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DESIGN BASIS REPORT

FOR
PIPING

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REVISION STATUS SHEET

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DETAILS / DESCRIPTION
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PIPING DESIGN BASIS

1.0

SCOPE

2.0

CODES & STANDARDS

3.0

DESIGN CRITERIA

4.0

MATERIALS

5.0

VALVING

6.0

GENERAL

7.0

THERMAL INSULATION

8.0

PAINTING

9.0

PROCESS DESIGN CRITETIA FOR PIPING

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ANNEXURE - A

PIPING MATERIAL SELECTION

ANNEXURE - B

MATERIAL SELECTION CHART

ANNEXURE - C

VALVE DATA SHEETS

ANNEXURE - D

SCHEDULE OF THICKNESS FOR THERMAL

INSULATION

ANNEXURE - E

DESIGN PROCEDURES FOR PIPE SUPPORTS

ANNEXURE - F

STRESS ANALYSIS DESIGN CRITERIA

ANNEXURE - G

MAJOR REQUIREMENTS OF IBR

ANNEXURE - H

ACCESSIBILITY REQUIREMENTS OF VALVES

& INSTRUMENTS

ANNEXURE - I

RECOMMENDED VELOCITY RANGE FOR

VARIOUS FLUIDS

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1.0

SCOPE:

1.1

This specification describes the basis for the overall design of steam, water & utility
piping of the power plant. It is intended to establish designs confirming to codes and
accepted practices currently applicable to piping systems.

2.0

CODES & STANDARDS:

2.1

The main design codes and standards, which shall be considered as minimum
requirements are listed below. Latest version of these shall be followed.
ANSI / ASME B31.1

Power Piping

ANSI B16.5

Steel Pipe Flanges and Flanged Fitting

ANSI B16.9

Factory - made wrought steel butt-welding

Fitting

ANSI B16.10

Face-to-Face & End-to-End Dimensions of

Ferrous Valves

ANSI B16.11

Forged Steel Fittings, Socket Welding and

Threaded

ANSI B16.34

Valves - Flanged and butt-welding ends

ANSI B16.20

Ring Joint gaskets and grooves for Steel pipe

Flanges

ANSI B16.25

Butt Welding Ends

ANSI B36.10

Welded and seamless wrought steel pipe

ANSI B36.19

Stainless Steel Pipe

ANSI B16. 21

Non Metallic Flat Gaskets for Pipes Flanges

ANSI B 18.2.1

Square and Hexagonal Bolts

ANSI B 18.2.2

Square and Hexagonal Bolts

API 590

Spectacle Blind for Sizes up to 24

EJMA

Expansion Joints

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API 594

Wafer type Check Valves

API 598

Valve Inspection Test

API 601

Metallic Gaskets for Piping

API 602

Compact Carbon Steel Gate Valves

API 609

Butterfly Valve 150 Psig

AWWA C 504

Rubber Seated Butterfly Valves

BS 5146

Inspection and Testing of Steel Valves

BS 5155

Cast iron & Carbon Steel Butterfly Valves

BS 5351

Steel Ball Valves

BS 5352

Forged Steel Globe & Check Valves

MSS SP 6

Standard finishes for contact surfaces

MSS SP 25

Standard marking system for Valves,

Fittings & Flanges

MSS SP 43

Wrought Stainless Steel Butt welded

Fittings

Mild Steel Tubes

IS-1239 (I)

IS-1239 (II)

Steel Fittings

IS-3589

Seamless or Electrically welded steel pipes for

Water, Gas, & Sewage (168.3 to 2032 mm
Outside diameter)

MSS-SP-58

Pipe Hanger & Supports Materials Design &

Manufacture

In addition to the above the following specifications shall form part of this project.
Technical Specification for Hot Insulation
Technical specification for Shop & Field
Painting

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Piping Material Specification

Valve Material Specification
Fabrication and Erection of Piping
Inspection, Flushing, & Testing of Piping
Pre commissioning & chemical cleaning
Non- Destructive examination

2.2

Boiler Code Piping:

a) 1995 ASME boiler and pressure vessel code Sec. I and Sec. VIII apply to certain
integral portions of steam, feed water and blow-off piping associated with boilers
and steam generating equipment, as defined by that code.
b) Certain portions of external piping shall meet the requirements of ANSI B31.1,
(1992) Power Piping Code, as defined by that code.
c) Steam and Feed water piping coming under the purview of the Indian Boiler
Regulations shall be designed in accordance with that code. Annexure-G lays
down the major requirements of Indian Boiler Regulations. Nevertheless,
requirements spelt out in respective ASME / ANSI codes shall be adhered to, as a
minimum.

3.0

DESIGN CRITERIA:

3.1

Operating Conditions:

3.1.1

Design conditions of pressure and temperature will be the most severe conditions
expected to co-exist under long-term operating conditions. These usual operations
include all functions such as throttling, blowing and bypassing likely to be used for
operation and control.

3.1.2

Temporary Conditions:
Usual operating conditions do not include more severe temporary conditions, such as
those abnormal operations like turbine over speed / over pressure conditions, as long
as the duration and parameters do not exceed the values defined in the respective
codes.

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Design Temperature:
Design temperature is the most severe sustained fluid temperature, subject to
conditions of section 3.1 above. Design temperature will be usually the maximum
fluid temperature.

3.3

Design Pressure:
The Design pressure of piping shall be the most severe condition of internal or
external fluid pressure, subject to conditions of Section 3.1 above arrived at in
conjunction with the following considerations.
-

Design pressure of the equipment to which it is connected.

Set pressure of safety valve which protects the system.

However, Piping systems operating under vacuum / likely to be operated under

vacuum shall be designed for full vacuum, also.
3.4

Design Life:
Piping system shall be designed for 7000 cycle based on the plant life of 30 years,
such that it operates without replacement and with normal maintenance, and shall
withstand the fluctuations in operating parameters and cycling, normally expected.

3.5

Piping Flexibility:
All piping must be designed for thermal expansion under start-up, operating and shut
down conditions such that the actual stresses shall be well within the allowable limits
of the pipe material and the forces / moments on the equipment shall be within the
limits defined by the equipment supplier.
Provisions for expansion or contraction shall normally be made with bends, offsets
and expansion loops. Expansion joints may be used on large diameter piping, relief
systems or where they are acceptable process wise and economically justified.
Stress analysis shall be done for piping meeting the conditions specified in the stress
analysis design criteria attached as Annexure-F.

3.6

Piping Supports:
All piping shall be adequately supported, guided or anchored so as to prevent undue
vibration, deflection or loads on connected equipment & piping and leakage at joints.
Piping at valves and equipment such as heat exchangers and pumps, requiring
periodic maintenance, shall be supported in such a way so that the piping can be
detached with a minimum temporary supports.

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The Design and Selection of supports shall be based on Design procedures for pipe
supports attached as Annexure-E.
4.0

MATERIALS:

4.1

Piping Material Selection:

Piping material selection attached as Annexure-A includes line service, pipe material,
type of construction and ANSI Rating. Piping Material Selection for this project is
attached as Annexure-A. The basis for material selection is as per Material Selection
Chart attached as Annexure - B.

4.2

Corrosion Allowance:

4.2.1

Unless otherwise specified in piping material specification, minimum corrosion

allowance, as shown below, shall be provided for all non-IBR piping systems.
Carbon Steel
Ferritic Alloys
Austenitic Steel
Non - Ferrous

1.5mm
1.5mm
0mm
0mm

4.2.2

For IBR piping, refer to the requirements under the IBR regulations.

4.3

Wall Thickness and Reinforcement:

4.3.1

Reinforcement requirement for nozzles / stubs or other welded branch connections

shall be as per Section 104.3 of ANSI B31.1 and shall additionally meet the
requirements of IBR for piping systems under the purview of IBR.

4.4

Line and Connection Size:

Minimum line size shall be 1 for long runs in the offsite area. Exceptions are there
for instrument piping, which may be minimum 1/4. Vents and Drains shall be 3/4
min. Pipe sizes 1-1/4, 2-1/2 and all other odd sizes such as 5 and 7 shall not be
used unless required to match the connections to Mechanical equipment.

4.5

Bends & Mitres:

4.5.1

Long radius welding elbows shall be used for changes in direction of piping. For
steam and feed water piping coming under the purview of the Indian Boiler
Regulation bend radii shall be as per that regulations. Short radius bends shall only be
used where space does not permit the use of long radius elbows and bends.

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Welded mitre bends, with a maximum included angle of 22.5 per segment, may be
used in utility piping systems, for sizes NB 350 and over, where the pressure and
temperature does not exceed 10 kg/cm2 and 120C respectively. In other services &
Higher-pressure conditions, the welded mitre bends may be used, provided they meet
process requirements.

5.0

VALVING:

5.1

Valves:

5.1.1

Design, fabrication and testing of valves shall generally conform to ANSI B16.34
(1981). Butterfly valves shall conform to AWWA C504.

5.1.2

All valves requiring attention during normal operation shall be accessible either from
grade, platform or Ladders.

5.1.3

All valves shall be suitable for installation in horizontal as well as vertical pipeline.

5.1.4

All globe valves shall be capable of being closed against the design pressure. Where
globe valve has been specified for regulation purpose, the disc shall be tapered plug
type and suitable for controlling throughout its lift.

5.1.5

All gate and globe valves shall have bonnet back seating arrangement to facilitate
easy replacement of packing with the valves in service.

5.1.6

All gate, globe and check valves shall be designed for reconditioning seating surfaces
and replacement of stem and disc without removing the valve body from the line.

5.1.7

Manual gear operators shall be provided to open / close the valve against the
maximum differential pressure across the valve such that the effort required to operate
does not exceed 25 kgf.
However, unless otherwise stated in P&ID, geared operators shall be provided as
below:

5.1.8

Gate and Globe valves ANSI #150

ANSI #300

with size 12 & larger

with size 8 & larger

Ball valves

ANSI #150
ANSI #300

with size 8 & larger

with size 6 & larger

Butterfly valves

ANSI #150

with size 8 & larger

All gate and globe valves of size 50 mm and below in vacuum services shall have
extra deep gland packing without any provision for water gland sealing.

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All gate and globe valves of size 80 mm NB and above in vacuum services shall have
adequately deep gland packing and shall be equipped with lantern rings to admit
pressurised water for gland sealing.

5.1.10 Integral bypass valves shall be provided for all gate valves as classified below. Size
and location of bypass valve shall be as per MSS-SP-45.
a)

Under pressure class of 600 lbs and above, where the sizes are 100 mm NB and
above

b)

Under pressure class of 300 lbs and 400 lbs where the sizes are 250 mm NB and
above.

5.1.11 Valve Data Sheets attached as Annexure - C gives a basis of valve selection for the
different systems
5.1.12 Valved drains, vents shall be installed at low and high points in piping systems, if
required for operation, maintenance or for draining purposes.
5.1.13 Drains & vents required purely for hydraulic or pneumatic test purposes are to be
shown on the isometric drawings and added to the P&IDS by the Piping erection
contractor.
To collect samples for laboratory analysis, dedicated sample connections are required;
sample points shall not be located in dead ends of piping.

6.0

GENERAL:

6.1

General Layout Requirements:

Pipes of sizes 80 mm NPS and above shall be shop fabricated as per the drawings and
pipes of sizes 50 mm NPS and below shall, in general, be field routed.

6.2

Accessibility:
For accessibility requirement of Valves & Instruments for the plant refer Annexure-H
of this specification.

6.3

Pipe Routing:

6.3.1

All Piping entering and leaving a plot area shall be grouped together as far as
practicable. Inside plot piping shall be routed on overhead pipe bridges wherever
possible.

6.3.2

Piping with Instrument connections shall be routed to ensure accessibility, if

necessary Platforms / Walkways shall be provided.

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6.3.3

Fire fighting water lines, if installed above ground shall not run along pipe bridges
and pipe racks but as practical along roads.

6.3.4

The elevations of overhead piping shall be as specified by the site requirements but
never be less than
-

6.8 M over Railroads / Railways

6.0 M over Main roads
6.0 M for crane access
4.0 M for truck access
3.0 M for fork lift truck access
2.2 M over Walkways inside buildings and Platforms.

6.3.5

The minimum horizontal clearance shall be 0.75 M for access ways and walkways,
however the minimum clearance shall be 0.9 M for frequently used main passages.

6.3.6

Buried Piping shall be considered for

-

6.3.7

Drainage or Sewerage.
Fire water lines.

Buried piping shall have a minimum cover of soil:

- Fire water lines (main)

- 0.9 M

- Road crossings for lines 24 & smaller

- 0.6 M

6.3.8

The load on the pipes should be equalized for lines crossings railroads / railways and
traffic roads by means of pipe sleeves or a culvert. The pipes shall be kept centrally in
the sleeves by distance pieces welded to the pipe or fixed to the sheeting if the line is
insulated.

6.3.9

As far as practical, piping shall run at the different elevations designated for northsouth and east-west banks and shall change elevation at change in direction.

6.3.10 Sleeves or holes through walls, floors of buildings shall have a size permitting the
passage of a flange of the relevant pipe size to facilitate the installation of fabricated
piping and to permit insulation work.
6.4

Relief System / Blow down system Piping:

Relief valve discharging steam, air directly to atmosphere shall be equipped with
drain or suitably piped to prevent accumulation of liquid at valve outlet.
Relief valve discharge piping shall be taken to safe location as per following

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3 M above top platform of column or structure

25 M horizontally away from Boiler.
50 M horizontally away from Boiler, if more than more one-relief system of
different set pressures is discharging into one common riser of vent stack.

Inlet and outlet piping of pressure relief valve shall be adequately supported to take
care of the thrust induced by the relief valve during popping.

6.5

Offsite and Yard Piping:

In general, the Pipes shall be laid at grade level on sleepers at 300mm higher from
grade level. Pipes at crossing of roads shall be by pipe-way bridges in general. Pipes
sleeves may be considered where one or two pipes are to cross the road.

6.6

Expansion and Contraction:

Piping systems shall have sufficiently flexibility to allow for thermal expansion and
contraction so as to prevent
-

Failure of piping components owing to over stress leakage at joints.

Excessive thrusts and moments on connected equipment anchor points etc.
Forces on equipment connection nozzles, in case where the forces exceed normal
conservative values.

Loops and offsets shall provide for flexibility in piping systems, especially for
noxious or hazardous fluids, Expansion joints shall be considered when limited space
will not give sufficient flexibility. Expansion joints shall be used only with adequate
guided and anchors. Loops and offsets shall be used in preference to bellow type
expansion joints wherever possible.
Bellow type joints shall not be subjected to torsional loads.
Horizontal piping expansion loops on pipe bridges shall have vertical offset to stay
clear of adjacent piping and any thermally expanded piping shall be anchored at the
plot limit.
Calculations shall establish stresses, forces and moments.
Pipe stress / flexibility analysis shall be executed with program: CEASAR II from
COADE

7.0

THERMAL INSULATION:

7.1

Thermal insulation shall be provided for all piping and equipment with surface
operating temperatures of 60C or above for one or more of the following reasons:

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a)

Conserve heat

b)

Maintain temperature for process control

c)

Provide for personnel protection.

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Design basis for selecting insulation thickness shall be as below:

Ambient Temperature
Cladding Temperature
Wind Velocity
Emissivity of Cladding
Hot Surface Temperature

7.3

REV:

:
:
:
:
:

40C
60C (max)
0.5 m / sec.
0.15
Fluid Design Temperature

Insulation material for hot insulation shall be as below:

i)

For sizes (including insulation thickness) up to 350 mm, Rock wool

preformed pipe sections of density 144 kg/m3 conforming to IS: 9842

ii)

For sizes 400 mm and above: In order to meet the sizes above
400mm, (Including insulation thickness) lightly resin bonded mattress
confirming to ASTM C547 class III shall be applied in addition to the
Rock wool preformed pipe sections.
The physical requirement of bulk density and chloride content,
thermal conductivity and PH value of the material shall be as follows:

iii)

Bulk Density
: 140 kg / cubic. Meters
Chloride content
: 20 PPM
Thermal conductivity: 0.43 m W/cm deg. C for mean temp 50 deg. C
0.52 m W/cm deg. C for mean temp 100 deg. C
0.62 m W/cm deg. C for mean temp 150 deg. C
0.68 m W/cm deg. C for mean temp 200 deg. C
0.80 m W/cm deg. C for mean temp 250 deg. C
0.90 m W/cm deg. C for mean temp 300 deg. C
7.4

Aluminum cladding shall be used as a weather protection over insulation unless

otherwise specified and shall conform to ASTM - B - 209 - 1060 Temper H-14.

7.5

Schedule of thickness for Thermal Insulation is attached as Annexure - D.

8.0

PAINTING:

8.1

Painting of pipe work shall be as per the painting specification. The procedures for
painting of insulated and non-insulated pipes, the colour codes, the method of
painting, etc. shall comply with the guidelines specified in the painting specification.

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PROCESS DESIGN CRITERIA FOR PIPING

9.1

General:

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The complete CPP piping shall mainly consist of following systems; viz. Boiler
feed pump suction piping, boiler feed pump discharge piping, boiler feed pump
recirculating piping, main steam piping, auxiliary steam piping, extraction steam
piping, condensate piping, Raw Water piping, DM Plant piping, fire water piping,
boiler blow down, vents, drains, etc. and low pressure utility piping.
9.2

Boiler Feed Pump Suction Piping:

A common suction line from deaerator/ feed water storage tank shall be provided
with branching off lines to individual boiler feed pumps. The common suction line
of BFPs shall be designed for rated flow of the operating BFPs + minimum
recirculation flow of the standby BFP and the branch off line shall be designed for
the rated flow of the pump.

9.3

Boiler Feed Pump Discharge Piping:

The discharge of boiler feed pumps shall be connected to the common discharge
header. From the discharge header feed water piping shall be routed to the steam
generator through, hp heater and feed water control stations. The feed water control
station shall have 1 x 100% and 1 x 40% control valves having flexibility in
operating the Boiler at varying load conditions. Feed water required for super
heater attemperation of the steam generators and other desuperheaters for auxiliary
steam in the power plant shall be tapped from the discharge headers of BFPs.

9.4

Boiler Feed Pump Recirculation Piping:

Separate recirculation line for each boiler feed pump shall be provided from the
non-return-cum modulating recirulation valves (Automatic Recirculation Valves)
with necessary isolation valves and pressure break down orifices and shall be
connected to the deaerator. Though the pressure reduction is achieved mainly
through the recirculation valve, the upstream of the pressure break down orifice
located near deaerator shall be kept 3 to 4 kg/cm2 above the deaerator pressure so as
to avoid flashing of water in the recirculation line thereby avoiding water hammer
and vibrations in the recirculation lines.

9.5

Main Steam Piping, Auxiliary Steam Piping and Extraction Steam Piping:
The main steam lines constitute the most important piping in a power plant and the
main steam piping from the boiler is connected to the turbine with adequate
expansion loop(s) to take care of the thermal expansions & to obtain adequate
flexibility so as not to exceed allowable reactions on boiler & turbine connections.

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Three separate extraction piping will be provided from the turbine to the H.P.
Heater, Deaerator and L.P. Heater to supply the steam. In order to meet the
transient condition, separate tap off will be provided from the main steam line to the
Deaerator extraction line through the Desuper Heater. Another tap off will be
provided in the main steam line to meet the steam requirement of turbine gland
steam ejector system.
Desuperheater spray requirement for auxiliary steam Desuperheaters and
superheater attemperators will be met by tap offs from the feed water pump
discharge header. On all pressure part tapping joints, 2 root valves shall be provided
in series.
9.6

Condensate Pump Suction Piping:

The common suction line from condenser hot well shall be connected to individual
condensate extraction pumps through branch lines and expansion joints. The piping
shall be sized for the maximum flow to the condenser under various modes of plant
operation.

9.7

Condensate Pump Discharge Piping:

The discharge from the condensate pumps shall be connected and fed to the
deaerator through ejector, gland steam condenser, drain cooler and L.P heater. A
tapping shall be provided for supplying spray water to turbine exhaust hood to
control the temperature. At the condensate outlet of GSC a minimum recirculation
line shall be taken and this will be directly connected to condenser to control the
level of the condenser.

9.8

Boiler Blow Down, Vents, Drains Etc.

Blow down piping shall connect the drains from boiler drum, super heaters, bottom
ring headers, etc. with the blow down tank. Pressure breakdown orifices shall be
provided before the blow down tank nozzle. Some high-pressure steam line drains
from different piping and equipment are connected to flash tank while others shall
be let off to the plant drains.

9.9

Low Pressure Utility Piping:

The low-pressure utility piping shall cover the following services.

1.
2.
3.
4.
5.
6.
7.
8.
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Make-up water
Instrument air
Service air
D.M.water
Fuel oil-HSD
Service and potable water
Cooling water
Auxiliary cooling water
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9. Raw water
9.9.1

Make up Water Piping:

Makeup water for the power plant shall be supplied from raw water reservoir. From
the raw water reservoir, raw water shall be pumped for cooling tower make up, the
DM plant requirement, air-conditioning ventilation system and service/drinking
water.

9.9.2

Instrument Air:
The instrument air shall be supplied through pipes from the common compressor
house located in the power plant. The header shall be run throughout the power
plant to meet all instrument requirements. Tapping for control valves in the
deaerator area, feed water control station etc., and for other instruments shall be
made from the header at all the nearest points.

9.9.3

Service Air:
The service air shall be supplied from the compressor house through service air
pipes. The header shall be routed through out the power plant. Tappings shall be
made from this header for various plant locations in Boiler area. STG building, coal
handling plant area as per the distribution list given in Compressed Air DBR.

9.9.4

DM Water:
The DM water piping from DM plant to the DM water storage tank and from the
storage tank to deaereator and other areas of requirement such as initial filling for
condenser hot well, H.P. and L.P. Dosing system will be routed through suitably
sized pipeline.

9.9.5

HSD:
Fuel oil pipeline shall be routed from the storage tank to boiler through transfer
pumps.

9.9.6

Potable Water:
Potable water pipe lines shall be routed separately throughout the power plant. The
material of potable water pipe shall be carbon steel conforming to IS: 1239 black
and galvanized.

9.9.7

Cooling Water:
The cooling water system shall be supplying cooling water to the condensers of the
steam turbine generators of the power plant.

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The common supply header and return header shall be buried along the T.G.
building for the turbine condenser. The buried piping shall be provided with
suitable external coating and wrapping.
Motor operated butterfly valves shall be installed at the discharge of each CW
pump. Gear operated butterfly isolation valves shall be installed on the return
header at the cooling tower inlet. CW pump suction piping shall have rubber
expansion bellows.
The butterfly valves shall conform to API 609 or AWWA C504 standards and
flanged type and shall be of cast steel body and disc with nitrile rubber seating.
9.9.8.

Auxiliary Cooling Water:

The auxiliary cooling water header shall be routed along with the main cooling
water piping. From the header branch lines for lube oil coolers, generator air
coolers, ash handling system compressors and plant air compressor and sample
coolers etc. The return piping shall be routed to cooling tower inlet header. The
material of construction shall be same as that of cooling water piping.
All piping to the coolers shall be provided with isolation valves of gate type at inlet
and globe valve, at outlet.

9.9.9.

Raw Water:
Raw water piping shall be routed from the existing raw water Reservoir (UMI) to
the proposed CPP raw water reservoir.
The Raw water piping shall be buried at 1.5 m below the ground. The material of
piping shall be carbon steel as per IS: 3589 ERW pipes. The buried piping shall be
provided with suitable external coating and wrapping.

9.10

Fire Water Piping:

Firewater piping shall involve piping for the fire hydrant system and high velocity
water spray systems.
Fire hydrant piping shall be routed from the fire water pumps to various hydrant
valve locations, the yard piping mainly being buried piping with suitable wrapping
and coating. The hydrant piping shall be ring main type (close loop system) so that
leakage/breakage at one location would not render the total system non-operational.
Suitable isolation valves, drains connected at all low points shall be provided.

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Optimum Line Sizing:

Following parameters for each service have been considered to arrive at optimum
line size:
a) Type of fluid, its properties under design condition.
b) Design flow rate
c) Recommended velocity
d) Pressure at source and receiver ie., available pressure drop through the lines
including fittings, valves and specialities such as strainers, flow elements etc.
For pumps, in addition to friction losses, static head is also considered while
estimating total pressure head required.
Annexure - I, gives the recommended velocity range, for various fluids.

REV.NO
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ANNEXURE - A
DESCRIPTION
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PIPING MATERIAL SELECTION

System

LIVE STEAM

Design
Design
Flange /
Temperat Pressure
Valve
ure
C
BAR(a) Rating(AN
SI)

Pipe
Material

Construction

500

66.89

900

ASTM- A335 SEAMLESS

Gr.P22

LP EXTRACTION STEAM

157.5

2.13

150

ASTM-A106 SEAMLESS
Gr.B

IP EXTRACTION STEAM

202.7

6.2

150

ASTM-A106 SEAMLESS
Gr.B

HP EXTRACTION STEAM

330.5

18.52

300

ASTM-A106 SEAMLESS
Gr.B

BOILER FEED WATER PUMP

SUCTION

145.5

6.0

150

ASTM-A106 SEAMLESS
Gr.B

BOILER FEED WATER PUMP

DISCHARGE

202.0

125.2

900

ASTM-A106 SEAMLESS
Gr.B

CONDENSATE PUMP
DISCHARGE (AFTER LEVEL
CONTROL STATION)
LP HEATER DRAIN

116.2

8.3

150

ASTM-A106 SEAMLESS
Gr.B

119.4

2.0

150

ASTM-A106 SEAMLESS
Gr.B

HP HEATER DRAIN (BEFORE C.V

STATION)

155.1

17.5

300

ASTM-A106 SEAMLESS
Gr.B

HP HEATER DRAIN (AFTER C.V

STATION)

155.1

13.0

150

ASTM-A106 SEAMLESS
Gr.B

DEAERATOR OVERFLOW &

BLOW

145.5

6.0

150

ASTM-A106 SEAMLESS
Gr.B

300/150

ASTM-A106 SEAMLESS
Gr.B

LINES TO DRAIN MANIFOLD

330.5/202.7, 18.52/6.20,
151.5
2.13

COOLING WATER SUPPLY

50

150

IS: 1239
IS: 3589

ERW
ERW

COOLING WATER DISCHARGE

50

150

IS: 1239
IS: 3589

ERW
ERW

INSTRUMENT AIR

50

10

150

ERW
ERW

SERVICE AIR

50

10

150

IS: 1239
GALV
IS: 3589
GALV
IS: 1239

DEMINERALISED WATER

50

14

150

ASTM-A312, SEAMLESS
TP-304

RAW WATER

50

4.8

150

IS: 1239
IS: 3589

ERW
ERW

POTABLE WATER

50

4.8

150

IS: 1239
GALV
IS: 3589
GALV

ERW
ERW

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ANNEXURE - B
MATERIAL SELECTION CHART
MATERIAL

CARBON CONTENT

DESIGN

TEMPERATURE
C

SEAMLESS PIPES
ASTM A106 Gr.B

0.30 Max.

427

ASTM A335 Gr.P1

0.10 - 0.20

468

ASTM A335 Gr.P11

0.15 Max.

570

ASTM A335 Gr.P22

0.15 Max.

600

ASTM A312 Gr.TP304

0.08 Max.

-200 to 500

ASTM A312 Gr.TP304L

0.035 Max.

-200 to 500

ASTM A672 Gr.B60

0.30 Max.

-46 to 300

API 5L Gr.B (ERW ; E = 0.85)

0.20 Max.

230

ASTM A312 Gr.TP304

0.08 Max.

-200 to 500

ASTM A312 Gr.TP304L

0.035 Max.

-200 to 500

ASTM A234 Gr.WPB

0.30 Max.

427

ASTM A234 Gr.WP1

0.10 - 0.20

468

ASTM A234 Gr.WP11

0.15 Max.

570

ASTM A234 Gr.WP22

0.15 Max.

600

ASTM A403 Gr.WP304

0.08 Max.

-200 to 500

ASTM A403 Gr.WP304L

0.035 Max.

-200 to 500

0.35 Max.

427

WELDED PIPES

FITTINGS

FORGINGS
ASTM A105
ASTM A182 Gr.F1

0.28 Max.

468

ASTM A182 Gr.F11 Cl.1

0.10 - 0.20

570

ASTM A182 Gr.F22 Cl.1

0.15 Max.

600

ASTM A182 Gr.F304

0.08 Max.

-200 to 500

ASTM A182 Gr.F304L

0.035 Max.

-200 to 500

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CARBON CONTENT

DESIGN

TEMPERATURE
C

CASTINGS
ASTM A216 Gr.WCB

0.30 Max.

427

ASTM A217 Gr.WC1

0.25 Max.

468

ASTM A217 Gr.WC6

0.20 Max.

570

ASTM A217 Gr.WC9

0.18 Max.

600

ASTM A351 Gr.CF8

0.08 Max.

-105 to 538

ASTM A193 Gr.B7

0.37 - 0.49

427

ASTM A193 Gr.B16

0.36 - 0.44

566

0.4 Min.

427

0.37 - 0.49

566

ASTM A515 Gr.60

0.30 Max.

450

ASTM A516 Gr.60

0.30 Max.

-46 to 300

ASTM A387 Gr.11 Cl.1

0.10 -0.20

570

ASTM A387 Gr.22 Cl.1

0.15 Max.

600

ASTM A240 Gr.304

0.08 Max.

-200 to 500

ASTM A240 Gr.304L

0.035 Max.

-200 to 500

BOLTS

NUTS
ASTM A194 Gr.2H
ASTM A194 Gr.7
PLATES

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ANNEXURE - C
VALVE DATA SHEETS
SL.
NO.

SYSTEM

SIZE

TYPE OF
END
ANSI
MATERIAL
VALVES CONNECITON RATING OF HOUSING

LP EXTRACTION Above 50 NB
Gate Valve
STEAM
Check Valve
50 NB & Below Gate Valve
Globe Valve

BW
BW
SW
SW

150#
150#
800#
800#

A216 Gr.WCB
A216 Gr.WCB
A105
A105

IP EXTRACTION Above 50 NB
Gate Valve
STEAM
Check Valve
50 NB & Below Gate Valve
Globe Valve

BW
BW
SW
SW

300#
300#
800#
800#

A216 Gr.WCB
A216 Gr.WCB
A105
A105

HP
EXTRACTION
STEAM

Above 50 NB

BW

600#

A216 Gr.WCB

Check Valve
50 NB & Below Gate Valve
Globe Valve

BW
SW
SW

600#
800#
800#

A216 Gr.WCB
A105
A105

BFP SUCTION

Above 50 NB
Gate Valve
50 NB & Below Globe Valve

BW
SW

150#
800#

A216 Gr.WCB
A105

BFP DISCHARGE Above 50 NB

Gate Valve
Check Valve
50 NB & Below Globe Valve

BW
BW
SW

900#
900#
1500#

A216 Gr.WCB
A216 Gr.WCB
A105

CONDENSATE
WATER

Above 50 NB

Gate Valve
Check Valve
Globe Valve
50 NB & Below Gate Valve
Globe Valve

BW
BW
BW
SW
SW

150#
150#
150#
800#
800#

A216 Gr.WCB
A216 Gr.WCB
A216 Gr.WCB
A105
A105

LP HEATER
DRAIN

Above 50 NB

BW

150#

A216 Gr.WCB

BW
SW
SW

150#
800#
800#

A216 Gr.WCB
A105
A105

Gate Valve

Gate Valve

Globe Valve
50 NB & Below Gate Valve
Globe Valve

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VALVE DATA SHEETS

SL.
NO.
8

SYSTEM

HP HEATER
DRAIN

SIZE

Above 50 NB

50 NB &
Below

COOLING
WATER

Above 50 NB
50 NB &
Below

10 DEMINERALISED Above 50 NB
WATER
50 NB &
Below

11 CHEMICAL
DOSING

REV.NO
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DATE

TYPE OF
END
ANSI
MATERIAL
VALVES CONNECITON RATING OF HOUSING
Gate Valve

BW

300#

A216 Gr.WCB

Globe Valve
Gate Valve

BW
SW

300#
800#

A216 Gr.WCB
A105

Globe Valve

SW

800#

A105

Butterfly
Valve
Globe Valve

FL

150#

A216 Gr.WCB

FL

800#

A105

FL

150#

A351 Gr.CF8

SW

150#

A182 Gr.F304

SW

150#

Polyethylene

Diaphragm
Valve
Globe Valve

Below 50 NB Ball valve

DESCRIPTION
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ANNEXURE - D
SCHEDULE OF THICKNESS FOR THERMAL INSULATION

TEMP.
C

Up to
100

101
to
150

151
to
200

201
251
301
351
to
to
to
to
250
300
350
400
Insulation Thickness (mm)
35
45
50
60

401
to
450

451
to
500

501
to
550

Pipe Dia
15 mm (1/2)

25

25

25

70

85

95

20 mm (3/4)

25

25

30

35

45

55

65

75

90

100

25 mm (1)

25

25

30

40

45

60

70

80

90

105

32 mm (1 )

25

25

30

40

50

60

70

85

95

110

40 mm (1 )

25

25

30

40

50

60

75

85

100

115

50 mm (2)

25

25

30

45

55

65

80

90

105

120

65 mm (2 )

25

25

35

45

55

70

80

95

110

125

80 mm (3)

25

25

35

45

60

70

85

100

115

130

100 mm (4)

25

25

35

50

60

75

90

105

120

140

125 mm (5)

25

25

35

50

65

75

90

110

125

145

150 mm (6)

25

25

35

50

65

80

95

115

130

150

200 mm (8)

25

25

40

50

65

85

100

120

140

160

250 mm (10)

25

25

40

55

70

85

105

125

145

165

300 mm (12)

25

25

40

55

70

90

105

125

150

170

350 mm (14)

25

25

40

55

70

90

110

130

150

175

400 mm (16)

25

25

40

55

75

90

110

130

155

180

450 mm (18")

25

25

40

55

75

90

110

135

155

180

500 mm (20")

25

25

40

55

75

95

115

135

160

185

550 mm (22")

25

25

40

55

75

95

115

135

160

185

600 mm (24)

25

25

40

55

75

95

115

140

165

190

ANNEXURE - E
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DESIGN PROCEDURES FOR PIPE SUPPORTS

The design loads for hangers & supports shall include the weight of pipe, the weight of
insulation and the weight of medium transported or the medium used for testing,
whichever is heavier. All components of hanger or support assembly shall be designed
for the above design load and the self-weight of hanger/support assembly.

Design and manufacture of hanger components including springs shall generally confirm
to MSS - SP58, MSS-SP69 and MSS-SP89.

The materials used in the construction of hangers, supports and accessories shall be the
most suitable for the service intended.

Material of lugs and welded attachment to pipes and pipe clamps shall be compatible
with parent pipe. However, welded pipe attachments shall be minimised.

The hangers shall be provided with suitable linkages to permit swing. The angle of
inclination shall not exceed 4 from the vertical plane.

The diameter of hanger rods for piping, 50mm NPS and smaller, shall not be less than
10mm.

Bolted pipe clamps, used with rod hangers, for pipe 50 mm NPS and smaller, shall have
a minimum thickness of 6mm.

Springs, for spring hangers, shall be of helical compression type and shall be provided
with means to prevent misalignment, buckling and eccentric loading and with stops to
prevent excessive travel.

Where variable spring hangers are specified, the units selected shall have support
variation of not more than 25% through its total travel range.

Constant spring hangers shall be specified where pipe thermal vertical movements
exceed 40 mm.

Constant support hangers shall have a field load adjustment range of +10% of the
operating load specified. The total travel of the unit selected shall be the calculated travel
of plus 20% to take care of possible discrepancies. Constant support hangers shall have
support variation of not more than 6% throughout the total travel range.

All rigid / spring hangers shall provide a means of vertical adjustment after erection.

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The threads on threaded parts such as hanger rods, nuts and turnbuckles shall conform to
applicable codes for the coarse-thread series with a medium class fit or equivalent.

All anchors shall be designed for rigid fastening to the structure either directly or through
a bracket. Anchors and guides shall be capable of withstanding the moments and forces
imposed by thermal expansion.

Pipe supports shall be designed such that a minimum amount of heat will be transferred
to the structure.

Stainless steel shim plates are required between stainless steel pipe and carbon steel
supports.

The maximum allowable deflection of supports due to the design loads in the direction of
the restraints shall be 3mm.

Shear lugs shall be provided for friction type clamped support on riser pipes. Friction
type clamped supports shall not be normally used on a vertical riser for critical systems.

The hanger shall be offset 1/2 of the thermal movement in cold position if swing angle of
the rod is in excess of 5 degrees, but not exceeding 10 degrees.

Suitable locking devices shall be used at all threaded connections of the hanger
assembly.

Each half assembly of a riser support shall be capable of supporting the entire load.

Overall rod length shall not be greater than 6m without proper evaluation.
Rigid Restraints:

Restraints fabricated out of structural steel shall have a clearance of 1.5mm in direction
of the restrained movement except in the downward direction.

Anchors shall only be used where full constraint of piping against three deflections and
three rotations are required.

Dependence on friction straps or bolted joints shall be avoided, to the extent possible,
especially in pipes, where design temperature exceeds 120.

ANNEXURE - F
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STRESS ANALYSIS DESIGN CRITERIA

General:
This criteria is established for piping flexibility analysis to be performed during piping
design work for the plant.

Application code & Specification :

Stress analysis of piping systems shall be performed in compliance with ANSI B31.1

Temperature :
Installation temperature
=
30 C
Design temperature :
Design temperature is the most severe sustained fluid
temperature subject to conditions of section 3.1 above.

Computer Software :
The computer pipe stress analysis shall be carried out using CAESAR - II ver. 3.24
computer software.

Basis for computer pipe stress analysis :

Detail pipe stress analysis shall be required for the following :
Pipe Diameter
(mm)
(in)
80
100
150
200
250
300
350
400
450
500 & above

3
4
6
8
10
12
14
16
18
20

Design Temperature
Carbon steel (deg. C)
Austenitic Steel
(deg. C)
& Ferritic alloys
> 440
> 390
> 300
> 260
> 260
> 200
> 230
> 160
> 190
> 130
> 160
> 120
> 140
> 100
> 130
> 90
> 120
> 80
> 100
> 80

All following piping connected to reciprocating / rotary equipments.

(i) Pipe diameters of 80mm to 200mm with design temp. greater than 60
(ii) Pipe diameter 250 mm & larger

Steam lines connected to turbine.

Feed water pump suction and discharge lines.
ANNEXURE - G

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MAJOR REQUIREMENTS OF IBR

Vessels (Reg. 2 (c) of IBR):

Any closed vessel exceeding 22.75 litres (five gallons) in capacity, which is used
exclusively for generating steam under pressure and include any mounting or other
fittings attached to such vessels, which is wholly or partly under pressure when
steam is shut off.

Piping:
Steam Pipe (Reg. 2 (k) of IBR):
Any pipe through which steam passes if
1.
Steam pressure exceeds 3.5 kg/cm2 above atmosphere, OR
2.
Pipe size exceeds 254 mm internal dia.

Note: Following are not under IBR

Steam Tracing
Heating coils or
Tubes of Tanks, heat exchangers
Feed Pipe (Reg. 2 (k) of IBR):
Any pipe or connected fitting wholly or partly under pressure through which feedwater passes directly to a boiler.

Material Certificates:
1. Any item part of steam piping i.e. pipes, valves, fittings, traps, safety valves must
have material certificates, countersigned by the local boiler inspector.
2. For imported items - certificates issued by an authority empowered by the Central
Boilers Board (as listed in the Appendix C of IBR) or under the Law in force in a
foreign country in respect of boilers manufactured in that country may be
accepted.

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Drawings:
1. Prior to fabrication of any items i.e. Boiler, fabricated pipe work which are
coming under the purview of the boiler drawings shall be submitted before
construction to the Chief Boiler Inspector of the State where the plants /
equipment / Pipe line will be installed.
2. The Chief Inspector shall after examination of the drawings and particulars shall
inform the proposers whether he is satisfied with the design and fitness of the
parts for the intended pressure and if not, what modification is necessary therein
with respect to design, material etc.

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ANNEXURE - H
ACCESSIBILITY REQUIREMENTS FOR VALVES & INSTRUMENTS
Valves,
Instrument, Centreline of item to be operated,
Equipment to be operated
located less than 3.6m above
grade, 2.75m above floor or
platform or 1.8m above wing
platform
Exchanger heads
Nil
Operating valves 2 &
Fixed ladder
ll
Operating
valves 3 & above
Platform
Motor operated valve
Platform
Control valves
Platform
Relief valves 2 & smaller
Fixed ladder
Relief valves 3 & above
Platform
Block valves 2 & smaller
Portable ladder
Block valve 3 & above
Platform (Note-1)
Battery limit valves
Platform
Pressure instrument
Fixed ladder if above 2.2m
hFixed
i h ladder if above 2.2m
Temperature instrument
hPlatform
i h
Sample points
Gauge glasses
Level controllers
Man ways / Manholes
Hand holes / Inspection
hNozzles
l
Vessel vents
Line drains & vents
Orifice flanges

Note:

1)

Fixed ladder
Platform
Platform
Platform
No access reqd. (Note-2)
Portable ladder
Portable ladder
Portable ladder

Centreline of item to be
operated, located more than
3.6m above grade, 2.75m
above floor or platform or
1.8m above wing platform
Platform
Fixed ladder
Platform
Platform
Platform
Fixed Ladder
Platform
Portable ladder
Platform (Note-1)
Platform
Fixed ladder
Fixed ladder
Platform
Fixed ladder
Platform
Platform
Platform
No access reqd.
Fixed ladder
Portable ladder
Portable ladder

Center line of Block valves located above 2.0 meter from the operating floor
which are required for normal operation shall be provided with portable platform
or chain for operation of valves.

2) Temporary arrangement for access should be feasible.

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ANNEXURE - I
RECOMMENDED VELOCITY RANGE FOR VARIOUS FLUIDS
A.

STEAM
Pipe Size

Average velocity in meter/second

Below
50 NB
15-20

1.Saturated steam up to 7.0 kg/cm2 (g)

2.Saturated steam over 7.0 kg/cm2 (g)

50 to 100 NB

15-25

3.Superheated steam up to 7.0 kg/cm2(g)

20-35

20-30

4.Superheated steam from 7.1 to 3.5 kg/cm2 (g)

20-35

5 Superheated steam from 35.1 to 70 kg/cm2

(g)

20-35

20-35

100 NB &
up
25-45
30-50

25-40

30-50

30-45

35-55

30-50

40-60

30-50

45-70

6. Superheated steam from 70 kg/cm2 (g)

20-35

7.Turbine by pass steam

200

For all

Line sizes

20

For all

Line sizes

60

For all

Line sizes

8.Exhaust steamline
atmosphere

from

the

line

to

9.Vacuum lines

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Water
Average Velocity
Meter / second

C.

Firewater lines

0.6. to 0.9

Feed water suction lines

1.0 to 2.5

Feed water discharge lines

2.5 to 5.0

Auxiliary cooling water (suction)

0.6 to 1.5

Auxiliary cooling water (discharge)

0.9 to 2.5

Condensate delivery lines

0.9 to 2.2

Condensate suction lines

0.4 to 0.7

Main cooling water lines (discharge)

0.9 to 2.5

Main cooling water lines (suction)

0.6 to 1.2

Viscous fuel oil

0.6 to 0.9

Gases

25 to 30

Oil and gas lines

Average Velocity
Meter/second
Lubricating oil and fuel oil suction
Lines (depending on viscosity)

0.5

Fuel oil supply lines (pre-heated)

3.0

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