BAKHRABAD SIDDHIRGANJ

PIPELINE PROJECT
Piping / Equipment

Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

TABLE OF CONTENT

1.0 DEFINATIONS................................................................................................................. 2

2.0 DESIGN CODES, STANDARDS & SPECIFICATION......................................................2

3.0 PIPING DESIGN CRITERIA.............................................................................................5

4.0 RESPONSIBILITIES OF THE CONTRACTOR..............................................................13

5.0 GUARANTEE TEST.......................................................................................................16

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 BAKHRABAD SIDDHIRGANJ
PIPELINE PROJECT
Piping / Equipment

Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

1.0 DEFINATIONS

EMPLOYER : Gas Transmission Company Limited

OWNER’S ENGINEER : Dorsch Consult Wasser & Umwelt GmbH

CONTRACTOR : The Company named as such in the deed.

SUB CONTRACTOR / : The Manufacturer / Supplier engaged by Contractor

VENDOR

SHALL/MUST/IS TO BE : A mandatory requirement

SHOULD : A non-mandatory requirement, advisory or Recommendation

2.0 DESIGN CODES, STANDARDS & SPECIFICATION

Design, engineering, fabrication, testing etc. shall be as per the latest edition of the following
codes, standards and ‘General Specifications’.

ASME B31.3 - Process piping

ASME B31.8 - Gas transmission and Distribution piping Systems.

OISD 118 - Layouts for Oil and Gas installations

ASME - Boiler and Pressure Vessel Code

Section VIII - Pressure Vessels, Division 1
Section IX - Qualification Standard for Welding and Brazing
Procedures

ASME Section V - Non-Destructive examinassions

API 6D - Spec. for Pipeline Valves

API 5L - Spec. for line pipe

API 6FA - Fire Test for valves.

API 594 - Wafer and wafer lug check valves.

API 598 - Valve Inspection and Testing.

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API 600 - Bolted Bonnet Gate Valves.

API 602 - Compact Steel Gate Valves.

API 607 - Fire Test for Soft-Seated Quarter-Turn Valves.

API 609 - Lug and Wafer type butterfly valves.

BS 1868 - Steel Check Valves (Flanged & Butt Welding Ends).

BS 1873 - Steel Globe & Globe Stop & Check Valves (Flanged &
Butt Welding Ends).

BS 5351 - Steel Ball Valves.

BS 5352 - Steel Wedge Gate, Globe & Check Valves, DN50 &
smaller.

BS 5353 - Specification for Plug Valves.

BS 5155 - Specification for butterfly valves.

BS 6755 Part 1 - Testing of Valves, spec. for production pressure testing

requirements.

MSS-SP-75 - Spec. for high test wrought butt welding fittings.

MATERIAL CODES

ASTM A105 - Forging, C.S for piping components.

ASTM A106 - Seamless C.S pipe for high temperature Service

ASTM A182 - Forged or rolled alloy steel pipe, flanges, forged fittings
and valves & parts for high temperature service.

ASTM A193 - Alloy steel and stainless steel bolting materials for high
temperature service.
ASTM A194 - Carbon & Alloy steel nuts for bolts for high pressure
and high temperature services.

ASTM A234 - Piping fittings of wrought carbon steel for moderate and

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elevated temperature.

ASTM A694 - Forging, carbon and alloy steel for pipe flanges , valves
and parts for high pressure transmission service.

ASTM A216 - Steel castings, carbon suitable for fusion welding for
high temperature service.

ASTM A153 - Zinc coating (hot dip) on iron and steel Hardware

ASTM A312 - Specification for seamless & welded austenitic

Stainless steel pipe.

ASTM A320 - Specification for alloy steel bolting materials for Low
temperature service.
ASTM A333 - Specification for seamless & welded steel pipe for Low
temperature service.

ASTM A350 - Specification for forging, carbon and low alloy Steel,
requiring notch toughness testing for piping
Components.

ASTM A352 - Specification for steel castings, ferrite & Martensitic, for
pressure containing parts suitable For low temperature
service.

ASTM A403 - Specification for wrought austenitic stainless Steel

piping fittings.

ASTM A420 - Specification for pipe fittings of wrought carbon Steel &
alloy steel for low temperature service.
ASTM A 388 - Standard Practice for Ultrasonic Examination of Heavy
Steel Forgings.

DIMENSIONAL / DESIGN STANDARDS:

ASME B1.20.1 - Pipe Threads, General Purpose (Inch)

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ASME B 16.5 - Pipe Flanges & Flanged Fittings

ASME B 16.10 - Face-To-Face & End-To End Dimensions of Valves

ASME B16.20 - Metallic Gaskets for pipe Flanges

ASME B16.21 - Non-Metallic Gaskets for Pipe Flanges

ASME B16.34 - Valves-Flanged, Threaded & Welding End

ASME B18.2.1 - Square & Hexagonal bolts & screws

ASME B18.2.2 - Square & Hexagonal Nuts

ASME B36.10 - Welded & Seamless Wrought Steel Pipe

ASME B36.19 - Stainless Steel Pipe

ANSI B16.9 - Factory made wrought steel butt welding Fitting

ANSI B16.11 - Forged steel fittings socket welding and threaded.

ANSI B16.47 - Large diameter steel flanges (NPS 26 through NPS 60)

3.0 PIPING DESIGN CRITERIA

3.1 GENERAL

3.1.1 The design criteria gives the minimum basic requirement for piping design to be carried
out. This shall be read in conjunction with the specifications attached elsewhere in the bid.

3.1.2 All design calculations for pressure requirements, vibrations, thermal expansions /
flexibility considering seismic factors etc. shall be made in accordance with code
requirements and submitted to the Employer for approval.

3.1.3 All piping systems shall be designed as per the requirements of ANSI B 31.3, ANSI
B31.8 and OISD 118.

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Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

3.1.4 All piping materials shall be tested as prescribed in the piping specifications and
standard codes and practices and certificates of conformance shall be furnished for review
and approval by Employer.

3.1.5 All piping material and components i.e. pipes, fittings, valves, flanges, gaskets and
bolting etc. shall be as per the piping specifications.

3.1.6 Piping general arrangement drawing / Isometric / support drawings etc shall be
prepared using good engineering practice as per the guidelines furnished in piping
specifications.

3.1.7 Thermal insulation and insulation for Personnel Protection shall be provided wherever
required as per P&ID and general specifications attached with the bid.

3.1.8 Threaded piping connections are not permitted.

3.1.9 Bidder shall calculate thickness / schedule against each size of each piping class and
provide the same irrespective of whether the thickness / schedule specified in the piping
class in the bid. Details furnished in the bid are indicative and bare minimum requirement.

3.1.10 Transition piece shall be provided between different grades of pipeline welding as
shown in P&ID’s.

3.1.11 In the event of conflict the following order of priority shall govern:
a) Piping design criteria
b) P&ID’s
c) Data sheet
d) Drawings
e) Specialty Item Specification
f) General Specification
g) Codes and Standards.

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Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

3.2 PIPING SPECIFICATIONS

3.2.1 The piping material specification shall be governed by the design conditions of
pressure, temperature, corrosion allowance and compatibility with contained media.

3.2.2 When two lines that operate at different pressure – temperature conditions are
connected, the valve segregating the two lines shall be rated for more severe service
condition.

a) Pipe wall thickness shall be calculated in accordance with ASME B31.3 / 31.8 for
piping except for Launchers / Receivers. Launchers / Receivers shall be designed as
per ANSI B31.8 / ASME SEC VIII Div 1. Corrosion allowance shall be as indicated in
piping material specification.

b) Contractor to calculate thickness / schedule against each size of piping class. Pipe
internal diameter from Launcher / Receivers shall be critically checked for the safe
passage of pig. Launcher / Receiver dimension shall be suitable for intelligent
pigging.
3.2.3 Branch connection details: Branch connections shall be in accordance with the piping
material specification attached elsewhere in the bid.

3.2.4 Layout considerations and scales.

Equipment layouts - 1: 75
Piping plans / support plans - 1: 75
Isometric drawings - None
- Metric system shall be used for all drawings
- True north and plant north to be shown.

3.2.5 Layout shall be designed to meet operation, maintenance, safety and statutory
requirements.

3.2.6 All piping shall be arranged to provide full access to all equipment for operation,
maintenance, removal and / or replacement with the minimum amount of labor and minimum

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dismantling of piping system. Block valves shall be provided for isolation of equipment and
instruments.

3.2.7 Piping shall be arranged to avoid liquid and gas traps. In the event this is not possible,
all gas traps shall have accessible plugged vents and liquid traps shall have accessible
plugged valve drains.

3.2.8 Control valves shall be installed with the actuator in a vertical upward position.
Manifold arrangements shall consider access, clearance, maintenance and removal of
control valve without removing of stop valves. Control valve manifold shall preferably be
located within view of associated instruments.

3.2.9 Pipes, fittings, flanges, and valve of sizes 3/8”, 11/4” 2½”, 3½” 4½” 5”, 7”, and 9” shall
not be used. However, where equipment is regularly supplied by the manufacturer with
piping connections of the above odd sizes, connection shall be made to approved nominal
sizes using reducers.

3.2.10 The clearance between two pipes shall be the minimum of flange to pipe distance
plus 25mm, or insulated flange to pipe insulation plus 25mm, in cases where the two pipes
are insulated, with the flanges staggered. Consideration shall be given to the expansion /
contraction in spacing of pipes.

3.2.11 The minimum clearance between hand wheels on valve manifolds shall be 75mm.

3.2.12 Minimum clearance for personnel access ways shall be as follows:

Overhead clearances: 2.2 meters.
Horizontal clearances: 1.2 meters

3.2.13 All allocated areas for safety access, service, maintenance and operation shall be
kept clear of piping or any other obstructions.

3.2.14 Contractor to update equipment layout based on final approved Sub

contractor/Vendor drawings / skid dimensions. Contractor to develop its own layout drawings
to suit their concept, based on safety distances as per OISD norms.

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3.2.15 Safety equipment layout shall be based on project equipment list and good
engineering practice.

3.2.16 Piping arrangement drawings shall cover all lines indicated in P&ID’s. Piping plans,
support plans and details, isometrics shall be developed using good engineering, practice
and guidelines.

3.2.17 Installation and mounting of instruments shall be as per fabrication and installation
specification.

3.2.18 All bends shall be of minimum 8D radius used on pigging lines to facilitate intelligent
pigging.

3.3 VALVE OPERATION

3.3.1 All valves, control valves and instruments shall be accessible from platforms or
permanent ladders and conveniently located for operation and maintenance.
3.3.2 In general, valve hand wheels and stems shall be kept out of operation interference.

3.3.3 Block valves in pipe work connected to equipment shall be installed as close to the
equipment as practical.

3.3.4 Valves on horizontal lines shall not be installed with hand wheels downward. Operating
valves more than 1.8 meters above grade level require platforms.

3.3.5 Locked open (or closed) valves shall be installed with their stem in horizontal position.
A stainless steel tag shall be attached to the stem, bearing the following: “THIS VALVE
MUST NOT BE CLOSED (OR OPENED) WITHOUT WRITTEN PERMISSION FROM
RESPONSIBLE AUTHORITY”.

3.3.6 For type of operation of valves refer to piping material specification document attached
elsewhere in the bid.

3.3.7 Underground valves shall be coated with coal tar epoxy.

3.3.8 Underground valves shall be provided with pup pieces, which will be as per pipeline
design criteria.

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Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

3.4 VENTS AND DRAINS

3.4.1 Hydrostatic test vent connections shall be in accordance with piping material
specification. Vents are not required on lines which are pneumatically tested and may be
omitted on alloy piping and on lines handling corrosive commodities. Vent size shall not be
less than ¾”

3.4.2 Piping and equipment shall be sufficiently drained at all low points to remove all liquid
from the system. Drains shall be provided with valve and shall not be smaller than ¾”.

3.5 SPECTACLE BLINDS

3.5.1 Spectacle blinds shall be provided as per the requirement shown in P&IDs.

3.5.2 Spectacle Blind assembly shall be provided with jack screws. All heavy flanges 12”
NPS and above shall be provided with jack screw holes for easy removal of flanges.

3.6 PIPING FLEXIBILITY AND SUPPORTS

3.6.1 Supports shall be designed in such a way as to comply with flexibility analysis results.
The following rules will generally have to be observed. The Contractor shall carry out stress
analysis of all the piping work at no extra cost to Employer. The report of stress analysis
shall be a part of Quality audit records and shall be submitted to Employer as Final
Documents submissions.

3.6.2 All piping shall be analysed and adequately supported, guided, anchored, or strutted
so as to prevent undue vibration, deflection, stress or strain on equipment. Thermal
expansion / contraction, dynamic effects (impact, wind, earthquake, vibration, etc.) and
weight effects (live loads, dead loads, test loads etc.) shall be considered in the analysis so
that the stresses created by those loadings shall not exceed the allowable stresses
prescribed by the “CODE”. When analyzing piping, particular attention shall be paid to
thermal expansion / contraction of lines subjected to sunrays and severe temperature
changes during start-up, operating and emergency conditions.

3.6.3 Piping flexibility shall be used in preference of any type of expansion joints. If a suitable

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PIPELINE PROJECT
Piping / Equipment

Doc. No. 1051-220-301 Piping Design Criteria Revision No. 0

piping configuration cannot be designed to eliminate the use of expansion joints, the matter
shall be discussed with the Employer before proceeding with any work.

3.6.4 Control valves and other piping components shall be properly supported and braced to
prevent excessive vibration. Any additional restraint shall be considered in the flexibility
analysis of the piping system.

3.6.5 Pipe supports shall be wide enough to ensure pipes do not fall off supports during
maximum expansion / contraction.

3.6.6 Small instrument tubing and piping shall be adequately supported and protected from
damage by impact.

3.6.7 Supports shall not interfere with clear passages provided for access to equipment,
machinery, instruments, handling of valves etc.

3.6.8 Whenever necessary, it should be possible to adjust supports so that they may be set
correctly.

3.6.9 Local compressive stresses on large-diameter pipes shall be taken into account, using
(where necessary) suitable reinforcing plates.

3.6.10 All supports shall be identified on design drawings as per the support standard
attached elsewhere in the bid.

 The end actions on equipment and machinery imposed by connected piping shall
be checked within the limits set for that type of equipment by manufacturer.

3.6.11 Latest version of Caesar software shall be used for performing stress analysis.

3.6.12 The layout of all piping work shall provide adequate expansion and contraction
without placing excess stresses or forces on piping materials or excess forces and
movements on anchors or equipment.

3.6.13 Flexibility analysis shall be carried out using latest CAESAR-II software for lines as
shown below:

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The following general guidelines shall be used to determine the type and extent of analysis
to be adopted. The guidelines are not exhaustive and do not replace good judgment and
experience particularly with regard to safety aspects of the design.
a) Pipe work connected to strain sensitive equipment.
b) 3” and above sizes are generally design for 10 ºC to 70 ºC except the following.
The lines connected to heaters at downstream side, piping connected to metering
and reducing pressure connected to downstream of PRS, down stream of venting or
pressure releasing valves.
Contractor has to analyze all possibilities where there will be a considerable drop in
the temperature will arise and design accordingly.
c) Lines subject to vibration.
d) Large diameter piping between closely spaced equipment.
e) Pipeline from Launcher to Receiver including the barrels shall be analysed as a
single system. All lines shall be analysed at design/operating temperature range.

3.7 FIRE FIGHTING SYSTEM

The Existing fire protective network shall be extended to cover the new area at Bakharabad
and new network shall be established at Haripur RMS and Siddhirganj RMS station.
Sufficient number of fire /smoke detectors, Fire extinguishers and CO 2 flooding system
shall be provided as per OISD norms.

3.8 SITE AND ENVIRONMENTAL DATA

The site and environmental data attached else where in the bid shall be referred for
reference and guidance only. Contractor has to verify data and shall use his own judgment.

3.9 BATTERY LIMITS

Battery limits for the stations shall be as mentioned in the bidding document.

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4.0 RESPONSIBILITIES OF THE CONTRACTOR

All below mentioned work shall be provided by Contractor.

4.1 All surveys such as pre-engineering, pre-construction, post construction, etc. shall be
carried out prior to start of job.

4.2 Design and detail engineering of all facilities in accordance with design parameters and
International codes and standards but incorporating changes / revisions which are not
adequately covered and reflected, considering that bid document is solely based on
functional specifications.

4.3 Preparation of all fabrication drawings, purchase specifications for piping materials and
specialty items, specifications and procedures for fabrication, installation, coating of all
buried fittings, pipes, valves etc, painting, hook-up, testing, pre-commissioning and
commissioning including the existing facilities where modifications are to be carried out.
Contractor shall prepare as-built drawings based on the site feed back.

4.4 Contractor shall procure and supply all materials required for temporary / permanent
installation of the piping system. All the components shall be suitable for the intended service
as mentioned in the piping specification and shall have a design life mentioned else where in
the bid. The contractor shall also procure and supply spares required for pre-
commissioning / commissioning and start-up as recommended for the items supplied by him
as per the specification attached in the bidding document. Contractor shall develop
specifications and submit to Employer for approvals which are not available in the bid.

4.5 Procurement including expediting and inspection of all materials and equipment for
construction and incorporation in the facilities.

4.6 Fabrication and assembly of all facilities including installation of equipment, piping
supports etc. into the facilities in accordance with the approved drawings and specifications.

4.7 Installation of all facilities, hook-up, testing and pre-commissioning all such activities
shall be witnessed.

4.8 Design engineering of all future facilities as described in the bidding document.

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4.9 Any other works specified elsewhere in the bid document.

4.10 Contractor shall furnish all the information as sought by the Employer in formats for its
data storage and retrieval system at no cost to the Employer.

4.11 Procurement of all piping material shall be done by Contractor / Sub contractor / vendor
after approval by Employer.

Necessary documents such as purchase specifications, test certificates shall be furnished

for review / approval.

4.12 Procurement of support material for pipe support, temporary support & scaffolding
materials, all types of welding materials, electrodes filler wires, hot/cold insulation materials,
primers and paints required. Arrangement of Radiography / UT machine as required by NDT
& all other facilities to complete the work in all respect shall be provided by the Contractor at
no additional cost to Employer

4.13 Contractor to plan and carry out suitable isolation, de-pressurization, purging, cleaning,
Hydro testing, flushing, drying, painting and removal of temporary supports, scaffoldings etc.
Contractor is to execute the job safely, without any operational hazard.

4.14 Any other work not specifically mentioned above but required for completeness of the
work as per specifications / drawings / codes & standards and instructions of Employer at
site.

4.15 It is the responsibility of the Contractor to ascertain space and exact routing for meeting
the requirements of finally approved P&IDs and design criteria.

4.16 The Contractor shall conduct necessary site surveys, prepare additional drawings / data
required which are not a part of the enclosed bid package to ensure that piping clears all
existing structures, cable trays, instrument racks and other equipments. The Contractor shall
gather all information from existing facilities in case as-built drawings are not available.

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4.17 Contractor Scope of work shall include modification / integration as per approved P&ID
and other requirement listed elsewhere in the bid package. For carrying out his scope of
work, Contractor may be required to open / dismantle / realign / modify any facilities or
instrument or piping or equipment of the existing facilities and the cost of the same shall be
included in the quoted price. It will be Contractor’s responsibility to make good, test and pre-
commission all such facility during and after completion of work with minimum period of
shutdown. Details of total shutdown if required for each modification / integration shall be
indicated in the bid against each activity.

4.18 Contractor shall perform the necessary modification / integration work on the basis of
actual physical conditions / data / parameters found during the site survey during pre-
engineering stage. Contractor shall not be entitled to any cost and time compensation on this
account.

4.19 Contractor shall do the necessary patch-up of insulation work where insulation are
opened during hook-up / tapping.

4.20 Contractor shall ensure, before submission of his bid, that the space allocated for the
various facilities for the modification is adequate and satisfactory. In case any additional
space / facility such as provision of any walkway / operating platform for maintenance and
operation of valve etc are required, the contractor shall indicate the same in his bid and the
cost shall be included in the lump-sum price.

4.21 While carrying out the modification of piping on existing facilities, Contractor to note that
the plant is in operating condition and if any part of the piping where modification is to be
carried out gets damaged/found damaged, Contractor shall supply / modify / change the
piping to suit his scope of work without any cost and time compensation on this account.

4.22 Contractor shall modify the support design wherever necessary to finalize the new
support without any interference with the existing facilities.

4.23 In case any existing facility is to be relocated or existing piping is to be altered in order
to carryout modification, Contractor shall execute these changes including testing etc.

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without any major shutdown. Contractor shall submit proposals for such unforeseen
modifications along with his bid and cost of these shall be included in lump-sum price.

4.24 If the bidding document / P&ID’s specifically require any existing facility to be altered or
reused, the same shall be done by the Contractor after verifying / checking the condition of
existing facility. If whole or any part of it is found to be defective, Contractor without any extra
cost shall replace the same.

In accomplishing the above task, the contractor shall take the total responsibility of executing
the project in accordance with this bid document including the supply of all materials and
consumables, construction equipment, labour etc. and will adhere to bid document
instructions and requirements in respect of all matters relating to the project.

5.0 GUARANTEE TEST

In addition to the routine tests and guarantees by the manufacturers for the items being
procured and installed, the Contractor to demonstrate as called for by the Employer by
carrying out additional tests viz. Hydro testing, NDT etc. at pressures and temperatures as
specified by the Employer in order to ensure that the entire system is safe and meeting the
parameters specified in the bidding documents.

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