Académique Documents
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2 4 JUL 2002
TEcHNlCA!. LlaRnRY (PRDH)
PROGRAMME
MODULE111 - FLEXIBILITY ANALYSIS
MONDAY, 22.07.2002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
Pipe Stresses
Pipe Stresses
Pipe Supports
Pipe Supports (contd.)
ASM
ASM
TNG
TNG
Thermal
Thermal
Thermal
Thermal
TNG
TNG
TNG
TNG
TUESDAY, 23.07.2002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
Stress Analysis
Stress Analysis
Stress Analysis
Stress Analysis
WEDNESDAY, 24.07.2002
0930- 1100
1115- 1245
1330 - 1515
1515 - 1645
Slw Demo
Slw Demo
Expansion Joints
Expansion Joints
ASP
ASP
TNG
TNG
Dynamic Analysis
Dynamic Analysis
Dynamic Analysis
Dynamic Analysis
GB
GB
GB
GB
Problem Solving
Problem Solving
Case Studies
Case Studies
GB
GB
ASPIASM
ASPIASM
THURSDAY, 25.07.2002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
FRIDAY, 26.072002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
GB :G BALASUBRAHMANYAM
TNG :T N GOPINATH
CLASSIFICATION OF LOADS
FAILURE MODES
AM)
Primary Loads
These are typically steady or sustained types
of loads such as internal fluid pressure,
external pressure, gravitational forces acting
on the pipe such as weight of pipe and fluid,
forces due to relief or blow down, pressure
waves generated due to water hammer effects.
The last two loads are not necessarily
sustained loads. All these loads occur because
of forces created and acting on the pipe. In
fact, primary loads have their origin in some
force acting on the pipe causing tension,
compression, torsion etc leading to normal and
shear stresses. Too large a load of this type
leads to deformation, often plastic. The
deformation is limited only if the material
shows strain hardening characteristics. If it has
no strain hardening property or if the load is so
excessive that the plastic instability sets in, the
system would continue to deform till rupture.
One says, that primary loads are not self
limiting. It means that the stresses continue to
exist as long as the load persists and
deformation does not stop because the system
bas deforxed int; a no-stress condition but
because strain hardening has come into play.
PIPE UNDER STRESS
...........................
.....
.
THE STRESSES
The MoC of any piping system is the most
tortured non-living being right from its birth.
Leaving the furnace in the molten state, the
metal solidifies within seconds. It is a very
hurried crystallization process. The crystals
could be of various lattice structural patterns
such as BCC, FCC, HCP etc. depending on the
material and the process. The grains, crystals
of the material have no time or chance to
orient themselves in any palticular fashion.
They are thus frozen in all random orientations
in the cold harmless pipe or structural member
that we see.
When we calculate stresses, we choose a set of
orthogonal directions and define the stresses in
this co-ordinate system. For example, in a pipe
subjected to internal pressure or any other
load, the most used choice of co-ordinate
system is the one comprising of axial or
longitudinal direction (L),circumferencial (or
Hoope's) direction 0 and radial direction (R)
as shown in Fig.1. Stresses in the pipe wall
are expressed as axial (S ), Hoope's (S ) and
L
(minimum). Solid
"
..
rn
and some
combination of them,
Axial Load
A pipe may face an axial force (F ) as shown
..
= (S
~ i ~ . pipe
2 : under ~
~~~~di
load bearing cross-section is the .crosssectional a& of the pipe wall normal to the
load direction, A . The stress can then be
m
calculated as
r
"tax
S =F /A
zero.
=rrd t
0
follows.
9*
S = P d l(4t)
L
=I
Bending Load
A pipe can face sustained loads causing
bending. The bending moment can be related
.to normal and shear stresses.
Pipe bending is caused mainly due to two
reasons: Uniform weight load and
concentrated weight load. A pipe span
supported at two ends would sag between
these supports due to its own weight and the
weight of insulation (if any) when not in
operation. It may sag due to its weight and
weight of hydrostatic test fluid it contains
during hydrostatic test. It may sag due to its
own weight, insulation weight and the weight
of fluid it is carrying during operation. All
these weights are distributed uniformly across
the unsupported span and lead to maximum
bending moment either at the center of the
span or at the end points of the span (support
.location) depending upon the type of the
support used.
Let the total weight of the pipe, insulation and
fluid be W and the IenHh of the unsumorted
.
span be L (see Fig. 5).
r,
Total load
.
i
,
--
)C--
b
-
Pinned Support
+
jJ
Fixed Support
Plnned Support
-.Fixed Support
"ax
=W a b / L
"lax
= W a2b/L
"us
Shear Load
Shear load causes shear stresses. Shear load
may be of different types. One common load
is the shear force (V) acting on the crosssection of the pipe as shown in Fig. 8.
is the
",
metal cross-section.
S =M c/I
Torsional Load
moment of inertia).
THEORIES OF FAILURE
A piping system in particular or a structural
part in general is deemed to' fail when a
stipulated function of various stresses and
strains in the system or structural part crosses
a certain thfeshold value. It is a nornlal
practice to define failure as occurring when
this function .in,the actual system crosses the
value of a similar function in a solid rod
specimen at the point of yield. There are
various theories of failure that have been put
forth. These theories differ only in the way the
above-mentioned fimction is defined.
Important theories in common use are
considered here.
material (S ).
Y
= (S
=S
= (S
L
=S
r
"?ax
= 0.5
= 0.5 S
H
= 0.5
rn
= S 12=S 12
L
of the material (S ).
Y
a c;:qressive load of
a r i ' s ~ s m e gradiilly
s
W (is. z !old of -W), .then I .knsile load of W
a r t ss on. Time w m g e d load is thus zero.
T k &es to fzilure are then measured. Tne
ex.~xiii:ents are repeated with different
a r q l i ~ d e sof load. The results would be
typicdly as in Table 1.
Table 1: Typical Fatigue Test Results
Experiment Applied Cyclic Cycles to
Number
Stress, psi
Failure
SECONDARY
DESIGN
LOAD
UNDER
CONCLUSION
Stresses in pipe or piping systems are
generated due to loads experienced by the
system. These loads can have origin in process
requirement; the way pipes are supported,
piping system's static properties such as own
weight or simple transmitted loads due to
problems in connecting equipments such as
settlement or vibrations. Whatever may be the
origin of load, these stress the fabric of the
MoC and failure may occur. This paper
attempted to present a rather simplistic view of
common loads and their implications on
stresses and failure.
Fatigue failure is an important aspect in
flexibility analysis of piping systems. Often
cyclic stresses in piping systems subjected to
thermal cycles get transferred to flexibility
providing components such as elbows. These
become the components susceptible to fatigue
failure. Thermal stress analysis or flexibility
analysis attempts to guard against such failure
through very involved calculations. That is the
subject matter of a series of papers to appear
in the columns of this jovmal.
SELECTION OF SUPPORTS
MR. T. N. GOPINATH
=m,,,.,n..
. ...
3.
4.
..
temperatures etc.
5.
6.
7.
1.
2.
3.
4.
5.
'Y &
+-- 1?"0
..Q
.:
" i l
nM
'1
Fig. 1.1
i:
+- 12"0
-,/T
Anchor
6"@
8
Fig. 1.2
Intermediate Anchor
LINE STOP
---- ---------_--- ---I
A3
E I
where,
%ax
CT
(N-m)
(Nlmm)
For either model, the support load remains the same. However,
depending upon the model chosen the stress in pipe varies. In
actual practice the pipe at the point of support is not free to
support fully, since it is partially restrained through its
attachment to piping segment beyond the support. If the pipe
runs between supports are equally loaded and of equal length,
segment end rotation could cancel each other causing the pipe to
behave as fixed-end beam. Therefore, the true case lies
somewhere between the two beam models. Hence, as a
compromise case, the stress is calculated as
where
S is the allowable stress as per the code in psi (N/mm2)
Span
Pipe Size
NB Inch
1
2
3
4
6
8
12
16
20
24
Water Service
Steam, Gas or
Air Service
M (ft)
2.7 (9)
4.0 (13)
4.6 (15)
5.2 (17)
6.4 (21)
7.3 (30)
9.1 (30)
10.7 (35)
11.9 (39)
12.8 (42)
SIGN AND
ENGINEERING
In case of concentrated loads, the support should be placed
as close as possible. When change in direction occurs, it
is considered a good practice to keep the span to 75% of
the tabulated values.
50mm IJP
m\
Nm::
EOlJlPMENT NOZZLE AT 'A' MOVES UP BY 5 0 m m FROM COLD TO HOT.
EOUIPMENT NOZZLE AT ,B. MOVES UP BY 25mm FROM COLD TO HOT.
PIPE-
ILLUSTRATED
EXAMPLE- PIPE HANGER DESIGN
.*.-\
..,~.,>,:..,
,.
y multiplying the
Coefficient of expansion by the vertical distance of each point
from the position of zero movement on the riser CD.
3.0 x 7.62
22.86 mm up at point C
6.1 x 7.62
a
,/
A X =
aX(~1)
a
CASE-
A2
Step I1
Make a simple sketch between two adjacent
points of known movement
'
(Refer
Case 3 o f
of
>,
Distributiot~
movements")
Step I11
(Pefer
>
Case 1 of
Distribution
of m o v e m e n t s " )
= -42.99 mm
say -43 mm
Vertical movement at H4 =43 mm down
= -19.70
mm say -20 mm
Vertical movement at H5 = 20 mm down
= -3.41 mm say -3
mm
Vertical movement at H6 = 3 mm down
= -20.81 mm
say 21 mm
Vertical movement at H7 = 2 1 mm up
Weight
150NB Sch
160 pipe
150 NB Sch
160 90 BW
LR Elbow
150 NB BW
1500 Ib class
Gate Value
Weight of
Insln (Ca Si)
Total Weight
Weight
Used in
calculation
'
kg-
kg.m
461.01
Reaction at the point A
0.9
Fig. 4.1:
787.4 - 512.2
275.17 kg.
.,.,; ..,.
161.10
Reaction at H2
Reaction at H3
1.95
=
82.62 kg
= 411.57 - 82.62
'
328.95 kg.
Fig.4.3: DISTRIBUTION OF LOAD BETWEEN H2 & H3
=
R Sin 8
Applying the above formula for the distance of CG from the center of the
arc for 150 NB LR elbow.
ICE M
0.2605 x
0.6668 x
44.0
32.0
=
=
1 1:46
2 1.34
496.1
372.08
0.750
404.88
404.88
Reaction at H3
0.750
Reaction at H4 .
539.84 kg
572.1 - 539.84
32.26 kg.
Kg-
.356.2
Reaction at H5
=
=
Reaction at H6
2.5
142.48 kg
268.5 - 142.48
126.02 kg
H6
439.4 Kg
'I'
2600
5200
5350
5800
1,
300>00
6100
4
king moment about H6
5.80
762.0
4419.60
1226.8
As the nozzle B is relieved of load
Reaction at H7
5697.93
5697.93
5.2
Reaction at H6
1226.8 - 1095.76
--
13'1.04kg.
Fig. 4.7: DISTRIBUTION OF LOAD BETWEEN H6 & H7 TO MAINTAIN ZERO REACTION AT NOZZLE B
SUMMARY OF LOADING
L
O
C
P
T
im !
..
... ..
REACTIO
N FO R m AD
ING
.
.
HANGER
m K G
512.23
486.42
TOTAL
1Pivot
(P)
LOW P~5IUIOW
Sina
Considering,
Substituting in Eqn.
Sin$
Sinp
Y
Sina
Since Y Sinp = X
Sinp
--F x = F(YZSirrp>
Thus F = KE
Spring Moment=
KE (YZSin4)
A
LW Sine =
KEY2 Sin 4
Therefore
LW
KEY2
This equation holds true for all position of load within its
travel range and "K", "Y", "2" and " W remain constant. It
is therefore true that perfect constant support is obtained.
But due to spring hysteresis, bearing friction, '
sliding friction of moving parts and manufacturing
tolerances, it is not normally possible to keep constant
effort throughout the travel range. The deviation is kept
very minimum by using PTFE washers and bushes at all
pivot points and life time lubricated antifriction bearings.
11'
MODEL V
MODEL - S
MODEL - K
MODEL - P
=mw, . w c a . .
2.
3.
4.
5.
6.
t ~ !
First select the basic model best suited for piping layout and the
physical structure available for mounting.
Establish the total travel by giving a positive allowance of about
20% to the calculated actual travel and in no case less than 25 mm
in order to allow for a possible discrepancy between calculated and
actual piping movement.
i.e. Total travel = actual travel + Over travel
Use the selection table supplied by manufacturer and locate the total
travel required at the corresponding table.
Move along the line until load nearest to the operating load to be
supported is located such that the load fits within a reserve range of
f 10% of the average of the maximum and minimum loads
specified.
If the total travel lies between the two indicated figures, the loads
between the successive travels can be incorporated.
The corresponding hanger size can be read fiom the respective
column.
Size
.... . ..
A,
B .
l3
B
A
I/
C 4
.
..J
Al
I
~ 1 5
I
Ci
D!
~.
.. .
.
.
.
.
.
5.2.1
5.2.2
5.2.3
5.2.2
TYPE-A
TYPE-D
TYPE-G
TYPE - E
TYPE - F
5.2.1
5.2.3
For determining the size of the hanger the load deflection table
shall be referred. In order to choose the proper hanger size the
data required is the actual load or the working load (alsofcalled
the hot load) and the amount and direction -of the pipe line
movement from cold to hot .
Locate the hot load in the table. To determine the cold
load, read the spring scale up or down for the amount of expected
movement. The chart must be read opposite fiom the direction of
pipe movement. The load arrived is cold load.
If the cold load falls outside the working load range of
hanger selected, relocate the hot load to the adjacent
mu.","
column and find the cold load. When both the hot and cold loads
are within the working range of a hanger, the size of the hanger is
the number found at the top of the column.
Should it be impossible to select a hanger in any
series such that both loads fall within. the working range,
consideration should be given for a constant spring hanger. Once
selected, the percentage load variation shall be checked as
follows:
Travel x Spring Rate x 100
Load Variation Percentage =
Hot load
This should be within 25% as specified in the code.
STRESS ANALYSIS
T. N. GOPINATH
1.1
1.3
1.3.2.
1.3.3.
1.3.4.
1.3.5.
..
1.4
Types of loads
1.5
i:
1S.2
Analytical
Model test
Chart method
2.2
Fig. 2.1
>
Fig. 2.2
Fig. 2.3
where,
= length
of pipe, In (rnm)
TIME -
STRESS
Fig. 2,5
+
I
t-
fR
y7
inplane displacement
\I(
Fig. 2,6
Fig. 2,7
Range of inplane displacement
-1- 1p
Fig.
..a
TIME ----b
Fig. 2.9
Allowable Stresses
--z
Wind load
Seismic load
Relief valve forces
Fluid hammer
Settlement
Equipment vibration
Weight of attachments
Weight of contents
dm
UTS
I--7
Fig.
2.10
- ..,.,.
-.r,.,-.,- ., ..
2.4.3
S Allowable
Factor f
Cycles N
Factor f
--
7,000 or less
..
--
1.0
0.9
0.8
0.7
----
0.6
0.5
0.4
0.3
A llowable
stress at ambient
S , = 20,000
Allowable
stress at Max. metal, temp.
S = 17,300
psi
24
of cycles = -' 365 x
Number
4
= 43,800
(total')
factor
The stress range .reduction
hence,
SA
f (1.25 S
0.7 ( 1.25
20527
psi
psi
..
2.4.4
Compressive S,
4
,
Mean Stress Axis
- API610
s - API 676
- API 617fNEMA
SM 23
Reciprocating compressors - API 6 18
Steam turbines
- NEMA SM 23
Air cooled heat exchangers - API 661
Shell and tube heat exchangers- Manf.Specific.
- Manf. Specific.
Fired heaters
For other static equipment such as Reactors, vessels
and tanks interaction with the fabrication engineer is
required to establish that the local stress developed
due to nozzle loadings are within the acceptable
limits.
1. Centrifugal pumps
3.2
Fx
F
F'2
75 D lbs
75 D lbs
75 D lbs
Mx
M
M'z
125 D ft.lbs
125 D ft lbs
125 D ft lbs
3.3
Centrifugal Compressors
",=?~..
Fc
Combined
resultant
where,
Vertical component of Fc
Horizontal components of Fc
at right angles to compressor shaft
Horizontal component of Fc
Parallel to compressor shaft
Component of Mc in a vertical plane at
right angles to compressor shaft
Component of Mc in a horizontal plane
Component of Mc in a vertical
plane parallel to the compressor shaft
+Y
Right angle t o
compressor shaft
Parallel t o
compressor shaft
a*
SUCTION
PLAN
Fig. 3.3
DISCHARGE
DISCHARGE
I
SUCTION
END VIEW
ELEVATION
Fig. 3.4
Fig. 3.5
+Z
Fig. 3.6
J.
d moments in the
connecting piping flanges and flange bolting which
should not exceed the allowable stress as defined by
applicable codes and explanatory notes.
Forces on inlet connections are to be transferred along
with moments to discharge connection to analyze the
compressor for resultant forces and moments. But, the
transfer of force will generate additional transfer
moments, which are added to the total of moments to
give resultant moments.
DESIGN CONDITION
Installation Temperature
Suction Temperature
Discharge Temperature
Inlet Piping
Fx =-11 kg
Fy = 266 kg
Fz = 52 kg
Mx = 292 kg.m
My = 104 kg.m
Mz = 94 kg.m
3OoC
35OC
55OC
Discharge Piping
Fx = -34 kg
Fy = 274 kg
'J
I
1
I
't,
9250- M
3
16+IPS - 16+20 =12"
Where D =
3
3
.'. Fall = 925x12-1419 = 3227 Ibs
3
> Fr
Fall =
COWRES SOR
DETAILS
-&DISCHARGE
Here
ie. Mr
D x F
Hence,
MTX
MTY
30.36 KG.M
25.98 KG.M
9.32 KG.M
Fx(KG)
Fy(KG)
Fz(KG)
Suction
-1 1
266
52
292
104
94
Disch
-34
274
133
133
182
50
Transfer
120
26
139
TOTAL
-45
540
185
455
312
283
Mx(KG.M)
My(KG.M)
Mz(KG.M)
Fc All =
where
462 DC
- Mc
18 + Deq
Dc -
Area = 29 1.04in2
~ o t a l ~ r=58208in2
ea
:.
Tc
-~ e =58208in2
d
J582:8x4
Deq =
Approx. 1.2%
Hence Forces (Total) on
compressor can be accepted
Allowable
Remarks
Ok
Fz
-45kg
185DC= 1267kg
Ok
Ok
Ok
Ok
Conclusion
The routing is acceptable as the values of forces
and moments are within limits except the combined
resultant force which is only marginally higher.
D (in inches)
3
1. The combined resultants of the forces and moments
of the inlet, extraction, and exhaust connections, resolved
at the centerline of the exhaust connection should not
exceed the following two conditions.
where,
f inlet,
extraction, and
.
,..-,.
.<.
Mc
125 Dc
125 DC
Fz = 100Dc
MZ =
The components are as follows :
FX = Horizontal components of Fc parallel to the
turbine shaft.
FY = Vertical component of FC
F2 = Horizontal component of Fc at right angles
to the turbine shaft.
Mx = Component of Mc around the horizontal
axis parallel to the turbine shaft
MY = Component of MC around the vertical axis
Mz = Component of Mc around the horizontal
axis at right angles to the turbine shaft.
Vertical
+Y
Right angle t o
turbine shaft
+Mx
Fx
+'
Parallel to
turbine shaft
.
,
,a"=-.7
Nozzle size
I
NB In
Forces in lbs
Moments in ft ibs
Fx
FY
Fz
Mx
MY
Mz
100
150
100
50
70
50
150
200
150
70
120
70
150
250
300
200
300
200
3.8
Fired Heaters
lbs
900
400
Twisting moment
1300
1300
ft-lbs
3.9.1
NORMAL OPERATION
STEAMOUT
START-UP
CRASH SHUT-DOWN
ANY OTHER NEAR GOVERNING
CONDITIONS
Fig. 4.1
.
I
.
.
cod^ ~f Practice
Basic Material of Construction of Pipe
Ambient I Installation temperature
Number of Thermal Cases
Flexibility Temperature (See Note)
Type of construction of pipe
Nominal Thickness of Pipe
Manufacturing tolerance
Corrosion allowance
Pipe Weight
Insulation Weight
Specific Gravity of Contents
Young's Modulus at AmbientIInstallation Temperature
Young's Modulus at Flexibility Temperature
Thermal Expansion at Flexibility Temperature
Allowable stress at Ambient1 Installation temperature
Allowable stress at flexibility temperature
Bend radius and type of bend
Branch connection type
Weight of attachments - Valves and Specialties
Terminal movements with directions
- -- --
'
-.-.
--
- - \
JJ>
'I''\-3
+z
J\\
---
c
Fig. 5.1
+/
Step 2
To determine value of L.
Step 3
To calculate resultant total displacement Y
From Appendix C, ASME B 3 1.3
Linear Expansion. between 70F and 400F.
e = 2.7"
I100
ft.
Fig. 5.2
Fig. 5.3
Fig. 5.4
Fig. 5.5
Fig. 5.6
Substituti ng P =
EI 6
144 L~
-,.-
.=>
1 = AB = B C = l o r n = 394 inches
E = 29.5 x lo6 lbsl in2
R = 6.62512 inches
6 = 1.7312 inches
(394)2 x
3267 psi
2 x 2
hence, P = 12 E I 11'
~
=IIZ
Z =IIR
Solving for f(S ) = 6 ER 6 / 1'
Where; R = Outer radius of pipe, inches
I = Moment of inertia of cross section, in4
E = Modulus of elasticity,lbslin2
1 = Length, inches
h2= 0.0025DoLT ft
ft.
Where ;
Do = Outside diameter in inch. (to nearest 1/z )
T = Temp. difference O F
(Design Temp. - Instln. Temp.)
'7
5.3
Fig. 5.8
where,
0 =Anglaf twistradians
T=Torsiormomentjn- i'us(mm N)
L =Lengthjnchegmrn)
TL
Fig. 5.9
Fig. 5.10
Fig. 5.11
Fig. 5.12
Fig. 5.15
a)
b)
FLEXIBILITY
FACTOR
( STRESS INTENSIFICATION
FACTOR
-
Closely spaced
mix bend
Single mitre
bend
L a
h516
152
h516
Tit--
aP
h 213
(r>
c o t e Ts
2 (r) 2
0.9
A%-
l+cot
h 213
1213
09
h 213
Welding Tee
as per ANSI
B 16.9
Q.9h 213
Reinforced fab
Tee with pad
or saddle
0.9
Unreinforced
Fabricated
Tee
0.9
Extruded
Welding Tee
-0.9-
Welding in
contour insert
0.9
h 213
Branch welding
on fitting
Q.%h 213
D . L
h 213
h 213
314 i.0 + 114
h 213
h20
T
rz
where,
s = mitre spacing at centerline, inches (rnm)
8 = one half of angle between cuts
r; = mean radius of pipe, inches (rnrn)
where,
c = ratio of tee to pipe section modulii.
y ARC Markyl. .
c h e s s inches (rnm)
= 1.60T as recommended by ARC Markyl
Re = Equivalent bending radius inches (mrn)
= 1.35 r2 as recommended by ARC Markyl
Substituting these values in the expression
for h
h = (Te I T )
312
.(Te1.35r/r22)
5.3.4 FLANGES
S I F for Flanges:
Pig. 5.16
1 5.3.7
I
I
I
Divide 'i' by
5 S, in SI units
Where;
S, = Sum of the longitudinal stresses due to
r sustained loads,
i
(ref. Appendix D- 1)
The product 0.75i shali never be taken as less than 1.
MA=resultant moment due to weight and
sustained loads, in-lb ( m - N)
SE =
SE
5 SA + f (S,-S,)
In USCS units
SE
MC
S,
(KPa)
= Range of resultant moments due to thermal
expansion, in- lb (mm - N)
= Allowable
OcPa)
4 tn
0.75 i MB
4 tn
P Do
0.75 i MA
lOOO(0.75 i) MA
lOOO(0.75 i) MB
5 KS, in SI units.
Where;
..
SL
SL
Fax
Am
(iiM i)
+ (ioM,)
Z
Am
S, in USCS units
4t
Pdo
IS, in SI units
6.2.2
s,=Jsb2+4st2
where
S, =Resultantbendingstress,psi(KPa)
St=TorsionalStress= Mt/2z,psi
1000Mt/2z,KPa
Mt =Torsionalmomentjn - lb (mm- N)
Z=SectionModulusof pipe,in3 (mm3)
where
&=in- planeSIF
io'out - planeSIF
Mi=in - planeBendizgMoment
Mo=out- planeBendngMoment
Z=SectionMo~lusofPipe
Mo
shall be as follows.
For Header,
-
- J(i
SL-
4,
)2
+ (i M
)2
in USCS units
in SI units.
For Branch,
g. = J
P+~~M,P
(ii~i
T,
r, =mean branch cross - sectional radius
T, =effective branch wall thicnkess ,
lesser of ?;h and (ii)wb)
Th=Thickness of pipe matching run of tee
or header exclusive of renforceme nt
T b=Thickness of pipe..matching branch
= 1%
6.2.2
'"
COMPARISON OF CODES
tify the difference in
,,
//
,/
/
/
/
/
6"(150mm) NB Sch. 40
------
- \
--..
.....
.
Fig. 7.1
6"(150mm) NB S c h 80
Fig. 7.2
3EyI
Hence, P
L3
E, y, L remaining the same, P = k I
3E Y
where k =
L3
For 6"(150 mm) NB Sch. 40 pipe
I = 1170 cm4
Z = 139 cm3
For 6" (150 mrn) NB Sch. 80 pipe
I = 1686 cm4
Z = X J cm3
Therefore,
Load P
Moment M
Stress = M/Z
Sch. 80
1686 k
1686 k L
8.4 k L
COLD SPRING
I
d
R = CR or C R, whichever
a
is greater
C , =l- S h E a
SEE",
R a = Estimated
instantaneous
reaction
or moments
at the installation
temperature
S
S
,= Computed
=
Maximum
displacement
allowable
stress
range
stress
at design temperature
PIPE SIZE
- 1" SCH 160
DESIGN TEMP. - 450' F
y
F
PIPE MUC
FY
25'
,/'
1 O',
,My2
AB = L, = 25'
BC = L 2 = 10'
CD=L3=5'
L,/L, = m = 2515 = 5
L2/L, = n = 1015 = 2
By referring to chart,
we get :
- CS (A106 Cr. B)
I
M/Y
1
FY
Fig. 9.1
K, = 8.61 K, = 4.35
Y(
1.60 K,
0.09 Kz
= 0.57
Turns
PIPE SIZE
- 4" SCH 160
DESIGN TEMP. - 450' F
Fig. 9.1
Torsional
Stress
=K t C D
- 4.35
'
3
510
4.5
Reaction Fy =K C Ip / L32
Reaction FZ=K
cI
p/b2
-Moment
Moment
XY
X2:
L 3k
= K xz C
AIL
L 2
= K xy
ft. lbs.
2035
0.4
10
5
543 ft. lbs.
3.3
Pipe
size
= 4"
Operatin = 450
g Temp.
OF
From table
Effective Elbow Diameter
Effective Elbow Length
4.7 feet
5'
: H=
25'
: W = 5'
From Table 1
Expansion factor fe for 450 OF = 73,000 psi [This can
also be calculated by the formula Expansion
incheslinch x Young's Modulus i.e
Hence,
Computed
Stress Range
S,=19,450
psi at 450
O F
CAESAR I1
4.
CAEPIPE
5.
PIPEPLUS
6.
TRIFLEX
7.
Q-FLEX
The pipe line geometry is fed into the system along with
all the parameters such as design temperatures, pipe sizes,
bend radii, type of branch connections, locations of anchor
points and restraints. This is termed as 'Modeling' the
problem. The model can be generated by anybody who
knows how to prepare the input. The programme executes
the solutions. First complete Analysis was done in the year
1957.The analysis of the solutions is the real engineering
and is the job of a Piping Engineer.
The layout and the design of the piping and its supporting
elements shall be directed towards preventing the
10.
ARRGT-1
COLUMN
VAPOUR R n U R N CONNECTION
/-A
Top T U B m H E m
SUPPORT LUG
LIQUID LEG
Fig. 11.1
ARRGT-3
SUPPORT STRUCTURE.
COLUMN
Fig. 11.3
ARRGT-2
::
'=-
q J L 3 7 r
COLUMN
P
SHELLSIDE INLET
COLUMN SHELL
SUPPORT LUG
b'
SHELLSIDE OUTLET
COLUMN SKIRT
-4
SUPPORT BRACKET
Fig. 11.2
..
ARRGT-1
TOP TUBESHER.
COLUMN
SUPPORT LUG
REBOILER SHELL
LIQUID LEG
-;-1
Fig. 11.1
SHELLSIDE OUTLEI
7.
8.
9.
10.
Mr. T. N. Gopinath
Fig 2.1
MATERIALS OF CONSTRUCTION
P
<
ovements
Lateral Deflection
Fig. 5.2
Fig. 5.3
Fig. 5.4
-s.
-m<,n.
IN ADDITION TO AXIAL,
LATERAL
AND
ANGULAR
MAVEMENTS, AN
EXPANSION JOINT MAY BE
SUBJECTED TO TORSIONAL
MOTION
OR
TWISTING,
TORSION IMPOSES SEVERE
STRESSES ON THE EXPANSION
JOINT AND ALL SUCH CASES
SHOULD BE REFERRED TO THE
MANUFACTURER.
Pig. 5.5
Fig. 6.1
--.-...
Bellow
1 1
- 1
Convolution Depth
Mean Dia.
Tangent
Crest
Root
Fig. 6.2
Bellow
Tangent
Collar
Reinforcing Rings
Lagging Shroud
Internal Sleeves
Limit Rods
Tie Rods
w
w
Shipping Devices
Pantographic Linkages Axial - Sing@ Doublt
Universal
swingH
~in~ed'
~imbal'
Pressure BalancedEll
Tied
Fig 9.2
Fig 9.3
qzr
COLD POSITION
Fig 9.5
4
'
a
1-
, !: Cl I
.I .
. -.!.
!
HO?'
POSITION
NEUTRAL POSITION
1.
Fig 9.7
,,
Process
Vessel
Fig 9.9
Fig 9.8
Fig 9.10
!G
IA
Fig 9.11
Fig 9.13
IA
Fig 9.15
Fig 9.14
Fig 9.16
Process
Vessel
Fig 9.18
EQUIPMENT
Fig 9.19
/////l//l////i//
Fig 9.20
Selection Chart
Sr.
No.
Type of
Expansion Joint
Elimination
of Pr. Thrust
Axial
Movement
Lateral
Movement
Angular
Rotation
Universal
Yes
Yes
Yes
No
Swing
No
Yes
Yes
Yes
Hinged
No
No
Yes
No
Yes
No
--
Axial
I
Gimbal
Pressure Balanced
Tied
Yes
Pipe Anchor
Main Anchor
Intermediate Anchor
Pipe Guides
Directional Stop / Anchor
Spring Rate
Spring Force
Pressure Thrust
Cycle Life
-
+----
BELLOWS CONVOLUTION
-------+
__+
INTERNAL (P0SITIVE)MPRESSURE
Fig 8.1
GUIDE
MAN ANCHOR
FIG B.
GUIDE
GUIDE
MAIN ANCHOR
I'
INTERMEDIATE AN CHORE
1I
I - - -
_ l]1
-GUIDE
MAN ANCHOR
FIG C.
INTERMEDIATE ANCHOR
COU) POSITKIN
I-..;.
HOT P OS ITKIN
I,
PLANER GUIDE
FIG F.
ANCHOR
Fig. F
Fig. H
Fig. I
Fig. J.
&/+
INIR(MEDIA1E N C HOR
NNIERMEDIAIE ANCHOR
-..
GUDE
.........
GUDE
Fig. M
--
1.
Squirm or Buckle
-m -r
T. N. GOPINATH
ISize of Core
I Pipe
Size of
Jacket Pipe
NB (mm)
Elbows :
Core pipe
NB (mm)
Bends Radius
(man)
Jacket Pipe
NB (mm)
Bend
Radius
(mm)
4
Remarks
NOTE 1
NOTE 1
76 (1.5D)
80
76 (ID)
95 (1.5D)
100
102 (ID)
NOTE 2
NOTE 2
NOTE 2
NOTE :
i> Use 1.SD(LR) std. elbow for jacket.
ii) Use l.SD(LR) std. elbow for core and lD(SR)
std. elbow for jacket. (Refer Fig. 2.1)
JACKETTED ELBOW
JACKET ELBOW
Pig. 2.1
Types of Jacketing :
I
I
c o r e pipe
-.jacket
Fig. 2.2 a
pipe
Fig. 2.2 b
flange
Fig. 2.2 c
Jumper Pipes :
Fig. 2.3 a
P a t t e r n II
Fig. 2.3 b
Pattern I l l
Fig. 2.3 c
Pattern IV
Fig. 2.3 d
Pattern V
Fig. 2.3 e
Spacers :
/
*CORE
PIPE
PIPE
~ S T I C T H
WELD
PlPE
CORE PlPE
Fig. 2.4
Spacer Details :
Process pipe NB (mm)
Dia of rod
'd' (mm)
Width of
flat 'WY
Minimum span
(mm)
(mm)
15
40
20
40
25
50
40
65
50
80
65
100
80
100
100
150
150
200
2000
2500
3000
14
3000
3500
19
4000
16
5000
1500
2000
BARRIER
-JACKET
.--.
-
FIG. 2.5
NOTE :- THE
MATERIAL OF
CONSTRUCTION OF
JACKET BARRIER
SHALL BE SAME AS
THAT OF CORE PIPE.
ID
OD
DIM Remarks
'X'
Cond./out
Hot oil/in
I
I
Jacket barrier
-*
Fig. 2.5b
SLEEVE
SLIP-ON FLANGE
WITH MODIFIED HUB
--FINISli
125-250 AARH
SIA.
..
'
. . . .
D"WT
RF ~
0
.'ORE HOLEDZ DIA THK.
:~l,
:'TI
. . . . .
. : .:
-
FORIS:.
1239
,HW.
CLASS.
.
.
37.5 .
...
....
.,.
.
.
22 .
'28.0
...
u
.
.22.5
.
.
.. . ..
~-
. . .
I
37.5
.
..
.'
'
is
n .
25
92
.28
.. -
~~~
'34.5
19&
-..
.....
. ..-,.... -..
-.-..
.- . .
......
.~..
.. - .
"
'
) 74.5
loo
iw
.
~~
. ..
. 91.0
.
151' . 1116.0
.
'
.
.. --~.. . . .
.
'
22 .,. 157
22
41'
'
.-.
157
. 41
. . . . . . . .
22
. '
216 . 47
, .I
PI
Design Pressure
a) Core - 300 psig (2 lKglcm2)
b) Jacket - 400 psig (28 KgIcm2)
Corrosion Allowance
a) Core -Nil
b) Jacket - 1/16" (1.6 mm)
Design Basis - ASME B3 1.3
'8
Core Pipe:
P = 300 psig
D = 6.625" ( for 6" NB )
S = 13500 psi ( for SS 304L pipe at 700" F )
E = 1.O ( seamless 'quality )
Y = 0.4
300 x 6.625
= 0.073"
t=
Hence,
2(13500 x 1-t 300 x 0.4)
b) Jacket Pipe:
P
E
Y
400 psig
- -*..
external
pressure
..
Factor'A = 0.000225
{ Refer ASME Section I1 Part D)
= 0.095"
Factor B = 2750
Refer ASME Section 11Part D Fig HA3)
-,.-
B 4 2750
- -X
D o l t 3 69.7.
'
52.6 psig
<+
Factor A
Factor B
=
=
0.0015
4800
237 psig
':*
Torheck6"NBSCHBOSpipeforthe
ternalpressure of 400 psig.
Factor A
Factor B
=
=
0.0038
5500
+++
+ To check the Selected Combination of pipe
ess for stresses due to Differential Expansion.
Stress
Strain =
Modulus of elasticity
Force
Area
Stress,
f =
Hence,
e = - f- E
P/A
Al/l
- P
-
.................. 3
ss and/or
ss or cs is the same,
.
-..b.,.,rs>...,
Suffix 'c' stands for carbon steel and suffix 's' stands for
stainless steel.
Hence,
Hence,
Es As
Als
A2 =
EcAc
+A
....................10
Q . . . . . . . . . . . . . . . . . . 12
.
$-
E =248xlO psl
Differential Expansion,
'.
'i,
Tension in cs pipe,
= 1.24 - 0.542
= 0.698"/10Q9
Strain in cs pipe,
Tension in cs pipe
= 1.24 - 0.617 = 0.623"/100'
Strain in ss pipe,
Strain in CS pipe,
12767 psi
< Stress Allowable (S)
Compressive stress in ss pipe
= 0.000514 x 24.8 x lo6
= 12747 psi
< Stress Allowable (S)
=
w+
+
4n EI
2
Where,
I
=.
=
1
inches
Moment of Inertia
40.49 in4
Distance between two supports in
Therefore;
608.29 inches
*:*
............................
. .
..
--.
. ..
..
... . ~.-.:.
-?
...
INTRODUCTION:
Piping is one of the niost important
part of a project for various process plants,
power plants, nuclear installations, refineries
and petrochemical complexes. The age-old
tradition in en,@neering was to rely on the
experience of layout engineers and draftsmen
to tackle the necessary drawing board work.
This trend changed with the advent -of
computers. The experience and learning by
failures was replaced by more scientific
methods of design and engineering.
After a few initial hurdles the basis of
design for piping systems were kproved
greatly to provide accurate solutions to piping
design problem. This ongoing process of
improvement in design procedures has
resulted in better techniques of analysis that
could be conducted-before erecting a pipeline
thereby leading to reliable designs.
Static analysis for piping has now
become very common place, thanks to the
very many people who worked hard to make
piping flexibility analysis software available
on PC platform at a reasonable price. These
packages nor only perform basic analysis but
also make conformity checks according to
various codes. These packages' also give
reports in easy to interpret form.
Most software packages are based on
Finite Element Method (FEM). After
perfecting the static analysis modules most
flexibility znalysis software authors turned
their attention to dynamic andysis. However,
other than nuclear codes the dynamic analysis
requirements are not rigorously dealt in the
Dynamic Analysis of piping
..
.,.
-.-
.. .
Initial spring
length when
fiee
,1
7
Static
deflection
0'
Static
E q ~ y b
Mass(m)
..
(5)
dt
..
mx+kx=O
(6)
Substituting on= $klm) the equation can be
re-written in the form
..
x+o:x=o
Solution to this equation is of the form
~ ( t =) CI cos 0.1
f C? sin ant
(7)
(8)
mg
..
F sin wt
(1 1)
..
(14)
X, = Cest
(17)
-r2
<
<
<
<
<
<
<
<
<=
-----------2 doan)
(24)
<
- .. . .. . .
AMPLIFICATION
NATURAL
VALUES)
FREQUENCIES
@IEGEN
experienced. However, from engineeriug .of the system due to excitation at the specific
practice- the f&t 7 modes are significant. The frequency. The mode shapes are also referred
effects of these modes are most pronounced to as "Eigen vectors".
The descriptions of the mode shapes
and are dangerous. Typically in piping the
frequencies tend to remain low. This would give a means of physical identity to the
mean that a high frequency excitation i- Iess response of a system. This is also the link
likely than a low frequency one.
between the conceptualization in the analysis
There zre situations where in the s u n and the physical moveLents of the piping.
.When the forcing function is a
of the effects of the higher frequencies have a
significant effect and need to be taken into combination of several frequencies of
account. Unlike other common machinery the excitation then the response for all of them
piping can get locally excited and the direction .can be evaluated based on the individual
of excitation can be complex with several responses by super imposing the effects of
segments of piping moving in unrelated each of these frequencies.
fashion. The excitation response would very
often result in displacements and velocities in SEISMIC ANALYSIS
planes other than the one in which forcing
Earthquake results in ground motions
function is acting.
The forcing function is the external that are a set of time variant excitation and
load applied on the system. However, the certainly deserves such analysis. The
inherent properties of the system control the frequency distribution would vary depending
response as much. This is related to the natural upon the location. The intensity or amplitude
frequencies of the system. Tke natural varies from time to time. The historic data
frequencies of a system are also referred as collected by seismological studies is utilized
"Eigen values".
to derive the excitation pattern. The data can
be obtained frdm broad divisions of
geographic categories.
, In most projects in order to ensure the
MODE SHAPES (EIGENVECTORS)
The equations of motion were safety of the plant and equipment site specific
developed for a single degree of freedom data is derived and provided foi the
system in the preceding paragraphs for engineering contractors. It is the duty of the
illustration purposes. The real life piping can people involved in engineering to ensure that
be imagined to be made up of a number of the equipment and piping are built to be able
spring mass damper system inter connected in to withstand the excitation forces due to
a complex fashion. This leads to the earthquakes.
possibility of innumerous combinations of
Such data is compiled into site specific
displacements. There are imumerous natural spectra giving excitation force in g's as a
frequencies associated with such a piping or fimction of time period.
Most seismic occurrences have a cut
structure.
The description of the preferred off frequency of 33 Hz. A seismic excitation
responsz of the system corresponding to each has never been found to be beyond 33 Hz.
of rhe natural irequencies can be derived from This makes the job of computing excitation a
rhe sysxm proprzies. This preferred response little easier. Nevertheless the practical piping
is referred ro as mode shapes. The mode has to be deliberately built to avoid a number
shape is a ser of vectors describing the motion
Dynamic Analysis of piping
.......
0.5
2
25
TIME PERIOD (SECONDS]
1.5
3.5
..
..
LOAD CASES
The load cases are defined by the
codes depending upon the mode of failure,
type of loads and the
of
occurrence. The types of load are as follows:
Primary loads:
These loads relate to the external
forces in a direct manner. They result in stress
levels in the body of the pipes, fittings, etc.
The stress levels increase with the increase in
the extemal load. There is no ceiling the
stress experiences as a consequence of such
loads. Typical example is the stress due to
internal pressure inside the pipe. These loads
result in direct yielding and failure of the pipe
if they exceed predetermined limits.
Increasing the section thickness can reduce
primary stress levels. The maximum shear
'
P I P m G ENGINEERING CELL
stress theory is the most *dely accepted
theory of failure for these loads.
'.
Secondary loads:
The secondary loads are generated
from external loads that are indirectly related
to the external loads. They are of self-limiting
nature. The failure is often result of repetition
of the loading cycle. This leads to fatigue
damage.
A typical example of secondary load is
the thermal load on piping due to temperature
change. The resulting stresses are due to
constraining the piping. Hence, by judicious
layout and use of proper bends and filtings the
stress levels can be limited.
In case the material reaches yield point
then the thermal expansion stress is relieved
and seizes to exist of the same order as it was
prior to the yielding.
The commonly experienced Secondary loads
are as follows:
Pressure transient
Thermal expansion
Vibration .
Anchor movement
Themal transient
OCCASIONAL LOAD CASE
The occasional load case may be
defined by the user according to the choice of
Dynamic Analysis of piping
. ALLOWABLE STRESSES
The basic allowable stresses are
calculated for each of the materials as a
function of the material properties. The basic
allowable stresses must have been dealt with
thoroughly in the static analysis lectures..
The fundamental requirement of most
codes is that the dynamic event is classified as
"Occasional load case" and the allowable
stress is therefore 1.33 times the hot allowable
stress, when it is considered together with the
sustained loads.
However, ASME Sec.111 gives a rnorejudicious evaluation of the allowable stresses
under various loading conditions.
1.
2.
3.
4.
5.
80
Dynamic A n d p i s of piping
'
'
14
..
..
:.
probabiiity
of
METHODS'
STRESSES
OF
ADDITION
OF
.
beyond the rigid body cut off frequency.
Since there is no amplification the
stress levels are not of importance. But the
support loads may be significantly affected by
the frequencies beyond the rigid body cut off
frequency.
ILLUSTRATIVE EXAMPLES
Example 1:
2 AT 8.9 Hz
~4
9
FIG.9 MODE SHAPE - 4 AT 16.953 Hz
11
'
T i e period
(secs)
0.1792
0.1124
8.900
The signiicant
modal frequencies
listed above correspond to the natural
frequencies of the pipe including the weight of
the insulation and the entire line being filled
with fluid of specific gravity 0.98. The mode
shapes are illustrated in figures 6 to 11. In
practice the displacement profile of the
response.of the piping will be as hdicated by
the mode shape plot when excited by an
excitation frequency close to the natural
frequency corresponding to the selected mode.
An important observation is that, the
frequency increases as we move away from
the first mode (funidamental mode). The
piping layout response to excitation for each
mode is characteristic. There' are parts of
piping which are hardly excited at a specific
frequency. The 5igec vectors aztually indicate
that most modes have pre-dominant
displacement dong one of the principal axes.
Typically such a discharge line could
be subjected to excitation due to slug flow,
water hammer, flow pressure variations and
other sources of external excitation forces.
One of the important sources could also be the
running frequency of the pump. R'c 5rst
investigate this possibiliry of excitation.
other sources of excitation are not investigated
Dynamic Analysis ofpiping
:.
... :.-.
'
%,
P I P P G ENGINEERJNG CELL
TABLE 2 FREQUENCY LISTINGOF
EXAMPLE 2
Mode Frequen
cy (Hz)
- 5.581
1
T i e period
(secs)
0.1792
. Mode
.
Frequenc
Frequency
i z p . r 2 1 .
Example 3:
In this example we study the impact.
Support
of
support
arrangement.
arrangement has a very strong influence on the
natural frequency of a system. h he support
arrangement is often changed at site to suit
site requirements or to accommodate
structural changes or to rectify layout clashes..
This is rarely reported back to the designers Example 4:
In this example we study the impact
for their concurrence. The support
arrangement can drastically shift the natural of schedule of pipes on natural frequencies.
frequency of a system and hence cannot be The layout and the loads are retained same as
ignored at any stage. Most parts of offsite example 2. However, the schedule of the pipe
h2s been chw.cpj from sch.30 tc sch.80. This
p i : r
affecr:i by such <:^..~^.<<j.
However, piping comecred to pumps md rumple demonstrates the impact of section
turbines are significantly affected by such properties on the natural frequencies. The
resulting natural frequencies are listed in
support modifications.
Table 4.
'
19
PIPING E N G N E F G CELL
In the field during erection it is
common place to have short supplies of
specific sizes and 1 or schedules of pipes.
Though good engineering practices do dictate
that the schedules are important in areas near
pumps, the field production pressures often
over rule such cautions. This is compounded
by .delivery problems if the pipes are of
specid wall thickness, involves special
fabrication requirements, third party
inspection, etc. So it is not rare that the site
engineers resort to using higher schedules
even near pumps assuming that they are safe
since the thickness is. higher. Unforhmately,
the higher thickness is essentially satisfactory
only for resisting internal pressure. Use of
higher schedules is unsatisfactory new pumps
due to higher thermal expansion end thrusts.
Most operating frequencies of pumps are
usually higher than the piping na0ual
frequencies. By using higher schedules we
arerunning frequency of typical pumps. Do
we understand that we are increasing the
risk by increasing the schedules?
TABLE 4 COMPARISON OF NATURAL
FREQUENCIES (EXAMPLE 4 VS.
EXAMPLE 2)
CONCLUSIONS
Dynamic analysis primarily is applied
to piping for the purpose of fail safe
performance under time variant loads. The
analysis can be conducted using PC based
software as on date. The dynamic analysis is
very sensitive to the mass and stiffness
properties of piping system.
If the natural frequency of any system
(including piping) is close to the excitation
frequency of the forcing function then, the
system experiences an amplification of the
excitation forces. This in turn leads to larger
displacements. Damping properties of piping
impose a ceiling to the magnitudes of
excitation.
Typically substitution of higher
schedules during construction should be
viewed critically or preferable referred back to
the designer in order to ascertain that the
increased stiffness and therefore higher natural
frequencies will not pose any excitation
problem to the piping.
most flow-induced vibration cannot be
solved by mechanical means and a flow
parameter correction is essential for such
problems.
..
. .
...
, .
.~
.-
-.
.
APPENDIX 1
. ,.'~7,z.:-
M-15
Oct 6,00
Table of Contents
------------------------------------
Q.A.3lock: Page 1 .
Options: Page 2
Layout: Page 2
Details: Bends: Page 2
Details: Valves: Page 3
Details: Rigid Elements: Page 3
Details: Anchors: Page 3
Details: Specified Displacements: Page 3 .
Details: Limit Stops: Page 3
Material 1: A106 Grade B: Page 4
Pipe sections: Page 4
Loads: Page 4
.
Sorted stresses: Page 6
...Code compliance: Page-7
Response spectrum: Loads on anchors: Page 8
Response spectrum: Loads on 1imit.stops: Page 8 .
Frequencies: Page 8
...........................................................................
..
Caepipe
Version 5.02C
Client
Project
E i l e Number
Report Number :
Model Name
Title
Analyzed
Prepared by
Checked by
Date:
Date:
- ...
caepipe
Version 5.02C
. . ..
M-15.
.A_.
..
Page 2
Oct 6,00
..
---------------------*-----------------------------------------------------
Options
...........................................................................
Piping code = 631.3 (1996)
Do not use liberal allowable stresses
Do nor include axial force in stress calculations
Reference temFerature = 21.11 (C)
Number of t h e m 1 cycles = 7000.
Use modulus at reference temperature
Include hanger stiffness
Do noi include Sourdon effect
go not use pressure correction for bends
presscre stress = PD I 4t
peak pressure factor = 1.00
Cut of: frequency = 100 Hz
Number of modes = 6
include missing mass correction
Do not use friction in dynamic analysis
Vertical direction Y
...........................................................................
: ,Node Type
OX (mm)
DY (mm)
DZ (mm) Mat Sec Load
...........................................................................
1 Title
2
10
3
30
4 '40
5
50
6
60
7
70
8
80
9
90
10 510
11 530
12 540
13 550
11 560
15 570
16 580
17
90
18 100
19 110
20 120
21 701
22 702
Data
Anchor
From
i
Rigid
Bend
1
1
.1
8
8
'8
8
1
1
1
1
1
1
1
1
1
1
8
8
8
8
8
8
8
8
8
8
LI
L1
L1
L1
Valve
Bend
From
Rigid
Bend
Valve
Bend
Bend
Location
Location
Anchor
L2
L2
L2
L2
L2
. -L1
L1
L1
L1
L1 Anchor
Linit stop
Lirnit stop
Bends
Bend
Node
Radius
(nnl
50
80
304.8 L
304.8 L
Thickness Bend
~ml
Ma:l
Flex.
Int. Angle Int.
Factor Node (deg) Node
Angle
(deg)
...........................................................................
701
45
i.
--.-... .
.+
-;:.
Page 4
oct 6.00
Caepipe '
Version 5.02C
Pipe material 1: A106 Grade B
...........................................................................
Density = 7750 (kg/m3),
Temp
(C)
-28.89
21.11
93.33
148.9
204.4
260
315.6
343.3
371.1
398.9
426.7,
454.4
482.2
510
537.8
565.6
593.3
NU
0.300,
E
(kg/mm2)
Alpha
lmm/mm/C)
~llowable
(kg/nrm2)
. 21022
10.552-6
10.93E-6
11.48E-6
11.88E-6
12.28E-6
12.64E-6
13.01E-6
13.19E-6
13.39E-6
13.57E-6
i3.77~-6
13.95E-6
14.11E-6
14.24E-6
14.35E-6
14.498-6
14.62E-6
14.1
14.1
14.1
14.1
14.1
13.3
12.2
12.0
11.6
9.14
7.59
6.12
4.57
3.16
1.76
1.12
0.70
20741
20248
19897
19475
19194
18772
18350
.I7928
17506
17014
16382
15749
15046
14343
13499
12655
Joint factor
1.00, Type = CS
\
.
...........................................................................
Pipe Sections
...........................................................................
Name
Nominal
Dia.
Sch
8"
O.D.
(mm)
Thk
(mm)
219.07
7.04
...........................................................................
30
'
1.5
12.5
136.2
125
0.00 (m/s)
Wind velocity
Shape factor = 0.60
Wind direction: X comp = 0.000, Y comp = 0.000, Z comp = 0.000
X spectrum: ~ a t e ~ o r y l
Factor = 1.0000
Interpolation:
Period
(sec)
1:Linear
Acceleration
(g's)
2:Linear
...
. ...
Caepipe
Version 5.02C
M-15
Y spectrum: Categoryl
Factor = 0.5000
Interpolation:
Period
(sec)
1:Linear
2: Linear
Acceleration
(9's)
Z spectrum: Categoryl
Eactor = 1.0000
Interpolation:
Period
(secl
1:Linear
Acceleration
(9's)
2:Linear
Page 5
Oct 6.00
. .
Caepipe
Version 5.02C
.:.'
.~ ....
M-15
...........................................................................
0.3
0.4
0.5
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.4
2.8 .
Page 6 .
Oct 6.00
0.825
0.781
0.721
0.665
0.526
0.429
0.355
0.31
0.266
0.237
0.219
0.177
0.163
t
Number of thermal loads = 1
Pipe Loads
...........................................................................
Load
Name
Pl
T1
(C) ( k g / d )
~1 .
L2
230
230
Node
SL
(kg/&)
T2
P2
(C) (kg/cm2)
. ..
P3
Specific Add.Wgt
T3
(C) (kg/cm2) gravity (kg/ml
Wind
Load
...........................................................................
25.0
0
Y
Y
0.980
...........................................................................
831.3 (1996) Code Compliance (Sorted Stresses1
------ sustained ------ ------ ~ ~ g a -----n ~ i -----~ ~ Occasional ----SLlSX
SE
(kg/&)
Node
SZ/SA
Node
SL+SO SL+SO/
(kg/&)
1.33SH
...........................................................................
120
90
580A
701
80A
508
llOA
100
808
40
30
10
1106
5806
50A
70
570
702
5508
530
543
5 10
550A
4.57
3.47
3.17
3.16
3.14
2.90
2.82
2.79
2.69
2.69
2.68
2.65
2.63
2.62
2.60
2.57
2.55
0.74
0.39
0.2i
0.21
0.17
0.12
0.'33
0.25
0.23
0.23
0.23
0.21
0.21
0.20
0.20
0.20
0.20
0.19
0.19
0.19
0.19
0.19
0.19
0.05
0.03
0.02
0.02
0.01
0.01
5506
702
120
550A 580A
90
701
80A
50A
506
1lOA
5808
1108
540
808
530
510
40
570
30
'
5.87
5.78
5.44
5.31
5.13
4.73
4.61
4.54
4.45
4.22
4.14
3.66
2.56
2.50
2.46
2.31
2.18
1.55
i.45
1.21
100
:.L7
70
10
1.02
0.88
0.28
0.28
0.26
0.25
0.24
0.23
0.22
0.22
0.21
0.20
0.20
0.17
0.12
0.12
0.12
0.11
0.10
0.07
0.01
0.C6
0.06
0.05
0.04
120
508
580A
BOA
llOA
808
5808
701
1100
5508
702
90
50A
10
570
70
I00
30
40
555A
5:O
530
540
11.1
8.07
7.42
7.40
7.11
6.96
6.82
6.66
6.33
5.91
5.25
5.09
4.82
4.48
4.07
3.99
3.96
3.61
3.35
2.97
251
1.45
1.04
0.61
0.44
0.41
0.41
0.39
0.38~
0.37
0.37
0.35
0.32
0.29
0.28
0.26
0.25
0.22.
0.22
0.22
0.20
0.18
0.16
0.14
0.08
0.06
25
?-??
'.:
R.S. Soni
Nuclear Recycle Group (Mech.)
Bhabha Atomic Research Centre
Trombay, Mumbai- 85
operation
Reactor core - housed in vessel.
Operating pressure - as low as atmospheric to 110
kgf/cm2
Operating temperature - ambient to 500'~.
depending upon the type of reactor
&-STEAM
OUTLET
(TO TURBINE)
STEAM GENERATOR
,'5.FEEDWATER
INLET
[FROM CONDENSER)
STEAM OIJTLET
(TO TURBliNEl
STEAM OUTLET
TO TURBINE
7DEMISTER
SECONDARy
MOISTURE SEPARATOR
,-ORIFICE
UPPER SHELL
Y-l
-SWIRL
VANE PRIMARY
MOISTURE SEPARATOR
/---
TUBE BUNDLE
RINGS
FEEDWATER INLET
ANTIVIBRATION BARS
DOWNCOMER 'FLOW
RESISTANCE PLATE
LOWER SHELL
-BLOWDOWN LINE
TUBE SHEET
PRIMARY MANWAY
PRIMARY COOLANT
OUTLET
PRIMARY COOLANT
-.
Stear11Separators
..
.: .
,. .... ...
.:.:::F&; 13.10. BWRf6 srean and recirculation water flow paths (General Electric
. .
..~
. .....
.
..... .;
..._
.....
...
.
.
,
.
,
:
'
:
,
r
.
~...,
: . .
.-
-.
-..
2 CALANORIA W E L L
3 C A L A N O R I A TUBES
4 EMBEDMENT RING
5 F U E L I N G TUBESHEET
6 E N D SHIELD L A l T l C E TUBES
7 END S H I E L D COOLING PIPES
8 INLET-OUTLET STRAINER
9 STEEL B A L L SHIELDING
10 E N D FITTINGS
11 FEEDER PIPES
12 MODERATOR OUTLET
13 MOOERATOR I N L E T
Fig. 13.12.
I n t c r n a l s t r u c t u r r . nf ;I
C'ANDU
r e u c t t r r ( A r c ~ m i cEnergy
of
Cari;rda.
Ltd.1.
Primary coolant
Secondary coolant
Moderator
Pressurizing
Feed and condensate
Instrumentation
Purification & demineralisation
Radioactive waste
Broadly classified into two groups:
o NucIear piping - handling radioactive fluid
o Other piping - handling non-radioactive and
conventional fluids
conventional piping
o Possibly first look - increase in safety factors
P & T consideration
PWR - High pressure & relatively low temperature,
Safety Classification
Safety classification is available for
NPPs - IAEA 50-SG-D I.
Various structures, systems and components (SSCs)
classified based on their safety role and their
importance.
Safety role decided based on the safety functions to be
performed and ranking of those safety fimctions.
required.
o Probability that the safety function would not be
o Safety class-2
o Safety class-3
o Safety class-4
o Component &
piping supports
containment
Important requirement
Various Loadings
Wight - DW + Live load
Pressure:
o Internal
o External
o Operating or transient
Temperature
o Operating
o Transient
o Nuclear heating
Wind loading
Dynamic loading
o Earthquake
o Flow induced vibration
o Relief valve discharge load
o Water 1 steam hammer
Recent Eqs'
oLatur1993,
=6.3
o Bhuj 2001, M
= 7.3
o HinduKush
March, 2002 M
= 6.7
o Kobe, Japan
1995 - 1996 M
= 7.9
o Chennai
~ c t o b e r200
, 1M
= 4.3
moderate EQs.
o Total collapse ruled out for maximum credible
EQ.
o Heavy plastic deformation with lot of cracking
allowed.
Radioactive facilities
o Very little damage permitted so as to have no
cracking to avoid radioactive fallouts.
o Moderate or heavy damage and collapse is not
envisaged at all.
o Very little plastic behavior permitted.
o Designed for EQ based on detailed seismic
Design Approach
Design by Analysis - Safety Class-1 & 2
Design by Rule - Safety Class- 2 & 3
Service Levels
Various loading categorized into four service levels
depending on their probability of occurrence
load decreases.
Risk = f (probability of occurrence x allowable stress)
As probability of occurrence decreases, allowable
stress increases for the same risk-level
Failure Theories
Safety Class- 1 - Maximum shear stress theory
Safety Class- 2 - Maximum principal stress theory
Safety Class- 3 - Maximum principal stress theory
Gl, = ( 0 1
02)/2I SJ2
Stress Intensity = 0 1 -
Max
02
< S,
)Tresca
- 1.80 Sm
- 2.25 S,
- 3.00 Sm
o,
02
= 20"
o,
> 20,
FIG. 1-9.2.1 DESIGN FATIGUE CURVE FOR AUSTENlTlC STEELS, NICKEL-CHROMIUM-IRON ALLOY, NICKEL-IRON-CHROMIUM
A N 0 NICKEL-COPPER ALLOY FOR S, > 28.2 ksi, FOR TEMPERATURES NOT EXCEEDING 800F
(For S, 5 28.2 ksi, use Fig. 1-9.2.2.)
Table 1-9.1 Contains Tabulated Values and a Formula for Accurate Interpolation of This Curve
ALLOY,
[K]{x, G n a ~1 I= M X (
I -2
;=I
Is,.
Where SAmax
= highest spectral acceleration in the interval
between the cutoff frequency and ZPA.
Alternately:
Structure type
Stress level 1
(OBE)
Welded aluminum
structures
Welded and friction bolted
steel structure
Bearing bolted steel
structure
Pre stressed concrete
structure
Reinforced concrete
structure
Piping
Equipment
"
NB-3000 - - DESIGN
Tahle NB-M8l(a)-I
TABLE NB-3681(a)-l
STRESS INOICESIFOR USE WITH EQUATIONS IN NB-3650
--
81
Internal Pressure
INote (211
c 100 for
~ . ...
CI
Kt
lN01c (411
[Note (411
--
< 50 lor
Moment Loading
INote (211
B Indices
~-
Thermal Loading
c
2
K2
[Note (4))
[Note (411
c3
c'3
K3
[Note (411
Notes
L m q i t ~ d i n a butt
l
welds in straight
pipe
(a1 flush
(b! as-weidcd I> !/,,, in.
(c1 as.wcldcd I C
ill.
'/,,,
0.5
1.5
NOTES:
Ill For indices not listed, see the note referenced at the end of the apoiicablc litlc.
(21 For the calculation of presrurc and rnornellt loads m d special inrt-vctinns regarding i q s . !?I through !:3!, rcr NB-3683.11dl.
(31 For definitions, applicability, and specific restrictions, see NB-3683.
(41 For Special instructions regarding the usc of there indices for ivl!ldcd products. in:errectny welds, abutting products, o r out-of-round
prad~cts,see NB-3683.2.
151 See NB-3683.3. Straight Pipe Remo!? From Weids.
(61 See NB-3683.4(al, Longitudinal Rut1 Welds.
(71 See NB-3683.4(bI, Ginh Butt Weldr.
(81 See NB-3683.4k). Ginh Fillet Weldr.
(91 5ce NB-3683.5(a), NB-4250 Transitions.
(101 See N8-3683.5(b). Transitions Within a 1:3 Slope.
( 1 11 See NB-3683.6. Concentric and Eccentric Reducers.
(121 See N6-3683.7, Curved Pipe or But2 Welding Elbow$. See ah0 NR-3683.?!2! an" NB-3683.2(bl.
1131 See NB-3683.8. Branch Connecttonr per NB-3643. See also FIB3683.l(dl.
1\41 SCP N H - l b R ? 9 . Hutt Welding Trer. S p r also NR-3683.lldl.
"3 s
............. (12)
21 '
Where M~*=
Mi in eq.(lO) except that it includes only
m
C,
Do
-M,
+ C 2 2I
.-
Where I&
3Sm<S,<3mSm
=
Y S? c4
0.7 E a
x = (PDo/2t)(l/S,)
y =3.33, 2.00, 1.20 and 0.80 for x = 0.3, 0.5, 0.7 and 0.8
respectively
i)
P r i y a r y Stress Index
Flexibility
Characteristic
Description
Welding elbow or
pipe bend [Note 1111
Flexibility
Factor k
Stress
Intensification
Factor i
Sketch
st,, Cot N
2 r2
2r
Branch cnd:
0.5
Run enrl:
Reinforced fabricated
tee [Note (511
Unreinforced
labricalod tee
FIG. NC-367
I
!(b)-1
(1))
Description
81
Flexibility
Factor k
92
Branch leg:
0.5
Run legs:
("')
I>
rn
Branch leg:
0.5
Run legs:
(?)'
s
B2, = 1.3
(5f'
[G)
.
Branch leg:
"(-
R,,,
it, = 4 5 - 1
T,
. ,
Sketch--
r'
(.-)[3)
T, r,
Run legs:.
i, = 0.4
Fig. NC3673.21bl-2
? 1.5
R,,
T;,
1 (-][GI
2 3.0
I'
J;,,
R,,
Run legs:
R ?
i, = 0.8 (-"I
T,:
'
(-)R,,,
B2, = 0.9
T,
r;,,
(-1R.,,
r,,
Fig. NC3643.2(bl.2
.2 ' 1
"
2.1 11..C.l
INots 1211
INotc (211
0.5
1.O
30 d e g tapered transition
[ANSI 816.25)
I,,r 0.237 in.
0.5
'
Fig. NC-4427.1
skctclie~i c - 11.
Ic.2). a!,<! IC-3)
1.3
2.1
1.3 + 0.0036 -2
Fig. NC-4511.1
I,.
1.O
1.3
+ 0.0036 D,il,, .
1.9
0.5 for a c 30
deg.
1 . 0 for 30 deg. c
o 5 60 deg.
threaded flange
\
1
0.5 + 0.01
lN01e 12)l
I
121'
Sketch
1.o
INote 1211
I
Flexibility
Factor k
8,
r,
::
(2)
c 2.0
\ t,
2.3
INote 12)l
............................ 00)
+ 0.25Sh)
Where
S, = material allowable stress at minimum temperature.
Sh= material allowable stress at maximum temperature.
r,, r2, ... = The ratio of any lesser temperature cycles for
which the expansion stresses has been
calculated
temperature cycles, N
Factor, f
1.o
7000 to 14,000
0.9
14,000 to 22,000
0.8
22,000 to 45,000
0.7
45,000 to 100,000
0.6
0.5
(1 .25Sh+ SA)
Piping-whip restraints provided to mitigate the effects.
n = no. of neutrons1 m3
o Increase in UTS
o Increase in hardness
Fig. 5.35. Effect of Copper on the Transition Temperature of ManganeseMolybdenum Steel Plate
.- 100.
'c'
"6
/'
,/--
/
50'
)
1
/
I
- .0089'0)
/---
/'
.2 ,4 .6 .8
----------.
1.0.2 .4
.6 .8
2.0.2.4
.6 .8
3.0.2.4
,6 .8
4.0
o Pneumatic test
o He-leak test
Hydrostatic test
o 1.25 times design pressure for safety class- 1
o 1.25 times design pressure for safety class -2 &3.
Pneumatic test
o 1.1 times design pressure.
o Soap bubbles should not be generated.
radioactive substances
o Leak rate < 5 x lo-' std cc per sec. of He.
Tolerances
Design of pipe supports based on nominal dimension.
(Similar to design of piping 1 equipment)
Good design practice call for
o Design to consider the degree of deviation from
TABLE K-1330-1
. 114 in
2 2 deg.
.... .
.....
.:
... ...
h
:
.
'
,
'
;
....._,
.
F.
Duilding
~lruclure
i 2 dog
--
- -- .. --
..
Cl
.'
.- b In
Table K-1330-1
- APPENDICES
TABLE K-1330-1
LOCAL INSTALLATION TOLERANCES FOR PIPING SUPPORTS (CONT'D)
Item
Total
Tolerance
Configuration
+3 in.
-6 in.
'3 in.
Attachment
+I14 in.
114in.
+So. -3-
Z 1 in.
No limit
Weld category
Butt welds
- Volumetric &
LPIMP
Weld joint category-B
Fillet or partial
Fillet & partial
penetration
penetration weld "ioint welds
- LPMP
- LP/MP
Comer welded
branches & piping
connections
Oblique fill
penetration
branches & piping
connections
Structural attachment
welded joints
> NPS 2
- RT or
LPMP
> NPS 2
- RT or
LPIMP
Butt welds
- RT
RT & LPMP
> NPS 4
- RTNT & LPMP
< NPS 4
- LPIMP
> NPS 4
- RTNT & LP/MP
< NPS 4
- LPMP
NPS 2
- RT or
LP/MP
inspection.
o Leak is detected through the crack so as to take a
nature
i.e. damping
o Various tests on piping components and
Pipe size
1998 code
(OBE)
(SSE)
(OBE) (SSE)
F 12'
1%
2%
5%
5%
> 12"
2%
3%
5%
5%
leakage.
o Periodic In-service-inspection (ISI) must -
EQ.
Conclusions
Duty to protect the plant personnel, public and
environment fiom 2 considerations:
o Loss of life & structural damage.
o Radiation fallout.
Piping Layout
Piping Layout
PROGRAMME
,
TNG
TNG
TNG
TNG
FRIDAY, 19.07.2002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
TNG
TNG
TNG
Guest Speaker
Coffee- 11.00
11.15
TNG :T N GOPINATH
TABLEI
-
SHEET- 1 OF 5
PIPING SYMBOLS
DESCRIPTION
CHANGE OF DIRECTION
AT 90'
DOWNWARD BENDING
1.1.1 BW elbow
1.1.2 SW elbow
UPWARD BENDING
1.2.1 BW elbow
1.2.2 SW elbow
L
1.2.3 Scrd elbow
PLAN
DESCRIPTION
I END VIEW 1 I
PLAN
END VIEW 2
BRANCHING
DOWNWARD
I
""T B
?+
UPWARD
3.2.1 BW Tee
+04
3.2.2 SW Tee
T 7
SHEET- 4 OF 5
DESCRIPTION
BRANCHING
3.2 I UPWARD
PARALLEL LINES
CROSS LINES
ROLLED ELBOW
ROLLED TEE
PLAN
I END VIEW 1
END VlEW 2
SHEET- 5 OF 5
DESCRIPTION
PLAN
VALVES
Hand Wheel Operated
Flgd Valve with
vertical hand wheel
Lever operated
Valve
CONCENTRIC REDUCER
ECCENTRIC REDUCER
rD-5
FSU/ FSD
SIZE
OVERALL
DIMENSIONS in mm
GENERAL NOTES
MATCHLINE AREA
I
I
1
.
REFERENCE DRAWINGS
MATCHLINE AREA - 4
KEY PAN
REVISIONS
R.NO
GNO.
I REV I
REV.
DESCRIPTION
DATE APPROVED
COMPANY NAME
C. S. Process Piping
Utility piping
equipment.
Valves should be drawn to scale with identification
number fkom the P&ID marked thereon.
Draw valve hand wheels to scale with stem l l l y extended.
If it is lever operated, then the movement of handle
position should be marked.
If a valve is chain operated, note the distance of the chain
fkom the operating floor.
Show location of each instrument connection with
encircled instrument number taken from P&ID.
Similar arrangement shall be shown as typical detail or
covered in a separate company standard as Instrument
Hook-up drawings.
Draw plan view of each floor of the plant and these views
should indicate how the layout will look like between
floors as seen from top.
+E
EL. 1 13.650M
EL. I 0 l .%OM
L
BOTTOM PUMPS
ALL DIMENSIONS IN MM
information:
Dimensions and angles.
Reference number of P & IDS, GA Drawings, line
numbers, direction of flow, insulation and tracing.
Equipment location and equipment identification.
Give nozzle identification on the connected equipment.
Give the details of flange on the equipment if the
specification is different fiom the connecting piping.
Size and type of every valve/ Direction of operation.
Size and number of control valve.
Location, orientation and number of each equipment.
P LAN
PROPERNORTH ORlENTATlON
PLAN
DIMENSIONING OF DRAWINGS
I
Flanged valves are located with dimension to flange faces. Nonflanged valves are dimensioned to their centres or stems.
For flanged joints show a small gap between dimension lines to
indicate gasket. Flanged joints can also be shown without
gasket but
cover the same with a general note and include gasket thickness
in the valve or equipment dimensions.
For Finished Floor (FF) the elevation shall be the high point of
the floor.
For field run piping, give only those dimensions which are
necessary to route piping clear of equipments and other
obstructions. Locate only those items which are important to
the process.
Underline out of scale dimensions or mark as NTS.
Do not terrninate dimensions at screwed or welded joints.
LAYOUT
-7
T.N. Gopinath
I I
ANCHOR
STRUCTURE FOR
ANCHOR SUPPORT
--
a) AS DESIGNED
Fig. 1.1a
Fig. l . l b
GG-
GGGGGG-
G-
Fig.
L.
1.
PROCESS
FLOW
DIAGRAMS
PIPING AND INSTRUMENT
DIAGRAMS (P &ID)
2.
3.
(PFD)/
-.
TYPES OF LAYOUTS :
=-
Inline Layout
Similar equipment grouping
Functional equipment grouping
2-
-I,.
COLUMN
nn
IIII
TOP TUBESHEET
7
SUPPORT LUG
SllELLSIDE INLIJ'f
-
SUPPORT BRACKET
SHELL BELLOWS EXPANSIONJOINT
LIQUID LEG
LSHELLSIOE OUTLET
TOP TUBESHEET
COLUMN SHELL
I/,
SUPPORT LUG
REBOILER SHELL
m..
-,
!,?id
SHELLSIDE OUTLET
BOITOMTUBESYgT
t_
''
SUPPORT BRACKET
TOP HEAD
TOP TUBESHEET
COLUMN
.-7
..,
SUPPORT LUG
-
SPRING SUPPORT
REBOILER SUPPORT
STRUCTLJRE
.
BELLOWS
EXPAESL0.NJOIN'I'
$1:
I ~ .
518
Fig. 2.2.1 TYPICAL PLOTPLAN OF AN OUTDOOR PETROCHEMICAL PLANT
1 ) A1 l
lltlN
E L L V A I I U N S A%
iN hlhl !AN1
li,l U E l i i i S .
Moinlence
road
Platform for
Platform
Cot Walk
i
i
Tube-bundle
removal areo
-iI
- I-i
I
-'
Process
equipment
.
i
Process
- I - equipment
Pipe rack
lubc-bundle
area
I removal
Pumps
Typicol platforms
on yard steel
Access
Oavil for removal
of tower internols
Air Coolers Over
Piperock
Alternative location
o f air coolers
Muinlence
rood
Fig. 2.2.3
Compressor
hours
Fig. 2.2.4
Fig. 2.2.5
\/f
opening
ond
removol
og itot; space
ROO(
Trolley b e o r (removable)
f o r m o t o r ond geor h o ~ l d l h q
o n d for mixer-shaft seol renewol
i' I
Elevation :
Construction ond
mointenonce occe
Main occess
'
Grade elevation
+ 100
Fig. 2.2.6a
1 'I 8 M
,CABLE PIPE
TRAY
Fig. 2.2.6b
o
o
o
o
Value Location
Electrical/Instrument Cable Trays
Statuary requirements
Miscellaneous
The pipe rack splits the plant area into convenient parts.
The pipe rack takes various shapes such as 'straight', 'L', 'T', and
'C' or 'U'. This configuration is based on the overall arrangement
and site conditions. Based on the incomingloutgoing lines and
locations, the pipe rack is laid.
I-.
I Process
Dead - e n d
equipment
y a r d . Lines e n t e r
a n d leave o n e e n d o f y a r d .
Fig. 2.3.1
Road
I-------
1
1
HOUSE
'
7
I
PROCESS EQUIPMENT
Road
S t r a i g h t - t h r o u g h y a r d . Lines c a n e n t e r a n d
leave b o t h e n d s o f t h e plot
Fig. 2.3.2
Process
Eq~~iptiien.I:
L-shaped y a r d . lines c a n e n t e r a n d
leave n o r t h a n d e a s t side o f t h e p l o t
Fig. 2.3.3
1
i
r-i
I
L..A
FROCESS-1
i EQUIPMENT I
I
Fig. 2.3.4
U-shaped
ya'rd. L i n e s c a n e n t e r
l e a v e all f o u r s i d e s o f t h e p l o t
Fig. 2.3.5
and
1 1
HOUSE
PROCESS
; EQUIPMENT
C o m b i n a t i o n o f L-
a n d T-sahped
Fig. 2.3.6
yard..
j
I
Complex yard-piping a r r a n g e ~ m e n t
f o r a very large c h e m i c a l plant.
Fig. 2.3.7
TYPE 1
TYPE 2
Fig. 2.3.8
TYPE 3
$1
$1
FUTURE
I I
PROCESS LINES (LOWER LEVEL)
I
Fig. 2.3.9a
I---
IiEAVY LINES
CW, CHW, CHB
OLD
I
I
I
PROCESS
SERVICE
GAS PW
I HOT PROCCSS I
Fig. 2.3.9b
I I(! I LLINI-I;
...
...
..A
NO DIFFERENCE
I N ELEVATIOr\I
qT
T U R N IN PIPERACKS
( C H A N G E I N ELEVATION W H E N
CHANGING
DIRECTION)
Fig. 2.3.10
Fig. 2.3.11
FLEX1
LOOP
ELEVATED -.,
EQUIPMENT
&,
'\
EXTENT OF
FIREPROOFING
FIREPROOF ENTIRE
COLUMN
Fig. 2.3.14
-i
EXTENSION
LOCATION
RELIEF HEADER
LOCATION
NEAR CENTRE. OF
RACK
II
II
II
II
I
BI
I
I
TOP LEVEL
Fig. 2.3.15
II
II
II
II
PRESENT
FUTURE
EXTENSION O F FIPCRACI\
Fig. 2.3.16
Fig. 2.3.17
VALVES
IN
- -EL > 2 2 0 0
!d TO BE CHAIN OPERATED
MAX 2 2 0 0
u0
W
0
I
MIN 2 1 0 0
'ty 4APPROX 1 7 0 0
- -- -- -- --
1300
1100
800
CHAIN
600
MIN 1 5 0
MAX 6 0 0
II-
5 0 0 MAX
Fig. 2.3.18
UTILITY
CONN
TO
PROCESS
Fig 2.3.19
EQUPT
COMMON
AS REQUIRED
ELEVATION
ARRANGEMENT OF BATTERY LIMIT
ISOLATION SINGLE LEVEL RACK
Fig 2.3.20
Fig 2.3.21a
ELEVATION b
Fig 2.3.211,
HIGHER OFF-SITE
RACK
#
UNIT
Fig 2.3.22
yv;R
OFF-SITE
-
RACK
--
5,
TYPE I
TYPE II
TYPE Ill
k
T
TYPE V
..
TYPE IV
Fig. 2.3.23
. :,.
. .... .
. ...
. ,.'
. ,. .. .
..
:....
...
. . ,.. .
. .... ,. .
b)
C)
d)
>
Petroleum
.. .
f)
Towers
--
Towers
,.
B
Platform
\4
Drums
lord irvgtn
Lines with one
and other end
can be located
yard elevotion.
end below
obove yard
o n either
--7
,
I lozzle
to nozzle
piping where
possible
Elevation for
orfice runs
I,
~~
lines
Fig. 2.3.24
Ground
elevation
+ 1'00 M
~
,,<a"
Petroleum
c)
d)
;:.
...
;.' ? . ,':. ''
'. .
...
....
.,...
.., ... .
.._
.id,.
?:. . .. ., .
. , ...
. .. .
.. ..,.
' C...
e)
,
i.,.~.
Q i.' .
. .
,,
~ owtrol rules
~
by the&State
~ % @ ~ r&hn&hpmg~t
ald
g;:v~on.
~
ACCESS
CO1,ITPOL VALVE
ASSEMBLY
AC,CESS
RACK
COLUMhI
SPACING
PLAN
LAYOUT O F P U M P S
REFINERY
I1 I
P E T R O C H E M I C A L P L A I IT
Fig. 3.1.la
\,
O
/
E'-,
MAIN
\
\
,A(-: (-:
'</
'-,
'
Fig. 3.1.lb
STARTER
SINGLE P U M P ARRANGEMENT
PAIRED P U M P ARRANGEMENT
PIJMP ARRANGEMENT
Fig. 3.1.2
TANK # I
. CURBWALL
--
I N A TANK FARM
Fig. 3.1.3
VACUUM TOWER
TO
REACTION # 2
P UMP # 2
TO
REACTION # 1
PUMP # 3
,1:>
',
;!:;.
ri
k:.
PUMP# 1
....I ,
1 --.,'
. .
~,
REACTION # 1
REACTION # 2
GROUPING O F PUMPS # 2
TO
REKTION # 3
Fig. 3.1.4a
SPOOL PIECE
FOR PUMP REMOVAL-
Fig. 3.1.4b
AT
ELEVATION
Fig. 3.1.5
DISCHARGE PIPING
SUCTION PIPING
ISOLATION VALVE
$)
PRESSURE
INDICATOR
CONCENTRIC
REDUCER
'Y' TYPE
STRAINER
REDUCER
F.S.D
PUMP CASTING
BYPASS LINE
BYPASS LINE
COOLER
LPLR
ELBOW
90'
TURNS
PIPE
BEND
I
LATERAL
DOUBLE
BRAN C H - O F F
OFFSET
ONE
ELEVATION
OPPOSING
CONVENTIONAL
ANGULAR
BRANCH
PLANE
TURN
CHANGES
JUNCTION
CONNECTIONS
Fig. 3.1.6
STREAM
STREAM
LINED
LINED
BRANCH
h)
i)
1Clearance
between
b o t t o m of pipe a n d
g r a d e f o r d r a i n valve
_U_75Clearance
e x c h a n g e r betwee3
flanges'
a n d c o n c r e t e plint
Clearance
for swinging
Fig. 3.3.1b
a)
b)
c)
dl
e)
f)
g)
h)
-.
j>
Access
Yard
piping
1-
Access l o valves
and instruments
T0-
'
exchanger having o b o d
(I
600 rrlrn s h d
Fig. 3.3.2a
tlian~eic~
'ford-piping
elevations
To p u m p
Dimensions of
2 to 3 ft
r-
Ond
Elevotions for p i ~ ) i n g
to odjocent equipwent
B
Exchanger piping i n elevation showing l o c a t i o n of
pipeline r u n s in r e l a t i o n t o
Fig. 3.3.2b
IIU~I-I
pipe ~ u c l . .
6. Stationary Tubesheet
Shell Cover
Shell Flange-Stationary Head End
Shell Flange-Rear Head End
Shell Nozzel
Shell Cover Flange
Expansion Joint
Floating Tubesheet
Floating Head Cover
Floating Head Cover Flange
3 1.
32.
33.
34.
35.
36.
37.
38.
39.
Pass Partition
Vent Connection
Drain Connection
Instrument Connection
Support Saddle
Lifting Log
Support Bracket
Weir
Liquid Level Connection
FRONT END
STATIONARY HEAD TYPES
REAR END
HEAD TYPES
SHEEL T W E S
~~
-L
ONEPASSSHELL
a
WILT ROW
BONNErmmOe.ALrnVER)
FIXED TUBESHEET
LIKEmB'STATIONARY HEAD
I
~r
NLEDNBESHEET
UKE1('STATIONARY HEAD
EMOVABLE
NBE
BUNDLE
ONLY
DIVIDED FLOW
K m L E TYPE REBOILER
-DIVIDED FLOW
EXTERNALLY SEALED
ROATMGNBESHEET
BEM
AEP
AKT
Fig. 3.3.3
r il
.77.-, T7 7.,. /
77.71/
Ti
Fig. 3.3.4a
Fig. 3.3.4b
Undesirable
Slope
Desirable
Slope
Rool
out
i) Conventional condensor
arrangement
Vent
wslz_t'y
Droin
Drain
Pipe
Rock
ii) Crovilv-flow
suction line obtoined
,
by chonging direction o f flow
through exchongel
:'s -qO-
I,
17
-.-
1
iii) Zig-zag
I,
Pipe
Kz-
I
flow pattern
Fig. 3.3.5
Vopour
3/5 L
Tongent line
Nozzle a n d m a n h o l e l o c a t i o n s
Fig. 3.4.1
Tongent line
r- Vessel
I. ugs
Comer Supports
Lug-supported d r u m s
(less economical design)
Lug-supported d r u m s
(More e c o n o ~ ~ i i c odesign)
l
Fig. 3.4.2
Building st,el
is /not
a t t a c h e d to reactorand drive
building and
Fig. 3.4.3
Access on wing
r
Access
steel
Building
-L
c. O ~ i c l c ~ (vI ~I I ~:iI
fig. 3.4.4
1.1.-I:III~
IIII~I:~)
Access
(Less e c o n o m i c a l )
Access,
(More economical)
Vertical D r u m
Fig. 3.4.5
Overhead
condenser
I--
Distillation
column
,,-
Reflux return
Reflux drum
Feed
-
I TO
Q
>-(
Bollom pump
Process flow diogrom
Fig. 3.5.1
strooge
Mar
2s
lacing rood
I V
pump J
suction
control--/
valve
Akrnote
suction line
Elevotion
Line to
equipmenl
ol grode
(reboiler)
Pipe rock
To
'\
~eament
./
equipment
0' grade
01 plotforrm bmckets
Plnn
. ,-,,
Fig. 3.5.2
Riser
Reboiler
Morimum
liquid level
Condensate pot
--7
Sleam condensote
Distillolion column
fYL-7
Condensale
Fig. 3.5.3
Minimum
liquid level
L Requit-ed
elevulion
difference between
liquid level in tower
ond exclionger
Required NPSH
Pumpout
bypass
Fig. 3.5.4
MR. T. N. GOPINATH
H
H
H
H
Refinery
Chemical IAgro Chemical / Petro Chemical / Organic
Chemical / Inorganic Chemical
Fertilizer
Pharmaceutical
Metallurgical
Power Generation
w
w
rn
H
H
H
provided it is contained in a
receptacle not exceeding 1,000 liters capacity.
rn
TABLE 1
Minimum distance
from Building or
Group of bldgshine of
adjoining property
Minimum distance
between Pressure
Vessels
5 metres
1 metre
ii
10 metres
1 metre
iii
15 metres
1.5 metres
iv
20 metres
2 metres
Above 40,000
30 metres
2 metres
TABLE 2
( in litres )
Minimum distance
from Building or
Group of bldgsfline
of adjoining
properb'
Minimum distance
between Pressure
Vessels
3 metres
1 metre
above 10,000
!
-Iiii
10 metres
Above 20,000
15 metres
2 metres
Diameter of l
vessel
Note : The distances specified above may be reduced by the Chief Controller in
ases where he is of the opinion that additional safety measures have been provided.
Establish the N-S and E-W (or X-Y) grids, the plant
north in relation to geographical north.
Establish the N-S and E-W (or X-Y) grids, the plant
north in relation to geographical north.
Establish the free area along the plot boundary as per
the statutory norrns.
Work out the area requirements for the green belt,
vehicle parking etc. as per the norms.
The process blocks shall be located in the sequential
order of process flow so that material handling
(solidlliquid) is minimum.
********
2 4 JUL 211112
TECHNICAL LIBRARY (PRDH)
Piping Specifications
~-
~~~
EPC Centre, B P Estate, Chhani, BARODA, TEL: 776206,771109 FAk776211, E-MAIL: rajesh-patel@enc.Itindia. .c0111
Piping Specifications
PROGRAMME
MODULE I :PIPING SPECIFICATIONS
TUESDAY, 16.07.2002
0930 - 1100
1115- 1245
1330 - 1515
1515 - 1645
Introduction to Piping
Engineering
Introduction to Piping
Engineering (contd.)
Pipe Sizing & Design
Pipe Sizing &Design (contd.)
ASM
ASM
TNG
TNG
TNG
TNG
ASM
ASM
.-
WEDNESDAY, 17.07.2002
0930 - 1100
1115-1245
1330 - 1515
1515 - 1645
ASM : A S MOHARIR
TNG : T N GOPWATH
Arun S Moharir
Present Affiliation
Professor, Chemical Engineering Department, Indian Institute of Technology, Bombay
Professor, Computer Aided Design Centre, Indian Institute of Technology, Bombay
Professional Qualification
Ph.D. (1981) in Chemical Engineering from Indian Institute of Technology, Kanpur, India
Communication Addresses
CAD Centre, IIT Bombay,
Powai, MUMB.41 - 400076, INDIA
Phone : 091-22-5726249,091-22-5767795 (office)
: 09 1-22-5704310 (Residence)
E-mail : amoharir@che.iitb.ac.in
Areas of Active Interest
Mathematical Modeling, Simulation, Optimization and Control of Chemical Processes,
Flowsheet Simulation,
Reactor Modeling,
Adsorptive Separation Processes,
Computer Aided Design and Engineering,
IT-based knowledge management in CPI (Chemical Process Industry) .
Recent Projects (2000 onwards)
Generalized Reactor Model : UOP
Parex and Molex Process Simulation : Reliance Industries L i t e d , Indian Petrochemicals
Corporation Ltd.
Generalized SMB Process Simulation : UOP
Catalyst Manufacturing Unit Operations Modeling : UOP
Distillation Column Hydraulics Modeling (Legacy Slw Conversion) : UOP
Flowsheet Simulation :UOP
Object Enabling of Legacy Slw written in Procedural Languages : Several Clients
Genomics/Proteomicsflowsheet modeling : Orochem Inc.
Hydrogen PSA Technology Development : Engineers India L i t e d , India
Training Programmes in CAD, CAE, CAPE etc. : Several Organizations
ChemicalAtlas (A Knowledge Portal for CPI) : Mathimitation Technologies, India
Other
Consultant to :UOP, Engineers India Limited, Mathimitation Technologies
Member of: Scientific Advisory Committee to Ministry of Petroleum, Govt. of India
Chairman :Fuel &Loss and Optimization group of Centre for High Technology, Govt. of India
MAJOR PHASES
Major phases in the life of a chemical process can be identified as follows.
Determination of techno-economic feasibility
Basic Engineering
Detail Engineering
Commissioning
Normal Operation
There is an explosion of investment as one goes from the first to the last phase. Normal tendency is
to spend very little initially by way of avoiding comprehensive analysis of process options etc. The
recent trend is to squeeze an additional phase between techno-economic feasibility and basic
engineering, called conceptual design, wherein one spends more time (and money) on analysis of
available options to select the option best in some sense. Although it tends to increase expenses
initially, the cost figures by the time the.facility reaches normal operation phase. are reduced
considerably. *Click here for better visualization of the effect of 'working harder and smarter' in
the initial stages.A piping engineer has a major role to play from detail eneineering onward.
However. some appreciation of the contents of the phases involved up to basic engineering is
desirable.
-
TECHNO-ECONOMIC FEASIBILITY
Economic gain drives industry, in general. Except perhaps during early small scale production
activities in metallurgical industry, economic gain has been a major consideration in decisions
regarding the choice and scale of any production activity. Safety and pollution considerations as
well as social issues seem to be gaining importance. In a way these are dso enforced throug!!
explicit or implicit profit governing means such as rewards/penalties. All said and done, such profit
motives have led to great technological innovations. Techno-economic feasibility study evaluates
any commercial scale venture from these angles. A technically feasible and economically viable
process sees the light of the day.For new products, technical feasibility is an important first aspect
to study.
It comprises of two parts as follows.
Chemical path feasibility
Engineering/Technologicalfeasibility
Chemical path feasibility essentially checks whether a suitable chemical conversion route exists to
produce a chemical with desired molecular structure from available raw material. The suitability of
the chemical conversion route is mainly in terms of rate and degree of conversion to desired
product at manageable temperaturelpressure conditions. For more insight into these aspects, *click
here. The sequence of operation which enables a kinetically and thermodynamically feasible
conversion route to be exploited for production is called Block Flow Diagram (BFD). This is the
first diagram in the life of a process and the process can be said to be born. *Click here for more on
BFD. The process represented in a BFD is then evaluated for its engineeringhechnological
feasibility. The idea is to verify whether the current level of engineeringhechnological skills allow
exploitation of the process on a commercial scale without exposing the men, machines and
environment to undue risk. Several decisions need to be taken at this stage. The contents of this
step are becoming more and more involved and include the conceptual design stage in recent times.
One virtually thinks through the choice of equipment, important process steps, possibility of
reducing dependence on external energy sources, reducing possible extent of damage in case of a
mishap etc. *Click here for more details on engineeringhechnological feasibility studies including
conceptual design and process synthesis.With the process synthesis task accomplished, conceptual
design stage of process development is over. The various equipment have been selected and their
capacities are approximately known. The capital cost and operating costs can be estimated
reasonably reliably at this stage. This information coupled with the raw material availability and
cost as well as the product demand and its market price help establish economic feasibility of a
pr0cess.A technically feasible and economically viable process is now destined to grow further.
BASIC ENGINEERING
Physicallchemical operations in a process are normally carried out under harsh conditions. The
temperatures, pressures are either super- or sub-ambient and the chemicals being handled could be
toxic and hazardous. It must be remembered that just as it is important to know what is happening
inside a particular piece of equipment, it is equally important to know as to what are the
implications of the happenings inside on the mechanical integrity of the confining hardware
(vessels) and whether the choice of material of construction of the vessels and pipes and their
mechanical design are adequate to handle normal and abnormal operations. Traditionally, chemical
engineers address the design issues related to happenings inside and mechanical engineers the
implications on the vessels/pipes. For the overall process safety and functioning, the issues should
be treated as inseparable. That is, unfortunately, not the case.
This Phase has essentially two components; the process design and mechanical design.
Process Design :
Process design is basically the detailed material and energy balance calculations over each unit in a
flow sheet. It also establishes the operating conditions, equipment size (not necessarily shape),
utility requirement etc. The results of these chemical engineering calculations are summarized in a
Process Flow Diagram (PFD).For processes which are continuous in nature and operate at steady
state, engineering simulation software are available and are extensively used. These provide
simulations of performance for imposed design and operating conditions. However, one would like
to decide the design and operating conditions for a given desired performance. For example,
process design of a distillation column would mean calculating the number of trays, feed tray
location, sidedraw locations, reboiler and condenser duties, reflux ratio etc. A reactor design would
mean arriving at the reaction temperature and pressure, reactor volume, recycle rate for given
conversion of feed into desired product. Simulators are used to try out various combinations of
designloperating conditions os as to arrive at a combination best in some sense (quality of product,
economics etc.).For example, one would try out different feed tray locations and reflux ratios on a
distillation simulation and study simulated performance. A feed location, reflux ration which give
desired distillate quality etc. would be a candidate design. There may several such designs which
serve the purpose. The best among them in some sense is the optimal design and is recommended.
Through simulation based process design of each unit in a flow sheet and of the flow sheet itself,
the entire material and energy balance calculations for the best design are available. This process
design stage culminates in the preparation of a PFD, one of the basic documents comprising basic
engineering package.
After the development of PFD, the focus shifts on the design of pipes connecting
equipments, choice and specification of instrumentation required to monitor and control process
performance, instrumentation to ensure process safety such as provision of trips, alarms etc.
Appropriate techniques for pipe sizing, pressure design of pipes, Hazard & Operability (HAZOP)
analysis, Control System Synthesis & Design (CSSD), etc. are used. HAZOP studies and reliability
data on certain equipment and pipe components (especially those having moving parts such as
pumps, control valves etc.) suggest the need for standby equipment, bypass valves etc. Need to
isolate dynamics of one equipment from next suggests the need for intermediate storage tanks.
These project engineering activities help develop a PFD into its next incamation, the Piping &
Instrumentation Diagram (P&ID). *Click here for more information on P&ID. PFD with its focus
on processes inside the equipment and P&ID with its focus on accessories connecting the
equipment and on-line instrumentation complete the basic process documentation. With all
equipment and accessories, their sizes and functioning known. a tentative plot plan showing
relative placement of equipment can be prepared. PFD also helps categorue the requirement of
various utilities such as cooling water, tempered water, demineralized (DM) water, steam, thermic
fluid, compressed air etc. Total requirement of each utility and its distribution among the equipment
develops a quantitative Utility Loading Diagram etc which could be used to develop Utility Flow
Diagram (UFD). A full pressure drop analysis of the entire flowsheet can be done at this stage to
ensure that the desired flows can indeed take place. Some individual pipe sizes or pipe sizes in a
segment of flow sheet could call for some adjustment to ensure the desired flow behavior.
Adequacy of the pipe sizes in case of operation at lower than design capacities (turn-down
conditions) and their ability to take additional load in case of throughput enhancement could also
need some pipe size tuning etc.
Mechanical Design :
Pressure design of piping gets done during the development of P&ID. The severity of
operation of each equipment and the nature of chemicals it needs to handle similarly allows choice
of material of construction of each equipment. Indenting process for bought-out equipment and
mechanical design of fabricated equipment can be taken up. Pressure vessel design concepts are
used for this design. It would involve calculating the shell wall thickness, closure type selection and
thickness calculation, selection of suitable gasket material with adequate yield stress and gasket
factor, choice of gasket location (Mean gasket diameter), gasket thickness, gasket width, placement
of bolts (bolt circle diameter), bolt material selection, number of bolts, diameter of bolts etc. A
vessel needs to have openings to serve as inletloutlet ports as well as for drainage, hand holes, man
holes, inspection holes etc. These could be on shell or closures. The shell and closure wall
thickness are designed primarily to ensure that the stresses in the walls even at weakest parts (along
welding sams) do not cross the allowable stress value even after corrosion or inspite of nonuniform
plate thickness (mill tolerance), etc. When openings are cut, stresses concentrate along the edges of
the opening and may exceed allowable stress value used in wall thickness calculations. Provision of
extra thickness, that is choice of a thicker wall could prove expensive. Theoretical findings that the
stress concentration in the event of cutting an opening in a wall is confined within a circle of
diameter double the diameter of the opening is used here to verify if provision of extra thickness in
this circle around the opening can keep stresses within allowable range. Reinforcing pads are then
recommended around the opening if necessary. For pressure vessels subjected to net external
pressure (for example, vessels operating under sub atmospheric pressures), compressive stresses are
developed. Design is more complicated here and need for stiffening rings to reduce chances of
failure due to buckling needs to be checked. Spacing between stiffening rings and cross-section of a
stiffening ring need to be arrived at.
Above elaborate design steps are lead to adequate design of not so tall vessels. Tall vessel design
need to be further checked for its adequacy to withstand wind load, seismic load, eccentric load etc.
TIllcoL
.--,Uu...Yllal
-~,i:+:,.-.
!oads may require enhancing vessel wall thickness andlor provision of stiffeners to
prevent buckling etc.
Pressure vessel design is this quite involved. However, design procedures are very well
documented in the codes and standards. Design software also exist to help develop designs which
comply with accepted codes.After attention is paid to each and every aspect, a fabrication drawing
is issued for fabrication to begin at an early stage. Equipment fabrication is time consuming. Also
in the field work, equipment need to be installed in place quite early so that pipe routing job can be
taken up.
The process design and the mechanical design of pipes and vessels involves extensive chemical and
mechanical engineering calculations. These calculations do not need any data on actual site for
plant location. The design depends mostly on process conditions. Some aspects of mechanical
design for tall vessels, such as meteorological data (wind speed) or seismic data are location
dependent, but hot on the actual plot of land. These calculations also do not depend on actual
relative placement of equipment on the plot etc. Further evolution of the project require the
knowledge of the actual site. Site preparation work and other outdoor construction activities can
begin once the site is selected. We have included further analytical aspects also in
construction phase for this reason.
DETAIL ENGINEERING
Further analytical work needs to be done before the final blueprint of a 3-D plant layout is finalized
and construction begins. Some of the activities listed under the construction phase here may well be
considered as belonging to the above discussed design phase itself. These are included here mainly
because plant site details are a part of inputs to the decision making. The choice of plant location, if
such a choice exists, is governed by politico-socio-economic considerations. The basic approach to
site selection is to assign weight factors to various relevant considerations and to select a site which
scores maximum overall points. Once the site where the process plant and associated facilities are
to hosted is decided, locational factors such as topography, prevailing wind direction, neighboring
site etc. are used to decide on the best plot plan. Apart from the process equipment and offsite,
other requirements such as control room, fire station, hospital, weigh bridge, effluent treatment
plant, etc. are allocated space on the site. The road map of the site also emerges during plot plan
exercise. Care is taken to follow certain guidelines for the location of typical facilities such as dusty
operations, fire bearing equipment, storage tanks, noisy operations, fire station, effluent treatment
plant, etc. *Click here for some typical examples.
Plot plan is science as well as art. A good engineer is one who makes the best utilization of a given
plot to place his facilities. There is a separate module on Plot Plan in the notes where good
engineering practices are covered in more detail.
The next activity is to decide on the location of each of the equipment in the process area. A unit
has its own requirement of space for erection, operation, maintenance etc. For examplz, a shadow
area must be earmarked besides a shell and tube heat exchanger so that the tube bundle can be
pulled out for maintenance. A pump must similarly have space around it s that the motor can be
taken out for maintenance. Large, heavy equipment require large, non-interfering foundations.
There are process-related constraints also as follows. Distance between two equipment connected
by a pipe carrying hot stream must be as less as possible to minimize heat loss. A thermosiphon
reboiler must have certain barometric leg provision and should be located a certain distance below
the distillation column. Suction drum should take care of NPSH requirement of a pump. Forgravity
flow, static head should be enough to maintain desired flow. Certain inter-unit distances have
emerged based on these and similar considerations. These provide good guidelines for equipment
IayoutAnother aspect of equipment layout is the orientation of the equipment on the slot assigned
to it. It decides the nozzle orientation and hence the piping layout. It also decides the accessibility
of different parts and accessories of the equipment. Accessibility, ease of maintenance, implications
on piping layout are the main considerations here.A piping engineer is deeply involved in plot plan
and equipment layout. These are decisions which virtually freeze the parameters for Piping Layout.
Equipped with a PFD, P&ID, individual equipment sizes, erection/maintenance/operation
requirements, safety requirements and also requirement of critical piping (piping which is likely to
expandcontract significantly and/or face vibrations during operation and require additional
consideration or accessories (such as expansion joints etc. to absorb pipe movement during
operation), a good piping engineer relies heavily on experience and engineering sense to develop a
good equipment layout. His decisions could have a bearing on the project cost as the piping
requirement, which constitutes almost 25% of the capital cost of a process plant can be favorably or
adversely affected by his layout.
After the units have been located and appropriately oriented on paper, the layout of the veins and
arteries of the plant, that is the pipes have to be laid out. This activity is called Piping Layout. It is
not as simple as connecting the outlet port of one equipment to the inlet port of another equipment
by the shortest or most convenient route. In fact, such direct connections are exceptional. A pipe is
firmly attached to the nozzles on the equipment. Equipment, by nature are fairly heavy structures
and should support the weight of connected pipes, provided the pipe connections are reasonably
short. For longish connections, pipe would sag under its own weight, under weight of its contents.
Heavy items on pipe such as valves add to this scenario. Also, the connecting nozzles may move
due to expansion/contraction of vessels or simply settlement of vessels. The pipe would
expandcontract during operation. All these operating time happenings develop stresses in pipe
wall. If not properly designed to withstand these stresses, pipe would fail during operation.
Considering all loads that would come on to the pipe during operation and mitigating their effects
with provisions of pipe supports, hangars, expansion joints, or rerouting of the pipe is the job of a
piping engineer who does the piping layout. Weight analysis and thermal stress analysis are
important in piping layout. These can be done today using. However, analysis of the stress
distribution churned out by these software for a candidate pipe routing and modifying the route to
make it safe requires a lot of experience and knowledge. There could be several routes which are
safe. Only one of these would be economical. Amving at this is the exclusive domain of a piping
engineer.
Piping layout is almost the last analytical exercise in the engineering of a process. It requires as
inputs a P&ID, equipment layout, piping elements pecifications, structural drawings of
buildingslplatforms, utility flow diagram, line list, equipment data sheets and drawings etc. Once a
safe and economical layout is arrived at, a piping engineer prepares a piping general arrangement
(GA) drawing showing the pipe routing associated with equipment, piping isometrics and
equipment nozzle orientation, With isometric drawings of all pipe routes available, a complete
quantification of pipe and piping elements requirement is possible.
The course has a separate module on Equipment & Piping Layout.Depiction of equipment and
piping layout in all its details is a major task. Normally a piping general arrangement (GA) drawing
presents a layout. Since a three dimensional layout is to be presented here in a two dimensional
view, lot of symbols need to be used to represent what the piping would look like in actual three
dimensional view. Details regarding piping elements (for example an elbow, tee, valve with lever
etc. has to be shown on a GA. Not only this, further details as to whether the tee is butt welded,
socket welded, flanged or screwed should also be indicated on a GA through choice of proper
symbols.
The knowledge of these piping symbols, their proper interpretation and a mental recreating of a
three dimensional perspective from GA is one of the major skills a piping engineer needs to
possess. Without this. his preparation of GA and his interpretation of others' GAS is going to be
meaningless. Piping ison~etricsare made out of the GA drawing. Isometric (ISO) drawings at least
have the 3-D feel which GAS lack. Isometrics are then used for piping stress analysis, fabrication,
spool drawings etc. Piping drawings make sense only if standard symbols and conventions etc. are
religiously followed. Although not a subject in any conventional engineering curriculum, the fact is
that piping engineers express themselves and understand each other through the language of
drawings. We have a special module on Piping Drawing for you with all important tips, examples
and exercises.
During the detail engineering phase, there is virtually an explosion of information and detail which
leads to an explosion of documents and drawings. All implementation details of activities to be
taken up by mechanical, civii, electrical, instrumentation departments are documented. There is a
tremendous activity in the drawing office as well as in field. It is difficult to discuss all the aspects
here. Coordination of all activities is normally left to the piping department. This is logical because
the basic drawings/documents such as PFD, P&ID etc. are released from here, and the final
drawings/documents prepared by other departments have a direct bearing on the plant, equipment
and piping layout. With all activities leading to the same goal, this coordination becomes important.
An integrated software platform, which serves as a repository of all information and decisions
regarding a project, is becoming popular for internal consistency of detailed engineering activities
as well as for efficient project management. It plays a major role in effective and timely completion
of projects of this complexity and criticality.
A software model of a 3-D layout of a process plant is gaining importance. It is replacing the
conventional plastic models of plant which were necessary and useful for easy visualization and
implementation. Unlike PFD, P&ID, etc., which were schematic drawings, a 3-D model is a
dimensional graphic and can be made to contain all details of a envisaged plant. It can have all the
data associated with a project. Apart from easy visualization, it offers checks for interference (a
proposed piping layout clashing with civil structure or equipment etc.), checks on ergonomics (is an
instrument readable by an average height operator etc.), checks on aesthetics. It can lead to
generation of derivative drawings such as piping isometrics, orthographic drawings of different
sections of plant etc. Bill of material for pipes and piping elements (pipe length, piping elements
such as elbows, tees, flanges, valves, specialties, etc.), procured equipment list (pumps etc.), etc.
could be easily extracted. Preparation of specification sheets or data sheets for equipment,
accessories can be automated around a 3-D model of the plant. Progress of project implementation
can be monitored and documented using 3-D drawings. 3-D drawings, offering virtual reality and
walkthrough effects etc., can be used for acclimatization and training of personnel much before the
plant becomes a reality. A 3-D model is a complete database as well as visual of a process plant and
its use would increase in coming years.
The fieldwork involves actual placement of equipment and routing of pipelines. Necessary civil
structures to serve as foundations of equipment, platforms, housing of various facilities,
supports/hangars for pipes, racks for pipes and electrical cables etc. Welding and fabrication,
painting, hydrostatic testing for pressure integrity of fabricated equipment and associated-piping,
thermal insulation and cladding to prevent heat ingresslegress or sweating or for personnel
protection etc. go on in full swing.
A piping engineer is expected to be aware of and knowledgeable about all these field activities
apart from the design office activities.Once the plant is ready in all respects. it is time to
commission it.
Commissioning involves taking the cold assembled plant to go on-stream and produce design
capacity. If the entire design and detail engineering has been done scientifically, if design intentions
are reflected in various designlengineering documents and drawings correctly and unambiguously,
if fabrication, erection and assembly has been done as per design intentions, then (and only then)
commissioning should be a smooth affair. This is normally not the case because lots of adhoc
decisions need to be taken on field during erection to take care of fabrication errors, late or nondelivery of items, design errors which were made at an early stage and went unnoticed, or even late
second thoughts. The project is normally on critical path during field work and not all these
decisions and their implications are thoroughly analyzed or probed.
Another reason why commissioning is not so easy is that the start up conditions are significantly
different that steady state conditions for which the plant has been designed and engineered.
Dynamic process simulation is a good software tool to evolve a good start-up policy. It helps
envisage the transient performance of an equipment as it goes through the start-up procedure and
also to study alternate procedures for start-up. It is not being used to significant extent today and
conventional and time tested (not necessarily optimal) start-up procedures are followed.All the
decisions of a piping engineer, especially those regarding piping layout, piping supports etc. are on
test during commissioning. The pipe literally moves as it goes to temperatures different than
installation temperature. Inadequacy in weight and stress analysis could surface at this stage by way
of pipe jumping supports, support collapsing, etc. A piping engineer's presence on sight is
important to handle such eventualities.
NORMAL OPERATION
For a well-designed and executed project, the problems during production phase are mostly
operational. If design capacity is achieved with ease, there is always an urge to improve throughput
by way of debottlenecking, reduce on energy bill by way of reducing pressure drop or retrofitting
of heat exchangers etc. These call for minorlmajor changes involving installation of additional
equipment, bypassing an existing equipment and related changes in pipe route. These changes may
be trivial from process point of view but their implications on mechanical design aspects could be
far-reaching. A trivially simple change may lead to adverse changes in type andlor magnitude of
stresses in piping systems causing their failure and disaster. A healthy practice is to involve a
piping engineer to be associated with every hardware change or operating point shift contemplated
during normal operation of a process plant. A limited HAZOP analysis of the proposed change is
also recommended to discover a hidden serious problem in a superficially trivial change. These
aiuali jobs are normally not supported by big consulting houses and an in-house piping engineer has
to manage these mini designlengineering assignments.
CONCLUSION
Important events in the life of a typical chemical process are described in this paper. Concept,
design, engineering and operation of a chemical ljrocess plant are truly multidisciplinary in nature.
A piping engineer has a major role to play during important events during the life span of a process.
He is one engineer who must have a broad knowledge of all aspects and their interplay.
a
..
v
D h 3 flow. The
;wli..c-~, non-;sc.~;.s&
BERNOULLI'S EQUATION
SINGLE PHASE PRESSURE DROP
CALCULATIONS
*
*
*
*
*
*
A possible approach
PrPE SIZING
t
..
Velocity considerations
.r-...
,~bsire
drop considerations
Economic considerations
BERNOULLI'S EQUATION
W).
'-4.
fl
['";4"'3
,C 1,
*d[
BAKER'S METHOD
Depending on the regime identified carlicr, an
appropriate correlation or plot is used to get Bakers'
modulus. cp? and it is multiplied with pressure drop with
only gas flowing to get the two phase pressure drop.
Fig.6 is used for dispersed flow.
Step I
~onsideronl~that
r h e ! i q u i d p ~ ' ~ l u d i n g h e t wliquids
o
,
is flowing through the pipe. Let these liquids bc I and I.. I
Using Lockhart Martinelli method or other method (say .:
Baker's), calculate the pressure drop per unir length that ..
would be caused in this case. Let this be hPu.
'
,....
.3.
.,
.-.
;$j
.--
Step II
$,
Consider only gaslvapor is flowing and calculate the ;$.
<
pressuredrop that ~ouidocctir~erunit
length using single ;
V*..
?
phase pressure drop correlation. Let this be AP,.
.:.
Step111
.
Calculate the Lockhart ~ & n e l l imodulus as wasdone
in the two phase flow situationas follows. .
.
X2= AP,
..
:*
.,.
1 AP,
Step IV
For this valueofmodulus, amultiplier YL?.e. Yu) orY,
(or Y,) is then read from the plot in Fig. 5 and it is
appropriately used in one of the follo~ingrelations to gct
thethree phase
drop, jAPjuv per unit length.
Multiplying this with the effective length (after including
equivalent lengths of the fittings) of the pipe, one ge& the
total three phase frictional pressure drop.
..
1.
i;
:..
.::
I:
?.
.\
:~
i:.
?,I'
<.
PIPE SIZING
...
\ .
?.
I;:
i
'.
SILVER JUBILEE
-.... ,
i
.
,.-
d m ~ a g the
c blades and cause vibration and noise. This
must be avoided at any cost. It is therefore imperative
thar thc pressm drop in Lhe suction pipe should be such
that the liquid is delivered to the pump at not less than the
vapor pressure at flowing tempenture.
Even when there is no pump, above considention
would apply. During its passage through the pipe, the
pressure of the flowing liquid should not drop below its
vapor pressure at flowing temperature. Otherwise
vaprization would rake place.
ECONOIMICPIPE SIZING
COST APPROACH
: LEAST ANNUAL
2.
'
...
dl' psi
W 1000 Ibshr
P
CP
p 1bs.lfi1
D inch
Substitutingthis in theearlier equation. the cost of
moving the fluid per year3
?..
.?
0.0657YK
..
.'
qu;u\titicsm as follows:
- ,I
Distributive Flow
a)
Bubble
b)
Mist
Intermittent Flow
Segregated Flow
e)
Stratilied
t)
Fig. 3
k h c . 1 2 c ~ i m c sforTwtr P h : w Flow
Annular
Dispersed
MmdV
or
Fannings
1ridion lac(or dim.
Bubble
Slug
0 = 14.2 X '"
(WJA)"
O=l.lwX'"'
0=15,4WX
(W,lA)"
(WJA)"
Plug
Annular
--
a = 4.8 - 0.3125 d
b = 0.343 0.021 d
d = I.D. at pipe. in
For pipe 12-in and
wer, used = 10.
Fig. 4
Baker parametersdetermined the type oftwo p h w i b w and appropriate two phase flow correlation x*s.unit loss
Fig. 5
I'arnmctcrs fur prcssttrc dnrp in liquid - gas flow throuph horizontal pipes
I IInscd IIII l.ocl;l~arl8.d hlartinclli. Chcm. Eng& Prog.. 45.39 ( 19.1 9)1
0.W 0.W
0.01 0.m
0.m 0.W
0.1
0.2
0.3 0.5
2 3
10
M 30 M
Fig. 6
L o c k h a r t hfartiaelli Corrclatiom rtlatcs vapour and liquid propcrtics l o csl.blished two pbaSc n o r modules.
3
4
N O U W PIPE SIZE
Pig. 7
A m a r l i z r d c a p i l l l corD Tor onc fool o r pipe.
8
Fig. 8
Annqal cost or operating onc'loot of pipc.
~n.
Tubing
Drawn
Clean, seamless
Glass
Miller (32)
mm
0.MX)I
m.
0.0025
0.0031
'
Moody (34)
mm
O.MXX)6
concrete
Smooth
Precasl
Rough
Cast Iron
Uncoated
Coated
0.001
0.01
0.0015
0.0025
0.025
0.25
0.001
0.01
0.02
0.006
0.006
0.001 8
0.025
0.25
0.5
0.15
0.15
0.046
C.Goo064.CCC.4
O.MM06-O.MW)4
0.00154.01
0.0015-0.01
0.0025
0.06
0.008
0.035
0.2
0.9
0.012
0.3
0.03
0.8
0.12
3.0
0.35
9.0
-A
0.01
0.005
025
0.12
wood
Birch veneer
Pine veneer
Rough
Kutateladze (29)
mm
m.
Sled
New
Light rust
Oeaerated salurated Steam
Condensale (heavy rust)
I1
lubes
0.012
0.3
Galvanbed
Smwth finish
Normal fhish
0.001
0.006
0.025
0.15
0.006
0.15
~crninal
Pipe Sks
In
_I
&-a
*,
*a.
3-1
I
1H
-L
*-.-L
..
2 of less
0.6
0.5
1.2
0.7
0.6
0.6
1.6
1.O
3 lo I 0
10 lo 20
_C
b u d 6 tine
.-
velociry Fffi
Velocity F'IS
Velocity FUS
Won
P u m ruem
t o 2
PWmdXimn)a(lolql
o;&n)aheaC.(~~l
BdNlsad
D T ~ ~
S
l rmsr
2a3
b a g
4109
2o.(
3 lo 5
510 12
5012
3mr
3105
3 lo 5
HydtmlOon rwkk
(Norrrul r i r a i t i s r )
PurrCsueion
1.5 10 2.2
2 to
D&qe
headsrlkmgl
Babr laad
2.5 :o 3.5
4 to 9
3 lo 5
haia
3 to i
3 10 5
V-r
510 12
oils
P W su&n
M&m Vmx&ty
1.5 10 3
0.4 la 0.7.5
M r p a (%I
Omns
3m5
1.5 10 3
S q x r neared Sleam.
S-
I".
. .
2wLeY
3 10 4
velocq FVS
..
4S b 1W
41080
JOlo60
5olol10
45 to 90
35 m 70
1050
~ a l o
120
5010120
8b10
12 lo 14
65 m 125
8010150
l m t o lw
65 lo 125
16 D 18
75mI35
IIOtoZ10
9010 1W
m l 0 1 ~
120!0220
10010 170
20
mlo
!a
Nolc : W i h i n
80 10 I45
hcdcn.
Rcboilcr down c o n c r (liquid)
Rcboilcr. i r c r (liquid and r w r )
Ovcrhcrd coodcnrcr
Two-pharc 13or
Comp<crror ruclian
Carnprcsror dirchugc
Intcl. swam lurbinc
Inlcl. gar lvrbinc
Rclicl v d v c dirchvgc
R c t i d r d v c c m r y p o i n ~31 rilcnc::
Two-?>ase
Dispersed
i3 ~ 0 , 1d.2
tise~
and EG. 131
Bubble
(w/AI~~'
Slug
low Corrslarions
Scrarified
0 '= 1 ~. 1 ~9 0 ~ 0
~ =~15.100X
~ ' ~
(w{A]~'-~
Avoid
slug flow
w,uI~.'
'
Wave
P!ug
Use Fig. 5
0. 2 7 , 3 1 5 ~ " " "
and Eq. (91
and [ l o ]
iw/""'7
Horizontal
Horizontal
pipe
pipe
Annula:
b =a,$
;
, =1;.3Ci
~ . 3 - 0-. 3C.021
: 2 5 dd
.* = :.D. 01 1 1 3 e . - 0
For j i p e 12-in anc
or?:, u s e d = 10.
j.
!
i
I
Cour;esy: Mr. Ovid aaker and The Oil and Gas Journal.
";)
%s>
FIG. 1. Baker parameters derxmine the type o i two-phase flow zzd ths ?jpropr:arc two- I
phase-now corelation ss's unir loss.
1
!
Lockhart-Marrinelli modulus, X 2
FIG. 3.
~ b c k h a r t - ~ a r t i n e lcorrelation
li
relates vapor and liquid properties to establish twophase flow modulus.
:;
...
.
Country
United States
Canada
3
4
5
France
United
Kingdom
Europe
Germany
Japan
India
Abbreviation
Organization
ANSI
American National
Canadian Standards
CSA
Association
AFNOR
Association Francaise
BSI
British standards
Institute
European Community for CEN
Standardization
Deutsches Institute Fur DIN
Normung
Japanese Industrial
JIS
Standards
Beauro Of Indain Standards
BIS
1.7 The Manufacturers Standardization Society of Valves and Fitting Industry Standard
Practices (MSS-SP)
1.8 The American Society of Mechanical Engineers (ASME)
API6D
API6F
API593 -
API598
API 600
API601
API602
API604
API 605 -
API607 -
API 609 -
Butterfly valves
API 1104-
2) AISI304
3) AISI316
13) ASMEB16.28
9)
ASME B 16.1 1
Square and hexagonal head Bolts and Nuts (in & mm)
In Part-II, the materials are listed in the Index based on the available forms such as plates,
castings, tubes, etc. and also on the numerical index.
he selection of ASTM specification depends upon the type of manufacture, form
of material, its mechanical strength and the corrosion properties.
The specification number is given on Alphabetical prefix, 'A' for Ferrous materials
and 'B' for Non-ferrous materials.
ASTM also specifies standard practice for numbering metal and alloys as Unified
Numbering System.
AOOOOl - A 99999
2.
C00001 - C 99999
3.
EOOOOl
4.
LOO001 - L 99999
5.
MOO001 - M 99999
6.
NO0001 - N 99999
7.
POOOOl - P 99999
8.
ROO001 - R 99999
9.
z00001 -
E 99999
99999
12. GOOOOl
G 99999
13. H00001
H 99999
AISI H Steels
Cast Steels
Stainless Steels
Tool Steels
manufacturers have given their own brand names for the various electrodes and are sold
under these names.
1.6 AWWA STANDARDS
The American Water Works Association (AWWA) standards refer to the piping
. elements required for low-pressure water services. These are less stringent than other
standards. Valves, flanges, etc. required for large diameter water pipelines are covered
under this standard and are referred rarely by piping engineers here.
-
1) C-500
2)
C-510
3) C-504
4) C-507
5') C-508
6) C-509
2) MSS-SP-25
3) MSS-SP-42
4)
MSS-SP-43
5) MSS-SP-56
6) MSS-SP-61
7) MSS-SP-67
Butterfly Valves
8) MSS-SP-68
BS 10
Flanges (obsolescent)
2)
BS 806
(withdrawn)
Metallic Spiral Wound Gaskets
Dimensions of Welded and Seamless Pipes &
Tubes.
23) BS 3601
24) BS 3602
25) BS 3603
26) BS 3604
27) BS 3605
29) BS 3974
30) BS 4090
31) BS 4346
32) BS 4504
33) BS 5146
34) BS 5150
35) BS 5151
36) BS 5152
37) BS 5153
38) BS 5154
39) BS 5155
40) BS 5156
41) BS5157
42) BS5158
Bureau of Indian Standards @IS) have so far not developed an Indian standard for
the design of Piping Systems. Hence, ANSI standards ASME B 31.1131.3 are widely
referred for the design. These standards also accept materials covered in other standards.
Unlike American Standards, Indian Standards cover dimensions and material
specifications under the same standard. There are also no groupings done based on the
series/branch of engineering as well.. Some of the most commonly referred Indian
Standards by the Piping Engineers are:
1)
IS -210
2)
IS -226
25) IS 3076
26) IS 3114
27) IS3516
28) IS 3589
29) IS 4038
46) IS 7719
47) IS 7806
SS Castings
48) IS 7899
49) IS 8008
50) IS 8360
51) IS 9890
52) IS 10221
53) IS 10592
54) IS 10605
55) IS 10611
56) IS 10711
57) IS 10805
Foot Valves
58) IS 10989
59) IS 10990
60) IS 11790
61) IS 11791
62) IS 11792
63) IS 12709
64) IS 13049
65) IS 13095
Butterfly Valves
66) IS 13257
67) IS 14333
There are certain other international standards also referred in the piping industry. They
are the DIN standards of Germany and the JIS standards of Japan. DIN standards are
more popular and equivalent British and Indian standards are also available for certain
piping elements.
Periodic renew of the standards by the committee is held and these are revised to
incorporate the modified features based on the results of research and feedback kom the industry.
Although some technological lags are unavoidable, these are kept minimum by those updations.
Hence, it is necessary that the latest editions of the codes and standards are referred for the design
and year of publication also to be indicated along with.
PIPING ELEMENTS
T. N. GOPINATH
One of the major tasks in any
process industry is the transportation of
materials often in fluid form from one place
to another. The most commonly adopted
method for the same is to force the fluid
through the piping system.
The piping
system is the inter-connected piping subject
to the same set of design conditions. The
piping system involves pipes but also the
fittings, valves and other specialties. These
items are known as piping components.
Code specifies the piping components as
mechanical elements suitable for joining or
assembly into pressure-tight fluid-containing
piping systems. Components include
1.0
Pipes
2.0
Fittings
3.0
Flanges
4.0
Gaskets
5.0
Bolting
6.0
Valves
7.0
Specialties
Piping element is defined as any
material or work required to plan and install
the piping system. Elements of piping
include design specifications, materials,
components,
supports, -. fabrication,
inspection and testing.
Piping elements should, so far as
practicable, conform to the specification and
standards listed in the code referred for
design. Unapproved elements may also be
used provided they are qualified for use as
set forth in applicable chapters of the code.
Piping specification is a document
specifying each of the components.
Different material specifications are
segregated in different "Piping Class".
Identification of the "Piping Classes"
depends on each Designer, and the logic
helshe adopts.
'
Piping Elements
IAatollic
Ferrous
i40leriols
Ilon-Ferrous
Moleriols
I
Copper
+
Aluminium
Iblickel
Copper
Alloys
Aluminium
Alloys
Ilickel
Alloys
*-
Cost
Iron
Steel
IIon-Melolic
Carbon
Steel
Steel
I
+
Lined
MSGL
MSRL
MS
PTFE
Lined
MS
PP
Lined
MS
PVDF
Lined
MS
MS
MS
FRP
Cemept Leod Ceramic
PP
Lined Lined
Lined
Lined
I
Lead
I'
PVC
CPVC
I
PP
I
HDPE
I
UHMW-HDPE
I
FRP
PTFE LDPE
I
LLDPE
Alloys
FIGURE 1.1
a)
Design Pressure as 10% higher
than the maximum anticipated operating
pressure.
b)
Design Temperature as 25" above
the maximum anticipated operating
temperature.
c)
When operating temperature is
15C and below, the design temperature as
the anticipated minimum operating
temperature.
The design should meet the
requirements of the relevant code.
The material used shall be in
accordance with latest revision of
standards. If ASTM materials are used,
then the
materials adapted by
A S W A N S I should be preferred.
The selection of materials in
general shall follow the norms below:
(The basis in the design code governs.)
Carbon steel shall be used up to
a)
800F (425OC).
b)
Low temperature steel shall be
used below - 2 0 ' ~(- 2gC)
c)
Alloy carbon steel shall be used
above 800F (425OC).
. .
d)
For
corrosive
fluids,
recommendations from the Process
Licensor to be followed.
1.0
1.1
PIPES
General
Piping Elements
Pipe Size
NB (Inch)
118
114
318
112
314
1
*1%
1%
2
*2%
3
*3%
4
*5
6
8
10
12
14
16
Eq. Metric
Pipe Size
NB (mm)
Outside
Dia (Inch)
Outside
Dia (mm)
6
8
10
15
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
0.405
0.540
0.675
0.840
1.050
1.315
1.660
1.900
2.375
2.875
3.500
4.000
4.500
5.563
6.625
8.625
10.750
12.750
14.000
16.000
10.3
13.7
17.1
21.3
26.7
33.4
42.2
48.3
60.3
73.0
88.9
101.6
114.3
141.3
168.3
219.1
273.0
323.9
355.6
406.4
1.3
Wall Thickness
Prior to ASME B 36.10 & ASME B 36.19
became effective,. the pipes were
manufactured as per the Iron Pipe Standard
(Ips)
with
wall
thickness
designations Standard (STD), Extra Strong
(XS) and Double Extra Strong (XXS).
Subsequently schedde numbers were added
as convenient designations. The pipe
thickness is designated by Schedule Number
and the corresponding thickness is specified
in the standard ASME B 36.10 for carbon
steel pipes & ASME B 36.19 for stainless
steel pipes.
Stainless steel pipes are available in
schedule 5S, 10S, 40s and 80s whereas
carbon steel pipes are available in schedule
10, 20, 30, 40,60, 80, 100, 120, 140, 160,
STD, XS, XXS.
Piping Elements
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
Beveled ends
Plain ends
Screwed ends
Flanged ends
SpigoUSocket ends
Buttress ends
Piping Elements
Advantages
a) Most practical way of joining big bore
piping
b) Reliable leak proof joint
c) Joint can be radiographed
Disadvantages
a) Weld intrusion will affect flow
b) End preparation is necessary
1.4.2 SOCKET WELD PIPE JOINTS
d
EXPANSION JOINT
TO PREVENT WELD
FROM CRAC'ING UNDER
1HER.WL W E S S
Advantages
a) ~asTerAlignment than butt welding
b) No weld metal intrusion into bore
Disadvantages
a) The 1/16"(1.5 mm) recess pockets
liquid
b) Use not permitted by code if Severe
Erosion or Crevice Corrosion is
anticipated.
..
-.
Advantages
a) Can be easily made at site
b) Can be used where welding is not
permitted due to material properties or
fire hazard.
c) Dismantling is very easy
Disadvantages
a) It is a point of potential leakage
b) Cannot be used when piping is
subjected to high bending moment.
Advantages
a) Easily made at site
b) Can be used where welding is not
permitted due to fire hazard
Disadvantages
Joint may leak when not properly
sealed
Use not permitted by code if severe
erosion, crevice corrosion, shock or
vibration are anticipated.
Stren,& of pipe is reduced as threads
reduce wall thickness
Seal welding may be required
Code specifies that seal welding shall
not be considered to contribute for
strength of joint
Piping Elements
Advantages
a) Can be easily made at site.
b) Can accept misalignment upto 10' at
pipe joints.
Disadvantages
a) Suitable for low pressure application.
b) Special configuration at pipe ends
required.
e) Spiral Welded
Pipes having helical seam with
either a butt, lap, lock-seam joint'which is
welded using either an electric resisrance,
electric fusion or double submerged arc
welding process.
1.5.2 Seamless
Pipes produced by piercing a billet
followed by rolling or drawing or both.
Pipe Materials
ASTM A 53 Welded and Seamless
Steel Pipe, Black and
Galvanized
ASTM A106 Seamless CS Pipe for
High Temp. Services
ASTM A120 Black and Hot Dipped
Zinc
coated
(Galvanized)
welded
and seamless pipe for
ordinary use
ASTM A134 Electric fusion welded
steel plate pipe
(Sizes 2 16" NB)
ASTM A135 Electric
resistance
welded pipe
ASTM A155 Electric fusion welded
steel pipe for high
temperature service
ASTM A312 Seamless and welded
austenitic stainless steel
pipes
ASTM A333 Seamless and welded
steel pipe for low
. . .~
temperature service
ASTM A335 Seamless ferritic alloy
steel pipe for high
temperature service
ASTM A358 Electric fusion welded
austenitic - chromenickel steel pipe for
Piping Elements
high
temperature
service
Carbon and ferritic
alloy steel forged and
bored
for
high
temperature service
Seamless
austenitic
steel pipe for high
temperature
central
station service
Welded large diameter
austenitic steel pipe for
corrosive
or
high
temperature service
Centrifugally
cast
femtic alloy steel pipe
for high temperature
service
Austenitic steel forged
and bored pipe for high
temperature service
Centrifugally
cast
austenitic steel pipe for
high
temperature
service
Centrifugally
cast
austenitic steel cold
wrought pipe for high
temperature service
Piping Elements
'
X
'(
3%
.-. i.'
,. p
a'
>.
%$$
Piping Elements
Tm=
+C
2 (SE + PY)
P
D
pipe)
Design temperature
= 675 + 25
S = 16500 psi
(Refer-ASME B 3 1.3 Appendix 'A'
Table A-1)
E = 1 (Joint Quality factor.
Refer ASME B3 1.3, Appendix
'4' Table A-IB)
Y = 0.4 (Refer Table 304.1.1)
C = 0.125" (Specified)
= 0.2097"
= 0.335"
+ 0.125"
Piping Elements
since L is unspecified.
Do
6.625
- -- - =69.7
t
0.095
From Graph (Fig. G) in ASME Section I1
Part D,
Factor A = 0.000225
From Graph (Fig. HA-3) in ASME Section
I1 Part D,
Factor B = 2750 for the above factor A and
for 7 5 0 ' ~
Allowable pressure
4
B
Pa =
3
Dolt
4 x 2750
= 52.6 psig
3 x 69.7
This is less than the Desim Pressure.
Therefore, assume higher thickness.
Consider SCH 80 S pipe
Nominal thickness = 0.432"
Minimum thickness = 0.875 x 0.432
= 0.378"
Do
6.625
- - -= 17.5
t
0.378
Do
is 0.0038
Factor A for the new value of
2.0
and at extrados
PIPE FITTINGS
'
\.<\'
Extrados
Pipins Elements
2.1
Classification Based On End
Connections
2.1.1 SOCKET WELDISCREWED END
FITTINGS
End Sonneclions
BUTTRESS
I
1
ELBOWS
45'
180'
TEES
RETURNS
90'
CROSS
TEES
CROSS
TEES
CAPS REDUCERS
STUBENOS
REDUCERS
SRELBOWS
UNIOHS
'
SPECIAL
FITTINGS
ECCEIdTRIC
REDUCERS
r
LRELBOWS
SWAGE NIPPLE
CONCENTRIC
CROSS
COUPLINGS
FULL
COLlPLlNGS
HALF
REDUCING
COUPLINGS COUPLINGS
FIGURE 2.1
STANDARD PIPE FITTINGS
LATROLET
Piping Elements
WID)
(R=1.5D)
Piping Elements
2.2.2 RETURNS
Returns change the direction through
180 deg. This is mainly used in heating
coils, heat exchangers, etc. Retums with
1.5D radius and 1D radius are available.
.......
-\ :
........
. .:
,
'1: -
- Socket weld
CROSS
This is a fitting very rarely used in
piping system. There are two types of
crosses, the straight and reducing. To reduce
the inventory, it is preferred to use tees
except where space is restricted as in marine
piping.
2.2.5 REDUCERS
. There
are two types of reducers
available, the concentric reducers and the
Eccentric reducers.
'C_.
,
Piping Elements
.r.
.-I
LW
1'
\
..,
':.I
-:,
Piping Elements
Fig. 2.23:Sweepolet
.--
I.'
i
...:9.
r)
-29
-:I
G-2
3.0 FLANGES
Flanges are used when the joint needs
dismantling. These are used mainly at
equipments, valves and -specialties. In
certain pipelines where maintenance is a
regular feature, breakout flanges are
provided at definite intervals on pipe lines.
A flanged joint is composed of three
separate and
independent although
interrelated components; the flanges, the
gaskets and the bolting; which are
assembled by yet another influence, the
fitter. Special controls are required in the
selection and application of all these
elements to attain a joint, which has
Piping Elements
3.2 Based
On
Pressure-temperature
Rating
The flanges are also classified by the
pressure temperature rating in ASME B 16.5
as below;
3.2.1
150 #
3.2.2
300 #
3.2.3
400 #
3.2.4
600 #
900 #
3.2.5
3.2.6
1500 #
3.2.7
2500 #
Pressure temperature rating charts, in
the standard ASME B 16.5, specify thenonshock working gauge pressure to which the
flange can be subjected to at a particular
temperature. The indicated pressure class of '
150#, 300#, etc. are the basic ratings and the
flanges can withstand higher pressures at
lower temperatures. . ASME B 16.5 indicates
the allowable pressures for various materials
of construction vis - a -vis the temperature?
ASME B16.5 does not recommend the use
of 150# flanges above 400 "F (200 "C).
.:.
,+i
..,,
w
I.
Piping Elements
'
+-!i<
1
1
: ,
I
I
..
. ~.
- .-
-..
21
Piping Elements
4.1 Selection
Proper selection of gasket depends upon
following factors.
4.1.1 Compatibility of the gasket material
with the fluid.
4.1.2 Ability to withstand the pressuretemperature of the system.
4.2 Type
Based on the type of construction, gaskets
are classified as:
4.2.1 Full Face
. 4.2.2 Inside bolt circle
' 4.2.3 Spiral wound metallic
4.2.4 Ring type
4.2.5 Metal jacketed
4.3 Material
Experience on the job and published
literature shall be used to select the gasket
material with respect to the compatibility of
the same with the fluid.
The material, which is most commonly used,
is the Compressed Asbestos Fibre.
Indian Standard IS 2712 specifies three
different materials at three different grades.
4.3.1 IS2712GrWll,W/2andWI3
- for Steam, Alkali and general
applications.
4.3.2 IS 2712 Gr All,
- for Acid applications.
4.3.3 IS 2712 Gr 011: 0 / 2 , 0 8
- for Oil applications.
Asbestos free gaskets are also available
for.above applications. For very comosive
applications, PTFE or PTFE enveloped
gaskets are used.
&,
,?
.\
>;
"'
'3
ir
...:.
I,
si
4.4 ~imensionalStandards
Gasket dimensions are covered under
the following standards.
4.4.1 API 601
- Metallic Gasket for Refinery Piping
4.4.2 BS 3381
- Metallic Spiral Wound Gaskets
4.4.3 ANSI B 16.20
- Metallic Gaskets for pipe flanges
4.4.4 ANSI B 16.21
- Non-metallic Gaskets for pipe
flanges.
5.0 BOLTING
Depending upon the service, its
~ressure/temperatureand the type of gasket,
type of bolting is selected.
For low pressure, low temperature
services, machined bolts are used and studs
Piping Elements
Piping Elernenrs
+'<
"'3
.$
>:
~2
9.1 Materials
* Carbon Steel shall be used for
temperature upto 425C (800 OF) only.
* Low temperature steel shallbe used for
temperature below -29 "C (-20 OF)
* Alloy steel shall be used for temperature
above 426 "C (SO 1 OF)
* Stainless steel shall be used for
corrosive fluids.
Basic material of
construction specified by Process Licenser
to be referred for the type.
* Galvanized steel piping shall be used for
services such as drinking water, instrument
air, nitrogen (LP) etc.
* Selection of Non-ferrous, Non-metallic
and Lined piping shall be as per the
recommendation from the Process Licenser.
9.3.2 FITTINGS
* Fittings shall preferably be seamless.
* Butt weld fittings shall be used for pipe
sizes 2" (50 rnm) NB and above for all
AlloyICarbon steel piping.
* For stainless steel piping where
thickness is less, all fittings could be buttwelding type.
* Welding tees shall be used for full size
branch connections. For reduced branch
sizes upto 2 steps less than run diameter, it
can be fabricated. For smaller sizes half
couplings shall be used.
Full size
unreinforced branch welding can be done
where pressure temperature condition are
mild.
Piping Elements
Piping Elements
VALVES
T. N. GOPINATH
GHARDA CHEMICALS LTD:
INTRODUCTION
Estimates reveal that a substantial
portion, approximately 8-lo%, of the
total capital expenditure of the chemical
process industry is used for the
procurement of valves. In terms of the
number of units also, valves exceed any
other piping component. Hence, proper
Functions of Vdves
Isolation
Regulation
Non-Return
Special Purpose
2.2
Needle Valves
2.3
Butterfly Valves
2.4
Diaphragm Valves
2.5
Piston Valves
2.6
Pinch Valves
Ball Valves
3.0
NON-RETURN
Plug Valves
3.1
Check Valves
Piston Valves
4.0
SPECIAL PURPOSE
Diaphra,m Valves
4.1
Multi-port Valves
Butterfly Valves
4.2
Pinch Valves
4.3
Float Valves
4.4
Foot Valves
4.5
4.6
ISOLATION
Gate Valves
REGULATION
Globe Valves
Valves
4.0
Gun metal
5.0
Carbon Steel
6.0
Stainless Steel
7.0
8.0
Poly
Propylene,
UHMW-HDPE etc.
9.0
Special Alloys
W - P E ,
Screwed ends
Socket weld ends
Flanged ends
Butt weld ends
Socketted ends
Wafer type ends
Buttress ends
The valves could also be classified based
on the materials of construction. There
can be any number of combinations
possible with the materials of
construction. It is for the piping engineer
to select the same in consultation with
the process engineer to suit the process
fluid. The environment in which the
valves are installed is also to be
considered for selection of materials of
construction. However, the most
commonly available materials are:
!.O
Cast Iron
Class
2.0
Ductile Iron
Class
3.0
Bronze
3. Trim
The trim is comprised of stem; Seat
Surfaces, Back Seat ~ d s h i nand
~
other small internal parts that
normally contact the surface fluid.
The table below indicates trim of
4. Wetted Parts
All parts, which come in contact with the
service fluid, are called the wetted parts.
..
.-.I,
5. Wire Drawing
This term is used to indicate the
premature erosion of the valve seat'
caused by excessive velocity between
seat and seat disc. An erosion pattern is
left as if a wire had been drawn between
the seat surfaces. Excessive velocity can
occur when the valve is not closed
tightly. A WOG (Water-Oil-Gas,
relatively cool liquids) disc is the best
defense against wiredrawing because its
resiliency makes it easier to close tightly.
Discs of hrder material are to be closed
cikefidly to prevent wire drawing. In
LPG Service, the wire drawing effect
causes a threat of anti-re~geration.The
ice formation on the wedge will obstruct
movement thereby increasing the leak
throu,oh seat further.
Valves
Gate
Globe
Angle globe
Swing check
Plug Rectangular
Plug Port
Ball - Regular
POfl
Ball - Full pon
- Position
Fully
open
Eouivalenr
(er;@ in pipe
dia
I!
340
145
50
18
"
40
"
9. Upstream Pressure
This is the pressure of the fluid that
enters the valve. This is sometimes
referred to as inlet or supply pressure.
11. LDAR
Sigifies "Leak Detection And Repair"
to ensure that the fugitive emissions
standards of EPA are met. Fugitive
emissions are the minute amount of
process media that escape into the
atmosphere though gland packing along
valve stem.
Maximum seat
leakage
A modification of
any class II,III or
IV valve where
design intent is the
s&e as the basic
class, but by
ageement between
user and supplier.
No test is required.
0.5% of rated
valve capacity
0.1% of ratec
valve capacity
12. LAER
Si,gifies "Lowest Achievable Emission
Rate". It is the minimum rate of fugitive
ermssicn, which is achieved by
deploying proper sealing arrangement.
Jlass IV
0.01% of ratec
valve capacity
5 x 10' ml pel
minute water pel
inch of orifice
diameter per psi
differential
1.5
2
2.5
3
4
6
S
Valves
n o w COEFFICIENT
I
=QTG
Q = ~ V Kv
G
d~
WHERE
Q =FL.owRATEINM~/HR
G = SPECIFIC GRAVITY OF LIQUID
P = P E S S W DROP ACROSS V-ALm IN BAR.
LESS THE DIFFERENTIAL / MORE THE BACK PRESSURE LESS THE now.
LESS THE DIFFERENTIAL /MORE THE BACK PRESSURE LESS THE FLOW.
THE ABOVE IS ESSENTIAL IN CALWLATING THE FLOW AS ALSO IN
SELECTING THE RIGHT TYPE AND SIZE OF THE VALVE.
TW M:
seat
T"m
~ 3 .
i\h-rid
Trim
kchss
Weid
(kg,m r i W Type
130
1 8 80 - N
25-23 0 - N
Had130
cna A n
N-0
130
CUN
130
klarl130
1 30
Co 0-A"
130
N-9
N-CUdIoy
1880-N
N-CU d l q
Tnrn5a54
1880-N
Trim5a5.4
14290-N
14z9Q.N
Tnrn5a54
cmt
Forged
ASTM A182 (F6a)
ASTM A1 82 (F304)
ASTM A182 (F310)
--..-
ASTM 8473
ASTM 8473
WM
team H.P.
;team LP.
solation
Legulation
ion-return
C.S. Body
stellited him
800# Globe
with SW ends
3) C.S. Body
stellited him
800# Piston
with SW ends
:) C S Body SS
Ball. Sp
PTFE seats.
800# SW ball
valve
a) CS Body
Stellited kim
300#1150#
Flgd Gate
with flex
Wedge
b) CS Body
13% Cr him
300#/1SO#
Flgd Piston
) C.S. Body
tellited him
00# Globe
vith SW ends
I) C.S. Body
tellited him
loo# Piston
vith SW ends
3.Body
jtellited
rim 8 0 G
Lift check
with SW
Ends
iston
alves are
osdier.
rom the
oint of
iew of
.nergy
onservaon they
re O.K.
I) CS Body
~tellitedhim
100#1150#
'lgd
ilobe
a) CS Body
stellited trim
300#/150#
Flgd swing
check
LLL
IALVES
'0 BE
iPPROVID BY
BR
t-)
a)
b)
c)
a)
b)
CSBody
13% Cr. Trim
800# Globe
with SW en&
CSBody
13% Cr. Trisr
800# Piston
With SW
ends
C S Body SS
Ball. Special
PTFE seats.
800:: SW ball
valve
CS Bodya
13% Cr. Trin
Flex wedge
150;: Flgd
Gate
CS Body
13% Cr tnm
150:: Flgd
Piston
)) CS Body
L3% c r &im
500#/150#
'lad Piston
r) CS Body
13% Cr. Trim
300# Globe
with SW ends
5) CS Body
13% Cr. Trim
800:: Piston
With SW en&
a) CS Body
13%Cr
trim I508
Flgd
Globe
b) CS Body
I3%Cr aim
150# Flgd
Piston
C.S. Body
13% Cr him
800# Lift
check With
SW Ends
C.S. Body
13% Cmim
150:: Lift
check With
SW Ends
Valves
3.
Condensate
4.
Utilities like
-Water, Air: JSHS
%" - 1 '/.."
2"- 12"
- 1 K'
a) C.S. Body SS a)
ball PTFE
seat 8008 SW
Ball
b) C.S. Body
13% Cr. Trim
8004 SW
Globe
SAi\iE
a) C.S. Body SS a)
Ball PTFE
Seat SOO*
Scrd. Ball
b) G.M. Body
b)
Bronze fim
Scrd Gate to
IS 778
C.S. Body
13% Cr.
Trim 8001:
SW Globe
valve
AS LP STEAM
C.S. Body a)
13% Cr.
Trim 800:
SW Globe
G.M.
Body
Bronze
.Trim S a d
b)
Globe to
IS 778
C.S.
Body
13% Cr.
Trim
800:: Lift
check
Wirh SW
Ends
G.M.
Body
Bronze
I Bronze
body not
Recommen
ded in
acidic
amosphere
Trim
I
2"- 12"
a) CIBody 13%
Cr disc 12%
wafer type
Butterfly
Gear
Operator
above 6" NB
b) CIBody 13%
Cr or 18% Cr
fim 12%
Flgd Gate to
IS 780
c) CS Body
13% Cr
uim 150:
Flgd Gate
d) Cast Iron
Body 13% Cr
plug 125 4
Fldg Lub.
Plug Valve
Scrd
check to
.
IS775
a) CI Body
a) cs ~ o d y Recornmen.
13% Cr disc
13% cr. dation for
Air CS
125# wafer
aim
Body
Ball
type Bunerfly
water
or
Gate
for
Gear Operator
w e
Isolation
above 6" NB
check
b) .CIBody
13% or
18% Cr
him 12%
Fkd
Globe
b) CIBody
13% or
18% Cr
~ 12%
flgd
swing
check to
IS 53 12
c) CS Body
13% Cr aim
1501: flgd
Globe
c) CS Body
l3%Craim
150:
flgd
-.
swing check
I
I
------I
__ _ _ __ _
!
I
I
!
Valves
5)
1W
a) C.S. Body
SteUited trim
Graphoil pkg
800# SW
Globe
b) C.S. Body
13% trim
800# SW
Piston with
suitable
se&g rings
,
CS. Body
Stellited
him
Graphoil -.
pkg 800#
SW Globe
b) CS.Body
13% trim
800# SW
Piston with
suitable
sealing
a) C.S.
Body
stellited
a)
.
800# SW
lift check
trim
M ~ S
2" - 12"
~.
a) CS Body
stellited @im
Graphoil pkg
300:: (iMin)
Flgd Gate
with 125 250
Flgd Finish
a) CS Body
stellited trim
graphoil pkg
300:: (Mii)
Flgd Gate with
.
125 -250
AARH Flgd
finish
b) CSBody
13% Cr @im
Graphoil pkg
300 # (Miin)
Flgd Piton
with Suitable
sealing ring
and 125 250 AARH
Flgdfinish
b) CSBody
13% Cr trim
Graphoil pkg
300 # (Min)
Flgd Piton
with Suitable
sealing ring and
125 - 250
AARH Flgd
f ~ h
Globe Valve
with CS Body
Monel I
Hastalloy C
him
a) C.S. Body
13% Cr.
trim 150#
~ l Globe
~ d
6)
Chlorine (Dry)
%" - 12"
7)
Solvent1 Process
(Carbon Steel)
%" - 12"
a) C.S. Body SS
Ball 150 Flgd
full port Ball
valve with
PTFEI GFT
seats
b) CS Body
13% Cr plug
150# Flgd
sleeved plug
seats
..
CS Body
stellited trim
300%(Min)
Flgd swing
check with
125 -250
AARHFlgd
Finish
Check (LaI
Swing ) valve
CS Monel I
Hastalloy C
trim
a) C.S. Body
13% Cr. trim
Flgd Lift
check %" to 1
%" and Flgd
swing check
2" & above
Valves
Solvent/ Process
:Stainless Steel)
Solvent/ Process
(Highly
Corrosive)
a) SSBody SS
ball 150 Fldg
full poa ball
valve with
F'TFE I GFT
seats
b) SS Body SS
Plug 150::
Flgd sleeved
plug
a) Ductile Iron
body % plug
lined with
fluoropoymer
plug valve
b) Ballvalve
with suitable
plastic body
and baU
I) SS body SS
jS Body SS
rim 150#
3gd swing
:heck
i)
Valves
Doctile
Iron
body
lined
with
fluoro
polymer
ball
check
valve
--do-
hitabi.iry with
remperanre to be
:hecked
Ball Valves
1.3
Plug Valves
1.4
Piston Valves
1.5
Diaphragm Valves
1.6
Butterfly Valves
1.7
Pinch Valves
Stem
Gland
Seat rins
Yoke
Packing
Gland Flange
Valve Port
Yoke Bush
Lantern
Back Seat Bushing
1.1.2
Bonnet
1.1.3
Wedge
Hand Wheel
Hand Wheel nut
Bonnet Gasket
Valves
1.1.1
Body
The body is the part which gets
attached to the vessel or piping. The
classification of the body could be done
depending on the end connections as
indicated earlier. Body could also be
specified based on the material of
construction of the same. This could be
cast, forged or fabricated.
The wall thickness and end to
endlface to face dimensions of the body
shall be as per the Regulatory code to
which it is designed.
The end flanges shall be
integrally cast or forged with the body. It
can also be attached by welding, if so
specified. The end connection shall suit
the rating specified. The flanged
connection shall be to ANSI B 16.5 or
any of the flange standards. The buttwelding end connection shall be to ANSI
B 16.25 or any other end preparation
required. The socket weldlscrew
connection shall be to ANSI B 16.11 or
any other equivalent standards. The body
can have auxiliary connection such as
drains, by-pass connections, etc.
1.1.2 Bonnet
The bonnet is classified based
on the attachment of the same to the
body. The type of connection normally
adopted are Bolted, Bellow sealed,
Screwed-on, Welded, Union, Pressure
sealed etc.
The bolted connection shall be
flanged, male and female, tongue and
groove or ring type joint. In low pressure
rating valves, it may be flat faced. The
bonnet gasket is selected to suit bodybonnet connection. It can be corrugated
flat solid metal, flat metal jacketed,
asbestos filled, metal ring joint, spiral
wound asbestos filled or flat ring
compressed asbestos in case of low
pressure rating, Teflon or Teflon filled
for corrosive applications.
The bellow sealed bonnets can
be bolted or welded on to the body.
These are selected for very critical
Valves
i I'
1.1.4 Stem
The stem connects .the hand
wheel and the wedge for operations. The
design can have rising stem and nonrising stem. The stem is operated
rotating the stem nut by hand wheel
mounted at the top of the yoke.
In the rising stem design, the
stem moves up along with the wedge to
open. This is called the OS & Y (Outside
Screw and Yoke) type of design. In case
of non-rising stem the wedge moves up
and down and the stem is stationary.
This is called the inside screw design.
Normally, bar stock or forging
are used for the construction of stem.
Valves
. Size
Valve Ratinz
14"NB & above
Class 150
12" NB & above.
Class 300
Class 600 & above 8" NB & above
Valves
IS
Sandwich design.
Flush bottom dzsip.
Extended body design.
.,
&
7..
..
..
Handh steel
stcticeiiminator
stainless Steel
+diLFtingscre~
Stcinles steel, siber p l c t d
Cwer nth, stainless stel
T q ccnrr, malleabk ircn
+
I
m r ~CItIOI,
stainless deel
fcrmed dbphragm, PTFE
,,G
.,
<,
De to ring. PTFE
.
3
Diaphragm. PTFE
t:;:-;
Bdtm dbphragm,
stainless st+
a!!!
B d t m adNstment p~effiure
buttom,steel
"
I
I
Bdtm C C d s
maleable iron
Cwer bots.dainkss~teel
Bdtcm adj~stmentzcrewbith
locknbi, stainless stml
&
Valves
1.4
PISTON VALVES
The main parts of the valve can
be identified as
1.4.1 Body
1.4.2
Bonnet
1.4.3
Piston
1.4.4
Valve rings
1.4.5
Lantern bush
1.4.6
Spindle
1.4.7
Gland
1.4.8
Packing
1.4.9
Hand wheel
Bonnet stud
Valves
--.
.
L:
Valves
4. Stem
5. Stem bushing
6. Compressor
7. Hand wheel
1?
8. Bonnet bolting.
The body and the bonnet are
made of casting. The material of
construction of the body depends upon
the service for which it is used. The body
can also be lined with corrosion resistant
materials like PTFE, Glass, Rubber, etc.
depending upon the corrosive nature of
the fluid or could be entirely made out of
plastic material. The diaphragm is
normally made fiom an elastic material
like PTFE or rubber. The diaphragm
presses against the body to give positive
shut off. The port can also be adjusted by
coneolling the position of diaphragm,
which is being done for cone01
applications. The diaphragm is secured
between the b o ~ e and
t the body. The
compressor attached to the diaphragm
facilitates the up and down movements.
There are two types of stem designs
possible in a diaphragm valve. They are
the 'Indicating' and Won-indicating' type.
In the indicating type, the position of the
spindle indicates the port opening. The
opening and closing of the valve is
effected by the hand wheel in a manually
operated valve. The material of
construction of the hand wheel could be
ductile /malleable iron or even plastic.
The body ends could be flanged,
screwed or butt-welded as required. In
case of diaphra-m valve with lined body,
the ends are always flanged and the
lining extends to the flanged surface.
The use of these valves is
restricted as they can withstand a
maximum operating pressure of 7 to 10
kg/sq.cm g. The damage to the
diaphra,m
occurs and hence the
maintenance is more frequent. On lined
valves, spark test is also conducted in
addition to the pressure tests. This is to
ensure that the lining is continuous and
no 'holiday' occurs.
There are no API or ANSI
standards for this type of valves. These
are covered by British Standard and
MSS-SP Standards.
1.6
BUTTERFLY VALVES
2. Disc
3. Shaft
4. Body seat
8. Hmdle.
.
The -difference between the
wafer lug and wafer type body design is
that the former has provision for all the
studs to pass through the body whereas
the latter has provision for only locating
bolts. The wafer lug design is also called
single flange design,
As regards the shaft is
concerned, there can be a single shaft or
a main shaft and a stub shaft at the
bottom of the disc. Single shaft is a
better design as it minimizes the
deflection. The shaft sealing can be done
with ' 0 ' . ring or stuffing box and
packing. These valve designs provide
inherent emission control advantages
over rising stem valves.
Valves up to 12" NB are
operated with lever. The lever can have
positions to control. the flow. Higher
diameter valves are provided with gear
unit and hand wheel. When used as
control valves, these can be provided
with actuators also.
The use of this type of valve for
high temperatures is limited by the
material used for seats. Only resilient
seats can provide positive shut off.
Metallic seating can also be provided for
use at higher temperatures but will not
provide positive shut off;
These valves can be used for
vacuum service. When used for
cryogenic service, the valve shall be
provided with extended shaft to clear the
insulation.
When used beneath a -hopper
for solid handling applicatiom, tight shut
off is troublesome since particles jam
between valve .closure surfaces. Further,
the valve must be strong to lift half the
disc against the wei$t of the solids in
the hopper. The advantages. of these
valves . are that the wear resistant
elastomer has a longer life expectancy
than the conventional metallic seated
2.3
Buttefly Valves
2.4
Diaphragm Valves
2.5
Piston Valves
2.6
Pinch Valves
'
PINCHVALVES
Pinch valves are also similar to
diaphragm valves. In Pinch valves, the
bodies provided with sleeves, which get
squeezed to control or stop the flow. The
sleeve could be of corrosion resistant
materials like Rubber or PTFE. The
body is normally made' from cast iron.
These are used for special services
where senice pressures are very low like
isolation of the hose co~ectionsetc. in
the chemical process industry. The body
is cast and can have flanged or screwed
ends.
Of late manufacturers . have
developed these valves to endure higher
pressures and temperatures (0 to 100 bar
& up to 120C respectively) for
application in mining and mineral
industry.
These valves are also not
covered under API or ANSI standards
and
are manufactured as per
Manufacturers' standards.
1.7
GLOBE VALVES
A typical globe valve has the
following parts, which could be
identified.
2.1
Valves
Needle Valves
1. Body .
..
..
... ..
2. Bonnet
3. Yoke
4. Backup Ring
5. Thrust Ring
6. Gasket
7. Gland
Gj
8. StudandNut
9. Plug
10. Seat Ring
11. Spindle
12. Plug Nut
13. Back seat
14. Clamp
15. Gland Bush
.-,;
p
.-
..
..
Body
The construction of the body
differs &om that of the gate valve. The
body ports are arranged such that the
flow is &om the underside of the disk.
Though the code specifies that the globe
valves shall be designed suitable for
installation in either direction of flow,
the preferred direction of flow for globe
valve shall be &om under the disk.
Normally the direction of flow is cast or
embossed on the valve body.
There are two types of port
designs possible, the full port and the
reduced port. In the full port design the
body ports shall be as large as
practicable design considerations permit.
However, in no case the net area of the
bore through the seat of globe shall be
less than the 85% of the area of the
actual pipe bore. In the reduced port
design, the port diameter is normally one
size less than that of the connected pipe.
2.1.1
2.1.2 Bonnet .
The body bonnet connection for
the globe valve is the same as that of
gate valves.
2.1.3 Disk
The disk of the globe valves
shall be:
Flat faced type
Plug type
Ball type
2 1. Hand Wheel
Needle type
V port type
..
NEEDLE VALVES
The needle valves, like globe
valves, are used for flow control.
i\lormally needle valves are used in
smaller sizes and are provided with
either screwed or socket weld end The
design of the needle valve can be exactly
same as that of the globe valve except
for the disk. In globe valves, the di'sk is
2.1.3 Stem
Valves
'
1.2
;
Screwed Ends
:Socket
Weld Ends
Valves
3.1
3.2
LIFT CHECK V S V E S
These valves operate by the
lifiing action of the disktelement. The
different types of lift check valves
available are 3.1
3.1.1
3.1.2
3.1.3
Non-s!m check
11
7
4. Seat
5. Guide
6. Gasket
7. Cover stud nut
3. Cover
Valves
3. Hinge
p.
k,)
4. Hinge Bracket
5. Gasket
-
8. Disc
9. Szat Ring
10. Hinge Pin
11. Disc Pin
Valves
12. Washer
b)
4.3
Float Valves
4.4
Foot Valves
4.5
4.6
MULTI-PORT VALVES
Any valve, which has more
than two ports, is classified as Multi-port
Valves. The multi-port valves on certain
services reduce the time for operating
and the over all costs. There are three
port valves and four port valves in
common use. Five-port designs are also
available. Two types of three port
designs are available viz. The 'T' port
' port. The possible flow
and the 2
patterns of these are as below:
4.1
L PORT VALVE
1 PORT VALVE
4.0
4.2
Valves
FLOAT VALVES
Float valves are used to control
the level of fluid in a reservoir. Only the
inlet of the valve is connected with the
supply pipeline and the outlet is'open to
the reservoir. There will be a float with.
lever, which controls the movement of
the piston reylating the flow.
4.3