffle.

(7) Others

a. Nozzle should not be located on the knuckle portion of vessel heads.

b. Valves should not be installed in the skirt as far as possible.

c. In general, nozzles should be oriented with an angular increment of 50.

3.3.3 Considerations for orientation in other vessels and heat exchangers

(1) Eorizontal vessel

Outlet nozzles and instrument nozzles should be located on opposite side to feed nozzles.

Feed 4

Vapor out #

Do not locate outlet nozzle here.

(2) Compressor suction drum

a. Special consideration should be paid for orientation of level instrument nozzle. (Improper orientation may cause shutdown of compressor. For detail. see ; 1

3402G -34-

‘ . . , , , ” . :

1”.

b. Two or more feed nozzles should be oriented in the same direction, if not, mist will be blown up. / t 9 :

Not good

(3) Vertical type heat exchanger

a. Orientation is effected by the

Even nuder

But, consult Process Engineer, is used. (Usually, outlet and the same.)

t

@

I \

t

sood

number of baffles,

._;.

Odd number

when total condensation inlet temperatures are

b. In case of two passes, inlet nozzles of shell side and tube side should be in the same direction.

. . .

(4) Access hole and vent hole in skirt

a. There is no special limitation on vent hole.

b. Access hole

1) Access holes should be ready to access, being oriented-in the same direction and grouped in each area as far as possible.

2) Two or more access holes in one skirt should be located symmetrically to the center of skirt.

340x -3% Three

\rer t. \?essel

Ill gene;:2 1 .

.- , ALEX.

3. PIPING

1. Manuals related to piping design

1.1 Realation between this design instruction and other manuals.

‘. . ‘. This design instruction is intended to cover the important items of

existing manuals and also to cover drafting requirements not included in such manuals.

The followings are existing manuals which are registered with Technical Department.

Of course, it is necessary to utilize such existing manuals together with this instruction.

1.2 Related manuals

TEM-1005

-2001

-2002

-3001

-3002

-3004

-3006

-3007

-3015

-3017

-3025

-3036

-3037

-3038

-3039

-3047

-3048

-3063

-3069

-3074

-3082

-3101

-3102

-3104

-3105

-3106

-3107

-3108

-3109

-3112

-3113

-3114

3402G -37-

General drafting rules

Specifications of transportation equipment

Plant layout

Abbreviations in piping

Drafting methods for piping

Prefabrication drawings

Types of sampling

Piping spacing

Underground piping

Piping Vibration

Weight of piping materials

Rack piping

Tower piping

Maximum allowable span for pipes

Standards for piping design

Checking of information drawings

Checking of planning and piping drawings ,=

How to use piping materials lists

Design standards for piping around compressor and turbine

Pump piping

How to use and maintain piping design control sheet

Drafting methods for plot plan

Matching drawings for piping at battery limit

Drafting of key plan

Drafting of steam tracing

Drafting of piping notes

Drafting of special piping .parts details

Drafting of hook-up drawings

Drafting of isometric drawings

Assign of drawing munbers

Drafting methods of planning drawing

Design of quencher (or desuperheater)

2. Drafting rule

2.1 Unit and scale

(1) mm should be used as a unit.

(2) In general, comma(,) should not be used in the indication of length.

(3) Nominal pipe diameters should conform to job P&I and UFD.

(4) Standard scales are as follows;

430, l/40, 450, 480, l/l00

NOTE : Scale column in the drawing made up of piping details should be entered with 'none', and scale column in the drawing made up of piping sections and details , should be entered with the scale of sections.

2.2 Lines to be used

0.9 mm

0.8 mm

Lines

0.5 mm

0.1 -

0.2 mm

Full line

Full line . . . . .

Full line

Full line

m--

One dotted chain line

em--

Two dotted chain line

w-m--- - -

Dotted line

Application

' BATTERY LIMIT HWJ.'CH LINE

I

Pipes and flanges ZB up to l2B (single line), section of steel I structure, ZB and larger in I

isometric drawing.

Pipes and flanges l.l/ZB and under I (single line), pipes and flanges I 14B and larger (double line), l.l/ZB and under in isometric ! drawing, indication of valve handle.!

Outline of equipment, structure and ; building, parts of piping such as i valve, strainer etc., hatching of f sectional area, dimension line, i

indication of platform floor and i pipe insulation. f

I Centerline of equipmemt and pipe. 1

j Future area and piping or others outside of TEC battery limit. I

!

Dnobserved portions of equipment structure, building and piping.

1 I

Size of line should be consistent ; with respective full line.

34026 -38-

2.3 Indication of pipes (Double line)

Scales for piping drawing

I/30 l/40 1150 l/80 lilO0

L

g -qg3 E[ti

HE0 - -2 14B z 16~

3. Piping materials

3.1 Pipe

3.1.1 Equation to determine the thickness of steel pipe (KHK.S 0302)

(1) When Do/t26 or P(1006~)/2.6

(2) When Do/t<6 or P>1006n/2.6

t=-- lOO$J-P r ( l- 1006n+p I+ c

t = Xinimum required thickness of pipe (mm) P - Design internal pressure (kg/cm2) Do= Outside diameter of pipe (mm) 6= Allowable stress of material (kg/cm2) D= Coefficient of pipe's longitudinal seam, usually 0.85, for

SMLS 1.0 C = Corrosion allowance (mm) and dimensional tolerance 12.5 8

3.1.2 Pipes requiring postweld heat treatment (PWHT)

Typical pipes are shown in the table below.

Steel grade JIS ANSI Thickness Remark

STPG38,42 A53GrA,B 219 mm STPT38,42 A106GrA,B 219 mm

Carbon Steel STPL39 -. A333Gr6 2_ 19 mm STS38,42 A524Gr1,II 219 mm STPY41 A139GrA Al9 mm SM41B A139GrB,C,D 219 mm

STPA12 A335GrPl 216 mm c-1/2Mo STPA22 A335GrP12 212.7 mm lCr-1/2Mo

Cr-MO STPA23 A335GrPll 212.7 mm l.l/4Cr-1/2Mo STPA24 A335GrP22 r: 12.7 mm Z.l/ZCr -lMo STPA25 A335GrP5 2 12.7 mm SCr-1/2Mo STPA26 A335GrP6 212.7 mm SCr-1Mo

3.1/2 Ni STPL46 A333Gr3 219 mm 3.1/2Ni

* It is,advisable to have minimum welded joints from cost reduction point of view.

3402G -39-

3.1.3 Pipe selection criteria *. !

Pipes should be i!

ected by using the attached sheet 1. 'Pipe Selection Criteria'. The following tables are actual data for ethylene-aromatic-plant in China.

i

Selection of pipe material

PIPE AND FITTING FLANGE, VALVE, FITTING BOLTING MAT'L STEEL

ST'D PIPE LARGE DIA.

TEMP.(OC) GRADE FITING PIPE FORGING CASTING BOLT/NUT FITTING

1 (PLATE) L 1 I I

18Cr-12Ni SDS316 & f SDS316 & SDS F316 61 SCS14 & SDS316 & -MO & HIGHER i HIGHER I HIGHER I HIGHER HIGHER

1

I

HIGHER i i

I

!

I I i 600

560 1 i - I - i I -, i SFHV.22B or;SCPH21

i j SNB16 or !

iSFHV.23B : j A193Gr.Bl6 ,

/

480 I ; A194Gr.4 : !*

420

350

-10

i SFHVlZB ; SCPHll ! SNB7 or ' 2 i jA193Gr.B7 i

/ . SF45 or ; SCPH2 i S25C,S28C i

'S45C or FcMB35 : Al84Gr.2H.

j PCD40 ; FC20 S35C/S25C : ; SF50 or I

; STPG38 or j SPV24 j SM41B or

; c3oc I ss41/ss41 : SGP. ; i j SS41/STPY41 : SS41

-46

-102

! AL-KILLED 1 STPL39 I

i SLA33A or ; ASTM i SCPLl I A320Gr.L7 i SLA33B i A350Gr.LF2 i I

'3.5 Ni i * A194Gr.4 j

!

STPL46 ! ASTM i

i ASTM j SCPL31 j I : A203Gr.D A350Gr.LF3 i ,

1 I i I

I

18Cr-8Ni SUS304TP i SDS304 SDSF304 j scs13 ' sus304

I i I I I

Scls304 i

3402G -4O-

3.2 Valve

3.2.1 Gear operated valve

Pressure I rating GATE I GLOBE

150 18B and Larger 128 and Larger 300 148 and Larger 1OB and Larger 600 l2B and Larger 8B and Larger 900 8B and Larger 6B and Larger

1500 6B and Larger 4B and Larger 2500 6B and Larger 4B and Larger

3.2.2 Special valve

(1) Valve provided with extension stem (2) Valve provided with lock (3) Valve provided with drain nozzle

3.2.3 Valve materiai ..'.

Standard of valve material (Body, bonnet and other main parts)

Kinds of steel

Carbon steel

Carbon steel (Al killed)

Low alloy steel C-Mo-Cr-Mo

Low alloy steel 35Ni

Stainless steel

T

Gray cast iron Spheroidal graphite cast iron Black heat---- cast iron

3.3 Fitting

Borg1 JIS

S28C (1) c3oc (1) SF45A(2) SF50A(2)

SFHV12B SFHV22B SFBV23B SFHV24B SFHV25 SFHV26B

SDSF304 SUSF316

Gas, JJS

Fc20 FCDS40

FCMBs35

A350Gr.LF2

VAL\ ed Steel

A182Gr .F304 A182Gr .F3 16

iron ASTM

A126CL.B A395

A47Gr.32510

A182Gr.Fl A182Gr .F12 A182Gr.Fll A182Gr.F22 A182Gr .F2 A182Gr.F9 A350Gr .L+F3

t SCPLl

SCPHll SCPH21 SCPH21 SCPH32 SCPHCl

SCPL31

SCS13A SCS14A

I Cast Steel I < JIS ASTM :

SCPH2

::

A216Gr.WCB i

---I

. A352Gr.ICB

A217Gr.WCl A217Gr.UC6 A2 17Gr .W6 A217Gr.WC9 A217Gr.C5 A217Gr.Cl.2 A352Gr .LC3

3.3.1 Bend

(1) Bend should be used in the following cases.

a. Lines which are subject to erosion due to abrasive solids in the fluid.

b. Downstream of pressure reducing valve which is liable to cause vibration due to high fluid velocity.

3402G -II-

Lines which are frequently inside-cleaned.

BP 3ding radius

Bending radius should be SD (D is pipe outside diameter). Allowance of 7% or more should be provided in thickness to compensate for the reduction of thickness due to bending.

1) High frequency -induction bending

Because high frequency induction bending machine has dimensional limitation, consult fabricator.

: ,- :. . .

.: ...

,2 Mitre bend

Mitre bends may be used for lines 16B and larger operated at f 7 kg/cm 2 and below and temperatures of 260°C and below or for ind larger operated at 10 kg/cm 2 and below and 200°C and below, but

the followings.

(1) One-weld mitre bend : :. _, One-weld aitre bends should,& used for air compressor suction

line operated at atmospheric Pressure, and vent line which is open to atmosphere.

.:. ._ :. :. .I. . . . ., . .:.: . . . . .... ..,:. _,: ".: : .\.. ..,. _ . . . :: ..'.... _. .:,.c 1. '. .Z..' ._ -.

.: ,.I . One weld mitre bend

(2) Two-weld mitre bend

Two-weld mitre bends should be used for low pressure process lines 248 and larger, a nd for all utility lines.

Two weld mitre bend . . :

. . ; . ; : . : . . : . . - . , .

1402G -42-

(3) Four weld mitre bend '

Four weld mitre bends should be used for lined pipes for gas and liquid containing abrasive solids, and for all process lines 16B to 24B.

l The angle of intersection not exceed 22.S".

Four weld mitre bend

between segments of mitre bend should

(4) Mitre bend for .underground piping (C.W.)

Refer to 8.14 'Dnderground piping' in this design instruction.

3.3.3 Reducer

(1) Special reducers should be used in the following cases.

a. When reduced to three or more line sizes down.

b. Lines 168 and larger for which standard reducer is not available.

c. When process fluid requires.

1) Diffuser for vibration prevention.

2) Special design for high pressure.

(2) Examples of installation

Lines l.l/ZB and smaller

,coN.(No ECC is available)

~lC100 m/m and ldger

When beam-to-beam span is 1000 mm or larger, top elevations of the beams may be the same, because of pipe deflection resulting from small diameter.

34026 -43-

Verticefl line

I

.-~

CON.

I

Piping with shoes

Branched connection

‘ , . ; . .

. . ._ . . . .

. . . . _‘.

-ECC. (In case of CON, drain will accumulate.1

* But, CON may be used for gas lines _ not hydraulic-tested.

Section drawing

3.3.4 Tee

(1) Wonrightangle branch connection

When branch connection is made by pipe-to-pi& welding, the amount of reinforcement should be determined, considering not only temperatures and pressures of piping but also external forces which will be applied to it. The angle of intersection between the branch and the run should not be less than IS".

Reinforcemnt pad should be rovided, if required.

Welded pipe to pipe connection

340x -II-

"(2) Welded branch

Tees 16B and larger should not be shop fabricated as far as possible, but should be field fabricated after determining the amount of reinforcement.

3.3.5 Standard application of fitting

Application of fitting should conform to attached sheet 2 'Standard application of fitting'.

3.3.6 Comparison of material between JIS and ASTM

Attached sheet 3 'Ccmparison table of JIS-material and ASTM-material' should be used.

Flange ,

(1) The use of flanges in pi&g should be limited to connections at flanged equipment and valves, except special cases such as :

a. Where dismantling of piping is required. Dismantling at the time of construction. Dismantling for cleaning of piping.

,~. : I .-_: '. -_ ..:.. ;. ::

:

(2) All bended portions in the piping requiring frequent cleaning (at least once a week) should be provided with flanged connections or j provided with the bend whose bending radius is SD min. (D : nominal pipe diameter). Flange-to-flange length should be up to 24 meters when pipe'is cleaned from its one end. Sufficient flanges should also be provided for piping requiring occasional cleaning.

(3) Sheet gaskets should be used for aluminum heat exchanger. Do not use vortex type. (Check P&I for piping spec.)

(4) When M and F or T and G facing is used, equipment flanges or .__ -._ instrument flanges should generally be female(m).

(5) When W and F or T and G facing is used, piping should be designed so as to allow easy dismantling for maintenance.

c

34026 -45-

pe .af work for piping materials

. Scope of work at equipment nozzle

(1) When standard flange connections (coverid in H-103) are used.

a. Connection between unit equipment and piping

Mating flange, bolts and nuts and gasket, by Piping Engineer

-

Unit equipment 5 (Pipe, by 'Piping Engineer)

(men though there is a spec. break in - P&I, they axe by Piping Engineer,

provided that mating flange is covered by H-103.)

Valve, by Piping Engineer

-_

5 (Pipe, by Piping Engineer)

Bolts and nuts and gasket, by Piping Engineer

340X -46-

b. Connection between unit equipment and instrument piping

by Piping Engineer .

Bolts and nuts and gasket) by Instrument Engineer

unit equipment

(Instrument,by Instrument Engineer)

Valve,. bolts and nuts and gasket, by Piping Engineer

Mating flanges, by Pipina EnUineer h

Valvr, by Piping Engineer Level instrument, by Instrument Engineer

A I

;. :. : ._:

.:_ _-. . .

by Piping

/ Hanifold (For manifolds, information of main dimensions etc. should be provided by Instrumen t Engineer, and detail design and procurement by Piping Engineer.

nuts and Engineer

gasket,

340x -47-

(2) When nonstandard flange connections (not covered in H-103) are used, connections between unit equipment and piping or instrument should be as follows :

a. In cases, only bolts and nuts are nonstandard.

Unit equipment

e Sa

- by %I y valve,

strument

Bolts and nuts, by Instrument Engineer

Engineer

.

\ Gasket; by Piping Engineer

Stud bolts and nuts, by Mechanical Engineer

(Pipe or instrument)

Mating flange and gasket, by Piping Engineer

b. In cases, only gasket is nonstandard.

Mating flange and bolts and nuts, by Piping Engineer

3402G -48-

c. In cases, only connecting flange is nonstandard.

Unit equipment

/ Mating flange, bolts and by Mechanical Engineer

$5 (Pipe or instrument)

nuts and gasket,

d. In cases of combination of a.b.c., to be consistent with the above rules.

(3) Blind flange attached directly to the nozzle of unit equipment.

Blind flange, bolts and nuts and gasket, by Mechanical Engineer

(4) Notes :

a. Though above mentioned scope of work is a standard practice, cofirmation of the scope should always be made by Piping Engineer.

b. In cases of rotating equipment or aluminum heat exchanger etc., check carefully for flanges which art officially standard but not covered in R-103 or flanges having larger thickness because of manufacturing or strength requirements.

c. When welded joints are used, attention should be paid to the dimensions of inside and outside diameter of pipes, their tolerances and end preparation etc.

d. When nozzle-to-nozzle connection of two pieces of equipment is made, check to ascertain who is the originator of bolts and nuts and gasket.

t. When special piping design is required for reformer and other equipment, consult the originator of such equipment without fail.

3402G -49-

Cng with instrument

of work between instrument engineer and piping engineer should in 'Split of work for piping materialsg, which is agreed by

be them .

ng with vendor's piping

. . :. .I'. : ,.

: ;,_ .-.

general, matching joints art made by welding. Attention should paid to the dimension of inside and outside diameter of pipes, ir tolerances and end preparation etc.

Mction or confirmation should be made without fail of anchor ts, support points, displacement etc. in relation to thermal ss.

I with customer'6 equipment and piping

neral, matching of pipes are made by welding. Attention should : I .:. ,I: - _ .:. ...

id to the dimension of inside and outside diameter of pipes ,. .:

,.,..:.. :.: ::'. -- . . :.,g :-. ,_ _ . . ., . . :

tolerances and end preparation etc. Special fittings shduli be

. . : :.: .:. :. ..- I . . . . . . . ...'

ed where required. ..:.

: _.I,

?r Supply equipment, when connected with TEC's piping should >fully checked for flanges and pipes not covered in Hll.03. ges not covered in R-103 are used, Buyer should be request& Ly their mating flanges. The confirmation of the above !d should be made without fail.

: .-. :..

2.1 Cel\?ral

InS1AlatiOn de::ign shoulc’ be in accordance with L-101. The outlil\? will mwn herctunder.

:

Z Hot :.,lsulation

5.2.1 Scope of ,rpplicat ic+l

(1) ;tfot. insul,\tion shou.‘.lj be appllc!d for equipment/piping of 800{: or nigher terclberature, exlcuding chere heat ‘loss is fzjrorable.

(2) lh->t insulat .iOn should be appliec’ for equil,ment/pipil\T of 800~ or lr*ter temperature, whtzn necessai*,y.

(3) Equipment an:’ its part:, shown below should ilot be inntllated.

a. Boti’\?r, Compretsor.

b. Expl,?sion joir ‘:( rotatic joint, 9; & valve 1 ad othel- similar mechanical equipment. :

:. Excha r\ger ‘s charnel cover.

Desigr

Design I:ri ter ia

Should A)E? in accol*lgance witL the case ‘.‘300 h/y ot JIS A 95111.

luid te,\perature .fx calculi\ tion of t1x.\ckness

general, operati.?g temperaLure of tht! fluid.

:ign tem\h?rature, hvhen heat-,: rotec ted.

Irated ti\por tempel’ature cortesponding to the prcb;sure, whc\l al temperature is unknown.

in

Of appl i cat ion

rsulatici\ should bc’ applied t’or equipm’?nt/piping c,f Sac or emperatXlre, exclut’ling where .Yeat absori)tion is f tvorable.

ulation should be applied for equipmel\t/piping ai: 50~ or !mperatr\re but unc’ttr ambient temperatul,e, in ordr?r to :ondensat:ion of moisture on the surfact? when :

\sation \rould caust’ electric danger.

sation \+Duld caustl damage tcl the equicllent.

. - . . -

, . . . - . _;

‘\

:ection

If application

nt/PiPin9 of 65°C or higher temperature, liable to be rd by operators during their work, should be hot-insulated iolated by protective means, in order to prevent ~1’s burn , when the equipment/piping is located:

800 mm above grade or floor.

00 mm from the edges of platform or walkway.

.: -.-:: . . . :.: :- .’ . . ; .::: .y: -: ; ...;.:_.: ,.

.“. ‘: . . : ; I .,: :.r.- :: .: .:. .:. ;_ ‘:. .:- :. .F’. : ::. .:

application

rack columns within hazardous area should be fed. The extent should be up to the first transverse

al or intermediate transverse beams -should not be ed. .'.

ure

ures should be fire-proofed, where the structures are .L. of a process unit handing flammable liquid, or Elapse of the structure can cause severe damage to Init. The fire-proofing should be for columns only, ting from foundation to 2nd floor.

:” . ‘.

.. : : _.

.,’ : - . . -

Support structure for furnaces

Support structure s d for furnaces should be fire-proofed, unless the furnace handles-only non-combustible fluid or there is only hydrocarbon vapor in the tubes. Even when the furnace handles only non-combustible fluid or there is only hydrocarbon gas in the tubes, the support structure should be fire-proofed, if the structure is within 6 m from a. furnace whose structure is fire-proofed. The fire-proofing should be for columns only, the extent being from the foundation to bottom of the furnace. Horizontal beams should not be fire-proofed.

.2 Design

(1) Fire-proofing lining material

Structural steel and vessel’s skirts for which fire-proofing is necessary should be covered with concrete of min. 50 mm thickness.

: .: : ;. :.. :

. . .’ . .

: - . : , .’ . . , : . . .

: : . . .’ . . . .

_. : . , . _:’ ._. : . :

, 3

(2) Configuration .

50

oise protection

i.6.1 Scope of application

(1) Insulation for noise protection should be applied especially on . .- . . .‘_

: :. . ,. I’ discharge pipk,ng of compressors or other similar piping (pressure reducing valve and its downstream piping).

(2) Specifically, the scope of application should be decided on at the stage of job.

-53-

:,

5.6.2 Design

(1) Noise protection material *.

Glass wool, rock wool, hard cement, etc.

6. Noise and vibration

6.1 Noise

6.1.1 General

(1) Purpose of noise control

Noise control should be made for the purpose of:

a. workmen's health

b. plant safety, in preventing distraction of operator's attention.

c. preventing public nuisance to noise.

(2) Noise protection design

For prevention of noise, considerations should be paid at the stage of design, as follows.

a. Select equipment/apparatus which produces lesser noise.

b. Layout should be such that equipment/apparatus producing large noise is located away from areas where regulative restriction iS severe, or located behind a building. Under certain circumstances, it may be necessary to:

1) attach a muffler to the source of noise.

2) wrap up the source of noise with sound absorption material.

3) provide sound protection wall around the source of noise.

4) enclose the source of noise with shielding of building and equipment.

6.1.2 Noise level limitation

(1) When customer's specification exists, design should be done, observing the specified values.

l L

3402G -54-

Location Max. Exposure

to noise noise level

Inside

Area visited occasionally, and Area where 1 Zh/day or '

I I

1QOdBA work is done occasionally. lOh/week i

of B.L. Walkway, and Area where maintenance work is 4h/day or i 95dBA done frequently during operation 20h/week I

Operation work area, and Area where Bh/day or 1 9OdBA maintenence work is done constantly during 4Oh/week operation. !

Control room, and Office 1 55dBA

Outside of B.L- 1 (In view of only the plant concerned) 1 - 1 60dBA

On the , boundary (In view of all plants within the whole j 65dBA

line of whole complex altogether) I I

complex

(2) When customer's specification is non-existent, design should be done, observing the followings as a rule in general.

34026 -55- . .

6.1.3 sources of noise

Kinds of major sources of noise are as follows. Specifically, noise control measures should be decided on, at the stage of job.

Kinds of source of noise

1.

-

2.

-

3.

-

4.

Classification Source of noise I

I Cycle(*l) Noise (*l:

enerw

Rotating machine and chemical machine

Piping system

,l. Putml 2. Canpre ssor r

I - --;I4

LIX?diUIp- hxqh medium high large

Machine proper

3. Blower medium I1 arae A PM1 i n” tnwar I 1. , “uw&a.raJ c”“s*

5. Air-fin cooler 6. Vibrating mill 7. others

low - medium medium low - medium large medium -

hiqh large medium- me-urn -

high lame I Driving 1. Steam turbine/Governor 1 high large F=t 2. Motor/Gear box high small Exhaust 1. Vent/Silencer high medium to 2. steam trap high medium-

large G-8. 3. Safety valve high large

1. Control valve, pressure reducing valve (*2)

high " large

PipiqJ 2. Butterfly valva 1+3) medyy x large parts c 3. Restriction orifice (*2)(*3) mediurp- xrh medium

4. Ejector . high I large 5. Steam desuperheater high large 1. Noise from rotating machine high med um-

i arae Piping 2. Noise from piping parts high large

I 3. High speed flow friction noise hign medium 1. Furnace iOge-aum I med=s -

Combustion 2. Boiler low--‘ medium I medium 3. Flare stack low large

I 1: Transformer low small

3ther s 2. Vessel high small 3. Air compressor suction port high large

Note : (*l) Values of cycle and noise energy shown in the table apply only in general. They are subject to change according to the size of equipment, etc.

(*2) Noise is produced when shock wave emerges. (*3) Noise is produced when cavitation occurs.

3402~ -56-

6.2 Vibration

6.2.1 General

(1) Purpose of vibration countermeasures

Vibration countermeasures should be provided for the purpose of:

a. preventing excessive stress due to vibration.

b. preventing deterioration of operating performance due to vibration.

c. establishing circumstances in which operators can run the plant without any anxiety.

d. preventing public nuisance due to vibration.

(2) Vibration prevention design

For the purpose of vibration prevention, piping route and piping supports should be designed under consideration of the followings.

a. Isn’t there any source of vibration? (in case of normal operation

and also of start-up) b. Isn’t it possible to remove the source of vibration, or to

replace it by one with lesser vibration producing force? c. Isn’t there any need to provide straight run length?

d. Isn’t there any need to increase thickness?

e. Isn’t the piping liable to suffer from any vibration? Is the location of supports appropriate?

f. Is the strength of supports sufficient?

g. Isn’t it possible to utilize shock absorber, in the case where thermal stress is severe?

h. Isn’t there any fear of resonance? . i. Isn’t the piping liable to force any equipment to vibrate?

34026 -5-f-

6.2.2 Vibration of piping

(1) Piping which requires consideration of vibration countermeasures Major sources of vibration which should be taken into consideration in the piping design and the causes of such vibration are as shown below. Furthermore, refer to '6. Loading Condition and Allowable Stress' for vibration load.

Fluid I Source of vibration Cause of vibration

rg pump Pressure pulsation i

Liquid Lntrifugal pump ! Surging (*3) ! ,^ a-. (Gas/llq Restriction orifice ! mixture) -Butterfly valve, Gate valve Cavitation (*4) I

Centrifugal pump 1

Gas/liquid mixed flow ! Two-phase flow (*5) ! Others I ,f Reciprocating compressor Roots type blower Pressure pulsation

I t

Gas, Steam

Centrifugal compressor Blower Restriction orifice Pressure reducing valve Safety valve Steam line

IOthers Wind

Surging j L

Shock wave (*6)

1 Discharge counterforce 1 1 Water-hammer i I 1 Wind pressure, Karman vortex,

I natural ; phenomennon I

1 Vibration of fixing point 1 Vibration of fixing point I

Note: (*3) For pumps which are liable to surge at start-up, vibration

prevention measures should be planned in advance. (*I) This is liable at high speed liquid flow. (*5) Two-phase flow lines are indicated specifically by Process

Engineer. (*6) Shock wave emerges when downstream pressure is lower than l/2

of upstream pressure.

34026 -58:

.

(2) Pipings which require attention with regard to resonance

Major sources of vibration which should be taken into account in the piping design in order to prevent resonance and conditions for occurrence to such resonance are as shown below.

Fluid Source of Vibration I

Conditions for resonance

Reciprocating pump ]

1. Coincidence of frequency of pressure / pulsation and natural frequency of liquid

t I Roots type pump column--pipeline (liquid column resonance)

Liquid 2. Coincidence of frequency of pressure Roots type flow pulsation and natural frequency of piping meter system Thermowell

i 1. Coincidence of frequency of Karman vortex and 1

natural frequency of thermowell Reciprocating 1. Coincidence of frequency of pressure ; compressor pulsation and natural frequency of gas

column--pipeline (gas column resonance) i Gas, Roots type blower 2. Coincidence of frequency of pressure steam pulsation and natural frequency of piping I (

i’ f I

I I system Thermowell 1

I Il. Coincidence of frequency of Karman vortex and, I natural frequency of thermowell * I

I

(3) Vibration of equipment caused by piping

Equipment shown below is liable to vibrate if piping is not designed properly. This requires particular considerations in the piping design.

Equipment ' Causes at piping 1 Causes at equipment

Excessive nozzle cunterforce f Misalignment of shaft coupling ; Centrifugal Mixing-in of air i Cavitation Pump Insufficiency of EPSH I

(incl. unbalanced flow) 1 I Centrifugal Excessive nozzle compressor counterforce

Misalignment of shaft coupling 1 I

Excessive nozzle Misalignment of shaft coupling Turbine counterforce

Mixing-in of drain 1 Unbalanced rotating shaft

7. Cathodic protection and grounding for static electricity protection

7.1 Cathodic protection

7.1.1 Object of its application and related laws and regulations Ascertain whether cathodic protection should be adopted or not, by ITB or in accordance with the customer's requirements. When it is to be adopted, ascertain about any related laws and regulations.

7.1.2 Consideratins required in design

Major points of consideration should be as follows. For details, refer to Eng'g Spec. H-119.

(1) Detail design should be made, based on accurate values of specific resistivity of soil, pH of soil, etc. which are to be obtained by site survey, etc.

3402G -59-

(2) It should be decided on in early stage, which of the impressed current system and galvanic anode system is to be adopted.

(3) Application extent of cathodic protection should be shown clearly.

(4) Ascertain about any place of electrical discontinuity.

7.1.3 Comparison between impressed current system and galvanic anode system

See the table shown below.

A COMPARISON OF GALVANIC ANODE SYSTEM AND IMPRESSED CURRENT SYSTEM

OUTLINE OF SYSTEM

MERITS

i !

!

IMPRESSED CURElNT SYSTEM

In this system, the negative pole of the external D.C power source is connected to the structure to be protected and the positSve pole to the electrode immersed in the electrolyte

1. Can be applied to a wide range of structures including, if necessary, large, uncoated structure.

2. Use is less restricted by the resistivity of the soil or water.

DEMERITS

3. Requires relatively simple controls and can be made automatic to maintain potentials within close limits despite wide variations of conditions.

4. Requires generally a small total number of anode and long life.

1. Requires a main supply to other source of electric power.

2. requires the effects on other structures that are near the groundbed of protected structures to be assessed.

GALVANIC ANODE SYSTEM

In this system, anode metal of lower potential than that of structure to be protected, is connected directly or with lead-wire to the structure

1. They are independent of any source of electric power.

2. Their usefullness is generally restricted to the provision of local protection.

3. They are less likely to affect any nearby structures because the output at any one point is 1 low.

4. They are relatively simple to install.

1. Their use may be impracticable except with soils or waters with low resistivity.

2. Their output can not be ; controlled but there is a * tendency for their current I to be selfadjusting.

3. They maybe required at a large number of positions. f Their life varies with conditions so that fill up the anode may be required.

3402G -6O-

.

7.2 Grounding for static electricity protection

(1) Grounding of piping (standard practice of installation)

All piping containing flammable gas or liquid should be wired and grounded as follows:

a. If any flange connection of the piping is connected by bolts or the like made of insulating material, all flanges should be provided with bonding wire (conductor).. .

b. When bolts are not made of insulating material, bonding should be made for each 30 m length pipe and grounding should be made at the place of the bonding.

c. Bonding wires should be connected to lug plates which are welded to flanges. They are not to be connected to bolts.

d. If length of piping connected to equipment is 30 m or shorter, such piping should be deemed as a part of the equipment and, therefore, bonding and grounding are not required.

(For reference)

a. Dangerous fluid which are liable to cause disaster due to static electricity.

Class 1 (Crude oil, Gasoline, Solvent naphtha, Tar, 1) Petroleum Light oil, etc.)

products Class 2 (Kerosene, Light oil, Diesel oil, Xylol, etc.) Class 3 (Fuel oil, Lube oil, Creosote oil, etc.)

2) Ether, Carbon disulfide, Collodion, Acetone, Acetic esters, Formic esters, Pyridine, Chlor-bensol, Animal/vegetable oils, etc.

3) Powder which can cause disaster due to staticelectricity, incl. non-conductive powder (systhetic resin, wheat flour, etc.) contained in pneumatic conveyor pipe.

b. Notes about electric charge

- Safe flow velocity is 1 m/s or lower, for petroleum products (API)

- For a given flow velocity, electric charge is larger when pipe dia. is larger.

- For a given pipe dia., electric charge is larger when velocity is larger.

340X -61-

(2) Standard practice of installing lugs

a. Bonding between pipes

Lug for bonding Luge to be fabricated instailed by piping

_. _ -. fabricator.

and

b. Bonding between valve and pipe

SW terminal

I V8mm2

Lugs' to be fabricated and installed by piping fabricator.

c. Rack piping should be connected to grounding main, for each 30 m length of pipe. Rack columns should be treated in the same way as the piping.

c IV14mm2

External damage protection Not required when there is fear of external damage.

pii= - no

Grounding main

34026 -62-

d. Dimension/material of lug and terminal

1) Dimensions

For insulated pipe(L=30+thickness of insUlation)

Dimension of Lug

2) -Material

To fit to tolt size

SUS terminal

When pipe material is alloyed steel or SDS, lug material..should .: be the same as

P ipe material.

8. Piping design details

8.1 Piping around tower and vertical t? tank

8.1.1 Layout

(1) Typical arrangement around tower

Location Of: manhole f---l ,.L

P 'iping to (Co nde

\- ' to eqti

b Area for piping

3402G -63-

(2) Considerations required with regard to maintenance are:

a. Replacement of filling b. Maintenance work for reboiler c. Lifting/dropping of valve and tower accessories (using pipe davitl

For all of above, enough area should be provided on grade.

(3) Installation height can be affected by:

a. NPSH of pump

b. Thermosiphon for reboiler

c. Head for spontaneous flow-down (gravity flow line)

d. Combination with reboiler of other neighboring tower

e. Pressure loss occurring in the line up to the control valve, when handling liquid which is at near its boiling point

f. Others

8.1.2 Nozzle orientation

For nozzle orientation, refer to 'Par. 3 Nozzle Orientation'

8.1.3 Piping around tower

(1) Height of nozzles at the bottom of tower

Elevations of bottom draw-off nozzle (X17) and drain nozzle (131) Elevations of bottom draw-off nozzle (X17) and drain nozzle (131) cannot be fixed uniformly. cannot be fixed uniformly. They are rather affected by the They are rather affected by the height of skirt, NPSH of pump and other conditions. height of skirt, NPSH of pump and other conditions. But, as far But, as far as possible, as possible, the followings should be observed in order to have the followings should be observed in order to have uniformity in each plant area. uniformity in each plant area.

In case of leg In case of leg

(*) To be decided on case by case, where considerations are required for NPSH of pump, headroom for operators (min.2100), and height of the destination point to which the piping is connected.

In design of bottom draw-off line to pump,

a. Suction line of pump should have least number of bends and shortest length.

b. No pocket should.be made in the piping.

C. Location of supports and shape of the piping should be given careful attention, so that any undue force caused by expansion of the piping will not be effected to the pump.

3402G -64-

(2, Installation of valves

In principle, valves should be installed against the nozzles directly, so that drain cannot accumulate 'there when the valve is shut.

Drain here.

Cal-l accumulate

tit Qood

(3) Flexibility of piping g-a

'. . . :

Attention.should be paid to the thermal expansion of piping When 'the piping is such that the feed positi& can be alterid by changeover operation of valves which are connected respectively. to -some number ,sf. Feed nozzles located at different elevations.

Loop should be avoided as far as possible.

f

Supports and piping route should be planned with attention to

.

any difference of expansion between the tower and the piping, _ . caused by temperature gradient within the tower or dissimilar materials used for the tower and me piping.

. \ Support

.

* Any control valve or anchor support should not be placed directly underneath vertical piping.

G 4:5-

Piping connected to each of neighboring towers or other fixed equipment should be checked with regard to sway and displacement of them due to wind pressure, earthquake, thermal expansion, etc., the procedure being as follows.

11. Displacement

1 due to extermal force

/ (wind pressure, ! earthquake) :2. Displacement ; due to heat !

I

alculation 1. Process

requirements b. Support 2. Guided 3 Esthetic . cantilever

appearance method A

ODT \1

OUT

(2 \1 /Any problem to be i discussed in consulltation with Process Engineer

I

I planning i

(Note) Use of bellows should be avoided

i

I Use

‘i

3402G -66-

(4) Clearance

Attention not to have contact.

. Attention not to have contact with reinforcing ring.

(5) Roundabout of piping

In general, rising piping should pass vertical center line of the nozzle to which the piping is connected. But, when inevitable, the piping may be as follows:

Kin 4z Min.

-

Min. Flexibility

(Use guide if H is short)

BV should be provided at a place near to the nozzle as far as possible. This applies even when there is &&&out of the piping. Supports should be provided in the vertical part of the piping.

(6) Reboiler

a. Outlet piping of reboiler should have least number of bends and shortest length, because pressure drop is critical in there. Furthermore, in case of thermosiphon type reboiler, attention is required because there are some restrictions with regard to the position of nozzle and the installation height of the equipment, in order to have proper circulation of the liquid.

b. Because the piping around reboiler is generally of large diameter, careful attention is required to the thermal stress and the load effected to nozzle. Especially in case where there is stand-by equipment, spring supports may be used to support the reboiler, in order to cope with temperature difference between the operating equipment and the stand-by equipment. (In general, spring support should not be used, however.)

3402G -67-

(7) Sampling piping

Sampling nozzles should preferably be located adjacent to the platform. If sample nozzles are inevitably located at a higher level, the sample piping should be extended downward to the platform or grade, as shown in the Fig. shown below.

- Sample connection

Platform Example of sampling piping

(8) 'Hose station and other small dia. piping

a. Pipings for hose station, methanol injection, PDI, fire-fighting, etc. should be extended upwardly altogether in a group as far as possible, so that tower clips can be planned accordingly.

b. Hose station should be located at the end of platform 20 that it does not interfere with manhole.

C. In case of especially tall tower, attention is required to any temperature difference between the tower and the piping, and to provide flexibility of the piping accordingly.

d. Attention is required to possible movement of pipe davit at the tower top.

3402G -68-

8.2 Piping around heat exchanger

8.2.1 Type of heat exchanger

Shell and tube type heat exchangers are expressed by three alphabetical letters as shown in the table below.

Front end station head types

Channel and remo+Sble--c&er

Bonnet (integral cover)

Channel integral with tube sheet and reiuovable cofef

*I ! LL; &ecial hi pressure h

P c osure

Steel types

One pass shell

-------

Wo pass shell #ith longitudinal saffle

T -------

1

Split flow

Double split flow

T

1 Divided flow

UJCI I I

Kettle type reboiler

Rear end head types

'4 e? pbe sheet k&'A stationary

Fixed tube sheet Lii"B" stqtiontiy

F$xe$ sube sheet Fe2 C stationary

Outside packed floatinu head

Floating head with backing devic

Pull through floatins head

U-tube bundle

Packed floatin tube sheet WI xi! lantern ring

3402G -69-

8.2.2 Considerations required for arrangement and piping

(1) Arrangement should be such that enough space is provided for operation on valves and instruments, and for walkway, as well.

(2) Where heat exchangers are installed side by side, coolant pipings and valve-operation positions should be placed at the same side of the heat exchanger.

(3) Space should be provided so that removal of channel cover, shell cover and tube bundle can be made easily.

(4) In case of heat exchagers installed within a building or a structure where trolley beam or the like is provided, it should be avoided to have any piping running just above the center line of the heat exchanger.

(5) Piping should be as short as possible, without having any unnecessary loop or pocket.

(6) Piping, when connected with a nozzle located far from the fixed-side saddle of heat exchanger,

de should be arranged under'

consideration of the heat ex #ger*e movement due to thermal . . . . .

! expansion. Usually, the saddle at the channel side is fixed. .' t

. .

Fixed side Sliding side

(7) In principle, valves, blinds, etc. should be installed against the nozzles.

(8) Consideration is required to have the shape of the piping in which no excessive force is effected to the nozzle caused by the weight or thermal expansion of the piping, together with consideration to have supports accordingly.

(9) Alteration of flow direction

When necessary, it can be done from the view points of piping design, maintenance or process requirement, etc., to alter flow direction, position of nozzle, etc. of a heat exchanger for which rating design has been made by Process Engineer.

However, such alteration should be made only after a study in close cooperation with Process Engineer, since the alteration can affect the rating of the heat exchanger.

Flow directions should be in principle such that:

3402G -7O-

a. Low temperature fluid flows upwardly, whereas high temperature fluid flows downwardly.

b. Preferably, high temperature and low temperature fluid flows are in counterflow relationship.

However, ‘I .,

c. if the fluids passing through the heat exchanger are liquid Or non-condensable gas, and tube-.@ide is of multi-pass configuration, inlet and outlet' can be exchanged each other, at shell side and also at tube side.

d. If tube side is of single pass configuration, inlet and outlet can be exchanged each other, provided that this exchange is made at both of shell side and tube side.

(10) Alteration of nozzle type

Floor or paving h sxc

(A) t Y&c

(B)

a. In general, (A)-type should be used.

b. When pipe dia. is iarge, it may require that heat exchanger’s installation height be increased. If there is any restriction of installation height, (B)-type should be used.

This occurs for example:

- When it is desired to have installation height same as the other heat exchanger.

- When heat exchanger is to be installed underneath the structure and any increase in the heat excha%er's installation height would require unnecessarily high structure.

- When heat exchanger is mounted on a horizontal vessel.

- When heat exchangers are to be stacked.

c. When (B)-type is used, this should be informed to vendor through Mechanical Engineer. So this should be decided on at the early stage of piping study.

- Dimension ‘a’ should be decided on by Piping Engineer.

- Dimension 'h' should be checked in accordance with the table of 'Drain piping dimensions for each type', which is included in 'Par. 9.14 Drain, vent'.

34026 -71-

8.2.3 Example of piping around horizontal type 'heat exchanger

(Example 1)

. . :..

. No p&icular consideratio ration

* In case of W.N. flange,. this s-hould be make-up size.

(Example 2) Piping to be removable

No particular consideration (determined case by case) required .for operation

These /7 lines

valve

to be symmetric when there is i~o in the lines

34026 -72-

- Supply lines for two units operated in parallel should be, in

general, symmetrical lines.

- No particular consideration is required for operation of cooling water vent valve.

(Example 3)

Cavitation is likely to happen due to pressure reduction in the neighborhood of the valve outlet.

Low insta we ferred

llati .on level is

(Example 4)

Flanges required for maintenance* . (determined case by case)

Long elbow

Support should be removable (If not, inconvenience is incountered when putting blind or removing pipe)

To allow installation of drain valve

- If necessary, flanges for the purpose of maintenance should be considered. In this case, attention should be paid also for the type of support.

8.2.4 Piping around rehoiler

(1) Determination of reboiler's leg length

a. .Where there is no stand-by reboiler (i.e. no changeover operation)

This pipe forces reboiler to slide

Piping should have . flexibility

3402G -73-

3402G -74-

1) Determine the height of legs, so that elongation of vessel AL1 is equal to that of reboilerAL2 +AL3.

2) When reboiler is slidable, supporting structure should be designed with consideration for friction counterforce exerted by the reboiler.

31 Reboiler should be slidable in such a way that ‘it can move sufficiently by the expansion force exerted onto the nozzle. We Teflon sliding plate.) '

4) Check should be done for strength of the nozzle.

- When r&oiler is made slidable to absorb the elongation of piping.

U,se sliding plates

Direction of sliding

Bolt holes &o be slotted in the direction of sliding

Bolt hole

de .-.

1: Length for allowing displacement d: Bolt hole dia. for the bolt used

Clearance required of sliding pad and

for provi+n liner (2omj

- When there is no need to make reboiler slidable (There is no need to have bolt holes slotted).

Thermal expansion absorbed by piping flexibility

Clearance required for provision of liner (2Oumd L

In general, it should be avoided to have bellows for alleviating thermal stress.

Bellows (riot to far as

be used possible

b. When there is stand-by reboiler (i.e. there is changeover operation).

1) Determine the height of leg, so that the elongation of reboiler AL2 +AL3 is equal to that of vessel ALl, and check the stresses of piping and nozzle neck which are produced when the reboiler is shut down.

2) If the result of this check is 'out', increase the flexibility of the piping by altering the size or type of the reboiler after a study in cooperation with Mechanical Engineer, and recheck the stresses. If this is not possible, the reboiler should be supported by springs. In this case, check of the stress produced by load change (due to deflection) of the spring is required. (In general, spring should not be used, however.)

When reboiler is to slidable, direction its movement llh0uia like this

3) Arrangement of reboilers and pipings in parallel should be symmetrical.

4) Route of the piping should be simple as far as possible, so that there will occur only small AP. After the route has been fixed, AP should be checked by Process Engineer.

34026 -75-

be of be

(2) Considerations required in view of maintenance

a. Removal of rehoiler head

Provide space for lifting up

Here, flanges are needed

Reboiler

Heat exchanger with welded nozzle

b. In case where one reboiler 'is put out of operation for maintenance while the other reboiler is under operation, consideration should be given for positions of valves and flanges (to enable removal of rehoiler's cover).

Area for removal of cover

Position bf valve *Provision of flanges

(3) Check of thermal stresses around reboiler

a. Calculation of the elongation of reboiler

1) Temperature when installed = -5°C (however, if for cold, 55Oc)

2) Calculate the difference of elongations of vessel and reboiler at max. operating. temperature, and check the stresses. (For nozzles, see Par.b)

3402G -76-

a. This is a kind of heat exchanger composed of a combination of elements, each being made up of two aluminum sheets and a wave-shaped fin brazed to the sheets ,. so that each fluid passes through respective space along the wave-shaped fin, and heat exchange accurs through the fin and the sheet.

b. Merits

1) Compared with,shell and tube type heat exchabger, several to about 10 times larger heat transfer area can be obtained with the volume being the same. Therefore, it is very compact and of light weight.

2) Efficiency of heat exchange is good .and loss is small. .,’ A^---

3) It is inexpensive when used for low-temperature service, because of its use of aluminum.

4) Various flow patterns can be obtained.

5) When shape of fin is appropriate, it is possible to keep high heat transfer performance even when flow velocity is small.

c. Demerits

1) Cleaning is not easy. Therefore, it is used only for fluid free of dirt or fluid purified by use of filter etc. installed nearby.

2) Material of construction is almost limited to aluminum.

34026 -78-

d. Some number of heat exchangers in combination are housed and cold-insulated within a box (shelter). The space between the heat exchabngers and the box wall is filled with pearlite etc. for the cold-insulation and N2-purged constantly to remove moisture in there.

N2 inlet'

(2) Planning/fixing of nozzle orientation :..i..

ai In general, all nozzles, excluding those for instruments, should be placed at the rack side

Access area

Rack piping

1) If any equipment to which the heat exchanger is connected is installed in the neighborhood, consideration is required to have some nozzles at the side opposite to the rack, in view of thermal stress and allowable load of nozzles.

_..-. ::

i

2) Because the direction of nozzle can be altered by provision of appropriate manifold within the box, the vendor should be consulted.

.~Rack piping

b. In general, platform and ladder should be installed at access

.43). Considerations required for piping

a. Because the allowable load of nozzle is generally very small, this load should be ascertained by reply from the vendor and consideration is required for arrangement of supports, accordingly.

b.

C.

d.

e.

f.

h.

side. However, platform should be installed at the rack side also so as to facilitate access to strainers installed at inlet nozzles and retightening of nozzle flanges.

.-

In addition to the above, because displacement of nozzles due to thermal expansion is unexpectedly large, and the fixing point differs from one heat exchanger to another, these matters should also be ascertained by reply from the vendor.

Because any welding on the box should not be done in order to avoid trouble, clips for support should be provided by vendor prior to shipment.

Attention should be paid to galvanic corrosion due to contact of aluminum with steel.

Because aluminum flange is soft, bolts should be accompanied by washers for protection of the flange.

Because aluminum flange is generally thick, special bolts should be used.

Flange gaskets should be sheet'gasket, so that they will not mar the flanges. (Check them against H-103.)

Because, in many cases, filters are installed at inlet nozzles, consideration is required for easy removal of the elements.

3402G -8O-

8.2.6 Piping around air cooler

(1) Considerations required for piping

When designing arrangement of piping around air cooler, considerations are required for the followings which are particularly important."\-,

a. In many cases, several number of air coolers are combined to become one item as equipmant. In this case, consideration is required for uniform distribution of fluid flow.

b. In the above case, header becomes very long and, inevitably, the problem of thermal expansion becomes more apparent, requiring careful study in this respect.

c. Arrangement of piping should be designed in such a way that no excessive force or moment will be effected to the nozzles of air cooler. This is because, if excessive force or moment is effected, tube bundle would tend to warp, to cause trouble such as leak at the tube-to-tube sheet joints. The allowable force or moment is limited to very low value and these values are presented by vendor of the air cooler. Therefore, arrangement of piping should be designed, based upon calculations of thermal stress, etc., so that requirements given by vendor are sufficiently met.

d. Vendor/purchaser B.L. conditions, together with scope of supply, should be clearly defined.

8.3 Piping around rotating machine

8.3.1 Piping around pump

(1) General

The followings are intended to supplement or revise the customer's requirements regarding pump piping and the manual TM-3074 (pump piping), and also to stipulate about the items ear-marked in the manual to be defined at the job stage. Therefore, matters other than the folllowings should be in accordance with TEM-3074.

t a. Arrangement of pumps should be as shown below. (See line-up of

discharge nozzles.)

f402G -al-

b. Height of pump's foundation

In case of pumps for general use

:’ . . .

. :

i

,.’

C.

For discharge ‘pay attention

piping,

thermal stress an vibration

Not to use chain valve, in general. Valve to be at 1.8m or less from operating floor. (If higher than 1.8, Operation stage is needed.)

PG to be seen fran the place of vlave Operation

EL.300 as a standard

Height of special pump's foundation should be defined for each case.

Piping around pump

1) Piping around pump should be as shown below.

Suction line to have large dia. short length. {If small dia. long length, cavitation can occur.)

w Provision of space , for removal of

'rotor

Adjustable support

Spare for removal of rotor. No spare required depending on pump model

This foundation, if uneven settlement is likely, to be one- body with pump's foundation as far as possible

2) Suction piping can be removed

v \ Provision of space for removal of strainer

should be designed in such a way that impeller without shifting of pump proper.

Provision of space for removal of impeller. No space required depending on

34026 -82-

Fundamental arrangement of pump's suction and discharge pipings (2)

a. End-top type

1). Arrangement with discharge valves in vertical run (in general, when discharge pipe size is

in 'general, use T-type strainer,. .Temporarily, : also cone type strainer.

2-6B).

Y-type strainer

At pump's main line, height of valve handle should b@ 1800 mm or less. If it is higher than 1880 am, operation stage should be provided.

2) Arrangement with discharge valves in horizontal run (in general, when discharge pipe size is 8B or larger).

Increase this length Increase this length when thermal stress when thermal stress is severe. is severe.

Use T-type strainer,

. . . ._.

e

P

T-type strainer in general.

3402G -%4-

d. Considerations required for suction piping c_L\qqd ~~uicel)

1) When suction line is long, rising slope of l/50 - l/200 toward the pump should be provided.

Air can stay here.

2)

3)

34026 -87-

‘I

Good Not good Reducer, used when pipe dia. changes, should be installed in top-flat posture.

Air can stay here. Air can stay here.

tit good

good Large-sized gate valve should horizontal stem posture.

Air can stay here.

Not good

preferably be installed in its

Large-sized Dia. (12B 1501: as a standard). Provide support so that no bending moment is effected to the valve body.

Not good FJood

4) Relative position with regard to suction pit when suction pipe is vertical.

(a) Approaching velocity Vm,, 50.3 m/s .

fb) Pit width should be B2 &2D

k) Distance between pumps should be B3 &2D

3402G -813-

Nominal dia. and various standard dimensions (for vertical shaft pump)

I - --__ _ . _ ----- - _- _.._.__

200 I 320-370 I 200 I 500 i 300 L-3" 1 JIurrr*Lu 1 220 1 300 420 -470 250 i

550 350 600 ! 400

350 I 650 1 300 ! 700 i 500 AnI7 I Ae;ll --.. 1 I n3n 720 I ! 350 I 800 I 550

350 850 I 600 10 1 400 ! 900 i 650

/ BOO 500 600 700 1020 1150 17nf-l 92 - I 1 [ 500 550 I 1000 1200 I - - - 4 *.a”” , 600 ; 1300 i I 900 1

1 I 1Arif-l i - _.v" I :

1000 1650 1 700 750 I 1500 1600 1 I (1100) 1700 800 1800 1 I

1 ! 1200 1800 1 900 I 2100 i

i 1350 1 2000 1 1000 I 2300 ! 0 I 1100 i 2400 1 --~. ! 1500 I .220

1650 2400 I 1200 2600 1 1800 I 2600 1 1300 i 2800 j 1950

2000 2800 1 1400 1 3000 I 2100 .\--L_. --a - . . . i - - vocel mm aeposltlon of sludge on the pit floor is anticipated, allowal

to cope with this should be added to the dimension of pit floor clearance.

ace

I Item I Ratio to nominal dia. d I

Bellomouth dia D ; 1.43 - 1.33d Pit floor clearance C 1.5 - l.Od f Immersion depth s 21.5d I Back wall clearance Bl sl.5d f Pit width

I __.--

B2 I z3d i I

Distance between pumps B3 I z3d I (Note) Where two figures are shown for the ratio, the left corresponds

to small dia. and the rigth to large dia.'

When inclined suction bellmouth is provided.

3402G -89-

.

When suction pipe is horizontal.

v - c

SZZ3d

I4 b

\ D-1.43-1.33d

I, (1

C2 ll.Sd

t

(3) Suction strainer for pump

Because there are two kinds of strainers - one necessary in view of process (permanent) and one necessary when the plant is not under normal operation (temporary) - the kind of strainer should be ascertained by reply from Process Engineer.

a. Permanent :.

1) !&eof-.such strainer is shown on P&I dia. '- .. . . ; 2) When' size is 3B or smaller, Y-type should be used, and when 4B

or larger, T-type.

b. Temporary

When size is IB or smaller, conical type should be used, and when 6B or larger, T-type.

P&I - desianation ‘Type . Example of use

TR P -b ‘-

34026 -9O-

(4) Method of attaching pressure gauge

In case of one pump In case of two pumps In case of three pumps

a. The above-shown arrangement should be adopted in order to have uniform view-direction.

b. In general, pressure gauges should be at the right side when viewing front face of the pump.

c. If pressure gauge contacts with any above-located piping, the direction of PG take-out boss should be turned 45O toward the valve operation side {so that the pressure gauge is still .' .,: visible).

d. Pressure gauges should be located within the range of vision from

the position of discharge valve operation and also from switch hIoIL

s1.1/2B 2B--3B

3402G -91-

Check valves of 4B or larger size should 3/4B flange nozzle connection.

be specified to have

(5) Cooling water and drain pipings for pump

When to be Use flange connection,

/ recovered

although vendor's standard is usually screwed connection

Pump-bed drain (Material by Piping Dep’t)

Casing drain

Drip funnel

I When to be discharged to outside

- Base drain should be led to oily sewer or chemical sewer, as dictated by the kind of fluid.

- Casing drain should be led to oily sewer, chemical sewer or liquid drain line (as indicated in P&I dia.).

34026 -92-

(6) Examples of piping around pump

a- piping for BEW pump (for referance)

I Bmass line

I t Minimum flow bmass

I I I Suction Line

Ylkintenance area (Vehicles Permitted to enter.)

rl- h

Maintenance area (Vehicles Permitted to enter.1

Discharge (Vibration occur. 1

\ - Eiinimu uypa-

/I\ - - at (Pav attention

1, to vibration, especially.)

line can occu

m flow bp

easily accessib

. t Maintenance area

cl-’

r

trt! gic

.I

.

b. Piping fo r turbine-driven BEW pump (for reference)

: i

When 8OOmm or more, provide 'stage

Turbin H Steam exhaus

Oil piping

rkf

t Pipe

34026 -94-

c. Oil piping for BFW pump (for reference)

Drip funnel .J$pQy '

: (Notes) 1.

i.

3.

4.

FQ~ high pressure pump, oil cooling unit as shown above is provided. When the pump is turbine-driven, gland condenser is provided in addition. In such-cases as this, although many small dia. pipings are attached, maintenance or operation work ehould not be inconvenienced by these pipings. in this respect.

Consideration is required

Oil piping belongs to the scope of vendor's supply as a unit piping. Because, in most cases is made without consideration for actual condition of

, the vendor's piping drawing

gurroundings, check the vendor’s drawing and ask revision, if necessary, in order to allow convenient operation and maintenance.

8.3.2 Piping around turbine

a. Piping around steam turbine for driving pump (for reference)

Exhaust pipe

/ - (During warming UP,

k large quantity 0:. steam' is exhausted.)

f%ee to five drain pipes \ (3/4B or the

turbine. w

c like) come from ~'U~yqTiJ \)

\ I L

\ Safety Valve

PUMP (should be p from turb in WSd.ble.)

11 .aced away e as far as

1 ,fl';-.xr+taln valve

‘2G -95- Spring./-- support Trap

b. Procedure of designing piping around turbine

1) Ascertain the possible displacement of turbine’s nozzle.

2) Plan the piping route and supports.

3) Determine the counterforce and moment effected to turbine, through calculation of thermal stress (for both of cold and hot).

4) If the counterforce and moment are within the allowable limit, carry out design of springs and place order of them.

5) Make information for design of support structure and foundat ion.

6) Plan steam drain and cooling water pipings.

7) Piping material take-off.

8) Make piping drawing and material take-off.

9) Make support drawing.

8.3.3 Piping around .compressor :: .-

Design standard for piping around compressor is as shown in TEM-3069. iiere, matters not coverd in TEM-3069 will be explained.

(1) Considerations required for piping design

a. On the suction line, position of pressure instrument should be at downstream side of suction strainer.

b. On the suction line, position of therasowell should be at upstream side of suction strainer.

c. If drain pocket can be produced, provide drain valves, without fail.

d. Piping above the compressor floor should preferably be once brought to under the floor, so that operation and maintenance works are facilitated. In this case, flange connection should be provided in the piping, ao that compressor casing can be removed easily.

e. In the space under the compressor floor, the process piping, oil piping, trace piping etc. are to be placed, tending to become congested. It is recommended to design routing of the whole piping by allocating.different elevations to different kind of piping respectively.

f. It should be avoided to have oil line in parallel above any steam or other high temperature line. /If there is, fire accident can occur. )

g. Vent line of oil system should be free from pocket, and should not have configuration such that gas cannot be vented due to piping weight or thermal expansion. When this is feared, the support span should be shortened or, if it is convenient, the line should be provided with slope.

h. It should be avoided to have exhaust from trap etc. in the compressor room.

3402G -96-

i. Selection of material and study of strength for the strainer should be done so that it has sufficient durability for 100% load. Furthermore, the strainer composed of perforated plate and wire mesh screen should be installed in such manner that the perforated plate comes to downstream side in view of gas flow. The wire mesh screen should be of 8 - 10 mesh as a standard.

(2) Considerations required for making civil information

a. Floor of compressor room and maintenance platform around the compressor should be separated, or rubber cushion etc. should be employed, so that any vibration of the compressor will not be transferred to the floor.

b. Maintenance platform should be of such construction that it is removable. When penetrated by piping etc., it should be split into two or three parts.

c. In order that maintenance work on large valves located below the floor can be done by use of overhead crane of the compressor room, provision of hole with removable cover in the floor should be made.

8.4 Piping around furnace

8.4.1 Considerations required in general

(1) It should be avoided to have any obstructing piping in the neighborhoods of walkway and peep holes, which are used when operating the furnace.

(2) Enough space should be provided for removal of burners.

(3) Piping around the furnace should be planned under consideratin for its relation with heater tubes.

a. Relation between outlet/inlet port of heater tube and the piping.

b. Relation between heater tubes and the piping when the former is removed. (Space for removal should be provided.)

c. Influences effected between heater tubes and the piping, by each other's fixing.

d. Method of connection between heater tubes and piping -- flange connection or welding.

8.4.2 Transfer line

(1) Outlet piping of heater is, in most cases, made of alloyed steel because of its high temperature, this requiring that the length be short as far as possible. Consideration is required for flexibility of the piping and also for proper supporting of it.

34026 -97-

(2) Arrangement of transfer line (for reference)

Determine spring hanger ranges considering furnace elengation.

Spring hanger Transfer line

8.4.3 Fuel piping

(1) Fuel gas piping

a. Branching of fuel gas feed piping should be made at the top of the feed header, so that uniform distribution can be obtained.

b. Example of header arragnement in fuel gas piping for iso-flow type heater (for reference).

ad& drain

Header is installed at outside of heater , on brackets fixed to the heater's legs. In this arrangement, valves to be operated at the time of ignition are not in the range of operator's vision. But, good flow condition can be obtained and construction is inexpensive. Because the valves operated at the time of ignition are, in general, not used for the purpose of control, but are used in either full open or full shut condition, it is not so much of problem, even though they are not within the operator's vision.

34026 -98-

Control valve drain

Gas manifold .

A header box, which is used as drain pot at the same time, is installed at underneath heater , and each piping from there is connected with burner. In this arrangement, because the header box is at the center area, enough space is left in around the heater. This is advantageous because of its ease of operation. On the other hand, however, in this arrangement, operator must stay for a long duration of time beneath the heater at the time of ignition or shut-down.

Control valve

Gas heater pitch to drain

der drain

A header is installed around the heater at a height just above peepholes and each branch piping goes down vertically in the vicinity of the peephole, to be connected with burner. This arrangement is especially advantageous, because these valves can be operated well within the reach of operator's vision. However, this arrangement is expensive in view of construction material and work required.

* Header drain should not be opened in the vicinity of the heater, in order to prevent fire hazard.

(2) Fuel oil piping

a. Heavy fuel oil supply piping coming from the tank should be made into a closed system, if necessary, so that excess oil circulates constantly.

34026 -99-

b. Example of fuel oil piping around burner (for reference).

Fuel

Peep ho le

Atomizing steam

Regulation valves for fuel oil and atomizing steam should be installed at places where operator can oprate each of these valves while looking at peephole.

(3) Installation of block valves and regulation valves

a. Block valves on the main fuel oil and fuel gas piping leading to the furnace should be located at a place 15 m away from the furnace so that rapid operation can be done in an emergency. (except where EmV is provided)

b. Regulatioh valves for fuel oil, fuel gas and atomizing steam piping leading to the furnace should be installed at places shown below.

- In case of wall burner type furnace, in the vicinity of burner, where peephole is conveniently seen.

- In case of floor burner type furnace, in the vicinity of burner.

8.4.4 Snuffing steam piping

(1) Snuffing steam piping should be provided for combustion chamber of furnace, for header box and for upper space of furnace arch.

(2) Arrangement of valves should be such that these can be operated at a place away from the furnace.

(3) Example of snuffing steam piping.

1 II 7 Snuffinq .I 11 .I -I

1 !/

line

BottomJ snuffing

\ Steam trap

3402G -lOO-

8.5 Rack piping

8.5.1 General

In general, lines which are run side by side on the pipe rack include the followings.

a. Lines connecting two pieces of equipment located 6 meters or more apart from each other.

b. Product lines going out to storage tanks or other unit plants from vessels, heat exchangers, pumps etc..

c. Incoming lines of raw material or other feeds. Instrument Cable

d. Blow-down lines (Flare lines). duct duct

e. Instrument ducts/Cable ducts.

f. Steam or codensate lines. One meter or more

g. Lines for N2 gas, plant air and instrument air.apart*

h. Lines for boiler feed water, city water, process water, pure water and cooling water other than those underground.

i. Lines for fuel oil and gases, and others.

j. Walkways, if required.

k. In general, tank-yard piping should be run on sleepers, whenever possible.

8.5.2 Height of pipe rack

(1) When heat exchangers are installed underneath the rack as shown below, the height of the rack should be determined based on the heighest portion of exchangers and their connected piping.

(2) When double-rack is used, the distance between the tops of the racks should be 2000 mm, as a standard.

(3) In general, racks in each unit, which are run in plant-east-west and plant-north-south directions should have their respective heights determined with a combination of 4n/6d8m and 5m/7m/9m.

3426G -lOl-

8.5.3 Location of pipes

Location of pipes should be as follows:

(1) Large-sized pipes (14B and larger) should be located as close to the sides of the rack as possible to reduce bendi$ng moments of the rack beams.

(2) In case of single-rack, utility piping should generally be located in the middle of the rack and process piping on both sides.

(3) In case of double-rack, utility piping should generally be located on the upper rack and process piping on the lower rack. But, large-sized pipes may be located on the upper rack in view of space.

a. Example of location on single-rack

Large Large sized Process Utilities Process SiFd

,dia. I I I I .

c c x/d

----I Instrument

34266 -

,b. Example of location on double-rack

Instrument d

m-generally for u&it

Lower rack--- generally for proces c: i.

piping

Ping

(4) Further details of the pipe's location should be as shown in the table below.

34266

u u a”

-

-?-

i

E

Piping

Blow-down (Flare) lines

Upper rack Lower rack

Side Middle Side Middle

0 1 I

Incoming feed lines 12B and larger l i I

0 I I

Incoming feed lines 10B and smaller 1 0 I I 0 I

Outgoing product lines 128 and larger I l 1

0 !

Outgoing procuct lines 10B and smaller :I :01 jo

Overheads of tower and drum, and lines 1 , connected to high position 0 , 0 I

, Overheads of tower and drum connected to pump or heat exchanger

ispecial 1 A I

o f o I I Delivery lines of pump

i

Lines subject to corrosion I 1 i I 0 ! 0

Lines connencting between equipment and i I

equipment on the grade i i

lo i"

Lines subject to vibration t 0 ; I

Steam lines of high or low pressure 0 ! 1 ; I

Condensate lines I ! 1 10; I

Boiler feed water lines

Lines for hose-station

(water, air, N2 etc.)

Plant-air lines

Headers of pump cooling water

Fuel oil and gas lines

Instrument air lines

Instrument ducts

i 0 I !O i i 0 I I i I 1

I IO to j

I

l When loop is required on the line

(5) Lines containing corrosive fluids should not be located above instrument, or cable ducts.

(6) Delivery lines of reciprocating compressors, pressure reducing valves, large-sized return water lines etc., if inevitably located on the rack, should be given special consideration for

-103- vibration prevention.

(7) The location of pipes and the position and type of anchor points on matching lines at B.L, should be clearly defined by consultation with parties concerned.

(8) A stage should be provided for the valve located on the rack requiring frequent operation and maintenance.

(9) In general, the ends of utility headers should be blind-flanged, except that large-sized pipes (14B or larger, as a guide) should be capped. But, use of dead ends should be minimum, considering flushing.

(10) When a loop is provided in condensate line it should be bent horizontally to prevent waterhammer. If it is impracticable to bend horizontally, bend it as shown in the drawings below.

(Example 1)

(Example 2)

8.: Slope is for each

max.30" .

(11) Loops other than for condensate lines should be grouped together for good appearance as shown below.

Lines should be laid on the rack in a sequence so that larger sized pipe or pipe having larger expansion and contraction comes closer to the side of the rack.

(12) Piping which is long in length, such as yard piping or pipe line, should have horizontal loops.

34266 -104-

(13) Dimensions of down-pipes insulation

Be careful not to attach a shoe close to the weld line.

(In general)

-Pot insulation

a. In general, the location of down-pipes is indicated by the dimension of beam-center-to-pipe-center. But, the dimension may be beam-center-to-pipe-surface, if required to facilitate supporting the pipes. I

b. In general, the beam-center-to-pipe-center dimension is 500 mm, except for large-sized pipes in which the distance between outside surface of the insulation and the beam flange could be less than 100 mm or the weld line would come on the rack beam.

8.5.4 Elevation of pipes

Elevation of pipes should be determined considering the height of shoe, cradle, saddle etc..

Pipes Insulation Th'k (mm)

Hot-insulated 25- 75 pipe 80-'125

130-175 180-225

Cold-insulated 25- 50 pipe 55-100

105-150 155-200

Bare pipe

Height of shoe, cradlt;nmgaddle

100 150 200 250

50 100 150 200

100

8.6 Critical lines

8.6.1 Critical lines in view of pipe strength.

Attention should be given to the following.

(1) Vacuum of such line as:

Piping around surface condencer.

(2) Thermal shock in such lines as:

a. Piping around steam desuperheater

b. Condensate line

Remarks

Do not use shoe etc., for pipes with personnel protection insulation.

Only for special design such as lines exceeding allowable span in Pipe List, or lines requiring vibration prevention.

34266 -105-

(3) Vibration due to shock waves in such line as:

The line downstream of pressure reducing valve in the minimum flow bypass line of compressor.

(4) Erosion of such lines as:

Decoking lines

(5) Cavitation erosion of such line as:

The line downstream of restriction orifice in the minimum flow bypass line of boiler feed water pump.

(6) Two-phase flow in such line as:

Line indicated by Process Engineer.

(7) Vibration due to wind or earthquake in such lines as:

Effluent lines from TLX of heaters to the header.

(8) Others

8.6.2 Critical lines in view of process

Attention should be given to the following.

(1) Pump NPSH

(2) Thermosiphon of reboiler or AL-heat exchanger.

(3) Lines requiring water head.

(4) Gravity flow or sloped lines

(5) Lines which are critical in view of pressure drop.

(6) Lines subject to clogging with powder or slurry etc.

(7) Lines for urea etc. which will solidify.

(8) Lines requiring witerizing.

(9) Lines subject to special design conditions such as quick change in the pressure or temperature , or repetition of such changes.

(10) Lines for caustic soda wr the like, for which the piping material selection is strictly dependent on its operating temperature.

34266 -106-

(11) Lines in which no uneven flow is allowed.

a. Examples of such lines.

1) Branch lines without valves. (Fuel feed line)

2) Heat exchanger piping without valves.

Flow is not regulated with

ow is regulated with valves

3) Piping around three heat exchangers without valves.

* For three or more heat exchangers for which symmetrical piping is impracticable, consult Process Engineer.

3426G -107-

4) Piping around reboiler

5) Turbine suction line (Main steam line --- usually by vendor)

Turbine

Main stop valve

3426~ -108-

b. Branch lines in which uneven flow is prevented.

Type ‘A’ Type 'B'

Type 'C'

.More than 20 times or mere of pipe inside dia.

Type 'D' I (t I

3 \ 3

Type ‘E’ Type ‘F’

8.6.3 Critical lines in view of cost.

(1) Large-sized piping

(2) Piping which is high in cost, such as for high temperature and pressure service, SUS pipes and pipes of special specification.

Cost comparison should be made for these pipings and the piping of higher cost should have priority in piping arrangement.

34266 -109-

8.7 Piping around safety valve

8.7.1 General

Safety valves act automatically so as to prevent a predetermined pressure being exceeded, thus internal pressure is maintained and pressure vessel is protected.

Safety valves are classified depending on fluids to which they are applied.

(1) Safety valve

For gases and vapors including air and steam.

(2) Relief valve

Mainly for liquids.

(3) Safety-relief valve

For both gases, vapors and liquids. In the following, the term 'safety valve' is used for all of the above mentioned valves.

8.7.2 Inlet piping of safety valve

(1) In general, safety valves should be installed in the piping close to the top of tower, but safety valves connected to the flare system should be installed close to the rack as shown below.

to rack

Safety valve

Application Pressure drops between of safety valve equipment and safety valve

Boiler 0.6 kg/c& or less General services 3 % or less of safety valve

I set-pressure 1 .

34266 -llO-

(2) The size of inlet line to safety valve should be equal to of larger than the size of inlet flange of the safety vlave.

For long inlet lines, consult Process Engineer to check for pressure drops. If the pressure drop is larger than the allowable limit, try as shown below.

(3) Safety valves should be installed so that they are accessible for maintenance.

a. Ample space should be provided for dismantling of safety valve body.

b. Space should be provided to allow dismantling of spring-adjusting-cap or operation of the handle.

I+- Clearance for adjusting

Lock bolts

c. When difficult to have access, ladder or platform should be used. But the platform is not required for places such as on the pipe rack, which are accessible.

(4) Safety valves should not be installed at a place where a turbulent flow or vortex is expected.

34266 -ill-

(5) Inlet lines to safety valves should not have branch line taken off them, except when the branch line is for bypassing.

(6) Inlet lines to safety valves should be taken off the portion Of the header as colse to the anchor point as possible, where effects of vibration or thermal, movement is small.

Support point

To be tinimum length

(7) When installing safety valve, supports for the valve body and for the connected piping should be considered.

(6) Welded pipe-to-pipe connections between inlet lines of safety valves and main lines should be provided with a reinforcement pad, if required, after determining the reaction force of discharge.

(9) TEM-3058 should be referred to for checking the inlet piping for reaction stresses at the header nozzle portion and the safety valve portion.

3426G -112-

8.7.3 Discharge line of safety valve

(1) General

a. The size of discharge lines of safety valves should be equal to or larger than that of the valve outlet flanges.

b. Elbows to be used in the discharge line should be of long radius.

(2) Discharging into the atmosphere

a. Safety valves, which discharge poisonous fluids (including N2) or flammable gases to the atmosphere through vent piping, should have the pipe extended at least 3 meters above any platform or roof within a 12 meter radius of the point of discharge. Safety valves, which discharge steam to the atmosphere, should have the pipe extended at least 3 meters above any platform within a 7.5 meter radius of the point of discharge.

12oC0, 7500 ,

Top of platform

b. Relief valves, which discharge poisonous liquids directly to the atmosphere, should have discharge piping provided with a protective device in order not to drop the liquids directly on the ground.

c. Cut angle of discharge pipe

In general, this type should be used.

To be used only when the direction of discharge is limited. Because the direction of reaction force changes, the nozzle and support to be carefully checked for strength. Not to be used for high pressure of 100 kg/cm2 or higher, in general.

3426G -1l3-

d.

(3)

a.

b.

In general, two or more discharge lines of safety valves should not be joined to the header close to each other. But, if required, they may be joined as shown in the drawing below.

Cross-sectional area of the header should nat be less than the sun-of cross-sectional area of the pipes to be joined.

Plare system

In general, all piping in flare system should be routed so as not to have pockets, and should be drained into the headers.

WF(Wet flare) DF (Dry flare)

If pockets, which contain moisture, exist in the safety valve discharge line connected to WE', the pockets should be steam traced. (Consult Process Engineer)

Vert.

c. Discharge lines of safety valves should be connected to the header at the point as close to its anchor points as possible. If this is impracticable, the discharge lines should have sufficient flexibility to absorb the movement of the header.

34266 -114-

d. Discharge lines should be connected to the header as follows: Liquid or drain lines are on the top of the header. The angles of intersection are 45O for 2B and larger and 90' for l.l/2B and smaller. All branched connections on the top or side of the header should have provision for flexibility.

1.1/2B-and smaller PLan

8.1.4 Examples of piping around safety valve

(1) Steam piping

I l Discharge

Support (To be supported- separateiy from the valve body)

Safety valve

w el

3m or more above workng area

bow

(Only 1 20K steam. T'

Y

pipe

Notes: 1. The pan should be separated from the discharge pipe. 2. Material of the pan should be equal to that of safety

valve outlet pipe. 3. When the piping between safety valve and pipe support

has sufficient flexibity, such type as shown below may be used instead of the above type.

3426G -115-

I Table of dimensions h/m) I

A B (PIPE)

2.1/2B 48

38 48

48 6B

5B 88

6B 88

188 1 10B

I~ 1OB I 12B

I 128 ' 1 14B

C(PIPE) D

10B 200

1OB 220

12B 250

148 300

148 350

460 4 420

520 q5 I 500

610 8 I 580

540 1 350 1 210

580 400 250

610 400 280

. 690 500 360

640 560 440

720 1 650 1 520

Method of supporting

To be slidable

(2) Piping for other than steam

Do not cut out of (perpendicular

.er than

po=g,“i,o ‘h discharging

rll 4' I

3m or more above

' 0 working area

Reaction force of discharging

Check nozzle far nttenath\

'. (Internal pressure increases with temperature increase)

) To be slidable II

1 To be piped to the grade, in case of

($)..; L<4D poisonous gases or liquids. (TO be piped to flare system, in case of flammable substances.) Only a hole, in case of innoxious substances.

34266 -116-

8.8 Pipi* wound instruahAB

8.8.1 General

(1) Instrument symbols

Instrument symbols should be mainly in accordance with the basic symbols in JIS 2 8204.

(2) Operability of instrument

Instruments should be installed in places which permit ease of operation and maintenance. Platform or ladder should be provided, if required.

(3) Size of instrument nozzle

Instruments Sizes Block Valves

Remarks

FG 3/4B Glove Piping, vessel and .B.X

PI, PIG I 3/4B I Glove I Ditto

PdI 3/4B Gate Places free of dirt

1.428 Gate Dirty places

TW, TG, TI InTC I l.l/ZB - I I Piping, vessel and H.X

LG

LI, LIC

1

3/4B Gate In general

2B Gate

2B Gate

Fluids O°C or lower

Displacement type with external cylinder

4B - Displacement type with internal cylinder

3/4B Gate DP cell type

LI

LI guide

1.42B - I

1.u2X2B - I

Float type

Float type

Analyzer / line Cracking heater effluent

3/4B I Gate I Other lines

S.sC I 3/4B I Gate For all lines

8.8.2 Pressure instrument

(1) Pressure instrument for general use

a. Size to be 3/4B (Except for diaphragm type)

b. Block valve to be glove valve

34266 -ii7-

c. Installation criteria

Connections should be taken off the top of pipes, except in case of vertical pipes. For vessels, connections should be located on the gas side, unless otherwise specified.

Lines generally used

(2) PdI

siphon tube

Steam line

a. Sise

3/4B Services free of dirt l.l/2B Services with dirt

b. Block valve

Gate valve

c. Installation criteria

The operation of block valves at vessels may be made from permanent ladder. Platform is required for transmitters because, in general, they are located adjacent to the block valve , in services on liquids or mist. However, the information, whether or not the platform is required, should be obtained from Instrument Engineer.

In general, ndzzleo for WI 'should b+ located On vesse&s, but,'. &en they.-are 'taken off the

:'.

of nozzle should l- -%I I Conform to ENG'G DWG.

:-. .:. ::

3426G -118-

8.8.3 Temperature instrument

type and size

Lines Types and sizes

Lines generally used l.l/2B Flanged connection below 100 kg/c& !

High pressure steam lines Bosswelded type 100 kg/&G and abave

Note: For TW(lhermaneter type etc.), 1.1/28 flange type should also be used.

te .t

:mper ,ature

Fl=qd tyl?= Boss-welded type

(2) Length of thermowell and insertion length

Insertion length a/d ) 10 (Refer to above shcam flanged type)

Length of thermowe

Note: H varies depending on the thicknesses of hot or cold insulation, and the length of thermowell varies accadingly.

34266 -11%

(3) Criteria of installation on pipe

Nozzles should be located onthe pipe so that the thermowell is directed aginst the fluid flow.

6~ and larger 3/4B-44B

1 t - -- -- \ a - --

q+p- . L

Reducer is not required for 3B and

I

CON

larger. J . . . . Vertical line

34266 -120-

(4) Location of temperature instrhment

The bottom end of thermowell should not come to the position higher than the terminal portion, wherever possible.

Thermowell should preferably be located on the vertical line rather than the horizontal line, and should be accessible for maintenance.

Do not locate the thermowell here'. Scale or the like is liable to deposit in the gap between nozzle and thermowell.

DO not locate the therru3well here, except where inevitable.

(Vertical section)

Clearance for

I 1200 -1300

3 1

/I”‘/“’ ” /////‘///f’ / /

. . . :

TemperatiAinstrument at a junct.i&~'of two flows

(Example) rU

TIC

4IY!iIY!

To be indicated in P&I respectively.

I 5m or more from point of flow junction,

120°c _

P 180’~

.:

._ ::

.,:

34266 -321-

8.8.4

(1)

a.

b.

Flow instrument :

Orifice

Installation practice of orifice

In general, orifices should be installed in horizontal Pipes located 600 mm or more above the grade or platform to allow ease of inspection.

Orifices may be installed in vertical pipes, if the fluid is dry gas or liquid if it is guaranteed that the pipe is completely filled with the liquid. However, this is subject to the approval of Instrument Engineer.

Type of orifice

1) Flange taps type (2B-14B)

I I

2) Throat taps type (16B and larger)

Upstream

10

3) Corner taps type

.eam tap

34266 -122-

4) Flow nozzle

34266 -123-

The length of straight pipe for flow nozzles should be the same as that for orifices.

Application

glow nozzles should be feed water lines etc..

n used for high pressure steam lines, boiler

L----r 4 t 1.1 I I a J 2, b 0

-,----L--e-

L

- By Instrument Engineer

Dimension (For reference)

5) -LOSS tube

For the required length of straight pipe, refer to venturi tubes. Spool pipe for removing the tube for maintenance is not requied.

Application

: .,:., : 1.

._ .'

LO-LOSS tubes should be used where pressure drop is critical. I

c. Required length of straight pipe for orifice

The length should be determined depending on the configurations of piping and the diameter ratio given in JIS 2 8762. (Diameter ratio of 0.7 should be used as a standard, but, Confirm

it by asking assigned engineer.)

Minimum required length of straight pipe between orifice and various fitting installed upstream or down stream of orifice. _. _ --

and others

Diameter ratio 0.5 or larger Thermwell whose diameter is 0.03D or smaller

whose diameter is

Notes: 1. When the'straight length is larger than that shown outside of parenthesis, the expected additional error is zero.

2. When the straight length is larger than that in parenthesis and less than that outside of parenthesis, the expected error in flow measurement is equal to the expected error for the len-gth shown outside of parenthesis plus 0.5%. The addition should be made as follows:

: :

._I . . ,

A( (m3/ )x100+0.5)%

3426G -124-

6. Dioection of BC:ifice taps

1) Orifice taps should preferably be located on the horizontal centerline in horizontal pipe runs. (To be applied for all services)

2) For dry or wet gases, and where there are space limitations.

3)

4)

For dry gases and liquids , and where there are space limitaions.

When the condense pot etc. is installed, clearance should be provided between the piping.

Be careful,

sufficient side pot and neighboring

Steam ‘-.. -. L"

l, Gases or liquids at

\\\ low temperatures 7.

34266 -12%

e. Location of differential pressure transmitter

In general, differential pressure transmitters should be installed on the horizontal plane which includes the pipe center line, and located adjacent to the orifice.

1) For wet gases

Upward slope

To be installed on the structure or platform.

2) For dry gases or liquids To be installed on the grade or platform,

Down slope

3) For steam

To be installed on thetgrade or platform,

::. : :_

* Location of differential pressure transmitters should be determined by Instrument Engineer. When operation stage is required, Piping Engineer should be informed of it by Instrument Engineer.

34266 -126-

(2) Turbine meter

Laminator should be used, when the straight length of 100 is not obtainable.

(ECC or CON)

CON-reducer should ix used to prevent deflection of flow.

(3) Magnetic flow meter

(Turbihe meter)

In general, magnetic flow meters should be installed in vertical lines. But, they may be installed in horizontal lines, provided that the line is completely filled with the liquids.

(4) Variable area flow meter ...

Variable area flow meters should be installed in vertical lines. The installation error should be within 2 8 as against the vertical line. The indicator should be located at 1,500 mm or less above the grade or platform.

34266 -127-

a. Plow meter (Local indicaton type)

Indicator

Type. Type 2

ff 1 I I-r 7 Indi ator

b. Flow meter (With local indicatipn and transmitter)

c. Flow meter (Tapered glass type) . .

Install it so as not to be affected by stresses of piping.

34266 -128-

(5) Positive displacement flow meter

8.8.5

(1)

(2)

a.

Install it so as to permit ease of reading. support should be considered by referring to the weight.

Indicator ,

. . f!!F . l

. . . I l

I

Restriction orifice (OR)

The straight pipe length should be determined according to the diameter ratio.

Type

Plate type

b, Socket weld type

TO be used mainly for high pressure lines 3/4B-l.l/2B.

c. Butt weld type

To be used mainly for high pressure lines 2B and larger.

34266 -129-

8.6.6 Liquid level instrument (Including L/A)

(1) Installation criteria (In general)

a. Liquid level instruments should be located so that the indication of normal liquid level is approximately at midscale.

b. Location of nozzles

1 Feed

Permissidle range of installation

\ Permissible range of installation

A baffle plate should be provided , if the liquid level instrument is installed outside the permissible range because of tower, tank construction work or other reasons.

(2) Displacement type (Outside cylinder type) _..-- -.

a. Side-side type Space should be for the lever's turning.

;; $3 II Vindicator

A

Space should be for opening the

I

provided 1800

provided cover.

34266 -l30-

: ;

b. Side-bottom type

(3) Displacement type (Inside cylinder type)

In general, this type should be installed on the top of vessels. Stage should be considered for reading and maintenance of the instrument.

,

‘I- .

~ .

Guide pipe /

for removal

Ample space should be provided for opening the cover.

34266 -131-

P

(4) Differential pressure type liquid level instrument

a. Differential pressure transmitter (bp/CELL Type)

3/4B gate

This pipe tobe horizontal.

Provide a stage for working. (To be informed by Instrument Engineer.)

b. Diaptiragm type

(5) Float type liquid level instrument

.

Wire hook

: 1. : :

: . .

34266 -132-

(6) Outside ball float tym (Xn general, not to be used)

The instrument body should be supported securely.

1/2B vent

1/2B drain .

Support Con&o1 valve

(7) Inside ball foat type (In general, not to be used)

Baffle plate should be provided/when liquid surface waves.

~ z ~s~~cted dfrectly

f 4-6B

(8) Electrode type level instrument

* 0

s + Clearance PI I

.

,fO?f removal

34266 -133-

(9) Gage glass

jMax.1200 I (Visible

-IL length)

.

t B T i

a. Reflex type‘ 3/4B (General use) Reflex type 2B (Liquid, 0°C or lower)

b. Through-vision type 3/4B (Caustic soda-solution)

For low temperature services, non-frost type is required, and care should be taken not to have interference with the ladder or platform.

8.8.7 Control valve

(1) Installation criteria

Control valves should be installed on the grade, floor or platform so as to facilitate the inspection and maintenance at any time, and stages should be provided, if required. w ____

Side handle, in preference to positioner, should be oriented toward maintenance side.

.

Contact Instrument Engineer for confirmation, when the valve with bottom flange is used.

l LOB or larger Min.800 For reference 12B or larger Min.900

Controivalves should be installed in horizontal lines so that the actuator is in upright position.

34266 -134-

(2) Sizes of bypass and block valves for control valve

C.V Line sizes Block valve Bypass Valve Size sizes sizes

2B and 2B and smaller Line size C.v body size smaller

2-l/28 and larger 2B C.v body size

2.1/2B and larger

2.1/28 and larger C.V body size C.V body size

Bypass valves for emergency valves should have the same size as the main line sizes.

Bypass valves for control valves should be globe valve, but gate valve may be used for bypass valves 6B and larger.

(3) Arrangement of control valve piping

a. Standard manifold of control valve.

Yin

Ii

8B and larger 450 :-

. . b. Manifold when the bypass valve comes to high position.

(Example)

34266 -135-

c. Manifold laid on a horizontal plane.

(Example)

L Easy to remove

d. Manifold on the pipe rack.

(Example) In general, not to be used

e. Manifold in which the line goes up from lower level to higher.

(Example)

f. Insertion of flanges, when bypass valve is joined by welding.

c -Insertion fl .anges

34266 -136-

8.9

Valve welded

Steam piping Control valve

(1)

a.

b.

C.

(2) Criteria for installation of steam drain

a.

b. C.

a.

e.

(3) Methods of draining

a. Superheated steam lines operated at 100 kg/cm2 or higher.

General

Insertion flanges

All branch lines from steam headers should.be taken off the top of the headers.

Single block valve should be provided in each branch, adjacently to the header.

Lines injecting steam into process lines should have a block valve and a check valve, adjacently to the point of injection.

The following positions of piping should be provided with drain valve and pipe to the sewers, where requiked, or should be provided with steam trap.

Ends of headers

Drain pockets

.-...

Every 3Od40 m length of long horizontal lines

Upstream side of control valves (To be shown in P&I)

Downstream side of control valves which will possibly close during operation (To be shown in P&I)

34266 -137-

b. Saturated rteaa liner

1) When main sizes are 3B or larger.

2) when main sizes are 2.42B or smaller.

2B-2.1/2B l.l/2B and smaller

c. Lines not req lb lng steam trap.

j/4B drain

(4) Type of trap

a. Exhaust-to-atmosphere typs .. ..

A block valve and a block-valved bypass should be installed on upstream side of the trap.

(Example) T

:,

(Sewer) (Header)

34266 -138-

b. Recovw ing type

1) When recovering directly into the condensate header, block valves on the upstream and downstream sides of the trap, and a block-valved bypass should of provided. (Any check valve on the downstreamside of the trap should be as shown in P&I.)'

To condensate

2) When recovering into the sub-header, only a block valve on the upstream side and a block-valved bypass should be provided.

I (5) Steam drain line

a. Steam lines operated at 100 kg/cm2 or higher.

Desuperheater a

Drain for warming pipe (Every 40m)

Vent stack

To have down up &d down, possible.

slope without as far as

Turbine

3426G -139-

b. 0th~ steam lines

Desugerheater

When not adversely affecting surroundings Vent stack

When vapor-clouded. (Refer to (6)a. for installation of vent stack.

(6) Vent stack

a. Installation criteria

The vent stack is required for the following.

1) Drains of steam operated at 100 kg/d or higher.

2) Around turbine

3)

4)

Turbine leak steam Line trap

Drains, when exhausted in the room. (But, not required, when the drain line is extended to outdoor.)

Other portions requiring the vent stack due to surrounding conditions.

34266 -140-

b. VS.9 (Vent stack small) typs

This type is to be used for exhausting from steam traps of low or medium pressure services.

support is required, where.H exceeds 5 meters.

.

Insulation for personnel protection

12x6~ Reducer

Drain 1.1/2B

Inlet of steam from traps

C. V.S.L (vent stack large)

This type should be used high pressure steam.

type

for exhausting of turbine-warming-steam OK

Inlet of steam from traps

Drain l.l/2B

protection

Note: For details of the foundation, anchor bolts, orientation of inlet nozzle etc., refe? to TEM-3107 ‘Detail DWG. of special piping parts’.

34266 -141-

(7)

a.

b.

C.

Desuperheater piping

=YW

1) Variable area type

Because.of high cost, this type should be used for import steam where there is a change of steam balance.

2) Atomizing Steam type

Because of low cost, this type should be used for general service, but not t6 be used where there is change of steam balance.

Support is not especially required, because desuperheater is regerded as a part of piping. Desuperheaters of atomizing steam type should be installed on the rack.

The length of straight pipes, bending radius, location of instrument taps etc., should conform to PC1 OK instructions by Instrument Engineer. The length shown in the drawing below are standard.

(Reference drawing)

Min.13m (Straight pipe) m

Notes: 1. To be arranged, so that the pipe is sealed with water at all times.

2. Check pipes for thickness.

3426G -142-

(8) Steam l ilencec piping

(Corrosion of instruments (Corrosion of instruments Interference with field Interference with field of vision Burn injury etc.) of vision Burn injury etc.)

When difficuty is found in the piping flexibility, the manufacturer should be requested to supply the silencer with a sliding nozzle.

Pipe should be sloped so as not to allow accumulation of condensate.‘ (Calculate elongation, and provide sufficient slope to cope with

,+

the elongation.) Attention should be paid to the vibration of outlet pipi of P.C.V. (Provision of supports or diverging nozzle should be considered.)

Pipe should be sloped so as not to allow accumulation of condensate (Calculate elongation, and provide sufficient slope to cope with the elongation.) Attention should be paid to

the vibration of outlet pipi of P.C.V. (Provision of supports or diverging nozzle should be considered.)

w

: - . . . : . . : .

: : . . . f

._ , , . -

. : , .

-

34266 -143-

(9) Stem drum piping

Reference drawing Noi se occurs, when safety. I' valv: is tested.

NO arichor is provided for drum, and I& drum is slidable to both~SideS.

entpiping (Air is vented, when the is hydrostatic-tested.)

Air is vented by.this bypass valve, when hydrostatic testino.

Auxiliary boiler or waste heat boiler i

Never allow a down slope toward the drum. (Attention should .be paid to the upward eloncjation o riser pipes.)

+

Attention shou

of this line.

Attention should be paid to vibration caused by two phas flovi. (Provide direction stoppers)

be at one side

Id

\ . only.

Length of 1-l. 2m is required to enter the manhole. . _/.

-Down comer line (To be symmetrical)

Attention should be paid to vibration, when sttiting up.

Note: For all lines connected to the drum , reaction forces due to thermal stresses should be calculated, and the nozzles should be checked.fot' strength.

i -. 8.10 Drain and vent

(1) Installation criteria

a. Positions where drains or vents are required.

Internal Drains Vents

fluids All drain pockets Gas pockets in lines 2.l/ZB or larger

Liquids Required Required (with valve) (with valve)

For Requ ir ed Not required operation Gases (with valve)

or not required, refer to note.

For Required Required hydrostatic Gases (Plug or blind (Plug or blind test flange) flange)

Notes: Drains are not required where condensate will not be produced at .

34266 -144- operating or ambient temperatures. . .

2) Drains and vents required by process and shown in P&I, should be installed as shown in the P&I.

3) Drain and vent together with valve should be provided for all equipment not automatically drained or vented. Connections should be located on the equipment, wherever possible, but may be located in connecting line, provided that no restriction such as valve is installed between the equipment and the connection.

b. Sizes of drains and vents not indicated in P&I.

General (Not specifically indicated)

Abrasive fluids and fluids having high viscosity when operated at lw temperatures.

Equipment connect ions

~ Main line size I Drains I Vents

~ 3/4B or smaller Main line _ size

3/4B or larger Min.3/4B -

2.1J2B or larger I I Min.3/4B

3/4B I 3/4B I

1B or larger Min.lB / Min.3/4B

Same with the connections

c. Locations of drains and vents

1) All drains and vents provided with single valves, should generally be cap-pluged OK blind-flanged.

2) Drain valves should be located where discharging fluid can be readily observed.

3) Drain valves should be located so as not to interfere with passage ways or access to other equipment.

4) Drains and vents discharging to atmosphere, should be oriented to the direction not to endanger personnel.

5) Heights of drains above the grade or floor.

Note: when hot-or-cold insulated the height should be min. 200 mm regardless of insulation thickness.

1. . .

. , . . -

34266 -145-

(2) Selection of valve

a. ANSI 6009 and lower classes

single block valves (Note 2)

b. ANSI 900# and higher class.es

Single globe valves (Note 3), lubricated plug valves, resilient double seated valves or two gate valves.

C. Hydrocarbon fluids having vapor pressures of 4.5 kg/cm2 abs. or higher at 48°C.

Two block valves (Note 2)

d. Corrosive fluids

Single globe valves (Note 3) or lubricated plug valves.

e. Poisonous hydrocarbon fluids

Two block valves (Note 2)

f. Single valves with blinds may be used for the items b,c,e.

(Note 2) In general, gate valves. (Note 3) Only for Vents.

8.11 Utility piping

8.11.1 Hose station

(1) Arrangements should be as shown in the drawing below.

(2) Connection sizes for hoses and fittings should be 3/4B as a minimum.

(3) Supply steam pressures are 2 kg/cm;! OK below.

34266 -146-

;

. .

(4) Length of h 088 should be 15 m.

TO be standardized in each area

d adjacen e connections)

f ffose banQ f. .:. a Hose 1, -- -- 1: ; ----- If ‘, 1 ‘1 , _ i--+ 3

& 150 J

(Detail of hoseconnection)

34266 - 147-

(Detail of hose rat

Notes: 1. The location of hose racks should be determined after consultation in the field.

2. All joints should be by welding.

8.11.2 Eye washer and shower

(1) Water for eye washers and showers should be taken from drinking water sys'tem. Nozzles should be manufacturer's proprietary divices suitable for outdoor installation.

(2) Pedal-operated valves should be provided.

'For reference'

Typical drawings of the eye washer and shower are shown in the following. Shapes and sizes shown here should be used only for reference in planning, and detail design should conform to manufacturer's drawings. The dimensions shown below are of NIKXI Company. There are cases in which the eye washer and shower are installed being combined into single units.

280~300~ a4

Eye washer Shower

(3) There are cases in which component parts are procured from more than two manufacturers for minimizing cost.

(4) In cold districts, provisions of winterizing should be considered. (steam tracing should be avoided. Apply insulation, and provide bypasses or blow valves to prevent staying of water from occurring.)

34266 -148-

8.11.3 Ejector piping

5 Elevation of ejector and related piping should be checked by Process Engineer in view of the function of the ejector. Steam, air or

water line

Suction lines should have minimum

(Straight pipe is preferable.)

8.11.4 Cooling water piping for pump, turbine etc.

The connection should be taken off the top of main line to prevent rust and dirt from entering.

8.12 Sample connection and analyzer

(1) Installation criteria

a. Sample connections taken off horizontal or sloped lines should be located on the side of the pipe , unless otherwise specified.

b. Vent connections should be a minimum of 3/4B. Drain and sample connections other than the following, should be a minimum of 3/4B.

1) Lines connected to equipment should be equal to the sizes of equipment connections.

2) Connections taken off the lines for abrasive fluids or fluids- '- :. having high viscosity at low temperature, should be a minimum of 1B.

c. Connections for process analyzers should be 3/4B, and a block valve of the same size should be provided.

d. Sample connections taken off product lines connected to tanks, should be located upstream of the control valve. Sample connections should be located adjacently to the sewer, whenever possible.

e. Sample connections taken off pipes or equipment for high temperature service should be provided with sampling cooler. Single cooler may be used for two or more sample connections.

f. For fluids having high viscosity at low temperatures, provision should be made to clean the line and cooler with steam or other media.

34266 -149-

,' (2) Type of valve

Sample connections should be valved as follows:

a. ANSI 3001 and lower classes

Single block valve

b. ANSI 400t and higher classes

Single globe or ball valve, of double gate valves

C. Hydrocarbon fluids having vapor pressure of 4.5 kg/cm2 abs. or higher at 48%.

Double block valves

d. Caustic fluids

Single globe valve or lubricated plug valve

8.13 Tank yard piping

8.13.1 Regulations and safe distance

When regulations in --- To conform to attached "Standard for Japan are applied. layout of outdoor storage tank yard..

When NFPA CODE is -- To conform to attached "Design manual applied. for tank' yard in conformity with

NFPA CODE 301".

8.13.2 Tank yard piping

(1) Piping outside oil (liquid) dike

Piping should be run on pipe racks or sleepers. The height of pipe racks should generally be a maximum of 6 n in view of loss prevention. There is no limitation for sleeper's height.

(2) Piping inside oil (liquid) dike

In general, piping should be run on sleepers. The height of sleepers should be determined based on tank nozzle height, pump nozzle height, dike height and pipe's laying sequence and branches etc..

34260. -150-

(3) Design of piping around tank

a. Grouping of piping inside dike

In general, piping should be grouped on the same sleepers, pump suction lines being routed to have the shortest possible run. Therefore, two or more groups of piping are required where there are many of tanks.

b. Pump suction piping

Piping should not have air pockets, tank nozzles being located at the highest elevation. (Drain pockets may be allowed.)

c. Flexibility of piping and flexible tube ..

To cope with settlement of tank (Settlement when full-water- tested, uneven settlement, settlement due to;earthquake)-; displacement of nozzle when full of oil, thermal expansion .etc., the pipe loops, expansion joints, flexible tubes may be used. However, in general, flexible tubes should be used for tank feed nozzles (other than for spherical tanks) and for pump suction nozzles. In this case, piping should be designed with a displacement of 100 mm.

: I .

. :

._

34266 -El-

Dimensions of flexible tubes are as follows: llni t . mm Y...hb . . -

Nominal Maximum displacements in vertical direction d

diameters 50 100 150 200 250 300 350 400

ND Actual length (L) of flexible metal hoses

40 500 600 700 800 900 1000 1100 1200 50 600 700 800 900 1000 1100 1200 I300 65 600 800 900 1000 1100 I.200 I.300 1400 a0 700 800 loo0 1100 1200 ~00 1400 1500

100 700 900 1100 I.200 I.300 1400 l500 1600 125 800 1000 I.200 I.300 1400 1500 1600 1800 150 800 1100 I.300 1500 1600 1700 1800 1900 200 900 1200 1400 1500 1700 la00 1900 2100 250 1000 1400 1500 1700 2000 2100 2200 2300 300 1100 1400 1700 1900 2200 2300 2500 2600 350 1200 1500 1800 2000 2200 2400‘ 2600 2800 400 I.300 1600 2000 2200 2500 2700 2900 3200

I Note: When placing an order with the manufacturer, be careful not

to use L' instead of L.

d. Piping around tank nozzle

1)

2)

3)

4) Emergency shutoff valves should be located as clash to the \ tanks as possible.

5)

6)

7)

8)

9)

In general, tank shutoff valves should be installed directly against the tank nozzles.

Tank shutoff valves and header changeover valves should be installed in a group, and a stage, which also serves as a walkway crossing over the grouped piping, should be provided for operation of such valves.

When the shutoff valve is heavy, the tank nozzles should be reinforced (consult vessel engineer) or a support installed on the tank shell. When the valve is supported on a foundation, such foundation should be integral with the tank foundation.

Where shutoff valve for safety valve is of gate valve, such gate valves should be installed in vertical line so that the valves are kept open even when the disc is disconnectd due to corrosion.

Sample connections should not be taken off the bottom of pipes or dead zones of piping.

Lines inside the dike should not be underground, except sewer lines. (Attention should be paid to the lines for fire extinguishing.)

Tank drain should be received by drip funnels, and led to ditches or sump boxes inside the dike through underground pipes. (Do not allow tank drain to flow directly to the outside of the dike.)

In general, pipes should not penetrate the dike.

34266 -152-

8.3.3.3 Drainage system

Refer to "8.14.4 Sewer lines" in this Design instruction.

8.13.4 Fire extinguishing system

Refer to "8.15 Fire extinguishing facilities" in this design instruction.

8.14 Underground piping

8.14.1 Lines to be installed underground

(1) Sewer lines

a. Oily

b. Non-oily

c. Chemical

(2) Water lines

a. Cooling

b. Drinking

c. Seawater

d.Industr ial water

(3) Fir@ extinguishing

a. Foam extinguishing

b. Firefighting water

(4) Trench

a. For cable

b. Lines required by process

(5) Sanitary

8.14.2 Design

(1) Priority when planning

Priority should be given to cooling water main l.ines of large size, and oily sewer lines or chemical sewer lines having a slope.

(2) Limitation for trench line

Trench lines in the unit should generally be limited to insulated lines and lines requiring inspection and repairing during operation.

(3) Limitation for use of flanged connection

Use of flanged connection should generally be limited to the connections to valve, equipment and machine.

34266 -153-

::’ ..’ _y;

I, ‘ . ,

. i . . . . . ,..

(4)

a.

b.

Minimum depth of underground piping

To be larger than freezing depth.

To be 1,200 mm at the top of pipes, which are run under the road and are not reinforced or otherwise protected.

(5) Spacing for underground piping

(This should not be applied to USSR job, which should be covered by USSR regulation for electrical equipment.)

Min. 50

Note: For dimensions Xl and X2 , consult Civil Engineer.

(6) Indication of pipe elevation

In general, underground piping should be indicated by top elevation.

a%~\ ’ ‘ ... Top. EL'indication

Bottom of pipe (B.0.P) elevation or invert (INV) elevation may be used only when required for special lines or limited portions.

a-IN,.,,.

I (Invert ele.vation)

:_ : .i: ..

.1:_

3426G -154-

(7) Jointing to aboveground piping

Underground piping is installed prior to aboveground piping works, and the ends of pipes should generally be capped as shown below until1 they become ready to joint.

Cap or plate

L 45' is preferable

(8) Protection for underground piping

Underground piping should be protected with concrete coating or sleeves, if required.

(9) Consideration to thermal expansion

Displacements due to thermal expansion of high temperature underground pipes should be limited to 40 mm. Surrounding of such pipes should be back-filled with sand.

8.14.3 Cooling water piping

(1) Design requirements

a. Large-sized piping should especially be designed to have simple routing, so as to minimize piping materials.

b. Drain pocket should be avoided, as far as possible.

c. Manholes should be installed for the inspection of pipe inside. Installation criteria are as follows:

1) Where main size is 248 or larger, run length is 200 m or more : and ,there is a pocket.

2) Pipes adjacent to B, L etc., where there is a block valve.

3) For large plant area such as ethylene plant, approximately one manhole for each area is a standard in consideration of above 1) and 2). (For example, one for quench and one for compressor ---.)

4) Manhole should be installed inside the valve pit, together with main block valve, instrument connection, and drain nozzle mentioned below, as far as possible.

3426G -155- -: >

5) Detail8 of the manhole are as follows:

c Manhole (Cooling water) . \

d. Drain nozzle should be installed for draining mud in the pipes. Installation criteria are as follows:

1) Where main size is 24B or larger and there is a pocket. (When the pipe dia. is reduced the pocket is produced, the reducer being top flat.)

2) Other places where accumulation of mud is expected.

3) Details of the drain nozzle are as follows:

Dr&n (Cooling water) I

(2) Piping materials (Fittings)

a. For jobs where JIS G3451 (Coated steel pipes for city water) is applicable, 90° bend class-l, 45' bend class-l, and tee class-l from among JIS 3451 (see attached tables below) may be used. However, these piping materials should be ANSI base, if, in a particular job, the thickness of the pipe is different from that of attached and the quantity of such materials is small, which would result in high cost.

34266 -156-

b. In case of ANSI base

1) In general, 90’ miter bend (short) With two segments, and 450 miter bend (short) with single segment, should be used.

2) Tees should generally be welded pipe-to-pipe type. (with . reinforcement, if necessary)

n ww

D*

I-_

n UU

!D

R a

3 I

L 350 i 14 I 355.6 533.4 : i 1 400 16 1 406.4 609.6 i 406.4 i

450 18 1 457.2 685.8 ' 457.2 500 20 1 508.0 762.0 : 508.0 550 22 1 558.8 838.2 1 558.8 600 24 i 609.6 914.4 1 609.6 650 26 1 660.4 990.6 1 660.4

I 700 1 28 1 711.2 1 ln66-a - - - . -

I 7119 I .-a.-

750 I 30 i 762.0 1 1 ! 762.0 -7

800 / 32 ! 812.8 i i:;;:: / 8.12'.8 -i 850 ! 34 t 663.6 1 1295.4 .! 963.6 T- 900 I 36 i 914.4 1 1371.6 I 914.4

,nnn I Ah I lnlc n i 1524.0 1 1016.0 ' r-r a .-mm - A” “ ” , 1” .L”.L”.” 1 . I . 1 1100 1 44 i 1117.6 1 1010.4 I 1111.6 1200 1 48 1 1219.2 1 182^ .-. :o .o ' ---- - i J.4J.Y.I

1350 I 54 1 1371.6 1 2057.4 1 1371.6 1 1500 1 60 \ 1524.0 ( 2286.0 1 1524.0 I

:’

_.

34266 -157-

JIS G3451 Coated steel piIJes for city water

90’ Bend Class-l

Unit: mm

1 Nomihal RtsideThicl Dia. Dia. -nes:

(A) D2 rit

Dimensions Reference Inside Dia. R J12 L *1 Weight

(kg)

1:

t: 200

89.1 4.2 60.7 230 231.6 123.2 114.3 4.5 105.3 230 231.6 123.2 139.8 4.5 130.8 230 231.6 123.2 165.2 5.0 155.2 250 267.0 134.0 216.3 5.8 204.7 310 273. I 166.2

170 170 170 200 190

400

ii: 450 500

709.6 709.6 709.6 802.0 878.6

6.24

lE6 15.9 26.5

267.4 6.6 254.2 360 286.5 193.0 318.5 6.9 304.7 410 299.9 219.8 355.6 6.0 343.6 460 263.3 246.6 406.4 6.0 394.4 510 276.7 273.4 457.2 6.0 445.2. 530 312.0 284.0

t: 140 140 170

550 959.0- 40.7 600 1039.4 55.1 600 1019.8 52.8 650 1100.2 65.0 700 1192.0 79.6

500

:: 800 900

508.0 6.0 496.0 5Go 290.1 609.6 6.0 597.6 660 366.8 711.2 6.0 699.2 790 371.7 812.8 7.1 798.6 790 371.7 914.4 7.9 898.6 860 420.4

iii:: 423.4 423.4 460.8

140 700 1180.6 87.7 190 850 1440.8 128 160 950 1590.2 165 160 950 1590.2 224 190 1050 1762.4 312

1000 1016.0 8.7 998.6 910 433.8 487.6 19O 1100 1842.8 398 1100 1117.6 10.3 1097.0 910 433.8 487.6 190 1100 1842.8 518 1200 1219.2 11.1 1197.0 970 439.9 519.8 180 1150 1919.4 635 1350 1371.6 11.9 1347.8 1020 453.3 546.6 180 1200 1999.8 798 1500 1524.0 12.7 1498.6 1070 466.7 573.4 180 1250 2080.2 984

1600 1628.0 14.0 1coo.o 1100 444.7 569.5 150 1250 20G8.4 1150 1800 1832.0 16.0 1800.0 1150 458.1 616.3 1.50 1300 2148.8 1540 2000 203G.o 18.0 2000.0 1200 471.5 643.1 150 1350 2229.2 2000

*l Pipe center line length

3426G -X58-

4S" Bend Class-l

Unit mm -I-

Dimensions T Reference 1 lomina. Dia.

(A)

OutsideThic Dia. - 1 Inside..

D2 nys Dia. R

89.1 4.2 80.7 370 114.3 4.5 105.3 370 139.8 4.5 130.8 370 165.2 5.0 155.2 430 216.3 5.8 204.7 430

267.4 6.6 254.2 550 318.5 6.9 304.7 610 355.6 6.0 343.6 680 406.4 6.0 394.4 740 457.2 6.0 445.2 800

508.0 6.0 496.0 8Go 609.6 6.0 597.6 980 711.2 6.0 639.2 1170 812.8 7.1 798.6 1170 .914.4 7.9 898.6 1290

1016.0 8.7 998.6 1350 1117.6 10.3 1097.0 1350 1219.2 11.1 1197.0 1410 1371.6 11.9 1347.8 1470

- Izl P3 L *1 Weight

(kg)

270.3 147.2 196.7 350 687.8 6.05 270.3 147.2 196.7 350 687.8 8.39 270.3 147.2 196.7 350 687.8 10.3 357.4 171 .o 271.9 450 885.8 17.5 344.5 195.0 247.0 450 884.0 26.6

331.6 218.8 222.2 450 882.0 37.4 318.6 242.6 197.3 450 879.8 46.6 3S3.6 270.6 218.3 500 977.8 50.6 340.7 294.4 193.5 500 975.8 57.8 327.7 318.2 168.6 500 973.6 65.0

314.9 342.2 143.8 : 500 972.0 7i.2 539.0 389.8 344.1 750 1467.8 131 438.1 465.4 265.4 750 1461.6 152 748.0 465.4 515.4 1000 1961.6 277 722.4 513.2 465.7 1000 1357.8 347

709.3 537.0 440.8 1000 1955.6 422 709.3 537.0 440.8 1000 1955.6 550 6’96.4 560.8 416.0 1000 1953.6 647 683.5 564.8 391.1 1000 1951.8 779 670.6 608.6 366.3 1000 1943.8 922

638.3 668.3 304.1 1000 1944.9 1080 638.3 668.3 304.1 1000 1944.9 1390 612.5 716.1 254.4 1000 1941.1 1740

1: 125

ii:

.:....:

:

250 300 350

, 400 450

1000 1100 1200 1350 1500

1600 1800 2000

*lPipe center line length

34266 -159-

04ominal Dia. 600X600A and smaller)

I (Nominal Dia. 7OOX25OA and larger)

:_ _::. .: -.

: ..

Note: Allowances ,for R are f Sam.

.: . .

34266 -160-

Nominal Dia.

(A)

Outside Dia Thickness Reference

02 d2 Weight (kg)

a0 x‘ 80 4.2 4.2 2so 250 6.38

100 X 80 100 x 100

89.1 114.3

250 7.63 250 8.75

250 a.92 250 9.46 250 10.7

13.6 14.2 14.7 16.9

125x 80 125 X 100 125 X 125

139.8 139.8 139.8

89.1 114.3 139.8

150 X 80 150 x 100 150 X 125 150 x 150

165.2 165.2 165.2 165.2

89.1 114.3 139.8 165.2

200 x 100 216.3 114.3 200 x 125 216.3 139.8 200 x 150 216.3 165.2 200 x 200 216.3 216.3

267.4 114.3 267.4 139.8 267.4 165.2 267.4 216.3 267.4 267.4

.I_

. . . . . . -

: .

250 x loo 250 x 125 250 x 150 250X200 250 x 250

6.6' 6.6

i:t 6.6

4.5

2: 5.8 6.6

36.7 37.3

ii:: 47.8

300 x 100 300 x 125 300 x 150 300 x 200 300 x 250 300X300

318.5 114.3 318.5 139.8 316.5 165.2 318.5 216.3 318.5 267.4 318.5 318.5

4.5

;:i

iit 6.9

44.8 45.3

:::

Zi:o"

950 x 150 550X200 150 x 250 so x 300 HIx350

355.6 165.2 355.6 216.3 355.6 267.4 355.6 318.5 355.6 355.6

6:O 6.0

86:: 6.0

55:: :-ii 6:0

ii:; 63.7 66.8 72.5

Kxl x 150 rc?o x 200 loo x 250

tixz 200X400

406.4 406.4 406.4

:Ei 40614

165.2 216.3 267.4 318.5 355.6 406.5

64.2

R f 72.7. 71.6:. :: 82.2.

150 x 150 350 x 200 150 X 250 150 x 300 250 x 350 150x 400 150 x 450

457.2 165.2 457.2 216.3 457.2 267.4 457.2 318.5 457.2 355.6 457.2 406.4 457.2 457.2

ii:8

ii::

ii:8 6.0

E:i i:; 6.0 6.0 6.0

71.2 73.5 76.4 78.7 77.6 79.0 91.7

80.3 82.7 84.8 83.7 84.8 85.9

101

500 X200 500 X 250 500 X 300 NO X 350 500 X 400 500 X 4SO 500 X 500

508.0 216.3 508.0 267.4 506.0 318.5 503.0 355.6 508.0 406.4 508.0 457.2 508.0 508.0

ii:8 6.0

2 6:o 6.0

.

Nominal outside Dia. Thickness Reinforcement Length Reference Dia.

(A) D2 d2 T t t1 8 Ii I Height ‘(kg)

600 X 200 609.6 216.3 6.0 5.8 - - 750 500 138 600 X 250 609.6 267.4 6.0 6.6 - - 750 500 140 600 X 300 609.6 318.5 6.0 6.9 - - 750 500 142 600 X 350 609.6 355.6 6.0 6.0 - - 750 500 141 600 X 400 609.6 406.4 6.0 6.0 - - 141 600 X 450 609.6 457.2 6.0 6.0 - -

z! to” 142

600 X 500 609.6 508.0 6.0 6.0 - - 750 500 142 600 X 600 609.6 609.6 6.0 6.0 - - 750 500 164

700 X 250 711.2 267.4 6.0 6.6 700 X 300 711.2 318.5 6.0 6.9

6G:: ;i 3: 600 168 600 171

700 X 350 711.2 355.6 6.9 6.0 i:: ;i s: 600 170 700 X 400 711.2 406.4 6.0 6.0 600 171 700 X 450 711.2 457.2 6.0 6.0 i:: 70 750 600 173 700 X 500 711.2 508.0 6.0 6.0 70 750 600 174 700 X 600 711.2 609.6 6.0 6.0 750 177 700 X 700 711.2 711.2 6.0 6.0

i:: 3: 750

ii: 203

800 X 300 812.8 318.5 7.1 6.9 BOO X 350 812.8 355.6 7.1 6iO

2 70 1000 700 298 70 1000 700 297

800 X 400 812.8 406.4 7.1 6.0 70 1000 800 X 450 812.8 451.2 7.1 6.0 t :: 70 1000 ;ii ii 800 X 500 812.8 508.0 7.1 6.0 800 X 600 812.8 609.6 7.1 6.0

X:8 70 1000 301 70 1000

zii 304

800 X 700 812.8 711.2 7.1 6.0 6.0 70 1000 306 800 X 800 812.8 812.8 7.1 7.1 6.0 70 1oOO

;t 355

900 X 300 914.4 318.5 7.9 6.9 ii:8 70 1000 900 X 350 914.4 355.6 7.9 6.0 70 1000 ;ii if:

900 X 400 914.4 406.4 7.9 6.0 70 1000 700 900 X 450 914.4 457.2 7.9 6.0 t :t 70 loo0 700 i:

900 X 500 914.4 508.0 7.9 6.0 6.0 70 1000 700 900 X 600 914.4 609.6 7.9 6.0 6.0 70 1000 700 iii

900 X 700 914.4 711.2 7.9 6.0 70 loo0 900 X 800 914.4 812.8 7.9 7.1 t.8 900 X 900 914.4 814.4 7.9 7.9 6:0

70 1000 z ;!t 70 1000 700 438

1000X 350 1016.0 355.6 8.7 6.0 28

70 1000 446 1000X 400 1016.0 406.4 8.7 6.0 70 1000 ii: 447 1000X 450 1016.0 457.2 8.7 6.0 70 1000 800 1000X 500 1016.0 508.0 8.7 6.0 X:i 70 800 zi 1000 1000X 600 1016.0. 609.6 8.7 6.0 ,. 6.0 ‘70 1000 449 1000X 700 1016.0 711..2 : 8.7 6.0 El 70 1000 !K 449 1000X 800 1016.0 812.8 8.7 7.1 70 1000 4sT 1000X 900 1016.0 914.4 8.7 7.9 6.0 70 1000 ~~ 465

1100X 400. 1117.6 406.4 10.3 6.0 70 1000 1100X 450 1117.6 451.2 10.3 6.0 28 70 1000 iii E 1100X 500 1117.6 508.0 10.3 6.0 70 1000 572 1100X 600 1117.6 609.6 10.3 6.0

ii:8 70 1000

~~ 570

1100X 700 1117.6 711.2 10.3 6.0 70 1000 568 1100X 800 1117.6 812.8 10.3 7.1 2: 70 1000 :i 572 1100X 900 1117.6 914.4 10.3 7.9 6.0 70 1000 80 575 1100X1000 1117.6 1016.0 10.3 a.7 6.0 70 1000 800 530

34266 -162-

Nominal Outside Dia. Thickness Reinforcement Length

Dia. (A) 02 a 7 t t1 B If f

1200x 400 1219.2 406.4 11.1 70 1000 900 1200X 450 1219.2 457.2 11.1 ::i ::: 70 1000 900 1200X 500 1219.2 508.0 11.1 6.0

66:; 70 1000 900

1200X 600 1219.2 609.6 11.1 70 1000 900 1200X 700 1219.2 711.2 11.1

ii:: 70 1000 900

1200X 800 1219.2 812.8 11.1 7.1 66:: 70 1000 900

1200x 900 1219.2 914.4 11.1 7.9 E 70 1000 900 1200X1000 1219.2 1016.0 11.1 8.7 70 1000 900 1200X1100 1219.2 1117.6 11.1 10.3 6.0 70 1000 900

1350X 450 1371.6 457.2 11.9 6.0 2: 70 1250 1000 1350X 500 1371.6 508.0 11.9 6.0 70 12.50 1000 1350X 600 1371.6 609.6 11.9 6.0 66:: 70 1250 1000 1350X 700 1371.6 711.2 11.9 6.0 70 1250 1000 1350X 800 1371.6 812.8 11.9 7.1 70 1250 1000 1350X 900 1371.6 914.4 11.9 7.9

i:: 100 1250 1000

1350X1000 1371.6 1016.0 11.9 8.7 6.0 100 1250 1000 1350X1100 1371.6 1117.6 11.9 10.3 100 1250 1000 1350X1200 1371.6. 1219,2 11.9 11 .I

2 100 1250 1000

1500X 500 1524.0 508.0 12.7 6.0 ;:i 100 1250 1000 1500X 600 1524.0 609.6 12.7 6.0 100 1250 1000 1500X 700 1524.0 711.2 12.7 6.0 1500X~800 1524.0 812.8 -12.7 7.1

;:: 100 1250 1000 100 1250 1000

1500X 900 1524.0 914.4 12.7 7.9 9.0 100 1250 1000 1500X1000 1524.0 1016.0 12.7 8.7 9.0 100 1250 1000 1500X1100 1524.0 1117.6 12.7 10.3 loo 12!% 1000 1500X1200 1524.0 1219.2 12.7 11.1

1f:i 100 1250 1000

1500X1350 1524.0 1.371.6 12.7 11.9 12.0 100 KEO 1000

1600X 600 1628.0 609.6 14.0 6.0 12.0 155 1500’ 1600X 700 1623.0 711.2 14.0 6.0 12.0 150 1500

Ei

1600X 800 1628.0 812.8 14.0 7.1 12.0 150 1500 1200 1600X 900 1628.0 914.4 14.0 7.9 12.0 150 ‘1500 1200 1600X1000 1628.0 1016.0 14.0 8.7 12.0 150 1500 1200 1600X1100 1628.0 1117.6 14.0 10.3 12.0 150 1500 1200

1800X 700 1832.0 711.2 16.0 6.0 12.0 150 1500 1400 1800X 800 1832.0 812.8 16.0 7.1 12.0 150 1500 1400 1800X 900 1832.0 914.4 16.0 7.9

i 12.0 150 1500 1400

1800X1000 1832.0 1016.0 16.0 8.7 12.0 150 1500 1400 1800X1100 1832.0. 1117.6 16.0 10.3 : 12.0 : 15d.F 1500 1409 1800X1200 1832.0 1219.2 t6.0:. 11.1. 12.0 150 1500 1400

!OOOX 800 2036.0 812.8 18.0 7.1 12.0 200 1500 1500 !OOOX 900 2036.0 914.4 18.0 7.9 12.0 200 lSO0 1500 !OOOXlOOO 2036.0 1016.0 18.0 8.7 12.0 200 1500 1500 !OOOX1100 2036.0 1117.6 18.0 10.3 12.0 200 1500 1500 !OOOX1200 2036.0 1219.2 18.0 11.1 12.0 200 1500 1500 !OOOX13.50 2036.0 1371.6 18.0 11.9 12.0 200 1500 1500

Reference

Weight (kg)

66133 673 672 669 673

ii; 700

1010 1010 1010 1000 1010 1020 1020 1040 lOS0

1190 1190 1190 1190 1190 1190 1200 1220 . 1230

1710 1710 1720 1730 1730 1750

2190 2200 2210 2220 2240 2250

2750 2750 2760 2780 2790 2800

34266 -163-

8.14.4 Sewer piping

(1) Type

Oily sewer

Chemical sewer

Non-oily sewer (Storm sewer)

(2) "Material

Type

Oily sewer

Chemical sewer

Non-oily sewer

Applications

1. Drainage from equipment handling oil. 2. Drainage of rain water from oily paving areas. 3. Waste water produced by decoking of cracking

furnace etc. 4. Drainage from the inside of oil dike. 5. Others indicated in P&I.

1. Drainage from equipment handling chemicals. 2. Drainage of rain water from chemical paving

areas. 3. Chemical drainage from control room, laboratory

and analyzers. 4. Others indicated in PSI.

1. Drainage other than those from oily or chemical 1 equipment.

2. Drainage of rain water other than those from i oily or chemical paving areas. I

3. Drainage of drinking water from buildings. 4, Drainage of firefighting water. I 5. Neutralized waste water from neutralization l I

tank. I

Material (In general)

1. Carbon steel pipe with outside anticorrosion tapes.

2. Concrete pipe should be used for 16B and larger when long distance. Consult Civil Engineer.

1. Carbon steel pipe with-outside anticorrosion tapes; (Careful study should be made on possible corrosion of steel due to acid and alkali.)

2. Cast-iron pipe 3. Ceramic pipe 4. PVC pipe

1. Carbon steel pipe

Remark

_ . . . .: ..-: ,I’

.;...

34266 -164-

(3) Design of oily and chemical sewers

a. In general, oily and chemical sewers should be installed underground, and should be of gravity flow type.

In general, oily and chemical sewers within the plant should be planned with a slope of l/300, and finally, flow velocities in between each catch basin or manhole should be checked by Process and civil Engineers.

: I

b. Design fiow quantity

Flow quantity should be based on rain water plus process water. me quantity should be determined by Civil Engineer based on process data, amount of rainfall, area of pavements, coefficient of discharge etc.

c. Design flow velocity

Design flow velocity should be 0.3-2.1 m/s.

d. Sizing of main sewer line

1) The'sizes should be determined by Civil Engineer, based on design flow quantity and design flow velocity. (For other than main line, by Piping Engineer.)

2) Minimum size of main lines should be 6B.

e. Shape and size of catch basin area

1) Catch basin areas should be paved with concrete etc., and their- periphery spill-walled. -. . .

2) One catch basin should be provided for each catch basin area.

3) One catch basin area should be a maximum of 400 m2.

4) A slope of l/150 or more should be provided.

5) Dimensions of each part should be as shown in the drawing below, as a standard.

Max.22.5m Max.22.sn 100 k

I i- It"

EL 0 EL-150

Catch bash.

34266 -165-

f. Determination of paving area

After receiving the information of equipment requiring paving from Process Engineer, Piping Engineer should determine the dimensions of paving area in cosideration of equipment maintenance, dismantling of piping, limitations of catch basin area etc..

g. The catch basin, sump box and manhole pit should generally be installed in the main lines at intervals of 25 to 30 m. Type of oily sewers should be such that water seal can be provided for prevention of spreading of the fire.

h. Drip funnel

Drip funnels should be located to-permit direct discharge from equipement and piping, and connected to the main line, catch basin or sump box. The size of drip funnel should be as shown below, depending on the size and number of discharge lines.

Drip funnel (Type 11

Perforated plate (MAT'L:SUS304) (4.99 '

Yltt

'Top EL 150, when non-pving

, WP. EL.-

,' (SEE DwG.1

Drip funnels inside of buildings or trenches, where floor is paved, should be as follows:

_: Drip funnel. (Typ6 2:)

te 1

34266 -166-

i. Cleanout

(Type 1)'

A sub-header should be provided for two OK more drip funnels. It should be provided with a cleanout at its end. (Each drip funnel serves as a cleanout, because its perforated plate is removable.)

I nChekered plate

Clean out

St Checkered plate (M&T'L SS4u

X6

ELO)

Clean out

~o~~ Detail "J"

Polyethylene caps, which were used when shipping, may be used.

'X6 Detail "G"

plate

34266 -167-

j. For catch basins or sump boxes which are 1 iable to produce flammable gases, water sealed covers should be provided, and the gases should be discharged to a safe place through 2B pipes.

k. Type and purpose of pit

1) Catch basin --- This is a pit for catch basin area.

(A) Typical types

Gratincf

Type "A"

Gratins

Type YzH (Seal type)

Type “B”

Type “D” (Seal type)

34266 -168-

(B)Sleeve

Connections of pipes to pits which vary depending on construction method or time schedule, should be determined after consulting with Civil Engineer, and the scope of works should be made clear. Here, dimensions for flanged sleeves are shown in the following.

I? 7 a

Pipe Size L

a($ 4 300 6 300 8 300

10 300 12 300 14 300 18 300

d(B) D(B) Id(B) D(ld) 2 100 112 420 .

t 4 i 180 ii 14 i 480 1

2) Sump box

Sump box is the intermediate pit which is installed when the intervals between catch basins or between a catch basin and a manhole pit exceed 25-30 m.

(A)Typical types

* When non-paving,' the height of 50 mm fr& each paving should be revised to read EL 150. (where GL=EM)

.:: . .:

34266 -169-

I Type “G”

(Seal type)

EL.3000

Type ,II" (-Seal type) (Seal type)

, (B)For sleeves, refer to those for catch basin.

:

3426G -170-

3) Manhole pit

Manhole pits are installed for the purpose of cleaning and inspection of long main lines , and provided with water seal effected by internal partition wall. Manhole pits should therefore be located adjacently to B.L Or the boundary of unit or area.

l When non-paving, the above dimension "SO" should'be revised to read EL 150. (where GL=ELO)

(B)Por sleeves, refer to those for catch basin.

I. Details of pit cover

Type “A* Type "Bm

T_vDe "C" Detail "B"

. . .:

,

34266 -171-

FB 50x6 FB 50x6 /

L 90x56x6

,ed late 4-I-F

t----hi I w

Type "D"

Type "F"

Type "G"

Type "H"

Detail "C"

S't Checkered'plate

u5Ox5Ox6

Detail 71"

34266 -172-

MAT'L SS41)

Detail "F"

_. A I

I

St Checkered Dla (MAT'L SS41) r100

I- /4 ' y+

50

Ml6 Nut /+I&- I

Ml6

Detail "G"

D&tail "H"

I 1 I I 1

L 90x56x6

Tvoe “El”

Type "I"

34266 -173-

m. Drainage from inside the oil (liquid) dike

Tank

- Drainage should be provided for both oily and non-oily separately.

An example is shown below.

To non-oily

* For storage tanks of ethylene and propylene etc., which will vaporize, only the valve for non-oily should be provided.

n. For catch basins located in the area of heaters etc., where fire is used, provisions should be made to keep the pits dry, and not to allow accumulation of water in the pits.

o. When structures or two or more story buildings require flocr drainage, the floor drainage pipes should be provided and connected to the main sewer line. In this case, the drip funnels should generally be in the scope of Civil Engineer. (Consult Civil Engineer.)

p. Sump Boxes should be provided at the corners of main lines. Inlet and outlet pipes of pits should be installed at right angle to the pit wall.

34266 -174-

q. The angle of intersection ot 415. should be used for branch lines except for the start points of drip funnels. The branch lines should be buried as close to the ground surface as possible.

Sub-header and main line are in different \ elevations, and they constitute three-

dimensional p.tpFng.

r. Symbols to be used in piping drawings should be as shown below, and should have identification number for each area.

--cz \ Y cc

Manhole (Oily sewer)

sump box (Oily sewer)

Catch basin (Oily sewer)

Manhole (Chemical sewer)

sump Dox (Chemical sewer)

ditch basin (Chemical sewer)

Drip funnel (Oily sewer)

Drip fu~el (Chemical sewer)

Clean out (Oily sewer)

Clean out (Chemical sewer)

Size of indication

Manhole 800X1600 (To sc'ale) Sump box 800 (To scale) Catch basin 800 (To scale) Drip funnel 2.54 Clean out 2.5Q

8. Preparation of General Drawing

It is recommended to make General Drawing, which includes the information such as types, sizes elevations, directions, and cover details of the pits, drip funnels , cleanouts and changeover valves at oil dikes etc., all together with each identification number. (The General Drawing should generally be made for congested plants having large number of items.)

34266 -175-

t. Preparation of Plow sheet

Plow sheets of the sewer system are usually not included in other P&I or Utility F.D, and it is recomendable to make the flow sheets for transmission OK confirmation of information, and for convenience of field construction and operation.

The followings are examples. -- --

I 6"

6 6"

Butadiene extraction unit

3rd n floor drain (700 m21

Zndty70f$;r drain

Except area of pLd .

8"

Pumps (Only .washing)

-- --

r------- --- Product tank area

t- 1

_. ‘:.

:;.

34266 -176-

,’

I

:. iIf= > --.:.

. ‘.’ : . .

ggs 34266

-177- 2 :‘;‘a

(4)

a.

b.

C. Design velocities should be 0.6 to 1.8 m/set. in gravity flow.

d. Types of sewers are U-shaped trough, ditch of concrete or brick and as excavated etc..

e.

f. The following considerations should be paid in the sewer design.

8.14.5

(1)

a.

b.

C.

d.

(2)

Design of non-oily sewer

In general, non-oily sewers should be designed by Civil Engineer.

Design flow quantity should be based on rain water and waste water.

The sewer should be provided on both sides of road, periphery of building with roof, and in a place where there is non-oily drainage, etc..

1) Interference of non-oily sewers with other underground piping. (When the amount of rainfall is larger, or the length of sewer

is longer, the bottom of the sewer is likely to become deeper;)

2) Isolation of paving area (Do not allow rainwater of oily or chemical paving areas to enter into the non-oily sewer.)

3) Interference with passage ways

Trench piping

Scope of application

Piping required by process. . .._.

Water-spray piping such as for steam curtains, water curtains etc..

Gravity flow lines whose main lines are located below the grade (G.L) and are liable to clog. (Example : Drain lines to underground tanks.)

When a line interferes with the passage for operation and maintenance.

Construction cosuaonly used 150

_.

._ . .

.:- 1..

Notes: a. Inside of trenches should be filled with sand, if required for safety.

b. Top covers may be of checkered plates or gratings. Sometimes, the cover is not required.

34266 -178-

c. In gener81, piping for steam curtains or water curtain8 should not be covered.

. But, when the trench interrupts a passage-way, the interrupted portion should be covered with a light cover.

d. For above mentioned(l)C gravity flow lines, 45O bends and 45O branches should be used, and nozzles for cleaning should be provided at cirtical points.

(Example of installatin of the cleaning nozzle) 450

Cover

8.15 Firefighting piping (When requlations in Japan are applied.)

8.15.1 Types of systems

(1) Water extinguishing system .

a. Hydrant system b. Water-spray and deluge systems c. Sprinkler system d, Water curtain (Including steam curtain)

(2) Air-Form sys tea

a. Outdoor air-foam extinguishing hydrant system b. Air-foam chamber system. ] . . : ..: .. _.

(3) (2% system .-.

8.15.2 Water extingushing system

1. Water for firefighting system should not be used for any permanent facilities other than for firefighting purposes.

2. Lines going to each yard should generally be underground, but the lines inside the tank-yard-dike should be aboveground.

(1) Hydrant system

a. Location of hydrant

Hydrants should be installed so that all equipment and buildings are included within a 40 meter radius of the point of the hydrants,

34266 -179-

b;L Hose box

Hose boxes should be located on the right side of the hydrants within 5 meter distance.

c. Piping planning

i) Main lines for firefighting water should be routed around each plant to contribute looped piping.

2) The main lines should have block valves so as to permit the isolation of any required sections.

(Example 1 *

3) For the main lines for which future expansion is expected, blind flanges should be provided.

4) Connection between the hydrant and the firefighting water line should be as shown below.

Hydrant

Firefighting water line

(2) water-spray and deluge systems

a. water-spray and deluge systems

These systems are applied for storage tanks of flammable liquids or explosive gases.

1) Spherical tanks should be provided with topnozzle-type deluge system, which covers all of the upper half surface, and bottom-spray-system, which covers all of the lower half surface of the tank.

34266 -180-

2) Top-nozzle-deluge or drencher system should be provided on the roop of cone roof tanks for liquefied petroleum gases. For tank shells, the drencher system should be used.

I I Deluge system

b. Piping planning

Drencher svsteo

:

1) Drencher heads should be located so that the cooling water covers the tank shell entirely.

2) Distribution valves and main valves should be installed in a safe place outside of dike. (15 m apart from the outside surface of tanks)

3) A strainer should be installed between the main valve and the distribution header.

Galvanized pipes should be used for piping downstream of the stq+irl$E- .:

4) Piping inside the dike should be above ground and provided with drain valves. The piping should not penetrate the dike.

5) Winterizing should be provided in cold districts.

._I..

: .

. : :

1: - : :

_. 1 . :

:

3426G -181-

6) Biping around tanks should be sloped to prevent staying of water.

(Example of piping at distrubution valves)

(Example of piping at spherical tank)

.

6FF AU EL.1000

3426G -182-

(3) Sprinkler system

a. Sprinkler system

This system is applied to warehouse-yards or bagging warehouses etc..

b. Piping planning

1) Main valves should be manually operated.

2) Strainers should be provided in the piping. Galvanized pipes should be used for down-stream piping of the strainer.

(4) water curtain and steam curtain

a. Water curtain and steam curtain

Water curtain is used for shielding against heat, and steam curtain for dilution of gases leaked.

b. Steam headers should be designed, taking into account the amount of steam and pressure drops etc..

c. Piping planning

1) Steam should be supplied from M.S headers. Consult Process Engineer.

2) When the length of header for steam curtain is longer than 15 m (TEC standard), the steam should be supplied to the header from two or more lines.

Inlet of steam

Control valve

steam curtain header

3) Manually operated control valves should be used and installed in a place ready to access when gas leakage occurs.

4) Pitch of holes in the steam curtain headers

34266 -183-

5) Steam curtain header should be installed in the trench as shown belaw.

Clearance for thermal expansion

one) - Drain trench -

8.15.3 Air-foam system

(1) Air-foam system

Air-foam system should be used for fire extingushing of nowwater-soluble and flammable substance such as naphtha, light oil etc..

a. Air-foam system includes two systems shown below.

1) Outdoor foam extinguishing hydrant.

2) Fixed air-foam system for tanks. (Air-foam chamber)

b. Air-foam chambers should be provided for the following storage tanks for hazardous materials.

1) Tanks whose liquid surfaces are 40 m2 (tank diameter of approximately 7.2 m) or more, or heights are 6 m or more.

.

oirer

c. Air-foam chambers should be provided for any tanks other than the above, where required.

:

3426G -184-

d. Air-foam 6y6tam6 should bc designed to allow fteding of foam liquid to the air-foam hydrant or the air-foam chamber6 from both the pressure balance tank and the air-foam firefighting truck.

fyq Foam liquid

Strainer Bt

Water for firefighting

To foam chamber

Connection to firef~~hting truck. (Connection should.be installed In a safe place alongside-the main road and also adjacent to the pressure balance tank.)

e. Air-foam extinguishing hydrant6 should be located so that concerned hazardous material6 are covered within a 40 10 radius of the hydrant.

f. Hazardous materials within a 15 m radius of the hydrant should be coverd also by other air-foam extinguishing hydrants.

(2) Number of air-foam chamber6

Tank diameter i

Le66 than l3 II! 13 1 to le66 than 19 1 19 a-to less than 24 m 24 a to le66 than 35 m 35 m to less than 42 m 42 m to le66 than 46 IQ 46 m to less than 53 m 53 m to less than 60 m 60 m to less than 67 m 67 m to less than 73 m 73 m to less than 79 m 79 m to les6 than 85 m 85 m to less than 90 m

Cone roof tank

1 1 I; . . . 2 3 4 6 8' 10 12 14 16 18

Floating roof tank

2 3; 4' 5 6 7 8 10 10 l2 12 14 14

34266 -185-

(3)

a.

Piping planning

When two of more foam chambers are installed on one tank, the following should be complied with.

1) Foam chambers should be located on the periphery of the tanks at uniform intervals.

2) The piping should be planned so as to obtain uniform distribution of the foam from each chamber.

b. Foam liquid piping is not required to be a loop system piping.

C. Foam liquid piping inside the oil-dike of tank yards should not be underground, and should not penetrate the oil-dike.

d. Foam liquid piping should be sloped(1/250) and be provided With drain valves at the lowest points so that the foam liquid in the piping can be drained completely. When the lowest points are underground, pits should be provided for the drain valves.

e. Feed water lines to the foam liquid tanks should be provided with strainers.

f. The foan liquid tanks and manual operated control valves should be located outside the dikes.

Block valves in the lines to be used for the hydrants of foam extinguishing system should be located outside the oil dikes and grouped together, as far as possible. They should be located 15 m apart from the outside surfaces of tanks.

h. The foam liquid tanks should be located in a place adjacent to the control rooms.

Foam chamber

Foam liquid tank

8.15.4 CO2 extinguishing system

I 3 From firefighting water main line

CO2 extinguishing system should be provided for the switch rooms, control rooms, computer rooms etc..

8.15.5 Cases where NFPA CODE is applied

Attached "Design of tank yards in conformity with NFPA CODE 30" should be complied with.

34266 -186-

MALONEY STEEh LTb

PROTEK ENGINEERS MALONEY FILE: CQ91-207 PAGE 2

l ,

l*O DESIGN BASIS

1.1 PRCCESS DESCRIPTION

Our offer Is based on the use of triethylae glycol as the dehydrating medium. The reasons fox the choice of a glycol drying system and for the use of TEC are outlined in section 3.10 and 3.11 of this quotation, The glycol contactor lower consists of a gas/liquid knock-out sections where entrained liquids are removed from the gas, The liquids are discharged under level control and the gas passes up through the vessel counter current with lean TEG, Mass transfer of water into the glycol from the gas takes place over the length of the coatactor before the gas leaves’the top of the tower as dry gas. The tower is fitted with a chimney tray between the knock-out and contacting sections in order to collect the rich glycol and from where it is discharged under level control. The tower has a mist extractor above the knock-out section to prevent entrainment of liquids entering theoontactor section and contacting the glycol and a second mist extractor below the gas outlet,to prevent entrainment of glycol in the dry gas, The contactor section has been designed using valve trays which we believe gives the most economical design. However a design using a structured packing would result In a more compact tower with consequent reduction in weight which would be a bonus on an offshore installation. We would be pleased to consider such a design if this basic offer is of interest. A glycol dehydration unit can de designed with a large number of variation of glycol flowrate and concentration, number of stages and degree of heat recovery on the regeneration package. The design offered has been computer rjptimized to provide the most cost effective design. The water rich glycol discharged from the chimney tray is piped to the regeneration package where it firstly, passes through a still reflux coil where it is preheated to approxLmately 162’F. Then the rich glycol is piped to a vessel operating at about 4 barg (60 psig) which serves as a flash drum and a hydro-carbon liquid skimmer. This vessel is a vertical three-phase separator sized to provide 15 minutes glycol retention time, thus assuring complete degassing of the rich glycol and removal of any liquid hydrocarbons which may have been entrained in the glycol solution. The degaeeed rich glycol is discharged from the flash drum through firstly a glycol sock filter which removes solids and then through a carbon filter which removes any remaining hydrocarbons, well treating chemicals or any other trouble-some impurities and then through a rich-lean glycol heat exchanger where it is further preheated to 350Q F. Having been preheated, degassed &.Jd filtered, the rich glycol is

ed to a feed point near the centre of the packed still. reflux

column where the water and glycol are separated by fractiona I al st I at on.

1. ,:, .::’

PROTEK ENGINEERS MALONEY FILE: CQ91-207 PAGE 3

1.1 PROCESS, DESCRIPTION

'HI

b 1.2

The still column reflux condenser is cooled by the rich glycal leaving the contactor tower. The sole purpose of the dietillation or still column is to vent water vapour and to recover all glycol vapours generated by heat in the reboiler, This method is so effective that glycol losses in the still overhead are small. As the rich glycol passes from the bottom of the still column downward into the reboiler, the temperature is further increased to the reboiler temperature of 204°C (4OO’F.f with heat being supplied by a gas fired heater. Normal reboiler temperature is 204*C. Alternatively the reboiler could be electrically heated at additional cost. Even though TEG begins to degrade at slightly above 204’C, glycol degradation ie not a problem when air is excluded from the system and when heater flux rates are reasonable. The lean glycol from the reboiler then passes through the glycol/glycol heat exchanger where it is cooled while preheating the rich glycol before passing to the gl.ycol accumulator. Before re-entering the contactor tower at the completion of the regeneration cycle further cooling is required which may be by sea water, process gas or ambient air. This offer is based on the use of sea water cooling using a litanium plate and frame heater exchanger. After final cooling the glycol is pumped into the top of the contactor tower using an electric driven positive displacement pump. This offer includes the supply of 2 x 100% duty pumps,

DESI.Gp DATA

Each dehydration unit ie designed to dry 165 MMSCFD of gas water saturated at 850 psig and 14O’F. to an outlet dewpoint of 57*F(14*C). Gas supplied at 980 psig contains less water and hence the equipment will handle gas from 850 to 980 pslg, The tower offered has sufficient contactor stages to maintain the 14°C dew point if the gas inlet temperature is increased to 155*F but gas throughput is then limited by the capacity of the regeneration package, and hence gas throughput must be reduced. If the system is operated with gas at 400 psig an extra stage must be added to the contactor tower in order to maintain the 14°C dew point and also the gas throughout must be reduced.

WlALONEY STEEL Mb

PR0TEK ENGINEERS MALONEY FILE: CQ91-207 PAGE 4

1,2 DESIGN DATA

Maximum gas throughputs are listed below in MMSCFD:

INLET TEMPERATURES INLET PRESSURE INLET PRESSURE &F 850 - 980 psi& 400 psig

140 165 90 145 151 82 150 138 76

,': 155 128 70

NB. Extra stage required for operation of 400 psig.

1.3 JJESIGN BASIS

Gas flow rate 165 MMSCFU Gas inlet pressure 850-980 psig Gas inlet temperature 1406F. Mechanical design pressure 1700 psig Gas molecular weight 21.3 Gas saturated with water at above inlet conditions. Gas outlet dewpoiat 57°F (14'C), Water removal rate 1220 lb/h. Lean glycol concentration 99.1% TEG Lean glycol circulation 27,785 lb/h, Rich $1~~01 circulation 29,005 lb/l Glycol circulation 2.5 USG/lb water removed Glycol contactor ID 81"

height s/s 21'6" for 850 psig 23'6“ for 400 psig

Contactor design pressure 1700 psig Contactor design code ASME VIII Div. 2 Reboiler operating temp. 400'F

pressure atmospheric

Reboiler heat load 2.5 x lo6 BTU/h Heat load recovered by reflux coil. 0.3 x lo6 BTU/h Heat load recovered by glycol/glycol

exchanger 3.5 x lo6 BTU/h

Total regeneration heat load 6.3 x lo6 BTU/h Reboiler capacity filLed 3.0 x 106 BTU/h

- - - - - __, - Wm.--(

WUONEV OTEEL LTD

PROTEK ENGINEERS MALONEY FILE: CQ91-207 PAGE 5

1.3 DESIGN BASIS

Gas consumptions if reboiler gas fired SO00 SCFH Power consumption if electr1caU.y heated 900 kw Gas consumption based on gas with GCV 1000 BTII/SCF

Glycol cooler sea watersupply Assumed 9O*F Sea water consumption 34,710 lb/h Sea water return lll°F

4? Power absorbed by glycol pump 34 hp (25 kw) Pumps motor fitted 40 hp (30 kw)

Pump power based on max pressure of 980 psig in contactor. Pumps casing designed for 1700 psig,

Regeneration skid dimensiona (apprax.) Height to top of still column

36’0” x 14’0” 36’ 0”

1.4 INSTRUMENTATION AND CONTROL

This offer is baaed on the minimum controls required for safe operations of the unit, We would be pleased to consider controls in more detail once your control philosophy is determined, For example we would need to know whether controls should be electric or pneumatic and whether controllers are to be local or provided by a remote DCS syatem,

CONTROLS INCLUDED ARE:

4) Contactor Tower: Level. controLler and control valve for knock-out section Level controller and control valve for chimney tray Level contwoller and control valve for glycol level High and low level ewitches for knock-out level section High and low level switches for chimney tray glycol Level gauge for knock-out section Level gauge for chimney tray glycol level.. Pressure gauge Temperature indicator

REBOILER: Temperature controller Fuel gas valve train consisting of fuel gas shut down valve, control/shut down valve, pilot valves , manual isolating valve, main,gas regulator, pilot gas regulator:. Flame f allure sensor Low level switch High temperature switch Level gauge

MALQNEY STEEL Ltll

PROTEK ENGINEERS MALONEY FILE: CQgl-207 PAGE 6

1.4 CONTROLS LNCLUDEU:

GLYCOL PUMPS Pressure gauge8 Relief valve6

2.0 EXLUSI,ON

FLASH TANK Level controller and control valve for glycol Manual valve for manual skim of hydrocarbon condensate ReguLaror and relief valves for gas blanket Level gauge High and low liquid level ewitches Pressure gauge Relief valve.

FILTERS fsolating valve8 Pressure gauges Differential pressure gauges Manual bypass valve for charcoal filter Thermal relief valves

All instrumentation controls and valves far process gas* All instrumentatlcn, controls and valves for sea water. Any instruments , controls or valves not listed in section 1.4 above Relief valves on contactcr tower, ESD valves or blowdown valves Accees platforms and ladders on contactor tower, Brackets far fitting of ladders/platforms are included. HIC and SSC testing We would would be pleased to advise prices for any of the above once your final requirements are known.

3.0

3.1

REPLY TO ATTACHMENT 2 OF YOUR RF-Q

Reboiler fuel gas demafid 5000 SCFH based on gas with GCV of 1000 BTU/SCF,

3.2 Electrical power requirement for electric reboiler 900 kw Nl3, This offer is based on the use of a gas fired reboiler.

3.3 The rsboiler offered is deeigned for uce with sweet dehydraeed gas. However controls, firetube, burner and exhaust stack may be specified for use with aour gas at extra cost if required.

MALONEY STEEL LTD

PROTEK ENGXNEERS MALONEY FILE: cp9 l-207 PAGE 7

3.4

.+a 3.5 Tb

3.6

3.7

3.8

3.9

3.10

\

3.11

Choice between electric heating or gas firing ie an economic trade off depending upon capital cost and relative costs of gas as opposed to electricity, An electric reboiler will take up less space which can be at a premium for offshore applications.. Thyristor control is recommended for electric heaters with the control panel mounted Indoors in a non-hazordous area. However the thytistor control panel cost is significant.

The dehydration unit may be turned down to 30% of design flow, i.e. to 50 MMSCFD at 850.-980 psig or to 30 MMSCFD at 400 p&g.

The unit offered is constructed from carbon steel. conforming to requirements fo NACE MR-01-75, Vessels are A-516-70. Vessels and pipework will be heat treated to ensure that weld hardness also complies with NACE MR-01-75,

Maloney dehydration systems are designed to minimize maintenance/downtime, Details of maintenance requirements and recommended spares holding can be discussed when control’philosophy is decided upon.

See section 1.2

See section 1.2

The alternative to a glycol dehydration system is a dry bed system. Dry bed systems are capable of dehydrating to lower dewpoints rhan glycol systems but equipment costs and energy costs are higher. The required dewpoint far this application is 14“C. which is relatively high and easily obtainable using a glycol system. There is thus no advantage in using a dry bed system in this case and economic disadvantages.

TEG has a lower vapour pressure than DEG or MEG. Consequently losses of glycol in the gas outlet stream are lower if TEG is used, especially when gas temperatures are high as in this case. DEG is normally only used when gas temperature is below 2O*C (68°F) and MEG only when gas is refrigerated. Also because of its lower vapour pressure the fractional distillation of the rich glycol is easier with TEG with lower Losses in the water vapour stream from the still column, A further advantage of TEG 1s its higher thermal stability enables the use of higher reboiler temperatures leading to higher concentrations of lean glycol without the use of gas stripping to increase glycol concentration,

MALONEY STEEL LTD

PROTEK ENGINEERS MALONEY FILE: CQ91-207 PAGE 8

3.12 The high gas inlet temperature specified in the RFQ has necessitated a regeneration package capable of removing large quantities of water due to the high water content of the saturated gas. Reduction of the gas temperature would lead to a reduction in size, weight, capital cost and energy costs. Each 5°F reduction in gas temperature reduces the energy requirement by approximately 8%. You may therefore wish to consider cooling the inlet gas to the contaccor tower.

4.0 REFERENCE LIST. OFFSHORE GLYCOL DEHYDRATION UNITS AND REGENERATORS

P .a .

YEAR FABRICATED 1976

LOC&CION North Sea

CAPACITY MMSCFD 375

1980 North Sea 100 1990 Gulf Thailand 75 Awaiting commissioning North Sea 47 Currently building North Sea 116

The last two references above are for use OR floating production platforms and are designed CO operate under condftions of severe roll, heave and pitch.

. Wilter removed per train : $.%G5 LB/HR (050 PSIG, 140°F)

. Lean glycvl : Conc:enl:t:at.i+ : 99.1 X weight Flow r3.t.e Cj.rculacion ioed

: 33 000 LB/HR : 2.75 Gall/LB

l Reboilcr duty : Calculat,c?di : 1300 KW (4.4 MMBTUIH) Installecl i : 1500 KV (5.1 MMBTU/H)

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3, DESCRlPTfON OF S1JPPI.Y FbR PACH TRAIN .------v---.

a) One gas dehydration gackake housj.nA

- One gas/glyc(>l. cont.nct.or, ba.cksd 1:ypc, including an integrated inlet. SCl-LIbber. , Sizing : z m diamer.er per 5r.G m height;

! - Ona caslglycol heat excha$ger, t.ubular BEM type, mounted along the absorber. ,

I - Including piping, valves,

I hcces+jories and i,nst-rumtnts, associated CO ccntactot and heat exchanger;

Skid s1.7.ing : II = 11 m I w = 3.5 m I L = 3.5 m I

I Estimat.ed empt.y wai&t. : 50 i.ona

- Two full glycol flow c:arjridg:e filters, able tr) remove all solids particles of 5 microns diamc!Rnr and ahow.

I - 1)ne side flow glyr:vl c:haIjc:oal filter, able t,o handle 20 X of rich glycol flow rate. I

i - OI~F! gly~~~.~l/glycvl heater ekc:hangcr, plate type of tubular type.

!

!

bundlel; (3) : 2,3 m diameter per 3 m long TL / TL

- Ont? sr.il.f- column, packed I I/i’e, 'i

34 inches diameter per 4 m height:

- One glycol surge drum, a@le to r’k?r:t?ive the glycol c:ontained in reboiler .

- Twn gJ.yr..ol recirculation frumps, rc?c:iprocating r.riplex type equipad with. their electrical muters: f

Including interc:onncr:t.~TIS piping, valves, inStrumant.3 and at:c(~s~;nries .

- Including heat insulation Skid sizing : I, :k I.5 m

W = 4,6 m i i = Up to 11 I

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11

Estimated empty wright. : 70

4. ANSWERS TO ATTACHEMENT

4.1. Futrl gas consumpr.i.on p e r c K a 1. n , based on a fue, BTU./SCF, fuel gas con+:;umpt..

i t ,it I. I ii

4.2. Elc:ct,rj.cal power rdql gl.yc0.l reboiler : 1305 KW

h.3. Fuel gas quality : available. Mjnimum pressure

4.4. Comparison of direct heated reboilsr.

. Elnct.rical.ly heat.ed - smaller vessel - smaller package - higher ixvestme:

which shall be

. Rebuiler - larger sizing - lower investmen

1 1

t-1 I i i , I

1

i I j I

still column installed.

:ons

z OF YOUR PAX

7 case of direct fired ~lycul reboile:: : gas hav !ng a Net heating value of 1005

,n will be : 7050 SCF/HR and per train.

.t-e1nent.s in case of elac:trically heated

referaLly quality in dehydrated gas as rt. battery limit 3 bar R.

fired heat.er vis a vis of elec:trically

3boi.ler : izing j izing : cost due to associated cnnt.rnl panel ruvideci +

cost

6.6. Metallurgy recommerlddtion due t 0 ::0Llr ser,vice. We will r'~~on'uW~lded ttr r:las the 1owek part ut the contac:rlor from bott.om up to thr first hundred mil limrrter~ of strut:t.ured packing.

Rich g!.ycol piping up to f;‘lash vessel, flash vrs$el. flash vc+ssel out.ler, gas piping should satrsfy recommenciations of NACE, Still cc~1um.n and internals shall be l)rc>vj $ctd in stainless steal.

4.7 Wlml operating at 400 thrnufihput. shall be reducef 4 st.rigl>ing gas shall be uticd.

4.0 W?len uperating at 145/l. reduced as fc~llows :

145°F : 10.5 MNSCFD 0 150°F : 127 MMSCFD

3 55°F : 112 MMSCFD

5. BUDGET PRIcrf --

Hutiget. pri~:e for the desii ~,lyc:ol d.ehydration trains is

j?ii.- DELXVERY TIME

Delivery time gf those unit.:;

7. Rl?FERENCL LIST -A..-

PROSER list of refercxes is

Staying at your disposal fol ;

‘PSIG instead of 850 PSIG t,hc inlt?‘t gas : down lo 7 + 4 MMSCFD and 1 SCPT/GALL or

Oll55”F the inlet gas t.hroughput shall be

n and sul)ply of four identical gas and : 38 000 000 FF

will be between 12 to 14 months.

added hert! after,

any other information you may require.

We remain,

Yvurs faf th.ful ly ,...* /--7

MC. RIGAIL t

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