Energy, Chemicals and Resources Document No: Page:

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Guideline
Effective Date: Rev. No:
Piping Design Guide 23-Jan-2019 0
Issuing Process: Process Owner: Date Last Reviewed:
Engineering and Technical Services CoP Piping Design Lead 23-Jan-2019

1.0 PURPOSE:.............................................................................................................................................. 3
2.0 SCOPE OF APPLICATION: ................................................................................................................... 3
2.1 PROCESSES: ....................................................................................................................................................3
2.2 CUSTOMERS: ...................................................................................................................................................3
2.3 INDIVIDUALS/ORGANIZATIONS: ........................................................................................................................... 3
2.4 EXCLUSIONS: ...................................................................................................................................................3
3.0 REFERENCES: ...................................................................................................................................... 3
4.0 DEFINITIONS: ........................................................................................................................................ 3
5.0 INTRODUCTION: ................................................................................................................................... 4
6.0 PROCESS:.............................................................................................................................................. 4
6.1 PIPE RACK PIPING............................................................................................................................................4
6.2 PIPE SPACING ................................................................................................................................................ 16
6.3 CONDENSATE DRIP LEG AND STEAM TRAP PIPING ARRANGEMENT ..................................................................... 21
6.4 EQUIPMENT PIPING – PUMPS ........................................................................................................................... 25
6.5 TOWER PIPING ............................................................................................................................................... 35
6.6 VESSEL PIPING .............................................................................................................................................. 48
6.7 REACTOR PIPING DESIGN ............................................................................................................................... 54
6.8 EXCHANGER PIPING DESIGN ........................................................................................................................... 60
6.9 REBOILER PIPING DESIGN ............................................................................................................................... 63
6.10 KETTLE TYPE EXCHANGER.............................................................................................................................. 73
6.11 SHELL & TUBE EXCHANGER ............................................................................................................................ 75
6.12 PLATE TYPE HEAT EXCHANGER ...................................................................................................................... 78
6.13 AIR COOLED HEAT EXCHANGERS (FIN FAN COOLER) ........................................................................................ 80
6.14 CENTRIFUGAL COMPRESSORS ......................................................................................................................... 86
6.15 RECIPROCATING COMPRESSORS ..................................................................................................................... 97
6.16 FURNACES OR FIRED HEATERS PIPING ........................................................................................................... 101
6.17 PIPING CONNECTED TO INSTRUMENTS ............................................................................................................ 124
6.18 SAFETY VALVE PIPING .................................................................................................................................. 134
6.19 CONTROL VALVE PIPING ............................................................................................................................... 142
6.20 SAMPLE CONNECTION .................................................................................................................................. 152
6.21 LEVEL INSTRUMENT PIPING ........................................................................................................................... 152
6.22 MISCELLANEOUS PIPING – U/S, S/S, STEAM TRACING & MANIFOLDS, JACKETING, V/D, .................................... 161
6.23 PIPE WELDS / FWS / FFWS / PIPE SPOOL TRANSPORTATION / SHIPPING BREAKS ............................................. 189
6.24 UNDERGROUND PIPING ................................................................................................................................. 198
6.25 OFFSITES PIPING.......................................................................................................................................... 201
6.26 OFFSITE STORAGE LPG PIPING STUDY.......................................................................................................... 217
6.27 COOLING TOWERS PIPING STUDY .................................................................................................................. 225
6.28 FLARE AND BLOWDOWN PIPING STUDY .......................................................................................................... 240
6.29 ROAD AND RAIL CAR LOADING PIPING STUDY ................................................................................................ 247
6.30 BOILERS ...................................................................................................................................................... 257
6.31 PIPE SUPPORTING ........................................................................................................................................ 268
7.0 RECORDS: ......................................................................................................................................... 289

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All rights reserved. The contents of this document are proprietary and produced for the exclusive benefit of Jacobs Engineering Group Inc. and its
affiliated companies. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise, without the prior written approval of Jacobs Engineering Group Inc.

The applicable version of this document resides in the Business Management System (BMS). All copies are considered to be uncontrolled.
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8.0 DESCRIPTION OF REVISIONS: ........................................................................................................ 289

9.0 FIGURES, TABLES, AND OTHER ATTACHMENTS: ...................................................................... 289
10.0 FLOW DIAGRAM ............................................................................................................................... 289

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1.0 PURPOSE:
To provide general guidelines to piping designers for good layout and engineering practices to be
followed while performing Piping layout and design related activities.

2.0 SCOPE OF APPLICATION:

2.1 Processes:
Processes: Project Management, Engineering and Technical Services, Quality.
Sub-processes: None
2.2 Customers:
Internal: Process owners, project managers, project team and engineering disciplines.
External: None
2.3 Individuals/Organizations:
Internal: Jacobs Engineering Group Inc. and all of its Lines of Business (LOB),
subsidiaries, operations, and departments.
External: None
2.4 Exclusions:
Internal: Project and program- specific requirement specified by the client and all other
Jacobs Lines of Business (LOB) except ECR.
External: None

The BMS will be implemented in a progressive manner and the following qualifications
apply to some references. This document will be updated throughout implementation.

References not yet available will not have a live link and are indicated by an “xxxx” in
the referenced document number i.e. BG-PO-DT-xxxx-LD. Reference existing
documents in the legacy Jacobs BPS or CH2M QMS.

References to documents available in the legacy Jacobs BPS or CH2M QMS which do
not yet have a specific BMS replacement document identified are indicated by an *
following the reference i.e. Records Retention*

3.0 REFERENCES:

Document # Document Title

0605.1.300 ENGINEERING DESIGN GUIDE – PLANT DESIGN (CE LUMMUS)

4.0 DEFINITIONS:
JJ-QL-PR-0001-JJ-G-01, BMS Glossary, contains all definitions from global policies, procedures, and
work instructions.

Acronym / Term Description

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5.0 INTRODUCTION:
This Piping design guide will:
Provide a general approach of pipe routing connected to various types of equipment,
instruments, and offsite services.
Enable a consistent approach to be adopted across projects while routing and designing
piping.
Enable low / mid-level designers to learn and develop their skill sets and produce high
quality deliverables.

Note: Piping designer using this guideline should have basic knowledge of piping systems

6.0 PROCESS:
6.1 Pipe Rack Piping
Pipe Rack Piping – Tier Loading

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General Notes:
• Locate larger and heavier lines as far as possible close to the pipe rack column on each side
• Locate Process lines preferably on first tier
• Locate Utility lines on above the process lines on upper tiers. Small size lines preferably on center of
top tier.
• Locate Steam and Condensate headers on top tiers preferably near to the columns so that loops are
accommodated and supported within the pipe rack structure
• Locate very large size cooling water lines on lower tiers
• Preferably Cable trays are to be located on top level of pipe rack
• Spacing between lines shall be as per project requirement
• Maintain same back off pipe clearance for all the lines coming down from the pipe rack
• During the early stage of the pipe rack design development, preliminary flexibility analysis of critical
lines must be carried out by Stress group and fix anchor bay locations
• Expansion loops to be indicated by Stress engineer. Care should be taken to ensure that loops are
supported and accommodated within the pipe rack structure.
• Line spacing should be checked for linear expansion at change of direction
• Locate Flare header at a height such that the Safety Valves can be kept as low as possible, preferably
on top most tier to ensure sufficient slope for self-drain into K.O. Drum.
• PSV out let tapping to flare header shall have 45° latrel connection in line with flow direction of header
towards K.O. Drum

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Typical Piping arrangement on Pipe Rack

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3D Model Snapshots of Pipe Rack Piping

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3D Model Snapshots of Pipe Rack Piping

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Battery Limit Piping arrangement

• Lines crossing battery limits normally will have valve and blind which requires access.
• Valves will be staggered either side of walkway to provide maximum clearance and be provided with
extension spindles to handwheels as required.
• Where lines are to cross battery limit at grade, valves will be brought down for access. This
configuration can also be followed at elevated battery limit structure.
• See diagram, liaise with the Piperack structural steel designer to establish pipe rack design at the
battery limit and to establish the required headroom clearance over the lower walkway.
• A simpler method of accessibility to battery limit valves is achieved as shown on diagram but is
dependent on the pipe rack design and the possible additional pipe support required for the overhead
loop.

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3D Model Snapshots - Battery Limit Piping Arrangement

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3D Model Snapshots - Battery Limit Piping Arrangement

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3D Model Snapshots - Battery Limit Piping Arrangement

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3D Model Snapshots - Battery Limit Piping Arrangement

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Flare Battery Limit Valve Handle in Downward Direction

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6.2 Pipe Spacing

Following tables are developed for use designers to determine the minimum distance
required between adjustment runs of pipes.
Pipe spacing TABLE is used for spacing bare pipe to bare pipe,
No insulation or flanges on either line.

Bare Pipe

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Pipe with Class 150 Flange

Pipe with Class 300 Flange

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Pipe with Class 600 Flange

Flanges with Class 900

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Pipe with Class 1500 Flange

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Pipe Spacing (Orifice flanges)

• It is not always possible to position the line that contains an orifice flange on the outside, so that the
taps are easily accessible.
• The arrangement shown on next diagram gives a guide to the clearances needed in a Piperack if the
orifice flanges are placed in between pipes.
• A clearance of 150 mm should be maintained between the edge of insulation and edge of the orifice
piping.

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6.3 Condensate Drip Leg and Steam Trap Piping Arrangement

Following details are a typical example, however designers to follow project specific
requirements.
Steam Trap Arrangement for Collected Condensate System.

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Steam Trap Arrangement for Drained Condensate System.

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Snapshot of Collected Condensate System

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Snapshot of Drained Condensate System

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6.4 Equipment Piping – Pumps

Pump Piping
Pumps handling flammable or combustible products should not be located under pipe
racks or process structures. The pump end should be located out from the edge of a
pipe rack. The motor end may be oriented either into the rack or away from it,
depending on client preferences. Pumps operating at high pressures should be
separated from major process equipment and other pumps.

General Notes as under

• Keep minimum 5D straight length in front of suction nozzle to avoid cavitation in pump

• Ensure minimum number of fittings in suction line

• Pump piping to be designed to allow for sufficient flexibility

• Provide proper type of support to avoid overstressing of pump nozzles

• Avoid running of pipe over the motor

• Horizontal suction line shall be designed to avoid pockets resulting from thermal expansion

• Ensure proper overhead clearance for pump lift-out during maintenance

• Provide sufficient working space for operation as well as maintenance of pumps

• Strainers shall be oriented in horizontal position for better maintenance

• Centre line of Valve operation shall not exceed 1600mm

• Discharge piping for the line sizes of 150mm above shall be routed on grade for better accessibility

for valves and flexibility within piping system

• All the access ways around the pump to be minimum 800 to 1000mm

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Typical End Suction Top Discharge Pump Piping with Turbine Drive

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Typical End Suction Top Discharge Pump Piping with Motor Drive

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3D Model Snapshot for Typical End Suction / Top Discharge Pump Piping

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Typical Side Suction and Side Discharge Pump Piping

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3D Model Snapshot for Side Suction and Side Discharge Pumps

3
4
10 1

General Notes:
1. Pump suction piping with support arrangement – Actual straight length requirement should be
validated as per vendors documents.
2. Pump discharge line with support arrangement - Actual straight length requirement should be
validated as per vendors documents.
3. Suction strainer – Clear access with strainer mesh removal volume
4. Discharge line Isolation valve – Platform for operating valve hand wheel.
5. Pump seal arrangement
6. Green volume shown around pump for access and maintenance
7. Pipe sleeper
8. Suction Header
9. Discharge Header
10. Removable spool for pump maintenance

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3D model Snapshot for Top Suction Top Discharge

3D Model Snapshot for Horizontal Centrifugal Pump – Top Suction Top Discharge

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General Notes:
1. Leave one side of pump clear for maintenance access.
2. Suction line perpendicular to pump centerline (split case, double suction pump).
3. 3 to 5 Dia. straight run (Min) suction and discharge line based on Vendor requirement
4. Removable spool
5. Seal plan piping
6. Ladder access to platform
7. Proportioning Motorized Valve (PMV's) Accessible from platform.
8. Clear space in front of pumps for rotor removal.
9. Suction piping with PMV'S supported from platform structure - Minimal loads on pump nozzles.
10. Clear space behind pump motors for removal.
11. Valve handwheels accessible from grade.
12. Clear access above pumps for crane access (pump & motor) removal.
13. Electrical cable tray to pump motor, does not obstruct access to pump & motor.

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Large Pumps with Compact Layout (Vertical Pumps)

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3D Model Snapshot – Vertical Sump Pump Piping

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6.5 Tower Piping

Tower Piping Study

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Column / Tower Piping Design - Study

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Column / Tower Piping Design - Study

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Tower Piping – General Notes (refer above study drawings)

1. Use minimum headroom clearance.
2. Where possible, link platforms to adjacent to Tower or structures. Check differential thermal
growth of vessels while connecting the platform to the other structure.
3. 900mm is the preferred distance for manhole from operating platform/grade.
4. Confirm support and guide locations with stress engineer. Stagger support and guide for
clearance.
5. Pipe support should be located a minimum distance from the nozzle.
6. Safety valves (SV) to atmosphere: SV to be located at first platform under top manhole for good
supporting of outlet pipe. Removal of SV is normally by tower davit.
7. Terminate SV outlet pipe a minimum of 3000mm above the operating platform.
8. Level instruments should always be located at end of platform.
9. Intermediate platforms are only required for additional manways, access to valves, level
instruments, or if the distance between platforms is greater than 9000 mm. (Also Check Client
requirements.)

Column / Tower Piping Design - Study

Following are the typical arrangements for:
FEED Nozzles,
Reflux Nozzles, and
Manholes for Single Crossflow Towers.

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3D Model Snapshot – Tower Piping

PLAN VIEW

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3D Model Snapshot – Tower Piping Isometric View

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3D Model Snapshot – Tower Piping – North End Elevation View

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3D Model Snapshot – Tower Piping – South End Elevation View

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3D Model Snapshot – Tower Piping

Elevation West End | Elevation East End

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Column top platform with PSV arrangement

Equally distributed piping from column

Supports using vessel clip with springs

Riser and Down comer piping

on column with common
supports

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Manhole oriented on one side for

removal of internals with clear drop
zone highlighted yellow

Lifting Trunion

Staggered ladder and platform

arrangement for access to
column top,nozzles and
manholes

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3D Model Snapshot – Tall Tower Piping

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6.6 Vessel Piping

Process vessels should be located next to their related equipment. Heads of horizontal
vessels should be lined up with the heads of exchanger shells to form a clear operating aisle
way. Attention should be given to elevation requirements for process considerations.

Vessel Piping Design - Study

See general notes on next sheet.

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Vessel Piping Design - Study

See general notes on next sheet.

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Vessel Piping Design - Study

Vessel Piping General Notes (refer above study drawings):

1. Elevation of lower platform to be established for access to instruments and manway.
2. Elevation of top platform to be approximately 175mm below face of all nozzles serviced from
platform.
3. Pump suction line to be run above minimum head clearance.
4. Bottom invert elevation of vessel to be fixed by NPSH of pump.
5. Platform required for manway access. Alternative location of manway is on top of drum.
6. Run piping at a common BOP elevation to simplify supporting.
7. Minimum dimension above grade to be 450mm BOP of insulation.
8. If inlet is gravity flow, line should slop to vessel.
9. Relief valve discharge to be high enough to allow line to enter top of flare header. If the relief valve is
not accessible from top platform, it must be relocated on the nearest platform.
10. Valves in control set in the off-gas line to be orientated so that they are accessible from top platform.

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3D Model Snapshot – Vessel Piping Arrangement

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3D Model Snapshot – Vessel Piping Arrangement

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3D Model Snapshot – Vessel Piping Arrangement

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6.7 Reactor Piping Design

Reactors should be situated at the periphery of a unit, away from adjacent units, cooling
towers and control rooms.
Reactor Piping Design - Study

Reactor Piping Design General Notes (refer above study drawings):

1. A top manway is provided for charging the Reactor with Catalyst. Outlet piping is connected to this
manway cover by a flanged elbow nozzle to facilitate the removal of a portion of this piping when
handling catalyst.
2. Provide adequate vertical clearance for temperature element removal.
3. Sidestep ladders are preferred.
4. Allow for heavy insulation thickness when running piping close to the Reactor.
5. A davit should be provided to facilitate the removal of piping and outlet nozzle cover, when there is
no monorail.

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Reactor Piping Design - Study

Reactor Piping Design General Notes (refer above study drawings):

1. The elevation of catalyst unloading nozzle is established to allow for a catalyst vibrator/collector to
be bolted into the unloading nozzle. For layout purpose a dimension of 3200mm shall be used.
2. Generally, the maximum straight length of ladder should be kept to 9M. if this is exceeded, additional
platforms are required.

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3D Model Snapshot – Reactor and Intercooler Piping Arrangement

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3D Model Snapshot – Reactor and Intercooler Piping Arrangement

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Reactor Piping Design - Study

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Reactor Piping Design - Study

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6.8 Exchanger Piping Design

Exchangers shall be located next to their related equipment or vessel in the sequence of
process flow, keeping large diameter and alloy piping to a minimum. Where possible, line up all
shell covers on the operating aisle way to maintain clearances. Channel ends should be directed
toward a road or maintenance way.

Shell & Tube Exchanger Piping Design - Study

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3D Model Snapshot – Shell & Tube Exchanger Piping

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3D Model Snapshot – Shell & Tube Exchanger Piping

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6.9 Reboiler Piping Design

Reboiler Piping Study – Vertical (Plan)

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Reboiler Piping Study – Vertical (Plan)

Vertical Reboiler Piping – general Notes (refer above study drawings):

1. If the vertical reboiler is directly connected to the column nozzle, instrument connection will be part
of reboiler nozzle.
2. Ensure access for nozzles.
3. The piping must be adequately flexible to take care of the differential expansion between reboiler
and column.
4. Ensure sufficient space for tube maintenance.
5. Piping below the reboiler support should be made sufficiently flexible to take care of any differential
expansion.
6. Often an expansion joint is provided in single pass, fixed tube exchanger. This may affect the
method of supporting of the exchanger and connecting piping.
7. The elevation of reboiler relative to tower to be verified with process engineer.
8. Exchanger may require guides as indicated on the drawing.

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3D Model Snapshot – Reboiler Piping – Vertical (Plan)

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3D Model Snapshot – Reboiler Piping – Vertical (Plan)

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3D Model Snapshot – Reboiler Piping – Vertical (Plan)

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3D Model Snapshot – Reboiler Piping – Vertical (Plan)

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3D Model Snapshot – Reboiler Piping – Vertical (Plan)

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Reboiler Piping Study – Horizontal (Plan)

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Reboiler Piping Study – Horizontal (Plan)

Horizontal Reboiler Piping - General Notes (refer above study drawings):

1. Maintain minimum clearances as indicated on the drawing.

2. Horizontal reboilers will normally be located at grade unless process conditions indicate otherwise.

3. When locating supports, sliding and fixed supports shall be based on the best solution for reducing
the differential expansion of piping.

4. If the reboiler is to be located at grade, then supporting elevation of reboiler is decided based on
Steam or Process Piping having sufficient clearance from grade (check specially for Steam draining
system).

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3D Model Snapshot – Reboiler Piping – Horizontal (Plan)

3D Model Snapshot – Reboiler Piping – Horizontal (Plan)

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6.10 Kettle Type Exchanger

Kettle Type Exchanger Piping Arrangement - Study

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3D Model Snapshot - Kettle Exchanger Piping Design (Plan & Section)

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6.11 Shell & Tube Exchanger

Shell & Tube Exchanger in Structure - Piping Study

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Shell & Tube Exchanger – General Notes (refer above study drawings):
1. To ensure that each exchanger receives an equal flow, the reductions in line size, and the piping
must be run symmetrically. This requirement should be indicated on P&I Diagram.
2. Establish requirements at an early stage of layout for structural members to support overhead vapor
line.
3. When provision is made for a future exchanger, the piping must be designed with a flanged branch
connection to facilitate connecting piping with the minimum of plant shut-down time.
4. It is important to line up the support of equipment in structures to minimize structural beams.
5. Ensure common headers for minimize supporting.
6. In some cases, the piping between the exchangers and the drum will have to be given a nominal
slope to ensure free drainage.
7. When exchangers are located on the middle or ground floors of a structure, permanent handling
facilities such as runway beams, may have to be built into the structure. The distance between the
floors may have to be increased to provide the extra headroom.
8. Ensure even distribution for overhead line.

3D Model Snapshot – Exchangers in Structure

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3D Model Snapshot – Exchangers in Structure

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6.12 Plate Type Heat Exchanger

3D Model Snapshot – Plate Type Heat Exchanger Piping Layout

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Plate Type Heat Exchanger Piping – General Notes

1. No piping shall obstruct or ingress into the plate removal space, maintenance access ways around

the exchangers.

2. Plate removal area should be accessible from road.

3. Piping connected to exchanger nozzles has to be provided with removable short spools to facilitate

faster and easier maintenance with minimal dismantling of piping. Breakout / Companion flanges

shall be used, or logical break shall be planned at isolation valve.

4. Valves on exchanger piping shall be easily accessible from grade and / or the exchanger structure.

Wherever not possible, the lines must be dropped suitably to make valves accessible.

5. Keep clear space between the exchangers for valve operation and maintenance.

6. Provide Pipe support so that pipe can be supported during maintenance after removal of spool

piece.

7. Avoid vent / instrument tap on the removable spool.

8. Drain valve should be located at 250mm from the grade (or as per client’s requirement).

9. At bottom nozzles connection use FSB eccentric reducer (if required) to facilitate complete drain out

of liquid at the time of maintenance.

10. At top nozzles connection use FST eccentric reducer (if required) to facilitate complete vent out the

air at the time of maintenance.

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6.13 Air Cooled Heat Exchangers (Fin Fan Cooler)

Air coolers shall be located as close as practical to their related equipment, either elevated above
pipe ways or grade mounted. Where practical, they should be grouped to share a common support
structure. Care should be taken when locating air coolers to prevent starvation of air flow, recycling
of air flow and ingesting hot exhaust air from lower air coolers or equipment.

Construction of Air Cooled Exchangers

• Typically, an air-cooled exchanger consists of a finned tube bundle with rectangular box Headers on
both end of the tubes.
• Cooling air is provided by one or more fans.
• Usually air blows upwards through a horizontal tube bundle.

• The fans can be either forced or induced draft depending on whether the air is pushed or pulled
through the tube bundle.

• The space between the fans and the tube bundle is enclosed by a plenum chamber which directs the
air. The whole assembly is usually mounted on legs or a pipe rack.

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Tube bundle details

Bay Arrangement for Air Cooler

One or more tube bundles, serviced by two or more fans, including the structure, plenum and other
attendant equipment

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Inlet and Outlet Piping Considerations – Symmetry for Equal / Balanced Flow

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3D Model Snapshot – Air Fin Coolers Piping Arrangement

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3D Model Snapshot – Air Fin Coolers Piping Arrangement

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6.14 Centrifugal Compressors

Compressors shall be located downwind from fired heaters. Large compressors of high value
and critical to a unit operation or the operation of several units should be given special
consideration. It may be advisable to locate these compressors in a separate building away from
operating units and depending on their value and replacement time, it may be advisable to
provide a separate building for each compressor.

Compressor Layout – General Notes

o Large centrifugal or reciprocating compressors shall be on a raised floor design so that piping

and auxiliaries can be located below main operating platform.

o Generally, compressors shall be positioned in one shelter for ease of operation and

maintenance.

o The general arrangement of compressor house shall consider the vendor drawings and

vendor recommendation, if any, for space and location of auxiliary units.

o The clear space between compressor shall be minimum 1.5 meter or half width of the

compressors.

o The clearance between rows of compressor and at the end of each compressor shall be 1.5

meters.

o Heavy parts such as upper or inner casing and rotor shall be accessible the hoisting

equipment like overhead crane or monorail at the center of the compressor bay and drop out

area shall be in the compressor house.

o The clearance above the compressor shall be provided for lifting purpose shall be minimum 3

meter or as per vendor recommendation.

o Space shall be reserved Front of the casing to pull the cartridge with a special extraction tool

for barrel type compressor.

o Space shall be reserved to drop the upper casing and impeller at grade level during inspection

and maintenance for horizontal split casing compressor.

o Full access around the compressor for operation and maintenance will be provided.

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Centrifugal Compressor Piping Arrangement – Study

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Centrifugal Compressor Piping Arrangement - Study

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Centrifugal Compressor Piping Arrangement - Study

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Compressor Piping Arrangement – General Notes (refer above study drawings)

1. The compressor house piping consists of suction / discharge piping, auxiliary equipment piping and
utility system piping.
2. Suction and discharge piping should preferably be routed at grade level to have a proper supporting
of these lines.
3. The main suction line with its components shall be as short and direct as possible. Minimum 5 times
diameter of straight run piping between elbow and the suction nozzle to allow dissipation of un
desirable flow distortion caused by elbows, valves and any other fittings upstream and velocity in
line.
4. The compressor suction lines a temporary start-up suction strainer shall be installed downstream of
the block valve of the compressor and as close as possible to the compressor suction nozzle.
5. If two or more compressors are combined, their suction pipes should enter at the top of the header,
except that suction pipes at least one pipe size smaller than the header may enter at the side of the
header.
6. Compressor discharge pipes shall have a check valve between the block valve and the discharge
nozzle as close as practical to the compressor discharge nozzle.
7. The discharge line with its main components shall be routed clearing the compressor and should be
as short and direct as possible through the aftercooler and in to the air receiver.
8. In order to prevent transmission of vibrations to a compressor house, compressor piping shall not be
supported or otherwise connected to the building structure.
9. Auxiliary piping shall be neatly routed along the base-plate and shall not extend across the operating
floor. This piping shall not obstruct inspection covers, bearing caps, upper valves of casings or any
other items which require access for operation or maintenance.
10. Air receiver shall be located the lowest point in the compressed air system and any condensate in
the system will drain to the air receiver particularly during shut down when large quantity of
condensate formation.
11. Distribution lines and risers should originate from a separate outlet connection on the air receiver
and shall be sloped towards air receiver.
12. Individual service branches shall be taken off the top of the headers.
13. Removable spool pieces shall be provided at compressor where needed to permit maintenance to
avoid major piping disassembly.

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3D Model Snapshot – Centrifugal Compressor Piping – (Plan View)

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3D Model Snapshot – Centrifugal Compressor Piping – (Elevation View)

3D Model Snapshot – Centrifugal Compressor Piping – (End View)

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3D Model Snapshot – Centrifugal Compressor Piping – (Isometric View)

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3D Model Snapshot – Centrifugal Compressor Piping (Plan view)

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3D Model Snapshot – Centrifugal Compressor Piping (Plan view)

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3D Model Snapshot – Centrifugal Compressor Piping – (Isometric View)

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6.15 Reciprocating Compressors

Reciprocating Compressor Piping Arrangement - Study

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Reciprocating Compressor Piping Arrangement – Study

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Reciprocating Compressors – Piping General Notes

1. All elements of the compressor suction and discharge piping shall be run as close to grade as
practical to facilitate the proper supporting of the system.
2. Use concrete sleepers for supports, spaced at varying distance (usually 3000 maximum) with no two
adjacent spans equal, to dampen the vibration of this piping.
3. Anchors should be placed as close as possible to elbows and tees at all changes of direction. Avoid
changing direction in more than one plane at a time.
4. Valves and instruments shall be accessible from operating platforms, wherever possible.
5. Provide maintenance access for piston withdrawal.
6. Cylinder maintenance access for piston withdrawal.
7. 2” and smaller lines connecting to suction and discharge piping between compressor and headers
shall be checked for possible use of heavier wall pipe due to vibration.
8. Compressor foundation and pipe support footings are to be independent of building foundations. Do
not support vibrating pipework from building steelwork.
9. Start-up strainers to be installed in the suction line to each compressor, stage.
10. Provide adequate access to driver for maintenance.

3D Model Snapshot - Reciprocating Compressors Piping

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3D Model Snapshot - Reciprocating Compressors Piping

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6.16 Furnaces or Fired Heaters Piping

Definition: A heater in which burners provide hot gasses that transfer their heat energy to a
process liquid or gas flowing directly through coils installed inside the heater vessel.
Common types of Fired Heaters:
• Box Type
• Circular Type
Special types of Fired Heaters:
• Pyrolysis
• Reformer

Equipment layout considerations for Fired Heaters:

• Elevation of the fired heater should be established considering the location of burners and the
combustion air ducting. Access for operation and maintenance should be the major
consideration.
• Where possible fixed heaters shall be located close to individual plot boundaries or main
access roads. Tube pull-out and lay down area shall be indicated. Crane access to heater for
tube removal and dropout and crane maneuverability space shall be provided.
• Heaters within process areas shall be located so as to minimize fire risks and explosions.
Heaters are normally located upwind of process units to avoid vapours being carried to these
sources of ignition.
• Hydrocarbon handling equipment’s, compressor houses, analyzer houses, control rooms, etc.
shall be minimum 15 m away from fired heater shell.
• Width of platforms around heater and burners shall be 1000 mm wide for ease and viewing
through peep holes.
• For heaters where steam is generated, the steam drum may be located on the structure
adjacent to the heater to minimize piping runs.
Piping Layout Considerations:
• Burner Piping shall be kept clear of all access and observation openings.
• Adequate Space for removal of heater tubes shall be kept for its maintenance.
• The large diameter transfer lines from heaters shall be short and adequately flexible. Flexibility
and supporting for this line shall be critical.
• Sufficient thought shall be given to make the inlet and outlet piping to and from heater as
symmetrical as possible with the use of same length and number of fittings. This arrangement
is beneficial from stress point of view and supporting. It also ensures equal flow.
• Piping external to the heater shall be minimized around the tube bundle pull out and drop
areas.
• Burner piping shall be so arranged that their valves are accessible when reviewing through
peepholes. Use manifold arrangement for burner piping.
• Burner piping shall be planned to allow sufficient headroom below the burners at grade for
proper access. Burner gun removal shall also be facilitated. Supporting of fuel header piping
to burners under hearth platform may also be considered.
• Access platforms are required for access to decoking swing elbows, soot blower operation
and damper control.
• Generally, heater piping being very congested and critical, all aspects of symmetrical layout,
shortest routes, aesthetics, stresses, flexibility and supporting shall; be looked into and given
its own weightage.
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CIRCULAR HEATERS – Piping study

Heater Parts: - (1) Radiant section (2) Convection section (3) Burners (4) Peed Doors (5) Explosion
doors (6) Damper (7) Access Door (8) Snuffing Steam connections (9) Sootblowers (10) Crossovers
(11) Instruments (12) Flame Failure system (13) Heater Piping.

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General Notes (see above details)

• Fuel Shut off Valves and Snuffing Steam Valve manifold to be located 15 meters from edge of
heater.
• Process outlet (transfer line) to be kept short as possible and run without pockets.
• Heater support columns should be utilized to support Piping wherever possible.

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General Notes (see above details)

• Platform required for decoking swing elbows and for Sootblowers operation.
• All piping may be anchored to heater steelworks.
• Process inlet piping to be kept symmetrical.
• Access door for tube removal to be kept clear of obstructions and piping.
• Break flanges are sometimes required to facilitate removal of tubes.

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General Notes (see above details)

• Platform required for decoking swing elbows and for Sootblowers operation.
• Decoking piping to be kept symmetrical about heater. Due to extreme temperature special
consideration should be given to flexibility and supporting.
• Heater vendor to be given all details of pipe supports loading.

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General Notes (see above details)

• Fuel stop valves to be located 15 meters distance from heaters.
• Valving to be located local to peep doors at heaters.
• Break joint required for removing burner. Unions may be permissible on fuel oil and steam.

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General Notes (see above details)

• Piping to be kept symmetrical.

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CABIN / BOX HEATERS – PIPING STUDY

Heater Parts: - (1) Radiant section (2) Convection section (3) Burners (4) Peed Doors (5) Explosion
doors (6) Damper (7) Access Door (8) Snuffing Steam connections (9) Sootblowers (10) Crossovers
(11) Instruments (12) Flame Failure system (13) Heater Piping.

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• Removable spool may be required for decoking.

• If decoking line to collecting box is located at grade, then make sure these are with removable
spool for crane access to heater.
• Fuel stop valves to be located 15 meters distance from heaters.

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6.17 Piping Connected to Instruments

Orifice Piping

Exploded View of Orifice Plate

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Meter Run Assembly –

Leading to an Orifice Plate

Meter run assembly is used up

to ½” size pipe diameter. The
assembly consists of orifice
plate between two integral
blocks having corner tap.
Generally, meter run pipe is
recommended with upstream
length of 750mm and
downstream length of 250mm.
Used for liquid, gas and steam
application.

Carrier Ring Assembly

Carrier ring carries orifice plate which can be sandwiched between the two flanges. They are used
when flanges are not sufficiently thick for tapping. Carrier rings are also used on lined pipes.
Generally, corner tapping is used.

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Straight Run Requirement for Orifice Plate Assembly

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Flange Tap Orientation for Orifices

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Flange Tap Orientation for Orifices

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Flange Tap Orientation for Orifices

Note: Installation of Orifice plates in Vertical lines should be avoided. If used the flow must be Upwards

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Flange Tap Orientation for Orifices

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3D Model Snapshot of Orifice Piping

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3D Model Snapshot of Orifice Piping

Magnetic Flow Meters

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Vortex Flow Meters

Coriolis (Mass Flow Meters)

Ultrasonic Flow Meter

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6.18 Safety Valve Piping

Safety Valve Piping Arrangement – Study

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Safety Valve Piping for Steam

Common Practice for Safety Valves Discharging to Flare or Blowdown

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General Notes for Safety Valve (SV) Piping (refer above study drawings)
1. Discharging vent point shall be at least 3.0 M away in vertical direction and 7.5 M away in horizontal
direction means no platform should be available in the vicinity of 7.5 M radius.
2. A separate platform could be used where SV could be located higher than flare / blowdown header,
such as air cooler platform.
3. Piping to SV must be free draining to the drum. No pockets.
4. Piping shall be free draining away from the SV in to the header.
5. Check with process engineer if the SV discharge piping needs to roll in to flare / blowdown header.
6. Where SV has to be located far away from the vessel process connection, the line size must be
checked to avoid too high a pressure-drop, and malfunction of the SV – Check with process
engineer.
7. When block valves are used around dual safety valves, an interlocking system connecting inlet to
inlet valves and outlet to outlet valves shall be provided. Three-way valves may be used in place of
dual block valves.
8. Drip pan shall be installed on discharge pipe to avoid water (Condensed steam) spillage on the
operating floor.
9. Paint code applied shall be same as inlet line (especially higher temp. shall be considered)
10. In some cases, all the weep hole and drip pan drain need to be piped together and routed till the
grade or open trench. This requirement may get changed as per client requirement.

Three-way valve in Dual-Safety-Valve

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3D Model Snapshot of Safety Valve Piping

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3D Model Snapshot of Safety Valve Piping

Relief Valves - Notes

• Relief valves shall be accessible for maintenance and, they Shall be located at platforms. Relief
valves with centerline elevations of more than 4.5 m (15’) above high point of finished surface shall
be accessible from platform.
• All relief valves shall be installed in the vertical position.
• Relief valves discharging to a closed system shall normally be higher than the collection header with
no pockets in the discharge line.
• If the relief valve block valves are gate valves, they are to be installed with the stems horizontal.
• Toxic or combustible fluids or gases Shall not be discharged near building intakes.
• When inlet or discharge block valves on pressure relief valves are required, they shall be car-sealed
open. Pressure relief valves on boiler drums shall not have block valves installed.
• Relief valves discharging to atmosphere shall do so at a safe location and have tailpipes extended to
a minimum of 3.0 m (10’) above operating platforms within an 8 m radius. Cut open end of vent
pipes at a 45° angle to the axis of the pipe. Tailpipes shall be guided to prevent movement. An 8
mm (5/16”) diameter weep hole shall be drilled in the bottom of discharge piping close to relief valve
outlet for moisture removal.
• All vents to atmosphere, whether manual or from a relief valve, shall be fitted with a mesh "Bird Screen"
at the exhaust end.
• Where possible, the supports for relief valve discharge piping shall be designed so that removal of the
relief valve does not require the use of temporary pipe supports.

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3D Model Snapshot of Safety Valve Piping

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3D Model Snapshot of Safety Valve Piping

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6.19 Control Valve Piping

Typical Notes for Control Valve Piping

1. Control valve should be adjacent to related equipment whenever possible.
2. Pipework in the control set has been arranged as to accommodate the removal of a spool piece
between the Gate Valve and Control Valve. This allows the Control valve to be removed for
maintenance purpose.
Control Valve Piping Arrangement - Study

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3D Model Snapshot of Control Valve Piping Arrangement

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3D Model Snapshot of Control Valve Piping Arrangement

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Control Valve Piping Arrangement - Study

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3D Model Snapshot of Control Valve Piping Arrangement

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3D Model Snapshot of Control Valve Piping Arrangement

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Control Valve Piping Arrangement - Study

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Control Valve Piping Arrangement – Study

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3D Model Snapshot of Control Valve Piping Arrangement

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6.20 Sample Connection

• Sample connections shall be indicated on the process flow diagrams. They shall be readily

accessible from grade or permanent platform.

• Sample connections in liquid service shall be located horizontally out from the pipe centerline.

• Sample connections in vapor service shall be located on top of the pipe.

6.21 Level Instrument Piping

General Notes for Level Instrument Piping

• The piping designer should select the most suitable mounting position for any particular level

controller with respect to space availability. The information that should be transmitted to

instrument group should show whether left or right-hand pilot is required and state number of

mounting position (i.e. no. 1) or any other selected position from the details shown in the next

sheets.

• Where a level gauge is required the preferred location should be adjacent to or visible from level

controller to enable the operator to check the operation of level controller.

• For maintenance and operation, the level controller should be accessible from grade, but the use

of platforms or if on structures, main operating level, is acceptable.

• Allow sufficient clearance in front of level controller for the opening of transmitter case door. Door

swing requirement are shown in the next sheets.

• Instrument vessel sketch should show position of level controller in relation to vessel liquid levels.

As a guide vessel “normal liquid level” should line up with.

o On Masoneilan controllers the “mid-range” position.

o On Fisher controllers the “float center” position.

• Arrangements and dimensions are based on Fisher and Masoneilan catalogues range 150 lb. to

600 lb.

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Level Instruments Piping Arrangement – Study

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3D Model Snapshot of Level Instrument Piping

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3D Model Snapshot of Level Instrument Piping

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Level Instrument on Tower – General Notes

1. A clearance of 800mm is required between the edge of the level controller and edge of platform to
maintain an access between the two ladders.
2. Ensure that the swing of the manway cover does not impede the level gauge standpipe.
3. Arrangement and dimensions are based on Fisher and Masoneilan catalogues rage 150lb to 600lb.
Level Instrument on Tower – Piping Study

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Level Instrument on Tower – Piping Study

To be read in conjunction with previous notes…

1. Level gauges and standpipe should be located such that they are easily read by operator and are
accessible for maintenance.
2. Where a displacer level controller is required on a vessel the level gauge or standpipe should be
located in close proximity to enable a check to be made on correct level controller operation.
3. Standpipes should be used where level fluctuations in a vessel and vessel diameter require more than
one level gauge to show liquid level. This arrangement cuts down number of vessel nozzles and allows
the correct placement of gauges spite of possible fabrication misalignment at nozzles.
4. When more than one gauge is required an overlap should be provided to give a continuous visible
range. (a) for end connected gauges overlap should be 250mm., (b) for side connected gauges overlap
should be 90mm.

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Level Instrument on Tower – Piping Study

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3D Model Snapshot for Level Instrument Piping on Tower

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3D Model Snapshot for Level Instrument Piping on Tower

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6.22 Miscellaneous Piping – U/S, S/S, Steam Tracing & manifolds, Jacketing, V/D,
Utility Station Piping
Note: Utility Station Design/requirement is always Project specific.

Typical Utility Station (Below Headers) – Option 1

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Typical Utility Station (Below Headers) – Option 2

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Typical Utility Station (Above Headers) – Option 2

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3D Model Snapshot for Utility Station at “Grade” Open System

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3D Model Snapshot for Utility Station at “Grade” Closed System.

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3D Model Snapshot for Utility Station on “Floor” (above headers)

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Safety Shower Piping

1. Following standards are for reference and may be used as basis to understand about safety
shower and its connections for designers to refer as a guideline.
2. However, client / project specific requirements may apply for safety showers.
Safety Shower Piping Arrangement - Study

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3D Model Snapshot of Safety Shower Piping Arrangement

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Safety Shower Piping Arrangement - Study

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Steam Tracing Piping

Steam Tracing Concept for Equipment, Piping and Instruments

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Steam Tracer Location Arrangement on Pipe

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Steam Tracer Arrangement on Valves

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Steam Tracer Arrangement on Equipment

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Steam Supply Manifold Vertical Type-1

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Steam Supply Manifold Vertical Type-2

Steam Supply Manifold Vertical Type-3

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Steam Supply Manifold Vertical Type-4

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Condensate Collection Manifold – Type 1 and 2

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Condensate Collection Manifold – Type 3

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Condensate Collection Manifold – Type 4

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3D Model Snapshot of Steam Tracing Manifold Piping Arrangement

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Steam Jacketed Piping

Jacketed Spool Fabrication

Notes:
1. All welding and testing of the inner process pipe is to be complete prior to any welding of the jacket.
2. Jacket sleeve needs to be in place between the flanges (loose) prior to welding up of the final flange.
3. Jacket sleeve shall be welded to one flange prior to fitment of the closing jacket split pieces.
4. Care shall be taken to ensure adequate weld separation is achieved in accordance with attachment 2
as a minimum.
5. Minimum spool length is 450mm.
Jacketed Pipe Spool Details

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Jacketed Pipe Spool Details

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Jacketed Pipe Spool Details

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Jacketed Piping Arrangement

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3D Model Snapshot of Steam Supply and Condensate Collection Manifolds

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Drain / Vent Piping

Following guidelines are not intended to change sizes already shown on the P&ID’s. These
guidelines should be used were drains and vents are being added due to physical design or
where drain and vent sizes are not shown on P&ID’s. As stated this should be used as a
guideline.
“However, use Project / Client specified guidelines where mandated”

Vent Valves: All locations

• Line sizes 18” and smaller use 1” Vent Valves
• Lines sizes 20” and larger use 2” Vent Valves

Pump Suctions:
• Line size 4” and smaller – use a 1” Drain Valve
• Line size 6” through 10” – use 1 ½” Drain Valve
• Line size 12” and larger use 2” Drain Valve

Pipe Line Drain Size Guideline: (please consider volume in using this guideline)
• Line Size 1 ½” and smaller use line size
• Line Size 2” through 6” use 1” drain valve (unless volume warrants larger size, not
expected)
• Line Size 8” and larger use 2” drain valve (unless volume warrants larger size, not
expected)

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3D Model Snapshots of Drain Piping

1500 lb Drain Piping with Double Block and Bleed Valve

Lined Pipe Drain

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Hydro test Vents

Vents (Process)

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6.23 Pipe Welds / FWs / FFWs / Pipe Spool Transportation / Shipping Breaks
Welds Philosophy
There are four (4) types of welds used on a project for piping:
• Shop Welds
These welds are for shop fabricated pipe spools and placed for correct material
assignment. These welds will be off site at a pipe fabrication shop. Isometric material
must be assigned accordingly.
• Field Welds (FWs)
There are welds done in the field during pipe system installation. These welds are placed
to break / split pipe spools in to manageable dimensions, manage material assignment,
manage spool transportation and enable spool fabrication, erection / installation with
minimum field welds. Isometric material must be assigned accordingly.
• Field Fit Welds (FFWs)
These welds are placed to allow pipe installation contractor with places to make an
adjustment in the field. FFWs are usually placed where dimensions are not firm (revamp
/ retrofit cases, new lines connecting to existing lines / equipment, etc.) or for field
adjustments before final installation.
These welds should allow for adjustments in three directions when possible.
These welds signify to the contractor that an additional 4”-6” has been added to the spool
for adjustment purposes. This additional dimension will not display in the bill of material
or be part of the Material Reporting. Contractor will need to cut and bevel pipe at these
locations prior to final welding.
• Tack Welds
Typically used to allow pipe contractor minor adjustment on shorter spools (Example
would be Pump Suction)
Can be used where flanged spool must pass through floor opening that cannot support
the outside diameter of the flange
Some of the weld specification absolutes are as under:
Every attempt should be made to ensure that Field Welds, Field Fit Welds and Tack Welds are
accessible in the field.
Locate field welds above platforms versus below platforms
Do not locate field welds against other components where accessibility is limited
Attempt to group field welds where possible
No welds should rest on Steel Members

Pre-Fabricated Pipe (Shop)

• All pipe 1” and larger (welded) to be shop fabricated
- Shop Isometrics depicting spools
• All threaded pipe systems to be field – use unions as necessary to facilitate construction
• All pipe ¾” and below to be field routed isometrics – supports by contractor

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Spool sizes (40 x 8 x 8)

Consideration must be given on where the spool is located and how the spool can be
installed.
• Does the spool need to pass through walls, floor, platforms?
- If flanged system, ensure flange can pass through wall and/or floor opening or add
tack weld to flange
• Will the spool be handled by rigging equipment?
• Will the spool be handled by people for installation?
• If you are not sure how the spool will be installed, then be conservative in your spool sizes
and add field joint as required
• Maximum Spool dimensions should be 40’ x 8’ x 8”
• This must match expected truck dimensions (to be verified)
- Please include the outside diameter when computing
• 40 x 8 x 8 is a very large spool, spool this size should allow for plenty of installation space
• Long Straight runs on Pipe Bridges (100’+) should be “Field Material” with mating spools on
the ends.
- For these long runs, pipe will be purchased from Pipe Supplier versus Pipe
fabricator, this saves in material costs and allows contractor to fill bridges or load
pipe racks with straight runs.

Field weld requirement: -

Following cases impose necessacity of field welds

• The transportation limit, typically imposed, is around 3M x 3M x 12M. 3D model must show this soft
envelope which can be used for catching any protrusion of any piping outside the limit. The designer
must ensure that the module limit has FW & is a natural weld instead of additional weld as explained
further in this document. The module limit is thus typically stands at approximately 300mm less all
around the transportation limit.

• Piping at existing steel structure & through platforms / floors: care must be taken for erection
feasibility as one piece spool.
If this is found difficult then the FW must be introduced. Following are exmaples :
- Expansion loop to be erected through existing rack
- 3D Piping cutting through platform
However such FW’s shall be placed at some natural welds without creating additional welds.

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• Piping to critical equipment nozzle

Some equipment need adjustment at nozzle v/s piping connection for proper flange alignment to
reduce strain (stress) at that point.
There also may be a fit up adjustment required thus this situation may impose FW at the piping
flange.
Ex- Pump inlet / out let
Adding FW at the piping flange helps.
Also in some cases the mating flange is supplied by pump
vendor & then it becomes a natural FW.

• Natural welds: Natural weld joints are weld joints which are connecting two piping components. Such
joints if utilised as FW / FFW then additional weld joints are saved.
Even for longer pipe runs like rack / sleeper there are natural weld joints at the random length span of
6m or 12m.
• Working with existing plant (Laser scans): When working for piping in existing plant , it must be
understood that the dimensions measured are during hot/operating condition of the pipe.
Whereas the revamping shall be done during shut down where in the same existing pipe is colder
with some dimensional changes.
Such uncertainty should be reviewed for possible requirement of appropriate FW.
Also when the dimension quality needs to be precise but can not be guranteed due to scan quality or
site survey then FW needs to be introduced.

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

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Philosophy of Use of Welds in Piping Design

6.24 Underground Piping

The following are the common underground services in a chemical / petrochemical /
refinery plants.
• Cooling water (line size normally ≥18″ NB)
• Fire Water
• Contaminated Rain Water Sewer from process catchment area. (CRWS)
• Oily Water Sewer (OWS)
• Liquid Effluent to the Effluent Treatment Plant.
• Closed Blow Down system (CBD)
• Sanitary system
• Storm Water
• Equipment drainage to slope tank
• Electrical cables
• Instrument cables
Material selection depends on the service, operating parameters, durability, economics
and availability. Some of the material used are commonly found are as follows
• Carbon Steel: For closed drain systems, cooling and fire water.
• Stainless Steel: For closed Chemical Drains
• Cast Iron or Grey Iron: Storm and Oily water drains
• Ductile Iron: Process water service
• Concrete Pipe: Used for Surface Drainage and 15-in and larger pipes. Although if it is
available in smaller sizes, economics may limit its use.
• Fiberglass Reinforced Pipe: Used in Corrosive service. It is limited to low pressure and
low temperature systems. When Fabricated it is designed to meet very specific needs.
• PVC Pipe: Commonly used for Corrosive Service
• Glass Pipe: Used for Floor drains in processing plants, especially for acid service.

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3D Model Snapshots for Above Ground (AG) to Under Ground (UG) Piping Interface

UNDERGROUND SYSTEMS
Unless otherwise specified, underground Piping shall be limited to Oily Water Sewers, Well Water lines,
Potable Water lines and Firewater distribution lines.
Fuel Gas may also be required to route underground.
Underground lines must not be routed under foundations.
Underground carbon steel lines shall be externally coated.
Piping up to and including 24” NPS, which carries or has the possibility of carrying water or liquids below
their pour point, shall be buried below frost line or with a minimum cover of 1.8 m (6’) for firewater systems
and/or 1.5 m (5’) for all other water systems. If it is not possible to provide this minimum cover, the pipe shall
be adequately protected from freezing with insulation, tracing or whatever means to maintain their flowing
characteristics, Water lines larger than 24" NPS only need a sufficient cover to ensure piping integrity from
maximum vehicle load. All Vertical risers shall be electrically heat traced and insulated with foam glass down
below the frost line.
Piping normally above ground but passing under plant roads shall be in sleeves or duct banks.
Road crossings shall normally be made at a 90° angle to the road axis unless approved by Owner.
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Under Ground Valve Pit Detail

PIPELINE ARRANGMENT IN TRENCHES

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6.25 Offsites Piping

Offsite Tankage Piping Study

Offsite Tankage Piping – General Notes (refer below study drawings):

1. Tank height more than 4.5 meters are required stairways. These are usually spiral and fixed to the

Tank walls.

Ensure that the first step is either facing the access ramp or next to the bund wall.

Escape ladders from tank interconnecting platforms should be similarly located.

2. Allow sufficient flexibility in pipe routing for differential settlement between tanks and bund walls, and

between pumps and bund wall.

3. Pump suction lines should be as short as possible and without pocket.

4. Allow sufficient space for Pumps to be serviced without interfering with roadway traffic.

5. The first pipe support should be at a sufficient distance away from tank to allow for tank settlement. If

settlement is considered, then the first support may need to be an adjustable.

6. Between pipe support sleepers is 6meters. If extra sleeper at 3meter distance is required for small

bore piping, it is preferable that these small-bore pipes be grouped together.

7. Keep expansion loop in “nests” for economy of supporting.

8. On long pipe runs above ground which may be left full of liquid and can be blocked in at both ends

for periods of time. Consideration must be given to thermal relief due to solar expansion and a safety

valve to be added if necessary.

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3D Model Snapshot of Tank Farm Layout and Piping

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6.26 Offsite Storage LPG Piping Study

• The type of pressure vessel used for the storage of L.P. Gas and high vapour pressure gasoline
components such as,
o Cylinders (bullets),
▪ Designed for a working pressure of about 17.25 bar G. are used for storage of
propane.
o Spheres,
▪ With working pressures ranging up to 6 bar G. are used for storage of propane-butane
mixtures and butanes.
o Spheroids.
▪ With working pressures ranging up to 3.5 bar G. are used for storage of butanes and
pentanes.

Horizontal Storage Bullets

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BULLET-TANK PIPING LAYOUT

Plan

Elevation

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BULLET-TANK LAYOUT WITH PROTECTION BERM

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TYPICAL DETAIL L.P.G. STORAGE SPHERE

General Notes for above typical details of Horizontal and Sphere storages:
• Horizontal bullets are normally supported on two saddles and installed with a nominal slope (1:200) to
allow drainage of possible entrained water or complete removal of hydrostatic test water.
• Vessel low point should be elevated to a minimum of 1500mm above grade to ensure free air
circulation under to clear any possible spillage. Elevation can be increased if required, to give proper
piping clearance.
• All L.P.G. storage vessels must be fitted with a pressure relieving device. If a block valve is fitted it
must be locked open.
• All nozzles other than pressure relief nozzles must be fitted with block valves (preferably direct onto
vessel).
• If 2 or more vessels are required, then interlinked platforms are preferred.
• All nozzles are located on top of sphere
• Piping is routed along the wall contour to get the supports from the sphere wall
• Pipes run on sleepers at grade
• Sphere contain mostly volatile liquid, so always stored under high pressure

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3D Model Snapshot of Horizontal Storage Piping

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6.27 Cooling Towers Piping Study

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General Notes for Cooling Tower Layout/Piping:

1. Process consideration should be given to pit elevation.

When pump elevation is established to suit flooded conditions, top of pump casing should be 150mm

minimum below water level.

All cooling towers have some form of water collection pit, regardless of type into which the cooling

tower basin slopes.

2. Flume outlet spacing is dictated by pump and driver dimensions. This info is required early in the job.

3. Cooling water return to tower may be directly coupled, it is advisable to use some form of flexible

coupling to minimize the effects of differential settlement.

4. Use group Piping to make pipe supporting easier and to reduce the number of small access platforms.

5. Locate suction pit drain and overflow connections together (if required) to minimize underground pipe

run.

6. Locate flume outlet valve directly on flume if flexible coupling is to be used.

7. Discharge valve location:

a. If a Gate Valve is used locate with check valve in horizontal close to pump so that pipe

supports can be located on pump foundation.

b. If Butterfly Valve is used locate in vertical, on underground header flange.

8. If recycle by-pass may be fitted with a control valve or control set.

9. PI’s, TI’s, Flow meters on large diameter underground pipe are to be located at manhole pit. Make

sure pits can be adequately drained.

An alternative to a pit is to bring these connections above grade for a short distance.

10. If possible try to locate supply and return lines, make-up lines together so as to minimize trenching

work.

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General Notes for Vertical Natural Draft (see above sketch):

1. The shape of cooling tower will vary depending upon local requirements (ambient temperatures,
prevailing wind strengths, height limitations.)
2. Vertical cooling towers can also be:

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a. Semi-Forced Draft i.e.: fitted with motor driven fans on the outside – usually between support legs.
b. Semi-Induced Draft i.e.: fitted with fans on the inside, but with the water distribution lathing on the outside.
This makes for a very large catchment pond, but it has the advantage of limiting water loss.

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6.28 Flare and Blowdown Piping Study

General Notes for above Details:

• Water Quench Blowdown Drum: A water quench blowdown drum is a vertical drum with an outlet stack
in which hot liquid can be cooled prior to ultimate disposal. Steam for dispersal of vapours can also be
introduced.
• Blowdown Drum and Vent: blowdown of liquid hydrocarbons which are not expected to vapourise
appreciably, is usually collected in a horizontal drum fitted with vent.

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General Notes for above Details:

• Flare Stack: a flare stack is a burning stack for safe disposal of hydrocarbon vapours. The vapours
usually pass through a knock-out drum in which liquids are separated. Stack are provided with piolet
flames and ignitor system to ensure continuous combustion of hydrocarbons.
• Flare stack are usually located downwind of the process plant and at least 90meters from any process
unit or equipment handling low flash point materials.
• Smokeless Flaring: is based on the principle of increasing the burning rate by the injection of steam
into a flame.

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General Notes for Flare system:

• Flare Knock-out drums: are preferably located near the flare stack in order to minimize liquid
condensation between the stack and drums.

• Seal Drum: is installed to provide protection against flame flash-back into the blowdown lines.

• Flare Header: is collects the vapours from the safety valves for safe discharge to the flare system.

• Relief system Piping: Safety valves are located as to allow discharge outlet downwards to the final
disposal point without pockets. The lowest point in a relief system should be the disposal drum or flare
knock-out drum.
The relief header in flare stack piping system should enter the top of the flare knock-out drum to permit
maximum utilization of the drum volume.

• Piping layout – Flare Area: consideration must be given to the number of lines crossing the roadway, for
adequate support, anchoring etc.…
Flare routing from knock-out drum to flare stack must be sloped back to the knock-out drum at a nominal
slope approx. 1:250, 1:200.
The elevation of the line will be dictated by the elevation of the pipe leaving the blowdown drum, but it is
essential to keep the line as low as possible.
a. To keep height of support posts down.
b. To keep the entry elevation to the flare stack low, as acceptable stack nozzle loads will be low and
some form of anchor support may be required to stop flare line deflecting flare stack.
Platform and ladders for stacks will be provided by stack vendor.
Lines running to flare tip may also be provided by vendor with low level termination points.

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6.29 Road and Rail Car Loading Piping Study

Road and Rail Clearances:
▪ Min. O/H clearance from top of rail - 6.9m
▪ Min. clearance for Heavy Haul Roads - 7.01m
▪ Min. clearance for primary access roads inside facility - 5.5m
▪ Min. clearance for secondary access roads inside facility - 4.5m
▪ Clearance under ISBL piperack stringers for maintenance access ways from under
piperack - 3.645m
General Notes:
1. Loading arms can be ordered to suit differing applications, and sizes can be for top or bottom loading
to determine the arc required.
First, to be established what type and size of tanker is to be used and how many filling points on that
tanker may be serviced by one loading arm.
Also, the speed and frequency of filling to considered.

2. For top loading arms a loading platform must be supplied. This platform has a double function in
providing access from the loading arm area to the tanker top by mean of some form of movable link
platform and placing the operator at the same or similar elevation to the tanker manhole platform.
Even when the tanker loading is from the bottom permanent platform access to tanker platform may
be required.

3. Metering into tankers can be wither local or remote mounted. This will be governed by the client/local
taxation department.
If locally mounted, it should be where it cannot be accidently damaged by incoming or outgoing tankers
and may require crash barrier protections.

4. Ideally loading areas should be designed to have a through flow of tankers and segregated parking
facilities should be provided for incoming and outgoing tankers.

5. If top loading arm are to be used, then each loading platform should be provided with two tanker
standing area for speed of tanker turnaround.
If bottom loading, then only one standing area is provided and should be located on the curb
side/pavement side of the tanker.

6. Some type of sprinkler system is usually provided in this area.

7. Complicated loading area arms using swing arms.

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6.30 Boilers
Description:
A steam boiler is a device in which water is boiled to generate steam.

Available water is usually not suited to be injected into a boiler. It contains a number of
impurities, which have to be removed. Additives are often used to prevent corrosion and
formation of scale.
Location and Arrangement:
Boiler plants, like all fired equipment, should be located up wind of process units to prevent
gases from being blown into burner flames. Actual arrangement of the boiler plant and
associated equipment varies from plant to plant depending on space required.

Piping:
Piping connections to boilers fall under the jurisdiction of the ASME Boiler Code. Refer to the
ASME Boiler and Pressure Vessel Code.

Access, Maintenance and Safety:

Boilers are generally large and heavy, and the designer must allow sufficient access space for
erection and assembly: Tube removal or repair, maintenance of drive units for Combustion air
blowers, unobstructed maintenance and operation space at burners, soot blowers, etc.

Boiler Layout Check List (Piping)

1. Verify size, rating, and type of connection for:
2. Boiler feed water
3. Chemical feed
4. Fuel gas or fuel oil
5. Intermittent blowdown
6. Continuous blowdown
7. Steam sample connections (superheater inlet coils and/or steam drum)
8. Steam connections for sootblower piping
9. Steam outlet
10. Superheater and economizer drains
11. Drip Pan for Steam PSV

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Boiler Glossary:
o Air Preheater - Mechanical device that preheats combustion air by absorbing heat from flue gas.
o Blowdown - Continuous Line from steam drum which flows continuously to remove solids and
insoluble suspended matter in boiler water.
o Blowdown Drum - Drum (normally vertical) that collects flow from continuous and intermittent
blowdown lines.
o Blowdown-Intermittent Line from bottom of mud drum which is used to blow sludge out of drum.
o Blowdown Pit - Underground concrete pit that collects flow from continuous and intermittent
blowdown lines.
o Boiler - A closed pressure vessel in which a liquid, usually water, is vaporized by the application
of heat.
o Casing - Sheet metal that encloses the boiler.
o Deaeration - Removal of air and gases from boiler feed water.
o Desuperheater - Header containing superheated steam into which water is injected to produce
saturated steam.
o Ducts - Sheet steel ducts which connect fan to air preheater and air preheater to boiler and
stack.
o Economizer - A heat recovery device (usually a series of coils) designed to transfer heat from
the products of combustion to a fluid, usually boiler feedwater.
o Fan - Motor or turbine driven fan that supplies combustion air to boiler. m. Firebox Refractory
lined steel box that houses tubes, steam and mud drums, sootblowers, and burners; the section
that produces steam.
o Mud Drum - Lower drum in firebox. Water to mud drum is fed from steam drum through
downcomer tubes. Sediment in water collects in bottom of drum.
o Power Boilers - Boiler used primarily to develop steam for power applications such as generating
electrical energy and feeding power turbines.
o Pressurized Boiler - Firebox which is sealed by mechanical means and with air pressure to be
air tight. q. Retractable Oil Gun Oil gun whose horizontal position can be adjusted during firing.
o Sealing Air - Air which seals observation ports, sootblowers connections, burners, etc. and
prevents escape of heat and gases. Also used to cool sootblowers steam lances.
o Sootblowers - Retractable or non-retractable permanently installed lances that rotate and spray
steam or air to clean tube exteriors.
o Stack - Cylindrical structure that exhausts flue gases to atmosphere.
o Steam Drum - Upper drum which is connected to the mud drum with downcomer tubes. Steam is
discharged from top of drum.
o Superheater - Separate set of coils in boiler firebox, which recirculates saturated steam in order
to raise the temperature of the vapor above the temperature corresponding to its pressure.
o Tri-Cocks (Gauge Cock) - Valves attached to a water column or drum for checking water level.
o Utility Boiler - Boiler used primarily to provide steam to service process plant requirements.
o Water Column (Instrument Bridle) - Vertical tubular member connected at its top and bottom to
the steam and water space of the steam drum respectively, and to which the water gauge,
gauge cocks, and high and low-level alarms may be connected.

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Typical Components of a Boiler Plant

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Boiler Area layout – Example

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6.31 Pipe Supporting

Pipe Support Span – Metal Pipe (SS / CS)

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Pipe Guide Support Spacing for Horizontal Lines – Metal Pipe (SS / CS)

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Pipe Guide Support Spacing for Vertical Lines – Metal Pipe (SS / CS)

Remarks:
1. The location of the lowest guide should allow thermal expansion of the horizontal pipe run
leading away from the vessel/pipe bridge/structure.
2. Use the expansion graph in this document to define the length of pipe to absorb the expansion
of the horizontal pipe run (min. req’d “L”)

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Pipe support arrangement for “Control Station” …

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Standard Pipe Support Structures, Welded connections...

Notes:
• Dimension “A” and “B” should be as minimum as possible, or do not exceed upon defined length on
support standard book.

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Standard Pipe Supports – Primary

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Standard Pipe Support – Secondary Steel Frames

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Standard Pipe Support – Springs and Hangers

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Standard Pipe Support - Secondary Steel Frames for Vessel and Vertical grouped pipes.

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7.0 RECORDS:
The following records shall be retained in accordance with this Guideline, JJ-QL-PR-0001-JJ, Control
of Documents and Records, and GPS01-106 Records Retention, or per contract requirements.

Responsible
Media, Location, and
Record Description Individual or
Indexing Method
Organization

8.0 DESCRIPTION OF REVISIONS:

Rev # Date Reason for Changes

0 DD-MMM-YY Initial release.

9.0 FIGURES, TABLES, AND OTHER ATTACHMENTS:

None

10.0 FLOW DIAGRAM

None

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