Outline of Piping Design

About Samsung

o Samsung Engineering Co. Ltd. was founded as the first engineering

firm in Korea in the year 1970 and has its headquarters in Seoul, South

Korea. It is headed by Mr. Ki-Seok Park who holds the position as

President and CEO and is based in South Korea. It comes under the category of Engineering Procurement and Construction Company (EPC) and provides a full range of Engineering services including feasibility studies, design, procurement, construction and

commissioning. The company has established business in more the 30 countries with major presence in United Arab Emirates, India, Thailand,

Shanghai, Trinidad and Tobago and Mexico.

About Samsung

o The modern scenario of an EPC company also has the commissioning

of the plant under the scope of work and hence takes the designation of

EPCC- Engineering Procurement and Construction . EPC contract

approach is preferred by plant owners because-

Reduces stress for owner Single point of contact for communication Ready availability of post-commissioning services Ensures quality and services Better cost and resource estimation before commencement
project

of

The scope of Piping Design

o The scope of piping refers to the entire design process of connecting the equipment using appropriate piping components

as determined by the process engineering team. Its comparable

to the human body, piping is equivalent to the veins that connect the main organs together.

Understanding the basic elements of Piping Design o The basic elements of Piping Design:
The main aim of piping design is to lay equipment, piping and other

accessories meeting relevant standard, statutory regulations and safety

requirement. Of course, there are other aspects as described below.

Plant Layout:
I. II. III. IV. V. Safety: Fire, Leakage, Easy escape, safety showers, eyewash Maintainability & Operability: Drop down zone, crane, fork-lift, hose station, platform, ladder, stair Cost: Economic layout (equipment/ piping), optimize materials Constructability: Transporting and erecting large equipment, space for fabrication, sequence of construction Others: Weather conditions, Wind Direction, Location, Relevant regulations, Product in/out, Utilities and drain location, Conditions around battery limit, Area for future expansion

Understanding the basic elements of Piping Design

First we produce Site Plan, then we develop overall Plot Plan, Unit Plot Plans. After Unit Plot Plans are in place, we develop

major piping in and around equipment. We do plan for piperacks

as well. Pipe routing studies and Nozzle /platform/ladder orientations are developed. Underground piping is given priority as the construction starts from underground. Based of size, temperature, pressure, flow type and equipment type to which the line is connected, we identify lines to be Stress Analyzed. We perform Stress Analysis using software like CAESAR II, AutoPIPE etc.

Understanding the basic elements of Piping Design Pipe Routing Studies:

Understanding the basic elements of Piping Design Equipment Nozzle Orientation:

Understanding the basic elements of Piping Design Underground Piping:

Purpose: Underground piping refers to pipes that are buried underground and it aims to optimize the design and construction processes of a plant by finding the most effective connection between each process and different utility. Scope: Underground piping routes (e.g. cooling water, sewer piping, trench piping) Equipment foundation location Underground electrical and instrument routes

Civil/structure-related information
Road layout, etc..

Understanding the basic elements of Piping Design Underground Piping:

Understanding the basic elements of Piping Design 3D Modeling and Review:

3DModel: Graphic data of various structures, equipment, piping, cables and building parts of a plant displayed in virtual space using 3D CAD. Review: A process carried out in appropriate design stages to examine whether the developing work is meeting the requirements of the client and recommended design standards. It is also done to understand and provide solutions for problems in the design. Purpose of Review: Clients Perspective
To ensure quality product To ensure safety To examine operability To examine repair/maintenance To examine environmental impacts

Understanding the basic elements of Piping Design

Engineering Companys Perspective To meet the clients requirements To prevent design errors To achieve better drawing quality To follow drawings and construction schedules To improve earnings and provide client satisfaction

Stages of Model Review:

30% Model review: Review from a plot plan point of view location, installation, construction, maintenance, and repair of the equipment
60% Model review: Review from an operation point of view process requirements, tray routes for piping. Also make appropriate changes from the 30% review. Major Line Routing reviewed and finalized. 90% Model Review: Overall review aimed at producing the final drawings. Make appropriate changes from the 30% and 60% Model Reviews.

Required Input: Workflow

Required Input: It ranges from PFD/P&ID, Line List, Data Sheets, Vendor Prints to the various deliverables of other disciplines like Structural Arrangement Drawings, Cable Layout, Level sketches of Instrumentation etc. Piping Activities: Preparing Site Plan, Overall Plot Plan, Unit Plot Plan, Nozzle Orientation, Rack sizing, Equipment/ Piping modeling, Laying out lines, Job instruction, Project Specification, Materials Take Off (MTO), Stress Analysis etc. Piping Outputs: Site Plan, Overall Plot Plan, Unit Plot Plan, Nozzle Orientation, Complete 3D model, Isometrics, Pipe MTO, Project Specifications, Piping GA drawings, Special Pipe Support Index/ datasheet, Support MTO, Insulation/ Paint MTO. Its an IPO cycle

Input

Output

Process

Importance statutory requirement in piping design

Statutory and Regulatory Requirements in Piping Designs.
When a plant is setup in any country, its design is governed by the statutory and regulatory requirement of that country. Some examples are as follows:

Petroleum and Explosive Safety Organisation (PESO):With an overall

objective of ensuring safety and security of public and property from fire and explosion, PESO as a statutory authority is entrusted with the administration of Explosives Act, 1884, Petroleum Act, 1934; Inflammable Substances Act, 1952 and other related acts.

Oil India Safety Directorate(OISD): e.g. OISD-STD-118-Layout for Oil &

Gas Installations, OISD-STD-117- Fire Protection Facilities for Petroleum Depot/ terminals etc.

Indian Boiler Regulation (IBR): IBR approval is required for IBR

equipment and lines.

Environment /Pollution related Norms: Also to be complied with such

as allowable emission rate of NOx, SOx

How piping design relates to other disciplines Internal and External Coordination
o As the work of piping design tends to overlap with that of Process, Mechanical, Civil/Architecture, Electrical, Instrument engineering teams

and others, it is important for a piping engineer to work in close

coordination with related departments all the while maintaining a broad and comprehensive view of the plant. Process is the upstream discipline for the engineering group. Process

provides PFD, Process Data Sheets, P&ID, Equipment List, Line List
etc. Mechanical group gives us Mechanical Data Sheet of Equipment. In the later stages of design, Vendor Prints (VPs) are made available.

Civil/ Structural/ Architectural group provides the required foundation

for equipment, structures for racks/ equipment, underground trenches, pits, structures for Miscellaneous Pipe Supports etc.

How piping design relates to other disciplines Internal and External Coordination
Instrumentation group supplies the data for inline and online instruments, control valves, relief valves.

Electrical gives the hazardous area classification drawings, cable

layout etc. All these disciplines are also involved in preparing the Plot Plans o Piping design has enormous implications on plant construction, operation

and function.
o Construction and Procurement may be internal/ external group depending on the project scope o The most important external group to be coordinated with is the Client. o There are other external groups such as the Licensor and the PMC. They are equally important. ITB to be thoroughly read to understand the PMC requirement and the Licensor requirement.

Piping components

The piping system involves not only pipes but also the fittings, valves
and other specialties. These items are known as piping components.

It includes:
Pipes Fittings Flanges Gaskets Bolting Valves Specialties

Piping components

Pipes

Closed annular circular cross sectional conduit used to convey fluid is

known as pipe.

The size of all pipe is identified by the nominal pipe size (NPS)
the outside diameters of tubes are numerically identical to the size
number for all sizes.

Up to and including size 12 inch the outside diameter is more than the
size designator.

Outside diameter of NPS 14 and larger pipe is the same as the size
designator in inches

Piping components
Fittings

90 deg elbow

45 deg elbow

Concentric reducer

Eccentric reducer

Equal Tee

Reducing Tee

Piping components

Flange Joints are used where joints need to be detached frequently due
to maintenance or any other means. Flange joints are to be used always
in pairs and are hold together by Bolts with proper Gaskets installed between the two flange facing.

Various types of flanges uses are:-

Weld neck flange Slip on flange Socket weld flange Lap joint flange Threaded flange Blind flange

Piping components

Gaskets are used to make fluid-resistant seal between two surfaces.

The common gaskets patterns for pipe flanges are the full-face and ring

types, for use with flat-faced and raised-face flanges respectively.

Widely-used materials for gaskets are compressed asbestos and asbestos-filled metal. The filled-metal gaskets is especially useful if maintenance requires repeated uncoupling of flanges, as the gaskets separate cleanly and is often reusable.

Choice of gasket is decided by:

Temperature , pressure and corrosive nature of the conveyed fluid Whether maintenance or operation requires repeated uncoupling Code/environmental requirements that may apply Cost

Piping components
Valves in the piping systems serve the functions of allowing, stopping,
regulating, and controlling the flow, to fulfill the intended objectives of

the system. Valves relieve the overpressure, help in maintaining or

breaking a vacuum. Valves also assist in maintaining the pressure or temperature of the flow medium within the desired range or limit.

Piping special
Items Strainers Steam Traps Air Traps Flame Arrestors Sight Glasses Vent Silencers Hoses system purpose to control solid particle size in the media to remove condensate from steam lines to remove moisture from air lines to prevent propagation of fire into equipments to provide visibility to flow to reduce noise level to provide flexible connections in piping

Piping supports

Rest

Anchor Axial stop/Directional Stop

Dummy leg support Spring Hanger Rest

Resting and Guide

Trunnion support

Piping stress analysis

Objectives of piping stress analysis: Nozzle load check with the allowable of the equipment

Ensure Stresses generated in the system are within allowable limit

Design of the Supporting Structure & restraints Interference check

Solve the dynamic problems due to the mechanical vibration,

acoustic vibration, fluid hammer, two phase flow, PSV forces etc

Piping stress analysis

Stress analysis using ceasarII

Piping stress analysis

The behavior & failure of the system depend on the type of loading applied or acting on the basis of designing due to which different types

of stresses generated within the system.

Types of load which are generated are classified as:

Primary VS secondary

Static VS dynamic
Sustain VS occasional

Piping stress analysis

Q&A Thank you