Piping Book2
Piping Book2
: 29040-PI-UFR-0001
Rev. : R0 Rev. : R0
INTRODUCTION TO PIPING INTRODUCTION TO PIPING
Uhde India Limited ENGINEERING Page : 1 Uhde India Limited ENGINEERING Page : 2
CONTENTS
1.0 INTRODUCTION:
Page
4.0 Piping Design Function and Size of Organisation 3 Capital cost of piping forms a large portion of the investment in the plant exceeded only by
that of major equipment. Pie Chart (Refer Annexure-1) shows the relative cost of various
material components of a plant. As can be seen from the chart, piping accounts for nearly
15% of the overall material cost. Pie Chart (Refer Annexure-2) shows the man-hour effort
that goes in to design engineering at home office for various engineering disciplines.
Normally, out of the total engineering effort covering project management, detailed
engineering, procurement, inspection and expediting, etc., 65% of the hours are required for
Annexure-1 Typical Material Cost Breakdown (Major Items) 1 Sheet detailed engineering. Out of this, 25% is required for piping engineering alone, the balance
40% accounting for civil, mechanical, electrical and instrumentation engineering.
Annexure-2 Typical Home Office Engineering Man-hour Breakdown 1 Sheet
Progress in piping engineering being very much dependent upon the feed back of equipment
Annexure-3 Typical Field Labour Cost breakdown 1 Sheet data (static and rotating) as also on control valves and other inline instruments, a close
monitoring of the schedule of orders for these equipment and follow up with vendors for data
and drawings is required to finalise Piping Plans, generate Isometrics, order bulk Piping
Material as well as Piping Speciality Items and release drawings to site for speedy
construction and thus facilitate prompt start up.
Apart from having in-depth knowledge of piping design one should have understanding of
material costs, metallurgy, piping fabrication methods and related costs to be able to provide
the most economical design. Piping design being central to detailed engineering effort,
working knowledge of other disciplines like civil, mechanical, electrical, instruments and
process engineering is required appreciate their problems / requirements and to be able to
seek the right information from them to proceed with his / her own work of piping design.
Pipes and pipelines are always subject to fluid pressures at varying temperatures. This results
in expansion and contraction of the pipes inducing stresses which get transferred to
equipment like pumps / compressors and other static equipment or rotating equipment
resulting in breakdowns. A good knowledge of structural engineering is therefore necessary
Applicable Revision:
for analysing and solving such problems. Needless to say that a thorough understanding /
Prepared: Checked: Approved: knowledge of safety codes and practices is a must for any one involved in chemical process
plant design and engineering.
Date: Date: Date: Ability to visualize in 3 dimension and infinite patience are the hallmark of a good piping
First Edition: R0 engineer. To be able to visualize piping schemes in various alternatives and choose the most
Prepared: DNL Checked: AKB Approved: RUD appropriate one is basic to good piping engineering practice. Piping engineering being a team
effort, good communication skills, good interpersonal relationship, ability to wok either as
member or as a leader of the team, be open to suggestion and application of new methods,
materials and design are important qualities that enable one to deliver quality work.
Date: Date: Date:
File Name: C-1 Server: Pune: KUMUS 207 VKO: KUMUS 209
Rev. : R0
INTRODUCTION TO PIPING
Uhde India Limited ENGINEERING Page : 3
The trend in recent years has been to develop and employ better techniques in piping design
to save time and also to improve accuracy. Computers are being extensively used to obtain
speedy solutions to more complex problems of plant design and to solve problems of stresses
in piping. Recent past has seen development of software for production of piping detail
drawings, piping isometrics, bill of material, estimation and cost control. Piping Engineer has
therefore the added responsibility in understanding and upgrading his / her knowledge on the
application of a growing number of techniques of this nature helping speedy work execution.
The most revolutionary advancement in the Piping Design in recent past had been the
concept of 3D Modelling of the Plant by using sophisticated Software such as PDMS. This
provides an opportunity to build the entire plant on soft media in a 3D environment to the last
degree of detailing, to be able to identify and rectify practically every problem related to design
and construction prior to actual commencement of erection activities at the Site.
M ajor equipments 60%
The size and scale of operations of a design engineering company does not affect either the
piping design requirements or the underlying design principles and practices. As the volume Typical
and complexity of work and the number of projects executed increase, so does the degree of M aterial Costs of
specialization increase. Piping layouts, piping specifications, detail drafting and material listing 2% M ajor Equipment
begin to emerge as functions handled by separate Specialist Groups within the department. P ai nt in g
There is little apparent similarity between piping design performed by a team of say ten 2% Commodities and
tio n
engineers from a small office and by a large company having hundreds of piping design I n s u la 8% Sub-Contracts
engineers. The job performed in both the cases is identical and has the same degree of
gs s &
relative importance to the whole project design organisation. The real difference lies in the in
i ld tu r e io n s
8%
number of projects handled by the design office. In a small office, the flow of work is such that
Instruments 5%
each project is substantially completed before the succeeding project commences. This B u ruc da t Piping 15%
requires a flexible organization with a small group, who is responsible for all aspects of St un
Fo
nts
design. In a large organisation, however, not only a large number of projects are executed
E q r ic a l
me
simultaneously but the size of the projects also vary. This requires different group of people
with a high degree of specialization for economic and administrative reasons.
ct
u ip
E le
In either case, piping design is the most lengthy and complex part of the whole design work
and almost would be on critical path of the project engineering schedule. ANNEXURE-1
in g
P ip 2 5 %
ig n
D es T ypical
H om e O ffice T ypical
E ngineering Field L abor
M ajor Instrum ents 10%
M an-hour Equipm ents 20% C osts
B reakdow n
ANNEXURE-2 ANNEXURE-3
Rev. : R0 Rev. : R0
PIPING DESIGN IN DETAILED PIPING DESIGN IN DETAILED
Uhde India Limited ENGINEERING Page : 1 Uhde India Limited ENGINEERING Page : 2
CONTENTS
1.0 INTRODUCTION:
Page
0.0 Cover Sheet 1 Any process can be divided into a number of unit operations. In a chemical process, unit
operations could include mixing, reaction, distillation, evaporation, drying, etc. In a mechanical
1.0 Introduction 2 process, unit operations would include cutting, machining, milling, grinding, fitting, welding,
etc. Similar divisions can be done in other branches of the engineering/ manufacturing.
2.0 Major Inputs for Piping Design 2 Piping forms major portion of Chemical Process Plants including petroleum refineries,
petrochemicals, pharmaceuticals involving both process piping and utility piping. In other
3.0 Interface with other Design Groups 2–4 processes, piping requirement may be limited to utilities only and the Piping Engineer will be
involved only to that extent.
The first document that will be required by the piping engineer to kick off his work would be
the Process Flow Diagram (PFD) along with approximate size of the process equipment and
utility packages. These are to be provided by the process engineer. Armed with this
information, piping department prepares a rough plant layout indicating the position of units
and utility packages. This becomes the basic document for developing the overall site plan.
In the meantime, the process department develops the piping and instrumentation diagram
(P&ID). The P&ID contains all the critical information required for piping and instrumentation
design. Piping department is required to use this along with the PFD and make study layouts
so that equipment, control stations and all other major items can be located properly.
Process department also prepares process data sheets for equipment and provides them to
Mechanical department. Mechanical department works out the load of each and every
equipment – static, dynamic, empty, full of fluid, operating weight etc. and indicates the type of
support required for each and every item. This data is provided by Mechanical department to
Piping department.
Piping department prepares plot plans indicating the load of each equipment and also the
Date: Date: Date: piping load. Equipment loading is provided by Mechanical department while the piping loads
First Edition: R0 are worked out by the Piping department themselves. Piping department also collects
Prepared: DNL Checked: AKB Approved: RUD information from Electrical and Instruments departments regarding the loads of their
equipment.
Civil engineering department prepares all the civil information / scope drawings as well as
detailed construction drawings. Piping department has to indicate the size and position of
Date: Date: Date:
pedestals, insert plates, floor openings and other requirements on the civil information
File Name: C-2 Server: Pune: KUMUS 207 VKO: KUMUS 209 drawings. Civil information drawing would thus indicate all the requirement of piping and
equipment erection. Many a time, a wall is required to be constructed after the erection of an
Directory: Pune: Refer\Pi\Training Manual VKO: Refer\Training Manual equipment.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0002 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0002
Rev. : R0 Rev. : R0
PIPING DESIGN IN DETAILED PIPING DESIGN IN DETAILED
Uhde India Limited ENGINEERING Page : 3 Uhde India Limited ENGINEERING Page : 4
Piping department is required to furnish the clear height required between each and every The final design is reviewed by all groups together (i.e. Process, Instrument, Electrical, Civil
floor in order to enable Civil department to design columns and beams. and Piping) on the Completed model. Owing to the unique 3D Space simulation it becomes
possible to anticipate various problems (maintenance/ operation/ erection) much before the
Civil drawings are to be checked once again by Piping department in order to ensure that no commencement of actual Plant installation at site. The solutions thus obtained are error free
loose ends are left and all the requirements are met. The civil construction drawings are in totality.
issued only after Piping gives clearance. It may be noted that each and every activity is
sequential and is centred around piping.
The next activity of the Piping department is to issue the nozzle orientation to Mechanical
department. This activity requires close co-ordination by the Piping department with Process
and Instrumentation departments. Nozzle orientation and elevation, support location,
insulation, cleat orientation, ladder, platform are some of the items to be covered in the nozzle
orientation sheet. Once nozzle orientation is provided, Mechanical part is complete and the
vessel is cleared in all respects for fabrication.
One of the most important areas of interaction with instruments department is on the hook-up
points. The battery limits concerning the scope of Instruments and Piping is to be clearly
marked in the drawing. This is to avoid either duplication or short ordering of material by the
Piping and Instrument departments.
Piping plan has to incorporate all the civil structures as well as electrical and instrument cable
trays in order to clearly show the non-interference with pipes and pipe supports. The other
important area is the rack piping. Rack distribution diagrams are made and loading of pipes
and cables are provided to the Civil department. Road crossings, change of direction of pipes
in the racks, movement of cranes are some of the important issues to be considered. Quite
often the data would be required from various departments at the same time and the Piping
engineer has to be well aware of this so that design does not proceed with incomplete
information.
Piping plans are to be issued to Process department for them to check and confirm that all the
requirements P&ID are met in these piping drawings.
Piping engineers prepare piping specifications based on the fluid list data provided by the
Process department. Piping specification and Bill of Material are issued to Procurement
department for procurement purposes.
Piping department prepares isometrics, which are to be provided to the fabricator for pipe
fabrication. Piping plans, isometrics, Bill of Material are issued to the Erection department to
facilitate fabrication and erection through erection contractors.
3D Design Approach:
As per the new concept of 3D Design the Plant is modelled on the Electronic Platform (by
using modern software such as PDMS) to the last degree of detailing prior to actual
commencement of erection at site.
This provides a unique opportunity to eliminate every possible interface problem amongst
various Groups involved in the design activities. In order to avoid communication gaps every
Group participates in building/ updating the model (portion related to their scope of work). For
instance the static equipment by Mechanical Group, structures and civil foundations by Civil
Group etc. PI Group naturally plays a central role in ensuring a proper co-ordination amongst
various groups during the progress of detailed engineering which, is incorporated in the above
3D Plant Model on regular basis.
The changes/ additions as a result of design progress, are jointly reviewed by various Groups
on the 3D Model to identify the consequential effects of these changes on their part of
engineering.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0003 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0003
Rev. : R0 Rev. : R0
INTRODUCTION TO OTHER BRANCHES OF INTRODUCTION TO OTHER BRANCHES OF
ENGINEERING ENGINEERING
Uhde India Limited Page : 1 Uhde India Limited Page : 2
1.0 INTRODUCTION:
CONTENTS
Since piping engineering is central to detail engineering activity and the piping engineer more
Page or less acts as the chief co-ordinator, a good grasp of the working and requirement of the
other engineering disciplines is essential for successfully delivering quality detailed
0.0 Cover Sheet 1 engineering within the allotted time. Let us briefly discuss the issues concerning the piping
engineer and knowledge level required in other branches of engineering to discharge his
1.0 Introduction 2 duties.
Many a time gravity flow lines are not clearly shown and unless the process is fully
understood, it may be difficult to route them at the correct elevation. Where gravity flow lines
are shown, piping has to ensure that there is no loop in the circuit and if provision of a loop
becomes unavoidable, one has to ensure that the outlet nozzle of the tank from which the
fluid flows, is always at a higher elevation than the inlet nozzle of the tank in to which the fluid
flows. Wherever there is separator of two miscible liquids, the bottom liquid is removed
through a siphon and the siphon height should be shown on the P&ID. In gas lines,
connection must be taken from the top and must be clearly indicated on the P&ID.
Concerning heat exchangers, co-current or counter-current, P&ID must match with equipment
data sheet.
Simple details like vents of safety valves, flare height etc. as shown in the P&ID has to be
checked by piping to ensure that they are practicable and conform to the standards.
Utility requirement at different consumer points must be clearly indicated, as the utility flow
distribution chart is to be prepared by the Piping Department.
Acid proof tiling or requirement of a special floor finish should be reflected in the P&ID.
Applicable Revision: Wherever acid or corrosive chemicals are used appropriate chemical resistant tiling should be
Prepared: Checked: Approved: considered in all such area where the acid / chemical is likely to come in contact with.
Date: Date: Date: Wherever glass lined equipment are shown in P&ID, care must be taken to ensure that the
First Edition: R0 temperature differential is within the specified limits as otherwise the vessel can get damaged.
Prepared: DNL Checked: AKB Approved: RUD A base understanding of the process can help avoiding any such eventuality.
In all the Process & Instrument Diagrams, the process department gives the line size, fluid
media and material of construction. Further filling up of P&ID, line list etc. is carried out by the
Date: Date: Date: piping group. A thorough study of the process can help in the proper selection of rating for
File Name: C-3 Server: Pune : KUMUS 207 VKO: KUMUS 209 components and help reduce the overall cost of the project.
Rev. : R0 Rev. : R0
INTRODUCTION TO OTHER BRANCHES OF INTRODUCTION TO OTHER BRANCHES OF
ENGINEERING ENGINEERING
Uhde India Limited Page : 3 Uhde India Limited Page : 4
Many a time, the process department would indicate on the P&ID, gravity flow lines with the Piping/ Mechanical:
maximum number of bends permitted. Piping Engineer must make every effort to reduce the
number of bends without affecting the aesthetic appearance of the piping scheme. • Nozzle Index and Nozzle Orientation.
• Foundation Bolt details and orientation.
The other important aspect to be noted in the P&ID, are the Symbols. The Symbols used • Platforms Cleats on Equipment – its orientation and levels etc.
must be of international Standard so that there is no confusion in understanding or reading a
P&ID. A good knowledge of fluid flow and understanding of pressure drop is very useful.
Piping/ Process:
Piping Engineer should have a fairly good idea about sizing of equipment, various codes and Piping/ Project Management:
engineering practices, stress and strain theory and such other basic principles. This is
required, as many a times, he has to check vendor drawings and clear them for fabrication • Finalization of Master Plot Plan after getting clearance/ agreement with Licensor, Client,
with the help of the Mechanical Engineer. Statutory Bodies etc.
• Finalization of Procurement Philosophy/ Spare Philosophy with Client
A basic knowledge of metallurgy is required. This will help the Piping Engineer in analyzing • Monitoring of Project Schedule and updating the month wise activity and follow-up/ co-
the reasons for selection of particular material of construction for pipes and piping items vis-a- ordination with Client, Vendor and Licensor.
vis the fluids that are required to be handled by them. Knowledge of metallurgy makes it • Progress Report/ Constraint Report.
easier to understand why code specifies certain heat treatment requirements and why quite
often a higher corrosion allowance is provided.
Piping/ Electrical:
The other branch of engineering where a lot of close co-ordination is required is Civil
Engineering. Knowledge of columns, beams and other structural items / details help in • Finalization of Cable Tray Layout and requirement of Insert Plates on RCC Column/
fulfilling the requirements of piping in an effective manner. Requirements of insert plates, Beam, Floor opening for Cables etc.
culverts and drains, pipe bridges or sleepers and other requirements are indicated by piping. • Cable connection/ Push Button supports near the Terminal Box of all motors.
Similarly, floor finish or slopes in the right direction etc,. are indicated by the Piping • Finalization of location of Switchboards, Lighting Fixtures floor wise.
department.
Piping/ Instruments:
4.0 INTERFACE WITH OTHER DEPARTMENTS:
• Review of IC comments on the PID revision due to change in any instrument.
The following are the highlights of the major activities where interdepartmental discussions • Finalization of Instrumentation GES regarding connection details of Instruments and
are necessary before the documents are released for execution. delineation of scope of procurement between PI and IC.
• Details of Instrument mountings/ dimensions.
• Review of approved Vendor Drawings for Instruments with respect to Isometrics (released
Piping / Civil:
for construction) as well as the piping arrangement around the Instrument.
• Finalization of IC Cable Tray requirement.
• Civil Skeleton/ Civil Information Drawings of Units, Pipe Rack and Tank Farms.
• Review of field routed instrument Cable Trays, keeping provision of accessibility, free
• Civil Drawing review/ release for construction.
space and interference with piping arrangement.
• Release of HOLDS at subsequent dates.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0004 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0004
Rev. : R0 Rev. : R0
INDUCED STRESSES IN PIPE INDUCED STRESSES IN PIPE
Uhde India Limited Page : 1 Uhde India Limited Page : 2
CONTENTS
Page
1.0 INTRODUCTION:
0.0 Cover Sheet 1
When the ends of the pipe ends are closed and pipe is subjected to an internal pressure ‘P’
1.0 Introduction 2 following stresses would act on each element of the pipe.
The effect of this may split the pipe into two halves as shown in fig.2. The failure of the pipe in two
halves in fact is possible across any plane, which contain diameter and axis of the pipe. Elements
resisting this type of failure would be subjected to stress and direction of this stress is along the
circumference. Hence the above stress is called Circumferential or Hoop Stress.
If -
Then
= P×D×L
Equating FB & FR
P × D × L = 2t × L × σH
Applicable Revision:
Prepared: Checked: Approved:
∴ t = P*D
2 * σH
Date: Date: Date:
First Edition: R0
or σH = P*D (1)
Prepared: DNL Checked: AKB Approved: RUD
2*t
Rev. : R0 Rev. : R0
INDUCED STRESSES IN PIPE INDUCED STRESSES IN PIPE
Uhde India Limited Page : 3 Uhde India Limited Page : 4
Considering that the pipe ends are chlsed and pipe is subjected to an internal pressure ‘P’ the
pipe may fail as shown in Fig.3. Elements resisting this type of failure would be subjected to stress
and direction of this stress is parrallel to the longitudinal direction of the pipe. Hence this stress is
called longitudinal stress.
Then
Equating FB & FR
2
P * ΠD = π D t * σL
4
∴ t = PD
4 * σL
or σL = PD (2)
4*t
NOTES:
1) On comparing equations 1 & 2, it is clear that when a pipe having diameter ‘D’ and thickness ‘t’
is subjected to an internal pressure ‘P’, the induced circumferential tress is double the induced
longitudinal stress.
Each element of the pipe is subjected to radial stress which acts in radial direction.
σR = P
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 1 Uhde India Limited CODES AND STANDARDS Page : 2
CONTENTS
The Piping System involves pipes, pipe fittings, valves and specialities. These are collectively
Page termed as ‘Piping elements’. Main items are as under :
• Valves
• Specialities
The basic material of construction is specified by Process Licenser / Process Engineer for all
process fluids depending upon,
• Nature of Service.
The Piping design criteria originates from medium list (process line list), which gives normal
and design conditions with respect to pressure and temperature, pipe size and material.
Applicable Revision: R1
Prepared: NNG Checked: AKB Approved: RUD
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 3 Uhde India Limited CODES AND STANDARDS Page : 4
• The design should meet the requirements of relevant piping design standards of ANSI /
2.0 PIPING ELEMENTS: ASME or BSI.
• The material used shall be in accordance with latest revisions of standards. If ASTM
materials are suggested, materials adapted by ASME / ANSI are preferred.
CLASSIFICATION BASED ON MATERIAL OF CONSTRUCTION
• Carbon Steel shall be used upto 425° C.
METALLIC NON-METALLIC LINED • Low temperature Steel shall be used below 20° C.
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 5 Uhde India Limited CODES AND STANDARDS Page : 6
Standard thickness of pipes are specified by schedule numbers. In American National Standard, material standards are covered under ASTM (American
Society of Testing Materials) and dimensional standard under ANSI (American National
Stainless steel pipe schedules as per ASME B 36. 19 are 5 S, 10 S, 40 S, 80 S. Standard Institute). Most of these Standards are adapted by ASME (American Society of
Carbon steel pipe schedules a per ASME B 36.10 are 10, 20, 30, 40, 60, 80, 100,120, 140,
160. Mechanical Engineers) and are specified alongwith.
Carbon steel pipes are specified as STD, XS and XXS. The American Standards referred by Piping Engineers are mainly the standards given below:
Normally the thickness of Carbon Steel and Stainless Steel pipes for same schedule number • American Petroleum Institute ( API ).
matches except as under : • The American Iron and Steel Institute ( AISI ).
• The American National Standard Institute ( ANSI ).
10” SCH80 / SCH80S • The American Society of Testing Materials ( ASTM ).
12” SCH40 / SCH40S • The American Welding Institute ( AWS ).
12” SCH80 / SCH80S • The American Water Works Association ( AWWA ).
14” SCH10 / SCH10S • The Manufacturers Standardization Society of Valves and Fitting Industry - Standard
16” SCH10 / SCH10S Practices MSS - SP )
18” SCH10 / SCH10S • The American Society of Mechanical Engineer (ASME)
20” SCH10 / SCH10S
22” SCH10 / SCH10S
4.1 API STANDARDS :
The pipes are normally available in standard length of 20 ft.( 6 m ).
The generally referred API Standard by the Piping Engineers are :
Type of Pipe based on Pipe Ends
API 5L - Specification for line pipe.
• Bevelled Ends. API 6D - Pipe line valves, end closures, connectors and swivels.
• Plain Ends API 6F - Recommended practice for fire test for valves.
API 598 - Valves inspection and test. R1
• Screwed Ends.
API 600 - Steel Gate Valves.
• Flanged Ends.
API 602 - Compact Design Carbon Steel Gate Valves for Refinery use.
• Spigot / Socket Ends ( lead cock joint ). API 607 - Fire test for soft seated ball valves.
API 609 - Butterfly valves
API 1104 - Standard for welding pipe line and related facilities.
Type of Pipes Based on Manufacture
• Welded. The American Iron and Steel Institute Standards specifies the material by its chemical and
Electric Resistance Welded ( ERW). physical properties. When specific model of manufacture of the element is not to be specified,
Electric Fusion Welded ( EFW ). then the material can be identified by the AISI standards. The most commonly used ANSI
Spiral Welded. specifications are:
Furnace Butt Welded.
Double Submerged Arc Welded.
AISI 410 - 13 % Chromium Alloy Steel
Forged and Bored.
AISI 304 - 18 / 8 Austenitic Stainless Steel.
For scientific design of the piping systems, selection of proper material of construction and to
detail out the material specification, knowledge of codes and standards are essential. Each
country has its own codes and standards. On global basis, American National Standards is
undoubtedly the most widely used code and compliance with its requirements is accepted all
over. Other than the American Standards, British Standards and Indian Standards are also
used for the design and selection of piping system.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 7 Uhde India Limited CODES AND STANDARDS Page : 8
4.3 ASME STANDARDS: ASME B 36.10 - Welded and seamless wrought steel pipes.
ASME B 16.1 - Cast iron pipe flanges and flanged fittings. STANDARD PIPE MATERIAL SPECIFICATION:
ASME B 16.11 - Forged steel socket welding and threaded fittings. ATM A134 Electric Fusion Welded Steel Plate Pipe (Sizes > 16” NB).
ASME B 16.20 - Ring joint gaskets and grooves for pipe flanges. ATM A135 Electric Resistance Welded Pipe
ASME B 16.21 - Non metallic gasket for pipe flanges. ASTM A139 Electric Fusion Welded Steel Plate Pipe ( Size > 4” NB).
ASME B 16.25 - Butt welding ends. ASTM A155 Electric Fusion Welded Steel Pipe for High Pressure Service.
ASME B 16.28 - Short radius elbows and 180 Degree returns ASTM A211 Spiral Welded Steel Pipe.
ASME B 16.47 - Large Diameter steel Flanges R1 ATM A312 Seamless and Welded Austenitic Stainless Steel Pipes.
ASME B 16.34 - Steel valves, flanged and butt welding ends. ASTM A333 Seamless and Welded Steel Pipe for Low Temperature Service.
ASME B 18.2 - Square and hexagonal head bolts and nuts. ASTM A335 Seamless Ferritic Alloy Steel Pipe for High Temperature Service.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0005
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 9 Uhde India Limited CODES AND STANDARDS Page : 10
END CONNECTIONS
ASTM A376 Seamless Austenitic Steel Pipe for High Temperature Central
Station Service.
SOCKET WELD SCREWED BUTT WELD FLANGED SPIGOT/SOCKET
ASTM A381 Metal Arc Welded Steel Pipe for High Pressure Transmission
Systems. TYPES
ASTM A405 Seamless Ferritic Alloy Steel Pipe Specially heat treated for high
temperature service.
BENDS TEES CAPS REDUCERS STUB COUPLINGS SWAGE UNIONS SPECIAL
ASTM A409 Welded Large Diameter Austenitic Steel Pipe for Corrosive or ENDS NIPPLE FITTINGS ( ‘Olets)
High temperature service.
ASTM A430 Austenitic Steel Forged And Bored Pipe for high temperature
service. 450 900 CONCENTRIC ECCENTRIC
ELBOW ELBOW REDUCERS REDUCERS
ASTM A451 Centrifugally Cast Austenitic Steel Pipe for High temperature
service.
FULL HALF REDUCING
COUPLINGS COUPLINGS COUPLINGS
ATM A452 Centrifugally Cast Austenitic Steel Wrought Pipe for High
S.R.ELBOW L.R.ELBOW
temperature service.
ASTM A524 Seamless Carbon Steel Pipe for Atmospheric and low
temperature service. LATROLET WELDOLET ELBOWLET THREADOLET SWEEPOLET NIPPOLET
SOCKOLET
ASTM A587 Electric Welded Low Centrifugally Cast Carbon Steel Pipe for
high temperature service. ( Sizes ≤ 4” NB ). CLASSIFICATION BASED ON END CONNECTIONS:
ASTM A660 Centrifugally Cast Carbon Steel Pipe for High temperature
Socket Welded/ Screwed Fitting
service
Classification based on the maximum cold non-shock working pressure.
ASTM A671 Electric Fusion Welded Steel Pipe for Atmospheric and low
temperatures ( Sizes ≥ 16” NB ).
• 2000 # Class - only in 16.11 for SCRD fittings
ASTM A672 Electric Fusion Welded Steel Pipe for High pressure service at • 3000 # Class
moderate temperatures ( Sizes ≥ 16” NB ). • 6000 # Class
ASTM A691 Carbon and Alloy Steel Pipe, Electric Fusion Welded for High
pressure service at High temperatures. ( Sizes ≥ 16” NB ).
ASTM A780 Seamless and Welded Ferritic / Austenitic Stainless Steel Pipe.
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PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
Uhde India Limited CODES AND STANDARDS Page : 11 Uhde India Limited CODES AND STANDARDS Page : 12
SOCKET WELD / SCREWED AS PER STD. ASTM MATERIAL SPECIFICATIONS TYPES OF FITTINGS:
Elbow
ASTM A105 Carbon steel forgings for piping Components
• L.R. Elbows.
ASTM A181 Carbon Steel forgings for general Purpose • S.R. Elbows.
• Pulled Bends.
ASTM A182 Alloy Steel forgings for High Temperature Services • Fabricated Bends.
ASTM A234 Wrought carbon steel and alloy steel pipe fittings for
moderate and elevated temperatures.
Tee
ASTM A350 Carbon steel and low alloy steel forgings for pipe
components • Forged Tees
• Fabricated Tees
• Stub Connections
Bevelled Weld Fittings
Minimum size standard reduction Tee / Reducer available is the lower size lower size of
Classification is based on corresponding pipe thickness (Major Size / 2).
ASTM A234 Wrought carbon steel and alloy steel pipe fittings for moderate • Concentric Reducers
& elevated temperatures. • Eccentric Reducers
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PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
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The American Water Works association (AWWA) standards refer to the piping elements
required for low pressure water services. These are less stringent than other standards. BS 806 - pipes and fittings for boilers
Valves, flanges, etc. required for large diameter water pipelines are covered under this
standard and are referred rarely by piping engineers here. BS 916 - black bolts, nuts and screws
Rev. : R1 Rev. : R1
PIPING ELEMENTS – SPECIFICATION, PIPING ELEMENTS – SPECIFICATION,
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Bureau of Indian Standards ( BIS ) have so far not developed an Indian Standard for the IS - 6392 - Steel pipe flanges.
design of piping systems. Hence, ASME standards B 31.1/31.3 are widely referred for the
design. These standards also accept materials covered in other standards as well. Unlike IS - 7240 - Code of practice for cold insulation.
American Standard, Indian Standards cover dimensions and material specifications under
the same standard number. There are no groupings also done based on the series/ Branch of IS - 7413 - Code of practice for hot insulation.
engineering as well. Some of the most commonly referred Indian standards by the piping
engineering are : IS - 8008 - HDPE Fittings.
IS - 780 - Specification for sluice valves-up to 300 NB Periodic review of the standards by the committee are held and these are revised to
incorporate the modified features based on the results of research and feed back from the
IS - 1239 - Part I & II specification for pipe and pipe fittings. industry. Hence, it is necessary that the latest editions of the codes and standards are
referred for the design and year of publication also to be indicated alongwith.
IS - 1364 - Bolts and Nuts.
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PIPE DESIGN PIPE DESIGN
Uhde India Limited Page : 1 Uhde India Limited Page : 2
CONTENTS
Page
1.0 General 2
The following method is issued for metallic pipes to calculate the wall thickness. The following
2.0 Thickness Calculation as per ASME B 31.3 2–3 parameter are to be known:
The required thickness of straight sections of pipe as per ASME B 31.3 is given by
tm = t + c
where,
If ‘T’ is the Nominal pipe wall thickness then, T ≥ tm + Manufacturer’s negative tolerance.
As per code,
where,
Date: Date: Date: E = Quality factor (Longitudinal weld joint efficiency for
First Edition: R0 pipe)
Prepared: DNL Checked: AKB Approved: RUD
Y = Coefficient as per Table - I, valid for t < D/6 and for
materials shown. The value of Y (dimensionless factor varying with
temperature) may be interpolated for intermediate temperatures.
Date: Date: Date:
File Name: C-6 Server: PUNE: KUMUS 207 VKO: KUMUS 209 d = Inside diameter of pipe.
Rev. : R0 Rev. : R0
PIPE DESIGN PIPE DESIGN
Uhde India Limited Page : 3 Uhde India Limited Page : 4
TABLE - 1
Allowable stress values for different ASTM pipe materials at various temperature are listed
TEMPERATURE °F under Table A1 ASME B 31.3 (Appendix A)
Formulae as given are applicable for t ≤ D/6, which in fact is the usual case. If the pipes are to be used for making bends, then it may be necessary to increase the
However, for t ≥ D/6 or for P / SE > 0.385, calculation of pressure design thickness for thickness ‘tm’ by a factor called bend thinning allowance. During bending the outer fibres get
metallic straight pipe requires special consideration of factors such as theory of failure, effect stretched and in order to maintain minimum wall thickness ‘tm’ at all point in a completed
of fatigue and thermal stress. bend, one has to add allowance for thinning.
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PIPE DESIGN PIPE DESIGN
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Unless the material is very costly, we usually decide minimum thickness for various pipe sizes
at the initial stage of the project on structural rigidity criteria.
Flattening of a bend, the difference between maximum and minimum diameters at any cross
section, shall not exceed 8% of nominal outside diameter for internal pressure. Following minimum thickness excluding corrosion allowance are recommended.
Following Bend thinning factors are recommended (refer Table C-4.5 “ Pipe Thickness for
th
bends” – Piping Handbook 7 Edition by M. L. Nayyor). Pipe Size Minimum Thickness
1/2” to 4” 0.06”
5” to 12” 0.09”
Radius of Pipe Bend Min. THK. recommended prior to bending 14” to 24” 0.12”
Some times we may arrive at a very low thickness which is adequate to sustain pressure - • Confirm that the standard manufacturing tolerance will not reduce the minimum
temperature conditions given but such pipes if used will not have enough structural rigidity calculated wall thickness or selected nominal wall thickness in the steps above.
and may get deformed even during handling. These pipes if used would require careful
handling and closer supports. • Confirm that the inside diameter of the pipe based on the selected nominal wall thickness
is compatible with the required inside diameter based on the fluid flow evaluation.
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ELBOWS ELBOWS
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CONTENTS
1.0 GENERAL :
Page
0.0 Cover Sheet 1 Elbows are used for changing direction in piping system.
2.0 Socket Welded Elbows 3–4 An elbow angle is defined as an angle by which the flow direction deviates from its original
direction.
3.0 Butt Welded Elbows 4–6
As shown in Figure - 1 & 2, the flow deviates by an angle θ from its original direction and
4.0 Screwed Elbows 6–7 hence elbow angle in this case is θ.
5.0 Flanged Elbows 7 An elbow angle can be anything greater than 0 but less or equal to 90°. A change in direction
greater than 90° at a single point is not desirable. Usually, we use 45° and 90° elbows while
6.0 Mitre Elbows 7-8 making piping layouts.
7.0 Sketch showing various elbow profiles 9 Refer Fig. - 3. Pipe direction is changing at point A using an elbow and again the direction is
changing at point G using another elbow.
In order to work out elbow angle at A, it is essential to consider a plane which contains arms
of the elbow. If there had been no change in direction at point A, the pipe would have moved
along line AD but pipe is moving along line AG. Plane AFGD contains lines AD and AG and
elbow angle θ is marked which denotes the angle by which the flow is deviating from its
original direction.
Elbow Radius :
For a smooth change in direction, elbows or bends are available in various radii. These radii
are expressed in terms of pipe nominal size expressed in inches. Elbows are available in two
radii,
Applicable Revision:
Prepared: Checked: Approved: a. Long radius elbows (Radius = 1.5D)
b. Short radius elbows (Radius = 1.0D)
where D is nominal pipe size in inches.
Date: Date: Date:
First Edition: R0
Prepared: DNL Checked: AKB Approved: RUD For radius more than 1.5D, pipe bends are used and these can be made to any radius.
However, 3D & 5D pipe bends are most commonly used. Usually in chemical, petrochemical
& refinery plants, long radius elbows are widely used. Pipe bends are preferred where
pressure drop is of a major consideration. Use of short radius elbows should be avoided as
Date: Date: Date: far as possible due to abrupt change in direction causing high pressure drop.
File Name: C-7 Server: PUNE: KUMUS 207 VKO: KUMUS 209
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ASTM A350 (Forged carbon and low alloy steel fittings for low temperature services)
End Connections :
The following type of end connections are available for connecting elbow/bend to pipe. Under ASTM A350, several grades are available depending upon chemical composition &
tensile properties.
• Socket welded
• Butt welded • Fittings comforming to ASME B16.11 are designated as Pressure class 2000, 3000 and
• Screwed 6000 fittings for threaded and Pressure class 3000, 6000 and 9000 for socket welded
• Flanged ends.
This designation identified the fittings with their ratings as shown below:
2.0 SOCKETED WELDED ELBOWS: (Refer Table 2, ASME B 16.11)
• Pipe is connected to socket welded elbow as shown in Fig. - 5, by having a fillet weld. Pressure Type Pipe used for
Class Rating Basis
• Socket welded elbows are available upto 2” nominal size. However, in UIL, our practice is Schedule No.
1
to use these elbows upto 1 /2” size only. / Wall
designation
• Dimensions of socket welded elbows are as per ASME B16.11 2000 Threaded 80 / (XS)
• Since there is possibility of fluid getting entrapped between pipe O.D and socket I.D., this 3000 Threaded 160 / --
may cause corrosion called crevice corrosion. Thus use of socket welded fittings should
be avoided for services where corrosion/erosion is of great concern. 6000 Threaded
-- / XXS
• Fillet welds are examined by using liquid dye penetrant or Magnetic particle inspection 3000 Socket-Welding 80 / (XS)
method. No radiography is possible for checking soundness of these welds.
6000 Socket-Welding 160 / --
• Since socket welded joints can not be radiographed, these fittings are not recommended
for critical services handling hazardous or highly inflammable fluids. For such services 9000 Socket-Welding -- / XXS
butt welded fittings are preferred.
• Socket welded fittings are forged and applicable material standards are as follows:
The above does not restrict the use of pipe of thinner or thicker wall with fittings. However,
when thinner pipe is used, its strength may govern and when thicker pipe is used, the strength
ASTM A105 (Forged Carbon Steel) of the fitting governs the rating.
These fittings are suitable for welding to all carbon steel pipes.
3.0 BUTT WELDED ELBOWS:
ASTM A182 (Forged Alloy Steel and Stainless Steel Fittings)
• Pipe is connected to butt welded elbow as shown in Fig. 6 by having a butt-welding joint.
Under ASTM A182 several grades are available depending upon chemical composition.
Selection would depend upon pipe material connected to these fittings. Fitting material should • Butt welded fittings are supplied with bevel ends suitable for welding to pipe. It is
have same chemical composition as that of pipe. important to indicate connected pipe thickness schedule while ordering. All edge
preparations for butt welding to conform to ASME B16.25.
Some of the grades available under ASTM A182 and corresponding connected pipe material
specification are listed below: • Dimensions of butt welded elbows are as per ASME B16.9. This standard is applicable for
carbon steel & alloy steel butt weld fittings of NPS 1/2” through 48”
GRADE PIPE MATERIAL SPEC • Dimensions of stainless steel butt welded fittings are as per MSS-SP-43. Physical
dimensions for fittings are identical under ASME B16.9 and MSS-SP-43. It is implied that
F 11 : ASTM A335 P11 the scope of ASME B16.9 deals primarily with the wall thicknesses which are common to
F 22 : ASTM A335 P22 carbon and low alloy steel piping, whereas MSS-SP-43 deals specifically with schedule
F304 : ASTM A312 Gr.TP 304 5S & 10S in stainless steel piping.
F304L : ASTM A312 TP 304L
F316 : ASTM A312 TP 316 • Dimensions for short radius elbows are as per ASME B16.28 in case of carbon steel &
F321 : ASTM A316 TP321 low alloy steel and MSS-SP-59 for stainless steel.
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• Butt welded fittings are usually used for sizes 2” & above. However, for smaller sizes up to
1
1 /2” on critical lines where use of socket welded joints is prohibited, pipe bends are used. available under this specification and corresponding connected pipe material specification are
These bends are usually of 5D radius and made at site by cold bending of pipe. listed below:
Alternatively, butt welded elbows can be used in lieu of pipe bends but usually smaller dia
lines are field routed and it is not possible to have the requirement known at initial stage
of the project for procurement purpose. So pipe bends are preferred. However, pipe GRADE PIPE MATERIAL SPEC
bends do occupy more space and particularly in pharmaceutical plants where major
portion of piping is of small dia. and layout is congested, butt welded elbows are WP 304 WP 304S :
preferred. WP304W : ASTM A312 TP304
WP304WX :
• Butt welded joints can be radiographed and hence preferred for all critical services.
CR 304
• Material standards as applicable to butt welded fittings are as follows:
WP 304L WP304LS :
ASTM A234: WP304LW : ASTM A312 TP304L
WP304LWS :
This specification covers wrought carbon steel and alloy steel fittings of seamless and welded
construction. Unless seamless or welded construction is specified in order, either may be CR 304L
furnished at the option of the supplier. All welded construction fittings as per this standard are
supplied with 100% radiography. Under ASTM A234, several grades are available depending
upon chemical composition. Selection would depend upon pipe material connected to these ASTM A420:
fittings.
• This specification covers wrought carbon steel and alloy steel fittings of seamless &
Some of the grades available under this specification and corresponding connected pipe welded construction intended for use at low temperatures. It covers four grades WPL6,
material specification are listed below: WPL9, WPL3 & WPL8 depending upon chemical composition. Fittings WPL6 are impact
tested at temp - 50° C, WPL9 at -75° C, WPL3 at -100° C and WPL8 at -195° C
GRADE PIPE MATERIAL SPEC temperature.
WPB : ASTM A53 Gr A/B, A106 Gr A/B • The allowable pressure ratings for fittings may be calculated as for straight seamless pipe
IS 1239, IS 1978, IS 3589 in accordance with the rules established in the applicable section of ASME B31.3.
WPC : ASTM A106 Gr.C
WP11 : ASTM A335 P11 • The pipe wall thickness and material type shall be that with which the fittings have been
WP22 : ASTM A335 P22 ordered to be used, their identity on the fittings is in lieu of pressure rating markings.
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• Usually effective radius of mitre-bend, defined as the shortest distance from the pipe
• Sometimes, seal welding is done for screwed joints in order to avoid leakage. However centre line to the intersection of the planes of adjacent mitre joints is 1.5D where D is the
screwed connection at instruments shall not be seal welded. nominal pipe size in inches. However, one can select any other radius if called for.
• Pipe threads are usually as per IS554 taper. • It is recommended to fabricate mitre bends after knowing length of Arm-1 & Arm-2 up to
next weld (Refer Fig. 7). So as to avoid two additional welds.
5.0 FLANGED ELBOWS: • Because of high stress intensification factor they are not recommended on high
temperature lines.
• Usually flanged elbows are used on cast-iron piping. Cast steel flanged elbows with liner • Pressure-temperature rating for mitre bend is not the same as for pipe and in order to
are used to some extent for lined piping such as carbon steel-PTFE lined (Refer chapter withstand same pressure-temperature conditions as applicable to pipe, a higher thickness
on lined-piping) is required for mitre bend.
As per ASME B31.3 (Cl. 304.2.3), the maximum allowable internal pressure shall be the
• Following standards are usually adopted for flanged elbows & other fittings: lesser value calculated from equation given below :
ASME B16.1 (Cast Iron Pipe Flanges and Flanged Fittings; Classes 25,125 and 250) These equations are not applicable when θ exceeds 22.5°
• The minimum material requirements for flanged cast iron fittings shall be as follows: where Pm = Maximum allowable internal pressure for mitre bend.
T = Minimum Miter Pipe wall thickness.
C = Sum of mechanical & corrosion allowances.
Rating Size Class of Iron R1 = Effective radius of mitre bend.
r2 = Mean radius of pipe using nominal wall thickness.
25 All ASTM A126 Class A S = Allowable stress of material at the given temperature.
125 1” - 12” ASTM A126 Class A or B E = Quality factor as applicable to pipe used for mitre bend.
1
125 14” & above ASTM A126 Class B θ = Angle of mitre cut or /2 the angle of change in direction at
mitre joint.
250 1” - 12” ASTM A126 Class A or B
250 14” & above ASTM A126 Class B
Thickness ‘T’ used in above equations shall extend a distance not less than ‘M’ from the
inside crotch of the end mitre welds where,
0.5
M = larger of 2.5 (r2 × T) or tan θ (R1 - r2).
The equivalent IS material usually used is IS 210 Gr. 220.
Usually extra thickness is available in pipe used for low pressure services and it is
possible to use the same pipe for making mitre bends. However a check is always required.
6.0 MITRE ELBOWS :
• An angular offset of 3° or less does not require design consideration as a mitre bend.
• These are usually used for low pressure, low temperature non critical services having 14”
inches and above. They are economical as compared to elbows in higher sizes and
hence preferred.
• Mitre bends are usually fabricated at site out of pipe by cutting and re-welding spools as
shown in Fig. 7. The Figure is for 5 piece 4 weld mitres. The change in direction at every
1
weld is 22 /2 °. We may also have 4-piece 3-weld mitre where change in direction at
every weld would be 30°. Usually 5 piece 4 weld mitres are preferred in order to have
smooth flow.
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ELBOWS TEES, COUPLINGS AND
Uhde India Limited Page : 9 Uhde India Limited STUB-CONNECTIONS Page : 1
Page
1.0 Introduction 2
4.0 Weldolet 3
Applicable Revision:
Prepared: Checked: Approved:
Rev. : R0 Rev. : R0
TEES, COUPLINGS AND TEES, COUPLINGS AND
Uhde India Limited STUB-CONNECTIONS Page : 2 Uhde India Limited STUB-CONNECTIONS Page : 3
Branch size may be smaller or equal to run size but cannot be larger. Tees having branch size 3.0 HALF COUPLINGS:
equal to run size are called equal tees & other as unequal tees.
A socket-welded tee has all ends suitable for fillet weld i.e. for run as well as for branch.
Instead of using a tee-fitting, it is possible to use pipe stub-in connection as shown in Fig.2. Similarly a butt-welding tees has all ends suitable for butt-weld. We may have a situation,
where run or header is having butt weld joints due to size 2” and above but branch is having
1
Limitations on this type of connection are explained later. fillet welds due to size less or equal to 1 /2”. Half couplings are used for taking such branches
as shown in Fig.3.
• These are used for services where fillet welds are permitted.
2.0 CLASSIFICATION:
• As a good engineering practice, it is recommended that half coupling is welded to pipe
Based on end connections, tees are classified as follows: first at proper location & orientation and hole is drilled subsequently. This is in order to
avoid any misalignment which may occur between bore of the coupling and hole drilled in
• Socket Welded Tees pipe.
• Screwed-End Tees
• Butt Welding Tees • While using half couplings, ensure that outside dia of coupling does not exceed pipe
• Flanged Tees outside diameter.
1 1
• For 1 /2” branch from 2” header if half coupling is indicated on the basis that joints in 1 /2”
2.1 Socket Welded Tees: line are of fillet type and joints in 2” line are of butt-weld type, we may find that coupling
O.D. is bigger than pipe Outside Diameter. It is recommended to use butt-welding tee in
• These are usually forged and used up to 2” run size on services where socket welded such situation.
connections are permitted.
• Usually half couplings are forged and applicable dimensional standard is ASME B16 11.
• Applicable dimensional standard is ASME B16.11 and material standards including rating
are same as those for socket welded elbows. • Applicable rating & material standards for half couplings are same as those for socket
welded tees.
1
• UIL practice is to use socket welded tees up to 1 /2” run size.
4.0 WELDOLET:
2.2 Screwed-end Tees:
• These are used where run as well as branch are having butt welding connections but
Their use including rating, dimensional and material standards are same as applicable to unequal tees are not available as per ASME B16.9. Weldolets are used as shown in
screwed elbows. Fig.4. (e.g. 16” × 3”. Where run & branch both are having butt welding joints and unequal
tees as per ASME B16.9 is available up to 16” × 6” size only.
2.3 Butt welding Tees: • The connection between weldolet and header is through fillet weld. In case this fillet weld
is not permitted for the service intended, then only option left would be to use unequal tee
• The dimensional standard applicable for equal and unequal tees is ANSI B16.9. These 16” × 6” along with 6” × 3” reducer on branch side.
are available from 1/2” through 48”.
• Weldolets are usually forged and dimensions are as per manufacturers standard.
• Unequal butt welding tees are available having branches up to one size lower than half
run size e.g. If run size is 8”, unequal tees are available in sizes 8” × 6”, 8” × 5”, 8” × 4” &
1 5.0 PIPE STUB-IN CONNECTIONS:
8” × 3 /2”.
• Applicable Pressure temperature rating and material standards are same as those for • Pipe stub-in connection is most economical way for making branch from run/header.
butt-welding elbows. These are usually used for all low temperature non critical services.
• Butt welding tees are usually used for size 2” and above and in smaller sizes for services • Due to high stress intensification factor, these are not recommended for high temperature
where use of socket weld joints is prohibited. and other critical services.
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d2 = Half width of reinforcement zone • No additional credit may be taken for a material having higher allowable stress value than
= d1 or ( Tb - c )+( Th - c )+d1 / 2 whichever is greater but in any case not more the run pipe.
than Dh
L4 = height of reinforcement zone outside of run pipe
= 2.5( Th - c ) or 2.5( Tb - c ) + Tr whichever is less. 6.3 Reinforcement calculations not required for Fittings:
Where There are however, certain branch connections which have adequate pressure strength or
Tr = Minimum thickness of reinforcing ring or saddle made from pipe. reinforcement as constructed. It may be assumed without calculation that a branch
connection has adequate strength to sustain the internal and external pressure which will be
= 0, if there is no reinforcing ring or saddle. applied to it provided:
i. Required reinforcement area = A1 = th × d1 • The branch connection utilizes a fitting (a tee, lateral, or cross).
ii. The areas available for reinforcement within reinforcement zone are: • The branch connection is made by welding a threaded or socket welding coupling or half
coupling directly to the run provided the size of the branch does not exceed NPS 2 nor
one-fourth the nominal diameter of the run.
a. Area A2 resulting from excess thickness in the run pipe wall
A2 = ( 2d2 - d1 ) ( Th - th - c )
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TEES, COUPLINGS AND REDUCERS
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Page
1.0 Introduction 2
3.0 Sketch 4
Applicable Revision:
Prepared: Checked: Approved:
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REDUCERS REDUCERS
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Screwed reducers:
1. 0 INTRODUCTION:
These reducers are also available in concentric type only and are in the form of coupling
having one end to suit bigger pipe and other end to suit smaller pipe. Applicable dimensional
Reducers are used to reduce or expand the line size. Basically, two types of reducers are standard is ASME B16.11 indicated for couplings. Material standards including pressure
available. ratings are same as those applicable to screwed elbows.
In this type of reducers reduction is concentric and centre line of the pipe remains same as
shown in Fig.1. These are generally used in vertical lines.
Eccentric Reducers:
In this type of reducer there is an eccentricity between centre line of bigger end and centre
line of smaller end. This eccentricity is to the extent that, outer surface of bigger end is in line
with the outer surface of smaller end called flat side as shown in Fig.2.
While locating this type of reducer in pipe line, one has an option of orienting flat side. Usually
for all horizontal lines, eccentric reducers are preferred with either the flat side up or down.
Eccentric reducers on horizontal lines with flat side down are preferred for following cases:
Eccentric reducers on horizontal lines with flat side up are preferred for all pump suction lines
excluding pumps handling slurry. This is to avoid air getting trapped inside the pipeline during
initial venting through pump casing.
2.0 CLASSIFICATION:
Applicable pressure rating, dimensional and material standards for butt welding reducers are
same as those applicable to butt welding elbows.
These reducers are available in concentric type only and are in the form of couplings having
one end socket to suit bigger dia pipe and other end socket to suit smaller dia pipe as shown
in Fig.3
Standards including pressure rating are same as those applicable to socket welding elbows.
Dimensional standard applicable is ASME B16.11 indicated for couplings.
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REDUCERS FLANGES
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CONTENTS
Page
1.0 General 2
7.0 Rating Table for Group 1.1 Material as per ASME B 16.5 9 - 11
Applicable Revision:
Prepared: Checked: Approved:
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FLANGES FLANGES
Uhde India Limited Page : 2 Uhde India Limited Page : 3
pre drilled holes through hub. During welding at the face, care should be taken so as
1.0 GENERAL: to avoid distortion and refacing.
iii. The strength of this flange as calculated from internal pressure consideration is
Flanges are used in piping for making joints which can be opened at a later date. They are approximately two-thirds that of a corresponding welding neck type of flange.
usually used for connecting piping to equipment, valves & control valves etc.
iv. The use of this type of flange is usually limited to moderate services where pressure
A flanged joint is composed of three separate and independent, although interrelated fluctuations, temperature fluctuations, vibrations and shocks are not expected to be
components: the flanges, the gasket, and the bolting, which are assembled by yet another severe. The fatigue life of this flange is approximately one third that of a welding neck
influence, the assembler. Proper controls must be exercised in the selection and application flange.
for all these elements to attain a joint, which has acceptable leak tightness.
v. Slip on flange is not recommended for corrosive and/or critical services.
2.0 CLASSIFICATION: vi. Use of slip on flange is usually limited to class 300 (refer para on pressure temp.
rating) and design temperature not exceeding 500° F.
Flanged joints may best be classified by dividing them into two general parts (Refer vii. It is essential to ensure proper alignment of bolt holes before welding this type of
Annexure-1) flange.
i. Welding-neck flanges have a long, tapered hub between flange ring & weld joint. This
2.1 Methods Of Attachment Of Flange To Pipe hub provides a more gradual transition from the flange ring thickness to the pipe wall
thickness, thereby decreasing the discontinuity stresses and consequently increasing
2.1.1 Screwed flanges: the strength of the flange. Also welding area is sufficiently away from the face to avoid
undue distortion.
i. This flange can be rapidly connected to threaded pipe without welding.
ii. This type of flange is attached to pipe by having butt weld which can be radiographed
if required.
ii. Screwed flange joints have the following inherent weaknesses and disadvantages
which restrict their use to moderate operating conditions.
iii This type of flange is preferred for extreme service conditions such as repeated
bending from line expansion or other forces, wide fluctuations in pressure or
a. Necessity of careful alignment of bolt holes.
temperature, high pressure, high temperature and sub zero temperature.
b. Flange faces may become distorted when attaching flanges to pipe.
c. Pipe frequently extends through flange beyond the face.
iv. This type of flange is recommended for the handling of costly, inflammable or
d. Tests indicate that in tension a threaded joint has less than 60% of the
explosive fluids where failure or leakage of a flange joint might bring disastrous
strength of the pipe.
consequences.
e. Material removed in threading results in a thinner wall section readily affected
by erosion and corrosion.
v. While ordering this type of flange it is necessary to indicate schedule number
thickness or I.D and O.D. of connected pipe so that bore of the flange as well as butt
welding ends can be machined to suit pipe.
iii. Threaded connection is susceptible to leakage under any type of cylic operation. This
vi. The welding neck flange also requires accurate alignment of bolt holes before
flange is not recommended for use on services which involve bending or thermal
welding.
cycles.
2.1.4 Lap - Joint Flanges :
iv. Usually screwed flanges are used for Galvanized piping.
v. Sometimes, steel screwed flanges are seal welded to guard against leakage through i. Lap joint flanges are used with a lap -joint stub.
the threads.
ii. The combined cost of the two parts is generally greater than the cost of a welding
2.1.2 Slip on Flanges: neck flange of the same size, rating & material. However, we have an option of using
an ordinary steel flange behind the lap on alloy and stainless steel pipe without
sacrificing internal corrosion protection, thereby, the combined cost of two parts may
i. Slip on type of flange is widely used because of its low initial cost.
be less than the cost of a welding neck flange which necessarily has to be of the
same material as that of pipe.
ii. Slip on flange is attached to pipe by fillet weld. The welding is either at the back or at
back and face. Usually this flange is double welded and vented with the use of 1/8”
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iii. This type of flange is used for all plastic piping. Sometimes plastic piping handling iv. The raised face is machined with spiral or concentric grooves. Depth and spacing of
corrosive fluids have galvanized backing flanges in order to have better corrosion these grooves vary depending upon finish required to suit the gasket used for making
resistance against spillages etc. joint. The edges of these grooves serve to deform and hold the gasket.
As per ASME B16.5, for raised face, either a serrated concentric or serrated spiral
iv. These flanges have about the same ability to withstand pressure without leaking as finish having from 24 grooves/inch to 40 grooves/inch shall be used. The cutting tool
the slip-on flange, which is less than that of the welding neck flange. employed shall have an approx.0.06 inch or larger radius. The resultant surface finish
shall have a 125 micron to 500 micron roughness. The finish of contact face shall be
iii. These flanges have the disadvantage of having only about 10% of the fatigue life of judged by visual comparison with Roughness Average ‘Ra’ standards and not by
welding neck flanges. For this reason, these flanges should not be used for instruments having stylus tracers and electronic amplification (Refer ASME B46.1)
connections where severe bending stresses exist.
v. The facing should not have any radial tool mark since the same would provide
iv. This type of joint avoids the necessity of accurate alignment of bolt holes since the shortest path for fluid to escape.
flange is free to revolve on pipe. This permits it to be readily aligned with bolt holes of
mating flange whether they are on “straddle centre line” or in some odd or special vi. The facing should be properly protected during transportation and handling at site.
position.
vii. Flat ring composition gaskets are normally used having a width equal to the width of
vi. These type of flanges are also useful in cases where frequent dismantling for the raised face where as flat metal gaskets may be used having a width equal to that
cleaning or inspection is required or when it is necessary to rotate the pipe by used with large tongue-and-groove type face.
swiveling the flange.
2.2.2 Flat face:
2.1.5 Socket-welded flanges:
i. Flanges with flat faces using full-face gaskets are usually used for making
i. These flanges are usually used upto 2” size for lines where socket welded joints are connections to ASME 25lb and 125 lbs. Cast iron flanges and flanged components.
permitted. This decreases the leverage in bolting, thereby reducing the tendency for the flange
to crack.
ii. In this type of flange, hub part has a socket to suit pipe and flange is attached to pipe
by having a fillet weld at the back. There is no provision for face welding in this type of 2.2.3 Male & Female Facings:
flange.
i. They have the disadvantage that the two mating flanges are not identical. For this
iii. Their use and limitations are same as those applicable to slip-on flanges. reason, these flanges are not as widely used as raised face flanges.
2.1.6 Blind Flanges: ii. Male & female facings have the advantage of confining the gaskets thereby
minimizing the possibility of blow-out of the gaskets. The outer diameter of the female
i. These are used to block-off the ends of piping and valves. These flanges are also face serves to locate and retain the gasket.
used extensively to blank off pressure vessel openings such as handholds and
inspection ports. iii. Male & female facings offer no protection against forcing the gasket into the line or
vessel.
ii. Blind flanges absorb high bending stresses but do not have to absorb stresses
caused by thermal expansion or by weight of the piping system. iv. Two type of facings are available under this category:
2.2.1 Raised Face: This type face is usually used in small lines for hydraulic service to effect a
high unit gasket pressure in a confined area. However, the facing is
unsuitable to withstand bending stress, nor recommended for lines subjected
i. Steel flanges with a raised face are extensively used because of the simplicity of the to high temperatures.
design.
b. Large Male & Female:
ii. Moderate unit gasket pressure is maintained with conventional machining and
assembly methods and facing is suitable for average service conditions. However for This type face affords the same loading and resulting unit gasket pressure as
severe service involving high pressure, high temperature, thermal shock or cyclic the raised face. Flat ring composition gaskets are normally used. The width of
operation, this type of flange facing may not be satisfactory. the face is so large that full face metal gaskets can not be used because of
the excessive tightening load required to seat the gasket.
iii. Flanges with rating of ASME 150 and 300lbs have 0.06 inch high raised face which is
included in the minimum flange thickness. However, flanges having higher ratings 2.2.4 Tongue-and-Groove Facings:
have 0.25 inch high raised face which is additional to the minimum flange thickness.
i. They have the disadvantage that the two mating flanges are not identical.
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v. Two type of facings are available under this category: i. Pressure-Temperature ratings are determined as per Annexure D of ASME B 16.5
For easy reference, ASME B16.5 Table 1A and Table 2 - 1.1 (rating for Group 1.1
a. Small Tongue-and-Groove: material) are attached in section 7.0.
This type of facing is generally used for small lines in hydraulic service to ii. For any temperature below -20°F, the rating shall be no greater than the rating shown
O
effect a high unit gasket pressure in a confined area. It has the disadvantage for –20 F.
of excessive gasket pressure under temperature change and pipe deflection.
O
The facing is unsuitable for lines subjected to high temperatures. iii. Socket welding and screwed flanges are not recommended for service above 500 F
O
or below –50 F if severe thermal gradients or thermal cycling are involved.
b. Large Tongue-and-Groove:
iv. At temperature in the creep range, gradual relaxation of flanges, bolts & gaskets may
This type face provides the minimum area that it is advisable to use with flat progressively reduce bolt loads. It may be necessary to arrange for periodic tightening
gaskets. Therefore this type of facing provides the minimum bolting load for of bolts to prevent leakage.
compressing a flat gasket. Also the gasket area is nearer the bolt circle
O
making it slightly more resistant to flange stresses and bending moments. v. When used above 400 F, class 150 flanged joints may develop leakage unless care
is taken to avoid imposing severe external loads and/or severe thermal gradients. For
vi. Due to constructional limitations, minimum flange rating available with tongue-and- other classes, similar consideration should be given above 750° F.
groove facing is ASME 300 lbs.
4.0 PLATE FABRICATED FLANGES:
2.2.5 Ring Joint Faces:
Some times on cost consideration for low pressure, low temperature, non-critical services, we
i. Ring joint type of facing offers the greatest protection under severe service conditions may use plate fabricated flange (slip on flange without hub) They are machined from plate of
or with the use of hazardous fluids. appropriate grade. These flanges are not covered under ASME B16.5 but one can specify
standard B.S.1560 which cover carbon steel plate flanges having flange dimensions identical
ii. This type face employing a metal ring of either oval or octagonal cross section as a to ASME 150 lbs. The plate used is B.S 1501-224 Gr.32A or its equivalent ASTM A516 grade
gasket, permits very high unit gasket pressure. 70 or IS 2062.
iii. This type of facing requires close tolerances and high standards of machining making 5.0 FLANGES AS PER DIN/BS:
it the most expensive gasket face.
Though the flanges as per ASME Standard are most common, sometimes, we may require a
iv. Internal pressure acts on the ring to increase the sealing force on the joint. mating flange to match an equipment flange which is either as per DIN or as per BS standard.
Flanges conforming to DIN standard are available in various pressure ratings such as PN6,
v. Mating flanges are identical. PN10, PN16, PN25, PN40, PN100.
vi. Gasket contact surfaces are below the flange face, thereby they get protected from Flanges conforming to BS standard are available in various pressure ratings. Refer BS 10;
damage. 1962 and BS 1560; 1989.
3.0 STANDARD:
There are a variety of Standards used in the design and selection of Flanges. The following
Codes and Standards relate to the pipe flanges:
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1.0 INTRODUCTION:
CONTENTS
Leak-proof metal-to-metal surfaces in which gaskets are not used are difficult to fabricate
Page even by use of very accurate machined surfaces. Irregularities in clearances of only a few
millionths of an inch will permit the escape of a fluid under pressure. The function of a gasket
0.0 Cover Sheet 1 is to interpose a semi-plastic material between the flange facings, the material which, through
deformation under load seals the minute surface irregularities to prevent leakage of the fluid.
1.0 Introduction 2–3 The amount of flow of the gasket material that is required to produce a tight seal is dependent
upon the roughness of the surface. The amount of force that must be applied to the gasket to
2.0 Gasket Types 3 cause the gasket to flow and seal the surface irregularities is known as the “yield” or “seating”
force. This force is usually expressed as a unit stress in pounds per square inch and is
3.0 Gasket Selection 3–5 independent of the pressure in the vessel. Thus, this yield stress represents the minimum
load that must be applied to the gasket to seat it even though very low pressure are used in
4.0 Standards 5 the vessel. Usually the gasket is seated by tightening the bolt load on the flanges prior to the
application of the internal pressure in the vessel.
5.0 Figure 6
Upon the application of the internal pressure in the vessel, an end force tends to separate the
flanges and to decrease the unit stress on the gasket. Figure 1.0 shows the three major
forces acting on the gasket.
Leakage will occur under pressure if the hydrostatic end force is sufficiently great and the
difference between hydrostatic end force and the bolt-load force reduces the gasket load
below a critical value. Also, it may be possible with too low a contact pressure on the gasket
for the gasket to be blown out by the internal pressure. The ratio of the gasket stress, when
the vessel is under pressure, to the internal pressure is termed the “gasket factor”. The
gasket factor is a property of the gasket material and the construction and is independent of
the internal pressure over a wide range of pressures. In selecting the proper gasket for an
existing closure, one of the first steps should involve the determination of the total amount of
force necessary to make the gasket yield and to maintain a tight seal under operating
conditions.
Appendix-2, Table 2.5.1 of ASME Section VIII Div.1 shows sectional views of some common
types of gaskets and lists the gasket factor 'm' and the minimum design seating stress, 'y' for
each type of gasket.
There is a considerable possible choice of gasket material in may applications. The decision
as to which gasket material is to be selected is often based upon the required gasket width. If
the gasket is made too narrow, the unit pressure on it may be excessive. If the gasket is
made too wide, the bolt load will be unnecessarily increased. A relationship for making a
preliminary estimate of the proportions of the gasket may be derived as followed :
Applicable Revision: R1
Prepared: NNG Checked: AKB Approved: RUD (Gasket seating force) - (Hydrostatic pressure force) = (Residual Gasket force )
The residual gasket force can not be less than that required to prevent leakage of the internal
fluid under operating pressure. Therefore
Date: 15.01.2001 Date: Date:
First Edition: R0
π
Prepared: DNL Checked: AKB Approved: RUD π (do2 - di2) y - π (do2 ) p = 2 2
(do - di ) pm
4
4 4
where,
Date: 14.09.2000 Date: 20.09.2000 Date: 31.10.2000
File Name: C- 11 Server: PUNE:KUMUS 207 VKO: KUMUS 209 y = yield stress, pound per square inch
m = gasket factor
p = internal pressure, pounds per square inch
Directory: PUNE: Refer \ Pi \ Training Manual VKO: Refer \ Training Manual do = outside diameter of gasket, inches
di = inside diameter of gasket, inches
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Above equation may be re-written as follows : iii. Flat-ring gaskets are widely used wherever service condition permits because of the ease
with which they may be cut from flat sheet and installed. They are commonly fabricated
do y-p m from such materials as rubber, paper, cloth, asbestos, plastics, copper, lead, aluminum,
di = y - p ( m + 1) nickel, monel, and soft iron. The gaskets are usually made in thickness from 1/64 to 1/8
in. Paper, cloth and rubber gaskets are not recommended for use above 250° F.
Asbestos-composition gaskets may be used up to 650° F or slightly higher, ferrous and
nickel-alloy metal gaskets may be used up to the maximum temperature rating of the
In the case where it is desirable to retain the gasket material selected and to retain the gasket flanges.
width, a gasket seating stress greater than y may be used with certain reservations. If the
seating stress greatly exceeds y, the gasket may be crushed, or a ductile, unrestrained gasket iv. Upon initial compression a gasket will flow both axially and radially. The axial flow is
be squeezed out between the flange faces. In general the use of seating stresses exceeding required to fill depressions in the flange facing and prevent leakage. Radial flow serves no
y should be limited to solid-metal gaskets in tongue-and-grove joints. useful purpose unless the gasket is confined.
Where a flange joint is heated, a greater gasket pressure is produced due to the
2.0 GASKET TYPES: difference between the flange body and the bolts. This greater pressure coupled with the
usual softening of the gasket material at elevated temperatures causes additional axial
and radial gasket flow. To compensate for this, the flange bolts are usually re-tightened a
Gaskets can be defined into three main categories as follows: second or third time after the joint is heated to the normal operating temperature.
• Non-metallic Gaskets: A thick gasket will flow radially to a far greater extent than a thin gasket. Some thin
gaskets show practically no radial flow at extremely high unit pressures. Consequently, for
Usually composite sheet materials are used with flat face Flanges and low pressure class high temperatures a thin gasket has the advantage of maintaining a permanent thickness
applications. Non-metallic gaskets are manufactured non-asbestos material or while a thick gasket will continue to flow radially and may leak, in time, due to the resulting
Compressed Asbestos Fibre (CAF). Non-asbestos types include arimid fibre, glass fibre, reduced gasket pressure. However in attempting utmost utilization of thin gasket
elastomer, Teflon (PTFE) and flexible graphite gaskets. Full face gasket types are advantage, one may find that gasket selected has insufficient thickness to seal the
suitable for use with flat-face (FF) flanges and flat-ring gasket types are suitable for use irregularities, in the commercial flange faces.
with raised face (RF) flanges.
The spiral wound asbestos-metallic gasket combines the advantages of both the thick
• Semi-metallic Gaskets: and thin gasket. Although a relatively thick gasket (most common types are 0.175” thick)
its spirally laminated construction confines the asbestos filler between axially flexible
Semi-metallic gaskets are composites of metal and non-metallic materials. The metal is metal layers. This eliminates the radial flow characteristics of a thick gasket and provides
intended to offer strength and resiliency while the non-metallic portion of a gasket the resiliency to adjust to vary service conditions. Spiral wound gaskets are available with
provides conformability and sealability Commonly used semi-metallic gaskets are spiral different filler materials such as Teflon, grafoil etc. to suit fluid compatibility. Spiral wound
wound, metal jacketed, Cam profile and a variety of metal-reinforced graphite gaskets. gaskets used with raised face flanges usually have an inner metal ring and an outer
Semi metallic gaskets are designed for the widest range of operating conditions of centering ring.
temperature and pressure. Semi-metallic gaskets are used on raised face, male-and-
female and tongue-and –groove flanges. iv. Laminated gaskets are fabricated with a metal jacket and a soft filler, usually of asbestos.
Such gaskets can be used up to temperatures of about 750° F to 850° F and require less
• Metallic Gaskets: bolt load to seat and keep tight than solid metal flat ring gaskets.
Metallic gaskets are fabricated from one or a combination of metal to the desired shape v. Serrated metal gaskets are fabricated of solid metal and have concentric grooves
and size. Common metallic gaskets are ring-joint gaskets and lens rings. They are machined into the faces. This greatly reduces the contact area on initially tightening
suitable for high-pressure and temperature applications and require high bolt load to seal. thereby reducing the bolt load. As the gasket is deformed, the contact surface area
increases. Serrated gaskets are useful where soft gaskets or laminated gaskets are
unsatisfactory and bolt load is excessive with a flat-ring metal gasket. Smooth-finished
3.0 GASKET SELECTION: flange faces should be used with serrated gaskets.
vi. Corrugated gaskets with asbestos filling are similar to laminated gaskets except that the
surface is rigid with concentric rings as with the case of serrated gaskets. Corrugated
i. The gasket material selected should be one which is not adversely affected physically or
gaskets require less seating force than laminated or serrated gaskets and are extensively
chemically by the service conditions.
used in low-pressure liquid and gas service. Corrugated metal gaskets without asbestos
may be used to higher temperature than those with asbestos filling.
ii. The two types of gaskets most commonly known are ring gaskets and full face gaskets.
The latter as the name implies, covers the entire flange face and are pierced by the bolt
vii. Two standard types of ring-joint gaskets are available for high-pressure service. One type
holes. They are intended for use with flat face flanges. Ring gaskets extend to the inside
has an oval cross section, and the other has an octagonal cross section. These rings are
of the flange bolt holes and consequently are self centering. They are usually used with
fabricated of solid metal, usually soft iron, soft steel, monel, 4-6% chrome, and stainless
raised face or lap joint flanges but may also be used with flat-faced flanges.
steels. The alloy-steel rings should be heat treated to soften them.
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viii. It is recommended that only Group No. 1 (Refer Appendix-I) or ring joint gasket be used
for class 150 flanged joints. When the ring joint or spiral wound gasket is selected, it is 5.0 FIGURE:
recommended that line flanges be of the welding neck type.
ix. If low strength bolts are used, gaskets are listed under group ‘Ia’ (Refer appendix-I) shall
be used.
4.0 STANDARDS:
IS 2712 covers six grades of Compressed Asbestos Fibre (CAF) sheets, classified based on
application as follows:
GRADE APPLICATION
w/1 Water, steam & for some chemicals - High Service conditions
w/2 Water, steam & for some chemicals - Medium Service conditions
w/3 Water, steam & for some chemicals - Low Service conditions
o/1 oils - High Service conditions
o/2 oils - Medium and nominal service conditions
a/1 acids - highly corrosive
Usually grades W/1, O/1, and a/1 are used in nominal thickness of 1.5mm for raised face
flanges and 3mm thick for flat face flanges.
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CONTENTS
1.0 INTRODUCTION:
Page
The flanges are drilled to receive bolts which, if of the proper material, will develop the full
0.0 Cover Sheet 1 flange strength and result in a satisfactory joint at the service intended.
1.0 Introduction 2 The term 'bolting material' covers bolts, studs and stud bolts.
2.0 Classification 2 As per ASME B16.5, one can use either square head machine bolts or studs for making a
joint. Bolts and studs are available in either fully threaded or partially threaded condition. The
3.0 Application 2–3 fully threaded structure ensures an equal distribution of elongation when the bolts are
tightened and avoid concentration of stresses that exist in partially threaded stock due to
4.0 Dimensional Standards 3–5 varying cross-sections.
Also, studs are preferred over bolts due to ease of insertion during assembly. At places, like
bolting of two valves together, there may not be sufficient clearance available for inserting
bolts due to valve body contour and use of studs is the only possible solution
2.0 CLASSIFICATION:
Since bolting material does not come in contact with fluid, its material compatibility with fluid is
not important. The selection of bolt material is determined based on service conditions and it
is wasteful to specify expensive alloys when carbon steel material is entirely suitable. It is
important for bolting material to have good tensile stress.
As per ASME B16.5, bolting material has been divided into three categories as follows:
Bolting materials having allowable stresses not less than those for ASTM A193 grade B7 are
listed as high strength bolts. ASME B16.5 Table 1B is enclosed for reference.
These and other materials of comparable strength may be used in any flanged joint.
Bolting materials listed as intermediate strength in Table 1B, and other bolting of comparable
strength, may be used in any flanged joint, provided the user verifies their ability to seat the
selected gasket and maintain a sealed joint under expected operating conditions.
Bolting materials having not more than 30 ksi specified minimum yield strength are listed as
Applicable Revision: low strength in Table 1B. These materials and others of comparable strength shall be used
Prepared: Checked: Approved: only in Classes 150 and 300 joints, and only with gaskets of group no. 1a. Flanged joints
using low strength carbon steel bolts shall not be used above 400°F or below -20°F.
i. For flanged joints in piping system where one or both flanges are of cast iron, bolts /
studs conforming to ASTM A307 Gr. B and nuts conforming to A194 Gr. 2 are usually used.
Date: Date: Date: Equivalent IS standards for such fasteners is IS 1367 CI. 6.6 / IS 1367 CI. 6.
File Name: C- 12 Server: PUNE: KUMUS 207 VKO: KUMUS 209
ii. For carbon steel flanges having ASME 150 rating on non-critical services, bolts / studs
conforming to ASTM A307 and nuts conforming to ASTM A194 Gr. 2 or fasteners conforming
to IS 1367 CI. 6.6 / IS 1367 CI. 6. are usually used.
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iii. For carbon steel flanges on process and critical services involving medium and TABLE 1B : LIST OF BOLTING SPECIFICATIONS
moderately high pressures and temperatures, bolts / studs conforming to ASTM A193 Gr. B7 Applicable ASTM Specifications
along with heavy hexagonal head nuts conforming to ASTM A194 Gr. 2H are usually used.
Bolting Materials [Note (1)]
iv. For very severe service conditions involving high temperatures upto 1100°F bolts / studs High Strength Intermediate Low strength Nickel and Special
conforming to ASTM A193 Gr. B7 along with nuts conforming to ASTM A194 are usually [Note (2)] Strength [Note 3)] [Note (4)] Alloy[Note 5)]
used.
Spec. Grade Notes Spec. Grade Notes Spec. Grade Notes Spec. Grade Notes
v. For low temperature carbon steel flanges, studs conforming to ASTM A320 Gr. L7 along No. No. No. No.
with nuts conforming to ASTM A194 Gr. 4 are usually used.
A193 B7 A193 B5 A193 B8 Cl.1 (6) B164 . (7),(8),(9)
...
vi. For all flange joints in plastic piping, low strength bolts / studs are usually acceptable. Use
A193 B16 A193 B6 A193 B8C Cl.1 (6)
of washers is recommended for joints in plastic piping.
...
vii) Some times in plastic piping, handling corrosive fluids, it is recommended that the A193 B6X A193 B8M Cl.1 (6) B166 . (7),(8),(9)
fasteners are supplied with cadmium plating or galvanized coating. This is in order to have
corrosion resistance against spillages, etc. A320 L7 (10) A193 B7M A193 B8T Cl.1 (6)
A320 L7A (10) A193 B8 Cl.2 (11) A193 B8A (6) B335 N10665 (7)
4.0 DIMENSIONAL STANDARDS:
A320 L7B (10) A193 B8C Cl.2 11) A193 B8CA (6)
A320 L7C (10) A193 B8M Cl.2 (11) A193 B8MA (6) B408 . (7),(8),(9)
Dimensional standards usually adopted for fasteners are as follows:
Studs bolts : ASME B 18.2.1 A320 L43 (10) A193 B8T Cl.2 (11) A193 B8TA (6)
Studs : DIN 976 Type B / DIN 934
Nuts : ASME B 18.2.2 B473 ... (7)
Male Threads : ASME B 1.1 C1. 2A
Coarse series (UNC) A354 BC ... A320 B8 Cl.2 (11) A307 B (12)
Female Threads : ASME B 1.1 C1. 2A
Coarse series A354 BD ... A320 B8C Cl.2 (11) B574 N10276 (7)
A540 B22 ... A320 B8T Cl.2 (11) A320 B8M Cl.1 (6)
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CONTENTS
GENERAL NOTE :
Page
Bolting material shall not be used beyond temperature limits specified in the governing code.
0.0 Cover Sheet 1
NOTES:
1.0 Exclusions 2
1. Repair welding of bolting material is prohibited.
2.0 Fluid Service Classification 2–3
2. These bolting materials may be used with all listed materials and gaskets.
3.0 Code Content in General 3–4
3. These bolting materials may be used with all listed materials and gaskets, provided it has
been verified that a sealed joint can be maintained under rated working pressure and 4.0 Design Criteria 4–6
temperature.
5.0 Other Loads on Piping 6–8
4. These bolting materials may be used with all listed materials that are limited to Classes
150 and 300 joints. See para. 5.4.1 for required gasket practices. 6.0 Allowable Stresses and other Stress Limits for Metallic Piping 8
5. These materials may be used as bolting with comparable nickel and special alloy parts. 7.0 Basis for Design Stresses 8 - 10
6. This austenitic stainless steel material has been carbide solution treated but not strain
hardened. Use A194
7. Nuts may be machined from the same material or may be of a compatible grade of ASTM
A194.
8. Maximum operating temperature is arbitrarily set at 500°F, unless material has been
annealed, solution annealed or hot finished, because hard temper adversely affects
design stress in the creep rupture stage.
8. Forging quality not permitted, unless the producer last testing or working these parts,
tests them as required for other permitted conditions in the same specification and
certifies their tensile, yield and elongation properties to equal or exceed the requirements
for one of the other permitted conditions.
9. This ferritic material is intended for low temperature service. Use A194 Grade 4 or Grade
7 nuts.
10. This austenitic stainless steel material has been carbide solution treated and stain
hardened. Use A194 nuts of corresponding material.
11. This carbon steel fastener shall not be used above 400°F or below -20°F. See also note
(4). Bolts with drilled or undersized hands shall not be used.
Applicable Revision:
12. Acceptable nuts for use with quenched and tempered bolts are A194 Grades 2 and 2H. Prepared: Checked: Approved:
Mechanical property requirements for studs shall be the same as those for bolts.
14. This special Alloy is intended for high temperature service with austenitic stainless steel. Date: Date: Date:
First Edition: R0
Prepared: DNL Checked: AKB Approved: RUD
Rev. : R0 Rev. : R0
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i. The fluid handled is nonflammable, nontoxic, and not damaging to human tissues.
1.0 EXCLUSIONS:
ii The design gage pressure does not exceed 150 psi (1035 kPa) and
ASME Code B31.3 excludes the following: (Refer Clause 300.1.3 of ASME B 31.3)
iii The design temperature is from -20°F (-29°C) through 366°F (186° C ).
a. Piping system designed for internal gage pressures at or above zero but less than 15 psi
(105 kPa), provided the fluid handled is nonflammable (Note-1), non toxic, and not damaging Category M fluid service:
to human tissue (Note-2) and its design temperature is from -20°F (-29°C) through 366°F
(186°C). A fluid service in which the potential for personnel exposure is judged to be significant and in
which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can
b. Power boilers as per ASME Boiler and Pressure Vessel Code and boiler external piping produce serious irreversible harm to persons on breathing or bodily contact, even when
which is required to conform to B31.1. In India IBR (Indian Boiler Regulation) is applicable for prompt restorative measures are taken.
this piping.
c. Tubes, tube headers, crossovers, and manifolds of fired heaters, which are internal to the 3.0 CODE CONTENT IN GENERAL:
heater enclosure.
d. Pressure vessels, heat exchangers, pumps, compressors and other fluid handling or Following chapters are covered under ASME B31.3
processing equipment, including internal piping and connections for external piping.
i. Chapter I : Scope & definition.
Apart from the above exclusions, the following considerations are also excluded:
ii. Chapter II : Design
1) Piping located on company property which, has been set aside for pipelines conforming to
ASME B31.4 or ASME B31.8. iii. Chapter III : Materials.
2) Plumbing, sanitary sewers, and storm sewers, and iv. Chapter IV : Standards for Piping Components.
3) Fire protection systems constructed in compliance with insurance underwriters’ or other v. Chapter V : Fabrication, Assembly and Erection.
recognized fire protection engineering standards. In India TAC (Tariff Advisory
Committee) guidelines are applicable for designing of fire protection systems. vi. Chapter VI : Inspection, Examination and Testing.
NOTES : vii. Chapter VII : Non-metallic piping and piping lined with non- metals.
2.0 FLUID - SERVICE CLASSIFICATION: (Refer Clause 300.2 of ASME B 31.3) As per code, owner is responsible for identifying those fluid services which are in categories D
and M. ASME B31.3 Appendix M gives guide lines for classifying fluid services.
Some of the requirements pertaining to design of category M fluid service piping are listed
Fluid service is a general term used in code concerning the application of a piping system,
below:
considering the combination of fluid properties, operating conditions and other factors which
establish the basis for design of the piping system.
i. Fittings conforming to MSS-SP-43 shall not be used.
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ii. Pipes conforming to ASTM A134 made from ASTM A139 shall not be used.
Piping or piping components, or portions thereof, that can be blocked-in or isolated from a
iii. A mitre bend that makes a change in direction at a single joint greater than 22.5° shall not pressure relieving device shall be designed for not less than the maximum pressure that can
be used. be developed under those conditions.
iv. Single-welded slip-on flanges shall not be used. Usually following basis is adopted for arriving at Design pressure.
v. Screwed flanges shall not be used except those employing lens rings or similar gaskets a. Design pressure of the equipment to which it is connected.
and those used in lined pipe where the liner extends over the gasket face.
vi. Valves having threaded bonnet joints shall not be used. b. Set pressure of the pressure relief valve which protects the system.
vii. Valves to have special provision to prevent stem leakage to the environment. c. Discharge piping of a centrifugal pump, for cases where the discharge can be blocked-in
and is not protected by a pressure relief valve, shall be designed for the largest of the
viii. Carbon steel pipes & fitting without impact testing shall not be used at temp below -20°F. following :
c. For category D fluid service, requirements of chapter I through VII are applicable. i. 1.25 times the rated pump differential plus the pressure at the pump suction (when
However, concessional provisions made in these chapters for category D fluid service may be equipment upstream of the suction is at its design or relieving pressure).
used.
ii. 1.1 times rated pump discharge pressure (gage).
Some of the concessional provisions as made for category D fluid service piping are as
follows: iii. Normal pump discharge pressure plus 25 psi.
i. Following carbon steel pipes may be used only for category D fluid service. iv. Maximum pump discharge or stalling pressure (when specified).
A. API-5L Furnace Butt-Welded. d. Discharge piping of a direct acting steam pump, not protected by a pressure relief valve,
B. ASTM A53,Type F shall be designed for the stalling pressure of the pump.
C. ASTM A120
D. ASTM A134 made from other than ASTM A285 plate. e. All systems operating below atmospheric pressure shall be designed for full vacuum.
E. ASTM A211
f. Piping systems leaving the process area shall be designed for a closed valve outside the
ii. A mitre bend which makes a change in direction at a single joint greater than 45° may be process area. If this causes an increase in flange rating for the piping outside the process
used only for category D. area, an acceptable alternate is to lock open all the block valves between the last block valve
in the process area and the downstream pressure relief. However, if the last block valve of a
iii. A bolted bonnet valve whose bonnet is secured to the body by less than four bolts or by a piping system leaving the process area is locked open, all block valves between the last block
U-bolt. valve in the process area and the downstream pressure relief must be locked open.
iv. Caulked joints such as bell type joints and soldered joints may be used only for category g. Where a line with a lower rating connects to a pipe or equipment with a higher rating,
D fluid service. such line shall be rated at the higher rating (and shall be the same material as the line of the
higher rating) to and including the first block valve or, when double block valves are used, to
d. Chapter IX is applicable for high pressure piping: and including the second block valve. Block valves on both sides of a control valve and the
by-pass valve shall be rated at the same specification as the line with the higher rating.
This chapter contains alternative rules pertaining to high pressure metallic piping which are
code requirements only when specified by the owner. High pressure is considered to be 4.2 Design Temperature: (Clause 301.3)
pressure in excess of that allowed by ASME B 16.5 class 2500 rating for the specified design
temperature and material group. However, there are no specified pressure limitations for the The design temperature of each component in a piping system is the temperature at which,
application of these rules. under the coincident pressure, the greatest thickness or highest component rating is required.
e. UIL practice is to design non-metallic piping as per DIN standards and hence chapter VII 4.2.1 Uninsulated Metallic Components :
is usually not referred.
For metallic piping with nonmetallic lining, and uninsulated.
4.0 DESIGN CRITERIA: (Refer Clause 301 of ASME B 31.3)
a. For fluid temperatures below 150° F (65° C), the component temperature shall be taken
4.1 Design Pressure: (Clause 301.2) as the fluid temperature unless solar radiation or other effects result in the higher
temperature.
The design pressure of each component in a piping system shall be not less than the
pressure at the most severe condition of coincident internal or external pressure and b. For fluid temperatures 150° F (65° C) and above, unless a lower average wall
temperature (minimum or maximum) expected during service. The most severe condition is temperature is determined by test or heat transfer calculation, the temperature for uninsulated
that which results in the greatest required component thickness and the highest component components shall be no less than the following values:
rating.
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1. Valves, pipe, lapped ends, welding fittings, and other components having wall thickness
comparable to that of the pipe: 95% of the fluid temperature; 5.2.3 Earthquake:
2. Flanges (except lap joint) including those on fittings and valves: 90% of the fluid Piping shall be designed for earthquake induced horizontal forces.
temperature;
5.2.4 Vibration:
3. Lap joint flanges : 85 % of fluid temperature.
Piping shall be designed, arranged, and supported so as to eliminate excessive and harmful
4. Bolting : 80% of the fluid temperature. effects of vibration which may arise from such sources as impact, pressure pulsation,
resonance in compressors, and wind loads.
4.2.2 Externally Insulated Piping :
5.2.5 Discharge Reactions:
The component design temperature shall be the fluid temperature unless calculations, tests,
or service experience based on measurements support the use of another temperature. Piping shall be designed, arranged and supported so as to withstand reaction forces due to
Where piping is heated or cooled by tracing or jacketing, this effect shall be considered in the let-down or discharge of fluids.
establishing component design temperatures.
5.3 Weight Effects: (Clause 301.6)
In UIL, Design Pressure and Temperature condition are given by Process (PE) dept. for each
line in the form of a fluid list initially and on line list later-on. The following weight effects, combined with loads and forces from other causes, shall be
taken into account in the design of piping.
Apart from pressure and temperature condition, following loads also act on piping system and These loads include the weight of the medium transported or the medium used for test. Snow
design of piping system should be such so as to take care of their effect. and ice loads due to both environmental and operating conditions shall be considered.
5.1.1 Cooling Effects on Pressure : These loads consist of the weight of piping components, insulation and other superimposed
permanent loads supported by the piping.
The cooling of a gas or vapor in a piping system may reduce the pressure sufficiently to
create an internal vacuum. In such a case, the piping shall be capable of withstanding the 5.4 Thermal Expansion and Contraction Effects: (Clause 301.7)
external pressure at the lower temperature, or provision shall be made to break the vacuum.
The following thermal effects, combined with loads and forces from other causes, shall be
5.1.2 Fluid Expansion Effects : taken into account in the design of piping.
Provision shall be made in the design either to withstand or to relieve increased pressure 5.4.1 Thermal Loads Due to Restraints:
caused by the heating of static fluid in a piping component.
These loads consist of thrusts and moments which arise when free thermal expansion and
5.1.3 Atmospheric lcing : contraction of the piping are prevented by restraints or anchors.
Where the design minimum temperature of a piping system is below 32° F (0°C), the 5.4.2 Loads due to Temperature Gradients:
possibility of moisture condensation and buildup of ice shall be considered and provisions
made in the design to avoid resultant malfunctions. This applies to surfaces of moving parts of These loads arise from stresses in pipe walls resulting from large rapid temperature changes
shut off valves, control valves, pressure relief devices including discharge piping, and other or from unequal temperature distribution as may result from a high heat flux through a
components. comparatively thick pipe or two phase flow causing bowing of the line.
5.2 Dynamic Effects: (Clause 301.5) 5.4.3 Loads due to difference in expansion characteristics:
5.2.1 Impact : These loads result from differences in thermal expansion where materials with different
thermal expansion coefficients are combined, as in bimetallic, lined, jacketed, or metallic
Impact forces caused by external or internal conditions (including changes in flow rate, nonmetallic piping.
hydraulic shock, liquid or solid slugging, flashing, and geysering) shall be taken into account in
the design of piping. 5.5 Effects of support, Anchor and Terminal Movements: (Clause 301.8)
5.2.2 Wind : The effects of movements of piping supports, anchors, and connected equipment shall be
taken into account in the design of piping. These movements may result from the flexibility
The effect of wind loading shall be taken into account in the design of exposed piping. and/or thermal expansion of equipment, supports, or anchors; and from settlement, tidal
movements, or wind sway.
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5.6 Reduced Ductility Effects: (Clause 301.9) 2. except as provided in (3) below, the lower of two-thirds of specified minimum yield
strength at room temperature (SMYS) and two-thirds of yield strength at temperature;
The harmful effects of reduced ductility shall be taken into account in the design of piping.
The effects may for example, result from welding, heat treatment, forming, bending, or low 3. at temperatures below the creep range, for bolting materials whose strength has been
operating temperatures, including the chilling effect or sudden loss of pressure on highly enhanced by heat treatment or strain hardening, the lower of one fifth of SMTS and one-fourth
volatile fluids. Low ambient temperatures expected during operation shall be considered. of SMYS (unless these values are lower than corresponding values for annealed material, in
which case the annealed values shall be used);
5.7 Cyclic Effects: (Clause 301.10) 4. two-thirds of the “yield strength at temperature”
Fatigue due to pressure cycling, thermal cycling, and other cyclic loading shall be considered 5. 100% of the average stress for a creep rate of 0.01% per 1000 hr.
in the design of piping.
6. 67% of the average stress for rupture at the end of 100,000 hr;
5.8 Air Condensation Effects: (Clause 301.11)
7. 80% of minimum stress for rupture at the end of 100,000 hr;
At operating temperatures below -312°F (-191°C) in ambient air, condensation and oxygen
enrichment occur. These shall be considered in selecting materials, including insulation, and b. Cast Iron:
adequate shielding and/or disposal shall be provided.
Basic allowable stress values at temperature for cast iron shall not exceed the lower of the
following:
6.0 ALLOWABLE STRESSES AND OTHER STRESS LIMITS FOR METALLIC PIPING:
1. one-tenth of the specified minimum tensile strength at room temperature;
(Refer Clause 302.3 of ASME B 31.3)
2. one-tenth of the tensile strength at temperature;
The allowable stresses defined in (a), (b) and (c) below shall be used in design calculations
unless modified by other provisions of this Code.
c. Malleable Iron.
a. Tension:
Basic allowable stress values at temperature for malleable iron shall not exceed the lower of
the following
Basic allowable stresses ‘S’ in tension for metals and design stresses ‘S’ for bolting materials,
listed in ASME B31.3 Tables A-1 and A-2, respectively are determined according to Para
1. one-fifth of the specified minimum tensile strength at room temperature.
302.3.2 of ASME B 31.3)
2. one-fifth of the tensile strength at temperature.
b. Shear and Bearing:
d. Other Materials:
Allowable stresses in shear shall be 0.80 times the basic allowable stress in tension tabulated
in Table A-1 and A-2. Allowable stress in bearing shall be 1.60 times that value.
Basic allowable stress values at temperature for materials other than bolting materials, cast
iron, and malleable iron shall not exceed the lowest of the following:
c. Compression:
1. The lower of one-third of SMTS and one-third of tensile strength at temperature.
Allowable stresses in compression shall be no greater than the basic allowable stresses in 2. Except as provided in (3) below, the lower of two-thirds of SMYS and two-thirds of yield
tension as tabulated in Appendix A. Consideration shall be given to structural stability. strength at temperature;
3. For austenitic stainless steels and nickel alloys having similar stress-strain behavior, the
7.0 BASIS FOR DESIGN STRESSES: (Refer Clause 302.3.2 of ASME B 31.3) lower of two-thirds of SMYS and 90% of yield strength at temperature (see (e) below);
The basis for establishing design stress values for bolting materials and allowable stress 4. 100% of the average stress for a creep rate of 0.01% per 1000 hr;
values for other metallic materials in this Code are as follows:
5. 67% of the average stress for rupture at the end of 100,000 hr;
a. Bolting Materials:
6. 80% of the minimum steesws for rupture a the end of 100,000 hr;
Design stress values at temperature for bolting materials shall not exceed the lowest of the
following. 7. For structural grade materials, the basic allowable stress shall be 0.92 times the lowest
value determined in (1) through (6) above.
1. Except as provided in (3) below, the lower of one fourth of specified minimum tensile
strength at room temperature (SMTS) and one fourth of tensile strength at temperature;
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CONTENTS
e. Application Limits: Clause 302.3.2 (e)
Page
Application of stress values determined in accordance with (d-3) above is not recommended
for flanged joints and other components in which slight deformation can cause leakage or 0.0 Cover Sheet 1
malfunction [These values are shown in italics in Table A-1, as explained in Note (4) to
Appendix A Tables]. Instead, either 75% of the stress value in Table A-1 or two-thirds of the 1.0 Pipes and Fittings 2
yield strength at temperature listed in BPV Code, Section II, Part D, Table Y-1 should be
used. 2.0 Comments on selection and Limitations of Components 2–6
Applicable Revision: R1
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be considered if the fluid is hazardous or very corrosive or if the fluid is above 500°F. also needed during operation wherever positive shutoff is required to prevent leakage of one
Where double block valves are used, a 3/4-in valve should be installed between the block fluid into another.
valves. See FIG.1
Blanks should be located in horizontal lines if possible. Blanks should not be used in vertical
water and steam lines in climates where danger of freezing exists.
FIG.1
Circular handletype blanks can be used for raised face joints in locations where the lines can
BLOCK VALVES be sprung easily to permit installation of the blanks. As a rule, this is easily accomplished only
in 4-in and smaller lines. Figure-eight-type blanks are used for larger lines and even then,
jackscrews may be needed to install the blank. Blanks should be made from a plate
specification approved for use in ASME B31.3, of substantially the same chemical
composition as the pipe.
• The bore of weld neck orifice flanges should match the inside diameter of the attached Carbon-steel machine bolts may be used to make flange connections for bolt metal
pipe. temperature from -20°F to 400°F inclusive. This restriction is quite conservative with regard to
pressure limit. Also, these bolts can be used quite safely to the limits of the Class 300
• ASME Standard B16.47 for Large Diameter Steel Flanges, governs steel flanges in sizes pressure class as permitted in ASME B16.5 with the use of appropriate gasketing material.
larger than 24 in. However, the designer must ensure that the flange drilling on such R1
flanges will match that of the equipment to which it is to be attached. MSS-SP-44 Steel The most widely used bolting materials in process plant are ASTM A193 Grade B7 stud bolts
Pipeline Flanges & ASME B16.47 - Large Diameter Steel Flanges are also useful with ASTM A194 Grade 2H heavy semifinished hexagonal nuts. These materials are
standards when using flanges larger than 24 in. acceptable from -50°F to 1000°F. A number of operating companies use these materials
almost exclusively to simplify inventories and reduce the possibility of misapplication of carbon
2.2 Selection and Limitations of Blanks -steel bolting. Carbon-steel bolting may be used with non-metallic gaskets with flanged
joints rated Class 300 and lower for bolt metal temperatures at -20°F to 400°F.
In a process plant, blanks are usually required to isolate individual pieces of equipment at
shutdown and to block off selected process lines positively at the process unit limits. They are
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th
2.6 Selection and Limitations of Strainers (Refer Ch. C7 – Piping Handbook, 7 Ed.) 3.2 Flanged Joints
The material for the strainer body (including bolting) should be equal to material specified for The number of flanged joints in a piping system is usually determined by maintenance and
the valves in the same service. The screen material generally should be the same as the erection considerations, including sufficient flanged joints for insertion of blanks during
valve trim (e.g., 11-13 percent chrome or Type 316 stainless steel for most services). The shutdown.
location of permanent strainers (as contrasted to the temporary cone type which is installed at
a flanged joint) also merits attention. 3.3 Expanded Joints
Centrifugal and reciprocating pumps handling material containing solids should have This type of joint is more commonly used on the piping and tubes for refinery heaters. They
permanent strainers provided in the suction lines to the pump or in the vessel from which the are excluded for use in hazardous and toxic services and under severe cyclic conditions.
pump takes suction. The free area of such strainers should not be less than three times the
cross-sectional area of the suction line. 3.4 Threaded Joints
In addition, permanent strainers or filters should be provided in the piping for the protection The threading of pipe with a wall thickness less than ASME B36.10M standard wall is not
of the equipment indicated in Table C 7.8 (Strainer Screen Openings for Equipment Inlet permitted, and the use of threaded joints where severe crevice corrosion or erosion may
th
Piping) of the Piping Handbook 7 Ed. The maximum clear opening for screens in these occur should be avoided. Economics will limit the use of threaded piping to small pipe sizes (2
strainers varies with the application, but it should not exceed the value recommended for the in and smaller) for most services; however, it is used for most galvanized piping.
particular type of equipment. The available pressure differential usually determines the
minimum clear opening for screens. All pipe threads on piping components must taper pipe threads in accordance with ASME
B1.20.1 except the following:
Permanent strainers should have baskets, which can be flushed clean during operation or
easily removed for cleaning. If considerable clogging of strainers is anticipated, the strainers • Pipe threads other than taper pipe threads may be used for piping components, where
should be of the self-cleaning or duplex type to permit continual flow of clean liquid. tightness of the joint depends upon a sealing surface other than the threads and where
experience or tests have demonstrated that such threads are suitable for the condition.
th
3.0 PIPING JOINTS: (Refer Ch. C7 – Piping Handbook, 7 Ed.)
• Couplings, 2 inch and smaller, with straight-tapped pipe threads may be used on piping
components with taper pipe threads if the design conditions do not exceed 150 psig or
The type of piping joint used must be suitable for the pressure temperature conditions and 400°F and if the fluid handled is non-flammable and non-toxic (Category D Fluid Service).
should be selected by giving consideration to joint tightness and mechanical strength under
the service conditions (including thermal expansion) and to the nature of the fluid handled with
respect to corrosion, erosion, flammability, and toxicity. In general, the number of disassembly 3.5 Flared, Flareless, and Compression Joints
joints is minimized; most joints are welded if the material is weldable.
Piping joints using flared, flareless, or compression-type tubing fittings may be used within the
Welded piping is used almost exclusively for transporting hydrocarbons and other flammable limitations of applicable standards or specifications. In the absence of such standards or
fluids. Bypass piping, alternate process connections, and auxiliary piping systems such as specifications, the engineer shall determine that the type of fitting selected is adequate and
gland oil, seal oil, lubricating oil, fuel gas, fuel oil, heating or cooling oil, flushing oil, flue gas safe for the design conditions in accordance with the following requirements:
and blowdown piping, are included. Welded construction is also used for all piping outside
process unit limits which is used for the transfer of hydrocarbons or most other process fluids. • The pressure design shall meet the requirements of the code.
Piping which is threaded or welded, depending primarily on economic considerations, includes
piping, other than specifically mentioned above, in services such as drains, vents, pumpouts, • A suitable quantity of the type and size of fitting to be used shall meet successful
sample connections, and certain instrument leads, which contain process fluids only upon performance tests to determine the safety of the joint under simulated or similar service
intermittent or occasional use of the piping involved and which are not an integral or essential conditions.
part of the process system.
• Fittings and their joints shall be suitable for tubing with which they are to be used.
3.1 Welded Joints
• Fitting shall not be used in services which exceed the manufacturer’s maximum pressure-
The Code permits welded joints in all instances in which it is possible to qualify welding temperature recommendations.
procedures, welders and welding operators in conformance with the rules of the Code. There
are, however, a few minor additional considerations for seal-welded (threaded) and socket-
welded joints limited to size NB 2”. For example, the Code cautions against the use of socket- 3.6 Caulked Joints
welded construction in cases where severe crevice corrosion or erosion occurs. The Code
also states that seal welds may be used to avoid joint leakage but that they shall not be
The term caulked joints applies to joints of the bell-and-spigot type which are permitted only
considered as contributing any strength to the joint.
for water service at pressures suitable for the pipe to which they are applied. Provisions must
be made to prevent disengagement of the joints at bends and dead ends and to support
lateral reactions produced by branch connections or other causes.
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3.7 Brazed and Soldered Joints • On ferritic materials to be used below 20°F, the welder’s identification mark should be
preferably be made with ink stencil. Steel stamping should be avoided.
Fillet-brazed or fillet-soldered joints may not be used in process piping, but soldered-type and
silver brazed socket-type joints are permitted in non-flammable non-toxic service. The low • Welding procedure for fillet welds and seal welds :
melting point of brazing alloys shall be considered where possible exposure to fire is involved.
The Code does not permit cracks in fillet or seal welds and limits undercutting to 1/32 in for
these welds. Fillet welds may vary convex to concave. If seal welding of threaded joints is
4.0 FABRICATION, ASSEMBLY AND ERECTION OF PROCESS PLANT PIPING: performed, the Code requires that all exposed threads be covered by the seal weld and that
the welding be done by qualified welders. In addition to the Code requirements, it is strongly
recommended that (1) threaded joints be made dry (without thread compound), (2) seal
Complete detail and exact requirements which relate to fabrication , assembly and erection of welds be at least two-pass (preferably three-pass) welds using a 3/32 in or 1/8 in electrode
1
the process piping systems are given in Chapter V of ASME B31.3. Important phases of the (5/32 in electrode is acceptable for 2 /2 in and larger pipe size), and (3) valve and union ends
Code treatment of these topics are covered briefly below. be welded by the electric arc process to minimize distortion and ensure that valves be closed
during welding.
4.2 End Preparation (Refer Clause 328.4) The following code requirements apply to girth butt welds and any longitudinal butt weld in a
piping component which is not made in accordance with a standard specification:
ASME B16.25 provides dimensional standards for weld end bevels. Preferably, the ends of
pipe and the edges of plate which are to be formed into pipe should be shaped by machine. • If the external surfaces of the two components are not aligned, the girth butt weld must be
Other methods of shaping may be used provided a reasonably smooth surface suitable for tapered between the two surfaces.
welding and free from tears, slag, scale and grease is attained. Oxygen or arc cutting is
acceptable only if the cut is reasonably smooth and true and all slag is cleaned from the flame
cut surfaces. • Tack welds, if not made by a qualified welder using the same procedure as the completed
weld, must be removed. Tack welds which are not removed should be made with an
If piping component ends are machined on the inside for backing rings, such machining must electrode which is the same as or equivalent to the electrode to be used for the first pass.
not result in a finished wall thickness, after welding, less than the minimum design thickness Tack welds which have cracked must be removed.
plus corrosion and erosion allowances. Generally a root gap of 1/8 in is used for joints
(including branch connections) without backing rings, except that where the pipe wall
thickness is less than 3/16 in, a 1/16 in root gap is generally used. • The types and limitations of imperfection required to be evaluated with various types of
examinations are shown in the Code.
4.3 Other Alignment Considerations (Refer Clause 328.4.3)
4.5 Preparation and Welding Procedure for Welded Branch Connections
Flange bolt-holes should straddle the established center lines unless other orientation is
required to match the flange connections on equipment. Slip-on flanges should be positioned Branch connections (including specially made integrally reinforced branch connection fittings)
so the distance from the face of the flange to the pipe end is about equal to the nominal pipe- which abut the outside surface of the run wall or which are inserted through an opening cut in
wall thickness plus 1/8 in. Welding neck orifice flanges should be the same bore as the pipe the run wall must be so arranged as to provide a good fit and be attached by means of full-
penetration groove welds.
to which they are attached and must be aligned accurately. Longitudinal seams in adjoining The recommendations for spacing and location of branch connections contained in Pipe
lengths of welded pipe should be staggered and located to clear openings and external Fabrication Institute (PFI) Standard ES7 should be followed. A good fit must be provided
attachments. between reinforcing rings and saddles and the parts to which they are attached. When rings
and saddles are used, a vent hole is provided (at the side and not at the crotch) in the ring or
The following restrictions, limitations or guidelines apply to welding of process piping: saddle to reveal leakage in the weld between branch and main run and to provide venting
during welding and heat-treating operations. Reinforcing pads should be proportioned so the
diameter of a vent hole is not greater than one-third of the pad width.
• Projection of weld metal into the pipe bore at welded butt joints should not exceed 1/16 in
th
for pipe 8 in and smaller or 1/8 in for larger pipe. Excessive projection on accessible joints 4.6 Fabrication Tolerances for Welded Piping (Refer Ch7 – Piping Handbook, 7 Ed.)
should be removed. Welds attaching welding neck orifice flanges to pipe should be
ground smooth on the inside. A widely accepted tolerance on face-to-face and center-to-face dimensions of welding piping
is ± 1/8 in (3 mm). As for the location of the flanges, their lateral translation in any direction
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SELECTION AND LIMITATIONS OF SELECTION AND LIMITATIONS OF
Uhde India Limited PIPING COMPONENTS Page : 10 Uhde India Limited PIPING COMPONENTS Page : 11
from the specified position should not exceed 1/16 in. (1.5 mm). Also the alignment of flanges Steel-to-cast-iron flanged joints must be assembled carefully in order to prevent damage to
should not deviate from the specified position, measured across any diameter, by more than the cast-iron flange. Both flanges in steel-to-cast-iron flanged joints should be flat faced.
1/32 in. These joints should be made up with extreme care, taking up on bolts uniformly after fitting
flanges into close parallel and lateral alignment. Flanges which connect piping to mechanical
4.7 Qualification equipment, such as pumps, turbines or compressors, should be fitted up in close parallel and
lateral alignment before tightening the bolting.
Qualification of the welding procedures to be used and of the performance of welders and
welding operators is required to comply with the ASME Boiler and Pressure Vessel Code.
Section IX 4.13 Cast-Iron Bell-and Spigot Piping
4.8 Defect Repairs Bell-and-spigot joints in cast-iron piping must be assembled using poured lead or other joint
compound suitable for the service. Usually each cast-iron bell-and-spigot joint is packed with
Weld defects which, require repair must be removed. All repair welds must be made with the hemp, poured full of lead (with a minimum number of pours), then caulked. The depression of
same welding procedure initially used. lead below the face of the bell, after joint caulking, should not exceed 1/4 in. (Lead wool can
be used where it is not permissible to pour lead).
4.9 Bending and Forming
Pipe may be bent by any hot or cold method consistent with material characteristics of the 4.14 Threaded Piping
pipe being bent and the intended service. It may be bent to any radius which will result in a
bend arc surface which is free of cracks and buckles. Any compound or lubricant used on threads must be suitable for the service conditions and
compatible with both the service fluid and the piping materials. Threaded joints which are to
Hot bending and forming must be done within a temperature range consistent with material be seal welded should be made up without any thread compound.
characteristics, end use, or heat treatment. It is recommended that hot bends in pipe sizes
1
1 /2 in and larger be packed with high temperature silica sand and that the pipe be uniformly 4.15 Erection of Corrugated Expansion Joints
heated before the hot bending operation. When pipe must be threaded before bending,
forging, or heat treating, all exposed threaded surfaces should be protected during heat Corrugated expansion joints should be installed as-shipped from the manufacturer or
treatment. compressed for the cold condition at erection, depending on anticipated direction and
magnititude of movement after the pipeline reaches operating temperature. The
4.10 Cleaning after Fabrication manufacturer’s recommended total travel should preferably straddle the calculated travel.
Following fabrication, all loose scale, weld spatter, slag, sand and other foreign materials 4.16 Erection of Valves
should be removed from the piping. PFI Standard ES5 ( Cleaning of Fabricated Piping) is an
acceptable standard for cleaning fabricated piping. Piping should not be painted in the Valve packing glands should be checked for the quality and quantity of packing, and
fabricating shop (i.e., before it has been erected and tested). lubricated plug valves should be provided with proper lubricant.
Heat treatment is used to avert or relieve the detrimental effects of high temperature and In addition to the major supports specified by the design drawings, minor supports as found
severe temperature gradient inherent in welding and to relieve the residual stresses created necessary in the field should also be installed to prevent undesirable vibration, sag, lateral
by bending and forming. movement, and stresses. Spring hangers, including constant-support type, should be checked
for proper adjustment of travel and be correctly positioned for the cold condition of erection.
The welding procedure qualification establishes the necessity for preheating and post-heating
welds (and the temperatures and soaking period to be used) in order to restore or obtain the 4.18 Cleaning of Lines after Assembly and Erection
physical properties of the materials (such as strength, ductility, and corrosion resistance)
needed to satisfy end use requirements. After completion of erection, scale, dirt, welding electrodes, slag and other foreign material
should be removed from the lines. Particular attention should be given to the cleaning of air
4.12 Bolting Procedure for Flanged Joints lines and compressors and blower, pump and turbine inlet piping. Before the initial operation,
steam lines to turbines and to steam ends of reciprocating compressors and pumps should be
It is a good practice to apply an antiseize thread compound to the bolts before the nuts are blown down with steam, 100 psig or higher.
installed. A mixture of graphite and oil is one of the best substances for this purpose.
Tightening og bolts should follow usual criss-cross sequential pattern to approximate pre-load All practical precautions should be taken to prevent the introduction of foreign matter into
seating of the Gasket pumps, instruments and other equipment. Cleaning may be accomplished by flushing out the
lines. Temporary strainers should be used at pumps during flushing operation unless spools
In bolting joints using spiral-wound gaskets, the gasket should be compressed to about 25
percent of the original thickness. Spiral wound gaskets conforming to API Standard 601 have or valves can be conveniently dropped out and suitable deflectors provided to prevent refuse
a 0.125 in thick outside gauge and centering ring. The gasket is seated when it is compressed from entering the pumps. Consideration should be given in dismantling those lines which
until the flange faces touch the gauge ring. cannot be adequately cleaned by flushing.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0014 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0014
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5.2.3 100 Percent Radiography
th
5.0 EXAMINATION, INSPECTION AND TESTING: (Refer Ch. 7 of Piping Handbook, 7 Ed.)
If 100 percent radiography is specified for welds in piping, each weld in the piping shall be
Before initial operation, piping installation should be inspected to the extent necessary to completely radiographed.
assure compliance with the engineering design and with the material, fabrication, assembly
and test requirements of the Code. An employee representative of the owner should be 5.2.4 Hardness Tests
responsible for this inspection. This examiner may delegate performance of any part of the
inspection to inspectors who may be employees of his own organization, of an engineering or The extent of hardness testing required shall be specified by the engineering design,
scientific organization, or of a recognized insurance or inspection company. considering the severity of the service, type of material and other pertinent factors.
A non-destructive examination (NDE) plan should be consistent with service severity, 5.3 Pressure Tests
incorporating process and mechanical factors. The NDE plan focus should be on those
pipelines where failure would produce the most harm to personnel or property. Some issues Before initial operation, piping must be pressure tested to assure leak tightness. If repairs or
the designer should consider when developing the NDE plan are as follows: additions are made following the pressure tests, the affected piping is retested, except that in
the case of minor repairs or additions, the owner may waive retest requirements. The
• Service factors: Corrosivity, toxicity and flammability - hazardous nature of flowing media. pressure test is maintained for a sufficient time, but not less than 10 min, to determine if there
The designer should apply a sound NDE program to detect flaws in these dangerous are any leaks.
streams.
Water is commonly used as the test fluid except when there is a possibility of damage due to
freezing or if the operating fluid or piping material would be adversely affected by water. If
• Mechanical factors: Temperature, pressure, cyclic conditions, thermal bending stresses, hydrostatic testing is not considered practical, a pneumatic test using air or another non-
vibration. Fatigued and highly stressed lines are more likely to fail than low-stressed lines. flammable gas may be substituted.
Detection and removal of flaws can provide additional service life.
A preliminary air test at not more than 25 psig, is made before hydrostatic test in order to
5.1 Visual Examination locate major leaks. If pressure tests are conducted at low metal temperatures, the possibility
of brittle fracture must be considered. Hydrostatic pressure tests are conducted at 1.5 times
All welds are required to be capable of compliance with the limitations on imperfections nominal design pressure, adjusted for temperature. ASME B 31.3 gives the Formula for
specified in the Code for visual examination. Visual examination consists of observation by temperature correction for Pressure Test as follows:
the inspector of whatever portions of a component or weld exposed to such observation,
either during or after manufacture, fabrication, assembly or test.
PT = 1.5 P ST / S
5.2 Supplementary Types of Examination
Where: PT = Minimum Test Gauge Pressure
The following supplementary types of examination are not required unless specified by the P = Internal Design Gauge Pressure
engineering design because of special service conditions requiring a high degree of freedom ST = Allowable Stress value at Test Temperature
from imperfections. If such examination is specified for a weld, it is only required that the weld S = Allowable Stress value at Design Temperature
examined be repaired, if necessary, so the weld imperfections comply with the limitations in
the Code for the type of examination used. If supplementary types of examination are Pneumatic tests are conducted at 1.1 times nominal design pressure.
specified, they should be performed after completion of any postheat treatment where
required. If any of the following types of examination is specified by the engineering design, it 5.4 Test Preparation
should be performed to the extent as follows:
All joints, including welds, are to be left non-insulated and exposed for examination during the
test. If a joint has been previously tested in accordance with the Code, it may be insulated or
5.2.1 Magnetic Particle covered. Piping designed for vapour or gas shall be provided with additional temporary
supports, if necessary, to support the weight of the test liquid. Expansion joints shall be
Magnetic Particle Examination is essentially a surface type examination. provided with temporary restraint, if required, for the additional pressure load under test of
shall be isolated from the test.
An area to be examined by magnetic particle examination can be completely examined or
examined on a random sampling basis, as specified. Equipment which is not to be included in the test shall be either disconnected from the piping
or isolated by valves or blanks.
5.2.2 Random Radiography
All pressure gauges, gauge glasses, flow meter pots, liquid level float gauges, and all other
X-Ray or gamma-ray radiography may be used. The selection of the method should be pressure parts of instruments, together with the piping connecting the instruments to the main
dependent upon its adaptability to work being radiographed. When random radiography of piping, should be included in the hydrostatic test. Relief valves and rupture disks should not
welds is specified by the engineering design, it should be done on the number of welds be subjected to the pressure test. If a pressure test is to be maintained for a period of time
designated. The engineering design shall specify the extent to which each examined weld and the test liquid in the system is subject to thermal expansion, precautions must be taken to
should be radiographed. Random radiography may also be used for examination of piping avoid excessive pressure built up.
components such as valve or fitting to any extent specified by the engineering design.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0016
CONTENTS
5.5 Pneumatic Testing
Page
If piping is tested pneumatically, the test pressure is set at 110 percent of the design
pressure. Pneumatic tests include a preliminary check at not more than 25 psig; the pressure 0.0 Cover Sheet 1
is then increased gradually in steps providing sufficient time to allow the piping to equalize
strains during test and to check for leaks. 1.0 Introduction 2
Applicable Revision:
Prepared: Checked: Approved:
Rev. : R0 Rev. : R0
PROJECT SITE SELECTION PROJECT SITE SELECTION
Uhde India Limited Page : 2 Uhde India Limited Page : 3
Site selection for a plant, keeping in view the various Corporate objectives of the Company Now-a-days, generally, as the plant would be operating on a sophisticated technology, it
requires careful considerations of the numerous factors that would go into making the plant would be essential to attract qualified professionals. This would involve ensuring a good
contribute towards its working environment and make it into a technologically and quality living which in turn would depend on availability of good schools and colleges, medical
economically viable unit. Decisions are strategic, long-term and non repetitive in nature. A services, good communication facilities, cultural and recreational opportunities, etc. Unless a
certain amount of imaginative planning for the future is also called for at the time of final good community infrastructure is available, it is found that attracting qualified professionals in
decision about the site to be selected. rather difficult.
Generally sites for a new plant will be allocated according to the general industrial
development policies of Govt. of India. The various factors which need to be considered for Availability of Raw Water:
site selection are briefly touched upon in the foregoing paragraphs.
It is recommended that the plant be located in close proximity to a perennial source of water
of adequate quantity which will meet the plant requirements and the other non plant
2.0 LOCATION FACTOR: requirements. Drawing the water by boring deep tube wells without the provision of a
perennial source is not preferable because the ground water may be depleted at a future date.
The location factor deserves careful attention simply because of its long term consequences. In summary, the Natural Water Table and flooding history should be duly considered.
Any mistake in selection of a proper location could prove to be costly. Improper location could
be a constant source of higher cost, higher investment, difficult marketing and transportation, Effluent Disposal:
dissatisfied and frustrated employees and consumers, low availability of high caliber
professionals, frequent interruptions of production and abnormal wastage. Once a plant is set The natural drainage facility for disposal of Effluent should be duly examined.
up at a particular location, it is very difficult to shift later to a better location because of
numerous economic, political and sociological reasons. Social reasons could include It would be economically advantageous if an effluent disposal facility after treatment, which
employee welfare, employment opportunities. Political reasons could be due to pursuance of can handle the produced quantity of effluent is readily available. Otherwise, transporting the
a policy of regional development and planning especially in a developing country like India. effluent by a drainage, to a safe disposal area which is far away has to tackle the legal and
ecological problems.
The location factor also requires that the following facilities are taken into consideration.
To ensure that the license is obtained for locating the plant in a no-industry district. Stable and uninterrupted power of required magnitude, without fluctuations in voltage and
frequency is important for the successful operation of the plant.
Transportation Facilities
Nearness to the available power facility will reduce the plant cost.
The raw materials and end products require to have uninterrupted receipt and dispatch
facilities through good road connections, proper linking with ports and railheads. Possibility of
an in-plant rail siding has to be looked into depending on the amount of raw materials and Wind and Seismic Factor:
products to be handled.
Prevailing wind direction, Maximum Wind Speed and seismic history of the site should be duly
Connection with Airports is important mainly from the point of view of easy movement of considered.
professionals. This is all the more important if foreign collaborations are involved in the plant.
Local availability of skilled and semi skilled manpower will add to the efficient running of the Industrial gas is now available at various places in our country from the Gas pipeline network.
plant. Industrial gas is the preferred source of energy as it is more efficient and contributes very little
towards industrial pollution. Now-a-days, for almost all plants, uninterrupted power supply is of
great importance and a gas based captive steam power generation unit will be very
Industrial Infrastructure: advantageous.
This is important in view of the fact that all supporting services required for the successful Accordingly, nearness of the site to a gas distribution network will be of great advantage in
operation of the plant like maintenance and repair of various machines and other items, view of long term planning and future expansions.
availability of workshops, plant services, etc. may not be feasible to be generated within
factory complex. Availability of communication facilities is also an important part of the
infrastructure. An existing vibrant infrastructure in the vicinity is much preferred than the need
based infrastructure getting developed after the plant commissioning.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0016 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0016
Rev. : R0 Rev. : R0
PROJECT SITE SELECTION PROJECT SITE SELECTION
Uhde India Limited Page : 4 Uhde India Limited Page : 5
Load bearing characteristics and acidity of the soil plays an important role in site selection.
Natural soil has got more load-bearing capacity as compared to filled soil. Consequently, the
cost of the civil foundation will be less in natural soil because piling to support heavy loads
1. Location 5
may not be required whereas in case of filled soil piling may be required.
2. Industrial 4
Infrastructure
4.0 ECOLOGY AND POLLUTION: 3. Community 4
Infrastructure
4. Availability of water 4
Now-a-days, there is a great deal of awareness towards maintenance of natural ecological
balance. Regarding the effect of pollution from specific type of plants, social obligations are to 5. Effluent disposal 4
be met. The nature of the site selected should preferably have some advantages to meet
these requirements. 6. Availability of Power 4
7. Availability of Gas 2
5.0 QUANTITATIVE ANALYSIS:
8. Site size and Nature 3
The above factors are considered at the time of site selection and the data collected are
analyzed, generally by the weight-cum-rating method, in order to finalize recommendation of 9. Ecology and 2
the potential site. Pollution
In the weight cum rating method, variable weights are assigned to each factor. Then each site
is evaluated on a 0-5 sliding scale for each of these factors. The assignment of points for
each site for each factor is obtained by multiplying the rating of the site by the weight of each
factor.
FATEHPUR
The overall site rating is then obtained as the sum of the assigned points for each site.
1. No Industry District.
The recommendation will be for the site having maximum overall rating. 2. Adjacent to N.H.2
3. 2 to 3 km from Delhi Howrah Broad guage line
4. 52 km from Kanpur
5. Population of 1 lakh
6. Semi skilled and skilled labour available
7. Industrial area is under development
8. Medium sized industrial units are at the border of Kanpur
9. Bus services are frequent
10. Some express Trains also stop at FATEHPUR
11. A Govt. hospital with 200 beds and several private nursing homes are available
12. Schooling facilities are available, No colleges - One ITI is available
13. One small bank is available
14. Communication facilities are meager
15. One housing complex is under construction so also a shopping complex.
16. Ganga river is 12 km away
17. Potable water is available at 150 ft. depth
18. No natural drain for discharge of effluent, also a safe disposal area could not be located
nearby.
19. 132 K V Sub station is near to site and requisite quantity of power is available
20. Industrial gas is not available
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0016 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0017
Rev. : R0 Rev. : R0
PROJECT SITE SELECTION PLANT LAYOUT
Uhde India Limited Page : 6 Uhde India Limited Page : 1
CONTENTS
21. Adequate area of plot is available for the plant. Rail siding is not possible without
additional land acquisition. Page
22. Min. & Max. temp. are 5C and 43 C respectively with an average rainfall of about 800
mm. 0.0 Cover Sheet 1
23. No record of seismic activity.
24. Resistance from ecology and pollution control group is expected. 1.0 Introduction 2
SEHUR
Rev. : R0 Rev. : R0
PLANT LAYOUT PLANT LAYOUT
Uhde India Limited Page : 2 Uhde India Limited Page : 3
Today’s trend at large and complex plants presents substantial risk potential. In order to
A process plant, which consists of the various different sections mentioned earlier should be
minimize the risks, certain norms are developed and practiced with respect to space
arranged so as to follow the general route of raw material to process, to Intermediate/Finished
allocations & relative locations and some specified distances are to be taken care of while a
product storage, to dispatch.
plant is designed. Many times, existing plants are modified to increase the capacity by
change/addition of certain equipment whereas the original space designs may not be
Generally block concept is prevalent for the Plant Layout wherein the entire plot area is
sufficiently cater for such changes. This also calls for a detailed analysis of the space
divided into blocks. The sizes of the blocks depend on the facilities to be accommodated.
allocation and consideration of any new additions.
While locating the blocks and further sub blocks within them, the following points are to be
Generally, the basis of keeping specific inter distances depends on the lessons learnt during
considered.
the past years from accidents which occurred in various plants throughout the world.
Accordingly, the specified minimum distances and the specified relative locations are
undergoing a continuous updation as new datas are generated and experiences increase.
Layout planning shall be in sequential order of process flow so that piping are also
minimum.
A few of the major points to be born in mind while venturing into plant layouts are explained
here.
The blocks shall be so arranged considering the prevalent wind direction that
flammable gases should not be carried by wind on to source of ignition.
The various process plants we come across are Petroleum refineries, Petrochemical
complexes. Fertilizer plants, and Chemicals and Pharmaceutical plants, which need special
Process unit block shall be centrally located with straight approach from main gate.
attention due to the nature of the materials and products handled in those plants. All these
plants involve various facilities such as raw material storage; intermediate and finished
Storage tanks shall be grouped according to product classification. In undulating
product storage, Process units and Control rooms; Flare System, Raw material/Product
areas, storage tanks shall be located in lower elevations.
loading and unloading facilities; Utilities generation and distribution; Waste water treatment
facilities; Non plant facilities such as Administration Buildings, Canteen, Workshops,
Utility blocks shall be located adjacent to unit blocks.
Laboratory, Security arrangements, Vehicle Parking space, Stores, Fire station, and
Township. Space allocation need to be provided to accommodate all these facilities.
Main blocks shall be located adjacent to unit blocks.
Before starting the development of Plant Layout the following information is a must.
Main power receiving station shall be close to the boundary line so that minimum
overhead power lines pass through the plant.
• Process Units and Capacities.
• A flow diagram indicating the process flow sequence. The electric sub stations in the plant shall be located in such a way that the cabling to
• Utility requirements. major load centers are minimum.
• Number of storage tanks and also open storage area.
• Raw material/Product receipt and dispatch philosophy. The location of power plants shall be near to the process/utility blocks and close to
• Covered storage required. main receiving station.
• Number of Flares.
• Grouping philosophy for utilities. Flare shall be located upwind of process units so that the inflammable gas from plant
• Non plant Buildings. is not carried towards flare.
• Environmental Considerations.
Truck loading facilities shall be located close to product movement gate. Rail loading
The data collected during the site selection stage shall be given due consideration at the time facilities are arranged generally at the periphery of the plant.
of plant layout. A few of the points are:
Effluent plant shall be located away from the other units on the down wind location.
• Site location map and Area topography contour map for the plot size, shape and the The preferred location is at lower elevation than the other plant units in order to
nature of the land. facilitate gravity flow.
• Prevailing wind direction.
• Source of water supply and the supply point with respect to the plot. Fire station and fire water pump house shall be at a safe place away from hazardous
• Electric supply point with respect to the plot. areas. Fire station shall be near to the main gate with straight approach to process
units and other critical areas.
• Effluent disposal point and the other drainages.
• Railway entry point.
Two adjacent process unit location shall be decided based on the annual shut down
• Approach roads to the plant. philosophy for the maintenance of the units. If the shut downs will be at different times,
• Raw material/Product movement by rail/road. it is preferable to increase the distance between the two points so that the risk for
• Surrounding areas of the plot and considerations to be given to the neighborhood. operating units due to hot jobs in the units under shut down can be minimized. Also
this will facilitate easy maintenance.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0017 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0017
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PLANT LAYOUT PLANT LAYOUT
Uhde India Limited Page : 4 Uhde India Limited Page : 5
Process units shall be located on the high ground. The environmental/security requirements now demand that a Green Belt area around the
plant boundary shall be provided. This is a belt of width 30m to 40m around the plant
The adjacent neighbourhood installations, if any, shall be taken into consideration boundary where no construction will be done.
before fixing the plant layout. The limitations imposed by the neighbourhood facilities
cannot be ignored, e.g. an ignition source. TABLE A
Flares, Furnaces/Heaters, Dusty operations and Cooling towers shall be oriented 1. Process Units to Flare 90 M
depending on the prevailing wind direction. The first two shall be located upwind of
Process units and the last two on the down wind directions of process units.
2. * Storage tank ‘Class A’ to Class Minimum of :
Due consideration of construction and erection of the plant shall be given while B’ or ‘Class A’ to Class A’ 15 M from Perimeter
deciding the plant layout, especially Tall Towers, Reactors, Furnaces, etc. shall not be or 0.5 D or d where,
at congested areas and sufficient open space shall be provided to have erection at any D=Dia. of Large tank
stage. d=Dia. of small tank
3. * Storage tank ‘Class A’ to 8M
Equipment requiring frequent maintenance shall have easy accessibility. So also Flameproof Pump
equipment having removable parts shall have free access for removal of the part and 4. * Storage tank ‘Class A’ to 20 M
also for the free access for hoisting equipment. Boundary
Provisions for future expansion shall be considered. It is preferable to have similar type 5. Loading / Unloading Tank Vehicle 15 M
of facilities in adjacent space for expansion. Care shall be given to give the expansion to Tank or Boundary
facilities without any disturbance to the existing facility. 6. Non-Flameproof Electric Pump to 15 M
tank Class A/B
Care shall be given to give the expansion facilities without any disturbance to the 7. Electrical Sub stn. to Process 15 M
existing facility. units
8. Fire stations to Process Units 60 M
The blocks developed are separated by roads in between for purpose of access and
safety. The fire fighting facilities are to be provided on these roads. 9. Boiler House to Process Units 45 M
There shall always be an alternative approach for fire fighting and maintenance in case 10. Cooling Towers to Boundary 30 M
one route is blocked.
11. Service Buildings to Process Units 60 M
The layout shall be so designed that truck traffic inside the plant is minimized.
12. Control Room to Process Unit 30 M
Boiler house, Air compressors, Fuel oil facilities shall be grouped into one block
adjoining the Process unit blocks, so that spreading of various utilities can be avoided
and also to facilitate easy operation. 13. Process Unit to Process Unit 30 M
The layout shall be designed so as to minimize capital cost for earthwork and 14. Process Unit to ADM Building 60 M
pavements, special foundations and extent of vacant plot as waste land.
Some of the major distances to be considered during plant layout are given in Table A.
The plant layout needs statutory approvals before implementation. Some of the statutory
approving codes are
* Petroleum Storage Tank
• Indian Factory Act.
• Indian Explosives Act.
• Petroleum and Carbide of Calcium Manual.
• Indian Electricity Rules.
• Insurance Association of India Fire Protection Manual.
• NFPA Code of Practice / TAC Rules.
The oil industry safety directorate gives some guidelines for plant layouts but does not
overrule the existing statutory requirements.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0018 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0018
Rev. : R0 Rev. : R0
GENERAL REQUIREMENT OF GENERAL REQUIREMENT OF
Uhde India Limited EQUIPMENT LAYOUT/ UNIT PLOT PLAN Page : 1 Uhde India Limited EQUIPMENT LAYOUT/ UNIT PLOT PLAN Page : 2
CONTENTS
1.0 BASIC CONSIDERATIONS:
Page
The relative arrangement of the various equipment and machinery laid in the particular unit /
0.0 Cover Sheet 1 area / building is indicated. It should meet the following requirements:
1.0 Basic Considerations 2 1.1 Process constraints like minimum elevations, distances, slopes, etc.
3.0 Development of Equipment Layout 2 1.3 Maintenance feasibility like monorail, fork-lift /mobile crane approach, working area,
etc.
4.0 Input Information 2-3
1.4 Ease of erection.
5.0 Contents 4
1.5 Industrial safety.
6.0 General Points 4-5
1.6 Statutory regulations e.g. Petroleum Act/ Gas Cylinder Rules, Static & Mobile
Pressure Vessel Rules and Factory Inspectorate Rules.
1.7 Aesthetics
The scale can be 1:50 on any size of sheet, depending upon the area coverage. As far as
possible a nearby road/pipe rack should be shown to make the approach/obstructions clear. If
most of the equipment are of large size then scale can be reduced to 1:100, 1:200 or 1:250
e.g. in case of big tank farms, ammonia storage tanks, etc.
This drawing is started when Process flow sheets and major equipment dimensions (e.g.
equipment list) are available. Piping Engineer should first develop a one-plane elevation of all
equipment to scale and relatively locate to fulfil process requirements. He should keep good
margins for nozzle lengths, bends, valves, slopes and distances between equipment, etc.
while locating the equipment. He must as well think of structural/concrete beam depths,
monorails, pipe-ways, cable trays, lighting, etc. while deciding the floor elevation.
This one-plane elevation view should be discussed internally and then with PE group who will
check relative locations & elevations of equipment. Routing of major & critical process lines
Applicable Revision: should also be discussed at this stage. After deciding floor elevations and number of floors,
Prepared: Checked: Approved: work can start on preliminary arrangement drawings which should show each floor plan as
well as elevation views at different sections.
Process:
Date: Date: Date:
File Name: C- 18 Server: PUNE: KUMUS 207 VKO: KUMUS 209 • Type of building/structure
Rev. : R0 Rev. : R0
GENERAL REQUIREMENT OF GENERAL REQUIREMENT OF
Uhde India Limited EQUIPMENT LAYOUT/ UNIT PLOT PLAN Page : 3 Uhde India Limited EQUIPMENT LAYOUT/ UNIT PLOT PLAN Page : 4
• Monorails/EOT/HOT requirement for maintenance. Following may be noted with regards to contents of the Unit Plot Plans:
Instrumentation: • Each Unit Plan to have a key plan of overall G.A. highlighting the area covered by that
Unit Plot Plan.
• Space requirement for instrument cables.
• All the equipment items should be located by co-ordinates of centre lines or dimensions
• Space & location requirements for Analyser cabinets/rooms, etc. from a column centre line. Orientation of equipment should be given by locating one big
size nozzle usually manhole in plan and elevation. Only elevations should be given. No
Electrical: vertical dimension lines will be added. All elevations should be with respect to +0.00
metres and should be finished elevations.
• Space requirement for cable racks & trenches.
• Pipe racks, cable racks, attached to the building will be shown. It is preferable to show
• Space for local Push Button Boards also the surrounding roads wherever possible.
• Economic consideration with regard to type of structure, column spacing & tie beam, • Sufficient sectional views will be drawn. It is better to cover area between two column
etc. meeting process requirements. grids (e.g. one bay) in one sectional view in order to maintain clarity. Requirement of
minimum clear, height, bottom elevation of monorails and elevation of top of brackets for
• Size and depth of Building Column Footings travelling cranes should clearly be marked in sectional views.
• Size and slope of Floor Drains • Critical lines requiring shortest route/minimum slope from process point of view and lines
of sizes> 500 mm, from interference and flexibility point of view should be included in the
Erection arrangement plan.
• Erection requirements such as bolted joints in the structure. • Include a table showing TON and Equipment Designation.
• Erection openings in floors. • Add pipe rack, cable tray loads for piperack plot plans.
• Extra space for derrick/crane, etc. • Mark various floor protection areas.
Preference for type of structure, maintenance facilities, like cranes, monorails, operational • Show major openings in floors.
amenities like office, toilet block, change room, lunch room aesthetical preferences, etc.
• Show major trenches, sumps and pits.
Details are received from all the above groups and the client and copies of Unit Plot
Plans including all revisions are distributed to all of them. It is advisable that all proposals be
discussed during conceptual stage itself with all groups so as to avoid major revisions at a 6.0 GENERAL POINTS:
later date.
Licensor: In absence of any other data agreed, following may be used for developing Unit Plot Plans:
Usually preliminary arrangement plans are furnished by the licensor (usually on 1:100 scale) • Minimum clear distance around every equipment : 600 mm
and our work is limited to update the same incorporating comments of various groups and
exact shape and dimensions of the equipment as and when received. • Minimum clear distance between two equipment : 600 mm
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0018 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0019
Rev. : R0 Rev. : R0
GENERAL REQUIREMENT OF UNIT PLOT PLAN
Uhde India Limited EQUIPMENT LAYOUT/ UNIT PLOT PLAN Page : 5 Uhde India Limited Page : 1
• Height of vertical cladding from finished floor level : 3.0 m 3.0 Pipe Berthing 4
• Minimum foundation height for equipment located : 200 mm 9.0 Check List for Plot Plans 7–8
on the ground from highest finished floor level.
Reference:
Applicable Revision:
Prepared: Checked: Approved:
Rev. : R0 Rev. : R0
UNIT PLOT PLAN UNIT PLOT PLAN
Uhde India Limited Page : 2 Uhde India Limited Page : 3
Furnace tube clearing and removal space as well as access to mobile crane shall be Table 1
provided.
The manholes in the towers shall be arranged in the direction facing the access way.
The required safety distances shall be provided with the equipment as well as for the
purpose of maintenance and operation.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0019 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0019
Rev. : R0 Rev. : R0
UNIT PLOT PLAN UNIT PLOT PLAN
Uhde India Limited Page : 4 Uhde India Limited Page : 5
5.0 PLATFORMS:
2.0 CLEARANCES:
Rev. : R0 Rev. : R0
UNIT PLOT PLAN UNIT PLOT PLAN
Uhde India Limited Page : 6 Uhde India Limited Page : 7
CENTERLINE OF CENTERLINE OF BLOCK VALVES LOCATED ABOVE 2.0 METER FROM THE
VALVES, INSTRUMENT, CENTERLINE OF ITEM THE ITEM TO BE OPERATING FLOOR WHICH ARE REQUIRED FOR NORMAL OPERATION SHALL BE
EQUIPMENT TO BE TO BE OPERATED, OPERATED, PROVIDED WITH PORTABLE PLATFORMS. CHAIN FOR OPERATION OF VALVES WILL
OPERATED LOCATED LESS THAN LOCATED MORE NOT BE USED.
3.6M ABOVE GRADE, THAN 3.6m ABOVE *
2.75 m ABOVE FLOOR GRADE, 2.75 ABOVE TEMPORARY ARRANGEMENT FOR ACCESS SHOULD BE FEASIBLE.
OR PLATFORM OR FLOOR OR
1.8M ABOVE WING PLATFORM OR 1.8m 9.0 CHECK LIST FOR PLOT PLANS:
PLATFORM ABOVE WING
TO PROVIDE: PLATFORM Overall Plot Plan:
TO PROVIDE:
EXCHANGER HEADS NIL PLATFORM • MAGNETIC AND PLANT NORTH
• REDUCED LEVEL AND SITE TOPOGRAPHY
OPER. VALVES 2” & FIXED LADDER FIXED LADDER
• PREVAILING WIND DIRECTION
SMALLER
• ROAD APPROACH TO SITE
OPER. VALVES 3” & PLATFORM PLATFORM
• RAIL APPROACH TO SITE
ABOVE
• BARGE OR SHIP DOCKS LOCATION
MOTOR OPERATED PLATFORM PLATFORM
VALVES • LOCATION OF INCOMING GAS, ELECTRIC POWER SUPPLY, WATER SOURCE ETC.
CONTROL VALVES PLATFORM PLATFORM • CO-ORDINATES AND DIMENSIONS OF VARIOUS UNITS
• PLANT ROAD SYSTEM
RELIEF VALVES 2” & FIXED LADDER FIXED LADDER • APPROACH ROAD FOR CRANE MOVEMENT TO VARIOUS UNITS
SMALLER • PATROLLING ROAD BY THE SIDE OF PLANT BOUNDARY WALL
RELIEF VALVES 3” & PLATFORM PLATFORM • SPACE FOR
ABOVE UNDERGROUND PIPING
BLOCK VALVES 2” & PORTABLE LADDER PLATFORM UNDERGROUND DRAINAGE SYSTEM
SMALLER UNDERGROUND FIRE HYDRANT MAIN
BLOCK VALVES 3” & PLATFORM PLATFORM PIPE RACK/ELECT./INST CABLE RACK
ABOVE BETWEEN ROAD AND PLANT BATTERY LIMIT
BATTERY LIMIT PLATFORM PLATFORM • RAIL/ROAD APPROACH FOR RAW MATERIALS AND FINISHED PRODUCT
• STORAGE AREA FOR KEEPING EQPT. & MACHINERY ETC. BEFORE ERECTION
VALVES PRESSURE FIXED LADDER IF FIXED LADDER • STATUTORY REQUIREMENTS LIKE EXPLOSIVE ACT, POLLUTION CONTROL, TAC
LIMIT ABOVE 2.2M HEIGHT ETC.
TEMPERATURE FIXED LADDER IF FIXED LADDER • PROVISION FOR FUTURE EXPANSION
INSTRUMENT ABOVE 2.2M HEIGHT • COOLING TOWERS
SAMPLE POINTS PLATFORM PLATFORM • FLARE STACK (TO BE LOCATED SUCH THAT THE FLAME IS CARRIED AWAY
TOWARDS BARREN OR UNINHABITED AREA)
GAUGE GLASSES FIXED LADDER FIXED LADDER
Unit Plot Plan:
LEVEL CONTROLLERS PLATFORM PLATFORM
Rev. : R0 Rev. : R0
UNIT PLOT PLAN GENERAL GUIDELINES FOR PIPING
LAYOUT
Uhde India Limited Page : 8 Uhde India Limited Page : 1
CONTENTS
• TALL TOWERS
• LOCATION OF FIRED HEATERS Page
• LOCATION OF PUMPS
• SPACE IN & AROUND THE PLANT FOR FIELD CONSTRUCTION OF TALL TOWERS 0.0 Cover Sheet 1
• SPACE BETWEEN TWO EQUIPMENTS:
• TO AVOID FOUNDATION FOULING 1.0 Introduction 2
• TO AVOID VIBRATION TRANSMISSION IN CASE OF ROTO DYNAMIC M/C
• TO ACCOMMODATE LADDERS AND CABLES IF ANY 2.0 Piping Plans 2–3
• MAINTENANCE SPACE AROUND THE EQUIPMENT
• SPACE FOR CATALYST LOADING, UNLOADING AND OPERATION IN CASE OF 3.0 General Guidelines for Routing 3
PACKED TOWER
4.0 Drawing Content 3–4
• SPACE FOR INTERNALS REMOVAL
• SPACE FOR CRANE OR DERRICK REQUIRED DURING ERECTION AND
5.0 Main Inputs 4
MAINTENANCE.
• SPACE FOR TUBE BUNDLE REMOVAL IN CASE OF HEAT EXCHANGER 6.0 Suggestions 5 – 14
• PLATFORM FOR ORIENTATION & MAINTENANCE OF
• EQUIPMENTS
• VALVES
• INSTRUMENTS
• PROVISION FOR FUTURE EXPANSION
• LIST OF EQUIPMENTS (CODE NO. & NAME)
Reference:
Applicable Revision:
Prepared: Checked: Approved:
Rev. : R0 Rev. : R0
GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 2 Uhde India Limited Page : 3
1.0 INTRODUCTION: Final piping plans is a document which shows the routing of all piping of size 2” and above in
plan view with clear cut sections if required. It also shows indicative routing of field routed
lines to the extent that clarity permits. These are issued for constructions.
One of the most important aspects of piping design is the arrangement (or layout) of piping.
This aspect is not related to the ability of the piping to contain the fluid under design
conditions but rather to efficient and safe operation of the plant. 3.0 GENERAL GUIDELINES FOR ROUTING:
The job of a piping layout engineer is like an architect, where he has to use his personal skill,
imagination and creative abilities in making layouts. In each case the system of piping Following points serve as guidelines while making a piping plan/study.
arrangement depends upon the particular situation. However, to ensure well laid out piping,
logical approach must be made and it is very essential that the layout of the plant is rational • The line routing should meet all the process requirements indicated on P & I Diagrams.
and carefully studied by piping engineer. Since piping plans are made area wise, it is
important that all aspects are studied together. • The lines should be located in neat and orderly manner (in groups or banks wherever
practicable)
2.0 PIPING PLANS: • The lines routing should permit use of standard fittings as per piping specification.
A piping plan is usually made in 1:33 1/3 scale for Process Units, 1:50 scale for Pipe-racks • The lines should be routed so as to have ease of supporting arrangement.
and Utility Storage Tank Area. Usually floor wise plans are made. Local sectional views are
given wherever elaboration is required. • Piping should not be located at grade especially in areas where frequent personnel
movement or traffic is likely. This is important when choice is to be made between
Normally a piping plan is prepared in two stages. In the first stage it is called a Piping-Study - sleepers and pipe rack.
Plan. A Piping-Study-Plan is basically a conceptual proposal consisting of pipe routings in
plans and sections (where necessary) of all pipe lines (2” NB and above) fulfilling all • Piping should be arranged so as to clear the movement of cranes/hoists, etc.
conditions laid down in P & IDs and identifying schematically locations of all control stations,
rotameter stations, valves, on line instruments, etc. The piping study plan should necessarily • All in line piping components requiring regular attention of maintenance personnel should
show all platform sizes, locations and elevations required for operation and maintenance of be readily accessible.
piping/instrument components. Lines less than 50 NB are generally not shown. However,
depending on the criticality and extent of small sized lines in a particular unit, lines less than • There should be adequate clear working space around equipment which require frequent
50 NB may be required to be shown. Usually, the study plan starts with the laying of critical maintenance/servicing.
lines first. Critical lines are those which are either of large diameter or having high
temperature or gravity lines. • All valves, control valves, instrument should be readily accessible either from grade or
permanent platforms.
The study piping plans along with Isometric sketches is discussed with other department (PE
& IC) in order to get their comments at conceptual stage. It also serves following purposes:
• There should be adequate platforms and ladder arrangement for column manways.
• Freeze the equipment locations after piping study satisfying all requirements as far as
• Piping should be arranged to allow removal of the equipment with minimum dismantling of
possible.
pipe work. Similarly, all dip-pipes should be removable easily.
• Finalize nozzle orientation and cleats for platforms & ladders associated with equipments.
• Pockets should be avoided wherever possible especially while routing relief headers.
• Feed data to stress group for thermal analysis of lines.
• Hot lines should be routed away from electrical conduits and steam condensate should
not be discharged into the ground in the vicinity of electrical conduits.
• Furnish top of foundation elevations & other related data to Civil for design.
• Hot lines should be routed so as to have flexibility.
• Furnish information to model group for preparation of a scaled model wherever
applicable.
• Sample piping should be as short as possible.
• Preparation of order bill of material for pipes & fittings used by other departments such as
IC/EL for finalisation of their cable routings. 4.0 DRAWING CONTENT:
• Piping plans are usually updated after getting comments from other departments as well
as from stress group and also after review of model by licenser/client where applicable. Following in general shall be shown on a piping plan but not limited to:
Comments are obtained through isometric sketches
• Plant ‘NORTH’ direction shall be indicated along with a key plan.
• The piping plans so frozen can now be used for development of final piping plans.
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024
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GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 4 Uhde India Limited Page : 5
• All equipment shall be indicated as per plot plan showing piping nozzles, instrument
nozzles and other nozzles like manhole, etc. 6.0 SUGGESTIONS:
• Special fittings not covered in piping specification shall be called out. d. Restrictions on length of piping or on horizontal leg.
• Each line shall be designated with the complete designation as per line list. e. Desired location of valve/control valve assembly, etc.
It is important to look for all such notings and piping arrangement should take care of all such
• Flow direction shall be marked for each line.
requirements.
• Valves shall be indicated with proper symbols to indicate difference in types, e.g.,Gate,
Globe, Non return, Butterfly, etc.
6.2 Instruments
• Valve hand wheel/ stem shall be indicated in the plan or in the section to indicate
a. In general all instruments whether in line or on line should be accessible.
orientation. Requirement of extended spindle with/without headstock as well as chain
operated valves shall be clearly marked.
b. There should be sufficient clearances around instruments for their removal.
• Drain funnels shall be located. c. Orifice Flanges:
• Utility stations as well as safety showers shall also be marked. 1. These can be located at a convenient elevation accessible by using either a stool or
ladder and not necessarily to be accessed from ground/operating floor.
• Centreline elevation or elevation of TOS shall be indicated for each line. All lines should
be completely dimensioned. 2. Orifice flanges in liquid lines should preferably be located in horizontal leg of piping.
Installation in vertical leg, if necessary, from layout consideration should be checked
• All support points for the pipes to be indicated with a correct symbol such as shoe, guide with IC department.
or anchor. It is not required to give the primary support coding. But if secondary supports
or special supports are required then corresponding number/code shall be indicated. 3. It is important to consider orientation of tapped holes. Usually orifice-flanges installed
in horizontal liquid lines have tapped holes from the sides and differential pressure
• Battery limits/match lines shall be shown clearly. instrument is mounted below line elevation. There should be sufficient clearance
between this pipe and the adjacent pipes so that taps & tubing from sides is possible.
Also, there should be sufficient clearance below the line (usually 600 mm) so as to
5.0 MAIN INPUTS: mount differential pressure instrument below the line. This is important when the lines
run over sleepers. For dry gas service, taps are usually from top and differential
pressure instrument is mounted above the line.
Main inputs as required from various departments in order to start the activity of study piping
plans are as follows: 4. Valves and various fittings, such as, bends, tees, reducers make flow more turbulent
which affect flow measurement accuracy. In order to overcome this problem straight
PE : Frozen P & I Diagrams, vendor drawings/catalogue information for lengths are recommended upstream and down stream of orifice flanges. These
pumps, compressors & other package items. straight lengths are usually expressed in terms of pipe diameter, such as, 10D, 15D
etc., and dependent upon the type of obstruction upstream of orifice flanges.
MQ : Static Equipment Specifications. Standard table as applicable for the project is to be used while making pipe routings.
IC : Frozen hook up diagrams indicating PI/IC interface. 5. At places where it is not possible to provide required upstream straight length for
orifice flanges, it is recommended that the same be discussed with IC.
PI : Piping specification, unit plot plans.
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024
Rev. : R0 Rev. : R0
GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 6 Uhde India Limited Page : 7
1. These should be installed in horizontal leg of piping as far as possible. In case a Nozzle projection from top of pipe is important so that required portion of thermowell
control valve is required to be located in vertical leg due to layout considerations, the comes in contact with the fluid. In case the projection is more, the length of thermowell
same should be discussed with IC. which will come in contact with fluid will get reduced and on the other hand if nozzle
projection is less, thermowell may hit to the bottom of pipe. Usually, the nozzle projection
2. On-off control valves can be mounted, in vertical leg of piping. from top of pipe is 150 mm for uninsulated lines and for insulated lines having insulation
thickness upto 50mm. Generally, following table is used:
3. A control valve located in vertical leg of piping, usually require a proper support for its
actuator. INSULATION THK NOZZLE PROJECTION
FROM TOP OF PIPE
4. Some of the control valves have side mounted actuators and these should be
properly looked into for interference while making layouts. 0 to 50 mm 150 mm
5. Some of the control valves have design which require removal of internals from 51 to 100mm 200 mm
bottom. It is important to identify such control valves with IC and sufficient clearance
below the control valve should be provided while making layouts. 101 to 150 mm 250 mm
Similarly, clearance above the control valve should also be looked into while routing 3. At elbows, nozzles for temperature measurement should be so oriented that the
by pass line or any other line above control valve. thermowell insertion is against the direction of flow.
2. At places where level gauge and level transmitter both are attached to a stand pipe, 1. Preferred valve hand wheel elevations are as follows:
such that centre of float is more or less also centre of level gauge, butt welding tees, if
called by piping specification are usually not possible to provide. Usually, half a. Vertical stem
couplings or branches with or without reinforcement are used. It is advised that an
enlarged sketch be made and feasibility of various connections be studied.
Sometimes, it becomes necessary to increase the stand pipe dia in order to Ideal Range: 1150 mm to 1300 mm
accommodate various tappings around its circumference which are more or less at
the same elevation. Good Range : 550 mm to 1150mm
1300mm to 1450 mm
f. Temperature Measuring Points:
b. Horizontal Stem
1. All temperature measuring points whether local indicators or transmitters require use
of thermowells which are inserted in pipelines. Thus, these points are to be located at
easily accessible level and local temperature indicators should also be at easily Ideal Range : 1050 mm to 1400 mm
readable level.
Good Range : 600 mm to 1050mm
2. Since thermowells are inserted in pipelines, following points should be kept in mind: 1400mm to 1800 mm
a. Line size 2. Valves located with stem vertical are preferred due to ease of maintenance and
minimum blockage of operating area. However, accessibility of handwheels should be
Small dia lines are required to be enlarged for inserting thermowells so that some checked.
minimum length of thermowell remains in contact with the fluid.
3. Valves can be located with their stems either vertical up or turned up to horizontal
Generally, following minimum line sizes are used for installing a thermowell: position. Valves installed with stem lower than horizontal are not preferred due to
higher chances of leakage through gland and stagnant.fluid in the space below casing
At Elbow : Minimum size 3” cover.
Usually, a drain is provided in the casing cover when the valve has to be located due
Straight Pipe : Minimum size 4” Some licensers do recommend to unavoidable circumstances with stem below horizontal.
6”. This is to be checked with project specification.
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024
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GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 8 Uhde India Limited Page : 9
4. Large size valves (12” and above) are usually gear operated. One should check the 4. When Safety Valves discharge vapours to the atmosphere, the outlet pipe should
orientation of gear box assembly and ensure that the handwheel is on operating side terminate at least 3 metres above equipment or any service platform located within a
and there is no interference of gear box assemble with any piping or structure. radius of 15 metres of the valve. A 3/8” dia weep hole for drainage at low point of line
should be provided. Also the top open end should either be provided with a rain hood or
5. Motorized valves should be checked for orientation of their actuators. These valves with a 45 degree elbow and open end cut vertically.
are also provided with handwheels for manual operation and hence it is important to
ensure that their handwheels are on operating side and there is no interference of 5. When Safety Valves discharge steam to the atmosphere, the outlet pipe should terminate
actuator assembly with any piping or structure. at least 3 metres above any service platform located within 8 metres of the valve. Outlet
pipe should have a 3/8” weep hole for drainage at low point of line should be provided.
6. Valves when located more than 2.2 m elevation from operating level due to process Also the top open end should either be provided with a rain hood or with a 45 degree
consideration are usually provided with chain wheels for their operation. Such valves elbow and open end cut vertically.
are located with their stem in horizontal and operated by a closed end chain from
operating floor. 6. Provision of lifting devices such as davit, chain pulley block should be made for all relief
valves weighing more than 45 Kgs.
The use of chain operated valves is recommended only in unavoidable cases and
that too for valves 2” and above sizes. Screwed end valves are not used with chain 7. Relief header shall not have pocket. Where this requirement cannot be met., ‘PE’ should
operators. be consulted for making provision of a knock out pot.
7. Valves when located below floor level due to process consideration are usually 8. Safety Vales invariably require strong and sturdy special supports in order to absorb
provided with extended spindles for their operation, such that the handwheels are at thrust. Also, the branches for inlet to Safety Valves are usually reinforced. Normally, a
operating level.; fixed type of support is provided close to Safety Valve and with this in mind main line
should be routed in such a way so as to have enough flexibility.
The extended stem of a valve passes through the floor and usually a headstock is
used which guide the stem. It is important to review the location of headstocks from
operation point of view and the openings in floor. 6.5 Interference:
8. Globe valves should be installed so as to close against the pressure. Utmost care is required while routing the lines so as to avoid interference of piping with
other pipes & structures. Following are the general types of interferences noticed:
9. Locked open valves should be installed with their stems in horizontal plane as far as
possible. This is to avoid closure of valve in case plug or disc gets disengaged from 1. Pipe to pipe
stem accidentally.
This type of interference may occur due to:
When block valves are used in branch lines at headers, they should be located in
horizontal runs, at high points, so that lines will drain both ways. • Flanges not considered initially while specifying the distance between adjacent pipes
but later on flanged joints added without checking the spacing.
10. The location of a non return valve whether in horizontal or in vertical leg of piping
depends upon its constructional feature and the same should be looked into while Normally, the pipes are spaced in such a way that they permit use of flanged joints but
making layout. flanges in adjacent lines are required to be staggered. In case flanged joints are
required to be adjacent, the spacing between pipes should be checked.
TYPE LOCATION
SWING CHECK VALVES Horizontal or in vertical with flow from bottom • Insulation thicknesses not considered properly:
to top.
LIFT CHECK VALVES Horizontal Sometimes it may happen that lines are hot but they are not required to be insulated.
(Piston or ball lift) However, accessible portions of such lines are insulated from personnel protection
point of view. Hence, it is important to consider insulation thickness of such lines while
Some ball lift type check valves particularly lined type permit installation in vertical spacing.
only with flow from bottom to top.
• Thermal movements of pipes not considered. Sometimes interferences are noticed
when pipes move under hot condition. Therefore, for all hot lines, it is important that the
6.4 Safety Valves: spacing be checked considering expected movements of pipes under hot condition.
1. All Safety Valves should be so located that they can be easily accessed. Same logic also applies when cold pull is provided.
2. Safety Valve inlet piping should be kept to minimum as far as possible. 2. Pipe to Equipment/Structure/Foundation
3. Safety Valve outlet piping should be self draining to the relief header or other • Depending upon plant hazard and fire potential equipments supported on structural
destination. Wherever, this is not possible, PE should be consulted before locating steel members, fire proofing is recommended. This is done by providing normally 50 to
such Safety Valves. 75 mm thick concrete layer over structural members. Extent of fire proofing depends
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024
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GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 10 Uhde India Limited Page : 11
• Pipes running close to equipment should be checked for their interference with equipment 5. Piping connected to nozzles having dip pipes should be provided with break up
after duly considering applicable insulation thickness. Similarly, there may be fire proofing flanges so that dip pipes can be removed.
up to certain height, for some of the fire potential equipment such as skirt supported
columns handling flammable liquids/vapours, etc. It is important to consider insulation as 6. Lines connected to nozzles provided on bolted covers of tanks and vessels to have
well as fire proofing thickness when pipes are routed close to such equipment. break up flanges so that bolted covers can be removed with minimum dismantling of
piping.
• Foundations of equipment handling corrosive fluids usually require Acid/Alkali resistant
lining. This has to be ascertained with PE/Licenser. Pipes running close to such 7. All strainers require clear space for removal of screens. Layout of piping should
foundations should be checked for their interference after duly considering Acid/Alkali permit easy removal of screens for strainers.
resistant lining. This lining can be as high as 75 mm thick.
a. Y or T Type Strainers
• While routing the lines at Grade level the elevation should be so decided that provision of
a drain connection with a valve should be possible. It is recommended that there should They are normally located in horizontal leg of piping with screens removable from
be minimum 150mm clearance between drain valve and paving. bottom. This allows accumulation of solid particles at bottom of screen which is a
preferred arrangement. These type of strainers when used at pump suctions required
• For all hot lines, thermal movements of t he pipe should also be considered while to be rotated about line axis by 45 degree and even in some cases by 90 degree in
checking interference with structure/beam/column. For steam lines running on piperack, order to facilitate screens removal which otherwise is not possible due to low
drip legs are provided and usually they are located close to beams so as to have ease of elevation of suction lines with respect to grade or paved area.
supporting for small diameter lines connected to steam traps. If not located properly,
these drip legs may interfere with beams during thermal expansion of the lines. b. Conical Strainers
• Nozzles located at bottom of saddle supported equipments, such as shell and tube heat These type of strainers require spool pieces having lengths at least equal to the
exchangers, horizontal pressure vessels, etc. Should be checked for interference of lengths of conical screens for installation in the lines. Normally, conical screens are
nozzle flanges with foundation. only procured and spool pieces are provided in piping for their installation.
2. Horizontal casing pumps having inlet and outlet nozzles on top, usually require space in
front for taking out impeller shaft. Connected piping as well as supports, if any, must clear 6.7 General:
this removal area.
It may happen that some of the equipment nozzles as well as Instruments have
3. Shell and tube type heat exchangers require clear space for removal of tube bundles and flange ratings higher than connected piping. All such places should be identified and
those with fixed tubes require space for rodding. Similarly, plate type heat exchangers marked clearly on study piping plans. In case any equipment nozzle is found to have
also require clear space for removal of plates. This space requirement for removal of flange rating lower than the connected piping, the same should immediately be
plates may be either at the back or on sides depending upon design. Reciprocating brought to the notice of ‘PE’ and ‘PI’ lead engineer. This requires a review of piping
compressors also have requirement of clear space for removal of pistons and piston rods, specification of connected lines as well as design parameters considered for
etc. equipment.
All such requirements should clearly be marked on study piping plans and piping should 1. While routing the lines, avoid making use of Non standard fittings. Study the piping
be arranged in such a way so as to clear these areas. specification in detail before starting the layouts.
4. Pipes should be routed in such a way that they do not hinder the movement of chain 2. Generally, Instrument and Electrical cable trays are placed above pipes so that
pulley blocks,EDT/HOT, etc., provided for maintenance purpose. Similarly, all leakages from pipes, if any, do not damage cables. At places, where cable trays are
erection/maintenance openings should be kept clear of piping. on either side of the pipelines, it is advised that hot pipes as well as lines carrying
flammable and corrosive fluids are not placed adjacent to cables.
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024
Rev. : R0 Rev. : R0
GENERAL GUIDELINES FOR PIPING GENERAL GUIDELINES FOR PIPING
LAYOUT LAYOUT
Uhde India Limited Page : 12 Uhde India Limited Page : 13
3. On pipe-racks bigger diameter lines should run close to columns as far as possible 14. Do not look your own battery limit area but ensure that lines continuing further from
and small diameter lines in middle portion of the pipe-rack width. This would result in your battery limit or incoming lines to your battery limit are properly represented by
having less deflections of pipe-rack cross beams. match lines on other drawings also with coordinates and elevations marked. For lines
which appear on two or more separate piping plans, it is advised that overall profile be
4. On piperacks having two or more tires, it is preferable to place all small dia lines on looked into.
one tier instead of distributing on all tires. This is in order to avoid intermediate cross
beams for support of lines at other tires except for the tier where small dia lines are 17. The choice of eccentric or concentric reducers should be made correctly. In order to
placed. simplify the situation following is recommended.
5. For all high temperature lines running on piperack, expansion loops are generally I. All reducers located in vertical legs: Concentric.
required. It is recommended that expansion loops be placed symmetrical with respect
to fixed points so as to cancel out the forces at intermediate anchors. II. All reducers located in horizontal legs: Eccentric.
Also, it is a good practice to place all high temperature lines adjacent to each other so 18. Eccentric reducers depending upon the position can be placed with flat side either on
that expansion loops are at one place for all the lines. top or bottom.
From the expansion loop consideration, it is preferred that all hot lines be at one end a. Usually, at all pump suctions, eccentric reducers have flat sides on top except for
of the piperack width so that width of the piperack is available for expansion loops pumps handling slurry where eccentric reducers are placed with flat sides on bottom.
and such loops are either contained within the piperack width or projection outside the
piperack is minimum. b. At all pipe rack locations, eccentric reducers are used with flat sides on bottom in
order to keep BOP same.
6. Avoid running lines over building main columns as this would hinder the extension of
columns, if required in future. Similarly, lines running on top of the beams with their c. At control valve assemblies, eccentric reducers can be placed with flat sides on
axis parallel are not preferred, since they may hinder the provision of railings or bottom.
parapet walls.
d. Eccentric reducers located in slurry lines should have flat sides on bottom.
7. All barometric leg piping to be kept straight as far as possible. Offsets, if unavoidable
should be made by using 45 degree elbows/bends and number to be kept to
minimum. This routing should be discussed with ‘PE’ and agreed upon. 19. Depending upon the line profile vents and drains are required mainly for:
8. Condensate discharge piping for a closed system should have minimum number of a. Hydrotesting of lines
bends. This is to avoid high back pressure acting on traps.
b. Venting and draining of lines during plant start up and shut down.
9. For all saddle supported equipments the choice has to be made by PI regarding one
of the saddles as fixed and other as guided. It is recommended that after routing For hydrotesting purpose, usually, 3/4” or 1” couplings with plugs are provided. There
major lines connected to such equipments, fixed saddle should be so selected that vents and drains are without valves.
vessel expansion favourable act towards absorption of thermal expansion by
connected pipelines. However, for venting of lines during plant start up and draining of lines during plant shut
down vent and drain points are provided with valves. These are to be identified by ‘PE’,
10. When piping is connected to two or more equipments in parallel the arrangement of while giving comments on Isometrics and are required to be marked on P & I diagrams.
piping should be symmetrical as far as possible. This is to have same pressure drop
in the system when stand by equipments are operated. Lines handling flammable and corrosive fluids can not be vented or drained into
atmosphere just like that. Usually, they are led to effluent collection system and again
11. For all lined piping, spacers should be provided for field adjustment. such cases are to be identified by ‘PE’
Generally, the equipments to which lined piping is connected are grouted at site after
assembling and erecting the lines. This allows the shifting of equipments to some 6.8 Column Piping:
extent for adjustment purpose. Thus, the location of spacers should be decided after
reviewing all the lines connected to such equipments and not each line in isolation. For routing the lines connected to columns in Petro-chemical & refinery projects, following
may be noted:
12. All gravity and slurry lines should be routed without pocket.
a. First decide orientation of nozzle connected to reboiler. This is required so that Re-
13. Expansion bellows are installed in piping where it is not possible to have in built boiler Outlet Piping is as short as possible and also symmetrical, if reboiler has got
flexibility due to process reasons. It is very important to provide proper supporting two nozzles.
arrangement when expansion bellows are used in order to ensure that they are not
subjected to thermal movements/loading other than calculated. b. Decide tray down comer orientation with respect to orientation of nozzle connected to
re-boiler.
TRAINING MANUAL – PIPING DOC No. : 29040-PI-UFR-0024 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
CONTENTS
c. Fix orientation of other nozzles after deciding tray down comer orientation.
Page
d. Start piping plan from top and move downward.
0.0 Cover Sheet 1
e. There should be a change in ladder direction after 6 to 8 m. A long straight ladder
with intermediate platforms is not desirable. 1.0 Introduction 2
f. Column davit to be located in such a way that ground is clear for lifting the material. 2.0 Piping Studies 2
g. While crossing from one ladder to another the passage should not go crossing the 3.0 Thermal Expansion 3
manholes, i.e., there should not be ladders on either side of the manhole.
4.0 Critical Piping 3
h. Exit from ladder to a segmented platform should be from one side only, i.e., ladder
should not be located between two segmented platforms at the same level. Passage 5.0 Instruments 3
from one platform to another via ladder is not recommended.
6.0 Piping Arrangement Considerations 3 – 10
i. Platforms should be minimum 1000 mm in width and maximum 2000mm.
7.0 The Drawings 10
j. All lines should run close to columns as far as possible. Lines, if passing through
platforms should not cut through toe angles of platforms. Also all these lines are 8.0 Piping Arrangement (Typical Sketches) 11 – 24
supported by providing pipe cleats to columns at proper orientation and elevation.
k. Control valve assemblies including valves, safety valves, instruments, etc. Should be
located on platforms adjacent to columns and not closer to railing as far as possible.
This is in order to reduce bending moment acting on columns due to weight of
platforms and piping.
Applicable Revision:
Prepared: Checked: Approved:
Arrangement shall provide for flexibility of lines to take care of thermal expansion and
The arrangement of piping is probably the most important consideration affecting the layout of contraction. Large reactions or moments at equipment connection shall be avoided.
petroleum, petrochemical and similar types of plants. The following in general, is the order of
importance in which piping systems should be considered. 4.0 CRITICAL PIPING:
• Alloy piping or special materials Where dynamic loading, limited pressure drop, or other severe service conditions apply,
• Large bore piping or lined pipe. particular care be taken while routing the piping.
• Low temperature pipe or other piping requiring thick and expensive insulation.
• Major headers for utilities or auxiliaries. DYNAMIC LOADING
• The routing of lines involving temperature where expansion and contraction necessitates
flexibility which should preferably be inherent in the layout. Pipe shall be arranged in an • Dynamic loading may be expected when pulsation flow (such as reciprocating
orderly manner and routed as direct as possible. compressors), high velocity flow, flashing fluid, fluctuating temperature or pressure or
mechanical vibration (including wind) conditions exists.
2.0 PIPING STUDIES: • Piping subject to possible dynamic loading shall be carefully designed and checked to
ensure that the size, configuration, mechanical strength, supports and restraints shall
prevent excessive stress or vibration.
After a basic equipment layout has been developed, piping study drawings shall be made for
units which have sufficient size and scope to warrant further investigation of equipment
arrangements, pipe rack widths and the like. OTHER SEVERE SERVICES
For units or areas which obviously do not require extensive study due to simplicity of piping Other severe services include erosive, corrosive, high or low temperature or pressure
involved, the piping layout may be started directly which will eventually be issued as conditions, or any fluids containing solids. Many such services require alloy or other special
construction drawings. materials. Piping in these services shall be routed to minimize the effects of service severity
and make most practical use of required special materials.
Responsibility for determining whether study drawings are required and the extent to which
they are to be carried, shall rest with Project Piping Engineer. PIPING AT CONTROL VALVES
The study drawings are intended to serve the following purposes: Special attention must be paid to any control valve which will contribute to excessive noise or
vibration due to Aerodynamics which must be carefully analyzed and designed so that its size
• To confirm equipment locations for review, comments and/or early approval by various and configuration downstream of the control valve will minimize these conditions. Special
concerned departments on the plant layout. attention should also be paid for Ejector piping and high vacuum piping.
• To enable the analysis of line expansions and supporting systems. For control valve manifolds arrangement.
• To enable other concerned departments i.e. Pressure vessel, Civil, Structural, Electrical, ORIFICE RUNS
Heat Exchanger, Process Departments to develop their work/check their requirements.
Horizontal meter runs are preferred. Necessary straight runs upstream and downstream
orifice plates shall be provided in accordance to api rp 550 part1. Sufficient clearance at
In general, study drawings consist of plans, elevations (where necessary) showing unit piping orifice flange for installation of instrument piping and seal pots, where required shall be
arrangement fulfilling all conditions laid down in P&ID manifold locations, platform, elevations, provided.
instrumentation etc. And schematic routing diagram of piping piping on the racks. They will
also indicate special requirements like monorails for exchanger bundle pulling or catalyst 6.0 PIPING ARRANGEMENT CONSIDERATIONS:
loading etc.
6.1 PIPE WAY ARRANGEMENT:
Piping Studies are prepared as line diagrams to form the basis of General Arrangement
Drawings and the details shown in the case of piping general arrangement drawings for • In general all piping within process area should be run above grade and piping in trenches
construction are not shown to that extent such as control valve manifolds are shown as a is to be avoided. Pipe bridges, racks and supports should be of the simplest form with a
block, only important elevations and arrangements are shown etc. minimum of cross bracing or in filling of steel work to give the maximum freedom for pipe
routing. On complex plant, pipe bridges or racks may contain two layers of pipe work.
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
• The plant layout determines the main yard piping runs, The first step in yard piping design The number of lines can be estimated by preparing piping studies in 1:100 scale with the
is careful study of plot plan and flow diagram. There are various shapes of yard piping total width (W in meter) will be as follows :
arrangements such as L, I, T and combination of various shapes. Pipe-ways shall
generally be run overhead for on plot units and shall generally not be more than three W = (F × n × s) + A
decks high. Where,
• To facilitate ease of erection and reduce bending moments, heavy lines (very large F = Safety factor = 1.5 if lines have been laid with the help of process flow
diameter lines, large lines full of liquid) should be located as close to the stanchions as diagram.
possible. Lines that require a constant fall, such as flare should be run on an extension on n = 1.2 if the lines have been laid with fully completed P&IDs.
the bent stanchions, the extension being varied at each bent to suit the fall. s = 300 mm (estimated average spacing 250 mm then s = 250 mm)
• Hot lines requiring expansion loops should be run on the outside edge of the pipe-way. A in meter is the additional width required
This will permit the loops to have the greatest depth over the pipe way and it will make it
easier for the loops to be nested. 1. for lines larger than 450mm O/D
2. for future lines
• Take off elevations from pipe ways should be at a constant elevation consistent with the 3. for instrument trays (about 750mm to 1000mm)for electrical cables (about 750mm to
range of pipe size involved. However, header be located on the pipe way on the side from 1000mm)
which the largest number of off takes are made.
The total width of rack can be 6M or 12 M having two banks (maximum)
• Elevation of yard piping is determined by the highest requirement of the following:
The spacing between yard pipe rack should be 5M to 6M. For lines 1 1/2” below,
1. Head over a main plant road for major mobile equipment, intermediate support shall be provided where large numbers of small lines are involved.
2. Headroom for access to equipment under yard. Intermediate supporting frame in between two pipe bends shall be provided where
required for supporting lines 1 1/2” and below.
The size of steel or concrete supporting yard piping should also be taken in account when
considering headroom. Generally those process lines should be located in the top bank
which interconnect to nozzles elevated higher than top yard bank. Process lines with one 6.2 TOWER PIPING:
end lower than the bottom yard elevation and other end above yard can be located on
either yard elevation. If both ends of a process line are lower than the bottom yard • A tower is usually a major part of a designers area. It is advisable to treat it as a central
elevation, they should be located in the bottom bank. The elevation of a line can also be piece of equipment and extend the design around this center. Columns, towers and
influenced by valves and instruments in the line. Often a more convenient access platform vertical vessels are to be arranged in a row with a common centerline if of similar size. If,
can be provided for valves arranged in the top yard bank. The preferred location of orifice however, diameters vary considerably, lining up with a common face will be found to be
runs is under the bottom bank for more convenient portable ladder access. beneficial.
• Whenever banks of pipe, either at grade or on pipe bridges or on rack change direction, it • During the initial stage of piping studies, piping designer should investigate in co operation
is advisable to arrange for a change of elevation. This gives opportunity to change the with vessel designer about the preference of lined up towers with interconnecting
sequence of pipes at each change of direction. However some large bore lines can make platforms, for convenient operation and maintenance access. The platforms are
a flat turn when entering and leaving yard. supported from towers. In such cases, slight alterations in tray spacing, internal piping
arrangement, skirt height and tower length can help to put all tower manholes on same
• Pipe economy depends primarily on the length of lines arranged in the yard. Fittings and elevations. In turn. lined up manholes will help platform arrangement, providing also
valves etc. are relatively few as compared to pipe length Fig 1. shows dimensions which common access to valve instrument.
will influence piping cost from a yard piping layout stand point. The careful selection of
dimensions between the yard and process equipment and pipe length interconnecting • When arranging common platforms for several towers in line, allowance must be made
equipment on opposite sides of the yard can minimize pipe length. The distance between for the differential expansion between towers. Suitably arranged hinges or slots in the
pipe rack stanchions and face of the process equipment should preferably be within 2,000 platforms between towers, which introduce flexibility into the platforms shall be provided.
to 3,000mm. All these feature shall be decided at the early stages of design because they affect good
piping arrangement.
• It is preferable to layout a long manifold of control and manual valves with the valve stems
all lined up and the entire arrangement stretching for two or three bays, under the pump • Main work of tower piping is connected with the proper orientation of nozzles and
alley. However access ways should always be provided at each bay between rows of provision of access to points of operation and maintenance. Generally, platforms of
pumps or fences of valve manifolds to gain access to adjacent equipment. manholes shall be utilized for operating and maintenance access for valves and
instruments. Small valves and instruments are usually arranged outside the platforms and
• The width and number of banks is influenced by : are operated from the ladder. Additional platforms are required for operating valves, line
blinds, relief valves (3” and above, orifice plates, transmitter of a level controller and
1. Number of lines, electrical, instrument trays and space for future lines in the yard, or handling davit.
• The operating aside is usually under pipe rack, so first ladder on tower should be on pipe
rack side. To handle heavy equipment (large size relief valves, large diameter, line 1. Analyze the functions of the internals.
blinds), a davit is usually needed. The davit should be on the side of the vessel away from
the rack. The area at grade should be kept clear for a dropout. for bigger diameter 2. Determine the desirable location of the shell connections relative to external
vessels, two davits shall be furnished. If it is located at the top of the tower, it can serve as requirements (piping platforms).
well for lifting and lowering the top internals to grade. Clearance for the lifting tackle to all
points which require handling is essential, as also sufficient access and removal space. 3. Layout of the internal piping required to satisfy preferred location shell nozzle and the
For reactor feeding catalyst, a permanent trolley beam over the filling manholes is usually preferred tray orientation, and if necessary adjust these to make a workable
provided with adequate access at grade for lifting and removal of the catalyst. adjustment.
• Fig.1 shows plan with segments of its circumference allotted to piping, nozzles, platforms Platforms, Ladders and Davit
and ladders, in a pattern which leads to a well designed layout. The complete
circumference of the tower is theoretically available to arrange the items. Piping should be Platforms are considered as work area for manholes and rest area when an intermediate
located radially as far as possible. area is added, if the height between two work platforms exceeds 9 metres.
• Fig.1 also shows the principal features such as manholes, platforms and pipe runs • Generally, layout analysis should be started from the top of the tower and those having
typically applicable to Tower piping arrangement. Nozzle elevations are determined by reboilers should be started from the bottom, but with the designer visualizing the layout as
process requirements and manhole elevations by maintenance requirements. For a whole. There will be no trouble in dropping the large lines (such as overhead vapour
economy and easy supports, piping should drop or rise immediately upon leaving the lines) straight down the side of the column. The lower spaces can then be laid out with
nozzle and run parallel and as close as possible. piping and nozzles knowing what space is already occupied by these large vertical lines.
• To make the orientation, follow the following steps: Condensers are often located at grade. In such cases, a large overhead lines drop right
alongside the tower to the condenser at grade. Condensers can also be elevated. An
Tray Orientation elevated condenser is more convenient from a tower piping layout standpoint because the
large overhead line leaves the immediate vicinity of the tower at a high level, leaving the
Right relationship between process nozzles and tower internals is very important. This is lower section open, say, for a ladder from grade to the first platform.
often influenced by reboiler draw off and return nozzles and orientation by flexibility
considerations. Changing from one pass to two pass, the two pass trays shall be rotated Whether the condenser is at grade or at an elevated level, the flexibility and thermal load
through 90 deg. to upper trays. problems connected with large diameter overhead lines must be considered.
Nozzles & Manholes • For valves and blinds, the best location is directly at tower nozzles. Valves in branch
connections or at nozzle should be in a position where the line will be self draining on both
Orientation of nozzles depends on the type of distributors and process requirements. sides of the valve. A dead leg over closed valve collects liquid or solids. The trapped liquid
Before detailing, details and type of distributors must be known to the designer. Then he can freeze, or , when opening the valve, without draining the leg, can upset process
could produce right orientation of nozzles shall be located on tray area and must be conditions.
accessible from ladder or platform.
All instruments should be oriented so as not to obstruct the passage way at the ladder
Temperature connections are usually located in the liquid space of tray downcomers. In exits or entrance. Convenient access and groupings of instruments and valve will help
some cases, it could be also in vapor space. In front of thermowell nozzles, a clearance of inspection and plant operation. Instruments should not be located adjacent to manholes.
approximately 600mm is required to remove thermowell. The manhole cover can damage instruments when being swung open during
maintenance.
Pressure connections are usually located on the vapor space just below the trays. All
instrument locations are to be confirmed by process department. Care should be taken • The tower elevation is governed by the following:
with interference such as between two reinforcing pads, one near the other, nozzle baffle
and down comer and weir dams. 1. Net positive suction head requirements if the tower bottom line is a pump suction line.
This can elevate the tower bottom tangent line.
Manholes should preferably be placed on road side on tray area so that it is convenient
for removal and lowering to grade of tower internals. Accessibility, whether internal or 2. Thermo siphon type reboiler circuit can also elevate a tower.
external is very important and is often not given enough consideration. A balance must be
made between the external accessibility of connections from ladders and platforms and 3. Gravity flow from tower bottom or from an elevated nozzle can also elevate a tower.
internal accessibility from shell manholes, handholes or removable section of trays.
4. Head room requirements.
For example, a shell manhole opening must not be obstructed by internal piping unless
the piping is removable through the manholes or can be slung clear from an internal To support the tower at the chosen elevation, a steel skirt down to grade or a combination
hitching point. In either case, the break flange bolts must be accessible from the manhole. of a short steel skirt and concrete plinths will be required.
The following considerations must be made at the initial stage of design as they bear
directly on the external arrangement of tower.
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
• Piping around tower shall be spaced taking into consideration the structural design of the Suction piping to centrifugal compressors should be designed to allow sufficient straight
supporting arrangement. Special care should be taken to see that supports for cold lines length i.e. 5 D minimum of pipe immediately ahead of suction nozzle, to allow dissipation of
do not interfere with the other pipes. For supporting tower piping from tower shell, undesirable flow distortion caused by elbows, valves, or other fittings upstream and velocity in
designer should select proper type . While locating clips, care shall be taken to ensure line.
that these clips are not located on the circumferential and longitudinal weld seams
indicated in the vessel date sheet. 6.6 BURNER PIPING AT FIRED HEATERS:
6.3 EXCHANGER PIPING: • Burner piping shall be kept clear of all access and observation openings. Adequate space
for removal of heater tubes shall be kept for its maintenance. Piping to the burners shall
Refer Figures 4 & 5 for the typical Heat Exchanger Piping Arrangement. Piping shall not run in be made using unions, flexible connectors to provide for easy and convenient removal of
the way of built-in or mobile handling facilities. Wrench clearance shall be provided at burners for maintenance
exchanger flanges.
• Supply piping of fuel gas shall be arranged for equal flow distribution and shall be
provided with condensate leg, knockout pots or other approved methods for the collection
6.4 PUMP AND TURBINE PIPING: and elimination of condensate.
Pump suction piping shall be arranged with particular care to avoid vapor pockets or 6.7 OFFSITE AND YARD PIPING:
unnecessary pressure drop. Eccentric reducers, properly oriented to avoid vapour pockets,
shall be used for line size reduction. Figures 7, 8 and 9 show the typical Pump Piping Offsite
Arrangement.
The various systems involved in Offsite piping are as below:
Pump location
• Raw product import and its storage
Where practical, line up center lines of all discharge pump nozzles. • Intermediate / finished product storage
• Product Dispatch / loading facilities
Access to Pump and Turbines
Utilities
Piping at pumps and turbines shall be arranged to provide maintenance access around
pumps and turbines. Removable spool pieces shall be provided as appropriate to permit Various system of utilities are as below:
maintenance without major disassembly.
• Steam, condensate and boiler feed water system.
Weight and Thermal Stresses • Compressed air system
• Service (plant) air
Suitable supports or anchors shall be provided and located for piping to pumps and turbines • Instrument air
so that excessive weight and thermal stresses will not be applied to the casings and access
• Cooling water system
areas around pumps and turbines are kept free. Careful design consideration shall be given to
• Caustic soda system
piping configuration to minimize these stresses.
• Flare system
• Fire protection system
6.5 COMPRESSOR PIPING:
Storage Tank
Large centrifugal or reciprocating compressors shall be on a raised floor design so that piping
and auxiliaries can be located below main operating platform. There are mainly two types of storage tanks:
• The tank dyke height shall not exceed more than 2 m 8.0 PIPING ARRANGEMENT (TYPICAL SKETCHES):
Pumping Station
Yard Piping
In Offsites, piping are run on concrete sleepers, which are minimum 300mm high from the
grade level. The span between two sleepers should be minimum 5m irrespective of sizes of
pipes.
The underground facilities such as cooling water header, effluent collection lines, service
water lines, drinking water lines, sanitary effluent lines, electrical cable trenches, street light
cable trenches, storm water drains, etc. are run close to the road.
An overall study of pipe routing diagram must be prepared carefully because an improvement
in this can save a large amount of piping. Using various piping standards of pipe spacing, the
width of the sleeper is determined. A final figure is arrived at by adding 20 to 30 % more
space which should be kept as a future expansion provision. Pipe-way bridges for crossing
the road are also determined by the study. Once the routing of various lines is finalized, the
next step is to decide the relative elevation of pipe sleeper, tank pad and pumping station.
Suction lines must be self draining towards the pump and at the same time, the pipe sleeper
elevation should not exceed beyond certain limits so that the jump at road crossing is avoided.
The sequence of lines should be adjusted in such a way that there are minimum bends and
jump overs.
Whenever there is common inlet and outlet of the tanks, there will be a valve manifold, which
connects incoming and outgoing lines. These manifolds should preferably be located outside
the tank farm and approachable from the road. Valves operating platform and cross over
should be provided wherever found necessary for operational ease.
Some times, because of excessive tanks settlement, the piping at tank connections are
overstressed. As such, these pipings are to be analyzed thoroughly. Over stressing of pipe
tank connection can be avoided by placing first pipe support sufficiently away from tank
nozzle.
The piping general arrangement drawings prepared considering all the above aspects are the
drawing for constructions.
In order to have ease in construction, isometric drawings of each one are prepared based on F I GURE - 1
the general arrangement drawings. Isometrics are drawn proportionally only and are not to
scale. The isometrics form the basis for fabrication of piping. Normally, 2” and above lines are
covered by isometrics.
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
FIGURE - 3
FIGURE - 2
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
FIGURE - 5
FIGURE - 4
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
FIGURE - 7
FIGURE - 6
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
FIGURE - 8
FIGURE 9
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
FIGURE - 11
FIGURE - 10
TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025 TRAINING MANUAL - PIPING DOC No. : 29040-PI-UFR-0025
CONTENTS
Page
1.0 Introduction 2
2.0 Thermodynamics 2
Applicable Revision:
Prepared: Checked: Approved:
Corrosion can be defined in a more simplistic way as deterioration of materials under the 4.1 UNIFORM CORROSION:
influence of an environment. Without exception, the corrosion of metals and alloys (majority of
materials used in industry) in aqueous environments (the most often encountered
environment) is an electrochemical reaction. A brief description of the electrochemical Though uniform corrosion is an idealized form of corrosion and cause less damage than the
principles for the beginners of corrosion are made before attempting on the forms of other forms of corrosion, it is more appropriate to understand this form of corrosion.
corrosion. For a more detailed study the participants can refer the bibliography given at the
end. This leads to uniform thinning of the structures. The attack is measured in terms of
penetration. They have the units mpy(mills per year)or mm per year. This can be determined
2.0 THERMODYNAMICS: by any gravimetry method. Depending on the applications the tolerance of the alloy towards
corrosion is chosen as given in the Table 1.
At the outset it is necessary to pose the question WHY DO METALS CORRODE? And set a
criteria for the process. Corrosion of metals and alloys involves oxidation from its metallic
state and therefore must obey the thermodynamic criteria as any other processes. Take for Table 1 : Range of corrosion rates
example, the corrosion of Mg in water, which can be represented by the following reaction.
Corr Application
osio
Mg + H2O(l) + 1/2 O2 = Mg(OH)2 G° = -142.6 K Cals n
Rate
<5 valves, pumps, shafts and
The corrosion of Mg is spontaneous as it leads to a -ve change in free energy. On the impellers
contrary the reaction of Au with H2O and O2 results in a +ve change in free energy and so Au 5-50 tanks, piping, valve bodies,
cannot be corroded. bolt heads
>50 not satisfactory
3.0 ELECTROCHEMICAL CRITERIA:
<.5 pharmaceuticals, implants for
bodies.
It must be remembered that corrosion of metals and alloys by aqueous media must
necessarily proceed through electrochemical process, hence it is imperative to set
electrochemical criteria for corrosion of metals. As indicated earlier, corrosion of metals 4.1.1 Prevention
involves oxidation of metals and alloys from their metallic state in ionic form. It is represented
as One or more of the following methods can be adopted to prevent uniform corrosion.
n+
M = M + ne (Oxidation) • Cathodic Protection
• Inhibitors
One can notice, the oxidation of metal simultaneously leads to release of electrons. Should • Protective Coatings
the reaction to continue there must be a sink for electrons. This is accompanied by a • Selecting Proper Materials
reduction reaction. WHAT ARE THESE CATHODIC REACTIONS?. One or more of the
following reactions are possible. They are
4.2 GALVANIC CORROSION:
+
2H + 2e = H2 (Hydrogen Reduction reaction)
+
O2 + 4H + 4e = 2H2O (Reduction of dissolved O2 in acidic media) When dissimilar metals or alloys differing in their galvanic or corrosion potential are employed
-
and if they are electrically shorted they induce this type of corrosion. The corrosion rate of the
O2 + 2H2O + 4e = 2OH (Reduction of dissolved O2 in basic media) alloy with lower corrosion potential will be accelerated by that of higher corrosion potential.
n+
M + ne = M (Metal Deposition)
n+ (n-1)+
4.2.1 Identification
M +e = M (Metal ion reduction)
• The active metal is corroded
Interestingly oxidation (also called anodic) and reduction (also called cathodic) reaction occur • Grooving of the interface
on the same surface of the metal. In uniform corrosion these anodic and cathodic sites keeps • Noble metal deposits from the stream
interchanging with respect to time. • Graphite lining or bricks
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4.3 CREVICE CORROSION: • They give rise to plug and layered types of attack.
• Change in color (from yellow to brown in the cases of brasses)
• X-ray diffraction can some times reveal selective removal of one element
Accelerated corrosion occurs if differential aeration exists due crevice, metal joining (lap • There can be a change in density in some cases.
joints, flanges etc.)or any deposits. Interestingly the location starving for oxygen is forced to
become anodic and the region having free access to oxygen becomes cathode.
4.5.2 Prevention
4.3.1 Identification
• Addition of any one of the elements namely Sn, As, Sb and P
• Rivets, flanges, lap joints are attacked internally. • Al addition reduces overall corrosion and to some extent dezincification.
• Deposits such as corrosion products, organic deposits, growth of organisms etc. cause
corrosion.
• Improper drainage of vessels, pipelines cause accelerated attack. 4.6 INTERGRANULAR CORROSION:
4.3.2 Prevention This type of corrosion occurs as a result of selective attack of the grain boundaries when
either grain boundary becomes highly active or phases prone to selective attack are formed.
• Avoid riveting, go in for welding Stainless steels, which are normally resistant to intergranular attack, when subjected to an
• Design for proper drainage heat treatment between 400-900 C become sensitive to intergranular corrosion (IGC). This
• For stainless steels high Mo content (316,317 and Haste alloys) reduces crevice range can vary depending on the composition of the alloy. This treatment is called
corrosion sensitization treatment and alloy is said to be sensitized. This is mainly due to the formation of
• Remove the deposits Cr23C6 and the consequent grain boundary depletion. Welding, a common practice in
• Use solid non absorbent gaskets fabrication causes such an IGC attack.
• Attack of the alloy away from the weldment called heat affected zone.
Alloys in presence of certain ions (such as halides) are prone to pitting. The rate of • Clear ditch type of attack along the grain boundary and consequent weakening seen at
penetration within the pit can be as high as one million times as compared to the higher magnification.
surroundings.
4.6.2 Prevention
4.4.1 Identification
• Choose low carbon and extra low carbon stainless steels (such ss are 3041,3161,3171)
• Pinholes • Choose Ti or Ta and Nb containing alloys (321,347)
• Normally grow in the direction of gravity • Provide a solutions treatment to redissolve the carbides (1050 °C, 30 m)
• The alloy environment combination is likely to promote pitting
• Pitting has taken place along inclusion
4.7 EROSION CORROSION:
4.4.2 Prevention
• Eliminate the specific ions responsible for pitting (say halides in the case of SS) When there is a relative movement of the corrosive environment with respect to the alloy it
• Choose alloy resistant to pitting. In stainless steels high Mo promotes resistance (haste can lead to erosion corrosion. Pipelines and heat exchangers are subjected to such a kind of
alloys, duplex stainless steels) failure.
• Mild steels serve better in chloride environment than SS if certain amount of uniform
corrosion is tolerated. Monel has more resistance in this environment.
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4.7.2 Prevention
0.0 Cover Sheet 1
• Reduce the velocity of the medium
• Choose hard materials 0.1 Introduction 2
• Avoid sharp turns
• Provide hard coatings. 0.2 Purpose of Pipe Support 2-5
4.9 FRETTING DAMAGE: 8.0 Pipe supports, general features for different piping systems 24 - 25
Moving/vibrating interfaces under load causes a damage akin to wear called fretting damage.
Here the relative movement is relatively small in angstroms. Typical failed surface under this
process is brought out in.
When there is a conjoint action of stress and environment. Stress corrosion cracking occurs
(SCC). However SCC is specific to environment. The alloys are susceptible to SCC only when
specific ions are present akin to pitting corrosion. In addition the alloys fail only if the stress
exceeds a threshold level below which they are safe.
4.10.1 Identification
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2.5 TO ABSORB 'VIBRATION OF PIPING SYSTEM' :
When the pipe is subjected to moving machinery or pulsating flow or very high velocity flow, pipe may start
1.0 INTRODUCTION vibrating vigorously and ultimately may fail, particularly if span is large. To avoid this it may be required to
introduce additional supports at smaller span apart from other requirements. It may not take axial load, but
The Piping Profile in general can be considered as a complex and rigid piping network consisting of various must control lateral movements.
piping components, which have different diameters and weights. At the same time the above network is also
subjected to temperature change while switching from installed to operating condition (and visa versa) 2.6 TO HAVE 'NOISE CONTROL' :
resulting into its thermal growth in various directions in proportion to the length of pipes. The structural
integrity of the above network must therefore take into account the overall weight effect of the profile In most of the plants, noise is resulting from vibration and if such vibrations are controlled, noise is reduced
besides its thermal growth. to great extent. In such lines, between clamp (i.e. support) and pipe, asbestos cloth is put to absorb vibration
and avoid noise.
A satisfactory design of the Piping System should therefore give a careful consideration to achieve the above
requirement. This is generally accomplished by providing external attachments (known as pipe supports) at Noise due to pulsating flow can be reduced by using a silencer in the line. Still if it is not below acceptable
various locations of the piping profile. level accoustic enclosure may be used. insulation over line also helps in reducing the noise.
This document deals with the basic purpose of the pipe supports, classification based on construction / 2.7 TO TAKE 'HYDRAULIC THRUST IN PIPING' :
functions and a few typical types of pipe supports.
The hydraulic thrust in the pipeline is present at certain point such as pressure reducing valve, relief valve,
In general it deals with metallic piping systems only. bellows etc.
If the control valve has large pressure differential and line size is more, then this force can be very high.
2.0 PURPOSE OF PIPE SUPPORTS The support should be provided and designed to take this load, otherwise this will load the piping system and
may cause failure.
A brief detail of the purpose of pipe support is described below.
Supports are required to support the line during all conditions i.e. during operation as well as during testing.
In case of vapour line this difference will be very large due to hydro testing. Supports should be designed
for this load (unless otherwise decided in the project).
Some times line is capable of having longer span but load coming on the support may be very large
(especially with large dia pipe lines). Then to distribute the load uniformly, more number of supports should
be provided with smaller span.
Note : 1. It may be noted that during testing condition there is no thermal load.
2. All spring supports are locked during testing.
Whenever thermal expansion is restricted by support, it introduces additional load on the support. Support
must be designed to take this load in addition to all other loads.
2.8 TO SUPPORT THE SYSTEM DURING 'TRANSIENT PERIOD OF PLANT AND STANDBY
CONDITION :
2.3 TO TAKE 'WIND LOAD' :
Wind introduces lateral load on the line. This load is considerable especially on large diameter pipe. This
tends to sway the line from its normal position and line must be supported guided against it. In case of large
diameter overhead lines, supported by tall support extended from floor, wind load introduces large bending
moment and should be considered critically.
The earthquake is normally associated with horizontal acceleration of the order of 1 to 3 m/sec2. This is
around 10% to 30% of the gravitational acceleration and introduces horizontal force of about 10 to 30% of
the vertical load (or supported mass). While designing support this should be taken care.
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In this case a limit stop is used which will not allow the Point C to move up above horizontal level.
Transient condition refers to the start-up or shutdown condition in which one equipment may get heated up (However it will allow downward movement during operating condition).
faster and other one get heated slower. Due to this the expansion of one equipment which in normal
operation will get nullified, may not get nullified and exert thermal load on supports. 2.11 TO SUPPORT THE SYSTEM FOR ERECTION CONDITIONS :
Standby condition is also similar. If there are two pumps, one being standby and both connected in parallel Erection condition can be different than the operating condition which should be considered while designing
(as shown), design and operating temp. of both the connections will be same. But the expansion of two supports.
parallel legs will not be nullified because at a time only one leg will be hot and another being cold.
When for maintenance certain equipment or component like valve is taken out, remaining system should not
be left out unsupported.
For example for normal operation a long vessel supported by three supports, S1, S2 & S3 is shown in
FIG-5. If support S2 is higher, than all load will act at S2 only. During erection if level of S2 is lower then
entire load will be divided into two supports S1, S2 only. Therefore foundation of S1, S2 & S3 should be
capable of taking such conditions.
Referring to the FIG-3, support 'S1' will be sufficient but when valve 'V1' is taken out for maintenance there
will not be any support for vertical leg. Therefore second support 'S2' may be required to take care of such
condition.
In shutdown condition all equipment may not be in the same condition as in operating condition.
For example, refer the pump discharge line in FIG-4, Point A is resting, Point B & C are spring supports
A pipe line supported by S1, S2 & S3 taken from vessel is shown in above FIG - 6. During operation there
will be no weight at S2 & S3 (as it is only guide), but wind condition will be there. Loads due to such
conditions must be considered while designing the supports.
and Point D is the pump discharge nozzle. The springs are, designed based on weights considering the
weight of fluid as well as pipeline and thermal movements. But during shutdown condition the fluid may be
drained and the pipe becomes lighter. Hence the spring will give upward reaction and shall load the nozzle
'D' beyond permissible limit.
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Broadly the pipe supports are classified in three groups as per following details / functions : This type of support is Rigid type in construction but is has few nuts and bolts arrangements for adjusting the
- General details supports with respect to the actual erected condition of pipe. The support can be adjusted for the erection
- Construction details tolerances in the piping. These are required for a better supporting needs at critical locations of pipe
- Functions ie. purpose supports.
These are described below in brief. Mostly all type of rigid supports can be modified by using certain type of nuts and bolts arrangement, to
make it as an Adustable support.
3.1 CLASSIFICATION AS PER GENERAL DETAILS :
Only a typical type of adjustable support is described under the topic 'Supports Generally used.'
A pipe line need to be supported from a foundation or an structure. The piping loads will be acting on these
foundations / structures. Since these foundations / structures are built on ground, they will exert an equal and 3.3 CLASSIFICATION AS PER FUNCTION (i.e. PURPOSE)
opposite reaction, while supporting the pipe.
Pipe supports classified as per functions are summarised in the Table at FIG.7. These are shown along with
In a pipe support, there will be some parts of support arrangement which is directly attached to the pipeline its basic construction, the symbols generally used and type of restraints it offers to the piping system.
and there will be some other parts which shall be directly attached to the foundation / structure supporting
the pipe.
It is the parts of support assembly which is directly connected to the foundation / structure and is
supporting the primary support attached to the pipe line.
Based on construction details, pipe supports are broadly classified in three types, as
- RIGID SUPPORTS
- ELASTIC SUPPORTS
- ADJUSTABLE SUPPORTS
This type of support arrangement is generally very simple and has maximum use in piping. It does not have
adjustibility to the erection tolerances. It will directly rest on foundation or structure which is supporting the
pipe. Common type of RIGID SUPPORTS are shoe type (welded), shoe type (with clamp) Trunnion type,
valve holder type, support brackets (Secondary Support). These are described under the topic 'Supports
Generally used'.
This type of support is commonly used for supporting hot piping. It shall be able to support pipes even
when the pipe is moving up or down at support point.
Common type of elastic supports are variable type spring supports, constant type spring supports. These are
described under the topic 'Supports generally used '.
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The supports classified as per function are further described as follows : 4.0 SUPORT DETAILS GENERALLY USED :
3.3.1 LOOSE SUPPORT : Following are the type of supports generally used in a project.
This is most commonly used support meant for supporting only the pipe weight vertically. It allows pipe to 4.1 SHOE TYPE SUPPORT :
move in axial as well as transverse direction but restricts only the vertical downward movement.
Shoe type support are the supports used maximum in any project. These can be directly welded to pipe or
3.3.2 LONGITUDINAL GUIDE : can be welded to a clamp put around pipe. Shoe type supports are used for supporting lines with insulations.
This type of support is used to restrict the movement of pipe in transverse direction i.e. perpendicular to Basically the detail is as follows :
length of pipe but allow movement in longitudinal direction. This is also a commonly used type of Basically it is used as a Loose support. With slight addition of details it can be also used as a guide, fix
support. Generally it is used along with Loose support. point, anchor, transverse guide, limit stops. It can also be modified to be used as Adjustable supports.
3.3.3 TRANSVERSE GUIDE : These are primary supports and will be supported on secondary supports (i.e. Foundation or structure)
This type of support is used to restrict the movement of pipe in longitudinal (axial ) direction but allows the
pipe to move in transverse direction. This is also referred as 'AXIAL STOP'. This type is less used as
compared to above two types. Generally it is used along with Loose support.
FIX POINT type of support is used to restrict movements in all three directions. ANCHOR type of support
is used to restirct movement in all three directions and rotation also in these three directions.
This can be considered as a combination of longitudinal and transverse guide. This type resist only the
linear movements in all directions but not the rotational movements. This avoids heavy loading of support as
well as pipe. Therefore this type of support is preferred over welded type.
This type of support prevents total movements i.e. linear as well as rotational. This type of support is used
when it is absolutely essential to prevent any moment/force being transferred further. It causes heavy
loading on support as well as pipe.
As name itself indicates it allows pipe movement freely upto a certain limit and restricts any further In this type of support, a dummy pipe is welded to the main line so that the dummy pipe becomes a rigid part
movement. This is useful when total stops causes excessive loading on piping and support or nozzle. of the main pipe line. Now this pipe is suitably supported on a secondary support (Foundation or a structure)
The basic detail is as follows :
This type of support should be used selectively, because of stringent and complicated requirements of
design, erection and operation.
When we need a pipe support whose construction or functional details are different from the available
details, then a special support detail sketch is prepared. The functions of this support can be any
combination of above functions.
As per piping requirement, the TRUNNIONS can be VERTICLE (as shown in FIG-9) or can also be in
HORIZONTAL. These are used for loose supports, guides, transverse guides, fix points, achors as well as
adjustable supports.
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transferring the valve load the support through the pipe section. The above support is therefore not called
4.3 HANGER SUPPORT : for, in case of Carbon Steel Piping.
As the name suggest, in a hanger suport the pipe is hung from an structure using a hanger rod.
This support is generally used on loose suport, guide support and fixpoint. Other functions are less common.
Spring Support is a special type of support which is used in the situations where the support point on the pipe
is expected to move up or down during the operating condition (due to thermal growth ) from its installed
position without spring, the pipe will therefore either lift from secondary support or will make an
unsuccessful attempt to press against the rigid secondary support. Both are detrimental to the structural
integrity of the Piping System.
The spring support basically employs a spring element, which can get compressed or open up depending
upon the thermal movement at the support point of pipe. By doing so it takes the vertical load of the piping
under both the situations. From the utility point, spring supports are classified as Variable spring type &
constant spring type. As per arrangement spring support can be classified as supporting the pipe from under
(i.e resting type) or as supporting the pipe from above (i.e. hanger type).
This basically consists of spring which can get compressed or expanded according to thermal expansion.
However this movement causes increase or decrease in supporting force depending on its stiffness and this
differential load is transferred to the pipe, but this is much less than that would be with rigid support or rigid
hanger.
Variable spring supports are further classified as 'HANGER TYPE' and bottom support type as described at
para 4.5.3 & 4.5.4.
In variable spring support variability factor is maintained generally within 25%. When the vertical
movement of support point is large and/or a very less magnitude of differential force from cold to hot
condition is permissible, then constant type of support is used. This is also basically spring support but load
is supported by it through a lever mechanism in such a way that when spring gets compressed effective
leverage is reduced and vice-versa. So that net supporting force remains constant, i.e. without any load
fluctuation.
Like variable spring supports, these are also available as Hanger type and bottom support types.
Hanger rods are used as a loose supports, which is free to lift up.
Valve Holder is special type of support, which is used in the situations where it is intended to directly
support the valve body through its flanges. It is an assembly of 2 holder plates bolted to the end flanges of
the valve to be supported. These holder plates are in turn connected (bolted) to a common base plate to
complete the valve holder assembly.
This support is relatively expensive since it involves many fabrication steps (e.g. machining / drilling of
holder plates etc.) The above support is therefore used only in the situations where it is absolutely necessary
to directly support the valve body owing the weak pipe material (e.g. Plastic Piping) which is incapable of
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4.5.4 BOTTOM SUPPORT TYPE (VARIABLE)
U-bolt type support is one of the most simplest and extensively used primary support item for supporting un-
insulated piping.
These are generally used as GUIDES. These can be used conveniently as fix points for smaller size, non-
insulated piping. For large dia pipes, its use as fix point is generally avoided.
In bottom support type variable spring, the pipe is resting on top of the spring load plate, as shown.
4.8 SUPPORT BRACKETS :
The selection is based on the availability of structure.
These are basically the secondary supports. All supports discussed before this has been primary supports.
In these two types manufacturer offers various models suitable for different types of attachment. These are
better described / shown in manufacturers catalogue viz. SARATHI & UMA whose catalogue for all the The support brackets are structural frames used in between the primary supports and the building structure.
above are available with us. The support brackets are fixed to the building structure or foundations. These are required at places where
the pipe can not be directly supported from a building structure or any foundation.
Note :
The members used for brackets are structural items like beams, channels, angles, plates etc.
From all the above description it may create the impression that constant spring supports are better than
variable spring supports, however it is not so. The reasons are : - Some of the basic guide lines for design of secondary supports (Brackets) are discussed below.
- constant support is costlier than the variable spring supports. 5.0 SECONDARY SUPPORT DESIGN CONSIDERATION :
- constant spring support cannot adjust itself to actual variation in load.
Although the design basis of a secondary supports (Brackets) is purely an structural design, but since the
4.6 ADJUSTABLE SUPPORT : piping loads are not purely static and many times, a large cantilever structures are required, it needs certain
special considerations in its design as follows :
As the name suggest, this type of support is capable of adjustment at site to accommodate erection tolerances
of piping. Basically all type of support can be easily modified and made adjustable. A typical example for 5.1 Supporting should not be done at any location for individual lines. The support details should be made
support at pump suction is shown below. keeping in view all the lines requiring supports at any particular location.
(In all the Figures to follow, member details shown as (-x-x-x) shall indicate suggested modification ).
Instead of supporting structures No.1, 2, & 3; one support sketch should be provided; it shall make the
arrangement compact and strong.
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Some of the suggested detail for the above support requirement are given below :
5.2 L-type support should be avoided as far as possible. It should be used only when 'H' as well as 'L'
dimensions are comparatively less and the suitability of the structure is properly seen.
The option given below should be the last option since it requires more work and the configuration looks
odd due to larger member size.
As an example we should avoid support details as given in this figure above.
As far as possible we should use support details which are connected both ends, no matter, even if the
dim.L' is as low as 350 mm.
• We should also avoid unnecessary extra projections when L=dimen. is becoming large.
When L-dim. is becoming large we should try to connect the loose end 'X' to some near by structure or else 5.3 T-Type supports whenever erected on beams, a good connection detail should be specified. Few examples
increase the member size and connection detail at insert plate 'I'. of connections details are mentioned here.
5.4 While supporting hot pipes, we must provide structure sizes sufficiently large so as to accommodate the
movement of pipes on the support structure.
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Few special supporting cases near pumps, tall vessels and exchangers are described as follows :
6.1 Case - 1 :
* In any case these lengths should not be less than 200mm. More than this, pipe movements due to thermal
expansion, wind, earthquake should be seen.
Whenever such type of small T-Post structure is there we must try to connect it to the near by structure.
This costs hardly anything but improves the structure support design.
5.5 It is normally noted that the structures are adequately designed for weight of the piping systems but in most
of the cases horizontal loads due to friction is over looked. These horizontal loads can be around 25 to 35%
of the vertical loads.
Therefore horizontal loads should be properly considered during the design of support structure.
Whenever these horizontal forces due to friction becomes so large that the system is not able to withstand
then we should provide a suitable means to reduce this friction. Some of the suitable means are as follows :
5.5.1 Provide roller support or Ball bearing supports. To avoid loading of suction nozzle due to control valve weight, which is nearby, if we provide a trunnion
(non insulated as per normal practice) to take weight of control valve, then during operation such nozzle will
5.5.2 Provide Grafoil sheets between pipe shoe and support structure. Similarly teflon sheets can be move up and lift the trunnion off its base. This will load the nozzle and purpose of trunnion will not get
provided. served.
This can be avoided by insulating trunnion, so that it will remain hot and will expand upwards and will
provide resting. Thus in most cases, the nozzle loading can be controlled without use of spring supports, near
pump nozzles.
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6.2 Case - 2 : Alternatively line may be supported at bottom (near pump) and loop may be provided at top as shown in
FIG-24
When supporting a line coming from top nozzle of a short vessel as shown in FIG-22, if the temperature and
material of the vessel and pipe line is same, then the line may be supported at ground level. 6.4 Case 4 :
While supporting suction and discharge piping to a pump, the supports being provided should be sufficient
to take care the maintenance requirements of the pumps i.e. if the valves / strainers, on the pumps are taken
out for maintenance, the lines should remain supported.
6.3 Case - 3 :
When supporting a line coming from a tall vessel and the line temperature is different from vessel, it should
be supported from vessel at the neutral point with respect to vessel. Such point is normally near the nozzle
itself (FIG-23). The pump should be connected through flexible loop connection to avoid nozzle loading.
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6.5 Case 5 :
In comparatively larger size pipes when a resting support is required at location "A", then an adjustable type
supports should be provided. This is necessary due to the maintenance requirements - such as changing of
gaskets, etc. (see FIG-27)
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A horizontal equipment will normally have two supports, saddle type. Normally one of them is made fixed In such case if saddle 'A' is fixed in figure 29, total expansion of 13m will be required to be absorbed by
and the other sliding type. pipe line.
Enclosed sketch showing a few typical cases will make the concept clear.
If saddle 'B' is fixed then vessel expansion of 4m will be nullified by pipeline expansion of 4m and only
7.1 Case - 1 differential expansion of 9 m will be required to be absorbed.
For the long vessel as shown in figure 28, selection of fixed saddle is decided by stiff connection 'A'. Now if
pumps are located at 'B' then expansion of 15mm (vessel expansion) and 5mm (pump line expansion) i.e.
total 20mm will load the pump nozzle excessively.
If pumps are located at 'C' then expansion of the pump line will nullify the vessel expansion, since both are in
the same direction hence this type of arrangement should be preferred if possible.
7.3 Case - 3
In such case by looking at line size in figure 30, one may think that more attention be given to 20"
connection. But looking correctly, saddle selection does not make any difference as both are at equal
distance from 20" pipe line. Then selection should be based in favour of 8" pump line i.e. saddle 'B' should
be fixed to reduce load on the pump.
Where ever it is possible to make a flexible piping to the pump, then in such situations, it is possible to make
both the saddles, SLIDING type.
In conclusion fixed saddle should be so chosen that expansion of vessel towards sliding saddle tends to
nullify or substantially reduce differential expansion passed onto connected pipe line. Fixed saddle should
be close to stiff piping connections to the equipment.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0028 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0028
Rev. : R0 Rev. : R0
PIPE SUPPORTS PIPE SUPPORTS
Uhde India Limited Page : 24 Uhde India Limited Page : 25
The hot insulated C.S. Piping never rests directly on secondary support. Shoe type support of carbon steel
with or without clamp is used. Trunnion type supports can be used if not objected by client / some licensors.
U-bolts are not used.
The hot insulated stainless steel piping ( ≤ 350º C) will generally use shoe type support of carbon steel with
clamp. A thin stainless steel sheet or an asbestos cloth is used between pipe and clamp. When welded type
shoe is required, then the pipe shall have an S.S pad welded to pipe. The C.S. shoe shall be welded to S.S.
pad.
When Trunnion is used, a short length of trunnion will be of S.S. or a S.S. pad shall be used.
The hot insulated Alloy Steel piping shall generally use shoe with clamp. When ever essential, welded type
shoe can be used. Trunnion type supports can be used if accepted by client / licensor.
The material of clamp and shoe shall be carbon steel or alloy steel depending on the pipe temperature.
Cold insulated piping generally use pipe shoe with clamps of carbon steel. The clamps are put over the cold
insulation blocks. Pipe shoe with clamp, put directly on the cold pipe will need special insulating blocks
between pipe shoe base plate and the secondary support member. In this case the support material need to
be compatible with the pipe temperature. Trunnion type supports are generally avoided.
The un-insulated carbon steel pipe (bare pipe) generally rests directly on the secondary support. For big dia
pipes generally NB ≥ 14", a pad is needed to avoid ovality formation in pipe at support. Generally U-bolts
can be used at guides. Guide lugs can also be used. For fix point at non-critical locations, beams need to be
welded at bottom of pipe.
The un-insulated, stainless steel pipe do not rest directly on the secondary supports. Shoe type support with
clamp of carbon steel is used for support. A thin stainless steel sheet or an asbestos cloth is used between
pipe and clamp.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1011 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1011
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited PIPERACK PIPING Page : 1 Uhde India Limited PIPERACK PIPING Page : 2
LIST OF ILLUSTRATIONS
CONTENTS
SR.NO. DWG.NO. DESCRIPTION
Page
1 PRP1 TYPICAL YARD PIPING ARRANGEMENTS
0.0 Cover Sheet 1
2 PRP2 TYPICAL CROSS-SECTION OF YARD PIPING
List of illustrations 2
3.0 Location of Valves & Instruments on Piperack 4 5 PRP5 LINE SPACING CHART
4.0 Yard Piping Arrangement 5-7
6 PRP6 PLANNING FOR LINE GROWTH
5.0 Illustrations 7
7 PRP7 LARGE DIAMETER LINES - CHANGE IN DIRECTION
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited PIPERACK PIPING Page : 3 Uhde India Limited PIPERACK PIPING Page : 4
2.4 After analysing all the requirements and arrangements, the dimensions are to be rounded off to the
1.0 GENERAL next whole number. Based on the economics, the width and the number levels e.g. two tier of 30
ft. wide or three tier of 20 ft. wide rack will be decided.
The piperack general arrangement is finalised during the development of overall plot plan. The
exact width of the piperack, numbers of levels and elevations, the access and maintenance The gap between the tiers shall be decided on the basis of the largest diameter pipeline and its
platforms are finalised during piperack piping study. branching. The difference between the bottom line of pipe in the rack and the bottom of a branch
as it leaves the rack shall be decided carefully, to avoid any interference due to support, insulation,
Normally, the piperack piping study, with its structural and platform requirements is the first priority size of branch etc. All branch lines from the main lines on piperack shall be taken aesthetically on
item for detail engineering of a process unit. a common top of steel (TOS).
The piperack may be an integral part of a process unit located in the middle of the unit or it may be With the above considerations, the conceptual arrangement of piperack are to be finalised.
an arterial part connecting several services of other process unit.
The following data and drawings are required to be studied before starting the detailed design of
piperack piping study: 3.0 LOCATION OF VALVES
Unit Plot Plan / Overall Plot Plan 3.1 Various factors shall be considered while locating each line, valve and instrument in a piperack. In
a standard process unit piperack, process lines are located on the lower levels, utility lines are on
Piping and Instrumentation diagrams
the next higher level and a separate top level is arranged for electrical and instrument cable trays.
Plant layout specification The requirements and locations of electrical and instrument cable trays alongwith their spacing,
protective cover, approach platform / walkways are to be discussed with the electrical and
Client specification instrument engineers.
Material of construction 3.2 The largest lines should be located near the supporting columns to reduce the overall load on the
Fireproofing requirements supporting beams.
The relief headers must be located above the top level of the rack to allow the line to drain to
blowdown drum. (Refer sketch No.PRP9). The designer should avoid locating pipeline over the
2.0 STEPS TO PIPERACK PIPING centreline of structural column for support so that the columns can be extended for future rack
2.1 The first step in the development of any piperack is the generation of a line-routing diagram. A line expansion.
routing diagram is a schematic representation of all process piping systems drawn on a copy of 3.3 Shut-off valves at utility headers are located inside the rack area in the horizontal position directly
piperack general arrangement drawing / or on the unit plot plan where the piperack runs in the above the header.
middle of the process unit.
Valves must be accessible from platforms or by chain operators (chain to fall free of obstructions
Based on the information available on the first issue of P&I Diagram / Process flow diagram i.e. hampering operation).
line size, line number, pipe material, operating temperature etc. the line routing diagram is to be
completed. 3.4 Refer sketch no.PRP-12. This view highlights features requiring additional considerations. The
width of the access way is determined by the space needed to maintain the equipment located at
2.2 Once the routing diagram is complete, the development of rack width, structural column spacing, grade below the piperack.
road crossing span, numbers of levels and their elevations should be started.
The valves are staggered on either side of the catwalk and handwheel extension stems are
Piperack column spacing shall be decided based on the economics of the pipe span as well as the furnished when necessary to facilitate operation.
truss arrangement to accommodate double the span for road crossing or avoiding underground
obstructions.
Piperack arrangement should be developed to suit the specific plant requirements. 4.0 YARD PIPING ARRANGEMENT
2.3 The piperack width can now be worked out with a typical cross-section of the rack with the levels. 4.1 The plant layout determines the main-yard piping runs. Refer sketch No.PRP-1 which shows
typical piperack layouts for various plant arrangements.
Normally, piperack carry process lines on the lower level or levels and the utility lines on the top
level. Instrument and electrical trays are integrated on the utility level if space permits or on a 4.2 Smaller plants usually have the simplest yard piping as shown in sketch No.PRP-1, A and B. In
separate level above all pipe levels. Fig.A, the process and utility lines enter and leave at the same end of the plot and Fig.B, presents
Any piperack design should provide provision for future growth to the extent of 25 to 30% on the a frequently adopted layout, with utility lines entering at one end and process lines at the opposite
rack clear width. end.
When flanges or flanged valves are required on two adjacent lines, the flanges are to be 4.3 In larger plants, yard piping becomes more complicated as shown in sketch No.PRP-1, D, E, F, G.
staggered. The piperack arrangement results from an overall plant arrangement, site conditions, client's
requirements and plant economy.
Thermal expansion or contraction must be accomodated by keeping sufficient clearance at the
location where the movements will occur.
The clearance of the first line from the structural piperack column is to be established based on the
sizes furnished by the civil / structural engineers.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1011 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1011
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited PIPERACK PIPING Page : 5 Uhde India Limited PIPERACK PIPING Page : 6
4.4 Pipelines in the piperack are classified as process lines, relief-line headers and utility headers. Pipe expansion forces, at some of these points, will affect yard support design.
Process lines : • Those process lines which interconnect equipment on the same side of the yard should be near
the edges of the yard bank. Lines which interconnect equipment located on both sides of the yard
Process lines are those
should be closer to the utility lines and can be placed either side of the yard. Position of product
(a) which interconnect nozzles on process equipment more than 20ft. apart (closer process lines is influenced by their routing after leaving the plant limit.
equipment can be directly interconnected with pipelines)
Right(left) turning lines should be on the right(left) hand side of yard.
(b) Product lines which run from vessels, exchangers, or more often from pumps to the unit limits
Utility lines serving individually one or two equipment items should be on the same side of the yard
to storage or header arrangement outside the plant.
as the equipment to which they connect.
(c) Crude or other charge lines which enter the unit and usually run in the yard before connecting
4.6 Piperack Elevation
to exchangers, furnaces or other process equipment e.g. holding drums or booster pumps.
Relief-line headers Refer sketch No.PRP-2 and PRP-3 for typical cross-section of piperack piping.
Individual relief lines, blow down lines and flare lines should be self draining from all relief valve Elevation of yard piping is determined by the highest requirement of the following :
outlets to knock-out drum, flare stack or to a point at the plant limit. A pocketed relief line system a) Headroom over a main road.
is more expensive, because usually an extra condensate pot is required with instruments, valves
and pumps. To eleminate pockets some relief line headers must be placed at higher elevation b) Headroom for access to equipment under the piperack.
above the main yard usually on a tee support on the extended piperack column. However, on c) Headroom under lines interconnecting the piperack and equipment outside the piperack.
some noncondensing gas systems self drainage is not so essential. Relief lines can be individual,
some with large diameters and occasionally high temperatures. The size of beam supporting the piperack piping should also be taken into account when
considering headroom.
Utility lines
Generally those process lines should be located in the top tier which interconnect two nozzles
Utility lines in the piperack can be put in two groups : elevated higher than the top tier. Process lines with one end lower than the bottom tier elevation
(a) Utility headers serving equipment in the whole plant. Such lines are : low and high pressure can run either in the top or the bottom rack. If both ends of a process line are lower than the
steam lines, steam condensate, plant air and instrument air lines. If required, cooling water bottom tier elevation, the line should be located in the bottom tier.
supply and return and service water can also be arranged on the piperack. The elevation of a line can also be influenced by valves and instruments in the line. Often a more
(b) Utility lines serving individually one or two equipment items or a group of similar equipment convenient access platform can be provided for valves arranged in the top tier of piperack. The
(furnaces, compressors) in the plant. Such lines are : boiler feedwater, smoothering steam, preferred location of lines with orifice runs is near the edge of the piperack with orifice flanges near
compressor starting air, various fuel oil lines, lubricating oil, cooling oil, fuel gas, inert gas and the column for more convenient protable ladder access. Refer sketch No.PRP-8.
chemical treating lines. The sketch No.PRP-2, upper right corner shows platform and walkway arrangements to valves,
Steam header should drain to the steam separator for more effective condensate collection. relief valves and instruments located in the piperack.
Branch connections to steam headers usually connect to the top to avoid condensate drainage 4.7 Piperack Piping Economy
to equipment.
The economy in piperack piping depends primarily on the length of lines arranged on the rack.
Instrument lines and Electrical cables Fittings, valves and instrument are relatively few in the piperack compared to pipelength.
Instrument lines and Electrical cables are often supported in the yard and extra space should be Sketch No.PRP-2 shows those critical dimensions (A,B,C,D & E) which will influence piping cost
provided for these facilities. The best instrument line arrangement eleminates almost all elevation from piperack piping layout point of view. These dimensions depend on the overall plant layout
changes between the plant and the control room. This can be easily achieved when instrument and should be carefully considered when the plot is developed.
lines are supported outside the piperack column on a suitable elevation.
Dimension 'A' is the total length of the piperack and is governed by the number and size of
4.5 Line Location equipment, structure and buildings arranged along both sides of the piperack. On an average,
• Refer sketch No.PRP20. It shows single-level yard piping. about 10 feet of rack length is required per process equipment (exchanger, drum, tower, unhoused
compressor etc.)
Regardless of service, heavy lines (very large diameter lines, large lines full of liquid) are placed
over or near the piperack columns. Centrally loaded column and reduced bending moment on the A control room located along the rack will increase the piperack piping cost because all lines must
beam will result in a lighter structural design. Next to these lines are placed all process lines and pass by without really being associated with the relatively long control room.
relief lines. Utility lines are in the centre portion of the yard. A general sequence of uitility lines is To shorten piperack length (Dimension 'A'), various methods are applied viz. equipment in pairs,
also shown on the sketch PRP-20. stacked exchangers, exchangers under elevated drums, drums or exchangers supported on
• It is advantageous, from point of view of support, to group hot lines requiring expansion loops. towers with common platforms, drums supported on exchangers, process equipment located
under the rack etc. These arrangements not only shorten the process interconnecting equipment
Refer sketch No.PRP-13, PRP-14. Loops elevated horizontally over the yard is the most common
directly but also shorten those lines which pass through this area and utility headers serving this
adopted design, having the hottest and largest diameter line outside.
area.
Line guides, line stops and anchor points are usually required along a hot line somewhere in the
piperack.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1011
Dimension 'D' and 'E' should be decided based on what is minimum necessary to reduce the COMPR. CONTR. RM
HOUSE
vertical piping lengths.
For economical design of piperack structure, an evaluation by a structural expert should be done.
This expert can determine whether steel or concrete or a combination of the two is the most
desirable choice and what span and spacing will give the most economical arrangement.
PROCESS EQPT. PROCESS EQPT.
CONTR. RM
COMP.
HO.
CONTR. RM
COMP. HO.
HEATERS
CONTR.
HO.
CONTR. RM
COMP. HO
COMP.
HO.
CONTR.
RM HEATERS
: R0 : R0
PLATFORM CATWALK
PLATFORM
INSTR.
LINES
LEAVE SPACE TO
EXTEND STRUCTURAL COLUMN
UTILITY LINES
ON TOP ROW
1500
CANTILEVERED
A IF NECESSARY
750
PLAN
PROCESS LINES
ON BOTTOM ROW
ALTERNATE GRADE
ROUTE
STEAM
CANTILEVER
INSTR.
CONTROL
D
LINES
VALVE
C B C
DIMENSIONS A,B,C,D&E DEPEND ON OVERALL PLANT LAYOUT AND INFLUENCE PIPING COST.
: 29040-PI-UPS-1011 : 29040-PI-UPS-1011
: R0 : R0
UTILITY LINES
PROCESS LINES
ELECTRICAL CABLE
TO STARTER
INSULATED
FLANGES
NOTES:
: R0 : R0
NO MOVEMENT
MUST CLEAR
AFTER 63 MM LINE "A" LINE "B"
LINE GROWTH
CHECK FOR
POSSIBLE INTER- ELEVATION 1
FERENCE
SHOE-LINE A
LINE GUIDES
* SHOE-LINE B
ELEVATION 2
END VIEW
STAGGER LOCATION 6
* IF INSUFFICIENT
SPACE BETWEEN LINES
LINE "B"
LINE "A"
MUST CLEAR
AFTER 63 MM
LINE GROWTH
ELEVATION 2
45° ELBOW
SIDE VIEW
: 29040-PI-UPS-1011 : 29040-PI-UPS-1011
: R0 : R0
RELIEF HEADER,
PREFERRED
LOCATION NEAR CENTRE OF RACK
: R0 : R0
PRESENT FUTURE
150 150
C
L
COL
PLAN
900
: 29040-PI-UPS-1011 : 29040-PI-UPS-1011
: R0 : R0
BATTERY LIMIT
10"-CS at 450°F
LINE BRANCHES
8"-CS at 390°F
6"-CS at 350°F
CATWALK
MULTIPLY COEFFICIENT OF EXPANSION BY LENGTH OF LINE
COMMON
CENTRELINE
EXTENSION STEM
AS REQUIRED
1200
1000
6"
8"
10"
LOCATE THE LINE REQUIRING THE LARGEST LOOP ON THE OUTSIDE
: R0 : R0
EXPN. LOOP
PUMPS
PLAN OP
E
SL STEAM TRAP
DRIP LEG
E
OP
ANCHOR STRUCTURE SL
K-BRACING TO ALLOW
PASSAGE/MOVEMENT
ELEVATION
NOTE: GROUP LINES WITH EXPANSION LOOPS. HOTTEST AND LARGEST LINE OUTSIDE.
: 29040-PI-UPS-1011 : 29040-PI-UPS-1011
: R0 : R0
#3
#4
#5
#2
WRONG FLAT TURNS ELEVATION #1
DIFFERENCE
#1
#2
#3
#4
#5
: R0 : R0
LIGHTING
PANEL
CONTROL
STATIONS
UTILITY
STATION
ELECTRICAL
PULL BOX
ROTAMETER
SECONDARY
PIPE RACK EA
AR
SS
CE
AC
S.
OL
CLC
WRONG LOCATION RIGHT LOCATION 450
-60
NS 0
TIO
TA
CLS
: R0 : R0
TYPICAL PIPELINE DISTRIBUTION ON A SINGLE-LEVEL PIPERACK TYPICAL PIPERACK PIPING AND EQUIPMENT RELATIONSHIPS
IN A PETROCHEMICAL PLANT
TOWER
TOWER
C B C
DEPENDING ON
MAX. PIPE DIA
750 TO 1000
DISTANCE WILL VARY
DRUM
E
ELEVATION OF
LINES TO ADJACENT
EQUIPMENT
1200
LINES WITH ONE
HEAD ROOM
EXCHANGER
D
END BELOW AND MIN.
OTHER END ABOVE
YARD CAN BE
LOCATED ON
EITHER YARD BANK
CONTROL
VALVE
PUMP SUCTION ACCESS TO ORIFICE IN LINES WITH BOTH ENDS LOWER
PUMPS VERTICAL LINE THAN BOTTOM YARD BANK
ARE LOCATED ON THE LOWER LEVEL
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1005 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1005
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 1 Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 2
4.0 Pump Piping 4-5 8 CPP8 TYPICAL PUMP SUCTION & DISCHARGE PIPING
Applicable Revision:
Prepared: Checked: Approved:
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 3 Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 4
1.0 GENERAL 2.4 With normal piperack column spacing of 6m, it is generally found that only two pumps of average
size can be arranged between the columns, with a preferred clearance of 1m between the pumps.
The design of a piping system can have an important effect on the successful operation of a The clearance between any structure / steel work and the pump discharge line shall be 0.75m
centrifugal pump. Such items as sump design, suction piping design, suction and discharge pipe minimum. For small pumps upto 18 KW, clearance between pumps should be 0.9m minimum. A
size and pipe supports must all be carefully considered. A typical horizontal centrifugal pump space of 2 - 2.5 m should be provided for working aisle.
installation is illustrated in Fig.CPP1, CPP2, CPP3.
A typical arrangement of pumps is illustrated in Fig.CPP4, CPP5, CPP6.
Selection of the discharge pipe size is primarily a matter of economics. The cost of various pipe
sizes must be compared to the pump size and power cost required to overcome the resulting 2.5 Means of lifting should be provided for pumps or motor weighing more than 25Kg.
friction head.
1.1 The suction piping size and design is far more important. Many centrifugal pump troubles are 3.0 "STEPS TO DO PUMP PIPING"
caused by poor suction conditions.
Step 1 : Collect the P&ID and the pump data sheet.
1.2 The suction pipe should never be smaller than the suction nozzle of the pump and in most cases it
should be at least one size larger. Suction pipes should be as short and as straight as possible. Step 2 : Study the pump data sheet and collect the similar (capacity / head) pump dimensions /
Suction pipe velocities should be in the 1.0 - 1.5 metre per second range, unless suction conditions nozzle position.
are unusually good. Higher velocities will increase the friction loss and can result in trouble some
air and vapour separation. This is further complicated when elbows or tees are located adjacent to Step 3 : Analyse the location and the space provided in the unit plot plan w.r.t. suction and
the pump suction nozzle. In that case uneven flow patterns or vapour separation keeps the liquid discharge line routing.
from evenly filling the impeller. This upsets hydraulic balance leading to noise, vibration, possible
cavitation and excessive shaft deflection. Cavitation, erosion damage, shaft breakage or Step 4 : Review the maintenance / operation space around and lifting facility.
permature bearing failure etc. may result.
Step 5 : Locate the control station, Electrical push button station, Electrical-trench, process fluid
1.3 On pump installations involving suction lift, air pockets in the suction line can be a source of drain, flushing / cooling connection as required for the pump model.
trouble. The suction pipe should be exactly horizontal or with a uniform slope upward from the
sump to the pump as illustrated in Fig.CPP7. There should be no high spots where air can collect Step 6 : Check elevations of all valve handwheels on suction as well as discharge line and provide
and cause the pump to lose its prime. Eccentric rather than concentric reducers with flat side top common platform for valve operation, if required.
should always be used.
Step 7 : Make Iso sketch for suction and discharge line with all the items as per P&ID and
1.4 If an elbow is required at the suction of a double suction pump, it should be in a vertical position if discuss with process engineer for any change.
at all possible. Where it is necessary for some reason to use a horizontal elbow, it should be a
long radius elbow and there should be a minimum of five diameters of straight pipe between elbow Step 8 : Finalise supports of the line and issue for stress analysis, if required.
and the pump suction as illustrated in Fig.CPP9.
Step 9 : Get the stress analysis report for Nozzle loads. Compare the allowable loads with the
actual load for any change & finalisation.
2.0 LOCATION
Step 10 : Finalise location of pump / drain or trench / Electrical cable route and issue civil
information to civil for foundation design.
2.1 Common location of pumps in chemical and petrochemical plant is under the piperack at grade.
Pumps are to be placed close to and below the vessels from which they take their suction in order Step 11 : Keep necessary insert plate on the foundation block for support of push button switch,
to have net-positive suction head (NPSH) required by the pump. small lines for flushing / cooling manifold.
2.2 Any reduction in suction line size required at pumps should be made with eccentric reducers, with
flat side up to avoid accumulation of vapour pocket. Changes in direction of suction lines should 4.0 PUMP PIPING :
be at least 600mm away from the pump suction.
4.1 HORIZONTAL CENTRIFUGAL PUMP :
2.3 Pumps should be arranged in line with drivers facing the access gangway. Clearances and piping
should provide free access to one side of the driver and pump. There must be good access to A typical horizontal centrifugal pump suction and discharge piping arrangements is illustrated in
gland / seal and coupling where most of the maintenance and adjustments are done. Fig.CPP7.
4.2 Pump suction piping shall be as short as possible and shall be arranged so that vapour pockets
are avoided.
4.3 Reducers immediately connected to the pump suction shall be eccentric type flat side up to avoid
accummulation of gas pocket.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1005 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1005
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
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4.4 For end suction pumps, elbows shall not be directly connected to the suction flange. A straight
piece 3 times the line size shall have to be provided at the suction nozzle. This is illustrated in 5.0 SUCTION BASIN OF PUMP
Fig.CPP8.
5.1 The basin for the intake of centrifugal pump shall be designed and sized properly for smooth
function of the pump. The recommendations of hydraulic institute is illustrated in Fig.CPP14.
The effect of elbow directly on suction is illustrated in Fig.CPP9.
5.2 The flow of fluid to the suction bell should be even, smooth and stream lined without any vortices.
4.5 For top suction, pump elbow shall not be directly connected to suction flange. A straight piece of
minimum 5 times the nozzle size shall have to be provided at the suction nozzle.
5.3 A typical sump with the components and relative dimensions of clearance and submergence is
illustrated in Fig.CPP15.
4.6 T-type strainers are to be used for permanent as well as temporary to avoid disassembly of suction
piping for strainer cleaning.
5.4 For multiple pump installations with high capacity pumps, the analysis of a proposed intake design
4.7 Piping shall be so arranged that forces and moments imposed on the pump nozzles do not exceed are often made by use of a scale model of the intake basin with all parts such as baffles, screens,
the allowable values specified by the vendor. gates, separating walls etc.
4.8 When a suction vessel operates under vacuum the vent connection of the pump has to be The large basin is required to ensure low inlet velocity (approx. 2 ft. per sec.) and to eliminate
permanently connected to vapour space of the suction vessel to allow possible filling of the pump vortexing at the bell mouth.
with liquid before it is started.
5.5 A typical sump pit with pump is illustrated in Fig CPP16. This sump is the collection pit of waste
4.9 For pumps handling hot fluid, the first factor concerns the support of pump piping which often material coming thru a pipeline. A screen at the mouth of the pump avoids choking / fouling of the
includes large expansion loops for flexibility. When the pumps are located below the piperack (to pump during operation. The discharge of the pump may go to a slope tank / pond / waste-removal
reduce possibility of hydrogen leakage over motor), support becomes easy otherwise the designer tanker.
should consult stress engineer for best location of stops and hanger. With the optimum layout and
support, it is to be ensured that the loadings on the pump nozzles are not exceeded beyond the
allowable limits.
4.10 Piping configuration for a group of pumps of similar size shall follow identical pattern and the stress
analysis of one pump piping should be applicable to the other pumps.
The auxilliary piping are usually cooling water to mechanical seals, bearings, stuffing boxes, gland
quench and lantern rring flush.
When pump fluid is used, a line is attached to the vent connection on the pump case. The
circulated seal fluid has to be sent back to pump stream or referred through the seal to pump
internal clearances.
In viscous or high temperature hydrocarbon liquids, the seal fluid medium circulates from external
source through connections on the pump seal.
Various auxilliary piping plan is recommended in API 610 for proper selection according to design
requirements.
4.12 Pump vendors usually supply the auxilliary piping and the neat arrangements of these piping and
its support are to be ensured by the designer while reviewing the vendor document. Fig.CPP10
illustrates one typical auxilliary pipig arrangement on the pump base plate.
4.13 A typical arrangement for piping and valves operation is illustrated in Fig.CPP11 with maintenance
and operation access.
4.14 A typical suction and discharge piping arrangement with common platform for operation of valves
connected to two adjacent pumps is illustrated in Fig.CPP12 and CPP13.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
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DISCHARGE
(LIQUID OUTLET)
IMPELLER
COUPLING SUCTION
(LIQUID INLET)
CASING
CASING DRAIN
ELEVATION
CL DISCHARGE
SHAFT
SUCTION EYE
BASE PLATE
CL MOTOR CL PUMP C
L SUCTION
AUXILLIARY
C CASING
PIPING L BASE PLATE
DRAIN
PLAN
CENTRIFUGAL PUMP, LIQUID END
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
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PIPING STUDY PIPING STUDY
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3A
3B
4A
4B
DISCHARGE
1A
1B
2A
2B
C
L OF DISCHARGE
NOZZLE
750 750
C
L OF PIPERACK
COLUMN
C
L OF DISCHARGE
CASING NOZZLE
IMPELLER VANES
SUCTION EYE
PUMP ACCESS WAY
IMPELLER CL OF PIPERACK
COLUMN
CL PUMPS
(IN LINE)
10C
10A
10B
9C
C
L OF DISCHARGE
9A
9B
NOZZLE
5A
5B
6A
6B
EQUIPMENT LINE
7A 8A
8B
7B
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
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CL CHANNEL
NOZZLES
CABLE TRAYS (TYP)
CL KO DRUM
C TOWER
6000
L
DROP OUT
AIR COOLER
AREA
DROP OUT
AREA
C TOWER
L
CL TOWER
C
L PUMP
(TYP)
NO PERMANENT STRUCTURE
FOR BUNDLE REMOVAL
C
L DRUM
3000
750 750
L
3000
PUMP (TYP)
UP ACCESS WAY
(TYP)
ACCESS STAIRWAY
MIN. CLEARANCE OF
CL DRUM
ALL OBSTRUCTIONS
5A-5B IA-IB 4A-4B 7A-7B
C
L TANK PUMPS PUMPS PUMPS PUMPS
EQUIPMENT ALIGNED
ON COMMON TAN LINE
C ROADWAY
L
C
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4
CHECK VALVE 4
GATE VALVE PI
6 PI
ECCENTRIC 6
1
REDUCER(FST)
LONG RADIUS 4
ELBOW
4
5 TEMP SUCTION
TEMP SUCT. STRAINER
STRAINER
5
1
1
(1a) CORRECT END SUCTION -TOP DISCHARGE SIDE SUCTION - SIDE DISCHARGE
(BASIC INSTALLATION) (BASIC INSTALLATION)
FOOT VALVE
(IF USED)
1) PIPE SUPPORTS (REST/GUIDE)SHALL BE PROVIDED AT PUMPS TO MINIMIZE
STRAINER WEIGHT AND THERMAL STRESSES BEING APPLIED TO PUMP NOZZLES
(NOT TO EXCEED MANUFACTURER'S RECOMMENDATION). LOCATION AND TYPE OF
SUPPORT MUST BE APPROVED BY PIPING STRESS ENGINEER.
2) REMOVABLE SPOOL PIECES IN SUCTION PIPING SHALL ALLOW FOR INSTALLATION
AND REMOVAL OF TEMPORARY SUCTION STRAINERS.
3) PIPING SHALL BE DESIGNED AND ARRANGED SO THAT CLEARANCE IS PROVIDED
FOR REMOVAL OF PUMPS AND / OR DRIVERS. FOR END SUCTION PUMPS THE
SUCTION COVER AND PUMP IMPELLER SHALL BE REMOVABLE WHILE THE SUCTION
AND DISCHARGE VALVES ARE IN PLACE.
4) VALVE HANDWHEELS SHALL BE ORIENTED WHENEVER PRACTICAL TO BE CONTAINED
CHECK VALVE WITH IN THE PERIMETER OF THE PUMP.
5) PERMANENT SUCTION STRAINERS MAY BE REQUIRED AND SHALL BE SHOWN ON FLOW DIAGRAM.
GATE VALVE 6) SUITABLE TEMPORARY SUPPORTING FACILITIES AT SUCTON LINES WHEN REMOVING STRAINER.
ECCENTRIC
REDUCER MOTOR
LONG RADIUS
ELBOW
SLOPE
PLAN VIEW DO NOT LOCATE HANDWHEELS
(TOP SUCTION-TOP DISCHARGE) OVER DRIVER OR COUPLING
(1b) CORRECT
(IF USED)
STRAINER
MOTOR
PLAN VIEW
(END SUCTION-TOP DISCHARGE)
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
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ECCENTRIC REDUCER-
WITH TOP HORIZONTAL MUST BE MIN.
5D
CASING VENT
D
VALVE STEM LEAK OFF
ELBOW MUST BE
VERTICAL WHEN
NEXT TO PUMP
CASE DRAIN
(2b) WRONG
(2a) PERMISSIBLE
ELEVATION END
BASE PLATE
DRAIN
PLAN
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C PUMP
L
FO
PUMP PLOT
AREA
FO
CL PUMP
PLAN
PLAN
ARRANGE SUITABLE PLATFORM
.. FOR OPERATION HEIGHT > 1500
HEIGHT 1500 MAX.
OPERATION
CL PUMP SUCTION
EL. VARIES
ELEVATION ELEVATION B
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
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B D
ALT.
TYPICAL SUCTION/DISCHARGE PIPING - FRONT VIEW
W
Vs=1fps Ve = 2fps & up
if A = less than 4W
Ve
W = (See Figure 2.26)
w =11/2 to 2D
D A
RECOMMENDED A NOT RECOMMENDED
CL DISCHARGE
CL MIN. FLOW
B
CL HC DRAIN
CL SUCTION
Add wall thickness
to CLdist. round off For B & C,
to give wall ends see Figure CPP15
B NOT RECOMMENDED
RECOMMENDED
D A
PI
Max. = 15° A
Preferred = 10° 2
Y
RECOMMENDED C NOT RECOMMENDED
Y D
V1
Z
P
V
Z
D U Y
C SUCTION
CL SUCTION
Baffles, grating or strainer should be introduced across inlet NOT RECOMMENDED UNLESS :
channel at beginning of maximum width section
Z = 2.5W or more (W = As per Figure 2.26) or
Z/P 1.0 1.5 2.5 4.0 10.0 V 1= 0.2 lps or less and
Y = Same as chart to left
L
FRONT VIEW
V = 2 lps
Min. 2F
V up to 8 lps
RECOMMENDED
E NOT RECOMMENDED
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1005
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PUMP
TYPICAL SUMP WITH PUMP
W/2
SINGLE PUMP
W
FLOW
W/2
W
TRASH RACK
SCREEN
MOTOR
MULTIPLE SUMP
DISCHARGE NOZZLE
W
FLOW
FLOAT
DRAIN OR
COLLECTION LINE
B Y
A SCREEN
B Y
TRASH RACK
AT SCREEN LOCATION
SHOWN. 15° MAX. WITH
VELOCITY REDUCED TO 0.5 FT./SEC
D
W = 2D WHERE
Y > 5D S - INCHES
A > 5D Q - FLOW (GPM)
C = 0.3D TO 0.5D D - INCHES
B = 0.75D
KRUPP UHDE STANDARD February 1997
Vessels and equipment Page 2 UN 2100-01 Part 2
UN
AIR-COOLED HEAT EXCHANGERS 2100-01 same shall take into consideration the arrangement and operating conditions.
General specification Part 2 The following temperature limits (max. fluid temperature) shall be observed:
a) L-FIN type ≤ 120°C (spiral tube with L foot fin)
Behälter und Apparate; Luftgekühlte Wärmeaustauscher; Technische Lieferbe- Supersedes 87-04 b) G-FIN type ≤ 400°C (spiral tube with grooved fin)
dingungen c) Extruded FIN type ≤ 200°C (bimetal tube with drawn-out fin)
d) Hot dip galvanized FIN type ≤ 250°C (round, elliptical or oval)
Contents
1 General .................................................................................................................................................................1 The selection of the material shall take into consideration any corrosive effects of the cooling air.
2 Design...................................................................................................................................................................1
Finned tubes of carbon steel shall be of the seamless type with a minimum wall thickness of 2 mm. Tubes of
3 Fabrication............................................................................................................................................................2 stainless steel, titanium or other non-ferrous metals may be welded in the longitudinal direction.
4 Tests and inspections .........................................................................................................................................3
5 Marking .................................................................................................................................................................3 The fin pitch shall not be less than 2 mm. The fins shall terminate at least 40 mm from the tube ends.
2.4 Fans
2 Design Low-noise and non-vibrating axial fans shall be used. Where noise suppression is of particular importance,
All components shall correspond to the latest state of technology. Deviations from generally proven designs
fans with 5 to 8 blades of special profiles and low peripheral speed shall be used. Preference shall be given to
and special designs require the written approval of the purchaser.
fan blades of glass-fibre-reinforced plastics.
2.1 Types, installation The fan blades shall be thoroughly balanced (statically and also dynamically as far as this is possible). They
Unless otherwise specified, forced-draught heat exchangers with blower fans shall be provided. shall be appropriately marked for installation. The blade angles shall be adjustable during shut-down.
Natural-draught air-cooled heat exchangers and heat exchangers with exhauster fans require written approval The use of fans which are adjustable in operation (pneumatically) may be required for reasons of control.
of the purchaser.
2.5 Drives
The arrangement of the cooling elements (horizontal, vertical, roof-type, V type or special type) is indicated in
The fans are driven by electric motors. Transmission may be direct or via V-belt drives. The use of gears re-
the technical specification. Deviations are permitted if the physical properties of the fluid to be cooled and the
quires the purchaser's approval. The rated output of the motors shall include allowances for extreme ambient
arrangement conditions are taken into consideration, but require the written approval of the purchaser.
temperatures as well as for possible blade adjustment (rated output: ≥ 1.2 times the required shaft power).
To ensure an unimpeded cooling air supply, all buildings and plant sections located in the vicinity of the air-
cooled heat exchanger shall be taken into account when determining the height of supports. Hot air recircula- 2.6 Louvers
tion shall be avoided. If louvers are required, same shall be arranged above the cooling elements or, in special cases, on the intake
side underneath the fans. The louvers shall be actuated manually or by means of actuators.
2.2 Cooling elements
The cooling elements (tube bundles) shall be of the torsion-proof and self-supporting type. The dimensions 2.7 Drawings
and weight of a cooling element shall facilitate transport and assembly. Facilities for absorbing the heat ex- The drawings must contain all essential components of the air-cooled heat exchanger and of the accessories
pansion of the tubes are required. Vibration of the tubes shall be prevented by suitable means. including all dimensions, position of the connections, as well as load data for the foundations, itemizing of the
individual parts with parts list, weights, and nozzle table.
The tubes shall be welded into the tube sheets. Rolling the tubes into the tube sheets is only permitted if ap-
proved by the purchaser in writing. 2.8 Materials
The materials used shall correspond to the technical specification. Only perfect materials and new gaskets
2.3 Tubes (finned tubes) must be used. Deviating, but equivalent, materials require the written approval of the purchaser prior to use.
The tube type to be used is indicated in the technical specification. If selection of the tube type is permitted,
3 Fabrication
Continued on pages 2 to 3
Fabrication shall be effected competently and properly while observing the applicable specifications, codes
Date Prepared Date Checked Date Approved
and standards.
Applicable Revision:
Prepared: Checked: Approved:
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4 HEP4 TYPES OF EXCHANGER : SHELL & TUBE, PLATE TYPE & AIR 29 HEP29 PIPING ARRANGEMENT FOR SPIRAL EXCHANGERS
COOLER EXCHANGER
5 HEP5 AIR COOLER EXCHANGER CONSTRUCTION DETAILS 30 HEP30 PIPING ARRANGEMENT FOR PLATE EXCHANGERS
6 HEP6 TYPICAL PLOT PLAN OF SEVERAL EXCHANGER APPLICATION 31 HEP31 OVERHEAD PIPING ARRANGEMENT FOR A CONDENSING AIR
COOLER
7 HEP7 ARRANGEMENT OF EXCHANGERS AND OPERATING SPACE
BETWEEN PIPING
8 HEP8 SAMPLE EXCHANGER ORIENTATION
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1.0 INTRODUCTION maintenance. Adequate space shall be provided on either side of paired exchanger and at both
Heat Exchangers are widely used equipments in the chemical, petrochemical and refinery type of ends of grouped exchanger for control and operator access as illustrated in Fig.HEP9.
plant. The control of heat within a plant operation is done by direct heat application in a furnace, or Groups of exchangers should be generally located by the alignment of channel nozzles in a vertical
by heat exchange in a shell and tube exchanger / plate heat exchanger. Types of heat exchanger plane so as to present an aesthetic appearance.
may be Shell and Tube, Aircooled (Fin-Fan), Plate type or Coil type(spiral).
The support saddle with oblong holes for provision of thermal expansion are normally located on the
1.1 Various process duties of heat exchanger have an effect on the layout aspects viz. saddle farthest from the channel end but the final location depends on the plant layout and the stress
a. Exchange of sensible heat between two process fluids. analysis of the connected piping.
b. Cooling with air or water.
c. Chilling with refrigerated liquid. Exchanger piping should be as direct and simple as possible by considering alternatives such as
d. Heating with steam or hot water. arranging exchangers side by side / stacking them for reversing flows.
e. Condense by water or a cold process stream.
f. Vapourising by steam (e.g. column reboiler) or any heat transfer liquid. Exchangers are sometimes mounted on structures, process columns and other equipment.
Special arrangements for maintenance and tube cleaning should be provided in such cases.
1.2 - Fixed tube exchangers are used when the temperature differences between shell side and tube
side fluid are small.
3.0 ACCESS FOR OPERATION & MAINTENANCE
- Floating head or U-type exchangers are used where there is a significant temperature
Internals of heat exchanger require periodic cleaning and repair. It is important that exchangers
difference.
and the surrounding piping are arranged to facilitate access to the internal parts.
- Kettle -type reboilers are used for evaporation in case of limiting pressure drop, otherwise
3.1 Horizontal clearance of at least 900mm should be left between exchangers flange to flange or
vertical reboilers are used for evaporation.
exchanger flanges to piping. Where space is limited, clearance may be reduced between alternate
exchangers but in no case clearance over insulation between channel flanges shall be less than
- Plate heat exchangers are generally used in low-pressure, low temperature applications. The
600mm.
plate exchanger occupies less space than shell and tube exchanger for equivalent heat
exchanger surface.
3.2 The channel ends of exchangers should face the local access road for tube bundle removal and the
shell cover should face the piperack. Pulled out bundles should not extend over main access road.
- Aircoolers are used for overhead condensers of column and consist of fin-tube bundles with a
header box to each end, having inlet on top of header-box at one end and outlet on bottom of
A typical exchanger arrangement with clearance for access, operation and maintenance is shown
header box at the other end.
in Fig.HEP7.
1.3 Various types of heat exchangers with application are illustrated in the schematic flow diagram
Access for tube bundle removal is usually 500mm more than the bundle length.
HEP1. The various parameters applied to heat exchangers are illustrated in Fig., HEP2, HEP3,
HEP4 & HEP5.
3.3 Mobile equipment should be used for handling tube bundles and covers at grade level. Expensive
built-in facilities e.g. lifting beams, monorails to be kept minimum.
1.4 For single pass arrangement of air-cooler exchangers, inlet nozzles are mounted on the top of the
header box and the outlet nozzles are located at the opposite end and mounted on the bottom of the
3.4 The use of tube-bundle extractor eliminates the need for permanent tube bundle removal structures.
header box. For double pass arrangement, the inlet and outlet nozzles are located at the same end.
These mechanisms weigh around seven tons and are capable of pull forces about 500,000lbs. The
tube-bundle is held in position by crane and balanced by the extractor's leveling cradle and pulled
2.0 LOCATION
out of its shell with pull rod attachments that use hydraulic force.
Exchangers should be located close to the major equipment with which it is associated in PFD /
P&ID. Reboilers are placed next to their respective towers and condensers are placed over reflux 3.5 For air-cooled exchangers, platform arrangements must suit maintenance access requirements.
drums. Exchangers between two distant pieces of process equipment should be placed at optimal Considerations must be given to fin-tube bundle removal, tube rodding out at header boxes, motor
points in relationship to piperacks. and fan access.
Most exchangers are to be located at grade level with elevations to have a clearance of 1m above 3.6 Provision of easily removable spool pieces, flanged elbows, break flanges or short pipe runs will be
Finished Ground Level (FGL). Elevated exchangers may be necessary to fulfill the NPSH helpful for maintenance of exchangers.
requirement of a downstream centrifugal pump.
3.7 Illustrations for exchanger location in unit plot plan alongwith the provisions of operating and
In case of large numbers of heat exchangers, they are grouped in one or more category to save maintenance space, accessibility are shown thru' Fig.HEP6, HEP7, HEP8, HEP9, HEP10, HEP11,
pipe work, structural work, provision of lifting and maintenance facilities, platform requirement etc. HEP12, HEP13, HEP14, HEP15 & HEP16 as typical cases.
Paired or grouped exchnagers shall be spaced to allow minimum 450mm preferrably 600mm
between the outside of adjacent channel or bonnet flanges to facilitate access to flange bolts during
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004
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Step 9 : Check, piping should not foul with exchanger removal either in the horizontal direction for
4.0 KEY WORDS bundle-pulling nor in the vertical for whole exchanger removal.
Shell and Tube
Step 10: Check, locally mounted PI, TI on equipment or process lines, sight glasses and level indicators
Fixed head
are visible from access aisles and valves are accessible from the aisles.
Floating head
Channel End
Step 11: Mark the supports / support arrangement on the piping study.
Bonnet End
Channel Flange
Step 12: Ensure accessibility / operation facility for all valves as well as the clearance kept are not less
Tube bundle removal
than the recommended minimum requirement.
Air Cooler (Fin-Fan)
Header Box 6.0 HEAT EXCHANGER PIPING
Nozzle loads
Platform
6.1 SHELL & TUBE
Support Structure
After all the required information has been collected for the piping design of a heat exchanger, the
Stacked heat exchanger
first step is to outline clearance and working space in front and around both ends of the exchanger.
Elbow nozzle.
These working spaces should be kept clear of any piping and accessories to facilitate channel,
Monorail
shell-cover and tube-bundle removal as well as maintenance and cleaning.
Maintenance accessway
The free space at the side of horizontal shell can be used for placement of control stations.
Plate type heat exchanger
The piping is elevated from grade to have a clearance of 300mm above the grade level. The piping
Inlet port
connected to channel head nozzles should be furnished with break flanges to facilitate the removal
Back flashing
of the channel head.
Plates and gaskets
Removal of individual plate
Steam lines connecting to a header in the yard can be arranged on either side of the exchanger
centerline without increasing the pipe length.
5.0 "STEPS TO DO HEAT EXCHANGER PIPING"
Cooling-water lines, if under ground, should run right under the lined-up channel nozzles of all
coolers.
Step 1 : Collect the mech. spec. of the heat exchanger.
Access to valve hand wheels and instruments will influence the piping arrangement around heat
Step 2 : Study the P&ID around the heat exchanger and identify the relationship with the connected exchangers. Valve handwheels should be accessible from grade and from a convenient accessway.
equipment viz. column or reactor. These accessways should be used for arranging manifolds, control valves and instruments.
Step 3 : Note the special process (functional) requirement along with the specific arrangement details Fig. HEP 20, HEP21, HEP22, HEP23, HEP24, HEP25, HEP26, HEP27 & HEP28 illustrates some
with respect to level or height difference from other related equipment like pumps. typical piping arrangement around shell & tube exchangers.
Step 4 : Study the nozzle schedule, its position on the equipment and verify with P&ID. 6.2 PLATE & SPIRAL EXCHANGERS
Step 5 : Make a sketch for the relative location and level. Find out the tube cleaning space in case shell Piping at spiral and plate exchangers is also arranged to allow opening of covers and removal of
& tube Heat Exchanger as well as the maintenance space of tube bundle length. plates.
Step 6 : Locate the control valve stations both for shell side and tube side fluids. Controls at the spiral exchanger are located on the ends of the unit, clear of the cover plate swing
area, piping attachment to cover plate nozzles of spiral exchanger will have break flanges.
Step 7 : Decide the flanged joints location for replacement of Heat Exchanger / maintenance facility.
Controls for plate exchanger are located at the front and one side of the exchanger. The piping is
Step 8 : Check, in general, that cooled streams flow downwards and heated streams flow upwards. This elevated to have clearance from grade as well as convenience for operation of valves.
arrangement is mandatory when there is a change of phase, desirable when the streams are
liquid but not important when the streams are gas or vapour or there is no super heating, Fig.HEP29 and HEP30 illustrates the typical piping arrangements around spiral & plate exchangers.
super cooling.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Piping for air coolers are not routed over tube banks or fans and should be kept clear of the EXCHANGER APPLICATION SHOWN ON A PROCESS FLOW DIAGRAM
designated space for motor maintenance.
CONDENSER
(AIR COOLER)
AIR
HEATER STEAM
WATER
SHELL & TUBE
COOLER
SHELL &
TUBE
REBOILER
STEAM
CHILLER
SHELL &
TUBE
KETTLE
REFRIGERANT
REFRIGERATION
PACKAGE
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1ST FLUID 2ND FLUID SHELL RELIEF VALVE REMOVABLE SHELL 2ND FLUID
ENTERS LEAVES NOZZLE CONNECTION TUBE BUNDLE NOZZLE ENTERS
(COLD) (WARM) (HOT)
OUT IN
TUBE SIDE SHELL SIDE
SHELL
VENT
REAR
HEAD
DRAIN
TUBE SIDE FIXED TUBE SHELL SIDE SHELL SUPPORT SHELL FLOATING
HEAD COVER SHEET SADDLE NOZZLE HEAD COVER
(TYP)
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
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MOTOR
MOTOR
OUTLET NOZZLE
SUPPORT MOTOR ACCESS SUPPORT
STEEL PLATFORM BEAM
PLATE EXCHANGER
SUPPORT CHANNEL
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2" MIN.
CLEARANCE 2'-6"
(750)
2" MIN.
PIPERACK
SPACE FOR
ACCESS
PULLING TUBES
C COLUMN
L
PLATE EXCHANGER 2'-6"
(750)
HIGH PRESSURE
EXCHANGERS
HORIZONTAL REBOILER
C
L COLUMN
(600)
2'
KETTLE TYPE
EXCHANGER
VERTICAL REBOILER
C
L COLUMN 2" MIN.
C COLUMN
L
PIPERACK
CLEARANCE 2'-6"
(750) SPACE FOR ACCESS
PULLING TUBES
2" MIN.
2'
SPIRAL
EXCHANGERS PRODUCT COOLERS
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TOWER
18"/.450
CONTROL
MINIMUM
VALVE (TYP.)
CONTROL
L
VALVE (TYP.)
OPERATOR OPERATOR
ACCESS ACCESS
C
L TOWER
CONTROL
- CHANNEL END TO FACE MAINTENANCE ACCESS WAY FOR TUBE BUNDLE REMOVAL. VALVE (TYP.)
- PROVISION OF ADEQUATE SPACE FOR BONNET REMOVAL.
OPERATOR OPERATOR
ACCESS ACCESS
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ELBOW NOZZLE
SPACE FRAME
12'-0"/3600
SAME SERVICE DISSIMILAR SERVICE SAME SERVICE
AUXILIARY ROAD
OR MAINTENANCE
ACCESS WAY
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
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TUBE BUNDLE
REMOVAL AREA
TOWER ALTERNATIVE
CHANNEL DESIGN
2'/600 TO 5'/1500
PLATFORM
REBOILER
HITCH POINTS FOR
COVER REMOVAL
PLATFORM
TUBE BUNDLE
MAXIMUM
WITHOUT
900 MIN.
REMOVAL AREA
12'-0"/
3600
3'-0"/
(MAXIMUM)
VESSEL NOZZLE
6'-0"/1800
LUG & SPRING LUGS
1"/.025 GAP
PLATFORM
ADD 1"/.025
PLATFORM SHIM
SUPPORT STEEL
GUIDE 2
18"/450
REMOVE MINIMUM 12'-0"/3600 MAXIMUM
WITHOUT PLATFORM
CHANNEL EXTRACT
SECTION 3'-0"/900 MINIMUM
UN-BOLT TUBE-BUNDLE
3 4
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
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CONTROL AND OPERATOR ACCESS FOR A PLATE TYPE HEAT EXCHANGER TYPICAL COLUMN-SUPPORTED AIR COOLER ARRANGEMENT
MOTOR
MOTOR
7'-0"/2100 MIN.
(TYP.)
(TYP.)
HEADER BOX
PLATFORM
CONTROL ASSY.
SPACE
(TYP.)
PIPE RACK
OPERATOR ACCESS
ADDITIONAL PLATFORM
IF LADDER RUN IS
LONGER
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LADDER TO
MAINTENANCE
PLATFORM (TYP.)
LADDER TO MOTOR
GRADE (TYP.) (TYP.)
PIPE RACK MAINTENANCE AIR COOLER KETTLE TYPE REBOILER SINGLE PASS SHELL
COLUMNS PLATFORM SUPPORT BEAM
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
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AIR COOLERS
C TOWER
ELBOW NOZZLES
L
DOUBLE PASS
OUTLET
LOCATION
REFLUX DRUM
GRAVITY FLOW
REDUCED SPACE
ALTERNATE
LOCATION
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PIPING TO NOZZLES OF HEAT EXCHANGERS ALTERNATE ARRANGEMENTS FOR LOCATING EXCHANGER NOZZLES
CL EXCHANGER
ALLOW SPACE
FOR PULLING
TUBES
OBLIQUE OFFSETS IN PIPING SIMILIAR 90°ELBOW
TO THOSE SHOWN. ALLOW EXCHANGERS NOZZLE
TO BE PLACED CLOSER.
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INTERMEDIATE SUPPORT
OPERATOR ACCESS REQUIRED FOR PIPING
ACCESS TO FLANGE BOLTS THAT IS OVER SPANNED
450
(ALL AROUND) BETWEEN PIPE RACK AND
450 EXCHANGERS
MAINTENANCE ACCESS
600 TO 900
INSTRUMENTS
COLUMN
CL TOWER
PIPE RACK
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LEVEL
GAUGE ELEVATION OF
CONDENSATE POT
SET BY PROCESS
CONDITIONS
TRUNNION
SUPPORT
ANTIFREEZE BYPASS
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HIGH TEMPERATURE,
HIGH PRESSURE
ALLOY PIPING
SYMMETRICAL PIPING
INDEPENDENT
STRUCTURE
SUPPORTING REBOILER
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COVER PLATE
SWING AREA
COOLING WATER
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AIR COOLER
PLATE REMOVAL AREA OPERATOR ACCESS
AIR COOLER
C
L PIPE RACK COLUMN
CONTROL VALVES
PLAN
C TOWER
L
ELEVATION
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CONTENTS
LIST OF ILLUSTRATIONS
Page SR.NO. DWG.NO. DESCRIPTION
6.0 Access and Maintenance Facility 10 9 CLP9 CROSS FLOW - TRAY DETAILS
10 CLP10 TRAY TYPES BY LIQUID PATHS
7.0 Platforms and Ladders 11
11 CLP11 PROCESS FLOW DIAGRAM IN TOWER AREA
12 CLP12 SAMPLE PIPING AND INSTRUMENTATION DIAGRAM
AROUND A COLUMN
13 CLP13 EVALUATION OF THE FLOW DIAGRAM FOR A
DISTILATION COLUMN TO VISUALISE AN ORDERLY
ARRANGEMENT OF PIPING
14 CLP14 TYPICAL PIPIERACK CROSS-SECTION OF A TOWER
AREA
15 CLP15 TYPICAL NOZZLE LOCATION AND PLATFORM
ELEVATIONS
16 CLP16 PLATFORM WIDTH REQUIREMENTS
17 CLP17 TYPICAL PLATFORM ORIENTATION
18 CLP18 DETAILS OF CIRCULAR PLATFORM BRACKET SPACINGS
Applicable Revision: 19 CLP19 TOWER PLATFORM AND LADDER ELEVATION
Prepared: Checked: Approved: REQUIREMENTS
20 CLP20 TYPICAL PLATFORM ARRANGEMENT
21 CLP21 DETAILS OF A TYPICAL DISTILLATION COLUMN
Date: Date: Date:
First Edition: R0 22 CLP22 DETAILS OF TOWER SKIRT
Prepared: AKB Checked: TNG Approved: RUD 23 CLP23 TYPICAL TOWER AREA DIVISION FOR VARIOUS
FACILITIES
24 CLP24 TYPICAL TOWER PIPING SUPPORT
Date:
Date: Date: 25 CLP25 TYPICAL ARRANGEMENT OF EXTERNAL PIPING AROUND
COLUMN
File Name: LB1003 Server: PUNE: KUMUS 207 VKO: KUMUS 209
26 CLP26 TYPICAL RELIEF VALVE SYSTEM OPEN AND CLOSED
SYSTEM
27 CLP27 PIPING G.A. FOR COLUMN REBOILER PUMP
28 CLP28 NOTES FOR PIPING G.A. FOR COLUMN REBOILER PUMP
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2.0 DISTILLATION
The distillation is separation of the constituents of a liquid mixture via partial vaporisation of the
mixture and separate recovery of vapour and residue.
Various kinds of devices called plates or trays are used to bring the two phases into intimate
contact. The trays are stacked one above the other and enclosed in a cylindrical shell to form a
column.
The feed material, which is to be separated into fractions, is introduced at one or more points
along the column shell. Due to difference in gravity between liquid and vapour phases, the
liquid runs down the column, cascading from tray to tray, while vapour goes up the column
contacting the liquid at each tray.
The liquid reaching the bottom of the column is partially vaporised in a heated reboiler to
provide reboil vapour , which is sent back up the column. The remainder of the bottom liquid is
withdrawn as the bottom product.
The vapour reaching the top of column is cooled and condensed to a liquid in the overhead
condenser. Part of this liquid is returned to the column as reflux to provide liquid overflow and
to control the temperature of the fluids in the upper portion of the tower. The remainder of the
overhead stream is withdrawn as the overhead or distillate product.
The Typical distillation process tower is illustrated in Fig.CLP-1 and crude distillation of
products across temperature range is illustrated in Fig.CLP-2.
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2.1 ABSORPTION AND STRIPPING Valve Trays: Commonly used valve trays are stamped out by big press and these trays come
with small valves attached to them which allow vapour traffic.
Many operations in petrochemical plants require the absorption of components from gas
streams into lean oils or solvents. The resultant rich oil is then stripped or denuded of the Sieve Trays: Sieve trays are perforated flat plates. They are inexpensive for small diameter
absorbed materials. The greatest use of this operation utilises hydrocarbon materials, but the vessels but large diameter towers must have extensive supports for these trays. Sieve trays
principles are applicable to other systems provided adequate equilibrium data is available. are used for heavy hydrocarbon fractionation.
A typical flow diagram of absorption-stripping system for hydrocarbon recovery from gaseous All trays have foam on top of liquid. The height of the foam will vary with the process. Foam
mixture is illustrated in Fig. CLP-3. may rise a foot or more above the tray liquid.
Liquid-gas contacting is made effective through the above trays by cross-flow or counter flow.
2.2 FRACTIONATION In counter flow plates, liquid and gas utilise the same openings for flow, thus there are no
downcomers.
A fractionation column is a type of still. A simple still starts with mixed liquids, such as alcohol
and water produced by fermenting grain etc. and by boiling produces a distillate in which the Perforated plate with liquid cross flow (sieve plate) is the commonly specified tray.
concentration of alcohol is many times higher than in feed. In petroleum industry, mixtures of These two types of flow is illustrated in Fig.CLP - 8.
not only two but a lot many components are dealt with. Crude oil is a typical feed for a
fractionation column and from it, the column can form simultaneously several distillates such as The two most commonly used types of tower viz. the trayed and packed arrangements are
wax distillate, gas oil, heating oil, naptha and fuel gas. These fractions are termed cuts. illustrated in Fig.CLP-6 and Fig.CLP-7 respectively.
The feed is heated in a furnace before it enters the column. As the feed enters the column, 3.0 REQUIRED INFORMATION
quantities of vapour are given off by flashing due to release of pressure on the feed.
The basic document listed in Cl.1.0 shall be studied thoroughly for conceptual arrangement of
As the vapours rise up the column, they come into intimate contact with down flowing liquid. piping around a column.
During this contact, some of the heavier components of the vapour are condensed and some of
the higher components of the down flowing liquid are vaporised. This process is termed 3.1 The basic layout and general engineering specifications describe :
refluxing. • The minimum access, walkways, platforms width and headroom requirements.
• Handling facilities for tower internals, manhole covers, line blinds, relief valves.
If the composition of the feed remains the same and the column is kept in steady operation, a • Maximum rise of ladders.
temperature distribution establishes in the column. The temperature at any tray is the boiling • Pipe-system requirements, such as open or closed relieving systems.
point of the liquid on the tray. 'Cuts' are not taken from every tray. The P&ID will show cuts that
• Minimum line-size and required hose-stations.
are to be made, including alternatives. Nozzles on selected trays are piped and nozzles for
• Access to valves and instruments.
alternate operation are provided with line blinds or valves.
3.2 Design Standards show:
The fractionator tower is illustrated in Fig.CPL-4.
• Details of ladder dimensions
• Ladder and platform position (Step through or side step landings)
The typical vacuum tower and stripper is illustrated in Fig.CLP-5. Stripper is used to strip
lighter materials from bottom of a main or a vacuum tower distilling crude bottom residue under • Toe-plate, handrail and safety-gate details.
vacuum.
3.3 P&ID and Technical specification of column provide :
2.3 INTERNALS • Process data showing interconnected equipment and piping.
• Pipe sizes and pipeline components.
Columns based on internal details are often called as either Plate Columns or Packed • Steam tracing and insulation thickness.
Columns. • Tower elevations and differences in related equipment levels.
Bubble Cap Trays: Bubbling action effects contact. Vapour rises up through 'risers' into A typical cross-section of a piperack running through the tower area of a refinery type plant is
bubble cap, out through slots as bubbles into surrounding liquid on tray. Liquid flow over caps, illustrated in Fig.CLP-14.
outlet weir and downcomer to tray below.
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A typical plan of equipments located in the refinery type of plants highlighting the maintenance 4.9 Flexibility and thermal load connected with the large-dia overhead lines to the condenser at
access is illustrated in Fig.CLP-32. grade level or higher level shall be considered. The relief valve protecting the tower is usually
connected to the overhead line. A relief valve discharging to atmosphere should be located on
3.5 Instrument standard shows: the highest tower platform.
• The location of instrument connections to tower for gauges, level controllers and level
alarms. In a closed relief-line system, the relief-valve should be located on the lowest tower platform
• Location of pressure and temperature connections without orientation. above the relief -system header. This will result in the shortest relief-valve discharge leads to
• The instrumentation systems around the tower are depicted in the P&ID. the flare header. The entire relief-line system should be self-draining.
3.6 Fabrication drawing / detail dimensional drg. of column provides : 4.10 From layout point of view, it is preferable to space the platform brackets on the tower equally
• Diameter and height of column. and to align the brackets over each other for the entire length of the tower. This will minimise
• Details and dimensions of internals. interferences between piping and structural members.
• Manhole
4.11 Nozzles and piping must meet process requirements while platforms must satisfy maintenance
• Process-piping connections in elevation (without orientation)
and operating needs. Access for tower piping, valves and instruments influence placement of
• Drum, pump, exchanger drawings giving details of adjacent process equipment or
ladders.
equipment supported on column itself.
4.12 In routing pipelines, the problem is faced to interconnected tower nozzles with other remote
An integrated piping study should be developed from the above information.
points. The tentative orientation of a given tower nozzle is on the line between tower centre and
the point to which the line is supposed to run. Segments for piping going to equipment at grade
The piping study should take care of all the general recommendations of piping arrangement
e.g. condenser and reboiler lines are available between ladders and both sides of manhole.
around the column and its related equipment and facilities as illustrated in Fig.CLP-25
See the Fig. CLP-21 / 31 for overall orientation of a distillation column.
"Typical arrangement of external piping around column"
Line approaching the yard/piperack can turn left or right depending on the overall arrangement
of the plant. The respective segments of these lines are between the ladders and 180°. The
segment at 180° is convenient for lines without valves and instruments, because this is the
4.0 SEQUENCE OF COLUMN PIPING STUDY point farthest from manhole platforms.
4.1 All available information / data from Equipment specification and P&ID shall be written on the The sequence of lines around the tower is influenced by conditions at grade level. Piping
elevation view of the column as illustrated in Fig.CLP-12, CLP-13 & CLP-15. arrangements without lines crossing over each other give a neat appearance and usually a
more convenient installation.
4.2 The designer now starts thinking about the proper orientation of nozzles and provisions for
access to the points of operation and maintenance. 4.13 The correct relationship between process nozzles and tower internals is very important. An
angle is usually chosen between the radial centreline of internals and tower-shell centrelines.
4.3 Considerations of the pipeline leaving the tower area and the adjacent piping shall be By proper choice of this angle (usually 45° or 90° to the piperack) many hours of work and
visualised. future inconvenience can be saved. Tower piping, simplicity of internal piping and manholes
access into the tower are affected by this angle. After this, the information produced by the
4.4 The first step is to orient the manholes preferably all in same directions. Normally, manholes designer results in selecting the correct orientation of tower nozzles.
shall be oriented towards dropout area within a 30° segment of column as this facilitates the
lowering of tower internals to the main access way. The manhole segment of platform should 4.14 A davit usually handles heavy equipment such as large-size relief valves and large-diameter
not be occupied by any piperack. blinds. If the davit is at the top of the tower, it can also serve for lifting and lowering tower
internals to grade.
4.5 A break in ladder rise (normal 5m, maximum 7m) will occupy another segment of column for Clearance for the lifting tackle to all points from which handling is required, and good access
platform. should be provided.
4.6 The levels of platforms are to be decided on the elevation view based on the manholes and 4.15 Very often, interpretation of process requirements inside a tower is more exact than for exterior
access to relief valves, instrument for viewing. piping design. The location of an internal part determines, within strict physical limits, the
location of tower nozzles, instruments, piping and the steelwork. The layout designer have to
4.7 All platform levels in the proper segments of the tower with ladder location should be drawn on concentrate on a large-scale drawing of tower-internal details and arrangement of process
plan view. The manhole shall be shown in proper segment with the angle of orientation, and piping to finalise the piping study.
the space for the swing of manhole cover taking davit hinge as centre.
4.16 Access, whether internal or external is very important. This includes accessibility of
4.8 Layout should be started from the top of the column with the designer visualising the layout as a connections from ladders and platforms and internal accessibility through shell manholes,
whole. There will be no difficulty in dropping large overhead line straight down the side of a handholes or removable sections of trays. A manhole openings must not be obstructed by
column, and leaves the column at a high level and crosses directly to the condenser. This internal piping.
clears a segment at lower elevations for piping or for a ladder from grade level to the first
platform.
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4.17 Reboiler-line elevations are determined by the draw off and return nozzles and their orientation 5.4 OVERHEAD CONNECTIONS
is influenced by thermal flexibility considerations. Reboiler lines and the overhead lines should
be as simple and direct as possible. The vapour outlet nozzle is usually a vertical nozzle on the top head of tower. In addition, the
vent and relief valve could be located on the top head with a typical platform arrangement for
4.18 Fig.CLP-23 shows the segments of tower circumference allotted to piping, nozzles, manholes, access to vent, instrument connections and top manhole. In a closed relief line system, relief
platform brackets and ladders as normally recommended to develop a well-designed layout. valve should be located on the lowest tower platform above the relief system header. This will
result in the shortest relief valve discharge leads. The entire relief line system should be self
5.0 NOZZLE ORIENTATION AND LEVEL draining.
Nozzles are located at various levels on the tower to meet the process and intstrumentation 5.5 BOTTOM CONNECTIONS
requirements.
The liquid outlet is located on the bottom head of the tower. If the tower is supported on skirt,
5.1 MANHOLES the nozzle is routed outside the skirt as shown in Fig.CLP-22. The elevation and orientation
of this line is generally dictated by the pump NPSH requirement and the pump suction line
Nozzles are to be oriented keeping provision for maintenance and operation needs. flexibility. (see Fig.CLP-30)
Manholes are usually located at bottom, top and intermediate sections of tower. These 5.6 TEMPERATURE & PRESSURE INSTRUMENT CONNECTIONS / LEVEL INSTRUMENTS
access nozzles must not be located at the downcomer sections of the tower or the seal pot
sections of the tower. The temperature and pressure instrument connections are located throughout the tower. The
temperature probe must be located in a liquid space and the pressure connection in a vapour
Where internal piping is arranged over a tray, manhole shall be provided but it should be space as shown in Fig.CLP 37.
ensured that the internals do not block the maintenance access through the manhole.
The level instruments are located in the liquid section of the tower usually at the bottom. The
Possible location of manhole and handholes within the angular limits of b° are illustrated in elevation of the nozzles is decided by the amount of liquid being controlled or measured and
detail-2 of Fig.CLP-21 by standard controller and guage glass lengths. Level controllers must be operable from
grade or platform and level guages / switches may be from a ladder if no platform is available.
5.2 REBOILER CONNECTIONS Fig.CLP-35, 36, 37, 38, 39 illustrates a few instrument connections on tower.
Reboiler connections are normally located at the bottom section of the tower. Detail-1 of 6.0 ACCESS AND MAINTENANCE FACILITY
Fig.CLP-21 shows reboiler draw-off connections for single-flow tray. This connection can be
very important for arranging tray orientation. The simplest, most economical location for 6.1 Access whether internal or external is very important. This includes accessibility of
reboiler connections with the alternative location within the angular limits of a° is shown. The connections from ladders and platforms and internal accessibility through shell manholes,
angle a° depends on the size of reboiler draw off nozzle and the width of the boot handholes or removable sections of trays.
(dimension 'b') at the tray down flow.
6.2 Tower maintenance is usually limited to removal of exterior items (e.g. relief or control valves)
The return connection from the thermosyphon reboilers is shown in detail-1 of Fig.CLP-21. and interior components (e.g. trays or packing rings) Handling of these items is achieved by
These lines should be as simple and as direct as possible, consistant with the requirements of fixed devices (e.g. davits or trolley beams) or by mobile equipment (e.g. cranes). When
thermal flexibility. davits or beams are used, they are located at the top of the tower, accessible from a platform
and designed to lower the heaviest removable item to a specific drop out area at grade level.
For horizontally mounted thermosyphon reboiler, the draw off nozzle is located just below the When mobile equipment is used, a clear space must be provided at the back (side opposite to
bottom tray and for vertically mounted recirculating thermosyphon reboiler, the draw off piperack) of the tower that is accessible from plant auxiliary road.
nozzle is located at the bottom head. For both the systems, the return nozzles are located
just above the liquid level as shown in Fig.CLP-33. Fig.CLP-16, 25, 29, 32 illustrates the access and maintenance facilities to be considered in
the piping arrangement around a tower.
5.3 REFLUX CONNECTIONS
On free-standing columns, access for major maintenance to insulation or painting will usually
Reflux nozzles are provided with internal pipes that discharge the liquid into the sealpot of the require the erection of temporary scaffolding. Space for scaffolding at grade level and
tray below. Detail 3 of Fig.CLP-21 shows the reflux connections. Care must be taken that provision of cleats on the shell to facilitate scaffold erection should be considered.
the horizontal leg of the internal pipe clears the tops of bubble caps or weirs. It must be
ensured that the internal pipe can be fabricated for easy removal through a manhole or can 6.3 Utility stations of two services viz. steam and air are usually provided on maintenance platforms.
be fabricated inside the tower shell. Steam and air risers should be located during piping study to keep adequate cleats for support.
(see Fig.CLP-20)
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Uhde India Limited COLUMN PIPING Page : 11 DISTILLATION SCHEMATIC PROCESS OF DISTILLATION TOWER
7.0 PLATFORMS AND LADDERS
CONDENSER
7.1 Platforms on towers are required for access to valves, instruments, blinds and maintenance
accesses. Platforms are normally circular and supported by brackets attached to the side of
the tower. Generally, access to platforms is by ladder. Fig.CLP-19 illustrates the platform
requirements.
7.2 Platform elevations for towers are set by the items that require operation and maintenance.
The maximum ladder run should not exceed 7m. REFLUX
TRAY
VAPOUR PRODUCT
7.3 Platform widths are dictated by operator access. The clear space on platform width shall be
min.900mm.
Vr Lr RECEIVER DRUM
For platforms with control stations, the width of platform shall be 900mm plus the width of RECTIFICATION
SECTION
control station.
The platform for manholes and maintenance access, adequate space for swing the cover
flange flange must be provided.
DISTILLATE PRODUCT
7.4 Top-head platforms for access to vents, instruments and relief valves are supported on head
by trunions. FEED FEED TRAY
7.6 It is preferrable to space platform brackets on tower equally and to align brackets over each
other over the entire length of shell. This minimises the structural design and interferences
Vs Ls
from piping.
STRIPPING
7.7 On very wide platforms or those that support heavy piping loads, knee bracing is required in SECTION
addition to the usual platform steel. The potential obstruction immediately under the knee
brace must be kept in mind during platform design.
7.8 Fig.CLP 15, 16, 17, 18, 19, 20 illustrates a few platform considerations.
DIRECT STEAM TO
BOTTOMS PRODUCT
REBOILER
BOTTOMS PRODUCT
BOTTOMS PUMP
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OFFGAS
80°F-220°F STRAIGHT RUN
(32°C-104°C) GASOLINE
1
2
220°F-315°F NAPHTHA 3 PREHEATER
(104°C-157°C)
CONDENSOR
WITH THE RISE IN TEMPERATURE OF CRUDE OIL, INITIAL BOILING POINT IS REACHED.
THE LIGHTEST MATERIAL, BUTANE IS PRODUCED FIRST, JUST BELOW 100°F (38°C).
THE HEAVIEST MATERIALS ARE PRODUCED BELOW 800°F (427°C).
THE DISTRIBUTION OF THE DIFFERENT PRODUCTS AT VARIOUS TEMPERATURE RANGES
ARE SHOWN ABOVE.
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FRACTIONATION
STILL-5 150°F
65°C
STILL-4 160°F
70°C
VACUUM TOWER
170°F
STILL-3 CONDENSER
75°C
REFLUX RETURN LINE
STILL-2 180°F
80°C
195°F
STILL-1 90°C
RECEIVER
STRIPPER
FEED
FURNACE
PUMP
BOTTOMS PRODUCT
150°F(65°C)
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GAS OUTLET
OVERHEAD
MAINTENANCE REFLUX
ACCESS
LIQUID INLET
PACKING
PACKING SUPPORT
BODY FLANGE
MAINTENANCE
ACCESS DRAN OFF
CHIMNEY
FEED
GAS INLET
REBOILER
DRAWOFF REBOILER
LEVEL INSTRUMENTS
RETURN
LEVEL
INSTRUMENTS
LIQUID OUTLET
MAINTENANCE
ACCESS
BOTTOMS
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CROSS FLOW
PERFORATED PLATE WITH LIQUID CROSS FLOW (THE SIEVE PLATE) IS COMMONLY
LIQUID SPECIFIED TRAY FOR NEW DESIGNER
LIQUID
VAPOUR
VAPOUR
DOWN FLOW
CROSS FLOW COUNTER CURRENT FLOW
COUNTER FLOW
CLEAR
VALVE CLOSED LIQUID
FROTH
DOWNCOMER APRON
FOAM
GAS FLOW
HOLES PUNCHED Ø2"-4"
TRAY BELOW
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OVERHEAD
CONDENSER
WEIR
LIQUID
FLOW
CAP
CAP AREA CAP AREA
AREA
TOWER
REFLUX DRUM
BAFFLE
WEIR
CAP AREA
CAP AREA CAP AREA
TRAY PAIRS
(a) (a)
PRODUCT
INLET VIEW
REBOILER
(b) (b)
OUTLET VIEW
Rev. : R0 : RO
PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 COLUMN PIPING : 1 OF 1
4"
VALVE HEADER 3"x4" TIC HANDLING DAVIT, IF REQUIRED,
100 TI AND MAKE IT ACCESSIBLE FROM
THIS PLATFORM.
11/2"VENT Ø10" 105-E
PT OVERHEAD
101 130°F FRC FR
Ø6" CONDENSER 190psig
(AIR COOLER) 1 6"
4'
TE 1 1
GRAVITY FEED
101
P-107-8"
T-100
4"
MANHOLES
P-101-3"
31'-6"
102 16 USE THIS MANHOLE PLATFORM 10-11 OUTLET. TI
FEED P-102-6" Ø6"(TYP.) FOR ACCESS TO VALVES, LINE
BLINDS, AND INSTRUMENTS.
CW-100-8" E-11
11,500,000Btu/h
ARRANGE THE TOWER, EXCHANGER 3 2 SHELLS
FE FCV FE
PT 100 AND PUMP ADJACENT TO EACH
101 101 Ø6"(TYP.)
103 OTHER FOR A SHORT PUMP CIRCUIT.
P-104-10" TI
15
27 FCV 115°F
100 Ø2" P-108-6"
4
10'
S-100-6" 6" 130°F
Ø8" PT
104
TE 115°F
103 LC MANHOLES
Ø8"
102 105-D TI BETWEEN
P-103-10" REFLUX DRUM TRAYS
31'-6"
101 101
4"
PIC PIC PIC PIC 29
101 3"(TYP.) 101 100 2"(TYP.) 100 P-22 11,200
bbl/(STREAM)(d) FR
STRAINER(TYP.) STRAINER(TYP.) 39°API 30
3" 8"
4"(TYP.) 3"(TYP.)
7
15'
103-PA 103-PB 104-PA 104-PB
BOTTOMS PUMP BOTTOMS PUMP REFLUX PUMP REFLUX PUMP LG 134°F LA
ARRANGE THE STRAIGHT RUN FOR 195psig
ORIFICE. PROVIDE ACCESS TO ELEVATE THE TOWER ACCORDING
8"
8in BLIND (INVESTIGATE HANDLING TO THE REQUIRED NPSH AND
OF BLIND). THE LINE APPROACHES SUCTION LINE LOSS. ARRANGE
FROM THE OVERHEAD CONDENSER SUCTION LINE TO PUMP
AND REFLUX DRUM OF ANOTHER TOWER. LOCATED BELOW THE PIPE RACK.
12'-6"
E-10
130.7 MOLES/H
26,000,000
38.3 MOLECULAR WEIGHT
8"
5000 Ib./h 4" Btu/h
Rev. : RO : RO
PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 COLUMN PIPING : 1 OF 1
NOTES: LEGENDS:
1. NOZZLES AND PIPING MUST MEET PROCESS REQUIREMENT. A,B,C, - TOWER NOZZLE LOCATION
2. PLATFORM MUST SATISFY MAINTENANCE AND OPERATING NEEDS. AL,BL,AG & BG - INSTRUMENT TAP LOCATION
MH - MANHOLE
TYPICAL PIPERACK CROSS-SECTION OF A TOWER AREA TL - TANGENT LINE
C LADDER 300°
L DAVIT 214'-0"
H
SEALPOT #1
270° 300Ib A H FACE OF FLANGE 207'-5"
DA
V T.L. 205'-0" PLATFORM 206'-9"
120 IT
°
A1
MH#1 203'-0"
53°
a 202'-6"
PLATFORM 199'-11"
PLATFORM 206'-9" PLATFORM 198'-11"
MH#5 0°
PLATFORM
157'-3"
C LADDER 60°
C LADDER 300° L
L
LINES BOTH ENDS HIGHER THAN PLATFORM MH#4 168'-6"
159'-11"
TOP YARD BANK LOCATED IN HIGHER LEVEL SEALPOT #16
PLATFORM 165'-9"
270° D 96°
C
12
6°
TOWER
PLATFORM 157'-3" & 159'-11"
EXPANSION LOOPS
ELEVATION OF PIPING
ADJACENT TO EQUIPMENT
MH#7 138'-0"
PLATFORM 134'-11"
C PLATFORM 134'-11"
L LAD 0°
DE R6
R3 DE
00° AD
ELEVATION OF PIPING CLL
BETWEEN YARD & AG 275°
ELEVATION OF EXCHANGER
LINES TO ADJACENT °
249 TRANSMITTER
EQUIPMENT AL ORIFICE
1200
HEAD ROOM
G 180°
END BELOW AND MIN.
3000
MH#8 0°
DROP OUT AREA
PLATFORM 112'-5" 18"DIA. OPENING
(SKIRT ACCESS) PLATFORM 120'-11"
CONTROL VALVE C
L LAD 0° CG 119'-9"
DE R6
PUMP SUCTION PUMPS COULD BE LOCATED ACCESS TO PUMPS PUMP TURBINE R3 DE CG
00° AD 118'-7"
INSIDE OR OUTSIDE WITH CLL CG 117'-0"
CONSIDERATION TO FREE SPACE MH#8 115'-0"
BG 275°
FOR PUMP ACCESS WAY 90°
J DG 113'-6"
J T.L. 113'-0" PLATFORM 112'-5"
263°
CG PLATFORM 111'-5"
G 109'-6"
°
249
BL
PLATFORM
111'-5"
4'-0"WIDE
G 180° 103'-6" 18" DIA. OPENING
(SKIRT ACCESS)
: RO Rev. : RO
PIPING STUDY
COLUMN PIPING : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
VALVE
0°
0°
T-100
T-100
LADDER
PLATFORM
CAGE
(TYPICAL)
TOE PLATE BRACKET LADDER
PLATFORM
3'-0"MINIMUM BRACKETS
900 (TYPICAL)
PLATFORM
PLATFORM EL.178'-1" & ABOVE EL. 169'-0"
HANDRAIL 123.800
PLATFORM EL.169'-0" TO 178'-1"
121.030 123.800
PLATFORM WIDTH
0°
0°
CONGESTED PLATFORM WIDTH REQUIREMENTS
T-100
T-100
PLATFORM WIDTHS ARE DECIDED AS PER OPERATOR ACCESS FOR PLATFROM WITH CONTROLS LOCATED AT
THE SIDE OF PLATFORM, THE WIDTH MUST BE 900MM PLUS THE WIDTH OF THE CONTROLS OR PROJECTIONS.
350
TOP HEAD MAINTENANCE ACCESS
LADDER(TYP)
DAVIT
PLATFORM PLATFORM
EL. 109'-0" EL. 139'-0"
VIEW-P
: RO Rev. : R0
PIPING STUDY
COLUMN PIPING : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
(Y°
14" )
TOP HEAD PLATFORM
VENT ACCESS
C
L LADDER
30°
10"(250)
MINIMUM
350
14"
MAINTENANCE &
BLIND ACCESS
SPECT. BLIND
RADIUS
INSIDE
15°
CL MANHOLE
PLATFORM TEMPERATURE &
(TYP.) PRESSURE POINT ACCESS BY
RADIUS
INSIDE
15°
LADDER OR PLATFORM
LADDER
(TYP.)
250
10"
NO ACCESS REQUIRED
(900 TO 1500)
3'-0" TO 4'-6"
900 TO 1400
3'-0" TO 5'-0"
MAINTENANCE &
VALVE ACCESS
BRACKET SPACING
MINIMUM
VESSEL I.D. X° Y°
12"(300) MINIMUM
UPTO TO 1220MM T.L.
30° 60° CONTROL INSTRUMENT &
(Ø4')
MAINTENANCE ACCESS
1220 TO 2440
22.5° 45°
(4') (8') LEVEL GAUGE ACCESS
BY LADDER OR PLATFORM DRAIN VALVE ACCESS
2440 TO 5180 FROM GRADE
15° 30°
(8') (17') GRADE
5180 TO 7620
11.25° 11.25°
(17') (25')
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
1/4"
+ 5" MIN.
18" SPACING)
8"VAPOUR OUT
3'-6"
1
1 1/2"REFLUX IN a. SIMPLEST REFLUX PIPE b. REFLUX PIPE MUST CLEAR
BUBBLE CAPS AND WEIRS
SEE DETAIL-3
3'
PREFERRED LOCATION DETAIL 3 : REFLUX CONNECTIONS
PIPING ACCESS NOT REQUIRED
PAST STANDPIPE 2 SEE DETAIL-2a b° c° c°
& INSTRUMENTS
3'
LEVEL INSTRUMENTS
3'
SIMILIAR TO DETAIL-3a TRAY AREAS
RISER
(7TRAYS AT 2'6"SPACING)
LADDER TO b° c° c°
UPPER LEVEL 6" FEED
LADDER
FROM GRADE
17'-6"
AM LADDER CAGE DOWNFLOW AREA
STE
45'-6"
AIR SEALPOT AREA
4 SEE DETAIL-2b
UTILITY
STATION
5'-3"
8" REBOILER DRAWOFF
8'-6"
PLATFORM MAINTENANCE ACCESS 1" DRAIN
a°
EL. 109'-0"
102.740 I.D.6'
b
20" REBOILER RETURN
MAX.
a°
SEE DETAIL-1
LIQUID
LEVEL
h
1"STEAMOUT
3'
5 BOTTOM TRAY
REBOILER DRAWOFF
3 = MANHOLES 6" BOTTOMS OUT
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
4'-0"
1200
Ø6"
9"
12"x18"/300x450
MINIMUM
VERTICAL PIPING AREA
SKIRT ACCESS OPENING
102'-6"/100.750
2.135
OPERATOR
7'.0"
ACCESS
BOLT HOLES
STIFFENING RING
BASE RING
EL. 100'-0"
100.000 0
60 X.
POINT OF SUPPORT PR
AP
101'-0'
100.300
LADDER LADDER
AREA AREA
Rev. : R0 : RO
PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 COLUMN PIPING : 1 OF 1
VENT
4"/100 MINIMUM
+ INSULATION RELIEF LINE
"
MIN
1 1/2"
UTILITY PIPING
INTERMEDIATE CUT
8"/200
MIN.
600
2'-0"
(BOP=BACK OF PIPE)
HEAVY CUT
BOP (HEAVIER FRACTIONS)
COMMON BOP
LOCATED PIPING
4"/100
FEED FROM HEATER
+INSULATION MINIMUM TO ADJACENT CONDENSOR
MANHOLE (FOR
SPARGER ACCESS)
RELIEF HEADER
VENT
SUPPORT `BOTTOMS'
SKIRT
`BOTTOMS' PUMP
VESSEL
CLIP PIPERACK
DRIVER
ACCESS DOOR
VENT
BASE RING
DRAIN ACCESS
ELEVATION
SPACE FOR INSTRUMENT
(OPTIONAL FOR LADDERS) VAPOUR
(TO ADJACENT CONDENSOR)
DROP-OUT `BOTTOMS'
AREA
HEAVY CUT
SPACE FOR FEED FROM HEATER
MANHOLES AND
`DROPOUTS'
(TRAY AND VALVE
HANDLING)
1 2
OPEN TO ATMOSPHERE RELIEF VALVE SYSTEM LOCATED ON
THE TOP OF TOWER. CLOSED RELIEF VALVE SYSTEM TO BE PSV
LOCATED AT A MINIMUM DISTANCE ABOVE THE RELIEF HEADER.
ALTERNATE LOCATION
DISTANCE
SAFETY
1 2
PSV
23 23
VAPOUR
HEADER FOR TE 9 21
AIR COOLER
OVERHEAD LINE LG 10 MAINTENANCE
PLATFORM
LIQUID
TE 9 21
PLATFORM
LG
LC LG
10
30 10 LT
USE PLATF. BRACKETS TYPE K,L,M,N,P,A & DROP OUT AREA LOCATE MANWAY DAVIT PIVOTS PROVIDE
SPACED PER ENG. STDS.
FOR FULL OPENING OF MANWAY COVER.
UNLESS OTHERVISE SPECIFIDED ON INDIV.
CONTRACT.
LADDER ACCESS TO GAGE GLASSES, LEVEL BACKS OF PIPES FOR INSULATED LINES.
CONTROLLERS TEMP. & PRESSURE
INDICATORS IS ACCEPTABLE.
300
550
350
300
300
500
PLAN
* FOR NOTES REFER DWG. NO. CLP28
: 29040-PI-UPS-1003 : 29040-PI-UPS-1003
: RO : R0
1) ALL RELIEF VALVES THAT DISCHARGE TO A CLOSED SYSTEM SHALL BE LOCATED AS 21) PIPING DESIGNER MUST VERIFY WITH PROCESS ENGINEERING THE LOCATION OF
CLOSE AS POSSIBLE TO THE VESSEL THAT IT PROTECTS, BUT ABOVE THE FLARE HEADER. THERMO WELLS TO BE LOCATED WHETHER IN LIQUID OR VAPOUR SPACE. TOWER
DISCHARGE PIPING TO BE SELF DRAINING DOWN TO FLARE HEADER. WHERE RELIEF
VALVES MUST BE LOCATED REMOTE FROM THE VESSEL, APPROVAL MUST BE OBTAINED 22) MANHOLE AND HEAT EXCHANGER CHANNEL COVERS SHALL OPEN AND BACK AGAINST THE
FROM PROCESS ENGINEERING TO ENSURE THAT THE PRESSURE LOSS UP TO INLET OF VESSEL WHERE REQUIRED TO MAINTAIN CLEAR PERSONNEL PASSAGEWAY IN FRONT.
RELIEF VALVE (INCLUDING LOSS IN RELIEF VALVE) DOES NOT EXCEED 3% OF
THE SET PRESSURE. 23) THE MAIN COOLING WATER SUPPLY AND RETURN SYSTEM SHALL BE LOCATED BELOW
GRADE ON BOTH SIDE OF THE UNIT PIPE WAY AS FAR AS PRACTICAL. A SECONDARY
2) PROVIDE SUPPORT ON RELIEF VALVE DISCHARGE PIPING TO MINIMIZE REACTION SUPPLY(COLD SERVICE WATER) AND RETURN SYSTEM WILL BE LOCATED IN THE PIPE
FORCES ON THE VALVE,EQUIPMENT OR ASSOCIATED PIPING. WAY FOR SMALL USERS SUCH PUMPS, SAMPLE COOLER ETC.
3) PROVIDE INTERNAL CLEARANCE FOR TEMPORARY STRAINERS. INSTALL STRAINER AGAINST 24) EXCHANGER FRONT FOOT IS FIXED WHEN COOLING WATER SUPPLY AND RETURN IS
THE FLOW. DO NOT POCKET PUMP SUCTION LINES. USE ECCENTRIC REDUCERS UNDER GROUND.
(TOP FLAT) AT PUMP SUCTION NOZZLES.
25) PIPING AND ELECTRICAL SHALL INFORM CIVIL ENGINEERING OF THE LOCATION OF ANY
4) PROVIDE CANTILEVERED SUPPORT STEEL ABOVE PUMP SUCTION AND DISCHARGE INSERT PLATES REQUIRED FOR ATTACHING AUXILIARY SUPPORTS.
PIPING FOR INSTALLATION OF SPRING SUPPORTS WHERE REQUIRED.
26) USE ACTUAL ELEVATION BASED ON APPROVED DATUM FOR THE PLANT.
5) PROVIDE CHAIN OR EXTENSION STEMS FOR VALVES IF CENTER LINE IS MORE THAN
7'-3" ABOVE OPERATING LEVEL. HOWEVER USE OF CHAIN OPERATED VALVES SHALL 27) PUMP VALVING MUST BE OPERABLE WITHOUT THE USE OF CHAIN OPERATORS.
BE AVOIDED AS MUCH AS POSSIBLE. EXTENSION STEMS ARE NOT REQUIRED ON
VALVES NOT NORMALLY OPERATED. OPERATOR
28) PROVIDE REMOVABLE SPOOLS AT EQUIPMENT FOR MAINTENANCE AS REQUIRED. ACCESS
DO NOT SUPPORT PIPING FROM REMOVABLE SPOOLS.
6) FOR MAINTENANCE BLIND INSTALLATION PROVIDE PLATFORM ACCESS TO ALL VESSEL
NOZZLES 3" AND LARGER WHERE TEMPORARY SCAFFOLDING CAN NOT BE INSTALLED
FOR VESSEL NOZZLES 2" AND SMALLER, LADDER ACCESS IS ACCEPTABLE WHERE 29) REQUIREMENT OF HEADER BOX PLATFORMS SHALL BE AS PER ENGG. STANDARD.
TEMPORARY SCAFFOLDING CAN NOT BE INSTALLED.
30) LOCATION AND ELEVATION OF FLARE HEADER SHALL BE DECIDED ON CASE
TO CASE BASIS FOR EACH UNIT.
7) PLATFORMING REQUIRED WHEN MANWAY CENTRE LINE IS ABOVE 12'-0" FROM GRADE. PUMP
31) VALVES 3" AND LARGER ON TOWERS SHALL BE ACCESSIBLE FROM A PLATFORM,
8) DO NOT INSTALL TEMPERATURE OR PRESSURE INSTRUMENTS IN REMOVABLE SPOOLS.
VALVES 2" AND SMALLER SHALL BE ACCESSIBLE FROM PLATFORM OR PERMANENT LADDER.
9) TE'S, PI'S, ETC. ON TOWERS SHALL BE ACCESSIBLE FROM A PERMANENT LADDER OR PLATFORM.
32) PIPE ELEVATIONS IN GENERAL AREA OF RACK COLUMNS. SELECT SPECIFIC
ELEVATIONS SHORT RUNS AT PUMPS, CONT. STATIONS MANIFOLDS ETC. AND THESE
10) FOR CENTRE LINE ELEVATIONS UP TO 5'-0" ORIENT GAGE GLASSES AND LEVEL THROUGHOUT THE UNIT 18'-0" MIN. CLEARANCE TO H.P. OF PAVING.
CONTROLLERS FOR VIEWING FROM OPERATING AISLE. ABOVE 5'-0" ORIENT FOR
VIEWING FROM A PERMANENT LADDER OR PLATFORM. 33) MAXIMUM HIGH POINT OF PAVING SHOULD BE 0'-6" ABOVE LOW POINT, TOP OF
ALL CATCH BASINS SHALL BE 0'-0" ABOVE LOW POINT. THE TOP OF CONCRETE
11) HEIGHT OF SHOES SHALL BE PER ENGG. STANDARD. PEDESTALS FOR STRUCTURAL STEEL COLUMNS SHALL BE 8" ABOVE HIGH POINT OF
FINISHED GRADE. THE HIGH POINT OF BUILDING OF CONTROL ROOM AND SUBSTATION
12) OPERATING AISLE AND MAINTENANCE ACCESS DOES NOT HAVE TO BE IN A STRAIGHT LINE. SHALL BE DESIGNED CONSIDERING REASONABLE CABLE SPACING UNDER THE FLOOR
AND SHALL BE APPROVED BY CLIENT. THE OTHER ENCLOSED BUILDING FLOOR SLABS
SHALL BE NOT LESS THAN 6" ABOVE HIGH POINT OF FINISHED GRADE. ALL
13) PIPE WAY WIDTH AND NUMBER OF PROCESS AND UTILITY DECKS REQUIRED ARE
UNENCLOSED BUILDINGS IN PAVED AREAS SHALL HAVE FLOOR HEIGHT TO MATCH
DETERMINED BY PIPING. INSTRUMENT AND ELECTRICAL REQUIREMENTS PLUS PROVISION
FOR FUTURE OF 10% TO 15%. PIPING TO REQUEST INTERMEDIATE BEAM SUPPORT
ADJACENT PAVING. ALL UNENCLOSED BUILDINGS IN UNPAVED AREAS SHALL HAVE
FLOOR HEIGHT 6" ABOVE ADJACENT GRADE. ALL FLOORS SHALL BE SLOPED FOR
TYPICAL MAINTENANCE ACCESS
FROM CIVIL ONLY AS REQUIRED. HOWEVER, PROVIDE INSERT PLATES AT THESE
DRAINAGE. EQUIPMENT FOUNDATION HEIGHT SHALL BE AS FOLLOWS:
LOCATIONS, IRRESPECTIVE OF PIPING REQUIREMENTS.
THE CLEARANCES FOR THE OPERATOR ACCESS
14) THE DIMENSION MAY VARY WITH COLUMN DIAMETER. LINE UP COLUMNS ON COMMON (a) THE TOP OF CENTRIFUGAL PUMP FOUNDATION SHALL BE A MINIMUM OF 3" ABOVE AND MAINTENANCE ACCESS CAN SOMETIMES, BE
CENTRELINES WHERE PRACTICAL. HIGH POINT OF FINISHED SURFACE. THE GUIDELINES FOR TOWER BOTTOM ELEVATION.
15) LOCATE CONTROL VALVES ALONG SIDE EQUIPMENT OR AT PIPE WAY COLUMNS. (b) THE TOP OF RECIPROCATING PUMP FOUNDATION SHALL BE MINIMUM OF 12"
WHEREVER POSITION IS BEST FOR THE PIPE RUN AND OTHER CONDITIONS. DO NOT ABOVE HIGH POINT OF FINISHED SURFACE.
POSITION CONTROL VALVES DIRECTLY BEHIND PUMPS. CONTROL VALVES WHICH
CONTROL THE LEVEL IN A VESSEL MUST BE LOCATED SO THAT GAGE GLASS IS (c) THE TOP OF FOUNDATIONS FOR VERTICAL VESSEL SHALL BE 8" ABOVE HIGH POINT
VISIBLE WHILE OPERATING BYPASS VALVE. OF FINISHED SURFACE.
TOWER
16) PIPING AND STRUCTURES SHALL BE ARRANGED TO PERMIT MOBILE EQUIPMENT TO 34) UTILITY STATION REQUIREMENTS:
APPROACH PUMPS AND MAKE LIFTS WITHOUT OBSTRUCTION. STEAM, AIR AND WATER AT GRADE: SPACED SO THAT ALL AREA CAN BE REACHED
WITH 50'-0" OF HOSE. STEAM AND AIR AT ALTERNATE LEVELS OF STRUCTURES AND
17) A MINIMUM OF 3'-0" CLEAR FOR SINGLE BLOCK VALVE AND 4'-3" CLEAR FOR VESSELS (LOCATE AT LEVELS WITH HANDWAYS). ALL LINES TO UTILITY STATIONS TO
DOUBLE BLOCK VALVE IS REQUIRED FROM ORIFICE FLANGES TO ANY BE 1". PROVIDE GATE VALVE ON EACH LINE AT HOSE CONNECTION. SEE ENGG. STD.
OBSTRUCTION FOR INSTALLING METER LEADS AND ORIFICE TAPS.
VERTICAL RUNS ARE PERMITTED FOR IN WARD FLOW ONLY FOR LIQUIDS AND DOWNWARD 35) "BUILT IN" EQUIPMENT HANDLING FACILITIES TO BE KEPT TO A MINIMUM. EQUIPMENT SHALL
FLOW FOR GASES AND STEAM. PORTABLE LADDER ACCESS TO ORIFICE FLANGES 22'-0" BE SUPPORTED AT OR NEAR GRADE TO PERMIT MAXIMUM USE OF MOBILE EQUIPMENT.
OR LESS ABOVE GRADE, PERMANENT LADDER OR PLATFORM IS REQUIRED OTHERWISE. FOR MAINTENANCE. EXCHANGERS WITH CENTRELINE 12'-0" AND LESS ABOVE GRADE TO
BE HANDLED WITH MOBILE EQUIPMENT. HORIZONTAL EXCHANGERS WITH CENTRELINE
18) THE TYPE OF PIPING CONFIGURATION FOR AIR COOLER INLET AND OUTLET SHALL MORE THAN 12'-0" ABOVE GRADE SHALL HAVE SUITABLE PERMANENT STEEL OR
BE AS INDICATED ON THE P & IDS. REINFORCED CONCRETE STRUCTURES. WITH TROLLEY BEAMS AND TROLLEYS
(EXCLUDING HOIST) FOR HANDLING INDIVIDUAL EXCHANGER PARTS. THE DESIGN OF
19) PROVIDE PERMANENT PLATFORMING FOR ACCESS TO UNIT BLOCK VALVES. SUCH STRUCTURES SHALL BE BASED ON THE USE OF MOBILE EQUIPMENT TO PULL
TUBE BUNDLES. THE TROLLEY HOIST WILL ASSIST IN SUPPORTING THE BUNDLE DURING
20) PROVIDE PIPE BRACKETS ON ALL TYPE ON VERTICAL VESSELS AS PER ENGG. STANDARD. PULLING AND WILL BE CAPABLE OF LOWERING IT TO GRADE FOR VERTICAL EXCHANGERS,
MOBILE EQUIPMENT SHALL BE USED FOR HANDLING PARTS AND PULLING BUNDLES.
36) ALL OVERHEAD PUMP SUCTION LINES SHALL DRAIN TOWARD THE PUMP WITHOUT POCKETS.
37) ALL TWO PHASE FLOW PIPING MUST BE NOTED ON P & ID. THIS PIPING MAY REQUIRE
SPECIAL DESIGN CONSIDERATION.
MAINTENANCE
38) ALLOW FOR 1" SHIMS (OR GROUT) ABOVE STEEL (OR CONCRETE). FOR VESSELS ACCESS
OVER 15'-0" DIAMETER ALLOW 1 1/2" FOR SHIMS (OR GROUT).
Rev. : R0 : RO
PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 COLUMN PIPING : 1 OF 1
8
30°
1 TO 27 T-100
-3"
C TRAYS 0°
01
P-1
Ø1"AIR & STEAM
UTILITY LINES
P1
L
DOWNCOMER °
TRAY#1 67.5
P-100-18"
C LADDER CL LADDER
T-100
L
270° 90°
0°
T1
.5°
A 90° 247
CLE CE
TOP
600
TOWER
SPA
AR
DAVIT
VENT
CONTROL STATION 300 CLEAR SPACE IN
CLEAR FRONT OF MANHOLE
180°
M1
PLAN EL.178'-1" & ABOVE PLAN EL.169'-0" TO 178'-1"
123.800 121.030 123.800
0°
P-102-6" C
P-104-10"
T-100
°
55 1
T-100
L
STATIC HEAD
RV-100-4"
0° L2
E °
67.5
P3
60
P2
0
°
67.5
270° 90°
D F CL LADDER
P-103-10" P-105-6" 90°
PUMP
.5°
247 T2
.5°
T3 247
CLE LAD
FRO
5°
22
AR
600 ACE
M
S DAVIT DAVIT
SP ER
D
DRAIN-3"
OPENING
G
180°
SKIRT
M2
180°
M3
PLAN EL.GRADE TO 139'-0" PLAN EL.139'-0" TO 169'-0"
100.000 111.890 111.890 121.030
REBOILER CONNECTION
a. HORIZONTAL REBOILER
OVERHEAD RETURN
CONDENSERS
DOWNCOMER
TOWER 10° 10°
DRAW-OFF (MAXIMUM)
TRIM COOLERS
RETURN
DOWNCOMER
HIGH DRAW-OFF
LIQUID
LEVEL ALTERNATE
DRAW-OFF
LOCATION
ALTERNATE
REBOILER RETURN
REBOILER LOCATION
BOTTOMS PUMP
ELEVATION TOWER
PIPE RACK
MAINTENANCE b. VERTICAL REBOILER
OVERHEAD CONDENSER
ACCESS WAY
RETURN
N DOWNCOMER
10° 10°
(MAXIMUM)
RETURN
BOTTOMS PUMPS
REFLUX PUMPS
HIGH DRAW-OFF
LIQUID AT ANY
LEVEL 25 MM GAP ORIENTATION
TOWER
ALTERNATE
RETURN
(PLAN ABOVE) LOCATION
DRAW-OFF
MAINTENANCE ROAD
TOWER REBOILER
PLAN ALTERNATE
DRAW-OFF
LOCATION
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003
Rev. : R0
Rev. : R0 PIPING STUDY
PIPING STUDY COLUMN PIPING Page : 1 OF 1
Uhde India Limited
Uhde India Limited COLUMN PIPING Page : 1 OF 1
DWG. NO. : CLP35
DWG. NO. : CLP34
OVERALL
LENGTH
TYPICAL INSTRUMENT VESSEL SKETCH
1/2 OVERALL
LENGTH WEIR HEIGHT APPRX.
PI CONN. 2
2/3 DIA REBOILER
1/2 PIPE DIA
SURGE VOLUME BY PROCESS
+300 MIN. 10
(SHOWN ON DATA SHEET)
VAPOR
6
ENGINEER IF NECESSARY T1 TE
(SHOWN ON DATA SHEET) 101 2
600
WEIR HEIGHT
LC LG C
L TUBE BUNDLE
2
3
SKIRT
11
PRODUCT
1
FOUNDATION
THERMOWELL
HIGH POINT OF PUMP AND OR COOLER
TEMP. INDICATOR
FINISHED SURFACE POSSIBLY BETWEEN REBOILER
AND CONTROL VALVE 15
PT P2
T2
DIAGRAMMATIC ELEVATION 102 16
TE
102
(FOR USUAL ARRANGEMENT SEE PLAN BELOW)
LG
101 1 1/2" 300# RF
3/4"THD LC
101
3"/75
NOTES:-
THIS ARRANGEMENT FOR KETTLE REBOILERS, WHICH IS THE TYPE MOST 27
PLAN PT P3
1200
COMMONLY USED, HAS MINIMUM LIQUID HELD IN COLUMN AND 103
Ø3"
L1
OPERATING SURGE IS IN KETTLE.
1) SET KETTLE AT MIN. ELEV. TO SUIT PRODUCT LINE PRESSURE DROP
OR PUMP SUCTION REQUIREMENTS. TE T3
1500
103
2) WEIR HEIGHT DEPENDS ON REBOILER SELECTION.
3) HEAD EQUALS NORMAL PRESSURE DROP FOR LINES AND REBOILER.
915
3"/75
4) HEAD AT MAX. LEVEL GIVES 100% SAFETY OVER NORMAL. L2 3/4"THD
5) USUALLY TRAY SPACING + 150MM. PROCESS WILL SPECIFY. 1/2"THD
180
T.L.
6) PROCESS WILL SET DIMENSION.
7) LG AND LC NOT REQUIRED ON COLUMN FOR THIS HOOK-UP.
8) SET SKIRT HEIGHT TO SATISFY NOTES 1,2 AND 3.
9) ANCHOR LOCATION DEPENDS ON RELATIONSHIP OF REBOILER WITH
COLUMN ANCHOR ONE END ONLY.
10) SURGE VOLUME IS NORMALLY A MIN. OF 2 MINUTES.
11) IF THIS IS THE COLUMN DRAIN. PIPE TO DRAIN FUNNEL.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
900 TO 2050
3/4"DRAIN
DOWNCOMER
MINIMUM
PLATFORM DOWNCOMER
PLAN ELEVATION
2" /50
VAPOUR
SINGLE MOUNTED LEVEL CONTROLLER
PRESSURE
LIQUID
VAPOUR
SPACE
TEMPERATURE
1/2"VENT LIQUID SPACE
LEVEL SWITCH
THERMOWELL
ORIENTATIONS
1/2"DRAIN Ø3/4"
Ø1"
SWITCH
DRAIN
LEVEL GAUGE
PLAN ELEVATION
SINGLE MOUNTED LEVEL GAUGE AND SWITCH
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1003
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited COLUMN PIPING Page : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
TYPICAL TEMPERATURE AND PRESSURE INSTRUMENT ARRANGEMENTS TYPICAL COMMON BRIDLE-LEVEL INSTRUMENT ARRANGEMENT
DOWNCOMER AREA
LOCAL PRESSURE GAUGES
5°
L1 5
Ø3" STANDPIPE L2
0°
LOCALLY MOUNTED
DIAL THERMOMETER
LC
101
LG
101
LADDER
(TYP) T-100
PLATFORM
EL. 109'-0"
(102.740)
: RO Rev. : R0
PIPING STUDY
COLUMN PIPING : 1 OF 1 Uhde India Limited COLUMN PIPING Page : 1 OF 1
8'-0"MIN.
.2435
Ø4" TO Ø8"
TROLLEY
BEAM SUPPORTS
DAVIT SUPPORT
FROM VESSEL
TROLLEY
BEAM
DAVIT
DROP AREA
DROP AREA
PLAN ELEVATION
PLAN ELEVATION
KRUPP UHDE STANDARD February 1997
Piping Page 2 UN 3002-01 Part 2
UN
MINIMUM WORKPLACE DIMENSIONS 3002-01
Part 2
Rohrleitungen; Arbeitsplatz-Abmessungen Supersedes 94-08
Figure 1. Dimensions in mm
Continued on page 2
Date Prepared Date Checked Date Approved
Behälter und Apparate; Plattenwärmeaustauscher; Technische Lieferbedingungen Supersedes 85-09 Materials other than those indicated in the documents require the purchaser's written approval even if they are
of equivalent quality.
2.7 Drawings
1 General The following items shall be shown in the drawings: main components of the plate heat exchanger including
1.1 Scope the dimensions, positions of the nozzles, foundation loads, list of itemized components including the weights,
This specification covers the requirements for design, fabrication and inspection of plate heat exchangers. and list of nozzles. A plate arrangement drawing shall also be prepared.
This general specification shall apply in conjunction with the related technical specifications, codes and stan-
dards such as the pressure vessel code. 3 Fabrication
The fabrication of the heat exchanger shall conform to the state of the art. The applicable specifications,
1.2 Contradictions and deviations codes and standards shall be observed.
If the requirements in this general specification are in contradiction with the relevant technical specification,
the latter shall apply. If the manufacturer intends or has to deviate from the standards cited in this specifica-
tion, such deviations require the purchaser's written approval. 4 Tests and inspections
When the plate heat exchanger is inspected by the purchaser and/or his representative, the following tests
and checks shall be performed:
2 Design • scope of supplies, including foundation bolts and special tools
The specified components shall conform to the state of the art. Any deviation from the approved designs or
any proprietary configuration require the purchaser's written approval. • dimensional accuracy and proper workmanship (visual inspection)
• compliance of the materials with the specification, parts list and codes
2.1 Types • material certificates
The plate heat exchangers shall be vertical unless otherwise specified. Wall-mounted heat exchangers or
• pressure test
other special types may be used if this is agreed with the purchaser. If hazardous fluids such as acids, liquors,
The plate heat exchanger shall be subjected to a pressure test on both fluid sides, i.e. the pressure in the
etc. are circulated in the heat exchanger, adequate splash guards shall be installed to protect the personnel.
tested chamber shall be maintained for 50 minutes, the other chamber having atmospheric pressure only.
Then, both chambers shall be subjected to a common pressure test, the pressure being maintained for
2.2 Frame 20 minutes. The chloride content of the water used for the pressure tests shall comply with Krupp Uhde
The frame consists of a frame plate with fluid inlet and outlet, an upper suspension rod, a lower guiding rod, standard UN V416-04 Part 1.
an end support and a pressure plate attached to said suspension rod. The heat exchanger plates are ar-
ranged between the pressure plate and the frame plate and linked by means of an adequate number of tie After performing the test and draining the heat exchanger, the vessel nozzles shall be closed.
rods housed in sleeves. The tightening torque required for the tie rods shall be indicated. The frame shall be
designed such that the capacity can be increased by approx. 10 %, i.e. up to 50 exchanger plates can be
added. 5 Nameplate and tagging
The plate heat exchanger shall have a nameplate according to Krupp Uhde standard UN 2000-09, Part 1. This
It is imperative that the plates can be easily and quickly installed and removed without using a crane or a plate shall be attached to the frame plate.
similar device.
Moreover, the individual plates shall be tagged such that the material number, type of plate and serial number
2.3 Plates are clearly visible.
Plates of the same shape (interchangeable) or of different shapes may be used, depending on the thermodynamic
and thermohydraulic requirements. It is recommended that the plates be designed for convenient handling.
Reference Krupp Uhde standards
2.4 Gaskets UN 2000-09 Part 1 nameplate for vessels
The external edges and the holes of said plates shall have gaskets to be glued to the contact surfaces. The UN V416-04 Part 1 water quality for pressure tests and flushing
gaskets may also be clamped or fixed by an adequate method. The gasket shall be shaped to isolate the flu-
ids on both sides such that they cannot be mixed. The hollow space between the two toric sides of the gasket
shall have a groove for discharging leak fluids.
2.5 Connections
In the case of single-pass constructions, the inlet and outlet connections shall be on the frame plate. If con-
nections have to be arranged on the frame plate side and the pressure plate side, the nozzles shall be clearly
indicated in the technical specification and workshop drawings. The pressure plate shall have back-flushing
connections, if required.
In order to provide adequate corrosion protection, the connection openings shall be lined with suitable materi-
als. Rubber liners require the purchaser's written approval.
Continued on page 2
Date Prepared Date Checked Date Approved
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 Uhde India Limited DRUM PIPING Page : 2
5.0 Platform Arrangements 5 10 DP10 PREFFERED NOZZLE LOCATIONS FOR A HORIZONTAL DRUM
11 DP11 TYPICAL PLATFORM ARRANGEMENT FOR A HORIZONTAL DRUM
6.0 Piping Arrangements 5
12 DP12 TYPICAL PLATFORM ARRANGEMENT FOR A VERTICAL DRUM
13 DP13 TYPICAL DRUM PLATFORM ARRANGEMENTS
TYPICAL PLATFORM AND LADDER ELEVATION REQUIREMENTS
14 DP14
FOR A HORIZONTAL DRUM
TYPICAL PLATFORM FLOOR SPACE AREA REQUIREMENTS FOR A
15 DP15
HORIZONTAL DRUM
16 DP16 TYPICAL PUMP SUCTION ARRANGEMENT
17 DP17 TYPICAL RELIEF VALVE SYSTEMS
18 DP18 TYPICAL DRUM PIPING ARRANGEMENT
19 DP19 DRUM LOCATION IN A TOWER REFLUX SYSTEM
LOCATIONS FOR FEED SURGE AND COMPRESSOR SUCTION
20 DP20
DRUMS
21 DP21 TYPICAL PIPING AND INSTRUMENTATION DIAGRAM
22 DP22 TYPICAL INSTRUMENT VESSEL SKETCH
Applicable Revision:
Prepared: Checked: Approved: 23 DP23 TYPICAL INSTRUMENT ARRANGEMENT
24 DP24 TYPICAL HORIZONTAL DRUM DAVIT ARRANGEMENT
Date: Date: Date: 25 DP25 TYPICAL DRUM BOOT LAYOUT
First Edition: R0
Prepared: AKB Checked: TNG Approved: RUD
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 3 Uhde India Limited DRUM PIPING Page : 4
1.0 GENERAL
1.1 The process vessels and drums are cylindrical hollow vessels used in process plants as 2.2 A typical process vessel sketch of a horizontal drum is illustrated in sketch DP-9. The preferred
intermediate containers. They are often used to provide surge volumes for liquid-vapour
nozzles locations on a horizontal drum is illustrated in sketch DP-10.
separations on distillation columns or separating mixtures of immiscible liquids. Other uses are
flash drums, condensate and other process liquid collectors and holding drums for additives and
3.0 LOCATION OF DRUMS
chemicals.
1.2 The piping study on drums shall consider the general requirements for drum plant layout and 3.1 Drums are located within a process unit either adjacent to related equipment (e.g. the reflux drum)
provide information required to locate nozzles, instruments, piping and controls for platforming and or as a stand alone unit (e.g. a condensate collection drum)
operation / maintenance access.
When operating within process sequence of related items (e.g. pumps, condensers and towers)
1.3 In the first study of plot plan, platform levels and details of vessel elevations are set from process the drum should be positioned to facilitate an orderly and economic piping interconnection between
requirements (net positive suction head - NPSH, gravity feed, barometric legs etc.) and from itself and those items.
considerations of access for safe and convenient operation and maintenance.
3.2 Within a conventional inline process unit, drums and their related items are generally located on
Methods of supporting vessels and operating platforms are detailed. Access for lifting equipment either side of a central piperack serviced by auxilliary roads for maintenance access.
or overhead hoists and trolley beams is arranged for removal of motors, mixers and internal heat
exchangers from process vessels. A platform should always be provided for the removal of such In certain cases (e.g. flash drums and deaerators), drums can be located above the piperack. In
heavy items of equipment and for access to manholes, sight glass, light glass etc. chemical plants, drums are located at all levels of enclosed or open structures.
Sketch DP-19 illustrates location of a reflux drum and sketch DP-20 illustrates a typical location of
1.4 The mechanical design of the drum may be carried out once the methods of support have been a feed surge drum and compressor suction drums.
determined and nozzle sizes and positions are finalised However, economic piping layout and
access to valves and nozzles also depend upon the position and orientation of vessel nozzles 3.3 Similar to towers, drum elevations are dictated by the NPSH (as illustrated in sketch DP-3)
which may be repositioned to give a better layout.
3.4 Drums for chemical collection systems are generally located below ground level inside concrete
Horizontal drums may be supported on saddles positioned about one-fifth of the drum length from pits as illustrated in sketch DP-4.
each T/L of the drum.
3.5 To locate a drum, the following information to be collected so that the level of drum can be
Vertical drums may be supported on 3 or 4 legs or skirts considering the size and load of the finalised.
equipment. Drum dimensions
Type of heads
1.5 In absense of any specific process requirement, the drum should be located at a minimum height Support details
depending on the valves and fittings that are below the drum. Platforming should be kept to the NPSH requirements of pump
minimum necessary to provide safe and suitable access to manholes and operating valves. Bottom outlet size
Minimum clearances
Location
1.6 A typical vertical drum and horizontal drum are illustrated in sketches DP-1 and DP-2. A typical drum elevation view is illustrated in the sketch DP-8.
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 5 Uhde India Limited DRUM PIPING Page : 6
The relief valve should be placed at a point on the top of the drum where the access platform can 6.5 Drain and vent lines may be located centrally or at the ends if the drum is horizontal and if desired,
also provide access to other valves connected to the top of the drum. the drain valve may be placed at the low point of the outlet piping.
The pressure connection should be placed in the vapour space at the top of the drum, so that the 6.6 Horizontal drums should always have small slopes towards the drain points.
face of the pressure gauge is visible from the ground or platform.
6.7 Level, pressure and temperature instruments are used to control the operation of the drum and
The temperature connection is usually close to the bottom outlet, pointing towards the access aisle should be in a position for optimum operation and maintenance.
or platform.
6.8 Level controllers, switches and gauges are either located individually or grouped from a common
Manholes can be positioned at the top, at the side or at one end of the vessel. bridle or stand pipe. The controller must be operable from grade or a platform, switches, gauges
and pressure / temperature connections may be operable from a ladder if no platform is available
Steam-out connections should be located at the end opposite to the maintenance access with at the required elevation.
additional vent in the bottom section of the drum as steam has a lower molecular weight.
6.9 The fixed saddle shall be on the same side of the vessel as the pump suction nozzle. In case of
The vent connection should be located in the top section of the drum at the end opposite the steam requirement of an emergency isolation valves, these valves shall be located directly on the vessel
out connection. nozzle. The position of the support shall allow for the installation of the valve and its actuator.
The drain should be located in the bottom section of the drum. 6.10 In order to gain access for maintenance and operations purpose, level transmitter (LT) and Level
indicator (LT) nozzles shall be arranged on either side of the access ladder with their centres
400mm from the ladder centerline.
5.0 PLATFORM ARRANGEMENTS
6.11 All instruments shall be grouped on vessels and drums such that the minimum number of ladders
5.1 A platform with good guard railings is necessary for access if the manhole is more than 3.5 m and platforms is required, without any compromise on accessibility.
above grade.
5.2 Platforms on drums are required for access to valves, instruments, blinds and maintenance
accesses.
5.3 Sketch DP-11, DP-12, DP-13, DP-14, DP-15 illustrates some of the typical platform requirements
for drum piping.
5.4 Platforming should be kept to the minimum necessary to provide safe and suitable access to
manholes and operating valves.
6.1 Piping for process drums should be arranged in conjunction with nozzle locations, platform
arrangements and the drums location to related equipment.
Piping should be positioned to facilitate the installation of supports with sufficient flexibility to
absorb any excessive stresses during operation.
Piping for tall vertical drums should be arranged according to the guidelines mentioned in the
piping study for column piping.
6.2 Sketch DP-16, DP-17, DP-18 illustrates some typical piping arrangement around drums.
6.3 Relief valves open to atmosphere on low elevated horizontal or vertical drums should be positioned
to allow the discharge piping to be routed to a convenient and safe location. Closed system relief
valve should be located at a convenient platform adjacent to the drum above the relief valve
header.
6.4 Normally, the liquid or vapour inlet is at the top and at one end of drum with liquid outlet on the
bottom and vapour outlet at the top at opposite end.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
VAPOUR OUTLET
VAPOUR OUT
LIQUID IN
DEMISTER PAD
VAPOUR IN
HIGH LIQUID LEVEL (HLL)
BAFFLE
MAINTENANCE
LEVEL
ACCESS INSTRUMENTS
LIQUID OUT
MAINTENANCE LEVEL INSTRUMENTS
ACCESS
LIQUID DRAIN
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPP-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
PUMP
C
L OF DRUM
PUMP
GRADE LEVEL
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
30°
REINFORCING PAD
SADDLES
CONCRETE PIERS
OR STEEL FRAMES
IN STRUCTURES
LEG HEIGHT
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
SLOPE
C 103.750
L
600
900
300
2700
PUMP
2100
450
GRADE EL +100.00
OPERATOR ACCESS
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
1/2 FLANGE
DIAMETERS + 4" /100
MIN. (TYPICAL)
3050 A
B
VAPOUR OUT LIQUID/ VAPOUR IN
A E P B
L E P
MIN. MIN. ALTERNATIVE
D + 5"
D+125 MIN MAINTENANCE
MA
(TYP.) ACCESS LOCATIONS
L1
WEIR
HLL (HIGH LIQ. LEVEL)
DIA. 1220
610
TL
F
LLL (LOW LIQUID LEVEL)
L2
450
VORTEX T
BREAKER
SADDLES
MIN. D
F MA T D CHECK
CLEARANCE
DRAIN
LIQUID OUT
D = NOZZLE DIAMETER
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PIPING STUDY PIPING STUDY
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LADDER
LADDER
SUPPORT
BRACKET
LADDER
SUPPORT
BRACKET
MAIN OPERATING
PLATFORM LEVEL MAIN OPERATING
PLATFORM LEVEL
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
VENT, INSTRUMENT,
BLIND AND VALVE ACCESS
LADDER
MAINTENANCE ACCESS
SUPPORT
TO SUIT
VALVE,BLIND AND INSTRUMENT ACCESS
BRACKET
VESSEL CLIP
d. COMMON PLATFORM
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
ALTERNATE ROUTING
FOR ADDITIONAL FLEXIBILITY
L DRUM
PUMPS
C
TEMPERATURE
INSTRUMENT
STEAM
OUT LADDER
DAVIT
SUPPORT
LEVEL
INSTRUMENTS
PLAN
LADDER MAINTENANCE
ACCESS
M
RU
CLD
3"-0"MIN./900
TOE GUARD
LINE UP PLATFORM
WITH SHELL OF PUMPS
DRUM
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Rev. : R0 Rev. : R0
PIPING STUDY PIPING STUDY
Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUMPIPING Page : 1 OF 1
P-200-JA
P-200-JB
N
SAFETY DISTANCE
PI PI
201 201
P-206-3"
FE
200
TOWER P-204-4"
FCV
200
E-200 P-202-6"
CLOSED SYSTEM
RELIEF VALVE LOCATION
D-200
IF DRUM PLATFORM IS
BELOW RELIEF VALVE
HEADER A P B
P-203-1 1/2"
F C L1 L2 F MH T D
RELIEF VALVE
HEADER ATMOSPHERIC RELIEF
P-205-2"
VALVE LOCATION
C
L DRUM
PLATFORM EL.
109'-4"
PIPE RACK
P-200-16" T-200
TRAINING MANUAL - PIPING DOC N O.: 2 9 0 4 0 -PI -U PS-1 0 0 2 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1002
Re v. : R0 Rev. : R0
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Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
DRU M LOCAT I ON I N A T OWER REFLU X SY ST EM LOCATIONS FOR FEED SURGE AND COMPRESSOR SUCTION DRUMS
N
N
ACCESS ROAD
FEED PUMPS
REFLUX PUMPS
FEED
SURGE DRUM
COMPRESSOR
SUCTION DRUM
REFLUX DRUM
TOWER
BOT T OM S PU M PS
Rev. : R0
PIPING STUDY
Uhde India Limited DRUMPIPING Page : 1 OF 1
TO ATMOSPHERE
1" VENT
P-200-16"
RV
RV-200-4" T2 PE
3"x4" TI 201
200
E-200
PE OVERHEAD CONDENSER
200
8"Ø
TE 1
201
4"Ø
P-205-2"
15
16
FEED P-201-6"
FROM -203-JA/B FE
GRAVITY FLOW
200
T-200
P-203-1 1/2"
P-202-6"
TOWER FCV
200
D-200
31 REFLUX DRUM
FROM P-207-8"
F-200 LG LC
1" VENT
201 201
PI
LG LC TE 200
200 200 200
1"SO TI
200 FCV FE
2"DRAIN
1"STEAM OUT 201 201
3"DRAIN
P-204-4"
TO P-208-6" PRODUCT
F-200 6"x3"(TYP.) P-209-6" 3"x2" (TYP.) P-206-3"
PI PI PI PI
203 204 201 202
STRAINER(TYP.) STRAINER(TYP.)
3"(TYP.) 6"x4"(TYP.) 2"(TYP.) 4"x2" (TYP.)
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Uhde India Limited DRUM PIPING Page : 1 OF 1 Uhde India Limited DRUM PIPING Page : 1 OF 1
L1 L2
3'-0"(MIN.) / 915
D-200
LC LG
201 201
DROP
AREA
KRUPP UHDE STANDARD February 1997
Source: TEMA-Standards
TYPICAL DRUM BOOT LAYOUT
Front end stationary head types Shell types Rear end head types
L
E
A Fixed tubesheet like "A"
stationary head
One pass shell
Split flow
P
BOOT
T
N Divided flow
D
X
W
Special high pressure closure Cross flow Externally sealed floating tubesheet
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PIPING STUDY PIPING STUDY
Uhde India Limited UNDERGROUND PIPING Page : 1 Uhde India Limited UNDERGROUND PIPING Page : 2
LIST OF ILLUSTRATIONS
CONTENTS
SR.NO. DWG.NO. DESCRIPTION
Page 1 UGP1 PROCESS COOLING WATER AND POTABLE WATER
SYSTEM
0.0 Cover Sheet 1 2 UGP2 COOLING WATER CROSSOVER PIPING
List of illustrations 2 3 UGP3 COOLING WATER TO EXCHANGERS
2.0 Types of underground system 3-5 5 UGP5 EMERGENCY EYEWASH AND SAFETY SHOWER
14 UGP14 INDICATIVE PFD FOR OWS , CRWS ( NOTES FOR DWG. NO.
UGP13 )
15 UGP15 G.A.FOR UNDERGROUND PIPING (DETAILS)
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PIPING STUDY PIPING STUDY
Uhde India Limited UNDERGROUND PIPING Page : 3 Uhde India Limited UNDERGROUND PIPING Page : 4
Oily water sewer shall collect oily waste / drain from pump, equipments through funnel
1.0 GENERAL points and shall run with separate headers and manholes in the units. The regular oil
contamination areas shall also be segregated and discharge from these areas shall be
1.1 The piping system is taken underground generally for the utility services like cooling water collected in catch basins to be joined in oily water sewer. Oily water sewer shall consist of
supply to various units and cooling water return to cooling tower for line sizes normally carbon steel sewer, funnel points, clean outs, RCC catch basins, RCC manholes, vent
18 inch NB and above, other water services with big pipeline sizes, big oil supply lines and pipes, flame arrestor etc.
various sewer systems in the process units of the chemical, petrochemical and refinery
type of plants. The term "underground" applies to the piping - both buried or in trenches. 2.3 Contaminated Rainwater Sewer (CRWS)
The underground system consist of gravity flow drainage system carrying process waste,
The areas which are contaminated due to floor wash drains etc. inside unit boundaries
spillage, reclaimable hydrocarbons, sanitary and storm water, firewater and drinking water
shall be demarcated. Contaminated areas collected in catch basin shall be drained
system.
through CRWS while un-contaminated areas, normally at periphery of the units shall be
1.2 Good engineering practice, local code / regulations, specific client requirements shall drained through ditches covered with grating.
govern the design of the underground piping system in the plant.
CRWS shall consist of undergound carbon steel sewer with corrosion protection, funnel
1.3 The following are the common underground services in a chemical / petrochemical / points, clean outs, RCC catch basins, RCC manholes, vent pipes, flame arrestor etc.
refinery plants.
Open ditches of units should have a bypass either to the CRWS or to storm water, drains
- Cooling water (line size normally ≥18" NB) of offsite.
- Fire Water This system collects surface drainage from areas containing hydrocarbon - bearing
equipment. This water must pass through a treatment facility before being discharged into
- Contaminated Rain Water Sewer from process catchment area.(CRWS) an uncontaminated system or natural body of water e.g. river or a stream.
- Oily Water Sewer (OWS) 2.4 Closed Blow Down (CBD) sewer
- Liquid Effluent to the Effluent Treatment Plant. This system picks up drains around boilers and steam drums and is run as a separate
- Closed Blow Down system (CBD) system preferrably to the battery limit.
- Sanitary system The system shall be designed as per P&ID and the effluent collected from equipments
through funnel points and underground piping system shall be connected to the
- Storm Water underground CBD drum.
- Equipment drainage to slop tank 2.5 Amine Blow Down (ABD) sewer
- Electrical cables The amine blow down system (ABD) shall be designed as per P&ID.
- Instrument cables The effluent shall be collected from equipments through above ground points into close
funnels connected to underground system. The main header shall be connected to the
underground Amine sump / drum.
2.0 TYPES OF UNDERGROUND SYSTEM
2.6 Fire Water Sytem
Various underground systems can be described in the following way both for Utility system and
sewer system. This system consists of a fire hydrant network around a process unit or equipment, with
branches as required for hydrants or monitors to protect the unit in case of fire.
2.1 Cooling Water System (CWS & CWR)
This is a close loop system starting from Firewater storage and pump to the specific
This is generally a buried system with protective wrapping and coating or with cathodic location of hydrants and monitors. This is always kept under a predetermined working
protection or both. pressure level.
Any valve for isolation of a part of the cooling water system shall be enclosed in a valve pit. 2.7 Potable Water System
The normal compacted earth cover shall be 1200 mm over the top of the pipeline. The This water is used for drinking, emergency eye washes and safety shower facilities.
earth cover over pipe (back-fill) shall be compacted to at least 95% Proctor compaction
Index to protect the pipe from aboveground loadings as per ASTM D-698. 2.8 Sanitary Sewer System
2.2 Oily Water Sewer (OWS) Sanitary sewer system collects waste from all toilet facilities provided in various plants and
non-plant buildings and shall be discharged to WWTP (Waste Water Treatment Plant)
This system collects waste, drips and leaks from equipment and piping in areas that
contain process equipment in non corrosive services. The layout engineer should consult Acids, caustics, hydrocarbons, rainwater or other chemical waste shall not be discharged
the process engineer to fully identify all such equipment and provide a drain hub at each to this system.
item. This system is routed to normally to a septic tank.
The piping engineer should locate the oily water drain hubs using the above ground piping
studies, setting each invert elevation and routing the line with relevant components /
fittings.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1010 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1010
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2.9 Underground Electrical and Instrument ducts The invert level at outlet point of CRWS and OWS shall be normally 1500mm below FGL.
In the beginning of a project, the decision to route the major electrical and instrument 3.4 Cleanout
conduits - above ground in the piperack or buried below grade shall be taken.
A cleanout is a piping connection in a sewer system that is located at grade level for
In case underground route is selected, electrical and instrument engineers shall be inspections or for cleaning the system.
consulted for the optimum layout of ducts by the plant layout engineer.
3.5 Vent Pipes
Where conduits enter the unit through a pull box and cables come above ground for
Vent pipes shall be located along piperack columns or building columns and should be
routing upto the terminal points, the space shall be kept free of piping, equipment or
taken 2m above the building parapet or last layer of pipes on a piperack.
associated maintenance access.
3.6 Valve Pit / Maintenance pit for flanges and instruments.
3.0 KEY WORDS
When the underground system needs valves for isolation and instruments for control, the
3.1 Catch Basin
normal practice is to enclose these valves and instruments in a RCC pit with cover. These
This device is used to collect surface drainage with an outlet liquid seal and sediment trap. valves and instruments in a pit can be operated as well as maintenance work can be done
with ease.
The sketch UGP9 illustrates a typical catch basin feature and UGP17 illustrates a typical
location of catch basins.
The maximum area coverage of a catch basin is approx 150 sqm. ie. 12mx12m or 4.0 PIPING ARRANGEMENT - UNDERGROUND
15mx10m.
4.1 The overall Plot Plan allocates the space for the major underground services in the
The area covered by a catch basin should be of square configuration, as far as possible. beginning of the project.
The catch basin should be located in the middle of the area as far as possible. The cooling water supply from cooling water pump discharge to the various units as well
as the cooling water return from the various units to the top of cooling tower is routed in a
Slope of pavement 1 in 100, e.g. HPP (Ridge of catch basin area = 100.00) and LPP (at
simple, straight orientation at a suitable depth avoiding any major road crossings.
catch basin peripherial drain = 99.85)
A typical cooling water and potable water system is illustrated in sketch UGP1.
No catch basins or manholes should be located within 15m radius of heaters.
Cooling water cross over piping is illustrated in sketch UGP2.
No vent pipes should be located within 15m of the heaters.
Area drainage around heater areas shall be done by pavement sloping towards open Cooling water lines to heat exchangers are typically illustrated in sketch UGP3.
ditches. Each catch basin shall be connected to manhole and shall be provided with fire Cooling water lines to pumps for various cooling requirements is illustrated in sketch
seal. UGP4.
3.2 Sealed Manholes 4.2 The potable water system supplies to various units and a branch is taken to the
Sealed manholes shall be provided at emergency eyewash and safety shower station as illustrated in sketch UGP5.
a. Unit battery limit and 4.3 Fire water system protects each piece of equipment by providing water through hydrants,
monitors or deluge spray systems.
b. Junction of sewers and at change in size of main header.
Each process unit will have its own underground firewater piping loop system.
These devices are provided so that the unit area is isolated from any fire in offsite
area/sewer. 4.4 A typical hydrant and monitor installations are illustrated in sketch UGP7 and a typical fire-
monitor is shown in sketch UGP8.
Within the unit area, sealed manholes in main headers should be provided in such
locations so that each sub-unit within the unit is isolated from the other areas. In case, this 4.5 Normally, chemical process units will have multiple drain systems designed to collect all
demarcation is difficult, one sealed manhole for every 30m length of main sewer in the unit corrosive or toxic chemical waste as well as surface drainage around the equipment.
shall be provided. Drain / sewer system in a plant can be categorised as :
Sealed manhole with bent pipes seal type shall be used for carbon steel pipes upto size - Uncontaminated storm water
16" NB and for greater than dia 16" NB and for all diameters of RCC pipes double
compartment type manholes should be used. - Contaminated storm water
3.3 Invert elevation - Oily water sewer
This term, usually associated with any underground line, refers to the elevation of the - Chemical and process sewer
inside bottom of the line. Because of the wide range of materials used in the underground - Sanitary sewer
piping system / drainage system with varying wall thickness, it is the constant that is used
to set the elevation on construction drawings. - Blowdown system
The starting invert level of CRWS shall be normally 750mm below HPP (High Point of
Paving)
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
- Uncontaminated storm water system generally collects all service water from equipment
areas, access ways, roadways to equipment. This collection is done through area drains,
catch basins, roof rain water downcomers.
- Contaminated storm water system collects surface drainage from areas containing
hydrocarbon processing equipment. This system water must pass through a treatment PROCESS COOLING WATER AND POTABLE WATER SYSTEM
facility before being discharged into an uncontaminated system or natural body of water
viz. river or a stream connected to a river.
- Oily water sewer system collects waste, drips, leaks from equipment and piping in non
corrosive process equipment area. The designer should identify all the specific drain
points in consultation with the process engineer.
- Chemical and process sewer system recovers acid or chemical drains from equipment /
piping as well as surface drainage by providing curbing and drain sump around such
equipment. NORTH BATTERY LIMIT
- Sketch UGP19 depicts a typical process drains - closed system.
- Sketch UGP21 illustrates a typical cross-section of a closed or chemical drain system.
OILY WATER SEWER
- Sanitary sewer system collects raw waste from lavatories and is either connected to the & STORM SYSTEM
UGP-18
municipal battery limit or routed to a septic tank. CL EL.98'-0
EMERGENCY EYEWASH
- Blowdown system picks up drains around boilers amd steam drums and is run as a & SAFETY SHOWER
separate system. It is permissible to connect the bowdown system to a sewer box in oily
water sewer system downstream of drainage from a furnace. CW
The width of trench should allow adequate clearance to valves and drains as required.
HW
4.7 A typical catch basin is illustrated in sketch UGP9.
A typical sewer box or manhole is illustrated in sketch UGP10.
A typical Dyked area drain sump is illustrated in sketch UGP11.
A typical lift station by vertical pump is illustrated in sketch UGP12.
4.8 A process area for the purpose underground drainage is subdivided into block areas with
CL EL.97'-0
high point ridge and low point catch basins / pits.
The low point catch pits are connected to manholes. CL EL.98'-0
HOT WATER RETURN (HW)
The manholes are interconnected by sloping piping and led to the battery limit valve pit and COLD WATER SUPPLY (CW)
finally discharged into the treatment pond.
Sketch UGP13-14, UGP15-16, UGP17 illustrates the details of the subdivision of the
process area into blocks with explanatory notes.
Sketch UGP18 illustrates how to handle oily water and storm water system. SOUTH BATTERY LIMIT
4.9 Closed drain system is illustrated by various sketch UGP19-20, UGP21, UGP22.
4.10 The underground electrical and instrument cables passing under a road or paved area is
taken through ducts embeded in lean concrete. Sketch UGP23 shows a typical
arrangement of such underground cabling details.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
Rev. : R0 Rev. : R0
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CL EXCHANGER
300
FIN. GRADE EL.+100
UNDERGROUND UNDERGROUND
PIPING PIPING
45°
45° CL COOLING WATER SUPPLY (CWS)
ELEVATION
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FOOT PEDAL
SHOWER HEAD
CLOSED
POSITION
STAY OPEN
BALL VALVE
(TYP.)
OPEN
POSITION
EYE WASH
ABOVE GROUND PIPING
UNDERGROUND PIPING
CLOSED
OPEN
FOOT PEDAL
ABOVE
GRADE
UNDER-
GROUND
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NOZZLE
CL DRAIN
TANK
MONITOR
A A
HYDRANT
CL FIRE HOSE
B B
CONNECTIONS
GRATING INV.EL.97'-11"
COVER
6"CI
GUARD POST
9"/230
INV.EL.97'8"
CONCRETE
COVER
GRADE
CATCH INV.EL.97'-2"
BASIN
BUFFALO
BOX
PLAN
GUARD
POST
SUPPORT
(BY CIVIL
ENGINEER)
AS REQUIRED
GRATING CONCRETE
LINE "B" COVER COVER
EL. 100'-0"
45°
15
P.) BLOCK
(TY VALVE
0
FIRE HOSE
/90
INV.EL.97'-11"
3"
CONNECTIONS
SECTION "A-A" (INV.=INVERT)
CL HYDRANT
MONITOR
SECTION "B-B" CL GUARD POST DRAIN GRAVEL
VALVE
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
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CATCH BASIN
NOZZLE
UNPAVED AREA PAVED AREA
CATCH BASIN
VENDOR
DRAIN VALVE CONTRACTOR
1200 ABOVE GRADE
CL VALVE
(2'-0")
600
6"/150
GRADE
1800 SQUARE
(6'-0")
ALTERNATE SUPPORT
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
Rev. : R0 Rev. : R0
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4" VENT TO
ATMOSPHERE STORAGE TANK
SLOPE
(CARBON STEEL)
A
DYKE SLOPE SUMP
TOP (BY CIVIL
ENGINEER)
A
DRAIN LINE
PLAN
8"/200
6"/150
CL OUTLET
INSIDE DYKE
EXTENSION STEM
PLATFORM
FIELD CUT &
15"/380
SUPPORT
INSIDE BOTTOM
ELEVATION
BUFFALO BOX
SUMP
GRADE
DRAIN LINE
VALVE USUALLY
CLOSED
SECTION `A-A'
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
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LIFT STATION
DWF
DIA.
SCOPE
SLOPE SLOPE
VELOCITY
DIA. DIA.
FUNNEL POINT TOTAL FLOW
FLOW FLOW (TYP.)
NOTE-6 & 16
NOTE-6 NOTE-6 (TYP.)
VERTICAL PUMP
UNCONTAMINATED AREA
ACCESS
HATCH
DISCHARGE LINE
MANHOLE
LADDER
RUNGS
NOTE-5
REFER
NOTE-14
REFER
NOTE-4
SEALED MANHOLE
CS PIPE CATCHPIT
1/8 BEND HPP FGL
6.05 5.75
CAST IRON
CONTAMINATED
AREA
TWO WAY
CAPACITY SIZED BY CATCHMENT HOG GRATING NC VALVE PIT
AREA 150SQ.M. UNCONTAMINATED AREA
PROCESS ENGINEERS (TYP.) NO
TO STORM
STORM WATER DRAIN WATER
DRAIN
FOR COLLECTION OF
SURFACE DRAINAGE FROM
UNCONTAMINATED AREAS
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1 2
INDICATIVE PFD FOR OILY WASTE SEWER & CONTAMINATED MATCH LINE W ---- DRG. K2-A1-5101
10
0(N
RAIN WATER SEWER & PROCESS LINE PS
10
100 (NPS 4)
0 (N
39 1901 KC-525 (NPS 21)
10
S=
100 (NPS 4)
PS
0(N
OF 4-150 (NPS 6)
4)
PS
4)
39PC-103A
S=
15 CL.
W=
CL. 39PC-105B
(TYP)
10
PS
CL. 39DM-101
4)
100 (NPS 4)
APRON
NOTES : 39PC-104
CL.
0(N
DF3-150(NPS 6) CO
PS
1. THE PFD IS FOR GUIDELINES AND REFERENCE ONLY.
4)
CO
CL.
S=
CL K2 PS-104 3 5
39PC-105A 2
CL.
2. THE PFD, DURING PREPARATION SHALL BE
100
HP.
(NP
SUPERIMPOSED ON THE EQUIPMENT PLOTPLAN.
S4
)
39 1919 KC-100 (NPS 4) IL 100 (NPS 4)
CL. S=
39 1903 KC-200 (NPS 8) IL K2-CB-3-109
CL.
FUNNEL POINTS ARE PROVIDED TO COLLECT PROCESS WASTE &
SL
K2 PS-119
OP
9 IL CO S4
E
CL. IL
)
S4
4. PFD SHALL FURNISH THE FOLLOWING DATA AT EACH SEGMENTS OF CRWS
(NP
100 (NPS 4) 39PC-105
S=
100
CL.
S=
A. DRY WEATHER FLOW
CL.
)
IL
S4
C. DIA OF PIPE
(NP
39 1918 KC-100 (NPS 4)
100 (NPS 4)
HP.
100
D. SLOPE CO S= CL.
K2-PS-102 CO
100 (NPS 4)
* BRANCH
CO
E. TOTAL FLOW
S=
CL.
F. VELOCITY
CL.
BOTTOM OF TRENCH
HP.
EL.
CL. PS COLS
S=
5. THE INVERT LEVELS OF THE PIPE MANHOLES SHALL BE LOCATED.
K2 PS-118
1 LATERAL * CL.
S=
4)
PS
CL. 39 VL-101 * LATERAL SUBLATERAL
0(N
CO
CL.
CL.
10
AND BRANCH ARE CALLED
CL. PS COLS
BOTTOM OF TRENCH EXAMPLE ONLY AND 8
7. PFD FOR WASTE COLLECTION SYSTEM SHALL BE FURNISHED EL. SHOULD NOT BE CALLED
CO CO
HP
SEPARATELY FOR ALL PROCESS UNITS. OUT ON UNDER GROUND
CL.
PIPING DRAWINGS. 39ES 101 A&B
HP
S=0.017
8. DESIGN RAINFALL INTENSITY = 125MM/HR.
CL. S=
100 (NPS 4)
19
100 (NPS4)
(TYP)
11
9. ALL FUNNEL POINTS SHALL BE AS PER PIPING GA / PROCESS P&ID. CL. K2-PS-101 IL 8
39-PC-101B 8
CL. CO CO
ELECTRICAL TRENCH
IL
10. SEALED MANHOLES SHALL BE PROVIDED AT FOLLOWING LOCATION. 100 (NPS 4) OF 4-150 (NPS 6) 39 1911 KC-200(NPS 8) K2 CB-3-107 39 1928 KC-100 (NPS 4) CO
S= W= S=
ELECTRICAL TRENCH
CO
S=
HP
b) AT JUNCTION OF SEWERS AND AT CHANGE IN SIZE OF MAIN HEADER, 100 (NPS 4) CO 10 1
39FT-101A 39FT-101B
ADDITIONALLY ALTERNATE MANHOLES SHALL BE SEALED MANHOLES. CL.
39-PC-101A CL.
IL
* SUBLATERAL
HP
11. ALTHOUGH VENT PIPES NOT SHOWN HERE, HOWEVER ALL SEALED K2-CB-3-106 39 1907 KC-200 (NPS 8)
(TYP)
7
HP FINISHED SURFACE
EL.
MANHOLES SHALL HAVE VENT PIPES AS PER DESIGN BASIS. CL.
W= IL S=
13. NO CATCH PIT, MANHOLE, DRAIN FUNNELS ETC. SHALL BE PROVIDED 11 NOTES:-
WITHIN 15.0M FROM HEATER, FURNACE, REACTOR ETC. 1. FOR GENERAL NOTES LEGEND AND DETAILS SEE DRAWINGS STDD-00-A1-5003 &
STDD-00-A1-5004
14. PFD SHALL FURNISH THE FOLLOWING DATA AT EACH SEGMENTS OF OWS/CRWS 12 2. ALL CHANGES OF DIRECTION AND ELEVATION IN SEWER SYSTEMS SHALL BE MADE WITH 1/8
(45°) BENDS AND/OR 45° PLAIN JUNCTIONS EXCEPT AS NOTED OR SHOWN OTHERWISE ON
A. PROCESS FLOW PLAN OR DETAIL DRAWINGS.
B. DIA. OF PIPE 15 3. UNLESS NOTED OTHERWISE ALL DRAIN FUNNELS
SHOWN ARE DF-1
C. SLOPE
SHOWN ARE DF-2
15
D. VELOCITY 4. UNLESS NOTED OTHERWISE ALL CLEANOUTS ARE CO-1.
7 5. UNLESS NOTED OTHERWISE TOP OF ALL CATCH BASIN SHALL BE AT EL.
15. STARTING INVERT LEVEL OF CRWS SHALL BE 750MM BELOW HPP. 6. UNLESS NOTED OTHERWISE EACH BRANCH RUN SHALL START AT AN INVERT LEVEL (IL) OF AT
THE UPPERMOST DRAIN FUNNEL WHERE THE SLOPE IS NOT INDICATED IN STALL THE LINE WITH A
UNIFORM SLOPE BETWEEN SPECIFIED INVERT LEVELS (ELEVATIONS)
16. INVERT LEVEL AT OUTLET POINT OF CRWS & OWS SHALL BE 1500MM BELOW FGL. 13 7. UNLESS NOTED OTHERWISE ALL UNDERGROUND STEEL LINES WITH AN ABOVE GROUND CONTINUATION
SHALL TERMINATE 300 ABOVE HIGH POINT OF FINISHED SURFACE
17. LEVELS FURNISHED ARE WITH RESPECT TO CHART DATUM. 16 8. JOINTS AND/OR WELDS ON UNDERGROUND PRESSURE SYSTEMS
SHALL BE LEFT EXPOSED UNTIL THE LINE HAS BEEN
HYDROSTATICALLY TESTED PER SP-50-9 K2-A1-5103
16 9. FOR THE TESTING OF UNDERGROUND GRAVITY SEWER A. AREA AND UNIT NUMBER. K2-A1-5101
K2-A1-5104
SYSTEMS SEE SP-00-11.
B. SHEET NUMBER TO CORRESPOND WITH THE THIS
10. ALL LINES SHALL BE INSTALLED IN STRICT ACCORDANCE WITH LAST TWO DIGITS OF THE DRAWING NUMBER K2-A1-5105
DRAWING
THIS DRAWING ISOMETRIC DRAWINGS OF THE FOLLOWING LINES
ONLY HAVE BEEN PREPARED TO ASSIST IN INSTALLATION. C. DRAWING NUMBERS SHALL BE INDICATED KEY PLAN
ON EACH INDIVIDUAL BILL OF MATERIAL.
11. FOR PIPING MATERIAL OF LINES NOT ON ISOMETRIC REFER TO 16
THE PIPING BILL OF MATERIAL OF THE APPLICABLE LINE NO.
12. UNLESS NOTED OTHERWISE ALL DRAIN FUNNELS WILL BE
LOCATED PER STANDARD DRG. STDD-00-A1-5003.
13. UNLESS NOTED OTHERWISE ALL NPS 4 LINES SHALL SLOPE AT 0.016.
* FOR DETAILS REFER DWG. NO. UGP13 14. UNLESS NOTED OTHERWISE ALL NPS 6 LINES SHALL SLOPE AT 0.013. * DIMENSIONS IN mm. UNLESS OTHERWISE STATED.
: 29040-PI-UPS-1010 TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1010
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PURPOSE :
PLOT SUBDIVIDED INTO DRAINAGE AREAS
10 ELEVATIONS
LIMITS OF PAVED AREAS HIGH POINTS AND VALLEYS SHALL BE SHOWN IN 16 PRESSURE TEST DATA
HAVE A NOTE REFERING TO THAT DRAWING PLUS ANY ADDITIONAL NOTES CRICKET LINES HIGH POINT CATCH BASIN
HIGH POINT OF FINISHED SURFACE OR PAVING IS SHOWN IN A BLOCK AT
PERTINENT TO THAT INDIVIDUAL DRAWING(eg. NOTES 10 TO 11). (TYP.) OF PAVING (HPP) (TYP.)
THE LOWER RIGHT HAND PORTION OF THE DRAWING LOW POINT OR TOP
OF CATCH BASIN ELEVATION MAY BE COVERED BY A NOTE WHERE TOP
18 KEY PLAN
OF CATCH BASIN ELEVATION IS DIFFERENT FROM THAT STATED IN THE
NOTE IT SHALL BE SHOWN ON THE DRAWING. SHOW A KEY PLAN ON EACH UNDERGROUND PIPING PLAN.
LINE NUMBERS ARE GIVEN FOR ALL PRINCIPLE HEADERS, SEWER MAINS, NOMINAL SIZES FOR STEEL PIPE AND FITTINGS SHALL BE GIVEN IN INCHES
LATERALS AND SUBLATERALS AND FOR BRANCHES CONNECTING DIRECTLY NOMINAL SIZES FOR PIPE AND FITTING OTHER THAN STEEL (eg. VITRIFIED
TO CATCH BASINS AND/OR MANHOLES. CLAY AND CONCRETE) SHALL BE GIVEN IN MM.
9 SYSTEM IDENTIFICATION
20 PIPING BILLS OF MATERIAL
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PAVED AREA
WEST BATTERY LIMIT
PUMP
ELEC.DUCT CLOSED
DRAIN
ELECTRICAL SYSTEM
DUCT
MH *3 MH *4 SPEC. CHANGE
MH *2 (TYP.)
PUMP PUMP
CATCH
BASIN GRADE
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3/4"
4"/100
DRAIN HUB
(REDUCER)
SUMP PUMP
SEE UGP 22
WP CL EL.97'-9"
SLOPE MIN. 1:50
UNPAVED AREA
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CONDUIT TO
OTHER USERS
SUMP PUMP SUMP
ELECTRICAL
PULL BOX
4"/100
CL HIGH POINT
PAVING
TOP EL. EL. 100
GRADE
SIZED BY CIVIL ENGINEERS