h-652 ecc specification for piping design-rev3

7/27/2019 H-652 Ecc Specification for Piping Design-rev3

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ABB Lummus Global B.V.

SPECIFICATION

LGN SSPE xx-xxxx-xx.xxx (2002-04-10) H-652 ECC Specification for Piping Design.dotH-652 ECC SPECIFICATION FOR

PIPING DESIGN-rev3.DOCPage 1 of 17

THISDOCUMENT/DRAWINGISTHEPROPERTYO

FABBLUMMUSGLOBALB.V.INCLUDINGALLPATENTEDANDPATENTABLE

FEATURESAND/ORCONFIDENTIALINFORMATIONANDITSUSEISCONDITIO

NEDUPONTHEUSERSAGREEMENTNOTTOREPRODUCE

THEDOCUMENT/DRAWING,INWHOLEORINPA

RT,NORTHEMATERIALDESCRIBEDTHEREON,NORTOUSETHEDOCUMENT/DRAWINGFORANYPURPOSEOTHERTHANASSPECIFICALLYPERMITTED

INWRITINGBYABBLUMMUSGLOBALB.V.

Client Shell Eastern Petroleum (Pte) Ltd. Always refer to this number

Plant Shell ECC Project Singapore 120.421 04217 H-652

Location Pular Ular, Singapore Dept./Sect. Project Specification

Doc. No. E-00000-PI-7737-0013 Rev. 3.00

Specification For:

PIPING DESIGN

IDOCS 13.3.2

2.00 2006-10-18 Revised A.F.D. JJVA JBRO ADB

1.00 2006-08-11 UPDATED A.F.D. JBRO JBRO ADB

3.00 2007-01-15 REVISED A.F.D. JJVA JBRO ADB

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED


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INDEX

SECTION PAGE



1. GENERAL 51.1 INTRODUCTION 51.2 RELATED SPECIFICATIONS 51.3 PLOTPLAN REQUIREMENTS 51.4 UNITS 52. PIPING SYSTEMS LAYOUT 52.1 GENERAL 52.2 UTILITY SERVICES 62.3 INSTRUMENT RELATED PIPING 63. PIPING COMPONENTS 73.1 JOINTING 73.2 FLANGES 73.3 SPECTACLE BLINDS AND SPADES 83.4 DRAINS AND VENTS 83.5 VALVES 83.6 INSULATION 94. PIPING AND LAYOUT CRITERIA EQUIPMENT 94.1 GENERAL 94.2 PUMPS 94.3 COMPRESSORS 104.4 STEAM TURBINES 104.5 HEAT EXCHANGERS 10


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INDEX (Contd)

SECTION PAGE



4.6 AIR-COOLERS 114.7 FURNACES AND HOT OIL PIPING 114.8 PRESSURE VESSELS AND COLUMNS 115. CLEARANCES 125.1 ESCAPE WAYS 125.2 VERTICAL CLEARANCES 125.3 HORIZONTAL CLEARANCES 125.4 OTHER CLEARANCES 136. ACCESSIBILITY 136.1 FROM GRADE OR PLATFORM: 136.2 BY A PERMANENT LADDER: 136.3 BY PORTABLE DEVICES OR SCAFFOLDING 146.4 NOTES 147. PIPING DRAWINGS 157.1 SCOPE OF PIPING DESIGN DRAWINGS 157.2 ISOMETRICS 157.3 PIPING PLAN DRAWINGS 158. ERGONOMIC ASPECTS OF VALVES 168.1 GENERAL 168.2 CATEGORY 1: CRITICAL VALVES 168.3 CATEGORY 2: NON-CRITICAL VALVES 168.4 CATEGORY 3: NON-OPERATIONAL VALVES 16


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INDEX (Contd)

SECTION PAGE



ATTACHMENTS

I ERGONOMIC VALVE POSITIONING 17


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1. GENERAL

1.1 INTRODUCTION

This specification describes the minimum requirements for design and layout of all onshoreprocess and utility systems for Lummus Based Projects.Where this specification is in contradiction with details on a PEFS, the PEFS shall prevail.

1.2 RELATED SPECIFICATIONS

Shop and Field Fabrication of Piping E-00000-PI-7737-0008

Piping Materials E-00000-PI-7706-0002

Piping Standard Drawings, H-653 E-00000-PI-7737-0014

Protective Steam Heating of Piping System E-00000-PI-7737-0009

1.3 PLOTPLAN REQUIREMENTS

Plotplan requirements and equipment spacing will be conform the Refinery Safety Code, sup-

plemented with the GE GAP guidelines, and the API and NFPA codes. The latest editions ofthese documents shall be used, unless otherwise indicated.

1.4 UNITS

Unless otherwise specified, metric, Celsius and kilogram units shall be applied, but nominal sizeof piping shall be in accordance with inch system (NPS).

2. PIPING SYSTEMS LAYOUT

2.1 GENERAL

Piping shall be routed such that the optimum piping layout is achieved in terms of processrequirements, flexibility to allow for thermal expansion and contraction, economics, ergonomics,operation, inspection, and maintenance. Having considered these factors, the number offlanges, fittings, valves and welds shall be minimized.

All lines within battery limits should be run side by side on elevated pipe racks. Crossing mainpipe racks shall be at different levels to facilitate changing direction and crossing pipelines.

All piping entering and leaving a plot area or processing unit shall be grouped together as far aspracticable. All piping shall be anchored at the plot limit and shall be agreed with client or partnercontractors.

Piping expansion loops in pipe racks and tracks shall be raised in elevation to stay clear of

adjacent piping, with the exception of flare headers and no pocket lines.

Normal pipe size in pipe tracks and main pipe bridges shall not be less than 1, based on asupporting steel span of 4 meter.


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Where block valves are used in branch lines at top of headers, they shall preferably be locatedin the horizontal run so that the lines will drain both ways.

For the following services, the branch lines shall be taken from the top of the header: flare,steam, plant air, instrument air, fuel gas, nitrogen, water lines 1 and smaller; Also vapor lineswith possible liquid entrainment shall be taken from top of the main header.

Small bore connections (1 and smaller) on piping subject to vibration, either induced by Processor at rotating equipment, shall be reinforced with gussets.

Flare Main headers shall run sloping 1:500 to the flare knockout drums, and Sub headers shallbe 1:200, unless otherwise noted on the flow diagrams.Slope requirements for other lines shall be noted on the PEFS and be1:500, unless otherwiseindicated.

Flushing connections shall be as close as possible to the block valves in process lines. Theflushing outlet in horizontal lines shall be at the bottom.

Sample connections should preferably be taken from a vertical line; Where this is not possiblethey should be taken from the side of a horizontal line.

Piping through walls or floors shall run through a sleeve or hole of sufficient size to facilitateinstallation of prefabricated piping and allow for insulation (if applicable). Sealing shall be applied

as appropriate.

2.2 UTILITY SERVICES

Where required for maintenance or cleaning purpose, utility stations shall be provided at gradeand at working levels for elevated equipment.The utility stations at grade shall be located advantageously in the units so that the requiredareas can be covered with a 15 m radius.

All steam lines (except superheated steam), shall be designed to avoid formation of condensateand shall be provided with adequate drip legs and steam traps at the lowest points.

Steam lines from different systems shall not collect in the same steam trap, but each systemshall have its own trap.Steam traps shall be accessible for maintenance.

2.3 INSTRUMENT RELATED PIPING

When a safety valve discharge is to atmosphere, the exhaust pipe shall terminate at least 2.5 mabove any service platform located within a radius of 7.5 m. A 10 mm weep hole will be providedfor drainage at the low point of the tail pipe. The end of the vent pipe shall be cut off straight andprovided with a bird screen.

Safety valves discharging to the flare header shall be located at a higher elevation than the flare

header. The lead and tail pipes shall be self-draining or sloping 1:500.

At the inlet and outlet of safety valves, the valve stem will always oriented horizontally.


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Lines smaller than 3 in which thermowell connections are required, shall be increased locally to3. The minimum straight length of the increased pipe diameter shall be 300 mm.

Level gauges shall be placed in such a position that the instrument is readable from groundlevel, platform or permanent ladder. When the visible level range in a glass is continued in asecond (staggered) level glass, both instruments shall be readable from the same location.

In control valve installation, sufficient clearance for actuator accessibility and/or removal shall beprovided.

3. PIPING COMPONENTS

3.1 JOINTING

The minimum distance between weld-edges shall be 50 mm for details, see par 11.3 of H-652

The distance between fillet and pressure retaining butt joints may be reduced to 6 mm. This isapplicable for saddles, dummy legs, shoes, brackets and the like interfering pressure retainingbut joints. Longitudinal welds seams shall be welded preferably within the range of 30 and 110respectively from the 12:00 position to avoid interference with the pipe supports and nozzles.

For carbon steel and austenitic stainless steel butt welds and reinforcements shall be separated

from full penetration welds 30 mm or one and a half (1.5) times the joint thickness, whichever isgreater. This requirement is intended specifically for nozzles and longitudinal or circumferentialwelds.

In general, joints in lined piping systems shall be flanged. Exceptions are made for lines whichcan be lined partly or completely after erection, and cement-lined piping.

Pipe spools for hot-dip galvanizing shall be with flanged ends, and have maximum dimensionsof 12m x 3m x 1m. These dimensions are to be confirmed by sub-contracting.

3.2 FLANGES

The use of flanges shall be kept to a minimum and shall only be installed for:

Pipe specification requirements.

All connections to equipment (except stated otherwise).

Pipe components like control valves and valves as specified in the particular pipingclasses.

To facilitate assembling and dismantling of lines (for maintenance purposes atequipment).

Where extra specified on PEFSs.

If raised face flanges are to be connected to flat-face flanges (cast iron, GRE or special flangeson equipment), a special flat-face flange shall be specified and indicated on the isometric.


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Flanges connected to equipment shall have the same rating as the equipment flange.

Bolt holes of all flanges shall straddle the vertical centerlines for horizontal piping and shallstraddle the plant north-south line for vertical piping. Exceptions may occur when connectingpipe flanges to equipment nozzles. In this case, a detail of bolt holes straddling a certaincenterline of that flange shall be stated on the piping detail drawing or isometric.

3.3 SPECTACLE BLINDS AND SPADES

Spectacle blinds and spades up to a weight of 25 kg can be installed in horizontal and vertical

lines. Spectacle blinds and spades with a weight over 25 kg shall only be installed in horizontallines and shall be accessible by mobile crane or be provided with a hoisting device.

3.4 DRAINS AND VENTS

Hydrostatic test vents and drains shall be provided, at all high and low points in piping. Ventsand drains for operation and maintenance are needed for taking systems out of operation withinthe limits of the Shell SHE policy and the local governmental permits. At these moment in timethese rules dictates that people should not be contacted with products and there should not beany environmental foreign materials wasted to the air or the sewer. The filing or emptying of sys-tems should be as much as possible be done through closed systems via hoses etc. . Thismeans that on lines containing liquids with environmental foreign materials there should be avalved low point drain (blinded), which can be hooked up with a hose to a sewer system, and a

valved high point vent installed. Lines containing gasses, without condensibles, and linessmaller than 3 can be purged with nitrogen and do not need valved low point drains but do needa valved purge connection at the block valves. Waterlines, airlines, nitrogenlines etc. do notneed valved low point drains because these are not environmental foreign materials.When plugs or screwed caps are provided, these shall be seal welded after testing. No testvents or drains are required in air and nitrogen lines.

When available, valved vents or drains provided for operational purpose, or pressure instrumentconnections (as indicated on the PEFS), may be used for hydrostatic test purpose.For list see E-00000-PI-7880-0063. ( 13.3.2 )

3.5 VALVES

Valves above roads and in overhead pipe tracks shall be avoided. The valve stem, handwheelor actuator shall not obstruct walkways or platforms.Valves shall not be located within a vessel skirt.

Gate valves installed around safety relief valves and in flare lines shall be positioned with thestem horizontal (preferred) or downward.See attachment I for ergonomic valve positions.

Valves in cryogenic liquid service with an extended bonnet shall be installed with the stemoriented upwards (preferred), or with a maximum inclination of 30 deg. to the vertical.Drain valves in cryogenic liquid service shall be installed likewise. The drain connections shallbe provided with support/bracing, preferably to the header.

Valves in cryogenic service with no-flow connections (such as vents and pressure gauges) andvalves in methanol service, where the trapped gas bubble protects the valve packing from toolow temperatures, may be installed at an angle up to 90 from vertical (i.e. they may be installedin vertical pipes).


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If a check valve is installed in such a way that when it closes liquid accumulates in the pipes, adrain is required upstream from the valve.

3.6 INSULATION

Personnel protection shall be applied to non-insulated piping or equipment with an operatingtemperature of 70C and higher, and extended to 2.0 m above and/or 0.8 m beyond any accessor operating area.

If personnel protection is required for surface temperatures 250 C. physical barriers such as

protective metal sheeting/screens shall be used instead of insulation.For surface temperatures > 250 C, insulation shall be used for personnel protection;

4. PIPING AND LAYOUT CRITERIA EQUIPMENT

4.1 GENERAL

Piping adjacent to equipment shall be arranged such that ample access is provided formaintenance, e.g. by cranes, forklift trucks, etc., and that removal and replacement ofequipment, or parts of equipment, can be performed requiring minimal removal of the piping.

Gussets, as per relevant piping standard, shall be installed to all connections 1 and smaller on

piping to equipment subject to vibration.

Piping systems in cryogenic service shall be kept as short as possible.

4.2 PUMPS

Piping at pumps shall be sufficiently flexible and adequately supported to ensure that under nocircumstances the nozzles of this equipment will be subject to stress that could disturb thealignment of the pump.

Pump suction lines shall be as direct as possible and shall be free draining to the pump suctionnozzle. Pockets in suction lines are not permitted, so as to avoid collection of vapor or gas.

To avoid cavitation in horizontal centrifugal pumps of the double-suction type, sufficient straightlength shall be provided immediately upstream the suction nozzle of the pump, so that equalflow distribution to both impeller sides is guaranteed.In addition, the first elbow in the suction line will have preferable a 90 angle to the pump shaftcenterline.

Eccentric reducers in pump suction lines shall be installed with the topside flat if suction headeris located below the suction nozzle, or when suction header is located above the suction nozzleand a horizontal piece of suction line is installed between reducer and first elbow.Where necessary, provision shall be made to facilitate removal of internal elements, housingsections and strainers.

For maintenance reasons, provision shall be made for draining the discharge and suction linesof pumps:


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Suction lines may be drained through pump casing. However, when eccentric reducerswith topside flat are used in suction lines, such arrangement may require an additionaldrain.

Vertical discharge lines shall be drained by a valved drain, connected to the checkvalve, or installed between the check valve and the first block valve.

Special draining and flushing hook-ups are required for pumps handling toxic, volatile orotherwise hazardous fluids. These will be indicated on the PEFSs.

4.3 COMPRESSORS

Suction lines between knockout drums and compressors shall preferably be as short aspracticable, without pockets and sloping downward towards the knockout drum. Where this isimpossible, the low points shall be provided with a drain/trap to remove any possibleaccumulation of liquid.

Pulsation dampeners or equipment with same effect, e.g. knockout drums, installed in suctionand discharge lines of reciprocating compressors shall be located as close as possible to thecompressors.Pulsation dampeners and piping between pulsation dampeners and compressors are normallypart of compressor vendors scope.

In compressor suction lines, temporary/permanent strainers shall be installed before start-up.Size shall be suction line size and they shall be installed in such a way that each one can beremoved easily.

Around each unit, enough spacing shall be provided for maintenance, dismantling, pistonremoval, crane access, etc. Break flanges shall be added when appropriate.

The suction and discharge piping layout shall be checked by the compressor vendor ifnecessary.

Piping to and from compressors shall be designed to keep vibration to a minimum. Avoidoverhanging weight of pipe. Gussets are to be provided as per relevant piping standard to allconnections 1 and smaller where required.

4.4 STEAM TURBINES

Piping to and from turbines shall be designed in such a way that expansion forces and momentson the turbine flanges will be kept to a minimum, and vibration in the piping system shall beprevented.

Ample spacing for crane access shall be provided for dismantling the turbine casing and lifting ofthe rotor.Liquid (condensate) in lines to the turbine shall be avoided by providing drip pockets and steamtraps. Distance between the last drip pocket and turbine shall be minimum.

4.5 HEAT EXCHANGERS


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A spool piece or flanged elbow shall be provided in the piping to the channel nozzles, to allowremoval of heads and to pull the bundle if applicable.Do not connect a valve directly to the channel side of the exchangers.

Enough space in front of the channel side of the exchanger shall be allowed for pulling the tubebundles or cleaning fixed tube bundles with cleaning rods.

For heat exchangers installed at ground level (single or stacked), or installed on the top floor of astructure, no fixed maintenance equipment shall be provided.Heat exchangers with a removable tube bundle and installed between two floors of a structure,which can not be reached by a bundle puller will be provided with a monorail.

4.6 AIR-COOLERS

To assure sufficient supply of air flow to fin fan coolers, a minimum clearance of 2.5 m or fandiameter shall be used between bottom of air inlet and the deck or floor on which the air cooleris installed. The effect of flooring (closed or open grating) shall be taken into account.

Accessibility shall be provided for maintenance to the drivers and the in and outlet nozzles of theair coolers.

No other equipment and pressure relief valves shall be installed underneath the total surface ofair coolers. Keep flange connections below air coolers to a minimum.

4.7 FURNACES AND HOT OIL PIPING

All piping around a furnace shall be arranged such that access to the burners, peepholes,observation windows, access doors, header box covers, etc. is maintained.

Piping at the burner front shall be arranged in such a way that it does not obstructinsertion/removal of lighting torches and/or burner guns.

Pipelines for liquid fuel, fuel gas, pilot gas, general service steam (steaming out and atomizingsteam) and purge air around furnaces shall be by subheaders with block valves at the mainheader. In general, symmetrical piping should be designed for branches to burners.

Smothering steam block valves and manifold must be located at a safe distance from thefurnace, minimum 15 m. Downstream the block valve a weep hole of 6 mm diameter shall beprovided at the lowest point.

4.8 PRESSURE VESSELS AND COLUMNS

Design of piping shall be coordinated with process requirements of equipment to achieve anoptimum nozzle position.

Inlet nozzles shall be arranged such, to avoid the inlet stream impinging on the vessel wall, oragainst level and gauge glass connections.

Interconnecting piping between vessels/columns without valves, may be considered as a part ofthe equipment and, therefore, may be subject to limitations and/or design requirements given by


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the applicable code and other regulations. This piping shall be marked on the PEFS in amanner, which distinguishes it from other piping.

For stripping steam to towers the check valve, vent and block valve shall be located close to thetower in horizontal position to prevent condensate from entering the tower.

Piping at columns should drop immediately when leaving the nozzle and run parallel and asclose as practicable to the column itself.

Columns and vessels that are grouped together shall, if practicable, be elevated in such a waythat their level gauges can be read from one (1) common level.

Level glass nozzle locations shall prevent impingement by process streams.

In general manholes are to be oriented towards the access side. Dropping areas andmaintenance areas are to be designated where applicable.

5. CLEARANCES

5.1 ESCAPE WAYS

Escape routes will lead from all stairways, congested plant areas or buildings to open areas.

Escape passages should have clear corridor widths of 0.9 meter and a clear headroom of 2.1meters above grade. Escape passages should preferably run straight avoiding abrupt changesof direction.

5.2 VERTICAL CLEARANCES

6.0 m over main roads.

6.0 m over railways.

4.0 m for truck/ crane access and plant roads.

2.7 m for normal overhead in the units and forklift truck access.

2.1 m for normal headroom over walkways and platforms.

5.3 HORIZONTAL CLEARANCES

0.75 m for access ways and walkways and 0.9m for thoroughfares / escapes.

1.0 m for maintenance areas.

2.8 m for forklift truck access.

1.2 m between pump foundations


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5.4 OTHER CLEARANCES

The minimum spacing between pipe shall be:

75 mm pipe to pipe, pipe to insulation and insulation to insulation.

30 mm flange to pipe and flange to insulation or the insulation of a pipe in trenches andpiperacks.

The distance between the insulation of a low-temperature pipe and any other object shall be atleast 100 mm

The minimum clearance underneath lines supported on sleepers shall be 400 mm from bottomof line to grade.

The minimum distance between handwheels and any obstruction shall be 100mm.

The minimum clearance below process drains shall be 150 mm.

6. ACCESSIBILITY

The following are the minimum accessibility requirements for principal operating components:

6.1 FROM GRADE OR PLATFORM:

Control valves, on-off valves.

Pressure Relief valves (except thermal relief valves).

Battery limit valves.

Operating valves 4 and over.

Operating spectacle blinds.

Manholes higher than 4000 mm above grade.

Flow meters (except orifice type).

Sample collection points.

6.2 BY A PERMANENT LADDER:

Operating valves 3 (150#) and smaller.

Level instruments on towers and vessels.

Pressure indicators.

Temperature indicators.


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Handholes.

Sample take-off points.

6.3 BY PORTABLE DEVICES OR SCAFFOLDING(maximum 4500 mm above grade):

Orifice type flow meters.

Restriction orifices.

Check valves.

Pressure connections (except indicators).

Temperature connections (except indicators).

Manholes on vessels with an elevation of 4000 mm and below.

6.4 NOTES

In addition to above accessibility requirements, considerations are to be made regarding

maintenance requirements such as extra space for catalyst handling, lay-down areas, overhaulrequirements, etc.Maximum use of available mobile equipment is to be implemented, otherwise permanentfacilities such as hinge points, monorails, etc. are to be provided.

Platforms in front of manholes shall have a minimum clear width of 900 mm and shall be locatedat an elevation in the range of 600-1200 mm below the centerline of the manhole. Recom-mended is 750 mm.

The orientation of manholes on towers and vessels shall preferably be to the direction of theroad, or away from pipe racks.

All nozzles on equipment, with or without spades,spacers or spectacle blinds, situated below

6.00m above grade or supporting platform, and should be only accessible during turn-arounds,do not need permanent acces facilities.

The maximum centerline-elevation of a valve handwheel above grade or platform shall be inaccordance with attachment - I. When an (operating) valve is unavoidably to be located at ahigher elevation, suitable provisions shall be made to make the valve accessible for operation.

On platforms, control valves and safety valves shall be installed inside the handrailings.


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7. PIPING DRAWINGS

7.1 SCOPE OF PIPING DESIGN DRAWINGSScope of Piping Design Drawings Extracted from 3D Model Site Plan. N

Overall ISBL Plot Plan N

Detailed ISBL Plot Plans Y

Section Plot Plans Y

Piping Area Key Plan N

Piping Plan Drawings Y

Piping Isometrics Y

Piping Bill of Materials (on isometrics) Y

All drawings shall be produced as per JOB standards.

7.2 ISOMETRICS

Isometrics shall be A3 size and include a bill of material.

Isometrics shall be made for:

Carbon steel lines all sizes.

Stainless steel and alloy steel lines all sizes.

Non Metal for underground lines all sizes

7.3 PIPING PLAN DRAWINGS

Piping plan drawings shall be A0 size and produced on scale 1 : 33 1/3


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8. ERGONOMIC ASPECTS OF VALVES

8.1 GENERAL

The minimum distance between handwheels and any other obstruction shall be100mmValves are classified into categories 1, 2 or 3, and this categories are specified on the PEFS .

8.2 CATEGORY 1: CRITICAL VALVES(see Optimum area of attachment I)

Frequently used valves, more than once every six (6) months Quick action is required

The chance of a failure is possible with serious consequences

Valves shall be operable from grade or permanent platform accessed by stairs

8.3 CATEGORY 2: NON-CRITICAL VALVES(see Optimum or Acceptable area of attachment I)

(Cat. 2B) Operating frequently is less than every six (6) months

(Cat. 2B) Quick action is not required

(Cat. 2A) The chance of a failure is small and may not lead to serious consequences

(Cat. 2A) Permanent access is aimed for extra cost should be justifiable. In case ofpermanent access is not being provided, auxiliary equipment (e.g. mobile platforms, sky-walkers and/or scaffolding) should be identified to gain access.

8.4 CATEGORY 3: NON-OPERATIONAL VALVES

Operational use is very rare and not in emergency.

Valves which do not need to be accessible by a permanent ladder or platform

Valves can be accessible by scaffolding, portable ladder, mobile platform, etc. when it isconvenient to do.


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ATTACHMENT - I

ERGONOMIC VALVE POSITIONING

Note: The height of access are revised from DEP 30.00.60.13-Gen to suit the people whohaving average height of 170cm.

h-652 ecc specification for piping design-rev3

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