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Pumps shall be located as close to the source of suction in order to minimize pressure drop in the system. The
line size and temperature will be the determining factors in piping layout.
A preliminary piping layout ( study layout ) shall be made to determine the requirement of spacing between
pumps especially in case of side suction/ side discharge, top suction/ top discharge pumps where straight
length requirement / platform / CPS requirement etc have to be considered.
Reducers in pump suction lines shall be as close as possible to the pump suction/discharge nozzles.
Eccentric reducers in pump suction lines shall be flat on top in order to prevent any entrained vapours in the
liquid from accumulating in the high point ( if installed bottom flat ) and thus causing cavitation in the pump.
Pumps in boiler feed water service operating close to vapour pressure of the liquid are susceptible to this type
of problems.
Reducers in pump discharge should be concentric in most cases. Eccentric reducers may be used in both
suction and discharge piping for top suction/top discharge pumps in order to obtain clearance between suction
and discharge piping.
Consideration must be given to lube oil and seal oil systems and any cooling water requirements. Care must be
exercised not to block access to the pump seals and bearings when routing these lines.. The pump data sheet
should always be reviewed to make sure these requirements are not missed. For very large pumps these may
be separate on skids.
When developing an equipment layout in pump areas, the layout designer must envision potential obstructions
around the pumps (e.g. large block valves, steam turbine piping, and tee-type pipe supports from grade). As
per Oil Industry Safety Directorate stipulation ( OISD 118 ) 1 mtr (1000mm ) is the minimum accepted spacing
between pumps.
Auxiliary piping shall be neatly routed along the base-plate and shall not extend across the operating floor. This
piping shall not obstruct inspection covers, bearing caps, upper halves of casings or any other items which
require access for operation or maintenance. In order to avoid a fire hazard, lubricating oil, control oil and seal
oil pipes shall not be routed in the vicinity of hot process or hot utility pipes.
When flexibility loops are required between pumps, it is necessary to partially run the lines over the pump and
driver. Every effort must be made to minimize maintenance obstructions by running the piping either outside
the area directly over the pumps or at a high enough elevation to permit the removal of the pump or driver.
The pump shall be placed in such a manner so that the suction nozzle elevation is always below the vessel/tank
nozzle and suction pipe shall be routed so that there is no pockets.
Pumps in vacuum service present special problems. Since the system operates at a negative pressure and very
high temperature, the pumps must be located very close to the suction source. This is often directly below the
tower or immediately outside the tower support columns. Pumps located directly beneath the tower can be
mounted on a special spring base as shown in sketch below.
In some rare cases one pump is installed as a common spare between two other pumps in different services.
The pump must be man folded in such a way to accomplish this.
Pumps may be single-stage or multi-stage. Multi stage pumps are usually side suction side discharge. These
pumps require significantly more space and faces layout problems. There is usually a straight run requirement
(example, 5 pipe diameters) between the suction flange and the first elbow as shown in Sketch. Due to the
heavier casing design for high pressures, allowable nozzle loads are often higher for multi-stage pumps making
pipe stress problems somewhat easier to resolve.
Function
Anti-vacuum Valve
Ball Valve
Boiler
Butterfly Valve
Calorifer
Expansion Vessel
Float Switch
Gate Valve
Loose Jumper
Type Stopcock
Non-return Valve
subjected to temperature change while switching from installed to operating condition (and visa versa)
resulting into its thermal growth in various directions in proportion to the length of pipes. The structural
integrity of the above network must therefore take into account the overall weight effect of the profile besides
its thermal growth.
A satisfactory design of the Piping System should therefore give a careful consideration to achieve the above
requirement. This is generally accomplished by providing external attachments (known as pipe supports) at
various locations of the piping profile.
This article deals with the basic purpose of the pipe supports, classification based on construction / functions
and a few typical types of pipe supports. In general it deals with metallic piping systems only.
To Support weight of Pipe during Operation & Testing
Supports are required to support the line during all conditions i.e. during operation as well as during testing.
In case of vapor line this difference will be very large due to hydro testing. Supports should be designed for this
load (unless otherwise decided in the project).
Some times line is capable of having longer span but load coming on the support may be very large (especially
with large diameter pipe lines). Then to distribute the load uniformly, more number of supports should be
provided with smaller span.
Note : 1. It may be noted that during testing condition there is no thermal load.
2. All spring supports are locked during testing.
To take Expansion Load
Whenever thermal expansion is restricted by support, it introduces additional load on the support. Support must
be designed to take this load in addition to all other loads.
To take Wind Load
Wind introduces lateral load on the line. This load is considerable especially on large diameter pipe. This tends
to sway the line from its normal position and line must be supported guided against it. In case of large diameter
overhead lines, supported by tall support extended from floor, wind load introduces large bending moment and
should be considered critically.
To take Earth Quake Load
The earthquake is normally associated with horizontal acceleration of the order of 1 to 3 m/sec2. This is around
10% to 30% of the gravitational acceleration and introduces horizontal force of about 10 to 30% of the vertical
load (or supported mass). While designing support this should be taken care.
To absorb Vibration of Piping system
When the pipe is subjected to moving machinery or pulsating flow or very high velocity flow, pipe may start
vibrating vigorously and ultimately may fail, particularly if span is large. To avoid this it may be required to
introduce additional supports at smaller span apart from other requirements. It may not take axial load, but
must control lateral movements.
To have Noise Control
In most of the plants, noise is resulting from vibration and if such vibrations are controlled, noise is reduced to
great extent. In such lines, between clamp (i.e. support) and pipe, asbestos cloth is put to absorb vibration and
avoid noise.
Noise due to pulsating flow can be reduced by using a silencer in the line. Still if it is not below acceptable level
acoustic enclosure may be used. insulation over line also helps in reducing the noise.
To take Hydraulic Thrust in Piping
The hydraulic thrust in the pipeline is present at certain point such as pressure reducing valve, relief valve,
bellows etc.
If the control valve has large pressure differential and line size is more, then this force can be very high.
The support should be provided and designed to take this load, otherwise this will load the piping system and
may cause failure.
To support the system during Transient Period of Plant & Standby Condition
Transient condition refers to the start-up or shutdown condition in which one equipment may get heated up
faster and other one get heated slower. Due to this the expansion of one equipment which in normal operation
will get nullified, may not get nullified and exert thermal load on supports.
Standby condition is also similar. If there are two pumps, one being standby and both connected in parallel (as
shown), design and operating temp. of both the connections will be same. But the expansion of two parallel
legs will not be nullified because at a time only one leg will be hot and another being cold.
To support the system during Maintenance Conditions
When for maintenance certain equipment or component like valve is taken out, remaining system should not be
left out unsupported.
To support the system during Shutdown Conditions
In shutdown condition all equipment may not be in the same condition as in operating condition. The springs
are, designed based on weights considering the weight of fluid as well as pipeline and thermal movements. But
during shutdown condition the fluid may be drained and the pipe becomes lighter. Hence the spring will give
upward reaction and shall load the nozzle beyond permissible limit.
In this case a limit stop is used which will not allow the Point C to move up above horizontal level.(However it
will allow downward movement during operating condition).
To support the system for Erection Conditions
Erection condition can be different than the operating condition which should be considered while designing
supports.
Loads due to such conditions must be considered while designing the supports.
Since the calculated value of schedule number is less than forty, then schedule 40 type of tube will be used.
Since the Di calculated is 0.627967922 ft, the from Appendix C-6 of Foust the NPS is 0.75 in.
Schedule Number
40
Do, in
1.05
t, in
0.113
Di, in
0.824
NPS, in
0.75
In the piping system design calculation, the equation below is used because the equation is for incompressible
fluid like tannery waste water.
Refer to the tables of this appendix to compute for the pump power requirement between two or more
equipment.
The velocity of the tannery waste water entering the next equipment can be solved as shown below,
The kinetic energy exhibited by the tannery waste water is calculated as shown. The compressibility factor,
alpha is determined using the Reynolds number.
Given the calculated Reynolds number, from Fig. 20-2 page 543 of Foust, locate the value of alpha. The alpha is
equal to 0.87.
The potential energy of the tannery waste water is calculated as well as shown.
The pressure involved in the specified location in different equipment can be calculated using the hydrostatic
pressure formula since the waste water is mostly composed of water.
f is a function of Reynolds number and E/D. From Appendix C-1 page 540 of Foust, at Di=0.824in E/D=0.00056.
From Appendix C-3 page 544 of Foust with Nre=253119.9664 and E/D=0.00056, f=0.02.
The length of the pipe used involves the straight pipes, fittings and valves.
For Lfittings, one fitting between the two equipment is needed. The fitting chosen is the 90 standard elbow.
For Lvalve, one fitting between the two equipment is needed. The valve used is the globe valve conventional
with wings or pin guided disk fully open. Refer to Appendix C-2a page 542 for the literature value.
Power requirement of the pump that will be used to deliver the waste water from one equipment to another can
now be calculated as shown below.
1.
2.
Short radius elbows:- SR elbows with centerline radius of curvature equal to the nominal pipe size Reducing
Elbows :- this elbows have centerline radius of curvature 1 times the nominal size of the pipe to be
attached to the larger end.
Bends :- Are made from straight pipe. Common bending radii are 3 and 5 times the pipe size. 3R bends are
available from stock. Larger radius can be custom made.
Returns :- It changes direction of flow through 180 degrees, and is used to construct heating coils, vents and
tanks etc.
Piping Design
Piping arrangements:Use standard available items wherever possible.
Do not use miters unless directed to do so.
Do not run piping under foundation.
Do not run steam lines under oil lines, fire hazards may occur.
Piping may have to go through concrete floors or walls. Establish these points of penetration as early as
possible and inform the group connected (civil) to avoid cutting existing reinforcing bars.
Include removable flanged spools to aid maintenance, especially at pumps, turbines, and other equipment that
will have to be removed for overhaul.
Steam lines, which are below grade in trenches provided with covers or (for short runs) sleeves.
Take gas and vapor branch lines from tops of headers when it is necessary to reduce the chance of drawing off
condensate or sediment, which may damage rotating equipment.
Maintain vent lines at higher and drain lines at lower elevations.
Clearing and Access:Route piping to obtain adequate clearness for maintaining and removing equipment.
Locate within reach or make accessible, all equipment subjected to periodic operation or inspection, with
special reference to check valves, pressure relief valves, traps, strainers and instruments.
Take care to not obstruct access ways i.e. doorways, truck-ways, walkways, lifting wells etc.
Elevations of lines are usually changed when changing horizontal directions where lines are grouped together or
are in a congested area, so as not block spaces where future lines may have to be routed.
Keep field welds and other joints at least 3 inches from supporting steel, building siding or other obstruction.
Allow room for the joint to be made
Allow room for loops and other pipe arrangements to cope with expansion by early consultation with staff
concerned with pipe stressing. Notify the structural group of any additional steel required to support such
loops.
Stresses On Piping
Thermal Stresses:- change in temperature of piping due either to changes in temperature of the environment
or of the conveyed fluid, cause changes in temperature in length of the piping. This expansion or contraction in
turn causes strain in piping, supports and attached equipment.
Settlement Strains:- foundation of large tanks and heavy equipment may settle or tilt slightly in the course of
time. Connected piping and equipment not on a common foundation will be stressed by the displacement.
Flexibility in piping
To reduce strains in piping caused by substantial thermal movement, flexible and expansion joints may be used.
However, the use of these joints may be minimised by arranging piping in a flexible manner. Pipe can flex in a
direction perpendicular to its length: thus, the longer an offset, or the deeper a loop, the more flexibility is
gained.
Pipe Racks
A pipeway is the space allocated for routing several parallel adjacent lines. A piperack is a structure in the
pipeway for carrying pipes and is usually fabricated from steel, or concrete and steel. Piperacks for only two or
three pipes are made from T-shaped member, termed Tee-head supports.
Piperacks are expensive, but are necessary for arranging the main process and service lines around the plant
site. They are made use of in secondary ways, principally to provide location for ancillary equipment.
Pumps, utility stations, manifolds, fire-fighting and first-aid stations can be located under the piperack. Lighting
and other fixtures can be fitted to stanchions. Air-cooled heat exchanger can be supported above the piperack.
The smallest size of pipe run on a piperack without additional support is usually 2inch. It may be more
economic to change proposed small lines to 2inch pipe, or to suspend them from 4inch or larger lines, instead
of providing additional support.
Valves in piping design
Valves are used for these purposes:Process control during operation.
Controlling services and utilities steam, water, air, gas and oil.
.
It is usual industry practice to classify the pipe in accordance with the pressure-temperature rating system used
for classifying flanges. However, it is not essential that piping be classified as Class 150, 300, 400, 600, 900,
1500, and 2500. The piping rating must be governed by the pressure-temperature rating of the weakest
pressure containing item in the piping. The weakest item in a piping system may be a fitting made of weaker
material or rated lower due to design and other considerations.
flow through it at some higher temperature during another mode of operation. It may be assigned two pressure
ratings at two different temperatures.
Review of Piping Fundamentals
Posted by Ankit Chugh on 9:08 AM 1 Comment
.
General
A pipe or a tube is hollow longitudinal
product. A tube is general term used for
hollow product having circular, elliptical or
square cross-section or for that matter cross
section of any closed perimeter.
A pipe is tubular product of circular crosssection that has specific sizes and
thicknesses governed by particular
dimensional standard. Tubes can be ordered
for any OD or ID and thicknesses, pipes are
ordered on basis of nominal sizes.
Classification:
Pipes can be classified based on methods of
manufacture or end use.
Methods of Manufacture:
Seamless Pipes are manufactured by drawing
or extrusion process. ERW Pipes (Electric
Resistance Welding pipes) are formed from a
strip which is longitudinally welded along its
length. Welding may be by Electric resistance,
high frequency or induction welding. ERW
pipes can also be drawn for obtaining
required dimensions and tolerances.
Classification Based on End Use:
Pipes are also classified as:
Pressure pipes or Process pipes
Line Pipes
Structural Pipes
1. Pressure pipes are those which are subjected to motive pressure and system pressure and or temperatures.
Fluid pressure in generally internal pressure due to fluid being conveyed or may be external pressure (e.g.
jacked piping) and are mainly used as plant piping.
2. Line pipes are mainly used for long distance conveying of the fluids and are subjected to motive pressures.
These are generally not subjected to high temperatures.
3. Structural pipes are not used for conveying fluids and therefore not subjected to fluid pressures or
temperatures. They are used as structural components (e.g. handrails, columns, sleeves etc.) and are subjected
to static loads only;
Pipes Dimensional Standards:
A. Diameters: Pipe are designated by. Nominal size, starting from 1/8" Nominal size and increasing in steps up
to 36 inches
For the Nominal size upto and including 12", there is one unique O.D. (different from nominal size) and 1.0.
would vary depending on schedule nuniber. For Nominal sizes 14" and above, 0.0. is same as Nominal size.
Thickness:
Pipe thicknesses are designated by schedule number (which determine internal pressure) or weight designation
like Std. (S), Extra Strong (XS) and Double Extra Strong (XXS). Pipe schedule number S is defined as:
Sch. No. S = 1000 P/S
Where P = Internal Pressure (PSI)
S = Allowable tensile strength of material used.
Common pipe schedules are Sch 40, Sch 80, Sch 120, Sch 160, for larger pipe sizes intermediate schedule
numbers (Sch 20 Sch 30 etc.) are also employed (Ref. pipe dimension Chart).
For Carbon steel, Pipe wall thickness tolerance is 12 1/2% i.e. Pipe wall thickness can, vary 12 1/2% from
thickness obtained from dimension chart.
For stainless steels schedule numbers are designated by su~Tix S i.e; lOS, 40S, 80S etc.
Length:
Pipes are manufactured in random length which is 20+ -2.5 and in double random length 40 + - 5.0.
Pipe Fittings:
Pipe fittings are the components which tie together pipe lines, valves, and other parts of a piping system. They
are used in making up a pipe line. Fittings may come in screwed, welded, soldered, or flanged varieties and
are used to change the size of the line or its direction and to join together the various parts that make up a
piping system.
The majority of pipe fittings are specified by the nominal pipe size, type, material and the name of the fitting.
Besides the end connections as above (screwed, welded, soldered, flanged) it is also possible to order bell and
spigot fittings, which are usually cast iron and used for low pressure service.
In general, a fitting is any component in piping system that changes its direction, alters its function, or simply
makes end connections. A fitting is joined to the system by bolting, welding or screwing, depending on many
variables in the system.
1. Butt-Welded Fittings
Welded fittings are used primarily in systems meant to be permanent. They have the same wall thickness as
the mating pipe. Among the many advantages of butt welded systems are the following:
They have a smooth inner surface and offer gradual direction change with minimum turbulence.
They require less space for constructing and hanging the pipe system.
They form leak-proof constructions.
They are almost maintenance free.
They have a higher temperature and pressure limit.
They form a self-contained system.
They are easy to insulate
They offer a uniform wall thickness through-out the system.
One of the major disadvantages of butt-welded systems is that are not easy to dismantle. Therefore, it is often
advisable to provide the system with enough flanged joints so that it can be broken down at intervals. (One of
the main uses of the butt-welded system, is for steam lines, which are usually in high temperature/ highpressure service).
2. Socket Welded Fittings
Socket welded fittings have certain advantages over butt-welded fittings. They are easier to use on small-size
pipelines and the ends of the pipes need not be beveled since the pipe end slips into the socket of the joint.
With socket welded fittings there is no danger of the weld protruding into the pipeline and
restricting flow or creating turbulence. Thus, the advantages of the socket welded system are:
The pipe does not need to be beveled.
No tack welding is necessary for alignment since joint and the pipe are self -aligning.
Weld a material can not extend into the pipeline.
It can be used in place of threaded fittings, therefore, reducing the likelihood of leaks, which usually
accompany the use of threaded fittings.
It is less expensive and easier to construct than other welded systems.
One of the major disadvantages of this type of fitting is the possibility of a mismatch inside the fitt~ng where
improperly aligned or mated parts may create a recess where corrosion could start.
Socket-welded fittings have the same inside diameter as standard (Schedule 4O), extra strong (Schedule 80),
and double extra strong (Schedule 160) pipe, depending. on the weight of the fitting and mating pipe. Socketwelded fittings rare covered in ASA 816.11. They are drilled to match the internal diameter of schedule 40 or
schedule 80 pipe.
3. Flanged Fittings
Flanged connections are found on piping systems throughout the petrochemical and power generation fields on
pipelines that are a minimum of 2 in.(5.08 cm ) in diameter. The majority of flanged fittings are made of cast
steel or cast iron.
Flanged steel fittings are used in place of cast iron where the system is subjected to shock or high-temperature/
high-pressure situations where the danger of fire is prevalent, because cast iron has a tendency to c rack or
rupture under certain stresses. A flange may be cast or forged onto the ends of the fitting or valve and bolted to
a connecting flange which is screwed or welded onto the pipeline, thereby providing a tight joint. An assortment
of facings, ring joint grooves, and connections are available in flange variations.
One advantage of flanged systems is that, they are easily dismantled and assembled. One of the disadvantages
is that they are considerably than an equally rated butt-welded system, because of the large amount of metal
that go into making up joints and flanges. Moreover, flanged fittings occupy far
more space than the butt-welded or screwed equivalents. Because of this higher weight load, a flanged system
becomes far more expensive to support or hang from the existing structure
Piping Design - Material Specification
Posted by Ankit Chugh on 2:39 AM 2 Comments
.
Basis of Specification
The following documents shall form the basis of project piping specifications:
Basic piping specifications from process department or process licensor.
Service summary indicating service against basic material of construction (MOC) for each service. This is
available either from process discipline or process licensor.
For utility piping, the project piping specifications for these services may be based on in-house experience.
However, the clients project manager shall be consulted in such cases before proceeding.
Design Criteria
1. Design Pressure
The design pressure of each component in a piping system shall be the severe condition of the following:
a. 1.1 x maximum operating pressure as given in line list or service summary.
b. Design pressure as given in the line list or the service summary by the Process Licensor.
c. Design pressure of equipment to which it is connected.
d. Set pressure of a pressure relieving device which protects the system.
Shut-off discharge pressure of a centrifugal pump, not protected by a pressure relieving device. If the shut-off
discharge pressure is unknown, it may be determined by the largest of the following:
i. 1.2 times the differential pressure at nominal flow plus the maximum pump suction pressure.
ii. 1.1 times the pumps discharge pressure at normal flow. Full vacuum for a system operating below
atmospheric pressure.
2. Minimum Wall Thickness
a. The required pipe wall thickness shall be determined in accordance with the ASME B 31.3 using the design
pressure and temperature mentioned above. The calculated wall thickness shall include mechanical allowance,
including manufacturing minus tolerance and weld joint efficiency factor plus the corrosion allowance.
Unless otherwise specified, the minimum corrosion allowance shall be:
Carbon Steel Alloy Steel: 1.5 mm
Ferritic Steel: 1.5.mm
Austenitic Stainless Steel for general purpose: 0 mm
The pipe wall thickness determined according to the above procedure shall be checked for ambient and
mechanical influences and other loadings described in the ASME B 31.3 in addition to the process pressure
temperature requirements.
The following minimum pipe wall thickness shall be used for carbon and low alloy steels of process and utility
piping including the items mentioned above.
NB
Welded Joint
Threaded Joint
112 and smaller
Sch 40
Sch 80
2" to 6"
Sch 40
8" to 12"
Sch 40
14" and over
Sch 40
3. Design Temperature
Design temperature as given in the line list for each pipeline. Design temperature as given for each service in
the service summary by Process Discipline or Process Licensor.
When maximum operating temperature (T) is given in line list or service summary, the design temperature (T)
shall be as follows :
T = T 0+ (+20) 0 C, When T0 is between 0 to 200 0 C
T = T 0+ (+10 to + 20 ) 0 C , when T0 is over 200 0 C
T = T 0+ (-5) 0C, when T 0 is 00 C and under
Where = T = Design Temperature
T 0 = Maximum Operating Temperature
The design temperature of a piping system shall be the design temperature of connected equipment.
For un-insulated piping, the design temperature may be determined in accordance with ASME B 31.3.
The reducing co-efficient for piping components not specific in the ASME B 31.3 shall be 95% for fluid
temperatures over 370 C .
4. Fittings
Long radius (R= 1.5 D) but welding elbows shall be used wherever possible. Unless otherwise specified, flanged
elbows shall not be used.
Pipe bends may be used in place of elbows, which shall not be used. Pipe bends may be used in place of
elbows, but the minimum-bending radius shall be 5 times the nominal pipe size.
Miter bends may be used within the limitations specified in the ASME B 31.3.
Generally for utility services (except steam) miter bends shall be used for pipelines 8" NB and above.
Branch connections shall be preferably made by fittings such as tees, half couplings or weldolets. If the ranch
connections are made by welding the branch pipe directly to the run pipe, the required reinforcement shall be
designed in accordance with the ASME B 31.3.
Fittings of 2 NB and larger shall be the butt weld type and fittings of 1 12 NB and smaller, socket weld or
threaded type.
As far as possible, use of threaded fittings shall be avoided, except in the case of galvanised piping for
instrument air and drinking water services.
5. Flanges
The number of flanges in piping systems shall be kept to a minimum and should be installed only to facilitate
maintenance and inspection and where construction or process conditions dictate. For instance:
Where pipelines are connected to flanged equipment and valves.
Where frequent dismantling of piping is required.
Where clearance for dismantling equipment such as compressors and reactor heads is required.
Where steel piping is connected to non-metallic or non-ferrous piping.
6. Flange Types
6.1 Slip-on Flanges
Slip-on flanges may be used where the following requirements are met :
i. Carbon steel piping
ii. Pipes handling non-toxic fluids
iii. Pressure - temperature conditions are within the ANSI 300 LB rating.
iv. Design temperature exceeds minus 20 0C
Slip-on flanges of austenitic stainless steel may be used within the limitations of item ii. through iv. above, if
justified from the cost point of view.
6.2 Welding Neck Flanges
Welding neck flanges shall be used in all instances where slip-on flanges, socket weld flanges and screwed
flanges are not permitted.
6.3 Socket Weld Flanges
For 112 NB or smaller, socket weld flanges may be used within the limitations specified in paragraph 4.3.4 but
S.W flanges shall not be used for piping under IBR purview.
6.4 Flanges Facing
Flat face flanges shall be used for connecting flanges to flat face cast iron or bronze piping components and
equipment. In this case, gaskets shall cover the whole flange face.
Raised face flanges shall in general be used:
i. For flanges of 600 LB or lower rating in process services.
ii. For flanges of 1500 LB or lower rating in utility services.
iii. Regardless of the above limitations a) and b) for design temperatures not exceeding 4500C.
Ring joint type flanges shall be used for flanges of 1500 LB rating or higher, or for design temperatures
exceeding 450 0C. The flanges can also be used for lower ratings, for service conditions which requires higher
degree of tightness. Small and large tongue and groove faced flanges shall be used for services requiring
higher degree of tightness and for all lethal services.
7. Bolting
Stainless steel galvanised cadmium plated nuts and bolt studs should be specified in cases where:
1. The spillage of pipeline fluids on the bolting shall corrode them.
2. The plant atmosphere may contain gases which may corrode the bolting.
The basic documents indicated above may not specify this clearly. However this needs to be verified during the
preparation of piping specifications and finalised in consultation with clients and project manager.
8. Gaskets
a. Specific approval from the Project Manager, Client Process Licencor, Process Discipline (as the case may be)
shall be obtained if material specifications are different from those specified in the basic documents.
b. Full-face gaskets shall be specified as far as possible, where both RF and Flat Face Flanges are used in the
same piping class (e.g. cast iron valves in carbon steel piping with raised face (RF) flanges).
9. Valves
The types of valves specified shall be as per either P&I Diagrams or as per basic piping specifications from
process licencor or Jacobs H& G Process Discipline.
Types of valves may be revised as per the clients requirements. However, this shall be done only after the
review of suitability of the same for the intended service and proper documentation of the change required.
Ball valves may be used in place of gate or plug valves with the following limitations.
i. Operating conditions are within the permissible pressure-temperature range of seat materials.
ii. The Fire safe type is used for flammable services.
Large diameter check valves shall be provided with anti-knock device if swing check valves are specified.
Check list for valve requisitions may be referred to if required, to specify special requirements for valves in the
project piping specifications.
10. Branch Connection Chart
The standard branch connection chart shall be used to specify use of tees, etc. for a specific piping class.
When the details following, order or preference shall be kept in mind to facilitate procurement and reduce cost
of materials (arranged in reducing order of preference i.e. (a) is most preferred).
a. Pipe to pipe branch.
b. Use of half couplings
c. Use of weldolets, sockolets. etc.
d. Seamless tees.
However requirements of basic documents shall not be diluted in this process
Carbon steel pipe is strong ,ductile, weldable, machineable, reasonably durable and is nearly always cheaper
than pipe made from other materials. If carbon steel pipe can meet the requirements of pressure, temperature,
corrosion resistance and hygiene, it is the natural choice.
Other metals & alloys :- pipe or tube made from copper, lead, nickel, brass, aluminium and various stainless
steels can be readily obtained. These materials are relatively expensive and are selected usually either because
of their particular corrosion resistance to the process chemicals, their good heat transfer or for their tensile
strength at high temperatures. Copper and copper alloys are traditional for instrument lines, food processing
and heat transfer equipment, but stainless steels are increasingly being used for these purposes.
Methods for joining pipe
Butt welded
Socket welded
Screwed
Bolted flange
Bolted quick coupling
Piping components
Elbows, Tees, Flanges, Gaskets, Nipples, Unions, Valves, Reducers, Steam traps, Bellows
Elbows or ells :Types of elbows
Long radius elbows:- normally used elbows are long radius with centerline radius of curvature equal to 1
times the nominal pipe size for inch and large sizes.
Short radius elbows:- SR elbows with centerline radius of curvature equal to the nominal pipe size Reducing
Elbows :- this elbows have centerline radius of curvature 1 times the nominal size of the pipe to be
attached to the larger end.
Bends :- Are made from straight pipe. Common bending radii are 3 and 5 times the pipe size. 3R bends are
available from stock. Larger radius can be custom made.
Returns :- It changes direction of flow through 180 degrees, and is used to construct heating coils, vents and
tanks etc.
Piping Design
Piping arrangements:Use standard available items wherever possible.
Do not use miters unless directed to do so.
Do not run piping under foundation.
Do not run steam lines under oil lines, fire hazards may occur.
Piping may have to go through concrete floors or walls. Establish these points of penetration as early as
possible and inform the group connected (civil) to avoid cutting existing reinforcing bars.
Include removable flanged spools to aid maintenance, especially at pumps, turbines, and other equipment that
will have to be removed for overhaul.
Steam lines, which are below grade in trenches provided with covers or (for short runs) sleeves.
Take gas and vapor branch lines from tops of headers when it is necessary to reduce the chance of drawing off
condensate or sediment, which may damage rotating equipment.
Maintain vent lines at higher and drain lines at lower elevations.
Clearing and Access:Route piping to obtain adequate clearness for maintaining and removing equipment.
Locate within reach or make accessible, all equipment subjected to periodic operation or inspection, with
special reference to check valves, pressure relief valves, traps, strainers and instruments.
Take care to not obstruct access ways i.e. doorways, truck-ways, walkways, lifting wells etc.
Elevations of lines are usually changed when changing horizontal directions where lines are grouped together or
are in a congested area, so as not block spaces where future lines may have to be routed.
Keep field welds and other joints at least 3 inches from supporting steel, building siding or other obstruction.
Allow room for the joint to be made
Allow room for loops and other pipe arrangements to cope with expansion by early consultation with staff
concerned with pipe stressing. Notify the structural group of any additional steel required to support such
loops.
Stresses On Piping
Thermal Stresses:- change in temperature of piping due either to changes in temperature of the environment
or of the conveyed fluid, cause changes in temperature in length of the piping. This expansion or contraction in
turn causes strain in piping, supports and attached equipment.
Settlement Strains:- foundation of large tanks and heavy equipment may settle or tilt slightly in the course of
time. Connected piping and equipment not on a common foundation will be stressed by the displacement.
Flexibility in piping
To reduce strains in piping caused by substantial thermal movement, flexible and expansion joints may be used.
However, the use of these joints may be minimised by arranging piping in a flexible manner. Pipe can flex in a
direction perpendicular to its length: thus, the longer an offset, or the deeper a loop, the more flexibility is
gained.
Pipe Racks
A pipeway is the space allocated for routing several parallel adjacent lines. A piperack is a structure in the
pipeway for carrying pipes and is usually fabricated from steel, or concrete and steel. Piperacks for only two or
three pipes are made from T-shaped member, termed Tee-head supports.
Piperacks are expensive, but are necessary for arranging the main process and service lines around the plant
site. They are made use of in secondary ways, principally to provide location for ancillary equipment.
Pumps, utility stations, manifolds, fire-fighting and first-aid stations can be located under the piperack. Lighting
and other fixtures can be fitted to stanchions. Air-cooled heat exchanger can be supported above the piperack.
The smallest size of pipe run on a piperack without additional support is usually 2inch. It may be more
economic to change proposed small lines to 2inch pipe, or to suspend them from 4inch or larger lines, instead
of providing additional support.
Valves in piping design
Valves are used for these purposes:Process control during operation.
Controlling services and utilities steam, water, air, gas and oil.
Isolating equipment or instruments, for maintenance.
Discharging gas, vapor or liquid.
Draining piping and equipment on shutdown.
Emergency shutdown in the event of plant mishap or fire.
Which size valve to use:Nearly all valves will be line size- one exception is control valves, which are usually one or two sizes smaller
than line size, never larger.
At control stations and pumps it has been almost traditional to use line-size isolating valves. However, some
companies are now using isolating valves at control stations the same size as the control valve, and at pumps
are using pump size isolating valves at suction and discharge. The choice is usually an economic one made by
a project engineer.
Where to place valves
Preferably, place valves in lines from headers (on piperacks) in horizontal rather than vertical runs, so that lines
can drain when the valves are closed.(in cold climates, water held in lines freeze and rupture the piping such
lines should be traced.
To avoid spooling unnecessary lengths of pipe, mount valves directly onto flanged equipment, if the flange is
correctly pressured.
A relief valve that discharges into a header should be placed higher than the header in order to drain into it.
Locate heavy valves near suitable support points. Flanges should be not closer than 12 inches to the nearest
support, so that installation is not hampered.
For appearance, if practicable, keep centerlines of valves at the same height above floor, and in-line on plan
view.
Operating access to valves
Consider frequency of operation when locating manually-operated valves.
Locate frequency-operated valves so they are accessible to an operator from grade or platform. Above this
height and up to 20feet, use chain operation or extension stem. Over 20feet, consider a platform or remote
operation.
Valves Operating Heights
Infrequently used valves can be reached by a ladder but consider alternatives.
Do not locate valves on piperacks, unless unavoidable.
Group valves which would be out of reach so that all can be operated by providing a plotform, if automatic
operators are used.
If a chain is used on a horizontally mounted valve, take the bottom of the loop to within 3feet of floor level for
safety, and provide a hook near by to hold the chain out of the way.
Do not use chain operators on screwed valves, or on any valve 1 inches and smaller
With lines handling dangerous materials it is better to place valves at a suitably low level above grade, floor,
platform, etc., so that the operator does not have to reach above head height.
Access to valve in hazardous valves
Locate main isolating valves where they can be reached in an emergency such as an an outbreak of fire or a
plant mishap. Make sure that personnel will be able to reach valves easily by walkway or automobile.
Locate manually-operated valves at the plant perimeter, or outside hazardous area.
Ensure that automatic operators and their control lines will be protected from the effect of fire.
Make use of brick or concrete walls as possible fire shields for valve stations.
Inside a plant, place isolating valves in accessible positions to shut feed lines for equipment and processes
having a fire risk.
Consider the use of automatic valves in fire systems to release water, foam and other fire-fighting agents,
responding to heat-fusible links, smoke detectors, etc., triggered by fire or undue rise in temperature advice
may be obtained from the insurer and the local fire department.
If there is no P&ID
Provide valves at headers, pumps, equipment, etc., to ensure that the system will be pressure-tight for
hydrostatic testing, and to allow equipment to be removed for maintenance without shutting down the system.
Provide isolating valves at all small lines branching from header.
Provide isolating valves at all instrument pressure points for removal of instruments under operating conditions.
Provide valved drains on all tanks, vessels, etc., and other equipment which may contain or collect liquids.
Protect sensitive equipment by using a fast-closing check valve to stop back flow before it can gather
momentum.
Consider butt-welding or ring-joint flanged valves for lines containing hazardous or searching fluids. Hydrogen is
especially liable to leak.
Provide sufficient valves to control flows.
Consider providing a concrete pit (usually about 4ft x 4ft) for a valve which is to be located below grade.
Consider use of temporary closures for positive shut-off.
Provide a bypass if necessary for equipment which may be taken out of service.
Provide a bypass around control stations if continuous flow is require. The bypass should be at least as large as
the control valve, and is usually globe type, unless 6-inch or larger, when a gate valve is normally used.
Provide an upstream isolating valve with a small-valved bypass to equipment, which may be subject to fracture
if heat is too rapidly applied on opening the isolating valve. Typical use is in steam system to lessen the risk of
fracture of such things as castings, vitreous vessels, etc.
Consider providing large gate valves with a valved bypass to equalize pressure on either side of the disc to
reduce effort needed to open the valve.
TYPICAL PIPING FOR END SUCTION - TOP DISCHARGE PUMPS (API PUMPS ONLY)
TYPICAL PIPING FOR END SUCTION - TOP DISCHARGE PUMPS (NON API PUMPS ONLY)
For permanent T-type and Y-type strainers installed in a horizontal suction line, the preferred position of the
clean-out connection is 30 to 40 degrees from the vertical making sure that there is enough clearance for
strainer removal at grade.
Consideration shall be given to the handling of large T type strainer covers, and a permanent handling device
(e.g. a davit) supplied if access by mobile equipment is not possible.
6.5 COMMON SPARE
Occasionally, one pump is installed as a common spare between two other pumps in different services. The
pump must be manifolded in such a way that accomplishes this. Figure 6 illustrates an arrangement commonly
used.
Due to the pulsating action of reciprocating pumps, the designer must consider space requirements for
pulsation dampeners. These are usually furnished with the pump but take up additional space.
Pump access is even more important for reciprocating pumps since they require more maintenance than other
pumps. Do not install any bend (i.e. 90 degree elbow) directly adjacent to the pump discharge. For typical
egress and clearance requirements, refer to Design Guide for Compressor Piping Layout (Reciprocating
Compressors) 3DG-P22-00008.
The discharge pulsation dampener must be installed as close to the discharge as possible. Pipe supports must
be given special consideration due to the pulsations.
9.0 ROTARY PUMP PIPING
Rotary pumps are used for very heavy or viscous fluids. They deliver a constant pulsation-free flow. Piping for
these pumps is very similar to that of centrifugal pumps but is usually characterized by the absence of block
valves in the suction and discharge piping. If block valves are used, a pressure relief valve must be installed
between the pump discharge and the block valve. The PRV discharge is usually routed back to the pump
suction.
10.0 PUMPS OPERATING BELOW ATMOSPHERIC PRESSURE
Pumps operating below atmospheric pressure (e.g. Vacuum Tower Bottoms Pumps) present special problems.
Since the system operates at a negative pressure and very high temperature, the pumps must be located very
close to the suction source. This is often directly below the tower or immediately outside the tower support
columns. Pumps located directly beneath the tower can be mounted on a special spring base as shown in Figure
9.
connection when routing these lines. (Figure 10) The pump data sheet shall always be reviewed to make sure
these requirements are not missed. For very large pumps these may be on separate skids.
12. Stress intensification factor (SIF) Where do we use this? Explain this term. How many types of these SIFs
exist?
Answer: Stress Intensification Factor (SIF) is a multiplier on nominal stress for typically bend and intersection
components so that the effect of geometry and welding can be considered in a beam analysis. Stress
Intensification Factors form the basis of most stress analysis of piping systems. As for the quantity, ask a Stress
Engineer.
13. When all design parameters are same, whose thermal expansion is higher among the following? A) Carbon
steel b) Stainless steel c) Duplex steel d) Cast Iron e) Galvanized Carbon steel.
Answer: b) Stainless steel
14. In a hose station the hose couplings used for water, air & steam should be different type. Do you agree?
Explain your view.
Answer: I agree. If they are all the same then the hoses can be connected to the wrong services and could
result in the injury of an operator (i.e.: thinking the hose is connected to water when it is connected to steam).
15. What is your view on the usage of Metallic expansion joints? When they become necessary and when they
could be avoided?
Answer: I do everything I can as a piping designer to avoid the use of all types of expansion joints. Expansion
joints are always the weakest point in any system where they are used.
16. A water cooler heat exchanger, located on a 20 m high structural platform. Water header is located u/g.
What precaution do you take, in case of Pressure loss in cooling water header?
Answer: I do not understand this question it does not appear to be a piping issue. I would assume that the
cooling water system has a (loss of) pressure sensor and the plant shut-down alarms and sequence would be
activated.
17. In what order do you arrange the pipes in the Pipe rack and why? How much % of area should be reserved
for Future expansion? Specify a range.
Answer: The largest hottest lines on the outside edge of the pipe rack working in with cooler lines in towards
the middle of the rack. This allows the longer loop legs as you lay the loops back over the other lines to the
other side of the rack and back. The lower temperature loops would be nested inside the larger, hotter loops.
Future rack space is normally at the direction of the Client. It may be anything from 0% to as much as 25%.
18. When a utility line (like condensate or water etc) is connected permanently to a process piping what
precaution we have to take to avoid cross contamination?
Answer: Option #1, double block valve with a drop-out spool.
Option #2, Double block valve with a spec blind.
Option #3, double block valves with a bleed valve.
19. A air fin cooler (2 air coolers with each having 2 inlet nozzles) needs a Typical piping arrangement. How
many types of piping arrangement is possible.
Answer: There are a number of ways to pipe a Fin-Fan cooler depending on what the P&ID call for?
Thanks to (for the answers)