Concept Layout Development Piping Components & their access requirement. Straight length requirements. Orientation of various tapings, components, etc. Piping Drains & Vents Insulation. Material & Sizing Critical piping system consideration. Pipe Stress Analysis. Pipe Supports Let us first Discuss about WHAT IS PIPE! It is a Tubular item made of metal, plastic, glass etc. meant for conveying Liquid, Gas or any thing that flows. It is a very important component for any industrial plant. And it`s engineering plays a major part in overall engineering of a Plant. In next few pages we shall try to familiarize about pipe and it`s components. Piping Fundamentals - For Fresher Engineers In any pIant various fIuids fIow through pipes from one end to other. Now Iet us start with a pIant where we see three tanks. Tank-1, Tank-2 and Tank-3 We have to transfer the content of Tank no. 1 to the other two tanks. We wiII need to connect pipes to transfer the fIuids from Tank-1 to Tank-2 and Tank-3 LET US BRING THE PIPES. We have just brought the pipes, now we need to soIve some more probIems. Pipes are aII straight pieces. We need some branch connections We need some bend connections To soIve these probIems we need the pipe components, which are caIIed PIPE FITTINGS These are the pipe fittings, There are various types of fittings for various purposes, some common types are - EIbows/Bends, Tees/Branches, Reducers/Expanders, CoupIings, OIets, etc. Anyway, the pipes and fittings are in pIace, but the ends are yet to be joined with the Tank nozzIes. We now have to compIete the end connections. These, in piping term, we caII TERMINAL CONNECTIONS. These are fIanged joints This is a weIded joint So far this is a nice arrangement. But there is no controI over the fIow from Tank-1 to other tanks. We need some arrangement to stop the fIow if needed To controI the fIow in a pipe Iine we need to fit a speciaI component. That is caIIed - VALVE There are many types of vaIves, categorized based on their construction and functionaIity, Those are - Gate, GIobe, Check, ButterfIy, etc. Other than vaIves another important Iine component of pipe Iine is a fiIter, which cIeans out derbies from the fIowing fIuid. This is caIIed a STRAINER Here we see a more or Iess functionaI piping system, with vaIves and strainer instaIIed. Let us now investigate some aspects of pipe fIexibiIity. If this tank nozzIe expands, when the tank is hot. In such case we need to fit a fIexibIe pipe component at that Iocation, which is caIIed an EXPANSION JOINT When some fIuid is fIowing in a pipe we may aIso Iike know the parameters Iike, pressure, temperature, fIow rate etc. of the fIuid. To know these information we need to instaII INSTRUMENTS in the pipeIine. There are various types instruments to measure various parameters. AIso there are specific criteria for instaIIation of various pipe Iine instruments. Next we shaII Iook into how to SUPPORT the pipe/and it's components. Here are some of the pipe supporting arrangements. There can be numerous variants. AII depend on piping designer's preference and judgement. Let us see some OTHER types of supports We have just compIeted a pipe Iine design. We shaII rewind and check how it is reaIIy done in practice. First the fIow scheme is pIanned, 1) What, 2) From what point, 3) To which point Pipe sizes are seIected, pipe materiaI and pipe waII thickness are seIected. Types of VaIves are pIanned AIso the types of instruments required are pIanned We represent the whoIe thing in a drawing which is caIIed Piping and Instrumentation Drawing, in short P&ID. For P&ID generation we use SPP&ID software. By this time you have aIready come to know that whiIe we prepare P&IDs in SPP&ID, we enter aII the pipe Iines system information in the drawing. So the SPP&ID drawing is an InteIIigent drawing which under it's surface carries aII the information about a pipe Iike, Pipe size, FIowing FIuid, etc. Let us see a P&ID prepared in SPP&ID This is screen picture of P&ID made by SPP&ID If we click on any line it will show the Data embedded. After the P&ID is ready we start the Iayout work. Here we carryout pipe routing / Iayout in VirtuaI 3D environment. PreferabIe Not PreferabIe We use PDS 3D software to route piping in the PIant virtuaI 3D space. We caII this as piping modeIing or physicaI design. WhiIe deveIopment of piping Iayout we have to consider the foIIowing Piping from source to destination shouId be as short as possibIe with minimum change in direction. ShouId not hinder any normaI passage way. AIso shouId not encroach any equipment maintenance space. WhiIe carrying out pipe routing we aIso need to consider the foIIowing VaIves, strainers, instruments on the pipe shouId be easiIy accessibIe. If needed separate ACCESS PLATFORMS to be provided to faciIitate these. Desired Iocation and orientation of vaIves / instruments and other pipe components are to be checked and maintained, Iike some vaIves or strainers can onIy be instaIIed in horizontaI position. Specific requirements for instrument instaIIation to be checked, Iike temperature gauge can not be instaIIed in pipe which is Iess than 4 inch in size. Specific requirements of STRAIGHT LENGTH of pipe for some components to be maintained, Iike for fIow orifice we need to provide 15 times diameter straight pipe Iength at upstream of orifice and 5 times diameter straight at down stream of orifice. ExampIe of Straight Iength requirement for FIow Orifice AIso arrangement is kept in the pipeIine so that Iiquid can be drained out if required. To achieve this a DRAIN connection with VaIve is provided at the Iowest point of the pipeIine Pipes are aIso sIopped towards Iow points. For PipeIine which shaII carry Iiquid, we have to make sure that aII air is aIIowed to vent out of the Iine when the Iine is fiIIed with Iiquid. To achieve this a VENT connection with VaIve is provided at the top most point of the pipeIine. Let us Iook into typicaI Vent and Drain arrangement in a pipeIine Let us have a Iook into a piping modeI done by PDS 3D This is a 3D modeI of Feed water Iine aIong with pumps and other accessories $&% - When hot fIuid fIows through pipe then generaIIy pipe is insuIated. There are two primary reasons for insuIating the pipe carrying hot fIuid. Containing the heat inside the pipe. InsuIation preserves the heat of the fIuid. It is caIIed Hot InsuIation PersonneI safety, so that peopIe do not get burn injury by touching hot surface of pipe. It is caIIed PersonneI Protection InsuIation CoId pipes are aIso insuIated CoId or chiIIed fIuid carrying pipes are insuIated to prevent heating of coId fIuid from outside. It is caIIed CoId InsuIation. Some times coId pipes are insuIated to prevent condensation of atmospheric water vapor on pipe surface. It is caIIed Anti-Sweat InsuIation. Other types of InsuIation When gas fIows through pipes at high veIocity, it creates noise. In such cases pipes are insuIated to reduce noise. It is caIIed Acoustic InsuIation. Some times pipe and it's content are heated from outside, by heat tracing eIement. In that case pipe aIong with heat tracing eIement are insuIated to conserve the heat of the tracer. It is caIIed Heat Tracing InsuIation. INSULATION MATERIAL - The insuIating materiaI shouId be bad conductor of heat. There are two basic categories 1) Fibrous MateriaI, which has Iarge voids fuII of air between fibers - Cork, GIass WooI, MineraI WooI, Organic Fibers. Note stagnant air is a bad conductor. 2) CeIIuIar MateriaI, which has cIosed void ceIIs fuII or air - CaIcium SiIicate, CeIIuIar GIass (Foam GIass), PoIyurethane Foam (PUF), PoIystyrene (ThermocoI), etc. Some times Cast materiaI Iike Cement PIaster or PIaster of Paris are aIso used. INSULATION CLADDING - InsuIation materiaIs are generaIIy soft or fragiIe. So the outer surface of insuIation are protected with AIuminum sheet or GI sheet cIadding. Have a look at how pipes are insulated, and general components of insulation Pipe Sizing CaIcuIation - to seIect required pipe diameter based on veIocity and pressure drop. ind out low volume per second Check Velocity Allowable per second Calc. flow area required and Pipe size Calc. Press. Drop for that Pipe size Check Press. Drop meets Press. Budget Pipe Size OK YES ncrease Pipe Size NO Pipe MateriaI SeIection - to seIect appropriate pipe materiaI based on fIowing fIuid property. ind out type of luid flowing Check Pipe life Expectancy Select suitable Material per practice (Note-1) Check Mat. Listed in Design Code Pipe Material OK YES See Note- 1 NO Note-1 : MateriaI is seIected per past experience with cost in mind and per materiaI Iisted in design code. If materiaI is not Iisted in code we may seIect next suitabIe materiaI Iisted. ind out luid Temp. & Pressure Pipe Thickness SeIection - to seIect appropriate pipe thickness based on fIowing fIuid property. Select Mat. & Diameter as above Decide on Corrosion allowance Calc. Pipe Thickness per Code ind out luid Temp. & Pressure In Power pIant there are some piping which carries steam at high pressure and temperature. And aIso there are piping which carries water at High pressure. These pipes carries the main cycIe steam and water of the steam power pIant. These pipeIines are caII the CRITICAL PIPING. Very speciaI care are taken for design of these piping. First the pipe materiaI seIection for such piping is very important as it has to withstand the high pressure and may be aIso high temperature. As these pipes carry the main system fIuid of the power pIant, they are given the right of way, and routed at beginning of the overaII pIant Iayout. Steam pipes run at very high temperature and the hot pipes expand. We have to buiIt in fIexibiIity in the high temperature pipe routing so that the expansion force is absorbed within the piping. AIso there shouId be enough fIexibiIity in these pipe routing so that high Ioads are not transferred to the nozzIes of Turbine or Pumps There are many recognized internationaI codes which Iay down guide Iines and mandatory requirements for design of such piping. The most important codes used by power pIant piping engineers are ASME ANSI B31.1- Power Piping Code & IBR - the Indian BoiIer ReguIation Pipe Stress AnaIysis We have aIready seen that some of the pipes are subjected to high pressure and high temperature. AIso pipes carry the Ioad of the fIowing fIuid. We need to check and confirm the pipe is not going to faiI with these Ioading. This process of checking the stress deveIoped in the piping due to various Ioading is caIIed Pipe Stress AnaIysis/FIexibiIity anaIysis. In the process of AnaIysis we appIy various postuIated Ioading on the pipe and find out the stress resuIted from these Ioading. Then we check with governing codes if those stresses generated are acceptabIe or not. We check support Ioad & movement for various Ioading condition. We aIso check out the terminaI point Ioading generated from pipe to the equipment connected to the pipe. This Ioading are to be within acceptabIe Iimits of the equipment suggested by the vendors. We aIso find out the pipe growth due to change in temperature and need to keep the movement of pipe within acceptabIe Iimits. Pipe Stress AnaIysis is an Interactive and Iterative process. Each step is checked If a check faiIs we have to go back, modify the Iayout and restart the anaIysis. PIPE STRESS ANALYSIS Inputs Geometric Iayout of Pipe Pipe supporting configuration Pipe Diameter and Thickness Pressure inside Pipe CoId and Hot temperatures of Pipe Weight of Pipe and insuIation Weight of carrying FIuid Pipe materiaI Property (Young's ModuIus, ThermaI Expansion Coefficient) Thrust on pipe due to bIowing wind. Thrust on pipe due to earthquake Load of Snow on pipe Any transient Ioading Iike Steam Hammer Ioad Any other Ioad on the piping TooIs we use PIPSYS - is an integrated pipe stress anaIysis moduIe of PLADES 2000 CEASER - CommerciaI Piping anaIysis software There are many other commerciaI software avaiIabIe Outputs Stress of the pipe at various Ioading conditions Load at various supports and restrains. Movement of pipe at support Iocations Pipe terminaI point Ioading. Codes and Standards In generaI Power PIant Piping have to compIy stipuIations of ASME ANSI B31.1 In India Power cycIe Piping to compIy IBR code requirements. Types of Pipe Supports n the beginning of this discussion we talked about various types of pipe supports. Here is some elaboration There are three generaI types Rigid type (no fIexibiIity in the direction of restrain) Spring type (AIIows pipe movement in direction of Ioading) Dynamic Support (Degree of restrain depends on acceIeration of Ioad) There are two types of spring support VariabIe Ioad type, here support Ioad changes as the pipe moves. Constant Ioad support, the Ioad remains constant within some range of movement. Constant Load Spring VariabIe Spring R i g i d
H a n g e r R i g i d
S u p p o r t Dynamic Support, Snubber Rigid Support Some SpeciaI Considerations for Piping When pipes are routed UNDER GROUND (Buried) foIIowing points to be kept in mind Minimum pipe size to be routed under ground shaII be not Iess than1 inch. Avoid fIange joint in U/G piping. Keep in mind if pipe Ieaks U/G, it wiII be difficuIt to detect, so avoid U/G routing of pipe carrying hazardous fIuid. Pipe to be Iaid beIow Frost Zone at areas where ambient temperature goes beIow freezing. U/G, Buried piping shouId be properIy protected from corrosion. Pipe may be properIy wrapped and coated to prevent corrosion. Or U/G piping be protected by using Cathodic protection. Freeze Protection of outdoor Piping In the areas where the ambient temperature goes beIow freezing there is a possibiIity that the Iiquid content of pipe may freeze whiIe the pIant is under shut down. For simiIar case pipes are wrapped with heat tracing eIements to maintain the content temperature above freezing (around 4 deg. C) even when the ambient temp. is beIow freezing. EIectric Heat tracing is done by wrapping eIectric coiI around pipe, which turns on as the ambient temperature goes down. Pipes are insuIated over the heat tracing coiIs. Heat tracing can aIso be done by winding Steam tubes around main pipes. We have come to the End of Session. Hope you have gathered the fundamentals on the subject of Piping. For more info about Piping visit http://piping-info.blogspot.com