or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than

the one for which it is given. FORMAT No. 0060-F-06

0
15.10.01
ISSUED AS STANDARD
BDG
SC
STANDARD PIPING DESIGN BASIS

SML
FORMAT No. : 0060-F-

CONTENTS

1.0 REFERENCED PUBLICATION.

2.0 DESIGN PHYLOSOPHY/ CRITERIA GENERAL.
2.1 EQUIPMENT LAYOUT.
2.2 UNIT PIPING.
OFFSITE & YARD PIPING.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

2.3

2.4 FLARE PIPING.

2.5 FLEXIBILITY ANALYSIS & SUPPORTING.
2.6 MATERIALS.
2.7 THERMAL INSULATION OF PIPING, EQUIPMENT
AND VESSELS.
2.8 PAINTING.
TABLE-I INSULATION THICKNESS FOR HEAT
CONSERVATION.
TABLE-II INSULATION THICKNESS FOR
PERSONAL PROTECTION.
TABLE-III INSULATION THICKNESS FOR
ELECTRICALLY TRACED LINES.
TABLE-IV JOB SPECIFIC BID REQUIREMENTS.
ANNEXURE-B ACCESSIBILITY FOR VALVES &
INSTRUMENTS.
ANNEXURE-C VERTICAL & HORIZONTAL GUIDES
SPECING.
ANNEXURE-D TECHNICAL REQUIREMENTS OF PIPING
MATERIALS.
ANNEXURE-E COLOUR CODING SCHEME.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given. FORMAT No. : 0060-F-

ANNEXURE-F

ANNEXURE-H
ANNEXURE-G

CLEARANCES.
INSULATED PIPING.
FIELD PAINT SYSTEM
PAINTING UNDER INSULATION FOR
FORMAT No. : 0060-F-

1.0 REFERENCED PUBLICATIONS.

The following codes and standards shall be followed unless otherwise specified.

ASME SEC.I - Rules for Construction of Power Boilers.

ASME SEC.VIII -Rules for Construction of Pressure Vessels.

ASME B31.1 - Power Piping

ASME B31.3 - Process Piping

express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

API RP 520 - Sizing, Selection and Installation of Pressure

Relieving Devices in Refineries.

API Std. 610 - Centrifugal Pumps for Petroleum, Heavy Duty

Chemical and Gas Industry Service.

ANSI/NEMA - Steam Turbines for Mechanical Drive Service.

SM 23

API Std. 617 - Centrifugal Compressors for Petroleum,

Chemical and Gas Industry Service.

API Std. 560 - Fired Heaters.

API Std. 661 - Air Cooled Heat Exchanger.

EJMA - Expansion Joints Manufacturers Association.

OISD-118 - Layouts for Oil and Gas Installations.

IBR - Indian Boiler Regulations.

NACE MR-0175 - Sulfide Stress Cracking Resistant Metallic

Materials for Oilfield Equipment.

NACE MR-0284 - Evaluation of Pipeline and Pressure Vessel

Steel for Resistance to Hydrogen Induced
Cracking.

NACE TM-0177 - Laboratory Testing of Metals for Resistance to

Sulfide Stress Cracking in H2S Environments.

2.0 DESIGN PHILOSOPHY / CRITERIA GENERAL

2.1 Equipment Layout

2.1.1 For equipment layout Petroleum Rules 1995, OISD Std.118 will be followed.

2.1.2 Refer Procon Clearance for Operation and Maintenance Requirements.

FORMAT No. : 0060-F-

2.1.3 Pipe-rack

In general, equipment layout shall be prepared considering straight pipe rack,

however other shapes like L/ T/ U/ H/ Z etc can also be considered based on area
available. The total width of pipe-rack shall include 20 % extra space for
modifications in unit at later stage.

The width of the rack shall be 6m, 8m, or 10m for single bay and 12m, 16m, or
20m for double bay having 4 tiers maximum. The spacing between pipe-rack
portals shall be taken as 6m in general. However it can be increased to 8m, in
which case an intermediate member shall be provided for supporting of small bore
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

line.

Clearance beneath pipe-rack shall be 3m minimum.

Road clearance shall be 7m minimum for main road and 5m for
secondary road.
Water lines more than 30 shall not be routed over rack.

2.1.4 Towers and Vertical Vessels

Towers and vertical vessels shall be arranged in a row with common center line,
decided by the largest vessels, placing O.D. of the equipment minimum 4m away
from the pipe-rack. A minimum clearance of 3m shall be allowed between tower
shells, but in any case adjacent towers shall be checked so that platforms do not
overlap (minimum 100mm horizontal gap shall be provided between platform of
adjacent towers) and that a minimum 900mm is left between tower plinths.

To handle heavy items (like relieve valves, blinds etc.) a davit or monorail is
required. The davit shall be on the side of the vessel/ column away from the rack.
The area at grade shall be kept clear for a dropout.

2.1.5 Horizontal Vessels

The horizontal vessels shall be laid perpendicular to pipe-rack and dished end
shall be placed minimum 4m away from the pipe-rack. The clearance between
horizontal vessel shells shall be minimum 2m or 900mm clear aisle whichever is
higher.

2.1.6 Pumps

Whenever practicable pumps shall be arranged in row with the center line of the
discharge on a common line, 3000mm away from the centerline of the rack
column. In general pumps shall be kept in open. Pumps shall be located outside
the pipe rack with motor towards the center of the rack and motor cable entry shall
be on the same side.

Pumps which are susceptible to fire and pumps for which specific notes are given
in P&ID shall be housed accordingly.

Clearance between two adjacent pumps shall be such that clear 900mm aisle is
available.
FORMAT No. : 0060-F-

All pumps with motor rating >= 55 KW are to be provided with monorail under
pipe-rack/ shed.

2.1.7 Exchangers

In most of the cases floating head of exchangers shall be placed on a line 4m

away from pipe-rack. Shell and tube type exchangers may have a removable shell
cover with flanged head. Tube pulling or rod cleaning area must be allowed at the
channel end. This shall be minimum tube bundle length +1.5m from the channel
head. In case of vertical exchanger, suitable platform shall be provided below the
top flange of channel or bonnet. Minimum clearance in between two horizontal
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

exchangers shall be 2m or 900mm clear aisle whichever is higher.

For heat exchangers on grade lying back to back, minimum clear gap of 15m shall
be provided.

2.1.8 Furnaces

Furnaces shall be located upwind or side wind of process units to blow any
combustible leaks away from the open flame. They shall be located minimum 90m
away from tanks and 30m away from control room. Distances for equipment
handling hydrocarbon from the furnace shall be strictly as per OISD norms.
Vessels/ reactors/ columns directly connected to the furnace (If required as per
P&ID) are exception. Stack height shall be minimum 6m above working platform in
the vicinity of 25m radius. In case of wall fired furnaces min. 2m wide platform with
escape route at each end is necessary.

2.1.9 Clearance and Accessibility

2.1.9.1 Crane Access & Tube bundle pulling

Drop-out area tube bundle length +1.5m shall be provided for tube bundle
removal. Monorail with chain pulley shall be provided for all heat exchangers,
except on grade & open to sky.

2.1.9.2 Access to Pumps

Clear access of 3.5m vertically and 4m horizontally shall be provided centrally

under main pipeways for small mobile equipment to service pumps.

2.1.9.3 Layout & Access Requirements for Platforms Ladders and Stairs

a. Dual access (i.e. one staircase and one ladder) shall be provided for
structure having length upto 22.65m (75ft). For large elevated structure, if
any part of platform has more than 22.65m (75ft) of travel, it shall have
staircase on both sides. Landing height of staircase should not be more
than 4m.

2.1.9.4 Clearances

Minimum clearances shall be as indicated in Annexure-H

FORMAT No. : 0060-F-

2.2 Unit Piping

2.2.1 Column/ Vessel Piping

Platform width shall be such that minimum 1m space is available beyond

manhole for movements.

Access platforms / ladders shall be provided along the column for valves
and instruments. Minimum width of platform shall be 750mm clear.

Maximum height of platform ladders shall be restricted to 5-6 metre.

express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

For upto two no. safety valves on column top platforms, davit is adequate,
for more than two no. safety valves, monorail with chain-pulley block shall
be provided. Load capacity for davit & monorail shall be minimum 0.5T.

2.2.2 Heater/ Furnace Piping

Block valves for emergency, snuffing steam valve shall be located

minimum 15m away from the heater, preferably on the upwind side of the
heater.
Nozzle forces and moments to be as per API 560

2.2.3 Pump Piping

A straight piece of minimum 5 times the nozzle size have to be provided

at the suction nozzle.

2.2.4 Relief System/ Blowdown System Piping

Liquid-vapour phase relief valves shall discharge into the flare header at
an angle 450 in the direction of header flow, to minimize the effect of
kinetic energy and to avoid accumulation of liquid.
Relief valve discharge piping shall be taken to safe location as per
following.

3m - above top platform of column or structure.

25 m - horizontally away from furnace

50 m - horizontally away from furnace, if more than one

System of different set pressure is discharging
Into one common riser of vent stack.

2.2.5 Steam Piping

Indian Boiler Regulations (IBR)

a) Steam lines with conditioned listed below fall in the scope of IBR.
FORMAT No. : 0060-F-

Lines having design pressure (maximum working pressure) 3.5

Kg/cm2 (g) & above.

Line sizes above 10 inside diameter having design pressure 1.0

Kg/cm2 (g) & above.
Lines with pressure less than 1.0 Kg/cm2 (g) is exclusion.

IBR requirements (in brief)

All materials used in lines falling under IBR must be accompanied with IBR
Inspection Cerficate.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

2.2.6 Steam Header & Supply lines

Line traps shall be thermodynamic type upto Class 600# & bimetallic for piping
Class 900# & above.

2.2.7 Steam Tracing/ Steam Jacketing

Maximum number of connections taken from a manifold is 12 including

spares.

Tracers shall be limited to the following run length upstream of traps:

Length of tracer pipe (Meters)

Size of
Steam Pressure
tracer
(inch)
20 50 100 150 200
psig psig psig psig psig
0.5
30 45 60 75 90

Tracers shall generally be of 0.5.

Size of the lead line to manifold shall be as follows:

Number of
Size of Lead Line
connections
2

3 1

4-6 1

7-12 2

Number of tracers required on a line shall be as follows:

FORMAT No. : 0060-F-

Size of Line Number of Tracers

Upto 4 1

6 to 16 2

18 to 24 3

26 & above To calculate

Steam Jacketing System

express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

A steam jacketed pipe consist of a product line which passes through the center of
a larger diameter steam line.

The nominal size of the inner pipe (CORE) and outer pipe (JACKET) in inches
shall be as per table below unless otherwise mentioned in project piping material
specification (PMS) or P&ID.

Core pipe Jacket pipe

1
1 2
1 3
2 3
4 6
6 8
8 10
10 12

The size of steam feeder to jacket shall be 4 to 5 meters or as mentioned in job

specification.

2.2.8 Utility Stations

Utility stations shall have three connections [one for LP steam (SL), one for Plant
Air (AP) and one for Service Water (WS) each of 1] unless otherwise specified in
P&ID.

The approach of utility station shall be considered 15m all around the station
location.

2.2.9 For piping Class 900# & above, hydrostatic vents/ drains, pressure connections &
orifice tap-offs shall be with double block valves with blind flange.
2.3 Offsite & Yard Piping
FORMAT No. : 0060-F-

In general, the pipes shall be laid at grade level on sleepers of concrete 300mm to
500mm high from grade level.

Clearance between lines shall be minimum C as given below.

C= (do + Df) / 2 + 25 mm+ Insulation thickness (es)
Where, do outside diameter of smaller pipe (mm)
Df Outside diameter of flange of bigger pipe (mm)

2.4 Flare Piping

Flare header shall be supported on shoe of height ranging from 100mm to 300mm.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

2.5 Flexibility Analysis And Supporting

2.5.1 Pipe Supporting Criteria & General Guidelines.

Pipe supporting shall preferably follow the basic span as given in Annexure-A.
Depending on the pipe size as a rule guides shall be provided on straight run of
pipes at intervals as specified in Annexure-C, unless specifically becomes non-
viable due to flexibility problems.

Bare pipes of size above 12 shall be supported with pad or shoe.

Pipe support design shall be such that deflection in piping system due to sustained
loads does not exceed 15mm in any case.

2.5.2 Method of analysis

Following lines shall be considered critical and shall mandatorily require formal
analysis.

Other lines may also need analysis, if required.

All process lines to and from fired heaters and steam generators.

All process lines to and from centrifugal compressor and blower.

All lines to and from turbines.

All pump lines and air coolers (6 & above and analysis temp> 65 0C &
less than 600C)

All other lines as below

4 to 6 Analysis temp above 3000C & less than 1000C
8 to 14 Analysis temp above 1500C & less than 800C
16 & above Analysis temp above 800C & less than 800C

All other critical lines (connecting to sensitive equipments.)

2.6 Materials
FORMAT No. : 0060-F-

Basic material selection of particular line depending on its service, temperature

and corrosivity shall be spelt out in process package. Detail material specification
shall follow the requirements stated herewith.

2.6.1 Pipe

a) Wall Thickness

Calculation of pipe thickness and branch reinforcement shall be based on

requirements of ASME B31.3-1999. Proper corrosion allowance and mill
tolerance shall be considered to achieve the selected thickness. (In case
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

of welded pipe the mill tolerance to be considered as 12 % (against

0.3mm)

As a rule the pressure-temperature combination to calculate wall

thickness shall be as follows:

Design
Material Class Size
Condition
Class
Upto 24
150 condition
Above 24 Line condition
Upto 16 Class
condition
300
Lines
C.S. & LTCS, Above 16
condition
Low Alloy upto Class
1 Cr-1/2 Mo, Upto 12
600 condition
2 Cr-1 Mo, 5
Cr- Mo, 9 Cr- Above 12 Line condition
1Mo Class
900 & Upto 8
condition
1500
Above 8 Line condition
Class
Upto 4
2500 condition
Above 4 Line condition
S.S. Class
Upto 12
150,300 condition
Above 12 Line condition
Class
Upto 6
600 condition
Above 6 Line condition
900,1500 Class
Upto 4
condition
Above 4 Line condition
FORMAT No. : 0060-F-

Class
Upto 2
2500 condition
Above 2 Line condition
Class
Upto 6
150 condition
Higher Alloys Above 6 Line condition
300-
All sizes Line condition
2500
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

MINIMUM REQUIREMENTS FOR PIPE THICKNESS:

In addition to the requirement covered in Para A & B given below, ratio of selected
pipe thickness (excluding mill tolerance and corrosion allowance) to pipe O.D.
shall not be less than 1/150.

A. Carbon Steel & Alloy Steels (Except steam tracing pipe):

& Min. Sch = S 160
1 to 2 Min. Sch. = S 80
Above 2 Min. Sch. = Std.
(For Seamless & Welded both)

B. Stainless Steel materials

& below Min. Sch.= 80S
1 to 2 Min.Sch. = 40S
Above 2 Min.Sch. = 10S
(For Seamless & Welded both)

b) Pipe Size

Pipe size shall normally be 0.5, 0.75, 1.0, 1.5, 2.0, 3, 4, 6, 8, 10,
12, 14, 16, 18, 20, 24, 26, 30, 36, 40, 44, 48, 52, 56, 60, 64,
72, 78, and 80.

c) Pipe Type

Material Size Type

CS, LTCS, AS, Upto 14 Seamless
(except for Cat D
fluids & LP
Hydrocarbons in Above 14 E.Fs.W.
offsites)
Upto 6 Seamless
SS Process lines
Above 6 Welded

Upto 1.5 Seamless

SS Non process lines
2 & Above Welded
FORMAT No. : 0060-F-

CS (Cat D fluids) ALL Welded

CS (LP Hydrocarbons Upto 6 Seamless

in offsites) Above 6 Welded

2.6.2 Fittings

a) SW fittings shall be 3000#, 6000#, and 9000# depending on the pipe

thickness S80, S160 and above S160 respectively.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

b) Upto 600# all branch connections shall be as follows.

Upto 1 NB Half Coupling/ Tee

2 and above Tee/ pipe to pipe (with / without reinforcement
pad)

c) For branch connection above 600# rating equal tee / unequal tee shall be
used for all sizes. Unequal tee may be replaced by weldolet upto branch
size of 8.

d) Mittres shall be used in Category D service above 6. For all other 150#,
300# classes mitres may be used after checking line condition for sizes
above 36 only.

b) Flanges

Flanges shall be as follows:

Class Size Type Remarks

Upto SW RF If non metallic gasket
1.50 used.
150#
Up to WN RF If metallic gasket is
1.50 used.
2 & WN For SS LJ FF & Stub
above RF/LJ Ends
150# FF
2 & SO RF If used in CAT D
above service.
Upto SW RF
300#, 1.50
600# 2 & WN RF
above
900,1500, ALL WN RTJ
2500

2.6. 4 Gaskets
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given. FORMAT No. : 0060-F-

Rating
Temperature (0C)
Type
Remarks
FORMAT No. : 0060-F-

Upto 4000C CAF NonHydrocarbon

Spiral SS304/ SS
150# Upto 3710C Specific requirement
316L+ CAF

Spiral SS316+
Above 4000C Specific requirement
Grafoil
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

Spiral SS304+
-
CAF
Upto 5000C
Spiral
For NACE classes
SS316L+CAF

Spiral SS304+
300# & 600# 5010C to 5400C -
Grafoil

Spiral SS316+
5410C to 7000C -
Grafoil

Spiral SS304H+
Above 7000C -
Grafoil

Below 450C to Spiral

-
800C SS304+CAF
150#, 300#,
600#
Spiral
Below 80C -
SS316+Grafoil

Below 450C SS304 RTJ -

900#, 1500#, Soft Iron/ 5 Cr-

-450C to 4000C -
2500# 1/2 Mo RTJ

5Cr 1/2 Mo/

Above 400C SS321/SS316 RTJ
-

2.6.5 Valves

a) SW Valves upto 1 inch - upto 600# ANSI Class.

b) Flanged cast valve above 1 - 150#, 300#, 600# ANSI Class.

FORMAT No. : 0060-F-

c) BW Valves all sizes - 900# Class & above.

2.6.6 NDT Requirements

As a rule, all hydrogen, oxygen, NACE and any other lethal service shall have
100% radiography on weld joints. Castings used in these services shall have
100% radiography. For high pressure application i.e. 600 lb upward 100%
radiography on weld joints shall be employed. In 100% radiography classes any
fillet welds employed shall have 100% MP in CS/ AS classes and 100% DP in SS
classes. Cat. D service does not require radiography. Classes in 150# for normal
hydrocarbon service shall be subjected to 10% radiography and fillet welds shall
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

be subjected to 10% DP/MP check. Classes in 300# for normal hydrocarbon

service shall be subjected to 20% DP/ MP check.

2.6.7 Strainers:

A Temporary Strainers :

1 & below for all services shall be Y-Type.

2 & above for steam service shall be T-Type.
2 & above for other than steam services shall be T-Type.

B Permanent Strainers:

Compressor suction, cold box inlet strainers shall be cone type

with reinforced perforated sheet cage design.
1 & above permanent strainer shall be as per process data
sheet.

2.7 Thermal Insulation Of Piping, Equipment & Vessels

2.7.1 Hot Insulation

The insulation of piping, equipments and vessels shall be carried out with the
following insulating materials and the thickness of insulation shall be chosen from
the tables enclosed.

a) Bonded mineral wool

Lightly resin bonded Rockwool Insulation shall conform to ASTM C592

class-II for blanket and ASTM C547 class-III for preformed pipe section.
Rockwool insulation as per IS 8183 and IS 9842 are also acceptable.
From ambient to 5000C. Pipe sections/ mattresses shall be as per
Annexure-I to insulation spec. 92006314SP2004.

Resin bonded pipe sections of glass wool may be used upto 350 0C.
Density shall not be less than 80 Kg/m3
b) Calcium Silicate
FORMAT No. : 0060-F-

Calcium Silicate block and pipe thermal insulation shall be composed

principally of hydrous calcium silicate reinforced with mineral fibres
(except slag wool). The specification shall conform to ASTM C533 Type-I
upto 6490C & Type-II above 6490C to 8710C.

c) Polyisocyanurate (ASTM C591 Type-II &III)

Rigid Polyisocyanurate foam block pipe fittings insulation shall be

manufactured with polyester or polyether resins, flammability retarding
agents, special catalysts and fluorocarbon blowing agent. This is suitable
for use upto 1250C. Selection of samples for testing shall be as per ASTM
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

C390 (Class IV frequency).

d) Cellular glass (Foam glass).

Cellular glass foamed are fused into unicellular foam can be used upto
temperature of 1250C.The testing of samples shall be as per ASTM C552.

2.7.2 Cold Insulation

Insulation for cold insulation (IC) for operating temperatures below 100C and dual
temperature (cold/hot) service where upper temperature limit is 120 0C shall be as
given below:

a) Polyurethane Foam

Preformed pipe sections and radial lags (for higher diameter pipe) of
polyurethane foam of shelf extinguishing type in accordance with ASTM
C591 TYPE-II Grade 2 shall be used as cold insulation material.

High density polyurethane foam block of bulk density more than 300
Kg/m3 shall be used for supports in cold lines.

Adhesive for bonding sections shall be Foster Fire Resistive Adhesive 81-
33 or blown bitumen type 85/25 shall be used.
Vapour seal like Forster Fire Retardant Mastic 60-30 or equal shall be
used.

Filler material shall be PUF dust or mineral wool mixed with specified
adhesive shall be placed lightly so as to fill irregular voids and at flashing
of insulation shall be Foster Foam Seal Sealer 30-45. Glass cloth to be
used for vapour barrier reinforcement, shall be open weave 10 mesh
having glass fibre thickness of 5 mils. Aluminium sheets shall be used for
cladding of vapour barriers.

b) Polyisocyanaurate (ASTM C591 type-II&III)

Refer clause 2.7.1. (c) for details.

2.7.3 Insulation Thickness

FORMAT No. : 0060-F-

The insulation thickness and type of insulation (Ih, It, Ic, Is, Ie and acoustics) to be
applied on equipments and vessels shall be as per equipment data sheet. In
absence of insulation thickness on equipment data sheet, insulation thickness as
specified in the enclosed tables shall be followed.

Insulation thickness on piping shall be as per line schedule. In absence of line

schedule Table-I (Heat Conservation-Ih & It), Table-II (Personnel Protection i.e. Is),
Table-III (Insulation over electrically traced lines i.e. Ie) shall be followed.

2.7.4 Weather Proof Jacket (Cladding)

express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

Aluminum jacketing shall be used as weather protection over insulation unless

otherwise specified and shall be as per ASTM B 209 alloy 3003 H16 or IS:737
designation 31000 (old NS3) condition H3 for flat sheets and H4 for corrugated
sheets. The thickness of the jacket as follows;

For all materials

For Calcium
except Calcium
Silicate
Silicate
0.56 mm
For shell of vertical 0.71mm (22 SWG)
(24SWG)
vessels, columns etc. corrugated.
corrugated

Storage tanks & tank 1.22 mm (18SWG) 0.56 mm

roofs Flat (24SWG) Flat

For all piping other

0.71 mm (22SWG) 0.56 mm
than grade piping in
Flat (24SWG) Flat
offsites
For Horton sphere &
horizontal vessels 0.71 mm (22SWG) 0.56 mm
shell & head, vertical Flat (24SWG) Flat
vessel heads
1.22 mm (18 SWG) 1.22 mm (18
For removable covers
Flat SWG) Flat

0.56 mm
0.56 mm (24SWG) (24SWG)
For grade piping in Galvanized steel as Galvanized steel
offsites per IS 277 Class I or as per IS 277
equivalent. Class I or
equivalent

2.7.5 Ancillary Materials

2.7.5.1 Aluminium Foil to protect stainless surfaces in temp.below 00C shall be 0.1 mm
(42 SWG) thick per ASTM B209 alloy 3003 H16 or IS-737 designation 31000 (old
NS3) condition H3.
FORMAT No. : 0060-F-

2.7.5.2 Bands/Wires for securing insulation shall be of ASTM B209 Alloy 3003 H16 or IS-
737 designation 31000 (old NS3) condition H3 or 18/8 Stainless steel. For
securing aluminium foil on stainless steel surface 24 SWG thick x 20mm wide
aluminium bands shall be used.

For securing fibrous insulation on piping, 24 SWG x 12 wide, aluminium bands

shall be used.

For securing fibrous insulation on equipments, 14 SWG x 20 wide aluminium

bands shall be used.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

For securing fibrous material on vertical storage tanks, galvanized steel 40 mm

wide x 3 mm thick flat shall be used.

For securing fibrous material on spheres, stainless steel bands of 25mm wide x
0.8mm thick shall be used.

For securing rigid insulation on pipe upto 16 O.D., annealed galvanized steel wire
of 16 SWG shall be used. Galvanizing coating shall have 600 g/m2 of surface area.

For securing rigid insulation on pipe 18 O.D. and above, galvanized steel band
20mm wide x24 SWG shall be used. Galvanizing shall be 600 g/m2 of surface
area.

For securing rigid insulation on vertical & horizontal vessels, galvanized steel band
20mm wide x 24 SWG shall be used. Galvanizing shall be 600 g/m 2 of surface
area.

2.7.5.3 For securing cladding on insulation on piping, aluminium band 12mm (min) x24
SWG thick shall be used.

For securing cladding on insulation on equipment, aluminium band 20mm wide x

24 SWG shall be used.

For securing cladding on insulation for vertical storage tanks stainless steel band
25mm wide x 24 SWG shall be used.

For securing cladding on insulation for spheres stainless steel band 25mm wide x
24 SWG shall be used.

2.7.5.4 Rivets used for securement of metal jacket shall be expanding aluminium POP
blind eye type, 9.5mm long x 5mm diameter.

2.7.6 Application

Support skirts of vertical vessels and columns shall be insulated both from inside
and outside to a minimum distance of 600mm from bottom tangent line. The
insulation must terminate at minimum 300mm above support concrete or steel
work.
The following items under hot insulation shall not be insulated unless otherwise
specifically asked.
FORMAT No. : 0060-F-

a) Pumps with operating temperature below 2000C .

b) Internally insulated or refractory lined equipment.

Vapour barrier shall be applied on all the vessels and equipments in cold services
and also for services upto 1250C

2.8 Painting

2.8.1 Scope of Painting

express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

The following surfaces and materials shall require painting :

Painting of pipes, fittings, valves surfaces under insulation of stainless steel

insulated piping system operating above 00C . Stainless steel lines operating
below 00C requires aluminium foil in lieu of painting.

2.8.2 Colour Coding

Painting work shall require to satisfy the Civil Defence requirements of the area
where the plant is being setup. All other colour coding shall be as per the table of
Colour Coding scheme for pipes, equipments, machinery and structures (refer
Annexure-E).

2.8.3 Surface Preparation

All surfaces to be painted shall be blast cleaned either by Air blasting or water
blasting using sand / steel grit to finish SA 2.5 as per SIS-055900/ISO-8501-1.
Only repair painting of shop primed piping shall be done with mechanical tools to
surface finish ST-3 as per SIS-0559 00/ISO-8501-1.

2.8.4 Painting Application

2.8.5 No surface shall be coated in rain, wind or in environment where injurious airborne
element exists, where surface temperature is below 5 F above due point, where
relative humidity is greater than 90 % and temperature is below 40 F.

2.8.6 Painting Materials

2.8.6.1 Inorganic Zinc Silicate (F-9) of 65-76 micron DFT Universal shop primer and repair
paint at site upto design temp of 400 C for all surface except stainless and higher
alloy piping. For surface above 400 C, heat resistant synthetic alluminium paint
(F12) shall be used.

2.8.6.2 Primers and finish paints are designated as follows :-

P2 Chlorinated Rubber Zinc phosphate primer.

P6 Epoxy Zinc phosphate, primer.
F2 Acrylic polyurethane finish paint.
F3 Chlorinated rubber based finish paint.
FORMAT No. : 0060-F-

F6 Epoxy-High Build finish paint.

F7 High build coatless epoxy coating.
F9 - Inorganic Zinc Silicate coating.
F11 Heat resistant synthetic Alluminium paint suitable upto 250 C.
F12 Heat resistant synthetic Alluminium paint suitable upto 500 C.

For filed paint system in different environment refer Annexure F.

Annexure D
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

Technical Requirements of Piping Material

Ends
Unless otherwise specified, the ends shall be to the following standard :

SW / SCRD : ASME B16.11

BW : ASME B16.25
FLANGED : ASME B16.5 and ASME B16.47 SERIES B
THREADING : ASME/ANSI B1.20.1 (NPT, Taper threads)

Face Finish
This shall be to MSS-SP-6/ASME B46.1 / ASME B16.5. the interpretation shall be :

Stock Finish : 250-1000 in AARH

Serrated Finish : 250-500 in AARH
Smooth Finish / 125 AARH : 125-250 in AARH
Extra Smooth Finish / 63 AARH : 32-63 in AARH

Austenitic Stainless Steel

- Wherever specified, Intergranular Corrosion (IGC) Test shall be
conducted as per following :
- ASTM A262 Practice B with acceptance criteria of 60 mils/year (max.0
for casting.
- ASTM A262 Practice E with acceptance criteria of No cracks as
observed from 20 X magnification & microscopic structure to be observed
from 250 X magnification for other than casting.
- For IGC test, two sets shall be drawn from each solution annealing lot;
one set corresponding to highest carbon content and other set
corresponding to the highest rating/thickness.

Item Specific Notes :

Pipes
- Double seam is allowed for sizes 36 and larger.
- Galvanized Pipes shall be only Hot Dip galv. To ASTM A53.

Fittings
FORMAT No. : 0060-F-

- Al welded fittings shall be double welded. Inside weld projection shall not
exceed 1.6mm, and the welds shall be ground smooth at least 25mm
from the ends.
- All welded fittings shall be normalized for CS, normalized & tempered for
AS; and 100% radiographed by X-ray for all welds made by fitting
manufacturer as well as for welds on the parent material.
- Bevel ends of all BW fittings shall undergo 100% MP/DP test.

Flanges
- For Ring joint Flanges, Blinds and Spacers, the hardness shall be as
follows :
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140

1% Cr. To 5% Cr. Mo. 150
Type 304, 316, 321, 347 180
Type 304L, 316L 140

Valves
- Valves of Class 900 & above shall be pressure-seal type. Threaded and
seal welded or welded bonnet may be employed upto sizes 1-1/2.
- Forgings are acceptable in place of Castings but not vice-versa.

Dimensions
- Face-to Face/End-to-End dimension shall be as per ANSI N16.10. in case
the same is not covered under B16.10, the dimension shall be as per BS
2080/Manufacturers Std.
- Valve under cryogenic service (temp. below 45 C) shall be as per BS-
6364 and shall be procured from prequalified vendor.

Operation
- Generally the valves are handwheel or lever operated. However, suitable
gear operator in enclosed gear box shall be provided for valves as follows
:

Valves Type Class For Size

Gate 150 12
300 12
600 12
900 6
1500 3
2500 3

Globe/Y-Globe/ 900 6
Stop-Check 1500 3
2500 3
Ball/Plug 150 6
300 6
600 4
FORMAT No. : 0060-F-

900 3
1500 3
Butterfly 150 10
300 6

- Hand wheel diameter shall not exceed 750mm and lever length shall not
exceed 500mm on each side. Effort to operate shall not exceed 35 kgf at
handwheel periphery.

By Pass
- A globe type valve (size as per ASME/ANSI B16.34) shall be provided as
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

by-pass to the following sizes of gate valves :

Class Size
150 26 & above
300 16 & above
600 6 & above
900 4 & above
1500 4 & above
2500 3 & above

Radiography of Cast Valves

A. Unless specified otherwise, the following valve

castings shall undergo radiographic examination (for all materials) :

Class Size Qty.

150# 26 & above 100% (except for Cat. D service)
300# 18 & above 100%
600# & above All 100%

B. For Hydrogen, oxygen, Nace, stress relieved piping

classes, additional radiography requirements shall be as follows (Over &
above the requirements covered under Para. A above) :

150# Upto 24 50%

300# Upto 16 50%

C. For Cryo/LT Classes, additional radiography

requirements shall be as follows (Over & above the requirements covered
under Para. A above) :

150# Upto 24 20%

300# Upto 16 20%

D. For alloy steel, stainless steel castings (not

covered in Para B & C above) shall be additionally radiographed as
follows ;

150# Upto 24 10%

300# Upto 16 10%
FORMAT No. : 0060-F-

- Radiography procedure, areas of castings to be radiographed, and the

acceptance criteria shall be as per ASME/ANSI B16.34
- All casting in Class 300# & above shall be radiographic quality casting.

Ball/Plug/Butterfly Valves

- The ball of Ball valves shall not protrude outside the end flanges.
- Ball valves shall be floating ball type/trunion mounted type as per
following :
Class Floating Ball Trunion Mounted
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

150 8 & below 10 & above

300 4 & below 6 & above
600 & above 11/2 & below 2 & above
- Use of soft seated ball/plug/butterfly valves shall be suitable selected
based on temperatures handled.

Strainer
- All 2 & higher sized Y type strainers shall be provided with 3/4 threaded
tap and solid threaded plug as drain connection. For less than 2, this
shall be size.
- For fabricated strainers, all BW joints shall be fully radiographed and fillet
welds shall be 100% DP/MP checked.
- All the strainers shall be hydrostatically tested at twice the design
pressure.

Expansion Joints
- The applicable codes are ASME B31.3 and EJMA (Expansion Joint
Manufacturers Association).
- Bellows shall be formed from solution annealed sheet conforming to the
latest ASTM spec. any longitudinal weld shall be 100% radiographed.
- The out of roundness shall be limited to 3mm. This is the max. deviation
between the max. & min. diamter.
- The actual circumference of the welding end shall be maintained to
3mm of the theoretical circumference.
- Bellows should be designed for 10,000 cycles (ANSI B31.3) minimum.

Support & Spring Assemblies

- The Material, Design, Manufacture and Fabrication shall be generally as
per MSS-SP-58/MSS-SP-89 and/or BS 3974.
- Testing of springs shall be as per BS 1726.

Gaskets
- Non-metallic ring gaskets as per ASME/ANSI B16.21 shall match flanges
to ASME/ANSI B16.5 upto 24, and ASME/ANSI B16.47 or AWWA for
sizes 24 unless otherwise specified.
- Spiral wound gasket as per ASME B16.20 shall match flanges to
ASME/ANSI B16.5 upto 24, and ASME B16.47 series B for sizes 24,
unless otherwise specified.
FORMAT No. : 0060-F-

- Inner and outer rings shall be considered for spiral wound gaskets based
on undermention philosophy :

OUTER ring :
(i) C.S. outer ring irrespective of temp./spiral strip material
(except subzero temperatures).

INNER ring :
(i) Material of inner ring to be C.S. for C.S. classes & same as
that of spiral strip material for other than C.S. classes.
(ii) 26 & above for all classes.
express or implied agreement of the Borrower that it shall not be reproduced, copied, transferred or used for a purpose other than the one for which it is given.

(iii) All sizes for vacuum classes.

(iv) 2 & above for Hydrogen classes.
(v) All sizes in H grades of S.S, SS347, SS321 classes.
(vi) For all sizes for classes with temperature beyond 427 C.

- RTJ Gaskets :
(i) To be used for Class 900# and above in line with OISD
recommendation.
(ii) Gasket material to be as follows :
CS Classes = soft iron
Upto 5% Cr = 5% Cr alloy steel
SS = Same as class material

Stud, Bolts, Nuts and Jack Screws

- All bolting shall be as per ASME/ANSI B18.2.1 for Studs, M/C Bolts and
Jack screws, and ASME/ANSI B18.2.2 for nuts.
- Threads shall be unified (UNC for 1 dia and 8UN for 1 dia) as per
ANSI B1.1 with class 2A fit for Studs, M/C Bolts and jack screws, and
class 2B fit for nuts.
- Stud bolt shall be threaded full length with two heavy hex nuts. Length
tolerance shall be in accordance with the requirement of table F2 of
Annexure F of ASME B16.5.
- The nuts shall be double chamfered, semi-finished, heavy hexagonal
type. Jack screw end shall be rounded.

Special service Requirements :

IBR
- IBR stands for Indian Boiler Regulation. For steam services, it is statutory
obligation to meet IBR requirements.
- For items under IBR, composition restrictions, test reports, painting, etc.
Shall be as per IBRs stipulations.

CRYO & Fire-Safe

- For items to be used under cryogenic conditions, temp below 45 C and
those required to be fire-safe, special designs and tests would b
applicable.

Impact Tests
- Welded Pipes and Fittings used below ASME Temp. 29 C shall be
impact tested as per requirement of ASME B31.3.