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PIPELINES BUILDING SPECIFICATIONS Date: February 1996 Revision: 2 Page: 0 BUILDING SPECIFICATION FOR PIPELINES

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  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 0

    BUILDING

    SPECIFICATION

    FOR

    PIPELINES

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 1

    List of Contents

    1. General Instructions

    2. Material Supply

    3. Low Pressure Steel Pipelines within the Work Premises

    3.1 General

    3.1.1 Area of Jurisdiction3.1.2 Labelling3.1.3 Symbols

    3.2 Construction Guidelines

    3.2.1 Nominal Widths, Outside Diameters, Wall Thickness, Material3.2.2 Calculation3.2.3 Pressure Stages3.2.4 Flange Connections

    3.3 Constructive Principles

    3.3.1 General3.3.2 Pipeline Supports3.3.3 Pipe Bends3.3.4 Flanged Joints3.3.5 Fittings3.3.6 Underground Pipelines3.3.7 Inside Cement Lined Pipes3.3.8 Hot Dip Galvanising3.3.9 Epoxy Pipe3.3.10 Pipe Heat Tracing

    Appendix A: Installation of Copper Heating Pipes to Pipelines

    4. Symbols

    5. Drawings

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 2

    1. General Instructions

    1.1 All pipeline installations are subject to the applicable- internationally recognized standards

    - regulations of the appropriate authorities referring to output and deliveries- accident prevention regulations- Oiltanking safety regulation- Oiltanking conditions of purchase- Conditions of contract- General conditions for construction and assembly work

    1.2 The pipelines to be installed are mainly those pipes laid on pipe sleepers as well asunderground PE coated or underground bituminized and Epoxy pipelines in a tankstorage terminal.

    1.3 The contractor has to inform himself about the condition of the construction site beforetendering. Additional or later claims due to the lack of knowledge of local conditions willnot be accepted. Before submitting his tender, the contractor has to inform himself aboutthe power and water supply conditions as well as about the ground conditions andaccessibility.

    1.4 The contractor is aware of and accepts the fact that other companies, such as steelworks, civil works, electrical works, etc. are also working on the site. This circumstanceis no reason for the contractor to present subsequent claims or to delay work.

    1.5 All costs, such as but not limited to construction site, fittings, barriers, proper storing ofmaterials, drawing of possibly required plans, supply of all necessary tools, equipment,etc., laying of provisional water pipes and dismantling them afterwards, power cables,etc. are included in the lumpsum price or unit rates.

    1.6 In order to carry out the work, the contractor has to supply the skilled and unskilledworkers as well as the necessary supervisory personnel and all the equipment, tools,lifting gear, transport vehicles, etc. The building and installation of possibly requiredcovered working places, changing and recreation and suitable storage rooms has to becarried out by the contractor. Oiltanking will advise the actual location.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 3

    Prior to the start of construction, all materials (pipes, fittings, etc.) have to be cleaned ofdirt. Welding materials, screws, fittings as well as incidentials are to be stored under dryconditions in suitable rooms.

    The contractor shall deliver all materials and fittings free of charge to the tank storageterminal unless otherwise agreed. The contractor is furthermore responsible for allnecessary transport on the site. After completion of work, the contractor has to clean theinstallations, pipelines, tankfields, etc. from all dirt incured through his work and has totake all spare materials into containers or to remove them without additional costsincurred by Oiltanking.

    The contractor is responsible that during the execution of his works no other work,previously completed, is damaged (insulation).Oiltanking reserves the right to have those damages rectified at contractor's cost.

    Welding work has to be carried out according to the international regulations by qualifiedwelders. All welding procedure specifications and qualifications have to be submitted forapproval, prior to the start of construction.

    1.7 Measurements given in the design documents and drawings shall be regarded asstandard. The contractor is obliged to check these measurements on site and has - incase of deviations - to adjust his pipelines to the actual conditions after consultation withOiltanking, without claiming additional cost (costs of alteration). Oiltanking reserves theright to carry out modifications of the construction plans during construction time. Forlump sum contracts, the modifications shall be minor.

    1.8 Interruptions of work are subject to a written approval of Oiltanking.

    Schedule dates have to be kept. In case of delay, Oiltanking has the right to suspendwork and to place an order with another contractor for completion. The contractor will bein no position of claiming any damages. Possible additional costs for Oiltanking have tobe borne by the contractor.

    1.9 If no lump sum price has been agreed, the work carried out will be measured, andagreed unit rates will be used for invoicing. In case of hourly-rate-payments, the timerecord sheets have to be handed over weekly to Oiltanking for approval, beforeinvoicing which shall be carried out on a monthly basis.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 4

    1.10 The contractor is liable for all damages, which occur mainly due to improper executionor by using bad or unsuitable materials. Upon request, these damages have to berectified by the contractor free of charge. Otherwise, Oiltanking has the right to hireanother firm at the cost of the contractor to eliminate the damage.

    The contractor's liabilty according to legal requirements remains untouched.The guarantee is valid from the day of the final inspection of work in accordance withthe terms of the contract.

    1.11 The Oiltanking purchase conditions, latest edition, apply. Conditions in the confirmationof order, delivery and sale conditions etc., which do not concur with the contents of theOiltanking order, require the particular written approval by Oiltanking before becomingeffective. Otherwise, these are not binding.

    1.12 For all welding works the contractor is obliged to engage welders with certificationsaccording to ASME, ANSI, DIN 8560 R II standard or equivalent. The welderscertificates are to be submitted to Oiltanking prior to the commencement of work. Thewelders also have to be qualified on site (work test) for Oiltanking approval.

    Oiltanking minimum requirements forX-Ray tests have to be carried out by the contractor, 5% of the round seams, however,at least 6 seams per welder. In case of defects found, two new welding seams have tobe tested at the cost of the contractor. Flange seams of DN 150 or more are weldedfrom the inside and outside.Deviation needs the approval of the Oiltanking project management, local requirementssuperceed the above in any case.

    X-Rays and the subsequent assessments shall be carried out by an independantcompany. Oiltanking or the appointed supervisory firm determines which of the seamshave to be x-rayed. The supervision of the work as well as of the welders is carried outby Oiltanking or the supervisory firm respectively.

    The weld metal must comply with the particular Quality Control Specification as well aswith the qualification conditions of the supervisory firm. The weld metal material mustalso be suitable for the quality of the material to be welded.

    1.13 All pipelines are subject to pressure test at a nominal pressure rate times 1.5 oraccording to instructions by Oiltanking after completion. The inspection has to be carriedout by Oiltanking or the supervisory firm respectively.The costs for the pressure tests including the supply of the necessary pumps, hoses,pressure gauges, blanks, adapters, etc. are part of the lump sum price or unit rates.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 5

    1.14 In case of overtime and working on public holidays, the contractor himself has to seekapproval of the authorities if required.

    1.15 Deviations from the Oiltanking Building Specification require the approval of OiltankingHamburg.

    1.16 Necessary Safety Precautions when working in storage tank terminals:The work to be carried out mainly takes place in storage tank terminals, where mineraloils of class 1-3 or chemicals are stored. Therefore it is essential that the regulationsand conditions concerning the handling of flammable/chemical liquids are observed withextreme care, as well as the particular Accident Prevention Regulations.

    All operations need the agreement of the terminal and/or the project managementbefore starting work.Persons involved in the work are to be informed before hand and about the safetystandards.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 6

    2. Material Supply

    Materials, if supplied by Oiltanking, do not cover the following:Insulation material for underground pipelines: bolts and nuts, gaskets, all pipe clamps,pipe supports, fixed joint points, etc. made of construction steel as well as mountings,protective steel plates, compensation rings according to Oiltanking or the relevantregulations.

    The following asbestos free gaskets shall be used as:- flatpackings according to ASTM, BS, DIN 2690 or equivalent for all mineral-oil

    and gasoline pipelines, Make Klinger OILIT or equivalent,- for all steam, water and molasses pipelines, Make Klingerit 400 Universal or

    equivalent,- for all LPG pipelines, Make Klingerit 1000 metal reinforced or equivalent,- all with antistick graphite coating both sides.

    For other media the types of gaskets and brands are, if required, determined byOiltanking.

    For reinsulating of PE coated pipes approved primer and band shall be used.

    For the reinsulation of bituminized pipes Bitumen band of 4 mm thickness or equivalentshall be used.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 7

    3. Low Pressure - Steel Pipelines within the Works Premises

    3.1 General

    3.1.1 Area of Application

    This part of the Building Regulation applies to the layout, construction and fitting of steelpipelines within the work premises of

    OILTANKING GMBH, HAMBURGand her branches and companies.

    3.1.2 Labelling

    All pipelines are to be marked as follows:Labelling example:150 P 123i.e. 150 = DN 150 pipe nominal diameter (PND)

    P = product123 = line number

    3.1.3 Symbols

    In all flow charts the symbols according to the drawing No. 0001-00 1/1-001/3 shall beused.

    3.2 Layout Regulations

    3.2.1 Nominal Width, Outside Diameters, Wall Thickness, Material

    Nominal and outside diameters of pipelines are only to be calculated according to thefollowing chart:

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 8

    nominal outside diameter min. wall Standard materialdiameter of the pipeline thicknessinch mm mm-----------------------------------------------------------------------------------------

    1" 33.4 3.4 seamless 1.5" 48.3 3.7 steelpipe St 37,0 2" 60.3 3.9 accd. to or 3" 88.9 5.5 API-5L equivalent 4" 114.3 6.0 Grade B

    orDIN 2448

    ---------------------------------------------------------------------------------------- 6" 168.3 6.4 welded

    8" 219.1 6.4 steel pipe St 37,010" 273.0 6.4 according or12" 323.9 6.4 to API-5L equivalent14" 355.6 6.4 Grade B16" 406.4 6.4 or20" 508.0 6.4 DIN 245824" 609.6 6.4

    Deviations from the chart require the approval of Oiltanking.LPG pipes shall be carried out at least in schedule 40.

    3.2.2 Calculations

    The caculation of the wall thickness shall be done according to DIN 2413 or equivalent.In case of additional pressure through an external force, the stress for the fittings aswell as for the pipeline is to be determined by calculating the total stress.For turn key contracts, pressure loss calculations shall be performed and submitted bycontractor for Oiltanking approval.

    3.2.3 Pressure Ratings

    The pressure ratings are determined in the contract. As a rule the following applies:All mineral oil and fire fighting water pipelines have to be constructed at a pressurerate of 150 lbs; steam, condensation and LPG pipelines at a rating of 300 lbs; liquidgas pipelines at a pressure rating of 600 lbs on special requirement.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 9

    Flanged Joints

    Welding neck flanges according to ANSI with contacts (smooth packing strip) WNRFare to be used for flange joints. Exceptions require the approval of Oiltanking.

    3.3 Construction Priciples

    GeneralLow points in pipelines have to be avoided. If this is not possible, drainvalves and ventvalves must be provided. Each location has to be equipped with a nozzle, a flange, agate or ball valve and a blind flange or, in case of several pipes, with a commonheader which terminates at the side of the pipetrack with an additional valve (size to beagreed).

    Expansion Possibilities of the pipelines and the screw connections have to beguaranteed to avoid extreme strain. The fitting of compensators requires the particularapproval of Oiltanking.

    Pipeline Structures in roofs and walls have to be fitted with collars to prevent ingress ofwater, or they have to be fitted with a wall ring respectively have to be welded.Junctions have to be welded at an obtuse angle, sloping connections at least below60o, T-joints are permitted. Welding and shoe saddles are not allowed to be used.Pipelines in which liquids can be blocked in between valves, must be fitted with asafety relief valve DN 1" as bypass in order to prevent an undue increase in pressurein case of an increased temperature of the product through sun, heating or similarinfluences.Pipes of pipelines laid next to each other shall have the following center distances (seechart):

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 10

    Pipe center distances A in mm:

    DN 25 40 50 80 100 150 200 250 300 350 400 500----------------------------------------------------------------------------------------------

    1" 130 140 150 170 190 220 250 280 310 350 380 430

    112" 140 150 160 180 190 230 260 290 320 350 390 440

    2" 150 160 170 180 200 230 260 300 330 360 390 450

    3" 170 180 180 200 210 250 280 310 340 370 410 460

    4" 190 190 200 210 230 260 290 320 350 390 420 470

    6" 220 230 230 250 260 290 320 350 380 410 450 500

    8" 250 260 260 280 290 320 340 370 410 440 470 550

    10" 280 290 300 310 320 350 370 400 430 470 500 550

    12" 310 320 330 340 350 380 410 430 460 490 520 580

    14" 350 350 360 370 390 410 440 470 490 510 540 600

    16" 380 390 390 410 420 450 470 500 520 540 570 620

    20" 430 440 450 460 470 500 530 550 580 600 620 670

    24" 500 510 520 530 540 570 600 620 650 670 690 740

    In case of insulated pipelines the center distances of the pipes have to be increased by theinsulating thickness. At manifolds and pumpstations, a greater distance is required. Detailshave to be agreed with Oiltanking.

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    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 11

    3.3.1 General

    When laying pipelines aboveground, the following minimum clearances have to beobserved:

    4.80 m above roads and streets2.20 m within buildings or above working platforms and operational ways

    These directive guidelines only apply if they do not contradict local regulations of theauthorities.

    For pipelines the height of the pipe support shall be at least 300 mm above ground andas common support concrete sleepers shall be used.

    Pipelines at equipment and pumps shall be supported in a way, that no stress from thepipeline system effects the connecting branches.

    The fitting has to be carried out without stress and misalignment. Pipeline connectionsto pumps have to be made in a way, that the pumps can be dismantled without priormoving of the motor.

    For all pumps a strainer/filter has to be installed on the suction side between the valveand the pump nozzle. All pumps are to be fitted with check valves, which have to beplaced at the pressure side between the pump nozzle and the valve. All pumps have tobe protected with a flow switch on the suction side against dry running. Low points onsuction side have to be strictly avoided.

    Meter stations have to be fitted with calibration and return pump connections, situatednot more than 4 meters away from an access area. Meter stations, filters and gasseperators must be fitted with drainage devices. For each pressure measuring point aflanged joint DN 2" reduced to DN 1" or stub with pipe schedule 80 1" must beprovided, fitted with a pressure gauge shut off valve or ball valve. The pressuremeasuring joints are to be mounted vertically.

    For each temperature measuring point a flanged joint DN 2" reduced to DN 1" orstub with pipe schedule 80 1" with a total length of 190 mm has to be provided for. Thepipeline must be at least DN 3" at the measuring point. In case of vertical pipelines thetemperature measuring joint must be fitted at an angle of 60o.For each analysingmeasuring joint a flanged joint DN 2" reduced to DN 1" or stub with pipe schedule 801" must be provided for, which will be fitted with a pressure gauge shut off valve.Pipe joints in protection pipes shall be 100% x-rayed before installation.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 12

    Joints used for taking samples at DN 2" reduced to DN 1" or stub with pipe schedule80 1" have to be fitted upwards on all pipelines.Basically only eccentric reductions for pipes shall be used.

    3.3.2 Pipeline Supports

    The welding of pipe supports at pipelines is not permitted, unless an approval is givenby Oiltanking. All pipelines not insulated shall rest directly on the supports. All pipelinesmust be sufficiently guided. This applies to pipes up toDN 3" with L-steel 30 X 4 or equalDN 4"...8" with L-steel 60 X 30 X 5 or equalDN 10"...14" with L-steel 80 X 7 or equalDN 16" and bigger with L-steel 130 X 12 or equal

    which are welded on supports and sleepers.

    The width between the supports for all pipelines shall be 6 m. Support brackets shallbe fitted on every second support. In front of extension bends the individual pipelinesup to DN 10" have to be secured by means of straps made of flat steel 50 X 6 or equal.

    Fixed point bearings have to be erected next to each other with a clearance of 300 mmon concrete based mounted U 140 supports or equivalent. The width of the foundationhas to be determined according to each form of strain and soil condition. The fixing ofthe pipelines at the fixed point bearing shall occur through iron rods and locking campswelded on the pipelines.

    3.3.3 Pipe Bends

    In case of all diameters, steel pipe bends for welding have to be fitted according toASTMA-A-Gr.B. Segmental pipe bends and flexible pipes are not permitted.

    3.3.4 Flange Connections

    The number of flange connections with the pipelines shall be reduced to a minimum,attention shall, however, be paid that in case of repair, machines, equipment andvessels can be removed without cutting the pipeline and that spectacle blinds can befixed in sufficient numbers. All flanged connections in manifolds shall have blinds (oneopen, one closed) to avoid a mixing of products.

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    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 13

    All blind flanges at the pipeline ends have to be equipped with a gate valve (DN 80) fordrainage.

    3.3.5 Fittings

    Up to DN 4" gate valves, globe valves, ball valves are to be used as shut off meansand at all diameters exeeding DN 4", only gate valves or ball valves will be allowed.Exception from this rule requires the approval of Oiltanking Hamburg. Ball valves DN1"/DN 3" have to be used as evacuation and aerating devices. All devices must beeasily accessable. The max. height from the ground to the center line of the handwheel is 1.80 m. If this height is not maintained, spindle extensions for platforms orfloor columns with universal drive must be provided.Safety relief valves must be accessable from ladders or platforms.

    3.3.6 Undergroud Pipelines

    All underground pipelines are in principle to be made of PE-coated pipes or from theoutside bituminized pipes.Fittings in underground pipelines, where the position is not clear and visible through agate valve shaft, must be marked separately by means of signs.Cover damages caused by transport and fitting have to be properly repaired by meansof PE- or bitume bindings.Points repaired in the cover as well as insulations fitted on the building site must betested with the insulation test equipment, 25 kV.

    Underground pipelines have to be sanded in with sand graining 0...3 mm. The sandlayer above and below the pipeline must be at least 10 cm, and 20 cm at the sides ofthe pipeline. The sanding has to be compressed according to the requirements. Thepipe base is to be approved by Oiltanking before the laying of the pipe, the completesanding as well as the filling of the ditch is started. This work has normally to be doneby the civil contractor.

    The ends of the pipelines have to be left free over a length of 150 mm from anycovering or insulation.The insulation of welding and flange connections can only be carried out after thewater pressure test has been completed.Ducts and sleeves shall be treated as underground piping.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 14

    3.3.7 Inside Cement Lined Pipes

    For fire- and oily sewer lines, inside cemented pipeline systems can be used. Thefollowing field construction and installation rules of cement lined pipes are valid.

    This following procedure shall be applied for handling and joining cement-lined pipesand fittings:

    A. Shipping and Handling Cement Lined Pipes and Fittings

    Bending of cement lined piping sections during shipping and handling shall not exeed5 degrees, as measured between a chord and tangent.

    Slings shall be used for lifting cement lined piping sections. The use of hooks in pipeends for lifting is prohibited.

    Support of shop lined pipes: During storage at the lining applicator's location and forshipment to the site location, cement lined pipes shall be supported at intervals notexeeding 10 feet or 3.0 m.

    B. Installation

    Pipelines shall be cut to the desired length using a disc cutter or similar equipmentwhich will not damage the cement lining. Flame cutting is not acceptable.

    The but joint shall be prepared as follows:

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 15

    Both ends of the cement lining and the gasket shall be coated with a thick solution ofsodium silicate (waterglass) before welding. The sodium silicate solution shall not bepermitted to dry for more than 2 hours prior to welding.

    Temporary fitup lugs or nuts shall be welded on the lines or fittings to be joined. Afterinsertion of the gasket, the joints to be welded shall be butted tightly by bolting acrossthese lugs or nuts.

    For lines greater than 6" diameter, at least 3 temporary lugs or nuts, evenly spaced,shall be used. These lugs or nuts shall be removed by grinding. Removal of lugs shallbe done only after welding of the root passes. A decrease of pipe wall thickness mustbe avoided.

    Cement lined pipes and fittings require careful handling during shipping, joining andinstallation to prevent damage to the lining. Knocking of lined pipes shall not bepermitted.

    C. Inspection and Test

    Before making any joint, the Oiltanking site representative must be informed to inspectthe pipe ends. Welding shall be done only after approval from Oiltanking.

    The completed line shall be hydrostatically tested.

    3.3.8 Hot Dipped Galvanising

    The steel surface shall be cleaned by chemical or mechanical treatment to removerust, scales, welding slacks, grease, paint or other foreign matter before galvanising.

    The standard of galvanising shall conform to BS 729 or equivalent.

    The length of the pipes should not exeed the available zink tube length, the connectionof the pipes must be done by flanges or clamps which need the approval fromOiltanking Hamburg.

    3.3.9 Epoxy Pipe

    For chemical products, fire- and oily sewer lines, Epoxy pipe systems can be used.Below, some general instructions for field installations are given:

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 16

    A. Handling

    Trucks must have flat floors, so that no chains or steelwires but only nylon slings of atleast 10 cm will be used.Storage is only allowed on wooden beams, 10 X 5 cm.The distance has to be not longer than 3 m.

    B. Jointing and Preparation Methods

    There are several systems available for field installation:- lamination- adhesive bonded joint- rubber seal joint- flanged joints- mechanical coupling

    For details see the manufacturer's specification.

    C. Cutting/Machining

    Cutting of Epoxy pipes can be done by hack saw till 100 mm (4") and above byabrasive cutting disc. Machining must be done with special tools. Contact themanufacturer.

    D. Installation

    For underground installations the contracter has to pay attention to trench, beddingand to side and back filling. In normal cases, this is the part of the work of the civilcontractor.Road crossings etc. need sleeves or similar protection (relief plates).Hydrants/stub connections have to be discussed with the Oiltanking projectmanagement.For above ground installations there are two categories:- laid on concrete sleeper,- laid on pipebridges.For all supports the contractor shall follow the manufacturer's recommendations. Linesizes, operating pressure, side way displacements and valves must be supportedseparately.Steel pipe clips shall have one layer of rubber on the inner side.Field test procedures have to be finished before back filling of the underground pipes.

    Safety precautions should be exercised for all works to avoid skin and eyes irritations;use dust masks, goggles, gloves and overalls.More details can be provided by the manufacturer/supplier.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 17

    3.3.10. Pipe Heat Tracing

    Heat tracing installations are fitted in all work premises, where highly viscous productsare transported or stored. The heat tracing should maintain or create the minimumtemperature, at which the products can still be transported through pumps.

    While calculating the necessary dimensions of the heat tracing heating, an outsideminimum temperature should be taken as basis. Basically the following types ofheating should be applied:

    - Heating with one or several steel pipes.- Copper pipes with Thermon and system steel plates.- Electrical heat tracing (part of the electrical contractor).

    A. Construction of Heat Tracings made of C-Steel

    In case of horizontally laid pipelines heating pipes must be spaced evenly around thebottom and in case of vertically laid pipelines evenly around the perimeter, fixed withtightening straps at a distance of 2.000 mm. Each section to be heated, should not belonger than 50 m. Deviations have to be approved by Oiltanking.

    Each pipe has its own tightening strap for fastening. During the arrangement of severalheating pipes the straps have to be stretched in a way, that the heating pipe can bemoved within the straps, although it fits tightly.

    In the case of alkaline and acid pipelines, distance pieces have to be fitted betweenthe tracing and the product pipe in order to avoid a direct heat transmission from thetracing to the product pipe.

    During the course of the heating sections sufficient expansion possibilities have to beprovided. Fittings, vessels, pumps, etc. have to be fitted with flange connections sothat reasonable dismantling possibilities are guaranteed.

    Before starting work, the technical execution has to be agreed with the projectmanagement and must correspond with the technical rules.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 18

    B. Heat Tracing with Copper Piping, Thermon and System Sheets

    Tracing pipe heating with Thermon-thermal conductive cement and the covering withsystem sheets is handled in the same way, as C-steel tracing Thermon-conductivecement has the ability to conduct the heat to the area to be heated. The thermalconductivity of Thermon guarantees in connection with the tracing, lying on theoutside, perfect heat transmission (paints must be removed).

    The execution has to be carried out according to the installation instructions inAppendix "A".

    The feed line of the steam and condensate distributors or equal are made of C-steel.Outside the insulation the transmission from the C-steel pipe to the copper pipingworks through an appropriate connection by the means of suitable bushings or screwjoints respectively.

    The contractor has to supply suitable additives for the soldering of copper pipes.Galvanized system sheets are needed for covering the heat tracing system. Fixing isdone by means of stainless steel, tightening straps at a maximum distance of 500 mm.

    In case of smaller pipelines or reduced heat consumption the copper pipe can be fittedwithout Thermon and system sheets. In such a case, strict attention has to be paid tothe fact, that the insulation material between steel and copper pipe or between copperpipe and the stainless steel tightening strap is fitted with asbestos free material.

    C. Pressure Tests

    Before fitting the insulation to the steel pipe, heating pipes must be subjected to apressure test. In case of a tracing pipe with copper piping and Thermon, this pressuretest has to be carried out before the fitting of Thermon and the system sheets.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 19

    Appendix A

    Installation of Copper Heating Pipes to Pipelines

    Tracing pipes should always run parallel with the pipeline for heatening and shouldtouch it directly, if possible.

    Tracing pipes have to be mounted sideways or in the upper third.

    If more than one tracing pipe is required, their distances must be even. The distancefrom mid to mid must in any case be not smaller than five times the rate of the outsidediameter of the tracing pipe. By using band irons made from stainless steel, all tracingpipes or system sheets must be fixed on the pipeline to be heated. The distance fromone tightening strap to another should be not more than 500 mm.

    As shown in the picture below, at least 3 tightening straps must be fitted to fasten thetracing pipe to the pipe bend.Tightening straps have to be fitted as closely as possible to the flanges in order toguarantee a good fastening.The distance from flange to straps should not be more than 100 mm, as shown in thepicture below.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 20

    This drawing shows the layout of two tracing pipes to a pipeline with flange connection.As for heating, flanges are critical points within a pipeline system, special attention hasto be paid to the correct layout.By using two tracing pipes in a pipeline with flange connections, one tracing pipe heatsthe flange, while the other one is led over the flange couple. At the next flangeconnnection the layout of the tracing pipe gets changed, i.e. that tracing pipe that waslaid over the first flange couple heats the flanges at the second connection and viceversa. By this the pressure drop is evenly spread over each tracing pipe.

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    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 21

    Installation of Tracing Pipes to Fittings, Machine Parts, etc.

    Heating pipes or pipe radiators should, if possible, be evenly spaced across the area tobe heated and the distance from the center of the heating pipes should be three timesthe outer diameter of that area to be heated. Before the Thermon is applied, theheating pipes, pipe radiators, etc. have to be securely fixed to that part to be heated.Hereby it is recommended to use tightening straps.

    Pic.1 Layout and fixing of tracing pipes with tightening strapsPic.2 Readily thermonised fitting, flange holes kept free for access of nut threadsPic.3 Heating pipe, tightening strap, Thermon-thermal conductive cement

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 22

    For heating of equipment, copper pipes with an outside diameter of not more than 12mm are best to be used. The heating pipes are simply wound round the fittings, onehas to be aware of sharp bends to fit firmly and to be then fixed with stainless steeltightening strap.

    Special attention has to be paid to the fact that sufficient space is left at the flangeholes, so that in case of thermonised fitting the fastening bolts and nuts threadsrespectively have sufficient space.

    The following chart shows the recommended outside diameter and the length of theheating pipe for the width of various fittings.

    Fitting recommended outside required length of requirement ofdiameter of heat pipe the heating pipe ThermonDN mm m kg---------------------------------------------------------------------------------------------

    15 (1/2") 8 0.5 1.0 20 (3/4") 8 0.9 1.3 25 (1") 8 0.9 2.0 40 (11/2") 8 1.2 2.5 50 (2") 10 1.5 3.0 80 (3") 10 2.1 5.0100 (4") 10 3.0 6.5150 (6") 10 4.5 9.5200 (8") 10 6.8 13.0250 (10") 10 7.5 16.5300 (12") 10 10.0 19.5350 (14") 12 12.0 23.0400 (16") 12 13.0 26.0450 (18") 12 15.0 29.0500 (20") 12 17.0 33.0600 (24") 12 20.0 40.0700 (30") 12 25.0 50.0

    Wall thickness of heat pipe: 1,0 mm

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    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 23

    Heating for the first Time

    The Thermon must dry in the air for at least 4 hours, before the entire tracing systemor part of it can be heated.

    At the beginning and over a period of 24 hours the temperature must not exceed 60-80oC. Starting temperature should preferably run at night. Thereafter the temperatureof the heat medium has to be increased to approx. 120oC and to be maintained forapprox. 4 hours. Hereafter, the temperature can be increased to the desired maximum.

    This first heating within the temperature limits mentioned above is essential to ensurethat the Thermon dries properly and that it receives the maximum binding tenacity.

    Packing and Storage

    Thermon is delivered in sealed cans, ready for use. After removing Thermon, the canshave to be closed immediately so that the remaining content can stay malleable formonths.

    Shake the Thermon before use.

    The storage temperature shall not exceed 65oC. The freezing point of Thermon lies byapprox. -1oC. Reaching this point, Thermon is not damaged in any way, as it can bereheated before any application.

    Thermon has an alkaline composition and should therefore not come into contact witheyes. Should it, however, happen, Thermon will be easily washed off with soap andwater. Nevertheless, it it recommended to wear gloves, when handling with Thermon.

  • PIPELINESBUILDING

    SPECIFICATIONSDate: February 1996 Revision: 2 Page: 24

    4. Symbols

    Controls/Gauges/Sensors

    P Pressure GaugePd Differential Pressure GaugeT Temperature Gauge (Sensor)Fm FlowmeterL Level GaugeA AnalyserW Weight Sensor

    Instrumentation

    I IndicatingR WritingC ControllingAH High Level AlarmAL Low Level AlarmCO Switching offCI Switching one Calibrated

    local remote controlled

    EXAMPLE:

    PIR pressure gauge, indicating, writing

    LAH level gauge, alarming at high level

    The following pages represent an extract only of often used symbols. For detailed information,see ISO 3511/1 - 4.

    In case of deviations, the drawings from contractors have to show a legend.