PIping

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TABLE OF CONTENTS

1. PIPING CODES & STANDARDS --------------------------------------------------------------------------------- 2

2. INTRODUCTION TO PIPING COMPONENTS ---------------------------------------------------------------- 4

2.1. Pipes ----------------------------------------------------------------------------------------------------------------- 4

2.2 Flanges -------------------------------------------------------------------------------------------------------------- 6

2.3. Pipe Fittings -------------------------------------------------------------------------------------------------------- 8

2.4. Valves ------------------------------------------------------------------------------------------------------------- 11

2.5 Fasteners ---------------------------------------------------------------------------------------------------------- 17

2.6 Gaskets ------------------------------------------------------------------------------------------------------------ 17

3. PIPING MANUAL : ------------------------------------------------------------------------------------------------ 19

3.1 Standard / General Specifications ----------------------------------------------------------------------------- 20

3.2 Pipe Class --------------------------------------------------------------------------------------------------------- 20

3.3 Instrument Nozzle Assemblies --------------------------------------------------------------------------------- 24

3.4 LINDE Support Standard --------------------------------------------------------------------------------------- 25

3.5 Special Parts ------------------------------------------------------------------------------------------------------ 26

4. MARIAN ------------------------------------------------------------------------------------------------------------- 27

4.1 Main Database ---------------------------------------------------------------------------------------------------- 27

4.2 MARIAN Modules ---------------------------------------------------------------------------------------------- 27

5. TECHNICAL PROCUREMENT --------------------------------------------------------------------------------- 29

5.1 Piping Inquiry Specification ----------------------------------------------------------------------------------- 29

5.2 Technical BID Evaluation -------------------------------------------------------------------------------------- 29

5.3 Technical Recommendation (TR) ----------------------------------------------------------------------------- 29

6. LINDE’S MATERIAL CONTROL SYSTEM (LMCS): ------------------------------------------------------ 30

6.1 “MTO” Database ------------------------------------------------------------------------------------------------ 30

6.2 “PROCUREMENT” Database --------------------------------------------------------------------------------- 30

6.3 “INSPECTION” Database -------------------------------------------------------------------------------------- 31

6.4 “TRANSPORT” Database -------------------------------------------------------------------------------------- 31

6.5 “RECEIPT” Database ------------------------------------------------------------------------------------------- 31

6.6 “ISSUE” Database ----------------------------------------------------------------------------------------------- 31

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1. PIPING CODES & STANDARDS The following codes and standards shall be used together with this standard specification for materials, design and dimensional requirements. American National Standard Institute (ANSI) American Society of Mechanical Engineers (ASME) ASME B 31.1 Power piping

ASME B 31.3 Process Piping for Petroleum refineries, Chemical, Pharmaceutical, Textile, Paper, Semiconductor & Cryogenic plant

ASME B 31.4 Piping generally used for transporting & distributing liquid Hydrocarbons & other liquids

ASME B 31.5 Refrigeration piping ASME B 31.8 Piping generally used for transporting & distributing Gases. ASME B 31.9 Building services ASME B 31.11 Slurry transportation piping system

ASME B 16.5 Pipe Flanges and Flanged Fittings NPS ½ Trough NPS 24 ASME B 16.9 Factory-Made Wrought Steel Buttwelding Fittings ASME B 16.10 Face-to-Face and End-to-End Dimensions of Valves ASME B 16.11 Forged Fittings, Socket- Welding and Threaded ANSI B 16.14 Ferrous Pipe Plugs, Bushing and Locknuts with Pipe Threads ASME B 16.20 Metallic Gaskets for Pipe Flanges- Ring-Joint, Spiral-Wound, and

Jacketed ASME B 16.21 Nonmetallic Flat Gaskets for Pipe Flanges ASME B 16.25 Buttwelding Ends ASME B 16.28 Wrought Steel Buttwelding Short Radius Elbows ASME B 16.34 Valves - Flanged, Threaded, and Welding End ASME B 16.36 Orifice Flanges ASME B 16.47a Large Diameter Steel Flanges NPS 26 Through NPS 60 ANSI B 18.2.1 Square and Hex Bolts and Screws (Inch Series) ANSI B 18.2.2 Square and Hex nuts (Inch Series) ASME B 36.10M Welded and Seamless Wrought Steel Pipe ASME B 36.19M Stainless Steel Pipe

American Petroleum Institute (API) API SPEC 5L Specification for Line Pipe API STD 594 Check Valves: Wafer, Wafer-Lug, and Double Flanged Type API STD 598 Valve Inspection and Testing API STD 600 Steel Gate Valves- Flanged and Butt-welding Ends, Bolted and Pressure Seal Bonnets API STD 602 Compact Steel Gate Valves- Flanged, Threaded, Welding, and

Extended- Body Ends API STD 609 Butterfly Valves: Double Flanged, Lug-and wafer Type

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Manufacturers standardizations society-standard practice

MSS SP-6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting-End Flanges of Valves and Fittings MSS SP-25 Standard Marking Systems for Valves, Fittings, Flanges & Union MSS SP-45 Bypass and Drain Connections MSS SP-61 Pressure Testing of Steel Valves MSS SP-67 Butterfly Valves MSS SP-75 Specification for High Test Wrought Butt Welding Fittings MSS SP-82 Valve Pressure Testing Methods MSS SP-95 Swadged Nipples and Bull Plugs MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings- Socket welding, Threaded and Buttwelding Ends

American Society for Testing and Materials (ASTM) ASTM Section II A Volume 1 & 2 ASTM Section V ASTM Section VIII Division 1 & 2 British Standards (BS)

BS 5351 Steel ball valves for petroleum, petrochemical & allied industries BS 5352 Specifications for steel wedge gate, globe & check valves 50 mm & smaller for petroleum, petrochemical & allied industries BS 5353 Steel plug valves

BS 1873 Steel globe & globe stop & check valves (Flanged & butt-welded ends) for petroleum, petrochemical & allied industries BS 6755 (Part 1&2) Testing of Valves

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2. INTRODUCTION TO PIPING COMPONENTS 2.1. PIPES Piping in a particular plant can be compared with arteries & veins in our body. There are mainly two types of pipes from manufacturing point of view. The first is Seamless pipes & second is Welded pipes. Various attributes of pipe are described below. A) End Preparation:

There are three types of end preparation of pipes. (a) Plain End (PE) (b) Butt weld or Beveled End (BW/BE) (c) Threaded End

B) Design & Dimension Standard:

This will provide the following information. Nominal Bore (NB), Thickness, Outside Diameter (OD), Tolerance & Weight.

The Dimension Standard for pipe is as follows. ANSI/ASME B 36.10 For Carbon Steel (CS), Low Temperature Carbon Steel

(LTCS), Low Alloy Steel (LAS) Pipes ANSI/ASME B 36.19 For Stainless Steel (SS) Pipes

C) Material

I. CS: It is used for temperature range from (–) 290C to 4270C. Most commonly used CS materials are as follows:

ASTM A 106 Gr. B (Seamless pipes) API 5L Gr. B (Seamless & Welded) ASTM A 53 Gr. B (Seamless & Welded) IS 1239 (Upto 6” & ERW) IS 3589 (Above 6”) II. LTCS: It is used for low temperature i.e. from (–) 460C to 3430C.

The most commonly used LTCS materials are as follows:

ASTM A 333 Gr. 6 (Seamless pipes) ASME A 671 (Welded pipes) III. LAS: It is used for high temperature i.e. (-) 290C to 538°C The most commonly used LAS materials are as follows:

ASTM A 335 Gr. P11, P12, P9 (Seamless pipes) ASTM A 691 Gr.C60, C65, C70 (Welded pipes)

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IV. SS: It is used for cryogenic temperature range i.e. from (-) 1960C to 5380C.

Most commonly used SS materials are as follows:

ASTM A 312 TP 304 / ASTM A 312 TP 304L ASTM A 312 TP 316 / ASTM A 312 TP 316L ASTM A 312 TP 321

(Various shortforms:

IS Indian Standard ERW Electric Resistance Welding LS Linde Standard)

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2.2 FLANGES Flanges are used to make a joint that is required to be dismantled. Various attributes of Flanges are described below: A) Type: There are five types of Flanges.

I. Weld Neck Flange

It has Butt Weld End Connection. Radiography Test (RT) is possible.

II. Socket Weld Flange

Here Fillet welding is done from outside only. Die Penetration Test (DP) is possible.

III. Slip On Flange

Here Fillet welding is done from inside as well as from outside. DP Test is possible.

IV. Threaded Flange

It is mainly used in Galvanized pipes.

V. Blind Flange

It is used for ending a line.

B) Facing: There are four types of facing.

I. Raised Face

It is specified up to 600 (psi) rating pipe class.

II. Ring Joint

It is specified from 900 rating (psi) & above pipe class.

III. Flat Face

It is only used for 150 (psi) rating pipe class. It is specified for utility fluids like Cooling Water and Low Pressure Nitrogen.

IV. Tongue & Groove

Its use is mainly dependent upon the nature of fluid to be handled. It is specified to handle extremely hazardous fluids like Liquid Ammonia.

C) Design and Dimension Standard: The dimensional standards generally used are

I. ANSI/ASME B16.5 for size upto 24’’ II. ANSI/ASME B16.47 series A & B for size above 24’’. Series B specifies compact

design & is used when space and cost are the main constraints.

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D) Material: Flanges are manufactured from following forged materials.

I. Carbon Steel – ASTM A 105 (used most of the times) ASTM A 181 (it is obsolete now)

II. Low Temperature Carbon Steel—ASTM A 350 Gr. LF 2

III. Low Alloy Steel – ASTM A 182 Gr. F 11 (generally used)

ASTM A 182 Gr. F 1/F22/F9

IV. Stainless Steel – ASTM A 182 Gr. F 304 ASTM A 182 Gr. F 304 L ASTM A 182 Gr. F 316 ASTM A 182 Gr. F 316 L ASTM A 182 Gr. F 321

ASTM Sec. II A defines ferrous material. It gives detail properties of Ferrous Material

- Chemical Analysis - Physical Properties (tensile strength, Yield strength, hardness, etc.) E) Pressure Class (Rating)

Rating is maximum allowable non-shock working gauge pressure. There are 150, 300, 600, 900, 1500, 2500 ratings. To select a pressure class the following two steps are followed.

I. Decide the group of material from Table 1A of ASME 16.5 II. Refer Table 2 of ASME 16.5 for design condition.

Spectacle Blind or Figure 8 Blind

It is not exactly a flange but it is kept between two flanges and is used for the temporary isolation of a line.

Design & Dimension Standard----LS 423-06 Material----Same as Flange Facing----Same as Flange

Generally it is used up to 10” & above 10” it is used in two separate pieces. One is known as Slip Plate (Blind Part) & second is known as Slip Ring (Hollow Part).

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2.3. PIPE FITTINGS

Pipe fittings are of different types. 2.3.1 Elbows: Used for change in direction of pipe routing.

(a) They are of 2 types 45° Elbow which can be

Short Radius Elbow, R = 1D Long Radius Elbow, R = 1.5D

90° Elbow which can be

Short Radius Elbow, R = 1D Long Radius Elbow, R = 1.5D

(b) According to End connection elbows can be classified as

Socket Weld : for size upto 1½’’ Butt Weld : for size greater than 1½’’ ( > 2’’ in Linde) Threaded : for size upto 1½’’ in G.I. Pipes

(c) Dimensional Standard For Socket Weld & Threaded Elbows: ANSI/ASME B16.11 For Bevelled end Elbows : ANSI/ASME B 16.9 Thickness for Beveled end fittings = Thickness of pipe Thickness for 3000# Socket weld elbows = Schedule 80 of respective pipe size. Thickness for 6000# Socket weld elbows = Schedule 160 of respective pipe size. Thickness for 9000# Socket weld elbows = Schedule XXS of respective pipe size. (d) Pressure class for Socket Weld & Threaded Pipe Fitting It is as follows: 2000 psi or 2000 rating - used only for threaded pipe fittings

3000 psi - used only for Socket Weld Pipe fitting & threaded pipe fittings 6000psi - used only for Socket Weld Pipe fitting & threaded pipe fittings

9000psi - used only for Socket Weld Pipe fitting & threaded pipe fittings (e) Material

Socket Weld and Threaded pipefitting are manufactured from following forged materials (1) Carbon Steel – ASTM A 105 (2) Low Temperature Carbon Steel- ASTM A 350 Gr. LF2 (3) Low Alloy Steel – ASTM A 182 Gr. F11(generally used), F1, F6, F9 (4) Stainless Steel – ASTM A 182 Gr. F 304, F304L, F316, F316L, F321

Butt Weld pipe fittings are manufactured from pipes

(1) Carbon Steel – ASTM A 234 Gr. WPB (2) Low Temperature Carbon Steel – ASTM A 420 Gr. WPL6 (3) Low Alloy Steel – ASTM A 234 Gr. WP11/WP22/WP9 (4) Stainless Steel – ASTM A 403 WP/304, 304L, 316, 316L, 321

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2.3.2 Tee: Used for taking a branch.

(a) Tee can be Equal/Straight tee – All 3 sizes are equal Unequal/Reduced tee – Branch size is always smaller

Points (b), (c), (d) and (e) are same as elbows 2.3.3 Half Coupling: Used to take a branch upto 1½’’ size.

End connections are Socket Weld & Threaded Used in Pipe class upto 300 rating

Points (c), (d), (e) same as elbow

2.3.4 Reducer/Expander: Used when change in pipe size is there.

Type – Concentric Reducer – Butt Weld Eccentric Reducer – Butt Weld

In case of Eccentric Reducer one side is tapered while the other side is straight. Here the difference in elevation of the axis exists leading to eccentricity. Its construction is like a trapezoid.

In case of Concentric Reducer both sides are tapered and the axis is also the same. Its construction is like a cone.

Eccentricity

Thumb Rule for Reduction: Higher Size

For E.g. if the Header Side is 6’’ then 6/2 = 3 and hence the next lower size possible is 2½’’. Hence it can be seen that reduction from 6’’ to 2½’’ is possible. Further reduction beyond 2 ½’’ is not possible. Reducers can be manufactured in small size.

Dimension Standard: ANSI/ASME B16.9 Thickness is same as the pipe thickness.

Material: Same as BW Elbows

2.3.5 Full Coupling: Used for Pipe to Pipe joint of small bore (upto1½’’)

End connections are Socket Weld & Threaded Dimensional Standard, Material and Pressure class same as Half coupling

Eccentric Reducer Concentric Reducer

2 Next Lower Size

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2.3.6 Weldolet:

Used to take Butt Weld branch for which Reducing tee is not possible Used in high pressure, high temperature pipe class from 900 rating

Dimension Standard:

MSS SP 97 Header and Branch size with thickness is to be specified

Material: Forged same as elbow / half coupling 2.3.7 Sockolets:

Same as Weldolet except there is a Socket weld end at Branch side. 2.3.8 Caps: Used at the end of the line for the termination of the line.

End Connection: The end connections are Socket weld } Threaded end }

Butt weld Above 2”

Dimension Standard: ANSI/ASME B 16.11 For SW & Threaded End ANSI/ASME B 16.9 For BW/BE Thickness for BW caps same as thickness of pipe. Material: Same as Elbow

Up to 1 ½”

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2.4. VALVES Valves are used for main three purposes listed below. For Isolation of flow. For Regulation of flow. For avoiding the reversal of the flow. The valves used for isolation cannot be used for regulation but other way round is possible. Various types of valves.

(1) Gate valve (2) Ball valve (3) Plug valve (4) Butterfly valve (5) Globe valve (6) Needle valve (7) Check valve (8) Control valve (Handled by Instrumentation Department) (9) Pressure relief valve or Safety valve (Handled by Instrumentation Department)

First five valves are used for isolating the flow, 5th & 6th valves are used for regulating the flow and 7th valve is used for avoiding the reversal of the flow. 2.4.1 GATE VALVE It is the most commonly & very widely used valve in industrial piping for isolation of the flow. It is manually operated and it is not recommended for regulation of the flow. Installation of this valve is possible from both the ends. Hence it is bi-directional valve. A) End Preparation:

(a) Cast Steel valves have Flanged or Butt weld end preparation. (b) Forged Steel valves have Socket weld or Threaded end preparation.

B) Design & Dimension Standard:

The dimension Standard for gate valve is as follows. API 600 For Cast Steel valves (Flanged/BW valves) API 602 Forged Steel valves (SW/Threaded valves) ANSI B 16.34 For Pressure & Temperature limitation & Rating ANSI B 16.10 For face to face dimension of Flanged & BW end API 598 For Testing of valve

C) Main parts: Gate valve has following main parts.

Body Bonnet Internals/Trim/Wetted parts: Parts that come in direct contact with the fluid. Gate valve has following Internals/Trim/Wetted parts.

Wedge / Seat Ring / Stem / Gland Bush

D) Pressure Class:

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There are 150,300,600,900,1500,2500 ratings for Flanged & BW valve. There is 800 rating for SW or Threaded valve.

E) Material: Forged Steel Cast Steel

CS ASTM A 105 ASTM A 216 Gr WCB LTCS ASTM A 350 Gr LF2 ASTM A 352 Gr LCB LAS ASTM A 182 Gr F11 ASTM A 217 Gr WC6 ASTM A 182 Gr F22 ASTM A 217 Gr WC9 ASTM A 182 Gr F9 SS ASTM A 182 Gr F304 ASTM A 351 Gr CF8 ASTM A 182 Gr F304L ASTM A 351 Gr CF8M ASTM A 182 Gr F316 ASTM A 351 Gr CF3M ASTM A 182 Gr F316L ASTM A 351 Gr CF3C ASTM A 182 Gr F321

2.4.2 GLOBE VALVE The fluid while passing through this valve changes its flow direction and hence this valve causes increased resistance to flow which result into considerable pressure drop. So this valve is not suitable where pressure drop is critical. This valve is mainly used for regulation of the flow. Inlet and outlet of this valve are fixed. Hence installation of this valve is unidirectional. Flow direction is marked on the valve body. A) End Preparation: Same as Gate valve. B) Design & Dimension Standard:

BS 5352 For SW/Threaded valves BS 1873 For Flanged/BW valves ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating ANSI/ASTM B 16.10 For face to face dimension of Flanged/BW end valves API 598 For Testing of valve

C) Main parts:

Globe valve has following main parts. Body Bonnet Internals/Trim/Wetted parts: Globe valve has following Wetted parts.

Disc Seat Ring Stem Gland Bush

D) Pressure Class: Same as Gate valve.

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E) Material: Same as Gate valve. 2.4.3 CHECK VALVE It is sometimes referred to as Non Return Valve. It is self-operated valve and allows the flow to pass in one direction and will not allow reverse flow. Installation of this valve is unidirectional. Flow direction is marked on the body. A) Type and End Connection:

1) Lift Check Valve (up to 1 ½’’) : Socket Weld / Threaded / Butt Weld 2) Swing Check Valve ( >= 2’’) : Flanged / Butt Weld 3) Wafer type Check Valve: Wafer type / Wafer lug type. It is to be kept between two

flanges. B) Design & Dimension Standard: BS 5352 For Lift Check Valve BS 1868 For Swing Check Valve API 594 For Wafer Check Valve ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating ANSI/ASME B 16.10 For Face to Face dimension API 598 For Testing of valve C) Main Parts: Lift Check Valve: Swing Check Valve: Wafer Check Valve: Body Body Body Cover Cover Plates Spring Disc Spring Disc Seat Hinge pin Seat Hinge Pin Disc Carrier D) Pressure Class: Same as Gate Valve E) Material:

Lift Check Valve (up to 1.5” & SW / Threaded / BW): Same as forged Gate Valve Swing Check Valve (>= 2’’& Flanged / BW): Same as cast steel Gate Valve Wafer type Check Valve (Wafer type / Wafer lug type): Same as cast steel Gate Valve.

Internals InternalsInternals

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2.4.4 BALL VALVE This valve is used for isolation & for quick on / off. It is mainly used in utility line i.e. cooling water, instrument air etc. and in hazardous and combustible fluid. Rotating the lever by 900 opens or closes this valves fully. Hence this valve is called quarter turn valve. Fire safe design as per API 607 is available for this valve. Installation of this valve is possible from both the ends. Hence it is bi-directional valve. 3-way and 4-way construction is possible in ball valve by providing “T” or “L” port in the ball. A) End Connection:

Socket Weld & Threaded End – up to 1.5’’, 3-piece design Flanged / Butt Weld- 2 piece design

B) Design & Dimension Standard:

BS 5351 For Ball Valves ANSI/ASME B 16.10 For Face to Face dimension

ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating API 598 For Testing of Valves

C) Main Parts:

Ball valve has following main parts. Body Ball valve has following internals.

Ball Seat Stem

D) Pressure Class: Same as Gate Valve E) Material: Same as Gate Valve

Here Seat material is PTFE (Poly Tetra Fluoro Ethylene) Fire safe valves are available as per API 607 & has following seats Primary Soft Seat of PTFE

Secondary Metal to Metal Seat

2.4.5 BUTTERFLY VALVE It is mostly used for isolation and in specific case used for regulation. Regulation is not as precise as Globe Valve A) End Connection: Same as Wafer check valve

Wafer type / Wafer lug type / Flange end/Butt end

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B) Design & Dimension Standard:

API 609 For Butterfly valve ANSI/ASME B 16.10 For Face to Face dimension ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating API 598 For Testing of valve

C) Main parts:

Butterfly valve has following main parts. Body Butterfly valve has following internals. Disc / Shaft / Seat

D) Pressure Class: Same as Gate Valve of cast steel type E) Material: Same as cast steel Gate Valve Seat Material: EPDM, Nitrile - These are one kind of Rubber, soft material EPDM- Ethylene Propylene Di Monomer 2.4.6 PLUG VALVE This valve is used for regulation, isolation and quick on / off in combustible or Hazardous fluid. 3-way and 4-way construction is possible in plug valve by providing “T” or “L” port in the plug. A) End Connection:

Socket Weld/Threaded Flanged/Butt Weld

B) Design & Dimension Standard:

BS 5353 For Plug valve ANSI/ASME B 16.10 For Face to Face dimension ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating API 598 For Testing of valves

C) Main Parts:

Plug valve has following main parts. Body Cover Plug valve has following internals.

Stem Plug Sealant

D) Pressure Class: Same as Gate Valve E) Material: Same as Gate Valve

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2.4.7 CONTROL VALVE ( handled by Instrumentation Department ) These valves are self operated type. They have actuators. Actuators operate on the signal received from an instrument. They are used for very fine throttling and to have desired process parameters (pressure, temperature, flow) of fluid. Control Valves can be of the following types based on parameters to be controlled: • Pressure control valve-Receives signal from Pressure Indicator / Pressure Transmitter. • Temperature control valve-Receives signal from Temperature Indicator/Temperature Transmitter • Flow control valve-Receives signal from Flow Indicator/Flow Transmitter There are two types of signal: • Pneumatic – Valve has pneumatic actuator.(tubing is used) • Electric – Valve has electrical (solenoid) actuator. (cables are used) Based on construction, control valve has following types: • Butterfly Valve • Globe Valve • Ball Valve A) End Connection: Flanged End or BW. Flange end is always preferred

because of regular servicing & maintenance. B) Material : Same as other cast steel valves. C) Design & Dimension Standard: Same as other valves. D) Pressure Class: Same as other valves. 2.4.8 SAFETY VALVE This valve is also known as Pressure relief valve. It is used for safe operation of plant. This valve releases excess pressure when it exceeds set pressure. Pressure is set by spring. Inlet of this valve is one size lower or equal to the inlet pipe size. Outlet is at least one or more size higher to outlet pipe size. A) Material & Pressure Class: Same as Gate Valve

Outlet Pressure class <= Inlet Pressure class

B) Main Parts:

Pressure safety valve has following main parts. Body / Bonnet Safety valve internals: Spring / Disc / Stem

C) Design & Dimension Standard: API 526: For Pressure & Temperature limitation and Rating and for Center to Face Dimension.

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2.5 FASTENERS

It consists of Bolts, Full threaded Stud Bolts and Nuts. Bolts have Hexagonal or Round head while Studs are without heads. One stud with two nuts forms a set of fastener. Fasteners are used for flange joints in piping to retain flanges and gaskets. Threading is done on the studs and bolts by two methods.

1. Cut threads using cutting tool on Lathe. 2. Thread Rolling using rollers on thread rolling machine.

A) Design & Dimension Standard:

ANSI/ASME B 16.5 For Studs (Length & Diameter) ANSI/ASME B 18.2.1 For thread types with details of Studs & Bolts ANSI/ASME B 18.2.2 For Nuts

B) Material:

(1) CS ASTM A 193 Gr B7 For Stud

ASTM A 194 Gr 24 For Nut (2) LTCS ASTM A 320 Gr L7 For Stud ASTM A 194 Gr 4 For Nut

(3) LAS ASTM A 193 Gr B16 For Stud ASTM A 194 Gr 4 For Nut (4) SS ASTM A 193 Gr B8 For Stud ASTM A 194 Gr 8 For Nut

2.6 GASKETS

Gaskets are used to avoid Static leakage and metal to metal contact. There are two types of gaskets from material point of view.

1. Metallic Gasket: Metal is used in the construction of Gasket either as main

material or as reinforcing material.. e.g.

Spiral wound gasket. Used with RF flanges up to 600 rating. Thickness of spiral wound gasket is 4.5 mm. Ring joint Gasket used with RJ flanges from 900 rating.

2. Non-metallic Gasket: Metal is not used in the construction of gaskets. e.g. Flat Gasket Thickness of this gasket is normally 2 to 3 mm. It is used in FF and T&G type of flange.

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A) Design & Dimension Standard:

ANSI/ASME B 16.20 For Metallic Gaskets ANSI/ASME B 16.21 For Non-metallic Gaskets

B) Material:

For Metallic Gasket (1) S.S. ring for ring joint gasket. (2) Spiral wound Gasket

(a) S.S. (as reinforcement) & for inner and outer (centering) ring. (b) Filler material as follows.

Graphite used for high temperature. PTFE used for low temperature. CAF – It is banned to use from health hazard point of view.

For Non-metallic Gasket

(1) Flat Gasket

(a) CAF (Compressed Asbestos Fiber)- It is banned to use from health hazard point of view. (b) PTFE (c) Graphite

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3. PIPING MANUAL : ANSI/SME B 31.3 is used in Process Piping of following plants. Petroleum Refineries. Chemical Plants. Pharmaceutical Plants. Textile Industries. Paper Industries. Semiconductor Plants. Cryogenic plants. For piping components it specifies following details: Thickness of components considering internal and external pressure Types of various Branch Flexibility and Supports Piping Manual is a basic document, prepared based on ASME B31.3, for

(1) Disciplines listed below of Piping Department.

Piping Design Piping Material Stress Analysis

(2) Instrumentation Dept. Piping Manual has following documents.

• Standard / General Specifications for piping material • Pipe classes or Piping specifications • Valve specification Sheets • Technical purchase specifications • Special part specifications(not covered in pipe class) • Instrument nozzle assemblies • Piping supports standard

Above documents are used in piping design and procurement.

Design Material selection with Properties

Fabrication Details

Testing requirements / Methods

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3.1 Standard / General specifications: It consists of

• Applicable code & standards • General specifications for fabrication • General specifications for welding • General specifications for procurement • General specifications for certification

3.2 Pipe class: It is derived from

• Fluid to be handled • Design pressure • Design temperature

Above three points are obtained from the P&ID / Process.

Based on the above information, material group & rating are to be decided using table 2 of 16.5 and table 2 of 16.34. Then pipe class / pipe specifications are developed.

3.2.1 Pipe Class: Provides various components with its

• Size range • End connection • Design & dimension standard • Valve Specification Sheet Number • Material Grade • Technical purchase specification • Additional remark (if any)

3.2.2 Pipe class has 3 distinct tables:

• Limit table(Pressure and Temperature limitation) • Thickness table(pipe thickness) • Branch table(for selection of branch component)

Limit table:

It specifies pressure and temperature limitation for the components listed in pipe class. From

this table, suitability of pipe class & its components for given design conditions is decided.

Thickness table:

It specifies schedule no & relevant pipe thickness for all the sizes. Similar thickness to pipe shall be used for Butt Weld pipefitting, Weld Neck Flange.

Pipe thickness is to be calculated for internal design pressure as per para 304.1.2 of ASME B 31.3. Pipe thickness Calculation formula is available in MS EXCEL.

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Branch Table:

It gives types of branch whenever it is required to be taken from header pipe. In German language “Abzweig” is “Branch”. So in LINDE pipe classes for all the branch types “A” is specified as commodity code. Actual type is to be selected from the table. Branch types are

Unreinforced Branch- here direct welding of branch pipe to header pipe is done. Reinforced Branch- here branch pipe is welded to header pipe with reinforced pad or ring. (As per R-SP-1020 of Linde based on ASME B 31.3) Equal / reduced tee Weldolet Sockolet Half coupling

Based on calculation as per para 304.3 of ASME B 31.3, above branches are designed & their dimensions are calculated. These branches are tabulated in branch table of a pipe class. Appropriate branch is to be selected from this table.

3.2.3 Pipe Class Designation

The piping class designation consists of maximum six characters. L A 1 R 6 1 Sequential Number Flange Facing Pressure Rating Material Group Job Letter

First digit – Job Letter

L Linde Standard Pipe Class C Special Pipe Class for a particular project

Second digit – Material Group

A Stainless Steel C Killed Carbon Steel (Low Temperature) D Carbon Steel / Carbon Steel for High Temperature G 1.25% Cr 0.5% Mo Steel N Ni-Materials (Monel)

Third digit – Pressure Rating

1 150 3 300 6 600 7 900 8 1500 9 2500

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Forth digit – Flange Facing

F Flat Face R Raised Face G Tongue and Groove J Ring Joint

Last digit – Sequential Number

01 – 49 DIN (Germany) Pipe Class 50 – 99 ANSI Pipe Class

For example, Pipe Class CD1R66 indicates that it is a special pipe class with material group as Carbon Steel having 150 pressure rating with Flange having Raised Face and it follows ANSI Standard 3.2.4 Item Codes:

Piping Items

R Pipe A Branch (Weldolet, Tee etc.) BD Cap BS Plug B45 Elbow 45° B90 Elbow 90° F Flange FSW Socket Weld Flange FSO Slip On Flange FWN Weld Neck Flange FTH Flange Threaded FB Blind Flange FM Orifice Flange FS Spectacle Blind FSB Slip Blind FSL Slip Ring MU Coupling MUR Coupling reduced RDE Reducer eccentric RDK Reducer concentric RSK Swadged Nipple SA, SB Mitre Bends type A B etc.

Flange unions

FVA Flange Union (Flange / Flange) FVB Flange Union (Orifice Flange) FV stands for Flange Union. FVC Flange Union (Flange / Spectacle / Flange)

FVE Flange Union (Flange / Wafer Item / Flange) D Gasket M Nut S Bolt

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Valves

A Globe Valve B Globe Valve with regulating disc D Lift Check Valve E Swing Check Valve F Gate Valve H Butterfly Valve K Ball Valve M Valve according to pipe class for instrument connection

Valves are generally written in codes with end condition. For that following letters are used.

B Butt welded ends F Flanged ends S Socket-weld-ends G Threaded ends WA Wafer / Wafer-lug type SG Socket weld/threaded ends

For example, A-B means Globe Valve, Butt welded ends D-G means Lift Check Valve, threaded ends H-WA means Butterfly Valve, Wafer/Wafer-lug type

Strainer: Three letters generally code strainers. First letter is always N which indicates that it is a strainer. Second letter indicates end condition.

B Butt welded ends F Flanged ends S Socket welded ends

Third letter indicates mesh size.

B mesh size 0.315mm C mesh size 0.4mm D mesh size 0.5mm G mesh size 1.0mm F mesh size 1.6mm H mesh size 2.5mm K mesh size 3.15mm

Writing T or Y indicates the type of the strainer that is T-type or Y-type. For example, NBB Strainer, T-type, mesh size 0.135mm, Butt welded ends. NSF Strainer, Y-type, mesh size 1.6mm, Socket weld ends. NFK Strainer, T-type, mesh size 3.15mm, Flanged ends.

Codes for End Connection

A Outer thread SS Socket-weld both ends B Buttweld TB Welding joint T-type/ Butt weld I Inner thread TS Welding joint T-type/ Socket-weld BB Buttweld both ends AA Outer thread both ends BF Buttweld/Flanged II Inner thread both ends F Flanged SI Socket-weld/Inner thread FF Flanged both ends

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3.3 INSTRUMENT NOZZLE ASSEMBLIES Various Instruments are

(1) Pressure Indicator and Transmitter Used on Piping & Equipment (2) Temperature Indicator and Transmitter Used on Piping & Equipment (3) Flow Indicator and Transmitter Used on Piping (4) Level Indicator and Transmitter Used on Equipment

Above Instruments require piping parts to sit on / fix on. Such piping components (Branch, Pipe, Flange, Valve, Flange Union etc.) are grouped together and an instrument nozzle assembly is formed for modeling and for BOM. Each assembly has an identifying number. This number is mentioned on P&ID. This assembly is created in PDS (for modeling) & in MARIAN (for BOM) with same identifying number. Designer can place the assembly by selecting its identifying number in PDS. In BOM an assembly appears with its no. and break up. Flange Union: Flange Union is an assembly of Gaskets, Stud bolts & Nuts. We do not model flange union. It is linked with flanges. In BOM we get gasket, stud bolts & nuts as an assembly. Following types of flange unions are available

FVA Flange Union for Flange to Flange joint FVC Flange Union for Spectacle blind FVE Flange Union for Wafer Check valve FVH Flange Union for Butterfly valve FVX Special Flange Union (for Safety valve inlet)

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3.4 LINDE SUPPORT STANDARD:

Supports are not defined in pipe class. They are independent of pipe class. So following LS are used for supports:

LS 802-01 for pipe spans It specifies size wise unsupported span of pipes carrying

gaseous or liquid fluids and having different insulation types & thickness.

LS series 540 onwards is for dimension & construction of various types of supports.

1) LS 540-01: For selection of supports.

Appropriate piping support type is to be selected from piping modeling

(Horizontal/Vertical), design temperature and insulation type & thickness.

This Standard specifies temperature limit, supports class/spec, type of supports, size range, designation of supports, applicable design & dimension standard, for material group.

2) LS 540-10: For material group (support class/spec.)

Piping support is an assembly of various structural components. This Standard specifies

material group with detailed material of each structural component.

Design temperature of line is to be considered for deciding material group (support class/spec.)

Basic types of supports are:

• Anchor • Sliding • Guiding • Resting

Above supports are used for Hot Insulated and Cold Insulated Piping and in both Horizontal and Vertical arrangement.

Construction is different for different combination of above.

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3.5 SPECIAL PARTS:

• Parts not defined in Pipe Class. • Parts not governed by specific design & dimension standard. • Parts have varying geometric or process details.

Some special parts are mentioned below:

3.5.1 Steam Trap

To avoid steam loss the condensate has to be removed or released from the pipeline. To ensure only condensate is released from pipeline, steam traps are used. Steam traps trap the steam & release condensate in atmosphere or in the close system. At every low point in the steam line, the steam trap is to be provided.

Differential Pressure and Condensate flow rate decides the type of steam trap.

Different types of Steam trap are:

• Thermodynamic type • Inverted Bucket type • Ball float type

First type is of small capacity & last two are of higher capacity. 3.5.2 Strainer

It is used to remove impurities, so as to avoid damage in downstream equipment / system. It is available for both gaseous as well as liquid fluids. For gaseous fluids mesh size is smaller i.e. in micron and for liquid fluids mesh size is relatively higher. There are three types of strainers • ‘T’ type BW ends • ‘Y’ type SW or Flanged ends • Conical strainer Wafer type (to be held between two flanges & for higher size)

3.5.3 Any component with one or more Specifications / Attributes beyond pipe class 3.5.4 Special Supports

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4. MARIAN MARIAN is a material management system for plant & pipeline engineering. Its main applications are in construction of processing plants for the chemical, pharmaceutical and mineral oil industries and for industrial pipeline and power station construction. MARIAN is an application package based on the ORACLE relational database. It consists of the database (tables) and the application (screens & lists). The user communicates with the database interactively in the application screens. 4.1 Main Database: (A) Product Group: STANDARD

• It is nothing but a common database for all the projects. • Projects are created in Product group • Components with binding set of rules based on DIN / ANSI Standards are already defined & grouped in product group STANDARD. • Same group with rules can be copied in to project. Then relevant or

necessary changes can be made in project database. (B) Project:

• Projects are created in Product Group STANDARD. • Applicable component group with rules is copied from Standard. • Project specific changes are made in project. • Ident number is built. • Pipe Classes are developed.

4.2 MARIAN has following modules.

1. Administration 2. Standardization 3. BOM 4. Requisition 5. Interface (with PDS for pipe class) 6. Procurement 7. Construction

4.2.1 Administration:

Administration of MARIAN Software, Various users, Various projects, Rights- Access-Security are done in this module.

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4.2.2 Standardization:

• Components are grouped based on binding set of rules with technical description in to pipe classes.

• We create unique Ident number for each component. • Ident number is the key field of the BOM / MTO database to link them with the database

of other departments. e.g. Procurement Dept. – They enter P.O. quantity against each Ident number, Inspection Dept. – They enter released quantity against each Ident number. So database of Procurement & Inspection dept. can be combined with BOM / MTO to know the status of each Ident with its description.

• Pipe Classes are prepared with limit, thickness & branch table in Standardization. 4.2.3 BOM:

• PDS models are transferred to MARIAN for BOM through Linde Shell. Linde Shell is interface program between PDS & MARIAN.

• PDS has MARIAN pipe classes in codified form, because PDS do not understand text. PDS has also limit, thickness & branch table.

• During transfer codified database of PDS model is decodified & compared with MARIAN pipe class and line wise BOM is generated with Ident number.

• Reports of line wise BOM to be taken for issuing with isometrics at site. 4.2.4 Requisition:

• It summarizes / consolidates the quantity of the components having same size & same pipe class. • This summery is called MTO (Material Take Off). It is used for Procurement.

4.2.5 Discoverer 3.1:

• BOM Report / Requisition Report can be opened & edited in MARIAN only. • Our client & vendors do not have MARIAN and so these reports are to be converted in

easily available office software like MS Excel, MS Access for linking with other department’s work. We use Discoverer 3.1 for this purpose.

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5. TECHNICAL PROCUREMENT

5.1 Piping Inquiry Specification

Piping inquiry specification is the set of documents, which contains all the technical specifications, and quantity (BOM) of piping items for floating inquiry to the sub-contractors for obtaining offers. Purchase indent is raised for this inquiry specification. Selected vendors and date, when the material is required at site is mentioned in the indent. Indent with inquiry sets is forwarded to procurement manager. Procurement manager floats the inquiry. On receipt of bids procurement manager distributes the bid to indenter & QA engineer.

5.2 Technical bid evaluation Technical aspects with respect to specified requirements and all the deviations are evaluated & note. Depending upon the product criticality, following informations are identified which will have bearing on product quality. • Deviations to scope of supply, material of construction, design requirements, • Compliance to specifications & other requirements. The following criteria may be considered in addition to above, if unregistered sub-contractors are considered. • Quality level of the sub-contractor • Important construction and performance features • Adequacy of design, manufacturing and testing facilities • Experience of sub-contractor for similar products The indentor resolves all queries/deviations with respect to technical specification by seeking clarification from all bidders to bring them technically at par. If required, detailed technical discussions are carried out to resolve the outstanding issues with sub-contractor.

5.3 Technical recommendation (TR) Technical bid evaluation and recommendation on the basis of sub-contractor’s offers and technical discussions is prepared. Technically acceptable subcontractors are recommended. This TR is forwarded to Project Manager with a copy to Procurement Manager. In the case of non-recommendation, reasons for the same may be elaborated. Copy of TR is attached herewith.

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6. LINDE’S MATERIAL CONTROL SYSTEM (LMCS):

LMCS is LINDE’s Material Control System developed in MS ACCESS. Linde Material Control system depicts the status of an item from requisition to reconciliation. By referring LMCS one comes to know about required, ordered and released quantity for each piping component. Following databases are created & linked. 6.1 “MTO” database from Plant Design Department for Required Quantity:

6.2 “Procurement” database from Procurement Department for Ordered Quantity:

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6.3 “Inspection” database from Q.A. Department for Released Quantity:

6.4 “Transport” database from Procurement Department for Dispatched Quantity:

6.5 “Receipt” database from Site for Received Quantity:

6.6 “Issue” database from Site for Issued for fabrication Quantity:

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For all above databases of various departments, ident number is the unique & common key. On ident number, relation is set between these databases and required report is prepared. For an ident number, we can create a query or report showing followings. Required quantity Ordered quantity Released quantity Dispatched quantity Received quantity Issued quantity Ref.A. following query shows procurement status of an item

Ref.B Following query shows status from requisition to reconciliation.