IS 15190-2: Acetylene Pipelines - Code of Practice, Part 2: For Pressures from 155 kPa (g) to 2550 kPa (g)

18 Pages·2002·1.9 MB·English

by  Bureau of Indian Standards

इंटरनेट मानक
Disclosure to Promote the Right To Information
Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.
“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ”
Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”
IS 15190-2 (2002): Acetylene Pipelines - Code of Practice,
Part 2: For Pressures from 155 kPa (g) to 2550 kPa (g) [MED
16: Gas Cylinders]
“!ान $ एक न’ भारत का +नम-ण”
Satyanarayan Gangaram Pitroda
““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee””
“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै”
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”

IS 15190 (Part 2) :2002 :“
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IndianStandard
ACETYLENE PIPELINES — CODE OF PRACTICE
PART 2 FOR PRESSURES FROM 155 kPa (g) TO 2550 kPa (g)
ICS 25,160.20; 77.140.75

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@ BIS2002
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
September 2002 Price Group 6
Gas Cylinders Sectional Committee, ME 16
FOREWORD
‘1’1is1Indian Standard (Part 2) was adopted by the Bureau of Indian Standards, after the draft finaIized by the
Gas Cylinders Sectional Committee had been approved by the Mechanical Engineering Division Council.
Acetylene gas isdistributed toconsumers from asource suchasageneration plant orcylinder discharge manifold
by means of pipelines. In view of the explosive behaviour of acetylene inpiping systems, special precautions
need to be taken in design, fabrication, erection, testing and commissioning of acetylene gas pipelines. This
Code stipulates engineering requirements for safe design, construction and commissioning of acetylene gas
pipelines. It is based on the concept of’ Working Ranges’, which also has been followed by Industrial Gases
Committee (IGC), Paris.
The co,lcept of’ Working Range’ includes acombination of parameters, such as ‘Deflagration Pressure Limit’,
‘Deflagration Pressure Limit’, nature and place of ignition.
Theguidelines given inthisCodearebasedonpublished information andobservations madebyvarious authorities
onthe subject ofacetylene gasinpipelines. Itisexpected that adherence tothe guidelines presented inthis Code
wiIIsignificantly reduce the safety hazard related to acetylene transmission through pipeline systems. Behaviour
of acetylene gas transmitted in pipelines isgiven in Annex A.
This Code is being published intwo parts. Part 1is asunder:
Part 1For pressure up to 155kPa (g).
Unless otherwise stated, the pressures mentioned inthis Code are gauge pressures.
This Code is intended to recommend safety requirements for design and construction of acetylene pipelines
having a working pressure rating of 155kPa (g) (1.55 kg/cm2g) to 2550 kPa (g) (26 kg/cm2g). This covers
pipelines connecting acetylene compressors and high pressure dryers aswell astilling and discharge manifolds
for acetylene. Unless otherwise stated, the pressures mentioned inthis Code are gauge pressures.
In preparation of this Code, assistance has been derived from the following publications:
a) Code of practice for acetylene pipelines based upon working range (IGC Document No. 9/78/E).
b) Standard for acetylene c ylinder charging plant, Compressed Gas Associates Inc., New York, U.S.A.,

specification No. G.1.4.

c) National Fire Protection Association Standard for acetylene cylinder charging plant, specification No.
NFPA51A.
d) High pressure gas manifolds — Under-Writers Laboratories Inc. U.S.A., specification No. UL-407.
The composition of tbe Committee responsible for formulation of this standard isgiven in Annex B.
For the purpose of deciding whether aparticular requirement of this standard iscomplied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS2: 1960‘Rules for rounding off numerical values (revised)’. Thenumber ofsignificant places retained inthe
rounded off value should be the same asthat of the specified value inthis standard.
1S15190 (Part 2) :2002
IndianStandard
ACETYLENE PIPELINES — CODE OF PRACTICE
PART 2 FOR PRESSURES FROM 155 kpa (g) TO 2550 kPa (g)
1SCOPE IS No. Titie
3624:1987 Specificationforpressureandvacuum
1.1 This Code (Part 2) applies to new plant and
gauge (second revision)
premises which may be engaged in production and
11006:1984 Specification for flash back arrestor
compression and filling of acetylene incylinders and
(flame arrestor)
premises where acetylene isdischarg~dfromdissolved
3 TERMINOLOGY
acetylene cylinder banksthrough dischargemanifolds,
Itisapplicable toanyaddition, modification orrevam- Forthepurpose ofthisCode,thefollowing definitions
ping of such plant or system. shall apply,
3.1 Deflagration — A flame produced by decom-
1.2 This Code does not cover the following
position orcombustion that travels into the unreacted
The existing plant or premises where acetylene is gasatavelocity, which islessthan that of sound. The
produced and filled in dissolved acetylene (DA) rate of propagation of a deflagration flame increases
cylinders or where acetylene is distributed from with the density, the temperature and the turbulence
cylinder bank through discharge manifolds. The ofunreacted gas. Since these three parameters tend to
plant, which only compresses acetylene for increaseasadeflagration progresses, therateofpropa-
chemical process orwhich only,produces compre- gation is usually not steady but tends to increase
ssed acetylene at less ,tirin.155 kPa (g) (1.55 kgl continuously and sometimes lead to detonation.
cm2g). Theinstallations where acetylene isdirectly
3.2Detonation —A flameproduced bydecomposition
used from one cylinder through hose assembly for
or combustion that travels into the unreacted gas a
welding, cutting, heating and heat treatment
rate above the speed of sound. Unlike a deflagration,
operations.
where the pressure ahead or behind the flame front
rises at the same time, a detonation involves a sharp
2 REFERENCES
difference in pressure between the reacted and
The following Indian Standards contain provisions, unreacted gas. The change from the low pressure of
which through reference in this text constitute the unreacted gas to the high pressure of the reacted
provision of this standard. At the time ofpublication, gas takes place in a shock wave at the front of the
the editions indicated were valid, All standards are flame.
subject to revision, and parties to agreements based
3.3Flame or Flash Back Arrestor — Anequipment,
on this standard are encouraged to investigate the
which quenches a flhrne front (flash back or decom-
possibility of applying the most recent editions ofthe
position). It shall be suitable for flame, which may
standards indicated below:
occur duetodeflagration and/or detonation. Itsdesign
IS No. Title and application shall be such that it shall withstand
308:1988 Dissolved acetylene gas (third andbeeffectiveinstopping aflame coming from either
revision) one or both directions (see also IS 11006).
554:1999 Pipe threads where pressure type
3.4 Manifolds — A system in which two or more
tight joints are required on the
individually valved, dissolved acetylene cylinders are
threads — Dimensions, tolerances
connected bypipes orhoses toacommon inlet header
and designation (jourth revision)
through which all cylinders are charged simul-
1040:1987 Calcium carbide (third revision)
taneously without dismantling the cylinders or are
1323:1982 Code of practice for oxy-acetyIene
normally discharged simultaneously through the
welding for structural work inmild
common outlet header.
steels (second revision)
2148:1981 Flameproof enclosures forelectrical 3.5 Portable Manifolds — They are basically two
apparatus (second revision) types:
2379:1990 Colour codeforidentificationofpipe
a) In this, gas passes from connected cylinders
lines (j%st revision)
through individual leads to asingle common
3043:1987 Code of practice for earthing
lead or block. From there through a single

,1
IS 15190 (Part 2) :2002
4(+,/
,. .!+
pressure reducing station (in case of a dis- 3.7 Nominal Diameter (DN)—Every partofapiping
charge manifold) to the consumption point. systemmanufactured byhotand coldrolling methods ‘,,
$
b) The cylinders areconnected through coupler/ andJorbypiercing andcolddrawing shallbeidentified
teesattachedtoshutoffvalveofea~hcyl~der. by itsnominal diameter. Nominal diameter isderived
Gas from each cylinder passes through the from the approximate inside diameter up to 100mm.
coupler/tees and joins the main stream The nominal diameter shall be designated by the ,,,
flowing through a common line. abbreviation DN.Thetypical designation ofapipeline p;.
system where nominal diameter is 50 mm shall be 8 ,.
3.6 Stationary Manifolds — These are essentially
DN 50.
manifolds supported onwallorfloorandprovided with
fittings for connecting individual cylinders bymeans 3.8 Predetonation Distance — The distance that a
of leads(pigtails). Incaseofdischarge manifolds, one deflagration travels in a Class 3 category pipeline
ormore permanently mounted regulators areprovided before itdevelops intoadetonation. For evaluation of
to reduce and regulate the pressure of the gas from predetonation distance, for systems under various
the cylinders. operating conditions at different pressures shalI be
taken from Fig. 1.
INITIAL PRESSURE CORRECTED To 15“ c (60”F) kg/cm2 (ABSOLUTE)
1
28.169 r 1 I I 1 I I I I I I I I I I 1
PREDETONATION
DISTANCE LIES
IN THIS AREA 1
14.084
MINIMUM R SUR
q 8
kt%fA#06” I D F R
VARIOUS TUBE SIZES
7.042 I x I I I
5.634 - *12 mm (0.5) —
\ I I
4.225 \
625 mm (1)
\ 1 I I
2.817 r 4s50 mm (2) .-..
I I\ \
I @100 mm (4)
1.408 u 7 I I I
I I‘ % @200I mm (8)
I 300 mm (12
0.704 1
! 1
I
I I I II I I I I I I
PREDETONATION DISTANCE, METRES ~
(DISTANCE Transverse BY FUME BEFORE DETONATION DEVELOPS)
NOTE—Foracetylenepressureof2.8 kg/cm2absolute,forexample,thepredetonationdistance liesintherangeof2.4 metresto16.75
lmetresprovidedthediameterofthetubesislargeenoughsothatitdoesnotprecludedetonationatthispressure.ThehorizontalIines01’IIw
abovefigureshowstheleastpressuresrequiredfordetonationinWbesofdifferentdiameters.Italsoshowsthatthe2.4to16.5metresmngc
Ibrdetonationtooccur,appliestotubeslargerthan35.5mminternaldiameterbutnotsmaller.
Theabovefigureappliestodetonationsthatdevelopinacetylenegasfromdeflagrationsandwhichinturn,isinitiatedtiomnon-shock
thermalsourceofinitiation.
FIG. 1EVALUATIONOFPREDETONATIONDISTANCEFORACETYLENE
PIPELINES UNDERVARIOUS OPERATINGCONDITIONS

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IS 15190 (Part 2) :2002 S1.f
1
3.9 Reflection — If incase ofdetonation the forward 4.2.3 The building/room housing shall be well . .
moving shock wave hits an obstruction such as the ventilated both at floor level and roof level. The :,
end of apipe or aclosed valve, the pressure increases ventilation provided should be such that flow of air is
considerably and the shock wave isreflected, similar not less than 3.3 m3/min/m2 of ceiling area. The
to water hammer. ventilators should be covered with two layers of
11meshes per linear centimetre stainless steel or any ~,,.
3.10 Working Pressure (Pw)— It is the maximum /., .
operating pressure in kPa of apiping system. non-corroding material wiremesh; brassmesh ifused, :, ,‘,,’
shall have not more than 65 percent copper content. ,
~
3.11 Acetylene Compression — Compression to a
4.2.4 Ifanyheating isrequired inthebuilding, itshall
pressure of 155kPa (g) (1.55 kg/cm2g) or above, the
beby steam orhot water.
pressure rises being achieved by compression either
in single stage or multiple stages. 4.2.5 Boiler, heaters and other heating equipment
employing flames or capable of creating sparks shall
3.12 Leads or Pig Tails — Flexible device made of
be housed in a separate building located 15m away
metallic reinforced rubber, teflon or steel suitable to
from the building housing the acetylene compression
connect themain manifold pipetothecylinderthrough
equipment, charging manifold ordischarge manifolds.
proper connections.
4.2.6 Electrical equipment and wiring in rooms
3.13 Unpierced Wall —Awallwhichmayhavepipes
housing compressor and equipment for filling and
orconduits passing through itorwindows, glazedwith
discharge of acetylene shall have flame proof fittings
safety glass andlor wired glass set in it, but such
conforming to IS 2148 and suitable for at least gas
openingsmust besealedtoprevent flowofairbetween
group classIIB.Alltheequipment shallbeelectrical Iy
the spaces separated by the wall.
earthed (see IS 3043).
4 LOCATION AND GENERAL ARRANGE- 4.2.7 The acetylene or acetone fire, normally, shall
MENT OF PREMISES AND SAFETY not be extinguished with hose water or portable fire
extinguishers. To avoid any fire, leak free pipelines
4.1 Location andgeneralarrangement ofbuilding shall
and good quality valves shall be used. However, for
conform to the Ministry of Industry, Government of
fweprotectionthefollowing precautions shallbetaken:
India, Notification No, 625 dated 7August 1983 or
any other notifications issued in this regard by the a) For waste disposal the receptacles should be
appropriate authority. self-closing metal (non-sparking type).
4.1,1 The building housing acetylene compressor, b) The area shall be equipped with hose of dia
filing manifold ofdischarge manifold oftheacetylene 40 mm (nominal bore) station equipment
manufacturing and charging plant shall be located at unless continuous water spraying over fitIing
least 15meters from public right ofwayandfrom line or discharge manifold is available. Alterna-

of adjoining property or building that may be built tively automatic sprinklers system may be

upon. Boundary wall or barbed wire f encing shall be provided ensuring that the water coverage is
laid around the building at a minimbm distance of not lessthan 13I/m/mzof floor area.
9 meters to avoid unauthorized entry of any person. c) Thefirehoseandwatersprayactuation valves
Clear sign boards ‘Hazardous area— No smoking in shall be so located that they can be operated
the premises’ and ‘No trespassing — No smoking or from out-door or at an exit.
open flame’ shall be displayed in the premises
4.2.8 Each plant shall adopt detailed emergency
prominently.
procedure and shall conduct periodic fire drill. A
4.2Thebuildings walIsshallbeconstructed preferably flameproof alarm shall be provided for summoning
of non-combustible materials. Any combustible fire fighting and to caution people inemergency.
materials used shall have afire resistance rating of at
4.2.9 Amaximum of 80cylinders (or480 cubic meter
least one hour.
of gas) shall be connected to a manifold under one
4.2.1 The compressor station or filling manifold or roof. In case more than 80 cylinders (or 480 cubic
discharge manifold shall not be housed in abuilding meter of gas) are to be connected under one roof,
which has a basement or floor below it or of a floor manifold shallbeseparatedbyaconcrete wallof2.5 m
above it, high and not less than 200 mm thick, so that in an
area isolated by the concrete walls, not more than 80
4.2.2 The roof of the buildings shall be made of light
cylinders (or480 cubic meter ofgas) areconnected to
material or be provided with explosion venting area
manifolds that canbe inoperation (filling/discharge).
of not lessthan 0.06 m2/m3of building volume.

3
IS 15190 (Part 2) :2002
5 ACETYLENE COMPRESSOR 5.2.1 All parts of the compressor coming in contact
with acetylene under pressure shall be tested hydrau-
5.1 Installation lically atthe test pressures given below:
5.1.1 The inlet and outIet piping of each compressor
Maximum Working Test Pressure
shallbeprovided withreadily accessibleshutoff valves
Pressure, Pw kglcm2g
that can be closed in an emergency.
lcgIcm2g
5.1.2 Drainlinesfromhighpressure[above155kPa(g) upto 0.2 3.75
(1.55 kg/cm2g)] oil separation condensate traps and 0.2 to 1.5 12to 24
drains shall be manifolded and leadto separators with Above 1.5 11XPW+IO
a safety valve set at 147 kPa (g) (1.5 kg/cm2g) the
5.2,2 The compressor shall have aconnection sothat
outlet of which shall be connected to inlet of
thewholeunitcanberinsed/purged with nitrogen andl
compressor suction or piped out to vent the gas at a
orwater.
height of at least 5 m and away from the building.
The condensate, liquid, etc, shallbepiped outside the 5.2.3 The compressor shallbepneumatically tested at
building away from any source of ignition and itsoperatingpressurebyholding pressure inthesystem
combustible material or shall be drained to eflluent for 24 hwithout any visible leak. The fall inpressure
water drains. shall not be more than 0.2 percent per hour of the
initial pressure.
5.1.3 The compressor shall be fitted with pressure
relief valve (safety valve) offull sizeonthedischarge 5.2.4 At suction and discharge ofthe compressor and
of each stage. at”each stage, pressure and temperatures measuring
devices shall beprovided.
5.1.4 The compressor shallbeprovided atsuction and
discharge with pressure switch or a similar fail safe 5.2.5 Where oil lubrication is provided oil pressure
device capable of shutting down the compressor ifthe gauge to show oil lubrication pressure shall be
compressor suction pressure falls below 250 mm of provided.
water column or if the discharge cross the maximum
5.2.5.1 Oil used for acetylene compressor should be
setpressure, whichisnocaseshallexceed2744 kPa(g)
conrpatible with acetylene.
(28 kg/cm2g). Shut-off valve or by pass valve for the
pressure switches shall not be installed. 5.2.5.2 Provision should be made to check oil level.
5.1.5 The flow of acetylene through the inter- 5.2.6Incaseoflubricatedcompressor having oilpump, ,..----
connecting piping shall be designed at velocity a suction filter for lubricating oil shall be provided.
specified below: Use of porous metallic or ceramic filter element is
recommended. Provisions shall be made so that they .J
Pressure Linear V elocity can be cleaned from time-to-time.
kgfcmzg mls

Upto 6 10 5.2.7 If Nitrogen Fails
6toll 5
Safe device is connected directly to the acetylene; it
llto21 3
shall have non-return valve and automatic devices to
21 to26 2.5
provide flow of nitrogen inthe compressor incase of
emergency.
5.1.6 Compressor shall be constructed so that the
acetylene is co’oled during and after each state of 5.2.8 The compressor shall be provided with a local
compression. When water is used, the flow of water aswell asremote emergency switching off device.
from cooling jacket and inter-coolers shall be visible
5.2.9 Aprecooler with condensate trap shall be provi-
to the operator.
ded inthe suction of the compressor.
5.1.7 Where the compressor iswatercooled, valveon
water inlet line shall be provided fbrregulating water 5.3 High Pressure Drier
ftow.
5.3.1 The high pressure drier shall have down-stream
5.1.8 Transmission beltwhen usedincompressor shall pressure regulator to regulate the back pressure at
be anti-static type. 1372 to 1666 kPa (g) (14 to 17kg/cm2g).
5.1.9 The piston speed shallnot bemore than 0.7m/s. 5.3.2 The desigp of the high pressure drier shal! be
such that the velocity of acetylene ‘shallincrease by
5.2Thetemperature of”acetyleneatthedischargevalve
0.20 to 0.25 mls.
of any stage shall not exceed 140”C.

4
“
4
IS 15190 (Part 2) :2002
Ci,:’
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5.3.3 Before and after the high pressure drier filters 6.6Theworking pressure ofacetylene pipe lines shall ,.,
.,
shall be provided. notbemorethan2548 kPa(g)(26kg/cm2g)absolute. $
.
j
5.3.4 Where calcium chloride is used as drying 6.7Pipeusedshallbeseamlesshaving awallthickness
medium, the drier shall have arrangements for blow calculated as given in 6.7.1”and 6.7.2.
offwith nitrogen oracetylene toremove airafterfresh
6.7.1 Where pipe materials as specified in6.2 isused
charge or after long stoppage f%omuse. ,,
the wall thickness shall be: f :
,,,
!,;.,.;
5.3.5 The drying agent like calcium chloride shall be a) wheretheendsofpipe, bends elbow,reducer, ~.’:.,,
filled inbaskets made ofsteelsheethaving perforation . .
enlarger,joints, openings arestrengthened by
of 5 mm diameter in triangular pitch, or any similar
alength atleast twice the inside diameter of
device, for ease of removal and discharging. ~
pipe and to a thickness twice the pipe
thickness, the thickness shall be 0.16 times
6 PIPING AND SAFETY DEVICES
of inside diameter. The strengthening may
6.1 High pressure piping are the pipes having a becomplied bywelding thereinforcement or
working pressure above 245 kPa (g) (2.5 kg/cm2g) by screwing orby bolting the reinforcement.
for useafter first stage ofthe acetylene compressor up
b) where noreinforcement isusedthe thickness
to filling manifold and for discharge manifold up to
of the pipe should be 0.30 times of inside
pressure reducing station.
diameter.
6.2 Piping and fittings shallbemade ofsteel,wrought
6.7.2 Where any other material isused other than 6.5
iron, malleable iron or copper alloy having less than the wall thickness (t) shall be:
65 percent copper. Unalloyed free silver or mercury
a) Where reinforcements are used according to
shall not be used.
6.7.l(a)
6.2.1 Steel isrecommended asthematerial ofconstru-
ction for acetylene transmission systems. Inapipeline 20x PWD
system, materials forallcomponents likejoints, seals, *=(200 xf)-(20x Pw)
gaskets, diaphragms, hosesshallbesochosenthatthey
are adequate resistant to the action of commercial b) Where reinforcement are not used:
grade acetylene, including its impurities as indicated
35x PWD
in IS 1040 and IS 308 and solvents like acetone (if t=
(200xf)-(35xPw) :...-
present), under the system operating conditions (that
is temperature and pressure) and resistant to where
atmospheric corrosion,
Pw = maximum working pressure in kg/cm’
6.3 AIIpiping and equipments shall be electrically absolute,

continuotis and connected to any g rounding electrode D = inside diameter in mm, and

as defined in IS 3043. f = allowable stress inkg/cm2.
6.4 Pipesizes ofmore than DN25 shallbeavoided as
6.7.3 The length of pipe (straight portion) shall be
far as possible, but in no case pipe size more than
such that itislessthan or exceeds the ‘Predetonat ion
DN40 shall be used. For higher flow, multiple pipes
Distance’.
of DN 25 isrecommended.
6.7.4Thereinforcements ofthepipesasrecommended
6.4.1 The diameter of apipeline shall be finalized so
in 6.7.1 aneed not be provided if flash back arrestor
that the required pressure is available at consumer,
fittedwithnon-return valves areprovided ateach such
with the maximum flow in a given pipe run. It is point. However, reinforcements atthe end ofthe pipe
recommended that the velocities be maintained shall be necessary, as flash back arrestors does not
between 2to 4 m/s for sizing of pipelines, serve anypurpose atthe ends.
6.5 Pipe material shall preferably have not less than 6.7.5All acetylene gaspipeline system shall beprote-
the following mechanical properties: cted.byflashback arrestors and non-return devices or
a combination of both. To prevent entry of air or
Tensile strength, A4in 3430 kPa(35 kg/cm2)
oxygen these should be fitted as near as practical to
Yield strength, A4in 2352 kPa (24kg/cm2)
any outlet point.
Elongation on gauge 28
length 5.65dS0, 6.7.6 The following locations shall be installed with
percent, Min flashback arrestors:

5