4lesson (Vessel Orientation)

PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 1 of 79 15/11/2002 Rev. 0 4. VESSEL ORIENTATION 4.
1 PREFACE
This lesson will cover the procedures required for vessel equipment studies, both horizontal and vertical vessels and the piping connected to them. Two things to keep in mind; first, use Fluor's standards as a guide, and second, the guidelines mentioned in this lesson may be different than jobs you may have worked on in the past. Some clients have their own engineering standards. 4.1.1 Lesson Objectives
Lessons provide self-directed piping layout training to designers who have basic piping design skills. Training material can be applied to manual or electronic applications. Lesson objectives are: To familiarize yourself with the more commonly used vessels, how they operate and some of their uses. To know the vessel types. To know how to assimilate the information and the miscellaneous components to determine a vessel orientation study. To make both vertical and horizontal vessel studies avoiding major mistakes and costly changes. To familiarize yourself with Fluor's standards on vessels and their components. (Fluor's standards are a guide; the standards used on your contract may differ). 4.1.2 Lesson Study Plan
Take the time to familiarize yourself with the lesson sections. Part of your training will be to complete the study exercise in the back of the lesson plan. The exercise may be done manually or electronically. The following information will be required to support your self study: Previous lesson plans; e.g. Pipe Stress Lesson #1 Fluor Technical Practices The following Fluor Technical practices are included in this lesson guide: 000.250.2650, Vessel Layout & Orientation - Piping 000.250.2152, Dummy Supports & Support Trunnions Trays 000.250.2651, Vessel Layout & Orientation -Trays It should take you approximately 60 hours to read this lesson plan, complete the exercise and be prepared to take the lesson test. If you have layout questions concerning this lesson your immediate supervisor is available to assist you. If you have general questions about the lesson contact Piping staff group.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 2 of 79 15/11/2002 Rev. 0
4.1.3
Study Aid
Videos on Process Plant Layout & Piping Design (SPED) supplement your layout training. It is suggested that you view these videos prior to starting the layout training. You may check-out a copy of the videos from the Knowledge Centre (Library). Proficiency Testing
4.1.4 4.2
There is a self test and a test grading master at the end of this lesson which allows the designer to evaluate their comprehension of this lesson. Questions are manual fill-in and True or False You may use material from previous layout training lessons during the testing. DEFINITION
Vessels are the heart, or main piece, of a refinery or chemical plant. Things happen inside vessels. In reactors, a chemical change is taking place. In fractionating towers or column, a separation is occurring. The vessel orientation, or location of nozzles on the shell, is critical to every piping layout. While orienting a vessel, the competent piping designer will call upon his past experience and his good judgment. 4.3 GENERAL VESSEL NOMENCLATURE
Process Vessel: A container for handling or chemically changing liquids and gases within a process system. Storage Vessel and Storage Tank: A container for storing liquids or gases prior to or following the process system. Vertical Vessel: A vessel whose longitudinal axis is in the vertical position. Horizontal Vessel: A vessel whose longitudinal axis is in the horizontal position. 4.3.1 TYPES OF PROCESS VESSELS
Fractionation Column: A vertical vessel containing trays or packing, which extracts from the process stream a certain required fraction such as butane or propane. Reflux Accumulator: Generally a horizontal vessel, without internal parts, which collects the liquid reflux and recycles a small portion back to the fractionation top tray. Reactor: A vertical vessel containing catalyst, which rearranges the molecular structure, and therefore changes the fractions in a process. Regenerator: A vertical vessel containing used catalyst (from a reactor) which regenerates (restores) the catalyst for re-use in the reactor.
4.3.2
TYPES OF STORAGE VESSELS
Spheres: A spherical shaped vessel, supported by a series of legs around its equator, which contains pressurized gases, or liquid and gas. Spheroid: Shape resembles a drop of mercury resting on a flat surface, and has special type supports. Used to contain pressurized liquids. Bullet: A large horizontal vessel containing pressurized gases, or liquid and gas. 4.3.3 VESSEL PARTS
Anchor Bolt Chairs: Gussets and plates welded to base plate and skirt to provide for anchor bolt attachment. Anchor Bolts: Bolts imbedded in concrete foundation and bolted to vessel anchor bolt chairs. Base Plate: Flat plate welded to the bottom of vessel supports and bearing on the foundation. Chimney Tray: A tray composed of chimneys extending above the liquid level of the tray permitting passage of the vapors upward. The tray collects and removes all liquid product from a specific portion of the vessel. Column Davit: A hoisting device attached by means of a socket to the top of a vessel. Used for handling relief valves, bubble trays, vessel internals, etc. Conical Head: Head formed in the shape of a cone. Coupling: A fitting welded into the vessel to which the piping is connected either by screwing or welding. This type of fitting is used for pipe sizes 2" and smaller. Distributor Tray: A perforated tray, which provides equal distribution of liquid over the vessel area. Risers on the tray extend above the liquid level to permit passage of vapors rising upward. Downcomers: Rectangular flat plates bolted to shell and trays, inside of fractionation columns. Used for directing process liquid and to prevent bypassing of vapor. Flanged and Dished (Torispherical) Head: Head formed using two radii, one radius called Crown Radius, and another called Knuckle Radius which is tangent to both the crown radius and the shell. Flanges (or pipe flanges): Fittings used to connect pipes by bolting flanges together. Flat head (or Cover Plate): Flat plate welded or bolted to the end of a shell. Fractionating Trays: Circular flat plates bolted to the shell inside of fractionation columns. Used to obtain vapor liquid contact which results in fractionation.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 4 of 79 15/11/2002 Rev. 0 Head: The end closure of a vessel or tank. Hemispherical Head: Head formed in the shape of a half sphere. Insulation Rings: Rings made of flat bar or angle, attached around the girth (circumference) of vertical vessels and spaced approximately 12'-0 3/4" apart. Used to support the weight of the vessel insulation. Ladders and Cages: Rung-type ladders with cages built of structural shapes to prevent a man from falling when climbing the ladder. These are bolted to and supported by clips on the outside of the vessel. Used for access up and down to the platforms. Manhole Hinges or Davits: Hinges or davits attached to manhole flange and cover plate which allows cover plate to be swung aside from the manhole opening. Mist Eliminator: A wire mesh pad held in place between two light grids. The mist eliminator disengages liquids contained in the vapor. Nozzle: Generally consists of a short piece of pipe welded in the shell or head, with a flange at the end for bolting to the "Piping." Platforms: Platforms bolted to and supported by clips on the outside of the vessel. Generally located just below a manhole, and at relief valves or other valves or connections that need frequent service. Reinforcing Pad: Plate, formed to the contour of shell or head, welded to nozzle and shell or head. Saddles: Steel supports for horizontal vessels. Seal Pans: Flat plates bolted or welded to inside of fractionation column shell below downcomer of lowest tray. Used to prevent vapor bypassing up through the downcomer. Semi-elliptical Head 2:1: Head formed in the shape of a half ellipse with major to minor axis ratio of 2:1. Shell: The cylindrical portion of a vessel or tank. Skirt Fireproofing: Brick, concrete or flame resistant material applied inside and outside of skirt to prevent damage to skirt in the event of a fire. Skirt Access Opening: Circular holes in the skirt to allow workman to clean, inspect, etc. inside of skirt. Skirt Vents: Small circular holes in the skirt to prevent collection of dangerous gases within the skirt. Skirt: Cylinder similar to shell, which is used for supporting vertical vessels. Stub-end: A short piece of pipe or rolled plate welded into the vessel to which the piping is connected by welding. Support Legs: Legs made of pipe or structural shapes, used to support vertical vessels.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 5 of 79 15/11/2002 Rev. 0 Support Grid: Grating or some other type of support which vapor or liquid can pass through. Used to support tower packing such as catalyst, raschig rings, etc. Toriconical Head: Head formed in the shape of a cone and having a knuckle radius tangent to the cone and shell. Vacuum Stiffener Rings: Rings made of flat bar, plate, or structural shapes welded around the circumference of the vessel. These rings are installed on vessels operating under a vacuum in order to prevent collapse of the vessel. Vacuum stiffener rings are also utilized as insulation support rings. Vessel Manhole: Identical to nozzle, except does not bolt to piping and has a cover plate (or blind flange) which is bolted to the flange. When unbolted it allows access to the inside of the vessel. Generally 18" or larger in size. Vortex Breaker: A device located inside a vessel at the outlet connection. Generally consisting of plates welded together to form the shape of a cross. The vortex breaker prevents cavitation in the liquid passing through the outlet connection. 4.4 NOZZLE NOMENCLATURE
VESSEL NOZZLE SYMBOLS - Fluor uses a system of nozzle symbols to make it easier to identify nozzles and couplings. These symbols also indicate the nozzle function. A. = B. = C. = D. = E. = F. = G. = Glass H. = J. = K. = Inlet Nozzle Outlet Nozzle Condensate Nozzle Drain or Drawoff * Feed Nozzle Level Gage or Gage Handhole Pump Out Nozzle * L. = Level Instrument Nozzle M. = Manhole N. = Reboiler Connection P. = Pressure Connection R. = Reflux Nozzle S. = Steam or Sample Connection T. = Temperature Connection V. = Vapor Out or Vent Nozzle W. = Relief Valve Nozzle
*Symbols "E" and "K" are sometimes used for special nozzles.
4.5
ASME BOILER AND PRESSURE VESSEL CODE
Standard rules for the construction of boilers and pressure vessels divided into sections which establishes design formulas, material selection, allowable stress values, methods of construction, inspection and nondestructive examination procedures for pressure containment vessels. 4.6 PROCESS DESCRIPTION OF A TYPICAL DISTILLATION OR FRACTIONATING COLUMN
Heat for vaporization is supplied by heating the crude feed stock in a furnace. The preheated crude (feed) is charged into the bottom of the fractionation column onto the feed tray at its boiling point at a pressure slightly above atmospheric. This is called the "flash zone." In the flash zone, the feed separates into liquid and vapors. The vapors rise up under the bubble-caps and bubble out through the reflux liquid on each tray (See Figure # 4-1, Typical Distillation or Fractionating Column).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 8 of 79 15/11/2002 Rev. 0 The vapors rise through the column contacting the downflowing reflux stream at each tray; as a result the lightest materials concentrate at the top of the column (overhead vapor). The vapor out the top of the column is condensed into liquid by the overhead (O.H.) condenser. The liquid is then accumulated in the O.H. reflux accumulator. Part of the liquid is returned to the column's top tray as reflux. The reflux flows across each tray on its way down the column by way of downcomers and bubble-caps. The portion of the column between the overhead and the feed is called the "rectifying section." This is where the counter current flow of reflux and vapor reach an equilibrium. This means the liquid head on each tray is just enough to allow the vapor to rise through the liquid and the vapor velocity is just fast enough to allow some of the liquid to drop through the same opening in the tray. The heavier materials concentrate at the bottom of the column (bottoms) and the intermediate materials in-between. Desired "side cut" products are withdrawn at appropriate levels (draw-offs). The portion of the column between the feed and the bottom tray is called the "stripping section." This is where additional light materials are released as vapor (stripped) from the heavier liquid portion of the feed by the addition of stripping steam into the "surge section" of the column. The portion of the feed that reaches the bottom of the vessel is the residue or bottoms liquid (See Figure # 4-2, Typical Flow of Liquids & Vapors inside a Fractionator Column).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 10 of 79 15/11/2002 Rev. 0 The top tray must be continuously fed with cooling reflux liquid or the trays would soon become dry. Reflux must be increased as side cuts are drawn off at several levels. The material on each tray is at its boiling point and the downflowing material is constantly changing composition as it picks up heat from the rising vapors. The vapor is always hotter than the liquid on the tray from which it is rising. The vapors are constantly being cooled by the cooler reflux on each tray. The vapor on the top tray is condensed into liquid. The liquid that is not returned to the column as reflux is a final product (See Figure # 4-3).
Figure # 4-3 Typical Fractionation Circuit 4.7 PROCESS DESCRIPTION OF A TYPICAL REFLUX ACCUMULATOR
A Reflux accumulator is a horizontal vessel that is sometimes called an overhead accumulator because it accumulates the overhead product from the fractionators noted in the paragraph above. The overhead leaves the fractionating tower as a vapor, is cooled and condensed in an exchanger and flows as a liquid (sometimes with some vapor) to the overhead accumulator. This vessel then holds a level of liquid used as "reflux" liquid, which is pumped back to the fractionating tower's top tray. Any liquid, above the fractionator's need for reflux, is pumped out as product. A reflux accumulator usually has few, if any, internals (See Figure # 4-1 through #4-3).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 11 of 79 15/11/2002 Rev. 0 4.8 4.8.1 HORIZONTAL VESSEL Vessel Location
Vessel headline distance from the pipeway is established by the Unit supervisor and is shown on the plot plan. The locating coordinate in the other direction might not be established for some time. Several studies in the adjacent areas will have to be done before we can establish coordinates for our L.C.P. Vessel Orientation
4.8.2
A vessel orientation will determine the location and orientation of: 4.8.3 Piping equipment connections Instrument connections Manholes and vents Ladders and platforms - size and height Anchored support Routing and support of piping to and from nozzles Horizontal Vessel Orientation Guidelines (See Figure # 4-4)
Generally, vessel and nozzle orientation should be as follows: Inlet should be at the opposite end of vessel (maximum distance) from the liquid and vapor outlets to prevent "short circuiting" of the flow. Level instruments and boot should be at the opposite end of vessel (maximum distance) from inlet. There is less liquid turbulence at the outlet end. It is important that these instruments be accessible per Specification 000.250.50001. Care must be taken in the study of the vessel to assure this accessibility. The instrument bridle connections are located in the surge section of the vessel. This end of the vessel is nearest the operating aisle. To allow for the horizontal growth due to thermal expansion, one support of the vessel is anchored and the other end is allowed to grow by way of a slide plate and slotted holes at the opposite support. Advantage should be taken of this vessel growth by making it work for you. For example, by anchoring the vessel at the support nearest the pipeway and letting the vessel grow away from the pipeway, the growth of the vessel will cancel out the growth of a line from the pipeway to the unanchored end of the vessel.
The inlet is normally located on the end of the vessel away from the pipeway. This arrangement then locates the level instruments next to the operating aisle for good accessibility per Specification 000.250.50001. The computer normally does the setting of the support legs on a horizontal vessel but sometimes we study and orient vessels before this information is available to Piping. A good "rule of thumb" to follow is: "D" = Vessel diameter, "L" = Vessel length tan. to tan, "S" = Distance from tan. to centerline of support leg Normal shell thickness vessels S = L/5 Thin shell thickness vessels S = D/4 Note: In this case the vessel head acts as a stiffener to the shell.
Vent is located at the opposite end of the vessel from the steam out and a maximum distance away.
Figure # 4-4 Horizontal Vessel General Arrangement
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 13 of 79 15/11/2002 Rev. 0 The vortex breaker is an internal baffle located at the inside bottom of the vessel on the liquid out nozzle. Its function is to prevent a whirlpool movement of the liquid. Such a movement would introduce vapor into the line to the pump and cause the pump to cavitate. A pump impeller will spin rapidly or cavitate if the pump suction chamber is not completely filled with liquid. This action is detrimental to the pump and reduces the required amount of liquid flow through the pump. (See Figure # 4-5).
Figure # 4-5 Vortex Breaker 4.8.4 Height of Horizontal Vessels
Heights of horizontal vessels are shown on the flow diagram. The Process Engineer determines what the vessel height will be by the Net Positive Suction Head (N.P.S.H.). This is the liquid head required to keep the pump suction primed. Pump suction lines from the vessel bottoms shall have a B.O.P. minimum of 8'-0" above H.P.F.S. If this requirement is not met, there are three alternatives: Vessel height can be increased to meet the minimum 8'-0" headroom requirement. Block the operating aisle with a low suction line. (Not recommended) Take the pump out of the pump row and locate it near the vessel so that the suction line does not cross the operating aisle.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 14 of 79 15/11/2002 Rev. 0 4.8.5 Ladders and Platforms
Side platforms are provided for access to manholes, instruments, valves and equipment, and for crossovers between ladders. The size of these platforms should be kept to a minimum. The width (2'-6" for Fluor Standard) is usually only enough to permit opening of the manhole cover or to provide a minimum of 1'-6" clearance between handrail and piping such as level controller, gage glass, level switch or safety valves. Platforming need not extend underneath valves and equipment to make them accessible. Projection of nozzles extending through a top platform must be such that the flange bolts are above the platform level. Avoid supporting heavy piping loads from platforms (generally more than 500 pounds). If it is found necessary to support piping from a platform, notify the Vessel Group. The Vessel Designer may have to "beef-up" the platform support brackets to take the added load. Vessel attachments, such as ladder support clips, platform support clips, vessel pipe supports, and guides are generally installed by the vessel fabricator in the shop. In a situation where post weld heat treatment (PWHT) is required of the vessel, it is important to remember, any changes to the vessel after heat treatment are not desirable. When the centerline of the vessel is no more 15'-0" above grade, no platform is required, per Specification 000.250.50001, (See Figure # 4-6).
Figure # 4-6 Vessel Below 15'-0"
FIGURE # 4-7 Vessel Above 15'-0"
When the centerline of a horizontal vessel is more than 15'-0" above HPFS, (See Figure #4-7), it is sometimes necessary to alter the piping arrangement and vessel orientation. It is seen here that a platform has been added on top of the vessel for access to the control valve assembly on the vapor outlet. If the manhole were located on the centerline of the vessel, it too would require a platform for access because it would be more than 15'-0" above grade. Since a platform was required on top of the vessel, the manhole was moved to this location to eliminate the need for an extra platform. General rule for determining the approximate minimum distance a manhole or nozzle can be located from the shell is (See Figure # 4-8).
Figure # 4-8 Manhole Location
A manhole located on top of a horizontal vessel may have a special davit for removal of the cover or a hinge (See Figure # 4-9, Manhole Cover Davit).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 19 of 79 15/11/2002 Rev. 0 The Vessel Group will furnish a ladder and platform standard drawing for your use. The Vessel Group will produce specific ladder and platform drawing. Information required to start orientation INFORMATION Flow Diagrams Job Specifications, Drafting Room Instructions and Standards Preliminary Job Information SOURCE
4.8.6
Piping Design Supervisor or Roller Board

Piping Design Supervisor and Fluor Standards, Job Book Project Manager, Design Coordinator or Piping Design Supervisor Piping Design Supervisor Vessel Design Supervisor or Piping Design Supervisor Flow Diagram or Process Engineer Vessel Drawing or Process Engineer Vessel Drawing, Flow Diagram or Process Engineer Vessel Drawing, Process or Instrument Engineer, Instrument Standard Drawings Customer via Project Manager, Design Coordinator and Piping Design Supervisor Piping designer supervisor
Flow Diagram Transposition (not provided in this lesson) Vessel Drawing or Vessel Quote Drawing
Drum Height Process Nozzle Elevations Normal Liquid Level and Other Liquid Levels Instrument Nozzle Elevations
Customer Requirements
Plot Plan
After gathering and evaluating this information, the Piping Designer is ready to commence the actual vessel study. An effort should be made toward uniformity in the arrangement of the various vessel components. For example, all ladders, platforms, manholes, level controllers, and gage glasses shall have similar orientations whenever economically feasible. However, uniformity is never an excuse for doing something incorrectly.
4.8.7
Steps to accomplish horizontal vessel study
1. Update your flow diagram from "Master". 2. Compare vessel outline to flow diagram. (a) (b) (c) (d) Vessel I.D. Tangent to tangent dimension N.L.L. Size, rating and quantity of nozzles
3. Calculate elevations. (a) Centerline of vessel based on minimum height on flow diagram (b) Process nozzles based on vessel outline (c) Verify or set instrument nozzles based on flow diagram and instrument standard drawing 4. Determine what items require platform or ladder access. 5. Study piping transposition. 6. Draw vessel outline to scale and get copies. 7. On these copies do rough sketches of piping and nozzle arrangements, combine and change sketches for optimum design using piping logic. 8. Piping logic considerations or priorities. (a) (b) (c) (d) (e) (f) (g) (h) Flow diagram Stress Economics Support and stability Lines run at standard elevations per unit plot drawing Aesthetics Operation, maintenance and safety Job standards
9. Your order of importance will change in each situation. For instance, economics would be more important than looks on a large alloy line. On a small carbon steel line, looks may be more important than economics. Commence actual study. You must be accurate and draw to scale; however, don't worry about drafting quality, linework, or lettering. "Rough and dirty" but legible and complete.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 21 of 79 15/11/2002 Rev. 0 4.9 4.10 DO HORIZONTAL EXERCISE # 1 (SEE EXERCISE SECTION) VERTICAL VESSEL
4.10.1 VESSEL Location (coordinates) The Unit Supervisor will establish the centerline for all vertical vessels. The location in the other direction might not be established for some time. Several adjacent studies will have to be done before we can establish coordinates for our L.C.P.
4.10.2 Vessel Orientation A Vessel Orientation will determine the location and orientation of: Piping and equipment connections Instrument connections Manholes Platforms (number, height and size) Ladders and cages Pipe supports and guides Davit location Access openings Drop zone Design of connecting piping with other associated equipment that will be established by the vessel orientation. Branches coming to and from the pipeway will be tied down with dimensions. Skirt access openings and vents
4.10.3 Manholes Manholes are flanged openings (usually 18" in diameter) in the side of a vertical vessel with a hinged bolted cover. When elevated over 15' above H.P.F.S., they are located immediately above platforms at various levels of the vessel. They provide for access and inspection of: Internal piping Vessel trays Tray bubble caps Internal condition of vessel
It must be noted that manhole orientation is restricted by internal tray arrangement as to where, around the circumference of the vessel, manholes can be located. Manhole orientation can not be located in downpour area of tray above. If such an orientation were made, the person making the inspection would immediately encounter a downcomer and would be unable to get to the other internals. The number of passes a tray has is determined by the number of downcomers it has. Single pass trays have one downcomer and two pass trays have two downcomers. The orientation range of manholes is restricted by the downcomers. The preferred location is parallel to the downcomer, facing the access way (opposite side of pipeway). (See Figure #4-10, Single Pass Tray)
The preferred range of orientation allows entry into the vessel over the tray. Entry over the downcomer could be a safety concern as well as a hindrance to personnel. Manhole orientation over a two-pass tray is more limited than that of a single tray. Entry over the downcomer is generally not acceptable, but still may be considered an option when faced with a design situation where other options are less desirable (See Figure # 4-11, Two Pass Trays).
As stated before, manholes are usually 18" in diameter except for columns with removable trays. In this case, having fewer, larger manholes for the removal of large tray sections may be more economical. The Vessel Design Group and not the Piping Designer usually determine the size of the manhole. Manhole covers are much too heavy for plant operators or maintenance personnel to lift. A manhole cover davit or hinge is used to hold the cover after it has been unbolted. It can then be swung out of the way to allow personnel to enter the vessel, (See Figure # 4-12, Davits). Orientate manhole to swing away from ladder leading to lower level. Manhole cover shall swing 100o without obstruction.
The elevations of manholes are set by tray arrangement and spacing. Consideration shall be given to raising or lowering manholes one tray to provide the most economical ladder and platform arrangement. Hinged manholes can also be used for a bottom entry, i.e., reactors. (See Figure # 4-13, Manhole Cover Hinge.)
4.10.4 Ladders and Platforms (Figure # 4-14, Vessel Layout & Orientation)
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 31 of 79 15/11/2002 Rev. 0 4.10.5 Platforms are provided for access to manholes, instruments, valves and equipment, and for crossovers between ladders. When one platform overlaps another, it must be at least 8'-0" above the lower one or have at least 7'-0" minimum headroom to support bracket, knee brace, etc. The size of platforms should be kept to a minimum. Platform width of 2'-6" (Fluor Standard) is usually only enough to permit opening of the manhole cover or to provide a minimum of 18 inches clearance between handrail and piping such as level controller, gage glass, level switch or safety valves (See Figure # 4-15A & Figure # 4-15B). Platforming is not required underneath valves and equipment to make them accessible.
Figure # 4-15A Manhole Clearances at Platforms
Figure #4-15B Ladders and Platforms for Vessels
The spacing of platforms served by a common ladder shall be in even one-foot increments so as to match the rung spacing on the ladders. The maximum straight run of ladder without offset shall be between platforms 30'-0". Except first ladder is maximum 29'-6" from H.P.F.S. (due to grade variation). Contract specifications should always be checked before starting ladder and platform design (See Figure # 4-16, Ladders and Platforms for Vertical Vessels)
Projection of nozzles extending through a top platform must be such that the flange bolts are above the platform level. Avoid supporting heavy piping loads from platforms (Generally more than 500 pounds). If it is necessary to support piping from a platform, notify the Vessel Group. The Vessel Designer may have to "beef-up" the platform support brackets to take the added load. Vessel attachments, such as ladder support clips, platform support clips, vessel pipe supports, and guides are generally installed by the vessel fabricator in the shop. In a situation where post weld heat treatment (PWHT) is required of the vessel, it is important to remember, any changes to the vessel after heat treatment are not desirable. For ladder details (See Figure # 4-17, Ladders at Vertical Vessels), Note the 7" minimum toe clearance and 15 degree maximum ladder slope.
A ladder with and without a cage has clearance requirements that a designer needs to consider in orienting a vessel. Do not overlook entrance hoop at bottom of ladder if it applies to your clearance problem (See Figure # 4-18, Ladders and Cages).
The Vessel Group will furnish a ladder and platform standard drawing for your use. The Vessel Group will produce specific ladder and platform drawing.
4.10.6 Piping @ Platforms Piping passing through a platform has hole diameter requirements. Normally, a hole large enough to let a flange pass through is cut and then a cover plate is put around the pipe as a safety precaution (See Figure # 4-19, Platform Cutout Detail). These holes must be located and sizes called out on vessel studies. With hot lines, insulation thickness or thermal movement must determine hole size.
4.10.7 Valving @ Vessels (Specification 000.250.50001) Vents to atmosphere, operating valves, and non-operating valves elevated above 15'-0" from H.P.F.S. shall be reachable from a ladder or platform. Vents and operating valves under 15'-0" may be chain operated or accessible from a permanent ladder. Non-operating valves under 15'-0" shall be accessible from a portable ladder. 4.11 TRAY TYPES (See Figure # 4-20, Tray Types)
4.11.1 BUBBLE TRAY ADVANTAGES 1. Very efficient 2. Need not be installed level 3. Corrosion not a factor 4.11.2 VALVE TRAY 1. 2. 3. 4. ADVANTAGES Most efficient of all types Inexpensive and lightweight Need not be installed level Corrosion not a factor DISADVANTAGES 1. None 1. 2. 3. 4. DISADVANTAGES Expensive Heavy and bulky Cast iron caps occasionally break Mounting bolts rust
4.11.3 SIEVE TRAY ADVANTAGES 1. Inexpensive 2. Lightweight 3. Good for heavy liquids 4.11.4 REMOVABLE TRAYS Vessels in heavy (dirty) service or with a high corrosion rate often have trays that are built in sections. These trays can be dismantled and removed through the vessel manholes for cleaning, repairing or replacing. 4.11.5 FIXED TRAYS (Non-removable) Vessels in light (clean) service or with no corrosion problem usually have fixed trays that can be steamed out in place. The number of downcomers it has determines the number of passes a tray has. Single pass has 1 downcomer, 2 pass has 2, etc. Four types of tray arrangement. (See Figure # 4-21, Vessel Tray Types). DISADVANTAGES 1. Must be installed level 2. Corrosion a factor
4.11.6 Feed Nozzles, Reflux Nozzles (Figure # 4-22 & # 4-23, Reflux Nozzles (for all single pass trays); # 4-24, Reflux Nozzle (above 2 pass tray/w centre downcomers) and # 4-25, Reflux Nozzle (above 2 pass tray /w side downcomers)
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 50 of 79 15/11/2002 Rev. 0 The reflux nozzle carries the reflux liquid back into the vessel where it enters the vessel at the topmost tray. It is important that this liquid be fed to the blank area portion of the tray for proper distribution. The blank area is used to form a liquid pool which "kills" the inlet velocity of the liquid. The liquid then is fed smoothly to the bubbling area over an inlet weir or under a baffle. The minimum height of the inlet weir is six inches. Feeds to columns require different handling than top refluxes. Feeds enter the vessel between trays and, therefore, do not have a blank area for entry and distribution. The tray spacing at the point of entry is often wider than what is normal to accommodate the internal piping or other distribution arrangements (See Figures # 4-26 & # 4-27, Liquid Feed Nozzles; # 4-28, # 4-29, and # 4-30, Feed Nozzles).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 56 of 79 15/11/2002 Rev. 0 Feeds are classified into two types: all liquid feed and vapor-liquid mixed feed. The type of feed and process conditions influences the internal design. Factors affecting feed internal design: Mixing - The internal piping must be arranged so as to obtain the best mixing between the fresh feed and the liquid from the tray above. Temperature Difference - If the fresh feed is directed against the downcomer from the tray above, an insulating baffle is required to prevent flashing of the liquid in the downcomer when temperature differences are 30 degree or more. The baffle plate also acts as an erosion shield for high inlet velocities.
Figures # 4-26 through # 4-32 show relationships between nozzles and downcomers; they do not restrict the designer on his choice of nozzle orientation. However, once a nozzle orientation is chosen, downcomer locations must have the proper relationship. All downcomers for trays with the same number of passes will be parallel. When a vessel contains trays with a different number of passes, the relationship between these downcomers will be detailed on the vessel outline. These figures are Fluor Standard. This information is covered in a more general manner on Technical Practice 000.250.2651 (See Figure # 4-37). On contract the vessel orientation standard drawing should give you all the information required to complete your vessel orientation. The Vessel Department will have the detailed standards or specs if you require more information. If a particular reflux detail is shown on a vessel outline, it can usually be changed to another standard detail if piping problems arise. Liquid drawoffs are classified into two types: partial drawoff and total drawoff.
For total drawoff, the inside of the outlet nozzle MUST be made flush with the bottom of the sealed downcomer to ensure complete removal of liquid. No drain holes are allowed (See Figure # 4-31, Total Drawoff). For partial drawoffs on trays, a shallow drawoff pan or trough is provided in the tray. The depth of this pan or trough equals nozzle sizes plus 6 inches. The outlet nozzle need not be flush with the bottom of the pan. Weep holes are used as required (See Figure # 4-32, Partial Drawoff for all Side Downcomers). Drawoffs to pump suctions may require deeper drawoff pans or troughs. 4.11.7 Vessel Trim See Figures # 4-33 Elevation Vessel Trim, # 4-34 Upper Plan Vessel Trim, # 4-35 Lower Plan Vessel Trim, and # 4-36 Orientation and Instrument Requirements Vessel trim is a term used to identify piping, instrument, and valves connected to the following connections on vessels: 1. Vents 2. Drains 3. Steamouts 4. Relief valves 5. Instruments including level controllers and gages
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 64 of 79 15/11/2002 Rev. 0 Temperature and samples may be taken of a liquid or a vapor. A connection in the downpour area near the lower tray would yield a liquid sample or a temperature reading of a liquid. A connection in the open area between two trays would yield a vapor sample or temperature reading of the vapor. If process conditions permit, sample or temperature connections may be varied one tray up or down to allow maximum economy in the ladder or platform arrangement. Review Technical Practice 000.250.2651 (See Figure # 4-37, Vessel Layout and Orientation Trays) for location of vapor organization range and liquid orientation range. These connections shall be located to be accessible from grade ladder or platforms, per specification 000.250.50001. Instrumentation that is associated with a control valve such as a level glass, pressure or temperature indicator need to be located within site of the control valve. 4.11.8 Vessel Davits See Figure # 4-38A and # 4-38B, Column Davit Details Many of the internals and valves attached to nozzles of vessels are very heavy. When maintenance is required, they must be removed and lowered to grade. The vessel davit is a device attached to the top of a vessel to facilitate the removal of vessel internals and valves and lowering them to grade. The side of the vessel used for raising and lowering these items is called the "vessel drop zone". This area must be kept clear of all piping and equipment and is usually located to the rear of the vessel (opposite side of the pipeway). Indicate the drop zone on the vessel orientation. A vessel davit is usually provided in the following cases: (See Technical Practice 000.250.2650 Note 6, Vessel Layout and Orientation Piping, Master Specification 000.250.50001, C, 6.) 1. The vessel exceeds a height of 30 feet above grade. 2. The vessel is not accessible with a mobile crane. 3. The vessel is not in a structure or grouped with other vessels where other lifting facilities are provided.
4.11.9 Vessel Skirt Access Openings (See Figure # 4-39, Vertical Vessel - Support Skirt Details) The openings, ranging in size from 8" to 18" in diameter depending upon the outside diameter of the skirt, are provided in the skirt of all vessels 18" and larger. Only one is provided unless the vessel is 5'6" or larger in outside diameter. In these cases, two access openings, preferably on opposite sides of the skirt, are provided. They should be located so as not to interfere with piping, ladders, and equipment. Avoid putting two access openings closer than 90o. Piping indicates orientation on studies. 4.11.10 Vessel Nameplates
Each vessel has an identifying nameplate affixed to it at some conspicuous location. This should be on the operating aisle side of the vessel. 4.11.11 Vessel Pipe Supports and Guides
(See Technical Practice 000.250.2650 [Figure # 4-44, Vertical Layout and Orientation Piping] Vessel Layout and Orientation) Most piping connecting to a vertical vessel needs to be supported and guided. The support takes the weight of the pipe off of the vessel nozzle that is not designed to support a large load. The guides stabilize the vertical runs of pipe, which sometimes are very long and require more than one guide. On PWHT vessels extreme care needs to be taken in placing all piping supports and guides, including small bore pipe (i.e. utilities and steam tracing). After the vessel has been fabricated and post welded heat-treated, nothing can be welded to the shell. It will be noted that the vertical runs of pipe are spaced 1"-0" (minimum) from the outside of the vessel to the back of the pipe. This is referred to as the "L" dimension (back of pipe to outside of vessel) and the preferred "L" dimension is 1'-0". This may be increased, however, to 1'-8" if this results in the elimination of an offset in the piping at the nozzle (See Figure # 4-40, Support Details; # 4-41 and # 4-42, Typical Guide/Support Applications). Supports are normally placed as close as possible to the nozzles to minimize differential expansion between vessel and pipe. See Technical Practice 000.250.2152 (Figure # 4-43, Support Trunnions) The support trunnion is attached to the pipe at a minimum distance from the weld and rests on the vessel support. Note shims are required for fabrication error. Pipe guides shall be provided as required according to Figure # 4-40, Details. Care should be taken not to locate guides too close to changes in direction and points of support in the pipe. This restricts the flexibility in the pipe and will result in some twisted guides or bowed lines. Reference to Item 11.2 on Technical Practice 000.250.2650.
4.11.12
Clearances
The following clearances are from the P.D.G. -Technical Practice 000.250.2040 "Arrangement of Equipment" and "Equipment and Pipeway Clearances" section, and Attachment 3: "Space Allocation at Support Columns." The minimum clearance for a forklift or similar equipment is 6'-0" horizontal by 8'-0" vertical. For portable manual equipment operation provide 3'-0" horizontal by 8'-0" vertical [See Figure # 4-45 (C1.2)]. The minimum clearance for mobile equipment access (hydraulic cranes, trucks, etc.) is 10'-0" horizontal by 10'-0" vertical [See Figure # 4-45 (C1.3)].
Figure # 4-45 4.11.13 Vessel Skirt Height
The height of the vessel skirt is shown on the flow diagram. The Process Engineer determines this height by the N.P.S.H. (Net Positive Suction Head). This is the height of a column of liquid (head) necessary to keep the bottoms out pump suction primed. Pump suction lines from the vessel bottoms shall have a minimum clearance of 8'-0" from bottom pipe or insulation above H.P.F.S. when crossing over an operating aisle (See Figure # 4-45).
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 75 of 79 15/11/2002 Rev. 0 The skirt height can be raised to achieve this or in some instances, the pumps can be placed alongside the vessel, so that the pump suction line does not need to cross the operating aisle. Mobile equipment should be a consideration in vessel orientation. (See Figure # 4-46, Mobile Equipment Dimensions)
4.11.14
Steps to Accomplish Vertical Vessel Orientation: 1. Update your flow diagram from "master." 2. Compare vessel outline to flow diagram a. Vessel I.D. b. Tangent to tangent dimension. c. Minimum skirt height. d. Number of passes. e. N.L.L. f. Size, rating, and quantity of nozzles. 3. Calculate elevations. a. Bottom tangent line based on minimum height on flow diagram. b. Process nozzles based on vessel outline. c. Verify or set instrument nozzles based on flow diagram and instrument standard drawing. 4. Determine which items require platforms or ladder access. a. Establish elevation ranges for platforms that must be. b. Draw a rough freehand elevation of vessel indicating platforms that are definitely required. c. Now add ladders and any additional platforms that may be required just to get up the vessel. Do a couple of different ways until you have minimized the quantity of platforms and/or ladders. 5. Study piping transposition. 6. Draw several outlines of vessel to scale. 7. On these outlines, do rough sketches of piping, nozzle orientations, ladder and platform arrangements. Combine and change sketches for optimum design and piping logic. 0 will always be due north. 8. Commence actual study. You must be accurate and draw to scale. However, do not worry about drafting quality, linework or lettering. "Rough and dirty", but legible and complete.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 78 of 79 15/11/2002 Rev. 0 4.11.15 Vertical Vessel Orientation Guidelines Based on Fluor Standards (Check Job Specifications for Specific Application) 1. Economy of piping based on transposition 2. Orientation of trays, downcomers, baffles in relation to nozzles and manholes 3. Pipe drop area towards pipeway 4. Manholes in rear of vessel-swing away from down ladders 5. Ladders in rear quadrants of vessel 6. Level gages and controllers visible from operating aisle, and not affected by reboiler return turbulence. 7. TI, PI's and SC's in proper area of tray. 8. Temperature instruments Pressure instruments Level instruments Steam outs Vents Valved nozzles Drains Water wash connections Spectacle blinds (vapor, pressure) Relief valves Notes : Reachable by hand for observation, maintenance or removal. 1. LG & LC handwheels max. 7'-3" above grade or platform. 2. Reach LG for cleaning with rod 3. Remove bolts on PSV 9. Davit length to reach over all manholes, PSV's, vent valves and to extend beyond top platform by 1'-6" to drop into clear maintenance drop area (rear of vessel). 10. Platform maximum of 30' apart and even elevations. 11. Platform size minimum 2'-6" for good access and maintenance (not skimpy or extravagant). 12. "L" dimension 12" preferred, 20" maximum, or special ("L" dimension down to 11" are ok). 13. Special supports minimized by using S.R. ells or slip-on flanges if allowed by piping specs. 14. "L" dimension of 12" bellow transition piece on coke bottle vessels. 15. Control valve manifolds for reflux or feed lines located properly considering vessel growth. 16. Vessel guides are located to minimize number required, there not spaced more than maximum distance apart and lowest guide is 25 pipe diameters above turn to pipeway.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 79 of 79 15/11/2002 Rev. 0 17. Clearance to walk past obstruction 1'-6" from outside of pipe, flanges, insulation, etc. 18. Skirt manways not blocked. 19. Skirt vents located. 20. Name plate visible from operating aisle, if possible. 21. PSV Tailpipe or line to flare supported. 22. Platforms used effectively: LG's, TI's, PI's, SC's, PSV's, Valves, accessible from platforms if possible without making platform excessively large. 23. No side step off to a common elevation platform on both sides of ladder, unless allowed by job instructions. 24. Level controller door will open 100o without obstruction. 25. Ladders are 16" wide inside, 7" minimum toe clearance, 1'-0" maximum. 26. Centerline of ladder to edge of step off is 1'-3". 27. Platform used for step-off only at least 2'-6" wide at vessel, i.e. 1'-3" on either side of ladder going up. 28. North arrow indicated. 4.12 DO VERTICAL VESSEL EXERCISES #2-4 (SEE EXERCISE SECTION)
This copy is intended for use solely with Piping Design Layout Training. For other purposes, refer to the original document available through Knowledge Online.
Client Name Project Name Contract Number
Master Specification 000 250 50001 Date 18Jan00 Page 1 of 16 Revision
PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING
This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.
Revision No.
Date
Originator's Name & Initials
Reviewed/Checked By Name & Initials
Pages
APPROVALS Lead Engineer Project Manager: Client Approval: ISSUED FOR : Construction
SIGNATURES
DATE
Other
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Record of Revisions
Revision No. Date Description
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1.0
GENERAL 1.1 Summary A. Scope of Specification This specification prescribes the design of above ground pressure piping systems, equipment layout, pipe routing, and drawing practices for refineries, chemical plants, and similar facilities (except plumbing inside of buildings). B. Related Specifications The following specifications prescribe items of related Work: 000.210.02720: 000.210.02730: 000.245.45001: Storm Sewer Systems And Culverts Sanitary Sewer Systems Fire Protection Design Criteria For Refinery And Petrochemical Facilities Piping-Material Specification Line Class-Process And Utility Piping Shop Fabrication And Handling-Process And Utility Piping Field Fabrication And Installation Process And Utility Piping Piping Tie-Ins Geographic Color Coding Piping Pressure Testing Packaged Equipment Piping Piping Flexibility Heat Tracing For Piping, Equipment, And Instruments Internal Cleaning Of Piping Systems Hot Insulation Cold Insulation Painting Piping Engineering
000.250.50003:
000.250.50025: 000.250.50026: 000.250.50027: 000.250.50030: 000.250.50050: 000.250.50112: 000.250.50200: 000.250.50300: 000.285.50028: 000.285.86110: 000.285.86130: 000.285.86210:
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Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications. 1.2 References The following referenced publications form part of this specification. Each publication is the latest revision and addendum in effect at the time of the project's execution unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, all Work included in this specification shall conform to the applicable provisions of the following referenced publications: A. Applicable Codes 1. ASME/ANSI (American Society of Mechanical Engineers/American National Standards Institute) Code for Pressure Piping, B31.3: Chemical Plant and Petroleum Refinery Piping. Note!!! The limits of piping covered by codes other than ASME/ANSI B31.3 shall be indicated on the P&IDs (piping and instrumentation diagrams). This specification may be used with other sections of the ASME/ANSI B31 Code and Section 1 of the ASME Code, where applicable. 2. 3. 4. OSHA Part 1910. National Fire Protection Association, Code No. 30. Applicable plumbing, heating and ventilation, or refrigeration codes for piping serving buildings and areas other than plant or process areas. Sour service piping (subject to sulfide stress cracking) shall be in accordance with NACE specification MR0175.
5.
B.
Design Documents Detail and specification numbers in this specification refer to Fluor Daniel practices and specifications, respectively.
1.3
Quality Assurance A. Approved department design guidelines and methods are used in conjunction with project requirements to achieve the desired level of quality. Project piping engineers and piping design supervisors monitor, review, and control the design and planning activities of personnel assigned to the project to ensure that applicable codes, practices, and specifications are being followed to meet project quality goals. Quality criteria shall be reviewed constantly during design planning activity.
B.
C.
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Master Specification 000 250 50001 Date 18Jan00 This copy is intended for use solely with Page 5 of 16 Piping Design Layout Training. Revision For other purposes, refer to the original document
available through Knowledge Online.
2.0
PRODUCTS 2.1 Materials A. Piping material shall be in accordance with Specification 000.250.50003; note any deviations on the piping drawings. Prepiped or packaged items shall be in accordance with Specification 000.250.50112. Install flat face flanges against flat face cast iron valves and equipment. Locking devices for valves shall be provided by the client. Minimum pipe size shall be 1/2 of an inch, except for connections to equipment. Do not use pipe sizes 1-1/4 inch, 2-1/2 inch, 3-1/2 inch, and 5 inch except for connections to equipment.
B. C. D. E.
2.2
Design Summary A. Base relation of units, location of equipment, and routing of pipe on economics, safety, ease of maintenance, operation, and construction requirements. The alignment of equipment and routing of pipe shall offer an organized appearance. Major lines normally shall be carried on overhead pipeways. In certain instances, they may be buried, providing they are adequately protected. Lines that must be run below grade, and must be periodically inspected or replaced, shall be identified on the P&IDs; Place these lines in covered concrete trenches. Cooling water may be run above or below ground, based on economics. Domestic or potable water shall be run underground. Pipe support spacings shall be maximized using the limits of pipe spans and structural integrity. Do not provide space for future equipment, pipe, or units unless required by the client or for process considerations. This requirement shall be indicated on the plot plan and P&IDs. Avoid dead ends, especially for piping where solids or fluids may congeal or form corrosive condensate. The location and spacing of offsite storage tanks and dike requirements shall be in accordance with National Fire Protection Association, Code No. 30, and OSHA part 1910.106 (b), where applicable. Spacing may be increased for construction requirements. Normally, route piping in offsite areas on sleepers. Stagger the sleeper elevations to permit ease of crossing or change of direction at intersections. Flat turns may be used when entire sleeperways change direction. Group offsite equipment, pumps, and exchangers to permit economical pipe routing. Locate this equipment outside of diked storage areas, except where indicated otherwise on the P&IDs.
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C.
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F.
G.
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H.
Locate cooling towers downwind of buildings and equipment to keep spray from falling on them. Orient the short side of the tower into the prevailing summer wind for maximum efficiency. Locate cooling towers a minimum of 100 feet from process units, utility units, fired equipment, and process equipment. Locate the flare stack upwind of process units, with a minimum distance of 200 feet from process equipment, tanks, and cooling towers. If the stack height is less than 75 feet, increase this distance to a minimum of 300 feet. These minimum distances shall be verified by Fluor Daniel Process Engineering. Keep the loading and unloading facilities that handle flammable commodities a minimum of 200 feet from process equipment, and 250 feet from tankage. Piping flexibility shall be in accordance with Specification 000.250.50200. The plant layout of equipment shall utilize common structures for equipment, vessels, and pumps. As a rule single installation of equipment will not require a structure. Project Specifications shall be reviewed and modified as necessary to reduce the Total Installed Cost on a project by using alternative Piping materials & components and alternative Pipeline fabrication & installation methods. Examples of these alternatives include the use of pipe bends instead of elbows and the use of hydraulically installed LOKRING Fittings.
I.
J.
K. L.
M.
2.3
Design Requirements A. Pumps 1. 2. Locate pumps close to the equipment from which they take suction. Design piping to provide clearance for pump or driver removal. Similarly, on end suction pumps, piping shall permit removing suction cover and pump impeller while the suction and discharge valves are in place. Arrange suction lines to minimize offsets. The suction lines shall be short and as direct as possible, and shall step down from the equipment to the pump. Suction lines routed on sleeperways may rise to pump suction nozzle elevation, subject to approval of Fluor Daniel Process Engineering. Orient valve handwheels or handles so they will not interfere with pump maintenance or motor removal. Valve handwheels or handles shall be readily operable from grade.
3.
4.
B.
Exchangers 1. Group exchangers together wherever possible.
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2.
Limit stacked shell and tube exchangers to four shells high in similar service; however, the top exchanger shall not exceed a centerline elevation of 18 feet above high point of finished surface, unless mounted in a structure. Keep channel end and shell covers clear of obstructions such as piping and structural members to allow unbolting of exchanger flanges, and removal of heads and tube bundles. Locate reboilers as close as possible to the equipment they serve. Normally, locate air coolers above pipeways.
3.
4. 5. C.
Vessels and Columns 1. Wherever possible, locate piping at columns radially about the columns on the pipeway side; locate manway and platforms on the access side. Manways should be on or about a common centerline to make use of a common lifting device or davit. Provide platforms at manways above 15 feet centerline elevation from high point of finished surface. The maximum distance for ladder runs and space between offset platforms shall be 30 feet. Position platforms so the manhole centerline is no less than 2 feet above the platform, with 2'- 6" preferred. The bottom of the manhole entry shall not be more than 3'- 6" above the platform. Provide combined platforms, where practical and economical, at multiple tower arrangements with common manway elevations. Provide vessel davits for handling items such as internals and relief valves on vessels exceeding a height of 30 feet above the high point of the finished surface, and on vessels not accessible by mobile crane. Orient davits to allow the lowering of appurtenances into the access area. Wherever possible, orient level instruments on the side toward the pipeway. Stacking two or more vertical vessels shall be investigated. This investigation shall consider the process conditions (commodities, temperatures, pressures), vertical height limitations, and piping layout for economic advantages. The stacking of vessels requires the acceptance of Process and Vessel engineering.
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6. 7.
D.
Fired Equipment 1. Locate fired equipment, if practical, so that flammable gases from hydrocarbon and other processing areas cannot be blown into the open flames by prevailing winds. Locate snuffing steam manifolds and fuel gas shutoff valves a minimum of 50 feet horizontally from the heaters they protect.
2.
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3.
Burner Valving a. Floor Fired Furnaces: Combination oil and gas firing valves shall be operable from burner observation door platform. For those fired by gas only, the valves shall be near the burner and shall be operable from grade. Side Fired Furnaces: Locate firing valves so they can be operated while the flame is viewed from the observation door.
b.
4.
Terminate heater stacks a minimum of 15 feet above any platform within a radius of 40 feet. Access and platforming requirements shall be in accordance with the contract fired equipment narrative specification. Pressure relief doors and tube access doors shall be free from obstructions. Orient pressure relief doors so as not to blow into adjacent equipment. The elevation of the bottom of the heater above the high point of the finished surface shall be in accordance with the contract fired equipment narrative specification.
5.
6.
7.
E.
Reciprocating Compressors 1. Suction and discharge lines that are subject to vibration (mechanical and acoustical) normally shall be routed at grade and held down at points established by analysis of the system. Accessibility and maintenance for large lifts such as cylinder, motor rotor, and piston removal shall be by mobile equipment. Clean suction lines internally per Specification 000.285.50028. The extent of cleaning shall be indicated on the P&IDs. Horizontal, straight line, reciprocating compressors shall have access to cylinder valves. Access shall be from grade or platform if required. Depending on unit size and installation height, horizontal-opposed and gas engine driven reciprocating compressors may require full platforming at the operating level. The sizing, routing, supporting, and restraining of the suction and discharge piping is subject to review by means of an analog computer study, as outlined in the compression specifications.
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3.
4.
5.
6.
F.
Centrifugal Compressors 1. Top suction and discharge lines either shall be routed to provide clearance for overhead maintenance requirements, or shall be made up with removable spool pieces.
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2.
Locate lube and seal oil consoles adjacent to and as close as possible to the compressor. Oil return lines from the compressor and driver shall have a minimum slope of 1/2 inch per foot to the inlet connection of seal traps, degassing tanks, and oil reservoir. Review the equipment arrangement for access and operation. Pipe the reservoir, compressor bearing, and seal oil vents to a safe location at least 6 feet above operator head level. Heavy parts such as upper or inner casing and rotor shall be accessible to mobile equipment. Support piping so as to minimize dead load on compressor nozzles; the load shall be within the recommended allowance of API-617. Clean suction lines internally per Specification 000.285.50028. The extent of cleaning shall be indicated on the P&IDs. Centrifugal compressors shall have full platforming at operating level.
3.
4.
5.
6.
7. G.
In-Line Instruments 1. Locate liquid level controllers and level glasses so as to be accessible from grade, platform, or permanent ladder. The level glass shall be readable from grade wherever practical. Relief valves shall be accessible. Wherever feasible, locate them at platforms that are designed for other purposes. Relief valves with a centerline elevation over 15 feet above high point of finish surface (except in pipeways) shall be accessible from platform or permanent ladder. Install thermal relief valves, 1 inch and smaller, in a horizontal position when it is impractical to install in the vertical position. Install relief valves, 1 1/2 inch and larger, in a vertical position. Normally, install relief valves that discharge to a closed system higher than the collection header. There shall be no pockets in the discharge line. Relief valves that discharge to the atmosphere shall have tail pipes extended to a minimum of 8 feet above the nearest operating platform that is within a radius of 25 feet. This requirement may be waived, provided a review of the proposed arrangement indicates that it does not present a hazard. Review relief valves discharging hydrocarbon vapors to the atmosphere within 100 feet of fired equipment for vapor dissipation. Provide steam traps at pocketed low points and at dead ends of steam headers. Also, provide traps on excessively long runs of steam piping, for sufficient condensate removal, and to ensure dry quality steam at destination. Steam traps located more than 15 feet above high point of finish surface, except in pipeways, shall be accessible from the platform. Piping Engineering
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8.
Indicate control, block, and bypass valve sizes on the P&IDs. Control valves shall be accessible from grade or platforms. In general, the instruments or indicators showing the process variables shall be visible from the control valve. Orifice runs should be located in the horizontal. Vertical orifice runs may be used with the approval of Fluor Daniel Control Systems Engineering. Orifice flanges with a centerline elevation over 15 feet above the high point of finished surface, except in pipeways, shall be accessible from a platform or permanent ladder.
9.
10. Locate orifice taps shall be located as follows: a. Air and Gas [- Top vertical centerline (preferred)] [- 45 degrees above horizontal centerline (alternate)] Liquid and Steam [- Horizontal centerline (preferred)] [- 45 degrees below horizontal centerline (alternate)] The piping isometrics details shall show the required tap orientations.
b.
c. H.
Temperature and Pressure Instrument Accessibility and Visibility 1. Temperature test wells located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by a portable ladder. Those located over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder. Temperature indicators shall be visible from grade, ladder, or platform. Thermocouple and temperature indicators located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder. Local pressure indicators shall be visible from grade, permanent ladder, or platform. Those located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder.
2. 3.
4.
2.4
Plant Operation A. Valve Operation 1. Indicate operating valves requiring attention, observation, or adjustment during normal plant operation on the P&IDs with the symbols O.V. They shall be located so as to be within reach from grade, platform, or permanent ladder. Operating valves may be chain-operated if the bottom of handwheel is over 7 feet above high point of finished surface or operating platform. Piping Engineering
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The centerline of handwheel or handles on block valves used for shutdown only, located less than 15 feet above high point of finished surface, and those located in pipeways, may be accessible by portable ladder. The centerline of handwheel or handles on block valves used for shutdown only and located over 15 feet above high point of finished surface, except those located in pipeways, shall be operable from permanent ladder or platform. In general, keep valve handwheels, handles, and stems out of operating aisles. Where this is not practical, elevate the valve to 6'- 6" (plus or minus 3 inches) clear from high point of finished surface to bottom of handwheel. Utility piping systems (air, water, steam, condensate, and nitrogen) going into separate process units shall have a battery limit block valves with a line blind only. Individual block valves to users within the process units are not required unless specified by the Client or Process engineering.
4.
5.
6.
B.
Sample Connections 1. Provide sample and test connections as indicated on P&IDs. They shall be readily accessible from grade or platform. In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free running of the liquid before sampling. Note samples that require cooling on the P&IDs, and provide a cooler.
2.
3. C.
Vents and Drains 1. The P&IDs shall indicate and size the vents, drains, and bleeds required for plant operation, except as noted in section C3 below. Provide plugged hydrostatic vents and drains without valves at the high and low points of piping. Provide valved bleeds at control valve stations, level switches, level controllers, and gauge glasses per job standard.
2.
3.
D.
Line Strainers 1. Provide temporary conical type strainers in 2 inch and larger butt weld pump suction lines for use during startup. Arrange piping to facilitate removal. Use permanent Y-type strainers on 2 inch and smaller screwed or socket weld pump suction piping. Provide temporary basket type strainers located at the suction pulsation device inlet for startup of reciprocating compressors. Arrange piping to facilitate removal of the strainer.
2.
3.
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4.
Provide temporary basket type strainers and locate them as close as possible to the compressor inlet flange for startup of centrifugal compressors. Arrange piping to facilitate removal of the strainer.
E.
Insulation Hot insulation for piping and equipment shall be in accordance with Specification 000.285.86110; cold insulation, with Specification 000.285.86130.
F.
Insulation Shoes 1. Provide insulation shoes where a line crosses a support for hot insulated piping in the following categories only: a. b. Aluminum lines. 3 inch and larger carbon and alloy steel lines with design temperatures over 650 degrees F.
2.
Large diameter lines (20 inches and over), stainless steel lines where galvanic corrosion may exist, lines with wall thickness less than standard weight, and vacuum lines shall be analyzed to determine if shoes or wear plates are needed.
G.
Cradles Provide cradles at supports for insulated lines in cold service and for acoustical applications.
H.
Personnel Protection 1. Provide eyewash and emergency showers in areas where operating personnel are subject to hazardous sprays or spills, such as acid. Indicate these items on the P&IDs. Provide personnel protection at uninsulated lines and for equipment operating above 140 degrees F when they constitute a hazard to the operators during the normal operating routine. Lines that are infrequently used, such as snuffing steam and relief valve discharges, do not require protective shields or coverings. Note valve and flange shields, if required, in the piping material specifications.
2.
3. 2.5
Maintenance A. Clearances Minimum clearances for equipment, structures, platforms, and supports shall be in accordance with the following table:
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Piping Engineering
ITEM ROADS
DESCRIPTION Headroom for primary access roads (from the crown) ..................... Width of primary access roads excluding 5 foot shoulders ............. Headroom for secondary roads (from the crown) ............................ Width of secondary roads excluding 3 foot shoulders ..................... Clearance from edge of road shoulders to platforms, equipment, pipe associated with equipment, or similar features ........................... 21' - 0" 20' - 0" 12' - 0" 10' 0" 5' - 0"
RAILROADS
Headroom over through-railroads (from top rail) ........................... **22' - 6" Clearance from track centerline to obstruction ................................ **10' - 0" Horizontal clearance for equipment maintenance by hydraulic crane (12T capacity) .......................................................................... Vertical clearance for equipment maintenance by hydraulic crane (12T capacity) ..................................................................................... Horizontal clearance for fork lift (5000 lbs capability) and similar equipment ........................................................................................... Vertical clearance for fork lift (5000 lbs capability) and similar equipment ........................................................................................... Horizontal clearance for equipment maintenance by portable manual equipment (A-frames, hand trucks, dollies, or similar equipment) .......................................................................................... Vertical clearance for equipment maintenance by portable manual equipment (A-frames, hand trucks, or similar equipment) .................
MAINTENANCE AISLEWAYS AT GRADE
10' - 0" 12' - 0" 6" - 0" 8' 0"
3' - 0" 8' - 0"
WALKWAYS
Horizontal clearance, not necessarily in a straight line .................... 2' - 6" Headroom (except for handwheels) ................................................. 7' - 0" Minimum width ............................................................................... Minimum clearance around any obstruction on the platforms ......... Headroom ......................................................................................... Maximum vertical distance between platforms ................................ 2' - 6" 1' - 6" 7' - 0" 30' - 0"
PLATFORMS
EQUIPMENT
Minimum maintenance space required between flanges of exchangers or other equipment arranged in pairs ................................ 1' - 6" Minimum maintenance space required for structural member or pipe ..................................................................................................... 1' - 0" Clearance from edge of road shoulder (the extreme projection) ...... 5' - 0" Horizontal clearance from hydrocarbon equipment (shell to shell) . 50' - 0" Exception: Reactors or equipment in alloy systems shall be located for economical piping arrangement. Clearance from edge of roads to shell .............................................. 10' - 0"
FIRED EQUIPMENT
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Piping Engineering
ITEM PIPE (aboveground)
DESCRIPTION Clearance between the outside diameter of flange and the outside diameter of pipe insulation .................................................................. *0' - 1" Clearance between the outside diameter of pipe, flange, or insulation and structural member ........................................................ *0' - 2" *With full consideration of thermal movements
[** Verify conformance with local regulations]
B.
Accessibility 1. Provide a means of egress (a continuous and unobstructed way of exit travel) from any point in a building, elevated equipment, or structure. Provide a secondary means of escape where the travel distance from the furthest point on a platform to an exit exceeds 75 feet. Access to elevated platforms shall be by permanent ladder. The need for stairways shall be determined by platform elevation, number of items requiring attention, observation and adjustment, and the frequency of items. Indicate stairways at structures on the plot plan. Provide safety cages and ladders per applicable details of Practice 000.215.5130 (Structural) and Practice 000.258.58045 (Vessels). Ladder safety devices such as safety belts and harnesses, may be used on boiler, flare stack, water tank, and chimney ladders over 20 feet in unbroken lengths in lieu of cage protection and landing platforms [Refer to OSHA 1910.27 (d)(5)]. Arrange equipment, structures, and piping to permit maintenance and service by means of mobile equipment. Provide permanent facilities as indicated on the plot plan where maintenance by mobile equipment is impractical. Provide a clear access area at grade for vessels with removable internals or for vessels requiring loading and unloading. Exchangers with removable tube bundles shall have maintenance clearance equal to the bundle length plus 5 feet measured from the tube sheet. Provide sufficient access and clearance at fired equipment for removal of tubes, sootblowers, air preheater baskets, burners, fans, and other related serviceable equipment.
2.
3.
4.
5.
6.
7.
8.
9.
10. Plant roads may be used as tube pull areas. C. Spectacle Blinds 1.
00025050001.doc
Provide spectacle blinds as indicated on the P&IDs. Piping Engineering
2.
Spectacle blinds shall be accessible from grade or platform. Blinds located in a pipeway are considered accessible. Blinds that weigh over 100 lbs shall be accessible by mobile equipment. Where this is not possible, provide davits or hitching points. Stagger closely grouped flanges with blinds.
3. D.
Utility Stations Provide utility stations with water, steam, or air as indicated below. Use a single 50 foot length of hose to reach the entire working area from the station. Hose, hose rack, and hose connections shall be provided by the client. 1. Provide water outlets at grade level only, in pump areas, and near equipment that shall be water washed during maintenance. Provide steam outlets at grade level only in areas subject to product spills, and near equipment that requires steaming out during maintenance. Provide air outlets in areas where air-driven tools are used such as at exchangers, both ends of heaters, compressor area, top platform of reactors, and on columns, so that each manway to be serviced is within the reach of a 50 foot hose.
2.
3.
3.0
EXECUTION 3.1 Design And Drawing Practices A. Model When called for in the Scope of Work an electronic model shall be built using the appropriate design program (PDS or PDMS). It shall be built in accordance with the applicable section of the project CAD documents and the PAG (Piping Applications Guide) Manual. When called for in the Scope of Work a physical model shall be built in accordance with the applicable section of the project physical model documents and Specification 670.250.50002. B. Types of Piping Documents 1. Aboveground piping plans: Drawings with sufficient detail to indicate pipe routing, intersections, anchors, guides, supports, provisions for expansion, spare equipment, and connections to associated apparatus. Show piping plan dimensions in feet and inches. When the dimensions are less than 1 foot, use inches. Draw sections and details to show routing of piping that cannot be clearly shown in the plan drawing. Draw piping as a single line, except in areas where double line may be required for verification of clearances. Show all piping on the piping plan.
00025050001.doc
Piping Engineering
2.
Piping isometrics: 11 inch by 17 inch drawings of individual lines, or portions of lines, complete with all information required for fabrication and installation. Provide isometrics when required by Fluor Daniel to expedite the fabrication and installation of pipe. The isometric drawing number is the same as the line number. Heat tracing schedules and details shall indicate the extent, size, routing, and tracing material. Pressure Test Summary and related documents shall indicate line test pressure, test medium, and other supporting data. These documents shall be issued to Field Construction for pressure testing.
3.
4.
C.
Symbols Piping symbols shall be in accordance with Practice 000.250.9817 and Practice 000.250.9818. Identify special items of piping material by an item code number on the P&IDs and isometrics. The symbol "F" in a hexagon may be used on drawings to denote that the line beyond this symbol shall be routed at the jobsite by the field, including location of valves, field supports, and instruments.
D.
Line Identification Clearly identify pipe lines by line numbers on P&IDs and drawings, and summarize on the Pipe Line List.
4.0
ATTACHMENTS Not applicable.
End of Specification
00025050001.doc
Piping Engineering
Practice 000 250 2040 Date 11Feb00 Page 1 of 5
PLANT ARRANGEMENT - TYPICAL UNIT PLOT ARRANGEMENT PURPOSE This practice establishes recommended guidelines to assist the Piping Designer for development of a unit plot arrangement.
SCOPE This practice is arranged in the following major sections: RESPONSIBILITY ARRANGEMENT OF EQUIPMENT EQUIPMENT AND PIPEWAY CLEARANCES PIPEWAY LAYOUT REFERENCES ATTACHMENTS
APPLICATION This practice is to be used as a guideline for the development of the unit Plot Plan.
RESPONSIBILITY It is the Lead Piping Supervisor's responsibility to ensure that this guideline is followed, along with any specific client requirements.
ARRANGEMENT OF EQUIPMENT Note!!! The numbers enclosed in parentheses below refer to specific notes in circles on Attachments 01, 02, and 03. Equipment Structures The plant layout of equipment shall utilize common structures for equipment vessels and pumps. As a rule single installation of equipment will not require a structure. Vertical Vessels Vertical vessels (A1) will be on a given centerline established by the largest vessel. The shell of the largest vessel will be 2'- 0" from the aisleway reference line. Vessels that are considered larger than the average vessel (A1.1) in a unit, will be established independently with the shell located 2'- 0" from the aisleway reference line. Manways in vertical vessels will normally be located on the side of the vessel away from the pipe rack. This leaves the pipe rack side clear for pipes going to and from the rack. Ladders will be located on either side of the vessel.
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Piping Engineering
PLANT ARRANGEMENT - TYPICAL UNIT PLOT ARRANGEMENT Stacking two or more vertical vessels shall be investigated. This investigation shall consider the process conditions (commodities, temperatures, pressures), vertical height limitations, and piping layout for economic advantages. The stacking of vessels requires the acceptance of Process and Vessel engineering. Horizontal Vessels Horizontal vessels (A2) will have the head of the largest vessel line up with the aisleway reference line. All other horizontal vessels in the same vicinity will have a common tangent line coordinate with the largest vessel. It may be economical for adjacent vessels to share a common saddle coordinate to utilize a common foundation. The minimum elevation from grade is usually shown on the P&ID if it is critical for process reasons. If no elevation is expressed and minimum is required, care should be taken to allow adequate clearance for piping. Exchangers Shell and tube heat exchangers (A3.1) will be lined up with their channel heads away from the pipeways, so that tube withdrawal is toward the outside of the unit. The shell heads will be lined up so that the largest head is in line with the aisleway reference line. All other exchangers are to be lined up to have a common channel nozzle coordinate. It may be economical for adjacent exchangers to share a common saddle coordinate to utilize a common foundation. "G"- fin or fin tube type exchangers will be located (A3.2) with the centerline of the shell nozzles lined up and located such that all piping remains clear of the aisleway reference line. Horizontal reboilers (A3.3) will preferably be located next to the equipment they service. Pumps Locate pumps close to the equipment from which they take suction (A4.1). Pumps handling flammable products are not to be located under pipeways carrying major product lines, air coolers, or vessels. Pumps handling non-flammable products may be located under pipeways and air cooled exchangers. Pumps located between pipeways and equipment row should be located to avoid being hazardous to pipeway and equipment. Industrial Risk Insurers IM.2.5.2 (IRI) indicates the minimum distance to be 10 feet clear (A4.2); this distance should be verified by the clients requirements. Layout pump suctions and discharges on common centerlines, allowing the use of common pipe supports (A4.3). Aircoolers Aircoolers will normally be located above the pipeways (A5).
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Piping Engineering
PLANT ARRANGEMENT - TYPICAL UNIT PLOT ARRANGEMENT Furnaces Furnaces should be located upwind or sidewind from the rest of the unit and be separated by at least 50 feet. Compressors Compressors should be located downwind from the rest of the unit, be separated from the other equipment, and preferably not located in an enclosed building. Valve Manifolds Operational valve manifolds, control valve manifolds and utility stations (A6) are to be located for operability and access.
EQUIPMENT AND PIPEWAY CLEARANCES Walkways 2'- 6" horizontal by 7'- 0" vertical (C1.1). Aisleway For forklift or similar equipment 6'- 0" horizontal by 8'- 0" vertical. For portable manual equipment operation 3'- 0" horizontal by 8'- 0" vertical (C1.2). Access Way Mobil equipment access (hydraulic cranes, trucks, etc.) 10'- 0" horizontal by 10'- 0" vertical (C1.3). Flange Clearance Between adjacent equipment (example: shell and tube heat exchangers) 1'- 6" clearance between flanges if no other access is required (C2). Foundation Footings Minimum (2'- 6") walkway clearances are required between foundations of any equipment and any adjacent equipment or piping. Pump Clearances For pumps extending under the pipeways, a minimum 10'- 0" (C4.1) clearance is required between pumps at opposite sides of the rack. This clearance need not be in a straight line down a series of pumps under the rack. Minimum clearance of 3'- 0" is required between pumps (C4.2). The 3'- 0" dimension is a minimum requirement between adjacent equipment, foundation or piping.
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Piping Engineering
PLANT ARRANGEMENT - TYPICAL UNIT PLOT ARRANGEMENT
Exchanger Clearances Clear aisleway for exchanger shell head removal will be 6'- 0" when using a fork lift truck or portable "A" frame (C4.3). 3'- 0" clear platform is required when using a mobile crane positioned at channel end to remove shell cover (C4.3.1). 3'- 0" clear when shell cover is fixed and removal is not required. Miscellaneous Clearances Platforms will be 1'- 0" minimum clear of piping or pipeway (C4.4.1). Allow clearance for drain funnels in front of pumps (C4.4.2). Road Clearances The requirements for drainage ditches or underground pipeway easement may increase the dimension from the edge of roads to equipment (C5).
PIPEWAY LAYOUT For pipeway support elevations (P1), refer to Practice 000.250.2041: Plant Arrangement - Pipeway Layout - Allowable Pipe Spans. Pipe support spacings shall be maximized using the limits of pipe spans and structural integrity.
Location of electrical and instrument raceways will be determined by one of the following: When electrical is located primarily aboveground (P2.1), raceways for electrical and instruments will be located as shown (vertical or horizontal, with horizontal being the alternate location), taking care not to interfere with pipe turn-outs and expansion loops. On projects where electrical is predominately aboveground, the top level of the pipeway (P2.2) will be reserved for electrical and instrument raceways.
Drop space (P3), if required, for utility, steam trap, or vent piping drop space width is set by minimum clearance for largest line and may be on either or both sides of pipeway as required. The centerline of line drops (P4) will normally be 2'- 0" from centerline of P.S. column or end of cantilever, whichever is applicable. Special consideration needs to be given to large diameter lines. Width of rack (P5) will be determined by the flow diagram transposition. Refer to Practice 000.250.2010: Plant Arrangement - Flow Diagram Transposition Instructions. For pipe support spacing (P6), refer to Practice 000.250.2041.
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Piping Engineering
PLANT ARRANGEMENT - TYPICAL UNIT PLOT ARRANGEMENT
REFERENCES Piping Engineering Practice 000.250.2005: Piping Engineering Practice 000.250.2010: Piping Engineering Practice 000.250.2015: Piping Engineering Practice 000.250.2041: Plant Arrangement - Plot Plan Development Instructions Plant Arrangement - Flow Diagram Transposition Instructions Plant Arrangement Location Control Plan Instructions Plant Arrangement - Pipeway Layout Allowable Pipe Spans
ATTACHMENTS Attachment 01: (11Feb00) Unit Plot Arrangement Attachment 02: (11Feb00) Section Thru Pipeway, Standard Arrangements Attachment 03: (11Feb00) Space Allocation At Support Columns
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Piping Engineering
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION EXERCISE Page 1 of 13 15/11/2002 Rev. 0 VESSEL ORIENTATION EXERCISE HORIZONTAL VESSEL EXERCISE INSTRUCTION EXERCISE #1 Orientate 28-V-6 Reference Material Figures # 1 thru #4 Show all orientation requirements needed to give study to "Vessels." Include block chart (See Figure # 1B) and section of manifold. 28-100CS comes from 28-E-7 in structure at channel out (bottom of 28-E-7). Face of 10" - 300# RF nozzle - El. 125' - 61/2" 28-13AS goes to P/W and East. 28-102CS goes to 28-C-1 at nozzle shown on plot plan. Material specification: "CS" 300# RF 304 S.S. 1-1/2" and smaller - S.W. constr. 1/8" gasket "AS" 150# RF 304 S.S. 1-1/2" and smaller - S.W. constr. 1/8" gasket. All pipe fittings and valve sizes can be found in practice 000.250.9810 All Butt-welded branches are reducing tees. Use WNK flanges in all size
Drawing to be 3/8" = 1'-0" scale. Level controller is top-to bottom-side. Students to determine correct elevation of LC and LG connections. Give coordinate at anchored support. Show 28-13AS and 28-102CS to first turn in P/W and show 28-100CS from the bottom tube outlet of 28-E-7.
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION EXERCISE Page 2 of 13 15/11/2002 Rev. 0
EXERCISE #1
Figure # 1A Example NOZZLE SIZE AND RATING FACE ELEVATION R 18"-600# RF C.L. 114"-6 1/2"
Figure # 1B
EXERCISE #1 Mechanical Flow Diagram
Figure # 2
EXERCISE #1 Plot Plan
Figure # 3
EXERCISE # 1 Vessel Orientation Figure #4 28-V-6 Cond. K.O. Drum Details
VERTICAL VESSEL EXERCISE INSTRUCTION EXERCISE # 2A 1. Encircle the items in sketch below that require platform. (plan is cut above 15'-0" from grade) 2. Using the relative location of the nozzle shown on the sketch below & the flow arrows as a clue identify the function of each. Name functions, 7 req'd (not letter callout).
Figure # 5
EXERCISE # 2B For each of the nozzles shown below, fill out the chart (see Figure # 7) for supports and guides, considering 3" min. between welds (Refer back to Figures # 4-40, and # 4-41).
Figure # 6
EXERCISE # 2B Chart
Figure # 7
EXERCISE 3A 1. In the illustration below (Figure #8) show the required number of supports & guides for the 3" line. Label each support or guide and give the elevation. Use Figures # 4-40 and # 4-41 for guide and anchor charts. Pipe shown is 3"-SCH. 40. Nozzle = 150#RF (1/16" gasket) Projection = 3'-6" from centerline of column. Use weld neck at nozzle.
Figure # 8 2. What is the minimum acceptable "L" dimension using Fluor Daniel standards. a. @ 6'-0" I.D. section b. @ 10'-0" I.D. section __________________ __________________ .
EXERCISE 3B 1. In the illustration below (Figure #9) show the required number of supports & guides for the 10" line. Label each support or guide and give the elevation. Use Figures # 4-40 and # 4-41 for guide and anchor charts. Pipe shown is 10"-SCH. 40. Nozzle = 150#RF (1/16" gasket) Projection = 3'-6" from centerline of column. Use weld neck at nozzle.
Figure # 9 What is the minimum acceptable "L" dimension using Fluor standards. a. @ 6'-0" I.D. section ______________ b. @ 10'-0" I.D. section ______________ .
EXERCISE # 4 1. Orientate 33-C-1 2. Drawing to be 3/8" - 1'-0" scale, produce cut @ each platform required. Give degree of platforms, ladders, and nozzles @ each plan. Indicate orientation of trays and call out odd and even numbers. Show M.H. swing and nozzle designations. Draw section of control valve manifold LCV line # 33-4AB-6" Show nozzle and pipe support block chart. Determine the elevation of LC and LG nozzle per Fluor standard. Hook up per details below (Figure #9). MATERIAL SPECIFICATION: "A" and "AB" 150# R.F. 1/16" gasket 1-1/2" and smaller SW construction. "B" 150# R.F. 1/16" gasket 1-1/2" and smaller SW connection. "N" 150# R.F. 1/8" gasket 1-1/2" and smaller SW construction. Use WNK flanges for all sizes and all specs. All branches are stub-in.
3. Dimensionally locate centerline of vessel from P.S. columns.
Figure # 10
EXERCISE # 4 1. Pilot arrangement below (Figure #11) to show equipment relationship for orienting column 33-C-1.
Figure # 11 Figure #12 P&ID Gas Amine Unit Figure #13 33-C-1 Squad Check Figure #14 33-C-1 Column Details
EXERCISE # 4 (CONT'D) NOZZLE CHART FOR 33-C-1 NOZZ. Example X SIZE & RATING 3"-150# R.F. ORIENTATION 30O CENTERLINE ELEVATION (Or as noted) EL. 112'-3"
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION TEST Page 1 of 7 15/11/2002 Rev. 0
HORIZONTAL VESSEL TEST

Number in Parenthesis Indicates Point Value of Each Question Name: ______________________
Completion - Fill in each blank with the word or words which best complete the statement or answer the question. 1. What is the min. B.O.P. above H.P.F.S. for a pump suction line crossing an operating aisle from a vessel bottom? __________________________________________________ (4 pts) The ______________________________ is used to prevent "whirlpool" movement of the liquid on the inside of the vessel at the ___________________________________ nozzle. What might be the result of allowing the liquid to "whirlpool?" ________________________ (9 pts) If a platform is not required on the top of the vessel, the usual location for the manhole is ________________________________________________________________________ (6 pts) We normally anchor the support _____________________________(nearest to or farthest from) the pipeway. Why? (9 pts) Sometimes you might find a manhole located as shown in the drawing below (Figure #1). What would be the reason for this? ____________________________________________ ________________________________________________________________________ (6 pts)
2.
3.
4.
5.
Figure # 1
Suppose you are doing a study of a horizontal vessel during the early stages of the job. No outline is yet available to you and you want to establish the support locations. You have the following information. Fill in the missing dimensions. (6 pts)
Figure # 2 7. What factors normally set the height of a horizontal vessel? (8 pts) (A) ___________________________________________________________________ (B) ___________________________________________________________________ True - False 8. 9. ________ The manhole is normally located on the end of the vessel nearest the pipeway. (4 pts) ________ The level control and gage glass bridle is usually found on the same end as the outlet. (4 pts)
10. ________ A horizontal vessel requiring a top platform would probably have its manhole on (4 pts) the top. 11. _______ Inlet and outlet connections should be on opposite ends of the vessels. Why? ___________________________________________________________________ (8 pts)
12. Identify each of the numbered nozzles in the sketch below by its correct symbol. (24pts) 12 thru 17
Figure # 3 18. 19. Place the symbol (4 pts) V on the drawing where you would find the vortex breaker.
Place the symbol X on the drawing where the vessel would probably be anchored. (4 pts)
VERTICAL VESSEL TEST

NUMBER in Parenthesis Indicates points value of each question. 1. 2. Name _______________________
On which side of a vessel are manholes generally located? _________________________ (3 pts) What determines where a platform is needed? ___________________________________ _______ _________________________________________________________________ (3 pts) Which items make up vessel trim? (List five) ____________________________________ ________________________________________________________________________ (10 pts) Where would you find the vessel trim line number? _______________________________ ________________________________________________________________________ ________________________________________________________________________ (3 pts) What are vessel davits used for? _____________________________________________ ________________________________________________________________________ ________________________________________________________________________ (3 pts) What is meant by a "Vessel Drop Zone"?________________________________________ ________________________________________________________________________ ________________________________________________________________________ (3 pts) On which side of a vessel would you expect to find the nameplate? ___________________ ________________________________________________________________________ (3 pts)
3.
4.
5.
6.
7.
8.
On the Figure # 4, locate a vapor sample connection and a liquid temperature connection. (4 pts)
Figure # 4 9. What is the definiton of "L" Dimensions? ________________________________________ ________________________________________________________________________ (3 pts)
10. Who is responsible for setting nozzle elevations? _________________________________ ________________________________________________________________________ (3 pts) 11. Which way should manhole covers swing? ______________________________________ ________________________________________________________________________ (3 pts) 12. What establishes the elevation of manholes? ____________________________________ ________________________________________________________________________ (3 pts) 13. Where are vessel supports generaly located? ____________________________________ ________________________________________________________________________ (3 pts) 14. On Figure # 5 what is minimum dimension "A"? __________________________________ ________________________________________________________________________ (4 pts)
15. On Figure # 5 mark an "X" on the line where you would probably support it. (4 pts)
Figure # 5
16. What type of connection do the following nozzle identification letters stand for? (4 pts each) "A" "R "F" "B" "S" "L" "V" "G" "M" ___________________________________________________________________ ___________________________________________________________________ _ __________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________
17. What are the maximum vertical runs of ladder without offset? (Do not include the 4' extension above platform.) (6 pts) A. ___________________________________________________________________
B ______________________________________________________________________ . 18. What is the "L" dimension of the piping configuration in Figure #6?. (3 pts)
Figure #6
PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION TEST GRADING MASTER Page 1 of 6 15/11/2002 Rev. 0
HORIZONTAL VESSEL TEST - GRADING MASTER

Number in Parenthesis Indicates Value of Each Question NamePoint
Completion - Fill in each blank with the word or words which best complete the statement or answer the question. 1. What is the min. B.O.P. above H.P.F.S. for a pump suction line crossing an operating aisle from a vessel bottom? 8'-0" (4 pts) ___ is used to prevent "whirlpool" movement of the 2. The ________vortex breaker_ liquid on the inside of the vessel at the _______ liquid outlet __________ nozzle. What might be the result of allowing the liquid to "whirlpool?" __cavitate pumps___________ (9 pts) 3. If a platform is not required on the top of the vessel, the usual location for the manhole is ___in the end of the vessel_______________. (6 pts) 4. We normally anchor the support ______ nearest to___________ (nearest to or farthest from) the pipeway. Why?__ to provide vessel expansion to aid piping flexibility _____________________________________ _________ __ (9 pts) 5. Sometimes you might find a manhole located as shown in the drawing below. (Figure #1) What would be the reason for this?___ centerline would be above 15'-0" requiring a platform __________________________________________________________________ (6 pts)
Figure #1
6. Suppose you are doing a study of a horizontal vessel during the early stages of the job. No outline is yet available to you and you want to establish the support locations. You have the following information. Fill in the missing dimensions. (6 pts)
2'-0"
6'-0"
2'-0"
Figure # 2 7. What factors normally set the height of a horizontal vessel? (8 pts) (A)___NPSH to pumps_ ___________________________ (B)___8'-0" minimum headroom clearance from BOP of the outlet lines and H.P.F.S__ _ True - False 8. ___F_____ The manhole is normally located on the end of the vessel nearest the pipeway. (4 pts) 9. ___T____ The level control and gage glass bridle is usually found on the same end as the outlet. (4 pts) 10. __T_____ A horizontal vessel requiring a top platform would probably have its manhole on the top. (4 pts) 11. ___T___ Inlet and outlet connections should be on opposite ends of the vessels. Why? _ to avoid short circuiting the vessel (8 pts) __
Identify each of the numbered nozzles in the sketch below by its correct symbol. (24pts) 12 thru 17
Figure # 3 18. Place the symbol (4 pts) V on the drawing where you would find the vortex breaker.
19. Place the symbol X on the drawing where the vessel would probably be anchored. (4 pts)
VERTICAL VESSEL TEST - GRADING MASTER

NUMBER in Parenthesis Indicates points value of each question. Name
1. On which side of a vessel are manholes generally located? Rear of vessel ( away from pipeway) (3 pts) 2. What determines where a platform is needed? Access to manholes and operating valves, blinds, and instruments (3 pts) 3. Which items make up vessel trim? (List five) relief valves , and instruments (10 pts) Where would you find the vessel trim line number? flow diagram (3 pts) What are vessel davits used for? to grade (3 pts) Vents, drains, steamouts,
4.
Under vessel title on
5.
Lowering vessel internals and attachments
6. What is meant by a "Vessel Drop Zone"? lowering items to grade. (3 pts)
The side of the vessel used for
7. On which side of a vessel would you expect to find the nameplate? (3 pts)
Operating aisle
8. On the Figure # 4, locate a vapor sample connection and a liquid temperature connection. (4 pts)
Figure # 4
9. What is the definiton of "L" Dimensions? (3 pts)
Back of pipe to outside of vessel Process engineer Away from ladder leading to lower level Tray arrangement and spacing As close as possible to nozzle 12"-6"
10. Who is responsible for setting nozzle elevations? (3 pts) 11. Which way should manhole covers swing? (3 pts) 12. What establishes the elevation of manholes? (3 pts) 13. Where are vessel supports generally located? (3 pts) 14. On Figure # 5 what is minimum dimension "A"? (4 pts)
15. On Figure # 5 mark an "X" on the line where you would probably support it. (4 pts)
12'-6"
Figure # 5
16. What type of connection do the following nozzle identification letters stand for? (4 pts each) "A" "R" "F" "B" "S" "L" "V" "G" "M" Inlet Reflux Feed Outlet Steam or sample connection Level instrument Vapor or vent Level gage or gage glass Manhole
17. What is the maximum vertical run of ladder without offset? (Do not include the 4' extension above platform.) (6 pts) A. 30'-0" between platform B. 29'-6" H.P.F.S. to platform 1'-0 13/16"
18. What is the "L" dimension of the piping configuration in Figure # 6? (3 pts)
Figure # 6

4lesson (Vessel Orientation)

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PIPING DESIGN LAYOUT TRAINING LESSON 4 VESSEL ORIENTATION Page 1 of 79 15/11/2002 Rev. 0 4. VESSEL ORIENTATION 4.

TYPES OF STORAGE VESSELS

ASME BOILER AND PRESSURE VESSEL CODE

Figure # 4-4 Horizontal Vessel General Arrangement

Figure # 4-5 Vortex Breaker 4.8.4 Height of Horizontal Vessels

Figure # 4-6 Vessel Below 15'-0"

FIGURE # 4-7 Vessel Above 15'-0"

Figure # 4-8 Manhole Location

Piping Design Supervisor or Roller Board

Steps to accomplish horizontal vessel study

Figure # 4-15A Manhole Clearances at Platforms

Figure #4-15B Ladders and Platforms for Vessels

Figure # 4-45 4.11.13 Vessel Skirt Height

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 1 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Originator's Name & Initials

Reviewed/Checked By Name & Initials

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 2 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 3 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 4 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 6 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Exchangers 1. Group exchangers together wherever possible.

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 7 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 8 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 9 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 10 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 11 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

Client Name Project Name Contract Number

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

MAINTENANCE AISLEWAYS AT GRADE

10' - 0" 12' - 0" 6" - 0" 8' 0"

3' - 0" 8' - 0"

Client Name Project Name Contract Number

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

ITEM PIPE (aboveground)

[** Verify conformance with local regulations]

Provide spectacle blinds as indicated on the P&IDs. Piping Engineering

Client Name Project Name Contract Number

Master Specification 000 250 50001 Date 18Jan00 Page 15 of 16 Revision

Figure # 4 9. What is the definiton of "L" Dimensions? ________________________________ (3 pts)