Vertical clearances

The minimum elevation of the bottom of overhead piping shall be in accordance with
DEP 80.00.10.11-Gen.
The minimum elevation of the bottom of overhead obstructions shall be:
• 6.0 m (20 ft) over railways
• 6.0 m (20 ft) over main roads
NOTE: In some situations the lower side of the pipe supports or the supporting steel dictates the minimum
elevation of overhead piping
It is recommended to always have one route to each unit and to the expansion areas
without pipe rack crossings.

6.2.5 Piping/cabling
The minimum elevation of the bottom of overhead piping shall be:
• 4.0 m (13 ft) for crane access
• 4.0 m (13 ft) for truck access
• 2.7 m (9 ft) for fork-lift truck access
NOTE: In some situations the lower side of the pipe supports or the supporting steel dictates the minimum
elevation of overhead piping.

6.7.2 Maintenance space

General
For good maintenance access and for safety (escape) reasons the area under the plant
pipe rack shall not be obstructed. An open space of at least 4 m (13 ft) wide over the entire
length of the pipe rack, not obstructed by manifolds, ladders, equipment etc. and accessible
from the roads shall be left available.

Distance between Pipes

All requirement of the section 3.8 of DEP 31.38.01.11-Gen., Piping-general requirements has to be considered.
The minimum distance between pipes shall be followed in accordance with section 5.8 of
DEP 30.00.60.20-Gen. The minimum distance between a flange (with insulation) and a pipe
or the insulation of a pipe in pipe tracks and trenches and on pipe racks shall be 30 mm
(1.2 in). The minimum distance between a flange (without insulation) and a pipe or the
insulation of a pipe in pipe tracks and trenches and on pipe racks shall be 75 mm (3 in) for
tools access.

For minimum vertical clearances, see section 5.8 of DEP 30.00.60.20-Gen.

The minimum distance between a flange (with insulation) and a pipe or the insulation of a
pipe in pipe tracks and trenches and on pipe racks shall be 30 mm (1.2 in.). The minimum
distance between a flange (without insulation) and a pipe or the insulation of a pipe in pipe
tracks and trenches and on pipe racks shall be 75 mm (3 in.) for tools access. The
minimum distance between pipe flange (without insulation) and any equipment, columns or
building wall shall be at least 75 mm (3 in.). (See dimensions A or B in Figure 26).
Figure 26
 The distance between the insulation of a low-temperature pipe and any other object shall
be at least 100 mm (4 in.) to allow for ice build up.

The distance between pipes shall allow for the turning of a spectacle blind, if present.

For pipe flanges size DN300 (NPS 12) and above, a min. of 460 mm (18 in.) shall be
provided as standing room between flange and any obstruction such as equipment, guard
rail etc. (see dimension B in Figure 26) for locations such as battery limit platforms, or
where the flange joint is meant for operations (e.g., vessel isolation) or maintenance (e.g.,
removal of valves, etc.). Due consideration shall be given to cold weather conditions which
may lead to the requirement of additional clearances over and above the minimum vertical
clearance of 460 mm (18 in.).

There shall be a minimum vertical clearance of 230 mm (9 in.) between low point drains
closure flange and soil, grade or platform. Due consideration shall be given to extreme
snow and ice conditions which may lead to requirement of additional clearances over and
above the minimum vertical clearance of 230 mm (9 in.).

DEP 30.00.60.20-Gen.
5.9 FLANGE HEIGHT
The space between a flange on a vertical pipe / vessel nozzles that penetrates decking
shall be the length of the flange bolt plus 25 mm (1 in.) (See dimension A on Figure 27
below). The same space requirement applies to a flange on a pipe that penetrates the
ground or grating on an elevated work platform.
DEP 30.00.60.20-Gen.
3. WORKSPACE ENVELOPE - MINIMUM REQUIREMENTS
3.1 STANDING POSITION
3.1.1 Minimal working volume
As a minimum, adequate standing workspace shall be provided wherever an operator or
maintainer is required to work. The minimum dimensions of this space shall be as shown in
Figure 1 and Table 1.

Figure 1 Minimal working volume in a standing posture

Table 1 Minimal working volume dimensions in a standing posture

NOTE: There will be exceptions e.g. for the purpose of determining sizes of
muster areas or individual standing room at embarkation stations on
offshore/marine facilities. The width and depth dimension should be
reduced to 610 mm (24 in.). Designers are directed to their regional
HFE TA, for exceptions. These dimensions, furthermore, have been
corrected for various types of PPE (i.e. Cold Weather clothing and
SCBA).

3.1.2 Standing and control surfaces

Displays, indicating instruments, mimic panels and controls mounted vertically or on flat
vertical surfaces for use by standing operators shall be located as shown in Figure 2, and
accompanying Table 2.

Figure 2 Control mounting height for standing personnel

Table 2 Control mounting heights – standing

Maximum effective forward reach (i.e. ability to grasp and turn/push/pull forward) shall be
460 mm (18 in.) from the front of the operator’s body.

3.1.3 Standing and display surfaces

Displays, indicating instruments, and mimic panels mounted vertically or on flat vertical
surfaces for use by standing operators shall be located as shown in Figure 3, and
accompanying Table 3.
Figure 4.1 Mounting heights for hand-wheel operated valves with vertical stems
NOTES: 1. Distances or heights are measured to handwheel centreline. For gear-operated valves with a
handwheel provided with a spinner handle, maximum horizontal distance is measured to the edge
of the handwheel furthest from the operator.
2. Heights are to be to the maximum extension of valve stem for rising stem valves.
3. These dimensions are appropriate male and female personnel worldwide from 5th to 95th
percentile, except that the top limit for the “Preferred” choice location should be reduced by
100 mm (4 in) to accommodate male and female populations in regions such as West Africa,
Southeast Asia, Southern China, parts of Latin America, India and Japan.
4. For valves located below 455 mm (18 in), sufficient clearance of at least 910 mm (36 in.) should
be provided behind the operator to accommodate a squatting posture.
Figure 4.2 Mounting heights for handwheel operated valves with horizontal stems
NOTES: 1. Distances or heights are measured to handwheel centreline. For gear-operated valves with a
handwheel provided with a spinner handle, maximum horizontal distance is measured to the edge
of the handwheel furthest from the operator.
2. These dimensions are appropriate for personnel worldwide, from the 5th percentile of the female
population to the 95th percentile of the male population, except that the top limit should be set at
1755 mm (69 in) for 5th percentile males and 66 in (1675 mm) for 5th percentile females in regions
such as West Africa, Southeast Asia, Southern China, parts of Latin America, India and Japan.
3. For valves located below 455 mm (18 in), sufficient clearance of at least 910 mm (36 in.) should
be provided behind the operator to accommodate a squatting posture.
Figure 4.3 Mounting heights for lever-operated valves with vertical stems
NOTE: These dimensions are appropriate for personnel worldwide, from the 5th percentile of the female
population to the 95th percentile of the male population, except that the top limit should be reduced to
1145 mm (45 in) to accommodate 5th percentile females in regions such as West Africa, Southeast
Asia, Southern China, parts of Latin America, India and Japan.
Grade/deck
Figure 4.4 Mounting heights for lever-operated valves with horizontal stems
NOTE: These dimensions are drawn for North American males, and are therefore appropriate for other
regions such as Northern Europe, Australia, UK, and Central Europe. These dimensions should be
reduced to 1805 mm (71 in) for 5th percentile males in areas such as West Africa, Southeast Asia,
Southern China, parts of Latin America, India and Japan, and 1725 mm (68 in) for 5th percentile
females in West Africa, Southeast Asia, Southern China, parts of Latin America, India and Japan. To
accommodate the same international population of 5th percentile females, horizontal stem valves
should be located at least 1145 mm (45 in) above the standing surface, rather than 1300 mm (51 in)
as shown.
Valves oriented with the stem in a horizontal position are preferred when the lever is
located between 150 mm and 760 mm (6 in and 30 in), or more than 1300 mm (51 in)
above the deck as shown in Figure 4.4. However, the maximum height above the deck to
the valve tip should not exceed 1905 mm (75 in). The valve handle is not permitted to rotate
down from centreline if there is a walking surface directly underneath.

Valves in a vertical section of the pipe e.g., located in a manifold or at battery limit, shall be
oriented with all the stems on the same side as shown in Figures 4.5 and 4.6, with a 75 mm
(3 in) clearance maintained between the lever and any obstruction.
Figure 4.6 Manifold or battery limit valves with 75 mm (3 in) minimum gap between
front face of lever’s outer surface and nearest flange/obstruction
NOTE: DEP 31.38.01.11-Gen., Section 3.8 requires that valves and flanges shall be staggered
whenever possible to ease operation and reduce space. This is acceptable as long as the
minimum clearance is maintained and valve heights comply with requirements of Table 4.2.

4.3.3.3 Valves operated from vertical ladders

Category 1 (C-1) valves shall not be located so that they have to be operated from a ladder
(caged or uncaged)
Other valves should not be located so that they have to be operated from a ladder, but if
this is unavoidable the following requirements shall apply:
• The handwheel or lever shall be located between 150 mm (6 in) and 610 mm
(24 in) from the edge of the ladder stringer in order to open and close the valves,
as shown in Figures 4.7 and 4.8;
• Valve location, orientation, and actuator type shall be selected to enable opening
or closing with one-hand only.
4.3.4 Valve maintenance considerations
4.3.4.1 Access
The minimum distance between valve flanges and any obstruction shall be the bolt length
plus 25 mm (1 in) to allow access for hand tools and torquing of bolts.
Where standing room is required for maintenance access to valve flanges, the clearance
between a flange and a wall, structural steel, or guardrail shall not be less than 460 mm
(18 in).
Piping Design Philosophy
11.1. Accessibility requirement in front or behind valves for operation / maintenance

A. For flange assembly the following piping components are considered as critical, as they are subject to
wear, failure, and removal/repair for maintenance/inspection:
- Control valves
- Actuated valves
- Spool pieces, spacers, spectacle blinds
- Suction strainers
- Basket filters
- On line flow meters
Two main cases should be considered:
1. For flanges with an overall external diameter below 500 mm (around 12” diameter pipe):
- 900 mm in front of the assembly (allow 1 man to stand and to work).
- 460 mm behind the valve (allow 1 man standing in front to access the back of the flange with tools and hands
for bolting/unbolting operation).
2. For flanges with an overall external diameter equal or greater than 500 mm (around 12” diameter pipe):
- 1300 mm in front of the assembly (allow 1 man to stand, squat and work).
- 900 mm behind the valve (allow 1 man standing and working at the back of the flange with his tools)

B. For all other cases (eg. manual valve) not listed above:
- 750 mm in front of the assembly (allow 1 man to stand and to work)
- 75mm behind valve for flanges with an overall external diameter less than 500 mm (around less than 12"
diameter pipe).
- 460 mm behind the valve for flanges with an overall external diameter equal or greater than 500 mm
(around 12” diameter pipe)
(To allow 1 man standing in front to access the back of the flange with tools and hands for
bolting/unbolting operation)

C. For all cases, a minimum of 300 mm has to be considered below the assembly.
DEP 30.00.60.20-Gen.
4.2 WEIGHTS AND LIFTING
The maximum weight to be lifted by one person using two hands, with the load close to the
body, shall be 23 kg (50 lbs).

The maximum weight to be lifted by a two-person lift shall be 46 kg (100 lbs).

All requirement of the section 3.9 of DEP 31.38.01.11-Gen., Piping-general requirements has to be considered.
3.9 SMALL BORE PIPING
Branches (including direct mounted instrument connections) to run pipes shall not be
smaller than the sizes as shown below.

Piping Design philosophy

8.15. Instrument Piping
8.15.1. General
In all high sour service piping, tapping size < DN 2” shall be avoided considering that they are more susceptible for failure.
all tapings for temperature and pressure shall be of DN 2”. All tapings for drain & vent shall be of DN 2” and above.

8.15.2. Flow Instruments

8.15.2. Flow Instruments
Straight length and installation requirements for various types of flow meters shall be in accordance with DEP 32.31.00.32-Gen Section 4
The installation requirements of pressure differential devices such as orifice plates and Venturi tubes shall be in accordance with ISO 516
For other types of flow measurement the Manufacturer's guidelines with regard to installation, commissioning and maintenance requireme

Refer cl.3.17 of DEP 31.38.01.11 for installation and orientation of tapping on orifice plate flanges for various services.

Following table is used during FEED stage. After receiving the manufacturer’s guideline during DD stage requirements shall be

8.15.3. Temperature Instruments

The minimum line size for installing temperature instrument is NPS 6. Temperature instrument
sizes for the sour service shall be minimum NPS 2 and for other services shall be as per standard piping classes.

No striaght length required for coriolis mass flow meters

o be considered.

ore susceptible for failure. Hence,

of DN 2” and above.

P 32.31.00.32-Gen Section 4.0.

e in accordance with ISO 5167-1.
g and maintenance requirements shall be followed carefully.

tage requirements shall be rechecked.

piping classes.
DEP 30.00.60.20-Gen
5.3 AIR COOLERS (FIN FANS)
The drive assembly access platform on exchanger banks, mounted on a pipe rack, shall
have an extension platform that permits lifting the motor with a crane. Maximum travel
distance of the motor to the lift point shall be 33 m (108 ft.). Platform extensions shall be
level.
DEP 30.00.60.20-Gen
5.2 ROTATING EQUIPMENT
The minimum clearance between pumps or pumps and piping shall at least be 1.2 m (48 in.) for small
pumps (< 18 kW) and 1.5 to 2 m (60 in. – 80 in.) for larger pumps (taking base plates, valve
hand wheels, pipelines, etc. into account).

Piping Design Philosophy

Removable spools shall be provided at each pump nozzle to permit disassembly of pumps without
disturbing the main runs of the suction and discharge lines.

DEP 31.38.01.11-Gen.
4.2.2.7 Suction piping of centrifugal pumps
Suction piping shall be as short and as direct as possible, avoiding high spots where
pockets of gas or air could accumulate. Only eccentric reducers (top flat) may be used for
pipe diameter changes in horizontal pipes. For slurry services, eccentric reducer (bottom
flat) shall be used for pipe diameter changes in horizontal pipes to avoid accumulation of
solids. For horizontal suction pipes, a drain shall be provided upstream of the reducer. In
vertical pipes, eccentric or concentric reducers may be used.

The length of the straight pipe from the last elbow to the suction nozzle shall be sufficient to
ensure minimum turbulence at the pump suction. The minimum length, which shall not
include any reducer, strainer or stop-flow valve, shall be as indicated in Table 5:
Piping Design Philosophy

Removable spools shall be provided at each compressor to permit disassembly of equipment without
disturbing the main runs of the suction and discharge lines. It should be ensured that the removable
spool clears the edge of the compressor to allow removal of the compressor.
KHF-00-PDFEED-MP-7180-00005-0000/04
8.0 EQUIPMENT LAYOUT & SEPARATION CRITERIA
·         Platform shall be provided in front of each heat exchanger where applicable, for
enabling installation of bundle pulling tool. Minimum length of platform shall meet
bundle length + 2 meter (for pulling device and command) + 1 meter (normal access
and maintenance). Platform shall be capable of carrying the weight of the bundle and
bundle pulling tool.
 Spiral stairs permitted only on tanks or other round structures whose diameter is greater than 2440
mm (96 in.), and where a normal stair design is inappropriate. For tank height more than 6 meters,
spiral staircase shall be provided, otherwise for tanks height 6 meter and below cage ladder to be
provided or as specified in mechanical data sheet.

 Two way stairs requiring stretcher access shall be considered in this project.
For access to tank roofs, spiral staircase shall be provided. Stair entry to the roof (landing) shall be located on
the upwind side of the prevailing wind direction. The spiral stair should ascend in clockwise direction to allow
the stair handrail to be on the right-hand side during descent.

Handrails shall be provided at the edge of the roof for the full circumference of all fixed roof tanks. Handrail is
to be provided to the center of the roof on all tanks exceeding 12.5m diameter if access is needed for nozzle
and associated valves etc.
Walkways and their steps higher than 1.5m above grade shall be provided with handrails on both sides

KHF-00-104133-MS-7771-00003-0000 / Rev 03
Specification of API Storage Tanks
4.1.4 Tanks less than 4500 mm inside diameter may be fabricated in shop and higher sizes
shall be site fabricated. Shop fabricated tank shall be provided with lifting lugs.
4.1.7 For tanks less than 4500 mm inside diameter, roof structure (rafter) construction is not
required and self-supported roof plate shall be considered in the design. If external
rafter is used in roof structure construction, shell standard drawing S 51.157-001 shall
be referred. For self-supported (no rafter) roof construction, the roof angle of 12 to 15
degree shall be considered, whereas for rafter supported roof, a slope of 1:6 shall be
considered in the design.
4.1.8 For tanks less than 4500 mm inside diameter, butt welded construction for bottom
plate may be considered, with back chip, MT examined and re-weld from other side
and the weld shall be ground flushed / smoothened to facilitate proper internal lining /
coating and avoid any damage to the lining. 100% Radiography shall be carried out for
the butt welded bottom plate joint, similar to those for radial joint of bottom annular
plate. For tanks with inside diameter of 4500 mm and more, lap welded bottom plate
construction shall be followed. Root MT and final MT shall be carried out for lap joints.
4.1.20 For tanks up-to and including 30 m in diameter, minimum two earthing bosses are
required. For tanks above 30m in diameter, minimum three earthing bosses are
required. The earthing bosses shall be in accordance with the drawings STD-4-0317-
001 and STD-4-0304-0001.

4.1.31 PVV's and blow off hatches shall be located very close to roof periphery.
4.1.33 Vacuum/Vent Nozzles are to be sited as near as possible to the blanket connection in
line with API 2000.
4.1.34 For Tank height more than 6 meters, spiral staircase shall be provided, otherwise for
tanks height 6 meter and below cage ladder to be provided or as specified in data
sheet.
drawing S 51.051. Cleats for handrail shall be taken from the tank top (preferably from
top curb angle). VENDOR shall also provide walkway / platform with handrails to
access Blow-off hatch, PVV and other nozzles / manways.
be located on
ction to allow

ks. Handrail is
ed for nozzle
Piping Design philosophy
8.16. Weld Proximity
For Shop and Field fabrication of piping refer DEP 31.38.01.31-Gen. and COMPANY specification
SP-1173 -Specification for Welding of On-plot Pipe work.

The toes of adjacent circumferential welds shall be separated by a minimum distance equal to the
nominal outside diameter of the pipe. Where this requirement cannot be met, the minimum distance
between the toes of adjacent circumferential welds shall not be less than five times the nominal wall
thickness or 50mm whichever is greater.

For circumferential welds on longitudinal welded pipes, the longitudinal welds shall be so positioned that:
·         The weld is at the upper segment of 120° of the pipe
·         Any two adjacent longitudinal welds shall be at least 45° apart or 200mm apart, whichever is less.

When it is not possible to meet the above separation requirements between two longitudinal welded joints,
the minimum separation shall be the greater of five times the nominal wall thickness or 50 mm provided
that the weld joint is fully radio-graphed and meets the acceptance criteria of SP-1173.

Minimum spool requirement for bolt removal

When the valve with or without spectacle blind/spacer is installed to a flange which is directly welded to
an elbow or a tee, ensure that the space between OD of the elbow/tee to the flange shall be more than
the length of the stud bolt so that bolts can be removed from the flange without obstruction of tee/elbow.
Refer the table below:
DEP 31.38.01.11-Gen
8.7.3.2 Ergonomic aspects
Spectacle blinds and spades shall be located so that they are accessible from ground level
or from platforms or walkways. The need for scaffolding shall be minimised.

For easier handling, spading points should not be installed in vertical piping; if this is
unavoidable, special precautions shall be taken to improve access and handling.

Turning a spectacle blind requires all bolts except two to be removed and a small opening
to be made between the flanges. A relatively large force is required to turn a large
spectacle blind. A spectacle blind cannot easily be turned using a crane or a hoisting
device, and therefore the need for cranes and hoisting facilities shall be avoided. Personnel
should not pull or lift loads exceeding 25 kg (56 lbm). If the required force to turn spectacle
blinds exceeds 25 kg (56 lbm), spades with spacers should be used instead.

Spectacle blinds requiring a force of more than 25 kg (56 lbm) are tabulated below.

Spacers and spades exceeding a weight of 25 kg (56 lbm) should be provided with a lifting
lug. A mobile crane or, if this is not possible, special hoisting facilities should be used for
handling such items.

Spades having a weight of more than 25 kg (56 lbm) are tabulated below.

DEP 31.38.01.11-Gen.
If spectacle blinds in horizontal pipes are insulated, the spectacle blind should point
downwards at an angle of 45° to avoid water leaking into the insulation (see
DEP 30.46.00.31-Gen.).

Piping Design Philosophy

Spacer/spade shall not be installed together with actuated valve. Lifting of items during operation &
maintenance is not achievable and hence, in such cases, interchanging the location of actuated valve and
manual valve is to be considered. These can also be located by providing additional flange joint outside the
limits of actuator as a secondary option.

However, spectacle blind can be installed together with actuated valve in downward orientation provided the
clearance between the center line of pipe and top of grade/platform is above the values indicated in the below
table.
DEP 31.38.01.29-Gen.
3.7 NON-INSULATED PIPES
In other cases, non-insulated pipes should rest directly on the supporting steel, except for
the following which should be supported on pipe shoes to avoid damaging the pipe wall:
a. Pipes with sizes larger than DN 600 (NPS 24);
b. Carbon steel pipes with a wall thickness less than schedule 20;
c. Stainless steel pipes with a wall thickness less than schedule 10S;
d. the pipe requires a slope;
NOTE: This is only for small slope corrections. The height of pipe shoes measured from the
underside of the pipe shall be maximum 400 mm (16 in).
DEP 31.38.01.11-Gen
8.7.3.2 Ergonomic aspects
A removable spool and blind flanges shall be used in the following situations:
a) where the nozzle is used for entry into the equipment;
b) where the nozzle is used for hoisting purposes (e.g. top nozzles on columns);
c) where the nozzle (e.g. the head of a heat exchanger) is used to remove internals
(e.g. the tube bundle);
d) where the nozzle is used for loading/unloading of solids (e.g. catalyst).
DEP 31.38.01.29-Gen.
3.7 NON-INSULATED PIPES
Non-insulated pipes shall be supported on main pipe rack beams with a 20 mm (3/4 in)
diameter round bar welded on top to avoid corrosion developing on the pipe along the
entire width of the construction member, or shall be supported on pipe shoes to avoid
damaging the pipe wall.

DEP 31.38.01.11-Gen.
b) Nominal pipe size in pipe tracks shall not be less than DN 50 (NPS 2);
c) Nominal pipe size in pipe racks shall not be less than DN 40 (NPS 1 ½);

DEP 31.38.01.11-Gen.
In a pipe rack, piping arrangements shall be implemented in accordance with
DEP 80.00.10.11-Gen. In addition, following shall beconsidered:
a) The cryogenic pipe should be located at the sides of the pipe rack to provide space
for expansion loops and to reduce the moments in the beams caused by the weight
and thermal expansion loads from the pipe.
b) The cryogenic pipes should be grouped separately and located on different pipe rack
tiers.
c) Complicated crossings should be avoided, e.g. by not installing pipe rack spurs
opposite each other.

DEP 80.00.10.11-Gen.
4.7 EXPANSION
During initial layout it is advisable to typically oversize (30 %) the capacity of instrument,
electrical, pipe racks/tracks and trenches to avoid expanding of these facilities during the
detailed design phase when more detailed information becomes available and plot area
may not be available anymore.

6.7.2 Maintenance space

For good maintenance access and for safety (escape) reasons the area under the plant
pipe rack shall not be obstructed. An open space of at least 4 m (13 ft) wide over the entire
length of the pipe rack, not obstructed by manifolds, ladders, equipment etc. and accessible
from the roads shall be left available.

6.11 PIPE RACKS

Following guidelines should be followed for pipe rack design:
a) It is common practice to locate process lines on lower level tiers. Process lines can
however also be located on higher level tiers if process requires (e.g. no
pocket/gravity flow) or for to achieve more optimum piping based on location of
connected equipment/lines.
b) Utility lines should be located on higher level tiers.
d) Heavy lines (large diameter lines or large lines full of liquid) are to be located on the
edge of the piperack.
e) Hot lines and cryogenic lines should be separated as much as possible.
f) The width of the pipe rack and the number of pipe rack tiers should be based on
the available space in the plot, the number of lines and civil/structural
considerations. In case the pipe rack width is beyond the economical width (from a
structural point of view), the number of pipe rack tiers can be increased to
accommodate all lines. For comparatively smaller piping, the option of providing
cantilever extension (generally up to 1.2 m [4 ft] wide) can be cost effective
g) Hot lines should be routed near the edge of the pipe rack to provide space for
expansion loops.
DEP 31.38.01.11-Gen.
8.5 BRANCH FITTINGS
Usage of “lateral welded-in contour insert” may be considered for oblique connections (at
an angle different from 90° but larger than or equal to 45°).
Piping Design Philosophy
11.2. Primary and Secondary Access & Egress to elevated platforms
A. Stairways shall be provided for access to and egress from elevated work platforms, walkways and other
elevated work areas where the frequency of use is once per shift or more.
B. If access requirement is less than once per shift, then stairways shall be provided where:
·         Access is required to Category 1 valves,
·         All battery limit valves and associated blinds, vents and drains
C. The above excludes stand-alone vessels or columns/towers not located in supporting structures.
D. For all other cases not listed above, ladder is acceptable for access and egress.
E. Wherever requirement of staircase is established, the number of staircase shall be based on the below
criteria:
·         If the platform length is less than 7 meter and area is less than 20m² then only one stair access for
primary means of access.
·         If the platform length is greater than 7 m and less than 25m OR area is greater than 20m² then only one
stair access is required as primary means of access and ladder as secondary means of escape.
·         If the platform length is > 25 m and less than or equal to 50 m then 2 stairicase as primary means of
escape
·         If the platform length > 50 m then a stairicase as primary means of escape within 25 m walking distance.
F. Wherever ladders are acceptable, the required number of ladder shall be based on the below criteria:
·         If the platform length is less than 7 meter and area is less than 20m² then only one ladder access for
means of access/ egress.
·         If the platform length is greater than 7 m and less than 50m OR area is greater than 20m² then two
ladders are required as means of access/ egress.
·         If the platform length > 50 m then ladder is required as access/ egress within 25 m walking distance.
G. The length of the dead-end platform shall not exceed 7m.

13. Stairways and Ladders

·         Side step ladders are to be provided.
·         Vertical distance between landings shall not exceed 9m when ladders are used. Multiple stage ladders shall be
staggered at least every 6 m.

Civil & Structural Design Philosophy

13.10 Structural Steel Works
Minimum width for access platform, walkways and stairs shall be 750mm and minimum head clearance 2100mm.
Maximum slope and riser for access stair shall be restricted to 40 degrees and 200mm.
Piping Design Philosophy
12. Platforms
Permanent platforms shall typically be provided where items are not accessible from the surrounding facilities.
The requirement of Permanent platforms shall be based on following minimum requirements:
· Access to equipment inspection or service opening, such as manholes
· Access to control valves, relief valves, strainers and level controls
· Operating level above 4m height from grade or more
· All elevated Category-1 valves as classified in Valve Criticality Analysis Report Doc no. KHF-00-
104133-HX-6854-00002-0000, all battery limit valves and associated blinds, Vents & Drains.
· All elevated sample connections
· Valves located on tower top
· Where access deteriorates due to weather conditions or maintenance activities
· Any elevated equipment where the tasks being undertaken require the use of both hands viz. valve
hand wheels greater than 120 mm (5 in.) are considered to be a two-handed operation.
· Level instruments, In-line/field instruments as per Appendix – 3 of DEP 32.31.00.32 – Gen.
· Permanent access platform for Line of sight H2S (LOS) detectors shall be provided if detector
retractable mechanism is not provided.

DEP 31.38.01.11-Gen.
3.3.1.3 Platforms
·         The length of a dead-end platform shall not exceed 7 m (23 ft).
DEP 31.38.01.11-Gen.
3.3.1.2 Horizontal clearances
Around manholes, a minimum of 760 mm (30 in) on each side of the manhole and a
minimum of 1220 mm (48 in) directly in front of the manhole shall be provided clear of
obstruction to allow for entry and exit.

DEP 80.00.10.11-Gen.
7.7.17 Manholes
For sizes of manholes see DEP 31.22.10.32-Gen.
Manholes should be facing towards an access road to allow reach by a mobile crane.
Manholes should be provided with a davit. Adequate clearance must be left for the swing of
the manhole cover on its davit. Piping shall not obstruct entrance to the manhole.
An access platform is required if the manhole centre is higher than 4 m (13 ft) above grade.
Up to 4 m (13 ft) scaffolding can be used. Platforms may also be used at lower elevations if
the frequency of using the manhole justifies this.

Piping Design Philosophy

9.3. Vessel and column Piping
For columns and vessels preferred manway centerline elevation from platform range is 600mm to 1100mm.
As per mail confirmation from Elango 27/5/2016

From: Elango R
Sent: Friday, May 27, 2016 6:22 PM
To: Saravanan G; K, Pranesh
Cc: Vijayakumar M; Sathiyakumar B; Viswanath G; N, Siddhartha; Nicholson L
Subject: RE: Reg. Column Manway Elevation from platform

Refer the  enclosed mail on Man hole elevation  sent to PDO.

Recommended man hole elevation range is discussed and finalized  to maintain 600 mm to 1100 mm .
DEP 31.38.30.11-Gen.
3.2 JACKETED PIPING
For typical details see (Appendix 3).
Recommended sizes are given in Table 4.Jacketed piping is applied for situations where
the heat input of (steam) tracing is not sufficient or where even small cold spots may cause
solidification of the product. The heating medium should be saturated low pressure (LP)
steam, medium pressure (MP) steam, or heat transfer fluid.
The process lines are in the centre of larger diameter steam lines. This is applied for
services which require a high heat input. Steam pressures up to 20 barg (300 psig) may be
considered.
The wall thickness of the inner pipe shall be designed to withstand the external pressure
exerted by the steam in the outer pipe. Differences in expansion shall be checked during
detailed design (for reference see ASME B31.3, 301.7.3, PD 5500, ASME Section VIII,
Div.1, Mandatory Appendix 9).
The inner and outer pipe shall be of the same grade of material.
Butt welds of the pipe within the jacket should be avoided. Otherwise these welds shall be
inspected and tested in accordance with DEP 31.38.01.31-Gen.
For consistency, jacketed lines shall also be identified in the Contractor's specification for
piping systems.
Generally, there are three methods of jacketing:
• fully jacketed from flange to flange, having jacketed valves;
• partly jacketed, having traced valves;
• hybrid systems, partially jacketed having standard valves and bolt-on jackets.
The use of fully jacketed lines shall be restricted to a minimum for economic reasons and
because of the bulky configuration. Fully jacketed lines are used when it is critical to
maintain the process fluid within a narrow temperature range. Fully jacketed lines are used
for very waxy process fluids, liquid sulphur lines, when rapid scaling (even on
valves/flanges) can be expected, and for slurry lines in polymerisation units, etc. The inner
pipe (process line) shall have oversize (reducing type) flanges, allowing the jacket to run
from flange to flange. The valves shall also be jacketed and have flanges of a size
corresponding to the jacket size. Fully jacketed systems shall only be applied when other
systems are not able to give the required heat input because of economic reasons and the
availability of the jacketed valves.
Partially jacketed lines should be used when there is still a high heat input demand but it is
less critical to maintain the process fluid within a narrow temperature range. Typical
applications are viscous slurry suction lines, drain collecting lines in trenches, etc. The
jacket shall be swaged to the inner pipe (process line) as close as possible to the process
line flanges. The valves are traced and are the same size as the process line flanges.
Hybrid jacketing combines advantages of partly and of fully jacketed systems. Bolt on
jackets are applied in positions where conventional jacketing would be expensive or difficult
to construct. Bolt on jacketing is commercially available for the application on valves,
elbows, tees, flanges etc., is capable to give a high and constant heat input.
The inner pipe and the outer pipe shall be of the same material or have the similar
coefficients of expansion.
For jacketed piping, detailed piping stress analysis (thermal and mechanical analysis) shall
be conducted to qualify the design.
Jacketed piping shall be designed such that a uniform temperature throughout the system
is obtained. Cold spots e.g. at flanges or valves, shall be avoided because they may cause
solidification of the product.
The annular space between the process and jacket pipes shall be maintained by spacers
size 6 mm x 75 mm (½ in x 3 in), welded to the inner pipe at maximum 3 m (10 ft) intervals.
The height of the spacer shall be such that the clearance between spacer and jacket pipe
inner is 1.5 mm (1/16 in). Jacketed pipe spools shall have a maximum length of 6 m (20 ft).
Each jacketed pipe spool shall have three nozzles supplied with welding neck flanges on
the jacket. At one side there shall be a nozzle for steam / heating fluid supply; at the other
side, there shall be one nozzle for condensate discharge (not required for liquid heating
fluid) and one nozzle for jump-over.
The steam inlet nozzle and the jump-over nozzle shall be located in line (on top if a
horizontal line); the condensate discharge nozzle shall be located opposite the jump-over
nozzle (at the bottom if a horizontal line).
If using heating liquid, the inlet nozzle and the jump over nozzle shall be located on
opposite ends and on opposite sides to one another. If the line is horizontal, the inlet nozzle
shall be located on the bottom. The jump over nozzle will therefore be on the top, at the
opposite end.
The nozzles shall be located as close as possible to the flanged spool ends.
The steam inlet nozzle shall have a 3 mm (1/8 in) thick wear (impingement) plate welded to
the inner pipe.
Steam shall be fed to the steam inlet nozzle of the jacket. Each pipe spool shall have its
own steam trap. The steam flow shall continue via the jump-over nozzle to the steam inlet
nozzle of the next spool, and so on. This is referred to as a "jacket circuit".
Each circuit shall have its own fresh steam supply. The requirements for the steam supply
and condensate return are similar to those for the tracing system, see (2.4).
The maximum length of a jacket circuit depends on the pressure drop and heat loss in the
steam system.
Although typical steam jacketed systems are normally relatively short, some steam jacketed
systems perform satisfactorily with circuits longer than 1 km (0.6 mi). Such long circuits
require temperature alarm instruments.
Test pressures and conditions for jacketed spools shall be determined, and stated on the
relevant documents (e.g. isometrics).
The steam condensate and jump-over piping shall be routed so that minimum forces will be
transferred to the nozzles.
 Section 2.1.4 ISOLATION VALVE OPERATION CONTROL

Piping Design Philosophy

8.9. Relief and Blow down System
Relief and blow down lines shall be sloped as per PEFS and pockets shall be avoided. Balanced bellows type
relief valves bonnet shall be provided with 2” flanged vent connection. Bonnet shall be designed to withstand
external piping load and bending moment due to pipe weight.

Atmospheric relief of process fluids or hazardous substances in the process plant is not permitted.

In case of non-hazardous services safety relief valve discharging to atmosphere vertically, the exhaust pipe
shall terminate at least 3.0 m above any service platform within a horizontal radius of 15.0 m and 30.0 m
horizontally away from any source of ignition for hydrocarbon discharge. A 13 mm weep hole shall be provided
for drainage at the low point of the tail pipe.

Pressure relief system layout shall be in accordance with DEP 80.45.10.10-Gen.

 DEP 80.45.10.10

Isolation gate valves in the relief

system SHALL [PS] have their stems in
the horizontalposition.

d pockets shall be avoided. Balanced bellows type

t connection. Bonnet shall be designed to withstand

ces in the process plant is not permitted.

harging to atmosphere vertically, the exhaust pipe

within a horizontal radius of 15.0 m and 30.0 m
arbon discharge. A 13 mm weep hole shall be provided

DEP 80.45.10.10-Gen.
Piping Design Philosophy
8.19. Instrument Piping
8.19.1. General
Globe control valves shall be installed with their diaphragm actuator stem in vertical position, with sufficient
clearance above the actuator and under the bottom flange to allow the control valve to be dismantled without
removing the valve body from the pipe. Minimum valve rating for Control valves shall be 300#.
Supports on piping with in-line instruments (control valve, safety relief valve etc) shall be located so that the assembly is
self-supporting when the instrument is removed, if required, for maintenance.
ith sufficient
antled without

ed so that the assembly is

8.8.3.6 Check valves
Piston/ball type check valves shall be used in horizontal pipes only. The
piston/ball type is normally used in sizes DN 15 (NPS ½) up/to incl. DN 50 (NPS 2). These
valves are more reliable when installed in horizontal piping, this minimises the chance of
the valve sticking open, since there is minimal piston friction

Swing type check valves contain a disc that is hinged at the top. Swing type check valves
may be used in horizontal pipes, and in vertical pipes when the flow is upwards. The swing
type is normally used in sizes DN 80 (NPS 3) and above.
DEP 31.38.01.11-Gen.
5.9 UTILITY HOSE STATIONS
The utilities required shall be specified by the Principal. Where utility hose stations are
specified they should be located so that all points of use in the area can be reached by
15 m (50 ft) long hoses. Each type of utility medium SHALL [PS] be provided with a
dedicated type of hose connection to prevent contamination and inadvertent connection to Each type of utility medium requirement for elevated strucutres and platforms shall be evaluated on case by case basis
the wrong utility medium. In the interest of safety and convenience utility hose station
connection points shall point downwards.
Utility hose stations with nitrogen connections shall have a check valve at each header
connection and at each utility hose station to prevent backflow of air or hydrocarbons.
Utility pipes to the manifolds shall branch off from supply headers which cannot contain
contamination, e.g. due to leaking heat exchangers, etc.

Utility station arrangement shall be in accordance with Principal standard arrangement

drawings. Utility stations should preferably provided at the following locations:

a) Pump and compressor areas shall have permanent utility stations as follows:
o Stations shall have steam, water, air, and nitrogen (if required) outlets.
o A block valve shall be provided at the coupling of each utility line.

b) Column and vessels shall have steam, water, air, and nitrogen, as required, piped to
all platforms. Block valves shall be provided at the origin of supply headers. Steam
and water lines shall have drains at low points.

c) Exchangers and furnaces shall be provided with steam, water, air, and nitrogen
connections as required.

d) Tool air, breathing air and nitrogen outlet connections shall have dedicated hoses
and fittings in order to prevent cross connection.

e) Utility station outlet connections shall have identification marking.

DEP 31.38.01.11-Gen.
3.14 CONNECTIONS FOR MANUAL SAMPLING
This section specifies requirements for manual sampling, not for on-line process stream
analyser connections (for the latter, see DEP 32.31.50.10-Gen.).

Dedicated connections shall be provided for sample collection.

The sampling point shall be positioned so that the valves are easy to operate and taking the
sample will not impair the safety of personnel or plant or cause environmental impact.

The sample shall be maintained in a single phase. The sample take-off shall be at a point
where the gas is at least 10 °C (18 °F) above dew point or the liquid is at least 10 °C
(18 °F) below the bubble point.

Samples should be taken from a vertical pipe where possible; where this is not possible:
a) For gaseous products in horizontal pipes, sample take-off connections shall be
installed at the top of the pipe.
b) For liquid products in horizontal pipes, sample take-off connections shall be
installed at the side of the pipe.

Sample take-off connections shall not be located at dead ends of piping. The length of the
sample piping system shall be kept as short as possible to minimize purging.

For liquid sampling, the sample point should be placed in the 4 o'clock position and shall be
positioned no further than the 5 o'clock position.

Sample take-off connections shall be easily accessible and should be at ground level.
However, sample pipes shall be as short as possible and not longer than 8 m (26 ft). As far
as practicable, sample connections shall be grouped together and provided each with a
sample cabinet which can be connected to one common drain facility.

Drain facilities shall be connected to a sample recovery system wherever possible.

Sample points shall have two valves: one at the take-off point from the process pipe and
another at the sampling point. The block valve at the take-off point shall have the same size
as a standard drain valve. The sampling valve size shall be maximum DN 15 (NPS ½) and
shall have good throttling properties. If a short sample take-off pipe cannot be fitted, a
closed loop shall be provided. The closed loop shall be a connection to the same process
stream, at different pressure. The loop shall be provided with block valves at the
connections with the process pipe.

Precautions shall be taken to avoid freezing or plugging of the sample pipe, e.g. for highpour-
point or viscous fluids.

The outlet of a single sample connection, if not connected to a sample cabinet, shall either
have a male thread and be closed with a threaded cap, or it shall have a quick-fit coupling
which seals when not connected to a sample receiver.

Sample outlets for fluids above their auto-ignition temperature, for LPG and for very toxic
products SHALL [PS] have a self-closing downstream valve. If the effluent could flash and
create sub-zero temperatures, the distance between the two valves SHALL [PS] be at least
0.6 m (24 in).

Connections for hot samples (i.e. 80 °C or above) shall be provided with a permanently
installed sample cooler. The PEFS shall indicate where a cooler is required.

If bleed lines are installed, they shall be led to a safe location.

For ergonomic aspects of piping systems associated sampling systems, see section 5.12 of
DEP 30.00.60.20-Gen.
DEP 30.00.60.20-Gen.
5.12 MANUAL SAMPLE POINT LOCATION
Manual sample points shall be close coupled to the process and should be located such
that they are accessible from grade. If impractical, permanent access by stair may be
acceptable.
Sample cabinets, when used, shall shield the operator from contact with the material being
sampled. A 25 mm (1 in.) hole at the top of the cabinet door with plug shall be provided to
allow the interior air to be gas tested prior to opening cabinet door. The cabinet door shall
be provided with view panel to see sample bottles/bombs being filled. The see-through
panel should be a plexi-glass type material.
The sample cabinet shall be labelled and capable of being opened without requiring any
tools or the removal of any securing fasteners or other devices.
Top of sampling cabinet shall be no higher than 1900 mm (74 in.) and the bottom no lower
than 760 mm (30 in.).
Sample cabinets shall be heated where appropriate depending on ambient environmental
conditions (cold weather).
Volatile and/or toxic substances shall be prevented from escaping into the local atmosphere
by a venturi device and vented to a safe location.
All connections for gas bombs shall be located inside the cabinet. Connections for liquid
lines may be located outside the cabinet but must be close coupled in climates subject to
freezing.
The last sampling valve at the sampling point shall be located outside the cabinet but such
that the operator can visually observe the sample being collected.
The minimum standing worker envelope shall be provided around sampling points to allow
operator to perform sampling tasks while using appropriate personal protective equipment
such as gloves and respirators.
The sample bottles and bombs shall be properly secured in place when located inside a
cabinet during sampling. Lighting should be provided inside the cabinet and a minimum
clearance of 50 mm. (2 in.) shall be provided around the circumference of the sampling
bomb when connected to allow adequate room to grip the bomb while wearing gloves.
DEP 31.38.01.11-Gen.
Drip leg

Piping in steam service shall be arranged such that steam condensate accumulation is
avoided.

Stagnant and reverse-flow conditions should be avoided in steam distribution systems.

All steam pipes shall have drip leg (boot) with steam trap at the low points and at the end to
remove steam condensate (e.g. during commissioning). Drip leg (boot) with steam trap
shall be installed at the following locations in both saturated and superheated service:

a) At low points or at natural drainage points, e.g. in front of risers, expansion loops,
changes of direction, (closed) valves and regulators. In saturated steam service,
steam traps shall be fitted to drain-pockets.

b) Steam traps shall be as near as possible to the steam condensate outlet of the
equipment or piping to be drained, unless a cooling leg is required

c) Upstream of vertical line sections.

d) Near “dead” ends. “Dead” ends include line sections to control valves, battery limit
valves and other block valves where steam can be at standstill and no back slope to
a line section with steam flow is provided.

e) In sections downstream of desuperheaters to remove injection water in excess of

evaporation capacity.

f) In steam lines at a maximum interval of 50 m (150 ft) equivalent length.

Placement of steam trap connection shall be on the side of the drip leg (boot). The end of
main steam headers shall be provided with valved blow-off connection of size minimum
DN20 (NPS ¾).
Where sagging of steam pipes is unavoidable, the position and sizing of drip legs shall
minimise the risk of transporting slugs of water from a sag over longer distance when steam
velocities have increased.

DEP 30.75.10.10-Gen.
4.4 DRAINS AND DRIP LEGS
Drip legs SHALL [PS] be provided to collect condensate formed in steam lines, to facilitate
drainage and to prevent entrainment of water slugs with fast moving steam causing water
hammer.

Drip legs SHALL [PS] be installed in both saturated and superheated service at low points,
upstream of vertical line sections, near “dead” ends including line sections to control valves,
battery limit valves and other block valves where steam can be at stagnant, in sections
downstream of desuperheaters to remove injection water in excess of evaporation capacity.

Minimum drip leg diameters are indicated in (Appendix C). The bottom of the drip leg shall
be fitted with a blow down valve for cleaning purpose.
Drip leg shall be provided in accordance with the following dimensions:

a) For steam pipe of size DN 150 (NPS 6) and above, the nominal diameter of the drip
leg shall be at least 50 % of the steam pipe size.

b) For steam pipe of size DN 100 (NPS 4) and below, the nominal diameter of the drip
leg shall be same as that of the steam pipe size.

c) Minimum distance of steam trap branch connection shall be 50 mm (2 in) from the
closure piping component weld.

d) To prevent re-entrainment from drip legs a minimum depth shall be applied. The
length of a drip leg shall be 2.0 times the nominal steam line diameter with a
minimum of 250 mm (10 in.) and a maximum of 500 mm (20 in), measured from the
bottom of the steam line to the bottom of the drip leg.

e) Steam lines shall be installed sloping towards the nearest drip leg and necessary
measures shall be incorporated to minimize line sagging. In case, where sagging of
lines is unavoidable, the position and sizing of drip legs shall be such that it
minimises the risk of transporting slugs of water from a sag over longer distance at
high steam velocities.

The drain line from the drip leg down to the steam trap shall have a first block valve that
can be operated from grade or a platform and a tee with a drain valve that can be used for
removal of condensate during line warming up, as bypass during trap maintenance and for
blow out of dirt collected in the vertical line to the steam trap. The other part of the tee
hooks up to the steam trap with an upstream second block valve and strainer.

In case of drainage from superheated steam lines, where condensate discharging from the
trap can be expected only during warm up and severe upset conditions, it is acceptable to
discharge the trap to the AC system in a safe manner. Discharges from superheated steam
lines where condensation during operation can be expected shall be hooked up to
saturated steam lines.

In case of drainage from saturated steam lines, the steam trap shall discharge into a
condensate recovery system. For start-up and trap checking, the discharge shall be
provided with a bypass valve to the AC system.

For energy and water conservation, steam traps should discharge into a closed system.
However, open discharge is acceptable for steam traps on superheated steam lines and on
remote lines with very small condensate flow. The maximum temperature of discharging
condensate shall be compatible with the receiving system and safety of people shall not be
jeopardized.

An open drain shall collect the condensate from discharges along pipe tracks with steam.
To prevent the steaming hot condensate in the drain from imposing a HSE risk, it will be
flushed with firewater using water hoses during line warm up.

APPENDIX C SIZING CAHRT INDICATING TYPICAL DRIP LEG DIAMETER

DEP 31.38.01.11-Gen.
Steam Trap

Selection of steam traps shall be in accordance with the following:

a) Steam traps in low pressure steam drip service shall be either inverted bucket style
mechanical traps or bimetallic thermostatic style traps.
b) Steam traps in medium pressure steam drip service shall preferably be inverted
bucket style mechanical traps; alternatively disc type thermodynamic traps may be
used.
c) Steam traps in high pressure steam drip service shall preferably be inverted bucket
style mechanical traps.
d) Steam traps provided for steam turbine inlet drip service shall be a thermodynamic
piston type trap.

A strainer (40 mesh screen size) with blow-off valve should preferably be installed
upstream of any steam trap which does not include an integral strainer. Strainers shall be
installed for any thermodynamic disc style trap or orifice trap.

A check valve shall also be installed downstream of any trap when steam condensate will
be discharged to an overhead return line or against a lift. The pressure due to the lift shall
be added to the pressure in the overhead return line when determining the total back
pressure against which the trap discharges.

Steam traps shall have a bypass arrangement if the downtime needed to replace or repair
them would cause a process problem.

Steam traps up to and including DN 40 (NPS 1 ½) should be welded and should have
removable internals to allow repair without performing hot work.

Steam traps shall be positioned so that they are easy to maintain and replace. The
connecting piping up to and including the first downstream block valve shall be designed for
the full steam pressure and temperature. Steam traps inside buildings shall have a bypass
and shall not discharge into an open drain inside the building. Block valves and bypass
valves up to and including DN 40 (NPS 1 ½) should be welded and have welded bonnets.

Open steam trap discharges shall be located away from doors, windows and air intakes. In
cold areas, icing-up of personnel access areas shall be prevented.
For equalizing of pressure around valves in systems other than steam systems, see
(3.12.7) of this DEP.

DEP 30.75.10.10-Gen.
4.5 STEAM TRAPS
The steam trap design, performance and manufacturing shall comply with the following
codes and standards:
• ANSI/ASME PTC 39.1
• ANSI/FCI 69-1
• ANSI/FCI 85-1
Steam trap selection shall be robust to avoid water hammer and frost damage. Trim
material for traps and strainers shall be stainless steel. For steam tracing traps, the body
material shall also be stainless steel.
The size of valves and piping at steam trap shall be the same as the trap.

Steam trap isolation valves shall be provided for steam trap maintenance without having to
turn off the steam supply at the root valve.

Bypasses around steam traps shall be installed to allow traps removal and repair and for
start-up. Refer to also DEP 31.38.01.11-Gen for requirements.

Steam traps shall not be insulated. For safety, the use of expanded metal screening
wrapped around a trap, instead of insulation, can provide personnel protection where
necessary.

Steam traps shall not discharge into the open within an operating area. Traps shall be
accessible and near the equipment being drained. The maximum distance between two
consecutive steam traps for steam headers shall not exceed 50 m (165 ft) for saturated
steam and 150 m (500 ft) for superheated steam.

Condensate collecting piping for grouped tracer traps shall be such as to avoid excessive
back pressure on traps and trap discharge lines and should be based on the lowest
expected steam supply pressure.

Each tracer shall have its own steam supply valve and steam trap.

For heat conservation service, each trap shall have a block valve upstream and
downstream of trap. Traps will have an integral strainer and plugged drain. In winterization
service, no blocks will be required at steam traps. Drains will be valved.

The condensate load per trap shall be calculated based on condensation during warming
up and heat losses, other condensate entering the steam line, e.g. from branches, actual
number of drip legs in section, etc.

Placement of steam trap connection shall be on the side of the drip leg. The end of the
main steam headers shall be provided with a valved blow-off connection of the minimum
DN 20 (NPS ¾) size.

Suitable steam trap types shall be selected for given applications, sized for their duty and
installed correctly for the type of the steam trap.

A strainer of 40 mesh screen size with a blow-off valve shall be installed upstream of any
steam trap which does not include an integral strainer. Strainers shall be installed for any
thermodynamic disc trap or orifice trap.

The pressure due to the lift shall be added to the pressure in the overhead return line when
determining the total back pressure against which the trap discharges.

The steam trap back pressure shall not exceed 50 % of the upstream pressure.

Steam traps up to and including DN 40 (NPS 1-½) size should be welded and should have
removable internals to allow repair without performing hot work.
Steam traps shall be positioned so that they are easy to maintain and replace. The
connecting piping up to and including the first downstream block valve shall be designed for
the full steam pressure and temperature.

Steam pipes shall not discharge steam condensate into sewer systems but instead shall
run to a safe location such as collecting steam condensate pits, accidentally-contaminated
water rundown systems, gravel pits, gullies, etc. The safe locations shall be combined as
far as practical.
DEP 31.38.30.11-Gen.
1.3.2 Specific definitions
CM Collecting Manifold for steam tracers
DM Distribution Manifold for steam tracers
lead the steam line from a DM to a tracer
steam trap an automatic device used to remove condensate from a steam system with
a minimum loss of live steam. For terminology and diagrams of steam traps,
reference is made to ISO 6704.
tail the steam line from a tracer to the CM
tracer steam heating piping which runs along the process pipe

3.1 STEAM TRACING

Single or multiple tracers are used, depending on pipe size and service. Guidance on the
number and size of tracers required for different line sizes and conditions is given in
Table 1 (metric units) and Table 2 (USC units):

Note: Sulphur melting poing : 115.2deg C

For the above table, the parameters used are:

• LP Steam 3.5 barg (50 psig), 150°C (300°F);
• 50 mm (2 in) mineral wool insulation for lines up to and including DN 100 (NPS 4);
• 90 mm (3½ in) mineral wool insulation for lines DN 150 to DN 600 (NPS 6 to
NPS 24);
• air temperature = minus 10°C (14°F);
• wind velocity = 10 m/s (33 ft/s).
Tracers shall not be provided with branches.

As an alternative to the above mentioned guidance on the number and size of tracers,
steam tracing systems can be designed to supply the largest of the following heat
requirements:
a. For lines DN 25 (NPS 1) and smaller, the theoretical heat requirement shall be
multiplied with a factor 1.5 to calculate the actual heat required to maintain the
minimum specified temperature.
b. For lines over DN 25 (NPS 1), vessels, and tanks, the theoretical heat requirement
shall be multiplied with a factor 1.25 to calculate the actual heat required to maintain
the minimum specified temperature.
c. For piping thaw-out and additional heat-up requirements, the theoretical heat
requirement shall be used to calculate the heat required.

Each tracer shall have a valve just after the steam supply header and just before the
condensate header.
``
Tubing can be used for tracing of piping systems and in-line equipment such as strainers.
Tracers shall follow the contours of the piping to be heated from the highest point sloping
towards the steam trap. Pockets should be avoided, and the maximum accumulated pocket
depth is 3 m (10 ft).

Single and multiple tracers shall run along the underside of horizontal lines, or at either side
of the supporting shoes. For details see (Appendix 2).

Multiple tracers may be connected to a common steam supply line, but each shall have an
individual steam trap and block valve.

If systems are designed to discharge sub-cooled condensate (i.e. below saturated steam
temperature), extra care shall be taken to ensure a constant slope of the tracer towards the
steam trap, in order to avoid excessive water hammer effects.

Multiple tracers on vertical pipes shall be equally spaced around the circumference of the
pipe.

Tracers on straight lines shall have expansion loops at 20 m (65 ft) intervals.
At line flanges the tracer shall also have flanges to permit dismantling.

The length of tracers shall not exceed the values specified in Table 3.

3.4 SUPPLY AND RETURN SYSTEM

3.4.1 General
A typical arrangement of a steam tracing system is shown in (Appendix 1).

A steam tracing system shall be designed to minimise potential leaks. Therefore, the
number of flanges and valves shall be restricted as far as possible. In determining the
number of valves, the question of performing repairs on steam traps on live lines should be
considered; see (8).

Steam traps and valves should be of the socket weld type and valves should have welded
bonnets.

Block valves should only be installed upstream of a distribution manifold and downstream
of a collecting manifold.

Although tracers fed from one distribution manifold should discharge into one collecting
manifold, this is often not possible. In systems where tracers from one distribution manifold
will discharge into several collecting manifolds, block valves in the leads shall be
considered to allow maintenance without total steam tracing shut-down.

Connections on distribution and collecting manifolds shall be provided for tracing of

instruments where specified. See DEP 32.37.10.11-Gen.

3.4.2 Steam supply

Tracing steam headers shall be supplied from the top of a main steam line, to avoid intake
of condensate. The tracing steam header shall have a block valve as close as possible to
the main steam header, for isolation of the tracing system. Steam supply to individual
tracers shall be taken from a distribution manifold.

For line sizing requirements see DEP 31.38.01.11-Gen.

For isolation during maintenance, there shall be at least one flanged connection next to the
isolating block valve between each manifold and its header.

Distribution manifolds shall be installed where a minimum of 3 leads can be grouped

together.

Recommended spare lead connections as indicated in Table 6.

Single tracers, with direct connections to the tracing steam and condensate headers, shall
only be applied in areas with less than 3 steam tracers and for lines which must retain
steam heating at all times.

The distance from the lead to the actual tracer shall be minimised.

3.4.4 Condensate return

For a proper heat exchange of the tracers to the process pipe it is important for the
condensate to be removed properly. Further it is also important to avoid water hammer.

For energy conservation, steam traps should discharge into a closed system. The steam
traps should be grouped together on a collecting manifold.

The collecting manifold should be vertical with a valved drain connection at the lowest
point.

The steam trap back pressure shall not exceed 50 % of the upstream pressure. Steam
traps shall be selected, sized, installed and maintained in accordance with the steam trap
vendor standards.

Steam flashing and water hammer will seriously degrade condensate lines which are too
small. Condensate lines of systems which discharge condensate at saturated steam
temperatures shall be sized to handle the flash steam content, not just the condensate. The
condensate volume after flashing is normally so small that it may be ignored.

There shall be no extra steam trap after a collection manifold.

Open discharges from steam traps (only at locations without a condensate collecting
system) shall be located so that steam clouds formed at the trap discharge do not hamper
operation/maintenance activities in the vicinity of the trap. The condensate should
discharge in a suitable drain or soakaway.

Open steam trap discharges shall be located away from doors, windows and air intakes. In
cold areas, icing-up of personnel access areas shall be avoided.

Steam pipes shall not discharge condensate into sewer systems but instead shall run to a
safe location such as collecting condensate pits, contaminated water rundown systems,
gravel pits, gullies, etc., and shall be combined as far as practical.

Condensate pipes in areas where frost can occur shall be provided with protective heating
or insulation.
KHF-00-PDFEED-MP-7180-00005-0000/04
Point 9.2 Roads
All hydrocarbon process equipments are 15m away from main tarmac roads.
Please refer the below snapshot, flow element tag number not updated by piping in model.

Tag numbers for FE & RO need to be updated by piping as per PEFS for flow elements.

Please update Flow element tag number for orifice plate and Transmitter tag number for Orifice tapping.

Example:

Tag number as per PEFS: 82FI-061, for this piping need to provide three tag numbers (one for orifice plate and another two

1.     82FE-061 (for Flow element)

2.     82FT-061. (for First tapping)
3.     82FT-061.. (for Second tapping)

Instrumentation will provide another two tag number for Transmitter & and its stanchion.

4.     82FT-061 (for Transmitter – by Instrumentation)

5.     82FT-061… (for Mounting Stanchion – by Instrumentation)
Specification for Thermal Insulation
KHF-00-104133-RA-7780-01003-0000 / Rev 02

Vendor shall fully comply with the Project Specifications, Project Specific Datasheets and/or international
codes and standards.
Clause 2.2 of DEP 30.46.00.31 Gen. – Sept 2011 shall be followed unless otherwise specified in the project
specific documents. The requirement for Hot Insulation and Cold Insulation shall be defined by Process
Discipline.
Insulation codes shall be as defined by Process Discipline and not necessarily as per clause 2.2.2 of DEP
30.46.00.31-Gen.
APPENDIX 2 – PERSONNEL PROTECTION GUARD DISTANCES AND INSULATION
THICKNESS
For process temperatures above 60 °C to 250 °C metal protection should be applied, without insulati
60 % rigid perforated sheets or wire mesh). For process temperatures > 250 °C, rock wool with metal
jacketing is recommended.

Criteria for the table below are:

Ambient temperature: 26 °C
Wind velocity: 18.9 m/s.
Surface temperature protection: max. 60 °C

Table: Recommended distances between perforated metal sheet/guards and bare surface, and
insulation thickness for personnel protection.
e applied, without insulation (e.g.
0 °C, rock wool with metal

and bare surface, and

DEP 34.14.20.31-Gen
3.2 UNDERGROUND PIPING
Whereas pipe material selection may be influenced by the degree of application of the
above requirements and in many instances influenced by local material availability, the
following shall apply wherever possible.
a) Pipe connections and materials shall be selected such that the underground sumps
and pipes and sewers in plant areas and tank farms areas can easily be installed
and will not give rise to leakage or collapse due to e.g.;
􀂃 settlement of subsoil,
􀂃 shock loads of aggressive hydrocarbons/chemicals released accidentally or
during plant shutdown (polluted effluent),
􀂃 cleaning of pipes by rodding,
􀂃 the use of low-pressure steam of 3.5 bar (50 psi).
􀂃 the insertion of high pressure jetting water of approximately 10 bar (150 psi).
b) GRE and carbon steel pipes passing through concrete walls of sumps and concrete
basins shall be provided with a puddle flange around the pipe, cast in the wall.
c) In instances where differential settlement or differential expansion between pipe
and sump can be expected, a flexible connection shall be applied.
d) All possible chemical components of the effluent shall be identified. Adequate
protection is required against continuous erosion, corrosion and attack by
aggressive chemicals.
e) Glass Reinforced Epoxy (GRE) is the preferred material for AC, CC and drip/drain
streams and shall comply with DEP 31.40.10.19-Gen.
f) For specific applications relating to chemical sewers, material selection shall be in
accordance with DEP 31.38.01.12-Gen. and DEP 30.10.02.13-Gen. as applicable.
g) Piping for domestic sewer systems and rainwater downpipes from buildings shall
be PVC, UPVC, HDPE, ABS or an equivalent approved material.
h) Funnel material shall be non-metallic, preferably GRE/GRP. HDPE may be used if
approved by the Principal.
i) In clean rainwater drains the use of PVC lines may be considered.
SP-2092Part 1 Rev.0
2.6 UV & Weathering Protection

External surface of the above ground Pipes and fittings shall be protected against weathering, sunlight, UV, etc. A resin-rich po
layer shall be applied, with a thickness of 0.3 to 0.5 mm. Use of UV resistance pigments in lieu of poly veil external layer may b
the company if sufficient qualification data in accordance with ASTM G90 is submitted for approval.
External surfaces of the buried pipeline or piping system materials should be manufactured with a resin rich top coat layer

3.6 PIPING THROUGH WALLS, STRUCTURAL DECKS AND CONCRETE FLOORS

BUILDINGS
3.6.1. General
Sleeves or holes through walls and floors of buildings and through table tops shall have a
size permitting the passage of a flange of the relevant pipe size, or the size of the required
insulation, whichever is the larger, to allow the installation of prefabricated piping.
Penetrations through walls and floors shall be sealed with a hydrocarbon-resistant filler
after piping installation (e.g. a collar shall be fitted around the pipe) to avoid chimney
draught in the case of fire. To prevent liquid dripping onto a lower deck, holes SHALL [PS]
be provided with concrete curbs, cast-in extended pipes or other means. The fire rating of
the wall or floor including the penetration SHALL [PS] be maintained.
Piping shall be routed to avoid penetration of major structural elements supporting decks
and walls.
Penetrations through structural decks shall minimize the propagation of corrosion and
stress concentrations.
Flange clearance on piping that penetrates the ground or grating on an elevated work
platform shall be in accordance with section 5.9 of DEP 30.60.00.20-Gen.
DEP 31.38.01.11-Gen.
3.4 PIPING BELOW GROUND LEVEL & 3.4.1 Buried piping
Buried piping shall be considered for:
• drainage, storm water, or sewage systems;
• fire water and other water pipes (for protection against heat or frost);
• large-diameter utility pipes (e.g. main cooling water ducts) so as not to impede traffic.
For pressurised hydrocarbon service, buried piping should be avoided.
Buried piping shall be designed and installed in accordance with DEP 34.14.20.31-Gen.
Site preparation and earthwork required for drain installation shall comply with
DEP 34.11.00.11-Gen.
Buried piping shall have a minimum cover of soil as shown below:
a) fire water pipe (mains) 0.6 m (24 in)
b) in areas inaccessible to heavy traffic 0.3 m (12 in)
a. in areas accessible to heavy traffic and at road
crossings, pipes of DN 600 (NPS 24) and smaller
0.6 m (24 in)
b. pipe over DN 600 (NPS 24) 0.9 m (36 in)
c) pipes crossing beneath railways 1.0 m (40 in)
d) in areas where only night frost can be expected 0.6 m (24 in)
e) in areas where daytime freezing can be expected 0.7 m (28 in)
The above soil cover depths depend on the outside temperature and the permeability of the
soil. In areas where prolonged freezing temperatures may occur, the suitability of the above
soil cover depths shall be confirmed.
The load on pipe crossing railways and roads should be equalised by means of pipe
sleeves or a culvert. The pipe shall be centered in the sleeves by use of distance pieces
welded to the pipe, or distance pieces fixed to the sheeting if the pipe is insulated for lowtemperature
service.
Insulated pipe should not be buried. If this is unavoidable, or if it is desired for life-cycle
economic reasons, the insulation material shall be able to withstand the stresses caused by
the thermal expansion of the pipe. Special attention shall be paid to avoid corrosion under
insulation (CUI) and the system shall be designed so that inspection for CUI is possible or
not needed.
Soil settlement and thermal expansion of the piping shall be taken into account in the
design of underground piping.
For buried pipe operating at a temperature of 60 °C (140 °F) or below, there SHALL [PS] be
a clear distance of at least 0.3 m (12 in) between the pipe and any electrical or instrument
cables.
For buried pipe operating above 60 °C (140 °F), the pipe shall be insulated to limit the outer
surface (cladding) temperature to a maximum of 60 °C (140 °F) and there SHALL [PS] be a
clear distance of at least 0.6 m (24 in) between the cladding and any electrical or
instrument cables.
Design of cathodic protection of buried pipe shall be in accordance with
DEP 30.10.73.10-Gen. For buried pipe with impressed current cathodic protection, there
SHALL [PS] be a clear distance of at least 1 m (40 in) between the pipe and any parallelrunning
cables, to prevent stray-current corrosion of the steel wire armouring of those
cables.
Buried piping SHALL [PS] be designed so that the complete system can be flushed and
cleaned. (e.g. “dead ends” should be avoided). For vents and drains, see (3.13).
For buried pipe systems where the emission of aromatic hydrocarbons and/or toxic fluids
(as defined in DEP 01.00.01.30-Gen.) is a HSE concern (e.g. pollution of ground water),
bolted joints shall not be used. Valves in these piping systems shall be installed in pits.
DEP 31.38.01.11-Gen.
3.4.2 Pipe tracks and pipe trenches
Piping outside process units (e.g. piping between process units and storage facilities)
should be supported on sleepers, at ground level in pipe tracks or below ground level in
pipe trenches. The choice between pipe tracks or pipe trenches is dictated by technical and
economic considerations, e.g. the number of road or rail crossings, the ground water level
and the length of the required trench. Pipe racks may be used if space at ground level is
limited or if the use of culverts or buried piping is uneconomical.
The distance between sleepers in pipe tracks and in pipe trenches shall be based on the
maximum allowed free span of the majority of pipes in accordance with (Appendix 11).
Smaller pipe requiring a shorter supporting distance shall be grouped together and be
supported on additional supports.
The elevation of the sleepers shall be decided as per the following:
• There shall be a minimum vertical clearance of 0.3 m (12 in) underneath the bottom
of safety critical carbon steel pipe in culverts or concrete trenches, to facilitate
inspection and coating maintenance.
Access for maintenance and for operation of valves, drains and instrumentation and that
pipes and insulation will remain above the highest expected storm water levels. Flanged connections shall not be
installed in trenches, in order to prevent the accumulation of gas
and liquid vapours in the trenches. Flanged connections SHALL [PS] not be installed in
enclosed trenches, in order to prevent the accumulation of volatile fluids in the enclosed
trenches.
Concrete trenches in process units SHALL [PS] be adequately drained into a liquid-sealed
drainage system and shall be covered with grating