Guidelines For Piping Design For Metallurgical Industries

GUIDELINES FOR PIPING DESIGN FOR METALURGICAL INDUSTRIES
MECON LIMITED RANCHI 834002
DOC.NO: MSTD-DESG-FS&PD-1405, REV-0
JUNE 2006
CONTENTS
CHAPTER NO.
01 02 03 04 05 06 07 INTRODUCTION PIPE SIZING PIPING LAYOUT DESIGN CONSIDERATIONS LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS PIPING MATERIAL SPECIFICATIONS REFERENCES
DESCRIPTION
PAGE NO. Page 1 of 2 to Page 2 of 2 Page 1 of 9 to Page 9 of 9 Page 1 of 9 to Page 9 of 9 Page 1 of 44 to Page 44 of 44 Page 1 of 8 to Page 8 of 8 Page 1 of 27 to Page 27 of 27
REV. NO.
DATE
PREPARED BY
CHECKED BY
APPROVED BY
1.V.KUMAR, AGM 0 27.06.2006 2.R.B.KUMAR, SR.MANAGER S.P.GUPTA. DGM V.K SAHAY, DGM I/C
CHAPTER -01
INTRODUCTION
MECON LIMITED
GUIDELINES FOR PIPING DESIGN
DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01
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01
INTRODUCTION
01.01 SCOPE 01.01.01 This document provides general guidelines and procedures for design of Inter Shop/yard and In-shop piping systems in Metallurgical Plants and other related industrial installations. The provisions & stipulations of this documents are applicable to all the utility fluids conditions & systems those listed is clause 01.01.04. These guidelines are general in nature and are to be applied by the piping designer judiciously considering the system parameters, plant & piping layout, prevalent ambient conditions, operation & maintenance practices etc. The provisions of this documents do not apply to the following:a) Fluids not listed in clause 01.02 i.e. chilled water, storm water, chemicals, lubrication oil, grease, hydraulic oil, sewerage etc. Equipment piping e.g. Hot blast, PCM lime Milk piping, etc. Tubes & Tube fittings. Gas lances. Coal Tar injection piping. Piping inside Power plant building Pipes for pneumatic conveyance
01.01.02
01.01.03
01.01.04
b) c) d) e) f) g)
01.02 CLASSIFICATIONS OF FLUIDS For the purpose of piping design, the fluids are classified under following broad categories: By-product Fuel Gases Hydrocarbon Fuel Gases Industrial Gases Liquid Fuels Compressed Air Steam Water - Industrial Water. - Drinking Water. - Deminaralized Water. - Soft Water.
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By-product Fuel Gases Gases generated during many of the metallurgical processes contain carbon monoxide (CO), hydrogen (H2), methane (CH4) and other hydrocarbons. These gases have substantial calorific value and are used as fuel for various heating requirements in the plant. The gases are generally made available from the production units after cleaning however, these may contain some residual impurities like suspended dust particles, moisture. Gases like Coke Oven Gas may also contain tar fog, H2S and other chemicals, etc. Some of the by-product fuel gases commonly used are as follows; Coke Oven Gas Blast Furnace Gas Basic Oxygen Furnace (BOF) Gas COREX Gas Top gas from Direct Reduction Furnaces
The above gases have different characteristics and calorific values and are used as fuel either alone or as mixture of gases to optimize their in-plant usage. Hydrocarbon Gases Hydrocarbon gases supplied from external sources are also used as fuel. This category includes the following: Natural Gas Liquefied Petroleum Gas (LPG) Coal Bed Methane Gas
Industrial Gases Industrial Gases are used in the metallurgical processes. Industrial gases are also used for cutting, welding, purging and other requirements like inert atmospheres in furnaces, etc. Oxygen is used for steel making, enrichment of air blast in blast furnaces, cutting & welding needs. Nitrogen is used for providing inert atmospheres as well as for purging purposes. Argon is used for metal refining providing inert atmosphere and welding. Acetylene is used for cutting and welding. Hydrogen and dissociated ammonia are used for generating inert atmosphere in heat treatment furnaces.
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Liquid fuels Liquid fuels are used in industrial installations as primary / supplementary fuel. These include: Fuel Oils as per IS: 1593-1982 Diesel Fuels as per IS: 1460-2002 Heavy Petroleum Stocks as per IS: 11489-1985
Compressed Air Compressed air is generally required for all industrial installations for distribution of service air and dry air (Instrument air) Steam Steam piping network is required for distribution of steam for heating / utility and purging requirements. The steam may be supplied from Captive power plants, utility boilers or waste heat recovery boilers. Water Water is used for cooling, drinking & flushing purposes in an industrial plant. Various kinds of water available in a steel plant are industrial water, make-up water, clarified water, drinking water, fire fighting water, DM water & soft water. The main source of water in industries are rivers, canals, tube wells, ponds, municipal supply, etc,.
01.03
Individual Piping system shall be provided for distribution of each of the above fluids from generating station to the consumers.
CHAPTER -02
PIPE SIZING
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GUIDELINES FOR PIPING DESIGN 02.00 02.01
DOC No MSTD-DESG-FS&PD-1405 Chapter No 02
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PIPE SIZING
DESIGN PARAMETERS Design pressure for various categories of piping shall be as follows : Low Pressure Fuel gas piping ( Up to 1500 mm WC MOP) All other gas piping (except Acetylene) Acetylene piping ranges Water piping Steam piping : 1.25 Times Max. Operating Pressure(MOP) But not less than 2000 mmWC minimum : 1.25 Times Max. Operating Pressure
: Test pressure based on Maxi.Allowable Working / Operating Pressure Refer para 02.02 below : 1.5 times Maximum System Pressure. : 1.5 times Maximum Operating Pressure.
Design temperature for all fluids shall be maximum working temperature of fluid. In case of ambient temperature, design temperature may be taken as 60 deg C for piping exposed to sun and 45 deg C for indoor piping. Flow rate for design purpose shall be taken as peak flow rate for the respective section. In case of branches to individual consumers, peak flow rate for the consumers shall be considered. For common branches and main headers, peak flow rate based on consumption pattern/ diversity factor may be used for pipe sizing. Future augmentation of flow rate for common piping shall also be taken into consideration for pipe sizing. 02.02 SELECTION OF PIPE SIZE Pipelines shall be sized by limiting the fluid velocity in the pipeline as per Table 02-01. Peak flow rate based on the distribution pattern shall be considered for sizing of pipes. Sizing shall be based on actual flow rate at worst combination of parameters e.g. lowest pressure and highest temperature. In case recommended velocity is dependant on diameter range, after initial sizing, velocity should be re-checked and if required, size should be recalculated. Nearest higher standard pipe size shall be selected after calculation. For water piping & critical applications of pipes for other services, pipe sizes should be re-checked after pressure drop calculations and availability of required pressure at consumer point. If required, pipe size may be increased to meet the pressure drop criteria.
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02.02.01
Acetylene pipes Acetylene differs from other fuel gases such as Natural Gas and propane because of its ability to decompose. In case of such reaction high energy is released which can travel as shock wave through piping. Velocity of shock wave depends on pipe size and in smaller cross section area, velocity is restricted and shock wave dies out after travelling some distance. This phenomenon is called deflagration and pressure developed in pipe is limited. In larger pipe, shock wave can travel fast and entire volume takes part in reaction and explosion may occur. This is called detonation and pressure developed in pipe is very high.
Based on the pressure and pipe size, the operating regime of acetylene is divided into three working ranges complied in IGC Document No. 9 / 78. The document gives recommendations for selection of pipe sizes and corresponding test pressures for each zone. Classification into zones is also given in IGC referred above. The pipe size shall be selected so that piping remains in safe zone or deflagration zone as per working ranges. Use of pipe size in detonation zone shall be avoided hence if required multiple pipes shall be used to carry the total flow rate required. Test pressure for working range I shall be 1.5 times maximum working pressure. In case of working range - II and working range III the design pressure shall be 10 times and 20 times ( Minimum 30 Bar ) of maximum working pressure respectively. While crossing hot zones acetylene pipeline are protected with heat shield or insulated depending upon the site requirement. 02.02.02 Oxygen pipelines In carbon steel pipes carrying oxygen at high pressure and high velocity, foreign particles, rust or scale can cause internal spark due to friction at high velocity and result in steel pipe catching fire which may spread vigorously in oxygen atmosphere. Several accidents have been reported due to such fires. Since cleanliness in erected piping system is always in doubt, it is recommended to adopt velocities given in Table A- 02.01 B. In areas where higher velocity may be required, SS pipes may be used. In pressure regulating stations where velocity as well as turbulence is large, copper pipes shall be used. For pipes above DN 150 size, CS pipes with inner copper sleeve can be used. In case of copper pipe having high conductivity, any spark is quenched and thus there is no chance of fire. For further details refer IGC Document 13 / 82.
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02.03 02.03.01
SIZING CALCULATION Calculation of Actual Flow Rate Flow rate of various gaseous fluids is indicated in Nm3/hr. This needs to be converted to Am3 / hr considering actual pressure and temperature parameters of the fluid using formula indicated below:PNVN ------ = TN Where, PN VN TN PA VA TA = = = = = = 1.033 Kg f / cm2 (Absolute) Volume in Nm3 / hr 273 deg. K Actual pressure of fluid in Kg f / cm2 (a) (Absolute) Actual Volume in m3 / hr Actual temperature of fluid in deg. K PAVA -----TA
For liquid pipelines (Fuel oil, water), no correction is necessary. 02.03.02 Pipe Size Calculation d2 --------------- . V. 3600 m3 / hr 4. 106 0.0009 d2 V m3 / hr ( Q ) 0.5 ---------------------------- mm ( 0.0009 V ) 0.5
____________
18.80 Q / V
Where Q = Flow rate in m3 / hr (Calculated as VA above)
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V d
= =
Permissible velocity in / sec. Inside diameter of pipe in mm
For steam service, flow rate is normally indicated in tonnes per hour. This need to be converted into m3 / hr by finding specific volume of steam at the given temperature and pressure using steam table and subsequently pipe size is worked-out based on velocity range indicated in Table A-02-01C. For steam service, velocity depends upon fluid condition as well as range of pipe diameter. Finally, pipe size is finalized based on trial and error method as carried out for fuel gas service. For moist gas, partial pressure at the operating temperature shall also be considered while calculating the actual flow.
TABLE 02-01 RECOMMENDED VELOCITIES FOR SELECTION OF PIPE SIZES

A : Low Pressure Fuel Gases Sl. No 1 2 3 4 5 6 7 Nominal Pipe Dia (mm) 20 80 100 - 250 300 500 600 800 900 1200 1300 2000 > 2000 Gas Velocity, m/sec (maximum)
BF & BOF Gas CO Gas, Natural Gas Mixed BF & Corex Gas
Remarks
2 3-4 5-6 67 8 - 10 11 - 18 20 - 25
2 45 67 78 9 12 13 20 23 - 28
2 4 5 57 7-8 8 11 12 19 21 - 27
B : Medium Pressure & High Pressure Gases Medium Nitrogen, Argon, Compressed Air, Instrument Air Oxygen LPG Acetylene Notes : 1. In case adequate pressure is available, velocity for inert gases and air can be increased up to 30 m/sec Pressure Range (kgf/cm2 g) Up to 6 6 - 16 16 - 40 Up to 16 16 - 40 Up to 3 Up to 1.2 Gas Velocity, m/sec (maximum) 8 10 12 16 Up to 20 10 8 8 8 Remarks See Note 1
See Note 2
Up to DN 25
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2. In case cleanliness of pipe is ensured, maximum velocity can be 20m/sec. In case SS pipes are used, velocity may go up to 30m/sec and for copper pipes velocity up to 60m/sec can be considered.
C:
LIQUID FUELS:Medium Liquid Fuels Pressure Range (kgf/cm2 g) All Pressures Velocity, m/sec (maximum) 1.5 Remarks
D : FOR STEAM Sl. Fluid Condition No 1 2 3 4 5

SATURATED AT SUB-ATMOSPHERIC PRESSURE SATURATED AT 1 TO 7 Kgf/cm2 (g) SATURATED ABOVE 7 Kgf/cm2 (g) -
Average Velocity, m/sec

Up to DN 50mm DN 50 to DN 150mm DN 200mm and above
Remarks
10 15
15 20
15 22 15 25 20 30 20 - 33
20 33 20 35 25 40 28 43
25 43 30 50 30 50 35 - 55
SUPERHEATED UPTO 7 Kgf/cm2 (g) SUPERHEATED ABOVE 7 TO 35 Kgf/cm2 (g)
E : FOR WATER Sl. No 1 2 3 Fluid Condition

PUMP SUCTION CONDENSATE WATER PUMP SUCTIONGENERAL SERVICE WATER GENERAL -
Average Velocity, m/sec

Up to DN 50mm DN 50 to DN 150mm DN 200mm and above
Remarks
0.4 0.6
0.6 - 0.7
0.6 0.9 0.4 1.0
0.7 1.3 0.6 2.0
0.9 1.5 1.0 -2.4
02.04 PIPE THICKNESS CALCULATION ( PIPE SUBJECTED TO INTERNAL PRESSURE) 02.04.01 For Fuel and industrial gasses pipeline the pipe thickness is generally calculated as per ANSI B31.3 1996 ( Process Piping )
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GUIDELINES FOR PIPING DESIGN t = PD/{2(SE+PY)} Where
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t = Calculated thickness in mm P = Internal design guage pressure in kPa D = Outside dia of pipe in mm S = Basis allowable stress for metals in MPa E = Quality factor as per (Table A-1B) of ANSI B31.3 Y = Coefficient from Table 304.1.1 of ANSI B13.3 C = Sum of mechanical allowances plus corrosion and erosion allowance. C = Corrosion allowance (min) in mm = = = 3.0 mm for BF, CO, BOF, Mixed and Corex gas for DN 100mm & above 1.5 mm for BF, CO, BOF, Mixed and Corex gas below DN 100mm & for other gases 1.5mm for other gases for all sizes
The above valves of corrosion allowance is for general guidelines. However, the same should be checked with Piping Material Specification (PMS) covered in Chapter 06. Thickness calculated on the basis of above formula is minimum thickness required for pipe under specified parameters. However, pipe thickness is selected based on the recommended minimum thickness / schedule indicated in PMS, covered in Chapter 06. 12.5% is added on calculated thickness as Mill tolerances. 02.04.02 Steam piping network comes under the purview of IBR and thickness calculation needs to be carried-out as per stipulations indicated in IBR and same needs to be approved by CIB. 02.04.03 Pipe thickness calculation for water pipelines The wall thickness of steel pipe is affected by a number of factors as indicated below: a) Internal pressure Maximum design pressure Surge or water hammer pressure External pressure Trench loading pressure Earth fill pressure Vacuum underground. Special physical loading Pipe on saddle supports Pipe on ring girder supports Practical requirement at site.
b)
c)
d)
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The thickness of pipe should be selected that which satisfies to most severe requirement. For detail of the above pressure/loading refer AWWA MANUAL M11 The nominal thickness of steel pipe as per IS:5822 (code of practice for water supply) shall not be less than the design thickness as given below plus the thickness for corrosion allowance: t= PD 2afe + P Where t = thickness of wall in mm P = internal design pressure in N/mm2 D= outside diameter in mm a = design factor (0.6 for working pressure and 0.9 for test pressure inclusive of surge pressure) f = Specified maximum yield stress in N/mm2 and e = Weld efficiency of the joint (0.9 for shop welding and 0.8 for field welding)
Corrosion allowance : It is preferable to design for the required wall thickness as determined by the loads imposed, then select living coatings and catholic protection as necessary to provide the required level of corrosion protection. 2 mm corrosion allowance for pipe up to DN 100 and 3mm corrosion allowance for pipe above DN 100 is generally considered. 02.05 02.05.01 PRESSURE DROP CALCULATION Low pressure gas Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at low pressure can be expressed by the basic hydraulic formula : f.l.v2. -------------------------2.g.d
where, H l d v g = = = = = Pressure drop (mmWC) length of pipe sector under consideration (m) Inner diameter of pipe (m) Velocity of gas (m/sec) Acceleration due to gravity (m2 / sec)
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GUIDELINES FOR PIPING DESIGN f =
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Friction co-efficient (dimensionless) depending on pipe diameter., velocity & viscosity of gas and type of flow) 0.03 to 0.045 (average value = 0.038) 0.04 to 0.05 0.02 to 0.03 (average value = 0.045) (average value = 0.025) for BF gas for CO gas for Natural gas
= = =
Large values of f shall be taken for pipes of size less than 200 mm and smaller values shall be taken for pipes of size more than 1500 mm. = density of gas (Kg/Nm3)
Equivalent pipe length for pipe-fittings, valves, etc. shall be taken into account for calculating pressure drop.
02.05.02
High pressure gas a) For working pressure of 10-15 kgf/cm2 Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at high pressure can be expressed by the formula:
------------------/ PH2 - Pk2 20.555 d 8/3 / ------------------ SLT
Where, Q d S L T PH PK = = = = = = = Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure Inner diameter in cm. Specific gravity of gas with respect to air Length of pipe in km Temperature of gas in deg. K Pressure of gas in Kgf/cm2 at one end of pipeline Pressure of gas in Kgf/cm2 at other end of pipeline
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b) For higher pressure, the above formula is modified as : ------------------/ PH2 - Pk2 20.555 d 8/3 / ------------------ SKLT
Where, Q d S L T PH PK K = = = = = = = = Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure Inner diameter in cm. Specific gravity of gas with respect to air Length of pipe in km Temperature of gas in deg. K Pressure of gas in Kgf/cm2 at one end of pipeline Pressure of gas in Kgf/cm2 at other end of pipeline Compressibility factor of gas at specified pressure and temperature or, alternatively _ _ 0.551 2 2 | P H - Pk | | ------------------- | | | SKLT |_ _|
25.0833 d 2.653
02.05.03 001.
Water Pressure drop in pressure water pipe line can be calculated by using modified Hazen Williams formula. ------------------------ I
V=3.83 CR d 0.6575 (gs)0.5525/v0.105 Where, CR d g s v = = = = =
Co-efficient of roughness Pipe diameter acceleration due to gravity friction slope viscosity of liquid.
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For circular conduits, v20C for water = 10-6 m2/s and g = 9.81 m/s2 The modified Hazan Williams formula derived as V = 143.534 CR r 0.6575 S 0.5525 h = [L(Q/CR)1.81]/ 994.62D4.81 in which, V CR r s D h L Q = = = = = = = = Velocity of Flow in m/s; Pipe roughness coefficient; (1 for smooth pipes; <1 for rough pipes) hydraulic radius in m; friction slope; internal diameter of pipe in m; friction head loss in m; length of pipe in m; and flow in pipe in m3/s --------------------- II --------------------- III
A nomogram for estimation of head loss by modified Hazen William formula is enclosed at Annexure- I 002. Pressure drop in gravity flow water pipeline (gravity flow line) can be calculated using Mannings formula:V = 1/n r 2/3 s1/2 For circular conduits: V =(3.968 x 10 -3 x d2/3 x s1/2)/n and Q = 8.661 x 10-7 x (1/n) x d8/3 x s1/2 Where, Q = Discharge in m3/hr s = Slope of hydraulic gradient d = Diameter of pipe in mm. r = hydraulic radius in meters v = velocity in m/sec n = Marming co-efficient of roughness ( For general design purpose n= 0.013 for plastic pipes & n= 0.15 for other pipes)
A nomogram for discharge etc according to Mannings formula is enclosed at Annexure-II 003. Pressure drop in valves & fittings:Fittings in a pipeline like valves, bends, tees, reducers, couplings, branches offer considerable resistance to flow of liquid. The loss of head caused by a fitting is partly due to the sinuous motion setup by the expansion of the steam to fill the pipe after its contraction in passing the valve and partly to the irregularities in the shape of the water way through the valve.
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Losses due to fitting are sometimes expressed in terms of the length of straight pipe of a given diameter which gives an equivalent loss of head. This method is very approximate as the equivalent length as depend upon pipe friction .. and to some extant on diameter. The head loss hf caused by a fully open valve or fitting during the flow of a liquid may be computed from the formula: hf = K V2 2g Where, K = resistance coefficient for valve or fitting V = Average velocity in a pipe of corresponding diameter in M/s, and g = Acceleration due ot gravity in m/s2 hf = head loss in m Resistance coefficient for valve and fittings as per IS: 2915- Part-II
Sl Description of valves and fittings No. 1. Loss in entrance a) Bell mouth b) Square edged 2. Loss at exist 3. Loss in sudden contraction 4. Loss in sudden enlargement
Resistance coefficient
0.04 to 0.05 0.47 to 0.56 1.0 0 to 0.5 (varying with dia ratio) 0.17 to 1.0 (varying with angle between the sides of the tapering section)
5.
Losses is fittings a) Elbow i Regular screwed 450 elbow ii Regular screwed 900 elbow iii Regular flanged 900 elbow iv Long radius flanged 450 elbow v Long radius flanged 900 elbow vi Long radius screwed 900 elbow b) Bends i Screwed return bend, close pattern ii Flanged return bend composed of two 900 flanged elbow a) regular b) long radius
0.3 to 0.42 0.55 to 0.90 0.21 to 0.30 0.18 to 0.20 0.14 to 0.23 0.22 to 0.60 0.75 to 2.2
0.38 0.25
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GUIDELINES FOR PIPING DESIGN c)
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Standard screwed Tee i Branch blanked off ii Line blanked off a) Flow from line to branch b) Flow from branch to line
0.4 0.85 to 1.3 0.92 to 2.15
d)
e) f) 6.
Long radius screwed Tee i Line blanked off a) Flow from line to branch b) Flow from branch to line Coupling and unions Reducing Bushing and coupling used as Reducer
0.37 to 0.80 0.50 to 0.52 0.02 to 0.07 0.05 to 2.0
Valves i Globe vales a) Composition disc globe valve b) Bevel seat globe valve c) Plug disc globe valve Gate valve a) Wedge disc gate valve b) Double disc gate valve Check valves a) Swing check valve b) Horizontal (lift) check valve c) Ball check valve Angle valve Y or blow off valve Foot valve
0.23 to 5.2 6.2 to 7.2 7.2 to 10.3 0.05 to 0.19 0.08 to 0.13 0.6 to 2.3 8 to 12 65 to 70 2.1 to 3.1 2.9 15
ii
iii
iv v vi
ANNEXURE - I
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ANNEXURE-II
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CHAPTER -03
PIPING LAYOUT
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GUIDELINES FOR PIPING DESIGN 03.00 03.01 03.01.01
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PIPING LAYOUT
GENERAL Routing and layout of piping system shall be as per good engineering practice. Following factors shall be taken into consideration while designing piping system. All functional requirements shall be fully satisfied. Adequate clearance is provided for equipment and operating personnel. Easy access for operation and maintenance of piping component. Convenient supporting points for piping, equipment, valves, etc. Adequate flexibility for thermal expansion / movements. Aesthetics and neat appearance.
03.02
PIPE LAYING FOR FUEL GASES. INDUSTRIAL GASES, LIQUID FUELS, COMPRESSED AIR & STEAM 01. The gas pipes installed along building wall should not cross window and door way. While laying high pressure gas pipes along the walls, the latter should be fire-proof. In doing so, the gas pipes should be laid along solid walls or above the windows of upper floors of plant buildings. When gas pipes are installed along external walls of buildings below window ways, installation of flange, thread joints and also installation of accessories is not allowed. Gas pipes of various service conditions may be laid along with oxygen on a common support provided conditions stipulated under various clauses are followed. The following conditions should be observed when installing gas pipes with other pipes: a) Additional pipes on existing gas pipes are allowed to be laid only with the permission of concerned plant and design organisation. b) In each case, the gas pipes and supporting structures should be checked with due consideration for additional loads and practical state of the metal structure of gas pipes. c) When installing with pipes carrying corrosive fluids they should be kept at least 500 mm below or by the side of the gas pipe at a distance of 500mm.
02.
03.
04.
05.
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If flange joints are provided on pipes carrying corrosive liquids, it is necessary to mount protective baffle plate against falling of corrosive liquids on gas pipes and their supports. Installation of flanged joints and flow components are not allowed on corrosive liquid pipes where the pipes pass above stairs and platforms. d) The associated gas pipes at the places on gas pipes where valves and other devices are mounted, should be kept at a minimum 800 mm distance from the main pipe. e) Drainage of the associate pipes should be laid to one side at a distance so that condensate does not fall on gas pipes/ its accessories, supporting structures and their elements, etc. 06. The branch line should generally be installed outside building along roof wall. Branch line having diameter less than 500 mm may be laid inside shop building. Branch line from gas main entering into building through building wall should pass through casings. Internal clearance between casing and pipe should be suitably filled up, wherever required. Gas branch line from gas main passing through roof covering should have circular opening. For this purpose, a circular opening should be made on roof and a taper hood should be provided on the branch line above the roof for protection from rain. Shop headers (except headers of By-product Plant) should be mounted at a height having minimum ground clearance of 4500 mm, when laying them outside the building wall. Layout of gas consuming units in various shops (except coke oven batteries) should be such that it is possible to bring the gas pipes above ground. Gas pipes of coke oven, natural gas and also their mixtures with blast furnace gas may be installed in channels and casings, in the region of gas supply to furnace and other consuming units.
07.
08.
09.
10.
11.
The following conditions should be observed for this purpose: a) Clearance between wall and bottom should be at least 400 mm, and for gas pipes of 200 mm and below clearances should not be less than the gas pipe diameter. b) Installation of flanges, threaded joints and accessories (except accessories for removal of condensate on a pipeline) is not allowed
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when it is laid in a channel. The number of welds on such gas pipes should be restricted to a minimum. c) Installation of gas pipes with air pipes to gas consumer units is allowed to be laid in channels. d) Channels with gas pipes, as a rule, should not cross other channels, In case, it is unavoidable, air tight tie-plate should be made and gas pipe should be placed in casing. Ends of casing should be taken out beyond the limit of tie-plate by 300 mm at both ends. Channels should have provisions for natural ventilation. 12. In case oxygen and acetylene pipes are laid in channels, in addition to above precautions, channels shall be filled with sand. Underground oxygen lines shall be laid in trenches back-filled with soil, unless specifically permitted otherwise by Purchaser/Engineer. Cathodic protection of the underground sections of the pipeline is recommended in addition to passive protection by coating and wrapping. Gas pipes in buildings should be located at places convenient for servicing, inspection and repair. It is not allowed to lay pipes at places where there are chances of damage due to shop transport. For gas lines installed in hot zone, it is recommended to provide protection against overheating of gas pipes. It is allowed to fasten gas pipes to frames of furnaces, boilers and other units provided these frames are checked for strength by calculations. Gas pipes are not allowed to pass through buildings producing or having materials liable to explode or burn and building of power distributing devices and substations and ventilation chambers and through buildings, in which gas pipe may be damaged by intensive corrosion. Gas pipes should not cross ventilation doors, air exhauster, flue pipes and also gas pipes should not be installed in insufficiently ventilated space and in underground buildings. Installation of high pressure gas pipes below main working platforms of shops is not permitted. Gas pipes along bridges should be made of seamless pipe and laid in the open at a horizontal distance of one metre from ends of pavements for passing of people and it should be within reach for servicing. Supporting
13.
14.
15.
16.
17.
18.
19.
20.
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elements of the bridge should be accordingly checked for loads from gas pipes. Laying of gas pipes in channels of bridges is not allowed. All welding joints of gas pipes in the area of their attachment to bridge should be radiographed.
21.
Gas pipes passing through walls, ceilings, and other structures of buildings of construction shall be encased in a steel pipe having inside dia at least 50 mm more than that of the oxygen pipe. The Gas pipe shall have no joints in the section at such crossings. The gap between the gas pipe and the outer pipe shall be filled with non/inflammable material, but allowing vertical and horizontal movement.
22. 23.
The laying of moist fuel gas pipelines shall be as per IPPS: 1-06-014-95 Pressure pipe work for gases and liquid fuels generally shall be routed overhead. All overhead interplant pipe work to be routed such that they will have a minimum clearance of 6.0m between bottom of supporting structures/pipes and road / railway track. The pipelines laid over hot tracks shall have a minimum clearance of 10.0m, in case of using protective 6.0m Buried shields in these places, this clearance shall be reduced to pipes, wherever laid, shall be provided with a minimum
earth covering of 1200mm in areas subject to temporary loads and minimum earth covering of 1000mm in areas not subject to temporary loads, unless otherwise specified.
24.
For the pipelines laid on roof, the distance from the external edge of the pipe to the roof shall be at least 0.5m.
25.
All shop headers, except for gravity fluids, shall be generally routed along columns in multiple rows at a height 4 to 6m above floor level. The connections to equipment shall be taken through suitable covered floor trenches for shops at ground floor and for basements, for elevated operating floors, the equipment pipe work connection may be taken below the floor level. All isolated single pipe connections to equipment shall be buried in the flooring / equipment foundations. Pipe work from basement
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and oil cellars to main equipment shall be routed in pipe tunnels / trenches with adequate spacing for easy maintenance. All pipe trenches shall be covered by chequered plate or by concrete slabs.
26.
The bleeder pipes for purging lines and other exhaust pipe work shall be routed upward along columns / gable ends and / or walls to a minimum height of 4,000mm above the roof level / platforms.
27.
For the gas pipelines laid along the building walls, the clearance between the gas pipelines and the wall shall be adopted so as to ensure the possibility for maintenance of the gas pipelines. The gas pipelines laid on the walls must not cross the window and door openings.
28.
Branch pipes from the headers to the building through walls and the roof shall be encased.
29.
Gas pipelines shall be earthed. When laid under the high voltage lines, a protective sheet guarding shall be provided above the gas pipelines. The guarding shall be earthed. The earthing resistance must be not over 10 ohm.
30
Platforms, access ladders, hand railing, etc. shall be provided for operation and maintenance of valves, instruments and controls. Manholes and hatches shall be provided for access inside the gas pipelines.
31.
At all the places of regular maintenance (gate valves, throttle valves, orifice plates, hatches, manholes, bleeders, etc.) if located at a height of over 2.5m from the maintenance level, provision shall be made for stationary platforms with the railings and stairs / ladders.
32.
On outdoor pipelines of diameter 1200 mm and over, a continuous walkway along the entire length shall be provided with hand railings on both sides. The height of the hand railings must be atleast 1.2m. In case of a number of pipelines, the passage shall be provided on the upper most pipeline.
MECON LIMITED
33.
To ensure the condensate drainage, the gas pipelines shall be laid with a gradient of about 0.005 towards the water drains.
Condensate drains shall be equipped with bleeders.
34.
Flash back arrestors shall be provided in each section of the pipe work for acetylene and LP gas to prevent flame propagation or pressure surges. They may be of hydraulic / cartridge type flash back arrestors or back pressure valves.
All branch pipes from main header shall be connected through a hydraulic arrestor.
Shut-off globe valves shall be provided on both the inlet and outlet sides of the arrestor and unions shall be provided for repair or replacement, if required.
35.
Oxygen pipelines are laid on either side of the fuel gas line as per the following norms.
Oxygen Pressure in Kg/cm2 Upto 0.1 Upto 0.1 0.1 to 16 16 to 35
Diameter of Oxygen pipe mm Upto DN 500 Above 500 Upto 500 Upto 200
Permissible gap in mm 300 600 800 800
Continuous installation is not allowed if the oxygen pressure is more than 16 Kg/cm2 and diameter of pipe is more than 200mm and also if the oxygen pressure is more than 35 Kg/cm2 for any size.
Minimum clearances of overhead oxygen pipelines (surface to surface) i) ii) iii) Explosion Hazardous shops Railway tracks Railway bridge and platform : : : 3 meters clearance 3 meters 3 meters
MECON LIMITED
GUIDELINES FOR PIPING DESIGN iv) v) Roads
DOC No MSTD-DESG-FS&PD-1405 Chapter No 03 :
Rev - 0 Page 7 of 12 upto
1.5 meters embankment 10 meters 3meters 4 meters 10 meters 0.5 meters 1.0 meters.
High voltage Transmission lines A. Parallel to pipelines B. Crossing the pipelines upto 20kv 35 to 150kv 220kv vi) To place of hot metal tapping and Source of open fire vii) Insulated L.T cables Bare conductor L.T 36.
: : : : : :
In respect of Acetylene pipes the main header shall run minimum 15 meters away from any building, fire protection facilities like water reservoir, pump house and storage tank facilities containing hazardous flammables liquids and fuel gas storage like gas holder. As far as possible, routing of high operating temperature pipelines, fuel gas or liquid fuel, steam, oxygen should be avoided along with the acetylene pipeline. All the Acetylene pipes and fittings shall be electrically grounded. At flanged and bolted connections jumpers or spring washers have to be installed for continuity of grounding.
37.
03.03
PIPE LAYING FOR UNDER GROUND / OVER HEAD WATER SERVICE PIPELINES:
01.
The Water pipes installed along building wall should not cross window and door way. When Water pipes are installed along external walls of buildings below window ways, installation of flange, thread joints and also installation of accessories is not allowed. Water Pipes of various service conditions may be laid along with oxygen on a common support provided conditions stipulated under various clauses are followed. Shop headers (except headers of By-product Plant) should be mounted at a height having minimum ground clearance of 4500 mm, when laying them outside the building wall. Water pipes in buildings should be located at places convenient for servicing, inspection and repair. It is not allowed to lay pipes at places where there are chances of damage due to shop transport
02.
03.
04.
05.
MECON LIMITED
GUIDELINES FOR PIPING DESIGN 06.
For the pipelines laid on roof, the distance from the external edge of the pipe to the roof shall be at least 0.5m.
07.
All shop headers, except for gravity fluids, shall be generally routed along columns in multiple rows at a height 4 to 6m above floor level. The connections to equipment shall be taken through suitable covered floor trenches for shops at ground floor and for basements, for elevated operating floors, the equipment pipe work connection may be taken below the floor level. All isolated single pipe connections to equipment shall be buried in the flooring / equipment foundations. Pipe work from basement and oil cellars to main equipment shall be routed in pipe tunnels / trenches with adequate spacing for easy maintenance. All pipe trenches shall be covered by chequered plate or by concrete slabs.
08.
Branch pipes from the headers to the building through walls and the roof shall be encased.
09.
Platforms, access ladders, hand railing, etc. shall be provided for operation and maintenance of valves, instruments and controls. Manholes and hatches shall be provided for access inside the pipelines.
10.
At all the places of regular maintenance (gate valves, throttle valves, orifice plates, hatches, manholes, bleeders, etc.) if located at a height of over 2.5m from the maintenance level, provision shall be made for stationary platforms with the railings and stairs / ladders.
11.
Under ground buried pipeline (Interplant network) All the process water, industrial water and drinking water are generally laid buried underground except the rubber lined demineralised water line. (Natural gas pipes run cross country are mostly laid underground with at least 2.0 meters earth cover.)
MECON LIMITED
GUIDELINES FOR PIPING DESIGN 12.
Underground Pipe tunnel of R.C.C Process water, contaminated water, may also be considered for laying inside a walkable underground R.C.C tunnel.
13.
Over-ground supported on R.C.C pedestals or sleepers. In Oil refinery, the process water, drinking water, firewater, and oil lines are generally laid on R.C.C pedestals or sleepers for interplant communication.
14.
In shop pipelines The inshop water pipelines are generally laid supported on building columns, or below the crane girder or with the floor beams.
15
Salient considerations in Design of pipe Layout in trenches / underground buried.
(i)
Spacing of pipes in Trenches / underground buried.
S.No 1. 2. 3. 4.
Nominal Diameter of Pipe, mm Upto 150 200 to 500 600 to 750 800 & above
A (mm) 300 400 500
B(mm) 200 300 500
Minimum 500 mm and will increase depending upon the pipe diameter.
(ii)
Earth Coverage Buried pipework is laid with earth cover sufficient to avoid damage from pressure of vibration caused by surface traffic. Minimum earth cover over the top surface
MECON LIMITED
of pipe shall be minimum 1200mm from the finished ground level in areas subject to temporary loads.
(iii)
Road and Railway crossing All the under ground pipes crossing railway tracks and roads where the depth of earth cover from the bottom of ties or road bed to the top of pipe is less than 1500mm, are to be protected by provision of encasing. The protection may be either culvert, concrete casing pipe or steel encasing pipe or R.C.C trench with cover.
Minimum size of casing pipe are given in the following table.
Service Pipe Diameter(mm) 100 150 200 250 300 350 400 500 600 16. 17. 03.04 01.
Minimum Diameter of Encasing pipe For flanged pipes (mm) 300 400 500 600 600 600 700 800 900 For welded pipelines(mm) 200 250 300 400 500 500 600 600 700
Laying of welded steel pipes for water supply shall be done as per IS: 5822 Laying of cast iron pipes shall be done as per IS: 3114
PIPE SUPPORTS (for Gases, Liquid fuel, gas & Water service pipelines) After routing the pipelines from originating station to various consumers it is necessary to support the pipelines suitably to keep in position in the interplant & inshop areas. PIPES IN THE INTERPLANT AREA. All the pipelines are laid over the trestles in the interplant area for transportation of fluids from their generating station to various consumers. These pipelines require
02. 001.
MECON LIMITED
support at definite intervals. Support intervals are decided on the basis of pipe dia. In general support intervals followed are indicated in table no. 05.01 & 05.02. 002. Saddle supports are used for large dia pipes i.e DN 500 & above. For saddle supports refer typical drawing no. MEC/11/40/TYP/DE/10/. Smaller dia pipe i.e below 500 mm dia are supported on channels of suitable size depending upon pipe dia to be supported. For such support refer piping drawing of the project. However, steams pipes of all sizes are supported on saddles only. Pipe with vertical fall are required to be held in position by providing U-Clamps or vertical restrictors /saddles provided with trestle structure, etc. Smaller dia pipe below DN 500 are held in position by means of U- clamp are provided at each supporting point in horizontal / vertical pipe route. For U-clamp details refer typical drawing No MEC/11/40/TYP/DE/10/. 005. All the above supporting arrangement should have provision of anchoring the pipe rigidly wherever required. In case of saddles /channels type supports, rigidly fixing at the location of F.P. (fixed points) are achieved by welding the saddle/channel with the supporting structures as well as with pipe. In case of U-clamps (for pipe below DN 80) the clamping nuts should be tightened fully for FP supports. 006. Large dia gas ducts are supported o trestles by using Saddle Supports. Roller Supports Boll Supports.
003.
004.
005.
Roller /ball are used for reducing frictional force on structures
03. 001.
PIPES INSIDE SHOP AREA. Pipes to be laid inside the shop are generally supported on the shop building/structural columns at a level with clear head room of 5.5 m.and at a location where it does not obstruct the activities. (i.e crane movement, equipment movement, etc.)
002.
Smaller dia pipe DN 200 & below are fixed by using U-clamps or by means of hangers as the shop structure permits. Large dia pipe with sizes above DN 200 are supported on building structural columns by means of saddles resting on structures extended from existing columns. Where ever saddles can not be provided, U-clamps are used to hold pipe in position.
003.
MECON LIMITED
004.
Large dia pipes are preferred to be supported by means of hangers mounted from structure. In specific cases where over head laying of pipeline is not possible, pipes may be laid under ground in channels. However, under ground laying of oxygen and acetylene pipeline and fuel gas pipeline shall be avoided. In case laid in channel then they should be covered with bed of sand. Such pipes shall be supported on pedestals with clear spacing between pipes.
005.
01.
Generally smaller dia pipes are laid over large dia pipes/ducts with supporting structures. Provided at definite intervals depending upon pipe sizes and their supporting spans Always clearance between two consecutive pipes are provided all along the route. These clearances are considered based on the following. Suitable to accommodate valves on both the lines. Mounting of valves and other equipment with flange connection are accommodated on pipelines. Clear space of 100-200 mm should be provided between two consecutive pipes.
02.
Table enclosed indicates the minimum distances to be maintained between pipelines. 03. Distances between large dia pipes/ducts (DN 500 & above) if laid parallel should be such that minimum 1000 mm clear space all along the route between the pipes/ ducts shall be maintained. This is required for inspection & maintenance of the pipes / ducts and mounted equipment, valves, instruments, etc. there on.
CHAPTER -04
DESIGN CONSIDERATIONS
MECON LIMITED
DESIGN CONSIDERATIONS
GENERAL Guidelines for selection of pipe sizes, routing and layout of piping and selection of piping material are covered in Chapter 02,03 and 06 respectively. In addition to the above, following factors influence the designing of piping network for various fluids : Composition and properties of Fluid Fluid flow rate Max working pressure Max. working temperature In door / outdoor installations Statutory regulations and clearance requirement, if any Corrosive nature of fluid Flammability and explosive nature of fluid
Considering the above factors recommendations described in subsequent clauses shall also be taken into account while designing the piping system 04.02 CONDENSATE DISPOSAL FOR FUEL GASES, COMPRESSED AIR & STEAM PIPELINES Fuel gases as well as other gasses contain moisture and other condensable impurities which get separated during fluid transportation through piping system, effective condensate removal system should be incorporated to prevent accumulation of condensate in pipes which otherwise may cause obstruction to proper gas flow and excess live load to the pipe/ structure. All piping for gasses containing moisture etc. like BF / Coke oven / BOF gas, Mixed gas, Compressed air, Steam & Natural gas are laid with gradient / slope. A slope of 5mm per meter run shall be provided for the above pipelines. In case of space constraint to accommodate slope, it may be reduced to 0.003 particularly for in shop piping. For straight length of pipeline, low / high points should be located generally at a distance 100 meters. However, in no case it should exceed 300 meters. Condensate drain points shall be provided at all low points. In case of low pressure gas lines, automatic drainage system though seal pots shall be provided. For compressed air lines and steam lines, automatic condensate / steam traps shall be provided. 04.02.01 Condensate Drain Arrangement for Low Pressure Gases i) Drainage should be provided at all the low points of gas pipes carrying moist gases for condensate removal. Disposal of condensate shall be through seal pots/ condensate drain installations.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN ii) iii) iv)
Distance between any two drain points of a gas pipe within a radius of 100 meters from gas cleaning plant should not exceed 60 meters. Drainage system for outdoor gas networks should be located in open air with necessary accessibility for operation. Pipes for condensate removal from inter shop gas pipes of blast furnace gas in a radius of 400 m from gas cleaning plant should be at least 80 mm diameter. For pipelines beyond 400 m and also for gas pipes for other moist gases, diameter of condensate removal pipes should not be less than 50 mm. Separate seal pots shall be provided for different gasses. Removal of condensate from branch line from inter shop gas pipe and inshop gas pipe should be carried out in separate condensate seal pots. Minimum height of the water seal in the condensate seal pot shall exceed the maximum working pressure of gas by 500 mm, but this height in no case shall be lower than 2000 mm. If necessary, the height of water seal can be increased by adding more than one seal pot in series. However, number of such seal pots shall not exceed three. Further base plate of seal pot shall have minimum thickness of 16 mm. While installing common seal pot for a number of gas pipe, height of water seal should exceed by 500 mm the maximum working pressure in any of the connected gas pipe.
v) vi) vii)
viii)
Design of condensate seal pots should ensure protection against leakage of harmful gases into building by providing vent of adequate height on the seal pot. Condensate seal pot shall be provided with purging facilities. Installation of condensate seal pot for inshop gas network is allowed inside the buildings. Condensate Drain Arrangement for Medium pressure / High pressures gas
ix) x)
04.02.02 i) ii)
Condensate disposal for gases having higher line pressure have to be done by using adequate pressure seal pots. In a high pressure seal pot the metallic float is utilized for disposal of condensate and prevent leakage of gas from the pot.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN iii) iv)
The seal pot should be air tight and wall thickness should be decided on the line test pressure. Condensate coming out of seal pot should be discharged into phenolic sewerage line or in a reservoir provided locally.
04.02.03
Steam Traps / Moisture Traps for Steam / Compressed air. At low points in steam & compressed air pipeline steam traps / moisture traps with strainer assembly will be provided to drain out the condensate. Selection of steam trap shall be as per IPSS: 1-06-039 02. Installation of steam traps shall be as per IPSS: 1-06-037 01.
04.03
PURGING & VENTING SYSTEM FOR FUEL GASES Piping system particularly piping for fuel gases is required to be purged with inert gas prior to charging of gas as well as during shut down before any maintenance job. System for feeding purge gas and venting of gas/ air from the piping system shall be provided for all fuel gas piping.
04.03.01
Purging i) Gas pipelines of blast furnace gas, coke oven gas, converter gas and mixed gas shall be equipped with nitrogen or steam pipe connection with isolation valve . The connection of nitrogen or steam pipeline to the gas pipeline shall be done by means of flexible hose which shall be connected only during the period of purging. Location of purge gas inlet points and vents shall be such that entire section of piping can be purged with minimum dead space. Purging points shall be provided at low points. Purging points shall not in any case be provided at bottom half of the gas mains. Purge points for fuel gas pipes upto DN 950 mm shall be of minimum DN 25 mm same for pipes of DN 1000 mm & above shall be of minimum DN 50 mm.
ii)
iii) iv)
04.03.02
Vents i) Bleeder/vents shall be provided for purging / venting any section of the pipeline. Bleeders shall be located generally at all high points in the piping system. Bleeder / vents shall also be provided at down stream / upstream of isolating devices & U-seals.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN ii)
All vents shall discharge at a safe height into atmosphere. The vents shall be above the operating floor / platform for vent valve or roof of the building 4m, but not lower than 8 meters from the ground level. In the presence of the aeration monitors on the roof of the building, the vents shall be located so as to eliminate the possibility of purged gas getting inside the premises. On straight lengths bleeder/vent shall generally be provided at an interval of 100 meters. All vents shall have T piece/cowl with bird screen preferably at the top. For isolation of bleeder/vent pipe flanged gate valve of rising stem type shall be provided. Sampling points (DN 25) below isolation valve with lubricated taper plug valve shall be provided in the line to monitor gas samples at the time of purging. Vent pipes of different gases shall not be connected through a common vent. Recommended sizes of bleeder / vent pipes corresponding to gas pipe diameter are indicated in Table 04.01
iii) iv)
v) vi)
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MECON LIMITED
Table 04.01 RECOMMENDED SIZES OF BLEEDER / VENT PIPES Pipe dia DN (mm) 20 25 40 50 65 80 100 150 200 250 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1800 2000 2200 2400 2500 2800 3000 3200 3500 Bleeder pipe dia. DN (mm) Low Pressure Fuel gas Natural gas/Corex Gas 50 50 50 50 50 50 50 50 80 80 80 100 100 100 150 150 150 150 150 200 200 200 250 250 250 250 250 250 300 300 20 20 20 20 20 20 20 25 25 25 25 50 50 50 80 80 80 100 100 100 150 150 150 -
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 04.04
VALVES AND ISOLATING DEVICES FOR GAS & WATER SERVICES:Isolating devices shall be provided in piping system for isolation of pipe sections as well as for isolation of all other mounted accessories for the purpose of operation and maintenance. They shall be suitable for the service conditions in all respects and located suitably considering ease of operation and maintenance. Isolation valves shall be provided at the following locations: On all pipe lines both at the source and at consumer ends On all branch pipes to individual buildings and shops On all bleeder / vent pipes, purge gas inlet points, drain points, sampling connections, etc. On all by-pass lines for large valve, regulators, filters, moisture traps etc. Instrumentation tapping points.
Relocation of isolation valves on request of CLIENT may also be considered if technically acceptable. Other types of valves required for piping system include the following: Check-valve on all pipelines requiring only unidirectional flow. Quick acting shut-off valves on gas/ air lines to furnaces and heaters as well as before each consumer or group of consumers. Pressure regulating valves for all pressure reducing installations, gas mixing stations and flow control system.
04.04.01
Selection of Isolating devices for Gas & Steam services:The gas cut-off arrangement shall ensure the possibility of complete cut-off gas along with fast and safe operation. Gate valves with rising stem shall be used normally for isolation in piping system. Pipe work for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter Gas, Mixed Gas with low operating pressure shall have some means of gas tight isolation of sections of the pipe work to facilitate maintenance work. These may be water seals, goggle valves, spectacle blinds, or gas tight isolators / slide plate valves, etc. For sections where the gas tight isolating device can not be provided, provision to insert blind flange at outlet of gate valve shall be made. Sectionalizing / isolation for purging of fuel gas lines may be done with Spectacle blinds.
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MECON LIMITED
Gas tight butterfly valves may be used for isolation near consumption points requiring frequent and quick operation. These can be valves with gas tight seating or eccentric valves for gas tight isolation. Emergency quick shut off valves shall also be double eccentric butterfly valves. For fluid lines with working pressure over 16 kg/cm2 (g), valves of DN 300 and above shall be provided with by-pass arrangement or depressurisation arrangement for pipe sections. 04.04.02 Selection of Actuators for Isolating devices for Gas services:Manually operated shut-off gate valves of size DN 300 to DN 450 for low pressure lines shall have gear drive. For high pressure lines, gear operator shall be provided as per manufacturers recommendations for limiting the operating torque to acceptable limits. Gate Valves of size DN 500 and above shall be provided with electric actuators. Electric actuators for fuel gas lines shall be of flame proof design if located in gas zone/inshop. In the interplant area these actuators need not be flame proof. Position and torque limit switches shall be provided on actuators. Manual over ride shall also be available in actuators. Goggle valves shall have electrical actuators for disc/ plate movement and electro hydraulic drive for flange separation. Manual arrangement for valve operation shall also be provided with gear and chain operation from convenient location. The hydraulic power pack for the valve shall include one motorized pump and one manual pump. Encased design goggle valve with vent should be used at locations closed to buildings. Electrically operated gate valves for gas pipelines of smaller diameter are recommended to be used only if they are incorporated in the automation scheme. All valves located remotely, requiring frequent operation and / or with automatic control shall be provided with electric drives, electro- pneumatic drive, solenoids etc. 04.05 04.05.01 OTHER FLOW COMPONENTS FOR GAS / STEAM SERVICE:Check Valves Check valves are used in piping system where unidirectional flow is required check valves can also used for stopping flow reversal incase of sudden stoppage of fluid flow like in the pump discharge. For small size pipes below DN 50, lift check valves are used. For DN 50 and above, swing check valves or dual plate check valve are used. Lift check valves can used only in horizontal pipeline it should not be used in vertical pipeline. For low pressure gas lines dual plate check valve are most suitable.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 04.05.02
Pressure Regulating Valves Irrespective of specified variations in upstream pressure, these shall maintain a reduced constant pressure on the downstream side of pipelines on which they are mounted. The valve shall be of globe / needle type, with material specifications, dimensional standards etc. as per the relevant piping Material Specification(PMS) for the service for which the valve is intended. Self actuated pressure regulators shall be used for pressure reduction in service piping. Spring loaded pilot operated regulators shall be used. In case precision control of pressure is required. Dome loaded regulators with additional pilot spring loaded regulator for pressurizing the dome may be used. For pressure regulators, maximum and minimum available pressure upstream of regulator and desired range of outlet pressure with maximum flow rate shall be specified. For process lines where continuous regulation/ control of pressure or flow is required, control valves shall be used.
001
For Compressed Air Pressure regulators of sizes up to DN 50 shall be complete with a prefilter having 40 micron porous bronze filtering element in shatterproof plastic or glass container, pressure regulator and pressure relief arrangement to prevent overpressure at downstream of the regulator. For higher sizes to meet larger flow rates, the pressure regulator shall be self actuating type as per manufactures standards, but capable of meeting the service conditions and duty specified.
002
For Steam For sizes up to DN 50, pressure reducing valves of single seated diaphragm type having in-built strainer, with screwed ends up to DN 20 for PN 10 and below and flanged ends for higher sizes and for higher PN. Body of main and pilot valves shall be of carbon steel / alloy steel castings / forging, diaphragms shall be of stainless steel, internal springs of stainless steel and pressure adjustment springs of spring steel. For higher sizes to meet larger flow rates, the pressure reducing valves shall be as per manufactures standards, but capable of meeting the service conditions and duty specified.
003
For Other Gases For dry air, nitrogen and argon the pressure reducing valves shall be of stainless steel. For oxygen service, the valve shall be of bronze construction and shall be degreased and cleaned to meet the service requirements.
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MECON LIMITED
For acetylene and LP gas services, the pressure regulators shall have material for the service. For acetylene, the materials of construction shall not have copper in excess of 70% by composition. (Refer IGC code). Pressure regulators for large diameter gas lines shall comprise butterfly type valves actuated by means of an oil hydraulic control system, which is actuated in turn by changes in the preset downstream pressure through impulse pipe work.
04.05.03
Pressure Relief Valves These shall be spring loaded type and shall automatically open when the pressure on the pipelines, on which they are mounted, exceed preset values. The valves shall have end connections and materials specified for throttling valves in relevant PMS. Relief / Safety valves for steam service shall have IBR certification. Relief valves shall have hand wheel / wrench for adjustment of preset value of relief pressure. Pressure relief valves shall always be used on outlet lines from the pressure reducing valves. Pressure relief valves shall be designed for full flow rate from pressure regulators. Set pressure shall be 10 % higher than the maximum working pressure at outlet of regulator.
04.05.04
Filters Filters are installed in piping system before the pressure regulators/ control valves and at consumer points depending on nature of fluid and technological requirements. For small size pipes below DN 50, Y-type strainers with sintered/ wire mesh cartridge may be used. For higher sizes, straight line mounted filters with removable cartridge shall be used. Filter element can be of wire mesh, sintered material, woven fibers or other suitable type as per process requirement. Filtration area shall be at least 500% of the inlet cross section area. Full flow rate, maximum working pressure, micron rating, allowable pressure drop, material of body and mesh shall be specified.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 04.05.05 Safety Shut-Off Valves
These shall shut-off in case the pressure on the upstream side of the valve becomes less than preset values. The valves shall be of globe type for DN 50 and below and butterfly type for sizes above DN 50; the material shall be suitable for service conditions. The valves shall be actuated by electromagnetic or pneumatic device working in conjunction with pressure switches located on the pipelines being safeguarded and shall include all components required for its functioning. 04.05.06 Flash back arrestor In acetylene piping, flashback arrestors shall be provided at the outlet of cylinder manifold system and at each consumer point. Flash back arrestor prevents travel of shock wave due to detonation/ deflagration in piping system. Dry type arrestors with packed cartridge shall be used. Number of arrestors in parallel may be used to take care of flow requirement. 04.05.07 Electrical continuity Metallic electro static jumpers shall be provided at all locations on all flanged in case of flammable gases and oxygen. This is to prevent accumulation of static electricity in pipe sections. Piping system shall be suitably earth at a regular length of pipeline. 04.06 MEASURING AND CONTROL DEVICES FOR GAS SERVICES:Instrumentation and control devices are required for monitoring the fluid distribution system, regulation of pressure and flow. Flow measurement shall be provided at battery limit of all production and consuming units, inlet/ outlet piping of storage installations, on surplus gas bleeder piping to flare system etc. When orifice plates are used, proper care shall be taken in piping layout for preventing accumulation of condensate by providing suitable slope or drain system. Requirement of straight length upstream and downstream of flow sensors shall be maintained as per instrumentation requirements. Normally the straight length recommended is 10 times pipe dia before inlet and 5 times pipe dia after outlet of device. Pressure measurement shall be provides at battery limits of production and consumer units, at outlet of storage systems, inlet and outlet of pressure regulators/ controllers, etc. Temperature measurement is provided at piping from gas cleaning plants and near consumer installations. Pressure and Flow Control valves are provided at gas mixing stations, main pressure regulating stations, flare stack piping, inlet/ outlet piping of storage installations (gas holders). For low pressure gas lines, butterfly type control valves are used. For high
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MECON LIMITED
pressure gases, globe valves may be used. Sizing of control valves is based on flow rate and pressure parameters. In most cases, the control valve size is lower than the main pipe size. Suitable reducers/ expanders shall be provided at inlet/ outlet of the control valves. In case of piping with possibility of condensate accumulation, eccentric reducers shall be used. 04.07 001 WATER PIPELINES VALVES Gate Valve:Gate valves are used for isolating or scouring of pipeline. They seal well under high pressure and when fully open, offer little resistance to fluid flow. Sluice valves are not intended to be used for continuous throttling, as erosion of the seats and body cavitation may occur. If small flow are required the by pass, valve is more suitable for this duty. 002 Butterfly Valve:Butterfly valves are used to regulate and stop the flow especially in large size conduits. They are sometimes cheaper than sluice valve for larger sizes and occupy less space. Butterfly valves with no sliding parts have the advantages of ease of operation, compact size, reduced chamber or valve house and improved closing and retarding characteristics. They would involve slightly higher head loss than sluice valve and also are not suitable for continuous throttling. 003. Globe valve:Globe valve have a circular seal connected axially to a vertical spindle and hand wheel. The seating is a ring perpendicular to the pipe axis. The flow changes direction through 900 twice thus resulting in high head losses. These valves are normally used in small bore pipe work and as taps, although variation is used as a control valve. 004. Check valves:Check valves, also culled non-return valve or reflux valve, automatically prevent reversal of flow in a pipeline. They are particularly used in delivery line of pump to prevent back flow when pump shut down. Dual plate check valves employ two spring loaded plates hinged on a central hinge pin, when the flow decreases, the plates close by torsion spring action without requiring reverse flow. As compared to conventional swing check valve which operates on mass movement, the Dual plate check valve are provided with accurate by designed and tested torsion springs to suit the varying flow condition. 005. Pressure Reducing Valves:These are used to automatically maintain a reduced pressure within reasonable limits in the downstream side of the pipeline. This type of valve is always in movement and requires scheduled maintenance on a regular basis.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 006. Pressure Sustaining Valves:-
Pressure sustaining valves are similar in design and construction to pressure reducing valves and are used to maintain automatically the pressure on the upstream side of the pipeline. 007. Pressure Relief Valve:These valves are provided in one or more summits of the conveyance main to keep the pressure in the line below given value by causing water to flow to waste when the pressure builds up beyond the design value. Usually they are spring or weight loaded and are not sufficiently responsive to rapid fluctuations of pressure to be used as surge protection device. 008 Ball Float Valves:Ball float valves are used to maintain a constant level in a service reservoir or elevated water tank. The equlibrium type of valve is the most effective and it is designed to ensure that the forces on each side of the piston are nearly balanced 009. Air Release Valve:Air release valves are designed specifically to vent, automatically and when necessary, air accumulations from lines in which water is flowing such accumulations of air tend to collect at high points in pipeline. Air which accumulates such peaks, reduces the useful cross sectional area of the pipe and therefore induce a friction head factor that lowers the pumping capacity of the entire line. The use of air release valve eliminates the possibility of this air binding and permits the flow of water without damage to pipeline. 010. Air Inlet Valve:In the design and operation of large steel pipeline, where gravity flow occurs, consideration must be given to the possibility of collapse in case the internal pressure as deduced below that of atmosphere. To prevent the pipe from collapsing, air inlet valves are used at critical points. Air inlet valves should be installed at peaks in the pipeline, both relative to the horizontal and relative to the hydraulic gradient. 011. Needle and Cane Valves:Needle and cone valves are more expensive that gate and butterfly valves but are well suited throttling of flow. They have a gradual throttling action as they close. They are resistant to wear even at high flow velocities. The method of sealing is to push an axial needle or spear shaped cone into seat. The needle and cone valve are not commonly used in water supply but are occasionally used as water hammer release valve when coupled to an electric or hydraulic actuator.
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 012. Ball Valve
Ball valves are normally used as quarter turn positive shut off valves. These valves offers minimum resistance to the flow. These valves are generally considered for throttling and flow control. Small size ball valves are used for instrument isolation e.g pressure gauges, pressure transmitter, temperature transmitter, pressure switch etc. Based on body construction the valves can be classified as Single piece, two piece, three piece, the short pattern & the long pattern etc. 013. Plug Valve. Plug valves like ball valves, are quarter turn positive shutoff valves. Two major types of plug valves are in use. They are the lubricated metal seated plug valves. These valves can have flanged, butt welded, screwed or socket weld. Plug valves are available in two way, three way and four way depends upon their application in water distribution lines. Plug valves are used as shutoff and flow control valves. 014. Foot Valve. Foot valves are a sort of non-return valves with strainers mounted at the open and of the pump suction pipe lines. There valves are used when the pump has negative suction. The check action of the valve .. the priming fluid & the pump while the pumps are filled before starting. The suction strainer help to hold the solids while the pump is sucking the fluid. 015. Gate Valve These are single seated valve used for slurry services. Being single seated valve, it can be used for only unidirectional operations. The edge of the gate is happed to shear the solids and the seal is used to keep the solids away from entering the space between the plates when open and to clean the sliding blade when it retracts. 016. Diaphram Valve Diaphragm valves are mainly used for low pressure corrosive services as shutoff valves These can also be used as control valves. Here, the diaphragm moves up and down to operate the valve. The valve body can be lined or lined. Lining material is selected to suit the corrosive nature of the service fluid there are two type of diaphragm valves available. They are weir type and straight flow type. The weir type is popularly know as Saunders type diaphragm valve. The use of these valves is restricted as they can withstand a maximum operating pressure of 7 to 10 kg/cm2. The damage the diaphragm occurs and hence thee maintenance is more frequent. Diaphragm valves are mainly used in DM water plant and chemical dosing lines.
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MECON LIMITED
EXPANSION AND FLEXIBILITY. All Pipe work shall be designed to provide sufficient flexibility against thermal expansion to prevent development of undesirable forces and moments at points of connection to equipment, at anchorage or at guide points. As far as possible flexibility shall be provided by planning route with change of direction or by the use of bends, loops or off-sets.. Whenever self-compensation can not be achieved by pipe routing, provision for thermal expansion shall be made by providing expansion loops or expansion joints as per following criteria : U loops shall be provided for all low pressure fuel gas piping up to DN 300 size and high pressure piping for all sizes. For low pressure fuel gas piping, disc type expansion joints (compensators) shall be provided for pipes of DN 300 and above. Stuffing box type Gland Compensators shall be used on low pressure coke oven gas lines. For high pressure piping, where U-loop is not possible, bellow type expansion joint may be provided. Bellow type compensators may also be provided in low pressure gas lines in case movement is in two planes (axial & angular)
While locating the expansion joints following guidelines should be followed: Disc / bellow compensators should be located preferably in the center of two fixed points. U-Compensators should be located in between two fixed points with variation in pipe lengths in the ratio of 1:2 (max). Gland Compensators are located near the fixed supports to facilitate smooth functioning. Disc, bellow and gland compensators shall have flanged connection with pipes
04.08.01
U-loop Compensator U-loops shall be provided in piping system using elbows/ bends as per piping material specification.
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MECON LIMITED
U-loops shall be in horizontal plane and loops for many pipes running in parallel may be provided at same location parallel to each other. Loops shall be in the same plane as the pipe route. However, in some cases, where there may be obstruction due to other parallel pipes, U-loop plane may be raised to clear the pipes by providing bends. Loops in vertical plane can be provided in exceptional cases if horizontal loop is not possible due to layout considerations. Provision shall be made in piping for draining of condensate, venting, etc. Height and width of expansion loops (U-loop) for various diameter of pipes can be taken from respective nomograms enclosed as Annexure - A 04.08.02 Disc Compensator Disc compensator is made by fabrication using sheets/ plates. Care shall be taken to ensure that thickness of compensating disc does not exceed the design thickness during manufacture. Depending on total displacement required, single or double disc compensators may be used. In no case compensators shall have more than three discs. Internal sleeve shall be provided for draining of condensate. In case continuous drainage system is provided at disc location itself, internal sleeve is not to be provided. 04.08.03 Bellow Compensator Bellow type expansion joints are made from SS sheet and can be single or multi layer with number of convulations. Depending on the application, bellow type compenstor may be selected from the following types: a) Axial Compensator Axial compensators are used in place where there is no deflection of pipe in transverse direction such compensators can take care of axial deflection (elongation / contraction) through its convolutes. b) Pressure Balanced Expansion joint A pressure-balanced elbow is used in application where transfer of excessive thrust to anchors or adjacent equipment due to internal pressure is not desirable. The design comprises a combination of bellows with tie rods to absorb axial motion while restraining pressure thrust. c) Hinged expansion joint
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MECON LIMITED
Hinged expansion joints are used to absorb angular movement when the movement occurs in one plane only. d) Universal expansion joint Universal expansion joints are used to take care of both axial & lateral deflection in pipes. 04.08.04 Loads due to Compensators Loads on anchor points due to bellow compensators are considered based on the feed back from supplier / manufacturer. Such loads depend upon number of convolutes and number of plies and their thickness.
04.09
SPECIAL CONSIDERATIONS FOR OXYGEN PIPING Filters should be installed in the oxygen pipeline system at the following points: a) b) c) At the outlet of the oxygen plant. Upstream of components having soft seating in contact with the oxygen stream e.g. pressure regulator and control valves. Upstream of components that have moving parts in contact with the oxygen stream e.g. flow measuring and limiting devices.
Provision shall be made for safe and easy access for frequent cleaning and / or replacement of the filter element. The larger capacity filters like (a) above should be provided with differential pressure gauge for monitoring the condition and providing indication for cleaning / replacement of the filter element. The filter bodies shall preferably be of copper alloy or stainless steel and filter element of copper alloy or glass cloth suitably earthed to the filter body with copper wires. Two (2) or more pressure relief valves should be provided downstream of each set of pressure reducing valves. One or more main relief valve(s) should be capable of discharging 100% of the full oxygen flow and limiting the pressure within the defined limits. The secondary relief valve should be sized to discharge the nominal leakage from the pressure reducing valves. The relief valves should be positioned as close as possible to the pressure reducing valves. The vent lines from the relief valves should be preferably of stainless steel or copper. Consideration should be given to providing of small size pressure equalisation bypass isolation valves across large diameter isolation valves in large pipeline systems so as to ensure safe pressurization of the downstream pipeline. Sonic velocities may occur during the initial stages of valve opening with possibility of high velocity transport of material / dirt particles in the system. If the valve opening action is rapid, there is also a possibility adiabatic compression and heating of the oxygen specially if additional
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closed valves exist downstream. The bypass pipe work and valve should be of copper or copper alloy. Fire break sections may be installed in the oxygen pipeline to limit the propagation of combustion in a steel pipeline. Fire break sections may be introduced immediately downstream of the main isolation and throttling valves where the velocities can be high. The fire break section will be either a length of copper pipe having the same inside diameter as the main pipe with flanges fitted at the two ends which is installed between the steel pipes or a copper insert tube made from copper sheet / tube and inserted inside the steel pipe downstream of the valves. The copper insert tube is generally used in large diameter steel pipelines. In steel pipelines care should be taken to install isolation valves on straight sections of the pipeline. Any pipeline component which is likely to cause a change in the flow pattern like reducer, bend, tee or Y connection, orifice plate etc. should be at a distance of at least four diameters away from the valve. For cleaning of the gaseous oxygen pipelines after erection, provision for pigging will be provided for pipelines having diameters upto DN 200. However, if the pipeline is pickled and phosphated as per approved procedure, pigging of pipelines is not essential. The bends on these pipelines will have a radius of 5 DN. DN 250 and above, extra care will have to be taken regarding cleanliness of these pipeline during installation. For line sizes DN 250 and above the bends will have a radius of 3 DN. Gaseous oxygen pipe work shall preferably have butt welded pipe joints. To reduce safety hazards the number of components should be kept to a minimum compatible with the system requirements. Flange joints are to be used only for connection of the pipe to the system components on the pipe work. Threaded joints and couplings should be sparingly used. 04.10 Piping system shall be designed with high degree of reliability so that the systems perform the duty of fluid handling without structural or functional failure under most adverse condition of plant operation anticipated. All piping systems shall be designed with sufficient corrosion and stress margins to ensure a life time without failure, not less than the life of the plant. 7000 complete cycle of operation shall be considered for stress analysis purpose. Piping system shall not impose reactions on equipment terminals exceeding permissible limits even under adverse operating conditions. Personnel injury from discharge of hot fluids from drains, steam traps, hot pipes or exposures to pipe vibrations shall be guarded against. 01. Pipes shall be sized for minimum pressure drops and considering the velocity limitation for various types of fluids. 02. Adequate flexibility shall be provided in the pipelines to keep stresses and reactions in the system arising due to thermal expansion or other effects within limits. Where the piping terminates at an equipment or at the terminal point of a
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system, the reactions and thermal movement imposed by piping on the equipment or the system concerned shall be well within the limits specified. 03. If cold springing of pipleline is used, care shall be taken in determining the location and amount of cold spring gap. Cold spring gap shall be located at points where the bending and torsional moments are minimum. Use of cold spring gaps less than 10mm shall not be acceptable and cold spring gaps above 100mm shall be avoided. All outdoor piping exposed to sunlight carrying fluid at a temperature less than 800C shall be designed considering thermal expansion corresponding to 800C and empty pipe as one of the operating conditions although not necessarily the worst. 04. All piping shall have butt welded connections with minimum of flanged joints for connection to vessels and equipment to facilitate erection and maintenance. All high pressure steam valves and accessories shall have welded connections. Standard fittings shall be used wherever practicable. Unless otherwise specified, for all welded lines with pressure above 4 kg/cm2 g and / or temperature above 2000C, branch connections with branch sizes upto 25% of welded mains shall be made with special forged steel welded fittings. 05. Bends for pipes for oxygen service shall have a radius of not less than three times the nominal pipe dia unless otherwise specified. 06. In general pipes having size 50mm and above, are to be joined by butt welding and 40mm below by socket welding / screwed connection. Threaded joints shall have to be seal welded except for galvanized pipes where Teflon sealing tapes shall be used. For galvanized pipeline, pipe joints which are to be made before galvanising shall be of welding type. Those joints which are to be made after galvanising shall be either flanged or screwed type. As far as practicable, whole fabricated piping assemblies shall be galvanized at a time in order to minimize the number of joints to be made after galvanising. 07. All pipelines shall be provided with drain connections, generally at the lowest point for removing accumulated condensate or water and line draining. The drains piping shall have drain pockets and isolation valves. Trap stations shall be provided where necessary. Lines shall be given proper slope towards the drain points. Drip legs on mainson line dia 150mm or over shall be at least 75% of the main dia with a depth twice the dia of the main or 600mm minimum from the centre line of the main to the trap off take unless otherwise specified. Drip legs on mains smaller than dia 150mm shall be full dia of the line. All drip legs for fluids which may deposit undesirable liquid or solid matter shall have full dia flanges for the bottom cover. 08. Pipe supports, anchors, restraints In general pipe supports, restraints, braces or anchors shall be located at those points in the building or outdoor where provision has been made for the loads imposed. Loads at the supporting points or restraints shall be determined sufficiently early and provisions shall be made in the building or outdoor structures for pipe supports. The Tenderer shall locate, design, supply and erect
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all the supplementary steel structures to properly secure and support all pipe hangers, supports, restraints, etc. Provision shall be made for support of piping which may be disconnected during maintenance work. All large pipes and all long pipes shall have at least two supports each arranged in such a way that any length of piping or valve may be removed without any additional supports being required. Supports, guides and anchors shall be so designed that excessive heat is not transmitted to the building steel. Supporting steel shall be of structural quality. Perforated, strap, wire or chain shall not be used. Support components shall be connected to support steel by welding, bolting or clamps. Bolt holes shall be drilled and not gas cut. Structural steel work for supporting shall be designed on the basis of a maximum design stress of 1265 kg/cm2. Pipe attachments coming in direct contact with pipes having surface temperature above 4000C shall be made of alloy steel. Use of insulating materials like asbestos between pipe clamp and pipe surface to meet the above temperature limitation shall not be permitted. The maximum spacing between two consecutive supports shall be not more than as specified. Pipe hangers and supports shall be capable of supporting the pipelines under all conditions of operation. They shall be capable of supporting the pipelines under all conditions of operation. They shall allow expansion and contraction without over stressing the piping system or overloading the terminal equipment due to variation in supporting effort. Rigid supports or hangers shall be permitted only for pipes with small movements. For hot lines, spring hangers shall be used. The maximum permissible load variation on the terminals of sensitive equipment between hot and cold conditions shall be limited to 6%. Variability in load between hot and cold conditions expressed as a percentage of the design load shall be taken as the criteria for spring selection for spring hangers. Variable spring hanger shall be set at cold conditions so that they take design load under operating condition after the designed thermal expansion has taken place.
Spring shall be encased in suitable cages and the hangers shall be provided with spring locking arrangement, external load and movement indicator and turn buckles for load adjustment. All the rigid hangers shall be provided with turn buckles for vertical length adjustments. Hangers rods shall be subjected and designed for tensile loads. At locations of high axial or lateral movement, suitable arrangement shall be provided to permit the swing. The swing from vertical position shall be within 40. Double nuts and locknuts shall be used for hanger rods and bolts in all cases. Hangers shall be designed so that they can not become disengaged by movements of supported pipe. The supporting structures at each support points shall be designed for the highest of the following loads to take into account the extra load during hydraulic testing. 1.25 times the maximum load under operating condition Weight of pipelines full of water (combined weight of pipe, insulation, valve attachment etc. plus weight of water)
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GUIDELINES FOR PIPING DESIGN -
Weight pipeline full of water as above plus any cold reaction as anticipated. Where the piping system is subjected to shock loads such as thrust imposed by the actuation of safety valves, hanger design shall include provision of shock absorbing devices of approved design. Vibration control devices shall be part of piping system design. Outdoor piping shall be designed with due consideration to expansion resulting from exposure to sunlight and care shall be taken to prevent progressive movement of long pipelines. Outdoor piping may be supported on shoes, saddles or steel sections. Effect of support friction especially for large dia pipelines shall be considered and friction forces minimized by suitable arrangement. Piping inside the trenches shall be supported at intervals on steel sections and the arrangement shall permit easy maintenance.
09
Valves and specialties All valves shall be of approved make and type. All valves shall be suitable for service condition i.e. flow, pressure and temperature under which they are required to operate. The valves for high and medium steam service shall have butt welded ends unless otherwise approved and the internal dia shall be same as that of the pipes to be joined. All gate/ sluice, globe and needle valve shall be fitted with outside screwed spindles and bolted type glands and covers. Spindle glands shall be of the bridge type construction and screwed glands will not be accepted. All high pressure valves having nominal dia more than 150mm, shall have integral steam bypasses concede to the valve body by means of welded joints. All gate/sluice, globe and needle valve shall be provided with hand wheel and position indicator. The face of each hand wheel shall be clearly marked with words open and shut with arrows to indicate the direction of rotation to which each refers. Arrangement limiting the travel of any valve in the open or shut position shall be provided exterior to the valve body. All globe valves shall be designed to prevent erosion of valve seats when the valves are operated partially opened. Valves which cannot be operated from the floor or walkways, shall be provided with suitable extension rods and linkages to facilitate operation from the floor or walkways. Chain operation will not be accepted for steam valves. Stems shall preferably be arranged vertically with gland at the top. In no circumstances must the gland be at the bottom. Valves shall not be installed in an inverted position. The design of valves shall be such that it will permit packing of glands under pressure. Where required, valve spindles shall be extended so that the hand wheel is at a height of about 1.0m above the level of the floor or platform from where the valves are to be operated. Where required, they shall be provided with head stocks and pedestals of rigid construction and where gears or bevel wheels are used, these shall be of cast steel or suitable grade cast iron with machine cut teeth.
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MECON LIMITED
Non return valves on all pumps discharges and steam line shall be of an approved non slamming type. Draining arrangement shall be made on both sides of the horizontal non-return valve where such a valve adjoins an isolating valve. Valve bodies shall be provided with removable access cover to enable the internal parts to be examined without removing the valves. Valves shall have a permanent arrow inscription on its body to indicate direction of flow. Gate sluice valves for low pressure service shall be outside screw rising spindle type. For these valves wherever necessary, chain operator shall be provided to operate the valve from the floor or walkways. Larger size gate valves for low pressure applications shall be provided with bypass and draining arrangement and valves with dia more than 350mm shall be provided with gear operator. For low pressure water applications, the non-return valves shall be lift check type for size upto DN 50mm and swing check type for higher sizes. Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm shall be of reinforced rubber and rubber lining of body shall have minimum thickness of 3mm. Generally plug valves shall be used in compressed air line. Plug valves shall be supplied with wrench operator. Valves shall be of taper plug type. Sampling valves for demineralised water shall be of cock type and stainless steel AISI 316. For motor operated valve, a 415V, 3 phase, 50Hz reversible speed motor shall be furnished. Motor shall be capable of producing not less than 1.5 times the required operator torque. Each operator shall be equipped with two adjustable limit and torque switch for both open and closed position. The motor shall be of high torque low starting current. Each operator shall be provided with auxiliary hand wheel for manual operation. The hand wheel shall automatically disengage when the operator is energized. Manual operator shall be of worm and gear type, having permanently lubricated, totally enclosed gearing with hand wheel diameter and gear ratio designed to meet the required operating torque. The operator shall be designed to hold the disc in any intermediate position between full opened & full closed without creeping and fluttering. Adjustable stop shall be built into the operator to prevent over travel in either direction. Operator shall be equipped with direct coupled position indicator and suitable locking device. Pressure reducing valves shall be perfectly stable, quiet and vibration less in operation when reducing the pressure for any throughput upto maximum and shall be suitable for continuous use at operating temperature. Valves shall be designed to prevent erosion of the valve seats. Safety valves shall be the direct spring loaded type and shall have a tight, positive and precision closing. All the safety valves shall be provided with manual lifting lever. Valves used for compressible fluids shall be of pop type. Safety valve shall be so constructed and adjusted to permit the fluid to escape without increasing the pressure beyond 10% above the set blow off pressure. Valve shall reset at a pressure not less than 2.5% and more than 5% the set pressure.
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The seat and disc of safety valves shall be of suitable material to resist erosion. The seat of valves shall be fastened to the body of valve in such away that there is no possibility of seat lifting.
10.Fabrication and installation of pipe work - Pipe joints shall be assembled with the inside of all pipes and fittings smooth, clean and free from burrs, scale, welding slag, sand and dirt. The inside edges of pipe and tubing shall be reamed after cutting to remove burrs. Screw threads shall conform to ANSI B 2.1 for taper pipe threads. All the threaded joints shall be made up with a lubricant or compound suitable for the service under which the piping is to be used. Welded joints shall conform to Code for pressure piping ANSI B31 1.0 (power piping) or approved equivalent, except where the welding of such joints is covered by other code requirements such as IBR, ASME pressure vessel and boiler code or approved equivalent. Branches shall in generally be formed by welding standard fittings. Pipe bends and tees shall be truly cylindrical and of uniform sections. Where permitted for certain services, elbows or branch connections may be formed from steel pipe. Unless otherwise agreed, slip-on welding flanges shall be used on pipe and for connection to low pressure equipment. Welded neck flanges shall be used for butt welding fitting as elbows, tees and reducers and for connection to high pressure equipment. Where class 125 ANSI flanges are bolted to 150 ANSI steel fittings, the 1.5mm raised face on the steel flange shall be removed. When bolting such flanges, a full face gasket shall be used. Equipment terminal flanges if consist of a different standard, a suitable companion flange shall have to be provided at the connecting points. Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges shall be 900 to the longitudinal axis of the pipe to which they are attached. Slipon flange when used, shall be welded in accordance with ANSI B31.1 or any other equivalent code. If distorted after welding, the flange shall be refaced. In all cases, flange faces, must be free from particles of weld metal. The flange face and the pipe projecting end shall then be machined to permit both pipe and flange to bear against. 11. All welding by the electric arc and gas welding process for pipe joints and fabrication shall be done by qualified welders and done according to appropriate IBR, ANSI code / regulations as applicable for welding, subject to accompanying code regulations and standards for filler metal, pressure, temperature and fluid carried. The ends of pipe and welding fittings shall be beveled according to the details shown in ANSI B31.1 or equivalent. All welds shall be made in such a manner that complete fusion and penetration are obtained without an excessive amount of filler metal beyond the root area. The reinforcement shall be applied in such a manner that it will have a smooth contour merging gradually with the surface of adjacent pipe and welded fittings.
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GUIDELINES FOR PIPING DESIGN 04.11 Fire water pipeline
Pipes shall be provided on the ring main concept where the number of landing valves installed on the pipe are more than five, In other cases (where the ring main is not possible and the pipes terminate with dead ends) the size of the branch pipes and the number of landing valves installed shall be as follows: Number of landing valves Upto Upto 1 3 5 Pipe dia 80 mm 100 mm 150 mm
Flexible rubber lined hoses (with circular woven jacket) alongwith necessary couplings, branch pipe with nozzle etc. shall be housed in a hose box or cabinet placed one for every landing valve. The hose box shall be provided with breakable glass cover and shall be hung near the landing valves in an easily accessible position.
04.12 Underground water pipelines Water pipelines outside any shop building or between two shop buildings may be buried underground. Gravity flow drainage pipes shall also be buried wherever necessary. However slurry pipeline under pressure shall be laid in covered trenches or tunnels. Buried pipelines shall be laid with 0.5 to 1.0 m gap between outside of pipes, minimum earth cover of 800 mm and minimum clearance from other underground structure of 1.0 m. Pipe laying shall be done using the relevant Indian Standard codes and practices specially the following: IS : 5822 : laying of welded steel pipes for water supply All pressure pipes shall be provided with a nominal slope and the gravity pipes shall be provided with slopes for self cleansing velocity. Manholes shall be provided on the gravity pipe lines at every point of change of direction of stope. The manholes shall be made of concrete with cast iron hatch and cover and rungs for approach to the bottom.
Valve on underground water pipeline shall be installed in concrete valve pits with proper removable cover of cast iron and proper drainage arrangement for the pit.
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Pipe crossing a railway track or road shall be protected by encasing in concrete or by laying it inside another encasing pipe of steel having a diameter two sizes higher than the main pipe. Buried steel pipes shall be painted and coated as per IS:10221 Insulation of underground pipes. 04.13. SLURRY WATER PIPELINE:FACTORS AFFECTING SLURRY WATER PIPELINE DESIGN: 1. 2. 3. 4. 5. 6. 7. 8. 9. Specific gravity of solids Size and shape of particles Density of conveying medium concentration of solids Liquid viscosity Slurry viscosity Flow rate Slope & Roughness of pipes Corrosion & erosion factors.
CRITICAL SETTLING VELOCITY (VC) The critical velocity at which a bed of particles begins to form is known as critical settling velocity Deposition velocity increases - Increase in particle size - Solids concentration - Particle density - Increase in pipe diameter Design velocity > Critical settling velocity Warmans Recommendations = Design velocity should be 30% higher than Vc
Calculation of Critical Settling velocity DURANDS EQUATION

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GUIDELINES FOR PIPING DESIGN Vc = FL ( 2gD x (s-s1) / s1)1/2 Where,
Vc = Critical settling Velocity FL = Froude constant D = internal dia of pipe = OD 2t S = Sp.gravity of dry solids S1 = Sp.gravity of media. FL depends upon particle size & volumetric concentration of slurry. SINCLAIRS EQUATION Vc = FL ( 2gD x (s-s1) / s1)1/2 (d/D)1/6 Where, d = d50 = Average particle size This is for lean slurry. Density of slurry, m = 100/((cw/s) + (100-cw)) / w) Where, cw s w = = = Concentration by weight Sp.gravity of dry solids Sp.gravity of flow medium
For BF GCP slurry m = 1.083 (s =4.3)
When, concentration is 10% Concentration by volume = cw . m / s For BF GCP slurry, When cw = 10% m = 1.083
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CORROSION PROTECTION OF UNDERGROUND BURIED M.S PIPES FOR WATER SERVICES:Buried steel pipes are liable to external corrosion and therefore need to be protected by the use of suitable coating. Steel pipes may be coated with any of the following methods as per the decision of the Purchaser. Types of Coating:i) ii) iii) Coat Tar enamel and fire glass polyester tissues in accordance with IS:10221. Corrosion Protection Tapes in accordance with IS:10221. Concrete lining as IS:1916 or Gunniting.
When the pipe is coated / wrapped before laying / putting into ground trench, the same should be made continuous after laying. After wrapping and coating individual pipe piece shall be tested in accordance with IS : 10221. Flanges shall be cleaned and are to be protected by plastic strips, bitumen strip and by pouring anticorrosive material. i) Cleaning of the external surface
Pipe surface shall be thoroughly cleaned and dried before the primer is applied. The pipe surface shall be free of dirt, grease, oil, rust, scale and other foreign material. Pipe surface shall be cleaned by any of the methods. Grit / shot blasting Stand blasting Mechanical cleaning by pneumatic wire brush. All oil and grease material shall be removed by suitable solvent and then surface cleaned by clear rag. ii) Coating of Primer The cleaned surface have to be immediately applied the coating of primer. Three types of primer are generally used i.e. (a) Coal Tar Primer (b) Asphaltic primer (c) Synthetic primer.
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GUIDELINES FOR PIPING DESIGN iii) Coating of Enamel
After the application of primer, coating of enamel is applied. Two types of enamel are generally used (a) Coat Tar enamel (b) Asphalt enamel. Depending upon the type of primer used the compatible enamel shall be used and it should be from the same manufacturer. iv). Applying the Wrapping Material
Three type of wrappings material are used (i) Glass Fibres (ii) Asbestos felt (iii) Kraft paper. The wrapping is being done in two phases. First the inner wrap of glass fibre tissues is applied. The second outer wrap is by means of glass fibre felt type 1 to IS:7193. In case outer wrapping is by asbestos felt then it should be thoroughly saturated with air blown coal tar / asphalt coating. In case outer wrapping is by kraft paper then the kraft paper shall be water proof and impregnated with coal tar / asphalt enamel. 04.15 CATHODIC PROTECTION FOR M.S BURRIED WATER PIPELINES:Mild Steel Pipes buried in corrosive soil need to be protected with the help of cathodic protection in addition to wrapping and coating. Cathodic protection system reverses the electro chemical force by creating an external circuit between the pipeline to be protected and an auxiliary anode (known as sacrificial anode) buried in the ground at a predetermined distance from the pipe. Direct current applied to the circuit is discharged from the anode surface and travels through the surrounding electrolyte to the pipe which is cathode. Two methods are available for generating a current of sufficient magnitude to guarantee the protection. In the first method the sacrificial anode material such as magnesium or Zinc is used to create galvanic cell. The electrical potential generated by the cell causes the current to flow from anode to the pipe and returning to the anode through a simple connecting wire. This system is generally used where it is desirable to apply small amount of current at a number of locations, mostly often on coated pipelines in lightly or moderately corrosive soils. The second method of current generation is to energise the circuit with on external DC power supply such as rectifier. The technique commonly referred to as impressed current method uses relatively inert anodes usually graphite or silicon cast iron connected to positive terminal of DC power supply with the pipe connected to negative terminal. This system is generally used where large amount of current is required at relatively few locations and in many cases it is more economical than sacrificial anodes. For cathodic protection, a corrosion survey including chemical physical analysis of the soil must be performed along the pipeline. Where the soil resistively is less than
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5000 ohms-cm. Cathodic protection in conjunction with appropriate wrapping and coating system shall be used. The cathodic protection shall conform to IS:8062 Part-II. For soil resistively above 5000 ohms-cm, cathodic protection shall be used in consultation with corrosion engineers.
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THERMAL INSULATION OF PIPELINES
Thermal insulation is applied to pipelines for two purpose. i) ii) To prevent heat loss to atmosphere in case of fluid being hot or to gain heat in case of the fluid it contains is cold or below ambient temperature. To ensure that the skin temperature of the equipment or pipe is not more than 600C which is a permissible limit prescribed by the Inspector of factories.
Insulation Materials Following insulating materials are normally used. i) ii) iii) Unbonded mineral wool made from slag or rock confirming to IS : 3677 or glass wool conforming to IS : 3690 Bonded mineral wool conforming to IS:8183 made from slag or rock or glass process from molten state into fibrous form and bonded with a suitable binder. Preformed fibrous pipe insulation conforming to IS:9842. The material shall be mineral wool processed from rock or glass fibres. Insitu Polyurethane / polyisocynurate insulation conforming to IS:13205 (applicable for max operating temperature of 1100C).
iv)
Thickness of Insulation Thickness of heat insulation to be provided is a function of the value of thermal conductivity of the material selected, the temperature of the fluid and the bulk density of the heat insulation material. Following table gives the bulk density for unbonded and bonded mineral wool with temperature limitations of hot face temperature. Unbonded Mineral wool 120 kg/m3 150 kg/m3 200 kg/m3 Bonded Mineral Wool (kg/m3) Slabs / mattresses Pipe sections Glass Wool Rock Wool 50 85 120 80 85 120 120 85 120 Max hot face Temp 0C 250 400 550
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Table for Insulation thickness Pipe size (outside dia) Pipe Insulation thickness in mm for various temperature ranges Between 3000C 50 75 Between 4000C 75 100 Between 5000C 100 125 100 125 Above
size 1000C Between and below 2000C
(outside dia)
101 and 201
and 301
and 401
and 5000C
Upto DN 50mm DN 65 to DN 100mm DN 125 & DN 150mm DN 200 mm DN 250 mm DN 300 mm Note:
25 25
50 50
50
75
75
100
125
150
50 50 50
75 75 75
75 100 100
125 125 125
125 150 150
150 150 150
The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS: 277 with following thicknesses:
-
Pipe sizes up to 300 mm OD Pipe sizes up to 300 mm OD equipment, flanges, valves
: :
0.63 mm 0.80 mm
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ANNEXURE A Page 1 of 17
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MECON LIMITED
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MECON LIMITED
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MECON LIMITED
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MECON LIMITED
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MECON LIMITED
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CHAPTER: 5
LOAD CALCULATIONS & FLEXIBILITY ANALYSIS
MECON LIMITED
Rev - 0
Page 1 of 8
LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS

Load Calculations for gaseous & Liquid pipelines:Loads from the piping system are transferred to the pipe supports and connected equipment. Depending on the direction of application, loads are calculated under two major heads : Vertical Loads Horizontal Loads
05.01.01
Vertical loads Vertical loads transferred to pipe supports comprise of the following : Dead weight of the pipes Weight of fluid in pipes Weight of insulation if any Condensate weight in gas pipeline Dust load due to deposition on pipeline Load due to mounted valves, compensator and fittings. Load due to saddles, supports and other service pipes Dead load and live load from Platforms and walkways
Empty weight of pipes shall be taken from standard weight tables. In case of pipes carrying liquid, fluid weight with full pipe section shall be considered. Following norms shall be followed for calculating the condensate load in low pressure fuel gas mains. Pipe dia. (mm) Height of filling of pipe Filling in crosscross-section with section (%) condensate (mm) 100 Full 88 35 500 30 14 500 800
1. Upto DN 500 2. DN 600 DN 1400 3. DN 1500 DN 3500
Load due to dust deposition shall be as follows : 50 Kg/m2 on pipelines at a distance within 100 m from dust generating plant (viz. Blast Furnace, Coke ovens, SMS, Lime and Dolomite plant etc.) 25 Kg/m2 on pipelines at a distance between 100 m to 500 m from dust generating plants. Sheet 1 of 8
MECON LIMITED
Rev - 0
Page 2 of 8
Weight of valves, compensators and other mounted accessories shall be taken from drawings/ catalogues. Live load on platform shall be taken as 500 Kg/m2. This is indicated to Structural Section for designing platforms. It is recommended to add 10% to 20 % of vertical load as a provision for pipes to be laid in future on the same route.
Horizontal loads Horizontal loads transferred to pipe supports comprise of the following: Load due to thermal expansion Load due to internal gas pressure i.e. blanking load, load due to annular space of compensator, unbalanced pressure load at branch locations, etc Load due to friction Wind load
Depending on the pipe configuration, horizontal loads can be in axial direction as well as in transverse direction. Horizontal loads due to thermal expansion, internal pressure and friction are calculated by carrying out flexibility analysis on individual pipe. Procedure is given in para 05.03. However, wherever possible, standard software package like CAESAR-II may be used for carrying out flexibility analysis and calculations of loads transmitted to supports and nozzles of equipment to which piping is connected. 05.02 LOCATION OF PIPE SUPPORTS Supports for pipes shall be provided based on pipe layout. Span between two consecutive supports for a pipe shall be limited to the values given in Table 05.01 and 05.02 Recommended spacing (C.L to C.L) between two pipes are indicated in Table 05.03. In specific cases where span between two supports can not be provided as per the table, alternative arrangement for intermediate support using bridge between trestles or guy rope supports may be considered. In exceptional cases where distance exceeds the limiting span, suitable stiffening of pipe section to prevent sagging may be considered. At sliding supports pipe saddle shall be allowed to rest on bearing plate for free movement. In case U-clamps are provided, clearance shall be maintained for pipe movement by providing two nuts on opposite sides. Sheet 2 of 8
MECON LIMITED
Rev - 0
Page 3 of 8
All intermediate supports shall be of sliding type. Anchor supports shall be located based on piping configuration and layout to provide adequate flexibility. Distance between two consecutive fixed supports in straight runs of pipe route should be approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it should exceed 100 m. However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm cold pull if any during erection may be given as per instructions of the respective drawings. To reduce friction force transmitted to supports, roller supports or anti friction pad supports can also be used. 05.03 FLEXIBILITY ANALYSIS Piping arrangement shall provide for flexibility of lines to take care of the thermal expansion, contraction and equipment settlement. Large reactions or moments at equipment connections shall be avoided . Expansion computation shall be made on the basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or ve ) design temperature(s) as given. i) Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest Edition). Analysis shall consider stress intensification factors as per ASME B31.3. Lines which shall be subjected to steam out conditions , shall be designed and analyzed at low pressure steam design temperature of line whichever is more. Lines having negative design temperature shall be analyzed for both conditions separately. Flexibility Analysis of lines shall be carried out using simplified methods or a comprenhensive computer program. Comprehensive computer analysis shall be carried out for the piping as per Cl. No. 05.03 (vii) For lines connected to equipment like vessels, pumps, filters, furnace, compressors or other strain sensitive equipment. The result of the analysis must satisfy the allowable loading on the nozzles of such equipment.
ii)
iii)
iv)
Piping shall be adequately supported for the weight of piping, water, attached unsupported components, wind, seismic, insulation and any other applicable forces. Care should be taken that these supports are adequate to prevent excessive stress, load or moments in either the piping or terminal nozzles of the equipment to which it is connected. Adequacy of supporting of lines having heavy valves shall be checked. The support shall be indicated in the piping General Arrangement Drawings and Isometrics as applicable. Sheet 3 of 8
MECON LIMITED
Rev - 0
Page 4 of 8
v) Safety valve manifolds and downstream of control valves shall be adequately supported to avoid vibrations.
vi) The following factors shall be considered in the stress analysis Friction for lines >= 8 NB ; @ steel to steel = 0.3: ( Sliding friction), @ steel to Steel =0.1 (Rolling friction), Corrosion Allowance. Initial displacement of nozzles at design temperature(s). Transverse deflections =25 mm( maximum) Longitudinal expansion/contraction = 200 mm (maximum) Special care to be taken to check for expansion loops and shoe support lengths shall be finalized accordingly. viii) The following shall always be analyzed using comprehensive computer analysis: a) b) c) d) All lines 4 and above and Design Temp.> 300 deg. C. All lines 8 and above and Design Temp. > 150 deg. C. Al l lines 16 and above and Design Temp. > 80 deg. C. All lines 6 and above and Design Temp. > deg. 65 C that are connected to rotating Equipment, Air Coolers or any other sensitive equipment. Any other system/line that stress engineer feels necessary for stress check.
e)
The report shall comprise of the following: Basic input data and calculated conditions. Layout isometric and supports configuration. Load cases and calculated member stresses. Forces, moments and displacements reports. Spring hangers design parameters. Allowable Stress Range. Additional requirements ( reinforcement pad etc.)
Sheet 4 of 8
MECON LIMITED
Rev - 0
Page 5 of 8
PROCEDURE FOR FLEXIBILITY ANALYSIS ( MANUAL)
Step I Draw free line diagram covering piping segment and branches on both sides of fixed support (F.S.) for which resultant load / stress is to be worked out. D B E C
A F.S. COMP F.S. COMP F.S.
Step - II Calculate effective dead load + live load (DL + LL) due to pipe & equipment at point B for segment AB & BC. Step - III Frictional Force Expansion joint / compensator is to take care of thermal elongation / contraction and hence its position is considered as fixed though there may be a very minor change in the location of expansion joint. Practically it is taken as zero displacement. Calculate frictional force f1 & f2 due to pipe segment DB and BE respectively. Frictional force = (DL + LL) x Co-efficient. Of friction Co-efficient., of friction for steel to steel shall be taken as follows : Sliding support Roller support Ball support PTFE pad support = = = = 0.3 0.1 0.1 0.05 to 0.09
Sheet 5 of 8
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Step - IV Anchor Force
Rev - 0
Page 6 of 8
Anchor force is to be worked out separately for segment AB and BC. Calculate total elongation / contraction for segment AB. l=l**t Where l l = = = = t = Thermal elongation / contraction in mm length of segment AB in meters co-efficient of thermal expansion 0.012 mm / m / 0c for steel Maximum temp. difference in 0C
Identify spring rate of the expansion joint / compensator (kg f/mm) Calculate anchor force due to segment AB using formula Anchor force a1 = Spring rate (Kg f/mm) x l.
Step - V
Calculate anchor force (a2) due to segment BC in similar way.
Force due to annular space of disc compensator / bellow compensator.: The annular space remains filled with gas and exerts pressure on the wall of compensator, which is turn, gets transferred to the fixed support.
Sheet 6 of 8
MECON LIMITED
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Page 7 of 8
Force due to annular space of compensator (c1 & c2) = /4 (D2 d2)p Where, D d p = = = I.D. of Compensator in mm I.D. of pipe in mm Test pressure of piping system in kgf/mm2(g)
Compensator force c1 and c2 shall be worked out for both the segments AB & BC respectively.
Step VI Blanking Load Blanking load comes into effect when there is change in direction of flow / at the location of isolation device. Direction of blanking load is towards the bend. Blanking load may be worked out using formula. B.L. = /4 x d2 x p Where d P = = ID of pipe in mm test pressure of piping network in kg f / mm2
As is evident, in Case I, no blanking load is applicable at fixed support B.
Sheet 7 of 8
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Step VII
Rev - 0
Page 8 of 8
Prepare the load diagram for the fixed support to be analyzed. Frictional force = f1 ( ) Anchor force = a1 ( ) Force due to compensator c1 ( Frictional force = f2 ( ) Anchor force = a2 ( ) Force due to compensator c2 ( ) FS
Blanking load = 0
Blanking load = 0
Based on above diagram, resultant force is worked out at point B. Resultant 1: Frictional force = f = f1 0.7 f2 ( Anchor Force = a = a1 0.7 a2 ( ), where f1 f2 ), where a1 a2 ), where c1 c2
Force de to compensator = c = c1 0.7 c 2 (
All the above forces in this case act along the axis of pipeline. There is no transverse force acting perpendicular to pipe axis. Hence, resultant axial force at B = (f + a + c) 05.05 WIND LOAD CALCULATION Wind load acts on transverse direction across pipe due to pressure of wind. Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind pressure due to cyclonic wind pressure shall be taken. Wind load for a section of pipe = Wind pressure X projected area x shape factor For circular pipes shape factor is 0.7. In case of multiple pipes, for each tier of pipes, largest pipe may be considered for calculating wind load.
Sheet 8 of 8
CHAPTER: 6
PIPING MATERIAL SPECIFICATIONS
MECON LIMITED
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06
06
06.01
PIPING MATERIAL SPECIFICATION

SCOPE This PMS covers the various piping specification for process and utility piping in Metallurgical plants and its related industrial Installation. Deviation from this specification may be necessary to conform to specific job requirements. In such cases a separate and specific PMS shall be issued with the approval of piping competent authority.
06.02
REFERRED CODES & STANDARDS All piping shall be designed in accordance with relevant latest codes and standards like B 31.1, B 31.3 and different IPSS (Inter plant standard for steel industry) Individual piping material specification has been designed to cover a set of services operating within fixed pressure and temperature.
06.03 06.03.01 06.03.02 06.03.03 06.04
PIPES Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for carbon steel pipe and to B36.10/B36.19 for stainless steel pipe. Pipe made by acid Bessemer process shall not be acceptable.Pipes shall be made by open hearth, electric furnace or basic oxygen process. All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted. FLANGES Flanges shall be in accordance with following codes except where otherwise noted. DN 15 to DN 600 (150 # - 600#) Above DN 600 ANSI/ANSI B16.5 / IS : 6392
API 605 / ANSI B16.47 / MSS-SP-44 / IS:6392 DIN etc.
Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be made with equipment or valve flanges with corresponding bolting. 06.04.01 Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME B16.5. The interpretation shall be as follows : Serrated Smooth (125 AARH) : : 250 500 Mu in AARH 125 250 Mu in AARH 32 250 Mu in AARH
For RTJ groves (32 AARH) :
Page 1 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN 06.04.02 06.04.03 06.05 06.05.01 06.05.02 06.05.03 06.05.04 06.05.05
Bore of WN flanges shall match the ID of the attached pipe Bore of slip on flanges shall suit the pipe OD and its thickness. Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2) is indicated in Table 06.01 FITTINGS Forged steel socket welded and threaded fittings shall be in accordance with ANSI B 16.11 unless otherwise noted. Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise noted. Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless otherwise specified. Fittings thickness and tolerance shall match pipe thickness and tolerance. Mitres and reducers fabricated form pipe may be use if specified in PMS, shall conform to IPSS:1-06-020-95. In no case mitres thickness and material shall be inferior to parent pipe. GASKETS Non metallic gasket shall conform to IS:2712. Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20. Ring type and spiral wound gasket shall be self aligning type. BOLTING Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992. Unless otherwise noted. THREADS Threads for threaded pipes, fitting flanges and valves shall be in accordance with B1.20.1 taper threads unless otherwise noted. Upto 2000C threaded joints shall be made with 1 width PTEE joining tape. Above 2000C threaded joints shall be seal welded with full strength fillet weld. All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid shall be seal welded with a full strength fillet weld.
06.06 06.06.01 06.06.02 06.06.03 06.07 06.07.01 06.08 06.08.01 06.08.02 06.08.03 06.08.04
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN 06.09 06.09.01 VALVES
Face to Face/End to End dimension of valves shall conform to B16.10 to the extent covered. For valves not covered in B16.10. reference shall be made to BS2080 and / or the manufacturers drawings. Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting ends of the piping class, unless otherwise specified. Pressure temperature rating for flanges and butt welding end valves shall be as per ANSI B16.34 except for ball, plug & butterfly valves. For these valves refer TABLE FOR PRESSURE TEMP. RATING FOR BALL, PLUG AND BUTTERFLY VALVES Unless called-out specifically, valves shall be as per the following Standards. Valve Gate Globe/Check Gate Gate Globe Check Gate/Globe/Check Ball Plug 15 400 15 300 Size mm 15 - 40 15 - 40 50 - 600 DN Rating 800/1500 800/1500 150/300/600 Des. Std. API-602 BS 5352 API-600 BS-1414 BS-1873 BS-1868 Testing Std. API-598 BS-6755 Pt-I API-598 BS-6755 Pt-I BS-6755 Pt-I BS-6755 Pt-I API-598/ BS6755 Pt-I BS-6755 API-598 /BS-5353 BS-6755 API-1898/ BS-6755 Pt-I /AWWA BS-6755 Pt-I
06.09.02 06.09.03
06.09.04
650 - 1050 150/300 50 200 50 600 150/300/600 150/300/600
900/1500/2500# B-16.34 BS-5351 API-599
Butterfly
80 above
& -
API-609/ BS5155 AWWA C504 BS-5156
Diaphram 06.09.05 06.09.06
ALL
If not covered in 06.09.04 the valve shall be as per B16.34 and relevant MSS SP Standard DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and utility service shall have bolted bonnets. Pressure seal bonnets or covers shall be used for Classes 900# and above to minimize bonnet leakage. However, valves with pressure seal bonnet shall have wall thickness & seal stem diameter as per API600. Welded bonnets or screwed & seal welded bonnets are acceptable for sizes lower than DN 50 for Classes 900# & above.
Page 3 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : BF Gas, CO Gas, BOF, Corex Gas & Mixed Gas SERVICE CONDITIONS : Maximum Working Pressure 1500mmWC Minimum Working Pressure 50 mmWC CORROSION ALLOWANCE : 2 m.m. Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 350 DN 400 to 750 DN 800 to 3500 Description ERW, PE; Sch Heavy ERW, BE; Sch Heavy ERW, BE; 6 mm Thk ERW/SWP,BE; 8 mm Thk Fabricated Electric Fusion Welded, BE; 10mm Thk. SW /Screwed Fittings (Elbow R=1.5D) BW (Elbow R=1.5D) Fabricated Miters bends & fittings from pipe / plate SORF; Serrated Finish SORF; Serrated Finish SORF; Serrated Finish Gasket: Thk. 2 mm Ring Type CAF Asbestos rope graphite impingnated. 8mm Gate valve; Screwed Gate valve; Flanged Dimension Standard IS : 1239 IS : 1239 IS : 3589 IS : 3589 IS : 3589 Material Specification IS:1239 - Black IS:1239 - Black IS: 3589 Gr.330 IS: 3589 Gr.330 IS : 2062, Gr.B Temp 60 oC Temp 5 oC
Fittings
DN 15 to 40 DN 50 to 150 DN 200 & above
IS : 1239 (P-2) IS : 1239 (P-2) IPSS-06-20 IS : 6392 Table - 5 IPSS:1-06-20 Table 3 IPSS:1-06-20 Table 3 As per Flange
IS : 1239 (P-2) Black IS : 1239 (P-2) Black IS : 2062, Gr.B IS: 2062, Gr.B IS: 2062, Gr.B IS: 2062, Gr.B IS : 2712 Gr W/3
Flanges #150
Upto DN 150 DN 200 to 300 DN 400 & above Upto DN 500 Above DN 500
Gaskets
Valves
DN 15 to 40 DN 50 to 550
API 602 IS : 14846 IPSS: 1-06-023
Body ASTM A105; Cr 13% Trim Body CI GR. FG 200 Body CI, Gr.FG-210
DN 600 to 1600 Gate valve; Flanged
Page 5 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 1800 & above DN 15 to 40 DN 50 and above DN 15 to 40 DN 50 to 300 DN 350 & above DN 15 / DN 25 Bolting All
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimension Standard MSS BS 5352 BS 1868 / API 594 BS 5352 BS 1873 BS 5155/ API 594 BS: 5158
Description Gate valve; Flanged Check valve SW Lift Type #800 Check Valve Flanged swing check valve/ dual plate #150 Globe valve SW / Screwed ; #800 Globe valve; Flanged ; Serrated Finish; #150 Butterfly valve WAF Type; #150 Screwed LUB.TAPERED PLUG VALVE M/C Bolts
Material Specification Body IS: 2062 GR. B Body A105, 13% Cr Trim Body A216;WCB, 13% Cr Trim Body A105, 13% Cr Trim Body A216 Gr WCB, 13% Cr Trim Body A216 Gr WCB;13% Cr Trim Body & PLUG : CI IS 210 FG 200
Piping Fabrication
Flanged Joints Pipes Joints
ASTM A193 Gr IS: 1364- 1992 B7 Nuts ASTM A194 Gr IS: 1364- 1992 2H At valve/ equipment location and for sectionalising & Maintenance. To be kept minimum DN 50 & below SW coupling DN 50 & above Butt welded
Fabricated pipes Temp Connections Pressure Tapping Vents Drains
Fillet welding using semi bandage on each segment. DN 40 Flanged set-on nozzle DN 20 SW Half Coupling Nipple Sch 80 with Gate valve to Spec. On lines >= DN 50 ; MEC std. On lines >= DN 80, MEC Std.
Note: For flange dimensions refer Table 06.01.
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MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : LPG /PROPANE SERVICE CONDITIONS : Maximum Operating Pressure 6 kgf /cm2 Minimum Operating Pressure Atm CORROSION ALLOWANCE : 1.5 mm. Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 300 DN 350 DN 400 & above DN 15 to 40 DN 50 to 150 DN 200 & above DN 15 to 40 DN 50 & above Gaskets Valves All sizes DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 DN 15 to 40 DN 50 to 600 Description Seamless PE Sch. 80 Seamless BE Sch.40 Seamless BE Sch.20 Seamless BE Sch.10 EFSW BE Thk. 6.0mm SW / Screwed Fittings # 3000 (Elbow R=1.5D) BW Fittings #150 (Elbow R=1.5D) Miter bends & fittings fabricated from pipe SW:RF : Serrated Finish; #150 SORF : Serrated Finish; #150 Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800 Gate valve Flanged RF Serrated Finish # 150 Globe valve, SW # 800 Globe valve : Flanged RF Serrated # 150 finish Check valve SW # 800 Lift type Check valve flanged RF Serrated finish # 150 Dimensional/ Design Standard B 36.10 B36.10 B36.10 B36.10 B36.10 ANSI B 16.11 ANSI B16.9 IPSS-1-06-020 B 16.5 B 16.5 B 16.21 API 602 API 600 BS 5352 BS 1873 BS 5352 BS 1868 Material Carbon Steel API 5L GR.B API 5L GR.B API 5L GR.B API 5L GR.B API 5L GR.B ASTM A 105 ASTM A234 Gr WPB Same as parent pipe ASTM A 105 ASTM A 105 IS : 2712 Gr W/3 Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Temp 60 oC Temp 5 oC
Fittings
Flanges
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MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 15 to 150 Bolting Miscellaneo us All DN 15 to 40 DN 15 to 40 DN 50 to 350 DN 400 to 600 Above DN 600 Piping Fabrication Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Drains
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS 5351 B 18.2 B 18.2 MANF STD. MANF STD. MANF STD. MANF STD. MEC STD.
Description Ball valve flanged RF Serrated finish #150 Studs / Bolts Nuts TRAP #150, THRMDNMC PERM. STR, SW, Y Type PERM. STR, BW, T Type PERM. STR, BW, T Type TEMP. STR, FF, CONE Type
Material Carbon Steel Body A216 Gr.WCB 13% Cr. Trim ASTM A193 Gr B7 ASTM A194 Gr 2H BODY A105, TRIM 13% CR , S: SS304 BODY A05: INT SS 304 BODY A234WPB : INT SS 304 BODY A234WPBW: INT SS 304 BODY A516GR. 70: INT SS 304
At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Nipple Sch 80 with Gate valve to spec. Gate DN 40 Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.
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MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : MEDIUM PRESSURE NITROGEN , ARGON,

& COMPRESSED AIR
SERVICE CONDITIONS : Maximum Operating Pressure 10.5 kgf /cm2 Minimum Operating Pressure Atm CORROSION ALLOWANCE : 1.5 m.m.
Temp 60 oC Temp 5 oC
Item Pipe
Size Range DN 15 to 40 DN 50 to 150 DN 200 to 350 DN 400 to 500 DN 550 to 600 DN 650 & above DN 15 to 40 DN 50 to 150 DN 200 & above DN 15 to 40 DN 50 to 600 DN 650 & Above
Description ERW, PE Sch. HEAVY ERW, BE Sch. HEAVY ERW, BE , THK 6.0mm ERW, BE , THK 8.0mm ERW BE Thk. 10.0mm ERW/ SAW, BE Thk. 10.0mm (min) SW / Screwed Fittings # 3000 (Elbow R=1.5D) BW Fittings #150 (Elbow R=1.5D)) Miter bends & fittings fabricated from pipe SW:RF : Serrated Finish #150 SORF : Serrated Finish #150 SORF : Serrated Finish #150 Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800 Gate valve Flanged RF Serrated Finish # 150 Globe valve, SW # 800 Globe valve : Flanged RF Serrated # 150 finish
Dimensional/ Design Standard IS:1239 IS:1239 IS:3589 IS:3589 IS:3589 IS:3589 ANSI B 16.11 ANSI B16.9 IPSS-1-06-020 B 16.5 B 16.5 B 16.47 / IS:6392 / API 605 B 16.21 API 602 API 600 BS 5352 BS 1873
Material Carbon Steel IS:1239 BLACK IS:1239 BLACK IS:3589 GR.330 IS:3589 GR.330 IS:3589 GR.330 IS:3589 GR.330 ASTM A 105 ASTM A234 Gr WPB Same as parent pipe ASTM A 105 ASTM A 105 ASTM A 105 IS : 2712 Gr W/3 Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim
Fittings
Flanges
Gaskets Valves
All sizes DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200
Page 9 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 15 to 40 DN 50 to 600 Bolting All
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS 5352
Description
Material Carbon Steel
Miscellaneo DN 15 to 40 us DN 15 to 40 DN 50 to 350 DN 400 to 600 Above DN 600 Piping Fabrication Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Drains
Check valve SW # 800 Body A105; 13% Cr Lift type Trim Check valve flanged RF BS 1868 Body A216 Gr.WCB Serrated finish # 150 13% Cr Trim Studs / Bolts B 18.2 ASTM A307 Gr B Nuts B 18.2 ASTM A563Gr B TRAP #150, MANF STD. BODY A105, TRIM THRMDNMC 13% CR , S: SS304 PERM. STR, SW, Y MANF STD. BODY A05: INT SS Type 304 PERM. STR, BW, T MANF STD. BODY A234WPB : Type INT SS 304 PERM. STR, BW, T MANF STD. BODY A234WPBW: Type INT SS 304 TEMP. STR, FF, CONE MEC STD. BODY A516GR. 70: Type INT SS 304 At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Sch 80 Nipple with Gate valve to spec. DN 40 Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.
Page 10 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : HIGH PRESSURE NITROGEN , ARGON, &

COMPRESSED AIR
SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2 Minimum Operating Pressure 10.5 kgf /cm2 CORROSION ALLOWANCE : 1.5 mm. Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 250 DN 300 to 350 DN 400 to 600 Fittings DN 15 to 40 DN 50 to 350 DN 400 to 600 Flanges DN 15 to 40 DN 15 to 600 Gaskets Valves All sizes DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 DN 15 to 40 Description Seamless PE Sch. 80 Seamless BE Sch.40 Seamless BE Sch.30 Seamless BE Sch. Std. EFSW BE Thk. Calculate SW Fittings # 3000 (Elbow R = 1.5D) BW Fittings (Elbow R = 1.5D) BW Fittings (Elbow R = 1.5D) SW:RF : Serrated Finish #300 WNRF : Serrated Finish #300 SPIRAL; THK. 4.4 mm Gate valve SW # 800 Gate valve Flanged RF Serrated Finish # 300 Globe valve, SW # 800 Globe valve : Flanged RF Serrated # 300 finish Check valve SW # 800 lift type
Page 11 of 27
Dimensional/ Design Standard B 36.10 B36.10 B36.10 B36.10 B36.10 ANSI B 16.11 ANSI B16.9 ANSI B16.9 B 16.5 B 16.5 API 601 API 602 API 600 BS 5352 BS 1873 BS 5352
Material Carbon Steel ASTM A106 Gr.B ASTM A106 Gr.B ASTM A106 Gr.B ASTM A106 Gr.B ASTM A672 B60 CL 12 ASTM A 105 ASTM A234 Gr WPB ASTM A234 Gr WPBW ASTM A 105 ASTM A 105 SS 304 SPR. WND + CA FIL Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A105; 13% Cr Trim
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 50 to 600 DN 15 to 150 DN 15 to 300
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS 1868 BS 5351 BS 5353
Description Check valve flanged RF Serrated finish # 300 Ball valve flanges RF Serrated finish # 300 Plug valve flanges RF Serrated finish # 300 Studs /Bolts Nuts TRAP #150, THRMDNMC PERM. STR, SW, Y Type
Material Carbon Steel Body A216 Gr.WCB 13% Cr Trim Body A216 Gr.WCB 13% Cr. Trim Body A216 Gr.WCB HARDEN PLUG ASTM A193 Gr B7 ASTM A194 Gr 2H BODY A105, TRIM 13% CR , S: SS304 BODY A105: INT SS 304
Bolting Miscellaneo us
All DN 15 to 40 DN 15 to 40 DN 50 to 350 DN 400 to 600 DN to 600
B 18.2 B 18.2 MANF STD. MANF STD.
Piping Fabrication
Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Drains
PERM. STR, BW, T MANF STD. BODY A234WPB : Type INT SS 304 PERM. STR, BW, T MANF STD. BODY A234WPBW: Type INT SS 304 TEMP. STR, FF, CONE MEC STD. BODY A516GR. 70: Type INT SS 304 At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Nipple Sch 80 with Gate valve to spec. DN 40 Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.
Page 12 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : LOW PRESSURE STEAM, CONDENSATE

& BOILER FEED WATER
SERVICE CONDITIONS : Maximum Operating Pressure 18 kgf /cm2 CORROSION ALLOWANCE : 1.5 m.m. Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 300 DN 350 to 400 Fittings DN 15 to 40 DN 50 to 600 DN 200 to 600 Flanges DN 15 to 40 DN 50 to 600 All sizes DN 15 to 40 DN 50 to 400 DN 15 to 40 DN 50 to 200 DN 15 to 40 DN 50 to 600 DN 15 to 150 Bolting Miscellaneo us All DN 15 to 40 Description Seamless PE Sch. 80 Seamless BE Sch.40 Seamless BE Sch.40 Seamless BE Sch.40 SW Fittings # 3000; (Elbow R=1.5D) BW Fittings (Elbow R=1.5D) BW Fittings (Elbow R=1.5D) SW:RF : Serrated Finish WNRF : Serrated Finish Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800 Gate valve Flanged RF Serrated Finish # 300 Globe valve, SW # 800 Globe valve : Flanged RF Serrated # 300 finish Check valve SW # 800 Lift type Check valve flanged RF Serrated finish # 150 Ball valve flanges RF Serrated finish # 300 Studs /Bolts Nuts TRAP #300, THRMDNMC
Page 13 of 27
Temp 360oC
Dimensional/ Design Standard B 36.10 B36.10 B36.10 B36.10 ANSI B 16.11 ANSI B16.9 ANSI B16.9 B 16.5 B 16.5 B 16.21 API 602 API 600 BS 5352 BS 1873 BS 5352 BS 1868 BS 5351 B 18.2 B 18.2 MANF STD.
Material Carbon Steel ASTM 106 GR.B ASTM106 GR.B ASTM106 GR.B ASTM106 GR.B ASTM A 105 ASTM A234 Gr WPB ASTM A234 Gr WPBW ASTM A 105 ASTM A 105 IS : 2712 Gr W/1 Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A216 Gr.WCB 13% Cr. Trim ASTM A193 Gr B7 ASTM A194 Gr 2H BODY A105, TRIM 13% CR , S: SS304
Gaskets Valves
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 15 to 40 DN 50 to 400 Piping Fabrication Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Vents Drains Note:
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard MANF STD. MANF STD.
Description PERM. STR, SW, Y Type PERM. STR, BW, T Type
Material Carbon Steel BODY A 105: INT SS 304 BODY A234WPB : INT SS 304
At valve/ equipment location and for sectionalizing & maintenance to be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Nipple Sch 80 with Gate valve to spec. DN 40 Flanged set-on nozzle On lines <= DN 40 ; MEC std. On lines >= DN 50 ; MEC std. On lines <= DN 40 ; MEC std.
1. Class of various items shall be selected based on the pressure of steam in the line ( For low pressure inferior class may be considered) 2. For higher pressure i.e, more than 18 bar the technologist (PP & EE) to be contacted for specification.
Page 14 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : LOW/ MEDIUM PRESSURE OXYGEN SERVICE CONDITIONS : Maximum Operating Pressure 15 kgf /cm2 CORROSION ALLOWANCE : 2 m.m. Cleaning, Pickling, Passivation & Degreasing As Per IGC : 33/86/E Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 300 DN 350 to 600 Fire Breaker DN 50 to 150 DN 200 to 600 Fittings DN 15 to 40 DN 50 to 600 Flanges DN 15 to 40 DN 50 to 600 All sizes DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 DN 15 to 40 DN 50 to 600 Description Seamless PE Sch. 80 Seamless BE Sch.40 Seamless BE Sch.40 Seamless BE Sch.40 Copper Pipe Copper Pipe SW Fittings # 3000; ( Elbow R=4D) BW Fittings ( Elbow R=4D) SW:RF : Serrated Finish WNRF : Serrated Finish PTFE LOX GRADE Gate valve; SW; # 800 Gate valve; Flanged; RF; Serrated Finish # 150 Globe valve, SW; # 800 Globe valve : Flanged RF Serrated # 150 finish Check valve SW # 800 lift type Check valve flanged RF Serrated finish # 150 Dimensional/ Design Standard B 36.10 B36.10 B36.10 B36.10 B36.10 B36.10 ANSI B 16.11 ANSI B16.9 B 16.5 B 16.5 B16.21 API 602 API 600 BS 5352 BS 1873 BS 5352 BS 1868 Material Carbon Steel ASTM A106 GR.B ASTM A 106 GR.B ASTM A 106 GR.B ASTM A 106 GR.B Deoxidised non Arsenic Copper Deoxidised non Arsenic Copper ASTM A 105 ASTM A234 Gr WPB ASTM A 105 ASTM A 105 ASTM D3293; TYPE 3; Gr. 1+A Body A182 GR. 304; /BRONZE ;13% CR Trim / BRONZE Body A351 GR.CF8 13% Cr Trim Body A182 GR. 304;/ BRONZE; 13% CR Trim/ BRASS Body Al BRONZE CASTING; TRIM BRASS; PTFE Seat Body A105; 13% Cr Trim Body & Trim A182 GR. 304 Temp 60 oC
Gaskets Valves
Page 15 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 15 & Above Bolting All
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS 5351 B 18.2 B 18.2
Description Ball valve flanged RF Serrated finish Studs/Bolts Nuts
Material Carbon Steel Body A351 GR.CF8 ; A182 GR. 304 Trim;PTFE Seat ASTM A193 Gr B7 ASTM A194 Gr 2H
Piping Fabrication
Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Vents Drains
At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Nipple Sch 80 with . Gate valve to spec. DN 50 Flanged set-on nozzle On lines <= DN 50 ; MEC std. On lines >= DN 50 ; MEC std. On lines <= DN 50 ; MEC std.
Page 16 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN PIPING MATERIAL SPECIFICATION SERVICE : HIGH PRESSURE OXYGEN
SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2 Minimum Operating Pressure 16 kgf /cm2 RATING :
# 300 Matching Companion Flanges of Valves & flow components as per corresponding rating.
CORROSION ALLOWANCE : 2 m.m. Cleaning, Pickling, Passivation & Degreasing As Per IGC : 33/86/E Item Pipe Size Range DN 15 to 40 DN 50 to 150 DN 200 to 300 DN 350 to 600 Fire Breaker DN 50 to 150 DN 200 to 600 Fittings DN 15 to 40 DN 50 to 600 Flanges DN 15 to 40 DN 50 to 600 Gaskets Valves All sizes DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 Description Seamless PE Sch. 80 Seamless BE Sch.40 Seamless BE Sch.20 Seamless BE Sch.10 Copper Pipe Copper Pipe SW Fittings # 3000; ( Elbow R=4 D) BW Fittings ( Elbow R=4 D) SW:RF : Serrated Finish; #300 WNRF : Serrated Finish # 300 CAF/ PTFE LOX GRADE Gate valve; SW; # 800 Gate valve; Flanged; RF;Serrated Finish # 300 Globe valve, SW # 800 Globe valve : Flanged RF Serrated finish; # 300 Dimensional/ Design Standard B 36.10 B36.10 B36.10 B36.10 B36.10 B36.10 ANSI B 16.11 ANSI B16.9 B 16.5 B 16.5 B16.21 API 602 API 600 BS 5352 BS 1873 Material Carbon Steel ASTM A106 GR.B ASTM A 106 GR.B ASTM A 106 GR.B ASTM A 106 GR.B Deoxidised non Arsenic Copper Deoxidised non Arsenic Copper ASTM A 105 ASTM A234 Gr WPB ASTM A 105 ASTM A 105 ASTM D3293; TYPE 3; Gr. 1+A Body A182 GR. 304; /BRONZE ;13% CR Trim / BRONZE Body A351 GR.CF8 13% Cr Trim Body A182 GR. 304;/ BRONZE; 13% CR Trim/ BRASS Body Al BRONZE CASTING; TRIM BRASS; PTFE Seat
Page 17 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 15 to 40 DN 50 to 600 DN 15 & Above Bolting Piping Fabrication All Flanged Joints Pipes Joints Pressure Tapping Temp Connections Vents Vents Drains Drains
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS 5352
Description Check valve SW # 800 Lift type
Material Carbon Steel
Body A182 GR. 304; /BRONZE ;13% CR Trim / BRONZE Check valve flanged RF BS 1868 Body A351 GR.CF8 Serrated finish # 300 13% Cr Trim Ball valve flanges RF BS 5351 Body A351 GR.CF8 ; Serrated finish #300 A182 GR. 304 Trim;PTFE Seat Studs B 18.2 ASTM A193 Gr B7 Nuts B 18.2 ASTM A194 Gr 2H At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 50 & below SW coupling DN 50 & above Butt welded DN 20 SW half coupling Nipple Sch 80 with Gate valve to spec. DN 40 Flanged set-on nozzle On lines <= DN 50 ; MEC std. On lines >= DN 50 ; MEC std. On lines <= DN 50 ; MEC std. On lines <= DN 50 ; MEC std.
Page 18 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN PIPING MATERIAL SPECIFICATION SERVICE : ACETYLENE
SERVICE CONDITIONS : Maximum Operating Pressure 2 kgf /cm2 CORROSION ALLOWANCE : 2 m.m. Item Pipe Size Range DN 15 to 40 DN 50 Pipe Fittings DN 50 and below Upto DN 40 DN 50 Upto DN 40 DN 50 Bolting Flanges All sizes DN 15 to 40 DN 50 Gaskets Valves All sizes DN 40 and below Isolation valve DN 50 DN 50 and below Non-return valve Upto DN 15 Description Seamless PE Sch. 80 Seamless BE Sch. 80 Bends Dimensional/ Design Standard B 36.10 B 36.10 -
Temp 60 oC
Material Carbon Steel ASTM A106 GR.B ASTM A106 GR.B Fabricated from parent pipes by cold bending with radius 3 DN ASTM A 105 ASTM A234 Gr WPB ASTM A 105 ASTM A234 Gr WPB ASTM A 193 Gr B7 ASTM A 194 Gr B2H ASTM A 105 ASTM A 105 IS:2712 Gr.W/3 BODY & PLUG: CAST IRON IS : 210 FG 200 BODY : CAST IRON GR FG -200 GM Check Valve (Lift Type) Screwed Rubber hose
Tees/Crosses & Reducers - forged, socket welded end. #3000 Tees/Crosses & Reducers - BW Seamless #300 Unions SW ends #3000 Unions BW seamless #300 Studs/ Bolts Nuts SW:RF : Serrated Finish #300 SORF : Serrated Finish #300 2 mm thick, ring type, CAF CI lubricated taper plug valve, screwed ends CI Gate valve; Flanged ends. GM Check Valve (Lift Type) Screwed Hoses to IS:447, with hose connection to IS:6016
Page 19 of 27
ANSI B16.11 ANSI B16.9 ANSI B16.11 ANSI B16.9 B 18.2 B 18.2 B 16.5 B 16.5 B16.21 BS: 5158 IS:14846
Hose assembly
IS:447/ IS:6016
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Flash back arrestors Size Range All sizes
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard --
Description Hydraulic or dry type. Screwed ends.
Material Carbon Steel SS/Brass
Page 20 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN PIPING MATERIAL SPECIFICATION SERVICE : LIGHT DIESEL OIL (LDO)
SERVICE CONDITIONS : Maximum Operating Pressure 8 kgf /cm2 CORROSION ALLOWANCE: 2 mm.
Temp 100oC
Item Pipe
Size Range DN 15 TO DN 40 DN 50 TO DN 80 DN 100 to DN 150 DN 200 to DN 450 DN 50 and below DN 65 and above DN 450 and below DN 450 and below DN 50 and below All sizes DN 15 to 40 DN 50 to 600
Description ERW , HEAVY, PE ERW , HEAVY, BE Medium seamless or ERW black ERW Bends
Dimensional/ Design Standard IS:1239 IS:1239 IS:1239 B 36.10
Material Carbon Steel IS: 1239 (Part I) IS: 1239 (Part I) IS: 1239 (Part I) ASTM A106 GR.B Fabricated from parent pipes by cold bending with radius 3 DN/ IS:1239 Part II Mitred bends with DN 1.5 radius /IS:1239 Part II up to DN 150 Fabricated from parent pipes. Fabricated from parent pipes IS: 1239 (Part-II)
Pipe Fittings
Mitred bends with DN 1.5 radius Tees/Crosses Reducers Screwed fittings Studs/ Bolts Nuts SW:RF : Serrated Finish #300 SORF : Serrated Finish #300 2 mm thick, ring type, CAF CI lubricated taper plug valve, screwed ends CI lubricated taper plug valve; Flanged ends. IS:1364 IS:1364 B 16.5 B 16.5 B16.21 BS: 5158 BS: 5158
Bolting Flanges
ASTM A 193 Gr B7 ASTM A 194 Gr B2H ASTM A 105 ASTM A 105 IS:2712 Gr.W/3 BODY & PLUG: CAST IRON IS : 210 FG 200 BODY : CAST IRON GR FG -200
Gaskets Valves
All sizes DN 40 and below Isolation valve DN 50 and above
Page 21 of 27
MECON LIMITED
GUIDELINES FOR PIPING DESIGN Item Size Range DN 50 and below Throttling valve DN 65 and above DN 50 and below Non-return valve. DN 65 and above Filters Hose assembly
DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06 Dimensional/ Design Standard BS:5352
Description CS Globe valve
Material Carbon Steel ASTM-A-105 BODY: ASTM A216 Gr.WCB, Screwed ends. ASTM-A-105 BODY: ASTM A216 Gr.WCB, Screwed ends. ASTM-A-105 Screwed ends. --
CS Globe valve
BS:1873
CS horizontal / Vertical Check valve (Lift-type) CS Swing check valve with renewable seat rings. Flanged ends.
BS:5352
IS:5312
--Self cleaning filter operating on the principle of edge filtration 15 m long hoses to IS: 635 or SAE-100R-3 with swivel both ends and one adaptor at one end for DN 50 and below. For DN 65 and above flanged couplings shall be used.
Page 22 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : DRINKING WATER SERVICE CONDITIONS : Maximum Operating Pressure 6 kg/cm2 Minimum Operating Pressure Atm CORROSION ALLOWANCE : NIL. Item Pipe Fittings Flanges Size Range DN 15 to 150 DN 15 to 150 All sizes Description ERW (Galv.); Screwed end; Heavy C.I Screwed fittings (Elbow R=1.5D) C.I.Fitting Screwed ; FF Blind Flanged; FF Gaskets Valve All sizes DN 15 to 40 DN 50 to 150 DN 15 to 40 DN 50 to 150 Gasket; FF; THK 2.00 mm Gate, Globe Valve;Screwed end ; CL.2 Gate Valve;Flanged FF; P1.6 ; Serrated Finish Check valve; Screwed ; Lift Type; CL2. Check Valve;Flanged FF; P1.6 ; Serrated Finish Globe Valve; Screwed ; CL.2 M/C Bolt Nuts Dimensional / Design Standard IS : 1239 IS: 1538 IS : 1239 (II) IS: 1538 IS : 6392 IS : 6392 B16.21 IS: 778 IS: 14846 IS:778 IS:5312 Material IS : 1239; (Galv) IS:1538 IS : 1239 (II); (Galv.) IS: 1538 IS 2062 (Galv.) IS 2062 (Galv.) Butyl Rubber Body IS: 318 GR.2; IS: 320 AL.I Body IS: 210 FG 200; IS: 320 A.I Body IS: 318 GR.2; IS: 320 AL.I Body IS: 210 FG 200; IS: 320 A.I Body IS: 318 GR.2; IS: 320 AL.I IS:1367 CL 4.6 IS:1367 CL 4 Temp 40 oC Temp 5 oC
DN 15 to 40 Bolting All
IS:778 IS:1364 IS:1364
Piping Fabrication
Flanged Joints Pipes Joints Pressure Tapping Vents Vents Drains Drains
At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below Unions; Screwed DN 50 & above Flanged Screwed. DN 20 SW half coupling Nipple Heavy with Gate valve to spec. On lines <= DN 40 ; MEC std. On lines >= DN 50 ; MEC std. On lines <= DN 40 ; MEC std. On lines <= DN 45 ; MEC std.
Page 23 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : DEMINERALISED WATER
SERVICE CONDITIONS : Maximum Operating Pressure 20kg/cm2 Minimum Operating Pressure Atm FLANGE RATING :
IS 6392 - Based on test pressure / surge pressure Matching Companion Flanges of Valves & flow components as per corresponding rating.
CORROSION ALLOWANCE : Nil
Item Pipe
Size Range DN 15 to 40 DN 50 to 150
Description Seamless Pipe PE SCH 10S Pipe, MS Seam less pipe Seamless Pipe BE SCH 10S Pipe MS Seam less pipe SW Fittings/ Scrd fittings (Elbow R=1.5D) Miter bends & fittings fabricated from pipe / Factory mady fittings SW RF Serrated Finish WN RF Serrated Finish Gasket; Thk. 3 mm Diaphragm Valve; Flanged; #150 Check Valve; SW; # 800; Lift Type Check Valve Flanged RF ; Serrated Finish; #150 Globe Valve; SW; # 800; Globe Valve; Flanged ; RF #150 Ball Valve; Flanged; RF; Serr. Finish; # 150 Studs Nuts
Dimension Standard ANSI B16.10 IS:1239 P-1 ANSI B16.10 IS:1239 P-1 ANSI B16.11 ANSI B16.9 IS : 6392 IS : 6392 As Per Flanges
Fittings
DN 15 to 40 DN50 & above
Material Specification ASTM A312 - TP 304 IS:1239, Rubber line ASTM A312 - TP 304 IS:1239, Rubber line ASTM A53 Gr A ASTM A182 Gr 304 Same as parent pipe / ASTM A403 WP ASTM A182 Gr 304 ASTM A182 Gr 304 IS:638; Type-A (Rubber) Body ASTM A351 Gr. CF8; A182 Gr. 304 Trim
Flanges Gaskets Valves
DN 15 to 40 DN 50 to 50 All sizes DN 15 to 150 DN 15 to 40 DN 50 and above DN 15 to 40 DN 50 to 150 DN 15 to 150
BS 5352 BS 1868 BS 5352 BS 1873 BS 5351 B18.2 B18.2
Body A105; 13% Cr Trim CI Body SS Trim Body ASTM A182 Gr. 304; 13% Cr Trim Body ASTM A351 Gr. CF8; A182 Gr. 304 Trim CI Body SS Trim ASTM A193 Gr B7 ASTM A194Gr 2H
Bolting
All
Piping Fabrication
Flanged Joints Pipes Joints
At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 50 & below SW coupling DN 50 & above Butt welded
Page 24 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : ALL WATER (EXCEPT DRINKING &
DEMINERALISED WATER)
SERVICE CONDITIONS : Maximum Operating Pressure 20kg/cm2 Minimum Operating Pressure Atm FLANGE RATING : Temp 60 oC Temp 5 oC
IS 6392 - Based on test pressure / surge pressure Matching Companion Flanges of Valves & flow components as per corresponding rating.
CORROSION ALLOWANCE : 2 m.m.
Item Pipe
Size Range DN 15 to 40 DN 50 to 450 DN 500 & above
Description ERW Pipes; PE; Medium/Heavy, Seamless SS ERW / SAW Pipes; BE; Medium/Heavy Spiral welded Rolled & Welded cold / hot bends / SW Fittings/ scrd fittings (Elbow R=1.5D) BW Fittings ; (Elbow R=1.5D) -doMiter bends & fittings fabricated from pipe Screwed / SW; FF Serrated Finish SOFF; Serrated Finish Gasket; Thk 3.0mm Gate Valve; Screwed End Gate Valve; Flanged; FF #150 Check Valve;Screwed; SW ;# 800; Lift Type Check Valve Flanged; FF; serrated Finish Swing / dual plate #150 Check Valve Flanged; FF; serrated Finish Swing / dual plate Globe Valve; /Screwed;SW; #800 Globe Valve ; Flanged; FF; Serrated Finish; Butterfly valve Page 25 of 27
Dimension Standard IS : 1239 IS : 3589 IS : 3589 IS : 1239 (II) / ANSI B16.11 ANSI B16.9 ANSI B16.9 IPSS-1-06-020 IS : 6392 IS : 6392 As Per Flanges IS:778 IS : 14846 IS:778 IS:5312 (P-I) IS:5312 (P-II)
Material Specification IS:1239; Black ASTM A53 Gr A ( BF Cooling) IS:3589; Fe 330, Fe410 IS:3589; Fe 330, Fe 410 IS:1239 (II) / ASTM A105 IS:1239 (II) / ASTM A234 WPB ASTM A 105 PB ( For BF Cooling) Same as parent pipe Plates to IS 2062 Gr-B IS:2002- Gr 2A Plates to IS 2062 Gr-B IS:2002- Gr 2A IS : 2712 Gr W/3 Body IS:318 LTB; IS: 320 HT1 Trim Body C.I IS:210 Gr FG 200; 13% Cr Trim Body IS:318 LTB; IS: 320 HT1 Trim Body C.I IS:210 Gr FG 200; 13% Cr Trim Body C.I IS:210 Gr FG 200; 13% Cr Trim
Fittings
DN 15 to 40 DN 50 to 150 DN 15 to 50 DN 200 & above
Flanges DN 15 to 40 DN 50 to 150 Gaskets Valves All sizes DN 15 to 40 DN 50 to 1200 DN 15 to 40 DN 50 to 600 DN 400 to 1200
DN 15 to 40 DN 50 to 300 DN 350 & above
IS:778 BS 1873 BS 5155
Body IS:318 LTB; IS: 320 HT1 Trim Body ASTM A216 WCB; 13% Cr Trim CI Body SS shaft & seat rings
MECON LIMITED
Item Bolting Size Range All Description M/C Bolts Nutss Piping Fabrication

Dimension Standard IS 1364 IS 1364
Material Specification IS:1367 CL4.6 IS:1367 CL 4
Flanged Joints Pipes Joints Pressure Tapping Temp. Conn. Vents Vents Drains Drains
At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below Unions; Screwed DN 50 & above Flanged Screwed. DN 20 SW half coupling Nipple Heavy with Gate valve to spec. Flanged Installation as MEC std. On lines <= DN 40 ; MEC std. On lines >= DN 50 ; MEC std. On lines <= DN 40 ; MEC std. On lines <= DN 40 ; MEC std.
Page 26 of 27
MECON LIMITED
PIPING MATERIAL SPECIFICATION SERVICE : Instrument Air (UP TO 1.5) SERVICE CONDITIONS : Maximum Operating Pressure Up to 10.55 kgf /cm2 RATING : Temp 65 oC
# 150 Matching Companion Flanges of Valves & flow components as per corresponding rating.
CORROSION ALLOWANCE : NIL Item Pipe Fittings Flanges Size Range DN 15 to 40 DN 15 to 40 DN 15 to 40 DN 15 to 40 DN 15 to 40 Gaskets Valves All sizes DN 15 to 40 DN 15 to 40 DN 15 to 40 Bolting Piping Fabrication All Flanged Joints Pipes Joints Temp. Conn. Pressure Tapping Vents Drains Description ERW ; Screwed end HEAVY Screwed Fittings # 3000 Screwed :RF : Serrated Finish #150 Blind Flanged RF : Serrated Finish #150 FIG. 8 Flange ; FF Serrated Finish #150 Gasket : Thk. 2.0 mm Ring type Gate valve SCRF; # 800 Globe valve, SCRF; # 800 Check valve SCRF; # 800 Lift type M/C BOLT Nuts Screwed Coupling Flanged Installation as MEC std. DN 20 SW half coupling Nipple HEAVY with Gate valve to spec. MEC std. MEC std. Dimensional/ Design Standard IS:1239 ANSI B 16.11 B 16.5 API 590 B 16.5 B 16.21 API 602 BS 5352 BS 5352 B 18.2 B 18.2 Material Carbon Steel IS:1239 (PART-I) GALV. ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) IS : 2712 Gr W/3 Body A105 ; 13% CR Trim Body A105; 13% Cr Trim Body A105; 13% Cr Trim ASTM A307 Gr B ASTM A563 Gr B
Page 27 of 27
TABLE: 05.03 MINIMUM SPACING (C.L TO C.L) BETWEEN TWO ININSULATED PIPES.
MM MAX 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600
MIN DIA 1 1-1/2 2 3 4 6 8 10 12 14 16 18 20 24
15 85 96 100 115 120 140 165 195 225 260 295 330 360 390 425 495
20 * 100 100 115 120 148 165 200 230 260 300 330 365 395 425 495
25 1 * * 105 120 125 145 170 200 235 265 305 335 365 400 430 500
40 1-1/2 * * * 125 130 155 175 210 240 270 310 340 375 405 435 505
50 2 * * * * 140 160 180 215 245 280 315 345 380 410 445 510
80 3 * * * * * 175 195 230 260 295 330 360 395 425 460 525
100 4 * * * * * * 210 240 275 305 345 375 405 440 470 540
150 6 * * * * * * * 270 300 330 370 400 435 465 495 565
200 8 * * * * * * * * 325 360 395 425 460 490 425 590
250 10 * * * * * * * * * 385 425 455 485 520 550 620
300 12 * * * * * * * * * * 450 480 510 545 575 645
350 14 * * * * * * * * * * * 495 525 560 590 660
400 16 * * * * * * * * * * * * 550 585 615 685
450 18 * * * * * * * * * * * * * 610 640 710
500 20 * * * * * * * * * * * * * * 665 733
600 24 * * * * * * * * * * * * * * * 785
NOTE :
FOE INSULATED PIPES, THICKNESS OF INSULATION FOR THE PIPES UNDER CONSIDERATION SHALL ALSO BE TAKEN INTO ACCOUNT.
MECON LIMITED
Rev -0 Page 1 of 9
IS 1239: Part 1: 1990 Mild steel tubes, tubulars and other wrought steel fittings, Part 1 Mild steel tubes -- (Old Standards)
IS 1239: Part 1: 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings Specification - Part 1: Steel Tubes
IS 1239: Part 2: 1992 Mild steel tubes, tubulars and other wrought steel fittings, Part 2 Mild steel tubulars and other wrought steel pipe fittings
IS 3589: 2001 Steel Pipes for Water and Sewage (168.3 to 2 540 mm Outside Diameter) Specification -- (Old Standards)
IS 3589: 2001 Steel Pipes for Water and Sewage (168.3 to 2 540 mm Outside Diameter) Specification
IS 6392: 1971 Steel pipe flanges
IS 2712: 1998 Gaskets and Packings - Compressed Asbestos Fibre Jointing - Specification
IS 1364: Part 1: 1992 /ISO 4014: 1988 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B - Part 1: Hexagon Head Bolts (Size Range M16 to M64) -- (Old Standards)
IS 1364: Part 1: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B Part 1: Hexagon Head Bolts (Size Range M 1.6 to M 64)
IS 1364: Part 2 : 1992/ISO 4017 : 1988 Hexagon head bolts, screws and nuts of product grades A and B Part 2 Hexagon head screws (size range M1.6 to M64) -- (Old Standards)
IS 1364: Part 2: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B Part 2: Hexagon Head Screws (Size Range M 1.6 to M 64)
MECON LIMITED
Rev -0 Page 2 of 9
IS 1364: Part 3: 1992 /ISO 4032: 1986 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B - Part 3: Hexagon Nuts (Size Range M1.6 to M64) -- (Old Standards)
IS 1364: Part 3: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B Part 3: Hexagon Nuts, Style 1 (Size Range M 1.6 to M 64)
IS 1364: Part 4: 1992 /ISO 4035: 1986 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B - Part 4: Hexagon Thin Nuts (Chamfered) (Size Range M1.6 to M64) -(Old Standards)
IS 1364: Part 4: 2003 /ISO 4035: 1999 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B - Part 4: Hexagon Thin Nuts (Chamfered) (Size Range M1.6 to M64)
IS 1364 : Part 5 : 1992/ISO 4036 : 1979 Hexagon head bolts, screws and nuts of product grades A and B Part 5 Hexagon thin nuts (unchamfered) (size range M1.6 to M10) -- (Old Standards)
IS 1364: Part 5: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B Part 5: Hexagon Thin Nuts - Product Grade B (Unchamfered) (Size Range M 1.6 to M 10)
IS 1364: Part 6: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B Part 6: Hexagon Nuts, Style 2 IS 2062: 1999 Steel for General Structural Purposes Specification
IS 2002: 1992 Steel plates for pressure vessels for intermediate & high temperature service including boilers
IS 14846: 2000 Sluice Valve for Water Works Purposes (50 to 1200 mm Size) Specification
IS 447: 1988 Rubber hose for welding (fourth revision) (Superseding IS: 3572: 1968)
MECON LIMITED
Rev -0 Page 3 of 9
IS 6016: 1982 Hose connection for welding and cutting equipment
IS 778: 1984 Specification for Copper Alloy Gate, Globe and Check Valves for Waterworks Purposes
IS 1538: 1993 Cast iron fittings for pressure pipes for water, gas and sewage IS 5312: Part 1: 1984 Specification for Swing Check Type Reflux (Non-Return] Valves for Water Works Purposes - Part 1: Single-Door Pattern
IS 5312: Part 2: 1986 Specification for Swing Check Type Reflux (non-return) Valves for Water Works Purpose - Part 2: Multi-Door Pattern
IS 1367: Part I: 1980 Technical Supply Conditions for Threaded Steel Fasteners - Part I: Introduction and General Information -- (Old Standards)
IS 1367: Part 1: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 1: General Requirements for Bolts, Screws and Studs
IS 1367: Part 2: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 2: Tolerances for Fasteners - Bolts, Screws, Studs and Nuts - Product Grades A, B and C
IS 1367: Part II: 1979 Technical Supply Conditions for Threaded Steel Fasteners - Part II: Product Grades and Tolerances -- (Old Standards)
IS 1367: Part 3: 1991 /ISO 898-1: 1988 Fasteners - Threaded Steel - Technical Supply Conditions - Part 3: Mechanical Properties and Test Methods for Bolts, Screws and Studs with Full Loadability -- (Old Standards)
IS 1367: Part 3: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 3: Mechanical Properties of Fasteners Made of Carbon Steel and Alloy Steel - Bolts, Screws and Studs
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IS 1367: Part V: 1980 Technical Supply Conditions for Threaded Steel Fasteners - Part V: Mechanical Properties and Test Methods for Set Screws and Similar Threaded Fasteners Not Under Tensile Stresses -- (Old Standards)
IS 1367: Part 5: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 5: Mechanical Properties of Fasteners Made of Carbon Steel and Alloy Steel - Set Screws and Similar Threaded Fasteners not Under Tensile Stresses
IS 1367: Part 6: 1994 /ISO 898-2: 1992 Technical Supply Conditions for Threaded Steel Fasteners - Part 6: Mechanical Properties and Test Methods for Nuts with Specified Proof Loads
IS 1367 : Part VII : 1980 Technical supply conditions for threaded steel fasteners Part VII Mechanical properties and test methods for nuts without specified proof loads -- (Old Standards)
IS 1367 : Part VII : 1980 Technical supply conditions for threaded steel fasteners Part VII Mechanical properties and test methods for nuts without specified proof loads
IS 1367: Part 8: 1992 Technical Supply Conditions for Threaded Steel Fasteners - Part 8: Mechanical and Performance Properties for Prevailing Torque Type Steel Hexagon Nuts -(Old Standards)
IS 1367: Part 8: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 8: Prevailing Torque Type Steel Hexagon Nuts - Mechanical and Performance Properties
IS 1367 : Part 9 : Sec 1 : 1993/ISO 6157-1 : 1988 Technical supply conditions for threaded steel fasteners Part 9 Surface discontinuities : Section 1 Bolts, screws and studs for general applications
IS 1367 : Part 9 : Sec 1 : 1993/ISO 6157-1 : 1988 Technical supply conditions for threaded steel fasteners Part 9 Surface discontinuities : Section 1 Bolts, screws and studs for general applications -- (Old Standards)
MECON LIMITED
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IS 1367: Part 9: Sec 2: 1993/ISO 6157-3: 1988 Technical supply conditions for threaded steel fasteners Part 9 Surface discontinuities : Section 2 Bolts, screws and studs for special applications
IS 1367 : Part 9 : Sec 2 : 1993/ISO 6157-3 : 1988 Technical supply conditions for threaded steel fasteners Part 9 Surface discontinuities : Section 2 Bolts, screws and studs for special applications -- (Old Standards)
IS 1367: Part 10: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 10: Surface Discontinuities Nuts
IS 1367: Part X: 1979 Technical supply conditions for threaded steel fasteners Part X Surface discontinuities on nuts -- (Old Standards)
IS 1367: Part 11: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 11: Electroplated Coatings
IS 1367: Part 11: 1996 /ISO 4042: 1989 Technical Supply Conditions for Threaded Steel Fasteners - Part 11: Electroplated Coatings -- (Old Standards)
IS 1367: Part XII: 1981 Technical Supply Conditions for Threaded Steel Fasteners - Part XII: Phosphate Coatings on Threaded Fasteners
IS 1367 : Part XIII : 1983 Technical supply conditions for threaded steel fasteners Part XIII Hot-dip galvanized coatings on threaded fasteners
IS 1367: Part 14: 1984 Technical Supply Conditions for Threaded Steel Fasteners - Part 14: Stainless Steel Threaded Fasteners
IS 1367: Part 14: 1984 Technical Supply Conditions for Threaded Steel Fasteners - Part 14: Stainless Steel Threaded Fasteners -- (Old Standards)
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IS 1367: Part 14: Sec 1: 2002 Technical Supply Conditions for Threaded Steel Fasteners Part 14: Mechanical Properties of Corrosion-Resistant Stainless-Steel Fasteners - Section 1: Bolts, Screws and Studs
IS 1367: Part 14: Sec 2: 2002 Technical Supply Conditions for - Threaded Steel Fasteners Part 14: Mechanical Properties of Corrosion-resistant Stainless-steel Fasteners - Section 2: Nuts
IS 1367: Part 14: Sec 3: 2002 Technical Supply Conditions for Threaded Steel Fasteners Part 14: Mechanical Properties of Corrosion-resistant Stainless-steel Fasteners - Section 3: Set Screws and Similar Fasteners not Under Tensile Stress
IS 1367: Part 16: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 16: Designation System for Fasteners IS 1367: Part XVI: 1979 Technical Supply Conditions for Threaded Steel Fasteners - Part XVI: Designation System and Symbols -- (Old Standards)
IS 1367: Part 17: 1996/ISO 3269: 1988 Industrial fastners - Threadeed steeel fasteners Technical supply conditions Part 17 Inspection, smapling and acceptance procedure
IS 1367: Part 18: 1996 Industrial Fasteners - Threaded Steel Fasteners - Technical Supply Conditions - Part 18: Packaging
IS 1367: Part 19: 1997/ISO 3800: 1993 Industrial fasteners - Threaded steel fasteners Technical supply conditions Part 19 Axial load fatigue testing of bolts, screws and studs
IS 1367: Part 20: 1996 /ISO 898-7: 1992 Industrial Fasteners - Threaded Steel Fasteners Technical Supply Conditions - Mechanical Properties - Part 20: Torsional Test and Minimum Torques for Bolts and Screws with Nominal Diameters 1 mm To 10 mm
IS 5155: 1969 Specification for Pipettes, Ostwald-Folin Type
MECON LIMITED
Rev -0 Page 7 of 9
IS 1593: 1982 Specification for Fuel Oils -- (Old Standards)
IS 1593: 1982 Specification for Fuel Oils
ARE 1460: 2000 Diesel Fuels Specification
IS 11489: 1985 Specification for Heavy Petroleum stock (HPS)
IS 5822: 1994 Code of Practice for Laying of Electrically Welded Steel Pipes for Water Supply
IS 5822: 1994 Code of Practice for Laying of Electrically Welded Steel Pipes for Water Supply
IS 10221: 1982 Code of practice for coating and wrapping of underground mild steel pipelines
IS 1916: 1989 Specification for steel cylinder pipe with concrete lining and coating
IS 7193: 1994 Specification for glass fibre base bitumen felts
IS 8062: Part 1: 1976 Code of practice for cathodic protection of steel structures, Part 1 Genral Princples
IS 8062: Part II: 1976 Code of Practice for Cathodic Protection of Steel Structures - Part II: Underground Pipelines
IS 8062: Part 3: 1977 Code of practice for cathodic protection of steel structure, part 3 Ship's hull
IS 8062: Part 4: 1979 Code of practice for cathodic protection of steel structures ,part 4 Galvanic protection of dockgates, caissons, piers and jetties
MECON LIMITED
Rev -0 Page 8 of 9
IS 3690: 1974 Unbonded glass wool for thermal insulation -- (Withdrawn Standards)
IS 277: 2003 Galvanized Steel Sheets, (Plain and Corrugated) Specification
IS 3690: 1974 - Unbonded glass wool for thermal insulation
IS 8183: 1993 Bonded mineral wool -- (Old Standards)
IS 13205: 1991 Code of practice for the application of polyurethane insulation by the insitu pouring method
IS 277: 1992 Galvanized Steel Sheets (Plain and Corrugated) - Specification -- (Old Standards)
IS 8183 : 1993 Bonded mineral wool
IS 9842: 1994 Preformed fibrous pipe insulation -- (Old Standards)
IS 9842: 1994 Preformed fibrous pipe insulation
IS 3677: 1985 Specification for Unbonded Rock and Slag Wool for Thermal Insulation
IS 875: Part 1: 1987 Code of practice for design loads (other than earthquake) for buildings and structures Part 1 Dead loads - Unit weights of building material and stored materials (Incorporating IS: 1911-1967) -- (Old Standards)
IS 875: Part 1: 1987 Code of practice for design loads (other than earthquake) for buildings and structures Part 1 Dead loads - Unit weights of building material and stored materials (Incorporating IS: 1911-1967)
IS 875: Part 2: 1987 Code of practice for design loads (other than earthquake) for buildings and structures: Part 2 Imposed loads
MECON LIMITED
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IS 875: Part 3: 1987 Code of Practice for Design Loads (Other than Earthquake) for Buildings and Structures - Part 3: Wind Loads
IS 875: Part 4: 1987 Code of practice for design loads (other than earthquake) for buildings and structures Part 4 Snow loads
IS 875: Part 5: 1987 Code of practice for design loads (other than earthquake) for buildings and structures Part 5 Special loads and load combinations
IPSS: CGA: Manual for water supply & water treatment- Govt. of India publications

Guidelines For Piping Design For Metallurgical Industries

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Guidelines For Piping Design For Metallurgical Industries

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GUIDELINES FOR PIPING DESIGN FOR METALURGICAL INDUSTRIES

MECON LIMITED RANCHI 834002

DOC.NO: MSTD-DESG-FS&PD-1405, REV-0

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

Where Q = Flow rate in m3 / hr (Calculated as VA above)

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

Permissible velocity in / sec. Inside diameter of pipe in mm

TABLE 02-01 RECOMMENDED VELOCITIES FOR SELECTION OF PIPE SIZES

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

D : FOR STEAM Sl. Fluid Condition No 1 2 3 4 5

Average Velocity, m/sec

SUPERHEATED UPTO 7 Kgf/cm2 (g) SUPERHEATED ABOVE 7 TO 35 Kgf/cm2 (g)

E : FOR WATER Sl. No 1 2 3 Fluid Condition

Average Velocity, m/sec

0.6 0.9 0.4 1.0

0.7 1.3 0.6 2.0

0.9 1.5 1.0 -2.4

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

------------------/ PH2 - Pk2 20.555 d 8/3 / ------------------ SLT

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

V=3.83 CR d 0.6575 (gs)0.5525/v0.105 Where, CR d g s v = = = = =

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

0.4 0.85 to 1.3 0.92 to 2.15

0.37 to 0.80 0.50 to 0.52 0.02 to 0.07 0.05 to 2.0

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 02

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

Condensate drains shall be equipped with bleeders.

Oxygen Pressure in Kg/cm2 Upto 0.1 Upto 0.1 0.1 to 16 16 to 35

Permissible gap in mm 300 600 800 800

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03 :

Rev - 0 Page 7 of 12 upto

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

Salient considerations in Design of pipe Layout in trenches / underground buried.

Spacing of pipes in Trenches / underground buried.

A (mm) 300 400 500

B(mm) 200 300 500

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

Minimum size of casing pipe are given in the following table.

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

Roller /ball are used for reducing frictional force on structures

DOC No MSTD-DESG-FS&PD-1405 Chapter No 03

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04

DOC No MSTD-DESG-FS&PD-1405 Chapter No 04