E&C — HR presents Certificate Course on Piping Engineering Batch IV >Date: 08th — 215 January 2008 >Timing: 8.30 am — 5.00 pm >Venue: * 4% Floor, Auditorium, EPC Block Powai * Computer Centre, IIT Bombay > Faculty: * Piping Cell, IIT Bombay. * In-house Functional experts from LTEM iE to update expertise in EPC :ARKADIP. Sina Larren bubro dude db Lamour b Toulro~ Senge Lundlt oth. Foudobad (%{asses reuaro Line ee 8th - 21st January 2008 Venue - Audito: Ath Floor, EPC Block , Powai campus [ Topie Faculty [Day tan, 2008 Tuestay =] os:30 - 9.00 [Fea & Snacks Reqinanwion [09:00 09:05 [Welcome Introduction MT. Rane - - Yogi Sriram: “| oo:0s 05:15 inauguration & Context Setting D.K, Gupta . Seecamae Pik 09:15 09.30 [Sci Taoducton by Parcs r 9.30 11.00 [Scope of Piping Engineering LA'S. Moar HAS 128 ng (Contd) LAS. Mohair Bas ane est = [Scope of Piping Engineer ng contd.) A.S. Moharir_ _| ss Bak = a Pipe Sizing : aS. Mohan fs Weds 08:30 09:00 [Fea & Snack = = os:00 = 11:00 |Pipe sizing fomtay ls.s. Mot a8 [Gare ean —- ——] 15-1235 [As Moharie Teas 13300 - | = 13.30 15:00 [A.S. Moharir iss — : e — ~ 15.152 1700 [Pipe siring (Tot [.s. Momare a [Day 3 Jon 10,2008 Thursday ea & Snacks | os:00- 14:00 [codes & Standards fr. N. Gopinath isons [Gate ek i [tras 1248 [Codes and Stantais(oneay T. N. Gopinath 25-30 Jom eae 13:30 15:00 Gopinath ewes 1515-7 a _ [T.N. Gopinath | [Baas 0 -] fos:30- 09:00 Tea & Snacks 7 09-00. 11-00 |riping Elements contd) : TN, Gopinath ita eet tak 11S— 1245 [Valves [T. N. Gopinath 0.90 oun 13.30-1500 [Valves (conta I. §. Gopinath [Tea trek | Valves (Contd) [EN Gopinath —] [F_N. Gopinath TN. Gopinath@ caine rope earn LES CALD Series Il -Teel Sth - 21st Janwary 2008 Ver ‘Certificate Course on Piping Engineering” - Bateh 1V ium , 4th Floor, EPC Block , Powai campus Timing aly Pot Plan [F_N. Gopinach [Fea Break _ Plot Plan (contd) [rN Gopinath [Day 6: Jan 13, 2008 Sunday [08:30 09:00 [Tea & Snacks. _ [09:00- 11:00 [Fquipment & Piping Layout [T.N. Gopinath eo 1:13 [Coffee Brak ~ - 1115-1245 [Equipment & Piping Layout (contd) [1.n. Gopinath fasts 13530 [Lunch Break 13.30: 15:00 [Equipment & Piping Layout (contd.) lr. N. Gopinath 5300-155 Fea weak ~ — 15.15 1700 [Equipment & Piping Layon [T_N. Gopinath [Day 7 : Jan 14, 2008 Monday — _ (08:30 09:00 [rea & Smacks r 09:00- 11:00 [Mechanical Design Fi [A.8. Moha [reo tras [Cofte Beak |A.S. Moharir 5 - 12:05 |Mechanical Desi 245-1330 [Lnnch break 13.30: 15:00 [Mechanical Design |A.S. Moharit fsio- isis [eaten : 15.15: 1700 [Mechanical Design Fun JA.S. Mobarir [Day 8: Jan 15, 2008 Tuesiay [08:30 09-00 [rea & Smacks (09.00 11:00 [Equipment & Piping Layout fio 1s [Gee ieak = x 115-1245 [Equipment & Piping Layout (contd..) Ir. N. Gopinath ras 1330 [Lent ek - 13.30: Pipe Under Stress [A.S. Moha i500 sis [Tea rea 15.15: 1200 [Pipe Under Stress (cont) |A.S. Mohair [Day 9 tan 16, 2008 Weunesday foasi0 09:00 [Tea & Snacks Jov.00- 13:00 [Visit o RC Mh los:00- 13:00 | Basics of Piping Engineering & 3 - D Modelling - 13.00- 1400 [Loca Drak Day 10: Jan 17, 2008 Thursday (08:50 09:00 [rea & Snacks sees ROR AAGSUEITY Cte [vivinat Pal os:00- 1x00 |Visitto RCE Muunbat Group Pe vaca [Rajesh Barigat 109:00 -13:00 [Basics of Piping Engineering & 3 - D Modelling - Group 1 IN i Daniel Is. rail 13.00 - 14.00 [Lench Break [Day 11: Fan 18, 2008 Frida Tape aT CMD wpe pe TTCLARSEN & roUBRO LinTED Eaconn CALD Series II -Technical "Cert 8th - 21st January 2008 Venue - Ai itorium , Ath EN amo” Comse on Piping Engineering" - Batch 1V loor, EPC Block , Powai campus Topie Faeuty —] Tae seas oo - 1:00 [Nove Reinorcenen lca las Pa hae Ta ease . : Itt - 1235 [NeeheReintececetcloualins (eodp fas. pat 12285 13:30 ~ [iemch Break "| 13.30 1500 [reaver Anapae fr Gopi said festa = > [as 12 fm 9,208 satay -| oso [few Sac 09:00 - 11:00 [Flexi Analysis (contd..) [T. N. Gopinath: | ia hs 115-1245 feiiity Amacom) Ns Gopinath 13.30 = 15:00 [Flexibility Analysis (contd...) 'T. N. Gopinath | 1515; 1700 [eit Anat omy oN Gonna Day 13: Jn 2, 2008 Sun - es- eae [Rese Sen [09:00 - 11: [Selection of Supports 7 - T.N. Gopinath: 100 - 1115 [Coffee Break _ tas Setection of Support com.) TEN. Gopinath i245. 13-30 Lunch Break ~ 0 Expomion ina IN Gopnan 15:15: 1700 [nckted ina IN. Gonian Day 1 Jan, 3008 Monday ack eel | sess Analysis acca Ins Pct Whe1S = 12:45 |Stress Analysis (Practical) A.S. Patil “| aan ome =] 1330-1500 fo Nok 15:00 - 15:15 [Tea Break . 15.45 : 16.45 |Quiz (Discussions and Results |A.S. Moharir 16.45 : 1700 Feedback Session |ae Certificate Course on PIPING ENGINEERING For Larsen & Toubro, Mumbai January 8" , 2008 — January 21°, 2008 Organized by Piping Engineering Cell Computer Aided Design Centre Indian Institute of Technology, Bombay Powai, Mumbai - 400 076AAO AAO AERA RRA RRR ARR ARAMA RAARAAA RAR RA ARAR AAD AT RRA Ee NL, SS SEE SL AY eas win es &PIPING ENGINEERING CELL, BIOGRAPHY OF A CHEMICAL PROCESS PROF. A. S. MOHARIR INTRODUCTION Like all living things, chemical processes and process plants have their distinct natures and features. Like us, a process functions through a complex chain of operations performed by its ‘organs (equipment) which in turn are supported by supplies through a maize of veins and arteries (pipes). Like us, they have a limited life span divided into various phascs just as we have childhood, adolescence, youth, adulthood and old age. The analogy can be stretched further. With ‘so much similarity with uss living things, why not talk of biography of a process as well? The life ‘of a chemical process, from concept to commissioning and beyond, involves almost all disciplines of engineering. So wide is the knowledge base required to walk a process through its expected life span and so intricately integrated the inputs from various specialization and decision processes are, that they make the conventional engineering disciplines such as chemical enginecring, mechanical ‘engineering, civil engineering, metallurgical engineering, etc. look attificial, A good chemical process engineer needs to have a very broad knowledge drawn from all these disciplines, ‘The idea of this biography is to take a bird’s eye view of the activities during the life cycle of a process and identify those activities, which together comprise Piping Engineering. MAJOR PHASES Major phases in the life of a chemical process can be identified as follows. Determination of techno-economic feasil Basic Engineering Detail Engineering Commissioning Normal Operation y-¢ ‘There is an explosion of investment as one goes from the first to the last phase. Normal tendency is to spend very litte initially by way of avoiding comprehensive analysis of process options ete, The recent trend is to squeeze an additional phase between techno-economic feasibility and basic engineering, called conceptual design, wherein one spends more time (and money) on analysis of available options to select the option best in some sense. Although it tends to increase expenses initially, the cost figures by the time the facility reaches normal operation phase, are reduced considerably. *Click here for better visualization of the effect of ‘working harder and smarter’ in the initial stages.A piping engineer has a major role to play from detail engineering onward. However, some appreciation of the contents of the phases involved up to basic engineering is desirable. Biography of a ChA PIPING ENGINEERING CELL, ‘TECHNO-ECONOMIC FEASIBILITY Economic gain drives industry, in general, Except perhaps during carly small scale production activities in metallurgical industry, economic gain has been a major consideration in decisions regarding the choice and scale of any production activity. Safety and pollution considerations as well as social issues seem to be gaining importance. In a way these are also enforced through explicit or implicit profit governing means such as rewards/penalties, All said and done, such profit motives have led to great technological innovations. Techno-economic feasibility study evaluates any commercial scale venture from these angles. A technically feasible and economically viable process secs the light of the day.For new products, technical feasibility is an important first aspect to study. It comprises of two parts as follows. Chemical path feasibility Engineering/Technological feasibility Chemical path feasibility essentially checks whether a suitable chemical conversion route exists to produce a chemical with desired molecular structure from available raw material. The suitability of the chemical conversion route is mainly in terms of rate and degree of conversion to desired product at manageable temperature/pressure conditionis. For more insight into these aspects, *click here, The sequence of operation which enables a kinetically and thermodynamically feasible conversion route to be exploited for production is called Block Flow Dia first diagram in the life of a process and the process can be said to be born. *Click here for more on BED. The process represented in a BFD is then evaluated for its enginecring/technological feasibility. The idea is to verify whether the current level of engineering/technological skills allow exploitation of the process on a commercial scale without exposing the men, machines and environment to undue risk. Several decisions need to be taken at this stage. ‘The contents of this step are becoming more and more involved and include the conceptual design stage in recent times. ‘One virtually thinks through the choice of equipment, important process steps, possibility of reducing dependence on extemal energy sources, reducing possible extent of damage in case of a mishap ete. *Click here for more details on engineering/technological feasibility studies including conceptual design and process synthesis. With the process synthesis task accomplished, conceptual design stage of process development is over. The various equipment have been selected and their capacities are approximately known. The capital cost and operating costs can be estimated reasonably reliably at this stage. This information coupled with the raw material availability and cost as well as the product demand and its market price help establish economic feasibility of a process.A technically feasible and economically viable process is now destined to grow further. BASIC ENGINEERING Physical/chemical operations in a process are normally carried out under harsh conditions. ‘The temperatures, pressures are cither super- or sub-ambient and the chemicals being handled could be toxic and hazardous. It must be remembered that just as it is important to know what is happening Biography of a Chemical Process 2PIPING ENGINEERING CELL inside a particular piece of equipment, it is equally important to know as to what are the implications of the happenings inside on the mechanical integrity of the confining hardware (vessels) and whether the choice of material of construction of the vessels and pipes and their mechanical design are adequate to handle normal and abnormal operations. Traditionally, chemical engineers address the design issues related to happenings inside and mechanical engineers the implications on the vessels/pipes. For the overall process safety and functioning, the issues should be treated as inseparable. That is, unfortunately, not the case. “This Phase has essentially two components; the process design and mechanical design. Process Design : Process design is basically the detailed material and energy balance calculations over each unit in a flow sheet. It also establishes the operating conditions, equipment size (not necessarily shape), utility requirement etc. The results of these chemical engineering calculations are summarized in a Process Flow Diagram (PRD).For processes which are continuous in nature and operate at steady ‘Sate, engineering simulation software are available and are extensively used. These provide simulations of performance for imposed design and operating conditions. However, one would like to decide the design and operating conditions for a given desired performance, For example, process design of a distillation column would mean caleulating the number of trays, feed tray location, sidedraw locations, reboiler and condenser duties, reflux ratio ete. A reactor design would ‘mean arriving at the reaction temperature and pressure, reactor volume, recycle rate for given conversion of feed into desired product. Simulators are used to try out various combinations of design/operating conditions os as to arrive at a combination best in some sense (quality of product, economics etc.).For example, one would try out different feed tray locations and reflux ratios on a distillation simulation and study simulated performance. A feed location, reflux ration which give desired distillate quality ete. would be a candidate design. ‘There may several such designs which serve the purpose. The best among them in some sense is the optimal design and is recommended. “Through simulation based process design of each unit in a flow sheet and of the flow shect itsclf, the entire material and energy balance calculations for the best clesign are available. This process design stage culminates in the preparation of a PFD, one of the basic documents comprising basic engineering package. ‘After the development of PED, the focus shifts on the design of pipes connecting equipments, choice and specification of instrumentation required to monitor and control process performance, instrumentation to ensure process safety such as provision of trips, alarms etc. Appropriate techniques for pipe sizing, pressure design of pipes, Hazard & Operability (HAZOP) analysis, Control System Synthesis & Design (CSSD), ete. are used. HAZOP studies and reliability data on certain equipment and pipe components (especially those having moving parts such as pumps, control valves etc.) suggest the need for standby equipment, bypass valves etc. Need to isolate dynamics of one equipment from next suggests the need for intermediate storage tanks. “These project engineering activities help develop a PED into its next ineamation, the Piping & Instrumentation Diagram (P&ID). *Click here for more information on P&ID. PED with its focus fon processes inside the equipment and P&D with its focus on accessories connecting the ‘equipment and on-line instrumentation complete the basic process documentation, With all equipment and accessories, their sizes and functioning known, a tentative plot plan showing relative placement of equipment can be prepared. PFD also helps categorize the requirement of various utilities such as cooling water, tempered water, demineralized (DM) water, steam, thermic fluid, compressed air ete. Total requirement of each utility and its distribution among the equipment hy of a Chemical Process 3PIPING ENGINEERING CELL develops a quantitative Utility Loading Diagram ete which could be used to develop Utility Flow Diagram (UFD). A full pressure drop analysis of the entire flowsheet can be done at this stage to ensure that the desired flows can indeed take place. Some individual pipe sizes or pipe sizes in a segment of flow sheet could call for some adjustment to ensure the desired flow behavior. ‘Adequacy of the pipe sizes in case of operation at lower than design capacities (tum-down conditions) and their ability to take additional load in case of throughput enhancement could also need some pipe size tuning ete. Mechanical Design : Pressure design of piping gets done during the development of P&ID. The severity of operation of each equipment and the nature of chemicals it needs to handle similarly allows choice of material of construction of each equipment. Indenting process for bought-out equipment and mechanical design of fabricated equipment can be taken up. Pressure vessel design concepts are used for this design. It would involve calculating the shell wall thickness, closure type selection and thickness calculation, selection of suitable gasket material with adequate yield stress and gasket factor, choice of gasket location (Mean gasket diameter), gasket thickness, gasket width, placement of bolts (bolt circle diameter), bolt material selection, number of bolts, diameter of bolts ete. A vessel needs to have openings to serve as inlevoutlet ports as well as for drainage, hand holes, man holes, inspection holes ete. These could be on shell or closures. The shell and closure wall thickness are designed primarily to ensure that the stresses in the walls even at weakest parts (along, welding sams) do not cross the allowable stress value even after corrosion or inspite of nonuniform plate thickness (mill tolerance), etc. When openings are cut, stresses concentrate along the edges of the opening and may exceed allowable stress value used in wall thickness calculations. Provision of cextra thickness, that is choice of a thicker wall could prove expensive. Theoretical findings that the stress concentration in the event of cutting an opening in a wall is confined within a circle of diameter double the diameter of the opening is used here to verify if provision of extra thickness in this circle around the opening can keep stresses within allowable range. Reinforcing pads are then recommended around the opening if necessary. For pressure vessels subjected to net external pressure (for example, vessels operating under sub atmospheric pressures), compressive stresses are developed. Design is more complicated here and need for stiffening rings to reduce chances of failure due to buckling needs to be checked. Spacing between stiffening rings and cross-section of a stiffening ring need to be artived at Above elaborate design steps arc lead to adequate design of not so tall vessels. Tall vessel design need to be further checked for its adequacy to withstand wind load, seismic load, eccentric load etc, “These additional loads may require enhancing vessel wall thickness anW/or provision of stiffeners to prevent buckling etc. Pressure vessel design is this quite involved. However, design procedures are very well documented in the codes and standards. Design software also exist to help develop designs which comply with accepted codes.Afer attention is paid to each and every aspect, a fabrication drawing, is issued for fabrication to begin at an early stage. Equipment fabrication is time consuming. Also in the field work, equipment necd to be installed in place quite carly so that pipe routing job can be taken up. ‘The process design and the mechanical design of pipes and vessels involves extensive chemical and mechanical engineering calculations. These calculations do not necd any data on actual site for Biography of a Chemical Process 4PIPING ENGINEERING CELL, plant location. ‘The design depends mostly on process conditions. Some aspects of mechanical design for tall vessels, such as meteorological data (wind speed) or scismic data are location dependent, but not on the actual plot of land. These calculations also do not depend on actual relative placement of equipment on the plot etc. Further evolution of the project require the Knowledge of the actual site, Site preparation work and other outdoor construction activities can begin once the site is selected. We have included further analytical aspects also in construction phase for this reason, DETAIL ENGINEERING Further analytical work needs to be done before the final blueprint of a 3-D plant layout is finalized ‘and construction begins, Some of the activities listed under the construction phase here may well be considered as belonging to the above discussed design phase itself. These are included here mainly because plant site details are a part of inputs to the decision making The choice of plant location, if such a choice exists, is governed by politico-socio-economic considerations. The basic approach to site selection is to assign weight factors to various relevant considerations and to select a site which ‘scores maximum overall points. Once the site where the process plant and associated facilities are to hosted is decided, locational factors such as topography, prevailing wind direction, neighboring site ete, are used to decide on the best plot plan. Apart from the process equipment and offsite, other requirements such as control room, fire station, hospital, weigh bridge, effluent treatment plant, ete. are allocated space on the site. The road map of the site also emerges during plot plan exercise. Care is taken to follow certain guidelines for the location of typical facilities such as dusty operations, fire bearing equipment, storage tanks, noisy operations, fire station, effluent treatment plant, etc, *Click here for some typical examples. Plot plan is science as well as art. A good engineer is one who makes the best utilization of a given plot to place his facilities. There is a separate module on Plot Plan in the notes where good engineering practices are covered in more detail. The next activity is to decide on the location of each of the equipment in the process area. A unit has its own requirement of space for erection, operation, maintenance ete, For example, a shadow area must be earmarked besides a shell and tube heat exchanger so that the tube bundle can be pulled out for maintenance. A pump must similarly have space around it s that the motor can be taken out for maintenance. Large, heavy equipment require large, non-interfering foundations. “There are process-related constraints also as follows. Distance between two equipment connected by a pipe carrying hot stream must be as less as possible to minimize heat loss. A thermosiphon reboiler must have certain barometric leg provision and should be located a certain distance below the distillation column. Suction drum should take care of NPSH requirement of a pump. For gravity flow, static head should be enough to maintain desired flow. Certain inter-unit distances have emerged based on these and similar considerations. These provide good guidelines for equipment layout. Another aspect of equipment layout is the orientation of the equipment on the slot assigned to it. It decides the nozzle orientation and hence the piping layout. It also decides the accessibility of different parts and accessories of the equipment. Actessibility, case of maintenance, implications on piping layout are the main considerations here.A piping engineer is deeply involved in plot plan and equipment layout, These are decisions which virtually freeze the parameters for Piping Layout. Equipped with a PFD, P&ID, individual equipment sizes, erection/maintenance/operation requirements, safety requirements and also requirement of critical piping (piping which is likely to Biography of a Chemical ProcessPIPING ENGINEERING CELL expand/contract significantly and/or face vibrations during operation and require additional consideration or accessories (such as expansion joints ete, to absorb pipe movement during operation), a good piping engincer relies heavily on experience and engineering sense to develop a good equipment layout, His decisions could have a bearing on the project cost as the piping requirement, which constitutes almost 25% of the capital cost of a process plant ean be favorably or adversely affected by his layout ‘After the units have been located and appropriately oriented on paper, the layout of the veins and arteries of the plant, that is the pipes have to be laid out. This activity is called Piping Layout. It is not as simple as connecting the outlet port of one equipment to the inlet port of another equipment by the shortest or most convenient route, In fact, such direct connections are exceptional. A pipe is firmly attached to the nozzles on the equipment. Equipment, by nature are fairly heavy structures and should support the weight of connected pipes, provided the pipe connections are reasonably short. For longish connections, pipe would sag under its own weight, under weight of its contents. Heavy items on pipe such as valves add to this scenario. Also, the connecting nozzles may move due to expansion/eontraction of vessels or simply settlement of vessels. The pipe would expand/eontract during operation. All these operating time happenings develop stresses in pipe wall. If not properly designed to withstand these stresses, pipe would fail during operation, Considering all loads that would come on to the pipe during operation and mitigating their effects with provisions of pipe supports, hangars, expansion joints, or rerouting of the pipe is the job of a piping engineer who does the piping layout. Weight analysis and thermal stress analysis arc important in piping layout. These can be done today using. However, analysis of the stress distribution chumed out by these software for a candidate pipe routing and modifying the route to make it safe requires a lot of experience and, knowledge. There could be several routes which are safe, Only one of these would be economical. Arriving at this is the exclusive domain of a piping engineer. Piping layout is almost the last analytical exercise in the engineering of a process. It requires as inputs a P&ID, equipment layout, piping elements pecifications, structural drawings of buildings/platforms, utility flow diagram, line list, equipment data sheets and drawings ete. Once a safe and economical layout is arrived at, a piping engineer prepares a piping general arrangement (GA) drawing showing the pipe routing associated with equipment, piping isometries and equipment nozzle orientation, With isometric drawings of all pipe routes available, a complete ‘quantification of pipe and piping elements requirement is possible. The course has a separate module on Equipment & Piping Layout.Depiction of equipment and piping layout in all its details is a major task. Normally a piping general arrangement (GA) drawing, presents a layout. Since a three dimensional layout is to be presented here in a two dimensional view, lot of symbols need to be used to represent what the piping would look like in actual three dimensional view. Details regarding piping elements (for example an elbow, tee, valve with lever ete, has to be shown on a GA. Not only this, further details as to whether the tee is butt welded, socket welded, flanged or screwed should also be indicated on a GA through choice of proper symbols. ‘The knowledge of these piping symbols, their proper interpretation and a mental recreating of a three dimensional perspective from GA is one of the major skills a piping engineer needs to possess, Without this, his preparation of GA and his interpretation of others’ GAs is going to be meaningless, Piping isometries are made out of the GA drawing. Isometric (ISO) drawings at least have the 3-D feel which GAs lack. Isometries are then used for piping stress analysis, fabrication, Biography of a Chemical Process 6PIPING ENGINEERING CELL spool drawings ete. Piping drawings make sense only if standard symbols and conventions ete. are religiously followed. Although not a subject in any conventional engineering curriculum, the fact is that piping engineers express themselves and understand each other through the language of drawings, We have a special module on Piping Drawing for you with all important tips, examples and exercises. During the detail engineering phase, there is virtually an explosion of information and detail which leads to an explosion of documents and drawings. All implementation details of activities to be taken up by mechanical, civil, electrical, instrumentation departments are documented, ‘There is a tremendous activity in the drawing office as well as in field. It is difficult to discuss all the aspects here, Coordination of all activities is normally left to the piping department. This is logical because the basic drawings/documents such as PFD, P8&ID etc. are released from here, and the final drawings/documents prepared by other departments have a direct bearing on the plant, equipment and piping layout. With all activities leading to the same goal, this coordination becomes important. ‘An integrated software platform, which serves as a repository of all information and decisions regarding a project, is becoming popular for internal consistency of detailed engineering activities ‘as well as for efficient project management. It plays a major role in effective and timely completion of projects of this complexity and criticality. ‘A software model of a 3-D layout of a process plant is gaining importance. It is replacing the conventional plastic models of plant which were necessary and useful for easy visualization and implementation. Unlike PFD, P&ID, etc., which were schematic drawings, a 3-D model is a dimensional graphic and can be made to contain all details of a envisaged plant. It can have all the data associated with a project. Apart from easy visualization, it offers checks for interference (a proposed piping layout clashing with civil structure or equipment