equipmentandpiping1.ppt

8/20/2019 EquipmentandPiping1.ppt

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EQUIPMENT & PIPING LAYOUT

T.N. Gopinath


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It is very appropriate to say that the Equipment and

Piping layout design is an ART and not a

SCIENCE. There is not a single formula available

for the design of Equipment and Piping layout. The

equipment layout design an be as rational as the

mathematis of fluid flo! but !ith the language of

pro"etive geometry. #athematis is abstrat$

geometry is visual. All engineering ourses havemathematis$ fe! have the sub"et of pro"etive

geometry but none has layout design


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%o!ever& systemati methods and proedures an be

developed from engineering priniples&

speifiations& pratial engineering 'no!(ho!& and

"ust SI#P)E C*##*N SENSE.

+uring the planning stages& the Piping

Engineer ould meet !ith simple ideas that an effet

substantial ost savings. )et us ta'e a pratial

e,ample to it.


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Fig.1.1a


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Fig. 1.1b


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The design must ta'e onstrutibility& eonomis&

safety& quality and operation into aount. All these

should be ahieved !ithin the shortest shedule and

!ill demonstrate the tehnial apaity along !ith

reative talent and ommon sense approah to problem

solving.

Although the tools to achieve these goals have

changed from pencil and paper to computer

graphics, the responsibilities of the Piping Engineer

remains the same.


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Design fo !onst"#tibi$it%

Ten Commandments-

eep It 'traight and 'imple eep Its 'trutures 'imple eep Its ' peifiation 'imple eep It 'hop 'tandard eep Its 'tandard 'imple eep It 'ame 'ie

eep It 'quare and 'quatty eep Its 'upport 'imple eep Its 'hedule 'ared eep Its 'ite 'uitable


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The mehanial design and development of the plant

has three ma"or steps vi.

/.0 Equipment layout design/./ Coneptual layout design

/.1 Piping layout design

The plant layout an be the biggest ost saver inhemial plant design ne,t to the Proess and

Equipment design. #oney !asted or saved an be

substantial bet!een alternate layouts. In addition to

apital ost& the plant layout also influenes theoperating and maintenane ost. These are long term

benefits that affet profitability.


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Inorretly established plant layouts an have seriousimpat on safety and operability. If the layout do not

have enough room& the plant !ill be overro!ded& and

unsafe and diffiult to operate and maintain. *n the

other hand& an overly generous layout results in

unneessary high apital investment.


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UP

UP

ROOM

TERRACE

DUCT

LIFTUP

UP

3500 5000

11 2 3 4 5 6 7 8 9 10 11 12 13

5000 5000 5000 5000 5000 5000 5000 4500 4500 2200

F

E

D

C

B

A

T-4107C-4203

T-4114UP

UP

UP

UP LIFT

N

ECP/15

ECP/15


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Equipment layout is an e,tension of the oneptual

layout in more detailed manner. In the same !ay as

the P2I diagrams are the basi douments of

hemial engineering design& equipment layout is the

basi doument of mehanial engineering design.

This is a omposite mehanial engineering design&

oordinating the design information to produe

onstrution dra!ings.


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The essentia$ (ata e)"ie( fo the

pepaation of an E)"ip*ent La%o"t is as

fo$$o+s,

0. PR*CESS 3)*4 +IA5RA#S 6P3+78

PIPIN5 AN+ INSTR9#ENT +IA5RA#S6P 2I+7

/. PR*:ECT +ESI5N +ATA

1. E;9IP#ENT SI


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TYPE' OF LAYOUT' ,

• Inline )ayout

• Similar equipment grouping

• 3untional equipment grouping


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ARRGT-1 :: VERTICAL THERMOSYPHON REBOILER WITH FIXED TUBESHEETS

VAPOUR RETURN CONNECTION

BOTTOM TRAY OF COLUMN

TOP TUBESEET

SUPPORT LU!

SELLSIDE INLET

SUPPORT BRAC"ET

SELL BELLO#S E$PANSION

%OINT

REBOILER SELL

LI&UID LE!

SELLSIDE OUTLET

BOTTOM TUBESEET'((

COLUMN


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ARRGT-1 :: VERTICAL THERMOSYPHON REBOILER WITH FIXED TUBESHEETS

BOTTOM TRAY OF COLUMN

' ((

COLUMN

VAPOUR RETURN CONNECTION

TOP TUBESEET

SUPPORT LU!

SELLSIDE INLET

SUPPORT BRAC"ET

REBOILER SELL

SELLSIDE OUTLET

BOTTOM TUBESEET

COLUMN SELL

BELLO#S E$PANSION %OINT


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ARRGT-3 :: VERTICAL FIXED TUBERSHEET REBOILER WITH INDEPEDENT

SUPPORT STRUCTURE.

(

COLUMN

VAPOUR RETURN

TOP EAD

REBOILER SUPPORTSTRUCTURE

SUPPORT LU!

LI&UID LE!

BOTTAM EAD

S"IRT

SPRIN! SUPPORT

BELLO#S E$PANSION %OINT

TOP TUBESEET

BOTTAM TUBESEET


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NE4 C*NCEPT ( C*#PARIS*N *3 AREA 8 >*)9#E

The follo!ing guidelines and autions are helpful in improving the auray omparisons.

i7 #a'e omparison to as similar a plant as

possible.

ii7 9se similar assumptions in analying bothe,isting failities and ne! design.

iii7 3or outdoor installation& !here volume has

less relevane than in and enlosed struture&

rely on the area omparison alone.

iv7 3or tan' farm& general guidelines ditated for

fire safety reasons or statutory requirements

govern.


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EQUIPMENT LAYOUT-UNIT PLOT PLAN

DA/ING GUIDE LINE'

The follo!ing are the guidelines generally follo!ed !hile ma'ing an Equipment layout8unit plotplan dra!ing.

a7 Equipment layout shall be dra!n in 0-?@ or 0-0@@

sale.

b7 A@ sie dra!ing sheet should generally be used for

equipment layout. If the area to be overed is small& A0

sie an be used.

7 Plae north arro! at the top right hand orner of the

sheet to indiate plant north.

d7 The area above title blo' to be 'ept free for general

notes and referene dra!ings.


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e7 All equipments are mar'ed !ith its equipment no.

as appearing in Equipment list 2 dimensions

6diameter& height8length et.7

f7 All equipments enter line are loated in plant

building !.r.t. the olumn grid. 3or layout of

outdoor plant 8 offsite faility& the equipment shall

be loated by o(ordinates.

g7 Coneptual layout& P 2 I+& vendor8fabriated

equipment dra!ings are to be used as basi

doument for preparing equipment layout

dra!ing.h7 4al'!ays& utouts& pipera's& floor drains& gutter&

trenhes& ramp et. if appliable should be learly

mar'ed in the dra!ing.


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i7 3or in house plant layout& the loation of stairases& lift 2

other utility areas should be learly sho!n.

"7 In equipment layout setional dra!ing& for eah equipment

its top most or bottom most elevations should be mar'ed.

'7 *rientation of equipment shall be learly mar'ed for all

the

equipments by orienting one of the ma"or noles.

l7 In ase of reators 8 tan's& the loation of manhole 8

handhole&

S58)5&)I et. shall be at aessible position.

m7 Equipment lifting utout shall be mar'ed learly in the


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n7 Equipment planned to be installed in future shall be

sho!n dotted.

o7 3or heat e,hangers& tube removal 8 leaning spae

shall be mar'ed.

p7 4hile loating the pumps are shall be ta'en to ensure

that the NPS% requirement is met.

q7 5eneral notes are !ritten on one of the dra!ings 6first7

and shall not be repeated on all layouts but referene

shall be given.

r7 +iretion of north shall be maintained same for all the

plans for the same plant 8 pro"et.


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s7 If more than one dra!ing is required to over a

speified area& then the math line shall be indiated learly

!ith the referene dra!ings.

t7 *ne of the general notes should speify the

absolute level of the area overed !ith respet to the plot.

u7 The equipment load& operating or test load

!hihever is ma,imum shall be onsidered for design and the

layout should indiate this along !ith the dynami fator

!herever appliable. This ould also be overed in table as

!ell.


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v7 3or reators !ith agitators& lifting beam shall be provided for

agitator removal.

!7 3or vendor equipments maintenane spae as reommended by

them for maintenane shall be provided.

,7 Equipment layout shall also indiated the positions of utility

stations& safety sho!er and eye !ash.

y7 Equipment elevation shall be so arranged to ensure gravity

flo!

!here speified.


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In terms of the equipment arrangement&

the equipment layout 6unit plot plan7 an basially be

divided into t!o onfigurations-

a7 The grade mounted horiontal arrangement asseen in the refineries and petrohemial plants&

and

b7 The vertial arrangement found in manyhemial proess industries.


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Irrespetive of the type of arrangement& there are ertain

basi priniples to be follo!ed !hile loating the equipment.

Eonomi piping Proess requirements

Common *peration

9nderground failities Climati onditions


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TYPI!AL !O'' 'E!TION OF AN INDOO

PO!E'' PLANT

Fig. 0.0.a


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TYPI!AL !O'' 'E!TION OF INDOO !2EMI!AL PLANT

Fig. 0.0.b


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A!!E'' PLATFOM'

The follo!ing guidelines shall be follo!ed for providing aess

platforms in the layout.

a7 3or all #anholes !ith entre line elevation above 1?@@

mm.

b7 3or instrument vision. The )5 should be vie!ed !hile

operating the bypass of the ontrol valve.

7 At B@@ mm ( 0?@@ mm belo! the #anhole.

d7 A minimum height of /.? m to be onsidered bet!een platforms to ta'e are of the headroom.

e7 The platform at the top of the to!er shall be at /?@ to 1@@

mm above the top dish.


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P2ILO'OP2Y OF IN3PLANT PIPING

o

o >alve )oation

o Eletrial8Instrument Cable Trays

o Statutory requirements

o #isellaneous


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AR+ PIPIN5

P 2 I diagram& equipment layout& piping speifiations&

equipment dra!ing and the vendor requirement for proprietaryequipment form the basis of a piping layout. In areas !here

piping is ritial& the equipment loations are fi,ed only after a

Dpiping study is made.

The first step in the development of pipe ra' is the generation

of a line F routing diagram. A line F routing diagram is a

shemati representation of all proess and utility piping systems

dra!n on a opy of plot plan or it ould be planometrirepresentation of the utility and proess line diagrams. Although

it disregards the e,at loations& elevations or interferenes& it

loates the most ongested area.


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The pipe ra' splits the plant area into onvenient parts.

The pipe ra' ta'es various shapes suh as Dstraight& D)& DT& and

DC or D9. This onfiguration is based on the overall arrangementand site onditions. =ased on the inoming8outgoing lines and

loations& the pipe ra' is laid.


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Fig. 0.4.1


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Fig. 0.4.0


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Fig. 0.4.4


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Fig. 0.4.5


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Fig. 0.4.6


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Fig. 0.4.


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Fig. 0.4.7

The onfiguration of pipe ra' is not determined !hile doing the


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g p p g

plant layout.

The arrangement results from an overall plant layout& site

onditions& lient requirements and above all plant eonomy.

The !idth of the pipe ra' is estimated as 4 G 6f , n , s7 H A H =

f G Safety fator

G 0.? if pipes are ounted from the P3+

G 0./ if pipes are ounted from P 2 I+.nGNumber of lines in the densest area upto the sie of ?@N=

s G 1@@mm 6estimated average spaing7

G //?mm 6if lines are smaller than /?@ N=7

A G Additional !idth for

607 )ines larger than ?@ N=

6/7 3or instrument able tray8dut

617 3or eletrial able tray

= G 3uture provision

G /@J of 6f , n , s7 H A

1 5 TO 2M


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Fig. 0.4.8

1)5 TO 2M

TYPE 1

5 TO 6M 1TO 1)2M

TYPE 2


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5 TO 6M

TYPE 3


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A pipe bent onsists of a vertial olumn or olumns and a horiontal

strutural member or members that arries piping system aboveheadroom.

Spandrels are horiontal strutural member loated along the

longitudinal entre line that are used for strutural stability& pipe support

or intermediate pipe bents.

The 2ea(oo* no*a$$% po9i(e( is as be$o+.


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Sr. +esription %eadroom

No. 6mm7

0. Clear head room under //@@

Strutures8pipe linesinside operating area.

/. %ead room over rail K@@@

6from top of rails7

1. Clear headroom above K@@@rest of road for rane

movement.

. Clear headroom above L@@

rest of road for tru'

movement.?. Clear headroom above ?@@

rest of road bet!een

proess units.


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Fig. 0.4.:a


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Fig. 0.4.1;


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Fig. 0.4.11


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Fig. 0.4.14


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Fig. 0.4.15


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Fig. 0.4.16


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Fig. 0.4.1


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Fig. 0.4.17


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Fig. 0.4.18


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Fig 0.4.1:


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Fig 0.4.0;


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Fig 0.4.01a


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Fig 0.4.01b


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Fig 0.4.00


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0.4.6 PIPING FO IN'TUMENT'

Instruments&!hen loated on piping &!ill need ertain

speifi requirement for it to perform the duty for !hih it is

provided. Piping Engineer should be a!are of these

requirements and should ta'e are of the same !hile routing

these pipe lines.

a7 3lo! measurement instrument need ertain straight lengthupstream and do!nstream of the instrument.This is normally

0?+ on the upstream and ?+ on the do!nstream.

b7 The pipe lines in !hih flo! meters suh as magnetiflo!meters &vorte, meters &turbinemeters et are loated should

be routed in suh a !ay that the line !ill be full !ith liquid all

the time.The pipe line should be supported on both sides of

meter.

7 Control valves are loated at grade at about ?@@mm height to


70/88

7 Control valves are loated at grade& at about ?@@mm height to

provide onvenient aess for operation and maintenane. =lo'

and bypass valve also form the same riteria. The standard

arrangements follo!ed are as per 3ig /.1./1. If po'eting the proess line is unaeptable& then a permanent or mobile platform

should be planned& as aess is very important. )oating ontrol

values on the vertial line should be avoided.If is unavoidable$ the

should atuator should be supported properly.The bypass should

be seleted for easy operation.

d7 Isolation valves for level gauges and pressure gauges shall be

made aessible. Aess and spae for the removal of level

ontrollers temperature probes &ondutivity probes&bottom flagsof the ontrol values et shall be provided. All primary and

seondary indiators of pressure& temperature& flo!& level&

positioners et. should be visible from the operating area.


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e7 Rotameters shall be plaed on vertial line and the inlet

should be from the bottom of the instrument.

f7 Thermo!ell shall be loated on the pipe line of required

sie.Instrument hoo' up shall be reffered for the requirement.

g7 Enough operating and maintane aess shall be onsidered

!hile loating any instrument.


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Fig. 0.4.04


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Fig. 0.4.05

The Considerations to arrive at an eonomial ra' desging


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The Considerations to arrive at an eonomial ra' desging

are

0. >ery large diameter lines or large lines full of liquid are

plaed nearer to the supporting olumns to redue

the bending moment on the rossbeams.

/. The hot lines that require e,pansion loops are grouped to

have the most eonomial support.

1. The anhor points on the hot lines are loated together to

have optimum design of the olumns.

. In an indoor plant the personnel failities suh asmehanial room& ontrol room& lo'er room& laboratory&

offies& storage room et. shall be grouped so that the pipe

ra' length ould be urtailed.


75/88

The e)"ie*ent as pe the fo$$o+ing sha$$ be

a(hee( to

a7 The 3atories At 0BM.

b7 The Petroleum At 0B1 2 The Petroleum

rules 0BKL.

7 The Stati and #obile Pressure >essels

6unfired7 Rules 0BM0.

d7 The 5as Cylinders Rules 0BM0.

e7 The Indian =oiler Regulations 0B?0.

f7 +evelopment ontrol rules by the State

Industrial +evelopment Corporation.


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B F #

TA N "

E C O N O M IS E R

B F #

P D O S IN !

B O IL E R F E E D

# A T E R P U M P

D O S IN ! TA N "

D O S IN ! P U M P

P I

M A N I F O L D

C O N S U M E R

S T

Y

S T

TO A TM O S )

* T Y P +

L ! L ! L ! L !

B L O # D O # N

D R A I N

B LO # D O # N TA N "

N O T E , -

P I P E L IN E S T E P U R V I E # O F I B R S O # N # IT T IC L I N E S )

IB R S C O P E

I B R S C O P E


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0.4.8 !ITI!AL E


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EQUIPMENT AND PIPING LAYOUT 3 PUMP'

Pumps rarely influenes the plant layout e,ept !here a

ommon standby for t!o servies or multiple duty pumps

might ditate the proess equipment arrangement. =ut the

pumps an never be treated as an independent entity& but to be

treated as part of the piping system !hih affets the

performane even if the basi seletion is faultless.


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The design of equipment and piping onfiguration

affet the energy used and apital ost of pumps. %ene&

eonomy of piping and strutures along !ith ease of

operation and maintenane are the prinipal aim !hile

arranging the pumps.


80/88

The primary goal in loating the pump is to minimie the

piping onfiguration !hile satisfying the performane and

fle,ibility requirements as !ell as allo!able loads that may

be sub"eted to the noles.

#ehanial or Chemial Engineers an no longer

onsider the pump as an independent entity& but to be treatedas a part of the Piping System.


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;

/ P9#PS IN PARA))E) *PERATI*N ;/O/;0

EAC% P9#P *PERATES AT 6;/8/& %/7

%


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Fig. 4.1.1a


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Fig. 4.1.1b


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Fig. 4.1.0


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Fig. 4.1.4


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In addition vent onnetion of pump has to be permanently onneted to the

equipmentandpiping1.ppt

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