Power Plant Fundamental

Piping System
Piping System - What is that?
Concept - Layout Development
Piping Components & their access requirement.
Straight length requirements.
Orientation of various tapings, components, etc.
Piping Drains & Vents
Insulation.
Material & Sizing, PDT/VDT selection.
Critical piping system consideration.
Pipe Stress Analysis.
1 Pipe Supports
 Special Considerations
 Piping Designer’s Input & Output GET-DET Training Prog.,2003-Somnath Kundu
 PIPING SYSTEM
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 SYSTEM

Now we will try to understand step

by step how a piping system is
formed based on the requirements

We shall start with a plane white

sheet
 In any plant various fluids flow through pipes
from one end to other.
Now let us start with a plant where we see three
tanks.
Tank-1, Tank-2 and Tank-3
We have to transfer the content of Tank no. 1 to

This is the plane white

the other two tanks.
We will need to connect pipes to transfer the
sheet we fluidsstart
from Tank-1with
to Tank-2 and Tank-3
LET US BRING THE PIPES.
Let us start drawing a
simple piping system
 We have just brought the pipes, now we
To solve these need to solve some more problems.
problems we need the
Pipes are all straight pieces.
pipe components, are
s
which are called p ipe s!
ome size
PIPE FITTINGS e n s rent
Ev diffe
of

We need some
branch
connections

We need some bend

connections
 These are the pipe fittings,
There are various types of fittings for various
purposes, some common types are -
Elbows/Bends, Tees/Branches,
Reducers/Expanders, Couplings, Olets, etc.

Anyway, the pipes and

fittings are in place, but the
ends are yet to be joined with
the Tank nozzles.

We now have to complete the

end connections.
These, in piping term, we call

TERMINAL CONNECTIONS.
 So far this is a nice arrangement.
But there is no control over the flow from Tank-1
to other tanks.
We need some arrangement to stop the
flow if needed

These are flanged joints

This is a welded joint

To control the flow in a pipe line we

need to fit a special component.

That is called - VALVE

There are many types of valves, categorized
based on their construction and functionality,
Those are - Gate, Globe, Check, Butterfly, etc.

Other than valves another important

line component of pipe line is a filter,
which cleans out derbies from the
flowing fluid. This is called a
STRAINER
 Here we see a more or less functional piping
system, with valves and strainer installed.
Let us now investigate some aspects of pipe
flexibility.

If this tank nozzle

expands, when
the tank is hot.

In such case we need to fit a flexible

pipe component at that location,
which is called an EXPANSION
JOINT
 When some fluid is flowing in a pipe we may
also like know the parameters like, pressure,
temperature, flow rate etc. of the fluid.

To know these information we need

to install INSTRUMENTS in the
pipeline.
 There are various types instruments to measure various
Next we shall look parameters. Also there are specific criteria for installation
into how to of various pipe line instruments.
SUPPORT the
pipe/and it’s
components.
 Here are some of the pipe supporting arrangements.
There can be numerous variants. All depend on
piping designer’s preference and judgement.

Let us see some OTHER types of supports

We have just completed a pipe line design.

We shall rewind and check how it is really done in practice.

 First the flow scheme is planned,
1) What, 2) From what point, 3) To which point
 Pipe sizes are selected, pipe material and pipe wall thickness are selected.
 Types of Valves are planned
 Also the types of instruments required are planned
We represent the whole thing in a drawing which is called Piping and
Instrumentation Drawing, in short P&ID. For P&ID generation we use CADME
software.
By this time you have already come to know that while we prepare P&IDs in
CADME, we enter all the pipe lines system information in the drawing.
So the CADME drawing is an Intelligent drawing which under it’s surface carries all
the information about a pipe like, Pipe size, Flowing Fluid, etc.
Let us see a P&ID prepared in CADME
This is screen picture of
P&ID made by CADME
If we click on any line it will
show the Data embedded.
These are the embedded
data of this line
Let us look in to a simple P&ID for understanding of P&IDs.

This is part
P&ID for DM
water transfer
system
Click to see Iso
After the P&ID is ready we start the layout work.
Here we carryout pipe routing / layout in Virtual 3D environment.

We use PDWB software to route piping in the Plant virtual 3D space.

We call this as piping modeling or physical design.
While development of piping layout we have to consider the following
 Piping from source to destination should be as short as possible with minimum
change in direction.
 Should not hinder any normal passage way. Also should not encroach any
equipment maintenance space.

Not Preferable

Preferable
While carrying out pipe routing we also need to consider the following
 Valves, strainers, instruments on the pipe should be easily accessible.
 If needed separate ACCESS PLATFORMS to be provided to facilitate these.
 Desired location and orientation of valves / instruments and other pipe
components are to be checked and maintained, like some valves or strainers
can only be installed in horizontal position.
 Specific requirements for instrument installation to be checked, like
temperature gauge can not be installed in pipe which is less than 4 inch in size.
 Specific requirements of STRAIGHT LENGTH of pipe for some components to
be maintained, like for flow orifice we need to provide 15 times diameter
straight pipe length at upstream of orifice and 5 times diameter straight at down
stream of orifice.

Example of Straight length requirement for Flow Orifice

 For Pipeline which shall carry liquid, we have to make sure that all air is
allowed to vent out of the line when the line is filled with liquid.
 To achieve this a VENT connection with Valve is provided at the top most point
of the pipeline.
 Also arrangement is kept in the
pipeline so that liquid can be
drained out if required.
 To achieve this a DRAIN
connection with Valve is provided
at the lowest point of the pipeline
 Pipes are also slopped
towards low points.

Let us look
into typical
Vent and
Drain
arrangement Pipe line Vents
in a pipeline and Drains
Let us have a look into a piping model done by PDWB
The Term PDWB stands for Piping Design Work Bench
This is a PDWB
model of Feed
water line along
with pumps and
other accessories
Let
Let us
uslook
lookin
into
toaaPiping
Piping Isometric Drawing
Isometric Drawing
From the Piping 3D Model
From
we the
create thePiping 3D Model
Piping Isometric we create the Piping Isometric drawings.
drawings.
These piping isometric drawings are used to fabricate and erect the piping
These isometric drawings
at job site.
are used to fabricate
and erect the piping
at job site.

This is part
Isometric for DM
water transfer
system

Click to see P&ID

INSULATION - When hot fluid flows through pipe then generally pipe is
insulated.
There are two primary reasons for insulating the pipe carrying hot fluid.
 Containing the heat inside the pipe. Insulation preserves the heat of the fluid. It
is called Hot Insulation
 Personnel safety, so that people do not get burn injury by touching hot surface
of pipe.
Cold pipesItare
is called Personnel Protection Insulation
also insulated
 Cold or chilled fluid carrying pipes are insulated to prevent heating of cold fluid
from outside. It is called Cold Insulation.
 Some times cold pipes are insulated to prevent condensation of atmospheric
water vapor on pipe surface. It is called Anti-Sweat Insulation.
Other types of Insulation
 When gas flows through pipes at high velocity, it creates noise. In such cases
pipes are insulated to reduce noise. It is called Acoustic Insulation.
 Some times pipe and it’s content are heated from outside, by heat tracing
element. In that case pipe along with heat tracing element are insulated to
conserve the heat of the tracer. It is called Heat Tracing Insulation.
INSULATION MATERIAL - The insulating material should be bad conductor of heat.
There are two basic categories
1) Fibrous Material, which has large voids full of air between fibers - Cork, Glass Wool,
Mineral Wool, Organic Fibers. Note stagnant air is a bad conductor.
2) Cellular Material, which has closed void cells full or air - Calcium Silicate, Cellular
Glass (Foam Glass), Polyurethane Foam (PUF), Polystyrene (Thermocol), etc.
Some times Cast material like Cement Plaster or Plaster of Paris are also used.
INSULATION CLADDING - Insulation materials are generally soft or fragile. So the
outer surface of insulation are protected with Aluminum sheet or GI sheet
cladding.

Have a look at how

pipes are insulated,
and general
components of
insulation
 Pipe Material Selection - to select appropriate pipe material based on flowing fluid property.

Find out type Find out Check Pipe Select suitable Check Mat. YES Pipe
of Fluid Fluid Temp. life Material per Listed in Material
flowing & Pressure Expectancy practice (Note-1) Design Code OK

NO
Note-1 : Material is selected per past experience with cost in
mind and per material listed in design code. If material is See Note-
not listed in code we may select next suitable material
listed.
1

Pipe Sizing Calculation - to select required pipe diameter based on velocity and pressure drop.

Find out Check Velocity Calc. flow area Calc. Press. Check Press. YES Pipe
Flow volume Allowable per required and Drop for that Drop meets Size
per second second Pipe size Pipe size Press. Budget OK

NO
Increase
Pipe Size

Pipe Thickness Selection - to select appropriate pipe thickness based on flowing fluid property.

Select Mat. Find out Decide on Calc. Pipe Check if S&L YES Selected
& Diameter Fluid Temp. Corrosion Thickness per PDT matches S&L PDT
as above & Pressure allowance Code (Note-2) requirement for Project

Note-2 : S&L has a standardized sets of piping materials suitable for various
NO
fluids and various service conditions, These are call - Piping Design Create new Created
Table (PDT). If calculated pipe thickness do not match with standard PDT for new PDT
PDT, Project Specific PDT are created with PDTS software. Project for Project
Piping Design Table and Valve Design Table
S&L has standardized sets of pipe and valves grouped based of various application.
These sets are call Piping Design Table (PDT) for pipes and fittings, and Valve Design
Table (VDT) for valves.

These Tables with all their physical data are consolidated in the PLADES 2000
Database.
When we create piping 3D model by using PDWB software all Pipe and Valve data are
fetched from Database and automatically inserted in the piping model based on the
PDT selected.
While we select pipe or valve material for any intended service we try to select the best
suited S&L PDT already available in the Database.
If in any case we can not find a suitable match we have to create a new project specific
PDT or VDT.
This creation of PDT and VDT is done through PDTS software.
The created design table is reviewed and approved by authorized person.
As it is approved PLADES Database is updated, and the NEW PDT can be used in
generation of piping model.
This is an example of
project specific PDT
 In Power plant there are some piping which carries steam at high pressure and
temperature. And also there are piping which carries water at High pressure.
These pipes carries the main cycle steam and water of the steam power plant.
 These pipelines are call the CRITICAL PIPING.
 Very special care are taken for design of these piping.
 First the pipe material selection for such piping is very important as it has to
withstand the high pressure and may be also high temperature.
 As these pipes carry the main system fluid of the power plant, they are given
the right of way, and routed at beginning of the overall plant layout.
 Steam pipes run at very high temperature and the hot pipes expand. We have to
built in flexibility in the high temperature pipe routing so that the expansion
force is absorbed within the piping.
 Also there should be enough flexibility in these pipe routing so that high loads
are not transferred to the nozzles of Turbine or Pumps
 There are many recognized international codes which lay down guide lines and
mandatory requirements for design of such piping.
 The most important codes used by power plant piping engineers are
 ASME ANSI B31.1- Power Piping Code & IBR - the Indian Boiler Regulation
Pipe Stress Analysis
 We have already seen that some of the pipes are subjected to high pressure
and high temperature. Also pipes carry the load of the flowing fluid.
 We need to check and confirm the pipe is not going to fail with these loading.
 This process of checking the stress developed in the piping due to various
loading is called Pipe Stress Analysis/Flexibility analysis.
 In the process of Analysis we apply various postulated loading on the pipe and
find out the stress resulted from these loading.
 Then we check with governing codes if those stresses generated are
acceptable or not.
 We check support load & movement for various loading condition.
 We also check out the terminal point loading generated from pipe to the
equipment connected to the pipe. This loading are to be within acceptable
limits of the equipment suggested by the vendors.
 We also find out the pipe growth due to change in temperature and need to
keep the movement of pipe within acceptable limits.
 Pipe Stress Analysis is an Interactive and Iterative process. Each step is
checked
 If a check fails we have to go back, modify the layout and restart the analysis.
 PIPE STRESS ANALYSIS
Inputs
 Geometric layout of Pipe
 Pipe supporting configuration
 Pipe Diameter and Thickness
 Pressure inside Pipe
 Cold and Hot temperatures of Pipe
 Weight of Pipe and insulation
 Weight of carrying Fluid
 Pipe material Property (Young’s Modulus,
Thermal Expansion Coefficient)
 Thrust on pipe due to blowing wind.
 Thrust on pipe due to earthquake
 Load of Snow on pipe
 Any transient loading like Steam Hammer
load
 Any other load on the piping
Tools we use
 PIPSYS - is an integrated pipe stress
analysis module of PLADES 2000
 CEASER - Commercial Piping analysis
software
 There are many other commercial software
available
Outputs
 Stress of the pipe at various loading
conditions
 Load at various supports and restrains.
 Movement of pipe at support locations
 Pipe terminal point loading.
Codes and Standards
 In general Power Plant Piping have to
comply stipulations of ASME ANSI B31.1
 In India Power cycle Piping to comply IBR
code requirements.
 PIPSYS - the analysis module of PLADES 2000

It is a very powerful and flexible,

integrated stress analysis
module of PLADES 2000.
We work in PIPSYS in close
interaction with PDWB piping
Models.
Here are some of the Screen
views

Geometry Plot screen - It

shows the model geometry

Opening screen - It has a Nick

name - The Blue Screen
 Types of Pipe Supports
In the beginning of this discussion we
Constant Load Spring
talked about various types of pipe
supports. Here is some elaboration
 There are three general types
 Rigid type (no flexibility in the
direction of restrain) Variable Spring

 Spring type (Allows pipe

movement in direction of loading)
 Dynamic Support (Degree of
restrain depends on acceleration
of load)

Rigid Support
Rigid Hanger
 There are two types of spring
support
 Variable load type, here support
load changes as the pipe moves.
 Constant load support, the load
Dynamic Support,
remains constant within some Snubber
range of movement.
Rigid Support
 Some Typical Pipe Support Drawings
Here is some typical Pipe support drawings showing some typical vendor supplied
component numbers. (See Support Catalogues in G drive g:\snl\techdocs)
 Some Pipe Support Hardware DetaIs
Here is some typical Pipe support hardware Pictorial views
 Some Special Considerations for Piping
When pipes are routed UNDER GROUND (Buried) following points to be kept in mind:
 Minimum pipe size to be routed under ground shall be not less than 1 inch.
 Avoid flange joint in U/G piping.
 Keep in mind if pipe leaks U/G, it will be difficult to detect, so avoid U/G routing of pipe
carrying hazardous fluid.
 Pipe to be laid below Frost Zone at areas where ambient temperature goes below freezing.
 U/G, Buried piping should be properly protected from corrosion.
 Pipe may be properly 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 below freezing there is a possibility that
the liquid content of pipe may freeze while the plant is under shut down.
 For similar case pipes are wrapped with heat tracing elements to maintain the content
temperature above freezing (around 4 deg. C) even when the ambient temp. is below
freezing.
 Electric Heat tracing is done by wrapping electric coil around pipe, which turns on as the
ambient temperature goes down. Pipes are insulated over the heat tracing coils.
 Heat tracing can also be done by winding Steam tubes around main pipes.
 Piping Designer’s Input & Output
INPUTS TO PIPING DESIGNER OUTPUT OF PIPING DESIGNER
From Process To Process
What Fluid Final Pipe Size and Pressure class
From Where to Where. Piping system Material
Pressure, Temp. and Flow rate. To Project
Type of Flow control. Plant Interface drawing
From Project Interface with existing facility
What Project Specific To Mechanical
Requirements. Pipe layout both A/G and U/G
Any existing facility or U/G work Equipment terminal Loading
From Mechanical To Civil
Equipment Locations and terminal Locations of Pipe supports
parameters Pipe support loading to
From Civil foundations and structures
Locations of foundations and Wall Penetrations
structures To C&I
From C&I Locations instruments, control
Types of control and instrument valves on piping isometrics
installation, tapping requirements To Electrical
From Electrical Pipe layouts both A/G and U/G to
Locations of electrical equipment, match cable, duct bank routing
cable tray and bus ducts Motor operated valve locations
 Congratulations

!!!

We have come to the

End of Session for Piping

Hope you have gathered enough knowledge

to talk intelligently

on the subject of piping

and also start work on piping