INDUSTRIAL PLANT ENGINEERING

Module 2. General piping systems layouts of industrial plants

Objectives:

1. Discuss the flow of pipeline layouts and instruments.

2. Enumerate types of piping materials.
3. Familiarization with piping codes and standards.

Contents:

Industrial piping systems are essential for transporting fluids (liquids, gases, or slurries) in industrial plants
such as oil refineries, power plants, chemical plants, and water treatment facilities. The layout and design of
these piping systems are critical to the efficiency, safety, and functionality of the plant. Below is an overview of
general piping system layouts used in industrial plants:

1. Layout Types
1.1. Straight Run Layout
• Description: Simplest layout with minimal directional changes.
• Application: Used in areas where piping runs in a straight line, such as long-distance transport or
between specific equipment.
• Advantages:
o Easy installation and maintenance.
o Minimizes pressure losses.
• Disadvantages:
o Requires more space.
1.2. Grid Layout
• Description: Piping arranged in a grid or matrix pattern.
• Application: Common in water distribution systems, firewater networks, and power plants.
• Advantages:
o Provides multiple flow paths for redundancy.
o Easy to isolate sections for maintenance.
• Disadvantages:
o Higher material and construction costs.
1.3. Loop Layout
• Description: Circular or looped arrangement for continuous flow.
• Application: Used in cooling water systems or process loops where uninterrupted flow is essential.
• Advantages:
o Reduces pressure drops and flow resistance.
o Maintains constant flow even during maintenance.
• Disadvantages:
o More complex to design and construct.
1.4. Branch Layout (Tree System)
• Description: Main pipe with smaller branch lines feeding equipment or areas.
• Application: Common in industrial plants for distributing fluids to multiple points.
• Advantages:
o Economical in terms of material.
o Simple design and construction.
• Disadvantages:
o Uneven flow distribution.
o Pressure drops at branch points.
1.5. Radial Layout
• Description: Piping radiates out from a central point.
 • Application: Used in storage tank farms or distribution hubs.
• Advantages:
o Centralized control.
o Efficient space utilization in compact layouts.
• Disadvantages:
o Can become congested at the central hub.
2. Key Considerations in Layout Design
• Fluid Dynamics: Minimize pressure drops, flow turbulence, and cavitation.
• Space Optimization: Ensure efficient use of available space without obstructing access to equipment.
• Material Selection: Choose appropriate materials for pressure, temperature, and corrosion resistance.
• Flexibility: Account for thermal expansion, contraction, and vibrations using expansion loops or joints.
• Safety: Ensure compliance with industry standards and codes (e.g., ASME, ANSI, API).
• Access and Maintenance: Layout should allow easy access for inspection, maintenance, and repairs.
• Energy Efficiency: Optimize pipe diameter and layout to minimize pumping energy requirements.
3. Common Components in Piping Layouts
• Pipelines: Main transport medium.
• Fittings: Elbows, tees, reducers, and couplings to connect and direct pipes.
• Valves: Control flow, pressure, and isolation (e.g., gate, globe, ball, and check valves).
• Flanges: Connect sections of pipe and facilitate disassembly.
• Supports and Anchors: Maintain structural integrity and accommodate thermal expansion.
• Pumps and Compressors: Provide the necessary fluid transport energy.
• Instrumentation: Pressure gauges, flow meters, and temperature sensors for monitoring.
4. Piping Arrangement in Specific Plants
4.1. Oil Refineries
• Extensive networks with interconnecting process units.
• Key features include pipe racks, underground piping for critical services, and high-temperature
insulated pipelines.
4.2. Power Plants
• High-pressure and high-temperature steam piping connected to turbines.
• Cooling water systems arranged in loop or grid layouts.
4.3. Chemical Plants
• Complex piping for transporting various chemicals between reactors, storage tanks, and separators.
• Corrosion-resistant materials (e.g., stainless steel, lined pipes) are common.
4.4. Water Treatment Plants
• Gravity-fed layouts for minimal energy consumption.
• Loop or branch layouts for distribution to various treatment stages.
5. Pipe Rack Design
Pipe racks are structural elements that support overhead piping systems:
• Single-Tier Pipe Racks: Used for small-scale systems.
• Multi-Tier Pipe Racks: Common in large plants for separating utility and process lines.
• Clearances: Maintain sufficient space for maintenance and heat dissipation.

2. PIPING MATERIALS, PROCESS TERMS, AND PIPING CODES

1. Piping Materials
The selection of piping materials depends on factors such as the type of fluid, pressure, temperature, corrosion
resistance, and cost.
1.1. Metallic Materials
1.1.1. Carbon Steel (CS)
• Uses: General-purpose pipes for water, oil, steam, and gases.
• Pros: Durable, cost-effective, suitable for moderate temperatures and pressures.
• Cons: Prone to corrosion if not protected.
1.1.2. Stainless Steel (SS)
• Uses: Corrosive fluids, food and pharmaceutical industries.
• Types:
o 304/316: Common grades with good corrosion resistance.
o Duplex SS: High strength and excellent corrosion resistance.
• Pros: Corrosion-resistant, high-temperature capability.
• Cons: Expensive compared to carbon steel.
1.1.3. Alloy Steel
• Uses: High-pressure and high-temperature applications (e.g., power plants).
• Examples: Chrome-moly steels (e.g., ASTM A335 P11, P22).
• Pros: Superior strength and thermal resistance.
• Cons: Higher cost.
1.1.4. Cast Iron (CI)
• Uses: Low-pressure applications like drainage and sewage systems.
• Pros: Cost-effective, excellent wear resistance.
• Cons: Brittle, not suitable for high-pressure systems.
1.2. Non-Metallic Materials
1.2.1. PVC (Polyvinyl Chloride)
• Uses: Low-pressure, non-corrosive fluid transport.
• Pros: Lightweight, corrosion-resistant, inexpensive.
• Cons: Limited temperature resistance.
1.2.2. HDPE (High-Density Polyethylene)
• Uses: Underground piping, water distribution.
• Pros: Flexible, corrosion-resistant, durable.
• Cons: Not suitable for high temperatures.
1.2.3. FRP (Fiberglass Reinforced Plastic)
• Uses: Corrosive environments (e.g., chemical plants).
• Pros: Excellent corrosion resistance, lightweight.
• Cons: Limited strength and temperature resistance.
1.2.4. PTFE (Polytetrafluoroethylene, Teflon)
• Uses: Highly corrosive or reactive chemicals.
• Pros: Non-reactive, extreme chemical resistance.
• Cons: Expensive and low mechanical strength.

2. Process Terms
Understanding key process terms is essential for piping design and operation.
2.1. Flow-Related Terms
• Laminar Flow: Smooth fluid flow with minimal mixing; occurs at low Reynolds numbers.
• Turbulent Flow: Chaotic flow with significant mixing; occurs at high Reynolds numbers.
• Velocity: Speed of fluid in the pipe (e.g., m/s or ft/s).
• Pressure Drop: Loss of pressure due to friction, elevation changes, or fittings.
2.2. Temperature Terms
• Operating Temperature: Actual temperature during normal operation.
• Design Temperature: Maximum expected temperature, including safety margin.
• Thermal Expansion: Elongation of pipes due to temperature changes.
2.3. Stress and Load Terms
• Internal Pressure: Pressure exerted by the fluid inside the pipe.
• Thermal Stress: Stress caused by temperature changes.
• Dead Load: Weight of the pipe, fittings, and fluid.
• Live Load: Variable loads (e.g., flow fluctuations, vibrations).
2.4. Common Fluid Transport Terms
• Single-Phase Flow: Transport of fluids in one phase (liquid or gas).
• Two-Phase Flow: Simultaneous flow of liquid and gas (e.g., steam-water mixtures).
 • Slurry: A mixture of solid particles and liquid transported through pipes.

3. Piping Codes and Standards

Piping codes and standards ensure safety, reliability, and compliance in industrial systems.
3.1. International Codes
3.1.1. ASME (American Society of Mechanical Engineers)
• ASME B31.1: Power Piping (used in power plants for steam, feedwater, and other systems).
• ASME B31.3: Process Piping (used in chemical, petroleum, and gas plants).
• ASME B31.4: Pipeline Transportation Systems for Liquids and Slurries.
• ASME B31.8: Gas Transmission and Distribution Piping Systems.
3.1.2. API (American Petroleum Institute)
• API 570: Piping Inspection Code.
• API 5L: Specification for Line Pipe.
• API 610: Centrifugal Pumps for Petroleum and Natural Gas Industries.
3.1.3. ASTM (American Society for Testing and Materials)
• ASTM A106: Seamless Carbon Steel Pipes for High-Temperature Service.
• ASTM A312: Seamless and Welded Stainless Steel Pipes.
3.2. European Standards
• EN 13480: Metallic Industrial Piping.
• ISO 15649: Piping Systems for Petroleum and Natural Gas Industries.
3.3. Other Regional Codes
• BS 1600 (British Standard): Steel pipes and fittings.
• CSA Z662: Canadian code for oil and gas pipeline systems.
3.4. Supporting Standards
• ASME B16 Series: Standards for flanges, fittings, and valves.
• ANSI (American National Standards Institute): Pipe dimensions, pressure ratings.

4. Additional Considerations
• Code Compliance: Adhering to the relevant code is legally required in most jurisdictions.
• Material Certification: Ensure materials meet the specified standard (e.g., mill test reports).
• Inspection and Testing:
o Hydrostatic Testing: Pressure testing with water.
o NDT (Non-Destructive Testing): Ultrasonic, radiography for weld integrity.

3. PIPING AND EQUIPMENT BASIS FOR SELECTION

The selection of piping and equipment in industrial plants is governed by various technical, operational, and
economic factors. Below is a comprehensive guide to the basis for selection of piping and equipment,
including the criteria and considerations involved.
1. Basis for Piping Selection
1.1. Fluid Characteristics
• Type of Fluid: Liquid, gas, slurry, or multiphase.
• Corrosiveness: Highly corrosive fluids (e.g., acids, alkalis) require materials like stainless steel, FRP, or
lined pipes.
• Temperature: High-temperature fluids may require alloy steel or insulated carbon steel.
• Pressure: High-pressure fluids require seamless pipes or specific alloys.
• Toxicity/Volatility: Special piping, like double-walled or jacketed pipes, may be needed for hazardous
fluids.
1.2. Design and Operating Conditions
• Design Pressure and Temperature: Piping materials and thickness must withstand the maximum
pressure and temperature during operation.
• Thermal Expansion: Use expansion joints or loops to accommodate expansion/contraction.
 • Flow Rate: Determine pipe diameter to ensure optimal flow velocity (e.g., to minimize erosion and
pressure drops).
• Abrasiveness: Slurry or particulate-laden fluids require wear-resistant materials (e.g., ceramic-lined
pipes).
1.3. Code and Standards
• Compliance: Adhere to applicable piping codes like ASME B31.3 (Process Piping) or B31.1 (Power
Piping).
• Testing and Certification: Verify that materials meet ASTM or equivalent standards.
1.4. Economic Considerations
• Material Cost: Balance between cost and durability (e.g., carbon steel for low cost, stainless steel for
corrosion resistance).
• Installation Cost: Factors like weight, ease of welding, and prefabrication impact installation costs.
• Lifecycle Cost: Consider maintenance and replacement frequency.
1.5. Safety and Environmental Factors
• Leak Prevention: Use high-integrity joints, flanges, and fittings for hazardous fluids.
• Insulation: Thermal insulation for personnel safety and energy efficiency.
• Environmental Regulations: Ensure emissions or leaks meet legal standards.
1.6. Special Requirements
• Cryogenic Applications: Use materials like stainless steel or aluminum that retain strength at very low
temperatures.
• Steam Systems: Select piping that handles high-temperature and pressure with minimal thermal
fatigue.
• Underground Piping: Use corrosion-resistant coatings or cathodic protection.

2. Basis for Equipment Selection

2.1. Process Requirements
• Capacity: Ensure the equipment can handle the required throughput (e.g., flow rate, volume).
• Process Conditions: Consider temperature, pressure, and chemical compatibility.
• Type of Operation: Batch or continuous operation influences equipment type (e.g., batch reactors vs.
continuous reactors).
2.2. Material of Construction
• Corrosion Resistance: Match equipment material with the fluid (e.g., Hastelloy for highly corrosive
fluids, stainless steel for moderate corrosion).
• Erosion Resistance: Use hard-facing or abrasion-resistant materials for handling slurries or abrasive
particles.
• Pressure and Temperature Ratings: Equipment must be rated for the maximum operating conditions.
2.3. Energy Efficiency
• Energy Consumption: Select equipment with lower energy requirements (e.g., energy-efficient pumps,
heat exchangers).
• Heat Recovery: Incorporate systems like economizers and heat recovery steam generators (HRSGs)
where feasible.
2.4. Operating Environment
• Indoor/Outdoor Installation: Equipment exposed to weather requires additional protection (e.g.,
corrosion-resistant coatings, enclosures).
• Hazardous Areas: Use explosion-proof equipment in areas classified as hazardous (e.g., according to
IECEx or NEC codes).
2.5. Maintenance and Reliability
• Ease of Maintenance: Equipment with modular or accessible components reduces downtime.
• Reliability: Proven technology and robust designs minimize failure risks.
2.6. Economic Factors
• Capital Cost: Initial cost of purchasing and installing the equipment.
• Operating Cost: Costs related to power, consumables, and regular maintenance.
• Lifecycle Cost: Total cost over the equipment's lifespan, including replacements.
2.7. Safety Standards
• Pressure Equipment Directive (PED): For pressure vessels and boilers.
• Seismic and Wind Loads: Ensure equipment design meets structural safety requirements for the
region.
• Noise and Emission Limits: Comply with OSHA or local environmental noise/emission regulations.
2.8. Common Equipment-Specific Considerations
• Pumps: Choose based on fluid type, head, flow rate, and efficiency. Centrifugal pumps are common for
liquids; positive displacement pumps are used for viscous or precise applications.
• Heat Exchangers: Tube material, type (e.g., shell-and-tube, plate), and size depend on the heat transfer
duty and fouling potential.
• Valves: Selection depends on service type (on/off, control), material, and pressure/temperature rating.
• Compressors: Consider suction pressure, discharge pressure, flow rate, and gas type. Centrifugal
compressors are used for high flow rates; reciprocating compressors are for high pressures.
• Reactors: Selection depends on chemical reaction type (e.g., stirred tank, fixed-bed, or fluidized-bed
reactors).

3. Selection Workflow
1. Define Process Requirements:
o Flow rate, pressure, temperature, and fluid properties.
o Operational needs (e.g., continuous vs. batch).
2. Check Standards and Regulations:
o Identify applicable codes (e.g., ASME, API, ISO).
3. Preliminary Sizing:
o Use process simulation software or design charts to size pipes and equipment.
4. Material Compatibility:
o Select materials suitable for the fluid and environmental conditions.
5. Evaluate Alternatives:
o Compare different options for cost, efficiency, and reliability.
6. Safety and Environmental Analysis:
o Ensure compliance with safety and emission standards.
7. Economic Analysis:
o Perform a cost-benefit analysis, including lifecycle costs.
8. Finalize Selection:
o Review specifications and conduct technical and economic feasibility checks.

4. PIPE SCHEDULE
Pipe scheduling refers to the specification of the wall thickness of a pipe, which is critical for determining the
strength and pressure-carrying capacity of the pipe. The term "schedule" is designated by a number, such as
Schedule 10, 40, 80, etc. These schedules define the relationship between the pipe's nominal size (NPS), its
outer diameter (OD), and its wall thickness.

1. Concepts
1. Nominal Pipe Size (NPS):
o A standard designation for the approximate diameter of the pipe.
o For sizes NPS 1/8 to NPS 12, the outer diameter remains fixed for a given NPS, and the wall
thickness changes with the schedule.
o For sizes above NPS 14, the NPS equals the outer diameter.
2. Wall Thickness:
o The schedule number determines the wall thickness of the pipe.
o Thicker walls allow for higher pressure ratings.
3. Schedule Number Formula:
o Schedule Number=1000×(P/S)
 P: Internal working pressure (psi)
▪
S: Allowable stress (psi) (material-dependent)
▪
4. Common Pipe Schedules:
o Schedule 10 (SCH 10): Thinner wall, lighter pipe.
o Schedule 40 (SCH 40): Standard wall thickness.
o Schedule 80 (SCH 80): Thicker wall, higher strength.
o Schedule 160 (SCH 160): Extra-thick wall for high-pressure applications.
o XXS (Double Extra Strong): Maximum thickness available for a given size.

2. Standard Dimensions
Below are example dimensions for steel pipes (in inches):

• OD: Outer diameter.

• Wall: Wall thickness.

Note:
* Definition:
• NPS (Nominal Pipe Size):
o A dimensionless number used in imperial systems, primarily in North America.
o Represents the approximate diameter of a pipe but is not directly equal to the actual outside
diameter (OD).
• DN (Diameter Nominal):
o A metric standard used internationally.
o Expressed in millimeters (mm) and represents the nominal diameter of the pipe.
o It is also dimensionless, as it does not strictly equal the actual pipe dimensions.
Measurement Systems
• NPS:
o Based on the imperial system (inches).
o For smaller sizes (NPS 1/8 to NPS 12), the OD is fixed, and wall thickness changes with the
schedule.
o For sizes above NPS 14, NPS equals the OD in inches.
• DN:
o Based on the metric system (millimeters).
o The DN number is approximately equal to the pipe’s nominal bore diameter (inside diameter
for standard wall thickness).
DN to NPS Conversion Table:

3. Selection Criteria
When selecting a pipe schedule, consider:
1. Operating Pressure and Temperature:
o Higher pressure or temperature requires thicker walls (higher schedules).
2. Material:
o Allowable stress varies by material (e.g., steel, stainless steel, PVC).
3. Fluid Characteristics:
o Abrasive or corrosive fluids may require thicker walls or corrosion-resistant materials.
4. Weight and Cost:
o Thicker walls increase the weight and cost, so ensure the schedule matches operational needs
without being excessive.

4. Practical Application
For example:
• A pipe carrying high-pressure steam in a power plant may require Schedule 80 or higher for strength.
• A pipe used in low-pressure water applications may only need Schedule 10 for cost-effectiveness and
light weight.
5. Codes and Standards
• ASME B36.10M: Covers dimensions of welded and seamless steel pipes.
• ASME B36.19M: Specifically for stainless steel pipes.

Design Calculation Consideration:

Selecting appropriate Pipe Schedule:

The Y factor depends on the material type and its temperature. Here are the most common values as defined in
ASME B31.3 Table 304.1.1:
Portion of Table A-1: Allowable Stresses for Common Materials
Sample Problem:

1. What is the DN designation of a pipe with a nominal pipe size 6?

2. A seamless wrought steel pipe with an outside diameter of 6 inches has an internal design
pressure of 500 psi and allowable stress of 20,000 psi. Assume a corrosion allowance of 0.0625
inches (commonly 1/16 inch). Determine the thickness and the appropriate pipe schedule.

3. A water distribution needs to deliver water through a horizontal pipe at a flow rate of 0.05m 3/s.
The allowable flow velocity is 2.0 m/s. Determine the required pipe diameter and the Reynolds
number assuming that the kinematic viscosity of water is 1.0x10 -6m2/s.
 4. Determine the thickness and pipe schedule of a ERW carbon steel pipe NPS 8 with an internal
design pressure of 1,200 psi, 1000°F, allowable stress 15,000 psi (from ASME Table A-1 for a
specific material), and corrosion allowance of 0.125 inches (1/8 inch).

Practice problem:

1. Determine the thickness and pipe schedule of a stainless steel pipe of NPS 4 with an internal design
pressure of 2,000 psi, 100 °F, allowable stress of 18,000 psi, weld joint efficiency of 0.9 and corrosion
allowance of 0.0625 inches (1/16 inch).

2. Water flows through a horizontal circular pipe at a volumetric flow rate of 0.02 m³/s. The flow is steady and
incompressible. The kinematic viscosity of water is 1.0 × 10⁻⁶ m²/s, and the density of water is 1000 kg/m³.
Calculate the diameter of the pipe if the flow velocity is 2 m/s and determine the Reynolds number for the
flow.

3. Water at 20°C flows through a horizontal pipe with an internal diameter of 50 mm and a length of 20 m. The
flow rate is 0.01 m³/s, and the kinematic viscosity of water is 1.0×10−6 m2/s. Determine the pressure drop in
the pipe if the flow is fully developed and turbulent. Assume a Darcy friction factor f=0.02.