Handout 2012

GOLD GATE ENGINEERING INSTITUTE
93/95 ALIMOSHO RD, IYANA IPAJA,

LAGOS.
www.goldgateengr.com
GOLDGATE ENGINEERING INSTITUTE. www.goldgateengr.com Page 1

Process Piping
Process Piping is the piping that convey fluids under pressure or vacuum inside the boundaries of a
Chemical plant, Petroleum refinery, Gas Processing plant, Petrochemical, Pharmaceutical, Textile,
Paper, Semiconductor & Cryogenic Plants falls under the scope of ASME B 31.3*
Process piping is a complex arrangement of pipes, valves, support clamps, other related components
and control instrumentation.
Pipe: It is a pressure tight cylinder which is used to carry fluid from one place to another. It carries
fluid as well as it pressure. Materials which are carried by pipes are
SOLID SEMI-SOLID LIQUID Gaseous
Powder Slurries (e.g. crude oil) water Air
Pellets Steam, H2, N2
The dimensional requirement to be followed for pipe is

ASME B36.10 Wrought Steel Pipe
ASME B36.19 Stainless Steel Pipe
Introduction to ASME codes and standards.
Standards: Can be defined as a set of technical definitions and guidelines for designers and
manufactures. Piping standards define application design and construction rules and requirement for
piping component. There are two types of standard: dimensional standard and pressure integrity
standard. Standards are considered voluntary because they serve as guidelines, not having the force
of law.
Dimensional Standard provides configuration control parameters for components. Meaning, to

ensure that similar component manufactured by different suppliers will be physical interchangeable.
Pressure-integrity standard provides for uniform minimum performance criteria. Meaning,

components designed and manufactured to the same standard will function in an equivalent manner
in terms of pressure- temperature.

Code: A code is a standard adopted by one or more government bodies and has the force of law, or
when it has been incorporated into a business contract. Piping codes defines the requirement of
design, fabrication, use of materials, test and inspection of pipes and piping system.
Piping codes provides specific design criteria such as permissible material of construction,
allowable working stress and load set that must be considered in design. In addition, rules are
provided to determine the minimum wall thickness and structural behaviors due to the effect of
internal pressure, dead weight, seismic load, live load, thermal expansion and other imposed internal
or external load.
ASME B 31 CODE
The ASME B31 code for pressure piping consists of a number of individually published sections,
each an American National Standard, under the direction of ASME committee B31, code for
pressure piping.
The code set forth engineering requirements deemed necessary for safe design and construction of
pressure piping.
• ASME B31.1 Power Piping

• ASME B31.4 Pipeline Transportation Systems
• ASME B31.5 Refrigeration Piping and Heat Transfer Components
• ASME B31.8 Gas Transmission and Distribution Piping Systems
• ASME B31.9 Building Services Piping
• ASME B31.11 Slurry Transportation Pipelines
Introduction to Piping System
Piping systems are like arteries and veins. Piping includes pipe, flange, fittings, bolting, gasket,
valves and the pressure containing portions of other piping components. It also includes pipe
hangers and supports and other supports and other item necessary to prevent over stressing.
1. They transport water from the source of water supply to the point of distribution, convey
waste from residential etc
2. Pipelines carry crude oil from oil wells to tank for storage or to refineries for processing.
3. The natural gas transportation and distribution lines convey natural gas from the source and
storage tank farms to point of utilization.

4. The fire protection piping networks in residential, commercial and other building carry fire
suppression fluids such as water, gases and chemical to provide protection of property.
5. The piping system in thermal power convey high-pressure and high-temperature steam to
generate electricity
Pipe Sizing
Just as manufacturing methods differ, there are also different ways to categorize the size of a pipe.
Pipe is identified by three different size categories: Nominal pipe size, outside diameter, and inside
diameter
Iron pipe size (IPS). It is used for representing diameter of pipe. It is dimensionless size designator
of the pipe which represents the inside diameter „ID‟ of the pipe.
OD = ID + 2t
OD = Outside diameter
T = thickness
Example: A pipe of IPS 6 means it as an inside diameter of 6”
Nominal pipe size (NPS). It is a dimensionless size designator of the pipe which represents the
outside diameter of the pipe e.g. NPS 6” means outside diameter of 65/8
NPS O.D
1 15/16
2 23/8
3 31/2
4 41/2
6 65/8
8 85/8
10 103/4
12 123/4
14 14
Note: Up to NPS 12” the OD is greater than the NPS while from NPS ≥ 14 are equal to the OD.

Nominal/Nominal Bore: It is a dimensionless Size designator of the pipe which represents the
outside diameter of the pipe in millimeters (mm).
NPS (Inches) DN (mm)

¼ 8
½ 15
1 25
11/2 40
2 50
3 80
4 100
6 150
8 200
10 250
12 300
14 350
Thickness of pipe: Wall thickness is a term used to describe the thickness of the metal used to
make a pipe. It is represented by calling out the schedule number. Schedule number is denoted by
„SN‟
SN = 100 x p
S
P = Internal pressure (psi or kg/cm3)
S = allowable stress
Example
NPS 6”
SCH NOS 20 = 0.206”
SCH NOS 40 = 0.403”
Wall thickness is also commonly referred to as pipe weight. There re 3 types

(1) Standard weight- STD
(2) Extra strong (XS) or Extra Heavy.
(3) Double extra strong (XXS) or double extra heavy.

PIPE ENDS
1) Plain ends (PE)
 For plain ends, sockets weld is used for joining the pipes.
2) Threaded or screwed end (TE)
 For threaded ends, threaded joints are used.
3) Beveled end (BE)
 Beveled ends are used for joining large bore pipes. Butt welding is used to join the
pipe
PIPE JOINING METHODS
Socket Weld
In a socket weld, the pipe is inserted into the socket, backed off slightly to make a gap between the
end of the pipe and the bottom of the socket, and the weld is made around the outside diameter of
the socket to the outside diameter of the pipe. The gap at the bottom of the pipe prevents thermal
expansion from stressing the joint during or after welding.
The disadvantage of socket welding is the 1/16 recess

or gap which pockets fluid and it is not recommended
by the code when the fluid is highly corrosive in
nature.
Threaded Joint
A mechanical joint between threaded pipes or between

a threaded pipe and threaded fitting. Typically used on
pipe 3‟‟ and below
Butt welded Joint:

This is the most suitable way of joining large bore pipe. It is more time consuming because the ends
have to be prepared by chamfering before butt welding. It is not permitted where there is chance of
fire hazards
Pipe Manufacturing Method
(1) Seamless (i.e. No joint in the pipe ) its manufactured up to NPS 18

(2) ERW – Electrical resistance weld
(3) EFW - Electrical fusion weld
(4) SAW- Sub merged Arc weld
(5) Spiral weld (Helical)
All these welded joints if 100% radiographer is equal to the seamless pipe efficiency.
N.B. Radiography is a method used to know the defect or flaws of a welding.
Pipe rating or P-T Rating
Pipes are classified into different classes based on P.T rating. There are 7 types of P.T ratings.
(1) 150# (2) 300# (3) 400# (4) 600# (5) 900# (6) 1500#
(7) 2500#.
(#)- Symbol for rating or class.
Sample Problem 1
Determine the flange rating/class for a new piping system to be installed at existing plant.
• Pipe Material: 11/4 CR- ½ Mo • Design Temperature: 700°F • Design Pressure: 500 psig
• Determine Material Group Number from code book

Group Number = 1.9
• Find allowable design pressure at intersection of design temperature and Group number
Check Class 150.

Allowable pressure = 110 psig < design pressure
Move to next higher class and repeat steps
• For Class 300, allowable pressure = 570 psig

• Required flange Class: 300
PIPE SYMBOL
Double Line Single Line
Single line for NPS 12 and below

Double line for NPS 14 and greater
NOTE
1. The most common material used for pipe is carbon steel (CS) 800oF or 427oC maximum.
2. Low allow steel- It can be used above 800F< 1200
3. Stainless steel- It can be used above 1200oF ≤ 2400oF.

Pipe Fittings
The purpose of fitting is to make the piping system more flexible. Flexibility in a piping system is
the ability of the pipe to absorb thermal growth.
1. Elbow- used for directional changes 2. Reducers- used for changing pipe size
3. Tee- used for branching of the main
TYPES OF ELBOWS
90O ELBOW
1. 90O Long radius elbow (LR ELL)
1½ X NPS
Radius “R”= centre to end dimension = 1½ X NPS
Drafting Symbols

Drop symbol for Pipe: It is an incomplete circle used to show the pipes and
fittings in the drawing when the Pipe is moving away from your view
- .
A rise symbol for pipe is used to show the rise of the pipe and fittings in th
drawing when the pipe is coming towards your view.
2 SHORT RADIUS ELBOW (SR ELL)
1 x NPS
NPS 2 3 4 6 8 10 12 14
R 2 3 4 6 8 10 12 14
Long radius elbow is the most commonly used elbow in piping, unless otherwise stated in the
drawing, the elbow is always considered as long radius elbow.
Short radius elbows are used when available space is less

More pressure drop and friction loss because of the sudden changes in direction.
MITER.
It is made by cutting pipes into angular pieces and then welding together all
those pieces. Miters are used for large bore pipes. Miters cannot be used for
high temp and pressure. Miter can be made at site and are cheaper than the
manufactured elbow. We have, single miter, two miter, three miter etc
depending on the number of weld joint

Reducing Elbow
It is used to serve the purpose of directional change as well as size
reduction of the pipe. Reducing elbows should always be drawn in
double line even for small bore pipes.
Radius R = centre to end dimensional = 1.5 x NPS
Note: that there are two NPS valves for the reducing elbow but we make use of the larger value for
calculating the radius of the elbow.
Drafting symbol
450 Elbow
It is used to change the pipe or flow direction by an angle

of 450
S Drafting symbol

NPS 2” 4” 4” 6” 8” 10” 12” 14”
O.D 23/8 31/2 41 / 2 65 / 8 85/8 103/4 123/4 14
B 13/8 2 21 / 2 33 / 4 5 61/4 71/2 83/4
WELD TEE
It is used to make a branching from the main pipe (Header). There
are two types.
1. Straight tee or equal tee.
2. Reducing tee.
NPS 2 3 4 6 8 10 12 14
OD 23/8 31 / 2 41 / 2 65/8 85/8 3 3
10 /4 12 /4 14
Centre to 21/2 33 / 8 41 / 8 55/8 7 81/2 10 11
End dimension

Another method of making branch connection alternatively to a weld tee is
(1) STUB IN and (2) STUB ON
STUB IN A hole is bored in the header equal to the body of the branch pipe. Here the branch
size is two or more size lesser than the header size.
Example
Header size NPS = 4
Branch size NPS = 2 or NPS 1
STUB ON In this type of branch connection a hole is bored in the header which is equal to the ID
of the branch pipe.
A stub- on is used when the branch size is one size less
than the header or equal to the header e.g. Header =
NPS4
Branch = NPS 3 or NPS 4.
A stub-in uses only one welding where as Tee has got three welds
Class work: Draw the drafting symbol of a stub-on.
Reinforcement Pad- A steel ring is cut from a plate with a hole equal to the branch `OD` which is
to be reinforced. It is then slipped into the branch and then welded to the branch and then welded to
the branch and header.
Drafting symbols
Reinforcement saddled-
It is a purchase fitting and it has got extra short neck to give
extra support to the branch pipe
Drafting symbols

O-LETS (SPEACIAL FITTINGS). These are also used for branch connections. Used when
standard Tee size is not available. They have the advantage of being installed without having to cut
the main pipe. There are different types of „O-Lets
1) Weld O-let (4) Sweep O-let
2) Socket O-let (5) Elbow O-let
3) Thread O-let (6) Later O-let.
WELD OLET: It is used for butt welded branch connection. Can withstand higher pressure
compare to a stub in. This is a purchased fitting
SOCKET OLET: It is used to make a branch connection for small bore pipes.
THREAD OLET:
It is used to make a branch connection for small bore

pipes.

SWEEP OLET
It is also used to make 90 degree reducing branch from

the main run of pipe. It is primarily developed for high-
yield pipe used in oil and gas transmission lines.
ELBOW OLET
It is used to make a branch connection at the elbow. It is used

mostly to insert instruments into small bore pipes.
LATEROLET
It is used to make a branch connection at an angle of 450 to

the header.
RETURNS:
It is used to make a turn off angle of 1800 in
the pipe. It is equal to combining two 900
elbows

CROSS:
It is used to make two branch connections at one point in a
header. There are 2 types of cross (1) equal cross
(2) Reducing cross. In equal cross, the branch size is equal
to the header size while in reducing cross, the branch size
is less than the header size.
REDUCERS: It is used either to reduce or expand the pipe size. They are of two types.
1. Concentric Reducer
2. Eccentric Reducer
NPS 2 3 4 6 8 10 12 14
O.D 23/8 31/2 41/2 65/8 85/8 3 3
10 /4 12 /4 14
End to 3 31/2 4 51/2 6 7 8 13
End
Eccentric Reducer Eccentric reducers can be used anywhere in the piping system. It is costlier than
concentric reducer. It is used on the pipe rack to balance the pipeline and also at the suction side of
the pump.
Eccentric reducers are always used with flat on top on the suction side of the pump to prevent
cavitation. Cavitation means that cavities or bubbles are forming in the liquid that we're pumping.
These cavities form at the low pressure or suction side of the pump, causing several things to
happen all at once. The cavities or bubbles will collapse when they pass into the higher regions of
pressure, causing noise, vibration, and damage to the impellers
The reducers are used on the suction and discharge sided of the pump as the pump nozzles are
always of less size compare to its attached external piping.

COUPLING
It is used primarily for connecting small

bore screwed and socket weld pipe to
large bore pipe header
It is used to make branches of small bore pipe from large bore headers. A
hole is bored in the header which is equal to the OD of the half coupling
Half Coupling: and then it is inserted into the hole and welded to the header. Half
coupling is used to join large bore header with small bore branch
connection.
One side is beveled & the other is threaded. It is generally used for (1) Sampling lines. (2) Vent
lines (3) Drain lines (4) Instrument connection.
CAP: It is used to close the open end of a pipe by means of welding.
Single line Double line
PLUGS
It is used to close the open end of a pipe. Plugs are manufactured for
screwed fittings only

SWAGE
It used as an alternative to the reducer when

greater reduction in size is required. It is specially
designed for screwed and socket weld pipe
connection with butt welded pipe (large bore
pipes).
These are of 2 types (1) concentric (2) eccentric
Swages are larger than reducers. The ends of the swages are defined as:
BPE – Both plane ends

PLE – Plan larger end
PSE – Plan small end
TSE – Threaded small end
BLE – Beveled large end
PLE
/TSE – Plain larger end / threaded small end.
BLE
/PSE – Beveled large end / plain small end.
Spool: A piece of pipe which is used to connect piping components is called a spool.
Fitting make up: When fittings are directly welded to one another

UNION
It is used to join threaded and socket welded pipes. A union is

used to allow for frequent disassembling. It cannot withstand
higher pressure.
Sockets and screw classes or rating (#) are classified into 4 classes
(i) class 2000
(ii) class 3000
(iii) class 6000
(iv) class 9000
Class 2000: It is used for screw fitting and the corresponding pipe size is schedule 80 or extra
strong.
Class 3000: It is used for screw as well as socket welded fitting and the corresponding pipe size is
socket / sch 80 (xs) and thread / sch 160.
Class 6000: It is used for socket weld as well as screwed fitting and the corresponding pipe size for
socket weld is sch 160 while threaded is (extra extra strong)
Class 9000: Used for only socket weld fitting and the schedule of the pipe used for this fitting is
double extra strong.
N.B – class 2000 and 3000 are the most used classes of them all.
* Dimensional standards are given by ANST / ASME

* Material of construction is given by ASTM (American Society of Testing & materials)
 The dimensional style used for screw & socket welded fitting is ASME B16.11, MOC (material of
construction) for screw & socket welded fitting is ASTM A105 – forged carbon steel fitting ASTM
or SA 105 for elevated temperature.

Note: Branching based on the type of service
No Type of Service branch direction/Location
1 cryogenic from top size of header

2 gases top side of header
3. Liquid from bottom side of the header
Cryogenic is services relating to very low temperature. For cryogenic service, ice formation in the
pipe can choke the branch hole if it is taken from the bottom of the header. A cryogenic liquid with
which many people are familiar is liquid nitrogen
FLANGE
It is used to join two pipes or pipes and fittings or pipe and other component. It is used in piping when
frequent dismantling is required. It is also at places where welding is not permitted due to fire hazards
or where dismantling is needed for maintenance of piping components. A flange joint contains three
Component (1) Flanges (2) Gasket (3) Nut & bolts
Flanges are the point of potential leakage when the bending stress in the piping system is high. The
dimensional standards of flanges are specified by ASME B16.1 for cast iron flanges and ASME B16.5
for stainless steel flange. The P-T rating for cast iron flanges are 25#, 75#, 125#, and 250#. The P.T
rating for steel flanges are of seven (7) types (1) 150# (2) 300# (3) 400# (4) 600# (5) 900 (6)
1500# (7) 2500#.

The flanges are designed based on the maximum operation / design condition using the code.
 Maximum operating condition- This is the maximum temperature and pressure reached during the
process.
 Design condition- This is the temperature & pressure for which the material is designed
TYPES OF FLANGES
Slip on flange
A Slip-on Flange is bored slightly larger than the outer diameter

of the matching pipe. The pipe slips into the flange prior to welding
both inside and outside to prevent leaks.
This is the first choice for non-critical services and for Temperature
up to 1000c. It has low hub compare to weld neck flange.
Weld neck flange:

Weld neck flanges are distinguished from other types of flange
by their long tapered hub and gentle transition of thickness in the
region of the butt weld joining them to the pipe. The long tapered
hub provides an important reinforcement of the flange proper
from the standpoint of strength and resistance to vibration.
Used for big or large bore pipes. Weld neck flange is used for butt welded connection (large bore
pipe)
It is the first choice for critical pipeline for high temperature & pressure. Primarily used for vessel
& equipment nozzle.
Where
NPS 2 3 4 6 8 10 12 14
O = Flange OD
O 61/2 81/4 10 121/2 15 171/2 201/2 23
T = Flange thickness
T 7/8 11/8 11 / 4 17/16 15/8 17/8 2 21/8
L = Length of the flange
L 23/4 31/8 33 / 8 37 / 8 43/8 45/8 51/8 55/8

Socket weld flange
A socket weld flange is used for size less than 2” (small bore).
It is used for non- critical pipeline and utilities. It is not used
for corrosive services like dil H2so4. Examples of utilities
are portable water, raw water, steam, sewage, borne,
condensate e.t.c.
Threaded flange
Thread flanges are used for low pressure & temperature

(non critical services) and for small bore pipes. They are
also used at point where welding is not permitted.
Loose/ Lap joint flanges
Loose flanges are used where stainless steel or exotic

piping materials are used to reduce the cost of the
piping. The loose flange is always of carbon steel
material. They are used for class 150# only. If the
class is higher than, we use the flange of the pipe
material. The stub end used in this type of connection
is also a fitting.
REDUCING FLANGE:
Reducing flanges are designed for use in
changing diameters in a piping system. A reducing
flange comprises a flange with one specified
diameter having a bore of a different and
smaller, diameter. Except for the bore and
hub dimensions, the reducing flange will
have dimensions of the larger pipe size.
.

Blind Flange:
It is use to closes the end of a pipe
Orifice Flange.
Orifice flanges are widely used in conjunction with orifice
meters for measuring the rate of flow of liquids and gases.
They are basically the same as standard welding neck and
slip-on flanges except for the provision of radial, tapped
holes in the flange ring for meter connections and additional
bolts to act as jack screws to facilitate separating the flanges
for inspection or replacement of the orifice plate. The
specific requirement for the installation of an orifice
flange is to provide 15 X diameter straight pipe length
at upstream side of the orifice and 5 X diameter straight
pipe at downstream of orifice.

Flange faces
1. Flat face Raised face Ring type joint
*Raised face is the most used and preferred flange type in the process industry.
*In a ring type joint, a metallic ring is used in the deep groove which is cut into the flange face.
It is generally used in the piping system for 900# and above classes. It uses a metallic ring
instead of a gasket.
ABBREVATIONS OF FLANGES
1. WNRF- Weld Neck Raised Face
2. WNFF- Weld Neck Flat Face
3. SORF- Slip-On Raised Face
4. SWRF- Socket weld Raised Face
5. SOFF- Slip-on Flat Face.
GASKET
It is used to provide a leak proof flange joint. The thickness of the gasket is taken as 1/8” or 3mm.
Gaskets are metallic as well as non metallic. The dimensional standard for metallic gasket is given
as ASME B16.20. The dimensional standard for non metallic gasket is given as ASME B16.21
The material for non- metallic gasket is compressed asbestos fiber (CAF).
Metallic gasket comes in stainless steel. The types of metallic gasket are
(1) Ring type joint (RTJ)
(2) Spiral wound gasket.
TYPES OF GASKET
1. Full Face 2. Spiral wound
3. Octagonal Ring type 4. Metal jacketed & inside bolt

Nut & Bolts
There are two types of bolts (1) machine Bolts (2) Stud Bolts
Machine Bolts: Has threads on one side and a head on the other side.
Stud Bolt: Has threads on both sides
VALVES
Valves are used to
(1) Isolate (on / off) (2) Throttling or regulation or control (3) direction control.
GATE VALVE
It is an isolation valve which is not preferred to be used for

regulation. Gate valves are designed to operate fully open of fully
closed. There is very little pressure loss through a gate valve. Gate
valves are used at the inlet and outlet of equipments and at the
suction and discharge side of a pump.
GLOBE VALVE
Globe valves are used primarily in situations where throttling of the

commodity is required. By simply rotating the hand wheel, the rate at
which the commodity flows through the valve can be adjusted to any
desired level.

ANGLE VALVE
An angle value can be used to change the direction of the flow

as well as to regulate the flow. So by using an angle value you
can avoid the use of an elbow and a global vale. It can be used
for higher temperature services like steam.
Check Value
It is basically a directional control valve which allows

the flow only in one direction. A check value is installed
on the discharge size of a pump to avoid pump damage.
Check values are of two types. 1. Lift check 2. Swing
check
BALL VALVE
A ball valve is used for isolation purpose. It is also used for throttling
purpose in low pressure services. It creates a leak proof seal. Ball
valves do not use a hand wheel but instead use a wrench to control
the flow. A 90° turn of the wrench opens or closes the valve.

Butterfly Valve
It can be used for both isolation as well as throttling purpose. It is

available up to NPS 56”. It offers low pressure drop as well as less
turbulence. A tight seal is not provided by the butterfly valve, so it
cannot be used for high pressure services. It can be used as a control
valve for higher sizes e.g (6” and above) as it is cheaper compare to
globe valve. It is used to control the slurries line in an oil gas refinery.
Plug Valve
It is used as an isolation valve. It can be used for higher temp &

pressure services at it can provide a tight seal. It uses a tapered
wedge to control the flow of the commodity.
PRESSURE SAFETY VALVE (PSV) / PRESSURE RELIEF VALVE (PRV)
It is used to relief extra pressure in the piping system. Pressure relief

valve (PRV) has a spring inside it which opens automatically when
pressure reaches unsafe level, i.e. it opens proportionately (high
pressure more opening, low pressure less opening)
Pressure safety valve (PSV) are pre-set pressure valves and the setting
is made by the manufacturers, further it cannot be adjusted. When the
set pressure is reached the wall is automatically fully opened.

Piston Valve
It is used for steam services. It can be used for

isolation as well as throttling
Control Valve
A control valve uses either pneumatic or hydraulic or electrical

means to control the flow of commodity automatically by using
sensors. In other to have a control valve we must have two isolation
valves as well as a bypass valve. The bypass valve is used during
the failure of the control valve. The bypass valve is also for
regulation purpose. So the valve type used here is a globe valve. A
control valve should be at least one size less than the pipe line size
Control valve as a tag mentioning the type of control valve on

the top of its actuator. If a control valve is for controlling flow it would be FC or FRL and if it is for
controlling pressure it will be PC. If it is for the controlling temperature it would be TC or TCV. The
class of the control valve is also mentioned by means of a call out as it as got a different P.T rating
than the pipeline in which it is installed. The bypass valve in control valve assembly is either on the
side of the control but never below the control valve. The height of the control valve is decided based
on the height of the actuator as this actuator contains readings which has to be noted by the operator.
1.5m to 1.7m is taken as the readable level.
 A control valve assembly has drain valve to dram the fluid in the case of control valve
maintenance.
 There can either be one or two drain lines.
 Control valve assembly as different arrangement depending on the conditions and the process
requirement. If the space is less, the isolation valves are located in the vertical line. Else they can
be located in the horizontal line also. Should be at 2” height from grade level on pipe rack.

N.B The face to face and end to end dimension for valves is given ASME B 16. 10
VALVES
Automatic control Manual control operators

(1) Pneumatic (1) wrench
(2) Hydraulic (2) Hand wheel
(3) Electrical (3) Chain operator: used
when the valve is installed
at a height where the
operator can not have
access.
Valve layout consideration.
*Valve should be accessible for repair, maintenance and replacement requirement.

*Always locate manual valves and then control valves.
*Valves should be located near the grade level-Gr level or HPP (high point paving) or FFL (finished
floor level)
* Valves should not be placed in the vertical lines as the fluid will be trapped in the vertical line
when the valve is closed or else provide a drawn line when a valve is placed in the vertical line
*Provide valves with chain operators when they are not in the accessible limit of the operator.
Values location in piping system

 Provide valve at the inlet and outlet for each mechanical equipment including vessels, tower,
pumps, compressors, heat exchanger, cooling tower & control value.
 Provide valve on the point of connection of header and branch (always on the branch)
 Control valve should be located at or near grade level on the pipe rack.

PIPING COMPONENTS
(1) Pipe
(2) FITTINGS Elbows, tee, O-lets, cross, lateral, reducers coupling,

Bends, swages, unions, half coupling, plug, cap nipples
(3) FLANGS weld neck, loose flange, blind flange,

Orifice flange, threaded flange
(4) VALVES Gate, globe, ball, checks, butterfly

Needle, piston
(5) Gaskets
(6) Nuts & Bolts
(7) Instruments PC (pressure indicator)

PLG (Pressure level gauge)
TI (temperature indicator)
Control valve
Safety valve
Orifice plate.
(8) Special items
 Strainers (filters):
They remove suspended particles from the piping system that
would otherwise damage your downstream equipments with no
additional pressure drop. Typical locations for strainers are
before control valves, pumps and turbine. We have Y type,
basket type, T type and dual strainers

 Sight glass : Is used for monitoring flow in pipelines for a wide range of applications
 Steam trap: It is used to remove the condense air from the steam line. It is installed at
regular intervals in the steam line.
 Flame trap: It is a device which allows gas to pass through it but stops a flame in order to
prevent large fire or explosion.
 Float valve: is a mechanism, or machine for filling water tanks, such as those found in flush
toilets, while avoiding overflow.
Expansion Joint / Bellows
It is a device used to allow movement in a piping system while

containing pressure and the medium running through it. They are
used to ensure flexibility in the piping system.
VENT AND DRAINS
For pipelines carrying liquid, we are to make sure that air is allowed to vent out of the line when
the line is filled with liquid. To achieve this, a vent connection with valve is provided at the top
most point of the pipeline. Also arrangement is kept in the pipeline so that liquid can be drained
out if required. To achieve this, a drain connection with valve is provided at the lowest point of the
pipeline. Pipes are usually slopped towards low point.

MECHANICAL EQUIPMENT
STATIC ROTARY OR ROTATIONING

1) Storage Tank (1) Pump
2) Horizontal Vessel (2) Compressor
3) Vertical vessel (3) Fans
4) Heat Exchange (4) Turbine
5) Reactor (5) Blower
Mechanical equipments are used to store, start, stop, heat, cool, transfer, mix and separate the
commodity flowing in the piping system.
HORIZONTAL VESSEL
It is a cylindrical shape vessel which has no

moving internal part. It is used to store
liquids or gasses. It has man hole which is
used for the maintenance purpose of vessel:
The diameter of the man hole is 18” – 24”.
The supports of the horizontal vessels are
called saddles. One of the saddles is fixed
and the other is a sliding. The sliding saddle
is used to accommodate the thermal
expansion of the vessel. Nozzles are provided
for the inlet and outlet of the fluid which is
stored in it.

HEAT EXCHANGER
A shell and tube exchanger consists of a tube bundle which is inserted in the shell. The heat is
transferred between two different fluids flowing in the shell as well as the tube. The tube bundle
which is in shell and tube heat exchanger as to be removed for maintenance purpose. So it is shown
in the drawing by mean of a rectangle with a cross also called drop out area. This space in the plant
should not be occupied by either piping or any other equipment. The space should always be kept
empty. The tube bundle is removed by means of a crane which is placed on top of the heat
exchanger by means of a mono rail.
PUMPS
Pumps, similar to the one shown below, are mechanical devices used to move fluids under pressure
from one location to another. Pumps accelerate the speed at which a commodity travels within a
pipe, thereby increasing its rate of flow. Pumps used in piping facilities will be one of the following
classifications: centrifugal, reciprocating, or rotary.
Centrifugal Pump:
A centrifugal pump is a rotodynamic pump
that uses a rotating impeller to increase the
pressure of a fluid. Centrifugal pumps are commonly
used to move liquids through a piping system.
The fluid enters the pump impeller along or near
to the rotating axis and is accelerated by the
impeller, flowing radially outward into a
diffuser or volute chamber (casing), from where
it exits into the downstream piping system.
Centrifugal pumps are used for large discharge
through smaller heads. Centrifugal pump is
the most commonly used pump, in the process
or power industry. It is of 2 types.

(1) Horizontal centrifugal pump (2) vertical centrifugal pump.
In horizontal centrifugal pump, the nozzle arrangement are given by (1) Top suction, top discharge
(2) End suction, top discharge (3) Side suction, side discharge.
The pumps are arranged under the pipe rack in a plant. All pumps are to have their centre line for
suction and discharge in the same line when there is an arrangement of series of the pump.
VERTICAL VESSEL/ COLUMN

The vertical vessel is a cylindrical vessel whose long
axis is perpendicular to the horizon. Easily the most visible
piece of equipment, some vertical vessels can exceed 200
feet in height. Fractionation columns have internal plates
called trays that aid in the separation and collection of the
various molecular compounds of a feed stock. The process of
breaking down a feed stock into its molecular compounds is
called fractional distillation. After further refinement and
processing, these compounds will become by-products such as
diesel, gasoline, kerosene, and many others.
RE – BOILER
A re-boiler is also a heat exchanger which is

particularly used for distillation column. It is placed
near the bottom of the distillation column to heat the
bottom product of the distillation column.

COOLING TOWER (CT)
It is used to cool the liquids coming out of the heat exchanger. It is of different types (1) Natural
Draft Cooling Tower (CF) (2) Natural Induced Draft Cooling Tower (3) Forced Draft Cooling
Tower (4) Induced Draft Cooling Tower.
STORAGE TANK
It is used to store raw material, semi finished product and product of a plant. Storage tanks are placed in
the tank farm area of the plant. The tank farm area occupies about 50% of the plant area in the refinery.
Types of storage tank of (1) Elliptical Head (2) Conical head (3) Floating Roof.
Conical Head Tank: - As a convention, it is placed outside of the building of the process plant. It is
directly placed or the foundation.
Floating Roof: - The floating roof of this tank, adjust itself depending on the amount of fluid present in
the tank. It is used to avoid evaporation of the fluid inside the tank. The liquid stored are generally
flammable. The layout standard for the storage tank layout is API – 650
DYKE WALL: - It is used to contain the leakages in the tank for which it is used. The height of the
dyke wall is obtained based on the volume of the liquid present in the tank.
BUND- A retaining wall designed to contain the contents of a tank or a storage vessel in the event of a
rupture or other emergency. A bund is also used all around the pump to contain the spillages of the
pump. Bunding is a legal requirement in many countries particularly around tanks, storage vessels and
other plant that contain liquids which may be dangerous or hazardous to the environment.

FLARE: - It is used to carry the waste gases from all part of the plant and leave it at a safe level in the
atmosphere. When the gases are poisoning they are burnt on top of the flare stack.
REACTOR: reactors are stationary vessels and can be classified as batch, semi batch, or continuous. A
reactor is design to allow chemicals to mix together under specific conditions by means of a catalyst. It
uses an agitator or mixer to mix the material inside it. The height of the agitator is 2/3 the length of the
reactor
SUPPORT
EQUIPMENT SUPPORT

1. SKIRT SUPPORT: For supporting tall equipment
2. LEG SUPPORT: For equipment supported on the floor and have smaller diameter (eg 1m)
3. LUG SUPPORT: For equipment supported on the floor which have larger diameter
Lugs have got larger welding area compare to leg support. So they are used for supporting large
diameter vessel compare to leg support.
PIPING SUPPORTS
Primary Support-Is a support which comes in contact with the pipe e.g. Shoe, Guide, U-Bolt, line
stop.
Secondary Support- It is the one which supports the primary support e.g. „L‟, „T‟, Goal post e.t.c.
Standard support: All primary & secondary supports which are present in the support standard are
called standard support.
Non- standard support (special pipe support [SPS]) – As per code, for weights beyond 250kg we
go for special pipe supports. For making SPS we have to make the sketch of the type of support and
give to the structural design engineer. For example, a shoe support used for a slope line is a non –
standard support.
PRIMARY SUPPORTS
SHOE
Pipe is often insulated to prevent heat loss or to ensure

worker safety. Resting insulated pipe directly on structural
support damages the insulation. To protect insulation on
pipes 3” and larger, pipe shoes are welded to the pipe at the
location where it rests on a support.

2. CLAMP
Clamps are used for small pipe sizes.
3. U-BOLT
U- Bolt are used for small pipe sizes (up to 4)
4. GUILD:
A guild is used to restrict the lateral movement of the pipe. It

is a plate for small pipe sizes and an angle for higher pipe sizes
and also an I-Beam for higher pipe sizes.
Hold-Down Guide
It is used to restrict the pipes movement in the

positive y-axis direction

Line stop/ limit stop: It is used to restrict the longitudinal movement of the pipe. Line stops also
comes in pairs.
N.B: The entire guide used are either of 0mm gap between them and pipe or of 3mm gap.
For small size pipes it will be a thick plate and as the size increase, it will be either an angle or an I-
Beam
SECONDARY SUPPORTS
1. Cantilever
2. ‘L’ Shape
Bracing is provided with the secondary support to sustain more loads. It is used generally to
support small pipe size.

3. T- Shape
T- Type secondary support is generally used for small size

pipes or less number of pipe. They are used with bracing
on both sides when the load on it increases. They can be
in the horizontal direction also to support the vertical
pipes.
4. F- Shape
5. Goal Post
Goal post are used when the loads of the pipes are high which
cannot be handle by a „L‟, „T‟ or invented „L‟ type of support.
Bracings are also added to be the goal post to add extra straight to
it.
Trunion or Dummy leg:
It is mostly used to support pipes at elbows. It is welded to the

pipe at its point of contact. It is also used for providing rest
support to the vertical pipes. A trunion is at least one size lesser
than the pipe it is supporting. When the pipe to be supported is of
exotic material or stainless steel, some parts of the trunion from
the upper side will be of the same material as that of the pipe,
and the remaining material will be carbon steel. The welding as
to be removed first, if you have to remove the trunion.

Pick Up Support
A pick up support is used to support small bore lines or small line with the help of larger lines which
are routed beside them. A pick up support is needed for the smaller size line as there support span is
less when compare to the large size lines.
N.B: A vessel cleat is a thick plate which is welded to the equipment to provide support to the pipes
or it is also used to provide support to the steel which is used under the platforms.
Supports are also taken from the structure of the platform by welding the secondary support to the
platform structure.
SPRING SUPPORT

It is used when the deflection is of minimum 5mm in the pipeline. In the case of nozzles of sensitive
equipment like pumps and compressors, it can be used for the deflection of 1mm also. They are two
types (1) Variable spring (2) Constant spring.
Variable spring- The Variable Support is a spring loaded device used for the support of piping and
equipment where normal vertical movement is anticipated. It is an assembly of spring contained in a
box which as got a plate at the top side of the spring to support the secondary or primary support of
pipe.
Two things can happen if a spring support is not used to absorb the thermal expansion (1) either the
pipe gets stress when the stress is in the allowable limit. (2) The pipe may fail when the stress
exceeds the allowable limit of the material.
Constant spring
A constant spring support is a type of pipe support used when there is vertical movement due to
thermal expansion at locations where transfer of stress is critical. Constant spring supports are
designed to provide a "constant" resistance throughout a specified travel range at critical points in a
piping system. These devices are used to avoid transfer of stress from support to support or to
critical connections of the piping equipment. Constant springs are costlier and bulky than the
variable spring.

HANGERS
Hangers are used to support the pipe from its top side. There two types of hanger support
(1) Pipe hanger (2) spring hanger.
 Pipe Hanger: A pipe hanger will have movement only in the lateral direction of pipe.
 A spring hanger: Has movement in the lateral direction as well as in the vertical direction.
The spring can either absorb or expand.
Rest Support: This kind of support has five degree of freedom (3 rotational and 2 translations)
Anchor Support: This type of support has got zero degree of movement.

FLOW DIAGRAM AND INSTRUMENTATION
Process flow Diagram (PFD)
Process Flow Diagram (PFD). It is a simple illustration that uses process symbols to describe the
primary flow path through a unit. A process flow diagram provides a quick snapshot of the
operating unit. Flow diagrams include all primary equipment and flows.
It shows relationships between major components in a system. A PFD also tabulate process design
values for the components in different operating modes, typical minimum, normal and maximum
values. A PFD does not show minor components, the piping systems, piping ratings and
designations.
A Process Flow Diagram - PFD - should include:

 process piping
 major equipment symbols, names and identification numbers
 control, valves and valves that affect operation of the system
 interconnection with other systems
 major bypass and recirculation lines
 system ratings and operational values as minimum, normal and maximum flow,
temperature and pressure
 composition of fluids

A Process Flow Diagram - PFD - should not include:
 pipe classes
 pipe line numbers
 minor bypass lines
 isolation and shutoff valves
 maintenance vents and drains
 relief and safety valves
 code class information
Indicator of the flow arrow is always required on the drawing because without the flow arrow, the
starting and end point of a particular pipeline or the process can not be known.
The PFD also indicates the maximum operating and the design condition for the process.
Design Pressure: It is 10% more than the maximum operating pressure.

Design Temperature: Maximum operating temperature + 25%
Utility flow Diagram (UFD) Utility Distribution Diagram (UDD)

It shows the values, instrument and piping for the utilities in the plant.
1. Instrumentation Air (IA)
2. Process Air
3. Plant Air
4. Potable Water
5. Brine
6. Drainage
7. Raw material
8. Cooling Water
9. Flare.
Piping & Instrumentation Diagram (P & ID)
A piping and instrumentation drawing is more complex. The P&ID includes a graphic
representation of equipment, piping and instrumentation. Modern process control can be clearly
inserted into the drawing to provide a process technician with a complete picture of electronic and
instrument system. Process operator can look at their process and see how the engineering
department has automated the unit. Pressure, temperature, flow, and level control loops are all
included on the unit P&ID

It shows the pictorial view of the whole plant. It is a single line diagram. It shows all the piping
required for the process plant. The number of elbows required for a particular line cannot be known
from a P & ID. The length of a pipeline cannot be known from a P & ID. It gives the slope of the
line.
A P&ID should include
 Instrument and designations

 Mechanical equipment with names and number
 All valves and their identification
 Process piping, sizes and identification
 Flow direction
 Vents, drains, special fittings, reducers etc
Line Numbering Pattern on P & ID
The pattern followed for line numbering is main line first then branch line, then sub branch line.
Line number pattern on P & ID
Size service line number specification insulation (type of

insulation)
(MOC)
Example
(1) 10” – IA – 1050 – CXI – IH100 insulation thickness
hot insulation
(2) 8” – P – 1021 – AX3 – IC

02 104 A15 6” (ST) (2-1/4 )
Unit no Line Pipe Pipe Steam Nos of Size of

(Equipment number speciation size tracing tracer
nos class
Could also be
ST- Steam tracing
EF- Electric tracing
SJ- Steam Jacket
IH- Insulation Hot
IC-Insulation Cold
NOTE:
 The series of the tags number should be the same e.g V – 101, T – 102
 Tag numbers should be given to all the piping components.
 The sizes of the PI & TI are not required on the P & ID. If given, ignore them.
 Sizes of the instruments should be as per details given by instrument vendor data or as given by
instrument Engr.
 Nozzles number may or may not be there on P & ID. If not present on P & ID, get it from process
data sheet or equipment vendor data.
 Nozzles size and line size can be different it need not be the same.
 For matching nozzle number on P & ID
(a) Compare the flow direction.
(b) Compare the service.
 In a P & ID the equipment details i.e. the dimension of the equipment as well as its tag number are
mentioned on the top side of equipment.
 Never try to match nozzle size to decide the nozzle number.
 HOLD – Sufficient information is not available. Instructing the contractor to await a later revision
of the drawing.
 If the nozzles are shown one below the other in a P & ID. It means that the upper nozzle is either at
the same level or above the lower nozzle.

 The level (height) of the equipment if shown one below the other, it means that the lower vessel is
lower than the upper vessel. But the P & ID doesn‟t give the exact height difference between the
two vessels.
 The location of the piping component is not exactly the same as it is appearing on the P & ID
(Note) control valves are never installed in the vertical lines.
Process data sheet / Vendor data sheet: This gives details of

(1) Design condition for the equipment (Design pressure & Temperature)
(2) It gives the material of construction (MOC) of the equipment
(3) It gives the nozzle schedule for the equipment (size, purpose and number of
the nozzle)
 Line list: It gives the details of all the line in the plant. Examples of the details are line size, line
number, service, MOC, P&ID number and the design condition or the maximum operating
condition.
 Battery Limit: It defines the scope of work
INSTRUMENTS
The major parameters measured by instruments are

Pressure (P)
Flow (F)
Temperature (T)
Level (L)
Each one is later branched out into many different applications.
Instrument Types
Gauges. Gauges are instruments that measure the liquid level inside a vessel or the temperature and
or pressure in the piping system. Level, temperature, or pressure gauges are locally mounted to
enable plant operators to obtain a visual reading.
Controllers. Devices used to maintain a specified liquid level, temperature, pressure, or flow inside
a vessel or piping system. They activate the control valve that regulates the level, temperature,
pressure, and flow in and out of the vessel.

Alarms. Signals via lights or horns that indicate the liquid level, temperature, or pressure inside a
vessel is too high or too low or that there is no flow or reverse flow.
Indicators. Devices used to indicate the liquid level, temperature, pressure or flow rate inside a
piping system.
Recorders. Devices used to record the liquid level, temperature, pressure, and flow rate inside a
vessel or piping system throughout a certain shift or period of time.
These same instruments may be found in combination such as Level Recording Controller. Here the
instrument not only records the liquid level but also sends a signal to a control valve to control the
liquid level inside the vessel
Instrument Symbols
LM Local Mounted
BM Board Mounted
FA Flow Alarm
FE Flow Element
FI Flow Indicator
FR Flow Recorder
FRC Flow Recorded & Controller
LA Level Alarm
LAH Level Alarm High
LAL Level Alarm Low
LI Level Indicator
LG Level Gauge
LC Level Controller
LRC Level recorder & Controller Pressure Instruments
PC Pressure Controller
PI Pressure Indicator
PG Pressure Gauge
PR Pressure Recorder
PIC Pressure Indicator & Controller
PRC Pressure Recorder & Controller
PSV Pressure Safety Value
PRV Pressure Relief Value
TI Temp Indicator
TA Temp Alarm

TW Thermo Well
TR Temp recorder
TRC Temp Recorder & Control
HCV Hand Control Value.
Instrument signal leads

1. Electrical - - - - - - - -
2. Pneumatic // // // //
3. Hydraulic L L L L
4. Magnetic
5. Capillary x x x x
N.B: In a flow diagram, the type of connection or the type of joint is not shown. While in a piping
drawing, the type of joint is to be shown.
Class work: draw the piping drawing of the flow diagram given on the board.
Class work
Piping Layout with Minimum Amount of Graphic information.

Piping Specification
A piping specification gives the details of design, fabrication & construction of the entire piping
component. It is used to know the pound rating of the piping component. It gives the corrosion
allowance for that particular class and MOC. It gives the design condition for the particular class.
A piping specification sheet is prepared for every class. It gives the details of type of end
connection, schedule number, MOC of the piping components, dimensional standard reference, type
of manufacturing based on the sizes for all the piping component.
Stress calculation is done using the information provided in the piping specification.
It gives the branching table for every class.
½ SW
” T
¾ SW SW
” T T
1” SW SW SW
T T T
1
1 SW SW SW SW
/4 T T T T
1 SW SW SW
SW SW
½ T T T T
T
2” HC HC HC
HC HC B
WT
21 HC HC HC HC HC B B
/2
3” HC HC HC HC HC B B B
4” HC HC HC HC HC B B B B
5” HC HC HC HC HC B B B B B
6” HC HC HC HC HC B B B B B B
8” HC HC HC HC HC W W B B B B B
10 HC HC HC HC HC W W W B B B B B
”
12 HC HC HC HC HC W W W B B B B B B

”
14 HC HC HC HC HC W W W B B B B B B B
”
16 HC HC HC HC HC W W W W W W W W SI S B
” O
18 HC HC HC HC HC W W W W W W W W SI SI S B
” O
20 HC HC HC HC HC W W W W W W W W SI SI SI S B
” O
22 HC HC HC HC HC W W W W W W W W SI SI SI SI S B
” O
24 HC HC HC HC HC W W W W W W W W SI SI SI SI
S B SI
” O
½” ¾” 1” 1¼ 1½ 2” 2 3 4 5 6 8 10 12 14 16 18 20 22 24
” ” ½” ” ” ” ” ” ” ” ” ” ” ” ” ”
SWT: Socket weld tee- Header & Branch- small bore.

BWT: Butt weld tee-for large bore.
W- Weld-Olet- for all large bore (where standard tee are not available generally b/w branch size 2”-
8”)
HC:-Half coupling
SI: Stub in – for large bore when branch is 2 sizes or move less than header.
SO: Stub on- for large bore when branch is one size less than header.

Principles of piping
1. Safety
2. Constructability (economics)
3. Maintainability
4. Operability.
Safety: Follow the codes as far as possible. Codes are rules and regulation made by the government
as mandatory. Use statutory regulation for making all the drawing of the project (plot plan, piping
G.A, Equip layout).
Constructability: It should be possible to construct piping easily, within a short time and
economically.
Maintainability: Every equipment has its own requirement for maintenance. A piping GA should
take care of the entire maintenance requirement for all the components in the plant. Instrument
should be located for easy reading and approach for maintenance. Provide platform where ever
required. Enough space should be kept for the maintenance of all equipment.
Operability: It should be possible to operate the plant easily as well as safely. Locate valves at
operating level (knee level to chest level). For valves which are not at operating level, provide either
platform or chain operators. Providing only ladders is not acceptable.

Equipment Layout
Various requirements dictate the location of equipment and supporting facilities within the
conventional operating plant, and so many factors must be considered when the designer is locating
equipment. Such considerations are
1. Plant Layout specification: This document highlights spacing requirements for equipments
and access width and elevation clearances for operator and maintenance access.
2. Economic Piping: In order to minimize the cost of piping, material should be located in
process sequence and close enough to suit safety needs, access requirements, and piping
flexibility. To do this, the designer first identify the alloy or heavy wall piping and route
them as short as possible.
3. Process Requirements: Equipment often must be located in a specific position to support the
plant‟s process operation (e.g. for pressure drop, line pocketing, and gravity feed).
4. Common Operations: Equipment that requires continuous operator attention or share
common utility and maintenance facilities should be located in the same are. For example,
compressors, Pumps and heat exchanger.
5. Real Estate availability: Generally, most new process units are built within an existing
facility in which a piece of land is dedicated to the new expansion. Older process units,
which have undergone many expansion, often leave a less than desirable piece of real estate
for new facility. This can be a problem for inline horizontal arrangement.
6. Climate Condition: Weather conditions could influence the location of equipment. In
severely cold climate, equipments should be housed. Also, the wind can influence the
location of such equipment as furnaces, cooling tower and stacks.

CONTROL POINT / BENCH MARK
 It is used as the origin from which the intersecting North, South or East/ West line are
leveled as co-ordinates using numerical valves.
 It is the reference point for the entire facility or the plant.
 It is located in a remote area in the plan, so that it does not get damage
 Control point co-ordinates are 0-0”,0‟-0”
 The North arrow in the layout should be placed in the top right corner of the drawing or in
the top left corner of the drawing.
 The details of the abbreviations in the drawing are provided on the right side of the drawing
in the form of notes and legends.
Equipment Location drawing: It is a drawing that shows the exact floor plan for location of
equipment in relation to the plan‟s physical boundaries.
Rulers for the development of equipment layout from the P & ID

1. First set the ground level.
2. Then set the equipment elevation with respect to flows.
3. Draw the first floor layout and show as cut outs equipments suspended in between floors.
4. Draw ground floor layout of equipment
5. Pumps should not be placed under the equipment but should be placed nearest to the equipment
as leakage from the equipment may harm the pump motor.
6. In the ground floor layout, show the suspended equipment as full line.
7. The equipment height should be checked to confirm if the equipment fits in the building or not. If
it does not fit, place the equipment outside of the building.
8. Conical roof tanks as a convention should be placed outside of the building.
9. Factory acts say that, they should be a minimum of 900-1000mm of distance between the
equipments and the edge of the building.
10. The cut out floor should have bonds on either side of the equipment to give additional support.
11. Round up the valve of the length of the process building.
12. Bottom of pipe should be with head height clearance so that it doesn‟t block the path.
13. First flour height is taken as 4m -5m as normal and 6meters as abnormal.
14. Horizontal equipments should be placed with saddle and platform.
15. Beam width of the building is generally taken as 400-600mm.
16. Check if the equipment clash with the building or with other equipment.
17. Give identity to all the columns (grid) in the plan & sectional view.
18. Roof is added to the building only if type of plant or client needs it.
19. Use staircase instead of ladders
20. Hazardous plants should have 2 staircases, one inside and the other outside of the building.

Piping Terminology Piping Call out
Grade level Gr EL + 100‟ -0”

Ground High point paving (HHP)
Level Finished floor level (FFL)
Piping or
Equipment Centre line elevation CL EL + 110‟ -0”
Foundation – Top of concrete T.O.C EL 101‟ -0”

Pipe –Bottom of pipe B.O.P EL 112‟- 0”
Equipment – Bottom of plate B.O.P EL 112‟- 0”
Flange –face of flange (for vertical lines only) F.O.F EL 112‟ -0”
Platform – Top of platform T.O PLAT EL. 115‟-0”

Structure – Top of steel T.O.S EL 121‟ – 0”

PLOT PLAN
Plot plan is one of the key documents produced during the engineering phase in any process facility.
It is used to locate equipment and supporting infrastructure and to establish the sequence of major
engineering and construction activities. Plot plan is an overhead view drawing, showing the overall
facility site and adjacent area that may include roadways, railways, harbors, aircraft landing zones
etc.
TYPES OF PLOT PLANS

 The grade mounted horizontal inline arrangement
 The structure mounted vertical arrangement

To develop a plot plan, the designer must assemble the following
 The equipment list
 The process flow diagram
 Specification
 Equipment size
 Material of construction
 List of all the facilities required for the plant or industry (The list must always include future
facilities required for increasing the capacity of the plant)
LIST OF FACILITIES
1. Process plant
2. Utilities : Boiler, cooling tower, air separation unit, chilling unit, air compressor or dryer unit,
gas generation unit, demineralized water plant, drinking water plan, effluent treatment plant, air
conditioning unit, process air compression etc.
3. Power facilities: (1) Diesel generation unit (2) coal generation plant (3) sub stations (4) motor
control centre (5) switch yards (6) Thermal plant.
4. Fire Fighting System: (1) Raw and fire water storages (2) pump house for the fire water (3)
office for the fire officers
5. Storages – (1) raw materials (liquids only) (2) semi finished product (3) product (4) By-
product.
6. Compressed gas storages: storages for gases like L.P.G, Nitrogen, Oxygen, Hydrogen etc.
7. Warehouse: For storing raw materials, semi finished product and final products which are solid
and which required a roof for storages.
Non plant facilities / Building
1. Administrative 8. Toilets
2. Canteen 9. Library
3. Security cabin 10. Guest House
4. Health center 11 Training center
5. R & D building 12 Weigh bride cabin
6. Workshop 13 Control room: To take care of control requirement for
7. Parking area th
e
in
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NOTE: Mechanical equipments within the facility are typically too small to be represented on a site
plan. Therefore the complete facility is usually divided into smaller areas called units. Each unit can
then be drawn separately on drawings called unit plot plans.
UNIT PLOT PLAN
Unit plot plans are generally defined by imaginary lines called battery limits. Battery limits are used
to establish a unit's boundaries. Unit plot plans show the location of all the buildings, equipment,
pipe racks, and other items of importance in the unit. True north and plant north are also shown. The
purpose of this drawing is not to show detail, but rather, the arrangement of various components to
be erected in the unit. The piping group is typically responsible for the development of the unit plot
plan. Unit plot plans are developed using the mechanical flow diagram, client specifications, codes,
and input from the client's engineers, and the plant manager who will ultimately oversee the
operation of the facility.
Piping General Arrangement Drawing
Piping General Arrangement Drawing (GA)
 A piping G.A contains the details of all the equipments of the plant, pipes, fittings, flanges,
gasket, nuts & bolts, valves, instruments special piping item, supports, elevations of the
pipelines either with centerline or with bottom of pipe elevators.
 The drops are shown by the drop symbol and the rise is shown by rise symbol.
 The length of the pipes can only be known by the elevations mentioned in the drawing.
 The north arrow most always be shown on the top right side corner of the drawing.
 As the G.A drawing is the top view of the whole equipment and piping arrangement in the
plan, maintenance area for very equipment should be left empty i.e. no piping should be
going in that area.

 Pipes should not be routed in the walking areas. If routed they should be with head height
clearance.
 Valve should be placed so that they can be comfortably operated (between knee & chest
height).
 Control valve assembly should be placed where the readings can be taken conveniently. It is
generally placed at a ground level at a height of 2 ft. If it as to be placed above the ground
level, then it is placed on the plat form of the equipment.
 Pumps all placed under the pipe rack with the center line of discharge in the same line for all
the pumps on both side of the pipe rack.
 Drain headers of different types will be placed underground of the area of the piping GA
either by burying or by routing them in trenches
Written information on GA drawing

1. Equipment location along equipment quadrants
2. Identification numbers
3. Elevation call out
4. Line numbers for the pipes
5. Flow arrow to show the flow direction
6. Dimensions to establish the pipe locations as well as equipment location.
7. Instruments symbols with their call out, tag number and identification numbers.
8. Ladders and platforms
G.A DRAWING IS PREPARED BY REFERRING TO THE FOLLOWING DRAWING
1. P&ID
2. Plot plan
3. Equipment layout
4. Process data sheet (PDS)
5. Line list
6. Piping specification.
PIPING G.A LAYOUT PROCEDURE
1. Draw the area limits or a battery limits by using match lines with respect to the control point.
2. Fill the title block information.
3. Place the North arrow on the top right hand corner of the drawing sheet.

4. Locate foundations for buildings, pipe rack columns, and mechanical equipment from the
coordinates used to develop the foundation location drawing and dimensions provided on the
equipment foundation drawing.
5. Draw equipment foundations.
6. Lay out equipment.
7. Draw the equip foundation, then show all the piping instrument, special items, fittings, valves,
flanges, gasket e.t.c.
8. Show all the platforms, ladders, walk ways, maintenance space for all the equipment.
9. Include the nozzle schedule for all the equipments in the drawing.
10. Show the elevations of the different tiers of the pipe rack on the pipe rack itself, reference point
for the drawing should be taken on one corner of the drawing.
11. Show the supports for all the pipes either on the piping GA or on a separate drawing for supports
when the line routed in piping GA are much.
12. The pipe supports are shown on the GA by writing SPS.
11. Every support may have a tag number related to that particular area.
Pump layout consideration
1. Maintain a minimum of 3ft clearance around pumps & equip for access & maintaence purpose.
2. Provide minimum of 5ft 6inches space at the motor.
3. Avoid lot of piping on the suction side of the pump.
4. Valve hand wheels should be located away from the pumps.
5. Section line of the pump should be as short as possible and as straight as possible to avoid
cavitation problems.
6. Use long radius elbows on the suction line of the pump.
7. In suction line, straight pipe = 3 x NPS to avoid the turbulence in the suction line.
8. Use eccentric reducers with FSU or FOT (flat side up or flat on top) on the suction side of the
pump. If it is not used, provide a vent on the suction side of the pump to remove the vapor formed in
the line.
10. A gate valve should be provided (isolation valve) along with the NRV (non-return valve) in the
discharge line of the pump.
11. The NRV should be placed before the gate valve in the discharge line of the pump.
12. Slope the suction line slightly towards the pump suction nozzle.
13. A strainer should be used at the suction side of the pump to arrest the foreign particles which are
entrained with the section liquid.

Tank & vessel layout consideration
1. The vessels must be able to withstand the temps & pressures which are present during the
process.
2. Vessels will have internal (i.e. internal parts eg tray)
3. The space between two adjacent tower or column should be 2-4 times their diameter.
4. This space should be provided for the top of the column to the bottom of it for lowering the
piping component from the top of the vessel by davits and crains.
5. Route the pipe from the highest point of the column first & also route the largest diameter pipe
first.
6. Keep access ways, ladders and platforms on one side of the column, freeing the other side of the
column for and pipes
7. The vertical run of the pipe from the top of the column to the bottom of it should be either away
from the platform of the column or by providing a hole in the platform
8. Inlets and outlets should be on the opposite ends for the horizontal vessel
9. Tank inlet should be placed at the topside (access way in the vessel means manhole) and outlet
and the bottom side of the tank.
10. The tank and the vessel should have vents and drains to relieve it from excess pressure and
unwanted liquids.
11. A P S V should be placed on the top of the vessels to relieve it from excess pressure
ISOMETRIES
 It give the three dimensional representative of the orthogonal view (2D view) by giving the
details of length, width and height.
 In isometric the North direction is shown to the up and right direction or to the up and left
direction
 Vertical lines are shown in isometric for pipes going up or down.
 The angle of the North is taken as 300 to the horizontal
 Always show the north arrow for clarifying the north for that particular isometric
 Isometric drawing is made for every single line of the project.
 Isometric is used for fabrication purpose and for preparing the final material take off (MTO)

 Material take-off is the process by which each individual component that makes up a pipe
configuration is tabulated for purchase or procurement. This means all piping components
(elbows, flanges, nuts, bolts, washers, gaskets, etc.) must be accounted for so that purchases
of those items can be made.
 Isometrics are drawn in two dimensions but it represents three dimension of the figure they
are drawn from.
 A minimum of one view is required to draw the isometrics and it is generally the top view. A
second view is taken when the isometric can not be drawn from the top view.
 The elbows are shown with square corners on isometrics.
 All the elevations of that particular line are to be shown in the isometrics with a call out.
 If the line deviates from the four main director (E.W.N.S). The offset of the line is shown by
hatching & mentioning the angle of offset and also the type of offset (horizontal / vertical)
 For horizontal offset we use „H‟ and for vertical offset we use „V‟
 If there are two offset, one horizontal & the other vertical at the same point of the line than it
is shown by two hatching triangle at the same point.
 The welding or the type of connections as to be shown on the isometric for the different
piping component.
 All isometric drawings are single drawing.
 An isometric is not drawn to scale but in proportion.

Piping Stress Analysis
It is the process of calculating the strains and resultant stresses in piping systems to determine if the
system
 Has adequate support to resist load such as pressure, weight, earthquake and wind.
 has sufficient flexibility to safely accommodate changes in length resulting from temperature
variations
 exerts sufficiently low reaction forces at restraints and equipment
The code establishes general rules for the evaluation of flexibility in the piping layout. The code
also sets up allowable range for expansion stresses in the code book. Design of piping system during
expansion shall follow these data and shall observe the following.
 Stress developed in the piping system operating at design temperature shall not exceed the
code allowable stresses
 Expansion loads transmitted by the piping to equipment shall not exceed those specified by
the equipment vendor and in no case shall misalignment, distortion or strains on connected
equipment result from excessive trust and movement of the piping.
Purpose of piping stress analysis is to ensure.

 Safety of piping and piping components.
 Safety of connected equipment and supporting structure.

 Piping deflections are within the limits.
Pipe Thickness Required For Internal Pressure
t = PD
2(SE+PY)
P = Design pressure, psig

D = Pipe outside diameter, in.
S = Allowable stress in tension, psi
E = Longitudinal-joint quality factor
Y = Wall thickness correction factor
tm t CA
tnom = tm
0.875
Sample Problem
Determine Pipe Wall Thickness, where
Design temperature: 650°F, Design pressure: 1,380 psig. Pipe outside diameter: 14 in.
Material: ASTM A335, Gr. P11 (11/4 Cr-1/2Mo), seamless
Corrosion allowance: 0.0625 in.
Solution
t= PD
2(SE+PY)

1380 X 14
t=
2{(16,200 X 1) + (1,380 X 0.4)}
t= 0.577 in.
Hence: t + c = 0.577 + 0.0625 = 0.6395 in.
Tnom = 0.6395
0.875
= 0.731 .

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GOLD GATE ENGINEERING INSTITUTE

93/95 ALIMOSHO RD, IYANA IPAJA,

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SOLID SEMI-SOLID LIQUID Gaseous

Powder Slurries (e.g. crude oil) water Air

Pellets Steam, H2, N2

The dimensional requirement to be followed for pipe is

Introduction to ASME codes and standards.

Dimensional Standard provides configuration control parameters for components. Meaning, to

Pressure-integrity standard provides for uniform minimum performance criteria. Meaning,

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• ASME B31.1 Power Piping

Introduction to Piping System

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Example: A pipe of IPS 6 means it as an inside diameter of 6”

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NPS (Inches) DN (mm)

Wall thickness is also commonly referred to as pipe weight. There re 3 types

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PIPE JOINING METHODS

The disadvantage of socket welding is the 1/16 recess

A mechanical joint between threaded pipes or between

Butt welded Joint:

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Pipe Manufacturing Method

(1) Seamless (i.e. No joint in the pipe ) its manufactured up to NPS 18

Pipe rating or P-T Rating

• Determine Material Group Number from code book

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• For Class 300, allowable pressure = 570 psig

Double Line Single Line

Single line for NPS 12 and below

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1. 90O Long radius elbow (LR ELL)

Radius “R”= centre to end dimension = 1½ X NPS

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2 SHORT RADIUS ELBOW (SR ELL)

Short radius elbows are used when available space is less

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Radius R = centre to end dimensional = 1.5 x NPS

It is used to change the pipe or flow direction by an angle

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Class work: Draw the drafting symbol of a stub-on.

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It is used to make a branch connection for small bore

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It is also used to make 90 degree reducing branch from

It is used to make a branch connection at the elbow. It is used

It is used to make a branch connection at an angle of 450 to

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It is used primarily for connecting small

CAP: It is used to close the open end of a pipe by means of welding.

Single line Double line

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It used as an alternative to the reducer when

These are of 2 types (1) concentric (2) eccentric

BPE – Both plane ends

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It is used to join threaded and socket welded pipes. A union is

* Dimensional standards are given by ANST / ASME

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No Type of Service branch direction/Location