Transcript of "Basic piping"

1. 1. Piping Fundamentals – For Fresher Engineers 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 Critical piping system consideration.
Pipe Stress Analysis. Pipe Supports
2. 2. 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
3. 3. 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 the other two tanks. We will need to connect
pipes to transfer the fluids from Tank-1 to Tank-2 and Tank-3 LET US BRING THE
PIPES .
4. 4. We have just brought the pipes, now we need to solve some more problems. Pipes
are all straight pieces. To solve these problems we need the pipe components, which
are called PIPE FITTINGS We need some branch connections We need some bend
connections Even some pipes are of different sizes!
5. 5. 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. We now have to complete the end connections. These, in piping
term, we call TERMINAL CONNECTIONS. Anyway, the pipes and fittings are in
place, but the ends are yet to be joined with the Tank nozzles.
6. 6. 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 To control the
flow in a pipe line we need to fit a special component. That is called - VALVE These
are flanged joints This is a welded joint
7. 7. 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
8. 8. Here we see a more or less functional piping system, with valves and strainer
installed. Let us now investigate some aspects of pipe flexibility. In such case we need
to fit a flexible pipe component at that location, which is called an EXPANSION
JOINT If this tank nozzle expands, when the tank is hot.
9. 9. 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.
10. 10. There are various types instruments to measure various parameters. Also there are
specific criteria for installation of various pipe line instruments. Next we shall look
into how to SUPPORT the pipe/and it’s components.
11. 11. 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
12. 14. <ul><li>We have just completed a pipe line design. </li></ul><ul><li>We shall
rewind and check how it is really done in practice. </li></ul><ul><li>First the flow
scheme is planned, 1) What, 2) From what point, 3) To which point
 </li></ul><ul><li>Pipe sizes are selected, pipe material and pipe wall thickness are
selected. </li></ul><ul><li>Types of Valves are planned </li></ul><ul><li>Also the
types of instruments required are planned </li></ul><ul><li>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 SPP&ID software. </li></ul><ul><li>By this
time you have already come to know that while we prepare P&IDs in SPP&ID, we
enter all the pipe lines system information in the drawing. </li></ul><ul><li>So the
SPP&ID drawing is an Intelligent drawing which under it’s surface carries all the
information about a pipe like, Pipe size, Flowing Fluid, etc. </li></ul><ul><li>Let us
see a P&ID prepared in SPP&ID </li></ul>
13. 16. This is screen picture of P&ID made by SPP&ID If we click on any line it will
show the Data embedded.
14. 17. After the P&ID is ready we start the layout work. Here we carryout pipe routing /
layout in Virtual 3D environment. We use PDS 3D software to route piping in the
Plant virtual 3D space . We call this as piping modeling or physical design.
<ul><li>While development of piping layout we have to consider the following
</li></ul><ul><li>Piping from source to destination should be as short as possible
with minimum change in direction. </li></ul><ul><li>Should not hinder any normal
passage way. Also should not encroach any equipment maintenance space.
</li></ul>Preferable Not Preferable
15. 18. <ul><li>While carrying out pipe routing we also need to consider the following
</li></ul><ul><li>Valves, strainers, instruments on the pipe should be easily
accessible. </li></ul><ul><li>If needed separate ACCESS PLATFORMS to be
provided to facilitate these. </li></ul><ul><li>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.
</li></ul><ul><li>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.
</li></ul><ul><li>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. </li></ul>Example of Straight length requirement for Flow
Orifice
16. 19. <ul><li>Also arrangement is kept in the pipeline so that liquid can be drained out
if required. </li></ul><ul><li>To achieve this a DRAIN connection with Valve is
provided at the lowest point of the pipeline </li></ul><ul><li>Pipes are also slopped
towards low points. </li></ul><ul><li>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. </li></ul><ul><li>To achieve this a VENT connection with Valve is provided
at the top most point of the pipeline. </li></ul>Let us look into typical Vent and Drain
arrangement in a pipeline PIPELINE DRAINS AND VENTS
17. 20. Let us have a look into a piping model done by PDS 3D This is a 3D model of
Feed water line along with pumps and other accessories
18. 21. INSULATION <ul><li>INSULATION - When hot fluid flows through pipe then
generally pipe is insulated. </li></ul><ul><li>There are two primary reasons for
insulating the pipe carrying hot fluid . </li></ul><ul><li>Containing the heat inside
the pipe. Insulation preserves the heat of the fluid. It is called Hot Insulation
</li></ul><ul><li>Personnel safety, so that people do not get burn injury by touching
hot surface of pipe. It is called Personnel Protection Insulation
</li></ul><ul><li>Cold pipes are also insulated </li></ul><ul><li>Cold or chilled
 fluid carrying pipes are insulated to prevent heating of cold fluid from outside. It is
called Cold Insulation . </li></ul><ul><li>Some times cold pipes are insulated to
prevent condensation of atmospheric water vapor on pipe surface. It is called Anti-
Sweat Insulation . </li></ul><ul><li>Other types of Insulation
</li></ul><ul><li>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 .
</li></ul><ul><li>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 . </li></ul>
19. 22. 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
20. 23. Piping Calculations Pipe Sizing Calculation - to select required pipe diameter
based on velocity and pressure drop. Find out Flow 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
Increase Pipe Size NO Pipe Material Selection - to select appropriate pipe material
based on flowing fluid property. Find out type of Fluid 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 : Material is selected per
past experience with cost in mind and per material listed in design code. If material is
not listed in code we may select next suitable material listed. Find out Fluid Temp. &
Pressure Pipe Thickness Selection - to select appropriate pipe thickness based on
flowing fluid property. Select Mat. & Diameter as above Decide on Corrosion
allowance Calc. Pipe Thickness per Code Find out Fluid Temp. & Pressure
21. 24. CRITICAL PIPING <ul><li>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. </li></ul><ul><li>These pipelines are call the CRITICAL PIPING .
</li></ul><ul><li>Very special care are taken for design of these piping.
</li></ul><ul><li>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.
</li></ul><ul><li>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.
</li></ul><ul><li>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. </li></ul><ul><li>Also there should
be enough flexibility in these pipe routing so that high loads are not transferred to the
nozzles of Turbine or Pumps </li></ul><ul><li>There are many recognized
international codes which lay down guide lines and mandatory requirements for
design of such piping. </li></ul><ul><li>The most important codes used by power
plant piping engineers are </li></ul><ul><ul><li>ASME ANSI B31.1 - Power Piping
Code & IBR - the Indian Boiler Regulation </li></ul></ul>
22. 25. PIPE STRESS ANALYSIS <ul><li>Pipe Stress Analysis </li></ul><ul><li>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. </li></ul><ul><li>We
need to check and confirm the pipe is not going to fail with these loading.
</li></ul><ul><li>This process of checking the stress developed in the piping due to
various loading is called Pipe Stress Analysis/Flexibility analysis .
</li></ul><ul><li>In the process of Analysis we apply various postulated loading on
the pipe and find out the stress resulted from these loading. </li></ul><ul><li>Then
we check with governing codes if those stresses generated are acceptable or not.
</li></ul><ul><li>We check support load & movement for various loading condition.
</li></ul><ul><li>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. </li></ul><ul><li>We also find out the
pipe growth due to change in temperature and need to keep the movement of pipe
within acceptable limits. </li></ul><ul><li>Pipe Stress Analysis is an Interactive and
Iterative process. Each step is checked </li></ul><ul><li>If a check fails we have to
go back, modify the layout and restart the analysis. </li></ul>
23. 26. PIPE STRESS ANALYSIS <ul><li>Inputs </li></ul><ul><li>Geometric layout
of Pipe </li></ul><ul><li>Pipe supporting configuration </li></ul><ul><li>Pipe
Diameter and Thickness </li></ul><ul><li>Pressure inside Pipe
</li></ul><ul><li>Cold and Hot temperatures of Pipe </li></ul><ul><li>Weight of
Pipe and insulation </li></ul><ul><li>Weight of carrying Fluid
</li></ul><ul><li>Pipe material Property (Young’s Modulus, Thermal Expansion
Coefficient) </li></ul><ul><li>Thrust on pipe due to blowing wind.
</li></ul><ul><li>Thrust on pipe due to earthquake </li></ul><ul><li>Load of Snow
on pipe </li></ul><ul><li>Any transient loading like Steam Hammer load
</li></ul><ul><li>Any other load on the piping </li></ul><ul><li>Tools we use
</li></ul><ul><li>PIPSYS - is an integrated pipe stress analysis module of PLADES
2000 </li></ul><ul><li>CEASER - Commercial Piping analysis software
</li></ul><ul><li>There are many other commercial software available
</li></ul><ul><li>Outputs </li></ul><ul><li>Stress of the pipe at various loading
conditions </li></ul><ul><li>Load at various supports and restrains.
</li></ul><ul><li>Movement of pipe at support locations </li></ul><ul><li>Pipe
terminal point loading. </li></ul><ul><li>Codes and Standards </li></ul><ul><li>In
general Power Plant Piping have to comply stipulations of ASME ANSI B31.1
</li></ul><ul><li>In India Power cycle Piping to comply IBR code requirements.
</li></ul>
24. 27. Types of Pipe Supports <ul><li>In the beginning of this discussion we talked
about various types of pipe supports. Here is some elaboration
</li></ul><ul><li>There are three general types </li></ul><ul><ul><li>Rigid type
(no flexibility in the direction of restrain) </li></ul></ul><ul><ul><li>Spring type
(Allows pipe movement in direction of loading)
</li></ul></ul><ul><ul><li>Dynamic Support (Degree of restrain depends on
acceleration of load) </li></ul></ul><ul><li>There are two types of spring support
</li></ul><ul><ul><li>Variable load type, here support load changes as the pipe
moves. </li></ul></ul><ul><ul><li>Constant load support, the load remains constant
within some range of movement . </li></ul></ul>Constant Load Spring Variable
Spring Rigid Hanger Rigid Support Dynamic Support, Snubber Rigid Support
25. 28. Some Special Considerations for Piping <ul><li>When pipes are routed UNDER
GROUND (Buried) following points to be kept in mind :
 </li></ul><ul><ul><li>Minimum pipe size to be routed under ground shall be not
less than1 inch. </li></ul></ul><ul><ul><li>Avoid flange joint in U/G piping.
</li></ul></ul><ul><ul><li>Keep in mind if pipe leaks U/G, it will be difficult to
detect, so avoid U/G routing of pipe carrying hazardous fluid.
</li></ul></ul><ul><ul><li>Pipe to be laid below Frost Zone at areas where ambient
temperature goes below freezing . </li></ul></ul><ul><ul><li>U/G, Buried piping
should be properly protected from corrosion. </li></ul></ul><ul><ul><ul><li>Pipe
may be properly wrapped and coated to prevent corrosion.
</li></ul></ul></ul><ul><ul><ul><li>Or U/G piping be protected by using Cathodic
protection. </li></ul></ul></ul><ul><li>Freeze Protection of outdoor Piping :
</li></ul><ul><ul><li>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. </li></ul></ul><ul><ul><li>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.
</li></ul></ul><ul><ul><li>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. </li></ul></ul><ul><ul><li>Heat tracing can
also be done by winding Steam tubes around main pipes. </li></ul></ul>
26. 29. We have come to the End of Session. Hope you have gathered the fundamentals
on the subject of Piping
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