PIPING ENGINEERING PLOT PLAN PROCEDURE AND PIPING LAYOUT GUIDE FOSTER WHEELER ENGINEERING STANDARDpeoet oft [GENERAL NOTES [LEW LTD GRADE i 0.220M UTILITY STATIONS| 6" PAVING PLATFORM ro) ts NORTH BATTERY LIMIT _N.3536.000. S) | concrete et 4000 oeiz 734k 3000. "| oases UP [eT 10000 eozz-1 House FILTER z 3 eH | “Beate: auo0 Mg ve TMT 404 92909 3 vere aieze-a 2259280: 5089 00 .289},000 cs INST PANEL velec-3 (ze9e3}) ower} oves7ad | vieze-a oost73} ree HE eS BL0ze=3 1002 13> Hrozz~a ‘goae-1ap ovoce=3 | foooz 133 s10z2~3 esp 1013000. 209 2409 2309 2200 2204 2 0 3700 —sisead 99973 azoze 1s0p.990 Se py 8 atiite 0081139. . asees p 0081739 ppl, fa] > Se oR eg i . § A= He 9922733, ——, era _ tige-s HE = au e129750 EL31950 EL 40301 woiee=3 =e oy evens Gp e110000 010113 1/t "| N 3514700 ACCESSWAY. .N,9534.000, “t doz 13) groze-3 Stoze=a = = 49902739 aio22-3 = J 1} vioze-3 , BATTERY LIMIT N.3476.000 voee=r 3! ‘saat i ®): 2 Tete ACESS) Ca ae soot LINTY AWSLLVE nS TITLE BLOCK SOUTH N.2478,000, qAccesswayENGINEERING PROCEDURE MANUAL FOSTER WHEELER LTD III-2-5.100 Tesued by A, MATHIE. [date DEC. 1970. PIPING DEPARTMENT REFERENCE MANUAL PLOT PLAN PROCEDURE 1.0 DATRODUCTION ‘The Plot Plan shall be drawn with the Plant North Arrow pointing The preferred For projects which will be modelled Plot Elevation drawings will not ‘ve made. For projects which will not be modelled Plot Elevation Plot Elevation drawings shall be the ‘The distribution of Plot Plan issue shall be in accordance with Project Co-ordination Procedure. During the development of the Preliminary Plot Plan a sketch giving a standard cross section through the plant shall be drawn and shall be issued to all Design Departments. For typical see III-2-5.101. Thie sketch is for F.W. Limited internal use only. + Plot Layout, Preliminary Intermediate (Rey. ‘0') and Final (Released for Construction). 2.0 DEVELOPMENT Stage ‘The Plot Layout may be the Plot Layout used at the proposal stace, the Client's Plot Layout, or shall be developed from Process Flow ‘Diagrams. For the latter, guidance fron Process and Project Engineers will be required. For typical Plot Layout see III-2-5.102. ‘Stage IL ‘The Preliminary Plot Plan is a development of the Plot Layout using Preliminary Equipment List, PAW. Ltd. and or sefety requirenents jenatics are The following shall be incor~ during this stage of development, porated on the Prelininary Plot Plan: ‘The Preliminary Plot Plan shall be issued to all Design Departments and to Process and Project Engineers for comment, after incorporating comments it shall be issued to the Client for comment. FID.2016,+ III-2-5.100 Piping Department Reference Manual | vow. O] page? of 5 Plot Plan Procedure 2.0 DEVELORGmT (Cont'd) Stage III ‘The intermediate stage of the Plot Plan is the development of the liminary plot plan to the first issue of a firm plot plan Ger. ‘O'), This will entail Piping Layouts of critical and congested areas and schematics of other areas. This work will be carried out using Rev. '0' issue of Engineering Plowsheets, Line Liets, Equipment Idet and F.W.Ltd. vessel drawings; Fired Heater outline and terminal point drawings; Pump and Compressor catalogue information; Air cooled exchanger outline drawings and Shell end Tube exchanger requisitions. It is essential to determine the routing of critical lines (i.e. Heater transfer lines, Tower overhead lines and bottom 1ines to Isometric sketches of these lines shall be issued to Group, Stress and Pipe Support Group for conment as early ble. Where supporting of these lines entails structures frames they shall be located on the Plot Plan. ‘The Plot Plen shall be issued at Rev. '0' after a dimensional check and all items not firmly located listed and held. A reproducible of the Plot Plan shall be issued to the Civil and Electrical Groups enabling them to proceed with underground piping and cable routing and area classification drawings. Stage IV he Final Plot Plan is a progressive development of the Rev. '0' issue. Piping layouts of all area shall be drawn during this stage finalising locations and elevations of equipment and with the receipt of Vendor's drawing enable Plot Flan to be checked. During this stage the Plot Plan shall be issued to all departments : advising then of revisions and changes and as early as possible shall be released for construction for the routing of underground piping and cables only. When all items of equipment have been finally located and Plot Plan checked it shall be approved and fully released for construction. 3.0 CONTENT OF PLOT PLAN ‘The Plot Plen shall include the following:- a. Location of all equiyment (including outline of "futures"), b. Dimensions, locations, and column numbers of all Structures and Buildings. c. Locations of all pipe rack pipe bents including basic elevations of lines in rack, and column numbers (FR Nos.). a. All pipe supports from grade where loading is above 500 ke. a e. Location of all horizontal drums from tan line. £. Location*of-e22~Shelmand-Tube "Exchangers "frow"channelenows 18.w| Piping Department Reference Manual TII-2-5.100 Plot Plan Procedure ren 0 Bot 3 3.0 CONTENTS OF PLOT FLAN & h Je ke Le a a °. Pe a re 8, t. we. oa oo x ‘Location-of all pumps from centre line of discharge nozzle. Tocation of Air fins from centre line of supporting columns, Location of Fired Heaters from centre line of Heater. Extent (by dimensions) of all paved areas. AID Utility Stations to be indicated by symbol. 411 withdrawal and drop out areas to be indicated. Location of fire wall and curbed areas. 411 steirvays and ladders from grad Battexyand or Unit Limit Co-ordinate Control House, Switchgear House and Transformers and Analyser Buildings. Control Panels. Worth Arrov and direction of prevailing winds. General Notes and Reference Drawings. All Platforms that can be clearly shown. on plot plan to be listed. Specialities - Point of Support For typical Plot Plan see III-2-5.103. Reference Datum Level.(2) [ENERGY LIMITED L ENGINEERING PROCEDURE MANUAL Ww PIPING DEPARTMENT REFERENCE MANUAL FOSTER WHEELER INDEX OF LAYOUT GUIDE III-2-5. issued by R.A. SQUILLARIO 105 TITLE GLOSSARY OF TERMS SCOPE OF LAYOUT MANUAL PLOT PLAN LAYOUT PIPING GENERAL REQUIREMENTS PIPING LAYOUT AT TOWERS & DRUMS : " "HEAT EXCHANGERS . " "PUMPS & TURBINES ” " "COMPRESSORS. : " "FIRED HEATERS " "PIPE RACKS “ " OFFSITES UTILITY PIPING PIPING STRESSING & FLEXIBILITY INSTRUMENTATION VALVES PIPING LAYOUT REQUIREMENTS FOR ELECTRICAL , INSTRUMENT AND VESSEL DEPARTMENTS. PIPING LAYOUT REQUIREMENTS FOR CIVIL DEPT. FWLBOI6/A Rest PAGE NO. 1 “ 7 28 40 47 51 56 60 66 7 82 90 92 93 to to to to to, to to to to to to to to to to NO. 13 16 a7 39 46 50 55 59 65 70 81 89 2 95 ev. conooceeo eo coo o DATE UNE, UNE “UNE UNE UNE, UNE UNE, UNE UNE UNE UNE UNE OULY UNE, UNE, UNE, JUNE 1972 1972 1972 1972 1972 1972 1972 1972 1972 1972 1972 1972 1981 1972 1972 1972 1972v Ww) Piping Department Reference Manual seawenlee ot Layout Guide Glossary of Terns eno" laaetl ABSOLUTE PRESSURE ABSOLUTE TEMPERATURE ABSORBER ACCUMULATOR AGITATOR APIS ANS.16 ASTM: AUTOMATIC CONTROL VALVE. BAROMETRIC LEG GLOSSARY OF TERMS USED IN THE PETROCHEMICAL INDUSTRY ‘The following list of terms and abbreviations is given as a guide. Pressured measured fron a perfect vacuum and expressed in bars (1 var = 10° War). Temperature measured above absolute zero (-273°C). A vessel (usually a tower) designe! to absorb gases by the use of Liquids as an agent. A vessel (drum) used to temporarily store or hold up Liquid. A revolving paddle like device used for mixing, normally motor driven. American Petroleum Institute. American National Standards Institute. American Society for Testing Materials. ‘A valve whose method of operation is controlled automatically, normally by an air motor (diaphragn). ‘A special kind of condenser used to maintain a vacum, This systen of condensing is comonly used in vacuum distillation, ‘A vertical pipe sealed off from the atmosphere normally by a water filled pit, and producing a vacuum above the water seal level.[ III-2-5.105 «0 page 2 Piping Department Reference Manual Layout Guide Glossary of Terns W BAMERY LDOT BELL AND SPIGOT JOINT BENT (STRUCTURAL OR PIPE RACK) BLIND FLANGE BLEED VALVE BLOW DOWN (STEAM PLANT) BLOWDOWN (HYDROCARBON PLAN) BLOWER ‘BOILER FEED BS. ‘BUND WALL ‘The boundry of a process or utility unit within a refinery or petro- chemical plant, A piping joint normally used on cast iron or concrete sewer piping and sealed with lead, hemp etc. A vertical plene of a steel structure, along a colum line, A plate type flange used to seal off ‘the end of a flanged pipe or vessel nozzle. \ A valve used to reliéve pressure in @ line after shut off (e.g. between @ double block valve assembly). A drain from the mud drum on a oiler which can be intermittent or continuous, Used to remove & percentage of highly concentrated minerals in boiler water. A collection system for hydrocarbon ‘iguids and/or vapours, vhich have deen discharged into headers by way of pressure relief valves or hand operated valves. - A machine used to pump or circulate gases Weter being fed into a boiler normally by a high pressure pump. British Standard 4n earth or concrete wall built around storage tanks or vessels to contain spillage in the event of a fracture or collapse of the tank orPiping Department Reference Manual Layout Guide Glossary of Terms TIT-2-5.105 a) if ‘BUDTERPLY VALVE CATALYST ! CATALYTIC CRACKING | CENTRIFUGE i CLAD PLATE CONTROL PANEL CONTROL: STATION DAMPENER DATUM A vane type valve, not normally a positive shut off, therefore used in lower pressure range lines. A substance used to cause or speed a chemical reaction without chemical or physical change to the catalyst. A process used to cause a chemical change in o41 vapours by the use of a catalyst. A machine to separate solids from liquids by the use of centrifugal force. Normally carbon steel plate which has & thin sheet of corrosion resistant metal rolled on one side, Usually used in vessel construction for economic reasons. A piece of equipment used for removing solide from liquids by settlement. A panel containing instruments and controls used to renotely control processes. A piping manifold normally containing a control valve with block valves and bypass. ~ A piece of equipment used to separate solids from gases or vapours. A omall vessel generally used with reciprocating compressors to reduce pulsation and vibration, The basic elevation reference point used for plant areas, normally equated to high or low point of paving and taken as 0.00M. For offeite areas, the datum at any point ie generally taken as local Ordnance Survey datum. FWL.2015/t,TIT~2-5.105 Piping Department Reference Manual ven. © | pagel, Layout Guide Glossary of Terns DEBUDANIZER = A process to renove tutané from the final product. DEPROPANTZER = A process to remove propane from the final product. DESALTER = A process to remove salts and other impurities from crude oil. DESUPERHEATER - A device for adding water to superh steam to remove the superheat. DIFFERENTIAL PRESSURE - he pressure difference between tvo points in a system, such as on opposite sides of an orifice plate. DOWIHERN - A substance substituted for steam as & heat carrying medium, for high temperature applications. DeP. CELL ~ in instrument used to transmit @fferential pressure, usually from orifice taps. ; ECONOMIZER = Aheat exchanger on a boiler, in which the flue gases are used to heat the air entering the combustion chamber, BYECTOR ~ A -vacuum producing device for removing air, gases or vapoure from condensers and vacuum equipment, FIRE PROOFED STEEL - A coating of concrete 50 mm thick applied to stee] structures supporting equipment, in order to prevent buckling of steel, due to excessive heat caused dy fire. FLAME ARRESTOR = A flanged item of equiyment usually containing gauzes etc., located to prevent flame travel along a Pipe. FLASH DRUM - A vessel in which hot liquide under pressure are allowed to vapourize by pressure reduction.Ww Piping Department Reference Manual Ua Layout Guide Glossary of Terns FLASH POIET FRICTION LOSS GLITSCH TRAY UNITE INTERFACE KNEE BRACE MOMENT CONNECTION MONORATL. MULTIPASS NON CONDENSIBLE ORIFICE METER PIPE ANCHOR the temperature at vhich hydrocarbon will ignite under certain conditions. A oupply of air under pressure 0.8. 85 supplied by an air blover, or when fans ero A drop in pressure due to friction between a pipe wall and the flowing medium. ‘A type of distillation tray used in towers. Concrete applied by sprey, used for example inside vessel skirts for fireproofing, and lining of offaite drainage trenches. ‘A supply of air produced by creating & vacuum e.g. a8 supplied to air fin tubes The level of separation between two non- miscible liquids in a vessel. dn angle bracing used for support in structural steel design. ‘wummsn «=~ ange to mnaoure differenti} Pronmize- ‘A rigid cantilivered connection used in structural steel design. A single overhead trolley beam. More than one pase through the shell or tube side of a heat exchanger. ‘A ges which cannot be condensed at the existing pressure and with the cooling mediun available. dn instrument which produces @ pressure differential for flow measurement. k pipe support item which prevents all novenent of a pipe at a fixed location. wut, ona 4[7 trr-25.105 rex 0 | page 6 Piping Department Reference Manual Layout Guide Glossary of Terms PIPE GUIDE PITO? TUBE PLENUM PURGE RASCHIG RINGS i REACTION REFLUX REGENERATOR RUPTURE DISC SLURRY SNUFFING STEAM STRIPPING STEAM - A pipe support item which only allows pipe movement in a fixed direction. - A flow measuring instrument. - A presoure chamber in a ventilation system. - Avapour, gas or Mauid injected into @ pipe or vessel or instrument to remove undesireable gas or liquids for safety or Process reasons, = Quick condensation of a vapour by liquid | BPray. - Type of packing used in a tower, usually ceramic rings. - The chemical change resulting from the mixture of chemicals or compounds under certain conditions. = Condensed product fed back into the top of a distillation colum, - A-vessei, equipment etc, used to revitalize a compound such es a catalyst by heating or washing. - Apiping item which generally consists of a @iaphragm placed between a pair of flanges. ‘This disphragn has a set bursting pressure, and vill rupture within the safety pressure eet for the piping or vessel. - Amixture of solids and liquids. - Steam used to blanket fires in fired heaters etc. - The steam used to atrip undesireable fractions| from a process strean, wut nse dnPiping Department Reference Manual Layout Guide Glossary of Terns ‘A Tank Storage area on refinery/petrochenical - ‘TANK FARM = plant. TRANSMITTER - Adevice for transmitting instrument signals for recording or controlling. ‘VACUUM TOWER = A tower in which the distillation process is operated under a vacuum. ‘viscosrty = The resistance of a liquid to flow. FWL, 2015/1,ITI-2-5.105 rev. 0 page 8 Piping Department Reference Manual Layout Guide - Scope of Manual 1,00 1,01 SCOPE OF Layour MANUAL ‘This mammal has been primarily prepared for the guidance and information of piping designers and draughtsmen engaged at F.W, Ltd., as a reference manual. The piping layout ete., considered throughout this manual refers specifically to oil refinery mits and associated Petro Chemical Plants, Vhen designing piping for other types of plant, special conditions, not covered by this manual may have to be considered. When a special type of plant is being designed, piping requirenents must be decided upon, in conjunction with the Project Engineering Dept. In any ease, at the start of a new contract, the Piping Section leader must chock that 4f this manuel is allowed to be used as a guide for the piping layout work on the Contract, that the designers are also conversant with the clients own basic practices and standards, and are avare that the clients requirements morally take preference, Piping layout dravings should be prepared to give sufficient information to model makers, strese engineers, piping @raughtemen and all interested specialist departments to perform end complete their part of the contract with maximum efficiency and minimum recycle work. ‘Time should not be spent in trying to give the layouts a "final drawing" finish or unecessary embellishments such as pump outlines etc. To save draughting tine, elbows, bends, valves and as many other details as possible should be drawn freehand. Since layout drewings are prepared early on in a contract, sone vondora equipment sizes may not be kmown, Careful consideration must therefore be given, to allowing adequate space,for such equipment on the layouts. This applies particularly to package units and special equipment, ‘Information for common items such es pumps, ejectors eto. may ‘be obtained from catalogues on the advice of Specialist lngineers, wor anee /oWw Piping Dopartnont Reference Mamual TTT-2.5.105 Layout Guide - Plot Plan Layout Toco 2,00 PLOT PLAN LAYOUT 2.01 The following itens must always be considered when laying out plot plans and piping: Process a) Process Requirements b) Economics o) Safety 4) Operation and Maintenance e) Construction £) Aesthetics 2,02 Process Requirements ‘he pre2iminary plot plen arrengonent should finst-be considered from a process peint of view, since the efficiency of the plant operation is of the greatest priority. ‘The equiyment should be laid out,from process tlow sheotsy, generally in-order-of process flow sequence, consideration being given to piporack routing, safety distances otc. Other conditions that should be taken into account process wise are, elevations of equipsent noted on flowsheots: ( may nedeeedtate-theuse"of strictures), minimizing lengths of crdtical-low pressure drop linesy"non-pockst ines, and pump suction lines, 2.03 Economics Economy in plant layout involves maxinising saving in inter connecting and supporting materials i.e. piping, electric cables, steelwork, concrete eto. the plant should be laid out as compactely es possible, consistent with maintenance of safety clearances, operational accessways ete. wun..2045/4.rev. 0 [page 10, Piping Department Reference Manual Layout Guide - Plot Plan Layout Wi 2.03 Economies (Cont'd)... Subject to process requirements, as much equigment as poseible should be located at grade to save the use of structure] material, and stacking of shell and tube heat exchangers. After an initial plot plan has been produced, the location of all equipment, and critical piping (transfer lines, pump suctions etc.) should be proved by the preparation of « piping schematic draving. ‘he use of concrete versus steel as & support material for structures, pipe bents etc. should be considered, based on the location of the site, availability of local materials, importation problems etc. 2.04 Safety In all cases in plant layout, safety is of utmost importance. Sufficient clearance between critical or high temperature items of oquipment-must-be-allowed: for operator and maintenance safety. toxic areas, control rooms and svitehgear houses, In sone processes, direct fired heaters may be required to be located near to reactors or heat exchangers, in order to economise on expensive alloy piping. Provisions for operator escape routes must be maintained e.g. escape ladders on structures and air fin exchangers. Access for fire fighting equipment must be carefully considered together with the supply and location of fixed Monitors, hydrants and hose reels. 2.05 Operation and Maintenance Road-access.around_and-within’the plant srea-nust-be-sdequate ‘for baintenance, and operation equipment to be safely manoeuvred, without endangering plant equipment, structures etc. Sufficient access must be provided to areas where equipment wust ‘be replaced, ove. compressor houses aid gensrator Stations or war,.oms/2.Piping Departnent Reference Manual T11-2-5.105 Layout Guide - Plot Plen Layout regu panera 2.05 2406 2.07 Operation and Maintenance (Cont'd). Ample space should be provided for storage of catalyst and chemical drums when necessary. Withdrawal areas for shell and tubs exchangers, tower internals punpo and cosprossor porte ote. should be considered, sneluding ccens to theseureasy) Paved areas should generally be provided around such items as pumps, shell and tube exchangers including withdrawal areas, below fired heaters and other areas where spillage is likely to occur, ‘he total extent of paving must agree vith clients specification. ge tion Although construction probleme seldom dictate the plot layout, occasions nay arise where due to equipment being extra large, or of awkward shape, special consideration must be given to @ location which will minimise difficult lifting conditions etc. ‘These problems are more likely to ocour when new-equipment has: to be fitted into existing unite on revasp contracts, Tn a1] the Construction Department should be consulted. Aesthetics Consideration should be given to the general appearance of & plant, Equipment should be lined up when possible, e.g. centre- lines of shell and tube exchangere, centrelines of pump dacherges, contrelines or faces of tovers and vertical drus, tangent Mnes of horizontal vessels. Main pipe racks and laterals should be run at set elevations. Where equipment sequences are for similar process requirements, then the piping configuration should be similar. Concrally a neatly laid out plot plan insofar se process requirements are concerned, tends to give an economic plant. our macM1 - 2 = 5.105 PIPING DEPARTMENT REFERENCE MANUAL - PLOT PLAN LAYOUT rev. 0 [page 12 TYPICAL PLAN OF PLANT IN PROCESS AREA | 2Oto | fxchanger i 4 | : : é a i oF) - = WO i za | _ zo) On flanged spools required for maintenance or dismantling of equipment (e.g. at shell and tube exchanger channel ends, pipe runs requiring cleaning). o) Piping which is lined, galvanised, stress 7 a) Piping on revamped unite which cannot be site welded, due to continuity of plant running, and hazardous location of pipe eved etc. run. Piping within units should be grouped wherever practicable et established elevations, i.e, specifie eisvations fer-Linss running Bast and West. the-atfrarence’ between” these elevations should be @ minimum of e-mme Tore are certain exceptions to this rule, for example, tover or drum suction lines having critical N.P.S.H. conditions may i have flat turns, also relief valve headers, which should not be trapped, should have turns without pocket: Generally vhen lines change direction, they should also chenge elevation. Piping at or around equipment, should be so arranged that the equipment nay be dismantled for inspection and maintensnce the minimun interference and removal of piping. Particular attention should be paid to clearences required for the removal of pump and turbine casings and shafts, pump drivers, exchanger undies, air fin bundles, compressor end engine pistons, compressor arivere and casings. Piping should be kept clear of mezholee, access openings, inspection points, davits,clearance areas for i with instrument vithdraval, and tower drop out areas+ ew mae feIII-2-5.105 Piping Department Reference Manual eto) reset e Layout Guide - Piping General Requirenents 3.08 The Piping Iesigner is usually responsible for commenting on vendors and P.W. drawings. Care should be taken that all equipment is checked against flowsheets and requisitions and ‘that Flange ratings etc., are compatible. wut, onss/oPiping Department Reference Mamal IIT-2-5.105 Layout Guide - Piping Layout Towers & Drums aenee roe 0 [page 17 SECTION 4,00 - PIPING LAYOUT AT TOWERS & DRUMS 4.01 The basic design of Tovers.is prepared by the Process Engineer, tues length and diameter .of tower, number and spacing of ‘rave tn tover, the number, oie and relative locations of nossies and instrument connections ‘to trays otc. the vessel details, and shell thickne Yosuel Specialist Department, but the Piping Designer suet orientate all nossles and instrument connections, 68 voll 6° dockding platform sizes and elevations. The platform siring ‘the structural steol designers to locate and select types shell by vessel vendor. are developed by the enable of platform support clips to be velded to 4.02 ‘The minimum elevation of the vessels are normally governed by pump H.P.S.H, requizesents, relationship to reboiiers etc. and ‘this information Ja given on the enginsering flowsheet. When necessary, elevations of vessels may be increased to improve headroon under bottoms lines etc., but care, mat be taken to ensure that these elevations are not go excessive that they win ead 40 mneconomical structures, concrete supports oF extra lengths of tover skirts. ‘Tho location of towers plan wise, is pasically eo the preliminary plot plan, but fixing dimensions of tovera are finalised by the Piping Designer. Groupe of towers can be Lined up by their centrelines ox by_backa_of toxex%- tthe distance between colums is governed by platforming (1.06 common or separate, the latter should be checked for overlapping), foundation sizes, and whether « comon foundation can be used for nore then one colum, access requirenents-and space for ar0P out area, ‘the tover drop out areas at grade, should be located to give ossy access, Whore. possible towers located adjacent to structures should utilise the structure platforms for access to ae minimise the tover skirt ttain the correct manvays etc., thus economising on Generally it is more economical to length, and maximise the use of concrete to & tover elevation, ‘Tis of course is dependent on the particular contract requirements. war, onsetso IIT-2-5.105 pace 18 - = Piping Department Reference Manual Layout Guide - Piping Layout Towers & Drums 4.02 4005 (cont'a) Special consideration must be given to the location of small @iameter towers (i.0.'600mn diameter or smaller), Due to the difficulty in some circumstances of making these towers self supporting, partial support fron an adjacent tower, or structure should be considered, and for tall towers guy ropes may be required. Some small diameter towers may be fabricated in flanged sections for maintenance purposes, and for these towers, access for mobile equipment or permanent facilities for dismantling purpos¢ must be made available. When preparing piping layouts for tower areas, the piping designer should have the following basic information:- a) Tower Scantling drawing ») Flovsheet showing minimum process requirements for elevations, instruments and piping, c) Preliminary plot plan shoving relative position of towers to other equipsent and the pipe rack. The following procedure should generally be adopted when commencing the piping layout: Draw on the layout sheet an elevation of the tover/towers to a scale of 1+ 100 and show on this elevation, to scale, all nozzles, manholes and instrument connections, estimating the locations of the latter if not Imown at this atage. (See also note 4.08). From this elevation the appropriate location of platform levels can be determined, and lengths of ladder runs ascertained. When ‘tisfied with these locations, a plan draving at each platform level should be prepared, so that nozzle orientation, piping runs and platform extents can be decided.4.04 4405 4.06 Piping Department Reference Manaul Layout Guide ~ Piping Layout Towers & Drums. AIL tower nozzles, manvays and instrunent connections, should be oriented to avoid interference with internal downcone: daffles, piping ete. ‘The use of internal piping inside towers, to allow simplification of external piping, should be kept to a minimum, since generally thie piping becomes an additional maintenance problem, and also piping supplied by a vessel vendor is generally nore expensive ‘then ordinary fabricated piping. F.W. Standard 10 B11.7 (London). shows preferred locations and alternatives for feed nozsles, draw off noszles, and manvays in towers, with single and double pass trays, In a packed column, nozzle orientation becomes « simpler task, since there are few obstructions these being mainly piping internals, Tray orientations must alvays be indicated on the layout draving s0 that the Vessel Department can check the validity of nozzle orientations, and that process flow is correctly maintained. For example when changing froma single pass to a double pass tray it 19 normal for the lover double pass trays to be rotated ‘through 90° for correct process flow. When doubts exist on tray orientation the Piping Designer should check with the contract Vessel Engineer. ‘The following tower process lines should not be pocketed:— a) Overhead Vapour Lines b) Heater Transfer Lines c) Side Stream Lines If in doubt about special process consideration in his aroa, ‘the Piping Designer should check with the Project Engineer before commencing the layout drawing. AlL pide strean drav-off lines from fractionating towers should drop imediately at the drav-off nozzle. ‘The shut off valve should be located as close to the dray-off nozzle as possible, and the line should drop at least = 1500 mm after the shut-off valve before changing direction.[ TLI-2-5.105 rev 9 page 20 Piping Department Reference Manual Layout Guide - Piping Layout Towers & Drunis. 4.06 4.07 (Cont'd)... Piping rune down tovers should be located where possible on one face of the tower to avoid penetration of platforms, and to simplify pipe supports, All safety valves mst be located so that they are accessible for maintenance fron a permanent platform, Generally all valves 2" and larger, blinds and spacers and control valves should be accessible from grade or a permanent platform, When nobile handling equimment cannot be used, large bore blinds and spacers should have permanent handling facilities such as davit or runway beam, as should all safety valves, Where possible valves and blinds should be located so as not to cause dead legs in piping. lines connecting towers and control valve minifolds at grade or a low platfom, should be flexible enough to absorb vertical expansion so as to avoid the use of spring supports at the manifold. 411 instruments points should be accessible from pernancnt platforms or ladders, Where possible level gauges and level controllers should be adjacent, and the gauge glass preferably be visible from the valve which controls the liquid level in the vessel. ‘Temperature instruments in towers should be so located in accordance with process requirements, i.6, the vapour space or liquid seal section, these locations should be confirmed by the contract instrument engineer before layout commencement, since platform and ladder access can be affected. Care should be taken when orienting temperature connections to make sure that thermocouples can be withdrayn without being obstructed by piping, steelwork, etc, Pressure instruments are normally located in the vapour epace.4.12 Layout Guide - Piping Layout Towers @ Drums. III-2-5.105 rex 0 [page 21 Piping Department Reference Manual Tower Platforming Wossle orientation has a great effect on platforming, and poor orientation will create unecononicel platforms. Platforms on towers should be kept to a minimm consistent with adequate access to valves, mamvays etc, ‘The shape of platforms to be used on towers (i.e. octagonal or circular), maximum ladder runs, access spacing etc. must be in accordance with the job specification, using clients or F.W, Standards. Platform access must generally be provided for the following:— Manways, handholes, blinds and spacers, davit or runway trolley operation, control valves, valves 2" size and over, and safety valves. ladder access is generally acceptable for the operation of 14" valves and smaller, these valves normally being for instrumentation. Some clients insist on full access to all noseles, therefore this point should be checked before commencing layouts. Cenerally manvays and nozzles below 4500 mm elevation, do not require platform access, providing that access from & portable ladder is practicable and acceptable to the client. Vanway olovations above platform levels should be between 750 mn end 1220 mn _to facilitate reasonable access. Manway hinges/davits should be oriented so that the manway cover opens away from the ladder and instrument access, and clears all other obstructions. Manways should be located to give good access to tower drop out area, so that tover internals, removed through the manway, require minimum manhandling to davit lifting tackle. Where possible platform support brackets should be the moment connection type, unless circumstances require the use of mee braced supports (e.g. thin vessel shell or small dieneter tower), When in doubt regarding type of support bracket to vse, the designer should consult the Structural Steel Section. wor, onan le‘THI-2-5-105 Piping Deoartment Reference Manaul 0 [pave 22 Layout Guide - Piping Layout Towers & Drums 4.12 (Cont'd)... Adequate clearance between platform levels must be maintained to give a minimum clear headroom of 2100 mm, For operation safety purposes, the use of split platforms should be avoided, Tower davits must be provided for handling safety valves, line blinds and spacers, and tover internals. Where excessive loads are involved oversize davits or runvay beam structures may have to be provided.4.21 4.22 IT-2-5,.105 Piping Department Reference Mamal Layout Guide - Piping Layout Tovers & Drums ‘Tangent line or bottom elevations of drums, should’be in accordance with process requirements and as noted on the flovsheet. Where no pro levation is noted, the drum should generally be located at a minimum height,. Consideration should also be given to any slope requirements indicated on the flowsheets. Care should be excorcised when locating nozzle order to take account of process requirements, e.g- making sure that the water draw off sumps are located upstream of outlet nozzles. Some nozzle locations may sometined be changed to simplify piping runs, but these changes must be acceptable process wise. In all cases vhere changes are required, check | with the Vessel Department, Adeaquate space and lifting facilities (when mobile equipment cannot be used) must be provided for maintenance and withdrawal of Agitators, coils etc. on drums in Drum platforming should be kept to a minimum consistent with auitable access to nozzles, valves, safety valves, manways, instruments etc. Ladder access is generally permissible for the operation of 14" valves and smaller on level instruments. win. oni8 AtW1-2-8.105 rou 0 — pave 24 PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — TYPICAL TOWEL PIPING LAYOUT W Note: Do not obstruct access to ladders @ angles sve pages 61,82, Tomperatire instr’s in liquid or vapour space, Check befere locating platforming & Ladders. Locate LG and LC together — We Bracket Positions per F.W. or Clients Stds. Where possible avoid § holes through platforms Locate manways to giveclear ¢|3 Zz access on to tray area Se "2000 Max for Clewanee per FW. I B38 clearance oF Clieis Ste, Clearance per FM. BSB or Clients Std. Nol, ah —_ 7 ‘, ' 6 Y i nb ‘Arrange feed A piping to give Locate: vatvas at ox symmetrical Nozzles wien flow conditions| possible »¥ = 4 300 to back of pipes ms) * for dimensions 2 An s Bless as £58 i a2 28 - ag a : LL a/, Oa ~~ tae ‘Access from ladder : aig when necessary oe 2g8 te) \ [fk 380 Normally : Keep skirt accessways clear of piping C 1. Dimensions are in millimetres, ‘Pur..on48/>. sPIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — TYPICAL TOWERS PLATFORM REQUIREMENTS org fz Clearance to suit Fall. oF For access clients standard. to Nozzle Bolting Step through ladder if clients standard allows Provide addit area for large Dia. blinded nozzles Tray Drop Out Area Note: Locate Davit to provide ample eel i si g : g sere = : eae 00 Min, Headroom coverage of manway areas and relief valves Manway Flt 50 [iad Max ladders runs to suit FN. Skirt length to suit job specification requirements on foundation heights Cage required for all ladder run in [excess of 2440 above grade or platform elevation Dimensions are in nillinetres.Downcomer odd Trays Plat. EL 2700 PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — TYPICAL TOWER PIPING LAYOUT ~_Plat. EL. Tan. Line ie e 09 © “.¢ C2) 2x0/ Xx = +4 © <- G ‘MaNc-c __ Grade EL. = 001M-2-5.105 rev. 0 [page 27 PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — TYPICAL DRUM PIPING LAYOUT W ‘sozjouFTTTH UT ery suoTeuemT — one 5 dnosg 1a19 Aq pasinpe aq 01 9215. pue edi vonepunoy -seppe} wauewsed Aq ‘9q ew saa9e wou ‘smoj|® psepuers sivo) pus arisoddo tue), “epe6 anoge $59) 10 sseoaud 1uns 01 adoig be Lo L = “ange pue “B'N.9 Buldd wos, 201 8q ‘Aew put pus siya ie pasinbas 1 wan ‘wmug Burdoyg 103aoe Piping Department Reference Manual 0 [page 26 layout Quide ~ Piping Layout at Heat Exchangers 5.00 HEAT EXCHANGERS The following list gives a description of the types of exchanger encountered in Refinery/Petro Chemical work. Exchanger. - Interchanges heat between one media and another, 4.e. cools one stream and heats the other, No heat loss or physical change occurs in the flowing media. Cooler ~ (Intercooler or Afterocaler) - oaseh or liquids are vater cooled without jcondensation occuring in gases, Subcooler ~ Vapour ia condensed by water cooling and the condensate is further cooled. Condenser - a) Vapour or Vapour mixture is water cooled ‘ith heat loss. >) Vapour or Vapour mixture is cooled by a cold process stream, which gives a direct interchange of heat, without heat loss. Chiller - A refrigerant is used to cool the process stroam below the freezing point of vater or below the prevailing cooling water temperature, - (Precheater) - te process strean ia generally heated up to its boiling point, but without Buch vapourization, ‘he heating nedia can be steam, dovthern or another process stream. - The bottoms process liquid in a tower is +. Febodled to provide vapour for the fractionation process, The heating media can be team or another process stream, Where large quantities of vapour are required a kettle type reboiler is used.IIT~2-5.105 WW Piping Department Reference Mamial Layout Guide ~ Piping Layout at Heat Exchangers ~ Waste Heat Boiler - Uses waste gas from other process equipment as _ steam generating media, Stean Generator, = Uses a process ges or liquid as a steam generating media. Vapourises a part of the process liquid stream by using steam or another hot Yapourizer (Evaporator) process media, 5.01 Shel) and chany All Exchangers should be located at grade where possible, with elevations kept to a minimum. ‘Theelevation of shell and tube exchangers 4s generally determined | by the lowest allowable bottom of pipe elevation of the largest dianeter pipe emanating fron a bottom nozzle. ‘The 3,0.P. elevation of these lines must include allowances for drain connections. : Groups of exchangers should generally be located on the plot plan ) by the alignment of the channel nozzles, Where tube bundle lengths i are the eame in a group of exchangers, the centrelines of the support feet, and hence the concrete piers should line up. On a | unit which hes piled foundations it is usually desireable to line up plore to simplify the underground support been erillage. ) Exchangers should not be stacked more than to high unless special provieion is made for maintenance purposes. 02 Where possible mobile equipment should be used for the handling of tube bundles, channel and shell head covers for exchangers located at grade, ‘The use of built in handling facilities should be kept to a minimum, Shell cover davite may be used when the shell heads are inaccessible to mobile equipuent. Where, for process or space saving reasons, it ia necessary to or concrete structure should be elevate exchangers, a ste provided. If a choice of structure material is dependent on economics, the Civil Depertment should be consulted. par, anac te° 5.02 (Cont'd)... 5204 5.05 30 Layout Guide ~ Piping Layout at Heat Exchangers ——___— aeeeeoees Piping Department Reference Manual | When exchangers are supported in a structure, suitable trolley beans and lifting tackle for handling exchanger parts should be provided. Consideration must also be given to maintenance facilities for vertical shell and tube exchangers vhich are usually supported in a structure, and may have a runway beam built in, On fixed tube exchangers space must be allowed for tube replacement or cleaning in situ. The question of mobile equipment versus built in maintenance should be agreed with the Project Department and client at the commencenent of the contract. Spacing between exchangers is governed by the allowance of adequate clear access between all obstructions. Where no access is required, a minimm of 375 mm — should be allowed between channel or shell flanges whichever is the greater. Piping layout at exchangers should be simple, and this can sometimes be accomplished by making physical changes to the exchangers, but these changes should not change the duty or increase the cost of the equipment. She general rule for fluid flow through a shell and tube exchanger ia to achieve contreflow i.e, heated media flow up, cooled media flow down. Yo simplify piping the following changes may be considered:. a) Change the diréction of flov.in both the shell and tube sides. >) Relocate nozzles longitudinally on shell. c) Straight nozeles may be changed to elbowed or tangential nozzles to reduce elevations and stacking heights. ‘The piping should be routed in euch a manner as to leave both the shell cover and channel end free of overhead obstructions so that aintenance facilities will not be impaired. Complex valving at exchangers should vhere possible be manifolded at grede by the shell side to allow easy operation, ‘he use of chain operated handwheels should be kept to a minimum. ae ante dn| Layout Guide - Piping Layout at Heat Bxchangers Piping Department Reference Manual 5.5 (cont'd)... Valves should not be located directly on top of channel nozzles as thie would cause an obstruction when removing channel ends. Also to save additional piping connections, the thernowell connections supplied in all exchanger nozzles and normally plugged, may sometines be utilized for permanent instrument locations, subject to the approval of the Project Department, In order to take up thermal expansions, one support foot of & shell ania tube exchanger has slotted holding down bolt holes. ‘These are- normally located on the foot furthest fron channel end, ‘ut the final location mist be decided by the stress section, wir nna laPiping Departaent Reference Manual Layout Guide = Piping Layout at Heat Bxchangers Air fins should be located after due consideration has been given to the provisions of mobile maintenance access for tube removal, and noise level restrictions, hen proce: and apace conditions allow, air fins should be located at grade. When this is not possible,air fins are generally located on top of structures or above pipe racks, 5:11" Sinee the air fin vendors allovable nozzle stresses must not be exoveded, all piping tieing into nozzles should be sufficiently supported and flexible. 411 air fin piping design must be confirmed by the stress section as being acceptable. Piping should not be routed in air fin areas in a way that vould obstruct maintenance, i.e, tube bundle removal, tube redding out at header bores, motor and fan access, or platform access, On multiple noszle air fin units, the pipe configuration should be designed to allow for equal flow conditions at nozeles, 5-12 Platform requirements on air fins must be decided in conjunction with the Project Department and Vendor at the commencement of the contract. - 5-13 When air fins are supported on structures or pipe racks, the supporting legs of the air fin should coincide with stanchions of the pipe rack structure where possible, so that air fin loads oan be directly transmitted. ‘This may involve uneven spacing \ of pipe rack bents, but will save on expensive support tie beams between stanchions, In any ease, an economic study is advised, to check extra steel, foundations etc. weer, anee tnPIPING DEPARTMENT REFERENCE MANUAL LAYOUT & GUIDE — PIPING LAYOUT AND HEAT EXCHANGERS = M-2-8.105, rev. 0 [page 33 SECTION 1 Hoot Exchanger Nomenclature To be read in conjunction with exchanger requisition, STATIONARY HEAD TYPES REAR HEAD TYPES Ve js REMOVABLE CHANNEL& COVER ——TY ONE PASS SHELL Luxe ‘A’ STATIONARY HEAD + af BONNET (INTEGRAL COVER) wP fs _ S vd PE eo WITH LONGITUDINAL BAFi sre Luke 'c” STATIONARY HEAD. pag Neosat NEF a Hi INTEGRAL WITH TUBE SHEET REMOVABLE COVER ‘OUTSIDE PACKED. FLOATING HEAD DOUBLE SPLIT FLOW ‘SPECIAL HIGH PRESSURE ‘CLOSURES. KETTLE TYPE AEBOIL: TUBE BUNDLE jijm2. 2-618 PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE ~ HEAT EXCHANGERS THIS DRAWING PROVIDES STANDARD DIMENSIONS SUITABLE FOR LAYOUT OF THE MORE COMMON TYPES OF EXCHANGER. Lh Sube Length [less 610% - tO remove Min. to remove| cover) bundle) od u Nom. ‘4880 TUBES 6100 TUBES Shell ; mo [230 [430 | 420 | sai | 4265 6630 | 540s [ av [25s [so [430 | seas | at65 e705 _| 5305, vo _[ eo [60 [aes [ss00 | ans 670 | 5335 tiv |} 290 | 860 [sto [seis | as 6895 | 5305 sso_|| 05 [560 [506 | sees | ans sass | 5395 | s10_|{ 30s | sas | seo | se90 | sono sero | 5260 0] 358 | 660 | s60 | 5790 | a900 rovo [S210 [ 710 |] 380 | cas | ss | sao | 000 ‘7050 | 6210 + yo | ae0 | eas | 620 | sees | sa50 7oss_| 5180 us|} 3e0 | eas | 650 | sees” | seas 708s | 5155 es 405 | 710 | 605 | se20 | aero 736 5130 as [40s [m0 [0 | sais | sero mies | 5130 sss] 430 | 785 | 725 | 6020 | se35 rao | 5055 ros || ass | 765 | 760 | 6070 | 3635 ms0 | S65 (toss ass | sis | 705 | coos | sass 7315_| 505s { j sno_| aes | ors | rs [6120 | 035 7340_| 505s 170 | 405 _| e400 | e460 | ors | 3810 7265 _| 5030 rzzo | 405 | e40 | 065 [6200 | aero 7420 | 5030 Dimensions are in millimetres.PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — HEAT EXCHANGER NOZZLE LAYOUT Alternat HEAT EXCHANGER DETAILS — FLOW CONDITIONS FOR SINGLE PASS SHELL piping arrgt. Cold streams always to be at bottom. "ull tubes in this direction SERIES FLOW PARALLEL FLOW e Preferred: Hot cooling Hot stream . = Hot heating Alternate =I md medi preferred a Apemate | Hot stream preferred | fey L I >) t= Ay ae ee t i {4 yy stream | ZA! Cold cooling Cold heating medium medium STACKED EXCHANGERS cookers HEAT EXCHANGERS lconnectod nozzles on stacked Outlet of stream being cooled Outlet of stream being heated angers to be on opposite to be at same end as Inlet of to be at same end as inlet, ds if possible to minimize of cooling medium of heating medium. felfect of unequal vertical and Horizontal expansion. *NOTE:— These streams may be changed if neccessary for improved11-2-6,105, PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE ~ TYPICAL EXCHANGER PIPING LAYOUT 150 Min clearance between pipe and Break flanges tobe fitted in Insulation i piping from channel nozzles when required by job spec. _7 Froterred Pipe_J Toute if flexibility Ss 159 Min clearance between ive and foundation, 150 Mi Exchanger centres are dependent on clearance requirements of valves and piping from nozzles giving Min. walkway. 150 Min clearance between pipe and exchanger davit. Access required at channel end for aL removal of exchanger 20'bin tube bundle ‘ Centerline elevation of =-ffr- exchangers is dependent fon clearance required between grade and bottom nozzle __and fittings Min, clearance required t L between 8.0.P. and “arade is 300 for ae uninsulated and 400 f 1g -Q_—_tor insulated pine. Generally valves may be fitted Elevation of mating directly on shell and bottom flange to be agreed ‘channel nozzles only. with U.G. Group Dimensions are in millimetres, owt ante in1-2 -5.105 rex 0 [page 37 PIPING DEPARTMENT REFERENCE MANUAL LAYOUT GUIDE — HEAT EXCHANGERS Wi Suonrdeuv03 moqy3 paibuy 1eo1dA1 9|220N pawoal J0 sn ayy Bulmoys s9jdwexgi } PIPING DEPARTMENT REFERENCE MANUAL W) LAYOUT GUIDE ~ TYPICAL EXCHANGER HANDLING EQUIPMENT Keep structure to a minimum size by utilising stanchion tie beams {8 supports and providing cantilevered platform. imum Clearances Per F.M or Clients, Elevation of lifting beams by Civil Group Stairway of ladder access dependent on size of structure & clients require= (@) rent Trolley bs extended to handle exchanger 7 2 Head removal. Type of Structure i.e, Stee! or Concrete to be decided ——>| by Civil Group Permanent Withdrawal Structure (If required). Dimensions are in millimetres. wr anse tn\W/ PIPING DEPARTMENT REFERENCE MANUAL M-2-5,105, LAYOUT GUIDE - TYPICAL AIR FIN PIPING rex 0 [page 39 PPiping should not be routed over the top of Air Fin bundles Plattonning at Ait Fn ructures er [eb Speci ation. ‘ Headers from and to Air Fin should be designed to give snifom flow tonoazies Minimum clearane] ‘of 2060 required between overhead] iping and nozzle| cess plat. When desiginin ee Air Fin piping Consul stress soup on pipe routing Air Fin Structures fare not to be used for pipe supports. ———*" |} jout vendors. permission. Dimensions are in millimetres. FHL,2015/1,