Jeres l-310 design of plant piping
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Jeres l-310 design of plant piping Document Transcript

  • 1. Jubail Export Refinery Engineering Standards JERES-L-310 Design of Plant PipingRevision Responsibility 14 May 5 JER Engineering Division 2009
  • 2. Jubail Export Refinery Material SpecificationsJERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Revision TrackingRevision Revision Date Scope of Revision Revised to update paragraphs: 14.8 5 14 May 2009 Adding paragraph: 11.9.3 Revised to update paragraphs: 11.6.3, 19.1.1, 19.1.2 4 03 February 2009 Corect Appendix C to Appendix B. Move section C.2.4 to 19.1.2 Revised to update paragraphs: 20, 20.1.2, 20.3.3, Appendix A &B, 3 10 October 2008 Modified par. 11.6.3, Add Table 4 for “Spare room on pipeways and pipe-racks” Adding new: 11.6.4, Figure-3. Revised to update paragraphs: 19.3, 20, 20.1.2, 20.3.3 2B 30 September 2008 Adding a new Appendix B Revised to update paragraphs: 11.6.3 2A 25 September 2008 Adding: new Table 4. Revised to update paragraphs: 3.1, 9.6, 11.4.5, 11.7.2, 11.7.3.4, 11.7.3.5, 2 31 July 2008 11.7.3.7, 13.2.4, 19.3, 19.4, 22, 23, 24 Adding: paragraph 13.3.6 and section 22. Updating Issued Rev. 0 for bid package to incorporate technical 1 20 May 2008 comments. 0 30 April 2008 Issued for a bid package. 03 31 March 2008 Issued for a bid package only for review 02 31 August 2007 A new section 11.8 is added to address battery limit piping layout. 01 30 March 2007 The first official JERESE-L-310 is issued. First draft issued is based on Saudi Aramco SAES-L-310 “Design of 00 26 February 2007 Plant Piping” issue date 24 February, 2007. Document was modified to incorporate amendments and modifications.This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 2 of 45
  • 3. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Table of ContentsSection Contents Page 1 Scope 5 2 Conflicts, Deviations and Clarifications 5 3 References 5 4 Definitions 8 5 Responsibilities 9 6 Applicable Codes and Standards 9 7 Design Package 9 8 Basic Design Parameters and Limitations 10 9 Material Selection for piping Components 13 10 Limitations on Pipe Sizes and Thickness 13 11 Piping Layouts 15 12 Spacing Requirements 23 13 Underground Piping 23 14 Pipe Support Design 24 15 Anchors and Guides 26 16 Non-Pressured Welded Attachments 28 17 Piping Joints and Flange Connections 28 This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 3 of 45
  • 4. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 18 Firewater Systems 30 19 Plant Utility Piping System 30 20 Utility – Process Connections 32 21 Vibration Consideration 34 22 Process Steam Piping and Heat Tracing 35 23 Identification of Chemical Cleaned Line 35 24 Testing and Inspection 35Appendix A Schematic Figures Figure 1: Typical piping arrangement for dead leg 36 Figure 2: Typical piping arrangement at battery limit Figure 3: Typical arrangement for Process-to-Utility Connection B Basis of Design for Utility Station 41 This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 4 of 45
  • 5. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 20091 Scope1.1 This standard supplements ASME B31 codes and defines additional minimum design requirements for pressure piping located within plant areas.2 Conflicts, Deviations and Clarifications2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution. Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.3 References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.3.1 Company References Company Engineering Standards JERES-A-112 Meteorological and Seismic Design Data JERES-B-017 Firewater System Design JERES-B-019 Portable, Mobile and Special Fixed Firefighting Equipment This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 5 of 45
  • 6. Jubail Export Refinery Material SpecificationsJERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 JERES-B-067 Safety Identification and Safety Color JERES-G-116 Cleanliness Standard for Lube/Seal Oil and Fluid Power Systems JERES-H-001 Coating Selection & Application Requirements for Industrial Plants & Equipment JERES-H-002 External Coatings for Buried Steel Piping and Pipelines JERES-H-005 Internal Coating for Vessels, Tanks and Equipment JERES-L-100 Applicable Codes & Standards for Pressure Piping Systems JERES-L-105 Piping Line Class and Materials Specifications JERES-L-108 Selection of Valves JERES-L-109 Selection of Pipe Flanges, Stud Bolts and Gasket JERES-L-110 Limitations on Piping Joints and Components JERES-L-120 Piping Flexibility Analysis JERES-L-125 Safety Instruction Sheet for Piping and Pipelines JERES-L-130 Material for Low Temperature Service JERES-L-131 Fracture Control of Carbon Steel Line Pipe JERES-L-132 Velocity Criteria and Basic Material Selection for Process Piping JERES-L-133 Corrosion Protection Requirements for Pipelines/Piping and Process Equipment JERES-L-136 Selection and Restrictions of Carbon Steel Pipe JERES-L-140 Thermal Expansion Relief in Piping JERES-L-150 Pressure Testing of Plant Piping and Pipelines JERES-L-315 Steam Tracing and Jacketed Piping JERES-L-350 Construction of Plant Piping JERES-L-351 Bolted Flange Joints Assembly JERES-L-410 Design of Pipelines JERES-L-450 Construction of On-Land and Near-Shore Pipelines JERES-L-460 Pipeline Crossings Under Roads and Railroads JERES-L-610 Non-metallic PipingThis document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 6 of 45
  • 7. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 JERES-O-101 Standard Security Fence - Category I JERES-P-315 Electrical Tracing for Piping and Equipment JERES-X-400 Cathodic Protection of Buried Pipelines JERES-X-600 Cathodic Protection of Plant Facilities Company Standard Drawings JERSD-L-0001 Heavy Welding Boss for Threaded Connections JERSD-L-0002 Pipeline Spacing Arrangements JERSD-L-0004 Bridge Weld and Typical Brace Seal Welded, Socket Welded Valves JERSD-L-0007 Standard Wear Pads for Unrestrained Pipelines JERSD-L-0014 Maximum Spans for Above Ground Unrestrained Pipelines 14" & Larger JERSD-L-0027 Heavy Welding Boss - Socket Weld Connections JERSD-L-0029 Corrosion Bar Wear Support JERSD-L-0038 Installation of Jack screws for Flanged Joints JERSD-L-0040 Steam Trap Typical Layout JERSD-N-0005 Flame Impingement Shield for Flangeless Valves3.2 Industry Codes and Standards American Petroleum Institute API SPEC 5L Specification for Line Pipe API RP-617 Axial and Centrifugal Compressors and Expander- Compressors for Petroleum, Chemical and Gas Industry API RP-1102 Steel Pipelines Crossing Railroads and Highways American Society of Mechanical Engineers ASME B16.1 Cast Iron Pipe Flanges and Flanged Fittings ASME B31.1 Power Piping ASME B31.3 Process Piping ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 7 of 45
  • 8. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 ASME B31.8 Gas Transmission and Distribution Piping Systems Uniform Plumbing Code (UPC)4 Definitions4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution. Company: Jubail Export Refinery. Company Representative: A designated person from the Company or an assigned third party representative. Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.4.2 List of Definitions Dead Legs: Piping sections that are potential for internal corrosion due to flow stagnation. Refer to Section 11 of this Standard for detailed criteria. Design Agency: Refer to JERES-L-100. Fully Restrained Piping: A pipe system that is restrained from axial and lateral movement by means of anchors, clamps and/or fixed supports. Unrestrained Piping: Piping system designed with sufficient flexibility to control stresses due to thermal or other movement. Process-Utility Connection: The piping which joins the utility header root valve to the block (root) valve of the process pipe or equipment. Temporary Connection: A connection made by means of metallic or non-metallic hose, or flanged break-away spool. The temporary connection is marked in a conspicuous manner and governed by plant operating instructions for use only under constant monitoring. Process Equipment: Piping, vessels, tanks and other plant equipment that contain hydrocarbon liquid or gas, toxic chemicals, including acids or caustics. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 8 of 45
  • 9. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Break Tank: A vented water reservoir controlled by the water level in the tank, from which the water can be pumped through a permanent connection with check valve and block valve into a single unit of process equipment. Water Supply System: The entire network of piping between a source of water (well or tank) and all delivery points.5 Responsibilities5.1 It is the responsibility of the design agency to design pressure piping systems that meet the requirements of the applicable Code and the additional relevant Company Standards, Specifications and Procedures as a minimum.5.2 Strict application of minimum standards does not prohibit nor limit the design agency from using good engineering practices and from introducing cost saving innovative ideas, subject to the approval by the Company Representative.5.3 Though this standard covers requirements related to design of piping systems, the design agency shall be acquainted with JERES-L-350 in order to design piping systems which will assess constructability with the most cost effective approach.6 Applicable Codes and Standards In addition to referenced Codes and Standards, the applicable Codes and Standards in accordance with JERES-L-100 shall apply as appropriate.7 Design Package The design of pressure piping located inside plant areas shall include the preparation of the documents listed below. These documents shall be given Company drawing numbers (where applicable in accordance with Company requirements) and become permanent Company records: − Process Flow Diagram (PFD) and / or Utility Flow Diagram (UFD) − Piping and Instrument Diagram (P&ID) − Piping Designation Tables − Calculation sheets supporting major flow data and pressure drop data shown on the Piping Designation Table. − Safety Instruction Sheets (SIS) for critical piping per JERES-L-125 This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 9 of 45
  • 10. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 − Piping Plan Drawings (details and sections must be shown on separate drawings) − Piping Section Drawings and details − Isometric Piping Detail Drawing − Piping flexibility calculations per JERES-L-120 − Hydrostatic Test Diagram − Pipe support and foundation location drawing − Pipe support and anchor detail drawings − Valves operating diagram (VOD) as required by Company Representative − Project Scope of Work or Project Specifications in which the piping shall be described, highlighting any special features or precautions such as concerning welding, adjustment of spring hangers, cold spring, etc.8 Basic Design Parameters and Limitations8.1 The design agency shall establish and/or verify that the design conditions are valid and fulfill the targeted performance objectives.8.2 The design agency shall consider future capacity increase and may propose pre- investment design features for Company review and approval.8.3 Design Factors & Allowable Stresses8.3.1 Plant piping designed in accordance with ASME B31.4 or ASME B31.8 the following shall apply: − For MAOP and wall thickness calculations the design factor shall not be more than 0.5. − Pressure variation under surge condition equals to 15% of MAOP is permitted for liquid service. − For longitudinal stress under sustained load the allowable stress shall not exceed 0.72 of SMYS. − The combined sustained and secondary stresses shall not exceed 0.90 SMYS in the piping system.8.3.2 Plant piping designed in accordance with ASME B31.1 or ASME B31.3 shall follow the Code allowable stresses. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 10 of 45
  • 11. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 20098.3.3 Maximum Stresses The calculated maximum stress at pressure test conditions including the hydrostatic load due to test fluid shall not exceed the SMYS.8.3.4 Occasional Loads and Pressure Variation For design conditions which include occasional loads such as wind, earthquake, or external hydrodynamic forces, or occasional short-term pressure variation above the normal maximum, the pressure rating of components and/or the allowable stress may be increased as permitted by the applicable Code for such conditions without additional restrictions.8.4 Design Pressure8.4.1 Piping systems designed in accordance to ASME B31.4 or ASME B31.8 shall have the design pressure as close as possible to the MAOP.8.4.2 Piping systems designed in accordance to ASME B31.1 or ASME B31.3 shall be designed to withstand the most severe combination of pressure and temperature.8.4.3 Void.8.5 Design Temperature8.5.1 The design agency shall specify the design temperature that matches the actual process conditions. Specific temperature conditions are addressed below.8.5.2 Pipe Temperature For the purpose to specify piping material, the metal temperature of the pipe and piping components shall be the same as the bulk temperature of the fluid transported by the piping system. No credit should be given for ambient heat losses unless such losses can be demonstrated to have significant cost advantage.8.5.3 Ambient Range For fluid temperatures at or above ambient, the design temperature shall not be less than the maximum expected actual fluid temperature at design flow rate and design pressure. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 11 of 45
  • 12. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 20098.5.4 Refrigerated Services For the purpose of determining impact testing requirements, the design minimum temperature shall be established for piping carrying fluids which have been refrigerated below ambient temperature, based on process design conditions.8.5.5 Auto-refrigeration For systems normally at or above ambient temperature which can occasionally be exposed to lower temperatures due to a sudden reduction in pressure (including causes such as leaks or ruptures) or due to blowdown of equipment, the design minimum temperature shall be the coincidental temperature when the pressure reaches 25% of the design pressure.8.5.6 Thermal Radiation Effects All above ground piping systems shall be evaluated in accordance with JERES-L- 140 for pressure build up due to the effects of solar radiation, ambient temperature, and other heat sources such as a flare or combination of these effects.8.6 Dynamic Effect The effects of dynamic forces external and internal dynamic forces shall be analyzed and the final design shall be suitable to accommodate such forces. Examples of such forces are earthquake, slug forces, pressure surge forces, etc.8.7 Sustained loads8.7.1 Sustained load shall include effects of internal design pressure, weight effects of pipe, components and contents.8.7.2 Traffic loads on buried piping shall be in accordance with API RP-1102.8.8 Meteorological and Seismic Design Data Data for meteorological and seismic condition shall be in accordance with JERES-A- 112.8.9 Flow Velocity Requirements8.9.1 General This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 12 of 45
  • 13. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Flow velocities inside piping systems shall be in accordance of the requirements per JERES-L-132.8.9.2 Gas Service Piping systems shall be designed with considerations to avoid and minimize the potentials of noise and piping vibration due to high velocities, slug flow, two-phase flow, acoustic fatigue, etc. For additional requirements, refer to Section 21 “Vibration Considerations” of this Standard.9 Material Selection for Piping Components9.1 All pressure piping components shall comply with Company Standards specified in the paragraphs listed below. However, it is the design agency responsibility to ensure selected material is adequate to the intended service.9.2 Material procurement of pipes, valves, fittings and gaskets shall be procured from the Company Approved Vendor List.9.3 Material specification and piping line classes shall be in accordance with JERES-L- 105.9.4 Material selection for line pipes and components shall be in compliance with JERES- L-130, JERES-L-132, JERES-L-133, and JERES-L-136.9.5 Valves selection for piping systems shall be in accordance with JERES-L-108.9.6 Flanges, bolts and gaskets shall be in compliance with JERES-L-109.9.7 All non-metallic piping system shall be designed and constructed in accordance with JERES-L-610 in addition to the applicable ASME B31 Code.9.8 Each pressure piping system located within a plant area shall be given a material specification code in accordance with JERES-L-105.9.9 Items specified by brand names or proprietary names are not intended to exclude equivalent items offered by other manufacturers.10 Limitations on Pipe Sizes and Thickness10.1 Sizes of Pipes and Fittings This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 13 of 45
  • 14. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 The outside diameter of steel pipe shall be in accordance with applicable API SPEC 1 3 5L and/or ANSI B16.9 standards. Intermediate sizes and the sizes: 8 , ¼, 8 , 1¼, 2½, 3½, and 5 inches shall not be used except when necessary to match equipment connections. In this case a suitable transition shall be made as close as practical to the equipment.10.2 Pipe (excluding stainless steel tubing) smaller than ¾-inch nominal size shall not be used for hazardous services (including vents and drains) except for instrument connections (such as shown on Standard Drawings) and on Vendor-supplied skid- mounted equipment or other (interior) applications where the pipe is adequately protected against mechanical damage.10.3 The wall thickness of the pipe and piping components shall meet the requirements of the applicable Code as a minimum.10.4 Piping wall thickness selection shall be governed by greater of minimum calculated code thickness including corrosion allowance or the minimum structural thickness provided in Table 1. Table 1 – Minimum Structural Pipe Wall Thickness (Ts) Nominal Pipe Welded Pipe Including Threaded Pipe Size (Inch) Seal/ Socket Welded (Not Seal Welded) (Inches) (mm) (Inches) (mm) ½ Thru 1½ 0.09 2.25 0.12 3.0 (1) (1) 2 Thru 3 0.09 2.25 0.12 3.0 4 Thru 12 0.10 2.54 - - 14 Thru 18 0.12 3.0 - - (2) (2) 20 Thru 30 D/150 D/150 - - 32 Thru 48 0.200 5.08 - - 50 and up 0.250 6.35 - - Notes: 1) Threaded pipe is allowed up to NPS 2" for existing facilities in hydrocarbon services and up to NPS 3" for utility piping. 2) "D" is the pipe outside diameter. 3) A stress analysis is required to confirm that the combined longitudinal stress does not exceed the code allowable limit based on factors such as pipe support spacing, allowable stress, design pressure, etc. This note applies to the entire Table 2.10.5 For carbon steel piping, the minimum nominal wall thickness shall not be less than the values listed in Table 2. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 14 of 45
  • 15. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Table 2 – Minimum Pipe Wall Thickness for Carbon Steel Pipes Low Pressure Utility Service Nominal Size (Inches) Hydrocarbon Service (ASME B16.1 Class 125) 2 and smaller SCH 80 SCH 40 (see 6.11) 3 through 10 SCH 40 SCH 40 12 through 32 6.3 mm 6.3 mm 34 and larger Diameter/135 Diameter/13510.6 The required corrosion allowance shall comply with the requirements of JERES-L-133. Commentary Note: For new piping, the corrosion allowance may be required to be added over the retirement structural thickness or the pressure design thickness particularly in when the minimum structural thickness is greater than the pressure design thickness. This will ensure that the actual pipe thickness will not be reduced to below retirement thickness before the corrosion allowance is depleted. This is in conjunction with fitness for service of plant piping once it becomes under operation.11 Piping Layouts11.1 General The design agency is responsible to provide piping layout that is economic and follows sound engineering practices. The piping layout shall assure safe operation, ease of construction, provide adequate access for maintenance activities, minimize consequence due to fire, and avoid congestion.11.2 Hydraulic Considerations11.2.1 The pipe size, layout and supports shall be designed such that all hydraulic requirements are met in terms of pressure drop and required through put.11.2.2 Piping systems shall be designed with considerations to avoid and/or minimize the potentials of noise and piping vibration due to high velocities, slug flow, two-phase flow, acoustic fatigue, etc.11.2.3 Piping systems in high gas velocities operating intermittently shall be designed with following considerations: − Excessive noise and vibration are avoided due to high gas velocities and pressure drop. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 15 of 45
  • 16. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 − Smooth transitions at flow intersections by means of laterals and long radius bends. − Pressure drop at intersections is minimized. − Sufficient length of lead-lines downstream pressure and or flow control valves. A minimum of 5 times diameter shall be provided.11.3 Corrosion Considerations The piping layout shall be designed in drainable to minimize corrosion in the piping systems due to presence of water pockets, dead legs, and any other situation leading to internal or external corrosion.11.4 Dead Legs Refer to Figure-1A through Figure-1C of Appendix-A regarding this section for clarification.11.4.1 Dead legs as defined in section 4 and leading to internal corrosion shall be avoided at the design stage and during construction. Corrosion mechanism due to dead legs is created mainly by flow stagnation enhanced with presence of settled water and solid depeosits.11.4.2 Void11.4.3 A section of a piping system meeting the following criteria is considered a dead leg: a) When a pipe branch or section is connected to a flowing stream where it is not self draining and is not normally flowing. b) The piping material has the potential for corrosion under flow stagnation condition. c) When the length of the section or branch , for 2 inch pipes and larger, is longer than three times its pipe diameter, or 1.22 m (4 ft) in length, the length of the dead leg is the distance measured from the outside diameter of the header (or run) to the near end of the branch valve. Refer to Figure-1A for explanation. For branch connections of 1-½ inch NPS and smaller, the length of the dead leg is the distance measured from the end of the boss to the near end of the valve. Refer to Figure-1B for explanation. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 16 of 45
  • 17. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 a) For axial dead leg as shown in Figure-1C, the stagnant section is always a dead leg regardless of dimension presented in point (c) above. This arrangement shall be avoided. Commentary Note: A by-pass line that is designed for a specific function is not normally considered to be a deadleg. However, if a specific ruling is required the Company Representative shall be contacted.11.4.4 Exemptions to Dead Legs A section of a piping system meeting the following criteria is not considered as a dead leg even if it meets the dimensional criteria above: c) The service is not wet. a) Piping material is corrosion resistant to corrosion caused by dead leg phenomena. b) The service does not lead to corrosion under stagnation condition based on Company past experience demonstrating this.11.4.5 In the case where a piping section is identified as dead leg and it is not avoidable from a construction point of view, then during project execution, a concurrence letter shall be signed by the Company Representative. These situations shall be brought to the attention of Company Representative and documented to facilitate periodical On Stream Inspection by the Company during the operating life of the facilities.11.5 Piping Flexibility11.5.1 The piping configuration shall be analyzed for adequate flexibility in accordance with JERES-L-120.11.5.2 The piping system shall not be too flexible to the point that it becomes subject to piping vibration problems.11.5.3 Expansion Joints11.5.3.1 Swivel joints, expansion joints, flexible pipe (metallic or non-metallic), hoses or similar devices shall not be used to reduce the stiffness of the piping system or to reduce load on equipment nozzles in flammable, toxic and hazardous services. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 17 of 45
  • 18. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200911.5.3.2 Subject to Company approval, expansion joints may be used for category D fluid service as defined in ASME B31.3.11.5.3.3 Expansion joints on lube oil systems in vendor standard designed lube oil skids may be acceptable subject to review and approval by the Company Representative.11.5.3.4 In the case where the use of expansion joint or others are not avoidable the installation proposal shall be approved by Company Representative. Also, a detailed piping flexibility analysis shall be performed in accordance with JERES-L-120.11.5.4 Pipe Expanded Joints shall not be used regardless of service type.11.6 Pipeways11.6.1 Above grade plant piping between plant equipment or between separate units within a plant area shall be designed and installed within pipeway boundaries as indicated on Plot Plans and Piping Plans.11.6.2 The Plot Plans and Piping Plans shall be laid out such that they shall provide the necessary access to all areas for operations and maintenance in accordance with JERES-B-054, JERES-B-055. The elevations of intersecting pipeways shall normally be at different levels to allow for future piping.11.6.3 When designing off-plot pipeways for process plants, consideration shall be given to provide additional rack space for future expansion. This consideration is subject to the approval of the Company Representative. The following Table 4 gives the Company’s philosophy and requirements for the provision of extra space for future expansion. Table 4: Spare room on Pipe ways and Pipe racks Pipe Supports Type Minimum Remarks Spare Main Pipe rack and Unit Pipe rack 15% Refer to Paragraph 11.6.4 Interconnecting pipe way or sleeper way 20% Internal dike sleeper way 15% This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 18 of 45
  • 19. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200911.6.4 Final pipe rack width shall be the widest pipe arrangement among the different levels plus 15% of this width. This final width shall apply for all levels.11.7 Piping Connected to Rotating Equipment11.7.1 For equipment loads refer to JERES-L-120.11.7.2 Piping Connected to Pump11.7.2.1 Piping systems shall be designed such that forces and moments imposed on the pump nozzles under any operating conditions do not exceed those allowed by the pump manufacturer. Piping stress analysis shall be conducted to ensure compliance to this requirement.11.7.2.2 The suction piping shall be designed to prevent the formation of gas or air pockets. Sufficient venting and draining provisions shall be included.11.7.2.3 Suction piping to all pumps, with the exception of vertically suspended double casing pumps and horizontal self priming pumps, shall have a straight length of pipe of at least 5 times the suction nozzle diameter immediately upstream of the nozzle. The suction piping layout of a double suction pump shall be submitted to the Pump manufacturer to verify. Pumps having suction piping diameter up to 4 inches and can not comply with this requirement due to space limitation shall be approved by the Company Representative.11.7.2.4 Reducers in suction piping shall be of the eccentric type with the flat side uppermost and shall be located upstream of the straight pipe length immediately upstream of the suction nozzle of the pump. In the event of there is not sufficient space to accommodate the straight length of piping immediately upstream of the pump, a specially fabricated reducer shall be provided for direct connection to the pump suction nozzle. This reducer shall be eccentric with the flat uppermost and shall have a taper angle not exceeding 12 degrees.11.7.2.6 A check valve shall be installed on the discharge piping of each pump. It shall be located upstream of the discharge block valve. Low lift seawater pumps discharging directly into an open canal are excluded from this requirement. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 19 of 45
  • 20. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200911.7.3 Piping Connected to Compressor11.7.3.1 Compressor Vendor machinery and piping engineers shall coordinate, confirm and document in conjunction with control system engineers or control systems vendors that the following piping and hydraulic parameters are satisfied for proper compressor operation, control and protection: a) Lag (dead) time is kept to an absolute minimum by minimizing recycle gas piping captured volume, (i.e., the volume of gas between the compressor discharge port, the discharge check valve and the recycle valve). b) Recycle piping must be self draining (i.e., the piping is sloped downward on both sides of the surge control valve). c) The anti-surge recycle line shall join the compressor discharge on a piping tee branch, located as close as possible to the compressor discharge. The anti-surge recycle line shall join the compressor suction line at the suction knock-out drum or suction piping upstream or downstream of knock-out drum in a 45° angled connection directing the recycle flow towards the compressor. d) A non-slam internal-spring assisted type check valve shall be located in each compressor section discharge piping immediately downstream of the piping tee for the anti-surge recycle line. e) Anti-surge recycle piping downstream of the recycle valve shall be of the same diameter as that of the compressor suction piping. g) Compressor interstage coolers and after coolers shall be located as close to the compressor discharge as possible, using minimum connecting piping volume.11.7.3.2 Emergency shutdown and isolation shall be provided in accordance with JERES-B- 058. Power-operated emergency isolation block valves shall be located upstream of the suction knock-out (K.O.) drum and downstream of the discharge K.O. drums (if provided). The recycle line shall tie in downstream of the suction isolation valve and upstream of the discharge isolation valve.11.7.3.3 An automatic vent valve that is actuated via an emergency shutdown (ESD) signal, shall be located on the suction K.O. drum or on the discharge piping between the compressor and any power actuated valve. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 20 of 45
  • 21. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200911.7.3.4 Strainers for Compressors A temporary spool-mounted stainless steel conical strainer of adequate strength and equipped with fine mish shall be installed in the compressor suction line during commission upstream of performance measuring devices. The design of the strainer shall be submitted to Company for review prior to fabrication and installation. After commissioning, Company may request that the strainer is kept installed after cleaning and removing of fine the mish. Commentary Note: This strainer is to protect the compressor from damage due to solid objects left in the piping system.11.7.3.5 Void.11.7.3.6 All compressor pressure and temperature sensors used for performance or surge control monitoring shall be installed at a maximum distance of three pipe diameters and a minimum of two pipe diameter from the compressor flanges; except for suction temperature sensor which shall be installed upstream of the suction strainer. In addition, pressure measuring points shall be at least three pipe diameters distant from any flow disturbances caused by valves, orifices, strainers, elbows or any other influences which could result in measurement inaccuracy. Pressure and temperature measuring devices shall be oriented 90 degree apart.11.7.3.7 Piping connections to the compressor nozzles shall be made in accordance with JERES-L-351, taking into account the specific flange fit up and bolting tolerances. No piping supports or support structure shall be placed over upward facing compressor nozzles that would restrict access for maintenance of the complete equipment skid. Each compressor nozzle shall be provided with an individual, removable, final piping spool. Allowable forces and moments on the compressor nozzles shall be per API STD 617 appendix G, when the forces and moments are resolved to the largest nozzle.11.7.3.8 Compressor suction piping between the suction drum and the compressor inlet shall be chemically cleaned and neutralized, or cleaned by high pressure hydrojetting following fabrication. All field fabricated piping forming any part of the buffer gas This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 21 of 45
  • 22. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 system to compressor dry gas seals or tertiary shaft seals shall be chemically cleaned and neutralized, mechanically cleaned or clean by high pressure hydrojetting. Lube oil system shall be cleaned in accordance with JERES-G-116.11.8 Unit Battery Limit Piping Layout Refer to Figure-1 of Appendix-B regarding this section.11.8.1 Process and utilities lines should be laid on different pipe rack levels. When, for layout convenience, they shall be located on the same level. Process lines shall be grouped at one side and the utilities lines at the other one.11. 8.2 ESD (Emergency Shut Down) Valves shall be located at ground level and platform shall be provided for ease of access.11. 8.3 All the other Battery Limit Valves (Manual or Automatic operated) shall be located on pipe rack served by a dedicated platform. Ground level installation is not mandatory. The valves should be vertically installed (horizontal stem); horizontal installation (vertical stem) is allowed whenever process or layout specifically requires it. Preference shall be given to vertical installation (horizontal stem).11.9 Safety Aspects for Specific Services11.9.1 Lines in hydrogen service shall be installed at the highest level of the pipe rack. Commentary Note: This is insure that damage to other lines will be minimized when a fire occurs11.9.2 Lines carrying highly corrosive material such as caustic service shall be installed at the lowest level of the pipe rack. Commentary Note: This is insure that damage to other lines will be minimized when a leak occur.11.9.3 Check valves in the vertical position shall be avoided. In case they are not avoidable, the type of check valves shall be of a kind that it shall not stuck in open position subject to prior approval by Company Representative. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 22 of 45
  • 23. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200912 Spacing Requirements12.1 Any deviation from requirements of this section shall be reviewed and approved by the Company Representative.12.2 The minimum spacing between lines supported on sleepers or pipe racks shall be as shown on Standard Drawing JERSD-L-0002.12.3 Above-grade piping shall be supported to provide a minimum of 300 mm clearance between bottom of the pipe and the finished grade.12.4 A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe.12.5 Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes, shall be located at a minimum horizontal distance of 610 mm (24 inches) from any fixed obstruction. This requirement does not apply to that part of the support which is attached directly to the piping, such as horizontal and vertical dummy extensions. Exception: When the above requirement cannot be met, the following criteria should be applied: a) Thermal piping stress analysis shall determine if branch clearance with obstruction is acceptable. b) If the thermal growth direction will result in a movement of the branch connection away from the obstruction, a minimum of 300 mm spacing will be acceptable. In addition to these requirements, guides and lines stops shall be provided per paragraph 15.2 for specific services such as two phase flow.12.6 Where a grease fitting is provided on isolation valves it is the designers responsibility to provide adequate maintenance access to the fitting.13 Underground Piping13.1 Underground pressure piping in any flammable and toxic services within the SSD fence shall not be used except as permitted in the following section. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 23 of 45
  • 24. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200913.2 Buried piping is permitted within SSD fence only at the following locations:13.2.1 Road, fence and dike crossings.13.2.2 New connections to existing buried lines.13.2.3 One hundred percent of the buried line can be inspected by instrumented scrapers.13.2.4 As dictated by JERES-O-101.13.3 Additional Requirements In case underground pressure piping has been selected, it shall be subject to the following additional requirements:13.3.1 No buried dead legs shall be allowed, including "effective" dead legs resulting from the buried portion of the line being frequently or normally valved off unless the line is designed to be self-draining and/or is internally coated per JERES-H-005.13.3.2 The buried piping (including appurtenances) shall be cathodically protected with impressed-current or galvanic anodes system to meet the requirements of JERES-X- 400 or JERES-X-600.13.3.3 The minimum cover over underground pressure piping shall be 450 mm in unpaved or paved areas and 750 mm under paved roads, except under a reinforced concrete slab or other protection subject to approval by the Company Representative.13.3.4 The buried piping (including appurtenances) shall be externally coated with an approved coating, in accordance with JERES-H-001.13.3.5 Underground piping subject to traffic loads (road crossings) shall meet the requirements of JERES-L-460.13.3.6 Where coating is not feasible due to temperature limitation, Contractor shall submit alternative approach insuring protection for piping system against external corrosion damage.14 Pipe Support Design14.1 Responsibilities14.1.1 Any deviation to this section shall be resolved through concurrence from the Company Representative. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 24 of 45
  • 25. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200914.1.2 It is the Design Agency responsibility to design the pipe supports to meet the requirements of hydrotesting, operational and empty conditions.14.2 Rigid pipe supports14.2.1 The rigid pipe supports should be utilized to maximum extent thus avoiding the use of spring supports and rod hangers wherever design permits.14.2.2 The designer shall ensure that all pipe supports will be active during operation of the lines, i.e., the pipe will be in full contact with the support and carries the load.14.3 Hanger rods14.3.1 Rod hangers shall not be used for lines 12" NPS and larger in liquid service or multi phase flow.14.3.2 Rod hangers shall be subjected to tensile loading only.14.3.3 Rod hanger assemblies shall be designed to allow for anticipated thermal movement.14.3.4 The maximum swing angle due to horizontal pipe movement shall be four (4) degrees.14.3.5 All hangers shall be provided with means for vertical adjustment.14.3.6 Suitable locking devices shall be used at all threaded connections of the hanger assembly (double nuts).14.3.7 Where atmospheric corrosion is a concern hanger rods shall be protected against external corrosion.14.4 Spring Supports14.4.1 Spring supports immediately downstream of rotating equipment shall be limited to 10-15% load variation.14.4.2 Supports shall be designed so that they cannot be disengaged by movements of the supported Pipe.14.4.3 All springs shall be in compression, so that failure will not result in the complete release of load. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 25 of 45
  • 26. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200914.4.4 Springs shall be factory set to the calculated cold settings by means of travel stops. Upper stops for load preset and lower stops for hydro-test shall be provided. These stops shall be banded or locked in place so they cannot be easily dislodged during erection or hydro-test. The travel stops shall be painted red and shall have a bright color tag indicating "Remove after Hydro-test."14.4.5 Each spring hanger assembly must be capable of sustaining the hydrotest load.14.4.6 Where atmospheric corrosion is a concern spring supports shall be protected against external corrosion.14.5 Ring Girders14.5.1 Above ground fully restrained piping shall be supported on ring girders, or 180- degree saddles with top strap, designed to prevent lateral buckling of the pipeline. Suitable electrical insulation strips shall be provided between the pipe and the support if required to prevent dissipation of cathodic protection current.14.5.2 If the ring girder supports of the above ground piping sections interfere with the cathodic protection of the buried sections (if some sections of the line are buried), electrical insulation between the pipe and the supports is required per JERES-X-400.14.5.3 The pipe surface covered by the ring girder or saddle and top strap shall be coated in accordance with JERES-H-001 to prevent corrosion of the pipe. Coating is not required if a fiberglass insulating spacer is epoxy bonded to the pipe after abrasive blasting the pipe surface to Sa 2-½ (near white metal blast).14.6 Low Friction Supports14.6.1 If Teflon sheets or similar low friction materials are used to reduce the design loads on piping and/or the supporting structure, provision shall be made to allow angular adjustment of the bearing surface during installation, so that an even distribution of the load can be assured.14.6.2 Low friction supports shall be designed such that sand or other debris cannot accumulate on sliding surfaces (by making the top surface larger than the bottom surface).14.7 Dummy Supports This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 26 of 45
  • 27. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200914.7.1 The dummy supports shall not create excessive stresses at the attachment welds to the run pipe. This can be accomplished by minimizing the length of the supports and/or increasing the size of the supports.14.7.2 A 6 mm weep hole shall be drilled for all dummy supports. The weep hole shall be located near the base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for all horizontal dummy supports.14.8 Support Spacing To mitigate wind-induced resonant vibration of the above-ground piping with diameters larger than 12-inch supported at regular intervals, the basic support spacing shall be selected so that the natural frequency of the piping in operating condition is outside the range of wind induced frequencies plus or minus 10% for wind speed above 9 m/s (20 MPH) which will cause vortex shedding.15 Anchors and Guides15.1 End Anchors The Design Agency shall ensure that above-ground restrained and buried pipelines terminating at the plant facilities be provided with end anchors. Commentary Note: The design and construction of end anchors for pipelines usually executed by different Design and Construction Agencies. Therefore, the assigned Contractor for coordination is responsible to coordinate between involved parties.15.2 Intermediate Anchors, Guides, and Line Stops15.2.1 The free movement of unrestrained piping, both in axial and lateral directions, shall be controlled and limited by properly located guides and anchoring points to within acceptable bounds.15.2.2 Intermediate anchors or axial line stops shall be provided for above-ground unrestrained piping between and/or at the center of expansion loops or offsets. The design load for such intermediate anchors shall include the effect of friction forces.15.2.3 Axial line stops and guides shall be provided for above ground unrestrained lines subject to slug forces in services listed below. Slug forces shall be estimated based on the worst case assumed velocity and average density of the liquid/vapor slug expected to occur. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 27 of 45
  • 28. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 The supporting structures shall be designed to withstand slug forces acting at changes in direction. However the pipe guides and stops shall yield prior to the pipe. The following are examples of services with potential slug flow, however this doesnt remove responsibility of the Deign Agency to identify others. Steam service − Two-phase flow lines − Liquid intermittent lines, such those used to control liquid level in the drums − Pressurized drain lines − Relief and blow-down lines − Flare lines − High-pressure gas lines15.3 Dampening Anchors Suitable dampening anchors shall be provided to hold down the piping and mitigate vibration as required at control valve stations, (surge) relief valves, and where flow surges can occur.16 Non-Pressured Welded Attachments16.1 During the design stage the following requirements shall be adhered to:16.1.1 Welded attachment irrelevant to the piping systems shall be minimized such as those for electrical conduits. Design should minimize the use of bimetallic welds.16.1.2 The pipe shall not be used to support other pipes and structures without an appropriate analysis.16.1.3 All structural attachments, which transfer loads to the pipe through welds, shall be welded to full encirclement sleeves or saddle pads if the piping is designed to operate at a hoop stress in excess of 50% of the allowable stress. The corners of the pad shall be rounded corners. ASME B31.4 paragraph 421.1(d) and ASME B31.8 paragraph 834.5(b), if applicable, shall not be waived.16.1.4 On the construction drawings, all welds to the pipe shall be shown as continuous with smooth finish.16.2 Wear Pads and Saddles This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 28 of 45
  • 29. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200916.2.1 Piping in hazardous services where condensation can form on the pipe, or operating within 30 m of the sea shall have wear pads or corrosion bars welded to the pipe at each support. Refer to JERSD-L-0007.16.2.1 Wear pads shall be installed when one of the following condition is presented: a. or saddles Piping in hazardous services where condensation can form on the pipe, or operating within 30 m of the sea shall have wear pads or corrosion bars welded to the pipe at each support. Refer to JERSD-L-0007.16.2.2 Excluded from this requirement are low pressure systems with hoop stress at design pressure below 20% of Specified Minimum Yield Strength (SMYS) of the pipe.16.2.3 Wear pads are also required for structural reinforcement as indicated in Standard Drawing JERSD-L-0014. Wear pads shall be fully welded to avoid ingress of moisture.16.2.4 Saddle-type supports: Saddle-type supports with pads shall be provided for piping 30-inch NPS and larger. In case saddle pipe support cannot be installed, the line shall be analyzed for localized stresses. The analysis shall be submitted to the Company Representative for review and approval.17 Piping Joints and Flange Connections17.1 The selection of the pipe joining method shall be in accordance with JERES-L-110.17.2 Selection of flange type, gaskets and stud bolts shall be in accordance with JERES- L-109.17.3 Flanged connections shall be avoided when butt-welded joints can be used in services and locations where leaks are likely to occur (e.g. cyclic or vibration services), or will cause serious hazard such as potentially toxic service, or are difficult to control, such as the following: a) Steam in ASME class 900 pressure rating c) In locations where the piping will be subjected to large bending or other external loads d) On buried piping17.4 Slip-on flanges when selected shall be welded at the front and back of the hub. The sealing face shall be free from and scratches, weld burns, etc. This requirement shall be reflected in relevant fabrication drawing. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 29 of 45
  • 30. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200917.5 Flanged connections with long exposed bolts for sandwiched components, other than standard spectacle plates and blinds, shall not be used in fire hazardous areas unless the bolting is protected by a fire resistant shield such as illustrated on Standard Drawing JERSD-N-0005 or equivalent method.17.6 Blinds and Spectacle Plates The piping design shall include provision for spectacle plates or blanks and spacers at flanged joints as needed to facilitate pressure testing, for blinding off during repairs or inspection, for positive product segregation, or for other operating reasons. Blinds shall be located to minimize fluid loss during closing.17.7 Jackscrews17.7.1 Joint assemblies which often require frequent separation include orifice plates, spectacle plates, spacers, screens, and drop-out spools shall be provided with jack screw to facilities separation and opening for maintenance. When flange separators are used, jackscrews are not required.17.7.2 Company Standard Drawing JERSD-L-0038 for jackscrews can be used as guidelines. Alternative designed shall be submitted for Company Representative approval.17.7.3 Jackscrews shall be installed to be accessible from both sides of the pipe. For orifice flanges, jackscrews shall be installed at 3 and 9 oclock positions. Commentary Generally piping layout shall be designed such that flanges can be separated without requiring of excessive force.17.8 Blind flanges shall not be drilled for connections such as drains, flushing, etc. unless a stress calculation per ASME SEC VIII D1, Appendix 2 shows that the flanges will not be over stressed.18 Firewater Systems Piping systems designated for fire protection water systems in plant areas shall comply with JERES-B-017. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 30 of 45
  • 31. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200919 Plant Utility Piping System19.1 Scope of Plant Utility Station19.1.1 This section of the standard defines additional limitations on piping used for connecting a supply of steam, water, air, nitrogen or other inert gas to process equipment in hazardous services except as stated below. It also includes connections for the purpose of purging or cleaning when the process equipment is not in operation.19.1.2 Utility stations shall be provided at these locations: - All process and utility units - Other facilities: - Liquid and liquefied hydrocarbons product pumping stations - Liquefied gases storage - Flare - Truck, rail tank car and ship loading stations - Industrial water treatment units - Analyzers shelters - Raw water pumping stations - Water conditioning units19.2 This section does not apply to purge connections to open furnaces or fire boxes. It also does not cover connections to process equipment where the process flow and utility flow remain physically separated such as in cooling water or instrument air.19.3 The design of utility Stations located in various plants within one plant area shall be uniform and shall be such that the risk of accidental connection to the wrong utility does not occur. The additional detailed requirements provided in Appendix-B shall apply to design and construction of Utility Stations.19.4 The connectors and color coding is shown in JERES-H-001 Table 3 shall be standardized for utility stations in new plants not governed by paragraph 19.3. Table 3 – Connectors and Color Coding for Plant Utility Stations Utility Hose Connection Color Code Demenralized Water 1-inch brass Aeroquip 5101 Blue-White stripe This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 31 of 45
  • 32. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Raw Water 1-inch brass Aeroquip 5101 Blue Air ¾-inch iron Dixon Air King AM-8 Green/Gray stripe Steam 1-inch steel Dixon Boss Wf-36 White Nitrogen 1-inch steel wing nut union Green/Orange stripe19.5 Hose connections, where applicable, shall be positioned at elevation not higher than 1200 mm above finished plant grade or above platform of multilevel equipment but not lower than 600 mm. They shall be pointing 45 degrees downward. The piping shall be securely bolted to a supporting structure and have adequate access. Utility connections shall be installed with minimum 150 mm clearance between each other.19.6 Each utility take-off connection shall be located at the top of the horizontal main header or auxiliary header. Root valves shall be provided for each utility take-off connection from a main header or auxiliary header which can not be taken out of service without shutting down a complete processing unit or operating facility.19.7 Instrument air take-off connections to the plant utility station shall always be provided with root valves.19.8 Each utility line shall be provided with an isolation valve just upstream of the specified hose connector (see paragraph 19. 4) at the termination. Ball or globe valves shall be used for air, water, and nitrogen services; globe or angle valves shall be used for steam service, unless otherwise specified by the Company Representative. Each line shall have a service name plate in Arabic and English indicating the service. The utility pipe and the ends of hoses provided with the station shall be color coded.19.9 The steam line shall have a steam trap and shall be insulated for personnel protection except for utility steam take-off lines. Utility steam take-off lines shall be insulated but shall not be provided with steam traps. Utility steam stations located above the utility steam header shall be self-draining towards the utility steam header. Utility steam lines to utility stations below the utility steam header shall be allowed to gather steam condensate, which is removed by operations before applying the utility steam.19.10 Drinking water system shall have dedicated system in accordance with Uniform Plumbing Code (UPC). Water supply systems which deliver drinking water shall not be connected to process equipment as a utility water source.19.11 Firewater systems shall not be connected to process equipment except via a temporary connection when the equipment is not in operation and not under pressure. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 32 of 45
  • 33. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Otherwise, each connection and its specific application shall be reviewed and approved by the Company Representative.20 Utility-Process Connections Requirements of this section are specific to the Utility-Process Connections. The arrangement of this connection shall follow the schematic provided in Figure-3 in Appendix-A.20.1 Temporary Utility-Process connections with components listed in the direction of the utility flow shall be as follows:20.1.1 The utility side shall have a block (root) valve, pressure gauge, check valve and a drain valve to depressurize the hose or the break-away spool. The process side shall also have a check valve, block valve and pressure gauge near the hose connection. When disconnected, both open piping ends shall be capped, or plugged, or fitted with blind flanges.20.1.2 The break-away spool shall be designed such that when not in use, it can be easily disconnected and kept at a dedicated, fixed location. Follow the arrangement of Figure-3 of Appendix-A. The spool shall be painted with stripes of color per the piping color code per JERES-B-067.20.2 No permanent connections other than air or steam shall be made to process equipment operating above 100°C nor shall water or steam be permanently connected to equipment that operate below 0°C.20.3 Permanent Connections Permanent connections without a break tank shall not be made except when the required service is continuous or frequent (at least twice per week) or needed for emergencies. Permanent connections without a break tank shall consist of the following (in the direction of the utility flow):20.3.1 The utility flow shall have instrumentation for automatic shut-off on low flow or low pressure (in addition to a check valve) in all cases where redundant protection against back flow is required by Company Representative.20.3.2 The utility side shall have a pressure gauge, block valve, bleed valve and spectacle blind or quick change blind (normally open).20.3.3 The process side shall have a check valve, bleed valve or drain, block valve. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 33 of 45
  • 34. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200920.3.4 The block valves of the connection shall be within sight of each other and shall be as close as practical to the process equipment. The pressure gauges and the position of the blind shall be clearly visible from a single point.20.4 Air connections to asphalt or hot oil piping through which air is supplied to blow the product to tankage, shall be provided with a water knock-out (KO) drum with drainage facilities. The line downstream of the KO drum shall not contain low points and shall have an additional drain valve immediately upstream of the process connection.20.5 When air is injected as a reaction agent, such as in Merox and air sweetening units, the control shall be such that the hydrocarbon/air mixtures will not enter the flammable range unless required by the process. Instrumentation shall be provided to shut off the air flow if the process flow fails. In addition, a restriction orifice shall be provided.20.6 The rating of all Components of a permanent connection shall be suitable for the more severe of pressure/temperature of the process or the utility service.20.7 For temporary connections the pressure/temperature rating of the process side shall extend to the hose or break-away spool.20.8 If the process fluid requires internal lining or material other than used in the utility system, the lining or the material shall extend from and include the check valve on the process side. Valves with bodies of gray cast iron, ductile iron, or low melting point alloys (such as brass or bronze) shall not be used in a permanent connection including the utility side. Valve bodies and trim in a permanent connection shall be suitable for both the process and the utility fluid with regard to corrosion and pressure rating.20.9 Operator access shall be provided to the block valves on either side and to the blind or break-away spool of the connection. Chain operated valves shall not be used.21 Vibration Consideration21.1 Piping system in gas service operating intermittently with high velocities of 0.2 Mach number and higher shall be designed not be subject to excessive noise and severe vibration. Following are requirements which will contribute in reduction of potential noise and vibration, however more could be applied by the Design Agency: a) Pipe intersections shall be at 45 degree inclination rather than 90 degree b) Pipe bends shall be of the long radius type with minimum 1.5 diameter. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 34 of 45
  • 35. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 c) Lead-lines downstream the pressure and/or flow control valves shall have sufficient length to allow for flow development and stabilization. A minimum length of 5 times diameter is recommended. d) For branches intersecting into another pipe at 90 degree having a diameter ratio less than 0.5, should be made with transition spool to increase this ratio at the intersection point to 0.5 or more.21.2 Branch connections (2” and smaller) Branch connections (2” and smaller) Branch connections (2” and smaller) in piping connected to rotating equipment or in locations where vibration can occur (such as near control valves, reciprocating equipment, etc) shall meet the following requirements: a) Connections in potentially severe vibration such as that of section 21.1 shall be of extended body valve (with reinforcement as required by the code) and shell not be of less than 1 ½ connection. b) All standard nipples (with reinforcing pad if required per code) shall be braced in accordance with Standard Drawing JERSD-L-0004. Nipples length shall be kept as short as possible. c) Where bracing cannot be effectively provided, schedule 160 close nipples shall be installed with reinforcing pad. Welding bosses (Standards Drawings JERSD- L-0001 or JERSD-L-0027) and/or integrally reinforced outlets of approved design (such as Weldolets, Thredolets and Sockolets) in Class 3000 or 6000, as applicable, which abut the pipe wall with a full penetration weld are acceptable alternatives without reinforcing pads.22 Process Steam Piping and Heat Tracing22.1 Steam lines shall be design with the following considerations: − Steam condensates shall not be accumulated in a manner to present steam hammering problems. − Steam traps shall be properly selected to perform as required for extended life between plant turn-around. − Steam traps shall be procured from reliable and approved manufacturers such that it will have an extended life. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 35 of 45
  • 36. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 200922.2 Steam lines shall have steam condensate collection and removal systems. The standard drawing JERSD-L-0040 shall be used as a guideline for such systems.22.3 Heat tracing shall be design wit the following considerations: − Steam tracing per JERES-L-315 is the default acceptable system for tracing piping systems within the plant facilities. − Electrical heat tracing, if utilized, shall be in accordance with JERES-P-315.23 Identification of Chemical Cleaned Line23.1 Lines that require chemical cleaning during construction shall be identified and marked up on the appropriate P&IDs and Line Index Tables in accordance with JERES-L-350. The systems to be cleaned shall have high and low point vents and drains installed.24 Testing and Inspection24.1 The design of the piping systems shall facilitate effective pressures testing per the requirements of JERES-L-150.24.2 Test procedures that may require special attention shall be prepared during the design stage.24.3 For capital projects where a project proposal will be developed, the scope of pressure testing requirements shall be prepared. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 36 of 45
  • 37. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Appendix A – FiguresList of Figures:Figure-1-A: Dead Leg Piping for vertical down for 2” pipe and largerFigure-1-B: Dead Leg Piping for vertical down for pipes smaller than 2”Figure-1-C: Axial Dead Leg Piping for vertical down for pipes sizesFigure-2: Typical piping arrangement at battery limitFigure-3: Typical arrangement for Process-to-Utility Connection This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 37 of 45
  • 38. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009Appendix A – Figure-1: Typical Schematic Explanation for Dead Leg Piping Figure-1-A: Dead Leg Piping for vertical down for 2” pipe and larger Figure-1-B: Dead Leg Piping for vertical down for pipes smaller than 2”. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 38 of 45
  • 39. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009Appendix A – Figure-1: Typical Schematic Explanation for Dead Leg Piping (continue) Figure-1-C: Axial Dead Leg Piping for vertical down for pipes sizes This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 39 of 45
  • 40. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Appendix A – Figure-2: Typical piping arrangement at battery limitFigure-2: Typical piping arrangement at battery limit Notes on Figure-2: 1. Emergency shutdown valves shall be located at the ground level.. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 40 of 45
  • 41. Jubail Export Refinery Material SpecificationsJERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Appendix A – Figure-3: Typical arrangement for Process-to-Utility Connection Figure-3: Typical arrangement for Process-to-Utility Connection Notes on Figure-3: 2. During normal operation the drop out spool with solid bar shall be connected to the piping. 3. Operations shall swing the drop out spool to the one with pipe when needed and shall return it back to the solid bar spool once process is returned to normal operation. 4. Contractor shall provide this arrangement regardless of operation requirements.This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 41 of 45
  • 42. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 Appendix B – Basis of Design for Utility StationB.1 Purpose This specification provides general guidelines for the provision and design of utility stations for the Jubail Export Refinery Project.B.2 General 1. Contractor shall be responsible for the provision and design of safe and efficient utility stations in accordance with the criteria and general guidelines provided in this specification. 2. This specification does not provide the specific details of the utility station, and therefore Contractor shall be responsible for the general arrangement, details and final design including piping support, block valve and hose connection in accordance with applicable project specifications and governing codes. 3. Contractor shall determine the total number of required utility stations in accordance with the indicated users, deployment and spacing required by this general guideline.B.3 Utility Conditions The utility conditions to be used for the design of utility stations are given under Project Specification, JERES-C-101, Basic Design Data.B.4 Installation Design 1. Each utility station shall be stand alone unit, side by side triplex configuration that shall include these utilities: Service air Service water Low pressure steam 2. Utility stations shall be provided with a 1 inch gate valve, quick connect/disconnect type hose connection, and the supply header and piping. 3. The gate valves provided for the utilities shall be spaced for efficient and easy operation and shall be located at a convenient height or a minimum one meter above ground, floor, platform or walkway. 4. For the utility stations located at grade, the supply headers shall be run on the pipe rack and the block valves installed vertically to facilitate efficient draining of the This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 42 of 45
  • 43. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 lines. For utility stations located on platforms, walkways and elevated locations, the block valves shall be installed horizontally. 5. For utility stations that are located remotely from an elevated pipe support, the headers shall be run at ground level for water and air only, and the station block valves installed horizontally. In this case a provision for draining the lines at the low points shall be provided.B.5 Location and Spacing 1. Utility stations are required to cover all areas of the above indicated units and Facilities, including elevated platforms serving tall towers and vessels and interconnecting service platforms and walkways around major equipment. 2. Utility hoses shall have a maximum of 10 meters length. Company requires that all areas accessible at grade, platform or walkway be easily reached and serviced by the 10 meters long utility hoses. Depending on the complexity and density of equipment in the area, utility stations may need to be provided at less than 20 meters spacing between adjacent stations to cover all areas. All utility stations shall have easy and fee access. 3. For tall towers and vessels, a utility station shall be provided at each platform level if it provides access to a manhole. 4. No utility station located at grade, platform or walkway shall be less than 5 meters from a gas compressor or equipment that handle hydrocarbons at more than 260C temperature. 5. Utility stations for boilers and power generators located at least 5 meters from the equipment and auxiliaries of the unit provide easy and free access to the utility stations. Contractor shall ensure and provide utility stations to cover all areas within the unit and easily reachable by the utility hoses. 6. At grade and within process units or facilities that have a central pipe rack, the utility stations shall be arranged aligned under the pipe rack to give free and unencumbered access to the stations.B.6 Utility Supply Headers 1. Utility supply header shall enter the unit via the unit’s central pipe rack. Where a facility does not have a pipe rack or available elevated support, the supply header may enter the facility at grade via a pipe way or an underground route for the air and water. Steam is not allowed at ground level. 2. In all cases, utility supply header shall be provided with a gate valve and a This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 43 of 45
  • 44. Jubail Export Refinery Material Specifications JERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 check valve at the battery limit. 3. Supply header shall be designed to allow for cleaning especially prior to the start up. Above ground header shall be provided with a blind flange at the terminal end of each run when branched.B.7 Air and Water Connection 1. Air and water supply lines to the individual utility stations may connect to the service air and the service water headers supplying the unit. If the service air and service water headers of the unit were intended to supply air and/or water for normal operation, as the case for the MEROX unit, or for specific operations such as heater decoking and catalyst regeneration, connection to these headers shall be possible only if the required utility conditions for the utility station and that for the service air and service water of the unit are compatible. 2. Should the service air system capacity of the plant be insufficient to supply the normal demand of fired heater decoking, catalyst regeneration, etB., an independent and dedicated service air system supplied by mobile air compressor shall be provided by Contractor for these operations.B.8 Steam Connection 1. Steam supply header for utility stations shall be separate and independent from the service steam supply header for unit operation within the unit battery limit. 2. The utility station steam header shall connect to the steam main at unit battery limit upstream of the block valve to facilitate supply of steam to the utility stations during unit shutdowns.B.9 Sizing Criteria 1. Service utility header and sub header for Process Units, Utility Units and OSBL installations shall be sized to satisfy utility demand corresponding to a third of total demand flow rate or a third of the total connections in the installation active, which ever is of greater value, and the line pressure at the most disadvantaged connection relative to pressure loss is no less than 85% of the operating pressure at unit battery limit for the same flow rate. 2. Header and sub header line size shall not be less than 2 inch NPS.B.10 Instrumentation 1. Provide utilities flow meters at battery limit and transmit flow measurement data to the control room in units using air and water during normal operation. This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 44 of 45
  • 45. Jubail Export Refinery Material SpecificationsJERES-L-310 Rev. 5 Design of Plant Piping 14 May 2009 2. In case utilities are used in specific operations such as fired heater decoking, catalyst regeneration, etc., flow elements shall be provided close to the consumer to allow connection of in situ flow recorder during the operation. 3. Provide pressure gauge at the unit battery limit for service air and service water headers. No pressure gauge is required for the service steam header normally used for the operation of the unit when it is connected to the main steam header as the main steam header is normally equipped with a pressure transmitter indicating the on site steam pressure at the control room.This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company. Page 45 of 45