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ENGINEERING MANUAL FOR PIPING LAYOUT

EM- L - 004
ENGINEERING MANUAL
FOR
PIPING LAYOUT

The present document or drawing is property of TECHNIP INDIA Ltd., and shall not, under any circumstances, be totally
or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent,
for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed
upon right of use.

01-10-08

Revised and Issued for Implementation

AM

JKR

BVR

23-11-98

PP

JKR

JKR

Rev

Date
DD/MM/YY

STATUS

WRITTEN BY
(name & visa)

CHECKED BY
(name & visa)

APPROVED BY
(name & visa)

DOCUMENT REVISIONS

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Sections changed in last revision are identified by a vertical line in the right margin

PIPING LAYOUT
CONTENTS
PART I
PIPING AND PIPING SPECIALITIES

PAGE
3

PART II
EQUIPMENT PIPING

18

PART III
INSTRUMENT PIPING

55

PART IV
OFFSITES PIPING

69

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PART I
PIPING AND PIPING SPECIALITIES

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PART I
PIPING AND PIPING SPECIALITIES

PAGE

1.0

PIPE RACKS

2.0

PIPE SPACING

11

3.0

STEAM TRAP PIPING

13

4.0

LIST OF DRAWINGS

16

4.1

803-ES-L-172

6 Sheets

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4.2

803-ES-L-034

4 Sheets

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4.3

803-ES-L-174

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SECTION 1
PIPE RACKS

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SECTION 1
1.0

PIPERACKS

1.1

SPACING FIGURE 1.1 ( See Drawing 803 ES L - 172 SHT 1 OF 6 )

1.1.1 On completion of the routing diagram, the pipe rack width/tier ratio at
selected line density locations can be determined by either:
a)

Using the formula


Where

0.50N
W = -------T
W = Approximate width in metres for the installed rack.
N = Number of lines given at the early stages of the
project.
T = Number of rack levels or tiers contemplated.

The above empirical formula allows for the following, when rack lines are
an average of 150NB size.

Average spacing of lines = 300 mm


25% increase in number of lines and re-sizing of lines.
25% of rack width for future lines.
Space for instrument and electrical cable trays.
For example:
Number of lines = 24
Number of levels = 2
W=

0.50 x 24
------------ =
2

12 metres
------------- = 6000mm wide pipe rack
2 levels

The rack width determined by this formula should be confirmed by detailed


piperack studies.
b)

Drawing piping sections through the rack.

1.1.2 Sections X-X and Y-Y on figure 1.1 indicates locations selected by
observations, where the number of tiers required may be subject to
adjustment.

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1.1.3 For minimum pipe spacing refer to section 2.


1.2

PIPERACKS LOCATION OF LINES - FIGURE 1.2


( See drawing 803 ES L - 172 SHT 2 OF 6 )
A cross section of a typical three (3) level piperack is shown on Sht 2 of 6.
Lines have been placed in the preferred location conforming to the
following:

1.2.1 Largest and heaviest line to the outside


1.2.2 Group steam and condensate lines on top tier with largest and hottest at
rack edge.
1.2.3 Small bore utility and instrument lines top level centre.
1.2.4 Large bore cooling water lines on bottom level (at rack edge) as most
users will be at grade. Check for possibility of running these lines
underground.
1.2.5 Rack take-offs and changes in direction of headers will generally be
executed by a change of elevation except for safety valve headers, which
must maintain a gradual slope to the knock out drum.
Branches should connect to the top of headers containing a gas or vapor
and to the bottom of headers containing liquids. Large lines which are
located near the edge of the piperack can turn out of the rack flat to save
fittings.
1.2.6 Equipment elevation and line destination will sometimes dictate the rack
elevations. As a general guide, short distance process line will occupy the
lower level and longer distance process lines will occupy the middle and
top levels. Utility header will normally run on the top level.
Carefully consider the economic routing and flexibility of exotic material
lines.
1.2.7 Structural tie-beams or longitudinals will be used for supporting line takeoffs. Side steel beams will only be added as needed for the support of
piping.

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1.2.8 Lines to be spaced according to line spacing chart. See Section 2.


1.2.9 Cable trays are preferably located on the top pipe rack level. Different
types of cables e.g.: instrument, high voltage, requires a definite
separation distance. Finalise with Electrical Design Department for an
estimated size of the cable trays and preferred position.
1.2.10 Position of lines may depend on location of utility and process lines
entering or leaving battery limits.
1.2.11 In general, lines that enter and leave the piperack from above the top level
are positioned on top level and lines that enter and leave the piperack
from below the lower level are positioned on lower level.
1.2.12 Where possible, Lines with orifice flanges should be located at the outside
of the piperacks with these flanges local to a structural column for ladder
access.
1.2.13 Group lines with cold insulation together and locate as remote as possible
from lines with hot insulation.
1.2.14 Indicate on piperack drawing that double random length pipe is preferred
and this should be on the final drawings.
1.3

PIPERACKS FLARE HEADER FIGURE 1.3 TO 1.4


( Drawing 803 ES -L- 172 SHT 3 of 6 )

1.3.1 Special consideration must be given to the Flare or Relief Header. This
line should slope in the direction of the flare knockout Drum and should
not be pocketed, See Section 11 of engineering manual EM/L/003 for
details.
1.3.2 Locate Flare Header at the edge of the rack to accommodate any flat
expansion loops that may be required
1.3.3 Locate Flare header to allow for safety valves and discharge piping to be
positioned above it without pockets and in to the top of the header.
1.3.4 Connections in to the header can be laterally at 45 Deg if pressure drop is
critical within the system. See Figure 1.4 Sht 3 of 6.

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1.4

PIPERACKS PIPING FLEXIBILITY FIGURE 1.5 TO 1.8


( Drawing 803 ES L - 172 SHT 4 of 6 )

1.4.1 Preliminary flexibility analysis takes place during the early stages of the
piperack development. Line temperature and insulation thickness if
known, should be indicated on lines to assist the Engineer.
1.4.2 Expansion loop nests should be located by the piping engineer relative
to the assumed location of anchors, See Figure 1.5. The loops will
generally rise to the established take-off level.
Figure 1.6 indicates typical steam / condensate loop arrangement. Note
that provision should be made for drip legs on inlet side of steam header
loops.
1.4.3 Lines of extreme temperature hot or cold, process or utility, which travel
long distances on the rack must be examined for adequate flexibility and
clearances with adjacent lines.
1.4.4 All branch lines that join headers in the rack should be checked for
adequate flexibility relative to the thermal movement of the headers, See
figure 1.7.
1.4.5 Line spacing should be checked for expansion clearance at changes of
direction, See figure 1.8.
1.4.6 See engineering manual EM/L/005 for additional information relating to
piping flexibility.
1.5

PIPERACKS BATTERY LIMITS FIGURE 1.9, 1.10, and 1.11


( Drawing 803ESL-172 SHT 5 of 6 & 803ESL-172 SHT 6 of 6)

1.5.1 Lines crossing battery limits will normally be valved requiring platform
access, See P&I diagrams for extent of valving.
1.5.2 Figure 1.9 shows a typical single level piperack where the elevation is to
be maintained across the battery limit. The walkway will be elevated to
clear the largest anticipated line and located to suit the largest valve.
1.5.3 Valves will be staggered on either side of walkway and be provided with
extension stems as required. Battery limit line locations are normally an
early priority.

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1.5.4 Where lines cross the battery limit at grade, valves will be located as
indicated in Figure 1.10.
1.5.5 Figure 1.11 shows a two level piperack the Battery Limit valves accessible
from a single platform.

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SECTION 2
PIPE SPACING

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SECTION 2

2.0

PIPE SPACING
The Drawing 803ESL034 ( 4 Sheets ) were developed for use by
piping design personnel to determine the minimum distance required
between adjacent runs of piping.

2.1

803ESL034 SHT 1 of 4 is used for spacing 150# and 300# bare pipe
to flanged bare pipe. Dimension A is given in the form of a chart.

2.2

803ESL034 SHT 2 of 4 is used for spacing 600# bare pipe to flanged


bare pipe

2.3

803ESL034 SHT 3 of 4 is used for spacing 1500# bare pipe to flanged


bare pipe.

2.4

803ESL034 SHT 4 of 4 gives spacing of lines in trenches and


sleepers, between lines with valves. The spacing must be increased when
the bare pipe is insulated in the above charts.
It may be also be noted that spacing shall be increased to accommodate
any lateral movement due to expansion and to prevent bumping of lines at
changes of direction.

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SECTION 3
STEAM TRAP PIPING

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ENGINEERING MANUAL FOR PIPING LAYOUT

SECTION 3
3.0

STEAM TRAP PIPING

3.1

STEAM TRAPS
There are various types of steam traps used in process plants.
Table 1 in Drawing 803-ES-L-174 SHT 1 of 3 gives data on Traps and
additional information, relative to the application of the steam traps
under various operating and climatic condition.
Check with process design department for the type of steam trap to be
used for to be used for the specific project.

3.2

STEAM TRAP ARRANGEMENTS


(see Drawing 803ESL-174 SHT 2 of 3 and 803ESL174 SHT 3 of 3)

3.2.1 All valves shown on the details on sheets 2 of 3 & 3 of 3 are gate valves
3.2.2 The drip pocket valve and blind flanges is to be used for periodically
blowing down. For safety, the valve should be piped to a drain or grade
3.2.3 A valve downstream of trap is required when the discharge to a header.
( See sheet 2 of 3 for collected condensate system and sheet 3 of 3 for a
drained condensate system ).
3.2.4 A strainer would be fitted in the line before the trap to prevent any particles
from interfering with the performance of the trap. However, in some cases
the strainer is an integral feature of the trap.
3.2.5 A by-pass is normally provided to allow for the steam trap to be replaced.
3.2.6 Insulation is needed in a cold environment if there is a risk of freezing as a
result of shutdown or intermittent operation, or in any climate for personnel
protection.
3.2.7 An isolating valve may be provided at the point of entry into the header.
Check individual project requirements.

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3.2.8 Drip pockets should be provided at the following positions on steam lines
where condensate collects:a) At low points before or at bottom of risers i.e: expansion loops in a
piperack.
b) On straight run steam headers approx. every 46,000 mm (150-0)
prior to rises and at dead ends. Check individual project
requirements.

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SECTION 4
LIST OF DRAWINGS

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SECTION 4

4.0

LIST OF DRAWINGS

4.1

803-ES-L-172

6 Sheets

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4.2

803-ES-L-034

4 Sheets

Rev 0

4.3

803-ES-L-174

3 Sheets

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PART II
EQUIPMENT PIPING

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PART II
EQUIPMENT PIPING

PAGE

1. 0

TOWERS

20

2.0

VESSELS

23

3.0

CIRCULAR HEATERS

25

4.0

CABIN HEATERS

31

5.0

REACTORS

37

6.0

SHELL & TUBE EXCHANGERS

40

7.0

PUMPS

46

8.0

CENTRIFUGAL COMPRESSORS

49

9.0

LIST OF DRAWINGS

53

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SECTION 1
TOWERS

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ENGINEERING MANUAL FOR PIPING LAYOUT

SECTION 1
1.0

TOWERS ( See Drawing 803ESL175 Sht 1, Sht 2, Sht 3, Sht 4, Sht 5,


Sht 6, Sht 7, Sht 8 )

1.1

Use minimum headroom elevation as specified on vessel drawing when


tower elevation is not governed by pump NPSH or reboiler requirements.

1.2

Where possible, link platforms to adjacent towers or structures. Review


differential thermal growth of vessels and possible need for pin connecting
platform to vessel.

1.3

900 mm is the preferred location. When not possible, keep within the
range of 750 mm minimum to 1250 mm maximum.

1.4

Confirm support and guide locations by stress analysis. Stagger supports


and guides for clearance.
Pipe support should be located at a minimum distance from the nozzle.
Provide a clearance of 150 mm from weld of elbow to top of pipe support.
As a general rule, guides may be located at 25 pipe diameters apart.
Lowest guide to be a minimum of 25 Pipe diameters above the lowest
elbow.

1.5

Safety Valves ( S.V ) to atmosphere: S.V. to be located at first platform


under top manhole for good supporting of the outlet pipe. Removal of S.V.
is normally by tower davit. Terminate outlet pipe a minimum of 3000 mm
above the highest platform within a vicinity of 8000 mm.
Safety valve to closed System: S.V. to be located at a convenient platform
above flare header. Support the valve and connecting piping by
strengthening the platform steel at that point. Overhead line to be
reviewed by process Engineer for proper line size between tower nozzle
and S.V. inlet, to ensure that the pressure drop does not exceed 3% of the
S.V. set pressure.

1.6

Level instruments may be close coupled to vessel or on a bridle or


standpipe. Liquid level ( L.L ) displacer should always be located at dead
end of platform.

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Never locate level instrument nozzles opposite to feed nozzle unless


protected by internal baffle. Check with Mechanical & Thermal Equipment
/ Process. Design department.
1.7

Overhead platform are only required for additional valve / level


instruments accessible or if the distance, between platforms is greater
than 9000 mm. (Check clients requirement for maximum ladder length).

1.8

Overhead line to be supported from tower. If the distance between the


tower and rack is excessive, then an extra support at the piperack may be
required. If the vertical movement of the overhead line is excessive, this
support may require a spring.

1.9

For dimension from back of pipe or insulation to vessel shell, see Section
1.13 below.

1.10

If access is required to a nozzle for operating a valve or inserting a blind


etc., additional sections of platform may be required.

1.11

For typical reboiler hookups, see Section 6. For Shell and Tube
Exchangers.

1.12

Vertical Vessel Piping ( See drawing 803ESL175 sheet 8 of 8 )


Vessel riser piping should be planned on a fitting-to-fitting dimension from
face of the vessel nozzle unless required otherwise by client.

1.13

In case the choice is left to the engineer, an arbitrary dimension (such as


overhead lines or where offsetting is required for clearances), use valves
d shown in Table A of above drawing and add O.R (outside radius) of
vessel to determine the radial distance of the riser from the centre line of
vessel.
If offsetting is required on risers, it is preferable to start the offset at a
point as close to the nozzle as possible.

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SECTION 2
VESSELS

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SECTION 2
2.0

VESSELS ( SEE DRAWING 803-ES-L-176 Sht 1, Sht 2, Sht 3 )

2.1

Elevation of lower platform to be established for access to instruments


and manway.

2.2

Elevation of top platform to be approximately 150mm below face of all


nozzles serviced from platform.

2.3

Pump suction line to be run above minimum head clearance.

2.4

Bottom invert elevation of vessel to be fixed by NPSH of pump.

2.5

Platform required at manway if centerline of drum is generally above 3


metres. Alternative location of manway is on top drum.

2.6

Run piping at a common B.O.P. elevation to simplify supporting.

2.7

Minimum dimension above grade to be 450 mm B.O.P. or insulation.

2.8

If inlet is gravity flow, line should slope to vessel.

2.9

Relief valve discharge to be high enough to allow to line enter top of


flare header. If in this case the relief valve is not accessible from top
platform, it must be relocated on the nearest platform with sufficient
elevation. If relief valve is located away from vessel, the line from drum to
relief valve must be checked for correct line size.

2.10

Valves in control set in the off-gas line to be orientated so that they are
accessible from top platform.

2.11

Level instruments to be positioned so that they are accessible from


ladder when the top connection elevation exceeds 3 metres.

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SECTION 3
CIRCULAR HEATERS

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ENGINEERING MANUAL FOR PIPING LAYOUT

SECTION 3
3.0

CIRCULAR HEATERS ( Drawing 803-ES-L-177 Sht 1, Sht 2, Sht 3, Sht 4,


Sht 5, Sht 6, Sht 7 & Drawing 803-ES-L-178 Sht 1, Sht 2, Sht 3 )
Circular heaters are selected generally for duties involving the cracking or
reboiling of lighter ends, i.e.: Kerosene cracking, Naphtha hydrocarbon
Cracking, Alkylation Reboiling, etc.

3.1

HEATERS PARTS
The following component parts are to be read in conjunction with Figures
3.1 and 3.2 in Drg 803-ES-L-177 Sht 1 of 7 & 803-ES-L-177 Sht 2 of 7.

3.1.1 Radiant Section It is the large part utilizing heat radiating from burners.
The tubes are in a vertical position.
3.1.2 Convection section This is the heat transfer section located directly
beneath the stack. The tubes are in a horizontal position.
3.1.3 Burners These are located at the base of the radiant section. They are
usually designed to burn fuel oil and fuel gas. Fuel oil is used to start-up.
When the plant is operating normally, fuel gas is produced from the
process plant for burners on fired heaters. Adequate space must be
allowed for removal of burner gun.
3.1.4 Peep Doors These are located in convenient positions to allow easy
observation of burner flames. Valves in the burner piping are usually
manifolded and located such that flame adjustment can be achieved
simultaneously with flame observation from a platform local to the peep
door.
3.1.5 Explosion Doors - (If required) These are designed to relieve pressure
should an explosion occur within the heater.
3.1.6 Damper This regulates the burner draft. The control is normally by cable
or linkage, to allow manual adjustment from grade. The system can also
be designed to function automatically.

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3.1.7 Access Door This is a removal door, which allows access into the heater
for inspection of tubes and refractory lining. Access doors must be kept
clear of external and internal piping.
3.1.8 Snuffing Steam Connections These are used to extinguish the flames
inside a heater in the event of the fire. They are usually located in the
base of radiant section and at the header boxes.
3.1.9 Soot blowers These are usually specified for heaters that use oil for fuel.
They are used to clear the tubes of soot by blowing steam through a
projecting lance.
3.1.10 Crossovers This is the piping connecting the radiant section with the
convection section, and it may be located inside or outside the heater.
Crossovers are usually supplied by the heater vendor.
3.1.11 Instruments
Draft Gauge Connection Usually located just beneath the damper
and in the radiant section. A differential pressure instrument is
connected to these points to measure the burner draft.
Tube Skin Thermocouple These measure the tube temperature in
the heater.
Sample Connection Usually located just below the damper.
Temperature Connections These are usually located in the stack
and also just below the convection section. A thermocouple is usually
located at the lower radiant section.
3.1.12 Flame Failure Systems If such a system is built into the heater
allowance must be made for a local cabinet. Orientation of the scanners
must be such that the flame can be seen. An air system will be required
for purging the scanners. Extra peep doors may also be required if its a
positive system.
3.1.13 Heater Piping Loads The heater requisition should state that it is the
responsibility of the heater vendor to provide adequate platform framing
and steel work to accommodate all external piping loads.

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At the early stages of the heater piping study, an effort must be made by
the piping engineer to establish piping loads for all externally connected
piping. This study is to be forwarded to the heater vendor so that provision
can be made with the support of the heater tubes and in the design of the
heater steelwork to accommodate these loads.
Piping Engineer must coordinate external piping flexibility requirement
together with tube movements given by the heater vendor. Liaison may be
required with heater vendor to support internal piping to ease any
supporting and flexibility problems associated with external piping.
3.2

PIPING ARRANGEMENT AT CIRCULAR HEATERS LOWER LEVEL


( Figures 3.3 & 3.4 Drawing 803-ES-L-177 Sht 3 of 7 & 4 of 7 )

3.2.1 Valving to be located local to peep doors at heaters.


3.2.2 Fuel shut off valve to be located a minimum of 15000 mm (50.0) from
edge of heater.
3.2.3 Snuffing steam valve manifold to be located a minimum of 15000 mm
( 50.0 ) from edge of heater.
See figure 3.8 (Drg 803-ES-L-178 Sht 1 of 3) for additional information
relative to Burner piping.
3.3

PIPING ARRANGEMENTS AT CIRCULAR HEATER INTERMEDIATE


LEVEL ( Figure 3.5 Dwg 803 ES L - 177 Sht 5 of 7)

3.3.1 Process outlet piping to be kept symmetrical about heater.


3.3.2 Process outlet (transfer line) to be as short as possible and run without
pockets. Special consideration should be given to flexibility and supporting
of this line.
The relative location of heater and associated process equipment is often
determined by this line.
3.3.3 Process piping shall be routed around heater so that they can be suitably
supported.

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ENGINEERING MANUAL FOR PIPING LAYOUT

3.4

PIPING ARRANGEMENT AT CIRCULAR HEATERS UPPER LEVEL


(Figures 3.6 and 3.7 Drg 803-ES-L-177 Sht 6 of 7 & Sht 7 of 7)

3.4.1 Platforms required for decoking and soot blower operation.


3.4.2 All piping may be anchored to heater steelwork. Flexibility of piping to be
determined and heater vendor suitably advised on resulting loads.
3.4.3 Process inlet piping to be kept symmetrical about heater.
3.4.4 Access door for tube removal to be kept clear of obstructions and piping.
3.4.5 Break flanges are sometimes required to facilitate removal of tubes.
3.4.6 Decoking piping to be kept symmetrical about heater. Due to extreme
temperature, special consideration should be given to flexibility and
supporting.
3.5

BURNER PIPING (Figure 3.8 Drawing 803-ES-L-178-Sht 1 of 3)

3.5.1 Break joints shall be installed in the fuel piping to burners so that burner
can be withdrawn easily.
3.5.2 Fuel piping can be run horizontally or vertically to suit head height
requirements.
3.5.3 Fuel headers to be run underneath platforms to facilitate supporting of
pipe.
3.5.4 Piping to burner gun should designed and routed such load or moment is
transmitted on to the burner gun.
3.5.5 Valving to be local to peep doors.
3.6

DECOKING HEATERS COILS


Depending on the type of feed stock, coke can build up inside the tubes.
this greatly reduces flow and heat transfer. This coke build up usually
occurs in very high temperatures and services where the heater feedstock
is a relatively heavy hydrocarbon.

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Heater decoking, if required, is accomplished during a shutdown of the


heater.
The tubes are purged of hydrocarbon vapors. Decoking steam is purged
into the heater coils, to blast coke from the inner walls of the coils. air is
finally introduced to burn out any remaining coke.
See P & I Diagrams for decoking details.
3.7

SOOT BLOWER PIPING

3.7.1 Soot blowers are specified for heaters that use oil for fuel and have a
convection section. As the oil is burned soot builds up on the exterior of
the convection tubes and reduces heat transfer. Soot blowers are then
used to clear the tubes of soot. Steam is blown through a lance, stroking
the outside of the tubes which dislodges the soot.
3.7.2 There are two basic types of soot blowers:
(a) Fixed Rotating
(b) Retractable Rotating
3.7.3 Access platforms are required for maintenance of soot blowers.
Retractable soot blowers require withdrawal space.
3.7.4 Slope steam piping away from inlet connection. Valving may be located
locally or manifolded at grade. Check requirements of soot blowing in
sequence. This may affect manifolding of soot blowers. See detail in
Drawing.

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SECTION 4
CABIN HEATERS

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SECTION 4
4. 0

CABIN HEATERS
The direct-fired heater is used in all distillation units, in many cracking
systems and in several processes such as Alkylation, Polymerization and
Reforming.
Most heaters are built with two distinct heating sections; a radiant section
which can receive heat directly from the flame and convection section
which recovers heat from the hot gases travelling to the stack.
The box or cabin type heaters are commonly used, as they are well suited
for large capacities.
The design of piping to and from the heater is generally conducted along
with stress analysis, particularly with regard to the process inlets and
outlets.
The heater manufacturer normally allows for inlet and outlet nozzle
displacement due to the expansion of tube supports within the heater
under hot or operating conditions. Also, to provide tube anchor within
close proximity of the nozzles together with tabulated allowable and
directional loading afforded by external piping.
Care should be exercised in designing the process outlets and transfer
Line, piping as they are sometimes subjected to somewhat turbulent
conditions. As for example, a heater is usually at higher temperature than
the fractionator vaporizer temperature, because self-evaporation occurs
as the fluid flows through the transfer line. The heat required for this
vaporization comes from the sensible cooling of the stock flowing in the
line. Also, if steam is present at the vaporizer a sizeable vaporization or
flashing occurs at the end of the transfer line, which causes a further
decrease in temperature. Efforts should be made, therefore, to maintain a
smoothness of flow in this piping.
An isometric sketch of the completed transfer line arrangement is usually
forwarded to the process design department for process requirement
clearance.

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4.1

HEATER PARTS
The following component parts are to be read in conjunction with Figure
4.1 (See Drawing 803-ES-L-179 Sht 1 of 6)

4.1.1 Radiant Section - This is the large part utilizing heat radiating from
burners. The tubes are in a horizontal position.
4.1.2 Convection Section - This is the heat transfer section, which is located
directly beneath the stack. The tubes are in horizontal position.
The rate of heat absorption tends to be high at the entrance to the
convection section because heat is delivered by both radiation and
convection. The feed, because it is cooler, is sometimes introduced
through tubes in this area, and in some instances steam is superheated or
water heated through these tubes.
4.1.3 Burners - These are located at the base of the radiant section. They are
usually designed to burn fuel oil and fuel gas. Fuel oil is used at startup.
When the plant is operating normally, fuel gas is produced from the
process plant for burners on fired heaters. Adequate space must be
allowed for removal of burner gun.
4.1.4 Peer Doors - These are located in convenient positions to allow easy
observation of burner flames. Valves in the burner piping are usually
manifolded and located such that flame adjustment can be achieved
simultaneously with flame observation from a platform local to the peep
door.
4.1.5 Explosion Doors - These are designed to relieve pressure should an
explosion occur within the heater. They are not always required.
4.1.6 Damper - This regulates the burner draft. The control is normally by cable
or linkage, to allow manual adjustment from grade. The system can also
be designed to function automatically.
4.1.7 Access Door - This is a removable door which allows access into the
heater for inspection of tubes and refractory lining. Access doors must be
kept clear of external and internal piping.

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4.1.8 Snuffing steam Connections These are used to extinguish the flames
inside a heater in the event of a fire. They are usually located in the base
of the radiant section and at the header boxes.
4.1.9 Sootblowers - These are usually specified for heaters that use oil for fuel.
They are used to clear the tubes of soot by blowing steam through a
projecting lance.
4.1.10 Crossovers - This is the piping connecting the radiant section with the
convection section, and it may be located inside or outside the heater.
Crossovers are usually supplied by the heater vendor.
4.1.11Instruments
- Draft Gauge Connection - Usually located just beneath the
damper and in the radiant section. A differential pressure
instrument is connected to these points to measure the burner
draft.
- Tube Skin Thermocouple - These measure the tube
temperature in the heater.
- Sample connections - Usually located just below the damper.
- Temperature Connections - These are usually located in the stack
and also just below the convection section. A thermocouple is
usually located at the lower radiant section.
4.1.12 Flame Failure Systems - If such a system is built into the heater,
allowance must be made for a local cabinet. Orientation of the scanners
must be such that the flame can be seen. An air system will be required
for purging the scanners. Extra peep doors may also be required if
positive draft system.
4.1.13 Heater Piping loads - The heater requisition should state that it is the
responsibility of the heater vendor to provide adequate platform framing
and steelwork to accommodate all external piping loads.

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At the early stages of the heater piping study, an effort must be made by
the piping designer to establish piping loads for all external piping. This
study must be forwarded to the heater vendor so that provision can be
made in the design of the heater steelwork to incorporate these loads.
Final piping loads with exact locations can be forwarded to the heater
vendor later.
Piping Engineer must study the external piping flexibility requirements
together with tube movements given by the heater vendor in assessing
external piping loads and method of supporting piping. Liaison may be
required with heater vendor to support internal piping to ease any
supporting and study flexibility associated with external piping.
4.2

PIPING ARRANGEMENT AT CABIN HEATER - LOWER LEVEL


( Figure 4.3 Drawing 803 ES L - 179 Sht 3 of 6 )

4.2.1 Fuel and inlet control valve sets to be manifolded at piperack columns.
Inlet control valving may need further investigation as to location. Fuel
stop valves to be located 15000 mm ( 50.0 ) distance from heaters.
4.2.2 Removable spools may be required for decoking if shown on P&IDS.
4.2.3 Fuel piping to burners are usually placed along sides of heaters and may
not necessarily be accessible from peep doors.
4.2.4 If decoking line to collection box is located at grade, make sure these are
removable spools for crane access to heater.
4.3

BURNER PIPING - ( Figure 4.4 Drawing 803 ES L - 179 Sht 4 of 6 )

4.3.1 Break joints shall be installed in fuel piping to burners so that burner can
be withdrawn easily.
4.3.2 Fuel piping can be run horizontally or vertically to suit head height
requirements.
4.3.3 Fuel headers to be run underneath platforms to facilitate supporting of
pipe.
4.3.4 Piping to burner gun should be designed and routed such that no load or
moment is transmitted onto the burner gun.

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4.3.5 Valving to be local to peep doors.


4.4

DECOKING - HEATER OILS


Depending on the type of feedstock, coke can build up inside the tubes.
This greatly reduces flow and heat transfer. This coke build up usually
occurs in very high temperatures and in services where the heater
feedstock is a relatively heavy hydrocarbon.
Heater decoking, if required, is accomplished during a shutdown of the
heater.
The tubes are purged of hydrocarbons vapours. Decoking steam is
injected into the heater coils, to blast coke from the inner wells of the coils.
Air is finally introduced to burn out any remaining coke.
See P&I diagram for decoking details.

4.5

SOOT BLOWER PIPING

4.5.1 Soot blowers are specified for heaters that use oil for fuel and have a
convection section. As the oil is burned, soot builds up on the exterior of
the convection tubes and reduces heat transfer. Soot blowers are then
used to clear the tubes of soot. Steam is blown through a lance, striking
the out side of the tubes which dislodges the soot.
4.5.2 There are two basic types of soot blowers:
( See drawing 803 ES L - 179 Sht 6 of 6 )
(a) Fixed Rotating.
(b) Retractable Rotating.
4.5.3 Access platforms are required for maintenance of soot blowers.
Retractable soot blowers require withdrawal space.
4.5.4 Slope steam piping away from inlet connection. Valving may be located
locally or manifolded at grade. Check requirements for soot blowing in
sequence. This may affect manifolding of soot blowers. See detail in
drawing.

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SECTION 5
REACTORS

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SECTION - 5
5.0

REACTORS

5.1

Figure 5. 1 ( Drawing 803 ES L -180 Sht 1 of 4 )

5.1.1 Platforms can be connected to reactor where welding to the vessel shell is
permitted. Consideration must be given to differential expansion between
adjacent shells. .
When welding to shell is not permitted, provide a separate platform
support structure.
5.1.2 Access can be by ladders and/or stairways or a combination of both. This
will depend on clients requirements for operation and maintenance.
5.1.3 The basic philosophy regarding catalyst handling ( mobile or built - in )
should be established during the planning phase of a project.
5.2

Figure 5.2 ( Drawing 803 ES L - 180 Sht 2 o f 4 )

5.2.1 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.
5.2.2 Provide adequate vertical clearance for temperature element removal.
5.2.3 Sidestep ladders are generally preferred.
5.2.4 Allow for heavy insulation thickness when running piping close to the
reactor.
5.2.5 A davit should be provided to facilitate the removal of piping and outlet
nozzle cover, when there is no monorai1.
5.2.6 Provision should be made for the temporary support of this piping during
catalyst filling.
5.3

Figure 5.3 ( Drawing 803 ES L - 180 Sht 3 of 4 )

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5.3.1 The catalyst unloading side of the reactors should be kept clear of all
obstructions at grade, including steelwork bracing.
5.3.2 Swing elbows should be used instead of valves and bypasses on the
process and regeneration piping. This eliminates some stress problems as
the hot and cold parts of the line are not tied rigidly together.
5.3.3 Locate thermowells between the reactor nozzle and the swing elbows on
the process and regeneration piping.
5.3.4 All valves on lines in hydrogen service should be "double blocked". This
includes operational drains, pressure instruments etc., as shown on P and
I diagrams.
5.3.5 Where ring joint flanges are used the piping must be arranged to allow for
valve removal.
5.3.6 In hydrogen service when the line is above auto-ignition temperature,
steam snuffing rings are usually provided around all flanges above 300
NB.
5.4

TIPS FOR REACTOR PIPING

5.4.1 Vessel clips should be avoided.


5.4.2 Consider the weights of pipes and fittings as they are for high pressure
service.
5.4.3 Consider all aspects of maintenance, operation and catalyst handling.
5.4.4 Be aware that an appreciable amount of thermal expansion of reactor
piping can be absorbed by the 4 heater tubes through proper supporting.
5.5

Figure 5.4 ( Drawing 803 ES L - 180 Sht 4 of 4 )

5.5.1 This elevation is established to allow for a catalyst shaker/vibrator to be


bolted onto the unloading nozzle. For layout purposes a dimension of
4000 mm shall be used.
5.5.2 Generally the maximum straight length of ladder should be kept to 9000
mm. If this length is exceeded, additional platforms are required.

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SECTION 6
SHELL & TUBE HEAT EXCHANGERS

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SECTION 6
6.0

SHELL AND TUBE HEAT EXCHANGERS

6.1

FIGURE 6.1 ( Drawing 803 ES L - 181 Sht 1 of 4 & 2 of 4 )

6.1.1 The preferred arrangement of exchangers is shown in Figure 6.1.


Establish a central area for access to piping. Adjacent exchangers can
then be located a minimum of 600 mm clearance between outside of
insulation to allow for maintenance and head removal.
6.1.2 150 mm is the minimum clearance to be allowed between any part of the
control valve ( diaphragm or body ) and the piece of equipment including
the foundations or insulation.
6.1.3 Breakout flanges are normally required on lines that are routed over
removable parts of equipment. Companion flanges against valves in
vertical run may be used for this purpose provided removable piece does
not become too hard to handle.
6.1.4 When locating supports, it must be decided which end will be fixed.
Selection should be based on the best solution for reducing the differential
expansion of piping. Water cooled exchangers are normally fixed at the
channel end support.
6.1.5 If the davit is fitted to the exchanger for removing the heads, the piping
must be routed well clear of its operating circle.
6.1.6 If the dimension is larger than 2100 mm to underside of the handwheel,
the use of a chain operator must be considered.
6.1.7 This arrangement of cooling water supply piping to small diameter
exchangers should be limited to 150 N B and smaller lines with a 300 mm
long filler added above valve to allow for adding mitre cuts should
misalignment between nozzle and underground connection be a problem.
For 200 NB and larger lines, design piping with two elbows and locate
valve in the fitting to fitting horizontal run.

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Consideration should be given to the use of elbow nozzles ( especially


stacked exchangers ) as these can help to lower the height of the
exchangers.
6.1.8 The small P.S.V is located between the inlet and outlet valves, to protect
the exchanger tubes, should both valves be accidentally closed. It should
be piped locally to grade or operating level.
6.1.9 When locating nozzles, it must be considered that a medium that gets
heated up should enter into the bottom and leave at the top. Similarly a
medium that gets cooled down should enter into the top and leave at the
bottom.
6.2

VERTICAL REBOILER PIPING - ( Figure 6.2 in Drawing 803 ES L 181 Sht 3 of 4 & 4 of 4 )

6.2.1 If the vertical reboiler is mounted nozzle, to nozzle with the column,
instrumentation will have to be contained in the nozzles and the
orientation specified at an early stage of the layout.
6.2.2 Extend column platforms to include reboiler when access is required t o
nozzles for valving and blinds above 4.5 metres.
Below 4.5 metres, a portable ladder is usually sufficient.
When the column platforms cannot be extended, a separate structure may
be required. Avoid the welding of, platform clips to exchangers.
6.2.3 The piping must be adequately flexible to take care of the differential
expansion between equipment and piping during the different cycles of
operation.
6.2.4 Space should be given to allow for tube maintenance while the exchanger
remains in situ. This often means that the platforms on the column above
the reboiler must be omitted or made easily removable.
6.2.5 If the reboiler is to be nozzle to nozzle it is usually preferred to support it
from the column by locating point of support as close to nozzle as
possible. An alternate is to locate the point of support at the same
elevation as the bottom tangent line of the column to minimize the
differential expansion.

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Piping below the point of support of the reboiler should be made


sufficiently flexible to take care of any differential expansion.
Spring supports may be required under reboiler supports when the point of
support is not located close to nozzle elevation or at lower tangent line of
column. Springs may also be required when reboiler is supported on a
separate structure.
6.2.6 Often an expansion joint is put into the shell of a single pass, fixed tube
exchanger. This may affect the method of supporting of the exchanger
and connecting piping.
This should be discussed with the piping stress section.
6.2.7 The elevation of reboilers relative to their tower shall be decided only in
close co-operation with the process design department, to ensure proper
functioning.
6.2.8 Exchanger may require guides where Length/Diameter ratio ( L/D )
exceeds 6.0.
6.3

HORIZONTAL REBOILER PIPING


( Figure 6.3 803-ES-L-182 Sht 1 of 6 & 2 of 6 )

6.3.1 If the headroom is sufficient to allow normal pedestrian access the


minimum distance should be 1000mm. When the headroom is insufficient,
the reboiler can be brought as close to the column as the pipe stress
conditions will allow.
6.3.2 Horizontal reboilers will normally be located at grade unless process
conditions indicate otherwise. When reboilers must be elevated, a
separate structure is to be provided for access during operations and for
maintenance. The structure platform will usually connect to the related
column platform.
6.3.3 When locating supports, it must be decided which end will be sliding and
which end will be fixed. Selection should be based on the best solution for
reducing the differential expansion of piping.
6.3.4 If the reboiler is to be closed at grade, the steam piping rather than the
process piping may determine the minimum elevation.

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6.4

KETTLE EXCHANGER PIPING ( Figure 6.4 Drawing 803 ES L 182


Sht 3 of 6 and Sht 4 of 6)

6.4.1 The kettle type exchanger can be used as a heater or cooler/chiller etc.
Steam piping is shown, but this may not necessarily be the most common
source of heat.
6.4.2 This type of exchanger is occasionally used as a reboiler, where large
quantities of vapours are handled.
6.4.3 When the level instruments are above the normal accepted operating
height, additional platforms or ladders may be required for these
instruments only.
6.4.4 Locate the instruments and the level control valves adjacent, if possible,
as this simplifies manual operation of the levels through the control valve
bypass valve.
6.4.5 Ladder and platform requirements to be determined by elevation of
exchanger.
6.5

EXCHANGERS IN STRUCTURES (Figure 6.5 - Drawing 803ESL


182 Sht 5 of 6 and Sht 6 o f 6 )

6.5.1 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 and I diagram.
6.5.2 Establish requirements at an early stage of layout for structural members
to support overhead vapor line.
6.5.3 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.
6.5.4 It is important to line up the supports of equipment in structures to
minimize the use of filler beams.
6.5.5 Where a number of exchangers are fed with a common service such as
steam or cooling water, a header system running below platforming should
be used.

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6.5.6 In some cases the piping between the exchangers and the drum will have
to be given a nominal slope to ensure free drainage.
6.5.7 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 floors may have t o be
increased to provide the extra headroom.
6.5.8 Piping should be routed clear of all handling facilities.

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SECTION 7
PUMPS

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SECTION 7
7.0

PUMPS

7.1

SINGLE SUCTION PUMP PIPING


( Drawings 803-ES-L-183 Sht 1, Sht 2, Sht 3, Sht 4, Sht 5, Sht 6 &
803-ES-L-184 Sht 1, Sht 2, Sht 3 )

7.1.1 Ensure that rear of pump does not restrict access requirements under
pipeway and that minimum clearances have been provided.
7.1.2 Ensure that maximum projection from pump does not restrict minimum
operating aisle required at equipment.
7.1.3 Provide bootleg with manual drain and steam trap.
7.1.4 Provide support to avoid overstressing pump nozzle.
7.1.5 If drip rings are not used, provide drain between block and, check valves.
Alternative is to boss and tap check valve.
7.1.6 Keep length run and number of fittings in suction line to a minimum.
7.1.7 Piping to be designed to a1low for sufficient support and flexibility.
7.1.8 This height to be increased where pipe runs over pump.
7.1.9 The running of pipe over the motor is acceptable only if the line is high
enough for lighting equipment access.
7.1.10 When this dimension exceeds 600 mm beyond steelwork the swing check
valve on the discharge line should be placed in the horizontal position.
7.1.11 Horizontal suction lines shall be designed to avoid pockets resulting from
thermal expansion. Provide slope as required.
7.1.12 Typical routing for piping with small thermal growth.
7.1.13 Where pump suction and inlet line are same size, use long radius
elbow.
7.1.14 Arrange piping to enable pump to be broken out for maintenance.
7.1.15 Ensure overhead clearance is sufficient for pump liftout.

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7.2

DOUBLE SUCTION PUMP PIPING

7.2.1 To avoid cavitation in horizontal centrifugal pump of the double suction


type, the suction, line shall be arranged so that equal flow distribution to
both impeller entrances is obtained.
7.2.2 Vertical lines may be connected to fin elbow directly fitted to the suction
nozzle provided this elbow is perpendicular to the pump shaft of
double - suction type pumps.
7.2.3 In all other cases, a straight length of 3 pipe diameters ( minimum ) shall
be provided immediately upstream of the suction nozzle of
double-suction type pump.

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SECTION 8
CENTRIFUGAL COMPRESSORS

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SECTION 8
8.0

CENTRIFUGAL COMPRESSORS
An understanding of the relationship of piping configurations to the
compressor equipment arrangement essential to achieve an economical
and workable layout. Centrifugal compressors piping study in this
section will concentrate on piping items and their relationship to the overall
layout.

8.1

Figure 8.1 ( Drawing 803 ES L -185 Sht 1 of 2 )

8.1.1 Suction and Discharge piping should preferably be run at grade to


facilitate pipe supporting.
8.1.2 Where possible, allow for valves to be placed in one area and hand
wheels facing in one direction for ease of operation.
8.1.3 Do not support piping from concrete compressor foundation or piers.
8.1.4 Use structural steel columns for overhead seal oil / reference gas balance
tank and associated platform requirements.
8.1.5 Surface condensers with staged air ejectors and associated valves, etc,
are most often purchased as a packaged unit. Therefore, vendor supplied
data as to mounted equipment location should be reviewed early for
compatibility to piping layout, etc. Check with package Units Design
Department for vendor supply and location requirements.
8.1.6 Allow clear space for tube withdrawal and end cover swing on surface
condenser.
8.1.7 Compressor control panel (Local mounted, Vendor Supplied) must be
accessible from turbine drive trip valve, i.e., Steam inlet. Turbine trip valve
is most often supplied with turbine. Check with Package Units Design
Department for requirements.
8.1.8 Compressor Structure, house or shelter must be an independent structure
and have a clear distance separation, including concrete foundation, from
Compressor foundation and piers.

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8.1.9 Lube / Seal oil console is supplied as a package unit. Therefore, Vendor
supplied data as to space requirements and interconnecting piping
requirements should be reviewed early with the Package Units Design
Department.
8.2

Figure 8.2 (Drawing 803 ES L 185 Sht 2 of 2)

8.2.1 *

Denotes thermal movements and direction, warm service (Typical)

* * Denotes thermal movements and direction, cold service (Typical)


8.2.2 Review elevation of concrete compressor table to assure adequate space
allowance for all components as described in Section 7 of Engineering
Manual EM/L/003. In addition, consideration shall be given to
requirements of expansion joint between surface condenser and turbine
exhaust nozzle. Also review with Machinery Department for requirements
of minimum straight run of piping upstream of compressor suction nozzle,
this may vary between 3 to 5 pipe diameters, which may affect the height
of the compressor table.
8.2.3 Height of condenser to be minimum from grade taking into consideration
N.P.S.H. requirements on condensate extraction pumps.
8.2.4 Check with compressor vendor for minimum clearance for removal of
largest removable section or driver. Consideration shall be given to
connected piping clearance requirements.
8.2.5 Heights of suction and discharge piping to be a minimum of 600 mm from
underside of pipe to grade. Check if clearance for the specific case is
adequate.
8.2.6 Ensure that grating on operating platforms is not attached to foundations.
8.2.7 Check all openings in foundations to ensure adequate clearances around
piping flanges, expansion joints, etc.
8.2.8 For Barrel-type compressors, platforms must be extended to permit
removal of rotor assembly.

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8.2.9 Check job / client instructions for requirements and type of suction
strainers. For compressor suction piping which are too small for manual
cleaning ( i.e.: under 750 NB ), a removable spool piece should be
provided to permit installation of the strainer at a convenient, accessible
location. Piping from strainer to equipment nozzle shall be noted for
special cleaning procedures.

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SECTION 9
LIST OF DRAWINGS

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SECTION 9
9.0

LIST OF DRAWINGS

9.1

803-ES-L-175

6 Sheets
Rev 0
2 Sheets
Rev 1
(Sht 2 of 8 & 3 of 8)

9.2

803-ES-L-176

3 Sheets

Rev 0

9.3

803-ES-L-177

7 Sheets

Rev 0

9.4

803-ES-L-178

3 Sheets

Rev 0

9.5

803-ES-L-179

6 Sheets

Rev 0

9.6

803-ES-L-180

4 Sheets

Rev 0

9.7

803-ES-L-181

4 Sheets

Rev 0

9.8

803-ES-L-182

5 Sheets
1 Sheet
(Sht 4 of 6)

Rev 0
Rev 1

9.9

803-ES-L-183

6 Sheets

Rev 0

9.10

803-ES-L-184

3 Sheets

Rev 0

9.11

803-ES-L-185

2 Sheets

Rev 0

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PART III
INSTRUMENT PIPING

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PART III

INSTRUMENT PIPING

PAGE

1.0

SAFETY VALVES

57

2.0

CONTROL VALVES

61

3.0

LEVEL INSTRUMENTS

63

4.0

LIST OF DRAWINGS

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SECTION 1
1.0

SAFETY VALVES

1.1

ON RELIEF LINE HEADERS

1.1.1 Individual relief lines, blowdown lines and flare lines should be selfdraining from all safety valve outlets to the knock-out drum, flare stack or
to a point at the plant limit.
1.1.2 A pocketed relief line system is usually more expensive, because it
requires a condensate knock-out pot with instruments, piping, valves and
pumps.
1.1.3 To eliminate pockets, relief line headers are usually placed at a higher
elevation above the main piperack, supported on an extended piperack
column tee support.
1.1.4 For some non-condensing gas system, self-drainage is not so essential
(refer to appropriate P & I flow diagrams and project specifications).
1.2

SAFETY VALVE INSTALLATION GUIDELINES

1.2.1 Safety valves should be installed as low as possible in the equipment


being protected.
1.2.2 If the safety type valve is used it should be installed in a vertical position in
the vapour space above the liquid.
1.2.3 If the relief type valve is used, it should be installed in a vertical position in
the liquid zone.
1.2.4 If two or more safety relief valves are required and are installed on one
connection, the cross-sectional area of the section should be equal to the
combined inlet of the safety devices connected to it.
1.2.5 The discharge piping should never be a smaller size than the valve outlet
size and should be so arranged that it will not exert excessive stresses on
the safety valve body.

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1.2.6

Atmospheric discharge pipes on valves in hydrocarbon service should be


provided with an adequate drain and snuffing steam connection. See P & I
diagram.

1.2.7 Safety relief valve should be installed in a location readily accessible for
maintenance.
1.2.8 Use ANSI B 31.1 Power Piping, latest edition, Appendix 2, in place of
API RP 520 Part 2 for non-mandatory rules for the design of safety valve
installations.
1.3

SAFETY VALVES AT TOWERS ( Discharging to atmosphere )


(FIGURE 1.1 803-ES-L-186 Sht 1 of 4)

1.3.1 Provide a 6mm diameter weephole at elbow low point. For high pressure
steam, Pipe weephole to a safe location.
1.3.2 Check extent of safety valve top works for davit clearances. Davits are
required for handling of safety relief valves 100 NB X 150 NB size and
above. Check davit swing or crane availability and access.
1.3.3 Snuffing steam if required ( locate block valve at grade ) See P & I
diagram.
1.3.4 Check with Process Design department for verification of inlet line size
when valve is not mounted directly vessel nozzle.
1.3.5 Safety valve discharge point should be positioned 3000 mm above the
highest working level of platform within a radius of 8000mm. It should be
noted that these dimensions may vary for different projects. Therefore
appropriate project specifications govern. In extreme cases, tail pipe may
need guiding or supporting.
1.4

SAFETY VALVES AT FLARE BLOWDOWN HEADER


( See drawing 803 ES L - 186 Sht 2 of 4, Sht 3 of 4, Sht 4 of 4 )

1.4.1 Other platforms such as aircooler platforms could be used for access to
valves When they are located higher than flare / blowdown header.
1.4.2 Piping to Safety valve is to be free draining to drum without pockets.

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1.4.3 Piping to be free draining away from valve into header.


1.4.4 Check whether SV discharge piping needs roll into flare/blowdown header.
1.4.5 When safety valve must be located away from vessel process connection,
the line size must be checked to avoid too high a pressure drop and
malfunction of SV.
1.4.6 When block valves are used around dual safety valves an inter locking
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 as
shown in Figure 1.2 See P&I diagram for requirements.

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SECTION 2
2.0

CONTROL VALVES

2.1

FIGURE 2.1 ( Drawing 803 ES L -187 Sht 1 of 7 )

2.1.1 Control valve should be adjacent to related equipment whenever possible.


2.1.2 A minimum clearance of 200 mm shall be provided between control valve
diaphragm and adjacent obstructions other than a passageway.
Exception: If plug removal is from the bottom, provide clearance to allow
for pivoting control valve to a position to facilitate plug removal.
2.1.3 A minimum clearance at 900 mm shall be provided between diaphragm or
block valve stems (open position for rising stem gate valves) and adjacent
items, whichever restricts passageway, for maintenance and access.
2.1.4 A minimum clearance of 75 mm shall be provided between adjacent hand
wheels.
2.2

Drawings 803 ES L 187 Sht 2, Sht 3, Sht 4, Sht 5, Sht 6, Sht 7)

2.2.1 Check for adequate clearance between control valve diaphragm and
adjacent valve or pipe, etc. when fixing dimension X as a fixing make-up
dimension.
2.2.2 Pipe work in the control set has been arranged to accommodate the
removal of a spool piece between the block valve and control valve. This
allows for the control valve to be removed for maintenance purposes.
Trunion base plate under removable piece is normally designed as a
guided sliding support without bolting.
2.2.3 Use line size drip pockets on 200NB and smaller lines and reduced size
drip pockets on 250NB and larger lines.
2.2.4 + 2100 means 2100 above H.P. paving or platform.

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SECTION 3
LEVEL INSTRUMENTS

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SECTION 3
3.0

LEVEL INSTRUMENTS
This section relates to the installation of level and gauge instruments on
vessels together with access and clearance requirements.
These
instruments may be mounted on stand pipes (bridles) or directly
connected to vessel nozzles. Level displacer gauges may be vendor
supplied or field fabricated.
In this section, the level displacers are shown as vendor supplied units
directly connected to the vessels and the gauge glasses are shown
connected to a standpipe. The actual requirements for a project are
shown on the P & I diagram.

3.1

LEVEL INSTRUMENT TYPE


( Drawings 803 ES L - 188 Sht 1 of 6 & Sht 2 of 6 )

3.1.1 Level controllers are normally ordered and furnished as left hand mounted
units. The piping designer should make every effort to incorporate this
mounting in the development of the vessel nozzle orientation. If this
becomes an impossibility, then the information should be transmitted to
the Instrumentation & Controls Design Department as soon as known.
There are a total of eight (8) rotational positions commercially available
but it is preferred that position number 1 to used whenever possible. See
Mounting positions on Sht 1 of 6 of above drawing.
3.1.2 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.
3.1.3 For maintenance and operation, the level controllers should be accessible
from grade or from ladders, platforms, structures, main operating levels,
etc.
3.1.4 Allow sufficient clearance in front of level controller for the opening of
transmitter case doors. Door swing requirements are shown as dimension
C on Drg No. 803ES-L-188 Sht 1 of 6.

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3.1.5 Instrument vessel sketch should show position of level controller in


relation to vessel liquid levels. As a guide the normal liquid level of the
vessel should line up with.
a. On Masoneilan controller the mid range position.
b. On Fisher controllers the float centre position.
3.2

LEVEL INSTRUMENT ARRANGEMENT


( Drawing 803 ES L - 188 Sht 3 of 6 & Sht 4 of 6 )

3.2.1 A clearance of 800 mm is required between the edge of the level


instrument and edge of platform to maintain access.
3.2.2 Ensure that the swing of the manway cover does not interfere with the
level gauge standpipe.
3.3

LEVEL GAUGES
( Drawings 803 ES L - 188 Sht 5 of 6 & Sht 6 of 6 )

3.3.1 Level gauges should be located so that they are easily read by operator
and accessible for maintenance.
3.3.2 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.
3.3.3 Standpipes should be used where level fluctuations in a vessel and vessel
diameter requires more than one level gauge to show liquid level. This
arrangement cuts down the number of vessel nozzles and allows for
correct placement of gauges.
3.3.4 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 250 mm.
b. For side connected gauges overlap should be 90 mm

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3.3.5 Standpipes exceeding 3050 mm (10-0) in length or in services 260 Deg C


(500 Deg F) and above shall have a flexible leg at the lower connection.
3.3.6 See P & I diagram for extent of valving on standpipe and gauge
connections.
3.3.7 Sht 6 of 6 shows multiple gauge hookups for five and seven gauge units.
Check with Instrumentation & Controls Design department for specific
project limitations.

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SECTION 4
LIST OF DRAWINGS

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SECTION 4

4.0

LIST OF DRAWINGS

4.1

803 ES L - 186

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803 ES L 187

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803 ES L 188

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PART IV
OFFSITES PIPING

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PART IV

OFFSITES PIPING

PAGE

1.0

OFFSITE TANKAGES

71

2.0

OFFSITE LPG STORAGE

75

3.0

COOLING TOWERS

79

4.0

ROAD AND RAIL CAR LOADING

83

5.0

LIST OF DRAWINGS

87

5.1

803-ES-L-189

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803-ES-L-190

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803-ES-L-191

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OFFSITE TANKAGES

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SECTION 1
1.0

OFFSITE TANKAGES

1.1

DRAWING 803 ES L 189 Sht 1 of 3

1.1.1 Tanks with a height in excess of 4500 mm require stairways. These are
usually spiral and fixed to the tank walls. Start stairway so 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.
1.1.2 Different types of tanks have different fixtures ( e.g.: fixed head water
spray, floating roof inert gas seal blanket ). Ensure that control or stop
valves are located outside bund walls.
1.1.3 Tank pad elevation is normally established at a height equivalent to the
as-settled position of the tank after hydrostatic testing. Allow sufficient
flexibility in pipe routing for differential settlement between tanks and bund
walls and between pumps and bund wall. The uses of flexible couplings
are suitable for services such as water but are not recommended for
hydrocarbons. Nozzle elevations shall be set by taking into account the
initial settlement.
1.1.4 Group pumps together, wherever possible, on a common foundation. This
should be compatible with Note 1.1.3 above and with the requirement that
pump suction lines should be as short as possible and without pockets.
1.1.5 Allow sufficient space for pumps to be serviced without interfering with
roadway traffic.
1.1.6 Allow sufficient space for fire-fighting equipment to be parked off
roadways. ( Note: Fire fighting equipment must have access to tankage
areas from two sides ).
1.1.7 For 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 added if
necessary.

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1.1.8 The first pipe support should be at sufficient distance away from tank to
allow for tank settlement. If settlement is considerable the first support
may need to be an adjustable or spring support. Consideration could be
given to supporting pipe from tank, with appropriate stiffening, if
necessary.
1.1.9 Distance normally chosen between pipe support sleepers is 6000 mm. If
intermediate support is required at 3000 mm for small bore piping, it is
preferable that these lines be grouped together for support from larger
uninsulated lines if possible or to minimize the number of additional
sleepers.
1.1.10 Intersecting pipetracks outside the bunded area must be at a different
bottom of pipe elevation. The differences in the elevations are to be
minimum, usually considering the largest pipe as the worst condition.
Flat turns are acceptable if all lines turn in the same direction.
1.1.11 Keep expansion loops in nests for economy of supporting.
1.2

DRAWING 803 ES L 189 Sht 2 OF 3

1.2.1 Tank base elevation is set to suit pump suction and piping requirements.
1.2.2 Lower manhole should be located close to stairway start point and
preferably below stairway, roof manhole should be oriented approximately
180 from lower manhole for air circulation during maintenance. Steam out
connection or inert gas purge connection should be located local to lower
manhole. Locate top manhole local to top platform.
1.2.3 If a combined pressure relief and vacuum breaker is required it must be
located at the high point of the tank.
1.2.4 Drain or pump out nozzles can be either as indicated or mounted above
base plate with an internal pipe to a sump.
1.2.5 Level instruments on tanks are normally fitted with a float type indicator.
This should be local to top manhole for maintenance. High level if fitted
has to be accessible from platform or stairway. Low level alarm should be
located so that reach is not affected by outlet nozzle.

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1.2.6 Inlet and outlet nozzles should be located together and pointing toward
inside bund pipe rack for simplicity of piping layout and valve operation.
Tank nozzles can be radial or parallel.
1.2.7 Floating Roof Tanks: Tank nozzle layout is similar to fixed roof tanks
except that roof nozzles will be grouped in the tank centre and are usually
located by tank vendor.
1.3

LINES THROUGH BUND WALLS ( DIKES )


( Refer Drawing 803 ES L - 189 Sht.3 of 3 )
The normal practices for handling pipe penetrations through bund walls
and under roadways are mentioned herein. Client approval to use these
methods should be obtained early in the project.

1.3.1 Uninsulated lines through earthen bund walls with no roadway above shall
be coated and wrapped and buried with no sleeving. The protective
coating shall extend a minimum of 300 mm beyond earthwork at the low
point on both sides.
1.3.2 Lines requiring sleeving:
a. Insulated lines through bund walls with no roadway above.
b. Insulated and uninsulated lines through bunds with roadway
above.
c. Insulated and uninsulated lines under plant roads.
These sleeves are normally made of corrugated galvanised metal and
extend to a point 300 mm beyond earthwork at the low point on both sides
of the wall or road.
Seal all sleeves on inside of bund walls with cement grout.
Provide sleeve guides within 300 mm of each sleeve end and not
exceeding 6000 mm centers. These guides shall be fabricated in
accordance with the details shown in drawing 803-ESL-189 Sht.3 of 3 and
attached to pipe by welding.

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SECTION 2
OFFSITE LPG STORAGE

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SECTION 2
2.0

OFFSITE LPG STORAGE


Liquid petroleum gas ( L.P.G ) is usually composed of propane, propylene,
butane and butylenes, alone or in combination.
The types of pressure vessels used for the storage of L.P.G and high
pressure gasoline components such as pentane are cylinders ( bullets ),
spheres and spheroids.
The type and working pressure of the vessel should correspond to the
highest vapor pressure of the individual material or mixture at the
design operating temperature.
In General :
Cylindrical vessels ( Bullets ) Designed for a working pressure of
about 17.25 bar G. are used for storage of propane up to a
maximum volume of 200 m3. ( Use multiple bullets for volumes of
200 400 m3 ).
Spheres With working pressure ranging up to 6 bar G. are used for
storage of propane butane mixtures and butanes with volumes
above 400 m3 are supported are supported on steel pipe section
legs.
Spheroids With working pressures ranging up to 3.5 bar G. are
used for storage of butanes and pentanes with volumes above
400 m3 are supported on a sand pad at grade.
The hydrocarbons stored in pressure storage vessels are liquid since they
are under pressure at ambient temperature. When such liquids escape
from pressure storage, they flash into vapor with a self-refrigerating effect
that sub-cools the remaining of the fluid.
Since the flashed hydrocarbons are heavier than air, they will collect in low
areas. It is therefore advisable not to use dikes around vessels in which
L.P.G and similar materials are stored but rather to allow free flow of air
around vessels, to disperse escaped vapors.

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Vessels should be located in well-drained area to allow escaping liquids to


flow away from the storage areas in the event of ground fires.
2.1

L.P.G. STORAGE ( See Drawing 803 ES L 190 Sht 1, Sht 2, Sht 3)

2.1.1 Horizontal storage bullets are normally supported on two saddles and
installed with a normal slope of 1 : 200, to allow drainage of possible
entrained water or complete removal of test water.
2.1.2 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, for piping clearances. Special
attention should be given to the positioning of the drain connection in cold
climate installations to prevent freeze-ups.
2.1.3 All L.P.G storage vessels should be fitted with a pressure relieving device
located on the high point of the tank at the end furthest away from the
manifold area. When atmospheric vents are permitted, the open end shall
contain a rain cap or equivalent device with a drain connection on the low
point directed away from the top of the tank.
2.1.4 All nozzles other than pressure relief nozzles shall be fitted with block
valves (preferably connected to nozzle). Inlet and outlet nozzles can be
fitted to either the top or bottom of the vessel. A bottom connection is
preferable as it minimizes top plat forming and makes for a more readily
accessible.
2.1.5 When two or more vessels are required, a common continuous platform
should be provided. Stairway access is normally required for platform
higher than 4500 mm above grade. Dead ended platform lengths should
be avoided. Manhole covers can be used for mounting instruments (all
instruments should be in vapor space) to reduce the number of
connections on the vessel.
2.1.6 General requirements for pipe routing are the same as for atmospheric
storage tanks. See section 1 in this part.
2.1.7 Eye wash and safety showers are to be provided and located at operators
level and or at grade.
2.1.8 LPG storage vessels shall be completely surrounded by fire water mains
including hydrants, monitors or combination of hydrant / monitor.

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2.2

REFRIGERATED GAS STORAGE


Large volumes of petroleum gases are usually refrigerated in to liquid for
storage. This requires the installation of a liquification plant stream of the
storage tank and if the gas is returned to the process plant a vaporizer
downstream of the storage tank.
Due to the cost of the equipment required to liquefy and vaporize the gas,
these installations invariably are only used for the storage of large
quantities of gas, i.e. natural gas.
The tanks usually comprise of an inner skin and an outer tank with domed
roof and have the space between skins filed with insulation. These tanks
must to contained within a bund wall, because of this they may be treated
in a manner similar to that of an atmospheric cone roof storage tanks. The
major differences are that the inlet and outlet lines are in cryogenic service
therefore contraction and not expansion of lines must be considered.
(Stress Analysis to be done)
Inlet and outlet lines will be from the roof of the tank instead from the shell
of the tank. The outlet line may be from mounted submerged pumps.
These lines must fall continuously from the tank to liquification or
vaporising plant, as a gas passing from a cold liquid expands adiabatically
and if trapped in a vapor pocket can easily rupture a pipe. Elevated
piperacks are normally provided for the support of this piping.
Above ground piping for any storage vessel or group of vessels shall not
be through other diked areas.
Piping manifolds and associated pumps and refrigeration equipment shall
not be located within diked areas of refrigerated storage vessels.
Refrigerated storage vessels shall be completely surrounded by water
mains including hydrants, monitors or combination of hydrant / monitor.

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SECTION 3
COOLING TOWERS

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SECTION 3
3.0

COOLING TOWERS

3.1

FIGURE 3.1 ( Drawing 803 ES L - 192 Sht 1 of 4 )

3.1.1 Figure shows a typical layout of horizontal cooling water pumps and
piping. Process consideration should be given to pit elevation as
pumps may be located below grade in a pit for pump priming conditions
( pumps flooded on start-up ). When pump elevation is established to
suit flooded conditions, the top of pump casing should be a minimum of
150 mm below water level.
All cooling towers have some form of water collection pit, regardless of
type, into which the cooling tower basin slopes.
3.1.2 Flume outlet spacing is dictated by pump and driver dimensions. If
cooling tower is of concrete construction then this information will be
required early in the job to allow early construction of tower and basin.
3.1.3 Although 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.
3.1.4 To simplify the supporting of pipe and to reduce the number of small
access platforms, the cooling water return by-pass valve, make-up water
control valve and pond level controller should be grouped together for
access from a common platform may also be used in connection with
chlorination equipment.
3.1.5 Locate suction pit drain and overflow connections together ( if required )
to minimize underground pipe run.
3.1.6 Locate flume outlet valve directly on flume if flexible couplings are to be
used. Some cooling tower basins are fitted with adjustable weirs which
cab be used for shut-off instead of valves.
3.1.7 Discharge valve location : If a gate valve is used locate with check
valve in horizontal close to pump, so that the supports can be located on
pump foundation. If butterfly valve is used, locate in vertical, on
underground header flange.

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3.1.8 Flexible couplings of the mechanical type should preferably be used on


suction and discharge lines to allow for shorter runs between pump and
suction pit and pump and cooling water supply header while still providing
for differential settlement. Also refer to section 7.0 in PART II for pump
piping.
3.1.9 If recycle by-pass is required it may be fitted with a control valve or
control set. Due consideration should be given to pipe flexibility because
of differential settlement and differential movement.
3.1.10 Accessibility to instrument and manholes in buried lines is normally
accomplished by manhole pits. This pit must be adequately drained. An
alternative to the pit is to run the portion of the line requiring access above
grade.
3.1.11 Consideration should be given to the practicalities of future
connections, i.e. : provide valve on flume so that cooling tower basin does
not have to be drained at a future date.
3.1.12 If possible try to locate supply and return lines, make-up lines together
so as to minimize trenching work.
3.1.13 Figure 3.2 on Sht 2 of 4 shows a typical layout of vertical cooling water
pumps and piping.
3.2

VERTICAL NATURAL DRAFT


Figure 3.3 ( Drawing 803 ES L - 192 Sht 3 of 4 )

3.2.1 The shape of cooling towers will vary depending upon local
requirements such as ambient temperatures, prevailing wind strengths
and height limitations.
3.2.2 Vertical cooling towers can also be :
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 system on the outside. This makes for a very large
catchment pond but it has the advantage of limiting water loss.

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3.3

HORIZONTAL INDUCED DRAFT


Figure 3.4 ( Drawing 803 ES L - 192 Sht 4 of 4 )

3.3.1 Overall length of tower is made up from a number of fan units.


3.3.2 The upper section of slats may have adjustable or automatic air inlet
louvers.
3.3.3 This dimension is usually set by tower vendor ( see note 3.1.2 above ).

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SECTION 4
ROAD AND RAIL CAR LOADING

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SECTION 4
4.0

ROAD & RAIL CAR LOADING

4.1

ROAD TANK CAR LOADING


( DRAWING 803 ES L - 191 Sht 1 of 4 & Sht 2 of 4 )

4.1.1 Loading arms can be ordered to suit different applications, and sizes and
can be for top or bottom loading. To determine the arc required, the
designer/engineer must first establish what type and size of tanker is to be
used, the speed and frequency of filling and the number of filling points on
that tanker to be serviced by one loading arm. Loading arm vendor should
be consulted as early as possible.
4.1.2 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 means of some form of movable link platform and placing
the operator at the same or similar elevation to the tanker manhole
platform. Permanent access to tanker platform may also be required when
tanker loading is from the bottom.
4.1.3 Metering into tankers can be either local or remote mounted. This will be
governed by the client / local statutory body. If locally mounted, it should
be located where it cannot be accidentally damaged by incoming or
outgoing tankers.
4.1.4 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.
4.1.5 If top loading arms are to be used, each loading platform should be
provided with two tanker standing areas for speed of tanker turnaround. If
bottom loading, only one standing area is needed and should be located
on the curb or pavement side of the tanker.
4.1.6 Some type of sprinkler or foam system is usually provided in this area and
correct location of this equipment is essential. Consult with project
engineering.
4.1.7 Tank car and truck vent lines shall be provided in accordance with the
requirements of the local governing codes.

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4.1.8 Roofed loading islands shall be provided with proper ventilation in roof
enclosures and an adequate roof drainage system.
4.1.9 Loading areas should be located within a reasonable and safe distance to
tankage supply, to plant perimeter road and to rail road ( R.R ) spurs off
the main R.R. right of way. They shall be controlled by a separate security
gate house and or enclosed with fencing as required by client security
procedures. A secured vehicle gate to the main plant area should be
considered.
4.1.10 Loading area should be equipped with the proper number of utility stations
for wash down and maintenance. Eye wash and safety showers area
normally provided and located at operators level and or at grade. See
utility P&I diagram for requirements.
4.1.11 An adequate drainage system shall be provided and located so as not to
spill liquids under the equipment being serviced.
4.1.12 Space should be allocated for future expansion of loading area when
future process areas are contemplated and shown on the overall plot plan.
4.1.13 Metering equipment, valves, filters and knock out drums to be located at
grade.
4.2

RAIL CAR LOADING ( DRAWING 803 ES L - 191 Sht 3 of 4 )

4.2.1 As dimensions of rail cars vary from country to country, the designer must
ascertain the size of rail car to be used so as to determine the center to
center dimensions for loading arms. Loading arm vendor should be
consulted as early as possible.
4.2.2 The loading bay of platform should be sufficiently far from the end of the
siding to allow for shunting of cars. Consideration should be given to a
through access R.R. siding rather than a dead ended track. If only one
product is to be loaded then one car length will be sufficient. If product
loading is multiple then consideration must be given to sequencing loading
arms to match preferred sequencing of rail cars. If one car is to be used
for various products, then some form of car flushing or purging may be
required.

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4.2.3 The centerline of railroad to edge of parked loading arm should be


1000mm + rail car width. The 1000mm dimension may be increased if
loading arm allows.
4.2.4 As any loading station is a potential fire hazard, the loading area should
have some form of fire protection equipment. Also design of piping and
support structures should be such, so as not to obstruct the operators
access.
4.2.5 Metering into rail cars can be either local or remote mounted.
4.2.6 A loading platform must be supplied for top loading arms. This platform
has a double function in providing access from the loading arm area to the
rail car top and placing the operator at the same elevation as the rail car
manhole platform. Permanent access to tanker platform may also be
required when tanker loading is from the bottom.
4.2.7 Arms Usually a minimum of 2 arms are fitted per platform. Steelwork is
to be designed so that arm can be turned a minimum of 270. Parked
loading arm is mechanically locked and interlocked with traffic lights.
These do not allow access into loading area when arm is not in park
position or on opposite side of platform.
4.3

DRAWING 803 ES L - 191 Sht 4 of 4

4.3.1 A more advanced type of rail loading installation is the automatic lance
operated rail loading. This entails a structure as basically outlined on
sheet 4 of 4. This type of operation gives a really fast turn around but is
expensive to install and a large demand for rail loading would have to be
anticipated to justify its installation.
4.3.2 On this type of installation and on the installation shown on sheet 3 of 4,
consideration should be given to having a double railroad system as the
cost of an extra track is small compared with the cost of a loading island.

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SECTION 5
LIST OF DRAWINGS

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SECTION 5

5.0

LIST OF DRAWINGS

5.1

803 ES L - 189

3 Sheets

Rev 0

5.2

803 ES L - 190

3 Sheets

Rev 0

5.3

803 ES L - 191

4 Sheets

Rev 0

5.4

803 ES L - 192

4 Sheets

Rev 0

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ENGINEERING MANUAL (EM-L-004)

PIPING DESIGN DEPARTMENT

SPECIMEN SIGNATURE
(FROM 01-OCT-2008)

S.
No.

Name

Signatory For

A.MARUTHAPPAN

Preparation

J.K.RAO

Checking

B V RAMANAKUMAR

Approval

Shall Sign / Initial As

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