100 General Information

Abstract
The Utilities Manual is a guide for the basic design and construction of utility
systems. It focuses on design fundamentals, guidelines for practical installations,
and specification and purchase of materials and services. It is applicable to large
and small facilities whether used for upstream production, downstream refining,
chemical manufacture, offshore production, or marketing. Its guidelines encompass
the experience of the Corporation’s Operating Companies. The manual is useful to
both engineers and operating personnel.

Contents Page

110 Codes and Industry Practices 100-2

111 Code Application
120 Government Regulations 100-2
121 OSHA Compliance
122 Boiler Piping
123 Foreign Applications
130 Company Practices 100-3
131 Corporation Piping Specification
132 Boiler Specifications
133 Company Engineering Specifications
140 Engineering Judgment 100-4
150 Personnel Safety and Protection of Equipment 100-5
160 Utility Connections 100-5
161 Utility Services Covered
162 Types of Utility Connections
163 Permits for Utility Connections
164 Permit Approval Procedures
165 Color Coding of Utility Connections

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110 Codes and Industry Practices

The various codes (such as ASME Section I and ANSI/ASME B31.1 in the United
States) contain practices necessary for safe systems, but are not intended to be
complete specifications for all phases of design. The Company recognizes this fact,
and the guidelines and specifications in this manual provide the supplemental
requirements normally needed to obtain economical systems for basic services. A
few requirements—where experience has shown them to be better choices—are
more stringent than code minimums. Engineers responsible for design and construc-
tion of utility systems are expected to be familiar with and to comply with the
appropriate codes even though some of their provisions may not be specifically
included in this manual.

111 Code Application

The Corporation Piping Specification included in the Piping Manual uses
ANSI/ASME B31.3 as its principal basis.
The Corporation Piping Specification also includes specifications for two pipe
classes for steam boiler external piping to the first block valve that comply with the
ASME Boiler and Pressure Vessel Code, Section I. This code is discussed in
Section 120.

120 Government Regulations

Engineers responsible for design and construction of piping in the United States are
expected to determine which codes are legally required and if there are any other
federal, state, or local regulations governing such construction. The Company
requires compliance with the most stringent practice.
In general, piping that conforms with ANSI/ASME B31.3 and the Corporation
Piping Specification will meet the legal requirements in North America for refin-
eries, loading terminals, and gas, natural gasoline, bulk, and chemical plants. Simi-
larly, conformance with ANSI/ASME B31.3 generally assures legal conformance
for producing facilities in North America.
All sections of ANSI/ASME B31 have been adopted by most provinces of Canada.
Some sections, including B31.3, have also been adopted by some states and locali-
ties in the United States; however, it is not a legal requirement in most states.

121 OSHA Compliance

In the United States, compliance with the Occupational Safety and Health Act
(OSHA) is mandatory. Other countries have similar legislation. For general petro-
leum industry piping, the major effect of OSHA is on construction safety and to
forbid the use of regular cast iron for flammable or combustible liquids having a
flash point below 200°F, or a temperature within 30°F of their flash point. Steel,
ductile cast iron or malleable cast iron are required. The details of OSHA regula-
tions are still changing, and the most recent revision should be reviewed.

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OSHA regulations strongly encourage use of the B31 codes by stating that compli-
ance with B31 codes and specific OSHA rules is prima facie evidence of compli-
ance with the basic requirements of OSHA.

122 Boiler Piping

Many state and local regulations require piping immediately connected to a boiler
or steam generator to conform to ASME Boiler and Pressure Vessel Code Section I,
Power Boilers. The engineer responsible for the design and construction of steam
generating facilities should refer to ASME Boiler and Pressure Vessel Code Section
I, to ANSI/ASME B31.1 Figure 100.1.2, and to local regulations to determine their
jurisdictional limits. ANSI/ASME B31.3 specifically covers steam piping beyond
the mandatory limits of B31.1 and, unless local regulations require otherwise, is
used for such steam piping.

123 Foreign Applications

For installations outside the United States and Canada, the engineer responsible for
utility design and construction should determine if there are national or local regula-
tions pertaining to design. For consistency in engineering and fabrication
ANSI/ASME B31 is preferred over local rules, unless local rules are more strin-
gent. The ANSI/ASME codes remain good guidelines where no other regulations
exist.

130 Company Practices

131 Corporation Piping Specification

Piping components are designed and fabricated according to current standards and
codes established by national bodies such as the American National Standards Insti-
tute (ANSI). The Corporation Piping Specification, developed and used by design
and operations centers within the Company, is based on these standards and codes.
Piping codes prescribe minimum practices necessary for safety. They are not
complete specifications. The Corporation Piping Specification adds requirements
normally needed to obtain safe and economical piping systems for basic fluid
services.

132 Boiler Specifications

Similarly to piping codes, ASME Section I provides minimum requirements for
design of steam boilers. The Company specifications in Section 2000 add require-
ments needed to obtain safe and economical installations.

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133 Company Engineering Specifications

The Company uses engineering specifications for purchasing piping components
and for fabrication and construction. Some of these specifications are in Section
2000. They are:
• UTL-MS-2771 Boiler Feedwater Deaerators and Deaerating Heaters
• UTL-MS-2829 Packaged Water-Tube Power Boilers
• UTL-MS-4090 Packaged Fire-Tube Boilers

140 Engineering Judgment

The availability of specifications for a given service does not eliminate the need for
sound engineering judgment in piping design. The piping engineer is not released
from the responsibility to think.
Every utility application should be reviewed in light of conditions the system might
be exposed to. What system upset pressures, temperatures, and fluid compositions
are possible? What are possible changes in service? Will the system be required to
alternate between two or more services?
In addition, it may be necessary or desirable to modify existing pipe classes to deal
with problems arising in specific applications, for example:
• Extraordinary conditions such as earthquake, high wind, other unusual
dynamic loadings, or unusual superimposed dead loads
• Cold climates which may require more use of steel valves, and special mate-
rials to avoid brittle fractures. Autorefrigeration in LPG service is discussed in
Section 1100 of the Piping Manual.
• Mercury, ammonia, or ammonium salts in cooling water or product, which
may dictate elimination of copper alloys (brass, bronze, etc.).
• Proximity to the ocean or excessive chlorides in cooling water or product may
rule out the 300 Series stainless steels.
• High H2S concentrations may limit the choice of copper alloys and place
restrictions on valve trim and weld hardness
• Emergency water and utility lines, which may require steel valves where
subject to fire damage or mechanical hazards
• Variation in corrosion allowance or selection of material used for handling of
corrosive material
• Use of lighter wall pipe for low pressure systems
• Use of standard schedule materials when maintenance considerations are high
priority
It is necessary that the user of this manual realize that its use does not release him
from his responsibility to use sound judgment in the selection of materials,

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fittings, valves, and other piping items to meet safety and economic considerations.
No attempt has been made to provide for all the in-between or gray areas.

150 Personnel Safety and Protection of Equipment

Throughout the plant design process, the designer must keep safety in mind. The
facility must be safe for all technical, operating, and maintenance personnel as well
as the general public. Unfailing attention must also be given to protection of the
facility itself to avoid the prospect of long, costly shutdowns.
Safety needs to be addressed in preparing the plot plans (plant layout) and the
piping and instrument diagrams (P&ID’s).
Plant layout is one of the first areas where safety becomes a factor. Careful thought
is required on location of fired equipment, which is a continuous source of ignition
when in operation. There are Company rules regarding spacing, location, and
setbacks (see the Safety in Designs Manual). However, each case is unique and
requires the judgement of the designer. The location of high pressure equipment is
important. Here, the attachments (piping and instrumentation) are the most likely
source of leaks. Easy access to operating valves and personnel protection from hot,
uninsulated surfaces are other safety considerations.
Instrumentation shown on piping and instrumentation diagrams should be simple,
proven and properly applied. Complex systems are prone to human error and
mechanical malfunction, and can be less reliable from a safety standpoint. Highly
interlocked shutdown systems can be so complicated that it becomes very difficult
to start up the process. This can lead to poor operating practices such as bypassing
shutdowns and alarms.
Generally, making facilities safe also protects equipment from damage that may
force extended shutdowns. Alarms, shutdowns (manual and automatic), and relief
valves provide such protection.
When developing P&ID’s the possibility of cross-contamination of streams due to
leaking equipment and pressure differentials must be carefully considered. Valves
cannot be considered leak-tight. Only line blanks and dropout spools can ensure no
leakage. Breaktanks are often used in drinking water service to ensure no contami-
nation. Also, various operating scenarios need to be thought about that could lead to
crossing of streams while in operation. See Section 160 for more information on
isolating systems.
The designer should be cautioned that the use of new, untested, or overly compli-
cated equipment, particularly for critical areas, may lead to unexpected problems
and increased start-up difficulties. This is especially true in areas where the estab-
lished practices and equipment work, are simple, and ought to remain so.

160 Utility Connections

When making connections to any utility system, the engineer or plant operations
staff must be very careful that the connection is done in a manner that will avoid

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any possible cross-contamination between the utility system and the connected
system. Avoidance should be such that not even apparently abandoned or tempo-
rarily unused process fluid lines are considered for such connections.
The following installation and permit procedures are provided as guidelines. Discus-
sion relates to all considerations; that is, the making, dismantling, or altering of
connections on any utility service line involving either permanent or temporary
connections. See below for further definition of both permanent and temporary
connections.

161 Utility Services Covered

Utility service lines are those lines routed throughout facilities in common use
areas, on pipeways, and within plant plot limits. All require a Utilities Connection
Permit. The utility service lines provide:
• Drinking water
• Fresh water—also referred to as raw water, fresh cooling, or makeup water
• Refinery feedwater—also referred to as treated water, boiler, or makeup feed-
water
• Stripped sour water
• Low-pressure salt water (LPSW)—also referred to as cooling water
• High-pressure salt water (HPSW)—also referred to as fire water
• Condensate (recovered condensed steam)
• LP Steam (low pressure—0 to 20 psig)
• MP Steam (medium pressure—20 to 150 psig)
• HP steam (high pressure—over 150 psig)
• Compressed air; variously known as high-pressure air, tool air, yard air, or
plant air
• Inert gas (CO2 and N2)
• Fuel gas/natural gas—also referred to as process gas
Treated as a separate category, with connection considerations over and above those
discussed in this manual, are fuel oil lines, sewer lines, and electrical facilities.

162 Types of Utility Connections

Recommended Connection Details
Figure 100-1 shows the recommended piping details for connection of various utili-
ties to various processes.

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Note Any connection not shown on this figure is not recommended.
Fig. 100-1 Requirements for Permanent Utility Connections (1 of 4)
DC DC
2 2
VC
2 DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
DC DC
2 2 DC
2
DC
2 DC
2
DC
2
VC
2
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Fig. 100-1 Requirements for Permanent Utility Connections (2 of 4)
DC
2
DC
2
DC DC
DC 2 2
2
VC
2 DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
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Fig. 100-1 Requirements for Permanent Utility Connections (3 of 4)
DC
2
DC
2
VC
2
DC
2
DC
2
DC DC
2
2
DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
DC
2
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Fig. 100-1 Requirements for Permanent Utility Connections (4 of 4)

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Drinking Water System Connections

Connections to the drinking water system should be limited to:
• Drinking fountains
• Eye bubblers or eyewash stations
• Safety showers, locker room showers, or hand-washing stations, potable water
for kitchens, and in general that intended for use or consumption by personnel
There should be no connection between drinking water systems and process lines or
other utility service lines. Temporary or permanent connections for washdown
should never be made.

Permanent Utility Connections

A permanent utility connection is a connection made to any utility service system
that will be left in place and available for repeated use. Such connections involve:
• Making connections to extend or increase the same service
• Making connections between utility lines in the same or different services
• Alterations to utility lines involving a change in design, location, or use
• Dismantling utility lines or connections to utility service lines
There should be as few permanent connections as possible.
The minimum acceptable method for installing permanent utility connections
(between utilities or other systems) depends upon the services connected.
Figure 100-1 shows the minimum connection requirements for various services.
More elaborate connections may be appropriate for certain, specific jobs.

Temporary Utility Connections

A temporary utility connection is defined as a connection made to any utility
service system that is expected to be in use for a brief period. Such connections
involve:
• Making connections from utility lines to process lines, drums, columns,
vessels, pumps, and other equipment.
A temporary utility connection is intended for one-time use such as a steam out or
purge of a line or vessel during or prior to a shutdown. The connection should be
dismantled when not in use.
A connection that is used over several shifts by more than one operator may require
more safeguards than a connection used briefly by one operator.
All temporary utility connection removable spools and temporary piping should be
marked with an identifying color of paint (purple is recommended).
Additional considerations for temporary connections include:
• All temporary utility connections should include, as a minimum, double block
valves, a check valve, bleeder valves, and a temporary spool. These valves and

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fittings must meet the highest piping classification required for the actual
upstream and downstream conditions of the connected systems.
• Temporary connections between freshwater or fire water lines and process or
chemical lines or equipment should have a double block valve, double check
valve arrangement with a bleeder hole between the upstream block valve and
check valve. The bleeder hole should have no valve or other shutoff device,
and while in use, should be observed continually to be certain that only water
is flowing out of the bleeder hole.
• The size and routing of the temporary piping should be adequate to prevent
mechanical failure and should be routed, barricaded, or flagged to prevent a
tripping hazard.
• Temporary utility connections using hoses should comply with plant practice.
• The temporary connections should be dismantled immediately after use.
Offplot Utility Connections. Utility connections for use external to the Company’s
plant should be approved by the plant engineer or manager. These connections
should be constructed as if they were on- plot; the criteria are identical.

Double Check Valves

Double check valves should be used only where cross-contamination will produce
significant danger to personnel or equipment; and then only with careful consider-
ation of the possible problems:
• Double checks will leak because one is sure to have insufficient ∆P to seat
correctly
• Double checks often leak even with high ∆P
• Double checks require extra vents or drains
• Double checks in utility connections often do not receive adequate maintenance
Statistical evidence indicates that double check valves give equal or worse leakage
than that from single check valves because the seating capability depends on differ-
ential pressure.
Sets of double check valves should be of two different valve styles. For instance,
use a split wedge style to contain the leakage from a piston check. The spring-
loaded split wedge valve seals better at the low ∆P that exists downstream of the
piston check valve.

163 Permits for Utility Connections

Utility Connections Requiring a Permit
We recommend that a Utility Connection Permit be completed and approved by the
plant engineer prior to making, dismantling, or altering a connection to any utility
service line, except for those connections listed below.

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Utility Connections Not Requiring a Permit

• Temporary connections that will not significantly increase the flow rate of the
utility
• Low-pressure salt water
– For piping NPS 2 and smaller, where made on plant side of last block
valve off main line, to extend same service
– Temporary connections to hydrants on LPSW systems for washing equip-
ment
• Temporary connections to hydrants on HPSW fire water systems where
approved by the plant engineer
• In utility systems for individual plants that are not connected to the general
utility system. An example would be isolated N2 systems
• Low- or medium-pressure steam traps (150 lb or less) connected to steam
condensate systems or for steam tracing systems

164 Permit Approval Procedures

The proposed design of permanent connections to utility systems should be
discussed with the plant engineer before extensive design or field work is started.
The discussions should include:
• Quantity of utility required
• Capacity of existing lines to provide the proposed change without degradation
of services to present users on the same line
• Disposition of wastes, effluent, discharge, exhaust, as a result of the proposed
connection
Final drawings for permanent connections should be submitted with the permit for
the plant engineer’s approval and to ensure that refinery drawings reflect an as-built
status.
Temporary connection permits (where required) should include sketches and a
schedule with a description of the proposed use.
During construction, the Utility Connection Permit should be available in the area
of the connection. This should resolve any questions about approval or correctness
of the installation.
A copy of all currently approved permits should be kept by the plant engineer.
Final Disposition of Utility Connection Permits. After a permitted connection is
installed, the installation should be inspected by a safety review team. The team
should review the permit during the inspection. When the completed installation is
approved, the plant engineer should sign the permit and revise the connection
drawing if required.

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Permit Form. Figure 100-2 shows one format used for a Utility Connection Permit
form.

165 Color Coding of Utility Connections

Color coding is recommended for all utility connections. Color coding and line or
connection identification should conform to the standards in use at the facility. The
following is suggested:
• BLUE - Nitrogen and inert systems
• WHITE - LPG
• ALUMINUM - NH3
• PURPLE - All drop out spools and temporary piping used in any connection
• GRAY - Exterior of electrical conduit, fuse and switch box doors
• RED - Connections for fire protection equipment from fire water system
• YELLOW - Indicates H2S hazard

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Fig. 100-2 Utility Connection Permit Form (Example)

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