0 0 25 Feb 2015 1547248031BEDPofMoundedBullet

EM131- 45-BEDP-101 2
PROJECTS & DEVELOPMENT DOCUMENT NO REV

INDIA LTD SHEET 1of4
BASIC ENGINEERING DESIGN PACKAGE
(BEDP)
FOR
INSTALLATION OF LPG MOUNDED BULLETS
FOR
NUMALIGARH REFINERY LIMITED,

ASSAM
Submitted by
PROJECTS & DEVELOPMENT INDIA LTD

NOIDA
2 24.02.2015 24.02.2015 CLIENTS COMMENTS INCORPORATED VKS SCA SCA

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
All rights reserved
EM131- 45-BEDP-101 2
PROJECT:BEDPFORLPGMOUNDEDBULLETS DOCUMENT NO REV
PLANT:NUMALIGARHREFINERYASSAM SHEET 2of4
CONTENT
No. of
CHAPTER DOCUMENT NO.
Pages
1.0 PROCESS
a) Design basis EM 131-45-DD-DB 101 Rev.1 14
b) Schematic diagram EM131-45-0046 Rev.1 1
Process Flow Diagram EM131-45-0047 Rev.1 1
c) Equipment List EM131-45-0930 Rev.1 2
d) Equipment Data Sheet
i) Bullets data sheet EM131-DD-45-VV101/102/103/104 Rev.1 6
ii) Drain Vessel Data Sheet EM131-DD-45-VV106 Rev.1 3

iii) Mercaptan Dosing Vessel Data
EM131-DD-45-VV105.REV.0 2
Sheet
45-PA-CF-101A/B,45-PA-CF-102A/B Rev.1,
iv) Pump Data Sheet 12
45-PA-112 A/B Rev.0
EM131-45-0020,21,22, 23,24 ,26,27,28,29
e) Piping & Instruments Diagram 9
Rev.1
f) Line List EM131-45-090 Rev.0 8
g) Instruments Data Sheet
i) Flow Instruments Data Sheet EM131-45-0115 Rev.1 4

ii) Pressure Instruments Data
EM131-45-0116 Rev.1 8
Sheet
iii) Temp. Instruments Data Sheet EM131-45-0117 Rev.1 3
iii) Level Instruments Data Sheet EM131-45-0118 Rev.1 11
iv) Control Valve Data Sheet EM131-45-0123 Rev.1 8
v) Safety Relief Valve Data Sheet EM31-45-0124 Rev.1 6

h) Fire Protection Security System
EM131-45-0025 Rev.1 1
& Safety Interlock Logic Diagram
I) Effluent Disposal System and EM131-45-EL-9501 Rev.0 2
All rights reserved

EM131- 45-BEDP-101 2
Adequacy of the Existing ETP
J) Flare Adequacy EM131-45-FL-9502 Rev.0 2
2.0 MECHANICAL
a)Design Philosophy EM0131/PNMP/T/1 Rev.0 42
b) Overall Plot Plan For Refinery
EM0131-5111-0001 Rev.0 1
and Marketing Terminal
c) Overall Plot Plan For Connecting
Pipe Rack and new Mounded EM0131-5111-0002 Rev0 1
Bullet Area
d) Equipment Plant Layout For
EM 0131-5111-0003 Rev.0 1
Mounded Bullet Area
e) Piping GAD for New Mounded
EM 0131-5111-601 Rev.0 1
Bullet Area
f) Piping Layout Plant of Fire
Hydrant & Sprinkler System For EM 0131-5111-602 Rev.0 1
Mounded Bullet Area
g) Equipment Design Philosophy EM0131-TS- 401 Rev.0 13
3.0 INSTRUMENTATION
Instrument Design Philosophy EM0131- PNIN-0701Rev.0 20
4.0 ELECTRICAL
a) Design Philosophy Electrical EM0131-45- PNEL-DP Rev.1 13
b) Single Line Diagram EM0131-7411-0985 Rev.1 1
c) Single Line Diagram of MLBD &
EM0131-7411-0986 Rev.0 1
DCDB
d) LT Switch Gear Room Layout EM0131-7411-0805 Rev.1 1
5.0 CIVIL
Civil Scope Drawing EM0131-1000-0001 Rev.0 1
All rights reserved

EM131- 45-BEDP-101 2
Executive Summary:
Numaligarh Refinery Ltd.(NRL) located at Numaligarh, Assam India intends to install new LPG
Mounded bullets. NRL is already having above ground LPG storage vessels and handling
facilities which are being used at present. NRL proposed to replace the old aboveground
vessels with mounded bullets of suitable capacity.
Mounded bullets provide intrinsically passive , safe environment & eradicates the possibility of
Boiling Liquid Expanding Vapor Explosion (BLEVE), through LPG handling possess many
challenges, due to its inherent dangerous properties, modern state of art safety features has
been taken into consideration while designing the facilities using different OISD codes.
As handling of LPG in above ground vessel has many challenges due to its inherent
dangerous properties, M/s NRL proposed to replace the old aboveground vessels with
mounded bullets of suitable capacity. New statues / guidelines suggest for mounded bullets
which proves to be safer compared to above ground storage vessels. The project envisages
construction of 4 nos. of mounded bullets of capacity 1760.56 m3 ( 1000MT) each and upon
successful completion / construction of mounded bullets existing 03 nos. of LPG Spheres and
01 LPG bullet will be dismantled up to ground level.
On award of the job, PDIL had reviewed and studied the scope of work and prepared the
Basic Engineering Design Package (BEDP) after thorough analysis of the data/information
furnished by NRL. PDIL team also visited the site for kick of meeting, finalization of root &
documents collection.
The scope of this report is to assess the BEDP of the proposed facility. The entire system has
been studied with respect to reliability of design, state of the art control philosophy with
intrinsic process safety consideration. Further, compliance of external safety measures like
Pressure Relief System , Fire Fighting System, Gas detectors have also been reviewed with
respect to statutory guidelines of OISD.
All rights reserved

1
INDIA LTD
CHAPTER -1
PROCESS

All rights reserved
EM 131-45-DD-DB 101 1
PROJECTS & DEVELOPMENT INDIA LTD Document No. Rev.
Sheet 1 of 14
DESIGNBASIS
1 05.02.2015 05.02.2015 Client Comments Incorporated VKS SCA SCA

EM131-45-DD-DB 101 1
DESIGN BASIS

BEDP FOR LPG MOUNDED BULLETS, NRL REFINERY Document No. Rev.
Sheet 2 of 14
CONTENTS

SN Item Page No
1.0 PREFACE 4
2.0 SITE METEOROLOGICAL DATA 5
3.0 PLANT DESIGN BASIS 6
3.1 LPG Composition 6
3.2 LPG Mounded Storage Facilities 6
3.3 Bullet Details 7
3.4 Normal Bullet Operation 7
3.5 Odorization 7
3.6 Very Dilute Caustic Draining from Bullet 8
3.7 LPG Pump Details 8
3.8 Corrosion Allowances 8
3.9 Pressure Safety Valve 8
3.10 Gas Detection system 8
3.11 Noise Criteria 9
3.12 Effluent Criteria 9

4.0 UTILITIES 10
a) Low pressure Steam 10
b) Service Water 10
c) Instruments Air 10
d) Inert Gas ( Nitrogen) 11
e) Plant Air 11
5.0 NUMBERING AND CODIFICATION 11
5.1 Equipments Identification 11
5.2 Piping Numbering 12
5.3 Instruments Numbering 12

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 3 of 14
6.0 CODES AND STANDARDS 12
6.1 Piping 13
6.2 Pressure Vessel 13
7.0 HAZARDOUS AREA CLASSIFICATION 13
8.0 UNITS OF MEASUREMENTS 14

Allrightsreserved
EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 4 of 14
1.0 PREFACE
Numaligarh Refinery Limited, (NRL) presently operates a 3 MMTPA refinery at
Numaligarh, District Golaghat, and Assam. The refinery commenced commercial
production in October, 2000.
This document presents the design basis to be used for the Preparation of BEDP for
Mounded Bullets at Numaligarh Refinery Limited (NRL).
Mounded bullets provide intrinsically passive & safe environment & eradicates the
possibility of Boiling Liquid Expanding Vapor Explosion (BLEVE), through LPG handling
possess many challenges, due to its inherent dangerous properties, modern state of art
safety features has been taken into consideration while designing the facilities using
different OISD codes.
As handling of LPG in above ground vessel has many challenges due to its inherent
dangerous properties, NRL proposed to replace the old aboveground vessels with
mounded bullets of suitable capacity. New statues / guidelines suggest for mounded
bullets which proves to be safer compared to above ground storage vessels. The
project envisages construction of 4 nos. of mounded bullets of capacity 1760.56 m3 (
1000MT) each and upon successful completion / construction of mounded bullets
existing 03 nos. of LPG Spheres and 01 LPG bullet will be dismantled up to ground
level.

Allrightsreserved
EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 5 of 14
2.0 SITE METEROLOGICAL DATA
Site Location Plant Location : Numaligarh, Golaghat District

State / Country : Assam / India
Nearest Railway Station : Golaghat
Nearest Airport : Jorhat
Nearest Sea Port : Kolkata
Nearest National Highway : NH-39
1.0 Barometric pressure 750 mm Hg
2.0 Normal ambient condition

Air temperature 35 0C
Relative humidity 73 %
3.0 Maximum / Design Ambient condition
Air temperature 380C
Relative humidity 85 %
4.0 Minimum Ambient Air 50C (Min)
Temperature
5.0 Rain fall
Heaviest in a day 160 mm
Maximum in one hour 90 mm
6.0 Wind
Wind code As per relevant IS code
Base wind pressure As per relevant IS code
7.0 Seismic Factor As per IS: 1893 Seismic Factor - 0.04
8.0 Elevation 90 m above Mean sea level
9.0 Average wind speed 36 km/hr
10.0 Maximum gust speed 140 km/hr

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 6 of 14
11.0 Site conditions Prevailing wind direction NE to SW
12.0 Precipitation
Annual mean
Maximum/hr
3.0 PLANT DESIGN BASIS
3.1 LPG Composition
Composition Mole % Mole % Mole %( Average for Design)

C3 30 45 37.5
C4 55 70 62.5
H2S < 10 ppm < 10 ppm < 10 ppm
Properties of LPG
Designation LPG
Design Sp. Gravity at 40 0C 0.558 ( Simulated)
0 2
Vapour pressure at 10/-/40 C , kg/cm a 3.35/-/7.51( Simulated)
0
Design Viscosity, at 10/-/40 C Cp 0.152/-/0.113 ( Simulated)
3.2 LPG Mounded Storage Facilities
System Design as per OISD -150

Four ( 4) Mounded bullets of 7,042.24 m3 capacity total
LPG Run Down from Refinery

Line sizing & Piping class 6 & B1A
Receiving rate (T/hr) 13.04
0
Operating/ Design Temperature ( C ) 40/65
Operating/ Design Pressure ( Kg/cm2a) 20.8/31.6

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 7 of 14
3.3 Bullet Details
Operating LPG storage capacity of each Bullet 1760.56m3

(Operating capacity considered as 85% level of the volumetric capacity of bullet)
Size Length (TL~TL) 52m X Diameter 7 m
Operating / Design Pressure 8.6 /14.5 kg/cm2g
Design Temperature (-) 27 to 55 0C
Material ASTM A 516 Gr.60,( IT) or equiv.
(Refer to clause no. 5.1 ,ii,(a) OISD-150)
Internal bottom surface up to 90 degree shall be provided with a coating suitable for
caustic, water, and H2S dissolve in LPG.
Filling Rate 15.0075 T/hr( 15% Extra)
Pump out Rate ( max) ( 267+27) 291 m3/hr
3.4 Normal Bullet Operation
One mounded bullet is receiving mode,

One dispatch mode
Two for recirculation & certification mode
3.5 Odorization
One mercaptan vessel (45-VV-105) having capacity of 200 L which is maintained by

positive pressure with N2.
The dosing rate is around 20 ppm.
Two nos. ( 45-PA- -112 A/B) (1W+1S) mercaptan dosing pump to be used.

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 8 of 14
3.6 Water Draining From Bullet
No. of Drain vessel 1 no ( Vertical cylindrical vessel)

Design Pressure 14.5 kg/cm2g
Design Temperature (-27) 0C to 55 0C
MOC CS
Capacity 0.5 m3
3.7 LPG Pump Details
Four nos. of LPG forwarding pump to be used.

Two nos. ( 45-PA-CF-101 A/B)(1W+ 1S) for loading gantry & two nos.( 45-PA-CF-102
A/B) ( 1W+1S) pump for bottling plant.
3.8 Corrosion Allowance
Internal Corrosion Allowance: 3 mm (minimum).
3.9 Pressure Safety Valve
Each vessel shall have at-least two Safety Relief Valves (SRV).
The full flow capacity of each SRV on mounded vessel(s) shall be minimum 30 % of
the capacity required for an equivalent size of above ground vessel.

The discharge of SRVs shall be connected to existing flare system.

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 9 of 14
3.10 Gas Detection System
Suitable gas detectors Infrared type shall be placed at critical locations in the LPG
storage area such as near the ROVs, and all pumps in inspection tunnel or dome
connection, near water draining/ sampling points.
First level alarm shall be set at 20% of Lower Explosive Limit (LEL) and second level
alarm at 60 % of LEL
3.11 Noise Criteria
a) Nearby equipment
The maximum allowable noise level nearby equipment shall be 85 dB within one meter
from the equipment, during normal operation and with control valves in line.
b) Near Working Environment

Overall noise level in the working environment shall be below 85dB at 1m.
c) Outside plant limit

The average noise level shall be 60 dB at 100 m from the boundary of plant.
3.12 Effluent Criteria
Gaseous Effluent
Details of existing flare header (Bullet header to be connected with existing header)
Size of existing flare header 24
Operating/Design tem. of flare header Amb / ( 65 /-27 0C )
Operating/Design Press. of flare header 0.2-1.7/4.5 Kg/cm2g
Normal/Max Back Press - /1.7Kg/cm2g
Existing load of flare header 162029 Kg/Hr
Installation of mounded bullets for the fire case load comes out 62161 Kg/Hr with
molecular weight 52.8.
All PSV/TSV discharge shall be routed to the new flare header which will be
connected to existing flare header

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 10 of 14
Liquid Effluents
Water coming with LPG shall be drained to drain vessel, and any dissolve LPG in
drain water shall be vented to flare in vapour form and water is drained to a Shallow
Sump (RCC) & finally to the storm sewer.
LPG pump drain is to be connected to drain vessel (45-VV-106), so that LPG in
vapour form is vented to Flare Header.
In view of above, no effluent is sent to Existing Effluent Treatment Plant & hence Load
of .Existing Effluent Treatment Plant is not increased.
Hence Existing Effluent Treatment Plant is Adequate due to Installation of Mounded
Bullets.
In Drain Vessel vent and drain valve normally are to be kept in closed condition. For
draining water from bullets, deadman type valve to be opened closely watching level
gauge in the drain vessel. When LPG comes along with water. There will be two layer
visible in the level gauge draining to be done slowly very carefully and initially from
time to time water is to be drained to shallow sump, If any LPG visible in the level
gauge . Then same to be vented in the flare before opening draining valve of the drain
vessel
4.0 UTILITIES
a) LP Steam :-
The Minimum, operating and design conditions for low pressure steam shall be as follows
Design temperature 200 0C
Design pressure 7.5 Kg/cm2g
Operating temperature 165 0C
Operating pressure 4.0 Kg/cm2g
Minimum temperature 155 0C
Minimum Pressure 3.5 Kg/cm2g
b) Service Water :-
Design temperature 650C

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 11 of 14
Design pressure 8 Kg/cm2g
Operating temperature Amb.
Minimum temperature Amb.
c) Instruments Air :-
Operating temperature Amb
Minimum temperature Amb.
Dew Point -15 0C at 7.5 kg/cm2a
d) Inert Gas ( Nitrogen) :-

Design pressure 10 Kg/cm2g
Minimum temperature Amb
e) Plant air :-

Allrightsreserved
EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 12 of 14
Minimum temperature Amb
5.0 NUMBERING AND CODIFICATION
5.1 Equipment Identification
The new equipment will be numbered using the 100 series.
Philosophy for Equipment Tag no.:

Unit No.- Equipment Code Seq. No.
Ex. 45-VV-101
5.2 Piping Numbering
New piping will be numbered using the 3000 series; pipe class will be as per existing
piping material specification
Philosophy for Line Tag no. :

Line size - Fluid- Line No. Unit no.- Pipe class - Insulation class
Ex. 6 P 45-3001 -B1A-N
5.3 Instruments Numbering
New instrument will be numbered using the 3000 series.

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EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 13 of 14
New instruments indicators / controls / interlock / shall be hooked up by NRL in the New/
Existing DCS / PLC.
Philosophy for Instruments Tag no.:

Area Code- Item Code - Item No.
Ex. Level Transmitter 45 - LT -3001
6.0 CODESANDSTANDARDS
The system will be designed in accordance with the latest addition of the codes and
standard.
List of codes and standards
ANSI American National Standard Institute

OISD Oil Industry Safety Directorate
API American Petroleum Institute
ASME American Society of Mechanical Engineers
IBR Indian Boiler Regulation
6.1 Piping
All process piping shall be in accordance with as per existing PMS.
6.2 Pressure Vessel

All pressure vessels shall be in accordance with ASME section VIII div1/2.
7.0 HAZARDOUS AREA CLASSIFICATION
Hazardous Area classified as Zone 1: Gas Group IIA IIB, Temp. Class-T3

Allrightsreserved
EM131-45-DD-DB 101 1
DESIGN BASIS

Sheet 14 of 14
8.0 UNITS OF MEASURMENT
The MKS system of units must be used in all engineering documentation and on
drawings with the exception of the following measurements, which must adopt the
stated preferred units.
The following units of measurements should be applied:
Temperature [C]
Pressure [kg/cm2g]/ bar
Volume [m3], [l]
Length/Diameter [m], [mm]
Mass or Weight [kg], [ton]
Volume( gases) [Nm3], [kmol]
Flow Rate( volume) [m3/h], [Nm3/h],
Flow Rate(mass) [kg/h],
Velocity [m/s]
Energy [KCal]
Heat Capacity [kCal/kg C]
Density [Kg/m3]

Allrightsreserved
EM131450930 1
PROJECTS&DEVELOPMENTINDIA DOCUMENTNO REV
SHEET1of2
EQUIPMENTLIST


FORM NO: 02-0000-0021F1 REV3 All rights reserved

EM131450930 1
EQUIPMENTLIST DOCUMENTNO REV

SHEET2of2
Sr. CODE EQUIPMENT REMARKS

No
1. 45-VV - 101 / 102 / LPG Mounded Bullet New Equipment

103 / 104
2. 45-PA-CF - 101 A/B LPG Transfer Pump( Gantry Loading) New Equipment
3. 45-PA-CF - 102 A/B LPG Transfer Pump(Bottling Plant) New Equipment
4. 45-PA-MP-101A/B Motor for LPG Transfer Pump( Gantry New Equipment

Loading)
5. 45-PA-MP-102A/B Motor for LPG Transfer Pump(Bottling New Equipment

Plant)
6. 45-VV-105 Mercaptan Dosing vessel New Equipment
7. 45-PA -112A/B Mercaptan Dosing Pump New Equipment
8. 45-VV-106 Drain Vessel New Equipment

EM131DD45VV101/102/103/104 1

SHEET1of6

PROCESSDATASHEET

FOR

MOUNDEDBULLETS

1 05.02.2015 05.02.2015 Client Comments incorporated VKS SCA SCA


EM131DD45VV101/102/103/104 1
SHEET2of6

Project:BEDPFORMOUNDEDBULLETS,
NUMALIGARHREFINERYLTD.NUMALIGARH.
TagNo.:45VV101/102/103/104
Equipment:LPGMoundedBullets
No.ofunits:Four(4) Service:LPGSTORAGE
Size:mm(ID)7000x52000(TLTL) Position:HorizontalCylindricalwithdishedends
DESIGNDATA MATERIALOFCONSTRUCTION
Shell:ASTMA516Gr60orEquiv.(Refer.Clauseno
Fluid:LPG
5.1,ii(a))ofOISD150(NOTE2&NOTE14.)
CapacityTypem3:2071.3(waterCapacity) Liningifany:NOTE2
Capacity(Max.LPGStored)m3:1760.56(85%
Head:
Capacity)
Flow(INLET)T/hr:13.04 NozzleNeck
PumpOutm3/hr:291(Max.) NozzleFlanges
Workingpressurekg/cm2g:2.3378.6 StudsandBolts
DesignPr.Kg/cm2g(Internal):14.5+Statichead
DesignPr.kg/cm2g(External):FullVacuum+Wtof Nuts
Mound
WorkingtempOC10/40/55 Gaskets
DesigntempOC:()27TO55 Distributors
SpecificGravity:0.500.57 Grates
Outlet(Vapour)/(Liquid)Kg/m3: AdditionalAttachmentsInternals:
CorrosionAllowance(mm):3
InternalAttachments:
All Right Reserved

EM131DD45VV101/102/103/104 1
SHEET3of6

NOZZLES MARK SIZE RATING REMARK
LiquidLPGInlet N1 6 300# WithDippipe
LiquidLPGOutlet N2 12 300# Note16
LPGVapourReturn/Balance N3 6 300#
RadarTypeLevelIndicator N4 6 300#
ServoTypeLevelIndicatorNote18 N5 6 300# HOLD

RadarTypeLevelIndicatorNote18 N6 6 300# Actualsizingshallbe
doneatthetimeof
Temp.IndicatorNote18 N7 2 300#
detailedEngineering
SafetyValve(NOTE3) N8A/B 8 300# (ByVendor/Contractor)
PressureTransmitter N9 2 300#
RecirculationLine N10 8 300# WithDippipe
SpareNozzle N11 2 300#
ManualVent N12 2 300#
Manhole1 M1 32 300#
Manhole2 M2 24 300#

All Right Reserved

EM131DD45VV101/102/103/104 1
SHEET4of6

Despatch CompleteSegments
SpecialInstruction

NOTES.
1. AllprocessdataareindicatedinBold&italic.
2. AsperOISD150InternalBottomportionoftheVessel(90oCAngle)shallbecoatedwith
anticorrosivecoatingsuitableforCAUSTIC.
Twonos.ofPSVwillbeprovidedonN8A/BforeachBullet.Onewillbeinlineandothershallbe
3.
spare.
4. Vesselwillbeslopedtowardsthebottomoutlet@1:200.
5. Thetopandsidesoilcovertobeofneutralmaterialwhichiswellcompactedtopreventwaterand
airerosion.
Themoundshouldhavegooddrainagetopreventanywateraccumulationonthemound.Material
shouldbefreefromabrasivematerialorparticleslikelytodamagetheequipment.
6. Theentirenozzletobeoutsidetheearthlevel/mound,suitablecoatingforexternalsurfacetobe
provided.
7. Vesseltobedesignedfortheexternalloading.
8. Thefireproofingtotheexposedvessel,bottomoutletlineinsidetunnel,nozzles&pipeshallbe
doneuptothefirstROV.
9. Alldrawings,documents,designcalculation,stageinspection&certificationshallbegotapproved
bychiefcontrollerofexplosives
10. Inspectiontunnelshallbeprovidedforbottomoutletnozzle(N2)asperOISD150
11 HydrocarbonLeakdetectorintheLiquidOutletLineTunnel&nearROVstobeprovided.
12. VortexbreakershallbeprovidedinthebulletOutlet.
13. Firefightingfacilitiesshallbeconsideredasperrelevantcode.
14. H2SinLPG<10ppm
15. AllnozzlesexceptN2shallbelocatedonthedome.
16. ManholeswithstaircaseshallbeprovidedontheBullettop.Accessplatformshallbeprovidedat
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EM131DD45VV101/102/103/104 1
SHEET5of6

theTopforaccessingofInstrument/maintenancealongwithhandrail.
MatchingflangewithROVs(BottomOutletnozzleN2)onbulletandpipingsideshallbeRTJtype.
17. Remoteoperatedvalves(ROV)shallbeprovidedoninletandoutletLPGnozzlefromBullet,Recycle
liquidLPG&vapourreturnline.Thesevalvesshallbefiresafedesign.
18. Radar&ServoGauge,Temperaturemeasurementshallbewithstillingwell.Perforations/slotsshall
beasperInstrumentationrequirement.
19. Safetyvalvesetpressureshallbe14.5kg/cm2g;itshallbedesignedfor21%overpressure(fire
sizing).Thefullflowcapacityofeachsafetyvalveshallbeminimum30%ofthecapacityrequired
foranequivalentsizeofabovegroundvessel.
20. DuringLPGfillinginbullet,thebulletshellshallexpandduetopressure.TheRCCwalldesignshall
beabletotakecareofthethrust.
21. Bullet&moundingshallbedesignedasperlatestOISD150.
22. Suitablecathodicprotectionshallbeprovidedforeachbullettoguardagainstcorrosion.Proper
electricalisolationwithisolationjoint/flangetobeprovidedsuitablyforallbulletflanges.
23. AreaClassification:ZoneI,IIA/IIB,T3.
24 Bottomdrawofflineshallhaveslopeangle1.50minimumdistanceof3mfromvesseltangentline
toROVatnozzleN2shallbemaintainedasperOISD150
25 Bulletendshallbehemispherical
26 FurtherdetailingbydetailedEngineerConsultants/Vendor.
All Right Reserved

EM131DD45VV106 1
PROJECTS & DEVELOPMENT
INDIA LTD, NOIDA DOCUMENT NO. REV
SHEET 1 OF 3

PROCESSDATASHEET

FOR

DRAINVESSEL

All rights reserved
PROJECTS & DEVELOPMENT EM131-DD-45-VV-106 1
REV
INDIA LTD, NOIDA Doc. No
VESSEL SPECIFICATION SHEET Sheet 2 of 3

Project : Installation Of Mounded Bullets at NRL , Numaligarh Plant/Section: 45
Location : Outdoor
Equipment : Drain Vessel Tag No: 45-VV-106
No. of units : One (1) Service: Caustic /Water Drain Out from Bullet
Size : 600mm ID 1600 mm HT (TL-TL) Position Hor: ( ) Ver: ( )
DESIGN DATA MATERIAL OF CONSTRUCTION (1)
Fluid : Drain Bullet Caustic Water / LPG Shell: Carbon Steel
Capacity (Normal/Rated) m3: 0.5 Lining If Any: Nil
Flow: INLET : m3 /hr Varies Head:
OUTLET : m3 /hr Nozzle Neck
Working pressure (Kg/cm2 g) 2.337- 8.6 Nozzle Flange
Design pressure (Kg/cm2 g) 14.5 Studs and Bolts
Working temp. oC 10/40/55 Nuts:
Design temp.(Max/Min) oC (-)27/55 Gaskets:
Specific Gravity ( Inlet) 0.5-.57 Distributers:
Corrosion Allowance (mm) 3 ( Due to Caustic water) Grates:
Additional Attachments Internals :
Internal Attachments:
MECHANICAL AND CONSTRUCTION DETAILS NOZZLES SIZE RATING

MARK
Joints L:iquid Inlet N1 2 300 #
Weld Efficiency Liquid Drain N2 1.5 300 #
Post Weld H.T Vapour Outlet N3 2 300 #
Radiography Level Gauge L1-2 * 300 # 4)
Design Code Level Transmitter Radar N4 * 300 #
Type
Manhole Thermo well N5 * 300 #
Boiling Stds. Safety Valve N6 * 300 #
Gasket Stds. Pressure Gauge N7 * 300 #
Supports Utility Connection N8 2 300 #
Anchor Bolts
Location
Insulation
Type Of Insulation :
General Notes: 1. All Process data are indicated in bold

2. Vessel shall be used for draining caustic water from LPG bullets
3. Safety valve shall be Fire Sized
4. Magnetic Flapper Type
5. * By vendor
Inspection:
Despatch: Complete/Segments
SPL. Instruction:
REVISION REVISION
Process Date No. Signature Date No. Signature Date
Dept.
Designed by: VKS 05.02.2015
Checked by: SCA 05.02.2015
Approved by: SCA 05.02.2015
EM131DD45VV105 1
INDIA LTD, NOIDA DOCUMENT NO. REV
SHEET 1 OF 2
PROCESSDATASHEET

FOR

MERCAPTANDOSINGVESSEL

All rights reserved
PROJECTS & DEVELOPMENT EM131-DD-45-VV-105 1
REV
INDIA LTD, NOIDA Doc. No
VESSEL SPECIFICATION SHEET Sheet 2 of 2

Project : Installation Of Mounded Bullets at NRL , Numaligarh Plant/Section: 45
Location : Outdoor
Equipment : Mercaptan Dosing Vessel Tag No: 45-VV-105
No. of units : One (1) Service: Mercaptan
Size : 440mm ID 1350 mm HT (TL-TL) Position Hor: ( ) Ver: ( )
DESIGN DATA MATERIAL OF CONSTRUCTION (1)
Fluid : Drain Bullet Caustic Water / LPG Shell: SS-316
Capacity (Normal/Rated) L: 200 Lining If Any: Nil
Working pressure (Kg/cm2 a) 1.2 Head:
Design pressure (Kg/cm2 g) 10 Nozzle Neck
Working temp. oC amb. Nozzle Flange
Design temp.(Max/Min) oC 65 Studs and Bolts
Corrosion Allowance (mm) 3mm Nuts:
Gaskets:
Distributers:
Grates:
Additional Attachments Internals :
Internal Attachments:
MECHANICAL AND CONSTRUCTION DETAILS NOZZLES SIZE RATING

MARK
Joints Mercaptan Inlet N1 1 150 #
Weld Efficiency Mercaptan outlet N2 1 150 #
Post Weld H.T Inert Gas Inlet N3 1 150 #
Radiography Level Gauge L1-2 2 150 #
Design Code Spare SP 1 150#
Manhole Vent V 1.5 150#
Boiling Stds.
Gasket Stds.
Supports
Anchor Bolts
Location
Insulation
Type Of Insulation :
General Notes: 1. All residual engineering to be carried on during detail engineering.
Inspection:
Despatch: Complete/Segments
SPL. Instruction:
REVISION REVISION
Process Date No. Signature Date No. Signature Date
Dept.
Designed by: VKS 24.02.2015
Checked by: SCA 24.02.2015
Approved by: SCA 24.02.2015
EM131-DD-45-PA-CF-101 A/B 1
DOCUMENT NO REV.
INDIA LTD
SHEET 1 OF 5
PROCESSDATASHEET

FOR

LPGTRANSFERPUMP
(45PACF101A/B)


EM131-DD-45-PA-CF-101 A/B 1
DOCUMENT NO REV.
INDIA LTD SHEET 2 of 5
OF 4
Project: Installation of Mounded Bullets at NRL

Section/ Item No. : 45 / 45-PA-CF-101 A/B
Refinery Ltd.
Applicable to: () Proposal ( ) Purchase ( ) As Built No. Req. (Two) Working/Stand by: (One)
Pump Type : () Hori ()Vertical Installation :( )Indoor () Outdoor Duty: ( ) Cont ( ) Intermittent
Barrel Type
Driver: Elect Motor Driver Furnished by: ( )Purchaser ()Pump Supplier
Pump Supplier/Manufacturer: Model: Sr. No:
OPERATING CONDITIONS
Liquid Handled: LPG Rated 267 m3/hr NPSH Reqd. m
Pumping Temp. Capacity Normal rpm
10/40/55 oC 240 m3/hr Pump speed
( Min./Nor/Max)
-/7.51/9.613 Min.
Vapor Pr. at PT:
Kg/cm2 a m3/hr Efficiency
( Min./Nor/Max) 0
@ 40 C
Spec Gr. at PT Max. Rated Power 110 kW
0.558 @ 40 0C 9.613 Kg/cm2a
( Min/Nor/Max) Consumption (Estd.)
Suction Normal 7.51 Kg/cm2a@
Pressure 40 0C
0.113 Cp @ Min. Max Power
Viscosity At PT. - Kg/cm2a
40 0C Consumption kW
15.5 /17.603
Kg/cm2a kW
Discharge Pressure(
pH Value ( At pump Driver Rating
Nor/Max)
discharge
flange)
Corrosion Due
H2S < 10 ppm Diff. Pr (Design). 7.99 Kg/cm2 Driver Speed
to rpm
Suspended
Diff. H at Rat. Cap. 152 m 5) Shut off Head
solids. m
Zero ( At
Max. Particle
NPSH Available pump suction Min. Cont .Flow m3/hr
size
flange)
CONSTRUCTIONAL FEATURES
Self Priming No Max. Allow Casing Pr. Kg/cm2g Jacketing For
No. of Stages Hydro Test Pr. Kg/cm2g Cooling Water Pr. Kg/cm2
o
Impeller Type Nozzle Suction Discharge Available Temp C
Imp. Dia Rated Max. Size Cooling Plan No.(API610)
Casing Type Rating Cooling Water Req. m3/hr
Casing Split Facing Flushing Plan No.(API 610)
Rot. Facing Coup. End Position Flushing Medium From Discharge
o
Casing Support Shaft Seal Temp C
2
Casing Drain Type :Size Pressure Kg/cm
Axial Thrust Balanced BY No. of Packing Rings Flow m3/hr
Running Stuffing Box brush Bearing Drive End Base Plate Type
Wearing Rings No. (common) Size
Clearance Guide Brush Sleeve Brg. Size Coup- Manufacturer
All rights reserved

EM131-DD-45-PA-CF-101 A/B 1
DOCUMENT NO REV.
OF 4
Balancing Disc/Drum Lubricator ling Type, Rating
For Vert. Subm. Pump Dim: See Sht. Lubricant Spec. Size, Spacer length
MATERIAL OF CONSTRUCTION
Bearing Cover
Casing SS316
Brush
Balance Rot. Ring
Impeller SS316
Disc/Drum Mech.
Diffuser Drip Tray Seal ( Sea Ring
Imp. Wearing Companion Yes) Spring/Bellow
Ring Flange
Cas. Wearing Gasket
Tie Rods
Ring
Shaft SS316 Stuff. Gland Seal
Shaft Sleeve Box Seal Cage
Bearing House Packing
TESTS & INSPECTION AS PER WEIGHTS DRGS. & DOCUMENTS AS PER ES 5106
ES 5106
Shop Test Reqd. For Witnessed for Bare Pump Kg Out Line Drg. No.
Performance Each/ One Pump Each/ One Pump Bare Plate Kg Sect. Drg. No.
Coupling/Gear Kg Seal Sect Drg. No.
Hydrostatic Each/ One Pump Each/ One Pump
Box
Each/ One Driver Kg Auxiliary Piping Drg.
NPSH Each/ One Pump
Pump No.
Disassembly Each/ One Pump Each/ One Pump Test Curve No.
Accessories : Base Plate: Anchor Bolts: Coupling: Coupling Guard:
Companion Flange With Gasket Bolts & Nuts For Comp Flange ( ) Minimum
Return Valve
All rights reserved

EM131-DD-45-PA-CF-101 A/B 1
DOCUMENT NO REV.
OF 4
DRIVER SPECIFICATION
Driver : 45-PA-MP-101A/B
Type : Electric Motor
Nos. Required : 2( 1W+1S)
Driving Fluid : Not Applicable
Steam Condition : Not Applicable
Hazardous Area Classification :
Zone-1
Group IIA IIB
Temp Class T3
Note:
1. Design NPSH considered Zero at suction flange of the pump.

2. Max. Shut off head shall not exceed 125% of the Rated differential head.
3. Design Sp.Gr.0.570 for power calculation.
4. Connection detail: Inlet/Outlet piping 12 300 # / 8 300 #.
5. Rated pump head at discharge flange.
6. Total system as per API PLAN 52 for mechanical seal (Dual unpressurized) shall be
supplied for each pump.
7. Composition and Properties

C3 30 45 37.5
C4 55 70 62.5
H2S < 10 ppm < 10 ppm < 10 ppm
All rights reserved

EM131-DD-45-PA-CF-101 A/B 1
DOCUMENT NO REV.
OF 4
Designation LPG
Design Sp. Gravity at 40 0C 0.558 ( Simulated)
Vapour pressure at 40 0C , kg/cm2a 7.51( Simulated)
Design Viscosity, at 40 0C Cp 0.113 ( Simulated)
All rights reserved

EM131-DD-45-PA-CF-102 A/B 1
DOCUMENT NO REV.
INDIA LTD HHEET 1 of 5
PROCESSDATASHEET

FOR

LPGTRANSFERPUMP
(45PACF102A/B)


EM131-DD-45-PA-CF-102 A/B 1
DOCUMENT NO REV.
Project: Installation of Mounded Bullets at NRL

Section/ Item No. : 45 / 45-PA-CF-102 A/B
Refinery Ltd.
Applicable to: () Proposal ( ) Purchase ( ) As Built No. Req. (Two) Working/Stand by: (One)
Pump Type : () Hori ()Vertical Installation :( )Indoor () Outdoor Duty: ( ) Cont ( ) Intermittent
Barrel Type
Driver: Elect Motor Driver Furnished by: ( )Purchaser ()Pump Supplier
Pump Supplier/Manufacturer: Model: Sr. No:
Liquid Handled: LPG Rated m3/hr NPSH Reqd. m
Pumping Temp. Capacity Normal rpm
10/40/55 oC 27 m3/hr Pump speed
( Min./Nor/Max)
3.35/7.51/ 9.613 Min.
Vapor Pr. at PT:
Kg/cm2 a m3/hr Efficiency
( Min./Nor/Max)
Max. Rated Power 17 KW
Spec Gr. at PT 9.613 Kg/cm2a@
0.5/-/0.558 Consumption
( Min/Nor/Max)
(Estd.)
Suction
Normal 7.51 Kg/cm2a
Pressure
40 0C
Min. 3.35 Kg/cm2a@ Max Power
Viscosity At PT. 0.152/-/0.113
10 0C Consumption kW
15.22 21.48
Discharge Pressure( Kg/cm2a kW
pH Value Driver Rating
Min/Max) ( At pump
discharge flange)
Corrosion Due
H2S < 10 ppm Diff. Pr (Design). 11.87 Kg/cm2 Driver Speed
to rpm
Suspended
Diff. H at Rat. Cap. 210 m 5) Shut off Head
solids. m
Max. Particle Zero ( At pump
NPSH Available Min. Cont .Flow
size suction flange) m3/hr
CONSTRUCTIONAL FEATURES
Self Priming No Max. Allow Casing Pr. Kg/cm2g Jacketing For
No. of Stages Hydro Test Pr. Kg/cm2g Cooling Water Pr. Kg/cm2
o
Impeller Type Nozzle Suction Discharge Available Temp C
Imp. Dia Rated Max. Size Cooling Plan No.(API610)
Casing Type Rating Cooling Water Req. m3/hr
Casing Split Facing Flushing Plan No.(API 610)
Rot. Facing Coup. End Position Flushing Medium From Discharge
o
Casing Support Shaft Seal Temp C
Casing Drain Type :Size Pressure Kg/cm2
Axial Thrust Balanced BY No. of Packing Rings Flow m3/hr
Running Stuffing Box brush Bearing Drive End Base Plate Type
Wearing Rings No. (common) Size
Clearance Guide Brush Sleeve Brg. Size Coup- Manufacturer
Balancing Disc/Drum Lubricator ling Type, Rating
All rights reserved

EM131-DD-45-PA-CF-102 A/B 1
DOCUMENT NO REV.
For Vert. Subm. Pump Dim: See Sht. Lubricant Spec. Size, Spacer length
Bearing Cover
Casing SS316
Brush
Balance Rot. Ring
Impeller SS316
Disc/Drum Mech.
Diffuser Drip Tray Seal ( Sea Ring
Imp. Wearing Companion Yes) Spring/Bellow
Ring Flange
Cas. Wearing Gasket
Tie Rods
Ring
Shaft SS316 Stuff. Gland Seal
Shaft Sleeve Box Seal Cage
Bearing House Packing
TESTS & INSPECTION AS PER WEIGHTS DRGS. & DOCUMENTS AS PER ES 5106
ES 5106
Shop Test Reqd. For Witnessed for Bare Pump Kg Out Line Drg. No.
Performance Each/ One Pump Each/ One Pump Bare Plate Kg Sect. Drg. No.
Coupling/Gear Kg Seal Sect Drg. No.
Hydrostatic Each/ One Pump Each/ One Pump
Box
Each/ One Driver Kg Auxiliary Piping Drg.
NPSH Each/ One Pump
Pump No.
Disassembly Each/ One Pump Each/ One Pump Test Curve No.
Accessories : Base Plate: Anchor Bolts: Coupling: Coupling Guard:
Companion Flange With Gasket Bolts & Nuts For Comp Flange ( ) Minimum
Return Valve
All rights reserved

EM131-DD-45-PA-CF-102 A/B 1
DOCUMENT NO REV.
DRIVER SPECIFICATION
Driver : 45-PA-MP-102A/B
Type : Electric Motor
Nos. Required : 2( 1W+1S)
Driving Fluid : Not Applicable
Steam Condition : Not Applicable
Hazardous Area Classification :
Zone-1
Group IIA IIB
Temp Class T3
Note:
1. Design NPSH considered Zero at suction flange of the pump.

2. Max. Shut off head shall not exceed 125% of the Rated differential head.
3. Design Sp.Gr.0.570 for power calculation.
4. Connection detail: Inlet/Outlet piping 6 300 # / 3 300 #.
5. Rated pump head at discharge flange.
6. Total system as per API PLAN 52 for mechanical seal (Dual unpressurized) shall be
supplied for each pump.
7. Composition and Properties

C3 30 45 37.5
C4 55 70 62.5
H2S < 10 ppm < 10 ppm
All rights reserved

EM131-DD-45-PA-CF-102 A/B 1
DOCUMENT NO REV.
Designation LPG
Design Sp. Gravity at 10/-/ 40 0C 0.5/-/0.558( Simulated)
Vapour pressure at 10/-/ 40 0C , kg/cm2a 3.35/-/7.51( Simulated)
Design Viscosity, at 10/-/40 0C Cp 0.152/-/0.113 ( Simulated)
All rights reserved

EM131-DD-45-PA -112 A/B 1
DOCUMENT NO REV.
PROCESSDATASHEET

FOR

MERCAPTANDOSINGPUMP
(45PA112A/B)


EM131-DD-45-PA-112A/B 1
DOCUMENT NO REV.
JOB NO. EM 131 ITEM: MERCAPTAN DOSING PUMP ITEM NO. 45-PA-112 A/B
Project : Installation of mounded bullets at NRL Plant/Section : / 45 Nos. Reqd. :2
refinery ltd. (1-Working, 1-
OPERATING CONDITION PERFORMANCE
Service: MERCAPTAN DOSING NPSH Required
No of Stages
Duty: Continuous Yes (X ) No () RPM
Liquid Handled : Mercaptan Efficiency
Location : Outdoor (X ) Indoor ( ) Max. Power Absorbed on the shaft of
@ Set Pr.
Capacity, Minimum / Normal / Litres /hr : Pump
Capacity, Maximum 1.8 Litres /hr : Reducer
Suction Pressure Atmospheric
Discharge Pressure 18 Kg/Cm2A
Fluid Temperature : Nor. / Max. Ambient
Vapor Pressure At P T. 1.12 Kg/C m2A( Flooded) Tests Required :
Viscosity At P.T. 1 Cst
Sp. Gravity At P.T. 0.84
Crystallisation Point N/A oC
NPSH. Avalable 3 M
Corrosion due to Mercaptan DRIVER : STEAM TURBINE ( ) MOTOR (X )
Solid in Suspension Driver to be supplied by Purchaser ( ) Pump Supplier
Max. Acceptable NPSHR m Recommonded HP
Diff.Press 16.88 Kg/Cm2 Recommended RPM
Flow Control 0-100 % Manually
CONSTRUCTION
Type: Lubrication System
Cylinder : Hori ( ) Vert.( ) Angle ( ) Lubricating Pump
No. mm Stoke mm Cooling Heating System
Pluger/Piston Dia. mm Cooling Heating Fluid
o
Average Piston Speed m/s Introduced at a Temp. of c
Piton Guides : No. Distance mm Washing System for Piston
Connecting Rod : Center to Centre mm Injection Fluid
Small end Bearing mm Caacity of Injection Fluid m3/hr
Big end Bearing mm Wt. of : Pump without Driver Kg
Main bearing mm : Heaviest Pieces Kg
No. Center to Center mm : Heaviest Pieces for normal maintenance Kg
Cross head Sliding Block : Surface mm2 : Bare Shaft of Pump Kg
Valve Valve Seats NOZZLE SIZE RATING FACING POSITION
Valve Spring Suction
Seal Gasket Discharge
Piston Seal System
Cylinder 1) Connecting Rod
Cylinder Liner Small end Bearing
Plunger/Piston Surface Treat : Big end Bearing
Power Frame Main Bearing
Packing Cross head Sliding Block
Packing Gland Piston Guides
Valve Seal Gaskets
Valve Seats Valve Spring Other Parts in contacted with Fluid
All rights reserved

EM131-DD-45-PA-112A/B 1
DOCUMENT NO REV.
JOB NO. EM131 ITEM: MERCAPTAN DOSING PUMP ITEM NO. 45-PA-112A/B
Project : Installation of mounded bullets at NRL Plant/Section : /45 Nos. Reqd. :2
refinery ltd. (1-Working, 1-Standy)
COUPLING BETWEEN DRIVER & PUMP MFR. FINAL DATA
Type: Manufacturer :
Pump Serial No. :
Reducer: Type Test Curve No. :
Ratio: ; Axes: Outline Dwg. No. :
Speed Variator: Pump Sheet Drg. No. :
Belts Or Chain Tracks: Seal Diam. Dwg. No. :
Coupling Between : Variator & Driver Wr. Clearance Diam. :
:Reducer & Variator/Driver Mech Seal/Packing :
:Pump & Reducer
Cooling Water:
Inlet Temp . oC :Capacity:
ACCESSORIES TO BE SUPPLIED
Pressure Indicator : Suction Side
: Discharge Side
: For Low Pressure Oil
: For High Pressure Oil
Temp Indicator For Bearing Metal:
Low Pressure Oil Pump :
Motor :
High Pressure Oil Pump:
Motor:
V-Belt:
Pulley:
Oil Cooler:
Motor Bed:
Safety Valve On Discharge Side:
Companion Flange For Suction Side & Discharge
Low Oil Pressure Safety Alarm Switch Or Device
NOTES: All the process data are in bold and italic.

1) Material in contact shall be SS-316.
2
2) PSV set pressure shall be 14.5 kg/cm g.
3) Vessel under N2 pressure.
4) Pulsation dampener are to be provided at suction & discharge side.
5) Diaphragm rupture detection Pressure switch is required.
6) Refer P&ID no EM 131-45-0022
7) Pump to be hermitically sealed glandless type.
8) Connection details : Inlet / Outlet piping 1 150 # / 1 300 #.
9) Pump Discharge PSV to be provided by pump vendor
10) All residual engineering to be carried on during detail engineering
All rights reserved

EM131 -45-0090 0
PDIL REV
PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO
NOIDA
SHEET1 of 7
LINELIST

0 06.02.2015 06.02.2015 For Issue BK VKS SCA
REV REV. DATE EFF DATE PURPOSE PREPD REVWD APPD
FORM NO: 02-0000-0021 F1 REV4 All rights reserved

LOCATION CONDITION SPECIFICATION

IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
MEDIU PIPE o PIPE CLASS
INCH P&ID FROM TO PRES. TEMP. PRES. TEMP C CLASS
M NUMBER o
() kg/cm2g C kg/cm2g MAX MIN
6 P 3001 21 6-P-44-1601-B1A NEW BULLETS 19.787 40 30.587 65 40 B1A N
8 P 3002 21 LPG CIRCULATION HEADER 45-VV-102 6.48 40 14.5 55 -27 B1A N
12 P 3003 21 LPG PUMP SUCTION HEADER 45-PA-CF-101A/B,102A/B 6.48 40 14.5 55 -27 B1A N
H FL 3004 21 45-VV-101 FLARE HEADER 0.6-2.6 Amb. 4.5 65 -27 A1A N
P MOUNDED BULLETS
6 3005 21 GANTRY LOADING 6.48 40 14.5 55 -27 B1A N
1)
P MOUNDED BULLETS B1A
8 3006 21 BOTTLING PLANT 6.48 40 14.5 55 -27 N
1)
6 P 3007 21 LPG RUN DOWN HEADER 45-VV-101 19.787 40 30.587 65 40 B1A N
P LPG PUMP SUCTION
12 3008 21 45-VV-101 6.48 40 14.5 55 -27 B1A N
HEADER
6 P 3009 21 VAPOUR BALANCE LINE 45-VV-101 6.48 40 14.5 55 -27 B1A N
P LPG PUMP SUCTION
12 3013 21 45-VV-102 6.48 40 14.5 55 -27 B1A N
HEADER
H P 3014 21 45-VV-101 PSV-3001B 6.48 40 14.5 55 -27 B1A N
H FL 3015 21 PSV-3001B FLARE HEADER 6.48 40 14.5 55 -27 A1A N
H P 3016 21 45-VV-101 PSV-3001A 6.48 40 14.5 55 -27 B1A N
H FL 3017 21 PSV-3001A FLARE HEADER 0.6-2.6 Amb. 4.5 65 -27 A1A N
18 FL 3018 21 FLARE HEADER 24-FL-44-1608-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N
H P 3019 21 45-VV-102 PSV-3002B 6.48 40 14.5 55 -27 B1A N
H P 3020 21 45-VV-102 PSV-3002A 6.48 40 14.5 55 -27 B1A N
H FL 3021 21 PSV-3002B FLARE HEADER 0.6-2.6 Amb. 4.5 65 -27 A1A N


IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
M NUMBER o
P VAPOUR BALANCE LINE B1A
6 3025 22 45-VV-103 6.48 40 14.5 55 -27 N
1)
P LPG PUMP SUCTION
12 3026 22 45-VV-101 6.48 40 14.5 55 -27 B1A N
HEADER
P LPG CIRCULATION HEADER
8 3027 22 45-VV-103 6.48 40 14.5 55 -27 B1A N
1)
H P 3028 22 45-VV-103 PSV-3003B 6.48 40 14.5 55 -27 B1A N
H P 3029 22 PSV-3003B FLARE HEADER 0.6-2.6 Amb. 4.5 65 -27 A1A N
H P 3030 22 45-VV-103 PSV-303A 6.48 40 14.5 55 -27 B1A N
P LPG PUMP SUCTION
12 3035 22 45-VV-104 6.48 40 14.5 55 -27 B1A N
HEADER
H P 3037 22 45-VV-104 PSV-304B 6.48 40 14.5 55 -27 B1A N
H FL 3038 22 PSV-3004B FLARE HEADER 0.6-2.6 Amb. 4.5 65 -27 A1A N
H P 3039 22 45-VV-104 PSV-304A 6.48 40 14.5 55 -27 B1A N
3042
P 3-P-45-3052-B1A,
6 3043 23 6-P-45-3043-B1A 14.207 10 26.8 55 -27 B1A N
3-P-45-3055-B1A
P 8-P-45-3046-B1A,
8 3044 23 8-P-45-3090-B1A 14.48 40 22 55 -27 B1A N
8-P-45-3049-B1A
12 P 3045 23 LPG PUMP SUCTION HEADER 45-PA-CF-101A 6.48 40 14.5 55 -27 B1A N


IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
M NUMBER o
8 P 3046 23 45-PA-CF-101A LPG DISCHARGE HEADER 14.487 40 22 55 -27 B1A N
P LPG CIRCULATION
8 3047 23 8-P-45-3046-B1A 6.48 40 14.5 55 -27 B1A N
HEADER
12 P 3048 23 LPG SUCTION HEADER 45-PA-CF-101B 6.48 40 14.5 55 -27 B1A N
8 P 3049 23 45-PA-CF-101B LPG DISCHARGE HEADER 14.487 40 22 55 -27 B1A N
LPG CIRCULATION
8 P 3050 23 8-P-45-3049-B1A 6.48 40 14.5 55 -27 B1A N
HEADER
6 P 3051 23 LPG PUMP SUCTION HEADER 45-PA-CF-102A 6.48 40 14.5 55 -27 B1A N
LPG DISCHARGE HEADER
3 P 3052 23 45-PA-CF-102A 14.207 10 26.8 55 -27 B1A N
(BOTTLING PLANT)
P LPG CIRCULATION
3 3053 23 3-P-45-3052-B1A 6.48 40 14.5 55 -27 B1A N
HEADER
6 P 3054 23 LPG SUCTION HEADER 45-PA-CF-102B 6.48 40 14.5 55 -27 B1A N
3 P 3055 23 45-PA-CF-102B LPG DISCHARGE HEADER 14.207 40 26.8 55 -27 B1A N
23 LPG CIRCULATION
3 P 3056 3-P-45-3055-B1A 6.48 40 14.5 55 -27 B1A N
HEADER
P LPG DISCHARGE
6 3057 23 FV-3001 14.487 40 22 55 -27 B1A N
HEADER(GANTRY LOADING)
P LPG CIRCULATION
6 3058 23 FV-3001 6.48 40 26.8 55 -27 B1A N
HEADER
P LPG DISCHARGE HEADER
3 3059 23 FV-3002 14.207 10 26.8 55 -27 B1A N
(BOTTLING PLANT)
P LPG CIRCULATION
3 3060 23 FV-3002 14.207 10 26.8 55 -27 B1A N
HEADER
H P 3061 23 LPG RUN DOWN HEADER TSV-3001 19.787 40 30.587 65 40 B1A N
H P 3062 23 LPG CIRCULATION HEADER TSV-3002 6.48 40 14.5 55 -27 B1A N
P LPG DISCHARGE
H 3064 23 TSV-3003 14.487 40 22 55 -27 B1A N
H P 3065 23 LPG PUMP SUCTION HEADER TSV-3004 6.48 40 14.5 55 -27 B1A N


IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
M NUMBER o
P LPG DISCHARGE HEADER
H 3066 23 TSV-3005 14.207 10 26.8 55 -27 B1A N
(BOTTLING PLANT)
H FL 3067 23 TSV-3001 3-FL-45-3073-A1A 0.62-2.62 40-180 3.7 240 40 A1A N
H FL 3068 23 TSV-3002 3-FL-45-3073-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N
H-FL-45-3067-A1A,
H-FL-45-3068-A1A,
H-FL-45-3070-A1A,
3 FL 3073 23 FLARE HEADER 0.62-2.62 40-180 3.7 240 -27 A1A N
H-FL-45-3071-A1A,
H-FL-45-3072-A1A &
H-FL-45-3093-A1A
LPG DISCHARGE HEADER
6 P 3074 23 6-P-44-5004-B1A 14.207 10 26.8 55 -27 B1A N
(BOTTLING PLANT)
LPG CIRCULATION
4 P 3075 23 6-P-44-5004-B1A 14.207 10 26.8 55 -27 B1A N
HEADER
H FL 3076 24 45-VV-106 PSV-3007A 0.6-2.6 Amb. 4.5 65 -27 B1A N
H FL 3077 24 PSV-3007A 2-FL-45-3080-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N
H FL 3078 24 45-VV-106 PSV-3007B 0.6-2.6 Amb. 4.5 65 -27 B1A N
H FL 3079 24 PSV-3007B H-FL-45-3077-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N
2 FL 3080 24 45-VV-106 2-FL-45-3073-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N

P LPG DISCHARGE
8 3090 23 8-P-45-1107-B1A 14.487 40 22 55 -27 B1A N
6 P 3091 23 6-P-45-1325B1A VAPOUR BALANCE LINE 6.48 40 14.5 55 -27 B1A N
H P 3092 23 LPG PUMP SUCTION HEADER PSV-3006 A1A N
H FL 3093 23 PSV-3006 3-FL-45-3073-A1A 0.6-2.6 Amb. 4.5 65 -27 A1A N


IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
M NUMBER o

2 AI 3001 21 INSTTRUMENT AIR INTERNAL DISTRIBUTION 6.5 Amb. 11.5 65 Amb. A3A N
2 SL 3001 21 LP STEAM BLINDED 4 165 7.5 200 155 A2A Ih
2 AP 3001 21 PLANT AIR UTILITY STATION-I 6.5 Amb. 11.5 55 Amb. A3A N
2 IG 3001 21 N2 UTILITY STATION-I 3.5 Amb. 10 65 Amb. A3A N
2 IG 3002 22 2-IG-45-3001-A3A 45-VV-105 3.5 Amb. 10 65 Amb. A3A/A1A N
1.5 WS 3001 21 SERVICE WATER UTILITY STATION-I 4.5 Amb. 8 65 Amb. A3A N
1.5 CRWS 3001 24 45-VV-106 SHALLOW SUMP 6.48 40 14.5 55 -27 B1A/A1A N
2 CRWS 3002 24 SHALLOW SUMP SS 6.48 40 14.5 55 -27 A1A N
2 D 3001 21/24 LPG BULLETS DRAIN 45-VV-106 6.48 40 14.5 55 -27 B1A N
2 D 3002 21 45-VV-101 BULLET WATER DARIN 6.48 40 14.5 55 -27 B1A N

1 OD 3001 21 HEADER HEADER 14.5 55 -27 B1A N
OD PUMP SUCTION( 45-PA-112
1 3002 22 45-VV-105 14.5 55 -27 A1A N
A)
OD 1-OD-45-3002-A1A PUMP SUCTION( 45-PA-112
1 3003 22 14.5 55 -27 A1A N
B)
1 OD 3004 22 45-PA-112A 1-OD-45-3005-A1A 14.5 55 -27 B1A N
1 OD 3005 22 45-PA-112 A/B 1-OD-45-3001-B1A 14.5 55 -27 B1A N
2 OD 3006 22 PSV-3005 4-FL-45-3073-A1A 14.5 55 -27 A1A N
1.5 OD 3007 22 45-VV-105 2-OD-45-3008-A1A 14.5 55 -27 A1A N
2 OD 3008 22 1.5-OD-45-3008-A1A ATM. 14.5 55 -27 A1A N
1.5 OD 3009 22 45-VV-105 PSV-3005 14.5 55 -27 A1A N


IDENTIFICATION
NORMAL DESIGN
REV
DIA. INS.
M NUMBER o
OD MERCAPTAN DOSING
1 3010 21 LPG RUN DOWN HEADER 14.5 55 -27 B1A N
HEADER
OD MERCAPTAN DOSING
1 3011 21 8-P-45-3010-B1A 14.5 55 -27 B1A N
HEADER
OD MERCAPTAN DOSING
1 3012 21 8-P-45-3002-B1A 14.5 55 -27 B1A N
HEADER
OD MERCAPTAN DOSING
1 3013 22 8-P-45-3027-B1A 14.5 55 -27 B1A N
HEADER
OD MERCAPTAN DOSING
1 3014 22 8-P-45-3036-B1A 14.5 55 -27 B1A N
HEADER
1-BD-45-3003-B1A,
1-BD-45-3005-B1A,
2 BD 3001 23/24 2-D-45-3001-B1A 6.48 40 14.5 55 -27 B1A N
1-BD-45-3007-B1A &
1-BD-45-3001-B1A,

3/4 BD 3002 23 12-P-45-3045-B1A 1-BD-45-3003-B1A 6.48 40 14.5 55 -27 B1A N
1 BD 3003 23 45-PA-CF-101A PUMP DRAIN OUT 6.48 40 14.5 55 -27 B1A N
3/4 BD 3004 23 12-P-45-3048-B1A 1-BD-45-3005-B1A 6.48 40 14.5 55 -27 B1A N
1 BD 3005 23 45-PA-CF-101B PUMP DRAIN OUT 6.48 40 14.5 55 -27 B1A N
3/4 BD 3006 23 6-P-45-3051-B1A 1-BD-45-3007-B1A 6.48 40 14.5 55 -27 B1A N
1 BD 3007 23 45-PA-CF-102A PUMP DRAIN OUT 6.48 40 14.5 55 -27 B1A N
3/4 BD 3008 23 12-P-45-3054-B1A 1-BD-45-3009-B1A 6.48 40 14.5 55 -27 B1A N
1 BD 3009 23 45-PA-CF-102B PUMP DRAIN OUT 6.48 40 14.5 55 -27 B1A N
NOTE: 1) Vice versa

EM 131-45-0115 1
PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO. REV.
SHEET 1 OF 4

PROCESSDATASHEET

(FLOWINSTRUMENTS)

All rights reserved
FORM NUMBER 02-0000-0021 F5 REV.1
This document is the property of Projects & Development India Limited (PDIL) and not to be copied or reproduced or exhibited to third parties without permission of PDIL.
PROCESS DATA FOR INSTRUMENTS

FLOW INSTRUMENTS
OPERATING CONDITIONS SET POINT
INLET Allow Temp Density FLOW ALAR TRIP
LOCATION : PRESSU Press (M3/hr) M
REV
TAG NO. EQUIP NO. / LINE FLUID STATE RE DROP REMARKS
NO.
NO. (Normal) (oC). SG MAX NOR MIN H L HH LL
Kg/cm2(a)
ORIFICE
1 FE-3001 8-P-45-3044-B1A LPG L 15.5 MIN 40 0.50-0.57 267 240 1)
METER
1
FT-3001 LOCAL
1
FIC-3001 CCR/DCS 1) 1) 3)
1
FT-3001A LOCAL PANEL 1)
1
FALL-3001A CCR/DCS 1)
1
FAHH-3001A CCR/DCS 1)
(X) INDICATES APPLICABLE

LEGEND :
L = LIQUID .
V = VAPOUR
NOTE: 1) All residual engineering to be carried on during detail engineering

2) Liquid flow rates are in m3/hr.
3) Min. Continuous flow through pump vendor 4) All Tags to be prefixed by unit no 45.
REV. EFF.
REV. PRPD. REVD. APPD. SHEET
DOCUMENT NO. DATE DATE
PROJECT:BEDPFORLPGMOUNDED
BULLETS,NRLREFINERY EM131-45-0115 1 05.02.15 05.02.15 VKS SCA SCA 2 of 3
FLOW INSTRUMENTS
REV
NO.
2
Kg/cm (a)
15.22- 0.50- ORIFICE

1 FE-3002 6-P-45-3043-B1A LPG L MIN 10-40 267 240 1)
19.34 0.57 METER
1
FT-3002 LOCAL
1
FIC-3002 CCR/DCS 1) 1)
1
FT-3002A LOCAL PANEL 1)
1
FALL-3002A CCR/DCS 1)
1
FAHH-3002A CCR/DCS 1)

LEGEND :
L = LIQUID .
V = VAPOUR
G = Gas
REV. EFF.

FLOW INSTRUMENTS
REV
NO.
2
Kg/cm (a)
1 INS. ORIFICE
RO-3001 H-AI-45-3005-A3A G 7.5 MIN AMB.
AIR METER 1)
1 ORIFICE
INS.
RO-3002 H-AI-45-3006-A3A G 7.5 MIN AMB. METER 1)
AIR
1 INS. ORIFICE
AIR
1 INS. ORIFICE
AIR
1 INS. ORIFICE
AIR
1 ORIFICE
RO-3006 H-AI-45-3005-A3A NI G 4.5 MIN AMB METER 1)

LEGEND :
L = LIQUID .
V = VAPOUR
G= GAS
REV. EFF.
EM 131-45-0116 1
SHEET 1 OF 8

PROCESSDATASHEET

(PRESSUREINSTRUMENTS)

All rights reserved
REV. P&ID TAG NO. LOCATION : FLUID FLUID PRESSURE (KG/Cm2g) TEMPERATURE SET POINTS REMARKS
NO. no. EQUIP NO. / LINE NO. STATE (C)
MI NOR MAX MIN/MAX ALAR TRIP
N (design) M
H L HH LL
1 P1 PT-3001 45-VV-101(N9) LPG L 2.35-6.51 14.5 (-)27/55 - - - -
1
P1 PI-3001 CCR/DCS
1 1)
P1 PAH-3001 CCR/DCS
1 PT-
P1 45-VV-101(N9)) LPG L 2.35-6.51 14.5 (-)27/55
3001A/B/C
1 1)
P1 PAHH-3001 CCR/DCS
1
1
P1 PT-3002 45-VV-102(N9) LPG L 2.35-6.51 14.5 (-)27/55 - - -
1
P1 PI-3002 CCR/DCS
1 1)
P1 PAH-3002 CCR/DCS
1 PT-
P1 45-VV-102(N9)) LPG L 2.35-6.51 14.5 (-)27/55
3002A/B/C
BASE CONDITIONS : UNITS :

0
TEMPERATURE : C
PRESSURE : Kg/cm2, g
LEGEND :L = LIQUID V = VAPOUR G = GAS NOTE : 1) To be decided by vendor.
2) All residual engineering shall be carried on during detail engineering.
3) Differential pressure across strainer shall be decided by vendor during detail engg.
4) By NRL 5) All tags to be prefixed by unit no 45.

2 of 8
PDIL EM131-45--0116 1 05.02.15 05.02.15 VKS SCA SCA

NOIDA DOCUMENT NO. REV REV. DATE EFF. DATE PPD REVWD APPD. SHEET
.
N (design) M
H L HH LL
1 1)
1
1
P2 PT-3003 45-VV-103(N9) LPG L 2.35-6.51 14.5 (-)27/55 - - -
1
P2 PI-3003 CCR/DCS
1 1)
P2 PAH-3003 CCR/DCS
1 PT-
P2 45-VV-103(N9)) LPG L 2.35-6.51 14.5 (-)27/55
3003A/B/C
1 1)
1
P2 PT-3004 45-VV-104(N9) LPG L 2.35-6.51 14.5 (-)27/55 - - -
1
P2 PI-3004 CCR/DCS
1 1)
P2 PAH-3004 CCR/DCS

0
TEMPERATURE : C

3 of 8

.
N (design) M
H L HH LL
1 PT-
P2 45-VV-104(N9)) LPG L 2.35-6.51 14.5 (-)27/55
3004A/B/C
1 1)
1
P2 PG-3005 1-IG-45-3002-A3A NITROGEN G 3.0 3.5 10 AMB./65
1
P3 PG-3006 12-P-45-3045-B1A LPG L 6.51 15.5 (-)27/55
1
P3 PG-3007 8-P-45-3046-B1A LPG L 15.5 21 (-)27/55
1
P3 PG-3008 12-P-45-3048-B1A LPG L 6.51 15.5 (-)27/55
1
P3 PG-3009 8-P-45-3049-B1A LPG L 15.5 21 (-)27/55
1
P3 PG-3010 6-P-45-3051-B1A LPG L 2.35-6.51 19.4 (-)27/55
1
P3 PG-3011 3-P-45-3051-B1A LPG L 2.35-6.51 25.6 (-)27/55
1
P3 PG-3012 6-P-45-3054-B1A LPG L 2.35-6.51 19.4 (-)27/55

0
TEMPERATURE : C

4 of 8

.
N (design) M
H L HH LL
1
P3 PG-3013 3-P-45-3055-B1A LPG L 2.35-6.51 25.6 (-)27/55
1 Mechanical seal
P3 PG-3014
arrangement for
1 pump( Refer
P3 PG-3015 P&ID)
1
P4 PG-3016 45-VV-106 LPG L 2.35-6.51 14.5 (-)27/55
1
T1 PG-3017 2-AI-45-3004-A3A INST. AIR G 4.5 6.5 11.5 AMB./65
1 T1 INST. AIR
PG-3018 H-AI-45-3005-A3A G 4.5 6.5 11.5 AMB./65
1 T1 INST. AIR
PG-3019 H-AI-45-3006-A3A G 4.5 6.5 11.5 AMB./65
1
T1 PG-3020 2-AI-45-3007-A3A INST. AIR G 4.5 6.5 11.5 AMB./65
1 T1 INST. AIR
PG-3021 H-AI-45-3008-A3A G 4.5 6.5 11.5 AMB./65
1 T1 INST. AIR
PG-3022 H-AI-45-3009-A3A G 4.5 6.5 11.5 AMB./65

0
TEMPERATURE : C

5 of 8

.
N (design) M
H L HH LL
1 3)
P3 dPT-3001 12-P-45-3045-B1A LPG L 6.51 15.5 (-)27/55
1
P3 dPI-3001 LOCAL
1
P3 dPI-3001 CCR/DCS
1 3)
P3 dPT-3002 12-P-45-3048-B1A LPG L 6.51 15.5 (-)27/55
1
P3 dPI-3002 LOCAL
1
P3 dPI-3002 CCR/DCS
1 3)
P3 dPT-3003 6-P-45-3051-B1A LPG L 2.35-6.51 19.4 (-)27/55
1
P3 dPI-3003 LOCAL
1
P3 dPI-3003 CCR/DCS
1 3)
P3 dPT-3004 6-P-45-3054-B1A LPG L 2.35-6.51 19.4 (-)27/55
1
P3 dPI-3004 LOCAL

0
TEMPERATURE : C

6 of 8

.
N (design) M
H L HH LL
1
P3 dPI-3004 CCR/DCS
1 FIRE
T1 PT-3005 H-FW-45-3002-A3A L 4) 4) AMB./65
WATER
1 T1
PI-3005 CCR/DCS
1 T1 FIRE
PT-3006 H-FW-45-3003-A3A L 4) 4) AMB./65
WATER
1 T1
PI-3006 CCR/DCS
1
T1 PT-3007 2-AI-45-3004-A3A INST. AIR G 4.5 6.5 11.5 AMB./65
1 T1 1)
PI-3007 CCR/DCS
1 T1
PT-3008 H-AI-45-3005-A3A INST. AIR G 4.5 6.5 11.5 AMB./65
1 T1 1)
PALL-3008 CCR/DCS
1 T1

0
TEMPERATURE : C

7 of 8

.
N (design) M
H L HH LL
1 T1
PALL-3009 CCR/DCS
1 T1
1 T1 1)
PALL-3010 CCR/DCS
1 T1
1 T1 1)
PALL-3011 CCR/DCS
1 T1
1 T1 1)
PALL-30012 CCR/DCS

0
TEMPERATURE : C

8 of 8

.
EM 131-45-0117 1
SHEET 1 OF 3
PROCESSDATASHEET

(TEMPERATUREINSTRUMENTS)

All rights reserved
(TEMPERATURE INSTRUMENTS)
REV. P&ID no. TAG NO. LOCATION : FLUID FLUID TYPE TEMPERATURE (C) PRESSURE SET POINTS REMARKS
NO. EQUIP NO. / LINE NO. STATE (KG/CM2g)
MIN NOR MAX MIN/ ALA TRIP
MAX(design) RM
H L HH LL
1 P1 TE-3001 45-VV-101(N7) LPG L LOCAL (-27) 10-40 55 2.35/14.5 - - - -
1 CCR/
P1 TI-3001 45-VV-101(N7) LPG L
DCS
1
P1 TE-3002 45-VV-102(N7) LPG L LOCAL (-27) 10-40 55 2.35/14.5
1 CCR/
P1 TI-3002 45-VV-102(N7) LPG L
DCS
1
1 CCR/
P2 TI-3003 45-VV-103(N7) LPG L
DCS
1
1 CCR/
P2 TI-3004 45-VV-104(N7) LPG L
DCS

0
TEMPERATURE : C
LEGEND :
L = LIQUID V = VAPOUR G = GAS NOTE :

2 of 3

.
(TEMPERATURE INSTRUMENTS)
REV. P&ID no. TAG NO. LOCATION : FLUID FLUID TYPE TEMPERATURE (C) PRESSURE SET POINTS REMARKS
NO. EQUIP NO. / LINE NO. STATE (KG/CM2g)
MIN NOR MAX MIN/ ALA TRIP
MAX(design) RM
H L HH LL
1 P4 TG-3005 45-VV-106(N5)
LPG L LOCAL (-27) 10-40 55 2.35/14.5
Note:- 1) All tags to be prefixed by unit no 45.

0
TEMPERATURE : C
LEGEND :
L = LIQUID V = VAPOUR G = GAS NOTE :

3 of 3

.
EM 131-45-0118 1
SHEET 1 OF 11

PROCESSDATASHEET

(LEVELINSTRUMENTS)

All rights reserved

LEVEL INSTRUMENTS
REV. TAG NO. LOCATION : FLUID TYPE OPERATING CONDITIONS SET POINT REMARKS
NO. EQUIP NO/ LINE
NO.
LEVEL SG VIS( CP) ALARM TRIP
H L HH LL
LOW NOR HIGH
1 LT-3001 45-VV-101(N6) LPG RADAR MIN 85% of ID 0.5-0.57 0.113-0.152 VESSEL ID
7000 MM
1 LI-3001 CCR/DCS
1 LAHH-3001 CCR/DCS 3)
1 LALL-3001 CCR/DCS 3)
1 LI-3001 LOCAL 1)
1
7000 MM
UNITS :
PRESSURE : Kg/cm2g (X) mm WC ( )VISCOSITY : CENTI POISE
LEVEL (from BTL) :mm (x) meter ( ) TEMPERATURE : OC
LEGEND : L = LIQUID , SG = SPECIFIC GRAVITY , H = HIGH , HH = HIGH HIGH , BTL = BOTTOM TANGENT LINE, V = VAPOUR
VIS = VISCOSITY (cp) , L = LOW , LL = LOW LOW
NOTE- 1) READABLE FROM GRADE, 2) CONNECTED WITH RADAR/SERVO TRANSMITTER, 3) ALL RESIDUAL ENGINEERING TO BE
CARRIED ON DURING DETAIL ENGINEERING. 4) ALL TAGS TO BE PREFIXED BY UNIT NO 45.

2 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
DOCUMENT NO. REV REV. DATE EFF. DATE PRPD. REVD. APPD. SHEET
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L HH LL
LOW NOR HIGH
1 LI-3002 CCR/DCS
1 LI-3002 LOCAL 1)
1
1 LT-3003 45-VV-101(N5) LPG SERVO MIN 85% of ID 0.5-0.57 0.113-0.152 VESSEL ID
7000 MM
1
LI-3003 CCR/DCS
1 3)
LAHH-3003 CCR/DCS
UNITS :
PRESSURE : Kg/cm2g (X) mm WC ( ) VISCOSITY : CENTI POISE
NOTE- 1) READABLE FROM GRADE, 2) CONNECTED WITH RADAR/SERVO TRANSMITTER 3) ALL RESIDUAL ENGINEERING TO BE CARRIED
ON DURING DETAIL ENGINEERING. 4) ALL TAGS TO BE PREFIXED BY UNIT NO 45.

3 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L H LL
H
LOW NOR HIGH
1 3)
LALL-3003 CCR/DCS
1 LI-3003 LOCAL 1)
1
7000 MM
1 LI-3004 CCR/DCS
1 3)
LAHH-3004 CCR/DCS
1 3)
LALL-3004 CCR/DCS
1 LI-3004 LOCAL 1)
UNITS :

4 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L HH LL
LOW NOR HIGH
7000 MM
1 LI-3005 CCR/DCS
1 3)
LAHH-3005 CCR/DCS
1 3)
LALL-3005 CCR/DCS
1 LI-3005 LOCAL 1)
1
7000 MM
1
LI-3006 CCR/DCS
UNITS :

5 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L HH LL
LOW NOR HIGH
1 3)
LAHH-3006 CCR/DCS
1 3)
LALL-3006 CCR/DCS
1 LI-3006 LOCAL 1)
1
7000 MM
1
LI-3007 CCR/DCS
1 3)
LAHH-3007 CCR/DCS
UNITS :

6 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L HH LL
LOW NOR HIGH
1 3)
LALL-3007 CCR/DCS
1 LI-3007 LOCAL 1)
1

7000 MM
1
LI-3008 CCR/DCS
1 3)
LAHH-3008 CCR/DCS
1 3)
LALL-3008 CCR/DCS
1 LI-3008 LOCAL 1)
UNITS :

7 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L HH LL
LOW NOR HIGH
7000 MM
1 LI-3009 CCR/DCS
1 3)
LAHH-3009 CCR/DCS
1 3)
LALL-3009 CCR/DCS
1 LI-3009 LOCAL 1)
1
7000 MM
1 LI-3010 CCR/DCS
1 3)
LAHH-3010 CCR/DCS
UNITS :
ON DURING DETAIL ENGINEERING 4) ALL TAGS TO BE PREFIXED BY UNIT NO 45.

8 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L H LL
H
LOW NOR HIGH
1 3)
LALL-3010 CCR/DCS
1 LI-3010 LOCAL 1)
1

7000 MM
1
LI-3011 CCR/DCS
1 3)
LAHH-3011 CCR/DCS
1 3)
LALL-3011 CCR/DCS
1 LI-3011 LOCAL 1)
UNITS :

9 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved
LEVEL INSTRUMENTS
REV TAG NO. LOCATION : FLUID TYPE OPERATING CONDITIONS SET POINT REMARKS
. EQUIP NO/ LINE
NO. NO.
H L H LL
H
LOW NOR HIGH
7000 MM
1 LI-3012 CCR/DCS
1 LI-3012 CCR/DCS 1)
1
1 LG-3013 45-VV-105 MERCAPT 1) 3)
AN / NI
1 LT-3013 45-VV-106(N4) LPG - MIN 550 MM 0.5-0.57 0.113-0.152 VESSEL
HEIGHT1
600 MM
UNITS :
LEVEL (from BTL) :mm (x) TEMPERATURE : OC

10 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved

LEVEL INSTRUMENTS
NO. EQUIP NO/ LINE
NO.
H L H LL
H
LOW NOR HIGH
1 3)
LI-3013 CCR/DCS
1 LG-3016 45-VV-106(L1-2) LPG 1)
UNITS :
ON DURING DETAIL ENGINEERING. 4) ALL TAGS TO BE PREFIXED BY UNIT NO 45.

11 of 11
EM131-45--0118 1 05.02.15 05.02.15
VKS SCA SCA
.
All rights reserved
EM 131-45-0123 1
DOCUMENT NO. REV.
INDIA LTD
SHEET 1 OF 8

PROCESSDATAFORINSTRUMENTS

(CONTROLVALVEDATASHEET)
1 05.02.2015 05.02.2015 Clients Comment6s Incorporated VKS SCA SCA

All rights reserved
PDIL PROJECT : BEDP FOR LPG MOUNDED BULLETS EM131-45-0123 1
NOIDA PLANT : NUMALIGARH REFINERYLIMITED, DOCUMENT NO. REV.
NUMALIGARH
SHEET 2 of 8

REV.NO. 1 1 1
TAG NO. ROV-3001 ROV-3002 ROV-3003
P&ID NO. EM131-45-0021 EM131-45-0021 EM131-45-0021
LOCATION : EQPT./LINE NO. 12-P-45-3008-B1A 6-P-45-3007-B1A 6-P-45-3009-B1A
SERVICE : ISOLATION OF LIQUID ISOLATION OF ISOLATION OF

LPG OUTLET FROM LIQUID LPG INLET TO VAPOUR BALANCE
BULLET BULLET LINE
FLUID / FLUID STATE : LPG/LIQ. LPG/LIQ. LPG/VAP.
INLET TEMPERATURE MAX : (0C) 40 40 40
0
DESIGN : ( C) (-)27/55 -/65 (-)27/55
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) 3.35 / - / 7.51 -/-/20.8 3.35 / - / 7.51
DESIGN (SHUT OFF),Kg/cm2(G) 14.5 30.587 14.5
3
FLOW RATE M / hr LIQ. VAP/GAS LIQ VAP /GAS LIQ VAP/G
AS
MIN
NOR 267 13.04 267
T/Hr
MAX 294 294
2
PRESSURE DROP FOR : Kg/cm
MIN FLOW MIN. MIN. MIN.
NOR FLOW MIN. MIN. MIN.
MAX FLOW MIN. MIN. MIN.
FLUID PROPERTIES @ OP. COND. :
SPECIFICE GRAVITY OR DENSITY( 0.5-0.57 0.5-0.57 6.64-16.5
Kg/m3) AT P.T.
VISCOSITY (MIN / MAX ) CP 0.113/ 0.152 0.113/0.152 0.113/0.152
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
ENERGY FAILURE POSITION CLOSE CLOSE CLOSE
LEAKAGE CLASS VI( TSO) VI(TSO) VI (TSO)
HAND WHEEL YES / NO YES YES YES
SET POINT FOR PR. REGULATING VALVE N.A. N.A. N.A.
INLET / OUTLET PIPE SIZE INCHES 12 /1 2 6 / 6 6 / 6
RATING & END CONNECTION 300 # RTJ 300 # 300 #
VALVE TYPE BALL BALL BALL
SOLENOID VALVE YES YES YES
LIMIT SWITCHES POSITION (OPEN / CLOSE) YES YES YES
POSITION INDICATOR / TRANSMETER
ACTION SLOW OPENING ( SLOW OPENING ( SLOW OPENING (
ADJUSTABLE) QUICK ADJUSTABLE) QUICK ADJUSTABLE) QUICK
CLOSING CLOSING CLOSING
FIRE SAFE TYPE VALVE (YES/NO) YES YES YES
Note- 1 ROV on all Liquid LPG service are Tight Shut Off ( Leakage Class VI)
2 Shut off pressure shall be consider 125% of max pressure , shall be confirm by pump vendor.
3 Bullets outlet line flange RTJ type shall be used.
4 Min flow of pump shall be consider 30 % of Normal flow, shall be confirm by pump vendor
5 All tags. to be prfixed by unit nos. 45.
1 05.02.2015 Clients Comments Incorporated VKS SCA SCA
REV REV. DATE PURPOSE PREPARED REVIEWED APPROVED
Ref: Dept. Procedures: 02-00PR-0010 All rights reserved PDS : 106 R3
NUMALIGARH
SHEET 3 of 8

REV.NO. 1 1 1
P&ID NO. EM131-45-0021 EM131-45-0021 EM131-45-0021
SERVICE : ISOLATION OF ISOLATION OF ISOLATION OF LIQUID

RECIRCUALTION LINE LIQUID LPG OUTLET LPG INLET TO BULLET
FROM BULLET
FLUID / FLUID STATE : LPG/VLIQ. LPG/LIQ. LPG/LIQ.
0
INLET TEMPERATURE MAX : ( C) 40 40 40
0
DESIGN : ( C) (-)27/55 (-)27/55 -/65
INLET PRESSURE MIN/NOR/MAX,Kg/cm2(A) 3.35 / - / 7.51 3.35 / - / 7.51 -/-/20.8
2
DESIGN (SHUT OFF),Kg/cm (G) 23.5 2) 14.5 30.587
3
FLOW RATE M / hr LIQ. VAP/GAS LIQ VAP /GAS LIQ VAP/GAS
MIN
NOR 267 267 13.04
T/Hr
MAX 294 294
2
Kg/m3) AT P.T.
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
INLET / OUTLET PIPE SIZE INCHES 8 /8 12 /12 6 / 6
RATING & END CONNECTION 300 # 300 # RTJ 3) 300 #

NUMALIGARH
SHEET 4 of 8

REV.NO. 1 1 1
P&ID NO. EM131-45-0021 EM131-45-0021 EM131-45-0022
SERVICE : ISOLATION OF ISOLATION OF ISOLATION OF LIQUID

VAPOUR BALANCE RECICULATION LINE LPG OUTLET FROM
LINE BULLET
FLUID / FLUID STATE : LPG/VAP. LPG/LIQ. LPG/LIQ.
0
0
DESIGN : ( C) (-)27/55 (-)27/55 (-)27/55
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) 3.35 / - / 7.51 3.35 / - / 7.51 3.35 / - / 7.51
2
DESIGN (SHUT OFF),Kg/cm (G) 14.5 23.5 2) 14.5
3
MIN
NOR 267 267 13.04
T/Hr
MAX 294 294
PRESSURE DROP FOR : Kg/cm2
Kg/m3) AT P.T.
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
INLET / OUTLET PIPE SIZE INCHES 6 / 6 8 / 8 12 / 12
RATING & END CONNECTION 300 # 300 # 300 # RTJ 3)

NUMALIGARH
SHEET 5 of 8

REV.NO. 1 1 1
P&ID NO. EM131-45-0022 EM131-45-0022 EM131-45-0022
SERVICE : ISOLATION OF ISOLATION OF ISOLATION OF

VAPOUR BALANCE LIQUID LPG INLET TO RECIRCULATION LINE
LINE BULLET
FLUID / FLUID STATE : LPG/VAP. LPG/LIQ. LPG/LIQ.
0
0
DESIGN : ( C) (-)27/55 -/65 (-)27/55
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) 3.35 / - / 7.51 -/-/20.8 3.35 / - / 7.51
2
DESIGN (SHUT OFF),Kg/cm (G) 14.5 30.587 23.5 2)
3
MIN
NOR 267 13.04 267
T/Hr
MAX 294 294
Kg/m3) AT P.T.
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
RATING & END CONNECTION 300 # 300 # 300 #

NUMALIGARH
SHEET 6 of 8

REV.NO. 1 1 1
P&ID NO. EM131-45-0022 EM131-45-0022 EM131-45-0022
SERVICE : ISOLATION OF LIQUID ISOLATION OF ISOLATION OF LIQUID

LPG OUTLET FROM VAPOUR BALANCE LPG INLET TO BULLET
BULLET LINE
FLUID / FLUID STATE : LPG/LIQ. LPG/VAP. LPG/LIQ.
0
0
DESIGN : ( C) (-)27/55 (-)27/55 -/65
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) 3.35 / - / 7.51 3.35 / - / 7.51 -/-/20.8
2
DESIGN (SHUT OFF),Kg/cm (G) 14.5 14.5 30.587
3
MIN
NOR 267 267 13.04
T/Hr
MAX 294 294
Kg/m3) AT P.T.
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
RATING & END CONNECTION 300 # RTJ 3) 300 # 300 #

NUMALIGARH
SHEET 7 of 8

REV.NO. 1 1 1
TAG NO. ROV-3016 ROV-3017 ROV--3018
P&ID NO. EM131-45-0022 EM131-45-0023 EM131-45-0023
SERVICE : ISOLATION OF ISOLATION OF PUMP ISOLATION OF PUMP

RECIRCULATION LINE DISCHARGE LINE DISCHARGE LINE
FLUID / FLUID STATE : LPG/LIQ. LPG/LIQ. LPG/VAP.

0
0
DESIGN : ( C) (-)27/55 (-)27/55 (-)27/55
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) 3.35 / - / 7.51 15.5/ - / 17.603 15.22 / - / 21.48
2
DESIGN (SHUT OFF),Kg/cm (G) 23.5 2) 22 2) 26.8 2)
3
MIN
NOR 267 267 27
MAX 294 294

Kg/m3) AT P.T.
MOL. WEIGHT 52.8 52.8 52.8
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
ENERGY FAILURE POSITION CLOSE OPEN OPEN
INLET / OUTLET PIPE SIZE INCHES 8 /8 8 / 8 6 / 6
ACTION SLOW OPENING ( QUICK CLOSING ( QUICK CLOSING (
ADJUSTABLE) QUICK ADJUSTABLE) SLOW ADJUSTABLE) SLOW
CLOSING OPENING OPENING

NUMALIGARH
SHEET 8 of 8

REV.NO. 1 1 1
TAG NO. FV-3001 FV-3001 PCV--3021
P&ID NO. EM131-45-0023 EM131-45-0023 EM131-45-0025
LOCATION : EQPT./LINE NO. 6-P-45-3057-B1A 3-P-45-3059-B1A 2-AI-45-3003-A3A
SERVICE : MIN. FLOW FOR PUMP MIN. FLOW FOR INSTRUMENT AIR FOR
( 45-PA-CF-101A/B) PUMP SPRINKLER SYSTEM
( 45-PA-CF-102A/B)
FLUID / FLUID STATE : LPG/LIQ. LPG/LIQ. AIR/GAS.
INLET TEMPERATURE MAX : (0C) 40 40 AMB.
0
DESIGN : ( C) (-)27/55 (-)27/55 65
2
INLET PRESSURE MIN/NOR/MAX,Kg/cm (A) / - / 15.5 15.22/ - / 19.38 5.5/ 7.5 / 12.5
DESIGN (SHUT OFF),Kg/cm2(G) 18.4 2) 23.5 2) 12.5
3
FLOW RATE M / hr LIQ. VAP/GAS LIQ VAP /GAS
MIN
NOR 72 4) 8.1 4)
MAX 80 4)
2
MIN FLOW MIN.
NOR FLOW 7.99 7.71 MIN.
MAX FLOW MIN.
3
SPECIFICE GRAVITY OR DENSITY( 0.5-0.57 0.5-0.57 6.5-8.1 Kg /M
Kg/m3) AT P.T.
VISCOSITY (MIN / MAX ) CP 0.113/ 0.152 0.113/0.152 0.02 cst
MOL. WEIGHT 52.8 52.8 28.85
CP / CV
COMP. FACTOR
ADDITIONAL FEATURES
ENERGY FAILURE POSITION OPEN OPEN OPEN
LEAKAGE CLASS
SET POINT FOR PR. REGULATING VALVE N.A. N.A. BY VENDOR
INLET / OUTLET PIPE SIZE INCHES 6 /6 3 /3 2/2
VALVE TYPE GLOBE GLOBE GLOBE
SOLENOID VALVE YES YES NO
LIMIT SWITCHES POSITION (OPEN / CLOSE) YES YES NO
ACTION QUICK OPENING ( QUICK OPENING ( Self Regulating
ADJUSTABLE) SLOW ADJUSTABLE) SLOW
CLOSING CLOSING

EM 131-45-0124 1
DOCUMENT NO. REV.
INDIA LTD
SHEET 1 OF 6

PROCESSDATAFORINSTRUMENTS
(SAFETYRELIEFVALVEDATASHEET)

All rights reserved
NUMALIGARH
Page 2 of 6

PRESSURE SAFETY VALVE
REV.NO. 1 1 1
TAG NO. PSV-3001 A/B PSV-3002 A/B PSV-3003 A/B
P&ID NO. EM131-45-021 EM131-45-021 EM131-45-022
SERVICE PR. SAFETY RELIEF PR. SAFETY PR. SAFETY
RELIEF RELIEF
LOCATION : EQUIP. NO. / LINE NO. 45-VV-101( N8A/B) 45-VV-102( N8A/B) 45-VV-103( N8A/B)
SAFETY VALVE TYPE BELLOW BELLOW BELLOW
Inlet size/Outlet size BY VENDOR BY VENDOR BY VENDOR
FLUID & STATE LPG/VAPOUR LPG/VAPOUR LPG/VAPOUR
PRESSURE Kg/cm2 A 3.35-7.51 3.35-7.51 3.35-7.51
O
TEMPERATURE C 10-40 10-40 10-40
DESIGN CONDITIONS
SET PRESSURE Kg/cm2 g 14.5 14.5 14.5
BACK PRESSURE (CONSTANT) Kg/cm2 g
BACK PRESSURE ( VARIABLE) Kg/cm2 g 0.62- 2.26 2) 0.62- 2.26 2) 0.62- 2.26 2)
BACK PRESSURE ( TOTAL) Kg/cm2 g
% OVER PRESSURE 21% 21% 21%
Relief Temperature AT (set + over pr.) OC 65 65 65
PHASE
LIQUID
RELIEVING CAPACITY Kg/hr
DENSITY AT SET COND. Kg/m3
VISCOSITY CP
% FLASH
GASEOUS
RELIEVING CAPACITY Kg/hr 62161 62161 62161
MOLECULAR WT. 52.8 52.8 52.8
LATENT HEAT AT SET COND. Kcal/kg 64 64 64
COMPRESSIBILITY FACTOR (Z) 0.84 0.84 0.84
SPECIFIC HEAT RATIO (CP / CV) 1.17 1.17 1.17
SOURCE OF OVER PRESSURE
EXTERNAL FIRE EXTERNAL FIRE EXTERNAL FIRE
VALVE DISCHARGE TO FLARE HEADER FLARE HEADER FLARE HEADER
NOTE1)Byvendordetailedengineering.
2)Allresidualengineeringtobecarriedonduringdetailengineering.
3)Vapourexpansioninblockedlineduetofire.
4)Alltagstobeprefixedbyunitno45.

REV REV. DATE EFF. DATE PURPOSE PREPD REVWD
APPD
All right reserved

NUMALIGARH
Page 3 of 6

REV.NO. 1 1 1
TAG NO. PSV-3004 A/B PSV-3005 PSV-3006
P&ID NO. EM131-45-022 EM131-45-022 EM131-45-023
SERVICE PR. SAFETY RELIEF PR. SAFETY PR. SAFETY RELIEF
RELIEF
LOCATION : EQUIP. NO. / LINE NO. 45-VV-104( N8A/B) 45-VV-105 6-P-45-3005-B1A
Inlet size/Outlet size BY VENDOR 1.5/- BY VENDOR
FLUID & STATE LPG/VAPOUR MERCAPTAN& LPG/VAPOUR
NITROGEN/
VAPOUR
OPERATING CONDITIONS By CLIENT
PRESSURE Kg/cm2 A 3.35-7.51 3.35-7.51
O
TEMPERATURE C 10-40 10-40
DESIGN CONDITIONS
SET PRESSURE Kg/cm2 g 14.5 14.5
BACK PRESSURE ( VARIABLE) Kg/cm2 g 0.62- 2.26 2) 0.62- 2.26 2)
% OVER PRESSURE 21% 21 %
Relief Temperature AT (set + over pr.) OC 65 65
PHASE
LIQUID
VISCOSITY CP
% FLASH
GASEOUS
RELIEVING CAPACITY Kg/hr 62161 2) 3)
MOLECULAR WT. 52.8 52.8
LATENT HEAT AT SET COND. Kcal/kg 64
COMPRESSIBILITY FACTOR (Z) 0.84 0.84
SPECIFIC HEAT RATIO (CP / CV) 1.17 1.17
SOURCE OF OVER PRESSURE EXTERNAL FIRE EXTERNAL FIRE BLOCK DISCHARGE
REV REV. DATE EFF. DATE PURPOSE

PREPD REVWD APPD
All right reserved

NUMALIGARH
Page 4 of 6

REV.NO. 1 1 1
TAG NO. PSV-3007 A/B TSV-3001 TSV-3002
P&ID NO. EM131-45-024 EM131-45-023 EM131-45-023
SERVICE PR. SAFETY RELIEF THERMAL RELIEF THERMAL RELIEF
LOCATION : EQUIP. NO. / LINE NO. 45-VV-106 6-P-45-3001-B1A 8-P-45-3006-B1A

FLUID & STATE LPG/VAPOUR LPG/LIQUID LPG/LIQUID
PRESSURE Kg/cm2 A 3.35-7.51 20.8 15.22-19.38
O
TEMPERATURE C 10-40 40 10-40
DESIGN CONDITIONS
SET PRESSURE Kg/cm2 g 14.5 26 24.3
PHASE
LIQUID
RELIEVING CAPACITY ( AS PER API 520) 2) 2)
Kg/hr
DENSITY AT SET COND. Kg/m3 0.50-0.57 0.50-0.57
VISCOSITY CP 0.113-0.152 0.113-0.152
% FLASH
GASEOUS
RELIEVING CAPACITY Kg/hr 290
MOLECULAR WT. 52.8
LATENT HEAT AT SET COND. Kcal/kg 64
COMPRESSIBILITY FACTOR (Z) 0.84
SPECIFIC HEAT RATIO (CP / CV) 1.17
SOURCE OF OVER PRESSURE EXTERNAL FIRE THERMAL THERMAL
EXPANSION EXPANSION

PREPD REVWD APPD
All right reserved

NUMALIGARH
Page 5 of 6

REV.NO. 1 1 1
TAG NO. TSV-3003 TSV-3004 TSV-3005
P&ID NO. EM131-45-023 EM131-45-023 EM131-45-023
SERVICE THERMAL RELIEF THERMAL RELIEF THERMAL
RELIEF
LOCATION : EQUIP. NO. / LINE NO. 8-P-45-3044-B1A 12-P-45-3003-B1A 6-P-45-3043-B1A
FLUID & STATE LPG/LIQUID LPG/LIQUID LPG/LIQUID
PRESSURE Kg/cm2 A 15.5 3.35-7.51 15.2-19.38
O
TEMPERATURE C 40 10-40 10-40
DESIGN CONDITIONS
SET PRESSURE Kg/cm2 g 19.4 14.5 24.3
PHASE
LIQUID
RELIEVING CAPACITY ( AS PER API 520) 2) 2) 2)
Kg/hr
DENSITY AT SET COND. Kg/m3 0.50-0.57 0.50-0.57 0.50-0.57
VISCOSITY CP 0.113-0.152 0.113-0.152 0.113-0.152
% FLASH
GASEOUS
MOLECULAR WT.
LATENT HEAT AT SET COND. Kcal/kg
COMPRESSIBILITY FACTOR (Z)
SPECIFIC HEAT RATIO (CP / CV)
SOURCE OF OVER PRESSURE THERMAL THERMAL THERMAL
EXPANSION EXPANSION EXPANSION
VALVE DISCHARGE TO FLARE HEADER FLARE HEADER FLAREHEADER

PREPD REVWD APPD
All right reserved

NUMALIGARH
Page 6 of 6

REV.NO. 1
TAG NO. PSV-3008 A/B
P&ID NO. EM131-45-023
SERVICE PR. SAFETY RELIEF
LOCATION : EQUIP. NO. / LINE NO. 45-PA-112 A/B

SAFETY VALVE TYPE
Inlet size/Outlet size BY VENDOR
FLUID & STATE MERCAPTAN &
VAPOUR
PRESSURE Kg/cm2 A
O
TEMPERATURE C
DESIGN CONDITIONS
SET PRESSURE Kg/cm2 g
BACK PRESSURE ( VARIABLE) Kg/cm2 g
% OVER PRESSURE
Relief Temperature AT (set + over pr.) OC
PHASE
LIQUID
RELIEVING CAPACITY ( AS PER API 520)
Kg/hr
VISCOSITY CP
% FLASH
GASEOUS
MOLECULAR WT.
LATENT HEAT AT SET COND. Kcal/kg
COMPRESSIBILITY FACTOR (Z)
SPECIFIC HEAT RATIO (CP / CV)
SOURCE OF OVER PRESSURE
VALVE DISCHARGE TO

PREPD REVWD APPD
All right reserved

EM 131-45-FL-9501 0
Sheet 1 of 2
EFFLUENTDISPOSALSYSTEMANDADEQUACYOFTHE
EXISTINGETP
0 05.01.2014 05.01.2014 Issued For Client Comments VKS SCA SCA

EM131-45-FL-9501 0
PROJECT: BEDP FOR LPG MOUNDED BULLETS,
NRL REFINERY Document No. Rev.
Sheet 2 of 2
LIQUID EFFLUENTS
Water coming with LPG shall be drained to drain vessel, and any dissolve LPG in
drain water shall be vented to flare in vapour form and water is drained to a Shallow
Sump (RCC) & finally to the storm sewer.
LPG pump drain is to be connected to Drain vessel (45-VV-106), so that LPG in
vapour form is vented to Flare Header.
In view of above, no effluent is sent to Existing Effluent Treatment Plant & hence Load
of .Existing Effluent Treatment Plant is not increased.
Hence Existing Effluent Treatment Plant is Adequate due to Installation of Mounded
Bullets.

Allrightsreserved
EM 131-45-FL-9502 0
Sheet 1 of 2

FLAREADEQUECY

0 05.01.2015 05.01.2015 Issued For Client Comments VKS SCA SCA

EM131-45-FL-9502 0
PROJECT: BEDP FOR LPG MOUNDED BULLETS,
Sheet 2 of 2

FLAREADEQUECY
Details of existing flare header (Bullet header to be connected with existing header)
Size of existing flare header 24
Operating / Design temp of flare header Amb /( 65 /-27 0C )
Operating/ Design Pressure of flare header 0.2-1.7/4.5 Kg/cm2g
Normal/Max Back Press - /1.7Kg/cm2g
Existing load of flare header 162029 Kg/Hr
Installation of mounded bullets for the fire case load comes out 62161 Kg/Hr with
molecular weight 52.8 7& flare size 18.
All PSV/TSV discharge shall be routed to the new flare header which will be connected
to existing flare header
Hence existing flare header is Adequate due to Installation of Mounded Bullets.

Allrightsreserved
1
INDIA LTD
CHAPTER -2
MECHANICAL

All rights reserved
EM00131/PNMP/T/1 0
PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO REV
SHEET 1 OF 42

DESIGN PHILOSOPHY - PIPING
NEW MOUNDED BULLET AT
NUMALIGARH REFINARY LIMITED

ASSAM
0 12-02-15 Issued for comments & Approval AK SKM PK

REV DATE EFF DATE PURPOSE PREPD REVWD APPD

EM00131/PNMP/T/1 0
DESIGN PHILOSOPHY PIPING
NEW MOUNDED BULLET AT DOCUMENT NO REV
NUMALIGARH REFINARY LTD.- ASSAM SHEET 2 of 42

CONTENTS
SECTION DESCRIPTION SHEET NUMBER

NUMBER
1.0 Scope 3
2.0 Design Philosophy 4
3.0 Codes, standards and supplementary 5

specifications
4.0 General Design 6
5.0 Design Philosophy / Criteria General 7
5.1 Equipment Layout 7
5.2 Pipe ways/ Rack Piping 14
5.3 Offsite & Yard Piping 21
5.4 Flare Piping 21
5.5 Sample Connections 22
5.6 Vents and Drains 22
5.7 Line Strainers 23
5.8 Spectacle Blinds 23
5.9 Flexibility Analysis and Supporting 23
5.10 Personnel Protection 27
5.11 Mechanical Handling 27
6.0 Materials 27
7.0 Painting 40
8.0 Welding 41

EM00131/PNMP/T/1 0

1.0 SCOPE
The scope of this document is pertaining to the Piping design philosophy; norms .and specific
requirements which shall be used for the preparation of BEDP for new mounded bullet
installation inside the Numaligarh Refinary Limited Assam.
1.1 Applicable Standard & Codes
Standard No. Title
ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings

ASME/ANSI B16.9 Steel Butt-Welding Fittings
ASME/ANSI B16.10 Face to Face and End to End Dimensions of Valves
ASME/ANSI B16.11 Forged Fittings Socket Welded and Threaded -
ASME/ANSI B16.20 Metallic Gaskets for Pipe Flanges Ring Joint, Spiral Wound,
and Jacketed.
ASME/ANSI B16.21 Non-Metallic Flat Gaskets for Pipe Flanges
ASME/ANSI B16.25 Butt-Welding Ends
ASME/ANSI B16.34 Valves Flanged, Threaded Welding End.
ASME/ANSI B16.47 Large Diameter Steel Flanges
ASME/ANSI B31.1 Power Piping
ASME/ANSI B31.3 Process Piping.
ASME/ANSI B31.5 Refrigeration Piping
ASME/ANSI B36.10M Welded and Seamless Wrought Steel Pipe.
ASME/ANSI B36.19M Stainless Steel Pipe
API 6D Specification for Pipe Line Valves (Gate, Plug, Ball and Check
Valves).
API 6FA Fire Test for Valves.
API 501 Specifications for Metallic Gaskets for Refinery Piping.
API 594 Check Valves:, Wafer-Lug and double flanged type
API 598 Valve Inspections and Testing.
API 599 Steel Plug Valves Flanged and Butt-weld ends
API 600 Steel Gate Valves Flanged and Butt-weld ends
API 602 Compact Carbon Steel Gate Valves
API 603 Class 150 Corrosion Resistant Flanged End gate valves.
API 604 Ductile Iron gate valves flanged ends.
API 606 Compact C.S. Gate Valve extended body.
API 607 Fire Test for soft seated Ball Valve.
API-608 Metal Ball Valves, Flanged, Threaded & BW Ends.
API 609 Butterfly Valves, Lug type & Wafer type.
IBR Indian Boiler Regulations
AWWA C207-D Large Dia. Steel Flanges (Ring Type).
EJMA Expansion Joints Manufacture Association.
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 & Unions
MSS SP 43 Wrought Stainless Steel Butt-weld Fitting
MSS SP 45 By-pass and Drain Connection.

EM00131/PNMP/T/1 0

NACE MR0175-94 Sulphide Stress Cracking resistant Metallic Material
NFPA National Fire Protection Association.
EN 10204 Metallic Products - Types of Inspection documents
OISD 2014 (Latest) Oil Industry safety Directive (Latest).
2.0 DESIGN PHILOSOPHY
2.1 General
2.1.1 Piping systems shall be in accordance with Clause 1.1, which permits the use of the
following specifications:
ASME B31.3 Process Piping.

OISD (Latest).
Materials, design, construction, testing and inspection shall be fully in accordance with the
selected specification.
2.1.2 The dimensions, manufacturing tolerances and marking of ferrous and non ferrous piping
components shall conform to the applicable standards .The design shall comply with all
applicable codes, laws and statutory regulations. The Detail Designing shall optimize the
layout with the approval of the owner and include any changes resulting from HAZOP
studies and taking into consideration the following :
i) General site layout taking into account the topographical geo-technical aspect of the
site.
ii) Access for maintenance and fire appliances.
iii) The interdependency of units and buildings with each other within the complex.
iv) Safety escape routes for personnel based on emergency or disaster management
plans in the event of environmental upset or fire.
v) Suitable drainage system of Project site.
2.1.3 Material of construction shall be suitable for specified process duty (both normal and
abnormal operations) and have a projected life and corrosion/ erosion allowance in
excess of minimum life of the project. Piping materials specified in existing piping
materials specification for the LPG SPHERE shall be used for selection of material of
construction of major services.
All materials under steam service shall be supplied with proper certificates in prescribed
forms
2.1.4 Design Pressure

The design pressure of each component in a piping system shall be the most severe
condition of the followings:
i) Design pressure of equipment to which it is connected

EM00131/PNMP/T/1 0

ii) Set pressure of a pressure relieving device which protects the system
ii) Shutoff discharge pressure of a centrifugal pumps, not protected by a pressure relieving
device
If the shutoff discharge pressure is unknown, it may be determined by the largest of the
followings:
a) 1.2 times the differential pressure at normal flow plus the maximum pump suction
pressure
b) 1.1 times pump discharge pressure at normal flow
iv ) Full vacuum for a system operating below atmospheric pressure
2.1.5 Design Temperature
The design temperature of a piping system shall be the design temperature of
connected equipment, unless the equipment is obviously overrated.
For un-insulated piping, the design temperature may be determined in accordance with the
ASME B31.3.
The reducing coefficient for piping components not specified in the ASME B31.3 shall be
95% for the fluid temperatures over 37C.
The design temperature for a steam traced or steam-jacketed piping shall be the higher of
the followings:
I) Fluid temperature
II) Normal operating temperature of steam
3.0 CODES, STANDARDS AND SUPPLEMENTARY SPECIFICATIONS:

3.1 General
3.1.1 The latest edition of codes listed in clause 1.1 shall be applicable for piping system design,
materials, fabrication, manufacture, erection, construction and inspection etc. For any item
not covered in the list of codes and standards / International Standards / proven design
may be finalized based on discussion with OWNER/Consultant.
3.1.2 Where conflict occurs, the order of precedence shall be:
a) Statutory Regulations
b) National, International and Industry Standards and Codes of Practice.
c) Technical Specifications
d) Requirements of the Latest relevant OISD.
3.1.3 Standards, Codes and Supplementary Specifications for piping design shall be applied as
follows:
Plant layout and fire protection piping to Dangerous Goods Regulations and Storage and
Handling of Flammable and Combustible Liquids, supplemented where required by
NFPA (National Fire Protection Association) Code 30.

EM00131/PNMP/T/1 0
I) Process and utility piping to ASME B31.3 Process Piping.
II) Sour service piping to NACE (National Association of Corrosion Engineers)

specification MR0175.
III) Plant layout and fire protection piping to Dangerous Goods Regulations and
Storage and Handling of Flammable and Combustible Liquids, supplemented
where required by NFPA (National Fire Protection Association) Code 30.
Fire protection system shall be designed and installed in accordance with applicable
NFPA (National Fire Protections Associations) Codes.
IV) Piping fabrication tolerances to ASME B31.3 and PFI (Pipe Fabrication
Institute) practice ES-3.
V) Color coding for identification of piping material to PFI Practice ES-22/ as per
owner's approval.
VI) Pipe wall thicknesses shall be in accordance with ANSI B36.10 or

B36.19. Identification of Pipe Contents.
4.0 GENERAL DESIGN
4.1 Design
4.1.1 Flanges for process and utility piping shall be in accordance with ANSI B16.5 and ANSI
B16.47.
4.1.2 Wherever possible all purchased equipment shall be supplied with flanges that comply with
ANSI B16.5.
4.1.3 The minimum size of piping to be used in pipe-racks shall be 2 NB.
4.1.4 With the exception of equipment connections the minimum size of piping shall be NPS.
4.1.5 Pipe sizes 1 , 2 , 3 and 5 NPS shall not be used except as connections to
purchased equipment.
4.1.6 Threaded pipe nipples between headers and vent, drain and instrument isolation valves
shall be Schedule 160 for CS and Schedule 80S for SS in the size range to 2 NPS.
4.1.7 Piping 2 NPS and above shall be butt-welded. All weld joints in piping 1 NPS and
below shall be socket welded using socket weld fittings.
4.1.8 In Class 600 and higher pressure rating double block and bleed valves shall be used for
systems open to atmosphere, such as vents and drains. Piping in hazardous service shall

EM00131/PNMP/T/1 0

have vents, drains and bleeds routed to a safe location. Category M substances shall be
vented to the flare system.
4.1.9 When a line of one material specification is connected to a line of higher material
specification, the connecting line shall be constructed of the higher material specification or
pressure rating up to & including the first block valve.
4.1.10 As a minimum, piping systems shall have isolation facilities as follows:
ASME B31.3 Category M service and Normal service (Class 900 and above) shall have
double block isolation valves with a downstream drop-out spool.
ASME B31.3 Normal service (Class 150 and 600) shall have a valve and downstream
spectacle blind.
ASME B31.3 Category D service shall have a valve and downstream spectacle blind.
Generally, equipment shall have provision for isolation of piping to each equipment
connection by means of valving and /or blinds as determined by service conditions.
4.1.11 Piping flexibility shall be achieved by the use of piping offsets and expansion loops
whenever possible. Expansion joints shall not be used without written permission of the
Owner.
5.0 DESIGN PHILOSOPHY / GENERAL CRITERIA
5.1 Equipment Layout
5.1.1 Basis of Equipment Layout
Equipment Layout shall be finalised based on the following data :
a) Site Location Plan

b) P&I Ds
c) Equipment Data Sheets
d) Wind Direction
e) Overall Plot Plan
f) Safety Distance and Specific Distance mentioned in Piping Design Basis and as
per statutory requirements.
5.1.2 Development of Equipment Layout
The following aspects shall be considered during development of equipment layout.
a) Process Requirement -Proper interconnection between equipment as per P&I Ds

to achieve the intended process parameters.
b) Economy of Piping material- Minimize the quantity of costly piping.


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c) Erection & Construction requirements:
Erection scheme and schedule of all equipment must be considered during

equipment layout to have smooth erection mainly in case of , heavy equipments
like thick walled Bullets, space for laying tall Vessels, approach roads for cranes /
derricks for lifting the column or reactors and requirement of special foundation /
pile etc.
d) Operation and Maintenance Requirement
- Overhead and side clearances for pumps.

- Horizontal & overhead clearances for easy movement of working personnel.
- Crane approaches for all the heavy equipments.
- Provision of monorail for pumps and compressor
- Provision 'of EOT crane for compressors.
- Provision of operator's cabin.
e) Similar equipment grouping - All pumps & Compressors etc. should be grouped
together for convenience of maintenance and safety wherever feasible.
f) The technological structures should be interconnected for easy movement of

operational personnel.
g) U/G piping corridors for main headers should be marked in equipment layout for
all underground piping.
5.1.3 Plant Layout & Design guidelines
5.1.3.1 General
The plant layout shall be based on ensuring adequate access, to allow construction,
inspection, maintenance and operation to be performed in a safe and efficient manner.
The alignment of equipment and pipe shall offer an organised appearance. The layout
shall be in accordance with, but not limited to the design practices described in this
criteria.
Where dynamic loading, limited pressure drop or other severe service condition applies,
particular care shall be taken in routing pipe lines.
Flushing connections shall be provided on all lines containing flammable or toxic

material, slurries, and materials which solidify when the line is dead. Sufficient
Nitrogen purging points shall also be provided. Supply piping of fuel gas shall be
arranged for equal flow distribution.
Trolley beams, pipe davits, shall be provided with appropriate removable hoists
mechanism for charging and discharging catalysts, chemicals, packing rings etc.

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Piping and all other services shall be arranged so as to permit ready access of Cranes for
removal of Equipment for inspection and servicing.
All utility and process piping shall be located above ground, and major lines shall be
located in overhead pipe ways.
The following lines may be buried providing they are adequately protected.
i) Fire water mains.

Ii ) Drain and Sewer (oily and chemical) lines from catch basin to mains and
manholes.
Lines that must be run below grade, and must be periodically inspected or replaced, shall
be identified on the P & IDs; these lines must be placed in covered concrete trenches.
Sleeper-ways shall not be used in process areas where they may block access for
personnel and equipment.
Fire protection system shall be designed as per NFPA, / TAC/ OISD and as per statutory
requirements.
Drip legs and dead ends shall be avoided, especially for piping where solids or fluids may
congeal from corrosive condensate.
Where sleeper ways are used the elevations shall be staggered to permit ease of crossing
or change of direction at intersections. Flat turns may be used when entire sleeper ways
change direction. Flat turns must not be used within pipe racks.
Locate flare stacks upwind of process units, with a minimum distance of 90 m from process
equipment, tanks and cooling towers.
Spacing and routing of piping shall be such that expanding/contracting lines (including
insulation) will not clash with adjacent lines, structures, instruments and electrical
equipment during warm up and cool down.
Piping to be sloped shall be indicated on the P&I Ds.
5.1.3.2 Pipe-Rack/T-Post/Small Portals
In general, equipment layout shall be prepared considering straight pipe rack, however
other shapes like L / T / U / H / Z etc can also be considered based on area available.
The width of the rack shall be 3M, single bay having four (3) tiers maximum. In general,
the spacing between pipe rack portals (span) shall be taken as 8 M for main rack. However
it can be decreased to 6 M depending on the size/number of the pumps to be housed
below pipe rack. Intermediate Beams between two portals shall be provided to support
smaller pipes <= 2". 20% extra space shall be provided on the pipe rack and portals on
each tier for future expansion/modifications.

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-Clearance beneath pipe rack shall be 3.8 M minimum.
-Road clearance shall be 9 M minimum wherever heavy duty crane movement is required
during construction and future maintenance.
-Road clearance shall be 7.5 M minimum for main roads.
-Road clearance shall be 5 M minimum for secondary roads.
-T-Portal's width shall not be more than 2.5 M and height shall not be less than.3.0 M
5.1.3.3 Pumps
Wherever practicable pumps shall be arranged in rows with the centre line of the discharge
on a common line. In general, pumps shall be kept inside the pipe rack. However in case of
smaller racks, pumps shall be kept on one side or outside the pipe rack to provide clear
access.
Pump foundation height shall be 300 mm above H.P.P.
Pumps which are handling hydrocarbon at temperature above 315C and pumps for which
specific notes are given in P&ID shall be necessarily housed outside the rack.
Gap between each pump foundation / and foundation of technical structure should be
sufficient for easy removal of equipment after piping. Clearance between two adjacent
pumps shall be such that clear 900 mm aisle is available.
All pumps not open to sky with motor rating >= 45 KW shall be provided with monorail. No
monorail should normally be provided for pumps outside rack and sufficient space below
rack shall be available for pump maintenance.
5.1.3.5 Clearance and Accessibility
5.1.3.5.1 Crane Access
Equipment, structures shall be arranged to permit crane access to service air coolers,
compressors and exchangers.
5.1.3.5.2 Access to Pumps
Clear access of 3.8M vertically and 4.5M horizontally shall be provided centrally under
main pipe rack for small mobile equipment to service pumps, wherever these are put under
pipe ways with prior specific approval. Pumps outside rack shall be approachable by small
cranes etc. from under the pipe rack.
5.1.3.5.3 Access to lower items to grade (Lowering Area)
Clear access shall be provided at grade on the access side for lowering external and
internal fittings from tall elevated equipment by providing pipe davits.

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5.1.3.5.4 Layout & Access Requirements for Platforms ladders and Stairs
For providing platform ladder & staircase following guidelines shall be followed.
- Two means of access (i.e. two ladders or one ladder and one stair case) shall be
provided at any elevated platform which serves three or more vessels & for B/L
valves operating platform.
- Platforms, ladders and stairways shall be the minimum, consistent with access and
safety requirements.
- Stairway for tanks to be provided on upstream of predominant wind direction.
i) Platform at elevated structure
a) Dual access (i.e. one staircase and one ladder) shall be provided at large
elevated structure if any part of platform has more than 22.65M (75 ft) of travel.
b) Mounded Bullet Top near Inlet of Vapour & Liquid shall have platforms with
interconnected walk-ways provided to service valving, and instruments. Access
requirements shall conform to paragraph (a) above.
ii) Platforms with stair access shall be provided for:
a) Location at which normal monitoring (once a day or more) is required or where

samples are taken.
b) Locations where vessels or equipment items need operator attention "such as

compressors, heaters, boilers etc.
iii) Platforms with ladder access shall be provided for:
a) Points which require occasional operating access including valves, spectacle

blind and motor operated valves, sampling points.
b) Man ways above grade on equipment.
iv) Ladder location
a) Wherever practicable, ladder shall be so arranged that users face equipment or

platform rather than facing open space.
b) Landings shall be staggered. No ladder shall be more than 6 M in one flight.

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5.1.3.6 Valves
5.1.3.6.1 Piping shall be so arranged that valves can be operated easily.

Frequently operated valves shall be located in such a way that the valves are easily
accessible from grade, platforms, stairs or ladders, and that the bottom of a hand wheel is
located less than 1.8 m above the operating floor level.
5.1.3.6.2 Other valves should also be accessible where they are located at more than 1.8 m above
the operating floor level. Chain-operated valves, shall not be used.
5.1.3.6.3 For valves in trenches, if hand wheels are located more than 300 mm below the cover
plate, the valves shall be provided with extension stems extending to within 100 mm below
the cover plate.
5.1.3.6.4 Manually operated valves, which are used in conjunction with locally mounted flow
indicators, shall be placed at the same operating level and located where the instrument
can be readily observed.
5.1.3.6.5 Double block valves with a bleeder connection shall be provided with interconnecting
piping where intolerable contamination could result from valve leakage.
5.1.3.6.6 Where block valves are installed in branch lines from headers, the valves shall be
located in horizontal runs at high points so that lines will drain both ways.
5.1.3.6.7 All valves shall be so installed that the stems are not below horizontal positions unless
otherwise specified.
5.1.3.6.8 All valves shown on the piping and instrument flow diagrams as located at nozzles of
equipment, such as towers and reservoirs, shall be connected directly to the nozzles.
5.1.3.6.9 Battery limit valves, if required, shall be grouped together and consideration shall be given
to provide a common operation platform.
5.1.3.6.10 Vessel nozzles located below the normal or emergency liquid level shall be provided with
the block valves as specified, if practical. Other vessel nozzles shall be provided with block
valves only if required for operation.
5.1.3.8 Control Valves
5.1.3.8.1 All control valves shall be easily accessible from grade or permanent platforms and
conveniently located for operations and maintenance.
5.1.3.8.2 Control valves shall be provided with block valves, a bypass valve and a drain valve.
Fitting (flange or pipe fitting) shall be provided between the control valve and the block
valves for easy maintenance. The drain valve shall be provided with the fittings (flange or
pipe fittings) upstream of the control valve.

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5.1.3.9 Block valves, bypass valve and drain valve may be omitted at the following
conditions:
1) Block valves
a) Where operating conditions are mild, and omission of the block valves will not
jeopardize safety or operability of the unit.
b) Where continuous operation using a bypass valve is impossible.
c) For the downstream block valve of control valve, where discharged to atmosphere.
2) Bypass valve
a) Where the block valve is omitted.

b) Where continuous operation using a bypass valve is impossible.
c) Where a globe valve is used instead of upstream block valve of a control valve, when
discharged to atmosphere.
3) Drain valve
Where operating conditions of piping for water, brine, nonflammable or nontoxic fluid are
mild.
5.1.3.10 Orifice
5.1.3.10.1 The length of straight run piping upstream and downstream of the orifice shall be in
accordance with API RP550, Manual on Installation of Refinery Instruments and Control
Systems, unless otherwise specified.
5.1.3.10.2 The straight run shall be designed for a beta ratio of 0.7. The smaller ratio may be used
where practical considerations preclude the longer straight run installation.
Orifice runs shall be located in the horizontal. Orifice flanges with a centre line elevation
over 4.5m above grade, including installed in pipe racks, shall be accessible from a
platform with permanent ladder.
5.1.3.10.3 Orifice taps shall be located as follows: (Please also refer specs. For Instrumentation)
i) Air, Gas and steam
Top vertical centerline (preferred)

45 degrees above horizontal centerline (alternate)
ii) Liquid
Horizontal centerline (preferred)

45 degrees below horizontal centerline (alternate)
iii) Tap orientation shall be shown on piping isometrics.
iv) Finally all orifice impulse tapping / spare tapping will have to be seal run

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5.2. Pipe Ways/Rack piping
5.2.1 Racks shall be designed to give the piping shortest possible run and to provide clear head
rooms over main walkways, secondary walkways and platforms.
5.2.2 Predominantly process lines are to be kept at lower tier and, utility & hot process lines on
upper tier.
5.2.3 Generally the top tier is to' be kept for Electrical (if not provided in underground trench as
per electrical design basis) and Instrument cable trays. Cable tray laying to take care of
necessary clearances for the fire proofing of structure.
5.2.4 Generally the hot lines and cold lines shall be kept apart in different groups on a tier. .
5.2.5 Generally the bigger size lines shall be kept nearer to the column.
5.2.6 Minimum spacing between adjacent lines shall be decided based on O.D of bigger size
flange'(minimum rating 300# to be considered), O.D of the smaller pipe, individual
insulation thickness and additional 25 mm clearance, preferably. Wherever even if flange is
not appearing the minimum spacing shall be based on above basis only. '
5.2.7 Actual line spacing, especially at 'L' bend and loop locations, shall take care of thermal
expansion / thermal contraction / non expansion of adjacent line. Non expansion / thermal
contraction may stop the free expansion of the adjacent line at "L' bend location.
5.2.8 Anchors on the racks are to be provided on the anchor bay, if the concept of anchor bay is
adopted. Otherwise anchors shall be distributed over two to three consecutive bays.
5.2.9 Anchors shall be provided within unit on all hot lines leaving the unit.
5.2.10 Process lines crossing units (within units or from unit to main pipe way) are normally
provided with a block valve, spectacle blind and drain valve. Block valves are to be
grouped and locations of block valves in vertical run of pipe are preferred. If the block
valves have to be located in an overhead pipe way, staircase access to platform above the
lines shall have to be provided.
5.2.11 Provision of block valves, blinds etc. shall be as per Process Design Basis and P & IDs.
5.2.12 All small bore piping shall be designed in a way so as to ensure adequate space for
maintenance and operation. For small bore piping intermediate support shall be provided in
between portals.
5.2.13 Stubs on sea water service shall be from top of main header.
Minimum branch size for tapping including for instruments e.g PG/ PTI TE etc. shall be of
3" NPD and 150 mm height on internal cement lined pipes.

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5.2.14 Aboveground lines shall be grouped to run on pipe racks or sleepers in so far as
practicable.
5.2.15 Hot lines on pipe racks or sleepers shall be grouped and expansion loops shall be nested
together. The number of expansion loops shall be kept to a minimum.
5.2.16 Piping handling corrosive fluids shall be run under piping handling non corrosive fluids,
and shall not, where possible, be run overhead across walkways or normal passages for
personnel.
5.2.17 All process and utility piping will be located aboveground within the plant battery limit,
except water mains.
5.2.18 All piping shall be arranged in horizontal banks, where possible, to facilitate supporting.
Banks running north-south shall be at different elevations from banks running east-west.
Exceptions are permitted to avoid unnecessary change in elevation at change of
direction or where essential to avoid pockets.
5.2.19 All piping shall be routed for the shortest possible run and have the minimum number of
Fittings consistent with provision for expansion and flexibility. All piping shall be
arranged in a neat manner, providing free access around all operating equipment.
5.2.20 Vertical lines at vessels shall run close to the vessel shell to facilitate supporting. The line
shall be arranged and grouped to allow the use of single support.
5.2.21 Lines carrying molten solids, slurries or highly viscous liquids shall have a sufficient
slope for each gravity flow.
5.2.22 The shortest and most direct layout possible shall be provided for gravity flow lines,
especially when the fluid is subject to solidification and when the differential pressure is
small.
5.2.23 Piping shall be arranged to facilitate handling of equipment for inspection or

maintenance.
5.2.24 Vapor collecting system shall be routed so that the vapor rises continuously from the
vessel being vented to a higher point without pocketing.
5.2.25 Pockets shall be avoided in lines, particularly those carrying corrosive chemicals, slurries,
vents, blow down lines, etc.
5.2.3 Pump Piping
5.2.3.1 Pump drives shall have clear access.

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5.2.3.2 Pump suction piping shall be as short as possible and shall be arranged with particular
care to avoid vapor pockets.
5.2.3.3 Reducers immediately connected to the pump suction shall be eccentric type flat side up to
avoid the accumulation of gas pocket. For end suction pumps, elbows shall not be directly
connected to the suction flange. A straight piece minimum 3 times the line size shall have
to be provided at the suction nozzle.
5.2.3.4 Pump discharge check valve if installed in vertical lines shall be fitted with a drain
connection as close as possible downstream of the valve.
When a suction vessel operates under vacuum, the vent connection of the pump has to be
permanently connected to vapour space of the suction vessel to allow possible filling of the
pump with liquid before it is started.
5.2.3.5 Unless otherwise specified T -type strainers shall be used on pump suction piping for sizes
2" and above.
5.2.3.6 Y-type strainers to be used for all sizes in steam services and for pump suction lines 1
and below.
5.2.3.7 All small bore piping connected to pump (drain to OWS & CBD, seat and gland leak drain)
shall have provision for break up flanges for removal of pumps.
5.2.3.8 Piping shall be so arranged that forces and moments imposed on the pump nozzle do not
exceed the allowable values as per API 610.
5.2.3.9 Pump discharge should preferably be routed away from the pump rather than towards the
motor side.
5.2.3.10 Pump cooling water connection shall be taken from the top of circulating cooling water
header.
5.2.4 Piping around Tanks Area
5.2.4.1 Nozzles for level controlling instruments shall be oriented within an angle not exceeding
60 degrees against the fluid inlet nozzles.
5.2.4.2 Nozzles shall be easily accessible from platforms or ladders, if provided with block
valves, sampling valves, instruments, and all other devices to be manually operated.
5.2.4.3 Fluid inlet nozzles shall be located as far apart as possible from fluid outlet nozzles.
5.2.4.4 Vessel working platforms where man ways and hand holes are located shall preferably be
provided with utility stations prescribed in paragraph 4.10.

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5.2.4.5 The first pipe support from tanks shall be located sufficiently away from the tank to prevent
damage caused by settling.
5.2.4.6 The number of pipelines in the tank dyke shall be kept' at minimum and shall be routed in
the shortest practicable way to main pipe track outside. the tank dyke, with adequate
allowance for expansion. With nozzle tank Dyke the piping connected to that tank shall only
be routed. Pad shall be provided at pipette sleeve interface at dyke wall entry point.
5.2.4.7 Manifolds shall be located outside the tank dyke & by the side of the roads, easily
accessible by the walkway.
5.2.4.8 Plug valves whenever specified shall be of pressure balance type.
5.2.4.9 Analysis shall be carried out to prevent damage to lines and tank connection caused by
tank settlement. If exceptionally high settlement is expected, Dressers coupling or
flexible ball joint may be provided, after necessary analysis.
5.2.4.10 Special consideration shall be given as regards to spacing of nozzles while installing
special item like hammer blind, MOV etc.
5.2.5 Steam Piping - Indian Boiler Regulations (IBR)
Generally steam lines with conditions listed below fall in the scope of IBR.
- Lines having design pressure (maximum working pressure) Above 3.5 Kg/cm2 (g)
- Line sizes above 10" inside diameter having design pressure 1.0 Kg/cm2 (g) & above.
- Lines with pressure less than 1.0 Kg/cm2 (g) are excluded.
- Users of steam like steam tracing lines, jacket of the steam jacketed lines, steam
heating coil within the equipment are excluded from IBR scope.
- Boiler feed water lines to steam generator, condensate lines to steam generator and
flash drum as marked in P&I D shall be under purview of IBR.
IBR requirements (in brief)
a) All materials used on lines falling under IBR must be accompanied with IBR
Inspection Certificate in original. Alternatively, photocopy of the original certificate
duly countersigned and attested by local IBR inspector is acceptable. Whereas for
supply, only IBR is the inspection authority.
b) Drawings like General Arrangement Drawings (GAD) and system isometrics / line
wise isometrics of lines falling under IBR must also be approved by IBR authority
of State in which the system is being installed.
c) All welders used on fabrication of IBR system must possess IBR welding
qualification certificate.

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d) IBR system must be designed to comply IBR regulations as well as ASME B31.3.
All design calculations towards the same must be approved by IBR authority.
e) IBR approval is obtained with requisite fees payable to Indian Boiler Board of the
State concerned.
f) Steam generators (boilers/heat exchangers) shall require exclusive IBR approval

along with its integral piping up to the final isolation valve.
g) The discretion of IBR authority of state is final and binding for the above cases.
5.2.6 Steam Header & Supply Lines / Steam and Condensate Systems
5.2.6.1 Steampipingshallbedesignedtohavecompletecondensateremoval.Driplegsshallbe
providedwithsteamtrapsatlowpointsinthesystem.

5.2.6.2 Allsteambranchconnectionsshallbetakenfromthetopoftheheader.

5.2.6.3 Returnexhauststeam/condensatelinesshallconnecttothetopoftheexhauststeam
Condensateheader.
5.2.6.4 Where block valves have been installed in the main steam header such that condensate
can collect either side of the valve when closed, a safe means of draining the condensate
prior to opening the valve shall be provided.
- Steam header shall be located generally on the upper tier and at one end of the rack
adjacent to columns.
- Branch lines from horizontal steam header, except condensate collection points, shall
be connected to the top of the pipe header.
- Isolation valves (if provided) on the branch line shall preferably be provided on the
horizontal run and outside the pipe rack.
- All branch lines shall be drainable.
- Drip legs & steam traps shall be provided at all low points and dead ends of steam
header. Drip legs at low points shall be closer to downstream riser and shall be
provided to suit bidirectional flows, if applicable.
- All automatic control for startup shall be provided with a steam trap in the steam inlet
line.
- All traps shall be provided with strainers if integral strainers are not provided.

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- Steam traps discharging to atmosphere shall be connected to storm water
drain/storm sewer, in case of open system. In case of condensate recovery, traps
shall discharge into condensate header.
- Expansion loops are to be provided to take care of the expansions within units.
- Wherever condensate is to be drained, proper condensate draining facility shall be

provided.
5.2.7 Instrument Air Piping
5.2.7.1 Instrument air lines shall not be connected to process lines, service lines, and other
equipment.
5.2.7.2 Instrument air shall not be used as plant air or service air.
5.2.7.3 Branch lines form the instrument air header shall be taken from the top of the header
and shall be provided with a block valve close to the header. Also in the upstream of
Instrument manifold , Gate valve has to be provided
5.2.8 Supports and Anchors
5.2.8. 1 Supports and/or anchors shall be provided close to changes in direction of lines, branch
lines and, particularly, close to valves to prevent excessive sagging, vibration and strain.
5.2.8. 2 Allowable spans between pipe supports shall be determined to keep the maximum
deflection within 16 mm.
5.2.8. 3 In cases where periodic maintenance requires removal of equipment, such as pumps and
relief valves, and where lines must be dismantled for cleaning, piping shall be supported to
minimize the necessity of temporary supports.
5.2.8.4 Spring-loaded hangers may be used on piping subject to thermal expansion or

contraction. In cases where the movement is very large, or the limitation of reaction and
stress are very severe, constant support spring hangers shall be used.
5.2.8.5 Suction and discharge lines of rotating equipment shall be supported as close as possible
to equipment nozzles, and shall be relieved of excessive strains by using proper pipe
supports.
5.2.8.6 Supports shall not be directly welded to pipes. Where welding is unavoidable, supports
having the same chemical composition as pipe shall be carefully welded.
5.2.8.7 All piping shall be properly supported to minimize vibration.
5.2.8.8 Outlet piping of safety and relief valves shall be supported so that the inlet piping is
capable of withstanding the reaction caused by operation of safety and relief valves.

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Furthermore, the supports shall be designed to minimize the stresses due to thermal
expansion and the stresses in the valve body due to the weight of piping.
5.2.8 .9 Expansion joints shall be guided and anchored to the extent necessary for their proper
operation and alignment.
5.2.8 10 Anchors shall provide sufficient fixation to substantially transmit all load effects into the
foundations.
5.2.8 11 Underground piping shall be given special anchoring consideration for differential
settlement.
5.2.9 Utility Stations
Requisite number of utility stations shall be provided near the unit to cater for the utility
requirement. Utility stations shall have three connections one for LP steam (SL), one for
Plant Air (AP) and one for Service Water (WS) one for nitrogen each of 1.0" with isolation
valves unless otherwise specified in P&ID.
Utility connection with nitrogen shall be provided with NRV along with isolation valve kept
at a separate location other than this cluster @ 15 M
Air and water lines shall have quick type hose connection and steam line shall have
flanged type hose connection. All connections shall be directed downward. All connections
shall have globe valve for isolation purpose. An inter connection with valve shall be
provided between steam and service water lines shall be provided. Inert gas hose, when
required, shall have built in non return valve in quick connection coupling of piping end.
Number of utility stations shall be such that all equipments shall be approachable from at
least one utility station. The approach of utility station shall be considered 15 M all around
the station location.
The Utility stations shall generally be located adjacent to pipe-rack column.
The utility stations shall also be provided on elevated structures like - technological
structure, operating platforms of vertical equipments etc.
Operating platforms having manholes must have a utility station. Utility station locations
shall be limited to a height of 35 M from H.P.P.
5.2.10 Fire Fighting
All fire fighting facilities shall be as per statutory norms. Fire fighting points are to be
provided for fighting fire as per OISD guidelines.
Sprinkler system shall be provided for pump & compressor house and the Nozzel
connection at the top of mounded bullets & man holes as per OISD.

EM00131/PNMP/T/1 0
5.3 Offsite & Yard Piping
In general, offsite piping (except tank ages area), electrical cable and instrumentation cable
shall also be laid either on pipe rack or pipe sleepers.
Wherever piping is laid on pipe sleepers, it shall have hard surfacing below it keeping a
gap of 300 mm from the bottom of the pipes. Hard surfacing should be completed before
start of pipe laying. Width of hard surfacing shall be about 1.0 meter more than the piping
corridor. This extra hard surfacing shall be for movement of operating personnel along the
piping corridor.
Pipes at road crossing shall be under culverts in general. Overhead pipe bridges may be
used for areas where pipe racks are provided. Where culverts are not provided, pipe
sleeves shall be used for underground road crossing. Culverts / overhead pipe bridges
shall be adequately designed to take care of future requirements. Minimum 20% extra
width shall be provided in all such structures.
Clearances between lines shall be minimum "C" as given below:
C=(do+Df)/2 + 25 mm + Insulation thickness(es) where,

Do - outside diameter of smaller pipe (mm)
Df - outside diameter of flange of bigger pipe (mm)
However this 'C' spacing between the offsite piping on the rack/sleeper can be suitably
increased so that the lines should not touch each other after insulation / lateral thermal
expansion.
Adequate clearance shall be provided for every long & high temperature lines to avoid
clashing at the bends. See 5.2.2 also for line spacing at 'L' bends and loops.
Expansion loops for all lines shall generally be kept at the same location.
Vents shall be provided on all high points & drains shall be provided at all low points. Drain
valves at sleeper piping shall be kept outside the sleeper way if the same is not accessible
and valves shall be put in horizontal only.
Places where piping is extended to make drain valves accessible - 2 nos. of stiffeners,
irrespective of pipe rating, shall be provided as per 5.13.1. Spacing of guides on each line
on a pipe bay shall not exceed the value given in clause 5.13.1
5.4 Flare Piping
Flare header shall be sloped towards flare knock-out drum. Only horizontal loop shall be
provided as per requirement to accommodate thermal expansion. The desired slope shall
be ensured throughout including flat loop. Flare header shall be supported on shoe of
height ranging from 100mm to 300mm.

EM00131/PNMP/T/1 0

Proper thermal analysis temperature shall be established including the possibility of
temperature gradient along the line before providing expansion loops. Efforts shall be
made to minimize the number of loops. Flare line between knock out drum and water seal
drum shall be designed for pressure fluctuations and adequately supported to avoid
vibrations.
5.5 Sample Connections
5.5.1 Sample connections shall be accessible from grade or platforms. In general, where liquid
samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free
running of the liquid before sampling.
5.6 Vents and Drains
5.6.1 The minimum size of vent and drain connections in shall be as follows:
For process & utilities lines :

4 & Below NPS
6 & 10 NPS 1
12 & above NPS 11/2
Vent & Drain shall be provided with the valve & blind flange. For all vents / drains of
process lines / utilities lines, double valves shall be required for 600 # & more rating.
Process vents and drains shall be indicated on the P&IDs
5.6.2 Vent, drain and sampling valves on process lines, not connected to a piping system, shall
be provided with appropriate end closures.
5.6.3 Vents shall be located at high points of pipelines when necessary.
5.6.4 Drains shall be located at low points to empty pipelines or equipment after testing or during
maintenance ( i.e for every loop).
5.6.5 All drains and vents shall be provided with valve, except that vents for test purpose for flare
liens (header), may be plugged. Exposed threads shall generally be seal welded.
Low-point hydrostatic drains and high-point hydrostatic vents shall be added as required;
locations to be determined during the design review
5.6.6 Vent valves shall be the globe or gate type and drain valves the gate type.
5.6.7 Valved bleeds shall be provided at control valve stations, level switches, level controllers,
and gauge glasses

EM00131/PNMP/T/1 0

5.7 Line Strainers
5.7.1 Provide temporary conical type strainers in 2 NB and above butt weld pump suction lines
for use during start-up. Arrange piping to facilitate removal.
5.7.2 Provide permanent Y-type strainers for pump suction piping below 2 NB Thd Or SW.
5.7.3 Provide temporary basket type strainers located at the suction pulsation device inlet for
start-up of reciprocating compressors. Arrange piping to facilitate removal of the filter.
5.7.4 Provide temporary basket type strainers and locate them as close as possible to the
compressor inlet flange for start-up of centrifugal compressors. Arrange piping to facilitate
removal of the filter.
5.7.5 Allowable pressure drop when specified shall be certified by vendor along with the offer. If
asked specifically, vendor shall furnish pressure drop calculations
5.7.6 All 2" & higher sized Y type strainers shall be provided with 3/4" threaded ,tap and solid
threaded plug as drain connection. For less than 2", this shall be " size.
5.7.7 Bottom flange of Y-type strainer shall not have tapped hole. Full length standard size studs
shall be used for joining blind flange.
5.7.8 For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be
100% DP/MP checked.
5.7.9 All the strainers shall be hydrostatically tested at twice the design pressure
5.8 Spectacle Blinds
5.8.1 Spectacle blinds shall be provided to isolate equipment. In hazardous service flanged drop-
out spools shall be provided for safety purposes. Both shall be shown on the P&IDs.
5.8.2 Spectacle blinds shall be accessible from grade or platforms. Blinds located in a pipe-rack
are considered to be accessible. Blinds that weigh over 40kg shall be accessible by mobile
equipment. Where this is not possible davits or hitching points shall be provided.
5.9 Flexibility Analysis And Supporting
5.9.1 Pipe Supporting Criteria & General Guidelines.
Piping system shall be properly supported taking into account the following points:
1. Load of bare pipe + fluid + insulation (if any).
2. Load of bare pipe + water fill.


EM00131/PNMP/T/1 0
3. Load of valves and online equipment and instrument.
4. Thermal loads during operation.

5. Steam-out condition, if applicable.
6. Wind loads for piping at higher elevation, e.g. transfer lines, column over head
lines, flare headers, etc.
7. Forced vibration due to pulsating flow.
8. Vibration due to two phase flow.
9. Loads due to internal pressure.
10. Any external loads/concentrated loads and cold load of springs.
Pipe supporting shall preferably follow the minimum basic span except for flare line in off
site on trestles in which case the maximum basic span shall be restricted to 18.0 meters,
irrespective of line size.
For sizes not covered or Guided by client, basic span shall be established based on project
requirement. For piping on rack or sleeper, as a minimum, providing resting support on
every grid of pipe rack / sleeper is mandatory. Depending on the pipe size, as a rule,
guides shall be provided on straight run of pipes at intervals. Unless specifically becomes
non-viable due to flexibility problems.
Additional supports, guides, anchors, special supports like spring supports and sway
braces shall be provided after detailed analysis of piping system to restrict the forces
experienced on nozzles of critical items like pumps, compressors, turbines, exchangers, air
fin coolers etc.
For lines which do not need any support otherwise but become unsupported by opening of
flange, etc, during maintenance and thereby may transfer the total load on a small branch
off, a permanent support shall be suitably provided which may be a spring support also.
Bare pipes of size 14" and above on elevated structures shall be supported with pad or
shoe. While bare pipes of size 6" and' above, on sleepers, corrosion pads shall be
provided.
Pads shall be provided for insulated pipes before welding the shoes for sizes 8" & above.
Adequate stiffening shall be provided for the following:
a) Lines in above 600#,

b) Lines having two phase flow,
c) Lines having Pulsating flow such as discharge of reciprocating compressors &
reciprocating pumps,

EM00131/PNMP/T/1 0

For pulsating flow lines detailed thermal and vibration analysis by analog study shall be
done to decide location of anchor supports and guides etc. Pulsating flow lines shall be as
identified by licensor/owner.
Wherever two phase flow in piping is expected, piping design shall be checked by dynamic
analysis to prevent vibrations.
Pipe support design shall be such that deflection in piping systems due to sustained loads
shall not exceed 15mm, in any case, between two adjacent supports.
As far as possible long trunnion types of supports (more than 0.5 metre) are to be avoided.
In case long trunnion support is unavoidable in straight length of pipe, trunnion height to be
restricted to 0.5 M and balance height to be made up by providing extended structure.
In the heaters where steam air decoking provision is there, the main lines and decoking
lines should be supported in a way so that either of the lines should not be in the hanging
position while connected to other one. Same philosophy shall be adopted for similar type of
switch over arrangement.
Piping passing through the technology structure or passing near the concrete column etc.
should have adequate annular space to avoid restriction of line movement during thermal
expansion. The gap should take care the thermal expansion along with insulation
thickness.
High density PUF blocks shall be considered for cold piping supports. Use of wood blocks
shall be avoided.
All pipes supports shall be so designed that there is no undue tension on equipment
flanges. Flange joints should not move away from each other in case of unbolting of the
joint.
5.9.2 Flexibility Analysis Criteria & General Guidelines
5.9.2.1 Formal computer analysis shall be performed on piping systems as per design philosophy
for stress analysis
5.9.2.2 The directions of forces and moments shall be in accordance with Welding Research
Council Bulletin 107 (WRC 107), with the exception that the radial force (P) shall be away
from the vessel. All forces and moments shall be assumed to act simultaneously and apply
at the nozzle/vessel interface.
5.9.2.3 Air coolers to API 661 shall be specified with Fx forces and Mz moments increased to 1.2
times the value shown in Figure 8 of API 661 for nozzle sizes 6NPS and larger to simplify
piping flexibility analysis and facilitate piping layout.
5.9.2.4 Piping stress analysis and equipment nozzle loading analysis shall be in accordance with
ASME B31.3 and the relevant API, ANSI/ISO and NEMA Codes.
5.9.2.5 API 610 Pumps


EM00131/PNMP/T/1 0

The allowable nozzle loads on centrifugal pumps shall meet the load criteria of API 610.
Heavy duty base plate shall be specified where the pump design temperature is in excess
of 150qC.
ASME or Manufacturers Standard Pumps
The allowable nozzle loads on horizontal centrifugal pumps design to ASME B73.1 shall be
specified by the manufacturer. For preliminary layout and analysis NEMA SM 23 criteria
shall be used for individual nozzles.
Other Horizontal Centrifugal Pumps
The allowable nozzle loads shall meet the load criteria specified by the manufacturer.
Vertical Turbine, Can-Types Pumps
The combined bending and tensional thermal stress in the piping attached to the nozzle
shall be limited to 25 percent of the allowable stress range shown in ASME B31.3. The
combined stress due to dead load and other sustained loads shall be limited to 25 percent
of the allowable hot stress.
5.9.2.6 For piping design purposes, differential settlement between items of major equipment on
separate foundations shall be taken as 10 mm.
5.9.2.7 Cold springing in piping shall not be permitted without written permission from the Owner.
Cold springing of piping directly connected to rotating equipment is not permitted under
any circumstances.
Piping shall be analyzed for expansion, contraction, differential settlement, relief, valve
reaction and effects mentioned at CI. 5.12.1.
The design of piping systems shall take into account the different conditions expected
during operation, start-up, shut-down, cold branch in case of standby pump, tracing, etc.
Hydrocarbon lines shall be designed for steam-out conditions, if specified in line schedule.
The use of expansion joints shall be considered only when space oar pressure drop
limitation does not permit pipe bends. Expansion joint of axial type shall be avoided.
Forces and moments due to weight, thermal loads and other imposed loads on the
equipment nozzle must not exceed the allowed loads for the equipment.
Minimum analysis temperature shall be the design temperature of the line as per line list.
5.9.3 Method of Analysis
Formal computer analysis shall be performed on piping systems as per design philosophy
for stress analysis during the execution stage.
The package used shall be latest version of CEASER / AUTO PIPE / SIMPLEX / CAEPIPE.
Only one of these packages shall be used for the project & not a combination of the above
packages.

EM00131/PNMP/T/1 0
All lines shall be analyzed at design I analysis temperature. In the absence of analysis
temperature lines shall be analyzed at design temperature.
However in case of wide difference in design and operating temperature, temperature for
analysis shall be established in process documents. (e.g. flare line )
All non-critical lines may be analyzed using other methods.
Special analysis methods shall be followed for lines involving pulsating flow such as those
connected to reciprocating pumps & compressors which require acoustical plus analog
study by approved agencies and shall require entire system analysis along with piping I
equipments.
Seismic analysis shall be done for line sizes 12 and above.
5.10 Personnel Protection
5.10.1 Eyewash and emergency safety showers shall be provided in areas where operating
personnel are subject to hazardous sprays, emissions or spills.
5.10.2 Personnel protection shall be provided on un-insulated lines and equipment operating
above 70qqC when they constitute a hazard to the operators during normal operation of the
facility.
5.10.3 Leakage indicating tape and spray impingement shrouds shall be provided at flanged joints
in hazardous service.
5.11 Mechanical Handling
5.11.1 Handling facilities such as davits and monorails shall be provided on vessels over 10m in
height where the weight of removable internal and/or external equipment is greater than
35 Kg.
6.0 MATERIALS
Basic material selection of particular line depending on its service, temperature and
corrosivity shall be spelt out in process package. Material specification shall follow the
requirements as specified in PMS as per existing Line no system & Spec Nos.PMS / VMS
shall be supplied by bidder during the execution stage and will be approved by owner /
PMC.PMS shall generally follow the requirements given in this section.
6.1 Piping Materials
6.1.1 All materials for piping components shall conform to the relevant code and/or specification.
6.1.2 All materials shall be new.


EM00131/PNMP/T/1 0
6.1.3 All plate, sections, pipe, fittings, flanges, valves and special items shall have Material Test
Certificates.
6.1.4 All alloy materials shall have Material Certificates verifying the alloy content.
6.1.5 All bolting and gasket material shall have Letters of Compliance as a minimum.
6.1.6 All alloy bolting and gasketing shall have material Letters of Conformance verifying the
alloy content.
6.1.7 ERW pipe and fittings shall only be used for category D service as defined by ASME
B31.3.
6.1.8 Category M and Normal Service piping as defined by ASME B31.3 shall use seamless or
100% radio graphed EFW pipe and fittings.
6.1.9 Only piping materials listed in ASME B31.3 shall be used for Category M and Normal
Service piping. For Category D utility piping, where scaling and impurities are to be
avoided (such as instrument air, potable water and deluge water) hot dipped galvanised
and threaded fittings may be used in sizes up to and including 4 NB. Galvanised piping
shall not be used in environments containing acids or other corrosive commodities. In
corrosive environments stainless steel piping material shall be used for such utility
systems.
6.1.10 For services defined within ASME B31.3 as Category M, no socket welded or threaded
construction or connections shall be used for process equipment piping systems.
Construction shall be by butt-welding with a minimum 20% radiography. Flanged
connections shall be minimised.
6.1.11 All insulation and gaskets shall be asbestos free.
6.1.12 Insulating flange sets shall be provided between dissimilar materials as required.
6.1.13 Aluminium or copper alloys shall not be used for any component in the piping systems.
6.1.14 The use of 1.25Cr-0.5Mo alloy shall be a minimum requirement for piping systems having a
design temperature above 425qC.
6.1.15 Nelson Curves in accordance with API 941 shall be applicable to piping system materials in
hydrogen service.
6.1.16 Material for Naphtha service shall be in accordance with NACE Std. MR-0175-94
(Sulphide Stress Cracking Resistant Material).
6.1.17 The minimum corrosion allowance for any material, other than stainless steel, shall not be
less than 1.6 mm. For stainless steel it is zero.

EM00131/PNMP/T/1 0

6.1.18 The requirements for austenitic stainless steel materials in contact with the process fluid in
the high pressure section of urea plants shall be as per Technical notes Urea Grade
piping Material (Refer Annexure-6A).
6.1.19 All instrument air pipe line shall be of SS304.
6.2 PIPE
6.2.1 Wall Thickness
6.2.1.1 Calculation of pipe thickness and branch reinforcement shall be based on requirements of
ASME B31.3. Proper corrosion allowance and mill tolerance shall be considered to achieve
the selected thickness.
6.2.1.2 For carbon steel and low alloy steel pipes (except for steam tracing piping) minimum pipe
thickness shall be:
S80 up to 0.75",
XS for 1" to 2",
STD for above 2"
For stainless pipes minimum pipe thickness shall be

40S up to 2",
10S for above 2"
6.2.1.3 The philosophy of minimum thickness/schedule is applicable for both seamless and welded
pipes.
6.2.1.4 The above mentioned minimum thickness/schedule criteria is not applicable to category -D
classes,
6.2.1.5 All welded pipes shall have uniform negative wall thickness tolerance of 12.5% for wall
thickness calculations purpose.
6.2.1.6 For thicknesses exceeding minimum thickness/schedule criteria, Schedule XS shall be

selected for CS & AS classes (for 2" & above). Intermediate schedules between STD &
XS shall be ignored. Similarly for SS classes (2" & above) S10, S20, S30 & 40S may be
selected beyond minimum thickness/schedule criteria.
6.2.1.7 If, the thicknesses exceed XS in CS &AS classes and 40s in SS classes, only then, the
thickness shall be calculated based on actual service conditions subject to a minimum of
80% class rating. Maximum 10% of corrosion allowance may be reduced in special cases,
to optimize the pipe schedules.
In general, the pressure-temperature combination to calculate wall thickness shall be as

follows:

EM00131/PNMP/T/1 0

Material Class Size Design Condition
C.S. (A 106 GR.,B, 150 Up to 24" Class condition
API-5L GR.B, A672
Above 24" Line condition #
GR.B60/C60 :CL 12)
300 Up to 14" Class condition
LTCS Above 14" Line condition #
(A333 GR.6), 600 Up to 8" Class condition
Above 8" Line condition #
Low Alloys 900 Up to 8 Class condition
(1.25% Cr- 0.5% Mo. Above 8" Line condition
2.25% Cr-1.0% Mo. Up to 4" Class condition
5%Cr-0.5% Mo. 1500 & 2500 Above 4" Line condition
9%Cr- 1.0% Mo
Above 24" Line condition ($)
SS (A312 TP304, 300 Up to 14" Class condition
304L.316L,321,347) Above 14" Line condition ($)
OR 600 Up to 6" Class condition
(A358 TP304,304L,316, Above 6" Line condition ($)
316L, 321,347) 900,1500 Up to 4" Class condition
Above 4" Line condition
Higher Alloys 150 Up to 6" Class condition
300-2500 All sizes Line condition
# Only If the thickness/schedule as per class condition exceeds XS

$ Only If the thickness/schedule as per class condition exceeds 40S
Up to sizes 48", D/t ratio shall be restricted to 100(max.) Where D is nominal dia. And t is
nominal thickness. However for category-D classes D/t ratio may be taken as max.150
where t is minimum calculated thickness excluding Corrosion and Manufacturing
allowance. The minimum corrosion allowance for all material shall be as specified by the
client & agreed during detail designing.
6.2.2 Pipe Size
Pipe sizes shall normally be 0.5", 0.75", 1.0", 1.5", 2.0", 3", 4", 6", 8", 10,12", 14", 16",
18",20",24",
6.2.3 Pipe Type
Material Size Type

CS, L TCS, AS Seamless (except for Cat Up to 14" Seamless
'D' fluids & LP hydrocarbon in offsite ) 16 and above E.F.S.W
SS Process lines Up to 6" Seamless

EM00131/PNMP/T/1 0

8 and above E.F.S.W
Up to 1.50" Seamless
SS Non process lines
2" & Above Welded
CS (Cat 'D' fluids) ALL size Welded
CS Up to 6" Seamless
(LP hydrocarbons (offsite) Above 6" E.F.S.W /Welded
Note
Instrument impulse piping for steam services shall be S-160 Seamless
6.2.4 Pipes
- Unless specifically exempted, welded pipes shall be acceptable only with longitudinal weld
made employing automatic welding.100% radiography for all welds
- Double seam 180 apart is allowed for sizes 36" and larger only.
- Galvanized Pipes shall be only Hot Dip galv. to ASTM A53.
ENDS
Unless otherwise specified in PMS, the ends of piping items shall be to the following
standards:
SW/SCRD : ASME B 16.11

BW : ASME B16.25
FLANGED : ASME B16.5 and ASME B16.47 ' '/
THREADING : ASME/ANSI B1.20.1 (NPT, Taper threads)
6.3 Fittings
6.3.1 Type of fittings shall be equivalent to pipe type. All fittings shall be seamless similar to pipe
specification in construction unless otherwise specified
6.3.2 Thickness of fittings at ends to match pipe thickness for BW fittings. For reducing BW
fittings having different wall thicknesses at each end, the greater one shall be employed
and the ends shall be matched to suit respective thickness
6.3.3 SW fittings shall be 3000#, 6000# and 9000# depending on the pipe thicknesses S80,
S160 and above S160 respectively.
6.3.4 All branch connections shall be as follows, unless specifically mentioned otherwise in PMS:
Up to 1-1/2" NB O-Iets/ Tee
2" and above Tees/O-Iets / Pipe to Pipe with or without

Reinforcement pad up to 600# rating.

EM00131/PNMP/T/1 0

Only Tee/ Red Tee/ Sweepolets above 600# rating.
6.3.5 Branch connections shall be preferably made by fittings such as tees, half couplings,
weldolets, H.P Nozzles. If the branch connections are made by welding the branch pipe
directly to the run pipe, the required reinforcement shall be designed in accordance with
the ASME B31.3. For underground piping, all branches shall be with reinforcement pad of 2
D diameter & thickness similar to header shall be used.
6.3.6 Fittings of NPS 2 and larger shall be butt weld type and fittings of NPS 1-1/2 and smaller
socket weld or threaded type. For the rating 900 # & above only butt welded fittings, valves
etc. have to be used. SW fitting are allowed up to 600 # only
Long radius butt welding elbows shall be used wherever possible.
Unless otherwise specified, flanged elbows shall not be used.
All welded fittings shall have maximum negative tolerance equivalent to pipe selected. .
All welded fittings shall be double welded for size 16 and above. Inside weld projection
shall not exceed 1.6mm, and the welds shall be ground smooth at least 25mm from the
ends.
For fittings made out of welded pipe, the pipe itself shall be of double welded type,
manufactured with the addition of filler material and made employing automatic welding
only.
All welded fittings shall be normalised for CS, normalised & tempered for AS; and 100%
radiographed by X-ray for all welds made by fitting manufacturer as well as for welds on the
parent material.
Bevel ends of all BW fittings shall undergo 100% MP/DP test
When fluids have the possibility of causing corrosion in crevice, socket welded piping fitting
will not be used
6.3.7 Mitres shall be used in Category 'D' service above 6". For other than Category 'D' fluid in
150# and 300# Class mitres can be permitted for sizes 'above 48". Mitres to be designed
as per ASME B31.3.However, use of mitres shall be minimum. All miters shall be with 100
% Radiography.
Miter bends may be used within the limitations in the ASME B31.3 only where they have
been stress analyzed and subject to approval of OWNER.
Bushings shall not be used.
6.4 Flanges
6.4.1 The number of flanges in piping systems shall be kept to minimum and should be installed
only to facilitate maintenance and inspection and where construction or process
conditions dictate. They are for instance:

EM00131/PNMP/T/1 0
1) Where pipelines are connected to at connections with flanged equipment and valves.
2) Where frequent dismantling of piping is required.
3) Where clearance for dismantling equipment, such as compressors and reactor heads, is
required.
4) Where steel piping is connected to nonmetallic or nonferrous piping.
6.4.2 Flange Type

1) Slip-on Flanges
a) Carbon steel piping

b) Piping handling nontoxic fluids.
c) Pressure-temperature conditions are within the ANSI 300Lb rating.
d) Design temperature exceeding minus 20C.
e) Many large temperature cycles are not expected.
Slip-on flanges of austenitic stainless steel may be used within limitation of item b)
through e) above, it justified from economical view point.
2) Welding Neck Flanges
Welding neck flanges shall be used in all instances where slip-on flanges, socket weld
flanges and screwed flanges are not permitted.
3) Socket Weld Flanges
For NPS 1-1/2 or smaller, socket weld flanges may be used within the limitations specified
in paragraph 3.3.2.1).
6.4 3) Flange Facings
1) Flat face flanges shall not be used.

2) Raised face flanges shall in general be used:
a) For flanges of 300LB or lower rating in process services.
For 150 # Rating, CAF Flat Ring Gasket, inside reinforced with Stainless Steel OR Glass
Filled Teflon Sheet Gaskets shall be used.
For 300 # Flanges, Spiral Wound Gaskets with Inner & Outer Rings shall be used.
b) For flanges of 150 Lb or lower rating in utility services.
c) Regardless of the above limitations a) and b), for design temperatures not exceeding
450C.
3) Ring joint type flanges shall be used for flanges of 900 Lb rating or higher, or for design
temperatures exceeding 450C. This is applicable for all type of service. The flanges can
also be used for lower ratings for service conditions which require higher degree of
tightness.

EM00131/PNMP/T/1 0

4) Large tongue-and-groove faced flanges shall be used for services requiring higher
degree of tightness , for sub zero temp , for ammonia service etc.
6.4 6 Flanges shall be as follows.
Rating Size Type Remarks

150 Up to 1.50" SW RF If non metallic gasket used.
Up to 1.50" WN RF If metallic gasket is used.
2" & above WN RF/LJ FF For SS LJ FF + Stub Ends
2" & above SO FF/WN RF If used in CAT 'D' service
300,600 Up to1.50" SW RF
2" & above WN RF except H2 SERVICE(*)
For 900,& Above All WN RTJ.
(*) For H2 service, use of WN RTJ flanges shall be as specified in PMS.
All flange joints on piping system including flanges on the equipment, manholes, etc shall
be tightened using Torque wrench I hydraulic bolt tensioner depending upon service
criticality.
6.5 1 Gaskets
Rating Material/ Temperature Type GASKET OR STRIP

service (OC ) MATERIAL + FILLER
MATERIAL/RTJ
GASKET MATERIAL
150 CS & SS Up to 371C PLAIN Asbestos free
(utilities)
150 CS &LTCS up to 371C Spiral wound SS316
(other than
utilities)
150 AS (all up to 371C Spiral wound SS316
services)
300 & 600 CS (all up to 427C Spiral wound / SS316
services, RTJ
except H2)
300 & 600 AS (all above 371C Spiral wound/ SS316+Grafoil
services, RTJ
exceptH2)
150,300, SS (other All Spiral wound/ SS316+GrC\foil
600 than RTJ (where trim material
utilities isSS304/316)
'SS316L+Grafoi
(where trim material
is SS304L1316L

EM00131/PNMP/T/1 0

300(*), CS All OCTAGONAL Soft Iron
600(*),900, RTJ
1500,2500
300(*), AS All OCTAGONAL 5Cr-Alloy steel
600(*),900 RTJ
1500,2500
300(*), (*), SS All OCTAGONAL SS
1500, 2500 * RTJ
only if RTJ is
specially
mentioned in
PMS.
Gasket material shall be asbestos free.
- Asbestos filler for spiral wound gasket shall not have any colour or dye
Full face gaskets shall have bolt holes punched out.
Non-metallic ring gaskets as per ASME/ANSI B16.21 shall match flanges to ASME/ANSI
B16.5 up to 24", and ASME/ANSI B16.47 or AWWA for sizes> 24" unless otherwise
specified.
- Spiral wound gaskets as per ASME B16.20 shall match flanges to ASME/ANSI B16.5 up
to 24", and ASME B16.47 series 'B' for sizes> 24" unless otherwise specified.
- Inner and outer rings requirement for spiral wound gaskets shall be as per PMS General
notes.
- Inner ring shall be provided for the following:
a) As per code. (B 16.20) requirement.

b) For sizes 26" & above in all classes.
c) For vacuum and hydrogen service.
d) For SS321, SS347 and H grade SS classes.
e) For classes where temperature is higher than 427C.
f) For 900# rating and above classes. (If PMS Specifies Spiral Wound Gasket)
- In case of RTJ gaskets, only octagonal section ring gaskets shall be used & shall have
proper marking stamped. Material certificate shall be available for the gasket.
- Hardness of RTJ gasket shall be 20 BHN (min) less than the corresponding flange
groove hardness.
6.5.2 Stud, Bolts, Nuts and Jack Screws
All bolting shall be as per ASME/ANSI 818.2.1 for Studs, M/C Bolts and Jack screws,
and ASME/ANSI B18.2.2 for nuts. Machine Bolts shall not be used in piping flange joint,
except for Butterfly Valves, which shall be lug type, having UNC Threads in lugs
facilitating opening of flanges from both sides.

EM00131/PNMP/T/1 0
Threads shall be unified (UNC for; 1" dia and 8UN for> 1" dia) as per ANSI B1.1 with
class 2A fit for Studs, M/C Bolts and jack screws, and class 2B fit for nuts.
Stud bolts shall be threaded full length with two heavy hex nuts. Length tolerance shall be
in accordance with the requirement of table F2 of Annexure 6 of ASME B16.5
The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be
made by the hot forged process.
The length of the studs/ bolts should be such that minimum two threads should be out of
the nut on either side.
All the stud bolt should have metallurgical certificates in case of Alloy/ SS metallurgy with
identified color marking at the stud ends/ bolt side face.
In corrosive atmosphere like Acid chemical storage area, cooling towers area, where SS
flanges are provided, fasteners should also be SS.
Heads of jack screws and M/C bolts shall be heavy hexagonal type. Jack screw end shall
be rounded.
Wherever bolt tensioning is specified stud bolt length shall be longer by minimum one
diameter do suit bolt tensioner. Excess threads shall be protected by a threaded cap.
6.6 Valves
6.6.1 Type
a) SW Valves up to 1-1/2 inch - up to 600# except ball & plug valves which shall be
flanged for all sizes.
b) Flanged cast valve above 1-1/2" for 150#, 300#, 600#
c) Welded Valves - 900# and above
Criteria for Isolation Valves
Installation Process Drain/ Pressure Level Flow Safety Control

Isolation Vent Taping Taping Element Valve Valve
150 / 300# Single Single Single Single Single Single Single
600 # Single Double Double Single Double Single Single
Above Double Double Double Double Double Double Single
600#
Note : For S/D & at battery limit , it will be as per process requirements

EM00131/PNMP/T/1 0
Criteria for Body Bonnet Joint & Ends of the Valves
Body / Bonnet Body / Bonnet Ends Ends

Rating Size - < 1.5 Size - > 1.5 Size - < 1.5 Size - > 1.5
150 / 300# Bolted T & G/M & F Bolted T & G/M & F SW Flanged
600 # RTJ RTJ or Pressure seal SW Flanged
Above 600# Pressure Seal Pressure Seal BW BW
6.6.2 General
- Valves of Class 600 & above shall be pressure-seal type. Threaded and seal welded or
welded bonnet may be employed up to sizes 1-1/2".
- All flanged valves (except forged) shall have flanges integral with the valve body.
- Valve Castings/Forgings purchased shall be from Local approved foundries/forging shop.
- Yoke material shall be at least equal to body material.
Valves shall have pure graphite as gland packing material. Asbestos and other gland
packing material shall not be used
- Forgings are acceptable in place of Castings but not vice-versa.
- No cast iron valves to be used in firewater or any other service.
- Valves in sea water service shall be with non ferrous trims and all wetted parts other than
trims shall be epoxy coated.
6.6.3 Valve Dimensions
- Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same is not
covered under B16.10, the dimension shall be as per BS 2080/manufacturer standard.
Valve under cryogenic service (temp. below -45C) shall be as per BS-6364 and shall be
procured from pre-qualified vendor.
- Generally the valves are hand wheel or lever operated. However, suitable gear operator in
enclosed gear box shall be provided for valves as follows :
Gear operators shall be specified for gate, globe, angle, ball, butterfly and plug valves as follows:

EM00131/PNMP/T/1 0

Gate Valves:
CL150 14NPS and larger
CL600 & 900 8NPS and larger
CL1500 & CL2500 3NPS and larger
Globe and Angle Valves:

CL600 6 NPS and larger
CL900 4 NPS and larger
CL1500 & 2500 3 NPS and larger
Ball Valves:
CL150 to 300 8 NPS and larger

Butterfly Valves:
CL150 to 600 8NPS and larger
Plug Valves:
Spectacle blinds and paddle blinds/spacers shall be provided per the pressure class and
size range divisions shown below:
Spectacle Blind Paddle Blind/Spacer

CL150 14NPS and below CL150 16NPS and above
CL300 10 NPS and below CL300 12NPS and above
CL600 8 NPS and below CL600 10NPS and above
- Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500 mm
on each side. Effort to operate shall not exceed 35 kgf at hand wheel periphery. However,
failing to meet the above requirement, vendor shall offer gear operation.
- Quarter-turn valves shall have "open" position indicators with limit stops.
6.6.5 By-Pass
- A globe type valve (size as per ASME/ANSI B16.34) shall be provided as by-pass for the
following sizes of gate valves :

EM00131/PNMP/T/1 0

Class Size
150 26" & above
300 16" & above
600 6" & above
900 4" & above
1500 4" & above
2500 3" & above
By-pass Piping, Fitting and Valves shall be of compatible material and design. Complete
fillet welds for by-pass installation shall be DP/MP tested.
NDT of by-pass valve shall be in line with main valve.
6.6.7 Ball/Plug/Butterfly Valves
- Each valve shall be supplied with a lever/wrench except for gear operated/motor operated
valves.
- Soft-seated Ball, Plug & Butterfly valves shall be supplied with antistatic devices.
- The ball of Ball valves shall not protrude outside the end flanges.
- Ball valves shall be floating ball type / trunnion mounted type as per following:
Class Floating Ball .Trunnion Mounted
150 8" & below 10" & above.

300 4" & below 6" & above
600 &
1" & below 2" & above
above
- Use of soft seated ball/plug/butterfly valves shall be suitably selected based on

temperatures handled.
- Butterfly valves shall be suitable for throttling application.
As a rule, they shall be limited to water services only. Butterfly shall be lug type, body
threaded only. Each butterfly valve shall be provided with the Bolts to be installed from both
sides separately.
Ball valves may be used in place of gate or plug valves with the following limitations:
i) Operating conditions are within the permissible pressure - temperature range of seat
materials.

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ii) Fire safe type is used for hydrocarbon services.
6.6.8 Special Valves (Orbit. Y -body Globe, Jacketed, Valves of all types)
SPECIAL VALVES shall strictly follow the requirements of Valve data sheet, Process data
sheet/Specialty data sheet.
- Special Valves shall be made out of 100% radiographic casting/ 100% ultrasound forging.
- Jacketed Valves shall be tested to 100% DP/ MP check on Jacket welding, 100%
radiography test of valve body, 100% hydro test of Jacket.
Large diameter swing check valves shall be equipped with an anti-hunting device only
where closing of the check valve could cause a surge.
6.10 Supports & Spring Assemblies
- The Material, Design, Manufacture and Fabrication shall be generally as per MSS-SP-58/
MSS-SP-89 and/or BS 3974.
- Testing of springs shall be as per BS1726.
7.0 PAINTING
7.1 Scope of Painting
7.1.1 The following surfaces and materials shall require painting.
a) All un-insulated C.S & A.S piping, fittings, valves, columns, vessels, drums, &
storage tanks, heat exchangers etc. including painting of identification marks on
insulated lines.
b) Identification color bands on all piping as required including insulated aluminium

clad, galvanized, SS and non ferrous piping.
c) Pipes, fittings & valve surfaces under insulation of carbon steel and alloy steel
insulated piping system.
d) Pipes, fittings, valves surfaces under insulation of stainless steel insulated piping
system.
e) All structural steel works, supports, walkways, handrails and platforms etc.
7.1.2 The following surfaces and materials shall not require painting:
a) Un-insulated austenitic stainless steel and higher alloy piping.


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b) Plastic and plastic coated materials.
c) Non ferrous material like aluminum, galvanized, brass, bronze piping etc.
7.2 Color Coding
Painting work shall require satisfying the requirements of the area where the plant is being
setup. All painting and color coding shall be as per local painting manual.
7.3 Surface Preparation & Painting Application
Surface preparation and painting application shall be as per Std Specification

No surface shall be coated in rain, wind or in environment where injurious airborne element
exists, where surface temperature is below 5 deg F above dew point, where relative
humidity is greater than 90% and temperature is below 40 deg F.
Paint application shall follow the strict instruction of paint manufacturer whose paint is
being employed.
All procedures from surface preparation to finish painting; including testing shall be well
documented through a quality procedure approved by PMC/OWNER
8.0 WELDING
8.1 Applicable Codes & Standards
All welding work, equipment for welding, heat treatment, other auxiliary functions and the
welding personnel shall meet the requirements of the latest editions of the following
accepted standards and procedures.
a) Process Piping ASME: B31.3

b) The Indian Boiler Regulations IBR.
In addition, the following codes and specifications referred in the code of fabrication shall
be followed for the welding specifications, consumable qualifications and non destructive
test procedures.
i) Welding and Brazing Qualifications ASME BPV- Sec. IX.
ii) Non destructive examination ASME BPV Sec. V.
iii) Material specifications: Welding rods, electrodes and filler metals ASME BPV Sec II
Part C.

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The additional requirements mentioned in this specification, over and above those
obligatory
as per codes, shall be followed wherever specified.
8.2 Welding Processes
8.2.1 Welding of various materials shall be carried out using one or more of the following
processes with the approval of the Engineer-in-charge.
- Shielded Metal Arc Welding process (SMAW)
- Gas Tungsten Arc Welding process (GTAW).
8.2.2 Automatic and semi-automatic welding processes shall be employed only with the express
approval of the OWNER / PMC. The welding procedure adopted and consumables used
shall be specifically approved.
8.2.3 A combination of different welding processes could be employed for a particular joint only
after duly qualifying the welding procedure to be adopted and obtaining the approval of
OWNER/ PMC.

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Sheet 1 of 13
DESIGN BASIS
PROJECT: DESIGN PHILOSOPHY FOR LPG MOUNDED

BULLETS, NRL REFINERY
CLIENT: NUMALIGARH REFINERY LIMITED,

NUMALIGARH
JOB No: EM 131
PREPARED BY
PROJECTS & DEVELOPMENT INDIA LIMITED, NOIDA
0 24.2.2015 24.2.2015 FOR ISSUE NB NB BM

EM131-TS-401 0

DESIGN PHILOSOPHY FOR LPG MOUNDED BULLETS,
Sheet 2 of 13
CONTENTS
1.0 SCOPE
2.0 GENERAL
3.0 APPLICABLE CODES STANDARDS RULES AND SPECIFICATION
4.0 MECHANICAL DESIGN
5.0 MATERIAL
6.0 FABRICATION
7.0 FABRICATION AND ERECTION METHODOLOGY
8.0 MINIMUM QUALITY CONTROL REQUIREMENTS
9.0 INSPECTION AND TESTING
10.0 HYDRO-TEST
11.0 SPARE

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Sheet 3 of 13
1.0 SCOPE
The intent of this specification is to define the supply cum erection of mounded
LPG storage system and covers complete design, preparation of fabrication
drawings, material procurement, transportation, fabrication at contractor's works,
inspection, transportation to site, site fabrication/assembly, coating, erection on
compact sand bed, assembly, welding, testing, cleaning & coating of the
mounded LPG storage bullets including mounted Instrumentation and civil work.
The specification shall be read in conjunction with code, specification sheet and
other enquiry documents. In case of conflict between code and enquiry the most
stringent requirement shall govern.
2.0 GENERAL
The responsibility of the supplier shall include but not be limited to the following.
Any other item/activity which is not listed here but is required for completion of
the supply as per the enquiry document shall also be the responsibility of the
supplier.
(a) Complete design of the equipment as per code/equipment specification

and any other enquiry documents; supply of civil load data for foundation
design
(b) To obtain approval of owner on design calculations, drawings.
(c) To obtain statutory approval of design calculations, drawings and other

documents wherever applicable.
(d) Procurement of all the materials whatsoever required to meet the scope of
supply
(e) Fabrication, inspection, testing, painting, packing and despatch of the

equipment
2.1 Fabrication/Erection methodology mentioned in this specification shall be

considered as a guide line.
3.0 APPLICABLE CODES, STANDARDS, RULES AND SPECIFICATIONS
3.1 Codes & Standards
The design, construction and testing of the Bullet shall be in accordance with the
relevant requirements out lined in following Codes / Standards.
For all the Codes/Standards the latest edition is valid.
I) ASME SEC VIII Div-I

II) PD 5500
III) ASME SEC VIII Div-II
IV) EEMUA 190

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Sheet 4 of 13
3.2 Rules & Regulations
All the relevant requirements outlined in the following rules, regulations and
recommendations shall also be complied with
i) EEMUA 190
ii) OISD 150
3.3 Coatings
External surfaces of bullet shall be coated as per applicable standards.
3.4 Cathodic Protection System
Cathodic protection of bullets shall be as per applicable standards.
4.0 MECHANICAL DESIGN
4.1 Complete mechanical design of equipment as per latest code of construction

shall be the responsibility of the supplier. Strict compliance with the requirements
of code / equipment specification and any other referred document shall be fully
ensured.
4.2 Detailed design calculations including elastic beam & FEM analysis for adequacy
of strength of all individual parts shall be made and submitted to owner for
comments and approval. After receipt of approval from owner the design of
equipment shall be considered as final. Any change/comment, made on design
calculations to satisfy the requirements of code/enquiry documents shall have to
be incorporated without any commercial implications
4.3 Any modification in design parameters as may be required by owner at any time
shall have to be suitably incorporated. Commercial implications, if any, due to
such changes shall be mutually discussed and settled.
4.4 All items whether internal or external which are welded directly to a shell or head
shall be of the same material category as that of the shell or head. This shall
apply to all nozzles, brackets, pads.
5.0 MATERIAL
5.1 All materials shall be covered with proper identifiable material test certificate
endorsed by third party / owner.
5.2 Unless otherwise specified material used for pressure parts shall be fully killed.
5.3 UTS of material for Bullet shell, head & stiffener shall be limited to 80,000 psi.
5.4 C.S. material shall be procured in normalised / annealed condition only

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Sheet 5 of 13
Production test coupon is mandatory and shall be employed for each heat,
thickness, long. seam, circ. seam, to head joint, site joint circ seam. Contractor
shall take care of this requirement in procurement of plates
5.5 Production test coupon for plate shall undergo heat treatment at temperature 610
10C for SR & 910 10C for normalising. Details of the mechanical test shall
also be indicated in mill test certificate. (one SR, two SR, one SR + one
normalising separately). Laddle analysis & product analysis results shall also be
indicated
5.6 Plate shall be procured with zero negative tolerance on thickness.
5.7 Material including weld and heat affected zone, used in low temperature service
shall be impact tested (Charpy-V) as per design code and material specification.
Impact test temperature and energy value shall be in accordance with code/ spec
ification requirement, unless specified otherwise.
5.8 C.S. and low alloy steel plates exceeding thickness of 50 mm shall be vacuum
degassed except for plate ring flanges.
5.9 In case of quenched and tempered steel material, plates shall be procured UT
tested after heat treatment (in mill)
5.10 All materials of pressure bearing components exceeding 18.0 mm thickness shall
be U.T. tested on surfaces and edges as per ASTM A 435.
5.11 All forgings shall be ultrasonically tested as per ASTM A 388 for thickness
greater than 100 mm with criteria shown in ASME Sec.Vlll Div.2 Para AM-203-2.
In case any defect is found, no repair by welding shall be allowed. ASME flanges
for equipment designed as per ASME Sec.VIII Div.l need not be ultrasonically
tested.
5.12 All forgings (including nozzle flanges) shall be examined for surface defects by
MP/DP after machining.
5.13 Pipe fittings and elbows shall be seamless.
5.14 All gaskets shall have cantering ring on outside diameter of gaskets & shall
extend upto bolting.
6.0 FABRICATION
6.1 The manufacturer of the equipment shall comply in all respects with the
provisions of the applicable code/standards and specifications including such
jobs as welding, fabrication, forming of heads etc. radiography, heat treatment,
inspection, testing and quality control unless otherwise specified.
6.2 While execution of job within Owner's site premises, Owner's safety rules/
regulations shall be strictly followed.

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Sheet 6 of 13
6.3 While execution of job within Owner's site premises, Owner's safety rules/
regulations shall be strictly followed.
6.4 All welding jobs shall be carried out by qualified welders using welding procedure
that has already been qualified to requirement of applicable code and
specification etc. and approved by the inspecting authority. All welding
procedures must be got approved from authorised inspecting authority before
starting any fabrication job.
6.5 Space may not be available for fabrication at site. Equipment shall be fabricated
in minimum number of sections at Contractor's shop. Closing circumferential
seams shall be welded in-situ position in mound.
6.6 Any material consigned by contractor to site which is damaged or lost in transit
shall be to the contractor's risk and he shall replace such material at his own
cost.
6.7 Materials whatsoever required for welder's qualification, welding procedure tests
and production control coupons shall be arranged by the contractor. All
instruments required during performance testing to establish guaranteed figures
shall be arranged by the contractor.
6.8 Selection of electrodes and filler wires shall be as per Standards/Codes and
specification. However the approval of brand names shall be taken from Owner
before their use. Tests required, if any, to satisfy the technical suitability of these
electrodes/filler wires shall be arranged and done by contractor without any price
implication
6.9 Welding parameters of any approved weld procedure shall not be changed
without prior approval of the Owner.
6.10 Suitable trench (with proper arrangement to safe guard the compactness of
mound) shall be made to carry out the insitu welding of closing circ. seams.
Width of trench shall be suitable for carrying out heat treatment and there after
coating of the closing seams
6.11 Plates of different thickness shall be made flush with the inner surfaces of
equipment unless otherwise stated
6.12 Bullet's dished head shall be hemispherical / torispherical type
6.13 C.S. dished head, if cold formed or hot formed below normalising temperature,
shall be subsequently normalised. Larger heads which cannot be formed in one
piece shall be fabricated in minimum number of pieces, with prior approval.
a) In two pieces, with the welding seam included in the middle third and
preferably on the centre line.

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Sheet 7 of 13
b) In petal construction with meridional seams and a central cap of diameter not
larger than 0.75 times the vessel OD and no. of petal shall be based on 3.0 m
plate width
6.14 Impact test shall be carried out on parent metal, weld and HAZ.
6.15 Production control coupons is required and shall be subjected to all tests like
Physticaltest impact test, hardness test etc. as required. In case of heat treated
equipment test coupons shall be given similar heat treatment along with the
equipment
6.16 Location of weld seams shall be kept so as to avoid coverage with initial mound
i.e. 120 to bullet centre line to permit visual inspection. Orientation of
longitudinal seams and position of circumferential seams shall be clearly marked
in the fabrication drawings. Equipment having diameter greater than 2 meters
shall have only two longitudinal weld. Orientation of longitudinal weld seams
between adjacent courses shall be staggered.
6.17 All sharp corners shall be rounded off with smooth radius. Inside edge of
manhole and hand holes at the internal surface shall be rounded to min. radius 5
mm.
6.18 All welding neck flanges shall be bored to suit nozzle I.D. Flange facing shall
have suitable concentric serrations for gasket seating.
6.19 Internal Stiffener Rings (T-type) shall be fabricated and fitted to the shell belts
and welded in position simultaneously to avoid distortion.
6.20 All parts involving welded construction including stiffeners shall have continuous
welds unless otherwise stated.
6.21 Suitable Rat hole/Notch shall be provided in stiffener to clear long seam weld
6.22 Due provision must be kept for draining out of liquid in the internal shell stiffener.
Drain/Vent notches shall be seal welded to avoid entrapping of water/liquid.
6.23 All manways, pads, nozzles, lugs for lifting, CP lugs etc., shall be fabricated and
welded on bullet section in shop before transporting to site. Contractor to ensure
the overall dimension of the bullet piece with nozzle welded can be transported
by ODC transporter
6.24 Due provisions must be kept for venting out entrapped gases during welding of
pads, flanges etc
6.25 All nozzles shall be self-reinforced type including dome unless otherwise
specified. If manhole & dome with pad construction is specified, all nozzle
reinforcing pads shall be tested pneumatically at 0.5 Kg/cm 2g pressure with

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Sheet 8 of 13
soap solution on attachment welds. Vent holes shall be plugged or filled with
non-hardening mastic to prevent ingress of water.
6.26 All internals fabricated in pieces shall be shop assembled and properly match
marked for easy assembly at site.
6.27 In case of bullets to be assembled at site, trial assembly in shop shall be carried
out and match marked for proper assembly at site. Each section to be assembled
at site shall be provided with lifting lugs to facilitate handling during transportation
and erection at site
6.28 Equipment shall be provided with suitable bracing / stiffeners to avoid any
damage during transportation and erection at site.
6.29 All flange bolts shall straddle centre line unless otherwise stated.
6.30 All butt-welds shall be double-V full penetration welds with back chipping and
rewelding from the second side. For those joints which are inaccessible for back
chipping, the root run shall be carried out with TIG process. Single Vee welding
with backing strips shall not be permitted. Submerged arc welding (SAW) is
preferred for better weld quality
6.31 Stress relieving is mandatory. Welding of all parts must be completed before
heat treatment of individual section. Final closing seams shall be electrically local
stress relieved
6.32 Counter flanges for the insulating joint shall be suitable to accommodate stud
bolt insulating sleeve and washers.
6.33 Bolts & Nuts
External bolting for gasketed flanges shall always be stud bolts and nuts. For all
the flanges according to ASME B 16.5 and API 605, the bolt threads shall be in
accordance with ASME B 1.1
UNC for dia < 1//
SUN for dia > 1//
For flanges not in standard, the threads shall follow the rules of ISO (diameter in
mm) Threads of bolts and nuts shall be coated before installation with lubricant to
prevent galling of the threads.
7.0 FABRICATION AND ERECTION METHODOLOGY
i) The Methodology proposed here is for the guidance of the Contractor.

ii) The Contractor shall provide a detailed methodology and this must be
submitted formally to the Owner for their acceptance.
iii) The following Methodology should be read in conjunction with the overall
Construction Methodology.

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Sheet 9 of 13
7.1 Bullets shall fabricated in minimum sections, duly tested, inspected, trial
assembled only for connecting ends, match marked and stress relieved at shop
and transported to site.
7.2 It is presumed that the Contractor will use steel plates having minimum 2.5
meters width. The plates should be ordered in such lengths so as to ensure that
there are Maximum two longitudinal weld joints in one shell belt of the bullets of
equal shell length
7.3 The Contractor shall roll and weld together the 2.5 metre wide plates into 2.5
metre wide shell belts and re-rolled after welding to the exact internal diameter
as per drawing
7.4 A number of the shell belts will be welded together to form section. The number
of shell belts forming a section depends upon the transportation of each section
from the fabrication shop to its final location on the mound sand.
7.5 It is proposed that hemispherical ends will be used for these bullets. However the
Contractor may wish to import pre-fabricated hemispherical ends or Petal
sections thereof
7.6 Coating of bullet sections will be done prior to installing the same on the sand
bed. Contractor shall follow recommendations of the applicator on handling and
transportation of coated sections / bullets with a view to eliminate / minimise
damage of coating in transit.
7.7 The sections for each bullet shall then be lifted and transported to the sand bed
in accordance with the overall Construction Methodology.
7.8 The first bullet section to be laid on the prepared, templated and leveled sand
bed will be the section adjacent to the R.C.C. Wall.
7.9 The other section will be installed in sequence and each section aligned with
adjacent section and tack-welded in place.
7.10 The Contractor shall ensure that prior to commencement of final circ. welding,
tank sections that are tack-welded together are dimensionally inspected to
ensure the alignment and other dimensional requirements of code have been
met.
7.11 After completion of the final circ. weld and approval of radiography, the whole
LPG bullet will be finally hydrotested. The whole bullet shall be air dried to
remove all moisture after hydrotesting. Removal of water from bullet shall be
done by employing a water draining pump and manually removing the balance
water till the bullet is completely emptied. Contractor shall arrange suitable
draining pump and air cornpressor.
7.12 Prior to commencing hydrotesting, the Contractor shall ensure that both the
outermost tank to be tested and the adjacent tank are supported upto 1200 from

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Sheet 10 of 13
the centre line on both sides of the tanks. This is to minimum sand bed level for
Hydrotesting. At the time of hydrotest the adjacent bullets on either side of the
bullet under test pressure shall be kept water filled, i.e., minimum three adjacent
bullets shall remain completely filled with water anytime during hydrotest to give
full load to mound.
7.13 After successful completion of the hydrotest the surface around the final circ.
welds shall be coated in accordance with coating specifications enclosed.
7.14 It is extremely important during the filling of the mound that the fill is raised
uniformly on each side of the tanks so as to avoid any pressure imbalance
whatsoever on any of the tanks.
7.15 During the whole fabrication process the Contractor will have to work strictly in
compliance with the QA/QC procedures and requirement, as set out code (latest)
and this specification.
8.0 MINIMUM QUALITY CONTROL REQUIREMENT
8.1 Quality Assurance (QA) shall mean the organizational set up, procedures as well
as test methods and facilities developed by contractor in order to assure that all
equipment leaving Contractor's shop are of the highest possible quality i.e. equal
to or exceeding the requirements specified.
8.2 Quality Control (QC) shall mean all the test, measurements, checks and
calibrations to be carried out in Contractor's shop in order to compare the actual
characteristics of the equipment with the specified ones, as well as the
documentation (certificates/records) containing the data or results of these
activities.
8.3 Contractor shall submit a description (manual) of his QA/QC with a view to this
specification alongwith offer.
8.4 QA/QC systems may be based on systems already developed and implemented
by Contractor for other similar plants. It is the contractual obligation of Contractor
to develop and implement adequate QA/QC system. Owner shall have the
prerogative to check all aspects of agreed QA/QC systems and to introduce
modification, if deemed necessary, during the execution stage.
8.5 QA/QC systems shall cover all products and services of the contract including
subcontracted jobs, if any, i.e. documentation and site works.
9.0 INSPECTION AND TESTING
9.1 All raw materials shall be inspected by third party at source and test certificates
endorsed by him to enable proper identification. All charges towards such
inspection shall be included in price

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9.2 All equipment shall be inspected during various stages of manufacture starting
from identification of raw materials to completion. The equipment shall be
considered acceptable only after final certification for acceptance is issued by the
inspector
9.3 Bought out items or items sub-contracted to other approved sub-suppliers shall
also be inspected at the sub-supplier's works. However, standard items like bolts,
nuts, ordinary gaskets etc. may be exempted from the inspection with specific
approval from owner.
9.4 Inspection order on third party shall also include specific instructions for making
copies of all correspondence from inspecting authorities to owner and reporting
monthly progress of the order to Purchaser. Complete responsibility of getting
approval of drawings, calculations and documents from inspecting authority shall
be that of the contractor.
9.5 The following NDT requirements are mandatory in addition to the requirements of
code/specifications
A) Radiography
i) Technique for radiography and acceptance criteria shall be as per code of

design and construction
ii) Radiography when called for shall be applicable to all pressure welds, i.e.
longitudinal and circumferential butt-welds.
iii) When formed heads are made of welded plates/petal construction all the
weld seams prior to forming and after forming shall be fully radiographed
iv) All the weld T-joints shall be radiographed.
B) Ultrasonic Examinations
i) Butt weld plate thickness > 50 mm as supplement to radiography.
ii) All butt-weld (after Heat Treatment)
iii) Full penetration welds of nozzle attachments on equipment shell/head as

substitute for radiography
iv) 4 inch around the nozzle opening (before cutting opening hole)
v) Any repair welds (before and after hydrotest)
vi) 100% T-joints after hydrotest.

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C) Magnetic Particle Inspection
i) Back Gauge of all butt-weld and final layer (from outside)
ii) 25% of butt-weld (from inside)
iii) All edges to be welded in shell of C.S. having thickness > 40 mm
iv) Edges of nozzle opening
v) Nozzle attachment welds (both sides)
vi) Knuckle surface of dished ends / toriconical, expansion bellows and pipe
bends
vii) Fillet weld of internal shell stiffener and R.F. Pads of nozzle and lifting lugs
viii) 1/3rd length of fillet weld of stiffener (both side) at 0 , 90 , 180 and 270
(after hydrotest)
ix) Root run and final layer of nozzle to shell weld
10.0 HYDRO-TEST
Contractor shall submit a procedure for Hydrostatic testing for approval by Owner
prior to commencement of testing. Time - Pressure graph shall also be submitted
All necessary precautions shall be taken to safe guard against the risk of brittle
fracture during hydrostatic test at site. It is suggested that the temperature of the
testing medium shall not be less than 15 C. After hydrotesting water shall be
drained in Owner's drains.
At the time of hydrotest the adjacent bullets on either side of the bullet under test
pressure shall be kept water filled, i.e., minimum three adjacent bullets shall
remain completely filled with water anytime during hydrotest for minimum 48
hours.
a) Hydrotest
i) All completed equipment shall be tested hydrostatically as per the

requirements of specifications/codes in presence of the inspecting
authority. Pneumatic test of completed equipment shall be carried out only
when specially mentioned in the specification sheets
ii) Unless otherwise stated, gaskets used during testing shall be same as
specified for operating conditions
iii) Sweet potable water shall be used for hydrotesting. Minimum duration to
hold hydraulic pressure shall be 4-5 hours

Allrightsreserved
EM131-TS-401 0
Sheet 13 of 13
b) Settlement
Mound settlement shall be checked after allowing sufficient time at different

filling stages of each bullet.
11.0 SPARE
10% Bolting & 200% Gasket for all flange joints.

Allrightsreserved
1
INDIA LTD
CHAPTER -3
INSTRUMENTATION

All rights reserved
EM131- PNIN-0701 0
DOCUMENT NO REV
INDIA LTD. Page 1 of 20
INSTRUMENT DESIGN PHILOSOPHY

Job NO : EM-131
Project : INSTALLATION OF FOR MOUNDED BULLETS
Client : Numaligarh Refinery Ltd., Assam
0 12.02.2015 12.02.2015 FIRST ISSUE HK RA SKT
P 18.12.2014 18.12.2014 FOR CLIENTS REVIEW HK RA SKT

EM131- PNIN-0701 0
DESIGN PHILOSOPHY OF INSTRUMENTATION
INSTALLATION OF MOUNDED BULLETS DOCUMENT NO REV
Numaligarh Refinery Ltd., Assam Page 2 of 20
CONTENTS
SECTION NUMBER DESCRIPTION SHEET NUMBER
1.00 Scope 03
1.01 Environmental Conditions 03
1.02 Area Classification and System Design Basis 03
2.00 General 03
2.01 Electronic Transmitters 04
2.02 Flow Measurement 05
2.03 Level Measurement 06
2.04 Pressure Measurement 07
2.05 Temperature Measurement 08
2.06 Control Valves / ROV 09
2.07 Safety Valves 10
2.08 Signal Transmission System 10
2.09 Local Instruments Installation 12
2.10 Pneumatic-Instruments Supply 12
2.11 Process Connection 12
2.12 Electric-Instruments Supply 13
2.13 Codes and Standards 14
2.14 Specific Requirements 16

2.15 Notes
16
EM131_INST_DESIGN_PHIL_Rev P.docx All rights reserved

EM131- PNIN-0701 0
1.00 SCOPE
This document defines the Design Philosophy, Standards, Engineering practices to be followed during
DEP activities for the project.
Brief description of the project indicating project and clients name, location, capacity etc. shall also be
indicated
1.01 Environmental Conditions

Climate [X] Ref Process Design Basis
Relative Humidity [X] Ref Process Design Basis
Atmosphere [X] Ref Process Design Basis
1.02 Area Classification and System Design Basis
Plant Instrumentation design shall be:

[X] Intrinsically safe (Exia), if not available then FLAMEPROOF Exd
Certificated by statutory authorities like (For Imported components)

[X] BASEEFA [X] EN (CENELEC) [X] PTB [X] FM [X] UL
NOTES
1. Petroleum And Explosives Safety Organisation (PESO)/ Chief Controller of Explosives (CCE), Nagpur
or Director General of Mines Safety (DGMS) in India certificate shall be furnished for all intrinsically
safe and Flame proof enclosures.
2. For locally manufactured Flame proof enclosures, testing shall be carried out by CMRI/ERTL in
addition to certificate of Petroleum And Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur
2.00 GENERAL
-Instrumentation Numbering Philosophy [X] Area Code Item Code Item Number
for Instrument Tag Nos. e.g. Level Transmitter 45-LT-3001.
-Control Room/Control Panel [X] New signals to be hooked-up to the new Control
System (Annexure-I)
-Satellite room requirement [X] New control system with satellite rack room.
- Field circuits design [X] HAZARDOUS Area Zone-1 IIA/B T3 as per IEC
norms
[X] Electrical/ Electronic Instrument : IP-67
Sensors, RTD, T/C, etc : IP-65
Local Gauges : IP-55
Pneumatic Instrument : IP-54
Solenoid Valves : IP-67
EMC compatibility & electrical safety as per latest
IEC standard.
- Field instrument protection [X] Ex(ia), if unavoidable Ex(d).
[X] IEC / ISA
- Equipments Electric rules [X] IEC / ISA
for control & acquisitions

EM131- PNIN-0701 0
- Installation Electric [X] Above ground in GI Cable Tray / Duct

- Multicables [X] If run in trench to be filled with sand
& covered
[X] In GI pipe underneath culverts
[X] API-RP-520
- Safety valve rule (Refer Mechanical) [X] ASME-SEC.VIII & I
[X] IBR for steam, BFW (Wherever
applicable)
[X] Existing System for existing Transfering
pumps.
[X] 110 V AC Ungrounded UPS
- Electric Supply [X] All applicable International Std.
- Engineering Std. [X] English
Unit for Measurement [X] M.K.S. System
- Temperature [X] C
- Flow-liquid [X] M3/Hr
- Gas [X] NM3/Hr at 0C and 1 Ata

- Steam [X] KG/Hr
- Mass [X] KG/Hr
- Level - Process [X] 0-100%
- Tank /Bullet [X] mm & Meter
- Pressure [X] Kg/cm2g
- Vaccum [X] Kg/cm2 A / mmWC
Interconnection/Communication between pkg. vendor Insts./ Radar / Servogauge Panel mounted near base of
Bullet.
[X] ISOLATED 4-20 mA analog signal
powered from main panel/PLC based
Control system
2.01 Electronic Transmitters
Type [X] Microprosessor based Smart type Universal Hart

Protocol with latest revision
Signal [X] 4-20 mA D.C. (2 wire loop)

+ super imposed Digital
Precision [X] +/- 0.075% F.S. min. (except draft range)
Rangeability [X] 1 : 100
Circuit [X] EExi for hazardous area
Enclosure Execution [X] Weather proof IP-67 min.
Body Material [X] SS
Process Connection [X] 1/2 NPT F through oval flanges

EM131- PNIN-0701 0
Manifold (Supported on 2 Pipe [X] Integral 3 Way Valves for Diff. Pr. Tr.
mounting) [X] Integral 2 Way Valves for Pr. Tr.
Power Supply [X] 2 Wire System
Electric Connection [X] 1/2 ANSI B 2.1 NPTF
SS Plugged
Local Indicator [X] Required - Digital
[X] All flow transmitters shall have square root
extraction function
Radio Frequency Protection [X] Yes
Programming Unit/ Calibrator [X] Yes , Universal type , HART
2.02 Flow Measurements

i) Orifice Plates - Nozzles
Orifice Plates [X] Square edged concentric type
Ratio of orifice to inside pipe [X] Maximum of 0.70 and minimum of 0.25
diameter
Calculation [X] ISO 5167 (Latest Revision)
Tapping [X] Integral Orifice for line size 1" and
below
[X] Flange Tapping line for upto 14
[X] Pipe Tapping for Over and above 14
Flanges [X] As per Piping Material specification
ii) Special Flow Meters

Type [X] Special mass flow meters -
(Coriolis Type) (Note 7)
Accuracy [X] 0.15% or better

EM131- PNIN-0701 0
2.03 Level Measurements
i) Level Transmitters/Controllers
Type and Selection for Bullets / [X] MB Lal and OISD requirement should be
LPG storage Vessels considered (including SIL certification) during the
selection of the gauge type and installation method.
Also, atleast one Level instrument should be of
Servo type (+/1 mm accuracy).
[X] Atleast 2 independent system should be provided
for redundancy
[X] The Control Room items (interfacing/ data
acquisition units/ HMI) shall be redundant for each
system.
[X] Guided wave type level transmitter having facility
to measure RVD and Temperature. Electronics
shall be capable of measuring upper liquid and
interface level simultaneously.
[X] Servo with Intelligent Tank Data Transmitter
Including density and AV.
Type and Selection for other normal [X] Direct Liquid Level measurement
services All the vessels shall be provided with atleast 2
nos. of Level transmitters of same level
reference. If same is used for control purpose,
PV of any one of 2 nos. LTs shall be soft
selectable from HMI for the controller as per
operator requirement.
Level transmitter shall be either Radar or DP type
If DP type transmitter is considered for level
measurement, only remote seal type shall be
used.
Internal displacer type of level transmitters shall
be avoided unless application necessitates its use.
[X] Interface level measurement: Atleast 2 nos. of
displacer type level transmitters shall be provided
for interface level measurement (if any)
Body Material [X] SS as a minimum
Electric Circuits [X] Ex(ia) for Hazardous Area, Ex(d) for Radar and
servo gauges
Enclosure Execution [X] IP-65 min.
Process Connections [X] 6with still well for radar and 6 servo gauge
[X] Manufacturer Std.
Electric Connections [X] 1/2 ANSI (NPT F), SS Plugged
Installation [X] Direct
Inventory Management system [X] With complete software package
ii ) Level Switches No Direct Level Switches. Switching shall be configured from

transmitted signals at PLC based Control System.

EM131- PNIN-0701 0
2.04 Pressure Measurements
i) Direct Pressure Gauges
Element [X] Industrial Bourdon gauge/diaphragm or

spring bellows type as per process
requirement
Sensor Material [X] 316SS min.
Dial [X] 150 mm min.
Case [X] Stainless Steel case
Zero adjust [X] With micrometer pointer
Process connection [X] 1/2 NPTM Bottom
Precision [X] +/- 1% F.S.
Glycerine filling [X] For vibrating locations
Other accessories [X] As required

[X] Blow-out discs are required for all
pressure gauges except for instrument air
services
[X] Integral 2 Way Valves
ii) Pressure Switches - No Direct Level Switches. Switching shall be configured

from transmitted signals at PLC based Control System.

EM131- PNIN-0701 0
2.05 Temperature Measurements

i) Field mounted gauge
Type [X] Bimetalic, heavy duty adjustable angle connected type
Dial [X] 150 mm min. Dials shall be of white, non-
rusting metal with black figures
Enclosure Execution [X] IP-55
Case and stem material [X] SS min
ii) Field mounted sensor

Element [X] Normally K type thermocouple as per IEC584
[X] Grounded
Type [X] MI insulated
[X] Duplex type (With dual entry)
Sheath Material [X] AISI - SS316 below 400 deg C design temp.
[X] Inconel 600 above 400 deg C design temp.
Temperature transmitter [X] Required
Temperature transmitter Fixing [X] Remote
[X] Location - field
iii) Thermowell
Type [X] Single Bar stock
Well Material [X] ASTM A 182 Gr.F316 or better as per
Flange Material [X] ASTM A 182 Gr.F316 or better as per
Process Connection [X] 1 1/2 ANSI B 16.5 RF
[X] Bullet Thermowell shall be welded to the
Bullet
Other [X] Wake frequency calculation to be
provided for all thermowells
iv) Multi-point temperature Sensor to be connected to Radar LT
Standard [X] DIN 43760
Element [X] Pt 100 OHM at 0 deg C

[X] Mineral Oxide insulated
Sheath Material [X] AISI - SS316 min
No of temperature elements [X] As per API STD 2543
Installation [X] In Thermowell
Nozzle [X] 2 Flange 300#

EM131- PNIN-0701 0
2.06 Control Valves / ROV

Sizing [X] ISA S 75.01
Base Type [X] Globe/ Butterfly for Control valve

[X] Ball valve for On/Off valve
[X] Fire Safe Full Bore for On-Off valve
[X] Metal seat / Soft seated for ROV as per
seating class
Process Connection [X] 1 1/2 ANSI B 16.5 RF
Body Material [X] As per process data and fluid under service
Trim Material [X] As per process data and fluid under service,
however SS316 as a minimum.
[X] Special trim for cavitating/flashing
services
Piping Connections [X] Flanged
Minimum Rating [X] 300 #
Actuator [X] Pneumatic diaphragm type with pressed
steel diaphragm case wherever applicable.
In case of piston actuator complete with
air locks, air bottles & other accessories to
achieve desired air failure position - for
ROV
Shut off valves [X] Size and port equal to the line size
Positioner [X] SMART ElectroPneumatic
[X] SS case gauges
[X] For all except on-off valves
I/P converter Input Signal Range [X] 4~ 20 mA
I/P converter Output Signal [X] 3~ 15 Psi
Range
Air Filter Regulator [X] Yes with gauges for individual positioners
and Individual SMART positioners
Accessories [X] All mounted & tubed
Solenoid [X] IP-67, 1/2 NPTF cable entry (No flying
lead), Normally energized condition and
shall be de-energized to initiate trip
[X] AISI 316 S.S. body
Solenoid Valve enclosure [X] Ex (ia) for Hazardous area
Limit Switch [X] Proximity sensor (P&F) for all valves
Handwheel [X] Side mounted
Noise level limit [X] 85 dBA for continuous service
ROV Operation [X] MB Lal and OISD requirement should be
considered
[X] Open/ close position status of each ROV
should be distinguishable at field itself
without opening the fire proof enclosure
(if any). If required additional open/ close
position indicator to be provided near
each ROV

EM131- PNIN-0701 0
2.07 Safety Valves

Sizing [X] API RP 520, 1990
[X] ASME Sec. I & VIII
Type [X] Direct Spring Loaded
Body and Bonnet Material [X] Piping material Specification
Lifting Lever [X] Packed, for all except air and
supper heat steam
Test Gag [X] For all
Bellows Criteria [X] Required
Piping Connections [X] Flanged
Spring [X] Phosphatized / Chrome plated if CS /

Zinc Plated CS
Centre Centre dimension [X] API 526
2.08 Signal Transmission System

Multicables running [X] New Perforated GI duct
[X] Galvanised Pipe Conduit if required
for Underground Cabling
[X] Galvanised Pipe Conduit for trench
crossing
[X] Flexible HDPE pipe for Fiber Optic
cable laying
Cable entry to control room [X] Multi Cable Transit (MCT) of
Roxtec make only shall be used for
leak proof sealing for cable entry to
control room(s) preferably above the
false ceiling, if the cables are run
overground.
[X] For cables coming underground from
plant area shall be routed through
MCT located below the false floor
level of control room
Cable Trays [X] Perforated GI tray
Secondary Cables [X] On cable tray
Signal and Power Cables [X] FRLS as per standard IEC 332-3 Part
3 Cat. A. Fire resistance cables
whenever specified shall be as per me
331 Cat. A.
Insulation Grade [X] 600 V/1000 V
[X] It shall meet insulation resistance,
voltage and spark test requirements as
per BS-5308 Part-2.

EM131- PNIN-0701 0
Cables [X] PVC insulated primary insulation of

85C PVC as per IS-583
[X] 1.5 mm2 Cu cable for single pair
signal/Thermocouple
extension/RTD cable/ solenoid
valves / flame detectors..
[X] 0.5 mm2 Cu cable for multipairs /
1.5 mm2 for multi-triad signal cable
[X] 2.5 mm2 Cu cable (Power cable
as per IS-1554 Part I)
[X] All cables armoured. Armour over inner
jacket shall be of Galvanised steel
wire/flat as per IS-1554 part I / lEC 502.
Inner and outer jacket [X] Extruded flame retardant 90 ac PVC to IS-
5831
[X] For signal and control cables, inner / outer
jacket colour shall be black. However
outer jacket colour shall be light blue, for
intrinsically safe application.
[X] For thermocouple extension cables the
inner/ outer jacket colour shall be as per
IS-8784
Pair/Triad Identification [X] Pair/Triad No. printed on each
core sequentially at 1 meter on core
Shielding [X] Pair/Triad for single pair signal cables.
[X] Individual Pair/Triad & overall shielded for
Multipair signal/Triad cable
[X] Overall for other control cables
Core Insulation [X] Colour of core insulation shall be black blue
in pair and black, blue and brown in a triad.
Junction Boxes
Type [X] Weatherproof IP 65 with Mounting brackets,
hinged door for IS signals
[X] Flameproof proof (EEx d) for non IS signal
[X] Multipair cable bottom entry
[X] Single pair cable side entry
Material [X] Die-cast Aluminium & epoxy painted
Cable Glands [X] With Junction Boxes
Cable Glands type [X] Stainless Steel
[X] Double Compression type
[X] Shrouds
Jn. Box Colour [X] Grey (Non IS) / Blue for IS loops
Note : Junction Boxes and cable glands will be certified according to CENELEC/IS Codes.


EM131- PNIN-0701 0
2.09 Local Instruments Installation
Instrument Installation [X] Remote

[X] Paving/platform/column
Impulse Piping [X] Material acc. to line spec.
[X] Rigid 1/2 seamless pipe
Impulse Tubing [X] OD annealed seamless SS316
Fitting for rigid pipes [X] Material acc. to line spec.(Note)

[X] Dimensions as per ANSI
[X] Welded
[X] Screwed where unavoidable
Fitting for Tubes (Impulse) [X] SS Compression (double ferrule) type
(Swagelok or equivalent)
Pneumatic Tubing and air supply tubing [X] Stainless Steel AISI-304 (Double
Compression)
Main Instrument air / branch header (Note 2) [X] Main instrument air header in SS
Note: Pipe fittings shall be standardized in two ratings of 30000 lbs and 60000 lbs. Higher ratings
wherever applicable as per pipe class.
2.10 Pneumatic Instruments Supply

Air Pressure [X] Min. 4 Kg/cm2 g
Max. 6 Kg/cm2 g
Dew Point [X] (-) 40C at atmospheric pressure
[X] (-) 27C at operating pressure
2.11 Process Connection :

a) First tapping points for all pressure, d/p signals shall be 3/4 NPT. Mechanical piping scope shall be upto 1st
isolation valve(s). Subsequent reduction to 1/2 size and impulse piping and connection shall be under the scope of
instrumentation.
b) Wherever diaphragm seals have been used, the vessel or piping nozzle shall be 3 flanged. Flange rating shall
conform to piping index.

EM131- PNIN-0701 0
2.12 Electric - Instruments Supply

110V AC 110V DC 24V DC* 110 V AC 230 VAC
50Hz.UPS Non UPS 50Hz
a) Distributed Digital [X] [ ] [ ] [ ] [ ]

Control system
b) PLC [X] [ ] [ ] [ ] [ ]
c) Relay based [ ] [ ] [X] [ ] [ ]
Interlock & Shutdown system
d) Solenoid Valves [ ] [ ] [X] [ ] [ ]
e) I/P, Transmitters, [ ] [ ] [X] [ ] [ ]
Voltage
f) Gas Detection System [ ] [ ] [X] [ ] [ ]
g) Analysers and [X] [ ] [ ] [ ] [ ]
Analyser System
h) Level Gauge [ ] [ ] [ ] [ ] [X]
illumination
i) Mass flow meter [X] [ ] [ ] [ ] [ ]
Note-a: 24 VDC wherever required shall be provided with Redundant Bulk Power supply unit with diode
O-ring.

EM131- PNIN-0701 0
2.13 Codes and Standards

The following additional Standards shall be used/and taken into account during instrument engineering and design.
OISD-GDN-144 Guideline on LPG Bottling plant (Design & fire protection facility)
IEC 13 Diagrams, Charts and Tables, Preparation of Logic Diagrams
IEC 534 Industrial - Process Control Valves
IEC 584 Thermocouples
IEC 605 Equipment Reliability Testing elements
IEC 611-12 Part 12 Graphical Symbols for Diagrams. Binary Logic
IEC 654 Measurement and Control equipment
IEC 751 Industrial Platinum Resistance Thermometer Sensor
IEC 801 Electromagnetic Compatibility for Industrial Process measurement and Control Eqpt.
IEC 848 Preparation of Function Charts for Control Systems
IEC 902 Industrial Measurement and Control Terms and Definitions
ISA S-5 .1 Instrumentation Symbols and Identification
ISA S-5.2 Binary Logic Diagrams for Process Operation
ISA S-5 3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and
Computer Symbols
ISA-S20 Instrumentation specification formats
ANSI/ISA S 5.1 Process Instrumentation Terminology
ANSI/ ISA S71.04 Environmental conditions
ANSI/ ISA S75.01 Control Valve Equations
ANSI/ ISA S75.02 Control Valve Procedure Capacity Test
ANSI/ ISA S75.03 Face-to-Face Dimensions for Flanged Globe Style Control Valve Bodies
ANSI/ FCI 70.02 Quality Control Standard for Control Valve Seat Leakage
BS 6020 Instruments for the Detection of Combustible Gases
DIN 3582 Screwed Plugs, Tapped Holes, with Whitworth Part 2 Pipe Threads: General Outlay of
Types
DIN 43760 Measurement Standard for RTD.
DIN 19243 Measurement and Control Electrical Sensors, Electrical Position Sensors and Signal
Converters used for Intrinsically safe two-wire DC System.
EN-50-014/020 Electrical Apparatus for Potentially Explosive Atmospheres
EN 54 Part I Components of Automatic Fire Detection System Introduction.
EN 54 Part 5 Heat sensitive Detectors - Point Detectors containing a Static Element.
ISO 3511.1 Process Measurement Control Functions and Instrumentation Representation Part I:
Basic requirements.
ISO 3511.2 Process Measurement Control Functions and Instrumentation Representation Part 2:
Extension of Basic Requirements.
ISO 3511.4 Process Measurement Control Functions and Instrumentation Representation Part 4:
Basic Symbol for Process Computer, Interface and shared Display/Control Systems.
ISO 4200 Plain End Steel Tubes, Welded and Seamless - General Table of Dimensions and
Masses per Unit Length.
ISO 5167 Measurement of Fluid by Means of Orifice Plates, Nozzles and Venturi Tubes Inserted
in Circular cross-section Conduits Running Full.
API RP 520 Sizing, selection and Installation of Pressure relieving devices in Refineries

EM131- PNIN-0701 0
API RP 521 Guide for Pressure Relieving and Depressuring System

API RP 2000 Venting Atmospheric and low pressure storage tanks
API- Chapter 5.4 : Accessory equipment for liquid meters Manual of
Chapter 6.2 Loading rack and tank truck metering system
Chapter 6.6: Pipeline Metering Systems Measurement
Chapter 12: Calculation of Standards Petroleum Quantities
2.1 & 12.2 Part 1 and 2
API-RP-550 Manual on Installation of refinery Instruments Part I and Control System
ANSI - B 16.104 Control Valve seat leakage
ISA-S 75.01 Control Valve sizing
ISA S 18.1 Specifications and guides for the use of general Annunciators.
IEC 529 Environmental Protection of equipment
ANSI B 2.1 Pipe threads
ANSI B 16.5 Steel pipe flanges, flanged valves and fittings
IEC 79.11/ Intrinsic safety code and practice
IEC-79.14 International Boiler Regulation
IS 2148 Flameproof enclosure of electrical apparatus

EM131- PNIN-0701 0
2.14 Specific Requirements
2.14.1 HC Gas Detectors

Type [X] Infra-red multi-beam type
[X] 3 wire transmitters
[X] Power supply -24 VDC
[X] Detectors to be connected to existing
PLC / DCS system
[X] Hooter and beacon 110VAC (Grouped)
[X] atleast SIL 2 certified.
[X] Shall be hooked up the new control system
Enclosure (Detector and Transmitter) [X] Stainless Steel
2.14.2 Fire Detectors

Type [X] Heat and Ionisation detector for fire
[X] Power through Fire Detection System
2.14.5 Earthing system :

a) Panels, racks, cabinets, consoles [X] Separate electrical earth grid
shelters etc. and all Junction boxes
with power more than 110 V
b) Signal earth [X] Separate dedicated earth grid (Note 8)
c) Barrier earth [X] Separate dedicated earth grid
(Only for Zener barriers, if applicable)

EM131- PNIN-0701 0
2.15 Notes:
1) Integral manifold shall be used for DP type flow Transmitter. Piping & SS Tubing shall be used for Impulse
lines. SS tubing shall be used between integral manifold & transmitter. Impulse line val ves shall be gate type.
2) 1/2 SS isolation valve for each pneumatically operated instrument shall be provided. Main Header line shall be
of minimum SS irrespective of the piping material specification.
3) For Trip Solenoid Valves, FMR (Field Manual Reset) is required at field.
4) For flow, level, Pressure & Temperature instruments, only transmitters shall be connected directly to system for
monitoring, controlling & generating alarm in DCS. Similarly for PLC shutdown loops also, only transmitters
(4 20 MA) shall be used & the same shall be connected to PLC as AI. No direct switches shall be used. For
pump seal vessel also, only level transmitter shall be used.
Three transmitters shall be used for critical closed loop control and for all trips.
5) Thermowell flange rating shall be 300# as a minimum or better as per piping/ rating. Flange & thermowell
material shall be ASTM A 182 Gr.F316 as a minimum or better as per piping class. This philosophy is followed
for licensed as well non-licensed units. Thermowell shall be single bar stock. Duplex type thermocouples shall
be used.
6) For split range control, two I/P converters shall be used.
7) Mass flow meter shall be provided with back pressure control with necessary block & bypass valves. Back
pressure control shall be carried out through separate transmitter and control valve.
8) PLC and DCS earth grids shall be separate, Earth grid shall be formed by integrating more than one earth pit.
As a minimum two earth pits shall be connected to one grid.
9) 2 years operational spares shall be ordered separately as recommended by suppliers. Mandatory spares,
commissioning spares & consumables shall form part of main instruments supply.
10) All limit switches shall be of Proximity type.
11) Local Panel lamps, pushbuttons & selector switches shall be ex-proof / IS type only
12) For split range control, two I/P converters shall be used.
13) Number of Gas Detectors to be finalised by LSTK contractor during detail engineering.

EM131- PNIN-0701 0
Annexure-I
New control system with satellite rack room:

Existing control room (CCR) is fully exhausted with cables and panels. Entry of new multi cables and panels are not
possible. Also, the existing control philosophy of the existing LPG spheres are very inconvenient i.e. the ROVs are
controlled from the Refinery PLC/DCS and same is connected to the NRMT control room via HMI and Aux. hardware
console from where the operation is carried out. On the other hand, the NRMT control room is also exhausted with
panels. As such, instead of hooking up of the proposed field instruments with existing system, a new control system
with satellite rack room (like existing HC detections system of Refinery) is recommended.
The proposed system configuration is enclosed for reference.
Installation:
a. At field:
x New Satellite rack room where the new control system (controllers/ panels/ marshalling system),
interfacing/ data acquisition units of TFMS etc. will be installed. All the field instruments will be
hooked with marshalling panels of this room.
x Satellite rack room: This room shall be unmanned. In addition to climate control, fire/smoke
detectors and other mandatory fire suppression system should be provided inside the rack room.
b. At NRMT control room:

x Auxiliary hardware console of the proposed control system (which will be hooked up with the
DI/DOs of control system of the satellite rack room via multi core/pair cables). This console will
consist of H/W selector switches/ push button for ROV operation, indication lamp (open/ close
feedback of ROVs/ valves), emergency switch etc. as applicable. Operation and monitoring of
ROVs/ deluge valves will be carried from this console.
x Redundant HMI/ workstation of the control system (which will be hooked up with the control
system of the satellite rack room via redundant FO cable network) for GUI of the entire
control/operation of the plant. One will be operator station and other will be Operator cum
Engineering station. The Operator cum Engineering station will be server grade machine with
redundant power supply and redundant storage (RAID). Both the HMI will be independent.
Failure of one HMI should not affect the other HMI. Operation and monitoring of ROVs/ deluge
valves including all other field instruments will be carried from these HMIs through GUI.
Additionally entire system related engineering/ configuration will be carried out from the
Operator cum Engineering station
x Redundant HMI/ workstation for TFMS. Atleast 2 independent system should be provided for
redundancy. Failure of one system should not affect the other system.
Note: Additional HMI (for ROV operation/ monitoring, TFMs data, monitoring/ control of other
field instrumentation) may be considered in field operator cabin in consultation with NRMT
Operation.

EM131- PNIN-0701 0
New Control System:
a. SIL 3 PLC with redundancy in all levels and with SOE. Power supply: 110 VAC, 50 Hz, UPS.
Availability/Adequacy of existing 110V UPS of NRMT should be checked. If the same is not adequate,
supply of new UPS should also be considered in consultation with electrical department.
b. Redundant HMI/ workstation for GUI of the entire monitoring/ controlling/ operation of the process
parameters/ ROV etc.
c. Auxiliary hardware console where the indication/ on off switches/ selector switches for ROV operation
will be provided as mentioned earlier.
d. Supply voltage to SOV (solenoid operated valve): 110VAC. Accordingly suitable SOVs should be
selected.
e. Isolation of IO devices: All the field IOs (AI/AO/DI/DO) should be isolated from the system IOs
incorporating the followings:
x Barriers for AI/AO.
x Barriers/Interposing relays for DI/DO.
f. Fused TBs: All the field DI/DOs should be connected via fused TBs only.
g. 3rd party connectivity (vendors scope):
x OPC connectivity (with data driver) for proposed Control System for hooking up with existing
DCS/OPC. The distance is around 3 KM. FO cable networking with OPC connectivity (with data
driver) to be provided by the vendor of control system for this provision. Proposed system
configuration is enclosed for reference.
x OPC/MODBUS connectivity for proposed TFMS for hooking up with proposed control system.
Accordingly entire control system Data including the TFMS data will be transmitted/received via
the OPC connectivity of control system to/from the NRLs existing DCS/OPC. Proposed system
configuration is enclosed for reference.

EM131- PNIN-0701 0

1
INDIA LTD
CHAPTER -4
ELECTRICAL

All rights reserved
EM131-45-PNEL-DP 1
Sheet 1 of 13
DESIGN PHILOSOPHY-ELECTRICAL
PROJECT: BEDP FOR LPG MOUNDED BULLETS, NRL REFINERY
CLIENT: NUMALIGARH REFINERY LIMITED,

NUMALIGARH
JOB No: EM 131
PREPARED BY
PROJECTS & DEVELOPMENT INDIA LIMITED, NOIDA
1 20.02.15 20.02.15 REVISED AS PER CLIENTS COMMENTS DKG KK KK

0 13.02.15 13.02.15 CLIENTS COMMENTS INCORPORATED DKG KK KK
P 30.12.14 30.12.14 FOR CLIENTS REVIEW/COMMENTS DKG KK KK
EM131-45-PNEL-DP 1

Sheet 2 of 13
INDEX
SL. NO. DESCRIPTION SHEET NO.
1.0 Scope 3
2.0 Basis of Design 3
3.0 System Details & Utilization Voltages 4
4.0 Power Supply Distribution 5
5.0 Protection 5
6.0 Control and Monitoring 6
7.0 Equipment Specification 6
8.0 Cabling 9
9.0 Illumination System 10
10.0 Earthing 11
11.0 Cathodic Protection 12
LISTOFATTACHMENTS
ATTACHMENT NUMBER DESCRIPTION NUMBER OF

SHEETS
EM131-7411-0985 Rev. 1 Single Line Diagram PMCC 1
EM131-7411-0986 Rev. 0 Single Line Diagram MLDB &DCDB 1
EM131-7411-0805 Rev. 1 LT Switch Room Layout 1

EM131-45-PNEL-DP 1

Sheet 3 of 13
1.0 SCOPE
1.1 This specification covers the basic philosophy of design and installation of electrical system for
Basic Engineering and design package for LPG Mounded Bullet of M/s NRL ,Numaligarh Assam
1.2 The electrical system shall generally comprise of incoming power supply and power distribution
upto consuming apparatus, lighting, earthing, etc. for satisfactory operation of Plant.
2.0 BASIS OF DESIGN

2.1 The electrical installation shall be designed to provide:
- Flexibility
- Service reliability
- Ease of expansion
- Ease of operation and maintenance
- Safety of Personnel
2.2 Codes and Standards

2.2.1 The installation and equipment shall generally comply with the relevant Indian Standard
Specifications and Codes of Practice.
2.2.2 In the absence of relevant IS for any particular equipment or in case of imported equipment,
relevant IEC shall be complied with.
2.2.3 In addition, the installation shall comply with the latest issue of following Rules/Acts/Regulations:-
a) Indian Electricity Rules
b) The Indian Electricity Act
c) The Indian Electricity (Supply) Act
d) The Factories Act
e) OISD standards
2.3 Site Conditions

2.3.1 The equipment shall be designed for the following site conditions: -
Design reference temperature - 450C
Relative humidity - 100%
Altitude above sea level - Less than 1000M
Climate - Tropical
Atmospheric pollution - Hydrocarbons

EM131-45-PNEL-DP 1

Sheet 4 of 13
2.4 Hazardous Area Classification

2.4.1 The hazardous zones classified as Zone 1: Gas Group IIA/IIB, Temp. Class-T3
2.4.2 All electrical equipments installed in the areas classified as hazardous shall be certified for such
use by a recognized authority such as CMRI, Dhanbad/CCoE, and Nagpur etc.
3.0 SYSTEM DETAILS AND UTILIZATION VOLTAGES
3.1 Voltage Levels

Power supply voltage (Normal) : 415V+ 10%, 50Hz + 5%, 3Ph, 4W
Power supply voltage (Emergency) : 415V+ 10%, 50Hz + 5%, 3Ph, 4W
Power supply voltage (DC Power) : 220V 5%, 2 W
x Utilization voltage : 415V+ 10%, 50Hz + 5%, 3Ph, 4W
240V +10%, 50Hz +5%, 1Ph, 2W
220V 5%, 2 W for Panic Lighting
Control Supply
L.T .Switch Gear : AC 240V +10%, 50Hz +5%, 1Ph, 2W
Instrumentation : 110V +5%, 50 Hz +2%, 1Ph, 2W
3.2 Voltage Ratings

- Motors below 160KW : 415V AC
- Space heaters : 240V, 1Ph AC
- Lighting Network : 415V / 240V AC /220V DC
- Power Sockets : 415V AC, 3Ph/ 240V AC 1Ph
- Control circuits of contractors : 240V AC
- Instruments : 110V AC
Note:
Exceptions to the above, voltage rating of motors may be made on practical and economic
considerations.
3.3 Fault Levels

The fault levels at 415V system shall be considered as follows:
415V bus : 43.1kA (31MVA)

EM131-45-PNEL-DP 1

Sheet 5 of 13
3.4 System Earthing

No change has been envisaged in the existing earthing system and hence neutral of 415V
supply system shall be solidly earthed.
4.0 POWER SUPPLY DISTRIBUTION

4.1 One dedicated switch room is envisaged which shall be constructed in safe area near the new
mounded bullet area to feed the power to all electrical equipments required for the project. A
tentative reference drawing ( Drg No. EM131-7411-0805 Rev. 1 ) is attached.
4.2 One 415V Normal, One 415V Emergency and One 220V DC power supply shall be made
available by M/s NRL to cater the various load of Bullet plant area.
4.3 Two number power supply feeder one normal and one emergency ( 630A ACB) shall be required
at power sending end. For this Two Nos. Extension panel (including adapter panel- if required) in
existing sub-station of NRMT for feeding LPG Bullet plant sub-station (New Switch room) shall be
considered which will be under vendor scope.
4.4 The New PMCC of bullet area have two section one normal and one emergency with bus coupler
arrangement . Both feeder is capable of supplying 100% load of PMCC .Both incomer will be in
operating mode while bus-coupler will be in off position. This new PMCC shall cater the various
load (Motor, Lighting , switch socket etc) of the bullet area. A tentative single line power
distribution drawing ( Drg No. EM131-7411-0985 Rev.1) is also attached for reference . This
shall be modified at detail engineering stage if required.
4.5 All electrical accessories i.e supply of electrical equipments, cable rack & supports , all power
and control cables required from receiving end power to consumer points and erection, testing,
commissioning of all items shall be under vendors scope of work .
5.0 PROTECTION
5.1 The following protection shall be provided for the different type of feeders.
Power Sending end(Existing SS of NRMT)

i) IDMTL over current & Earth Fault with Electronic numerical relay
Power Receiving end (New PMCC)

i). Incoming and Outgoing Feeders:
Switch Fuse unit --- Switch - Fuse controlled feeders
ii) Contactor Controlled for all LT Motors

EM131-45-PNEL-DP 1

Sheet 6 of 13
--- Switch - Fuses , contactor with electronic motor protection relay .
6.0 CONTROL AND MONITORING

6.1 Ammeter and voltmeter with selector switch shall be provided for incomer feeder for PMCC.
6.2 Start and stop push buttons in Local Control Station (LCS). Auto-manual selector switch shall also
be provided on Local Control Station if required from process point of view.
6.3 Ammeter in switchgear and in LCS for motors above 15KW or as required from process point of
view.
6.4 Ammeter on central control panel as required shall be provided.
6.5 Indication lamp for ON, OFF and Fault in switchgear
6.6 Indication lamp for Motor space heater ON in LCS for motor rated 30 KW and above.
7.0 EQUIPMENT SPECIFICATION

7.1 General Constructional Features:
7.1.1 The equipment shall be suitable for tropical climate conditions and corrosive atmosphere.
7.1.2 The equipment to be installed in indoor plant area shall be enclosed in dust, damp and vermin
proof enclosure equivalent to IP: 54 as per IS.
7.1.3 The equipment to be installed in outdoor area shall have Minimum IP: 55 enclosure. In addition,
aluminum canopy shall also be provided as far as practicable.
7.1.4 The equipment to be located in hazardous areas shall be suitable for hazard involved and shall
have the following additional degree of protection: -
Equipment Zone-1 / 2
i) Motor Exd
ii) Local Control Stations Exd
iii) Lighting fixtures Exd
iv)Switch sockets Exd

v) Junction Boxes Exd
7.1.5 The minimum clearance and creepage distances shall be as per relevant IS and positively
maintained after connections.
7.1.6 All the electrical equipment shall be provided with rolled aluminium / brass heavy duty double
compression type cable glands and crimping lugs for the cable sizes required.

EM131-45-PNEL-DP 1

Sheet 7 of 13
7.1.7 The outside surface of all equipment shall be painted after suitable pre-treatment by the
application of two coats of rust and corrosion resisting epoxy based paints. The final shade shall
be no. 631 as per IS-5.
7.2 Switch Boards

General
7.2.1 A New PMCC shall be installed in safe area in new switch room near Bullet Area to cater LT loads
required for the project.
7.2.2 The switchboards shall be adequately rated and shall have PVC insulated busbar system suitable
for rated voltage. In all removable joints shrouds shall be provided.
7.2.3 The PMCC shall be provided with two incomers feeders i.e one normal and one emergency
feeder of 100% rated capacity(draw out type SFU) and one bus coupler with required number of
outgoing feeders. Both incomers and bus-coupler shall be mechanically interlocked .. In normal
operation, both incomer will remain online and bus-coupler in off position. When one incomer
trips, bus coupler will be in closed and vice versa. Min 20% spares feeders shall be made
available in the switch board.
7.2.4 The switch boards shall be draw out type, adequately rated and be suitably sized . The short
time rating of bus bar shall be 1 second. All LT motors shall be controlled through contactor with
Electronic motor protection relay.. Switch fuse feeders of 100A / 63A / 32 A shall be provided for
unforeseen loads
7.2.5 One Main lighting Distribution board(MLDB) shall be considered for feeding the normal and
emergency lighting. MLDB shall have two incomers from i.e one normal and one emergency. &
Outgoing feeders required for indoor and outdoor lighting. Normal and emergency power supply
shall be received from PMCC.Incomer feeders shall be contactor controlled. In case of failure of
normal supply, emergency supply will come inline automatically.MLDB shall have indoor and
outdoor bus. Outdoor bus shall be controlled by Photo cell Min 20% spares feeders shall be
provided for future use. Single line diagram ( Drg No. EM131-7411-0986 Rev. 0 ) is also attached
for reference.
7.2.6 One DC Distribution board(DCDB 220V) shall be considered for feeding the power to indoor and
panic lighting .PANIC light shall be switched ON automatically on failure of normal and
emergency power supply to main lighting board and panic light shall switch OFF automatically on
resumption of mains or after 1 hour of power failure. Location of these lights shall be judiciously
decided from safety considerations. Single line diagram ( Drg No. EM131-7411-0986 Rev. 0 )is
also attached for reference.
EM131-45-PNEL-DP 1

Sheet 8 of 13
7.3 Motors
7.3.1 The rating of LV motors shall be selected from the sizes as recommended in ISS. The margin
between the installed power and absorbed power shall be as recommended by the driven
machine supplier but shall not be less than the following: -
Motor Rating % margin on BHP of driven m/c.

Less than 22KW 125
22KW to 55KW 115
75KW and above 110
7.3.2 The motors shall be continuous having maximum rated duty as per IS.
7.3.3 All motors shall be energy efficient type having efficiency class of IE2 as per IS: 12615 and high
power factor type.
7.3.4 All motors shall be TEFC type suitable for Hazardous area having IP-55 degree of protection
and shall be Class-F insulated with temperature rise limited to that of Class-B. Aluminium canopy
shall be provided as extra protection from rain.
7.3.5 All motors shall be suitable for DOL starting at 80% of the rated voltage available at terminals.
7.3.6 All motors rated 30KW and above have space heater provision.
7.4 Local Control Stations

The motors shall be provided with appropriate Local Control Station (LCS) in the field. The
enclosure shall be of cast aluminium. These LCS shall be of hose proof and in addition flameproof
execution for hazardous area. These shall house controlling switch and indicating elements as
required.
7.5 Switch Sockets

Sufficient number (Minimum two nos.) of FLP inter-locked type 63A, 415V, 3Ph welding socket
and 15A, 240V, 1Ph switch sockets shall be provided in various plant locations to facilitate the
maintenance work. 63A welding receptacles shall be fed from new PMCC Panel. Minimum two
number welding receptacles shall be connected in one circuit. Generally 3Ph sockets shall be
provided at 50M interval and 1Ph socket at 25M interval. Maximum 2 Nos. of 63A switch sockets
and 4 Nos. of 15A switch sockets shall be connected to one circuit.

EM131-45-PNEL-DP 1

Sheet 9 of 13
8.0 CABLING
8.1 Cable
8.1.1 The Power & Control Cables shall be Multi stranded, and armoured type. All LT cables shall be
PVC-A-FRLS-PVC and all HT cable shall be XLPE-A-FRLS-PVC.
8.1.2 The cable sizes shall be selected in accordance with current rating based on:
a) Load Current
b) The site ambient condition, method of laying and the no. of cables laid together
c) Permissible voltage drops as specified below:-
i Motor feeding cables referred to the rated current - 5%
ii Motor feeding cables referred to the starting current - 10%
8.1.3 The minimum size of power cables shall be 16 sq. mm (Al) and 2.5 sq. mm (Cu).
8.1.4 The control cables shall be 2.5 sq. mm (Cu). No. of cores shall be selected as per requirement of
the control plus 20% spare cores.
8.2 Cable Laying
8.2.1 The incoming cables for PMCC shall be laid on the existing cable racks to the extent possible
where space is available. In case of non-availability of space in existing cable rack, supports shall
be taken from existing one for new cable racks, but in case where existing support is not
available, contactor shall include support and new cable racks in his scope.
8.2.2 For M.S. fabricated ladder trays, the rung spacing shall be 300 mm. The minimum size of
structural members shall be 50 x 50 x 6 mm for angles and 50 x 6 mm for flats.
8.2.3 The cable trays shall be designed to avoid any sharp bend in the cables. The corners of the cable
trays shall have a smooth circular radius, as required
8.2.4 The width of the cable trays shall preferably be 300 mm and 600 mm.
8.2.5 In paved areas near the equipment, if required, the cables may be laid in buried G.I. pipes. Where
cables rise up from under-ground, protection by means of G.I. pipe upto a minimum height of 300
mm above grade level shall be provided with open ends sealed
8.2.6 All cable terminations shall have crimping type lugs. Copper crimping lugs shall be used with
copper and aluminium crimping lugs shall be used with aluminium cables.

EM131-45-PNEL-DP 1

Sheet 10 of 13
9.0 ILLUMINATION SYSTEM
9.1 LED lamp equivalent to HPMV/ Fluorescent lamp as indicated below shall be considered for
indoor / outdoor area lighting. The minimum illumination levels and type of fixtures in the various
sections of the plants is as mentioned ;
AREA LUX TYPE OF FIXTURES
Operating platforms
- Safe area 100 80/125W HPMV well glass

- Hazardous areas 100 80/125W HPMV well glass
Non-operating platform/general process areas & walk ways
- Safe areas 50 80/125W HPMV well glass/ 2x40W fluorescent

- Hazardous area 50 80/125W HPMV well glass
The illumination level in different areas shall be as per code of practice for industrial lighting in
accordance with IS 6665.
-
9.2 The specified illumination level shall be maintained after considering maintenance factor of 0.6 for
plant and outdoor areas and 0.7 for indoor areas and utilization factors as per manufacturers
catalogues for the size of room and type of fixtures.
9.3 Normally minimum mounting height of the fixtures shall be as follows:-
Type of Fixture Wattage Mounting Height

Fluorescent ( Equivalent LED) 20W / 40W 2.5M
Mercury Vapour 80W / 125W 3.2M
( Equivalent LED) 250W 6.0M
400W 8.0M
DC Panic light( Equivalent LED) 100 W 2.5M
9.4 For lighting fixtures and 15 Amp plug socket circuits, 3 core 2.5 sq. mm Cu cable shall be used.
9.5 Various Flameproof and weatherproof LSDB for Indoor and outdoor lighting shall be considered
for feeding indoor and outdoor lighting which will be in vendor scope
9.6 Lighting fixtures shall be fed from nearest Lighting Sub-Distribution Board and Junction Box with a
consideration that the load on one lighting Sub-circuit of LSDB and Junction Box does not exceed
1000W approx.
EM131-45-PNEL-DP 1

Sheet 11 of 13
9.7 15A plug sockets shall be fed through separate circuit of LSDB / Junction Box.
9.8 100% of lighting shall be provided for emergency lighting.
9.9 220 V DC supply shall be made available by M/s NRL for DC/panic lighting which shall be
installed at convenient location in plat area for safe evacuation of operation personnel .For this
wall mounted DC distribution board shall be considered in the substation.100W DC incandescent
lamp or equivalent LED lamp shall be used for DC/Panic lighting.
9.10 Street lighting

9.10.1 63A TPN outlet from outdoor Lighting Bus of PMCC shall be taken direct to the TPN junction box
to be mounted on pole through 4x16/25 Sq. mm Al cable and looped from pole to pole.
9.10.2 Tubular stepped poles as per IS:2713 suitable for minimum mounting height of 7M / 9M for
fixtures respectively shall be used.
9.10.3 Overhang shall not exceed 25% of road width.
9.10.4 Indoor lights shall be controlled from the Sub-Distribution Board directly and outdoor light shall
be controlled by photo cell/clock switch and by-pass switches located in the switch room. In
plant area , additional wall mounting Sub-Distribution Boards if required shall also be installed.
10.0 EARTHING
10.1 Earthing system shall be provided as per IS: 3043
10.2 Detail earthing adequacy study to be done by the vendor .Soil resistivity data at min. five places of
plant area shall be calculated by Vendor. Required numbers of earth pits and connection to the
existing earth grid at two points shall be in vendors scope.
10.3 This earthing grid shall be used to connect the earthing conductors of the new electrical/non-
electrical equipment.
10.4 Individual electrical equipment shall be earthed by GI strip / GI wire / Al cable. Earth buses shall
be provided in plants for earthing groups of electrical / non-electrical equipment to earthing
grid / rings.
10.5 Size of earthing conductor for the electrical equipment in plants shall be as per IS: 3043.
10.6 All electrical equipment and lighting fixtures shall have two external earth connections.
EM131-45-PNEL-DP 1

Sheet 12 of 13
10.7 Flameproof equipment, in addition, shall have one internal earth connection.
10.8 All steel structures, tanks, vessels, pipes, pipe joints, valves etc. shall be earthed against static
charge accumulation by 50x6 mm GI strip. The no. of earth connections shall be as follows:-
Equipment having diameter Hazardous area Non hazardous area

30 mts 2 2
10.9 Wherever process equipments are mounted on steel structures, the structures shall be earthed
instead of earthing the individual equipment.
10.10 The pipe structures shall be earthed at not more than 25M apart.
11.0 CATHODIC PROTECTION:

11.1 M/s NRL intends to install 4 Nos. Mounded Bullets. For proper functioning of Mounded bullets,
both from safety and economy point of view, the bullet shall be protected against corrosion that is
potential danger to the health of the bullet. To protect the bullet from corrosion cathodic protection
is required.
11.2 Depending on soil condition, Cathodic Protection shall be provided for the Mounded Bullets
installed inside the plant area.
11.3 An Impressed Current Cathodic Protection system for the bullet required to be protected. The
design life for Impressed Current Cathodic Protection shall be minimum 25 years. All data
required in this regard shall be taken into consideration to develop an acceptable design and
for proper engineering of the system.
11.4 The design, selection and installation of equipment and material for cathodic protection system
shall confirm to requirements of the latest revision of following standards:. .
NACE Standard RP-0572 : Recommended Practice for Design, Installation, Operation and
Maintenance of Impressed Current Deep Ground Bed.
OISD 113 : Classification of Areas for Electrical Installation at Hydrocarbon Processing
and Handling Facilities.
OISD 147 : Inspection and Safe Practices during Electrical Installations.
IS: 8062: Code of Practice for Cathodic Protection of Steel Structures.
IS: 5572 Classification of Hazardous Areas (Other than mines) For Electrical Installations: Areas
having Flammable Gases and Vapors.
IS: 2148 Flame proof Enclosures For Electrical Apparatus.
Any other standard applicable for the equipment being used for CP System.

EM131-45-PNEL-DP 1

Sheet 13 of 13
11.5 In the absence of IS for any particular equipment or in case of imported equipment, relevant
IEC shall be complied with.
11.6 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
11.7 The equipment shall also confirm to the provisions of India Electricity rules and other
Statutory regulations currently in force in the country.
11.8 Work shall be carried out in accordance with all applicable local laws and regulations.
11.9 Required Soil Resistivity data shall be provided by the Owner if available.
11.10 The system shall consist of suitable nos. automatic transformer rectifier unit, Power
distribution Board, Anode Junction Boxes with resistor, Cathode Junction Boxes, Monitoring
Junction Boxes, Earthing Junction Boxes with Solid State Polarization Cells, Cu/CuSO4 & Zinc
Reference Electrodes & Polymeric Anode Strings spaced evenly and placed on the periphery
of the tanks. Reference cells and anodes (Anode flex) shall be suitably located at various
locations near the tank surface
11.11 Each bullet shall be isolated from the other bullet, including any buried structures in the
vicinity, bullets and electrical/instrumentation earthing system.
11.12 All cables shall be sized such that no excessive voltage drops occur which reduce the
capacity of the system. All cables shall be insulated and sheathed to withstand the prevailing
site condition. Drain cables and ground bed feeder cables shall be armoured. All cables shall
be buried in soft sand at a depth of at least 0.5m, provided with cable protection tiles on
winding tape as considered suitable for the area. All the cables shall be identified by cable
tag where they come above ground.

NORMAL POWER SUPPLY EMERGENCY POWER SUPPLY
FROM EXTENSION PANEL OF FROM EXTENSION PANEL OF
EXISTING NRL ELECTRICAL EXISTING NRL ELECTRICAL
SUBSTATION SUBSTATION
VSS VSS (0-500V)
(0-500V)
SFU,4P SFU,4P
400A 50KA 400A 50KA
C.T. C.T.
400/1A 400/1A
ASS ASS (0-400A)
(0-400A)
415V, 400A, 3Ph&N, 50Hz, 50KA INDOOR BUS
10A 9A 8A 7A 6A 5A 4A 3A 2A 1A 1 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B
SWITCH
400A
63A 63A 63A 100A NO. 32A 100A 63A 63A 100A
SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW
TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN TPN
415V
C.T. C.T. C.T. 2.5 KVA
C.T. C.T. C.T. C.T. C.T. C.T.
110V
LCS LCS LCS LCS LCS LCS LCS LCS LCS
C.T. C.T. C.T. C.T. C.T. C.T. C.T. C.T. C.T.
CONT. CONT. CONT. CONT. CONT. CONT. CONT. CONT. CONT.
M M M M M M M M M
SPARE SPARE TO TO SPARE SPARE MERCAPTAN LPG TRANS. LPG TRANS. LPG TRANS. LPG TRANS. MERCAPTAN SPARE SPARE TO TO RTU SPARE
WELDING MLDB 3.7 KW 110.0 KW DOSING PUMP PUMP MOTOR PUMP MOTOR PUMP MOTOR PUMP MOTOR DOSING PUMP 18.0 KW INST. MLDB WELDING CATH.
SOCKET MOTOR ( GANTRY LOADING) BOTTLING PLANT BOTTLING PLANT (GANTRY LOADING) MOTOR SUPPLY SOCKET PROTN.
3.7 KW 110.0 KW 18.0 KW 18.0 KW 110.0 KW 3.7 KW
NOTES:
1. MOTOR FEEDER SHALL HAVE FOLLOWING TYPE
M
RATING FEEDER TYPE RELAY TYPE
C.T.
UPTO 110 KW SFU+CONT. MPR
ASS ABOVE 110 KW A.C.B. MPR
2. MOTOR RATING INDICATED IS TENTATIVE.
VSS THIS WILL BE REVISED AFTER RECEIVING FROM VENDOR.
3. BOTH INCOMERS SHALL BE 100 % OF RATED CAPACITY.
ON FAILURE OF EITHER OF INCOMER OTHER WILL TAKE
100 % LOAD
4. THIS SLD IS ONLY FOR REFERENCE & SHALL BE REVISED
DURING DETAIL ENGG. FOR REFERENCE ONLY
5. APPROX. TOTAL LOAD OF MOUNDED BULLET AREA
IS CONSIDERED 150 KW.
FROM PMCC FROM PMCC
FEEDER NO. 7A FEEDER NO. 7B
C.T.
MLDB
VSS
VSS (0-500V) VSS (0-500V)
PHOTO
CELL
SWITCH SWITCH
TPN TPN
100A 100A
PHOTO
CELL
110A
110A
CONT. CONT.
415V, 125A, 3Ph&N, 50Hz, 50KA OUTDOOR BUS INDOOR BUS
100A
8 7 6 5 4 3 70A 2 1 9 10 11 12 13 14 15 16 17
32A TPN, 32A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN, 63A TPN,
SW SW SW SW SW SW SW SW SW SW SW SW SW SW
32A 32A 63A 63A 63A 63A 63A 63A 63A 63A 63A 63A 63A 63A
OUTDOOR LIGHTING INDOOR LIGHTING
(LSDB AND SPARE) (LSDB) 15A SWITCH SOCKET AND SPARE
220 VOLT
D. C SUPPLY
FROM NRL
(0-250V)
220V D.C DIST. BOARD
30A
(0-30A)
PANIC LIGHTING BUS
32A 32A
220V,40A, 2 WIRE 1 2 3 4 5 6 7 8 9 10
16A SW 16A SW 16A SW 16A SW 16A SW 16A SW 16A SW 16A SW
16A 16A 16A 16A 16A 16A 16A 16A
FOR
INDOOR USE OUTDOOR USE
1
INDIA LTD
CHAPTER -5
CIVIL

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EM131- 45-BEDP-101 2

PROJECTS & DEVELOPMENT DOCUMENT NO REV

BASIC ENGINEERING DESIGN PACKAGE

INSTALLATION OF LPG MOUNDED BULLETS

NUMALIGARH REFINERY LIMITED,

PROJECTS & DEVELOPMENT INDIA LTD

2 24.02.2015 24.02.2015 CLIENTS COMMENTS INCORPORATED VKS SCA SCA

a) Design basis EM 131-45-DD-DB 101 Rev.1 14

b) Schematic diagram EM131-45-0046 Rev.1 1

Process Flow Diagram EM131-45-0047 Rev.1 1

c) Equipment List EM131-45-0930 Rev.1 2

d) Equipment Data Sheet

i) Bullets data sheet EM131-DD-45-VV101/102/103/104 Rev.1 6

ii) Drain Vessel Data Sheet EM131-DD-45-VV106 Rev.1 3

g) Instruments Data Sheet

i) Flow Instruments Data Sheet EM131-45-0115 Rev.1 4

iii) Level Instruments Data Sheet EM131-45-0118 Rev.1 11

iv) Control Valve Data Sheet EM131-45-0123 Rev.1 8

v) Safety Relief Valve Data Sheet EM31-45-0124 Rev.1 6

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Adequacy of the Existing ETP

J) Flare Adequacy EM131-45-FL-9502 Rev.0 2

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All rights reserved

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD

1 05.02.2015 05.02.2015 Client Comments Incorporated VKS SCA SCA

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD

2.0 SITE METEOROLOGICAL DATA 5

3.0 PLANT DESIGN BASIS 6

3.1 LPG Composition 6

3.2 LPG Mounded Storage Facilities 6

3.3 Bullet Details 7

3.4 Normal Bullet Operation 7

3.6 Very Dilute Caustic Draining from Bullet 8

3.7 LPG Pump Details 8

3.8 Corrosion Allowances 8

3.9 Pressure Safety Valve 8

3.10 Gas Detection system 8

3.11 Noise Criteria 9

3.12 Effluent Criteria 9

2.0 SITE METEROLOGICAL DATA

Site Location Plant Location : Numaligarh, Golaghat District

1.0 Barometric pressure 750 mm Hg

2.0 Normal ambient condition

3.0 PLANT DESIGN BASIS

3.1 LPG Composition

Composition Mole % Mole % Mole %( Average for Design)

3.2 LPG Mounded Storage Facilities

System Design as per OISD -150

LPG Run Down from Refinery

3.3 Bullet Details

Operating LPG storage capacity of each Bullet 1760.56m3

3.4 Normal Bullet Operation

One mounded bullet is receiving mode,

One mercaptan vessel (45-VV-105) having capacity of 200 L which is maintained by

3.6 Water Draining From Bullet

No. of Drain vessel 1 no ( Vertical cylindrical vessel)

3.7 LPG Pump Details

Four nos. of LPG forwarding pump to be used.

3.8 Corrosion Allowance

Internal Corrosion Allowance: 3 mm (minimum).

3.9 Pressure Safety Valve