1057-GOAL-L-DB-1001 - Rev C - Piping Design Basis PDF

DOC.
NO 1057-GOAL-L-DB-1001
GREEN OIL AND LUBES, OLTENITA,

CLIENT: PROJECT NO. 1057
ROMANIA
SHEET NO. Page 1 of 38
PROJECT USED LUBE OIL RE-

EPC TITLE REFINING PLANT
CONTRACTOR:
CHEMIE-TECH DMCC LOCATION OLTENITA, ROMANIA
PIPNG DESIGN BASIS
REVISION
C 11.01.2018 Issued For Approval JJP KBR SGJ
B 05.09.2016 Issued For Approval PDT SKV ALV
A 02.07.2016 Issued For Approval PDT SKV ALV

REV NO. DATE DESCRIPTIONS PRE BY CHK BY APP BY
GREEN OIL AND LUBES,
OLTENITA, ROMANIA PIPING DESIGN BASIS
PROJECT NO : 1057 1057-GOAL-L-DB-1001
TABLE OF CONTENTS
1 INTRODUCTION ......................................................................................................................... 4
1.1 PROJECT SUMMARY .......................................................................................................... 4
2 ABBREVIATION .......................................................................................................................... 4
3 CODES AND STANDARDS ......................................................................................................... 6
4 PURPOSE ................................................................................................................................... 8
5 PROCESS SPECIFICATION ....................................................................................................... 8
6 SITE CONDITION ........................................................................................................................ 9
NOTES .......................................................................................................................................... 10
7 GENERAL TECHNICAL REQUIREMENT ................................................................................. 10
7.1 UNITS OF MEASUREMENT .............................................................................................. 10
7.2 END CONNECTION ........................................................................................................... 11
7.3 FLANGE FACE FINISH ...................................................................................................... 11
7.4 VALVE END TO END DIMENSIONS .................................................................................. 11
7.5 RADIOGRAPHY OF CAST VALVES .................................................................................. 11
7.6 STRAINERS ....................................................................................................................... 11
7.7 HOSES ............................................................................................................................... 11
7.8 GASKETS........................................................................................................................... 11
7.9 STUD BOLTS & NUTS ....................................................................................................... 11
8 SCOPE OF WORK .................................................................................................................... 12
9 FACILITY DESCRIPTION .......................................................................................................... 12
9.1 FLASH DISTILLATION PLANT ........................................................................................... 12
9.2 HYDROTREATMENT PLANT ............................................................................................. 13
10 ELECTRICAL HEAT TRACING SYSTEM .............................................................................. 13
11 GENERAL / DESIGN CONSIDERATIONS ............................................................................. 14
11.1 EQUIPMENT LAYOUT ....................................................................................................... 14
11.2 PIPING DESIGN ................................................................................................................. 15
11.3 PIPING LAYOUT ................................................................................................................ 15
11.4 ABOVE GROUND PIPING.................................................................................................. 16
11.5 UNDERGROUND PIPING .................................................................................................. 16
11.6 EXCHANGER PIPING ........................................................................................................ 16
11.7 COLUMN / VESSEL PIPING .............................................................................................. 16
11.8 PUMP PIPING .................................................................................................................... 17
PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 2 of 38

11.9 PRESSURE RELIEF SYSTEM / BLOW DOWN SYSTEM PIPING ..................................... 17

11.10 UTILITIES ....................................................................................................................... 18
11.11 FLARE PIPING ............................................................................................................... 18
11.12 TANK FARM PIPING ...................................................................................................... 18
11.13 PIPING SUPPORTS ....................................................................................................... 18
11.14 MATERIALS .................................................................................................................... 18
11.15 FITTINGS ........................................................................................................................ 19
11.16 FLANGES ....................................................................................................................... 19
12 FLEXIBILITY ANALYSIS ........................................................................................................ 19
12.1 PURPOSE OF STRESS ANALYSIS ................................................................................... 19
12.2 PIPING STRESS ANALYSIS DELIVERABLES................................................................... 20
12.3 SELECTION CRITERIA FOR STRESS CRITICAL LINES .................................................. 20
12.4 METHODOLOGY FOR CAESAR MODEL .......................................................................... 21
12.5 SUPPORT LEGEND ........................................................................................................... 38

1 INTRODUCTION
Green Oil & Lubes has planned to setup a Used Lube Oil Re Refining Plant at Oltenita,
Romania with Capacity of Flash Distillation Plant to process feed of 200 MT/day Used Lube
Oil. Flash Distillation output ( From FFE / WFE ) Capacity shall be 150 MT/day. The Output
of Hydro-treatment Unit is 147 MT/day of Base Oil with API Grade II or API Grade II+ quality.
Chemie Tech DMCC has been appointed as an EPC contractor for Basic & Detailed
Engineering, Procurement & Supply, Installation, Testing and Commissioning of 200 MT/Day
Capacity Used Lube Oil Re-refining Plant at Oltenita, Romania.
Chemie Tech DMCC, Dubai (EPC Contractor) has appointed M/s Green Industrial
Technologies (GIT-Greece) as a consultant for Basic Engineering of Hydro Treatment (HDT)
Plant.
1.1 PROJECT SUMMARY
Project Name Used Lube Oil Re-refining Plant
Project Number 1057
Project Location Oltenita, Romania
Company Green Oil and Lubes
EPC Contractor Chemie-Tech DMCC
2 ABBREVIATION
The Following Abbreviation are used in this project
Code Description
API American Petroleum Institute
AS Alloy Steel
ASME The American Society Of Mechanical Engineers

ASTM American Society For Testing And Materials
BE Beveled Ends
BS British Standard
BW Butt Weld
CS Carbon Steel
FF Flat Face
ISO International Organization For Standardization

NACE (N) National Association Of Corrosion Engineers
MOC Material Of Construction

P&ID Piping & Instrumentation Diagram
PMS Piping Material Specification
VMS Valve Material Specification
dft Dry Film Thickness
NDE Non Destructive Examination
RF Raised Face
SE Screw Ends
SORF Slip On Raised Face
SS Stainless Steel
SW Socket Weld
U/G Underground
A/G Above Ground
WNRF Weld Neck Raised Face
A/G Above Ground
AIV Acoustic Induced Vibration

BOP Bottom of Pipe
DLF Dynamic Load Factor
FIV Flow Induced Vibration
GRE Glass Reinforced Epoxy

IBC International Building Code
IFC Issued for Construction

NEMA National Electrical Manufacturers Association
NPS Nominal Pipe Size
OD Outer Diameter
P&ID Piping & Instrumentation Diagram
PROJECT Used Lube Oil Re-Refining & Hydrogenation Plant
PSV Pressure Safety Valve

SIF Stress Intensification Factor
U/G Under Ground

Any and all persons, firms, partnerships, companies, bodies,

entities or a combination thereof including sub vendors and
suppliers, who are providing GOODS (including any of the
VENDOR/SUPPLIER/ foregoing whose purchase orders are novated or assigned by
MANUFACTURER COMPANY to
CONTRACTOR) and the successors and assigns of such
persons, firms, partnerships, companies, bodies, entities or a
combination thereof.
3 CODES AND STANDARDS
Below listed standards shall be used for design & Engineering of plant.
Code / Standard Description
2014/68/EU Pressure Equipment Directive (PED)
ASME B31.3 ed.2014 Process Piping

ASME B1.1 ed.2003 Unified Inch Screw Threads
ASME B1.13M Metric Screw Threads — M Profile

ASME B1.20.1 ed.2013 Pipe Threads, General Purpose (Inch)
ASME B1.20.3 Dry seal Pipe Threads (Inch)
Cast Iron Pipe Flanges and Flanged Fittings — 25, 125, 250 &
ASME B16.1
800 Classes
ASME B16.3 Malleable Iron Threaded Fittings
ASME B16.4 Gray Iron Threaded Fittings
ASME B16.5 ed.2013 Pipe Flanges and Flanged Fittings

ASME B16.9 ed.2012 Factory-Made Wrought Butt welding Fittings
ASME B16.10 ed.2009 Face-to-Face and End-to-End Dimensions of Valves
ASME B16.11 ed.2011 Forged Fittings, Socket-Welding and Threaded

Metallic Gaskets for Pipe Flanges — Ring Joint, Spiral Wound,
ASME B16.20 ed.2012
and Jacketed
ASME B16.21 ed.2011 Non-metallic Flat Gaskets for Pipe Flanges
ASME B16.34 ed.2013 Valves — Flanged, Threaded, and Welding End

ASME B16.48 ed.2010 Steel Line Blanks
ASME B18.2.1 ed.2012 Square and Hex Bolts and Screws — Inch Series
ASME B18.2.2 ed.
Square and Hex Nuts (Inch Series)
latest
ASME B36.10M
Welded and Seamless Wrought Steel Pipe
ed.2004

ASME B36.19M
Stainless Steel Pipe
ed.2004
API 5L ed.2012 Specification for Line Pipe
API 6D ed.2008 Pipeline valves
API 594 ed.2010 Check Valves: Wafer, Wafer-Lug, and Double Flanged Type
API 599 ed. latest Metal Plug Valves—Flanged, Threaded and Welding Ends
Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas
API 600 ed.2009
Industries
Compact Steel Gate Valves - Flanged, Threaded, Welding, and
API 602 ed.2009
Extended-Body Ends
API 608 ed.latest Metal Ball Valves—Flanged, Threaded, and Welding Ends
API 609 ed.latest Butterfly Valves : Double Flanged, Lug– and Wafer-Type
BS 1868 Steel check valves(flanged and butt-welding ends) for
ed.1975 + A1 1990 the petroleum, petrochemical and allied industries
Steel globe and globe stop and check valves(flanged and butt-
BS 1873 welding ends) for the petroleum, petrochemical and allied
industries
Steel gate, globe and check valves for sizes DN 100 and smaller,
ISO 15761 ed.2002
for petroleum and natural gas industries
ISO17292 Metal Ball Valves For Petroleum Industries
Petroleum and natural gas industries -Materials for use in H2S-
NACE MR0175/ISO
containing environments in oil and gas-General principles for
15156-1
selection of cracking-resistant materials
Petroleum and natural gas industries- Materials for use in H2S-
NACE MR0175/ISO
containing environments in oil and gas-Cracking-resistant carbon
15156-2
and low alloy steels, and the use of cast irons
NACE MR0175/ISO Petroleum and natural gas industries - Materials for use in H2S-
15156-3 containing environments in oil and gas-Cracking-resistant CRAs
(corrosion-resistant alloys) and other alloys
ASME VIII
Pressure Vessels and Boiler Code
Division 1 ed.2015
ASME II Part A ed.2015 Materials – Ferrous Materials Specifications.
ASME V ed.2015 Non-Destructive Examination.
ASME IX ed.2015 ASME IX Welding and Brazing Qualifications
MSS SP 58 Pipe hangers and supports - materials, design and manufacture

4 PURPOSE
This Piping Design basis describes the Used Lube Oil Re-Refining design criteria
implemented to carry out Design for Used Lube oil Re-refining Plant.
The Re refining of Lube Oil shall be carried out by following Plants.
● Flash Distillation Plant
● Hydro-treatment Plant
The purpose of this document is to establish a basis for the piping system related to Used
Lube Oil Re-refining plant at Green oil and Lubes industries contains Process plant,Utility
piping, Storage tank farm piping, Day tank (intermediate storage) area, under-ground piping
etc.
Also this document provides a basis for the selection, execution and reporting of pipe stress,
pipe support loads and design, and nozzle loading activities. The goal is to achieve pipe
stresses in compliance with the applicable code, nozzles loads meeting the equipment
allowable, support loads, and acceptable pipe movements.
It also contains an appendix section that covers many modelling techniques and provides
other useful information.
5 PROCESS SPECIFICATION
8.333 MT / hr
Plant Capacity (ULO Feed Rate) 200 MT / Day
66,666 MT / Year
Stream factor 8000 Hrs / Year
Planned Maintenance 15 x 2 times days
Type of Plant Continuous
Turn Down ratio 50%
Raw Material Used Lube Oil
Treatment Units Flash Distillation + Hydro treatment

Base Oil
Finished Product
(Middle Distillate~SN-50 Or Heavy Distillate~SN-50)
By Product Diesel ( Light Oil ) & Asphalt

6 SITE CONDITION
Sr No Parameters Description Remarks / Source
1 Elevation Above Sea Level (m) 5 – 15 PUG Oltenita / 2013
2 Maximum Rainfall (mm/hr) - -

150 l / s / hector
3 Design Rainfall 15 minutes STAS 9470 / 1973
1 / year
4 Average Speed Of Wind (km/hr) 85 PUG Oltenita / 2013
5 Design Wind speed (km/hr) 90 CR 1-1-4 / 2012
Temperature data (°C)
6 Average Annual Temperature (°C) +11.35 PUG Oltenita / 2013
7 Ambient Highest Temperature (°C) +41.4
8 Ambient Lowest Temperature (°C) -25
Humidity data
Relative Humidity (Max / Min /
9 93 / 77.6 / 86.7 PUG Oltenita / 2013
Average ) %
10 Power (Public distribution system) Note 1
10.1 Medium Voltage
10.1.1 Phase 3
10.1.2 Frequency , Hz 50
10.1.3 Voltage , kV 20
10.2 Low Voltage
10.2.1 Phase 3/1
10.2.2 Frequency , Hz 50
10.2.3 Voltage , V 400 / 230
Other Data
13 Environment -
14 Ground Water depth 3.5 – 5.5 m
15 Seismic Risk Class ag = 0.25g P100-1 / 2013
16 Snow sk = 2.0 kN / m2 CR 1-1-3 / 2012
17 The maximum depth of frost m 0.70 – 0.80

NOTES
Voltage levels shall be in accordance with std. SR EN 60038 (similar to IEC 60038, series I).
The most common used voltage levels in public distribution systems are 20 kV (medium
voltage) and 400/230V (low voltage). For industrial plants, as common practice, electrical
loads up to 160 kW are supplied from a three phase, 4 wire system, 400/230V (TN system)
and loads greater than 160 kW are supplied from 6 kV (a power transformer 20/6 kV may be
used).
7 GENERAL TECHNICAL REQUIREMENT
7.1 UNITS OF MEASUREMENT
All units of measurement shall be based on the Metric System of Measurement. The
following units shall be used.
Application Unit of Measurement
Temperature °C or K
Pressure bar (g) , bar (a) , mbar
Vacuum mbar
Mass kg
Volume m3 , liter, Nm3
Flow rates kg/hr, m3/hr, Nm3/hr
Heat kcal
Power kW
Dynamic Viscosity cP
Kinematic Viscosity cSt
Density kg/m3
Length m, mm
Pipe Diameter / Pipe Size mm , inch
Thickness mm
Area m2
Velocity m/s
Noise Level dB
Frequency Hz
Voltage V
Stress kN/mm2
Load / Force kN, kgf

7.2 END CONNECTION
Unless otherwise specified, the ends shall be to the following standard:
Threaded / Socket-weld ASME B-16.11
Butt-weld ASME B-16.9
Flanged ASME B-16.5
7.3 FLANGE FACE FINISH
This shall according to ASME B-46.1 / ASME B-16.5.

7.4 VALVE END TO END DIMENSIONS
Face-to-Face/End-to-End dimension of valves shall be as per ANSI B16.10. In case the

same is not covered under B16.10, the dimension shall be as per Manufacturer's Std.
7.5 RADIOGRAPHY OF CAST VALVES
All castings shall be of radiographic quality. Radiographic requirement of 10% shall be

ensured by sample radiography before proceeding with the actual production. Radiography
procedure, areas of casting to be radio graphed, and the acceptance criteria shall be as per
ASME/ANSI B16.34.
7.6 STRAINERS
Allowable pressure drop when specified shall be certified along with the offer.
All types of strainer mentioned in P&ID’s,dimensions (Face to face, center line to bottom etc)
should be provided in data sheet if there is any restriction in layout point of view. Strainer
shall have draining arrangement as per process requirements.
For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be
100% dye penetrant / magnetic particle tested.
7.7 HOSES
Suitability of hoses shall be guaranteed for the service and working conditions specified in
the requisition, even if the material is not specified in the material requisition for any
particular service. All hoses shall be clearly marked with service and working pressure.
Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations. Complete
Hose assembly shall be tested at 1.5 times the design pressure.
7.8 GASKETS
Gaskets used are of Metallic and Non-Metallic type.
Metallic gaskets shall confirm to ANSI B16.20 and Non-Metallic gaskets shall confirm to
ANSI B16.21.
7.9 STUD BOLTS & NUTS
Bolting for flanges and flanged valves shall consist of stud bolt threaded entire length with
two hexagonal nuts.
Material for stud bolts shall be ASTM A 193 Gr.B7 and Hexagonal nuts shall be ASTM A 194
Gr.2H. Dimensions and tolerances of stud bolts and nuts shall be according to ASME B
18.2.1 and ASME B 18.2.2.

8 SCOPE OF WORK
The Scope of work mainly comprises of Basic Engineering, Detailed Engineering,
Procurement, Installation & commissioning for Used Lube Oil Re-Refining Plant. The design
work will cover basic engineering of distillation plant and detailed engineering of distillation,
hydro-treatment & utilities at Oltenita, Romania.
● Piping
Piping design & detailed engineering in accordance with ASME B-31.3 and project approved
documents. Also supply, fabrication, construction, installation, Testing & commissioning of
overall Piping.
 Overall piping routing with mechanical, civil, structural, Electrical & instrumentation work.
 Piping to complete with valves, fittings, supports, strainers etc.

9 FACILITY DESCRIPTION
Used Lube Oil Re-Refining Plant mainly consists of following sections.
● Flash Distillation Plant
● Hydro-treatment Plant
9.1 FLASH DISTILLATION PLANT
In general the process is to recover the lube oil base stock from used lubricating oil (ULO) &
purify it further by hydrotreating to produce API Grade II / API Grade II+ base oils.
The process is completed in following sections.
● Filtration & Pre-treatment
● Dehydration & Diesel (Light Oil) Removal
● Medium Distillate (MD) recovery
● Heavy Distillate (HD) recovery
The following are the brief details about the above sections, for detailed description please
refer Process Description Document (1057-GOAL-P-PD-1001).
9.1.1 FILTRATION & PRE-TREATMENT
This section involves the filtration of feed for smooth running of plant. The feed in Tank farm
area first get screened & analysed based on pre-treatment for correct specifications. Water
content in used lubricating oil (ULO) feed shall be as low as possible & not more than 7%.
9.1.2 DEHYDRATION & LIGHT OIL (DIESEL) REMOVAL
In this section the water content in the feed gets removed. The other components having
lower boiling point than water will also get separated from used lubricating oil (ULO) by
heating & flashing. The evaporator is used in order to dry out the feed completely from Water
content & Light oil like Diesel.
9.1.3 MEDIUM DISTILLATE RECOVERY

The Pre-Heated process oil will then enter specially designed two nos. of Falling Film
Evaporator. Separation of Medium distillate (MD) shall be achieve by Vacuum. Also heating
shall be provided by Thermic Fluid to carry out separation. The vapours generated in Falling
Film evaporator will be separated out in separator.
The vapour from the Medium Distillate Collection Vessel will pass through condenser +
cooler for condensing out any entrainment carried over from the process. It will be collected
in a trapped liquid separator vessel.
The liquid part gets pumped from bottom of separator to next section for Heavy Distillate
(HD) Recovery.
9.1.4 HEAVY DISTILLATE (HD) RECOVERY
The bottoms from Falling Film Evaporator, is first distributed among four nos. of Wiped Film
Evaporators. There are 4 nos. Wiped Film Evaporators (WFE’s) used in the plant. They are
similar in construction & will be operated in parallel.
The product obtained from WFE’s is ‘Heavy Distillate’ (HD) at 30°C and by-product is
‘Asphalt’ at 271 °C.
9.2 HYDROTREATMENT PLANT
For detailed process descriptions please refer Process Description Document (1057-GOAL-
P-PD-2001).
10 ELECTRICAL HEAT TRACING SYSTEM
During winter season ambient temperature can go up to (-) 25°C, Electrical heat tracing
system shall be design accordingly.
The electric heat tracing system on the Plant Piping, Instruments, Import and Export
pipelines and Storage Tanks shall be utilised to maintain temperature of fluid from -25 °C to
25°C.

11 GENERAL / DESIGN CONSIDERATIONS
11.1 EQUIPMENT LAYOUT
11.1.1 BASIS OF EQUIPMENT LAYOUT
Equipment layout shall be developed on the following data:
Sr No Description
1 P&IDs
2 Overall Plot Plan
3 Wind direction
4 Equipment Data Sheets
5 Indicative Equipment Layout from Process Licensor/ CTL Process
6 Process Package
11.1.2 Development of Equipment Layout
The following aspects shall be considered during development of equipment layout
(a) Process Requirement - i.e. proper interconnection between equipment as per P&IDs to
achieve the intended process parameters.
(b) Economy of Piping material- Minimise the quantity of costly piping.
(c) Erection & Construction requirement -Erection scheme and schedule of all equipment
must be considered during equipment layout to have smooth erection mainly in case of
tall columns, heavy equipments like thick walled reactors, space for laying tall column,
approach road for cranes / derrick for lifting the column or reactors and requirement of
special foundation / pile etc.
(d) Constructability, Operation and Maintenance Requirement like Overhead and side
clearances for exchangers and pumps, Provision of exchangers tube bundle pulling
area, Horizontal & overhead clearances for easy movement of working personnel ,
Crane approaches for air coolers/fired heaters/exchangers. Provision of catalyst loading /
unloading facilities, Provision of monorail/mobile crane for maintenance of pumps,
Provision of hydro extractor/monorail for maintenance of exchangers and Provision of
HOT crane for compressors, Provision of Analyser shelter.
(e) Similar equipment grouping - All columns, exchangers, pumps etc. should be grouped
together for convenience of maintenance and safety wherever feasible.
(f) The technological structures should be inter-connected for easy movement of

operational personnel.

(g) All areas requiring crane access for erection or specific maintenance purpose e.g.
catalyst loading etc., hard stand for construction, tube bundle pulling area and drop-
out/laydown areas shall be marked on the equipment layout.
11.2 PIPING DESIGN
11.2.1 All Piping shall be designed as per ASME B 31.3 ed.2014 is used as base code related to
piping.
11.2.2 Piping systems, and the piping components thereof, shall fulfil all requirements of the
Pressure Equipment Directives (PED).
11.2.3 Piping systems are identified by line numbers in accordance with the line numbering system
as mentioned in P&ID’s
11.2.4 All straight nipples shall be made from the same pipe material as specified in the PMS.
11.2.5 Piping shall be arranged in a neat and simple manner. Piping including supports, valves
shall be located so as not to present obstructions or stumbling hazards nor-interfere with
equipment operation and maintenance
11.2.6 Minimum overhead clearance for piping and walkways.
11.2.7 Piping shall be designed to minimize pockets and low points. Service utility piping shall
11.2.8 Have additional take off points located in piping and be terminated in such a manner as to
facilitate extending the line at a later date.
11.2.9 Piping headers shall be terminated with blind flanges and shall be installed to allow for
Future expansion of the header where called for by design drawings.
11.2.10 Valve drain shall be installed on equipment that is not self-draining.
11.2.11 Slope shall be maintained for all drain/ blow down lines as indicated in P&ID’s.
11.2.12 Piping design shall follow the material, dimension standard, design calculation and other
requirement as per PMS and VMS.
11.3 PIPING LAYOUT
11.3.1 The following provisions shall be ascertained during piping layout:
11.3.2 Proper access to all operating points including valves and instruments.
11.3.3 Proper access to inter-related operating points for specific purpose.
11.3.4 Economic routing with minimum required bends and flanges.
11.3.5 Proper head room.
11.3.6 Safety and escape routes.
11.3.7 Stresses in piping within allowable limits.
11.3.8 Proper maintainability. (E.g. removal of strainer filters, accommodating sample connection
bottle, elevation for reading of instrument/ gauges.)
11.3.9 Slope of drain/ blow down lines.

11.4 ABOVE GROUND PIPING
In a pipe rack the heaviest and/or the hottest pipes should be located at the sides of the pipe
rack to provide space for expansion loops and to reduce the moments in the beams caused
by the weight and thermal expansion of the pipes.
The minimum elevation of the bottom of overhead piping shall be:
6.0 m over main roads;
4.0 m for crane access;
4.0 m for truck access;
2.1 m for head-room clearance.
11.5 UNDERGROUND PIPING
As per Civil / Structure Design Criteria Doc No : 1057- GOAL-S-DB-5001-E, the maximum
frost depth is 0.7 m to 0.8 m and hence minimum piping depths shall be followed.
Fire Water pipes (main) : 0.8 m (minimum)
Pipes of NPS 24 and smaller : 0.8 m (minimum)
Pipes over NPS 24 : 0.8 m (minimum)
In areas accessible to heavy traffic and road crossing : 1 m (minimum)
In areas inaccessible heavy traffic : 0.8 m (minimum)
For buried pipes which have impressed current cathodic protection, there shall be a clear
distance of at least 1 metre between the pipe and any parallel-running cables, to prevent
stray-current corrosion of the steel wire armouring of those cables.
11.6 EXCHANGER PIPING
Exchanger piping shall not run in the way of built in or mobile handling facilities.
Wrench clearance shall be provided at exchanger flanges.
Piping shall be arranged so that they do not hinder removal of shell end and channel cover
and withdrawal of tube bundle.
11.7 COLUMN / VESSEL PIPING
Piping from column shall drop or rise immediately upon leaving the nozzle and run parallel
and close as practicable to vessel.
Piping shall be grouped as far as possible for the ease of supports and shall run on the rack
side of the column.
Piping shall be supported from cleats welded on the vessel as far as possible.
Proper guides at recommended intervals shall be provided for long vertical lines.
Access platforms/ladders shall to be provided along the column for valves and instruments.

For ease of operation and maintenance, column and vessels which are grouped together,
shall have their platforms at the same elevation and should be interconnected by walkways.
However each column / vessel shall have an independent access also.
Column / vessel platforms should be designed in such a way so that all the nozzles should
be approachable from platforms.
Piping at columns/vessel nozzles shall be arranged so that blanks can be easily installed for
hydro testing.
Unless specifically indicated in P&IDs control valves shall preferably be kept at grade.
Piping intended for vacuum services shall be routed as short as possible with minimum
bends and flanged joints.
Piping support cleats for safety valves shall be independent meant for safety valves only &
shall be designed considering impact loading.
11.8 PUMP PIPING
Piping at pumps should be sufficiently flexible and adequately supported to ensure that
under no circumstances the nozzles of the equipment will be subject to stress that could
disturb the alignment of the pump.
Pump suction lines should be as direct as possible. Pockets in suction lines are not
permitted so as to avoid collection of vapor gas.
Eccentric reducers in pump suction lines should be installed with the topside flat to avoid
collection of vapor or gas (except for vertical inline pumps with suction line in the same plane
as the pump shaft).
Wherever necessary, provision shall be made to facilitate removal of internal elements,

housing sections and strainers.
Piping arrangement shall permit insertion and removal of strainer internals without disturbing
machine installation alignment.
Locating a strainer on the suction side of pumps is critical in protecting the pump from
damage.
Pressure gauge in the pump discharge line shall be visible from the operation position of
discharge block valve.
External force and moment acting on the pump nozzle shall not exceed the allowable
values specified by the manufacturer.
11.9 PRESSURE RELIEF SYSTEM / BLOW DOWN SYSTEM PIPING
Wherever the inlet line size is higher than the safety valve inlet size, reducer shall be
installed adjacent to inlet of safety valve.
Relief valve shall be installed in vertical position, so as to allow free drainage of the inlet pipe
work.
Inlet and outlet piping of pressure relief valves should be adequately supported to take care
of the thrust induced by the relief valve during popping.

11.10 UTILITIES
Requisite number of utility stations should be provided to cater the utility requirements. Utility
connections should be provided for fire water, raw water, potable water, plant air, oily water,
Hot Oil, Cooling water, Instrument air,Nitrogen,etc. as specified in P&ID.
11.11 FLARE PIPING
Flare header shall be sloped towards flare knock-out drum. Expansion loop shall be provided
in horizontal plane as per requirement to accommodate thermal expansion.
The desired slope shall be ensured throughout including flat loop.
Flare header shall be supported on shoe.
Proper thermal analysis temperature shall be established including the possibility of

temperature gradient along the line before providing expansion loops. Efforts shall be made
to minimize the number of loops.
Flare line between knock out drum and water seal drum shall be designed for pressure
fluctuations and adequately supported to avoid vibrations.
11.12 TANK FARM PIPING
Within the bunded area the number of pipes shall be minimised and they shall be routed in
the shortest practicable way from the tank to the bund wall. Where practical, the pipes shall
be grouped together. Access should be provided to manholes, drains and other facilities on
the tanks.
Pipes connected to tanks shall be sufficiently flexible to cope with thermal

expansion/contraction, tank settlement.
Piping shall be connected and supported after hydrostatic testing of the tank. Piping in tank
farms shall be supported by concrete sleepers or steel frames. If relatively small-bore pipes
are installed along with bigger pipes in tank pits having a concrete floor, steel frame supports
may be used as intermediate supports between concrete sleepers.
Pipe elevation shall be provided in such a way that it should cross other structure with
minimum 50 mm clearance or entirely covered under structure. For safe operation maximum
possible clearance shall be kept.
11.13 PIPING SUPPORTS
All piping shall be adequately supported, so as to prevent undue vibration, deflection /

expansion, or loads on connected equipment and piping, and leakage at joints.
Long trunnion type supports are to be avoided. Trunnion type supports are to be provided
with reinforcement pad on the pipe/elbow.
Piping shall be adequately supported for weight of primary and secondary type loads.
11.14 MATERIALS
Basic material selection of particular line depending on its service, temperature and
corrosively of the medium shall be as spelt out in process package.

Painting shall be done as per Painting specification Doc No. 1057-GOAL-L-SP-1001 and
Coating and wrapping specification Doc No. 1057-GOAL-L-SP-1002 will be prepared for
Buried Piping.
11.15 FITTINGS
MOC of all fittings shall be compatible to the pipe material and shall be marked according to
MSS-SP-25.
Thickness of fittings at ends to match pipe thickness for BW fittings.
SW fittings shall be according to PMS.
All branch connections shall be as follows, unless specifically mentioned otherwise in PMS
The diameter of reinforcement pad shall be twice the OD of branch pipe, unless otherwise
specified. The thickness of the pad shall be same as the run pipe unless otherwise specified.
Material of the RF pad shall be same as that of Run pipe.
11.16 FLANGES
Flanges for metallic piping shall be as follows:
Flanges up to 24” NB shall be as per ASME B16.5 unless otherwise specified. Serrations
shall be concentric for all RF & FF flanges to avoid radial tool mark up on finished surface &
to avoid formation of continuous leak path.
For Non-Metallic piping, flanges for all sizes shall be slip on loose flange with stub- end.
12 FLEXIBILITY ANALYSIS
12.1 PURPOSE OF STRESS ANALYSIS
The purpose of carry out piping stress analysis activities are,
12.1.1 To ensure that all loads (sustained, occasional, and thermal) are acting on the piping system
must be within code limits.
12.1.2 To avoid piping stresses in excess of those permitted by the referenced Codes and
Standards.
12.1.3 To avoid the leakage at flange joints.
12.1.4 To avoid premature failure of equipment due to excessive piping forces and moments
applied to connected equipment.
12.1.5 To avoid excessive stresses in the supporting or restraining elements.
12.1.6 To avoid unintentional disengagement of piping from its supports.
12.1.7 To avoid excessive interference with thermal expansion or contraction of the piping system
or connected equipment which is otherwise adequately flexible.
12.1.8 To avoid damage to piping components and equipment due to shock loading, e.g. slug flow.
12.1.9 To avoid excessive piping sag in piping systems which need drainage slope.

12.2 PIPING STRESS ANALYSIS DELIVERABLES.
Complete the analysis report to compile all the documentations as per the following order.
12.2.1 Cover Sheet.
12.2.2 Caesar II input and output reports including stress, load and displacement summaries for
Sustained, Design / Maximum operating cases.
12.2.3 A3 size stress sketches.
12.2.4 Latest PID and Critical Line List (relevant sheets only).
12.2.5 Material specifications (relevant sheets only).
12.2.6 All back up calculations, e.g. PSV reaction load.
12.2.7 Flange leakage checks calculations.
12.2.8 Trunnion calculations.
12.2.9 Computed stresses summary sheet.
12.2.10 Equipment general arrangement drawing.
12.2.11 Equipment data sheets for allowable nozzle loads where applicable.
12.2.12 Nozzle load summary sheet.
12.2.13 All native files along with .C2 file shall be submitted after final documentation.
12.2.14 Special support drawing & MTO.
12.3 SELECTION CRITERIA FOR STRESS CRITICAL LINES
Temperature T, Pipe Diameter D. Criticality

Piping Material
Degree C Inch Description
T ≥ 260˚C D ≥ 2" All Critical.
All D ≥ 16" All Critical.
T ≤ -29˚C D ≥ 2" For Carbon Steel Critical.

Other than Carbon
T ≤ -45˚C D ≥ 2" Critical.
Steel
T ≥ 260˚C D ≤ 1½ " All VC (Visual Check)
12.3.1 Pipes subjected to full vacuum for pipe size above 2”.
12.3.2 Lines with pressure > 900 psig.
12.3.3 All lines 2” and above connecting to static/vendor/supplier equipment/skids.
12.3.4 All lines 2” and above connecting to strain sensitive and rotating equipment.

12.3.5 All lines connected to reciprocating compressor, reciprocating pump and vibrating
equipment’s.
12.3.6 Two phase flow lines having size 2" and above.
12.3.7 For pipe size 6” and above which runs more than 50m straight run.
12.3.8 Buried pipes (for pipe size 4” & above).
12.3.9 For pipe size 2” & above subjected to Differential settlement or significant imposed
displacements.
12.3.10 Lines connecting to PSV/Relief Valves or Bursting Discs
 For line size 2" and above.
 Set Pr.7 Kg/cm2 and above.
12.3.11 Flare lines with 3” and above.
12.3.12 All lines 2" and above subject to short-term emergency, upset, or steam-out conditions, as
defined by Process.
12.3.13 All jacketed lines.
12.3.14 All lines designated by process as being Category “M”.
12.3.15 All lines that are glass, or refractory lined.
12.3.16 All non-metallic piping, line size 8” & above.
12.3.17 Line, which stress engineer feel critical.
12.3.18 Process pipes connected with rotating equipment’s.
12.4 METHODOLOGY FOR CAESAR MODEL
12.4.1 Naming Of CAESAR II File
Stress file name shall be numbered: Sample - STS-1010
System prefix + [1000-Tank Farm/ 2000-GIT/ 3000-CTL/ 4000-Utility] + [10-System

Numbering Sequence]
12.4.2 Code ASME B31.3
 ASME B31.3 code shall be considered for stress analysis of piping.
 Stress range reduction factor f=1 shall be used for this project. (3000 < N < 7000)
 Installation temperature for stress analysis shall be taken as 21 Deg C
If, there is any line subjected to displacement cycles N more than 7000 (as identified by
Process), the Stress Range Factor (f) shall be calculated based on Clause No: 302.3.5 and
Fig. 302.3.5 of ASME B 31.3.
Computer analysis program shall be CAESAR II, which compiles analysis according to code
requirements of ASME B31.3.

12.4.3 SIF
Finite Element Analysis (FEA) program shall be used for SIF calculation of non-standard
branch connections.
12.4.4 CAESAR II Co-ordinate System
As a uniform approach, following Global Coordinate System shall be used in all CAESAR II
calculations.
“-X” indicates plant north direction and X, Y & Z are three perpendicular axis.
NORTH
X
Z
12.4.5 Liberal Stress Allowable
It is recommended that stress calculations shall be performed using non-liberal allowable

stress range to limit the effect of future changes e.g. as caused by design development.
Liberal allowable stress options may be used with the client approval if necessary.
12.4.6 Pipe Sag
Allowable Pipe sag or pipe deflection in vertically downward direction shall be kept 10mm for
Sustained case.
12.4.7 Friction
The effect of friction shall be calculated at support location based on the following:
Contact Surface Condition Coefficient
Steel to Steel 0.3
Steel to smooth Concrete 0.5
Polished Stainless Steel to Stainless steel 0.15
PTFE to stainless steel 0.10
Use of Teflon pads shall be avoided as far as possible.
12.4.8 Input of Design Parameters

The following temperature cases are generally used:
T1: Normal Operating Temperature
T2: Max. Design Temperature
T3: Min. Design Temperature
T4: Max Operating Temperature (ie. Ope.Temp. + 20 deg C)
However, user shall be careful to select T1 temperature as basis for spring selection.
Temperature cases shall be verified, for the following cases, if applicable:
Where piping is heat traced and subjected to a ‘process flow off/heat tracing on’, the process
piping metal temperature shall be considered 100% of the tracer element design
temperature.
If the difference between design temperature and operating temperature is more than 20 deg
C then system stress should be qualified at design temperature whereas nozzle qualification
should be done at max. Operating temperature value equal to (Ope.Temp + 20) deg C.
If design temperature is lower than Solar radiation temperature, Solar radiation temperature
= 82 deg C should be considered for both applied load and stress range calculations.
Sustained stress shall be calculated using design pressure.
12.4.9 Stress Levels/Axial Expansion
Recommended level for solving for sustained stresses is within 50-70 % of hot code
allowable stress Sh, for the material. Piping with high SIF element can be accepted with
sustained stress higher than 70% of Sh.
Recommended level for solving for expansion stresses is within 90% of Sa, the code
allowable stress using liberal stress evaluation method. Piping with high SIF element can be
accepted with expansion stress higher than 95% of Sa.
12.4.10 Trunnion Supports
Use of Trunnion supports shall be minimized. Use of Trunnion supports shall be followed
only in the following cases as far as possible.
 At control valve stations
 At pump suction
 In pipe racks/ tracks
 On long vertical runs
 At PSV Locations if cannot be avoided
Trunnion calculation shall be attached with final stress report
Note: For Stress Critical lines, Trunnion shall be checked for Header Stress and Trunnion
Stress by using the Kellogg Method.

TRUNNION MODELLING IN CAESAR-II SHOULD BE DONE AS PER BELOW:
A. Trunnion On Pipe (More Detailed Modelling):
Diameter, thickness &

Element Type of element SIF
temperature
Imaginary Rigid element
(with zero
Shall be of pipe diameter,
weight) from center line of
pipe thickness, pipe
Node 20 to 22 pipe to pipe No SIF.
material, and pipe
surface / Trunnion
temperature
intersection point (equal to
half OD of pipe)
With Trunnion diameter,
Trunnion
thickness, Trunnion
Trunnion modeled as
Node 22 to 25 material, No SIF.
Pipe element
at ambient temperature &
with no
pressure & no fluid content
B. Trunnion on Elbow
Trunnion on elbow shall be modelled as above.
The element 20 to 30 is broken at node 25 at weld point / tangent point of elbow.
From node 25, additional rigid element (node 25 to node 26) of line temperature is to be
inserted in downward direction, of length equal to elbow dimension, so that we come back to

centre line elevation of the line, where all other supports on the pipe are modelled. Then
from node 26, the Trunnion element (node 26 to node 27) is modelled as pipe element of
ambient temperature, and actual support is modelled at bottom of Trunnion.
Diameter, thickness &
Element Type of element SIF
temperature
Node 25 to 26 Rigid element (with zero Shall be of pipe diameter No SIF.
weight) from elbow weld and pipe thickness, pipe
point to center line of pipe material and pipe
temperature.
Node 26 to 27 Trunnion modeled as Pipe With Trunnion diameter, No SIF.
element Trunnion thickness,
Trunnion material at ambient
temperature with no
pressure & no fluid content.
Welding of Trunnion on elbow causes stiffening of the elbow. In order to account for this
effect, the elbow shall be modelled as flanged type elbow.
The above demonstration is for vertical Trunnion on elbow in vertical plane, but may be used
for other orientations of Trunnion & Elbow.
12.4.11 Equipment Modelling
Equipment modelling for Vessels, Columns and Exchangers shall be done as per below.
Saddle expansion shall be ignored for Exchangers, since the expansion from these items is
insignificant.
Expansion due to vessel skirt should be included in stress models, particularly for high
temperature vessels like process columns and Reactors as applicable.
Equipment deflection due to wind to be confirmed if available and same shall be considered
for tall vertical equipment like process columns, reactors etc.
Nozzle flexibility between nozzle and vessel can be used if required.

Step 1. Start from fixed saddle - Model element 10 to 20 as a rigid element with zero weight
& vessel properties, including dia. and thickness & length equal to half diameter of
vessel. Model fixed saddle as anchor at node 10.
Step 2. Model elements 20 to 30 and 30 to 40 as rigid elements with zero weight & vessel
properties. Dimensions are to be taken from vessel fabrication drawing.
Step 3. Model element 40 to 50 as a rigid element with zero weight & vessel properties,
including dia. and thickness & length equal to half diameter of vessel. Model sliding
saddle as rest support and guide at node 50.
Step 4. Model element 30 to 60 as a rigid element with zero weight & vessel properties,
including dia. and thickness & length equal to half diameter of vessel.
Step 5. Model element 61 to 70 as a pipe (nozzle Wall thk. as per Vendor’s Dwg.) and
height equal to nozzle Projection minus flange length. Define CNode 60 for node 61,
Nozzle load to be checked at node 61.
Step 6. Model element 70 to 80 as flange with same rating as that of connected flange. The
above Equipment modelling method is applicable for Column, Heat Exchanger,
Vessel.
12.4.12 Modelling of Non Critical Branch Points
Weldolet /Sockolet / Sweepolet SIFs shall be modelled to include SIF in header stress
calculation at all small bore branch connections. SIFs, appropriate for the type of fitting, for
the small bore connection branch, shall be modelled even though the small bore branch
connection piping is not modelled in CAESAR II. FE-SIF values from Run (cylinder-cylinder
only) calculations may be used for these connections.
Lines that are not in critical criteria, that tie-in to stress critical lines may have a significant
effect upon complete system flexibility. Such lines shall be analyzed based on the criteria
given below. However, any line not falling in below criteria but deemed to have effect on
stress system comprising critical lines due to its layout needs to be added to Stress critical
system.
Mind that all connected small bore piping shall have sufficient flexibility to suit the expansion
of the header.

12.4.13 Spring Hangers & Struts

Spring hangers type is the preferred option than can type for spring supports taken from
equipment. At locations where springs /struts are used height/length of the assembly shall
be verified with final civil drawings.
For critical equipment like compressors and turbines where struts are used, it is
recommended to perform internal stress analysis to include stiffness of structure to ensure
correct boundary conditions.
Support stiffness required to qualify the nozzle load needs to be given to Civil.
Variable spring hangers are recommended where the load variation is not exceeding the
values given below for various systems:
 6% for the systems connected to Compressors and Turbines
 15% for the systems connected to Pumps
 25% for the systems connected to Static Equipment’s
Can Type Springs (i.e. Type F) shall be modelled with Friction for horizontal movement when
the horizontal movement exceeds 5 mm. Refer guidelines below for modelling Spring Cans
with Friction. Rigid Strut & Spring Hanger shall be modelled without friction.
Modelling Spring Can With Friction :
In Many systems, portions of the pipe are supported by spring cans. These spring cans
perform the same function as spring hangers, except that they are below the pipe, pushing
up in some models, these spring cans are allowed to side on their foundation, subjecting the
system to friction forces.
Each support of this type needs the following:
 A rigid element from the pipe center to the top of the can. Length equals pipe radius +
insulation thickness + cladding thickness + shoe height + any trunnion heights.
 A CNode to connect to the spring. Except for the vertical spring stiffness, all other
displays of freedoms are rigidly connected.
 A rigid element representing the height of the spring can.
These points are illustrated in the example below.

Alliteratively, element 15-20 can be omitted with the + Y restraint (with friction) placed
directly on node 15.
This modelling technique can be used in situations where the shoe or Trunnion slides on top
of a bolted spring can.
Where spring supports are provided on liquid lines WNC (Weight no fluid contents) load
case shall be included to check stress and nozzle load during accidental draining. This
check is mandatory for tanks and strain sensitive equipment.
In case of Can Type Springs requirement of Guided Column and Limits for horizontal travels
shall be requested in Spring Data sheets. Any changes on spring property by vendor based
preliminary spring data sheet needs to be used in stress analysis as user defined spring.
12.4.14 Spring Support Selection
Spring selection and hot load setting shall be set in CAESAR-II to the normal operating
temperature (T1). The selected spring shall be checked for the maximum and minimum
design temperatures for top/ bottom out condition.
As per modelling procedure, Operating Temperature is T1. Therefore, the second load case
for determining hanger travel shall be “CASE 2 (HGR) W+T1+P1” (not with T2). The
selected spring shall be checked for the entire range from max/min temperature to ensure
that it is within recommended working range.
Hydro Test load shall be indicated in Spring Support Data Sheets. Adequacy of the spring
casing to withstand the Hydro Test load shall be confirmed by Vendor. Hydro Test load up to
2 times the Operating load is generally complied by Spring Support Vendors. For cases
where Hydro Load is higher (in higher size lines), suitable Temporary Support arrangement
shall be used at suitable location close to Spring Support location during Hydro Test.
Temporary Support needs to be removed after Hydro Test. All Spring Supports shall be in
locked condition during Hydro Test.
12.4.15 Pumps
Evaluate the calculated external loads on Pump nozzles according to the allowable values
specified by the pump vendor in principle. However, where the API STD 610 is applicable,
evaluate the piping loads based on the criteria specified in API STD 610, Par. 5.5 and Annex
F. For Non-API pumps, evaluate the piping loads according to the allowable values specified
by the pump vendor or relevant codes.
Where the nozzle size of the pump exceeds, evaluate the piping loads according to the
vendor’s allowable values. Pump nozzle loads need to qualify in Sus & Ope conditions
only.
12.4.16 Operation Mode around Pumps
Three operation cases illustrated below should be typically analysed for pump piping system
with a stand-by pump. The installation temperature should be applied to the line between the
block valve and the pump nozzle of stand-by pump, if No. of Pumps More than 2 then same
philosophy to be used for preparation of operation Cases.

Both Pump A & Pump B in Operation Pump A in Operation & Pump B in Stand By
Pump A in Operation & Pump B in Stand By
Temperature Cases (operation conditions) of analysis model are in the order shown
below.
 Temp. Case 1: Both Pump A and Pump B in operation
 Temp. Case 2: Pump A in operation and Pump B in stand-by
 Temp. Case 3: Pump A in stand-by and Pump B in operation
Line temperature condition shall be as per the below criteria.
 Analysis temperature (1) = Operating temperature.
 Analysis temperature (2) for stagnant leg from branch point to block valve on the stand-
by pump (non-operating) are as follows:
 Insulated/Non-insulated line: Mean temperature of line design/operating and installation

temperature.
 Steam traced line- as per confirmation from Process department.

12.4.17 Reciprocating Compressors
For lines connected to Reciprocating Compressor Acoustic simulation and Mechanical

response study shall be carried out by vendor.
Piping stress engineer shall perform thermal analysis and provide support as per span
recommended by Vendor.
Some general guidelines other than covered above:
 Do not use unreinforced branch connections
 Eliminate as many bends as possible.
 Avoid long over hangs and long unguided risers.
 Group pipes together as much as possible and run them as close as possible to grade
 Place vibrations supports (Hold down guides/clamps supports) at or adjacent to heavy

loads and near piping discontinuities like tee, reducers. Concentrated loads can usually
be handled by placing a hold down as close as possible on both sides of the load.
 Anchors and stops should be provided as possible without interference with any thermal
movements.
 Piping support structure should have independent foundation.
 Frequency shall be maintained minimum 4Hz unless specified by vendor.
12.4.18 Storage Tank

Storage Tanks are made from Plates. Storage tanks are designed in accordance with API
standards. Since plate are used of low thickness, the allowable Nozzle loading due to piping
also comes down and will not be same as that of pressure vessel.
Problem faced in the Storage tank settlement, due to settlement of the Tank nozzle load
goes up. To cope up the settlement following measures can be adopted.
 Obtained the values of settlement during hydro test and post hydro test from civil
department. Normally major part of settlement takes place during the hydro test and rest
during the course of operating life. For analysis, purpose take settlement after the hydro
testing. Ensure with client that no piping would be connected during the Hydro-test of the
Tank.
 When settlement is small (< 50mm), the first support may be located away from the
nozzle to avoid over loading of the nozzle.
 When settlement is larger (> 50mm), then the nozzle loads can be reduced by using
spring support as first support from tank nozzle or for larger settlement values flexible
metallic hoses can be used on the nozzles. If spring supports are used these should not
be ‘F’ type but should be selected hanger type to adjust the structural arrangement of the
supports if the actual settlement is more than expected.
 OR First support in front of the Tank nozzle should be taken from the tank foundation
itself to avoid spring. Second support can be located as far as per the support span.
A. Calculate the following design parameters of tank nozzle connection by Vessel Team.
 Displacement and rotation of tank connection
 Stiffness coefficients of tank connection

 Tank nozzle design parameters such as non-dimensional quantities and limit piping
loads
B. Calculate the piping loads at the nozzle to reflect the displacements and stiffness
coefficients of tank nozzle connection into the analysis model.
C. Evaluate the calculated piping loads per vendor allowable.
D. If the calculated loads cannot be accepted by the Vessel Team, consider the
optimization of the current piping design (modification of piping configuration and
restraint conditions) to reduce the external piping loads on the nozzle.
E. When the reduction of the nozzle loads proved “Not Practical”, ask the Vessel Team to
evaluate the loads by means of the detail FEA method.
12.4.19 Tank Settlement
Storage Tanks: Differential settlement of tanks is particularly important and data shall be
obtained prior to the design of piping and this shall provide the:
 Amount of settlement (and recovery) that will occur following construction and hydro test.
This is generally called immediate settlement. Initial settlement can be generally ignored
as the pipes are connected to the Tank Nozzles only after performing hydro test of tank.
12.4.20 D/T Ratio >100
For Pipe having ratio D0 / T > 100, SIF should be calculated by FEA analysis.
12.4.21 PSV’S
PSV reaction force F (With DLF as 2) shall be applied horizontal as well as vertical direction,
reverse direction to discharge flow in pop up case. PSV standby cases shall be generated as
applicable. Thermal stress check shall include load case for displacement range check
corresponding to standby conditions as per B 31.3 Appendix S S303
Temperature cases are built as per below:
SAMPLE CASE Normal Oper. Max. Design Min. Design
Process / In let Temp.(deg. C) T1 T2 T3
Flare / Out let Temp.(deg. C) T1 T2 T3

TEMPERATURES
LOAD
CONDITION
CASE
L1 L2 L3 L4 L5 L6 L7 L8 L9
L1 Normal Operating T1 T1 T1 T1 T1 T1 T1 T1 T1
L2 Maximum Design T2 T2 T2 T2 T2 T2 T2 T2 T2
L3 Minimum Design T3 T3 T3 T3 T3 T3 T3 T3 T3
Normal Operating : A-
Normal
Ambi Ambi Ambi
L4 Operating (A-PSV T1 T1 T1 T1 T1 T1
ent. ent. ent.
Blowing+F1) : B-Stand
By
Normal Operating : B-
Normal
Ambi Ambi Ambi
L5 Operating (B-PSV T1 T1 T1 T1 T1 T1
ent. ent. ent.
Blowing+F1) : A-Stand
By
 PSV reactions forces should be as advised by the vendor, or can be calculated known formula’s
based on API RP 520.
 PSV Reaction force is included in normal operating case.
 For open system in addition to the exit pipe reaction force to be applied at PSV point also. These
forces should not be applied simultaneously.

12.4.22 Rigid Elbow
In order to take into account the rigidity, at elbows directly welded to flanges and elbows with
 Trunnion, modelling shall be as below; by selecting the ‘Bend Type’ option.
 Elbow without flange but with a Trunnion : 1-Single Flange where d/D>0.6
 Elbow with flange at one end and no Trunnion : 1- Single Flange
 Elbow with flange at both ends and no Trunnion : 2-Double Flange
 Elbow with flange at one end and a Trunnion : 2-Double Flange
 Elbow with flange at both ends and a Trunnion : 2-Double Flange

12.4.23 Wind Loads
Occasional stress due to wind load shall be checked for all size, which are located over 10 m
elevation.
12.4.24 Earthquake Loads
Occasional stress due to seismic load shall be checked for all formally analysed pipes.
12.4.25 Snow and Ice Load:
Snow load is simply a uniform load in units of weight per length (lb/ft, N/m, etc.). Multiply the
depth/thickness of snow/ice on the piping by the density of snow/ice and the pipe outside
diameter to calculate the uniform load. If the piping enters a building or will otherwise have
no snow/ice load simply re-activates the uniform load at that node and enter all zeroes. For
snow/ice loads the uniform load will always be negative in the vertical direction. The load
cases are the same as described for seismic, wind, and wave.
12.4.26 Support Lift Off
Support lift off cases shall be checked for all OPE cases. Permissible lift off will be a max
2mm and if more than 2mm hot sustain stress shall be checked.
12.4.27 Gaps At Restraints
The standard guide and limit stop gap will be as per the support design standard.
Non-uniform gaps on either side of the guide and axial stops shall be avoided. At non-
convergence of Caesar-II, friction stiffness shall not be lowered. To resolve convergence full
Y type that does not lift up shall be included and for supports that lift up friction factor for the
supports shall be removed.
12.4.28 Flare System Design
For lines discharging to Flare header & Flare header analysis, the following additional
checks shall be carried out in consultation with Process based on P& IDs/ Operation
sequence.
 1+1 scenarios for PSVs
 Fluid density to be considered in Flare systems

Particularly for Projects where liquid service is predominant like Oil, Condensate, LPG etc.
Assumption of Fluid density 1/3 of Water may not be always conservative. This data needs
to be obtained from Process (Output of Process Flare Net Study).
Similarly, for Projects where Gas service is predominant, 1/3 of Water density may lead to
over conservative design. This shall be considered as below: Vapour density for the portion
of Flare Header up to which there are no chances of Liquid carryover from PSV. Mix density
(L+V) from the point of Liquid carryover PSV discharge to KOD inlet. Refer schematic shown
below for clarity.
12.4.29 Flange Leakage
Max. Allowable axial force & bending moments at flange joint shall be checked in
accordance with Pressure Equivalent method using Caesar II at corresponding case
temperature. If this simplified method predict that leakage could occur, then in-depth flange
analysis using ASME B&PV Sec. VIII Div-1 is required.
Selection criteria for checking flange leakage as below:
Flanges with rating 600# or more.
Flanges with rating 300# and size greater than 12”.
Pipe flanges carrying category M fluid service.
Pipe flanges carrying Hydrogen or other flammable fluid.
All stress critical PSV lines.
Flanges in jacketed piping.
12.4.30 Non-Metallic Piping
The stress analysis of Non-Metallic piping is the responsibility of Supplier/ Vendor. Non-
Metallic piping support types and spans shall be as per the Vendor recommendations.
12.4.31 Steam Out
Lines subject to steam out shall be considered for flexibility analysis at the steam out
temperature if it exceeds the design temperature. The analysis should consider whether
equipment and piping are steamed out together or separately. Allowable nozzle loads for
steam out conditions should be agreed with equipment suppliers as early in the project as
possible.

Where piping flexibility requirements for steam out condition are significantly greater than
those required for design conditions, consideration should be given to pipe disconnection at
equipment nozzle, and piping and equipment steamed out separately. A disconnection
schedule detailing all effected equipment nozzles shall be compiled by stress group and
issued to site as an operational requirement. Lines to steam purged vessels that cannot be
disconnected during steam purging shall be designed with sufficient flexibility to
accommodate the thermal displacement of the vessel.
12.4.32 Packaged Equipment
Unless agreed otherwise, the piping to packaged Equipment shall be anchored on Vendor
piping as close to the Vendor interface as practical. The Anchor shall be of three way
restraint (Partial Anchor –Restraint in X, Z & Y Directions i.e. Restraint in Axial, Transverse &
Vertical Directions). Nearby supports on either side shall be Guides. Where Partial Anchor is
not practical on Vendor piping inside package, qualifying the Nozzle loads and Support
design shall be based on Stress Analysis of combined System of Vendor piping and external
piping or other suitable methods.
12.4.33 Slug Flow
In mixed flow where slugging is expected in a piping system, slug loads shall be calculated
and applied in both axes axial (Fx) & orthogonal (Fy) directions at all changes of direction.
However for Tees, the resultant slug load to be applied only at the flowing directions.
Slug force shall be calculated based on formula given below. The slug forces will be acting
on the different elbows at different time and the input in the software shall consider the
same.
For Elbows the slug load is as follows:

Fx = DLF*(ρ)(A)(V2)*(1-Cos θ)
Fy = DLF*(ρ)(A)(V2)*(Sin θ)
For Tees the slug load is as follows:
F = DLF*(ρ)*(A)*(V2)
Where,
F : Load due to slug, at change in direction in Newton
Ρ : Density of the slug in Kg/m3
A : Inside area of pipe cross-section in m2
V : Velocity of moving slug in m/sec
Θ : Angle of bend in Degrees
DLF : 1 for dynamic analysis & 2 for static analysis

Slug force need not to be applied at the elbow in the vertical down comer.
Slug properties shall be obtained from Process group.
Equivalent static analysis in Caesar II shall be performed to simulate slug loading in piping
system with the slug force calculated as above.
12.4.34 Two Phase Flow Line / Mixed Phase Flow Line
Two phase lines having slug/plug flow: Detailed analysis as per stress spec. Guide locations
shall be confirmed by Stress Analysis.
Avoid use of Guides with Gaps. If there is specific requirement for Gaps at Guides, prefer
only standard Guide Gap (3mm Gap). Stress Analysis shall ensure that such Guides are
“ACTIVE” for all Cases.
Axial Stop/ 3 Way Restraint is recommended in each long leg of piping in each direction.
Stress Engineer based on displacement pattern shall recommend suitable locations for the
same without imposing higher thermal loads.
Modal analysis can be done to get a feel of system rigidity. First natural frequency of 4 Hz
should be targeted. Achieving this frequency all the time may not be feasible. This shall need
not be part of output report.
12.4.35 Buried Piping
Analysis of buried piping shall be carried out up to virtual anchor for metallic pipe. In case of
non-metallic piping entire buried portion to be included in the model.
For buried pipeline analysis shall be as per applicable ASME pipeline codes such as ASME
B31.4/ASME B31.8/ISO 14692(GRE Piping).
For systems with buried piping, the soil input parameters as below shall be obtained from
Civil. Select soil model type in Caesar-II “CAESAR-II Basic model". Soil properties after back
fill & Compaction shall be considered. Effect of Axial Stress due to longitudinal force is
significant in buried piping. For buried piping, to take care the effect of F/A in Secondary
Stress calculation.

12.4.36 Stress Analysis Load Cases
As a guideline following load cases are to be followed for pipe stress analysis.
 Hydro Test case
 Operating case
 Sustained case
 Expansion case
 Occasional case
12.4.37 General
Adjustable type support is recommended for suction and discharge lines of pumps,
compressor, turbine etc. near the nozzle.
Standard method of supporting to column lines shall be trunnions at 90 degrees to nozzle

and at an elevation as close as possible to bend. All other supports on vertical shall be guide
supports.
Wear pads/Bearing plates recommended for bare SS lines resting directly on structural steel
to avoid corrosion.
Requirement of wear pad is dependent on contact length of supporting member. Stress

engineer needs to check requirement as per available contact length.
Holds down guides are recommended a few locations as per line configuration. Stress
engineer shall ensure that hold down support is not restricting upward thermal movement.
Supports for non-stress critical lines shall strictly follow the allowable Support Span Charts
and Guide Span Charts in conjunction with the Notes thereof (particular care to be taken for
the reduction of allowable span in cases where one or more bends are present between
supports or where there are in-line items such as Valves and Instrument items), as per the
Pipe Supports Standard design drawings issued on the Project. Supports shall also be
added near concentrated weights in piping such as close to Valves, Flange pairs, Flow
Nozzles, Strainer, etc.
GRP/GRE/FRP/HDPE lines shall be supported as per vendor recommendation.
All Piping supports shall be checked for adequate weld clearance as stipulated in
specification between supports and pipe welds. Shoe lengths shall be adequate to take care
of Expansion.
12.4.38 Stress Report

 The pipe stress analysis report shall contain the following as a minimum:
 Description of Input data, Assumption, Recommendation and conclusion
 Extract of Process critical line list for specified system
 Process Engineering Flow Schemes(PEFS) with system identification
 Applicable Equipment drawing with data sheet
 Applicable Piping Class
 Isometric drawing (If applicable)
Spring hanger data sheets (If applicable)

 Load case report

 Stress summary
 Restraints summary extended report
12.5 SUPPORT LEGEND

1057-GOAL-L-DB-1001 - Rev C - Piping Design Basis PDF

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DOC.

GREEN OIL AND LUBES, OLTENITA,

SHEET NO. Page 1 of 38

PROJECT USED LUBE OIL RE-

PIPNG DESIGN BASIS

C 11.01.2018 Issued For Approval JJP KBR SGJ

B 05.09.2016 Issued For Approval PDT SKV ALV

A 02.07.2016 Issued For Approval PDT SKV ALV

PROJECT NO : 1057 1057-GOAL-L-DB-1001

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 2 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

11.9 PRESSURE RELIEF SYSTEM / BLOW DOWN SYSTEM PIPING ..................................... 17

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 3 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

1.1 PROJECT SUMMARY

Project Name Used Lube Oil Re-refining Plant

Project Number 1057

Project Location Oltenita, Romania

Company Green Oil and Lubes

EPC Contractor Chemie-Tech DMCC

The Following Abbreviation are used in this project

API American Petroleum Institute

ASME The American Society Of Mechanical Engineers

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 4 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

NACE (N) National Association Of Corrosion Engineers

MOC Material Of Construction

VMS Valve Material Specification

dft Dry Film Thickness

NDE Non Destructive Examination

WNRF Weld Neck Raised Face

A/G Above Ground

AIV Acoustic Induced Vibration

FIV Flow Induced Vibration

GRE Glass Reinforced Epoxy

IFC Issued for Construction

NPS Nominal Pipe Size

PROJECT Used Lube Oil Re-Refining & Hydrogenation Plant

PSV Pressure Safety Valve

U/G Under Ground

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 5 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

Any and all persons, firms, partnerships, companies, bodies,

3 CODES AND STANDARDS

Code / Standard Description

2014/68/EU Pressure Equipment Directive (PED)

ASME B31.3 ed.2014 Process Piping

ASME B1.13M Metric Screw Threads — M Profile

ASME B16.5 ed.2013 Pipe Flanges and Flanged Fittings

ASME B16.10 ed.2009 Face-to-Face and End-to-End Dimensions of Valves

ASME B16.11 ed.2011 Forged Fittings, Socket-Welding and Threaded

ASME B16.34 ed.2013 Valves — Flanged, Threaded, and Welding End

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 6 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

API 6D ed.2008 Pipeline valves

ASME V ed.2015 Non-Destructive Examination.

ASME IX ed.2015 ASME IX Welding and Brazing Qualifications

MSS SP 58 Pipe hangers and supports - materials, design and manufacture

PIPING DESIGN BASIS (1057-GOAL-L-DB-1001) Page 7 of 38

PROJECT NO : 1057 1057-GOAL-L-DB-1001

The Re refining of Lube Oil shall be carried out by following Plants.

● Flash Distillation Plant

Planned Maintenance 15 x 2 times days