Guidelines for Piping Design in Metallurgical Industries

GUIDELINES FOR PIPING DESIGN
FOR
METALURGICAL INDUSTRIES
MECON LIMITED
RANCHI – 834002
DOC.NO: MSTD-DESG-FS&PD-1405, REV-0 JUNE’ 2006

CONTENTS
CHAPTER DESCRIPTION PAGE

NO. NO.
01 INTRODUCTION Page 1 of 2 to
Page 2 of 2
02 PIPE SIZING Page 1 of 9 to
Page 9 of 9
03 PIPING LAYOUT Page 1 of 9 to
Page 9 of 9
04 DESIGN CONSIDERATIONS Page 1 of 44 to
Page 44 of 44
05 LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS Page 1 of 8 to
Page 8 of 8
06 PIPING MATERIAL SPECIFICATIONS Page 1 of 27 to
Page 27 of 27
07 REFERENCES
REV. DATE PREPARED BY CHECKED APPROVED

NO. BY BY
1.V.KUMAR, AGM
0 27.06.2006 S.P.GUPTA. V.K SAHAY,
2.R.B.KUMAR, SR.MANAGER DGM DGM I/C
CHAPTER -01
INTRODUCTION
MECON LIMITED DOC No MSTD-DESG-FS&PD-1405 Rev -0
GUIDELINES FOR PIPING DESIGN Chapter No: 01 Page 1 of 3
01 INTRODUCTION
01.01 SCOPE
01.01.01 This document provides general guidelines and procedures for design of Inter
Shop/yard and In-shop piping systems in Metallurgical Plants and other related
industrial installations.
01.01.02 The provisions & stipulations of this documents are applicable to all the utility
fluids conditions & systems those listed is clause 01.01.04.
01.01.03 These guidelines are general in nature and are to be applied by the piping
designer judiciously considering the system parameters, plant & piping layout,
prevalent ambient conditions, operation & maintenance practices etc.
01.01.04 The provisions of this documents do not apply to the following:-
a) Fluids not listed in clause 01.02 i.e. chilled water, storm water, chemicals,
lubrication oil, grease, hydraulic oil, sewerage etc.
b) Equipment piping e.g. Hot blast, PCM lime Milk piping, etc.
c) Tubes & Tube fittings.
d) Gas lances.
e) Coal Tar injection piping.
f) Piping inside Power plant building
g) Pipes for pneumatic conveyance
01.02 CLASSIFICATIONS OF FLUIDS
For the purpose of piping design, the fluids are classified under following broad
categories:
• By-product Fuel Gases

• Hydrocarbon Fuel Gases
• Industrial Gases
• Liquid Fuels
• Compressed Air
• Steam
• Water
- Industrial Water.
- Drinking Water.
- Deminaralized Water.
- Soft Water.
By-product Fuel Gases
Gases generated during many of the metallurgical processes contain carbon monoxide
(CO), hydrogen (H2), methane (CH4) and other hydrocarbons. These gases have
substantial calorific value and are used as fuel for various heating requirements in the
plant. The gases are generally made available from the production units after cleaning
however, these may contain some residual impurities like suspended dust particles,
moisture. Gases like Coke Oven Gas may also contain tar fog, H2S and other chemicals,
etc. Some of the by-product fuel gases commonly used are as follows;
• Coke Oven Gas

• Blast Furnace Gas
• Basic Oxygen Furnace (BOF) Gas
• COREX Gas
• Top gas from Direct Reduction Furnaces
The above gases have different characteristics and calorific values and are used as fuel
either alone or as mixture of gases to optimize their in-plant usage.
Hydrocarbon Gases
Hydrocarbon gases supplied from external sources are also used as fuel. This category
includes the following:
• Natural Gas
• Liquefied Petroleum Gas (LPG)
• Coal Bed Methane Gas
Industrial Gases
Industrial Gases are used in the metallurgical processes. Industrial gases are also used
for cutting, welding, purging and other requirements like inert atmospheres in furnaces,
etc.
• Oxygen is used for steel making, enrichment of air blast in blast furnaces, cutting
& welding needs.
• Nitrogen is used for providing inert atmospheres as well as for purging purposes.
• Argon is used for metal refining providing inert atmosphere and welding.
• Acetylene is used for cutting and welding.
• Hydrogen and dissociated ammonia are used for generating inert atmosphere in
heat treatment furnaces.
Liquid fuels
Liquid fuels are used in industrial installations as primary / supplementary fuel. These
include:
• Fuel Oils as per IS: 1593-1982

• Diesel Fuels as per IS: 1460-2002
• Heavy Petroleum Stocks as per IS: 11489-1985
Compressed Air
Compressed air is generally required for all industrial installations for distribution of
service air and dry air (Instrument air)
Steam
Steam piping network is required for distribution of steam for heating / utility and
purging requirements. The steam may be supplied from Captive power plants, utility
boilers or waste heat recovery boilers.
Water
Water is used for cooling, drinking & flushing purposes in an industrial plant. Various
kinds of water available in a steel plant are industrial water, make-up water, clarified
water, drinking water, fire fighting water, DM water & soft water. The main source of
water in industries are rivers, canals, tube wells, ponds, municipal supply, etc,.
01.03 Individual Piping system shall be provided for distribution of each of the above fluids
from generating station to the consumers.
CHAPTER -02
PIPE SIZING
GUIDELINES FOR PIPING DESIGN Chapter No – 02 Page 1 of 14
02.00 PIPE SIZING
02.01 DESIGN PARAMETERS
Design pressure for various categories of piping shall be as follows :
Low Pressure Fuel gas piping : 1.25 Times Max. Operating Pressure(MOP)
( Up to 1500 mm WC MOP) But not less than 2000 mmWC minimum
All other gas piping : 1.25 Times Max. Operating Pressure

(except Acetylene)
Acetylene piping : Test pressure based on Maxi.Allowable

ranges Working / Operating Pressure
Refer para 02.02 below
Water piping : 1.5 times Maximum System Pressure.
Steam piping : 1.5 times Maximum Operating Pressure.
Design temperature for all fluids shall be maximum working temperature of fluid.
In case of ambient temperature, design temperature may be taken as 60 deg C for
piping exposed to sun and 45 deg C for indoor piping.
Flow rate for design purpose shall be taken as peak flow rate for the respective
section. In case of branches to individual consumers, peak flow rate for the
consumers shall be considered. For common branches and main headers, peak flow
rate based on consumption pattern/ diversity factor may be used for pipe sizing.
Future augmentation of flow rate for common piping shall also be taken into
consideration for pipe sizing.
02.02 SELECTION OF PIPE SIZE
• Pipelines shall be sized by limiting the fluid velocity in the pipeline as per Table
02-01.
• Peak flow rate based on the distribution pattern shall be considered for sizing of
pipes.
• Sizing shall be based on actual flow rate at worst combination of parameters e.g.
lowest pressure and highest temperature.
• In case recommended velocity is dependant on diameter range, after initial
sizing, velocity should be re-checked and if required, size should be
recalculated.
• Nearest higher standard pipe size shall be selected after calculation.
• For water piping & critical applications of pipes for other services, pipe sizes
should be re-checked after pressure drop calculations and availability of
required pressure at consumer point. If required, pipe size may be increased to
meet the pressure drop criteria.
02.02.01 Acetylene pipes
Acetylene differs from other fuel gases such as Natural Gas and propane because of
its ability to decompose. In case of such reaction high energy is released which can
travel as shock wave through piping. Velocity of shock wave depends on pipe size
and in smaller cross section area, velocity is restricted and shock wave dies out after
travelling some distance. This phenomenon is called deflagration and pressure
developed in pipe is limited. In larger pipe, shock wave can travel fast and entire
volume takes part in reaction and explosion may occur. This is called detonation
and pressure developed in pipe is very high.
Based on the pressure and pipe size, the operating regime of acetylene is divided
into three working ranges complied in IGC Document No. 9 / 78. The document
gives recommendations for selection of pipe sizes and corresponding test pressures
for each zone. Classification into zones is also given in IGC referred above. The
pipe size shall be selected so that piping remains in safe zone or deflagration zone
as per working ranges. Use of pipe size in detonation zone shall be avoided hence if
required multiple pipes shall be used to carry the total flow rate required.
Test pressure for working range – I shall be 1.5 times maximum working pressure.
In case of working range - II and working range – III the design pressure shall be
10 times and 20 times ( Minimum 30 Bar ) of maximum working pressure
respectively.
While crossing hot zones acetylene pipeline are protected with heat shield or
insulated depending upon the site requirement.
02.02.02 Oxygen pipelines
In carbon steel pipes carrying oxygen at high pressure and high velocity, foreign
particles, rust or scale can cause internal spark due to friction at high velocity and
result in steel pipe catching fire which may spread vigorously in oxygen
atmosphere. Several accidents have been reported due to such fires. Since
cleanliness in erected piping system is always in doubt, it is recommended to adopt
velocities given in Table A- 02.01 B.
In areas where
higher velocity may be required, SS pipes may be used. In pressure regulating
stations where velocity as well as turbulence is large, copper pipes shall be used.
For pipes above DN 150 size, CS pipes with inner copper sleeve can be used. In
case of copper pipe having high conductivity, any spark is quenched and thus there
is no chance of fire.
For further details refer IGC Document 13 / 82.

02.03 SIZING CALCULATION
02.03.01 Calculation of Actual Flow Rate
Flow rate of various gaseous fluids is indicated in Nm3/hr. This needs to be

converted to Am3 / hr considering actual pressure and temperature parameters of the
fluid using formula indicated below:-
PNVN PAVA
------ = ------
TN TA
Where,
PN = 1.033 Kg f / cm2 (Absolute)
VN = Volume in Nm3 / hr
TN = 273 deg. K
PA = Actual pressure of fluid in Kg f / cm2 (a) (Absolute)
VA = Actual Volume in m3 / hr
TA = Actual temperature of fluid in deg. K
For liquid pipelines (Fuel oil, water), no correction is necessary.
02.03.02 Pipe Size Calculation
∏ d2
Q = --------------- . V. 3600 m3 / hr
4. 106
= 0.0009 ∏ d2 V m3 / hr
( Q ) 0.5
d = ---------------------------- mm
( 0.0009 ∏ V ) 0.5
____________
= 18.80 √ Q / V
Where
Q = Flow rate in m3 / hr (Calculated as VA above)

V = Permissible velocity in / sec.
d = Inside diameter of pipe in mm
For steam service, flow rate is normally indicated in tonnes per hour. This need to be
converted into m3 / hr by finding specific volume of steam at the given temperature and
pressure using steam table and subsequently pipe size is worked-out based on velocity
range indicated in Table A-02-01C. For steam service, velocity depends upon fluid
condition as well as range of pipe diameter. Finally, pipe size is finalized based on trial and
error method as carried out for fuel gas service.
For moist gas, partial pressure at the operating temperature shall also be considered
while calculating the actual flow.
TABLE 02-01
RECOMMENDED VELOCITIES FOR SELECTION OF PIPE SIZES
A : Low Pressure Fuel Gases

Sl. Nominal Pipe Gas Velocity, m/sec (maximum) Remarks
No Dia – (mm) BF & BOF CO Gas, Natural Gas Mixed BF
Gas & Corex
Gas
1 20 – 80 2 2 2
2 100 - 250 3-4 4–5 4 –5
3 300 – 500 5-6 6–7 5–7
4 600 – 800 6–7 7–8 7-8
5 900 – 1200 8 - 10 9 – 12 8 – 11
6 1300 – 2000 11 - 18 13 – 20 12 – 19
7 > 2000 20 - 25 23 - 28 21 - 27
B : Medium Pressure & High Pressure Gases

Medium Pressure Range Gas Velocity, m/sec Remarks
(kgf/cm2 g) (maximum)
Nitrogen, Argon, Up to 6 8 –10 See Note 1
Compressed Air, 6 - 16 12 – 16
Instrument Air 16 - 40 Up to 20
Oxygen Up to 16 10 See Note 2
16 - 40 8
LPG Up to 3 8
Acetylene Up to 1.2 8 Up to DN 25
Notes :
1. In case adequate pressure is available, velocity for inert gases and air can be increased
up to 30 m/sec
2. In case cleanliness of pipe is ensured, maximum velocity can be 20m/sec. In case SS

pipes are used, velocity may go up to 30m/sec and for copper pipes velocity up to
60m/sec can be considered.
C: LIQUID FUELS:-
Medium Pressure Range Velocity, m/sec Remarks

(kgf/cm2 g) (maximum)
Liquid Fuels All Pressures 1.5
D : FOR STEAM
Sl. Fluid Condition Average Velocity, m/sec Remarks
No Up to DN 50 to DN DN 200mm
DN 50mm 150mm and above
1 SATURATED AT - 10 – 15 15 – 20
SUB-ATMOSPHERIC
PRESSURE
2 SATURATED AT 1 TO 15 – 22 20 – 33 25 – 43
7 Kgf/cm2 (g)
3 SATURATED ABOVE 15 – 25 20 – 35 30 – 50
7 Kgf/cm2 (g)
4 SUPERHEATED 20 – 30 25 – 40 30 – 50
UPTO 7 Kgf/cm2 (g)
5 SUPERHEATED 20 - 33 28 – 43 35 - 55
ABOVE 7 TO 35
Kgf/cm2 (g)
E : FOR WATER
Sl. Fluid Condition Average Velocity, m/sec Remarks

No Up to DN 50 to DN DN 200mm
DN 50mm 150mm and above
1 PUMP SUCTION - 0.4 – 0.6 0.6 - 0.7
CONDENSATE
WATER
2 PUMP SUCTION- 0.6 – 0.9 0.7 – 1.3 0.9 – 1.5
GENERAL SERVICE
3 WATER GENERAL 0.4 – 1.0 0.6 – 2.0 1.0 -2.4
02.04 PIPE THICKNESS CALCULATION

( PIPE SUBJECTED TO INTERNAL PRESSURE)
02.04.01 For Fuel and industrial gasses pipeline the pipe thickness is generally calculated as per
ANSI B31.3 – 1996 ( Process Piping )
t = PD/{2(SE+PY)}
Where
t = Calculated thickness in mm
P = Internal design guage pressure in kPa
D = Outside dia of pipe in mm
S = Basis allowable stress for metals in MPa
E = Quality factor as per (Table A-1B) of ANSI B31.3
Y = Coefficient from Table 304.1.1 of ANSI B13.3
C = Sum of mechanical allowances plus corrosion and erosion allowance.
C = Corrosion allowance (min) in mm
= 3.0 mm for BF, CO, BOF, Mixed and Corex gas for DN 100mm & above
= 1.5 mm for BF, CO, BOF, Mixed and Corex gas below DN 100mm & for other
gases
= 1.5mm for other gases for all sizes
The above valves of corrosion allowance is for general guidelines. However, the same
should be checked with Piping Material Specification (PMS) covered in Chapter 06.
Thickness calculated on the basis of above formula is minimum thickness required for
pipe under specified parameters. However, pipe thickness is selected based on the
recommended minimum thickness / schedule indicated in PMS, covered in Chapter 06.
12.5% is added on calculated thickness as Mill tolerances.
02.04.02 Steam piping network comes under the purview of IBR and thickness calculation needs
to be carried-out as per stipulations indicated in IBR and same needs to be approved by
CIB.
02.04.03 Pipe thickness calculation for water pipelines
The wall thickness of steel pipe is affected by a number of factors as indicated

below:
a) Internal pressure
• Maximum design pressure
• Surge or water hammer pressure
b) External pressure
• Trench loading pressure
• Earth fill pressure
• Vacuum underground.
c) Special physical loading

• Pipe on saddle supports
• Pipe on ring girder supports
d) Practical requirement at site.

The thickness of pipe should be selected that which satisfies to most severe
requirement. For detail of the above pressure/loading refer AWWA MANUAL M-
11
The nominal thickness of steel pipe as per IS:5822 (code of practice for water
supply) shall not be less than the design thickness as given below plus the thickness
for corrosion allowance:
t= PD Where t = thickness of wall in mm

2afe + P P = internal design pressure in N/mm2
D= outside diameter in mm
a = design factor (0.6 for working pressure
and 0.9 for test pressure inclusive of surge
pressure)
f = Specified maximum yield stress in
N/mm2 and
e = Weld efficiency of the joint (0.9 for shop welding
and 0.8 for field welding)
Corrosion allowance : It is preferable to design for the required wall thickness as

determined by the loads imposed, then select living coatings and catholic protection
as necessary to provide the required level of corrosion protection. 2 mm
corrosion allowance for pipe up to DN 100 and 3mm corrosion allowance for pipe
above DN 100 is generally considered.
02.05 PRESSURE DROP CALCULATION
02.05.01 Low pressure gas
Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at low
pressure can be expressed by the basic hydraulic formula :
f.l.v2.ρ
H = --------------------------
2.g.d
where,
H = Pressure drop (mmWC)
l = length of pipe sector under consideration (m)
d = Inner diameter of pipe (m)
v = Velocity of gas (m/sec)
g = Acceleration due to gravity (m2 / sec)

f = Friction co-efficient (dimensionless) depending on pipe diameter.,

velocity & viscosity of gas and type of flow)
= 0.03 to 0.045 (average value = 0.038) for BF gas
= 0.04 to 0.05 (average value = 0.045) for CO gas
= 0.02 to 0.03 (average value = 0.025) for Natural gas
Large values of “f” shall be taken for pipes of size less than 200 mm
and smaller values shall be taken for pipes of size more than 1500
mm.
ρ = density of gas (Kg/Nm3)
Equivalent pipe length for pipe-fittings, valves, etc. shall be taken into account for
calculating pressure drop.
02.05.02 High pressure gas
a) For working pressure of 10-15 kgf/cm2
Pressure drop (mm WC) due to friction inside pipeline carrying fuel gas at high
pressure can be expressed by the formula:
-------------------
/ PH2 - Pk2
Q = 20.555 d 8/3 / -------------------
√ SLT
Where,
Q = Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure
d = Inner diameter in cm.
S = Specific gravity of gas with respect to air
L = Length of pipe in km
T = Temperature of gas in deg. K
PH = Pressure of gas in Kgf/cm2 at one end of pipeline
PK = Pressure of gas in Kgf/cm2 at other end of pipeline

b) For higher pressure, the above formula is modified as :
-------------------
/ PH2 - Pk2
Q = 20.555 d 8/3 / -------------------
√ SKLT
Where,
Q = Flow rate (m3 / hr ) calculated at 200 C and 760 mm Hg pressure
d = Inner diameter in cm.
S = Specific gravity of gas with respect to air
L = Length of pipe in km
T = Temperature of gas in deg. K
PH = Pressure of gas in Kgf/cm2 at one end of pipeline
PK = Pressure of gas in Kgf/cm2 at other end of pipeline
K = Compressibility factor of gas at specified pressure and temperature

or, alternatively
_ _ 0.551
2 2
| P H - Pk |
Q = 25.0833 d 2.653 | ------------------- |
| SKLT |
|_ _|
02.05.03 Water
001. Pressure drop in pressure water pipe line can be calculated by using modified Hazen
Williams formula.
V=3.83 CR d 0.6575 (gs)0.5525/v0.105 ------------------------ I
Where,
CR = Co-efficient of roughness
d = Pipe diameter
g = acceleration due to gravity
s = friction slope
v = viscosity of liquid.
For circular conduits, v20ºC for water = 10-6 m2/s and g = 9.81 m/s2
The modified Hazan Williams formula derived as
V = 143.534 CR r 0.6575 S 0.5525 --------------------- II
h = [L(Q/CR)1.81]/ 994.62D4.81 --------------------- III
in which,
V = Velocity of Flow in m/s;

CR = Pipe roughness coefficient; (1 for smooth pipes; <1 for rough pipes)
r = hydraulic radius in m;
s = friction slope;
D = internal diameter of pipe in m;
h = friction head loss in m;
L = length of pipe in m; and
Q = flow in pipe in m3/s
A nomogram for estimation of head loss by modified Hazen William formula is enclosed at
Annexure- I
002. Pressure drop in gravity flow water pipeline (gravity flow line) can be calculated using
Manning’s formula:-
V = 1/n r 2/3 s1/2
For circular conduits:
V =(3.968 x 10 -3 x d2/3 x s1/2)/n and

Q = 8.661 x 10-7 x (1/n) x d8/3 x s1/2
Where, Q = Discharge in m3/hr

s = Slope of hydraulic gradient
d = Diameter of pipe in mm.
r = hydraulic radius in meters
v = velocity in m/sec
n = Marming co-efficient of roughness ( For general design purpose
‘n’= 0.013 for plastic pipes &
‘n’= 0.15 for other pipes)
A nomogram for discharge etc according to Manning’s formula is enclosed at Annexure-II
003. Pressure drop in valves & fittings:-
Fittings in a pipeline like valves, bends, tees, reducers, couplings, branches offer
considerable resistance to flow of liquid. The loss of head caused by a fitting is
partly due to the sinuous motion setup by the expansion of the steam to fill the pipe
after its contraction in passing the valve and partly to the irregularities in the shape
of the water way through the valve.
Losses due to fitting are sometimes expressed in terms of the length of straight
pipe of a given diameter which gives an equivalent loss of head. This method is
very approximate as the equivalent length as depend upon pipe friction .. and to
some extant on diameter.
The head loss hf caused by a fully open valve or fitting during the flow of a liquid
may be computed from the formula:
hf = K V2
2g
Where,
K = resistance coefficient for valve or fitting

V = Average velocity in a pipe of corresponding diameter
in M/s, and
g = Acceleration due ot gravity in m/s2
hf = head loss in m
Resistance coefficient for valve and fittings as per IS: 2915- Part-II
Sl Description of valves and fittings Resistance coefficient

No.
1. Loss in entrance
a) Bell mouth 0.04 to 0.05
b) Square edged 0.47 to 0.56
2. Loss at exist 1.0
3. Loss in sudden contraction 0 to 0.5 (varying with dia
ratio)
4. Loss in sudden enlargement 0.17 to 1.0 (varying with
angle between the sides of
the tapering section)
5. Losses is fittings
a) Elbow
i Regular screwed 450 elbow 0.3 to 0.42
ii Regular screwed 900 elbow 0.55 to 0.90
iii Regular flanged 900 elbow 0.21 to 0.30
iv Long radius flanged 450 elbow 0.18 to 0.20
v Long radius flanged 900 elbow 0.14 to 0.23
vi Long radius screwed 900 elbow 0.22 to 0.60
b) Bends
i Screwed return bend, close 0.75 to 2.2
pattern
ii Flanged return bend
composed of two 900 flanged
elbow 0.38
a) regular 0.25
b) long radius
c) Standard screwed Tee

i Branch blanked off 0.4
ii Line blanked off
a) Flow from line to branch 0.85 to 1.3
b) Flow from branch to line 0.92 to 2.15
d) Long radius screwed Tee

i Line blanked off
a) Flow from line to branch 0.37 to 0.80
b) Flow from branch to line 0.50 to 0.52
e) Coupling and unions 0.02 to 0.07
f) Reducing Bushing and coupling used 0.05 to 2.0
as Reducer
6. Valves
i Globe vales
a) Composition disc globe valve 0.23 to 5.2
b) Bevel seat globe valve 6.2 to 7.2

c) Plug disc globe valve 7.2 to 10.3
ii Gate valve
a) Wedge disc gate valve 0.05 to 0.19
b) Double disc gate valve 0.08 to 0.13
iii Check valves
a) Swing check valve 0.6 to 2.3
b) Horizontal (lift) check valve 8 to 12
c) Ball check valve 65 to 70
iv Angle valve 2.1 to 3.1
v ‘‘Y” or blow off valve 2.9
vi Foot valve 15
ANNEXURE - I
ANNEXURE-II
CHAPTER -03
PIPING LAYOUT
MECON LIMITED DOC No MSTD-DESG-FS&PD-1405 Rev - 0
03.00 PIPING LAYOUT
03.01 GENERAL
03.01.01 Routing and layout of piping system shall be as per good engineering practice.
Following factors shall be taken into consideration while designing piping system.
• All functional requirements shall be fully satisfied.

• Adequate clearance is provided for equipment and operating personnel.
• Easy access for operation and maintenance of piping component.
• Convenient supporting points for piping, equipment, valves, etc.
• Adequate flexibility for thermal expansion / movements.
• Aesthetics and neat appearance.
03.02 PIPE LAYING FOR FUEL GASES. INDUSTRIAL GASES, LIQUID

FUELS, COMPRESSED AIR & STEAM
01. The gas pipes installed along building wall should not cross window and
door way.
02. While laying high pressure gas pipes along the walls, the latter should be
fire-proof. In doing so, the gas pipes should be laid along solid walls or
above the windows of upper floors of plant buildings.
03. When gas pipes are installed along external walls of buildings below
window ways, installation of flange, thread joints and also installation of
accessories is not allowed.
04. Gas pipes of various service conditions may be laid along with oxygen on
a common support provided conditions stipulated under various clauses
are followed.
05. The following conditions should be observed when installing gas pipes
with other pipes:
a) Additional pipes on existing gas pipes are allowed to be laid only with the
permission of concerned plant and design organisation.
b) In each case, the gas pipes and supporting structures should be checked
with due consideration for additional loads and practical state of the metal
structure of gas pipes.
c) When installing with pipes carrying corrosive fluids they should be kept at
least 500 mm below or by the side of the gas pipe at a distance of 500mm.
If flange joints are provided on pipes carrying corrosive liquids, it is

necessary to mount protective baffle plate against falling of corrosive
liquids on gas pipes and their supports.
Installation of flanged joints and flow components are not allowed on

corrosive liquid pipes where the pipes pass above stairs and platforms.
d) The associated gas pipes at the places on gas pipes where valves and other
devices are mounted, should be kept at a minimum 800 mm distance from
the main pipe.
e) Drainage of the associate pipes should be laid to one side at a distance so

that condensate does not fall on gas pipes/ its accessories, supporting
structures and their elements, etc.
06. The branch line should generally be installed outside building along roof
wall. Branch line having diameter less than 500 mm may be laid inside
shop building.
07. Branch line from gas main entering into building through building wall
should pass through casings. Internal clearance between casing and pipe
should be suitably filled up, wherever required.
08. Gas branch line from gas main passing through roof covering should have
circular opening. For this purpose, a circular opening should be made on
roof and a taper hood should be provided on the branch line above the roof
for protection from rain.
09. Shop headers (except headers of By-product Plant) should be mounted at
a height having minimum ground clearance of 4500 mm, when laying
them outside the building wall.
10. Layout of gas consuming units in various shops (except coke oven
batteries) should be such that it is possible to bring the gas pipes above
ground.
11. Gas pipes of coke oven, natural gas and also their mixtures with blast
furnace gas may be installed in channels and casings, in the region of gas
supply to furnace and other consuming units.
The following conditions should be observed for this purpose:
a) Clearance between wall and bottom should be at least 400 mm, and for
gas pipes of 200 mm and below clearances should not be less than the
gas pipe diameter.
b) Installation of flanges, threaded joints and accessories (except

accessories for removal of condensate on a pipeline) is not allowed
when it is laid in a channel. The number of welds on such gas pipes

should be restricted to a minimum.
c) Installation of gas pipes with air pipes to gas consumer units is

allowed to be laid in channels.
d) Channels with gas pipes, as a rule, should not cross other channels, In
case, it is unavoidable, air tight tie-plate should be made and gas pipe
should be placed in casing. Ends of casing should be taken out beyond
the limit of tie-plate by 300 mm at both ends.
Channels should have provisions for natural ventilation.
12. In case oxygen and acetylene pipes are laid in channels, in addition to
above precautions, channels shall be filled with sand.
13. Underground oxygen lines shall be laid in trenches back-filled with soil,
unless specifically permitted otherwise by Purchaser/Engineer. Cathodic
protection of the underground sections of the pipeline is recommended in
addition to passive protection by coating and wrapping.
14. Gas pipes in buildings should be located at places convenient for

servicing, inspection and repair. It is not allowed to lay pipes at places
where there are chances of damage due to shop transport.
15. For gas lines installed in hot zone, it is recommended to provide protection
against overheating of gas pipes.
16. It is allowed to fasten gas pipes to frames of furnaces, boilers and other
units provided these frames are checked for strength by calculations.
17. Gas pipes are not allowed to pass through buildings producing or having
materials liable to explode or burn and building of power distributing
devices and substations and ventilation chambers and through buildings,
in which gas pipe may be damaged by intensive corrosion.
18. Gas pipes should not cross ventilation doors, air exhauster, flue pipes and
also gas pipes should not be installed in insufficiently ventilated space and
in underground buildings.
19. Installation of high pressure gas pipes below main working platforms of
shops is not permitted.
20. Gas pipes along bridges should be made of seamless pipe and laid in the
open at a horizontal distance of one metre from ends of pavements for
passing of people and it should be within reach for servicing. Supporting
elements of the bridge should be accordingly checked for loads from gas
pipes. Laying of gas pipes in channels of bridges is not allowed. All
welding joints of gas pipes in the area of their attachment to bridge should
be radiographed.
21. Gas pipes passing through walls, ceilings, and other structures of buildings
of construction shall be encased in a steel pipe having inside dia at least 50
mm more than that of the oxygen pipe. The Gas pipe shall have no joints
in the section at such crossings. The gap between the gas pipe and the
outer pipe shall be filled with non/inflammable material, but allowing
vertical and horizontal movement.
22. The laying of moist fuel gas pipelines shall be as per IPPS: 1-06-014-95
23. Pressure pipe work for gases and liquid fuels generally shall be routed
overhead. All overhead interplant pipe work to be routed such that they
will have a minimum clearance of 6.0m between bottom of supporting
structures/pipes and road / railway track. The pipelines laid over hot
tracks shall have a minimum clearance of 10.0m, in case of using
protective shields in these places, this clearance shall be reduced to
6.0m Buried pipes, wherever laid, shall be provided with a minimum
earth covering of 1200mm in areas subject to temporary loads and
minimum earth covering of 1000mm in areas not subject to temporary
loads, unless otherwise specified.
24. For the pipelines laid on roof, the distance from the external edge of the
pipe to the roof shall be at least 0.5m.
25. All shop headers, except for gravity fluids, shall be generally routed along
columns in multiple rows at a height 4 to 6m above floor level. The
connections to equipment shall be taken through suitable covered floor
trenches for shops at ground floor and for basements, for elevated
operating floors, the equipment pipe work connection may be taken below
the floor level. All isolated single pipe connections to equipment shall be
buried in the flooring / equipment foundations. Pipe work from basement
and oil cellars to main equipment shall be routed in pipe tunnels / trenches
with adequate spacing for easy maintenance. All pipe trenches shall be
covered by chequered plate or by concrete slabs.
26. The bleeder pipes for purging lines and other exhaust pipe work shall be
routed upward along columns / gable ends and / or walls to a minimum
height of 4,000mm above the roof level / platforms.
27. For the gas pipelines laid along the building walls, the clearance between
the gas pipelines and the wall shall be adopted so as to ensure the
possibility for maintenance of the gas pipelines. The gas pipelines laid on
the walls must not cross the window and door openings.
28. Branch pipes from the headers to the building through walls and the roof
shall be encased.
29. Gas pipelines shall be earthed. When laid under the high voltage lines, a
protective sheet guarding shall be provided above the gas pipelines. The
guarding shall be earthed. The earthing resistance must be not over 10
ohm.
30 Platforms, access ladders, hand railing, etc. shall be provided for operation
and maintenance of valves, instruments and controls. Manholes and
hatches shall be provided for access inside the gas pipelines.
31. At all the places of regular maintenance (gate valves, throttle valves,
orifice plates, hatches, manholes, bleeders, etc.) if located at a height of
over 2.5m from the maintenance level, provision shall be made for
stationary platforms with the railings and stairs / ladders.
32. On outdoor pipelines of diameter 1200 mm and over, a continuous

walkway along the entire length shall be provided with hand railings on
both sides. The height of the hand railings must be atleast 1.2m. In case of
a number of pipelines, the passage shall be provided on the upper most
pipeline.
33. To ensure the condensate drainage, the gas pipelines shall be laid with a
gradient of about 0.005 towards the water drains.
Condensate drains shall be equipped with bleeders.
34. Flash back arrestors shall be provided in each section of the pipe work for
acetylene and LP gas to prevent flame propagation or pressure surges.
They may be of hydraulic / cartridge type flash back arrestors or back
pressure valves.
- All branch pipes from main header shall be connected through a hydraulic
arrestor.
- Shut-off globe valves shall be provided on both the inlet and outlet sides of
the arrestor and unions shall be provided for repair or replacement, if required.
35. Oxygen pipelines are laid on either side of the fuel gas line as per the
following norms.
Oxygen Pressure Diameter of Oxygen Permissible gap in

in Kg/cm2 pipe mm mm
Upto 0.1 Upto DN 500 300
Upto 0.1 Above 500 600
0.1 to 16 Upto 500 800
16 to 35 Upto 200 800
Continuous installation is not allowed if the oxygen pressure is more than

16 Kg/cm2 and diameter of pipe is more than 200mm and also if the oxygen
pressure is more than 35 Kg/cm2 for any size.
Minimum clearances of overhead oxygen pipelines (surface to surface)
i) Explosion Hazardous shops : 3 meters clearance

ii) Railway tracks : 3 meters
iii) Railway bridge and platform : 3 meters
iv) Roads : 1.5 meters upto

embankment
v) High voltage Transmission lines
A. Parallel to pipelines : 10 meters
B. Crossing the pipelines upto 20kv : 3meters
35 to 150kv 220kv : 4 meters
vi) To place of hot metal tapping and
Source of open fire : 10 meters
vii) Insulated L.T cables : 0.5 meters
Bare conductor L.T : 1.0 meters.
36. In respect of Acetylene pipes the main header shall run minimum 15
meters away from any building, fire protection facilities like water
reservoir, pump house and storage tank facilities containing hazardous
flammables liquids and fuel gas storage like gas holder.
37. As far as possible, routing of high operating temperature pipelines, fuel

gas or liquid fuel, steam, oxygen should be avoided along with the
acetylene pipeline. All the Acetylene pipes and fittings shall be electrically
grounded. At flanged and bolted connections jumpers or spring washers
have to be installed for continuity of grounding.
03.03 PIPE LAYING FOR UNDER GROUND / OVER HEAD WATER SERVICE
PIPELINES:
01. The Water pipes installed along building wall should not cross window
and door way.
02. When Water pipes are installed along external walls of buildings below
window ways, installation of flange, thread joints and also installation of
accessories is not allowed.
03. Water Pipes of various service conditions may be laid along with oxygen
on a common support provided conditions stipulated under various clauses
are followed.
04. Shop headers (except headers of By-product Plant) should be mounted at

a height having minimum ground clearance of 4500 mm, when laying
them outside the building wall.
05. Water pipes in buildings should be located at places convenient for

servicing, inspection and repair. It is not allowed to lay pipes at places
where there are chances of damage due to shop transport
06. For the pipelines laid on roof, the distance from the external edge of the
pipe to the roof shall be at least 0.5m.
07. All shop headers, except for gravity fluids, shall be generally routed along
columns in multiple rows at a height 4 to 6m above floor level. The
connections to equipment shall be taken through suitable covered floor
trenches for shops at ground floor and for basements, for elevated
operating floors, the equipment pipe work connection may be taken below
the floor level. All isolated single pipe connections to equipment shall be
buried in the flooring / equipment foundations. Pipe work from basement
and oil cellars to main equipment shall be routed in pipe tunnels / trenches
with adequate spacing for easy maintenance. All pipe trenches shall be
covered by chequered plate or by concrete slabs.
08. Branch pipes from the headers to the building through walls and the roof
shall be encased.
09. Platforms, access ladders, hand railing, etc. shall be provided for operation
and maintenance of valves, instruments and controls. Manholes and
hatches shall be provided for access inside the pipelines.
10. At all the places of regular maintenance (gate valves, throttle valves,
orifice plates, hatches, manholes, bleeders, etc.) if located at a height of
over 2.5m from the maintenance level, provision shall be made for
stationary platforms with the railings and stairs / ladders.
11. Under ground buried pipeline (Interplant network)
All the process water, industrial water and drinking water are generally
laid buried underground except the rubber lined demineralised water line.
(Natural gas pipes run cross country are mostly laid underground with at
least 2.0 meters earth cover.)
12. Underground Pipe tunnel of R.C.C

Process water, contaminated water, may also be considered for laying
inside a walkable underground R.C.C tunnel.
13. Over-ground supported on R.C.C pedestals or sleepers.

In Oil refinery, the process water, drinking water, firewater, and oil lines
are generally laid on R.C.C pedestals or sleepers for interplant
communication.
14. In shop pipelines

The inshop water pipelines are generally laid supported on building
columns, or below the crane girder or with the floor beams.
15 Salient considerations in Design of pipe Layout in trenches / underground

buried.
(i) Spacing of pipes in Trenches / underground buried.
S.No Nominal Diameter of Pipe, mm A (mm) B(mm)

1. Upto 150 300 200
2. 200 to 500 400 300
3. 600 to 750 500 500
4. 800 & above Minimum 500 mm and will increase depending
upon the pipe diameter.
(ii) Earth Coverage

Buried pipework is laid with earth cover sufficient to avoid damage from pressure
of vibration caused by surface traffic. Minimum earth cover over the top surface
of pipe shall be minimum 1200mm from the finished ground level in areas subject
to temporary loads.
(iii) Road and Railway crossing

All the under ground pipes crossing railway tracks and roads where the depth of
earth cover from the bottom of ties or road bed to the top of pipe is less than
1500mm, are to be protected by provision of encasing. The protection may be
either culvert, concrete casing pipe or steel encasing pipe or R.C.C trench with
cover.
Minimum size of casing pipe are given in the following table.
Service Pipe Minimum Diameter of Encasing pipe

Diameter(mm) For flanged pipes (mm) For welded pipelines(mm)
100 300 200
150 400 250
200 500 300
250 600 400
300 600 500
350 600 500
400 700 600
500 800 600
600 900 700
16. Laying of welded steel pipes for water supply shall be done as per IS: 5822
17. Laying of cast iron pipes shall be done as per IS: 3114
03.04 PIPE SUPPORTS (for Gases, Liquid fuel, gas & Water service pipelines)
01. After routing the pipelines from originating station to various consumers it is
necessary to support the pipelines suitably to keep in position in the interplant &
inshop areas.
02. PIPES IN THE INTERPLANT AREA.
001. All the pipelines are laid over the trestles in the interplant area for transportation of
fluids from their generating station to various consumers. These pipelines require
support at definite intervals. Support intervals are decided on the basis of pipe dia. In
general support intervals followed are indicated in table no. 05.01 & 05.02.
002. Saddle supports are used for large dia pipes i.e DN 500 & above. For saddle supports
refer typical drawing no. MEC/11/40/TYP/DE/10/………………….
003. Smaller dia pipe i.e below 500 mm dia are supported on channels of suitable size
depending upon pipe dia to be supported. For such support refer piping drawing of
the project.
004. However, steams pipes of all sizes are supported on saddles only. Pipe with vertical
fall are required to be held in position by providing U-Clamps or vertical restrictors
/saddles provided with trestle structure, etc.
005. Smaller dia pipe below DN 500 are held in position by means of U- clamp are
provided at each supporting point in horizontal / vertical pipe route.
For U-clamp details refer typical drawing No MEC/11/40/TYP/DE/10/………………….
005. All the above supporting arrangement should have provision of anchoring the pipe
rigidly wherever required.
In case of saddles /channels type supports, rigidly fixing at the location of F.P. (fixed
points) are achieved by welding the saddle/channel with the supporting structures as
well as with pipe.
In case of U-clamps (for pipe below DN 80) the clamping nuts should be tightened
fully for FP supports.
006. Large dia gas ducts are supported o trestles by using
- Saddle Supports.
- Roller Supports
- Boll Supports.
Roller /ball are used for reducing frictional force on structures
03. PIPES INSIDE SHOP AREA.
001. Pipes to be laid inside the shop are generally supported on the shop
building/structural columns at a level with clear head room of 5.5 m.and at a location
where it does not obstruct the activities.
(i.e crane movement, equipment movement, etc.)
002. Smaller dia pipe DN 200 & below are fixed by using U-clamps or by means of
hangers as the shop structure permits.
003. Large dia pipe with sizes above DN 200 are supported on building structural columns
by means of saddles resting on structures extended from existing columns. Where
ever saddles can not be provided, U-clamps are used to hold pipe in position.
004. Large dia pipes are preferred to be supported by means of hangers mounted from
structure.
005. In specific cases where over head laying of pipeline is not possible, pipes may be laid
under ground in channels. However, under ground laying of oxygen and acetylene
pipeline and fuel gas pipeline shall be avoided. In case laid in channel then they
should be covered with bed of sand.
Such pipes shall be supported on pedestals with clear spacing between pipes.
01. Generally smaller dia pipes are laid over large dia pipes/ducts with supporting
structures. Provided at definite intervals depending upon pipe sizes and their
supporting spans
02. Always clearance between two consecutive pipes are provided all along the route.
These clearances are considered based on the following.
• Suitable to accommodate valves on both the lines. Mounting of valves and

other equipment with flange connection are accommodated on pipelines.
• Clear space of 100-200 mm should be provided between – two consecutive

pipes.
Table enclosed indicates the minimum distances to be maintained between pipelines.
03. Distances between large dia pipes/ducts (DN 500 & above) if laid parallel should be
such that minimum 1000 mm clear space all along the route between the pipes/ ducts
shall be maintained. This is required for inspection & maintenance of the pipes / ducts
and mounted equipment, valves, instruments, etc. there on.
CHAPTER -04
DESIGN CONSIDERATIONS
04.00 DESIGN CONSIDERATIONS

04.01 GENERAL
Guidelines for selection of pipe sizes, routing and layout of piping and selection of
piping material are covered in Chapter 02,03 and 06 respectively. In addition to the
above, following factors influence the designing of piping network for various
fluids :
- Composition and properties of Fluid

- Fluid flow rate
- Max working pressure
- Max. working temperature
- In door / outdoor installations
- Statutory regulations and clearance requirement, if any
- Corrosive nature of fluid
- Flammability and explosive nature of fluid
Considering the above factors recommendations described in subsequent clauses

shall also be taken into account while designing the piping system
04.02 CONDENSATE DISPOSAL FOR FUEL GASES, COMPRESSED AIR &

STEAM PIPELINES
Fuel gases as well as other gasses contain moisture and other condensable impurities
which get separated during fluid transportation through piping system, effective
condensate removal system should be incorporated to prevent accumulation of
condensate in pipes which otherwise may cause obstruction to proper gas flow and
excess live load to the pipe/ structure.
All piping for gasses containing moisture etc. like BF / Coke oven / BOF gas, Mixed
gas, Compressed air, Steam & Natural gas are laid with gradient / slope. A slope of
5mm per meter run shall be provided for the above pipelines. In case of space
constraint to accommodate slope, it may be reduced to 0.003 particularly for in shop
piping. For straight length of pipeline, low / high points should be located generally
at a distance 100 meters. However, in no case it should exceed 300 meters.
Condensate drain points shall be provided at all low points. In case of low pressure
gas lines, automatic drainage system though seal pots shall be provided.
For compressed air lines and steam lines, automatic condensate / steam traps shall be
provided.
04.02.01 Condensate Drain Arrangement for Low Pressure Gases
i) Drainage should be provided at all the low points of gas pipes carrying moist
gases for condensate removal. Disposal of condensate shall be through seal
pots/ condensate drain installations.
Page 1 of 47
ii) Distance between any two drain points of a gas pipe within a radius of 100
meters from gas cleaning plant should not exceed 60 meters.
iii) Drainage system for outdoor gas networks should be located in open air with
necessary accessibility for operation.
iv) Pipes for condensate removal from inter shop gas pipes of blast furnace gas in
a radius of 400 m from gas cleaning plant should be at least 80 mm diameter.
For pipelines beyond 400 m and also for gas pipes for other moist gases,
diameter of condensate removal pipes should not be less than 50 mm.
v) Separate seal pots shall be provided for different gasses.
vi) Removal of condensate from branch line from inter shop gas pipe and inshop
gas pipe should be carried out in separate condensate seal pots.
vii) Minimum height of the water seal in the condensate seal pot shall exceed the
maximum working pressure of gas by 500 mm, but this height in no case
shall be lower than 2000 mm.
If necessary, the height of water seal can be increased by adding more than
one seal pot in series. However, number of such seal pots shall not exceed
three. Further base plate of seal pot shall have minimum thickness of 16 mm.
While installing common seal pot for a number of gas pipe, height of water
seal should exceed by 500 mm the maximum working pressure in any of the
connected gas pipe.
viii) Design of condensate seal pots should ensure protection against leakage of
harmful gases into building by providing vent of adequate height on the seal
pot.
ix) Condensate seal pot shall be provided with purging facilities.
x) Installation of condensate seal pot for inshop gas network is allowed inside
the buildings.
04.02.02 Condensate Drain Arrangement for Medium pressure / High pressures

gas
i) Condensate disposal for gases having higher line pressure have to be done by
using adequate pressure seal pots.
ii) In a high pressure seal pot the metallic float is utilized for disposal of
condensate and prevent leakage of gas from the pot.
Page 2 of 47
iii) The seal pot should be air tight and wall thickness should be decided on the
line test pressure.
iv) Condensate coming out of seal pot should be discharged into phenolic
sewerage line or in a reservoir provided locally.
04.02.03 Steam Traps / Moisture Traps for Steam / Compressed air.
At low points in steam & compressed air pipeline steam traps / moisture traps with
strainer assembly will be provided to drain out the condensate. Selection of steam
trap shall be as per IPSS: 1-06-039 – 02. Installation of steam traps shall be as per
IPSS: 1-06-037 – 01.
04.03 PURGING & VENTING SYSTEM FOR FUEL GASES
Piping system particularly piping for fuel gases is required to be purged with inert
gas prior to charging of gas as well as during shut down before any maintenance job.
System for feeding purge gas and venting of gas/ air from the piping system shall be
provided for all fuel gas piping.
04.03.01 Purging
i) Gas pipelines of blast furnace gas, coke oven gas, converter gas and mixed
gas shall be equipped with nitrogen or steam pipe connection with isolation
valve . The connection of nitrogen or steam pipeline to the gas pipeline shall
be done by means of flexible hose which shall be connected only during the
period of purging.
ii) Location of purge gas inlet points and vents shall be such that entire section
of piping can be purged with minimum dead space. Purging points shall be
provided at low points.
iii) Purging points shall not in any case be provided at bottom half of the gas
mains.
iv) Purge points for fuel gas pipes upto DN 950 mm shall be of minimum DN 25
mm same for pipes of DN 1000 mm & above shall be of minimum DN 50
mm.
04.03.02 Vents
i) Bleeder/vents shall be provided for purging / venting any section of the

pipeline. Bleeders shall be located generally at all high points in the piping
system. Bleeder / vents shall also be provided at down stream / upstream of
isolating devices & U-seals.
Page 3 of 47
ii) All vents shall discharge at a safe height into atmosphere. The vents shall be
above the operating floor / platform for vent valve or roof of the building 4m,
but not lower than 8 meters from the ground level. In the presence of the
aeration monitors on the roof of the building, the vents shall be located so as
to eliminate the possibility of purged gas getting inside the premises.
iii) On straight lengths bleeder/vent shall generally be provided at an interval of

100 meters.
iv) All vents shall have T piece/cowl with bird screen preferably at the top. For
isolation of bleeder/vent pipe flanged gate valve of rising stem type shall be
provided. Sampling points (DN 25) below isolation valve with lubricated
taper plug valve shall be provided in the line to monitor gas samples at the
time of purging.
v) Vent pipes of different gases shall not be connected through a common vent.
vi) Recommended sizes of bleeder / vent pipes corresponding to gas pipe

diameter are indicated in Table – 04.01
Page 4 of 47
Table –04.01
RECOMMENDED SIZES OF BLEEDER / VENT PIPES
Pipe dia Bleeder pipe dia. DN (mm)

DN Low Pressure Fuel gas Natural gas/Corex Gas
(mm)
20 - 20
25 - 20
40 - 20
50 50 20
65 50 20
80 50 20
100 50 20
150 50 25
200 50 25
250 50 25
300 50 25
400 80 50
500 80 50
600 80 50
700 100 80
800 100 80
900 100 80
1000 150 100
1100 150 100
1200 150 100
1300 150 150
1400 150 150
1500 200 150
1600 200 -
1800 200 -
2000 250 -
2200 250 -
2400 250 -
2500 250 -
2800 250 -
3000 250 -
3200 300 -
3500 300 -
Page 5 of 47
04.04 VALVES AND ISOLATING DEVICES FOR GAS & WATER SERVICES:-
Isolating devices shall be provided in piping system for isolation of pipe sections as
well as for isolation of all other mounted accessories for the purpose of operation and
maintenance. They shall be suitable for the service conditions in all respects and
located suitably considering ease of operation and maintenance.
Isolation valves shall be provided at the following locations:
• On all pipe lines both at the source and at consumer ends

• On all branch pipes to individual buildings and shops
• On all bleeder / vent pipes, purge gas inlet points, drain points, sampling
connections, etc.
• On all by-pass lines for large valve, regulators, filters, moisture traps etc.
• Instrumentation tapping points.
Relocation of isolation valves on request of CLIENT may also be considered if

technically acceptable.
Other types of valves required for piping system include the following:
• Check-valve on all pipelines requiring only unidirectional flow.

• Quick acting shut-off valves on gas/ air lines to furnaces and heaters as
well as before each consumer or group of consumers.
• Pressure regulating valves for all pressure reducing installations, gas
mixing stations and flow control system.
04.04.01 Selection of Isolating devices for Gas & Steam services:-
The gas cut-off arrangement shall ensure the possibility of complete cut-off gas along
with fast and safe operation. Gate valves with rising stem shall be used normally for
isolation in piping system.
Pipe work for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter Gas,
Mixed Gas with low operating pressure shall have some means of gas tight isolation
of sections of the pipe work to facilitate maintenance work. These may be water
seals, goggle valves, spectacle blinds, or gas tight isolators / slide plate valves, etc.
For sections where the gas tight isolating device can not be provided, provision to
insert blind flange at outlet of gate valve shall be made.
Sectionalizing / isolation for purging of fuel gas lines may be done with Spectacle
blinds.
Page 6 of 47
Gas tight butterfly valves may be used for isolation near consumption points
requiring frequent and quick operation. These can be valves with gas tight seating or
eccentric valves for gas tight isolation.
Emergency quick shut off valves shall also be double eccentric butterfly valves.
For fluid lines with working pressure over 16 kg/cm2 (g), valves of DN 300 and
above shall be provided with by-pass arrangement or depressurisation arrangement
for pipe sections.
04.04.02 Selection of Actuators for Isolating devices for Gas services:-
Manually operated shut-off gate valves of size DN 300 to DN 450 for low pressure
lines shall have gear drive. For high pressure lines, gear operator shall be provided as
per manufacturer’s recommendations for limiting the operating torque to acceptable
limits.
Gate Valves of size DN 500 and above shall be provided with electric actuators.
Electric actuators for fuel gas lines shall be of flame proof design if located in gas
zone/inshop. In the interplant area these actuators need not be flame proof. Position
and torque limit switches shall be provided on actuators. Manual over ride shall also
be available in actuators.
Goggle valves shall have electrical actuators for disc/ plate movement and electro
hydraulic drive for flange separation. Manual arrangement for valve operation shall
also be provided with gear and chain operation from convenient location. The
hydraulic power pack for the valve shall include one motorized pump and one
manual pump. Encased design goggle valve with vent should be used at locations
closed to buildings.
Electrically operated gate valves for gas pipelines of smaller diameter are
recommended to be used only if they are incorporated in the automation scheme.
All valves located remotely, requiring frequent operation and / or with automatic
control shall be provided with electric drives, electro- pneumatic drive, solenoids etc.
04.05 OTHER FLOW COMPONENTS FOR GAS / STEAM SERVICE:-

04.05.01 Check Valves
Check valves are used in piping system where unidirectional flow is required check
valves can also used for stopping flow reversal incase of sudden stoppage of fluid
flow like in the pump discharge. For small size pipes below DN 50, lift check valves
are used. For DN 50 and above, swing check valves or dual plate check valve are
used. Lift check valves can used only in horizontal pipeline it should not be used in
vertical pipeline. For low pressure gas lines dual plate check valve are most suitable.
Page 7 of 47
04.05.02 Pressure Regulating Valves
Irrespective of specified variations in upstream pressure, these shall maintain a

reduced constant pressure on the downstream side of pipelines on which they are
mounted. The valve shall be of globe / needle type, with material specifications,
dimensional standards etc. as per the relevant piping Material Specification(PMS) for
the service for which the valve is intended.
Self actuated pressure regulators shall be used for pressure reduction in service
piping. Spring loaded pilot operated regulators shall be used. In case precision
control of pressure is required. Dome loaded regulators with additional pilot spring
loaded regulator for pressurizing the dome may be used. For pressure regulators,
maximum and minimum available pressure upstream of regulator and desired range
of outlet pressure with maximum flow rate shall be specified.
For process lines where continuous regulation/ control of pressure or flow is required,
control valves shall be used.
001 For Compressed Air
Pressure regulators of sizes up to DN 50 shall be complete with a prefilter having 40

micron porous bronze filtering element in shatterproof plastic or glass container,
pressure regulator and pressure relief arrangement to prevent overpressure at
downstream of the regulator.
For higher sizes to meet larger flow rates, the pressure regulator shall be self
actuating type as per manufactures standards, but capable of meeting the service
conditions and duty specified.
002 For Steam
For sizes up to DN 50, pressure reducing valves of single seated diaphragm type
having in-built strainer, with screwed ends up to DN 20 for PN 10 and below and
flanged ends for higher sizes and for higher PN. Body of main and pilot valves shall
be of carbon steel / alloy steel castings / forging, diaphragms shall be of stainless
steel, internal springs of stainless steel and pressure adjustment springs of spring
steel.
For higher sizes to meet larger flow rates, the pressure reducing valves shall be as per
manufactures standards, but capable of meeting the service conditions and duty
specified.
003 For Other Gases
For dry air, nitrogen and argon the pressure reducing valves shall be of stainless steel.
For oxygen service, the valve shall be of bronze construction and shall be degreased
and cleaned to meet the service requirements.
Page 8 of 47
For acetylene and LP gas services, the pressure regulators shall have material for the
service. For acetylene, the materials of construction shall not have copper in excess
of 70% by composition. (Refer IGC code).
Pressure regulators for large diameter gas lines shall comprise butterfly type valves
actuated by means of an oil hydraulic control system, which is actuated in turn by
changes in the preset downstream pressure through impulse pipe work.
04.05.03 Pressure Relief Valves
These shall be spring loaded type and shall automatically open when the pressure on
the pipelines, on which they are mounted, exceed preset values. The valves shall
have end connections and materials specified for throttling valves in relevant PMS.
Relief / Safety valves for steam service shall have IBR certification. Relief valves
shall have hand wheel / wrench for adjustment of preset value of relief pressure.
Pressure relief valves shall always be used on outlet lines from the pressure reducing
valves. Pressure relief valves shall be designed for full flow rate from pressure
regulators. Set pressure shall be 10 % higher than the maximum working pressure at
outlet of regulator.
04.05.04 Filters
Filters are installed in piping system before the pressure regulators/ control valves
and at consumer points depending on nature of fluid and technological requirements.
For small size pipes below DN 50, Y-type strainers with sintered/ wire mesh
cartridge may be used. For higher sizes, straight line mounted filters with removable
cartridge shall be used.
Filter element can be of wire mesh, sintered material, woven fibers or other suitable
type as per process requirement. Filtration area shall be at least 500% of the inlet
cross section area.
Full flow rate, maximum working pressure, micron rating, allowable pressure drop,
material of body and mesh shall be specified.
Page 9 of 47
04.05.05 Safety Shut-Off Valves
These shall shut-off in case the pressure on the upstream side of the valve becomes
less than preset values. The valves shall be of globe type for DN 50 and below and
butterfly type for sizes above DN 50; the material shall be suitable for service
conditions. The valves shall be actuated by electromagnetic or pneumatic device
working in conjunction with pressure switches located on the pipelines being
safeguarded and shall include all components required for its functioning.
04.05.06 Flash back arrestor
In acetylene piping, flashback arrestors shall be provided at the outlet of cylinder

manifold system and at each consumer point. Flash back arrestor prevents travel of
shock wave due to detonation/ deflagration in piping system. Dry type arrestors with
packed cartridge shall be used. Number of arrestors in parallel may be used to take
care of flow requirement.
04.05.07 Electrical continuity
Metallic electro static jumpers shall be provided at all locations on all flanged in case
of flammable gases and oxygen. This is to prevent accumulation of static electricity
in pipe sections. Piping system shall be suitably earth at a regular length of pipeline.
04.06 MEASURING AND CONTROL DEVICES FOR GAS SERVICES:-
Instrumentation and control devices are required for monitoring the fluid distribution
system, regulation of pressure and flow.
Flow measurement shall be provided at battery limit of all production and consuming
units, inlet/ outlet piping of storage installations, on surplus gas bleeder piping to
flare system etc. When orifice plates are used, proper care shall be taken in piping
layout for preventing accumulation of condensate by providing suitable slope or drain
system. Requirement of straight length upstream and downstream of flow sensors
shall be maintained as per instrumentation requirements. Normally the straight length
recommended is 10 times pipe dia before inlet and 5 times pipe dia after outlet of
device.
Pressure measurement shall be provides at battery limits of production and consumer

units, at outlet of storage systems, inlet and outlet of pressure regulators/ controllers,
etc.
Temperature measurement is provided at piping from gas cleaning plants and near
consumer installations.
Pressure and Flow Control valves are provided at gas mixing stations, main pressure
regulating stations, flare stack piping, inlet/ outlet piping of storage installations (gas
holders). For low pressure gas lines, butterfly type control valves are used. For high
Page 10 of 47
pressure gases, globe valves may be used. Sizing of control valves is based on flow
rate and pressure parameters. In most cases, the control valve size is lower than the
main pipe size. Suitable reducers/ expanders shall be provided at inlet/ outlet of the
control valves. In case of piping with possibility of condensate accumulation,
eccentric reducers shall be used.
04.07 WATER PIPELINES VALVES
001 Gate Valve:-
Gate valves are used for isolating or scouring of pipeline. They seal well under high pressure
and when fully open, offer little resistance to fluid flow. Sluice valves are not intended to be
used for continuous throttling, as erosion of the seats and body cavitation may occur. If small
flow are required the by pass, valve is more suitable for this duty.
002 Butterfly Valve:-
Butterfly valves are used to regulate and stop the flow especially in large size conduits. They
are sometimes cheaper than sluice valve for larger sizes and occupy less space. Butterfly
valves with no sliding parts have the advantages of ease of operation, compact size, reduced
chamber or valve house and improved closing and retarding characteristics. They would
involve slightly higher head loss than sluice valve and also are not suitable for continuous
throttling.
003. Globe valve:-
Globe valve have a circular seal connected axially to a vertical spindle and hand wheel. The
seating is a ring perpendicular to the pipe axis. The flow changes direction through 900 twice
thus resulting in high head losses. These valves are normally used in small bore pipe work
and as taps, although variation is used as a control valve.
004. Check valves:-
Check valves, also culled non-return valve or reflux valve, automatically prevent reversal of
flow in a pipeline. They are particularly used in delivery line of pump to prevent back flow
when pump shut down.
Dual plate check valves employ two spring loaded plates hinged on a central hinge pin, when
the flow decreases, the plates close by torsion spring action without requiring reverse flow.
As compared to conventional swing check valve which operates on mass movement, the
Dual plate check valve are provided with accurate by designed and tested torsion springs to
suit the varying flow condition.
005. Pressure Reducing Valves:-
These are used to automatically maintain a reduced pressure within reasonable limits in the
downstream side of the pipeline. This type of valve is always in movement and requires
scheduled maintenance on a regular basis.
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006. Pressure Sustaining Valves:-
Pressure sustaining valves are similar in design and construction to pressure reducing valves
and are used to maintain automatically the pressure on the upstream side of the pipeline.
007. Pressure Relief Valve:-
These valves are provided in one or more summits of the conveyance main to keep the
pressure in the line below given value by causing water to flow to waste when the pressure
builds up beyond the design value. Usually they are spring or weight loaded and are not
sufficiently responsive to rapid fluctuations of pressure to be used as surge protection device.
008 Ball Float Valves:-
Ball float valves are used to maintain a constant level in a service reservoir or elevated water
tank. The equlibrium type of valve is the most effective and it is designed to ensure that the
forces on each side of the piston are nearly balanced
009. Air Release Valve:-
Air release valves are designed specifically to vent, automatically and when necessary, air
accumulations from lines in which water is flowing such accumulations of air tend to collect
at high points in pipeline. Air which accumulates such peaks, reduces the useful cross
sectional area of the pipe and therefore induce a friction head factor that lowers the pumping
capacity of the entire line. The use of air release valve eliminates the possibility of this air
binding and permits the flow of water without damage to pipeline.
010. Air Inlet Valve:-
In the design and operation of large steel pipeline, where gravity flow occurs, consideration
must be given to the possibility of collapse in case the internal pressure as deduced below
that of atmosphere. To prevent the pipe from collapsing, air inlet valves are used at critical
points.
Air inlet valves should be installed at peaks in the pipeline, both relative to the horizontal
and relative to the hydraulic gradient.
011. Needle and Cane Valves:-
Needle and cone valves are more expensive that gate and butterfly valves but are well suited
throttling of flow. They have a gradual throttling action as they close. They are resistant to
wear even at high flow velocities. The method of sealing is to push an axial needle or spear
shaped cone into seat.
The needle and cone valve are not commonly used in water supply but are occasionally used
as water hammer release valve when coupled to an electric or hydraulic actuator.
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012. Ball Valve
Ball valves are normally used as quarter turn positive shut off valves. These valves offers
minimum resistance to the flow. These valves are generally considered for throttling and
flow control. Small size ball valves are used for instrument isolation e.g pressure gauges,
pressure transmitter, temperature transmitter, pressure switch etc. Based on body
construction the valves can be classified as Single piece, two piece, three piece, the short
pattern & the long pattern etc.
013. Plug Valve.
Plug valves like ball valves, are quarter turn positive shutoff valves. Two major types of plug
valves are in use. They are the lubricated metal seated plug valves. These valves can have
flanged, butt welded, screwed or socket weld. Plug valves are available in two way, three
way and four way depends upon their application in water distribution lines. Plug valves are
used as shutoff and flow control valves.
014. Foot Valve.
Foot valves are a sort of non-return valves with strainers mounted at the open and of the
pump suction pipe lines. There valves are used when the pump has negative suction. The
check action of the valve .. the priming fluid & the pump while the pumps are filled before
starting. The suction strainer help to hold the solids while the pump is sucking the fluid.
015. …… Gate Valve
These are single seated valve used for slurry services. Being single seated valve, it can be
used for only unidirectional operations. The edge of the gate is happed to shear the solids
and the seal is used to keep the solids away from entering the space between the plates when
open and to clean the sliding blade when it retracts.
016. Diaphram Valve
Diaphragm valves are mainly used for low pressure corrosive services as shutoff valves
These can also be used as control valves. Here, the diaphragm moves up and down to
operate the valve. The valve body can be lined or lined. Lining material is selected to suit the
corrosive nature of the service fluid there are two type of diaphragm valves available. They
are weir type and straight flow type. The weir type is popularly know as ‘ Saunders’ type
diaphragm valve. The use of these valves is restricted as they can withstand a maximum
operating pressure of 7 to 10 kg/cm2. The damage the diaphragm occurs and hence thee
maintenance is more frequent. Diaphragm valves are mainly used in DM water plant and
chemical dosing lines.
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04.08 EXPANSION AND FLEXIBILITY.
All Pipe work shall be designed to provide sufficient flexibility against thermal
expansion to prevent development of undesirable forces and moments at points of
connection to equipment, at anchorage or at guide points.
As far as possible flexibility shall be provided by planning route with change of

direction or by the use of bends, loops or off-sets..
Whenever self-compensation can not be achieved by pipe routing, provision for

thermal expansion shall be made by providing expansion loops or expansion joints as
per following criteria :
• U loops shall be provided for all low pressure fuel gas piping up to DN
300 size and high pressure piping for all sizes.
• For low pressure fuel gas piping, disc type expansion joints
(compensators) shall be provided for pipes of DN 300 and above.
• Stuffing box type Gland Compensators shall be used on low pressure coke
oven gas lines.
• For high pressure piping, where U-loop is not possible, bellow type
expansion joint may be provided. Bellow type compensators may also be
provided in low pressure gas lines in case movement is in two planes
(axial & angular)
While locating the expansion joints following guidelines should be followed:
• Disc / bellow compensators should be located preferably in the center of

two fixed points.
• U-Compensators should be located in between two fixed points with

variation in pipe lengths in the ratio of 1:2 (max).
• Gland Compensators are located near the fixed supports to facilitate

smooth functioning.
• Disc, bellow and gland compensators shall have flanged connection with
pipes
04.08.01 U-loop Compensator
U-loops shall be provided in piping system using elbows/ bends as per piping
material specification.
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U-loops shall be in horizontal plane and loops for many pipes running in parallel may
be provided at same location parallel to each other.
Loops shall be in the same plane as the pipe route. However, in some cases, where
there may be obstruction due to other parallel pipes, U-loop plane may be raised to
clear the pipes by providing bends.
Loops in vertical plane can be provided in exceptional cases if horizontal loop is not
possible due to layout considerations. Provision shall be made in piping for draining
of condensate, venting, etc.
Height and width of expansion loops (U-loop) for various diameter of pipes can be
taken from respective nomograms enclosed as Annexure - A
04.08.02 Disc Compensator
Disc compensator is made by fabrication using sheets/ plates. Care shall be taken to
ensure that thickness of compensating disc does not exceed the design thickness
during manufacture.
Depending on total displacement required, single or double disc compensators may

be used. In no case compensators shall have more than three discs.
Internal sleeve shall be provided for draining of condensate. In case continuous
drainage system is provided at disc location itself, internal sleeve is not to be
provided.
04.08.03 Bellow Compensator
Bellow type expansion joints are made from SS sheet and can be single or multi layer
with number of convulations. Depending on the application, bellow type compenstor
may be selected from the following types:
a) Axial Compensator
Axial compensators are used in place where there is no deflection of pipe in

transverse direction such compensators can take care of axial deflection
(elongation / contraction) through it’s convolutes.
b) Pressure Balanced Expansion joint
A pressure-balanced elbow is used in application where transfer of excessive

thrust to anchors or adjacent equipment due to internal pressure is not
desirable. The design comprises a combination of bellows with tie rods to
absorb axial motion while restraining pressure thrust.
c) Hinged expansion joint
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Hinged expansion joints are used to absorb angular movement when the
movement occurs in one plane only.
d) Universal expansion joint
Universal expansion joints are used to take care of both axial & lateral
deflection in pipes.
04.08.04 Loads due to Compensators
Loads on anchor points due to bellow compensators are considered based on the feed
back from supplier / manufacturer. Such loads depend upon number of convolutes
and number of plies and their thickness.
04.09 SPECIAL CONSIDERATIONS FOR OXYGEN PIPING
Filters should be installed in the oxygen pipeline system at the following points:
a) At the outlet of the oxygen plant.
b) Upstream of components having soft seating in contact with the oxygen

stream e.g. pressure regulator and control valves.
c) Upstream of components that have moving parts in contact with the oxygen
stream e.g. flow measuring and limiting devices.
Provision shall be made for safe and easy access for frequent cleaning and / or
replacement of the filter element. The larger capacity filters like (a) above should be
provided with differential pressure gauge for monitoring the condition and providing
indication for cleaning / replacement of the filter element. The filter bodies shall
preferably be of copper alloy or stainless steel and filter element of copper alloy or
glass cloth suitably earthed to the filter body with copper wires.
Two (2) or more pressure relief valves should be provided downstream of each set of
pressure reducing valves. One or more main relief valve(s) should be capable of
discharging 100% of the full oxygen flow and limiting the pressure within the
defined limits. The secondary relief valve should be sized to discharge the nominal
leakage from the pressure reducing valves. The relief valves should be positioned as
close as possible to the pressure reducing valves. The vent lines from the relief valves
should be preferably of stainless steel or copper.
Consideration should be given to providing of small size pressure equalisation bypass

isolation valves across large diameter isolation valves in large pipeline systems so as
to ensure safe pressurization of the downstream pipeline. Sonic velocities may occur
during the initial stages of valve opening with possibility of high velocity transport of
material / dirt particles in the system. If the valve opening action is rapid, there is also
a possibility adiabatic compression and heating of the oxygen specially if additional
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closed valves exist downstream. The bypass pipe work and valve should be of copper
or copper alloy.
Fire break sections may be installed in the oxygen pipeline to limit the propagation of
combustion in a steel pipeline. Fire break sections may be introduced immediately
downstream of the main isolation and throttling valves where the velocities can be
high. The fire break section will be either a length of copper pipe having the same
inside diameter as the main pipe with flanges fitted at the two ends which is installed
between the steel pipes or a copper insert tube made from copper sheet / tube and
inserted inside the steel pipe downstream of the valves. The copper insert tube is
generally used in large diameter steel pipelines.
In steel pipelines care should be taken to install isolation valves on straight sections
of the pipeline. Any pipeline component which is likely to cause a change in the flow
pattern like reducer, bend, tee or “Y” connection, orifice plate etc. should be at a
distance of at least four diameters away from the valve.
For cleaning of the gaseous oxygen pipelines after erection, provision for “pigging”
will be provided for pipelines having diameters upto DN 200. However, if the
pipeline is pickled and phosphated as per approved procedure, pigging of pipelines is
not essential. The bends on these pipelines will have a radius of 5 DN. DN 250 and
above, extra care will have to be taken regarding cleanliness of these pipeline during
installation. For line sizes DN 250 and above the bends will have a radius of 3 DN.
Gaseous oxygen pipe work shall preferably have butt welded pipe joints. To reduce
safety hazards the number of components should be kept to a minimum compatible
with the system requirements. Flange joints are to be used only for connection of the
pipe to the system components on the pipe work. Threaded joints and couplings
should be sparingly used.
04.10 Piping system shall be designed with high degree of reliability so that the systems
perform the duty of fluid handling without structural or functional failure under most
adverse condition of plant operation anticipated. All piping systems shall be designed
with sufficient corrosion and stress margins to ensure a life time without failure, not
less than the life of the plant. 7000 complete cycle of operation shall be considered
for stress analysis purpose. Piping system shall not impose reactions on equipment
terminals exceeding permissible limits even under adverse operating conditions.
Personnel injury from discharge of hot fluids from drains, steam traps, hot pipes or
exposures to pipe vibrations shall be guarded against.
01. Pipes shall be sized for minimum pressure drops and considering the velocity
limitation for various types of fluids.
02. Adequate flexibility shall be provided in the pipelines to keep stresses and
reactions in the system arising due to thermal expansion or other effects within
limits. Where the piping terminates at an equipment or at the terminal point of a
Page 17 of 47
system, the reactions and thermal movement imposed by piping on the equipment
or the system concerned shall be well within the limits specified.
03. If cold springing of pipleline is used, care shall be taken in determining the
location and amount of cold spring gap. Cold spring gap shall be located at points
where the bending and torsional moments are minimum. Use of cold spring gaps
less than 10mm shall not be acceptable and cold spring gaps above 100mm shall
be avoided. All outdoor piping exposed to sunlight carrying fluid at a temperature
less than 800C shall be designed considering thermal expansion corresponding to
800C and empty pipe as one of the operating conditions although not necessarily
the worst.
04. All piping shall have butt welded connections with minimum of flanged joints for
connection to vessels and equipment to facilitate erection and maintenance. All
high pressure steam valves and accessories shall have welded connections.
Standard fittings shall be used wherever practicable. Unless otherwise specified,
for all welded lines with pressure above 4 kg/cm2 g and / or temperature above
2000C, branch connections with branch sizes upto 25% of welded mains shall be
made with special forged steel welded fittings.
05. Bends for pipes for oxygen service shall have a radius of not less than three times
the nominal pipe dia unless otherwise specified.
06. In general pipes having size 50mm and above, are to be joined by butt welding
and 40mm below by socket welding / screwed connection. Threaded joints shall
have to be seal welded except for galvanized pipes where Teflon sealing tapes
shall be used. For galvanized pipeline, pipe joints which are to be made before
galvanising shall be of welding type. Those joints which are to be made after
galvanising shall be either flanged or screwed type. As far as practicable, whole
fabricated piping assemblies shall be galvanized at a time in order to minimize
the number of joints to be made after galvanising.
07. All pipelines shall be provided with drain connections, generally at the lowest
point for removing accumulated condensate or water and line draining. The
drains piping shall have drain pockets and isolation valves. Trap stations shall be
provided where necessary. Lines shall be given proper slope towards the drain
points. Drip legs on mainson line dia 150mm or over shall be at least 75% of the
main dia with a depth twice the dia of the main or 600mm minimum from the
centre line of the main to the trap off take unless otherwise specified. Drip legs
on mains smaller than dia 150mm shall be full dia of the line. All drip legs for
fluids which may deposit undesirable liquid or solid matter shall have full dia
flanges for the bottom cover.
08. Pipe supports, anchors, restraints
- In general pipe supports, restraints, braces or anchors shall be located at those
points in the building or outdoor where provision has been made for the loads
imposed. Loads at the supporting points or restraints shall be determined
sufficiently early and provisions shall be made in the building or outdoor
structures for pipe supports. The Tenderer shall locate, design, supply and erect
Page 18 of 47
all the supplementary steel structures to properly secure and support all pipe
hangers, supports, restraints, etc.
- Provision shall be made for support of piping which may be disconnected during
maintenance work. All large pipes and all long pipes shall have at least two
supports each arranged in such a way that any length of piping or valve may be
removed without any additional supports being required.
- Supports, guides and anchors shall be so designed that excessive heat is not
transmitted to the building steel. Supporting steel shall be of structural quality.
Perforated, strap, wire or chain shall not be used. Support components shall be
connected to support steel by welding, bolting or clamps. Bolt holes shall be
drilled and not gas cut. Structural steel work for supporting shall be designed on
the basis of a maximum design stress of 1265 kg/cm2. Pipe attachments coming
in direct contact with pipes having surface temperature above 4000C shall be
made of alloy steel. Use of insulating materials like asbestos between pipe clamp
and pipe surface to meet the above temperature limitation shall not be permitted.
The maximum spacing between two consecutive supports shall be not more than
as specified. Pipe hangers and supports shall be capable of supporting the
pipelines under all conditions of operation. They shall be capable of supporting
the pipelines under all conditions of operation. They shall allow expansion and
contraction without over stressing the piping system or overloading the terminal
equipment due to variation in supporting effort. Rigid supports or hangers shall
be permitted only for pipes with small movements. For hot lines, spring hangers
shall be used. The maximum permissible load variation on the terminals of
sensitive equipment between hot and cold conditions shall be limited to 6%.
Variability in load between hot and cold conditions expressed as a percentage of
the design load shall be taken as the criteria for spring selection for spring
hangers. Variable spring hanger shall be set at cold conditions so that they take
design load under operating condition after the designed thermal expansion has
taken place.
Spring shall be encased in suitable cages and the hangers shall be provided with
spring locking arrangement, external load and movement indicator and turn buckles
for load adjustment. All the rigid hangers shall be provided with turn buckles for
vertical length adjustments. Hangers rods shall be subjected and designed for tensile
loads. At locations of high axial or lateral movement, suitable arrangement shall be
provided to permit the swing. The swing from vertical position shall be within 40.
Double nuts and locknuts shall be used for hanger rods and bolts in all cases. Hangers
shall be designed so that they can not become disengaged by movements of
supported pipe.
- The supporting structures at each support points shall be designed for the highest
of the following loads to take into account the extra load during hydraulic testing.
- 1.25 times the maximum load under operating condition

- Weight of pipelines full of water (combined weight of pipe, insulation, valve
attachment etc. plus weight of water)
Page 19 of 47
- Weight pipeline full of water as above plus any cold reaction as anticipated.
- Where the piping system is subjected to shock loads such as thrust imposed by
the actuation of safety valves, hanger design shall include provision of shock
absorbing devices of approved design. Vibration control devices shall be part of
piping system design.
- Outdoor piping shall be designed with due consideration to expansion resulting

from exposure to sunlight and care shall be taken to prevent progressive
movement of long pipelines. Outdoor piping may be supported on shoes, saddles
or steel sections. Effect of support friction especially for large dia pipelines shall
be considered and friction forces minimized by suitable arrangement. Piping
inside the trenches shall be supported at intervals on steel sections and the
arrangement shall permit easy maintenance.
09 Valves and specialties
- All valves shall be of approved make and type. All valves shall be suitable for
service condition i.e. flow, pressure and temperature under which they are
required to operate. The valves for high and medium steam service shall have butt
welded ends unless otherwise approved and the internal dia shall be same as that
of the pipes to be joined.
- All gate/ sluice, globe and needle valve shall be fitted with outside screwed
spindles and bolted type glands and covers. Spindle glands shall be of the bridge
type construction and screwed glands will not be accepted. All high pressure
valves having nominal dia more than 150mm, shall have integral steam bypasses
concede to the valve body by means of welded joints.
- All gate/sluice, globe and needle valve shall be provided with hand wheel and
position indicator. The face of each hand wheel shall be clearly marked with
words “open” and “shut” with arrows to indicate the direction of rotation to
which each refers. Arrangement limiting the travel of any valve in the “open” or
“shut” position shall be provided exterior to the valve body. All globe valves
shall be designed to prevent erosion of valve seats when the valves are operated
partially opened. Valves which cannot be operated from the floor or walkways,
shall be provided with suitable extension rods and linkages to facilitate operation
from the floor or walkways. Chain operation will not be accepted for steam
valves. Stems shall preferably be arranged vertically with gland at the top. In no
circumstances must the gland be at the bottom. Valves shall not be installed in an
inverted position. The design of valves shall be such that it will permit packing of
glands under pressure. Where required, valve spindles shall be extended so that
the hand wheel is at a height of about 1.0m above the level of the floor or
platform from where the valves are to be operated. Where required, they shall be
provided with head stocks and pedestals of rigid construction and where gears or
bevel wheels are used, these shall be of cast steel or suitable grade cast iron with
machine cut teeth.
Page 20 of 47
- Non return valves on all pumps discharges and steam line shall be of an approved
non slamming type. Draining arrangement shall be made on both sides of the
horizontal non-return valve where such a valve adjoins an isolating valve. Valve
bodies shall be provided with removable access cover to enable the internal parts
to be examined without removing the valves. Valves shall have a permanent
“arrow” inscription on its body to indicate direction of flow.
- Gate sluice valves for low pressure service shall be outside screw rising spindle
type. For these valves wherever necessary, chain operator shall be provided to
operate the valve from the floor or walkways. Larger size gate valves for low
pressure applications shall be provided with bypass and draining arrangement and
valves with dia more than 350mm shall be provided with gear operator. For low
pressure water applications, the non-return valves shall be lift check type for size
upto DN 50mm and swing check type for higher sizes.
- Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm

shall be of reinforced rubber and rubber lining of body shall have minimum
thickness of 3mm. Generally plug valves shall be used in compressed air line.
Plug valves shall be supplied with wrench operator. Valves shall be of taper plug
type. Sampling valves for demineralised water shall be of cock type and stainless
steel AISI 316.
- For motor operated valve, a 415V, 3 phase, 50Hz reversible speed motor shall be
furnished. Motor shall be capable of producing not less than 1.5 times the
required operator torque. Each operator shall be equipped with two adjustable
limit and torque switch for both open and closed position. The motor shall be of
high torque low starting current. Each operator shall be provided with auxiliary
hand wheel for manual operation. The hand wheel shall automatically disengage
when the operator is energized.
- Manual operator shall be of worm and gear type, having permanently lubricated,
totally enclosed gearing with hand wheel diameter and gear ratio designed to
meet the required operating torque. The operator shall be designed to hold the
disc in any intermediate position between full opened & full closed without
creeping and fluttering. Adjustable stop shall be built into the operator to prevent
over travel in either direction. Operator shall be equipped with direct coupled
position indicator and suitable locking device.
- Pressure reducing valves shall be perfectly stable, quiet and vibration less in
operation when reducing the pressure for any throughput upto maximum and
shall be suitable for continuous use at operating temperature. Valves shall be
designed to prevent erosion of the valve seats. Safety valves shall be the direct
spring loaded type and shall have a tight, positive and precision closing. All the
safety valves shall be provided with manual lifting lever. Valves used for
compressible fluids shall be of pop type. Safety valve shall be so constructed and
adjusted to permit the fluid to escape without increasing the pressure beyond 10%
above the set blow off pressure. Valve shall reset at a pressure not less than 2.5%
and more than 5% the set pressure.
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- The seat and disc of safety valves shall be of suitable material to resist erosion.
The seat of valves shall be fastened to the body of valve in such away that there is
no possibility of seat lifting.
10.Fabrication and installation of pipe work

- Pipe joints shall be assembled with the inside of all pipes and fittings smooth,
clean and free from burrs, scale, welding slag, sand and dirt. The inside edges of
pipe and tubing shall be reamed after cutting to remove burrs. Screw threads shall
conform to ANSI B 2.1 for taper pipe threads. All the threaded joints shall be
made up with a lubricant or compound suitable for the service under which the
piping is to be used.
- Welded joints shall conform to “Code for pressure piping ANSI B31 1.0 (power
piping) or approved equivalent, except where the welding of such joints is
covered by other code requirements such as IBR, ASME pressure vessel and
boiler code or approved equivalent.
- Branches shall in generally be formed by welding standard fittings. Pipe bends

and tees shall be truly cylindrical and of uniform sections. Where permitted for
certain services, elbows or branch connections may be formed from steel pipe.
Unless otherwise agreed, slip-on welding flanges shall be used on pipe and for
connection to low pressure equipment. Welded neck flanges shall be used for butt
welding fitting as elbows, tees and reducers and for connection to high pressure
equipment. Where class 125 ANSI flanges are bolted to 150 ANSI steel fittings,
the 1.5mm raised face on the steel flange shall be removed. When bolting such
flanges, a full face gasket shall be used. Equipment terminal flanges if consist of
a different standard, a suitable companion flange shall have to be provided at the
connecting points.
- Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges
shall be 900 to the longitudinal axis of the pipe to which they are attached. Slip-
on flange when used, shall be welded in accordance with ANSI B31.1 or any
other equivalent code. If distorted after welding, the flange shall be refaced. In all
cases, flange faces, must be free from particles of weld metal. The flange face and
the pipe projecting end shall then be machined to permit both pipe and flange to
bear against.
11. All welding by the electric arc and gas welding process for pipe joints and
fabrication shall be done by qualified welders and done according to appropriate
IBR, ANSI code / regulations as applicable for welding, subject to accompanying
code regulations and standards for filler metal, pressure, temperature and fluid
carried. The ends of pipe and welding fittings shall be beveled according to the
details shown in ANSI B31.1 or equivalent. All welds shall be made in such a
manner that complete fusion and penetration are obtained without an excessive
amount of filler metal beyond the root area. The reinforcement shall be applied in
such a manner that it will have a smooth contour merging gradually with the
surface of adjacent pipe and welded fittings.
Page 22 of 47
04.11 Fire water pipeline
- Pipes shall be provided on the ring main concept where the number of landing valves
installed on the pipe are more than five, In other cases (where the ring main is not
possible and the pipes terminate with dead ends) the size of the branch pipes and the
number of landing valves installed shall be as follows:
Number of landing Pipe dia

valves
1 80 mm
Upto 3 100 mm
Upto 5 150 mm
Flexible rubber lined hoses (with circular woven jacket) alongwith necessary couplings,
branch pipe with nozzle etc. shall be housed in a hose box or cabinet placed one for every
landing valve. The hose box shall be provided with breakable glass cover and shall be
hung near the landing valves in an easily accessible position.
04.12 Underground water pipelines
Water pipelines outside any shop building or between two shop buildings may be buried
underground. Gravity flow drainage pipes shall also be buried wherever necessary.
However slurry pipeline under pressure shall be laid in covered trenches or tunnels.
Buried pipelines shall be laid with 0.5 to 1.0 m gap between outside of pipes, minimum
earth cover of 800 mm and minimum clearance from other underground structure of 1.0
m. Pipe laying shall be done using the relevant Indian Standard codes and practices
specially the following:
IS : 5822 : laying of welded steel pipes for water supply
All pressure pipes shall be provided with a nominal slope and the gravity pipes shall be
provided with slopes for self cleansing velocity.
Manholes shall be provided on the gravity pipe lines at every point of change of direction
of stope. The manholes shall be made of concrete with cast iron hatch and cover and
rungs for approach to the bottom.
Valve on underground water pipeline shall be installed in concrete valve pits with proper
removable cover of cast iron and proper drainage arrangement for the pit.
Page 23 of 47
Pipe crossing a railway track or road shall be protected by encasing in concrete or by

laying it inside another encasing pipe of steel having a diameter two sizes higher than the
main pipe.
Buried steel pipes shall be painted and coated as per IS:10221 “ Insulation of underground
pipes.”
04.13. SLURRY WATER PIPELINE:-
FACTORS AFFECTING SLURRY WATER PIPELINE DESIGN:
1. Specific gravity of solids

2. Size and shape of particles
3. Density of conveying medium
4. concentration of solids
5. Liquid viscosity
6. Slurry viscosity
7. Flow rate
8. Slope & Roughness of pipes
9. Corrosion & erosion factors.
CRITICAL SETTLING VELOCITY (VC)
The critical velocity at which a bed of particles begins to form is known as critical
settling velocity
Deposition velocity increases

- Increase in particle size
- Solids concentration
- Particle density
- Increase in pipe diameter
Design velocity > Critical settling velocity
Warman’s Recommendations = Design velocity should be 30% higher than Vc
Calculation of Critical Settling velocity
DURAND”S EQUATION
Page 24 of 47
Vc = FL ( 2gD x (s-s1) / s1)1/2
Where,
Vc = Critical settling Velocity
FL = Froude constant
D = internal dia of pipe = OD – 2t
S = Sp.gravity of dry solids
S1 = Sp.gravity of media.
FL depends upon particle size & volumetric concentration of slurry.
SINCLAIR’S EQUATION
Vc = FL ( 2gD x (s-s1) / s1)1/2 (d/D)1/6
Where,
d = d50
= Average particle size
This is for lean slurry.
Density of slurry, ρm = 100/((cw/ρs) + (100-cw)) / ρw)
Where,
cw = Concentration by weight
ρs = Sp.gravity of dry solids
ρw = Sp.gravity of flow medium
For BF – GCP slurry
ρm = 1.083 (ρs =4.3)
When, concentration is 10%

Concentration by volume = cw . ρm / ρs
For BF GCP slurry, When cw = 10%
ρm = 1.083
Page 25 of 47
04.14 CORROSION PROTECTION OF UNDERGROUND BURIED M.S PIPES

FOR WATER SERVICES:-
Buried steel pipes are liable to external corrosion and therefore need to be protected
by the use of suitable coating. Steel pipes may be coated with any of the following
methods as per the decision of the Purchaser.
Types of Coating:-
i) Coat Tar enamel and fire glass polyester tissues in accordance with
IS:10221.
ii) Corrosion Protection Tapes in accordance with IS:10221.
iii) Concrete lining as IS:1916 or Gunniting.
When the pipe is coated / wrapped before laying / putting into ground trench, the
same should be made continuous after laying. After wrapping and coating
individual pipe piece shall be tested in accordance with IS : 10221.
Flanges shall be cleaned and are to be protected by plastic strips, bitumen strip and by
pouring anticorrosive material.
i) Cleaning of the external surface
Pipe surface shall be thoroughly cleaned and dried before the primer is applied. The
pipe surface shall be free of dirt, grease, oil, rust, scale and other foreign material. Pipe
surface shall be cleaned by any of the methods.
• Grit / shot blasting

• Stand blasting
• Mechanical cleaning by pneumatic wire brush.
All oil and grease material shall be removed by suitable solvent and then surface
cleaned by clear rag.
ii) Coating of Primer
The cleaned surface have to be immediately applied the coating of primer.
Three types of primer are generally used i.e.

(a) Coal Tar Primer
(b) Asphaltic primer
(c) Synthetic primer.
Page 26 of 47
iii) Coating of Enamel
After the application of primer, coating of enamel is applied. Two types of enamel are
generally used (a) Coat Tar enamel (b) Asphalt enamel.
Depending upon the type of primer used the compatible enamel shall be used and it
should be from the same manufacturer.
iv). Applying the Wrapping Material
Three type of wrappings material are used (i) Glass Fibres (ii) Asbestos felt (iii) Kraft
paper. The wrapping is being done in two phases. First the inner wrap of glass fibre
tissues is applied. The second outer wrap is by means of glass fibre felt type 1 to
IS:7193. In case outer wrapping is by asbestos felt then it should be thoroughly
saturated with air blown coal tar / asphalt coating.
In case outer wrapping is by kraft paper then the kraft paper shall be water proof and
impregnated with coal tar / asphalt enamel.
04.15 CATHODIC PROTECTION FOR M.S BURRIED WATER PIPELINES:-
Mild Steel Pipes buried in corrosive soil need to be protected with the help of cathodic
protection in addition to wrapping and coating.
Cathodic protection system reverses the electro chemical force by creating an external
circuit between the pipeline to be protected and an auxiliary anode (known as
sacrificial anode) buried in the ground at a predetermined distance from the pipe.
Direct current applied to the circuit is discharged from the anode surface and travels
through the surrounding electrolyte to the pipe which is cathode.
Two methods are available for generating a current of sufficient magnitude to

guarantee the protection. In the first method the sacrificial anode material such as
magnesium or Zinc is used to create galvanic cell. The electrical potential generated by
the cell causes the current to flow from anode to the pipe and returning to the anode
through a simple connecting wire. This system is generally used where it is desirable to
apply small amount of current at a number of locations, mostly often on coated
pipelines in lightly or moderately corrosive soils.
The second method of current generation is to energise the circuit with on external DC
power supply such as rectifier. The technique commonly referred to as impressed
current method uses relatively inert anodes usually graphite or silicon cast iron
connected to positive terminal of DC power supply with the pipe connected to negative
terminal. This system is generally used where large amount of current is required at
relatively few locations and in many cases it is more economical than sacrificial
anodes.
For cathodic protection, a corrosion survey including chemical – physical analysis of

the soil must be performed along the pipeline. Where the soil resistively is less than
Page 27 of 47
5000 ohms-cm. Cathodic protection in conjunction with appropriate wrapping and

coating system shall be used. The cathodic protection shall conform to IS:8062 Part-II.
For soil resistively above 5000 ohms-cm, cathodic protection shall be used in
consultation with corrosion engineers.
Page 28 of 47
04.15 THERMAL INSULATION OF PIPELINES
Thermal insulation is applied to pipelines for two purpose.
i) To prevent heat loss to atmosphere in case of fluid being hot or to gain heat in case of the
fluid it contains is cold or below ambient temperature.
ii) To ensure that the skin temperature of the equipment or pipe is not more than 600C
which is a permissible limit prescribed by the Inspector of factories.
Insulation Materials
Following insulating materials are normally used.
i) Unbonded mineral wool made from slag or rock confirming to IS : 3677 or glass wool
conforming to IS : 3690
ii) Bonded mineral wool conforming to IS:8183 made from slag or rock or glass process
from molten state into fibrous form and bonded with a suitable binder.
iii) Preformed fibrous pipe insulation conforming to IS:9842. The material shall be mineral
wool processed from rock or glass fibres.
iv) Insitu Polyurethane / polyisocynurate insulation conforming to IS:13205 (applicable for

max operating temperature of 1100C).
Thickness of Insulation
Thickness of heat insulation to be provided is a function of the value of thermal conductivity of

the material selected, the temperature of the fluid and the bulk density of the heat insulation
material.
Following table gives the bulk density for unbonded and bonded mineral wool with temperature
limitations of hot face temperature.
Unbonded Bonded Mineral Wool (kg/m3) Max hot face

Mineral wool Slabs / mattresses Pipe sections Temp 0C
Glass Wool Rock Wool
120 kg/m3 50 85 120 250
150 kg/m3 80 85 120 400
200 kg/m3 120 85 120 550
Page 29 of 47
Table for Insulation thickness

Pipe size
Insulation thickness in mm for various temperature ranges
(outside dia)
Pipe size 1000C Between Between Between Between Above
(outside dia) and 101 and 201 and 301 and 401 and 5000C
below 2000C 3000C 4000C 5000C
Upto DN 50mm 25 50 50 75 100 100
DN 65 to DN 25 50 75 100 125 125
100mm
DN 125 & 50 75 75 100 125 150
DN 150mm
DN 200 mm 50 75 75 125 125 150
DN 250 mm 50 75 100 125 150 150
DN 300 mm 50 75 100 125 150 150
Note:
The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS: 277
with following thicknesses:
- Pipe sizes up to 300 mm OD : 0.63 mm

- Pipe sizes up to 300 mm OD
equipment, flanges, valves : 0.80 mm
Page 30 of 47
ANNEXURE –A
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CHAPTER: 5
LOAD CALCULATIONS & FLEXIBILITY

ANALYSIS
GUIDELINES FOR PIPING DESIGN Chapter No– 05 Page 1 of 8
05.00 LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS
05.01 Load Calculations for gaseous & Liquid pipelines:-
Loads from the piping system are transferred to the pipe supports and connected
equipment. Depending on the direction of application, loads are calculated under two
major heads :
• Vertical Loads
• Horizontal Loads
05.01.01 Vertical loads
Vertical loads transferred to pipe supports comprise of the following :
• Dead weight of the pipes

• Weight of fluid in pipes
• Weight of insulation if any
• Condensate weight in gas pipeline
• Dust load due to deposition on pipeline
• Load due to mounted valves, compensator and fittings.
• Load due to saddles, supports and other service pipes
• Dead load and live load from Platforms and walkways
Empty weight of pipes shall be taken from standard weight tables.
In case of pipes carrying liquid, fluid weight with full pipe section shall be
considered.
Following norms shall be followed for calculating the condensate load in low
pressure fuel gas mains.
Pipe dia. (mm) Height of filling of pipe Filling in cross-

cross-section with section (%)
condensate (mm)
1. Upto DN 500 Full 100
2. DN 600 – DN 1400 500 88 – 35
3. DN 1500 – DN 3500 500 – 800 30 – 14
Load due to dust deposition shall be as follows :
• 50 Kg/m2 on pipelines at a distance within 100 m from dust generating plant (viz.
Blast Furnace, Coke ovens, SMS, Lime and Dolomite plant etc.)
• 25 Kg/m2 on pipelines at a distance between 100 m to 500 m from dust generating
plants.
Sheet 1 of 8
Weight of valves, compensators and other mounted accessories shall be taken from
drawings/ catalogues.
Live load on platform shall be taken as 500 Kg/m2. This is indicated to Structural
Section for designing platforms.
It is recommended to add 10% to 20 % of vertical load as a provision for pipes

to be laid in future on the same route.
Horizontal loads
Horizontal loads transferred to pipe supports comprise of the following:
• Load due to thermal expansion

• Load due to internal gas pressure i.e. blanking load, load due to annular space
of compensator, unbalanced pressure load at branch locations, etc
• Load due to friction
• Wind load
Depending on the pipe configuration, horizontal loads can be in axial direction as

well as in transverse direction.
Horizontal loads due to thermal expansion, internal pressure and friction are
calculated by carrying out flexibility analysis on individual pipe. Procedure is given
in para 05.03. However, wherever possible, standard software package like
CAESAR-II may be used for carrying out flexibility analysis and calculations of
loads transmitted to supports and nozzles of equipment to which piping is connected.
05.02 LOCATION OF PIPE SUPPORTS
Supports for pipes shall be provided based on pipe layout. Span between two
consecutive supports for a pipe shall be limited to the values given in Table 05.01 and
05.02
Recommended spacing (C.L to C.L) between two pipes are indicated in Table 05.03.
In specific cases where span between two supports can not be provided as per the
table, alternative arrangement for intermediate support using bridge between trestles
or guy rope supports may be considered. In exceptional cases where distance exceeds
the limiting span, suitable stiffening of pipe section to prevent sagging may be
considered.
At sliding supports pipe saddle shall be allowed to rest on bearing plate for free
movement. In case U-clamps are provided, clearance shall be maintained for pipe
movement by providing two nuts on opposite sides.
Sheet 2 of 8
All intermediate supports shall be of sliding type. Anchor supports shall be located
based on piping configuration and layout to provide adequate flexibility.
Distance between two consecutive fixed supports in straight runs of pipe route should
be approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it
should exceed 100 m.
However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm
cold pull if any during erection may be given as per instructions of the respective
drawings.
To reduce friction force transmitted to supports, roller supports or anti friction pad
supports can also be used.
05.03 FLEXIBILITY ANALYSIS
Piping arrangement shall provide for flexibility of lines to take care of the thermal
expansion, contraction and equipment settlement. Large reactions or moments at
equipment connections shall be avoided . Expansion computation shall be made on
the basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or –ve )
design temperature(s) as given.
i) Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest
Edition). Analysis shall consider stress intensification factors as per ASME
B31.3.
ii) Lines which shall be subjected to steam out conditions , shall be designed and
analyzed at low –pressure steam design temperature of line whichever is
more. Lines having negative design temperature shall be analyzed for both
conditions separately.
iii) Flexibility Analysis of lines shall be carried out using simplified methods or a
comprenhensive computer program. Comprehensive computer analysis shall
be carried out for the piping as per Cl. No. 05.03 (vii) For lines connected to
equipment like vessels, pumps, filters, furnace, compressors or other strain
sensitive equipment. The result of the analysis must satisfy the allowable
loading on the nozzles of such equipment.
iv) Piping shall be adequately supported for the weight of piping, water, attached
unsupported components, wind, seismic, insulation and any other applicable
forces. Care should be taken that these supports are adequate to prevent
excessive stress, load or moments in either the piping or terminal nozzles of
the equipment to which it is connected. Adequacy of supporting of lines
having heavy valves shall be checked. The support shall be indicated in the
piping General Arrangement Drawings and Isometrics as applicable.
Sheet 3 of 8
v) Safety valve manifolds and downstream of control valves shall be adequately

supported to avoid vibrations.
vi) The following factors shall be considered in the stress analysis

- Friction for lines >= 8” NB ; @ steel to steel = 0.3: ( Sliding friction), @
steel to Steel =0.1 (Rolling friction),
- Corrosion Allowance.
- Initial displacement of nozzles at design temperature(s).
- Transverse deflections =25 mm( maximum)
- Longitudinal expansion/contraction = 200 mm (maximum) Special care to
be taken to check for expansion loops and shoe support lengths shall be finalized
accordingly.
viii) The following shall always be analyzed using comprehensive computer

analysis:
a) All lines 4” and above and Design Temp.> 300 deg. C.

b) All lines 8” and above and Design Temp. > 150 deg. C.
c) Al l lines 16” and above and Design Temp. > 80 deg. C.
d) All lines 6” and above and Design Temp. > deg. 65 C that are
connected to rotating Equipment, Air Coolers or any other sensitive
equipment.
e) Any other system/line that stress engineer feels necessary for stress
check.
The report shall comprise of the following:
- Basic input data and calculated conditions.

- Layout isometric and supports configuration.
- Load cases and calculated member stresses.
- Forces, moments and displacements reports.
- Spring hangers design parameters.
- Allowable Stress Range.
- Additional requirements ( reinforcement pad etc.)
Sheet 4 of 8
05.04 PROCEDURE FOR FLEXIBILITY ANALYSIS ( MANUAL)
Step I
Draw free line diagram covering piping segment and branches on both sides of fixed
support (F.S.) for which resultant load / stress is to be worked out.
D B E C
F.S. COMP F.S. COMP F.S.
Step - II
Calculate effective dead load + live load (DL + LL) due to pipe & equipment at point
B for segment AB & BC.
Step - III
Frictional Force
Expansion joint / compensator is to take care of thermal elongation / contraction and

hence its position is considered as fixed though there may be a very minor change in
the location of expansion joint. Practically it is taken as zero displacement.
Calculate frictional force f1 & f2 due to pipe segment DB and BE respectively.
Frictional force = (DL + LL) x Co-efficient. Of friction
Co-efficient., of friction for steel to steel shall be taken as follows :
Sliding support = 0.3

Roller support = 0.1
Ball support = 0.1
PTFE pad support = 0.05 to 0.09
Sheet 5 of 8
Step - IV
Anchor Force
Anchor force is to be worked out separately for segment AB and BC.
Calculate total elongation / contraction for segment AB.
∆l=l*α*∆t
Where
∆l = Thermal elongation / contraction in mm
l = length of segment AB in meters
α = co-efficient of thermal expansion
= 0.012 mm / m / 0c for steel
∆t = Maximum temp. difference in 0C
• Identify spring rate of the expansion joint / compensator (kg f/mm)
• Calculate anchor force due to segment AB using formula
Anchor force a1 = Spring rate (Kg f/mm) x ∆ l.
• Calculate anchor force (a2) due to segment BC in similar way.
Step - V
Force due to annular space of disc compensator / bellow compensator.:
The annular space remains filled with gas and exerts pressure on the wall of compensator,
which is turn, gets transferred to the fixed support.
Sheet 6 of 8
Force due to annular space of compensator (c1 & c2) = π/4 (D2 – d2)p
Where, D = I.D. of Compensator in mm

d = I.D. of pipe in mm
p = Test pressure of piping system in kgf/mm2(g)
Compensator force c1 and c2 shall be worked out for both the segments AB & BC
respectively.
Step VI
Blanking Load
Blanking load comes into effect when there is change in direction of flow / at the location of
isolation device. Direction of blanking load is towards the bend. Blanking load may be
worked out using formula.
B.L. = π/4 x d2 x p
Where d = ID of pipe in mm
P = test pressure of piping network in kg f / mm2
As is evident, in Case I, no blanking load is applicable at fixed support “B”.
Sheet 7 of 8
Step VII
Prepare the load diagram for the fixed support to be analyzed.
Frictional force = f1 ( ) Frictional force = f2 ( )

Anchor force = a1 ( ) Anchor force = a2 ( )
Force due to compensator c1 ( ) Force due to compensator c2 ( )
FS
A C
Blanking load = 0 B Blanking load = 0
Based on above diagram, resultant force is worked out at point “B”.
Resultant 1:
Frictional force = f = f1 – 0.7 f2 ( ), where f1 ≥ f2
Anchor Force = a = a1 – 0.7 a2 ( ), where a1 ≥ a2
Force de to compensator = c = c1 – 0.7 c 2 ( ), where c1 ≥ c2
All the above forces in this case act along the axis of pipeline. There is no transverse force
acting perpendicular to pipe axis. Hence, resultant axial force at “B” = (f + a + c)
05.05 WIND LOAD CALCULATION
Wind load acts on transverse direction across pipe due to pressure of wind.
Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind
pressure due to cyclonic wind pressure shall be taken.
Wind load for a section of pipe = Wind pressure X projected area x shape factor
For circular pipes shape factor is 0.7.
In case of multiple pipes, for each tier of pipes, largest pipe may be considered for
calculating wind load.
Sheet 8 of 8
CHAPTER: 6
PIPING MATERIAL SPECIFICATIONS
MECON LIMITED DOC No MSTD-DESG-FS & PD-1405 Rev - 0
GUIDELINES FOR PIPING DESIGN Chapter No - 06 Page 1 of 27
06 PIPING MATERIAL SPECIFICATION

06.01 SCOPE
This PMS covers the various piping specification for process and utility piping in
Metallurgical plants and its related industrial Installation.
Deviation from this specification may be necessary to conform to specific job

requirements. In such cases a separate and specific PMS shall be issued with the
approval of piping competent authority.
06.02 REFERRED CODES & STANDARDS
All piping shall be designed in accordance with relevant latest codes and
standards like B 31.1, B 31.3 and different IPSS (Inter plant standard for steel
industry)
Individual piping material specification has been designed to cover a set of

services operating within fixed pressure and temperature.
06.03 PIPES
06.03.01 Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for
carbon steel pipe and to B36.10/B36.19 for stainless steel pipe.
06.03.02 Pipe made by acid Bessemer process shall not be acceptable.Pipes shall be made
by open hearth, electric furnace or basic oxygen process.
06.03.03 All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted.
06.04 FLANGES
Flanges shall be in accordance with following codes except where otherwise

noted.
DN 15 to DN 600 (150 # - 600#) ANSI/ANSI B16.5 / IS : 6392
Above DN 600 API 605 / ANSI B16.47 / MSS-SP-44 / IS:6392

DIN etc.
Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be
made with equipment or valve flanges with corresponding bolting.
06.04.01 Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME
B16.5. The interpretation shall be as follows :
Serrated : 250 – 500 Mu in AARH
Smooth (125 AARH) : 125 – 250 Mu in AARH
For RTJ groves (32 AARH) : 32 – 250 Mu in AARH
Page 1 of 27
06.04.02 Bore of WN flanges shall match the ID of the attached pipe Bore of slip on
flanges shall suit the pipe OD and its thickness.
06.04.03 Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2)
is indicated in Table 06.01
06.05 FITTINGS
06.05.01 Forged steel socket welded and threaded fittings shall be in accordance with
ANSI B 16.11 unless otherwise noted.
06.05.02 Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise
noted.
06.05.03 Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless

otherwise specified.
06.05.04 Fittings thickness and tolerance shall match pipe thickness and tolerance.
06.05.05 Mitres and reducers fabricated form pipe may be use if specified in PMS, shall
conform to IPSS:1-06-020-95. In no case mitres thickness and material shall be
inferior to parent pipe.
06.06 GASKETS
06.06.01 Non metallic gasket shall conform to IS:2712.
06.06.02 Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20.
06.06.03 Ring type and spiral wound gasket shall be self aligning type.
06.07 BOLTING
06.07.01 Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992.
Unless otherwise noted.
06.08 THREADS
06.08.01 Threads for threaded pipes, fitting flanges and valves shall be in accordance with
B1.20.1 taper threads unless otherwise noted.
06.08.02 Upto 2000C threaded joints shall be made with 1” width PTEE joining tape.
06.08.03 Above 2000C threaded joints shall be seal welded with full strength fillet weld.
06.08.04 All threaded joints irrespective of pressure and temperature on lines carrying toxic
fluid shall be seal welded with a full strength fillet weld.
Page 2 of 27
06.09 VALVES
06.09.01 Face to Face/End to End dimension of valves shall conform to B16.10 to the
extent covered. For valves not covered in B16.10. reference shall be made to
BS2080 and / or the manufacturer’s drawings.
06.09.02 Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting
ends of the piping class, unless otherwise specified.
06.09.03 Pressure temperature rating for flanges and butt welding end valves shall be as per
ANSI B16.34 except for ball, plug & butterfly valves. For these valves refer
TABLE FOR PRESSURE TEMP. RATING FOR BALL, PLUG AND
BUTTERFLY VALVES
06.09.04 Unless called-out specifically, valves shall be as per the following Standards.
Valve Size DN Rating Des. Std. Testing Std.

mm
Gate 15 - 40 800/1500 API-602 API-598
Globe/Check 15 - 40 800/1500 BS – 5352 BS-6755 Pt-I
Gate 50 - 600 150/300/600 API-600 API-598
Gate 650 - 1050 150/300 BS-1414 BS-6755 Pt-I
Globe 50 – 200 150/300/600 BS-1873 BS-6755 Pt-I
Check 50 – 600 150/300/600 BS-1868 BS-6755 Pt-I
Gate/Globe/Check 900/1500/2500# B-16.34 API-598/
BS6755 Pt-I
Ball 15 – 400 BS-5351 BS-6755
Plug 15 – 300 API-599 API-598
/BS-5353
BS-6755
Butterfly 80 & - API-609/ API-1898/
above BS5155 BS-6755 Pt-I
AWWA /AWWA
C504
Diaphram ALL - BS-5156 BS-6755 Pt-I
06.09.05 If not covered in 06.09.04 the valve shall be as per B16.34 and relevant MSS SP
Standard
06.09.06 DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and
utility service shall have bolted bonnets. Pressure seal bonnets or covers shall be
used for Classes 900# and above to minimize bonnet leakage. However, valves
with pressure seal bonnet shall have wall thickness & seal stem diameter as per
API600. Welded bonnets or screwed & seal welded bonnets are acceptable for
sizes lower than DN 50 for Classes 900# & above.
Page 3 of 27
PIPING MATERIAL SPECIFICATION

SERVICE : BF Gas, CO Gas, BOF, Corex Gas & Mixed Gas
SERVICE CONDITIONS : Maximum Working Pressure 1500mmWC Temp 60 oC

Minimum Working Pressure 50 mmWC Temp 5 oC
CORROSION ALLOWANCE : 2 m.m.
Item Size Range Description Dimension Material

Standard Specification
Pipe DN 15 to 40 ERW, PE; Sch Heavy IS : 1239 IS:1239 - Black
DN 50 to 150 ERW, BE; Sch Heavy IS : 1239 IS:1239 - Black
DN 200 to 350 ERW, BE; 6 mm Thk IS : 3589 IS: 3589 Gr.330
DN 400 to 750 ERW/SWP,BE; 8 mm IS : 3589 IS: 3589 Gr.330

Thk
DN 800 to 3500 Fabricated – Electric IS : 3589 IS : 2062, Gr.B
Fusion Welded, BE;
10mm Thk.
Fittings DN 15 to 40 SW /Screwed Fittings IS : 1239 (P-2) IS : 1239 (P-2) Black

(Elbow R=1.5D)
DN 50 to 150 BW (Elbow R=1.5D) IS : 1239 (P-2) IS : 1239 (P-2) Black
DN 200 & Fabricated Miters bends IPSS-06-20 IS : 2062, Gr.B

above & fittings from pipe /
plate
Flanges Upto DN 150 SORF; Serrated Finish IS : 6392 IS: 2062, Gr.B
#150 Table - 5
DN 200 to 300 SORF; Serrated Finish IPSS:1-06-20 IS: 2062, Gr.B
Table 3
DN 400 & SORF; Serrated Finish IPSS:1-06-20 IS: 2062, Gr.B
above Table 3
Gaskets Upto DN 500 Gasket: Thk. 2 mm Ring As per Flange IS : 2712 Gr W/3
Type CAF
Above DN 500 Asbestos rope graphite
impingnated. Ǿ8mm
Valves DN 15 to 40 Gate valve; Screwed API 602 Body ASTM A105;
Cr 13% Trim
DN 50 to 550 Gate valve; Flanged IS : 14846 Body CI GR. FG 200
DN 600 to 1600 Gate valve; Flanged IPSS: 1-06-023 Body CI, Gr.FG-210
Page 5 of 27

DN 1800 & Gate valve; Flanged MSS Body IS: 2062 GR. B
above
DN 15 to 40 Check valve SW – Lift BS 5352 Body A105, 13% Cr

Type #800 Trim
DN 50 and Check Valve Flanged BS 1868 / API Body A216;WCB,
above swing check valve/ dual 594 13% Cr Trim
plate #150
DN 15 to 40 Globe valve SW / BS 5352 Body A105, 13% Cr
Screwed ; #800 Trim
DN 50 to 300 Globe valve; Flanged ; BS 1873 Body A216 Gr WCB,

Serrated Finish; #150 13% Cr Trim
DN 350 & Butterfly valve WAF BS 5155/ API Body A216 Gr
above Type; #150 594 WCB;13% Cr Trim
DN 15 / DN 25 Screwed BS: 5158 Body & PLUG : CI
LUB.TAPERED PLUG IS 210 FG 200
VALVE
Bolting All M/C Bolts ASTM A193 Gr IS: 1364- 1992
B7
Nuts ASTM A194 Gr IS: 1364- 1992
2H
Piping Flanged Joints At valve/ equipment location and for sectionalising & Maintenance.
Fabrication To be kept minimum
Pipes Joints DN 50 & below SW coupling
DN 50 & above Butt welded
Fabricated pipes Fillet welding using semi bandage on each segment.
Temp DN 40 – Flanged set-on nozzle
Connections
Pressure DN 20 – SW Half Coupling Nipple Sch 80 with Gate valve to Spec.
Tapping
Vents On lines >= DN 50 ; MEC std.
Drains On lines >= DN 80, MEC Std.
Note: For flange dimensions refer Table 06.01.
Page 6 of 27

SERVICE : LPG /PROPANE
SERVICE CONDITIONS : Maximum Operating Pressure 6 kgf /cm2 Temp 60 oC

Minimum Operating Pressure Atm Temp 5 oC
CORROSION ALLOWANCE : 1.5 mm.
Item Size Range Description Dimensional/ Material -

Design Carbon Steel
Standard
Pipe DN 15 to 40 Seamless PE Sch. 80 B 36.10 API 5L GR.B
DN 50 to 150 Seamless BE Sch.40 B36.10 API 5L GR.B

DN 200 to 300 Seamless BE Sch.20 B36.10 API 5L GR.B
DN 350 Seamless BE Sch.10 B36.10 API 5L GR.B
DN 400 & EFSW BE Thk. 6.0mm B36.10 API 5L GR.B
above
Fittings DN 15 to 40 SW / Screwed Fittings ANSI B 16.11 ASTM A 105
# 3000 (Elbow R=1.5D)
DN 50 to 150 BW Fittings #150 ANSI B16.9 ASTM A234 Gr WPB
(Elbow R=1.5D)
DN 200 & Miter bends & fittings IPSS-1-06-020 Same as parent pipe
above fabricated from pipe
Flanges DN 15 to 40 SW:RF : Serrated Finish; B 16.5 ASTM A 105
#150
DN 50 & above SORF : Serrated Finish; B 16.5 ASTM A 105
#150
Gaskets All sizes Gasket : Thk. 2.0 mm B 16.21 IS : 2712 Gr W/3
Ring type CAF
Valves DN 15 to 40 Gate valve SW # 800 API 602 Body A105 ; 13% CR
Trim
DN 50 to 600 Gate valve Flanged RF API 600 Body A216 Gr. WCB
Serrated Finish # 150 13% Cr Trim
DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A105; 13% Cr
Trim
DN 50 to 200 Globe valve : Flanged BS 1873 Body A216 Gr.WCB
RF Serrated # 150 finish 13% Cr Trim
DN 15 to 40 Check valve SW # 800 BS 5352 Body A105; 13% Cr
Lift type Trim
DN 50 to 600 Check valve flanged RF BS 1868 Body A216 Gr.WCB
Serrated finish # 150 13% Cr Trim
Page 7 of 27

Design Carbon Steel
Standard
DN 15 to 150 Ball valve flanged RF BS 5351 Body A216 Gr.WCB
Serrated finish #150 13% Cr. Trim
Bolting All Studs / Bolts B 18.2 ASTM A193 Gr B7
Nuts B 18.2 ASTM A194 Gr 2H
Miscellaneo DN 15 to 40 TRAP #150, MANF’ STD. BODY A105, TRIM
us THRMDNMC 13% CR , S: SS304
DN 15 to 40 PERM. STR, SW, Y MANF’ STD. BODY A05: INT SS
Type 304
DN 50 to 350 PERM. STR, BW, T MANF’ STD. BODY A234WPB :
Type INT SS 304
DN 400 to 600 PERM. STR, BW, T MANF’ STD. BODY A234WPBW:
Type INT SS 304
Above DN 600 TEMP. STR, FF, CONE MEC’ STD. BODY A516GR. 70:
Type INT SS 304
Piping Flanged Joints At valve/ equipment location and for sectionalizing & maintenance
Pipes DN 40 & below SW coupling
Joints DN 50 & above Butt welded
Pressure DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.
Tapping Gate
Connections
Vents On lines <= DN 40 ; MEC std.
Drains On lines <= DN 40 ; MEC std.
Page 8 of 27

SERVICE : MEDIUM PRESSURE NITROGEN , ARGON,
& COMPRESSED AIR
SERVICE CONDITIONS : Maximum Operating Pressure 10.5 kgf /cm2 Temp 60 oC

CORROSION ALLOWANCE : 1.5 m.m.

Design Carbon Steel
Standard
Pipe DN 15 to 40 ERW, PE Sch. HEAVY IS:1239 IS:1239 BLACK
DN 50 to 150 ERW, BE Sch. HEAVY IS:1239 IS:1239 BLACK

DN 200 to 350 ERW, BE , THK 6.0mm IS:3589 IS:3589 GR.330
DN 400 to 500 ERW, BE , THK 8.0mm IS:3589 IS:3589 GR.330
DN 550 to 600 ERW BE Thk. 10.0mm IS:3589 IS:3589 GR.330
DN 650 & ERW/ SAW, BE Thk. IS:3589 IS:3589 GR.330

above 10.0mm (min)
Fittings DN 15 to 40 SW / Screwed Fittings ANSI B 16.11 ASTM A 105
# 3000 (Elbow R=1.5D)
DN 50 to 150 BW Fittings #150 ANSI B16.9 ASTM A234 Gr WPB
(Elbow R=1.5D))
DN 200 & Miter bends & fittings IPSS-1-06-020 Same as parent pipe
above fabricated from pipe
Flanges DN 15 to 40 SW:RF : Serrated Finish B 16.5 ASTM A 105
#150
DN 50 to 600 SORF : Serrated Finish B 16.5 ASTM A 105
#150
DN 650 & SORF : Serrated Finish B 16.47 / ASTM A 105
Above #150 IS:6392 / API
605
Ring type CAF
Trim
Trim
Page 9 of 27

Design Carbon Steel
Standard
Lift type Trim
Bolting All Studs / Bolts B 18.2 ASTM A307 Gr B
Nuts B 18.2 ASTM A563Gr B
Type 304
Type INT SS 304
Type INT SS 304
Above DN 600 TEMP. STR, FF, CONE MEC’ STD. BODY A516GR. 70:
Type INT SS 304
Pressure DN 20 – SW half coupling Sch 80 Nipple with Gate valve to spec.
Tapping
Connections
Page 10 of 27

SERVICE : HIGH PRESSURE NITROGEN , ARGON, &
COMPRESSED AIR

Minimum Operating Pressure 10.5 kgf /cm2 Temp 5 oC
CORROSION ALLOWANCE : 1.5 mm.

Design Carbon Steel
Standard
Pipe DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM A106 Gr.B
DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM A106 Gr.B
DN 200 to 250 Seamless BE Sch.30 B36.10 ASTM A106 Gr.B
DN 300 to 350 Seamless BE Sch. Std. B36.10 ASTM A106 Gr.B
DN 400 to 600 EFSW BE Thk. B36.10 ASTM A672 B60 CL

Calculate 12
Fittings DN 15 to 40 SW Fittings ANSI B 16.11 ASTM A 105
# 3000 (Elbow R = 1.5D)
DN 50 to 350 BW Fittings ANSI B16.9 ASTM A234 Gr WPB
(Elbow R = 1.5D)
DN 400 to 600 BW Fittings ANSI B16.9 ASTM A234 Gr
(Elbow R = 1.5D) WPBW
#300
DN 15 to 600 WNRF : Serrated Finish B 16.5 ASTM A 105
#300
Gaskets All sizes SPIRAL; THK. 4.4 mm API 601 SS 304 SPR. WND +
CA FIL

Trim
Trim
lift type Trim
Page 11 of 27

Design Carbon Steel
Standard
DN 15 to 150 Ball valve flanges RF BS 5351 Body A216 Gr.WCB
Serrated finish # 300 13% Cr. Trim
DN 15 to 300 Plug valve flanges RF BS 5353 Body A216 Gr.WCB
Serrated finish # 300 HARDEN PLUG
Bolting All Studs /Bolts B 18.2 ASTM A193 Gr B7

Type 304
Type INT SS 304
Type INT SS 304
DN to 600 TEMP. STR, FF, CONE MEC’ STD. BODY A516GR. 70:
Type INT SS 304
Tapping
Connections
Page 12 of 27

SERVICE : LOW PRESSURE STEAM, CONDENSATE
& BOILER FEED WATER
SERVICE CONDITIONS : Maximum Operating Pressure 18 kgf /cm2 Temp 360oC
CORROSION ALLOWANCE : 1.5 m.m.

Design Carbon Steel
Standard
Pipe DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM 106 GR.B
DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM106 GR.B

# 3000; (Elbow R=1.5D)
(Elbow R=1.5D)
DN 200 to 600 BW Fittings ANSI B16.9 ASTM A234 Gr
(Elbow R=1.5D) WPBW

Ring type CAF
Trim
Trim
Lift type Trim
DN 15 to 150 Ball valve flanges RF BS 5351 Body A216 Gr.WCB
Serrated finish # 300 13% Cr. Trim
Bolting All Studs /Bolts B 18.2 ASTM A193 Gr B7
Page 13 of 27

Design Carbon Steel
Standard
DN 15 to 40 PERM. STR, SW, Y MANF’ STD. BODY A 105: INT SS
Type 304
Type INT SS 304
Fabrication to be kept minimum
Tapping
Connections
Note:
1. Class of various items shall be selected based on the pressure of steam in the line ( For
low pressure inferior class may be considered)
2. For higher pressure i.e, more than 18 bar the technologist (PP & EE) to be contacted for
specification.
Page 14 of 27

SERVICE : LOW/ MEDIUM PRESSURE OXYGEN

Cleaning, Pickling, Passivation & Degreasing As Per IGC : 33/86/E

Design Carbon Steel
Standard
Pipe DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM A106 GR.B
DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM A 106 GR.B

Fire DN 50 to 150 Copper Pipe B36.10 Deoxidised non
Breaker Arsenic Copper
DN 200 to 600 Copper Pipe B36.10 Deoxidised non
Arsenic Copper
# 3000; ( Elbow R=4D)
( Elbow R=4D)

Gaskets All sizes PTFE LOX GRADE B16.21 ASTM D3293; TYPE
3; Gr. 1+A
Valves DN 15 to 40 Gate valve; SW; # 800 API 602 Body A182 GR. 304;
/BRONZE ;13% CR
Trim / BRONZE
DN 50 to 600 Gate valve; Flanged; RF; API 600 Body A351 GR.CF8
DN 15 to 40 Globe valve, SW; # 800 BS 5352 Body A182 GR. 304;/
BRONZE; 13% CR
Trim/ BRASS
DN 50 to 200 Globe valve : Flanged BS 1873 Body Al BRONZE
RF Serrated # 150 finish CASTING; TRIM
BRASS; PTFE Seat
lift type Trim
DN 50 to 600 Check valve flanged RF BS 1868 Body & Trim A182
Serrated finish # 150 GR. 304
Page 15 of 27

Design Carbon Steel
Standard
DN 15 & Above Ball valve flanged RF BS 5351 Body A351 GR.CF8 ;
Serrated finish A182 GR. 304
Trim;PTFE Seat
Bolting All Studs/Bolts B 18.2 ASTM A193 Gr B7

Pressure DN 20 – SW half coupling Nipple Sch 80 with . Gate valve to spec.
Tapping
Connections
Page 16 of 27

SERVICE : HIGH PRESSURE OXYGEN

Minimum Operating Pressure 16 kgf /cm2 Temp 5 oC
RATING : # 300
Matching Companion Flanges of Valves & flow components as per
corresponding rating.

Cleaning, Pickling, Passivation & Degreasing As Per IGC : 33/86/E

Design Carbon Steel
Standard

Fire DN 50 to 150 Copper Pipe B36.10 Deoxidised non
Breaker Arsenic Copper
DN 200 to 600 Copper Pipe B36.10 Deoxidised non
Arsenic Copper
# 3000; ( Elbow R=4 D)
( Elbow R=4 D)
Flanges DN 15 to 40 SW:RF : Serrated Finish; B 16.5 ASTM A 105
#300
# 300
Gaskets All sizes CAF/ PTFE LOX B16.21 ASTM D3293; TYPE
GRADE 3; Gr. 1+A
Valves DN 15 to 40 Gate valve; SW; # 800 API 602 Body A182 GR. 304;
/BRONZE ;13% CR
Trim / BRONZE
DN 50 to 600 Gate valve; Flanged; API 600 Body A351 GR.CF8
RF;Serrated Finish # 300 13% Cr Trim
DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A182 GR. 304;/
BRONZE; 13% CR
Trim/ BRASS
DN 50 to 200 Globe valve : Flanged BS 1873 Body Al BRONZE
RF Serrated finish; # 300 CASTING; TRIM
BRASS; PTFE Seat
Page 17 of 27

Design Carbon Steel
Standard
DN 15 to 40 Check valve SW # 800 BS 5352 Body A182 GR. 304;
Lift type /BRONZE ;13% CR
Trim / BRONZE
DN 50 to 600 Check valve flanged RF BS 1868 Body A351 GR.CF8
DN 15 & Above Ball valve flanges RF BS 5351 Body A351 GR.CF8 ;
Serrated finish #300 A182 GR. 304
Trim;PTFE Seat
Bolting All Studs B 18.2 ASTM A193 Gr B7
Tapping
Connections
Page 18 of 27

SERVICE : ACETYLENE

Design Carbon Steel
Standard
DN 50 Seamless BE Sch. 80 B 36.10 ASTM A106 GR.B
Pipe DN 50 and Bends - Fabricated from

Fittings below parent pipes by cold
bending with radius 3
DN
Upto DN 40 Tees/Crosses & Reducers ANSI B16.11 ASTM A 105
- forged, socket welded
end. #3000
DN 50 Tees/Crosses & Reducers ANSI B16.9 ASTM A234 Gr
- BW Seamless #300 WPB
Upto DN 40 Unions – SW ends #3000 ANSI B16.11 ASTM A 105
DN 50 Unions – BW seamless ANSI B16.9 ASTM A234 Gr
#300 WPB
Bolting All sizes Studs/ Bolts B 18.2 ASTM A 193 Gr B7
Nuts B 18.2 ASTM A 194 Gr B2H
#300
DN 50 SORF : Serrated Finish B 16.5 ASTM A 105
#300
Gaskets All sizes 2 mm thick, ring type, B16.21 IS:2712 Gr.W/3
CAF
Valves DN 40 and CI lubricated taper plug BS: 5158 BODY & PLUG:
below valve, screwed ends CAST IRON IS : 210
Isolation valve FG 200
DN 50 CI Gate valve; Flanged IS:14846 BODY : CAST IRON
ends. GR FG -200
DN 50 and GM Check Valve (Lift – GM Check Valve
below Type) Screwed (Lift – Type) Screwed
Non-return
valve
Hose Upto DN 15 Hoses to IS:447, with IS:447/ IS:6016 Rubber hose
assembly hose connection to
IS:6016
Page 19 of 27

Design Carbon Steel
Standard
Flash back All sizes Hydraulic or dry type. -- SS/Brass
arrestors Screwed ends.
Page 20 of 27

SERVICE : LIGHT DIESEL OIL (LDO)
SERVICE CONDITIONS : Maximum Operating Pressure 8 kgf /cm2 Temp 100oC
CORROSION ALLOWANCE: 2 mm.

Design Carbon Steel
Standard
Pipe DN 15 TO ERW , HEAVY, PE IS:1239 IS: 1239 (Part I)
DN 40
DN 50 TO DN ERW , HEAVY, BE IS:1239 IS: 1239 (Part I)
80
DN 100 to DN Medium seamless or IS:1239 IS: 1239 (Part I)
150 ERW black
DN 200 to DN ERW B 36.10 ASTM A106 GR.B
450
Pipe DN 50 and Bends Fabricated from
Fittings below parent pipes by cold
bending with radius 3
DN/ IS:1239 Part II
DN 65 and Mitred bends with DN Mitred bends with DN
above 1.5 radius 1.5 radius /IS:1239
Part II up to DN 150
DN 450 and Tees/Crosses Fabricated from
below parent pipes.
DN 450 and Reducers Fabricated from
below parent pipes
DN 50 and Screwed fittings IS: 1239 (Part-II)
below
Bolting All sizes Studs/ Bolts IS:1364 ASTM A 193 Gr B7
Nuts IS:1364 ASTM A 194 Gr B2H
#300
DN 50 to 600 SORF : Serrated Finish B 16.5 ASTM A 105
#300
Gaskets All sizes 2 mm thick, ring type, B16.21 IS:2712 Gr.W/3
CAF
Valves DN 40 and CI lubricated taper plug BS: 5158 BODY & PLUG:
below valve, screwed ends CAST IRON IS : 210
Isolation valve FG 200
DN 50 and CI lubricated taper plug BS: 5158 BODY : CAST IRON
above valve; Flanged ends. GR FG -200
Page 21 of 27

Design Carbon Steel
Standard
DN 50 and CS Globe valve BS:5352 ASTM-A-105
below BODY: ASTM A216
Throttling valve Gr.WCB, Screwed
ends.
DN 65 and CS Globe valve BS:1873 ASTM-A-105
above BODY: ASTM A216
Gr.WCB, Screwed
ends.
DN 50 and CS horizontal / Vertical BS:5352 ASTM-A-105
below Check valve (Lift-type) Screwed ends.
Non-return
valve.
DN 65 and CS Swing check valve IS:5312 --
above with renewable seat
rings. Flanged ends.
Filters Self cleaning filter -- --

operating on the principle
of edge filtration
Hose 15 m long hoses to IS: 635 or SAE-100R-3 with swivel both ends and
assembly one adaptor at one end for DN 50 and below. For DN 65 and above
flanged couplings shall be used.
Page 22 of 27

SERVICE : DRINKING WATER
SERVICE CONDITIONS : Maximum Operating Pressure 6 kg/cm2 Temp 40 oC

CORROSION ALLOWANCE : NIL.
Item Size Range Description Dimensional / Material

Design
Standard
Pipe DN 15 to 150 ERW (Galv.); Screwed end; IS : 1239 IS : 1239; (Galv)
Heavy C.I IS: 1538 IS:1538
Fittings DN 15 to 150 Screwed fittings (Elbow IS : 1239 (II) IS : 1239 (II); (Galv.)
R=1.5D) IS: 1538 IS: 1538
C.I.Fitting
Flanges All sizes Screwed ; FF IS : 6392 IS 2062 (Galv.)
Blind Flanged; FF IS : 6392 IS 2062 (Galv.)
Gaskets All sizes Gasket; FF; THK 2.00 mm B16.21 Butyl Rubber
Valve DN 15 to 40 Gate, Globe Valve;Screwed IS: 778 Body IS: 318 GR.2; IS:
end ; CL.2 320 AL.I
DN 50 to 150 Gate Valve;Flanged FF; P1.6 ; IS: 14846 Body IS: 210 FG 200; IS:
Serrated Finish 320 A.I
DN 15 to 40 Check valve; Screwed ; Lift IS:778 Body IS: 318 GR.2; IS:
Type; CL2. 320 AL.I
DN 50 to 150 Check Valve;Flanged FF; IS:5312 Body IS: 210 FG 200; IS:
P1.6 ; Serrated Finish 320 A.I
DN 15 to 40 Globe Valve; Screwed ; CL.2 IS:778 Body IS: 318 GR.2; IS:
320 AL.I
Bolting All M/C Bolt IS:1364 IS:1367 CL 4.6
Nuts IS:1364 IS:1367 CL 4
Pipes DN 40 & below Unions; Screwed
Joints DN 50 & above Flanged Screwed.
Pressure DN 20 – SW half coupling Nipple Heavy with Gate valve to spec.

Tapping
Page 23 of 27

SERVICE : DEMINERALISED WATER
SERVICE CONDITIONS : Maximum Operating Pressure 20kg/cm2 Temp 60 oC

FLANGE RATING : IS 6392 - Based on test pressure / surge pressure

Matching Companion Flanges of Valves & flow components as per corresponding rating.
CORROSION ALLOWANCE : Nil

Pipe DN 15 to 40 Seamless Pipe PE SCH 10S ANSI B16.10 ASTM A312 - TP 304
Pipe, MS Seam less pipe IS:1239 P-1 IS:1239, Rubber line
DN 50 to 150 Seamless Pipe BE SCH 10S ANSI B16.10 ASTM A312 - TP 304
Pipe IS:1239 P-1 IS:1239, Rubber line
MS Seam less pipe ASTM A53 Gr A
Fittings DN 15 to 40 SW Fittings/ Scrd fittings ANSI B16.11 ASTM A182 Gr 304
(Elbow R=1.5D)
DN50 & above Miter bends & fittings ANSI B16.9 Same as parent pipe /
fabricated from pipe / Factory ASTM A403 WP
mady fittings
Flanges DN 15 to 40 SW RF Serrated Finish IS : 6392 ASTM A182 Gr 304
DN 50 to 50 WN RF Serrated Finish IS : 6392 ASTM A182 Gr 304
Gaskets All sizes Gasket; Thk. 3 mm As Per Flanges IS:638; Type-A (Rubber)
Valves DN 15 to 150 Diaphragm Valve; Flanged; Body ASTM A351 Gr.

#150 CF8; A182 Gr. 304 Trim
DN 15 to 40 Check Valve; SW; # 800; Lift BS 5352 Body A105; 13% Cr Trim
Type
DN 50 and above Check Valve Flanged RF ; BS 1868 CI Body SS Trim
Serrated Finish; #150
DN 15 to 40 Globe Valve; SW; # 800; BS 5352 Body ASTM A182 Gr.
304; 13% Cr Trim
DN 50 to 150 Globe Valve; Flanged ; RF BS 1873 Body ASTM A351 Gr.
#150 CF8; A182 Gr. 304 Trim
DN 15 to 150 Ball Valve; Flanged; RF; BS 5351 CI Body SS Trim

Serr. Finish; # 150
Bolting All Studs B18.2 ASTM A193 Gr B7
Nuts B18.2 ASTM A194Gr 2H
Joints
DN 50 & above Butt welded
Page 24 of 27

SERVICE : ALL WATER (EXCEPT DRINKING &
DEMINERALISED WATER)
SERVICE CONDITIONS : Maximum Operating Pressure 20kg/cm2 Temp 60 oC

FLANGE RATING : IS 6392 - Based on test pressure / surge pressure

Matching Companion Flanges of Valves & flow components as per corresponding rating.

Pipe DN 15 to 40 ERW Pipes; PE; IS : 1239 IS:1239; Black
Medium/Heavy, Seamless SS ASTM A53 Gr A ( BF
Cooling)
DN 50 to 450 ERW / SAW Pipes; BE; IS : 3589 IS:3589; Fe 330, Fe410
Medium/Heavy
DN 500 & above Spiral welded IS : 3589 IS:3589; Fe 330, Fe 410
Rolled & Welded
Fittings DN 15 to 40 cold / hot bends / SW Fittings/ IS : 1239 (II) / IS:1239 (II) /
scrd fittings (Elbow R=1.5D) ANSI B16.11 ASTM A105
DN 50 to 150 BW Fittings ; ANSI B16.9 IS:1239 (II) /
(Elbow R=1.5D) ASTM A234 WPB
DN 15 to 50 -do- ANSI B16.9 ASTM A 105 PB ( For BF
Cooling)
DN 200 & above Miter bends & fittings IPSS-1-06-020 Same as parent pipe
fabricated from pipe
Flanges Screwed / SW; FF Serrated IS : 6392 Plates to IS 2062 Gr-B
DN 15 to 40 Finish IS:2002- Gr 2A
DN 50 to 150 SOFF; Serrated Finish IS : 6392 Plates to IS 2062 Gr-B

IS:2002- Gr 2A
Gaskets All sizes Gasket; Thk 3.0mm As Per Flanges IS : 2712 Gr W/3
Valves DN 15 to 40 Gate Valve; Screwed End IS:778 Body IS:318 LTB; IS: 320
HT1 Trim
DN 50 to 1200 Gate Valve; Flanged; FF #150 IS : 14846 Body C.I IS:210 Gr FG
200; 13% Cr Trim
DN 15 to 40 Check Valve;Screwed; SW ;# IS:778 Body IS:318 LTB; IS: 320
800; Lift Type HT1 Trim
DN 50 to 600 Check Valve Flanged; FF; IS:5312 (P-I) Body C.I IS:210 Gr FG
serrated Finish Swing / dual 200; 13% Cr Trim
plate #150
DN 400 to 1200 Check Valve Flanged; FF; IS:5312 (P-II) Body C.I IS:210 Gr FG
serrated Finish Swing / dual 200; 13% Cr Trim
plate
DN 15 to 40 Globe Valve; /Screwed;SW; IS:778 Body IS:318 LTB; IS: 320

#800 HT1 Trim
DN 50 to 300 Globe Valve ; Flanged; FF; BS 1873 Body ASTM A216 WCB;
Serrated Finish; 13% Cr Trim
DN 350 & above Butterfly valve BS 5155 CI Body SS shaft & seat
rings
Page 25 of 27

Bolting All M/C Bolts IS 1364 IS:1367 CL4.6
Nutss IS 1364 IS:1367 CL 4
Pipes DN 40 & below Unions; Screwed
Joints
DN 50 & above Flanged Screwed.
Pressure DN 20 – SW half coupling Nipple Heavy with Gate valve to spec.
Tapping
Temp. Conn. Flanged Installation as MEC std.
Page 26 of 27

SERVICE : Instrument Air (UP TO 1.5”)
SERVICE CONDITIONS : Maximum Operating Pressure Up to 10.55 kgf /cm2 Temp 65 oC
RATING : # 150
Matching Companion Flanges of Valves & flow components as per
corresponding rating.
CORROSION ALLOWANCE : NIL

Design Carbon Steel
Standard
Pipe DN 15 to 40 ERW ; Screwed end IS:1239 IS:1239 (PART-I)
HEAVY GALV.
Fittings DN 15 to 40 Screwed Fittings ANSI B 16.11 ASTM A 105
# 3000 (GALV.)
Flanges DN 15 to 40 Screwed :RF : Serrated B 16.5 ASTM A 105

Finish #150 (GALV.)
DN 15 to 40 Blind Flanged RF : API 590 ASTM A 105
Serrated Finish #150 (GALV.)
DN 15 to 40 FIG. 8 Flange ; FF B 16.5 ASTM A 105

Serrated Finish #150 (GALV.)
Ring type
Valves DN 15 to 40 Gate valve SCRF; # 800 API 602 Body A105 ; 13% CR
Trim
DN 15 to 40 Globe valve, SCRF; # BS 5352 Body A105; 13% Cr
800 Trim
DN 15 to 40 Check valve SCRF; # BS 5352 Body A105; 13% Cr
800 Lift type Trim
Bolting All M/C BOLT B 18.2 ASTM A307 Gr B
Nuts B 18.2 ASTM A563 Gr B
Piping Flanged Joints
Fabrication Pipes Screwed Coupling
Joints
Temp. Conn. Flanged Installation as MEC std.
Pressure DN 20 – SW half coupling Nipple HEAVY with Gate valve to spec.
Tapping
Vents MEC std.
Drains MEC std.
Page 27 of 27
TABLE: 05.03
MINIMUM SPACING (C.L TO C.L) BETWEEN TWO ININSULATED PIPES.
MM MIN 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600
MAX DIA ½” ¾” 1” 1-1/2” 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24”
15 ½” 85 * * * * * * * * * * * * * * *
20 ¾” 96 100 * * * * * * * * * * * * * *
25 1” 100 100 105 * * * * * * * * * * * * *
40 1-1/2” 115 115 120 125 * * * * * * * * * * * *
50 2” 120 120 125 130 140 * * * * * * * * * * *
80 3” 140 148 145 155 160 175 * * * * * * * * * *
100 4” 165 165 170 175 180 195 210 * * * * * * * * *
150 6” 195 200 200 210 215 230 240 270 * * * * * * * *
200 8” 225 230 235 240 245 260 275 300 325 * * * * * * *
250 10” 260 260 265 270 280 295 305 330 360 385 * * * * * *
300 12” 295 300 305 310 315 330 345 370 395 425 450 * * * * *
350 14” 330 330 335 340 345 360 375 400 425 455 480 495 * * * *
400 16” 360 365 365 375 380 395 405 435 460 485 510 525 550 * * *
450 18” 390 395 400 405 410 425 440 465 490 520 545 560 585 610 * *
500 20” 425 425 430 435 445 460 470 495 425 550 575 590 615 640 665 *
600 24” 495 495 500 505 510 525 540 565 590 620 645 660 685 710 733 785
NOTE : FOE INSULATED PIPES, THICKNESS OF INSULATION FOR THE PIPES UNDER CONSIDERATION SHALL ALSO BE TAKEN
INTO ACCOUNT.
IS 1239: Part 1: 1990 Mild steel tubes, tubulars and other wrought steel fittings, Part 1
Mild steel tubes -- (Old Standards)
IS 1239: Part 1: 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings -
Specification - Part 1: Steel Tubes
IS 1239: Part 2: 1992 Mild steel tubes, tubulars and other wrought steel fittings, Part 2
Mild steel tubulars and other wrought steel pipe fittings
IS 3589: 2001 Steel Pipes for Water and Sewage (168.3 to 2 540 mm Outside Diameter) -
Specification -- (Old Standards)
IS 3589: 2001 Steel Pipes for Water and Sewage (168.3 to 2 540 mm Outside Diameter) –
Specification
IS 6392: 1971 Steel pipe flanges
IS 2712: 1998 Gaskets and Packings - Compressed Asbestos Fibre Jointing - Specification
IS 1364: Part 1: 1992 /ISO 4014: 1988 Hexagon Head Bolts, Screws and Nuts of Product
Grades A and B - Part 1: Hexagon Head Bolts (Size Range M16 to M64) -- (Old
Standards)
IS 1364: Part 1: 2002 Hexagon Head Bolts, Screws and Nuts of Product Grades A and B -
Part 1: Hexagon Head Bolts (Size Range M 1.6 to M 64)
IS 1364: Part 2 : 1992/ISO 4017 : 1988 Hexagon head bolts, screws and nuts of product
grades A and B Part 2 Hexagon head screws (size range M1.6 to M64) -- (Old Standards)
Part 2: Hexagon Head Screws (Size Range M 1.6 to M 64)
Grades A and B - Part 3: Hexagon Nuts (Size Range M1.6 to M64) -- (Old Standards)
Part 3: Hexagon Nuts, Style 1 (Size Range M 1.6 to M 64)
Grades A and B - Part 4: Hexagon Thin Nuts (Chamfered) (Size Range M1.6 to M64) --
(Old Standards)
Grades A and B - Part 4: Hexagon Thin Nuts (Chamfered) (Size Range M1.6 to M64)
IS 1364 : Part 5 : 1992/ISO 4036 : 1979 Hexagon head bolts, screws and nuts of product
grades A and B Part 5 Hexagon thin nuts (unchamfered) (size range M1.6 to M10) -- (Old
Standards)
Part 5: Hexagon Thin Nuts - Product Grade B (Unchamfered) (Size Range M 1.6 to M 10)
Part 6: Hexagon Nuts, Style 2
IS 2062: 1999 Steel for General Structural Purposes – Specification
IS 2002: 1992 Steel plates for pressure vessels for intermediate & high temperature service
including boilers
IS 14846: 2000 Sluice Valve for Water Works Purposes (50 to 1200 mm Size) –
Specification
IS 447: 1988 Rubber hose for welding (fourth revision) (Superseding IS: 3572: 1968)
IS 6016: 1982 Hose connection for welding and cutting equipment
IS 778: 1984 Specification for Copper Alloy Gate, Globe and Check Valves for
Waterworks Purposes
IS 1538: 1993 Cast iron fittings for pressure pipes for water, gas and sewage
IS 5312: Part 1: 1984 Specification for Swing Check Type Reflux (Non-Return] Valves for
Water Works Purposes - Part 1: Single-Door Pattern
IS 5312: Part 2: 1986 Specification for Swing Check Type Reflux (non-return) Valves for
Water Works Purpose - Part 2: Multi-Door Pattern
IS 1367: Part I: 1980 Technical Supply Conditions for Threaded Steel Fasteners - Part I:
Introduction and General Information -- (Old Standards)
IS 1367: Part 1: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part 1:
General Requirements for Bolts, Screws and Studs
Tolerances for Fasteners - Bolts, Screws, Studs and Nuts - Product Grades A, B and C
IS 1367: Part II: 1979 Technical Supply Conditions for Threaded Steel Fasteners - Part II:
Product Grades and Tolerances -- (Old Standards)
IS 1367: Part 3: 1991 /ISO 898-1: 1988 Fasteners - Threaded Steel - Technical Supply
Conditions - Part 3: Mechanical Properties and Test Methods for Bolts, Screws and Studs
with Full Loadability -- (Old Standards)
Mechanical Properties of Fasteners Made of Carbon Steel and Alloy Steel - Bolts, Screws
and Studs
IS 1367: Part V: 1980 Technical Supply Conditions for Threaded Steel Fasteners - Part V:
Mechanical Properties and Test Methods for Set Screws and Similar Threaded Fasteners
Not Under Tensile Stresses -- (Old Standards)
Mechanical Properties of Fasteners Made of Carbon Steel and Alloy Steel - Set Screws and
Similar Threaded Fasteners not Under Tensile Stresses
IS 1367: Part 6: 1994 /ISO 898-2: 1992 Technical Supply Conditions for Threaded Steel
Fasteners - Part 6: Mechanical Properties and Test Methods for Nuts with Specified Proof
Loads
IS 1367 : Part VII : 1980 Technical supply conditions for threaded steel fasteners Part VII
Mechanical properties and test methods for nuts without specified proof loads -- (Old
Standards)
IS 1367 : Part VII : 1980 Technical supply conditions for threaded steel fasteners Part VII
Mechanical properties and test methods for nuts without specified proof loads
Mechanical and Performance Properties for Prevailing Torque Type Steel Hexagon Nuts --
(Old Standards)
Prevailing Torque Type Steel Hexagon Nuts - Mechanical and Performance Properties
IS 1367 : Part 9 : Sec 1 : 1993/ISO 6157-1 : 1988 Technical supply conditions for threaded
steel fasteners Part 9 Surface discontinuities : Section 1 Bolts, screws and studs for general
applications
steel fasteners Part 9 Surface discontinuities : Section 1 Bolts, screws and studs for general
applications -- (Old Standards)
IS 1367: Part 9: Sec 2: 1993/ISO 6157-3: 1988 Technical supply conditions for threaded
steel
fasteners Part 9 Surface discontinuities : Section 2 Bolts, screws and studs for special
applications
steel fasteners Part 9 Surface discontinuities : Section 2 Bolts, screws and studs for special
applications -- (Old Standards)
IS 1367: Part 10: 2002 Technical Supply Conditions for Threaded Steel Fasteners - Part
10: Surface Discontinuities – Nuts
IS 1367: Part X: 1979 Technical supply conditions for threaded steel fasteners Part X
Surface discontinuities on nuts -- (Old Standards)
11: Electroplated Coatings
IS 1367: Part 11: 1996 /ISO 4042: 1989 Technical Supply Conditions for Threaded Steel
Fasteners - Part 11: Electroplated Coatings -- (Old Standards)
IS 1367: Part XII: 1981 Technical Supply Conditions for Threaded Steel Fasteners - Part
XII: Phosphate Coatings on Threaded Fasteners
IS 1367 : Part XIII : 1983 Technical supply conditions for threaded steel fasteners Part
XIII Hot-dip galvanized coatings on threaded fasteners
14: Stainless Steel Threaded Fasteners
14: Stainless Steel Threaded Fasteners -- (Old Standards)
IS 1367: Part 14: Sec 1: 2002 Technical Supply Conditions for Threaded Steel Fasteners -
Part 14: Mechanical Properties of Corrosion-Resistant Stainless-Steel Fasteners - Section
1: Bolts, Screws and Studs
IS 1367: Part 14: Sec 2: 2002 Technical Supply Conditions for - Threaded Steel Fasteners -
Part 14: Mechanical Properties of Corrosion-resistant Stainless-steel Fasteners - Section 2:
Nuts
IS 1367: Part 14: Sec 3: 2002 Technical Supply Conditions for Threaded Steel Fasteners -
Part 14: Mechanical Properties of Corrosion-resistant Stainless-steel Fasteners - Section 3:
Set Screws and Similar Fasteners not Under Tensile Stress
16: Designation System for Fasteners
IS 1367: Part XVI: 1979 Technical Supply Conditions for Threaded Steel Fasteners - Part
XVI: Designation System and Symbols -- (Old Standards)
IS 1367: Part 17: 1996/ISO 3269: 1988 Industrial fastners - Threadeed steeel fasteners -
Technical supply conditions Part 17 Inspection, smapling and acceptance procedure
IS 1367: Part 18: 1996 Industrial Fasteners - Threaded Steel Fasteners - Technical Supply
Conditions - Part 18: Packaging
IS 1367: Part 19: 1997/ISO 3800: 1993 Industrial fasteners - Threaded steel fasteners -
Technical supply conditions Part 19 Axial load fatigue testing of bolts, screws and studs
IS 1367: Part 20: 1996 /ISO 898-7: 1992 Industrial Fasteners - Threaded Steel Fasteners -
Technical Supply Conditions - Mechanical Properties - Part 20: Torsional Test and
Minimum Torques for Bolts and Screws with Nominal Diameters 1 mm To 10 mm
IS 5155: 1969 Specification for Pipettes, Ostwald-Folin Type

IS 1593: 1982 Specification for Fuel Oils -- (Old Standards)
IS 1593: 1982 Specification for Fuel Oils
ARE 1460: 2000 Diesel Fuels – Specification
IS 11489: 1985 Specification for Heavy Petroleum stock (HPS)
IS 5822: 1994 Code of Practice for Laying of Electrically Welded Steel Pipes for Water
Supply
IS 5822: 1994 Code of Practice for Laying of Electrically Welded Steel Pipes for Water
Supply
IS 10221: 1982 Code of practice for coating and wrapping of underground mild steel
pipelines
IS 1916: 1989 Specification for steel cylinder pipe with concrete lining and coating
IS 7193: 1994 Specification for glass fibre base bitumen felts
IS 8062: Part 1: 1976 Code of practice for cathodic protection of steel structures, Part 1
Genral Princples
IS 8062: Part II: 1976 Code of Practice for Cathodic Protection of Steel Structures - Part II:
Underground Pipelines
IS 8062: Part 3: 1977 Code of practice for cathodic protection of steel structure, part 3
Ship's hull
IS 8062: Part 4: 1979 Code of practice for cathodic protection of steel structures ,part 4
Galvanic protection of dockgates, caissons, piers and jetties
IS 3690: 1974 Unbonded glass wool for thermal insulation -- (Withdrawn Standards)
IS 277: 2003 Galvanized Steel Sheets, (Plain and Corrugated) – Specification
IS 3690: 1974 - Unbonded glass wool for thermal insulation
IS 8183: 1993 Bonded mineral wool -- (Old Standards)
IS 13205: 1991 Code of practice for the application of polyurethane insulation by the in-
situ pouring method
IS 277: 1992 Galvanized Steel Sheets (Plain and Corrugated) - Specification -- (Old
Standards)
IS 8183 : 1993 Bonded mineral wool
IS 9842: 1994 Preformed fibrous pipe insulation -- (Old Standards)
IS 9842: 1994 Preformed fibrous pipe insulation
IS 3677: 1985 Specification for Unbonded Rock and Slag Wool for Thermal Insulation
IS 875: Part 1: 1987 Code of practice for design loads (other than earthquake) for buildings
and structures Part 1 Dead loads - Unit weights of building material and stored materials
(Incorporating IS: 1911-1967) -- (Old Standards)
and structures Part 1 Dead loads - Unit weights of building material and stored materials
(Incorporating IS: 1911-1967)
and structures: Part 2 Imposed loads
IS 875: Part 3: 1987 Code of Practice for Design Loads (Other than Earthquake) for
Buildings and Structures - Part 3: Wind Loads
and structures Part 4 Snow loads
and structures Part 5 Special loads and load combinations
IPSS:
CGA:
Manual for water supply & water treatment- Govt. of India publications

Guidelines for Piping Design in Metallurgical Industries

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GUIDELINES FOR PIPING DESIGN

DOC.NO: MSTD-DESG-FS&PD-1405, REV-0 JUNE’ 2006

CHAPTER DESCRIPTION PAGE

REV. DATE PREPARED BY CHECKED APPROVED

01.01.04 The provisions of this documents do not apply to the following:-

c) Tubes & Tube fittings.

e) Coal Tar injection piping.

f) Piping inside Power plant building

g) Pipes for pneumatic conveyance

01.02 CLASSIFICATIONS OF FLUIDS

• By-product Fuel Gases

By-product Fuel Gases

• Coke Oven Gas

• Acetylene is used for cutting and welding.

• Fuel Oils as per IS: 1593-1982

02.00 PIPE SIZING

02.01 DESIGN PARAMETERS

Design pressure for various categories of piping shall be as follows :

All other gas piping : 1.25 Times Max. Operating Pressure

Acetylene piping : Test pressure based on Maxi.Allowable

02.02 SELECTION OF PIPE SIZE

02.02.01 Acetylene pipes

02.02.02 Oxygen pipelines

For further details refer IGC Document 13 / 82.

02.03 SIZING CALCULATION

02.03.01 Calculation of Actual Flow Rate

Flow rate of various gaseous fluids is indicated in Nm3/hr. This needs to be

PN = 1.033 Kg f / cm2 (Absolute)

PA = Actual pressure of fluid in Kg f / cm2 (a) (Absolute)

TA = Actual temperature of fluid in deg. K

For liquid pipelines (Fuel oil, water), no correction is necessary.

02.03.02 Pipe Size Calculation

Q = Flow rate in m3 / hr (Calculated as VA above)

V = Permissible velocity in / sec.

d = Inside diameter of pipe in mm

A : Low Pressure Fuel Gases

B : Medium Pressure & High Pressure Gases

2. In case cleanliness of pipe is ensured, maximum velocity can be 20m/sec. In case SS

Medium Pressure Range Velocity, m/sec Remarks

Sl. Fluid Condition Average Velocity, m/sec Remarks

02.04 PIPE THICKNESS CALCULATION

C = Corrosion allowance (min) in mm

02.04.03 Pipe thickness calculation for water pipelines

The wall thickness of steel pipe is affected by a number of factors as indicated

c) Special physical loading

d) Practical requirement at site.

t= PD Where t = thickness of wall in mm

Corrosion allowance : It is preferable to design for the required wall thickness as

02.05 PRESSURE DROP CALCULATION

02.05.01 Low pressure gas

H = Pressure drop (mmWC)

l = length of pipe sector under consideration (m)

d = Inner diameter of pipe (m)

v = Velocity of gas (m/sec)

g = Acceleration due to gravity (m2 / sec)

f = Friction co-efficient (dimensionless) depending on pipe diameter.,

= 0.03 to 0.045 (average value = 0.038) for BF gas

= 0.04 to 0.05 (average value = 0.045) for CO gas

= 0.02 to 0.03 (average value = 0.025) for Natural gas

ρ = density of gas (Kg/Nm3)

02.05.02 High pressure gas

a) For working pressure of 10-15 kgf/cm2