General Piping

System and Lay

out of Industrial
Plant

Group 2
Introduction to
Piping System
• A pipe can be defined as a tube made of metal,
plastic, wood, concrete or fiberglass. Pipes are used
to carry liquids, gases, slurries, or fine particles. A
piping system is generally considered to include the
complete interconnection of pipes, including in-line
components such as pipe fittings and flanges.
Pumps, heat exchanges, valves and tanks are also
considered part of piping system. Piping systems
are the arteries of our industrial processes and the
contribution of piping systems are essential in an
industrialized society.
• Photo shown illustrates the
magnitude of piping required in a
typical chemical process plant.
Piping systems accounts for a
significant portion of the total
plant cost, at times as much as
one-third of the total investment.
Piping systems arranged within a
very confined area can be added
challenge to piping and support
engineers.
Piping Material
• The material to be used for pipe manufacture must be chosen to suit the
operating conditions of the piping system. Guidance of selecting the correct
material can be obtained from standard piping codes. As an example, the
ASME Code for Pressure Piping contains sections on Power Piping. Industrial
Gas and Air Piping, Refinery and Oil Piping, and Refrigeration
• Piping Systems. The objective being to ensure that the material used is
entirely safe under the operating conditions of pressure, temperature,
corrosion, and erosion expected. Some of the materials most commonly used
for power plant piping are discussed in the following sections.

 Steel - is the most frequently used material for piping. Forged steel is extensively
used for f it ting while cast steel is primarily used for special applications. Pipe is
manufactured in two main categories- seamless and welded.

 Cast Iron - has a high resistance to corrosion and to abrasion and is used for ash
handling systems, sewage lines and underground water lines. It is, however, very
brittle and is not suitable for most power plant services. It is made in different
grades such as gray cast iron, malleable cast iron and ductile cast iron.
 Brass and Copper- Non-ferrous material such as copper and copper alloys are
used in power plants in instrumentation and water services where
temperature is not a prime factor...
Commercial Pipe Sizes

• Commercial pipe is made in standard sizes each

having several different wall thicknesses or weights.
Up to and including 304.8 mm (12 inch) pipe, the
size is expressed as nominal (approximate) inside
diameter. Above 304.8 mm, the size is given as the
actual outside diameter. All classes of pipe of a
given size have the same outside diameter, with the
extra thickness for different weights on the inside.
Commercial Pipe Sizes

• There are two systems used to designate the various

wall thicknesses of different sizes of pipe. The older
method lists pipe as standard (S), extra strong (XS)
and double extra strong (XXS). The newer method,
which is superseding the older method, uses schedule
numbers to designate wall thickness. These numbers
are 10, 20, 30, 40, 60, 80, 100, 120, 140 and 160. In
mo s t s izes o f p ip e, s ched ule 4 0 co r res p o nd s t o
standard and schedule 80 corresponds to extra strong.
• Dimensions and the mass in kg/m of different sizes of steel pipe with varying wall
thicknesses is shown below:
Pipe Fittings
• A f it ting is used in pipe systems to connect straight pipe sections, adapt to
different sizes or shapes and for other purposes, such as regulating (or
measuring) f lu id f low. Pipe Fittings (especially uncommon types) require
money, time, materials and tools to install, and are an important part of
piping and plumbing systems. Valves are technically f it tings, but are usually
discussed separately.
 Nipples - for making close connections. They are threaded on both ends with
the close nipple threaded for its entire length.

 Couplings - for connecting two pieces of pipe of the same size in a straight
line.

 Unions - for providing an easy method for dismantling piping.

 Tees and Crosses - for making branch line connections at 90°.

 Y-bends - for making branch line connections at 45°.

 Return Bends - for reversing direction of a pipe run.

 Plugs and Caps - for closing off open pipe ends or fittings.

 Bushings - for connecting pipes of different sizes. The male end f it s into a
coupling and the smaller pipe is then screwed into the female end. The
smaller connection may be tapped eccentrically to permit free drainage of
water.

 Reducers - for reducing pipe size. Has two female connections into which the
different sized pipes f it . May also be made with one connection eccentric for
free drainage of water.
Methods of Connecting Pipe
• There are three general methods used to join or connect lengths
of pressure piping. These are:
1. Screwed Connections.

2. Flanged Connections.

3. Welded Joints.
Screwed Connections
• In this method, threads are cut on each end of the pipe and screwed f it tings
such as unions, couplings, and elbows are used to join the lengths. This
method is generally used for pipe sizes less than 101.6 mm (4 inch) for low
and moderate pressures. It has the advantage that the piping can be easily
disassembled or assembled. However, the threaded connections are subject
to leakage and the strength of the pipe is reduced when threads are cut in
the pipe wall.
Flanged Connections
• This method uses f langes at the pipe ends which are bolted together, face to
face, usually with a gasket between the two faces. Flanged connections have
the advantage over welded connections of permitting disassembly and are
m or e con v e n i e n t t o a s s e m b l e a n d d i s a s s e m b l e t h a n t h e s cr e w e d
connections. Gaskets are usually used between f la nge faces. Gaskets are
made of a comparatively soft material which, when the f langed connection is
tightened, will f il l in any small depressions in the f la nge faces and thus
prevent leakage
Welded Connections
• In this method, the pipe lengths are welded directly to one another and
directly to any valves or f it tings that may be required. The use of these
welded joints for piping has several advantages over the use of screwed
connections or f la nged connections. And the main disadvantage of using
we lde d joint s for piping is t he ne ce ssit y of obt aining a skille d we lde r
whenever a connection is to be made
Piping Drainage
• In t h e ca se of st e a m pi pi n g, i t i s n e ce ssa r y t o con st a n t l y dra i n a n y
condensate from the lines. If this is not done then the condensate will be
carried along with the steam and may produce water hammer and possibly
rupture pipes or f it tings. In addition, the admission of moisture carrying
steam to turbines or engines is most undesirable. Various devices are used
to rem ove t his condensat e and m oist ure from t he lines and t hese are
discussed in the following sections.
Steam Separators
• Steam separators, sometimes called steam purifiers are devices which, when
i nst a l l e d i n t he st e a m l i ne , wi l l re m ov e m oi st ure dropl e t s a nd ot he r
suspended impurities from the steam. To do this, the separator either causes
the steam to suddenly change its direction of f lo w or else it impar ts a
whirling motion to the steam. Both of these causes the moisture and other
particles to be thrown out of the steam stream
Steam Traps
• The purpose of the steam trap is to discharge the water of condensation
from steam lines, separators and other equipment without permitting steam
to escape. In addition, most traps are designed to discharge any air present in
the lines or equipment. Steam traps should be installed in lines wherever
condensate must be drained as rapidly as it accumulates, and wherever
condensate must be recovered for heating, for hot water needs, or for return
to boilers. They are a "must" for steam piping, separators, and all steam
heated or steam operated equipment.
Piping Insulation
• Most piping systems are used to convey substances that are at temperatures
much higher than that of the surrounding air. Examples would include the
main steam piping and feedwater piping. In order to reduce the amount of
heat lost to the surrounding air from the hot substance, the piping is covered
with insulation. The insulation not only retains the heat in the hot lines but
also preve nt s t he t e m pe rat ure inside t he proce ss plant building from
becoming uncomfortably high. In addition, insulation of hot pipe lines will
prevent injury to personnel due to contact with the bare surfaces of the pipe.
• In the case of piping which carries substances at a lower temperature than that
of the surrounding air, insulating the piping will prevent sweating of the pipe and
consequent dripping and corrosion.
• Som e of t he m ore com m on m at e rials use d for piping insulat ing are t he
following:

 Diatomaceous Silica - This material is bonded with clay and asbestos and is
used for temperatures up to 1030°C

 Asbestos - Pipe covering sections are molded from asbestos f ibre and are used
for temperatures up to 650°C

 Calcium Silicate - This insulation is made from silica and lime and is suitable
for temperatures up to 650°C

 Cellular Glass - This material is glass which has been melted and foamed and
then molded into pipe covering forms. It can be used for temperatures up to
430°C
 Magnesia (85%) - This material is composed of magnesium carbonate with
asbestos f ib re. It is available in molded form for pipe covering and also is
supplied in powdered form to be mixed with water to form an insulating cement
which is used to cover pipe f it tings. Magnesia pipe covering is suitable for
service up to 315°C.

 Glass Fiber - This is glass that has been processed into f ibres and then formed
into pipe covering sections which are suitable for temperatures up to 190°C

 Plastic Foams - These are plastics that have been processed into a foam during
manufacture and then formed into pipe covering sections. They are available for
temperatures as low as -170°C and as high as 120°C.
Industrial Plant Layout
• Plant layout is the most effective physical arrangement, either existing or in
plans of indust rial facilit ie s ie arrange m e nt of m achine s, proce ssing
equipment and service departments to achieve greatest co-ordination and
efficiency of 4 M's (Men, Materials, Machines and Methods) in a plant.

• Layout problems are fundamental to every type of organization/enterprise

and are experienced in all kinds of concerns/undertakings. The adequacy of
layout affects the efficiency of subsequent operations
Industrial Plant Layout
• It is an important pre-requisite for ef ficient operations and also has a great
deal in common with many problems. Once the site of the plant has been
de ci de d, t he ne xt i m por t ant probl e m be fore t he m anage m e nt of t he
enterprise is to plan suitable layout for the plant
• Following points should be considered in designing a layout
 It should follow minimum material handling and minimum in process
inventory.

 It should be designed such way that it should utilize space properly.

 It should provide employee safety and comfort
 It should be flexible to change according to future product requirement
 Minimize production time
Types of Plant Layouts
Product Layout

• In this layout all machines, equipment and work stations are arranged
according to sequence of operation of products and closer to each other. It is
also called as Line Layout In Product Layout Raw Material is fed at one end
and Finished Product is Came Out at another end from last workstation.
Product Layout
• It is also known as line (type) layout. It implies that various operations on raw
material are performed in a sequence and the machines are placed along the
product flow line, Le, machines are arranged in the sequence in which the raw
material will be operated upon. This type of layout is preferred for continuous
production, Le..
• involving a continuous flow of in-process material towards the finished
product stage. Figure below shows a product type of layout
Process Layout
• In this layout, machines or equipment grouped and installed in one area,
according to their function. For example, lathes are installed in one area and
grinding machines are grouped in one area. It also called as functional Layout.
In t his layout , m achine s are not ar range d according t o t he ope rat ion
sequence of a product. Product or products will move in between theses work
stations according to their operation sequence. This will result in zig zag
movement of material and higher material movement compared to product
layout
Process Layout
• This functional layout is also characterized by keeping similar machines or
similar operations at one location (place). In other words, all lathes will be at
one place, all milling machines at another and so on, that is machines have
been arranged according to their functions. This type of layout is generally
employed for industries engaged in job order production and non-repetitive
kind of maintenance or manufacturing activities. Figure 6 shows a process
layout product movement
Combination Layout
• Combination layout is the combination of process layout and product layout.
In this layout advantages of both product and Process layout are obtained. In
such cases m achinery is arranged in a process layout but t he process
grouping (a group of number of similar machines) is then arranged in a
sequence to manufacture various types and sizes of products. The point to
note is that, no matter the product varies in size and type, the sequence of
operations remains same or similar.
Figure below shows a combination type of layout for manufacturing different sized gears.
Fixed Layouts
• In f ix ed Layout the Product is f ix ed or it remains Stationary at specif ic
l oca t i on a n d a l l Ma ch i n e s, Me n a n d Ma t e r i a l i s m ov e d a r ou n d i t t o
manufacture it. We can follow this layout when the product is huge. Layout by
fixed position of the product is inherent in ship building, aircraft manufacture
and big pressure vessels fabrication. In other types of layouts discussed
earlier, the product moves past stationary production equipment, whereas in
this case the reverse applies, men and equipment are moved to the material,
which remains at one place and the product is completed at that place where
the material lies.
Factors Influencing Industrial Plant Layout

 Man Factor - Safety & working conditions, skill levels, and number of workers.

 Material Factor - It includes the various input materials like raw materials,
semi- f in ished par ts and materials in process scrap, f in ished products,
packing materials, tools and other services.

 Machi ne r y Fact or - The ope rat i ng m achi ne r y i s al so one of t he m ost

important factors therefore all the information's regarding equipment and the
tools are necessary for inspection, processing and maintenance etc.
Factors Influencing Industrial Plant Layout

 Movement Factor - A good layout should ensure short moves and should
always t e nd towards com ple t ion of product . It also include s
interdepartmental movements and material handling equipment.

 Waiting Factor - Whenever material or men is stopped, waiting occurs which

costs money. Waiting includes handling cost in waiting area, money tied up
with idle material etc. Waiting may occur at the receiving point, materials in
process, between the operations etc.
Factors Influencing Industrial Plant Layout

 Service Factor - It includes the activities and facilities for personnel such as
f ir e protection, lighting, heating and ventilation etc. Services for material
such as quality control, production control, services for machinery such as
repair and maintenance and utilities liked power, fuel/gas and water supply
etc.

 Building Factor - It includes outside and inside building features, shape of

building, type of building (single or multistory) etc.
Factors Influencing Industrial Plant Layout

 Flexibility Factor - This includes consideration due to changes in material,

machinery, process, man, supporting activities and installation limitations
etc.. It means easy changing to new arrangements or it includes f le xibility
and expendability of layouts.