Piping Spec.

Section : TGPS –L1
Date : July, 2008

Turkish Petroleum Refineries Co.
Đzmit Refinery Page No : 1 / 43
RESID UPGRADING PROJECT Revision : 0
REFINERY PIPING
1.0 GENERAL
1.1 Scope
1.1.1 This Specification outlines the requirements for design, materials,

arrangement, fabrication, testing and inspection of refinery process and
utility piping, both inside and outside Process Unit areas.
1.1.2 The intent of this specification is not to supersede the applicable code,
but to supplement it with certain conditions not fully covered therein.
1.1.3 Any conflict between the requirements of codes and specifications

mentioned herein shall be referred to Owner for clarification and
Owner's decision shall govern
1.2 Project Specifications
1.2.1 Requirements of referenced project specifications in this specification as

well as Licensor project and piping specifications, if any, shall be
considered in design, materials, fabrication, testing and inspection.
1.2.2 Piping classes for services shall be as identified by licensor in his piping
specifications and P&I drawings. Piping material shall be selected in
strict conformity with the requirements of:
a. piping classes given in Licensor piping specifications.
b. project specifications by Owner/Licensor.
c. TGPS-A9.
Any variations or substitutions are not permitted unless approved in

writing by Owner.
Date : July, 2008
1.2.3 In case no piping specification is provided by Owner/licensor for any

service it shall be provided by Contractor and submitted for Owner's
approval.
1.2.4 Contractor shall also prepare new piping project specifications, in table
form, based on the piping specifications provided by Owner/Licensor to
show details such as codes, materials, types for each piping component,
thicknesses for each size, maximum allowable pressures at various
temperatures with the specified thickness, test conditions, piping
classes, corrosion allowance, welding specifications, etc.
1.3 Reference to Manufacturer's Names and Catalogue Numbers
1.3.1 Valves and other components for piping shall be selected in accordance
with the requirements of piping project specifications or piping classes
provided by Owner/licensor. Manufacturers names and catalogue or
drawing numbers for valves and other components shown in these
documents indicates Owner's preferences. Equivalent items may be
substituted provided that:
a. the substitutions are equivalent in all aspects, such as design,

material, construction, quality. It is Contractor's responsibility to
prove equivalency.
b. Owner's approval has been obtained.
2.0 DESIGN
2.1 Design Codes
Piping shall normally be designed, fabricated, inspected and tested in

accordance with ANSI/ASME B31.3, Chemical Plant and Petroleum Refinery
Piping. Piping within the jurisdiction of the ASME Boiler and Pressure Vessel
Code, section I, Power Boilers, shall be designed, fabricated, inspected and
tested in accordance with ANSI/ASME B31.1, Power Piping.
The applicable edition of the codes and standards shall be that in effect on the
contract date.
2.2 Pressure and Temperature
2.2.1 The temperature used for determining the pipe class shall be the highest
design temperature of connected equipment, except that where one
piece of equipment is intentionally overrated, the design temperature
shall be equal to the maximum operating temperature plus 50oF.
Date : July, 2008
2.2.2 The pressure used for determine the pipe class shall be the highest
based on the following :
a. Highest design pressure of the equipment to which it is connected.
b. Set pressure of the pressure relief valve which protects system.
c. For cases of a centrifugal pump where discharge piping can be

blocked in and is not protected by a pressure relief valve, the
pressure shall be the maximum pump discharge or stalling pressure.
If the maximum pump discharge or stalling pressure is not available
use the largest of the following:
- 1.25 times the rated pump differential plus the maximum pump
suction pressure.
- 1.1 times rated pump discharge pressure.
- Normal pump discharge pressure plus 25 psi.
d. Discharge piping of a direct acting steam pump, not protected by a

pressure relief valve, shall be designed for the stalling pressure of the
pump.
e. All system operating below atmospheric pressure shall be designed

for full vacuum.
f. Piping systems leaving the process area shall be designed for a

closed valve outside the process area. If this causes in increase in
flange rating for the piping outside the process area, an acceptable
alternate is to lock open or car seal open all of the block valves
between the last block valve in the process area and the downstream
pressure relief. However, if the last block valve of a piping system
leaving the process area is locked open or car sealed open, all block
valves between the last block in the process and the downstream
pressure relief must be locked open or car sealed open.
2.2.3 Where piping with a lower pipe class connects to piping or equipment
with higher pipe class, such piping shall be rated at the higher pipe class
(and the materials of the piping shall be in accordance with the sever
process piping which are connected) to and including the first block
valve, check valve and spectacle blind (or blind) or double block valves
are used, to and including second block valve. Block valves on both
sides of a control valve and the by-pass valve shall comply with the
higher pipe class and with severe piping materials (better quality
material).
Date : July, 2008
2.2.4 Pressures and temperatures of air, steam, exhaust, condensate, water,

fuel oil, and fuel gas systems shall be in accordance with project
specifications. If the pressures and temperatures shown are normal
operating values, the design pressure shall be equal to the maximum
operating pressure plus 10 %, and the design temperature shall be
equal to the maximum operating temperature plus 50oF (28oC).
2.3 Pipe Thickness Determination
2.3.1 Minimum required pipe wall thicknesses shall be based on the design
temperature and pressure as determined in par. 2.2 above and ANSI
/ASME B31.3. The total pipe wall thickness shall include manufacturer's
minus tolerance, and weld joint efficiency factor in the case of fusion
welded pipe, plus the specified corrosion allowance. Seamless or
welded elbows shall follow the same criteria and shall also include the
loss of thickness from bending (forming).
2.3.2 A reduction of no greater than 10% of the specified corrosion allowance

is permitted in the case where a pipe of the next higher schedule or
standard thickness can be avoided to satisfy the specified corrosion
allowance. If the corrosion allowance on the pipe class is referred to as
a minimum, then this 10% reduction is not permitted.
2.3.3 Unless service conditions require greater corrosion allowances, the

minimum corrosion allowance used in determination of pipe wall
thickness shall be as follows:
a. for carbon steel and low chrome alloys : 0.062 inch.

b. for stainless steels and higher alloys : 0.030 inch.
2.3.4 When the pipe thickness is determined, by 2.3.1, 2.3.2, contractor shall
consider and insure that the thickness is adequate to resist all external
forces from thermal, mechanical,, and other sources in addition to the
process pressure-temperature requirements.
2.3.5 A table stating the minimum required thickness for all piping shall be
made by Contractor and supplied to Owner for his use as a pipe retiring
thickness table.
2.3.6 Pipe thicknesses for 2 inch. and smaller pipes shall not be less than
schedule 80.
Date : July, 2008
2.3.7 Schedule thicknesses as per ANSI B36.10 shall be used and the
calculated thicknesses shall be increased to the next higher schedule
accordingly.
2.3.8 Only standard schedule piping shall be used for pipes over 2 inches. for
carbon steel and low alloy steel. Schedule 10s in stainless steels and
higher alloys shall be used.
2.4 Expansion and Contraction
2.4.1 All piping must be analyzed so that it or its component parts are not
overstressed during start up, operating, normal and emergency
shutdown, and steam out conditions.
2.4.2 All forces and moments imposed on equipment, due to the expansion or
contraction of piping connected to the equipment, shall be kept within
the allowable limits set for that type of equipment , within the limits set
by the equipment manufacturer.
2.4.3 When analyzing piping, design temperature of equipment and piping

shall be used.
2.4.4 Stress analysis shall be performed by Contractor for all critical circuits
and relevant reports shall be provided.
3.0 PIPING GENERAL REQUIREMENTS
3.1 Documents
3.1.1 Contractor shall prepare Process and Instrument diagrams (P&I

diagrams) for the units in accordance with P&I diagrams provided by
Licensors. P&I Diagrams shall be redrawn completely by Contractor and
Copy of any part of Licensor's diagrams shall not be used in the
preparation.
3.1.2 Contractor shall prepare either piping plans and elevations or plans and
isometric detail drawings for all on-plot piping unless otherwise specified
in the project specifications. Minimum scale shall be 1/4 inch equals 1 ft.
3.1.3 Short piping runs between adjacent process units and between process
units and adjacent power unit shall be considered as on-site piping.
Date : July, 2008
3.1.4 Contractor shall complete a line index, for each unit. All isometric detail
drawing numbers shall be shown on these line indexes.
3.1.5 Contractor shall prepare a line list, for each unit. Line lists shall contain
the following as a minimum.
Line number and pipe sizes.

Line numbers of the connected lines.
Operation and design temperatures and pressures.
Test pressures (minimum and maximum allowable).
Class number.
Welding specification number.
Insulation or painting code.
Minimum required thickness.
Related P&ID numbers.
3.1.6 A system of line identification, piping class identification and material

item code shall be used.
3.1.7 If bills of material for piping isometrics form part of the drawing, then
code numbers need normally only be shown on the bill of materials.
However, code numbers should also be shown on the drawing for those
valves and out-of-class materials, which a symbol on the drawing cannot
uniquely and completely define, even when read in conjunction with the
bill of material.
3.1.8 Contractor shall prepare material take-off for each unit separately.
Material take-off shall be revised time to time to reflect up to date
condition and Owner shall be provided with copies of the material take-
offs periodically.
3.1.9 Contractor shall provide lists detailing the type of packing supplied in
valves.
3.2 Layout Requirements
3.2.1 Piping shall be run above ground wherever practicable and, within
process units and utility facilities, overhead piping shall generally be
used.
3.2.2 The elevation and layout of overhead pipe ways and clearance from
grade and at access way shall be as specified in TGPS-A5.
3.2.3 Offsite piping may be run in grade pipe ways with at least 10 inch
minimum clearance to bottom of pipe.
Date : July, 2008
3.2.4 Adequate clearance as required for maintenance shall be provided

above and/or below valves and fittings such as:
Control valves with top stem removal.

Control valves with bottom stem removal.
Strainers.
3.2.5 Wherever it is necessary to lay steel lines underground, and where the
maximum line temperature is less than 180 ºF (80 ºC), the piping shall
be provided with a wrapped coating as per TGPS-S1. Underground lines
over 180 ºF shall be sleeved or cased or buried in Gilsulate or equal,
approved by Owner. Buried lines shall have a minimum of 20 inch cover
over the pipe or casing.
3.2.6 Valves shall be located in accordance with Drawing TD-20321 unless

Owner's approval to deviations is obtained.
3.2.7 All piping shall be arranged to provide full access to all equipment for
operation and maintenance with a minimum amount of labour.
3.2.8 Piping and structures shall be arranged to permit mobile lifting

equipment to approach pumps and make lifts without obstruction.
3.2.9 Pipe lines shall be designed to avoid liquid and gas traps. In the event
this not possible, all gas traps shall have plugged vents, and liquid traps
shall have plugged valve drains. Plugged vents shall comply with
paragraph 3.9.11 of this specification.
3.2.10 All lines shall enter and leave the unit from the certain location at the
battery limit and block valves shall be provided for each line at this
location.
3.2.11 At least 25 percent excess area of the occupied area on the main pipe
racks and pipe ways, in units and offsite, shall be provided for future
piping, and this area shall be clear lane along the pipe rack or pipe way.
3.2.12 Exchanger piping and pipe supports shall be located so that they do not
interfere with the removal of channel covers and tube bundles when
mobile lifting equipment is used. For exchangers located at ground level,
piping shall not extend past the channel cover.
3.2.13 Tube removal areas for fired heaters and heat exchangers shall be kept
clear of all piping and pipe supports.
Date : July, 2008
3.2.14 Where commercial style bolt tensioners are specified, adequate

clearance shall be provided around flanged connections for installation
and operation of the bolt tensioners.
3.3 Piping - General
3.3.1 Pipe material shall be as given in Owner/Licensor's piping specifications

and seamless pipe shall be used unless otherwise specified.
3.3.2 Owner's approval shall be required for any deviation from the material
specifications or for the substitution of pipe or fittings manufactured to a
claimed equivalent specification.
3.3.4 All type 321 or type 347 stainless steel pipe, fittings, valves, and flanges
shall be in the stabilized heat treated condition.
3.3.5 The sizes 1¼", 2½", 3½" and odd numbered sizes 5", 7" etc. shall not be
used for carbon and alloy steel lines. Piping equipment connections of
these sizes shall be changed immediately to a standard size.
3.3.6 All process and chemical piping within unit limits (off-site and on-site)
shall be suitable for steam out at shutdown without overstressing the
piping or connected equipment. Drain valve assembles for both sides of
the battery limit block valves shall be installed.
3.3.7 All lines shall be cleaned after hydrostatic test in accordance with the
requirements of the project specifications.
3.3.8 Adequate supports must be provided for all pipe and fittings: particular
attention must be paid to the support of heavy valves and fittings on
small lines which may be subject to vibration.
3.3.9 All bottom supported insulated lines shall be provided with 3 inch high
shoes so that the insulation need not be cut back over the point of
support.
3.3.10 Wear plates are required for all pipe supports.
3.3.11 Unless otherwise indicated in piping specifications, lines 1 ½” inch and

smaller shall be joined by socket welding fittings.
Date : July, 2008
3.3.12 All process connections to instruments shall follow the appropriate

process piping specifications up to and including the first block valve
from the equipment or line to which the instrument is connected.
3.3.13 Consideration shall be given to the expansion of pipe as a result of

process or climatic conditions. The expansion shall preferably be
absorbed by the use of loops or bends. The use of expansion joints shall
be avoided.
3.3.14 Where XXS piping is used minimum size shall be 1 inch.
3.3.15 Where a vent line, drain line, etc., connects to a process line that has
special trim valves, all valves in the connecting line shall have the same
special trim.
3.3.16 Where a sample connection connects to a process line, the tie-in shall
be made only at the side or top of the line.
3.3.17 No pipe smaller than 3/4 inch shall be used, except for connections to
instruments, steam tracing, air connections to control valves, and
connections to vendor's equipment.
3.3.18 Sufficient cleanout connections and flanges shall be provided for all
lines subject to cleaning.
3.3.19 Flanged connections required to permit dismantling lines for

maintenance, inspections, or removal of equipment shall be provided.
3.3.20 Where threaded connections are required use Moly-lit or Fel Pro-C100.
Teflon tape is acceptable in lieu of sealant compounds for design
temperatures up to 400 ºF.
3.3.21 Unions are not permitted when using socket weld pipe classes except
in non-flammable, non-toxic utility services such as air, water, steam,
nitrogen, and condensate, where unions shall be limited to 1 inch
maximum pipe size and Class 300 flange rating. Flanges shall be used
in place of unions for all other socket weld construction.
3.3.22 Tags showing the line number shall be attached to all process and utility
lines inside and outside battery limit after construction and this shall be
repeated for each 20 m of pipe length.
3.3.23 Branch connections from steam, air, gas and water headers shall be
from the top of header with a block valve, except that branches, 2 inch
and larger, may be from the top or the bottom of the header.
Date : July, 2008
3.4 Valves and Fittings
3.4.1 Valves and fittings shall be selected in accordance with Owner's /

Licensor's piping specifications and pipe classes.
3.4.2 All operating valves shall be located for ease of operation and
maintenance. When valves cannot be reached from the ground or
platform, chain wheel operators for 2 inch and larger valves and
extended stems for smaller valves shall be provided as indicated on TD-
20321. Ladder access to valves on vent lines and gauge glasses is
permitted; however, all valves 2 inch and larger at vessel nozzles shall
be operable from platforms.
Branch lines shut-off valves at headers which are not required for
normal operation shall be provided with the standard hand wheels.
3.4.3 Where valves are to be operated by chain wheels, provide impact type
operators.
3.4.4 All control valves shall be easily accessible from grade or permanent
platforms, and conveniently located for operation.
3.4.5 In all cases, sufficient clearance shall be provided for control valves for
removal of diaphragm case, plug, and stem.
3.4.6 Platforms shall be provided for access to all pressure relief valves.
Lifting devices shall be provided for pressure relief valves weighing
more than 45 kg.
3.4.7 Contractor shall provide lists detailing the type of packing supplied in
valves.
3.4.8 Provide safe leak confining covers on all valves and flanges for services
carrying chemicals or corrosive fluids dangerous to the eyes or skin.
Covers shall give clear indication of leak (e.g. by colour change).
Date : July, 2008
3.4.9 Where flanged lubricated plug cocks are used, they shall have the same
ANSI face to face dimensions as equivalent gate valves (except when
steam jacketed); over 8 inches provide gear operation.
Lubricated plug cocks are limited to a design temperature with the limit
of the lubricant used and to services which will not dissolve the lubricant,
unless the contamination of the process fluid is not a problem
Contractor shall provide a list of services where lubricated plug cocks
are used giving the fluid carried, maximum temperature and lubricant.
Lubricated plug cocks are not permitted where lubricant may
contaminate process stream objectionably.
3.4.10 The use, make and type of ball valves and other soft seated valves is
subject to Owner's approval.
3.4.11 Check valves 12 inch and larger in liquid services to be equipped with
dash pots.
3.4.12 Ball valves shall not be used for tank isolation.
3.4.13 In viscous and/or heavy fouling services consideration shall be given to

the use of swing check valves.
3.4.14 Butt welding end valves shall have ends bored to suit pipe wall
thickness.
3.4.15 Small relief valves and unvalved vent connections shall be flanged
where the following conditions apply:
a. Design metal temperature is above 750 ºF for carbon steel or

above 900 ºF for alloy steel.
b. Flanges rating (i.e. system rating) is 900 or higher.
3.4.16 Control valves and other piping components shall be properly supported
and braced to prevent excessive vibration. Any additional restraint shall
be considered in the flexibility analysis of the piping system.
3.4.17 One side Screwed valves shall only be used for valve vents, drains and
orifice tap connections. Screwed side shall not be on process line.
3.4.18 Screwed control valves and relief valves, where permitted, shall not be
seal welded, unless close-coupled flanges have been fitted to such
valves.
Date : July, 2008
3.4.19 All valves which contain or contact a process fluid that is at least ten
weight percent volatile organic compounds, with the exception of heavy
liquids, shall be located for ease of fugitive emission monitoring as
required by environmental regulations. In general, such valves shall be
located such that they may be monitored without elevating the
monitoring personnel more than 6.5 feet above of a support surface;
however, it is Contractor's responsibility to determine and implement
specific details of compliance requirements as applicable under U.S.
EPA Standards of Performance. 40 CFR Part 60 Subparts VV or GGG,

or 40 CFR Part 61 Subpart J.
3.4.20 For cable controlled valves, the cable shall be carried in a 3/4 inch pipe,
with roller elbows at all turns, to a control point in a non-hazardous
location.
3.4.21 Where block valves are used in branch lines at headers, they shall be
located in horizontal lines, at high points, so that lines will drain both
ways.
3.4.22 Globe valves shall be installed so as to close against the pressure.
3.4.23 Where a locked open or car sealed open valve is used, a metal tag shall
be attached to the valve. This tag shall read: '' This valve must not be
closed without written permission from responsible authority '' and
"Yetkili makamdan yazılı emir olmadıkça kapatılamaz."
3.4.24 Valves shall be installed so that the stems are not below the horizontal
positions. Locked open or car sealed open valves shall have their stems
in the horizontal position.
3.4.25 Gear operators or motorized valves shall be provided as indicated on

the Piping and Instrument Diagrams. If none are indicated, gear
operators as recommended by the valve manufacturer for the intended
service shall be provided. However gate valves 14 inch and larger for
Classes 125, 150, 300, and gate valves 10 inch and larger for Class 600
and higher shall be equipped with gear operators (bevel gear) as a
minimum requirement. Gear operators for plug, butterfly and ball valves
shall be furnished in accordance with valve manufacturer's
recommendation.
3.4.26 Flanged and butt welding end steel gate valves, sizes 1 inch to 24 inch,
shall conform to API 600. Where applicable socket-welding-end gate
valves, 2 inch and smaller, conforming with API 602 may be used.
Date : July, 2008
3.4.27 Gate and globe valves 4 inch or larger in size in steam services shall be
equipped with line mounted warm-up by passes.
3.4.28 Gate valves shall normally be supplied with flexible discs for high
temperatures.
Seat rings of gate valves shall be screwed and seal welded.
3.4.29 Elbolets and latrolets are only to be used for thermowell connections.
3.4.30 Thredolets are only used for removable threaded connections e.g.
screwed relief valves, screwed thermowells, screwed plugs.
3.4.31 Bushings shall not be used.
3.4.32 Swage nipples shall be made of seamless pipe (schedule 80 minimum

for sizes 2 inch and smaller) of the same material and shall have at least
the same finished minimum wall thickness as the pipe in the lines.
3.4.33 Long radius weld elbows shall be used wherever possible.
3.4.34 Fitting construction shall be as follows:
a. 1 ½ inch and smaller, socket weld.

b. 2 inch and larger, butt weld.
3.4.35 Valves at control valve manifolds shall be sized in accordance with the
following table, unless otherwise shown on the Piping and Instrument
diagrams.
Control Line Block By-Pass

Valve Size Size Valve Size Valve Size
3/4 3/4 3/4 3/4

3/4 1 1 1
3/4 11/2 11/2 1
3/4 2,3,4 2 1
1 1 1 1
1 11/2 11/2 11/2
1 2,3,4 2 11/2
11/2 11/2 11/2 11/2
11/2 2,3,4 2 2
2 2 2 2
Date : July, 2008
2 3,4,6 3 3
21/2 3,4,6 3 3
3 3 3 3
3 4,6,8 4 4
4 4 4 4
4 6,8,10 6 6
5(6" flanges) 6,8,10,12 6 6
6 6 6 6
6 8,10,12 6 6
8 8 8 8
8 10,12 10 10
10 10 10 10
10 12,14 12 12
Where piping is expanded after a control valve assembly for flashing

condition, the block valve downstream of the control valve shall be equal
to or one size smaller than the expanded downstream piping.
When reducers are used, the maximum reduction shall not be greater
than two nominal line sizes per reducer.
3.5 Flanges
3.5.1 Dimensions of various classes of flanges shall be in accordance with the

appropriate ANSI or MSS standard.
3.5.2 Flange construction shall be as follows:
a. 1 ½ inch and smaller, socket weld
b. 2 inch and larger, welding neck bored to suit pipe
3.5.3 Where austenitic flanges mate with ferritic steel flanges, the flange
facing shall be as follows:
a. For class 2500 rating only, flange facing for 8 inch nominal pipe
size or less shall be ring joint.
b. Flange facing for all nominal pipe sizes greater than 8 inch in
class 2500 rating, and for all sizes in Class 1500 rating and
below, shall be raised face with the gasket surface finish
comparable to 125 Ra and shall utilize a stainless steel spiral
wound gasket with an inner metal ring.
Date : July, 2008
3.5.4 The design and details for flanges of piping and the mating flanges on
vessels, exchangers, valves, etc., which are not standard ANSI sizes,
are the responsibility of Contractor. The design of such flanges shall be
based on the method outlined in ANSI/ASME B31.3 Paragraph 304.5.1.
It is also Contractor's responsibility to inform equipment suppliers of
these details to insure all mating flanges will match. The design of
flanges on equipment must also conform to the applicable code
governing that type of equipment.
3.5.5 Welding neck flanges are preferred. Slip-on flanges shall not be used.
3.5.6 Where 125 Ra is specified for flange surface finish, the range for
acceptance shall be 63 Ra minimum to 250 Ra maximum. Finishes shall
be judged by visual comparison with surface finish roughness standards
conforming to ANSI B46.1. It is Contractor's responsibility both to
comply with the above finish requirements and to assure that such
flange finishes be protected from damage during shipping, storage, and
installation.
3.5.7 Finish of surfaces which will contact gaskets shall be spiral serrated
finish.
3.5.8 Welding neck flanges shall be either bored to suit pipe wall thickness or
tapered internally where necessary to meet the requirements of ANSI B
31.3
3.5.9 Orifice flanges shall be bored to suit pipe wall thickness.
3.6 Gaskets
3.6.1 Metal jacketed and corrugated metal gaskets for raised face flanges
shall be sized in accordance with ANSI B16.5, Annex E, Table E2B,
Figure E7.
3.6.2 Spiral wound gasket design shall be such that the gasket factor (m)
conforms to the limits of gasket Group 1b of ANSI B16.5. The minimum
gasket design seating stress (y) shall be either the manufacturer's
recommended value or the values in Group 1b of ANSI B16.5,
whichever is greater.
3.6.3 Gaskets shall be selected in accordance with the requirements of

Owner/Licensor's piping specifications and pipe classes.
Date : July, 2008
3.6.4 Spiral wound gaskets with internal retaining rings shall be used where
the flange rating is class 900 or where the fluid being handled is
abrasive.
3.6.5 Octagonal ring joint gaskets shall be used for the flanges over class
1500.
3.6.6 Gasket compounds are subject to Owner's approval.
3.6.7 The use of aluminium or aluminium clad gaskets is prohibited.
3.7 Bolting
3.7.1 Unless otherwise specified better quality because of piping service

requirement, bolting shall be selected as follows:
a. Stud bolts ASTM A 193 B7 threaded full length with 2 ASTM A

194 2H shall be used at design temperature of -20oF (-30oC) to
1000oF (540oC) for carbon steel and low alloy steel.
b. For stainless steel flanges and nickel and nickel alloy flanges
shall be bolted with stud bolts ASTM A 193 B8M threaded full
length with 2 ASTM 194 6F.
3.8 Strainers
3.8.1 Strainers shall be installed at suction side of all pumps between the
block valve and suction flange. Strainers for centrifugal pumps
preferably shall be in line welded ''Y'' or ''T'' type with a flanged cleanout
nozzle. Cone type strainers are not acceptable for centrifugal pumps
with more than two stages.
a. If cone type strainers are used, contractor confirm that piping

layout permits easy installation and removal of the strainer
without disturbing the pump alignment or adjacent piping, and
that adequate straight piping is provided to accommodate the
strainer.
b. Strainers and block valves shall be full line size.
c. Perforated plate with approximately 1/8 inch diameter holes or 6

mesh screen with 0.063 inch diameter wire is recommended for
the strainer screen. The effective screen area shall not be less
than 250 percent of the pipe cross-sectional area, with an open
area of not less than approximately 40 percent. A fine mesh
overlay may be installed for start-up.
Date : July, 2008
d. The strainer body material shall conform to the specification of

pipe in which the strainer is installed. The screen material shall
be Type 304 or 316 stainless steel unless specified otherwise in
the Piping and Instrument Diagram.
3.8.2 Strainers shall be installed at suction side of all compressors between

the block valve and suction flange.
a. Strainer installations must be compatible with the requirements of

the compressor vendor.
b. If cone type strainers are used, Contractor shall confirm that

piping layout permits easy installation and removal of the strainer
without disturbing the pump alignment or adjacent piping, and
that adequate straight piping is provided to accommodate the
strainer.
c. Strainers and block valves shall be full line size.
d. Perforated plate with approximately 1/4 inch diameter holes or 3

mesh screen with 0.12 inch diameter wire is recommended for
the strainer screen. The effective screen area shall not be less
than 250 percent of the pipe cross-sectional area, with an open
area of not less than art-up.
e. The strainer body material shall conform to the specification of

pipe in which the strainer is installed. The screen material shall
be Type 304 or 316 stainless steel unless specified otherwise in
the Piping and Instrument Diagram.
3.9 Vents and Drains
3.9.1 Pumps handling the following shall have their vents routed to a closed
system:-
a. Fluids which contain toxic gases in lethal or dangerous

concentrations, (e.g. H2S).
b. Fluids which are toxic, corrosive or otherwise dangerous.
c. Fluids with a vapour pressure greater than atmosphere at

operating temperature.
Date : July, 2008
d. Fluids with a flash point below 100 º F
e. Vacuum services
f. Oil stocks that solidify at ambient temperature.
Other pump vents shall be routed to oily water, clean water or chemical
sewers as appropriate.
3.9.2 Pump case drains shall be valved.
3.9.3 Gauge glass and level controller drains shall generally be routed to oily
water sewer, except that water and other safe clean liquids may
discharge on to paving provided no hazard (e.g. freezing) is involved.
3.9.4 Drains from columns and drums shall be routed to oily water sewer and
be valved as follows:
a. Operating and shutdown drains-double block valves with 1

bleeder-no blind, plug or cap.
b. Operating water drain from LPG drums shall conform to TD-

20211.
3.9.5 Low point drains shall be valved and plugged.
3.9.6 Equipment and gauge glass drains etc., shall as far as possible be
grouped together at base of equipment (column, drum) and open ended
over a sealed catch basin.
3.9.7 Drains for Minas crude and heavy oil stocks that solidify at minimum
ambient temperatures shall not be routed to sewer, but to a suitable
container.
3.9.8 Control valve manifolds shall generally be provided with a valved and
plugged drain (or vent) on one side of valve.
3.9.9 High point vents shall be plugged or blinded unless required for normal
operations in which case they shall be valved and plugged.
3.9.10 Unvalved, plugged, vents or drains installed only for the purpose of
hydrostatic testing during construction shall be seal welded.
Date : July, 2008
3.9.11 Plugs, where required, shall be 3/4 inch minimum and shall be
fabricated from solid bar or hex bar stock of the same material as the
valve, fitting or pipe which is to be plugged. Plugs shall be extended and
shall have a hex head which shall be both visible and accessible after
insulation is applied (and covered). Where piping requires the use of
plugs , thredolets of the same material and equivalent wall thickness as
the pipe in the lines (3000# minimum) shall be attached to the piping for
such use. This kind of vents shall be seal welded after hydro testing and
this seal welds shall be checked visually and with liquid penetrate
examination.
3.10 Steam Out Connections and Utility stations
3.10.1 Permanent connections shall be provided on connecting piping for

steaming out columns and vessels in hydrocarbon or chemical service,
and for adequate cleaning of lines. Permanent steam out connections
shall not be located at the drainage points of equipment or lines where
drainage of condensate would be obstructed.
3.10.2 Steam, air and water hose stations (3/4 inch air and water,1 inch steam)
, each with a 50 feet length of hose, shall be provided at ground level
and stations shall be located to reach any point in the process, offsite
and utility areas.
Steam and air stations shall be provided for elevated structures and
towers at alternate levels that all parts of elevated structures and all
manholes of towers can be reached with not more than 50 ft of hose.
Terminate each station with a screwed gate valve facing downward (or
safer location) and fitted with coupling and hose.
Provide a rack to support a coiled hose at each group of utility

connections at grade.
Offsite areas include pump stations; truck, rail or drum loading racks;
antiknock compound facilities, including blending area; and waste
treatment areas. Utility areas include boiler, water treating, cooling tower
and refinery fuel systems.
Date : July, 2008
3.11 Blind and Block Valves
3.11.1 Blinds shall be installed in the lines as shown on P&I Diagrams.

However blinds shall be provided in all lines at process unit limits.
Spectacle blinds (figure 8) shall normally be used up to 12 inch size. For

sizes 14 inch and larger use ring-spacer and single-blind.
Where the piping arrangement is such that the pipe can not be easily
sprung for the thickness of the paddle blind, a ring spacer shall be used.
Spectacle blinds, single blind and ring spacers shall be of the same
material as the line in which installed.
3.11.2 Provide blinds at vessels either immediately at the vessel or at the

nearest equipment (so long as the connecting piping is self-draining or
drainable).
3.11.3 Remote operated emergency isolation valves shall be provided for all
columns and drums bottom (liquid) draw off lines, if applicable or
specified by licensor. These valves shall be located outside of skirt.
3.11.4 On all piping connections to pressure vessels size 1½ inch and smaller,
provide block valve against pressure vessel. No special provision for
permanent access to the valve is required providing it can be reached
by portable ladder.
3.11.5 All permanent utility connections to lines or vessels containing

hydrocarbons or chemicals shall consist of a block valve next to the
equipment followed in turn by a check valve, a bleeder and a final block
valve.
3.11.6 On all piping connections to columns below the liquid level, provide
block valves at column nozzles.
3.11.7 Process lines operating below 700 ºF (370 ºC) shall have block valves at
column nozzles.
Date : July, 2008
3.11.8 If unit limit block valve and blinds are in an overhead pipe way, the
following shall be provided:-
a. Drain lines to a common oil sump drum which is connected by a

pump out pump to the slop line (a concrete sump is not acceptable).
b. An adequate drip trough located below the spectacle blinds draining

to the common oil sump drum mentioned in (a) above.
c. Sample points for all rundown lines at unit limits, arranged to drain
surplus samples to common oil sump drum mentioned in (a) above.
d. Stair access to platform above lines.
e. Adequate supports for piping when flange connections are broken

for blinding.
3.11.9 Double seated soft seat valves with bleeders are preferred in lieu of gate
valves and spectacle blinds in shipping and transfer pump manifolds.
Consideration shall be given to the use of quick change elbow type
blinds.
3.12 Steam Piping
3.12.1 Supply steam separators in any saturated steam line entering process
units (for water slug removal) and in steam supply line to multistage
turbine drivers. Provide steam-oil type separators in exhaust lines from
each reciprocating pump where steam directly contacts lubricating oil.
3.12.2 Steam traps shall be provided for steam separators, header drainage
pockets, and low points in lines where required.
3.12.3 Thermostatic traps shall be used whenever possible. All traps shall be
provided with strainers; integral strainers are preferred.
3.12.4 Manufacturers and type of traps are subject to Owner's approval.
3.12.5 Branch take-offs from steam and exhaust headers and sub-headers
shall have a block valve at the header.
3.12.6 Provision of silencers, if considered necessary, to atmospheric exhaust

steam pipes shall be in accordance with the project specifications.
Date : July, 2008
3.12.7 Discharge piping from safety valves in high pressure steam services
shall not be directly connected to the valve body, but arranged similarly
to that shown in Drawing TD-20236.
3.12.8 In design of steam supply lines to turbine drivers, consideration shall be

given to the temperature drop at minimum flow conditions.
3.13 Relief and Blow down Systems
3.13.1 Avoid pockets in relief and blow down lines. If unavoidable, provide a
trap out pot (with gauge glass and float drainer) at each low point.
3.13.2 Supply steam (operable from grade or first platform) to the tail pipe of
each relief valve which discharges vapours that condense at
atmospheric temperature or where possibility of ignition occurs.
3.13.3 The discharge from small thermal expansion relief valves shall generally
be installed in a by-pass around the block valves where possible.
Otherwise valves should be open ended over sewer catch basins or
other drainage openings with the open ends clearly visible.
3.13.4 Refer to TGPS-J2 for Relief and Flare Systems.
3.14 Pump Piping
3.14.1 Valves in suction and discharge lines at pump shall be sized as follows:
a. Line size except as noted in ''b''.
b. Where the pump discharge line is larger than the pump

discharge, its check valve, if required, and shut-off valve shall be
one size larger than the discharge connection on the pump.
3.14.2 Check valves shall be installed in the discharge piping of all centrifugal
pumps.
3.14.3 For boiler feed water and other high head pumps subject to discharge
throttling and requiring a minimum liquid flow rate to prevent overheating
or vaporization of the liquid, the check valve shall incorporate an integral
by-pass valve. The type of valve shall be subject to Owner's approval.
Date : July, 2008
3.14.4 In the case where check valve would be 1½ inch size or smaller, and
where the pump is handling viscous and/or heavy fouling stock (e.g.
asphalt plant feed), a swing check valve of 1½ inch minimum size shall
be used to minimise pressure drop and valve sticking.
3.14.5 Provide strainers in the suction sides of the pumps as described in item
3.8 above.
3.14.6 A warm-up by-pass system shall be provided between a pump and its
spare when the spare must be brought close to operating temperature
before switch-over, kept at operating temperature in anticipation of
automatic switch-over, or kept warm in winter.
3.14.7 The part of suction line between suction block valve and the pump
(suction block valve included) shall be designed to the same conditions
as the discharge line.
3.14.8 Provide removable pipe spools at each pump to permit:-
a. Disassembly of equipment without disturbing continuation of

suction and discharge lines.
b. Removal of strainers for inspection and cleaning without

disturbing pipe suspension.
3.14.9 Overhead suction lines shall drain toward the pump without pockets.
3.14.10 Pumps with top suctions shall utilize concentric reducers.
3.14.11 A NPS ¾" drain shall be installed on the discharge side of the check
valve body or downstream of the check valve, depending on size.
3.14.12 Piping shall be arranged to allow the removal of the pump for
maintenance. In line pumps with motor drivers not exceeding 75 HP
may be supported directly by suction and discharge piping, with
distance between pump flange and pipe support centreline not to
exceed 1 ½" times the pipe diameter.
3.14.13 End suction pumps should have straight runs of 5-10 pipe diameters
minimum.
3.14.14 More than one pipe diameter reducing in a single reducer can result in
excessive turbulence and noise and should be avoided.
The reducers should be limited to one pipe diameter to avoid
excessive turbulence and noise.
Date : July, 2009
3.14.15 Reducers shall be installed just ahead of the pump suction when the
pipe is larger than the pump nozzle. If used, suction reducers shall be
installed as follows:
- Concentric reducers shall not be used.

R1 - If liquid source below or straight, eccentric reducer flat side above.
- If liquid source above, eccentric reducer flat side below.
3.14.16 Elimination of air pockets by piping configuration or by provision of

vents at high points shall be achieved.
3.14.17 Complete drainage through low points without disassembly of piping

shall be achieved.
3.15 Compressor Piping
3.15.1 For piping associated with compressors, consideration shall be given to

the amplitude and spectral frequency distribution of pulsations. An
analogue study of the compressor piping shall be completed if required
for determination of such pulsation values.
3.15.2 Suction lines to centrifugal and reciprocating compressors shall be laid

out to avoid liquid traps.
3.15.3 For reciprocating compressors, the suction line between the liquid
knock-out drum and compressor suction connection shall be steam
heated and insulated unless otherwise agreed by Owner. Pulsation
dampeners and volume battles (if fitted) shall be fitted with drains
(including weep holes between internal compartments) and steam
heated and insulated.
3.15.4 Reciprocating compressors shall not normally be provided with a check

valve.
3.15.5 Sufficient blinding points must be provided for compressors to enable

them to be completely isolated from the adjoining gas and utility
systems. These blinding points must be easily accessible and as a
general rule should be located against the first isolation valves away
from the compressor to eliminate the necessity for the installation of
special flanges. Where springing of pipe work will present a problem,
suitable spacers or spectacle blinds must be fitted.
Date : July, 2008
3.15.6 Provide strainers in the suction sides of the compressors as described

in item 3.8 above.
3.15.7 All reciprocating compressor suction piping from knock-out drum

through to cylinder inlet nozzle (including inter stage piping, pulsation
dampeners and volume bottles) shall be thoroughly discalced by
acidizing or grit/shot blasting and inhibited. Lube oil and seal oil piping
associated with centrifugal compressors, turbines, and all other
machinery shall be similarly treated. Hydrochloric acid shall not be
used for cleaning austenitic stainless steel piping.
3.15.8 Removable spool pieces per paragraph 3.15.7 shall be provided.
3.15.9 Air compressor suction piping shall be equipped with on air intake filter.
The intake filter opening shall be located in such a position as to
prevent the entrance of dust, moisture, corrosive gases, etc.
3.15.10 Process gas compressor suction piping shall include a block valve
upstream of the pulsation damper or surge bottle.
3.15.11 Compressor handling gas at or near its dew point shall be equipped
with secondary liquid separating facilities in the suction pulsation
dampers or surge bottles. Rotary compressors in similar service but
not requiring suction pulsation damper equipment shall be provided
with liquid removal facilities immediately adjacent to the compressor
suction connection.
3.15.12 A quick-response check valve, such as mission Due-check, shall be

installed in the discharge of each centrifugal compressor. Installation
shall be as close to the nozzle as practicable to reduce possible
damage to the compressor during surge conditions and to prevent
backflow during an emergency.
3.15.13 A block valve shall be provided in each compressor discharge, down

stream of any check valve.
3.15.14 Silencers, if required, shall be installed in the suction and discharge

piping as close to the compressor nozzles as practicable. In order to
optimize layout, the silencers may be arranged with side or end
connections. Silencer shell and flanges shall conform to the
appropriate piping material specifications.
Date : July, 2008
3.16 Fired Heater Piping
3.16.1 The supply of fuel and fuel gas shall enter the unit from the unit from
an outside source in an overhead pipe rack, with a block valve installed
in the line at the unit limit.
3.16.2 The fuel gas lines to fired heaters shall be designed to avoid sending
condensed liquid to the burners with knock-out pots.
3.16.3 A separate sub-header from the main header shall supply each row of
burners. These sub-headers shall preferably be of equal length, and
shall terminate with blind flanges for clean-out. The control
arrangement shall be located at the heater, preferably as near as
possible to the burner manifold.
3.16.4 Separate leads to each burner shall be taken from the sub headers.
The shut-off valves at each burner shall be provided with position
indicators and shall be so located as to be accessible from a working
level or from grad, preferably close to burners.
3.16.5 Piping at fired equipment, regardless of burner type of fuel

combination, shall be arranged in an orderly fashion to permit normal
observation and maintenance access for personnel. Piping shall not
obstruct header boxes, tube removal areas, observation parts, etc.
Flexible tubing or metal house may be used to permit burner
adjustment or removal without dismantling the piping.
3.16.6 Every required safety system and/or additional instrumentation shall be

furnished in accordance with TÜPRAŞ tender documents and/or
licensee documents.
3.16.7 A NPS ¾" valved steam-out connection to the fuel oil pipes, accessible
from grade or a platform, is required to facilitate blowing out the burner
tips. The steam for this service shall be taken from the atomizing
steam system.
3.16.8 Oil headers shall from loops at or near the heater, the line being routed
to return to its source. Heavy fuel oil piping shall not be died ended.
3.16.9 Steam tracing of main and secondary fuel oil loops and instrument lead
line is required for heavy fuel oil piping.
Date : July, 2008
3.16.10 Atomizing steam shall be taken from the nearest point on the main
steam supply header. A shut-off valve shall be installed in the
atomizing steam header near the steam main. Steam traps shall be
provided to drain all low points of the atomizing steam system.
3.16.11 A separate steam sub-header shall supply each row of burners, the
headers not necessity being of equal length.
3.17 Piping at tanks
3.17.1 Lines shall be sealed at bund walls and fire walls.
3.17.2 Piping design must allow for tank settlement and, if applicable, for
earthquake effects. Adequately designed pipe bends or stainless steel
bellows type expansion joints may be used.
4.0 FABRICATION
4.1 Materials
4.1.1 All carbon steel materials used in pipe fabrication which are joined by
welding shall have a maximum carbon content of 0.26. Any specification
quoted hereunder for pipe and fittings is subject to this limitation.
4.1.2 All Chrome-Moly materials used in pipe fabrication which are joined by
welding shall have a maximum carbon content of 0.15. Any specification
quoted hereunder for pipe and fittings is subject to this limitation.
4.1.3 Piping materials for piping used in the services subject to NACE
Standard limitations shall meet NACE requirements.
4.1.4 Filler metal shall be specified in the engineering design and shall
conform to the requirements of the BPV Code, Section IX. A filer metal
not yet incorporated in Section IX may be used with the OWNER's
approval if procedure qualification test, including an all-weld-metal test,
is first successfully made.
4.1.5 All piping materials shall be in conformance of piping project

specifications of licensee, TÜPRAŞ tender documents and related
codes and standards.
Date : July, 2008
4.2 Preparation of Welding
4.2.1 Cleaning
Internal and external surfaces to be thermally cut or welded shall be
clean and free from point, oil, rust, scale and other material that would
be detrimental to either the weld or the base metal when heat is applied.
4.2.2 End Preparation
- But weld end preparation is acceptable only if the surface is machined

or ground to bright metal.
- Butt welding end preparation contained in ASME B16.25 or any other

end preparation which meets the procedure qualification is acceptable.
- If components ends are trimmed as shown in Fig. 328.4.2 sketch (a)

ad (b) of ASME B31.3 to accommodate consumable insert, or as
shown in Fig.K328.4.3 of ASME B31.3 to correct internal misalignment,
such trimming shall not result in a finished wall thickness before
welding less than the required minimum wall thickness tm.
- It is permissible to size pipe ends of the some nominal size to improve

alignment, if wall thickness requirements are maintained.
- Where necessary, weld metal may be deposited on the inside or

outside of the component to permit alignment or provide for machining
to ensure satisfactory seating of inserts.
- When a butt weld joints sections of unequal wall thickness and the
thicker wall is more than ½ times the thickness of the other, end
preparation and geometry shall be in accordance with acceptable
design for unequal wall thickness in ASME B16.5.
4.2.3 Alignment
a) Girth Butt Welds

- Inside diameters of components at the ends to be joined shall be
aligned within the dimensional limits in the welding procedure and the
engineering design, except that no more than 1.5 mm (1/16 in.)
misalignment is permitted.
- If the external surfaces of the two components are not aligned, the
weld shall be tapered between the two surfaces with a slope not
steeper than 1:4.
b) Branch Connection Welds
The missing on the main line pipe internal and branch pipe internal
shall not be more than 1.5 mm (Fig.K328.5.4 dimension m of ASME
B31.3)
Date : July, 2008
4.3 Welding Requirements
4.3.1 General
4.3.1.1 Before commencement of fabrication Qualification on Welding

Procedures and Welders in accordance with TSP-W1 and TSP-
W9 shall be made by contractor.
4.3.1.2 Each qualified welder and welding operator shall be assigned

on identification symbol. Unless otherwise specified in the
engineering design, each pressure containing weld or adjacent
area shall be marked with the identification symbol of the
welder or welding operator.
4.3.1.3 Peeling is prohibited on the roof pass and final pass of weld.
4.3.1.4 No welding shall be done if there is impingement on the weld

area of rain, snow, sleet, or excessive wind, or if the weld area
is frosted or wet.
4.3.1.5 The welding sequence and procedure and any heat treatment
for a welding end shall be such as to pressure the seat
tightness of the valve.
4.3.1.6 Each qualified welder shall be equipped with heating torch to

made preheating and post heating if necessary, and heating
thermostat to keep the electrode in hot and dry.
4.3.1.7 Welds may be made either by the manual metal arc, inert gas
or other processes approved by Owner.
4.3.1.8 Fit-up, alignment and spacing of every joint, and limitations for
the use tack welds shall be as specified in the related TSP.
4.3.1.9 Preheating and post heating shall be carried out when it is

required by TSP-W2, W3, W4, W5 W6 and W7.
4.3.1.10 All threaded connections shall be seal welded, except in water

and air services and screwed relief valves, thermowells and
drain plugs.
Date : July, 2008
4.3.2 Fillet and Socket Welds
4.3.2.1 Fillet welds (including socket welds) shall be as shown in figure

328.5.2.A of ASME B31.3. The size of the fillet welds shall be
determined in accordance with that figure.
4.3.2.2 The typical weld details for slip-on and socket welding flanges,
and minimum welding dimensions for other socket welding
components shall be in accordance which ASME B31.3
Fig.328.5.2B and 328.5.2C.
4.3.2.3 If slip-on flanges are single welded, the weld shall be at the
hub.
4.3.2.4 All fillet welds of crom-moly piping attached to pressure

containing components shall be ground to a smooth, concave.
4.3.3 Seal Welds
4.3.3.1 Seal welds are not permitted for the piping classes 1500 and
over, and low temperature piping.
4.3.3.2 Seal welding shall be done by a qualified welder. Seal welds

shall be with GTAW process and shall cover all exposed
threads.
4.3.3.3 Galvanized steel piping shall not be seal welded.
4.3.4 Weld Repair
A weld defect to be repaired shall be removed to sound metal. Repair

welds shall be made using a welding procedure qualified in accordance
with TSP-W9, recognizing that the cavity to be repaired may differ in
contour and dimensions from the original joint. Repair welds shall be
made by welders or welding operators qualified in accordance with TSP-
W9. Preheating and heat treatment shall be as required for the original
welding.
Date : July, 2008
4.4 Bending and Forming
Pipe shall be hot or cold bend in accordance with a written procedure to any
radius which will result in surface free of crack and free of buckles. The
procedure shall address at least the following, as applicable:
a) Material specification and range of size and thickness.

b) Range of bend radii and fibre elongation.
c) Minimum and maximum metal temperature during bending.
d) Method of heating and maximum hold time.
e) Description of bending apparatus and procedure to be used.
f) Mandrels or materials and procedure used to fill the bore.
g) Method for protection of thread and machined surfaces.
h) Examination to be performed.
i) Required heat treatment.
j) Postheat treatment dimensional adjustment technique.
The radius of bend shall be as noted on the piping drawing and P&ID drawing;
minimum radius specified shall be in accordance with PFI Standard ES-24, but
not less than five diameters.
4.4.1 Bending
a) Bend flattening. The difference between the maximum and minimum
diameters at any cross sections of a bend shall not exceed 8% of
nominal outside diameter for internal pressure and 3% for external
pressure. Removal of metal shall not be used to achieve these
requirements.
b) Bending Temperature
- Cold bending of quenched and tempered ferretic materials, the
temperature shall be at least 28oC (50oF) below the tempering
temperature.
- Hot bending shall be done at a temperature above the

transformation range and in any case within a temperature range
consistent with the material and the intended service.
Date : July, 2008
4.4.2 Forming
Piping components shall be formed in accordance with a written
procedure. The temperature range shall be consistent with material
characteristics, end use, and specified heat treatment. The thickness
after forming shall be not less than required by design. The procedure
shall address at least the following as applicable:
a) Material specification and range of size and thickness.

b) Maximum fibre elongation expected during forming.
c) Minimum and maximum metal temperature during bending.
d) Method of heating and maximum hold time.
e) Description of forming apparatus and procedure to be used.
f) Materials and procedures used to provide internal support during
forming.
g) Examination to be performed.
h) Required heat treatment.
4.4.3 Required Heat Treatment
4.4.3.1 Hot Bending and Forming
After hot bending and forming, heat treatment is required for all
thicknesses of P.Nos.3,4,5,6,10A and 10B materials that are
not quenched and tempered. Times and temperatures shall be
in accordance with TSP-W1 and related TSP for piping material
welding requirements. Quenched and tempered materials shall
be reheat treated to the original material specification.
4.4.3.2 Cold Bending and Forming
a) After cold bending and forming, heat treatment in accordance

with (b) below is required, regard less of thickness, when
specified in the engineering design or when the maximum
calculated fibre elongation exceeds 5% stain or 50% of the
basic minimum specified longitudinal elongation for the
applicable specification, grade and thickness for P.Nos.1
through 6 materials (unless it has been demonstrated that the
selection of the pipe and the procedure for making the
components provide assurance that the most severally formed
portion of the material has retained on elongation of not less
than 10%).
Date : July, 2008
b) Heat treatment is required regardless of thickness and shall

conform to the temperatures and durations given in the related
TSP for piping material welding and TSP-W1, except that for
quenched and tempered materials, the stress relieving
temperature shall not exceed a temperature 28oC (50oF) below
the tempering temperature of the material.
4.5 Branch Connections
4.5.1 Fittings shall be used as outlined here below. If stub-in connections are
used, they shall be analyzed and designed for proper reinforcement in
accordance with ANSI/ASME B 31.3. All reinforcement pads shall be
provided with a vent hole tapped 1/8 inch NPT. Reinforcement pad
welds shall be air tested tight. Upon completion of all fabrication and
testing, the vent holes in all reinforcing pads shall be left unplugged.
4.5.2 Full size branch connections shall be made with forged tees. Reducing
branch connections from 1 ½ inch and smaller lines shall be made with
forged reducing tees. Reducing branch connections from larger lines
shall be as follows:
a. Carbon steel
- Sockolets, thredolets or similar fittings for branches 1 ½ inch

and smaller.
- Weldolets or similar fittings for those branches 2 inch thru 8 inch

which require more reinforcement than extra weld metal, nozzle
welds for those which do not..
- Nozzle welds, with reinforcement if required, for branches 10

inch and larger.
b. Alloy steels
- Sockolets, thredolets or similar fittings for branches 1 ½ inch and

smaller.
- Nozzle welds for branches 2 inch and larger, with reinforcement if

required. Weldolets shall not be used.
c. Stainless steels and high nickel alloy steels
- Sockolets, thredolets or similar fittings for branches 1 ½ inch and

smaller, except from thin wall pipe.
Date : July, 2008
- Nozzle welds for branches 2 inch and larger (except from thin wall
pipe), with reinforcement if required. Weldolets shall not be used.
- Neither weldolets nor nozzle welds are suitable for branches from
thin wall pipe, i.e. whose size is 12 inch or less and nominal wall
thickness is schedule 10S or less fittings (tees) shall be used for
branch connections in thin wall pipe. Where the size difference
would require use of more than one fitting, one alternative would be
to substitute a short length of Sch. 40S pipe, with ends bevelled to
match Sch. 10S. It would then be acceptable to make a nozzle
weld, since the extra wall would provide adequate reinforcement.
4.5.3 Holes for branch connections less than 1½ inch on the piping shall be
made by machine drilling or any other method accepted by Owner, and
flame cut shall not be used.
4.6 Mitre Bends
4.6.1 Mitre bends shall not be used.
4.7 Tolerances
4.7.1 Tolerances for fabrication shall be as follows:
Length:
(Centre to centre, centre to flange ± 1/8" thru 10"
face, flange face to flange face) ± 3/16" 12" thru 36"
Alignment of flange face: 90 deg. to pipe centreline

+/- 3/64" per foot of diameter
Flattening:
Internal pressure lines 8% of O.D.
External pressure lines 3% of O.D.
Date : July, 2008
5.0 ASSEMBLY AND ERECTION
5.1 General
5.1.1 Alignment
a) Piping Distortions. Any distortion of piping to bring it into alignment for

joint assembly which introduced a detrimental strain in equipment or
piping components is prohibited.
b) Cold spring. Before assembling any joints to be cold sprung, guides,

supports and anchors shall be examined for errors which might
interfere with desired movement or lead to underised movement. The
gap or overlap of piping prior to assembly shall be checked against the
drawing and corrected if necessary.
Heating shall not be used to help in closing the gap because if defects
the purpose of cold spring.
c) Flanged joints. Before bolting up, flange faces shall be aligned to the
design please within 1 mm in 200 mm (1/16 in/ft) measured across any
diameter; flange bolt holes shall be aligned within 3 mm (1/8 in.)
maximum of set.
5.2 Flanged Joints
5.2.1 Preparation for assembly. Any damage to the gasket seating surface
which would prevent gasket seating shall be repaired, or flange shall be
replaced.
5.2.2 The minimum distance from the front face of a slip-on flange to the pipe
end shall be equal to the lesser of pipe wall thickness or 6 mm (1/4 in.)
5.2.3 Unless otherwise noted on piping drawings, flange bolt holes shall
straddle the vertical and horizontal centrelines, and shall match the
orientation of mating flanges.
5.2.4 Bolting torque

a) In assembling flanged joints, the gasket shall be uniformly
compressed to the proper design loading.
b) Special care shall be used in assembling flanged joints in which the

flanges have widely differing mechanical properties. Tightening to a
predetermined torque is recommended.
Date : July, 2008
5.2.5 Bolt length

Bolts should extend completely through their nuts. Three or four thread
shall be longer on each nuts.
5.2.6 Gaskets
No more than one gasket shall be used between contact faces in
assembling a flanged joint.
6.0 EXAMINATION
Examination applies to quality control functions performed by the manufacturer (for

components only), fabricator, or erector.
6.1 Responsibility for Examination
Inspection does not relieve the contractor, the manufacturer, the fabricator, or
the erector of the responsibility for :
a) Providing materials, components and workmanship in accordance with the

requirements of contract and of the engineering design.
b) Performing all required examinations and
c) Preparation suitable records of examinations and test for the OWNER's use.
6.2 Examination Requirements
Prior to initial operation each piping installation, including components and

workman ship shall be examined in accordance with TSP-W1, related piping
welding standards, TSP-W8 and this specification. The type and extend of any
additional examination required by the engineering design, and the acceptance
criteria to be applied, shall be specified.
a) For P.NOS.3,4 and 5 materials, examination shall be performed after

completion of any heat treatment.
b) For a welded branch connection the examination of and any necessary

repairs to the pressure containing weld shall be completed before any
reinforcing pad or saddle is added.
c) A sample examination from each lot of bulk material (bolt, nut, pipe, etc.)
shall be made chemical and mechanical examination in accordance with
related codes and standards in the Contractor cost.
Date : July, 2008
6.2.1 Acceptance Criteria
Acceptance criteria shall be as stated TSP-W8 and other TSP's for the
each kind of material and other contract documents and related codes.
6.2.2 Defective Components and Examination
a) Defects (imperfections of a type or magnitude not acceptable by the

specified criteria) shall be repaired, or the defective item shall be
replaced)
b) Repaired or replaced items shall be examined as required for the

original work.
6.2.3 Progressive Sampling for Examination
When required spot or random examination reveals a defect:
a) Two additional samples of the same kind (if welded or bonded joints,
by the same welder, bonder, or operator) shall be given the same
type of examination; and
b) If the items examined as required by (a) above are acceptable, the

defective item shall be repaired or replaced and re-examined, and all
items represented by these two additional samples shall be accepted;
but
c) If any of the items examined as required by (a) above reveals a

defect, two further samples of the same kind shall be examined for
each defective item found by that sampling; and
d) If all the items examined as required by (c) above are acceptable, the
defective item (s) shall be repaired or replaced and re-examined as
specified, and all items represented by the additional sampling shall
be accepted : but
e) If any of the items examined as required by (c) above reveals a

defect, all items represented by the progressive sampling shall be
either:
- Repaired or replaced and examined as required; or

- Fully examined and repaired or replaced as necessary, end
re-examined as necessary to meet the requirements of the
contract documents.
Date : July, 2008
6.2.4 Extend of Required Examination
Piping shall be examined to the extend specified herein or to any greater

extend specified in the engineering design, and any other contract
documents.
6.2.4.1 Visual Examinations
a) Materials and components, 100% for all kind of piping

classes and piping materials.
b) Fabrication, 100% for all kind of piping classes and piping

materials.
c) Pressure-containing threads. 100% examination for finish

and fit is required. Items with visible imperfections in thread
finish and/or the following defects shall be rejected :
- Tapered threads failure to meet gauging requirements in

API Std. 5B;
- Straight threads excessively loose or tight fit when

gauged for light interference fit.
d) 100 % of welds.
e) All piping erection shall be examined to verify dimensions

and alignment. Supports, guides and points of cold spring
shall be checked to ensure that movement of the piping
under all conditions of start-up, operation and shut-down will
be accommodated without binding or constraint.
6.2.4.2 Radiographic Examinations
a) All girth, longitudinal, and branch connection welds shall be

100 % examined for the piping class 1 and class 2 in
accordance with TSP-W1, TSP-W8 and related welding
specifications.
b) Ultrasonic examination shall not be substituted for

radiography for piping class 1 and class 2, but may
supplement it.
c) In-process examination shall not be substituted for

radiography.
Date : July, 2008
d) Not less than 10% of circumferential but and mitre grove

welds shall be examined fully by random radiography in
accordance with TSP-W1, TSP-W8 and related welding
specifications.
e) Socked welds and branch connection welds which are not

radio graphed shall be examined by magnetic particle or
liquid penetrate methods for the piping classes 1 and piping
classes 2. For classes 3 and classes 4 shall be examined in
accordance with related welding specifications, TSP-W1 and
TSP-W8.
f) Radiographic examination shall be properly distributed

among the welders, according to welds performed and
relevant to the repairs. A minimum of two welds from each
welder shall be included in the welds radio graphed.
g) Owner's interpretation of radiographs is final.
6.2.4.3 All cast valve bodies and flanges (if integral) with a flange rating
of Class 900 or higher in hydrogen service shall be examined in
accordance with paragraphs 7.2 through 7.5 of Appendix VII,
ASME Section VIII, Division I regardless of casting quality
factor. For sizes 2'' or less, where radiography is impractical,
the following examination shall be performed:
a. 100 percent magnetic particle or liquid penetrate

examination.
b. A high pressure leak test of the valve body using helium at a

minimum of 1.5 times design pressure for a minimum of ten
minutes. No leakage is permitted.
6.2.4.4 Requirements for radiographic examinations as well as the other

examinations are given in the specification TPS-W8 and related
piping welding specifications.
Date : July, 2008
7.0 HEAT TREATMENT
7.1 All carbon steel pipe welds except socket welds in wet hydrogen sulphide
service shall have a maximum weld hardness of 200 Brinell. At least one
hardness reading shall be taken of every piping joint with the reading taken
near the centre of the weld. Readings shall be made with a Telebrineller or
equal instrument calibrated at 200 Brinell. Where weld hardness exceed the
200 Brinell maximum, such welds must be post weld heat treated.
7.2 For carbon steel pipe butt welds, post weld heat treatment shall be carried out
when the nominal thickness of the thickest component to be joined is over 19
mm. For joint configuration other than butt weld (e.g. full penetration branch
connections and fillet welds), the material thickness requiring post weld heat
treatment shall be assessed as per ANSI/ASME B31.3 par. 331.3.6.
7.3 The post weld heat treatment is required for Chrome-Moly piping welds and
bends and other parts worked either hot or cold for any thickness and type of
welded joint.
7.4 In the case of butt welds or branch connections in 1/2 Moly piping, post weld
heat treatment shall be carried out when the thicker component measured at
the joint, is over 15 mm, except for piping in hydrogen service for which heat
treatment is required when the above thickness is over 10 mm.
In the case of fillet welds, heat treatment shall be carried out when the pipe wall
thickness is over 15 mm.
7.5 No heat treatment is required for Type 304, 304L, 316 or 316L, 316 Ti, 316 Cb,
321 or 347 stainless steel pipe, in wall thickness less than 3/4, unless otherwise
specified.
Type 321 or 347 stainless steel pipe in wall thicknesses 3/4 or greater, shall be
post weld heat treated.
7.6 Welded joints in caustic service shall be stress relieved in accordance with
requirements of related TUPRAS welding practice.
7.7 Additionally, post weld heat treatments shall be made when it is required due to
hardness limitations as specified in the specifications TSP-W2, W3, W4, W5,
W6, W7, W8 and W9.
Moreover, heat treatment shall be carried out when it is indicated in piping

specifications, or it is required by NACE.
Date : July, 2008
8.0 REQUIRED LEAK TEST
Prior to initial operation, and after completion of the applicable examinations required,
each piping system shall be tested to ensure tightness. The test shall be a hydrostatic
leak test in accordance with OWNER's tender documents and following by Contractor :
a) Each weld and each piping component, except bolting and individual gaskets to be
used during final system assembly, shall be hydrostatically or pneumatically leak
tested. The organization conducting the test shall be made by Contractor to ensure
that during the required leak testing of components and welds, adequate protection
is provided to prevent injury to people and damage to property from missile
fragments, shock waves, or other consequences of any failure which might occur in
the pressurized system.
b) In addition to the requirements of (a) above, a leak test of the installed piping
system shall be conducted at a pressure not less than 110% of the design pressure
to ensure tightness, except as provided in (c) below.
c) If the leak test in (a) above is conducted on the installed piping system, the
additional test in (b) above is not required.
d) None of the following leak test may be used in lieu of the leak tests required.
- Initial service leak test

- Sensitive leak test
- Alternative leak test
8.1 All fabricated piping shall be hydrostatically tested by Contractor.
8.2 Clean fresh water shall be the primary hydrostatic test medium unless use of a
different medium is approved by Owner. Hydrostatic testing of austenitic
stainless steel shall be done with potable quality water having a chloride
content less than 50 ppm. If chloride content is greater than 50 ppm, up to a
maximum of 250 ppm, a sufficient quantity of sodium nitrate shall be added to
provide a test medium of 0.5%by weight sodium nitrate solution. This is also
required when testing through equipment, such as vessels, exchangers, etc.,
containing austenitic stainless steel regardless of piping materials. Water with
chloride content of greater than 250 ppm shall not be used for hydro testing.
Date : July, 2008
8.3 Test Pressure
The hydrostatic test pressure at any point in a metallic piping system shall be
as follows:
a) Not less than 1.5 times the design pressure.
b) For design temperature above the test temperature, the minimum test
pressure shall be calculated by eq.
PT=1.5 P.ST/S, except that the value ST/S shall not exceed 6.5:
Where
PT= Minimum test gage pressure

P = Internal design gage pressure
ST = Stress value at test temperature
S = Stress value at design temperature
c) If the test pressure as defined above would produce a stress in excess of the
yield strength at test temperature, the test pressure may be reduced to the
maximum pressure that will not exceed the yield strength at test
temperature.
9.0 PACKING FOR SHIPMENT
9.1 All flange faces shall be protected against corrosion by applying a suitable
protective coating and shall be protected from damage during shipment by
suitable wooden or hardboard covers attached to the flange.
9.2 Ends of pipe and open ended branch connections (including small fittings such
as bosses) which are not flanged shall be fitted with push-fit plastic protection
caps.
Date : July, 2008
10.0 REFERENCES
TD-20236 Exhaust piping for steam safety valve

TD-20321 Standard valve installation guide
TD-20234 Piping connections to burners
TGPS-A5 Layout and spacing of refinery units and equipment
TGPS-A9 Selection of metallic materials
TSP-W1 Welding of ferrous materials general requirements
TSP-W2 Carbon steel piping welding
TSP-W3 0.5 Molybdenum steel piping welding
TSP-W4 Chromium Molybdenum steel piping welding
TSP-W5 Austenitic stainless steel piping welding
TSP-W6 Nickel and nickel alloy steel piping welding
TSP-W7 Welding of piping components of different steel types
TSP-W8 Piping welding examinations
TSP-W9 Qualification of the welding procedures, welders and welding
operators of ferrous materials
TGPS-J2 Relief and flare systems
11.0 ATTACHMENTS
Attachment A :
UD-50.142 (Sht.1 thru Sht.16) Tüpraş Piping Specifications

UD-50.142 (Sht.1 thru Sht.12) Specification for Instrument Piping Materials
Addendum to TÜPRAŞ Piping Specification
Attachment B : Support types for pipes

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Section : TGPS –L1

Date : July, 2008

1.1.1 This Specification outlines the requirements for design, materials,

1.1.3 Any conflict between the requirements of codes and specifications

1.2 Project Specifications

1.2.1 Requirements of referenced project specifications in this specification as

a. piping classes given in Licensor piping specifications.

b. project specifications by Owner/Licensor.

Any variations or substitutions are not permitted unless approved in

1.2.3 In case no piping specification is provided by Owner/licensor for any

1.3 Reference to Manufacturer's Names and Catalogue Numbers

a. the substitutions are equivalent in all aspects, such as design,

b. Owner's approval has been obtained.

2.1 Design Codes

Piping shall normally be designed, fabricated, inspected and tested in

2.2 Pressure and Temperature

a. Highest design pressure of the equipment to which it is connected.

b. Set pressure of the pressure relief valve which protects system.

c. For cases of a centrifugal pump where discharge piping can be

d. Discharge piping of a direct acting steam pump, not protected by a

e. All system operating below atmospheric pressure shall be designed

f. Piping systems leaving the process area shall be designed for a

2.2.4 Pressures and temperatures of air, steam, exhaust, condensate, water,

2.3 Pipe Thickness Determination

2.3.2 A reduction of no greater than 10% of the specified corrosion allowance

2.3.3 Unless service conditions require greater corrosion allowances, the

a. for carbon steel and low chrome alloys : 0.062 inch.

2.4 Expansion and Contraction

2.4.3 When analyzing piping, design temperature of equipment and piping

3.0 PIPING GENERAL REQUIREMENTS

3.1.1 Contractor shall prepare Process and Instrument diagrams (P&I

Line number and pipe sizes.

3.1.6 A system of line identification, piping class identification and material

3.2 Layout Requirements

3.2.4 Adequate clearance as required for maintenance shall be provided

Control valves with top stem removal.

3.2.6 Valves shall be located in accordance with Drawing TD-20321 unless

3.2.8 Piping and structures shall be arranged to permit mobile lifting

3.2.14 Where commercial style bolt tensioners are specified, adequate

3.3 Piping - General

3.3.1 Pipe material shall be as given in Owner/Licensor's piping specifications

3.3.10 Wear plates are required for all pipe supports.

3.3.11 Unless otherwise indicated in piping specifications, lines 1 ½” inch and

3.3.12 All process connections to instruments shall follow the appropriate

3.3.13 Consideration shall be given to the expansion of pipe as a result of

3.3.14 Where XXS piping is used minimum size shall be 1 inch.

3.3.19 Flanged connections required to permit dismantling lines for

3.4 Valves and Fittings

3.4.1 Valves and fittings shall be selected in accordance with Owner's /

3.4.12 Ball valves shall not be used for tank isolation.

3.4.13 In viscous and/or heavy fouling services consideration shall be given to

a. Design metal temperature is above 750 ºF for carbon steel or

b. Flanges rating (i.e. system rating) is 900 or higher.

EPA Standards of Performance. 40 CFR Part 60 Subparts VV or GGG,

3.4.22 Globe valves shall be installed so as to close against the pressure.

3.4.25 Gear operators or motorized valves shall be provided as indicated on

Seat rings of gate valves shall be screwed and seal welded.

3.4.31 Bushings shall not be used.

3.4.32 Swage nipples shall be made of seamless pipe (schedule 80 minimum

3.4.33 Long radius weld elbows shall be used wherever possible.