PROJECT STANDARDS AND SPECIFICATIONS piping design

1 KLM TechnologyGroupProject :1of62 Rev: 01 June2011 KLM Technology Group#03-12 Block Aronia,Jalan Sri Perkasa 2 Taman Tampoi Utama81200 Johor BahruMalaysiaPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS AND SPECIFICATIONS )TABLE OF CONTENTSCOPE2 REFERENCES2 DEFINITIONS AND TERMINOLOGY3 UNITS4 GENERAL design REQUIREMENTS4 design Procedure4 Basic Design4 Detail Engineering Design5 ABOVE-GROUND piping SYSTEMS12 piping Design12 design Condition12 Pipe14 piping Components14 Valves18 Instrument Piping20 Safety and Pressure Relief System23 Block and Bypass Valves23 Vents and Drains24 Blow down25 Utility Piping25 Jacketed Piping34 piping Adjacent to Equipment36 piping Layout Design46 piping Flexibility (Additional to ANSI B )48 piping Supports48 Insulation60 Painting61 piping Connections to Existing Plant (Additional to ANSI/ASME B )61 APPENDIX A62 KLM TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page2of62 Rev: 01 June2011 SCOPEThis PROJECT Standard and Specificationcovers minimum requirement(s) forgeneral aspects to be considered in design of piping for petroleum andpetrochemical plants to be designed in accordance with ANSI whichincludes but not limited to the following:-Loading and unloading oil & gas gathering central equipment, in accordance with ANSI-B house and compressor stations (booster stations).

2 -Tank farms and oil/gas Standard is not intended to be applicable to the following systems:-Heating, ventilation and domesticwater system within building (HVAC).-Steam piping system: within the steam generation unit and power stationplant designed in accordance with ANSI piping systems-Hydraulic systems-Offshore facilitiesREFERENCEST hroughout this Standard the following dated and undated STANDARDS /codes arereferred to. These referenced documents shall, to the extent specified herein,form a part of this standard. For dated references, the edition cited applies. Theapplicability of changes in dated references that occur after the cited date shallbe mutually agreed upon by the Company and the Vendor. For undatedreferences, the latest edition of the referenced documents (including anysupplements and amendments) (American National Standard Institute / American Society ofMechanical Engineers) "Chemical Plant and Petroleum Refinery piping " "Welded and Seamless Wrought Steel Pipe" "Pipe Flanges and Flanged Fittings" (American Petroleum Institute)650"WeldedSteel Tanks for Oil storage "RP-521 "Guide for Pressure-Relieving and Depressuring Systems"KLM TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page3of62 Rev.

3 (British Petroleum)C P-3"Plant Layout"C P-14"Over Pressure Protection Systems"C P-16"Passive Fire Protection of Structures & Equipment" "Forced Drought Burners for Fired Process Heaters" (British Standard Institution)BS 3293" specification for Carbon Steel Pipe Flanges (over 24"nominal size) for the Petroleum Industry"BS 4485" water Cooling Towers" (Expansion Joint Manufacturers Associations) (National Association of Corrosion Engineers)MR-01-75"Standard Material Requirement Sulfide Stress CrackingResistant Metallic Material for Oil Field Equipment" (National Fire Protection Association)30-12"Flammable and Combustible Liquids Code" Health and Safety Executive GuidanceDEFINITIONS AND TERMINOLOGYB attery Limit-The boundary of a process unit, enclosing all equipment and unitlimit block Spring-Cold spring is the intentional deformation of piping duringassembly to produce a desired initial displacement and group of units, the operation of which are interlinked.

4 (On smallplants, the term "complex" may refer to all the process units on the plant).Depot-A storage area with capacityless than 5000 tones with import and person or party which is responsible to the Company forengineering/ design of the :Any specific application of the terms and responsibilities for the parties definedabove, are a matter for the conditions of contract on a TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page4of62 Rev: 01 June2011 Executor-The party which carries out all, or part of the construction, installationand commissioning aspect for the pressure service steam-above 24 barg (normally 40 barg)Low pressure service steam-up to 7 bargMedium pressure service steam above-7 barg up to 24 bargPiping System-It covers the overall systems of pipes and piping components, fittings, valves, nozzles and supports, that are employed to transferliquid,gas, steam, etc.

5 Between the equipment such as tanks, pumps, vessels and Relieving-Uniform heating of a structure or portion thereof to a sufficienttemperature and maintaining for a specified period to relieve the major portionofthe residual stresses followed by uniform and controlled (Area)-A main production component of a refinery plant or chemicalcomplex, distillation unit, utility unit, supply, water supply and treatment, steamgeneration, powergeneration and similar Standard is based on International System of Units (SI) except whereotherwise design REQUIREMENTSD esign ProcedureThe design of piping is characterized by two successive phases as DesignThe following documents are minimum requirements for piping design in Plan and/or Equipment Layout- piping and Instruments Diagrams- piping SPECIFICATIONS Relating to Individual IdentificationListKLM TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page5of62 Rev: Engineering DesignLayout for erection and Detailed piping Drawings for construction shall beproduced during this design of piping shall include but not limited to the following:-Final (detailed) P&ID ( piping & Instrument Diagram).

6 -General plot plot plan or equipment ground piping ground piping and foundation plans (erection drawings).-Isometric identification (Material Take Off list).- piping material support analysis model (optional).-Pressure testing P& and instrumentation diagram (P&ID)The following items shall be considered and shown in the P& and information of s position and size, for vessels and of , drains and relief systems for lines and and tracing on class (wall thickness and material).-Control systems and loops (Instrumentation).The Utility Flow Diagrams (UFD) is a type of P&ID that represents theutility systems within a plant and shows all equipment and piping inrespect of utilities ( water , air, steam,..). plot plan-The general plot plan shall give the layout of the whole plant(s).

7 Itshould be prepared to one of the following scales: 1:500, 1:1000,1 following items shall be shown in plot plan:oBattery limits of complex (Area boundary).oGeographic and conventional or plant , with regard to the nominal plant 0 TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page6of62 Rev: 01 June2011oCoordinates of main roads,process units, utility units, buildings, storage tanks and main pipe of flares and burn of prevailing :Plant coordinates may be started from point N = O and E = arrangement of units areas, storage areas, buildings, and devicesfor shipment to be provided within the plant, shall be decided on thebase of the following factors:oSoil road or rail access of pipelines to and from of prevailing law and regulation which may affect the location of units andstorage elevation for location of units and equipment (such asstorage tanks, waste water unit, oil/ water separator, etc.)

8 -The units shall be separated by roads. Major roads shall haveminimum width of 6 m., with maximum length of 400 m. The minorroads shall have minimum width of 4 m. (Minor roads shall not be in anarea classified as zone 0 or 1).-Aplant may contain one or several process units. Where any unitprocesses flammable fluids and may be operated independently ( unit may be shut down with others in operation).The minimumspacing between equipment on the two adjacent units shall beat least20 units processing flammable fluids, the central control building shallbe adjacent to a road. It shall not be located in any area classified aszone 0 to fenceoAll sites (plants or complex) shall be within a security public building, such as administration office, restaurant, clinic,etc.

9 , shall be located outside of the process area for case (d) the minimum space between security fence andunits boundary shall be 20 m, and between security fence andequipment shall be 30 case of special units such as flammable material storage withvapor release and toxic materials, minimum space shall be at least60 m from site boundaries adjacent to centers of population(domestic, work or leisure).KLM TechnologyGroupProject Engineering StandardPLANT piping SYSTEMSDESIGN CRITERIA( PROJECT STANDARDS ANDSPECIFICATIONS)Page7of62 Rev: 01 June2011-Except where they are an integral part of a process unit, site utilityunits should be grouped together in an area classified as water pumps and equipment shall be sufficiently remote fromprocessing, storage and loading area, where a major fire could waste water treatment facilities shall be located at the lowestpoints of areas for road transport shall have adequate spaceto provide access for filling, parking and maneuvering.

10 A drive throughrack arrangement is preferred. The loading and unloading facilitiesshould be downwind or crosswind from process units and sources ofignition, based on the direction of prevailing location, spacing, orientation and general design considerationshall bein accordance with the Standard requirementsoAccess ways within the plant shall be provided for maintenance,emergency case, and for fire fighting from the road around theplant. piping system shall be laid in such a way to make possiblepassage of mobile widths of access way shall be as follows:Vehicular access ways within mPedestrian access ways and elevated walk mStairways and mFootpaths in tankage mMaintenance accessaround equipment:1moMinimum headroom clearance for access ways shall be as follows:Over railways or main mOver access roads for heavy trucks:6 mFor passage of truck:4 mFor passage of mOver fork-lift truck planThe unit plot plans shall be designed based on general plot drawing shall be prepared in one of the following scales: 1:200, 1 drawing shall show the following items.