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    Machinery Outfitting Design Manual

    Copyright:

    © All Rights Reserved
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    972 visualizzazioni82 pagine

    Machinery Outfitting Design Manual

    Caricato da

    Soeghy Alie
    Machinery Outfitting Design Manual

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    © All Rights Reserved
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    = ENGLISH JES u = MACHINERY OUTFITTING DESIGN MANUAL, on engines, motors, electrical engineering, shipbuilding technology, materials, engineering work, slong with knowledge on economy and capability and experience system engineering. ‘That is to say, machinery outfitting design is put into practice only by engineers with the knowledge and capability a5 mentioned above. From the past, pieces of the knowledge or experience which are required for machinery outfitting design have been handed down from generation 0 generation fiagmentary by 2 large number of engineers involved in this field. Thers is almost nothing that these prescious know-how and experiences have been written systematically. So, the detail of machinery outfitting design is hard to grasp not only for beginners engaged in the practical work but for manufacturers of marine engineers and equipments, naval architects or electrical engineers Under suck a circumstance as this, the Marine Engineering Society in Japan, being taken the leadership by Machinery Plant Committee completed August, 1977 the work which is together materials that is pieces of knowledge and experience. and to compile these materials into # manual, This manual covers the principal of each design on the following items: (1) Selection of major machineries and ‘equipments, (2) General arrangement of engine rooms, (3) Shaftings and propellers, (4) Piping system, (5) Piping arrangement, (6) Automation and instrumentation, (7) Ductings, (8) Floors and ladders, (°) Tanks, (10) Painting’ Corrosion protection, (11) Insulation and lzggina, (12) Spare parts-Tools. ‘Among the items mentioned above, we chose piping system for this manual. Becaute, the piping system makes the very core of machinery outfitting design. Every machinery that composes a system is linked together by pipings. Arranging pipes to machinery is called pipings, which may be compared to human vein. In this sence, piping system engineer: should be well versed in piping engineering, economics, and all equipments that compose ships. = : The piping systems, planned by machinery outfitting designers with such know-hows and experiences as men- tioned above, finally take shape of General Piping Diagrams in the Engine Rooms. ‘The general piping diagrams in engine rooms show connection of each machinery equipped in the « ‘and make constnuction of the whole machinery pat clear. Inthe work of preparing the piping system, it is required tw have good comprehension towards each machinery and to pipe for maintaining the capacity Because, improper piping, even if fine the capacity of each machinery, cannot give ful play to it, besides it might cause leakage, clogging or a bad influence on machinery or some other big accidents. Therefore, pipings, as a plant which links each machinery together, should be recognized to have the same im- portance as machinery. In this manual, piping and machinery are taken for one system {com the point of view that make one body. This manual ako covers piping materials and fittings in Chapter 1, Determination of pipes size in Chapter 2, Graphical symbols for marine piping system in Chapter 3. These chapters are arranged to make a practical applica- tion in each case. Chapter 4 describes examples of piping systery in diesel ships, and covers outline of each system, machinery and equipments and decisions of these particulars Items which have to be considered in each system are aso given in this chapter. Expecially about decision of particulars of machinery, practical examples are given for biginner engineers. [As to copper pipes, seamless copper pipes with good anticorrosiveness, good heat conductance and good workability are used in general Typical ones are phosphorousdeoxidized copper seamless pipes and tubes (C1221T) used for heat ‘exchangers and tough-pitch copper. seamless. pipes ‘and tubes (TCUT) used for control pipings Other pipes are copper alloy pipes, plastic pipes, etc {As to copper alloy pipes, there are zinc base alumi- ‘num-brass pipes (which is called albrac or yorcalbro by manufactures, quality of them are almost the same) and nickel base copper-nickel pipes. Both of them have good workability and anti- ‘corrosiveness, especially nickel base one has excellent quality under high pressure and high temperature ‘working conditions. Both aluminum-brass pipes and cuppronickel pipes are mainly used for cooling sea water pipings. Plastic pipes generally made from polyvinyl chroride which are used for sanitary piping in the accommoda- tion 13 Fittings (1) Pipe flange (A) Application standard Pipe flanges are classified according to nominal pressures and the nominal pressure is decided with the maximum working pressure and above generally But maximum working pressures in steam, com- pressed air, gas, water, oil, etc. pipings can be rated beyond the nominal pressure, provided condition of fluides. Limitation of maximum working pressure in respect with material of flanges, conditions of fluids is specified in JIS B 2201. (B)_ Kinds of pipe flanges Pipe flanges are generally classified several kinds according to the method of connection and type of the flange surface. Followings show commonly used flanges. (@)_ Welded neck flanges (JIS B 2233) (Fig. 1.1) Welded neck flanges are butt welded to the pipe and has cone fillet for reinforcement. This type of flange has most safety construction and is suitable for high pressure, high temperature and low temperature use. (b) Slip-on welded flanges (JIS B 2221, 2222) (Fig. 12) Slip-on welded flanges are inserted a pipe into the plate flange and fillet welded both sides of the flange, and suitable for’ use from low pressure to middle pressure pipings. (©) Composite flange (JIS F 7804) (Fig. 13) ‘Composite flanges are used for copper and copper alloy pipings having SOmm and above considering ‘economic point of view. Material: inside flange: cast bronze outside lange: mild steel (2) Pipe joints Pipe joints in broard sense, includs pipe Manges, Fig LL Weed neck ange Fi. 12 Spon welded ane ' (1 Fig. 1.3 Composite lange expansion joints, pieces, ete., but here mentioned are conly about pipe joints of flangeess pipings used for low pressure pipings. Recently, flange joints in pipings are used joints instead of flanges, that is lange-less pipings for the purpose of saving labour fee of piping works, preven- tion of leakage, retightening of pipings, etc To high temperature and high pressure pipings such as main steam pipings in turbine ships, flangeess pipings have been conventionally applied, but recently flange ess pipings are also applied low pressure pipings in order to get the merit of flange-lss pipings. ‘The followings are about commonly used joints Tor fange-lesspipings. (A). Buttwelding joints (Fig. 14) Buttwelding joints are one of the methods of flange- less pipings. Joint part of pipes are buttwelded instead of flanges. But this method is not entirely applied to in consideration of a burn of galvanized pipes, lined or coated pipings. Bevels of welding part of pipes are shown on Fig. 14. in cosy ete> 12 ed fr0p the gbove tn :Bevels mgy_be chon pised S52 Sr hlovy thicehess“e! Fig. 1.4 Buttwelding joints (B)_ Sleeve joints Sleeve joints as shown on Fig. 15, is used in the part where flanges have conventionally used. ‘The thickness of sleeves T varies like the followings; equivalent to SGP, SCH#40, SCH#80, etc. in accord: ance with thickness of the pipes. ‘SCH #80 equivalent thickness of the sleeves are com- monly used in order to minimize kinds of sleeves, Agee ch nei 1S. Sleeve joints (C)_ Coupling joints ‘There are many kinds of coupling joints, most of them are sealed fluids by tightening a elastic rubber packing with a nut and there are some countermeasures against pipes falling off. (D)_ Union joints (Fig. 1.6, Fig. 1.7) Union joints are mainly used for small bore pipings, there are two kinds shown on Fig. 1.6 and Fig. 1.7. ‘One is that it keeps tightening by inserting packings between the bodies and nipples (Fig. 1.6), the other is that it keeps tightening with no packings by of bodies and nipples the contact conical angles of the both 37 degrees or 90 depres (Fig. 1.7). ‘The former one is generally used for 10 ke/em? or less rating, the lator one is generally used for 10 kg/ em? and above rating. ‘As to materials of unions, steel is used for steel pipes and copper alloy is used for copper pipes and as to fitting to pipes, welding is made for steel pipes, brazing is made for copper pipes. Materials of union joints are specified in JIS F 7436 7485. eating Fig. 1.6 Fig. 1.7 (G) Valves and cocks (A). Application standard ‘As to application standard of valves and cocks used for general pipings in ships is specified in JIS F 7300 “application standard of valves and cocks in ships Valves and cocks should be selected to suit most working temperature and pressure, and application purpose in accordance with the application standard. For butterfly valves, valves for high temperature for high pressure use which are not covered in JIS, ‘manufacturer's standards are generally used. Table 1.1 shows examples of materials for valves and cocks, (B) Application and construction with distinction of function for valves and cocks (a) Globe valves and angle valves Globe valves and angle valves are used for control of flow-rate besides closure, and are applicable for high pressure and high temperature use. ‘They are the most reliable valves. Globe valves are designed for straight piping lines and angle valves are designed for bended parts. (b) Gate valves Gate valves are not structurally suitable to control flow-rate and are generally used for condition of full shut of open. Gate valves are convenient for piping in narrow space especially in case of big bore, because they have less pressure drop less dimension in distance between flanges compared with globe valves. But inside-threaded-type gate valves are not suitable for use in high temperature and high pressure condition and it takes a Tong time for full opening or full shutting the valves. (© Check valves ‘Check valves are installed where a reversal of flow is possible, There are serew down check valves, lft check valves and swing check valves. ‘Screw down check valves are used where flowrate control is necessary in combination with anti-back flow function. There are globe type ones and angle ones Lift check valves are used where only anti-back flow function is necessary. In lift check valves, there are also globe-type ones and angle-type ones. Swing check valves can operate ‘under low pressure difference and used where low fluid resistance is needed. But they ate not structurally Suitable for use under high temperature, high pressure and pulsation uids condition. (@) Cocks "Two way cocks are used where quick shutting or opening operation is needed, three way cocks are used ‘where flow directions change are needed. But they are fot structurally suitable for use under high tempera: ture and high pressure condition. (©) Butterfly valves Butterfly valves are suitable in the case of shutting cor opening fluids and controlling the flow-rate. Butterfly valves are light in weight, easy in opera- tion and low in cost. Construction, materials, ete. of butterfly valves are different according to manufac turers as there are no JIS standards about butterfly valves and are produced ‘according to each manufac- turer's standard, Errosion of corrosion might be caused in case unfit application and material selection is done. This is why they are installed according to recommendation through experience of each manufacturers. (6) Automatic temperature controller ‘Actuating is devided into two types; one is diect operating type, another is pneumatically operating. For temperature control there are heating by steam. cooling by cooling water and heating by electricity In the case of heating, temperature is controled by increase or decrease of steam flow or electric currents In the case of cooling, temperature is controlled by ‘flow adjustment of the by-pass uid and the fluid to be cooled by coolers. The following are given outlines of direct operating and pneumatically operating two fr three way temperature control valves. (@) Twooway direct operating temperature control valves (Fig. 1.8) ‘A vapour pressure ofa fluid filled in the bulb which is installed at the outlet of heaters varies according to the temperature increasing or decreasing, The vapour pressure is transmitted in tun to @ diaphragm of the valve assembly directly through a capillary, and the valve conteols the temperature by adjusting the flow of steam. (i) Two.way pneumatically operating temperature control valves ‘A vapour pressure ofa fluid filled in the bulb which is installed at the outlet of heaters varies according to the temperature increasing or decreasing The vapour pressure is transmitted in turn to a pilot valve in a controller through a capillary and the vapour pressure is transmitted with a pneumatic signal pressure The transmitted pneumatic signal pressure actuates a diaphragm and a valve, and the valve controls the temperature by adjusting the flow of steam. A posi- tioner is necessary to control a valve in case of a high steam pressure, or bigger control valves in size or bigger actuating power is required. The positioner amplifies ‘pneumatic signal pressure from the controller. (iil) Three-way direct operated temperature control valves (Fig, 19) Thieesvay direct operated temperature control valves selfcontain temperature sensing element, and the valve is installed as a flow diverting valve. The flow is automatically proportioned between the bypass and the cooler to maintain the fluid temperature For an example, Fig. 1.9 shows a wax operated temperature control valve. Fig. 1.8 Two-way direct operating temperature control valve (Gv) Three-way pneumatically operating temperature control valves (Fig. 1.10) Three-way pneumatically operating. temperature control valves consist of temperature transmitters, controllers, positioners (if necessary) and three way diaphragm valves. Temperature difference detected by the thermo bulb is transmitted to a pneumatic signal pressure by the controller and actuates the three way control valve which is mounted downstream of the cooler to adjust the flow between the by-pass and the cooler, consequently the temperature is kept constant, Fig. 1.9 Three-way direct operated temperature control valve k Fig. 1.10 Three-way pneumatic operated temperature control valve = () Relief valves, Relief valves are installed in pressure vessels or pressurized pipings directly and are used to prevent an over pressure beyond the limited pressure from ‘being built up in the lines. For example, in case the reducing valves become out of order, the relief valves are used (0 prevent high pressure fluids from flowing directly to the low pressure lines. The flowing capacity of the relief valves may not be necessarily blowed off at maximum capacity of the equipments under their limited pressure. Relief valves and safety valves are at times commonly used, but the safety valves ae used as safety devices of pressure vessels which are accumu lated with big amount of energy such as boiler drums and it is necessary to blow off at maximum evapolation tate of the equipments below the designed pressure Fig. 1.11 shows an example of flanged type relief valves. Fig. 111 Relief valve (b)_ Reducing valves Reducing valves are special valves which are installed in pipings so as to control the pressure of a fluid, that is high pressure steam or air, at a constant value lower than the higher pressure source. ‘The valve has mechanisms to detect a deviation between the set pressure and a reduced pressure, to amplify this deviation pressure and to operate a main valve by the amplified pressure. Accordingly, the valve controls the secondary pressure ofa fluid at a constant value according to the fluid demand by means of these mechanisms. There are two kinds of reducing valves; one is direct operated type and another is pneumatic operated type. ‘A direct operated type is self-contained the above three mechanism and a main valve is operated by an inlet pressure. ‘A pneumatic operated type is the combination of controllers which detect and amplify the secondary pressure and diaphragm valves, which require supplied energy, that is control air. For direct operating reducing valves, pilot operated reducing valves (which is shown in Fig. 1.12) are commonly used, but the bigin-ize ones are difficult to manufacture, besides it needs consideration about pressure difference between inlet and outlet pressure. (4) Strainers (A). Purpose of application Strainers are installed in suction lines of pumps, reducing valves and machineries. The strainer serves to prevent foreign particles from entering machineries or valves interior hinding injures to machineries. (®) Classification Strainers are clasified as water strainers, oil strain ers, steam strainers, air strainers, etc. according to fluids. According to the shape of bodies, they are classified as type Y, type can, type H, ete. According to constriction, clasified as simplex and duplex. For simplex strainers there ae rose boxes and mud boxes used for bilge and ballast lines. Simplex strainers are used for intermittent use lines such as ballast lines, and duplex strainers are used for continuous use lines such as suction lines of main engine lubricating oll ines. TS F 7202 = 7209 and JIS F 7220 ~ 7225 cover strainers in ships. (©) Application standard ‘There is no application standard of strainers. However Table 1.2 shows application standard for mesh of the gauze of oil strainer with many experi- fences in ships for reference. (Machineries manufac turer’s standard recommendation shall be followed, ifany) ‘A mesh of wire gauze on Table 1.2 is based on JIS F 7207 Application for Wire Gauze of Oil Strainer for Marine Use. Table 1.2 Application standard for wire gauze of oil Fig. 1.12 Reducing valve Diawere vess |"Orwine APPLICABLE PE LINES ‘om Te | 0305 | Heo ings ayo wane pomp mon ae | 0315 | tnbcwng ot aing ie : Be] 0258 | Sect wo targa po Son ae ‘Src bunnt oo pep, Soca er eg @ | om Ge | 0153 | any ins of ming ot pp, Dery tera Sarg bom pe een nein eee, | ie rin nin tt ten, | we | om Too) 0108 | Fest spar wane mS enn) 750] est | Foc adies ci wrmmer forge Bewlens) | oo | 00m | Poor orem fi pomp) (5) Steam traps If large condensate remained in steam heaters or pipings, it might cause decreasing of heating surface, ‘water hammering and corrosion. ‘Steam traps may be called drain traps. For steam traps, there are several types such as impulse type, dise type, float type, ete ‘The impulse type steam trap is shown in Fig. 1.13. While inflowing condensate is low in temperature, control chamber pressure is low and consequently, the valve is pushed upward, permitting condensate discharge. When steam comes, control chamber pressure is raised by increased flash rate, the valve is pushed down to close steam flowing. ‘The disc type steam trap is used a disc valve instead of a conical one of the impulse type as shown in Fig, 1.14, but principal function is the same to the impulse type, that is when condensate arrives at the traps, the valve disc tilts upward due to flow impulse of con- densate to discharge condensate, and when process fluid has been changed from condensate to steam, upper side of the disc valve chamber pressure is raised ‘and disc valve is pushed down to close steam flow. ‘The float type steam traps as shown Fig. 1.15 discharge condensate by floating action, that is when ‘condensate arrives at the traps, the float is floated permitting condensate discharge, and when stem comes, the bi-metal plate is curved by the heat to stop air vent. valve in order to stop steam flow. Fig. 1.13 Impulse ype Fig. 1.14 Dis type LIS Float type (6) Packings (A)_Purpose and classification ‘There are gaskets for pipe flanges, pipe joints and valve bonnets and packings for valve stems. The gaskets and. packings should be selected to have suitable char- acteristics and durability for using condition JIS F 7102 “Application Standard of Packing and Gaskets to Piping System for Marine Machinery” speci fies application standard of packings and gaskets used. for pipe Manges, pipe joints, valve bonnets, valve stems and the like of piping system for marine machinery, It is recommended to apply this application standard. Recently, however, general purpose packings which can be applied for every piping lines are on the market. ‘These packings are widely used. (1) Expansion joins (A) Purposes ‘Thermal expansion joints are installed in exhaust 3s pipings for main diesel engines, generator diesel engines, auxiliary boilers, and in exhaust steam pipings for cargo oil pumps, safety valves on the boiler, etc. in order to absorb thermal expansion of pipings and equipments. ‘And for the purpose of absorbing the vibration of hulls and equipments, expansion joints are installed in forced draft ductings for boilers and exhaust gas Pipings from turbo chargers of main diesel generators, (B) Selections of joints ()_Elongations of pipings due to heat expansion Elongations of pipings due to heat expansion are to be calculated by equations (1.1) and (1.2) taking into consideration of temperatures, materials of pipes and length of pipings. The calculation decides specification and distance of the joins. Al=p(T-t) 1) et) {AL Elongition of pipings due to heat expan sion (mm) SEE B +: Coeficient of heat expansion of pipes (mm/m/°c) + Maximum working temperature (C) Minimum working temperature CC) Length of pipes (m) + Number of joints Maximum expandable length of joint (mm) (b) Adjusting of face to face dimension of a joint ‘As expansion and extraction of pipings are absorbed by heat expansion joints, Therefore, before installing of the heat expansion joint, the face to face dimension ofthe joint should be calculated by equation (1.3) based on atmospheric temperature at the installation, range of working tem- perature and maximum expandable length of the joint, and adjustment of the face to face dimension of the joint to be done, W-6-Boo a3) where L, +: Face to face dimension of the joint (mm) L,: Maximum face to face dimension of the joint (mm) {+ Maximum expandable or extractable length of the joint (mm) Maximum working temperature °C) Minimum working temperature or atmos pheric temperature (°C) tz: Atmospheric temperature at the installa- tion °C) (8) Orifices (A)_ Purpose of applications Purpose of applications of orifices are given as fol- lows. However, these are not necessarily solely existent but have many purposes combined together. 1, Pressure reduction 2. Keeping minimum flow rate (including protection of over heat of pumps and warming up) 3, Flow rate distribution 4, Flow rate control 5. Limitation of flow rate 6, Pressure adjustment (B) Application ‘Application of orifices are complied with fluids according to their purpose, however, orifices are seldom used for solely-used important pipings such as fuel ol pipings. (©) Construction and materials There are many types of construction, though it is simple, Fig, 1.16 shows an example. Materials applied with are SUS 304. on ror atrection Fig. 1.16 Orifice (D) Calculations There are many formulas for orifices calculation. ‘The following shows one of examples among of them, however, there is not much difference with other formulas. (@) In the case of liquids Fundamental equations are 3600 mole @ : Coefficient of flow rate D = Internal diameter of pipe (m) P,,P; : Fluid pressures before and after of the orifice (kg/m?) hy.hy : Primary and secondary heads of the uid (m) a: Area of orifice hole (m?) 1 + Specific gravity of fluid before orifice (kg/m*) 4 + Diameter of orifice (m) Coefficients of flow rate a are obtained from the equation (1.6). From the equation (1.6), mais 012511 DV =P) «is obtained from Fig. 1.17 with ma which is caleu- lated by the above equation, ‘Also m is obtained from m= mala ‘According to equation (1.5), d is aD conttictente of flow rate & Fig. 1.17. maa for standard orifice (b) Incase of steam or air Incase of P VP = Pas --- ++ (16) = (ay where Q = Flow rate in volume (m? /h) m : Ratio of throttle G + Flow rate (kg/h) 4 + Diameter of orifice (m) © + Coefficient of flow rate (0.62) a: Area of orifice hole (m?) Vs: Specific volume of fuid at before orifice Ps Indet pressure (kg/m?) Pz Outlet pressure (kg/m?) K : 1441 for air, 130 for super heated steam, 1.135 for saturated steam Pc: Critical pressure, 0.527 P for air, 0.546 P for super heated steam, 0.577 P for dry saturated steam (Pieces for steel pipes Each piping which composes pipings is the com- bination of pieces and pipes. Piccss are divided into screwed pieces and welded pieces. Screwed pieces generally have tapered gas threads for their connections and are used for water, oil, stam, air, gas te. of low pressure lines, AS to kinds of screwed pieces, there are elbows and bends for bending flow direction and tees for branch flow and reducers for connection of different diameter of pipes. Welded pieces have less radius than mechanical bended pipes or hot bended pipes have. The welded pieces are flangedless as connections to pipes are ap- plied butt welding, therefore for narrow space pipings, welded pieces are usually applied JIS B 2301, 2302, 2304 are specified kinds, mate- fials dimensions, et. of serewed and welded pieces. 1.4 Insulation and lagging (1) General (A) Purpose Insulation and lagging are generally applied for saving heat loss, inprovement of thermal efficiency of equipments, safety for crews, protection against fre, etc. that i, in pipings, which require insulation, radia tion surfaces are covered with insulation materials as much as possible. Pipings, heaters, etc. are lagged for protection against fire, injury and to minimize temperature in the engine room rise with heat transmission from fluids in pipings.. (B) Design conditions Pipings which handle fuids of temperature over 60°C are generally insulated and lagged. However, piping systems which have not an aim to insulate, such 48 cooling fresh water lines, might be omitted insula tion even the fluid temperature exceeds 60°C. Never. theless, a spot where there is the possibility of causing injury is generally insulated or lagged. ‘On insulation or lagging. the insulation surface temperature is designed 55°C against 30°C engine room ambient temperature, and the insulation surface temperature is designed 60°C against 35°C engine room ambient temperature. (@) Calculation for thickness of insulation materials of pipings The rate of heat transmission through insulation on pipes can be calculated by the equation, 22m (ty =), 2ms (ty Wn dildo ly aly 22a (tat = ty) Ty da/dg a where + Rate of heat transmission (keal/m? h.°C) AriAgiAsioueiAq + Thermal conductives (kcalfmn hc) ta: Fluid temperature (°C) ty: Surface temperature @C) tuitaso5tya. 2 Boundary temperatures °C) dy: Diameter of pipe (mm) 4yidy;ouidy : Diameter of each insulation material (mm) Since the rate of heat transmission by a radiation from the insulation surface to the engine room must be the same. +13) 5: Film coefficient for convection from the surface of the insulation (keal/m? h.°C) tc : Engine room ambient temperature °C) Accordingly, equations (1.12) and (1.13) work out each thickness of insulation materials on the asump- tion that boundary temperatures t,, tz, ne (tq >1 > ty ota >t >t) Ilustrative example Piping line: Tkglem? Steam line Fluid temperature t, = about 170°C Engine room ambient temperature ty = 30°C Diameter of pipe: Nominal 80A Material of insulation: Moulded calusium silicate cover No.2 Insulation material surface temperature ty = 55°C The thermal conductive of the insulation material is A= 0.046 + 0.0001 keal/mh °C = 0.046 + 0.0001 x (170 +55)/2 = 0.0725 keal/mh°C where 4: average temperature ec 8 = tatty) By equation (1:12) and (1.13) assuming the film coefficient for convection from the surface of the insulation as = 10 keal/m? h." mAs (ty Indie dy ag (tg ~tc)= Hence, 4, Nad fd = 27 (ta =10) = Ce) 21-0.0525- (170-55) 7-10 @5= 30) ‘Accordingly, x= 23 mm is obtained from Fig 1.20 which shows clatonship between necessary thickness Of insulation material and dyly d/do which means 23 mm and above thickness of insulation is required, = 0.05267 In the above equations and the example of the calculation, the outer surface temperatute ofthe pipe, that is inside surface temperature of the insulation material is assumed to be of the same temperature of the fhuid t4°C because of the fact that temperature difference along wall pass at the steel pipe and tem- perature ilference between the fluid and the stel plate due to the heat transmision are small For examples, followings show coefficients of heat teansfer between Muid and steel surface a, and co: efficients of heat transfer between ambient and surface of insulation material a Coefficients of heat transfer in pipes aq kealf mnC Oil ~ steel pipe : 100 ~ 300 keal/m*h"C Water ~ steel pipe : 400 ~ 5,000 kealim?h°c Surface coefficient of heat transfer between air in the engine room and surfce of insulation materials my Keal/m?h°C is generally taken 10 Keal/m?h’C for the calculation for the thickness of insulation materials os a2 | “ost Sous 3 “un0| ae mn cou | om TEA oN ee ee Tues of inmulation mperials Fig. 1.20 Thickness of 10 a Tucinees of innulation saterials (on) insulation materials vs do In dy [dy Sie (3) Insulation materials for pipings Table 1.3 shows one of the examples of insulation ‘materials for pipings which are generally used for. The selection of insulation materials needs con- sideration of insulation performances, materials’ cost, fitting labour fees, environmental condition at fitting and vibration proof. Fig. 1.21 and Fig. 1.22 show examples of practice for general pipings and for exhaust g2s pipings or boiler up take, ose wes (wea ass Five covered (sweae' te Saat ees) oBagp gucim sew on ua Oe ‘inet Ass Fm Fig. 1.22 Exhaust gas pipe and boiler uptake Table 1.3 Materials of piping insulation Service Freermat Designation | s15 wo. | tenpecature | density |conductivity Use for rimsecrey | (aren) | exeai/m nec) {:mean comp.) Caicive siticate [a 9510- | 650 0.22 and [0.046+0,0001 8 Exh. gas piping cover, No.2 a7 tes Boiler up take General pipings ‘00 0.22 ana [o.032-0.000126 Exh. 988 pipings, Boiler Jcover not less uo take, Super neaced noc [Cover Nod | 9504 | 400 o-036+0.000120 Ditto. woot a7 ‘Cover 0.3 00 0-044+0.00012 8 biete ope Wont ‘00 o.038+0.00014 0 ateeo Rope wo? | 00 Foie [700 o-a3e+0,000128 Dine 28 | cover 1 9505- ) 300 [0.077+0.00018 6 ‘General pipings Tope rn ad Ban 0.085 bite aR ee RR ga and boiler wp ! t Gene 35] 2 LS Corrosion protection for pipes and fittings (1) Corrosion protection for pipes The corrosion problems in pipings of the machinery part are somewhat different in condition (corrosion environment and fluids) from the other parts. Inside surfaces protection against corrosion should be primari- ly considered rather than outside surfaces ones. (A) Classified application (Table 1.4) Table 14 protection {etan pot nto operation | edtdee [rcssas | ertonton eeosction seventeen a (B)_ Inside surface corrosion protection or pipes © Materials of corrosion protection AAs to materials of corrosion protection, there are amti-corrosive paints, anticorrosive oils, vapourize protective coatings, anticorrosive solutions, etc. In the selection, the followings should be considered. It is advisable to paint or coat both inside and outside surfaces without delay after the completion of fabrica- tion of pipes. © Unnecessty to peel off coating films. ‘© No influence or less influence to the fluids or gases. © Cheap in costs (materials fees, labour fees, trans- portation fees). © Linings and coatings There are several methods of linings or coatings of inside pipes for sea water cooling lines (including circulating lines). The followings show some examples. Neo-plene lining thickness 3 mm Induction heated resine lining thickness 1.2 mm (Poly ethylene) Tarepoxy coating thickness 0.2 mm In case the above linings or coatings are applied, attach importance to corrosion protection for heat exchangers. (©) Outside surface corrosion protection For outside surface corrosion protection of pipes is generally applied two coats of anti-corrosive paints, however, for high temperature fluids pipings such as exhaust gas lines, main steam lines, ete, itis better to apply one coat of heat resistance paint considering burning and strench. As anti-corrosive paints, red lead base, zinc chromate or red oxide paints are applied. (D)_ Flushing Tentative corrosion protection of pipings might be insufficient for some piping lines in case outfitting ‘works exceed half year ‘Accordingly, a8 a final corrosion protection, flush ing is done inside of some piping lines, such as main steam lines, lubricating lines, etc. (2) Corrosion protection of fittings (A) Corrosion protection of valves, cocks, ete. Inside surface of valves, cocks, etc. are generally not painted. However, big in sizes and essential use cones such as hull attached valves may be painted with anti-corrosive paints or lined with synthetic rubber. (B)_ Other Corrosion protection for fittings such as strainers ‘ll separators, chemical dosing equipments, hoppers, etc. follow each line which belongs to. Parts which the ‘material made from anticortosive materials are not applied with corrosion protections. CHAPTER 2. DETERMINATION OF PIPE SIZES 21 General Pipe size should be determined to be able to transfer fMuids necessary within the certain second, most eco- nomically and safe. For that purpose, the determina- tion needs full consideration of pipes strengths heat expansion, heat loss, friction loss, water hammer, corrosion, ete. besides economics in order to ration: alize the relation between the flow velocity in pipes and pipe sizes. ‘As mentioned above, velocity in pipes is an impor- tant factor especially in the determination of pipe sizes The following formulas are the general elation between pipe sizes and fluids velocity in pipes. Q : Flow rate (m?/s) vm : Average velocity in pipe (m/s) A: Internal area of pipe (m*) D + Internal diameter of pipe (i) The fluid velocity in pipes is determined in relation with a pressure loss in the piping or in relation with corrosion of pipes. For examples of the former are steam, steam exhaust lines of main steam turbine generator turbine. suction lines of condensate pumps. 1.5 Corrosion protection for pipes and fittings (2) Corrosion protection for pipes ‘The corrosion problems in pipings of the machinery part are somewhat different in condition (corrosion environment and fluids) from the other parts. Inside surfaces protection against corrosion should be primat ly considered rather than outside surfaces ones. (A) Classified application (Table 1.4) Table 14 lareace [sox inside auctace —[alfides is sotstons, ott, ee.) (B)_ Inside surface corrosion protection or pipes © Materials of corrosion prote: {As to materials of corrosion protection, there are anticorrosive paints, anticorrosive oils, vapourize protective coatings, anticorrosive solutions, ete. In the selection, the followings should be considered. It is advisable (o paint or coat both inside and outside surfaces without delay after the completion of fabrica- tion of pipes. © Unnecessty to peel off coating films. No influence or les influence to the fluids or gases. © Cheap in costs (materials fees, labour fees, trans- portation fees). © Linings and coatings There are several methods of linings or coatings of inside pipes for sea water cooling lines (including circulating lines), The followings show some examples. Neoplene lining thickness 3 mm Induction heated resine lining thickness 1.2 mm (Polyethylene) Tarepoxy coating thickness 0.2 mm In case the above linings or coatings are applied, attach importance to corrosion protection for heat exchangers. (C)_Outside surface corrosion protection For outside surface corrosion protection of pipes is generally applied (wo coats of anti-corrosive paints, however, for high temperature fluids pipings such as ‘exhaust gas lines, main steam lines, etc., itis better to apply one coat of heat resistance psint considering burning and strench. As anti-corrosive paints, red lead base, zine chromate or red oxide paints are applied. (D)_ Flushing ‘Tentative corrosion protection of pipings might be insufficient for some piping lines in case outfitting works exceed half year. ‘Accordingly, a8 a final corrosion protection, flush ing is done inside of some piping lines, such as main steam lines, lubricating lines, ete (2) Corrosion protection of fittings (A) Corrosion protection of valves, cocks, ete. Inside surface of valves, cocks, etc. are generally not painted. However, big in sizes and essential use ‘ones such as hull attached valves may be painted with ‘anticcorrosive paints or lined with synthetic rubber. (B)_ Other _— Corrosion protection for fittings. such as strainers, cll separators, chemical dosing equipments, hoppers, ete, follow each line which belongs to. Parts which the material made from anticorrosive materials are not applied with corrosion protections, CHAPTER 2. DETERMINATION OF PIPE SIZES 2. General Pipe size should be determined to be able to transfer fluids necessary within the certain second, most eco- romically and safe. For that purpose, the determina- tion needs full consideration of pipes strength; heat ‘expansion, heat oss, friction loss, water hammer, corrosion, ete, besides economics in order to ration- alize the elation between the flow velocity in pipes and pipe sizes. 'As mentioned above, velocity in pipes is an impor- tant factor especially in the determination of pipe sizes The following formulas are the general relation between pipe sizes and Muids velocity in pipes. -n + QA) Pe Oa) Q : Flow rate(m?/s) vim? Average velocity in pipe (m/s) ‘A Internal area of pipe (m?) D + Internal diameter of pipe (m) The fluid velocity in pipes is determined in relation with a pressure loss in the piping or in relation with corrosion of pipes. For examples of the former are steam, steam exhaust lines of main steam turbine. generator turbine. suction lines of condensate pumps. feed water pumps and lubricating oil pumps, etc. For ‘examples of the latter are corrosion of sea water lines and corrosion of valves and seats, etc., of high tem= perature steam and feed water lines. For the other examples, air lines which contain water are liable to cause a hamming under high speed condition, and steam-drain diphase lines such as out- let side of drain traps are also liable to cause water hammering. 2.2 JIS standard velocity of flow in pipes of ship machinery (By JIS F 7101-1954) This standard covers the velocity of flow in pipes for miscellaneous pipe lines of ship machinery. The velocity of flow in this standard is specified with respect to the type of machinery, the kind and nature of fluid Fig. 2.1, as a rule, should be applicable to the Piping for steam, exhaust, compressed air, water and oil (including sea water and bilge). And the standard velocity of flow shall be based fon the designed capacity of the machinery to which pipes are directly connected. In a specially designed ship, when itis impracticable to follow this standard, the velocity of flow should be determined by taking into consideration the appli- cable items out of fluid viscosity and heating system, static head corresponding to the installed height, length equivalent to straight pipe construction and types of pipe fittings, conditions of the inside face of the pipe, weight and volume of piping, etc. The velocity of flow for lined pipes, intermittent use pipings and emergency use pipings may be ex- ‘ceeded to the standard velocity of flow. VELOCITY oF F406 IN 166 (avs) Fig. 2.1. Standard velocity i 23. Pressure drops (1) General Fluids pressure drops in pipings are generally caused by pressure drops due to frictional resistances of fluids in pipes (AP,) and pressure drops due to frictional resistances in valves and fittings. ete. (AP;), and are sven from following the equations. ipings +++ @23) so Ay) ie G5): AP : Total pressure drops (kg/cm?) AP,: Pressure drops due to frictional resistances. ‘of fluids in pipes (kg/em*) AP;: Pressure drops due to frictional resistance of fluids in valves and fittings, ete. (ksfem*) Friction factor Resistance coefficient for valve or fittings Internal diameter of pipe (m) Length of pipe (m) ‘Average velocity in pipe (m/s) + Specific gravity (kg/m?) ‘Acceleration due to gravity (m/s*) we 20. st) 2 Correction of C, for lashing fuids Liquids with saturated or the like temperature cause flashing phenomenon (expansion in volume) at the valve plug port, for which the flow will not be in- i ; eeKyre aoc a= where Py: Inlet pressure ke/cm? abs, K_: Factor of allowable pressure drop (refer to Fig. 2.15) 1 AP: P, ~P2 ke/em™ Incase of He AP: P) wherein Fig. 2.15 1 Glove type (double and single seated) and Angle type (Inner valve iz is equal to.the valve bore) 2 Sweep flow angle type 3. Anale type (low to shut) (inner valve size is equal to the 50% of valve bore) 4 Angle type (flow to shut) (inner valve size is equal to the 25% of valve bore) ACTOR OF ALLOMBLE PRESSURE FOP Fig. 2.15. Correction for flushing fluid @ Air-gases where Py >05 Py c,- YSU) @.13) 406/(P; =P.) Pi where P, <0 P i oS Te): 4) where {Q : Max, flow rate (airgases) Nm? /h P Inlet pressure kg/em? abs. (15.6°C) =~ = + Outlet pressure kg/em? abs. Specific gravity (Ait 1: Fluids temperature °C (ii) Steam. ‘where P; > 0.5 P w =P2)Pa cy 194V@; where P; <0.5P w Cage Ko 2.16) where W : Max. flow rate kg/h Py: Inlet pressure kelem? abs. Py: Outlet pressure ke/em? abs. K + Correction coefficient to super heat (KE + 00013 x degC of super heat K = | in case of saturated steam (B) Decision of differential pressure 40 — 60% of total pressure drop in the systent should be preferably imposed on a control valve. at least 15% is necessary from the point of optimum con: trolling view. CHAPTER 3. GRAPHICAL SYMBOLS FOR MARINE PIPING SYSTEM 4 Graphical symbols for piping and fittings to be used in marine piping diagram are specified in JIS F 7006- Table 32 Control and regulation parts 1976 “Graphical Symbols for Marine Piping System”. eas The graphical symbols ae classified as given below, [=== = = eo (1) Pipes and pipe joints (Table 3.1) aa 1 2) Control and regulation parts (Table 32) =e ees | 3) Valve and cocks (Table 33) E i (4) Pipe fittings (Table 3.4) on i (S) Control and instrumentation (Table 35 — 38) I Remarks: 8 = : () In Table 3.1 to 38, the symbols marked with (*) | ate same as specified in 1SO/R538 (CONVENTIONAL . = SIGNS TO BE USED IN SCHEMES FOR THE IN- re STALLATION OF PIPELINE SYSTEM IN SHIPS). I P (2) Examples of application of symbols are show in a Fig. 3.1 to Fig. 3.4. ft a rs oe ? Table 3.1. Pipes and pipe joints ee as == Ee g =I + [= +. g Se a se Table 33 Valves and cocks — fm foe | ot tm ot ce = = ou] BP [owt 4 meme ae = ieee ene 2 = = | ae e ee & x= ae Sa ae Se | eee a ere re aaa aI | ee ee es a aoe lege (| poe St} — a = = fara 5 Re pe te E19 | | 4 | lee 3] |B |B wo |) BY og | at bf oee ¥e| ow 1 [Bes it T ° Table 34 Pipe Gittings , =| oe ee er 4] <]4]ala|

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