GUJARAT STATE PETRONET LIMITED

CHHARA LNG CONNECTIVITY PROJECT

DESIGN BASIS - PIPING

Document Number: GSPL-P218-PP-DEB-7001

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00 13-05-22 ISSUED FOR RFP AP UK NM/VCK DD/RD

Rev Date Purpose Prepared Checked Approved Approved

LARSEN & TOUBRO LIMITED

L&T Knowledge City, NH-8,
Between Ajwa-Waghodia Crossing,
Vadodara- 390019, Gujarat
0170-FMT-01 Copyright Larsen & Toubro Limited. All rights Reserved.
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CONTENTS
1.0 INTRODUCTION ..................................................................................................................3
2.0 PURPOSE ............................................................................................................................3
3.0 DEFINITION & ABBREVIATIONS .......................................................................................3
3.1 DEFINITIONS.......................................................................................................................3
3.2 ABBREVIATIONS ................................................................................................................4
4.0 CODES & STANDARDS ......................................................................................................6
5.0 PIPING DESIGN CRITERIA AND SPECIFICATION ............................................................8
6.0 PIPING MATERIAL ............................................................................................................ 10
6.1 GENERAL .......................................................................................................................... 10
6.2 PIPES ................................................................................................................................ 11
6.3 FITTINGS ........................................................................................................................... 11
6.4 FLANGES, SPECTACLE BLINDS & GASKET ................................................................. 11
6.5 BOLTS & NUTS ................................................................................................................. 12
6.6 VALVES ............................................................................................................................. 12
6.7 INSULATING JOINTS ...................................................................................................... 15
7.0 PIING LAYOUT DESIGN GUIDES ..................................................................................... 15
7.1 LAYOUT ............................................................................................................................ 15
7.2 UNDERGROUND PIPING .................................................................................................. 17
7.3 CLEARANCE AND ACCESSIBILITY ................................................................................ 18
7.4 PLATFORM, LADDERS AND STAIRWAYS...................................................................... 19
7.5 VENT & DRAINS ............................................................................................................... 19
8.0 STRESS ANALYSIS & SUPPORT .................................................................................... 20
9.0 EQUIPMENTS.................................................................................................................... 22
10.0 INSTRUMENTS CONNECTION ......................................................................................... 22
10.1 PRESSURE INSTRUMENTS ............................................................................................. 22
10.2 TEMPERATURE INSTRUMENTS ...................................................................................... 22
10.3 CONTROL VALVES .......................................................................................................... 23
10.4 SAFETY VALVES .............................................................................................................. 23
10.5 PIG SIGNALERS ............................................................................................................... 23
11.0 WELDING & POST WELD HEAT TREATMENT ............................................................... 24
12.0 HYDROSTATIC TESTING ................................................................................................. 24
13.0 SITE AND ENVIRONMENT DATA..................................................................................... 24
14.0 EXTERNALLY COATING/PAINTING & INSULATION ...................................................... 25
15.0 PREPARATION OF PIPING DRAWINGS .......................................................................... 26
16.0 GUARANTEE TEST........................................................................................................... 28

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1.0 INTRODUCTION

Gujarat State Petronet Limited (“GSPL” or “Owner is pioneer in developing energy

transportation infrastructure and connecting natural gas supply sources and LNG terminals to
growing markets. GSPL is continuously expanding its pipeline network in Gujarat to reach the
demand centers. Presently GSPL is operating more than 2700 kms approx. of gas pipeline in
Gujarat. The receipt of gas from the sources and its transportation and distribution is intended
to be carried out through high-pressure cross-country trunk transmission gas grid.

GSPL intends to set-up a new 36” dia. cross-country gas pipeline of approximately 88.628 km
from Lonthpur to Chhara LNG station with associated facilities via 3 numbers of SV stations
(One number of existing station at Gundala and one number of new station near by existing
SV station at Pati Mansa & one number of new SV station at Bodidar).

2.0 PURPOSE
This documents covers the minimum basis for the overall design of piping system associated
with for proposed 36” NB pipeline for CHHARA LNG CONNECTIVITY PROJECT of GSPL.

The EPC contractor shall be responsible for ensuring that the design of piping system
conforms to all applicable codes, statutory requirements and accepted practices, and fulfills all
design requirements of the P&ID’s, Process Design basis, maintenance and access
requirements and the requirements listed in various project engineering specifications, to
achieve successful, trouble free commissioning and operation of the pipeline for the intended
design life.

This design basis shall be read in conjunction with others specifications attached elsewhere
in the bid.

3.0 DEFINITION & ABBREVIATIONS

3.1. DEFINITIONS

Owner : Gujarat State Petronet Ltd (GSPL)

Consultant/ Engineering : LARSEN & TOUBRO LIMITED.
Consultant (EC)
Contractor : Any supplier for goods and services or supplier/
manufacturer of equipment or construction contractor

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appointed/ nominated by Owner and that is not a sub-

contractor of Consultant for the Services it provides.
Contractor shall also include EPC Contractor/
Construction Contractor/ Supplier to be appointed for
construction of the Project.
Sub-Supplier/ Sub-Contractor : Any natural person, private or public entity, or a
combination of the above, to which any part of the
Goods/material to be supplied or execution of any part
of the Services is subcontracted by the Contractor. The
terms “Sub-suppliers”, “Sub-contractors” and
“Vendors” can be used interchangeably
Party : Any one of the Owner or the Consultant
Parties : Both Owner and the Consultant
Third Party : Any other person or entity as the context requires
TPIA : Third Party Inspection Agency for Site Construction,
manufacturing / production of material required till the
project completion for ensuring the quality at site and
at manufacturer's premise.
Services : The services to be performed by the Consultant for and
in relation to the Facility and includes the detailed
Scope of Work mentioned in this document
Project : Chhara LNG Connectivity Project
BEP : Basic Engineering Package
RFP : Request for Proposal
FEED : Front End Engineering & Design
Associated Facilities : Dispatch, Receipt Stations & Sectionalizing valve
stations etc.
Site : The land, location, RoU and/or includes any other place
as may be designated by the Owner in connection with
the Facility where the Services are to be provided/
performed by the Consultant
Site Office : Office set up provided by EPC Contractor during
Construction phase

3.2. ABBREVIATIONS

A/G : Aboveground

API : American Petroleum Institute

ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and Materials

BOP : Bottom of Pipe

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BS : British Standard

CS : Carbon Steel

DF : Design Factor

DFT : Dry Film Thickness

EPC : Engineering Procurement Construction

FEED : Front End Engineering Design

FFL : Finished Floor Level

FGL : Finished Grade Level

GOV : Gas Over Oil Operated Valve

HOV : Hydraulic Operated Valve

HPP : Highest Pavement Point

HSAW : Helical Submerged Arc Welding

HSE : Health Safety and Environment

ID : Internal Diameter

IS : Indian Standard

ISO : International Organization for Standardization

LTCS : Low Temperature Carbon Steel

LSAW : Longitudinal Submerged Arc-Welding

NDT : Non Destructive Test

NGL : Natural Grade Level

NPS : Nominal Pipe Size

NTS Not To Scale

OD : Outside diameter

OISD : Oil Industry Safety Directorate

P&ID : Process & Instrumentation Diagram

PFD : Process Flow Diagram

PMC : Project Management Consultant

PNGRB : Petroleum and Natural Gas Regulatory Board

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PWHT : Post weld Heat treatment

QOEC : Quick Opening End Closure

SCADA : Supervisory Control and Data Acquisition

SCH : Schedule

SS : Stainless Steel

TOP : Tap off Points

TOS : Top of steel

U/G : Underground
4.0 CODES & STANDARDS

ASME B 31.3 : Process Piping

ASME B 31.8 : Gas Transmission and Distribution Piping System
ASME B 1.1 : Unified Inch Screw Thread
ASME B 1.20.1 : Pipe Threads, General Purpose (inch)
ASME B 16.5 : Pipe Flanges and Flanged Fittings
ASME B 16.9 : Factory-made Wrought Steel Butt Welding 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
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 : Butt Welding Ends
ASME B 16.34 : Valves - Flanged, Threaded and Butt Welding End
ASME B 16.47 : Large Diameter Steel Flanges
ASME B 16.48 : Steel Line Blanks
ASME B 18.2.1 : Square and Hexagonal Bolts and Screws
ASME B 18.2.2 : Square and Hexagonal Nuts
ASME B 36.10 : Welded and Seamless Wrought Steel Pipe
ASME B 36.19 : Stainless Steel Pipes
ASME Sec V : Non Destructive Examination
ASME Sec IX : Qualification Standard for Welding, Brazing, and
Fusing Procedures; Welders, Brazers and Welding,
Brazing, and Fusing Operators
ASME Sec VIII Div. 1 : Rules for Construction of Pressure Vessel

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API 5L : Specification for Line Pipe

API 594 : Check valves: Wafer and Wafer-lug, and Double
Flanged type
API 6FA : Specification for Fire test for valves
API 598 : Valve Inspection and Testing
API 607 : Fire test for Soft-Seated quarter-turn valves
API 609 : Lug and Wafer type Butterfly valves
API 6D : Specification for Pipe Line valves
API 1102 : Steel Pipeline Crossing Railroads and Highways
API 1104 : Welding of Pipelines and Related Facilities
ASTM International : Annual Book of ASTM Standards
BS 1873 : Steel Globe and Globe stop and Check valves
(Flanged and Butt-welding ends) for the Petroleum,
Petrochemical and allied Industries
BS EN 12266 - 2 : Industrial valves - Testing of Valves
BS EN 10204 : Metallic products – Types of Inspection Documents
G.S.R. 808 (E) : Petroleum and Natural Gas Regulatory Board
(PNGRB) Notification
ISO 10474 : Steel and Steel Products – Inspection Documents
MSS SP-6 : Standard finishes for contact faces of Pipe Flanges
and Connecting – end Flanges of valves and
Fittings
MSS SP-25 : Standard marking system for Valves, Fittings,
Flanges and Unions
MSS SP-44 : Steel Pipeline Flanges
MSS SP-45 : Bypass and Drain Connections
MSS SP-53 : Quality Standard for Steel Castings and Forgings
for Valves, Flanges, Fittings, and Other Piping
Components - Magnetic Particle Examination
Method
MSS SP-54 : Quality Standard for Steel Castings and Forgings
for Valves, Flanges, Fittings, and Other Piping
Components - Radiographic Examination Method
MSS SP-55 : Quality Standard for Steel Castings and Forgings
for Valves, Flanges, Fittings, and Other Piping
Components - Visual Method for Evaluation of
Surface Irregularities
MSS SP-58 : Pipe Hangers and Supports - Materials, Design,
Manufacture, Selection, Application, and Installation
MSS SP-61 : Pressure Testing of Valves
MSS SP-75 : High-Strength, Wrought, Butt-Welding Fittings

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MSS SP-93 : Quality Standard for Steel Castings and Forgings

for Valves, Flanges, Fittings, and Other Piping
Components - Liquid Penetrant Examination
Method
MSS SP-94 : Quality Standard for Steel Castings and Forgings
for Valves, Flanges, Fittings, and Other Piping
Components - Ultrasonic Examination Method
MSS SP-97 : Integrally reinforced forged branch outlet fittings –
socket welding, threaded and butt welding ends
MSS SP-137 : Quality Standard for Positive Material Identification
of Metal Valves, Flanges, Fittings, and Other Piping
Components.
OISD-STD-118 : Layout for Oil & Gas Installation
OISD-STD-141 : Design and Construction requirements for Cross
Country Hydrocarbon Pipelines
OISD-STD-226 : Natural Gas Transmission Pipelines And City Gas
Distribution Networks
IS-875, Part-3 : Wind Load on Buildings and structures
IS-1893, Part-1 & Part-4 : Criteria for Earthquake Resistance Design of
Structure

5.0 PIPING DESIGN CRITERIA AND SPECIFICATION

5.1. Overall piping systems shall be designed as per the requirements of ASME B31.8. latest
editions and shall be in line with applicable statutory guidelines in force time to time and in
compliance to Petroleum and Natural Gas Regulatory Board (PNGRB) requirements with
compliance of Safety/ quality compliance shall be as per PNGRB standards, over & above the
standards and other local statutory compliances. All design calculations shall be made for the
design parameters and flexibility considering design pressure, thermal expansions, undue
vibrations, seismic factors (IS-1893) and any uncertainty in loads and displacements other
than design or operational values in accordance with code requirements and submitted to the
Owner/Consultant for approval.
5.2. The Piping system along with associated facilities same shall be designed for a design life
same as that of pipeline.
5.3. Pipe work shall be capable of sustaining, without overstress or unacceptable displacement,
the following loads under design and test condition shall be considered as minimum.
a. Self Weight
b. Weight of fluid during testing
c. Internal pressure – maximum design & Test

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d. Thermal expansion and contraction due to temperature gradients

e. The soil dead weight loading due to depth of cover (if applicable)
f. Earthquake load as per IS-1893, Part-1 & Part-4
g. Wind load as per IS-875, Part-3
5.4. All supply material pipe, valves and fittings shall be new and unused and shall have legible mill
coding as to type and grade of material.
5.5. All piping material and components i.e. pipes, fittings, valves, flanges, gaskets and bolting etc.
shall be as per the piping material specifications and tested as prescribed in the piping
specifications, standard codes, practices and certificates of conformance shall be furnished for
review and approval by Owner/Consultant.
5.6. Equipment layout/Piping general arrangement drawing/Isometric/support drawings etc. shall
be prepared using good engineering practice and as per the guidelines furnished in piping
specifications and shall be submitted for review and approval by Owner/Consultant.
5.7. Contractor shall furnish all the specifications and design basis which will enable to complete
the pipe line network, but not limited to, the following specifications and codes.
a. Specifications for Welding, NDT, Fabrication, Erection, Testing, and Drying shall be
prepared.
b. Establish specifications, design and layout for firefighting wherever applicable including
fire and gas detection system, fire hydrant and sprinkler system, for all stations wherever
applicable.
c. In addition to these; Health, Safety and Environmental requirements shall be specified,
addressing all relevant requirements for safe and reliable execution of the project in
accordance with international standards.
5.8. In case of any conflict between various requirements, Order of precedence/priority shall be as
mentioned in the scope of work documents, job specs, etc. attached elsewhere in the bid. In
case of any conflict between various requirements of specifications and code requirements,
the most stringent requirement shall be followed and the decision of Owner/Consultant in the
resolution of the conflict shall be final and shall be implemented by contractor without any time
and cost implication.

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6.0 PIPING MATERIAL

6.1. GENERAL

6.1.1. The piping material specification shall be governed by the design conditions of pressure,
temperature, corrosion allowance and compatibility with contained media.

6.1.2. When two lines that operate at different pressure/temperature conditions are connected, the
valve segregating the two lines shall be rated for more severe service condition.

6.1.3. Pipe wall thickness shall be calculated in accordance with ASME B31.8 code except for Utility
piping.

6.1.4. Pig Launchers/Receivers shall be designed as per ASME B31.8/ASME SEC VIII Div. 1.

6.1.5. All above ground piping system shall be of low temperature seamless pipes of equivalent
grade to match with 600# pressure and temperature rating. However, piping above 12 NB shall
be of LSAW, API 5L X-70, PSL 2 Grade.

6.1.6. Contractor shall calculate and verify thickness/schedule against each size of piping class.

6.1.7. Cast iron, brass or Bronze material shall not be used unless otherwise specified.

6.1.8. Threaded piping connections are not permitted except for utility and instrument connection.

6.1.9. Any NDT of pipe and fittings shall be carried out after completion of all manufacturing process
like heat treatment, stress relieving etc.

6.1.10. Transition piece shall be provided between two different grades & thickness of line pipe, as
shown in P&ID’s.

6.1.11. Internal bore of all fittings, Pig traps and pup pieces shall match with mainline (ID match with
connecting line pipe) shall be critically checked for safe passage of pig.

6.1.12. Any branch connection to pipeline (A/G & U/G) and underground piping, the minimum branch
size shall be 2” and for above ground the same shall be as per P&ID’s.

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6.1.13. All the piping components impact test shall be conducted at a test temperature of -200 C in
addition to Impact Test temperature specified in the respective material specifications. The
energy absorbed value at -200 Deg C shall be minimum 28J & Average 35 J Average.

6.2. PIPES

6.2.1. Minimum NPS ½ pipe shall be used. Pipes having nominal diameter ¼”, 3/8”, 1 ¼”, 2 ½”, 5”,
7”, 9” and 22” shall not be used. If any equipment/skid having connections at these sizes,
suitable expander to be provided.

6.2.2. The pipe shall be LTCS seamless up to 12” and above 12” shall be welded (LSAW) – API 5L
PSL2 Pipes.

6.2.3. Pipe 2” and below shall have minimum thickness equivalent to SCH 160.

6.2.4. The transition piece shall be provided between two different grade and thickness of the line
pipes.

6.3. FITTINGS

6.3.1. Fittings made of cast iron and ductile iron shall not be used.

6.3.2. Fittings for size 2” and above shall be butt weld end type and for below size 2” shall be socket
weld end type.

6.3.3. Elbows shall have long radius.

6.3.4. Branch fittings shall be as per PMS.

6.3.5. All fittings shall confirm to ANSI 600 # and meet LTCS properties and Impact Test values at -
20 °C in addition to Impact Test requirement as per the respective material code & standard.

6.4. FLANGES, SPECTACLE BLINDS & GASKET

6.4.1. Flanges shall comply with ASME B16.5 for diameter up to 24”. For above 24” shall comply with
ASME B 16.47 series A.

6.4.2. Flanges for size 2” and above shall be Weld Neck Raised Face (WNRF) type and for below
size 2” shall be raise face with socket weld end type.

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6.4.3. Type of flanges face and its surface finish shall be as AARH 250 and as per PMS.

6.4.4. Spectacle blinds shall be provided as per the requirement shown in P&ID’s and shall be flat
face type for raise face flanges.

6.4.5. Spectacle Blind assembly shall be provided with jack screws unless otherwise specified.

6.4.6. Gasket shall comply with ASME B16.20 and dimensionally suitable for use with flanges
described in reference flange standards ASME B16.5, ASME B16.47, series A.

6.4.7. For 600 # Spiral wound graphite filled gasket with both inner and outer ring. The inner ring &
Spiral material shall be SS 316.

6.4.8. Asbestos in any form in gaskets shall not be used.

6.5. BOLTS & NUTS

All Stud bolts & nuts shall be suitable for Low temperature application.

6.6. VALVES

6.6.1. All valves up to size 1-1/2" size shall be have socket welding ends for 600#.

6.6.2. All ball valves provided shall comply API 6D, fire safe design requirements as per API 6FA
and shall have anti-static design.

6.6.3. Globe valve shall comply with BS 1873.

6.6.4. All the main line valves shall be double block and bleed type and double piston effect for low
temperature application.

6.6.5. Underground valves to be fully welded, while aboveground valves can be fully welded or bolted
type. Ball valves shall be of two piece (2) or three piece (3) construction including Body & Side
Pieces.

6.6.6. All butt weld valves shall be provided with Pup-Pieces of length as per Table 6-1 as minimum.
Internal bore of all valve pup pieces shall match with connecting line (ID match with connecting
line pipe). Valves stem height shall be at normal operating height up to chest level from finished
Ground Level. For underground valve stem height shall be decided during detail engineering.

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Table 1: Minimum Pup piece Length

Valve Size (inch) Minimum Pup-Piece Length (mm)

Up to 4” 200

6” 300

12” 350

18” 500

36” 1D

EPC Contractor to follow the minimum length of pup pieces as mentioned in above table
however if there is any impact due to HAZ (Heat affected zone) then EPC Contractor/ Vendor
to demonstrate by carrying out the field trial during EPC stage that provided Minimum Pup-
Piece length is sufficient.

6.6.7. Material of Construction for pressure contacting parts and other parts of valve shall be as per
QAP & Data sheet.

6.6.8. The first isolation valves from Mainline shall be welded end types of ball valve. All mainline
and underground valves shall be of welded body and welded end type.

6.6.9. All isolation valves shall be equipped with spectacle blind at downstream of the valve or as per
P&ID’s.

6.6.10. Ball valves shall be Side entry and shall be full bore type only, irrespective of their location.

6.6.11. All ball valves of above 2” size shall be Trunnion mounted.

6.6.12. The face to face dimensions of valves shall be based on API 6D/ANSI B16.10.

6.6.13. Ball valves below 4” size for A/G service shall not require vent, drains & plugs on valve body
unless specified. However, for underground service drain with double ball valves (Socket
welded), one needle valve and depressurizing Plug shall be provided. MOC of valve, plug and
tube shall be SS316.

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6.6.14. Ball valve below 6” size A/G service shall have only drain connection with series connection
one ball valve (Socket welded), one needle valve and depressurizing Plug. However for U/G
service shall have only drain connection with series connection of double ball valve (Socket
welded), one needle valve and depressurizing Plug. MOC of valve, plug and tube shall be
SS316.

6.6.15. Ball valves 6” and above for A/G service shall have both vent and drain facility with one ball
valve (SS-seal welded), needle valve and Plug arrangement. MOC of valve, plug and tube
shall be SS316). Ball valves 6” and above for underground service shall have both vent and
drain facility with double ball valves (socket welded), needle valve with Plug. MOC of valve,
plug and tube shall be SS316.

6.6.16. For 6” and above valves seat (both seats) & stem sealant injection facility shall be provided
and shall have secondary sealant injectors for sealant injection under full line pressure for seat
and stem seals. Material of construction for sealant connection shall be SS 316, sch 160 and
all valves shall have anti-blow out stems. The stem and seat sealing connection shall have a
check valve integrated in the main valve body, a ball valve close to the body tap and another
ball valve and sealant fitting with built in spring loaded check valve.

6.6.17. All vent, drain and sealant injection fitting shall be of SS 316 material of SCH 160.

6.6.18. All vent, drain & Sealant connection shall be socket welded type.

6.6.19. No hole or tapping shall be provided in the valve body, end piece and pups other than Drain,
vent & sealant connection.

6.6.20. All mainline valves shall be operated locally as well as through SCADA.

6.6.21. Hand wheels made of aluminum alloy are not allowed.

6.6.22. All valve pressure components shall be suitable for low temperature service with impact
tested at -20 °C in addition to Impact Test requirement as per the respective material code &
standard.

6.6.23. All Mainline valves to be GOV/ HOV as per P&ID and shall have ASTM A350 LF2 CL1/ ASTM
350 LF6 Class 2/ ASTM A694 F70 body including the Launcher/ Receiver Valves as per
datasheet of valves.

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6.6.24. Valves to be installed underground shall be coated with 800 micron thick high build epoxy
coating (Duracoat, Epigen or equivalent) or 1.5 mm (min.) thick PU coating.

6.6.25. Underground valves shall be provided with pup pieces which will be as per pipeline design
criteria and datasheets.

6.7. INSULATING JOINTS

6.7.1. Insulating Joints shall be provided to electrically isolate the buried pipeline from above ground
pipeline and shall be installed in above ground portion of the pipeline, immediately after the
buried to above round transition at the scrapper station.

6.7.2. Insulating joints shall be monolithic type and shall allow smooth passage of all kind of pigs.

6.7.3. Minimum length pup piece shall be as per Table 1 of design basis & material of pup piece of
Seamless/ LSAW type shall be provided.

6.7.4. Design shall comply with ASME SEC VIII Div. 1.

7.0 PIPING LAYOUT DESIGN GUIDES

7.1 LAYOUT

7.1.1. All piping shall be routed in an orderly manner and grouped in banks wherever possible to
provide an economical layout and have the minimum number of fittings consistent with ease
of support and with the proper provision for expansion and flexibility and ease of maintenance
and shall follow Inter distance requirement as per PNGRB T4S & OISD 226.

7.1.2. Where possible Piping shall be grouped and run at common BOP on sleepers for ease of
supporting.

7.1.3. Piping to be arranged for ease of inspection and servicing. Maintenance areas are to be kept
clear of piping as far as possible. Piping shall be designed so that vessel connections and
other pertinent components can be isolated for safe maintenance.

7.1.4. Piping or equipment requiring occasional cleaning or maintenance shall be provided with break
flanges for dismantling.

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7.1.5. All components requiring operation or maintenance, where practical shall be located where
they can be operated or serviced conveniently. Access shall be provided to such components
if they are located out of reach from platform.

7.1.6. The piping arrangement shall provide for isolation by operation of valves or other components
to accomplish safe isolation.

7.1.7. Connections from the header for air, nitrogen, fuel gas will be from the top and Liquids to be
either from the side or bottom.

7.1.8. Bypass spools in piping shall be designed to permit the removal of the components bypassed
without removing isolating block valves. A drain valve shall be provided to drain liquids
between isolating valves.

7.1.9. Control valves shall be installed with the actuator in a vertical upward position. Manifold
arrangements shall consider access, clearance, maintenance and removal of control valve
without removing of stop valves. Control valve manifold shall preferably be located within view
of associated instruments.

7.1.10. Sufficient space shall be provided around all the Valves to permit access for operation and
maintenance. All valves shall be located such that they are accessible for hoisting equipment
where needed.

7.1.11. Block valves in pipe work connected to equipment shall be installed as close to the equipment
as practical.

7.1.12. The discharge point of vent shall be at least 15 meter away from the nearest leakage point
(as per PNGRB guidelines) and at least 3 meter above the nearest operating platform or
nearby structure within radius of 15 meter whichever is higher.

7.1.13. Bolt holes on fabricated piping items shall straddle the vertical and North/South Center lines
unless otherwise specified on the piping drawing.

7.1.14. If there is slope requirement in line, the same shall be provided in line with P&ID’s.

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7.1.15. Control valves, relief valves shall be accessible from equipment or ground levels and
grouped at main operating levels if possible. Valve stems should not be positioned below a
horizontal center line.

7.1.16. Low Pockets in lines including dead legs shall be avoided at all times. In the event this is not
possible, all gas traps shall have accessible plugged vents and liquid traps shall have
accessible plugged valve drains.

7.1.17. Circumferential butt welds shall be separated by the maximum possible distance. For piping
of sizes 4”NB and above, butt welds shall be no less than 1D or 200 mm whichever is greater.
For piping 3” and below, minimum spacing shall be 1D or 100 mm whichever is greater.

7.1.18. Piping, racking and equipment should not be suspended from the underside of impact
protection structures.

7.1.19. The minimum pipeline center shall have 1000mm minimum elevation from FFL inside
process area.

7.1.20. The minimum clearance between hand wheels on valve manifolds shall be 100 mm.

7.1.21. All allocated areas for safety access, service, maintenance and operation shall be kept clear
of piping or any other obstructions.

7.1.22. Equipment layout shall be updated based on final approved vendor drawings/skid
dimensions. Equipment layouts provided in the bid are only indicative. Contractor to develop
layout drawings to suit his concept, based on safety distances as per OISD & PNGRB norms.

7.2 UNDERGROUND PIPING

7.2.1. All valves in underground process piping shall be of welded type with stem extension (one
piece only) for ease of operation and shall be as per the proven vendor standard. Valve pit
not required within station premise until unless specified.

7.2.2. Underground piping shall basically be joined by welding. Flanged or threaded joints shall be
avoided.

7.2.3. Minimum clear gap between buried piping and electrical & instrument cables shall be 500 mm.

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7.2.4. No steel supporting structure shall be used in underground piping.

7.2.5. Clear gap between underground pipes shall be minimum 300 mm.

7.2.6. Underground piping shall have minimum soil cover of 1 meter from the top of pipe.

7.2.7. No underground piping shall be located under equipment, equipment modules etc.

7.2.8. For all underground Valves and UG/ AG section shall be provided with supports.

7.3 CLEARANCE AND ACCESSIBILITY

7.3.1. All equipment, structures, platform, piping and its supports shall be arranged to provide the
following minimum clearances.

a. Vertical Clearances (in mm)

I. Escape, Maintenance, Access & Walk ways Overhead Clearance : 2200

II. Between bottom of pipe and top of Grade level : 1000

III. Bottom of valve flange or drain and top of grade level : 300

b. Horizontal Clearances (in mm)

I. Maintenance and walkways : 750

II. Escape and Access ways : 1200

7.3.2. The clearance between two pipes shall be sum of half the flange OD and half the pipe OD plus
50 mm. Insulation thicknesses to be added for insulated pipes & flanges.

7.3.3. Equipment should always be segregated between hazardous and non-hazardous areas, and
deviations must be referred to the layout supervisor for confirmation and/or clarification.

7.3.4. Sufficient space shall be provided around butt welded valves for in-situ maintenance and
inspection.

7.3.5. Valve operating hand wheel to match pipeline center line which shall be 1 to 1.2 m high from
process area (maximum). If height is more, then access platform to be provided.

7.3.6. The vent headers shall be at least 7.0 m above the Top of the road and in case of vent line

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crossing the internal station roads. However, the same shall not be less than 3 meter from
nearest platform within 15 meter radius.

7.4 PLATFORM, LADDERS AND STAIRWAYS

7.4.1. Platforms, ladders and stairways shall be provided for access and safety requirements as per
requirement stated elsewhere in this documents.

7.4.2. Elevated stations requiring attention for operation and/or maintenance shall be supplied with
a permanently fixed ladder and/or platform. Maintenance platforms shall be provided for all
pressure vessels and other relief valves over 1500 mm above ground level. Access shall not
be provided to equipment nozzles where flanges are provided only for initial assembly of the
piping.

7.4.3. Gauges, instrumentation, cable trays and small-bore piping shall not interfere with access for
routine maintenance.

7.4.4. Access and permanent maintenance facilities shall be provided for all valve’s and equipment
subject to regular maintenance and major change out e.g. cleaning/renewal of gas/oil/sand
filters.

7.4.5. Elevation of platform to be established for access to instruments, valves and man way as per
good engineering practice if required.

7.4.6. Platforms, crossovers shall be provided for ease of operation, maintenance.

7.5 VENT & DRAINS

7.5.1. Valve vent and drains shall be in accordance with process requirements as shown in the
P&ID’s.

7.5.2. The main vent pipe shall be routed to safe location in line with minimum required distance
stated in OISD, PNGRB Standards and other guidelines attached elsewhere in the bid and
must be checked any minimum height requirement to dispose it off.

7.5.3. Test Vent & Drains:

a. Vent size shall not be less than 3/4”. All high points shall be vented by plugged, capped

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or blind flange connection after testing unless otherwise specified.

b. Piping and equipment shall have a low point drain to remove all liquid from the system.
Drains shall be provided with valve and shall not be less than 3/4”.

8.0 STRESS ANALYSIS & SUPPORT

8.1. Stress analysis shall be carried out for above ground installations up to virtual anchor. The
purpose of the analysis is to demonstrate that the pipe work arrangement has sufficiently
flexible to prevent thermal expansion, contraction pressure loads and any occasional loads or
movements of supports from causing.

- Failure of piping or supports from overstress or fatigue

- Joint failure

- High stress or distortion in pipe work and fittings

- Excessive loads on connected equipment’s

8.2. The scope of the stress analysis shall include as a minimum/maximum design conditions,
maximum load reversal, testing condition and fatigue.

8.3. All piping shall be analyzed and adequately supported/guided so as to prevent undue vibration,
deflection, stress or strain on equipment.

8.4. Thermal expansion/contraction, dynamic effects (impact, wind, earthquake, vibration, etc.) and
weight effects (live loads, dead loads, test loads etc.) shall be considered in the analysis so
that the stresses created by those loadings shall not exceed the allowable stresses prescribed
by the “CODE”.

8.5. When analyzing piping, particular attention shall be paid to thermal expansion/contraction of
lines subjected to sun rays and severe temperature changes during start-up, operating and
emergency conditions.

8.6. Lines that may be subject to large moments require adequate flexibility in-built into the design.

8.7. Stress analysis calculations shall be carried out at the pipeline operating temperature,
maximum/minimum design temperatures and design pressure using installation temperature
of 21 °C.

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8.8. Stress sketches in isometric form shall be submitted along with the stress analysis report.

8.9. COADE Engineering Software CAESAR II (Latest version) shall be used for performing stress
analysis.

8.10. Buried sections may be modeled by the soil modeler module of Caesar II using its default
method, which automatically calculates and inserts the soil stiffness and the soil resistances
in the stress model.

8.11. Supports shall be designed in such a way as to comply with flexibility analysis results.

8.12. The design should be such that anchor supports are not necessary.

8.13. Expansion Joints and spring supports shall not be used.

8.14. Control valves and other piping components shall be properly supported and braced to prevent
excessive vibration. Any additional restraint shall be considered in the flexibility analysis of the
piping system.

8.15. Pipe supports shall be wide enough to ensure pipes do not fall off supports during maximum
expansion or contraction.

8.16. Small instrument tubing and piping shall be adequately supported and protected from damage
by impact.

8.17. Supports shall not interfere with clear passages provided for access to equipment, machinery,
instruments, handling of valves etc. Whenever necessary, it should be possible to adjust
supports so that they may be set correctly.

8.18. Local compressive stresses on large-diameter pipes shall be taken into account, using (where
necessary) suitable reinforcing plates.

8.19. All supports shall be identified on design drawings as per the pipe support standard. The end
actions on equipment and machinery imposed by connected piping shall be checked within
the limits set for that type of equipment by manufacturer.

8.20. Bracing and supports for pressure relief valve risers shall be designed to prevent vibrations
during operation and to permit independent removal of pressure relief valve from piping

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systems.

9.0 EQUIPMENTS

9.1. Permanently fixed equipment shall be supported on the ground/civil structure as applicable.
The concrete pedestal detail shall be incorporated into the respective structural Detail
drawings.

9.2. Launcher/Receiver dimension shall be suitable for intelligent pigging.

9.3. As a minimum barrel length shall be suitable for longest anticipated pig size for launchers
receivers and branches from the barrel shall be taken by means of olets. Dimension of the
barrel shall be sufficient for intelligent pigging.

9.4. Quick Opening End Closure (QOEC) shall be Band lock type. QOEC should be operable within
time of 2 min. Sufficient space shall be allowed for pig handling. Locking Mechanism shall be
made of SS.

9.5. Traps shall have a pressure indicator positioned such that it will be visible for personnel
operating the trap doors. Piggable piping between risers and launchers and/or receivers shall
utilize 5D bends unless directed otherwise.

9.6. Barrel shall have min. two supports suitable for taking pipeline anchorage force.

10.0 INSTRUMENTS CONNECTION

10.1. PRESSURE INSTRUMENTS

Local pressure indicators shall be visible from platform or permanent ladder. Gauge glasses
shall be accessible from a platform, or a ladder. Pressure gauges and gauge glasses shall be
located where they can be read from platforms.

10.2. TEMPERATURE INSTRUMENTS

10.2.1. Temperature elements or thermowells shall be accessible from grade level, platforms or
permanent ladder. They shall not be installed below the horizontal line. Temperature indicators
shall be visible from grade, platforms or permanent ladder. Clearance of thermowells must be
checked in all lines.

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10.2.2. Minimum line size to install thermowells shall be 4” size. For size below 4” expanders to be
used to increase line size locally to 4”.

10.3. CONTROL VALVES

10.3.1. On/Off and control valves shall generally be installed in a horizontal line.

10.3.2. On/Off and control valves shall be easily accessible from the grade or permanent platform
and be conveniently located for ease of operation, maintenance and removal.

10.3.3. Piping shall be designed so as not to impose any forces or moments on any control valve in
excess of those permitted by the manufacturer.

10.3.4. Where control valves are smaller than line size, the reducer shall be placed adjacent to the
valve. Spools or reducers between flanged block and control valves shall be made long
enough to allow for the use of bolt tensioners and permit bolt removal in screwed lines.

10.3.5. Where high-pressure drop conditions exist across control valves, sonic harmonics together
with extreme noise levels can be expected. Piping subjected to these conditions must be
carefully analyzed and designed to ensure that its size and configuration downstream of the
valve prevents transmission of excessive vibration and noise.

10.4. SAFETY VALVES

Safety relief valves shall be installed vertically and as close as possible to the equipment or
piping to be protected. If for installation reasons (e.g., accessibility) the inlet connection length
of safety valves has to be larger than usual, the pressure drop in the related section of pipe
must be checked.

10.5. PIG SIGNALERS

10.5.1. Pig signallers (Intrusive/Non-Intrusive type) shall be with welded ends.

10.5.2. Signaler on Pig Launcher/Receiver shall be intrusive type.

10.5.3. Pig signaler shall be bi-directional type with trigger mechanism suitable for maintenance
under line pipe pressure.

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10.5.4. Refer instrumentation design basis & relevant instrument specification attached elsewhere
in the bid.

11.0 WELDING & POST WELD HEAT TREATMENT

11.1. All welding shall be carried out by approved WPS & Qualified welder.

11.2. All butt welds for process piping shall be 100% radiographed & ultrasonic tested (UT) and for
utility piping

11.3. NDT requirements shall be as per approved inspection test plan.

11.4. All fillet welds shall be 100% magnetic particle tested.

11.5. Only low hydrogen electrode shall be used for Submerged Arc Welding (SMAW) process. The
joints below 2” size shall be welded by gas Tungsten Arc Welding (GTAW) process only.

11.6. Post weld heat treatment shall be performed after welding in accordance with respective Code
& Standards.

12.0 HYDROSTATIC TESTING

12.1. Hydrostatic testing of terminal piping shall be carried out separately. Piping at terminals as
well as other intermediate facilities shall be tested in accordance with requirement stated in
respective Code & [Link] 1.5 times the design pressure. The test duration shall be 6
hours minimum.

12.2. In addition to above, all terminal piping (dispatch/receipt), Intermediate Pigging Stations (IPS)
shall be pneumatically tested with nitrogen at 95 barg for all 600# piping. The test duration
shall be 4 hours minimum.

13.0 SITE AND ENVIRONMENT DATA

The site data attached elsewhere in the bid shall be referred for this purpose. For
meteorological data, EPC contractor has to collect the same from meteorological department.

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14.0 EXTERNALLY COATING/PAINTING & INSULATION

14.1. Considering the environment of the pipeline project (attached elsewhere in the bid package)
and the design life 40 years for the pipeline, station piping shall be protected by the following
design methods and considerations:

a. Consideration of suitable piping & fittings Material of Construction and piping class.
b. Providing thermal insulation and insulation for Personnel Protection wherever required
as per P&ID’s.
c. Selection of proper coating & painting methods as per the international codes and
standard industrial practices.
d. Painting of entire Station Piping with anti-corrosive Paints.
e. Corrosion resistant coating and wrapping as applicable along with cathodic protection
for underground piping.

14.2. Colour Coding:

Ball Valve (Above Ground) : Off- White – RAL 9010

Globe Valve (Above Ground) : Oxford Blue – RAL 5005

Check valve (Above Ground) : Oxford Blue-RAL 5005

All Underground Valves : Grey Epoxy

Pipelines & Station pipes (A/G) : Yellow Golden

Launcher / Receiver : Yellow Golden

Structural support (Civil) : zebra strips

14.3. Corrosion resistant coating shall extend up to 500 mm above the aboveground/underground
transition point.

14.4. Max design temperature for coating should be considered +80 oC.

14.5. Valves and above ground pipes need to be properly blasted to achieve surface finish of SA 2
1/2 before the application of paints.

14.6. Under Ground Valves shall be coated with 800 micron thick high build epoxy coating
(Duracoat, Epigen or equivalent) or 1.5 mm (min.) thick PU coating.

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14.7. Painting of above ground piping shall be as per specifications for Normal/Highly Corrosive
environment as applicable. Exterior surfaces of aboveground piping, shall be applied with Paint
system S7.09 in accordance with TABLE A7 of ISO 12944-5 suitable for highly saline &
corrosive environment.

14.8. Piping items to be installed underground shall be coated with 800 micron thick high build epoxy
coating (Duracoat, Epigen or equivalent) or 1.5 mm (min.) thick PU coating.

15.0 PREPARATION OF PIPING DRAWINGS

15.1. TITLE BLOCKS

At least following information shall be reflected in the TITLE BLOCK.

a. The title of document, including the contract name.

b. The document serial number, including the contract number, area code and sub area
code.

c. The date and revision number of document.

d. The purpose of issue of document with the signatures/initials of the persons, who drafted
checked and approved the document.

e. Owner, PMC, EPC, DEC & Vendor Details (as applicable).

f. Revisions shall be clearly identified on all documents/drawings and modified portions

shall be clouded in case of drawings (Δ shown with Revision) in case of documents,
identified with vertical line at right side of the lines or clause with brief maintain of changes
in revision history long.

15.2. LIST OF DOCUMENTS/DRAWINGS

All documents/drawings shall be listed. From the list it should be possible to keep track of
various issues and revisions of the documents. The list shall be regularly updated to reflect
the latest revisions based on project requirements.

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15.3. DRAWING SCALE

Equipment layouts : 1: 200/1:300

Piping GAD : 1:50/1:33

Isometric Drawings : NTS

15.4. OTHERS

15.4.1. The metric system shall be used for all drawings.

15.4.2. True north and Plant North to be shown.

15.4.3. The Piping GAD shall provide all information required for preparation of isometric drawings
and installation of piping. Sectional views and details to be drafted to facilitate the preparation
of isometric drawings. Line marking shall be as per P&ID’s. Identification of valves shall be as
indicated in piping material specification.

15.4.4. Piping GAD shall cover a material take off table for all stations.

15.4.5. Pipe supports or pipe support tags shall be marked on piping GAD and support drawings
shall be furnished separately for Owner/Consultant representative’s review/information. The
Support Arrangement shall be as per the Pipe Support Standards.

15.4.6. Piping arrangement inside Vendor’s skid not required to be shown on piping General
arrangement drawings.

15.4.7. All piping lines shall be identified as shown in P&ID’s. The direction of flow and insulation
shall be indicated if any.

15.4.8. Isometric drawing shall be prepared for each line serial number indicated in P&ID’s. All pipe
supports or with support tag in line with pipe support standard shall be shown and located on
isometric drawings.

15.4.9. A list of materials with necessary quantities to fabricate a given line shall be prepared and
shown for each relevant isometric drawing.

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16.0 GUARANTEE TEST

In addition to the routine tests and guarantees by the manufacturers for the items being
procured and installed, the EPC contractor to demonstrate as called for by the
Owner/Consultant by carrying out additional tests viz. Hydro testing, NDT etc. at pressures
and temperatures as specified by the Owner in order to ensure that the entire system is safe
and meeting the parameters specified in the bid documents.

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