PROJECT DESCRIPTION

AND SCOPE (IBR)

Document No.
C001-15-16-43-IBR01
Rev. No. 0
Page 3 of 22

PROJECT DESCRIPTION:
M/s. Chennai Petroleum Corporation Limited (CPCL) intends to revamp Crude Distillation /
Vacuum Distillation Unit-II (CDU / VDU-II) for production of diesel product from the unit
conforming to ASTM D86 95% (Vol) recovery temperature as 360 0C (max) as required per
EURO-IV Diesel Specification under their Diesel Quality Improvement Project. The unit is being
revamped for a crude processing capacity of 4.3 MMTPA.
SCOPE:
This document describes in brief the facilities to be provided for the CPCL project at Manali,
Chennai that comes under the purview of INDIAN BOILER REGULATIONS. These steam
generation and distribution facilities are being designed under the provisions of IBR & will be
finalised on the basis of advice/approval by the Chief Inspector of Boilers.
All steam lines either operating at a pressure of 3.5 Kg/cm 2g & above or exceeding 254 mm
inside diameter and pipes carrying High Pressure Condensate/Boiler Feed Water to steam
generator have been included for IBR approval.
The documents being submitted for IBR approval have been divided into two volumes. This
document forms Volume-1 and is a cover document of CPCL project. It contains the project
description, calculations for wall thickness and branch reinforcement requirements, welding
details and supporting details.
The second volume (Volume-2) shall contain IBR piping system details and shall include
Isometrics/System drawings, Index of Lines under IBR purview and detailing of Total lengths of
Pipes and Fittings coming under IBR.
STEAM SYSTEM under CPCL Project
Steam is supplied to CDU / VDU II units and offsites of refinery II from cogeneration plant
through pressure reducing and desuperheating station (PRDS).

Super Saturated Medium Pressure (SSM) Steam

Medium Pressure (MP) Steam
Low Pressure (LP) Steam

The operating conditions of different systems under IBR are as follows:Norma

Steam Level
Units
l
Mech. Design
Super Saturated Medium Pressure (SSM) Steam
Pressure
Kg/cm2 g
11.5
13.5
Temperature
C
350
370
Medium Pressure (MP) Steam
Pressure
Temperature
Pressure
Temperature

Kg/cm2 g
10.5
15.0 / FV
C
220
280
Low Pressure (LP) Steam
Kg/cm2 g
C

Format No. 3-1643-0403 Rev. 1

3.5
170

7.0 / FV
240
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PROJECT DESCRIPTION
AND SCOPE (IBR)

Document No.
C001-15-16-43-IBR01
Rev. No. 0
Page 4 of 22

General:
Materials for pipes in A2A / B2A specs confirm to the Regulations 344 of IBR, 1950 and are
sufficient to withstand the intended pressure and temperature. The details of pipe wall thickness
and branch reinforcement calculations are attached for reference and confirmation.
It is also confirmed that the carbon content of carbon steel pipes and fittings is not more than
0.25%. Flange, bends and fittings are strictly as per the specifications attached and conform to
the respective regulations of IBR, 1950. It is confirmed that fabricated long radius bends at site
are not used for A2A / B2A specs.
The lines have been stress analysed and supported thoroughly. The stresses are within
allowable limits.
All Piping materials shall be supplied with certificate in FORM-IIIA or III-C wherever the same
are supplied by IBR approved mills in India or abroad. All other materials procured in India shall
be duly inspected and certified by the concerned CIB of the state in which the manufacturing
takes place. However in cases where such materials are procured from mills abroad, test
certificates indicating chemical composition and physical properties duly inspected and
approved by IBR recognized agencies shall be furnished.
Notes:
1.

Radiography shall be as per IBR requirements and stress relieving as per Welding
Specifications.

2.

Pipe cut lengths for small bore pipes shall be confirmed at site prior to fabrication.

3.

Code of construction is ASME B31.3 and IBR.

4.

For support details, refer Support Legend and attached Support Standards.

5.

Typical details of Weld Joints shall be as per Welding Specification and welding details.

6.

Line number, design and operating pressures/temperatures are as per the Line Index.

7.

Hydrostatic test pressure shall be as indicated in the typical welding detail.

Format No. 3-1643-0403 Rev. 1

Copyrights EIL All rights reserved