Member, Mapua Alumni Association

Alberta Chapter
RAY ALVARADO, P.E.
PROCESS ENGINEERING
PIPING ENGINEERING
PIPELINE ENGINEERING
Presentation Breakdown
INTRODUCTION

PROCESS
ENGINEERING

PIPING
ENGINEERING

PIPELINE
ENGINEERING
Acronyms
CAE Computer Aided Engineering
CAD Computer Aided Design
HMB Heat and Mass Balance, a Process activity
CFD Computational Fluid Dynamics
FEA Finite Element Analysis
PFD Process Flow Diagram
P&ID Piping and Instrumentation Diagram
LDT Line Designation Table
ROW Right of Way, for pipeline routing
HDD Horizontal Directional Drilling, for pipeline
crossing
HVAC/R Heating, Ventilation, Air Conditioning &
Refrigeration

PROCESS ENGINEERING
PROCESS ENGINEERING
PROCESS ENGINEERING - an early project activity for analysis of
physical separation or chemical conversion. It follows project definition
and early financial studies. System-wide Process simulation nowadays is
computer-aided e.g. heat-and-mass balances, logical block flows, control
philosophies, and equipment selection.

Important Deliverables:
Process Flow Diagrams(PFDs) - schematic showing major process
equipment, main fluid flows, and basic stream characteristics (pressure,
level, temp., flow).
Piping and Instrumentation Diagrams(P&IDs) - schematics with much
more detail and confirmed data. Shown here are process condition
limitations, major machinery specifications, minor equipment data, pipe
size/details, instrumentation types, and more precise
controls/automation.
Line Designation Tables (LDTs) - spreadsheet report showing details
of every piping section e.g. start-end point, process variables, and other
mechanical data.
PROCESS ENGINEERING
Usual entry-level positions:
Chemical Process Engineer
Mechanical Process Engineer
Process Simulation Specialist

Minimum Skill Sets for a Junior Process Engineer:
Undergraduate degree in Chemical Engineering,
Mechanical Engineering, or Chemistry-related
academic programs.
Basic knowledge of Fluid Statics/Dynamics,
Thermodynamics, Heat Transfer, and Chemical Unit
Operations.
Supplemental knowledge in Process Equipment
Design, Distillation Theory, Stoichiometry, and Chemical
Reactions.
PROCESS ENGINEERING
CHEMCAD Process Simulation, Screen Images
PROCESS ENGINEERING
Heat and Mass Balance (HMB) Study, Selexol
Process
PROCESS ENGINEERING
Early concept of an oil refinery
PROCESS ENGINEERING
Example of Process Flow Diagram (PFD)
PROCESS ENGINEERING
Example of Piping & Instrumentation Diagram
(P&ID)
PROCESS ENGINEERING
Process Engineering and Beyond:
Next-Generation Process Simulators..higher
processing speeds, capable of more simultaneous
calculations, broader chemical database.
Multi-Physics Tools to the Mainstreamthese
software can now be fully integrated with existing
Process Simulators.
Intelligent 2D Diagramsembedded data on
PFDs and P&IDs will pop up once a particular
element is clicked or highlighted on the drawing.
PIPING ENGINEERING
PIPING ENGINEERING
Screen shots of CAEPIPE, a widely-used pipe
stress analysis software, showing the Input
Geometry:
Piping layout
imported from
CAD 3D Model, or
manually re-created
PIPING ENGINEERING
Stress Output.watch for the Reds!
RED areas have
higher calculated
stresses
(needs re-work)
PIPING ENGINEERING
Animation features...it moves!
Shows areas of
excessive movement,
direction of thermal
growth, lift-off at
support points, etc.
PIPING ENGINEERING
If not analysed properly, pipes may..
deform and collapse
.or lift-off from
supports
PIPING ENGINEERING
PIPING ENGINEERING - a Mechanical sub-discipline
mainly to validate Piping Designs pipe-fittings layout,
inside enclosed industrial areas, by computational analysis
or technical reasoning.
Such activities follow right after critical and major piping are
completely laid out and supported.

PIPE - a closed cylindrical conduit for moving fluid (liquid,
gas, solid particles) from one location to another, either by
gravity or applied pressure.
FITTINGS - are transition elements for connecting pipes
into an assembly or conduit network. Elbows, tees,
flanges, reducers, and couplings are examples.
PIPING - logical assembly of pipes, fittings, valves, and
supports.

PIPING ENGINEERING


Important Deliverables:
Static & Dynamic Pipe Stress Analysis, Reports -
computer-aided, hand calculations, and by-inspection
judgement.
Finite Element Analysis (FEA) - on equipment nozzles,
header branches, and support attachments.
General Pressure Calculations wall thickness, branch
reinforcement, leak-strength testing, and hot-tap
calculations.
Sizing of Engineered Restraints - for spring supports,
rollers, sway braces, sway struts, seismic snubbers, etc.
Detailing of Special Pipe Supports - as required by
stress analysis results or vendor special requests.

PIPING ENGINEERING
Plant Piping
3D layout of
piping
and pressure
vessels
Offshore platform
piping
and equipment
PIPING ENGINEERING
Usual entry-level positions:
Piping Design Engineer
Pipe Stress Engineer
Piping Materials Engineer

Minimum Skill Sets for a Junior Piping Engineer:
Undergraduate degree in Mechanical Engineering,
Chemical Engineering, or related sub-discipline.
Basic knowledge of Structural Mechanics, Strength of
Materials, Fluid Dynamics, Machine Elements Design,
Materials Science, and Welding Technology.
Supplemental knowledge in Chemical Processes, Heat
Transfer, Thermodynamics, and Stationary/Rotating
Mechanical Equipment.
PIPING ENGINEERING
Examples of Engineered Restraints
Constant spring can
Variable spring hangers
Sway strut assembly
Seismic
snubber
Sway brace assembly
PIPING ENGINEERING
Example of Custom-Ordered Supports
Support clamp with
fabric lining, for
vibrating lines
Rigid hanger clamp,
for pre-insulated line
Pipe clamp and shoe, for
pre-insulated cold line
PIPING ENGINEERING
Piping Engineering and Beyond:
Full Integration of computational Analysis Software
with 3D CAD Modelseamless and bi-
directional compatibility of both CAD and CAE
activities, thus substantial savings of time and
resources.
FEA/CFD Multi-Physics to the
Mainstreamcomplex analysis and engineering
calculations can now be simultaneously
performed e.g. structural mechanics, fluid flow,
vibration, and heat transfer.
Opportunities in Oilfield Frontier Areas.more
complex piping needs for fixed offshore platforms,
floating FPSOs, marine tanker, and Arctic process
modules.
PIPING ENGINEERING
FEA & Multi-Physics Analysis Tools
Multi-Physics Analysis
(thermal + structural)
of vessel
FEA of stab-in
branch
FEA of
crimped pipe
PIPING ENGINEERING
CFD & Multi-Physics Analysis Tools
ANSYS 3D Multi-Physics (wind +
thermal + struct.) around reactors
ABAQUS 2D Multi-
Physics (fluid flow +
thermal)
COMSOL 3D Multi-Physics
(fluid
flow + thermal) through
elbow
PIPELINE ENGINEERING
PIPELINE ENGINEERING
PIPELINE ENGINEERING - a Mechanical sub-discipline mainly to
validate Pipeline Designs overland or seafloor routing, by
computational analysis or technical reasoning, outside the fenced
industrial area.
Such activities usually start after initial project development, geodetic
(land) or bathymetric (ocean) surveys, and preliminary right-of-way
routing.
Pipelines are generally classified into:
Land Pipelines, Underground (Buried)
Land Pipelines, Aboveground
Underwater Pipelines
Important Deliverables/Involvement:
Hydraulic Analysis, Steady-State and/or Transient (Surge)
Pipeline Stress Analysis
HDD (Horizontal Directional Drilling) and Crossing Studies
Lateral and Upheaval Buckling Analysis
PIPELINE ENGINEERING
Usual entry-level positions:
Pipeline Design Engineer
Pipeline Stress Engineer
Pipeline Hydraulics Engineer

Minimum Skill Sets for a Junior Pipeline Engineer:
Undergraduate degree in Mechanical or Civil
Engineering.
Basic knowledge of Engineering Surveying, Structural
Mechanics, Strength of Materials, Fluid Dynamics,
Machine Elements Design, Materials Science, and
Welding Technology.
Supplemental knowledge of Heat Transfer,
Thermodynamics, and Stationary-Rotating Mechanical
Equipment.
PIPELINE ENGINEERING
Land Pipeline Routing
Natural gas pipeline
right-of-way Routing Study
taken from terrain survey
Plan-and-Profile Drawing,
with data from routing study
and terrain survey
PIPELINE ENGINEERING
Pipeline Analysis
River
crossing..suspension
bridge and cable stay
details for Trans-Alaska
Pipeline
Seismic analysis.and
mitigation measures for Trans-
Alaska Pipeline while crossing
the Denali fault line
PIPELINE ENGINEERING
Engineered Pipeline Supports
Detail of H-Support
and side bumpers
Trans-Alaska Pipeline ammonia-filled
H-Support, with cooling fins, pile
driven through permafrost
PIPELINE ENGINEERING
Underwater Pipelines
Underwater gas pipeline
on uneven seafloor, with
free-spanned sections
Underwater pipelines, for
oil-
and-gas production
gathering
PIPELINE ENGINEERING
Seafloor Routing Study of underwater oil
pipeline
PIPELINE ENGINEERING
Pipeline Stability Analysis & FEA
Overstress at seabed touchdown
area, due to excessive bending
from pipelay surface vessel
PIPELINE ENGINEERING
Pipeline Engineering and Beyond:
Integration of Pipeline Surveys with Routing
Selectionin intelligent 3D format, these
related activities will be fully synchronized for
accuracy and cost savings.
Pipeline 3D Models Imported Into Multi-Physics
Simulation..like stress analysis, hydraulic
surge, flow assurance, global buckling, or ice
gouging hazards.
Deeper, Colderin search for oil and gas, the
industry is pushing the limits of pipeline
technology beyond the worlds Continental Shelf
and in harsher Arctic environments.


PIPELINE ENGINEERING
Arctic Pipelines, Ice Gouge Hazard Analysis &
FEA
Burial depth is
critical, to prevent
pipeline damage
Gouged seafloor imaging Berg gouging
Sea ice gouging
PIPELINE ENGINEERING
CFD & Multi-Physics Analysis Tools (ANSYS)
3D CFD (fluid flow +
thermal) at junction
3D CFD (fluid flow +
structural) through valve
3D CFD (fluid flow
only) through blades
Trivia Question:
Whats the difference
between
PIPING and
PIPELINES?
Other than spelling, of course.
Answers:
PIPING
Inside the enclosed industrial area or fenced plot limits.
Physical configuration can be very complex.
Mostly of short length, specified in feet or meters.
Uses lower grade steel, thus pipe wall is thicker.
Can operate at very high temperatures and pressures, or
conversely at cryogenic temperatures and partial vacuum.
PIPELINES
Outside the enclosed industrial area or fenced plot limits.
Physical configuration is usually simple, from point A to
point B.
Almost always very long, specified in miles or kilometres.
Uses higher grade steel, thus pipe wall is thinner.
Usually operates at moderate temperatures and high
pressures.