3/28/2017 Piperackpipingstudy

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Piperackpipingstudy:
Mythispostexplainsthestepsrequiredtobeperformedforcarryingoutpiperackpipingstudy.

Generalarrangementofthepiperackisfinalizedduringthedevelopmentoftheoverallplotplan.Thepiperackmaybeanintegralpartofa
processunitlocatedinthemiddleoftheunitoritmaybeanarterialpartconnectingseveralservicesofotherprocessunits.

Thefollowingdataanddrawingsarerequiredtobestudiedbeforestartingthedetaileddesignofpiperackpipingstudy:

UnitPlotPlan/OverallPlotPlan
PipingandInstrumentationdiagrams
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Plantlayoutspecification
Clientspecification
Materialofconstruction
Fireproofingrequirements

Normally,thepiperackpipingstudy,withitsstructuralandplatformrequirementsisthefirstpriorityitemfordetailengineeringofaprocess
unit.

Thepointswhicharefinalizedduringthepiperackpipingstudyare:

Exactwidthofthepiperack
Numbersoflevelsandelevations
Accessandmaintenanceplatformsrequirements

Therearenumberofpipelineswhichareroutedthroughthepiperack.Beforestartingthepiperackpipingstudyitisessentialtoclassify
thesepipelines.Pipelinesinthepiperackareclassifiedasprocesslines,relieflineheadersandutilityheaders.

Processlines:
(a)Whichinterconnectnozzlesonprocessequipmentmorethan20ft.apart(closerprocessequipmentcanbedirectlyinterconnectedwith
pipelines)

(b)Productlineswhichrunfromvessels,exchangers,ormoreoftenfrompumpstotheunitlimitstostorageorheaderarrangementoutside
theplant.

(c)Crudeorotherchargelineswhichentertheunitandusuallyrunintheyardbeforeconnectingtoexchangers,furnacesorotherprocess
equipmente.g.holdingdrumsorboosterpumps.

Relieflineheaders:

Individualrelieflines,blowdownlinesandflarelinesshouldbeselfdrainingfromallreliefvalveoutletstoknockoutdrum,flarestackor
toapointattheplantlimit.Apocketedrelieflinesystemismoreexpensive,becauseusuallyanextracondensatepotisrequiredwith
instruments,valvesandpumps.Toeliminatepocketssomerelieflineheadersmustbeplacedathigherelevationabovethemainyard
usuallyonateesupportontheextendedpiperackcolumn.However,onsomenoncondensinggassystemsselfdrainageisnotsoessential.
Relieflinescanbeindividual,somewithlargediametersandoccasionallyhightemperatures.

Utilitylines:

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Utilitylinesinthepiperackcanbeputintwogroups:

(a)Utilityheadersservingequipmentinthewholeplant.Suchlinesare:lowandhighpressuresteamlines,steamcondensate,plantairand
instrumentairlines.Ifrequired,coolingwatersupplyandreturnandservicewatercanalsobearrangedonthepiperack.

(b)Utilitylinesservingindividuallyoneortwoequipmentitemsoragroupofsimilarequipment(furnaces,compressors)intheplant.Such
linesare:boilerfeedwater,smootheringsteam,compressorstartingair,variousfueloillines,lubricatingoil,coolingoil,fuelgas,inertgas
andchemicaltreatinglines.

Steamheadershoulddraintothesteamseparatorformoreeffectivecondensatecollection.

Branchconnectionstosteamheadersusuallyconnecttothetoptoavoidcondensatedrainagetoequipment.

InstrumentlinesandElectricalcables:
InstrumentlinesandElectricalcablesareoftensupportedintheyardandextraspaceshouldbeprovidedforthesefacilities.Thebest
instrumentlinearrangementeliminatesalmostallelevationchangesbetweentheplantandthecontrolroom.Thiscanbeeasilyachieved
wheninstrumentlinesaresupportedoutsidethepiperackcolumnonasuitableelevation.

STEPSTOPIPERACKPIPING:

Thefirststepinthedevelopmentofanypiperackisthegenerationofalineroutingdiagram.Alineroutingdiagramisaschematic
representationofallprocesspipingsystemsdrawnonacopyofpiperackgeneralarrangementdrawing/orontheunitplotplan
wherethepiperackrunsinthemiddleoftheprocessunit.

BasedontheinformationavailableonthefirstissueofP&IDiagram/Processflowdiagrami.e.linesize,linenumber,pipematerial,
operatingtemperatureetc.thelineroutingdiagramistobecompleted.

Oncetheroutingdiagramiscomplete,thedevelopmentofrackwidth,structuralcolumnspacing,roadcrossingspan,numbersof
levelsandtheirelevationsshouldbestarted.

Piperackcolumnspacingshallbedecidedbasedontheeconomicsofthepipespanaswellasthetrussarrangementtoaccommodatedouble
thespanforroadcrossingoravoidingundergroundobstructions.

Piperackarrangementshouldbedevelopedtosuitthespecificplantrequirements.

Thepiperackwidthcannowbeworkedoutwithatypicalcrosssectionoftherackwiththelevels.

Normally,piperackscarryprocesslinesonthelowerlevelorlevelsandtheutilitylinesonthetoplevel.Instrumentandelectricaltraysare
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integratedontheutilitylevelifspacepermitsoronaseparatelevelaboveallpipelevels.

Anypiperackdesignshouldprovideprovisionforfuturegrowthtotheextentof25to30%ontherackclearwidth.

Whenflangesorflangedvalvesarerequiredontwoadjacentlines,theflangesaretobestaggered.

Thermalexpansionorcontractionmustbeaccommodatedbykeepingsufficientclearanceatthelocationwherethemovementswilloccur.

Theclearanceofthefirstlinefromthestructuralpiperackcolumnistobeestablishedbasedonthesizesfurnishedbythecivil/structural
engineers.

Afteranalyzingalltherequirementsandarrangements,thedimensionsaretoberoundedofftothenextwholenumber.Basedonthe
economics,thewidthandthenumberlevelse.g.twotierof30ft.wideorthreetiersof20ft.widerackwillbedecided.

Thegapbetweenthetiersshallbedecidedonthebasisofthelargestdiameterpipelineanditsbranching.Thedifferencebetweenthebottom
lineofpipeintherackandthebottomofabranchasitleavestherackshallbedecidedcarefully,toavoidanyinterferenceduetosupport,
insulation,sizeofbranchetc.Allbranchlinesfromthemainlinesonpiperackshallbetakenaestheticallyonacommontopofsteel(TOS).

Withtheaboveconsiderations,theconceptualarrangementofpiperackistobefinalized.

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Fig1Typicalcrosssectionforcompositepiperack

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