Suvidya Institute of Technology Mumbai PIPING ENGINEERING 01/08/2005 Issued for Implementation WN boy Vow tb] DATE DESCRIPTION ‘PREPARED BY APPROVED BY |Smeneyaastitute of Technology Piping Engineering Chapter—] 1. PREFACE 0. pulld Technocrat Engineers and sound Indian Work force to compete Global requirements, young, 2 Conse ait top notch professionals fans ‘Software, Consultancy & Industrial background formed 2 Consortium and Led a Foundation of “Suvidya Institute of Technology” Out of weatth of Detait Technology designed and practical sessions are recognized by Tech, State of education, atest technology & global competion, Suvidya Institute of Drofessional courses with is a combination of Theory, Latest industrial practices, institute ofers number of courses to cover wide spectrum of Iduetian aspects, & Education Board & Industries. 1 tae telures are not at all dry accumulations Of facts but it has way of thinking about things, a way {2 find solutions from obviously Huzziing problems, make you equip to be in lead role. It will ank you competency, °UeMents, which rete key ese knowiedge, and execution power that define competence, Piping el Coss Content has been prepared by Mi, Vasant Mestry (Chairman, SIT) being affliated to piblng Engineering Industry since last 18 years and approved by Mr. V. M. Sheth (General Manager, EnoNScAKER KVERNER POWERGAS Lio) having-vide and.tich experience in the field of Piping Engineering of 30 years, uration Month Eligibitit Diploma & Degree in Mechanical, Chemical & Production Engineering Diploma & Degree in Mechanical, 6 Months Chemical & Production Engineering r5e tress Analysis s Equipment Diploma & Degree in instrumentation & | 6 Months Electronics Engineering Diploma & Degree in Civil Engineering | 6 Months | Structurar Engineering ighway & Bridge —— Engineering Diploma & Degree in Civil Engineering | 6 Months _ HVAC Diploma & Degree in Mechanical & 6 Months Production Engineering | Electrical Sysienc pt = Electrical Systems Design | Diploma & Degree in El .ctrical 6 Months & Electronics Engineerin cra Waste Water) Dpioma & dogs ae Engi [2 Years] Engineering BSC Graduates praineeting Design & — Tr SeceHES a ee Drafting Piping Design & Drafting Ti Draughtsman 6 MonthsPage No. No. Description 1 Introduction to Piping 03.. To... 05 2 [Codes and Standards 06.. To.. 10 3 Plot Pian Development 14..To.. 18 4 | Piping Elements 19. T0.. 27 5 |VaNe 28.. To.. 39 6 |Special Parts 40.. To.. 51 7 [Equipment and Piping Layouts 52.. To.. 73 8 [Basics of Stress Analysis. = ~~~ 74. To., 109 9 [Reference Documents 110., To.. 143 144.. To.. 160 [symbols‘Suvidya institute of Technology Piping Engineering ChHAPTER-ISuvidya Institute of Technology Piping Engineering Chapter—1 INTRODUCTION TO PIPING ROLE AND RESPONSIBILITIES OF PIPING ENGINEER 4. Role of Piping Engineer 2). Design b) Construction ©) Commissioning 4). Operation / Production 2. Responsibilities of Piping Engineer 2). Piping Engineer is responsible for a substantial part of total project cost. b) Economic and accurate design. ©) Co-ordination with other department. d) Meet requirement of compact completion period. ) Co-ordination with site. 4) Modification due to site conditions, 9) Must be adequate to meet the process specification and physical conditions in which’ the plant is to ‘operate. h) Adequate design must be achieve at an economic cost within the project budget. i) Clear, consistent and reliable data, 1) Standardization of engineering design methods. k) Maximum use of standards. 3. What Piping Engineer should know about? Piping engineer requires not only wide engineering knowledge not necessarily in depth, but certainly’ in understanding but he, must also have an understanding of engineering economics and costs, of metallurgy, ‘of methods of pipe fabrication and erection. He must have some knowledge of mechanical, civil, electrical and Instrument engineering so as to discuss requirements and problems with specialists in these fields. This will be more clear with the data piping department requires from other disciplines as given an Annexure A. He should be co-operative, lead or take part in teamwork, be alive to the application of new methods, ‘materials and designs. He must be aware of standards, codes and practices. There are several aspects of engineering technology, which the piping engineer must know something about ~ least suffciently to discuss rationally, any particular subject with specialists concerned. More importantly, he must have sufficient broad knowledge to know that certain conditions can arise at the-early stages of plant design, where lack of awareness can cause difficulties and even disasters. A fairly knowledge of structural engineering is a most. Piping in operation is always in movement and Subjected to pressures and forces with consequent reactions on mechanisms such as pumps, compressors and equipment in general, and on structures and related piping. Lack of knowledge’ can cause errors Sufficient to cause machine or equipment breakdown or to overstress and even cause collapse of structures, ‘Agood knowledge of safety codes and practices is also essential, ‘Above all, a piping engineer should be very well conversant with drafting procedures and practices.‘Suvidya Institute of Technology Piping Engineering INPUTS AND OUTPUT OF PIPING DEPARTMENT ————_____ _ PROCESS DEPARTMENT ‘| OUTPUT OF PIPNG DEPARTMENT * PRID ° PLOTPLAN © UNELST +—— + RACK PIPING © EQUIPMENT UsT + STUDY PIPING OF UNIT © PROCESS DATA SHEET © TENDERING MTO DATASHEET OF ECPTS. * EQUPHENT LAYOUT + PIPING LAYOUT © BULKMTO i PT.GROUP ’ EQUPIMENT DRAWING = |___ * - STRESS ANALYSIS. © PACKAGE UNIT DRAWING © NOZZLE ORIENTATION ew + PIPEISOMETRIC & 470 © AS BUILT DRAWING | ENT DEPARTME ~ = Pen AY WT PIPING | FEG FABRICATED EQPT, GROUP, . | Dy © NOZZLE ORIENTATION _— EPARTMENT + VESSELLUG/CLEAT |___Locarion ELECTRICAL DEPARTMENT CABLE TRAY WIDTH ————_—_—__---] [ com oepaRtwer + GENERAL ARRANGEMENT DEPART DRAWINGS OF PIPE RACK ee mie Sara OF BEM LINCLUDING LOAD . COLUMN FOUNDATION, PIPE + PLATFORMS,LADDER, OVERHEAD RACK, SLEEPERS, : ‘CRANES MONORAIL STUIRCTIRE PLATFORM >} Locanons curourmserr —_, ‘+ TOGELEVATION & LOADANCHOR [ STRESS Deparruew BOLT SIZE & NOBOLT LOCATION ANALYSIS REPORT FOR ALL EQPT. © SUPPORT SELECTION fp 7 | srmess ‘STRESS DEPARTMENT ROMETRICS OF SESS ——s| CRITICAL LINES WITH SUPPORT _Locarion [ wistRumewraTiOn a * CONTROL VALVE LOCATION ‘+ INSTRUMENT LOCATION‘Suvidya Institute of Technology = - Piping Engineering CHAPTER‘Suvidya Institute of Technology Piping Engineering Chapter tI CODES & STANDARDS, ODE; A group of general rules or systematic procedure for design, fabrication, installation and inspection prepared in such a manner that it can be adopted by legal jurisdiction and made into law. STANDARDS Documents prepared by a professional group or committee which are believed to be good and proper engineering practice and which contain mandatory requirements RECOMMENDED PRACTICES : Documents prepared by professicnal group or committee indicating good engineering practices but which are optional, Companies also develop Guide in order to have consistency in the documentation. These cover various engineering methods which are considered good practices, without specific recommendation or requirements. Codes and Standards as well as being regulations, might be considered as ‘design alds" since they provide guidance from experts. Each country has its own Codes and Standards. On global basis, American National standards are undoubfedly the most widely used and compliance with those requirements are accepted world over. In India, other than American standards, British standards and Indians are also used for the design and selection of equipment and piping systems. Difference between CODES AND STANDARDS. Codes provide the design criteria, such as Permissible material of construction, allowable Working stresses, which must be considered in deign. In add rules are provided to Determine the minimum wall thickness, structural behavior Due to intemal Pressure, dead WE, seismic Loads, Thermal expansion ete, ‘Standards provides Specific design criteria rutes for Individual piping components such as valves, fitings, fanges. ‘The STDS are mainly of two Types (1) Dimensional STDS (2) Pressure Integrity STOS Dimensional STDS : They provides configuration control Information for components. The main purpose of Dimensional STD is lo assure Similar components manufactured by different supplier will be physically Interchangeable. This does not imply that all such similar configured mater Products Will perform equal performance wise they may be Different, but their face to face & End to End Dimension are same. Pressure Integrity STDS : They Provide performance criteria. The components designed & manufactured to the same STDS Will fun an equivalent manner. For example, all NPS 10 class 160 ASTMA-108 flanges, which are constructs by the ASMEJANSI STD B 16.5, Pipe flanges &flanged fitings, have pressure Temp Rating of 220 Psig at 300F : 4.0 AMERICAN STANDARDS: Not all American standards are issued directly by American National Standards Institute, The material standards «wre covered under ASTM (American society for Testing and Materials) and dimensional standards under ANS! (American National Standards Institute). Most of these standards are adapted by ASME (American society of Mechanical Engineers). ‘The American Standards referred by Piping Engineers Are mainly the standards by 4.1. The American Petroleum Institute (API). 4.2 The American tron and Steel Institute (AISI). 4.3 The American National Standards Institute (ANSI), 41.4 The American Society for Testing and Materia's (ASTM). 1.5 The American Welding Society (AWS). 1.6 The American Water Works Association (AWWA). 1.7 The Manufactures Standardisation Sociely of Valves and Fitting Industry-Standards practices (MSS-SP) 1.8. The American Society of Mechanical Engineers (ASME). oe‘Suvidya Institute of Technology Piping Engineering APISTANDARDS, ‘The generally referred API standards by the Piping Engineers are 1) APIBL. ‘Specification for Line pipe 2) APIED Pipeline valves, End closures, Connectors and Swivels. 3) API GF Recommended Practice for Fire Test for valves. 4) APIS93 Ductile Iron Plug Valves-flanged ends. 5) API598 Valve inspections and Test 8) API600 Steel Gate Valves. 7) APIEOt Metalic Gasket for Refinery piping. 8) API602 ‘Compact Design carbon steel Gate. 9) API 604 Dustie ron Gate Vaives-flanged ends. 10) API 605 Large Diameter Carbon Steel Flanges. 44) API607 Fire test for soft seated ball valves. 42) API 608 Butterfly valves. 13) API1104 Standard for welding pipeline and facies. 14) API 594 Wafer Type Check Valve 4.2. AISI STANDARDS The American Iron and Steel Institute Standards specifies the material by its chemical and physical properties. When specific model of manufacture of the elements is not to be specified then material can be identified by the AISI standards, The most commonly used AISI specifications are : 1)ASME B 31.1. Power piping. 2)ASME B31.2 Fuel Gas Piping. 3) ASME B 31.3 Process Piping. 4) ASME B 31.4 Pipeline Transportation System for hydrocarbon and other Liquids. 5) ASME B31.5 Refrigeration Piping. 8) ASME B 31.8 Gas Transmission and Distibutor Piping system, T)ASME B31.9 Building Service Piping 8) ASME B 31.11 Slurry Transpiration Piping system. Of the above the most commonly used code is ASME 31.3 Refineries and chemical plants are designed based on the same. All power plants are designed as per ASME B 31.1. Other major ANSUASME standards referred for the piping elements are : O1) ANSI B 1.1 Unified inch Screw Threads. 02) ANSI / ASME 8 1.20.1 Pipe Threads general purposeEx ANSI B2.1) 03) ANSI JASME B 16.1 Cast Iron Flanged Fittings. 04) ANSI /ASME B 16.3 Malleable iron Threaded Fiting 05) ANSI /ASME B 16.4 Cast iron Threaded Fitting 06) ANSI JASME B 16.5 Steel pipe fanges and Flanged Fiting, 07) ANSI /ASME B 16.9 Steel Butt welding Fiting, 03) ANSI ASME B 1.10 Face to face end fo ond dimersions of valves 816.11 ‘orged steel Socket welding and Threaded Fiting, 10) ANSI ASME B 16.20 Melaic Gaskeis fo pipe fanges-ring spiral wound and jacketed flanges. 411) ANSI ASME B 16.21 Non Metallic Gasket for pipe flanges, 42) ANSI /ASME B 16.25 Butt Welding Ends, 13) ANSI /ASME B 16.28 Short Radius Elbows and Retums. 14) ANSI JASME 8 16.34 ‘Steel Valves, flanged and butt welding 18) ANSI JASME B 16.42 Ductile ron Pipe Flanges & Flanged Fittings Ciass 150 to 300 16) ANSI /ASME B 16.47 Large Diameter Steel Flanges-NPS 26-60 17) ANSI /ASME 8 18.2.1 Square and hexagonel head Bolts and Nuts8 2(in & mm) 18) ANSI /ASME B 36.10 Welded and seamless Wrought Steel pipes 19) ANSI /ASME B 36.19 Welded and Seamiess Austenitic Stainless Steel pipe. 20) ANIS/ASME B 46.1 Surface Finish Of Flanges‘Suviaya institute of Tecnology ping Engineering 14.4STM STANDARDS feat mernta"ds Consist of 16 section on defntons and classifications of ‘material of construction and {est methods. Most ofthe ASTM standards are adootca w ‘ASME and are specified in ASME section Il ‘The section Ii has four parts, aa 7 seen 144 Part-A {‘errous materials specifications 742 Patt-B Non ferrous metals specitcation 143° Pait-C Specification for welding materias 144° Part-D Properties of materials, {n Part I, the materials are listed in the Index based on the available forms such as plates, casting, tubes, etc. And also on the numerical index Me Selection of ASTM specication depends upon tho required Manufactures, from of material, its ‘mechanical strength and the corrosion properties, TThe specifcation number is given on Alphabeticelprefix‘A’ for Ferrous materials and ‘B’ for Non-ferrous, ‘materials, 4.3. AWS STANDARDS 7 he American Welding Society (AWS) standards provides information on Welding fundamentals, weld Seite, mers taning qualification, testing and inspection of welds and Suse ‘pplication alec asg Los Individuals electrode manufacturers have gven tok oun Sena eens Various électrodes and are sold uncer these names, 4.8 AWWA STANDARDS ‘The American Weter Works Association (AWWA) standards refer to the Piping elements required for iow Baige damotey somes, These are less shingent than other standards Vawes, anges, at required for 2192 ameter water pipelines are covered under this standard and ane sero rarely by piping engineering here, 1-600 ~ Gate Vales for water & sewage system 1 2)C-510 - Cast Iron sluice Gates 3)C-804 - Rubber Seated Butterfly Valves 4) 0-507 - Ball valves 6°48 8) C-508 - Swing Check Valves 2"-24 6)C-509 ~ __ Resiient Seated Gate Valves for water & sewage. 1.2. MSS-STANDARDA In addition to the above standards and materi! codes, there are standarls Practice followed by Mee Gourers. These publched es advisory standards and ate widely folwed. The mecce ‘common, MSS-SP standards referred for piping are : DMSS-SP-6 —___Standard Finishes for Contact Surface for Flongos. 2)MSS-SP-43—~ ——_Wroughi Stainless Stee! Butlweld Fitings, 3) MSS-SP-56 Pips Hanger Supports: Matarisis, Design and Manufacture 4) MSS-SP.97 Standard for ‘O" let fitings. 20 BRITISH STANDARDS : ie to find a British Standard which may be substituted for American Hangers, For exemple, BS 2080-Britgh Standard for Face to Face / End to End reer of valves is ential to ANS! /ASiE B 16. 10. Simlrly BS 3799 and ANSI JASME B16 11 ane ‘compare, qhere are British Standards referred by Indian Manufacturers for the constructicg of Piping elements Such a8 valves. The most commoniy referred British standarus in the Industy ors‘Suvidya Institute of Technology Piping Engineering 1)BS 1414 - Gate valves for petroleum industry 2)BS 1868 - —_Steel Check Valves for petroleum industry 3) BS 1873 Steel Globe and Globe Stop & Check Valve (Flanged and Butt welding Ends) for petroleum, petrochemical and allied industries. 4)BS 2080 - Face to Face/ End to End dimensions of Valves 5)BS 5143 - —_ Inspection and Testing of valves (withdrawn, superseded by BS 6755) 6)8S5158 - —_ Diaphragm valves for general purposes. 7)BS5351 - —_ Steel Ball Valves for petroleum industries 8)BS5352 - Steel Gate, Globe, Check valves < 2°NB 9)BS6755 - Testing of valves. 10)BS 7244 - Flame Arrestor. 30 INDIAN STANDARDS : Bureau of Indian Standards (BIS) have so far not developed an Indian standards for the design of Piping systom, Hence, ANSI standards ANSI B 31.1/31.3 are widely referred for the design. These standards also accepted materials covered in other standards. Unlike American Standards, Indian Standards cover dimensions and material specification under the same standards. There are also rho grouping done based on the series/ branch of engineering well. Some of the most commonly referred Indian Standards by the Piping Engineers are - 5 4)1S-210 = Grey Iron Casting 2) 18-226 = ‘Structural Steel (superseded by 1S 2062) 8) 11239 = Specification for Mild Steel Tubes and Fitting i Part! 8 ' 40)19 1536 - —_Centrifugally Cast Iron Pipes. 41)1S 1837 - Vertically Castron Pipes. 42)18 1538 - Cast Iron Fitting. 20)1S 2062 ~ Steel for general structure purposes. ‘There are certain other international standards also referred in the piping industry. They are DIN standards of Germany and the JIS standards of Japan. DIN standards are more popular and ‘equivalent British and Indian standards are also available for certain piping elements, Periodic review of the standards by the committee are held and these are revised to incorporate the modified features based on the results of research and feed back from the industry. Although some technological lags are unavoidable these are kept minimum by those updations. Hence, it is necessary that the latest editions of the codes and standairds are referred for the design’and year of Publication also to be indicated along with. MAJOR ORGANIZATION FOR STANDARDS : Sr.No. Country Organization Abbreviation 1 USA ‘American National ANS! / 637° 2. Canada Canadian Standards Association CSA 3... France Association Francaise ‘AFNOR 4 ‘United Kingdom British Standards Institute BSI 5. Europe Europe Community for Standardisation CEN 6. Germany Deutsches Institute for Normung. DIN % Japan Japanese Industrial Js 8. India Bureau of Indian standards. BIS -10-Suvidya Institute of Technology Piping Engineering CHAPTER-LN FO TTPA) DENTELOP IMENTSuvidya institute of Technology ‘Chapter = It PLOT PLAN ‘The plot plan is one of the key documents produced during the engineering phase in any processing Facihy. Irie used! fo locate equipment and supporting infstructure and to establish the sequence of major engineering and construction actviies. Plot plans are used by almost every engineering group with & Srjost tases fores om estimating and through construction, The plot plan is developed by the plant yout Sener, usualy atthe proposal stage ofthe project, and remain the responsibly of the designer togh sea tiauctor, Simiar process units engineered for two clients may look vasly different for various oo eee Tncluding avaiable real estate, soil and climate conditions, and client philosophy on operations, eterna and safely. For these reasons, standardization of process unt plot plans is, dieu: Nevoaheleee, as most operating facities use common equipment (e.g. shell and tube heat exchangers, ecoure vessels, pumps, and compressors) it's possible to apply a few basic rules that sut most clients ahd processes and that enable the plant layout designer to approach the task of arranging the equipment and supporting factities in an orderiy manner. ‘Tho Plot Plan in The Process Unit ‘This chapter highlights the general requirements for process unit plot plan arrangement, It identifies the ‘Mercute reared to cate operating equipment and supporting facities to cuit operator and maintenance ‘access, constructbility, process operation, safety, and costeffective design. Definition : ‘The process unit plot plan is arangement drawing that highlgh's the equipment and SUPPORT feciities Teo nipe racks and buidngs.). These afe required fora given process integrated within @ common Bary (c.g pe vac signed for independent operation and shutdown. The final plot plan identifies al he cares te by designated number and shows, to scale, the basic shapes ofthe equipments and suppoving Free peathg them in both the vertical and the horizontal planes. General, the arrangement is shown f The pon wth elevated vows furnished only for clay (e.g. in the vertically structured plant). Plot Plans deicloped vith tree dimensional cad modeling have the advantage of producing muttple plans, elevators, Se oeet wis views wth no additonal effort. The plot plan is used forthe function discussed in the folowing section, Piping design:- ‘The plot plan is used to produced equipment arrangement studies that facttale the Poon eestor of above and below ground process and ulilty piping systems and to estimate piping material quantities, ing:-_ The plot plan is used to develop grating and drainage plans, holding ponds, dked jon and structural design s, and all bulk material estimates. Electrical engineering:- The plot plan is used to produced area classification drawing fo locate switchgear and in coming substation and motor contol centre, to route cables, and to estimate bulk materials, Instrument engineering:- The plot plan Is used to locate analyzer house and cable trays, assist in the location of the main control house, and estimate bulk materials. Systems engineering: - The piot plan is used to facitate hydraulic design tine, ne sizing, and uty lock flow requirements. Scheduling:- The plot plan is used to schedule the orderly completion of engineering activities. Construction:- The plot plan is used to schedule the erection sequence of al Plant equipments, which theludes rigging studies for large lifts, constructbiliy reviews, marshaling, and lay down areas throughout the entire construction phase. Estimating :- The plot plan is used to estimate the overall cost of the plant. Client use :- The plot plan is for safely , operator, and maintenence reviews and to develop an as built record of the plant arrangement. -12-‘Suvidya Insutute of Tecnology aig Enguweeting PLOT PLAN DEVELOPMENT Developing a plot plan is not an exact science, because the arrangement of the plant must be set at the beginning of the project before all equipment requirements and configurations are finalized and before all of the mechanical problems associated with the design are solved. Plot plan arrangement isa reflection of the designers ability to anticipated mechanical problems and provide the necessary access for operation and maintenance as well as the designer general experience with plant layout requirements. The intended goal is to produce a safe, cost-effective operational plant, which will probably remain in use for 20 years. ‘Therefore, it is important that any errors in arrangements be recognized and eliminated during the plot plan development phase ofthe project because they can be costly to correct once the plant is in operation. ‘The project site is selected by considering the various factors that plant should be technologically and ‘economically viable. The many industrial policies of the government is also need to be considered for selection of site. Important requirement such as power, water, effluent disposal, manpower etc. have also to be taken into consideration. After selection of site next activity is to development'of PLOT as per the requirement of relevant industries like- : i) Refinery ii) Chemical/ Agro Chemical Petrochemical / Organic - Inorganic Chemical. ii) Fertilizer iv) Pharmaceutical v) Power plant etc “The development of plot plan is a much involve job. While locating the various units! facies within the plot, consideration shall be given for the operation, maintenance, safety aspect related to the plant and that of the nelghbored, fre hazards, location of power and water supply, expansion facities, man-material movements, ete. ina balanced manner. Before the activity of development of the plot plan starts, there are a lot of data, related plan starts, there are ‘alot of data, related to all cisciplines of engineering, to be collected and analysed and / or made use of Data to be collected before starting can be classified as follows 4.0 BASIC DATA 4A. CIVIL: Givildata contain survey map and Contour map (for plot levels). The contour map wil also ‘shown the bench marks indicating the mean sea level (MSL) to indicating the mean sea level of the plot. 4.4.4 SOIL SURVEY : conducted to check soil bearing capacity. 4.2. ELECTRICAL: Contain details about voltage supply required to the various plant. 4.3. NON PLANT FACILITIES : covers all supporting facities for any chemical plant like a) Administrative Block b) Canteen c) Workshop 4d) R&D, CC Laboratory and Pitot plan €) Gate Housel Time! Security Office 4) Security Towers 9) Vehicle Parking fh) Medical center i) Ware house }) Fire Station k) Weight Bridge 4.4 METROLOGICAL DATA: 4) Minimum, maximum and normal temperature during the year ) Rainfall 6) Intensity and direction of the wind @) Seismic zone e) Flocd level -13-‘Suvidya Institute of Technology Piping Engineering 1.4 PROCESS DATA ‘These are some typical points and may change as per various types of plants. a) ‘Sizelcapacity of the process unit b) the type of plant, indoors or outdoor ©) Sequence of process flow to locate the process unit in the proper manner. d) Hazardous nature of the plant to keep proper distance, €) The overall operating philosophy of the plant such as, Fully Automatic : Partally Automatic Manual Batch/Continuous ) Raw material receipt and product dispatch, 9) Storage philosophy. Above ground and/ or underground, h) Effluent plant capacity and discharge points. i) Number of fares, 1.8 UTILITY DATA ) supply points of Raw water. ) Quaiity of water. ©) Water consumption ¢) different types of utilies such as Steam, Air, nitrogen, DM water, €) soft water, cooling water, Chilled water, Brine etc. 1.8 STATUTORY REQUIREMENTS : ‘The following authorities set norms required for f the Green belt, Floor area ocoupatién, Floor space roads, Free area to be maintained along the plot boundary, Height and tread of the steps, Floor to Floor distance, requirement of distance to be maintained between the units, requirements within the Petroleum storage and gas storage, fire fighting requirement height of chimney, etc. ) State Industrial Development Corporation (SIDC) ) Central state Environmental Pollution Control Boards (PCBS) ©) Factory Inspectorate 4) State Electricity Board (SEB) ©) Chief Controter of Explosive (CCOE) 1) Static and Mobile pressure Vessel Rules (SMPV) 9) Traffic Advisory Commitee (TAC) h) Aviation Laws |) Chief Inspector of Bolers (C18) }) Ol Industry Safety Directorate (O1SD) k) Food and Drug Administration (FDA) !) Ministry of Environment and Forest (MOEF) 1.7 PLANT FACILITIES : 2) Main Plant Builing ) Usiity Building ©) Effluent Treatment Plant d) Flare ©) Cooling Tower 1) Boiler House 9) Sub station / Electrical Station, h) Tanker parking ) Tank Farm 4) Fire water Tank & Drinking Wester Tank. -14-‘Suvidya Institute of Technology Piping Engineering 1.8 DEVELOPMENT OF PLOT PLAN: While developing plot plant to need following data, 9 3) D) Block dimensions of all plant and nonplant facilities. Wind Direction North direction Rack and sleepers with. Flare location 90 mtr away from any bidg in downward of wind direction. Road width 8mtr, émtr and all inner roads mtr. and 1mtr shoulder required both side of ‘oad (foot path) and then provide storm water drain Both side road required on main plat ‘Storm water drainage for roads. Consider future expansion 50%. , 1 F.S.I. (Floor Space Index) means 50% construction area, Green belt 1/3 of plot area. Tankfarm location down side of wind direction. Cooling tower location downward of wind direction. ETP location downward of wind direction Non expiosive chemical storage Explosive chemical storage as per classification Petroleum product as per classification. Water requirement 24 hrs. minimum: Domestic 100 lit. per person per day Water requirement for Boiler ‘Water requirement cooling tower ‘Washing - 10-15 litres per day per sq. of floor Gardening ~ 5 litres per day per sq. ft of garden area Inter unit distance based on the type and nature of the process. Location of substation approximately center of plot. Safety distance for the storage based on the relevant statutory regulations 1.9 STEP TO BE CONSIDERED WHILE DEVELOPING THE PLOT PLAN ‘Study map and develop grade levels. (RL. Reference Level) ‘Mark grid lines in. X-Y direction at 10 mtr each, Establish the area along the plot boundary as per the statutory norms Work out the area requirement for the green bel, parking ete. as per the norms ‘The process units shall be located in the sequential order of process flow so that material handing minimum also try to reduce rack length. ‘Arrange units considering wind direction as per the requirement, Group storage tanks as per process classification Centralised control room shall be located in safe area close to process plant. Two adjacent process units shall be located based on annual shut down philosophy so that hot work shall not affect the operation, Locate electrical station at center ofthe plot for minimum cabling. Process unit shall be located on higher ground away from the unwanted traffic. Process units shail be served by peripheral roads for easy approach, Utility block shall be Kept at safe area close to process plants. Receiving stations shall be placed near the supply points, Ware houses shall be located close to the material gate to avoid truck traffic within the process area. Locate fre tanks near to main gate. Locate ETP away from process and utility area and down ward direction of wind, Locate Workshop, contractor's shed, storage yard, etc. by peripheral roads. Normally provide two gates one for man entry and other for material handling. Provide weigh bridge at material handling gate. Locate Admn. Building, Laboratories neat man entry gate. Inter unit distances as per statutory authorities guide lines. 15+Suvidya Institute of Technology Piping Engineering 2.0 Layout of Liquid Storage ; Petroletim Act: - Passed in Parliament C.C.0.E. Nap For Maharashtra. Definition of Petroleum: - Any liquid hydrocarbon or mixture of hydrocarbon or any flammable mixture contain hydrocarbon comes under the petroleum Act. i Classification of Petroleum: - Petroleum Product is classified on the basis of their lash pt Flash point.: - The minimum temp at which liquid eyelids vapors and gives momentary fash when ignited, Class A- < 23% Class B- 23°c to 65% Class C- 65° to 93°¢ Exemption from storage tank license, Class A- not more than 30 Littes Class B- not more than 2500 litres, not more than 1000 later. At a place Class C- not more than 45 k!= 4500 litre. All enclosure should have the drain, The slope of the Drain will be not less than 1% from tank toward enclosure. Normally closed Gate valve should be provided outside of enclosure. ‘Storage Tank should be 90 meter away from boiler, furnace stil, except Day tank in Boiler LAYOUT CONSIDERATIONS FOR EXPLOSIVE TANK FARM: @) Petroleum storage tanks shall be located in dyked enclosure with roads all round the enclosure. b) _Dyked enclosure should be able to contents the complete contents o’ the largest tank in the tank farm in case of an emergency. Enclosure capacity shall be calculated after deducting the volume of the tanks up to the height of enclosure, A tree board of 200 mm shell be considered in fixing the height ofthe dyked. ©) The height of tank enclosure dyked shall be at east 1M and shall not be more than 2 M above average ground level inside. However, for excluded petroleum it can 600 mm. 4) Petroleum Class A and Class B petrcleum can be stored in the same dyked enclosure when Class Cis stored together, al safety stipulations applicable to Class A and B shall apply. ) Excluded petroleum shall not be stored in the dyke. ) Tanks shall be arranged in two rows so that each tank is approachable from the surround road. 9) The tank height shall not exceed one and a half times the diameter of tank or 20 M whichever is less. 4) Minimum distance between the tsnkeskelrandhe tank shell and the inside of the dyke wall shall not be less than one half the height of the tank. Height is considered from bottom to the top curb angle. |) Its better that the comer of the bund should be rounded and not at right angles as itis dificult extinguish fire in a 90 angle comer because ofthe air compression effect. }) There should be a minimum of two access points on opposite sides of the bund to allow safe access escape in all wind directions. ; ') Distance to be observed around facilites in an installation shall be as per the relevant chart furnished in the petroleum Rules. LAYOUT OF GAS STORAGE: 2) Storage Vessels are not allowed below ground level. They are to be installed above ground level. b) Vessels shall be located in open. ©) Vessels are not to be installed above one another. 4) __ If vessels in the installation are more than one the longitudinal axis of vessels should be parallel to ‘each other. ©) Top surfaces of vessels are required to be made in one plane. f) Vessels installed with their dished ends facing each other shall have screen walls in between them. 9) The distance to be observed between two vessels in one installation and distance from building or group of building or ine of adjoining property are given in Table 1 & Table 2. h) The area where vessels, pumping equipment, loading and unloading facilities and direct fired vaporized are provided shall be enclosed by an Industrial A type Fence at least 2 M high along the perimeter of safety Zone }) The minimum distance to be observed around installation shall be as per the guidelines in SMPV Which are reproduced in Table 1 and 2. -16-‘Suvidya Institute of Technology Piping Engineering TABLE 1 itres) PHY Of Vessels (in | tlm ist Building or Between pressure ep ms Property )EGvae | nacre ar Sretes Teves Not above 20,000 1.5 metres Nv ‘Above 20,000 but 20 metres + 7 Sais at [Peer a a TABLE 2 son srr rane Fon wont cass r-. ‘Minimum distance from v Not above 2000 Smetres Timeire oe W “Above 2,000 but — ‘S metres. 75 metre ~ mW ‘Above 10,000 but 10 metres (02 meires ies Note: The distance specified above may be reduced opinion that additional safety measures have been provided, by the Chief Controller in cases where he is of the - TABLE-3 MINIMUM CLEA BE CONSIDERED IN A PROG! (As per OISD guidelines ) 1 | Process units to fore 90M 2 | Storage tanks class A/B 0.50 or 18M for cless VB, 6M for Class 3 | Storage tank to vehicle 15M~ Class A'S Lntoading 3M Class © 4 | Vehicle unloading to 15M~ Class AB boundary facing 3M Class C 5 | Storage tank periphery 18M~Class 18 to boundary facing 45M~ Class C 6 | Electic substation to 15M process unites 7 | Head room over mai 76M refinery roads 8 | Head room over main 6M service roads 9 | Head room over 48M ~forcranes secondary roads 36M ~ for trunks age‘Suvidya Institute of Technology Piping Engineering Mi OY i al ly AS in ae Oe Ce a fh tl a aistalelsl Ff ll eae Sssuvidya Insitute of Technology Piping Engineering CHAPTER-DVY‘Suvidya Institute of Technology Piping Engineering Chapter IV PIPING ELEMENTS 1. Pipe Pipe is identified by NPS (Nominal Pipe Size) or NB (Nominal Bore) with wall thickness defined by “SCHEDULE NUMBER". Non Standard Pipe is specified by nominal size with wall thickness stated ANSI Standard B 36.10 establish wall thickness for pipe ranging from %" to 8", Small Bore pipes normally use 14" NPS to 1%'NPS, Large Bore pipe 2° & Above and not commonly used pipe sizes are 1%’, 214", 314" & 5° Straight Pipe in SRL (Single Random length) is 6mtr & DRL (Double Random Length) is 11 meter. The end of these length are PE (Plain End) for Small Bore & BE(Bend End) for large Bore (Butt Welded) Pipes. The most used Steel pipe fro Process lines and for welding Bending & Coiling is made to ASTM A-63 or ASTM A ~106. Both pipe is fabricated seamless or seamed by ERW in grade A& B. Grade B have higher tensile strength. Three grades of A106 are available Grade A, B, & C in order of increasing Tensile strength. Methods for Joining Pipe. Welded & Screwed Joints: Line Sizes 2° Above are usually butt welded this being the most economic leak proof way of joining larger diameter piping line sizes 1%" & Below are usually either screwed or socket welded. Socket Welded Joints: Like screwed piping, socket welding is used for lines sizes 1%” & smaller but the advantage that absence of leaking is assured this is a valuable factor when flammable, toxic or radioactive fluids are begin conveyed the use of socket welded joint is not restricted to such fluids etc... Bolted Flange Joints: Flange is expensive. For the most part are used to make with flanged vessel equipment, valve & for process lines which may require periodic cleaning. Flanged joints are made by bolting together two flange with a gasket between them to provide a seal ‘Components for Butt Welded Piping System Where Used | Advantage Disadvantage | How ointis made For mest process, uly Most pracicabie way of | intruding weld metalimay | The end ofthe pipe is and sence piping johning larger pipes & | affect iow Fitings are similar fitings which ofers beveled by the BurT- reliable, leak proof manufacturer. The two WELDED Joints, pars are algned, properly ‘gapped, tack welded, 8 then a continuous weld is ___| madeto complete the joint. Fornes conveying | Ensoraigamenton | 1. The 11@nch recess | The end ofthe pipe i flammabie,toxe, ot | smalines than butt | joint pockets nui finished ft. tis located in expensive metal, | welding. Tack welding fs the iting, vabe, flange, where no leakage can be | un-necessary. 2. Use not pemmited by __| ete, and a continuous fitet SOCKET. | permited.Forsteam:300 ‘ANSI B31.1 1969 i severe | weld is made around the WELDED | 19600 PSI&semetime | 2Nowold metalcan | vibration or crevice Grcumerence. 450PSISteam For | enlerbore. comosion is aniipated Coresionconditons, 00 index under 3. Joint wil nt leak, “Contesion’ wien property For ines conveying |". Easily made rom pipe | 7. Use nol permited by services, and forsmatir | & fins on site ANSI 31.1 1869 severe process piping. erosion, crevice comosion, 2. Minimizes fre hazard. | shock, or vibration Is ‘when instaling piping in| anticipated, nor at area where flammable | temperatures over 925 F. .gase8 oF Kquids are SCREWED resent 2, Possible leakage of joint 3. Seal welding may be required. 4, Strength of th pipe is reduced, a8 forming the ‘crow thread reduces the wall thickness. -20-Suvidya Institute of Technology Piping Engineering 2. FITTINGS: Fitting's permit a change in direction of piping, a change in diameter of pipe or a branch to be made from the main pipe. Threaded fitting have pressure class designation of 2000, 3000, 6000. Socket welded fitting have Pressure class designation of 3000, 6000, & 9000. CORRELATION OF CLASS OF THREADED & SOCKET WELDED FITTINGS WITH SLIDER / WEIGHT OF Pressure Class 2000 3000 6000 9000 Threaded Fitting 80xs 160 xs, Socket Welded 80Kxs 160 XxS ‘Some ofthe fitting are: a) Elbows :- Elbows make 90 & 45 changes in direction of the run of pipe. The elbows normally used Long Radius (LR) radius is 1.5 D Short Radius (SR) Elbows are also available Radius is 1D. Elbows - 45° , Long Radius Elbow BUIT WELD ELBOW, (R=L5D) b) —_ Reducing Elbows :- Reducing Elbows are also available to make 90 degree change with change inline size. -%4-Suvidya Institute of Technology Piping Engineering ©) Return :- Return change direction of flow thru 180 degrees, and is used to construct heating coils, vents on tanks, etc, 9) Tees: Butt — Welding Tees, Straight or reducing are employed to-make 90-degree branches from the main run of pipe. Straight tees, with branch the same size as the run, are readily available. Reducing tees have branch smaller than the run. Bullhead tees have branch larger than the run, and are very seldom used but can be made to special order. None of these tees requires reinforcement. ~UTTANELOING Tees ) Reducer (or Increaser) :- joins a larger pipe to a smaller one. The two available types, concentric ‘and eccentric. The eccentric reducer is used when it is necessary to keep either the top or the bottom of the line level- offset equal % x (larger ID minus smaller ID). -22-‘Suvidya Institute of Technology Piping Engineering f) __Swage :- is employed to connect butt-welded pipirig to smaller screwed or socket ~ welded piping. {In butt-welded lines, used as an alternative to the reducer when greater reductions in line size are reducers, Fequired. Regular swages in concentric or eccentric from give abrupt change of line size, as do 4 9) Mitered Bend The use of miters to make changes in direction is practically restricted to low- Pressure lines 10-inch and larger if the pressure drop is unimportant; for these uses regular elbows would be coster. 2elece miTER Mitre Bend 90° h) pipe. Suitable where extreme temperature, shear, impact and vibratory stresses apply. Regularity of the bore is maintained. WELDINGAECK FLANGE Welding-Neck Flange, Regular & long:- Regular welding-neck flanges are with butt-welding fitfings. Long welding-neck flanges are primarily used for vessel and equipment nozzles, rarely for anim 393128: *23-‘Suvidya Institute of Technology Piping Engineering Slip-On Flange: Itis cheaper fo buy than the welding-neck flange, but is costier to assemble. itis. ) easer to align than the welding-neck flange. Calculated strengths under internal pressure are about one third that of the corresponding welding-neck flanges. EB vanor roree j) Reducing Flange:- Suitable for changing line size, but should not be used if abrupt transition would create undesirable turbulence, as at pump connections. Available to order in welding-neck and eccentric types, and usually from stock in slip-on type. esos 800401 (ZL ol é Expander Flange:- Application as for welding-neck flange-see above. Increases pipe size to first or second larger size. Alternative to using reducer and welding-neck flange. Useful for connecting ta valves, compressors and pumps. LySuvidya Institute of Technology eee Lap Joint, or ‘Van Stone! Flange:- Economical i costly pipe such as stainless steel is used, as the flange can be of carbon steel and only the lap-joint stub end need be of the line material. A stub end must be used in a lap-joint, and of the same material they will be more expensive than @ welding-neck flange. Useful where alignment of bolt holes is difficult, a8 with spools to be attached to flanged nozzles of vessels. m) ‘Stub-In:- Term for a branch pipe welded directly into the side of the main pipe run-it is not a 5, “This is the commonest and least expensive method of welding a full-size or reducing branch for pipe 2-inch and larger. n) Special Fittings : 2 BRANCH‘Su vidya Institute of Technology Piping Engineering Special ftings Contd, 9) socxoLeT ‘THREADED LATROUET Bolts & Nut : ‘Two types of bolt are available in the market. Machine Bolt and Stud Bolt. They can be fullyor partially threaded but full threaded bolts are preferred. In Industry generally stud bolts are used as fasteners but for blind holes on equipments Machine bolt is the only option. Length of the bolts is calculated as per ASME B16.5. Nuts used are of hexagonal shape. And for machine bolts Hexagonal head is preferred. For low pressure, low tem machine bolt otherwise use studs The Bolts are provided with hexagonal head hexagonal nuts & Washer. STUDS are provided with hexagonal nuts & two Washers The length of Joints of all pressure class are specified in ANSI 16.5 ——-'8)) “om 7 -262Suvidya Institute of Technology Piping Engineering can be mainly categctized in to two types — to ASME B16.20 and nonmetallic gaskets to fed in to Spiral Wound, Corrugated Metallic an metallic and Non Metallic. Metallic "ASME B 16.21. Metallic Gasket .d Ring Type Joint (RTJ). p) Gasket : Gaskets gaskets are referred can be further be divid Ty y T ey oY lov. é NARS TIPES OF CipmrGe 5.2; Tongue aud Groove Joint To wis cn lov,Suvidya insutute of Technology Piping Engineering CHAPTER-V VWALWESSuvidya Institute of Technology Piping Engineering CHAPTER -V VALVES 4. BALL VALVE Ball valve is also an Isolation valve but in some cases it is also used as a regulation valve. It is preferred where the quick opening/closing is desired. Ball Valves are also designed to be operated fully open or fully closed with any liquid containing particles that could scratch the ball. Many people use them successfully for throtting clear water. Ball valves have low pressure drops, open and close quickly, are simple, and are ‘rouble free. With the development of Teflon seals, ball valves have grown in popularity. Opening or close in aball valve too quickly can cause fd hammer. Tne | Nenana 7 | Suan] Rea | as asta 0199 GB - Ms ASTM 194 Ge 2 ° 3 | boa 7 [cus ace za 65 (STH Az Ge WEB) BNE 35 (5196) [ss asia, [ew eH) oO 6.0 © o E:N oltbles F: PCO G : le Ol. TA 7 “ate lelole wm] [a | ep z Es AT — ze | | 2 |v |» 2 wpafefefolfelela [oa | vos | 25 [io | 0 | eo | a a @ Le 2 = ne | 6 [a | oo 70 | is = ver fa | a v08 | 2 2 2 2 7 [es [ep pm] + wo [me [ae fe pie] [0 | vos |r foe | «| 0 | a © « . . ao [a |e [0 we |e [25 [268 | 105 | 2 | ant wo | a7 | 216 | 8 | am 0 [ee | eo | ze | 2 Le -29-‘Suvidya Institute of Technology Piping Engineering: 2. GATE VALVE Gate Valve is an Isolation Valve which is not preferred to be used for regulation. Gate Valves are designed to operate fully open of fully closed. Because they operate slowly they prevent fluid hammer, which is detrimental to piping systems. There is very litle pressure loss through a gate valve. In the fully closed position, gate valves provide a positive seal under pressure. However, under very low pressure, ie. 5 psi, light seepage would not be considered abnormal with this kind of valve. Size range: 15 mm to 300 mm Flanged to ASA, DIN or BS for class 150 and 300 Parts List and Materials of Construction No. Part ary. Materia! 1 Body 1 | ASTMA351 CreMicre I: 2 Bonnet 1 | ASTM A351 CrBMiCFa 3 Wedge 1 | ASTM A361 CFBM/CF8 Ne 4 Stem 1 [alsisteraisiz04 5 Gland Sleeve 1 [ AIst3iB/aisi304 6 Yoke bush 1 | Phosphor Bronze 7 Gland Flange 1 | Carbon Steet Cr. ploted 8 Clamping Stud | Asreqd] Carbon Stee! Cr. plated 9. Clamping Nut As requ. Carbon Steel Cr. plated 10 Gland Bott 2” | Garhon Steet r. plated 11 Gland Nut 2 | Carbon SteetCr. plated 12 Key 1 | Carbon Steet cr. plated | 13 Nut 1 | Carbon Steet Cr. plated | 14 Hand Wheel 1 | Malteable ron/Castiron 15 Packing As reqd.| Tellonv/npregnatod asbestos. 16 Gasket 1 || Tefton/Compressed Asbestos Note: 1 1) Alternatively valves ean be provided with renewable seat-rings. 2 Valves are algo available in ASTM AQ51 CF12M/CF12 Material ‘Sectional View of a Cast 8S. Gate Valve. Dimensions (mm) A Asnbos c she ASANDS cues 150 300 ASARSS Ti Clase 180" Class 909 Closed’ Open ‘Open Claee 160 Clase 300, maa 1997-1480 m8. 5 Ws ia 17 958 fee yao mo . msm 2eo 2D mono 9° 230 a m8 m8 as aso mss wos 2a 5B aS 8 ms’ RS ass e200 za. Sts. aes S70 (280 3 aa) eer os = 300 F ir, Me OOH woos. 80 DESIGN FEATURES: 1) Designed for exceptionally low pressure drop 3) Two piece design of gland flange provides 2) Back seating arrangement permits the re- centralising effect to the gland sleeve, thus placement of packing with valve under fully producing a uniform clamping plressure on open condition. the packings. -30-‘Suvidya Institute of Technology Piping Engineering 3. GLOBE VALVE Globe is a Regulation Valve. Globe valves, as is the case with all valve designs, have both advantages and disadvantages. Like a gate, they close slowly to prevent fluid hammer. You can throttle the flow and they will not leak under low pressure when they are shut off. Flow and pressure control valves as well as hose bibs generally use the globe pattern. The disadvantage of this design is that the "Z" pattern restricts flow more than the gate, ball, or butterfly valves. Parts List and Materials of Construction No. Part Ory. Material 1 Body 1 |ASTMA351 CFaMICFS. 2 [Bonnet 1 [ASTMA351 CFSMICFB. 3 [Disc 1 [ASTMA351 CFaMICF 4 |Stem 1 [AIsi3te/Aisi 304 5 |Glond Sleeve i [aisi3ie/aisi304 6 [Retaining Ring 1 falsi3ie/AIsi304 7 [Yoke bush 1 [Phosphor Bronze 8 |Gland Flange 1 |Carbon Stee! Cr. plated 8 [Clamping Stud | Asreqd | Carbon Steel Cr. plated 10 {Clamping Nut ‘As reqd. | Carbon Stee! Cr. plated 11 | Gland Bott 2 |Carbon Steet Cr. plated 12 |Gland Nut 2 | Carbon Steel Cr. plated 18 |Grub Screw 1 | Carbon Stee! Cr. plated 14 |Nut 1 |Carbon Steet Cr. plated 18 |Washer 1 [Carbon Stee! Cr. plated 16 |HandWheel 1 |Malleable IroniCast fron 47 |Packing ‘As reqd.| Teflon/impregnatod asbestos 18 |Gasket 1 |Teflon/Compressed Asbestos 19 |Seat 1 [Tetton 20 |Nut 1 [alsiste/atsts04 ‘Valves are also available In ASTM A351 CFIAMIGF 12 material Sectional View of 8 Cast $5. Globe Valve. (DIN) oO Dimensions (mm) iT 2 - ~ € Tie ASAB OS oN SAKES aT SaaS Gin 19_cas0 N01 Goan 1 Gansta _NOTBNOW Gass 50 _clsea00 NTO 016 _“Ciosed Open Goned__Open_Gosed__Oben N16 ams CHS Bee Be Mom, mo oa 8 meres i ee ao Pe US em Bem Be me te a ne rr a re re ae ee Mm es. eo SSD SBR Bo bs mes sss 200880 Fee ee ee Mo. Sas cs, bess asso goo as 00 | Bee Be ooo ao DO 8D Fn ee ee DESIGN FEATURES | 1) Back seating arrangement permits the | re-placement of packing with valve under \ fully open condition. 2) Two piece design of gland provides cen- i tralising effect on gland sleeve thereby producing uniform clamping pressure on the gland paking. Cast Stainless Steel type 916 & 304 Globe valves-bolted bonnet outside screw and yoke Size range: 18 mm to 200 mm Flanged to ASA, DIN , DIN of BS for class 150 & 300 ND 10 & 16. -3I- Sectional View of Cast 8.5. Globe Velve. (ASA & BS)Suvidya Institute of Technology 4, BUTTERFLY VALVE Piping Engineering Butterfly Valve is also an Isolation Valve and in large bore itis preferred over gate valve due to its low weight and compact design. Butterfly valves, like ball valves, operate with a 1/4 turn. They are generally used for handling large flows of gases or liquids, including sluries, but should not be used for throtting for extended periods of time. They are also very compact relative to flanged gate and ball valves. ‘Technical Data Specitcatlons Slee range: $0 to S00 mm Pressure rating : 16 bar max ‘emp. rating: Malo wil be selected according w service. Materials of Constrton : Body + Cast tonto IS: 210 Gt. FG 260, ‘ie iegraly mowed ise. + ClIS 210 FG 260 Nite Encapsuates. ‘Aist304 7 AISES16/FO 260/Pb/86 par {Ghents Specication (on epocie order fat eda col). Shaft -: AISI 410 (Heat rote) ‘No valle wih special FRICTION-LESS Toton PTFE coating Standards + Valves comply wit 88 5155, API 609, MSS SP 67 ar 180 §752 Valves designed to Fe ‘wthout gaskets betvogn fanges ole to ‘ANSI 125, OIN. NO 10/16, 8S 10 tabios DE and F of BS 4805 PN 10/16, abos 6, 7.8 of SG418 and Toblos 11, 15 817 riss302. | Engineering Options = 1. Gear Operation on request, 2. Pneumatic / Motorised Acuation on request 2. Extention Spindle, Chain whee! Arrangement on request Dinshslrwinnm Nn: Fao face cimensins genie ins condo wh ne compressed) —Froelngh exceeds Wis cen by 5mm may, depending on ev ze ie dmarson rconet tation novaTinG msien, ‘sec was -32- [ouensonarormns ines Varese Wee ] 15] 120 | 200] 280 | S00 LS |e fe | so | Face be 2 we fe |e] 7 v8 za | ae |e | ot Body at © Cae in oiop oF Bin | a | ea | 08 | 300 | ar Fw ene ve Gen i bons sae | a7 | vee | yee | Bar | Bre B Masinon da of boo “ea | vee | F670 396 | see Msi ngs dae ‘a0 | 200] 900 | 620 | 20 | ozo Fw contd oor TE Lengo fed oparr | tao | 190 | 19 | 320 | soo | 300 [vas | aes | aa Fw cota vor Na Giant ot a | a | & | 2s | tor | tee [ions aoe | 200 protrude det | L |Suvidya Insitute of Technology Piping Engineering 5. PLUG VALVE Like the ball valve, a plug valve has an unobstructed flow, yet requires only a 90 degree turn to open it. It also requites very litle headroom. Stem corrosion is minimal because there are no screw threads. Almost all plug valves now are furnished with an elastomer-coated plug and will seal off drip tight. However, plug valves are available in much larger sizes than ball valves and are highly suitable for highly viscous fluid. Technical Data: anvtaeturing Sid: MSS SP -73 Testing St. BS 5146 End Connections: Flanged to BS 10 Todo D, € or F/ Sctowod BSP /NPT Material Boxy [GIS zIOGAFE =H) Fiug | 1S 210 GRFG 20), Shinioss Steal 304 Working & Test Pressures : Material Specifications : Body - Cast Iron ((S 210 Gr. FO 220) Plug - Cast ron (IS 210 Gr. FG 260) Nuts /Bols = Carbon Steet OTe Bares ody ea | Toged 05t-0" 0 Fanped st | 0 [Semmeaase 0 Fisgod CASS 128 0 Ssiewed ASA 0 Dimensions : Toaaiba. aS [ies ae at [10 [8 aor oe Edie End Serwesy | 65 | 114 | 18 Features. ‘The simple and robust design of Hawa’ seif lubricat- ing plug valves makes them specially suitable for» processing industries handling gases and liquids, ‘where smooth flow of liquids without clogging, is essential Manufactured in close grain cast iron, Hawa selt lubricating plug valves are precision built for longer lasting, rouble free service. ‘The valves incorporate a rotary tapered plug ina taper seated body, with a device to renew lubr- ‘ants. The lubricant eases plug rotation and also serves to complete the seat, ‘The valves provide an absolute tight shut-off with operational ease. An important designing feature of these valves ensures automatic lapping, grinding and self lubrication while in operation. ‘The lubricant grooves in the plug and the corre- ‘sponding recesses in the valve body are so located that whenever a lubricating groove crosses a post during rotation, itis automaticaly isolated fromthe lubricant supply and other grooves. Thus, the loss of lubricant into the pipeline is prevented. ‘The above features make Hawa Taper Plug Valves ideally sultable for processing industries for flow ccontrof of gas and liquids in normal or viscose form.‘Suvidya Institute of Technology Piping Engineering 6. CHECK VALVE itis basically @ directional Control Valve which allows the flow only in one direction. itis available in Lif type ‘and swing type and now a days wafer type check valve is also becoming popular because of its low weight and compact design. Technical Data : WareR Manufacturing Std. = 85 1868 Tee Tasting & inspection Std. API 595/85 9146 Face Face fo per ANSI B 1810 US End Connections "Flanged 3s per ANSI B 165 AF/BS 1860 wAe , cs = = [ asta aas 6 oF win 2] ema 7 + [bee 1 [es wih | Seat Ring 1 [CS wath 13% Ct. Facing Tioga Sat br Ay Sale [amr 7] ste a, 20 o | Beat 1 [asm a oc wc i" [ asm ss 6c crac 7] eer 7 [asm aie owe 7st x crCTONETN oe ea Congres Aes Fn 9 | Suse ne ASTM AN Ge OT | Gow Pas ar Ww [asta se 6 crac — 1 | Bracke siocinien ‘CARBON STEEUSS. 9008 316 tao | roo Pate | 750 PSG eo | 2175 PIG | 600 PSIG 559 fez | SBERVIGE FATING Ee Gas. | Press | Tom ‘0 | eco | ver | om sso | weorsia | sore ‘ores | aor worse | aor © a Piste in Coed Poston Diet Open fst Paes ly opened Tap View slow begins") under mal flow DUAL PLATE CHeck VALVE Lier Type creck VALVE 3Suvidya Institute of Technology Piping Engineering 7. NEEDLE VALVE Needle valve is a type of globe vaive only with the wedge having needle shape. It is used for precise control of flow. Rest of al features are same as globe valve. -36-‘Suvidya Institute of Technology Piping Engineering 8. DIAPHRAGM VALVE Diaphragm valves are used whenever either the fluid is highly corrosive or high degree of purity is required in process e.g. pharmaceutical and food processing industry. nto e6by Wancko ens UNL BODT- RANGED NOS SEAEATD ENDS DIMENSIONS IN MILLIMETRES t Tbs) wpe]? Nonoa Sie Tama jor [one TOF [fo to 05 | Fa navor [rene to2[remroa| ¢ | ¢ : 5 se 108 WS cy cs 30 zo a uw pte om a eC) : 75 io] ar] 8 Toa a7 7 . Ea fry 6 153 135 17 130 ~ @ wo [ss] 67 150 er 8 so ies 180] 198 1 176 wa a mo [ a8 36 8 30 28 a Loe 130 aes [280 100 [os | ee 785_ 8 aus | ene fua 918i[SNL20 = [9] ae | 395 200) 700 530 — Te 495, 350 Peay, — 565 350, 200 ro ee TI 700 ~r “Face Dimensions of Flenged Valves Conform 10 85: 5156—1974 “Tomaner on Dnansins ‘owe Op snare 200 ‘3800200 wp loan nce 400 = ; ‘ore 400 op snd nog 800 ‘ore 600 : ANFORMATION REQUIRED WHILE TECHNICAL SERVICE NQUIRINGT7ORDERING. . ate ‘Ak toam of qualified and wollexperisneed ‘engineers Nomina ican Figure Number. slocesi parr eens ear a Fluid to bs handled ‘selection and application of Leader Valves. Maximum Working Pressure and Temperature iaronant ‘Whether flangas are. feqhired ile, if nothing TANT: is specified, flanges aio left undid. ©" pue to contiaubus. development. programme the dosign and data. given in this leaflet are subject to Scoop of inecton itt 'be_caried at at our 2 SINWeiks bole’ despatch. «Change without notice, 1Suvidya Institute of Technology Piping Engineering 9. FLUSH- BOTTOM VALVE. Usually a globe type, designed to minimize pocketing, primarily for conveniently liquid from the low of a tank, | ANGLE OF OUTLET: 6a “Cone ing | 1 $5306 Seniag | [Ten aoe see] 1 ssa io [ssa 1 ssai6 TP se55e Gast Paton a Yeuebara OA] casenseel——| ‘Gian Sud Nal | P| Caton Se “harteeerg [1] Caton Se Tarawa] “2 | Caton See Tat [OT ean oi 1 ie Tid Tea Presse Boy PSIG wee ee warps bee et @ | ie [40] 89 | 0 ae [52 [of [90 zr [wo] 4 199 Fra [eat | 19 10 Boal EV See | SERIES : 9000 HANDLE, VISCOUS, SLURRY, CLEAN, FLUIDS. c ‘ALSO FOR FERMENTATION SERVICES: sizes’: 1" Thru 12" RATING : ANSI-150/300& Equivalent in BS/DINAIIS = 3:77- iw 2 16 Thru 1200Suvidya Institute of Technology Piping Engineering 9. SAFETY VALVE ‘An automatic pressure relieving device actuated by the static pressure upstream of th valve, and characterized by rapid full opening or pop action. It is used for steam, gas, or vapor service. 1 sorte 4 * Sate vale (Courteay Cresby-Ashion Valve 10. RELIEF VALVE ‘An automatic pressure relieving device actuated by the static pressure upstream of the valve, which opens in proportion to the increase in pressure over the opening pressure. *. ot vai, (Courtesy Cretby-Ashton Valve C2)Suvidya Institute of Technology Piping Engineering CHAPTER-VI‘Suvidya Institute of Technology Piping Engineering Chapter—vi SPECIAL PARTS 1 STRAINER ~ Basket strainers and Y strainers each have design parameters that wil G Specie applications. Taking a ite timo to identity application specif wil nena tet you select a Strainer that will perform as expected in your piping system, 14 1.2 BASKET TYPE: Maximum Capacity with Minimum Pressure Loss ‘The Basket Strainer prevents costly shutdowns and protects yaur piping system and equipment, Ideal for Steam, air, water, cll and gas lines, our basket strainer removes the dit from the system that can damaae ‘moving equipment, Strainer also helps maximize the life of pumps and other equipment. Ruggedly constructed, it features a closed bottom and cast iron drain plug, Stainless steel basket for lon life, Available in sizes from 2° thru 20°, body castings and strainer screens are available in a variety of ‘materials, perforations and mesh linings for virtually every application, Atea tastitute of Technolo Piping Engineering Eimensions Cappooxtmate)in mm. FoR C-1 SoA 5 © | MAXW.PRESSURE & TEMP FOR IBR Cl. SE (aso STRAINER E i387 165.1 2052 [2286 eNSIONS CAPpreximale)in mm. FeR(ce ene . [S10 TABLE FTI ois [sao 87 150.450 | 150_[ 160" 4873 =f i5.0 ¥e5_|165_[-165| 05 [203.2 200 [200 | 200~|"200 [344.5 =| 220" | 220 [2351235 | 298.5 5080 | 395 | 405 | 425 [450 | 6500) 2033 203.2 esprars. 4laSuvidya Institute of Technology Piping Engineering 2. STEAM TRAPS : {igam Trap isan automatic valve for discharging condensate from steam ne without releasing steam, ‘Various type of steam traps avaiable inthe market. Somme ofthe commonly used steam traps are Fey GRMODYNAMIC STEAM TRAP : This is nothing more than a stee! pate with a hole. Some are grfed afer a pancake bind and others are made es an integral part of a union, The basic princpel bono Waar a? 8 that the expanded volume of steam compared to condensate has a toting effect ot tre cree wee BroPerly sized orice, condensate, at its lower specific volume wil pass through the opening at a Fa teetalivaly Slow vetociy, As steam begins to reach the orice plate the condensate wil begin fo oxpana ‘Behe condensate expands, the velocity through the orfce wil increase and the thrtting action wil eto Tress According to the laws of physics, you can have mass flow or you can have Increased velocty through a fixed opening but you cannot have both, Disadvantages to this trap are its limited capacity range, its inability to discharge a large volume of air at Startup and its tendency to be nothing more than a leak source when live steam reaches the orifice If fine Steams allowed to blow through the orice for an extended period the orffee can becorne enlarged through fresion, This. over time, provides a larger, more erratic, opening. Which, in turn, provides an increasingly larger and costler leak source. 7 Sizes and Pipe Connections : 15 NB and 26. NB Semwed 8S? NPT Socket Welsabie ends imiting Conditions PMO ~ Max. operating pressure for sewed ends 31.84 kg cm? PMO ~ Max. operating pressura for SW. ends 44.0 igen! TMO ~ Max. operating temperature ware Coll hydrate test pressure B80 kent PMOB ~ Maximum operating bese pressure on outlet should pot ‘excved 80% of net pressure Miimum inlet pressure lor sststaciony o Materials aes Aisa 5 Svaher Can Optional extras STUB Aa insulating cover ipatton To pe unduly influencad Ey excessive nes ins sth as when seta 10 lw outside temperatures, win, ov. et Installation : Peter n hvizonta pipe with cise ontop. Car be fie in ther postions it unavoibia, Sallent Features : 1 Complete stoniss steel constnicvon arsutes better mechanical end corrosion esisiant pronerios 2 The disc and seat hardened by a specie swustion hamring RODeSS to aout 45 RC to arable withstand cones water ammesing condition, 23) Seet nie part of the body, etnseatogfsroga -wrore ins teed gaskets. 4) Condensate enty below the ess concn to discon, Erautes clean ord corte it of ise with teleerc 1o 2a ‘ eliminating any lecakzed weor and toa, 5} Aninbult stsiner screen of alequtaly geo fd trouble tree operation ™ 42 ensues angSuvidya Institute of Technology Piping Engineering Gpplcations include drip legs, healing cols, steam tracers and various process and utity requirements Gensideration, asin the dsc trap, must be ven to providing suficent Upstream pipiig capacity for the aeotine avon Of condensate. As with the disc tap and the Belanced Pressure tap, the designer srowia Provide an upstream reservoir suficent enough to contain the residual condensate preventing it trex, Backing up into equipment. A 12" to 18° run of pipe, in most cases, should be sufficient: If the possibilty ast {or the flow rate of condensate to fuctuste to a point ator above the capaciy of the trap alonger e- {ager dlameter section of pipe may be required in order to contain the condensate between the ee ave equipment. Description : Thermostat Seah Trapiir Van ited 7th an Oui at sing 000 heving 08 mm. perforions , 7 Vv Sizes and Pipe Connections : 15 89 nd 20 3, Screwed BSPTINET Seeket Welt Fss Limiting Conditions Asxirum Operating Condons PMO" Moe Opeatrg Pressure 71 ta MO — Max Opening Temparuio soe Cold totes presse ate Materials - No. Part Materal = ~~ i Gor Forges aon Saad 167050 2. ese Sisioes Ses! 7A 307 3. Wake Se sia Tt 5. Steer Sean” Suinea Sta Toe 5 Cove Gatat —— Compresseeasbosios Fe 8. Boy Ferg aon 1S HoH — 1 tore SSRIS Sad A sae — d Azle spats te shown ove! 18h epproved 8°12) anc AY 2 canbe supped on request I Dineslon point) iim [ ee 1 Nae ee t a i a Capsule Filling For BPT 21 Capacities: Chart For SPT21 Siac he tap is spd wit ig C whi wil open es Char ‘opruinatey 29 coburn temper saa AS an ononal stesive ie vapcn ce pies wih Weg 0g $d Spee seronmatey io ow sews iempence, BES LS shih epee eopoumat . 2 Biel He: me strate copes mars is mst ta cony EE Dates on theo e9, cps io have 9 Baus CCopsute Filling For AV-21. a” i Aa sane te AV 2 iwi gC. bead etEta ot -wny Hot Water Copaciy __ Colé Water CopitySuvidya Institute of Technology Piping Engineering 2.3 INVERTED BUCKET TYPE STEAM TRAP : This trap operates on the principal of an inverted water lass (the component referred to as the bucket). The air and CO, entrapped in the inverted bucket provides Buoyancy keeping the inverted bucket inits raised position. Extending parlaly inside this inverted bucket is 2 dip tube, which Is where the condensate and steam enter. In the top ofthe inverted bucket is a vent hole, This allows air and CO, to continually dscharge. Attached to the top of the inverted bucket is a lever and valve assembly, which is attached to a valve seat insert. I ‘The Inverted Bucket Trap can be used over a wide range of pressures and temperatures to trap process and utility equipment, as a drip trap and in selected HVAC service. It can be installed inside or outside. However, if'an Inverted Bucket Trap is specified for outside service in a freezing environment, a stainless steel type Would be highly recommended. These encapsulated traps, ike Armstrong's model 1010, have the capacity, due to thelr material of construction, to withstand inadvertent freeze ups. When condensate inside the freezes, thé trap expands lke a balloon. Once thawed it goes right back into service. Sizes and pipe connections: HMO0- 15 NB. screwed BSPIINPT HANI0-20 NB, screwed BSPTNPT HM2- 25 NB, screwed BSPTIPT imiting Conditions: Maximum body design conditions 13bar9 PMA-max.allowsble pressure aber ‘TMA-max alowadle temperature 220deyc Cou hyarauletest pressure 2bbar ‘Maximum operating condtions depend upon ore sv PMX: max dilerental pressure Model ‘a Puxtban Haas 100) 017 enon HMia7 330, Trunand 35: ian 40. Materials : Ton iatenal - Cover Cestiran Cover Studs & Nuts Steet for15NB.820NB MBX 30mm {:25N8 Mi2>.50mm 3 bedy Castiron Bucket Staless tee! 5 Valve Guide Plate Stainioss see! | Sciens Ma 10 5 Vato Guide Pate Stainiess i 1 Ferrvle ‘Stainless stect i iF fest I | sizes ass RC -4-‘Suvidya Institute of Technology Piping Engineering 2.4 BALL FLOAT STEAM TRAP : As the name implies, the Flost & Thermostatic Trap utilizes two individual ‘mechanisms that operate in conjunction with one another. The float operates a valve that controls the discharge of condensate. The thermostatic element controls the release of air and CO;. The float itself, ‘which is normally ball type, is located in the lower portion of the trap body. It is attached to a rod which is, in tum, attached to the body of the rap in such a way that its free to pivot about that point, allowing the float the freedom to move vertically. Near the end where the rod is attached to the body a valve is attached to the ‘od, The valve is positioned so that when the floats at rest the valve is seated in the outlet ofthe trap. ‘This trap can be used in Process and ultlity applications as well as HVAC service. Its a good choice for high capacity requirements. However, it does not stand up well in conditions where the trap may be subjected to ‘water hammer andior freeze up. The float and thermostatic element can be damaged by water hammer and feet can be damaged by freeze up. If selected, given those considerations, this is an excellent multi-use Size: 15,20,25,40850NB ‘Available types & Limiting Conditions: FT20TV WITH BUILTIN THENMOSTATIC AIR VENT FFTZ0SLRWITH BUILT INSTEAM LOCK FELEASE ARRANGEMENT £1 20-4.5 MAX, DIFFERENTIAL PRESSURE OF 45 AR 7120-10 MAX. OFFERENTIAL PRESSURE OF 10 BAR, F120. 14 MAX DIFFERENTIAL PRESSURE OF 14 BAR 120-21 MAX. DIFFERENTIAL PRESSURE OF 21 BAR =F720-92 MAX, DIFFERENTIAL PRESSURE OF 32 BAR. ‘4A8X, BODY DESIGN CONDITION 32 848 AT 427 DEG ‘MAX COLO HYDRAULIC TEST PRESSURE. 648AR END CONNECTIONS: SCAEWEO BSPT/ NPT-ANS 9. 2.1/SOCKET 'WELDABLE TO ANSIB.16.11/FLANGED- ANSIB.16 8. CLASS. 160, 900, 600,08 TABLEH, J. KONNND 10, 16.25.40, 15 NB AGA 160 FLANGE Aveo only with weld on Hongo. Flange thickness is common for ach sizes shown in ‘dimensions det +. £12032 BAR diferent rosureaolable oni 8, | 20 0d 25 NB sizes. ot | Material: peseeesesdyseeLsnIEEsIETSIEEINOOEenEE ES | __Ne. Past 1 Base cast Stee! RSIMATI GRLWCR. 1 Tz CoverBakstNuts Carbon Stes! HighTensio ‘3 overGosket __ComprossedAsbestos 4 Cover Cast Stoe! ASIMATIS | : GA.WCB, | Te Wane seat StaissSteol __AISIATO | Te aweSentGeeket Stinlessteel_—_AISI30 7 PivetFramenssy. Stainless See! a Set Screws B BaiFlowts Laver _ Stainless Se Sto Avent Stainless Stoo! AISTOTG | Yo AirvintSeatGasketStsinlesStesl___ AISI | TTsthunt Stainless Steet AIST 12 SUR JitGesket Soft Steal _ 13 SLASeat, Stainless Stee! ‘AiSi410 THaSURSeat Gasket Stainless Stoo! ‘ISISO8 15 SupponFreme StinessSteel ASI 916 IG PivotFeme ——StrnlesSteo!——AISI3I Install “The trap should bo ted with Hat am in sion plano 80 tt raises shd as voraly wih diction of Now as shonin tho body ofthe wep -45-Suvidya Institute of Technology Piping Engineering 3. FLAME ARRESTOR : ‘AFLAME ARRESTOR is a device which allows gas to pass through it but stops a flame in order to prevent a larger fire or explosion. There is an enormous variety of sitvations in which flame arrestors are applied Anyone involved in selecting flame arrestors needs to understand how these products work and their performance limitations. For that purpose, this paper provides an introduction to the technology and terminology of flame arrestors and the types of products available. End-of-line, vent-to-atmosphere type Most flame arrestor applications and designs fall into two major categories. One group consists of end-of- line flame arrestors, also known as the vento-atmosphere. arrestors may be installed.in furnace air inlets ‘and exhaust stacks, The Davy lamp might be considered another example of that sor. In4tine, deflagration or detonation type The other major category consists of in-line flame arrestors, also known as deflagration and Detonation flame arrestors. (Speaking non technically, deflagration means rapid burning, detonation means explosion.) Selecting end-of-ine flame arrestors. ‘As explained before, end-oF4ine defagration flame arrestors are designed for unconfined flame propagation, also referred to as atmospheric explosion or unconfined deflagration. They simply bolt or screw onto the process or tank connection. These designs incorporate well-established but simple technology. Most use a single element of crimped wound metal ribbon that provides the heat transfer naeded to quench the flame before it gets through the arrestor element, The main points of concern when selecting an arrestor for end- of-line applications are as follows: a) Hazardous group designation. : ) Flame stabilization performance characteristics of the arrestor compared to the system potentia’ for flame stabization for sustained periods of me ©) Process gas temperature 4) Pressure drop across the arrestor during venting flow conditions, relative to the bystem’s maximum allowable pressure and vacuum €) Materials of construction that meet the ambient and process conditions for example, extremely cold climate, salt spray, chemically aggressive gas, etc. Connection type and size. ) Instrumentation requirements Selecting in-iine flame arrestors The various dynamic states explained ear for confined flames can be very dangerous for a process system due to the tremendous energies associated with detonation pressure and fiame velocity. Things happen fast and can tum catastrophic. These multiple dynamic states increase the challenge of providing @ flame arrestor product or products which stop the fame and withstand the enormous pressures caused by explosions within the confined piping. The very wide range of possible behavior for a confined flame causes. {wo particular problems for flame arrestor products. First, the high-pressure deflagration, and stable detonation states have very stable kinetics of buming, and tho flame is moving very fast Therefore the arrestor must be able to absorb the flame’s heat much faster than is required by standard Jow-to-medium- Pressure deflagration conditions. Second, the instantaneous. impulse pressures caused by the shock waves. Of overdriven detonation subject the arrestor to forces of up to 34,000 kPajg). Thus, the arrestor must be structurally superior to standard low-pressure deflagration arrestors. 46 -‘Suvidya Institute of Technology Piping Engineering 4, EXPANSION JOINT:- 4.1 What is Expansion Joint ‘An expansion joint is a device used to allow movement in a piping system \while containing pressure and the medium running through i Frequenty, thermal growth, equipment movement, vibration or pressure pulsation can couse movement in a piping system. ‘When flexibity for this ‘ovement cannot be designed into the piping system itsel, an expansion Joints the deal solution 4.2MOVEMENTCAPABILITIES : ‘There are four basic movements that can be applied to.a bellows. These are Axial, Lateral, Angular and Torsional as ilustrated below. Belows Behave like springs in a piping system. When they are compressed, {hey resist the movement the same as a spring would, The spring rate ofa bellows is entrely dependent on bellows geometry and material properties, 8) Axial movement is the change in dimensional length of the bellows from its free length in a direction paralle! to its longitudinal axis, +} b) —_Anguiar movement is the rotational displacement of the longitudinal axis of the bellows toward a point of rotation. ©) Lateral movement is the relative displacement of one end of the bellows to the other end in a direction perpendicular to its longitudinal axis (shear). | a. 4) Torsional movement is the rotation about the axis through the center of a bellows (twisting). EJS ) DISCOURAGES ANY. TORSIONAL ROTATION OF METAL BELLOWS Exbansion JONES. Torsion destablizes an expansion joint reducing its ability to contain pressure and absorb movernent. a7Suvidya ° of 9) Institute of Technology Piping Engineering Flanges-including special anges, slip-on, or angle flanges, a Vanstone ends are modified flanged ends with the added flexbilty of resolving bolt-hole misalignment. ! | \ Weld ends allow any pipe or duct to be attached to a bellows for welding into a system, 4.3 TYPE OF EXPANSION JOINTS: ) a) b) °) Unrestrained Assembiles Saile, Expansion Joint Assemblies are the sinplest type of expansion jot consisting of a single bolows element welded to end fitings, ether ange or pipe ans ile winlversal Expansion Joint Assemblies consist of two bellows connected by a center spool piece Moveenge of Pie ends. The universal arrangement alows greater aol latoar con angular movements than a Single Bellows Assembly. anal ogc Pressure chamber. This allows a greater number of convolvions te be used forlarge axial movements, without fear of bellows instability. Externally Pressurized z Expansion Joints have the added benefit of self-draining Convolutions if standing media is a ‘concem. Anchors and guides are an essential part of a {900d instalation, 48‘Suvidya Institute of Technology Piping Engineering li) Restrained Assemblies a) Tied Singlo Bellows Assemblies add tied rods to a Single Bellows Assembly to increase design flexibility in @ piping system. The tie rods are attached to the pipe or flange with lugs that carry the pressure thrust of the system, eliminating the need for main anchors. b) Tied Universal Assemblies are similar in construction to a Universal Assembly except that tle rods absorb pressure thrust and limit movements to lateral offset and angulations only ang ©) Hinged Bellows Assemblles limit movement to angulations in one plane. Hinged Assemblies are ‘normally used in sets of two oF three to absorb large amounts of expansion in high pressure piping systems. 4d) Gimbel Bellows Assemblies are designed to absorb syste pressure thrust and torsional twist, \while eliowing angulations in any plane. Gimbal Assemblies, when used in pairs or with a Single Hinged unit, have the advantage of absorbing movements in muli-planer piping systems. a) Ties rods are devices, usually in the form of bars or rods, attached to the expansion joint assembly and are designed to absorb pressure loads and other extraneous forces lke dead weight. ey b) Limit rods are used to protect the bellows from movements in excess of design that occasionally ‘occurs due to plant malfunction or the failure of an anchor, LIMIT RODS DO NOT CONTAIN THE PRESSURE THRUST DURING NORMAL OPERATION. ie 49 4.4 ACCESSORIES & OPTION‘Suvidya Institute of Technology Piping Engineering ©) Purge connections are used in conjunction wth internal liners to lower the stn temperature of the bellows in high temperature applications such as catalytic cracker bellows. re iners {Internal Sleeves) are used to protect the bellows internally am e) Covers (Shrouds) are used to protect the bellows externally. [cg STANDARD END CONNECTIONS FOR STEELOFLEx 53, al dq) 5.HOSES CORRUGATED FEKILE METALLIC HOSE 6, RUPTURE DISKS 1. fas Forward-Acting Scored Bursting Dise + Absolute “failsafe” rating * Operation up to 95% of minimum burst pressure # Gas, iquid, or vapor service + Nonfragmenting design ‘+ Longer service life, due to scoring after crowning 2, pro Precision Reverse-Operating Bursting Disc Scoring on vent side to minimise product build-up Lowpressure service Operation up to 95% of minimum burst pressure High-cycting service Damage-safe design 50Suvidya Institute of Technology Piping Engineering 3. co Composite Bursting Disc + Liquid or gas service * Operation up to 85% of minimum burst pressure + High-cycling service we + Nonfragmenting design 7 SIGHT FLOW INDICATORS 7A Flanged & Threaded Sightflow Indicators Type P * Simple Maintenance: Glasses can be individually removed & replaced BSPINPT threaded or ANSI150/300 & PN16 f'anged Carbon steel, stainless steel or special materials, Sizes from 1/2" to 8" Intemal Flap or Paddle Wheel fro flow indicators NAGE MRO 175 conformance Lining with HALAR, ECTFE or PFA available Pressures up to 40 Bar & temperatures up to 250°C CE Marked under the Pressure Equipment Directive 7.2 Tubular Sight Glass Type T + Sizes from %' to 8° ANSI 150 or PN16 + Pressures up to 10 Bar * Borosilicate glass tube with stainless steel flanged ends * Special flange materials such as Duplex avaitable + Viton O-ring or PTFE and other seal materials Perspex shield for extra protection ‘Available lined with HALAR ECTFE or PFA CE Marked and PED Compliant Visual Flow Indicators for Sterile Service + Designed for high purity applications, + Internally-flush style + Meets 3-A & FDA specifications * Polished stainless steel Sterile clamp or butt weld connections. * Ratings up to 10 Bar. * Standard finish to Ra< 0.8m, finer finish to Ras 0.1m available + Suitable for SIPICIP 7-4 Standard Metaglas® Discs for Sightports and Sight Flow Indicators + Direct replacement for conventional glass + Sizes from 45mm to 350mm + Pressure ratings up to 200 bar + Standaid materials: duplex stainless steel / borosilicate glass * Other materials and sizes available on request 7.8 LJ Star D-Ended Rectangular Sightglass Fittings * For welding into or onto vessel wall + Radiuses base flange available ‘= Complete with fully gasketed glass plate and bolting ‘+ Operating pressures up to 10 Bar depending on viewing area * Sizes: Viewing length up to 610mm, viewing width up to 102mm wide * Operating Temperature: Up to 243°C with Borosilicate Gass * Materials: stainless steel or hastelloy 51ee ‘Suvidya Institute of Technology Piping Engineering‘Suvidya Institute of Technology Piping Engineering CHAPTER - Vil GENERAL GUIDE LINES FOR DEVELOPING EQUIPMENT AND PIPING LAYOUT PIPING DESIGN SPECIFICATIONS PIPING LAYOUT GENERAL Criteria for Developing Equipment and Piping layouts (G. + Process + Operations © Maintenance + Economy Preferred pipe Lengths Random mili lengths of pipe (approximately 20 fee!) normally are specified for piping within battery mis. Double mil lengths should be used where feasible for yard piping oF for piping installed in long, uninterrupted runs. Piping Size Changes Except 25 mosifed in individual piping system specifeatons, use anucers, reducing fitings, and swaged ripples for size changes In the pipeline. Change of Direction Except as modified in individual Piping System Specification, use ena ner than elbows for change in crection up and 4° NPS. Preferred bends are ose made with the oo eerie OD. Ifthe contract bender is not avaiable atthe project st, field bends shai be no smaller than 8D, BRANCH CONNECTIONS individual Piping System Specifications re-select types of ranch eiwotion appropriate fr the system. The folowing criteria for pre-selection apply. Une reinforced stud ~in branch connections are used only at pressures where meta in the pipe wwall nt required for pressure or other loadings is considered reinforcement. ea eerecenent of welded branches & not recommended. It the need for pad reinforcement is, eae oo ctal nemever, use ring type (encirclement type for near fullsize branches) rather than sleeve of saddle type. Welding outlet fitings or Sweepolets are economical and adequate forall but ful ~ Stee branches, where Welding tees are the more economical choice. Do not use complex reducing tees or crosses 4 PIPE SIZE LIMITATIONS’ Company practice imposes limitation on pipe sizes and establishes minimum Aare Rs wa thickness requirements for economy and utity . These limitation and requirements include ‘1A ODD SIZE nominal pipe sizes 1/8", 38", 1%, 214 and 6" are nol used unless required by special a glen mmcenton to this practice include adapters to connection of purchased equipments and 24° NPS pipe required for hydrant valve connection in fire protection system - 4.2 Minimum pipe and connection sizes TO assure adequate strength and minimum support spacing ‘process lines and ufity supply nes ae ” NPS of large - minimum pipe size it major pipe way is 2" NPS srroce Where smaler lines are requied, intermediate support from larger fines in the pipe way shall be used to prevent excessive sagging. 412.1 Vents and drains, vents connection and drain connection in piping normally are 1/2: NPS oF larger taimum pipe size in major pipe ways is 2" with the exceptions in piping serving shuries » abrasive fluids, ‘or material sof high velocity are 1° NPS minimum. 412.2 instruments connection, general Except 23 specificaly noted, instruments take off ‘connection are %" NPS minimum. 4123, Orifice runs and connections Orifice connections are %4" NPS for primary pressure rating through ‘ANSI 600!b 3/4” NPS for ANSI 900!b and higher. 4.24 Level Connections’ connections in fo vessel for external dispiacers or floattype instument a z NPS flanged. Other connections are sized as required , but shall be rot less than 74° NPS through for the block valve. Level gage connection shal be ” NPS minimum. Level gage columns shall be 2"NPS ‘minimum, 4.25 Température connections piping 11/2" NPS and smaller is enlarged to 2° NPS ot thermowell connections, -58-wuvicya Instute of Technology Piping Engineering 1.3 Minimum wall thickness_ minimum wall thickness for threaded pipe is Schedule 80 for carbon steel, schedule 40 for galvanized steel, and Schedule 40sor equivalent for other metals and alloys, Minimum wall thickness for small branch take ~offs 1" NPS and smaller is Schedule 160 for carbon steel, ‘Schedule 40 for galvanized steel, and Schedule 80s or equivalent for stainiess steel and alloys. 2. PIPING ARRANGEMENT Piping Layout shall provide an orderly arrangement with the most direct routing possible. Arrangement shall result in the simplest, most economical methods of support consistent with adequate flexibility Equipment piping shall be arranged so that equipment may be dismantled for inspection or maintenance with minimum interference to the piping. Use of flanges for dismanting of lines shall be held to a minimum. Some fluid services will require more flanges for this purpose than other, e.g, lines that handle slurries, ine thal must be frequently cleaned out and lines that cannot be re-essembled. by welding. Such lines will be clearly identified in the pipeline schedule, Piping shall be arranged so arranged so that changed in direction are made with a minimum number of fitings and crossovers, Lines passing through building walls above floor levels shall be run through sleeves inserted through the wall. Sleeves shall be of sizes adequate to accommodate thermal insulation thickness shown on the piping Drawings. A framed opening may be used in lieu of individual sleeves to accommodates bank of parallel lines if closures are included as necessary to prevent passage of weather, flammable vapors and fir. Piping Elevation Layout of piping in banks shall be established so that the north — south and east ~ west piping runs are at altemate elevation Piping normally shall change elevation when changing direction, but there exception that include: ‘Where space in building is limited, piping may make flat tums or be placed in vertical racks against walls, ‘Suction lines with critical suction condition may have flat turns. Relief header which should not be trapped may required flat turns Piping which must run flat or slightly pitched for drainage ( steam supply, blow-down header etc,.) may require Nat turns, Cross-Country pipe fines, underground pipe lines, single lines off battery limits, and piping making the last tum before termination may have flat tums. Hot lines requiring expansion loops shall be carried, where possible, at the highest level of established pipe elevation to avoid blocking the run of other lines. ; 2.2 Clearances. . 2.2.4 Vertical Clearances Minimum vertical clearance for overhead piping shall be: 22-0" 0r7000mm over plant main roads, over cranes 160" or 000mm over plant main roads, over truck . 12-0" 0r4500mm over plant secondary roads, and over access ways inside battery limits. 10-0" or 3000mm —_ in passage areas between towers and pumps. '-0" or 260mm within buildings and over stairways. 7 oF 2200mm over platforms, walkways, passageways, and outdoor work areas, Piping at grade shall have 1-6" minimum clearance between uninsulated pipe or insulation surface of insulated pipe and high point of paving or terrain. Piping in pipe trenches shall have 1'- 6" minimum. clearance between bare or insulated pipe and the trench floor. 2.2.2 Horlzontal Clearance Minimum horizontal for piping shall be: 8'-6" from the centertine of rail tracks. Minimum clear width of passageways shall be 3'- 0" 0-6" between un insulated pipe or insulation surface of insulated pipe in pipeways, pipe trenches, or at grade,‘Suvidya Institute of Technology Piping Engineering Piping Accessibility The maximum distance from bottom of hand-operated valve hand wheels to grade or platform levels shall be 6-9" extension stems or chain operators shall otherwise be provided. ‘Special attention shall be given to the location of valves for convenience in operation from grade, and shalt be protected with a standard valve box. Valves below grade shall be provided with extension stems or other means of operation, servicing, removal, and service. Itis preferred that flanges and unions for pipe dismantling not be located above passageways. 2.3.1 Access from Platform The following shall be accessible from a platform if not accessible for service from grade: 1. Pipe-connected devices that must be regularly observed, adjusted, or serviced during operation. 2. Control vaive assemblies (preferably located at grade, but acceptable at platform level if this simplifies, piping). 3. Relief valves and rupture disc assemblies. 4. Valves 4" NPS and larger which must be frequently operated. lem shall be grouped where possible, to minimize the number and size of piatforms. Consideration shall be given to servicing other elevated items from these platforms, but if this would require undue enlargement of Platforms, or would complicate piping runs, other acceptable access shall be used. 2.3.2 Access from permanent Ladder Access from a permanent ladder is acceptable for the following, ‘Gage glasses, if top connection is higher than 6'- 6" above grade or platform Items if higher than 16' 0" above grade. ‘Small valves that must be frequently operated. Block valves 4° NPS larger not frequently operated, Level controllers and alarms. 2.3.3 Access from portable Ladder Access from a portable ladder is acceptable for the following for the following when not more than 16° - 0" above grade: Biock valves smaller than 4" NPS not frequently used Orifice flanges, Pressure and temperature instrument connections. line and equipment vents. Arrangement for Fluid Flow Piping arrangement shall meet these provisions: Piping shall be arranged so that it drains to equipment wherever possible. Flow through exchanger, cooler, jackets, and similar items shall be arranged to minimize gas or air pocket. Generally, cooling water shall enter at the bottom, leave at the top unless this arrangement result in a pocket ‘on the process side. ‘Steam mains or header shall run levels, or slope downward in the direction of low. Low points, dead ends, and intermediate points shall be equipped with drip pockets and condensate traps. Expect for isolated traps, all condensate in battery limits shall be piped to a collection system, or through a stem pig or separator to closed sewer connection. Exhaust heads shall be used when steam is vented in operating areas, and elsewhere as required. Heads shall be at least 12 feet above any platform or personnel area within as radius of 40 feet. Branch lines in steam, air, inert gas, and for fuel gas system shall exit from the top of the header. Condensate lines shall enter the top of a header. |‘Suvidya Institute of Technology Piping Engineering 3. ARRANEGEMENT AND APPLICATION OF VALVES. 3.4.4 Removal Access Clearance shall be provided for removal of valves closures and internal parts where the valves is intended for inne servicing Means shail be provided for their removal without disturbing the block valve or valves. Means shall be provided at pumps , compressors , or drivers to permit their removal without disturbing block valves. For this purpose , 8 spool piece , flanged check valves , fitting, or strainer against the nozzle will be considered satisfactory 3.4.2 Orientation valves stems shal lie no lower than horizontal, if possible. They shall be oriented so that stems or operating chains do not fallin passageways or obstruct head room. Other Consideration valves in acid or caustic fluid service should be located no more than 4° above foor level fo avoid eye and face injury in the event of packing failure. Acid valve stems should be vertical if possible. Do not install valves inside vessel skirts. Application of valves Block valves Block valves are specified by number in the piping system specification, and may be gate valves, or ball valves. General application of grate valves include: Tank Nozzles Block valves generally are provided on vessel nozzles except the following: ‘Vapor and reboiler lines, Safety and relief valve or rupture disc connections. ‘Atmospheric vent ines. Lines that require block valves for other purpose within 30 feet of the vessel All bottom outlets should have block valves , or flush-type or piston valves to serve the same purpose. Heat Exchangers When the head exchanger is essential to operation and must be kept on-stream between maintenance turnarounds, provided valves only as require to conserve fluid on shut-down for maintenance (ea., inwater lines where large headers would have to be drained to remove the exchange ). ‘Where the heat exchanger is to be off-stream at any time during operation, valves on both process and heat transfer fuid lines are require both at inlet and outlet. Pumps Both discharge and suction lines are valved. Locate the block valves ahead of the suction strainer if a strainer is provided. Compressors Suction and discharge are always valved. Auxiliary lines for lubricating oll and flushing water are valved at equipment. Cooling water lines exposed to freezing are valved at the header. ‘Turbines Steam supply lines requite valves. Auxiliary ines are valved as for compressors, Manifolds Block valves are provided at each branch in the manifold where process or ulility flow is to be directed selectively. Utlity Headers Major branches of ullty headers need not be valved. Branches 2° NPS and smaller should be valved at the header with the exception that where a larger branch serves grouped equipment operating 23s a unit, only the large branch shall be valved. If possible, group battery limit block valves at the distribution headers for common access. Safety Block Valves Fuel lines to furnaces , heaters, engines ,ete., must be valved in a location accessible in an emergency. Provide block valves at battery limits or other accessible location for flammable gases and other hazardous fluids. Double Block Valves Provide two block valves in series for the following services : Venting , draining , and sampling for liquid hydrocarbons over 66 psia vapor pressure at 100 F. ‘Sampling in any service ANST 600 Ib and higher. ‘Venting and draining in any service ANST 900 Ib and higher. Provide double block valves with bleed valve between them for the following {a) Interconnection between two services where cross flow during operation is not permitted. (b) Connection to vessels which may have to be entered for inspection or work . Regulating valves Regulating valves are specified by number in the piping system specifications, ‘and may be globe valves, diaphragm valves, of ball valves. General application of regulating valves include: -56-‘Suvidya Institute of Technology Piping Engineering ‘Sampling Where samples must be drawn in open containers, sampling valves must be regulating valves, preferably needle globe valves. Utility control Stearn and compressed air valves at equipment are globe or other type regulating valves. Cooling water and other utilities may be controlled either by block or regulating valves, depending on project requirement Bypass Service Any bypass around automatic control valves or other automatic regulators usually are conttolled by regulating valves through 4” NPS, block valves above 4” NPS. Check Valve Check valves are specified by number in piping system specifications, and may be swing check valves or ft check valves. General application of check valves include. Pump Discharge A Check valves should be installed below the block valve where backflow of fluid from a pump would be harmful. A vertical check may be desirable. Vacuum Header A check valve in a vacuum header near the ejector may prevent a harmful kick-back if steam fails.A swing check valve with carefully balanced disc is required to avoid excessive pressure drop at low absolute pressure. ‘Anti-Siphoning Check valves may be used to prevent siphoning where liquid or gas is fed sub-surface in a vessel and proper ant-siphoning is not possible. Utility Interconnections Check valves are used in utility services at interconnections to lines or equipment, of at manifolds, where a hazard would result from invasion of the line by another fluid. All interconnecting steam lines require check valves to automatically prevent reverse flow. 4, SPECIAL PIPING ARRANGEMENTS, PIPING OUTLINES, AND PIPING CONNECTIONS. 4A Piping for disposal of Discharged Materials:- Relief valve tail pipes for atmospheric discharge of flammable vapors not classified as pollutant or toxic shall extend at least twenty feet above the highest ‘working level or roof within a radius of forty feet unless analysis shows that it will be less expensive to discharge to a closed system for disposition. Non-pollutant and non-hazardous liquids shall be discharged into funnels or waste inlets at grade, Non- pollutant and non-hazardous vapors may be discharged into the atmosphere; however, discharge shall be directed away from personnel and equipment, and the effluent must not be allowed to become a hazard or a nuisance. Lethal, toxic, oF pollutant materials shall not be discharged to the atmosphere. They shall recycled to process or discharged to a closed system for disposition, Underground. Piping For fire protection sprinkler mains shall be located above sewers 36” clear of building foundations, and below the frostline at the location. Valve risers for wet sprinkler systems inside buildings shall be protected from mechanical abuse and secured with tie rods. Enclosed housings for sprinkler system Valves within buildings shall be accessible from the outside. Piping Connection: Safety Showers and Eyebaths:- Safety showers and eyebaths must be located in the proximity of chemical hazards. Exact locations and travel distances between location are subjects for safety review. standard hook-ups for these facilities are provided in section 6 of the piping standards Manual. Potable water connections:- connection between the city water supply (or other primary source) and utility or process water systems other than potable shall be equipped with an air gap, proprietary back-flow preventer, or other device to prevent contamination of the water source. A check valve will not suffice for this purpose. Fire Control system Connections:- Piping supplying smothering snuffing, and protective heating steam be separately connected to steam headers so that itis available during a shut-down. Vent and drain connection:- Provide bleeder vent and drain connections or fines on all pressure equipment. Provide valve vent connections for trapped high points of piping 3° NPS and larger, and valve drain connections for low points of piping located above grade. Route casing vents and drains for pumps in nonvolatile service to the pumps base plate oF into a sewer or gutter. Route casing vents and drains for pumps handling material near the auto-ignition point through a cooler to an effluent collections system.‘Suvidya Institute of Technology Piping Engineering ‘Steam or Inert Gas purging:- When required by the service, provide means for purging process equipment with steam or gas: Provide a 1" NPS line for purging vessels of 100 to S000 cubic foot Volume, and all vessels in low temperature service, Provide a 11/2 NPS line for vessels of greater volume than 000 cubic feet. Purge furnace coils with piping permanently connected to each coil inlet line. 4.4 Piping Outlets:- 4.44 Utility Outlets Utility steam, air, and water outlets for hose and hose fitings shall be located so that working areas in buildings end structures may be reached with a 0-foct length of hose. Steam pressure at hose stations shall not exceed 125 psig Provide means for clearing sample lines and coolers with steam in services handling materials that become highly viscous when cold. 4.42 Washing Out When required by the service, provide means for filing process equipment with water and washing out 4.3 Blanks Provide bianks (slip-binds) atthe following locations: ‘At inlet and outlet connections to equipment (other than pumps, compressors, turbines, and blowers) that must be periodically removed from service for maintenance, inspection, or altemating operation; and when provision of such blanks will minimize hazard to personnel. In furace piping at locations that will permit simultaneous testing of the fumace and piping. ‘At battery limits in fuel piping; and in process piping connected to other piping that may be used during a unit shut-down. PIPING DESIGN SPECIFICATIONS INSTRUMENT PIPING 4. INSTRUMENT CONNECTION Flow Instrument Connections: orifice runs shall be located to take advantage of the most nearly constant flow conditions- generally upstream of control valves. Vertical up-flow is the preferred orientation of vertical orifice runs. Where wet gas or wet steam is carried, a trapped drain shall be installed at the bottom of the riser. Orientation of tab nipples and block valves shall be as shown on individual Instrument Installation Details for the service. 4.4.4 Orifice Runs:- Where space is not @ consideration, orifice runs shall have at least 50 nominal pipe diameters upstream and 5 nominal pipe diameters downstream of the orifice plate. Where space is limited, minimum runs shall be in accordance with AGE-ASME Reports 16/PR and 17/PR. Orifice runs smaller than 2° NPS shall be specially-calibrated factory made assemblies of proper wall thickness. Level Instrument Connections:- When multiple gage glass assemblies are required for a vessel, a ‘strong back’ gage glass column, 2° NPS minimum, shall be provided to minimize the number of vessel ‘openings. This column and its valve must be shown on the piping drawings. Gage glass connections shall be made to the colurnn in the Instrument Installation Details. ‘Temperature Instrument. connection:- Thermometer, thermowell, and thermocouple connection shall be placed so that accuracy of the temperature measurement is not adversely affected by insufficient immersion of flow. Adequate immersion can best be achieved at elbows in the piping. if heat transfer fluid is used in thermowells, orient them on or above the horizontal. Insine Instruments:- Indine instruments shall be installed so that they do not support the attached piping, so that they are not strained by thermal expansion of the attached piping, and so that they can be readily removed for servicing, 2. CONTROL VALVES:- Control valves may be automatically-regulated or hand-operated valves of the type specified by instrument design to control the flow or pressure of fluids within process specifications. Control valves generally are labeled according to the process-controlled funtion with which they are associated. Control valves generally shall be installed without block valves or valves bypass. However, control valves in critical services (e.g. those in which component failure is likely To interrupt a continuous operation or vital plant service) may require a bypass with block, drain, and bypass valves. The bypass arrangement must in ‘each case be economically justified or shown to be essential for safely. Drain valves, when provided on both upstream and downstream side of control valves, shall be 24" NPS valves meeting pipeline specifications. SB- «Suvidya Institute of Technology Piping Engineering Arrangement of Control Valves:- Bypass valves, when required at control valves, shall be arranged to permit observation of the pertinent meter, gage, or equipment which shows the process condition being controlled. Control valves across which there is severe flashing or gas expansion shail be located as near as possible to the downstream vessel. 3. RELIEF VALVES AND DEVICES:- Relief valves and devices of the type specified by instrument design may be used as overpressure protection devices for pressure equipment, and for piping systems when equipment is connected without intervening block valves. Relief valve applications include: 1) Protection for piping: Piping systems shall be protected when pressure-temperature conditions, Described in par. 1 of pL2 STO 12 exist. In process areas, where there is a block valve in a turbine exhaust line, an atmospheric relief valve shall be provided capable of discharging the full load steam rate without exceeding the casing design pressure Sentinel valves used as warning devices are not permitted as substitutes for proper relief. 2) Vacuum Systems:- Vacuum systems must be provided with relief valves when the system may be over pressured during loss of vacuum. Protection should be considered for vacuum caused by emptying hydrostatic test water, or by condensing steam after steaming-out equipment, 3 /Miscellaneous:- Pipeline or equipment in which liquid contents may be locked _ should be checked for the necessity of a relief device. Fired furnace cols are not provided with separate overpressure protection. Piping systems are not protected from pressures caused by fires. Arrangement of Relief Devices & piping:~ Pressure relief devices shall be located and oriented as follows: 41. Install relief valves directly on the vessel wherever possible. 2. Always instal relief valves in the vertical position. 3. Do not install relief valves at or near condenser headers or piping which causes sharp reversals of flow. 4. Orient line-mounted relief valves to discharge in a direction closely paralleling line flow to minimize bending stress on the line due to back-thrust. 5. When rupture discs or safety vaive and rupture disc combinations are required, refer to the ASME Uunfired pr. vessel code for discussion of arrangement, venting requirements, and instruction in precautions to be taken. Piping for Relief Devices Follow these instructions for relief device inlet piping: 1) To prevent consideration and subsequent freezing of atmospheric moisture on relief valve seats in cold (below 32 F) service, provide un-insulated vertical piping to the valve long enough to provide a dead air ‘space adequate to keep the valve from reaching a temperature below the atmospheric dewpoint. Brace the inlet pipe to prevent overstressing by the large bending moment at discharges. 2) Inlet piping or vessel nozzle shall not be smaller than the valve inlet size. 3) To avoid chatter, for 2% maximum pressure drop due to friction loss. This means 2% of the set pressure, and is equivalent to approximately one-half of the blow down. 4)When closed discharge systems are used, compute thermal stresses on valve inlet piping. '5) Install vacuum breakers with the minimum of pipe, and equip with bird screens. Follow these instructions for rellef device discharge piping: 41) In no case shall the cross-sectional area of discharge piping be less than that of the valve outlet. 2) Maximum allowable back pressure in discharge piping is 10% of the valve set pressure. 3) Size discharge piping for rupture discs on the basis of pr. requirement rather than capacity requirement. 4) Provide catch pots or other devices for rupture disc vents so that accidentally released particulate ‘emissions will not discharge to the atmosphere. 5) Used pressure balanced valves to protect pumps, turbines and compressors discharging to suction if suction pressure varies, A conventional valve may very widely in pop point under these conditions. 6) Keep discharge piping for relief device as straight and as short as possible. If elbow are required, use the Jong radius type only. 7) Support discharge piping for relief devices free of the valve and carefully align so that forces acting on the valves will be minimum under normal operating conditions. 8) Relief device discharge piping must be adequately anchored fo prevent sway or vibration while the valve is discharging. 9) Arrange discharge piping for relief devices so that a liquid head will not accumulated above the valve, and 80 that the liquid is drained to the safe location. 59:‘Suvidya Institute of Technology Piping Engineering PIPEWAYS AND SUPORTS 4.PIPEWAYS:- Piping normally shall be run in overhead pipeways in battery limits; but the economy of running piping at grade or in pipe tenches shall be considered when space, operating conditions, and personnel congestion in battery limits permit Outside battery limits, piping is more economically supported at grade level if the straight runs are long enough. The length of straight runs required for economical at-grade support varies with the type of pipe and the size and number of pipes, and shall be calculated on a case basis, 41.1 Overhead Pipeways, Single Tier Where space and economics permit, itis preferred that piping be run ina single ter of lines. Pipe column supports with solid-web structural members are preferred for pipeway and bridge construction, with normal spacing of supports 20.0". When itis necessary to increase the spacing of supports, and if the distance between supports is so great that large lines cannot serve to support small lines without overload, pipe bridges of beams or trusses are Used and designed to meet project conditions. On single-level pipeways, the center section normally is reserved for utity piping, with process piping on either side. Critical process piping is run the outside extremities. 1.2 Overhead Pipeways, Multiple Tier Wrien a single level pipeway becomes so wide that more than two stanchions per bent are required, it may be more economical fo use multiple tiers andl reduce the width of the pipeway, Size, configuration, and weight of structural members for multiple tier pipeways are determined by a Combination of wind loading and weight of pipe. Normal spacing of supports is 240", When multiple tiers of piping are required, use the upper levels for utility piping, the lower levels for process Piping. Distance between the tiers shall be governed by take-off requirements for the larger lines. 1.3 Grade Level Support Of Pipeways Piping run at grade level shall be supported on wooden railroad ties or concrete sleepers, depending on the piping load. Normal spacing of supports is 20°0" Grade-level piping shall cross plant roadways by means of expansion loops. The center section of grade- level pipeways in reserved for utity piping, with process piping on either side. Critical process piping is run on the outside extremities. 1.4 Electrical Installations in Pipeways Electrical cables and instrument tubing in cable trays, wiring conduit, instrument piping, and instrument sensing monitors frequently are run in pipeways. Position and arrangement of these items shall be determined in consultation with E & | design. 1.5 Thermal insulation for Personnel Protection Lines in pipeways require thermal insulation for Personnel protection when both of the following conditions prevail a) Temperature of the uninsulated line is 140F or greater in above grade pipeways or inside battery limits, ‘160F or greater in grade-level pipeways outside battery limit. ) Position of the line is such that it can be readily contacted from grade, or from fixed ladders or platforms. The bottom of all uninsulated lines, and of all ines insulated for personal protection, shall be at one elevation. The bottom of lines insulated for process or economic reasons shall be at a higher elevation to permit installation of shoes for clearance of the insulation, 2. PIPING FLEXIBILITY: CODE establishes general rules for theevaluation of flexibility in the piping layout. The codes also sets up allowable ranges for expansion stresses in Par 302.3.2 (c). Design of piping system ‘expansion shall follow these data, and shall observe the following limits: a) Stresses developed in the piping system operating at design temperature shall not exceed of code- allowable stresses, ) Expansion loads transmitted by the piping to equipment shall not exceed those specified by the equipment vendor, and in no case shall misalignment with, distortion of, or strains on connected equipment result from excessive thrust and movement of the piping. ©) Loads transmitted to structures and foundation shall not be the cause for extreme and expensive designs. 2A Mechanical Means For Absorbing Pipe Movements: Expansion loops are preferred means for absorbing pipe movements. Where expansion loops are not feasible, ball type or corrugated bellows type mechanical joints may be used. Packed time expansion joint are not used in Company practice. 2.2 Cold Springing: Cold springing generally shall not be used to reduce expansion effects. Where cold springing is recommended, it normaly shall be limited to 50% of the line movement. However, in special cases where physical limitations such as equipment and structures prevent designing the necessary flexibility, cold springing greater than 60% may be considered. The amount of cold springing must be noted ‘on the Piping Drawings. -69-Suvidya Institute of Technology Piping Engineering 2.3 Movement of Anchors: Piping shall be anchored so that movement due to thermal expansion is ‘absorbed in the expansion loops or mechanical joints, in pipe bends, of by changes of direction. Anchor or ‘guide the pipe so that it can move only in the direction parallel to its centerline. Consider thrust due to internal pressure in the design of such anchors. 3. PIPING SUPPORT : Pipe Supports should be as simple 2s conditions allows, Stock items are used ‘where practicable, especially for piping held from above. To support piping from below, supports are usually made to suit from plate stock, pipe and piece of structural steel. The weight of piping is usually carried on ‘supports made from structural steel or concrete. 3.4 General Support Provisions Support from below the pipe is preferred to hanging support where practicable. ‘Support horizontal process and uliity lines so that sags and pockets in the lines are held to the minimum. Suitable hangers, supports, and anchors shall be installed at change in pipe direction, and at heavy valves ‘or other concentrations of loadings. Pipelines o suction and discharge connections pumps, compressors, etc. shall be supported in such manner that there will be no strain in or misalignment of the equipment. Pipe shoes generally will not be provided for bare pipe or pipe insulated for personnel protection. Shoes shall be provided for insulation clearance for pipe insulated for process or economic reasons. 3.2 Recommended Support Spans Spacing of support elements shall be such that piping spans will be ‘adequate to provide safe transport of fluids under pressure and other loading when the pipe approaches its recommended wall thickness retirement level. Recommended spacing of support shown.in Table |, correction factors shown in Table Il are to use where applicable. SPACING OF PIPE SUPPORTS E SIZE SPAN SUPPORT AND RESTRAINT SELECTION mm ft meters _| FACTORS. 25 7 40, 9 ‘Weight /load 50 | 10" Available attachment clearance 54 Availabilty of structural steel ‘80 1 Direction of loads and/or movement. ee Design temperature so_} 13 Vertical thermal movement at supports 100 44 125 16 150. AT 200 49 250 22 300__| 23 350 25. 400 27 450, 28 500 | 30 : 550__| 32 | Calculation for pipe support spacing When project conditions will not Permit pipe support to be spaced as shown in tables | and It caloulate the spacing as follows. Nev 4WF Where: allowable spacing of supports in feet section modulus of pipe, inches allowable stress (use % of allowable stress valves) ‘weight of line full of liquid plus insulation and permanent Loads, ibs/ft. ry = Suu N Zz s weSuvidya Institute of Technology Piping Engineering 3.3 Rigid Supports a) Hanger : Device which suspends piping (usually a single line) from structural steel, concrete or wood. Hangers are usually adjustable for height. Safe loads for threaded hanger rods shall be based on the root area of the threads, b) ANCHOR : A rigid support which restrict all six movements three Translational and three rotational along piping. Construction may be from steel plates, brackets, flanges rods etc. ooSuvidya Institute of Technology Piping Engineering 4) GUIDE : A means of allowing a pipe to move along its length, but not sideways. ©) SHOE : A metal piece atiached underside of pipe which rest on supporting steel. Primarily used to Teduce wear from sliding for lines subject to movements. Permits insulation to be applied to pipe. This single T shaped shoe support can be used up 8° NPS pipe size. 7 gree —— PIPE “swe __- SHOE STEEL SUPPORT SK NY __ _— StTRVeTURAL SuProRE {) SADDLE TYPE SHOE: A welded attachment for pipe requiring insulation and subject to longitudinal or raling movements. Saddle may be used as a guide support andiine size 10°NPS and above, — Pee pay PLATE SADDLE SADDLE reel SuPer 4) SLIDE PLATE: Siding Supports shall be designed to resist the forces due to fiction in adition to the loads imposed by bearing. Dimensions of the supports shall provide for the expected movement of the supported piping. ~ 85Suvidya Institute of Technology Piping Engineering 3.4 Flexible Supports : Spring supports allows variation in the length of pipe due to changes in temperature and are offen used for vertical lines. @) Variable Spring Support : These device consist of a coil spring in a housing. The spring permit ‘ limited amount of thermal movement. Up to 50 mm thermal movement these type of supports can be used. A variable spring hanger holding up a vertical line will reduce ‘ts lifting force as the line expands towards it. A variable spring support would increase its lifting force as the line expands towards it. Both place load on the piping system. Where this is undesirable , a constant load hanger can be used instead. ‘Spring supports shall be designed to exert a supporting force at the point of attachment equal to the load as determined by weight balance calculations. They shall be provided with means to prevent misalignment, bucking, or eccentric loading of the springs, and to prevent intentional disengagement of the load, b) Constant Spring Support : This device consists of a coil spring and lever mechanism in a housing. Movements of the piping, within limits, will not change the spring force holding up the piping; thus no additional forces will be introduced to the piping system. When thermal expansion is more than 50mm use constant spring support. Constant-support spring hangers shall provide a substantially uniform supporting force throughout, the range of travel. Hangers of this type shall be selected so that their travel range exceeds expected movements, ©) Snubbers: One end of the unit is attached to piping and the other to structural steel or concrete. 7 ‘The unit expands or contracts to absorb slow movement to piping but is rigid to rapid movements. 4) Welding to pipe: ifthe applicable codes permit lugs may be welded tothe pipe. Welding support to pre lined pipe wil usually 5 9 and there fore lugs etc, must be welded to pipe and fitings before the lining is applied. 3 -%Seen Piping Engineering PIPING LAYOUT NOTES PIPING ARRANGEMENT GUIDE LINE: 1. Simple arrangement and short lines minimize pressure drop and lower pumping cost. 2, Design pipe in such a way that the arrangement is flexible, reduces stresses due to mechanical or thermal movement. 3. Inside building piping is usually arranged parallel to building steelwork to simplify supporting and improve appearance. 4. Outside building piping can be arranged: ~—_i) On Pipe Rack ii) On Sleepers ili)In Trenches iv) Vertically against steel work PIPING ARRANGEMENT : 1, Use standard available items wherever possible. 2. Do not use miters unless directed to do so. 3. Do not run piping under foundations. 4. Piping may have to go through concrete floors or walls. Establish these points of penetration as early as possible and inform the group concemed to avoid cutting existing: reinforcing bars. 5. Preferably lay piping such as lines to outside storage, loading and receiving facilities at grade on pipe sleepers. If there is no possibility of future roads or site development. 6. Avoid pocket in steam line, it very difficult to collect condensate. Steam line may be run below grade in trenches provide with covers or in sleeves. 7. Include removable flanged spool to aid maintenance, especially at pump, turbines and other - equipment that will have to be removed frequently. 8. Take gas and vapor branch lines from top of header where it is necessary to reduce the chance of drawing off condensate. 9. Avoid pockets in lines, arrange piping so that lines drain back into equipment or into lines that can be drained. 10. Vent all high point and drain all low points of lines. Carefully place drain and vent valves that can be easily drained or purged during shutdown, ARRANGE FOR SUPPORT 1. Group lines pipe way’s & Support piping from overhead REMOVING EQUIPMENT AND CLEARING LINES. Provide union and flanged joint in lines as necessary and in addition use crosses instead of Tee’s and Tee instead of elbow to permit removing material that may solidify. CLEARANCES AND ACCESS 1. Route piping to obtain adequate clearances for maintaining and removing equipment. 2. Locate within reach, or make it accessible, all equipment subject to periodic operation / Inspection with special reference to check valves, pressure relief valves, traps, strainers and instruments, 3. Take care to not obstruct access way’s, door way’s, escape routes, truck ways, walkway’s and lifting bay's etc. 4, Position equipment with adequate clearance for operation and maintenance, In some circumstances these clearance may be inadequate, For example with shell and tube heat exchangers space must be provided to permit withdrawal of tubes. Page 1 of 9 -6S-Suvidya Institute of Technology 3 6 7. 8, 9, Piping engines Insure very hot lines are not running adjacent to the line carrying temperature sensitive fluid, or elsewhere, where heat might be undesirable, Establish sufficient headroom for HVAC duct work, essential electrical runs and at least ‘wo elevations for pipe run North ~South. Elevations of lines are usually changed when changing horizontal direction. Stagger flanges with 300mm minimum clearance from supporting steel. Keep field weld and other joints at least 75mm from supporting steel. MINIMUM HORIZONTAL CLEARANCES. 1 2 3 Operating space around equipment Centerline of railroad to nearest obstruction Manhole to Railing/ any obstruction MINIMUM VERTICAL CLEARANCES Bene Over walkway, platform or operating area Bottom of pipe (BOP) Over stairway Over high point of roadway’s MINIMUM HORIZONTAL DIMENSIONS 750 mm. ') Straight Track 2500mm ii) Curved Track 2800mm 1000mm 2.0 mtr 2.2 mtr 2.2 mtr i) Minor roadway's 4.5 mtr ii) Major roadway’s 6 mtr iii) Over Railroad / Crane 7 mtr 1. Width of walk way at floors level 1000mm 2. Width of elevated walkway o stairway 750mm 3. Width of maiEscape Route 1500mm 4. Width of Secondary Escape Route 1000mm 5. Space infront of Manhole 1000mm 6. Width of rung of fix ladder 40mm 7. Width of way for forklift 2500mm MINIMUM VERTICAL DEMENSIONS 1. Manhole centerline from floor/Platform 4000 m VALVE OPERATING HEIGHT - 7 7 VALVE HANDWHEEL CENTERLINE (HANDWHEEL/ STEM Se eect) aTENnen DESCRIPTION CENTYERLINR PARALLEL TO’ | cei VPRIN PARALLEL TO? OR*Y" AXIS. IN HORIZONTAL Pesan AXIS. INHORIZONTAL POSITION) Min Operating Height 0.610mtr 0.610mtr Preferred Operating Height 1.070mtr To 1.4mtr 1.14mtr To 1.3 mtr Maximurn Operating Height 17mtr Lame Page 2 of 9 —6omSuvidya Institute of Technology Piping Engineering PIPE RACK 1. A pipe rack is a structure in the pipe way’s for carrying pipes and is usually fabricated from steel or concrete. 2. The vertical members of the rack are termed stanchions & horizontal member termed Spandrel. 3, Pipe racks may be single Tier (deck) or double Tier. It may go up to 3 to 4 Tier as per the space constraint 4, Only for two or three pipes, Pipe Rack can be made from ‘T” shaped member. 5. Pipe Racks are expensive but are necessary for arranging the process and ulility lines around the plant. 6. Pumps, Utility stations, Manifolds, Firefighting and First aid stations can be located under pipe rack. 7. Lighting and other fixtures can be fitted to stanchions (vertical member) ‘Air cooled heat exchanger’s can be supported above the pipe rack. 9. ‘The smallest size of pipe run on a pipe rack without additional support is usually 2". It may be more economic to change proposed small lines to 2” pipe. KEY POINTS: rack keep process lines at first tier and utility line at second tier. 1. “Ln double pi ig over stanchions (vertical column ) as this will prevent adding another 2. Do not run pi deck. 3. Place large liquid filled pipes near stanchions to reduce stress on horizontal member. 4, Heavy liquid filled pipes (12” and above) are more economically run at grade piping should be supported on sleepers at 300 mm above grade level. 5. Hot and cold pipes are usually insulated and mounted on shoes. 6. The height of relief header is fixed by its point of origin and the slope required to drain the line to a Header/Tank etc 4. Electrical and instrument tray’s are best placed on top tier, It can also be attached to out rigger or brackets out side rack. Vertical tray’s can be attached to stanchions, 8. When change in direction of a horizontal line is made it is best, also to make a change of elevations. This avoids blocking space for future lines and also easy to change line sequence. 9. Ifspace permit pipes should be racked on a single deck. 10, Pipe racks are usually not over 25 ft or 7.5 mtr in width. 11. Minimum clearance under pipe rack is determined by available mobile lifting equipment under rack. 12. When setting elevations of pipe rack try to avoid pockets in the pipes. 13, Group hot lines requiring expansion loop at one side of the pipe rack. 14. Locate utility stations, control stations and fire hose point adjacent to stanchions for supporting Page 3 0f9 CtSuvidya Institute of Technology Piping Engineering VALVES Valves are used in piping for following purposes: 1. Process control during operation. 2. Controlling services and utilities. Isolating equipment or Instruments for maintainance. Discharging gas, vapor, liquid, Draining piping and equipment on shutdown. Emergency shutdown in the event of plant mishap or fire. VALVE SIZES Nearly all valves will be equal to line size, except in control valve. Control valve is normallr one size smaller than line (For more Information refer HOOK-UP of Control Valve). VALVE LOCATION 1. Preferably place valves in line from Headers (on pipe line) in horizontal rather than vertical uns so that lines can drain when the valves are closed. (In cold climate water held in lines May freeze and rupture, the piping such lines should be traced.) 2. To avoid spooling unnecessary length’s of pipe mount valves directly on to flanged equipments, 3. A relief valve that discharge into a Header should be placed higher than the header in order to drain into it. 4. Locate heavy valve suitable support points, flange should be not closer than 300mm to the hearest support so that installation is not hampered 5. For appearance, if practicable keep centerlines of valves at the same height above floor and in Fine on plan. OPERATING ACCESS TO VALVES 1. Consider frequency of operations when locating manually operated valve. 2. Locate frequently operated valve at accessible height to an operator from grade or platform, Maximum Operating Height of Valve is 1.7mtr, Above this height and up to 6mtr, use chain operators or extension stem. Over 6mtr consider a platform or remote operation. In frequently used valves can be reached by ladder but consider alternatives. Do not locate valve on pipe racks unless unavoidable. Group valve which would be out of reach so that all can be operated by providing platform. If chain is used on a horizontally mounted valve take the bottom of the loop to within 1000mm above the floor level and provide a hook near by to hold the chai Do not use chain operator on screwed valves, or on any valve 1.5”and smaller. With lines handling dangerous materials it is better to place valves at suitable low level above grade. Page 4 of 9 68suvidya Institute of Technology Piping Engineering ACCESS TO VALVES IN HAZARDOUS AREAS 1. Locate main isolation valve within reach in emergency, make sure that personnel will be able to reach valve easily by walkway / vehicles, Locate manually operated valves at the plant perimeter or outside the hazardous area, Ensure that automatic operators and their control lines are protected from the effect of fire Make use of brick or conerete walls as possible fire shields for valve stations. Consider automatic valves in fire fighting system. Provide access for mobil lifting equipment to handle heavy valves, If possible, arrange valves in such a way that support will not be on removable spool. MAKE MAINTENANCE SAFE 1. Make use of Blind valve, Spectacle plates or double block and bleed valves where Positive shutoff is required either for maintenance or process needs, ORIENTION OF VALVES 1. Donot point valve stems into walkway, truck way, ladder space etc. 2 Unless necessary, do not arrange valves with their stems pointing downwards or at any angle below horizontal. Sediment may collect in the gland packing and score the stem 3. A projecting stem may be hazard to person, 4. Ian inverted position is necessary, consider employing a drip shield CLOSING DOWN LINES: 1. Consider valve closing time in shutting down or throttling large lines for long distance lines, IF THERE JS NOP & ID 1} Provide valves at headers, pumps, equipment ete, ensure that the system is pressure tight for hydrostatic testing and to allow equipment to be removed for maintenance without shutting down the system, 2. Provide Isolating valves in all small lines branching from headers, 3, Providing Isolating valve at all Instrument, for removal of Instrument under operating conditions. 4. Provide valve drains on all tanks, vessels ete, and other equipment which may contain or collect liquids, 5. Protect sensitive equipment by using fast closing check valves to stop back flow before it can gather momentum. &. Consider butt welding or rng joint flanged valves for line containing hazardous fluids. 7. Consider seal welding screwed valves if used in hydrocarbon service, Consider providing a concrete pit ft x 4f for a valve which is located below grade. 9. Consider use of temporary closures for positive shut off, 10. Provide bypass if necessary for equipment which may be taken out of service, 11. Provide bypass around control station if continuous flow is required. Bypass should be at least as large as the control valve, 12. Consider providing large gate valve with valved bypass to equalize pressure on either side Of the disc to reduce effort needed to open the valve. Page S0f9 64sSuvidya Institute of Lechnology: le biol Taree aehicboas TOWER PIPING COLUMN OPERATIONS The feed is heated before it enters the column, as feed enters the column quantities of vapor are given off by flashing due to the release of pressure in the feed. AAs the vapor raise up the column they come to intimate contact with down flo components of down flowing liquid are vaporized. This process is termed refluxing. 1. Trays are various designs. Their purpose is to collect a certain amount if liquid but allows vapor to pass up through them so that vapor and liquid come into contact. 2. Packing are for increasing residence time. 3. Product from the column are piped to collecting tanks are termed drum or accumulator. 4. Normally all material enters and leave the column through pipes therefore columns are located close to pipe racks. 5. If the vapor from the top of the column is condensable itis piped to a condenser to form a liquid, Condenser may be mounted at grade or sometimes on the side of the column, 6. A stein heated heat exchanger termed a Reboiler used to heat material drawn from a select, level in a column, 7. Material from bottom is termed Bottoms. Vapor from top is termed Overheads. COULMN OPERATIONS AND REQUIREMENT S _ Manholes are necessary to allow installation and removal or tray parts. Platforms and ladders are required Yor personnel access to valves on nozzles, to manholes and to column Instrument. Davitis needed to raise and lower column part 4. Manholes should be located away from piping, if required manhole can be placed off the column centerine. . 5. Elevations of nozzles are taken from the column datasheet. 6. Platforms are required under manholes, valves at nozzles, level gauges controllers if any and pressure relief valve, 7. Columns may be grouped and sometimes interconnecting platforms between columns are used, 8. Individual platforms fora column are usualy shaped as a circular segment. 9. Platform is required atthe top of the column for operating a davit, a vent on shutdown and for free access tothe safely relief valve. This top platform may be rectangular or square. 10. Ladder length is usually restricted to 6 mtr_ between landings. If operating platforms are further apart than the maximum permissible ladder height a small intermediate platform is provided. 11, Ladders and cages should be conform to the company standard and satisfy the requirement of the US dept of labor (OSHA) part 1910-D DAVIT : Davit should be located at the top of the column, So that it can lower and raise the column parts. Page 6 0f 9 +0 1g liquid. During the contact some of the heavier component of vapor are condensed and some or the lighterSuvidya Institute of Technology Piping Engineering ARRANGING THE COLUMN PIPING To achieve simplicity and good arrangement some trial and error working is necessary. 1. Allocate space for vertical lines from lower nozzles. Avoiding running these lines through platforms if possible. 2. Lines from top of column tend to be larger than others, allocate space for them first. Keeping the lines parallel wall of the column makes supporting easier. 3. Provide access for mobile lifting equipments. 4, Provide clearance to grade under the suction line. 5. Avoid pockets in Bottoms lines, INFORMATION NEEDED TO ARRANGE THE COLUMN PIPING 1. Plot plan showing space available for column location. 2. Details of equipment s which are connected to the column. 3. P &ID, NPSH of bottoms pump & instrumentation, 4. Column data sheets. 5. Line list. — 6-~Details if trays and other Internal parts. 7. Restriction of heights of ladder. 8. Operational requirement if any. BOTTOM PUMP AND ELEVATION OF COLUMN ‘The elevation of column is set by the i) _NPSH required by the bottom pump. ’). The access requirement under section line. iif) Requirement for Thermosyphone Reboiler VALVES ON COLUMN 1, Valves & Blinds which serve the tower should be positioned directly on nozzles for economy. 2. Platform should be located to give access to large valves. 3. Small valves may be located at the end of platform. 4. Control valves should be accessible from operating platform. 5. Pressure relief valve should be placed at the highest point in the line and should be accessible from the top platform. 6. Valve should not be located within the skirt of the column, INSTRUMENTS AND CONNECTIONS 1, Temperature connections should be located to communicate with liquids in the tray. 2, Pressure connection should be located below the trays. 3. Access for instrament can also be provided by ladder. 4. All gauges must be visible while operating valve. 5. For locating instruments of one end of a circular platform may go for a narrower platform. Page 7 of9 4Suvidya Institute of Technology Piping Engineering UTILITY STATIONS A Utility stations usually combines three service lines carrying steam, compressed air and water. Steam line is normally 3]4” minimum and the other two services are usually carried in 1” ‘These services are for cleaning local equipments and floors, The steam line i fitted with globe valve and air and war lines with gate valve. Utility stations should be located at some convenient steel column for supporting & all areas seive and should be reachable within SOft isto CONTROL STATION A control stations is an arrangement of piping in which a control valve is used to reduce or regulate the pressure or rate of flow of steam, gas or liquid. DESIGN POINTS 1. For best control, place control station close to the equipment it serves and locate it at grade or operating platforms. — 2. Provide pressure gauge connections downstream of the station valve. ~~ 3. Preferably do not sandwich vaive, place at least one of the isolating valve in vertical line so that the spool can be taken out allowing the control valve to be removed. _-—4. Provide valved drain near to and upstream of the control valve. To save space drain can be placed on the reducer. . a 5. The drain valve allows pressure between the isolating valve & control valve to be released. One drain is used if the control valve fails open. & both drains if the control valve fails closed 6. Locate stations in rack piping at grade, next to column for easy supporting.Suvidya Institute of Technology Piping Engineering HEAT EXCHANGER Data needed to plan Heat Exchanger Piping LL P&ID 2. Exchanger data sheet 3. Design Code of Heat Exchanger : TEMA RCB GENERAL GUIDE LINES: 1, Provide Shell with pressure relieving device to protect against excessive shell side pressure in the event or internal pressure. Put corrosive fluids inside the tubes, as these are easily cleaned and cheaper to replace than the shell. Pot the hotter fluid inthe tubes to reduce heat loss tothe surroundings If steam is used to heat the fuid in an exchanger, passing the steam through the shell has advantages. For example : Condensate is far easier to handle from shell side. Insulation on shell is normally required to protect pé¥sonnel, to reduce the rate of condensate formation and to reduce heat losses, Pass cooling liquid through the tubes if the exchanger is not insulated for economic operation. Ifthe heat transfer is between two liquids, a counter current flow pattern will usually give greater overall heat transfer than a parallel flow pattern, Arrange nozzles.to suit best piping and plant layout LOCATING HEAT EXCHANGER Position exchanger so that piping is as direct and simple as possible Flevate heat exchanger to allow piping to the exchangers bottom nozzles to be aiyanged above grade or floor level. Exchangers are sometimes of necessity mounted on structures, process columns and other ‘auipment, Special arrangement for maintenance and tube handling will be required. OPERATING AND MAINTENANCE REQUIREMEN T Access to operating valves and Instruments. Operating space for davit, monorails or crane etc. Space is needed for tube bundle removal for cleaning and around the exchangers bolted ends and the bolted channels to shell enclosure. Access for tube bundle removal is often given on manufacturers drawings and is usually about 1.5 times the bundle length. 15 t0 20 ft clearance should be allocated from the outs side or last exchanger inorder to mobile lifting equipment access and tube handling. Page 9 0f 9 73‘Suvidya Institute of Technology Piping Engineering CHAPTER-WIl BASICS OF STRESS ANALISIS‘Suvidya institute of Technology Piping Engineering Chapter : vin STRESS ANALYSIS Responsibilities of Stress Engineers STRESS ENGINEER 2 Nominated by Chief Piping Engineer / Lead Stress Engineer a) Carry Out Flexibility analysis 5) Identify all the load cases to be considered in analysis Review study drawing to ensure sufficient flexibiity in critical piping ©) Identify and review all critical piping support ©) Summarize Equipment Nozzle Loading communicate to others ) Perfor flange leakage calculation for high pressure piping. 1) Communicate critical support loading to civil 9) Prepare Spring Schedule! Bellow Specification for procurement 1) dentiy requirement of reinforcement pad due to stress consideration }) Decide on position of fixed saddle of horizontal Heat Exch. and Vercels 4) Review Vendor data regarding nozzle loading etc. ') Documentation of Analysis Reports Other Methods to check the flexibility > Using Nomographs a) To perform quick flexibility check ») Toestimate preliminary anchor loading for civil structural design ¢) Todo preliminary exp, loop sizing on pipe rack at early stage of the job 4) To review visual analysis lines to avoid expensive CAESAR analysis > Using Computer application ~ CAESAR. a) Highly versatile application program ©) Based on Finite Element Analysis Method ©) Results are acceptable to world wide Engineering companies > What Is Flexibility Analysie? . Fundamentals of Primary & Secondary Stresses b. Analytical Method to calculate Displacement & Stresses ©. Checking Flexibiity using nomographs 4. Guidelines for ines connected to Critical Equipment ©. Stress Analysis using CAESAR-II 1. Various Load Cases 9. Spring Supports h. Expansion Joints i. Sttess Analysis- Responsibities & Methodology J. Fundamentals of Buried Pipe Analysis > What is Flexibility of the Piping System? Abilty to absorb thermal growth of the piping system ay —; CS > torrent 4% 4 —- Flexible - ty -‘Suvidya Institute of Technology > What is Flexibility of the Pi System? Ability to absorb thermal growth of the piping system > How to provide Flexibility inthe piping system? By change in direction using BENDS, utilzing Expansion joints > What code states about Flexibility in the Piping syster "Piping system shall be designed to have sufficient flexi from overstress, leakage at jints or detrimental thrusts and moments" > How to conclude whether system is Flexible or not? Stress Analysis ‘Acceptability Criteria > mm? bily to prevent pipe movements from causing failure Piping System — flexible and safe only IF following criteria are satisied Criteria ¥ Thermal stress <= Allowable Stress Range “Sustained (Primary) Stresses <= SH or SC “Max Thermal Displacement ~ Axial / Lateral Piping sagging ¥Flange Leakage ¥ Support Loading Nozzle Loading Vessels and Heat Exchangers Centrifugal Pumps Centrifugal Compressors ‘Reciprocating Compressors “Air Cooled Exchangers ¥Steam Turbines h the Pig > Primary Stresses ® Direct Shear and Bending in ® Caused due to~ Dead Weight # Pipe © Piping Internal Pressure nature Comparison Basis ANSI B 31.3 > Project Design Basis Project Design Basis Project Design Basis > Project Design Basis Project Design Basis, >Project Design Basis PAPI-610 >aPI- 617 >aAPI-618 DAPI — 661 >NEMA~ 23, Component @ Fluid @ Snowilce Occasional Load .@ Wind © SeismicLoad_ ¢ PRV Thrust ® Caused due to~ Y Thermal Expansion > Local Stresses «© Piping System ® Localised Bending and Shear in nature ® Caused due to— +s © Equipment‘Suvidya Institute of Technology u Piping Engineering ¥ Local load like Ioad on welded lug on pipe Code Allowable STRESSES > Primary Stresses ® Checking Criteria Y Induced Stresses <= Shor Sc —_]__». ? How to FIND Shand Sc > Secondary Stresses B Checking Criteria ¥ Induced Stresses <= Sa —————> 7 How to FIND Sa . cop > wor => As © Thermal exp. installed At Elbow >> Outer fibre- Tension Inner fibre- Compr. wr come © Bending stresses diminishes due to plastic deformations © At Elbow >> pr. Sh= allowable stress at elev. Temp, Sc= Allowable Stress at amp. Temp Table A-t for Metallic piping Table K- 1 for High Press Piping ‘Sa= Allowable Stress Range Refer 831.3, Sa= fx (1.25 Sc + 0.25 Sh) OPERATIN c= COLD © Thermal contraction © ALEIbow >> Outer fibre- Com Stresses Relaxed -CYCLIC ~ FATIGUE Number of + cycle Conclusion? ‘Stress Loading type Failure type Failure time ‘Stress Range- Definition Yield Stress (Sy) ‘Allowable Stress Range (Sa) Reduced allowable = 1.25 (Sc + Sh) Provision of Primary stresses = Sh wot =1.5 x Allowable Tensile Stress (Sc or Sh) = (1.5 x Sh) + (1.5 x Sc) = 1.5 (Sc+ Sh) ‘To account for simplification in calon To account for localized stresses Allowable Stress Range (Sa) = (1.25 Sc + 0.25 Sh) xf f= Stress reduction factor = {For life cycle up to 7000 = 0.9 For life cycle 7001~ 14000 = 0.8 For life cycle 14001 ~ 22000 = 0.7 For ife cycle 22001~ 45000 0.6 For life cycle 45001 ~ 100000 0.5 for life cycle 100001 & over “6gylemperature ‘Suvidya Institute of Technology Piping Engineering inear Coef. of Thermal Expn (Ref, B31.3, Table C-1) (Yomsaeestese | 's Modulus of Elasticity [or maareea | 831.3, Table C-6) Guided Cantilever Method A = 48(L)’ $/ ED. S =ED/48 (Ly rd, Evaluation.in & Out Pi SIE ‘Sb=V(li x Mi)? + (lox Mo)? /Z. IF factor - In Plane we lo= SIF factor ~ Out Plane B 31.3 Table D-1 2: Sectional Modulus of Elasticity =3.142 x (Do? -Di?)/ 32 St= Mtl (2x2) Se=VSb2 +4 x Si2 For safe design Se <= Sa i 29‘Suvidya Institute of Technology Piping Engineering General Working Procedures Review a) Review Piping Specification b) Review piping Study Drawing around critical equipment )_ Identify critical civil structural requirements ) Review all applicable project standards ) Quick check using Excel spreadsheet for pipe wall and Br. Rein. Calculation f) Prepare Preliminary Stress Critical Line List 4g) Review Pipe-Rack study layout- Establish preliminary exp...loop location h) Establish preliminary Pipe- rack loading for structural design > Detailed Review a) Identify CAESAR Stress Models- Include group of lines in single model b)_ Perform detailed stress analysis based on issued stress critical line list ©) Analyse visual check lines using simplied manual techniques d) Communicate with civil, Véssel and Mechanical groups for loading > Final Approval a) Freeze the Stress model based on final isometrics b) Documentation of Input and Output Reports > Simplified Method To Check Piping System Flexibility Basis — Code B 31.3 para 319.4.1 IF DxA <=K Then Piping is Flexible (-uy D= Pipe OD (mm) ‘A= Resultant Displacement (mm) L= Developed Length (mts) U= Anchor Distance (mrs) K= 2083 2 Only two points of fixation a No change in pipe size 4 © No intermediate restraint Overview 2) Purpose of Support b) Type of Supports ©) Pipe Support Standard . 4d) Pipe support Instructions and Design Guide ) Pipe Support- Span Table 1) Pipe Support - Trunnion Calculation of PI ts ) To Support dead weight of piping system ») To minimize Pipe sagging To take Expansion load in the piping syste @ To absorb wind load and Seismic load ©) To absorb Vibration in the piping system ) To Suppress the Noise level in the pulsating piping system 9) To absorb Hydraulic Thrust in the piping system 1) To absorb the pressure Thrust of Bellow To support the system during shut down / Maintenance Cond. -19-su ay 3) b) 9) a) e NOYE INSUUNG OFT gy pes of pipe Supports Based on Functions Loose or Resting supports Longitudinal Guide Supports Transverse Guide Supports ee Limit Stops Based on Construction Rigid Support Bolted Type Adjustable Supports Elastic Suppots,§ << ‘Types of pipe supports- Details > a ») a > 2) b) °) 4) > a » Primary Supports U- Bolts and Clamps Shoe —7 Welded Type |_____yClamped Type Road Hangers ‘Secondary Supports Attachment from Steel Structures ‘Attachment from RCC Structures Attachment from Equipment Attachment from Grades Other Supports. TTrunnion Supports PTFE Sliding Supports SPRING Supports > I 4 Nv. v. vl > > 1 M mH Vv. w. Spring Hangers / Supports Why required 27? ‘Types of Spring supports a) Variable Type b) Constant Force Type Principal of working Terminology a) Cold Load b) Hot Load ©) Spring Rate 4) Travel Technical Specification Instruction for Field Installation Expansion Bellows Why to use 22? Why not to use 22? Material of Construction Metalic Bellow Non- Metalic( rubber/Fabric) ‘Types of Metallic Bellows a) Axial b) Universal ) Tied d) Swing e) Hinged ) Gimbal 9) Pressure Balanced Welded Type Non-Welded T) Welded Type Constant Type Variable Type Snubber Type ype Mi. vil, vill. Back Thrust of Un-tied bellow Selection Criteria Technical Specification Instruction for Field Installationsa Institute of Technology DESIGN BASIS FOR STRESS ANALYSIS Piping Engineering ‘STRESS ANALYSIS DESIGN Cl RIA DESIGN CODES 1.4 | Process Piping Steam Piping ANSI B 31.3 - 1999, Addenda 2002 ‘STRESS CRITICAL 12) | UNE UIST BASIS DESIGN 13 _ | CONSIDERATIONS Pressure (Design/ Operating/ 1341 | Max.op.) Flexibility Temperature (Design? Max.op. Operating) 1.32 | ForLine Analysis For equipment expansion Imovernent Reference Installation 4.3.3. | temperature for analysis. 21.4 Deg. C 3 | Minimum Site ambient 5.0 Deg. C temperature 713.4 | Wind pressure/ velocity 18875 Parti (Specify factor w.r.t height) Refer Annexure B (page 1 of 2) 1.3.5 | Seismic coefficient ‘As per IS - 1893 (1984) Refer Annexure 8 (page 2 of 2) 7.56_| Two Phase Flow ‘To be analyzed on semi-static approach. 1.3.7_| Composite Analysis NA 1.3.8 _| Solar Expansion esr DegS = 1.3.9 | Steam out condition - (specify wiwout equipment) With Equipment 1.3.10 | Friction factor for various surface Steel to steel =03 Stee! 1o Graphite = 0.15 ‘Steel to PTFE = 0.1 Roller bearing = 0.05 Carbon stee! to concrete = 0.5, Mill Tolerance + 125% +1-6.0 % for pipes from plates, insulation Thickness & Weight As specified inline fist Usage of cold pull Notallowed. RIL to be consulted before use. Usage of expansion bellows i yes, specify probable vendor Yes, RIL to be consulted, 14 | Special care in stress analysis is, Plug/ slug flow lines Vibrating service Column overhead lines. Piping connected to strain sensitive equipment required for + Jacketed piping © Water Hammer * Pipe wall thickness & stiffener requirement tobe checked for vacuum 2 LOAD CASE CONSI 2.1 | Sustained Load Case 1. Design Pressure as speciied in the tine list for individual lines will be used within the Piping system weight analysis 2. Design pressure a8 specified in the piping ‘specification index will be used for pipe and pipe component pressure calculation. ight of the piping system will be taken from software library. 4, Max. operating pressure in case of lines + 6Oewith bellows, 22 Operating load Case 7. Thermal Loads willbe calculated sing elastic modulus at max. op. Temperature for hot ines and min. op. temperature for cold tines 2. Thermal stress will be calculated using elastic modulus at 21.1°C for all hotlines. 3. Solar radiation effect shall be consideration if ong line is exposed to sun light for @ long time with stagnant fluid or emply. 4. No. of thermal cycles 7000 5. Sustained + Expansion loads+ Equipment displacement 23 Sustained Stress Range 7, Sustained Load Highest stress value <70 % of allowed stress value, If higher consult stress lead engineer & RIL. 24 Displacement Stress Range 1. Temp. Load + Eqpt displacement 2. Highest stress value <80 % of allowable stress value. If higher consult stress lead engineer & RIL. If Liberal Stresses are used; the highest stress value < 75 % 25 ‘Steam out case (Occasional Load Case) 7. Where applicable, steam out temperature will be Design Temp for Low: Pressure Steam 12.190 2. Considered as occasional load case fro stress check only. 3. Incase line temperature is above steam ut temperature, steam out case will not exist, 4, Steam out case willbe done with line connected to equipment. 28 Wind Load case (Occasional Load Case) 7 Sustained load * Wind case for Code Stress Check 2. Operating Load + Wind Load Case only for support loading, 3, Wind & Seismic shat! not be considered together. 4, Lines connected to tall equipmenY structure sway due to wind shall be considered for line wind design in terms of nozzle & support. See Clause 3 in Annexure A 21 Seismic Load Case (Occasional Load Case) 1. Sustained load + Seismic load code check 2. Operating Load + Seismic load only for feading. 28 Start up & Shut down Load case Consider this case for 4. Column connected lines 2. Continuous Reactor connected line 3, Intermittent operation lines. (Process group to be referred) 29 Fire Case “Thermal Stress in this case should not exceed lesser of the following: ‘* 2 times the basic allowable displacement stress range (Sa) as quoted in section 302,3.5 of ASME B 31.3 piping code ‘* 3 times the basic allowable stress at ‘temperature (S) as per table A1 of ASME 1831.3 piping code. (Fire case temperature to be taken fromSuvidya Institute of Technology Piping Engineering prOcess Group) ‘As identified in ine ist for pressure & Test 2.40. | Hydrostatic Test case Medium. Lines to be hydro tested shall checked in sustained case for weight full of water 3 ANALYSIS OPTION 3 | Pressure Stess POUT 32 | Vertical Direction Y Axis include axal force in Stress 33 | calculation ss 3.4 [Use Liberal allowable Stress __| Ves Refer Clause 34 For Thin Walled lines 24° & Above 35 | Bourdon Effect Note : Pipe bowing effect to be considered fro steam condensate ines. 4 NOZZLE LOADING 41 | Fabricated Equipment (To Be decided by case basis) 4.2 _ | Nozzle flexbility Consideration | WRC 107/297, Local stresses in cylindrical shells = Due to external nozzle loads. Proprietary Equipment: Centrifugal Pumps ~ | API610- 7° Ecition/ vendor allowable Reciprocating Compressor API 618- 1995, 6” Edition 43. | AirCooled Heat Exchangers | API 661-2000 Centrifugal Compressors API 617- 1995, 6” Edition Steam Turbines NEMA SM 23. 1901 Lined Equipment Vendor Allowable _ 1. In Case where flange loading calculation need to be done following shall be used, At flange location, the axial force and bending moment will be computed in terms of equivalent pressure due to external loading and wil be evaluated against the flange rated pressure at the internal design pressure. Falz quip. Pressure due e to extemal loadin 8 ELANGE LOADING ial Force a Mb = Bending moment Dm = Mean gasket diameter Flange loading calculation will be done fro flange above 12" in size, forthe following service fluids, REC; DEG; VEG; REG; SLR; CAT; RH; STA; INR; EG; SH; SCH; HTF; NZH; DH; DGH; VGH; HM. Safely valve Control valve with open closed discharge: Use calculated dynamic force and feed as force fice the outlet of the relief valve. STD. Used for PSV 6 REACTION FORCE reactions API- 520 (1996) ANSI B 31.1/ B 31.3 CALCULATION as applicable Bursting Disc: Reaction force calculation dyrimic fofoe and fead ‘a. The spring hanger shall be designed for ‘operating temperature case. Once the spring ‘anger is selected by program (C-11), then 8 SPRINGS ‘samé data shall be checked at design ‘temperature condtion. Spring Hanger design shall be on the basis of Carpenter & Paterson's catalogue. “82‘Suvidya Institute of Technology Piping Engineering ’b. The spring load variation shail not be more than 25%, Beyond that constant spring hanger shall be used. ¢. Forall the spring hangers on the liquid lines, the WNC (Weight No Content) case must be checked. In WNC case the nozzle loads must be within the allowable tmits. 9 DISPLACEMENTS. Wax. Permitted displacement in horizontal, 4. Axial direction = +/- 100mm 2, Lateral Direction =45mm (This is specific ro pipe rack lines. In other cases, Itcan exceed the above, provide there is no clash with adjacent lines / structures) Max. Permitted sagging in vertical direction 1, Vertical deflection in piping system between ‘wo adjacent supports due fo sustained loading shall be limited to. ‘a. 6mm max. for stem b. %of gradient for slopping lines. c_12.7mm max. For all other lines TOOLS 70.1 | Software & Version CAESAR Th 10 102 | GEOMETRICAL DATABASE 1. Software library shaifbe used for piping ‘components, valves etc. including weight of the components. In case not available relevant vendor data to be used. 2. Insulation thickness shail be entered from line list 3. Specific gravity shall be as follows, Liquids lighter than water = Actual Liquids heavier than water = Actual Vapour! liquid mixture = 0.1 Steam/ Vapour = 0.01 " DOCUMENTATION 7. Allegible Stress isomeitic fo each syst model shall be submitted. The stress isometric shall clearly define important nodes, dimensions end displacements, axis and support type and locations. 2, Caesar II Input and output files of .a & *j Extensions. 3. Computer output hard copy that includes 2) Summary of forces, moments, and res at each node for all stress analyzed load cases. b) Summary of displacement at sustained & design load cases. ©) Summary of Stresses at sustained, desigh & ‘occasional cases. 4) The Ste up file and the input echo including element, uniform loads, restrains, unit & ttle. ints ) Spring Hanger Summary. 1, Delsan Conditions: Stress analysis will be carried out at the stress analysis temperature marked by the process licensor. Salient Points are below: 8) The flexiblity analysis shall consider the most sever operating temperature condition sustained during ‘startups, normal operation, shutdown, of regeneration. The analysis shall be performed for the maxinium temperature differential. The effect of minimum installation & solar temperatures (65.0 deg C) shall be considered in determi ig the maximum temperature differential ‘The analysis Load cases in CAESAR 1I will be as follows, ‘Load Case |- Operating temperature (T1) ae‘Suvidya Institute of Technology Piping Engineering Load case II- Design temperature (T2) b)_ The mean installation temperature shall be assumed as 21.1.C. 'c) Operating conditions shall be used to calculate the thermal forces on the pump nozzles in order to meet the vendor or API 610 allowable, Design conditions shall be used to calculate the stress in the pipe. 4) Steam Out Lines requiring steam out will be designed for fexbility at steam out temperature. This is applicable only when the steam out temperature is more than operating temperature or design temperature. Steam out ccase shall be considered as line & equipment being steam out together. 2. Critical Lines Selection: _ ‘The practices outlined herein establish the minimum requirements to which the Piping Stress Analysis shall adhere in the performance of quality assurance activities to ensure adequate engineering review of Piping systems. B. Formal computer analysis shall be performed on the following piping systems: 4. AITBR Lines. 2. Process lines that are 2.1. 2 and larger, with design temperature of 150 C and above. 22 10° To 18" Lines with design temperatures over of 65 C and above. 3._ Lines connected to stain sensitive equipment such as compressors, blowers and pumps, that are 3.1 2" and larger, with design temperature of 150 C and above. 3.2 10" To 18" Lines with design temperatures of 100 C and-above. 3.3 20" and above Lines with design temperatures over of 65 C and above: 4. Lines that are connected to air-cooled heat exchangers, process heat exchangers and pressure vessels, that are 1 2" and larger, with design temperature of 150 C and above. 2 10" To 18" Lines with design temperatures of 100 C and above. 320” and above Lines with design temperatures over of 65 C and above, 4 4 4 5. Jacketed Piping. 6. Lines subjected to excessive settlement, 7. Two phase flow lines prone to vibration 8. Lines with expansion joints as indicated in the P & ID. C. As a minimum, engineering analysis by visual inspection or short- cut manual calculations shall be perfoxmed onthe folowing systems (hen they donot fal under Category 8): 2" and larger lines with design temperature of 150 C and above, under the category of utility lines. 2 Zend ave process lines, to and from strain sensitive equipment, below 150 C (300 F). 3. Relief systems, whether closed or relieving to atmosphere, with considerations for attached or detached discharge pipes. 4, Bare lines exposed to suniight shall be check for a solar incidence temperature of 65 deg. C, visually or ‘by manual calculations. if necessary a formal computer analysis will be carried out. In addition to the above criteria, computer analysis should be considered for any special piping, as decide by Stress Engineer, in consultation with client 3.Wind Effect: ‘The wind effect shall not be considered forthe lines in the close areas. For the lines targer than 12" sail siameter which are in the open areas, and the elevation is 10.m & above the wind effect is to be considered (Gail Dia. =Pipe Dia. + Insulation Thk. + Cladding Thk.). For all lines, the shadow effect of neighboring Jnesivessels/structural wil be considered before applying wind effect. The wind load shall be as per Annexure-C, 2 of 2. All pipe supports shall be designed for the wind load when the wind case is governing,| | Suvidya Institute of Technology Piping Engineering 4, EarthquakelSeismic Loads: Allthe stress citical ines need to be checked for seismic load conditions. The Horizontal seismic coefficient is to be considered as per the seismic zone. Selsmic analysis willbe carried out as per static method. Static earthquake loads are applied in a manner similar to be static wind loads. The static loading magnitude is considered to be in direct proportion to the weight, Earthquake loads are defined in terms of ‘Gravitational acceleration constant (g)’. For e.g. ifan earthquake load is modeled as having a magnitude equal to 0.5 g in the X- direction, then half the system weight is turmed into a uniform load applied inthe X- Earthquake static load cases are set up and determind exactly as they are for wind occasional loads, ie.the same load case, non-linearity and directional sensitivity logic. The earthquake uniform loads will be applied in2 directions (x,2) Earthquake check will be for fui containment/system survival only. Allowable loads on equipment will be correspondingly considered. Allowable will be the yield stress at relevant temperature. {All pipe supports shall be designed for seismic loads when the sesmic case is governing. 5 . Nozzle Loads: For all static equipment, the nozzle loads shall be checked at design temperature. The actual nozzle loads shall-be compared against allowable nozzle loads es per applicable code and Loads on static equipment nozzles above 24” in size shall be informed to vessels department respective of magnitude of load. If any load exceeds the above-mentioned criteria then it shall be communicated to respective vendors for formal approval of the same. For lines with bellows, the nozzle loads will be consideied for the maximum operating pressure case. Spring support variation near equipment will be minimum, nozzle. Rotary equipment nozzle loads shall be checked at normal operating temperature. If normal operating temperature is not available, the maximum operating temperature or design temperature shall be use to establish nozzle loading, Allowable forces and moments for rotating equipment may be increased by 50 percent, for reactions occurring, only when the pump is not operating ie. steam, etc. order to maintain cold loads at the equipment Seismic Coefficient ‘The Horizontal Seismic coefficient is calculated by Response spectrum method, as per IS 1893-1984. ‘As per the seismic Zone The horizontal seismic coefficient is calculated as follows, = BLL Fo. (Salg) = 0.1008 Where, (Horizontal seismic coefficient) = B (coefficient depending on soil foundation system) = 1.2 | {Important factor ofthe structure) = 1.5 Fo {Seismic zone factor) = 0.2 ‘Salg (average acceleration coefficient Caesar Il Input to use ‘g? Option for Uniform Loads, Where g = 1008 8S (C Cpe orcySuvidya Institute of Technology Piping Engineering Wind Loading Wind Load Calculation is as per IS: 875 (Part 3)- 1987 Basic Wind speed, Vp = 44 mis Design Wind Speed, Vs =Va ks, ke ks ‘Where ky = 1.07 risk coefficient ke = 1.0 topography factor a= terrain factor which varies with height Hence Vs =1.07 Ye, ke Design Wind pressure, P, =0.6 V," kNim? Height ke ve By & Ms Kivi Upto 10m 0.98 46.14 1.28 0.96 16m 1.02 48.02 138 1.04 20m 1.05 49.43 4.47 4.10 30m 14 51.79 161 121 50m 1.15 5414 176 1.32 92m 1.209 56.92 1.94 1.48 ‘Shape Factor C; (Code Section D. Also BS Cp-3) DxV2<6 ameter of Pipe + Insulation in Inches) 6<= Dx V2.<12 xV2<23 xV2 G Recommend Caesar Il Input to include Cyand the P, to be included in the Wind Load Generator. Use of u in Caesar Il input not recommended Itis to checked whether Seismic governs before doing extensive Wind Runs. BSCharts and Tables CAL Properties and Weights of Pipo Naina] West [aver] Mur a a sila Peteaon at | ue [aide | Ort | som | SE] at” | at at | Bm | Slee | Mego 7 ae Bian | Behale [auch tuck] eter | Ms Tera | Me Pipa ‘eter ‘Number nets nea whe Thadins - ince icra) ince gueince] tees | sch! || cher} cy | ay Del i é LE | are MS [water pore 10S} 0.049 | 0.043 | 0.307 0.055 0.0008 | 0.0043} 18.6 "| 127] 0180] 000 34" |3td. 40 40s} 0.088 | 0.080 0.289 0.072 0.001 | 0.0052 | 28.7 | o129|° 0245] O.025 0405 | XS 80 sos} 9.095 | 0.083 |: 0.215 oer |. 00012] oot} 475 | 018} oa} ‘boo , 1 $02} O087 | naio}. aor | Soom} oéies|'ise | oreo] asso “Seer 36" Ftd. 49 408} 0.088 0.077 | 0.364 0.195 0.0038 | 0.0123 | 207 | o163| 0495} oot 9540 | XS 80 sas} 0.19] 0.108 | o302 0.187 0.0038 | 0.0140 | 322 | 3158} 0538] oat aa bis Joost | oss! oir | oonse| omr| eae { oar] ava| oxo 4” [Sud 40 405} 0.001 | 0.080 0.493 0.107 2.0078 | 0.9218 | 12.81 | 0200] oes} 0.089 Ot] *S © si osm janio) ows) oair | canes | Sane] St | O20) 9888 | cows 7 x gon} oar | cows! oor! 695 | oa! osn| osse 4 Ios a ts gen} 02% | ooiri|: ostar| a7 | oan| Sat] gust eso [ks 5 Se ose} osm | com] oom] ser | oa} sae | oi 12 [aur aoe] cate | cae | coat} cosmr| ara | $282] M8] ouat foxes Ga }oass) ease) aoe | ocees] asi] ara | ga| 132) car 7 Ss} 008s |o087| 10] zat | ocaas ose} ose] o2as x! 10S} 0.083 | 0.073 0.252 00207 | 0.0860} 426 | 0343] oas7 0.266 080 Js, 40 dts] ous | ove cass | ccsro) come] is | case|. Sas | gas MS go SJeuutfous| ora] ou | cous} aos! oa: | oan | sar | aaer MO /AS| it] aa] osm f- Gasar| Same] sed | Saat] Ser | our xs owsfozr| ost] ons | oasre! ano | ato | oane| iit | 9388 , os] o1a [sore] is} 9288 | caso! ore | 200] oats] ose | cure Y dejo) om] 197) oss | ort] Gaus | 3am | Sus] oust] gare ‘ae fsa we asfous] aus] tom] te | tome] GUS | 32 | ae tas | oar XS. s09/o1r0 fous] cos! on | aos | oxen oer] aur | vos 100 0.250] 0.210! Osis 0838 ff o125 0,190 0.987 | 2.84 0.226 mx poset} oais| oan} tos | giat | Sate oat] seo | cam 336 SeCHARTS AND ‘TABLES 331 cy eyes, ct sus Cels -Propgortion and Weights of Pipe Continued / Nominal] Weight Mink * a Bend | pa dius ‘Weight of ‘ Ze) oes || can regen | 3 flim cit] ae | We ma | Mee | etc gt ro ea acs Tat | saoua | Me aril | roe | Woe | mee Scat [toe | Jee 4 ai =o inde inches fochea inches | Inches | squaretnches | Inches "| inches? } ¥/ft . D. tite a a T a MR 58} 0.0845 | 0.087 | 1.530 023 0195 | 1.23 i eis [tat| tea] os tia | air ( oa. ao takai oun | in| ties | 2 we ‘ raso | x3, -e9 raasl oan | oer | 1.218 “399.4 | 0.80 | 000 | 1.160 oa | oan | 42s ozs | oss | 60s xs ose | 0384 | 0.806 osn | oa | 112 sg 008s | ogy | 1.70 oss | oes xan | 407 og} 0.00 | cons | 1.082 oz | 0280 200 | 0.96 ta, 40 40s} 04s | 0497 | 1.010, osio | 0390 am | 088 data sea | -or7 xo. foam [oss | ras] 143 ogee | sis | oss | sar | ot wae Yfke | xm wsfonm forts | ism] 127 iexs oaet foaso| i | a0 fim | ass | oss | sat | cat : ss{oots [oasr | 2205] oat cats | pass |'om | ito | “in stslouee faoss| air] ozs | caso | can | soz | oso | 2m | 158 wu std, 40 O.158 | 0.195 | 2.007 107 0.660 | 0501 | 1.50 | 0.70 3.05 145 1 2516 4°] xg ‘9p so] o.2t8 | 0.101} 2.000] 148 osss',| 0731 F ie \o3is |oso| ten] ai | tue] oar hes cass feses| ism] ass] ist | a0 : se{ooss | oars} .2m0| ar | ora | auoe i sts]o10 [ovos| aes) ter | oaes | oer lw ao astoges [oure| a | iro | tse | a8 x80 wsfase| oan] ann) aa | ast | oe feo * * Po.s75 | 0,828 | 2.125. 2.95, 2.35 166 Pfs sf agen [oases | ani | < dma | Zar | 200. 53} 0003 un | one ' ws} oam tea | un or @ wfom : aa | im 3.500::| XS 2 ‘e09| Ho 3.03 390 |” 293 a tay | toe | tas. xs" 7 sar 348 x 38) 0988 tor 9.80 alee ua i 3%" -|Std, 40 408} 268 3.39 ‘ 4.000 | XS 80 80S) 0.518 3.68 4 cas: “foe on ‘ oss |oors | asa] 138 o.iz0| 0.105] 4260 ]° 185 ast | 0207 | 4028]. 317 ager | 020s | 3428) dat 195 js 178 | 0300] 155°] se | 027 } sar | oom} asi | 10g | 551 . 427" 0.99} 14p-|-150 | 408 0.438 | 0.382 | 3.624]. 5.59. ut 518 iat | 14s | 190° 447 . asst |o4ss| sass] "a2 ] ass | ss0--| a2] va | aos |. 402 ‘ sau [osso| aisa| aio | iss | azo | aat | var | ons | ase ae G 7 G330 DESIGN OF PIPING ‘SYStiznis Cel, Properties and Weights of Pipe— (értinued ‘var | Mak ay Sees] Bd | rraiy |_Weeheor $83] gag | tlt]: | Moet | che Wal | Wat | Dian ‘erie kfm] oer |S ante | MO beer unid O2t | Pipe | Weer ae sat pnd | tee Talon toch Inches square Incest | inchoo! | Yire wy | we t @ acne a | vk tp per fe oper ft se{ coe [cons | sas [67 098 oa 3s | a3 4g] 0384 | oxr7 | 5225] 220 843 oa, ait | 983 ise. 40 aos| ose | ozan| soi7] 430 | asa o4o| tess | as | 860 st -| X80 sos} oats | oaze| sats] cin | 207 ooo | ras | 208 | re 5.89 Sha 129 | 000] 0438 | 4588) 708 oo | 1g0 | me] ae | 83 | Bae a ba ma [an | 83] aah EH ° m fa fa | am a xs aa fae | ant | Bu nm ef we | sa. | oise) are | cue Ww 530 841 o1e8| 473 | s03 Noio"| or | a s i : | mia is veo ‘|r [oa | tas | mie in | cu to nas] as | op | 199 it | ars 3 10: uso} ss [aoe [ter i | 40 1060 ass | 55.0 120 100 19 | 426 » woo} a fae | ao a 2 tears] asa | in | $8 i (Sid. 80 16250]. 18.4 02 18 026 x8 0. |taio|/ ce |ismo| “ee | SE | TOS ae os jose | emo | aoa | oe | ah Ps ww! o fed pe 108: ‘ i a a o 1100 MB ry ue xo | Gin] te [at | 0 wm fin | can] 8 fie | oe 2 1560 105 0268] 523 | 192 626 . ia mo mo | can] tir [an | Sf 1800 237 0.308 | 6.12 | 245, 55.0. * * qouo DESIGN OF. PIPING SYSTEMS C-l, Properties and Weights of Pipe — Continued Ter Cro a =| sfomeat i ot | 3 Digro- | Schedule [Thiek Mell | ape lar |. Number > | nar iochen Sasha ects) inches |squareincea faces! | neha wy | ee D 4 1 2 ‘a | taper feb pert 7% ae [30] op wa » ws. [oa | 8 500 (Sta. 208°\ 7 80.6 10.6 x 22° | mo | soe 3 xs ms | amo | it 6 0 ss | im | ie 108 ui | imo | ie us " « 5) iso | ite 138 ‘8.000 wa | imo | ig 19 0 sa | igo | 204 m sa | ao | ae "| oso} sar. 208 ng | ao | ma | ome} S00” | 204 sor | mo | sos | oom] sac | 20 sos | amo | a8 | ogee] err | aur 0 us || ase | as7 | ood) eos | sar | xo ls 20 za. | ano | oar | oom} eae | ree | 20 x3 30 gos | weo | ie | oss] eao fae | 25 © ssa |- woo | imo | cove} eas |x | tn0 330 | ao | se | oso] eas fase | 20 A 4s¢ | ao | aio | ooer| eat fase [air 2 © wo | to | 26 | onee| 70 | ts0° | 16 2.000 ss | ano | on | ons] ear [i [us 0 sé} mmo | a7 | ase] axe [200 | 100 100 wa |. amy | ssa 359 | 109 1% sa |’ a0 | ie 20 | sea 10 wo |. tam | a | as eo | 3068 1 ur |" tio.) amo ara. » wi |p " Sid 20. 1040, 182 184 Xs 50 | ats 10 0 wo | dsr 18 ao | 2 X6 aes 0 woo | a5 m. fim bed) 3710 309 186 17a 6 4050 «| 388 28 168 2 sn | a a | 18, sso | in wr | uo 420 7620 052 420 un to wo | te 4 fa 460 3 sa ur 10 ‘yal0 a 0.017 | 10.5 98.9 "} 24 0 seo | ass | con fins fun | an ae soo | 6 | cose fing. [ist | as 0.000 of. ose2 fossa} za! 320 Tsou | ste | case | ao, . 4s fam | a %"]qsas| O57 | zero] srs | eon | fis | Gest] 04: [az [ae S7Ojoss}mso| sss | to | a | coated |i | at qi' CHANTS “AND TABLES um C2." ‘Thermal Expansion, Carbon and Alloy Steele 100 200 _ $00." 400 $90 600 700__800.- 900 EXPANSION, IN, PER 100 FT ° 0" [100 200.309 1400 800 600" 700 -B00' 800 1000. 100 1200 1300 1400 #800 (Toe - TEMPERATURE, F Materials (Nominal Analysis) 1, Carbos, carbon-d% molybdenum, and 4% chromium-4% nlybdonum sles 2 1% to 8% chromn-4% to 1% molybdenum sees, : 3, Ato 10% chrorlunn4% to 11% molybdoatm stels, 4 18% chromium 8% nist stesa (AIS! types 302, £03,204, 321, and 347), ‘Not: This char i eproduced form elandand of The M. WY. Kellogg Company that was und in the preparation ofthe sample sslelation ie eis bok Tein atin fll agreement ith dat in ASA BOL. 1H185, q2342 6 tevin? TENSILE MODULUS OF ELASTICITY, 10° LB/IN’ is Feproduced from a alandard of The M, W. Kellogg Company that w -leulatons fn this be DESIGN OF PIPING’ sysTEMS C3, Modulus of Elssticity, Carbon and Alloy Stecls 30 8 & 8 22 a 20, fe io- B00" 300400800 G00.” TOO TEMPERATURE F MATERIALS ig CARBON srexL 2 OMROMIUN-RICKEL STAINLESS STEELS SUCH AS Alsi TYPES 304, 308, 310, 316, 347. 2, FeARITIC ALLOY steces SUCH AS. cARDON-WOLYBOENOM, Yee 10 10% crnouiun-uory, MSI TYPES. 408, 410, 430, 448. “oo n0 1000 «1106 Tae 300 "TEMPERATURE! F 2 ued nthe preparatipa ofthe sample ook. This not in fll agreement with data in ASA DOLI 196 93CHARTS AND TALLES Ms ‘Ch Chart for Criterion in Par. 620(a) in Code for Pressuro Piping ASA; BS1.1 34 VU , _Anchor distance, ft ‘D” Nominal diameter, i. Analysis of piping ts mandatory if Hew D = Nomital diameter of pipe, in 1» Developed pipe length ft ¥ = Resultant of resteained thermal expansion tnd not lapar terminal displacements, is, Um Anchor dttanca(ength of ataight line {oinlg anchors), f, P= Tomporatore, F. *'The temperature seale may be used i ¥/9 whan tures no oplacemeat of te aschor polnts, Basis of Chart Analyse of ppg is manditory i he Yoong eitton Us ob atids by ETS .;oy DESIGN 0 ’ PIPING SYSTEMS C5, LENGTH OF LEG REQUIRED ‘Twordter 30) 3i 30 28 2" 18 . * NOMINAL IPE SIZE = tt 28 Ss 6 Tw BIO Ny Multiply L by K to obtain length ofl BC required, as er System, Both Ends Fixed, Thermal Expansion in.Plane of Members Lm Length of eg AB, I. - (= Unit linnr thera expanaion, n/t, Valuo of B uned «! 2010p, 54 = Codo allowable stress range (1.258, + 0.258), palsCHARTS AND TABLES 348 C-6 MOMENTS AND. FORCES ‘Two-Member System, Both Ends Fixed ‘Thermal Expansion in Plane of Members 96 ken ; suien K) pom, . 125 | 1.316 833 | «263 425 | 547 5 72.6 For Chart C-16: Multiply $ value from chart by My to obtain maximum streas for case shown, For Chart C-17: Multiply é value from chart by F to obtain muximum defection fo; case chown, \o4Suvidya Institute of Technology Piping Engineering CHUAPTIER-DX REFERENCE DOCUMENTS‘Suvidya Institute of Technology Piping Engineering CHECK ITEMS & POINTS. General. 1. Dwg. No. Rev. No, Issue Date. Issue Description and North direction property marked. 2. Issue column is property highlighted 3. Comectness of symbols used. Check with plot plan. 1. Location as per plot plans. 2. Corordinates confirmed 3. Elevations confirmed Check with Mechanical department inputs. 1-— Checked as per Engg. Dwes. Nozzle Nos-shown Nozzle schedule shown Nozzle orientation shown Lugs/Legs elevations / orientations checked Fixed / siding support located Local platform Ladders / stairways shown Size and type of rotary equipment marked Overall size and access requirement for package item Ser AwayD Check with civil / structural design Grid Nos. confirmed . All elevations shown IF ladders for operation / Maintenance shown Fouling with piping checked Foundation co-ordinates & heights confirmed Location of local support (Check fouling with near by foundation) oe aes Check with Instrumentation. 1. Instrument- piping design scope, for hook-ups of levél, flow, temperature & pressure ‘instruments. End connection & F/F or E/E dimensions of all instruments Level gauges and transmitter's access / viewing direction. Instrument cable tray / duct route and its supporting ‘Local control panel, location, access around this door opening Location of analyzer tapings Instrument air manifold location and end connections ‘Straight length requirements for flow instruments ~ Spas around flow orifice for valye operation. - . . 10, straight length requirement after control value to avoid vibration if required M. eee / Maintenance space required for control valve ~ 12. Installation / Maintenance space required for thermo well 13. Location of instramént junction boxes, Check with electrical / cables trenches 1, Fouling with eabletays 14 g.,‘Suvidya Insfitule of Technology Piping Engineering 2: Orientation of junction box for electrical motors and fouling with piping 3. Consideration for maintenance & requirement of lifting equipments 4, Grounding & bonding requirement for piping Piping Design 1. Line Nos. / material specification and insulation given as per P & ID diagrams 2, Matching connections at equipment nozzles, headers, continuation Dwg, (UG & ‘NG piping) 3, Tie-in connections location and type with package units ‘4, Spacing between pipes, including insulation (if applicable) 5, Elevation for plan view, center line elevation in isometrics view 6. Fouling with other lines structures, platforms etc, 7. Flow direction for lines 8. Accessibility for valve operations 9. Tap off for instrumentation @ln-Line instruments dimensions <&maintenance requirement 10. Special Piping items no marking 11, Satisfy all General Notes shown on reference P& I Diagram 12. Any special process requirements 13. Scope demarcation between piping &other (like package Units Instn.Client ete.) 14, Type of joint at battery limits 15. Design check with Stress Analysis 16. Support Nos.Location & Type 17. Access Requirement for equipment erection and maintenance 18, Safety precaution and regulations 19. Aesthetic look 20. Hydro test vents and Drain shown 21. Hose station shown 22.” Bye washer shown 23. — Check with respect to U/G piping layout 24, Allinstrument tag nos.marked 25. All Equipment nos.marked 26. Center line elevation for all horizontal equipment nos:marked 27. Adequacy of proper supporting 28. Safety valve discharge line supporting 29. Additional steam condensate trap at low points 30. Instrument Air and Steam trace manifolds. Inter Department check 1. Process Dept.Commenis Redeived/Followed 2. Comments from instrumentation Received/Followed 3. Comments from statutory authority Followed (if any) Other documents 1. Loads due to various pipe restraints issued to civil 2., Insert Plate information issued fo civil Dept. 3. Vendor Drawing for special piping parts checked 4. Other specialities, if any e 5. Plot plan updated to match piping plans wn‘Suvidya Institute of Technology Piping Engineering ) 4-Confirmation for the following design data 1.1 Loading points a). Ensure anchor point of piping system b) Ensure support method and loading for Inst/Blect. Facility ©) Ensure subject to be applied wind load. And seismic load 4) Ensure loading point of maintenance load ¢) Ensure loading point on a girder , 1.2 Direction of loading a) Ensure thermal reaction force by piping system b) Ensure consideration to start —up condition , 1.3 Kinds of loading I Long term loading y a, Ensure thermal reaction force b. Ensure piping loading. (Classify bare pipe, insulation or full water loading) ¢.” Ensure thrust force due to intemal pressure and spring force in the expansion joint 4. Ensure duct. Loading (instrumental/electrical duct or tray) Short term loading Ensure loads during pressure test. Ensure loading at maintenance period Ensure wind load, seismic load Ensure consideration on start -up condition Ensure friction force eae se 2.Confirmation for the maintenance and operation , 2.1Maintenance ) Ensure overhead clearance for maintenance way b) Ensure maintenance method for pump etc. 4 ©) Ensure preparation of maintenance beam or lifting jig 2.2 Operation a) Ensure necessity of patrol way ) Ensure connection to adjacent structure ©) Ensure interval of ladders and/ or stairs installation 3.Preparation of information ‘Confirm the latest referenced document for preparation of information Ensure existence and location of expansion joint, ifany Note for allowed or not-allowed place for bracing and its type Note for the limitation of beam depth - Ensure pipe rack layer height and support method for girder (interference. with beam and other construction) oe 6. Note fot interferenoe with under constructions, (Foundation beam and other construction) < Peo tapleege 7. Check interference of piping with instrumentation / electrical duct, column, beam, brace {consider insulation and thermal movement) 8. Arrangement of rack piping confirm whether laxge bore piping and /or high temp piping located closed to main colurins od 9.- Check a possibility of integration of column with adjacent structures. ypeepe \ ane ADSitti del ellie elie ee 10. Confirm the method for adjustment of installation height for horizontal drum and heat exchanger etc. (by the means of additional cradle or extension of saddle) 11. Confirm whether the axis direction of steel members was considered to the direction of loading 12. Confirm whether the information for opening was indicated. 13, Ensure whether the hold items were listed up and marked up in the drawing. Plant Battery limits = Plant battery limits and fence is shown as per the General Plot plan/Owner’s requirement/statutory requirement Basie Design data 1. Equipment layout provided by Licensor/Basic engineering package is referred. 2. Plant Finished grade level is shown. 3. Geographical &Plant north are shown & angle between them is shown. 4, Prevalent wind direction is shown = Access roads 1. Width of Roads is as per client’s requirements. 2. Road around the units are provided in such a way that crane access is available. 3. Requirement of firefighting is met. Arrangement of Equipments in Unit. 1. Equipments are arranged in process sequence for short piping runs and operational and maintenance ease. 2. Pipe rack should be kept preferably in the center of unit so that unit can be split in the ‘two or more areas of equipments, 3. Pumps should be arranged in two rows close to and on either side of Pipe Rack. 4, Heat Exchangers and vessels should bé grouped together forming outer rows on both side of Pipe Rack. 5. Heat Exchanger should be located perpendicular to the pipe rack on the outer row and adequate tube removal space is provided. 6, Fired heaters should be kept at open end of the unit and upwind from the remaining ‘equipments. 7. Air fin coolers are installed preferably above the pipe rack. Pump handling high temperature /hydrocarbon materials are not installed below the air fin cooler. 9. Towers/columns should. be located along the pipe rack towards open area for unobstructed erection as well as maintenance of internals at grade 10. Tall tover are preferably located at one place, so that platforms at higher elevations can be interconnected for operators convenience. 11. only day tanks ate located within Battery limit 12. Knock out dram, drain collection /blow down drums are located at one comer and far away from fired equipments within the plant, 13, Requirement of monorail for maintenance for pumps &' motor below pipe rack is checked, aS‘Suvidya Institute of Technology Piping Engineering Equipment spacing 1. For deciding distance between equipments, consideration have been given for piping near equipments, erection, operation, maintenance owner’s / licensor’s requirement & safety distance as per relevant statutory guidelines. i 2. Consideration is given for catalyst loading and other pre commissioning related Compressor House - 1. Elevation of compressor foundation is decided after considering straight length requirement for suction piping if suction nozzle is at bottom. 2. Center to center distance between to compressor is kept as per the vendor's recommendation 3. Dropout area is earmarked clearly as per the maintenance procedure 4, Width, length & height of the compressor house are decided after considering operation & maintenance requirement including space for future installation. 5. Capacity for EOF/HOT or other applicable lifting device is 10% more than the weight of the heaviest single piece to-be maintained / owner's requirement / vendor's recommendation Structures 1. Minimum height (head room) is maintained between two platform (floors) as per the local Factory rules ete. 2. Stairs /ladder including escape routes are planned as per the requirement of local Factory rales ete, 3. Removable platforms/gratings are provided as per the requirements. 4. Structure for lifting/material handling devices are planned Pipe rack 1, Pipe rack is located in such a way that run of piping is minimum. 2. Enough spare space is available as per the contract requirement. 3. For straight run of pipe rack without break is as per the requirement of civil. AFD & AFC plot plans are issued after incorporating the followings. 1. Feed back of details design (piping GA dwgs) 2. Grid numbers and spacing of Pipe rack & Structural including major supports. 3. Size of the Foundation ete for major equipments. ‘ wySuvidya Institute of Technok Piping Engineering logy ‘Abbreviation i_[MILP_— [Mixed integer Linear Progamming | [41 | FCCU | Fiuid Catalytic Cracking Unit 2. | mint | Mixed integer Non Linear [42 [MSL | Mean Sea Level Programming, 43 | SIDC | State Industrial Development 3__|HEN | Heat Exchanger Network Corporation ‘4._| PFD__| Process Flow Diagram ‘44 [PCB | Polluion Control Board '5._| UNS | Unified Numbering System 45 | SEB | State Electricity Board 6._[ AWS | American Welding System 46 | CCOE | Chief Controller Of Explosives 7._ AWWA | American Water Work Assocation | [47 | SMPV_| Static & Mobile Pressure Vessel [IPS [tron Pipe Sizes 48 TAC ___| Tariff Advisory Committee 9__| PBE | Pain Both Ends 49 | CIB | Chief Inspector Of Boilers 10_| PLE | Plain Large End 50 | O1SD | Oil Industry Safety Directorate 11. | PSE__| Piain Smail Ends 51. [FDA __| Food & Drug Administration ; 12. | TSE | Threaded Small Ends 52 | PDS | Process Data Sheet 43. RTS | Ring Type Joint 53 | FEG | Fabricated Equipment Group “4. | MSRL | Mild Steel Rubber Lined 54 | NEMA | National Electric Manufacturer's { 15. | MSGL__| Mild Steel Glass Lined . Association 16. | WOG | Water Oil Gas 55 | NPSH _ | Net Positive Suction Head 17. | LOAR | Leak Detection & Repair 56 | USCS | United States Costumer Sysiem 78. [LAER | Lowest Achievable Emission Rate | [87 |PCC | Plain Cement Concrete . | 49. | TOG | Top Of Grout 20. | GAD | General Arrangement Drawin FSU 21. | SCH | Schedule S—) | 88 [gp._| Flat Surface Up/Down 22. | LAG [List Annual Gost 0. | Tema | Tubular Exchanger Manufacture” 23. | BPT__| British Pipe Thread | a Associate ' 24. | NPS | Nominal Pipe Size 0. [RSA | Response Spectrum Analysis 25. | ERW__| Electric Resistance Welded 61. | MRS | Mut Response Spectrum 26. | EFW | Electric Fusion Welded 62: [URS —[ Unitonm Hseponee Specttim | [2r-[SORF—T Stip On Raise Face = Eee ar ont Meera 728. | WNRF _ [ Weld Neck Raise Face 63. | EMA | eat ten 29 | AARH | Arithmetic Average Roughness agacetion Height 64, | BPV_ | Boller Pressure Vessel |. [30 MSWG "| Metallic Spiral Wound Gasket 65. | BCU__| Body Center Unit ! 31 [EPA | Environmental Protection Agency 66_| FCU__| Face Centre Unit | 32 | BLE | Beveled Large End 67.| PID __| Process input Data | 33 [TG ‘Tongue/Groove 68 | LHR | Longitudinal Hook's Radi | 34 | FF Flat Face 69. | AHR | Axial Hook's Radial 35. | RE Raies Fass. 70 | LOPE | Low Density Poly Ethylene | 36 [OSRY_| Outside Sorew & Yoke 71_| PWHT | Post Weld Heat Treatment 37-| PIFE —{ Poly Tetra Fluro Ethylene 72, | FST | Fire Safe Twindish 38 | EPDM | Ethylene Propylene Diene Mia Monometer 73 [TPH | TonPer Hour 30 | TOS | Top Of Structure 40 | FOF | Face Of Flange‘Suvidya Institute of Technology VS Piping Engineering Hot Face Temperature Other Than Steam Service mre @ om [10 0s 2a [37 [32] 28 | 483 Temp | to to to to 10 to to to. To eos aa [ae 260 [316 [avi | a7 | 482} 538 25& | 95 as | 40 | 40 40 | 50 50 65 65 below 40. 25. 25 | 40 [| 40 40 | 50 | 50 65 65 | 50 40_| 40 | 40 50 30 | 65 | 65 75 75 80, 40 40_| 40 50 50 | 65 65 15 80 100. 40 40_| 50. 15 75 | 75. 30 | 100 | 100 soy | 40 | 40 | 50 | © 75_| 75 80_| 100-| 100 | Sey tao tao 50 | 75 [75 | too | 100 fis | 8 35040} 40_[ 50 [75 | 75 | 100_| 100 ms | 15_| Sey [ay tao fos | 75 | 100 | 400 | too | tas} 1S 350 fo} 40 | 6s | 75 | 100 | 100 | 100 | US 5 400740 [ 4065 [75100 | 100 | 100 | 11S 15 oad 80 7S | too | too} 300 | as |S $50 [403065 7S] 100 | 100 | oof 15 | AS ee eee aban bad || 7S | 100 | “Hoo | too | 1s | 1S Vessel & mat | so | 65 | 75 | 90 | 115 | 125 | 150 } 180 | 180 surface | _ | _ HLF oF | 14010 | 201 to | 301 to | 401 to | 501 to | 601 to | 701 to | 801 to | SHI TO Temp. | 200 | 300 | 400 | soo | 600 ]. 700 soo | 900 | 1000 [Notes : Thickness is insulation only and exclude any finishing material. Cold Conservation Insulation Thickness (mm) Vs. Cold Face Temperature. TABLE DL CF ] as ] +7 | 40 | 2 4 7 0 | 6 7 2 [ 328 Temp to to to. to to to to to to => | +6 | i | +5 5 9 {15 | 2 | 27 | 35 PipeW 15 25 2B 70 0 30, 6 [| & 6 80 {20 35 25 40 40 50. 65 65 5 80 25 25 25 40 40 50. 65 65 65 80, 80, 40 40 50. 50 80 | 65 |. 80 80. 90. 40 25 40 40 50 50, 65 65 80 90, 50. 25 40. 50. 350 65 65 80. 380 9 | 100] 40 40. 30 | 65 80 80 90 90 90 150 | 40 40 30 65 80 80 90 90 100, 200 40 40 50 65 80 [80 90 | 100 | 100 2501. 40 30 a 65 80 90 90 | 100 | US: 300 [50 30. | 65 65 80 90} 100 | 15] 115 350_{ 50 50 5 65 BO [9000] ats | 125 | 400 |_50 50 65 80 90 100 is 125 125 430] 50. 6 80 80 90 | 100 | 41s {125 | 140 500__|_50 65 80 80 90 | too] 15 | 325 {140 Flat | 65 65 80 80 90} 100 f 125 | 140° | 150 Surface ONG‘Suvidya institute of Technology PROPERTIES OF MATERIALS ee ee STAINLESS STEEL P-No.8 Group Ho. 1 TABLE TABLE 3 i Product Spee. te, Grade Notes Product Spec, Wo, Grade Notes pute sazeo noe 23] Pate Sk240 32623 | Sis. saz Hoe? |S fate Samo 3723 2 Sms Tb, $4213 TP3OeH Bag [sme gee te 2 3 Sis Pp sagi2 Tree 2 | [SE] Sei. te saz ° ‘Smiz.Pp. SA3I2_TP308H (RG [smu py sanz tess 2 é Snore. Sarees 2 |B]B8 | sma tm shone ren 2 Shit, Pp. SA376 TP30RH = |g | smis pe. aURSee Sk cs S/H Eke Se eo For, SA182 F308 2] gh | smi pe SA a E Fors. Shn82 F304 ZZ [ca rp. Saas TesoH 8 ir share oe 235 |8 fog SAI FB For. An ai TABLE 2 é Bar SAAT? 316-235, ea & = a |_Preduct_ Spec.tio. rage _Noles_| 6 TABLE 4 El fee sao soe - de Product Spee. No. Grade etes ‘Bl aa| sis to. seas reso — | 3 BY] HE] sos ro sane trot — | 8 | pute samo 316L — Bel Fe 1 an 53 | smi — Shjex’ sane Sow 5 [SPSELSSS RS Gene tie — + BE| rors. sauez Fost 4 Ba SAAIG BLS MAXIMUM ALLOWABLE STRESS VALUES, 1.006 pst. aaa FOR METAL TEPORATURES ROT HACEENNG DEG. a] _tabePaeicel geo [300 [ao Tso [oo | 30 | 100 130 [soo [aso | son [NOTES 7 pepe fer per pao] we [se pos oe Tor pie Pier] = H tes [ace [ree Fes [ca | ree [ez [ne | tne -1os [a [a ae ee repee eter] do a [ie [ime [no | 03 | 97 [25 | 94 2a] on] oe as ei |e [iw fis [ins [ra | ne [os [os rei arf as tar pas peetaepery sy a Fy [ish P83 [its [ea [too | 9s | 92 | 90 | en] a | ee svc | “FOR METAL TEMPERATURES NOT EXCEEDING DEG. *. ! vos |e om [sf a |e 0 [x0 Ba |mz] se] ia) 61 | a7 sa] 29] 2a fue] 14 1 Talat | ar Eat ao | as (us | is oe aa tH wy i, iy ioe [oe faa Lon aes far | od as do [ta These highe | 2 Rete 5. Rect 4)'Specfed wa. 1 SURE gt eneral pssnze chris for material bx of rallunetion i653. ‘hese sree Valves rey sevul in danersial changes dve to for Manges or gasket jor peratures ctove 100°, hee stess values may be wed soa ninioum tverature of HO" snd yscacang in wt lye elares above 100" F, hes streivalucs apply oy when the carb 4 9.046 or higher. Ge rateal shea rece by heath it, ‘or rapidly cooling by other MEANS. ie ‘for of bartock fs persed for stTéing rings only. Juss cened 8% ot dno expe 90% of the nha emer Us of de scea values are vet ther npgieetions where sig smeuits of distension gx 1 i‘Suvidya Institute of Technology Types of Sexviee a. Manways b. Inspection openings «PSV Instrument connections ce. Vents i. Drains g. Process connections Flanges Types a. Slip on b. Weld neck, long weld neck ©. Lap joint @ Blind c. Screwed E Plate flanges g Studding outlets Reverse type flange Reducing flange Graylock hub connector Socket weld “lange Facing Flat face Raised face Finish (smooth, standard, serrated) Ring joint Tongue and groove Male and female Gaskets 1. Types - Ring, non-asbestos sheet Flat metal Spiral wound Metal jacketed. Corrugated metal Rings (hexagonal or otal) angular ring) bh Elastomeric (rubber, cork, etc.) Internals 1. Types a. Trays, seal pans b. Piping distributors Yielding metal gasks:s {Yens ring, delta ring, ree~ Piping Engineering Baffles Demisters Packing Liquid distributors Vortex breakers Bed supports Coils yt ge Nene Accum ay compte: Petre Shower Ty‘Suvidya Institute of Technology Support grid one cllector Liaud inlet i ring chon Elerenidstibuor Locoing grid a Liquid inlet nt distributor ube ditibuor tocoing gtd Suppo grid Suppot grid ons caller Figure F-2. Typica! sacked cokimn, Piping Engineering 3 Layer of 14 Alba aN eS EA X “ower Dtbton Tay aya! Drain Te frien 8 er) "Layer "iets 3 Loyer Ve" Kinet Sar tinens Figure F-. Typical reactor internals.14" Retox in| > See Detail 3 |--see Dewi 28 “Similar to Det132 , Yapor outlet at top of had Detail 5: Overhead-line connections bs. Vepor outlet inside the sei [7 Simitar to Deta 2 ~See Del 2 Wie a, Restricted orientation Detail 4: Distributors Reboler drawott 20" Rebate return See Detail © = Mentotes Suasmout 8" Bottoms out | I 4 Simple Ftion pipe. Ret pipe rut clear ‘babble ape ond wets Detail 3: Reflux connections iba evind Ee Single lew rey : Reboiler conneotions Seca 20 A”eee rato 089° Ye, Pate 941 Gear 12) eee wes woo |) Punters 16° | ee Fister 1557 ue _saa'o" Prato 194.355 9" [het eL aso Puen 120-1 rage 10:0" Elevation ao Manse F.C. Tage fine‘Suvidya Insitute of Technology Piping Engineering 0 a PIPING ELEMENT SPECIFICATION | ° . BASE MATERA | NSULATION : YES 08 WO. —-| coson sven. [mone ; cos SERVICE : MEDUM PRESSURE STEAM VOL = FaTWG & PAGING + 1509» RF CONDITIONS CORROSION ALLOWANCE : 1.5 mm wPalds bale [2 [fel] =]2)-|=]*l=[*] an NOMINAL size we imn]s [ee | 25 [0 | so] 10 | 20] 20| rol 250] s00|as | -00| 0] soem | THEKNESS Gron7ineh) za]aa [aa] a7 [sofes[ eo [7a SCHEDULE WUNGER/THIGRESS }———— son. 40 sa [WATER 7S A108 or. B, SEAMLESS - B loos aa eas OMENSION STANDARO vs! & 360 oe PIPE TO PIPE JOINT ‘SW COUPLNG| BUTT WELD 2 [ne sue oN & BUND, RASED FACE _ 8 [arerar [ASTM A105 / 1S 2002 Gr _ _| A [mean Saas is 8 165 TE 50 3000) |W by, SOMLESS To SUT BPE TH = g TERA 7g A105 | AST Aca34 GW — a | DIMENSION STANDARD ANS1B 16.11) ANSI B 169, R150 - wm | PE sw BW, SEAMLESS: _ 8 bans [2007 | Tyo sur san oe —————— E [ouENSeN stom wa 6 teni| ear tes —_ MATERUL ASTM A=105] ASTM A-234 Gr. WPB _ ooo [34 | “Lecco pact t0) S20} 70 |g —RENFORCED Sét ON eae ” aso | 18 S SOCKOLET yyetu eof | T Trreaboter rTonull a : & —UnrenronceD ser ov sof ae] UNRENE , vfulufule » 300 | 12 | 8® BUTT wel Tee vlv{u}v[ulu 8 ape] HAE Sous somo chepepe peters mole | sc. scxmwn Tee ufvfulepupepele 8| "aan [00 f+ wlew[uju[v}vlwlvjuly > Boi 3 ow ijewlewlulululululululv 18 =f? / olwleolulujulu[vjulululu 4 oh mwlolw[vlv[uly[ululy|vpuly , - et ow | sw [ov [ve-[ve [ve [ue [we] wo] ve [ne | He | nee 1 | 3 sw | sw | sw} he | We [He [ae [ue [ie | He | THe | He | He | He ‘ 3 | ye Se Pe ef ee fe [ne [ 1 alae sate ls wll w lea la [a i aE {80 | 100 150 | 200 | 250 | 300 | 350 | 400 | 450| 500 | 600Piping Engineering PP DOD I DEAE RGSS OL WHSSINSS TS SONVEE 1 SELON ‘GSMINOSY SAVOISILUSO 1931 SRN (GNTSE0 BA WA BSHIVENG HIM ONTZIS| “TETRA BAAL NOUENNOO ONG] Baa von SV ONAL zowu BIO Noiuwouroass BOW inwir08 eeaivn INSET 7008 ea) ‘wansesea isa = TEORORD ATONGO WNVA BOWED (GaXLSNTN@ _ NOUNSIZ0 358N0S Rows WaLSaARN 40 ZONVASIO| f = ez Tt ‘BVIOL © Suvidya Institute of Technology 423eee eee VALVE DATA SHEET (GATE ,GLOBE,CHECK.NEEDLE, BALL BUTTERFLY, PLUG) VALVE NO. ITEMS MARKED m ARE APPLICABLE GENERAL PE OF VALVE | _ [SIZE RANGE [CODE & STO [RATINGICLASS, MATERIAL SERVICE CONDITION [PIPING CLASS - X MEDIUM - icin TEMP a IPRESSURE(GARG) TEST & INSPECTION [APPLICATION _ OTHER REQUIREMENTS 7 IG) GEARED HANDWHEEL: NPS [CI FLEXIBLE SOLID WEDGE (AS PER API A ACCESSORIES |ODRANNOZZLE MATERIAL: : IONIPPLEATSWENDS MATERIAL: [D LOCKING DEVICE PB Pressure seal Bonnet ___NBINon Bonnet ‘UB.Union Bonnet PC:Pressure seal Co _ ISRS:Inside Screw and Rising Stem FLGD:Flanged SW:Socket Weld. BW:Butt Wet RF-Ralsed Face. RTJRing Type Joint : Long Bolt Bonnet NBR: Butadiene-acrlonitile Rubber (TFE:Reinforced PTFE PTFE-Poly Tetra Fluoro Ethylene. ABBREVIATION: BB:boted Bonnet BC:Bolted Cover \WB:Welled Bonnet WC:Wekded Cover ISNS:Inside Screw and Non rising Stem (OS&Y:Outside Screw and Yoke «‘Suvidya Institute of Technology Piping Engineering DATASHEET FOR SPECIAL PIPING PARTS (RUPTURE DISC) fear =e ae Pewor Fran Sse Satoh Ti [osama fess [Sonce Csi or Eqapm Ney see pes) is lowneien rt _ i fre = sa ican) — pease Fesreias begs ema [Gach How te gh eit [ore Tenses [Ean ges? fearon eens e—— [son Peas rcs Fran Sonaon (es) = ema Gatn_tres/ [PatNo. = PPC-ONE TOCOO esta ita a 35 - » Ee aa a —| ner | Rae loa [sass | : ni ace [TS fag Scion C10. = one ninco ptosis a Se a oe gaa inihg gan ob re Se ep [ waning Rage] Bust TOE oe oF sm Hes, Es oe 310% 10 ra - ra aes pS i pate ET ein i ST wa See cnc cae Oto psu bers ohn le Tage ape Scena [Bataan Tensor Tie SOraPe Owe Tare ee =OaWPa 35008 5 Ping Fon Fa ae AD Sn PISS ns‘Suvidya Institute of Technology Piping Engineering DATA SHEET FOR SPECIAL PIPING PARTS. (SIGHT GLASS) em Ret toe [toa Tat aio [Pac oa Fon. [Secunia Regist Ne (Revo Ra z feamnoaty Ne Seo [our 1 [Senos ine Rao Easier) Tee Ba fconcton rit [ete — (HPS) r — Spee Be fra nore ca [site t [researe atenZi6) in Jorenton INemavitac aE — [Femperaure Boge. = Newari aE [—— [Focere tansy — Tt 7 = locsen lee [Temperate Deg 7 [ [Sasa aan eg [rat ign aie ra AAG) — ere [eam [cee [Speen | Fangs 7 anew Ea Presi ss |Piping Engineering ‘Suvidya Institue of Technology “FIBV1LAOOV LON ST ONISINVATYDORLOITa INO OSINVATWD d1Q JOH 36 TTIVHS waLdvay

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