Piping Design Criteria01

RAJASTHAN RAJYA VIDYUT UTPADAN
NIGAM LTD.
2 × 660 MW CHHABRA SUPERCRITICAL
LARSENT & TOUBRO LTD. TPS, STAGE –II, UNIT 5 & 6 L&T – S&L LIMITED
DESIGN CRITERIA FOR Rev: A
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PIPING SYSTEM Date: 01 MAY 2013
L&T - S&L Job No.:L764000 Document No.: L764000-CV03-00-ZEN-130001 Page 2 of 20
Revision Summary Sheet
REV. DETAILS/DESCRIPTION DATE
A FOR APPROVAL 01/05/2013

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TABLE OF CONTENTS
1.0 INTRODUCTION .................................................................................................................... 4
2.0 APPLICABLE DESIGN CODES & STANDARDS ................................................................. 5
3.0 PRE-REQUISITE FOR PIPE COMPONENT STANDARD DESIGN....................................... 7
4.0 PRESSURE & TEMPERATURE RATING OF PIPE ............................................................ 11
5.0 PIPING HANGER AND SUPPORT ...................................................................................... 11
6.0 PIPING INSULATION .......................................................................................................... 14
7.0 PIPING SPECIALTIES......................................................................................................... 14
8.0 PIPING MATERIAL ............................................................................................................. 14
9.0 PIPE ARRANGEMENT DESIGN PLAN ............................................................................... 15
10.0 PIPE SUPPORT DESIGN STANDARD ............................................................................... 18
11.0 GENERAL REQUIREMENTS FOR STRESS & FLEXIBILITY ANALYSIS .......................... 19
12.0 REFERENCES..................................................................................................................... 20
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1.0 INTRODUCTION
This document describes the design criteria of Piping System for 2 × 660 MW
CHHABRA SUPERCRITICAL TPS, STAGE –II, UNIT 5 & 6. This document needs to
be used in conjunction with the relevant standards as mentioned in the Piping
Material Specification, Valve list, relevant P&IDs and relevant system design criteria
documents.
The plant consists of two Supercritical Boilers with two set of steam turbines and the
associated equipment and auxiliaries. The entire plant mechanical system and its
associated equipment and auxiliaries are subdivided in the systems listed below:
 Main, Reheat Steam System & HP/LP Bypass system

 Feed water System
 Heater Drain & Vent Systems
 Extraction Steam System
 Aux Steam System
 Condensate System & Condensate polishing plant
 Condensate Storage & Transfer System
 Condenser Air Removal System
 Main Cooling Water System
 Aux. Cooling Water System
 Closed cooling water System
 Fuel Oil System
 Instrument & Service Air System
 DM Water System
 Sampling System
 Compressed Gas System
 Service & Potable Water System
 Raw Water System
 Chemical Dosing System
 Plant Waste water collection & treatment system
 Electro chlorination system
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 Fire protection system & HVAC

The detail design criteria of these respective systems are mentioned in separate
documents.
2.0 APPLICABLE DESIGN CODES & STANDARDS
The primary and principal piping design code shall be Power Piping ASME B31.1.
Bid specification Piping for the package facilities may be designed in accordance with the
requirements and manufacturer’s standard. All Piping covered under this specification shall comply with
applicable codes & all currently applicable statutes, regulations and safety codes in the locality where the
standards.
piping will be installed. The piping shall also conform to the latest applicable
standards specified. All codes and standards referred to in the specification shall be
understood to be the latest version on the date of offer made by the Bidder unless
otherwise indicated. Nothing in this specification shall be construed to relieve the
Bidder of this responsibility.
Publications of the following nationally recognized organization are applicable to the

design, manufacture, and testing of the piping & fittings included in the specification to
the extent specified therein.
 American Society of Mechanical Engineers (ASME)

 ASME B31.1 Power Piping Code
 Indian Boiler Regulations(IBR)
 ASME Section I Power Boiler
 ASME Section IX Welding Qualification
 American Society of Testing and Material (ASTM)
 American Institute of Steel Construction (AISC)
 National Fire Protection Association (NFPA)
 American Welding Society (AWS)
 American Water Works Association (AWWA)
 American Petroleum Institute (API)
 Pipe Fabrication Institute (PFI)
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 Steel Structure Painting Council (SSPC)

 Manufacturers Standardization Society of the valve and fittings Industry Inc.
(MSS)
 British Standards Institute (BSI)
 Indian Standard(IS)
 International Organization for Standardization (ISO)
 Pipe Fabrication Institute (PFI), USA Standards
Some of the relevant standards and references are as follows:-

ASME B31.1 Power Piping
ANSI B1 20.1 Pipe Thread.
ANSI B 16.5 Steel pipe flanges and flanged fittings.
ANSI B 16.9 Wrought steel butt-welding fittings.
ANSI B 16.11 Forged steel socket welding and screwed fittings.
ANSI B 16.25 Butt welding ends.
ANSI 36.10 Welded & seamless wrought steel pipe.
ANSI B 36.19 Stainless steel pipe.
ASTM A-105 Forging, carbon steel, for piping components.
ASTM A-335 Alloy steel pipe
ASME-Sec.-8, Div-1 Boiler & Pressure Vessel Code
ASME B16.20 Metallic Gasket for Pipe Flanges
ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
Forged or Rolled Alloy & Stainless Steel Pipe
ASTM A 182 Flanges, Fittings and Valves and parts for High
Temperature Service
Alloy & Stainless Steel Bolting Material/ Nuts for
ASTM A 193/ 194
High Temperature Service
IBR With latest amendments where applicable
API-5L Specification for Line Pipe
Dimensions of pipe threads where pressure tight
IS-554
joints are required on the threads.
Code of practice for use of metal arc welding for
IS-816
general construction in mild steel.
Code of practice for training and testing of metal arc
IS-817
welder.
IS-823 Code of procedure for manual metal arc welding of
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mild steel.
IS-1239 Mild steel tubes, tubular and other wrought steel
(Part-I & II) fittings.
Black hexagon bolts, nut lock nuts (dia. 6 to 36 mm)
IS-1363
and black hexagon screws (dia 6 to 24mm).
Technical supply conditions for threaded steel
IS-1367
fasteners.
IS-2016 Plain washers.
IS-3589 Steel Pipes for Water and Sewage
IS-2062 Structural steel (fusion welding quality)
IS-3138 Hexagonal bolts and nuts (M-42 to M-150)
Color code for identification of pipelines used in
IS-9404
thermal power plants.
Hexagonal Bolts, Screw and Nuts – Grade A &
IS – 1364
Grade B
API-1104 Standard for Welding Pipeline and Facilities
PFI ES – 3 Fabricating Tolerances
PFI ES – 5 Cleaning of Fabricated piping
Access holes and plugs for radiographic inspection
PFI ES - 16
of pipe welds
Wall thickness measurement by Ultrasonic
PFI ES - 20
examination
Pipe bending methods, Tolerance. Process and
PFI ES - 24
Material requirement
Internal Abrasive Blast Cleaning of Ferrite pipe
PFI ES - 29
material
The codes and standards specified above are indicative but not exhaustive.
3.0 PRE-REQUISITE FOR PIPE COMPONENT STANDARD DESIGN
3.1. Pipe:
3.1.1. The representation of pipes will be in any of the following methods
DN 250 x Sch.40 or DN250 x STD or OD 273 x 22 AWT or ID 340 x 60 MWT
3.1.2. For piping material refer clause no.8.0.
3.1.3. Unless otherwise specified in the system design criteria, in any case a minimum
corrosion allowance of 0.75 mm shall be considered while selecting thickness.
1.0mm
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3.1.4. Unless otherwise specified or approved or unsuitable due to corrosion or other

considerations, all pipes are to be seamless drawn steels and follow ASME
B36.10. Accordingly Stainless Steel Pipe will follow ASME B36.19.
3.1.5. The following standard pipe sizes will be used for different systems:
Diameters DN 15, 20, 25, 40, 50, 80, 100, 150, 200, 250, 300, 350, 400 etc.
3.1.5.1. Piping systems larger than DN 600 for water service may be designed as per
AWWA standard. (Applicable in case of BOP lines only)
3.1.5.2. Pipes with diameter size smaller than DN25 may be used only for Control Air,
Chemical Dosing, Sealing Water, Instrument connections, Cooling Water
connections to equipment, sampling pipes, etc.
3.1.6. The maximum allowable velocity of flow in pipes will be as per relevant system
design criteria.
3.1.7. Pipe Thickness
3.1.7.1. Straight Pipe receiving Internal Pressure: Thickness of Straight Pipe receiving
internal pressure will be calculated based on thickness table given under ASME
B31.1 of Power Piping Code 104.1.2 & also stipulated in IBR.
3.1.7.2. Statutory requirements as laid down in Indian Boiler Regulations (latest edition)
will also be taken care in pipe system designs. Pipe wall thickness as calculated
by ASME Code formula will also be checked for IBR requirements for piping
systems falling under IBR purview. The higher thickness of the two (ASME & IBR)
shall be adopted.
3.1.7.3. Straight Pipe Receiving External Pressure Thickness of Straight Pipe receiving
external pressure will be calculated based on ASME Boiler and Pressure Vessel
Code Division 1, Section VIII UG-28, UG-29 and UG-30.
3.1.7.4. For carbon and alloy steel piping, Pipe size DN50 and smaller shall have
minimum thickness of schedule 80 and piping DN80 & larger shall have a
minimum thickness of schedule STD.
3.1.7.5. For Stainless steel, piping DN50 and smaller shall have a minimum thickness of
Sch. 40S. Piping DN80 & larger shall have a minimum thickness of Sch.10S.
3.1.8. Hydro Field Test:
 Unless otherwise indicated in system design criteria for relevant systems, all
piping systems shall be hydro tested at 1.5 times the design pressure.
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3.1.9. All piping threads shall confirm to ASME B 1.20.1 except where otherwise
specified.
3.1.10. Unless otherwise stated, the design of steam trap discharge piping shall be
based on clause 122.11.2 of ASME B31.1.Steam drain pipe will be designed for
same conditions as the main piping up to the last drain valve in each drain line.
3.1.11. Wherever possible, steam trap discharges will run individually to the receiver.
Condenser or Flash Tank shall serve the purpose of receiver as per the system
requirements.
3.1.12. Steam trap discharges are to be ganged to a condensate return header in
accordance to the following:
Arrange steam trap discharges of varying pressures to enter the header in
descending order of pressure, with the highest discharge pressure farthest from
the receiver.
3.2. Pipe Fittings:

All branch connections shall be realized through the use of tees, crosses and laterals
to the extent such standard fittings are available as per ASME standards. When
intersection welds are employed due to non-availability of standard fittings, they shall
be of suitable structural adequacy by virtue of intrinsic weld connection, reinforcing
plates or rings or material inherent in the branch. Etc.
3.2.1. Generally, butt welding will be employed for joining pipes DN80 & above and
Socket welding will be employed for pipes DN50 and below, where weld
connections are required. Pipe joints shall be designed in accordance with ASME
B31.1.
3.2.2. Threaded joints shall conform to that specified in clause 114 of ASME B31.1, in
which specific consideration shall not be limited only to the pipe type and size.
Screwed (Threaded) coupling shall be used for galvanized pipes of DN50 and
below. Below 25mm bore connections, compression type (union) couplings may
be used in positions where leakage will not introduce any hazard. The threads
shall be entirely covered by the seal weld and only qualified welders shall carry out
such seal welding.
3.2.3. All welded branches shall be reinforced where needed as per the applicable
codes/regulations.
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3.2.4. Temperature connection stubs shall be prepared as per approved drawing for the
temperature connection.
3.2.5. Flanges may be used for coupling of pipes where welding is not possible and / or
frequent maintenance is predicted or when piping has lining / coating or when the
piping is not critical in terms of operating pressure, temperature and fluid
properties. Flange joints including flange type, bolting & gasket shall conform to
that specified in Table 112 of ASME B31.1.
3.2.6. All flanges and contact surfaces shall be concentric with the axis of the piping. All
flanges and fittings shall be accurately machined and drilled true to the template.
3.2.7. Flanges will also comply with the requirements of code to which the piping is
designed i.e. ASME 16.5 for flanges up to 24” NPS, ASME 16.47 / AWWA C207
for greater than 24” NPS.
3.2.8. Dimensions of steel BW fittings for sizes not covered in ASME B16.9 shall confirm
to MSS SP-48, MSS SP-44.
3.2.9. Bolts, Studs, nuts and washers for flanges shall be galvanized for Carbon Steel &
Plastic flanges and stainless steel for stainless steel flanges.
3.2.10. Elbow, Bend, Return, Miter can be used for changing the direction of flow in the
pipe.
3.2.10.1. Long radius elbows will be used where elbows are required. However for high
pressure steam pipes like MS and HRH lines, bends will be used. Unless
otherwise stated, pipe bends for critical piping such as main steam pipe, hot
reheat pipe shall conform to that specified in clause 104.2.1 of ASME B31.1.
3.2.10.2. Bends used, will be of pulled type or forged. Hot bending with packing may be
used for larger sizes according to facilities available, but hot bends in alloy or
stainless steel may only be made after prior approval.
3.2.10.3. Bend thinning allowance shall be provided for all bends as per the
recommendations of ASME B31.1.
3.2.10.4. All pipe bends shall be made true to angle. Plane with no negative tolerance and
shall have a smooth surface free of flat spots, Crease and corrugations. A cross
section through any bend portion of the pipe shall be true in diameter. Thinning
allowance shall be considered as per ASME B31.1. The ends of pipe bends shall
be beveled according to ASME B 16.25. After bending, the bent portion shall have
the minimum calculated thickness as per ASME B31.1. Necessary ultrasonic test
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is to be carried out to ensure the minimum thickness at the bent (elongated)

portion. Measurements shall be taken in accordance with PFI standard ES-20
using the "Pulse Echo" method.
3.2.10.5. Bending on Pipes shall only be done where indicated on the isometric drawings or
when allowed by the applicable piping class, otherwise formed elbows shall be
used. No wrinkling, excessive thinning or flattening is allowed. Excessive
scratches, gauge or die marks will be the grounds for rejection. Bending tolerance
and minimum tangents of bends shall be in accordance with PFI standard ES-24.
3.2.10.6. All piping bends are subjected to heat treatment as required by clause 129.3 of
ASME B 31.1.
3.2.11. For change of diameter of the pipe, Reducer or Swage (MSS SP-95) will be used.
Eccentric reducers will be used on pipe rack or pump suction lines for maintaining
the elevation of pipe and to avoid cavitation respectively. Concentric reducers will
be used for change in diameter of pipe with that of nozzle of equipment etc.
3.2.12. Tee is generally used to branch off from the main line. Refer piping material
specification for branch connection details.
3.2.13. “Lateral” is used, where the branch off from the main line is at an angle of less
than 90°.
3.2.14. Other fittings like Full Coupling, Half Coupling, Reducer Insert, plugs, caps; Union,
Olets, etc are also used, where required.
3.3. Valve:
Valves for all the piping systems shall be in line with the HP valve specification, LP
valve specification and Butterfly valve specification.
4.0 PRESSURE & TEMPERATURE RATING OF PIPE

For Pressure and Temperature rating of pipes, the preferred standard Classes of
150, 300, 600, 800, 900, 1500, 2500, 4500 or special rating of ASME B16.5 and
ASME B16.34, will be used as the basis, and accordingly Pipe Material
specification and Valve List will be prepared. Pipe Material specification will be
uniformly applied to each & every system.
5.0 PIPING HANGER AND SUPPORT

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5.1. All piping supports will be designed in accordance with the provisions of ASME
B31.1 or the standard to which the pipe work is designed. Pipe Hanger and
Support design shall be as per MSS–SP-58.
5.2. All supports will be provided with means of adjusting the tension of springs,
height of supports and the length of rods or straps. All such adjusting devices will
be capable of being securely locked.
5.3. Parts of supporting elements for high working temperature piping will be made of
suitable alloy steel or will be protected so that the temperature of the
supporting member will be maintained within the appropriate temperature limits of
the material.
5.4. Load variation of Variable spring hanger should be less than 20% (Not more than
10% for critical piping systems) and load variation in constant spring hanger must
be restricted to 6%.
5.5. The supporting arrangements of all piping systems will be designed with due
regard to any additional loads imposed during hydro testing & cleaning and steam
blowing operations.
5.6. Support shall be so designed and fabricated that, in the event of spring failure;
they do not release the pipe.
5.7. Helical compression type spring will be provided with the means to prevent
misalignment, buckling, eccentric loading or excessive travel, with a working
stress not exceeding 10N/mm2 at the most favorable loading conditions.
5.8. The supports shall be designed to meet all static and operational conditions to
which the piping system and connected equipment shall be subjected. These
conditions shall include Hydrostatic Test loadings, thermal expansion and
contraction, occasional loadings, impact loadings etc. The piping system shall be
adequately supported such that the system is sufficiently flexible to allow for the
thermal expansion and contraction as well as be rigid enough to take the
occasional (seismic and wind) and impact loadings.
5.9. All pipe supports shall be designed so they do not disengage due to thermal
movements of the supported pipe. All spring supports must be locked during In-
service Hydro Test. For systems where thermal growth or contraction shall occur,
sufficient clearance shall be provided to prevent interference between supports
and surrounding equipment during this growth.
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5.10. Clevises, turnbuckles and other such accessories connecting to rods shall be
forged steel and compatible with the rod material. Welding of extension pieces to
support rods shall not be done.
5.11. All Constant Support and Variable Support units shall be provided with
Hydrostatic Test and erection locks, installed and preset in the cold position on
the units before they are shipped. The locks will be removable and replaceable in
a cold position and will be provided with permanent means of attaching them to
the support unit when not in use.
5.12. Attempts shall be made to use variable spring and rigid hangers as much as
possible. Rigid hangers shall preferably be used where vertical movement of the
pipe is negligible.
5.12.1. Variable spring supports/hangers may be used provided the following conditions
are met.
 The variation in supporting effort between hot and cold condition does not
exceed 20% of the load, which is higher of the operating condition, and cold
setting load.
 The resulting effect of load take-up/release by a group of hangers in a span
does not overstress the piping span or cause overloading at equipment
terminals.
5.12.2. Otherwise, constant load type support/hangers must be used. On the other hand
rigid hangers can be used where possible without exceeding the stipulated limits
of terminal forces and moments and the stress.
5.13. Snubbers will be used to absorb the shocks during occasional loads, i.e., thrust
due to safety valve discharge, steam hammer, etc. where required.
5.14. All large pipes and all long pipes shall have at least two supports each arranged
so that any length of pipe or valve may be removed without any additional
supports being required.
5.15. Variable springs shall be furnished with travel stops. The travel stops shall be
factory installed at the "cold" position.
5.16. Spring hangers should not be loaded more than 80% of the spring travel range.
5.17. Hanger rods (except rigid hangers where both tension and compression may
occur) shall be subjected to tensile loading only. At hanger locations where lateral
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movement is anticipated, suitable linkage and rocking washers shall be provided

to permit swing.
5.18. Tie rods/struts shall preferably be used for restraints to achieve low friction
restraining. The Tie-rods/struts shall have proper arrangement and adequate
length, so that, thermal movements in other directions, which are intended to be
free are not constrained and there is no appreciable shift in centerline of pipe or
the elevation of the supporting point on pipe due to sway. The design shall have
provisions for adjusting the length to take up any slack and securely locking in
position permanently once adjustment is done.
5.19. All relevant hangers shall be designed to take the dynamic movements for
dynamic loading in addition to the thermal movements.
6.0 PIPING INSULATION

Thermal Insulation for all the piping systems shall be in line with the design
requirements specified in “DESIGN CRITERIA DOCUMENT FOR THERMAL
INSULATION” (Reference-13.3).
7.0 PIPING SPECIALTIES

7.1. Traps: Traps are used to eliminate the condensate formed in the steam or gas /
airlines and form a water hammer free line. Traps are to be so designed that the
discharge the condensate water automatically.
7.2. Strainers: Unwanted substance in the fluid system is removed through strainer. It
is used to protect components like Pump, Control Valve, Steam Trap, etc. Inside
the entity of strainer is installed structure, either perforated or of wire mesh.
Screen/screening elements plays an important part in filtering out unwanted
substance. Generally it has 40 meshes at the inlet of pump, and during trial runs
60 mesh is used and the same will be replaced after the trial runs are completed
and the supply fluid is ensured of free from impurities. However respective pump
supplier recommendations will be sought for mesh size.
7.3. Expansion Joints: These are used to increase the flexibility in the pipelines and to
protect equipment.
INCLUDE AIR VALVES
ALSO
8.0 PIPING MATERIAL
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8.1. Carbon Steel is used for most of the piping in the Power plant but is restricted to
Pipe design temperature of 410 °C. For any temperature above 410 °C Alloy
Steel will be provided. However Stainless steel is used, where corrosion effect is
severe or as a special requirement.
8.2. The design of main & branch piping for CW will be in accordance with AWWA
M11.
8.3. Buried (Underground) piping will be coated and wrapped and also confirming to
IS: 10221 & AWWA C203-93.
8.4. Selection of Piping Materials will be as per Piping Material Specification. INDICATE
DOC.NO
9.0 PIPE ARRANGEMENT DESIGN PLAN

9.1. General Guidelines:
9.1.1. All piping will be routed to provide a neat and economical layout requiring a
minimum number of fittings.
9.1.2. Overhead piping, inclusive of fittings, insulation & support steelwork, will have a
minimum vertical clearance of 2.3M above access platform & walkways, and 6.0
M minimum above roadways. IT SHOULD BE 7.5 M. Refer clause 5.4.6 of bid
9.1.3. specification.
Drains and vents are to be provided at lowest and highest points of every system
to drain out/remove the non-condensable gases from the system during hydro
test, startup conditions etc.
9.1.4. Only steam pipes will have a minimum drainage slope of 1:100 and slope will
preferably be in the direction of flow. However at hot condition, minimum slope of
1:200 shall be maintained. It is Turbine exhaust not the feed pump exhaust.
9.1.5. Exhaust line from turbine driven feed water pump, will be routed as directly as
possible to the condenser.
9.1.6. Valve stem will be installed vertically, but for handling purpose it can be installed
and turned horizontal up to 90 Deg., if required.
9.1.7. As far as possible all process pipes will run above ground on pipe supports.
Wherever the pipes have to cross roads or other facility, this will be through
proper pipe trench or pipe rack.
9.1.8. No Valves or any components will be installed on the pipe stretch running in the
trench, until and unless it is unavoidable. Under such unavoidable circumstances,
the valve if placed will have the hand wheel projected out of the trench for easy
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operation / maintenance and all such components will be indicated in the

respective drawing.
9.1.9. All the fuel oil lines in the plant battery limit will be routed above ground
/trench/culvert.
9.1.10. In case of having a requirement of Flange & Flanged valve in the two adjacent
lines, the location of flanges / valves will be so selected that the operation &
maintenance of the same can be easily taken up.
9.1.11. Pressure Gauge installed in Pump suction/discharge lines and other similar
piping systems will be as close to the equipment as possible.
9.1.12. Temperature gauge, which is installed after the Intersection of two branch lines,
has to be placed at an appropriate distance where exact reading of thoroughly
mixed fluid can be recorded.
9.1.13. Long radius elbows will be used wherever change in the direction of pipe routing
is required. However bends will be used for Main Steam & Hot Reheat piping
systems in general.
9.1.14. Pipe wall penetration sleeves will be suitable selected beyond insulation with due
consideration to insulation thickness clearances and maximum pipe movement.
9.1.15. Straight length of pipe, for flow measuring devices will satisfy ASME
recommendations and/ or manufacturer recommendations.
9.1.16. All motor operated valves, control valves and frequently operated manual valves
will be accessible from or near a floor, above or below or from a platform. Manual
valves, if required will be facilitated with extended stem.
9.1.17. All valves operators like positioners, limit switches etc. will be accessible for
ALL THE LINES GOT CONNECTED TO
maintenance, calibration etc.
BOILER ARE UNDER IBR PERVIEW.
9.1.18. Steam & Feed Water Lines with conditions listed below fall in the scope of IBR.
9.1.18.1. Lines having design pressure (max. working pressure) above 3.5 Kg/cm2 (g).
9.1.18.2. Line sizes above 10" inside diameter having design pressure 1.0 Kg/cm2 (g) &
above.
9.1.18.3. Lines with design pressure less than 1.0 Kg/cm2 (g) are excluded.
9.1.18.4. Users of steam like steam tracing lines, jacket of the steam jacketed lines and
Steam heating coil within the equipment are excluded from IBR scope.
9.1.18.5. Boiler feed water lines to steam generator, flash drum shall be under purview of
IBR.
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9.1.18.6. For Alloy Steel and carbon steel pipes and fittings conforming to ASTM A335
Gr.P11,P22 and P91, A106 Gr.B & C respectively, the manufacturer shall certify
the following values in tabulated form as required at various working metal
temperature in IBR, Form III A.
 Et = 0.2 % Proof Stress
 Sc = 0.01 Creep Rate in 100,000 hours - average values (Min values 20% lower)
 Sr = Stress to rupture in 100,000 hours- average values (Min values 20% lower)
 These certified values shall be furnished along with the offer.
For A106 Gr. B & C pipes, only Et values need to be furnished.
a) Ladle analysis: Carbon less than / equal to 0.25% and sulphur less than / equal
to 0.05% for all pipes under IBR.
9.1.19. Drip legs shall be provided at the lowest point in the steam system to remove
condensate.
9.1.20. All stubs welded to the pipe including welded Thermo-wells & instrument source
tapings shall be installed on the pipe prior to stress relieving.
9.1.21. Installation of Control Valve
9.1.21.1. Control valves will be placed on the horizontal run of pipe with suitable access.
9.1.21.2. Valve stem will be vertically upright in general.
9.1.21.3. Enough space will be provided between the valve and the ground/platform for
supporting and maintenance.
9.1.21.4. While installing control valve on pipe passing overhead/ceiling, the pipe routing will
be turned down to a lower elevation, and the control valve will be installed just
above the ground / floor level. Valve Stem will be vertically upright and there will
be enough space between valve & ground level for maintenance purpose.
9.1.21.5. If reducers are to be installed in the upstream and downstream of Control valve
under such circumstances the reducers will be welded to the control valve so as to
minimize the spool, unless valve operators interfere with one another.
9.1.21.6. Control valves which supply water to the Condensate Makeup System and
Condenser Hot Well, will be installed as close to the Condenser as possible, so as
to avoid / minimize the effect of water hammering and flashing in the downstream
pipeline.
9.1.22. Installing of Isolation valve and Check Valve
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EPC TENDER PACKAGE
9.1.22.1. Remote manually operated valves in the pipe system, if required will be oriented,
taking into account location and support of the operator. Chain wheel operation
will be the last option for the maintenance of valve i.e. a valve which is normally
open at all times. If a chain wheel operator is necessary, the valve will be located
so that the chain may be fastened against the building column and avoiding the
obstruction to passage.
9.1.22.2. Stem of all manual valves should be in vertically upright position, unless other
orientations eliminate the need for remote operating devices or platforms, without
degrading the performance of valve.
9.1.22.3. Swing and either spring loaded or non-spring loaded lift check valves will be used
Check Valves of greater or equal to 400NB shall
for general service.
have dash pot arrangement.
9.1.22.4. Swing or non-spring loaded lift check valve will be located in the horizontal
position and non slam and spring loaded lift check valves in either horizontal or
vertical position. Non-slam check valves will be located in the riser originating at
the pump discharge.
9.1.23. Installing Position of Safety & Relief Valve
9.1.23.1. Unless otherwise stated the safety relief valves shall be installed as per
Manufacturer’s recommendation
9.1.23.2. Safety valves will be located as close as possible to the equipment.
9.1.23.3. Safety valve will be located at a minimum of 10D (ID) downstream from tangent
point of any bend or elbow or extension nozzle of main run.
9.1.23.4. When two or more SRVs are to be located adjacent to one another along the
steam header pipe, the distance between centerlines of any two valves shall be
greater than or equal to 1.5 times the sum of the inlet internal diameters of the two
adjacent valves Spacing between three or more SRVs should be unequal.
9.1.23.5. Safety valve vents will run straight, separately and as short as possible.
9.1.23.6. Keep the distance between the centre line of the safety valve and the vertical
centerline of the discharge elbow to a minimum.
9.1.23.7. Each valve discharge piping will be oriented parallel to the axial centerline of the
pipe it is protecting.
9.1.23.8. Slip joint in the outlet of SRVs shall be used as & when required.
10.0 PIPE SUPPORT DESIGN STANDARD

NIGAM LTD.
EPC TENDER PACKAGE
10.1. Piping will be supported & anchored in an appropriate manner in accordance with
the provisions of ASME B31.1 or the standard to which the piping is designed.
10.2. Supporting straps around flanges or welded joints will not be accepted.
10.3. Particular attention will be paid to sliding surfaces in guides and sliding supports
and to springs employed in variable & constant load supports. Stainless Steel and
low friction plastic may be provided for important sliding surfaces.
10.4. Pipe support material should not interfere / obstruct the equipment or with any
shall be structures and should have adequate space for maintenance.
merged with
10.5. Support material has to be appropriately selected for the particular type of pipe.
section 5.0
10.6. Special attention has to be given while designing supports for pipes operating at
high temperatures
10.7. The maximum distance between two consecutive supports will generally be as
per ASME B31.1, Table 121.5.
10.8. The sum of the longitudinal stresses, SL due to pressure, weight & other
sustained loads shall not exceed the basic material allowable stress in the hot
condition.
10.9. If at any locations, the supports are to be taken from concrete structure / slab, the
location of the insert plates are to be defined to civil for incorporation of same in
their drawings.
10.10. In case of vertically hanging type support, hanger rod vertical swing angle should
not exceed 4°.
10.11. For pipes having design temperature above 150 Deg.C, bottom supports shall be
avoided as far as possible and hanger type supports shall only be used.
However, where bottom support cannot be avoided, the same shall be provided
with suitable shoes along with balls/rollers/rockers to minimize frictional
resistance against thermal movements. The material of shoe as well as the
ball/rockers/rollers shall be suitable for the design temperature of the supported
pipe and shall be of sufficient hardness so as to permit a reasonably long life
keeping its roundness and maintaining a low friction factor. Where a constant
load type support is required, the bottom support shall also be of constant load
type.
11.0 GENERAL REQUIREMENTS FOR STRESS & FLEXIBILITY ANALYSIS

NIGAM LTD.
EPC TENDER PACKAGE
General requirements for stress & flexibility analysis for all the piping systems shall
be inline with the design requirements specified in Design Criteria Document for
“DESIGN CRITERIA DOCUMENT FOR PIPING STRESS ANALYSIS”
12.0 REFERENCES
12.1. ASME B31.1 Power Piping.
12.2. Design Criteria Document for Thermal Insulation- L764000-CV03-00-ZEN-130004
12.3. Design Criteria Document for Piping Stress Analysis-L764000-CV03-00-ZEN-
130003.

Piping Design Criteria01

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RAJASTHAN RAJYA VIDYUT UTPADAN

Revision Summary Sheet

REV. DETAILS/DESCRIPTION DATE

A FOR APPROVAL 01/05/2013

1.0 INTRODUCTION .................................................................................................................... 4

2.0 APPLICABLE DESIGN CODES & STANDARDS ................................................................. 5

3.0 PRE-REQUISITE FOR PIPE COMPONENT STANDARD DESIGN....................................... 7

4.0 PRESSURE & TEMPERATURE RATING OF PIPE ............................................................ 11

5.0 PIPING HANGER AND SUPPORT ...................................................................................... 11

6.0 PIPING INSULATION .......................................................................................................... 14

7.0 PIPING SPECIALTIES......................................................................................................... 14

8.0 PIPING MATERIAL ............................................................................................................. 14

9.0 PIPE ARRANGEMENT DESIGN PLAN ............................................................................... 15

10.0 PIPE SUPPORT DESIGN STANDARD ............................................................................... 18

11.0 GENERAL REQUIREMENTS FOR STRESS & FLEXIBILITY ANALYSIS .......................... 19

 Main, Reheat Steam System & HP/LP Bypass system

 Fire protection system & HVAC

2.0 APPLICABLE DESIGN CODES & STANDARDS

Publications of the following nationally recognized organization are applicable to the

 American Society of Mechanical Engineers (ASME)

 Steel Structure Painting Council (SSPC)

Some of the relevant standards and references are as follows:-

3.0 PRE-REQUISITE FOR PIPE COMPONENT STANDARD DESIGN

3.1.4. Unless otherwise specified or approved or unsuitable due to corrosion or other

3.2. Pipe Fittings:

is to be carried out to ensure the minimum thickness at the bent (elongated)

4.0 PRESSURE & TEMPERATURE RATING OF PIPE

5.0 PIPING HANGER AND SUPPORT

movement is anticipated, suitable linkage and rocking washers shall be provided

6.0 PIPING INSULATION

7.0 PIPING SPECIALTIES

9.0 PIPE ARRANGEMENT DESIGN PLAN

operation / maintenance and all such components will be indicated in the

10.0 PIPE SUPPORT DESIGN STANDARD

11.0 GENERAL REQUIREMENTS FOR STRESS & FLEXIBILITY ANALYSIS

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