SP PI PP 001 (General Piping System)

DOCUMENT NO.
PT Caltex Pacific Indonesia
REV.
SP-PI-PP-001
DATE :
1
SHEET :
SEPT 26, 2001

Nurhasan Nurhasan Shawn
OF
49
SPECIFICATION
PREPARED BY CHECKED BY APPROVED BY
NHS NHS SPD
GENERAL PIPING SYSTEMS
PT. CALTEX PACIFIC INDONESIA
REV
DATE
PAGES
DESCRIPTION
PREPD
CHKD
APPD
0 1
9/26/01 1/7/02
ALL ALL
ISSUED FOR IMPLEMENTATION CPI SPEC REVIEW TEAM (TRB, ANDR, TOTO, KWK)
NHS Team
NHS Team
SPD Team
TABLE OF CONTENT 1. GENERAL...................................................................................................................................... 3 1.1. 1.2. 1.3. 1.4. 2. Scope................................................................................................................................... 3 Reference ............................................................................................................................ 3 Terminology ........................................................................................................................ 3 Conflicting Requirements ................................................................................................... 4
DESIGN .......................................................................................................................................... 4 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. General ............................................................................................................................... 4 Design Pressure.................................................................................................................. 6 Design Temperature ........................................................................................................... 8 Design Minimum Temperature ........................................................................................... 9 Occasional Variations (Short Term Conditions) Rating..................................................... 9 Steam out Philosophy........................................................................................................ 9 Line Designation Tables ................................................................................................... 10
3.
EQUIPMENT LOCATION AND ACCESSIBILITY .............................................................. 10 3.1. 3.2. 3.3. 3.4. Definitions......................................................................................................................... 10 Accessibility General ..................................................................................................... 13 Accessibility of Valves ...................................................................................................... 14 Instrument Location and Accessibility.............................................................................. 15
4.
PIPING DESIGN AND ARRANGEMENT GENERAL....................................................... 16 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 4.8. 4.9. 4.10. 4.11. General ............................................................................................................................. 17 Elevations.......................................................................................................................... 17 Change in Direction.......................................................................................................... 17 Injection Points. ................................................................................................................ 18 Pockets and Dead Ends .................................................................................................... 18 Unit Blocks........................................................................................................................ 18 Unit Pumpout/off Test System........................................................................................... 19 Precommissioning............................................................................................................. 19 Break Joints ...................................................................................................................... 19 Insulation Support Rings .................................................................................................. 19 Insulating Pipe Flanges (Electrical)................................................................................. 19
General Piping Systems SP-PI-PP-001 Rev. 1
4.12. 4.13. 4.14. 4.15. 4.16. 4.17. 4.18. 4.19. 4.20. 4.21. 4.22. 4.23. 5.
Vents in Piping.................................................................................................................. 19 Drains in Piping................................................................................................................ 20 Drains Piping (Aboveground)........................................................................................... 21 Blinds ................................................................................................................................ 22 Utility Stations .................................................................................................................. 25 Instrument Piping ............................................................................................................. 26 Safety Showers and Eyewash Fountains........................................................................... 28 Sample Connections.......................................................................................................... 28 Clearances ........................................................................................................................ 29 Block Valves...................................................................................................................... 29 Check Valves..................................................................................................................... 31 Pipe Plugs ......................................................................................................................... 32
PIPING DESIGN AND ARRANGEMENT SPECIFIC SERVICES ................................... 32 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11. 5.12. 5.13. 5.14. 5.15. 5.16. Vessel Piping..................................................................................................................... 32 Heat Exchanger Piping..................................................................................................... 33 Pump Piping ..................................................................................................................... 34 Compressor Piping ........................................................................................................... 37 Fired Heater Piping.......................................................................................................... 39 Relief System Piping ......................................................................................................... 39 Steam and Condensate Piping .......................................................................................... 40 Air Piping.......................................................................................................................... 43 Water Piping ..................................................................................................................... 43 Oxygen Service Piping...................................................................................................... 44 Underground Piping ......................................................................................................... 44 Offsite Interconnecting Piping.......................................................................................... 45 Tankage Piping ................................................................................................................. 46 Truck and Tank Car Loading Facilities............................................................................ 47 Fluid Catalytic Cracking Units (FCCU) .......................................................................... 47 Acid and Caustic Lines ..................................................................................................... 48
OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:
ADDENDUM 1: Project Specific Clarifications & Requirements
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1.
GENERAL 1.1. Scope This specification provide guidelines for designing of the piping system inside and outside of plant Unit for PT. CALTEX PACIFIC INDONESIA (COMPANY). Wherever a different exists between this specification and the detailed drawing, the drawings shall govern. No deviation shall be made from this specification without written authorization from COMPANY. 1.2. Reference 1.2.1. Related Specifications SP-ME-VS-001 SP-PI-PP-005 SP-PI-PP-002 PP-PI-PP-008 SP-PI-PP-004 PP-PI-PP-001 PP-CI-SS-001 PP-CI-SS-002 1.2.2. Code and Reference 1.2.2.1 ASME/ANSI (American Society of Mechanical Engineers/American National Standards Institute) Code for Pressure B31.1, B31.3, B31.4 and B31.8. OSHA Part 1910. National Fire Protection Association, Code No. 30. Sour service piping (subject to sulfide stress cracking) shall be in accordance with NACE Specification MR 0175. General Pressure Vessel Specification Hot Insulation Piping Specification Piping Fabrication, Erection, Inspection and Testing Coating and Wrapping for Piping Piping Cleaning Procedure Steel Structure Erection Procedure Steel Structure Fabrication Procedure
1.2.2.2 1.2.2.3 1.2.2.4 1.3. Terminology
In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.3.1. COMPANY Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection. 1.3.2. CONTRACTOR
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Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified by Contract, Scope of Work, or Work order. 1.3.3. Vendor Refers to the selected by COMPANY or CONTRACTOR, which is responsible for the purchase agreement or purchase order of the goods/services specified in this specification. Note: For EPC (Engineering, Procurement and Construction) project purposes: The terminology shall have the meanings as above. For Direct Procurement by COMPANY purposes: Vendor shall also be responsible as CONTRACTOR. 1.4. Conflicting Requirements 1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANYs attention for resolution and approval in writing. However, the most stringent requirement shall apply. Should conflicts exist between this specification and other documents, the following order of precedence shall govern: Scope of Work Data Sheets. This Specification Other COMPANY Specifications Other Referenced Publications Approved for Construction Drawings Vendors Code 2. DESIGN 2.1. General 2.1.1. Material 2.1.1.1 Piping material shall be in accordance with SP-PI-PP-002 Piping Specification; note any deviation on the piping drawings. Pre-piped or packaged items shall be in accordance with pre-piped or packaged specification. Minimum pipe size shall be 1/2 of an inch, except for connections to equipment. Do not use pipe sizes 1-1/4 inch, 2-1/2 inch, 3-1/2 inch, and 5 inch except for connections to equipment.
1.4.2.
2.1.1.2 2.1.1.3 2.1.2.
Design Summary
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2.1.2.1
Lines shall be located such that they have the shortest possible run consistent with good engineering practice and require minimum number of fittings. Piping shall be arranged to allow the removal of equipment without removing the block valves adjacent to the equipment and associated piping. Major lines normally shall be carried on aboveground pipeways. In certain instances, they may be buried; they shall be coated for external protection in accordance with SP-PI-PP-004 Coating and Wrapping for Piping. Process and steam line under railroad tracks or roadways shall be installed in concrete culvert. Do not provide space for future equipment, pipe, or units unless required by the client or for process considerations. This requirement shall be indicated on the plot plan and P&ID. Avoid dead ends, especially for piping where solids or fluids may congeal or form corrosive condensate. Vent and drain valves shall be installed in dead ends. The location and spacing of storage tanks and dike requirements shall be in accordance with National Fire Protection Association, Code No. 30, and OSHA part 1910.106 (b), where applicable. Spacing may be increased for construction requirements. Pumps and exchangers to permit economical pipe routing. Locate this equipment outside of dike storage areas, except where indicated otherwise on the P&IDs. Piping shall be designed such that it has enough flexibility to avoid the excessive stresses and end reactions. The calculation uses the conditions that result in the largest differential temperature, when comparing average ambient temperature to operating temperature, steamout temperature, etc. The equipment nozzle load due to piping expansion may be calculated using the operating temperature condition.
2.1.2.2
2.1.2.3
2.1.2.4
2.1.2.5
2.1.2.6
2.1.2.7
2.1.2.8
2.1.2.9
2.1.2.10 Piping shall be supported, anchored, and guided to prevent undue line deflection, stresses, excessive vibration, and to protect piping and connected equipment from excessive loading and expansion stresses. The maximum pipe sag between supports shall be 25 mm (1 inch) or one-fourth of the NPS, use whichever is less when full water. For lines NPS 1 and smaller shall be limited to a maximum sag of half of NPS. 2.1.2.11 Branch connections in utility lines shall be valved. They shall be located in the horizontal section of the line as near to the to header as possible unless, if by locating them at the edge of pipe rack, they can be grouped and made accessible from a platform. For gases and vapours, including steam, the connection shall be to the top of the header. Branch connection for liquid lines in pipe rack including cooling water headers, should be to the bottom of the header.
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2.1.2.12 Check valve shall not be installed in vertical line with downward flow. 2.2. Design Pressure Design pressure of piping shall be determined on the following basis : 2.2.1. Design pressure generally shall not be less than maximum sustained operating pressure plus the following allowance:
Maximum Sustained Operating Pressure Less than 50 psig 51 250 psig 251 500 psig 500 - 1000 psig Greater than 2001 psig
Allowance 10 psi 25 psi 10% MOP 100 psi 10% psi
Allowances less than the above shall require individual consideration and written COMPANY approval. Allowance shall not be required for conditions described in paragraphs 3.2.2 through 3.2.5 below. 2.2.2. Discharge piping of centrifugal pumps and centrifugal compressors shall have a design pressure that is not less than maximum discharge pressure of all conditions. Design pressure shall include consideration individually of the following type of single jeopardy conditions, if they are appropriate, and combinations of these conditions that are expected to occur simultaneously. Normally, multiples of these, and sometimes, all conditions may occur simultaneously and therefore should be considered in combination. 2.2.2.1 Maximum pressure at suction flange. If appropriate, the following shall be considered: Suction pressure safety valve at its set pressure. Maximum liquid level in pump suction system. Maximum shutoff supply pressure from suction booster pump. 2.2.2.2 Maximum head at low or no flow. Purchased pump curve shall be used for pumps, or it shall be assumed that maximum pump head is 130% of pump design head. Maximum liquid density, such as lowest API and/or coldest pumpage anticipated. Maximum molecular weight gas anticipated. Maximum driver speed. Speeds above constant speed or speed control range, such as overspeed trip setting, shall be considered, if appropriate, but associated discharge pressure shall only be within occasional (short term) pressure rating of piping in accordance with Section 3.5.
2.2.2.3 2.2.2.4 2.2.2.5
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2.2.3.
Design pressure of piping protected by a pressure relief valve (PRV) on an interconnected equipment system shall not be less than piping pressure expected when pressure relief valve reaches set pressure. Protected piping upstream of the PRV location shall have a design pressure sufficiently higher than PRV set pressure to account for maximum system pressure drop between protected piping and PRV location. Protected piping downstream of PRV location shall have a design pressure at least equal to PRV set pressure to account for minimum pressure drop of zero for no flow. Design pressure of piping shall not be less than maximum pressure that may occur for any of the following type conditions. 2.2.4.1 2.2.4.2 2.2.4.3 2.2.4.4 2.2.4.5 2.2.4.6 2.2.4.7 2.2.4.8 2.2.4.9 Starting up operations, including any start-up procedure, operation, or routing. Shutting down operations, including any shutdown procedures, operating, and pumpout. Switching operations, including any cyclic regeneration, spare pump switching, and coke drum switching. Regeneration procedures. Equipment by passing. Turndown operations. Pump shutoff. Control valves in fully open or fully closed position. Block valves in fully open or fully closed position, except for locked valves.
2.2.4.
2.2.4.10 Blocked exits. 2.2.4.11 Equipment trip or shutdown. 2.2.4.12 Misoperation. 2.2.4.13 Maintenance, repair, or neutralization procedures. 2.2.4.14 On-stream testing procedures. 2.2.4.15 Steam-out (see Section 3.5) or purging operations. 2.2.4.16 Other causes of increased pressure. 2.2.5. Design pressure of flare system piping and other PRV discharge piping shall be : At least 50 psig. Not less than maximum back pressure during any relief. 2.2.6. Design pressure shall be considered coincident with piping design temperature determined per Section 3.3, except if a more economical design is used by giving piping two or more sets of design pressure/temperature combinations. For example, hydrotreater reactor piping may have separate design combinations for hydrotreating (high pressure) and regeneration (high temperature). Design shall
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include features to prevent inadvertent combinations of high pressure and temperature. 2.3. Design Temperature Design temperature of piping shall be determined on the following basis: 2.3.1. Design temperature shall not be less than maximum sustained fluid operating temperature plus an allowance that is normally 50F. An allowance less than 50F shall require individual consideration and written COMPANY approval. Allowance shall not be required for conditions described in paragraph 3.3.2 through 3.3.4 below. Design temperature of piping shall not be less than maximum fluid temperature that may occur for any of the following type conditions: 2.3.2.1 2.3.2.2 2.3.2.3 2.3.2.4 2.3.2.5 2.3.2.6 2.3.2.7 2.3.2.8 2.3.2.9 Starting up operations, including any start-up procedure, operation, or routing. Shutting down operations, including shutdown procedures, operations, and pumpout. Switching operations, including any cyclic regeneration or coke drum switching. Regeneration procedures. Equipment by-passing. Turndown operations. Control valves in fully open or fully closed position. Block valves in fully open fully closed position, except for locked valves. Equipment trip or shutdown.
2.3.2.
2.3.2.10 Misoperation. 2.3.2.11 Maintenance, repair, or neutralization procedures. 2.3.2.12 Steam-out (see section 3.6) or purging operations. 2.3.2.13 Other causes of increased temperature. 2.3.3. Flare system piping and other PSV discharge piping shall have a design temperature that is determined from temperature of fluid being relieved, taking into account temperature change across PSV and thermal affects in discharge piping. Design temperature of heat traced and insulated piping shall not be less than maximum metal temperature expected for no flow conditions. For steam tracing, steam saturation temperature at steam supply pressure shall be used. Design temperature of internally insulated piping shall be based on heat transfer calculations or tests. Thermal expansion stress calculations for piping shall be based on the higher of:
2.3.4.
2.3.5. 2.3.6.
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2.3.6.1 2.3.6.2
Piping design temperature and or piping operating temperature. Occasional (short term) temperature rating of piping, if applicable, per Section 3.5.
Thermal expansion stress calculations shall also consider piping design minimum temperature per Section 3.4. 2.3.7. Piping metallurgy for corrosion resistance shall be selected in accordance with maximum sustained operating temperature without adding 50F allowance of paragraph 3.3.1. If appropriate for corrosion resistant/time duration, higher temperature basis of paragraph 3.3.2 shall be used. Except if multiple design pressure/temperature combinations are used as described in Section 3.2, paragraph 3.2.6 piping design temperature shall be considered to be coincident with piping design pressure.
2.3.8.
2.4.
Design Minimum Temperature Design minimum temperature of piping shall be determined on the basis of the following: 2.4.1. Design minimum temperature of piping shall not exceed winter dry bulb design temperature except for any of the following: 2.4.1.1 2.4.1.2 2.4.1.3 2.4.2. Piping that is located inside a heated building. Piping that is heat traced and insulated. Piping that is underground.
Design minimum temperature of piping subject to autorefrigeration caused by low pressure vaporization of a volatile liquid, such as propane, shall not be greater than atmospheric pressure boiling temperature of liquid. If liquid is a mixture, bubble point temperature of mixture at atmospheric pressure shall be used. (Note ASME B31.3 provision for exempting impact testing at lower temperatures if pressure and longitudinal stresses are low).
2.5.
Occasional Variations (Short Term Conditions) Rating 2.5.1. 2.5.2. Occasional variations refer to occasional, short duration variations of pressure, temperature, or both above piping design pressure and temperature. Occasional variations (short term pressure and/or temperature) ratings may be used for conditions other than those outlined in Section 3.2 and 3.3, they shall conform to requirements of ASME B31.3.
2.6.
Steam out Philosophy 2.6.1. In steaming out equipment and piping systems, during a shutdown or in preparation for start-up, steam (normally medium pressure) is bled into system toward a large piece of equipment where sufficient vents and drains are open to prevent appreciable pressure buildup. Steam-out design shall be based on premise that piping and equipment are at no time subject to steam pressure above 50 psig or to metal temperatures above 300F.
2.6.2.
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2.7.
Line Designation Tables A tabulation of the following information shall be provided for each line: Line number. Normal pipe size. Service symbol per SP-PI-PP-002. Piping Material Service Specification (PMSS) per SP-PI-PP-002. Insulation type, thickness, and heat tracing. Line service or fluid handled. Line origin. Line termination. Process design flow rate. Maximum sustained operating pressure. Maximum sustained operating temperature. Line design pressure. Line design temperature. Line design minimum temperature. Occasional (short term) pressure rating, if used. Occasional (short term) temperature rating, if used. Pipe material. Pipe wall thickness or schedule. Corrosion allowance. Pressure test fluid and test pressure. Remarks.
. 3. EQUIPMENT LOCATION AND ACCESSIBILITY 3.1. Definitions 3.1.1. General 3.1.1.1 The limits described in this sections shall be observed if location and accessibility are specified, unless either: More restrictive limits are specified (in this or other specifications) for individual pieces of equipment. Engineering warrants special consideration for abnormal conditions, such as equipment located in pits or congested areas.
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3.1.1.2 3.1.2. At Grade 3.1.2.1 3.1.2.2
Grade in this specification means the high point in paved areas and actual elevation at the point involved for unpaved areas. Mechanism or part to be operated, serviced, or maintained shall be neither less than 6 inches nor more than 7 feet above grade. An elevation of 4 feet above grade is a convenient working elevation and shall be maintained as closely as the configuration of piping will permit.
3.1.3. 3.1.4.
Accessible for Operation from Grade Mechanism or part to be operated shall be no more than 7 feet above grade. Accessible from Grade Mechanism or part to be operated, serviced, or maintained shall be 14 feet or less above grade without obstruction above, alongside, or below which would prohibit maintenance from a portable ladder or a scaffold.
3.1.5.
On a Platform Equipment or part shall be: 3.1.5.1 3.1.5.2 Entirely within perimeter of platform. Neither less than 6 inches nor more than 7 feet above platform. Equipment or part shall be located for convenient operation, servicing, or maintenance either on, next to, or above a platform. Where equipment or part is located next to a platform, center of operating mechanism shall be not more than 1 foot 6 inches outside of handrail and neither more than 5 feet nor less than 6 inches above platform. Where equipment or part is located above a platform, top of mechanism shall be neither more than 7 feet nor less than 6 inches above platform.
3.1.6.
Accessible from a Platform 3.1.6.1 3.1.6.2
3.1.6.3
3.1.7.
Accessible from a Permanent Ladder Mechanism or part to be operated, service, or maintained shall be no more than 3 feet from centerlines of a permanent ladder.
3.1.8.
Accessible for Operation Equipment shall be either : Located at grade Accessible for operation from grade. On a platform.
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Accessible from a platform. Accessible from a permanent ladder. Minimum clearances for equipment, structures, platforms, and supports shall be in accordance with the following table: Item ROADS Description Clearance
Headroom for primary access roads (from 21 0 the crown) Width of primary access roads excluding 5 20 0 foots shoulders Headroom for secondary roads (from the 12 0 crown) Width of secondary roads excluding three 10 0 foot shoulders
RAILROADS
Clearance from edge of roads shoulders to 5 0 platform, equipment, pipe associated with equipment, or similar features. Headroom over through-rails (from top 22 6 ** rail) Clearance from over track centerline to 10 0 ** obstruction
MAINTENANCE Horizontal clearance for equipment 10 0 ACEESS WAY AT maintenance by hydraulic crane (12T GRADE capacity) Vertical clearance for equipment 12 0 maintenance by hydraulic crane (12T capacity) Horizontal clearance for fork lift and 6 0 similar equipment (5000 lbs. Capability) Vertical clearance for fork lift and similar 8 0 equipment (5000 lbs. Capability) Horizontal clearance for equipment 3 0 maintenance by portable manual equipment (A-frames, hand trucks, dollies, or similar equipment) Vertical clearance for equipment 8 0 maintenance by portable manual equipment (a-Frames, hand trucks, or similar equipment). WALKWAYS Horizontal clearance, not necessary in a 2 6
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straight line Headroom (except for hand-wheels) PLATFORMS Minimum width Headroom from stairwell treads 7 0 2 6 7 0
Minimum clearance around any obstruction 1 6 on the platform Headroom Maximum vertical distance between Minimum to clearance behind a ladder Minimum handrail clearance EQUIPMENT 7 0 30 0 0 7 0 3
Minimum maintenance space required 1 6 between flanges of exchanger or equipment arranged in pairs Minimum maintenance space required for 1 0 structural member of pipe
FIRED EQUIPMENT
Clearance from edge of road shoulder (the 5 0 extreme projection) Horizontal clearance from hydro-carbon 50 0 equipment (shell to shell) Except: Reactors or equipment in alloy of roads to shell
Clearance between from edge of roads to 10 0 shell VALVE HANDWHEELS PIPE (aboveground) Clearance between the outside of hand 0 1 * wheel and any obstruction Clearance between the outside diameter of 0 1 * flange and the outside diameter of pipe insulation Clearance between the outside diameter of 0 2 * pipe, flange, of insulation and structural member * With full consideration of thermal movements. ** 3.2. Accessibility General 3.2.1. Provide a means of egress (a continuous and unobstructed way of exit travel) from any point in a building, elevated equipment, or structure. Verify conformance regulations with local
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3.2.2. 3.2.3.
Provide a secondary means of escape where the travel distance from the furthest point on a platform to an exit exceeds 75 feet. Access to elevated platforms shall be by permanent ladder. The need for stairways shall be determined by platform elevation, number of items requiring attention, observation and adjustment, and the frequency of items. Indicate stairways at structures on the plot plan. Provide safety cages and ladders per applicable details of COMPANY Safety in Designs. Ladder safety devices such as safety belts and harnesses, may be used on boiler, flare stack, water tank, and chimney ladders over 20 feet in unbroken lengths in lieu of cage protection and landing platforms. Refer to OSHA 1910.27 (d)(5). Arrange equipment, structures, and piping to permit maintenance and service by means of mobile equipment. Provide permanent facilities as indicated on the plot plan where maintenance by mobile equipment is impractical. Provide a clear access area at grade for vessels with removable internals or for vessels requiring loading and unloading. Exchangers with removable tube bundles shall have maintenance clearance equal to the bundle length plus 5 feet measured from the tube sheet. Provide sufficient access and clearance at fired equipment for removal of tubes, soot blowers, air preheater baskets, burners, fans, and other related serviceable equipment. Plant roads may be used as tube pull areas.
3.2.4. 3.2.5.
3.2.6.
3.2.7. 3.2.8. 3.2.9.
3.2.10. 3.3.
Accessibility of Valves 3.3.1. General 3.3.1.1 3.3.1.2 3.3.1.3 3.3.2. 3.3.2.1 3.3.2.2 Convenient operation from grade shall be preferred. Block valves in lines shall be located as low as possible without deviating from normal piping configuration. Accessibility requirements described in Section 5.3.2 shall be met. Block valves and check valves at vessel nozzles and relief valves shall be located on a platform. Operating valves, emergency valves, and unit limit block valves shall be accessible for operation from grade, be located on a platform, or be accessible from a platform. Actuated valves that are remotely operated shall be accessible from grade or from a platform. Except as otherwise noted, the following block valves or valves associated with intruments listed below shall be accessible for operation: Displacement level instruments.
Accessibility Requirements
3.3.2.3
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Gauge glasses. Other instrument block valves. 3.3.2.4 Valves in underground lines with any of the following characteristics shall be located in a valves box for access: Valves that require periodic blinding. Valves in steam, condensate, and corrosive chemical service. Battery limit water line block valves (all services), including their unit side drain valves and instrument connections. 3.3.2.5 If conditions other than those listed in paragraph 5.3.2.4. exist, valves in underground lines shall be burried in earth and made accessible as follow: A hand wheel shall be located above grade with an extension stem. A vertical pipe sleeve from 6 inches above grade to bonnet that is large enough in diameter to accommodate extension stem connector for valves in unpaved areas and permit access for tightening of packing glands bolts for valves in concrete paved areas shall be provided. Pipe sleeves may be reinforced concrete, cast iron, or steel (standard wall minimum). Gear boxes for gear operated valves shall be located approximately 3 feet above grade with a housed extension stem. 3.4. Instrument Location and Accessibility 3.4.1. General 3.4.1.1 3.4.1.2 3.4.2. 3.4.3. Instrument that are required to be located in relation to a platform shall be located at platforms used for other purposes. If no platform is available at desired location, a permanent platform shall be provided.
Pressure Relief Valves Pressure relief valves shall be accessible from grade or on a platform. Control Valves 3.4.3.1 3.4.3.2 3.4.3.3 Control valves shall be located at grade or on a platform. Top of valves positioner shall not be more than 6 feet above grade or a platform. If plug must be removed from bottom of valves, 6 inch minimum distance above grade or a platform shall be increased to conform to valve manufacturers recommendation. Exceptions may be made if overall dimensions of valve exceed these limitations.
3.4.3.4
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3.4.4.
Liquid Level Displacement Instruments 3.4.4.1 Level displacement instrument pilot mechanisms shall be accessible from grade or a platform, except that distance above a platform to top of pilot mechanism case shall be limited to 5 feet. Where located on a platform, necessary clearance shall be provided. Where located next to a platform, center of float cage shall be no more than 1 foot outside of handrail. Face of pilot mechanism shall be oriented such that it is accessible and visible from platform.
3.4.4.2 3.4.4.3
3.4.5.
Orifice Flanges (Including Block Valves) Orifice flanges and their block valves and other flow metering devices shall be accessible from grade or from a platform. Where accessible from a platform, they shall be located at an elevation that permits line mounted transmitter accessibility.
3.4.6.
Pressure Gauges Pressure gauges and associated valves shall be accessible from grade, from a platform, or from a permanent ladder or located on a platform.
3.4.7.
Thermocouples, Bimetal Thermometers, and Wells Thermocouples, bimetal thermometers, and wells shall be accessible from grade, from a platform, or located on a permanent ladder.
3.4.8.
Gauge Glasses and Gauge Columns Gauge glasses and gauge glass columns (and all associated valves) shall be accessible for operation.
3.4.9.
Pressure Points and Block Valves In Piping Pressure point connections and block valves in piping shall be either: 3.4.9.1 3.4.9.2 3.4.9.3 Located on a platform. Accessible from grade. Accessible for operation from either: Grade. A platform. A permanent ladder.
3.4.10.
Pneumatic or Electronic Transmitters Pneumatic or electronic transmitters for temperature, pressure and flow shall be mounted no higher than 5 feet above grade or platform.
4.
PIPING DESIGN AND ARRANGEMENT GENERAL
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4.1.
General 4.1.1. 4.1.2. 4.1.3. Piping shall be fabricated and examined accordance with SP-PI-PP-004. Field welds piping that passes through column lines of structures, foundations, platforms, or grade shall be located at least 1 foot outside of or above such items. The following bolted flanged connections shall be installed using bolt tensioners; 4.1.3.1 4.1.3.2 4.1.3.3 4.1.4. 4.1.5. Class 900, NPS 12 and larger, service above 500F. Class 1500, NPS 8 and larger. Class 2500, NPS 4 and larger.
Live loading (Belleville springs-washers) shall be considered for flange bolting in high temperature or cycling services that have a history of flange leaks. Unless specified otherwise, all low points shall have drain connections with 2 block valve, all high points shall have vent connection with 1 block valve.
4.2.
Elevations 4.2.1. Piping within unit limits shall be located overhead, except as follow: 4.2.1.1 4.2.1.2 4.2.1.3 4.2.2. Drainage lines. Pump suction lines that do not take suction from elevated equipment. Fire water mains.
Overhead lines within or adjacent to pipe racks shall be located at specific elevations. Longitudinal and transverse lines shall be located at different elevations. Elevations shall be selected to avoids restrictions of pipe rack space.
4.3.
Change in Direction 4.3.1. Piping shall not be run diagonally except as follows: 4.3.1.1 4.3.1.2 4.3.1.3 4.3.2. For short runs close to radial equipment nozzles. To simplify piping near exchanger connections. To obtain substantial savings.
Long diagonal runs shall avoids elevations used for regular banks of piping. Changes in direction shall be made with either 1 radius weld elbows, threaded or socketweld elbows (if permitted in PMSS), or pipe bends. 4.3.2.1 Choice of ells or bends shall be based on overall cost. However, orderly appearance of plant nor orderly spacing of pipes in pipeways shall be sacrificed to obtain savings gained by using occasional pipe bends. If available space does not permit use of 1 radius weld elbows, short radius weld ells may be used.
4.3.2.2 4.3.3.
If specified or approved by COMPANY, an overall design using larger radius bends (such as NPS 4) may be considered if:
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4.3.3.1 4.3.3.2 4.4. Injection Points. 4.4.1. 4.4.2. 4.4.3.
An overall savings in energy is realized. It can be determined that available pipe fabrication (bending) facilities will provide competitive costs and schedules to support construction.
Injection of water, steam, chemical, or other media into piping on a regular or continuous basis sometimes causes accelerated corrosion and/or erosion. Selection of materials and locations and design of injection points shall include consideration of this phenomenon. Effects shall be considered to be limited to the following: 4.4.3.1 4.4.3.2 Upstream limit of effects is a minimum of 1 foot or 3 pipe diameters upstream of injection point, whichever is greater. Downstream limit of effects is the second change in flow direction or 25 feet beyond first change in flow direction, whichever is less.
4.5.
Pockets and Dead Ends 4.5.1. Two phase lines and overhead vapor lines shall not have pockets. Pockets in other lines should be avoided. If pockets cannot be avoided, line shall have suitable drains. Dead end piping shall not be used to reach a support. If necessary, dummy leg supports shall be used. Dead legs shall be minimum by locating block valve close to flowing pipe for vents, drains, and other branches that are normally not flowing.
4.5.2. 4.5.3. 4.6.
Unit Blocks 4.6.1. General 4.6.1.1 4.6.1.2 Lines enter or leave process unit limits shall have block valves. Unit limit block valves in gas or vapor service, where condensate may freeze, shall be located in a horizontal run of line to prevent freezing of condensation during down periods.
4.6.2.
Air, Steam, and Water Lines Lines from headers that service more than one unit shall have block valves located outside unit limits.
4.6.3.
Overhead Process Lines Lines crossing process unit limits shall have a block valve inside unit limits and include a drain in piping on unit side of block.
4.6.4.
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Underground Process Lines

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Lines crossing process unit limits shall: Have a block valve located above grade at the point where line enters or leaves paving. Include a drain in piping on unit side of block. Block valve provided at the pump meets this requirement for underground suction lines to pumps located inside process unit limit. 4.7. Unit Pumpout/off Test System 4.7.1. 4.7.2. 4.8. Pumpout facilities for emergencies or normal shutdowns shall be designed in accordance with DP 70. Product lines that must connect to off test lines shall be manifolded inside and near unit limits.
Precommissioning Flushing drains and break spools shall be considered for precommissioning.
4.9.
Break Joints 4.9.1. 4.9.2. 4.9.3. 4.9.4. Lines connected to vessels with weld and nozzles shall have a flanged joint. Flanged joint shall be used for blinding after purging and freeing line and vessel of gas to permit entry into the vessel. Flanged joint may be at first flanged equipment connection away from vessel. Flanged joint shall be located to avoid high or low trapped points in line between joint and vessel. If possible, high point of line shall vent back to vessel. If such venting is not possible, a valved vent to atmosphere shall be provided. Flanged joint shall be either: Accessible from grade. On a platform.
4.9.5.
4.10.
Insulation Support Rings Insulated NPS 3 and larger lines that are vertical or which slope at an angle less than 60 degrees from vertical shall have insulation support rings.
4.11.
Insulating Pipe Flanges (Electrical) Insulated flanges for electrical isolation shall conform to manufacturers recommendations.
4.12.
Vents in Piping 4.12.1. 4.12.2. High points of suction lines, except those that self vent to vessels by sloping up to towers, shall have valved vent connections to vent during operation. If air cannot be admitted to high points by other existing means, high points of lines NPS 3 and larger that must be drained shall have valved vents.
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4.12.3.
High points of piping NPS 3 and larger shall have valved vents as require for hydrostatic testing in accordance with the following: 4.12.3.1 Steam lines that require hydrostatic testing shall have NPS 1 threaded valves on schedule 160 nipples welded in line. After initial test, nipple shall be cut to inch in length and sealed with a weld cap. 4.12.3.2 Vents on other lines shall be valved, be minimum size, and conform to applicable PMSS.
4.12.4.
Valved vents open to atmosphere in hydrocarbon, hydrogen, steam, or chemical service shall have a cap, plug, or blind flange on atmospheric side of valve. Socketweld vent valves shall have a short pipe nipple with pipe one end threaded and capped. Where vents from equipment under pressure or piping under pressure have extended piping downstream of block valve and more than one turn in line and threaded fittings, line shall be supported to prevent whipping. If possible, vent connections shall be located in accessible locations adjacent to platforms or structural members. Vents located below grade on underground lines shall consist of a threadolet, nipple, and valve. After testing is completed, nipple and valve shall be removed, and plug shall be installed and seal welded to threadolet. Provide plugged hydrostatic vent. Single block valve for class 300 and below and double block valve in class 600 and higher.
4.12.5.
4.12.6. 4.12.7.
4.12.8. 4.12.9. 4.13.
Drains in Piping 4.13.1. 4.13.2. 4.13.3. Piping system shall have valved drains at all low points. Points with no other means to drain pockets of liquid that might from above a control or block valve shall have valved drains. Unless they serve as drains for large equipment (exchangers, etc.), 4.13.3.1 NPS inch for NPS 14 and smaller piping and NPS 1 for NPS 16 & larger piping 4.13.3.2 Single block valve for class 300 and below and double block valve in class 600 and higher. 4.13.4. Drains in piping from exchangers: 4.13.4.1 Sized in accordance with SP-ME-VS-001. 4.13.4.2 As a minimum NPS 1 . 4.13.5. If a vessel requires steam-out or purging for cleaning or entry, all lines connected to vessels without a block valve at vessel connection shall have a valved steamout drain. To permit complete purging of line or lines vessel, drain shall be located on vessel side of and adjacent to first block valve in the line or block valve in each branch line.
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4.13.6.
Valved drains open to atmosphere in hydrocarbon, hydrogen, steam, or chemical service shall have a cap, plug, or blind flange on atmospheric side of valve. Socketweld end drain valves shall have a short pipe nipple with one end threaded and capped. Drain valves for operating drains, such as water drawoffs, or sample valves open to atmosphere in hazardous services, such as services with H2S or LPGs, shall have dead-man handles (auto close). If specified drain valve is a gate valve, a ball valve shall be added. Low point piping drains shall require dead-man handles. Drains located below grade on underground lines shall consist of a threadolet, nipple, and valve. Unless approved by COMPANY, drain rings shall not be used.
4.13.7.
4.13.8. 4.13.9. 4.14.
Drains Piping (Aboveground) 4.14.1. General 4.14.1.1 Permanent piping shall be installed as described below between drains and sewer hubs for draining: Hydrocarbons C6 and heavier with temperature of 180F or less. Acids, caustics, or other chemicals for which special sewer system are provided. 4.14.1.2 Drains lines may be run to any oil sewer hub within a 15 foot maximum horizontal radius of drains, provided a tripping hazard is not created. 4.14.1.3 Piping arrangements shall not create tripping hazards or limit access. 4.14.1.4 Support for drains lines shall conform to requirements for supports for vent lines described in Section 6.12.5. 4.14.2. Vessels 4.14.2.1 Drains shall be valved and blinded. 4.14.2.2 Drains shall be piped to terminate approximately 2 inches above a sewer hub at grade. 4.14.2.3 Piping downstream of blind shall be standard weight carbon steel (Sch. 80 for NPS 1 1/2 and smaller). 4.14.3. Pumps 4.14.3.1 Pumps in services described in Section 7.3.4 shall have case drains piped to sewer hub located at end pump foundation. 4.14.3.2 Construction of such piping shall conform to PMSS of pump discharge piping (except all welded construction as a minimum). Piping shall consist of the following: Schedule 160 minimum nipple, either welded or threaded and seal welded to case. Socket welded (unless PMSS specifies butt welded or flanged)
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valve mounted as close to pump case as practical. API 602 extended body valve welded directly to pump case shall be preferred. Socket welded union (unless PMSS specifies flanged) for removing drain pipe. Drain pipe terminating approximately 2 inches above top of hub. Threaded cap. 4.14.4. Compressor Cases Drains shall be piped in accordance with Section 6.14.3 to a hub or floor drain on compressor deck or to grade. 4.14.5. Elevated 4.14.5.1 Equipment or piping drains at elevated locations (e.g, elevated compressor decks and condenser system structures) shall have drain piping (not directly connected to piping or equipment drain) run from those locations to grade. 4.14.5.2 Drains piping shall end approximately 2 inches above sewer hub.
4.14.5.3 Drain piping shall be: Standard weight carbon steel pipe (Sch. 80 for NPS 1 ). NPS 1 minimum size. 4.14.5.4 Drain piping shall have funnels, swages, or reducers at each level where draining is anticipated. 4.14.6. Unit Block Valves Lines at unit limit block valves shall be drained to a collection pan or pipe trough installed and piped to a sewer hub at grade. 4.14.7. Reservoirs Reservoirs (30 gallons or more) shall have permanent drain lines routed to sewer hubs. 4.15. Blinds 4.15.1. Operational Blinds 4.15.1.1 Operational blinds shall be supplied for the following: Isolating equipment during operation of a process unit. Isolating equipment for repair or inspection if whole unit has not been gas freed. Testing various sections of unit. Testing equipment.
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Preventing leakage during operations. 4.15.1.2 Operational blinds shall be supplied on the following: Each fired heater. a. Fuel gas supply line to heater line blind (Hammer or COMPANY approve equal). b. Pilot gas supply line to heater line blind (Hammer or COMPANY approve equal). c. Atomizing steam to heater. d. Snuffing steam to heater. e. Fuel oil supply to heater. f. Fuel oil return from heater. g. Soot blower steam supply line. h. Process lines in and out of heater, including steam lines. i. Flue duct on each heater if duct is common to more than one heater. These blinds shall be designed for safe installation without entry into duct. Heat Exchangers (Shell and Tube or Air Fan Coolers). a. Exchanger or series of exchanger in the same service shall have shell and sides blinded in and out of exchanger (or series if more than one is involved). b. Shell and tube exchanger in parallel banks shall be blinded on shell and tube in and out on each bank. Compressors. Each compressor on compressor side out suction and discharge block valves. Pumps Each pump, that is spared, on pump side of suction and discharge block valves. Vessels. All lines, including steam lines, in and out of vessel at vessel nozzles. With COMPANY approval, the following may be excluded: a. Overhead vapor line from fractionator to shell and tube condenser: Blind shall be provided for all lines in and out of overhead accumulator drum such that fractionator-accumulator drum system can be gas-freed and blinded off as a system. b. Overhead vapor line from fractionator to air fan condenser: Blind shall be at inlet to air fan condenser, and steam-out drain (s) shall be provided at low point in line upstream and adjacent to blind. c. Large FCCU catalyst lines and overhead vapor lines to fractionator.
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Unless spare reboilers are provided, blinds shall not be required on reboiler systems. Vents and drains open to atmosphere in hydrocarbon, hydrogen, steam, or chemical service shall have a blind on atmospheric side of valve. If a block valve or blind is not provided at vessel nozzles, a blind shall be required on vessel side of first block valve in line. Steamout drain at this location shall conform to Section 6.13. Steam to hydrocarbon piping connections: Blinds shall provided at all points where steam lines that are not used for process or emergencies are permanently connected to hydrocarbon lines. Blinds shall not be required on steam lines that have swing ells for isolation. All process lines and all lines that contain toxic or hazardous materials which enter or leave process units shall be blinded as follows: a. Operational blinds shall be provided on unit side of all unit limit block valves (see Section 6.6). b. Blinds shall be installed on pump side of block valve on underground suction lines to pumps, where unit limit block valve is located at pump. Figure 8 blinds shall not be installed in cold insulated piping systems. If piping cannot be sprung for installation of blinds, spacers shall be provided. Operational blinds shall be accessible either from grade or on a platform. If access with mobile equipment is not possible, handling davits shall be provided for all blinds or spacers weighing more than 150 pounds. Exposed finished surfaces of blinds shall be greased for protection after installation. 4.15.2. Piping System Isolation 4.15.2.1 A positive means of isolating interconnected piping systems shall be provided for maintenance and testing (e.g., vents, PSV bypasses, blowdowns, and other connections between process services and flare system or utility to process piping). 4.15.2.2 Isolating may be provided by double block and bleed valves, operational blinds or, for small threaded or socket welded lines, a set of flanges. 4.15.2.3 If equipment of system can be isolated without shutting down an entire unit, above provisions shall be provided in any interconnected lines to other equipment or systems (blowdown lines, etc.). 4.15.3. Construction Test Blinds
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4.15.3.1 Blinds necessary for testing lines and equipment during construction, other than those specified in Section 6.15.1 shall furnished with initial installation. 4.15.3.2 These blinds shall be removed from joints before installation can be accepted mechanically. 4.16. Utility Stations 4.16.1. General 4.16.1.1 Utility hose stations for steam, water and air shall be provided at convenient locations throughout process units. 4.16.1.2 Stations shall be provided at fired heaters, heat exchanger groups (including air fan coolers), tower groups, pump groups, at compressor, and at each main working level in elevated structures. 4.16.1.3 If specified, nitrogen stations shall be provided. 4.16.1.4 Utility stations shall be located such that no more than 50 feet of hose is required to service a piece of equipment. 4.16.1.5 Provide spectacle blinds as indicated on the P&IDs. 4.16.1.6 Spectacle blinds shall be accessible from grade or platform. Blinds located in a pipeway are considered accessible. Blinds that weigh over 100 Ibs shall be accessible by mobile equipment. Where this is not possible, provide davits or hitching points. 4.16.1.7 Stagger closely grouped flanges with blinds. 4.16.2. Air Hose Stations 4.16.2.1 In addition to utility hose stations, air hose stations shall be located to permit removal of bolts from manways, exchanger, and similar large bolted connections with an air tool and not more than 50 feet of hose. 4.16.2.2 Manways or large bolted connections more than 20 feet above grade shall have a station at platform serving manway or connection. Station shall be mounted on top of handrail. 4.16.2.3 Air hose stations shall not be required at remote locations where portable air compressors can be used for maintenance (e.g., tank farms). 4.16.3. Steam Hose Stations 4.16.3.1 Utility steam service shall have intermediate pressure steam. 4.16.3.2 If normal operating pressure of steam exceeds 180 psig, a 7/16 inch union mounted restriction orifice shall be installed immediately upstream of hose station valve. 4.16.3.3 Steam supply piping shall be arranged as an auxiliary branch that can be blocked off without affecting operations. 4.16.4. Hot Water Stations
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4.16.4.1 If specified, hot water stations shall be provided. 4.16.4.2 Station shall have mixing devices that mix steam and service water. Mixing devices shall manufactured by Vendor or COMPANY approved equal. 4.16.5. Utility Hose and Couplings 4.16.5.1 Hose couplings at utility stations shall conform to plant standards. 4.16.5.2 Nitrogen connections shall be unique such that they cannot be mixed with air, steam, or water. 4.16.5.3 Utility hose will be furnished by plant. 4.17. Instrument Piping 4.17.1. Connections 4.17.1.1 Instrument connections, including size, schedule, flange rating, and block valve specifications, shall conform to PMSS. 4.17.1.2 Connections not defined by PMSS or not otherwise specified shall conform to minimum size and schedules specified in SP-PI-PP-002.
4.17.2.
Piping Details Specific requirements for piping between instrument and it block valve or piping associated with instruments, such as orifice runs, control valves, pressure relief valves, and gauge glass columns, are typically defined in instrument specifications.
4.17.3.
Accessibility Accessibility shall conform to Section 5.4. 4.17.3.1 Locate liquid level controllers and level glasses so as to be accessible from grade, platform, or permanent ladder. The level glass shall be readable from grade wherever practical. 4.17.3.2 Relief valves shall be accessible. Wherever feasible, locate them at platforms that are designed for other purposes. Relief valves with a centerline elevation over 15 feet above high point of finish surface (except in pipeways) shall be accessible from platform or permanent ladder. 4.17.3.3 Install thermal relief valves, 1 inch and smaller, in a horizontal position when it is impractical to install in the vertical position. Install relief valves, 1 1/2 inch and larger, in a vertical position. 4.17.3.4 Normally, install relief valves that discharge to a closed system above the collection header. There shall be no pockets in the discharge line.
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4.17.3.5 Relief valves that discharge to the atmosphere shall have tail pipes extended to a minimum of 8 feet above the nearest operating platform that is within a radius of 25 feet. 4.17.3.6 Do not locate relief valves discharging hydrocarbon vapors to the atmosphere within 100 feet of fired equipment for vapor dissipation. 4.17.3.7 Indicate control, block, and bypass valve sizes on the P&IDs. Control valves shall be accessible from grade or platforms. In general, the instruments or indicators showing the process variables shall be visible from the control valve. 4.17.3.8 Orifice runs should be located in the horizontal. Vertical orifice runs may be used with the approval of COMPANY. Orifice flanges with a centerline elevation over 15 feet above the high point of finished surface, except in pipeways, shall be accessible from a platform or permanent ladder. 4.17.3.9 Orifice taps shall be located as follows: Air and Gas Top vertical centerline (preferred) Liquid and Steam Horizontal centerline (preferred) The piping isometrics details shall show the required tap orientations. 4.17.3.10 Temperature and Pressure Instrument Accessibility and Visibility Temperature test wells located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by a portable ladder. Those located over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder. Temperature and pressure indicators shall be visible from grade, permanent ladder, or platform. Thermocouple and temperature indicators located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder. Local pressure indicators shall be visible from grade, permanent ladder, or platform. Those located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or
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permanent ladder. Siphon/Pig tail and gate valve should be installed in pressure indicator on steam lines. 4.17.3.11 Provide utility stations with water, steam, or air as indicated below. Use a single 50 foot length of hose to reach the entire working area from the station. Hose, hose rack, and hose connections shall be provided by COMPANY. Provide water outlets at grade level only, in pump areas, and near equipment that shall be water washed during maintenance. Provide steam outlets at grade level only in areas subject to product spills, and near equipment that requires steaming out during maintenance. Provide air outlets in areas where air-driven tools are used such as at exchangers, both ends of heaters, compressor area, top platform of reactors, and on columns, so that each manway to be serviced is within the reach of a 50 foot hose. 4.18. Safety Showers and Eyewash Fountains 4.18.1. Potable water safety showers and eyewash fountains shall be provided wherever hazardous chemical, such as caustic, acid, or other injurious and corrosive materials, are handled. This requirement shall apply to laboratory, as operating areas. Safety showers and eyewash fountains shall be located within 25 feet of hazardous materials area. If concrete paving is not present, shower shall have 4 inch thick and 2 foot square concrete slab underneath. Dimly lit areas shall have a green 25 watt electric bulb near safety shower. Shower/eyewash location shall be identified with 4 inch wide green and white diagonal stripes painted on four sides of column or other background available at that location. Striped area shall extend from 2 feet above grade to 6 feet above grade. Eyewash fountains shall be 30 to 36 inches above grade.
4.18.2. 4.18.3. 4.18.4. 4.18.5.
4.18.6. 4.19.
Sample Connections 4.19.1. 4.19.2. 4.19.3. 4.19.4. 4.19.5. Sample connections shall be separately defined in detailed drawing. Sample coolers shall be standard commercial type. Provide sample and test connections as indicated on P&IDs. They shall be readily accessible from grade or platform. In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free running of the liquid before sampling. Note samples that require cooling on the P&IDs, and provide a cooler.
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4.20.
Clearances 4.20.1. General 4.20.1.1 Clearances shall conform to the following; Except for special cases at manifolds and other equipment located at grade or vessels in structures, the following minimum overhead clearances shall be maintained above high point finished paving or above platforms within process unit limits: a. At least 16 feet of clear headroom over areas designed as tube bundle handling areas for exchanger at grade, trucking areas, and roadways inside adjacent to process units limits. The minimum clearance of 12 feet x 12 feet for servicing equipment under process unit main pipe racks shall be excluded. b. At least 6 feet 8 inches of clear headroom over platform and walkways. This minimum clear headroom shall also apply to piping at grade, close to equipment. The minimum of 8 feet high shall be observed for all other horizontal piping that crosses process unit passage ways and working areas. For minimum lateral and vertical spacing, lines supported on sleepers at grade or on overhead pipe supports shall be assumed to have staggered flanges. Minimum line spacing shall be determined by providing at least 1 inch of clearance between the outside of one line flange (or flange insulation if insulated) and the outside of adjacent line (or line insulation if insulated). Pumps, Compressors, and Drivers Sufficient space shall be provided at and around pumps, compressors, and drivers to enable maintenance and removal of all internal and external parts. Control Valves Control Valves shall be located such that front of valve manifold as a minimum has 2 feet 6 inches of access.
4.21.
Block Valves 4.21.1. Emergency Block and Depressuring Valves Emergency block valves to isolated equipment and systems or to depressure system in emergencies. 4.21.2. Branch Line Block Valves 4.21.2.1 Primary branch lines are branches that are connected directly to main header in the pipe rack. Utility service primary branch lines shall have block valves except in: Services in which main header may be shut off without affecting unit operating in event of failure in branch line.
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NPS 3 and larger cooling water branches. 4.21.2.2 Secondary branch lines are branches that are connected to primary branches. Utility service secondary branch lines do not require block valves except in steam service in which some secondary branches from a single primary branch are in intermittent service and some from the same primary branch are in continuous service. Where this occurs, intermittent service lines shall have a branch line block valve. 4.21.2.3 Steam branch line block valves shall be located in horizontal run of branch. 4.21.2.4 Except as specified in paragraph 6.21.2.5, primary branch line block valves shall be located at outside edge of pipe rack. Unless specified otherwise, access for operation (platform or chain wheels) shall not be provided. 4.21.2.5 Take-off valves shall be provided at intervals of 25 feet along the main instrument air header. 4.21.3. Block Valves at Change of Specification Block valves between lines or between lines and equipment of different services shall conform to the most severe service, except: Valves at vessel process steam or steam-out connection shall be of type material required for vessel service. Resilient seats shall not be used if steam temperature exceeds seat limitations. Rating of valve shall be suitable for maximum condition governed by vessel or steam conditions. 4.21.4. Double Blocks and Bleeder Double block valves and bleeder shall not be used, except follows: 4.21.4.1 To prevent contamination of product. With COMPANY approval, single positive shut-off valves with integral bleed may be substituted for double blocks and bleeder for this service. 4.21.4.2 To provided back-up valve if valve on drain or vent freezes due to vaporization of light hydrocarbon. 4.21.4.3 As required for pumps vents per Section 7.3.5. 4.21.4.4 Steam supply branches permanently connected to hydrocarbon lines. 4.21.4.5 If specified, vessel drain valves. 4.21.5. Valve Operating Devices 4.21.5.1 NPS 14 and larger gate valves shall have gear operators. 4.21.5.2 For frequently operated gate valves, gear operators for smaller valves shall be considered as follow: a. Class 300 NPS 12 and larger. b. Class 600 NPS 10 and larger. c. Class 900 NPS 6 and larger.
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4.21.5.3 Quarter turn valves shall conform to valves description. Smaller sized valves shall conform to manufacturers standard or recommendations for gear operators. 4.21.5.4 If remote mechanical valve operating devices are required, chain operators shall be used in preference to valve extension stems on overhead valves larger than NPS 1 . 4.21.5.5 Chain operators shall not be used on valves NPS 1 and smaller. 4.21.5.6 Valves with chain operators or hand wheel extensions shall not have threaded end connections. 4.21.5.7 Valve extension stems, chain wheels, and associated supports shall be galvanized. 4.21.5.8 Valves that are required to be locked open or closed shall have chain or bar devices for use with padlocks. Padlocks to suit master lock system will furnished by COMPANY. 4.21.5.9 Valve Operation Indicate operating valves requiring attention, observation, or adjustment during normal plant operation on the P&IDs with the symbols O.V. They shall be located so as to be within reach from grade, platform, or permanent ladder. Operating valves may be chain-operated if the bottom of handwheel is over 7 feet above high point of finished surface or operating platform. The centerline of handwheel or handles on block valves used for shutdown only, located less than 15 feet above high point of finished surface, and those located in pipeways, may be accessible by portable ladder. The centerline of handwheel or handles on block valves used for shutdown only and located over 15 feet above high point of finished surface, except those located in pipeways, shall be operable from permanent ladder or platform. In general, keep valve handwheels, handles, and stems out of operating aisles. Where this is not practical, elevate the valve to 6'6" (plus or minus 3 inches) clear from high point of finished surface to bottom of handwheel. 4.22. Check Valves 4.22.1. 4.22.2. If it is required by the design, a check valve shall be provided between block valve and pump in discharge line of centrifugal pumps. Lines which connect lines or equipment of different service with potential of back flow of fluid or other source of backpressure that could create a hazardous condition shall have a check valve.
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4.22.3.
Steam supply lines to heat exchangers shall have check valves if maximum operating pressure of fluid being heated is the same or higher than steam line pressure. Check valves on a line flowing into a pressure vessel shall be located in a horizontal position, such that downstream side will be self draining in to vessel. Steam supply branches permanently connected to hydrocarbon lines shall have a check valve.. Two check valves in series shall be considered in the following situations: 4.22.6.1 A single check valve failure would result in a relief case. 4.22.6.2 A single check valve failure could destroy mechanical equipment through unrestricted reverse flow.
4.22.4. 4.22.5. 4.22.6.
4.23.
Pipe Plugs Pipe plugs in tapped connections in piping and equipment that are not required to be removed during operation and maintenance shall be seal welded in hydrocarbon, hydrogen, chemical, and steam services.
5.
PIPING DESIGN AND ARRANGEMENT SPECIFIC SERVICES 5.1. Vessel Piping 5.1.1. Wherever possible, locate piping at vessels radially about the vessels on the pipeway side; locate manway and platforms on the access side. Manways should be on or about a common centerline to make use of a common lifting device or davit. Provide platforms at manways above 15 feet centerline elevation from high point of finished surface. The maximum distance for ladder runs and space between offset platforms shall be 30 feet. Position platforms so the manhole centerline is no less than 2 feet above the platform, with 2'- 6" preferred. The bottom of the manhole entry shall not be more than 3'- 6" above the platform. Provide combined platforms, where practical and economical, at multiple tower arrangements with common manway elevations. Provide vessel davits for handling items such as internals and relief valves on vessels exceeding a height of 30 feet above the high point of the finished surface, and on vessels not accessible by mobile crane. Orient davits to allow the lowering of appurtenances into the access area. Wherever possible, orient level instruments on the side toward the pipeway. Block Valves at Vessel Nozzles.
5.1.2.
5.1.3.
5.1.4. 5.1.5.
5.1.6. 5.1.7.
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5.1.7.1
Except for pressure relief valve nozzles, block valves shall be installed adjacent to vessel on all nozzles NPS 1 and smaller and on all steam, air, water, vent, drain, and instrument connections, regardless of size. Pressure relief valves bolted directly to vessel block valves shall be readily removable without need for removal of block valves from vessel. Otherwise, a spool piece shall be furnished between pressure relief valve and block valve. Double block valves, with intermediate bleed for checking leakage or blowing out clogged drain nozzle, may be specified for towers. Unless specified otherwise in paragraph 7.1.7.1, block valves shall not be required in lines or at vessel nozzles for the following lines. Vapor lines to condensers. Liquid and vapor lines and from shell and tube reboilers. Lines from condensers to accumulator drums. Large special FCCU catalyst lines. Block valve requirements in fired heater outlet transfer lines to vessels are to be defined in a separate proposed detailed drawing. Block valves in pump suction lines are defined in Section 7.3.2.
5.1.7.2
5.1.7.3 5.1.7.4
5.1.7.5 5.1.7.6 5.1.8.
Valves or flanges shall not be located inside a vessel skirt. Valves at vessel nozzles shall be flanged valves, except in services that permit threaded couplings for vessel connections. A separate steam-out connection shall be provided to introduce steam for purging at down periods, except: Vessels in air, steam, and water service. Vessel provided with process steam. For this case, minimum size of vessel connections shall conform to SP-ME-VS-001. Special vessels with process considerations that that require other means of purging or prohibit use of steam.
Steam-out Connections. 5.1.8.1
5.1.8.2 5.1.8.3 5.2.
Type and rating of valves at steam-out connections shall be in accordance with Section 6.21.3. Snuffing steam requirements for pressure relief valves shall be discharged to atmosphere.
Heat Exchanger Piping 5.2.1. General 5.2.1.1 If necessary for bundle puller clearance, a removable section of piping shall be provided at bottom of shell and tube channel connections.
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5.2.1.2 5.2.1.3 5.2.1.4
Dimensional design requirements for standard plant bundle puller shall be provided to engineering CONTRACTOR. Grouped exchangers together wherever possible. Keep channel end and shell covers clear of obstructions such as piping and structural members to allow unbolting of exchanger flanges, and removal of heads and tube bundles.
5.2.2.
Shell and Tube Coolers and Condensers Backwash piping shall not be required for cooling water systems, such as closed tempered water and closed jacket water systems.
5.2.3.
Shell and Tube Heater (Steam) Steam and condensate piping for shell and tube heaters shall conform to SP-MEME-012.
5.2.4.
Vents and Drains 5.2.4.1 5.2.4.2 Except for vents and drains in shell and tube exchangers, venting and draining shall be accomplished in associated piping. Exchanger operating vents and shell cover drains open to atmosphere shall be valved and blinded. Non operating nozzles that were provided in channel, shell, and header box shall be blinded for testing.
5.3.
Pump Piping 5.3.1. General 5.3.1.1 5.3.1.2 Sufficient space shall be provided at and around pumps to enable maintenance and removal of all internal and external parts. In hydrocarbon or other flammable fluid service, threaded construction shall not be used for piping connected to pump, including branch piping within 6 feet of pump suction or discharge flanges or through suction or discharge block valves, whichever is greater. Socketweld unions are acceptable. Piping NPS 1 and smaller connections in piping within 6 feet of pump shall be made considered with self-reinforced fittings (sockolets, weldolets, or equal). If high differential pressure may cause reverse flow and damage to rotary equipment, two check valves in series may be considered. Precautions in Section 7.4.2 shall apply. Locate pumps close to the equipment from which the suction taken. Design piping to provide clearance for pump or driven removal. Similarly, on end suction pumps, piping shall permit removing suction
5.3.1.3
5.3.1.4 5.3.1.5 5.3.1.6 5.3.1.7
July, 2002
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cover and pump impeller while the suction and discharge valves are in place. 5.3.1.8 Arrange suction line to minimize offsets. The suction line shall be as short and direct as possible, and shall step down from the equipment to the pump. Suction line routed on sleeper ways may rise to pump suction nozzle, subject to approval of COMPANY. Orient valve handwheels or handles so they will not interfere with pump maintenance or motor removal.
5.3.1.9
5.3.1.10 The temporary strainer shall be furnished for start up proposed. 5.3.2. Suction Piping 5.3.2.1 5.3.2.2 Centrifugal pump suction lines from tankage shall be arranged to be self venting to tank, pump, or both. Pump suction lines shall have a block valve as close as practical to pump nozzles or swage at pump nozzles. Unless NPSH calculations show a smaller valve is suitable, valve shall be full line size. If suction side can be subjected to discharge pressure by leakage through discharge check valve, pump suction block valves and piping to pump shall have a pressure class or rating equal to discharge piping. This can occur if two or more pumps discharge into a common header. Inlet piping shall have a minimum of 4 diameters straight pipe, unless specified otherwise by COMPANY or Manufacturer.
5.3.2.3
5.3.2.4 5.3.3.
Discharge Piping If block valve is located at pump nozzles in discharge lines from single service pumps, valve may be same size as pump discharge nozzles, provided velocity through valve does not exceed 11 fps.
5.3.4.
Pump Case and Cylinder Drains Case drains shall be provided in accordance with Section 6.14.3 for liquids toxic or injurious to personnel and liquids subject to freezing or set up at or above minimum ambient temperatures.
5.3.5.
Pump Vents 5.3.5.1 5.3.5.2 All pump shall have a valved vent. Vent connection for pumps with top discharge nozzles shall be in pump discharge piping between pump and first valve. Other pumps shall have valved vent connected to top pump case. Valved vents shall be piped as follows: If vapor pressure of pumped hydrocarbon is greater than atmospheric pressure at pumping temperature, vents shall be piped to a closed system as follows: a. Vent piping shall be connected to flare system. In absence of flare system, COMPANY shall be consulted regarding
5.3.5.3
July, 2002
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disposal. b. Vent to closed system shall have double block valves and intermediate bleeder at pump connection. c. Vent piping shall be connected into top of closed system header. If vapor pressure of pump hydrocarbon is less than atmospheric pressure at pumping temperature or for pumps handling nonhydrocarbon materials, vents shall be piped to drains hub of appropriate sewer. Toxic, valuable, or hazardous materials or materials pumped at high pressure or temperature shall receive special consideration. If suction pressure is below atmospheric pressure, such as vacuum residuum service, vents shall be piped to vessel from which liquid is being pumped, unless pump nozzles are arranged such that pump case will vent back to vessel through suction piping. If necessary vent line shall be steam traced for liquids. 5.3.6. Suction Strainers 5.3.6.1 Temporary Strainers Suction of all pumps shall have temporary line strainers between pump suction flange and block valve. Design shall allow removal of spool piece if pump is blocked in. If a flanged spool piece exists in piping configuration that will contain and/or permit removal of a basket without additional pipe fittings, basket type strainers shall be provided. Temporary strainers shall be installed before start-up and shall be removed following start-up. Basket type temporary strainers shall as a minimum provided an open area that is 150% of cross sectional area of suction line (not pump connection). Temporary strainers shall be carbon steel unless carbon steel is not expected to serve satisfactorily for a short time (start-up). 5.3.6.2 Permanent Strainers If permanent pump suction strainers are necessary, such as in oilcatalyst slurry lines and coking service, strainers that can be cleaned in place shall be designed. If required, permanent strainers shall be installed between pump suction block valve and pump. Material for permanent strainers shall meet or exceed applicable service conditions and be at least equal in corrosion resistance to pipe material. 5.3.7. Product Recirculation
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Pumps with minimum flow less than that allowed by pump design range shall have recirculation piping from pump discharge to suction vessel for heat dissipation. 5.4. Compressor Piping 5.4.1. General 5.4.1.1 5.4.1.2 Sufficient space shall be provided at and around compressors to enable maintenance and removal of all internal and external parts. In hydrocarbon or other flammable fluid service, threaded construction shall not be used for piping connected to compressor, including branch piping within 6 feet of compressor suction or discharge flanges or through suction or discharge block valves, whichever is greater. Socketweld unions are acceptable. NPS 1 and smaller connections in suction and discharge lines within 6 feet of compressor shall be made with self-reinforced fittings (sockolets, weldolets, or equal). Distance between knockout drum from each stage and compressor shall be minimized. Low spots in piping between knockout drum(s) and compressor shall be avoided. Piping shall be sloped such that it drains condensation back to drums. Deviations shall be subject to COMPANY approval. To collect and dispose of liquid that may be present in the line, vane-type separator or coalescer shall be installed at all low points. Gas compressor headers shall be suitable arranged and properly anchored for thermal expansion and vibration absorption. Minimum natural frequency of separate structures or anchors shall be 10 times maximum rpm of compressors. Suction and Discharge lines and their support system. Design shall be such that natural frequency of piping system does not respond to forcing frequency of equipment under all modes operation up to and including fourth harmonic of piping systems natural frequency. Particular attention shall be given if using short radius fittings or other restrictions that may cause vibration of piping system due to acoustics of piping and its contents. 5.4.3. Strainers 5.4.3.1 Except for compressors that take suction through a filter located close to compressor, suction line of all compressors shall have a temporary line strainer. Strainer shall be located between block valve and compressor.
5.4.1.3
5.4.1.4 5.4.1.5
5.4.2.
Thermal Expansion and Vibration 5.4.2.1 5.4.2.2 5.4.2.3
5.4.3.2
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5.4.3.3
Strainer shall have a free flow area not less than 150 % of pipe area. Pressure drop shall not exceed amount permissible in compressor design. Strainer support ring and/or stiffeners shall be carbon steel. Strainer mesh shall be 304 stainless, 10 x 10 with 1/32 inch wire. A removable flanged spool piece or other suitable means shall be provided for easy installation and removal of strainer. Suction piping immediately upstream and downstream of strainer shall have valved pressure taps. Taps shall be manifolded to a pressure gauge such that either pressure can be read. Strainer shall be installed in new installations and shall be reinstalled after subsequent maintenance or change to compressor suction line. Strainers shall be retained in line for minimum time required to ensure a clean suction line. This period shall not normally exceed time required for first run.
5.4.3.4 5.4.3.5 5.4.3.6
5.4.3.7 5.4.3.8
5.4.4.
Snubbers Snubbers (bottles or dampeners), if required in compressor, shall be designed in accordance with ASME B31.3.
5.4.5.
Internal Pipe Cleaning. 5.4.5.1 If cleaning of compressor suction piping is necessary, particularly for non-lubricated type reciprocating compressors, the following shall be considered : Pickling in fabricators shop may require fabrication in flanged spools to avoid field welding after pickling. Other cleaning methods, such as mechanical cleaning of welds and weld spatter, hydroblasting, or grit blasting, shall be considered. Pickling after erection in field shall require extra care to ensure that all low points are completely drained of pickling agent. Piping shall be tested prior to cleaning or after cleaning with suitable, non-rusting liquid After cleaning, piping shall be protected from rusting prior to startup of compressor 5.4.5.2 Lube, seal, flushing, and hydraulic oil piping systems shall be designed and purchased to maximize internal cleaning prior to delivery to job site. Interconnected piping between skids, consoles, and machines shall be designed for separate cleaning prior to assembly of system. Discharge check valves for reciprocating compressors shall be nonslam type.
5.4.5.3 5.4.6.
Check Valves 5.4.6.1
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5.4.6.2
Discharge check valves, including those in spillback and bypass lines, shall be sized in accordance with all design cases, especially low flow cases. Centrifugal air blowers that manifold into a common discharge line shall have an atmospheric, silenced vent in each blower discharge line. Each line shall also have a check valve.
5.4.7.
Blower Discharge Piping 5.4.7.1 5.4.7.2
5.5.
Fired Heater Piping 5.5.1. Fuel Gas and Fuel Oil Piping 5.5.1.1 5.5.1.2 Unless approved by COMPANY, flexible hose shall not be used in lieu of fixed pipe to fuel gas or fuel oil burners. If rigid piping will place undue strain on burner, COMPANY will consider approval of flexible hose. If approved, flexible metal hose shall be 316 SS with external single woven wire braid.
5.5.2.
Process Piping If there is liquid or two-phase flow at heater outlet and design requires manifold or outlet connections in a common header, branches shall enter header at 450 or less.
5.5.3.
Decoking and Catalyst Regeneration 5.5.3.1 5.5.3.2 Removable pieces shall be located at grade or on a platform. Manifold or other valves shall not be located near catch basin into which effluent is discharged.
5.5.4.
Location of Instruments All instruments and instrument connections shall be located at a minimum distance of 50 feet from shell of fired heaters except direct connected pressure gauges, draft gauges, thermocouples, damper operators, stack sample connections, flame scanning, and ignition systems.
5.6.
Relief System Piping 5.6.1. General 5.6.1.1 5.6.1.2 5.6.2. Relief system shall be designed to follow process requirement. Piping for relief valve inlet and discharge shall be designed in considering on over pressure protection system. Connections shall be to top of flare header, normally at 900
Connections to Header 5.6.2.1
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5.6.2.2 5.6.3. Isolation
If problems, such as layout limitations or velocity, exist, connections at 450 may be considered
Isolation between flare header and connecting piping shall conform to section 6.15.2. 5.6.4. Relief Valve Piping 5.6.4.1 5.6.4.2 5.6.4.3 5.6.4.4 Relief valve discharge piping shall be self draining (no pockets) from relief valve into flare header. Deviations shall be subject to COMPANY approval. Header shall be sloped a minimum of 1/6 inch per foot to unit knockout drum. Discharge piping open to atmosphere shall: Be galvanized Have an NPS low point drain piped to a safe location. 5.6.4.5 5.6.5. Valves 5.6.5.1 Unless pressure drop is considered for line sizing, inlet and outlet block valves for relief valves, except TSVs shall be full port valves. API 600 valves are full port. NPS 1 and NPS 2 valves shall be specified full port or checked. Gate valves and butterfly valves shall be oriented such that valve stem is in a horizontal position. Unless flare system will be shut down with process unit, main header at process unit limits and offsite drum shall have flare knockout drum isolation valves. Valves shall be V-900E4 butterfly valves. Supports for headers inside process unit limits to blinding location down stream of unit knockout drums shall be designed for hydrotest. Supports for offsite flare headers shall be designed for pneumatic testing A blinding location shall be required at or near base of flare stack. Open end of discharge piping shall be covered by screen or hinged flap to prevent entry by birds.
5.6.5.2 5.6.5.3
5.6.6.
Flare Header Support 5.6.6.1 5.6.6.2 5.6.6.3
5.7.
Steam and Condensate Piping 5.7.1. Header and Branches 5.7.1.1 Steam piping to all unit and to equipment groups located either inside or outside of unit limits shall be arranged in separate sub-header supply systems provided with block valves at connections into the main.
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5.7.1.2
Steam branch lines to offsite areas, such as tank farms, cooling tower pumps, and docks, shall have block valves at point of take off from main lines to permit isolation for maintenance. Additional block valves shall be installed in main lines and branch lines defined in paragraph 7.7.1.3, if steam line is long and has several widely spaced lines off main or branch headers. Steam trap shall be installed before each block valve defined in paragraph 7.7.1.4. If length of line downstream of gate valve exceeds 150 feet, valved (throttling type) bypass shall be provided as follows: Gate Valve Size NPS 6 8-10 *12-20 *24 *30 and up By pass Line and Valve Size NPS 0-50 psig 51-425 psig 426-1550 psig 1 1.5 1.5 2 2 4 2 2 6 2 2
5.7.1.3
5.7.1.4 5.7.2.
Steam Gate Valve Bypasses 5.7.2.1
*NOTE if downstream line length exceeds 400 feet and steam pressure is greater than 50 psig, gate valves NPS 12 and large shall have one NPS 2 valve. Bypass for main plant steam distributing lines that cannot be shut down without shutting down several process units shall have two valves. 5.7.2.2 5.7.3. 5.7.3.1 5.7.3.2 5.7.3.3 5.7.4. If possible, by pass connections shall be in piping adjacent to valve. Steam separator, where required in steam lines to steam drivers, shall preferably be horizontal type. If required by piping layout, steam separators may be vertical type. Material shall conform to material shown for block valves in individual PMSS. Sufficient space shall be provided at and around drivers for pumps and compressors to enable maintenance and removal of all internal and external parts. Expansion joints, if used, shall be packless and corrugated type, suitable for maximum design pressure of steam system. Control valves for steam turbines (except for scavenger type) shall be located as follows: Steam Separator
Piping to Pumps and Turbines 5.7.4.1
5.7.4.2 5.7.4.3
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Control valves (regardless of size) for automatic start-up turbines shall be located at grade adjacent to turbine or pump. Control valves (NPS 6 and smaller) for manual start-up turbines shall be located at grade adjacent to turbine or pump. 5.7.5. Steam Condensate Systems 5.7.5.1 Overhead steam condensate collecting systems shall be provided to collect condensate from all traps within process unit areas. Condensate shall be handled in the following order of preference: Condensate shall be discharged from individual steam header traps to the next lower pressure steam system if available in area and if sufficient differential pressure exists between steam systems to ensure proper trap operation. If a condensate collection system is provided on unit, trap condensate shall be discharged directly to that system. Trap condensate shall be discharge shall into cooling tower water return system. 5.7.5.2 Separate steam condensate collecting systems are preferred to collect condensate from each different pressure steam system on process unit. Condensate streams with temperature difference greater than 40F shall be collected in same header. Each separate condensate collecting system on process unit shall generally consist of a main header with connecting subheaders running to areas in which traps are located. Steam connection shall be provided at end condensate header. Connection shall be used for warm-up steam and as bleed steam to reduce header knocking. Condensate subheaders and main header shall be routed, without pockets, to a condensate flash drum venting to next lower pressure steam system, if sufficient pressure is available, or to atmosphere, if sufficient pressure is not available. Flash drum liquid shall be pumped back to boiler. Condensate collecting systems shall be designed to avoid excessive back pressure on traps. Sizing such condensate systems shall consider the following: Flashed steam produced when traps discharge. Continuous blowing of traps caused by faulty operation or insufficient condensate to seal trap against steam leakage. Back pressure at trap discharge. 5.7.5.6 5.7.6. Condensate shall be collected from steam traps outside process unit limits, if practical.
5.7.5.3
5.7.5.4
5.7.5.5
Steam Lines to Atmosphere
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5.7.6.1 5.7.6.2 5.8. Air Piping 5.8.1. 5.8.2. 5.9.
Steam relief valve discharge lines and blowdown lines to atmosphere shall be in accordance with SP-PI-PP-002 Low point of line shall have adequately sized drain and valve assembly.
Branch line connections from horizontal headers shall be in top of header. Air lines permanently connected to process lines shall have a positive means of back flow prevention in addition to a check valve.
Water Piping 5.9.1. General 5.9.1.1 Potable water connections shall be provided for: Drinking. Ablutionary. Culinary. Eyewash. Safety showers. Sample sinks. Wash up (inside buildings). 5.9.1.2 5.9.1.3 5.9.2. Each piece of equipment connected to potable water system shall have an isolation valve. If approved by COMPANY, toilets and urinals in remote locations may have non-potable water. Offsite cooling water shall conform to Section 7.12. Each branch of cooling water supply and return lines shall have block valves to permit independent shutdown of each piece of equipment or bank of coolers. Branch line take offs for piping shall be made in the top of cooling water supply header.
Cooling Water on Process Units 5.9.2.1 5.9.2.2
5.9.2.3 5.9.3. 5.9.4. Drains
All water lines shall have drains to drain above grade portion of lines. Piping For Hydrostatic Test 5.9.4.1 5.9.4.2 After initial hydrostatic test for vessels, lines, and equipment, it shall be assumed that future fillings for tests will be by hose. Supply lines used for test water have an NPS 2 valved connection not more than 50 feet from any vessel.
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5.9.5.
Valve by pass (Hot Process Water) If hot process water exceeds 500 psig and/or 450F, valved bypassed aroun all gate and globe valves shall be provided for warm-up circulation in accordance with section 7.7.2.
5.10.
Oxygen Service Piping 5.10.1. 5.10.2. 5.10.3. 5.10.4. 5.10.5. Material shall be selected in accordance with SP-PI-PP-002. Internal cleaning of piping shall conform to PP-PI-PP-001. Design of piping shall consider cleaning requirements. Piping shall have adequate vents, drains, and capability to circulate chemicals. Elevation changes shall be minimized.
5.11.
Underground Piping 5.11.1. General 5.11.1.1 Underground lines shall be located, designed and installed per the appropriate ASME B31.3, ASME B31.4 or ASME B31.8 code. 5.11.2. External Coating and Cathodic Protection 5.11.2.1 All coating of pip shall be in accordance with SP-ME-ME-025 Coating and Painting Specification. 5.11.2.2 Unless specified otherwise, lines above 150F shall not have external protective coating. 5.11.2.3 Necessity, extent, and type of cathodic protection shall be determined for each project in accordance location, service, and plant experience. 5.11.3. Sleeves 5.11.3.1 General Sleeves shall be sized at least 2 nominal pipe sizes larger than protected line. Sleeves shall provide ample installation clearance for the greatest outside diameter of bells, hubs, insulation, etc. Sleeves shall have a minimum cover of 6 inches between top of sleeve to bottom of railroad ties or top of roads not paved with concrete. On concrete paved roads, minimum cover between top of sleeve to bottom of concrete shall be 3 inches. Pipes in sealed sleeves shall be centered with suitable centering devices. 5.11.3.2 Sleeves for Bare Lines Bare lines under temporary and permanent roads and railroad spur tracks shall have pipe sleeves as follow: If required by governmental regulations or railroad easements.
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If size is NPS 12 or smaller and distance between top of line (outside of bells) and bottom of railroad ties and/or surface of road at low point is 12 inches or less and lines are any of the following: a. Cast iron or concrete. b. Pipe of any material crossing under concrete paved roads and main plant roads (paved or unpaved). c. Pipe of any material in exteremely hazardous locations where hot work is impractical. All line sizes, regardless of depth below surface, if temperature exceeds 150F. Non-metallic lines (except concrete and other non-metallic sewer lines). Vital main roads, extremely hazardous locations, concrete paved roads, and special requirements shall be specified by project. 5.11.3.3 Sleeves for Insulated lines Underground insulated lines (except lines insulated with GilsoTherm or similar materials) shall have pipe sleeves, regardless of size and depth below surface. Sleeves shall be sealed, or other means shall be provided to prevent entrance of water. Insulated lines which pass through tank farm dikes shall have pipe sleeves. A fire resistant seal shall be provided between pipe and sleeve at outside face of dike. Sleeve shall be sloped towards the inside. 5.11.4. Flanged and Threaded Connections 5.11.4.1 Except at flanged valves located in valve boxes, buried hydrocarbon, acid, or caustic lines inside of unit limits shall not have flanged or threaded connections. 5.11.4.2 Except at flanged valves located in valve boxes, buried hydrocarbon and caustic lines outside of limits shall not have flanged or threaded connections. If welding is not permitted, hydrocarbon lines may be connected to existing lines with flanged or threaded flanged connections. 5.11.4.3 If PMSS permits threaded construction, piping buried under paving shall be welded construction. 5.12. Offsite Interconnecting Piping 5.12.1. General 5.12.1.1 Offsite facility interconnecting lines (i.e., tank farm, utility facilities, loading/unloading docks, or racks) and lines between process units and offsite shall be checked for hydraulic transient (surge or water hammer). If there is potential for hydraulic surge or water hammer, hydraulic transient analysis shall be performed and submitted to COMPANY for approval.
July, 2002 Page 45 of 48
5.12.1.2 Slow-closing valves shall be used to control hydraulic surge or water hammer. If hydraulic transients cannot be controlled within reasonable valve closure times, two speed valve operators may be used. Other surge reduction devices, such as air chambers, hydraulic accumulators, and bypass lines, may be used if approved by COMPANY. 5.12.1.3 Air shall be eliminated from lines through use of eccentric reducers, air eliminators, vents, etc. 5.12.1.4 Motor operators may be considered for all large valves that will be operated frequently. Motor operators shall not normally be required on maintenance or isolation valves. Valves that are remotely operated shall have motor operators. 5.12.1.5 Unless approved otherwise, interconnecting process lines shall not be run underground. 5.12.2. Cooling Water Piping 5.12.2.1 Piping with circulating water rate of 10,000 gpm or more shall be analyzed for transient conditions caused by valve closure, pump start, or unexpected pump shut-off (power failure). Analysis of hydraulic transients shall be submitted to COMPANY for approval. 5.12.2.2 Cooling water circulating pump discharge piping immediately downstream of check valve and block valve may be located underground to facilitate anchoring the line. 5.12.2.3 Pump discharge lines with NPS 16 or larger check valve shall be analyzed for water hammer caused by closure of check valve. 5.12.3. Cooling Towers Return Water Piping 5.12.3.1 Cooling towers circulating cooling water in hydrocarbon service shall have open vents. 5.12.3.2 Vents shall be located at top of each cooling water return riser at tower to permit escape of any gases leaking into system. 5.12.3.3 Cross-sectional area of vents shall be sized to handle maximum volume of gas resulting from an exchanger tube rupture as determined by tube rupture analysis. 5.12.3.4 Vents shall release this calculated volume of gas without overpressuring cooling tower water distribution headers. 5.12.3.5 Height of each vent stack shall be determined by cooling tower Vendor. 5.12.3.6 Vents shall not normally be required on return risers for cooling towers serving steam service condensers, or similar systems, where escape of gases is considered remote. 5.13. Tankage Piping 5.13.1. Provisions for Tank Settlement
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5.13.1.1 Tank piping shall be designed to withstand a predetermined amount of tank settlement after initial tank hydrotest. 5.13.1.2 Tank settlement shall preferably be accommodate using piping arrangement and/or flexible supports. 5.13.1.3 Flexible connections in hydrocarbon service shall not be used. If flexible pipe joints are used for other services, COMPANY approval shall be required. Two Dresser Coupling Style 38 connections spaced a minimum of 10 feet apart shall be provided. Standard Dresser harnesses shall be used to prevent pipe from slipping out of coupling. 5.13.2. Piping Penetrating Tank Farm Dikes 5.13.2.1 Piping shall preferably be routed to avoid penetrating dike walls. 5.13.2.2 Unsleeved pipes that penetrate tank farm dikes shall have pipe to dike anchor/seal. 5.13.2.3 Insulated pipe shall be sleeved per Section 7.11.3. 5.13.3. Block Valves (For Flammable Liquid Storage Tanks) 5.13.3.1 Except where chemical characteristics of liquid stored are incompatible with steel, steel block valves shall be used for each connection to an aboveground storage tank through which liquid can normally flow. 5.13.3.2 Block valves shall be bolted directly to flanged tank nozzles. 5.13.3.3 Support for large block valves at tank nozzles shall be considered to prevent overstressing tank shell. 5.14. Truck and Tank Car Loading Facilities Facilities that contain normal butane and lower atmospheric boiling point hydrocarbons shall have an excess flow upstream of loading line block valve to provide hose break protection and a check valve on storage tank in vapor return line. 5.15. Fluid Catalytic Cracking Units (FCCU) 5.15.1. Check System 5.15.1.1 To check movement of large lines and expansion or rotation of joints, a system of reference points shall be set up. 5.15.1.2 System shall be shown on a drawing. Theoretical design movements to reference points and maximum allowable movements of joints shall also be shown on drawing. 5.15.1.3 Measurements shall be taken before initial start-up. 5.15.2. Valve Taps 5.15.2.1 Slide valve that are normally operated during an operating period shall have an NPS 1 tapped connection in stuffing box wall opposite lantern
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gland for introducing emergency plastic packing. Tapped connection shall have an NPS 1 schedule 160 nipple and block valve. 5.15.2.2 Gate in catalyst lines and other services lines connected to catalyst lines shall have bossed and tapped connections. Connections shall have permanent piping for aeration or purge. Piping shall be shown on process and instrument flow diagrams. 5.16. Acid and Caustic Lines 5.16.1. Location 5.16.1.1 Except if working area, passage, or access to equipment would be obstructed, acid and caustic lines shall be located aboveground on low supports. Acid or caustic lines shall not be located below grade without COMPANY approval. 5.16.1.2 Where use of low supports is not practical on process units, acid and caustic lines shall be located on overhead supports. 5.16.1.3 Acid lines at road crossings and similar obstructions shall be located on overhead supports. 5.16.1.4 Acid lines crossing earth dikes or levees shall be located on low aboveground supports. 5.16.1.5 If suction or other flow conditions make location of acid lines on aboveground or overhead supports impractical, the lines shall be installed in concrete trenches. 5.16.1.6 Acid and caustic piping shall be arranged to avoid close proximity to hot process piping. 5.16.2. Insulation 5.16.2.1 Insulation shall be used as necessary to prevent gain or loss of heat. 5.16.2.2 Insulating shall be performed in accordance with SP-PI-PP-005.
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SP PI PP 001 (General Piping System)

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DOCUMENT NO.

PT Caltex Pacific Indonesia

SEPT 26, 2001

PREPARED BY CHECKED BY APPROVED BY

NHS NHS SPD

GENERAL PIPING SYSTEMS

PT. CALTEX PACIFIC INDONESIA

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: Project Specific Clarifications & Requirements

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

1.2.2.2 1.2.2.3 1.2.2.4 1.3. Terminology

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

2.1.1.2 2.1.1.3 2.1.2.

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

Allowance 10 psi 25 psi 10% MOP 100 psi 10% psi

2.2.2.3 2.2.2.4 2.2.2.5

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

3.1.1.2 3.1.2. At Grade 3.1.2.1 3.1.2.2

Accessible from a Platform 3.1.6.1 3.1.6.2

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

3.2.7. 3.2.8. 3.2.9.

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PIPING DESIGN AND ARRANGEMENT GENERAL

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

4.3.3.1 4.3.3.2 4.4. Injection Points. 4.4.1. 4.4.2. 4.4.3.

4.5.2. 4.5.3. 4.6.

Underground Process Lines

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

4.12.8. 4.12.9. 4.13.

PT. CALTEX PACIFIC INDONESIA

General Piping Systems SP-PI-PP-001 Rev. 1

4.13.8. 4.13.9. 4.14.