Appendix A - 76 CMXG Design Guideline.pdf

OC-ALC/76 CMXG/MXCPM DESIGN

STANDARDS AND GUIDELINES

OC-ALC/76 CMXG/MXCPM Design Standard

Section Subject

ELECTRICAL ELECTRICAL EQUIPMENT REQUIREMENTS

Rev 0, June 26, 2002 Page 1

TABLE OF CONTENTS

Section Page

1.0 SCOPE 3

2.0 CODES AND STANDARDS 3

3.0 ELECTRICAL EQUIPMENT 3

4.0 ELECTRICAL DESIGN REQUIREMENTS 8

5.0 ELECTRICAL CONSTRUCTION REQUIREMENTS 9

6.0 TESTING AND CHECKOUT 13

Rev 0, June 26, 2002 Page 2

REVISION RECORD APPROVAL SIGNATURES

REV. DATE STATUS REMARKS INITIATOR APPROVAL

0 06/29/02 Approved J. Lane J. Lane

1 07/03/02 Approved J. Kornele J. Lane

Rev 0, June 26, 2002 Page 3

1.0 SCOPE

1.1. This specification defines the minimum requirements for the design, materials, fabrication, testing, and preparation for shipment of electrical equipment and components and systems part of packaged equipment. This specification is to be used in conjunction with and supplementary to the mechanical equipment specification that describes the function, capacity and other requirements of the package. This specification does not cover specific requirements for motors, control panels, controllers, and lighting. If the specific proposed equipment contains these or higher voltage equipment, other standards or specifications should be referenced and included with the purchase documentation.

2.0 CODES AND STANDARDS

2.1. In addition to the requirements of this specification, the electrical construction and all equipment and materials of construction shall be in conformance with the latest requirements of the following:

2.1.1. NFPA 70, National Electrical Code (NEC)

2.1.2. NEMA Standards

2.1.3. Insulated Power Cable Engineers Association (IPCEA)

2.1.4. Institute of Electrical and Electronics Engineers (IEEE) Standards

2.1.5. Instrumentation, Systems and Automation Society (ISA)

2.1.6. American Petroleum Institute (API) Recommended Practices

2.1.7. Any Federal, State or Local Enforcing Authority

2.1.8. Where a conflict exists between any of the above codes or standards, the more stringent shall apply.

2.2. When listing is available, all equipment and materials of construction shall be listed for the intended service by Underwriters Laboratories, Inc. (UL), or other Nationally Recognized Testing Laboratory (NRTL) such as CSA, ETL, or FM.

3.0 ELECTRICAL EQUIPMENT

3.1. Material Criteria

3.1.1. Electrical equipment and wiring shall be suitable for the electrical area classification in which the equipment will be installed and the jobsite climatic conditions (see data sheet).

3.1.2. All material shall be new.

Rev 0, June 26, 2002 Page 4

3.1.3. Unless otherwise agreed the vendor shall select components for the package from approved manufacturers listed in a mutually acceptable equipment list.

3.1.4. Specific substitution of materials stated in this specification or data sheets shall be submitted to OC-ALC/76 CMXG/MXCPM for approval.

3.2. Conduit and Fittings

3.2.1. All aluminum conduit and fittings shall be copper free (0.4% max. copper) aluminum and shall be installed in a manner to be isolated from steel using appropriate non-corrosive materials.

3.2.2. PVC coated conduit shall have a minimum 40 mil thickness. All beam clamps and miscellaneous attachment hardware shall be PVC coated or otherwise designed to prevent damage to the PVC coating.

3.3. Conduit Bodies, Junction Boxes, and Terminals

3.3.1. All aluminum conduit outlet bodies shall be copper-free (0.4% max. copper) aluminum.

3.3.2. All junction/terminal boxes shall be sized to allow three inches around terminals.

3.3.3. An additional 25 % spare terminal space shall be provided for all terminal boxes. All terminal strips shall be mounted on aluminum backpans.

3.3.4. Terminal blocks shall be heavy duty type, rated for 600 volts AC.

3.3.5. All NEMA 4X boxes shall have 316 stainless steel hinged covers and hardware. A 1/4" weep hole shall be drilled in the bottom of all boxes to drain moisture accumulations.

3.4. Wiring

3.4.1. All grounding wires and grounding bonding jumpers shall have green insulation.

3.4.2. An equipment grounding conductor shall be installed in all conduits containing power wiring.

3.4.3. Wire and cable used for special vibration monitoring equipment (e.g. from detector to proximeter) shall be supplied by the vibration monitoring system manufacturer.

3.4.4. Multi-conductor cable for instrumentation circuits shall have conductors grouped, twisted, shielded, and be rated with an insulation level equal to or exceeding that specified by the equipment device manufacturer. Control and shutdown circuit conductors shall be equally rated, twisted, and shielded when specified.

3.4.5. Current transformer circuit leads shall be not less than #10 AWG, and terminated at short circuiting type terminal blocks.

3.4.6. Extra flexible wiring (increasing number of copper strands) shall be provided at door hinges or other locations where leads may be subject to flexing.

Rev 0, June 26, 2002 Page 5

3.4.7. All cable assemblies shall be capable of passing IEEE, standard 383, flame test.

3.4.8. Single pair instrument, control, alarm and shutdown wiring shall be colored black and white and enclosed in a neoprene or PVC overall jacket. Instrumentation wiring shall be twisted and shielded with drain wire. Control, alarm and shutdown wiring shall be twisted and shielded with drain wire when specified. Triad (three wires) wiring shall be colored black, white, and red, twisted, shielded with drain wire enclosed in a neoprene or PVC overall jacket. 600 volt rated cable for control, alarm and shutdown shall be colored red and black.

3.4.9. Multiple pair instrument, control, alarm, and shutdown wiring shall have each pair numbered.

3.5. Instrumentation Sensing Devices

3.5.1. All instruments used in process measurement (e.g. flow, pressure, differential, etc.) in hydrocarbon service shall be double barrier devices per article 501-5 f(3) of the NEC.

3.5.2. Instruments located in Class 1 Division 1 or Division 2 areas that require maintenance, calibration or adjustments that would expose energized parts shall be listed and installed utilizing the intrinsically safe methodology if possible.

3.5.3. Contractor shall comply with ANSI/ISA RP-12.6-95, Wiring Practices for Hazardous (Classified Locations) Part 1: Intrinsic Safety in the selection and installation of all intrinsically systems.

3.5.4. Indicating instruments shall be semi-flush mounted panel type with expanded scales

3.5.5. Pressure Transmitters

3.5.5.1. Pressure Range: Various, includes gauge, absolute and differential

3.5.5.2. Turndown: 200:1

3.5.5.3. Transmitter Output: 4 – 20 mA DC w/ HART protocol.

3.5.5.4. Construction: SST flange, 316L SST isolating diaphragm, TFE O-rings, silicon fill fluid, polyurethane-covered aluminum housing

3.5.5.5. Mounting: 2” Pipe

3.5.5.6. Accuracy: 0.04% or 0.075% of Span as required

3.5.5.7. Process connections: ¼” NPT

3.5.5.8. Approvals: FM Intrinsic Safe and Explosion Proof

3.5.5.9. Approved Mfgrs: Rosemount., Foxboro

3.5.6. Flow Meters

Rev 0, June 26, 2002 Page 6

3.5.6.1. Selection: Mass flow shall utilize the coriolis measurement principle. Volume flow meters may use coriolis, turbine, pitot tube orifice type meters.

3.5.6.2. Turndown: 100:1 for coriolis, 10:1 for all others.

3.5.6.3. Transmitter Outputs: 2 each 4 – 20 mA DC

HART or Profibus as specified 1 each Pulse output, 0-10 Khz, 24 VDC

3.5.6.4. Construction: Stainless Steel, elastomers shall be Teflon or Viton

3.5.6.5. Accuracy: 0.50% of rate or as specified by Technical Order specifications.

3.5.6.6. Approvals: Class I Divison 1 Group D, FM Intrinsic Safe or Explosion Proof

3.5.6.7. Approved Mfgrs: Mass Flow: Endress & Hauser. All other.

3.6. Contact Making Devices

3.6.1. Contacts for use in low energy circuits shall be gold plated or gold flashed and listed in the Manufacturer's catalog as suitable for dry circuit applications.

3.6.2. Contacts for use in control and instrument switches located outdoors shall be hermetically sealed, where available, to provide maximum protection against dust and corrosion and allow for use of Division 2 rated equipment.

3.7. Indicating Lights

3.7.1. Indicating lights shall be the heavy-duty, oil-tight, full voltage type.

3.8. Digital Displays

3.8.1. 4 – 20 mA input.

3.8.2. Loop powered with 5.2VDC maximum drop @ 20 mA.

3.8.3. 0.56” minimum digit size. Red LED readout preferred.

3.8.4. NEMA 4/4X rated, surface mount enclosure.

3.8.5. FM approval, Class I, II, III; Div 2, Groups A, B, C, D, F, G.

3.9. Control Panels

3.9.1. Control panels shall be designed and built according to UL 508A Outline of Investigation for Industrial Control Panels”

3.9.2. Enclosure

Rev 0, June 26, 2002 Page 7

3.9.2.1. Programmable Logic Controller (PLC) enclosure shall be a UL labeled, NEMA 4, painted steel enclosure for Class I Divion 2 Group D areas.

3.9.2.2. Enclosure bodies and doors shall be 14-gauge steel.

3.9.2.3. Paint shall be ANSI 61 gray polyester powder coating inside and out over phosphatized surfaces.

3.9.2.4. Seams shall be continuously welded and ground smooth, no holes or knockouts.

3.9.2.5. External mounting feet shall be supplied.

3.9.2.6. Collar studs shall be provided inside for mounting the backpan.

3.9.2.7. Enclosure door shall be grounded via a copper grounding-strap attached at one end to a stud on the enclosure door, and at the other end to the panel ground.

3.9.2.8. In order to exclude liquids and contaminants, construction shall include a rolled lip around three sides of the door and all sides of any enclosure opening.

3.9.2.9. An oil resistant door gasket attached with oil-resistant adhesive shall be held in place with steel retaining clips.

3.9.2.10. Twelve stainless steel door clamps shall be on three sides of the door in order to insure a watertight seal.

3.9.2.11. Removable door hinge shall be of stainless steel.

3.9.2.12. Hasp and staple shall be provided for padlocking.

3.9.2.13. A high-impact, thermoplastic data pocket shall be included on the inside surface of the door.

3.9.3. Terminals

3.9.3.1. Modular, single level, 6 mm wide, compression clamp-style.

3.9.3.2. 600 VAC, 30 A.

3.9.3.3. 35 mm, DIN rail-mount.

3.9.3.4. Rated to accept #22 to #10 AWG wire.

3.9.3.5. UL recognized.

3.9.3.6. Colors

3.9.3.6.1. Circuit terminals: Gray.

3.9.3.6.2. Grounding blocks: Green/Yellow.

Rev 0, June 26, 2002 Page 8

3.9.4. Appropriate hardware and accessories, such as end plates, jumpers, and end clamps, shall be provided, as required, to make a complete system.

3.10. Intrinsic Safety Barriers

3.10.1. Intrinsic safety barriers shall provide galvanic isolation. Zener diode barriers are unacceptable.

3.10.2. All intrinsic safety barriers shall be DIN rail mountable.

3.10.3. When integrating the intrinsic safety barriers into the control panel, the Contractor shall follow all the manufactures recommended installation procedures. Utmost care must be taken to separate intrinsically safe wiring from other wiring.

3.10.4. Approved manufacturers

3.10.4.1. Pepperl+Fuchs

3.10.4.2. Phoenix Contact

3.10.4.3. Entrelec

3.11. Isolators

3.11.1. Optical Isolators shall be provided between the PLC system and the computer.

3.11.2. Optical isolators shall:

3.11.2.1. Provide 2500 V isolation between inputs and outputs

3.11.2.2. Consist of a DIN rail mountable, terminal block-style socket base and a pluggable optical coupler module.

3.11.2.3. The pluggable optical coupler module shall be available separately.

4.0 ELECTRICAL DESIGN REQUIREMENTS

4.1. Early in the design phase plot plans and section views of the facility shall be marked with the proposed electrical area classification. For enclosed locations with mechanical ventilation systems, the electrical area classification around air intakes and exhausts shall identified on the plot plans and section views. The marked plot plan and any supporting data shall be submitted to OC-ALC/76 CMXG/MXCPM for approval per the project documentation requirements.

4.2. The electrical area classification shall be based on the latest edition of NFPA 70.

4.3. A table shall be provided that lists all flammable and combustible gases, vapors, and liquids that may be present. The group, auto-ignition temperature, and the NEC temperature identification number shall be shown in the table.

Rev 0, June 26, 2002 Page 9

4.4. Control and electrical rooms should normally be located in unclassified locations.

4.5. Existing electrical area classification drawings shall be reviewed and revised as necessary whenever modifications or new additions to a facility are made.

4.6. Control, alarm and shutdown circuits shall be fail-safe. The sensing or output device will be de-energized on loss of control power or open circuit which should provide a safe mode of failure.

4.7. Electrical devices shall be selected on the basis that a momentary voltage fluctuation up to 20% of nominal operating voltage shall not cause the equipment to shutdown unless otherwise specified.

4.8. Suitable circuit protection shall be supplied for controls so that any one electrical fault does not affect more than one unit or system.

4.9. A disconnecting means shall be provided to permit servicing of individual systems or control components.

4.10. Elementary and wiring diagrams shall be furnished for all control circuits. Elementaries shall be drawn in the form of ladder diagrams with line numbers marked for each rung of the ladder. Relay contact usage shall be indicated in the margin adjacent to the relay coils with the line number where the contact appears (NC contact identified by underlining of line number). A unique wire number for wiring between all devices shall be assigned and identified on the drawings.

5.0 ELECTRICAL CONSTRUCTION REQUIREMENTS

5.1. Aluminum Mounting

5.1.1. Aluminum shall not be fastened directly to steel or other dissimilar metal.

5.1.2. In locations (i.e., gulf coast, cooling towers, etc.) requiring aluminum to reduce corrosion problems, aluminum boxes and bodies shall be isolated using insulating standoffs or 1/8 in.

thick PVC sheet between the aluminum and the steel. They shall be fastened using 316 stainless steel bolts and nuts with insulating washers.

5.2. Conduit Systems

5.2.1. Threaded joints on conduit shall have at least five full threads engaged.

5.2.2. All threaded connections on conduit, fittings, boxes, and box covers shall be treated with a thread lubricant suitable for maintaining a conductive path between the various components and shall be suitable for the application.

5.2.3. Devices requiring replacement or removal for maintenance shall have a union located at the device. If a seal is required, the union shall be installed between the device and the seal, unless the device has pigtails, in which case the seal shall be installed between the device and the union.

Rev 0, June 26, 2002 Page 10

5.2.4. Conduit drains or drain seals shall be installed at each low point where moisture is likely to collect.

5.2.5. Conduits shall only be installed in the sides or bottom of all boxes in outdoor areas subject to moisture or condensation.

5.2.6. All grounding connectors shall be bonded together with bonding jumpers.

5.2.7. All PVC coated conduit shall be made up with a strap wrench. All damaged areas of the coating shall be repaired according to manufacturer's guidelines.

5.2.8. Conduits shall be grounded with grounding bushings in electrical areas that are classified as hazardous.

5.3. Grounding

5.3.1. The enclosure backpan shall include a grounding-stud.

5.3.2. The enclosure door shall be bonded to the backpan grounding-stud.

5.3.3. An isolated grounding bar shall be included on each panel.

5.3.4. The equipment grounding terminal of each device shall be bonded with a green wire, routed to an isolated grounding bar.

5.3.5. Equipment grounding conductors shall not jump from device to device, but shall be individually routed to the isolated ground bar.

5.3.6. The isolated grounding bar shall be bonded with one green wire, routed to the panel ground stud.

5.3.7. Analog signal connections to the pressure transmitter and to the digital display shall be isolated via intrinsically safe barriers.

5.4. Seals

5.4.1. All electrical seals shall be installed with the pouring compound and other materials manufactured by the same seal manufacturer. Conduit seals shall be installed as required but not filled with sealing compound before final equipment inspection and approval by OC- ALC/76 CMXG/MXCPM. Seals in vertical conduits that are longer than 4 ft shall be of the drain type.

5.5. Wiring

5.5.1. Where shielded instrumentation and thermocouple extension wire is provided by vendor, the drain wires shall be terminated on separate terminals adjacent to the signal terminals.

The drain wire terminals shall not be grounded. Drain wire will be grounded at other end of cable by others. Shielding for signal wires shall be maintained as close as practical to terminal connections. The shield shall be continuous from end to end. The shielding shall

Rev 0, June 26, 2002 Page 11 be grounded only at the power supply end unless recommended otherwise by the manufacturer. The ungrounded end shall be insulated with tape.

5.5.2. Except for lighting circuits, all wiring shall be run in continuous lengths from point of origin to destination. Any splices or taps shall be approved by OC-ALC/76 CMXG/MXCPM both as to type and location.

5.5.3. Splices in conductors of lighting circuits shall be made with connectors such as Scotchlok type "Y, R, G, and B".

5.5.4. For termination of devices with leads, splices shall only be made with insulated, compression type butt connectors with OC-ALC/76 CMXG/MXCPM's approval only.

5.5.5. Each cable shall be tagged with the cable number using a laminated, engraved phenolic tag (black lettering on white background) fastened to the cable with a plastic cable tie at each end.

5.5.6. Minimum size for signal wires shall be #18 AWG. All signal wiring shall be properly shielded and grounded.

5.5.7. Minimum size for power conductors shall #14 AWG except where the equipment manufacturer requires a smaller wire gauge.

5.5.8. Wire shall be UL listed. MTW wire shall be used for control panel wiring and THHN shall be used for general power wiring.

5.6. Color Coding

5.6.1. Power Wiring

5.6.1.1. AC Single Phase

5.6.1.1.1. Hot Black

5.6.1.1.2. Neutral White

5.6.1.1.3. Ground Green

5.6.1.2. DC

5.6.1.2.1. Positive Blue

5.6.1.2.2. Negative Yellow

5.6.1.2.3. Ground Green

5.6.1.3. Discrete Signal Wiring

5.6.1.3.1. AC switched Brown

Rev 0, June 26, 2002 Page 12

5.6.1.3.2. DC switched Red

5.6.1.4. Analog Signal Wiring

5.6.1.4.1. Analog (+) Purple

5.6.1.4.2. Analog (-) Gray

5.7. Wire markers

5.7.1. White, shrink-on type.

5.7.2. Characters shall be machine applied, not handwritten.

5.7.3. Raychem “Shrinkmark” or Tyton “Shrink Tag” or equal.

5.8. Wireway

5.8.1. All panel wiring shall be routed in slotted, PVC, wire duct.

5.8.2. All duct will be the same color, either white or gray,

5.8.3. All duct shall be supplied with matching cover.

5.9. Panels

5.9.1. Panels shall be assembled according to UL508A.

5.9.2. Equipment mounting:

5.9.2.1. All equipment mounted inside the enclosure shall be mounted on the enclosure backpan, not onto the enclosure itself.

5.9.2.2. The backpan will be drilled and tapped only. Through-holes with nuts on the back of backpan are unacceptable.

5.9.2.3. Self-tapping screws are unacceptable.

5.9.2.4. All wire will be routed in wireway.

5.9.2.5. AC and DC wiring will be segregated as much as possible and where they must cross shall do so at 90 degree angles.

5.9.2.6. Each end of every wire shall be permanently marked with the destination of the other end of the wire.

5.9.2.7. All wire labels shall be completely shrunk down prior to shipment from the manufacturer’s facility.

5.9.3. Installation of wiring devices:

Rev 0, June 26, 2002 Page 13

5.9.4. Wire ferrules, fork terminals, or ring terminals shall be used at each and every wire end.

5.9.5. The wiring devices shall be fully crimped with the tool recommended by the manufacturer of the device.

5.9.6. Only one wire shall be crimped into each device, unless that device is specifically designed for more than one wire.

5.9.7. Only one wire will be permitted per device terminal, unless that terminal is specifically designed to accept more than one wire.

6.0 TESTING AND CHECKOUT

6.1. The Government shall have the option to witness any and all testing, both at the Contractor’s facility and on-site. The Government POC shall be notified at least 48 hours prior to testing.

6.2. All panels and general wiring shall be thoroughly tested at the manufacturer’s facility, and documentation shall be provided to show that the testing was completed. The testing documentation shall bear the following information:

6.2.1. Description of the test

6.2.2. Equipment identification number

6.2.3. Equipment Service

6.2.4. Equipment model number.

6.2.5. Equipment manufacturer

6.2.6. Drawing Number

6.2.7. Test Date

6.2.8. Initials of the tester.

6.3. The manufacturer’s testing for PLC installations shall include:

6.3.1. Verifying all digital inputs from the field terminal blocks via the PLC processor’s input table

6.3.2. Verifying all digital outputs from the field terminal blocks via the PLC processor’s force table

6.3.3. Checking zero, span, and midrange of all analog inputs from the field terminal blocks via the PLC processor’s input table.

6.3.4. Checking zero, span, and midrange of all analog outputs from the field terminal blocks via the PLC processor’s output table.

Rev 0, June 26, 2002 Page 14

6.4. General Wiring

6.4.1. All system circuit wiring resistance to be tested phase to phase prior to hook-up. Megger voltages shall be at least the nominal working voltage of the system. Resistance readings shall be provided to the Government for approval.

6.4.2. All system circuit wiring to be tested phase to ground minimum resistance prior to hook

up. Megger voltages shall be at least the nominal working voltage of the system. Resistance readings shall be provided to the Government for approval.

VESSELS AND TANKS PRESSURE VESSELS -GENERAL

REQUIREMENTS

SECTION PAGE

1.0 SCOPE

2.0 CODE AND STANDARDS REQUIREMENTS

3.0 DESIGN AND CONSTRUCTION

4.0 NAME PLATES

5.0 INSPECTION AND TESTING

6.0 PREPARATION FOR SHIPMENT

7.0 VENDOR DATA REQUIREMENTS

8.0 VENDOR DATA MATRIX

0 06/26/02 Approved J. Lane J. Lane

1.1 The purpose of this specification is to cover the general design, fabrication, testing, and preparation for shipment of carbon steel pressure vessels operating at or above 15 psig in accordance with the ASME Boiler and Pressure Vessel Code Section VIII, Division 1 (the Code).

1.2 This general specification, combined with specific equipment specifications, data sheets, and supplementary specifications is appropriate for use in specifying production separators, scrubbers, freewater knockouts, filters, emulsions treaters, dehydration contactors and regenerators, pulsation bottles, etc. In case of conflict between documents, notify GOVERNMENT and clarification will be issued.

1.3 If Jurisdictional Rules require approval and/or inspection of vessels, drawings or calculations, the Vendor shall obtain any such approval and include the documentation noted in Section 8.0, Vendor Data Matrix.

2.0 CODE AND STANDARDS REQUIREMENTS

2.1 The vessels shall be designed, fabricated, tested, and stamped in accordance with the Code. The vessel shall be designed to withstand the loadings exerted by internal or external pressure, weight of the vessel and its contents, wind, earthquake, reaction of supports, and when specified, loads imposed by connecting piping. Derivation and application of earthquake load shall be as directed in the Uniform Building Code (UBC). Other loads, such as wind and roof live load, shall be derived and applied according to ANSI/ASCE 7-88, "Minimum Design Loads for Building and Other Structures", unless a) compliance with local building codes is required, and b) the local codes require use of UBC for all loads. Local codes shall always be considered, however, since there may be some required modifications to the methods described in either the UBC or ASCE 7-88, based on local conditions.

The design shall also be adequate for transportation and erection loads.

2.2 The vessels, and all accessories, shall comply with applicable OSHA, state, or local regulations.

Caged ladders, or acceptable safety slide devices, shall be provided when climbing height exceeds 20 ft.

2.3 The vessel shall be registered with the National Board of Boiler and Pressure Vessel Inspectors when specified.

2.4 Any piping provided beyond the vessel limits shall be designed and fabricated per ANSI B31.3 Chemical Plant and Petroleum Refinery Piping, unless otherwise specified.

3.0 DESIGN AND CONSTRUCTION

3.1 General

3.1.1 The pressure limiting component shall be identified on Vendor's drawings.

3.1.2 The minimum thickness of shells and heads shall be 1/4 in.

3.1.3 Internals shall have a minimum thickness of 1/4 in. Attachment of internals to the vessel shall be made by a full fillet weld with a minimum leg size of 1/4 in. Internals shall be constructed of a material compatible with the vessel shell.

3.2 Welding Procedures

3.2.1 Vendor shall prepare and qualify Welding Procedure Specifications (WPS) in accordance with the ASME Code, Section IX, which shall be available to and followed by all welders.

3.2.2 Copies of all applicable welding procedure specifications, procedure qualification records, and welder performance qualification tests specified in the Vendor Data Matrix, shall be submitted for approval prior to start of fabrication.

3.2.3 The Vendor will be responsible to be certain that the Essential Variables specified on the WPS are followed during production welding. Variables which will affect weld and heat affected zone (HAZ) hardness include, but are not limited to: ambient temperature, preheat temperature, interpass temperature, travel speed, total heat input, post weld heat treat, etc. When specified in the Vendor Data Matrix, the Vendor shall maintain records of these essential variables during production welding. Any such records shall become a part of Vendor's pressure vessel file.

3.3 Connections

3.3.1 Nozzles NPS 3 and larger shall be flanged. Connections NPS 1½ and smaller shall be threaded. Nozzles NPS 2 shall be flanged or threaded as specified on the data sheet. Flanged nozzles shall utilize weld neck or long weld neck flanges or H-neck forgings. When threaded connections are used for process inlets or outlets, relief valves, or are subject to external loading, they shall be made with 3000# full couplings. On vessels not in vibrating service, 3000# thredolets may be used for instrument connections or drains not subject to external loading. 3000# half couplings may be used when shorter nozzles are required for instruments. Special nozzle connections are to be used when indicated on the data sheet.

3.3.2 Pipe wall thickness for nozzles and extensions shall be at least extra-strong (XS).

3.3.3 Unless noted otherwise on the data sheet, flanges rated ANSI Class 600 and lower shall be raised face, and flanges rated ANSI Class 900 and higher shall be ring type joint.

3.3.4 Flanged nozzles, manways, and inspection ports shall extend at least 6 in. from the shell to the face of the flange. Full couplings for threaded connections shall extend at least half coupling length outside the shell. For insulated vessels, these minimum nozzle extensions shall be increased by the thickness of the insulation and the protective covering.

3.3.5 Stud bolt lengths shall be per ANSI B16.5 where applicable. In other cases, stud lengths shall be such that the last thread on all nuts is engaged and the studs do not extend more than 1/4

in. beyond the nuts.

3.3.6 The use of elbows connected directly to the vessel should be avoided. When used, weld elbows shall be long radius.

3.3.7 A drain shall be provided for each compartment of the vessel. Drains shall be at least NPS 2 unless otherwise specified or approved by GOVERNMENT.

3.3.8 When specified on the data sheet, vortex breakers shall be furnished on all liquid outlets except siphon type outlets.

3.3.9 Nozzles entering the bottom of vertical vessels shall be avoided. When nozzles must enter the bottom, they shall be piped at least 6 in. beyond the skirt with butt weld seamless pipe and fittings.

3.3.10 Vessels specified to be in corrosive service shall be provided with inspection openings as required by the Code paragraph UG46 or as specified on the data sheet. Inspection openings or manways may also be specified on the data sheet for vessels in non-corrosive service. Lifting aids shall be furnished with each manway or inspection opening cover as follows:

Cover Weight Lifting Aid Example (lbs) >87 Davit NPS 16 Class 150

Blind Flange 30 thru 87 Two Handles NPS 6 Class 600

Blind Flange 15 to 30 One Handle NPS 6 Class 150

Blind Flange <15 No Aid Required 8" x 10" Oblong

Plate 3/4" Thick

3.3.11 Flange bolt holes shall straddle horizontal and vertical centerlines.

3.3.12 All flanged connections (other than H-neck forgings) on pressure vessels specified to be in vibrating services shall have mechanical reinforcement in the form of weld pads. The cross sectional area of the reinforcing pad [ A5 per Code Figure UG-37.1] shall be at least equal to the total cross sectional area of reinforcement required [ A ]. (Extra thickness in vessel wall [ A1 ], extra thickness in nozzle [ A2 ], internal nozzle projection [ A3 ], internal welds [ A43 ] and external welds [ A41 ] shall not be included as available for reinforcement.)

3.3.13 Nozzles for instruments which require fixed center dimensions shall be set with jigs.

3.4 Attachments

3.4.1 Where required for structural integrity, vessels shall have distribution pads under lifting lugs. Lifting lugs on insulated vessels shall project far enough for shackles to clear the insulation and protective covering.

3.4.2 Reinforcements, saddles, and lifting lugs forming closed areas on the vessel external surface shall have at least one NPS ¼ threaded vent hole. Longitudinal seams shall be located to clear openings, their reinforcing pads, and saddle wear plates. Circumferential seams of shell shall be located to clear openings, their reinforcing pads, tray and insulation support rings, and saddle wear plates. When the covering of circumferential seam by reinforcing pad is unavoidable, the seam shall be ground flush and examined prior to welding the reinforcing pad in place.

3.4.3 Vertical vessels shall be provided with skirts with minimum thickness of ¼ in. Skirts 4

ft. in diameter and less shall have at least one access opening at least 4 in. ID. Skirts larger than 4

ft. shall have two 18 in. OD access openings. Two vents shall be provided in the upper part of the skirt. All skirt openings shall be reinforced. Pipe penetrating skirt openings shall have a 1 in.

annular space between the pipe and the opening reinforcement. The base ring shall be continuously welded to the skirt.

3.4.4 When specified, horizontal vessel saddles shall be provided with a minimum ¼ in. thick wear plate continuously welded to the shell.

3.4.5 Unless the vessel is specified to be welded to a deck or skid, the skirt or saddles shall have holes for anchor bolts. Anchor bolt holes shall be at least 7/8 in. in diameter.

3.4.6 Ladders, platforms, walkways and other external attachments shall be supported by the vessels with welded tabs. On insulated vessels, the tabs shall extend far enough to allow insertion and make-up of bolts and nuts without damaging the insulation or protective covering.

3.5 Materials of Construction

3.5.1 All material used in fabrication shall comply with the material requirements of the Code. Materials with specified minimum tensile strength over 70,000 psi shall not be used unless the Vendor justifies in writing as an option in his quotation that the higher strength materials are suitable for the specific service environment and application and GOVERNMENT approves that justification by accepting the option for higher strength materials in the purchase order.

3.5.2 All materials of construction shall meet the requirements of the Code paragraphs UCS 66 and 67, for the specified minimum design metal temperature and coincident pressure.

3.5.3 All pipe and pipe fittings shall be seamless.

3.5.4 Metallurgy of non-pressure containing attachments and associated weld filler metal shall be compatible with shell and head materials to which attached.

3.5.5 Platforms, ladders, and walkways shall be open steel serrated bar grating. When specified, they shall be hot dip galvanized.

3.6 Construction

3.6.1 Backing strips or rings shall not be used.

3.6.2 Nozzles, manways, and inspection ports shall be installed by inserting the neck of the flange, the coupling, or the pipe nipple through the vessel wall and welding with full penetration welds. Internal joints and projections shall be ground smooth or to a radius to minimize flow resistance. Reinforcements shall be attached at the nozzle with full penetration welds. Fillet groove welds for thredolets shall have weld thickness tw of at least 1/4 in. and at least as thick as schedule 160 pipe [see Code UW-16(f)(4)]. The weld shall have a concave surface to blend smoothly between the vessel wall and the thredolet.

3.6.3 Welded internal or external attachments, except insulation support rings, shall be attached with continuous fillet seal welds. Insulation support rings may be skip welded. Lifting lugs and tabs for ladders and platforms shall not be welded over vessel seams. All attachments shall be welded to the vessel prior to post weld heat treatment (PWHT) if required, pressure testing, and internal coating.

3.6.4 Sharp edges on internal and external surfaces shall be removed by grinding to reduce risk of personal injury during fabrication, handling, and inspection. Additional grinding and special fabrication requirements for vessels to be internally coated shall be per the referenced supplementary specification.

3.6.5 Threaded openings shall be re-tapped prior to pressure testing.

3.6.6 Nozzles shall be located from the base line and the centerline of the vessel within the following tolerances:

• Distance from base line to nozzle centerline: + 1/8 in..

• Angular rotation of nozzle centerline around centerline of vessel: + 1/8 in..

• Projection of nozzle face from vessel centerline: + 1/8 in..

These tolerances may be exceeded on large vessels (> 48 in. diameter) with GOVERNMENT approval.

3.6.7 Alignment of flange faces and ends of couplings used for nozzles shall be checked by placing a straight edge across the nozzle. They shall not deviate more than 1/16 in. per ft from planes parallel or perpendicular to the centerline of the vessel.

4.0 NAME PLATES

4.1 The markings required by the Code are to be provided and in addition, the nameplate shall include GOVERNMENT's purchase order number, equipment tag number, diameter, seam-to-seam length, the date tested, National Board registration number (when required), Testing Authority (if applicable), the manufacturer's name and the manufacturer's serial number.

4.2 The nameplates are to be of stainless steel securely attached or to a suitable bracket seal welded to the shell. The bracket shall extend beyond insulation on insulated vessels. If the vessel requires stress relief heat treatment, any welding to attach the nameplate or attachment bracket to the vessel shall be completed before stress relief. The nameplates shall be protected from blasting and painting.

5.0 INSPECTION AND TESTING

5.1 Inspection, testing, and quality control are the responsibility of the Vendor.

5.2 Radiography, ultrasonic examination, and hydrotesting shall be performed after PWHT and prior to painting and coating.

5.3 When indicated "yes" on the data sheet, GOVERNMENT, or GOVERNMENT's designated representative, will make inspections of vessels during construction, inspect vessel before and after final closure, witness hydrostatic tests and make a final inspection of all vessels prior to shipping.

Vendor shall give GOVERNMENT one week's notice prior to closures, of tests, and of the date vessels are available for final inspection. Vendor shall provide access and facilities to GOVERNMENT to inspect all material and work in progress. All radiographic films and the records of examinations shall be available for review by GOVERNMENT.

5.4 Minimum requirements for radiography and ultrasonic examination are as follows:

5.4.1 Vessels with design pressures of 125 psig and less, which are not specified to be in vibrating service.

No radiography or ultrasonic inspection required. Inspect per the Code paragraph UW-11 (c).

5.4.2 Vessels with design pressures from 126 psig up to and including 740 psig not specified to be in vibrating service.

• Spot radiography per the Code paragraph UW-11 (b).

5.4.3 Vessels with design pressures over 740 psig not specified to be in vibrating service.

• Full radiography per the Code paragraph UW-11 (a).

5.4.4 Vessels specified to be in vibrating service.

• All butt welds (Category "A", "B" and "D") shall be radiographically examined and evaluated along their full length per paragraph UW 51 of the Code. Corner joint welds (Category "D" and "C") shall be ultrasonically examined and evaluated per Appendix 12 of the Code.

5.5 Closed areas such as compartments, coils, jacketed areas, etc., shall receive separate hydrostatic tests prior to the vessel hydrostatic test. Saddles and reinforcements with vent holes shall have the holes left open during the vessel hydrostatic test.

5.6 The minimum hydrostatic test pressure per the Code is 1½ times the MAWP multiplied by the lowest ratio (for the materials of which the vessel is constructed) of the allowable stress at test temperature to the allowable stress at design temperature.

5.6.1 Vessels having a corrosion allowance in excess of 1/8 in. and which are limited by a component other than a flange rating, shall be hydrostatically tested for the new and cold condition. The test pressure shall be 1½ times the MAWP of the vessel as calculated using the new (uncorroded) material thickness and using the allowable stress at the test temperature. This "New and Cold Test Pressure" shall be identified on Vendor's drawings.

5.7 The test pressure shall be held for a period of one hour. Following hydrotest, the vessel shall be drained free of standing water and sealed.

6.0 PREPARATION FOR SHIPMENT

All nozzle flange faces shall be coated with rust prevention grease and shall be further protected with a wood, metal, or plastic cover to prevent damage during shipment. Female NPT connections are to be protected with suitable thread protectors. Male NPT connections shall be protected by forged steel caps.

7.0 VENDOR DATA REQUIREMENTS

7.1 Forward all requested data to: GOVERNMENT at the address indicated on the Purchase Order.

7.2 All data must be forwarded by a transmittal letter, identified as follows:

7.2.1 Project ID

7.2.2 P.O. Number

7.2.3 Date

7.2.4 Equipment

7.2.5 Tag Number

7.2.6 Vendor Name

7.2.7 Vendor Telephone

7.2.8 Vendor Contact

7.3 All data must be microfiche quality. Reproducibles for approval over 11 in. x 17 in. should be front-printed sepias not to exceed 22 in. x 34 in. in size. Data 8-1/2 in. x 11 in. or 11 in. x 17 in. should be on opaque paper, not sepia.

7.4 GOVERNMENT specifications should be checked for additional data requirements.

7.5 Data requested for approval must be approved before fabrication unless waiver is provided by

GOVERNMENT.

7.6 Vendor shall submit all data as indicated on Vendor Data Matrix, Section 11.0.

8.0 VENDOR DATA MATRIX

DOC DESCRIPTION FOR REVIEW FOR APPROVAL FINAL/CERTIFIED

NO. C=Copy R=Reproducible

#C/R DATE #C/R DATE #C/R DATE

1 Drawing List

2 Design Calculations

3 Completed Data Sheets

4 Dimensional Outlines(w/weights)

5 Fabrication Details

6 Erection/Assembly Dwgs

7 Recommended Spare Parts (priced)

8 Completed Parts List

9 Installation/Operating/Maint. Manuals

10 Weld Procedure Specifications

11 Procedure Qual. Records

12 Welders Performance Qual. Tests

13 Test Procedures

14 Code Data and Test Reports

a) Manufacturer's Data Report

b) Mill Test Report

c) Hydro/Pneumatic Test Data

d) Heat Treatment Charts

e) Name Plate Rubbing

f) Hardness Tests

15 Production Welding Essential Variables Record

OC-ALC/76 CMXG/MXCPM DSTD 120

PIPING AND VALVES-ASME B31.3 PIPING DESIGN

1.0 SCOPE

2.0 CODES AND STANDARDS REQUIREMENTS

3.0 LINE IDENTIFICATION SYSTEM

4.0 PIPING DESIGN

5.0 PIPING LAYOUT

6.0 PIPE SUPPORT AND PIPING FLEXIBILITY

7.0 RELIEF DEVICE PIPING

8.0 MATERIALS

9.0 VALVES

10.0 LINE IDENTIFICATION SCHEDULE

11.0 VALVE IDENTIFICATION SCHEDULE

12.0 BRANCH CONNECTION SCHEDULES

0 06/29/02 Approved J. Lane J. Lane

1 07/03/02 Approved J. Lane J. Lane

1.1 This specification defines the minimum requirements for the design of piping systems covered by ASME B31.3 piping code, with operating temperatures between –20°F and 500°F.

1.2 This specification is applicable for all the following Process Classifications:

• Non-corrosive –Service Class R

• Corrosive(Mildly) –Service Class S

• Corrosive(Highly) –Service Class T

1.3 In case of conflict between documents, notify GOVERNMENT, and a clarification will be issued.

2.0 CODES AND STANDARDS REQUIREMENTS

2.1 Except as amended by this specification, the piping design shall be in accordance with the latest edition of the following Codes and Standards:

2.1.1 ASME B31.3 Chemical Plant and Petroleum Refinery Piping

2.1.2 OSHA Occupational Safety and Health Act Rules and Regulations

2.2 Latest edition of API, ANSI, and other Industry Standards as referenced herein.

3.0 LINE IDENTIFICATION SYSTEM

3.1 Each line on the piping arrangement drawings and the flow diagrams shall be identified with the nominal line size, the fluid designation, the line number, and the service and pressure class in accordance with the identification system shown on Line Identification Schedule, Section 10.0.

3.2 Each valve on the piping arrangement drawings and the flow diagrams shall be identified with the size and identifying number in accordance with the identification system shown on Valve Identification Schedule, Section 11.0.

4.0 PIPING DESIGN

4.1 Pipe Size

4.1.1 The sizing criteria for process fluid and vapor lines shall be determined on a case-by-case basis. Sizing criteria shall be based on pressure drop, erosional velocity, slugging, or a combination of these.

4.1.2 Control and bypass valves shall be sized for the service. Block valves for control valves shall be run size.

4.1.3 Suction and discharge piping for all pumps shall be at least one pipe size larger than the respective pump inlet or outlet connection.

4.1.4 Pipe sizes 1¼ inches, 2½ inches, 3½ inches, and 5 inches shall not be used except when necessary to connect to purchased equipment. When such sizes are used, the pipe size shall be increased to the next larger standard size at the first practical point in the piping system.

4.1.5 Piping smaller than ½ inch shall not be used. Stainless steel tubing with formed bends and tubing fittings shall be used when smaller sizes are necessary.

4.2 Pressure Rating Considerations

4.2.1 Changes in pressure rating of piping systems shall be made at relief or block valves. The valves which divide the two systems shall be rated for the higher pressure service. Block valves used on either side of control, relief, and check valves, all bypass valves, and all piping to block and bypass valves shall be rated for the higher pressure service.

4.2.2 Every system where failure of a pressure controller or other malfunctions might result in a pressure build up which would exceed the maximum allowable operating pressure (MAOP) of the system shall be equipped with a pressure relieving device.

4.2.3 The wall thicknesses of pipe and fittings shall be selected such that the MAOP of the pipe and fittings will equal or exceed the corresponding ANSI flange rating of the particular line class. Where design pressure does not correspond to an ANSI Class, alternate wall thickness requirements may be determined by calculation per ASME B31.3.

4.3 Joint Selection - Welded or Threaded

4.3.1 Process piping sized 3 inches and larger shall use buttweld fittings.

4.3.2 Process piping sized 2 inches shall use either buttweld or threaded fittings.

4.3.3 Process piping sized 1½ inches and smaller shall use either socketweld or threaded fittings. Each run shall use either threaded or socket welded fittings, exclusively.

4.4 Threaded Joint Requirements

4.4.1 Threaded fittings shall not be seal welded.

4.4.2 Threaded connections shall not be used in stainless steel piping.

4.4.3 Threaded connections shall not be used in triethylene glycol service or high pressure ethylene glycol service.

4.4.4 Use of threaded connections shall be minimized in potentially vibrating service, such as reciprocating compressor piping between the suction scrubber and the after cooler and reciprocating pump suction and discharge piping.

4.4.5 Use of threaded connections shall be minimized in ANSI 900 and higher service.

4.4.6 Threaded nipples shall be long enough to be held with a pipe wrench when fittings are in place on each end. Close and all-thread nipples shall not be used.

Nipples used with socket-welded fittings shall have plain ends.

4.4.7 No street elbows or threaded bushings shall be used in process or utility piping.

Hex bushings (but not flush bushings) may be used with tubing fittings for connecting instruments.

4.4.8 Instrument connections shall be threaded beyond the first block valve off of process piping in socketweld services.

4.5 Flanged Joint Requirements

4.5.1 Process piping sized 3 inches and larger shall use weld neck flanges.

4.5.2 Process piping sized 2 inches shall use either weld neck flanges or threaded fittings.

4.5.3 Slip-on flanges shall not be used without approval by GOVERNMENT.

4.5.4 Flanges of ANSI pressure class 400 shall not be used except when necessary to connect to equipment.

4.5.5 Standard flange facing shall be Raised Face (RF) for ANSI Class 600 and lower and Ring Type Joint (RTJ) for ANSI Class 900 and higher and all API 6A Flanges. With GOVERNMENT approval, raised face flanges may be used in higher pressure services when required to mate to existing equipment, or in cases such as compact valve manifolds or parallel meter runs where there is insufficient flexibility to allow flanges to be separated enough to remove RTJ gaskets. When mating of an RTJ flange to a RF flange cannot be avoided, the gasket shall be a Pikotek® gasket specifically approved for the mis-match combination.

4.5.6 Steel flanges which mate with equipment having cast iron, ductile iron, or plastic flanges shall be flat faced flanges. Full face gaskets shall be used with all flat faced flanges.

4.5.7 Reducing flanges shall not be used if space is available for pipe reducers or reducing elbows.

4.5.8 Special bolted connectors such as "Grayloc", may be used with GOVERNMENT's approval, when appreciable savings of space, weight or ease of disassembly are of an advantage. Pressure rating shall be per manufacturers specifications.

4.6 Reducers

4.6.1 Eccentric reducers (straight side up) shall be used in pump suction connections.

Eccentric reducers (straight side down) shall be used in compressor suction connections.

4.6.2 Reducing fitting thickness shall match heavier pipe wall thickness. If the fitting thickness differs from the lighter pipe wall thickness by more than 1/16 inch, then the fitting shall be taper bored at an angle between 18 degrees minimum (1:3 slope) and 30 degrees maximum to correct the difference to no more than 1/16 inch.

4.7 Elbows

4.7.1 Buttweld 90° elbows shall be long radius elbows unless restricted by space.

Short radius elbows may be used if needed and approved by GOVERNMENT.

Short radius elbows shall be derated to 80 percent of the calculated allowable working pressure of seamless pipe of the same size and nominal wall thickness and the same or equivalent material. Miter elbows shall not be used.

4.7.2 Buttweld tees with weld caps shall be used in place of elbows for severely erosive services. Tees with caps or long radius elbows may be used in mildly erosive services.

4.8 Branch Connections

4.8.1 Branch connections shall be made in accordance with Branch Connection Schedules, Section 12.0. Fabricated "Stub-in" or "Stub-on" connections are not permitted.

4.8.2 "Elbolets" shall be restricted to connections for thermowells. "Elbolets" may be used for drains and vents when no other fittings are practical. They shall not be used for branch process piping.

4.8.3 Branch connections for valves, gauges, thermowells, instrument bridles, level indicators, etc. on thermally insulated main pipe runs shall extend through the pipe insulation a sufficient distance so that valves can be operated and equipment can be dismantled for maintenance without removing the insulation on the main pipe run.

4.8.4 All branch connections for instrument air or instrument gas lines shall be taken off the top of the header. Instrument air and gas headers shall be equipped with valved low point drains which are easily accessible.

5.0 PIPING LAYOUT

5.1 Piping shall be laid out so that equipment such as control valves, relief valves, start-up strainers, pump casings and rods, heat exchanger bundles, etc., can be removed with a minimum amount of dismantling and without providing additional supports. Access to manholes and access openings shall not be obstructed.

5.2 A sufficient number of flanges or unions shall be provided in all piping to allow removal of valves and equipment for maintenance.

5.3 When isolating block valves are provided for control valves or other pieces of equipment, piping spools shall be provided to permit removing piping between isolating block valves. Drain and vent valves shall be provided to relieve fluids trapped between isolating valves.

5.4 Spectacle blinds or removable piping spools shall be provided at all piping connections to all vessels and tanks which have provisions for personnel entry.

5.5 Piping systems shall be laid out so that all valves, strainers and instruments can be operated and serviced conveniently. When possible, valves shall be accessible at grade level. Ladders or platforms shall be provided for valves or equipment which cannot be reached from grade level. Chain mechanisms for valves shall not be used without GOVERNMENT approval.