Page 1 of 15

HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY
DHT PROJECT

PART : III
SECTION : A

TITLE: STRESS DESIGN BASIS

DOCUMENT NO: 44LK-5100-00/L.02/0004/A4

26.06.09

15

Revised as marked &

Issued as Amendment
no.2

DRP

PSK

RMP/PVS

09.12.08

15

Issued for FEED

DRP

PSK

RMP/
PVS

Rev No.

Issue Date

Pages

Description

Prepared
By

Checked
By

Approved
By

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

DOC NO: 44LK-5100-00/L.02/0004/A4

44LK 5100

Part - III
Section- A
Sheet 2 of 15

TABLE OF CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

DEFINITIONS

4.0

SELECTION

5.0

RELATED DOCUMENTATION

6.0

PIPE STRESS ANALYSIS AND SUPPORTING

7.0

CODES AND STANDARDS

8.0

SOFTWARE USED

9.0

DOCUMENT REQUIRED

10.0

ATTACHMENTS

10.1

CRITERIA FOR IDENTIFYING CRITICAL LINES

10.2

CATEGORISATION FOR SEISMIC ANALYSIS

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

DOC NO: 44LK-5100-00/L.02/0004/A4

44LK 5100

1.0

Part - III
Section- A
Sheet 3 of 15

PURPOSE
This design basis deals with the subject of Identification of Stress Critical pipelines and
preparation of Critical line list. This procedure also defines the minimum requirements for
performing stress analysis, design and location of spring, support and extent of system
analysis with the extent of documentation required for flexibility analysis
Purpose of piping stress analysis is to ensure:

2.0

Safety of piping and piping components

Safety of connected equipment and supporting structure

Piping deflections are within the limits

SCOPE
This specification covers the supply of engineering services to perform a complete piping and
pipe support analysis for new and modified piping systems for HPCL Mumbai Refinery for its
DHT Project.

3.0

DEFINITIONS

3.1

CRITICAL LINES / CRITICAL LINE LIST

Critical lines or Critical Line List as referred to in this procedure relates to Piping Stress
Critical Lines and does not include or refer to process critical lines.

3.2

STRESS ANALYSIS TEMPERATURE

Stress Analysis Temperature refers to either Maximum Operating Temperature or Steamout temperature / hot Nitrogen purging temperature of the lines under review whichever is
higher. In absence of the above values, it refers to the Design Temperature of the line under
review. The Line List should be strictly followed in obtaining the above temperature

3.3

DESIGN PRESSURE
Design Pressure refers to the Design Pressure of the line under review as indicated on the
Line List. Design Pressure is as defined in clause 301.2 of ASME B 31.3.

3.4

TEMPERATURE FOR FLEXIBILITY ANALYSIS

The temperature to be used for the flexibility analysis shall be taken as the maximum /
minimum temperature which the pipe will see under any combination of different normal /
abnormal operating conditions, as defined in clause 301.3 of ASME B 31.3. Where piping is
0
exposed to direct sunlight, solar radiation temperature of 70 C is considered in establishing
the maximum temperature of piping. Even, for non-critical piping exposed to direct sunlight on
pipe rack or elsewhere, expansion loops, wherever essential, are provided to take care of
pipe movements resulting from piping skin temperature due to solar radiation.
0

In general, unless there is a difference of more than 50 C between working temperature and
the design temperature, the design temperature should be taken as Flexibility temperature.If
0
the difference is higher than 50 C the stress analysis temperature is needed to be decided in
consultation with process Licensor/Group.
The temperature under Fire Condition are not considered for stress analysis except for flare
lines.
Ambient Temperature shall be considered as 21 0 C. the assumed piping installation
temperature. The displacement stress range from this installation temperature to the
minimum recorded ambient temperature of 120C being less than the same from installation

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

DOC NO: 44LK-5100-00/L.02/0004/A4

44LK 5100

Part - III
Section- A
Sheet 4 of 15

temperature to the maximum operating temperature of hot piping in most cases the later
governs as per clause 319.2.3 of ASME B 31.3.
4.0

METHOD OF ANALYSIS
A line is selected and listed as a Critical Line provided it falls under any one of the
categories defined in Attachment 10.1 and is intended to include the special
requirements of Piping Stress Engineer. It is hence defined as any line for which a
flexibility review is required or where pipe supporting is deemed to be critical and needs
review by a Stress Engineer.Hence all lines following outside the categorization are
deemed non critical which can be reviewed using nomographs manual calculation and/on
visual analysis.
All lines in this list essentially need a formal computer analysis with a trunion
calculation,Flange leakage calculation and nozzle load calculation as required,Very large
diameter (thin walled)pipes and ducts need special design consideration which should be
highlighted.

4.1

LINES DEEMED TO BE SUPPORT CRITICAL

Lines subjected to two-phase flow
Cross country pipelines.
Lines with pipe thickness Sch 160 or greater
Lines DN 400 and above with pipe thickness less than 8 mm.
Lines DN 250 and above with corrosion allowance 3 mm and above
Lines with high concentrated loads such as heavy valves or fittings etc.
Lines downstream of Relief Valve / letdown Control Valves / bursting (rupture) discs.
connecting to vent or flare systems or discharging to atmosphere.
Liquid Blow down Lines
Lined pipes
Non-metallic pipes

4.2

LINES NEEDING DYNAMIC ANALYSIS

There are instances where in the frequency of the applied load is comparable to the
natural frequency of the piping system. Such systems tend to store the energy and
release it according to certain scientific laws. Such a system is dynamic in nature and the
study of the response of such a system is referred to as Dynamic Analysis. Examples of
such kind of systems are Relief Valve discharge lines, Safety valves / rupture discs, water
hammer and surge in pipelines, two phase slug flow in pipelines, reciprocating pumps and
compressor piping, submarine piping,pipelines subjected to earthquake of large
magnitude etc.

4.3

SPECIAL PIPING
Special piping forming part of reformer tubes, heater internal piping, etc. are treated as
proprietary piping and nozzle loading at the Interface connections are to be co-ordinated
with vendor.

4.4

Pipelines which will require seismic analysis,Refer to Attachment 10.2

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

DOC NO: 44LK-5100-00/L.02/0004/A4

44LK 5100

Part - III
Section- A
Sheet 5 of 15

5.0

RELATED DOCUMENTATION

5.1

CRITICAL LINE LIST FORMAT.

The critical line list shall be prepared from the project line list document by inserting
following relevant fields such as
Stress category Critical (C) or Non-critical (NC), stress package no., stress analysis
temperature, support critical nature of the line, dynamic loadings, steam out / purge
temperature etc.
The list shall reflect analysis status of line that includes its input received date from design
& output handover date to design and specific remark if any.

5.2

LINES AFFECTING THE FLEXIBILITY OF CRITICAL LINES

a) Non-critical Lines found to affect the flexibility of critical lines which have not been
included during the initial review are subsequently added to the Critical Line List.
b) Non-critical Lines on which advice may be sought by the Lead Piping Engineer are
not
normally entered into the Critical Line List but covered verbally, or by a
memorandum if a record is required.
c) All non critical lines (having size more than half of main run size) that tie into critical
lines should be considered as critical upto first anchor if they have significant effect
on main line flexibility.

6.0

PIPE STRESS ANALYSES AND SUPPORTING

6.1

Piping support Criteria and General Guidelines :

Piping system shall be properly supported taking in to account of the following points:
a. Sustained Loads:

Weight of piping (Bare pipe, service fluid, valves, flanges etc.)

Weight of insulation (if any)

Weight of online equipment (if any)

Weight of instruments (if any)

Pressure relief load due to safety valve operation

Wind / Seismic loads (as and when required)

Dynamic loads due to pulsating flow/two phase with slug flow

Pressure-Thrust loads in case of expansion joints.

b. Thermal Loads
Thermal loads due to operating / design / steam out / decoking or any other abnormal
condition.
Pipe supporting shall be preferably follow the basic span as given in Piping Design
Basis (Annexure D), except for flare line in offsite on trestles in which case the basic
span shall be restricted to max.18m. For sizes not covered in Piping Design Basis,
basic span shall be established based on project requirement. For piping on rack or
sleeper, as a minimum, providing resting support on every grid of pipe rack / sleepers
mandatory. Guides shall be provided on straight run of pipes at intervals as specified
in piping design basis (Annexure C), unless specifically becomes non-viable due to
flexibility problems.

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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44LK 5100

Part - III
Section- A
Sheet 6 of 15

Additional supports, guides, anchors, special supports like spring supports and sway
braces shall be provided based on detailed analysis of piping system to restrict the
forces on nozzles of critical equipments like pumps, compressors, turbines,
exchangers, fin-fan coolers etc.
A permanent support, either resting or spring support shall be provided for lines which
do not need any supporting otherwise but require supporting during maintenance.
Pads will be provided at pipe supports, for all sizes and services of lines irrespective of
whether shoes are required or not.
Adequate care shall be taken for small bore(1 inch NB and below) branch from
piping. For all lines in 600# and above classes - lines having two phase flow and lines
having pulsating flow such as discharge of reciprocating compressors and
reciprocating pumps, all small bore branches (vents, drain, orifice traps, pressure /
temperature tapings, sample connections), PSV / TSV inlets etc., shall be provided
with 2 number stiffeners at 90 Deg to each other from main pipe to impart adequate
stiffness to the branch connection. The stiffeners shall be made from 6 mm thick flats
of material equivalent to the pipe material. Irrespective rating, the stiffeners shall be
provided for all orifice taps, all small bore tapings from PSV inlet / outlet lines and all
small bore tapings from control valve manifolds.
For pulsating flow lines, detailed thermal and vibration analysis by analog study shall
be done to decide on location of anchor supports and guides etc.
In case of two phase with slug flow lines, piping design shall be checked by dynamic
analysis to prevent vibrations.
Piping support design shall be such that deflection in piping systems due to sustained
loads shall not exceed 15mm, between two adjacent supports.
Long trunion type of supports (more than 0.5m) is to be avoided. In case long trunion
support is unavoidable, trunion height shall be restricted to 0.5m and balance height to
be made up by providing extended structure.
In case of heaters having the provision for steam-air decoking, the main lines and
decoking lines should not be in hanging position when not in operation.
Piping passing through technological structure or passing near the concrete column
etc. should have adequate space or gap considering insulation, to avoid restriction of
line movement during thermal expansion.
High density PUF block shall be considered for cold piping supports. Wooden blocks
may be used for load taking supports on vertical lines or as anchor supports.
All pipe supports shall be so designed that there is no undue tension on equipment
flanges.
6.2

Flexibility Analysis Criteria and General Guidelines:

6.2.1

Piping stress analysis shall follow ASME B31.3 and shall complete to prevent over
stressing of pipe during operating conditions with wind and seismic loadings. During
sustained, occasional (wind and seismic) & thermal expansion loading on piping, the
material allowable stresses shall be as per ASME B 31.3 for ASTM materials. For DIN
material specifications the allowable stress values shall be calculated as per ASME B 31.3
clause 302.3.2(d), wherein yield strength and ultimate strength values at temperature shall
be taken from DIN material standards. For DIN material specifications, the other material
properties viz. elastic modulus, density, coefficient of thermal expansion shall be taken

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HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 7 of 15

from the respective DIN material standards.

6.2.2

Analysis shall include, but not be limited to the following; thermal, dead weight, internal
pressure, wind and seismic, and a combination of these based on ASME B 31.3.

6.2.3

At a minimum, two (2) orthogonal horizontal components and a vertical component of

ground motion will be considered in the seismic analysis. The seismic design shall be as
per UBC, seismic zone-3. The minimum seismic accelerations applied to the piping
system in the horizontal and vertical plane shall be 0.3g and 0.15g respectively as per
seismic zone-3 of UBC. Accelerations shall be combined and applied as follows to
determine the most unfavourable condition:
0.7X, 0.7Z, 1.0Y

(Y is vertical)

1.0X, 0.3Z, 1.0Y

0.3X, 1.0Z, 1.0Y

Where, X and Z = 0.3 and Y = 0.15

Based on the above combinations, the magnitude and direction of accelerations shall be
applied to the piping system as follows:

X-Direction

Z-Direction

Y-Direction (Vert.)

0.21g

0.21g

0.15g

0.3g

0.09g

0.15g

0.09g

0.3g

015g

Direction of loading () shall produce the most unfavourable condition.

6.2.4

Wind analysis shall follow ASCE-7 using a basic wind velocity of 160 km/h. At a minimum,
wind loading shall be applied to all components in two (2) perpendicular horizontal
directions at elevation 10 m and above. Shape factor for piping shall be considered as 0.7.
ASCE-7 Exposure category C [kz = 0.85 for z <4.6 m & kz= (0.10044* z)^0.2105 for z >=
4.6 m up to 274m] & gust factor of value 1.5 shall be considered for taking care of effect of
height and topography. Wind and seismic loading will not occur simultaneously.

6.2.5

Analysis of all nozzles loading on vessels within the piping boundaries is covered in this
specification. Nozzle analysis shall follow the guidelines of ASME Section VIII, Division 1,
and WRC 297 & 107 (latest editions). Nozzle stresses shall fall within the allowable as per
ASME.

6.2.6

All forces on connections to equipment shall not exceed maximum allowable as specified
by equipment vendor.

6.2.7

Pipe supports loads shall be based on the maximum loads determined by the piping
analysis. JE shall evaluate all pipe support loading including friction forces due to thermal
expansion using good engineering judgement. Adjustments shall be made to the piping
system and model such that the pipe supports loads are within a reasonable uniformity
throughout the piping system.

6.2.8

Various Load cases built in Caesar II to check stress in piping system are listed below.

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 8 of 15

Load Case

Type

Remarks

1)
2)
3)
4)

WW+HP
W+T1+P1
W+T2+P1
W+T1+P1+U1

HYD
OPE
OPE
OPE

Seismic load (0.21g,0.15g,0.21g)

5)

W+T1+P1+U2

OPE

Seismic load (0.3g,0.15g,0.09g)

6)

W+T1+P1+U3

OPE

Seismic load (0.09g,0.15g,0.3g)

7)

W+T1+P1-U1

OPE

Seismic load (0.21g, 0.15g, 0.21g)

8)

W+T1+P1-U2

OPE

Seismic load (0.3, 0.15g,0.09g)

9)

W+T1+P1-U3

OPE

Seismic load (0.09g, 0.15g, 0.3g)

10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)

W+T1+P1+WIN1
W+T1+P1+WIN3
W+P1
W+P2
L2-L12
L3-L12
L4-L2
L5-L2
L6-L2
L7-L2
L8-L2
L9-L2
L10-L2
L11-L2
L12+L16
L12+L17
L12+L18
L12+L19
L12+L20
L12+L21
L12+L22
L12+L23

OPE
OPE
SUS
SUS
EXP
EXP
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC

WIN1 +X direct wind load

WIN3 +Z direct wind load

P1- Maximum Operating Pressure

W Dead Weight

T1-Maximum Operating Temperature

WW Water Weight

P2-Design Pressure

WIN Wind Load

T2-Design Temperature

U - Uniform Load

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 9 of 15

HP- Hydro test Pressure

L2 Load Case

SUS, EXP, OCC, HYD, OPE Various load types, viz., sustained, expansion, occasional, hydro test,
operating etc.
6.2.9

7.0

The general guideline for stress analysis of Jacketed lines are as follows :
a.
b.

Provide Spider (or spacer) at every 10 (3 m) and locate approx. 4 (100 mm) from elbow.
Connect core to jacket by connect node and anchor.

c.

Verify clearance between core and jacket for thermal expansion.

CODES AND STANDARDS

The following codes and standards shall apply in the design and analysis of the
systems covered under this specification:

piping

Allowable Stress ASME B 31.3

Piping
ASME B 31.3

8.0

Nozzle Loadings

As per specifications enclosed in the BID

Wind Analysis

ASCE 7 98

SOFTWARE USED
COADEs piping stress analysis software Caesar II, Version 5.0 or above shall be used
for Pipe stress analysis. Pipe thickness & material allowable stress values will be
manually fed as input.

9.0

DOCUMENT REQUIREMENT

9.1

A written report shall be submitted on the piping and equipment analysis. The report shall
include all pertinent information that shall include but not be limited to the following :
Location and type of pipe supports with loads and movements.
Location of expansion joints and movements.
Vertical and horizontal loads including moments at all support points.
Vertical and horizontal loads including moments on all equipment and vessel
connections.
Caesar II analysis report, which shall include as a minimum, restraint forces,
movements and stresses for all load cases. For flange connection, loaded with high
bending moments and/or tensile forces in piping or at equipment connections, Caesar
II flange leakage report will be provided. For piping analyzed, if subjected to hydro test,
hydro test load case will be made in Caesar II to check for loading under hydro test &
the requirement of any additional temporary supports for hydro test.
Detailed nodal model used for the stress analysis
All assumptions and limitations applied to the analysis.

9.2

All dimensions and analysis shall be performed using metric and SI units.

9.3

The final report / stress package folder shall be submitted as follows:

1. Front sheet with Approval status

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 10 of 15

2. Isometrics with Hand written following information.

Node numbers
Type of supports selected by stress engineer
Springs / Bellows data required for procurement like spring rate, loads, tide/untied
information and SM (special material) identification.
Maximum Expansion and sustain stress values with node number
Nozzle/Anchors initial movements and piping imposed forces and moments on
the same

Support loads (anchors, guides or rest) only they are above limit (The limit is
defined in the beginning of the project in consultation with civil)
Design and maximum operating conditions
Coordinate axis system considered for inputs
Dimensional details for piping designer to locate supports in piping model/layout.
3. Check list as per JE work instructions.
4. Following outputs
Load Cases
Restraint summary
Spring hanger report, if any
5. Stress critical line list extract for the lines analysed
6. Piping material specifications
7. Equipment drawings with allowable loads, if available
8. PID

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 11 of 15

ATTACHMENT 10.1
CRITERIA FOR IDENTIFING CRITICAL LINES.
SR
NO

Temperature
T, Degree C

Pipe
Diameter
D,Inch
NB

Piping
Material

Service and Description

All

D>2

All

All

D>3

All

3
4
5

T < (-) 45
T > 200
T > 100

All
All
All

T > 65

D>3
D>3
D > 16
(see note
3)
D>3

Category M (Lethal) fluid service per ASME B31.3 (Ref. Note

4).
Piping which is exposed to winds of speed > 75 mph.(Ref
Note 5)
All Services.
All Services.
All Services.

7
8A

T > 65
T < (-) 29

D>2
D>3

NonMetallic
All
All

8B
9

T > 65
DeltaT > 27
(Note 2)
T > 65

D>3
D>2

All
All

Lines with pressure > 900 psig.

Piping connected to nozzle load-sensitive equipment, (see
note 1)
air-cooled exchangers and rotating equipment (see note 1).
Jacketed piping.(D=Inner Pipe NB)

D>4

All

Internally lined pipe (except glass lined).

T < (-) 29

D>4

All
T < (-) 40

All
D>4

All
Metallic

Glass lined piping.

Underground Piping/Cross Country Piping.

T > 80

D>4

Metallic

Underground Piping/Cross Country Piping.

T < (-) 29

D>8

Metallic

Underground Piping/Cross Country Piping.

T > 70

D>8

Metallic

Underground Piping/Cross Country Piping.

All
All

D> 2
D> 2

All
All

Safety Relief Valve Outlet Pipeline.

Pipelines connected to expansion joints or bellows (except
rubber bellows used for alignment purpose).

10
A
10
B
11
12
A
12
B
12
C
12
D
13
14

All Services.

Note :
1. Load sensitive equipment include fired heaters,boilers / steam generators, Reformers,lined
vessels with lining of brittle material,non-ferrous equipment,Graphite heat exchangers,plate &
frame heat exchanger,Spiral Heat Exchangers,Equipment on load Cells etc.
2. Also include lines connected to nozzles having differential settlement / Thermal displacement
more than 12 mm.
3. Delta T refers to the differential temperature between the process piping and jacket.
4. Very large diameter pipes (dia / thickness >100)and ducts need to be designed using finite
element analysis methods.
5. Category M Fluids involve toxic and harmful fluids which are identified by process.These
services are lethal and hence critical.They need mandatory flange leakage calculations. To get
the loads at flanges,a computerised stress analysis is required.
6. For critical lines in seismic prone, plants refer Attachment 10.2 for categorisation.

Jacobs
HPCL, Mumbai
LSTK

Stress Design Basis

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Part - III
Section- A
Sheet 12 of 15

ATTACHMENT 10.2
Categorization for Seismic analysis
Definition: Plant Piping located in earthquake prone areas of the country will experience accelerations
imparted through foundations, structures and various equipment. Criticai piping {toxic, flammable, high
pressure, high temperature, emergency) which must remain leak;tight or operable (deliver, control or
shutoff flow) during or following the event, have nozzle loads within vendor's set limits, have minimum
sway to avoid impact or interference with adjacent equipment / pipes / structures need seismic analysis to
determine the effects.
Based on Indian code IS 1893-2002, areas falling under Zones IV and V are categorized as "Severe"
while Zones II and III are prone to earthquakes of "Moderate" or "Low" intensity. The IS 1893-2002
guidelines for BUILDINGS to be seismically designed are as beiow;
For regular buildings, if the building height is greater than 40 m in Zones IV and V or greater than
90 m in Zone II and III
;
For irregular buildings, if height is more than 12 m in Zones IV and V and more than 40 m in
Zones II and III,
Method: Process Plants normally fall within the irregular building category and hence the piping and
equipment are to be analysed accordingly. To get realistic results, it is essential that seismic analysis for
piping be carried out using the Dynamic analysis method viz. Time History method or Modal Response
Spectrum method. Piping connected to tail columns/vessels, chimneys and any slender structure should
preferably be analysed using dynamic analysis. Long-run piping on tall slender structures (such as flare
piping on trestles) should be analysed using composite analysis. For toxic/lethal piping systems, the
seismic anchor movements also need to be imposed during the dynamic analysis. However for
simplification's sake wherever dynamic analysis is not mandatory by the client or the response
spectra cannot be derived from data available, seismic design can be done using the Equivalent
Static (static coefficient) method.

The seismic accelerations, response spectra and anchor movement values are to be obtained from the
Civil Group.
For seismic analysis, earthquake loadings shall not be considered to act simultaneously with wind. Also it
is to be noted that cross-country pipelines, buried piping & piping for nuclear installations will need
rigorous analysis and the selection criteria below does not apply. Refer LWI 220 for explanatory
techniques for seismic design of piping systems (under development)
Selection: With due considerations to fluid criticality and intended operation, in order to assess maximum
impact it is recommended that only critical piping with higher sizes (i.e. higher mass and/or at higher
elevations which in turn reflects as higher force) be seismicaiiy computer analysed. Since not explicit in
Indian codes, following guidelines are a conservative selection.

All critical piping systems aboveground with a weight (self+fluid+insuiation) greater than 410
kg/m (corresponds to a 24" STD schedule water filled pipe).

All critical piping systems above ground with any portion routed at a height (height as per the
above IS 1893 building categorization) with a weight greater than 210 kg/m (corresponds to a 16"
STD schedule water filled pipe). Give due consideration to piping connected to tall equipment &
piping routed on tall slender structures.
All emergency service critical piping systems above ground with any portion routed at or
greater than 25m with a weight greater than 110 kg/m (corresponds to a 10" STD schedule
water filled pipe).
Smaller critical lines (3" to 10") routed above 10 m elevation need to be seismically analysed
provided the wind load does not govern.

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HPCL, Mumbai
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Piping < 410 kg/m and below 10m elevation and non-critical piping can be considered as nonseismic critical. Such systems shall be made rigid overall preferably by having every 2Fld / 3rd
support (appx 12m) as a seismic lateral restraint (guide) and every straight run (> 3 times
standard supporting span) with a longitudinal (axial) restraint. Equivalent Static Analysis needs to
be done only if peak spectral acceleration / static seismic coefficient is > 0.3 g, max

component weight is > 200kg and pipe centerline is > 1m.

Branch lines can be decoupled from the run lines if Irun > 25 leaned where I = moment of inertia.
These guidelines are indicated graphically on Sht 2 of 2 of this attachment.

Jacobs
HPCL, Mumbai
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Stress Design Basis

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Section- A
Sheet 14 of 15

ATTACHMENT 10.2

Notes :
1. For site specific Zoning as per IS 1893, refer Project Initiation Checklist in Project
Procedure
2. If Dynamic Analysis is not mandatory by the client or the response spectra cannot be
derived from data available, Equivalent Static Analysis can be done. However, if
Equivalent Static Analysis yields uneconomical results, Dynamic Analysis methods
may be adopted to achieve realistic results.
3. Piping in this category are non-seismic critical. Systems shall be made rigid overall
preferably by having every 2nd / 3rd support (appx 12m) as a seismic lateral restraint
(guide) and every straight run {> 3 times standard supporting span) with a longitudinal
(axial) restraint. Equivalent Static Analysis needs to be done only if peak spectral
acceleration / static seismic coefficient is > 0.3 g, max component weight is > 200kg and
pipe centerline is > 1m.
4. A Tall equipment (tower.etc) located at grade is analogous to a Building (RCC or steel
frame structure). Piping connected to be categorized accordingly.
5. Piping on tall slender structures (such as flare piping on trestles) should undergo
composite analysis.

Jacobs
HPCL, Mumbai
LSTK
44LK 5100

Stress Design Basis

DOC NO: 44LK-5100-00/L.02/0004/A4

Part - III
Section- A
Sheet 15 of 15

6. Emergency services are isolation/relief systems which reduce the potential of a major
hazardous accident such as emergency process control, emergency pressure relief,
emergency venting / blowdown, emergency shutdown, emergency purging / cooling, etc
classified as safety critical by Process.

PIPING MATERIAL SPECIFICATION

RATING

: 300 #

Client

: HINDUSTAN PETROLEUM CORP. LTD.

BASIC MATERIAL

: CARBON STEEL

Project - Location

: DHT MUMBAI

SPECIAL REQUIREMENT

:-

PMC

: JACOBS ENGINEERING. INDIA PVT. LTD.

CORR. ALLOWANCE

: 0 MM / 3MM (UP TO 2") Document No.

REVISION

:1

: 44LK-5100-00/L.02/0101/A4

PIPE CLASS

B5Y
Page 1 of 5

TEMPERATURE ( Deg. C ) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

TEMP
PRESS

0
52.11

38
52.11

50
51.09

65
50.48

70
49.66

SERVICE
SEA COOLING WATER SUPPLY & RETURN

NOTES
1

NDT REQUIREMENT SHALL BE AS PER JOB SPECIFICATION 44LK-5100-00/L.02/0103/A4.

USE BUTTERFLY VALVES INSTEAD OF GATE VALVES FROM 10" ONWARDS IN WATER SERVICE AND UP TO 700C.
DESIGN PRESSURE FOR BUTTERFLY VALVES IS LIMITED UPTO 10 BAR.

BUTTERFLY VALVES FOR THE SPEC ARE PN10 RATED WITH A MAXIMUM PRESSURE OF 10.2 KG/CM2G

ALL BLIND FLANGES, FIG 8 FLANGES AND SPACER & BLINDS SHALL BE FRE-LINED FOR THE WETTED PORTIONS.

BLIND FLANGES AND SPACER & BLINDS SPECIFIED TO MANUFACTURER'S STANDARD SHALL BE DESIGNED FOR 700C AND 6.6 KG/CM2G TO SUIT 150#,
FF, 125 AARH, AWWA C207 CL.D FLANGES.

FOR U/G STEEL PIPES, PIPE WALL THK.SHALL BE CALCULATED AS PER SERVICE REQUIREMENT BY USING APPLICABLE CODES AS
B 31.3 / 31.4, AWWA-M-11 AND API RP-1102 AND HIGHER OF THREE THK.

ALL PIPING COMPONENTS EXCEPT VALVES AND STRAINERS FOR SIZES 3" & ABOVE SHALL BE CEMENT LINED AT SITE.

VALVES AND Y-TYPE STRAINERS FOR SIZES 3" & ABOVE SHALL BE INTERNALLY FRE-LINED EXCEPT THE TRIMS.

FORGINGS ARE ACCEPTABLE INSTEAD OF PLATE MATERIAL FOR BLIND FLANGES AND SPACER & BLINDS.

10

FOR SIZES >24", SPACER & BLIND SHALL BE DESIGNED BY THE MANUFACTURER AS PER ASME B 31.3

11

FOR SIZES ABOVE 30", TEMPERATURE AND PRESSURE RATINGS SHALL BE 700C & 6.6 KG/M2G RESPECTIVELY.

12

AWWA C207 CL.D FLANGES SHALL BE OF HUB TYPE.

13

CORROSION ALLOWANCE SHALL BE 3.00MM FOR SIZES UP TO 2" AND NIL FOR SIZES 3" AND ABOVE.

SPECIAL NOTES

ITEM

SIZE

DESCRIPTION

MAINTAINENCE
JOINTS

ALL

FLANGED

PIPE JOINTS

0.5" TO 1.5"

SW COUPLING

2" TO 2.5"

BUTT WELDED

3" & ABOVE

FLANGED

ON LINES 1.5"

AS PER P & ID

ON LINES 2"

AS PER P&ID OR 0.75".

ON LINES 1.5"

AS PER P & ID

ON LINES 2"

AS PER P&ID OR 0.75".

TEMP. CONN.

1.5"

FLANGED

PRESS. CONN.

0.75"

SCRD NIPPLE WITH VALVE

DRAINS

VENTS

A. CODE

PIPING MATERIAL SPECIFICATION

RATING

: 300 #

Client

BASIC MATERIAL

: CARBON STEEL

Project - Location : DHT MUMBAI

SPECIAL REQUIREMENT : -

PIPE CLASS

: HINDUSTAN PETROLEUM CORP. LTD.

PMC

B5Y

: JACOBS ENGINEERING. INDIA PVT. LTD.

CORR. ALLOWANCE

: 0 MM / 3MM (UP TO 2") Document No.

REVISION

:1

: 44LK-5100-00/L.02/0101/A4

Page 2 of 5

BRANCH CONNECTIONS
44
42
40
36
34
T

32

30

T R

28

T R R

26

T R R R

24

R R R R

20

T R

R R R R

18

T R R

R R R R

16

T R R R

R R R R

14

T R R R R

R R R R

12

T R R R R R

R R R R

10

T R R R R R R

R R R R

T R R R R R R R

R R R R

R R R R R R R R

R R R R

5
T

4
3

R R R R R R R R

R R R R

2
T

P P P P P P P P

P P P P

P P P P P P P P

P P P P

P P P P P P P P

P P P P

T T

P P P P P P P P

P P P P

T T T

P P P P P P P P

P P P P

RUN PIPE NB

CODE

DESCRIPTION

SADDLE FUSED JT

TEES

H. COUPLING

WELDOLETS

PIPE TO PIPE

INSTRUMENT TEE

REINFORCED

REFER NOTES

SOCKOLETS

SWEEPOLET

THREADOLET

44

42

40

36

34

32

30

28

26

24

22

20

18

16

14

12

10

BRANCH PIPE NB

22

PIPING MATERIAL SPECIFICATION

RATING

: 300 #

Client

BASIC MATERIAL

: CARBON STEEL

SPECIAL REQUIREMENT : -

: HINDUSTAN PETROLEUM CORP. LTD.

Project - Location : DHT MUMBAI

PMC

: JACOBS ENGINEERING. INDIA PVT. LTD.

CORR. ALLOWANCE

: 0 MM / 3MM (UP TO 2") Document No.

REVISION

:1

Input
Id.

Item
Type

Page
of 5
PIPE3CLASS

: 44LK-5100-00/L.02/0101/A4

Lower
Size
(Inch)

Upper
Size
(Inch)

Sch/
Thk

Dmn. STD Material

Description

B5Y
Commodity
Code

Pipe Group
PIP

PIPE

00.500

00.750

S160

B36.10

ASTM A 106 GR.B

PE, SEAMLESS

PIP

PIPE

01.000

01.500

XS

B36.10

ASTM A 106 GR.B

PE, SEAMLESS

PIP

PIPE

02.000

02.000

XS

B36.10

ASTM A 106 GR.B

BE, SEAMLESS

PIP

PIPE

03.000

06.000

STD

B36.10

ASTM A 106 GR.B

BE, SEAMLESS

PIP

PIPE

08.000

10.000

10.00

IS-3589

IS-3589 GR.330

BE, WELDED

PIP

PIPE

12.000

14.000

12.00

IS-3589

IS-3589 GR.330

BE, WELDED

PIP

PIPE

16.000

18.000

14.00

IS-3589

IS-3589 GR.330

BE, WELDED

PIP

PIPE

20.000

20.000

14.00

IS-3589

IS-3589 GR.330

BE, WELDED

PIP

PIPE

24.000

48.000

CALC

IS-3589

IS-3589 GR.330

BE, WELDED

NIP

NIPPLE

00.500

00.750

B36.10

ASTM A 106 GR.B

PBE, SEAMLESS

NIP

NIPPLE

01.000

01.500

B36.10

ASTM A 106 GR.B

PBE, SEAMLESS

1
1
1
1
1
1
1

Flange Group
FLG

FLNG.SW

00.500

01.500

B-16.5

ASTM A 105

300, FF/ 250 AARH

FLG

FLNG.SO

02.000

24.000

B-16.5

ASTM A 105

300, FF/ 250 AARH

ASTM A 105

300, FF/ 250 AARH

ASTM A 105, FRE LINED

300, FF/ 250 AARH

ASTM A 105, FRE LINED

300, FF/ 250 AARH

ASTM A 105, FRE LINED

300, FF/ 250 AARH

ASTM A 105, FRE LINED

300, FF/ 250 AARH

FLG

FLNG.SO

26.000

48.000

AWWAC207 CL.D

FLB

FLNG.BLIND

00.500

24.000

B-16.5

FLB

FLNG.BLIND

26.000

48.000

FEF

FLNG.FIG.8

00.500

08.000

FEF

SPCR & BLND

10.000

24.000

FEF

SPCR & BLND

26.000

48.000

AWWAC207 CL.D
ASME
B-16.48
ASME
B-16.48
MNF'STD

ASTM A 285 GR.C,FRE LINED 300, FF/ 250 AARH

Fitting Group
ELB90

ELBOW. 90

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELB90

ELBOW. 90

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELB90

ELBOW. 90

02.000

02.000

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELB90

ELBOW. 90

03.000

06.000

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELB90

ELBOW. 90

08.000

48.000

ELB45

ELBOW. 45

00.500

00.750

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

B-16.11

ASTM A 105

SW, 6000

ELB45

ELBOW. 45

01.000

01.500

ELB45

ELBOW. 45

02.000

02.000

B-16.11

ASTM A 105

SW, 3000

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELB45

ELBOW. 45

03.000

06.000

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELB45

ELBOW. 45

08.000

48.000

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

TEQ

T.EQUAL

00.500

TEQ

T.EQUAL

01.000

00.750

B-16.11

ASTM A 105

SW, 6000

01.500

B-16.11

ASTM A 105

SW, 3000

TEQ

T.EQUAL

02.000

02.000

B-16.9

ASTM A 234 GR.WPB

BW

TEQ

T.EQUAL

03.000

06.000

B-16.9

ASTM A 234 GR.WPB

BW

TEQ

T.EQUAL

08.000

48.000

B-16.9

ASTM A 234 GR.WPB-W

BW

TRED
TRED

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

TRED

T.RED

02.000

02.000

B-16.9

ASTM A 234 GR.WPB

BW

M: TO MATCH PIPE SCHEDULE

M,M

Note
No

PIPING MATERIAL SPECIFICATION

RATING

: 300 #

Client

BASIC MATERIAL

: CARBON STEEL

SPECIAL REQUIREMENT : -

: HINDUSTAN PETROLEUM CORP. LTD.

Project - Location : DHT MUMBAI

PMC

: JACOBS ENGINEERING. INDIA PVT. LTD.

CORR. ALLOWANCE

: 0 MM / 3MM (UP TO 2") Document No.

REVISION

:1

: 44LK-5100-00/L.02/0101/A4

Lower
Size
(Inch)

Upper
Size
(Inch)

Sch/
Thk

Dmn. STD Material

Description

T.RED

03.000

06.000

M,M

B-16.9

ASTM A 234 GR.WPB

BW

TRED

T.RED

08.000

48.000

M,M

B-16.9

ASTM A 234 GR.WPB-W

BW

REDC

REDUC.CONC

02.000

02.000

M,M

B-16.9

ASTM A 234 GR.WPB

BW

Input
Id.

Item
Type

Page
of 5
PIPE4CLASS

B5Y
Commodity
Code

Fitting Group
TRED

REDC

REDUC.CONC

03.000

06.000

M,M

B-16.9

ASTM A 234 GR.WPB

BW

REDC

REDUC.CONC

08.000

48.000

M,M

MNF'STD

IS-3589 GR.330

BW

REDE

REDUC.ECC

02.000

02.000

M,M

B-16.9

ASTM A 234 GR.WPB

BW

REDE

REDUC.ECC

03.000

06.000

M,M

B-16.9

ASTM A 234 GR.WPB

BW

REDE

REDUC.ECC

08.000

48.000

M,M

MNF'STD

IS-3589 GR.330

BW

SWGC

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105

PBE

M,M

SWGE

SWAGE.ECC

00.500

03.000

BS-3799

ASTM A 105

PBE

CAP

CAP

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CAP

CAP

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CAP

CAP

02.000

02.000

B-16.9

ASTM A 234 GR.WPB

BW

CAP

CAP

03.000

06.000

B-16.9

ASTM A 234 GR.WPB

BW

CAP

CAP

08.000

48.000

B-16.9

ASTM A 234 GR.WPB

BW

CPLF

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLF

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLH

CPLNG.HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLH

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

Valves Group
GAV

VLV.GATE

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED

TIN BRONZE, TRIM-IS 320
ALLOY HT2

SCRF, CL.2, 3000,

B-1.20.1

GAV

VLV.GATE

02.000

24.000

API-600

BODY-ASTM A 216 Gr.WCB,

FRE LINED
TRIM-BRONZE

FLGD, 300, B16.5,

FF/125AARH

GAV

VLV.GLOBE

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED

TIN BRONZE, TRIM-IS 320
ALLOY HT2

SCRF, CL.2, 3000,

B-1.20.1

GAV

VLV.GLOBE

02.000

16.000

BS-1873

BODY-ASTM A 216 Gr.WCB,

FRE LINED
TRIM-BRONZE

FLGD, 300, B-16.5,

FF/125AARH

CHV

VLV.CHECK

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED

TIN BRONZE, TRIM-IS 320
ALLOY HT2

SCRF, CL.2, 3000,

B-1.20.1

CHV

VLV.CHECK

02.000

24.000

BS-1868

BODY-ASTM A 216 Gr.WCB,

FRE LINED
TRIM-BRONZE

FLGD, 300, B-16.5,

FF/125AARH

CHV

VLV.CHECK

26.000

48.000

API-594

BODY-ASTM A 216 Gr.WCB,

FRE LINED
TRIM-BRONZE

FLGD, 300, AWWA C207,

FF/125AARH

BFV

VLV.BTRFLY

03.000

24.000

API-609/
BS-5155

BODY-ASTM A 105 / A216

GR.WCB, FRE LINED
TRIM-BRONZE

FLGD, 300, B-16.5,WAF/

FF/125AARH

BFV

VLV.BTRFLY

26.000

48.000

BS-5155

BODY-ASTM A 216 Gr.WCB,

FRE LINED
TRIM-BRONZE

FLGD, 300, AWWA C207,

FF/125AARH

M: TO MATCH PIPE SCHEDULE

Note
No

PIPING MATERIAL SPECIFICATION

RATING

: 300 #

Client

BASIC MATERIAL

: CARBON STEEL

SPECIAL REQUIREMENT : -

: HINDUSTAN PETROLEUM CORP. LTD.

Project - Location : DHT MUMBAI

PMC

: JACOBS ENGINEERING. INDIA PVT. LTD.

CORR. ALLOWANCE

: 0 MM / 3MM (UP TO 2") Document No.

REVISION

:1

Input
Id.

Item
Type

Lower
Size
(Inch)

Upper
Size
(Inch)

Page
of 5
PIPE5CLASS

Sch/
Thk

: 44LK-5100-00/L.02/0101/A4

Dmn. STD Material

Description

Bolt Group
BOM

BOLT.M/C

00.500

16.000

B-18.2

BOLT:A307 GR.B, GALV

NUT: A563 GR.B, GALV

BOS

BOLT.STUD

18.000

48.000

B-18.2

BOLT:A193 GR.B7,GALV
NUT: A194 GR.2H, GALV

Gasket Group
GAS

GASKET

00.500

24.000

B-16.21ANSI B
16.5

Buna-N (Nitrile)

FULLFACE, 300, 2MM

GAS

GASKET

26.000

48.000

AWWAC207 CL.D

Buna-N (Nitrile)

FULLFACE, 300, 2MM

Trap/Strainer Group
TSR

STRNR.TEMP

03.000

24.000

MNF'STD

B:A285 GALV,
INT: SS 304

CONE TYPE, 300,

FF/125AARH

PSR

STRNR.PERM

03.000

24.000

MNF'STD

B:A216 GR.WCB (GALV);

INT: SS 304

FLANGED, Y-TYPE,
300, FF/125AARH

M: TO MATCH PIPE SCHEDULE

B5Y
Commodity
Code

Note
No