ACKNOWLEDGEMENT

First of all, I acknowledge without hesitation, the grace of GOD the Almighty, in this arduous journey. Undoubtedly it is he alone who deserves all the credit for this work. With the deep sense of gratitude .I acknowledge the active guidance, help and co operation rendered by our external guide Mr. MD KAMAL, and the Managing director of IPEBS. His able guidance has sustained the effort that has led to the successful completion of this project. I am highly grateful to guide Mr. MD KAMAL for making all the facilities available and help rendered in this project work. My sincere thanks to Mr. MD OBED (Asst professor) internal guide without whose help, this project would not have come about. I would also like to thank my parents for their love, care and support without which I wouldn't have been able to complete the project. I express thanks to all those who helped me directly or indirectly in successful completion of this project.

ABSTRACT
This project presents the procedure and the problems associated with ht e process piping and it also presents the method adopted by computer program in analyzing the effects and in preparing the data for it. It also presents the engineering decision making on design of piping layout as the part of design and analysis of process pipe networks, serves to identify whether a given pipe arrangement can cope with weight, thermal & pressure stress at safe operational levels. Advantages in saving man hours and usefulness in guiding experts in piping layout for process industry

CONTENTS
INTRODUCTION PIPING 2 2 1

PIPING SYSTEM PIPE 7

ASPECTS OF PIPE8 FITTINGS 13 FLANGES 31 VALVES 36 49 51 53 54

SPECIAL ITEMS INSTRUMENTS FLOW DIAGRAM

CLASSIFICATIONS INSULATION 58

VENDOR DATA OR PROCESS DATA SHEET PIPING MATERIAL SPECIFICATIONS 65

59

LAYOUT TERMIN LOGY& ABBREVIATIONS 66 EQUIPMENT LAYOUT/ UNIT PLOT PLAN 67

PIPING GENERAL ARRANGEMENT DRAWING (PIPNG GA) 78 GUIDELINES FOR PREPARING THE PIPING GENERAL ARRANGEMENT (G.A) 78 79

GENERAL ARRANGEPMENT (GA) DRAWING PROCEDURE ISOMETRICS/PIPING ISOMETRICS PIPE SUPPORTS 98 81

APPLICATIONS 102 CHALLENGES OF PIPING.... ...104

INTRODUCTION
Piping systems are like arteries and veins. They carry the lifeblood of modern civilization. In a modern city they transport water from the sources of water supply to the points of distribution; convey waste from residential and commercial buildings and other civic facilities to the treatment facility or the point of discharge. Similarly, pipelines carry crude oil from oil wells to tank farms for storage or to refineries for processing. The natural gas transportation and distribution lines convey natural gas from the source and storage tank forms to points of utilization, such as power plants, industrial facilities, and commercial and residential communities. In chemical plants, paper mills, food processing plants, and other similar industrial establishments, the piping systems are utilized to carry liquids, chemicals, mixtures, gases, vapours, and solids from one location to another. The fire protection piping networks in residential, commercial, industrial, and other buildings carry fire suppression fluids, such as water, gases, and chemicals to provide protection of life and property. The piping systems in thermal power plants convey high-pressure and high-temperature steam to generate electricity. Other piping systems in a power plant transport high- and low-pressure water, chemicals, low-pressure steam, and condensate. Sophisticated piping systems are used to process and carry hazardous and toxic substances. The storm and wastewater piping systems transport large quantities of water away from towns, cities, and industrial and similar establishments to safeguard life, property, and essential facilities. In health facilities, piping systems are used to transport gases and fluids for medical purposes. The piping systems in laboratories carry gases, chemicals, vapours, and other fluids that are critical for conducting research and development. In short, the piping systems are an essential and integral part of our modern civilization just as arteries and veins are essential to the human body. The design, construction, operation, and maintenance of various piping systems involve understanding of piping fundamentals, materials, gencric and specific design considerations, fabrication and installation, examinations, and testing and inspection requirements, in addition to the local, state and federal regulations.

PIPING
Piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid. Piping also has many other industrial applications, which are crucial for moving raw and semi-processed fluids for refining into more useful products. Some of the more exotic materials of construction are Inconel, Titanium, chrome-moly and various other steel alloys.

PIPING SYSTEM
Modern process facilities handle a myriad of chemical substances and compounds at various process temperatures and pressures. The piping system specified to transport these fluids must be compatible with the intended service conditions. Since most of these facilities are one of a kind, the process piping materials selected for construction will be specific application driven. Today, numerous construction materials are available, both metallic and non-metallic in nature. Installed cost variations may be as much as tenfold or even more, depending on the materials suitable for the application. Life cycle cost considerations must also be taken into account during the material selection phase to reflect subsequent repair and replacement requirements. Whereas process piping material selection is specific application driven and will vary dramatically on a case by case basis, utility piping systems are basically the same across various process plants. Basic materials of construction and mode of construction will differ little from one plant to another for services such as air, water, and steam. Pipes are the most delicate components in any process plant. They are also the busiest entities. They are subjected to almost all kinds of loads, intentional or unintentional. It is very important to take note of all potential loads that a piping system would encounter during operation as well as during other stages in the life cycle of a process plant. Ignoring any such load while designing, erecting, hydro-testing, start-up shut-down, normal operation, maintenance etc. can lead to inadequate design and engineering of a piping system. The system may fail on the first occurrence of this overlooked load. Failure of a piping system may trigger a Domino effect and cause a

major disaster. Stress analysis and safe design normally require appreciation of several related concepts.

An approximate list of the steps that would be involved is as follows. 1. Identify potential loads that would come on to the pipe or piping system during its entire life. 2. Relate each one of these loads to the stresses and strains that would be developed in the crystals/grains of the Material of Construction (MOC) of the piping system. 3. Decide the worst three dimensional stress states that the MOC can withstand without failure. 4. Get the cumulative effect of all the potential, loads on the 3-D stress scenario in the piping system under consideration. 5. Alter piping system design to ensure that the stress pattern is within failure limits.

Typical process plant piping

The goal of quantification and analysis of pipe stresses is to provide safe design through the above steps. There could be several designs that could be safe. A piping engineer would have a lot of scope to choose from such alternatives, the one which is most economical, or most suitable etc. Good piping system design is always a mixture of sound knowledge base in the basics and a lot of ingenuity. Piping system includes pipe, fittings, flanges, bolting, gaskets, valves, and the pressure containing portions of other piping components. It also includes pipe hangers and supports and other items necessary to prevent over pressurization and overstressing of the pressure containing components. It is evident that pipe is one element or a part of piping. Therefore, pipe sections when joined with fittings, valves, and other mechanical equipment and properly supported by hangers and supports, are called piping system.

General Description:Piping is indispensable to petroleum refineries, chemical plants, and other process units. Piping for most process units represents the major item of unit investment. Typical total erected piping cost ranges from 25 to 50 percent of the total cost of a unit. Consequently, the piping engineer often faces the necessity of making careful and realistic compromises between design features and cost without sacrificing minimum safety standards. This chapter provides a basic guide to the design of process piping, with specific emphasis on petroleum refineries, chemical, and other related processing plants. It attempts to provide an overview of the fundamental design principles used by the ASME Pressure Piping Code, Section B31.3, and Process Piping. This Code prescribes requirements for materials and components, design, fabrication, assembly, erection, examination, inspection, and testing of piping and acceptance criteria are provided that relate to the ASME B31.3 Code.l This will also provide guidelines for the design and layout of specific systems typically found in petroleum refineries and related petrochemical processing. Further expanded scope of including piping typically found in petroleum Plants, refineries; in chemical, pharmaceutical, textile, paper, semiconductor, and cryogenic plants; and in related processing plants and terminals. Provides a schematic diagram illustrating the scope of ASME B31.3 for process piping of a typical refinery or chemical plant.
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Scope is piping systems which convey: 1. Petroleum products. 2. Raw, intermediate, and finished chemicals. 3. Gas, steam, air, and water. 4. Fluidized solids. 5. Refrigerants. 6. Cryogenic fluids. Some fluid services are further categorized by the Code according to the following category services, which need to consider the combination of fluid properties, operating conditions, and other factors which establish the design basis of the piping systems involved: Category D Fluid Service-a service in which the fluid handled is non-flammable, nontoxic, and not damaging to human tissue, and the design pressure does not exceed 150 psi (1035 kPa) and the design temperature is between 20 and 366F (29 and 186C). Part 3 (starting with Section 305) of the Piping Code covers specific design and fabrication requirements permitted for piping of Category D fluid services to reflect the less than severe conditions involved for these systems. Category M Fluid Servicea 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 produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken, pertains to piping designated by the user as being in Category M fluid service. High-Pressure Fluid Servicea service in which the user specifies the application of B31.3 for piping design and construction for fluid services with high design pressures. High pressure is considered by the Code to be pressure in excess of that allowed by the ASME B16.5 Class 2500 rating for the specified design temperature and material group.2 However, there are no specified pressure imitations for the application of these rules. Normal Fluid Servicea fluid service pertaining to most piping covered by B31.3, i.e., not subject to the rules for Category D, Category M, or High Pressure Fluid service, and not subject to severe cyclic conditions. Code B31.3 to help the user determine the
8

applicability of Category D and Category M Fluid services as distinguished from Normal services. Types of Systems As applied to this section, process piping refers, except as excluded below, to all piping within the property limits of a chemical or petroleum processing plant installation. In addition to the main process units, this will typically include feed and product loading terminals, fuel oil and gas processing facilities, utility systems, waste and water treatment units, and bulk and atmospheric storage tank farms.

Chemical Plant Piping:As compared to refinery systems, typical chemical plant piping applications are usually smaller in size, mostly below NPS 8 (DN 200). Operating pressures for some services can be higher, but temperatures are generally lower and the presence of corrosive fluids is typical. The use of exotic alloy materials, thermoplastics, and thermo set resin materials in piping construction is common because of the highly corrosive nature of some chemicals. Many chemical plant piping systems convey flammable and/or toxic substances.

PIPE:
Pipe is a tube of cylindrical cross section used to carry solids or fluids from one place to another place under pressure. The pipe has to conform to the dimensional standard of the various organisations for standards as listed below:S. no. Country. 1 2 USA/AMERICA CANADA organization ASME/ANSE Standard Council Of Canada abbreviation ASME/ANSI scc

3 4 5

GREAT BRITAIN British Standard institute FRANCE GERMANY Association Francise Dutch institute for normung

BSI/BS AFNOR DIN

INDIA

Bureau Of Indian Standard

BIS/IS

JAPAN

Japan Industrial Standards

JISC

EORLD

International Organization For Standard ISO

ASME B36.1OM Welded and Seamless Wrought Steel Pipe ASME B36.19M Stainless Steel Pipe

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ASPECTS OF PIPE:
1) PIPE SIZE/DIAMETER 2) WALL THICKNESS 3) PIPE WEIGHT 4) PIPE LENGTH 5) PIPE ENDS 6) PIPE JOINING METHODS 7) PRESSURE TEMPRATURE RATING(P-T) #/CLASS 8) PIPE MANUFACTURING METHODS 9) PIPE GRADES 10) PIPE SYMBOLS

DIAMETER: Representation:a) I.P.S(iron pipe size) :It is dimensionless size designator of pipe it represents the inner diameter of pipe. b) NPS(nominal pipe size):It is dimensionless size designator of pipe it represents the outer diameter of pipe (fps). c) NB/DN(nominal bore/diameter nominal):It is dimensionless size designator of pipe .it represents the outer diameter of pipe (metric units). Initially a system known as iron pipe size (IPS) was established to designate the pipe size. The size represented the approximate inside diameter of the inches. An IPS 6 pipe

11

is one whose inside diameter is approximately 6 inches (in). Users started to call the pipe as 2-in, 4-in, 6-in pipe and so on. To begin, each pipe size was produced to have one thickness, which later was termed as standard (STD) or standard weight (STD.WT.). The outside diameter of the pipe was standardized. As the industrial requirements demanded the handling of higher-pressure fluids, pipes were produced having thicker walls, which came to be known as extra strong (XS) or extra heavy (XH). The higher pressure requirements increased further, requiring thicker wall pipes. Accordingly, pipes were manufactured with double extra strong (XXS) or double extra heavy (XXH) walls while the standardized outside diameters are unchanged. With the development of stronger and corrosion-resistant piping materials, the need for thinner wall pipe resulted in a new method of specifying pipe size and wall thickness. The designation known as nominal pipe size (NTS) replaced IPS, and the term schedule (SCH) was invented to specify the nominal wall thickness of pipe. Nominal pipe size (NPS) is a dimensionless designator of pipe size. It indicates standard pipe size when followed by the specific size designation number without an inch symbol. For example, NPS 2 indicates a pipe whose outside diameter is 2.375 in. The NPS 12 and smaller pipe has outside diameter greater than the size designator (say, 2, 4, 6,). However, the outside diameter of NPS 14 and larger pipe is the same as the size designator in inches. For example, NPS 14 pipe has an outside diameter equal to 14 in. The inside diameter will depend upon the pipe wall thickness specified by the schedule number. Refer to ASME B36.10M or ASME B36.19M. Refer to App. E2 or E2M. Diameter nominal (DN) is also a dimensionless designator of pipe size in the metric unit system, developed by the International Standards Organization (ISO). It indicates standard pipe size when followed by the specific size designation number.

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TABLE
Pipe Size Designators: NPS and DN NPS 1/8 1/4 3/4 1/2 3/4 1 11/4 11/2 2 21/2 3 DN 6 8 10 15 20 25 32 40 50 65 80 NPS 31/2 4 5 6 8 10 12 14 16 18 20 DN 22 100 125 150 200 250 300 350 400 450 500 NPS 550 24 26 28 30 32 34 36 38 40 42 DN 44 600 650 700 750 800 850 900 950 1000 1050 NPS 1100 48 52 56 60 64 68 72 76 80 1200 1300 1400 1500 1600 1700 1800 1900 2000 DN

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NOTES:For sizes larger than NPS 80, determine the DN equivalent by multiplying NPS size designation number by 25. Without millimeter symbol. For example, DN 50 is the equivalent designation of NPS 2. Refer to the above table for NPS and DN pipe size equivalents.

WALL THICKNESS:The wall thickness of pipe is represented by:SCHEDULE NUMBER (SCH NO/SCH) Ex;5,5S,10,10S,20,20S,40,40S,60,80,120,140,160S Stainless steel SCH no without S For carbon (alloy steel pipe) T=(PxO.D)/2ISE + PYl ' TD = t + allowances. TD=TD + 12.5%MT Where:T = Basic Thickness. P = pipe size. O.D = Outer Diameter. S = Basic Allowable Stress. E = Weld Joint Quality Factor of Pipe. Y = Co-efficient. TD = Mill Tolerance. T D = Nominal Thickness of pipe. Schedule is expressed in numbers (5, 5S, 10, 10S, 20, 20S, 30, 40, 40S, 60, 80, 80S, 100, 120, 140, 160). A schedule number indicates the approximate value of the expression 1000 P/S, where P is the service pressure and S is the allowable stress both expressed in pounds per square inch (psi). The higher the schedule number, the thicker the pipe is. The outside diameter of each pipe size is standardized. Therefore, a
14

particular nominal pipe size will have a different inside diameter depending upon the schedule number specified. Note that the original pipe wall thickness designations of STD, XS. and XXS have been retained; however, they correspond to a certain schedule number depending upon the nominal pipe size. The nominal wall thickness of NPS 10 and smaller schedule 40 pipe is same as that of STD.WT. Pipe. Also, NPS 8 and smaller schedule 80 pipes has the same wall thickness as XS pipe. The schedule numbers followed by the letter S are per ASME B36.19M, and they are primarily intended for use with stainless steel pipe. The pipe wall thickness specified by a schedule number followed by the letter S may or may not be the same as that specified by a schedule number without the letter S. Refer to ASME B36.19M and ASME B36.10M.10. 11 ASMEB36.19M does not cover all pipe sizes. Therefore, the dimensional requirements of ASME B36.10M apply to stainless steel pipe of the sizes and schedules not covered by ASMEB36.19M.

PIPE WEICHT:a) Standard weight (STD) b) Extra strong/extra heavy (XS/XH) c) Double extra strong/double extra heavy (XXS/XXH)

NOTES:Based on the pipe size, the relationship between the pipe weights & schedule no changes.

PIPE LENGTH:1) Single random length 2) Double random length 3) Customised length application. (+,-) 6m or (+,-) 20 feet (+,-) 12m or (+,-) 40 feet as per customer requirement used in pipe line

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PIPE ENDS:1. Threaded/Screw end 2. Plain end 3. Bevelled end

PIPE JOINING METHODS:1) Screw/Threaded Joining Method. 2) Socket Weld Joining Method. 3) Butt Weld Joining Methods.

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PRESSURE TEMPRATURE RATING(P-T RATING):1) 150# 2) 300# 3) 400# 4) 600# 5) 900# 6) 1500# 7) 2500#

PIPE MANUFACTURING METHODS: Seamless Electric resistance weld(ERW) Fusion butt weld(FBW) Submerged arc weld (SAW) Double Submerged arc weld (DSAW) Spiral weld (SW)

PIPE SYMBOLS: Single line Double line

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FITTINGS
Fittings are used in a piping system to add flexibility to the system. Fittings are fabricated pieces of pipe that are used to make changes of direction (elbow), branch from a main pipe (tee), or make a reduction in line size (reducer). Because fittings are the part of the piping system, they must match as closely as possible in specification and rating to the pipe to which they are being attached. Fittings like pipe, are manufactured and classified according to wall thickness. There are many more wall thicknesses of pipe however then there are thicknesses of fittings. Fittings are commercially manufactured in standard weight, extra strong schedule 160 and double extra strong In the petrochemical industry most companies have guidelines known as piping specification that state pipe 3 inches and larger will be fabricated with butt welded connections. These specification or specs, as they are more commonly called, may also require pipe smaller than 3 inches to have screwed or socket weld connections. For uniformity, the previously mentioned specification will be used throughout as a basis for determining pipe connection requirements. However, this is not to say this is the only spec that can be written. There may be cases where small bore pipe is butt welded, while larger sizes may screw or socket welded. Commonly used fittings are:1. Elbows 2. Tee 3. Reducer

ELBOW
Based on end connection elbows are of following types. Butt-welded elbow. Socket elbow. Threaded elbow.
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> > >

Available in 90& 45 elbows. Available in short radius & Long radius pattern. Available as reducing elbow.

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 90 Elbow Of all the fittings, the elbow is the most often used. Simply put the elbow or ell is used when a pipe changes direction. Elbows can turn up, turn down, turn left, and turn right or any angle in between 90 degree ells can be classified as one of the following Long radius ell Short radius ell Reducing ell Mitred ell

Of these four types, the long radius elbow is the one used most often, When determining the length of an elbow, one must established the centre to end dimension. The centre to end dimension is the measurement from the centre line of the fitting to the end of the fitting. Notice the relationship between the nominal size and the length of the fitting. The fittings length is equal to the nominal pipe size plus one half of the nominal size. Simple formula in the next column makes calculating this dimension easy to remember. The length of the fitting is equal to 1 1/2 times the nominal pipe size. Nominal pipe size * 1 1/2 = fittings length Example 8 inches *1 1/2 =12 inches Note: Use this formula for butt weld fittings only. Long radius elbow Dimensional sizes of fittings are typically provided by the manufacturer of the fittings. Manufacturers issue dimensioning charts containing lengths or a particular fitting. The dimensional charts used to establish size of fittings discussed in the text are listed on the welded fittings. As a reference portions of flanges chart are used throughout, when fittings measurements are needed. Using the welded fittings flanges chart, find the 90
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long radius elbows. The measurement represents the centre to end length of the fitting. To find the flttings lenght in inches, locate the appropriate nominal pipe size. Long radius elbow L_ Center J TO END 0.0. ._^___^RAD-= 1 1/2 X NOMINAL SIZE Figure shows centre to end dimension of a long radius elbow

Short radius elbow Another elbow that may be used under certain circumstances and with permission the customers is the 90 short radius elbows. The 90 short radius ell makes a much sharper turn than thus the long radius ell. Conversely, the short radius ell creates a rather large pressure drop inside the line and docs not have the smooth flow characteristics the long radius ell has. For these reasons the short radius ell is seldom used. A simple formula can be used to calculate the centre to end dimension of the fitting for the 90 short radius ell the length of the fitting is equal to the nominal pipe size. Nominal pipe size* 1= fittings length

21

 Mitred elbow The last 90 elbow we will mention is the inhered elbow. The mitered elbow is not an actual fitting, but instead is a manufactured turn in the piping system. This elbow is made by making angular cuts in a straight run of pipe and then welding the cuts together after they have been rolled to a different angle. The mitered elbow may be classified as one, two, three or four weld miters. The number of welds used depends on the smoothness of flow required through the turn. A two weld miter will create more turbulence with in the pipe then a four weld miter.

22

 45 Elbow Another important fitting is the 45 elbow. This elbow is also used to make changes in direction with in the piping system. The obvious difference between the 90 and 45 elbows is the angle formed by the turn. Because the 45 elbow is one-half of a 90 elbow. It is logical therefore, to assume a design using two 45 ells to make a directional change instead of two 90 elbows would result in considerable savings. These savings are not only related to the cost of the fittings but also to savings in the physical space needed to route the pipe. Two 14 inches 90 elbows require 42 inches to alter the course of a piping run. This is considerably more than 17 1/2 inches needed by two 45 elbows. Unlike the 90 ell, there is not a formula that can be applied to establish the centre to end dimension of the 45 ell. Simply dividing the length of the 90 by two will not work. The dimension of this fitting must be found on the welded fitting flange.

23

Tees are used for making 90 branch from main run of pipe..Branch size may be of same size or less than the main header size.

BUTT-WELDING TEES

24

 Drawing the weld tee Prior to drawing the weld tee, two dimensions must be found. These dimensions are required to determine the centre to end length of the header and the length of the branch end. if a straight tee is being used, the C dimension found on the welded fittings-flanges chart must be added twice to find the total length of the fitting. On straight tee, the C dimension is also used as the length of the branch end. If a reducing tee is being drawn, the M dimension must be substituted as the length of the branch end. The M dimensions found the Taylor forge, seamless welding fittings chart. STUB IN Another method of making a branch connection is called a STUB IN. the STUB IN is most commonly used as an alternative to the reducing tee. The stub in is not an actual fitting but rather a description of how the branch connection is created. A hole is bored into the header pipe, either the size of the OD r ID of the branch and the branch is then stubbed into it. The two pipes are fitted together and then welded. Although the branch connection can be the same pipe size or smaller as the header, it cannot be larger.

25

How close stub-ins is made is an important consideration a general rule is to allow a minimum of three inches between belts. This means a minimum of three inches should be allowed between the outside of branches made from a common header and the header should be attached no closer than three inches to a fitting. it provide the minimum measurements allowed between branches and fittings on an 18 header.

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 STUB IN REINFORCEMENT Even though the use of the stub in is limited by the pressure temperature and commodity with in a pipe, its use is becoming increasingly more popular .it's cheap advantage over the tee is cost. Not only can the cost of purchasing a fitting be avoided but the stub in required only one weld where as the tee required three, when internal condition such as pressure or temperature of the commodity or external forces such as vibration or pulsation are placed on stub in, special reinforcement may be necessary to prevent the branch from separating from the header. Three reinforcement alternatives are listed below:Reinforcing pad:-resembling a metal washer that has been bent to conform to the curvature of the pipe, the reinforcement pad is a ring cut from a steel plate that has a hole in the centre equal to the diameter of the branch connection. it is slipped onto the branch pipe then welded to both branch and header. Welding saddle:-a purchased reinforcing pad the welding saddle has a short neck design to give additional support to the branch. O-LETS: - purchased fittings o-lets have one end shaped to the contour of the header and the other end manufactured to accept the type of end connection being used on the branch. Weld o-lets are manufacture for butt weld fittings. Sockolets is made for socket weld fittings. And thread o-lets are available for screwed fittings. Other o-lets are manufactured to be used to make connections at angles other than 90.

27

28

COUPLING Another type of fitting used to make branch connections is the coupling used primarily for connecting small bore screwed and socket weld pipe to large bore pipe headers, the coupling is also used extensively where instrument connections are required. There are two common methods used to make branch connections with coupling:1. The coupling rests on the external surface of the pipe header and is welded from the outside. 2. A hole is bored in to the pipe header large enough to accept the OD of the coupling. The coupling is inserted into the hole and is then welded. Although this fitting is used in butt-welding applications as a branch connections, its primary use it to connect lengths of screwed and socket-weld pipe together. Some clients may stipulate, however, that all socket-weld pipe must be connected with butt-weld, rather than a coupling.

REDUCER When the piping designer wants to reduce the diameter of a straight run of pipe are reducing fitting must be used. Appropriately named, the reducer is available in two styles:> Concentric - having a common centre line
29

> Eccentric- having offset central lines The concentric reducer maintains the same centre line at both the large and small ends of the fitting. The Eccentric reducer has offset central lines that will maintain a flat side on the top or bottom of the fitting, depending on how the fitting is rolled prior to welding. The Eccentric reducer is used in pipe racks to maintain a constant bottom of pipe (BOP). Because pipe supports with in a pipe rack arc of the same elevation, a pipe must have consistent bottom of pipe elevation so it can rest on is support throughout its entire length. Using a concentric reducer in a pipe rack would not permit the small diameter and of the pipe run to rest on a pipe support. Eccentric reducers are also used on pump suction nozzle to keep entrained air from entering the pump. By keeping a flat on top (FOT) surface, vapour pockets can be eliminated. It is important that a designer not forget to include the dimensional difference between the two central lines of an eccentric reducer when calculating the elevations of pipe in a pipe rack. The formula for calculating this difference is OFFSET= (LARGE ID- SMALL ID)/2 (Where ID indicates for inner diameter.) A quicker though less accurate method, is to take one-half the difference between the two outside diameters

30

 DRAFTING SYMBOLS FOR THE CONCENTRIC AND ECCENTRIC REDUCERS The orthographic views for the concentric and eccentric reducers are shown in figure. No matter the size of the reducer, it is always drawn as a double line symbol. The call-outs that must be included with the eccentric reducer. The large end is always listed

31

first, no matter the direction of flow, and the flat side must be indicated.

WELD CAP
The last weld fitting we will discuss is the weld cap. It is used to seal an open end of pipe. When dimensioning the positional location of a weld cap on a drawing, indicate only the length of the run of pipe. The cap will be welded to the end and need not be included in the length dimension of the run of pipe. The weld cap is another fitting that is drawn as a double line symbol for all sizes of pipe. The length of the fitting is found on the Taylor forge seamless welding fitting chart. When representing the cap on a drawing, use an ellipse to construct the round end of the fitting. The weld dot on the single line symbol is drawn as a half circle only.

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 SCREWED AND SOCKET WELD FITTINGS

Screwed and socket-weld fittings perform the same basic functions as butt-weld fittings. There are, however, a few differences that must be examined. Screwed and socket-weld fittings are normally reserved for installations using fittings 3" and smaller. Screwed and socket-weld fittings are also available in cast iron, or forged steel. Cast iron and malleable iron fittings are typically used on low pressure and temperatures lines such as air, water, or condense. Lines containing high pressure and temperature commodities, which are subject to movement and vibration, require fittings made of forged steel. Forged steel screwed and socket-weld fittings are manufactured in two pressure classes- 3000# and 6000#. Dimensional charts for screwed and socket-weld. These dimensioning charts supply measurements for 3000# and 6000# fittings. Most screwed fittings are manufactured with internal, female threads per American standard and API thread guidelines. Some fittings such as plugs and swages, however, are manufactured with external threads. The socket-weld fitting is replacing the screwed fittings as the choice of many fabricators because it offers greater strength. Even through screwed fittings can be seal
33

welded if necessary, strength of the fitting is decreased when the threads are cut during the manufacturing process. Socket-weld fittings can be easily fitted and welded without the need of special clamps or tack-welds which are often required to hold a butt-weld fitting in place of final weld is made. Like butt-weld fittings, screwed and socket-weld fittings are used to make similar configurations in a piping system. Screwed and sockets weld fittings differ in size and shape, but they achieve the same purpose as the butt-weld fittings. Socket and screwed-weld fittings are drawn with square corners using short hash marks to represents the end of the fittings.

34

UNIONS
The union, is a fitting placed within a piping configuration that will allow the assembly to be disassembled for inspection, repair, or replacement. Manufactured for screwed and socket-weld applications, the union is represented on drawings. Unions should be positioned in locations that will facilitate the easy removal of critical pieces of equipment.

35

PLUG
The plug, like a cap, is designed to close off the end of a run of pipe. Plugs are manufactured for screwed fittings with male threads and are screwed into the end of a pipe to create a seal.

PIPE NIPPLES
3y design, screwed and socket-weld fittings cannot be assembled by placing one fittingdirectly in contact with another fitting. Screwed fittings are manufactured with threads on the inside of the fittings, and socket-weld fittings have an internal socket that prevents fitting makeup- assembly. To facilitate the assembly of screwed and socked-weld fittings, small lengths of pipe nipples are used between fittings. Pipe nipples can vary in lengths depending upon the distance required to fabricate the pipe configuration. A close nipple is one of that provides the minimum length of pipe between fittings. Remember, screwed and socket-weld fittings have certain amount of lost pipe due to thread engagement and socket-depth. Therefore, each size pipe has a different minimum length for the direction of a close nipple.

36

Many companies will use 3" as the standard minimum pipe nipples. This length will accommodate the amount of pipe lost inside the fittings on each end as well as provide sufficient wrench clearance during assembly for the larger screwed and socket-weld pipe sizes.

Figure shows different type of swages Swages are unique in that they can be used in screwed, socket-weld, or butt-weld configurations. When used in these configurations, swages will have different end preparations. Screwed swages will have thread ends (TE), socket-weld swages plain ends (PE), and butt-weld swages have beveled ends (BE). Because socket weld swages are inserted into mating fittin, many companies allow the substitution of beveled and swages.

USE OF FITTINGS
Thus far, we have discussed each fitting individually. We will now look at each fitting relates to other fittings when used in the design of various piping systems.

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Depending on the given situation, fittings will either be welded to each other or separated by lengths of pipe. Welding one fitting directly to another is called fitting make-up. Most situations involving the erection of the piping system require the designer to use pipe of various length between the fittings. In these cases, pipe is cut to the required length and the ends are beveled in preparation for welding to the fittings. When fittings are not assembled as fitting make-up and are separated by a piece of pipe, most companies stipulate the pipe must be at least one pipe diameter(nominal size) in length with a three inches minimum spacing for pipe six inches and smaller. By maintaining this minimum spacing between welds, a pipe can conveniently be cut, beveled and welded without interference. The three inches minimum spacing is a standard used throughout the piping industry. Welds may be seem insignificant to the designer, but, it goes without saying, a piping facility could not be built without them. Use weld dots on single line pipe symbols and weld lines on double line pipe symbols.

FLANGES
Flange is a ring-shaped designed to be used as an alternating to welding or threading various piping system used throughout the piping system. Flanged connection are used as alternating to welding because they can easily be disassembled for shipping, inspection, maintenance, or replacement. Flanged connection is preferred over threaded connection because threading large bore pipe is not an economical or reliable operation. The flange is an important component of any piping system. Flanges are primarily used where connecting or dismantling is needed. Flanges are used to connect Pipe to pipe, which require frequent dismantling. Pipe to equipment. Pipe to valves.

The design standard for Flanges is ASME B 16.20->for metallic gasket The design
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standard for Flanges is ASME B 16.21 ->for non-metallic gasket

Classification Based on P-T ratings flanges as 150# 300#400#600# 900# 1500# 2500# ** Based on attachment flanges are classified as i. ii. iii. iv. v. vi. vii. Slip-on Socket weld. Screwed. Weld Neck Reducing Lap joint. Blind

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Flange is attached by welding inside as well as outside. Pipe is set back 1/16 "from the face of flange. Internal weld is subjected to corrosion, hence not preferred for corrosive service. Poor resistant to shock & vibration. Cheaper to buy but costlier to assemble. Easier to align. The strength is about 1/3 that of the corresponding weld neck flange.

2) SOCKET WELD FLANGE:-

Socket weld flange

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Welded only on one side, hence not recommended for severe service Used only for small bore pipes Not recommended for service above 250C & below -45C

3) SCREW FLANGE: Used to connect screwed pipe to flanged items. Used only for small bore pipes Not recommended for service above 250C & below -45C Used where welding cannot be used for hazardous reasons.

4) WELD NECK FLANGE: Flanges are attached by butt-welding to pipes. Suitable where extreme temperature, shear, impact & vibratory stress apply. Welding can be radia-graphed. Costly.

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5) REDUCING FLANGE: Used to connect bigger pipe to smaller pipes. Available in slip-on or weld neck type. Should not be used if abrupt transition would create undesirable turbulence. Specified by the line size of smaller pipe & OD of the flange to be mated.

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6) LAP JOINT FLANGE: It is used to connect pipe of costlier material like stainless steel. This is used along with stub-end. Material of stub-end will be as pipe & flange will be of cheaper material like carbon steel. Stub-end will be butt welded to the pipe & flange is kept loose over it. It is also useful where alignment of bolt is difficult.

7) BLIND FLANGE: Generally used to close the pipe end which needs to be reopened later. Its

function is similar to a cap or a plug.

CLASSIFICATION OF FLANGE FACE:i. Flat face. (FF) ii. Raised face. (RF) iii. Ring Type Joint. (RTJ) iv. Tongue & groove Joints,

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v. Male/female Joints.

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VALVES
A valve is a device that regulates the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a direction from higher pressure to lower pressure. The industries in which the majority of valves are used are oil and gas, power generation, mining, water reticulation, sewerage and chemical manufacturing. Valves may be operated manually, either by a hand wheel, lever or pedal. Valves may also be automatic, driven by changes in pressure, temperature, or flow. These changes may act upon a diaphragm or a piston which in turn activates the valve, examples of this type of valve found commonly are safety valves fitted to hot water systems or boilers. By definition a valve is a device that controls the flow of the fluid. But today valves can control not only the flow, but also the rate .the volume, the pressure & direction of fluid within a pipe. Valves are not limited to fluid .they can control the liquid, gases, vapors, slurries or dry materials. Valves can turn on or off, regulate, modulate or isolate. They can range in size from a fraction of an inch to as large as 30 feet in diameter & can vary in complexity from a simple brass valve, available at the local hardware store, to a precision designed, highly sophisticated coolant system control valve made of exotic metal alloy used in nuclear reactor. They can handle temperature from cryogenic region to molten metal exceeding 1500F and valves can contain pressure ranging from severe vacuum to 20,000 pounds per square inch. Valves are manufacture in numerous sizes, body style, and pound rating to meet a wide variety of application needs. Valves end preparations can be screwed, socket-weld, beveled or flanged. Flanged valves are manufactured to either raised, flat or ring-type joint faces.

VALVES PARTS
1) BODY:-It is pressure containing part of the valve & the p-t rating of the valve decided based on the valve body.

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2) BONNET:-it is the cover for opening the valve body & it is accruable in different types a) bolted bonnet b) welded bonnet c) screwed bonnet 3) STEM:-it is part which make valve open or closed, when hand wheel rotated 4) DISC:-Connected to either permanently or temporally 5) SEAT:-It is the part of the valve on which disc sits it helps in sealing of the opening CLASSIFICATION OF VALVES BASED ON FUNCTION 1) ISOLATION OR ON/OFF 2) THROTTLING OR CONTROLLING OR REGULATING 3) CONTROLLING DIRECTION OF FLOW 4) SPECIAL PURPOSE VALVE 1) ISOLATION VALVE:It is used to stop the fluid flow in the line, so it can be used in completely open position or completely closed position 2) THROTTLING VALVE:The fluid drawing is always from one side only. CLASSIFICATION OF VALVES BASED ON P-T RATING 1) 150# 2) 300# 3) 400#
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4) 600# 5) 900# 6) 1500# 7) 2500# 8) 800# CLASSIFICATION OF VALVES BASED ON CONNECTION 1) FLANGED VALVES 2) BUTT WELD VALVES 3) SOCKET WELD VALVES 4) THREADED VALVES 5) WAFER TYPE VALVES COMMON VALVE TYPES GATE VALVES:It is most commonly used isolation valve in process piping. It is general service valve that is used primarily for on-off Non-throttling application. When fully opened, the gate valve creates minimal obstruction to the flow. Gates valve control the commodity through the pipe with a flat, vertical wedge that slips or down as the hand wheel is turned or hand wheel is rotated, the wedge will slide through the valve body to block or release the flow.

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GLOBE VALVES:it is most common used throttling valve in process piping. Simply rotating the hand whee the rate at which the commodity flows through the valve can be adjusted to any
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desired leve Having the valve seat parallel to the line of flow is an important feature of globe valve th feature makes the globe efficient when throttling as well as yielding minimal disc & se erosion. The design of the globe valve body forces the flow of the commodity to change direction within the valve itself. This change in direction creates substantial pressure drop & turbulence therefore not recommended when flow resistance & pressure are to be avoided. Drawing symbol is similar to those of gate valve.

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CHECK VALVE/ NON RETURN VALVE:It is used to control the flow control of fluid. It is self operated valve by the force of the luid .check valve differ significantly from gate & globe valves. Check valves are designed to prevent backtlow. Backtlow means flow that has reversed itself within a pipe & begin to flow backwards. The two most common types are swing & lift check valves. Check valves do not use hand wheels to control the flow of fluid.

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BALL VALVE: Ball valve is an isolation valve but in some case it can be used as a regulation valve. It is designed to operate fully open or fully closed. Ball valve is quarter turn valve hence it can be quickly opened or closed. It is suitable for gas, compressed air & slurry services. Quick opening / closing causes fluid hammering. Pressure drop is less.

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PLUG VALVE:It is used for insulating purpose for process piping. It uses either a hand wheel or wrench to operate the valve. Plug valves provide a tight seal against hard to hold commodities & requires a minimum amount of space for installation. Plug valves are designed with etched grooves along the tapered plug to permit a lubricant to seal & lubricate internal surfaces as well as to provide a hydra ling jacking force to lift the plug within the body, thus easy operation.

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BUTTERFLY VALVE:Butterfly valve has a unique body style. Butterfly uses a circular plate or wafer operated by a wrench to control flow. Used for both isolation & throttling purpose for low pressure lines. Butterfly valves have minimal turbulence & pressure drop, they are good for on off & throttling service & perform well when controlling large flow amounts of liquids & gases. However these valve do not normally create a tight seal & must be used in low pressure situation or where some leakage is permissible.

DIAPHRAGM VALVE: Mainly an isolation valve but cat can be used for regulation also. Mainly used for low pressure corrosive fluid or where high degree of purity is requires e.g.. Pharmaceutical & food processing industries. Diaphragm moves ups & down to operate the valve. Body & bonnet is made of casting. Body is lined with corrosive resistant materials. Diaphragm is generally made of rubber or PTFE.

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There is no API or ANSI standard available for this valve. these are covered by British standards & MSS-SP standards.

NEEDLE VALVE: It is a type of globe valve. Only the wedge in the shape of needle. Used for the precise flow of fluid. Generally used for instrument, gauge & meter line service.

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PISTON VALVE:It is used for both isolation & throttling in process piping & are similar in construction tc globe valve. It uses a piston instead of disc specially used in steam services. RELIEF VALVE/ SAFETY VALVE:It is used to remove extra pressure , either from a line or from an equipment. They a installed at the top of piping or equipment. Slope is given in system to remove from water collect it in knock out drum. Relief valves use a steel as a means to automatically open when pressure reach unsafe levels.

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CONTROL VALVE:It is a regulating valve which is operated automatically either by means of pneumatic connection or by electric, hydraulic connection. The control valve assembly should be placed either on the ground or on the equipment
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platform, so that axis can be provided to the platform. The control should be provided at a height not more than 2 feet from the ground.

SPECIAL PURPPOSE VALVE:The valve which is used for purpose other than two, isolation & control valve are called special purpose valves. Special purpose valves are classifieds are as follows:1) Flush buttom tank valve
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2) Foot valve 3) Float valves 4) Multiport valve GASKET Gaskets are used to provide fluid resistant seal between the flanges. It can be metallic or non metallic type. Metallic gasket is referred to ASME B 16.20 & non -metallic gasket is referred to 16.21. Gaskets are commonly produced by cutting from sheet materials, such as gasket paper, rubber, silicone, metal, cork, felt, neoprene, nitrile rubber, fiberglass, or a plastic polymer. Metallic gasket is further categorized as Spiral wound, corrugated metallic & ring type joint. Selection of Gasket depends on following factor: P-T rating of the fluid service. Corrosive nature of the fluid service. Code requirement. Cost

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1) Full face gasket 2) I.B.C gasket (inside bolt circle) or ring type BOLTS & NUTS The bolt holes are provided in multiple of four i.e. 4, 8,12,16. The number of bolt holes depends upon the size of the pipe & the rating of the flange & it is given by code Angular location of bolt holes=360/ no. of holes Two types of bolt are generally used in the industry Machine bolts Stud bolts

NOTES:> Design standard for bolt & nut is ASME B 16.5. > For low P-T machine bolt is preferred otherwise studs. > Bolts are provided with hexagonal head, hexagonal nuts & washer.

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SPECIAL ITEMS Strainers Strainers are used in a piping system to protect the equipment sensitive to dirt or other solid particle that may be carried by fluids. During start-up, temporary strainers are placed upstream of pumps to protect from construction debris, which may be left over during construction these are called Start-up /Temporary strainers. onical start-up temporary strainer Permanent strainers are installed upstream of control valves, stream trap & instrument to protect it from solid particle. There are two type of permanent strainer. Y- Type strainer. Basket strainer. Y-TypeStrainer

Strainer ^^^;:l\:'l:".V:j-r:yV/ Y-Type strainer

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An expansion bellows is a device used to allow movement in a piping system while containing pressure & the medium running through it. The Bellows are generally employed in a piping system in one of the following situations:-

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> When the space constraints do not permit providing adequate flexibility by conventional methods (e. g. expansion loops etc.) for maintaining the system stresses within acceptable limits. > When conventional solutions (e.g. expansion loops etc.) create unacceptable process conditions (e.g. excessive pressure drop). > When it is not practical to limit the piping induced loads on the terminal nozzles of the connected equipment within admissible limits by conventional methods. > When the equipment such as Compressors, Turbines, Pumps etc. necessitate isolating the mechanical vibrations from being transmitted to the connected piping. INSTRUMENTS FLOW DIAGRAM INSTRUMENTS

Instruments function by sensing changes in the variables they monitor. The four basic instrument groups are: Flow (F) Level (L) Pressure (P) Temperature (T)

The types of instruments used to sense, control and monitor these variables are: Controller (C) Indicator (I) Gauge (G) Alarm (A) Recorder (R)
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To indicate a change or to control the flow, level, pressure, or temperature, an instrument must first sense a change in the variable. Once a change has been detected, the instrument then transmits this information via mechanical, electronic, or pneumatic means to a control panel where it can be observed and recorded. At the same time, the instrument may activate other devices to affect and change process conditions in the facility. Some instruments are read in the plant at the instrument's actual location. Others are displayed on a control panel located in an operator's control room. INSTRUMENT TYPE GAUGES

Gauges are instruments that measure the liquid level inside a vessel or the temperature and/or pressure in the piping system. Level, temperature, or pressure gauges are locally mounted to enable plant operators to obtain a visual reading.

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FLOW DIAGRAM In a piping, flow diagram is use for laying out the pipes. FLOW DIAGRAM INSTRUMENT CONNECTION SYMBOLS INSTRUMENT AIR LINE INSTRUMENT ELECTRICAL INSTRUMENT CAPILLARY TUBING FLOW DIAGRAM ABBREVIATIONS CSO - CAR SEAL OPEN CSC - CAR SEAL CLOSED DF - DRAIN FUNNEL LC - LOCK CLOSED LO - LOCK OPEN NC - NORMALLY CLOSED NO - NORMALLY OPEN PO - PUMP OUT SC - SAMPLE CONNECTION SO - STEAM OUT

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CLASSIFICATIONS 1) Block Flow Diagram (BFD) 2) Process Flow Diagram (PFD) 3) Mechanical Flow Diagram (MFD) / Piping and Instrumentation Diagram (P&1D) 4) Utility Flow Diagram (UFD) / Utility Distribution Diagram (UDD) (1) BLOCK FLOW DIAGRAM (BFD)

It is the lsl type of flow diagram which shows the flow between units or blocks in a plant. (2) PROCESS FLOW DIAGRAM (PFD)

It is schematic drawing which shows the following:(A) Major Equipment of the Plant (B) Main Piping (C) Flow Direction (D) Major Instrument (E) (3) Design Conditions PIPING & INSTRUMENTATION DIAGRAM (P & ID)

It is a schematic drawing which shows elevation view of the equipment. It consists of following details(1) All the equipments required for the plant. (2) All the piping required for the plant. (3) All the components required in the piping and for the equipments.

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(4) All the instruments required for the piping and equipments. (5) Special elements required for the piping direction of flow of fluid. (6) Tag number of all the equipments either at the top of the drawing or within the equipments. (7) The line number for all the lines in the P & ID. NOTE:> Nozzle number on the P & ID may or may not be provided .get it from Equipment vender data or equipment process data sheet > Nozzle sizes and the line sizes may or may not be same > For matching the nozzle number in P & ID with the equipments vendor data (A) Compare the flow direction of fluid (B) Compare the service for which a nozzle is used (C) The details of the instrument or the P& ID are provided in instrument. Vendor data or instrument hook-up drawing. If there is a mismatch between the information on the vendor data and P & ID. then it has to be classified to the client by a TQ (technical query). r The changes made in the drawing are indicate on the drawing along with their revision number. > If two nozzles on the equipment are shown one below other in the P&ID it means that they can be either one below the other or at the same elevation from the ground, which can be classified by seeing the nozzle schedule of that equipment.

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The above P&ID diagram shows following information: Size of the reducer in line 01-8-c30-6U is 8(1*6 & 01-7-C30-4D is 8fJx4D. The size control valve in a line 01-7-c30-4 is 3 . C30 denotes material specification on this P&ID. The size of drain valve in line 01-7-c30-4D for horizontal vessel is 3/4D &2D. 3 control valve and man hole on this P&ID. r- Size of drain line on the line 01-2-c30-l0: IH is 3/4 . Size of pump suction is 8D and discharge nozzle is 4(71. PCV (pressure control valve), LCV (low control valve), FCV (flow control valve) are used in this P&ID. Size of the valve in the vent line of the vessel V101 is 2D & for vessel V102islD. There are 36 trays used in vessel VIOL 2 pressure safety valve of 43x8D are used in this P&ID. Size of bi-pass control valve in the control valve assembly is 3D. There are 16 number of lines used in this P&ID. y Size of drain line of the pump is 1/21D.

LINE NUMBER ON P&ID

Stepl- Main line based on the flow direction. Step3- Branch of main line based on flow direction. Step5- Sub branch of main line based on flow direction. NOTES(1) - The sizes of the instruments, should be taken from instrument Vendor data, if given on P&ID ignore them.
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(2)-The sequence of the components in a line from its start point to end should

point

be as per the P&ID only. But the pressure indicator and temperature indicator, location can be interchange to the line. (3)-The lines are numbered on the P&ID starting with the main line first based on the flow direction then the branch line, and then the sub branch line.

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LINE NUMBER PATTERN ON P&ID

Size

Service

Area/code

Line number

Material specification

Insulation/tracing

INSULATION (1) (2) (3)

Hot insulation (IH or H) Cold insulation (IC or C) Personal protection (PP-always 25 mm)

TRACER/TRACING Tracer is provided on the process line by means of small auxiliary lines up to l'/2",to supply heat to the process line and it can be either 1 or 2 or 3 in numbers which are tied up to the main line , either by means of wires and foils. LINE LIST It consists of the details of all the lines in an area or in a plant in the following manners: It is used as a reference at every stage of the project to the work on the

line. While making the line list consider the outgoing lines to include them in the line list, then consider the line coming or going to other areas or unit from or to our area. The from column of line list may contain either the equipment number or the lint number or the PSV number from which the line starts and same is the two columns of lines. Design Conditions:Design pressure = maxD operating pressure (p) + 10% (P)

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Or = max LI operating pressure (p) + 25 PSI Design Temperature = MaxD operating temperature (T) + 25 VENDOR DATA OR PROCESS DATA SHEET Vendor diagram or process data sheet provided in the P&ID for following details: Nozzle schedule of equipments. Dimension of equipments. Location of equipments.

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PIPING MATERIAL SPECIFICATIONS It provides details for design for fabrication & construction of piping system. (1) It is used by piping draftsman to find what dimensions they must allow for the piping component in the piping layout & to make the MTO (material take-off) to order proper material. (2) It is used by shop fabricator to select proper material. (3) It is used by instrument to select proper material & flange rating for the instrument. (4) It is used by the stress analysis group to establish rating of piping system. (5) It is used by purchasing & the project department to specify proper material. IT CONSISTS OF THE FOLLOWING DETAILS:(1) Services(fluids) for which it is used, (2) MOC (material of construction) of the piping components. (3) Corrosion allowance if present. (4) Design condition. (5) The details of the all piping component used in that piping material specification. (6) The details consist of information in the form of a table, starting with size range material specification (ASTM), end type of the component, thickness, class of the component reference dimensional standard, remarks if any.

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EQUIPMENT LAYOUT/ UNIT PLOT PLAN This drawing consists of equipment plan & sectional view at different elevation. It is also called as UNIT PLOT PLAN. This drawing consists of location of equipment in a plant. It is basically divided into two configurations: 1. Arrangement of equipments for an outdoor plant, which involves locating all the equipments at the grade level on either side of a pipe rack in a rectangular area. 2. Arrangement of equipments for an indoor plant, which involves locating the equipments in concrete or steel structure building one above the other at different elevations. The equipment layouts of either type should follow certain basic principles while locating the equipments. (1) Economic piping: To minimize the cost of piping; equipment should be located in process sequence and close enough to suit safety needs, access requirements and flexibility. (2) Process requirements: The equipment layout should support requirements such as minimum Pressure drop, gravity feed and loop. The piping engineer should discuss such requirements with process engineer before proceeding with the arrangement. (3) Underground Facilities: Piping Engineer should investigate the facilities such as storm water drain, effluent drain fire water, cooling water to be placed underground before deciding the equipment position. (4) Climatic conditions: Weather conditions influences the type of enclosures and the location of equipment. Wind influences the location of furnaces, cooling towers and stacks.

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PIPING GENERAL ARRANGEMENT DRAWING (PIPNG GA) It is a drawing of equipments, piping & the entire piping component. Reference drawing required for making the PIPING GA drawing are as follows:> P&ID > EQUIPMENT LAYOUT r PLOT PLAN Line list

> PDS or equipment vendor data > > Piping material spccification(PMS)

GUIDELINES FOR PREPARING THE PIPING GENERAL ARRANGEMENT (G.A) (1) Process equipment & piping have priority on the piping G.A. the piping drawings are started after fixing the position of the equipment. (2) Equipment layout is reproducing on the piping G.A to its scale and drawn on reverse side in case of manual drawing & in case of CAD drawing separate layer is used to draw the equipment layout. (3) Related background details which govern by pipe rooting such as drain line or floor drains, HVAC ducts, electrical & instrument cable tray are also drawn in different layer in CAD drawing or on the reverse side on manual drawing. (4) Utilities sections location is also established so that the most conveniently utility heade--can be carried out. (5) The piping drawing should be developing in such a way that the process requirements are satisfied. (6) Performance & economics have to be considering in parallel while during the

pipe rooting. (7) Piping is represented by single line up to the size of 150 NB (6D) & double line for sizes 200 NB& above on the piping G.A.
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(8)

In single line representation only the centre line of the piping is drown using solid line & in double line actual size of the pipe is drawn & centre line of it is mark with the dotted line.

(9)

Line numbers are shown against each line exactly in the same way as represented in the P&ID.

(10)

The change in the specification in the line should be shown considering the P&ID .The specification change is indicated immediately to the downstream of either the wall or the flange or the equipment.

(11) (12)

Valves should be drawn to scale with their identification number as per P&ID. Draw valves hand wheels to steam fully extended & if it is lever operated then the movement in the handling position should he mark on the drawing.

(13) floor. (14)

If a valve is chain operated note the distance of the chain from the operating

Show location of each instrument connection with in circled instrument no taken from the P&ID.

(15)

Draw the plan views of each floor of the flange & these views should indicate how the layout will look between the floor when seems from top.

(16)

Each line should be identified by the line number& should also show the insulation and tracing requirement of the line if required.

(17)

Lines if required shall be broken to show the required details of the header line without drawing other views.

(18) (19)

Do not draw detail that can be covered by a note (or) callout on the drawing. Draw plan view to a layer scale for any part of the drawing needing more details & identified that part as details A, or detail B, or detail.

(20)

Draw isometric sketches of the parts or elevation sketches to clarify

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complicated piping or piping which is hidden in the plan view. (21) Sections of the plan views are identified by numbers such as 1-1 or 2-2, or 3-3, or & details by alphabets such as details A, details B etc. (22) Full section through the complete G.A drawing may be avoided. If isometric drawing are used & whose details can be shown by using part section drawings. GENERAL ARRANGEPMENT (GA) DRAWING PROCEDURE Draw the areas limits or the battery limit or match line using the control point reference. (1) Fill the title block information. (2) Place the north arrow on the upper right hand corner of the drawing. (3) Locate foundation of pipe racks columns, mechanical equipments from the coordinates used to developed foundation location drawing and provide dimensions as per the equipment foundation drawing. (4) Draw the equipment foundation and pipe rack column and give the number to column (grid no). (5) Draw the equipment and represented the equipment centre line & outlines. (6) Draw the piping connecting the equipment and include all the piping components in the piping along with the instrument. (7) Show the nozzle SCH for each equipment on the right side of the drawing sheet. (8) Add platforms, ladders, cages, pipe support for the lines. (9) Include the line numbers are shown in the P&ID for each line. (10) Place the locating dimensions for all the pipes with respect to equipment or grid column. (11) Show callout for elevation of the piping either by using centre line or bottom line
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of pipe abbreviations. (12) Include the notes on the right side of the drawing. (13) Include the reference drawing used below the notes.

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ISOMETRICS/PIPING ISOMETRICS It is the 3-dimensional line drawn on a 2-dimensional space. It shows the height, width& length dimensions. It is drawn for each line in the plant which is consists of only lines. Equipment are not required to be shown in the isometric drowns except nozzle of the equipments. Isometrics are drawn single line irrespective of the line size. This is not drawn to scale, but drawn proportionately. This drawing is drawn for the piping general arrangement drawing. The north arrow is placed at a 30 to the horizontal line.

READING ISOMETRIC SKETCHES To understand an isometric sketch of a piping system it might start by trying to visualize the inside of a room in which the pies are located. Try to look into this room. The room is drawn in thin lines; the pipe layout is in dark Object lines.

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The isometric sketch is reduced to Merely the pipe diagram itself.

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Here is an example of another isometric pipe diagram with 90'fittings. To compare orthographic and isometric drawings, look at the sketches in Figure Sketch A is an isometric sketch of the PLAN and ELEVATIONS in Sketch B.A remember point is that in an isometric sketch vertical lines are shown in a vertical position, and horizontal lines are drawn at an angle of 30 to an imaginary horizontal line. An isometric drawing is three dimensional and is more picture-like than an orthographic drawing.

Dimensioning isometrics Length dimension and informational notes and callouts are used on isometrics to define the pipes exact routing in a plant or facility. Placement of dimension on the drawing establishes precise length between fitting, valves, equipment connection etc. Information such as co-ordinates, elevations, nozzle projection, pipe size and rating are used to calculate the pipe line in isometrics. Dimensions arc providcd:(1) Centre to eentre of fittings (2) Centre of fittings to face of flange.

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OFFSETS An Offset is a piping arrangement that includes two parallel pipes and two fittings of the same angle. An Offset permits a pipeline to move off course (around and obstruction such as a bema or a joist). SIMPLE OFFSETS

A simple offset is an offset which has two parallel pipes and two angles of the same degree on the same plane.

The centrelines of pipes A and B are parallel. The angles of the offset are both 45 1/4. Run, Set, and Travel All offsets are calculated on the basis of the RIGHT triangle. The three sides of the triangle have designated pipe fitting names; the hypotenuse is called the TRAVEL. The other two sides are called the SET and RUN.

In pipe fitting terms, this is what these names represent: SET refers to the distance between the centrelines of the two parallel pipes.These pipes arc always a set distance apart.

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Offsets are referred to by the angle of the fittings used to connect the pipes. An offset can range from an 1 1/2 offset to a 90offset. In an isometric drawing of an offset, the offset is usually represented within an imaginary box which shows the set and the run distances.

^v On a drawing of an offset, usually only one side of the offset triangle is dimensioned and the two fitting angles are identified. The pipe fitter must be able to calculate the other sides of the offset triangle in order to fabricate the offset in the field. Since all offsets are based on the concept of the right triangle and since at least one angle and one side has a known dimension, it is possible to calculate the other dimensions using either the principles of trigonometry or simple offset Table of Multipliers for Calculating Simple Offsets. > Calculation of Simple Offset Dimensions:This manual provides with two ways to calculate the important dimensions of an
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offset. Obviously the easiest method is the one which permits to look up all the information we need. This is possible by using Smoley's Table of Multipliers for Calculating Simple Offsets. If this table is not available to, we can always '"resort", to trigonometry tables to find the dimensions to check the calculations. * Trigonometry Method Calculating the distances of an offset involves trigonometry functions. The TRAVEL is the same as the HYPOTENUSE; the SET and RUN correspond to the other two sides of a right triangle. SINE of an angle =SIDE OPPOSITE/HYPOTENUSE. COSINE of an angle =SIDE ADJACENT/HYPOTENUSE. TANGENT of an angle =SIDE OPPOSITE/SIDE ADJACENT. For calculating an offset, a fitting angle is known. Therefore, knowing the dimension of one side, and find out the other side.

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PIPE SUPPORTS > Purpose of Pipe Support Supports are implied for following purposes: To support the weight of pipe & components during operation & testing. To take the load due to thermal expansion. To absorb vibration in the piping system. To take the hydraulic thrust in piping. To support the system during shut down condition. To support the system during maintenance. To take earthquake load. To take wind load. > Classification of Pipe Support Primary Support:-This is directly attached to the pipe. Secondary Support:- This is directly attached to the structure or foundation to support the primary support. Primary support can be of following types:Rest support

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This is most commonly used support meant for supporting only the pipe weight vertically. It allows pipe to move in axial as well as transverse direction but restricts only the vertical downward movement. Pipe simply rest on the structure. shoe weld support This is generally used to support insulated lines, which cannot be directly supported on steel structure. Usually 1- beam cut into two half is used as a shoe. Shoe height depends upon the insulation thickness. It allows pipe to move in axial as well as transverse direction but restricts only the vertical downward movement. Shoe is directly welded to the pipe.

This type of support is used to restrict the movement of pipe in transverse direction i.e. perpendicular to length of pipe but allow movement in longitudinal direction. This is also a commonly used type of support. Anchor support This type of support is used to restrict movements in all three directions.

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Saddle type is used to support bigger insulated pipes 10.. & above. It is used as a guide support. > Trunion support Trunion support In this type of support a dummy pipe piece is welded directly to the main pipe & other end is suitably supported on the secondary support. Trunion can be either in horizontal or vertical as per the requirement. Spring support Some time support point may move up or down due to thermal expansion or vibration in the system. The system employs a spring elements, which can get compressed or released depending upon the load exerted on it. Spring support can either be resting or hanger type.

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 Hanger support As the name suggest in hanger support pipe is hung from the overhead structure using the hanger rod.

APPLICATIONS COLLIERIES AND MINES Coal washing plants and reduction works, drainage, effluent and slurry pipelines. SUGAR INDUSTRY Acids, ammonia, brine, carbon dioxide, sugar solutions, syrups, molasses, water and effluent pipelines, tanks, spray irrigation. CHEMICAL WORKS Acids, alkalis, gases, solutions, water and effluent pipelines. STEEL

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FACTORIES Pickling and etching lines, acids, water, effluent, slurry pipelines and vessels. NUCLEAR POWER PLANTS AND POWER STATIONS Water, chemicals and safe radioactive drainage, sea water, effluent pipelines. PAPER BOARD MILLS Alum, bleach, caustic soda, pulp stock, water pipelines and vessels. COKE OVEN PLANTS, COAL GAS WORKS Acids, ammonium sulphate, Ammonia by-products, slurry and drainage pipelines and tanks. AIRCRAFT AND AUTOMOBILE INDUSTRIES, PLATING SHOPS Planting solutions, fume removal ductwork, pickling and etching plants, water, drainage and effluent pipelines and vessels. BREWERIES, DISTILLERS, SOFT DRINKS FACTORIES Alcohol, beer, brine, caustic soda, carbon dioxide, spirits, de-mineralised water, bottling, pipelines and tanks. OIL REFINERIES Air, water, acids, and alkali pipelines. RAILWAYS Air, water lines, carriage cleaning lines. HOSPITALS Laboratory drainage, storage tanks and pipelines. SEWAGE WORKS Compressed air lines for activated sludge.

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WATER WORKS AND WATER TREATMENT PLANTS Chemicals and dosage lines, compressed air pipelines. SALT MINES Brine and water pipelines. TEXTILE AND SYNTHETIC FIBRES, LEATHER TANNING Acids, alkalis, bleach peroxide, acetic acid, dye liquors, sulphide, water, hot effluent pipelines. ADVANTAGES High impact strength High resistance against corrosion-internal and external High chemical resistance Toughness Flexibility Ease of handling and laying Can be made in long lengths Excellent resistance against abrasion Weather resistance Expected life of 50 years or more Smooth surface with low friction losses, i.e. hydraulic smooth C-value (Hazen Williams) = 150-165, K-value (Prandtl - Coal brook) = 0.007mm Very low water absorption Suitable for high temperature application (PP)

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CHALLENGES OF PIPING Corrosion Prevention Pipeline Maintenance Leak detection for long distance pipelines Pipe Coating Concrete Coating Blending Welding Deep Water Services Pipeline Cleaning & Operating Efficiency

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