L&T Summer Training Report

LPG-LEF DISTILLATION UNIT DESIGN
2012
CHAPTER 1: INTRODUCTION
1.1 About Larson and Toubro
1.1.1 Companys Vision:
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1.1.2 Companys History: L&T was founded in Bombay (Mumbai) in 1938 by two Danish engineers, Henning Holck-Larsen and Soren Kristian Toubro. Both of them were strongly committed to developing India's engineering capabilities to meet the demands of industry.
Figure 1 Founders Henning Holck-Larsen (4.7.1907 27.7.2003) Soren Kristian Toubro (27.2.1906 4.3.1982)
Henning Holck-Larsen and Soren Kristian Toubro, school-mates in Denmark, would not have dreamt, as they were learning about India in history classes that they would, one day, create history in that land. In 1938, the two friends decided to forgo the comforts of working in Europe, and started their own operation in India. All they had was a dream. And the courage to dare. Their first office in Mumbai (Bombay) was so small that only one of the partners could use the office at a time! In the early years, they represented Danish manufacturers of dairy equipment for a modest retainer. But with the start of the Second World War in 1939, imports were restricted, compelling them to start a small work-shop to undertake jobs and provide service facilities. Germany's invasion of Denmark in 1940 stopped supplies of Danish products. This crisis forced the partners to stand on their own feet and innovate. They started manufacturing dairy equipment indigenously. These products proved to be a success, and L&T came to be recognized as a reliable fabricator with high standards. The war-time need to repair and refit ships offered L&T an opportunity, and led to the formation of a new company, Hilda Ltd., to handle these operations. L&T also started two repair and fabrication shops - the Company had begun to expand.
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1.1.3 Companys Overview: Larsen & Toubro Limited (L&T) is a technology, engineering, construction and manufacturing company. It is one of the largest and most respected companies in India's private sector. More than seven decades of a strong, customer-focused approach and the continuous quest for world-class quality have enabled it to attain and sustain leadership in all its major lines of business. L&T has an international presence, with a global spread of offices. A thrust on international business has seen overseas earnings grow significantly. It continues to grow its overseas manufacturing footprint, with facilities in China and the Gulf region. The company's businesses are supported by a wide marketing and distribution network, and have established a reputation for strong customer support. L&T believes that progress must be achieved in harmony with the environment. A commitment to community welfare and environmental protection are an integral part of the corporate vision. In response to changing market dynamics, L&T has gone through a phased process of redefining its organization model that facilitates growth through greater levels of empowerment. The new structure is built around multiple businesses designated Independent Companies or ICs. 1. Hydrocarbon 2. Heavy Engineering 3. L&T Construction 4. L&T Power 5. Electrical & Automation 6. Machinery & Industrial Products 7. Information Technology 8. Financial Services 9. Shipbuilding 10. Railway Projects
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1.1.4 Faridabad Campus: At L&T Faridabad Campus, there are 8 Strategic Business Units (SBU), namely: L&T Gulf L&T Railways Business Unit (RBU) L&T Valdel L&T Engineering L&T Mitsubishi Heavy Industries (MHI) L&T Howden L&T Power L&T Sargent & Linde (S&L)
1.1.5 L&T Engineering: L&T Engineering is the engineering part of L&T Engineering & Construction (E&C). L&T E&C is an EPC firm i.e. Engineering, Procurement and Construction. LTEN Faridabad does the engineering for Fertilizer and Oil & Gas plants. The current ongoing projects are NFL Ammonia Feedstock Changeover and ONGC Additional Gas Processing Facility Project. The total strength of engineers in LTEN is around 250.
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Departments:
1. Mechanical Mechanical department is further divided into Rotary and Static Department. The departments key role is to design rotary and static equipments as per the clients requirement. The equipments are designed according to the international standards or the standards set by the client or Project Management Consultant (PMC). 2. Process Process department is the heart of engineering department. Process parameters selection for various items/equipments (electrical, mechanical, instrumentation, piping) is decided by process based on plant process requirements and licensors technology. 3. Piping Piping department is responsible for preparing equipment layouts & isometrics. It is also responsible for generating 3D model of the plant using PDS software, which helps in avoiding clashes between the equipments and pipes. It also does the stress analysis for pipe lines, using CAESAR software.
4. Electrical It deals with sizing of electrical equipments such as transformers, switchboards, cables, motors etc. It also prepares layouts such as cable tray layouts, substation equipment layouts, hazardous area layouts and lighting layouts etc. The codes followed by the electrical department are IS (Indian Standards), IEC, ANSI or as per the client requirement .
5. Instrumentation It deals with the designing of DCS (Distributed Control System) from where plant is controlled. Also, designing of valves, meters, control panels, gauges, etc.
6. Civil Department is responsible for designing of buildings (Sub Station and Control Rooms), technical structures, pipe rack and also foundation for various equipments such as pumps, columns, tanks etc.
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1.2 About Project

1.2.1 Background Crude oil, also called petroleum, is a complex mixture of carbon and hydrogen (hydrocarbons), which exist as a liquid in the earth's crust. Crude oil and associated gas produced from ONGCs Mumbai high and satellite fields are transported to their Uran onshore facilities through sub-sea pipelines for further processing. Crude oil and gas are brought to Uran from Mumbai High and satellite fields of western offshore through two sets of trunk lines MUT lines and through HUT lines. The offshore gas from 28inch MUT line and 26 inch HUT line is received at slug catchers where condensate, formed within the pipelines during transportation, gets separated. The condensate free gas is routed to Gas Sweetening Unit (GSUs) which presently consist of two trains for removal of CO2 and H2S gas as acid gas. The remaining gas beyond the processing capacity of GSUs is directly sent to consumers along the lean gas coming from the plant. After removal of CO2 and H2S, the treated gas (sweet gas) is routed to LPG recovery units for extraction of value added products like LPG, Naptha and Ethane-Propane. The condensate received at slug catchers and that generated in the plant is routed to existing Condensate Fractionating Units (CFUs) for removal of lighter hydrocarbon and further extraction of LPG and Naptha.
Gas Sweetening Unit (GSUs)
1. It is designed to separate acid gas component such as CO2 and H2S from Sour
gas. The separation achieved with the help of Amine solution in an Absorber column. 2. The purpose of the Sulfinol solvent regenerator is to remove H 2S, CO2, COS and RSH from the rich solvent and return solvent to the absorber system with low enough residual CO2 and H2S to allow these system to meet their treating requirements. 3. Acid Gas from the Regenerator is transferred to the Acid gas stack.
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Condensate Handling Unit (CHUs) 1. It is designed to handle excess of water along with condensate during normal operation and intermittent pigging operators of upstream BUT/MUT/HUT trunk lines.
Condensate Fractionating Units (CFUs) It is used to remove light ends and to recover LPG and Naptha from Pipeline Condensates. The new CFU will operate in parallel with existing CFU and it will consists of Condensate Receiving System, Stripper, LPG Column & Off Gas Compression Section. The utility section of the unit comprises of cooling water, instrument air, Plant air, Nitrogen, Service water besides blow down system, flare system and condensate recovery system.
LPG Recovery Unit (LPUs) 1. It is designed to recover maximum LPG from sweetened gas coming from gas Sweetening units and produce value added products viz. LPG, NGL & Lean gas. 2. LPG recovery unit consists of feed gas compression and pre-cooling, Feed Gas drying and regeneration, Chill down and expansion, Lean gas compression, Propane refrigeration system and Fractionating system.
1.2.2 Objectives 1. Our objective is to design a piping for columns in LPG Recovery Unit where LPG and Naptha are produced from sweet gas. 2. In reference to the figure below, gases extracted from sea bed are sent to the Condensate Handling Unit (CHUs) condensate trapped in gas is further extracted and the remaining gas is send to Gas Sweetening Unit (GSUs), from where it goes further to LPG Recovery Unit to extract LPG and Naptha from it. 3. Whereas the condensate from CHUs after getting filtered moves to the Condensate Fractionating Unit (CFUs), from where it again forms LPG and Naptha. 4. Finally LPG and Naptha are stored in their storage tanks respectively.
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CHAPTER 2: LITERATURE OVERVIEW
2.1 Refinery Process

An oil refinery or petroleum refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas. Oil refineries are typically large, sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units. Common process units found in a refinery: 1. Desalter unit washes out salt from the crude oil before it enters the atmospheric distillation unit. 2. Atmospheric distillation unit distills crude oil into fractions. 3. Vacuum distillation unit further distills residual bottoms after atmospheric distillation. 4. Catalytic reformer unit is used to convert the naphtha-boiling range molecules into higher octane reformate (reformer product). 5. Fluid catalytic cracker (FCC) unit upgrades heavier fractions into lighter, more valuable products. 6. Hydrocracker unit uses hydrogen to upgrade heavier fractions into lighter, more valuable products. 7. Alkylation unit produces high-octane component for gasoline blending. 8. Isomerization unit converts linear molecules to higher-octane branched molecules for blending into gasoline or feed to alkylation units. 9. Steam reforming unit produces hydrogen for the hydro treaters or hydrocracker. 10. Slug catcher used when product (crude oil and gas) that comes from a pipeline with two-phase flow, has to be buffered at the entry of the units. 11. Solvent dewaxing units remove the heavy waxy constituents petrolatum from vacuum distillation products. 12. Solvent refining units use solvent such as cresol or furfural to remove unwanted, mainly aromatics from lubricating oil stock or diesel stock. 13. Utility units such as cooling towers circulate cooling water, boiler plants generates steam, and instrument air systems include pneumatically operated control valves and an electrical substation. 14. Storage tanks store crude oil and finished products, usually cylindrical, with some sort of vapor emission control and surrounded by an earthen berm to contain spills. 15. Alternative processes for removing mercaptans are known, e.g. doctor sweetening process and caustic washing.
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Figure 4 Refinery Flow diagrams and Petroleum products
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2.2 Process Flow Diagrams (PFDs)

A Process Flow Diagram - PFD - (or System Flow Diagram - SFD) shows the relationships between the major components in the system. A PFD does not show minor components, piping systems, piping ratings and designations. A PFD should include: 1. 2. 3. 4. 5. 6. Process Piping Major equipment symbols, names and identification numbers Control, valves and valves that affect operation of the system Interconnection with other systems Major bypass and recirculation lines System ratings and operational values as minimum, normal and maximum flow, temperature and pressure 7. Composition of fluids Function of the Flow Diagram: 1. Ideas and thoughts as to the physical system of an industrial process start out in somebodys head (typically an engineer or technician/designer) 2. These are transferred to paper, chalkboards or dry erase boards as sketches and verbal descriptions 3. Once the initial bugs are worked out of the process sketch, then a drafter converts the sketches into a flow diagram 4. This drawing can be altered and revised many times during the design process of the system 5. The main thing this drawing does is give a visual as to the intended system being designed sometimes it takes having this type of visual representation to allow other considerations or views of the process to be realized, redesigned, modified and re-engineered. 6. It is the basis for feedback, discussion and revisions by the project engineer and clients. 7. An Eg of PFD is given on next page:
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Figure 5 Typical Example of PFD
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2.3 Piping and Instrumentation Diagrams (P&IDs)

The piping and Instrument Diagram (P&ID) provides a schematic representation of the piping, process control, and instrumentation which shows the functional relationships among the system components. The P&ID also provides important information needed by the constructor and manufacturer to develop the other construction input documents (the isometric drawings or orthographic physical layout drawings). The P&ID provides direct input to the field for the physical design and installation of field-run piping. Typical P&ID characteristics: 1. shows all valves and instrumentation 2. Piping is detailed and contains some fittings 3. Tanks and vessels show all nozzles and flanges 4. Values associated with pipe are show; such as flow rates, temperature, pressureetc.
Figure 6 Typical P&ID
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2.4 Material Take off Sheets (MTOs)

Definition used by the ISA (International Society of Automation) : A Material Take Off (MTO) is the process of analyzing the drawings and determining all the materials required to accomplish the design. We then use the material takeoff to create a bill of materials (BOM). Inspection does not aid in creating a bill of materials. Procurement and requisition are activities that occur after the bill of materials is complete. Material Take Off (MTO) is a term used in engineering and construction, and refers to a list of materials with quantities and types (such as specific grades of steel) that are required to build a designed structure or item. This list is generated by analysis of a blueprint or other design document. The list of required materials for construction is sometimes referred to as the Material Take Off List (MTOL).
Table 1 Typical MTO
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2.5 General Arrangement Drawings (GADs)

These drawings indicate the locations of main equipments in the plant. The main piping items, valves, and fittings are also indicated in the General Arrangement or GA drawings. Most often the piping is indicated using a top-view. Sometimes a side view of the pipe rack is also presented on the GA drawing. General arrangement drawings are also developed for individual equipments. These drawings present the main dimensions of that equipment using 2D views, top-view, side-view and sometimes front-view. All the nozzles for concerned equipment are indicated on the equipment General Arrangement or GA drawing.
Figure 7 Typical GAD
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2.6 Isometrics
The Iso, as isometric are commonly referred, is oriented on the grid relative to the north arrow found on plan drawings. Because iso's are not drawn to scale, dimensions are required to specify exact lengths of piping runs. PIPING isometrics are generally produced from orthographic drawings and are important pieces of information to engineers. In very complex or large piping systems, piping isometrics are essential to the design and manufacturing phases of a project. PIPING isometrics allow the pipe to be drawn in a manner by which the length, width and depth are shown in a single view. Isometrics are usually drawn from information found on a plan and elevation views. The symbols that represent fittings, Valves and flanges are modified to adapt to the isometric grid. Usually, piping isometrics are drawn on preprinted paper, with lines of equilateral triangles form of 60. Pipe lengths are determined through calculations using coordinates and elevations. Vertical lengths of pipe are calculated using elevations, while horizontal lengths are calculated using north-south and east-west coordinates.
Figure 8 Different views in Piping
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Orthographic view
Isometric view
Figure 9 Typical Isometric Drawing The image on the right shows a isometric view of the same pipe as here on the left. The red lines show the pipe, the black dots are the butt welds and A, B & C are the dimensions of front to center line and center line to center line
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CHAPTER 3: BASICS OF PIPING
3.1 Categories of Piping Piping is divided into three categories:

1. Large bore pipe: Generally includes piping greater than two inches in diameter. 2. Small bore pipe: Generally includes piping which is two inches and smaller in diameter. 3. Tubing: Tubing is supplied in sizes up to four inches in diameter but has a wall thickness less than that of either large bore or small piping.
3.2 Pipe Terminologies and Definitions

3.2.1 Nominal Pipe Size: The term diameter for piping sizes is identified by nominal size. The manufacture of nominal sizes of 1/8 inches through 12 inches inclusive is based on a standardized outside diameter (OD). The 14 inch and larger sizes have the OD equal to the nominal pipe size. Tubing however is sized to the outside diameter for all applications. Pipe Sizes 3/8'', 1 1/4'', 3 1/2'', 4 1/2' and 5 inches are considered as non-standard and should not be used except to connect to equipment having these sizes. In this case the line is increased to a standard size as soon as it leaves the equipment.
3.2.2 Schedule Number Pipes are manufactured in a multitude of wall thickness. These wall thickness have been standardized so that a series of specific thickness applies to each size of piping. Each thickness is designated by a schedule number rather than the actual wall thickness. The original thickness was referred to as standard (STD), extra strong (XS) and double extra strong (XXS). These designation or weight classes have now either been replaced or supplemented by SCHEDULE NUMBERS in most cases. Schedules begin with 5 and 5s followed by 10 and 10S, then progress in increments of ten through Schedule 40 and then finally by increments of twenty to Schedule 160. Wall thickness for Schedule 40 and STD are the same for sizes 1/8'' to 10''. Schedule 80 and XS also have the same wall thickness for 1/8'' through 8'' dia pipe. Schedules 5 and 10 are generally used for stainless steel piping.
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3.2.3 Pipe Length Pipe is usually supplied in random lengths. The shortest, longest and average length may vary for piping of different materials, sizes and wall thickness schedules. Typically an average length of 20 feet is used for carbon steel pipe, but double random lengths are available from most suppliers and are generally preferred especially for rack installations.
3.2.4 Pipe Ends 1. Plain ends (PE) are cut square and reamed to remove burrs. This type of end is used for mechanical couplings, socket weld fittings or slip on flanges. 2. Beveled ends (BE) are required for most butt-weld applications. 3. Threaded ends (TE) are used for screwed joints. Pipe order is placed as threaded both ends (TBE) or threaded one end (TOE).
3.3 Standard Piping Materials

3.3.1 Carbon Steel It is one of the most commonly used pipe materials. The specifications that cover most of the pipe used are published by the ASTM (American Society for Testing of Materials) and ASME ( American Society Of Mechanical Engineers ) e.g. A106 is a Carbon Steel material specification and is available in grades A,B and C. The grades refer the tensile strength.
3.3.2
Stainless Steel Pipe It is virtually non-magnetic. There are eighteen different grades and type 304 L is the most widely used. L denotes low carbon content and is best suited for welding.
3.3.3
Chromium-Molybedenum Alloy This pipe is commonly referred to as ''chrome-moly''. There are ten grades of this type of pipe material and are covered by ASTM 335. Chrome - moly pipe is used extensively in heat exchangers.
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3.3.4 Plastic Thermoplastic pipe available in compositions eg polyvinyl chloride (PVC), Polyethylene (PE), Polypropylene (PP) Thermosetting (Fiberglass) pipe.
3.4 Piping Components

3.4.1 Flanges Flanges are divided by class which is normally rated by working pressure in pounds per square inch. They are available in a variety of primary pressure ratings from 25psi to 2500 psi. Selection of the proper flange facing depends on the combination of many factors: 1. Flange material 2. Gasket Material 3. Bolt Strength 4. Operating Pressure and Temperature 5. Fluid Properties Contained Types of Flanges: 1. Weld Neck Flanges are the most common type of flanges used and preferred for the majority of service conditions. The strength of the fitting increases and stress is distributed so that this style can withstand extreme temperature. Shear, impact, bending and vibratory loading.
Figure 10 Weld Neck Flange

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2. Socket Weld flanges are most commonly used on two inch and smaller p i p i n g .
Figure 11 Socket Weld Flange 3. Slip-on Flanges are sometimes preferred because of its lower installation cost and because it can accommodate slight misalignment. The calculated strength of the slip-on flange under internal pressure is approximately two thirds that of the weld neck style flanges and its life under fatigue is about one-third that of the weld-neck.
Figure 12 Slip-On Flange
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4. Threaded Flanges are attached by screwing the flange onto the threaded
end of the pipe. As with other threaded fittings its use is restricted to systems having relatively low operating temperatures and pressures.
Figure 13 Threaded Flange
5. Lap Joint Flanges are used in piping that will be frequently dismantled.
The flange is free to revolve on the pipe thus avoiding the problem of accurate alignments.
Figure 14 Lap Joint Flange
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3.4.2 Elbows They make an angle between adjacent pipes. There are standard elbows of 90 degrees and 45 degrees. Long radius 90 deg elbow: Radius of bend = 1.5 times the nominal pipe diameter. Short radius 90 deg elbow: Radius of bend = nominal diameter. Reducing elbows are 90 deg elbows with two different size ends
Figure 15 Elbow 3.4.3 Tees
Figure 16 Tees
Straight Tee has three openings. Two have the same axis while the third is perpendicular to this axis for connecting a branch line. Reducing Tee is similar to a straight tee except that the branch line connection is smaller in size. 3.4.4 Lateral pipe fittings They are of two types: Straight Lateral pipe fittings have three outlets two of which have the same axis and a third on the side joined at 45 deg angle from the main axis. Reducing Lateral fittings are similar to straight laterals except that the branch connection is smaller in size.
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3.4.5 Reducers
Concentric Reducers are pipefitting with different nominal diameters on each end while maintaining the same centerline. Eccentric Reducers are pipefitting with different nominal diameters on each end and the fitting is flat on one side with an eccentric centerline. Eccentric reducers are used for connecting different size pipes especially at centrifugal pump inlet connections for preventing air pockets which may cause the pump to CAVIATE.
Figure 17 Reducers
Figure 18 Swage nipples
3.4.6 Swage nipples A Swage Nipple is a reducing fitting used to join piping of different sizes. Care must be taken in matching the correct pipe schedules and end styles when ordering. Swages are available in both concentric and eccentric types.
3.4.7 Pipe caps Pipe Caps is specialized fittings that are used to close an open end.
3.4.8 Strainers Strainers are used to remove solid particles from liquids. They generally have a permanent screen that can be cleaned by emptying, washing or blowdown. Strainers are generally placed in the main line so that all of the process fluid passes through them.
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Strainers are either permanent plant components designed for the life of the plant or temporary components for the removal of construction residue during initial start up.
3.4.9 Weldolets They are integral reinforcement fittings used for branch connection strength. They are designed to minimize stress concentrations and provide integral reinforcement.
(a)
(b) (c) Figure 19 Different Weldolets (a) Weldolet (b) Tapered Weldolet (c) Straight Weldolet
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3.4.10 Full Couplings and Threaded Unions
Full couplings are used to join a pipe segment to another pipe or pipe fitting. Screwed Unions are basically screwed joint that can be disassembled within a completed system for subsequent maintenance.
Figure 20 Full Couplings
3.5 Valves
3.5.1 Definition and Function A Valve may be defined as a mechanical device by which the flow of liquid or gas may be started, stopped or regulated by a movable part that opens, shuts or partially obstructs one or more ports or passageways. A Valve may be designed to direct, start, stop, mix or regulate the flow, pressure, or temperature of a process fluid. A Valve by nature of their design and materials can : Open and Close Turn on and off Regulate Isolate extremely large array of liquids and gases. 3.5.2 Valve Materials Carbon Steel is the ideal material for non-corrosive fluids. It is also used for steam and condensate services. Carbon Steel is readily available in most common general service valves and generally inexpensive. It is recommended in temperatures up to 425 Deg Celsius in continuous service or up to 535 Deg Celsius in non-continuous service.
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Stainless Steel is very corrosion resistant, extremely strong and is commonly specified for high- temperature application temperatures at 535 Deg Celsius and higher. The cost of Stainless Steel is higher than carbon steel but less than other alloy steels. Chrome-Molybdenum steel is a good material that falls between the characteristics of carbon steel and stainless steel. It can handle higher pressure and temperatures than carbon steel making it ideal for high pressure steam or flashing condensate applications. Special alloys are specified for special service or severe service valves e.g. Hastealloy B & C may be selected for a highly acidic fluid service or Monel or bronze body may be selected for a pure Oxygen Service.
3.5.3 Types of valves
Figure 21 Types of Valves
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1. Gate valves:
A Gate valve is a multi turn valve in which the port is closed by a flatfaced vertical disk that slides at right angles over the seat. It is primarily designed for on-off service, where it is operated infrequently. It can be applied to general service, oil, gas, air slurries, heavy liquids, steam, non-condensing gases and liquids, corrosive liquids
2. Globe valves: A Globe valve is a linear motion valve and is generally used for both onoff throttling applications. Although the globe design can handle high-pressure classes, due to the thrust limitations of the hand operator globe valves are usually applied to lower pressure applications.
3. Ball valves The valves, which are best, used for on-off service, as well as moderate throttling situations that require minimal accuracy. They are made in three general patterns: Venturi port, Full port and Reduced port
4. Butterfly valves In a Butterfly valve the fluid moves from the inlet to the outlet, with the disk being the only obstruction to the flow.
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Unlike gate or globe valve designs, where the closure element moves out of the flow stream, the butterfly disk is located in the middle of the flow stream. It creates some turbulence to the flow, even in the open position.
5. Check valves Check valves (also known as non-return valves) are automatic valves that prevent a return or reverse flow of the process. The check valve operation is dependent upon the flow direction of the process, which may be created by a pump or pressure drop.
6. Plug valves It is a quarter-turn manual valve that uses a cylindrical or tapered plug to permit or prevent straight-through flow through the body. Plug valves are either lubricated or non-lubricated. For non-lubricated valves, the plug may be inserted from the top or bottom of the valve body.
7. Diaphragm valves Diaphragm Valves consist of a rigid body formed with a weir placed in the flow path, a flexible diaphragm which forms the upper pressure boundary of the valve, a compressor which is used to force diaphragm against the weir, and the bonnet and hand wheel which secure the diaphragm to the body and actuate the compressor. They are manufactured in Variety of end connections: Welding end socket or butt welding, flanged, screwed or threaded, clamp ends, solvent cement joint ends for thermoplastic valves and male sanitary threaded ends.
8. Safety valves They are also known as pop safety valves. They are spring loaded, quick opening, full flow valves for systems containing pressurized, compressible fluids such as steam, air, or other vapors or gases. The set pressure is adjusted by increasing or decreasing the spring compression. The difference between the opening pressure and the closing pressure is called blowdown.
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9. Relief valves They are similar to safety valve but open only slightly at set pressure. Instead of full opening, they open wider if the pressure increase above the set pressure. Relief valves are normally used for liquids, such as water or oil, where release of a small volume will rapidly lower the pressure.
3.6 Gaskets
A gasket is a malleable material, which can be either soft or hard, that is inserted between two parts to prevent leakage between that joint. Pressure is applied by bolting or using a clamp to compress the gasket firmly in place. Gaskets are made from all different types of materials, depending on the temperature, pressure or fluid characteristics of the process. Gaskets are used in valves for three major purposes: To prevent leakage around the closure mechanism To prevent leakage of fluid to atmosphere To allow the function of internal mechanisms that depend on separate fluid chambers, such as pressure balance trim
Figure 22 Gaskets
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3.7 Piping nomenclature

3.7.1 Need for nomenclature Several documents are required as a part of design of process plants. Out of these the documents related to piping are: 1. Piping & Instrumentation Diagram (P&ID), 2. Piping Layout 3. Piping Elevation etc. Each of these documents contains several lines of different sizes, MOC and service. Thus it becomes necessary to identify each line and assign a unique identity to each of them. A line can be identified by its number, fluid to be handled, location in plant, line size, MOC etc. These parameters are the basic elements of line identity and when put in a proper order forms what is called as Elements/Parameters of Piping Nomenclature .
Figure 23 PIPING NOMENCLATURE
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3.7.2 Detailed description Parameter 1: Line Number 1. Line Number is a unique number assigned to every line. Every line must have a different line number i.e. the number should not be repeated for various lines. 2. The simplest way of line numbering can be assigning numbers 1, 2, 3 and so on to lines. 3. Depending on the type of fluid the lines can be further numbered. For example lines for process fluids can have numbering in one range, say, 1 to 100, utility lines can have numbering falling in another range, say, 101 to 200 and so on. 4. Yet another way of line numbering can be assigning letters/alphabets to various fluid services and accordingly numberings the lines. For example the process lines can be assigned letter 'P', utility lines can be assigned letter U and then depending on various lines the number follows the corresponding letter e.g. P123 indicates process line with no.123. Parameter 2: Fluid to be handled 1. Process lines are meant for handling various fluids. The fluids handled can be classified as Process fluids (which further includes the raw materials, the intermediate streams and the final product). 2. Utilities (which includes cooling water, chilled water, steam, thermic fluids, soft water, DM water etc.). 3. For nomenclature, each of these lines are given specific codes depending on the fluid handled e.g. CHS may indicate chilled water supply, CHR may indicate chilled water return DMS may indicate DM water supply and so on. Parameter 3: Location in plant 1. This parameter is included in the nomenclature so as to indicate the origin of any stream in various locations of the plant. 2. The various sections of plants are Raw material storage, processing, Intermediate Product Storage, Final product storage, Water treatment section, utility section, waste treatment section etc. 3. These sections can be indicated as RMS-SEC for Raw Material Storage section, PRO-SEC for processing section, WTP-SEC for Water treatment section-WSTSEC for waste treatment section, UTI-SEC for Utility section and so on. 4. Each of these sections can be numbered depending on the process flow and this number appears in the nomenclature. For example Raw Material Storage section can be designated as I, Processing Section by II and so on. Parameter 4: Line size 1. Although the selection of line is a job of piping engineer, the line sizing can be done by Process or Piping engineer. Commercial pipes are available either as NB (Nominal Bore ) based or OD (Outside Diameter) based depending on the material of construction.
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2. The standard sizes on NB basis are 25, 50, 80,100,150,200 etc. The corresponding sizes on OD basis are 33.4, 60.3, 88.9, 114.3, 168.3, 219.1 etc. The same are mentioned in the nomenclature. Parameter 5: Material of Construction 1. Commercial pipes are available with various materials of constructions. Most commonly used materials are CS, AISI 304, AISI 316, Copper, PVC etc. 2. In the nomenclature MOC can be written as it is like CS for Carbon steel, AISI 304, AISI 316 etc. for various grades of Stainless Steel. Type 2 second way can be giving code for various MOC. For example Code 1 can denote CS, Code 2 can denote AISI 304 and so on. Parameter 6: Insulation 1. Heat transfer is the common operation used in Process industries. Process equipments and pipes are insulated either to prevent heat loss to the surroundings or to prevent heat gain from the surroundings. 2. Accordingly there are two types of insulations hot and cold. Depending on the temperature inside the pipe and that of the surroundings, the nature of insulation differs. The terms H and C can thus be used to indicate the type of insulation. 3. The inclusion of this parameter in the nomenclature is essential because it indicates the nature of fluid in the pipe which is mainly required for personnel safety in the plant. Parameter 7: Phase 1. Materials that are handled in Process plants exist in different phases. In general the flow can classified as single phase flow, two phase flow and three phase flow. 2. Single phase flow indicates flow of solid, liquid, gases or vapors. Two phase flow indicates combination of any two of these e.g. solid + liquid, solid + gases, liquid + vapors etc 3. Three phase flow indicated combination of any three of these. The inclusion of this parameter in the nomenclature may be optional, but the inclusion proves to be very helpful especially when the process involves several phase flows through various lines in the plant. Type 1) 4. The details of phase can be given by complete name of the phase like solid, liquid etc. Type 2) Letters such as S, L, G and V can be used to denote respectively solids, liquids, gas and vapors. Parameter 8: Other Details 1. At times it becomes necessary to provide additional details in the nomenclature. 2. These include jacketing of pipe, pipe tracing, special lines like IBR etc. The additional detail can be indicated as it is in the nomenclature.
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CHAPTER 4: PROJECT WORK
4.1 Analysis
Though the LPG recovery unit consists of many components but our main focus is on two columns: 40-C-401 & 40-C-402. So throughout the entire project work all the DESCRIPTION, WORKING PROPORTION AND DESIGN CALCULATIONS will be in context of two COLUMNS.
4.1.1 Process description

The Fractionation section consists of two columns: 1. Light end fractionation column (LEF) Liquid from HP & LP separator under level control LIC-1301 & LIC 1501 (cascaded with flow) after exchange of cold in feed gas chiller and then fed to LEF column(40-C-401) on 9th tray. The column has a total of 40 valves trays. The column operates at a pressure of 28.2kg/cm 2g at the top. Reflux is generated by condensing part of overhead vapors in LEF Condenser (40-E-406) by using LP separator overhead vapors and fed to the column top by reflux pump (40-P-401A/B) under flow control. Reflux drum level is controlled by LIC/FIC-2001 cascade acting on the reflux flow to the column. Temperature at the inlet of the LEF reflux drum is controlled by bypassing LEF condenser and hence controlling condensation of LEF column overhead vapor. In case of lower condensing temperatures, a split range control bypasses cold lean gas from LP separator passing through LEF column condenser. Lean gas is generated at the LEF column overhead vapor with main constituents of methane, ethane. Cold from uncondensed LEF column overhead vapors is recovered in Feed gas chiller and the gas is then used for regeneration of feed gas dryers. Thermosiphon type LEF column Reboiler (40-E-407) is provided at LEF column bottom using LP steam. Steam flow to reboiler is controlled by 39th tray temperature. Liquid from LEF column bottoms is withdrawn under LIC-1904/FIC-1901 cascade at approximately 97 degree Celsius and fed to LPG column (40-C-402). Steam Condensate from LEF column bottom reboiler is routed to steam condensate recovery system within ISBL under level control of reboiler condensate pot (40-V-404).
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2. LPG column Bottom liquid from LEF column is taken to LPG column (40-C-402) on the 22nd tray. This column has 52 valve trays and is designed to separate LPG (propane and butane) from heavier components. The column is operated at a pressure of 15kg/cm2g at the top. The pressure is maintained by varying surface area of LPG column condenser. LPG product is withdrawn as overhead liquid product from Reflux Drum (40-V-408) under level control (LIC-2201) and sent to existing LPG storage. Reflux is sent back to column through LPG column Reflux Pumps (40-P-402A/B), under flow control (FIC-2201). The column bottom has a thermosiphon type Reboiler (40-E-409) using MP steam.Steam flow to reboiler is controlled by a 51st tray temperature. NGL from column bottom is cooled to 40 degree Celsius by water cooler (40-E-410) and then sent to storage under level control (LIC-2102) of LPG column bottoms. Provision for diverting off-sped NGL to the crude stabilization unit has also been kept, in case NGL rundown temperature goes higher than 50 degree Celsius due to fouling of rundown cooler or LPG column temperature going down due to any operational failure. Steam condensate from LPG column bottom reboiler is routed to steam condensate recover system with ISBL under level control of reboiler condensate pot (40-V-409).
4.1.2 Process flow diagram (PFDs) It is designed to recover maximum LPG from sweetened gas coming from gas Sweetening units and produce value added products viz. LPG, NGL & Lean gas. LPG recovery unit consists of feed gas compression and pre-cooling, Feed Gas drying and regeneration, Chill down and expansion, Lean gas compression, Propane refrigeration system and Fractionating system. PFD of the process is shown on the next page:
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Figure 24 PFD of LPG recovery Unit.

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4.1.3 PIPING AND INSTRUMENTATION DIAGRAM (P&IDs) Here are P&IDs of two Fractionating Columns: 3. 40-C-401
Figure 25 P&ID of 40-C-401 fractionating column
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4. 40-C-402
Figure 26 P&ID of 40-C-402 fractionating column

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4.2 Working proportions

4.2.1 Capacity The unit is designed to process a total of 5.65 MMSCMD of sweet gas.
4.2.2 On stream factor No of operating days per year: 330
4.2.3 Turndown capacity It is 50% of designed capacity.
4.2.4 Feed specifications It has been designed for the following composition of sweet gas from GSU:
Table 2 Feed specification of LPG unit

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4.2.5 Product specification The specifications of LPG, NGL & Lean gas from the unit have been considered as:
Table 3 Specification of LPG, NGL & Lean gas
4.2.6 Battery limit conditions The battery limit temperature and pressure conditions for the incoming and outgoing process streams are indicated below:
Table 4 Battery limit conditions

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4.3 Designing and its calculations

4.3.1 PFDs As done in section 4.1.2
4.3.2 P&IDs Main P&ID of any column or reboiler consist of all the piping and instrument related information so as to be circulated within both departments- Piping and Instrumentation. Since I am allotted PIPING task, I deduced that official P&ID of column 40-C401 and 40-C-402 to the extent such that it is of use for piping only. All these changes were done in AUTOCAD 2012 version and PDF files of them are shown below: 1. 40-C-402
Figure 27 P&ID of LPG column 40-C-402 after Alterations

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2. 40-C-401
Figure 28 P&ID of LEF Column 40-C-401 after Alterations
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4.3.3 Elevations of LPG & LEF column 1. 40-C-402 LPG column
Figure 29 ELEVATION of LPG COLUMN 40-C-402
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2. 40-C-401 LEF COLUMN
Figure 30 ELEVATION OF LEF COLUMN 40-C-401
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4.3.4 MTO of 40-C-402
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Table 5 MTO of 40-C-402 COLUMN
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4.3.5 Pipe thickness calculation for Spec B1A Pipe wall thickness calculation in accordance with ASME B 31.3 paragraph 304.1 (A) Nomenclature tm = Minimum required thickness, including mechanical, corrosion and erosion allowance,(mm) t = Pressure design thickness, (mm) c = the sum of mechanical allowance (thread or groove depth) plus corrosion and erosion allowance, (mm) P = Internal design gauge pressure, (N/mm2) D = outside diameter of pipe, (mm) E = Quality factor from table A-1A or A-1B S = Stress value for material from table A-1, (Ksi) Y = Coefficient from table 304.1.1, valid for t<D/6 and for materials shown MT = Manufacturing tolerance from material Specification Tm = Minimum required thickness including manufacturing tolerances (B) Calculation Equations t = P*D/(2(S*E+P*Y)) tm = t + c Tm = tm/(1-(MT/100)), where MT expressed as % or Tm = tm + MT, where MT expressed in mm
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Table 6 PIPE THICKNESS CALCULATION FOR SPEC B1A (D<14)
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Table 7 PIPE THICKNESS CALCULATION FOR SPEC B1A (D>14)
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4.3.6 GAD of LPG & LEF column
Figure 31 GAD of LPG & LEF COLUMN
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4.3.7 Isometric of line no 1.5-SL-40-1904-D1A-IH
Figure 32 ISOMETRIC OF LINE NO 1.5-SL-40-1904-D1A-IH
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CHAPTER 5: SUMMARY AND CONCLUSION

In Oil and Gas industry, in order to setup a plant PIPING plays a critical role. Fluid is transferred through pipes between different and within processing units. Our project is based on piping of a sub unit of LPG Recovery plant in ONGC, URAN. For piping, in this project as well as other units; elementary steps are almost same and are mentioned below: 1. 2. 3. 4. 5. 6. 7. PFDs and Descriptions of each unit. Multiple P&IDs of single PFD showing detailed description of each Equipment. Mechanical Data Sheets (MDS) for every equipment. MTOs for each processing unit. GADs for whole unit. Modeling of plant through software like PDS/PDMS. Extraction of isometrics.
After this designing section, these isometrics are issued for construction sites. And the modeling is done in accordance with following standards: 1. OISD 118. 2. ASME B16.5, B31.3 & B36.10. Before Modeling, calculations are done for the elevations of equipments, pipe diameter, pipe thickness and nozzle orientation.
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BIBLIOGRAPHY
1. 2. 3. 4. http://en.wikipedia.org/wiki/Oil_refinery http://pipingdesigners.com/Training%20-%20section%202b.htm http://www.epcpj.com/check-list-for-piping-material-take-off/ http://wiki.answers.com/Q/What_is_the_difference_between_Material_take_off_and_ Bill_of_materials_in_piping 5. http://www.wermac.org/documents/isometric.html 6. http://www.wermac.org/documents/pid.html 7. http://www.enggcyclopedia.com/2011/08/general-arrangement-ga-drawings-piping/ 8. http://www.engineeringtoolbox.com/pfd-process-flow-diagram-d_465.html 9. OISD Guidelines Table 1 & Table 2. 10. Product Material Specification (PMS) by ONGC. 11. Piping Design Basis 6812-00-16-43-DB-01 by EIL. 12. ASME standards B16.5, B31.3, and B36.10.
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Appendices
Appendix i: Legend Sheet
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Appendix ii: Product Material Specification (PMS) B1A
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B2A
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Appendix iii: ASME B16.5
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ASME B31.3
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ASME B36.10M
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LPG-LEF DISTILLATION UNIT DESIGN

1.1 About Larson and Toubro

1.1.1 Companys Vision:

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

1.2 About Project

Gas Sweetening Unit (GSUs)

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

CHAPTER 2: LITERATURE OVERVIEW

2.1 Refinery Process

LPG-LEF DISTILLATION UNIT DESIGN

Figure 4 Refinery Flow diagrams and Petroleum products

LPG-LEF DISTILLATION UNIT DESIGN

2.2 Process Flow Diagrams (PFDs)

LPG-LEF DISTILLATION UNIT DESIGN

Figure 5 Typical Example of PFD

LPG-LEF DISTILLATION UNIT DESIGN

2.3 Piping and Instrumentation Diagrams (P&IDs)

Figure 6 Typical P&ID

LPG-LEF DISTILLATION UNIT DESIGN

2.4 Material Take off Sheets (MTOs)

Table 1 Typical MTO

LPG-LEF DISTILLATION UNIT DESIGN

2.5 General Arrangement Drawings (GADs)

Figure 7 Typical GAD

LPG-LEF DISTILLATION UNIT DESIGN

Figure 8 Different views in Piping

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

CHAPTER 3: BASICS OF PIPING

3.1 Categories of Piping Piping is divided into three categories:

3.2 Pipe Terminologies and Definitions

LPG-LEF DISTILLATION UNIT DESIGN

3.3 Standard Piping Materials

LPG-LEF DISTILLATION UNIT DESIGN

3.4 Piping Components

Figure 10 Weld Neck Flange

LPG-LEF DISTILLATION UNIT DESIGN

Figure 12 Slip-On Flange

LPG-LEF DISTILLATION UNIT DESIGN

Figure 13 Threaded Flange

Figure 14 Lap Joint Flange

LPG-LEF DISTILLATION UNIT DESIGN

Figure 15 Elbow 3.4.3 Tees

LPG-LEF DISTILLATION UNIT DESIGN

Figure 18 Swage nipples

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

3.4.10 Full Couplings and Threaded Unions

Figure 20 Full Couplings

LPG-LEF DISTILLATION UNIT DESIGN

3.5.3 Types of valves

Figure 21 Types of Valves

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

LPG-LEF DISTILLATION UNIT DESIGN

3.7 Piping nomenclature

L&T Summer Training Report

L&T Summer Training Report