Pdvsa: Engineering Design Manual

PDVSA
ENGINEERING DESIGN MANUAL

VOLUME 13II
ENGINEERING SPECIFICATION
PDVSA N TITLE
H251 PROCESS AND UTILITY PIPING DESIGN

REQUIREMENTS
1 DEC. 98 GENERAL REVISION 21 Y.K. A.A. J.E.R.
0 FEB.89 FOR APPROVAL 33 J.S. J.G. E.S.
REV. DATE DESCRIPTION PAG. REV. APPD. APPD.
APPD.BY Alexis Arvalo DATE DEC. 98 APPD.BY Jess E. Rojas DATE DEC. 98
E PDVSA, 1983 ESPECIALISTAS

ENGINEERING SPECIFICATION PDVSA H251
PDVSA
REVISION FECHA
PROCESS AND UTILITY PIPING 1 DEC. 98

DESIGN REQUIREMENTS Pgina 1
.Men Principal Indice manual Indice volumen Indice norma
Index
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Piping Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Design Pressures and Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Corrosion Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 DESIGN DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Line and Connection Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Material Specification Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Screwed Nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 End Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Blinds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Bypasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 GENERAL INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . 8
4.1 Provisions for Expansion and Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Supports and Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Joints and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Branch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Valve Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6 Centrifugal Pump Piping Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Vents and Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 REQUIREMENTS FOR INDIVIDUAL PIPING SYSTEMS . . . . . . . . . 15
5.1 Requirements for Process Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Requirements for Steam Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Requirements for Water and Air Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Utility Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Drainage and Sewage Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.6 Firewater Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1 GENERAL
1.1 Scope
1.1.1 This specification covers general requirements for the design of process and
utility piping systems and supplements the requirements of the ASME Code
B31.3, Process Piping, under which the piping systems are to be designed.
1.1.2 The number and extent of piping systems to be provided in the plant shall be as
indicated on the Piping and Instrument (P&I) diagrams and plant drawings.
1.1.3 Requirements indicated on Piping and Instrument (P&I) diagrams prevail over this
specification.
1.1.4 This specification does not cover design requirements for liquid transportation or
gas transmission pipeline systems outside battery limits.
1.2 References
Latest editions of the following Engineering Specifications and codes form integral
part of this specification, to the extend indicated herein:
1.2.1 Petrleos de Venezuela S.A. (PDVSA)
H221 Piping Materials
H231 Piping Fabrication Requirements
HG251 Pipe Supports Design Criteria
Manual de Ingeniera de Riesgos
1.2.2 American Society of Mechanical Engineers (ASME)
B31.3 Process Piping
1.3 Regulations
Should there be any conflict between Venezuelan laws, standards and
regulations, this specification and ASME standards, the order of prevalences shall
be as follows:
1. Venezuelan laws, standards and regulations
2. This specification
3. ASME B31.3.
2 DESIGN
2.1 Piping Layouts
2.1.1 All piping shall be routed for the shortest and economical run. Layout shall be
sufficient flexible to offset thermal effects, in order to avoid:
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a. Failure for excessive thermal expansion stress

b. Flanged joint leakage
c. Excessive loads to connected equipment
2.1.2 Generally all lines, inside battery limits of process units, shall be run on overhead
pipe supports. Exceptions are fire water lines and drain lines. New pipe racks shall
have 10 percent of available width unused for future lines.
2.1.3 Lines that cannot be run overhead shall be run on sleepers.
2.1.4 The use of pipe trenches within units shall be avoided.
2.1.5 Lines outside battery limits generally shall be run at grade on sleepers except in
areas adjacent to units where vehicular and pedestrian access is required. for
vertical clearance, see paragraph 2.2.1.
2.1.6 Large, thin walled lines in nonflammable service, such as cooling water lines,
may be buried and continuously supported on sand cushions.
2.1.7 Piping insulated for Hot Service over 3 inches and larger nominal diameter shall
not be supported directly on structural steel or on a round smooth bar welded to
structural steel, and shall be provided with pipe shoes or saddles, with the bottom
of the pipe 75 mm (3 inches) above the top of supporting structural steel. Pipe
shoes or saddles shall be of sufficient length to handle any possible line
expansion.
All piping over 3 inches nominal diameter with operating temperature 121 C (250
F) and over supported directly on concrete sleepers shall be provided with pipe
shoes or saddles, with the bottom of the pipe 75 mm (3 inches) above the top of
supporting concrete. Pipe shoes and saddles shall be of sufficient length to handle
any possible line expansion.
2.1.8 Bare pipes shall rest directly on structural steel provided a smooth round steel bar
(1/2 or 3/4 inch diameter) be welded on structural steel in order to minimize
contact area and corrosion.
2.1.9 Where possible, all lines shall be run at levels which would enable them to be
supported on structural steel at a common elevation.
In process areas, specific elevations shall be selected for lines running north and
south and other specific elevations for lines running east and west. These
elevations shall be used throughout the unit, except where pockets must be
avoided.
2.1.10 All piping and accessories shall be arranged to facilitate support.
2.1.11 Piping arrangement shall be planned for ease of equipment removal for
inspection, servicing and/or maintenance.
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Piping and structures shall be arranged to permit mobile lifting equipment to

approach process equipment and make lifts without obstruction.
2.1.12 Maintenance areas shall be clear of piping insofar as possible.
2.1.13 Control valves, relief valves, etc. shall be accessible from platforms or grade and
grouped at main operating levels.
2.1.14 Deflections over 1/2 inch are not permitted in all lines.
2.1.15 All process and utility piping entering battery limits shall be provided with a block
valve. Piping leaving battery limits shall be provided with block valve with the
Owners representative approval only.
2.1.16 Buried pipe shall be externally coated, and provided with cathodic protection if
required.
2.1.17 Where a drain valve is required, bottom of pipe (BOP) shall be above ground or
base level so a plug can be easylly installed and/or removed. A 100 mm (4
inches) minimum clearance is recommended.
2.2 Clearances
2.2.1 Clearance for equipment, structures, platforms, piping and its supports shall be
in accordance with Appendix I.
2.2.2 To permit access for the removal or maintenance of a pipe line, a minimum side
clearance of 25 mm (1 inch) shall be provided between parallel lines, outside of
insulation or between flange and pipe (insulation).
Thermal movements shall be taken into consideration in determining side
clearances.
Clearance for maintenance personnel shall be allowed for removal of interior lines
in multiple pipe line racks.
2.2.3 The lowest point of all flanges or insulation on lines run in trenches shall be a
minimum of 75 mm (3 inches) above the floor of the trench.
The minimum horizontal walkway clearance between piping and mechanical
equipment shall be 915 mm (36 ft).
2.3 Materials
Materials of construction for individual piping systems and specific operating
conditions shall conform to the requirements of Engineering Specification Piping
Materials, PDVSA H221.
2.4 Design Pressures and Temperatures

2.4.1 The design pressures and temperatures to be used as a basis for the design of
piping systems and the selection of standard piping material components shall be
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in accordance with the requirements of the ASME Code B31.3, with the maximum
operating conditions shown on the applicable P&I diagrams.
2.4.2 Piping shall be designed for the maximum expected severe coincidental of
conditions of pressure and temperature during normal operation, arrived on the
basis of the following considerations:
a. Design pressure of the equipment to which it is connected.
b. Set pressure of the safety valve which protects the system.
c. Discharge piping of a centrifugal pump not protected by a safety valve shall
be designed for the higher value of:
1. Maximum suction pressure plus normal differential pressure.
2. Normal suction pressure plus maximum differential pressure.
d. All systems operating below atmospheric pressure shall be designed for full
vacuum.
e. All piping leaving the battery limits shall be designed for a closed valve at the
battery limits of destination plant or off site installation.
f. The design pressure shall apply from the source to the last valve before
entering equipment at a lower pressure.
2.5 Corrosion Allowance

Minimum corrosion allowances as listed in Engineering Specification Piping
Materials, PDVSA H221 shall be provided in all process and utility piping
systems.
3 DESIGN DETAILS
3.1 Line and Connection Sizes
3.1.1 Allowable pipe sizes in inches are: 1/2, 3/4, 1, 1 1/2, 2, 3, 4, 6, 8, 10, 12, 14, 16,
18, 20, 24 and larger, in 6inch increments.
3.1.2 In general, the minimum pipe sizes shall be 1/2 inch for utility lines; 1 inch for
process lines; no size limitations for instrument connections and steam tracing
lines; 4 inches for underground sewer lines; and 1 1/2 inches for other than sewer
underground lines.
3.2 Material Specification Changes

3.2.1 When a piping system of one material Line Spec is connected to a piping system
of a higher rated material Line Spec, the connecting piping system shall be
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constructed of the higher rated material Line Spec up to and including the first
valve in the connecting piping system.
a. The higher rated material Line Spec shall be used up to and including the
valve on the bypass around equipment or pressure reducing valves.
b. Block valves after the reducing valves shall be of the higher rated material
Line Spec.
3.2.2 Where vessels have higher design ratings than the connecting lines, the valves
at the vessels shall equal the pressure rating of the vessels if the valves are
normally closed during operation.
3.2.3 Drilled holes in orifice flanges shall be upward in gas or vapor lines, and lateral
in liquid lines. Other orientations require Owners representative approval.
3.3 Flanges
3.3.1 The use of flanges in piping shall be limited to connections at flanged equipment,
valves and appurtenances as indicated on P&I diagrams.
3.3.2 Flanges shall also be provided in cases such as:
Where frequent dismantling of piping is required.
Where plastic, nonmetallic or internally coated piping systems cannot be
welded or otherwise joined except by flanges.
To provide clearance for dismantling of equipment such as pumps,
compressors, reactors, etc.
Where is not permitted to fabricate welding pipe.
Where it is not feasible to weld piping sections of dissimilar materials, e. g.
Carbon Steel to Cast Iron, Carbon Steel to FRP, etc.
3.4 Screwed Nipples

3.4.1 All carbon steel and ferritic alloy steel screwed nipples shall be of Schedule 80
minimum thickness.
a. Close nipples shall not be used.
3.4.2 Austenitic stainless steel and nonferrous alloy screwed nipples shall be
Schedule 40S minimum thickness.
3.5 Valves
3.5.1 Valves shall be provided of the type and number shown on the P&I diagrams.
3.5.2 Double block valve and bleeder installations shall be provided as shown on the
P&I diagrams where necessary to avoid product contamination, or a hazardous
condition.
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3.5.3 The type of valve shall be in accordance with Engineering Specification, Piping
Materials, PDVSA H221.
3.5.4 Facetoface dimensions of gate, globe, check, ball, and plug valves shall be in
accordance with ASME B16.10.
3.5.5 Block valves shall in general be gate, ball, butterfly or plug valves.
3.5.6 Globe valves in sizes 3 inches and larger shall be used only when throttling is
required.
3.5.7 Plug or ball valves shall be used (when operating temperature is within acceptable
limits) in lieu of gate valves for services where solids may collect to prevent the
seating of the wedge.
3.5.8 Gear operators (manual) shall be supplied for gate and globe valves (which are
operated more than four times a year), ball and plug valves, and firesafe butterfly
valves in the following sizes and larger:
VALVE TYPE AND SIZE (NPD)
ASME Primary Gate or Globe Ball or Plug Firesafe Butterfly (3)

Rating, Class in. mm in. mm in. mm
150 (1) 14 350 8 200 8 200
300 (2) 10 250 8 200 6 150
400 8 200 6 150 4 100
600 8 200 6 150 4 100
900 6 150 4 100
1500 4 100 3 80
2500 3 80 3 80
NOTES
(1) Includes ASME Class 125 and 250 cast iron.
(2) Includes ASME Class 300 ductile iron.
(3) This valve type not generally available above ASME Class 600.
a. The valve is to be used in service conditions which require that it be opened
or closed as quickly as possible in the event of equipment malfunction or
operation failure.
b. The valves for which gearing is to be supplied shall be indicated on the
applicable P&I diagrams.
3.5.9 For ASME Class 600 and over, valves shall be provided with pressure equalizing
bypass globe valve, as indicated in Appendix II, when the operating differential
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pressure across the closed valve approximately equal the pressure rating of the
valve at the operating temperature.
3.5.10 The valves for which bypasses are to be furnished shall be indicated on the
applicable P&I diagrams.
3.5.11 Integral valve bypass shall not be used unless absolutely required due to design
limitations. If used, it shall be globe valves only.
3.5.12 The bypass valve and the related bypass piping shall be of the same piping class
as the principal valve.
a. Check valves shall be suitable for installation in horizontal or vertical lines where
a reversal of flow may occur.
3.5.13 Stem positions of all valves shall be indicated on the drawings, preferably not
below the horizontal.
3.5.14 Pipe lines containing hazardous solutions (i.e. acids, caustic, etc.) shall not have
valve stems below the horizontal.
3.6 End Closures

3.6.1 Only with the approval of Owners representative, welded end closures shall be
welding caps for all process service lines and for all other services with design
pressures over 1,02 bar (14,7 psi) (gauge) or in vacumm service.
3.6.2 Flat plate closures may be for piping over 12 inches size and with a design
pressure between 0 bar (gauge) and 1,01 bar (14,7 psi) (gauge) in
nonflammable services.
3.7 Blinds
3.7.1 Blinds shall be supplied only to the extent required for normal operations and as
shown on the P&I diagrams.
3.7.2 Blinds (spacers and spectacles) shall normally be installed on all process lines at
battery limits and where required to facilitate testing, inspections or maintenance
of equipment.
3.8 Bypasses
3.8.1 Bypasses around equipment and control valves shall be supplied only to the
extent required for normal operation and as shown in the P&I diagrams.
4 GENERAL INSTALLATION REQUIREMENTS

4.1 Provisions for Expansion and Flexibility
4.1.1 Provisions for thermal expansion and contraction shall be made in all lines in
accordance with the requirements of the ASME Code B31.3.
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4.1.2 Provisions for expansion shall normally be made with pipe loops. Cold strains
shall be avoided and may be used with the approval of Owners representative
only.
4.1.3 All piping systems shall be designed so that the loads and moments applied at the
flanges of mechanical equipment shall not exceed the permissible reactions on
the equipment nozzles, as indicated by suppliers and/or standards.
4.2 Supports and Anchors

4.2.1 All piping shall be supported and shall be provided with anchors, sway braces or
vibration dampeners to prevent excessive expansion forces on equipment and
excessive vibration.
4.2.2 Piping at valves and mechanical equipment, such as pumps, requiring periodic
maintenance shall be supported so that the valves and equipment can be
removed with a minimum necessity of installing temporary pipe supports.
4.2.3 Piping supports shall be designed as part of the piping system in accordance with
the objective and procedures outlined in PDVSA HG251.
4.3 Joints and Connections

4.3.1 Joining in all piping systems equal or larger than 2 inches pipe size shall be
accomplished by butt welding.
4.3.2 Joining in piping 11/2 inches diameter and under shall be accomplished by
socket welding preferably. Screwed connections shall require Owners
representative approval.
4.3.3 Unless otherwise indicated on project specifications, flanged connections shall be
used to connect all piping, vessels, equipment, instruments, relief and safety
valves, etc. (see subtitle 3.3.).
4.3.4 Steel flanges used for the attachment to flat faced cast iron flanges shall be flat
faced.
4.4 Branch Connections

4.4.1 Welded pipe to pipe connections shall be designed so that the angle of
intersection between the branch and the run shall not be less than 45.
4.4.2 Integrally reinforced branch welding fittings which abut the outside surface of the
run wall, in sizes 4 in. NPS (100 mm) and larger, are not permitted under any of
the following conditions:
a. The d/D ratio (branch diameter/header diameter) exceeds 0.8.
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b. The run piping wall thickness is less than schedule 40.

c. The run piping wall thickness is less than 0.75 in. (19 mm) where outside
diameter exceeds 36 inches (900 mm).
4.4.3 Pad reinforced branch connections are not permitted when the piping design
temperature is 427 C (800 F) or greater.
4.4.4 If padtype reinforcement is used for full size branch connections, it shall be of the
completeencirclement type.
4.4.5 Fabricated branch connections. Branch connections shall be directly joined to the
header with full penetration weld. All branch connections to headers 16 in.(400
mm) diameter and larger shall be visually inspected, both internally and externally.
Reinforcing pads (when required) shall be added as a subsequent fabrication step
after visual inspection. Vent shall be 1/8 in. (3.2 mm) drilled hole.
4.4.6 Connections 11/2 inches NPS (40 mm) or smaller shall be welded to run piping
by using a coupling, or a schedule 160 or greater nipple, or an integrally reinforced
branch welding fitting. 2 inches NPS and smaller branch connections shall be
provided with a block valve close to the header.
4.5 Valve Installations

4.5.1 Frequently operated valves and unfrequently operated valves required for
emergency operations, on which the centerline of the stem is more than 2,3 m
above the pavement or platform levels, shall be provided with remote operating
devices, like an impact type chain wheel. Clamp type chain wheel is permitted for
gear operated valves only. Extended stems or fixed ladders, stairs or platforms
are also permitted for easing operation provided do not obstruct walkways and
passageways.
a. Chain wheels shall not be used on screwed valves.
b. Chains shall hang to within 915 mm of the operation level and they shall be
attached to columns or walls so as not to obstruct passageways.
4.5.2 Other unfrequently used valves which are more than 2,3 m above the pavement
or platform level shall be installed so they the can be reached from a portable
ladder or mobile platform.
4.5.3 Frequently operated valves in trenches shall be provided with extension stems
extending to within 100 mm (4 inches) below the cover plate if the hand wheels
are more than 305 mm (12 inches) below the cover plate.
4.5.4 Valves at towers shall be located directly against or close to the tower nozzles
unless physical interference would prevent proper operation of the valves. Valves
shall not be located inside vessel skirts.
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4.5.5 All valve outlet ends in process and steam services which do not connect to a
piping system shall be provided with an appropriate end closure.
a. Threaded ends shall use a plug.
b. Socket weld ends shall use a nipple and a screwed cap.
c. Flanged ends shall use a blind flange.
4.5.6 Gate or globe valves which normally operate open shall be installed so stem is in
horizontal position.
4.5.7 Block valves shall be provided on 11/2 inches or smaller branch connections at
a maximum distance of 230 mm (9 inches) from header, in utility services like
instrument and service air; service, crude and makeup water; steam and
condensate.
4.5.8 Instruments gate or globe valves shall be installed so stem is in horizontal position.
4.6 Centrifugal Pump Piping Installations

4.6.1 Discharge and suction valves shall be arranged per Fig. 1.
4.6.2 Check valve installation in the pump discharge line shall be per Fig. 1 and the
following:
a. A single check valve shall be installed if there is any possibility of a reverse
of flow.
4.6.3 Combined stop/check valves may be used in water service under ASME Class
300 rating.
4.6.4 Valve sizing shall be as follows:
a. Check valves and discharge block valves shall be linesize. However, if the
discharge line is two or more sizes larger than the pump discharge nozzle,
the valves may be the next standard size smaller.
b. Suction valves shall be linesize. However, a size reduction to one size
larger than the nominal size of the pump suction nozzle may be used if:
1. The result is a lower total installed cost, and.
2. The effect on NPSH is tolerable at design and alternate operating
conditions.
4.6.5 Suction valve ratings shall be as follows:
a. With a single pump in the line, the suction valve shall have a
pressuretemperature rating equal to the suction line rating.
b. When two or more pumps are manifolded, the suction valves and any
components between the valves and the pumps shall have a
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pressuretemperature rating of not less than 3/4 the maximum discharge

pressure of the pump at normal operating temperature.
4.6.6 Pressure Relief (PR) valve installation for mechanical seal protection. When two
or more pumps are manifolded and the failure pressure of the pump mechanical
seal is less than the pump casing design pressure, a PR valve shall be provide
between the suction valve and the pump. The PR valve shall be set to open no
higher than the seal rated pressure and shall be sized for a flow equivalent to 10%
of pump design flow plus the flow through any drilled check valve or bypass line.
4.6.7 Discharge from the PR valve shall be piped to the pump suction source upstream
of the suction valve.
4.6.8 Length of suction line.
For pumps taking suction from drumless condensers, the length of the sloped
horizontal suction line under the condenser must be minimized to avoid local
vapor lock caused by velocity loss.
4.6.9 Minimum sloping of suction line.
If vapors may be present in the suction line, it shall be sloped not less than 1:50
downward, from the vessel toward the pump.
If it is impracticable to slope the line due to layout considerations, alternate piping
arrangements, to avoid high point vapor traps, shall be approved by the Owners
representative.
4.6.10 Reducers in horizontal suction shall be eccentric and shall be installed as shown
in Fig. 1, to avoid pocketing of vapors in the horizontal line.
4.6.11 Strainer installation:
a. Temporary strainer shall be installed per Fig. 1 unless permanent strainers
have been specified.
b. Piping layout shall permit insertion and removal of the temporary strainer
without disturbing equipment alignment. Pipe fittings such as Tees, Y s,
or fabricated piping spool pieces are acceptable for this purpose.
c. The design and location of permanent strainer shall permit cleaning without
removing the strainer body.
4.6.12 Suction liner for double suction pumps shall not be installed with a horizontal
elbow closer than 5 pipe diameters of straight run pipe to the pump suction nozzle.
WARMUP FACILITIES
4.6.13 Piping shall be installed per Fig. 1, details A or B as applicable, to provide a
continuous flow of fluid through the pump and piping when a pump is idle or
outofservice, for either of the following conditions:
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a. If the pumping temperature exceeds 230 C (450 F).

b. If the ambient temperature may be at, or below, the pour point of the process
fluid.
4.6.14 Warmup facilities for other than coking and slurry service shall be installed per
Fig. 1 Detail A and the following:
a. The drilled check valve shall have the hole sized to provide a flow of 3 to 5%
of normal pump flow, but the hole shall not be less than 6,3 mm (1/4 in)
diameter.
b. If a high differential pressure precludes meeting the 3 to 5% flow limitation
per subparagraph a. above, or as an alternative to a drilled check valve, a
bypass with a flow restrictor is acceptable on pumps with discharge nozzles
2 in. NPS (50 mm) diameter and larger.
4.6.15 A drilled check valve or bypass piping per Fig. 1 Detail A shall be installed when
the pump is designed for automatic startup and when the daily mean temperature
may fall below the temperature for acceptable operating viscosity.
LOW FLOW PROTECTION

4.6.16 A low flow protection system shall be installed for pumps expected to operate for
extended periods of time at less than 20% of their best efficiency point (BEP) flow
rating. The low flow protection system shall be designed to assure continuous
pump operation at flows exceeding 20% of BEP flow rating.
The low flow protection system shall either be piped back to the pump suction
source; or through a cooler and back to the pump suction. Alternative system
design shall be submitted to the Owners Engineer for approval.
Boiler feed water pumps. An automatic, combined lowflowbypass/check valve
shall be provided for each pump (in lieu of an unvalved orificed bypass).
4.6.17 External Forces and Moments
Forces and moments caused by piping on pump nozzles or couplings shall be
calculated by Piping Engineer. Considerations shall be taken for special
conditions like not operation periods, thermal expansions, types of baseplate and
steamout. Reactions and moments shall not exceed permissible values as
indicated in applicable pump codes or standards, or pump manufacturer.
Deviations permitting higher loads require approval of the Owners
representative. Such approval will be based on proof submitted by the pump
vendor or manufacturer that the specified pump nozzle or coupling deflection will
not be exceeded.
For inline pumps, piping forces shall be determined with the pump considered as
a rigid, but unanchored segment of the piping system.
PDVSA
REVISION FECHA

4.7 Vents and Drains

4.7.1 Vents and drains shall be provided in accordance with P&I diagrams.
4.7.2 In general, venting and draining shall be accomplished through vessel and/or
equipment connections.
a. Vessel vents and drains may be located in overhead or bottom piping,
provided no valves or blinds are located between the vent or drain
connections and the vessels.
4.7.3 Plugged vents (valves omitted) shall be provided on high points of pipe sections
and on high points of 6 and larger inverted U shaped pipe sections when the
sections are to be hydrostatically tested.
a. High point vents shall not be required when one or more of the following
conditions exists:
Inverted U shaped piping to be hydrostatically tested is 4 and smaller.
Piping system is pneumatically tested.
Piping system receives only service tests (i.e. cooling water supply and return
systems, plant and instrument air, lube and seal oil systems, steam tracing, and
potable water systems).
Piping system is hydrostatically tested at atmospheric pressure (i.e. storage
tanks, mixing tanks, and associated piping).
An accessible flanged joint exists at the highest point in the system to be tested.
4.7.4 Valved drains shall also be provided on low points of all pipelines
4.7.5 Drains emptying into open receptacles shall terminate 50 mm above the top of the
drain receptable and the discharge shall be visible from the location of the drain
valve.
4.7.6 Unless otherwise noted on piping drawings or P&I diagrams, the minimum size
of vent and drain connections shall be 3/4 inch. For hydrostatic tests, 3/4 inch and
11/2 inches drains shall be provided for 10 inches lines NPS and smaller, and
12 inch lines NPS and greater, respectively.
4.7.7 The minimum vent and drain connection sizes for vessels shall be in a accordance
with Appendix III.
4.7.8 No permanent drains or vents shall be provided in hydrogen carrying lines. Any
vents or drains installed for hydrostatic testing shall have valves removed and
connections plugged and weld sealed after testing.
4.7.9 A 3/4 inch drain shall be installed upstream of each control valve, between block
valve and control valve.
PDVSA
REVISION FECHA

4.7.10 When a piping spool is between a check and a block valves, the spool shall be
provided with a valved drain.
5 REQUIREMENTS FOR INDIVIDUAL PIPING SYSTEMS

5.1 Requirements for Process Piping Systems
5.1.1 Sample connections and sample coolers shall be supplied to the extent shown on
the P&I diagrams. Avoid long dead legs.
5.1.2 All sample connections shall normally be 3/4 inch.
5.1.3 For pipe in a horizontal or inclined plane, the sample connection shall be located
at the side of the pipe unless otherwise indicated on the P&I diagrams.
5.1.4 Unless otherwise indicated on the P&I diagrams, the piping systems for pumping
out towers and equipment shall be a part of the regular process piping of the unit.
5.1.5 Relief valves which discharge to atmosphere through discharge piping shall have
the pipe extend at least 3 meters (10 ft) above any platform or working area within
a 7,6 meter (21,5 ft) radius of the point of discharge.
5.1.6 Relief valves shall be connected to flare or other disposal system only when so
indicated on the applicable P&I diagrams.
5.1.7 Relief valves have a minimum of piping between the protected line or equipment
and the valve inlet and shall be accessible.
5.1.8 The low point of the relief valve outlet piping when discharging to the atmosphere
shall be provided with a 6 mm minimum weephole.
5.1.9 Relief headers shall be continuously sloped to knockout drums. Slope shall be
indicated on P&I diagrams.
5.2 Requirements for Steam Systems

5.2.1 Steam piping systems shall be supplied to the extend shown on the utility flow
diagrams and normally shall include systems for the distribution of steam required
for process operations, steam turbines, service steam, steam tracing, and
equipment steamout.
5.2.2 All branch connections from steam headers shall be taken off the top of the
header.
5.2.3 Single block valves shall be provided in branches, adjacent to the headers, to the
extent shown in the steam P&I diagrams.
5.2.4 Single block and check valves shall be provided adjacent to the point of injection
of steam into any process stream
PDVSA
REVISION FECHA

5.2.5 Single block valves shall be supplied adjacent to the header in the inlet line to each
steam turbine and adjacent to the discharge header in the outlet line unless the
discharge is to atmosphere of surface condenser.
5.2.6 Steam relief valves shall discharge to atmosphere through discharge piping
extending at least 3 meters (10 ft) above any platform or working area within 7,6
m (21,5 ft) radius of the point of discharge.
5.2.7 The low point of the relief valve outlet piping shall be provided with a 6 mm (1/4
in) minimum weephole when discharging to the atmosphere.
5.2.8 All steam lines shall be designed to avoid unnecessary traps.
5.2.9 Where traps cannot be avoided, steam traps with drains shall be designed into the
piping to remove condensate.
5.2.10 Traps which discharge to a high pressure condensate system generally be
provided with a bypass with glove valve and two block valves.
5.2.11 Traps which discharge to a low pressure condensate or discharge to the open air
will have no bypass.
5.2.12 Before each steam trap inlet, a free blow type drain valve shall be installed in
direction of flow.
5.2.13 Traps inside battery units shall generally discharge to a condensate return system
or sewer.
5.2.14 Traps outside battery limits shall discharge to a suitable location, such as a ditch,
flash pots or as defined on the P&I diagrams.
5.2.15 Steam traps discharging into a overhead condensate system or closed system
shall be provided with a check valve unless the steam trap acts as a nonreturn
valve.
5.2.16 Steam traps shall be protected by a Y type strainer installed before the trap or
a builtin strainer, independently of selfcontained strainer trap.
5.2.17 A steam trap shall be accessible for removing or maintenance.
5.2.18 Steam tracing shall be provided in accordance with Engineering Specification
Steam Tracing Piping Requirements, PDVSA HD201.
5.3 Requirements for Water and Air Systems

5.3.1 All process cooling water line shall be installed so that the equipment being cooled
will remain full of water in the event of shutdown of the cooling water pumps.
5.3.2 Shutoff valves in supply branches shall be located as close to the main header line
as possible.
PDVSA
REVISION FECHA

5.3.3 And instrument air piping system and a plant air system shall be provided as
shown on the P&I diagrams.
5.3.4 Air supply lines shall be provided with drip legs and blowdown connections.
5.4 Utility Outlets

5.4.1 Valved utility service outlets for steam, water and air (service stations, flush,
steamout, etc.) shall be provided where shown on utility flow diagrams and
drawings.
5.4.2 Areas to be served by the utility flow outlets shall be within reach of hose 15 meters
long.
5.4.3 The utility outlet connections shall be grouped together as much as possible in the
same sequence namely, air, steam, water, nitrogen. The size shall be 1 inch.
5.5 Drainage and Sewage Systems

5.5.1 Separate drainage and sewage systems shall be designed in accordance with
Engineering Specification Underground Piping for Drainage Systems Design
Requirements, PDVSA HE251.
5.6 Firewater Protection System

5.6.1 All firewater protection systems shall be designed in accordance with PDVSA
Manual de Ingeniera de Riesgos.
PDVSA
REVISION FECHA

APENDIX I
MINIMUM OVERHEAD CLEARANCES
ITEM MINIMUM CLEARAN-

CES*
ROADS, ACCESSWAY AND CRANEWAYS:
HEADROOM FOR PRIMARY ACCESS ROAD (WHERE 6400 mm (210)
MAJOR MAINTENANCE VEHICLES ARE EXPECTED
TO PASS)
PUMP MAINTENANCE ACCESSWAY HEADROOM 3650mm (120)
PROCESS AREA CRANEWAY HEADROOM 5335 mm (176)
PUMP MAINTENANCE ACCESSWAY HORIZONTAL 3050 mm (100)
CLEARANCE, NOT NECESSARILY IN A STRAIGHT
LINE
CLEARANCE FROM EDGE OF ROAD TO 1525 mm (50)
PLATFORMS, EQUIPMENT, PIPE, ETC.
NORMAL OVERHEAD, INSIDE BATTERY LIMIT 4880 mm (160)
PLANT ROADS, OUTSIDE BATTERY LIMIT, 6100 mm (200)
CLEARANCE
RAILROADS:
HEADROOM FROM TOP OF RAIL 6550 mm (216)
CLEARANCE FROM TRACK CENTERLINE TO 2590 mm (86)
OBSTRUCTION (ANY)
MAINTENANCE PASSAGEWAYS AND WALKWAYS:
HORIZONTAL CLEARANCE, NOT NECESSARILY IN A 915 mm (30)
STRAIGHT LINE
HEADROOM (EXCEPT FOR HANDWHEELS, WHICH 2290mm (76)
MAY BE 6 6 (1980 mm)
CLEARANCE UNDER PIPEWAY:
ACCESS FOR VEHICULAR EQUIPMENT 3650 mm (120)
ACCESS FOR PORTABLE SERVICE EQUIPMENT 3050 mm (100)
PIPE ON SLEEPERS:
CLEARANCE, BOTTOM OF PIPE TO FINISHED 305 mm (10)
GRADE, UNLESS OTHERWISE SPECIFIED IN
PROJECT SPECIFICATIONS
PDVSA
REVISION FECHA

ITEM MINIMUM CLEARAN-

CES*
EQUIPMENT:
MINIMUM MAINTENANCE SPACE REQUIRED 915 mm ( 30)
BETWEEN SHELLS OF EXCHANGERS OR OTHER
EQUIPMENT ARRANGED IN PAIRS
MINIMUM MAINTENANCE SPACE REQUIRED TO 305 mm (10)
STRUCTURAL MEMBER OR PIPE
FIRED EQUIPMENT: 3050 mm (100)
CLEARANCE FROM EDGE OF ROADS TO SHELL
PIPE (ABOVE GROUND):
CLEARANCE BETWEEN OUTSIDE DIAMETER OF 25 mm (01)
FLANGE AND OUTSIDE DIAMETER OF PIPE OR
INSULATION
CLEARANCE BETWEEN OUTSIDE DIAMETER OF 25 mm (01)
PIPE OR INSULATION AND STRUCTURAL MEMBER
CLEARANCE IS DEFINED AS THE CLEAR SPACE
BETWEEN EXTREME PROJECTIONS.
PDVSA
REVISION FECHA

APPENDIX II
BYPASS VALVES GLOBE
(Pipe Size In Inches)
GATE VALVE RATING AND BYPASS GLOBE VALVE SIZE

SIZE 150 300 400 600 900 CLASS
CLASS CLASS CLASS CLASS and Over
NONE NA
4 3/4
6 3/4 3/4
8 3/4 3/4
10 1 1
12 1 1 1
14 to 20 1 1 1
24 1 1 1
PDVSA
REVISION FECHA

Fig 1. TYPICAL SCHEMATIC PIPING AND VALVES ARRANGEMET

Suction Piping Discharge Piping
(Vertical) (Vertical)
Lateral (To Lateral (From

Parallel Pump) Parallel Pump)
Lateral Lateral
Alternate Location of Reducer Alternate Location of Incraser

See
Detail A
and Discharge Valve
Detail B Low Point Drain (Note 1)
Suction Valve for wzrmup
Spool of Reducer facilities PI Increaser, if required
Strainer (Note 2) Vent, Drain or Gage Connection

Vent, Drain, or Gage Connection
Pump
Flanges
PR Valve (Note 3)
Strainer (Note 2) Casing Vent, if especified
Alternate Location Alternate

for Reducer Discharge Piping
Alternate (Horizontal)
Discharge Piping
(Horizontal)
Reducer shall be
Drain eccentric and Pump Flange
installed as shown Casing Drain, if specified
Notes:
(1) A low point drain is not required if the check valve is drilled and a casing drain is provided.
(2) Temporary or Permanent Strainer. Alternative location for Permanent Strainer, as required, will be specified.
(3) PR Valve location, if required for pump casing or mechanical seal protection.
Suction Discharge Suction Discharge

WARMUP WARMUP
Top or
min. (Note 3) Side min.
FLOW Takeoff
distance RESTRICTOR distance
min. min. (Note 4)
distance distance
FLOW DRILLED FLOW

RESTRICTOR CHECK RESTRICTOR
(Note 2) VALVE (Note 2)
1 NPS BYPASS
BYPASS
Alternative
to DRILLED
CHECK VALVE
Notes:
DETAILS A & B: (1) Line flexibility shall be provided for thermal expansion between pump lines and warmup and bypass lines.
(2) Flow Restrictors sized to provided a flow of 3 to 5% of normal pump flow, but not less than 1/4 in. diam.
DETAIL B only: (1) Lines sized for a max, velocity of 6 ft/sec., but not less than 1 in. NPS
(2) Flow Restrictors sized to provide a flow as specified.
Acceptable Metric Equivalents
in. 1/2 NPS 3/4 NPS 1 NPS 1/4 diam. 6 ft/sec 0.1 lb/gal
mm 15 20 25 6.3 1:8 m/s 11.98 kg/m 3

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PDVSA

ENGINEERING DESIGN MANUAL

H251 PROCESS AND UTILITY PIPING DESIGN

1 DEC. 98 GENERAL REVISION 21 Y.K. A.A. J.E.R.

0 FEB.89 FOR APPROVAL 33 J.S. J.G. E.S.

REV. DATE DESCRIPTION PAG. REV. APPD. APPD.

E PDVSA, 1983 ESPECIALISTAS

PROCESS AND UTILITY PIPING 1 DEC. 98

PROCESS AND UTILITY PIPING 1 DEC. 98

PROCESS AND UTILITY PIPING 1 DEC. 98

a. Failure for excessive thermal expansion stress

PROCESS AND UTILITY PIPING 1 DEC. 98

Piping and structures shall be arranged to permit mobile lifting equipment to

2.4 Design Pressures and Temperatures

PROCESS AND UTILITY PIPING 1 DEC. 98

2.5 Corrosion Allowance

3.2 Material Specification Changes

PROCESS AND UTILITY PIPING 1 DEC. 98

3.4 Screwed Nipples

PROCESS AND UTILITY PIPING 1 DEC. 98

VALVE TYPE AND SIZE (NPD)

ASME Primary Gate or Globe Ball or Plug Firesafe Butterfly (3)

PROCESS AND UTILITY PIPING 1 DEC. 98

3.6 End Closures

4 GENERAL INSTALLATION REQUIREMENTS

PROCESS AND UTILITY PIPING 1 DEC. 98

4.2 Supports and Anchors

4.3 Joints and Connections

4.4 Branch Connections

PROCESS AND UTILITY PIPING 1 DEC. 98

b. The run piping wall thickness is less than schedule 40.

4.5 Valve Installations

PROCESS AND UTILITY PIPING 1 DEC. 98

4.6 Centrifugal Pump Piping Installations

PROCESS AND UTILITY PIPING 1 DEC. 98

pressuretemperature rating of not less than 3/4 the maximum discharge

PROCESS AND UTILITY PIPING 1 DEC. 98

a. If the pumping temperature exceeds 230 C (450 F).

LOW FLOW PROTECTION

PROCESS AND UTILITY PIPING 1 DEC. 98

4.7 Vents and Drains

PROCESS AND UTILITY PIPING 1 DEC. 98

5 REQUIREMENTS FOR INDIVIDUAL PIPING SYSTEMS

5.2 Requirements for Steam Systems

PROCESS AND UTILITY PIPING 1 DEC. 98

5.3 Requirements for Water and Air Systems

PROCESS AND UTILITY PIPING 1 DEC. 98

5.4 Utility Outlets

5.5 Drainage and Sewage Systems

5.6 Firewater Protection System

PROCESS AND UTILITY PIPING 1 DEC. 98

ITEM MINIMUM CLEARAN-

PROCESS AND UTILITY PIPING 1 DEC. 98

ITEM MINIMUM CLEARAN-

PROCESS AND UTILITY PIPING 1 DEC. 98

GATE VALVE RATING AND BYPASS GLOBE VALVE SIZE

PROCESS AND UTILITY PIPING 1 DEC. 98

Fig 1. TYPICAL SCHEMATIC PIPING AND VALVES ARRANGEMET

Lateral (To Lateral (From

Alternate Location of Reducer Alternate Location of Incraser

Strainer (Note 2) Vent, Drain or Gage Connection

Strainer (Note 2) Casing Vent, if especified

Alternate Location Alternate