Private Residence on Plot #9, Sec.

E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract

SECTION 43 00 00 LIQUEFIED PETROLEUM GAS (LPG)

REVISION HISTORY

0 1 0 Rev

Sep. 2011 May. 2011 Feb. 2011 Date

Issued for Tender Detailed Design Submission Preliminary Submission Description of revision

AK AK AK Prepared by

AK AK AK Checked by

HM HM

Authorized by

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract

SECTION 43 00 00 Liquefied Petroleum Gas (LPG) INDEX

PART 1 - GENERAL.......................................................................................................................................... 2 1.1 1.2 1.3 1.4 1.5 REFERENCE ................................................................................................................................. 2 DESCRIPTION OF WORK............................................................................................................ 2 QUALITY ASSURANCE .............................................................................................................. 2 SUBMITTALS ............................................................................................................................... 2 PRODUCT DELIVERY, STORAGE AND HANDLING.............................................................. 3

PART 2 - PRODUCTS ...................................................................................................................................... 3 2.1 2.2 2.3 2.4 LPG STORAGE TANK ................................................................................................................. 3 CONTAINER APPURTENANCES .............................................................................................. 5 PIPING, FITTINGS AND VALVES ............................................................................................. 8 GAS LEAK DETECTION SYSTEM............................................................................................. 9

PART 3 - EXECUTION ................................................................................................................................... 12 3.1 3.2 GENERAL................................................................................................................................... 12 TESTING AND COMMISSIONING .......................................................................................... 12

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract PART 1 - GENERAL 1.1 REFERENCE Conform to General Requirements for Mechanical Services. 1.2 1.2.1 1.2.2 1.2.3 DESCRIPTION OF WORK Furnish and install LPG installation as indicated on drawings This section specifies the requirements for the LPG components. Provide electrical work related to this section and complying with requirements of electrical devision. QUALITY ASSURANCE Manufacturers Qualifications: Firms regularly engaged in manufacture of LPG storage tanks and distributory components with characteristics, sizes and capacities required, whose products have been in satisfactory use in similar service for not less than 5 years. Professional CONSULTANT Certification: Approval/compliance certification shall be submitted from the following agencies to certify that the professional CONSULTANT is legally qualified to practice in the jurisdiction where project is located and who is experienced in providing consultation services of the kind indicated: a) b) c) d) 1.4 1.4.1 Local Civil Defense Authority (Abu Dhabi Civil Defense) ADNOC FOD NFPA 58 British Standards Code of Practice LPG 1TA.

1.3 1.3.1

1.3.2

SUBMITTALS Product Data: Submit manufacturers product specifications, installation and startup instructions. Shop Drawings: Submit shop drawings indicating tank locations, weight loadings, required clearances and LPG pipe work distribution complete with valves, fittings and controls. Submit the following elements of the LPG Distribution and Storage System: Pipe and fittings, valves, dielectic unions, strainers, meters, instruments, storage tanks, leak detection and alarm system. Steel Pipes: Statement from manufacturer on his letterhead that the pipe furnished meets the international standards specified and contained in this section.. Subcontractor shall submit the Mill certification papers, also known as material test reports, for the pipe furnished for this project, in English. Code numbers on these papers to match the code numbers stenciled on the pipe. Chemical analysis indicated on the mill certification papers to meet or exceed the requirements of the referenced International Standard specification.

1.4.2

1.4.3

1.4.4

1.4.5

Certificates to be provided for welding procedure with qualification of welders including list of welders names and symbols. Wiring Diagrams : Submit manufacturers electrical requirements for power supply wiring. Submit manufacturers ladder-type wiring diagrams for interlock and control wiring. Clearly differentiate between portions of wiring that are factory installed and portions to be fieldBureau of Excellence in Architecture & Design www.bead-architects.com Revision (0) Project :A10 - 18 September. 2011

1.4.6

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract installed.

1.4.7

Maintenance Data: Submit maintenance data and parts lists for each component control and accessory, including trouble shooting maintenance guide. Include this data, product data, shop drawings and wiring diagrams in maintenance manual. List of spare parts for two years operation and maintenance of complete system. PRODUCT DELIVERY, STORAGE AND HANDLING Handle LPG System components carefully to prevent damage, breaking, denting and scoring. Do not install damaged components, replace with new. Store LPG system components in clean dry place. Protect from weather, dirt, fumes, water, construction debris, and physical damage.

1.4.8 1.5 1.5.1

1.5.2

PART 2 - PRODUCTS 2.1 2.1.1 LPG STORAGE TANK General a) This section includes design, fabrication and marking provisions for containers, and features normally associated with container fabrication, such as container openings, appurtenances required for these openings to make the containers gastight entities, physical damage protecting devices, and container supports attached to, or furnished with the container by the manufacturer. Containers shall comply with 2.1.1 (c) or shall be designed, fabricated, tested and marked using criteria which incorporate an investigation to determine that it is safe and suitable for the proposed service, is recommended for that service by the manufacturer and is acceptable to the authority having jurisdiction Containers shall be designed, fabricated, tested and marked (or stamped) in accordance with the Regulations of the U.S. Department of Transportation (DOT), the "Rules for the Construction of Unfired Pressure Vessels", Section VIII, Division 1, ASME Boiler and Pressure Vessel Code, or the API-ASME Code for Unfired Pressure Vessels for Petroleum Liquids and Gases applicable at the date of manufacture. Containers showing serious denting, bulging, gouging or excessive corrosion shall be removed from service. Repair or alteration of containers shall comply with the Regulations, Rules or Code under which the container was fabricated. Other welding is permitted only on saddle plates, lugs or brackets attached to the container by the container manufacturer. Heating or cooling coils shall not be installed inside storage containers. Containers shall be painted either with yellow colour using a paint made with a medium yellow chrome pigment or white colour with a titanium oxide pigment.

b)

c)

d)

e)

f) g)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract

2.1.2

Container Design or Service Pressure a) The minimum design, or service, pressure of DOT specification containers shall be in accordance with the appropriate DOT regulations. The minimum design pressure for ASME containers shall be in accordance with Table 2.1.2. Containers shall be designed to be self-supporting without the use of guy wires and shall satisfy proper design criteria taking into account wind, seismic (earth-quake) forces, and hydrostatic test loads. Design pressure (see Table 2.1.2) shall be interpreted as the pressure at the top head with allowance made for increased pressure on lower shell sections and bottom head due to the static pressure of the product. Table 2.1.2 For Gases with Vapor Pressure in psig Minimum Design Pressure in psig (MPa (MPa gauge) at 100 Deg.F (37.8 Deg.C) gauge) ASME Code not to Exceed Section VIII, Division 1, 1980 Edition (Note 1) 80 (0.6) 100 (0.7) 100 (0.7) 125 (0.9) 125 (0.9) 156 (1.1) 150 (1.0) 187 (1.3) 175 (1.2) 219 (1.5) 215 (1.5) 250 (1.7) 215 (1.5) 312.5 (2.2) e) Wind loading on containers shall be based on wind pressures on the projected area at various height zones above ground in accordance with Design Loads for Buildings and other structures, ANSI A58.1. Wind speeds shall be based on a Mean Occurrence Interval of 100 years.

b)

c)

d)

2.1.3

Container Openings a) Containers shall be equipped with openings suitable for the service in which the container is to be used. Such openings may be either in the container proper or in the manhole cover, or part in one and part in the other. Connections for pressure relief valves shall be located and installed in such a way as to have direct communication with the vapor space, whether the container is in storage or in use. If located in a well inside the container with piping to the vapor space, the design of the well and piping shall permit sufficient pressure relief valve relieving capacity. If located in a protecting enclosure, design shall be such as to permit this enclosure to be protected against corrosion and to permit inspection. Containers shall be fabricated so that they can be equipped with a fixed liquid level gauge(s) capable of indicating the maximum permitted filling level(s).

b)

c)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract 2.1.4. Container Markings a) Containers shall be marked as provided in the Regulations, Rules or Code under which they are fabricated and in accordance with 2.1.4 (b) and 2.1.4 (c). When LP Gas and one or more other compressed gases are to be stored or used in the same area, the containers shall be marked "Flammable" and either "LP-Gas," "Propane" or "Butane." ASME containers shall be marked as noted hereunder. The markings specified shall be on a metal nameplate attached to the container, so located as to remain visible after the container is installed. The nameplate shall be attached in such a way that corrosion of the nameplate or the container will be minimized: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) 2.2 2.2.1 Service for which the container is designed; i.e. underground, above ground, or both. Name and address of container supplier or trade name of container. Water capacity of container in lb or U.S. Gallons. Design pressure in psig. The wording "This container shall not contain a product having a vapor pressure in excess of- psig at 100 deg.F". Tare weight of container fitted for service for containers to be filled by weight. Outside surface area in sq. ft. Year of manufacture. Shell thickness Head thickness OL - OD HD Manufacturer's Serial Number. ASME Code Symbol.

b)

c)

CONTAINER APPURTENANCES General a) This section includes fabrication and performance provisions for container appurtenances, such as pressure relief devices, container shut off valves, backflow check valves, plugs, liquid level gauges and pressure gauges connected directly into the container openings. Container appurtenances shall be fabricated of materials suitable for LP-Gas service and resistant to the action of LP-Gas under service conditions The following shall also apply: i) Pressure containing metal parts of appurtenances, shall have a minimum melting point of 1500 deg. F (816 deg.C) such as steel, ductile (nodular) iron, malleable iron or brass. Ductile iron shall meet the requirements of ASTM A 395 or equivalent and malleable iron the requirements of ASTM A 47 or equivalent. Cast iron shall not be used for parts such as bonnets or bodies.

b)

ii) c)

Container appurtenances shall have a rated working pressure of at least 250 psig (1.7 MPa gauge). Gaskets used to retain LP-Gas in containers shall be resistant to the action of LP Gas. They shall be made of metal or other suitable material confined in metal having a melting point over 1500 deg. F (816 deg.C) or shall be protected against fire exposure, except that aluminium O-rings and spiral wound metal gaskets are acceptable. When a
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d)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract flange is opened, the gasket shall be replaced.

e)

Each tank shall be equipped with at least: i) ii) iii) iv) A continuous liquid level monitor with remote indicator. A fixed maximum level gauge eg. of the vent-valve type, with 1.5 mm or less orifice diameter. A shut-off device for each connection of the outlet pipes for both gaseous and liquid phases and in addition an excess flow valve for the liquid phase. A safety relief valve, it may be of the internal or external type. The minimum rate of discharge shall be calculated to the formula: Discharge rate = 10.6552 S0.82m3/Min air at 1 atm. S = Total exterior surface in m2.

2.2.2.

Pressure Relief Devices a) Containers shall be equipped with one or more pressure relief devices which shall be designed to relieve vapor. DOT containers shall be equipped with pressure relief valves or fusible plug devices as required by DOT Regulations. ASME containers for LP-Gas shall be equipped with direct spring-loaded pressure relief valves conforming to applicable requirements of the Standard on Safety Relief Valves for Anhydrous Ammonia and LP Gas, UL 132; Standards for Safety Relief Valves of the Factory Mutual Research Corporation; or other equivalent pressure relief valve standards. The start to leak setting of such pressure relief valves, with relation to the design pressure of the container shall be in accordance with Table 2.2.2. Table 2.2.2 Containers All ASME Codes prior to 1949 Edition and the 1949 Edition paragraphs U-68 and U-69. ASME Code, 1949 Edition Paragraphs U-200 and U-201 and all ASME Codes later than 1949

b)

c)

Minimum 110% 100%

Maximum 125% 100%

Manufacturers of pressure relief valves are allowed a plus tolerance not exceeding 10 percent of the set pressure marked on the valve. d) Pressure relief valves for ASME containers shall also comply with the following: i) Pressure relief valves shall be of sufficient individual or aggregate capacity as to provide the relieving capacity for the container on which they are installed and to relieve at not less than the rate indicated before the pressure is in excess of 120 percent of the maximum (not including the 10 percent referred to in the footnote of Table 2.2.2) permitted start-to-leak pressure setting of the device. Each pressure relief valve shall be plainly and permanently marked with: The pressure in psig at which the valve is set to start-to-leak; Rated relieving capacity in cu ft. per minute of air at 15.6 deg. C and 0.1 MPa absolute. The manufacturer's name and catalogue number. Example: A pressure relief valve is marked 250-4050 AIR. This indicates that the valve is set to start to leak at 1.7 MPa gauge; and that its rated relieving capacity
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ii)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract is 1.9m3/s of air.

iii)

Shut off valves shall not be located between a pressure relief device and the container, unless the arrangement is such that the relief device relieving capacity flow specified in 3.2.4 (a) will be achieved through additional pressure relief devices which remain operative. Pressure relief valves shall be so designed that the possibility of tampering will be minimized. Externally set or adjusted valves shall be provided with an approved means of sealing the adjustment.

iv)

2.2.3.

Connections for Flow Control (Filling, Withdrawal, Equalizing). a) Shut off valves, excess-flow check valves, back flow check valves and quick closing internal valves, used individually or in suitable combinations, at container filling, withdrawal and equilizing connections, shall comply with 2.2.3 (b) and 2.2.3 (c). Filling, withdrawal and equilizing connections shall be equipped with the appurtenances for the appropriate type and capacity of container and the service in which they are to be used. Cylinder valve outlet connections on all DOT cylinders from which vapor can be withdrawn, shall not be interchangeable with those used for liquid withdrawal. Manual shut off valves shall be designed to provide positive closure under service conditions. Excess flow check valves shall be designed to close automatically at the rated flows of vapor or liquid specified by the manufacturer. Excess flow valves shall be designed with a bypass, not to exceed a No. 60 drill size opening, to allow equalization of pressure. Backflow check valves, which may be of spring loaded or weight-loaded type with in line or swing operation, shall close when flow is either stopped or reversed. Both valves of double backflow check valves shall comply with this provision. The appurtenances specified herein above may be installed as individual components or as combinations completely assembled by the appurtenance manufacturer.

b)

c)

d)

e)

f)

2.2.4.

Liquid Level Gauging Devices a) Liquid level gauging devices shall be provided on all containers filled by volume. Fixed level gauges or variable gauges of the slip tube, rotary tube or float types (or combinations of such gauges) may be used to comply with this provision. Variable liquid level gauges shall be so marked that the maximum liquid level, or percent of capacity of the container in which they are to be installed, is readily determinable. The markings indicating the various liquid levels from empty to full shall either be directly on the system nameplate and on the gauging device.

b)

c)

2.2.5

Other Container Connections a) Container openings shall be equipped with a positive shut off valve in combination with an excess-flow valve. First and second stage vapour pressure regulators shall be sized to bring down the
Revision (0) Project :A10 - 18 September. 2011

b)

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Sec. 43 00 00

Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract pressure of gas to the required pressure. The regulators shall be complete with pressure relief and venting devices in accordance with NFPA 58.

2.3 2.3.1.

PIPING, FITTINGS AND VALVES General This section includes basic design provisions and material specifications for pipe, tubing, pipe and tubing fittings, valves used to connect container appurtenances with the balance of the LP Gas system.

2.3.2.

Pipe a) b) c) d) LPG fill line shall be seamless steel to BS 1387 Class C. Below grade Distribution pipework shall be seamless steel to BS 1387 Class-C with factory applied polyethylene sleeve. Above grade distribution pipework shall be copper to BS 2871 Table Y Final connections to equipment shall be soft copper tubes to BS 2871 TableX.

2.3.3.

Pipe and Tubing Fittings a) b) Pipe joints in steel, brass or copper pipe shall be welded or brazed. Fittings used at pressure higher than container presure such as on the discharge of liquid transfer pumps shall be suitable for a working pressure of at least 350 psig (2.4 MPa gauge). Fittings used with liquid LP-Gas, or with vapor LP-Gas at operating pressures over 125 psig (0.9 MPa gauge) shall be suitable for a working pressure of at least 250 psig (1.7 MPa gauge). Fittings for use with vapor LP-Gas at pressure not exceeding 125 psig (0.9 MPa gauge) shall be suitable for a working pressure of 125 psig (0.9 MPa gauge). Soldering or brazing filler material shall have a melting point exceeding 1,000 deg. F (538 deg. C).

c)

d) e)

2.3.4.

Valves, Other than Container Valves a) Pressure containing metal parts of valves (except appliance valves), including manual positive shut off valves, excess flow check valves (either manually or automatically operated), used in piping systems shall be of steel, ductile (nodular) iron, malleable iron or brass. Ductile iron shall meet the requirements of ANSI/ASTM A 395 or equivalent and malleable iron the requirements of ANSI/ASTM A 47 or equivalent. All materials used including valve seat discs, packing, seals and diaphragms shall be resistant to the action of LP Gas under service conditions. Valves shall be suitable for the appropriate working pressure, as follows: i) Valves used at pressures higher than container pressure, such as on the discharge of liquid transfer pumps shall be suitable for a working pressure of at least 350 psig (2.4 MPa gauge). [400 psig (2.8 MPa gauge) WOG valves comply with this provision].
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b)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract ii) Valves to be used with liquid LP Gas, or with vapor LP-Gas at pressures in excess of 125 psig (0.9 MP a gauge), but not to exceed 250 psig (1,.7 MPa gauge), shall be suitable for a working pressure of at least 250 psig (1.7 MPa gauge). Valves (except appliance valves) to be used with vapor LP Gas at pressures not to exceed 125 psig (0.9 MPa gauge) shall be suitable for a working pressure of at least 125 psig (0.9 MPa gauge).

iii)

c)

Manual shut off valves, excess flow check valves and backflow check valves used in piping systems shall comply with the provisions for container valves. Emergency shut off valves shall be approved and incorporate all of the following means of closing. i) Automatic shut off through thermal (fire) actuation. When fusible elements are used they shall have a melting point not exceeding 250 deg.F (121 deg.C). Manual shut off from a remote location. Manual shut off at the installed location.

d)

ii) iii) e)

Solenoid valves shall be intrinsically safe construction suitable for 24V DC power supply.

2.4

GAS LEAK DETECTION SYSTEM A gas leak detection system shall be installed to monitor for gas leaks at different locations of the gas network.

2.4.1

Control Panel a) The central control panel shall be located in the control room at Administration Building and shall easily be accessible in the event of an emergency. The central panel shall have a modular design incorporating input alarm/display module for each gas detector. Each channel shall have indication for low alarm at 15% LEL, high alarm at 30% LEL and fault at 0-100% LEL indicator. Main LPG supply shall be shut off at 30% LEL indication. c) The concentration of the gas shall be displayed on a common indicator with selector switches to display the concentration of the desired channel or zone indicator. Below the gas control panel is the system control panel which shall have the following indications: AC healthy DC healthy Sprinkler on Gas pressure low Gas pressure high Gas solenoid valve operated Common fire signals Gas leak high The panel shall have the following switches: Sprinkler manual operate Gas manual shut off Test lamp
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b)

d)

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract System reset 2.4.2 Gas Detectors The gas detectors shall use a pellistor sensor to detect flammable gases and vapours. The sensor shall be housed in a stainless steel, flame proof housing, fitted onto an explosion proof junction box.

2.4.3

Sounder Flasher A sounder cum flasher unit shall be installed in the vicinity of the panel located in a visible area.

2.4.4

Cables MICC cables of at least 1.5 sq. mm area shall be used to interconnect between each detector and the control panel.

2.4.5

Logic of operation When low level gas leak is detected in any zone, local internal alarm and indication shall show on the control panel. When high level gas leak is detected in any zone, the following sequence shall occur: a) b) The solenoid valve in the gas distribution channel shall be closed automatically. External alarm shall be operated.

Connection to the fire alarm system: In the event of a fire alarm signal, the following sequence shall occur: a) b) The solenoid valve in the gas distribution channel shall be closed automatically. The sprinkler system over the LPG storage tanks shall operate.

In the event of an emergency, it shall be possible to by pass the automatic system and operate the system manually, this shall include: a) b) c) Manual shut off/on of the gas through the emergency shut-off push button. Manual operation of the sprinkler system On/Off Manual reset

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract PART 3 - EXECUTION 3.1 3.1.1 GENERAL All pipe work, pipe supports and brackets shall be painted with 2 undercoats and 2 finishing coats of yellow colour paint. LPG piping shall be painted with a specific colour different than other pipes. Orange or yellow colours are recommended. Valves shall also be painted. Direction arrows to indicate the flow of gas in the system shall be painted. The system in parts and as a whole shall be tested to ensure that it will operate safely, without leaks and to the satisfaction of the local Civil Defence Authority. Commissioning of the system shall be carried out to demonstrate that all the equipment and the whole system are in good working order. The LPG contractor shall accommodate any additional testing required by authorities such as Civil Defence in order to obtain their acceptance of the system. The gas network shall be leak tested using gases such as nitrogen or argon. Oxygen or flammable gases will not be used. The leak test shall include all the different pressure stages of the system including: a) b) c) d) 3.1.7 The filling line operating pressure up to 20 bar. The tank and high pressure stage operating pressure 16.5 bar The first stage regulator operating pressure 1.5 bar. The second stage pressure, operating pressure 37 mbar.

3.1.2

3.1.3

3.1.4

3.1.5

3.1.6

Test pressure shall be at least 1.5 times the operating pressure. The leak test duration shall be 1 hour. The specified test pressure shall be monitored for a minimum of one hour during which the soap water method shall be used to leak test every joint. If no leak is detected and the pressured gauge indicates no drop in the test pressure then the system will be proven to be leak free. If a leak is found, the leaking joint shall be repaired or the leaking equipment shall be replaced. The testing procedure shall be repeated to prove the complete system as leak free. A test report shall be submitted for approval. TESTING AND COMMISSIONING Before installations are handed over or subjected to inspection and testing, the entire installation shall be thoroughly cleaned, both internally and externally. Purging Vessels and their ancillary equipment shall be purged until the oxygen level is reduced below that which will support combustion before commissioning. When purging into or out of service is required this shall be carried out in accordance with LPGA Code of Practice No. 17.

3.1.8

3.1.9 3.2 3.2.1

3.2.2

3.2.3

LPG shall not be introduced into a pipework system unless it has passed a leak test for the entire system to be commissioned, and signed records are available.

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Private Residence on Plot #9, Sec. E/49, Eastern Mangrove, Abu Dhabi, UAE Main Contract 3.2.4 Purging of pipework systems shall only be carried out by or under the supervision of competent persons. Pipework should be purged with an inert gas e.g. nitrogen, so that the oxygen level is reduced to less than 9% by volume, before introducing LPG. Purge gas should be introduced in a controlled manner using an adjustable pressure regulator. When commissioning liquid systems, sudden chilling of the system from rapid vaporisation shall be avoided by precharging with LPG vapour up to vapour pressure before introducing liquid, or by pre-pressurisation with the inert gas. During the introduction of LPG the gas shall be released at a safe location and must not be allowed to accumulate in any confined space. The introduction of LPG may be undertaken in sections if necessary, provided suitable purge gas release points have been provided.

3.2.5

3.2.6

3.2.7

END OF SECTION

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