15749975-Guidelines-for-Piping-Design-for-Metallurgical-Industries

GUIDELINES FOR PIPING DESIGN FOR METALURGICAL INDUSTRIES

MECON LIMITED RANCHI – 834002

DOC.NO: MSTD-DESG-FS&PD-1405, REV-0

JUNE’ 2006

CONTENTS CHAPTER NO.

REV. NO.

DESCRIPTION

PAGE NO.

01

INTRODUCTION

02

PIPE SIZING

03

PIPING LAYOUT

04

DESIGN CONSIDERATIONS

05

LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS

06

PIPING MATERIAL SPECIFICATIONS

07

REFERENCES

DATE

PREPARED BY

Page 1 of 2 to Page 2 of 2 Page 1 of 9 to Page 9 of 9 Page 1 of 9 to Page 9 of 9 Page 1 of 44 to Page 44 of 44 Page 1 of 8 to Page 8 of 8 Page 1 of 27 to Page 27 of 27

CHECKED BY

APPROVED BY

S.P.GUPTA.

V.K SAHAY,

DGM

DGM I/C

1.V.KUMAR, AGM 0

27.06.2006 2.R.B.KUMAR, SR.MANAGER

CHAPTER -01 INTRODUCTION

MECON LIMITED GUIDELINES FOR PIPING DESIGN

01

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

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INTRODUCTION

01.01 SCOPE 01.01.01

This document provides general guidelines and procedures for design of Inter Shop/yard and In-shop piping systems in Metallurgical Plants and other related industrial installations.

01.01.02

The provisions & stipulations of this documents are applicable to all the utility fluids conditions & systems those listed is clause 01.01.04.

01.01.03

These guidelines are general in nature and are to be applied by the piping designer judiciously considering the system parameters, plant & piping layout, prevalent ambient conditions, operation & maintenance practices etc.

01.01.04

The provisions of this documents do not apply to the following:a)

Fluids not listed in clause 01.02 i.e. chilled water, storm water, chemicals, lubrication oil, grease, hydraulic oil, sewerage etc.

b)

Equipment piping e.g. Hot blast, PCM lime Milk piping, etc.

c)

Tubes & Tube fittings.

d)

Gas lances.

e)

Coal Tar injection piping.

f)

Piping inside Power plant building

g)

Pipes for pneumatic conveyance

01.02 CLASSIFICATIONS OF FLUIDS For the purpose of piping design, the fluids are classified under following broad categories: • • • • • • •

By-product Fuel Gases Hydrocarbon Fuel Gases Industrial Gases Liquid Fuels Compressed Air Steam Water - Industrial Water. - Drinking Water. - Deminaralized Water. - Soft Water.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

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By-product Fuel Gases Gases generated during many of the metallurgical processes contain carbon monoxide (CO), hydrogen (H2), methane (CH4) and other hydrocarbons. These gases have substantial calorific value and are used as fuel for various heating requirements in the plant. The gases are generally made available from the production units after cleaning however, these may contain some residual impurities like suspended dust particles, moisture. Gases like Coke Oven Gas may also contain tar fog, H2S and other chemicals, etc. Some of the by-product fuel gases commonly used are as follows; • • • • •

Coke Oven Gas Blast Furnace Gas Basic Oxygen Furnace (BOF) Gas COREX Gas Top gas from Direct Reduction Furnaces

The above gases have different characteristics and calorific values and are used as fuel either alone or as mixture of gases to optimize their in-plant usage. Hydrocarbon Gases Hydrocarbon gases supplied from external sources are also used as fuel. This category includes the following: • • •

Natural Gas Liquefied Petroleum Gas (LPG) Coal Bed Methane Gas

Industrial Gases Industrial Gases are used in the metallurgical processes. Industrial gases are also used for cutting, welding, purging and other requirements like inert atmospheres in furnaces, etc. •

Oxygen is used for steel making, enrichment of air blast in blast furnaces, cutting & welding needs.

•

Nitrogen is used for providing inert atmospheres as well as for purging purposes.

•

Argon is used for metal refining providing inert atmosphere and welding.

•

Acetylene is used for cutting and welding.

•

Hydrogen and dissociated ammonia are used for generating inert atmosphere in heat treatment furnaces.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No: 01

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Liquid fuels Liquid fuels are used in industrial installations as primary / supplementary fuel. These include: • • •

Fuel Oils as per IS: 1593-1982 Diesel Fuels as per IS: 1460-2002 Heavy Petroleum Stocks as per IS: 11489-1985

Compressed Air Compressed air is generally required for all industrial installations for distribution of service air and dry air (Instrument air) Steam Steam piping network is required for distribution of steam for heating / utility and purging requirements. The steam may be supplied from Captive power plants, utility boilers or waste heat recovery boilers. Water Water is used for cooling, drinking & flushing purposes in an industrial plant. Various kinds of water available in a steel plant are industrial water, make-up water, clarified water, drinking water, fire fighting water, DM water & soft water. The main source of water in industries are rivers, canals, tube wells, ponds, municipal supply, etc,.

01.03

Individual Piping system shall be provided for distribution of each of the above fluids from generating station to the consumers.

CHAPTER -02 PIPE SIZING

MECON LIMITED GUIDELINES FOR PIPING DESIGN 02.00

PIPE SIZING

02.01

DESIGN PARAMETERS

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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Design pressure for various categories of piping shall be as follows : Low Pressure Fuel gas piping ( Up to 1500 mm WC MOP)

: 1.25 Times Max. Operating Pressure(MOP) But not less than 2000 mmWC minimum

All other gas piping (except Acetylene)

: 1.25 Times Max. Operating Pressure

Acetylene piping ranges

: Test pressure based on Maxi.Allowable Working / Operating Pressure Refer para 02.02 below : 1.5 times Maximum System Pressure. : 1.5 times Maximum Operating Pressure.

Water piping Steam piping

Design temperature for all fluids shall be maximum working temperature of fluid. In case of ambient temperature, design temperature may be taken as 60 deg C for piping exposed to sun and 45 deg C for indoor piping. Flow rate for design purpose shall be taken as peak flow rate for the respective section. In case of branches to individual consumers, peak flow rate for the consumers shall be considered. For common branches and main headers, peak flow rate based on consumption pattern/ diversity factor may be used for pipe sizing. Future augmentation of flow rate for common piping shall also be taken into consideration for pipe sizing. 02.02

SELECTION OF PIPE SIZE • • • • • •

Pipelines shall be sized by limiting the fluid velocity in the pipeline as per Table 02-01. Peak flow rate based on the distribution pattern shall be considered for sizing of pipes. Sizing shall be based on actual flow rate at worst combination of parameters e.g. lowest pressure and highest temperature. In case recommended velocity is dependant on diameter range, after initial sizing, velocity should be re-checked and if required, size should be recalculated. Nearest higher standard pipe size shall be selected after calculation. For water piping & critical applications of pipes for other services, pipe sizes should be re-checked after pressure drop calculations and availability of required pressure at consumer point. If required, pipe size may be increased to meet the pressure drop criteria.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

02.02.01

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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Acetylene pipes Acetylene differs from other fuel gases such as Natural Gas and propane because of its ability to decompose. In case of such reaction high energy is released which can travel as shock wave through piping. Velocity of shock wave depends on pipe size and in smaller cross section area, velocity is restricted and shock wave dies out after travelling some distance. This phenomenon is called deflagration and pressure developed in pipe is limited. In larger pipe, shock wave can travel fast and entire volume takes part in reaction and explosion may occur. This is called detonation and pressure developed in pipe is very high.

Based on the pressure and pipe size, the operating regime of acetylene is divided into three working ranges complied in IGC Document No. 9 / 78. The document gives recommendations for selection of pipe sizes and corresponding test pressures for each zone. Classification into zones is also given in IGC referred above. The pipe size shall be selected so that piping remains in safe zone or deflagration zone as per working ranges. Use of pipe size in detonation zone shall be avoided hence if required multiple pipes shall be used to carry the total flow rate required. Test pressure for working range – I shall be 1.5 times maximum working pressure. In case of working range - II and working range – III the design pressure shall be 10 times and 20 times ( Minimum 30 Bar ) of maximum working pressure respectively. While crossing hot zones acetylene pipeline are protected with heat shield or insulated depending upon the site requirement. 02.02.02

Oxygen pipelines In carbon steel pipes carrying oxygen at high pressure and high velocity, foreign particles, rust or scale can cause internal spark due to friction at high velocity and result in steel pipe catching fire which may spread vigorously in oxygen atmosphere. Several accidents have been reported due to such fires. Since cleanliness in erected piping system is always in doubt, it is recommended to adopt velocities given in Table A- 02.01 B. In areas where higher velocity may be required, SS pipes may be used. In pressure regulating stations where velocity as well as turbulence is large, copper pipes shall be used. For pipes above DN 150 size, CS pipes with inner copper sleeve can be used. In case of copper pipe having high conductivity, any spark is quenched and thus there is no chance of fire. For further details refer IGC Document 13 / 82.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

02.03

SIZING CALCULATION

02.03.01

Calculation of Actual Flow Rate

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Flow rate of various gaseous fluids is indicated in Nm3/hr. This needs to be converted to Am3 / hr considering actual pressure and temperature parameters of the fluid using formula indicated below:PNVN ------ = TN

PAVA -----TA

Where, PN

=

1.033 Kg f / cm2 (Absolute)

VN

=

Volume in Nm3 / hr

TN

=

273 deg. K

PA

=

Actual pressure of fluid in Kg f / cm2 (a) (Absolute)

VA

=

Actual Volume in m3 / hr

TA

=

Actual temperature of fluid in deg. K

For liquid pipelines (Fuel oil, water), no correction is necessary. 02.03.02

Pipe Size Calculation

Q

d

=

∏ d2 --------------- . V. 3600 m3 / hr 4. 106

=

0.0009 ∏ d2 V m3 / hr

=

( Q ) 0.5 ---------------------------- mm ( 0.0009 ∏ V ) 0.5

____________

=

18.80 √ Q / V

=

Flow rate in m3 / hr (Calculated as VA above)

Where Q

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

V

=

Permissible velocity in / sec.

d

=

Inside diameter of pipe in mm

Rev -0 Page 4 of 14

For steam service, flow rate is normally indicated in tonnes per hour. This need to be converted into m3 / hr by finding specific volume of steam at the given temperature and pressure using steam table and subsequently pipe size is worked-out based on velocity range indicated in Table A-02-01C. For steam service, velocity depends upon fluid condition as well as range of pipe diameter. Finally, pipe size is finalized based on trial and error method as carried out for fuel gas service. For moist gas, partial pressure at the operating temperature shall also be considered while calculating the actual flow.

TABLE 02-01 RECOMMENDED VELOCITIES FOR SELECTION OF PIPE SIZES A : Low Pressure Fuel Gases Sl. No 1 2 3 4 5 6 7

Nominal Pipe Dia – (mm) 20 – 80 100 - 250 300 – 500 600 – 800 900 – 1200 1300 – 2000 > 2000

Gas Velocity, m/sec (maximum) BF & BOF Gas

CO Gas, Natural Gas

Mixed BF & Corex Gas

2 3-4 5-6 6–7 8 - 10 11 - 18 20 - 25

2 4–5 6–7 7–8 9 – 12 13 – 20 23 - 28

2 4 –5 5–7 7-8 8 – 11 12 – 19 21 - 27

Remarks

B : Medium Pressure & High Pressure Gases Medium Nitrogen, Argon, Compressed Air, Instrument Air Oxygen LPG Acetylene

Pressure Range (kgf/cm2 g) Up to 6 6 - 16 16 - 40 Up to 16 16 - 40 Up to 3 Up to 1.2

Gas Velocity, m/sec (maximum) 8 –10 12 – 16 Up to 20 10 8 8 8

Remarks See Note 1

See Note 2

Up to DN 25

Notes : 1. In case adequate pressure is available, velocity for inert gases and air can be increased up to 30 m/sec

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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2. In case cleanliness of pipe is ensured, maximum velocity can be 20m/sec. In case SS pipes are used, velocity may go up to 30m/sec and for copper pipes velocity up to 60m/sec can be considered.

C:

LIQUID FUELS:Medium Liquid Fuels

Pressure Range (kgf/cm2 g) All Pressures

D : FOR STEAM Sl. Fluid Condition No 1 2 3 4 5

SATURATED AT SUB-ATMOSPHERIC PRESSURE SATURATED AT 1 TO 7 Kgf/cm2 (g) SATURATED ABOVE 7 Kgf/cm2 (g)

SUPERHEATED UPTO 7 Kgf/cm2 (g) SUPERHEATED ABOVE 7 TO 35 Kgf/cm2 (g)

Velocity, m/sec (maximum) 1.5

Average Velocity, m/sec Up to DN 50mm

DN 50 to DN 150mm

DN 200mm and above

-

10 – 15

15 – 20

15 – 22

20 – 33

25 – 43

15 – 25

20 – 35

30 – 50

20 – 30

25 – 40

30 – 50

20 - 33

28 – 43

35 - 55

Remarks

Remarks

E : FOR WATER Sl. No 1 2 3

Fluid Condition

Average Velocity, m/sec Up to DN 50mm

PUMP SUCTION CONDENSATE WATER PUMP SUCTIONGENERAL SERVICE WATER GENERAL

DN 50 to DN 150mm

DN 200mm and above

0.4 – 0.6

0.6 - 0.7

0.6 – 0.9

0.7 – 1.3

0.9 – 1.5

0.4 – 1.0

0.6 – 2.0

1.0 -2.4

-

Remarks

02.04 PIPE THICKNESS CALCULATION ( PIPE SUBJECTED TO INTERNAL PRESSURE) 02.04.01 For Fuel and industrial gasses pipeline the pipe thickness is generally calculated as per ANSI B31.3 – 1996 ( Process Piping )

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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t = PD/{2(SE+PY)} Where t = Calculated thickness in mm P = Internal design guage pressure in kPa D = Outside dia of pipe in mm S = Basis allowable stress for metals in MPa E = Quality factor as per (Table A-1B) of ANSI B31.3 Y = Coefficient from Table 304.1.1 of ANSI B13.3 C = Sum of mechanical allowances plus corrosion and erosion allowance. C = Corrosion allowance (min) in mm = = =

3.0 mm for BF, CO, BOF, Mixed and Corex gas for DN 100mm & above 1.5 mm for BF, CO, BOF, Mixed and Corex gas below DN 100mm & for other gases 1.5mm for other gases for all sizes

The above valves of corrosion allowance is for general guidelines. However, the same should be checked with Piping Material Specification (PMS) covered in Chapter 06. Thickness calculated on the basis of above formula is minimum thickness required for pipe under specified parameters. However, pipe thickness is selected based on the recommended minimum thickness / schedule indicated in PMS, covered in Chapter 06. 12.5% is added on calculated thickness as Mill tolerances. 02.04.02 Steam piping network comes under the purview of IBR and thickness calculation needs to be carried-out as per stipulations indicated in IBR and same needs to be approved by CIB. 02.04.03 Pipe thickness calculation for water pipelines The wall thickness of steel pipe is affected by a number of factors as indicated below: a)

Internal pressure • Maximum design pressure • Surge or water hammer pressure

b)

External pressure • Trench loading pressure • Earth fill pressure • Vacuum underground.

c)

Special physical loading • Pipe on saddle supports • Pipe on ring girder supports

d)

Practical requirement at site.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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The thickness of pipe should be selected that which satisfies to most severe requirement. For detail of the above pressure/loading refer AWWA MANUAL M11 The nominal thickness of steel pipe as per IS:5822 (code of practice for water supply) shall not be less than the design thickness as given below plus the thickness for corrosion allowance: t=

PD 2afe + P

Where t = thickness of wall in mm P = internal design pressure in N/mm2 D= outside diameter in mm a = design factor (0.6 for working pressure and 0.9 for test pressure inclusive of surge pressure) f = Specified maximum yield stress in N/mm2 and e = Weld efficiency of the joint (0.9 for shop welding and 0.8 for field welding)

Corrosion allowance : It is preferable to design for the required wall thickness as determined by the loads imposed, then select living coatings and catholic protection as necessary to provide the required level of corrosion protection. 2 mm corrosion allowance for pipe up to DN 100 and 3mm corrosion allowance for pipe above DN 100 is generally considered. 02.05

PRESSURE DROP CALCULATION

02.05.01

Low pressure gas Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at low pressure can be expressed by the basic hydraulic formula :

H

=

f.l.v2.ρ -------------------------2.g.d

where, H

=

Pressure drop (mmWC)

l

=

length of pipe sector under consideration (m)

d

=

Inner diameter of pipe (m)

v

=

Velocity of gas (m/sec)

g

=

Acceleration due to gravity (m2 / sec)

MECON LIMITED GUIDELINES FOR PIPING DESIGN f

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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=

Friction co-efficient (dimensionless) depending on pipe diameter., velocity & viscosity of gas and type of flow)

=

0.03 to 0.045 (average value = 0.038)

for BF gas

=

0.04 to 0.05

(average value = 0.045)

for CO gas

=

0.02 to 0.03

(average value = 0.025)

for Natural gas

Large values of “f” shall be taken for pipes of size less than 200 mm and smaller values shall be taken for pipes of size more than 1500 mm. ρ

=

density of gas (Kg/Nm3)

Equivalent pipe length for pipe-fittings, valves, etc. shall be taken into account for calculating pressure drop.

02.05.02

High pressure gas a) For working pressure of 10-15 kgf/cm2 Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at high pressure can be expressed by the formula:

Q

=

------------------/ PH2 - Pk2 20.555 d 8/3 / ------------------√ SLT

Where, Q

=

Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure

d

=

Inner diameter in cm.

S

=

Specific gravity of gas with respect to air

L

=

Length of pipe in km

T

=

Temperature of gas in deg. K

PH

=

Pressure of gas in Kgf/cm2 at one end of pipeline

PK

=

Pressure of gas in Kgf/cm2 at other end of pipeline

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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b) For higher pressure, the above formula is modified as :

Q

=

------------------/ PH2 - Pk2 20.555 d 8/3 / ------------------√ SKLT

Where, Q

=

Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure

d

=

Inner diameter in cm.

S

=

Specific gravity of gas with respect to air

L

=

Length of pipe in km

T

=

Temperature of gas in deg. K

PH

=

Pressure of gas in Kgf/cm2 at one end of pipeline

PK

=

Pressure of gas in Kgf/cm2 at other end of pipeline

K

=

Compressibility factor of gas at specified pressure and temperature or, alternatively

Q

02.05.03 001.

=

25.0833 d 2.653

Water Pressure drop in pressure water pipe line can be calculated by using modified Hazen Williams formula.

V=3.83 CR d 0.6575 (gs)0.5525/v0.105

------------------------ I

Where, CR d g s v

= = = = =

_ _ 0.551 2 2 | P H - Pk | | ------------------- | | | SKLT |_ _|

Co-efficient of roughness Pipe diameter acceleration due to gravity friction slope viscosity of liquid.

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 02

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For circular conduits, v20ºC for water = 10-6 m2/s and g = 9.81 m/s2 The modified Hazan Williams formula derived as V = 143.534 CR r 0.6575 S 0.5525

--------------------- II

h = [L(Q/CR)1.81]/ 994.62D4.81

--------------------- III

in which, V CR r s D h L Q

= = = = = = = =

Velocity of Flow in m/s; Pipe roughness coefficient; (1 for smooth pipes; Critical settling velocity Warman’s Recommendations = Design velocity should be 30% higher than Vc

Calculation of Critical Settling velocity DURAND”S EQUATION Page 24 of 47

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

Vc = FL ( 2gD x (s-s1) / s1)1/2 Where, Vc = Critical settling Velocity FL = Froude constant D = internal dia of pipe = OD – 2t S = Sp.gravity of dry solids S1 = Sp.gravity of media. FL depends upon particle size & volumetric concentration of slurry. SINCLAIR’S EQUATION Vc = FL ( 2gD x (s-s1) / s1)1/2 (d/D)1/6 Where, d = d50 = Average particle size This is for lean slurry. Density of slurry, ρm = 100/((cw/ρs) + (100-cw)) / ρw) Where, cw ρs ρw

= = =

Concentration by weight Sp.gravity of dry solids Sp.gravity of flow medium

For BF – GCP slurry ρm

=

1.083 (ρs =4.3)

When, concentration is 10% Concentration by volume = cw . ρm / ρs For BF GCP slurry, When cw = 10% ρm = 1.083

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MECON LIMITED GUIDELINES FOR PIPING DESIGN 04.14

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

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CORROSION PROTECTION OF UNDERGROUND BURIED M.S PIPES FOR WATER SERVICES:Buried steel pipes are liable to external corrosion and therefore need to be protected by the use of suitable coating. Steel pipes may be coated with any of the following methods as per the decision of the Purchaser. Types of Coating:i)

Coat Tar enamel and fire glass polyester tissues in accordance with IS:10221.

ii)

Corrosion Protection Tapes in accordance with IS:10221.

iii)

Concrete lining as IS:1916 or Gunniting.

When the pipe is coated / wrapped before laying / putting into ground trench, the same should be made continuous after laying. After wrapping and coating individual pipe piece shall be tested in accordance with IS : 10221. Flanges shall be cleaned and are to be protected by plastic strips, bitumen strip and by pouring anticorrosive material. i)

Cleaning of the external surface

Pipe surface shall be thoroughly cleaned and dried before the primer is applied. The pipe surface shall be free of dirt, grease, oil, rust, scale and other foreign material. Pipe surface shall be cleaned by any of the methods. • Grit / shot blasting • Stand blasting • Mechanical cleaning by pneumatic wire brush. All oil and grease material shall be removed by suitable solvent and then surface cleaned by clear rag. ii) Coating of Primer The cleaned surface have to be immediately applied the coating of primer. Three types of primer are generally used i.e. (a) Coal Tar Primer (b) Asphaltic primer (c) Synthetic primer. Page 26 of 47

MECON LIMITED GUIDELINES FOR PIPING DESIGN iii)

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

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Coating of Enamel

After the application of primer, coating of enamel is applied. Two types of enamel are generally used (a) Coat Tar enamel (b) Asphalt enamel. Depending upon the type of primer used the compatible enamel shall be used and it should be from the same manufacturer. iv).

Applying the Wrapping Material

Three type of wrappings material are used (i) Glass Fibres (ii) Asbestos felt (iii) Kraft paper. The wrapping is being done in two phases. First the inner wrap of glass fibre tissues is applied. The second outer wrap is by means of glass fibre felt type 1 to IS:7193. In case outer wrapping is by asbestos felt then it should be thoroughly saturated with air blown coal tar / asphalt coating. In case outer wrapping is by kraft paper then the kraft paper shall be water proof and impregnated with coal tar / asphalt enamel. 04.15

CATHODIC PROTECTION FOR M.S BURRIED WATER PIPELINES:Mild Steel Pipes buried in corrosive soil need to be protected with the help of cathodic protection in addition to wrapping and coating. Cathodic protection system reverses the electro chemical force by creating an external circuit between the pipeline to be protected and an auxiliary anode (known as sacrificial anode) buried in the ground at a predetermined distance from the pipe. Direct current applied to the circuit is discharged from the anode surface and travels through the surrounding electrolyte to the pipe which is cathode. Two methods are available for generating a current of sufficient magnitude to guarantee the protection. In the first method the sacrificial anode material such as magnesium or Zinc is used to create galvanic cell. The electrical potential generated by the cell causes the current to flow from anode to the pipe and returning to the anode through a simple connecting wire. This system is generally used where it is desirable to apply small amount of current at a number of locations, mostly often on coated pipelines in lightly or moderately corrosive soils. The second method of current generation is to energise the circuit with on external DC power supply such as rectifier. The technique commonly referred to as impressed current method uses relatively inert anodes usually graphite or silicon cast iron connected to positive terminal of DC power supply with the pipe connected to negative terminal. This system is generally used where large amount of current is required at relatively few locations and in many cases it is more economical than sacrificial anodes. For cathodic protection, a corrosion survey including chemical – physical analysis of the soil must be performed along the pipeline. Where the soil resistively is less than Page 27 of 47

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

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5000 ohms-cm. Cathodic protection in conjunction with appropriate wrapping and coating system shall be used. The cathodic protection shall conform to IS:8062 Part-II. For soil resistively above 5000 ohms-cm, cathodic protection shall be used in consultation with corrosion engineers.

Page 28 of 47

MECON LIMITED GUIDELINES FOR PIPING DESIGN 04.15

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

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THERMAL INSULATION OF PIPELINES

Thermal insulation is applied to pipelines for two purpose. i)

To prevent heat loss to atmosphere in case of fluid being hot or to gain heat in case of the fluid it contains is cold or below ambient temperature.

ii)

To ensure that the skin temperature of the equipment or pipe is not more than 600C which is a permissible limit prescribed by the Inspector of factories.

Insulation Materials Following insulating materials are normally used. i)

Unbonded mineral wool made from slag or rock confirming to IS : 3677 or glass wool conforming to IS : 3690

ii)

Bonded mineral wool conforming to IS:8183 made from slag or rock or glass process from molten state into fibrous form and bonded with a suitable binder.

iii)

Preformed fibrous pipe insulation conforming to IS:9842. The material shall be mineral wool processed from rock or glass fibres.

iv)

Insitu Polyurethane / polyisocynurate insulation conforming to IS:13205 (applicable for max operating temperature of 1100C).

Thickness of Insulation Thickness of heat insulation to be provided is a function of the value of thermal conductivity of the material selected, the temperature of the fluid and the bulk density of the heat insulation material. Following table gives the bulk density for unbonded and bonded mineral wool with temperature limitations of hot face temperature. Unbonded Mineral wool 120 kg/m3 150 kg/m3 200 kg/m3

Bonded Mineral Wool (kg/m3) Slabs / mattresses Pipe sections Glass Wool Rock Wool 50 85 120 80 85 120 120 85 120

Page 29 of 47

Max hot face Temp 0C 250 400 550

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No – 04

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Table for Insulation thickness Pipe size

Insulation thickness in mm for various temperature ranges

(outside dia)

size 1000C Between

Pipe

(outside dia)

and

Between

101 and 201

below 2000C

Between

and 301

Between

and 401

3000C

4000C

Above

and 5000C

5000C

Upto DN 50mm

25

50

50

75

100

100

DN 65 to DN

25

50

75

100

125

125

50

75

75

100

125

150

DN 200 mm

50

75

75

125

125

150

DN 250 mm

50

75

100

125

150

150

DN 300 mm

50

75

100

125

150

150

100mm DN 125 & DN 150mm

Note: The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS: 277 with following thicknesses: -

-

Pipe sizes up to 300 mm OD Pipe sizes up to 300 mm OD equipment, flanges, valves

Page 30 of 47

:

0.63 mm

:

0.80 mm

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CHAPTER: 5 LOAD CALCULATIONS & FLEXIBILITY ANALYSIS

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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05.00

LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS

05.01

Load Calculations for gaseous & Liquid pipelines:Loads from the piping system are transferred to the pipe supports and connected equipment. Depending on the direction of application, loads are calculated under two major heads : • •

05.01.01

Vertical Loads Horizontal Loads

Vertical loads Vertical loads transferred to pipe supports comprise of the following : • • • • • • • •

Dead weight of the pipes Weight of fluid in pipes Weight of insulation if any Condensate weight in gas pipeline Dust load due to deposition on pipeline Load due to mounted valves, compensator and fittings. Load due to saddles, supports and other service pipes Dead load and live load from Platforms and walkways

Empty weight of pipes shall be taken from standard weight tables. In case of pipes carrying liquid, fluid weight with full pipe section shall be considered. Following norms shall be followed for calculating the condensate load in low pressure fuel gas mains. Pipe dia. (mm)

1. Upto DN 500 2. DN 600 – DN 1400 3. DN 1500 – DN 3500

Height of filling of pipe Filling in crosscross-section with section (%) condensate (mm) 100 Full 88 – 35 500 30 – 14 500 – 800

Load due to dust deposition shall be as follows : • •

50 Kg/m2 on pipelines at a distance within 100 m from dust generating plant (viz. Blast Furnace, Coke ovens, SMS, Lime and Dolomite plant etc.) 25 Kg/m2 on pipelines at a distance between 100 m to 500 m from dust generating plants. Sheet 1 of 8

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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Weight of valves, compensators and other mounted accessories shall be taken from drawings/ catalogues. Live load on platform shall be taken as 500 Kg/m2. This is indicated to Structural Section for designing platforms. It is recommended to add 10% to 20 % of vertical load as a provision for pipes to be laid in future on the same route.

Horizontal loads Horizontal loads transferred to pipe supports comprise of the following: • • • •

Load due to thermal expansion Load due to internal gas pressure i.e. blanking load, load due to annular space of compensator, unbalanced pressure load at branch locations, etc Load due to friction Wind load

Depending on the pipe configuration, horizontal loads can be in axial direction as well as in transverse direction. Horizontal loads due to thermal expansion, internal pressure and friction are calculated by carrying out flexibility analysis on individual pipe. Procedure is given in para 05.03. However, wherever possible, standard software package like CAESAR-II may be used for carrying out flexibility analysis and calculations of loads transmitted to supports and nozzles of equipment to which piping is connected. 05.02

LOCATION OF PIPE SUPPORTS Supports for pipes shall be provided based on pipe layout. Span between two consecutive supports for a pipe shall be limited to the values given in Table 05.01 and 05.02 Recommended spacing (C.L to C.L) between two pipes are indicated in Table 05.03. In specific cases where span between two supports can not be provided as per the table, alternative arrangement for intermediate support using bridge between trestles or guy rope supports may be considered. In exceptional cases where distance exceeds the limiting span, suitable stiffening of pipe section to prevent sagging may be considered. At sliding supports pipe saddle shall be allowed to rest on bearing plate for free movement. In case U-clamps are provided, clearance shall be maintained for pipe movement by providing two nuts on opposite sides. Sheet 2 of 8

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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All intermediate supports shall be of sliding type. Anchor supports shall be located based on piping configuration and layout to provide adequate flexibility. Distance between two consecutive fixed supports in straight runs of pipe route should be approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it should exceed 100 m. However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm cold pull if any during erection may be given as per instructions of the respective drawings. To reduce friction force transmitted to supports, roller supports or anti friction pad supports can also be used. 05.03

FLEXIBILITY ANALYSIS Piping arrangement shall provide for flexibility of lines to take care of the thermal expansion, contraction and equipment settlement. Large reactions or moments at equipment connections shall be avoided . Expansion computation shall be made on the basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or –ve ) design temperature(s) as given. i)

Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest Edition). Analysis shall consider stress intensification factors as per ASME B31.3.

ii)

Lines which shall be subjected to steam out conditions , shall be designed and analyzed at low –pressure steam design temperature of line whichever is more. Lines having negative design temperature shall be analyzed for both conditions separately.

iii)

Flexibility Analysis of lines shall be carried out using simplified methods or a comprenhensive computer program. Comprehensive computer analysis shall be carried out for the piping as per Cl. No. 05.03 (vii) For lines connected to equipment like vessels, pumps, filters, furnace, compressors or other strain sensitive equipment. The result of the analysis must satisfy the allowable loading on the nozzles of such equipment.

iv)

Piping shall be adequately supported for the weight of piping, water, attached unsupported components, wind, seismic, insulation and any other applicable forces. Care should be taken that these supports are adequate to prevent excessive stress, load or moments in either the piping or terminal nozzles of the equipment to which it is connected. Adequacy of supporting of lines having heavy valves shall be checked. The support shall be indicated in the piping General Arrangement Drawings and Isometrics as applicable. Sheet 3 of 8

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DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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v) Safety valve manifolds and downstream of control valves shall be adequately supported to avoid vibrations.

vi) The following factors shall be considered in the stress analysis Friction for lines >= 8” NB ; @ steel to steel = 0.3: ( Sliding friction), @ steel to Steel =0.1 (Rolling friction), Corrosion Allowance. Initial displacement of nozzles at design temperature(s). Transverse deflections =25 mm( maximum) Longitudinal expansion/contraction = 200 mm (maximum) Special care to be taken to check for expansion loops and shoe support lengths shall be finalized accordingly. viii)

The following shall always be analyzed using comprehensive computer analysis: a) b) c) d)

e)

All lines 4” and above and Design Temp.> 300 deg. C. All lines 8” and above and Design Temp. > 150 deg. C. Al l lines 16” and above and Design Temp. > 80 deg. C. All lines 6” and above and Design Temp. > deg. 65 C that are connected to rotating Equipment, Air Coolers or any other sensitive equipment. Any other system/line that stress engineer feels necessary for stress check.

The report shall comprise of the following: -

Basic input data and calculated conditions. Layout isometric and supports configuration. Load cases and calculated member stresses. Forces, moments and displacements reports. Spring hangers design parameters. Allowable Stress Range. Additional requirements ( reinforcement pad etc.)

Sheet 4 of 8

MECON LIMITED GUIDELINES FOR PIPING DESIGN 05.04

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PROCEDURE FOR FLEXIBILITY ANALYSIS ( MANUAL)

Step I Draw free line diagram covering piping segment and branches on both sides of fixed support (F.S.) for which resultant load / stress is to be worked out. D

B

E

C

COMP

F.S.

COMP

F.S.

A F.S.

Step - II Calculate effective dead load + live load (DL + LL) due to pipe & equipment at point B for segment AB & BC. Step - III Frictional Force Expansion joint / compensator is to take care of thermal elongation / contraction and hence its position is considered as fixed though there may be a very minor change in the location of expansion joint. Practically it is taken as zero displacement. Calculate frictional force f1 & f2 due to pipe segment DB and BE respectively. Frictional force = (DL + LL) x Co-efficient. Of friction Co-efficient., of friction for steel to steel shall be taken as follows : Sliding support Roller support Ball support PTFE pad support

= = = =

Sheet 5 of 8

0.3 0.1 0.1 0.05 to 0.09

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DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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Step - IV Anchor Force Anchor force is to be worked out separately for segment AB and BC. Calculate total elongation / contraction for segment AB. ∆l=l*α*∆t Where ∆l

=

Thermal elongation / contraction in mm

l

=

length of segment AB in meters

α

=

co-efficient of thermal expansion

=

0.012 mm / m / 0c for steel

=

Maximum temp. difference in 0C

∆t •

Identify spring rate of the expansion joint / compensator (kg f/mm)

•

Calculate anchor force due to segment AB using formula Anchor force a1 = Spring rate (Kg f/mm) x ∆ l.

•

Calculate anchor force (a2) due to segment BC in similar way.

Step - V Force due to annular space of disc compensator / bellow compensator.: The annular space remains filled with gas and exerts pressure on the wall of compensator, which is turn, gets transferred to the fixed support.

Sheet 6 of 8

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DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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Force due to annular space of compensator (c1 & c2) = π/4 (D2 – d2)p Where,

D d p

= = =

I.D. of Compensator in mm I.D. of pipe in mm Test pressure of piping system in kgf/mm2(g)

Compensator force c1 and c2 shall be worked out for both the segments AB & BC respectively.

Step VI Blanking Load Blanking load comes into effect when there is change in direction of flow / at the location of isolation device. Direction of blanking load is towards the bend. Blanking load may be worked out using formula. B.L. = π/4 x d2 x p Where d P

= =

ID of pipe in mm test pressure of piping network in kg f / mm2

As is evident, in Case I, no blanking load is applicable at fixed support “B”.

Sheet 7 of 8

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS&PD-1405 Chapter No– 05

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Step VII Prepare the load diagram for the fixed support to be analyzed. Frictional force = f1 ( ) Anchor force = a1 ( ) Force due to compensator c1 (

Frictional force = f2 ( ) Anchor force = a2 ( ) Force due to compensator c2 ( )

)

FS

A

C

Blanking load = 0

B

Blanking load = 0

Based on above diagram, resultant force is worked out at point “B”. Resultant 1: Frictional force = f = f1 – 0.7 f2 (

), where f1 ≥ f2

Anchor Force = a = a1 – 0.7 a2 (

), where a1 ≥ a2

Force de to compensator = c = c1 – 0.7 c 2 (

), where c1 ≥ c2

All the above forces in this case act along the axis of pipeline. There is no transverse force acting perpendicular to pipe axis. Hence, resultant axial force at “B” = (f + a + c) 05.05

WIND LOAD CALCULATION Wind load acts on transverse direction across pipe due to pressure of wind. Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind pressure due to cyclonic wind pressure shall be taken. Wind load for a section of pipe = Wind pressure X projected area x shape factor For circular pipes shape factor is 0.7. In case of multiple pipes, for each tier of pipes, largest pipe may be considered for calculating wind load.

Sheet 8 of 8

CHAPTER: 6 PIPING MATERIAL SPECIFICATIONS

MECON LIMITED GUIDELINES FOR PIPING DESIGN

DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

06

PIPING MATERIAL SPECIFICATION

06.01

SCOPE

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This PMS covers the various piping specification for process and utility piping in Metallurgical plants and its related industrial Installation. Deviation from this specification may be necessary to conform to specific job requirements. In such cases a separate and specific PMS shall be issued with the approval of piping competent authority. 06.02

REFERRED CODES & STANDARDS All piping shall be designed in accordance with relevant latest codes and standards like B 31.1, B 31.3 and different IPSS (Inter plant standard for steel industry) Individual piping material specification has been designed to cover a set of services operating within fixed pressure and temperature.

06.03

PIPES

06.03.01

Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for carbon steel pipe and to B36.10/B36.19 for stainless steel pipe.

06.03.02

Pipe made by acid Bessemer process shall not be acceptable.Pipes shall be made by open hearth, electric furnace or basic oxygen process.

06.03.03

All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted.

06.04

FLANGES Flanges shall be in accordance with following codes except where otherwise noted. DN 15 to DN 600 (150 # - 600#) Above DN 600

ANSI/ANSI B16.5 / IS : 6392

API 605 / ANSI B16.47 / MSS-SP-44 / IS:6392 DIN etc.

Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be made with equipment or valve flanges with corresponding bolting. 06.04.01

Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME B16.5. The interpretation shall be as follows : Serrated

:

250 – 500 Mu in AARH

Smooth (125 AARH)

:

125 – 250 Mu in AARH

For RTJ groves (32 AARH) :

32 – 250 Mu in AARH

Page 1 of 27

MECON LIMITED GUIDELINES FOR PIPING DESIGN 06.04.02 06.04.03

DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

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Bore of WN flanges shall match the ID of the attached pipe Bore of slip on flanges shall suit the pipe OD and its thickness. Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2) is indicated in Table 06.01

06.05

FITTINGS

06.05.01

Forged steel socket welded and threaded fittings shall be in accordance with ANSI B 16.11 unless otherwise noted.

06.05.02

Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise noted.

06.05.03

Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless otherwise specified.

06.05.04

Fittings thickness and tolerance shall match pipe thickness and tolerance.

06.05.05

Mitres and reducers fabricated form pipe may be use if specified in PMS, shall conform to IPSS:1-06-020-95. In no case mitres thickness and material shall be inferior to parent pipe.

06.06

GASKETS

06.06.01

Non metallic gasket shall conform to IS:2712.

06.06.02

Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20.

06.06.03

Ring type and spiral wound gasket shall be self aligning type.

06.07

BOLTING

06.07.01

Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992. Unless otherwise noted.

06.08

THREADS

06.08.01

Threads for threaded pipes, fitting flanges and valves shall be in accordance with B1.20.1 taper threads unless otherwise noted.

06.08.02

Upto 2000C threaded joints shall be made with 1” width PTEE joining tape.

06.08.03

Above 2000C threaded joints shall be seal welded with full strength fillet weld.

06.08.04

All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid shall be seal welded with a full strength fillet weld.

Page 2 of 27

DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

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06.09

VALVES

06.09.01

Face to Face/End to End dimension of valves shall conform to B16.10 to the extent covered. For valves not covered in B16.10. reference shall be made to BS2080 and / or the manufacturer’s drawings.

06.09.02

Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting ends of the piping class, unless otherwise specified.

06.09.03

Pressure temperature rating for flanges and butt welding end valves shall be as per ANSI B16.34 except for ball, plug & butterfly valves. For these valves refer TABLE FOR PRESSURE TEMP. RATING FOR BALL, PLUG AND BUTTERFLY VALVES Unless called-out specifically, valves shall be as per the following Standards.

06.09.04

Valve

Size mm

DN Rating

Des. Std.

Testing Std.

Gate

15 - 40

800/1500

API-602

API-598

Globe/Check

15 - 40

800/1500

BS – 5352

BS-6755 Pt-I

Gate

50 - 600

150/300/600

API-600

API-598

Gate

650 - 1050 150/300

BS-1414

BS-6755 Pt-I

Globe

50 – 200

150/300/600

BS-1873

BS-6755 Pt-I

Check

50 – 600

150/300/600

BS-1868

BS-6755 Pt-I

Gate/Globe/Check

900/1500/2500# B-16.34

API-598/ BS6755 Pt-I

Ball

15 – 400

BS-5351

BS-6755

Plug

15 – 300

API-599

API-598 /BS-5353 BS-6755

Butterfly

80 above

& -

API-609/ BS5155 AWWA C504

API-1898/ BS-6755 Pt-I /AWWA

Diaphram

ALL

-

BS-5156

BS-6755 Pt-I

06.09.05

If not covered in 06.09.04 the valve shall be as per B16.34 and relevant MSS SP Standard

06.09.06

DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and utility service shall have bolted bonnets. Pressure seal bonnets or covers shall be used for Classes 900# and above to minimize bonnet leakage. However, valves with pressure seal bonnet shall have wall thickness & seal stem diameter as per API600. Welded bonnets or screwed & seal welded bonnets are acceptable for sizes lower than DN 50 for Classes 900# & above. Page 3 of 27

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DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

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PIPING MATERIAL SPECIFICATION SERVICE : BF Gas, CO Gas, BOF, Corex Gas & Mixed Gas SERVICE CONDITIONS : Maximum Working Pressure 1500mmWC Minimum Working Pressure 50 mmWC

Temp 60 oC Temp 5 oC

CORROSION ALLOWANCE : 2 m.m. Item

Size Range

Description

Pipe

DN 15 to 40

Fittings

ERW, PE; Sch Heavy

Dimension Standard IS : 1239

Material Specification IS:1239 - Black

DN 50 to 150

ERW, BE; Sch Heavy

IS : 1239

IS:1239 - Black

DN 200 to 350

ERW, BE; 6 mm Thk

IS : 3589

IS: 3589 Gr.330

DN 400 to 750

ERW/SWP,BE; 8 mm Thk

IS : 3589

IS: 3589 Gr.330

DN 800 to 3500

Fabricated – Electric Fusion Welded, BE; 10mm Thk.

IS : 3589

IS : 2062, Gr.B

DN 15 to 40

SW /Screwed Fittings (Elbow R=1.5D) BW (Elbow R=1.5D)

IS : 1239 (P-2)

IS : 1239 (P-2) Black

IS : 1239 (P-2)

IS : 1239 (P-2) Black

IPSS-06-20

IS : 2062, Gr.B

Upto DN 150

Fabricated Miters bends & fittings from pipe / plate SORF; Serrated Finish

IS: 2062, Gr.B

DN 200 to 300

SORF; Serrated Finish

DN 400 & above Upto DN 500

SORF; Serrated Finish

IS : 6392 Table - 5 IPSS:1-06-20 Table 3 IPSS:1-06-20 Table 3 As per Flange

DN 50 to 150 DN 200 & above Flanges #150

Gaskets

IS: 2062, Gr.B

DN 15 to 40

Gasket: Thk. 2 mm Ring Type CAF Asbestos rope graphite impingnated. Ǿ8mm Gate valve; Screwed

API 602

DN 50 to 550

Gate valve; Flanged

IS : 14846

Body ASTM A105; Cr 13% Trim Body CI GR. FG 200

IPSS: 1-06-023

Body CI, Gr.FG-210

Above DN 500 Valves

IS: 2062, Gr.B

DN 600 to 1600 Gate valve; Flanged

Page 5 of 27

IS : 2712 Gr W/3

MECON LIMITED GUIDELINES FOR PIPING DESIGN Item

DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

Size Range

Description

DN 1800 & above

Gate valve; Flanged

DN 15 to 40 DN 50 and above DN 15 to 40 DN 50 to 300 DN 350 & above DN 15 / DN 25 Bolting

All

Piping Fabrication

Flanged Joints Pipes Joints

Rev - 0 Page 6 of 27

Dimension Standard MSS

Material Specification Body IS: 2062 GR. B

Check valve SW – Lift Type #800 Check Valve Flanged swing check valve/ dual plate #150 Globe valve SW / Screwed ; #800

BS 5352

Body A105, 13% Cr Trim Body A216;WCB, 13% Cr Trim

BS 5352

Body A105, 13% Cr Trim

Globe valve; Flanged ; Serrated Finish; #150 Butterfly valve WAF Type; #150 Screwed LUB.TAPERED PLUG VALVE M/C Bolts

BS 1873

Body A216 Gr WCB, 13% Cr Trim Body A216 Gr WCB;13% Cr Trim Body & PLUG : CI IS 210 FG 200

BS 1868 / API 594

BS 5155/ API 594 BS: 5158

ASTM A193 Gr IS: 1364- 1992 B7 Nuts ASTM A194 Gr IS: 1364- 1992 2H At valve/ equipment location and for sectionalising & Maintenance. To be kept minimum DN 50 & below SW coupling DN 50 & above Butt welded

Fabricated pipes

Fillet welding using semi bandage on each segment.

Temp Connections

DN 40 – Flanged set-on nozzle

Pressure Tapping Vents

DN 20 – SW Half Coupling Nipple Sch 80 with Gate valve to Spec. On lines >= DN 50 ; MEC std.

Drains

On lines >= DN 80, MEC Std.

Note: For flange dimensions refer Table 06.01.

Page 6 of 27

MECON LIMITED GUIDELINES FOR PIPING DESIGN

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PIPING MATERIAL SPECIFICATION SERVICE : LPG /PROPANE SERVICE CONDITIONS : Maximum Operating Pressure 6 kgf /cm2 Minimum Operating Pressure Atm

Temp 60 oC Temp 5 oC

CORROSION ALLOWANCE : 1.5 mm. Item

Size Range

Description

Pipe

DN 15 to 40

Fittings

Seamless PE Sch. 80

API 5L GR.B

DN 50 to 150

Seamless BE Sch.40

B36.10

API 5L GR.B

DN 200 to 300

Seamless BE Sch.20

B36.10

API 5L GR.B

DN 350

Seamless BE Sch.10

B36.10

API 5L GR.B

DN 400 & above DN 15 to 40

EFSW BE Thk. 6.0mm

B36.10

API 5L GR.B

SW / Screwed Fittings # 3000 (Elbow R=1.5D) BW Fittings #150 (Elbow R=1.5D)

ANSI B 16.11

ASTM A 105

ANSI B16.9

ASTM A234 Gr WPB

Miter bends & fittings fabricated from pipe SW:RF : Serrated Finish; #150 SORF : Serrated Finish; #150 Gasket : Thk. 2.0 mm Ring type CAF Gate valve SW # 800

IPSS-1-06-020

Same as parent pipe

B 16.5

ASTM A 105

B 16.5

ASTM A 105

B 16.21

IS : 2712 Gr W/3

API 602

Body A105 ; 13% CR Trim Body A216 Gr. WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim Body A105; 13% Cr Trim Body A216 Gr.WCB 13% Cr Trim

DN 50 to 150

Flanges

Material Carbon Steel

Dimensional/ Design Standard B 36.10

DN 200 & above DN 15 to 40 DN 50 & above

Gaskets

All sizes

Valves

DN 15 to 40 DN 50 to 600 DN 15 to 40 DN 50 to 200 DN 15 to 40 DN 50 to 600

Gate valve Flanged RF Serrated Finish # 150 Globe valve, SW # 800 Globe valve : Flanged RF Serrated # 150 finish Check valve SW # 800 Lift type Check valve flanged RF Serrated finish # 150

Page 7 of 27

API 600 BS 5352 BS 1873 BS 5352 BS 1868

MECON LIMITED GUIDELINES FOR PIPING DESIGN Item

Size Range

Description

DN 15 to 150

Ball valve flanged RF Serrated finish #150 Studs / Bolts Nuts

Bolting

All

Miscellaneo us

DN 15 to 40

Dimensional/ Design Standard BS 5351 B 18.2 B 18.2

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Material Carbon Steel Body A216 Gr.WCB 13% Cr. Trim ASTM A193 Gr B7 ASTM A194 Gr 2H

TRAP #150, THRMDNMC PERM. STR, SW, Y Type PERM. STR, BW, T Type PERM. STR, BW, T Type

MANF’ STD.

Above DN 600

TEMP. STR, FF, CONE Type

MEC’ STD.

Flanged Joints

At valve/ equipment location and for sectionalizing & maintenance To be kept minimum DN 40 & below SW coupling DN 50 & above Butt welded DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec. Gate DN 40 – Flanged set-on nozzle

DN 15 to 40 DN 50 to 350 DN 400 to 600

Piping Fabrication

DOC No MSTD-DESG-FS & PD-1405 Chapter No - 06

Pipes Joints Pressure Tapping Temp Connections Vents Drains

MANF’ STD. MANF’ STD. MANF’ STD.

On lines