equipment and piping 1

7/29/2019 Equipment and Piping 1

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EQUIPMENT & PIPING LAYOUT

N.Todkar


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It is very appropriate to say that the

Equipment and Piping layout design is an ART andnot a SCIENCE. There is not a single formula

available for the design of Equipment and Piping

layout. The equipment layout design can be asrational as the mathematics of fluid flow but with

the language of projective geometry. Mathematics

is abstract; geometry is visual. All engineeringcourses have mathematics; few have the subject of

projective geometry but none has layout design


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However, systematic methods and procedures

can be developed from engineering principles,

specifications, practical engineering know-how,and just SIMPLE COMMON SENSE.

During the planning stages, the Piping

Engineer could meet with simple ideas that can

effect substantial cost savings. Let us take apractical example to it.


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Fig.1.1a


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Fig. 1.1b


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The design must take constructibility,

economics, safety, quality and operation intoaccount. All these should be achieved within the

shortest schedule and will demonstrate the

technical capacity along with creative talent and

common sense approach to problem solving.Although the tools to achieve these goals have

changed from pencil and paper to computer

graphics, the responsibilities of the Piping

Engineer remains the same.


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Design for Constructibility

Ten Commandments:

Keep It Straight and Simple

Keep Its Structures Simple

Keep Its Specification Simple

Keep It Shop Standard Keep Its Standard Simple

Keep It SameSize

Keep It Square and Squatty

Keep Its Support Simple

Keep Its Schedule Sacred

Keep Its Site Suitable


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The mechanical design and development of the

plant has three major steps viz.

2.1 Equipment layout design2.2 Conceptual layout design

2.3 Piping layout design

The plant layout can be the biggest cost saver inchemical plant design next to the Process and

Equipment design. Money wasted or saved can be

substantial between alternate layouts. In addition to

capital cost, the plant layout also influences theoperating and maintenance cost. These are long term

benefits that affect profitability.


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Incorrectly established plant layouts can have

serious impact on safety and operability. If thelayout do not have enough room, the plant will be

overcrowded, and unsafe and difficult to operate

and maintain. On the other hand, an overly

generous layout results in unnecessary highcapital investment.


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UP

UPROOM

TERRACE

DUCT

OPEN SPACE

LIFTUP

UP

6500

6000650025003000

3500 500011 2 3 4 5 6 7 8 9 10 11 12 13

5000 5000 5000 5000 5000 5000 5000 4500 4500 2200

FED

C

B

A

C-4101T-4116

T-4104T-4107

C-4203

T-4211T-4121

R-4126R-4109T-4122T-4125T-4123T-4124

T-4114UPUP

F-4211H-4211P-4008T-4216R-4206H-4212

H-4212

R-1402 C-4201T-4213R-4202R-4201UPUP LIFT

SECOND MEZZ. FLOOR PLAN AT EL. 19.20.40M. N

T-4104C-4102

C-4103

ECP/15

ECP/15


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Equipment layout is an extension of the

conceptual layout in more detailed manner. In

the same way as the P&I diagrams are thebasic documents of chemical engineering

design, equipment layout is the basic

document of mechanical engineering design.

This is a composite mechanical engineeringdesign, coordinating the design information to

produce construction drawings.


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The essential data required for the

preparation of an Equipment Layout is as

follows:

1. PROCESS FLOW DIAGRAMS (PFD)/

PIPING AND INSTRUMENT

DIAGRAMS (P &ID)

2. PROJECT DESIGN DATA

3. EQUIPMENT SIZES AND BUILINGS


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TYPES OF LAYOUTS :

Inline Layout

Similar equipment grouping

Functional equipment grouping


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ARRGT-1 :: VERTICAL THERMOSYPHON REBOILER WITH FIXED TUBESHEETS

VAPOUR RETURN CONNECTION

BOTTOM TRAY OF COLUMN

TOP TUBESHEETSUPPORT LUGSHELLSIDE INLET

SUPPORT BRACKETSHELL BELLOWS EXPANSIONJOINT

REBOILER SHELL

LIQUID LEGSHELLSIDE OUTLET

BOTTOM TUBESHEETdcc

COLUMN


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ARRGT-1 :: VERTICAL THERMOSYPHON REBOILER WITH FIXED TUBESHEETS

BOTTOM TRAY OF COLUMN

d cc

COLUMN

VAPOUR RETURN CONNECTION

TOP TUBESHEET

SUPPORT LUG

SHELLSIDE INLET

SUPPORT BRACKET

REBOILER SHELL

SHELLSIDE OUTLET

BOTTOM TUBESHEET

COLUMN SHELL

BELLOWS EXPANSION JOINT


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ARRGT-3 :: VERTICAL FIXED TUBERSHEET REBOILER WITH INDEPEDENTSUPPORT STRUCTURE.

c

COLUMN

VAPOUR RETURN

TOP HEAD

REBOILER SUPPORTSTRUCTURE

SUPPORT LUG

LIQUID LEG

BOTTAM HEAD

SKIRT

SPRING SUPPORT

BELLOWS EXPANSION JOINT

TOP TUBESHEET

BOTTAM TUBESHEET


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The following guidelines and cautions are helpful

in improving the accuracy comparisons.

i) Make comparison to as similar a

plant as possible.ii) Use similar assumptions in

analyzing both existing facilities and

new design.

iii) For outdoor installation, wherevolume has less relevance than in

and enclosed structure, rely on the

area comparison alone.

iv) For tank farm, general guidelines

dictated for fire safety reasons or

statutory requirements govern.


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EQUIPMENT LAYOUT DRAWING GUIDE LINES

The following are the guidelines generally

followed while making an Equipment layout

drawing.

a) Equipment layout shall be drawn in 1:50 or

1:100 scale.

b) A0 size drawing sheet should generally be used for

equipment layout. If the area to be covered is small,A1 size can be used.

c) Place north arrow at the top right hand corner of

the sheet to indicate plant north.

d) The area above title block to be kept free forgeneral notes and reference drawings.


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e) All equipments are marked with its equipment no. as

appearing in Equipment list & dimensions (diameter,

height/length etc.)f) All equipments center line are located in

plant building w.r.t. the column grid. For layout of outdoor plant /

offsite facility, the equipment shall be located by co-ordinates.

g) Conceptual layout, P & ID, vendor/fabricated equipment

drawings are to be used as basic document for preparing equipmentlayout drawing.

h) Walkways, cutouts, piperacks, floor drains, gutter, trenches,

ramp etc. if applicable should be clearly marked in the drawing.


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i) For in house plant layout, the location

of staircases, lift & other utility areasshould be clearly shown.

j) In equipment layout sectional drawing, for each

equipment its top most or bottom most elevations should

be marked. k) Orientation of equipment shall be clearly marked for all

the equipments by orienting one of the major nozzles.

l) In case of reactors / tanks, the location of manhole /

handhole, SG/LG,LI etc. shall be at accessible position.

m) Equipment lifting cutout shall be marked clearly in the

drawing.


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n) Equipment planned to be installed in future

shall be shown dotted.o) For heat exchangers, tube removal /

cleaning space shall be marked.

p)While locating the pumps care shall be taken to ensure

that the NPSH requirement is met.

q) General notes are written on one of the drawings (first)

and shall not be repeated on all layouts but reference

shall be given.

r) Direction of north shall be maintained same for all the

plans for the same plant / project.


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s) If more than one drawing is required to cover a

specified area, then the match line shall be indicated clearlywith the reference drawings.

t) One of the general notes should specify the

absolute level of the area covered with respect to the plot.

u) The equipment load, operating or test load

whichever is maximum shall be considered for design and the

layout should indicate this along with the dynamic factor

wherever applicable. This could also be covered in table as

well.


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v) For reactors with agitators, lifting beam shall be

provided for agitator removal.

w) For vendor equipments maintenance

space as recommended by them for

maintenance shall be provided.

x) Equipment layout shall also indicated the

positions of utility stations, safety shower and eye wash.y) Equipment elevation shall be so arranged to

ensure gravity flow where specified.


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In terms of the equipment arrangement, the equipment

layout (unit plot plan) can basically be divided into two

configurations:

a) The grade mounted horizontal

arrangement as seen in the refineries

and petrochemical plants, and

b) The vertical arrangement found inmany chemical process industries.


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Irrespective of the type of arrangement, there are certain

basic principles to be followed while locating the equipment.

Economic piping Process requirements

Common Operation

Underground facilities

Climatic conditions


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TYPICAL CROSS SECTION OF AN INDOOR

PROCESS PLANT

Fig. 2.2.6a


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TYPICAL CROSS SECTION OF INDOOR CHEMICAL PLANT

Fig. 2.2.6b


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PHILOSOPHY OF IN-PLANT PIPING

o

o Value Location

o Electrical/Instrument Cable Trays

o Statuary requirements

o Miscellaneous

o


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So, the first step in the development of pipe rack is the

generation of a line routing diagram. A line routing

diagram is a schematic representation of all process and utility

piping systems drawn on a copy of plot plan or it could beplanometric representation of the utility and process line

diagrams. Although it disregards the exact locations, elevations

or interferences, it locates the most congested area.


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The pipe rack splits the plant area into convenient parts.

The pipe rack takes various shapes such as straight,L,T, and

C orU. This configuration is based on the overall arrangement

and site conditions. Based on the incoming/outgoing lines and

locations, the pipe rack is laid.


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Fig. 2.3.1


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Fig. 2.3.2


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Fig. 2.3.3


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Fig. 2.3.4


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Fig. 2.3.5


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Fig. 2.3.6


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Fig. 2.3.7

The configuration of pipe rack is not determined while doing


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g p p g

the plant layout.

The arrangement results from an overall plant layout, site

conditions, client requirements and above all plant economy.

The width of the pipe rack is estimated asW = (f x n x s) + A + B

f = Safety factor

= 1.5 if pipes are counted from the PFD

= 1.2 if pipes are counted from P & ID.n=Number of lines in the densest area upto the size of 450NB

s = 300mm (estimated average spacing)

= 225mm (if lines are smaller than 250 NB)

A = Additional width for

(1) Lines larger than 450 NB(2) For instrument cable tray/duct

(3) For electrical cable tray

B = Future provision

= 20% of (f x n x s) + A

1 5 TO 2M


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Fig. 2.3.8

1.5 TO 2M

TYPE 15 TO 6M 1TO 1.2M

TYPE 2


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5 TO 6M

TYPE 3

The Headroom normally provided is as below.


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y p

Sr. Description Headroom

No. (mm)

1. Clear head room under 2200

Structures/pipe linesinside operating area.

2. Head room over rail 7000

(from top of rails)

3. Clear headroom above 7000crest of road for crane

movement.

4. Clear headroom above 600

crest of road for truck

movement.5. Clear headroom above 4500

crest of road between

process units.


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P & I diagram, equipment layout, piping

specifications, equipment drawing and the vendor

requirement for proprietary equipment form the basis of a

piping layout. In areas where piping is critical, theequipment locations are fixed only after a pipingstudy is

made.


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Fig. 2.3.9a


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Fig. 2.3.10


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Fig. 2.3.11


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Fig. 2.3.13


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Fig. 2.3.14


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Fig. 2.3.15


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Fig. 2.3.16


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Fig. 2.3.17


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Fig. 2.3.18


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Fig 2.3.19


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Fig 2.3.20


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Fig 2.3.21a


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Fig 2.3.21b


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Fig 2.3.22


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2.3.5 PIPING FOR INSTRUMENTS

Instruments,when located on piping ,will need certain

specific requirement for it to perform the duty for which it is

provided. Piping Engineer should be aware of there

requirement and should take care of the same while routing

these pipe line.

a) Flow measurement instrument need certain straight lengthupstream and downstream of the instrument.This is normally

15D on the upstream and 5D on the downstream.

b) The pipe lines in which flow meters such as magneticflowmeters ,vortex meters ,turbinemeters etc are located should

be routed in such a way that the line will be full with liquid all

the time.The pipe line should be supported on both sides of

meter.

c) Control valves are located at grade at about 500mm height to


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c) Control valves are located at grade, at about 500mm height to

provide convenient access for operation and maintenance. Block

and bypass valve also form the same criteria. The standard

arrangements followed are as perFig 2.3.23. If pocketing theprocess line is unacceptable, then a permanent or mobile platform

should be planned, as access is very important. Locating control

values on the vertical line should be avoided.If is unavoidable; the

should actuator should be supported properly.The bypass should

be selected for easy operation.

d) Isolation valves for level gauges and pressure gauges shall be

made accessible. Access and space for the removal of level

controllers temperature probes ,conductivity probes,bottom flagsof the control values etc shall be provided. All primary and

secondary indicators of pressure, temperature, flow, level,

positioners etc. should be visible from the operating area.


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e) Rotameters shall be placed on vertical line and the inlet

should be from the bottom of the instrument.

f) Thermowell shall be located on the pipe line of required

size.Instrument hook up shall be reffered for the requirement.

g) Enough operating and maintance occur shall be considered

while locating any instrument.


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Fig. 2.3.23


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Fig. 2.3.24


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The requirement as per the following shall be

adhered to

a) The Factories Act 1948.

b) The Petroleum Act 1934 & The Petroleum

rules 1976.

c) The Static and Mobile Pressure Vessels

(unfired) Rules 1981.

d) The Gas Cylinders Rules 1981.

e) The Indian Boiler Regulations 1951.

f) Development control rules by the State

Industrial Development Corporation.


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BFW

TANK

ECONOMISER

BFW

HP DOSING

BFWLINE

BOILER FEED

WATER PUMP

DOSING TANK

DOSING PUMP

PI

MAINSTEAM

MANIFOLD

CONSUMER

ST

Y

ST

TO ATMOS.

(TYP)

LG LG LG LG

BLOW DOWN

DRAIN

BLOW DOWN TANK

NOTE:-

PIPE LINESTHE PURVIEW OF IBR SHOWN WITH THICH LINES.

IBR SCOPE

IBR SCOPE


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2.3.8 CRITICAL EXAMINATION TECHINIQUE

The quality of the equipment and piping layout can be

established by the Critical Examination Technique where you

ensure that all the following parameters are well addressed

a) It is process adequate?b) It is operator friendly?

c)It is construction clear?

d)Has adequate maintenance access provided?

e)How to evacuate in case of emergency?f)Has safe fire fighting access provided?

g)Standard practices where applicable has been adopted?

h)Is the piping arrangement aesthetic ?

i)Is supporting arrangement adequate and aesthetic ?

j) Is piping adequately flexible ?


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Pumps rarely influences the plant layout except where a

common standby for two services or multiple duty pumps

might dictate the process equipment arrangement. But the

pumps can never be treated as an independent entity, but to betreated as part of the piping system which affects the

performance even if the basic selection is faultless.


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The design of equipment and piping configuration

affect the energy used and capital cost of pumps. Hence,

economy of piping and structures along with ease of

operation and maintenance are the principal aim whilearranging the pumps.


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The primary goal in locating the pump is to minimize the

piping configuration while satisfying the performance and

flexibility requirements as well as allowable loads that may

be subjected to the nozzles.

Mechanical or Chemical Engineers can no longer consider

the pump as an independent entity, but to be treated as a part

of the Piping System.


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Fig. 3.1.1a


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Fig. 3.1.1b


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Fig. 3.1.2


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Fig. 3.1.3


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equipment and piping 1

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