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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 Piping Fundamentals – For Fresher Engineers 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 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 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 To solve these problems we need the pipe components, which are called We have just brought the pipes, now we need to solve some more problems Pipes are all straight pieces sa e pip es! e om t siz s en feren v E dif of PIPE FITTINGS We need some branch connections We need some bend connections re 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 Next we shall look into how to SUPPORT the pipe/and it’s components There are various types instruments to measure various parameters Also there are specific criteria for installation of various pipe line instruments This is screen picture of P&ID made by SPP&ID If we click on any line it will show the Data embedded 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 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 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 times diameter straight at down stream of orifice Example of Straight length requirement for Flow Orifice ⑥ 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 ⑥ To achieve this a VENT connection with Valve is provided at the top most point of the pipeline ⑥ Also arrangement is kept in the pipeline so that liquid can be drained out if required ⑥ To achieve this a DRAIN connection with Valve is provided at the lowest point of the pipeline ⑥ Pipes are also slopped towards low points Let us look into typical Vent and Drain arrangement in a pipeline This is a 3D model of Feed water line along with pumps and other accessories Let us have a look into a piping model done by PDS 3D 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 not get burn injury by touching hot surface of pipe is called Personnel Protection Insulation Cold pipesItare 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 of Fluid flowing Find out Fluid Temp & Pressure Check Pipe life Expectancy Select suitable Material per practice (Note-1) Check Mat Listed in Design Code YES Pipe Material OK 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 See Note1 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 YES Drop meets Press Budget Pipe Size OK NO Increase Pipe Size Pipe Thickness Selection - to select appropriate pipe thickness based on flowing fluid property Select Mat & Diameter as above Find out Fluid Temp & Pressure Decide on Corrosion allowance Calc Pipe Thickness per Code ⑥ 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 ⑥ These pipelines are call the CRITICAL PIPING ⑥ Very special care are taken for design of these piping ⑥ 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 ⑥ 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 ⑥ 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 ⑥ Also there should be enough flexibility in these pipe routing so that high loads are not transferred to the nozzles of Turbine or Pumps ⑥ There are many recognized international codes which lay down guide lines and mandatory requirements for design of such piping ⑥ The most important codes used by power plant piping engineers are ⑥ ASME ANSI B31.1- Power Piping Code & IBR - the Indian Boiler Regulation Pipe Stress Analysis ⑥ 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 ⑥ We need to check and confirm the pipe is not going to fail with these loading ⑥ This process of checking the stress developed in the piping due to various loading is called Pipe Stress Analysis/Flexibility analysis ⑥ In the process of Analysis we apply various postulated loading on the pipe and find out the stress resulted from these loading ⑥ Then we check with governing codes if those stresses generated are acceptable or not ⑥ We check support load & movement for various loading condition ⑥ 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 ⑥ We also find out the pipe growth due to change in temperature and need to keep the movement of pipe within acceptable limits ⑥ Pipe Stress Analysis is an Interactive and Iterative process Each step is checked ⑥ If a check fails we have to go back, modify the layout and restart the analysis PIPE STRESS ANALYSIS Inputs Tools we use ⑥ Geometric layout of Pipe ⑥ PIPSYS - is an integrated pipe stress analysis module of PLADES 2000 ⑥ Pipe supporting configuration ⑥ Pipe Diameter and Thickness ⑥ Pressure inside Pipe ⑥ CEASER - Commercial Piping analysis software ⑥ Cold and Hot temperatures of Pipe ⑥ There are many other commercial software available ⑥ Weight of Pipe and insulation Outputs ⑥ Weight of carrying Fluid ⑥ Stress of the pipe at various loading conditions ⑥ Pipe material Property (Young’s Modulus, Thermal Expansion Coefficient) ⑥ Load at various supports and restrains ⑥ Thrust on pipe due to blowing wind ⑥ Movement of pipe at support locations ⑥ Thrust on pipe due to earthquake ⑥ Pipe terminal point loading ⑥ Load of Snow on pipe Codes and Standards ⑥ Any transient loading like Steam Hammer load ⑥ In general Power Plant Piping have to comply stipulations of ASME ANSI B31.1 ⑥ Any other load on the piping ⑥ In India Power cycle Piping to comply IBR code requirements Types of Pipe Supports In the beginning of this discussion we talked about various types of pipe supports Here is some elaboration Constant Load Spring ⑥ There are three general types ⑥ Rigid type (no flexibility in the direction of restrain) Variable Spring ⑥ There are two types of spring support ⑥ Variable load type, here support load changes as the pipe moves ⑥ Constant load support, the load remains constant within some range of movement Rigid Support ⑥ Dynamic Support (Degree of restrain depends on acceleration of load) Rigid Hanger ⑥ Spring type (Allows pipe movement in direction of loading) Dynamic Support, Snubber Rigid Support Some Special Considerations for Piping When pipes are routed UNDER GROUND (Buried) following points to be kept in mind: ⑥ Minimum pipe size to be routed under ground shall be not less than1 inch ⑥ Avoid flange joint in U/G piping ⑥ Keep in mind if pipe leaks U/G, it will be difficult to detect, so avoid U/G routing of pipe carrying hazardous fluid ⑥ Pipe to be laid below Frost Zone at areas where ambient temperature goes below freezing ⑥ U/G, Buried piping should be properly protected from corrosion ⑥ Pipe may be properly wrapped and coated to prevent corrosion ⑥ Or U/G piping be protected by using Cathodic protection Freeze Protection of outdoor Piping: ⑥ 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 ⑥ For similar case pipes are wrapped with heat tracing elements to maintain the content temperature above freezing (around deg C) even when the ambient temp is below freezing ⑥ 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 ⑥ Heat tracing can also be done by winding Steam tubes around main pipes We have come to the End of Session Hope you have gathered the fundamentals on the subject of Piping [...]... 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 ⑥ These pipelines are call the CRITICAL PIPING ⑥ Very special care are taken for design of these piping ⑥ First the pipe material selection for such piping is very important as... 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 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... absorbed within the piping ⑥ Also there should be enough flexibility in these pipe routing so that high loads are not transferred to the nozzles of Turbine or Pumps ⑥ There are many recognized international codes which lay down guide lines and mandatory requirements for design of such piping ⑥ The most important codes used by power plant piping engineers are ⑥ ASME ANSI B31.1- Power Piping Code & IBR... earthquake ⑥ Pipe terminal point loading ⑥ Load of Snow on pipe Codes and Standards ⑥ Any transient loading like Steam Hammer load ⑥ In general Power Plant Piping have to comply stipulations of ASME ANSI B31.1 ⑥ Any other load on the piping ⑥ In India Power cycle Piping to comply IBR code requirements Types of Pipe Supports In the beginning of this discussion we talked about various types of pipe supports Here... Pipe to be laid below Frost Zone at areas where ambient temperature goes below freezing ⑥ U/G, Buried piping should be properly protected from corrosion ⑥ Pipe may be properly wrapped and coated to prevent corrosion ⑥ Or U/G piping be protected by using Cathodic protection Freeze Protection of outdoor Piping: ⑥ In the areas where the ambient temperature goes below freezing there is a possibility that... movement in direction of loading) Dynamic Support, Snubber Rigid Support Some Special Considerations for Piping When pipes are routed UNDER GROUND (Buried) following points to be kept in mind: ⑥ Minimum pipe size to be routed under ground shall be not less than1 inch ⑥ Avoid flange joint in U/G piping ⑥ Keep in mind if pipe leaks U/G, it will be difficult to detect, so avoid U/G routing of pipe carrying...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... and high temperature Also pipes carry the load of the flowing fluid ⑥ We need to check and confirm the pipe is not going to fail with these loading ⑥ This process of checking the stress developed in the piping due to various loading is called Pipe Stress Analysis/Flexibility analysis ⑥ In the process of Analysis we apply various postulated loading on the pipe and find out the stress resulted from these... Geometric layout of Pipe ⑥ PIPSYS - is an integrated pipe stress analysis module of PLADES 2000 ⑥ Pipe supporting configuration ⑥ Pipe Diameter and Thickness ⑥ Pressure inside Pipe ⑥ CEASER - Commercial Piping analysis software ⑥ Cold and Hot temperatures of Pipe ⑥ There are many other commercial software available ⑥ Weight of Pipe and insulation Outputs ⑥ Weight of carrying Fluid ⑥ Stress of the pipe... also slopped towards low points Let us look into typical Vent and Drain arrangement in a pipeline This is a 3D model of Feed water line along with pumps and other accessories Let us have a look into a piping model done by PDS 3D 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