ESSAR OIL LIMITED

VADINAR REFINERY EXPANSION

PIPING DESIGN PHILOSOPHY
PROJECT DOCUMENT NO.
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ESSAR ENGINEERING CENTRE, MUMBAI
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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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DETAILS OF REVISION REV NO
23/04/07 ISSUED FOR REVIEW 00
07/05/07 ISSUED FOR DESIGN 01
03/09/07 ISSUED IN REVISED FORMAT 02
11/10/07 CABLE ROUTING PHILOSOPHY IN PIPE RACK INCORPORATED 03






















































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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



ESSAR ENGI NEERI NG CENTRE , MUMBAI Page 3 of 20
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Contents
1. Scope........................................................................................................4
2. Conflicts and Deviations .............................................................................................4
3. Reference Documents................................................................................................4
4. Responsibilities ......................................................................................................4
5. Applicable Codes and Standards ...............................................................................5
6. Design Package..........................................................................................................5
7. Design Condition and Limitations...............................................................................5
8. Material Selection for Piping Components .................................................................8
9. Limitations on Pipe Sizes and Thickness...................................................................9
10. Piping Layout............................................................................................................10
11. Lines Spacing Requirements....................................................................................12
12. Underground Piping..................................................................................................12
13. Pipe Supports Design...............................................................................................13
14. Anchors and Guides .................................................................................................15
15. Non-Pressured Welded Attachments .......................................................................15
16. Instrument Piping......................................................................................................16
17. Plant Utility Piping System........................................................................................16
18. Utility-Process Connections......................................................................................17
19. Chemical Cleaning Line Identification......................................................................19
20. Testing and Inspection..............................................................................................19















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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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1. SCOPE

This specification supplements ASME B31 codes and defines additional minimum design requirements
For pressure piping located within plant areas.

2. CONFLICTS AND DEVIATIONS
2.1 Any conflicts between this specification and other applicable Engineering Specifications, Standard
Drawings, or industry standards, codes, and forms shall be resolved in writing with the Company.
2.2 Direct all requests to deviate from this Specification in writing to the Company.

3. REFERENCE DOCUMENTS
The selection of material and equipment, and the design, construction, maintenance, and repair of
equipment and facilities covered by this specification shall comply with the latest edition of the
references listed below, unless otherwise noted.
3.1. INDUSTRY CODES AND STANDARDS
American Society of Mechanical Engineers
ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and
Other Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
3.2. ENGINEERING SPECIFICATIONS
EECS-20-102-001 Piping Material Specification
EECS-20-102-003 Technical supply conditions for pipes & pipe fittings.
EECS-20-100-002 Piping Fabrication
EECS-20-100-003 Piping Erection and Pressure Testing.
EECS-20-102-006 Piping Flexibility Analysis
EECS-20-102-011 Codes & Standards for Pressure Piping.

4. RESPONSIBILITIES
4.1. It is the responsibility of the design consultants to design pressure piping systems that meets the
requirements of the applicable Code and relevant Standards, Specifications and Procedures as a
minimum.
4.2. Strict application of minimum standards does not prohibit nor alleviate the design agency from
using good engineering practices and from producing innovative ideas.
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EECS-20-102-002-03 03



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5. APPLICABLE CODES AND STANDARDS
In addition to referenced Codes and Standards, the applicable Codes and Standards in accordance with
EECS-20-102-011 shall apply.

6. DESIGN PACKAGE
The design of pressure piping located inside plant areas shall include the preparation of the documents
listed below.
These documents shall be given drawing numbers and become permanent plant records:
Process Flow Diagram (PFD) & Utility Flow Diagram (UFD)
Piping and Instrument Diagrams (P&ID)
Line Designation Table.
Calculation sheets supporting major flow data and pressure drop data shown on the Piping
Designation Table.
Equipment Layouts
General Arrangement Drawings (Piping)
Piping Section Drawings and details.
Piping Isometric Drawings.
Material Take Offs.
Piping flexibility calculations.
Hydrostatic Test Diagram / Recorded data.
Pipe support and foundation location drawing.
Special Online Items.
Material Requisions Datasheets for Piping Elements like Pipe, Flanges, Valves, Gaskets etc.
Any other document if specifically required.
Design Consultants shall submit all the above documents time to time for review/approval.

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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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7. DESIGN CONDITION AND LIMITATIONS
7.1. Design consultants shall establish and/or verify that the design conditions are realistic and fulfil the
targeted operational and design capacity.
7.2. The design Consultants may specify design conditions exceeding immediate design requirements if
there are long term economical justifications for future capacity increase.
7.3. Design Factors & Allowable Stresses
7.3.1. Plant piping designed in accordance with ASME B31.1 or ASME B31.3 shall follow
stress given in the codes.
7.3.2. Maximum Stresses
The calculated maximum principal stress due to test conditions shall not exceed the
allowable stresses given in the codes.
7.3.3. Unexpected Loads and Pressure Variation
For design conditions which include unexpected loads such as wind, earthquake, or
External hydrodynamic forces, or occasional short-term pressure variation above the
normal maximum, the pressure rating of components and/or the allowable stress may
be increased as permitted by the applicable. Codes for such conditions without
additional restrictions.
7.4. DESIGN PRESSURE
7.4.1. Piping systems designed in accordance to ASME B31.1 or ASME B31.3 shall be designed to
withstand the most severe combination of pressure and temperature.
7.4.2. The variation allowance by the Code in the internal pressure should be taken as an
Advantage for a cost effective design.
7.5. DESIGN TEMPERATURE
7.5.1. The design consultants shall specify the design temperature that matches the actual process
conditions. Specific temperature conditions are addressed below.
7.5.2. Pipe Temperature
For the purpose to specify piping material, the metal temperature of the pipe and piping
components shall be the same as the bulk temperature of the fluid transported by the piping
system No credit should be given for ambient heat losses unless such losses can be
demonstrated to have significant cost advantage.
7.5.3. Ambient Range
For fluid temperatures at or above ambient, the design temperature shall not be less than the
maximum expected actual fluid temperature at design flow rate and design pressure.
7.5.4. Refrigerated Services
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PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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For the purpose of determining impact testing requirements, the design minimum
temperature shall be established for piping carrying fluids which have been refrigerated
below ambient temperature, based on process design conditions.
7.5.5. Auto-refrigeration
For systems normally at or above ambient temperature which can occasionally be exposed to
lower temperatures due to a sudden reduction in pressure (including causes such as leaks or
ruptures) or due to blow down of equipment, the design minimum temperature shall be the
coincidental temperature as may be encountered actually subjected to minimum when the
pressure of 25% of the design pressure.
7.5.6. Thermal Radiation Effects
All above ground piping systems shall be evaluated for pressure build up due to the effects of
solar radiation, ambient temperature, and other heat sources such as a flare, heaters, blowers
or combination of these effects.
7.6. DYNAMIC EFFECT
The effects of dynamic forces external and internal dynamic forces shall be analyzed and the final
design shall be suitable to accommodate such forces. Examples of such forces are earthquake, slug
forces, pressure surge forces, steam & water hammer, Safety valve thrust force, etc.
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EECS-20-102-002-03 03



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7.7. SUSTAINED LOADS
7.7.1. Sustained load shall include effects of internal design pressure, weight effects of pipe,
components, contents, and any external weights like insulation.
7.7.2. Traffic loads on buried piping shall be considered.
7.8. MECHANICAL LOADINGS:
7.8.1. Wind and earthquake loads shall be determined in accordance with the governing Code(s),
standard(s) and the data specified in the UOP Project Specifications.
7.8.2. Pipe supports shall be capable of supporting pipe full of water at ambient temperature.
7.8.3. Where free draining requirements are specified they shall be met under all conditions,
taking into account piping deflections.
7.8.4. Stress, deflection, and fatigue shall be evaluated for the applicable loading conditions.
7.8.5. The piping system evaluation shall include operating, start-up, shutdown, and steam out
conditions.
7.8.6. The piping system shall be properly designed to avoid severe cyclic conditions.
7.8.7. Piping associated with compressors requires that the amplitude and the spectral frequency
distribution of pulsation be accommodated.
7.8.8. Pipe supports shall be designed to withstand all loading combinations including any
factional forces due to the sliding of supports.
7.9. ROAD CROSSINGS
7.9.1. Where ever road crossings are encouraged either pipe rack above the roads or culverts.

7.10. DESIGN FLOW VELOCITY
7.10.1. Limitation on flow velocities inside piping systems shall apply.
7.10.2. Higher velocities may be permitted if there are technical and economical justifications.
7.10.3. Piping systems shall be designed with considerations to avoid and/or minimize the potentials
of noise and piping vibration due to high velocities, slug flow, two-phase flow, acoustic
fatigue, etc.
7.10.4. Piping systems in gas service operating intermittently with high velocities shall be designed
with following considerations:
Excessive noise and severe vibration shall be avoided.
Pipe intersections should be at 45 degree inclination rather than 90 degrees.
Pipe bends shall be of the long radius type with minimum 3 diameters.
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EECS-20-102-002-03 03



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Lead-lines upstream of & flow element shall have sufficient length to allow for flow
development. A minimum length of 15 times diameter upstream and 5 times diameter
downstream is recommended.

8. MATERIAL SELECTION FOR PIPING COMPONENTS
8.1.All pressure piping components shall comply with Standards specified in the paragraphs listed
below. However, it is the design consultants responsibility to ensure selected material is adequate
to the intended service.
8.1.1. The selection of material in general shall be as given below-
a) Carbon Steel, for temperature less than or equal to 425
0
C.
b) Low temperature Carbon Steel, for temperature less than -29
0
C to -45
0
C.
c) Stainless Steel, for temperature below -45
0
C.
d) Alloy steel, for temperature greater than 425
0
C.
e) For corrosive fluids, process licensor recommendations should be followed.
f) Material procurement of pipes, fittings, valves and gaskets shall be in compliance with
approved vendor list.
8.1.2. Material specification & line classes shall be in accordance with EECS-20-102-001
8.1.3. Valves selection for piping systems shall be in accordance with EECS-20-102-017
8.1.4. Flanges, bolts and gasket shall be in compliance with EECS-20-102-018
8.2.All non-metallic piping system shall be designed and constructed in accordance with the applicable
ASME B31 Code.
8.3.Items specified by brand names or proprietary names are not intended to exclude equivalent items
offered by other manufacturers.


9. LIMITATIONS ON PIPE SIZES AND THICKNESS
9.1.SIZES OF PIPES AND FITTINGS
9.2.The outside diameter of steel pipe shall be in accordance with applicable standards. Intermediate
sizes and the sizes:
8
1
, ,
8
3
, 1, 2, 3, and 5 inches shall not be used except when necessary to
match equipment connections. In this case a suitable transition shall be made as close as practical
to the equipment. Mating flanges can be treated as special items.
9.3.Pipe (excluding stainless steel tubing) smaller than -inch nominal size shall not be used for
hazardous services (including vents and drains) except for instrument connections and on Vendor-
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EECS-20-102-002-03 03



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supplied skid-mounted equipment or other applications where the pipe is adequately protected
against mechanical damage.
9.4.The wall thickness of the pipe and piping components shall meet the requirements of the applicable
Code as a minimum.
9.5.Piping wall thickness selection shall be governed by greater of minimum calculated code thickness
including corrosion allowance or the minimum structural thickness provided in Table 1.
Table 1 Minimum Structural Pipe Wall Thickness (T
s
)
Nominal Pipe
Size (Inch)
Wall Thickness
(Inches) (mm)
Thru 1 0.09 2.25
2 Thru 3 0.09 2.25
4 Thru 12 0.10 2.54
13 Thru 18 0.12 3.0
18 Thru 30 0.15 3.8
32 Thru 48 0.180 5.08
50 and up 0.250 6.35

9.6.For carbon steel piping, the minimum nominal wall thickness shall not be less than the values listed
in Table 2.





Table 2 Minimum Pipe Wall Thickness for Carbon Steel Pipes
Nominal Size
(Inches)
Hydrocarbon
Service
Low Pressure Utility
Service

1 1/2 and smaller SCH 80 SCH 40
2 through 10 SCH 40 SCH 40
12 through 32 6.3 mm 6.3 mm
34 and larger D/135 D/135
Notes:
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EECS-20-102-002-03 03



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"D" is the pipe outside diameter.
A stress analysis is required to confirm that the combined longitudinal stress and bending
stress does not exceed the code allowable limit based on factors such as pipe support
spacing, allowable stress, design pressure, etc. This note applies to the both Table 1 & 2.

10. PIPING LAYOUT
10.1. GENERAL
The design consultant is responsible to provide piping layout that is economic and follows sound
engineering practices. The piping layout shall assure safe operation, ease of construction, provide
adequate access for maintenance activities, minimize consequence due to fire, and avoid congestion.
10.2. Hydraulic considerations
10.2.1. The pipe size, layout and supports shall be designed such that all hydraulic requirements are
met in terms of pressure drop and required through analysis.
10.2.2. Piping systems shall be designed with considerations to avoid and/or minimize the potentials
of noise and piping vibration due to high velocities, slug flow, two- phase flow, acoustic
fatigue, etc.
10.2.3. Piping systems in high gas velocities operating intermittently shall be designed with
following considerations:
Excessive noise and vibration are avoided due to high gas velocities and pressure drop.
Smooth transitions at flow intersections by means of laterals and long radius bends.
Pressure drop at intersections.
Lead-lines upstream & flow element shall have sufficient length to allow for flow
development. A minimum length of 15 times diameter upstream and 5 times diameter
downstream is recommended.

10.3. CORROSION CONSIDERATIONS
The piping layout shall be designed in a way to minimize corrosion in the piping systems due to
presence of water pockets, dead legs, and any other situation leading to internal or external
corrosion. In general minimum corrosion allowance of 1mm is considered for carbon steel piping &
0mm of stainless steel piping.
10.4. DEAD LEGS
Dead legs leading to internal corrosion shall be avoided at the design stage. A dead leg is created
mainly by flow stagnation.
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EECS-20-102-002-03 03



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A section of a piping system meeting the following criteria is considered a dead leg:
When a pipe section is connected to a flowing stream where it is not self draining and is
not normally flowing.
The piping material has the potential for corrosion in service.
10.5. PIPING FLEXIBILITY
10.5.1. The piping configuration shall be analyzed for adequate flexibility.
10.5.2. The piping system shall not be too flexible to the point that it becomes subject to piping
Expansion J oints
10.5.2.1. Swivel joints, expansion joints, flexible pipe (metallic or non-metallic), hoses or
similar devices shall not be used to reduce the stiffness of the piping system or to
reduce load on equipment nozzles in flammable, toxic and hazardous services.
10.5.2.2. They may be used for category D fluid service as defined in ASME B31.3.
10.6. PIPE RACKS
10.6.1. Above grade plant piping between plant equipments or between separate units within a plant
area shall be designed and installed within pipe rack boundaries as indicated on Plot Plans
and Piping Plans.
10.6.2. The Plot Plans and Piping Plans shall be laid out such that they shall provide the necessary
access to all areas for operations and maintenance .The elevations of intersecting pipe racks
shall normally be at different levels to allow for future piping.
10.6.3. When designing off-plot pipe racks for process plants, consideration shall be given to
providing extra rack space for future expansion.
10.6.4 Electrical and Instrumentation cables :
Following concepts shall be adopted for routing of electrical and instrumentation cables
throughout the refinery complex.
i) Electrical HT cables shall be laid underground in trench with slab cover in ISBL and
OSBL including tankage area.
ii) Electrical LT cables shall be laid above ground on top tier of pipe rack in ISBL and
OSBL area.
iii) Instrument cables shall be taken above ground on top tier of pipe rack in ISBL and
OSBL area.
iv) Instrument fiber optic cables shall be taken under ground through conduit in ISBL and
OSBL area.
v) Flange guards shall be used for hydrocarbon lines located near the cable trays in pipe
Rack.

03
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EECS-20-102-002-03 03



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10.7. CLEARANCES AND ACCESSIBILITY
10.7.1. The minimum clearance required over roads, walkways, platforms, etc. shall be as follows:
Railroads/railways: 7.0 meter
Access roads, main roads, crane access: 7.0 meter
Fire fighting equipment: As required by local authorities
Plant roads within the unit: 4.5 meter
Overhead within the unit area: 2.8 meter
Fork lift truck access : 2.8 meter
Above walkways and platforms: 2.1 meter
10.7.2. Valves 4 and above shall be installed with the operating device not higher than 1.5 meter
above the operating level. Valves 3 and smaller, temperature indicators, level instruments,
pressure indicators may be accessible from ladders. All battery limit valves shall be
accessible fro grade or platform.
10.7.3. The minimum clearance over the actuator of a control valve shall be 180 mm and under the
bottom of the valve clearance shall be minimum 300mm.

11. LINES SPACING REQUIREMENTS
11.1. The minimum spacing between lines supported on sleepers or pipe racks shall be as shown on
standard drawing.
In general minimum spacing shall be-
a) 50mm pipe to pipe, pipe to insulation and insulation to insulation.
b) 25 mm flange to pipe and flange to insulation.

11.2. Above-grade piping shall be supported to provide a minimum of 300 mm clearance between bottom
of the pipe and the finished grade.
11.3. A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement
between above ground piping crossing with any structure (including pipe support structure). This
clearance is also required for above ground piping crossing with another pipe.
11.4. Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes,
shall be located at a minimum horizontal distance of 610 mm (24 inches) from any fixed
obstruction. This requirement does not apply to that part of the support which is attached directly to
the piping, such as horizontal and vertical dummy extensions.
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EECS-20-102-002-03 03



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12. UNDERGROUND PIPING
12.1. Underground pressure piping where permitted shall be subject to the following additional
requirements:

12.2. No buried dead legs shall be allowed, including "effective" dead legs resulting from the buried
portion of the line being frequently or normally valved off unless the line is designed to be self-
draining and/or is internally coated.
12.3. The buried piping (including appurtenances) shall be cathodically protected with impressed-current
or galvanic anodes system for soil resistivity less than 5000 Ohm-cm
12.4. The minimum cover over underground pressure piping shall be 450 mm in unpaved or paved areas
and 1000 mm under paved roads, except under reinforced concrete slab or other protection.
12.5. Sleeves of suitable strength shall be provided at road crossing/ culverts.
12.6. The buried piping (including appurtenances) shall be externally coated with an approved coating.

13. PIPE SUPPORTS DESIGN
13.1. RESPONSIBILITIES
It is the Design consultants responsibility to design the pipe supports to meet hydro testing,
operational and emptying conditions requirements.
13.2. RIGID PIPE SUPPORTS
13.2.1. The rigid pipe supports should be utilized to maximum extent thus avoiding the use of spring
supports and rod hangers wherever design permits.
13.2.2. The designer shall ensure that all pipe supports will be active during operation of the lines,
i.e., the pipe will be in full contact with the support and carries the load.
13.3. HANGER RODS
13.3.1. Rod hangers shall not be used for lines 12" NPS and larger in liquid service or multi phase
flow.
13.3.2. Rod hangers shall be subjected to tensile loading only.
13.3.3. Rod hanger assemblies shall be designed to allow for anticipated thermal movement.
13.3.4. The maximum swing angle due to horizontal pipe movement shall be four (4) degrees.
13.3.5. All hangers shall be provided with means for vertical adjustment.
13.3.6. Suitable locking devices shall be used at all threaded connections of the hanger assembly
(double nuts).
13.3.7. Where atmospheric corrosion is a concern hanger rods shall be protected against external
corrosion.
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EECS-20-102-002-03 03



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13.4. SPRING SUPPORTS
13.4.1. Spring supports immediately downstream of rotating equipment shall be limited to 10-15%
load variation.
13.4.2. Supports shall be designed such a way that they cannot be disengaged by movements of the
supported Pipe.
13.4.3. All springs shall be in compression, so that failure will not result in the complete release of
load.
13.4.4. Springs shall be factory set to the calculated cold settings by means of travel stops. Upper
stops for load preset and lower stops for hydro-test shall be provided. These stops shall be
banded or locked in place so they cannot be easily dislodged during erection or hydro-test.
The travel stops shall be painted red and shall have a bright colour tag indicating "Remove
after Hydro-test."
13.4.5. Each spring hanger assembly must be capable of sustaining the hydro test load.
13.4.6. Where atmospheric corrosion is a concern spring supports shall be protected against external
corrosion.
13.5. RING GIRDERS
13.5.1. Above ground fully restrained piping shall be supported on ring girders, or 180-degree
saddles with top strap, designed to prevent lateral buckling of the pipeline.
13.5.2. Suitable electrical insulation strips shall be provided between the pipe and the support if
required to prevent dissipation of cathodic protection current.
13.5.3. The pipe surface covered by the ring girder or saddle and top strap shall be coated with
approved epoxy coating to prevent corrosion of the pipe. Coating is not required if a
fiberglass insulating spacer is epoxy bonded to the pipe after abrasive blasting the pipe
surface.
13.6. LOW FRICTION SUPPORTS
13.6.1. If Teflon sheets or similar low friction materials are used to reduce the design loads on
piping and/or the supporting structure, provision shall be made to allow angular adjustment
of the bearing surface during installation, so that an even distribution of the load can be
assured.
13.6.2. Low friction supports shall be designed such that sand or other debris cannot accumulate on
sliding surfaces (by making the top surface larger than the bottom surface).
13.7. DUMMY SUPPORTS
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EECS-20-102-002-03 03



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13.7.1. The dummy supports shall not create excessive stresses at the attachment welds to the run
pipe. This can be accomplished by minimizing the length of the supports and/or increasing
the size of the supports.
13.7.2. A 6 mm deep hole shall be drilled for all dummy supports. The weep hole shall be located
near the base plate for all vertical dummy supports, and near the run pipe at 6 o'clock
position for all horizontal dummy supports.

14. ANCHORS AND GUIDES
14.1. END ANCHORS
The Design Agency shall ensure that above-ground restrained and buried pipelines terminating at
the plant facilities be provided with end anchors.
14.2. INTERMEDIATE ANCHORS, GUIDES, AND LINE STOPS
14.2.1. The free movement of unrestrained piping, both in axial and lateral directions, shall be
controlled and limited by properly located guides and anchoring points to within acceptable
bounds.
14.2.2. Intermediate anchors or axial line stops shall be provided for above-ground unrestrained
piping between and/or at the centre of expansion loops or offsets. The design load for such
intermediate anchors shall include the effect of friction forces.
14.2.3. Axial line stops and guides shall be provided for above ground unrestrained lines subject to
slug forces in services listed below. Slug forces shall be estimated based on the worst case
assumed velocity and average density of the liquid/vapor slug expected to occur.
14.2.4. The supporting structures shall be designed to withstand slug forces acting at changes in
direction. However the pipe guides and stops shall yield prior to the pipe.
The following are examples of services with potential slug flow; however this doesn't
remove responsibility of the Deign Consultant to identify others.
Two-phase flow lines
Liquid intermittent lines, such those used to control liquid level in the drums
Pressurized drain lines
Relief and blow-down lines
Flare lines
High-pressure gas lines
14.3. DAMPENING ANCHORS
Suitable dampening anchors shall be provided to hold down the piping and mitigate vibration as
required at control valve stations, (surge) relief valves, and where flow surges can occur.
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PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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15. NON-PRESSURED WELDED ATTACHMENTS
15.1. During the design stage the following requirements shall be adhered to:
15.1.1. Welded attachment to the piping systems shall be minimized. Design should avoid the use of
bimetallic welds.
15.1.2. The pipe shall not be used to support other pipes and structures without an appropriate
analysis.
15.1.3. All structural attachments, which transfer loads to the pipe through welds, shall be welded to
full encirclement sleeves or saddle pads if the piping is designed to operate at a hoop stress
in excess of 50% of the allowable stress. The corners of the pad shall be rounded corners.
ASME B31.4 paragraph 419.1(d) and ASME B31.8 paragraph 834.5(b), if applicable, shall
not be waived.
15.1.4. On the construction drawings, all welds to the pipe shall be shown as continuous with
smooth finish.
15.2. Wear Pads and Saddles
15.2.1. Piping in hazardous services where condensation can form on the pipe, or operating within
30 m of the sea shall have wear pads or corrosion bars welded to the pipe at each support.
15.2.2. Excluded from this requirement are low pressure systems with hoop stress at design pressure
below 18% of Specified Minimum Yield Strength (SMYS) of the pipe.
15.2.3. Wear pads shall be fully welded to avoid ingress of moisture.
15.2.4. Saddle-type supports: Saddle-type supports with pads shall be provided for piping 30-inch
NPS and larger. In case saddle pipe support cannot be installed, the line shall be analyzed
for localized stresses.

16. INSTRUMENT PIPING
Instrument piping within the scope of the Code shall meet all the applicable requirements of the
Code.

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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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17. PLANT UTILITY PIPING SYSTEM
17.1. This section of the standard defines additional limitations on piping used for connecting a supply of
steam, water, air, nitrogen or other inert gas to process equipment in hazardous services except as
stated below. It also includes connections for the purpose of purging or cleaning when the process
equipment is not in operation.
17.2. This section does not apply to purge connections to open furnaces or fire boxes. It also does not
cover connections to process equipment where the process flow and utility flow remain physically
separated such as in cooling water or instrument air.

17.3. The design of utility Stations located in various locations within one plant area shall be uniform and
shall be such that the risk of accidental connection to the wrong utility is eliminated.
17.4. The connectors and colour coding for utility piping shall be specification EECS-20-102-015.
17.5. Hose connections, where applicable, shall be positioned at elevation not higher than 1200 mm above
finished plant grade or above platform of multilevel equipment but not lower than 600 mm. They
shall be pointing 45 degrees downward. The piping shall be securely bolted to a supporting
structure and have adequate access. Utility connections shall be installed with minimum 140 mm
clearance between each other.
17.6. Each utility take-off connection shall be located at the top of the horizontal main header or auxiliary
header. Root valves shall be provided for each utility take-off connection from a main header or
auxiliary header which can not be taken out of service without shutting down a complete
processing unit or operating facility.
17.7. Instrument air take-off connections to the plant utility station shall always be provided with root
valves.
17.8. Each utility line shall be provided with an isolation valve just upstream of the specified hose
connector at the termination. Ball or globe valves shall be used for air, water, and nitrogen services;
globe or angle valves shall be used for steam service. Each line shall have a service name plate in
Hindi and English indicating the service. The utility pipe and the ends of hoses provided with the
station shall be color coded.
17.9. The steam line shall have steam trap and shall be insulated for personnel protection except for utility
steam take-off lines. Utility steam take-off lines shall be insulated but shall not be provided with
steam traps. Utility steam stations located above the utility steam header shall be self-draining
towards the utility steam header. Utility steam lines to utility stations below the utility steam header
shall be allowed to gather steam condensate, which is removed before applying the utility steam.
17.10. Water supply systems which deliver drinking water shall not be connected to process equipment as
utility water source, except via a break tank designed to prevent backflow.
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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



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17.11. Firewater systems shall not be connected to process equipment.


18. UTILITY-PROCESS CONNECTIONS
Requirements of this section are specific to the Utility-Process Connections, in addition to the
requirements of this standard.
18.1. Temporary Utility-Process connections with components listed in the direction of the utility flow
shall be as follows:

18.1.1. The utility side shall have a block (root) valve, pressure gauge, check valve and a drain valve
to depressurize the hose or the break-away spool. The process side shall also have a check
valve; block valve, and pressure gauge near the hose connection.
18.2. No permanent connections other than air or steam shall be made to process equipment operating
above 100C nor shall water or steam be permanently connected to equipment that operate below
0C.
18.3. Permanent connections without a break tank shall not be made except when the required service is
continuous or frequent (at least twice per week) or needed for emergencies. Permanent connections
without a break tank shall consist of the following (in the direction of the utility flow):
18.4. The utility flow shall have instrumentation for automatic shut-off on low flow or low pressure (in
addition to a check valve) in all cases where redundant protection against back flow is required.
18.4.1. The utility side shall have a pressure gauge, block valve, bleed valve and spectacle blind or
quick change blind (normally open).
18.4.2. The process side shall have a check valve, bleed valve or drain, block valve and pressure
gauge.
18.4.3. The block valves of the connection shall be within sight of each other and shall be as close as
practical to the process equipment. The pressure gauges and the position of the blind shall
be clearly visible from a single point.
18.5. Air connections to asphalt or hot oil piping through which air is supplied to blow the product to
tankage, shall be provided with a water knock-out (KO) drum with drainage facilities. The line
downstream of the KO drum shall not contain low points and shall have an additional drain valve
immediately upstream of the process connection.
18.6. When air is injected as a reaction agent, such as in Merox and air sweetening units, the control shall
be such that the hydrocarbon/air mixtures will not enter the flammable range unless required by the
process. Instrumentation shall be provided to shut off the air flow if the process flow fails. In
addition, a restriction orifice shall be provided.
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DOCUMENT NO REV
PIPING DESIGN PHILOSOPHY
EECS-20-102-002-03 03



ESSAR ENGI NEERI NG CENTRE , MUMBAI Page 20 of 20
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18.7. The rating of all Components of a permanent connection shall be suitable for the more severe of
pressure/temperature of the process or the utility service.
18.8. For temporary connections the pressure/temperature rating of the process side shall extend to the
hose or break-away spool.
18.9. If the process fluid requires internal lining or material other than used in the utility system, the lining
or the material shall extend from and include the check valve on the process side. Valves with
bodies of gray cast iron, ductile iron, or low melting point alloys (such as brass or bronze) shall not
be used in a permanent connection including the utility side. Valve bodies and trim in a permanent
connection shall be suitable for both the process and the utility fluid with regard to corrosion and
pressure rating.

19. CHEMICAL CLEANING LINE IDENTIFICATION
19.1. Lines that require chemical cleaning during construction shall be identified and marked up on the
appropriate P&ID's and Line Index Tables. The systems to be cleaned shall have high and low point
vents and drains installed.

20. TESTING AND INSPECTION
20.1. The design of the piping systems shall facilitate effective pressures testing.
20.2. Test procedures that may require special attention may be prepared during the design stage.