Beruflich Dokumente
Kultur Dokumente
TOROMOCHO PROJECT
DISTRIBUTION A B C 0 1 2 3 4 5 6 7 8 9 10
Client 03/24 4-3 6-15
Procurement
Field
4-3
Note: Signed originals on file
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
INDEX
PAGE
1 SCOPE ...........................................................................................................................4
5 VALVES........................................................................................................................20
6 GASKETS.....................................................................................................................21
15 FUELS ..........................................................................................................................25
22 TANKS..........................................................................................................................29
24 ATTACHMENTS...........................................................................................................43
1 SCOPE
This Piping Design Criteria shall be used by design personnel as a guide for design of
process and services piping systems, preparation of drawings, preparing bills of material,
and writing of piping specifications for the Toromocho Project, property of Minera
Chinalco Per S.A.
Special consideration must be taken for equipment and material at the plant site related
to the altitude and climatic conditions. (See Appendix A, Standard Technical and Site
Data).
All piping work shall conform to Peruvian Standards, applicable Norm Regulations,
codes and ordinances, if there are.
All material, fabrication, assembly and installation, where applicable, shall conform to the
current editions of the following codes and standards:
Standard Title
ANSI American National Standard Institute
A13.1 Scheme for the Identification of Piping Systems
A40.8 National Plumbing Code
API American Petroleum Institute Standards
ASME American Society of Mechanical Engineers
ASME B31.3 Chemical Plant and Petroleum Refinery Piping (for piping
within plant boundary limits).
ASME B31.1 Code for Power Piping
ASME B31.11 Slurry Transportation Piping System
Boiler and Pressure Vessel Code
ASTM American Society for Testing Materials
ASTM A53 B Pipe Steel, Black and Hot Dripped. Zinc Coated, Welded and
Seamless
ASTM A105 Carbon Steel Forgings for piping Applications
ASTM A106 B Seamless Carbon Steel pipe High Temperature Service
ASTM A181 Carbon Steel Forgings For General Purpose Piping
ASTM A182 Forged or Rolled Alloy and Stainless Steel pipe Flanges, forged
Fittings and Valves and Parts for High-Temperature Service
ASTM A193 Alloy Steel Bolting material high temperature
ASTM A194 Carbon and Alloy Steel Nuts for Bolts High-Pressure and High-
Pressure and High-Temperature Service
Standard Title
ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures
ASTM A240 Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for
pressure Vessels and for General Applications Seamless,
Welded, and Heavily Cold Worked Austenitic Stainless Steel
Pipes
ASTM A312 Seamless, Welded, and Heavily Cold Worked Austenitic
Stainless Steel Pipes
ASTM A403 Wrought Austenitic Stainless Steel Piping Fittings
ASTM A536 Ductile Iron Casting
ASTM D3350 HDPE
AWS American Welding Society
AWWA American Water Works Association Inc
CGA Compressed Gas Association
FM Factory Mutual Engineering Division Recommended Practices
HI Hydraulic Institute
IAPMO International Association of Plumbing and Mechanical Officials,
Uniform Plumbing Code
IBC International Building Code, 2006
MSS Manufacturers Standardization Society of the Valve and
Fittings Industry
NACE National Association of Corrosion Engineers (RP0294-94 for
sulphuric acid tanks)
NFC National Fire Codes
NFPA National Fire Protection Association
UBC Uniform Building Code
UFC Uniform Fire Code
UL Underwriters Laboratories, Inc. Standards
As indicated above the following specifications are applicable to this document and shall
be used in conjunction with this Design Criteria:
Where specialty piping items are not adequately covered in the above
documents, they shall be designed and engineered to meet the requirements of:
In the event of conflict between the applicable codes and standards, or with
drawings and specifications, the primary referenced code shall govern. Unless
otherwise indicated on the specific section of this specification, the primary code
shall be ASME B31.3.
3 PIPING DESIGN
3.1 GENERAL
Piping design and arrangement shall follow the appropriate section of the latest
edition of the Standard Code for Pressure Piping ASME B31.1 and the job
specifications and instructions. Where there is a conflict between this guide and
the specific job instructions, the latter shall prevail.
Cathodic protection for buried steel pipes shall be included in a separate field
sub-contract services documents. Details are shown on electrical drawings.
Where a line with a lower pressure rating connects to a line or equipment with a
higher pressure rating, it shall take the specification of the higher rating and
including the first block valve, or and including the second valve when double
block valves are used. All class breaks shall be shown on both the P & IDs and
the piping drawings.
No reduction in line size shall be made on the downstream side of control valves.
All branch lines shall be provided with block valves at or near the header.
When design pumps manifolds or other particular facilities, including lined pipes
and fittings, the maximum of uniformity and interchangeability of pieces shall be
considered and spare or replacement parts shall be supplied.
Process yard pipes shall have flanged joint each 250 meters and for process
areas each 36 meters.
All piping work shall be designed according to the wind seismic conditions and
parameters in Appendix A.
3.2 FLEXIBILITY
Expansion joints along the pipe systems shall be avoided, but if required based
on layout restrictions, they shall be fully capable of withstanding at least 1-1/2
times the normal movement and all working stresses imposed on them by the
pressure and temperature of the contained fluid and the expansion of the pipeline
and anticipated transient.
If expansion joints are used, piping upstream and downstream from expansion
joints shall be guided, anchored and supported so no misalignment can occur.
3.3 CLEARANCES
Platforms and main walkways shall have generally a minimum lateral clearance
of 900 mm 750 mm at man way covers, local walkways and elevated walkways.
Flanges and drain fittings shall clear the trench floors by 80 mm minimum.
Clearance between the sides of pipes to the equipment shall not be less than
1,500 mm.
Any deviations from the clearances mentioned above must be approved by Aker
Solutions and shown on the drawing.
3.4 ACCESSIBILITY
Valves and control valve manifolds in overhead and under floor piping systems
and in piping at process equipment shall be located so they are readily and
safety accessible for operation and maintenance. All manual valves shall be
operable from grade or a platform, or be chain operated.
Passage between unit areas shall be kept free of piping at grade. Lines may be
laid below grade or a ramp may be provided for access.
Where maintenance access precludes the use of forklifts or similar lifting devices,
overhead cranes or hoists shall be utilized. Should piping restrict overhead
access, removable spools shall be provided.
Pipe supports, guides, hangers and anchors shall conform to ASME B31.3,
limited as herein specified.
Supports for plastic HDPE (High Density Polyethylene) pipes shall be adequate
to prevent sagging due to the weight of the pipe and its contents. The
manufacturers recommendation shall be followed.
Lines for corrosive liquids and slurries that operate intermittently and require
draining shall be sloped from end to end. The sag at mid span between adjacent
supports shall not exceed the change in elevation between these supports.
Pipe guides shall be of the sliding shoe or roller type. Clips are acceptable for
small piping 50 mm (2 in.) nominal size and smaller.
Anchors for HDPE pipes shall be designed to prevent lateral displacement and
movement at fittings. Anchors will be installed as close as possible to flanges
and changes in direction, in accordance with recommendations of manufacturers.
Alloy steel pipe, rubber or HDPE lined pipes and plastic pipes that cannot be
welded to carbon steel tee anchors shall be anchored by clamping in place.
All lines shall be designed so that expansion forces and moments transmitted to
equipment is less than that allowed by the equipment. Expansion joints and
loops shall be provided as required.
Piping sections requiring frequent dismantling for maintenance, such as for the
installation of blinds or removal of equipment, shall be provided with permanent
supports for the dismantled conditions.
3.5.1 Pipeways
When pipeways would be used for future expansions will be sized for
present requirements plus 40% (minimum).
TABLE I:
PIPE MATERIAL
Nominal Pipe
Size HDPE
Carbon Steel Stainless Steel
(Water or similar)
Max. Span Max. Span O.D. Max. Span
Sch.
mm In Sch. Min. (m.) (m.) (mm) (m.)
Min.
Where the control valve is line size, the block valves shall be line size. Where
the control valve is smaller than line size, a pressure drop study shall be made
and where possible, the block valves shall also be the same size, as the control
valve.
Bypass valves shall be sized to have a flow coefficient (Cv) at least equal to that
of the fully opened control valve. The bypass valve shall be the throttling type of
valve as specified in Piping Material Classes 000-GD-P-007, according to the
service commodity and material class. The particular drains shall be installed
between the upstream block valve and the control valve.
The design temperature, pressure and the service commodity in the line
determine the line material class. The material class shall be identified as
illustrated in paragraph 3.8.3.
Piping material will agree with document 000-GD-T-001, Process Design Criteria
and 000-GD-P-007, Piping Material Classes.
3.8.1 Layout
DD-FFF-GGG-001-MMM-XX 2
(*) For plastic pipes (HDPE) use line size according to equivalence
shown on Table II.
The Valves and Specialty Items (VASI) are identified with a unique
Code No. and a description of the materials of construction for the
body, trim, seal and seat. The nominal pipe size is included when
shown on the P&IDs and listed on the material requisitions.
Where: DD XX- YY
Example: 4C2
PIPING MATERIAL
NOMINAL CARBON STEEL STAINLESS STEEL HDPE
CPVC OR PVC
DIAMETER N. D. / O. D. N. D. / O. D. (mm)
(mm)
(in) (mm) (mm) (Note 1)
15 / 21.30 15 / 21.30 20 15
20 / 26.70 20 / 26.70 25 20
1 25 / 33.40 25 / 33.40 32 25
1 40 / 48.30 40 / 48.30 50 40
2 50 / 60.30 50 / 60.30 63 50
3 80 / 88.90 80 / 88.90 90 80
4 100 / 114.30 100 / 114.30 110 100
6 150 / 168.30 150 / 168.30 180 150
8 200 / 219.10 200 / 219.10 225 200
10 250 / 273.10 250 / 273.10 280 250
12 300 / 323.90 300 / 323.90 315 300
14 350 / 355.60 350 / 355.60 355 350
16 400 / 406.40 400 / 406.40 400 400
18 450 / 457.00 450 / 457.00 450 450
20 500 / 508.00 500 / 508.00 500
22 550 / 559.00 550 / 559.00 560
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 14 of 43
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
PIPING MATERIAL
NOMINAL CARBON STEEL STAINLESS STEEL HDPE
CPVC OR PVC
DIAMETER N. D. / O. D. N. D. / O. D. (mm)
(mm)
(in) (mm) (mm) (Note 1)
24 600 / 610.00 600 / 610.00 630
28 700 / 711.00 700 / 711.00 710
30 750 / 762.00 750 / 762.00
32 800 / 813.00 800 / 813.00 800
36 900 / 914.00 900 / 914.00 900
40 1,000 / 1016.00 1,000 / 1016.00 1,000
All piping shall be in accordance with the Piping Material Classes 000-GD-P-007.
Except for lines in which velocities are of critical importance, the following
nominal pipe sizes shall be avoided: 10 mm (3/8-in), 32 mm (1-1/4-in), 65 mm (2-
1/2-in), 90 mm (3-1/2-in) and 125 mm (5-in).
With the exception of instrument leads, the minimum size of a line to be run
overhead shall be 25 mm (1 in) unless otherwise approved by Aker Solutions.
This size may be reduced to 20 mm (3/4 in) where the run is not over 6.100 mm
in length and connecting to steam traps or moisture traps, hose connections or
similar short runs.
3.9.1 Valves
Pipeline block valves shall be the same size as the line unless
calculation indicates otherwise. In no case shall the pump suction
valve be smaller than the size of the pump inlet. Valves on pump
discharge piping shall be the same as the line size.
Block valves (root valves) at main line takeoffs shall meet the
specification for the main line.
Clear liquid lines shall be sized so the velocity is low for small sizes,
increasing in proportionate amounts for larger sizes. The NPSH
calculation shall always be considered for all pump suctions.
All service lines shall be sized so that pressure does not drop below
minimum requirements at the end of the most resistant branch line
with design flow in that line.
Branch lines shall be sized based on pressure drop available. When
the velocity based on pressure drop available exceeds the
recommended velocities or if the excess pressure is objectionable, a
flow restriction orifice shall be provided and the line size will be based
on recommended velocities.
Generally, fluid velocity for water and similar viscosity fluids shall be
following:
Pipe Diameter (mm) 254 (10) 304.8 (12) to > 609.6 (24)
609.6 (24)
Pump Suction (m/s) 0.5 to 1.0 1.0 to 1.5 1.2 to 1.6
For air blower line (low pressure), shall be sized with a velocity of 4 to
5 m/s and a maximum drop pressure will not exceed 5 % of the initial
line pressure.
Moisture of steam and gas lines shall be provided with drip legs and
automatic moisture traps.
Fluid velocity for concentrated sulfuric acid shall be equal or less than
0.5 m/s in case of carbon steel pipe and 1.0 m/sec for stainless steel
pipes.
For all pipes the calculated working pressure shall be less than the
maximum pressure shown on Piping Material Classes, 000-GD-P-
007.
When using steel pipe, changes in direction shall be made with fittings
or bends.
Butt-welding elbows are preferred over bends.
Pipe bends can be used for hydraulic oil piping, the bends shall have
a minimum bending radius of five times the nominal pipe diameter,
except where noted on drawings. If space does not permit, bends of
three-diameter may be used with the approval of the Aker Solutions
design supervisor.
One-weld miter elbows may be used for large air compressor intake
lines. Multiple-weld miter elbows (see AWWA C-208) may be used
for low pressure services and auxiliary vent and flare lines. Pressure
rating of mitered elbows and bends shall be verified by Aker Solutions
and shall meet ASME B31.3 requirement.
3.9.9 Branches
Branch instrument air piping shall be taken off at the top of the
header.
Screwed fittings shall be Class 300 per ANSI B16.3, Malleable Iron Threaded Fittings,
minimum.
Reducing tees may be used for connections provided the branch is not reduced more
than two pipe sizes. Where used, it shall be indicated on the drawings. Butt-fused
HDPE reducing tees shall not be used.
HDPE fittings will be molded up to 10 diameter and will be mitered for diameter greater
than 10.
Flange types are denoted on individual piping material classes specifications. The bore
of welding neck flanges shall match the inside diameter of the pipe.
Steel flanges mating with ANSI Class 125 iron, FRP, plastic and rubber-lined pipe
flanges shall be the corresponding ANSI Class 150 flat face with full face gaskets.
Gasket is required on rubber faced joints. Steel flanges mating with ANSI Class 250 cast
iron flanges shall be ANSI Class 300 raised face.
Facing for flanges in joints containing spiral wound gaskets shall be smooth finished to a
roughness measurement in the range of 3.2 to 12.5 microns (125 to 500 micro in) RMS.
Forged steel welding fittings are preferred over cast iron fittings. Cast steel welding
fittings or flanges shall be considered where the cost advantage is appreciable and they
meet specification.
The design will only consider standard fittings. Special fittings shall be approved by Aker
Solutions piping supervisor.
For lined pipes and fittings, the use of standard pipes and fittings shall be maximized.
5 VALVES
Gate valves, ball valves or plug valves shall be used in wide open or closed (on-off)
service. Gate valves shall not be used in throttling service. Tight shutoff valves shall be
used on low temperature light hydrocarbons, gas, propane, fuel oil, compressed air
piping and in other services where required.
For throttling service, use globe valve for sizes up to 100 mm (4 in), butterfly valves for
150 mm (6 in) and larger. For low pressure slurry application, pinch valve shall be used
for throttling.
The use of angle valves shall be avoided, except for fire protection use.
Unless otherwise indicated on the drawings, the valves shown at Table IV shall be
furnished with a manual, variable position gear operator.
TABLE IV:
6 GASKETS
Non-asbestos composition gasket suitable for the conveyed fluid, 1.6 mm (1/16) thick,
shall be used for temperatures up to 260 C, on raised face flanges.
Spiral wound gasket per API 601 standard with centering ring like Flexitallic Style CG or
an equivalent shall be used for temperatures above 260 C.
For ANSI Class 125 flanges mating with cast iron valves or pumps with cast iron
casings, 3.0 mm (1/8 in) thick elastomer full face gaskets shall be used. Ring gaskets
1.6 mm (1/16 in) thick shall be used with ANSI Class 250 cast iron flanges.
On vacuum lines operating at 380 mm (15 in) Hg and higher, flat faced flanges and 3.0
mm (1/8 in) with full face red rubber gaskets shall be used.
Both suction and discharge piping shall be supported so that no load is transmitted to
the equipment.
A temporary strainer shall be provided in all pump suction lines during construction start-
up. The strainer shall be installed between the block valve and the pump. Piping shall
be arranged to provide easy removal for cleaning and inspection.
Positive displacement pumps shall be provided with a full capacity relief valve between
the pump discharge and the first block valve. Discharge from the relief valve shall be
routed back to the source, not back into the pump suction, unless otherwise specified.
Overhead pump suction lines shall be arranged to drain from the equipment towards the
pump.
Where two or more centrifugal pumps have a common manifold, a check valve shall be
installed in the discharge of each pump. A check valve shall be installed in the
discharge of a centrifugal pump where back pressure on the discharge side is
continuous and could cause the pump to run backwards. The check valve shall be
placed between the pump and the block valve. Where the size of the discharge line will
not permit block valves to be installed adjacent to check valves, they shall be placed in
overhead runs.
Connections to end suction pumps shall be made with pipe spools to permit access to
the pump. Flanged elbows may only be used if the 10 times diameter straight run rule
shall be observed.
Low points in suction and discharge lines of pumps shall be provided with valve drain
connections.
Flexible rubber joints at the suction and discharge shall be considered on low pressure
systems.
Deviations from the above for special cases of pump service may be made and shown
on piping drawings.
Pressure gage connections shall be provided in all pump discharge lines and shall be
located between the pump and the first valve.
Main compressed air lines shall be installed with a slope in the direction of flow of not
less than three tenths of one percent (0.3 %).
Moisture drain traps should be installed at low points of main air lines.
10 STEAM LINES
Steam lines adjacent to the boiler only shall be designed in accordance with ASME
B31.1. ANSI B31.3 covers steam lines in the plant.
Branch steam lines shall be taken off at the top of the steam main and shall be provided
with a shutoff valve adjacent to the main.
Main steam lines shall be installed with a slope in the direction of flow of not less than
one tenth of one percent (0.1%). No deflection pockets between supports will be
permitted.
Steam traps shall be located at low points in the system or at intervals as specified on
drawings. Traps shall be provided with a test valve, strainer and check valves.
Steam out connections shall be provided with double block and bleed.
All hot piping shall be checked for excessive thermally induced stress forces and
movement.
Discharge piping of safety valves shall avoid the use of elbows and reductions and shall
be designed in accordance with Appendix II of ASME B31.1. Means of collecting
condensate from safety valve discharge stacks shall be provided to discharge the
condensate safely.
11 UNDERGROUND PIPING
All buried steel pipe, including lines in sand filled trenches, where the normal flow
temperature is below 65 C, shall be protected from external corrosion as shown in the
individual piping material classes.
Sleeves made of steel pipe, HDPE culvert material or standard corrugated culvert shall
be used for lines, 300 mm (12 in) and larger, crossing under railroads, roads and areas
where concentrated loads may occur.
All pressure pipes with slip-type joints, mechanical joints or couplings, except drainage
and sewer lines, shall be anchored at ends of runs and at turns with concrete thrust
blocks. Consideration shall be given to the use of positive locking mechanical joint
special anchoring tees and connecting pieces for fire hydrant and hydrant valves
installation to eliminate anchor blocks at hydrant ends.
All underground piping shall be supported for the full length by the bottom of the trench,
except where clearance for joints must be provided. All buried pipe installation details
shall be shown on drawings.
Where pipe with slip-type joints are used, block valves in branch lines shall be anchored
to prevent separation.
Drainage and sewer lines, except chemical waste lines, installed below the floor slabs or
paved roadways, shall be PVC, type 1, grade 1, schedule 80.
Where pipes are buried in traffic area, a minimum of 1,200 mm (4 ft) of cover shall be
provided.
All underground piping containing corrosive and other hazardous material shall be
sleeved with corrosion resistant plastic pipe sleeves or double walled pipe. The
secondary containment sleeve or outer wall of double walled piping shall drain into pits
or sumps. The pipes and its sleeves shall be sloped for self draining.
The aboveground pipes for corrosive or hazardous solutions shall be sleeved after a
risks analysis.
Any piping containing corrosive or hazardous material shall be routed in trenches, if they
must be routed below grade level. Otherwise, laying the lines underground will require
secondary containment with leak detection system. Pipe trenches containing fluids
routed in the same trench shall not cause evolution of toxic gases due to possible
leakage of any of the piped fluids.
Lines containing corrosive or hazardous material shall be sloped so that they can be
completely drained.
Vent and drain connections installed to facilitate hydrostatic testing shall be plugged and
sealed after testing.
All flanged joints on acid piping shall have covers to prevent liquid sprays from defective
gaskets, etc. For the discharge of sulfuric acid tanks, double valves for shut-off shall be
considered.
Slurry piping shall be designed in accordance with ASME B31.11 and with minimum
amount of change of direction to reduce abrasion and chances of plugging. Where
possible, slurry shall flow in a direct line from one equipment item to another. Valving for
this application shall be avoided.
Low points in slurry service shall be avoided. However, if a low point cannot be avoided,
a low point drain shall be provided.
If possible, rubber hoses or pipe bends shall be used in place of elbows. Minimum bend
radius shall be five (5) pipe diameters.
Piping shall have Victaulic couplings and be arranged and supported to allow easy
dismantling for maintenance purposes.
Flushing connections shall be provided as shown on the P&IDs and on all pump suction
and discharge lines and at other points in the system where the possibility of plugging
exists.
Slurry lines shall be sloped 2% to permit self-draining unless otherwise noted on the P &
ID. In no case shall the slope be less than 1%.
Pump suction lines shall be minimum length and no bends or elbows shall be used.
Removable suction spool shall be provided for impeller maintenance. The use of valves
in pump suction lines shall be avoided, but if required, the valve shall be knife type.
When a standby pump is included in the design, the piping joining the operating pump
and its spare shall be designed to prevent plugging of the non-operating portion of the
piping and shall be provided with water flush connections and drains.
Hose stations for air and water shall be provided at approximately 24-meter (80 ft)
intervals inside the process buildings.
Supply lines to hose stations shall be 25 mm (1 in) diameter and shall have a shut-off
valve at the hose station. Hoses shall be 30 meter lengths with quick coupling.
Sediment legs, blowdown valves and drain traps shall be installed in air lines at low
points and dead ends.
Branch utility lines shall have block valves adjacent to the main line. In general, these
valves shall be accessible.
All gaseous utility branch lines shall be taken off the top half of supply headers.
Drain connections shall be provided in all above ground liquid lines so that they can be
completely drained.
15 FUELS
Liquefied petroleum gas installations shall conform to the Standard for the Storage and
Handling of Liquefied Petroleum Gases as outlined in NFPA Standards 30 and 58, and
Chapter 43 of Factory Mutuals, Industrial Loss Prevention.
Fuel oil installations shall conform to NFPA Standards 30, 31 and 395.
16 FIRE PROTECTION
Fire protection systems shall conform to the standards of the NFPA, UBC or UFC.
Fire pumps shall be in accordance with NFPA Standard 20. Where required, two fire
pumps and a jockey pump shall be provided. One fire pump shall be diesel engine-
driven for standby service, the other and the jockey pump shall be electric motor-driven.
Outside fire protection systems shall be installed in accordance with NFPA Standard 24.
An underground fire protection loop shall be provided to distribute fire protection water
throughout the plant facility with sectional valves to minimize potential impairments.
17 PIPE SLEEVES
Floor: Sleeves shall be of standard weight pipe anchored in place, flush at bottom and
projecting curb height at lease 100 mm above the finished floor, sized to allow 13 mm
clearance around the pipe or insulation. See Standard MSD-P-102L, "Piping Sleeve
Selection."
Concrete or block walls: Lines passing through concrete or block walls shall run through
sleeves inserted in the walls. Sleeves shall be one size larger than pipe diameter or O.D.
of insulation. Openings for lines running through outside walls shall be provided with
flashing or rain shields.
Pipe lines shall pass through pavement vertically and shall be provided with adequate
protection to prevent corrosion at its point of contact with the paving.
Pipes penetration through roofs shall be minimized or avoided if possible. Vents through
roofs shall be flashed and sealed in accordance with AK Architectural Design Standards.
Oily water sewer - carries process drainage and contaminated surface water
from point of entry to a treating or disposal facility.
Seal box in oil water sewers - a compartment to prevent explosive mixtures of air
and gases from traveling from one area to another.
Sump or lift station - a terminal point in a gravity flow sewer line from which the
waste water is pumped.
Branch sewer - a line which picks up two or more laterals and connects to a
main.
Main - a trunk sewer which discharges into a treating point or another sewer.
Outfall sewer - a line which carries clean or treated water to a disposal point.
18.4 DESIGN
Drawings shall show size, location, gradients, and invert elevations of all sewer
lines.
Manholes in oily water sewers shall be sealed and vented when required. In
lateral and branch line manholes, top of inlet pipe shall be a minimum of 150 mm
(6) below the invert of the outlet pipe. Manholes shall be provided with access.
In general, underground sewer pipe shall not be smaller than 4 inch (100 mm) in
diameter.
Catch basins shall be spaced for adequate surface drainage and located where
they are fully accessible for inspection and cleaning. See Standard SD-P-503D,
"Catch Basins and Trench Details."
High points of lines shall be provided with vent connections. Vent connections shall be
located, where possible, in accessible locations adjacent to platforms or structural
members.
Drains shall be provided at all low points of the system. Drains shall be provided at each
point where liquid might form upstream of a control or shutoff valve during operation or
cleaning.
All drains emptying into open funnels shall terminate approximately 50 mm (2) above
the top of the funnels.
Upstream side of control valves for corrosive and hot process services.
Above all block or check valves in vertical steam, acid or caustic lines.
Drain piping for steam trap shall be insulated to 2,500 mm above grade or floor level.
A Piping Line List shall be prepared for the design of process and utility lines. Vents and
drains shall be omitted. Line List will include: start of line, end of line, P & ID, test
pressure and type of insulation.
Material specifications for pipe, valves, fittings and specialty items shall conform and be
in accordance with General Specification 000-GD-P-007, Piping Material Classes.
Color coding for pipes will be detailed in General Specification 000-GC-S-002, Civil,
Structural and Architectural Design Criteria.
22 TANKS
All open tank capacities shall be calculated to include a free board of 300 mm (11.8) to
450 mm (17.7).
All tanks shall be provided with a roof and shell manhole, vents, drains and overflow
connection pipes.
The operating volume of tanks will be calculated between the bottom of the overflow and
the minimum operating liquid level.
The vents shall be verified with flows of inlet and outlet pipe.
Consideration shall be given to the use of non-metallic materials for tank construction
where required by corrosive conditions.
Tanks live volume shall be sized considering a minimum of one (1) minute of the
retention time, based on the design flow.
Non-pressure tanks shall be calculated in accordance with API 650 Standard. The
pressure vessels shall be designed in accordance with ASME, Boiler and Pressure
Vessel Code.
For transportation clearances and load restrictions and limitations, refer to Appendix A,
Standard Technical and Site Data, Section 18.0.
Design flow for piping systems will be based on Process Flow sheet quantities,
unless otherwise specified by Process or by the Project Engineer:
The design pressure shall be in accordance with the relevant standards and shall
be equal or greater than the highest pressure resulting from the following events /
criteria:
All pipe elements installed in a pump discharge line, from pump discharge
through to first isolation / shut-off valve, without pressure relieve device, shall
have a design pressure equal or greater than the pump discharge pressure for
zero flow.
The design temperature shall be equal or greater than the highest temperature
resulting from the following events / criteria:
Slurry gravity lines shall have a continuous slope or adequate fall for
the design capacity and without the line having low points / pockets.
Where a low point / pocketed line can not be avoided, valve purge
connections shall be provided.
For free surface slurry gravity lines, design basis shall be for a flow
depth of between 30% - 60% of pipe diameter (D) or launder width
(B). Refer Fig.1. Breathers shall be provided to allow free surface flow
without surging.
A
D
he he
B
he = 0.3 - 0.6 D
he = 0.3 - 0.6 B
Fig. 1
For fine slurry ( d50 < 200 m) shall be calculated using the modified
Durand formula, for all section type with free surface flow.
For thick slurry ( d50 > 200 m) shall be calculated using the Durand
formula, for section with D or B <= 10 (D= pipe diameter, B=width of
launder).
For thick slurry ( d50 > 200 m) shall be calculated using the modified
Durand formula, for section with D or B > 10 for all section type with
free surface flow. For launder to replace D per h.
Durand Formula:
D
Vd FL 2 g i s 1
1000 L
For full pipe and fine slurry, settling velocity will be estimated with the
Wasp formula.
Wasp Formula
1
d 6 D
Vd F ' L 50 2 g i s 1
Di 1000 L
Where:
d50: particle diameter such 50% by weight of the particles are smaller
than d50 (mm)
Slurry velocity shall not be greater than 6.0 m/s to minimize abrasion
in pipe / launder.
For non frothing slurry, the free surface gravity flows shall be
calculated using the Manning formula. In considering the slurry
viscosity, the Manning coefficient (n), will be calculated relative to the
friction factor (f). Friction factor (f) will be calculated in accordance
with the Colebrook formula.
1 f
Manning coefficient n Rh 6
8g
Where:
1 e 2.51
Colebrook Formula 2 log10
3.7 D Re f
f
Where:
Re = Reynolds number
e = absolute roughness of pipe or launder wall.
Rh = Hydraulic Radius (m)
Slurry gravity lines shall have a continuous slope with adequate fall for
the design capacity and without low points/ pockets.
For flow of slurry with froth, free surface slurry gravity lines shall be
designed for flow depth of approximately 20% - 50% of launder width
(B) calculated with froth factor included. Refer Fig 3.
B (or D)
A
For concentrate launders
it is recommended
A = 6R = 3D
R
he
he = 0.2B to 0.5B
Fig. 3
For frothy slurry, the calculation shall be made for maximum flow
increased by froth factor. The physical proprieties of slurry, specifically
the specific gravity and viscosity, shall not be modified.
Refer 23.5.1. 5
The flow velocity (V) shall be greater than the settling velocity. In any
event, the flow velocity shall not be greater than 6.0 m/s to minimize
abrasive wear.
Non froth slurry must be selected such that the maximum flow
including the fluctuation does not exceed 75 % of the flow range
indicated in the pump curve.
For frothy slurries, the maximum flow will not exceeds 60 % of the
flow range indicated in the pump catalog, without considered the
incorporate air slurry
The power will be calculated with the TDH without being corrected for
the solid effect
The Tip speed of the impeller shall not be higher than 30 m/s to avoid
wearing out the impeller and casing.
All water systems shall be designed for pressurized flow- i.e. line
flowing full, including gravity lines.
The flow velocity shall provide for the pressure drop rates set out in
Annex A.
For water flow, the pressure drop will be calculated in accordance with
the Darcy formula:
V 2 L
Darcy Colebrook Formula H c f
2 g D
Or
V 2 L
H c 4 f '
2 g D
1 e 2.51
Colebrook Formula 2 log
f 3.7 D Re f
1 0.27 e 7 0.9
Churchill Formula 4 log
f' D Re
The static head shall be calculated from the pump centerline to the
highest point of the discharge line.
The pipe sizing for gases will be made in accordance with attachment
SD-P-117 General Allowable Velocities. The design flow shall be 1.5
of the nominal flow (balance flow).
Lp
v2
R 2x
2g
HN
H
L 5D
H2 0, 5 m
H1 =1.2 Bc
Bc D
De= (H/3)0.5
Lc 2 Lp
Fig N 2
H1 The vertical clearance of the outlet must at least 20% more than
the critical Bernoulli (Bc) head defined for design flow
De The depth of the box under the floor of the discharge section
must be considered in order to have a buffering cushion for the slurry.
The minimum depth of this cushion will be (H/3) 0.5
The discharge piece must ensure that the flow runs in the flume,
accelerating towards normal height conditions. If possible normal
conditions must be reached at the ends of the transitions piece.
H (Q / CS ) 2
2g
Where:
Above grade concrete and steel sumps for horizontal slurry pumps
handling fine materials (minus 6 mm) will be rectangular in plan, with
vertical sides and sloped back wall. Back wall slope will be 50
degrees from the horizontal unless noted otherwise on the design
drawings.
Freeboard will be not less than 300 mm above the liquid level at the
maximum overflow conditions. The overflow will be not less than one
pipe size larger than the pump suction opening.
Quick opening wedge type drain caps will be used on all above
ground sump.
Drains will be designed to open easily and leak-proof.
All sumps, other than sample transfer sump, either floor or above
grade, will include provision for injecting process water in the bottom
to remove settled solid and in the top to adjust solid concentration.
24 ATTACHMENTS