Revision: 01

Petroleum Development Oman LLC Effective: Dec-2021

Petroleum Development Oman L.L.C.

Piping – Engineering & Layout Design Requirements

Document ID SP-2376

Document Type Specification

Security Restricted

Discipline Mechanical Static

Owner Abdulnabi Al-Balushi, UEMS

Issue Date December-2021

Revision 01

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the
whole nor any part of this document may be disclosed to others or reproduced, stored in a
retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic
recording or otherwise) without prior written consent of the owner.

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i Document Authorization
Authorised for Issue

ii Revision History
The following is a brief summary of most recent revisions to this document. Details of all revisions
prior to these are held on file by the issuing department.

Revision Date Author Scope / Remarks

No.

1.0 05-Dec-2021 Saud Al Harthy First issue

DES3

iii Related Business Processes

Code Business Process

EP.64 Design, Construct, Modify and De-Commission Facilities

iv Related Corporate Management Framework (CMF) Documents

The related CMS Documents can be retrieved from the Corporate Management System Portal
(CMS).

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Table of Contents
1. INTRODUCTION ........................................................................................................ 5
PART I PIPING – ENGINEERING & LAYOUT REQUIREMENTS ....................................... 16
1 PIPING BASICS ....................................................................................................... 16
1.1 GENERAL ................................................................................................................ 16
1.2 DESIGN CONDITIONS ............................................................................................ 16
1.3 PIPING ABOVE GROUND LEVEL .......................................................................... 17
1.4 PIPING BELOW GROUND LEVEL.......................................................................... 19
1.5 SMALL BORE PIPING ............................................................................................. 20
1.6 INSTALLATION OF FLANGES ............................................................................... 22
1.7 INSTALLATION OF VALVES .................................................................................. 23
1.8 UTILITY, DRAIN AND VENT CONNECTIONS ........................................................ 24
1.9 CONNECTIONS FOR MANUAL SAMPLING .......................................................... 25
1.10 THERMOWELL CONNECTIONS ............................................................................ 26
1.11 ORIFICE FLANGES AND ORIFICE METER RUNS ................................................ 28
1.12 DISPLACER CHAMBERS ....................................................................................... 28
1.13 GALVANISED PIPING ............................................................................................. 28
1.14 PIPING IN VIBRATING SERVICE ........................................................................... 28
1.15 WELL CONDUCTORS, WELLHEADS, XMAS TREES AND FLOWLINES ON
DIRECT VERTICAL ACCESS WELLS .................................................................... 29
1.16 RETRIEVABLE PROBE, COUPON AND INJECTION QUILL SYSTEMS ............. 29
1.17 REQUIREMENTS FOR PIPING TIE-IN CONNECTIONS ........................................ 30
1.18 GROUNDING AND STATIC ELECTRICITY ............................................................ 31
1.19 IRON SULFIDE - PYROPHORIC SCALES ............................................................. 32
1.20 PIPING THROUGH WALLS, STRUCTURAL DECKS AND CONCRETE
FLOORS OF BUILDINGS ........................................................................................ 32
1.21 DISTANCE BETWEEN PIPES ................................................................................. 32
1.22 OFFSITE PIPING SYSTEMS ................................................................................... 32
2 PIPING ADJACENT TO EQUIPMENT .................................................................... 33
2.1 GENERAL ................................................................................................................ 33
2.2 PUMP, STEAM TURBINE AND COMPRESSOR PIPING....................................... 33
2.3 HEAT EXCHANGER PIPING ................................................................................... 35
2.4 FURNACE AND BOILER PIPING............................................................................ 36
2.5 PRESSURE VESSEL PIPING.................................................................................. 36
2.6 RELIEF SYSTEMS ................................................................................................... 37
2.7 LEVEL GAUGES ...................................................................................................... 37
2.8 INSTRUMENTATION ............................................................................................... 39
2.9 PACKAGED EQUIPMENT PIPING.......................................................................... 40
2.10 VESSEL TRIM .......................................................................................................... 40
3 UTILITY PIPING ....................................................................................................... 40
3.1 GENERAL ................................................................................................................ 40
3.2 FIRE WATER............................................................................................................ 40
3.3 WATER FOR PURPOSES OTHER THAN FIRE WATER ....................................... 40
3.4 STEAM ..................................................................................................................... 40
3.5 UTILITY HOSE STATIONS ...................................................................................... 41
4 TANK FARM PIPING ............................................................................................... 41
5 PIPING COMPONENTS ........................................................................................... 42
5.1 GENERAL ................................................................................................................ 42
5.2 PIPE .......................................................................................................................... 42
5.3 PIPE JOINTS ............................................................................................................ 43
5.4 FITTINGS.................................................................................................................. 46
5.5 BRANCH FITTINGS ................................................................................................. 46
5.6 FLANGES AND FLANGE ISOLATION SETS ......................................................... 47
5.7 PIPING AND EQUIPMENT ISOLATION .................................................................. 48
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5.8 VALVES .................................................................................................................... 50

6 INSULATION ............................................................................................................ 65
PART II PIPING DESIGN REQUIREMENTS EXTRACTED FROM DEP 31.38.01.25 ................. 66
1. PIPE SIZING ............................................................................................................. 66
1.1 GENERAL ................................................................................................................ 66
1.2 PRELIMINARY PIPE SIZING ................................................................................... 67
1.3 FINAL PIPE SIZING ................................................................................................. 67
2. PIPING BASICS ....................................................................................................... 67
2.1 DESIGN CONDITIONS ............................................................................................ 67
2.2 PIPING LAYOUT ...................................................................................................... 68
2.3 INSTALLATION OF VALVES .................................................................................. 68
2.4 UTILITY, DRAIN AND VENT CONNECTIONS ........................................................ 68
2.5 CONNECTIONS FOR MANUAL SAMPLING .......................................................... 68
2.6 PIPING SYSTEMS IN FREEZING CLIMATES ........................................................ 69
2.7 NOISE ....................................................................................................................... 69
3. PIPING ADJACENT TO EQUIPMENT .................................................................... 69
3.1 PUMP, AND COMPRESSOR PIPING ..................................................................... 69
3.2 PRESSURE VESSEL PIPING.................................................................................. 70
4. UTILITY PIPING ....................................................................................................... 70
4.1 COOLING WATER ................................................................................................... 70
4.2 STEAM ..................................................................................................................... 71
4.3 UTILITY HOSE STATIONS ...................................................................................... 71
5. PIPING COMPONENTS ........................................................................................... 71
5.1 PIPING AND EQUIPMENT ISOLATION .................................................................. 71
5.2 VALVES .................................................................................................................... 72

APPENDICES
APPENDIX A ADDITIONAL REQUIREMENTS FOR SPECIFIC SERVICES ....................... 73
APPENDIX B PIPING SYSTEM DEVELOPMENT BASED ON CONSTRUCTION
CLASSES ................................................................................................................. 75
APPENDIX C DEVIATIONS APPROVAL WITH APPLICABLE MITIGATIONS .................. 78
APPENDIX D SHALL [PS] STATEMENTs FOR DEP 31.38.01.24 (VER.44) AND DEP
31.38.01.25 (VER.45) ............................................................................................... 81
APPENDIX E SKETCH OF ALUMINIUM CLADDING FOR CRA PIPE PROTECTION
FROM MOLTEN ZINC ............................................................................................. 82

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1. INTRODUCTION

1.1 SCOPE
This SP specifies requirements and gives recommendations for engineering and layout of
piping systems built in accordance with ASME B31.3 and pipeline facilities (pump stations,
compressor stations, valve stations, pig stations) built in accordance with pipeline codes
such as ISO 13623, ASME B31.4, ASME B31.8, NEN 3650 and PD 8010. It applies to
piping for all types of process fluids (including fluidised solids), and all utility fluids.
Piping covered under equipment design codes is excluded from the scope of this SP.
Oil and gas risers, hull piping subjected to Classification Society rules (except for piping
associated with topsides process systems), subsea piping systems, utility piping in living
quarters and plant buildings are excluded from the scope of this SP.
Cross-country sections of pipelines - with the exception of pipeline facilities - designed in
accordance with codes such as ISO 13623, ASME B31.4, ASME B31.8, NEN 3650 and PD
8010 are excluded from the scope of this DEP. Sketches of the interface between pipelines
and other equipment are included in ASME B31.8 and ISO 13623.
Piping fabrication requirements are covered SP 2404.
Piping systems of “boiler proper piping” as referenced in ASME B31.1, Section 100.1.1 are
covered by ASME Section I.
Piping systems of “boiler external piping” (steam, feed water and blow down piping
systems) as referenced in ASME B31.1, Section 100.1.1 are covered by ASME B31.1.
Refer to Appendix-D. for SHALL[PS] requirements applicable to both DEM1 DEP
31.38.01.24 & DEP 31.38.01.25.
This SP excluding process design requirements which shall be referred to DEP 31.38.01.24
and SP 2373 which is in place of DEP 31.38.01.25. in addition, this SP contains piping
design requirements as per DEP 31.38.01.24 and DEP 31.38.01.25.
This SP addresses piping design requirements excluding process design requirements
referred from DEP 31.38.01.24 & DEP 31.38.01.25. SP-2373 addresses the process
requirements referred from DEP 31.38.01.25.

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1.2 DEFINITIONS
1.2.1 General definitions

Shall The word 'shall' is to be understood as mandatory requirement.

Should The word 'should' is to be understood as strongly recommended.

May The word ‘may’ indicates a permitted option.

Petroleum Development Oman L.L.C. Muscat, Sultanate of Oman
Company/
Principal The Principal may also include an agent or consultant authorised to
act for, and on behalf of, the Principal.
The term Principal as used in this SP may be synonymous with the
term Purchaser depending on the context in which the term is used.

Contractor A party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a
project or operation of a facility. The Principal may undertake all or
part of the duties of the Contractor.

Manufacturer/ A party that manufactures or supplies equipment and services to

Supplier perform the duties specified by the Contractor.
The terms Supplier and Manufacturer as used in this SP are
synonymous with the term Vendor depending on the context in
which the term is used.
Petroleum Development Oman L.L.C. Muscat, Sultanate of Oman
Company/
Principal The Principal may also include an agent or consultant authorised to
act for, and on behalf of, the Principal.
The term Principal as used in this SP may be synonymous with the
term Purchaser depending on the context in which the term is used.
Any person/party whom the Purchaser/ Company certifies as acting
Inspector
for and on behalf of the Company to inspect items to be purchased
and/or the work done by the Vendor/Sub-Vendor.
Process conditions with a hydrogen partial pressure greater
Hydrogen
than 7 bara (101.5 psia)
Service
"Sour" service and "Critical Sour" service, both of which are defined
Sour Service
SP-1190.

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1.2.2 Specific definitions – General

Term Definition

Deadleg Components of a piping system that normally have no significant flow.

Some examples include blanked branches, lines with normally closed
block valves, lines with one end blanked, pressurized dummy support
legs, stagnant control valve bypass piping, spare pump piping, level
bridles, relief valve inlet and outlet header piping, pump trim bypass
lines, high-point vents, sample points, drains, bleeders, and instrument
connections.

Execute Detailed engineering and implementation stage of the project

phase

FEED phase Front end engineering design stage of the project

flashing fluid Fluids listed in Energy Institute IP 15 as Class 0, I, II (2) and III (2).
Where warm/hot surfaces are within the distances defined in API RP
505:2018, section 14.3, fluids listed as Class II (1) and III (1) also are
included.

Flowline Piping which carries well fluid from wellhead to manifold or first process
vessel

fluid gas, vapour, liquid or combinations thereof

HP steam Typically steam between 40 barg and 100 barg (580 psig and
1450 psig)

large bore Pipes of size DN 80 (NPS 3) and above

MP steam Typically steam between 12 barg and 18 barg (175 psig and 260 psig)

pipe track Piping route typically consisting of multiple pipes, where pipes are
routed at grade level using concrete sleepers as pipe supports

pipe trench Piping route typically consisting of multiple pipes, where pipes are
routed below grade and uncovered using concrete sleepers or
pedestals as pipe supports.

Pipeline System of pipes and other components used for the transportation of
fluids between (but not within) plants. A pipeline typically extends from
pig trap to pig trap (including the pig traps). If no pig trap is fitted, the
pipeline extends to the first isolation valve within the plant boundaries.

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Term Definition

Piping Assembly of straight and bent pipes, fittings, flanges, gaskets, valves
and other components (e.g., expansion joints, swivel joints, strainers,
devices for mixing, separating, distributing, metering and flow control). It
also includes pipe supporting elements and insulation.
Piping does not include supporting structures (such as frames of
buildings, stanchions or foundations) or equipment (e.g., heat
exchangers, vessels, columns, pumps) or instrument impulse pipes.
Instrument specifications apply downstream the last joint of the last
process to instrument valve or valve assembly, defined for the
instrument connection in the mechanical piping class. This can include
the 5 mm restriction nipple where applicable.

Piping class Assembly of piping components, suitable for a defined service and
design limits, in a piping system.

Severe Piping systems in severe operating conditions include high pressure

operating (ASME Class 1500 and above) and high temperature services (i.e.,
conditions above 450 °C (840 °F)), or in batch processes with rapidly fluctuating
temperatures

Small bore Piping components of size DN 50 (NPS 2) and below

spec break Physical location as a single point dividing one piping class from
another.

Standard Piping components which are covered under DEP piping classes with
Piping corresponding MESC numbers.
Components

Superheated Steam with a temperature of 25 °C (75 °F) or more above saturation

steam temperature at steam pressure.

long-run Piping with length more than one pipe support span
piping

pipe stress Engineer approved by the Principal to undertake pipe stress analysis for
engineer a project. The engineer is responsible for obtaining data from disciplines
as appropriate, creation, maintenance and issue of the pertinent pipe
stress analysis documentation detailed within this standard, analysis
and approval of all stress critical lines and the timely dissemination of
pipe support/restraint information

Piping class Assembly of piping components, suitable for a defined service and
design limits, in a piping system. The piping classes are contained in
the following DEP binders:
DEP 31.38.01.14-Gen. - Piping classes
DEP 31.38.01.23-Gen. - Piping classes developed primarily for use in
the oil, multi-phase, water and gas pipeline systems from a wellhead to
a plant facility administered primarily to the CSA Z662 standard.

Very Toxic Includes very toxic – acute / very toxic – chronic / very toxic –
environment. For details, see SP-1125 & DEP 01.00.01.30-Gen.

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1.2.3 Specific definitions – Valves

Term Definition

back seat A feature within linear motion valves, where an integral seat within the
stem can be back seated against the bonnet. This arrangement allows
for safer packing adjustment or emergency sealing of the stem in the
fully open position.

bellows Flexible, thin-walled, circumferentially corrugated cylinder. It can have

integral ends and can expand or contract axially under changing
pressure.

bellows Type of seal that utilizes bellows for providing positive metallic sealing.
sealed The ends of the bellows are fastened to the bonnet and closure
member/stem. The bellows expands and contracts with stem travel.

clean service Fluids free from solids.

closure Moving part of the valve which closes off the seat, e.g., ball, disc, gate.
member

cost of Total lifetime cost, associated with purchasing, installing, operating and
ownership maintaining.

Cv Measure of flow resistance of the valve. Defined as flow capacity in US

gallons per minute with 1 psi differential pressure.

dirty service Fluids with solids that can deposit, compact, solidify, erode, scour and
seriously impair the performance of valves unless the correct type is
selected.

double block Arrangement of valves, which includes two valves in series and has a
and bleed bleed valve between. Total isolation of the pipework is achieved when
both valves are closed, and the bleed is open. Special integral DBB
units are available to reduce weight and to give minimal joints. The
valve ends can be flanged, hub type or butt weld.

emission Classification of the external leakage rate of the valve.

class

extended Extension used when the media is at high or low temperatures. Its
bonnet function can be to isolate the gland from the high or low temperature
zone so as to maintain integrity of the stem seal and the operation of
the valve. The extension can also be required to locate the gland
outside the insulation.

floating ball Ball valve in which the ball is not rigidly held on its rotational axis and so
is free to float between the seat rings.

flow capacity- Different valve types have relatively higher/lower flow capacities, due to
resistance their inherent resistance to flow, this is measured as a Cv.

fouling/ Liquids or slurries, carrying suspended particles that can form a deposit
scaling on surfaces or build up in pockets within a valve. These can seriously
service impair the performance of valves unless the correct type is selected.

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Term Definition

full bore Valve in which the bore (port) is equal to the bore of the connecting
pipe.

linear motion Valve that has a sliding stem that pushes the obturator closed or pulls it
valve open. They are capable of being adapted to bellows sealed. See also
rising stem.

needle valve Manual flow-regulating valve which gives a small aperture change
relative to the stem travel.

non-operable Valves which do not require to be operable below -29 °C (-20 °F).
at low
temperature

non-return Valve that allows fluid flow in only one direction. Also known as check
valve valve.

obturator Valve closure member (e.g., ball, gate, globe, disc)

on-off valve Basic operation of a valve to start or stop the flow of a fluid, also
referred to as isolating or stop valves.

outside screw Non-rotating, linear motion stem, where the threads are outside the
and yoke valve body and not subjected to possible negative effects of the process
(OSY) fluid.

Piggable Suitable for running a pig through. Normally-full bore valves.

positive body Dedicated feature within a double seated valve which gives an actual
cavity relief connection of the close valve cavity with either the high pressure or low
pressure side of the valve.

pressure seal Design of bonnet/cover where the body to bonnet/cover seal is pressure
bonnet/ cover assisted.

quarter turn Valve (such as ball, plug, butterfly) which requires a 90-degree
valve operation of the stem to move from the fully open to the fully closed
position. They will readily accept any type of actuation (pneumatic,
hydraulic, electric).

reduced bore Valve in which the bore (port) is smaller than the bore of the connecting
pipe.

retainerless Check valve without drilled holes through the body to facilitate the
check valve assembly of the valve.

rising stem Non-rotating, linear motion stem, where the threads are outside the
valve body and not subjected to possible negative effects of the process
fluid.

safety/relief Pressure relief valve that is designed to relieve excessive pressure.

valve

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Term Definition

seat Part of a valve against which a closure member effects a tight shut-off,
or a rate of shut-off, the material can be soft (polymeric/ elastomeric) or
metallic, or a combination of both.

shut-off A valves ability to give leak tight shut-off when closed for different types
capability of fluid.

throttling Intentional restriction of flow by partially closing or opening a valve.

torque seated Valves where the operator can apply more torque to seat the valve.
valve These are preferred by operators particularly for dirty service.

trunnion Part of a ball valve which holds the ball on a fixed axis and which allows
the ball to turn.

valve Susceptibility to obstructed operation due to solids build up.

clogging

1.3 GENERAL ABBREVIATRIONS

Term Definition

CAD Computer Aided Design

DN Diameter Nominal. The DN prefix indicates the nominal diameter of a

piping system component in millimetres.

GTAW Gas Tungsten Arc Welding

HFE Human Factors Engineering

MDO Maintenance Drop-Out

MESC Materials and Equipment Standards and Code. The MESC codes are
contained in the Catalogue Management Tool (CMT) system

NPS Nominal Pipe Size. The NPS prefix indicates the nominal diameter of a
piping system component in inches

PEFS Process Engineering Flow Scheme

PFS Process Flow Scheme

TSO Tight Shut-Off

VGO Vacuum Gas Oil

ASL Atmospheric safe location

EJMA Expansion Joint Manufacturers Association

LCO Light Cycle Oil

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1.4 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

Unless specifically mentioned, the latest edition of each publication shall be used, together
with any amendments/supplements/revisions thereto.

COMPANY STANDARDS
SP-2170 Specification for Shell & Tube Heat Exchangers
SP-2070 Specification for Air Cooled Heat Exchangers
SP-2069 Specification for Pressure Vessels
SP-1201 Procurement Specification for Pipeline Ball Valves
SP-2187 Specification for Storage Tanks (Suppliment to API 650 13th edition March 2020)
SP-2279 Specification for Flare systems
SP-2342 Specification for Standard Piping Bulk MESC Items
SP-2385 Plate & Frame Heat Exchangers- Amendments/Supplements to ISO15547-1
SP-2374 Tank Repair Methods Based on API 653 Mar 20
SP-1188 Specification for Chemical Injection Skids
SP-2376 Piping – Engineering, Layout & Process design Requirements
SP-2373 Piping – Process Design Requirements
SP-2390 Piping Stress Analysis Specification
SP-2411 Pipe Supports
SP-2404 Shop and field fabrication of piping
SP-2051 Specification for Flushing, Pressure Testing, Pickling and Sensitive Leak Testing
SP-2342 Specification for standard piping items
SP 1127 Layout of Onshore Facilities
SP-2215-1 Human factors engineering in projects
SP-2215-2 Human factors engineering – control room design
SP-2215-3 Human factors engineering – physical workspace design

SP-2215-4 Human factors engineering –human machine interface design for situation awareness

SHELL STANDARDS

Standard drawings index DEP 00.00.06.06-Gen.

Metallic materials – Selected standards DEP 30.10.02.11-Gen.

Non-metallic materials – Selection and application DEP 30.10.02.13-Gen.

Wet H2S requirements for downstream pressure vessels and piping DEP 30.10.02.17-Gen.

Metallic materials - Prevention of brittle fracture in new assets DEP 30.10.02.31-Gen.

Plant model construction and review DEP 30.10.05.11-Gen.

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Thermal insulation DEP 30.46.00.31-Gen.

Protective coatings for onshore and offshore facilities DEP 30.48.00.31-Gen.

Steam, condensate and boiler feed water systems DEP 30.75.10.10-Gen.

Unfired pressure vessels DEP 31.22.00.31-Gen.

Piping classes – Basis of design DEP 31.38.01.10-Gen.

Piping classes DEP 31.38.01.14-Gen.

Piping classes - Service and material selection index DEP 31.38.01.84-Gen.

Hot-tapping on pipelines, piping and equipment DEP 31.38.60.10-Gen.

Glass-fibre reinforced plastic pipeline and piping systems DEP 31.40.10.19-Gen.

Acoustic insulation for piping (amendments/supplements to ISO 15665) DEP 31.46.00.31-Gen.

Instruments for measurement and control DEP 32.31.00.32-Gen.

Assessment and design of the fire safety of onshore installations DEP 80.47.10.30-Gen

INTERNATIONAL STANDARDS

Pipe threads, general purpose (inch) ASME B1.20.1

Pipe flanges and flanged fittings, NPS 1/2 through NPS 24 metric/inch standard ASME B16.5

Factory-made wrought buttwelding fittings ASME B16.9

Metallic gaskets for pipe flanges - ring-joint, spiral-wound and jacketed ASME B16.20

Cast copper alloy pipe flanges and flanged fittings Classes 150, 300, 600, 900, 1500, ASME B16.24
and 2500

Buttwelding ends ASME B16.25

Valves - Flanged, threaded, and welding end ASME B16.34

Large diameter steel flanges NPS 26 through NPS 60 metric/inch standard ASME B16.47

Process piping ASME B31.3

Welded and seamless wrought steel pipe ASME B36.10M

Stainless steel pipe ASME B36.19M

Petroleum and natural gas industries — Materials for use in H2S-containing NACE MR0175
environments in oil and gas production

Petroleum and natural gas industries. Drilling and production equipment. Wellhead and ISO 10423

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christmas tree equipment

Bolted bonnet steel gate valves for the petroleum, petrochemical and allied industries ISO 10434

Testing of valves – Fire type-testing requirements ISO 10497

Petroleum and natural gas industries - Pipeline transportation systems ISO 13623

Petroleum and natural gas industries - Pipeline transportation systems - Pipeline valves ISO 14313

Petroleum and natural gas industries - Materials for use in H2S-containing environments ISO 15156
in oil and gas production

Metal ball valves for petroleum, petrochemical and allied industries ISO 17292

STANDARDS DRAWINGS

Wall type gauge glass with reflex or transparent glass S 10.050

Y-type strainers, ANS classes 150 and 300 S 38.002

Bucket-type suction strainer, carbon steel, ANSI class 150 S 38.004

Product sample cooler (cooling water: fresh or brackish) S 38.013

Sample cabinets with inlet on top - Material: carbon steel or low-alloy steel S 38.037

Sample cabinets with inlet on top - Material: stainless steel S 38.038

Spade blinds for ASME flanges S 38.042

Spacer for ASME flanges, for replacement of spades S 38.043

Displacer chambers S 38.056

Overall dimensions of plate-type level gauges, through-vision and reflex type S 38.059

High pressure welding thermowell for piping systems, DN 50 (NPS 2) S 38.112

Flanged thermowell, DN 40 (NPS 1-1/2), ASME classes up to 1500 inclusive S 38.113

Flanged thermowell, DN 50 (NPS 2), ASME classes up to 2500 inclusive S 38.114

Orifice flanges, raised face, with flange tappings. ANSI classes 300 to 2500 incl., S 38.130
Nom. size DN 50 to DN 600 incl.

Orifice flanges, raised face, with corner tappings. ASME classes 300 and 600, S 38.131
Nom. size DN 50 to DN 600 incl.

Orifice flanges, raised face, with parallel flange tappings. ASME classes 300 to S 38.132
2500 incl. nom. size DN50 to DN 600 incl.

Orifice meter runs with flanged ends, ASME classes 150 to 1500 incl., Nom. size S 38.134
DN 15 to DN 40 incl.

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Steam ring to horizontal flanges of DN 150 (NPS 6) and above in hydrogen service S 38.141

Two steam rings to horizontal flange of DN 150 (NPS 6) and above (with spectacle S 38.142
blind, spade, spacer or orifice)

Steam ring to vertical flange of DN 150 (NPS 6) and above in hydrogen service S 38.143

Two steam rings to vertical flange of DN 150 (NPS 6) and above in hydrogen S 38.144
service (with spectacle blind, spade or spacer)

Pressure test vent and drain connections S 38.154

Process vent and drain connections S 38.155 (all sheets)

Pressure connection assemblies with flanged isolation valves and fittings S 38.156 (all sheets)

Temperature instrument connections S 38.157

Orifice flange connection assemblies with flanged valves and fittings S 38.158 (all sheets)

Orifice meter run connection assemblies with flanged valves and fittings S 38.159 (all sheets)

Typical bracings for small bore branches of piping (e.g., drain/vent point) S 44.030

Typical bracings for small bore branches of piping (e.g., orifice instrument S 44.031
connection)

Typical bracings for small bore branches of piping (e.g., pressure instrument S 44.032
connection)

Steam lance S 88.005

1.5 CONFLICTING REQUIREMENTS

All other conflicts between the requirements of this specification, related specifications,
standards, codes and requisition and data sheets shall be referred to the Company for
clarification before proceeding with the manufacturing.

1.6 DUAL UNITS

This SP contains both the International System (SI) units, as well as the corresponding US
Customary (USC) units, which are given following the SI units in brackets. When agreed by
PDO, the indicated USC values/units may be used.

1.7 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this SP indicates text that is non-normative and is provided as
explanation or background information only.

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PART I PIPING – ENGINEERING & LAYOUT REQUIREMENTS

1 PIPING BASICS

1.1 GENERAL
1. Refer to the following DEPs and MESCs for the selection of piping construction:
a. DEP 31.38.01.10-Gen.;
b. DEP 31.38.01.14-Gen.;
c. Standard form DEP 31.38.01.84-Gen.;
d. MESC Group 74 (pipe);
e. MESC Group 76 (fittings and flanges);
f. MESC Group 77 (valves);
g. MESC Group 81 (bolting);
h. MESC Group 85 (gaskets and packing).
2. Refer to (Appendix B) for the requirements for the piping system development of all
piping systems.
3. Project modifications to piping classes should be minimized.
4. Refer to SP-2411 for the requirements for pipe supports.
5. Piping layouts having dead legs where any of the following can happen shall be
subject to the review and approval of the Principal:
a. water can accumulate and freeze;
b. materials of construction are affected by corrosive fluids;
c. particles or bulk solids can accumulate;
d. stagnant flow can lead to polymer growth (e.g., ethylene oxide service).
6. Design reviews shall be performed in stages to verify the proposed physical or
3D CAD models to confirm that the optimum piping layout is achieved in terms of
process requirements, HFE, commissioning, operation, inspection and maintenance.
a. Refer to DEP 30.10.05.11-Gen for the requirements for model reviews.
b. Proposed physical or computer piping 3D CAD models shall be subject to
approval by the Principal before proceeding for construction of piping systems.
7. Valves shall not be installed above roads.

1.2 DESIGN CONDITIONS

1. Refer to Part II of DEP 01.00.01.30-Gen. for the determination of the design pressure
and design temperature.
The selected design pressure (i.e., upper design pressure) subsequently
determines the pressure-temperature rating of the piping class.
2. For preventing brittle fracture in metallic piping, refer to DEP 30.10.02.31-Gen. for the
design and engineering aspects associated with LDT and MMT.
3. For dissimilar metal weld joint design requirements, refer to SP 2404, and either DEP
30.10.60.18-Gen. or DEP 30.10.60.32-Gen., whichever applies.
4. Piping layouts having dead legs where any of the following can happen shall be
subject to the review and approval of the Principal:

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a. water can accumulate and freeze;

b. materials of construction are affected by corrosive fluids;
c. particles or bulk solids can accumulate;
d. stagnant flow can lead to polymer growth (e.g., ethylene oxide service).
5. The proposed location of spec breaks in high temperature (> 400 °C (> 752 °F)),
corrosive or sour (in relation to the Nelson curve) shall be designed to prevent
corrosion occurring under normal and marginal/upset conditions.
a. In all such cases, the design shall be subject to approval by the Principal.
6. Piping up to and including DN 600 (NPS 24) shall be designed for full vacuum at
ambient temperature.
7. Piping DN 600 (NPS 24) and larger shall be designed for one of the following as
appropriate:
a. full vacuum when containing condensable gases such as steam and in situations
where sub-atmospheric pressure may occur as the result of liquid surge or
steam-out;
b. the Lower Design Pressure (LDP) as defined in DEP 01.00.01.30-Gen.
8. Vacuum rings shall not be used.
9. For additional requirements for specific services, refer to (Appendix A).

1.3 PIPING ABOVE GROUND LEVEL

1.3.1 General
1. For requirements associated with layout including equipment arrangement of onshore
facilities, refer to SP-1127.
3. Equipment which is a potential source of fire shall not be located under pipe racks.
4. For minimum clearances and platform extent requirements, refer to SP-2215.
1.3.2 Piping layout
1. Piping entering and leaving a plot area or a processing unit should be grouped
together based on the process and utility piping.
2. Except for the services mentioned under (Part I, 1.4), piping shall be routed above
ground level or in inspectable culverts at road crossings.
3. Routing study of major piping shall be carried out in order to develop the plan for final
equipment location.
4. Piping with instrument connections shall be routed so that safe access to these
connections is ensured.
5. Changes in direction shall not create pockets in piping systems without a drain
connection arrangement.
6. Piping shall be arranged for ease of removal of equipment for inspection or servicing,
with maintenance areas kept clear of piping.
a. Piping shall not be routed above equipment such as heat exchangers, pumps,
compressors, in-line component but routed along the side of such equipment.
7. All uninsulated adjacent lines shall be located so that the bottom of pipes (BOP) are at
the same elevation depending upon the method of support.
8. Adjacent lines that are mounted on pipe shoes or reinforcing pads which share the
same supporting steel shall be located such that bottom of shoe or reinforcing pad are

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at the same elevation as the bottom of adjacent lines without pipe shoe or reinforcing
pads.
9. The difference in elevation between lines running in plane north or south and lines
running in plane east or west should be a minimum of 1 m (3.3 ft).
10. Piping should be routed to provide a simple, shortest-possible run, allowing easy
support and with the minimum number of fittings adequate for expansion and flexibility.
11. Piping shall be routed such that overhead clearance (headroom) or stumbling hazards
such as obstruction to walkways and other paths of travel or equipment movement are
avoided.
12. Diagonal and skewed angles of piping layout in horizontal plane should be avoided.
13. Piping connected to more than one piece of equipment (e.g., a pump and its spare)
shall be designed and supported in accordance with the following:
a. excessive loads on equipment do not occur when one branch of the pipe is
disconnected (e.g., during maintenance operations);
b. if multiple nozzles are applied, (e.g., on air cooler banks) the connecting piping is
designed so that small dimensional errors in construction can be accommodated;
c. the piping itself is adequately designed to compensate for any thermal expansion
due to differential temperatures between operating equipment and spare
equipment.
14. Pipe sizes that require support spacing closer than 6m shall have intermediate beams
installed between main pipe rack stanchions.
Rationale: The distance between the stanchions for pipe racks is typically 6m but
will be optimised based on pipe rack loading and the distribution of pipe sizes.
15. The pipe rack width depends on the number of lines and future expansion where
generally is kept about 5 m with a height from grade of 3 m to first tier bottom. This
elevation should be optimised based on the crossing road, crane approach, vehicle
access anticipated and headroom clearance.
The number of tiers and clearence between the various tiers should be determined
based on the number of pipes / size / pipe entry dimension/ cable routing etc. In
general, the clearance between the various tiers shall be maintained common space
across each tiers.
The utility lines are to be placed on the top level and process lines on the bottom level
if possible. For minimum pipe size for pipe rack and pipe track refer to part II of this
SP.
16. If a pipe rack forms part of a structure, or is located next to a structure, the stanchions
of the pipe rack should be in line with the columns of the structure, to make optimal
use of space for incoming and outgoing pipes.
17. In a pipe rack, piping arrangements with complicated crossings should be avoided,
e.g., by not installing pipe rack spurs opposite each other.
18. Piping or components of austenitic stainless steel, duplex stainless steel, nickel alloy
or 9 % nickel steel SHALL [PS] be designed such that they are protected from
contamination with molten zinc due to fire. This SHALL [PS] is mitigated as per sketch
in Appendix-E or alternative arrangements can be followed e.g using painted structural
material in place of galvanized structures which needs to be approved by PDO TA.
19. For design requirements of fire water piping, refer to DEP 80.47.10.30-Gen.

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1.4 PIPING BELOW GROUND LEVEL

1.4.1 Buried piping
1. Where heavy cranes or lifting loads are expected to pass over the buried pipe, pipe
wall thickness shall be verified in accordance with API RP 1102.
2. If burying of insulated pipe is unavoidable, or if it is desired for life-cycle economic
reasons, the insulation material shall be able to withstand the stresses caused by the
thermal expansion of the pipe.
a. The design detail and coating system shall be suitable for CUI service and
configured so that inspection of the system for CUI is either possible or not
necessary (e.g., TSA coating).
3. For the case of any metallic buried piping, the required coating and external protection
shall be addressed in the MSR by UEC team.
4. Buried piping should be considered for the following services:
a. drainage, storm water, or sewage systems;
b. fire water and other water pipes (for protection against heat or frost);
c. large-diameter utility pipes (e.g., main cooling water ducts) so as not to impede
traffic.
5. Buried piping shall not be used for pressurised hydrocarbon service unless approved
by the Principal’s designated Mechanical Static Technical Authority.
6. Refer to DEP 34.14.20.31-Gen. for the requirements for non-pressurised buried piping
shall be designed and installation.
7. Refer to DEP 34.11.00.11-Gen. for the requirements for site preparation and
earthwork required for drain installation.
8. Buried piping shall have a minimum cover of soil as shown in Table-1:

Table 1 Minimum soil cover for buried piping

fire water pipe (mains) 0.6 m (24 in)

in areas inaccessible to heavy traffic 0.3 m (12 in)
in areas accessible to heavy traffic and at 0.9 m (36 in)
road crossings
NOTE: 1. Local regulations might require larger minimum soil cover. The soil cover
depth can also increase due to outside temperature or permeability of the soil.
2. In case of GRE piping at road crossings, the pipe shall be protected by
installation within a steel or HDPE casing pipe.
3. Refer to point.14

Local regulations might require larger minimum soil cover. The soil cover depth can also increase
due to outside temperature or permeability of the soil.
9. The load on pipe crossing roads should be equalised by means of pipe sleeves or a
culvert.
a. The pipe should be centered in the sleeves by use of distance pieces welded to
the pipe, or distance pieces fixed to the sheeting if the pipe is insulated for low-
temperature service.
10. Insulated pipe should not be buried.
11. For buried pipe operating ≤ 60 °C (140 °F), there shall be a clear distance of at least
0.3 m (12 in) between the pipe and any electrical or instrument cables.

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12. For buried pipe operating above 60 °C (140 °F), there shall a clear distance of at least
0.6 m (24 in) between the pipe and any electrical or instrument cables.
13. For buried pipe systems where the emission or leakage of aromatic hydrocarbons or
very toxic fluids is a HSE concern (e.g., pollution of ground water or saturation of the
soil), the following shall apply:
a. no bolted joints;
b. valves installed in pits.
14. In case of any constraints to maintain the min soil cover due to existing under ground
facilities, additional sort of protection shall be provided like concrete slab, channel,
sleeve, culvert etc. subject to approval of the company with design calculation to
prove the imposed stress is within allowable limit.
1.4.2 Pipe tracks and pipe trenches
1. Piping outside process units (e.g., piping between process units and storage facilities)
should be supported on sleepers, at ground level in pipe tracks or below ground level
in pipe trenches.
a. The choice between pipe tracks or pipe trenches should be dictated by technical
and economic considerations, e.g., the number of road or rail crossings, the
ground water level and the length of the required trench.
b. Pipe racks may be used if space at ground level is limited or if the use of culverts
or buried piping is uneconomical.
2. The distance between sleepers in pipe tracks and in pipe trenches shall be based on
the maximum allowed free span of the majority of pipes in accordance with SP-2390
a. Smaller pipe requiring a shorter supporting distance shall be grouped together
and be supported on additional supports.
3. The elevation of sleepers shall meet all of the following:
a. provide a minimum vertical clearance of 0.3 m (12 in) underneath the bottom of
carbon steel pipe in culverts or concrete trenches, to facilitate inspection and
coating maintenance;
b. allow access for maintenance and for operation of valves, drains and
instrumentation;
c. ensure that pipes and insulation will remain above the highest expected storm
water levels;
d. ensure that pipes and insulation will remain above the highest expected
accumulation levels of snow.
4. Flanged connections shall not be installed in trenches where the emission of aromatic
hydrocarbons or very toxic fluids is a HSE concern (e.g., pollution of ground water).

1.5 SMALL BORE PIPING

1. Branches to run pipes shall not be smaller than the sizes as Table 2.
Table 2 Minimum branch size to run pipe size

Run Size Branch Size

DN 20 through DN 50 (NPS ¾ through NPS 2) DN 20 (NPS ¾)
DN 80 through DN 300 (NPS 3 through NPS 12) DN 25 (NPS 1)
Greater than DN 300 (Greater than NPS 12) DN 40 (NPS 1 ½)

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2. For direct mounted instrument connections, the minimum size of branch connections
to run pipes shall be in accordance with Table 2.
a The mechanical strength of instrument connections shall be improved by using
the bracing of these branches to the run-pipe (see Standard Drawings S 44.030,
S 44.031, and S 44.032) if such connections are causing Longitudinal
/ Circumferential bending moments on the run pipe of (Refer to figure-1 as an
example- Note that applicable cases are not limited to this figure):
b. Non-direct-mounted instrument-connections should be kept as simple as possible.
c. The length of the branch should be minimised (fitting-to-fitting), with isolation
valve(s) as per latest piping classes:
i. with monoflange/slimline (DB&B) valves where design temperature is lower
than 150 °C (300 °F);
ii. with only tubing or a pressure gauge connected to the isolation valve.

Figure-1: Examples of Longitudinal / Circumferential bending moments on the run pipe

3. Larger piping should be used instead of using support bracing (attachments) to small
bore piping for situations where increased mechanical strength is required.
4. For critical situations (e.g., where vibration of piping is expected), the mechanical
strength of instrument connections may be improved by using reducing nozzles, e.g.,
weldolet DN 40 (NPS 1 ½) – reducer DN 40/15 (NPS 1 ½ / ½) – welding neck flange
DN15 (NPS ½).
5. In branches with flanged valves, branch fittings with flanged outlets shall be used in
order to reduce the number of welds.
6. The branch size shall be restricted to minimum 2’’ for the following cases:
i. High H2S concentration/ toxity level as per SP-1190.
ii. For Waxy/ sand service, highly viscous fluid or where ice is anticipated,
pressure transimitter where diaphragm seal type is recommended by C&A.
iii. Internally coated / lined branches where it is restricted by coating limitiations
such as, Roto/ PEliner, FBE, Glass Flakes pipes etc.
7. Refer to DEP 32.31.00.32-Gen. for the requirements for level connections.
8. Pressure points should be as short as possible.
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9. In case of any branch connections fitted with unsupported valve causing Longitudinal
/ Circumferential bending moments (Ref.figure-1) on the run pipe of cases mentioned
above on this section clause 2a shall be braced (see Standard Drawings S 44.030,
S 44.031 and S 44.032).
a. In cases of long connection or vibrating service, the pressure gauge block and
pressure gauge shall be supported separately.
b. The DSS small bore branch (2” & smaller) with forged branch fittings (e.g
Nippolet/weldolet) shall be braced as per the standard drawings irrespective of service
conditions.
10. Any small bore connections that are needed at the following locations shall be DN 80
(NPS 3) or larger:
a. on piping between the compressor nozzle and pulsation bottles;
b. on all piping directly connected to the compressor.
11. For situations where vibration of piping could be expected, like near compressors,
small bore branch fittings connecting points to the main piping should be located at
positions where vibration amplitudes are lower, such as near fixed points at pipe
supports.
12. If the recommendation above (Part I, 1.5, Item 11) cannot be achieved, then the small-
bore piping shall be braced to the main piping in accordance with Standard Drawings
S 44.030, S 44.031, and S 44.032.

1.6 INSTALLATION OF FLANGES

1.6.1 General
1. For high pressure piping systems (ASME Class rating 2500 or higher) connected to
vessels, butt welded connections may be considered.
2. For flange alignment and tolerances, refer SP-2404. and ASME PCC 1 page 57.
3. Flanges in piping systems shall be installed only to facilitate maintenance and
inspection and where construction or process conditions dictate.
4. Piping systems with RTJ flanges shall be designed to allow removal of equipment and
pipe sections without the need to remove very long sections of piping system.
5. Refer to DEP 30.06.10.12-Gen. for requirements for installation of flanges in LPG
services
1.6.2 Flange joints in severe operating conditions
1. To reduce bolt stress variations in high temperature or cyclic service, hardened
washers may be installed under the nuts.
2. Bolt relaxation is a possible scenario after first 1000 hours of operation, therefore the
Contractor shall review the tightness of bolts for severe operating condition piping
systems, retightening could be needed soon after re-start as follows.
1. flange joints shall be applied with maximum required torque and/or elongation,
taking care not to overstretch the bolts;
2. check shall be performed by turn of the nut method.
1.6.3 Bolt torqueing and hydraulic bolt tensioning
1. For bolt torqueing and hydraulic bolt tensioning, refer to SP-2020.

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1.7 INSTALLATION OF VALVES

1.7.1 General
1. The number of different types of valves should be minimised.
2. Refer to SP-2215 for the requirements for valve position indication.
3. The block valves at battery limits shall be grouped such that they are accessible from
single walkways.
a. A drain/vent connection shall be installed as close as possible to the battery limit
block valves and spades, for draining, venting and testing purposes.
4. Valves in horizontal pipes shall be positioned with their stem on or above the
horizontal, except as follows:
a. butterfly valves shall be positioned with the stem horizontal in services where
fouling substances could collect in the lower shaft bearing;
b. gate valves should be positioned with the stem horizontal in services where
fouling substances could collect in the bottom cavity;
c. valves shall be positioned with the stem horizontal in systems where a
component failure (e.g., wedge pin) could cause closure of the valve and lead to
unsafe situations (e.g., flare systems);
d. Refer to Section 8.3.2 of DEP 80.45.10.10-Gen. for additional requirements.
5. Main block valves on branch piping systems should be arranged for self-draining on
both sides or provided with drain points at the block valve.
6. For valve installation requirements of special fluid services, see (5.8.8).
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.
7. For the cases mentioned in section 3.4 where C&A recommends to utilize diagrphm
seal, Modular type DBB is to be used.
8. Mono-flange slim line SBB valve to be utilized in lieu of ½’’ isolation vlave for case of
stainless steel instrumentation air distribution branches.
1.7.2 Selection of gear drives for valves
1. Refer to SP-2215 for the requirements for gear drives.
2. The selection of motorised actuators shall be subject to the approval of the Principal.
1.7.3 Manifolds for control valves
1. The block valves at each side of the control valve shall be of the straight-through type.
2. The bypass valve shall have an installed Cv at least equal to, but not more than twice,
the Cv of the control valve.
a. The extent to which a bypass valve is necessary shall be determined in
consultation with the Principal’s Operations Technical Authority.
For example, see SP-2350.
b. Where bypass is determined by the Principal’s Operations Technical Authority to
be necessary, the bypass valve shall be capable of throttling.
c. Where bypass is determined by the Principal’s Operations Technical Authority to
be necessary, the bypass valve shall be of the same type as the control valve,
but with handwheel operation only.
3. In the following services the bypass pipe shall be designed so that there are no
vertical dead ends where liquid can collect
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a. fouling process conditions;

b. steam;
c. hydrocarbons containing water.
1.7.4 Human Factors engineering aspects of valves
1. For human factors engineering aspects of valves, see SP-2215
1.7.5 Control valve installation
1. Sufficient clearance shall be provided above and below the control valve for
dismantling purpose without removing the valve body from the pipe.
2. Globe control valves shall be installed with their diaphragm actuator stem in the
vertical position.
3. Control valves shall be located so that they are accessible for hoisting equipment
when components exceed the maximum weight for lifting in SP-2215
a. Refer to SP-2350 for further requirements for control valves.
4. The bypass line shall not be located directly above the control valve.

1.8 UTILITY, DRAIN AND VENT CONNECTIONS

1.8.1 General
1. Minimum pipe wall thickness for vent/drain connections in carbon steel piping systems
shall be maintained as Sch.80 for butt welded and socket welded piping systems.
2. Where threaded connections are utilized for galvanised CS of IA system, the minimum
wall thickness shall be as per the piping class.
1.8.2 Pressure test drain and vent connections
1. To facilitate removal of bulk hydrotest fluids in a safe and efficient manner, the
minimum branch pipe sizes in Table 3 shall be used for test vent and drain
connections, unless the bulk hydrotest fluids can be safely and efficiently removed
through other connections:
Table 3 Minimum branch sizes for test vent and drain connections

Run Size Branch Size

DN 15 (NPS ½) DN 15 (NPS ½)
DN 20 through DN 50 (NPS ¾ through NPS 2) DN 20 (NPS ¾)
DN 80 through DN 300 (NPS 3 through NPS 12) DN 25 (NPS 1)
Greater than DN 300 (Greater than NPS 12) DN 40 (NPS 1 ½)

2. For installations where bulk hydrotest fluids can be safely and efficiently removed
through other connections, the low point drain and high point vent size may be
reduced to DN 20 (NPS ¾) for all run pipe sizes DN 20 (NPS ¾) and greater.
a. The supply connection should be of a size that will allow the system to be filled
within a reasonable time and be fitted with a temporary, flanged globe valve to be
used for depressurising.
3. Vent flanges for HP steam and MP steam pipes may be replaced by welded caps after
the hydrostatic test.
a. These welds shall be non-destructively examined to the same standards as the
other welds in the system
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b. These welds shall be monitored during initial operation at operating pressures.

4. Refer to DEP 31.38.01.10-Gen for the specifications for test drain and vent
arrangements.
5. For pressure test vent and drain connections, refer Standard Drawing S 38.154.
6. Flanged pressure test vent and drain connections shall be used for all piping systems
that require PWHT during fabrication.
7. Where vent or drain connections need to be more than 500 mm (20 in) long (e.g., due
to thick insulation on the main pipe), supports or bracings or a larger branch size shall
be applied, refer to Standard Drawing S 44.030.
8. Drain and vent connections shall be installed, without valves, at all low and high points
in each piping system to facilitate venting and draining after pressure testing after
construction or repair of the system.
a. The location of the connections shall permit the complete removal of the test
medium after the test.
10. Drains shall be located so that there is a minimum 230 mm (9 in) of clearance or
sufficient free space underneath to install temporary facilities to discharge the drained
liquid.
11. Vents and drains should be as short as possible.
12. The required vent/drain for the SS & DSS piping shall be reviewed during the
constructability modal review and accordingly the provision should be shown in the
model. This shall take into account of the possible individual hydro test loop and the
free drain of the system. This is to ensure no water stagnation left behind after
hydrotest.
1.8.3 Process and utility drain and vent connections
1. For process vent and drain connections, refer to Standard Drawing S 38.155
2. The status of vent and drain valves used for instrument maintenance or for
decommissioning of plant during turnarounds, as well as those used for operational
venting and draining shall be clearly visible from the operator vantage point at access
platforms and walkways.

1.9 CONNECTIONS FOR MANUAL SAMPLING

1. The outlet of a single sample connection, if not connected to a sample cabinet, shall
have one of the following:
a. a male thread and be closed with a threaded cap;
b. a quick-fit coupling which seals when not connected to a sample receiver.
2. The following DEP Standard Drawings should be used:
a. S 38.013;
b. S 38.037;
c. S 38.038.
3. For design of steam sampling, refer to ASTM D1066.
4. For on-line process stream analyser connections refer to DEP 32.31.50.10-Gen.
5. The sampling point shall be positioned such that all of the following are met:
a. valves are accessible;
b. there is sufficient standing space (refer to SP-2215);

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c. taking the sample will not impair the safety of personnel or plant or cause
environmental impact.
6. Samples should be taken from a vertical pipe where possible.
7. Where samples are taken from a horizontal pipe section, the sample take-off location
shall be oriented as follows:
a. for gaseous products, at the top of the pipe;
b. for liquid products, at the side of the pipe, no further than the 5 o'clock position.
The preferred location is the 4 o'clock position.
8. Sample take-off connections shall not be located at dead ends of piping.
9. Sample pipes shall not be longer than 8 m (26 ft).
a. Sample piping should be as short as possible.
10. As far as practicable, sample connections should be grouped together and provided
each with a sample cabinet which can be connected to one common drain facility.
11. If bleed lines are installed, they shall be led to a safe location.
12. For HFE aspects of piping systems associated with sampling systems, refer to SP-
2215.

1.10 THERMOWELL CONNECTIONS

1. Flanged thermowells shall be designed in accordance with the following options:
a. For run pipe DN 80 (NPS 3) and larger and shall be selected from Table 4:
Table 4 Thermowell sizing

ASME class ratings Schedule Thermowell size Standard Drawing

150-1500 160 and below DN 40 (NPS 1 ½) S 38.113
150-1500 XXS and above DN 50 (NPS 2) S 38.114
2500 DN 50 (NPS 2) S 38.114

Rationale: To ensure adequate mechanical strength without compromising the functionality.

DN 50 (NPS 2) is selected for Class 2500 and for Class 1500 schedule XXS because the
wall thickness does not allow the thermowell to fit in a DN 40 (NPS 1 ½) pipe.
b. Alternate design of thermowells shall be capable of accommodating the selected
standardised length of thermocouple as indicated by dimension L1 of Standard
Drawing S 35.409
i. Alternative designs shall not allow the possibility of inserting a thermocouple
without a thermowell.
2. Refer to (Table 5) for the standardised length of flanged thermowells:

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Table 5 Standard thermowell length

Thermowell length Used for:

230 mm (9 in) pipes DN 80 and DN 100
(pipes NPS 3 and NPS 4)
255 mm (10 in) pipes DN 150 and larger
(pipes NPS 6 and larger)
305 mm (12 in) equipment (Pressure vessels)
355 mm (14 in)
405 mm (16 in)
455 mm (18 in)

3. If thermowells longer than 255 mm (10 in.) are required for pipes (e.g., if solidified
product on the pipe wall might influence the measurement), longer thermowells from
the equipment range may be applied after the mechanical strength of the thermowell
has been checked with respect to the flow speed and vibration.
4. In pipes with turbulent flow, only thermowells with a maximum length of 230 mm (9 in)
should be used in order to reduce vibration and forces on the thermowell.
Rationale: In pipes with turbulent flow, the temperature difference between the
centre of the pipe and near the pipe wall is negligible so the shorter thermowell will
not adversely affect the measurement accuracy.
5. Thermowells should not be installed in pipes with continuous two-phase flow.
As the vortex shedding frequency (i.e., Strouhal Frequency) approaches the
thermowell natural frequency, the tip displacement and stresses are greatly
magnified and the thermowell can fail due to the large amount of energy it absorbs.
6. The thermowell Manufacturer/Supplier shall supply thermowell vibration calculations
per ASME PTC 19.3 TW to demonstrate that the ratio of wake frequency (fw) to natural
frequency (fn) is less than 0.8 where in-line resonance is not a concern.
a. If in-line resonance is a concern, the ratio of wake frequency to natural frequency
shall be 0.4.
b. If the design does not meet ASME PTC 19.3 TW requirements, in order to
comply with ASME PTC 19.3 TW one or both of the following shall be applied:
i. increase the thermowell base diameter;
ii. reduce the thermowell insertion length.
7. Thermowell insertion length may be reduced at no loss of accuracy where the flow
regime is of a high Reynolds number (i.e., 1 x 107 or greater) in order to satisfy ASME
PTC 19.3 TW requirements.
Rationale: In high Reynolds flow regimes (1 x 107 and greater), the boundary layer
is very thin.
Measures to avoid vibrations include:
• the use of short thermowells;
• the use of welded thermowells;
• roughening the part of the thermowell exposed to the flow, e.g., by knurling
(standard design);

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• the use of tapered thermowells (standard design);

• placing the thermowell at a point with lower fluid velocity;
• not installing thermowells downstream of flashing or cavitating valves or other
restrictions where the flow is turbulent.
8. Welding thermowells according to Standard Drawing S 38.112 shall only be installed
if, due to high velocity and density of the fluid, the bending loads are too high for
flanged thermowells or if they might be subject to vortex induced vibration.
a. Flanged thermowells should normally be selected.
9. For thermowell installation requirements, refer to DEP 32.31.00.32-Gen.

1.11 ORIFICE FLANGES AND ORIFICE METER RUNS

1. Orifice flanges, raised face, with flange tappings shall be in accordance with Standard
Drawing S 38.130.
2. Orifice flanges, raised face, with corner tappings shall be in accordance with Standard
Drawing S 38.131.
3. Material and components for instrument connections shall be determined based on the
relevant piping classes.
Meter runs measure more accurately due to straight lengths.
4. Orifice meter run sizes DN 15 (NPS ½), DN 20 (NPS ¾), DN 25 (NPS 1) and DN 40
(NPS 1 ½) shall be in accordance with Standard Drawing S 38.134.
5. Typical bracings for small bore branches of piping (e.g., orifice instrument connection)
shall be in accordance with Standard Drawing S 44.031.

1.12 DISPLACER CHAMBERS

1. Displacer chambers for displacer type level instruments shall be in accordance with
Standard Drawing S 38.056 and S 38.057.
2. Loads on equipment nozzles caused by the weight or thermal expansion of displacer
chambers shall be checked.
a. To check thermal expansion forces, it shall be assumed that the equipment is at
design temperature and the displacer chamber is at ambient temperature.

1.13 GALVANISED PIPING

1. Galvanised piping in sizes DN 15 up to DN 50 (NPS ½ to NPS 2) should be
constructed from pre-galvanised screwed pipe and fittings.
2. Galvanised piping DN 80 up to DN 250 (NPS 3 up to NPS 10) should be made from
pre-fabricated pipe spools where the spools are flanged and restricted to shapes that
permit hot dip galvanising after fabrication.
Rationale: The maximum size of these spools is limited by the available galvanising
bath and by the means of transport.
3. Field welds may be applied only on galvanised systems that will be full of liquid in
service.
4. Application of GRP piping should be considered in lieu of galvanised piping for sizes
DN 25 (NPS 1) and larger, as it is generally more economical.

1.14 PIPING IN VIBRATING SERVICE

1. Partial penetration welds or reinforcing pads shall not be used.

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Rationale: To prevent partial penetration welds and reinforcement pads to the

piping system. A typical example: pipe supports are sometimes executed with
partial penetration welds; this practice cannot be accepted. Also, the use of a
reinforcement pad as a solution cannot be accepted.
2. Butt-welded components shall be lined up per SP-2404
3. Weld roots shall be one of the following, in order of preference:
a. ground smooth for inspection if possible;
b. constructed using GTAW if it is not possible to grind the root smooth.
4. In addition to the standard non-destructive examination requirements for the finished
weld, the root weld shall be examined by magnetic particle/liquid penetrant
examination and also by visual inspection.

1.15 WELL CONDUCTORS, WELLHEADS, XMAS TREES AND FLOWLINES ON DIRECT

VERTICAL ACCESS WELLS
1. To prevent erosion problems, flowlines shall use capped tees for all 90-degree
changes in direction.
a. Where flow-induced vibration is anticipated, or pressure drop is critical,
consideration should be given to the use of 5D bends.
b. Capped tees shall be used for heavily erosive service, i.e., when sand production
is expected.
2. For gas production flowlines that could be subject to high flow velocities, consideration
should be given to the inclusion of high integrity erosion monitoring facilities within the
flowline.
3. Refer to SP-2390 of stress analysis for additional requirements.

1.16 RETRIEVABLE PROBE, COUPON AND INJECTION QUILL SYSTEMS

1. For erosion/corrosion monitoring, the design shall be with the order of preference as
shown below:
a. use of non-intrusive inspection is the preferred option;
b. design based on fully retrievable probe, coupon with a specific restriction that
retrieval activity be performed in fully depressurised condition;
c. for situations where it is not possible to fully depressurise, refer to (Part I, 1.16,
Item 3).
2. If situations remain where it is not operationally possible to de-pressure the system,
and on-line retrieval from pressurized lines is justified, the design shall be as follows,
depending on the operating pressure, the retrieval tool, and the orientation:
a. for pressurized lines operating at or below 8.5 barg (120 psig), retractor tools of
stuffing box and outside yoke and screw design, or pressure-balanced retrieval
tools may be used;
b. for pressurized lines operating above 8.5 barg (120 psig), only pressure balanced
retrieval tool shall be used as follows:
i. for extractions in the 3-9 o’clock orientation: hydraulic retrieval tools;
ii. hydraulic retrieval tools shall not contain external moving parts;
iii. hydraulic retrieval tools shall allow operators to work away from the tool;

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iv. for extractions in the 9-11 o’clock or 1-3 o’clock orientation: mechanical-
telescopic tools may be used, if an external liquid source is provided for
back-pressurization and forward flushing;
v. for extractions in the 11-1 o’clock orientation: pressure balanced retrieval
tools may be used without external liquid back-pressurization and forward
flushing facilities;
vi. at the orientation boundaries, the least restrictive requirements may be
selected.
3. Refer to DEP 31.38.01.20-Gen. or DEP 31.01.10.10-Gen., whichever is applicable, for
the requirements for injection points and injection quill systems.
4. Where installations are on the bottom half of the line, hydraulic systems shall be
selected.
5. Where installations are on the top half of the line, hydraulic or mechanical systems
may be used.
6. Where mechanical systems are selected they shall be provided with the following:
a. hydraulic pump for back pressurization prior to unseating the plug;
b. wire brush tool for pressurized thread cleaning;
c. thread chaser for pressurized thread cleaning for cases where wire brush
cleaning proves ineffective;
d. thread tap for pressurized thread tapping for cases where thread chasing proves
ineffective;
e. set of three no-go thread gauges to gauge bottom, middle and top parts of the
internal access fitting threads, to allow periodic thread condition monitoring;
f. adaptor fitting to fit over an access fitting, if threads become worn out;
g. abandonment fitting, to abandon access fittings and protect the created dead leg
from continued corrosion.

1.17 REQUIREMENTS FOR PIPING TIE-IN CONNECTIONS

1.17.1 General
1. Hot tap tie-in connection shall only be considered when both “cold tie-in connection”
and “hot tie-in connection” cannot be executed on the existing piping system due to
process operations limitations.
2. Hot tap tie-in connections shall be done within the restrictions given in
DEP 31.38.60.10-Gen. and SP-2276.
3. An existing valved or flanged connection should be used tie-in to existing piping
systems.
a. Where an isolation valve or flanged connection is not readily available in the
existing piping system, a hot tie-in connection (cut and weld type of tie-in
connection) should be used.
The types of tie-in connections typically used for the connection of new piping
system with an existing piping system include:
Cold tie-in connection (i.e., flanged connection);
Hot tie-in connection (i.e., cut and weld type of connection);
Hot tap tie-in connection.

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1.17.2 Design
1. All piping components of the tie-in connection shall be in accordance with the existing
piping system piping class up to the first isolation valve.
2. Branch connections shall be designed in accordance with the ASME B31.3.
1.17.3 Location
1. For hot tap tie-in connection location requirements refer to DEP 31.38.60.10-Gen.
1.17.4 Welding and inspection
1. Refer to SP-2404 for the requirements for welding and inspection of piping tie-in
connections.
1.17.5 Documentation
1.17.5.1 Hot tie-in connections
1. The supporting documentation for a hot tie-in connection shall consist of the following:
a. design calculations for branch connection;
b. drawings;
c. work procedure.
2. The tie-in design package shall, as a minimum, include a general
arrangement/isometric view to define the tie-in connection.
3. The work procedure shall include the following:
a. site preparation;
b. cleaning/purging/flushing;
c. reinstatement;
d. Tie-in connection check list completed at each step by the relevant action party.
1.17.5.2 Hot tap tie-in connection
1. Refer to DEP 31.38.60.10-Gen. for the requirements for hot tap tie-in connection
documentation.
2. The Hot tie -in proposal needs Prior PDO approval and all the relevant documents
shall be reviewed and approved by PDO TA2.

1.18 GROUNDING AND STATIC ELECTRICITY

1. Refer to DEP 80.64.10.11-Gen. for requirements to prevent build-up of static electricity
on piping systems, instrument bridles and the loading hoses.
2. Piping systems that are isolated from ground as a result of the piping installation
practices shall be identified and included when preventing static electricity build-up.
3. Design details shall be provided to bond isolated pipe to ground to dissipate static
electricity.
Rationale: The development of static electricity can be impacted by the fluid type
and conductivity, the fluid velocity and the fill rate in equipment and on piping
systems where isolating gasket kits are used between dissimilar metals.
Most metallic piping systems would otherwise only be connected to ground at their
equipment connections, which results from the use of non-conductive pads or rods
beneath the pipe and insulated U-bolts at the pipe supports.

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1.19 IRON SULFIDE - PYROPHORIC SCALES

1. The design of piping systems subject to pyrophoric scaling shall include breakout
flanges for safe removal and handling of piping systems.
Rationale: Pyrophoric scales resulting from the deposition of iron sulphide is a potential
hazard.
2. Venting and purging connections shall be provided to facilitate the safe handling of
piping removed from those piping systems.

1.20 PIPING THROUGH WALLS, STRUCTURAL DECKS AND CONCRETE FLOORS OF

BUILDINGS
1. Sleeves or holes through walls and floors of buildings and through table tops shall
have a size permitting the passage of a flange of the relevant pipe size, or the size of
the required insulation, whichever is the larger, to allow the installation of prefabricated
piping.
2. Penetrations through walls and floors shall be sealed with a hydrocarbon-resistant
filler after piping installation (e.g., a collar fitted around the pipe) to avoid chimney
draught in the case of fire.
3. Piping shall be routed to prevent penetration of major structural elements supporting
decks and walls.
4. Flange clearance on piping that penetrates the ground or grating on an elevated work
platform shall be in accordance with SP-2215.

1.21 DISTANCE BETWEEN PIPES

1. Refer to SP-2215 for additional constraints.
2. The minimum distance between a flange (without insulation) and a pipe or the
insulation of a pipe in pipe tracks and trenches and on pipe racks shall be 75 mm (3
in) for tool access.
3. The minimum distance between a flange (with insulation) and a pipe or insulation of a
pipe in pipe tracks and trenches and on pipe racks shall be 30 mm (1.2 in).
4. The distance between the insulation of a low-temperature pipe and any other object
shall be at least 100 mm (4 in).
5. The distance between pipes shall allow for the turning of a spectacle blind, if present.
6. Where thermal expansion can occur, the distance between pipes shall be increased
as required to allow for movements caused by the thermal expansion.
7. Adjacent pipe guides should be staggered to minimise pipe space requirements.
8. Adjacent flanges should be staggered to minimise pipe space requirements.
9. Adequate clearance shall be provided for manifold piping and between hand wheels or
wrenches of valves in accordance with SP-2215.
10. Valves and flanges should be staggered whenever possible to ease operation and
reduce space.

1.22 OFFSITE PIPING SYSTEMS

1. Overhead piperacks should be kept to a minimum.
2. All piping should be located in pipetracks at grade and supported on concrete
sleepers. Individual pipes may be supported from concrete piers.
3. Where double pipe banks are required, steel columns and supports stooled up from
concrete piers or sleepers should be used, with longitudinal tie beams if necessary.
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a. As a minimum, a clearance of 1000 mm (3.3 ft) between the two banks shall be
provided.
4. Where individual pipes at grade are required to cross a road, they shall be designed in
accordance with the requirements given in Part I, 1.3.
a. Where pipetracks cross under roads the piping shall be routed through open
concrete culverts or through conduit pipe.
5. Wherever possible, changes in direction should be accomplished by in-plane turning.
6. Where pumps associated with storage tank are located at a distance more than 100 m
(300 ft) away from the tank, the suction lines shall not be pocketed.
7. Except for in-line piping components and in-line instrumentation items, the use of
flanges should be avoided in offsite piping systems.

2 PIPING ADJACENT TO EQUIPMENT

2.1 GENERAL
1. If equipment flanges deviate from the standard sizes selected from the piping classes,
the matching pipe flanges shall be ordered with the equipment.
2. Piping and pipe supporting structures shall be designed so that access is provided for
maintenance or removal of valves, in-line instruments, tube bundles and shell/channel
covers (e.g., cranes and trucks) and for operational reasons (e.g., filter cleaning).
a. Removal or replacement of equipment shall be possible with a minimum
dismantling of piping.
Removable pipe spools could be required. If needed, the installation of removable
spools will need to take into account the spool asymmetry, vertical clearances and
manoeuvring space available, and insulation.
b. Small pieces of equipment and ancillaries which need regular supervision or
maintenance should be installed on elevated plinths in order to improve access.
3. Valves shall be installed on all equipment drains and equipment vents;
4. Equipment and piping containing slurries shall have minimum size DN 25 (NPS 1)
drain connections, unless the type of drain valve dictates a larger size (e.g., ram-type
valve);
5. Refer to DEP 30.06.10.12-Gen. for the requirements for operational drains for
equipment and piping containing liquefied petroleum gases to be in accordance with
DEP 30.06.10.12-Gen.;
6. If equipment can be adequately drained or vented via connected piping, then the
installation may be executed without the use of a dedicated equipment drain or
dedicated equipment vent.
7. For drainage systems refer to SP-1126.
8. For ergonomic aspects of elevated work platforms and decks associated equipment
refer to SP-2215.

2.2 PUMP, STEAM TURBINE AND COMPRESSOR PIPING

2.2.1 General
1. Onshore reciprocating compressors and integral piping should be supported on a
common slab to avoid differences in settlement between the compressor body and the
connected piping.

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Rationale: Uneven settlement of pipe supports and rotating equipment foundation

leads to introduction of additional stresses in the piping system and connected
rotating equipment. Piping at pumps, compressors and steam turbines needs to 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 jeopardise its operation.
2. Auxiliary piping shall be routed along the base-plate
a. Auxiliary piping shall not extend across the operating floor.
b. This piping shall not obstruct inspection covers, bearing caps, upper halves of
casings or any other items which require access for operation or maintenance.
c. This piping shall not obstruct maintenance access ways.
3. In order to prevent a fire hazard, lubricating oil, control oil and seal oil pipes shall not
be routed within 1 m (3 ft) from the surface of hot process or hot utility pipes.
4. For human factors aspects of piping systems associated rotating equipment, refer to
SP-2215.
2.2.2 Pumps
1. For Y-type strainers, see Standard Drawing S 38.002./STD-000000-MP-2321.
2. For bucket type strainers, see Standard Drawing S 38.004.
3. Pumps shall be protected at initial start-up by inserting a temporary fine mesh
(40 mesh) screen on the upstream side of the permanent strainer.
4. Pump casing drain valves shall be located at the edge of pump base plate and not
under the pump casing.
5. If a Y-type strainer is used, then it shall be installed pointing downwards or at an angle
of maximum 45° from vertical, in order to improve access for cleaning.
6. Suction piping of centrifugal pumps should be as short and as direct as possible,
avoiding high spots where pockets of gas or air can accumulate.
7. For suction piping of centrifugal pumps, the minimum length of the straight pipe from
the last elbow, that does not include any reducer, strainer or isolation valve, shall be
as indicated in Table 6.
Table 6 Minimum straight length for suction piping of centrifugal pumps

Type of pump Position of suction piping Minimum straight

length
Vertical close-coupled perpendicular to pump shaft 4D
Single suction, not applicable 4D
end suction type
Single suction, at top of pump 4D
top-top connection
in same plane as pump shaft 1.5 D
Double suction perpendicular to pump shaft (preferred 3D
situation)
any position other than perpendicular 1) 5 D to 10 D
NOTE: 1. Refer to (Part III, 4.2.2, item 7).

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8. A longer straight length than shown Table 6 might be required, therefore it should be
studied how unequal flow to the impeller eye can best be prevented.
a. The advice of the pump Manufacturer/Supplier should be sought in this respect.
2.2.3 Steam turbines
1. Piping shall be designed to permit steam-blowing up to the inlet and outlet flanges of
the turbine before start-up.
2.2.4 Compressors
1. The length of straight pipe required upstream/downstream of compressor inlet/outlet
nozzles shall be as per Table 7 and Table 8.
a. For components not listed, a minimum of 3D shall be used.
Table 7 Minimum straight length for compressor inlet

Type of Compressor Inlet opening preceded Minimum Straight Length

by below piping between piping component
component and Inlet nozzle
Centrifugal compressors, Elbow 3D
axial compressors or
combinations thereof and Reducer 5D
compressors with interstage Valve 10D
side stream inlets
Flow device 5D

Table 8 Minimum straight length for compressor outlet

Type of Compressor Outlet opening Minimum Straight Length

followed by below between Outlet and piping
piping component component
Centrifugal compressors, Elbow 3D
axial compressors or
Reducer 5D
combinations thereof and
compressors with interstage Valve 5D
side stream outlets
Flow device 10D

2. With the following exception, if two or more compressors are combined, their suction
pipes should enter at the top of the header,
a. Suction pipes at least one pipe size smaller than the header may enter at the side
of the header.
3. The suction pipe between a knock-out drum and the compressor shall slope down
towards the knock-out drum, having no pockets in the line.
a. The suction pipe between a knock-out drum and the compressor should be as
short as reasonably practicable.

2.3 HEAT EXCHANGER PIPING

2.3.1 General considerations
1. Piping connected to shell-and-tube exchanger channel box shall be self-supported or
provided with permanent supports so that the channels can be removed without
having to provide temporary supports for the piping.

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2. Sufficient space for access and maintenance shall be kept between adjacent heat
exchanger inlet and outlet valve manifolds.
a. The piping shall be designed to provide wrench room for unbolting exchanger
channels, and maintain 150 mm (6 in) minimum clearance between the following
components:
i. pipe flanges and the exchanger shell or insulation;
ii. pipe or insulation and the exchanger flanges.
3. Channel piping shall be arranged with a removable section between the exchanger
and block valves so that full access is available for bundle pulling and tube cleaning.
a. To allow removal of covers, heads, channels, bundles and shells, pipes shall not
be supported on heat exchanger shell or heads.
4. For HFE aspects of piping systems associated heat exchangers, refer to SP-2215.
2.3.2 Reboiler piping systems
1. Thermosyphon reboiler should be located as close as possible to the columns that
they serve.
2. All reboiler piping runs should be as short as possible, dictated by process and
mechanical stress requirements and not for layout convenience.
3. Thermosyphon outlet piping shall not include any pocketed or downward sloping
sections.
a. Reboiler return piping shall be free-draining.
4. For vertical thermosyphons, including printed circuit and plate-fin exchanger types, the
reboiler return piping shall contain no more than one 90° long radius bend and one
horizontal section of minimum length.
5. Reboiler vapour return piping shall be free draining and drain towards the reboiler.
2.3.3 Air cooled heat exchanger piping systems
1. Piping of air cooled heat exchangers should be arranged symmetrically to provide
uniform distribution to inlet manifolds.

2.3.4 Printed circuit, plate-and-frame, and plate fin heat exchanger piping systems
1. The design of the permanent strainer shall be such that it could withstand a reverse-
flow condition.

2.4 FURNACE AND BOILER PIPING

1. For furnace and boiler piping, refer to DEP 20.05.60.10-Gen., DEP 30.75.10.30-Gen.,
and DEP 31.24.00.30-Gen.

2.5 PRESSURE VESSEL PIPING

2.5.1 General considerations
1. Pressure vessels that do not have a drain located directly on the vessel shall have a
drain on the bottom outlet pipe:
a. The drain valve shall be outside the skirt.
b. The minimum size of drain for pressure vessel over 15 m3 capacity shall be DN
80 (3 NPS).
2. Pressure vessels which are grouped together should have platforms and
interconnecting walkways at the same elevation.

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a. Refer to SP-2215. for the access requirements, particularly the number of

stairways and ladders to the platforms.
3. Pressure vessels grouped together should have their level gauges at a common
platform level.
4. To allow removal of covers, heads, channels, bundles and shells, pipes shall not be
supported on heads.
a. To satisfy vapour disengagement requirements for liquid pipes from draw-off
trays in columns, there shall be at least 1500 mm (60 in) from the draw-off flange
down to the reducer.
This 1500 mm (60 in) also applies if more than one liquid draw-off nozzle is
connected via an equal tee.
5. Transfer pipes from furnaces should have welded instead of flanged connections to
columns in order to prevent leakage.
6. Piping shall be arranged and supported such that spectacle blinds can be readily
installed for maintenance purposes.

2.6 RELIEF SYSTEMS

1. Refer to DEP 80.45.10.10-Gen. for the requirements for pressure-relief systems.

2.7 LEVEL GAUGES

2.7.1 General
Conventional level gauges are of plate type level gauges which are not permitted for the
HC service / chemical service, therefore magnetic level gauges shall be used.
1. If level measuring instruments are used in combination with level gauges, then the
level gauges shall indicate the entire range of measured liquid level.
2. For the selection of level gauges in LPG service, refer to DEP 30.06.10.12-Gen.
3. Drain valves on level gauges shall be accessible and clearly visible from the operator
vantage point at access platforms and walkways.
2.7.2 Level gauge types
2.7.2.1 Magnetic-type level gauges
Magnetic-type level gauges have high integrity due to their enclosed construction. Long
magnetic-type level gauges are available which eliminate the need for multiple level
gauges.
1. Magnetic-type level gauges shall be of the magnetic-coupled level indicator type.
2. Each level gauge shall have a DN 20 (NPS ¾) flanged vent and drain connection,
each with a cap or blind.
3. Refer to GU-1006 for standardized magntic level gauge datasheet.
4. The magnetic level gauge and related piping components shall be in accordance with
the applicable piping class of equipment.
Where the base material of the piping class is different to the material of the
magnetic level gauge, this could lead to an increase in the level gauge flange
pressure class rating
5. Chamber pipe and associated flanges and fittings shall be of stainless steel as a
minimum and carbon steel pipe not used.
a. If the DEP piping class applicable to the vessel requires a superior material,
materials shall be in accordance with the applicable DEP piping class.
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6. The range of the level transmitters shall cover the full range of the level indicator.
The specific gravity of the fluid to be measured will be specified by the Principal.
7. Butt welds shall be examined in accordance with the appropriate construction class in
SP-2404.
8. Pressurized floats shall not be used.
9. Floats shall be installed after hydrostatic pressure testing.
10. Flanged vent and drain connections shall be provided.
11. The housing shall be designed so that no moisture or dirt can enter (e.g., filled with
inert gas and hermetically sealed).
12. Gate valves that isolate the level measurement chamber from the process shall have
the same flange rating as the vessel nozzle and the same size as the connections to
the level chamber.
2.7.2.2 Gauge glasses
2.7.2.2.1 General
1. Gauge glasses shall only be used for interface level measurement.
a. Single section gauge glasses shall be used for liquid/liquid interface level
applications.
b. Separate vessel nozzles shall be provided for single section gauge glasses for
interface level applications.
2. Gauge glasses for applications in temperature below 0 °C (32 °F) shall have non-
frosting extension blocks in accordance with MESC SPE 76/045.
3. When specifying a level gauge in condensing services (e.g., steam), the process
temperature/pressure in the vessel shall be used.
4. Tubular gauge glasses shall not be used for any level application.
5. To ensure clear visual access for the operator, level gauges shall not be placed
behind pipes or other obstacles.
a. The level gauge shall be positioned so that it can be read from the operator's
normal working position at ground level, platforms or ladders.
6. Sufficient clearance for access and maintenance shall be provided if lighting is to be
installed on level gauges.
7. If a light is needed to read the level gauge, the level gauge shall meet one of the
following:
a. preferably, be less than 1 m (40 in) away from where the operator is standing;
b. if above is not possible, then install lighting behind the level gauge.
2.7.2.2.2 Plate-type level gauges
1. For details of plate-type level gauges, see Standard Drawing S 38.059.
Plate-type level gauges have standard centre-to-centre nozzle distances of 450 mm
(17.8 in), 840 mm (33 in) and 1230 mm (48.4 in).
2. Reflex-type level gauges without lighting shall be used except as follows:
a. Through-vision type level gauges with lighting may be used for adhesive liquids
which give unclear readings on reflex-type level gauges (i.e., where a liquid film
remains after the level has dropped).

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2.7.2.2.3 Wall-type gauge glass

1. For details of wall-type gauge glasses, see Standard Drawing S 10.050.
2. Wall-type gauge glasses may be used only up to a design pressure of 41 barg
(595 psig) and a design temperature of 300 °C (570 °F).
3. Transparent type gauge glass shall be used for indicating the interface between two
liquids.
4. Reflective type gauge glass shall be used for indicating the interface between clear
(non-fouling liquid) liquid and gas/vapour.
5. Transparent glass shall be used for indicating the interface between fouling liquid and
gas or vapour.
2.7.2.3 Bull's-eye level gauges
1. Bull's-eye level gauges may be used only in ASME Class ratings 900 and 1500.
2.7.3 Installation of level gauges
2.7.3.1 General
1. All requirements shall be specified on the data sheet for level gauges
(DEP 31.33.10.92-Gen.) and the requisition sheet for level gauges (DEP 31.33.10.93-
Gen.).
2.7.3.2 Connections
1. Refer to DEP 31.22.00.31-Gen. for the requirements for alignment tolerances of flange
pairs of level gauges.
2. The block valves shall be fitted in either of the following configurations:
a. between the level gauges and the stand pipe;
b. between the stand pipe and the equipment.
3. If there are more than two pairs of level gauge connections, one or more stand pipes
shall be used.
a. The minimum diameter of a stand pipe shall be DN 80 (NPS 3).
b. The equipment connections shall be DN 50 (NPS 2).
2.7.3.3 Gauge glasses
1. If the required level range is too large for a single gauge, multiple level gauges shall
be used, with the connection nozzles staggered for a visible overlap of at least 25 mm
(1 in).
a. If multiple level gauge glasses are used, the visible length shall be the measured
distance from the bottom visible portion of the lower gauge glass section to the
top visible portion of the top gauge glass section.
Long magnetic-type level gauges are available which obviate the need for multiple
gauge glasses.
2. If the visible level range in a gauge is continued in a second (staggered) level gauge,
or the if level is used to check another level instrument, then both levels shall be
readable from the same location.
3. If a level gauge has to be heated, the heating element shall be external.

2.8 INSTRUMENTATION
1. Refer to DEP 32.31.00.32-Gen. for the requirements for mounting in-line instruments
2. Refer to DEP 32.37.10.11-Gen. for the requirements for instrument impulse pipes.
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3. For pressure instrument connection details, refer to S 38.156.

4. For temperature instrument connection details, refer to S 38.157.
5. For orifice instrument connection details, refer to S 38.158.
6. For meter run instrument connection details, refer to S 38.159.
7. For HFE aspects of instruments, see SP-2215.

2.9 PACKAGED EQUIPMENT PIPING

Vendor shall ensure all interfacing information which affects design shall be obtained and
projected during the engineering development of the packaged equipment. The piping
within package shall be supported with the required rigid supports (guide/limit stop) to
eliminate any pipe disturbance during material handling/transport and severe operating
conditions.

2.10 VESSEL TRIM

1. For each vessel trim, a piping line number or numbers shall be allocated for each
vessel.
2. Piping isometric drawing shall be prepared to detail the trim for each vessel or
equipment item.

3 UTILITY PIPING

3.1 GENERAL
1. For utility connection requirements, see utility, drain and vent connections section of
this SP.
2. Piping materials for all utility services shall be selected from applicable piping classes.

3.2 FIRE WATER

1. Where fire hydrant valve inlet connection size is DN 65 (NPS 2 ½), fire water piping
crossover connection for the fire water hydrant valve shall be executed using a
reducer of DN 80 x DN 65 (NPS 3 x NPS 2 ½).

3.3 WATER FOR PURPOSES OTHER THAN FIRE WATER

1. For potable and industrial water, non-metallic piping should be used.
2. Water hose connections shall be located so that any required location can be reached
with one or two 15 m (50 ft) long hose(s).
3. Hose stations shall have a valve, a connection of the quick-coupling type, one or two
15 m (50 ft) water hose(s) and a hose rack.

3.4 STEAM
1. Refer to DEP 30.75.10.10-Gen. for the requirements for piping in steam systems.
2. Atmospheric relief device discharge piping should be corrosion resistant (e.g., hot dip
galvanized or stainless steel construction)
a. Atmospheric relief discharge piping shall have a weep hole of 13 mm diameter (½
in) at the lowest point of pipe to ensure complete removal of all liquids
accumulated in the discharge piping system.
3. All steam pipes shall have a drip leg (boot) with steam trap at the low points and at the
end to remove steam condensate (e.g., during commissioning).

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4. A drip leg (boot) with steam trap shall be installed at the following locations in both
saturated and superheated service:
a. in saturated steam lines at a maximum interval of 50 m (165 ft)
b. in superheated steam lines at a maximum interval of 150 m (500 ft).
5. The end of main steam headers shall be provided with valved blow-off connection of
size minimum DN20 (NPS ¾).
6. Selection of steam traps shall be in accordance with Table 9:
Table 9 Steam trap selection

Service Steam Traps Type(s)

Low pressure steam (1.3.2) drip service inverted bucket style mechanical traps or
bimetallic thermostatic style traps

Medium pressure steam (1.3.2) drip service Disc type thermodynamic traps

High pressure steam (1.3.2) drip service thermodynamic piston/disc type traps

Steam turbine inlet drip service thermodynamic piston/disc type traps

Process services based on process requirements

7. Steam traps used for process services shall be provided with a unique equipment tag
number.
8. Steam traps up to and including DN 40 (NPS 1 ½) should be welded and have
removable internals to allow repair without performing hot work.
9. Refer to DEP 30.75.10.10-Gen. for the layout requirements for steam systems.
10. Open steam trap discharges shall be located away from doors, windows and air
intakes.
a. In areas subject to freezing, icing-up of personnel access areas shall be
prevented.

3.5 UTILITY HOSE STATIONS

1. In the interest of safety and convenience, utility hose station connection points shall
point downwards.
2. Where utility hose stations are specified, they should be located so that all points of
use in the area can be reached by one or two 15 m (50 ft) long hoses.

4 TANK FARM PIPING

1. Piping shall be connected and supported after hydrostatic testing of the tank.
2. Within the bunded area, the number of pipes should be minimised and be routed in the
shortest practicable way from the tank to the bundwall.
a. Where practical, the pipes should be grouped together.
3. Piping run at grade shall be ≥ 0.3 m (12 in) above grade to the bottom of the pipe.

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4. If relatively small-bore pipes are installed along with bigger pipes in tank pits having a
concrete floor (e.g., in chemical plants), steel frame supports may be used as
intermediate supports between concrete sleepers.
5. There shall be access to manholes, mixing nozzles, drains and other facilities on the
tanks.
a. Small bore utility piping required for more than one tank may be routed along an
interconnecting overhead walkway, if available.
6. Pipes may only be routed through bund walls if they cannot be passed over such walls
(e.g., suction pipes).
a. For bundwall crossings, refer to DEP 34.11.00.11-Gen.

5 PIPING COMPONENTS

5.1 GENERAL
1. For instrument connections, manual sampling connections, vent and drain
connections, length of the connections should be as short as possible
5.1.1 Special piping components
1. Piping components not typically specified in piping classes, such as certain types of
blow-down valves, non-slam check valves, injection quills and non-standard thermo-
well or branch devices shall be defined as special piping components. Refer to GU-
1006 for standardized piping & static special components.
a. Special piping component number shall be allocated and used on all relevant
documents, including the PEFS drawings.

5.2 PIPE
5.2.1 Metallic pipe
1. For metallic pipe, refer to DEP 30.10.02.11-Gen. and ASME B31.3.
2. Metallic pipe shall be in accordance with ASME B36.10M or ASME B36.19M.
3. The corrosion allowance for carbon steel and ferritic alloy steel pipes shall be at least
1 mm (0.04 in).
5.2.2 Non-metallic pipe
1. For the selection of non-metallic materials, refer to DEP 30.10.02.13-Gen.
2. For glass-fibre reinforced plastic (GRP) piping systems, refer to DEP 31.40.10.19-Gen
and SP-2092.
a. For GRP piping classes, refer to DEP 31.38.01.14-Gen.
5.2.3 Lined piping
1. For plastic-lined piping classes, refer to DEP 31.38.01.14-Gen.
2. All internally lined carbon steel pipes with a diameter of DN 250 (NPS 10) and larger
shall be fabricated in flanged sections.
a. All flanged sections shall be hydrotested prior to coating.
b. Field welding of coated piping components shall not be permitted.
3. The design shall address the following design condition limitations for lining material:
a. pressure – temperature rating combination;
b. conveying fluid compatibility;

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c. coupling materials;
d. electrical conductivity of the piping system.
4. Nominal sizes of lined piping shall be in accordance with ASME B36.10M or
ASME B36.19M, unless otherwise specified.
5. Plastic-lined piping shall be in accordance with ASTM F1545, except that welding neck
flanges are allowed.
a. Threaded flanges shall not be used.

5.3 PIPE JOINTS

5.3.1 Metallic piping
5.3.1.1 Welded joints
1. Refer to SP-2404 for the requirements for shop and field fabrication of steel piping.
2. Preparation shall be in accordance with ASME B16.25.
a. Permanent backing rings shall not be used.
3. Welds requiring postweld heat treatment (PWHT) should be prefabricated as far as
possible, thereby minimising the number of field welds.
5.3.1.2 Selection of gaskets and packing
1. For uniformity, and to prevent mistakes, all nozzles on a piece of equipment should be
provided with the same type of gasket.
2. The most stringent design condition shall determine the required gasket.
3. Where a flat face flange is required, the counter-flange shall also have a flat face and
full-face gaskets applied.
4. For liquid service above Class 300# and for gas service regardless of pressure class,
insulation joints consisting of an insulated manufactured composite joint system shall
be used.
Rationale: Insulated manufactured composite joint systems are more reliable than
solid phenolic type gasket and bolt sleeves.
5. If graphite-sealing materials cannot be used, e.g., for product contamination reasons,
other materials shall be selected as follows:
a. for temperatures up to 200 °C (390 °F): PTFE-based materials;
b. for temperatures ≥ 200 °C (390 °F): ceramic type materials (Mica).
6. Lip seal gaskets should be used for flanged connections where possible leakage is a
major concern, or for equipment that does not need to be opened with a frequency of
less than 10 years.
5.3.1.2.1 Compressed asbestos fibre and manmade mineral fibres
1. Compressed asbestos fibre (CAF) shall not be used as filler material in metallic
gaskets or as flat sheet gasket.
2. As a replacement to CAF flat sheet gaskets, the following types of gaskets should be
considered:
a. preferably graphite filled spiral wound gaskets;
b. alternatively, foil or expanded metal reinforced graphite gaskets;
3. Manmade mineral fibres (MMMFs) shall not be used.

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5.3.1.2.2 Spiral wound gaskets

1. With the following exceptions, spiral wound, AISI 316(L), graphite filled gaskets shall
be selected for diameters up to DN 600 (NPS 24):
a. Graphite filled gaskets shall not be used in seawater service.
b. Spiral wound/Monel 400 graphite filled gaskets may be used up to a design
temperature of 450 °C (850 °F).
2. For design temperatures above 450 °C (850 °F), pure graphite with an oxygen
inhibitor shall be used.
3. For spiral wound gaskets that require inner rings, the inner ring shall match the
windings.
4. Spiral wound gaskets shall be coloured in accordance with ASME B16.20.
5. Where piping systems are subjected to pigging operation, the usage of inner rings
shall be determined based on the reduced inner diameter at the gasket.
5.3.1.2.3 Covered serrated metal gaskets (cammprofile)
1. For flanged connections above DN 600 (NPS 24), covered serrated metal AISI-
316(L)/graphite gaskets with a "lateral" profile height shall be selected.
2. For design temperature greater than 400 °C (750 °F), use pure graphite with an
oxidation or inhibitor or high temperature sealing material such as mica.
3. Use of covered serrated metal gaskets with a convex profile shall be subject to
approval by the Principal.
Rationale: To verify that the use of these gaskets is appropriate and acceptable.
Serrated metal gaskets with convex profile are used if serrated metal gaskets with a
lateral profile cannot provide an adequate seal (e.g., in weak flanges or where the
flange facing is not perpendicular to the design plane).
4. Covered serrated metal gaskets (Cammprofile) may be resurfaced with graphite and
re-used based on the recommendation from the Manufacturer/Supplier.
5.3.1.3 Selection and installation of bolting materials
1. Stud bolts and nuts shall be completely threaded in accordance with ANSI B1.1 and
the following:
a. sizes 25 mm (1 in) and smaller to be Coarse Thread Series (UNC);
b. sizes larger than 25 mm (1 in) to be 8-Thread Series (8 UN);
c. threads shall be machine cut or rolled.
2. The stud bolt length shall be determined per ASME B16.5 or ASME B16.47.
a. Where spectacle blinds, wafer valves, orifice plate, are installed, the stud bolt
length shall be increased by the thickness of such devices and the extra gaskets.
3. Studs of 50 mm (2 in) diameter and larger shall be the larger of one nut thickness or
40 mm (1 ½ in) longer than normal to permit use of a bolt tensioner.
4. Nuts shall be semi-finished, heavy, hexagon.
5. Nuts shall have a height equal to the bolt diameter.
6. Per ASME B31.3, for non-insulated components with fluid temperatures ≥ 65 °C
(150 °F) the bolting temperature shall not be less than 80 % of the fluid temperature.
7. The use of tension control type fasteners should only be considered if fasteners
cannot be bolt-tensioned and would otherwise be torqued.

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8. The use of non-sour service bolts on flanges of sour systems shall comply with all of
the following:
a. the bolts are not in contact with the sour fluid;
b. the bolts are not insulated;
c. natural air ventilation is unrestricted.
d. tape, if used, is removed immediately after successful testing of the joint.
Rationale: If non-sour service bolts are used on flanges of sour systems, the
practice to use masking tape for flange tightness testing carries the risk of bolt
corrosion in case this tape is not removed after start-up.
i. The tape shall be brightly contrasting in colour.
9. Where austenitic stainless steel bolting grades are required, following grades shall be
selected:
a. ASTM A193 Grade B8M-Class 2 (AISI 316) for the following services:
i. Non-sour service in non-maritime structures (onshore non-jetty facilities)
where valve heads and manifold bodies are AISI 316, Alloy 400, or Alloy
500
b. ASTM A193 Grade B8M-Class 1 (AISI 316) for the following services:
i. Sour service in non-maritime structures (onshore non-jetty facilities) where
valve heads and manifold bodies are AISI 316 stainless steel
c. ASTM A193 B8MLCuN-Class 1B (6Mo) for the following services:
i. Where valve heads and manifold bodies are Alloy 6B, or Alloy C276
10. The use of hardened washers should be considered on TSA-coated flanges,
especially at flange locations that will be frequently broken and re-made
Rationale: Damage to the TSA coating (due to galling) can lead to aluminium
deposits on the nut bearing surface causing inaccuracy when torque tightening the
bolts.
5.3.1.4 Coated bolts
1. Refer to DEP 30.48.00.31-Gen. for the requirements for coating of bolts (fasteners).
5.3.1.5 Threaded joints
1. Threaded joints, where permitted, shall be NPT pipe threads per ASME B1.20.1.
2. Where non-seal-welded threaded pipe joints are used, a thread sealant/lubricant shall
be used on the pipe threads of all connections to ensure the threads are tight.
3. Where pipe unions are acceptable, they shall be limited to Class 300 systems:
a. Unions shall be made of forged steel;
b. Unions shall have a working pre ssure of at least 3000 psi;
c. Unions shall be of the ball-to-full bearing arc or ball-to-cone, metal-to-metal
seated type;
d. Unions shall consist of a head or cone piece, a tail or ball piece, and a connecting
nut.
e. Gasketed unions shall not be used.
f. Unions should not be used between large bore (Part I, 1.3.2) piping and the first
branch valve.

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5.3.1.6 Flexible hose connections

1. Flexible hose connections shall be secured by hose safety cables for fluid services
other than category D fluids, as defined in (Appendix B) when they are in use.

5.4 FITTINGS
5.4.1 General
1. Fittings shall be in accordance with ASME B16.5, ASME B16.9, ASME B16.24 or
ASME B16.47, as applicable for the type of fitting.
2. Fabricated fittings employing intersection welds shall only be used in crosses, and
when designed in accordance with the relevant design codes or regulations.
3. The use of reducing elbows, straight crosses, reducing outlet crosses and short radius
elbows shall be subject to approval by the Principal
4. Short radius elbows shall not be used where the likelihood of erosion is high in
accordance with ISO 13703.
Rationale: This could result in a threat to the integrity of the piping system.
Where short radius bends are used, the pressure drop and the stresses in the
piping system to be kept within the allowable limits. Although ISO 13703 is
specific to offshore applications, the principles for this clause apply equally to
onshore applications.
5. For very toxic - acute fluids fluid services, “pipe-to-pipe” branch connections shall not
be used.

5.5 BRANCH FITTINGS

5.5.1 General
A branch fitting connects a branch pipe to the run pipe.
1. Branches should be connected at 90° to the run pipe.
2. Butt-welding tees should be used for branches equal in diameter to the run pipe.
3. Butt-welding tees with equal or reducing outlets should be used for services where
flow disturbance is to be minimised.
4. The reinforcing method shall be determined based on the economic aspects and
service conditions.
5. Where butt-welding tee fittings are available as a listed component in ASME B31.3,
butt welding tee fittings shall be used in severe cyclic service (as defined in
ASME B31.3).
6. Branch connections shall not be made on elbows or tees.
7. Branch connections should not be made on reducers
8. Where branch connections are made on reducers, the following shall apply:
a. limit the branch connection to a maximum DN 40 (NPS 1 ½) and the run-size of
the fitting at the branch position to a minimum DN 150 (NPS 6);
b. on eccentric reducers, locate the branch at the flat side of the reducer.
9. “Lateral welded-in contour insert” may be used for oblique connections (at angles
greater than or equal to 45 degrees, but not 90 degrees).

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5.6 FLANGES AND FLANGE ISOLATION SETS

5.6.1 Flanges
1. Flanges shall be raised-face in accordance with ASME B16.5 or ASME B16.47 or
calculated in accordance with ASME Section VIII.
2. Flanges over DN 600 (NPS 24) shall be in accordance with ASME B16.47 series A
3. Flanges for wellhead and X-mas tree connections with a pressure rating ≥ 5K shall be
in accordance with ISO 10423/API 6A.
4. The flange facing finish shall be in accordance with ASME B16.5 or ASME B16.47, as
applicable.
5. Slip-on flange joints shall not be used in hydrogen service, wet H2S, or high
temperature services (i.e., above 450 °C (840 °F)) or severe cyclic service (as defined
in ASME B31.3).
6. Flange bolt holes shall straddle the pipe centre lines.
7. If a flat face flange is required (e.g., GRE piping in ASME Class rating 150) the
counter flange shall also have a flat face in accordance with ASME B16.5.
a. Flat face flanges shall be provided with full-face gaskets.
8. For bolt material and temperature limitations, refer to (Part I, 5.3.1.3) and DEP
30.10.02.11-Gen.
9. Flanges shall be forged close to final shape before machining to ensure adequate
grain flow at changes of section.
5.6.2 Flange isolation sets
1. Flange isolating sets shall be used at the interface between:
a. cathodically protected systems and non-cathodically protected systems;
b. two different cathodic protection (CP) systems; namely Impressed current and
sacrificial anodes.
2. Flange isolating sets between flanges of carbon steel and a nobler material in systems
not protected by CP shall be installed for the following:
a. in strong acid service;
A strong acid is one which is essentially 100% ionised in solution.
b. in sour water with free sulphur present;
c. in oxygenated water service.
3. Flange isolating sets between flanges of carbon steel and a nobler material should be
considered for the following:
a. significantly wet uninsulated gaskets (e.g., flanges protected by frequently
operated deluge systems, or flanges near cooling towers);
b. flanges enclosed in wet thermal insulation.
4. Where flange isolation sets are selected, the pipework shall be electrically isolated at
the pipe supports (e.g., with rubber/thermoplastic pads).
5. In sour environments, longer isolation spools shall be used, because of the potential of
FeS bridging the isolation as it is conductive.

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5.7 PIPING AND EQUIPMENT ISOLATION

5.7.1 Integral double-block-and-bleed valves
1. For single-body, single-stem double-block-and-bleed (DBB) applications, only two
valve concepts shall be used:
a. double expanding gate valve with body bleed valve;
b. double expanding plug valve with body bleed valve.
Rationale: Common mode failure is prevented by independent alignment of closure
member parts to mating seats. The single stem of the double expanding gate valve
or double expanding plug valve is in compression when closed. This eliminates the
dominant stem failure modes.
An additional advantage of the double expanding gate valve and double expanding
plug valve is that external seating forces can be applied to assist seat tightness,
especially for the low differential pressure seat of the DBB configuration.
2. The double expanding gate valve and double expanding plug valve shall achieve gas
tight sealing.
3. Valve design shall be subject to approval by the Principal before choosing the concept
of the double expanding gate valve instead of choosing a double-block-and-bleed
assembly made out of individual valves.
Rationale: To verify that the valve design is appropriate and acceptable. Internal
obstruction of one of the closure member parts renders the entire valve dysfunctional.
4. The following integral double-block-and-bleed valves may be used:
a. integral double ball valve with body bleed valve;
b. integral double plug valve with body bleed valve.
Rationale: Only the valve body is shared in these designs. Therefore, these valve
concepts can be considered as similar to double-block-and-bleed assemblies made
out of individual valves.
5. The bleed valve shall comply with piping class valve requirements.
5.7.2 Positive isolation
1. Spectacle blinds, spades, spacers and blind flanges shall have the same ASME Class
rating as the piping.
a. For spectacle blinds, spades and spacer, see ASME B16.48 for size range up to
DN 600 (NPS 24).
b. For sizes above DN 600 (NPS 24), see Standard Drawings S 38.042 and
S 38.043.
2. If spades with spacers are required which are outside the range of Standard Drawing
S 38.042 and Standard Drawing S 38.043, their outside diameter shall be equal to the
diameter of the raised face of the mating flange:
a. Spacers and spades should have two centering pieces welded to their
circumference.
i. These centering pieces should have a bolt hole of the same diameter and
bolt circle diameter as the mating flange.
3. Spades, instead of spectacle blinds, shall be installed for either of the following:
a. pipes with operating temperatures below 0 °C (32 °F);
Rationale: To prevent icing problems.

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b. pipes where the operating temperature is below the dew point

Rationale: To prevent excessive condensation and corrosion in high humidity
locations.
4. Spades and spacers should be used for or high temperature services (i.e., above 450
°C (840 °F)) due to loss of temperature to the surroundings.
5. A thin (3 mm to 5 mm (0.12 in to 0.20 in)) blind plate shall only be used if it can be
guaranteed that there will be no differential pressure between both sides of the
isolation point (not even via a utility or instrument connection).
a. The blind plate shall be provided with gaskets on both sides in order to prevent
damage to the surfaces of the mating flanges.
6. Piping shall be designed, supported and installed so that the flanges do not move
when the bolting is removed for spading purposes.
a. The piping shall be sufficiently flexible to be able to install the required isolation
fittings (spades, blind plates) and have sufficient space to turn spectacle blinds,
where provided.
7. Where temperature differences between the bolting and valve assembly as part of
normal operation is a possibility, in such circumstances, shielding should be used
instead of passive fire protection solution.
8. Any application of passive fire protection or shielding applied to maintain the required
fire duration shall be subject to the approval of the Principal to review in terms of
mechanical integrity due to corrosion under insulation.
9. If spectacle blinds in horizontal pipes are insulated, the spectacle blind should point
downwards at an angle of 45° to prevent water leaking into the insulation (see
DEP 30.46.00.31-Gen.).
5.7.2.1 Layout aspects
1. Spectacle blinds and spades shall be located so that they are accessible from ground
level or from platforms or walkways.
a. The need for scaffolding should be minimised.
2. Access into underground manholes shall be provided with isolation valve(s) that can
be operated from above ground before spading of any pipe that connects to the
underground manhole.
3. If spading points are installed in vertical piping, access and handling facilities shall be
provided.
4. A spectacle blind cannot easily be turned using a crane or a hoisting device, and,
therefore, the need for cranes and hoisting facilities should be avoided.
5. If the required force to turn spectacle blinds exceeds 23 kg (50 lbs), then one of the
following shall be implemented to ensure safe turning of the spectacle blind:
a. additional mechanical handling equipment and procedures;
b. alternatively, using spades with spacers.
Spectacle blinds requiring a force > 23 kg (50 lbs) are shown in Table 10.
Table 10 Spectacle blinds greater than 23 kg (50 lbs)

ASME Class rating Size

150 DN 300 (NPS 12) and larger
300 DN 250 (NPS 10) and larger

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ASME Class rating Size

600 DN 200 (NPS 8) and larger
900 DN 200 (NPS 8) and larger
1500 DN 150 (NPS 6) and larger
2500 DN 150 (NPS 6) and larger

Spades weighing more than 23 kg (50 lbs) are shown in Table 11.
Table 11 Spades heavier than 23 kg (50 lb)

ASME Class rating Size

150 DN 350 (NPS 14) and larger
300 DN 300 (NPS 12) and larger
600 DN 250 (NPS 10) and larger
900 DN 200 (NPS 8) and larger
1500 DN 200 (NPS 8) and larger
2500 DN 150 (NPS 6) and larger

6. Spades and their corresponding spacers shall be clearly tagged and stored in
adequate facilities when not in use.
7. Spades without a spacer shall not be used for spading rotating equipment, in order to
avoid distortion problems.
To remove a spacer (or its replacement spade) half of the bolts need to be removed
and the flanges opened slightly. To install a spade between two flanges that did not
have a spacer, requires the flanges to be opened by a distance equal to the
thickness of the spade plus one gasket.
a. Spades without a spacer should only be applied in relatively flexible piping
systems.
8. Spacers and spades exceeding a weight of 23 kg (50 lbs) shall be provided with a
lifting lug.
9. A removable spool and blind flanges shall be used in the following situations:
a. where the nozzle is used for entry into the equipment;
b. where the nozzle is used for hoisting (e.g., top nozzles on columns);
c. where the nozzle (e.g., the head of a heat exchanger) is used to remove internals
(e.g., the tube bundle);
d. where the nozzle is used for loading/unloading of solids (e.g., catalyst).

5.8 VALVES
5.8.1 General
The scope of this section includes standard valves, selected for DEP piping classes. It
does not include designs of pressure relief valves (refer to DEP 80.36.00.30-Gen.) or
control valves (refer to SP-2350) Valves are categorised in a standard selection and one
requiring a deviated selection due to the service. This can be the valve type or design.

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i. For valves engineering requirements refer to SP-2342.

5.8.2 Description and application of commonly used types of valves
5.8.2.1 Ball valves
1. Threaded ball valves shall only be used for water service.
2. Full-bore ball valves shall be selected instead of a reduced bore valve if any of the
following applies:
a. if pigging is required;
b. erosive service;
c. if the process cannot accommodate the increased pressure drop that will result
from the use of a reduced bore ball valve.
Ball valve seats can be soft (thermoplastic) or metallic. Soft seated ball valves are
lower in cost than metal seated ball valves, but have a limited temperature rating,
as described in (Part II, 8.8.9).
3. Soft-seat materials should not be used in dirty services on floating ball valves.
5.8.2.2 Plug valves
1. Lubricated plug valves only will be of inverted pressure balance type and therefore
shall be used if the product allows the use of lubricant.
a. Lubricants shall contain a base oil and a viscosity improver such as amorphous
or fumed silica.
Rationale: Lubricated plug valves are typically used in dirty upstream applications,
where contamination of the process fluid is not a cause of concern. The valves are
however heavier and more expensive than ball valves. They are also extensively
used on gas pipeline systems as bypass valves to mainline ball valves, blow-down
valves on valve stations and kicker valves. They can be delivered in exotic
materials such as duplex SS and higher alloy overlay.
2. For double block and bleed non-piggable upstream applications where space and
weight is a consideration, double isolation plug valves may be installed instead of two
valves in series.
Other plug valve designs, which are non-lubricated and can therefore be used
downstream are the eccentric and expanding plug designs.
3. Plug valves are double seated valves which incorporate a cavity between the seats, or
above and below the plug, and therefore the cavity relief requirements shall be as per
SP-2342.
Rationale: Plug valves are not torque seated. Plug valve ends can be flanged, hub
type or butt weld.
5.8.2.3 Butterfly valves
1. Offset butterfly valves should be installed, whenever possible, with the shaft to the
high-pressure side in the scenario when the valve is closed (this is not necessarily the
flow direction).
Rationale: Concentric butterfly valves are the lowest cost, followed by double-offset
and triple-offset. Double-offset butterfly valves have a considerably lower operating
torque than triple-offset, resulting in a lower actuated valve package. Triple offset
butterfly valves are either double flanged or butt weld ends. These valves are in
many services replacing gate valves.
Shut-off performance is more reliable with the shaft to the high pressure side in the
scenario when the valve is closed, since differential pressure pushes the disc in to

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the seat. In the other shut-off direction, shut-off is less reliable but the operating
torque is substantially lower, enabling smaller actuators to be used.
2. Butterfly valves shall not be installed back to back, due to the disc protruding beyond
the face or valve end.
3. Soft seated butterfly valves should not be used in dirty services.
Rationale: Soft seated butterfly valves are cheaper than metal seated but have a
limited service temperature).
4. Wafer-type valves shall not be used because of their increased vulnerability to fire.
Rationale: The exposed tie bolts will expand quickly when near a fire, causing joint
leakage.
5. Wafer-lug type valves have shielded bolting and may be selected for water service.
6. Double flanged valves should be used for process applications for maintenance
reasons
Rationale: Double flanged valves can simply be un-bolted and lifted from the line,
whereas with corroded threaded wafer lug type, removal of the studs might not be
possible.
7. To prevent closure of the disc in turbulent services, butterfly valves shall be installed
with stem orientation dissecting the flow pattern in two symmetrical halves.
8. If it is specified that the valve will be installed underground or at a level below the
operator’s position, the valve shall have a stem extension and extension casing.
a. The casing shall be fully enclosed and externally coated for corrosion prevention.
9. For gear operated valves, the gearbox shall be mounted directly on the valve.
a. The gearbox input shaft shall be extended.
10. The design of the stem extension and protector (if applicable) shall be subject of
approval by the Principal.
5.8.2.4 Gate valves
1. Gate valves should be selected for steam service.
2. Gate valves ends shall be as per SP-2342 for steam service
3. Depending on the size, the following wedge gate valves may be selected:
a. DN 15 (NPS ½) up to DN 40 (NPS 1 ½): solid wedge type gate valve;
b. flexible-wedge type gate valves larger than DN 40 (NPS 1 ½):
c. flanged, hub type, butt weld or socket weld valve ends as allowed per (Part II,
8.3.1.2).
4. Through conduit slab gate valves should be considered for dirty or fouling service
where the body bowl of a wedge gate valve could collect solids that will interfere with
the movement of the gates.
Rationale: Through conduit expanding gate valves have a further advantage of a special
design which incorporates a gate made in two segments, which are expanded when
closed to give gas tight shut off on both seats. The performance of both seats can be
verified via a body bleed valve.
5. Gate valves shall include a seal between the male and female segments to isolate the
valve centre cavity from pipeline debris.
5.8.2.5 Globe valves
1. The valve ends shall be flanged for all services and upto 400 deg cel.
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Globe valves are torque seated valves.

5.8.2.6 Check valves
5.8.2.6.1 General Services
1. For line sizes from DN 15 (NPS ½) up to and including DN 50 (NPS 2), check valves
should be of the piston type or ball type.
2. Piston and ball check type valves shall only be installed in horizontal pipe-runs.
There is no spring specified in these types of valves in the DEP piping classes.
3. For line sizes ≥ DN 80 (NPS 3), check valves should be of the swing type.
4. Swing check valves shall not be used in vertical pipes having downward flow.
Other flow configurations are acceptable (vertical pipe with upward flow, and
horizontal pipe).
5. For line sizes DN 300 and greater, check valves should be of one of the following
types:
a. swing type check valve;
b. dual-plate double flanged type check valve;
Dual plate check valves are available with both hinge pin retainer and the
retainerless design (which has no external leak paths, is the most commonly used
type). Dual plate check valves are commercially attractive over swing type check
valves.
6. Valve ends shall be flanged for all services and upto 400 deg cel.
7. For dual plate check valves, the wafer lug body type shall only be used if the valve is ≥
DN 80 (NPS 3) in water service. The wafer lug body type may be used in HC service
due to space constraints which shall be approved by Principal.
5.8.2.6.2 Acidic Services
1. For acidic service, floating ball check valves that incorporate a polymeric liner with a
minimum thickness of 3 mm (⅛ in) shall be used.
The lined body material is usually nodular iron which has restricted low
temperatures of -20 °C (-4 °F) for PN 10 and -10 °C (14 °F) for PN 16. The flanges,
however, are Class 150 as standard. These valves are available in ASME Class
rating 150, up to DN 200 (NPS 8)
5.8.2.6.3 Protection against hydraulic surge of liquid
1. If hydraulic surge of liquid is a concern and a check valve has been specified as a
mitigation, then one of the following types of check valves shall be used:
a. axial flow check valve;
b. tilting disk check valve;
c. dual plate check valve.
5.8.2.7 Process to instrument valves
A process to instrument valve unit is a means of interfacing between process piping and
instrumentation systems. These units are specifically designed to minimise weight,
external leak paths and the need for instrumentation manifold valves.
1. When process-to-instrument valves are selected, they shall be all ball valves or all
needle type globe valves.
a. Ball valves shall only be selected under the following circumstances:

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i. application temperatures up to 150 C (300 F) for up to Class 1500

ii. application temperatures up to 120 C (250 F) for Class 2500
b. Needle type globe valves shall only be used up to 150C (300F) regardless of
class.
c. Needle type globe valves shall only be selected for clean services.
2. For applications >150 °C (300 °F), standard piping class valves shall be used.
5.8.3 Metallic trim materials
1. For gate and globe valves DN 50 (NPS 2) and larger, in non-sour service -29 °C to
400 °C (-20 °F to 750 °F), type 410 stainless steel may be used instead of 316 type
stainless steel.
Rationale: The standard choice of stem material for both carbon and stainless steel
valves is 316 type stainless steel.
2. 410 Type stainless steel may be used for butterfly valve stem material in moderate
sour service -29 °C to 400 °C (-20 °F to 750 °F).
3. 17-4PH material shall not be used for sour service valves.
a. For higher grade materials, the stem should be equal or better than that of the
valve trim.
4. Duplex SS stems only shall be used up to 300 °C (570 °F).
5. Higher strength materials (eg.Alloy 718/625/825) in stead of 316 type stainless steels
shall be selected for butterfly valve stems with prior approval from PDO
6. The metal seat facing material for all valves should be Stellite 6.
a. Tungsten carbide may be used for abrasive service.
b. Triple offset butterfly valves utilising laminated seats on the disc may use duplex
stainless steel for the metal laminations.
c. Since these components are in compression the normal maximum temperature
may be extended from 300° to 400 °C (570 °F to 750 °F).
7. The wire type springs material shall be Alloy 718 or Principal-approved equivalent.
Rationale: To ensure adequate material selection. Alloy 750 has exhibited SCC
problems.
5.8.4 Bolting materials
1. Bolting materials for valves shall be implemented in accordance with Table 12.
Table 12 ASTM Fasteners used in Buying Descriptions MESC

Valve Non-sour service

Material Bolt/Stud Nut Buy description temp limits
T min T max1

C.S A 193-B7 A 194-2H -29 °C (-20 °F) +410 °C (770 °F)

LT C.S A 320-L7 A 194-7 -50 °C (-58 °F) +400 °C (750 °F)

A.S A193-B16 A 194-7 -29 °C (-20 °F) +500 °C (930 °F)

S.S & DSS A193 B8M Class 1 A 194-8M -196 °C (-320 °F) +550 °C (1020 °F)

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Class 2 can be used for non-sour, but Class 1 is same cost and max temp. 500 °C
(930 °F).

Sour service (NACE MRO175-2002)

Valve Sour service
Material Bolt/Stud Nut Buy description temp limits
T min T max1
C.S A 193-B7M A 194-2HM -29 °C (-20 °F) +400 °C (750 °F)

LT C.S A 320-L7M A 194-7M -50 °C (-58 °F) +340 °C (645 °F)

S.S & DSS A193 B8M Class 2 A 194-8MA -196 °C (-320 °F) +450 °C (840 °F)

NOTES: 1. Maximum temperatures taken from ASME B31.3.

2. A194-4 has been discontinued and replaced with A194-7

5.8.5 Non-metallic seat and seal material

1. Table 13 and Table 14 shall be used for the selection and application of non-metallic
materials for use in MESC valves used in DEP piping classes.
Non-metallic materials, both thermoplastic and elastomeric, are commonly used in ball,
butterfly and plug valves. Thermoplastic materials can be found in seats, seals, lip-seals,
liners and sleeves. Elastomers are used for valve liners and O-rings.
2. For Explosive Decompression (ED) and valves which require ED resistant elastomer
seal material, refer to DEP 30.10.02.13-Gen.
Rationale: Valves in gas service class 600 and above, having elastomeric seals,
are susceptible to failure due to explosive decompression. ED occurs in both gas or
liquid services containing dissolved gases. High pressure gas which is also
absorbed in liquids permeates in to the elastomer. On depressurisation the gas
expands causing structural failure to elastomer seal material.

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Table 13 Selected thermoplastics

Material Min. lower Max. Max. seat Max. Max seal Application notes
design seat design seal design
temperature pressure temperature pressure temperature
class class
Virgin/filled/ Not suitable for
-200 °C 150 °C
modified 300 Styrene/Butadiene
(-330 °F) (300 °F) 200 °C service
PTFE 2500
(390 °F)
-200 °C 150 °C
Filled PTFE 600
(-330 °F) (300 °F)
-200 °C 120 °C 120 °C Use for low
PCTFE 1500 2500 temperature services
(-330 °F) (250 °F) (250 °F)

Benign services only

Nylon 12G -60 °C 120 °C 150 °C (i.e. Non-polar
1500 2500
or 612 (-75 °F) (250 °F) (300 °F) molecules, high
molecular weight >120)
-60 °C 150 °C Not resistant against
PEEK 1500 concentrated nitric acid,
(-75 °F) (300 °F) 230 °C
2500 sulphuric acid
-60 °C 120 °C (445 °F)
PEEK 2500
(-75 °F) (250 °F)

Table 14 Selected elastomers

Pressure Material Lower design Design Application notes

class temperature temperature

300 HNBR -29 °C +150 °C Not suitable for aromatic

Hydrogenated (-20 °F) (300 °F) hydrocarbons and phenol.
Nitrile
600-1500 HNBR -29 °C +150 °C Not suitable for aromatic
Hydrogenated (-20 °F) (300 °F) hydrocarbons and phenol.
Nitrile ED Restricted to 5 % H2S.
300 FKM Fluoro -29 °C +200 °C Not suitable for steam, hot
elastomer LT (-20 °F) (390 °F) water, methanol, amines,
strong alkalis, freons.
600-1500 FKM Fluoro -29 °C +200 °C Not suitable for steam, hot
elastomer ED (-20 °F) (390 °F) water, methanol, amines,
and LT strong alkalis, freons.
Restricted to 2 % H2S.
150 EPDM Ethylene -29 °C +130 °C For butterfly liners in water
Propylene*** (-20 °F) (265 °F) service, class 150 only.

5.8.6 Valve packing materials

1. A valve and its associated packing shall be considered as one system when being
subjected to the design validation test (DVT).
2. All valves shall be fitted with packing identical to the one used during DVT.

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3. For rising stems, the upper and lower packing shall be braided with either graphite or
carbon yarn.
Rationale: These packings have the ability to wipe the stem clean.
5.8.7 Valve selection criteria
5.8.7.1 General
1. Table 15 should be used to select a valve, taking the following into account:
a. piping / design requirements:
i. size;
ii. pressure rating;
iii. end connections;
b. process requirements:
i. fluid characteristics;
ii. maximum operating and design pressures;
iii. lower design temperature, maximum operating temperature and design
temperature; refer to Part II of DEP 01.00.01.30-Gen.
iv. flow capacity/resistance;
v. liquid or gas;
vi. clean service;
vii. suspended solids;
viii. fouling service;
ix. bi/uni-directional shut-off;
x. shut-off requirement (bubble tight, firesafe);
xi. Shell toxicity classification, per Part III of DEP 01.00.01.30-Gen.
xii. frequency of operation;
xiii. manual or actuated;
xiv. throttling requirement;
xv. total cost of ownership

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Table 15 Valve selection

Advantages and disadvantages of On - Off valves Non - return

valve types
Quarter turn valves Rising stem

Ball Butterfly Plug Gate Globe Check

Reduced bore Full bore Conc. Double OS Triple Y - Piston/ Dual
OS Reduced port Wedge Slab Expanding Straight Swing
type Ball plate

Soft Metal Soft Metal Soft Soft Metal M/M Sleeved Lubr M/M M/M M/M M/M M/M Metal Metal Metal

Shut Off capability clean service 1 2 1 2 1 2 2 2 1 1 2 1 1 2 2 3 3 3

Shut Off capability dirty service 10 2 10 2 2 10 3 2 2 1 3 1 1 3 3 3 3 3
Possible external leakpaths 2 2 4 4 2 3 3 4 4 4 4 4 4 4 4 2 5 1
Pressure drop/ flow restriction 3 3 1 1 2 3 4 4 4 4 2 1 1 10 4 8 3 5
Throttling capability 8 5 10 7 3 3 3 5 5 3 3 8 8 1 1 NA NA NA
Manual Operation

Effort to operate 1 3 2 4 2 3 4 6 4 8 7 8 8 6 6 NA NA NA
Speed of operation 1 2 2 4 1 2 3 4 2 4 10 10 10 8 8 NA NA NA
Expected life clean service 1 2 2 4 1 2 3 3 2 1 2 1 1 2 2 2 2 2
Expected life dirty service 8 2 10 2 2 4 3 4 4 2 3 2 1 3 2 3 2 2
Possibility of being pigged NP NP 1 1 NP NP NP NP NP NP 1 1 1 NP NP NP 1 NP
Possibility of creating surge pressure 6 6 8 8 10 8 8 2 5 3 2 1 1 2 2 2 4 2
Possibility of exc. cavity pressure liquid
service 8/3 * 3 8/3 * 3 NA NA NA 3 3 8 9 9 9 NA NA NA NA NA

Weight 3 3 6 6 1 1 2 5 5 5 10 9 10 8 8 8 8 2
Size 3 3 5 5 1 1 2 4 4 4 10 9 10 8 8 8 8 3

Pressure drop over an equivalent pipe length

65 65 8 8 25 55 60 60 60 60 13 8 8 135 80 135 50 75
based on the number of pipe diameters

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On-Off valves

Quarter turn valves Rising stem

Advantages and disadvantages of
valve types Ball Butterfly Plug Gate Globe

Reduced bore Full bore Conc. Double Triple Reduced port Wedge Slab Expand Straight Y-
OS OS ing Type
Soft Metal Soft Metal Soft Soft Metal M/M Sleeved Lubr M/M M/M M/M M/M M/M
Ease of pneumatic actuation 1 1 1 1 1 1 1 1 1 2 10 10 10 10 10
Ease of hydraulic operation 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2
Actuated

Ease of electric actuation 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2

Rapid operation 1 1 2 2 1 2 2 3 3 3 8 8 8 4 4
Power required to operate 1 2 2 4 1 2 3 5 4 6 8 8 8 7 7
Actuator weight 1 2 2 4 1 2 3 5 4 6 8 8 8 7 7
Actuator size 1 2 2 4 1 2 3 5 4 6 8 8 8 7 7

Rating: 1 is best and 10 worst.

* = Floating Ball/Trunnion Mounted
M/M = Metal-to-Metal
NP = Not Possible

NA = Not Applicable

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5.8.7.2 Valve emission tightness class requirements

1. Valves selected for services not listed in (Part I, 5.8.8) should be as listed in Table
16.
Table 16 Valves for services not listed in (Part I, 5.8.8)

Valves End * Size [DN] Size (NPS) ASME Valve standard MESC Emission
class SPE 77 class
rating
availability

min max mi max

n
Ball, floating, reduced bore, FL 15 - 250 ½ - 10 150 ISO 17292 110 BH AH
soft and metal seated
FL 15 - 100 ½ - 4 300 ISO 17292 110 BH AH

FL 15 - 50 ½ - 2 600-2500 ASME B16.34 110 BH AH

Ball, trunnion, reduced bore, FL 80 - 600 3 - 24 150-900 ISO 14313 / 130 BH AH

soft and metal seated API SPEC 6D

FL 80 - 400 3 - 16 1500 130 BH AH

FL 80 - 300 3 - 12 2500 130 BH AH

Ball, floating, full bore, soft and FL 15 - 150 ½ - 6 150 ISO 17292 110 BH AH
metal seated
FL 15 - 100 ½ - 4 300 ISO 17292 110 BH AH

FL 15 - 40 ½ - 1½ 600-2500 ASME B16.34 110 BH AH

Ball, trunnion, full bore, soft FL 50 - 600 2 - 24 150-900 ISO 14313/ 130 BH AH
and metal seated API SPEC 6D
FL 50 - 400 2 - 16 1500 130 BH AH
FL
50 - 300 2 - 12 2500 130 BH AH

Plug, sleeved FL 20 - 300 ¾ - 12 300 API 599 107 AH

Plug, lubricated FL 15 - 600 ½ - 24 150-1500 API 599 107 BH

Plug, lubricated FL 15 - 300 ½ - 12 2500 API 599 107 BH

Butterfly, double offset, soft FL 200 - 1200 8 - 48 150-300 API 609 cat B 134 BH AH
seated

Butterfly, triple offset, metal FL 200 - 1200 8 - 48 150-300 API 609 cat B 134 BH AH
seated
FL 200 - 600 8 - 24 600 API 609 cat B 134 BH AH

FL 750 - 1200 30 - 48 600 ASME B16.34 134 BH AH

FL 200 - 1200 8 - 48 900 ASME B16.34 134 BH AH

Gate, wedge type, bellows FL* 15 - 40 ½ - 1½ 150-1500 ISO 15761 / 101 AH

sealed, welded bonnet API 602

FL 15 - 40 ½ - 1½ 2500 ASME B16.34 101 AH

Gate, wedge type, bolted FL* 15 - 40 ½ - 1½ 150-1500 ISO 15761 / 101 BH

bonnet API 602

FL 15 - 40 ½ - 1½ 2500 ASME B16.34 101 BH

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*SW DN15-50 [NPS ½ - 2]), class 150-1500 optional

NOTES: The order of precedence for selecting an external standard is:
1. International Standards (ISO)
2. De facto international standards (API, ASME)
3. Regional standards (CEN standards)
4. Industry Standards (EEMUA, NACE)
5. National Standards (BS)

5.8.8 Additional service related requirements

1. For the requirements of other services which are not depicted in this SP like hydrogen,
oxygen, etc. refer to applicable sections in DEP 31.38.01.24.
5.8.8.1 Steam service
1. Refer to Table 17 for the selection of valves in steam service.
2. Check valves up to DN 40 (NPS 1 ½) in steam service shall have welded cover but
be flanged in order to allow routine removal for inspection and testing.
3. Check valves in critical applications in steam service (e.g., preventing back flow of
condensate, which can ultimately cause rupture of equipment) shall be flanged in
case of welded bonnet and fitted with a bolted bonnet or a pressure seal bonnet in
case of welded ends.
4. Check valves DN 50 to DN 600 (NPS 2 to NPS 24) in steam service should be swing
type since they generally have a higher Cv than dual plate check valves.
Rationale: This is important since velocities are generally high and maximum use
of the available energy is required.
a. For sizes ≥ DN 750 (NPS 30), dual plate check valves shall be used.
5. To prevent binding of wedge and seat, parallel slide gate valves should be used for
class 1500# and above for clean steam service and the valve intent for uni-
directional isolation purpose
Rationale: Gate valves in steam service will be subject to temperature changes;
any liquid trapped within the valve cavity could expand and cause excessive
cavity pressure. The welded seat and backseat are incorporated to minimise
possible erosion damage between seating elements and the body.

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Table 17 Valves for steam service

Valves End* Size [DN] Size [NPS] ASME Valve MESC Emission
class rating standard SPE 77 class
min max min max
Butterfly, triple FL 200 - 1200 8 - 48 150-300 API 609 cat B 134 No class
offset, metal
FL 200 - 1200 8 - 48 600 API 609 cat B 134 No class
seated
BW 200 - 1200 8 - 48 900 ASME B16.34 134 No class

Check, FL* 15 - 50 ½ - 2 150-1500 ISO 15761 / 101 No class

piston/ball type, API 602
welded cover FL 15 - 50 ½ - 2 2500 ASME B16.34 101 No class

Check, swing FL 80 - 600 3 - 24 150-300 BS 1868 104 No class

type, bolted
BW 80 - 600 3 - 24 600-1500 BS 1868 104 No class
cover
BW 80 - 300 3 - 12 2500 BS 1868 104 No class
Check, dual FL 750 - 1200 30 - 48 150-300 API 594 133 No class
plate type
FL 750 - 1050 30 - 42 600 API 594 133 No class
FL 1200 - 1200 48 - 48 600 ASME B16.34 133 No class
FL 750 - 1200 30 - 48 900 ASME B16.34 133 No class
Gate, wedge FL 80 - 600 3 - 24 150-300 ISO 10434 / 102 No class
type API 600
BW 80 - 600 3 - 24 600 102 No class
Gate, wedge BW 80 - 600 3 - 24 900-1500 ASME B16.34 160 No class
type, pressure
BW 80 - 300 3 - 24 2500 ASME B16.34 160 No class
seal bonnet
Globe straight, FL* 15 - 40 ½ - 1½ 150-1500 ISO 15761 / 101 No class
welded bonnet API 602

Globe, straight, FL 50 - 200 2 - 8 150-300 BS 1873 103 No class

bolted bonnet
BW 50 - 150 2 - 6 600 BS 1873 103 No class
Globe, straight, BW 80 - 150 3 - 6 900 ASME B16.34 101 No class
pressure seal
BW 80 - 100 3 - 4 1500-2500 ASME B16.34 101 No class
bonnet
BW 80 - 100 3 - 4 1500-2500 ASME B16.34 101 No class

*SW DN15-50 [NPS ½ - 2], Class 150-1500 optional.

5.8.8.2 Low temperature and cryogenic service

1. If gate, globe, ball or butterfly valves which normally operate with fluid temperatures
between -29 °C to -50 °C (-20 °F to -58 °F) need an extended bonnet, then the
bonnet, either integral or bolt-on, should ensure the distance from the largest valve
flange or body diameter can be lagged up to the valve top flange. This is not
applicable for valves operate between -29 to -50 occasionally.
The bonnet is designed to ensure the gland is clear of any required insulation.
Valves which by design can accept the -50 °C (-58 °F) lagging requirement
without requiring an extended bonnet are gate and globe valves >DN 40 (NPS
1½), and triple offset butterfly valves.
Valves which do need an extended bonnet to accept -50 °C (-58 °F) lagging are
ball valves, gate and globe valves <DN 50 (NPS 2), and double offset butterfly
valves.
2. The valve stem shall be positioned vertically up to a maximum angle of 30° from
vertical.

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3. Because moisture can affect the performance, low temperatures valves shall be
supplied dry, degreased and sealed.
Low temperature valves are subject to temperature changes, consequently, any
liquid trapped within the valve cavity can expand and cause excessive cavity
pressure
5.8.8.3 Heat transfer fluid
1. To reduce the potential number of leak paths, valves having butt weld ends should
be used.
Rationale: Heat transfer fluid is flammable. Also, many heat transfer fluids are
carcinogenic.
Since the fluid is generally clean, the need for maintenance is minimal.
2. Valves should also either be bellows sealed or have emission class AH.
a. Refer to DEP 20.05.50.10-Gen. for the installation requirements.
3. Valves for heat transfer fluid shall be selected in accordance with Table 18.
Table 18 Valves for heat transfer fluid service
Valves End* Size [DN] Size [NPS] ASME Valve MESC Emission
class standard SPE 77 class
Min Max Min Max rating

Butterfly, triple BW 200 - 900 8 - 36 300 ASME B16.34 134 AH

off set
BW 200 - 600 8 - 24 600 ASME B16.34 134 AH

Check, BW* 15 - 40 ½ - 1½ 300-600 ISO 15761 / 101 No class

piston/ball type, API 602
welded cover
Check, swing BW 50 - 600 2 - 24 300-600 BS 1868 104 AH
type, bolted
cover

Check, dual FL 750 - 1200 30 - 48 300 API 594 133 No class

plate type,
retainerless
Gate, wedge BW* 15 - 40 ½ - 1½ 300-600 ISO 15761 / 101 AH
type, bellows API 602
sealed, welded FL 15 - 15 ½ - ½ 300-600 101 AH
bonnet
Gate, wedge BW 50 - 600 2 - 24 300-600 ISO 10434 / 102 AH
type, bolted API 600
bonnet
Globe, straight, BW* 15 - 40 ½ - 1½ 300-600 ISO 15761 / 101 AH
bellows sealed, API 602
welded bonnet

Globe, straight, BW 50 - 200 2 - 8 300-600 BS 1873 103 AH

bolted bonnet

*SW DN15-50 [NPS ½ - 2], Class 300-600 optional.

5.8.8.4 Cooling and fire-fighting water

1. Valves selected for cooling and fire-fighting water shall be as shown in Table 19.
Valves for cooling and fire-fighting water are generally non-fire safe, low pressure and
low-cost valves.

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Table 19 Valves for cooling water service and fire-fighting water service

Valves End Size [DN] Size [NPS] ASME Valve standard MESC Emission
SPE 77 class
Min max Min max class
rating

Ball, floating, reduced bore, FL 25 - 50 ½ - 2 150 ISO 17292 110 No class

soft seated
TH 15 - 50 ½ - 2 800 ISO 17292 110 No class
Butterfly, concentric, lined FL 200 - 1200 8 - 48 150 API 609 cat A 106 No class
Check, piston/ball type, FL 25 - 50 1 - 2 150 ISO 15761 / 101 No class
bolted cover API 602

Check, piston/ball type, FL 25 - 50 1 - 2 150 BS 5154 se A 105 No class

screwed cover
TH 15 - 50 ½ - 2 PN 25 BS 5154 se A 105 No class
Check, dual plate type, FL 80 - 1200 3 - 48 150 API 594 133 No class
retainer less
WL 80 - 1200 3 - 48 150 API 594 133 No class
Gate, wedge type, screwed FL 25 - 50 1 - 2 150 EN 12288 105 No class
bonnet
TH 15 - 50 ½ - 2 PN 25 EN 12288 105 No class

5.8.9 Description and application of other types of valves

1. Refer to Table 20 for valves other than those described in (Part I, 5.8.8) which can
be considered for special process requirements.
Table 20 Valves for special process requirements

Term Definition
Through A conduit gate valve is a type of parallel slide valve and is used in
Conduit Gate pipelines where pigs are run through the piping to perform cleaning
Valve or Slab of built up deposits or debris. Another area of application is in
Gate Valve erosive service. When fully open the valve has a continuous smooth
full bore.
Diaphragm A diaphragm valve is a valve which incorporates a resilient
Valve diaphragm which provides tight shutoff and also isolates the body
from its operator. The operator consists of a plunger and hand wheel
assembly. Diaphragm valves are ideal for corrosive, slurry and
sanitary services. They are easily and inexpensively actuated with
pneumatic and electric actuators.
Diverter/mixing A valve having more than one inlet/outlet. It is important that diverter
Valve valves are designed with an external position indication system that
is "mistake-proof" or similar and can be verified visually even if fitted
with an actuator. It is also important that the valve cannot be
disassembled and re-assembled incorrectly ensuring that the valve
always indicates the true position.
Flush bottom A drain valve without a dead nozzle end, used on equipment.
Valve
Knife Gate A knife gate valve is a gate valve used for solids slicing.
Valve
Pinch Valve A pinch valve is particularly suited for applications of slurries or
liquids with large amounts of suspended solids. It seals by means of
one or more flexible elements, such as a rubber tube, that can be
pinched to shut off flow.

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Piston Type A shut-off valve which includes a pressure balanced piston

Valve eliminating pressure differentials across the piston. Stroke times are
subsequently very fast, with smaller actuators and a low mass of
moving parts in the valve. Fast stroke times are essential for high
integrity pressure "protection systems (HIPPS) and emergency
shutdown applications.”

6 INSULATION
1. For thermal insulation of piping (including for personnel protection) of piping, refer
DEP 30.46.00.31-Gen.
2. Refer to DEP 30.46.00.31-Gen. for the requirements for acoustic insulation.
3. 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.
4. If bolted joints with a design temperature above 400 °C (750 °F) are insulated, the
bolt stress (after relaxation) shall remain within the required seating stress of the
applied gasket type.

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PART II PIPING DESIGN REQUIREMENTS EXTRACTED FROM DEP 31.38.01.25

1. PIPE SIZING

1.1 GENERAL
1. Up to and including size DN 600 (NPS 24), the pipe sizes in Table 1 shall be used
with the following limitations:
a. due to their vulnerability to damage and their limited mechanical strength, sizes
DN 15 (NPS ½) and DN 20 (NPS ¾) should not be used except for short branch
connections;
b. nominal pipe size in pipe tracks shall not be less than DN 50 (NPS 2);
c. nominal pipe size in pipe racks shall not be less than DN 40 (NPS 1-½).
Table 1 Pipe sizes

DN 15 (NPS 1/2) DN 200 (NPS 8)

DN 20 (NPS 3/4) DN 250 (NPS 10)

DN 25 (NPS 1) DN 300 (NPS 12)

DN 40 (NPS 1-½) DN 350 (NPS 14)

DN 50 (NPS 2) DN 400 (NPS 16)

DN 80 (NPS 3) DN 450 (NPS 18)

DN 100 (NPS 4) DN 500 (NPS 20)

DN 150 (NPS 6) DN 600 (NPS 24)

2. For small bore piping, refer to SP-2390.

3. Unless economically justified otherwise, the range of pipe sizes above
DN 600 (NPS 24) shall be restricted to those in Table 2, to avoid the purchase of
many different sizes of pipe and fittings:
Table 2 Pipe sizes above DN 600 (NPS 24)

DN 750 (NPS 30) DN 1400 (NPS 56)

DN 900 (NPS 36) DN 1600 (NPS 64)

DN 1050 (NPS 42) DN 1800 (NPS 72)

DN 1200 (NPS 48) DN 2000 (NPS 80)

4. For Greenfield projects, refer to DEP 01.00.09.10‑Gen. for the identification of piping.
DEP 01.00.09.10‑Gen. excludes Brownfield projects and projects at existing sites
from its scope. Brownfield projects and existing site projects will use the existing
site conventions.
5. Refer to DEP 31.38.01.10‑Gen. for the requirements for the identification of piping
classes.

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1.2 PRELIMINARY PIPE SIZING

1.2.1 Two-phase flow
1. The length of piping subject to two-phase flow should be minimised e.g., by locating
the control valve close to the downstream equipment.
a. Refer to DEP 31.22.05.12‑Gen. for distance requirements for piping in separator
systems.

1.3 FINAL PIPE SIZING

1.3.1 Pressure surge analysis
1.3.1.1 Detailed surge analysis
1. When a piping system has been checked for surge potential by a full surge analysis
and transient analysis, the following shall be reported to the Principal for approval:
a. selection of surge scenarios and operational conditions;
b. final surge pressure analysis;
c. selection of the most severe surge;
d. selection of representative piping section;
e. final static and dynamic stress analysis with the consideration of unbalanced
forces.
1.3.1.2 Pressure gradient criterion
1. For instantaneous pressure increase (e.g., due to vapour collapse), the full pressure
increase shall be taken into account when calculating the axial load on the support.
2. The axial loads on the support due to vapour collapse, a pressure increase of up to
5 bar/s is calculated as given in Equation 24. The axial load shall be verified as the
load can be significant for a rapid pressure increase.

where:
F = axial load on the support
Δp = pressure change (output from software packages dedicated to
surge analysis)
A = pipe cross sectional area
3. If the Δp calculated in (1.3.1.2, Item 2) divided by the distance between directional
changes (e.g., elbows) is less than 5 mbar/m (0.02 psi/ft) for a steel piping system,
then a detailed analysis of the anchor support may be omitted.
1.3.2 Two phase flow
1. If slug or intermittent flow regimes cannot be totally eliminated, the piping system
shall be analysed and supported in accordance with SP-2390.
1.3.3 Installation requirements for flow instruments
1. Refer to DEP 32.31.00.32‑Gen. for installation requirements for flow instruments.
2. PIPING BASICS

2.1 DESIGN CONDITIONS

1. In situations where different design conditions exist in one piping system, different
piping classes, if used, shall be divided by a spec. break.

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a. Spec. breaks between piping classes of different materials shall be executed as

flanged connections.

2.2 PIPING LAYOUT

1. Where corrosion, erosion or plugging is expected in all-welded piping systems, this
shall be indicated on the line list.
a. All welded piping systems shall be designed and installed to allow for the
removal and replacement of the lines where corrosion, erosion or plugging is
expected.

2.3 INSTALLATION OF VALVES

2.3.1 Manifolds for control valves
1. Provisions shall be made for draining and/or depressurizing the control valve
manifold.
a. At least one drain valve shall be provided just upstream or downstream of the
control valve, depending of the physical lay-out.
b. Shut-off valves shall have a drain valve on the downstream side so that the
shut-off valve can be leak-tested.
2. Start-up strainers shall be provided upstream of control valves with labyrinth-type
low-noise trims.
2.3.2 Body cavity relief (pressure equalisation) provisions in valves
1. Refer to SP-2342 for body cavity relief requirements.

2.4 UTILITY, DRAIN AND VENT CONNECTIONS

2.4.1 Process and utility drain and vent connections
1. If required for operation/maintenance, valved drain connections shall be installed at
low points, and valved vent connections at high points in piping systems.
a. These connections shall be hooked up to a closed system.
2. The number of vent and drain connections with valves should be minimised.
3. For mechanical robustness a minimum branch pipe size of DN 20 (NPS ¾) shall be
used for process vent and drain connections, except for piping systems DN15 (NPS ½)
for which equal size drains/vents are required.

2.5 CONNECTIONS FOR MANUAL SAMPLING

1. Sample take-off connections shall not be located at dead ends of piping.
2. If bleed lines are installed, they shall be routed to a safe location.
3. From mechanical point of view the minimum branch pipe sizes in Table 3 shall be
used for sample connections:
Table 3 Minimum branch size for sample connections

Run Size Branch Size

DN 15 (NPS ½) DN 15 (NPS ½)

DN 20 through DN 50 (NPS ¾ through NPS 2) DN 20 (NPS ¾)

DN 80 through DN 300 (NPS 3 through NPS 12) DN 25 (NPS 1)

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Greater than DN 300 (Greater than NPS 12) DN 40 (NPS 1 ½)

2.6 PIPING SYSTEMS IN FREEZING CLIMATES

1. Dead legs should not be included in piping systems operating in freezing climates.

2.7 NOISE
1. To protect personnel from harmful noise, the following should be considered to
minimise noise in piping systems where the Mach number exceeds 0.3:
a. prevent abrupt changes in flow direction;
b. maintain a minimum distance between the upstream elbow and a control valve
of 10D, and a minimum distance between a control valve and the downstream
elbow of 20D;
c. use venturi (conical) type reducers to prevent abrupt changes in flow pattern;
d. use flow-straightening vanes to reduce large-scale turbulence;
e. increase wall thickness of pipe and fittings to attenuate sound and vibration;
f. use acoustic insulation or shielding around pipe and fittings to absorb or isolate
sound;
i. refer to DEP 31.46.00.31‑Gen. for requirements and recommendations on
the use of acoustic insulation to control noise;
g. use flow stream silencers.
Most noise in piping systems can be attributed to control valves. The sound
pressure level can be calculated for control valves from formulae contained in
IEC 60534-8-3 or data supplied by the various manufacturers. Valve trims can be
selected which minimise the noise levels.
3. PIPING ADJACENT TO EQUIPMENT

3.1 PUMP, AND COMPRESSOR PIPING

3.1.1 General
1. Cooling water pipes to pumps and compressors shall not be less than DN 20 (NPS
¾).
a. For detailed requirements on small bore piping connections, refer to PART I of
this SP and SP-2390.
2. Pipes DN 25 (NPS 1) or less shall have the take-off connection from the top of the
water main pipe in order to prevent plugging during operation.
3.1.2 Pumps
1. The liquid volume between the check valve and the pump discharge block valve
should be as small as practical.
a. A vent or drain valve should be provided in situations where the check valve is
not bolted directly to the isolation valve where trapped volume exceeds 50 litres
(15 gallons).
3.1.2.1 Srainers
1. In a vertical suction pipe, a Y-type strainer shall be permanently installed pointing
away from the pump.

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Rationale: This is a Human Factors Engineering requirement to enable optimal

access for maintenance.
2. In horizontal suction pipes, Y-type or bucket-type strainers may be used.
3. Bucket-type strainers should be used for suction pipes DN 450 (NPS 18) and larger.
Rationale: This is a Human Factors Engineering requirement to enable optimal
access for maintenance
4. The installation of a Y-type strainer in the suction of double-suction pumps shall not
disturb an even flow to the suction nozzle of the pump.
5. The use of strainers other than Y-type and bucket type strainers shall be subject to
approval by the Principal.
3.1.2.2 Venting/flushing
1. The vent pipe for cryogenic service shall meet the following criteria:
a. follow the shortest practical route to the suction drum;
b. have no pockets;
c. be large enough to allow the liquid level to equalise with the level in the suction
drum without creating vapour pockets in the pipe.
3.1.2.3 Suction piping of centrifugal pumps
1. Eccentric reducers shall be used for pipe diameter changes in horizontal suction
pipes.
a. For slurry services, eccentric reducers shall be installed bottom flat to avoid
accumulation of solids.
b. For all other services, eccentric reducers shall be installed top flat to avoid
vapour pockets.
2. In vertical pipes, eccentric or concentric reducers may be used.
3.1.3 Compressors
1. Screens and filters shall be reinforced to prevent their collapse or failure and
subsequent entry of debris into the compressor, see Standard Drawing S 38.041.
2. Temporary start-up strainers shall be as follows:
a. 200 mesh start-up screen for reciprocating compressors;
b. 40 mesh to 60 mesh screen for centrifugal compressors.

3.2 PRESSURE VESSEL PIPING

3.2.1 General considerations
1. Block valves should be located directly against the vessel nozzles.
4. UTILITY PIPING

4.1 COOLING WATER

1. Cooling water return risers at cooling towers shall have a full-size vent.
a. Vent shall extend above the highest tower deck for a distance as required by
distribution system pressure drop with one cell out of service and full design flow
over the remaining cells.
2. Main distribution pipes shall have facilities at the lowest points to permit complete
draining within 6 hours.
a. Venting facilities shall be provided to relieve air pockets.

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3. If economical, concrete pipe or channels may be used for atmospheric pressure

cooling water return pipes.

4.2 STEAM
1. Steam pipes shall have valved isolation at the boundary of the process unit.
a. Flanges shall be provided at these locations to allow for spading (spades or
spectacle blinds) to isolate the steam systems during maintenance of the unit.
2. Pipes to consumers shall branch off from the top of the steam supply pipe in order to
prevent steam condensate from going to the steam consumers.
3. Exhaust steam pipes shall enter at the top of the exhaust collecting pipe to prevent
steam condensate from running back into neighbouring steam consumers.

4.3 UTILITY HOSE STATIONS

The Principal will provide the requirements for the utilities at utility hose stations.
1. Utility pipes to the manifolds shall branch off from supply headers which cannot
contain contamination, e.g., due to leaking heat exchangers.
2. Utility station requirement and arrangement shall be subject to review and approval
by the Principal.
3. Utility stations should preferably be provided at the following locations:
a. Tool air, breathing air and nitrogen outlet connections should have dedicated
hoses and fittings in order to prevent in order to prevent cross connection.
b. Utility station outlet connections should have identification markings.

5. PIPING COMPONENTS

5.1 PIPING AND EQUIPMENT ISOLATION

5.1.1 Standard isolation
5.1.1.1 General
Valve isolation is the standard way of separating systems. This type of isolation is
provided in all cases where no specific tightness requirements are justified and where
planned use of the isolation can be foreseen during the design stage. Valve isolation is
only a step in achieving positive isolation, see (8.2.3).
1. The take off point of the bleed should be at the top of the line, especially in fouling
systems.
a. Alternatively, the bleed may be installed at the bottom of the line provided that a
gland sealed rod out device can be attached to the drain valve.
Rationale: Where a bleed valve is provided, the purpose of the bleed is to verify
that the isolation valve has seated and tightness has been reached before
spading, and to provide a means of draining or depressurising the volume between
the spade/blind and isolation valve.
5.1.1.2 Integral double-block-and-bleed valves
1. Double-seated valves with one-piece closure members (e.g., gate, ball and plug
valves) and a body bleed shall not be considered as proper double-block-and-bleed
valves since a common mode failure might make both isolations ineffective.

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a. They may be used to give a more reliable isolation than single-seated valves, or
to prevent product contamination (e.g., in oil movement operations).
5.1.2 Positive isolation
5.1.2.1 General
1. The use of quick-acting blinds or line blind valves (e.g., "Hammer") for frequent pipe
blinding shall comply with the following:
a. all parts of the quick acting blind shall be suitable for the fluid medium;
b. operating these blinds can expose large openings to atmosphere, the quick
acting blind shall be installed between isolation valves, with vents and drains on
both sides of the quick acting blind;
c. quick-acting blinds shall not be used in following fluid services:
i. flashing fluid services.
ii. fouling /scaling fluid services.

5.2 VALVES
1. Tight Shut Off (TSO) valves shall be provided with facilities for testing of seat
tightness while on-stream

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APPENDIX A ADDITIONAL REQUIREMENTS FOR SPECIFIC SERVICES

This appendix specifies design, fabrication, inspection and testing requirements for
specific process services that supplement the requirements of DEP 30.10.60.18-Gen.,
DEP 30.10.60.32-Gen., and DEP 31.38.01.31-Gen.

B.2 SULPHURIC ACID SERVICE

1. The requirements in (B.2.1) through (B.2.3) shall be applied for piping systems in
sulphuric acid service (with concentration > 65 wt%) designed with a corrosion
allowance more than 1 mm (1/16 in).
B.2.1 Design
1. For sulphuric acid service, piping shall be sized for a nominal velocity of 0.75 m/s
(2.5 ft/s) or less in straight sections and designed to avoid sudden changes in flow
direction, turbulence and extreme changes in velocity.
2. For sulphuric acid service, the use of pipe bends and elbows should be restricted as
far as possible.
3. For sulphuric acid service, pipe bends shall comply with one of the following:
a. have a radius of at least 5 D (where D is the nominal pipe diameter);
b. use two 45-degree LR elbows with at least 10 D straight section between the
elbows;
4. For sulphuric acid service, the length of lined carbon steel spool pieces shall be at
least 20 D.
5. For sulphuric acid service with equal branches, factory-made wrought buttwelding
tees shall be used.
6. For sulphuric acid service with unequal branches other than instrument
connections/drains/vents, 45° laterals, Y-type or sweep-in junctions shall be used.
7. For sulphuric acid service, fabricated pipe to pipe connections, or fabricated fittings
shall not be used.
8. For sulphuric acid service, if reducers are used then, they shall reduce not more than
one pipe size and be concentric in vertical pipe runs.
Refer to Section 2.1 of DEP 31.38.01.25-Gen. for acceptable pipe sizes.
9. For sulphuric acid service in a horizontal pipe where a concentric reducer could
inhibit drainage (i.e., where the reduced diameter is in the direction of drainage), an
eccentric reducer (bottom flat) with the reduced bore matching the connecting bore
shall be used.
10. For sulphuric acid service, spool pieces of fully corrosion-resistant unlined material
or carbon steel lined with fully-resistant material (e.g. PTFE, piping class 18160)
shall be used in the following situations:
a. if pipe bends have a radius of less than 5 D; or
b. if reducers with reductions of more than one pipe size are required; or
c. if velocities locally exceed 0.75 m/s (2.5 ft/s).
11. For all piping systems in sulphuric acid service (for all concentrations), horizontal
pipes shall be self-draining, having a slope of at least 1:100.
B.2.2 Fabrication
1. For sulphuric acid service, GTAW shall be used for piping DN 50 (NPS 2) and
smaller and for the root pass of larger size piping.

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B.2.3 Identification
1. Piping shall be clearly marked "SULPHURIC ACID SERVICE" after prefabrication,
either by painting or by applying adhesive tape, to indicate that it is for sulphuric acid
service.
2. For sulphuric acid service, the piping class number and the pipe designation shall be
painted on each part.

B.6 WET H2S/SOUR SERVICE

Types of material damage that can occur as a result of aqueous hydrogen charging
include sulphide stress corrosion (SSC) cracking of hard weldments and
microstuctures, hydrogen blistering, hydrogen induced cracking (HIC) and stress-
oriented hydrogen induced cracking (SOHIC).
SSC is the occurrence of brittle fracture under the combined action of stress and H2S
dissolved in water. Hydrogen blistering, HIC and SOHIC are the occurrence of lamellar
cracking, often connected or (in the case of HIC and SOHIC) propagating in a stepwise
manner.
Hydrogen blistering, HIC and SOHIC are most commonly associated with plate or strip
product forms and are much less common in seamless pipe or wrought products
(although HIC has been experienced in seamless products having a poor
microstructure due to incorrect chemistry or heat treatment). Furthermore, in some
high pH refinery process streams a form of alkaline stress corrosion cracking (ASCC)
could occur. ASCC is normally mitigated by applying PWHT to welds and cold formed
products.
B.6.1 Designations of wet H2S/sour service and material requirements
Wet H2S service is the term commonly used for refinery and gas plant environments
containing water and H2S (plus other corrosives or contaminants), whereas "Sour"
service is the term traditionally used for similar environments in exploration and
production services. However, the chemical composition of the environments is often
quite different, and these differences are described in (B.6.2) and (B.6.3). For (B.6.3),
refer to Appendix-D as it is SHALL (PS) requirement.
Although the definitions of these services differ between upstream and downstream,
the approach to materials selection and testing has been standardised and is
described in the piping classes specifically designated for “Sour" service and in the
referenced MESC piping specifications. In terms of material specifications, Exploration
and Production "Sour" service is equivalent to Refinery/Gas Plant "High Sour" service.
B.6.2 "Wet H2S" service (refinery/gas plant applications)
1. Refer to DEP 30.10.02.17-Gen. for the requirements for piping systems subjected to
wet H2S service in refinery/gas plant applications.

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APPENDIX B PIPING SYSTEM DEVELOPMENT BASED ON CONSTRUCTION CLASSES

D.1 INTRODUCTION
This appendix specifies the basic design framework for development of “fit-for-
purpose” piping systems, and also ensures that selective attention is applied to critical
aspects of design development where needed to prevent costly omissions and design
effort recycle.
1. Piping system design development shall be in accordance with the following
framework
a. Step-1: Identify the hazards for the piping system based on pressure,
temperature and the contained fluid; refer to (D.2.2);
b. Step-2: Based on fluid categorization and associated hazards, construction
class ranking shall be determined; refer to (D.2.3) and (D.2.4);
c. Step-3: Piping design requirements shall be based on the construction class;
refer to (D.3).
The concept of this framework is based on the following:
• The main function of pressure containing envelope piping system is to
reliably hold pressure and prevent leaks/loss of containment;
• Different piping systems represent different operational risks and/or
threats to successful project execution; and,
• There will always be limited resources to address all possible concerns
and threats in a completely exhaustive manner.

D.2 HAZARD ANALYSIS AND APPLICATION OF CONSTRUCTION CLASSES

D.2.1 General
The application of this guideline and construction class determination follows the
conclusions of a hazard analysis. The main objective of hazard analysis is to recognize
process hazards and assist with establishing appropriate construction controls
consistent with the level of risk inherent within the process.
D.2.2 Step-1: Identifying hazards for piping systems and categorization of fluids
D.2.2.1 General
The main objective of identifying hazards is to assist with establishing appropriate
construction classes consistent with the level of risk inherent within the process.
D.2.2.2 Process fluid-related effects
1. For the purpose of this hazard analysis, either explosion potential or fire potential
shall be used.
Rationale: Process fluid related effects include health potential and explosion
potential/fire damage potential.
Health potential:
A health potential exists in process fluids with very toxic - acute and
very toxic - chronic toxicity that could lead to a fatality either in the short
or in the longer term,
Very toxic (Part I, 1.3.2) substances are those substances that are very
hazardous for the environment or human health. Process streams that
contain very toxic substances require a specific design to limit
emissions and thereby potential exposure.
Fire damage potential/explosion potential:
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Explosion potential is defined as the presence of process fluids which

can form gases under atmospheric conditions in quantities that can lead
to formation of explosive mixtures of sufficient damaging potential.
Fire damage potential is defined as the presence of process fluids with
flash point (FP) below their operating temperature in sufficient quantities
to cause major damage if ignition occurs after loss of containment.
DEP 31.38.01.84-Gen. gives details of explosive/flammability
classification for each fluid associated with piping classes. Fluids with
flammability classification “F/F+” are considered to be fire potential
fluids. Similarly, fluids with explosive classification “E” are considered to
explosion potential fluids.
D.2.2.3 Operation-related effects
Operation related effects include design conditions, like design pressure and “elevated
temperature service and severe cyclic conditions” as defined in clause 300.2 of
ASME B31.3.
1. For definition of design conditions, refer to Part II of DEP 01.00.01.30-Gen.
Design pressure has been classified into two sections:
• Flange ASME Class ratings - 150, 300, 600 and 900;
• Flange ASME ratings Classes - 1500 and above.
For severe cyclic service, conditions applying to specific piping components or
joints in which SE computed in accordance with ASME B31.3, para. 319.4.4
exceeds 0.8SA (as defined in ASME B31.3, para. 302.3.5), and the equivalent
number of cycles (N in ASME B31.3, para. 302.3.5) exceeds 7000; or other
conditions that the designer determines will produce an equivalent effect.
For elevated temperature service, a fluid service in which the piping metal
temperature has a design or sustained operating temperature equal to or greater
than Tcr as defined in Table 302.3.5 of ASME B31.3.
2. Based on the hazards for piping systems, fluids shall be classified into four
categories as follows:
a. Fluids with design pressure 1035 KPa (150 psi) or less with design temperature
between -29 °C and 186 °C (-20 °F and 365 °F) and the fluid is non-flammable
and “not very toxic” (per Part III of DEP 01.00.01.30-Gen.) are designated as
Category “D”.
b. Fluids with pressure in excess of that allowed by the ASME rating Class 2500
for the specified design temperature and material group are designated as
Category K.
c. All gaseous or flashing fluids classified as “very toxic acute” in accordance to
Part III of DEP 01.00.01.30-Gen., and all Hydrofluoric acid services, are
designated as “Category M” (therefore substances like benzene or liquid acids
and caustic fluids are excluded from this category).
d. Fluids other than “Category K”, “Category M” and “Category D” are designated
as “Category N”.
D.2.3 Step-2: Assigning construction classes
D.2.3.1 General
1. Construction classes shall be used during detailed design development and as an
input into operation and inspection procedures for piping systems.
Rationale: The construction class is a summary expression of rated hazards and
concerns affecting safety of a particular piping system or group of piping systems

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The term construction class used in this Appendix is a different concept than the
design class used at the early stages of project development. Design class
determines an overall project approach such as plant layout, equipment
capacities, sparing, sizing, whereas construction classes focus on the integrity of
design.
2. Based on fluid categorization, selection of materials and associated hazards as
explained under Step-1, construction classes shall be assigned as follows:
a. Class-1 (sub-classifications as Class 1a, Class 1b) (D.2.3.2);
b. Class-2 (sub-classification as Class 2a,) (D.2.3.3);
c. Class-3 (sub-classifications as Class 3c, Class 3d) (D.2.3.4);
d. Class-4 (sub-classification as Class 4d) (D.2.3.5).
D.2.3.2 Class-1 (sub-classifications as Class 1a, Class 1b)
This construction class covers all very toxic (Part I, 1.3.2) piping systems (except
sulphuric acid, hydrochloric acid, acetic acid, sodium hypochlorite, caustic soda) and
also piping systems with fluid “Category K”. These systems are subjected to special
design and quality control attention as mentioned in the mitigation plan.
1. The quality framework shall address additional surveillance level for procurement
and construction phases to assure that all design parameters are met for these
piping systems.
D.2.3.3 Class-2 (sub-classification- as Class 2a,)
This construction class covers all normal fluid piping systems (including sulphuric acid,
hydrochloric acid, acetic acid, sodium hypochlorite, caustic soda) with flange ratings –
1500, 2500 and using “including Cr-Mo steels, stainless steel, and nickel base alloys”
as base material and also for Category N piping systems in elevated temperature
service / cryogenic service
1. Class 2 systems shall be designed and quality control attention as mentioned in the
mitigation plan.
D.2.3.4 Class-3 (sub-classifications as Class 3c, Class 3d)
This construction class covers all normal fluid piping systems (including sulphuric acid,
hydrochloric acid, acetic acid, sodium hypochlorite, caustic soda) with the following:
• Flange ASME Class ratings – 1500, 2500 and using “Carbon steel and C-Mn
steels with a minimum specified tensile strength ≤ 500 N/mm² (73 ksi)” as base
material.
• Flange ASME Class ratings – 150 to 900.
1. Class 3 systems shall be designed and quality-assured as mentioned in the
mitigation plan.
D.2.3.5 Class-4 (sub-classification as Class 4d)
Class 4 construction class is a “basic code design” with minimum or no special
requirements. This construction class is typically used for utilities (restricted to a
maximum design pressure of 1035 KPa (150 psi).
1. Under Class 4, “lower than usual” surveillance levels and pre-qualification efforts
may be applied, if approved, and known Manufacturers are selected.
2. Higher degree of reliance may be placed on the Supplier’s quality assurance (QA)
systems.

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APPENDIX C DEVIATIONS APPROVAL WITH APPLICABLE MITIGATIONS

1- Annulus Vent for PE Lined Piping

Annulus vent connection has to be treated as prover connection, which shall meet the
requirements as per SP-2373 The provision should be with single isolation valve.

2- Fluid Category Classification for “Very Toxic” Service

a. Very Toxic Fluid Streams with less than 2500# rating

All fluid streams classified as “Very Toxic” as per fluid toxicity classification and less than
2500# rating will be considered as Category –N.
PDO has proven past record of using piping systems with fluid Category –N for Very
Toxic Streams with H2S content of more than 500ppm. A detailed evaluation based on
ASME 31.3, Fig M300 selection chart, shows that this service falls under base code
(chapter 1-VI), which is for fluid category –N service. The relevant chart from ASME B
31.3 is pasted below.

However, in view of the criticality of these fluid services and piping, the following
additional measures shall be implemented as a precautionary safeguard for these piping
carrying “Very Toxic” fluid streams:
i. The size of branch shall be of minimum of 2”(inch).
ii. The >= DN 100 (NPS 4) for flange ASME Class ratings 300 and above shall be
qualified Flange leakage calculation.
iii. Full hydro test and Sensitive leakage test are mandatory.

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Construction class selection, which governs the NDT requirements and inspection levels,
shall be as per the following table.

b.Very Toxic Fluid Streams with 10000# rating

Fluid streams classified as “Very Toxic” as per fluid toxicity classification and of 10000#
rating will be considered as Category –K and will be designed as per ASME B 31.3
Chapter IX rules and other DEP/SP requirements for Category K fluid streams.

3- Buried Piping with interface flange joint without pit

In case of interface flange joint of HC piping DSS with GRE pipeline installed buried
without pit, all the below criteria shall be compiled:
1. Suitable material coating & wrapping requirement shall be addressed and applied in
the MSR.
2. Coating and soil back filling is required as per applicable standards & procedures.
3. Flange joint shall undergo gross leakage test (N2 @ 3-5 barg) followed by in-service
leak test as covered under SP-1208 and cross referred therein to SP-2290.
4. Flange joint will be externally coated only after successful In-service leak testing.
5. All flange management activities shall be witnessed and qualified by the PDO quality
inspector.
6. Use portable Gas monitor to detect HC near the interface area during in-service leak
test.
7. Provide Inspection program for the buried line & flange.

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4- Isolation Valves on the Tank Nozzles

For the tanks where isolation valves cannot be located directly on the tank shell side
nozzles due to lack of space to approach, accessibility, operability, pipe supporting and
othe reasons , the following shall be complied for locating the isolation valve away from
the tank Nozzle:
a. The piping between the nozzle and the first isolation shall be fully rated as per the piping
class.
b. Eliminating small bore branches (less than 2") which are prone to failure.
c. 100% RT for weld joints.
d. Flange management as per SP-2020 which is normal part of construction SOW.

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APPENDIX D SHALL [PS] STATEMENT FOR DEP 31.38.01.24 (VER.44) AND DEP 31.38.01.25 (VER.45)

Appendix D-
MANDATORY SHALL (PS) REQUIREMENTS.xlsx

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APPENDIX E: SKETCH OF ALUMINIUM CLADDING FOR CRA PIPE PROTECTION FROM MOLTEN ZINC (Ref. Part-I, clause 1.3.2 point 18)

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