Engineering, Procurement, Construction,

Erection, Installation, Testing, Commissioning,

startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 1 of 16

Piping Design Basis ISSUED FOR

APPROVAL
And DEC 12, 2017

Flexibility Criteria

Sign Sign Sign

A Issued for Approval 12/12/2017 FM

Client
Rev Description Date Prepared by Checked by Approved by
Approval

DOCUMENT TITLE: PIPING DESIGN BASIS AND FLEXIBILITY CRITERIA

DOCUMENT NO: (CALIBRI 11)

PROJECT NO: (CALIBRI 11)

CODE JOB NO DOC TYPE SEQ NO REV

 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 2 of 16

TABLE OF CONTENTS
1.0 INTRODUCTION 4
2.0 OBJECTIVE 4
3.0 DEFINITIONS 4
4.0 ABBREVIATIONS 5
5.0 REFERENCE SPECIFICATIONS 5
5.1 COMPANY SPECIFICATION 5

5.2 GUIDELINES 5

5.3 INTERNATIONAL STANDARDS 5

6.0 ORDER OF PRECEDENCE (FIXED) 6

7.0 SCOPE OF WORK 6
8.0 PIPING DESIGN 7
8.1 GENERAL 7

8.2 PIPING ROUTING 8

8.2.1 GENERAL 8
8.2.2 DISTANCE BETWEEN PIPES 8
8.3 FLANGES 9

8.4 SPECTACLE BLINDS, BLANKS AND SPACERS 9

8.5 BURIED PIPING 9

8.6 STRAINERS 9

8.7 RELIEF AND BLOWDOWN SYSTEM 9

8.8 VENT AND DRAIN CONNECTION 10

8.9 INSTRUMENT PIPING CONNECTION 10

8.10 EQUIPMENT PIPING 10

8.11 MAINTENANCE ACCESS 10

8.11.1 VALVES ORIENTATION AND ACCESS 10

8.11.2 INSTRUMENT ACCESS 11
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 3 of 16
8.11.3 UTILITY STATIONS 11
8.11.4 MATERIAL HANDLING 11
8.12 BOLT TORQUEING AND TENSIONING 11

8.13 COATING AND WRAPPING 11

8.14 PAINTING 12

9.0 PIPE SUPPORTS AND SPANS 12

10.0 PIPING FLEXIBILITY AND ANALYSIS 12
10.1 GENERAL 12

10.2 PIPE SUPPORT FRICTION AND GAPS 13

10.3 STRESS CRITICAL LINE LIST SELECTION CRITERIA 13

10.3.1 CRITICAL LINE LIST 13

10.3.2 EXTENT OF PIPING ANALYSIS 13
10.3.3 CLASSIFICATION OF LINES 13
11.0 ALLOWABLE NOZZLE LOADS FOR EQUIPMENT 16
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 4 of 16

1.0 INTRODUCTION
Pak-Arab Refinery Limited (PARCO) owns 364 KM long 18"/16" dia. API 5L X-52 MFM Pipeline.
The pipeline is designed for transporting High Speed Diesel (HSD) and Superior Kerosene (SK)
since it commissioned in 1997. The pipeline starts in the North of Pakistan at Mahmood Kot
near Muzaffargarh and ends at Machike near Sheikhupura. It has two Pump Stations (viz- Pump
Station # 5 (PS-5) & Pump Station #7, Faisalabad) and two Terminal Stations (viz. Terminal
Station # 3 (TS-3) at Faisalabad & Terminal Station # 4 (TS-4) at Machike). Pump Station- 5 is
connected with High Speed Diesel storage tanks and MCR HSD/SK tanks located at Terminal
Station # 3 to transfer these products in batches. Currently HSD is being delivered to TS-3,
Faisalabad via Gantry facility as both HSD and SK are delivered to OMCs storage tanks located at
TS-4 through pipeline.
COMPANY intends to review and check the adequacy of Pump Station (PS-7/ TS-3) & Terminal
Station (TS-4) FEED Package prior to start the EPC services. The Scope of Work for EPC
Contractor includes all activities required to perform engineering, procurement,
erection/installation, testing, and completion of all civil, mechanical, electrical and
instrumentation works for Phase – II works at PS-7/TS-3 located at Faisalabad & TS-4 at
Machike. Contractor shall provide all services including pre-commissioning and commissioning
for the implementation of the project in conformity with the requirements.

2.0 OBJECTIVE
The objective of this document defines the requirements for the piping design and layout of TS-3
and TS-4 terminal stations. The project scope involves the development of brown field area at
Faisalabad and Machike Terminal Stations. Piping design basis as covered by this document is
applicable for all on-plot piping at TS-3 and TS-4 that is governed by ASME B31.3 process piping
code.

3.0 DEFINITIONS

COMPANY/ CLIENT Pak Arab Refinery Ltd. (PARCO)

CONTRACTOR China Petroleum Pipeline Bureau (CPP)

CONTRACTOR or the party who is in charge of awarding

PURCHASER
agreement on behalf of COMPANY / CONTRACTOR for the supply

The party to the contract and/or purchase order which has

VENDOR/SUPPLIER undertaken the obligation to supply the goods and/or services
which are ordered and specified herein.

Engineering, Procurement, Construction, Erection, Installation,

Testing, Commissioning, startup and handover of MFM MOGAS
PROJECT
Project (MFMMP) Phase-II, TS-3, Faisalabad & TS-4, Machike
Stations.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 5 of 16

SHALL Indicates a mandatory requirement.

Indicates a strong recommendation to comply with the

SHOULD
requirements of this document.

4.0 ABBREVIATIONS
API American Petroleum Industry
ASME American Society for Mechanical Engineering
OGRA Oil & Gas Regulatory Authority
CAD Computer Aided Design
ISO International Standard Organization
NFPA National Fire Protection Association
FEED Front End Engineering Design
MTO Matrial Take Off
ESDV Emergency Shutdown Valve
DLF Dynamic Load Factor
NPS Nominal Pipe Size

5.0 REFERENCE SPECIFICATIONS

5.1 COMPANY SPECIFICATION
Specification for Painting and Protective Coating (03-0198-GS-9502-0)
Specification of Coating / Wrapping of Buried station piping (03-0198-GS-9517-0)
Piping Specification (3677 003201)

5.2 GUIDELINES
Oil & Gas Regulatory Authority (OGRA)-2009 Depots for the Storage of Petroleum Products
SRO-624(1)/2009

5.3 INTERNATIONAL STANDARDS

ASME B31.3 Process Piping
ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24 Metric/Inch
Standard
ASME B16.9 Factory Made Wrought Butt Welding Fittings
ASME B36.10M Welded and Seamless Wrought Steel Pipes
ASME B36.19 Stainless Steel Pipes
ASME Sec.II Part D Section II-D: Properties - Materials
ASME B16.11 Forged Fittings, Socket-welding and Threaded
ASME 16.20 Metallic gaskets for pipe Flanges-Ring Joint, Spiral Wound and
Jacketed
ASME 16.25 Butt welding Ends
ASME B16.34 Valves-Flanged, Threaded and Welding Ends
API STD 600 Steel Gate Valves – Flanged and Butt-Welding Ends, Bolted
Bonnets
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 6 of 16

API STD 602 Steel Gate, Globe and Check valves for NPS 4 and Smaller for
the Petroleum and Natural Gas Industries
API STD 603 Corrosion Resistant, Bolted Bonnet gate valves- Flanged and
Butt welding ends
API STD 608 Metal Ball Valves – Flanged, Threaded, and Welding Ends
API STD 609 Butterfly Valves: Double flanged, lug and wafer type
API STD 594 Check Valves-Flanged, Lug, Wafer and Butt Welding
ISO 10497 Testing of Valve, Fire Type Testing Requirement
DEP 70.10.90.11 Spare Parts
ASME B16.36 Orifice Flanges
ASME B16.48 Line Blanks
API 650 Welded Steel Tanks for Oil Storage
API 610 Centrifugal pumps for petroleum, petrochemicals and Gas Industries
API 685 Seal less centrifugal pumps for petroleum, petrochemical and Gas
Industry process service
API 676 Positive Displacement Pumps
NFPA Codes NFPA 20, NFPA30, NFPA70 etc

6.0 ORDER OF PRECEDENCE (FIXED)

The Contract Documents are complementary; what is called for by one is as binding as if called
for by all. If Contractor finds a conflict, error or discrepancy in the Contract Documents, he shall
call it to Owner's / Engineer's attention in writing at once and before proceeding with the Work
affected thereby; however, in resolving such conflicts, errors and discrepancies, the documents
shall be given precedence in the following order:
a Modifications
b Agreement
c General Conditions
d Supplementary Conditions
e Specifications
f Drawings

7.0 SCOPE OF WORK

Scope of piping design work for phase-II at TS-3 & TS-4 shall include the following:
 Review of FEED study package.
 Preparation of the Plot Plans (Overall Plot Plan) as per spacing tables provided in OGRA-2009
“Depots for the Storage of Petroleum Products” to meet process sequence, technical safety,
construction requirement, operation requirement and maintenance feasibility.
 Preparation of 3D model in CADWORX, the extent of 3D model shall include fully detailed
piping down to and including 1” plus electrical and instrument design elements and shall
provide view-only access to the 3-D CAD as a part of final documentation.
 Piping layout above ground & underground with sectional details.
 Piping general arrangement drawings and key plans regardless of size.
 Development of road crossing drawing.
 Development of Tie-ins details.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 7 of 16

 Carryout pipe stress analysis for critical lines on CAESAR II latest version.
 Piping Isometrics and MTOs.
 Pipe supports / sleepers details.
 Facility Layout Report.
 Preparation of data sheets, specifications and requisitions for items (e.g. piping, valves, and
strainers etc.) applicable for the project.
 Preparation of Tie-in list.
 Piping drawings shall show all pipe supports, guides, springs, etc. and shall provide necessary
calculations or explanation for use of special supports (If any).
 Provide details and procedures for tie-in piping to the existing Facility and shall ensure that
new piping system will not cause any overstress/overloading to the existing system and
supports with necessary anchoring.
 Review all vendors’ drawings and other documents to ensure compliance with
specifications.
 Review of both the supplier and vendor’s drawings to ensure that adequate operating and
maintenance access is provided to entire equipment.
 New firefighting system shall be installed at TS-3 and TS-4 for the new Mogas Tanks (T-407,
T-510 A/B respectively) with respect to existing firefighting system. The system shall include
the fire water tanks (T-456, T-560 for TS-3 and TS-4 respectively), foam pourers, fire
hydrants, and fire monitors etc. and all interconnecting piping according to international
codes and standards and local regulatory authorities to protect the station from fire hazard.
 Road shall be constructed all around the tank to provide access to it from all sides.
 Technical Bid Evaluations for all static and piping items.
 Equipment Erection/Installation data summary, Plans and Procedures.
 Site datum or reference points, to be consistent with the level used for Existing facilities, and
incorporate accordingly into its design.
 Tanks piping shall be checked to enable the absorption of nozzle displacement caused by the
tank settlement, or piping displacement caused by nozzle rotation due to tank shell
deformation.
 New DRA skid and all interconnecting piping shall be installed at TS-3 to increase the thru
put of the MFM pipeline from Faisalabad to Machike.
 The existing open/closed drain system at TS-3 & TS-4 shall be used for both Mogas and HSD
services. But due to service change, associated piping, receiver, Launcher and Mainline,
open/close drains connections to be revised (if required) as per new requirement.
 List of two years’ operating spare parts in consultation with vendor.

8.0 PIPING DESIGN

8.1 GENERAL
Piping shall be designed, constructed and tested in accordance with the latest edition of ASME
B31.3 Process Piping Code.
In situations where different design conditions exist in one piping system, different piping
classes, if used, shall be divided by a specification break. Spec. breaks between piping classes of
different materials shall be executed as flanged connections.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 8 of 16

8.2 PIPING ROUTING

8.2.1 GENERAL
 Piping shall be routed so that the optimum piping layout is achieved in terms of process
requirements, ergonomics, operation, inspection and maintenance. Having considered these
factors, the number of flanges, fittings and welds shall be minimized.
 In pipe sleepers/rack the heaviest and/or the hottest pipes shall be located at the sides of
the pipe sleepers to provide space for expansion loops (if any).
 Piping expansion loops in pipe sleepers/rack shall be raised in elevation to stay clear of
adjacent piping, with the exception of flare headers and "no pocket" lines.
 All piping entering and leaving a plot area or unit shall be grouped together as far as
practicable with enough support and guides. Allow space for pipe movement due to
temperature changes at day /night and winter/summer.
 Dead ends and pockets in line are to be avoided.
 Drain piping shall be adequately and continuously sloped at 1:800 minimum to eliminate the
possibility of creating liquid pockets, Elbows, bends and flanges shall be avoided as much as
possible.
 Try to take all branch piping from utility headers from the top of the header to prevent
plugging.
 Suction piping of centrifugal pumps shall be as short and as direct as possible avoiding high
spots where pockets of gas or air could accumulate. Only eccentric reducers (top flat) may
be used for pipe diameter changes in horizontal pipes. The length of the straight pipe from
the last elbow to the suction nozzle shall be sufficient to ensure minimum turbulence at the
pump suction.
 Piping shall be flexible enough to be able to install the required isolation fittings (spades,
Spectacle Blind) and there shall be sufficient space to turn spectacle blinds, where provide.
 Piping and pipe supporting structures shall be designed so that access is provided for
maintenance or removal of valves, in-line instruments and for operational reasons (e.g.,
filter cleaning). Removal or replacement of equipment shall be possible with a minimum
dismantling of piping, removable pipe spools shall be provided for this purpose.
 Earthing connection to be provided to avoid build-up of static electricity on piping systems,
instrument bridles and the loading hoses.

8.2.2 DISTANCE BETWEEN PIPES

 The minimum distance between a flange (with/without insulation) and a pipe or the
insulation of a pipe in pipe sleepers and trenches and on pipe racks shall be 75 mm.
 The minimum distance between pipe flange (with/without insulation) and any equipment,
columns or building wall shall be at least 75 mm.
 Adjacent pipe guides shall be staggered, in order to minimize pipe space requirements.
 Adequate clearance shall be provided between hand wheels or levers of valves for ease of
operation and access.
 Where required, the distance between pipes shall be increased to allow for movements
caused by thermal expansion.
 The distance between pipes shall allow for the turning of a spectacle blind, if present.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 9 of 16

8.3 FLANGES
Flanges shall be applied for piping connections at flanged equipment nozzles and inline piping
elements such as valves, strainers, instruments, etc. However, flanges shall also be provided
where frequent dismantling of piping and/or maintenance required.

8.4 SPECTACLE BLINDS, BLANKS AND SPACERS

Spectacle blinds, blanks and spacers shall be installed in accordance with P&ID’s and respective
piping classes. Pipes with wafer and/or lug type valves may require an extra flanged connection
for installing a spade flange or removal of a pipe spool. If spectacle blinds in horizontal pipes are
insulated, the spectacle blind shall be pointed downwards at an angle of 45° to avoid water
leaking into the insulation. Piping shall be designed, supported and installed so that the flanges
do not move when the bolting is removed for spading purposes. Spectacle blinds and spades
shall be located so that they are accessible from ground level or from platforms or walkways.
The need for scaffolding shall be minimized. Bolted joints with spectacle blinds, spades or
spacers inserted shall only be insulated, such that the status of the insert remains clearly visible
to the operator at all times and from the normal approach path or vantage point.

8.5 BURIED PIPING

Following shall be the minimum soil cover for buried piping:
Areas inaccessible to heavy traffic 0.3m (12in)
Areas accessible to heavy traffic and at road crossing 0.9m (36in)
Soil settlement and thermal expansion of the piping shall be taken into account for the design of
underground piping. For buried pipe operating at temperature of 60°C (140°F) or below, there
shall be clear distance of at least 0.3m (12in) between the pipe and any electrical or instrument
cables. If heavy cranes or lifting loads are to be expected to pass over the buried drain headers
the wall thickness shall be verified as per API RP 1102.

8.6 STRAINERS
The element mesh size of strainers if any shall be in accordance with downstream equipment
vendor’s recommendation. A fine mesh overlay or screen for pump suction may be installed for
startup if required. Piping arrangement shall permit insertion and removal of permanent and
temporary strainer internals without disturbing machine installation alignment.

8.7 RELIEF AND BLOWDOWN SYSTEM

Pockets in relief and blowdown lines shall be avoided. Relief valve discharge side piping shall be
self-draining towards the disposal. The minimum slope shall be 1:200 for tail pipe.
If possible, connecting sub-headers shall be connected to the top of the header; in any case,
they shall drain into the header.
In case of non-hazardous services safety relief valve discharging to atmosphere, the exhaust
pipe shall terminate at least 3.0 m above any service platform. An 8mm weep hole shall be
provided for drainage at the low point of the tail pipe.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 10 of 16

8.8 VENT AND DRAIN CONNECTION

Vent and Drain connections shall be installed at all low and high points in each piping system to
facilitate venting and draining for pressure testing after construction or repair of the system.
The location of the connections shall permit the complete removal of the test medium after the
test.

8.9 INSTRUMENT PIPING CONNECTION

Piping with instrument connections shall be routed so that safe access to these connections is
ensured. Instruments other than control valves and relief valves shall be capable of being
isolated for intrusive maintenance while associated section of plant remain on line. The straight
length requirement for different Instruments shall be free from any protrusions. Moreover, the
isolating valves shall be located at outside of straight length required for instruments. The
instruments shall be safely located to an area of minimum pipe vibration.

8.10 EQUIPMENT PIPING

In general piping shall be sufficiently flexible and adequately supported to minimize the
equipment nozzle loads within allowable. Stress Analysis shall be performed as per section-10 of
this document to determine the connected piping loads and moments on equipment nozzles.

8.11 MAINTENANCE ACCESS

Permanent maintenance lay down areas and easy access shall be integral part of the design and
layout of the facilities.
A clear access area shall be provided for each equipment module in the event that it must be
removed from its location for repair/maintenance purposes. All such equipment removal shall
be performed without any structural or piping alterations. In addition, access ladders or working
platforms shall be provided in order to minimize scaffolding requirements.
Adequate space for swinging a spectacle blind, reinstalling the blinds, removal and storage of
test blinds shall be considered.

8.11.1VALVES ORIENTATION AND ACCESS

Valves in horizontal pipes shall be positioned with their stem on or above the horizontal, except
gate valves shall be positioned with the stem horizontal in services where fouling substances
can collect in the bottom cavity. The minimum distance between hand wheels and any
obstruction shall be 75 mm. The location of valve hand wheels and/or stems shall not obstruct
walkways or platforms. Valves shall not be installed above roads. Chain-operated valves shall
not be used except with prior approval of Company for specific applications (these valves are
difficult to operate and the chain may cause hazardous situations).
There shall be sufficient clearance to lift and remove the valves. In case of valves located below
operator positions, extension stems shall be used. Control valves shall be located so that they
are accessible for hoisting equipment where needed. Globe control valves shall be installed with
their diaphragm actuator stem in vertical position, with sufficient clearance above the actuator
and under the bottom flange to allow the control valve to be dismantled without removing the
valve body from the pipe.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 11 of 16

Motor operated valves and other major isolation valves shall be at grade level or provided with
a safe access. ESDV, SDV and other major isolation valves are to be at grade level or shall be
provided with safe access.
All routinely operated valves, sample points, vents and purge points shall be accessible or
operable from permanent decking, platform or grade. If not, chain wheel may be specified if
required after Owner approval.

8.11.2INSTRUMENT ACCESS
Gauges, instrumentation, cable trays, small bore equipment, underground, above ground and
buried piping shall not interfere with access for routine maintenance. Portable platforms shall
be provided to maintain instruments not accessible from the ground level.
All sight-glasses, gauges and manually controlled by-passed shall be visible and easily accessible.
Suitable access shall be provided for installation/removal of corrosion coupons by means of
retriever tools.
All instrument panels, switchboards and electrical panels should have rear access to facilitate
maintenance particularly during breakdowns including the pressurized panels. Electrical sockets
(i-e Welding Machine, Hydro testing Machine etc.) shall be provided near all major equipment
for connecting the portable equipment/tools during routine /shutdown maintenance.
Platforms/access required for maintenance of top foam pourers at tanks and level switches.

8.11.3UTILITY STATIONS
Utility service points for water, air, shall be provided at various locations for maintenance and
cleaning purpose. The hose station connection shall be pointed downward.

8.11.4MATERIAL HANDLING
Detailed Materials Handling Study shall be performed and ensure that the Facilities are provided
with adequate temporary or permanent facilities for the handling of Materials. This shall
include, but not be limited to, the need for permanent derricks, lift ports and crane access. In all
cases the handling study should ensure the safe lifting of equipment over live hydrocarbon lines
for maintenance.
If any equipment is common to two or more systems, the isolation shall be provided for both or
all the systems in order to ensure the operation of those which are not subject to maintenance.

8.12 BOLT TORQUEING AND TENSIONING

Bolt Torqueing and Tensioning shall be as per XXXXXX

8.13 COATING AND WRAPPING

Coating and wrapping shall be carried out as per “Specification of Coating / Wrapping of Buried
Station Piping” (03-0198-GS-9517-0).
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 12 of 16

8.14 PAINTING
Painting shall be carried out as per “Specification for Painting and Protective Coating” (03-0198-
GS-9502-0).

9.0 PIPE SUPPORTS AND SPANS

Piping supports and span shall be as per Pipe Supports Standard Drawings (XXXXXX).
Clamped type pipe supports are susceptible to corrosion because water may collect between
the support and the pipe. If Clamped type pipe supports are used in situations where corrosion
may be expected, precautions shall be taken to protect the pipe and the supports against
corrosion e.g. by avoiding the ingress of water under insulated pipes.
Insulated pipes shall not rest directly on their insulation but pipe shoes shall be applied. The
pipes shall not rest directly on concrete.
For pump alignment purpose, adjustable type supports shall be provided in suction and
discharge piping at a minimum distance from the pump suction and discharge nozzles.
The elevation of pipe sleepers shall:
 Provide a minimum vertical clearance underneath the bottom of carbon steel pipe in
culverts or concrete trenches, to facilitate inspection and coating maintenance.
 Allow access for maintenance and for operation of valves, drains and instrumentation.
 Ensure that pipes and insulation will remain above the highest expected storm water levels.
Vertical pipes/Risers branching from tanks and other vertical vessels shall have a resting support
near the nozzle and to be guided at regular intervals to protect the pipe against vibrations, wind
load and/or buckling.
Use of spring supports shall be minimized. Pipe support will be provided in such a way that it
will take the load in all operation and shutdown conditions.

10.0 PIPING FLEXIBILITY AND ANALYSIS

10.1 GENERAL
Pipe Stress Analysis shall be performed for the critical lines using CAESAR II, latest version.
Piping systems shall be routed, supported, anchored or guided so that thermal
expansion/contraction, weight effects including the pipe contents, insulation, pressure effects
and movements due to earthquakes will not result in stresses in the piping or loads on the
connected equipment in excess of those permitted by ASME B31.3 and the equipment design
code.
The analysis shall satisfy, but not be limited to, the following requirements:
 Stresses shall be within the allowable specified by code.
 Forces and moments on the equipment nozzles shall be limited within the allowable.
 Excessive lateral/axial loads on support structure shall be avoided.
 Thermal displacement of the pipe shall be within 125 mm on pipe rack / track.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 13 of 16

 Pipe sag due to weight of pipe and contents shall be from 3mm to 5 mm for condensate and
two phase lines.
 Hot/cold philosophy for various combinations of working and stand by criteria.
 Wind load on larger pipe (>= NPS 10") at elevated structure (>=10 m).
 Soil settlement for tanks.
 Pressure relief loads shall be considered with Dynamic Load Factor (DLF) of 2.
 Both static and dynamic loading (if applicable) shall be considered in the stress analysis of
piping.
 Piping at pumps and tanks shall be sufficiently flexible and adequately supported to prevent
the equipment nozzles from being subjected to any stress that could disturb their alignment
or internal clearances or otherwise affect the equipment and jeopardize its operation.

10.2 PIPE SUPPORT FRICTION AND GAPS

Following coefficient of friction value will be used in pipe stress analysis:
 PTFE/Teflon/Graphite 0.1
 Caron Steel on Carbon Steel 0.3
 Steel on Concrete 0.45
 Stainless Steel on Carbon Steel 0.3
 Stainless Steel on Stainless Steel 0.3
The pipe supports (guide) will normally designed with standard +3mm gap on both side.
Similarly, zero gap supports will be identified for additional care during construction.

10.3 STRESS CRITICAL LINE LIST SELECTION CRITERIA

10.3.1CRITICAL LINE LIST
The critical line list identifies lines from the line list which meet the criticality criteria as shown in
Fig-1 (Piping Criticality Diagram) below.
10.3.2EXTENT OF PIPING ANALYSIS
No formal analysis is required for the following piping system:
 Duplicates, or replaces without significant changes, a system operating with a successful
service records.
 Can readily be judged adequate by comparison with previously analysed systems
 Is of uniform size, has no more than two points of fixation, no intermediate restraints, and
fall within the limitation of the equation as per section 319.4.1 of B31.3 Code:
Dy
≤K1
(L−U )2
D = Outside diameter of pipe
y = Resultant total displacements strains to be absorbed by the piping system
L = Developed length of piping between anchors
U = Anchor distance, Straight line between anchors
K1 = 0.03 for US customary unit (208.3 for SI unit)
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 14 of 16

10.3.3CLASSIFICATION OF LINES
The following critical features are reviewed for the classification of the piping systems:
 Design Temperature & pressure
 Diameter
 Displacement
 Pipe material
 Service
 Equipment connections
 External Loads
Based upon above features the lines are divided into four categories:
Category#1
Lines falling into this category shall be computer analyzed and brought specifically attention.
The review is to be carried out very early in the project for the following conditions:
 Large diameter pipes where the pipe diameter exceeds NPS 36”.
 Lines designed for greater than 7,000 thermal cycles (ASME B31.3, Fig 302.3.5).
 Lines in category “M” fluid service (per ASME B31.3).
 Lines in service where Design. Temp. Below –46°C.
 Process lines connected to Compressors.
 Lines using vacuum stiffener rings.
 Non-metallic piping.
 Jacketed piping.

Category #2
Lines in this category require mandatory computer analysis by Contractor during detailed design
phase:
 All process lines connected to Reciprocating Pumps and Compressors, Centrifugal
Compressors, Blowers and Fired Heaters.
 All process lines to and from Turbines and Centrifugal Pumps NPS 3” and larger.
 Lines to and from Air Coolers and Storage Tanks, NPS 2” and larger above 160°C and/or
below -60°C.
 Lines to and from Storage Tanks, NPS 4" and larger above 110°C and/or below -28°C.
 All lines to and from Air Coolers NPS 4” and larger.
 All lines to Storage Tanks, Pressure Vessels, Heat Exchangers and Package Units NPS 10” and
larger.
 Lines containing Expansion Joints and Bellows.
 Refractory lined pipe.
 Lines subject to Full Vacuum (NPS 2” & above).
 PSV Suction & Discharge Lines (NPS 2” & above).
 All lines subject to 2-phase flow / slugging (NPS 2” & above).
 Lines subject to large displacements/settlement (NPS 2” & above).
 All lines designated as Category 2 due to temperature in Figure 1.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 15 of 16

Category #3
Lines in this category require mandatory investigation; the analysis can be done by any
recognized approximate method such as guided cantilever or by computer using a simplified
model if appropriate.
 All boiler code piping.
 All pipe rack piping where line size is NPS 6” or larger.
 All lines designated as Category 3 due to temperature in Figure 1.

Category #4
All lines designated as Category 4 due to temperature in Figure-1. Lines in this category can be
analyzed by visual inspection or approximate methods using engineering judgment in
accordance with ASME B31.3.
 Engineering, Procurement, Construction,
Erection, Installation, Testing, Commissioning,
startup and handover of MFM MOGAS Project
(MFMMP) Phase-II, TS-3, Faisalabad & TS-4,
Machike Stations
PIPING DESIGN BASIS AND FLEXIBILITY
CRITERIA
CLASS DOCUMENT NO: XXXXXX Page 16 of 16

11.0 ALLOWABLE NOZZLE LOADS FOR EQUIPMENT

In Piping Stress Analysis, the compliance of piping loads on equipment nozzle is necessary. There
are two types of equipment to which piping system is connected:
 Static Equipment
 Rotating Equipment
The allowable nozzle loads shall be as per International standards or as agreed with the
manufacturer.