Line List Input Design Guide

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PTD-DGS-128 PREPARED BY

PROCESS TECHNOLOGY PROCEDURES

A. Winstead

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DATE

20-Jan-2004

APPROVED BY DEPARTMENT:

PROCESS ENGINEERING

A. Bourji

SUBJECT:

LINE LIST INPUT DESIGN GUIDE

REVISION DATE

22-Apr-2004

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3

Table of Contents 1.0 PURPOSE........................................................................................................................2 2.0 DEFINITION.....................................................................................................................2 2.1 Abbreviations......................................................................................................2 2.2 Glossary...............................................................................................................3 2.3 P&ID CADD Software..........................................................................................3 3.0 LINE LIST GUIDELINES.................................................................................................4 3.1 Process Engineering Requirements.................................................................4 3.2 Quality Control....................................................................................................4 3.3 Review of non-Process Information..................................................................4 3.4 Line List Process Data.......................................................................................4 3.4.1 Line Size..................................................................................................4 3.4.2 Piping Specification ..............................................................................5 3.4.3 Insulation Thickness .............................................................................5 3.4.4 Insulation Code .....................................................................................5 3.4.5 Stream Phase..........................................................................................8 3.4.6 Service Code (Line Service)...................................................................8 3.4.7 Operating Pressure.................................................................................8 3.4.8 Operating Temperature...........................................................................8 3.4.9 Design Pressure......................................................................................9 3.4.10 Design Temperature - Maximum. .....................................................10 3.4.11 Design Temperature - Minimum. ......................................................11 3.4.12 Excursion Temperatures.....................................................................11 3.4.13 Stream Flowing Density......................................................................11 3.4.14 Comments...........................................................................................11 4.0 ATTACHMENTS............................................................................................................12 4.1 Sample Line List................................................................................................12

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1.0 PURPOSE The purpose of this design guide is to present the process engineer with requirements for supplying line list information. The instructions in this guideline are generalized. instructions may be substantially different.

Project-specific and client-specific

2.0 DEFINITION The line list is a table that lists compiled data relevant to the piping shown on the P&ID’s. It is a companion document to the P&ID that lists both the line information shown on the drawings, and more detailed information. Usually, each project will have a line list for each process unit within the project scope. The information on the line list is arranged alphanumerically by line number. The line list is a joint effort of Process, Piping, and Mechanical. On projects that use intelligent P&ID CADD software, CADD will also participate. Piping or CADD start the line list by creating tables with the line numbers, sizes, etc., shown on the current version of the P&ID’s. The document is passed to Process, which fills in the information listed below. Mechanical and Piping use Process information to complete the line list. Note that on projects using intelligent P&ID CADD drawing software, the computer will generate the line list by gathering data from the P&ID’s, and will calculate some of the line list data such as insulation thickness, etc. 2.1

Abbreviations

Unless otherwise noted, all abbreviations and symbols used in this guideline are defined as follows: AC: CC: CJ: CP: CT: ET: IW: FP: GT: HC: HJ: HT: NI: PF: P&ID: PP: PS: SJ: ST: 147943477.doc

Acoustic Control Insulation Cold Service Insulation Chilled Fluid Jacketed Condensation Control Chilled Fluid Traced Electric Traced Insulation for Winterization Fire Protection Insulation Glycol Traced Heat Conservation Insulation Hot Fluid Jacketing Hot Fluid Traced No Insulation Prevention from Freezing Insulation Piping and Instrumentation Diagram Personnel Protection Insulation Process Stability Insulation Steam Jacketed Steam Traced

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These abbreviations are consistent with PIP standard PIC 001. Be advised that the client may prefer other abbreviations. Units used in this design guide are U.S. traditional. Use the project specified units when completing the line list. 2.2

Glossary

Process. The term “process” is used to denote the department, group, or engineer who develops the P&ID’s. The term “process engineer” could refer to Process Engineers, Process Systems Engineers or Mechanical Systems Engineers. Mechanical. The term “Mechanical” is used to denote the department, group, or engineer who handles both the static and rotating equipment. Mechanical will also have responsibility for metallurgy and other physical characteristics of piping. Piping. Piping, sometimes referred to as “Piping Design,” denotes the department, group, or engineer who handles the design of the piping as well as tie-in locations. CADD. An acronym for Computer Aided Design Drafting. Also denotes the department, group, or individual that operates the drafting software and computers. Stress. Denotes the mechanical or piping design engineer or engineers responsible for performing stress calculations on piping. Battery Limit. A boundary within a plant, marking the edge of a unit or other specific area. This term is often abbreviated “B.L.” or “B/L” or some variation thereof. Grade. The term “grade” sometimes refers generally to the ground or pavement surface, or sometimes more technically refers to a reference elevation that roughly corresponds to the surface elevation. Regeneration. A periodic procedure whereby the catalyst or desiccant in a reactor or drier is reactivated after becoming saturated with contaminants or moisture. Regeneration usually involves heating and purging the catalyst or desiccant with a flow of hot liquid or vapor, which can result in a set of operating conditions significantly different than the normal operating conditions. 2.3

P&ID CADD Software

Intelligent P&ID CADD Software. Software products such as Intergraph PDS-2D and SmartPlant 2-D that automatically create line lists from the P&ID database. The Line List is an output of the P&ID design, so the P&ID’s must be completed or updated to produce a completed or updated line list. Non-intelligent P&ID CADD Software. Software products such as AutoCADD and Microstation that do not have a database associated with the P&ID graphics. The Line Lists are manually created apart from these CADD software outputs. 147943477.doc

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3.0 LINE LIST GUIDELINES 3.1

Process Engineering Requirements

The line list contains several columns for the various items of data to be entered for each line. Section 3.3.2 of this document lists and defines those line list data items for which the process engineer might be responsible on a given project. The format of the line list, and the required items of data for each line, can vary somewhat from one project to the next. 3.2

Quality Control

The Line List is an Engineering document. As such, both Piping and Process have the responsibility for maintaining the integrity of the document. Process has primary responsibility for certain information on the line list, as described in Section 3.4 of this document; and the process engineer shall cooperate with both Piping and CADD in producing a complete and accurate line list for the project. The process engineer doing the initial line list work has the responsibility to ensure that the work is done properly. Although all work must be checked by a second engineer, this does not in any way reduce the obligation of the primary process engineer to supply the correct information the first time. The checking engineer has the responsibility to review the work performed by the responsible engineer and must resolve all perceived discrepancies prior to issuing the information to Piping. In the event that discrepancies cannot be resolved between the two engineers, a third supervisory engineer should be consulted to resolve the dispute. 3.3

Review of non-Process Information

There are numerous items on the line list for which the process engineer does not have responsibility; nevertheless, the process engineer assigned to the line list should provide a cursory review of the following information provided by Piping or the drawing software: • • •

P&ID Number [Flow Diagram Number] Terminal Point From [Source] Terminal Point to [Destination]

Likewise, these items can only be revised by changing the P&ID’s. Marking the Line List table will not result in changes to the Line List. 3.4

Line List Process Data

3.4.1 Line Size Process lines are sized following the criteria listed in the Hydraulic Guidelines (PTD-DGS131). The resulting line size must be shown on the P&ID and on the line list. 147943477.doc

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All process lines that have size changes or branches of a different size shall be listed more than once on the line list – one listing for each line size. For each line on the P&ID, intelligent P&ID CADD software will automatically generate a listing for each line size shown on the P&ID. A listing for each size of the same line is necessary because line list data such as insulation thickness or pipe schedule will depend on the line size. The P&ID, not the line list, is the controlling document for line sizes. Valid entries or changes to line sizes must be made on the P&ID. 3.4.2 Piping Specification The process engineer needs to be familiar with the piping specifications for the project such that the proper specification is assigned to each line. Only the process engineer is familiar with the required operating conditions for the unit and that individual has the responsibility to insure that the piping specification is adequate for the range of conditions. If project pipe specifications are not yet available, but the process engineer is directed to enter preliminary information, then the best estimate of the pipe flange rating and material should be entered on the P&ID and line list. The process engineer also should make certain that the specification breaks are shown properly on the P&ID’s. On some projects the process materials specialist may be assigned the task of reviewing the piping specifications shown on the line list and P&ID’s. 3.4.3 Insulation Thickness The need for insulation and the subsequent amount of insulation is based upon the normal operating temperature. For a given process line the insulation code (purpose) must first be determined. The insulation thickness is then obtained from the appropriate insulation table based on the purpose at the normal operating temperature and nominal pipe diameter. The process engineer should use the project’s insulation tables provided by project management or by the client representatives. If such tables are not provided, then use the tables in Section 4.2 of this document. Note that on some projects using intelligent P&ID CADD software, the computer will calculate the insulation thickness and enter it into the line list, based on the normal operating temperature, nominal pipe diameter, insulation code, and tracing requirement specified by Process. Occasionally, alternate "routine" operating temperatures are the basis for specifying insulation thickness, see Section 3.3.8: Operating Temperature. 3.4.4 Insulation Code 147943477.doc

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The process engineer must determine the insulation purpose for each line. Generally, depending upon the process and the client, that could include the following categories: none (i.e. bare pipe), personnel protection, heat conservation, cold conservation, process stabilization, condensation control, freeze protection, or fire protection. NOTE:

These codes may vary depending on client and project instructions; e.g., some clients use “N” for no insulation.

A.

None (NI). Insulation is not needed for any reason, neither for process nor for safety. The “NI” designation is optional.

B.

Personnel Protection (PP). Based upon the normal operating temperature, insulation is not required for process reasons but is required for safety. In other words, an individual could be injured (burned) by touching the pipe if it were not insulated. Typically, personnel protection insulation is placed on lines and equipment operating at 140 ºF and above. Personnel protection insulation is not applied for piping in cold service. This means the following: 1)

The process engineer marks the line list (and P&ID) for personnel protection regardless of actual physical location of the line. The purpose of the insulation is to reduce the surface temperature of the line to 140 ºF or below so that injury is unlikely in case of contact. Refer to the project-specific Insulation Table for Personnel Protection for insulation thickness. Use the table in Section 4.2 below if project-specific tables are not available. The process engineer will determine the insulation thickness from the table (although Piping may elect to use metal shielding - metal mesh guards - instead of insulation).

2)

Piping will decide whether or not to actually insulate the line and also as to what type of insulation will be applied (if any). Piping will not actually insulate the line if it is not physically possible (or likely) that someone could be hurt by the line. For example, if the line leaves the grade level and goes into the pipe rack, Piping will usually insulate up to a height of seven feet and not the remainder of the pipe because it is highly unlikely that someone will come into contact with the line above that height. Piping, not Process makes this determination. If a line has a routine operation, which does not necessarily represent "normal operation", then those temperatures should also be considered "normal" for insulation purposes. For example, regeneration lines may be normally idle or may operate at relatively low temperatures, but during regeneration mode would be well in excess of 140 ºF. Although regeneration does not represent "normal operation", it does represent a normal routine, albeit infrequent, activity. The lines should be PP insulated to protect against injury during regeneration periods.

C.

Heat Conservation (HC). Insulation for hot energy conservation is driven by economics. Refer to the project-specific Insulation Tables for Heat Conservation for

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insulation thickness. If project-specific tables are unavailable, use the tables in Section 4.2 below. The process engineer will determine the insulation thickness from the appropriate chart. D.

Cold Conservation (CC). Insulation for cold energy conservation is driven by economics. Cold service insulation is intended to reduce heat gain and to control excessive moisture condensation. Refer to the project-specific Insulation Tables for Cold Service for insulation thickness. If project-specific tables are unavailable, use the table in Section 4.2 below. The process engineer will determine the insulation thickness from that chart.

E.

Process Stabilization (PS). This is generally specified when loss of heat from the line would result in loss of process control. For instance, large process lines associated with distillation columns are sometimes insulated to protect against a loss of heat that could occur in the event of a sudden rainstorm. Even though heat loss may not be undesirable, sudden changes could upset column performance and cause the production of off-specification material. Refer to the project-specific Insulation Table for Process Stabilization for insulation thickness. If this table is unavailable, instead use insulation thicknesses from the Insulation Table for Personnel Protection. If no project-specific tables are available, then use insulation thicknesses from the table for Personnel Protection in Section 4.2. If the line requires heat tracing for Process Stabilization, in order to maintain a specific temperature, then the process engineer shall specify this temperature on the line list. Refer to the project-specific Insulation Table for insulation with heat-tracing to determine the appropriate insulation thickness. In the absence of a project-specific table, use insulation thicknesses from the Personnel Protection table in Section 4.2 below.

F.

Heat Tracing (GT, ET or ST). Refer to the Winterization Design Guide, PTD-DGS112, and to the project-specific guidelines, to select the type of tracing to be used for a particular line or piece of equipment. The process engineer needs to specify the heat tracing requirements including the type of tracing, whether glycol, electric or steam. Lines are typically heat traced to prevent rupture caused by freezing, to prevent congealing of the process fluid, or to provide process stability, e.g., to guard against condensation in compressor suction lines. Furthermore, if the line is to be maintained at a certain temperature, that temperature must also be specified.

G.

Freeze Protection (PF). Certain lines, such as utility water lines, may be insulated but not traced in order to prevent the line from freezing. Use project-specific Insulation Tables for freeze protection insulation to determine the required insulation thickness. If the project does not have such a table, refer instead to the Insulation Tables for Heat Conservation and use the minimum insulation thickness for the line size in question. (The minimum thickness will correspond to the lowest listed temperature.) If no project-specific tables are available, use the Heat Conservation table in Section 4.2 below. The process engineer should also consult the Winterization Design Guide, PTD-DGS-112, for further instructions on freeze protection of piping.

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3.4.5 Stream Phase The process engineer must indicate on the line list, or P&ID, depending on CADD software, whether the line is filled by a vapor (V) steam, a liquid (L) stream, or a two-phase (2P, L/V or M) stream. 3.4.6 Service Code (Line Service) A column in the line list tabulation is sometimes provided for designating the line service if the service is not part of the P&ID line tag format for the project. The process engineer must then become familiar with the project identification system and enter the proper acronym on the line list (e.g. STM for medium pressure steam, N2 for nitrogen, etc.). The service codes can be found on the project’s Symbols and Legend Sheets provided with the P&ID’s. The process engineer is responsible for showing the correct service code on both the P&ID and the line list. The process engineer may occasionally find that the service code is too generic to convey specific information that affects the pipe design. The presence of corrosive or erosive contaminants in a fluid, for example, may create the need for different materials than required for clean fluid. The process engineer may use the ”Comments” column of the line list to describe these special circumstances. On projects using intelligent P&ID CADD software, this information must be placed on the P&ID, from which it will be copied to the line list by the computer. 3.4.7 Operating Pressure The value specified is the normal pressure for the line during the normal mode of operation. If there are alternate "routine" operating scenarios that should be considered, the pressure for that operation should also be listed on the line list. For example, regeneration would be an alternate "routine" operation. Note however, that any alternate pressure must be properly linked with the corresponding alternate temperature. Otherwise, a "pseudo" worse case scenario could be inadvertently generated where the highest pressure is linked to the highest temperature, even though that scenario would never occur, and thereby cause the need for a higher piping specification than which is actually needed. Lines that are normally open to the atmosphere should be listed “Atm” for atmospheric, unless the project’s line list format requires a numerical entry. If a number is required, the process engineer should enter the numerical value for atmospheric pressure (“0” for gauge pressure). 3.4.8 Operating Temperature The value specified is the normal temperature for the line during the normal mode of operation. 147943477.doc

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If there are alternate "routine" operating scenarios that should be considered, the temperature for that operation should also be listed on the line list. For example, regeneration would be an alternate "routine" operation. Again, note the need for properly linking alternate operating temperatures with the appropriate alternate pressure (see Section 3.3.7). Lines that are normally at ambient temperature should be listed as " “Amb” for ambient, unless the project’s line list format requires a numerical entry. If a number is required, use the ambient temperature listed in the site-specific meteorological data in the project’s engineering design guidelines. 3.4.9 Design Pressure The design pressure for the line should be determined from the following criteria: A.

The design pressure of the equipment to which it is attached.

B.

Either the operating pressure (psig) plus 25 psi, or the operating pressure (psig) plus 10 percent, whichever is greater.

C.

The maximum pump (centrifugal) discharge (“deadhead”) pressure. Refer to the Pump Selection Design Guide (PTD-DGS-101) for method of calculation.

D.

Lines which normally vent or drain to atmosphere, such as tail pipe lines from relief valves discharging to atmosphere, should be listed as "atm" for atmospheric. However, if the project’s line list format requires a numerical entry, then the process engineer should enter the numerical value of atmospheric pressure (“0” for gauge pressure). If a design value is listed for these lines, Construction will be obligated to hydrotest them even though it is not necessary.

E.

The set pressure of the relief valve that protects the system.

F.

Piping leaving the battery limit should be designed for a closed valve outside of the battery limit.

G.

All piping and equipment operating below atmospheric pressure should be designed for full vacuum (as well as positive internal pressure).

H.

All piping and equipment in steam service should be designed for full vacuum (as well as positive internal pressure). All piping and equipment in steam service should be designed for full vacuum (as well as positive internal pressure).

I.

When a line with a lower design pressure connects to a line or a piece of equipment with a higher design pressure, the line should be designed for the higher pressure up to and including the first block valve or when utilizing double block valves, to and

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including the second block valve. Block valves on both sides of a control valve and the bypass valve should all be designed for the higher pressure. When more than one of the above listed criteria applies, the process engineer should comply with the criterion that would result in the most conservative design. 3.4.10 Design Temperature - Maximum. The maximum design temperature for the line should be based on one of the following criteria: A.

Design temperature of the connected equipment except when the equipment is obviously overrated. Caution: Equipment is often mechanically rated for 650ºF even though the actual process requirement may be far below this. In such instances, specifying 650ºF on the line list could force Stress and Piping to perform an inordinate amount of work to accommodate a design temperature that is not actually needed by the process.

B.

The normal operating temperature plus 50ºF for operating temperatures < 750ºF.

C.

The normal operating temperature plus 25ºF for operating temperatures > 750ºF.

D.

Lines which normally vent or drain to atmosphere, such as tail pipe lines from relief valves discharging to atmosphere, should have a design temperature equivalent to the temperature of the fluid that would flow through the line when it is put into service. Usually, that is the normal temperature of the adjacent line that is in service under normal circumstances. Flare lines also fall into this category. Normally, the flare header operates close to ambient temperature conditions and only during relief or emergency depressuring situations will the temperature change significantly. For flare lines the design temperature will be equivalent to the flowing temperature under relief discharge conditions.

E.

For air, nitrogen, fuel gas, water systems, and other controlled plant utilities, the operating margin for design conditions can be reduced below the standard 50ºF to whatever seems appropriate for the particular situation. A design margin of 20ºF is often suitable. For example, for a utility air system operating at 100ºF, a design temperature of 120ºF could be used.

F.

Situations may arise where the operating margin for design conditions may force a pipe specification change resulting in significant extra costs. In those situations the process engineer should re-evaluate the operating margin and determine whether or not the margin can be prudently lowered so as to make use of the lower specification. Where the higher operating margin is deemed to be appropriate, the piping specification should be changed to the higher rating.

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3.4.11 Design Temperature - Minimum. The minimum design temperature for a line is only entered on the line list when one of the following criteria will result in a temperature below the normal winter design temperature for the plant: A.

Design temperature of the connected equipment.

B.

The normal operating temperature minus 25ºF.

C.

Lines which normally vent or drain to the flare header, such as emergency depressuring lines, should have a design temperature based upon the minimum temperature that the line will reach during the depressuring of the process line. It may be necessary to simulate the flash or to review a Mollier diagram to determine this value. Caution:

D.

Be certain that the final destination pressure is accurate. A low pressure could result in an extremely low minimum design temperature.

Situations may arise where the operating margin for design conditions may force a pipe specification change resulting in significant extra costs. In those situations the process engineer should re-evaluate the operating margin and determine whether or not the margin can be prudently lowered so as to make use of the lower specification. Where the higher operating margin is deemed to be appropriate, the piping specification should be changed to the higher rating.

3.4.12 Excursion Temperatures This is the value the piping and equipment will be exposed to during extremely infrequent conditions, such as steam-out during the start-up. Usually the equipment is under minimum pressure during these temperature excursions. The primary purpose is to indicate to Piping and Stress, the expansion requirements for the line. 3.4.13 Stream Flowing Density This value is sometimes not shown on the line list tabulation; however, its addition to the line list will minimize the effort involved in relaying this same information to Stress when stress analysis is performed on the line. This information needs to be provided for liquidfilled and two-phase-flow lines. For two-phase flow, the liquid-phase density should be entered on the line list since during start-up and other scenarios the steady state amount of vaporization may not be present. 3.4.14 Comments Generally, the line list has a "comments" or "remarks" section. The process engineer can denote any special requirements or design criteria in this section. For instance, if the design pressure is based on the deadhead pressure of a pump, it can be stated here. On 147943477.doc

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projects using intelligent P&ID CADD software, this information must be placed on the P&ID, from which it will be copied to the line list by the computer. 4.0 ATTACHMENTS 4.1

Sample Line List The example provided here is a useful illustration of a line list, but no standard format for line lists exists. The process engineer must recognize the fact that line list format and content can vary considerably from one project to the next.

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4.2 Insulation Tables The insulation tables on the following pages address insulation thicknesses for heat conservation, cold service, and for personnel protection. On most projects, the client or the project management will provide the design team with insulation tables. The process engineer should always first consult the project design guidelines and other documentation, or check with supervision, in order to obtain the appropriate insulation tables before starting the line list. Project-specific insulation tables are preferred since they can be tailored to the project specific site ambient conditions, installed cost of insulation and value of energy. The tables below should be used only when project-specific insulation tables are not provided to the design team.

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TABLE IA – ECONOMIC INSULATION THICKNESS FOR HEAT CONSERVATION OF HOT PIPING AND EQUIPMENT CALCIUM SILICATE, PERLITE AND MINERAL WOOL FOR OPERATING TEMPERATURE 580°C (1075°F) AND BELOW Maximum Operating Temperature of Material Within Pipe °C (°F)

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°C

60-110

111-160

161-210

211-260

261-310

311-360

361-410

411-460

461-510

511-580

°F

(140-230)

(231-320)

(321-410)

(411-500)

(501-590)

(591-680)

(681-770)

(771-860)

(861-950)

(951-1075)

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Pipe Size (Inch)

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Heat Conservation Insulation Thickness in mm (Inches)

0.75

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

1.0

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

1.5

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

51(2.0)

51(2.0)

51(2.0)

2.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

64 (2.5)

64 (2.5)

3.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

64 (2.5)

64 (2.5)

64 (2.5)

64 (2.5)

4.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

6.0

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

64 (2.5)

64 (2.5)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

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89 (3.5)

76 (3.0)

76 (3.0) 89 (3.5)

76 (3.0)

76 (3.0)

89 (3.5)

102 (4.0)

64 (2.5)

76 (3.0)

76 (3.0)

102 (4.0)

102 (4.0)

64 (2.5)

76 (3.0)

76 (3.0)

102 (4.0)

64 (2.5)

64 (2.5)

76 (3.0)

102 (4.0)

102 (4.0)

102 (4.0) 114 (4.5)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

102 (4.0)

102 (4.0)

114 (4.5)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

102 (4.0)

102 (4.0)

127 (5.0)

8.0

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

64 (2.5)

64 (2.5)

76 (3.0)

10.0

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

64 (2.5)

64 (2.5)

12.0

38 (1.5)

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

64 (2.5)

14.0

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

64 (2.5)

16.0

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

64 (2.5)

18.0

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

20.0

38 (1.5)

51(2.0)

51(2.0)

24.0

38 (1.5)

51(2.0)

51(2.0)

89 (3.5)

PROCEDURE NO.

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38


26.0

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

64 (2.5)

76 (3.0)

102 (4.0)

114 (4.5)

127 (5.0)

102 (4.0)

114 (4.5)

127 (5.0)

28.0

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5) 89 (3.5)

30.0

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

FLAT

38 (1.5)

51(2.0)

51(2.0)

64 (2.5)

76 (3.0)

102 (4.0)

114 (4.5)

140 (5.5)

152 (6.0)

190 (7.5)

VERTICAL FLAT(2)

38 (1.5)

38 (1.5)

38 (1.5)

51(2.0)

64 (2.5)

76 (3.0)

102 (4.0)

127 (5.0)

152 (6.0)

203 (8.0)

Design Basis: (1) Based on natural gas @ $1.0/MMBTU, one year payback, ambient temperature 20°C (68°F) and wind speed 4.4m/s (9.8 mph) and aluminum jacket “e”=0.1.

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TABLE IB – ECONOMIC INSULATION THICKNESS FOR HEAT CONSERVATION OF HOT PIPING AND EQUIPMENT CERAMIC FIBER FOR OPERATING TEMPERATURE 581°C (1076°F) – 927°C (1700°F) Minimum Operating Temperature of Material Within Pipe °C (°F) °C

581-649

650-704

°F

(1076 -1200)

(1201-1300)

Pipe Size (Inch)

147943477.doc

705-760

761-816

817-871

872-927

(1301-1400)

(1501-1600)

(1501-1600)

(1601-1700)

Heat Conservation Insulation Thickness in mm (Inches)

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0.75

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

1.0

89 (3.5)

102 (4.0)

102 (4.0)

127 (5.0)

127 (5.0)

152 (6.0)

1.5

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

152 (6.0)

2.0

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

152 (6.0)

178 (7.0)

3.0

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

4.0

114 (4.5)

127 (5.0)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

6.0

114 (4.5)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

203 (8.0)

8.0

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

229 (9.0)

PROCEDURE NO.

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10.0

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

229 (9.0)

12.0

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

14.0

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

16.0

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

18.0

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

229 (9.0)

250 (10.0)

20.0

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

24.0

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

279 (11.0)

26.0

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

279 (11.0)

PROCEDURE NO.

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28.0

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

279 (11.0)

30.0

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

279 (11.0)

FLAT

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

279 (11.0)

Design Basis: (1) Based on Mean Annual Minimum Ambient Temperature of 20°C (68°F), Summer Normal Wind Speed of 4.4 m/s (9.8 mph) and SS steel “e” = 0.3. (2) Maximum allowable heat loss = 100 BTU/hr.-ft2-°F.

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TABLE IIA – PERSONNEL PROTECTION INSULATION THICKNESS TO MAINTAIN JACKET BELOW 60°C (140°F) CALCIUM SILICATE, PERLITE, AND MINERAL WOOL FOR OPERATING TEMPERATURE 580°C (1075°F) AND BELOW Maximum Operating Temperature of Material Within Pipe °C (°F)

147943477.doc

°C

60-110

111-160

161-210

211-260

261-310

311-360

361-410

411-460

461-510

511-580

°F

(140-230)

(231-320)

(321-410)

(411-500)

(501-590)

(591-680)

(681-770)

(771-860)

(861-950)

(951-1075)

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Pipe Size (Inch)

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Personnel Protection Insulation Thickness in mm (Inches)

.75

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

1.0

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

1.5

25 (1.0)

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

2.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5) 38 (1.5)

38 (1.5) 38 (1.5) 38 (1.5) 38 (1.5)

38 (1.5) 38 (1.5) 51 (2.0)

51 (2.0) 51 (2.0)

51 (2.0)

51 (2.0)

51 (2.0)

PROCEDURE NO.

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3.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

4.0

25 (1.0)

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

6.0

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

8.0

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

38 (1.5) 38 (1.5) 51 (2.0) 51 (2.0)

38 (1.5) 51 (2.0) 51 (2.0) 51 (2.0)

51 (2.0) 51 (2.0) 64 (2.5) 64 (2.5)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0) 76 (3.0)

76 (3.0) 89 (3.5)

PROCEDURE NO.

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10.0

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

12.0

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

14.0

38 (1.5)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

16.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0) 51 (2.0) 51 (2.0)

64 (2.5) 64 (2.5) 64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

76 (3.0) 76 (3.0) 76 (3.0)

76 (3.0) 89 (3.5) 89 (3.5) 102 (4.0)

89 (3.5) 102 (4.0) 102 (4.0) 102 (4.0)

PROCEDURE NO.

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18.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

20.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

114 (4.5)

24.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0) 102 (4.0)

26.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

89 (3.5)

102 (4.0)

114 (4.5)

28.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0) 127 (5.0) 127

PROCEDURE NO.

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30.0

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

89 (3.5)

102 (4.0)

114 (4.5)

(5.0) 127 (5.0)

FLAT

38 (1.5)

38 (1.5)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

114 (4.5)

140 (5.5)

152 (6.0)

190 (7.5)

VERTICAL FLAT (2)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

64 (2.5)

76 (3.0)

102 (4.0)

127 (5.0)

152 (6.0)

203 (8.0)

Design Basis: 1) Insulation thickness is based on annual mean ambient temperature of 30.5°C (87°F), average summer wind speed of 4.4 m/s (9.8 mph) and maximum surface temperature of 60°C (140°F).

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TABLE IIB – PERSONNEL PROTECTION INSULATION THICKNESS TO MAINTAIN JACKET BELOW 60°C (140°F) CERAMIC FIBER FOR OPERATING TEMPERATURE FROM 581°C (1076°F) – 927°C (1700°F) Minimum Operating Temperature of Material Within Pipe °C (°F) °C

581-649

650-704

705-760

761-816

817-871

872-927

°F

(1076-1200)

(1201-1300)

(1301-1400)

(1501-1600)

(1501-1600)

(1601-1700)

Pipe Size (Inch)

147943477.doc

Personnel Protection Insulation Thickness in mm (Inches)

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.75

64 (2.5)

76 (3.0)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

1.0

64 (2.5)

76 (3.0)

89 (3.5)

89 (3.5)

102 (4.0)

114 (4.5)

1.5

76 (3.0)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

2.0

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

3.0

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

152 (6.0)

4.0

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

178 (7.0)

6.0

102 (4.0)

114 (4.5)

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

8.0

102 (4.0)

127 (5.0)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

PROCEDURE NO.

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10.0

114 (4.5)

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

12.0

114 (4.5)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

14.0

114 (4.5)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

16.0

127 (5.0)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

18.0

127 (5.0)

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

20.0

127 (5.0)

152 (6.0)

178 (7.0)

178 (7.0)

203 (8.0)

229 (9.0)

24.0

127 (5.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

26.0

127 (5.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

PROCEDURE NO.

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28.0

127 (5.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

30.0

127 (5.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

FLAT

152 (6.0)

152 (6.0)

178 (7.0)

203 (8.0)

229 (9.0)

254 (10.0)

Design Basis: (1) Insulation thickness is based on annual mean ambient temperature of 30.5°C (87°F) and average summer wind speed of 4.4 m/s (9.8 mph) and maximum surface temperature of 60°C (140°F).

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TABLE III – COLD INSULATION THICKNESS IN MILLIMETERS (INCHES) FOR CONTROL OF JACKET CONDENSATION AT DESIGN AMBIENT CONDITIONS – CELLULAR GLASS INSULATION Minimum Operating Temperature of Material Within Pipe °C (°F) °C

26 - 10

9-4

3 - (-1)

(-2) - (-7)

°F

(78 - 50)

(49 - 40)

(39 - 30)

(29- 20)

Pipe Size (Inch)

147943477.doc

(-8)-(-12)

(-13)-(-18)

(-18)-(-29)

(-30)-(-46)

(-47)-(-59)

(-60)-(-73)

(-74)-(-87)

(19 -10)

(9 - 0)

(-1) – (-20)

(21)-(-50)

(-51)-(-75)

(-76)-(-100)

(-101)-(-125)

Cold Insulation Thickness in mm (inches)

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.75

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

1.0

25 (1.0)

38 (1.5)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

76 (3.0)

89 (3.5)

1.5

25 (1.0)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

89 (3.5)

2.0

25 (1.0)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

89 (3.5)

102 (4.0)

3.0

25 (1.0)

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

89 (3.5)

102 (4.0)

4.0

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

6.0

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

114 (4.5)

8.0

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

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10.0

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

102 (4.0)

114 (4.5)

127 (5.0)

127 (5.0)

12.0

38 (1.5)

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

140 (5.5)

14.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

114 (4.5)

127 (5.0)

140 (5.5)

16.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

127 (5.0)

127 (5.0)

140 (5.5)

18.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

127 (5.0)

140 (5.5)

152 (6.0)

20.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

102 (4.0)

127 (5.0)

140 (5.5)

152 (6.0)

24.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

114 (4.5)

127 (5.0)

140 (5.5)

152 (6.0)

26.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

114 (4.5)

127 (5.0)

140 (5.5)

152 (6.0)

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28.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

89 (3.5)

114 (4.5)

127 (5.0)

140 (5.5)

152 (6.0)

30.0

38 (1.5)

51 (2.0)

51 (2.0)

64 (2.5)

76 (3.0)

36.0

38 (1.5)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

89 (3.5)

114 (4.5)

127 (5.0)

140 (5.5)

165 (6.5)

76 (3.0)

102 (4.0)

114 (4.5)

140 (5.5)

152 (6.0)

165 (6.5)

FLAT

38 (1.5)

51 (2.0)

64 (2.5)

64 (2.5)

76 (3.0)

76 (3.0)

102 (4.0)

114 (4.5)

140 (5.5)

152 (6.0)

165 (6.5)

Design Basis:

(1) Insulation thickness is based on ambient temperature of 30.5°C (87°F), wind speed of 0.0 m/s (0.0 mph), 80% humidity, and white aluminum jacket “e”=0.8. 147943477.doc

PROCEDURE NO.

REV.

DATE

PTD-DGS-128

3

20-Jan-04


(2) Maximum heat loss at ambient temperature: 19 kcal/m2h (7 BTU/ft2hr).

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Line List Input Design Guide

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