Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Philosophy
for
Piping Design
Onshore
Document Number
TO-HQ-02-037-00
Issue Issue or Revision Description Origin Date Chk Date Appd Date Appd Date
Rev By d By By By
OMV Exploration & Production GmbH
Contents
3.0 ABBREVIATIONS...........................................................................................................6
4.0 INTRODUCTION.............................................................................................................7
12.0 VALVES........................................................................................................................17
12.1 Control Valves.......................................................................................................................... 18
29.0 CERTIFICATION...........................................................................................................41
1.0 PREFACE
2.0 DEFINITIONS
3.0 ABBREVIATIONS
4.0 INTRODUCTION
Most of the risks to safety in the oil and gas industry are from the
production process by release of hydrocarbons. Hazards associated
with the uncontrolled release of hydrocarbons are as follows:
• Over pressure
• Leak
• Liquid overflow
• Gas blowby
• Under pressure
• Over temperature
• Direct ignition source
API 607 Fire Test for Soft Seated Quarter Turn Valves
5.2 References
The piping specified and supplied for the Project shall otherwise be in
accordance with the relevant codes, good industry practices and shall
meet agreed Project Specifications.
The design of all piping systems shall be in accordance with the latest
edition of the codes and standards listed in Section 5.
9.4 Fabrication
All welds shall be inspected by NDE such as RT, UT, PT and MT to the
levels required by ASME B31.3.
All NDE shall be performed on carbon steel piping after final PWHT.
The chloride content of water shall not exceed 30 ppm for testing of
piping fabricated from any austenitic stainless steel.
9.5.3 Repairs
The minimum size for process piping shall be NPS 1”, or NPS 2” when
installed in pipe racks (unless flow velocity is critical). NPS 1” shall not
be run for long distances.
The minimum size for utility piping shall be NPS 2” when installed in
pipe racks.
All piping and piping components shall be specified in the piping material
class datasheets, which shall be included in a Piping and Valve Material
Specification.
The Piping and Valve Material Specification shall include as the minimum:
• A section detailing the general requirements
• A fluid list with reference to the applicable piping class
• Pipe class data sheets with branch tables
• Valve datasheets
Flanges greater than NPS 24” in accordance with ASME B16.47 Series
B are preferred and shall be checked against the requirements of
ASME VIII Div 1 Appendix 2.
All piping NPS 1 ½” and below, with the exception of instrument piping,
may be socket welded subject to the following conditions:
Miter bends shall be avoided. Stub ins shall be avoided. Flange bolting
shall be inch series stud bolts. Fitted bolts shall not be used.
Bolt tensioning shall be performed on all flanged joints where the stud bolt
diameter is 1 1/8” diameter or greater. The stud bolt length shall include
allowance for one additional nut thickness.
12.0 VALVES
When required fire testing in accordance with API 6FA, API 607 or BSEN
ISO 10497 shall be performed as applicable and an independent authority
shall provide test certification.
Where the installation of check valves in vertical piping is required the flow
must be upward. A drain on the downstream side shall be provided.
Where control valves are less than the piping line size, the required
reducers shall be installed adjacent to the valve.
All piping shall be routed such that a simple, neat and ergonomic layout
is provided, allowing for easy supporting and flexibility.
Cable trays at crossings shall be run above piping where ever possible.
Where the above cannot be avoided all potential leak sources shall be
eliminated.
With the exception of fire fighting piping systems piping shall not be
located within instrument, electrical or telecommunication
control/switchgear rooms.
Galvanised steel piping shall not be run above austenitic stainless steel
piping and contact between galvanised structural steel and austenitic
stainless steel piping shall be avoided.
In particular piping layout shall allow the clearance required for the
removal of pump and turbine casings and shafts, pump and fan drivers,
exchanger bundles, compressor and engine pistons.
Piping shall be designed with sufficient random lengths and field welds,
particularly at rotating equipment, to permit efficient installation of spool
pieces and the completion of tie-ins, without causing undue strain to
equipment or piping.
13.3 Piperacks/Pipeways
The minimum distance between two pipe rack levels shall be 1.2m and
shall take into account pipe sizes and insulation thickness.
Condensate piping shall be located on the lowest pipe rack level where
applicable.
13.4 Grouping
The grouping of hot and cold piping together shall be avoided. Hot,
un-insulated piping should be at a higher elevation that cold piping.
The heaviest piping and largest bore piping shall be located the furthest
from the centre of the pipe rack.
A contingency shall be included in the design of the pipe rack width for
future expansion of the plant.
Utility headers shall be arranged on the top of multi tiered pipe racks.
14.0 ISOLATIONS
In addition to main inlet and outlet piping, isolation shall also include
drains, vents and other interfaces.
For piping where liquids can be shut in and there is a source of heat
(including environmental heating) a thermal RV shall be installed.
Philosophy for Piping Design Document Number Rev Page
Onshore TO-HQ-02-037 00 22 of 41
OMV Exploration & Production GmbH
15.1 General
Where deck level supports for piping are required they shall be supported
on integral extensions of the equipment support structure and not the
equipment base plate. This shall apply to both resilient and fixed supports.
Provision shall be made for the isolation of equipment with blinds or the
removal of spool pieces for maintenance and pressure testing.
15.2 Pumps
Where possible, suction piping shall be self venting to the suction source.
The suction piping shall ensure that the NPSH requirements specified in
Document No TO-HQ-02-039 - Philosophy for Rotating and Reciprocating
Equipment Onshore are met.
In horizontal piping runs eccentric reducers shall be used, with the flat side
uppermost where there is a possibility for air of gas pockets. Concentric
reducers shall be used in vertical piping.
A check valve shall be installed in the discharge piping of each pump. The
check valve along with all vent, drain and gauge connections shall be
located between the pump discharge and first block valve.
Where a bypass line with isolation valve is installed, the pressure rating
shall be of the same pressure rating as the discharge piping.
15.3 Compressors
All suction piping between the knock out (scrubber) vessel and
compressor shall be arranged to prevent the trapping or collection of
liquid.
Piping shall continuously slope downwards from the suction cooler to the
knockout (scrubber) vessel. Piping shall be routed so that any condensate
drains back from the compressor suction to the knockout (scrubber)
vessel.
All small bore branch connections not permanently hard piped shall be
provided with anti-vibration bracing.
15.4 Turbines
Exhausts shall be routed to a non hazardous area and shall not prove
hazardous to personnel or foul the air inlet.
Fuel piping shall not run directly over the engines, their exhaust or any
other area where leakage can impinge on a hot surface.
Where positive static head is required from the day tank, the minimum
operating level shall be 300mm above the fuel injection pump inlet.
The drain line from the day tank shall be positioned such that the drain line
outlet piping into the main drain is visible from the drain valve location.
When an exhaust spray cooler is used the exhaust piping shall be sloped
a minimum of 45 degrees downwards from the upstream spray cooler to
prevent back flow of water into the engine.
Piping at vessel nozzles shall be arranged such that blanks can be readily
installed and valves easily removed for maintenance. Check valves if
required shall be installed in the horizontal position against the block valve
at the vessel nozzle.
Where shell and tube exchangers utilise water cooling, the requirement for
backwashing and chemical cleaning shall be evaluated.
For air cooled exchangers the branch piping between the headers and
exchanger header boxes shall accommodate thermal expansion of the
headers.
Where freezing of the cooling medium may occur, provision shall be made
for the draining of the cooling medium from a blocked exchanger.
Thermowells for inlet and outlet temperature measurement for each fluid
service shall be provided and where exchanger nozzles will not permit the
necessary immersion depth these shall be located in the adjacent piping.
The launcher/receiver shall be sloped towards the trap closure and a tray
provided, with a drain, for spillage retention.
The junction between the production piping and the inlet/outlet to the
launcher/receiver shall be designed to prevent pigs from entering the
production piping. This normally consists of a barred Tee.
Air system piping shall have a self draining facility provided at all low
points for the collection of condensate.
Air traps shall have isolation valves, balance lines and drains to local
collection points.
Instrument air headers and manifolds shall not be dead ended but
supplied with blind flanges for cleaning and maintenance.
All branches and take offs shall be from the top of headers.
Discharge piping from air compressors shall enter into headers from
above in order to prevent filling of the standby compressor with
condensate.
Drain points shall be from the bottom of a header and steam take off from
the top.
Utility stations shall be provided as required for air, water, steam/hot water
and/or nitrogen. Each station shall be numbered and located in general
working areas at ground or platform level.
Water, nitrogen and plant air systems shall be equipped with hose reels so
that all areas can be reached with a 15m length of hose.
Hose connections shall be such that flexible hoses can only be used for
their intended service.
All piping systems shall be in accordance with API 521 and Document No
TO-HQ-02-036 – Philosophy for Flare, Relief and Blowdown Onshore.
All relief piping and headers shall be designed to eliminate pockets, but if a
relief valve must be located at a level below the elevation of the header,
an automatically operated drain valve shall be installed at the valve outlet
and be piped to a collecting vessel or closed drain.
Relief valve headers shall slope towards the flare knock out drum.
The minimum slope of all laterals and headers shall be 2mm in 1000mm.
When piping is buried, signs shall be spaced along its route to mark its
location.
Design of underground piping shall take into account external loads due to
backfill, road or rail crossings etc.
Branch offtakes for deluge nozzles shall avoid location at the bottom of the
header to avoid plugging of the nozzles.
Deluge isolation valves shall be installed behind the safe area firewall.
Fire monitors and upstands shall be protected from vehicle impact, by pipe
frames.
Piping and fittings shall be supported and braced for water hammer from
the fire pumps.
Fire water deluge system piping shall be sloped to drain. Low point drains
shall be provided and drainage shall be to the open drain system.
The layout shall be in a “ring system” which allows provision of fire water
to each area from two sides.
Philosophy for Piping Design Document Number Rev Page
Onshore TO-HQ-02-037 00 32 of 41
OMV Exploration & Production GmbH
All vessel drains, drains from gauge glasses and other instrumentation
discharging to an oily water drain system shall be constructed from hard
piping.
Fire seals shall be provided for open drains, catch basins, exits from
hazardous areas, penetrations through firewall and also to sectionalise the
drain system.
Floor drains shall consist of catch basins welded flush to the floor. They
shall be a minimum of 300mm wide and covered with removable grating.
In confined areas circular bell type drains, welded flush to the floor may be
used and shall be of 150mm diameter minimum with a removable strainer
plate installed.
Bell type drains may be used above ground for conveyance of drainage to
atmospheric drain system. They shall be accessible and visible to the
operator at the drain valve.
All storage tanks nozzles below the roofline shall be equipped with a block
valve.
Hoses should not be used as a first choice for any hydrocarbon process.
Where hoses are to be used, they shall be suitable for the intended
service fluid.
Where the vents and drains required for operational purposes are
insufficient for hydrostatic pressure testing, additional vents and drains
shall be provided.
Where vents and drains exist specifically for hydrostatic pressure testing
shall be blanked off with a blind flange.
Drain piping shall run to the nearest floor drain, avoiding walkways.
Open drains shall be valved and located such that discharge may be
observed.
Open pipe ends shall extend well into tundishes to avoid spillage.
Vents and drains in sour service shall be hard piped to a closed drain
system.
All vents and drains piped to a closed drain system shall be double valved
for all piping pressure classes.
Valved drain connections shall be installed at low points of all above grade
lines, on each side of fail close control valves and all lines at battery limit
block valves (on the unit side).
All pressure vessel drains and vessel trim drains discharging to an oily
water drain system shall have permanent piping.
Sample connections shall be located such that they are accessible from
grade, floor or permanent platform.
The sample points shall have two valves. One valve at the take off point
from the process piping, with another at the sampling point. The valve at
the take off point shall be sized as a standard drain valve. The valve at the
sampling point shall be NPS ½” maximum with good throttling properties.
Gas sample points shall have their take off located at the top of horizontal
piping.
Sample outlets for self igniting or toxic fluids shall have a self closing
downstream valve.
due to high fluid velocity and density, for flanged thermowell fittings.
Alternatively short thermowells can be used.
For temperature connections in piping less than NPS 4” the piping shall be
locally enlarged to NPS 4”.
22.0 STRAINERS
Strainers are required to be installed to the suction piping of all pumps and
compressors, and shall be installed between the equipment and its
isolation valve.
Strainers shall be installed in all piping that convey fluids which may
contain solid particles, unless equipment is specifically designed to handle
these fluids, and at other locations where specified on P&ID’s.
The allowable pressure drop and required particle filtration size shall be
specified by during FEED.
The strainer shall have a mesh size with minimum free area of 250% of
the cross sectional area of the pipe in which it is installed.
Bypass valves and piping shall conform to the same piping classification
as the primary valve.
The minimum spacing for pipe supports shall be such that stress
developed in the piping shall be less that the allowable stress under
sustained loading in accordance with ASME B31.3
The spacing between pipe supports shall not exceed 6m. The maximum
deflection in the piping shall not exceed the distance between supports
divided by 360 (L/360).
Cold springing of piping is generally not permitted. The use of cold spring
shall be approved by OMV.
The use of spring type supports shall only be considered when no other
method of supporting is feasible, including re-evaluation of support
location and alternative piping routes.
All small bore branches less than NPS 2” shall be provided with
anti-vibration gusset supports welded to the main piping.
Expansion bellow type joints shall meet the requirements of ASME B31.3,
Appendix X.
• NPS
• Service Fluid Designation
• Piping class designation
• Sequential number
• Insulation type designation
Each line shall be listed on a piping line list which shall as a minimum
contain the following information relevant to the line number:
• P&ID number
• Fluid
• Fluid phase
• Pipe routing (from and to)
• Operating and design pressure
• Operating and design temperature
• Pressure test type and test pressure
• Insulation type and thickness
• Stress critical
All carbon steel and low alloy material used in sour service shall comply
with, but not be limited to the requirements of NACE MR0175/ISO
15156, (Material Requirements-Sulphilde Stress Cracking Resistant
Material for Oilfield Equipment, latest Edition).
29.0 CERTIFICATION