SC Joe ‘| a Perey Design g Volo Rip WeaverProcess Piping Design ~- Volume 1 Piping designers, engineers, students and college instructors—this book is for you. In the two volumes of Process Piping Design, Rip Weaver systematically presents a complete course in the design of piping systems for processing plants. Weaver has drawn on his own extensive ex- perience to explain each phase of piping design and its attendant problems. He writes in the simple descriptive language, of the field man about stan- dards of the industry published here for the first time. Process Piping Design can be used as a text for schools or businesses. It takes up where Process Piping Drafting, already a text in over 40 schools and used in over 50 countries, ends. Easy-to-understand and absolutely complete, this book includes review questions at the end of each chapter and dozens of illustrations by the author as well as many from industrial publications. This Is the reference book on the design of piping systems. It deals in depth with problems and solu- tions of vital interest to all those involved in the design or installation of industrial piping. No one in the process industries can afford to be without It. Rip Weaver Mr, Weaver has more than 25 years experience in aratting, design, and engineoring. with. private business. During his career he has trained hundreds of drating technicians. His drafting books are used as textbooks in hundreds of schools in the United ‘States and Canada, In addition, his workbooks alow inetructors and students to cover more course material more {Uickly and easiy. Mr. Weaver has published numerous articles in trade and technical magazines and is known for his practical epproach to taining and his easy-to-read texts. He is currently employed by Pullmart-Kellogg at its world headquarters in Houston, Texas, Book Division P.O. Box 2608 Houston, Texas 77001 BR) Gulf Publishing Company Process Piping Design Volume 1 1. General Piping 2. Process Terms 3. Plant Arrangement and Storage Tanks 4. Process Unit Plot Plans 5. Piping Systems and Details é 7. 8 8 Pipe Fabrication: Vessels . Instrumentation |. Appendix on Conversions Volume 2 Pumps and Turbines Compressors Fired Heaters Exchangers Piping Flexibility Books by Rip Weaver: Process Piping Drafting Process Piping Drafting Workbook Process Piping Design, 2 Volumes Modern Basic Drafting Modern Basic Drafting Workbook Parts 1 and 2 Structural Drafting Piper's Pocket Handbook Cover design by Bob Peterman ISBN 0-87201-759-1Process Piping DesignProcess Volume 1 General Piping Process Terms Plant Arrangement and Storage Tanks . Process Unit Plot Plans Piping Systems and Details . Pipe Fabrication . Vessels . Instrumentation Volume 2 Pumps and Turbines ‘Compressors Fired Heaters Exchangers Piping FlexibilityPiping Design Volume 1 | | Rip Weaver | caBooks by the Author Process Piping Drafting Process Piping Drafting Workbook Process Piping Design, 2 Volumes Modern Basic Drafting Modern Basic Drafting Workbook, Parts 1 and 2 Structural Drafting Piper's Pocket Handbook First Printing, March 1973 Second Printing, August 1974 Third Printing. December 1974 Fourth Printing. January 1977 Fifth Printing, February 1979 Sixth Printing, November 198] Piping design is both demanding and strenuous. It ‘makes relaxation imperative. This book is dedicated to the three men who have helped me relax the ‘most: my brother, Joe Weaver, Joe Garrett and Kenneth Campbell. Copyright © 1973 by Gulf Publishing Company, Houston, Texas. All rights reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without permission of the publisher. Library of Congress Card Number; 72-8432 ISBN: 0-87201-759-1Contents Pretace Introduction 1 General Piping, 1 Piping Materials Methods of Manufacturing Pipe Pipe Diameters, Thicknesses and Schedules Fittings and Flanges Valves 2 Process Terms, 26 The Hydrocarbon Hydrocarbon Structures Fractionation Piping Equilibrium Liquids Two-Phase Flow Hot Vapor By-Pass Static Head Steam Data 3 Plant Arrangement and Storage Tanks, 37 Site Data Hilly Terrain Block Plot Plan The Process Biock Storage Tanks Tank Dike Regulations Storage Tank Design A Refinery Exercise Dike Area Drainage Storage Tank Piping Foam Protection System 4 Process Unit Plot Plans, 57 Equipment Plot Plan Preliminary Plot Plan Dimensions Plot Plan Exercise Foundation Location Plan Excavation Plan Flow Diagram Transportation Piping Drawing Index Equipment SettingContents, continued 5 Piping Systems and Detalls, 73 Underground Piping Sewer System Terms Sewer Flow Diagram Cast Iron Soil Pipe and Fittings Designing Systems Student Exercise Design Guidelines Underground Pressurized Systems Fire Water Underground Cooling Water Pump-Out system Glycol Lines Steam Tracing Steam Tracing Design Practice Tail Pipe Cuts 6 Pipe Fabrication, 92 Welding Shop Details Pipe Bends Miter Welds ‘Small Fittings The Triangle The Cutback 7 Vessels, 119 Definitions Horizontal Vessels Piping Arrangement for Elevated Vessels Manhold Davits and Hinges Vertical Vessels 8 Instrumentation, 149 Instrument Types Instrument Functions Dual Instruments Transmitters Thermowells Other Temperature Instruments Pressure Instruments Flow Instruments Orifice Flange Taps Level Instruments Level Gage Control Valves Appetidix, 171 Conversions Index, 209Preface This two-volume set on Process Piping Design has been written to supple- ‘ment my first book, Process Piping Drafting. 1 have purposely used a very practical writing style for both of these efforts, applying my personal practical experience rather than trying to present the technical aspects of piping. In Process Piping Design I have elected to have each chapter self-sustaining. I have reproduced some charts and tables but only those required in learning the basics of piping design. To become a competent piping designer requires many years of experience plus a talent for creative thinking. Piping designers must call on their knowledge for each design job but also must apply their own ingenuity daily. I like to call that horse sense. Many piping designers have told me that their job is 25% knowledge, 25% experience and 50% horse sense. This book will try to deal with the first 25% and touch on the last 50%, F aor Corporation has been very farsighted by instigating piping drafting and piping design training classes and they have been very generous in allow- ing me to reproduce some of their instructional material. I wish to take this opportunity to thank Fluor for its assistance.Introduction Ina refining or petrochemical complex, piping constitutes the major expen- diture of all the design disciplines. Piping consumes about 50% of the design engineering manhours, 35% of the material cost of the plant and about 30% of the labor cost in the field. Inept piping design in the office can increase the cost of a plant. The design engineering department of a contractor designing refinery or petrochemical complexes consists of four main functions: piping, structural, electrical and vessels. The piping section encompasses flow diagrams, model making, insulation and painting, piping material take-off, piping material control, instrument design and piping design itself. Experienced piping designers know the functions of all of these groups. They also must have a broad knowledge of the structural, electrical and vessel sections. And they must know the many pieces of equipment that they must pipe up, the numerous details of piping, the materials necessary for various services, piping flexibility basics and field construction practices. Then comes a general knowledge of plant operation and maintenance, When all of this is considered, it is easy to see why there is always a shortage of experienced, competent piping designers. Irorically, piping design is the one subject that has been neglected in the schooi systems. This is largely due to the fact that adequate textbooks were not available. No book can teach a person to become a piping designer but it can teach the fundamentals and how to apply them to become a designer.Process Piping Design1 General Piping The dictionary describes pipe as a long tube of clay, concrete, metal, wood, ete., for conveying water, gas, oil or other fluids. A fluid is defined as any substance that can flow—liquid or gas. Pipe has been with us for over 5000 years Each year introduces new purposes for piping which create demands for new and improved mate- rial specifications and ingenuity on the part of the piping designer. Piping has advanced from its ear- lier function of transporting water through wooden conduits from the mountains’ melting snow to the village below. Today piping can be found almost any place one looks, from the piping in an automo- bile to the complic:..d maze of piping in a process plant. A piping designer is one who designs piping systems. Since piping is so widely used, the piping designers cannot learn the complete field of piping, and consequently they have become more special- ized, going into the fields of process piping, pipe line piping, steam power plant piping or one of the many other categories. Process piping design is, in the author's estima- tion, the most interesting specialization in the piping field, Each process piping unit presents a new challenge to the designer. Each plant is custom: designed, and while there is some similarity be- tween a crude unit of 50,000 barrels a day and one of 75,000 barrels a day, there is no duplication, A piping designer may work on two or three crude units in his entire career. There are literally hun- dreds of different types of units in a refinery or petrochemical complex. Each type of unit presents its own piping challenges. How, then, can one learn process piping design from a book? It can’t be done. A book can present the basic similarities that exist in many types of units and introduce guidelines for competent de- sign. From there on, the process piping designer must utilize his personal judgment. Piping Materials The term piping means not only pipe but the fittings, flanges, valves and other items which form part of the overall piping system. Piping materials are divided into two basic classes, metallic and non- metallic. Nonmetallic piping might be glass, ceram- ete. The metallic piping is again divided into two classes, ferrous and nonferrous. Ferrous Is are those of, containing, or derived from iron and are most commonly used in process piping. Ferrous metals are carbon steel, stainless steel, chrome steel, cast iron, etc. Nonferrous met- als include aluminum.2 Process Piping Design Table 1-1. ‘Some Steel Pipe Specifications astm Number Type __Materit fora | AS3 GrA,B Carbon Steel A106 Gr.A,B Carbon Steel Grade B is most commonly specified ‘Seamless. Grade B is preferred and mostly used, In the modern plant, almost all carbon steel pipe is this specification. Manufactured in welded and seamless | 4339 Gra Carbon Stes! Used for sub-er0 temperatures. Incorporates j special testing. For use 10 50°F sss PL Carbon Moly Basically a carbon steel with molybdenum, Used in medium high temperature service A335 PLL ‘Chrome Moly 144% chrome, 4% molybdenum. Used in higher | temperature, corrosive series Ag3s Ps Chrome Moly $% chrome, molybdenum, Used in higher temperature, corrosive services ass Po Chrome Moly 9% chrome, 1% molybdenum. Used in high temperature highly corrosive series, A312 304 Stainless ‘Used for temperatures below -5O°F and for contosive service at higher temperatures, Widely sed for food product piping. Aad 316 Stainless Used for high temperature highly corrosive service. a3s2 Stainless Used for very high temperature highly corrosive aa? Stainets Used in harsher conditions than Type 321 sates, A-333 Gr3 Nickel 34% nickel. Used for temperatures from -50°F to -150°F, Table 1-1 lists some of the many hundreds of welded together to form a longitudinal weld. The, ferrous*metals available for pipe. Those listed are the most commonly-used in process units. For a complete listing see the ASTM book, Ferrous Mate- rials* Methods of Manufacturing Pipe Pipe diameter, wall thickness, material specifi- cation and delivery requirements are determining factors in the selection of the manufacturing proc ess. Steel piping is made by lap-welding, spiral welding, buttwelding and seamless methods, Welded’ pipe types are made from flat plates which are rolled to form round shapes; the edges are then “Refer to ASTM Standard, Part 1: Steel Piping, Tubing and Fittings longitudinal weld reduces the pressure . attaining characteristics of pipe and the ANSI (American Na- tional Standards Institute—formerly ASA) piping code reduces the allowable stress of this method of manufacture by imposing a “joint efficiency” of less than 100%, Seamless piping has a joint effi- ciency of 100% since there is no longitudinal joint. Welded pipe also can attain this 100% joint effi- ciency rating with special quality control proce- dures such as stress relieving and full x-ray exami- nation. However, these add to the cost and may not be needed. In the smaller sizes, seamless piping is quite often as economical as welded if 100% joint efficiency is specified. Whatever method of manufacture is specified, a “mill tolerance” must be added to the minimum calculated wall thickness. Plate is manufactured to ;Table 1-2 ‘Commercial Wrought Stee Pipe Data 3 Nom= | Outside [Schedule] Wall] Inside | Arca | _ Transveree | Moment] Weight | Weight [External] Section iat | Diam- |°“Now | Thick- | Diam | “cf” | tnccrnal Ares | Mar Surface, Modulus Eine | "ane? | Taese”| Peter” | metas | “7 285" | sarin | Pipe | Water sie | D) | se | “we |e | ow ole? | (0) | Pounds | Pounds | Sa Fe.) (a2) Note | square | Square | Sgoare [Inches to| "pet | por fect pe fove| Cb, _toches |_| Inches | inches | Tnches | Tnches | Peet’ [st Power! foe _|ot pipe |'of pipe Ye 1 oan | Re] -O6E | 269) G71) 0868 OOD] —OOIOo ran) ans 106s % | sox_| 095 | ‘21s | _‘0925| ‘0364 ‘00025 | _‘o0122|__‘314|_‘o1e | ‘106 | ‘00602 7 | as) 088] “10a [0007 | —on33i) ane) 04s tar) O17 Ya_|_ 0840 | ox | ita | 302 ‘0716 | -00050 | _-00377|_‘s35| ‘os |_‘141_| [01395 is —0t| 83 “191000133 | 00729 — S67 | — 08] 78] —on160 Ye_| 0675 | pox | fim | “433 21405 | ‘00098 | ‘00862, 738 | ‘ost | _178 | 07554 We] 109] ar “4000011 |) 01709 ——as0-) Ia —290-| 00069 wy | oso | ame | te | Se 2340 | o0i63 | ‘o200s| 1.087| “tos | ‘dan | area % 10" | tay | abe “Hyoe| ‘ootts | ‘c2a13 r300| ‘ora | a0 | “tener x | 36 | 388 030" | ‘booss | ooana)_ 704 | gs | 330 | oer | TIS) ane S30 00971 | —Oy7oa 1.130) 351 | 278} 0708S ¥ oo | am | de | oa 4330 | (00300 | ‘oa9) 1473| “tan | “zs | “tgsat % } 1050 seo" | ais | “ena 2961 | ‘00206 5363 1940] 18 | [275 | “10036 i 434 146 | ‘00103 | :05792|_2:440| ‘064 | ‘275 | ‘11032 on Sead ogo | 087.678) 75 Se 7190 | ‘boise | ose") 2a71| 33 _ 7 ‘81s | '8365| “Zzi7| ‘ooner | “last | deao| 30 39 | vore0| 281” | ‘bores | ives | Ses5| a2 | TR e083) 1458] o1oN | Toa] D977 — a9 ae erte ize | ‘8813 | 1353 | ‘oosor | aie | i996 | 850 a Uieo | toro} 057 | ‘doraa | taue | 3304] 88 ose | ssa | ‘30 | ‘Oona | Sat | Sata] 33 TeI0 | 7995) Ease ovals | 3099] 2717 | ar 1%] 1900 | 1a | ons | gon] 36n| Jes % Fatty fosre | ‘aaa | X62 “Gow | 100 wooed | ‘Se78| aos | ‘Sr 7087 | S| — 6687 Bsr Tas a lee 1339 ‘1030 | ‘sero | 30m] 138 ca) 1689 ‘iss | rier | 340] ‘o | 1803 ouss| rat | 3on| 3% Tar] ai322 | 1890] 579 | 207 aloe 3383 | 2354 asa | tse | 360 | Lay Tae | 29s Ore | Yass | soot | 14 iz | Som oie | dent_| 1390 | 107 | 3066 2m 1s |3.017 | 758 | 3.20 eu ees | 2900 | 3.016 case | 3.8% | 02s | 256 500 | Zone | 408 oss | Som | tea | 235 | 2500 | 5.468 cases | S900 | ia3e | Tao 35481680 ‘oa70] 4 788-|— S11] a9 Fh | _ +000 330 | 3.678 | cooi70 | 6250 | 2si_| ae $006 | 78 tas40] 7.25] 1079] 350 daze | 407 toes | S'a10 | lean | a0 4 | 4500 Hehe | 3585 trie’ | ares’ | 100 | a7 3438 | oat os | 1397 | bast | 42 332 | 8.101 tse | 1826 | se | 358 507 [4300 1380] 15.16] a6 |-a7 a5 | can 263 | 2067 | 2078 | 380 5 | 5s $303 | 7555 use | 35373 | ro | 3.09 $51 | S650 rors | 3003 | 32536 | 633 4003 | 11 340, oor_| 3343 | 38s | Sat $065) S581 ine | 814] 1897 | Te S7et | sats | 30.07 | “tsi | ous | esr | 11: 6 | 602s S01 | 170° 3597 | ‘tes | fier | Sea Sis |1332 213g | ‘tees | S857 | 450 age | ise _|inse | ‘thos _| 6633 | S36 Eis] oy [5185] SO] or | ae son | 736 [ote | ‘sss | eae | laze Hise | i489 Faer | 640 [S003 | Swe | ea | iegs 23s | test Fai |1048 [ass | Sue | fas | See Piss | 20:38 elas Fes 1276 [Asoo | Sit |aasy | 4359 Pise | test 7439/1496 | 45.46 | aos lier | Soar 2386 |e fio [ize |40s9 | ar |1a0s | soles 2286 | 32.58 Foor |1953 |3u's0 | ders |issy | e230 2288 | 38.8 Gas |ar30 [apis | sre lisze | Saar Hise | 3's Sai [rer [3646 | ase lies | ae 288 | 3648 Source: Crane Co. (Table 1-2 continued on following page) Note 1: The letters s, x, and xx in the column of Schedule Note 2: The values shown in square feet for the Transverse Numbers indicate Standard, Extra Strong, and Double Intemal Area also represent the volume in cubic feet per Extra Strong Pipe, respectively, {foot of pipe length,(Table 1-2 continued) Nom | Outside [Schedule Wall") Inside “Transverse Moment) Weight | Weight [External] Section ial | Disrme | No. Thiek- | Brame | rncernalAren |WSor™| MOPS | MCP leeface| Modulus Be | Pe erase nal Ares | thia| pipe | Woter ste | (Dr | sew | | note? |) | Poands | Pounds | Sa. Fe. | (aE Note 1 Sauore | Sere linens to per | porte | pot oot | 25) ches | laches laches Tethes | Peer’ UR Roverl_oe_(BE pipe Lt pipe am 250) SET Tii7 | 2805 > i676) Za) aS ao | Sar 009 | 1374 | Sa2a| 3396 | Zan | dsr | os | es is too | das | 3h30 | Zand | aor | 300 Fbe nao | S478 | 3255 | Zang 10 | wozs0 | a0 | 385 iiss Bas | 633 | SUI] Pee 00 | 718 | 8.13 266.1 | 76.93 | 29's3| 2814 1 | kas | ots 3342 | $5.20 | 796 | Pend 140 | 1000 | 203 sora | aoets | teow | 281 eo 195 2 3003 | Tiss | 3as0 | Tats | (eco T7863 | TS 38 S107 3 | 0 Maso | 7972 | rasa | 4337 | 4074 s | 3s 1310 | Jaga | 793) 0% | $8.00 4Y | te 11193 | 3273 | 3003) $3.83 | aso | vx | “300 05:43 | 3528 | Sur's | esc | dead 12 | anzs | et |e foes | 3372 | 008 | 73:16 | 46:00 % | reek | Gage | Get] ear | aa 100 | Sore | 10730 | tise 130 | 1000 eis | i545 3535 Ho | iis Foo | 133.66 | 3732 | teo_| sia | io.t2e | 5a | wo | 38a ! T0350 13300 WS 36716205 | 2 | Bae S84 | W368 | 8a.88 ie 13330 grea | sesy | S578 20 1 aot) ear y 13.000 isa | 7209 14 | 1800) 66 isis Sena | S41 *0 12500 6873 | 108.13 100 1s sis | 130.73 120 ihaid S208 13000 | 140 11500 i wire | 170.22 | 160 ise 170 | 99.02 ita 13.300 Fy | | abs | | am oo 16 | wo | | | 100 j | ie j 140 | 180 10 20 | va | s | 2076 | | 3 | Me | ores | x Be | 1s soo 8 | an | | ie | Soe | | 2 | | 20 | 2.00 | 9 | 100 30 140 | 10 4588'5 | 37901 10 j i TIsIsa] BRAT | 0s | 13420 | 94.2 | x | 2549.5 | 125.49, ij ié | 3843.0 | 140°80 | % Sas | 7na7 24 | 0 | gesn's | 236.11 #0 $4720 | don 36 | 100 6849.9 | 567-40 | 120 Fe2s.0 | 429.39 140 an f02s.0 | 485.13 | | t60 iso $8589 | 54198 | Lae.naGeneral Pi a tolerance of 0.01”. Pipe made from plate (all pipe with a longitudinal seam) will have 0.01” added to its calculated minimum thickness for this, mill tolerance. Seamiess pipe is made by a process, that requires a tolerance of 124%. Seamless pipe is made from hot, round solid billets of steel. A mandrel is centered and pene- trates the hot billet, expanding the solid piece toa hollow pipe. This method of manufacturing ‘can cause some possible thin spots in the pipe wall; consequently, the 124% tolerance is imposed. Special manufacturing of seamless pipe. such as, centrifugally cast or special forging, is specified for very thick requirements. This type is cast or forged to a thicker wall and is precision machined, inside and out, and the tolerance is usually nil The piping engineer or designer must recognize the method of manufacture and its related mill tol- erance before calculating the minimum wall thick- ness required for his piping, The various methods of manufacture also de- termine the length of the delivered pipe. Com- monly, pipe is made in “random length” which is #20'0", and in “double random length” which is 240-0". Unless double random length is specified, the manufacturer will ship single random. For long, straight runs of piping, considerable savings can be made by utilizing the longer pieces, saving butt- welding Centrifugally cast and special forged pipe will be shipped in 6-12’ lengths. Since these are ma- chined inside and out, the lengths are very short. This adds numerous buttwelds to long runs of pipe, increasing the system cost. Consequently, this method of manufacture is utilized only where the other methods cannot produce the desired pipe more economically. And any economic evaluation ‘must consider the number of buttwelds. ipe Diameters, Thicknesses and Schedules Table 1-2 lists pipe data for most commercially available sizes. Normally, sizes 1%”, 24", 3%” and 5” ate considered as_noncommercially ‘manufac- tured and are not specified by a piping designer. Equipment manufacturers will employ these sizes avd the piping designer will have to attach a flange or reducer to this connection but should immedi- ately increase to the next larger size for his piping. Pipe and tubing are not the same, Tubing is specified by its outside diameter; 4" tubing is 4” OD, 4” pipe is 4.5"OD. This is usually specified as 4” IPS (Iron Pipe Size) for pipe and can also be defined by specifying 4" schedule 40. The schedule number defines the OD and the “Nominal” wall thickness for IPS piping. Nominal wall thickness is the average wall of the pipe-not the minimum wall. To ascertain the minimum wall, the mill tolerance must be sub- tracted. Fittings and Flanges Welding fittings are manufactured to match the companion pipe. However, it is not mandatory that the fitting and the pipe have the same thickness. While pipe of several schedules is available, fittings are not stocked for all schedules. Fittings are usu- ally specified as standard weight, extra strong, schedule 160 and double extra strong. It is usually advantageous to specify the fitting thickness of the next higher available weight if the pipe wall thick- ness is not standard, extra strong, etc. As an exam- ple, with 14” schedule 10 (0.250” wall) the stand- ard_weight fitting would be specified, which is 0.375" wall. For 14” schedule 40 (0.438” wall) the extra strong fitting would be specified, which is 0.500” wall For pipe sizes 2” and below, welding fittings are usually not used. For low pressure, noncritical service, the sctewed fitting is specified, while for higher pressures and most process systems, the soc- ketwelding fittings are employed. Figure 1-1 describes forged steel screwed fit- tings and Figure 1-2 gives dimensional data for them. Figure 1-3 describes forged steel socketwelding fittings and Figure 1-4 gives tivcir dimensions. Starting in 1970, the 2000-pound series was dis- continued by most manufacturers. The 3000- pound series would be used with schedule 40 and schedule 80 pipe. Socketwelding costs a small amount more than screwed fittings. This cost reverses into an overall installed savings as socketwelded systems withstand the hydrostatic testing and remain a leak-free sys- tem for years. Figure 1-5 describes steel buttwelding fittings and Figure 1-6 gives their dimensions. The fittings depicted in Figure 1-5 are the ones that may be specified by a piping designer. Howev- er, due to delivery and cost, additional practical data is:Coupling t Process Piping Design ,2090-Found Me. 243, 2000:Povnd 3000:Foved No. 383, 3000-Fowed £000-Pound Ne. 663; 8000-Foved Mo. 387, 3000-Fommd No, 388, 3000-Povnd Ne 389, 3000. Pound No. 667, 6000-Fomd Na. 68, 4000-Pound ‘Temp. | Psi, Non-Shock Carbon Stee! ASTM'NIOS, Grade 1 7000] _ 3000 3 23s toe | 3 x0 Soo 33 | ino & Te 00 2605 e ie én isto Ea Fi 700 1960 Fad | ao ies aan 10 oS 00! sare | sive can soo 1000"? | 83 | 38s e000 Pound | Pound | Pound WI0.G. |W.0G./WO.G. 2000 S15 5830 5210 a8, $620 4300, 3920 3550 "Product used within the jurisdiction of ‘Section 1, Bower Boilers, f the ASME. [Boller and Pressure Vessel Code issu Jeet to the same maximum temperature Itmications placed upon the material ‘Table P7, 1939 econ thereat ‘Product used within the jurisdiction of Section Power Piping, of the ASA Gok fog Pressure Piping 831 5 subs limitations placed: upon piping ‘same general composition tt 1855 edition chert Figure 1-1, Forged steel socketwelding fi Grane Co. ‘of the fable 2a Recommendations: These are unusually strong, rugged fitungs. They are ideally suited for high pressure hydraulic lines and for high pressure-temmperature service in oil refineries, oil land gas. feds, central power stations, and industrial and chemical plants The 2000-Pound W.O.G. Fittings, exceptionally compact and light in weight, are intended for services beyond the temperature range of mal- leable iron fittings and for many relative pressure installations where the extra strength and safety afforded by steel fittings are desired. Materials and design: Elbows, tees, crosses, and Y-bends are forged solid; the caps, couplings, reducers, plugs, and bushings are machined from. solid steel. Carbon steel billets or bar stock used in the manufacturing process are subject to rigid specifications for strength, toughness, and resistance to temperature and shock The fittings feature liberal metal sections through- out and have an ample factor of safety over the recommended working pressures. All openings are drilled; on forged fittings, each opening is, reinfor:o with a wide band which completely surrounds the thread chamber, extending beyond the last thread. The design provides the requisite strength, adds to the compact, neat appearance, and permits a sure wrench grip. ‘Threads: Threads are long and are accurately cut to gauge. All openings are in true alignment and chamfered to permit easy entrance of pipe. MSS ratings: Working pressures agree with those in the MSS Standard for Forged Steel Screwed Fit- Face Buthing tings, No. SP-49-1956. No, 01, 6600-Pound & 90° Street Elbow No. 664, 6000:Pound > Mo. 245, 2000-Pound Ne. 668; 6000-Pound (i Round Head Plug Mo, 208, 2000-Pound Me. 309, 3000-Pound No, 602, 6000-Povnd Bi Me, 600, 6000-Pownd rings (2000, 3000, 4000 and 6000 pound W.0.G. Reprinted courtesy ofGeneral Piping 7 E x 1 4 F pam ECW pol i 90° thew 1 45° thew coon ey) rr Psi i Reduce Mat Coptng so T»)® «| >]*]F/e)"|s]® = 2000-Pound W.0.. Fittings Sap | elt] | I 3 7 a ithe 1) 1% | Whe | [Se [He [0 1 | aig [he) 1% [109%h6) He [Ke | [ame | 3° liste 1% | 1% | MAr | Iie 22 | 1% Mel 41%6) 3% | Bhs BA | 28 iaessl as | a Laas 384 (31940) Piel | 2 BRT 3 [Me] 3 | 2 PI Che | 4% [PMs % | 3 | 3% | 2" lst 37 | 36 | ie | 2 | | | 4 | 4%%e | 8% | 3¥ | 5% | 4%6 | 544 | 3000-Pound W.0.G. Fittings [Re] eal Ty | > [ime | jee fae] ad | me | ay | whe] % [ime | WH [ whe | oe | am | nel or | ae Lake Le tay am |e | Te) TH (1H) 1H [THe | MH | | | DAs | the | Mae | 1% | BAW | 13% | 2% | 2 Behe] Wau [20840 2 | ae | 2 | 296 | ae 3 [rife 31 23 Lnemsa! ate [ate] 296 She _2-| Hea] Be | he | BM [He |e ae | amel & 2h |e | 4% | Vel $000-Pound W.0.G. Fittings - [ "aa ] % ]Mhe [MMe | 1 i mM] % | % ihe! ie [tie Pak [ame | 1 | ate | ae 1% | T | he [MeL GE [te [atte | ae | ae | 158 | 138 | hie | he | nig | ase | a | : PT aie [tS Me LE | 8k Le [a ee |e |e | Bhs | Whe | he | 1% | Phe | 1% | 24 | 2 [HMHel HH | Be] 2 | 1% | I 28a aN fo| 2he | 2° | 2446 | 2 | 2H | a%h0 | SHH |a%e| THe | 2M | 2% | he ™% | the| 23M] 2% |28Mat 2% |24%46) 23 | Ore | 494° |2>%6e] 2m | 24 | Le ua | a | 88a 24 | he | 8 | 3He | Sie a | 3" | fe 2 Tel 4 | 3%] 4 13% | 3% [the mm | 3% fe | a | 38 | a8 34 | 4 [nage a” Levies | | sg | are | 584 Lal s' | aw Figure 1-2. Forged steel screwed fittings (dimensions in inches).Recommendations: These unusually rugged, durable fit- ‘ings are ideal for small (up to and including 4") welded lines on relatively low pressure service, for high pressure hy- draulic lines, or for high pres sure-temperature service The r00%Pound WOG Fite tings ae for use with Sehedule soot Standard pipe the ja0e-Pound, with Schedule Bs 1242, 2000-Fownd WOG No. 1382, 3000-Pomd WOG Ne.1462, 4000-Pomd Woe NGL No, 1662, 6000-PemdWOG Ne 1ae3, 6000-Fomsa woe with Sehedate 40 or Stam ‘ith Schedule 80 or B wim Double Es 1m. Water, Ol, Oil Ve No. 1243, 2000-Fomd WO No. 1383, 3000-Foma WOS. 1463, 4000-owd WOS Schedule 160 pip Sirona pine Working Pressures* | [2000 73000 7 4000 | 6000 Deg. | Pound| Pound! Pound) Pound Fant | WOG'| WoC) Wo!) WO" "000-3000 000-000 150 | 1970 | 3685 | 3sa0 | Seis 200 | 1940 | 2915 | 3885 | 5630 250 | 1915 | 3875 95) Teas) 350 | 1975 | 2810, s a 400 | 1850 | 2775 | 3700 450 | isio | 2713 | 3620 | S430 500_| 1735 | 2605 | 3470 | S210 or Entra Stfong pg’ the carbon | $90 1238 | es | 300 | Sn sooc-Pound, with Schedule “Bisel” | S50) 1640-1 3a neo -ass Hoe pipe -'.' and the toc: qgray a ros) $28 | 4249 | Zale | ako | dezn Pound, with Double Extra ‘Strong pipe. Design: Elbows, tees, crosses, and Y-bends are forged solid their openings are reinforced with a wide band which com- pletely surrounds the socket chamber, extends well beyond the back of the socket, and meets recognized requirements for socket-weld dimensions, Reducer ine serts, couplings, reducers, and caps are machined from solid steel. Openings of all fittings are drilled and the ends. are bored to ship over pipe, Materials: The fittings are made from high grade carbon steel (ASTM A105, Grade II) of unusual strength. and toughness. It is particularly suit- able for fusion welding American Standard: These fittings conform to the American Standard for Steel Socket-Welding Fittings (B16.11- 1940). This Standard includes elbows, Figure 1-3, Forged steal socketwelding fittings (2000, 3000, 4000 and 6000 pound W.0.6.). Grae | 79 | 200 | 1305 | 1960 | 2610 | 3920 80_|_ 1775 | 3365 | 3850 [ions (eas 80-00 sso | “ha | 13z0 | ieee Bs | TB | tom | 1 | Hao Soo | is | "SHS | ASS | tess a ee sso | as | Gee | "ass | ties srs | Ss | Soo | eee | i205 1000 | 235 | 355 |_ 475 | ‘715 to | ss | ss [ars | iis tees, crosses, and couplings in sizes v-inch and smaller for use with Schedule 49, Schedule 8o, and Schedule 160 pipe ‘*Note: When pipe is rated in accordance with the Code for Pressure Piping or any other Code, these fittings may be used for the same pressures and temper atures as the pipe even though suc! ratings exceed those in the table above The fittings, of course, must be made of a material having chemical and phys- ical properties comparable to the pipe, and must be of suitable weight, as indicated by the schedule numbers 45° Y-Bend 5, 2000-Foond WOS 5, 3000-Pomd WOS 1485; 4000-Rownd WOS. No: 1668, 6000-FemaWOS , 2000-Pound WO 3; 3000-Foond WOR,General Piping 9 Dimensions of reducing sizes are the some as those of ees the stroight size corresponding fo the largest opening eal 415° thow Teo con Seed conning Raaucee Se ]A]B]C]DIE|FIGIN]J[EI[LEIMINIP|®|S|TI[U]V 2000-Pound WOG Fittings, for use with Schedule 40 or Standard Pipe % [3 [74a] ?%4a] 3% | Me | The [1942] 3142] 42) 1 [He] 1% | MHe) 1 | He) MH | % Wes he % | te The 1 ive am | 111% | te —h % | the | he Lose! 3 Lame | Lm | % Ye | 1H [Ihe] *he | 14 [346 ie] 14 | TA | Me | 144 [he 1 | Me Whe He) oe fail ae] 3" a;e 6 | eK | 1% Ash Latent 34 al ie! 2 Ye Mm | aha hel ea 21 tha] BB ate | HT the 2 Ue 1 the 3 24 |e DY eke A" 2 | Te 3 ™% aye] te he) | ai 4 12% | | 3% | 14 3 aM % 24/1 | aie | 15% 4 3h | 46t 1196 | S96 (antalya 3 {uy | 34 Le re a Wo ratio ee eats ows oc % aa] ha The | Waa] a] Yaa] |e] ]#]% % 143] Ms The | 1a | Hae 1 hid 1% el 2 % 1p 1%e Yay ital wel a Lagl 3 | | Lg Law| % | an 1 [3¥%4e |2%e he Me | 1 a lag He 1% Maid aig | 3 1% |e 14 113% | 146 | he 2402 BhelM he, 3H hel 2% is Be) 2K) i Banat eay Tie] BB % A) 1M 2 lamlim| | 3" 3 Ba Othe 4°44 MH | | 3 | IK 7% 3/15 154 | 3% | 35% ‘ VO ah | te | 3 | 1% 3° | 33% | 24 | 16 | Ah | ABhe 1 % pad] | aa am 4 Lathe! 286 1pe) 261 584 | 304 | 154 | 14 | 5 5% 3 hig 5% 4000-Poand WOG Fittings, for use with Schedule 160 Pipe Wie] % | %e| | HA] T | | | 1 |e] %e | 1 | Me] Me] || UH |TH| \am| 3hel 1% | Me | Me [Ae | Hh (MAAK Ye | 3 l118K6: He | He | 14 | he 1% | 1s] he] Pe) 26/1540 | 1846) He | 2546) 1% |e | 246 M%4el 9 [2246] 194 | He | 2 | 1M 2 lim hala hen he 22 Latha| SH NHel he TA hal 2 Le 3% Yh PMsaDHoal he 1 M46 29 V43] 294 | Te [AM OTAe | 4% [Poel 2 | % | 3 | 1% 288 [1 | 16 [Soho aen esa] 146 [angel amnel a | [oe | % | 3%] 14 Pa APAPAPAG RARE DA| % | 44 | 1H 33412 al ag 2 ig reall 4% Lag] tl ase 3g (6000-Pound WOG ree for use with Double Extra Strong Pipe % Me *Aa| The | lhe] Ye | % | Me [The] 14 [142/16] 3 [2] WA | Me | The [he] he mlm age Lig | ig 1¥4 | 40 ¥46) 14 [3% amie | He | 1 | Me | 14 | amr van’ | fA Te 4a) a4 1/15 | %% | [2 he] 2%e 2helAl re 1% _| 2 |aMg! 1Hi9| 2%46 | 2%40 | Ihe! 5% 1TH 1M | 1a DMA Ma the 4a) Piss Bsa] DH | MBs Ae | 4 24 Ae A ashe hfe 14a) [274s | Se 7h Be ame | 3% [1 | 1% 4° ape] 0 igs) 4) 3% | 1% | 4 ST La | ate aL ate | ate ak | ae Figure 1-4, Forged stel socketwelding fittings (dimensions in inches)10 No. 959.6 00 Mo. 373 & Shon Radive ‘No. 373 E, long Radler Figure 1-8, Steel buttwelding fittings for use with standard pipe, Reprinted courtesy of Crane Co. Process Piping Design Thickness: Standard fittings in sizes 12-inch and smaller are made for use with Standard pipe (the heaviest weight fon 8, 10, and 12-inch sizes). In sizes 1g-inch and larger Standard fittings are made for use with OD. pipe Serinch thick Materials: Unless otherwise specified, the fittings are made of carbon steel conforming to’ requirements of ASTM Specification A 234, Grade B, Fittings made of Grade A carbon steel, genuine wrought iron, stainless steel, or other materials can be furnished ‘when specified, information on request. American Standard: These fittings conform, in types and sizes included therein, to the American Standard for Steel Butt-Welding Fittings, Bi6.9-1958. ‘The Standard does not include sizes smaller than 1-inch, nor does it include go" elbows with a long tangent on tne end, short radius 90° elbows, crosses, shore radius return bends, or shaped nipples. 90° elbow with long tangent: The No. 335 E are 90° long radius elbows having a long tangent on one end to permit welding on a slip-on welding flange.” The tangent end is not beveled; the other end is beveled Cranelap stub ends: Cranelap stub ends, made of Grade B'seamless steel pipe lapped to the full thickness of the pips wall. and Cranelap flanges aiford an ideal method of installing flanged equipment ina welded line ‘The swivel flange eliminates the cifficulty of aligning bole holes and permits installingthe equipment at any angle. Shaped nipples: Shaped nipples eliminate the use of templates when saddling one pipe upon another, they save erection time and assure an sccurate fit. Both ends are beveled for welding When ordering. be sure to specify both the pipe size and the nominal size of the header on which the nipple will be used: header sizes which the nipples are shaped to fit are cluded in the Upper table on the facing page Prices: Prices are furnished on request Ordering reducing tees and crosses: Wh-n ordering reducing tees and crosses, specify the size of openings if the sequence of the lower case letters (a and b) shown on their illustrations at the left U, asoe 90° Shoped Nipple a Ne. 351€ 45° Shoped Ni ccontie ReducerCc} =o Short Redivs General Piping American Standard: These fittings conform, in sizes and types included therein, to the American Standard, Bib.o-1958 Thickness: Standard Fittings 12-inch ang smaller are made for use “with Standard pipe (heaviest weight on 8, 10, and 12-inch sizes); sizes 14-inch and larger are made for use with O.D. pipe Sgrinch thick. Extra Strong Fittings 12-inch_and smaller are made for use with Extra Strong pipe: larger sizes are made for use with O.D. pipe ¥4-inch thick. Schedule 160 Fittings are made for use with Schedule 160 pipe, Double Extra Strong Fittings are made for use with Double Extra Strong pipe Tet > oni " SepA]BITe] DIET Fege_| Serong % [mT % | «0 ] 0 % | m the | tie Whe #0 | Vlg] i He [ime | aim | 2 2 wo | & Mal 1% | 1% | tame | a | ate | 2% | 30 TH) MA] SM | Me BME Im] 8 Th | 80 2’) 3) 2 | a | am | am fim] 4 3% wo | 2] - fl aw 0 | 9 a“lael sl sy |e |ay | 7d 6 é «| » 3a) 8 [RTO |B PH HY Tse © | = a] ela) mm | am | ae | am) 8 8% | Oe 0 | » § lm) § | 8 | 3H | S| ae The 0 | 0 6 | 9°} 6 | 10%! 394 | 58 | ay | 8 «| #0 ofa) s fm] e746 1054 «0 | #0 wo | 15 | 10 | a7 | 6%] sm] & | 20 124 «| @ Ba Lan eS] | i | mia | na | ag |e | oie | 38 16% 30_| 1% | | 16 wey? Te | 18% | 12 | 3% [204] 4 | 90] w | | as 11% [1K] 8 | 36 a | az | a | 26% | a5 i 2 | 30 | 20 nig] as | 9 | 40 as {iz} 4 [30% | 20| 2 | 36 mae ae iow) Ll a4 [Snel i | Figure 1-6. Steel buttwelding fittings (dimensions in inches). Courtesy of Crane Co,12 Process Piping Design Welded flanged joints can be furnished in the types illustrated here. The Cranelap stub ends with Cranelap flange, also illustrated, afford an auxiliary flanged connection for welding, Application: Any of the welded flanged joints shown at the right can be applied to straight pipe, pipe bends, the ends and nozzles of welded headers, and the flanged ends of welded assemblies, Special shop ‘equipment assures the perfect alignment of flange faces on all Crane Welded Flanged Joints Welding: The shop welding of these flanged joints is performed by Crane welders working under ap- proved procedure control Special piping materials: These types of welded flanged. Joints can be furmished ‘on many. special Piping materials, including numerous alloy seca Sith factities for heatereating atte fobrieion (Complete information and prices will be furnished on application, Seat Welded ond Relaced r Welded For! ond Bact nd Refced Forged Steel Screwed Flange, Seal-Welded A Crane Forged Steel Screwed Flange is used in this joint. The pipe and the flange are accurately threaded; the flange is macie up tight on the pipe. seal-welded, and then refaced. The joint is sealed by fillet-welding the back of the flange to the pipe, thus assuring no leakage through the threads. The refacing assures perfect alignment of the flange faces, and that the end of the pipe is flush with the face of the flange, The threads retain the function of holding the lange securely on the pipe, hence there is no shearing action, Forged Steel Welding Neck Flange Crane Welding Neck Flanges are of forged steel. They are machined with a beveled end and bored to match the inside diameter of the pipe to which they are applied. A butt-weld is used to attach the welding neck flange to the pipe, which is also machine beveled. Forged Steel Slip-On Welding Flange Crane Forged Steel Slip-On Welding Flanges are bored for a snug fit on the pipe and, when applied to fabricated piping, are welded at the front and back ‘through the two methods defined below and illustrated at the right. ‘Type No. 1: Type No. 1 is Crane standard for welded flanged joints using Forged Steel Slip-On Welding Flanges. Regular flanges are utilized with the lend of the pipe set back from the face of the flange and the flange welded to the pipe both in front and back. ‘Type No. 2: Type No. 2 is furnished on special order only: slip-on flanges with a special iront groove for welding are used. The pipe is flush with the flange face; this is accornplished by refacing, after both the front and back of the flange are wel. xd to the pipe Code limitation: When piping must comply with the American Standard Code for Pressure Piping or the ASME Boiler and Pressure Vessel Code, the use Of the slip-on flanged joint is permissible on all sizes of flanges listed under Primary service pressure ratings up to and including the goo-pound class and in sizes 2}4-inch and smaller of the 1500-pound class, of the American Steel Flange Standard (ASA Bi6.5-1957) Cranelap Stub Ends and Cranelap Flange The Cranelap stub end with Cranelap flange can be applied to fabricated piping. Both the stub end and the pipe are machine beveled. A butt-welk! is used to complete the joint. This type of joint has all of the advantages of the regular Cranelap joint In most cases, piping can be fabricated with Cranelap joints applied directly, which eliminates the weld necessary for the application of the Cranelap stub end with Cranelap ange Figure 1-7. Flanging processes—welded flanged joints. Reprinted courtesy of Crane Co.General Piping 13 The Crane line of Forged Steel Flanges comprises the complete assortment of straight and reducing, types illustrated on this page. Made in seven diferent pressure classes... 150, 300, 490, 609, 1990, 1500, and 25co-Pound .... they are avail- able in a variety of materials and with various flange facings, providing a correct type for any service requirement, ducing Serewed Flange ho. 558%, 300-Pownd 400-Fownd = $00-Pound 1266, 900-Poond 1856 E, 1500-Poune Materials: Crane flanges are made of carbon steel forgings having a highly refined grain structure and generally excellent physical prop- ‘Sip-On Welding Flonge certies well in excess of recognized minimum ° ‘arose fesse Toes feauiremares 2 2 In the 150 and oopound pressure clases, the She oreo ROINE lees flanges are regulary’ made Of carbon seal one 3 $eoand BA, Sotemg forming to ASTM Specification A 181, Grade II, on special order, they can be furnished heat. 1595 © 1500:Posnd fo. 1594 €, 1500-Povnd treaced (normalized of annealed) to conform to ASTM Specification A 105 Grade IT In the 4o0-pound and higher pressure classes, the flanges are regularly made of carbon steel conforming to ASTM. Other types of facings such as ring joint, female, tongue, groove, ete an be furnished. see pages 332 to 335 for complete information, Specification A 105, Grade II In addition, flanges of any pressure Aor bering, soe page 314) In addition, flanges in 300-pound and class are available with @ flat face 130-Fowed higher pressure classes can be made to (raised or male face removed) : the flat easel order of Crane No. 5 Chrome-Molyb- face will have a spiral serrated finish doocrona denum Forged Steel (ASTM A182 Me. 1268 &, 900:Poond Grade Fa). American Standard: The dimen- sions and drilling of all flanges con- form to the American Steel Flange Standard B16 §-1957, for their respec tive pressure class. This Standard does not include slip- ‘on welding flanges of the 2500-pound Finish of flange faces: The Yrinch raised faces and the ¥4-inch large male faces are regularly furnished with a serrated finish. A smooth finish can be furnished when specified, Drilling: The flanges are regularly furnished faced, drilled, and spot faced to the corresponding ressure class of the American Stancucd. They can be 156 1500-Pound > class nor sizes y-inch and’ larger of furnished faced only, when specified We. fie's, Serene the 15co-pound lass; in such classes Reducing flanges: The Reducing 400-Pound andsizes, Craneslip-on weldinaflanges Screwed and Reducing She- Gr Wak teary seem have the same dimensions as Amer ican Standard Steel Screwed Flanges, being bored instead of threaded Flange facings: The 150 and 300 Pound Screwed, Shp-On_ Welding, Welding Neck, and Blind Flanges are regularly furnished with an American Standard byinch raised face ing Flanges, illustrated above, are avsilable in any size reduction; prices are based on the outside diameter of the flange. For ordering information, see page 311 Reducing Welding Neck Flanges and Eccentric Reducing Screwed or Slip- On Welding Flanges can be made to Wo. 1562 €, 1500. nd os The aforementioned flanges, in goo- "der; information on request. Ne. 556%, 150-Pound ound and higher pressure classes, are Reducing Cranelap Flanges are not re- No: 297 5: 300-Pound regularly furnished with an American Seancars Jocnch’ male face (large commended and, consequently. are not ‘manufactured. Another type of flanged joint or connection should be used Figure 1-8. Forged steel flanges. Reprinted courtesy of Crane Co. 400-Fownd180 1855 570 sas ws as 3470 3190 3055 Das ws 2640 2500 2085 78s, 1485, 1s os 785 630 530 14 Process Piping Design Steam, Water, Oil, Oil Vapor, Gas, or Air Metal [Temp] Pounds per Square Inch, Non-Shock Dex | 130 | 300 | 400 | ¢00 | 900 | 1500 fa. | tb | tb. | te. | | oe | eee | Sa | Tao | Teo] 00 3 | 1420 | 2130 | 3880 2100 | 3500 070 | 3480 MIS ys 330 ss ans 2955, ‘Sec zm Flanges 2580 2250 as 1120 | 21500 Tras 305 200 | A115 25659 | 94s [are | ass | 7708 eo" | 40 | 3600 15+| 70] 555 Te cemperatures lower an 70D Fat fte the same as those for Carbon Stel Flanges. 70" | | 48S | Gas | 968 | vas | 2s 790 450 | 600 | 900 | 1350 | 2250 } soo |. | as | sss | 35 | 1250 | 2000 aso | | as | S10 | 765 | 1150 | 191s ws 365 | 490 | 735 | 1100 | 1830 No.5 | 90 350 | 465 | 700 | 1050 | 1750 Sargrier: | as | 335 | 44s | 665 | 1000 | toes feivbdenuim| geo | | Sus | 420 |_ eas | “350 | 1585 Flanges" |—975 || 300°) 400) 600 | 900 | 1500 (made to order}} 1000 250 500 | 760 | 1250 | iors his a0 | as | 1070 100 ‘80 355 | sas | 9m to7s || as aso |_435 | 20 1100 115 nas | 300 | 65 | ase 35 190 | 285 | «0 1150 75 150 | 225 | 95 | 175 6 15 | 190 | 315 [L200 50 tos |_1ss |_ 355 | ‘Where welded con- struction suced. con Sderation iven to the possibil {ty of graphic forme at temperatures above 775.F *Product used within the jr ‘ction of Section | Boers, of the ASME. Boiler and Preseure Vessel Code, is Subject to the same mavirsum temperature limit placed pen the’ mat FableP?!T359edition thereat ‘should Be on steel ‘Product used within the jurisdic tion of Setion 1. Power he ASA Cage for Pressure BLT subject tothe same max mum temperature imitations placed upon. piping of feneral composition in Table 2a F595 easton thereat. 20 ASA and API Standards: Crane ressure-temperature ratings con- form to those listed in the American, Steel Flange Standard, ASA Bi6.5- 1957, and in the American Petroleum Institute (API) Standard No. ece, Fourth Edition, 1958. Cold service: For temperatures between minus 20 F and plus 100 F, the ratings shown in the table for F will apply For temperatures below minus 20 F, steels with suitable impact strength must be used, pressure ratings for such steels will be the same as shown an the table for 100 F Gaskets: The use of chese ratings requires gaskets conforming to re- quirements set forth in American Standard Bio.s-1957 ‘The user is responsible for selecting gaskets of dimensions and materials Capable of withstanding the required bolt loading without injurious crush- ing, as well as being suitable for the service conditions in all other respects. Flange facings: Unless otherwise ordered, Crane. screwed, slip-on welding, welding neck, and. blind flanges of the 150 and, 300-pound classes are furnished with a Mg-ineh raised face. In the 4co-pound and higher pressure classes, these flanges are Turished with @sinch Targe male face Cranelap flanges and joints: These ratings also apply to Cranelap flanges, the rating being dependent upon the type of facing applied to the lapped pipe end. Ratings for Cranelap joints are contingent upon the use of pipe of proper material having an equal oF higher rating. ‘Consideration should is ieee lation (sealing) when N's: Get Moe {vibdenum Stee Is used at temperatures above tivo ng. of Pipe Figure 1-9. Forged steel flanges—working pressures, Reprinted courtesy of Crane Co. sliahine titties ere aGan TERT a oT, Slip-On Welding Flan 100, 900, ond S00-Pound 00 | 43% 16.00) 43% 18.00| 5% 20,00| 5% | p4.00 6. 450) 2 % 2% 8.63 [24g 1075) 4 1278| 4% 14.00| 435 16.00 5 18.00 | 53 .00 | 53% 24.00| 6 Figure 1-10, Forged steel flanges (dimensions in inches). Courtesy of Crane Co. (Figure 1-10 continued on following page)16 Regular Facings In 150 and 3co-pound pressure classes, the screwed, slip-on welding, welding neck, “and blind flanges are furnished wich a ypinch raised face In 400-pound and higher pres sure classes, the -aforemen tioned flanges have inch ‘male face (large male) ‘American Standard The dimensions and drilling of flanges conform to the Amer- jean Steel Flange ‘Standard Bio 5-1957, for their respective pressure class, This Standard oes not include slip-on weld~ ing flanges in the 25c0-pound class nor sizes j-inch and larger of the 1 500-pound class Crane flanges of this type have the same dimensions as Amer ican Standard, Steel Screwed Flanges, being bored instead of threaded. Cranelap Flanges Cranelap flanges also are recommended for use in com- bination with Cranelap stub ends. When 3-inch 5 co-pound flanges with fing joint facing are to be bolted to Cranelap joints, orders must so specify’, they require a groove of special pitch diameter Galvanizing Galvanized flanges can be fur- ished to order, Figure 1-10 continued) Process Piping Design FiGi|H %e | | HMA 3 | 4% |e) 2) Se Toa | Me |e | | Ta Me | 084) Ie 12%) 105! 1 % % Se | he! he | 132] Ie % 1M 1M 294 | 1.66 1% rc ” Th! Oh 3%) Mm 1901 1% 2 1) 3%) 8 5 | he he | 238| Ie Mm | 7% 1% | 4% | 5% Se | 3M 2.88) 15% 3" Lm 3 6% jg 344 | 3.50, 1194, S00 10% Bie) 84 Ty) 4) 4.50) 2% ee 13) 134 | 74s | 10% 2% | 4M 5.56) 2% mn Sie 1 6.63 2 TOW Bae | 10% | 19% | 12) 1% 3%) 863) 3 20M | 1% IT | t6 MM © 10.75 43% 234 | 244 | 16% 20% | 20| 134 atthe Om 1400/8 4 5 6 ’ 10 | am | as a9! 20) 1m 6M 1278) 45%, 4 16 18 a arise at aot 71600 ie 29%) 3% | 2 | 25% 7Y% |18.00) 6 i [33h] fae HA oa te ee ee oiean! ie Tae pe eT +) 380 3 4 1%] 1M OMe) 9% 4% | 4.50, 2% 5 13% | 2 | 7%e Hh 8 5 | 5.56) 3% on (| fod 288 Laat LB si | eas Pound ~ 8 | 18%) 2% | 10% Tae Ts) 4 | 6% | 863) 4yy vee] BE UTE] TBST Te | aa | at | et Langs) wit | te] 7oe| SR PHY S| || SE SR RSA ak eh ei) Go Ee ean) Te) 27%) 3H | 24H | DOL | 5%) 4 | 16.00 jas [oa ae | a) [a0] am | 8 | sso [|e] | Bae 2 6% | 9% | 20.00 | 24 | sig zy silo ay | | ni leoo — Mea MT THT one % | 5% he mela | | ae | 1.05 2 pee me fam | ae | aa | | 6% | 1% ae 14% 4) tm | 1 2% | 1.66 Mm? Tm am ae Ta IK | aM) 10 2 | 8% | 1% | 3% | 64 8) Mm 4 2.38 1500 | 2% | 9% | 1% | 4% | 7%) 8 | 1 | 2m | 4% | 288 Pound 10% 1%q | S| 8 18) 1m 2% 4% 3.50) Ps a ce 4% | 4.50 ee peel eee elle cali “a 15% | 3% | 8M | 12% | 12| 1% | 40 6% | os Paae [ioe sie ae ie) S| 8 | 85 wo fas [ae fase is an) am | ote | Ae 07s] °F 1 | 26% | 4% | 15° 22% | 2 | 7% | 11% 12.75) 9% 54 | wey! 25° Lae | 244 | | tag liao] 9 Mm | 5% | Ms| 1% | 3% | % 1% e | 2%— | 0.84) 1%e Me | ose | at lasted ose | | St fie] Se | tos is tLe | ae M% 1%" | ay | 132| 196 ny | oi | nie | 2h | 34 34 | 1166 a4 me eee 3% | 1.90) 2% 3% | 2.38] 2% 2500 | 2 [| a | | 5% | 288 | 3% Pound |_ 3 | 12 | 2% il 654 | 3.50/38 4 | 3 | he HL 8 | 7% | 450) 44 16% | 38% Hae [9 | 5.56) 5% ! 191 a 8 | 2 |e! | 1034 | 663 | sul Ua] 8 [10% | 17%) 12 7 P| 863) dese | oe [oak fe a] ae | 3 [tee Jaa! 4 30 as\| ne | 12 | 934 | 10 | ty 12.75)General Piping 7 seb in 4 & ZAR SN 1c Groove for either Oval or Octagonal Ring. Se 150 and 400, 600, 900, 1300, (Ova sings Bt grooves hoing ihe arround bottom: a00sPovne ‘end 2500: Pound nel cingr only AY grooves having’ © Rot bottom: nd Flange te 2h 3 4 TH |RID Mel He Pe He Mha) | Baa] Te % 2" |R2/ 34) % | She \% | sal BE| 4) | She | S42 % [37129 a | aie ois the % Bh | RB He He Yin Hie, 4 % | R36! 5% | oe tee | 68 4 * R40 | 6% Sie Sel ay) 8H Ra ol Se | 963 | 986 | 44 4 Ra 9% | Me She 0%) | 8% iret Se |13'| 8 jroo) [eee] oe lade) ALB e | | RAAB anaes 154 ches” When Sinch 300.1 808 Powd ting font valve. Ming oF Tie | Re# ae Lat | &% fone ore be hed Conlon [is | Res |204! ¢ ny | (Seiad ect ey mo [Re oe] a let] oe 24 R76 |26% Me | Me 7M | % RUT a| |The | 3h | Me | The % | RIB| 146 Sie %e| Me M42) M362 [ae te a ee ak os) ae pase oe ees Ring! [_ Bo ts Cwm | sie ROE) A | B/C) D le] FL 0 0 PRT HE] ga ogo 30-0000 | | Bie 2 Re. ~ ft T | fa] wm Ras | 2% | sel the |e Lise! M4 |seel 1 [R20 [v6 Me | Wan, Me | a) |e a BRB) aM | is ha| She | The [ie _ | ral R26) “a | ane aude) st [ises) the |e 54) 4 43 a |e |e Sa 88h he | thal 3s 544 % % % Noo: | 34 | R34) 6 |] She OS | 15m th _ | 4 | Ra | 8% | He Tha Tha] %e| 67%) S | 514] 5% Ve fo [5 [Ral an | ue thal taa| he 844 | 5 [894 ork 7 Pound 6 | R45 856 | he Yaa! thal He 94415441 6 | 64 1a [8 | R49) 10% | the As | Ysa |"Az| Ye |10%) 6 | 6%4|7% % [10 | Rss] 12% | He Ya tar *ha| 146% | 744] 814 ™% | 2 jm [Re] | He Yaa tha|%0 164) 74 | 8° | 53 1 | R61! 16% | %e Ya Yaa She) 18-1744! 8%) 944 He PROS TUBE |The [1he) % [960 Hie | oe he] He] 20] 8] [eT 20 (ag en) | ce 9b aes He leat at "ond 24 | wo /R73! a | | ml telineel Se lela ea] 25 omc ang 2k 24 4 ae ba |ee77 | a7) 56 | re ings the AL as hava |e andl 2a | aa 13a ie oe oe Figure 1-11. Ring joint facing and rings, American standard (dimensions in inches), Reprinted courtesy of Crane Co,18 “Flex Gate" Valves Aeguloty Wished in sins 2 to 12 Inch ovallble on order in nent Sane Crom's poteled onepiace Rar Ih dn Sod though th cantor fay. perms eoch die foe fo ‘Move indgpendey ofthe ater Crane “Flex Gate” Valves offer host of benefit. The de- sign effec easy operation ler ‘srequleed to seat ond vn: the dee wil not ik closed. position, ‘even it closed while hot ond allowed $0 inisalignent of sea line defection... and he voh are tight over @ wide range of Pressures on both the inlet seat fd the outlet seat —~ Glond Ronse water, oil, and oil vapor lines ~~ clone — Rae pve designs assure high utility in Sfing box spocer — Bonnet bushing Body set ving ward in fine valve construction Process Piping Design A complete line . . . featuring Crane's patented “Flex Gate’ design in sizes 2 to 12-inch 5 Polar Otter Crane 150 and 300-Pound Cast Steel Wedge Gate Valves offer dependable service in steam, Quality materials and fine work- Tanship combined with cested severe service. A variety of trim materials are furnished The line, in the popular 2 t0 12- inch size range, introduces Crane's “Flex Gate” Valves with patented one-piece flexible wedge disc... a major step for- “Flex Gate” Valves: Crane Flex Gate" Valves feature new concept in valve design a flexible wedge dise, Instead of being made solid with both seat- ing faces maintained in the same sency TE Posen, exo = or resiliency «is attained by having the two faces separated from each other except Sl wedge da a fo. a small section at the center, See the two," 28, illustrations ae the left. (300:Found Valve titrated The shape of the flexible disc can be likened to two wheels on a very short axle. The “axle” or spud at the center of the disc is amply strong to carry the two halves of the disc together at all times... and yet, it permits a degree of action between them. It is this “flexibility” that makes the disc tight on both faces over a wide range of pressures... . prevents sticking during temperature changes, and assures minimum operating torque. Although each disc face can move independently of the other .... up to two full degrees . . . the construction is one-piece. There are no loose parts to cause harmful vibration, Solid Disc Valves: Crane Solid Wedge Disc Valves, illustrated at the upper right, are regularly furnished in the 1}4-inch size and in sizes 14 to 24- inch; they are optional in sizes 2 to 12-inch. As in the "Flex Gate” design, careful engineering and workmanship are combined to produce a quality product highly dependable in severe service. The disc is the solid web type. The facings are smoothly and accurately machined, and are then ground to a mirror-like finish, The disc is care~ fully fitted into the vaive so that an even, wide, and true contact is made with the corresponding faces of the body seat rings, Disc guides; stem connection: Both the flexible disc and the solid dise have long, machined guide slots which engage the guide ribs in the body to maintain true alignment of the disc throughout its travel. The seating faces do not contact each other until the valve is virtually closed. A tee -aead disc-stem connection prevents lateral strains on the stem. Figure 1-12. Cast steel wedge gate valves—-150 to 300 pound. Reprinted courtesy of Crane Co. |General Piping 19 Face to face: Flanged valves of the 150 and 300- pound pressure classes are regularly furnished with a Linch raised face; those of the 460, 600, 900, 1500, and 2500-pound classes are regularly furnished with Yyzinch high large male facing; face to face dimen- Sions include these facings. All flanged and butt-welding valves conform to the ‘American Standard for Face-to-Face Dimensions of, Ferrous Flanged and Welding End Valves, Bt6.10- 1957, for their respective pressure class, This Stand- ard does not include 34-inch steel valves, Clase c[ pj e | cm [Sef Bp | a 7 ae | 9% | we) 8 | *| 2 11% | 204 | 9 a" fw | 3 y ly | » I | 2 | 42% | 20 150-Pound Pes ae n | a | sam) 33 3 70 | 7 38 38 | 7% | 30 2 | em | 30 | & | om | 3 @ | & (ik) 3 ss} ss |" | io is Tae] | is fam | i nin |aa| we uw | «| an| 2 2) sam | ae a | 3 | ay| » m | 3% | | 3 su0-Pound ioe 40% | 40% | 774 | 30 a aa | sa | so | 3s » i) 10) 16) 8 ” ie ei [tence ; 7 a] a |» |» ae | om | do 2” | sate | ay | ary | 0 3 | 50m | 36 ayy | 0am | tore | 20m | a 45_| 120% |_36_| 1500-Pound | 5 | tare | ise | 28 | 14 7 e) epee +) [ay | Pa 5 m [is || te 5 | tig | dere | soy | 0 [3 oh [sh | ow | if Ee 8 aay | 234 | Sout | | dat | oom | ss |e $o-Pound 9 | 26% | 26% | 59% | 24 T 2 a0 | 30" | 7m | Dimension of 2500-Pound Valves [i |: [aga] B peerene| communes 16. | 35% | 35% | 80% | 27 Figure 1-13. Cast steel wedge gate valves~150 to 1500 pound dimensions, Reprinted courtesy of Crane Co,20 Process Piping Design Crane Steel Globe and Angle Valves “embody ments in design and materials or general the &. lett) Thi All sizes of "x: Body and bonnet: The body and bonnet have heavy metal sections with liberal reinforcement at points subjected to greatest stress, ‘The bonnet is fitted with a stem hole bushing, Bonnet joint: A ring-type bonnet joint holds pres- sure easily on the 400, 600, 900, 1500, and 2500- pound valves, assuring tightness and maximum strength. On’ 150 and 300-pound valves, a close- fitting male and female bonnet joint retains the gasket and accurately centers the working parts The 3oc-pound and higher pressure valves have through stud bolts in the bonnet joint. The 15 pound valves employ studs, threaded into the bon- net flange on the body Stuffing box: The stuffing box on all valves is deep, assuring tightness and long packing life. The stuffing box is the lantern-type on all except the t50-pound valves. When wide open, the valves can be repacked while under pressure Gland: A two-piece ball-type gland and gland flange assure even pressure on the packing without binding on the stem. The gland flange is held in place by svinging eye bolts; the belts will not Stem: The stem is of liberal diameter and has un- usual strength. Threads are clean and accurately cut and have long engagement with the yoke bush. ing, The stem and disc are held together by a dise stem ring, which permits the disc to swivel Drilling: Flanged valves of each pressure class are furnished with the end flanges faced, drilled. and spot faced (FD & SF) unless otherwise ordered, Disc and seat trimmed valves (forsceam, water, trimmed valves forsteam. water, oil oF oll vapor service) in siaes teinch and smaller have a plug type disc and seat (illustra neh si dise ‘and seat (not illustrated) inch vaives do ni dise stem guide, trimmed valves or oil or oil vapor service) are furnished with a 35° and a ball shaped seating face con the dise (illustrated at right) Body seat ring: All valves have the shoulder-type screwed-in body seat ring for utmost tight- ness and security; in “U trimmed valves, the’ rings are also seal brazed’ or seal welded. many” refine- The “xR” and “U" e has a flat taper seat Type Dive When orders so specify, flanged valves can be furnished faced only Flange facings: The 150 and 300-pound flanged valves are regularly furnished with an American Standard U-inch raised face on the end flanges; the 490, 00, 960, 1500, and 2500-pound flanged valves regularly have a 34-inch male face (large male) When so ordered, valves can be furnished with other types of facings, such as ring joint, female, tongue, Broove, ete Finish of flange faces: The M%sinch raised faces of the 150 and 300-pound valves and the 14-inch male faces of the 40c-pound and higher pressure class valves are regularly furnished with a serrated finish, A smooth finish can be furnished on the raised or male faces, when specified, American Standard: In design and materials, Crane Cast Steel Globe and Angle Valves exceed the fequirements of Standards issued by the American Standards Association, ‘The butt-welding valve ends and the dimensions and drilling of end flanges on flanged valves conform to the American Steel Flange Standard, B16.5-1957, for their respective pressure class, Flanged and butt-welding valves conform to the American Standard for Face-to-Face and End-to- End Dimensions of Ferrous Flanged and Weldir3 End Valves, Bi6,10-1957, for their respective pris- sure class. This Standard does not include 3}-inch steel valves, Figure 1-14. Cast steel globe and angle valves. Reprinted courtesy of Crane Co.General Piping 21 Dimensions, in Inches All dimensions shown below apply to valves without gears di: mensions "HH and "H’ apply also to valves wth gears For sites Feguerly fornahed with gears, see axtoriued ("I note ot right ‘Angle Valves Cisse Sie Globe Valier at | Flanged) BuncWelding 1 Se —]),Flanged or Valves | Flanges Bau-Welding Screwed | Buce-Weldingt en 2) 8 m8 Rm) 8 [Rm] a ie] e mal oi ee ee | eee Heel a Fil ae peels rs 3% 10% | I | o Pound’ ye 19% | 11 | 19% | 8%) 17% | 10 Be ne 7% | 10 6 |e | mm | 6 | ame] ae svi | 726" | sot |e su [am |e a a if ak] | RET DS eas 3 2% 18 | 20%) | | ome | am | 30 [fered ereem ee [omelette Pound “4 TT | 2% | 14 5 | 15% | aoe 7% | 2614 | 6 © me wm fare | am | % | 20 | 8 shit | dow || a || | Seid | oe ‘ BM | Ie 38H pa Pe : Lome | ts | aif | mel Far | ase | im | | oe a | 38% 2314 | 38% | i 113% | 38% | 27 4 | 9 Ted aig |" | any | oe fam | a aie ia [ay 7 | 2 | te me) | We a 30% | 20 | Some | 10 om | a0 353s fon | 3s fw 16% | 28% | ingl sbute-welding valves aevenade only inthe 6 pound clase in sises 2" 34. Srand wrneh {When 2inch 200 ard theo ange al Ting joint lacing ste ta be belted to Orders must so speci beter is required Figure 1-15. Cast steel globe and angle valves. Reprinted courtesy of Crane Co. 1 with anelap lots, a groove of special patchy da "Ball-bearing yoke;gearing: Crane Cast Steel Globe and Angle Valves, in the larger sizes of the joc-pound and higher pressure classes, “are regularly furnished with a ball-bearing yoke and spur or bevel gears, as follows 300:Pound inch 400-Pound. band Ranch @00-Peund:©/..'3 and conch S00-Pound. "14 and eineh 1500-Poun Simeh Orders must state whether spur or bevel gearsare wanted: see page 149 for description, When specified, the above vaives can be furnished with- ut gears (plain bearing yoke) Note: All dimensions apply to valves without gears. Face to face (HH) and center to face (H) dimensions also apply to valves with gears; for addi- tional dimensions of geared valves; see page 49, Face to face: Thx .30 and 3oorpound flanged valves are regularly furnished with a Yeinch raised face: valves of the 4oo-pound and higher preesure clases havea 14 inch high large male face. The face to face (HH) and center to face (H) dimensions include this facing, Flanged and butt-welding valves conform to the Ameri. can Standard for Face-to-Face Dimensions of Ferrous Flanged and Welding End. Valves, Bi6.1c-1957. This Standard does not include steel valves in the 34-inch size.22 150-Pound Ne. 147 X. 150.Poume No! 189 X 300:Pome Nol 175 x, $00, Fer Oi, Oi “Steam oF Ne. 147¥4 X, 150-Found 4X, 300-Povnd N60v4 x, 400-Pomnd {$00-Fownd 900:Pownd 9915, 1800-Pound Figure 1-16. Cast steel swing check valves. Reprinted courtesy of Crane Co. Process Piping Design A tugged line . .. designed for severe service on oil, oil vopor, steam, and water li Grane Cast Steel Swing Check Valves. described on these facing pages, em: body the many refinements in design and materials necessary to withstand Materials: These valves, in all pres- sure classes, are regularly furnished with a body and cap made of Crane Carbon Steel conforming to. require- ments of ASTM A216, Grade WCB. ing materials are Exelloy to Exelioy (Class “"X"" trim), suitable for steam, water, oil, oil vapor, air, or gas Design: On flanged and butt-welding valves the full port area is maintained without pockets, from the inlet port to the valve seat, t0 avoid turbulence. On the outlet side of the valve seat, the body is of generous proportions, allow- ing full swing of the disc and minimiz- ing erosion and flow resistance. Body seat ring: A shoulder-type screwed-in body seat ring provides ‘maximum tightness and security. Cap joint: Valves of the 150 and 3yo0-pound pressure classes have a male and female type cap foint Valves of the 400, 100; 900, 1500, and 2 500-pound pressure classes have a ring. type cap joint. Crane Triplex Steel studs and stud Bolts assure an unusually strong and tight joint. The 1so-pound valves are equipped with studs’ all other valves have through stud bolts, Flange facings: The 150 and 300- pound flanged valves are regularly fur- riished with an American Standard ig Inch raised face on the end flanges. The 409, 600, 990, 1500, and. 2500- pound flanged valves are regularly fur- nished witha Yanch male fce (ange rom Section of Com Steet Swing Check Vale Teoh fot th ‘When so ordered, flanged valves can be furnished with other types of facings such as ring joint, female, tongue. groove, ete. Finish of flange faces: The }y-inch raised faces and the }4-inch male faces are regularly furnished with a serrated finish ‘A smooth finish can be furnished on raised or male faces, when specified. Standards: In design and materials, Crane Cast Steel Swing Check Valves exceed the requirements of Standards issued by the American Standards Association and the American Petro- eum Institute. The end flanges on flanged valves as well as the dimensions of butt-welding. valve ends conform to the American Steel Standard, Br6.5-1957, for their respective pressure class. Flanged and butt-welding valves of all classes, in sizes 12-inch and smaller, conform to the American Standard for Face-to-Face and End-to-End Dimen- sions of Ferrous Flanged and Welding End Valves, Bi6.1¢-1957, fo, thet respective pressure class. This Stand- ard does not include 34-inch steel valves. Flanged and butt-welding valves of all classes conform also to the API Stand- ard for Pipe Line Valves, No, 6-D, Ninth Ed ion, April, “1960, Thi Standard does not include 2 334 or 5- eeDrilling: Flanged valves are regularly furnished ‘with end anges faced, drilled and spot faced (FD & SF): they are drilled to the corresponding pressure class of the American Standard: they can be furnished faced only, when specified Face to face: Face to face dimensions (M) of flanged valves include the lynch raised face on the 150 and 300-pound pressure classes and the 4 male face on the 4c0-pound and higher pressure classes Butt-welding valves: Unless otherwise ordered, 150 and 300- pound butt-welding valves are bored to match the inside diam- eter of standard pipe (heaviest weight on the 8, 10, and 12-inch sizes). For all other pressure classes, orders must specify the diameter of the bore (1.D. of pipe) Smaller size 400 and 900- pound valves: For smaller size 40o-pound. valves, use the 600- pound valves. For smaller size co-pound vaives, use the 1 500- pound valves, 2500-pound valves: Prices, ‘weights, and dimensions of 2500- pound valves are furnished on request. For sizes and general description General Piping _ Weights and Dimensions — on Request 23 || Pounds, Each Dimensions, in Inches Screwed'Flonged) Burt- | Screwed er Valves ide [os |e P z wus =) s [om | 4 | 5 | 30 8% | 5% a | so | es | 50 mm | 6 aie rr 10%) 6% 4°] 6 | 00 | to fim | 7 | am | iso | 5 j wo} no a | 8 Pound|_¢ || | _ 200 | 160 uw |is ey 350) 360 jam | 0m 0 ty wy | 124 2 7 | mmm | 19% ju | | 1200 I 35° | on | 6 | 1450 I [39 | request _ 2 a | me] 7) | | 10m | So | ie | sx" | so | no | wo | ae | oe | int | oy 4 180] 130 13% Pouna | § | 30% we el 14 * 4 0 15 2 1634 ie 10 5 2 so | 6 124 Pound) 5 | 1% wo | y b ™% | 1% | 2 ™ 2 0 | Pound 5 «| * 0 2 T3 oo | 4 Pound | 6 cease ene ra 2 ™% us | 170 16% 1500 |_ 3 | wo [ato dae Pound | 4 7 ] 630 ] 390 u% | 13% 5 950 | 480 20% | sy 6 1360, 780 7% | 15% 8 nioo_| 1320 ay | my ich Cranclap Joints: When 3.inch 300 and 600:pound flanged valves ‘with ring joint facing are to be bolted to Cranelap joints, orders masta spells ‘A groove’ special pitch diameter is required Figure 1-17. Cast steel swing check valves, Reprinted courtesy of Crane Co.24 Process Piping D 1. Avoid the use of the cross, Cost and deliv- ery are undesirable. 2. Use eccentric reducers only where absolute- ly necessary. They cost almost twice as much as concentric reducers. 3. Reducing elbows are a cost saving (and are generally available) for sizes 8” and below for the large end in carbon steel materials. Avoid their use in alloy materials. 4. Avoid the use of the 90° elbow with long, tangent on one end. 5. The short-radius elbow causes additional pressure drop in a piping system. Use it only where close connections are needed. 6. Avoid the shaped nipples. Stub the pipe di- rectly into the header, Figure 1-7 shows how flanges are joined with pipe. Figure 1-8 describes the seven basic pressure classes, Figure 1-9 gives their allowable working pressures and Figure 1-10 supplies flange dimen- sional data. Figure 1-11 gives dimensions for ring joint facing and ring numbers. Valves The three basic valve types are gate, globe and check. Figure 1-12 describes gate valves. Note that the stem rises up, raising the disc into the bonnet and offering relatively smooth fluid flow through the valve body. Flow can enter either end of the gate body. Figure 1-13 gives dimensions for gate valves. When drawing valves always show the stem in the open position, dimension D. The handwheel is lo- cated about one pipe size below the top of stem. Always show the handwheel diameter, dimension E, to scale. Gate valve handwheels should not be oriented below the horizontal. It is preferable that they be vertical, however horizontal installation will keep the bonnet cavity relatively free of loose debris. It can easily be seen that if the bonnet cav- ity is below the flowing fluid, a trap is created for collection of debris, condensate, etc. Figure 1-14 describes the globe valve. The slobe body is designed for throttling. Flow must enter the valve and flow up, against the seat, and change direction again to the outlet end. This tur- bulent flow causes pressure drop and pressure drop is money in a piping system. The globe body pat- tern is also more expensive to make than the gate pattern, Consequently, globe body valves should be specified only where throttling is required and must be used often for throttling. It is the author's opinion that specifying globe valves for control valve by-passes is too costly for nine out of ten installations. Some people will say that the valve is for throttling so a globe body is needed. However, this valve is closed almost all the time and a gate valve would be able to handle the necessary throttling. would be cheaper, and, be- cause of the body design, a gate valve could be used which is one size smaller than the required slobe valve. Figure I-15 gives dimensions for globe and angle valves. On a globe valve, the handwheel is fixed to the stem and as the valve is opened the handwheel rises with the stem. When drawing the globe valve, always show the handwheel in the open position, dimension K, and show the hand- wheel diameter, dimension L, to scale. The angle valve is quite expensive and should be avoided. Globe valves larger than 6” are seldom justified. Figure 1-16 depicts cast steel swing check valves. The check valve is designed to permit flow in only one direction, In Figure 1-16 the flow en- ters the valve on the left side and the pressure raises the disc, allowing flow through the valve. Velocity of the fluid keeps the disc raised up in the cavity. As flow subsides or stops, the disc spring forces the disc down on the seat, preventing flow from reversing, ‘The swing check valve is the most commonly specified type of check valve. It is very efficient for constant flowing fluids. It should never be used for pulsating flow such as reciprocating pump or com- pressor installations. For pulsating flow, the piston or ball type check valve, spring loaded, should be specified. The swing check valve should not be installed with flow in the down position. The weight of the fluid upstream of the disc would tend to open the disc when the line pressure was less upstream, thereby permitting the flow to reverse, destroying the “check” feature of the valve. Check valves should be installed horizontally or with the flow going up. Piston checks are generally for hori-ontal installation only. Figure 1-17 gives dimensional data for cast steel swing check valves. einisconatiote taint orcncaie remeronul 12 25 Chapter 1 Review Test Define “ferrous” metal, Name one “non-ferrous” metal, — Name {four pipe (minufectutine, sie thiog, eee eee ee ee tees es EEE ETE Define ANSI What is meant by “joint efficiency?” What is meant by “mill tolerance?” . The mill tolerance for plate is The mill tolerance for seamless pipe is Random length pipe is + feet long, Supply the following outsdie diameters for IPS pipe Pipe Size op 6 10” 12” 16" fom a The OD of a 6” tube is Define the difference between “minimum” and “nominal” wall 1B. 14. Why is socketwelding preferred over screwed systems? An eccentric reducer costs almost___the cost of a concentric reducer, What type of valve shall be specified for control valve by-passes?_-2 Process Terms To understand the complete piping problem, the piping designer must realize certain process bas- ics. When handling utilities, the designer knows that steam cools and forms condensate which must be drawn off. This is accomplished with a “steam trap” installed at selected low points in the steam system, But his education must also include how to handle “two-phase flow,” “equilibrium liquids,” “hot vapor by-passes” and other special conditions. The Hydrocarbon Hydrocarbon is the term applied to most proc- ess fluid designations. A hydrocarbon is a mixture of the atoms hydrogen and carbon. How they are mixed and the quantities mixed are very impor- tant. Whether the hydrocarbon is in a liquid or vapor state must be known by the designer. Crude oil is a hydrocarbon which may be ” or “sour,” depending on its percent of “mercaptans,” a sulfur-bearing compound. A sweet stream is one with véry low or no sulfur content. while the sour stream ranks high in mercaptans. Sour streams must be sweetened by removing the mercaptans or the piping and equipment will be subject to corrosion by contact with the sulfur. ‘These mercaptans are separated out and sent to a 26 unit for disposal. One type of disposal unit is the Merox unit, shortened from mercaptan oxidation, licensed by UOP, Universal Oil Products. Crude oil also contains salt, which must be re- moved, This is accomplished by running the crude through a desalter, usually located in the crude unit of a refinery. Hydrocarbon Structures Methane is the lightest hydrocarbon, having one atom of carbon and four of hydrogen. This is stated CHy. The next lightest hydrocarbon is eth- ane which contains two atoms of carbon. Table 2-1 lists the lightest 20 hydrocarbons by weight. Hydrocarbons consist of only two elements, but the number of the hydrogen and carbon atoms and their arrangement in the molecule cause the wide variety of products we know. The arrange- ment generally is divided into two classes, the straight chain (aliphatic) and the ring (napthenic and aromatic). ‘Atoms combine to form a chemical molecule and each carbon atom holds or can contain four hydrogen atoms or their equivalent. When this hap- pens the carbon atom is said to be saturated. The force holding the atoms together is called the bond and is indicated by a small straight line. i i iProcess Terms 27 Table 241 Nomenclature of Hydrocarbons No. of Paraffin No. of Paraffin C Atoms Name C Atoms Name 1 Methane 11 Undecane 2 Ethane 12 Duodecane 3 Propane 13 Tridecane 4 Butane 14 Tetradecane 5 Pentane 15 Pentradecane 6 Hexane 16 Hexadecane 7 Heptane 17 Heptadecane 8 Octane 18 Octadecane 9 Nonane 19 Nonadecane 10 Decane 20 Eicosane Figure 2-1 shows the chemical composition of some hydrocarbons and how these chains are built ‘These are the straight chain series of paraffins. Of the 20 hydrocarbons listed in Table 2-1, the first four are normally gases and have a very low boiling point. The next 13 are liquids and the last three are solids. As a CH, is added, the hydrocar- bon is heavier and the boiling point and melting point rise Fractionation Fractionation is the most widely used opera- tion in process plants today and has been for hun- dreds of years. Crude oil is sent to the crude tower for fractionation as its first processing step. Any process unit will have several fractionation (some- times referred to as distillation) towers. Fractionation is the separation of lighter from heavier fluid components, which occurs while these fluids are in contact with each other and are in equilibrium. Equilibrium liquid is liquid that is at it’s boiling point due to pressure and temperature. Assume that two pure separate liquids are placed in a container. One liquid, say pentane, is lighter than the other, say heptane (refer to Table 2-1). By application of an exact amount of heat, the lighter fluid, pentane, can be vaporized while the heavier fluid remains a liquid. Then the two fluids are separated into two containers; one fluid is a liquid and one a vapor. As the vapor cools it returns to its liquid state and is pure pentane. This is simple fractionation. 4 CARBON ATOM HYDROGEN (4 BONDS) ATOM (1 BOND) H I H—C—H | H METHANE STRUCTURE (CH) HOH HOH OH i | ott H—C—C—H H—C—C—C—H I | | ot HOH HOH OH ETHANE PROPANE STRUCTURE STRUCTURE (C,H6) (CaHy) ‘This structure can continue for the complete hydrocarbon series. Note that adding one atom of carbon adds two hy: drogen. Figure 2-1. Composition of the hydrocarbon molecules. Multiple fractionation occurs in a fractionating tower. Each tray has liquid c! wilferent weight and temperature. As the hotter vapors rise up the tower they make physical contact with the cooler liquid on each tray. As the vapor cools, the heavier hydrocarbons drop out in liquid form and become part of the tray's liquid. Conversely, as the hotter vapors heat the tray liquid, some of the lighter hydrocarbons vaporize and join the vapor on its upward journey. As a result, fractionation is occur- ring on every tray in a tower. Also, each tray con- tains liquid that is in equilibrium, liquid that is at its boiling point. > As liquid floods the uppermost tray, meeting the warmer vapors, fractionation occurs. As the liq- uid runs down the tower, the lighter hydrocarbons28 Process Piping Design Figure 2:2. Incorrect equilibrium piping. are fractionated out, leaving a heavier liquid. Each tray down, then, contains a heavier liquid. The heavier the liquid, the hotter the temperature must, be to vaporize hydrocarbons. Hot vapors from a reboiler enter the tower's vapor space below the bottom tray, making con- tact with the heavy hydrocarbons on the bottom tray. As the vapors rise, a calculated temperature drop occurs at each tray, maintaining just enough temperature to vaporize lighter hydrocarbons and dropping the vapor temperature enough so that the heavier hydrocarbons will condense out. Piping Equilibrium Liquids Equilibrium liquids require the piping de- signer’s special attention. By definition, the liquid, at its pressure and temperature, is at its boiling point. Should the piper induce a very small amount of pressure drop in the piping system, the equilibri- um liquid will start flashing, resulting in two-phase flow, increased line velocity and a fluid that is dif ficult to control and impossible to measure. In some instances flashing does no harm, but the piping designer must first recognize what liq uids are in equilibrium, and second, when flashing can be tolerated. The mein streams that contain equilibrium liq- uids are any tray draw-off, tower bottoms, two- phase flow and reboiler liquid draw-offs. The big- gest piping pr blem occurs at reboiler liquid draw- offs Figure 2-2 shows incorrect piping of reboiler liquid draw-off. The piping designer has the prob-~— Process Terms 29 Figure 2-3. Correct equilibrium piping. Jem of routing the reboiler liquid from the area behind the weir, through a pair of orifice flanges (meter run), through a level control valve and into the main pipeway or rack. Liquid is drawn off at nozzle A, runs horizontally, and rises at B. Because the liquid must push against the head of liquid in riser B, pressure drop is induced in the system and flashing will start. The meter run, C, cannot prop- erly measure two-phase flow. The control valve, D, cannot control properly. If this installation were fabricated and installed, it would have to be dis- mantled and rebuilt in the field, a costly mistake. Figure 2-3 is one correct method of piping equilibrium liquid. Liquid is drawn off through nozzle A, stays horizontal through meter run B and the control valve, then rises vertically at C. Now, flashing occurs after thc measuring and con- trol functions and if excessive flashing occurs, the line size can be increased to keep the velocity low, By keeping both the meter run and the control valve below the liquid level in the reboiler, flashing is prevented in this run, This reboiler liquid is often a product going to storage. It usually must be cooled before going to a product tank. Cooling will drop this liquid below its equilibrium point and condense any flashed va- pors. Then it is preferable to locate the meter run and the control valve downstream of the cooler. The basic rule for piping equilibrium or any liquid subject to flashing is to keep pressure drop to a minimum and have no vertical risers before measuring or control devices.30 Process Piping Design ony pPY EXCHANGER A EXCHANGER “B” IMPROPER TWO-PHASE PIPING EXCHANGER’A’ EXCHANGER "BY PROPER TWO-PHASE PIPING Figure 2-4. Proper and improper two-phase piping.Process Terms 31 FIRED 1 HEATER — Figure 25. Piping at fired heaters. ‘Two-Phase Flow Next to adequate, flexibility, two-phase flow causes piping designers the most problems. Two- phase flow occurs when both liquid and vapor are in the same pipe, flowing together. Since the pipe’s friction reacts more on the liquid portion, the va- pors tend to flow at a greater velocity. The real problem occurs when two-phase flow must be di- vided equally into separate piping systems. Figure 2-4 shows improper and proper two- phase piping at exchanger inlets. In the improper illustration, the major portion of the flow would be routed to exchanger B. This would cause ex- changer A to have less pressure drop and exchanger B to have more when both exchangers were de- signed for the same pressure drop, as well as for the same heat transfer duty. Since A has less pressure drop and the liquid’s velocity will direct it to B, another problem is evident. The vapor of the two- phase flow will take the path of least resistance and most of it will go to exchanger A. Now exchanger A is getting the vapor and B is getting the liquid. But the heat transfer rate of both exchangers is designed for equal flow of liquid and vapor. So they will not transfer heat as designed. And be- ‘cause these exchangers will not perform as de- signed, the process unit will not perform and must bbe shut ¢'>wn for correction. And this is because a piping designer did not recognize he was piping two-phase flow, or if he knew he was not know- ledgeabte enough to design the piping.32 Process Piping Design OVERHEAD VAPOR LINE FRACTIONATING TOWER, Pont ‘A -7 HOT VAPOR BY-PASS AIR Cooler, OVERHEAD ACCUMULATOR, Figure 2:6. Hot vapor by-pass In the proper illustration, the two-phase flow enters the horizontal pipe midway between the two exchangers. The pressure drop is the same to either one so there‘is no path of least resistance and the flow of both liquid and vapor will be equal to both exchangers. Figure 2-5 is a flow sketch of piping at a four- pass fired heater. This is a very common piping installation where the heater inlet is all liquid flow and the outlet is two-phase flow. And in nine out of ten cases this installation is completely unneces- sary and excessively expensive! To analyze this statement, the liquid heater feed, item 1, is divided into four streams to match the four passes of heater tubes. Each stream has a slobe valve, item 2, for throttling and a flow indi- cator (orifice or meter run), item 3. Each heater pass outlet has a temperature indicator. To operate the heater, flow is regulated with the globe valves to ensure that each pass has the same flow, while the temperature indicator shows the desired outlet temperature. The piping is correct to this point. The incorrect design occurs downstream of the TI located in each pass outlet. Someone has coined the magic term two-phase flow and has decided that this means symmetrical piping. And symmes: cal piping means money and piping problems. This can be doubly expensive if the heater outlet is al- Joy material. Symmetrical piping is necessary for two-phase flow if there is no method of control, and distribu- tion must be made. But in Figure 2-5 distribution is made while the fluid is all liquid, controlled by the globe valve and metered by the flow indicator to insure that streams A, B, C and D are all equal flow. If the flow is equal going into the heater it must be equal coming out. Only in cases of very low pressure, such as a crude charge heater service, should symmetrical piping be considered. In higher pressure installations the outlets should be com-Process Terms 33 POINT "A, 125’ OF WATER HEAD QUALS 54 PSIG, & WATER TOWER DESIGN PRESSURE 50* Figure 2.7. Impact of water head. bined in the most economical manner and routed on its way, The outlet pass differential pressure @rop is so minor that it is of no actual conse- quence, Any time a competent piping designer sees symmetrical piping called for he should seriously question its need, especially if it is on a fired heater outlet. Hot Vapor By-Pass Figure 2-6 is a hot vapor by-pass schematic. ‘The tower overhead vapor line is routed to an air cooler (fin-fan). This could be a shell and tube ex- changer. The condensed. vapor is then directed to the overhead accumulator. To maintain pressure on the accumulator, a hot vapor by-pass is installed. Hot overhead vapor is by-passed around the cooler and is routed to the pressure control valve, which allows pressure to enter the accumulator as re- quired. Hot vapor by-passes should never be pocketed. The pressure control valve should be installed above the top of the accumulator and the by-pass piping should continuously drain from point A to point B. As this by-passed vapor cools, due to rainfall on the line or cool air cooling the line, condensate34 Process Piping Design Table 22 Water Static Head Pressures Feet of Pressure Feet of Pressure Water psig Water psig 1 043 26 11.26 2 0.86 27 1169 3 130 28 1212 4 173 29 1285 5 216 30 1299 6 259 31 13.42 7 3.03 32 1386 8 3.46 33 1429 9 3.89 34 14.72 10 433 35 15.16 u 4.76 36 15.59 2 $20 37 16.02 B 5.63 38 16.45 14 6.06 39 16.89 15 649) 40 17.32 16 693 4 17.75 a 736 2 18:19 18 179 B 18.62 19 8.22 44 19.05 20 8.66 45 19.49 21 9.09 46 19.92 2 9.83 47 2035 2B 9.96 48 20.79 24 1039 49 21.22 25 10.82 50 21.65 is formed. With the small amount of differential pressure between points A and B, a pocket of liq- uid head might not be overcome and the hot vapor by-pass would not work. There is generally less than 10 psig differential between these two points. The pressure control valve is usually specified as a butterfly type to keep pressure drop to a minimum but this will consume 2-3 psig. Line loss due to friction may consume another 2-3 psig. This only leaves about 4 psig and that would not overcome much liquid head. Static Head Hydraulic: ¥s the term used for the action of liquids in motion or at rest. Unconfined liquids seek the lowest possible level and a horizontal posi- tion. Feet of Pressure Feetof Pressure Water psig Water psig 31 22.09 16 32.92 52 22.52 1 33.35 33 22.95 B 33.18 54 23.39 9 34.21 55 23.82 80 34.65 56 24.26 81 35.08 37 24.69 82 35.52 58 25.12 83 35.95 59 25.55 84 36.39 60 25.99 85 36.82 6 26.42 86 37.28 62 26.85 87 37.68 63 27.29 88 38.12 64 22 89 38.55 65 28.15 90 38.98 66 28.58 on 39.42 67 29.02 92 39.85 68 29.45 93 40.28 69 29.88 94 40.72 70 3032 95 41s 1 30.75 96 41.58 n 31.18 7 42.01 B 31.62 98 42.45 14 32.05 99 42.88 15 3248 100 4331 Liquids at rest cause a pressure equal in all di- rections and perpendicular to any surfaces in con- tact with the liquid. This pressure is caused by th: weight of the liquid above the point in question plus the pressure at the top level of the liquid. The liquid height is called static head, pressure head or quite often just head. To calculate the head pressure one must multi- ply the height of liquid by the specific gravity and divide by 2.309. Specific gravity is the item’s weight compared to water, which has the assigned specific gravity of one. Consequently, a column of water 2.309" high would exert 1 psig of pressure at its base. This would be called 1 pound of head. To this head pressure one must add the pressure above the liq- uid to get the actual pressure at the base of the liquid.Process Terms 35 Table 2-3 ‘Saturated Steam Data Steam Temp Steam = Temp Steam Temp sig we cy °F sig °F 147 Tae 53 290 414 15 145356 300417 20 1502 ase 320424 25 iss) 6 340429 30 160364 360434 35 165366 380440 40 70) a 36 400445 45 175371 420 449 50 1e0E 373 440454 55 185375 460459 60 190 378 480463 65 195380 500 467 70 200382 550477 18 205384 600486 80 210386 650 49s 85 AG 85 700 503 90 220 390 750 SU 95 as 292) 800518 100 230394 850525 105 Zas | 356) 900 $32 110 240397 950 538 ns 245 399 1000545 120 250 401 125 260 404 130 270408 135 28000 411 This becomes very important when calculating the hydrostatic pressure of vessels and piping sys tems. For instance, in Figure 2-7 there is a tower system designed for SO psig. This requires a hydro- static test pressure of 75 psig. This test pressure must be measured at the highest point in the sys- tem, point A. To attain this pressure at point A the field brings in a hydrotest pump and fills the system full, of water. The piping designer knows this pump is located at grade. He must calculate the height from the pump’s pressure gage to point A, divide by 2.309 and add this to the required test pressure. In this case 54 psig must be added to 75 psig, totaling, 129 psig, which is the pressure that must be ob- tained at the pressure gage to satisfy the 75 psig hydrostatic conditions. The vessel designer must also consider the stat- ic water head when calculating the tower head and shell thickness. This added weight is considered in the design of the support for the tower. It becomes very critical when vessels are located high in a steel or concrete structure. In most organizations it is the piping designer's responsibility to furnish the field hydrostatic test flow diagrams, showing the required hydrotest pressures for each line in the system. It is impera- tive that static head calculations be made for each system and that proper test pressures are assigned, Table 2-2 gives the pressures caused by water head from 1' to 100’. For greater heights the fig- ures shown may be added, i.e., for 125” add the figure for 100' and 25". ‘Steam Data Steam is generated by heating water to such a temperature that it vaporizes and this vapor is steam. Steam is invisible, The boiling point of water is 212°F, or 100°C, at sea level atmospheric pressure, 14.7 psig. Boiling point is the temperature at which a liquid boils, changing into a vapor with the application of heat. ‘The pressure applied to a liquid such as water greatly changes its boiling point. Water will boil at 32°F with a pressure of 0.0885 psig. Place water under 1000 psig pressure and the temperature must. reach 544°F to make steam. Saturated steam is steam which is at its mini- mum temperature for its pressure. No additional heat (called superheat) has been added. Saturated steam data is given in Tuble 2-3. Superheated steam is saturated steam to which additional “degrees of superheat” have been added. Its condition is usually expressed by the degrees of superheat above the saturation point and by its Pressure. Superheated steam has gas characteristics; when compressed the pressure increases, when heated its volume increases at constant pressure and its pressure rises if the volume remains con- stant. Adding superheat to steam and maintaining. the same pressure then gives more steam for each pound of water. One cubic foot of water at 14.7 psig and 212°F becomes 1606 cubic feet of saturated steam. One pound of this steam will occupy 26.8 cubic feet. Water weighs 62.4 pounds per cubic foot.36 9. Chapter 2 Review Test Define “mercaptan.” What is a “sweet” stream? What is the lightest hydrocarbon? what (ofa (esturated hydrocarbon? Define “fractionation.” Define “equilibrium liquid.” Whatlis (wo phase (iow) = ee Define “flashing.” What is the purpose of a reboiler? 10, What is symmetrical piping? u Hot vapor by-passes shall never be —______. Deicide What is “toad? Define “specific gravity.” Superheated steam is usually expressed by ———————______ meee ge3 Plant Arrangement and Storage Tanks This chapter will deal with general plant ar- rangement and will probably be the most contro- versial chapter in the book. For each “grass roots” plant being designed a different approach can be justified. There is not enough space in this book to explore all possibilities and their justifications. One basic conception is presented with some alter nate methods of plant layout. Site Data Assuming the plot area is ample, the first thing a layout designer must know is the topography. If the site is relatively flat, many problems will not be encountered. But for a flat site, the most impor- tant item to know is the soil condition. Some flat sites have been filled by some means over the years. How good is the load-bearing characteristic? Generally, the natural soil will have good allow- ables while the filled areas may not, requiring all foundations with heavy loads to be pile supported. The plant is basically divided into two areas, offsite and onsite. The offsite portion consists of storage tanks, loading or unloading facilities, cool- ing tower, steam generation, electrical power gener- ation when not purchased, electrical transformer substation(s), flare(s), waste disposal facilities, buildings, plant roads and other items as needed. 37 The onsite part of a plant is limited to the process units. This is the area of heaviest concentration of loads and should be located in the area of best soil. The offsite will need from 75-80% of the total plot area and, depending on storage capacities, will be about the same percentage of the total plant cost. Hilly Terrain When the plant is to be built on a hilly site, the soil is usually pretty good and is not a major con- sideration for locating onsite vs. offsite, The author advocates knocking off the top of the hill to con- struct a relatively flat site for the process units, with the offsites | ated below. This has several advantages which outweigh the disadvantages. First, and most important, it offers maximum safety to the greatest number of personnel working in the process units and offices. The higher eleva- tion produces head for natural flow into product or rerun storage tanks. By locating the loading facilities still lower, the designer can make the loading pumps smaller if not eliminate them entirely. The entire sewer system is greatly simplified with waste treatment located at the lowest possible elevation, eliminating costly waste lift pumps. Soil removed from the hilltop is utilized as tank dike material or for leveling sublevels.38 Process Piping Design L Zz io FUTURE, Wi PROCESS PROCESS UNITS [Fg ONITS, 22 Ew 20 FUTURE RERUN RERUN STORAGE CRUDE STORAGE FUTURE. PRODUCT PRopucT STORAGE. TRUCK, RAIL | PRODUCT WASTE FUTURE $ PIPELINE |BLENDING| [TREATING CRUDE SALES Figure 3+, Refinery block plot planPlant Arrangement, Storage Tanks Block Plot Plan Alter the site topography has been established and the preliminary soil report has been studied, the plot designer is ready to make a block plot plan. When the plant site is lat and soil conditions are good, the designer needs to know the quantity and size of the tanks, location of access highways, railroads, barge or ship docks, prevailing wind di- rection and the area’s climatic conditions. If there are incoming utilties such as purchased electrical power or potable water, these locations may effect the plot layout. Figure 3-1 is a block plot plan for a refinery To develop this, the designer must 1. Establish plot limits Define process units and area required Estimate storage dike areas Know and allow for plant expansion Locate waste treating at lowest elevation Locate process units on best soil Locate rerun storage near process units Locate truck, rail and pipe line sales near roads, railroads or existing pipe line tie-in point 9. Locate product blending near sales area 10. Locate product tanks near product blend- ing 11. Keep plant road system in mind 12. Locate utilities generation near process units Keep in mind the cooling tower and electri- cal substation location eI awn eE 13, These blocked areas are &timited and located ~ in relation to each other within the plot limits. When this is approved the designer must establish the actual space requirements for each block. The Process Block To determine the space required for the proc- ss units one must know what units are to be built, the general capacity of each unit and the flow be- tween units. This data can be obtained from the proces:.engineer. 39 Figure 3-2 is the block plot plan for the process area of Figure 3-1. The crude oil is pumped from the crude storage tanks to the crude unit so this process unit is to be located near the crude storage area, The interconnecting pipeway routes both process and utility lines to the different units. By establishing this blocked area, the designer is ready to set the sizes of each process unit, the unit pipe- way sizes, the interconnecting pipeway size and fir nally the required plot size for all the process units. Tentatively set are the junctions to the intercon- necting pipeway from crude storage, other storage and utilities generation. Storage Tanks To establish plot areas for storage tanks the designer must have a fairly good knowledge of tanks, how they are designed and when to use what type as well as operation and maintenance proce~ dures Tanks for storing liquids at atmospheric pres- sure are built in two basic styles, floating roof di sign where the roof floats on top of the liquid, rising and falling with the level, and the cone roof design where the roof is fixed. Cone Roof Design Figure 3-3 is a cone roof tank of 200” in diame- ter and 48° in shell height, storing 368,000 barrels. The size of large tanks is limited by the plate thick- ness of the bottom course, which should not ex- ceed 1%”, By using special high-strength steels, itis Possible to utilize very large tanks withos' #xceed- ing this maximum plate thickness. Soil conditions and cost of land are economic factors in the selection of tank dimensions. For very poor soil, tanks with low shell height but larger diameters usually are more economical than high shells and smaller diameters because the higher the shell, the greater the head pressure on the soil. If the pressure becomes greater than the soil allowable bearing pressure, pile-supported foundations will be necessary and this is very ex- pensive.Process Piping Design CRUDE UNIT UNIT PIPEWAY VACUUM UNIT ROAD REFORMING UNIT UNIT PIPEWAY HYDROCRACKING UNIT ROAD LIGHT ENDS RECOVERY INTER CONNECTING PIPEWAY UNIT PIPEWAY TREATING UNITS Figure 3.2. Process area block plot plan. (Rotated 90° counterclockwise)Plant Arrangement, Storage Tanks a Figure 3-3. Cone roof tank. Courtesy of Chicago Bridge and Iron Co, Piling is to be avoided but there are times when there is no choice, If land is very costly or just is, not available, it is justifiable to construct high shells and utilize the expensive piling, Figure 3-4 shows a “pancake” tank design, 200° in diameter but only 14° for the shell height, providing 78,000 barrels of storage on “marshy” soil unable to support conventional tank height without elaborate pile foundations. Large cone roof tanks usually have columns to support the roofs with a roof slope of 3%" to 1-0". Since these roofs are fixed, there is always a vapor space above the liquid. These tanks must be vented to the atmosphere and quite often the los: of this vapor is so extensive that it warrants specifying the more expensive floating roof tank design. Floating Roof Design For storing volatile liquids, floating roof stor age tanks have three distinct advantages. They re- duce evaporation loss, greatly increase safety from fire and minimize air pollution. Figure 3-5 shows how the floating roof (a) eliminates filling loss, (b) reduces breathing loss and (c) provides effective fire protection and lightning safety.42 Process Piping Design (@) te) Figure 3.5. Floating versus cone roof design. The floating roof, by minimizing vapor space, reduces breathing loss (b), and provides effective fire protection and lightning safety (c). It also corrosion. Courtesy of Chicago Bridge and ron Co.Plant Arrangement, Storage Tanks 43 Figure 3-6. Pontoon roof design tank. The pontoon roof has a compertmented annualar ring ef pontoons and a single deck. Courtesy of Chicago Bridge and Iron, Figure 3-6 depicts the pontoon roof design. This has a compartmented annular ring of pon- toons and a single - deck center. The most expen- sive design is the double-deck roof which has two complete decks with an insulating air space be- tween, which makes it the most efficient of all floating roofs for handling the more volatile liq- ids. Why do people specify the more expensive floating roof tank whew the cone roof is more eco nomical? In terms of economy only, consider an 80,000 barrel cone roof tank in average service. In normal operation it will lose 2700 barrels of gaso- line per year by evaporation. At 42 gallons per barrel that loss would be over 100,000 gallons a year, a very substantial loss. And over 90% of this loss is preventable with a floating roof design. Table 3-1 gives data on storage tanks designed of standard steel in accordance with API Standard 650 for welded tanks. Table 3-2 gives tank data for typical API Stand- ard 650 welded oil storage tanks for Appendix D and high - stress design (Appendix G), Tank Spacing The National Fire Protection Association has Published several volumes of recommended prac- tice concerning fire protection. Volume 1, Flam- mable Liquids, pertains to storing liquids and sup- plys guidelines for storage tank location, spacing and dike requirements. The following text and ta- bles comply with the NFPA recommendations. Liquids are divided into three basic classes: flammable liquids with flash points below 100°F, flammable liquids with flash points over 100°F but below 140°F and combustible liquids with flash points over 140°F but below 200°F. Table 3-3 de- fines these classes. Table 3-4 shows the further restrictions based fon the actual storage conditions. Tables 3-5 through 3-9 are used to set the actual tank spacing in feet, from property lines, public ways or impor- tant buildings. Shell to shell tank spacing is restricted by para- graph 2120 of the NFPA as follows:44 Process Piping Design Table 3-41 API Standard 650 Welded Oil Storage Tanks | sens be sere” i |e wane 18 Bo] ET SR us x | may i klk rai BB & & x “ ae ua we loe tw fw ayaa = apaae 8 BY] RL PRSine wa os en Deane Ba pron # BL RE] BY gE] * Saami a3 w]e le ls Beale Ba Ss | spate cy | | Bo] B | om | * | dame ea «|e |e ls hte EY B | Ee] ee]. aa ‘ea wz |u| mw |e 1 Deane = | & | # aeai Ey go) | | gy F Sank 49.0 ass | 203 | & % Tr hate #8 at | an | i Batt Ey a wee | ee m | az|m|e | s yeaa ia aie aa | | | ao] i) |B] RY] * | wo | aso aa | os av | w » |» | G2) #2 | HER) | P| ee | Hea e: | a2 | num | ae e | oe tow fw | ape s2 | 3] ays | at a] ¢ Pett eee ee | By) ge] & | x | BBR ge | 3 x a) ge] e x a) 8 & aH | P|] El] « na | ate ane “| Bm] s Po & | ¢ | £ fy « a | 8 ca a | g ] ¢ eo | we | gee | ae | ae | ae | a | | x 82) 82) Re) |) |e |e |e 3) 2 | Be | Bl] «|» yee | ag | tee ew) He | pols ies | 83 | ae ; |e | & ie mala | ee 3 Rik 3 B | E | 7 kf. $ 8 E ig 2 PG is a 388 BB |; eB] * 33h Ey 38 Ble 33 Source: Chicago Bridge and Iron Co. ‘Weight include stoieway, roof ond shell connection in root for vent and usual inlet and outlet connections in shell, Plot thicknesses shown ere for eight fost wide rings, but rng widths ond plate thicknestes may vary fo wit available tock, Standard tanks ore furnished with shell plotes conforming to the latest edon of ASTM Specification A283, grade C. eyPlant Arrangement, Storage Tanks 45 Table 3.2 ‘API Standard 650 Tanks for High Stress Desi For Appendix D and Appendix G Wig i Pounds fo 085 Product Spetie Groviy— copay |_T Binet a Foe woioe ct and Conte Rt froning in “Appendix D Design High Siro Design (App. G) fet | ovemeter | tigtt | ie Coven] wn a? No Coonan] Ta? = Allowance Corrosion Allowance Corrosion tseansreny | Atowance | geen’) | Sema a7 | coo | a0 278,200 788,400 = = S090 soo | 380 321/000, 334000 _ 7 gis | 1000 | feo a12200 i270 7 = 78330 | 1000 | 560 479.000 496,400 7 - oat Sye00 ot2200 = 7 vies00 | i200 | seo 899.200 mioa00 _ = 121600 | 140.0 | 48.0 300,200 814,800 - 7 153500 | 49 | seo 931/300 946,400 _ 7 7900 | 1600 | 3830 | ear'o00 | 1pstioo0 = 200500 | 1600 | 360 | 120%000 | 1,222,000 - - zi7s00 | 1800 | dao | oe000 | 1327909 = = asafz00 | 1800 | Seo | 1's20000 | 1'3a8'000 = = 268400 | 2000 | 48.0 | 1,599.00 | 1,617,000 = - araa00 | 3000 | seo | tesxooo | 1605908 _ - 325000 | 2200 | 480 | 142000 | t'sss000 | 1.763000 | 1.778000 379100 | 2200 | 560 | 2266000 | 2279000 | 2013000 | 2000,300 367000 | 2400 | 48-0 | Z30r000 | Z3rsc00 | 26a¢00 | 3937890 asiz00 | 2400 | 360 | Zeero00 | 270800 | 2588808 | 2,101,000 453500 | 2600 | 48.0 | 2691000 | 2705000 | 2428000 | 2432000 526000 | 280.0 | 480 | S4tz000 | Siacooo | 24980o | 3452000 529,500 | 260.0 | 56:0 | steno | seencrr | 27¢9%00 | 3662090 «04900 | 3000 | 49.0 - - 2204000 | 3214000 siso0o | geo | Se0 z _ 399.000, erase | 230 | Ge = = 3505,000 697,500 | 3200 | 400 e - 3634000 | 3,445,000 yoso00 | 3000 | S80 = = scence! | SeeNere’ rea | Soo | feo = = “Zosspoo | “thoxboo 7ev00 | 3430 | 490 7 - 4.163000 |} 4172000 | seonwet | stanties Source: Chicago Bridge and lren Co. 1) Maximum tonk size limited by 1¥%a" maximum plate thickness. 21 The deo of nk sas storing products wih specie gravity of 091 or Iss governed by the hydrortai test (provided mo corrosion allowance i specified) 3) Type of steel sup 5 with design metal temperature specified; Ether AST A283 Grade C; ASTM A131 Grade A, 8, oC; or ASTM A131 Grade C. Normelized In cold cimotes, the higher cost of Ihe quclity see! required may offset ‘ony anticipated sving from weight reduction when compared with on API Stondard 650 shell design” 4) For certain tank sizes, circumferential stiffening rings ore not mandatory by Aj 5) The high sre design uses high strength steels having @ minimum tensile strength of 70,000 psi, @ minimum yield of 50,000 psi, ond ian improved notch-toughness. The vse of high strength steels makes It possible to build larger tanks without exceeding 116" plate ‘highness. The weight of circumferential windgirders is included inthe Appendix G design (Bars of 100 mph wind, yendix D design but ore recommended by CBB,Class 1 Class 1A Class 1B Class 1C Class 11 Class It No Class No Class Condition 1 Condition 2 Condition 3 Condition 4 Flammable Liquid Flammable Liquid Flammable Liquid Flammable Liquid Flammable Liquid Combustible Liquid Unstable Liquid Process Piping Design Table 33 ‘Tank Liquids Classification Flash point below 100°F and vapor pressure not exceeding 40 psia at 100°F Flath point below 73°F, boiling point below 100°F Flash point below 73°F, boiling point 100°F or above Fash point 73°F or above but below 100°F Flash point below 140°F but at or above 100°F Flash point above 140°F but below 200°F Will polymerize, decompose, condense or become selfreactive under shock, temperature or pressure Liquids with boilover characteristics such as crude oil Table 34 Restrictions for Conditions of Storat Class I through III liquids stored below 2.5 psig or equipped with emergency venting which will not permit pressure to exceed 2.5 psig. Use ta- ble 355 Class I through III liquids stored above 2.5 psig ‘or equipped with emergency venting which will permit pressure to exceed 2.5 psig. Use Table 3-6. ‘Unstable liquids. Use Table 3-7. Liquids with boilover characteristics. Use Table 38. Three feet minimum distance between any two flammable or combustible liquid stor- age tanks, Minimum distance between adjacent tanks (all services except unstable liquids and crude in production areas), 1/6 the sum of their diameters; unless one tank is less than % the diameter of the other tank, spacing shall be 3 the diameter of the smaller tank. Crude Petroleum in production areas- minimum. spacing; capacity under 3000 barrels-3"; capacity over 3000 barrels— diameter of smaller tank. Unstable flammable or combustible liquid- ¥% the sum of tank diameters. Local authorities (fire protection, insur- ance, etc.) may require greater spacing for grouped tankage (3 or more rows or irregu- lar pattern) to allow access for fire fighting. 6. LPG Containers (Liquified Petroleum Gas) 6.1 20' minimum spacing to flammable or combustible liquid tank 6.2 When adjacent flammable or combus- tible liquid tanks are diked, LPG com tainers shall be a minimum of 10" out side centerline of dike. Suitable means shall be taken to prevent accumulation of flammable liquid under LPG tanks (dikes, curbs or grading is acceptable). Tank ¢ Regulations ‘The NFPA establishes minimum dike regula tions in Volume 1, paragraph 2170. Earthen dikes ~~ Lev acne| Plant Arrangement, Storage Tanks Table 35 Tank Spacing Table—Condition 1 47 ‘Type of Tank Protection Minimum Distance (Feet) from Property Line Which May Be Built On, Including the Opposite |_ Side of a Public Way ‘Minimum Distance (Feet) from Nearest Side of Any Public Way Floating roof Protection for exposures % times diameter of tank but need not exceed 90° 1/6 times, diameter of tank but need not exceed 30 No Protection Diameter of tank but need not exceed 175° 1/6 times diameter of tank but need not exceed 30° 44 times diameter of tank but need 1/6 times diameter of tank but need vestcat Approved foam or with inesting system | not exceed 90’ and not not exceed 30° and not weak | onthe tank ___|_less than 5" less than 5 roo! Protection for Diameter of tank but need not | 1/3 times diameter of tank but to exposurest exceed 175" need not exceed 60" shell ‘Twice diameter of tank but need | —1/3 times diameter or tank but seam No protection not exceed 350° need not exceed 60° Horizontal Approved inerting and system on the 4 times Table 39 but not 4 times Table 3.9 but not vertical, tank or approved | less than 5” less than S' with foam system on emergency relief vertical tanks venting to limit pressures 10 25 psig | Protection for exposurest Table 39 Table 3-9 No protection Twice Table 3.9 Table 39 ‘Protection for exposures shall mean fire protection for structures on property adjacent to tanks, When acceptable to the authority having jurisdiction, such structures located (1) within the jurisdiction of any public fire department or (2) within or adjacent to plants having private fire brigades shall be considered as having adequate protection for exposures. Table 3.6 ‘Tank Spacing Table—Condition 2 } Minimum Distance (Feet) from Type of Tank | Protection | Property Line Which May Be Built | Minimum Distance (Feet) On, Including the Opposite Side from Nearest Side of of a Public Way Any Public Way Protection | 1% times Table 3-9 but shall 1% times Table 3-9 but not for less than 25° less than 25” exposures Any type No protection | 3 times Table 3-9 but not 1% times Table 3.9 but fess than 50" not less than 25°48, Table 3:7 Tank Spacing Table—Condition 3 Type of Tank | Protection Minimum Distance (Feet) from | Minimum Distance (Feet) from | Property Line Which May Be | Nearest Side of Any Public | Built On, Including the Way | Opposite Side of a Public Way Tank protected with any Horizontal one ofthe following and Approved water spray vertical Approved inerting tanks with | Approved insulation and | Table 3-9 but not less than 25’ | Not less than 25° emergency | refrigeration relief | Approved barricade venting = permit Protection for 214 times, Table 3-9 but not less pressure not exposures than $0” ___|_ Not tess than 50” eee No Protection 5 times Table 39 but not less of 25 psig than 100" Not less than 100" Tank protected with any cone ofthe following Horizontal Approved water spray and Approved inerting Twice Table 39 but not less | Not less than 50" vertical Approved insulation and | than SO! | tanks refrigeration with Approved barricade | emergene ~ relist Protection ‘or exposures | 4 times Table 39 but not less | Not less than 100° venting than 100" 1 permit —— pressure No protection 8 times Table 39 but not less | Not less than 150" over 2.5 psig than 150" are usually specified by the designer; however, con- crete wall dikes are sometimes used where plot costs are high or where earth fill material is either expensive or just not available. Dike requirements are generally specified by the customer, local regu- latory bodies or, if neither of them have estab- lished specifications, the minimums noted below may be used 1, The area surrounding a tank or group of tanks shall be provided with either drainage or dikes to protect adjacent property and waterways (from a rupture and/or spill) un- Jess the jurisdictional authority has waived this requirement (which never happens). 2. Drainage system shall comply with the fol- lowing: 2.1.Slope not less than 1% away from the tank toward the drainage system. 2.2.Drainage system shall terminate in va- cant land or impounding basin having ‘minimum capacity of the largest tank served. 2.3.The terminating area and the route of the drainage system shall be so located that burning liquids in the system will not seriously expose tanks or adjacent property, 2.4. che drainage system, including drainage pumps, shall not discharge to adjoining property, natural water courses, public sewers or public drains unless no hazard is constituted or its design does not per- Seceiee RRR Re. HOH 0Plant Arrangement, Storage Tanks Table 38 ‘Tank Spacing Table—Condition 4 Minimum Distance (Feet) from Property Line Which May Be } Built On, Including the Opposite Side of a Public Way Minimum Distance (Feet) from Nearest Side of Any Public Way | Diameter of tank but need not exceed 175° 1/3 times diameter of tank but need not exceed 60° ‘Twice diameter of tank but need not exceed 350° 1/3 times diameter of tank but need not exceed 60° Diameter of tank but need not exceed 175" 1/3 times diameter of tank but need not exceed 60° ‘Twice diameter of tank but | need not exceed 350° 2/3 times diameter of tank but need not exceed 120° ‘Type of Tank | Protection Protection for Floating exposures roof No protection Approved foam or inerting system Fixed Protection roof for exposures No protection 4 times diameter of tank but need not exceed 350° 2/3 times diameter of tank but need not exceed 120" Table 39 ‘Tank Spacing Table Reference from Tablet 35 through 28 Capacity Tank (Gallons) Minimum Distance (Feet) from Property Line Which May Be Built On, Including the Opposite Side of a Public Way Minimum Distance (Feet) from Nearest Side of Any Public Way 275 or less 276 t0 750 751 to 12,000 12,001 to 30,000 30,001 to 50,000 50,001 to 100,000 100,001 to $00,000 500,001 to 1,000,000 1,000,001 to 2,000,000 2,000,001 to 3,000,000 3,000,001 or more s 10 15 20 30 50 80 100 135 165 17550 Process Piping Design Figure 3-7. Typical dike design. mit flammable or combustible liquids to be released. (Note: this implies the requirement of separator facilities in all but the most remote locations) 3. Diked areas shall comply with the fol- lowing when protection of adjoining prop- erty is accomplished by retaining the liquid around the tank with dikes: 3.1,For other than crude petroleum tanks with fixed roofs, the minimum capacity of the diked area shall be not less than can be released from the largest full tank, (Diked area capacity not to in- clude capacity of enclosed tanks {other than the largest tank] below height of the dike.) For crude petroleum tank or group of tanks with fixed roofs, minimum diked area capacity shall be the full capacity of the tank or tanks enclosed. (Diked area capacity not to include capacity of enclosed tanks below the height of the dike.) 3.3 Dike construction requirements: 3.3.1. Maximum average height of 6° above interior grade. 3.3.2, Earthen walls over 3° high shall have 2° wide flat section at the top. 3.3.3. Slope consistent with te angle of Tepose of the material 3.3.4, Drains from diked areas to be lo- cated at most remote location from tank, controlled to prevent flamma- ble or combustible materials from entering adjacent property, natural waterways or public drains and sew- ers. 3.4 Diked areas containing two or more tanks shall be subdivided by drainage channels or curbs to prevent spills from endangering adjacent tanks within the diked area as follows: 3.4.1. Normally stable liquids in: a. Cone roof tank with weak roof to shell seam, b. Floating roof tanks ¢. Crude petroleum in production areas-any type tanks: 1 subdivision for each tank in excess of 10,000 barrel ca- pacity 1 subdivision for each group of tanks (no tank exceeding 10,000 barrel) having aggre- gate capacity not exceeding 15,000 barrel capacity 3.4.2. Normally stable liquid in tanks not covered in 3.4.1 1 subdivision for each tank in ex- cess of 100,000 gallons capacity (2500 barrels) 1 subdivision for each group of tanks (no tank exceeding 100,000 gallons) having aggre- gate capacity not exceeding 150,000 gallons (3570 barrels)Plant Arrangement, Storage Tanks 51 Figure 38, Truck access into diked area, 3.4.3. Unstable liquid-any type tank-l subdivision each tank (exception- tanks protected by water spray system per NFPA No. 15 require no additional subdivision) (Subdivision by drainage channels is preferred), Curbs shall be not less than 18” high. Figure 3-7 shows a typical earthern dike design. Item A should be 2-0” minimum with 3'-0” pre- ferred for tall dikes. Item B is the freeboard and should be 1'-0" minimum for crude oil for boilover wave, Tanks holding other commodities require no freeboard. C is a 1'-0” layer of clay that prevents penetration of liquid through the bank. Top soil and grass should be applied above this clay blanket to prevent erosion. The slope of the dike wall should match the angle of repose for the area’s soil. A slope of 14 to 1 is depicted as a design guide and may be used until actual soil data is known Many authorities will demand truck access into the tank's diked arvas for fire fighting. When large Pumps are located within the diked area, truck ac- cess also is necessary. Some customers require truck access for genccal maintenance. Figure 3-8 shows how to design the truck access. Ramp slope is 10% maximum, or 1” to 10”. 3.4.4, Storage Tank Design In many companies the design of atmospheric storage tanks rests with the piping designer since it is a nonpressure vessel. It then becomes his task not only to orient the nozzles but to specify the tank materials and sizes. To do this he must have more than a passing knowledge of tank design and material specifications, Tank materials for hydrocarbon service are di- vided into three basic types: intermediate strength steels such as ASTM A285-C for general service (also ASTM A516 for atmospheric and low-temper- ature service and ASTM AS15 for intermediate and higher temperature service), high-yield strength steels used for larger and taller tanks to keep shell thicknesses to a minimum (ASTM A514 and A317) and the low-temperature steels used for a pressure containing tank (ASTM A537). Water tanks are specified usually as A283-C, a low grade steel. Before specifying the material, the designer must consider that the higher strength steels will cost more per pound, Freight will be less but how much Less will depend on the plant location. By utilizing the higher allowable stresses, the shell wall thickness is reduced. Base plate, roof and framing are not affected. Any corrosion allowance specified52 Process Piping Design Figure 3-9. Aerial view of British Petroleum’s refinery in Germany. Courtesy of Chicago Bridge and Iran. Co. must come out of the wall of the more expensive Some of these materials require special weld- \d quality control procedures which add to the total cost. Large thin shells may require special bracing during construction and permanent stiffen- ing due to wind loading Some designers may proudly say they saved 10,000 pounds by using the high-strength steel for their tank, but this may have made the installed cost more expensive, The installed cost is what is important and a careful summation of the many factors is necessary before final material selection. The advantage of the high-strength steel is uti- lized in designing tanks to larger diameters and heights than would be permitted by the allowable stiesses of the lower strength metal. Usually larger and fewer tanks are more economical than more tanks of a smaller size. The height is limited by the soil bearing allowable. The diameter is limited by the shell material thickness. Economy cannot be the only consideration in sizing tanks. Flexibility of operation, plant loss in case of a tank failure or fire and the quantity of energy in one tank must be considered. A tank farm fire is a powerful menace and the larger the tank, the bigger the fire. Each tank selection is a difficu't problem and must be based on the items listed plus factors pe~ culiar to the application. Selection can be made after a careful summation of all conditions.Plant Arrangement, Storage Tanks 53 Figure 3-10, Crude tank dikes A Refinery Figure 3-9 is an aerial view of British Petrole- um’s Vohburg refinery in West Germany where Chicago Bridge and Iron’s German division built 161 tanks and vessels with an aggregate capacity of over 6.5 million barrels of storage. The refinery has 4 capacity of 100,000 barrels per day. These tanks range in size from a small 10° dia- meter corrosion inhibitor tank to the large 168° in diameter Horton Floating Roof tanks used for crude oil storage. In this installation, 41 tanks are of the floating roof design, 112 are dome roof (or cone roof) and eight are spheres. Spheres are used to store propane, butane, propylene and butylene under pressure In the foreground, the large crude tanks are located four to a unit with road access around the unit for the fire-fighting equipment. Large crude tanks are diked separately. It is usual practice to limit a diked area to 250,000 barrels In the center of the tank farm are the rerun and transfer storage tanks, unitized with like or similar commodities bunched together in one diked area. Farther in the background are the product storage tanks, again unitized, with the LPG spheres in the far background, located near the product loading area, the railroad. ‘The process units, right center, utilize two common stacks for all the fired heaters in the plant, with the waste heat exhausting almost 500° high. Hv ducts, large enough to walk through, connect each heater to these stacks. (In most of Germany this type of design is required to try to keep the air as pollution free as possible.) The Vohburg installation is considered a large refinery; however, there are many over twice its size, Exercise A crude storage area has six floating roof stor- age tanks with a total storage. capacity of 3,000,000 barrels. The soil beariig will allow a tank height of 56-0". What tank diameter is needed? (Tanks are the same diameter.)os Process Piping Design & * OP 4 A + ~ 7 ~ § er ~ a SLOPE 4 / Figure 3-11, Diked area drainage plan. Refer to Figure 3-10 and supply the following: Dimension A with 67-0" dike height. Cubic yards of earth needed for dikes, Dimension A with S'-0" dike height. Cubic yards of earth needed for dikes. Square feet of plot area saved with 670” dike. If this oil has a specific gravity of 0.85, what is the head pressure on the tank’s base plate with the tank full. Express in pounds per square foot. Diked Area Drainage Each diked area must be drained to rid the area of rainwater. Figure 3-11 shows how to design this drainage system. All gravity flow is directed toward the catch basin. Note that surface water is sloped away from the tanks (see tank A, which is typical). This is done to keep the tank supports as dry as possible, For very large diked areas, two catch ba- sins may be required. Coming from the catch basin a line is routed through the dike to a gate valve which is normally closed. This valve discharges to the storm water Grain system. The valve is kept closed to contain the oil within the diked area in case of a rupture. After a rain, the valve is opened to drain off the surface water and is then closed again Storage Tank Piping Each storage tank will have most of the follow- ing piping systems: inlet, outlet, overflow, manual drain, vent, steam if tank heating is necessary and possibly a foam system for fire fighting. The inlet and outlet nozzles are both located near the bot- tom of the tank. The outlet goes to a “booster pump”, a low- head, high-velocity pump that boosts the pressure enough to get it from the tank to the unit’s “charge pump.” If possible, the booster pump is to be located outside of the diked area. To keep this pump suction as short as possible, locate tanks closer to the dike near the pump. It is not neces- sery to have the tank in the middle of the diked area. Also, diked areas may be rectangular instead of square.Plant Arrangement, Storage Tanks 85 |_s7 STORAGE TANK L—— TANK OUTLET NOZZLE i “ | S55 | S278 | sires ; | oe i a Shin —— + = existing PLANT Fac! aire os BATTERY LIMITS Figure 4-1, Plot plan for process unit.Plot Plans 59 4.0 Minimum horizontal clearance between equipment and/or piping shall be 2-6”. Exception: clearance between exchanger flanges may be 1'-6". 5.0 Main pipeway supports will be spaced evenly and at 20-0" maximum. Pickup supports shall be supplied for lines 3” and below, supporting them from the larger lines. 6.0 For pipe racks supporting air coolers (fin-fans), 30-0" width is desirable. Air cooler tube length will be 3: 7.0 Locate pumps under the pipeway with the centerline of discharge 2-0” out from under the pipe rack (2-0" from centerline of rack columns). 8.0 There are two operating aisles, one under the pipe rack and one between the Pumps and the equipment line, Control valve stations located 2-0" from the rack column centerline shall have their handwheels turned in under the rack. 9.0 Locate exchangers for adequate tube removal space at the channel end (refer- red to as the front end) and locate the back head on a line 80" from the pipe rack column centerline. This is called the equipment line. 10.0 Locate vertical vessels by locating the largest diameter vessel’s OD on a line 2-0" away from the equipment line or 10-0” from the rack column centerline. Line up all other vertical vessels’ center- lines with this one. 10.1 Horizontal vessel heads will line up with the equipment line, Laying Out the Plot Plan Most plot plans are first roughly sketched on the back of an old print to establish relative loca tions. Many designers use paper cut-outs, taping them to a scaled drawing of the plot area. The easiest method is to use a 1/8” = 1-0" scale model, with a magnetized plot board. Once the plot plan has been completed it is photographed for record Purposes and for customer approval. Since a book cannot utilize a magnetized model or paper cut-outs, the rough sketch proce- dure will be explained. The following data is need- ed but does not have to be complete Process flow diagram for unit. Plot size. Rough equipment sizes Control building location (off-plot or in unit); if in unit show the approximate size. Location of off-plot main pipeway (for unit connections). 6. Which lines are alloy, large carbon steel or other, which must be kept as short as pos- sible Pepe For item I, refer to Figure 4-2. This rough process flow diagram has been sketched in a hurry by a process engineer to give the piping designer some idea of the equipment and the major piping involved. It is incomplete and subject to careful study by the designer laying out the plot plan, Some items the piping designer will consider are: 1. Pumps are shown as single units for P-1—P-6, but each unit is actually two Pumps, the operating one and the spare. Common spares may be utilized later. 2. FF-1-PF-5, air coolers, should be located on the pipe rack. Each unit may be several cells, but the process engineer has given a hint by showing FF-4 as the largest one. This indicates that it is larger than the oth- ers but not necessarily just two cells. 3. Vessel sizes are not known at this time. This is not important for relative locations of equipment but must be known to fina- lize equipment locations. A good tule of thumb is to consider all vessels as 96" diam- eter for units with large throughput and 72" for smaller units until sizes are deter- mined. 4. Exchanger sizes are also unknown. The re- boiler E-2 is guessed as 72” OD while other shell and tube units are considered as 36” diameter. Estimate tube bundles of 20-0" length for E-1, E-3, and E-4, Figure 16'-0" tube bundie length for reboilers. 5. Since F-I and F-2 «ie pump-through type reboiler furnaces, it can be assumed that they are vertical type heaters about 20-0"Process Piping Design “weifelp mols ss6001d yBnoy “Z-p aunty ‘31s ar paaoadPlot Plans 61 diameter. Piping at reboiler heaters is usu- ally all carbon steel so assume no alloy piping in the unit. The plot plan designer knows to keep the fired heaters at a minimum of 50'-0" trom any piece of equipment containing hydrocarbon. The only ex- ception to this is reactors, which are located about 20'-0" from heaters to keep the alloy lines shorter. This unit has no reactors so this is not a considera tion here Figure 4-3 is a plot plan for multiple process units. The dotted spaces indicate the future light ends unit, the equipment shown in Figure 4-2, The plot is sized at 60° x 220° with the fired heater area mmediately south of the unit. This process area is well laid out with the fired heaters to the outside away from the units but with ample access. The units themselves have a common control building with easy access to all areas for the operators. The main pipeway will con- tain all utility, feed and product headers Figure 4-4 is a rough layout for the light ends unit plot plan. It is made freehand and to no scale The existing rack is drawn and equipment is sketched in according to flow of the process streams. Note in Figure 4-2 that the first feed goes to E-1 to preheat the T-I feed liquid. So E-1 is located as the first piece of equipment on the plot. The flow goes from E-1 to T-1, the fractionating tower, so it is placed next to E-l, leaving some room between them for operator walkway and, anticipating a large spread footing octagon for T-1, ample room to Keep the two foundations from touching. The reboiler, E-2, is located next to T-1 Since the liquid line from T-1 goes to E-2, usually low and blocking walkthrough access, reboilers are located close to towers and their back foundation usually rests on the tower octagon. The overhead condenser E-3, is located next to E-2, since the overhead line will be oriented on the east side of T-1 and will be able to span across E-2 to E-3 shellside connection. The next piece is the accumulator V-1, which is placed next to the condenser. This keeps the complete system from E-I to V-* flowing in se- quence The same philosophy is used for locating the other pieces of equipment. The only items out of sequence are the combined air coolers, FF-1, 2, 3 and 5, The largest duty will occur at FF-3, the overhead condenser; consequently, its piping will be the most expensive, which governs its placement between T-2 and V-2. The air coolers (fin-fans) were not located on top of the pipe rack because there was no space left on the existing rack. ‘A small rack has been added to route process and utility lines to the two reboiler fired heaters. This rack will have the two liquid lines to the re- boiler and the return lines to the two towers T-2 and T-3, plus fuel oil, fuel gas, atomizing steam, snuffing steam, instrument air, utility station air, water and steam, and electrical conduits plus possi- bly the instrument tray, which carrys the pneu ‘matic signals to the control building. The two heaters are located close together so that one ladder or stairway from grade can serve a platform common to both heaters. The operator can then check both heaters without having to go up and down and back up again. This design is often overlooked but is an initial savings and an operator convenience. Now the designer is ready to get the supervi- sor’s approval on the sequence layout, With a cri cal eye the supervisor scans the plot plan and the flow diagram. To him it looks good except for one piece of equipment. Can the student find the error without reading on? It is actually a costly error in judgment, Large insulated lines are costly to install. Every insulated elbow is expensive. The experienced su- pervisor’s eye tells him the most expensive lines in this unit are the hot lines to and from the fired heaters. Consequently, these lines should be routed as straight as flexibility will allow and with a mini- mum number of elbows. The error is in locating T-2. By changing places with T-2 and V-2 a great savings is assured. The liquid line from the bottom Pump is shortened and about eight elbows are saved. The reboiler return line has an even greater saving. T-3 is not exchanged with F-4 as no fittings are involved. Some straight pipe could be saved but this would be offset by adding more pipe to the feed to E-4 coming from the west. Pump locations are not considered during this preliminary layout. It is planned that they will be located under the rack but their final position will not effect the length of the process string,62 Process Piping Design Pott + -t—-T a | [eKstInd ain FIRE WAY I i: y. ‘| Pa y ‘ < a ig} | Iw w < « / i wy Fj} i Ved a wv Z)JPratronm-|/ | ivacuur ||ZJ/crune | |< < 3] iN unit [| unity | SJ} oni *) oY wv Qo] * | its E wo 2. I | Z4 | 4 E | = 4 Li. | |i ihe} = x. Q a rai | a] id a | w © \ t iz i | LI _| iL = inal “FT a Sy 7 — ma | 1a c 7 iM |_| Coes = 1et i BLDe. ta CI | tz, cas | i : TREATING|| COOLING it Pq) ener ToweR—” ipl | re 15) ea MAINTENANCE ROAD oe I TRS T Ste 7 = Se Figure 43. Plot plan for multiple process units. RNR a li i Sa eetPlot Plans Figure 44. Rough layout for light ends plot plan, 63 EXISTING| RACK exsTING ONIT64 Process Piping Design Now that the designer has an approved se- quence plot plan, he is ready to establish prelimi- nary dimensions. Again, this can be done with no equipment sizes. A lot of progress is lost on design because people think they need all the answers be- fore they can do any thing. Preliminary Plot Plan Dimemsions Figure 4-5 is a freehand sketch made to estab- lish preliminary plot plan dimensions. Final dimen- sioning is done when equipment sizing is com- pleted and piping layout is in the final stage. To establish preliminary dimensions the designer makes certain assumptions based on his experience and training. Assumptions and conclusions are listed below. Dimension 1. Locate E-1 from tne plot limit line; 5-0" clearance is maintained. Assuming a maximum of 48” exchanger channel flanges, set this dimension at 5-0" plus 2-0", or 7'-0", Dimension 2. Locate T-1 from E-1. T-1 is as- sumed to be 72" diameter. Since there are pumps taking suction, the skirt will be about 20" high. Below tray 1 there is a surge space of about 14’. Assume trays are spaced at 2-6". Between tray 1 and tray 15 there are 14 spaces at 2'-6, or 35'-0" Between trays 15 and 16 there is a cone section of about 4-0". From trays 16 to 22, there are six spaces at 2-6", or 15'-0". The vapor space above tray 22 is about 4'-0". Adding all of these, the designer learns that the tower is about 82'-0" tall With normal soil bearing, a tower of this size will require a foundation with a spread footing about 18" wide. These are cutagon shaped. E-I footing is estimated to be 4'-0" wide. To keep spread foot- ings clear and to allow ample walkway between, dimension 2 is established as 9'-0" (one-half of T-1 octagon) plus 2'-0" (one-half of E-1 footing) plus 21-0" for clearance to total 13-0". Dimension 3. Locate E-2 from T-1. E-2 is a kettle type reboiler and will be elevated a little above grade. The liquid line from T-1 will probably be low enough to block walking between these two pieces of equipment, so E-2 is located so the back support will rest on the T-1 octagon. This makes the octagon a “combined footing” therefore, dimension 3 should be less than 9'-0" (one-half the octagon). One-half of T-1 OD is 3'-0". One-half of E-2 OD is assumed to be 3-0", Allowing 1'-0" clearance, dimension 3 becomes 3'-0" plus 3-0" plus 1'-0" or 7'-0". Dimension 4. Locate E-3 from E-2. There are three things to consider in estimating this dimen- sion. The spread footings must clear (about 6/0" will accomplish this). The equipment must clear (6'-0" will clear this). Since there was no walkway west of E-2, access for maintenance and operation should be provided on the east side. The 2'-6" ac- cess path added to one-half of E-2 OD of 3'-0” plus one-half of E-3 diameter of 1'-6" makes dimension 4 total 70". Dimension 5. Locate V-1 from E-3. V-I has pumps taking suction from it so it will be elevated about 14'-0" or higher. The main consideration is to clear the spread footings. The V-I footing is assumed to be 6’-0" wide. E-3 footing is about 40" wide so 5'-0" plus 1/-0” clearance would suffice. Dimension 5 then becomes 6'-0". Dimension 6. Locate V-2 from V-1. V-2 also has pumps taking suction from it so it will be ele- vated about the same as V-1. Assuming 72” diame- ter for both vessels and a common platform between them with 6'-0" for working space, dimen- sion 6 becomes 120" Dimension 7. Locate combined air cooler from V-2. Equipment clearance is all that is necessary since foundations will be relatively small. Dimen- sion 7 becomes 8-0". Dimension 8 Estimate width of air cooler. Four separate cooling cells are located in one cool- ing frame. The product coolers, FF-1, 2 and 5, are generally small-duty units and will require one or two cells per unit. FF-3 is an overhead condenser and has larger duty which may have three or four cells. Assume a total of eight cells 5'-0" wide or 40'-0" plus frame of 2-0" to total 42'-0" for di- mension 8. Dimension 9. Locate T-2 from air cooler. T-2 has 30 trays so it will be taller than T-1. The spread footing (octagon) is assumed to be wider than the one required for T-1 by 2'-0", which makes it a 20-0" octagon with an allowance of 2'-0" for one- half of the air cooler footing and 2-0" for clear- ance, dimension 9 totals 10-0" plus 4'.0", or 140". Dimension 10. Locate pipe tack from T-2. Here the footings must clear so the 14'-0" dimension is, usedPlot Plans = PLoT Umit FF-/ FED FES E-4 ite =- 3 T-3. Fe-4 IS +— ———, 4 Figure 4.5. Preliminary plot plan dimensions.66 Process Piping Design Dimension 11. Establish pipe rack width. To do this accurately the pipe sizes must be known. For this purpose assume a 14'-0" width, Dimension 12 Locate E-4 from pipe rack. Footings must clear and some accessway between, rack columns and exchanger should be provided. ‘Assume 6’-0" Dimension 13. Locate T-3 from E-4. T-3 has 36 trays so it will be taller than T-2, but we can assume that the 200" octagon will be large enough. By using the same procedure used for de- termining dimension 9, dimension 13 also is 14-0" Dimension 14. Locate FF-4 from T-3. Use the same 14.0" Dimension 15. Estimate width of air cooler. FF-4 is in overhead condensing service and the process flow diagram indicates it is the largest of all the air coolers. Assume five cell, 5’ wide plus 2'-0" frame, or 27'-0". Dimension 16. Locate V-3 from FF-4. Use same procedure as dimension 7. Dimension is 8-0" Adding all these estimated dimensions, the de- signer finds he has used 213'-0" of plot length. Since the total plot length is 220'-0" (Figure 4-3), \V-3 is located 7'-0" from the east battery limits. As more firm information is developed some of the above dimensions may vary slightly, but if so there is no more plot length available and the designer will have to adjust other dimensions to suit, per- haps combining some foundations. Plot Plan Exercise The designer is now ready to draw the plot plan to scale. The student is to do this, assuming that the existing rack is 30'-0" wide and rack bents are spaced at 20'-0" with the last bent at the east plot limit, 7'-0" from V-3 centerline. Assuming no common spare pumps, locate pumps under the rack with the centerline of discharge 2'-0" out from the rack column centerline. Each pumping service shown in Figure 4-2 has two pumps, one operating and one spare. Locate pumps to keep suction lines short. Use equipment sizes and dimen- sions as estimated in this chapter. Fin-fans are 2-6" long. Draw all pumps 2-6" wide by 6'-6" long. Use 1” = 10'-0" scale. Remember, plot plans do nor show dimensions. Foundation Location Plan Figure 4-6 is the foundation location plan for the plot plan shown in Figure 4-1. This shows the location of all underground concrete by coordinate and to scale, The underground portion of founda. tion is shown dotted while the conerete portion projecting above grade is shown with a solid line, Using Figure 4-6 as a guide, the student is to prepare a foundation location plan for the equip. ment shown in Figure 4-5. Figure 4-3 supplies the two basic coordinates of the existing unit, called the “bench mark.” Bench marks also supply exist. ing elevation base. Excavation Plan When the field construction crew moves onto the job site the first thing they want to do is exca- vate. To do this they need a plot plan marked with the bottom of concrete elevations or an excavation plan, usually a transparency of the plot plan show- ing the excavation depth and periphery. Flow Diagram Transposition The flow diggram transposition is the first ef fort of laying out the major piping systems. It is made on a print or sepia of the plot plan. Piping sketched in from equipment to equipment, show- ing all meter runs and control valve locations. No effort is made to orient tower nozzles at this stage but the piping is shown going to the towers. This transposition is sometimes called the flow diagram overlay. Its best to develop this drawing after mechani cal and utility flow diagrams are prepared showing line sizes and full instrumentation. Then one trans- position is made for the process lines and one for the utility ines. A piping drawing index is made for each proc- ess unit to show the extent of area covered by each piping drawing and the drawing numbers showing the piping details for that area. Figure 4-7 is a pip- ing drawing index for the plot plan shown in Fig- ure 4-1. The student is to prepare a piping drawingPlot Plans 67 {fo}. “tn — ene HB he sus o4e)_f {i} —_{g]} "3 ore Hl toe seo) fH) ff anaes tg Hl _ 18-9 ama) for Figure 41 {on-+ aa) Boe rR Figure 4-6. Foundation tocation pl68 Process Piping Design index for his plot plan of the light ends unit, Try to keep the piping areas no wider than 60-65". Equipment Setting The plot plan designer will come in contact With many different kinds of equipment, depend- ing on the type of unit he must lay out. Each subsequent chapter in this book will go into detail about most of these items but, in general, the de- ner must know how to locate equipment for plot plan purposes and the following is offered as a guide to this. Fractionating Towers Fractionating towers are located on a common centerline about 12-14’ from the rack columns. The first ladder from grade should be located on the pipe rack side for easy access by the operators. Towers over 50" high are to have davits for han- dling vessel trays. A clear drop area is to be pro- vided on the side away from the rack. Exchangers Exchangers set the “equipment line.” This the location of the back head, usually set at from the pipe rack column. Shell and tube type exchangers may have a removable shell cover, a flanged head. Access must be provided for equip- ment to handle this cover, usually from under the rack. Tube pulling or rod cleaning area must be allowed at the channel end. This should be the tube length plus 5’ from the tube sheet, Double pipe exchangers are located with the tront end toward the rack. Tube removal space should be allowed but, for one to four units, is not manda- tory if grade mounted, as mobil maintenance equipment can pick up the entire unit and trans- port it to the repair shop. Control Buildings Control buildings are to be centrally located because they are home base for all the unit opera- tors, This also keeps instrument leads shorter. Con- trol buildings should have road access. Keep proc- ess equipment 25’ away. In the original layout keep hydrocarbon equipment 50° away as control buildings usually get larger than originally planned To size control buildings, get the instrument engi- neer to size the control board and space needed for future board. Then consider requirements for of- fices, toilet facilities, lockers, tables and chairs for a lunch room, stoves, refrigerators, any electrical switchgear (consult the electrical engineer) or pos- sibly an air compressor and related equipment for the plant instrument air system. Allow space for the heating and/or air-conditioning unit. Some cus- tomers want a small lab area in the control building to test samples taken in the unit Fired Heaters Fired heaters are located a minimum of 50’ from hydrocarbon-containing equipment: however, reactors may be closer. The fired heaters must have road access for equipment needed for tube repair or replacement. Vertical heater tubes (tubes are mounted vertically) are pulled up from the top with a crane. Horizontal box type heaters must have tube removal space allocated behind the heat- cr equal to the tube length plus 10". A lightly tray- eled road can be utilized as part of this mainte- nance area Cooling Towers Cooling towers are to be located where the pre- vailing wind is directed to the small side. This al- lows both long sides to intake an equal amount of circulating fresh air. Many people locate cooling towers exactly opposite, directing the prevailing wing to the slatted long side. This allows one-half the tower to intake fresh air but the downwind side is starved. Locate cooling towers away from fired heaters, flare stack or any heat producing item. Air to the cooling tower must be as cool as possible to do its duty. Supply road access to cool- ing towers for maintenance of pumps, chemical additive equipment and for handling screens. Pump pits may be located anywhere around the tower. It is not necessary to center them along the long side. Many installations, utilize the short side. Locate pump pits to keep piping runs to a minimum, Piping Piping determines most equipment locations. Alloy piping costs much more than carbon steel, sometimes a thousand dollars a foot, so special at-Plot Plans 69 EXISTING PLANT FACILITIES 3 § 5 i e g i :70 Process Piping Design tention is needed to keep these lines short. Large insulated lines are also kept short. Many times the insulation is almost as costly as the pipe and is an expense often overlooked by the designer. Reboilers Reboilers are to be located next to the tower they serve except for pump-through type fired heaters. Kettle type reboiler elevation is deter mined by the tower liquid. Thermosiphon reboilers are regular shell and tube type exchangers. Horie zontal thermosiphon exchangers are located at a ‘minimum elevation, Vertical thermosiphon types are usually supported by the tower and are located on the back side to be accessible to the mainten- ance equipment. Large vertical types may require a supporting structure. Consult the vessel engineer to see if the tower can support the reboiler or reboil- ers. There may be more than one, Compressors Compressors have two basic categories, centrif- uusal and reciprocating. Drivers may be electric motor, gas engine, gas fired turbine or steam tur- bine. Locate compressors to keep suction lines as short as possible. Reciprocating compressors are usually housed in a tropical type building with a drop-curtain wall extending to within 8° of the floor. In areas of severe winter, such as Canada, they are fully housed. Keep the building far enough away from the pipe rack to allow for the suetion drum and the suction and discharge headers on the sleepers Large motor-driven compressors may require room behind the building for transformers. Always allow room at one end of the building for parts drop and pickup area. Compressor buildings must have truck access Centrifugal compressors should be mounted outside unless the customer requires a shelter. Al- low a large area for the lube and seal oil console, usually about 15 x 20’, with truck access. Locate the console outside the building, if a building is required, and at grade, behind the building, away from the pipe rack. Motor-driven compressors may require a large transformer. If the compressor is turbine driven, a large surface condenser may be needed. If it is necessary, locate the surface con- denser above the compressor. Electrical Starter Racks Electrical starter racks and switchgear must be located as early as possible. Consult the electrical department to get the size and, with them, deter- mine the location, Maintenance Maintenance requirements must be considered during early plot plan development. Shell and tube exchangers should not be stacked over three units high and then only if the centerline of the top unit is not over 15° from grade. For exchangers te- quiring four shells, stack them two high by two wide Between two major processing units allow for a road, if space is available, and clearance for a 25- ton crane. Provide accessways from main plant roads into unit roads. Erection Erection of the new equipment must be con- sidered. For large diameter and long towers, con- sider how the field crew can get them in the plant and where they can lay them for erection. For field-constructed equipment such as very large ves- sels and reactors space must be allowed for field construction, Future Expansion Future expansion must always be considered, Future pumps, vessels and exchangers are often overlooked. Consult the process engineer for these requirements,18, 19, 20, n Review Test This is a composite review of the first four chapters. The student should be able to answer 20 of Ferrous metals differ Define ANSI. the questions in his own words, without referring to the text. from nonferrous because they A joint efficiency is applied to a____ joint, Seamless piping has a. % joint efficiency. Pipe made from plate has a mill tolerance of. Seamless pipe has a mill tolerance of, %. Random length carbon steel pipe is + feet long. What is the difference between pipe and tubing? Name the three basic Which valve is for throttling?. What type of check valve is specified for pulsating flow? Define hydrocarbon, Define mercaptan, Which is the lightest Define fractionation. types of valves,, hydrocarbon? . What is flashing? __ a (Define) equal rium: = ee Define head. Define two-phase flow. What is hydrotesting Define topography. _ and why is it done?.72 Process Piping Design 21, Define cone roof vs. floating roof tank, ___ 227 What) deteanines funk) helgit sense ee eee meee ee eee ee ee eee ee eee ee eee eee 23, What are the advantages of the floating roof tank? 24. There are___gallons per barrel of oil, 25. What is the purpose of “foam” and how does it work? HAROLD HERRERA B. Proyectista Mecénico5 Piping Systems Every piping installation is resplendent with systems, each having something in common with yet different from—the last unit the designer fin ished. The fractionation system (see Chapter 2) is the most common system since it is the basis of all process units. All offsite and onsite units have drainage systems to handle surface or rain water, oily drips and drains or special liquids such as caus- tics, acids, ete. Most process units have one or two flare systems. Steam tracing systems are similar from job to job. This chapter will discuss these and other systems. Details are also similar from unit to unit. Many details should be standardized in the industry, but because they are not, countless millions of dollars are spent and man-hours are wasted developing a way to do something that has already been done 50 times before by other designers. This chapter will present details showing ways to solve problems Which are not standardized but do the job. Piping fabrication is done on all piping. Most process pipe is fabricated in a pipe shop and shipped to the job site in “shop spools” to be as- sembled by the erection workers. Most piping de- signers know very little of a pipe fabricator’s prob- lems or how he gets his work done. While his costs are high, the shop’s stre.mlined efficiency and as- sembly line techniques make shop fabrication cost less than field fabrication, 73 and Details Underground Piping Underground piping is broken down into two main categories: process systems and utility sys- tems. Underground process lines should be avoided; however, there are times where this is the best installation and this will be discussed in other chapters. Underground utility systems are classified into two divisions: gravity flow and pressurized systems Gravity Flow Systems Gravity flow systems depend on the pull of gravity for flow. Consequently these lines must have a constant slope from liquid origin to ter- minus. Recommended minimum slope is 1/8" per foot, or 1’ per 100 of line. Piping is supplied for the following systems: 1. Storm water or clean water includes rain water, wash water and fire water run-off. This is usually collected from paved areas by a catch basin and piped to a separation pit or API separator to separate any oils that may get into the system and will then g0 to a creek, river or possibly a large evaporation pond.74 Process sewer, sometimes called oily sewer or dirty water sewer, includes drips and drains from pumps, vessels, sample con- nection funnels and other dirty drains. This system is routed through a separator and the hydrocarbons are usually recovered. 3. Combined sewer is the sewer that collects both storm and process sewers, utilizing only one piping system. must be routed through a large API separator capa- ble of handling the combined flow to sepa- rate hydrocarbons from water. While the combined system saves money on piping costs, the savings are usually offset by larger separation facilities costs. The com- bined system is rarely used today. 4. Sanitary sewers are the systems that carry human waste. These are routed to a large sanitary system or, if handled locally, to a septic tank and its related field. 5. Corrosive sewers are designed as a separate sewer system within the unit. This includes acids, amines, carbonates and others. Some of these circulate within the unit, with all funnels draining to a separate header which ig routed to a local sump. A sump pump cither retums sewage to the pressurized system or sends it out of the unit for dis posal, possibly to a neutralizing pit. Some acids, such as sulphuric acid, are pumped to storage, then shipped to a reclaiming plant where the acid is recovered. As these systems vary widely, the materials of construction will be somewhat different than nor- mal and each selection must be thoroughly investi- gated. If vitrified clay or cast iron soil pipe is se- lected, careful attention must be given to the mate- rial selected to be used at the joints. Sewer terms are different and often confused with terms applied to overhead systems. Inverts are used as a dimensional reference point on all but carbon steel piping. Inverts are the elevations of the inside bottom of the sewer line. In the larger sizes of vitrified clay pipe, the thickness is very large and must be considered when calculat- ing clearances from other lines or underground concrete, The use of a concentric reducer or in- creaser will change the invert elevation and must be calculated. Process Piping Design When carbon steel pipe is selected for gravity sewer systems, dimensioning is to the bottom of pipe (BOP), expressed as an elevation. Inverts are also expressed as an elevation. ‘The liquid flow is determined by the slope of a gravity system which in tum is governed by the inverts’ set. The designer must be concerned with the elevation of the intemal surface, the invert, regardless of wall thickness. A joint’s intemal sur- face must line up even though the two wall thick- nesses differ. The gravity systems’ flow must be as smooth as possible, Without projections which would form weirs or dams, providing a point for solids to accumulate and block flow. Reducer Selection When reductions in line sizes for headers are required, special care must be taken in selecting the type of reducer. Because of inconsistent termi- nology, there is a great deal of confusion when defining a line reduction in either clay or cast i material. Proper terminology is defined below. All terms are specified in the direction of flow. 1. Vitrified clay: Concentric is all that is available. a. For increasing line size use increaser with bell on small end. b. For reducing line size use reducer with bell on large end. 2. Cast iron soil pipe: Concentric only is available. a, For increasing line size use reducer with bell on small end. b, For reducing line size use increaser with bell on large end. 3. Cast iron pressure pipe: Concentric and ec- centric are available. a. For increasing or reducing line size use reducer. End types must be called out for both ends to match adjoining fit- ting or pipe. b, Eccentric reducers are available in lim- jed sizes and patterns but their use should be avoided. Before specifying, the designer must be sure proper sizes are commercially available.Piping Systems ‘Sewer System Terms 1 To discuss any sewer system, verbally or on paper, the designer must know the terms that fake up the system. These are Mains: Sewers for collection from two or more laterals: usually located in roadway easements. 2 Mains shall be sealed at regular intervals, with manholes, to prevent the spread of fire or gas backup, Laterals: Sewer lines collecting from two or more sublaterals and discharging to mains through a sealed manhole. 5 Sublaterals: Sewer lines connecting branches and catch basins to laterals, Brauches: Collect from various drain funnels or catch basins and tie into sublaterals. Funnel: Liquids collection point, usually projec ing 2" above the finished surface. For carbon steel systems, a 6"x4" concentric swage is an economical funnel. Lines from funnels should not be smaller than 4” to prevent clogging. For other materials a 6"x4" reducer could be used; 6" should be the minimum size for the funnel collection end. The swage is specified over the reducer because the swage is longer and will have a deeper bowl area for splashing. : ing or other surface is sloped to the catch basin, Catch basin is usually about 2' square by 1" to 14" deep and covered with grating. ‘Manhole: A central collection box of a size that a man can enter to clean the sewer laterals. In- coming lines are usually sealed to prevent 5 backflow of fire or gases. Sewer Materials j Selection of sewer material depends on pres- | sure, temperature, durability, cost (of material and | labor), availability and the fluid. Carbon steel pipe, properly coated, is quice often used. Vitrified clay 1 and cast iron soil pipe are widely used. It is very difficult to establish hard and fast rules for mate- tial selection. Experience ith the particular appli- cation is the best asset. The plant sites soil cor- rosiveness must also be considered. Catch Basin: Used to collect surface drainage. Pav- 4. 15 Vitrified clay pipe is economical. It is used for gravity systems handling surface drain- age and sanitary sewers. Since this piping has joints mechanically assembled, it should not be used under buildings or 6” or thicker concrete paving. If the com- modity being handled is 150°F or hotter, special joint material may be necessary Cast iron soil pipe is used for gravity sys- tems, When vitrified clay is specified, use cast iron soil pipe under buildings and thick paving. If the fluid is too hot for vitrified clay, use cast iron soil pipe for the necessary length to cool the fluid. Carbon steel piping is preferred by many designers because it is easily installed, It is subject to extemal corrosion and must be coated to ensure long life. The old stand- ard coating is tar and felt paper, usually referred to as “tar and feathers.” This is the cheapest coating but has many disad- vantages. It is easily damaged during han- dling and damages are not always properly repaired. The author recommends coating with plastic at the mill, such as “Scotch- kote” or “Plicoflex.” This costs more ini- tially but is almost impossible to damage and lasts for many years in the ground, Cast iron water pipe is used for gravity sewers where the use of 12! or longer sec- tions makes a more economical installation than the 4' to 6’ lengths of vitrified clay or cast iron soil pipe. Also specified for pres- surized water systems. Concrete pipe is generally used for surface drainage headers for sizes 24" and larger. Investigate cost, freight and availability be- fore specifying it. Concrete-lined steel pipe is used for pres- surized corrosive service where pressures are greater than allowed for cast iron pip- ing, Duriron pipe is sometimes specified for highly corrosive special drains. Because of its high silicon content it is very brittle— like glass-and has high breakage from han- dling, which adds to its already expensive cost.76 Process ee LINVERT POINT spicot Eno Figure 6-1, Cast iron bell and spigot pipe detail. Joints for Cast Iron Piping Cast iron pipe and fittings are equipped with bell and spigot ends. Figure 5-1 pictures the pipe detail. The joint can be sealed with lead and oakum, cement or a rubber or neoprene ring fit- ting into the groove shown. Lead and jute or oakum is standard joint material for surface water systems. To ensure operational tightness, the joint material must be kept moist. The conveyed liquid accomplishes this. Bell and spigot joints are rarely used in gas pressurized systems. Pressures of up to 200 psig can be held by the joint for liquid service. For high pressure water service, such as fire water systems, bell and spigot pipe and fittings are available with bolting lugs to prevent joint separation For pressurized systems, thrust blocks are ap- plied at turns or points of thrust to restrict joint separation, Thrust blocks are generally a mass of concrete. ‘The mechanical joint, a modification of the bell and spigot joint, is used in low pressure gas istribution systems. However, the main use of the ‘mechanical joint is for higher pressure fire water systems operating above 150 psig. The author re- stricts all cast iron piping to water and sewer sys- tems. For any hydrocarbon gas service, welded car- bon steel is recommended. ‘The mechanical lock joint groove which is shown in Figure 5-1 is located in the bell end. The groove accommodates a rubber or neoprene gas- ket. For installations where sagging is likely to oc- cur the mechanical lock joint is recommended. ‘This might be river crossings running above the water, supported by the bridge, or underground where soil heaving is expected. The Gulf Coast soil calls for this joint detail rather often. The mechanical roll-on joint is a low cost mechanical joint with a round rubber gasket over the spigot end. When the spigot is pulled into the bell, the ring is seated in the bottom of the bell, Outside the rubber gasket, braided jute wedged behind a projected ridge confines the gasket to retain pressure in the piping system. A bituminous compound seals the mouth of the bell, retaining the jute and gasket. Both bell and spigot and mechanical joint fittings can be used with this pipe. Table 5-1 Sewer Flow Diagram Symbols TH) Manhote GB catch basin o— Drain funnel o-e Drain funnel with seal cor running trap s(t Manhole with sealed in‘et —=-s-{3 Catch basin with sealed outlet ) Clean outPiping Systems 7 CONTROL BLDG. Wed. 1 i) vn vs) PURER 1 ' EXISTING 1 | ! PRAtS Figure 5-2. Typical process sewer flow diagram, For special service conditions, the piping de- signer might employ the mechanical screw-gland joint which will contain oil, gas and water at great- er pressures, the ball-and-socket joint which pro- Vides great flexibility at the joints, or the universal pipe joint which is a rather stiff joint. The Dresser coupling is a compression-sleeve coupling. It is used with plain end cut pipe of ei ther cast iron or steel in both underground and aboveground installations for air, gas, water and oil. This type of joint is quite often installed with- out proper anchors or bracing and when the line is, pressured it will come apart. Properly installed, this, joint will have anchors or braces at turns on both, sides of the joint. These joints are a fine economi- cal design for lines needing a small amount of ex- pansion. Improperly installed they result in total chaos. The Victaulic coupling is a split-coupling joint used with cast iron and carbon steel piping. This coupling is joined to the pipe or fitting via grooves cut near the ends. It is acceptable for use in liquid or vapor service, will take some expansion and al- lows considerable angular displacement. This joint, is easily installed and/or broken apart. Sewer Flow Diagram ‘The sewer flow diagram is the easiest way to communicate information about the drainage system to the layout designer and the customer. Finalizing locations of drain funnels, where man- holes are in the system, locations of seals, etc., are much easier settled on a flow diagram than on the finished sewer drawing. Although most companies do not prepare a sewer flow diagram, many man- hours would be saved if they did. If proper design information is given to the layout designer and his checker, a better job can be done in about half the expended man-hours, Because these flow diagrams are not commonly made, the symbols used are different in each com- pany that does make them. Table 5-1 depicts symbols which are used and could be standardized by the industry. Figure 5-2 is a typical process sew- Cast Iron Soil Pipe and Fittings Cast irori soil pipe and fitting standards are es- tablished by the Cast Iron Soil Pipe Institute, 202978 Process Piping Design y. (reLescoenig ceneTH) Figure 5-3. Dimensions of service cast iron soid pipe and fittings. Courtesy of Cast Iron Soil Pipe Institute, Table 5:2 Dimensions of Hubs, Spigots, and Barrels for ‘Service Cast Iron Soil Pipe and Fittings Outside Inside diameter, Outside Inside “Thickness diameter of spigot? * Diameter Telescoping diameter, of Size! of hub? Bead of barrel? lengths? of barrel? barrel? A w 7 Y 2 T inches inches inches inches inches inches inches i ? ‘soe 62 230 50 138 oly | 3 398 52 330, 238 256 0 a aoa 482 430, 500 398 8 5 soa 5.62 530, 3.00 498 18 é 698 oz 630 30 598 is : 935 85 838 350, 798 B 10 1138 1088 1030 330 398 28 2 13530 1288 1230 435 1134 8 15 1838 16.00 1562 425 1500 31 Distance from Thickness of hub Wiath of lead groove © Depth of lead groove Width of, "Spiaet’ ‘end, pipe and Size" ‘Hub body Over bead hub head? bead?’ fittings® ‘S(min) A (mind F 2 Giminy __G (max) inches inches inches Tneher inches Trees inches Inches > os 034 ors 069 oe O10 ‘or 3 “i6 37 ‘aL 55 28 “10 3 4 ag 37 38 a 38 10 3B 5 16 3 38 ai 38 10 3 é 18 3 a ai 2 10 3B : » a4 rs ub 3 a3 38 10 2 33 rs m3 38 13 19 2 B 33 (4a 138 a7 18 19 5 30 38 14a 138. a 18 19 Source: Cast Iron Soil Pipe Institute, Cast Iron Soil Pipe and Fittings Handbook. 'Nominal inside diameter. 2For tolerances see Table 3, Cast Iron Soil Pipe and Fittings Handbook. Laying length, all sizes~Single hub S'0" less Y, for S-foot lengths; single hub 10°0”; Double hub 10°0” less ¥, for 10-foot lengths. ‘Ifa bead is provided on the spigot end, M may be any diameter between J and M. SHub ends and spigot ends can be made with or without draft, and spigot ends can be made with or without draft, and spigot ends can be made with or without spigot bead.Piping Systems 73 y. (FeLescoPnie LencTH) Figure 5.4. Dimensions of extra heavy cast iron soil pipe and fittings. Courtesy of Cast Iron Soil Pipe Institute. | Table $3 Dimensions of Hubs, Spigots, and Barrels for Extra Heavy Cast Iron Soil Pipe and Fittings Ouse diameter Inside of Outside Inside diameter spigot? diameter, Telescoping diameter Thickness Size! of hub? Bead of barrel? length? of barrel? of barrel? A M J ¥ 8 T inches inches Inches inches inches inches 2 3.06 275 238 2.00 19 3 419 3.88 350 3.00 25 f 4 5.19 438 450 4.00 25 5 619 5.38 5330 5.00 35 6 719 688 650 6.00 25 8 9150 9.00 8.62 8.00 31 10 1162 1.3 10.75 10.00 37 12 13.75 13.13 12.75 12.00 37 15 17.00 16.25 15.88 15.00 44 Distance from Thickness of hub Width of lead groove to Depth of lead groove Wiath of Spigot end, pipe and Hub body Over bead hub head? bead? $ firings? Simin) A (mind F w ° Giminy __G (max.) inches inches Tnches Taches Tnches inches Tnches Tnches 2 O18: 037 0.75 0.69 0.28 0.10 0.13 3 25 4B 81 75 28 10 13 4 25 43 88 ‘81 ort 110 113 5 3 43 88 31 28 10 13 6 25 43 38 81 2B 110 113 8 34 39 Lia 112 38 15 119 10 40 ‘65 119 12 38 15 19 12 40 65 144 138 a7 15 19 15 46, am 1a 138 47 115 119) Source: Cast Iron Soil Pipe Institute, Cast Iron Soil Pipe and Fittings Handbook. 1 Nominal inside diameter. 2For tolerances see Table 3, Cast fron Soil Pipe and Fittings Handbook, Laying length, all sizes—Single hub 5'0” less Y, for 10-foot lengths; single hut. 10°0”; Double hub 10°0” les Y, for 10-foot lengths. “E'bead is provided on the pigot end, M may be any diameter, between J and M. Hub ends and spigot ends can be made with or without draft, and spigot ends can be made with or without draft, and spigot ends can be made with or without spigot bead80 Process Piping Design K Street, N.W., Washington, D.C. 20006, They have published an excellent book on all cast iron piping called Cast /ron Soil Pipe and Fittings Hand- book, which should be in every designer's library. Cast iron soil pipe is available in sizes 2-15” Sizes are the nominal inside diameter of the pipe. The wall thickness varies with the class specified, which changes the outside diameter. Laying lengths vary, but in general will be either 5 or 10’, ‘See Tables 5-2 and 5-3 and Figures 5-3 and 5-4 for details, Fittings are manufactured in sizes to match the pipe. Terms are different than the ones for carbon steel and the designer must specify the correct term. For instance, the 90° ell is called a 1/4 bend, The 45° ell is a 1/8 bend. Cast iron fittings also employ bends of 1/5, 1/6 and 1/16. These terms are devised according to what fraction of 360° they turn All junctions are made with fittings. Welding is not employed. Fittings are available for line inter- sections, clean-outs, etc, Flow is always directed into the barrel of the pipe or fitting (see Figure 51). Joints are usually made with twisted jute (or oakum) and calked with lead. Jute is a vegetable fibre. Cotton and hemp are also sometimes used. These materials are ordered by the pound. Lead joint requirements are calculated to be 12 ounces per inch of diameter. Thus an 8" diameter pipe would require 6 pounds of lead. Jute is estimated at 10% of the lead requirement by weight. The 8” pipe would need 0.6 pounds of jute. To order joint material, the piping designer must count all joints by sizes and calculate the total weight of joint ma- terials. Ten precent is added iv ihis total to allow for waste. Designing Systems To design a sewer system the designer must know the depth of cover required, The highest point in his horizontal piping must be below the frost line or the liquids could freeze in the line. With a slope of 1" per 100’, the lowest point could be very deep. Lines are also located below frost lines to protect them from “heaving,” rising and falling caused by frozen earth thawing and freez~ ing. Frost lines of each area are designated in the general specifications. In any event, underground lines should have a minimum of 3° of cover in un. paved areas for protection against truck traffic, 4. cover of 1/-6" is the minimum under paved areas, Student Exercise ‘The plot plan, Figure 4-1, and the foundation location plan, Figure 4-6, comprise a unit for which the designer must prepare an underground piping plan and elevation. The student will make these drawings as a class exercise. Figure 5-2 is the Process sewer. Assume a frost line of 3°. Use car. bon steel material and supply dimensions or coor. dinates necessary for fabrication and installation, Locate funnels and lines by coordinates in plan, To design the storm sewer, the designer must divide the process area into drainage areas to facil- tate the removal of liquids as quickly as possible. If possible, drainage areas should be square. Paved drainage areas should have a maximum of 2500 square feet of surface per catch basin. The student is to designate the surface drainage areas, locate the catch basins and route the total flow to the existing manhole. The centerline coordinates of the existing manhole are W.610'-0" and N.1090%0", High points of paving extremities are W.610-0" and W.655'-0", N. 975'-0" and N.1205'-0" Drainage area slopes shall be limited to a mini- mum of 0.01” per foot and a maximum of 0.04" per foot. The maximum total drop allowed is 6” from the high point of paving to the lowest point at the catch basin. After completing the drawing, prepare a bill of material listing all material necessary to install the two sewer systems. Refer to Figures 5-5, drain funnel installation, and 5-6, typical clean-out detail, for design data. Upon completion, students may exchange drawings, checking one anothers work. Design Guidelines Manholes should be located at all major inter- sections and in line turns of major headers, which are 90°. For sewer line sizes up to 24”, provide manholes every 300’ and for line sizes over 24", provide them every 500" for cleaning the system. Manholes may be square or round.Piping Systems 81 HIGH POINT OF GRADE OR PAVING G44" CONC. SWAGE MINIMUM 4° MINIMUM SIZ& =" ONE WELD MITRE. Figure 5:5, Drain funnel installation, Clean-outs shall be installed at dead ends of process sewers, or where the line turns a total of 90° or at a 45° turn preceded by 50° of straight- run pipe. Locate clean-outs so that cleaning may be accomplished in the flow’s direction. Drain funnels, may be considered as clean-outs if the line from the funnel is short and total turns do not exceed 135°, When routing underground lines always check: 1, Location of underground electrical en- velopes, their sizes and elevations, 2. Lines entering or leaving buildings routed by architectural or structural groups. 3. Location, and elevation of all foundations, whether they are spread footings or grade beams. Sewer piping must clear. 4. Angle of repose of the soil. Foundations must not be underreamed by excavation for sewer piping. Any time a pipe is run deeper than the foundation (if not on pil- ing) and within a few feet of it, check the structural group about possible underream- ing. If there is no other route for the pipe, the structural group may have to lower their footing. Underground Pressurized Systems Fire water, cooling water, closed process drains and pump-out systems are the more common pres- surized underground lines. Carbon steel is the most commonly used material for these systems. Transite piping is often used in pressurized brine systems and some people specify it for fire- water service, Transite is an asbestos material, very light in weight and, since it does not rust, it needs no external protection when laid underground, It is also used in some aboveground special service The Johns-Manville “Ring-tite” joint is the author's selection of transite joints. It is easily joined by the field people and keeps installed costs at a minimum while furnishing an excellent pres- sure-cont-ining closure. Johns-Manville will be hap- py to supply catalogs, at request, showing full de- tails of their transite pipe and Ring-tite coupling Joint82 Process Piping Design FILL WITH BITUMASTIC. PAVING oR GRADE. CAST IRON FERRDLE AND BRASS PLUG 4°1Ps 47 ONE. WELD MITRE Figure 5-6. Typical clean-out detail Fittings of transite material are very different and limited in types. Corrosion Proof Fitting Com- pany manufactures most fittings and Johns-Man: ville selis their fittings. Tyler Pipe Industries of Tyler, Texas, makes a cast iron fitting for use with transite pipe Mechanical joint cast iron is also very popular for pressurized systems. The Clow Company is one of the larger manufacturers of this. When specify- ing mechanical joint piping, either tie rods or thrust blocks must be used. Consult the Clow cata- log for details. Fire Water Every day people see fire plugs but not many consider the design of the underground fire system. fe plugs and monitors are furnished in plant pro- tection systems. Monitors are used to direct water to protect specific risks which may not be accessible with a portable hose stream or where the fire hazard is such that prompt application of water is nécessary. They are also used where the area would be ex- tremely hazardous to occupy during an emergency. Monitors may be fixed on one target, but usually they are left free to rotate by. the operator. They emit as much water as a 24” hose which requires three men to handle. The Elkhart Brass Mfg. Co., of Elkhart, Indi- ana, is a large producer of monitors. Figure 5-7 shows three types of their monitors. Fire plugs are located around the perimeter of each process unit, 5’ from the road’s edge, at all road intersections and one between road intersec- tions if this distance exceeds 250’. Locate them about 50’ from an area or building where special protection is desired. Do nor locate them where falling buildings or walls would injure the fire fight ers or possibly knock over the fire plug, resulting in a loss of system pressure when it is needed the most. Fire water headers are usually 8", while branches to plugs are 6”. Valves should be installed at intervals in the main header to make it possible to shut off small sections for repair or a new line tie-in without having to shut down the system. Pro- vide valves so that no break or repair will shut down more than 1000’ of the system. Fire water mains should be looped, allowing hydrants and monitors to be fed from two direc- tions, greatly increasing the possible delivery of wa- ter without excessive friction loss. Flushing co: nections, 4” size, should be located at the ends or far comers of the main. Fire water will freeze and must be located under the area frost line. For safe- ty, locate it 1” below frost line. Minimum cover should be 3' except under railroads where this is increased to 4’, If the main is routed under a rail- road the author suggests a culvert or pipe sleeve for load protection. Underground Cooling Water For most installations, underground cooling water supply and return lines are utilized for two reasons. First, they eliminate possible freezing, and second, they are cheaper. Some companies insistPiping Systems 83 Elkhart manufactures a complete line of Deck Pipes or ‘Monitor Nozzles. There are eight different styles and three different sizes to choose from. Elkhart monitor nozzles are the only ones manufactured with double row, full diameter nylon bearings. These ““King-sized”” bearings make the nozzles extremely easy to operate at high pressures and never need to be lubricated, Even at high pressures, one rman can easily control any of these nozzles. Nozzles are normally supplied with a discharge tube and one tip. 600, GPM. 1100 GPM, and hydrant Monitor nozzles are supplied ith a 24” x 2%" No, 282 discharge tube and No. 181 tip. 2000 G.P-M. Monitor nozzles are supplied with a 31" x 3%" No. 284 discharge tube and No. 181-3 tip. All 293 and 294 Monitors are available with a gauge and gauge guard at extra cost. Frequently it is desirable to use a ‘combination straight stream and fog nozzle on these monitors such as the CF (500 G.P.M.), CJN (2000 G.P.M), 5500 G.P.M.), JN (1000-G.P.M,) or the remote controlled Sky Chief nozzle, When these are used, tubes and tips are ‘not necessary and price of these can be applied against the price of the fog nozzle. Monitors are available with either female TIPT or ASA flat-faced flanged bases (see list of available bases), All discharge tubes are equipped with double stream shapers. Brass body painted 12d — speci either polished brass or chromium plated trim. Elkhart Monitor Nozzles 292 Handle Operated Monitor Full 360° rotation with lock —Maximum elevation with handle control ~ Has positive elevation lock. 292-6 for discharges from 200 to 600 G.P.M. 292-11 for discharges from 600 to 1100 G.P.M 292-20 for discharges from 1100 to 2000 G.P.M. 293 Single Wheel Operated Monitor Full 360° rotation with lock —Maximum elevation by wheel operated worm gears which lock positively unless the wheel is turned 293.6 for discharges from 200 to 600 G.P.M, 293-11 for discharges from 600 to 1100 G.P.M. 293-20 for discharges from 1100 to 2000 G.P.M, 294 Double Wheel Operated Monitor Wheeloperated worm gears control both vertical and horizontal operation and lock automatically — full 360° rotation, 294-11 for discharges from 600 to 1100G.P.M, 294-20 for discharges from 1100 to 2000 GP.M. Figure 6-7. Fire monitor nozzles. Courtesy of Elkhart Brass Mfg. Co., Ine.84 Process on cooling water in overhead pipeways, but this means that their racks will be larger and laterals to exchangers will be longer and consume more fit- tings. The most economical system will employ un- derground headers routed outside of the channel end of exchangers, causing very short lateral lines. If possible during plot plan development, locate all exchangers using cooling water on one side of the unit pipeway. This would eliminate having two sets of supply and return headers. If one or two small water users must be located on the opposite side, a subheader could be run across the unit from the main header to feed them, Locating the cooling water headers at the chan- nel end of the exchangers leaves the area under the unit pipe rack clear for underground drains and electrical distribution envelopes. It simplifies main- tenance when needed and keeps these big headers free and clear of foundations. Space underground cooling water supply and return headers at least 5’ apart (clearance between steel) to keep heat from being conducted through the earth from the hotter return header to the cooler supply header. Branches are to have 1'-6" clear for shovel room only. Pump-Out System ‘The closed process pump-out system is usually Jocated underground. It is a pressurized carbon steel pipe connecting to the unit's vessels, ex- changers and some pumps, routed to a pump mani- folded so it can be used as a pump-out pump, which pumps the unit down discharging to a stor- age tank in the tank farm. This system is run with 90° elbows; clean-outs and manholes are not pro- vided. Glycol Lines col lines in cold process gasoline plants should always be run underground. These are routed to inlet gas chillers and are discharged from positive displacement pump. This pump raises the pressure from 50 psig to over 1000 psig and due to, ‘the pump design the small glycol line is subject to intense pulsation from each thrust of the pump’s plunger. When this line is located overhead it has a ‘good chance of shaking, rattling in the rack, and eventually fatiguing and leaking at joints, ing Design Steam Tracing Tracing is the term used to describe the trans. fer of heat from a foreign source to piping systems Tracing is usually accomplished by a steam tracer line, but sometimes this gives way to electric trac. ing, where an electrical wire transmits heat to the pipe. Figure 5-8 shows how steam tracers are in: stalled inside insulated lines. Steam traced lines may have one or more tracers depending on the amount of heat transfer required for the fluid. In. sulation for steam traced lines must be sized one size larger than line size to accommodate the trac- er. For example, 8" insulation would be ordered for 6" lines, etc. Since electrical tracing employs a flat tape, oversized insulation is not necessary. Steam tracing is used to keep liquids from freezing in cold climates, to keep a viscous liquid from setting up or solidifying and to vaporize small amounts of hydrocarbon condensate that may form in a vapor service. One-half inch copper tubing, with flared fit- tings, is the most common and least expensive method of steam tracing. Properly installed, all flared joints will be located outside the insulation where any leak can be observed and repaired. This also will prevent damage to insulation should a leak occur. Steam of 100 to 150 psig is usually econom- ically available for tracing. ‘Steam Tracing Design Practice ‘The “Low January Average” is available from the U.S. Weather Bureau office for any particular area, The Weather Bureau calculates this by aver- aging the low temper-tures for the entire month. ‘This Low January Average is used as the design low temperature for determining extent of tracing or “winterizing.” For a Low January Average of 30°F or higher, winterizing is specified only where a sustained reading below 30°F is recorded several days of the month, lasting 24 hours or longer. For a Low January Average of 0°F to 29°F, water must be protected from freezing. Trace water to maintain a temperature of approximately 75°F, Hydrocarbons containing water must have tracing applied to “dead leg” areas, where water (which is heavier) can settle out and become @ freezing hazard.Piping Systems 85 Figure 8. Section of steam tracer. All fluids with pour points at or above the low ambient design temperature should be traced to maintain a temperature approximately 10°F above their pour point. Pour point temperatures of all fluids are available from chemical engineering handbooks. For a Low January Average below 0°F: Winterizing is required for water and aqueous solu- tions. Trace to maintain temperature of approximately ISR. Fluids with pour points at or above the low ambient design temperature should be traced to maintain a tem erature approximately 100° above their pour point. Speci Sosidertion is given to the folowing Buried lines, because of the deep frost line. Air intakes to boilers and other heating equipment. Cooling towers and air coolers Equipment Winterizing: Pumps are preferably winterized with companion pip ing. Compressors, blowers and other mechanical equip: ‘ment are specified for operation at low ambient design temperature, Storage tanks and vessels have winterized type drains TRACER SUPPORT SHOE J. pipe suppor Water draw off sections of vessels and bottoms of Air or Gas receivers where water can collect ate heat traced. Materials for Steam Tracing Tracers shall be O.D. tubing, Soft annealed copper tub: ing shall be used where temperature of the product line ‘or tracing steam does not exceed 400°F. Above this temperature dead soft annealed hydraulic quality, low carbon seamless steel tubing shall be used, For stainless steel lines, the tracer material shall be low carbon steel. Stainless steel instrument leads shall be traced with copper tubing. For aluminum pipe lines, the tracer material shall be, stainless steel ce For conditions where the tracer could overheat lines containing acid, caustic, amine, phenolic water, or other chemicals insulation spacer blocks shall be installed be- tween tracer and pipe. Each traver shall have its own trap. Tracer traps shall discharge to sewer. If condensate must be collected, ‘minimum usable pressure is 25 psig. Tracer Size and Length a. Required tracer size is determined by piping heat loss and tracer steam pressure found in the “Heat Loss Chart” (Figure 5-9).“109 400} jo AsaUuNog “BulDen wears 40} 1849 SSO] WOH} “6S OUND ny i iPiping Systems 87 b. Minimum tracer size is 3/8" O.D. tubing; ‘maximum size is 1” O.D. tubing. For econo- my, where “Heat Loss Chart” indicates the requirements for multiple tracers, a single tracer with heat transfer cement should be considered, When using heat transfer cement, tracers of 3/8” and 1/2" are recommended. If more tra fr area is required, multiple tracers of 3/8” and 1/2” are used. 4. Maximum tracer lengths are based on tracer size and steam pressure as follows: 1, Steam pressure 15 thru 25 psig: 200' for 3/8" and 1/2" tracers, 300! for 3/4" and 1" tracers. Steam pressure 50 thru 200 psig: 200" for 3/8" for 3/4” and 1 ind 1/2" tracers, and 400° tracers Tracer lengths for tracing with heat transfer cement shall be based on recommendation of manufactucer, ‘Tracer Pocket Depth Pocket depth is the distance the tracer rises in the di- rection of flow from a low point to a high point, The total pocket depth is the sum of all risers of the tracer. Maximum tracer total pocket depth is equal to 40% of tracing steam gage pressure expressed in feet, tiple: Tracing steam 150 psig; 150 x 40 = 60' total pocket depth. Figure 5-9, heat loss chart, is used to determine the size and number of steam tracers, Note that this chart is based on still air and heat loss must be increased by the factors shown for the area’s nor- mal winter wind velocity. Example #1, water lin ‘A 4" water line is to be maintained at 35° minimum fluid temperature. The low ambient design temperature is-10" ‘At, = 35° minus (10°) = 45. Available steam 50 psig at 250°. Table 5-4 Flow Diagram Legend for Winterizing ST Steam traced and minimum insulation STS. Steam traced with spacers and minimum insulation STT Steam traced with heat transfer cement and insulated |SJ_ Steam jacketed pipe and insulated | ET__ Electric traced and minimum insulation ETT Blectric traced with heat transfer cement and insulated WD Winter drained and no insulation WC Winter circulated and no insulation WE Winter flushed and no insulation Equipmenty List the symbol with the ttle. ST 1" insulation, steam traced ET 1" insulation, electric traced PP 1" insulation, process protection Instruments: umber circle. List the symbol next to the instrument ST Steam traced and minimum insulation ET Electric traced and minimum insulation WS Winter seal Minimum fluid temperature = 35°. tz = 250° minus 35° 15 Entering a 4" line and 45 for At, and 215 for Atz, one 3/8" O.D. tracer is indicated. Example #2, Process Line: ‘An 8" line is to be maintained at 125° minimum fluid temperature. The low ambient design temperature is 25°, ‘ty = 125° minus 25° = 100°. ‘Available steam 150 psig at 365°. Minimum fluid temperature = 125°, ‘At, = 365° minus 125° = 240°. Entering an 8" line and 100° for At, and 240° for Aty ‘one 3/8” O.D. tracer is indicated, Winterizing Flow Diagram Symbols Winterizing is accomplished by several means, in addition to steam tracing. Whatever the means, winterizing must be shown on the flow diagram to88 Process Piping Design Figure 5-10. Ds ecting flow in flare header. communicate it to the customer, the field, the op- eration people and the piping designer. The usual place to communicate this is immediately after the line number and size. For instance, 427A-6" ST means that line 427 is material specification A, 6” line size, and is steam traced. Winterizing symbols may vary between companies, but Table 54 de- picts terminology that is fairly common. Flare Systems Flare is the term used for the system which disposes of a plant's waste gases. Flare stacks are the tall structures that route the gas to the atmos- phere, usually with a “flare tip” which ignites the ‘as. Not all flare stacks are ignited. In some parts of the world, such as Lake Maracaibo in Venezuela, the government will not allow a flame and the gas is vented directly to the atmosphere. Flare headers are the lines in units that receive relief valve discharges, vents, etc., and route this gas to a flare knock-out drum which separates any liquid that may have condensed in the line, Waste Fo PSV DISCHARGE as from the knock-out drum is then routed to the flare stack. Knock-out drums are located at the flare stack to keep the line from the drum to the stack as short as possible. It is quite normal to have two flare headers and two knock-out drums feeding one flare stack or possibly separate stacks. One is for the low pres- sure flare, for relief valves set at 175 psig or below, and one is for the high pressure flare, for relief valves with set pressures above 175 psig. This pres- sure break poin* ill vary from plant to plant and is determined by a process pressure drop calcula- tion and allowable back pressure in the low pres- sure flare header. When two flare headers are re- quired, the utility flow diagram will show the pres- sure break point and which lines will vent into each header. Flare headers must be self-draining from origin to the flare knock-out drum. There should be no rises in the header as these will form pockets where condensed liquids will accumulate and eventually block the vapor flow. Lines from relief valves to the flare headers must also be routed to be self-draining into the topPiping Systems 89 RELIEF VALE > NY is7 MANDAL DRAIN ROUTE TO DRAIN FUNNEL, -— FLARE HDR, Figure 5-11, Drain valve installation for flare line, of the header. This means relief valves will be lo- cated higher than the flare header and the unit flare header is usually one of the highest lines in the pipe rack to keep it flowing down to the knock-out drum. High pressure relief valve dis- charges should have the flow directed into the header. This would apply for relief valve set pres- sures of over 1000 psig. Figure 5-10 shows the pip- ing detail for directing flow into a flare header. There are cases where it is impossible or im- practical to keep relief valve outlets self-draining to the flare header. But in no case can a liquid pocket, be allowed to cause uncalculated back pressure on the relief valve. When pressure must be relieved, the relief valve must have a smooth flowing outlet line to rid the piping of overpressure. When the relief valve outlet must be lower than the flare header, piping shall conform to Figure 5-11, drain, valve installation for flare line. The manual drain valve must be accessible from grade or platform. This installation would require regular draining by the unit operators. Note that the flare line goes into the top of the flare header. This must always 20 in the top to prevent any condensate which may be in the header from backing up in the lateral coming from the relief valve. Dead legs in cold climates must be steam traced to prevent freezing. Steam tracing may evaporate all condensate in the leg and this is one method of ridding dead legs of accumulated liquids. Even when steam tracing is used the manual drain valve must be provided. If the dead leg is in a spot where it prevents access (by ladder or platform) to the drain valve, provide two valves. One shall be located at the dead leg, as shown in Figure 5-11, which shall al- ways be left open. The other valve shall be located at the drain funnel and this will be the operating valve. The line to the operating valve will be steam traced in cold climates. The-valve at the dead leg is90 Process Piping Design ae RELIEF VALVES SQUARE CUT & PLAIN END \ provipe 4" weep HOLE AT LOW POINT Figure 5-12. PSV discharging to atmosphere provided as an emergency shut-off in case of a break in this small line. Relief valves are usually located to relieve va- pors. Hydrocarbon vapors are sometimes vented to the atmosphere if located very high on top of tall towers. Figure 5-12 shows how to route this to the atmosphere. The tail pipe is to terminate a mini- mum of 7-6" above any platform within a 40" radi- us. Relief valves must be accessible from a plat- form, Always mount relief valves with the spring vertical except for small liquid thermal relief valves, which may be installed with the spring in a horizontal position. Never route liquid reliefs to a flare header. ‘These are to be routed to a nearby drain funnel or, if none is available, run the PSV discharge line to within 6" of grade. In cryogenic piping it is normal to route liquids to a flare header: however, these light hydrocarbons usually immediately flash into vapor as they become warmer. Te pe Cuts, There is a very old myth among piping design- ers that calls for a 45° bevel on relief valve tail pipes discharging to the atmosphere. This myth has been handed down from generation to generation and in almost every plant today the beveled tail pipe is seen. The idea proposed by the myth is that beveling will direct the outlet velocity away from a platform or building. ‘The square cut end shown in Figure 5-12 will direct the discharge upward, away from platforms, etc., and will do it at the minimum cost. The 45° h-vel is more expensive to cut and results in extra waste pipe. The real falacy of this myth is seen when observing the actual installation where bevels have been cut which, in effect, direct the velocity toward operating platforms! This is caused by improper orientation of the bevel. The square cut end design eliminates all orientation problems,a1 Chapter 5 Review Test ‘The student should be able to answer the following questions. If three or more are missed, re- read the chapter. 1. Underground es should be avoided. 2. Underground utility systems are classified in two divisions. Name them. and 3. The minimum slope for gravity sewers is, 4, Define storm water sewers. 5, What is in a combined sewer? — 6, Define sanitary sewer. 7. What is an invert? 8. What is a catch basin? 9. Cast iron soil pipe is available in sizes. to, 10. A 90° elbow in cast iron is called —_______. 11. Cast iron joints are usually sealed with. 12. All sewer lines are to be located below the —__. 13. To keep liquids from freezing in cold climates is one use of 14, A flare system disposes of a plant's —_________§ ____, 15. When discharging to the atmosphere, relief valve tail pipes are to have their ends______cut.6 Pipe Fabrication Fabrication is the assembling and attaching of component pieces to make a completed item. Fab- ication of piping, the joining together of weldable pipe and fittings, is done by field personnel at the job site and by “shop fabricators,” a shop located at a metropolitan area with access to qualified per- sonnel and all materials on a large scale. Shop fabri- cation is usually less costly than field fabrication due to modern assembly line techniques and access to the latest fabrication equipment. This savings will average 10-15% over the usual field fabri tion. Because shops have instant communication with steel mills and large suppliers, they can locate special materials or fittings for their customers’ needs. And as they buy huge quantities of piping materials yearly, they can get the best possible prices. Shop fabrication. thus saves money on bixth, Tabor and materials, Most pipe shops employ all union personnel. The national union agreement calls for all pipe 2” and smaller to be fabricated in the field. By ar- rangement with the local union, smaller pipe may be shop fabricated. They usually agree to this if they cannot supply enough people to field fabri- cate the work. Normally, pipe 3” and larger is shop fabricated. Long straight runs are not supplied by shops. This Pipe is sent directly to the field. Underground pipe is field fabricated. Shops fabricate pipe for all companies. Each company’s drawings and specifications are sent to the shop in many different kinds of forms. Half of 92 their drawings are supplied as fully dimensioned plans and elevations. The other half are line isome- tics, referred to as “spools” by contractors. Shops do not call isometries spools. Shops prepare a drawing of a piece that is shippable and they call this piece a spool. A line isometric may produce a dozen shop spools. Welding Shops have welders and engineers fully quali- fied to make almost any type of weld necessary. Most large contractors, such as Fluor, have com plete welding specifications and procedures which shops use. However, for customers who do not fur- nish welding specifications, shops have their own specifications. Welding symbols ‘have been standardized by AWS, the American Welding Society. Figure 6-1, welding symbols, shows these standards. ‘Shop Details The shop’s drafting room prepares drawings of shop spools, showing every piece and every detail dimension necessary for fabrication. With each shop piece drawing a list of material is shown with cut lengths for each * iece of pipe to the closest 1/16". When plans and elevations are supplied, a “take-off” man is given the job of preparing a fePipe Fabrication 93 rough sketch of the shop spool. The sketch is checked by a “take-off checker.” Then it is passed to the detail draftsman who produces a finished drawing, the shop spool. Take-off men sometimes make a line isometric to pass on to draftsmen, When isometrics are furnished to the shop. the take-off man is usually by-passed and the line iso: metric goes to the draftsman, He makes the de sion of where to locate shop piece break points and completes the detail drawing. The drawing is then checked by a “break-down checker.” Some com- panies have spools checked twice to ensure accura- ey Shop spools are drawn orthographically and as isometries. Some shops do single line spools while some do double line. Texas Pipe Bending Co. in Houston has done all kinds and now does single line spools in isometric except for single plane spools, which are drawn orthographically Figure 6-2, orthographic pipe spool, is drawn orthographically because the pipe is in one plane. Figure 6-3. isometric pipe spool, shows how shop spools are drawn to show more than one plane. Figure 6-4, isometric spool with miters, shows detail miter dimensioning. Note that the pipe’s to- tal length is shown in the material list. igure 6-5, shop spool with bends, is drawn orthographically because it is in one plane. All bend data is shown in the boxes at the drawing’s top. The material list gives the total length of pipe needed to complete the spool Pipe Bends Pipe bends are used to ake tums without us- ing fittings. The pipe is usually filled with sand, heated and bent to a radius and angle as specified. The bend’s radius should not be less than 5 pipe diameters. For a 12" line this would be 5’. Fabrication shops have developed charts and tables to aid detail draftsmen. These charts are use- ful to piping designers as well. Tables 6-1 and 6-2, 30° bend data, supply dimensional data for 30° bends. Tables 6-3 and 6-4, 45° bend data, supply the same information for 45° bends. Tables 6-5 and 6-6, 60° bend data, supply dimensions for 60° bends. Table 6-7, 90° bend data, shows 90° bend dimensions. To read this table, for a 3-6" radius, see 3'-0” at the top and go down to 6” (at the left) which would supply the arc dimension of 5°6". iter Welds Miter welds are often specified in low pressure services as elbow substitutes. In very lange lines fit- tings are unavailable and miter weld elbows are used, Where pressure drop must be held to a mini- mum, the four-weld miter is used. Two-weld 90° miters are used for maximum economy, but they cause the greatest pressure drop. The three-weld miter is a compromise. Table 6-8, miter welding dimensions, gives full details on miters. For angles of 45° or less the one-weld miter is common. ‘Small Fittings ‘The pipe fabricator is concerned with dimen- sions that affect the length of pipe he must supply. Table 6-9, screwed and socketweld fittings, gives dimensions of interest to pipe fabricators, Normal thread engagement is also shown. The Triangle Piping designers run pipe vertically, horizontal- ly and at angles. The most common angles formed are 30° and 45°. By construction, piping draftsmen make 90° triangles and apply their math back: ground to solve triangles formed by these angles. Pipe shops have developed triangle tables to aid in quick solutions. Tables 6-10 and 6-11, 30° offsets, supply solutions for 30° triangles. Tables 6-12 and 6-13, 45° offsets, show 45° triangle solutions. ‘The Cutback A cutback is the dimension from the header centerline to the nozzle’s nearest point. Cutback dimensions are needed to determine the exact length of the nozzle pipe. Table 6-14, 90° cutback for standard weight pipe and Table 6-15, 90° cutback for extra heavy pipe, give the cutback dimensions when the nozzle’s ID rests on the header’s OD. ble 6-16, cutback at elbows, supplies dimen- sions for cutbacks occurring at 90° elbows. The formula shown can be applied for sizes not listed. |Process Piping Design Bosic weld symbols ond their location significance a gs ne BST FY Neh Ne tee | die Se sisieone [Fa [Pg o an] FR z tee z Ti ee | ner > [ME eS alae 2? fa ae ot SERS Fat en ho 1 Pater ho, Net we, hot a no, a Not cee faite | ake | dete] atte ce] dite | ee ‘Supplementary symbols Typical welding symbols ; rs aa Back ar Backing weld symbol Wels ot cone | Fie wad a = hy epee woe Oo e a ive i Location of elements of @ welding symbol ‘Seracing weld symbol indicating ellop auface Fah aya ae Fo eee Lang wid Tete Ir maenge | | stem oe haere welding symbol SlogeredIaarmien- Tet welding symbol a ee en ‘Sigl=¥ geo wading Syme sre en ‘Supplementary symbols used with welding symbols Fa wei yma ut joint Figure 6-1. Welding Symbols. Courtesy of Texas Pipe Bending Co,, Inc. sah i ies