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14
nov Posted by: ANTONY in Design guidelines , Learn Piping, Piping Design system , Piping Tips, Process plant Layout , Process Tips
Introduction
The purpose of the compressed air piping system is to deliver compressed air to the points of usage. The compressed air needs to be delivered with enough volume, appropriate quality, and pressure to properly power the components that use the compressed air. Compressed air is costly to manufacture. A poorly designed compressed air system can increase energy costs, promote equipment failure, reduce production efficiencies, and increase maintenance requirements. It is generally considered true that any additional costs spent improving the compressed air piping system will pay for them many times over the life of the system.
Piping materials
Common piping materials used in a compressed air system include copper, aluminum, stainless steel and carbon steel. Compressed air piping systems that are 2" or smaller utilize copper, aluminum or stainless steel. Pipe and fitting connections are typically threaded. Piping systems that are 4" or larger utilize carbon or stainless steel with flanged pipe and fittings. Plastic piping may be used on compressed air systems; however caution must used since many plastic materials are not compatible with all compressor lubricants. Ultraviolet light (sun light) may also reduce the useful service life of some plastic materials. Installation must follow the manufacturer's instructions. Corrosion -resistant piping should be used with any compressed air piping system using oil-free compressors. A non-lubricated system will experience corrosion from the moisture in the warm air, contaminating products and control systems, if this type of piping is not used. It is always better to oversize the compressed air piping system you choose to install. This reduces pressure drop, which will pay for itself, and it allows for expansion of the system.
The discharge piping from the compressor should be at least as large as compressor discharge connection and it should run directly to the after cooler. Discharge piping from a compressor without an integral after cooler can have very high temperatures. The pipe that is installed here must be able to handle these temperatures. The high temperatures can also cause thermal expansion of the pipe, which can add stress to the pipe. Check the compressor manufacturer's recommendations on discharge piping. Install a liquid filled pressure gauge, a thermometer, and a thermo well in the discharge airline before the after cooler. Proper support and/or flexible discharge pipe can eliminate strain.
1. The main header pipe in the system should be sloped downward in the direction of the compressed air flow. A general rule of thumb is 1" per 10 feet of pipe. The reason for the slope is to direct the condensation to a low point in the compressed air piping system where it can be collected and removed.
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2. Make sure that the piping following the after cooler slopes downward into the bottom connection of the air receiver. This helps with the condensate drainage, as well as if the water-cooled after cooler develops a water leak internally. It would drain toward the receiver and not the compressor.
3. Normally, the velocity of compressed air should not be allowed to exceed 6 m/s; lower velocities are recommended for long lines. Higher air velocities (up to 20 m/s) are acceptable where the distribution pipe-work does not exceed 8 meters in length. This would be the case where dedicated compressors are installed near to an associated large end user.
4. The air distribution should be designed with liberal pipe sizes so that the frictional pressure losses are very low; larger pipe sizes also help in facilitating system expansion at a later stage without changing header sizes or laying parallel headers.
Pressure Drop
Pressure drop in a compressed air system is a critical factor. Pressure drop is caused by friction of the compressed air flowing against the inside of the pipe and through valves, tees, elbows and other components that make up a complete compressed air piping system. Pressure drop can be affected by pipe size, type of pipes used, the number and type of valves, couplings, and bends in the system. Each header or main should be furnished with outlets as close as possible to the point of application. This avoids significant pressure drops through the hose and allows shorter hose lengths to be used. To avoid carryover of condensed moisture to tools, outlets should be taken from the top of the pipeline. Larger pipe sizes, shorter pipe and hose lengths, smooth wall pipe, long radius swept tees, and long radius elbows all help reduce pressure drop within a compressed air piping system. The discharge pressure of the compressor is determined by the maximum pressure loss plus operating pressure value so that air is delivered at right pressure to the farthest equipment. For example, a 90 psig air grinder installed in the farthest drop from the compressor may require 92 psig in the branch line 93 psig in the sub-header and 94 psig at the main header. With a 6 psi drop in the filter/dryer, the discharge pressure at the after cooler should be 100 psig.
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can be conducted during the shutdown or during unexpected production stoppages. Air Leakage = On load time Q x ------------------------------------- On load time + Off load time Where Q = compressor capacity
Leakage reduction
Leakage tests can be conducted easily, but identifying leakage points and plugging them is laborious work; obvious leakage points can be identified from audible sound; for small leakage, ultrasonic leakage detectors can be used; soap solution can also be used to detect small leakage in accessible lines. When looking for leaks you should investigate the following: CONDENSATE TRAPS -Check if automatic traps are operating correctly and avoid bypassing. PIPE WORK - Ageing or corroded pipe work. FITTINGS AND FLANGES - Check joints and supports are adequate. Check for twisting. MANIFOLDS - Check for worn connectors and poorly jointed pipe work. FLEXIBLE HOSES - Check that the hose is moving freely and clear of abrasive surfaces. Check for deterioration and that the hose has a suitable coating for the environment e.g. oily conditions. Is the hose damaged due to being too long or too short? INSTRUMENTATION - Check connections to pneumatic instruments such as regulators, lubricators, valve blocks and sensors. Check for worn diaphragms. PNEUMATIC CYLINDERS Check for worn internal air seals. FILTERS Check drainage points and contaminated bowls. TOOLS Check hose connections and speed control valve. Check air tools are always switched off when not in use. The following points can help reduce compressed air leakage: Reduce the line pressure to the minimum acceptable; this can be done by reducing the discharge pressure settings or by use of pressure regulators on major branch lines. Selection of good quality pipe fittings. Provide welded joints in place of threaded joints. Sealing of unused branch lines or tapings. Provide ball valves (for isolation) at the main branches at accessible points, so that these can be closed when air is not required in the entire section. Similarly, ball valves may be provided at all end use points for firm closure when pneumatic equipment is not in use. Install flow meters on major lines; abnormal increase in airflow may be an indicator of increased leakage or wastage. Avoid installation of underground pipelines; pipelines should be overhead or in trenches (which can be opened for inspection). Corroded underground lines can be a major source of leakage.
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25
B.P. Nansi
Piping is an asset for any project. The plant will be as good as the piping layout. Good piping will increase efficiency and bad piping will reduce efficiency. But there is more important effect of bad piping. It can even cause an accident. The plant piping can make or break a plant.
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Piping layout is engineering and art. It should ease the operations, help the production and should be pleasant aesthetically. A beautiful piping layout is a plus point to the managers, workers, maintenance crew and the visitors. The principle for layout design is: plant integrity, operation, maintenance and lifecycle cost. Here are some points for design engineers, project engineers, project managers, piping fabricators and contractors: n Take input from engineering departments, operations and maintenance personnel n Follow codes, standards and recommended practices n Plan the equipment layout for (1) operability, (2) maintenance and also (3) for piping n All relief pipes, especially steam relief pipe, must release at a distance and at a height, at a safe point. A sudden release of steam can hurt an unaware worker n Expansion bends, loops and expansion joints will keep pipe stress low. Use them for long run piping n Stress analysis of all piping systems is a good investment. Stress analysis will bring out proper layout and that will decrease the original cost, save pumping energy and will reduce the maintenance/replacement of pipe n Location of supports, guides, and anchors is a vital point. Involve your civil engineer at the beginning to give you support structures n Low points drains and high points vent is an intelligent practice n Keep all valves accessible for operation n Keep all gauges, recorders, thermometers etc at the level for easy reading and attending Pipe openings Many pipes; viz water supply, raw fluids, fuel gas etc enter a process building and many pipes viz. final product, condensate, cooling water etc leave the process building. Often the entry-exit is through walls. This needs well-defined and well-planned pipe openings. The building is constructed much before the piping contractor comes in. Often, either the pipe openings are not planned or planned bad or forgotten or, later, the piping layout changes. When that happens, take that there is a site crisis. When piping contractor starts erecting, he finds that there is no opening. Walls are broken. This has happened many times at many places and will happen again. It is one of the commendable points to avoid such situation. Be vigilant. Interference This is another big challenge. Interference of a pipe with another pipe or with equipment or with a structure etc is a common scene in many piping layouts. That is because either the piping engineer has 'goofed' or the 'other' things have changed after the piping layout was done. Be careful. A serious issue happens when a pipe, as designed, is going through a beam or a column. This is an embarrassing situation. What happens is that you can break a wall, but you just can not touch a beam or column. Invariably the piping is changed. That brings in factors of pressure loss, stress analysis and aesthetics. That is why the piping engineer has to be vigilant. Pump piping This is a challenge. All centrifugal pumps have NPSH requirements. That has to be given for efficient and safe operation of the pump. The piping layout has to be right. Even after careful evaluation and selection, a centrifugal pump may not operate as expected. Pipe color codes & ID When you paint the pipes, follow a color code. Indian Standard defines which colour tells what fluid. For insulated pipes, give colour-coded bends. Then label all pipes to tell what service is inside. Also paint-write line ID numbers on the pipes. A right piping layout will be cost effective, because it saves money at installation, but saves energy in pumping service. Ensure your project has the right layout
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The purpose of this guideline is to simplify and standardise the approach to pipe support design and selection for common support applications with the aim to improve quality, efficiency and productivity. The document shall be read in conjunction with the office standard pipe support drawings and the office piping stress analysis guide.
Pipe Support Identification Tagging:
Each pipe support standard detail drawing contains a legend for support identification tagging applicable to the supports in the drawing. Normally all the supports, covers under Standard Piping supports will be STD Pipe Supports. If the supports needs modification or above the STD pipe support range (e.g. max length, height, pipe range) then it should be considered as Special Pipe Support (SPS). All SPS as designed and checked by Civil discipline.
Pipe Support Register:
Standard pipe supports, project specific pipe supports and temporary pipe supports will be listed in the project pipe support index drawing. Special pipe supports and temporary support frames are part of the Structural design and will be listed in the Structural discipline project deliverables.
Piping Fabrication Isometrics:
The Material section of the piping fabrication isometric will call up all standard pipe supports. The following information will be included: Pipe support identification tag and description / nominal pipe size / quantity Pipe support components that are welded to pipe, such as welded shoes and Trunnions, will be shown under Fabrication Materials. Pipe support components that are field fitted, such as U-bolts, guides, line stops, will be shown under Erection Materials. The Drawing section of the fabrication piping isometric will show all the above pipe supports and will also reference structural SPecial Supports (SPS). Pipe support position will be dimensioned on the isometric drawing. This position corresponds to the location point indicated on the pipe support detail drawing. Also shown in the Drawing section of the isometric will be clarification notes, such as no gaps, nonstandard gaps and support orientation if required.
Other Supports:
Use of spring hangers, snubbers and other such devices shall be specified by Stress Engineer. The project pipe support register will contain all design information required for procurement of these items. Supports for extreme conditions, such as for very low operating temperature or acoustic vibration, shall be engineered, designed and procured from a reliable supplier. These supports shall be designed for and installed in accordance with the Suppliers instructions.
Small Bore Brace:
Small bore brace is typically used to protect a small size branch from damage. Branch lines in sizes 2 and below are considered small bore and prone to fatigue failures in vibrating piping systems. They are also prone to mechanical damaged by an external force. The failure is usually at the branch weld to the main line or weldolet. Small bore branches are normally braced for that reason. Bracing shall be to the branch flange in preference to the branch pipe. Nipoflanges shall be used in preference to weldolets. Small bore brace will not be required on small branches when: The branch is continuous and supported and there is no valve within the first span; Standard tees are used; The piping is used for utility services.
Shoes:
For carbon and stainless steel piping welded shoes shall be used instead of clamped shoes where the temperature limit for clamped shoes has been exceed or where specified / approved by Stress Engineer for strength purposes.
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Randomposts shoes shall not be used on lined piping, piping in expensive material, piping PWHT ShareWelded Share Recent Translate L 3ink Menu
before shoe installation and piping galvanized before shoe welding. Long length shoes shall be used where specified by Stress Engineer, a line stop is required or there is an excessive support movement in longitudinal direction. On insulated lines the standard shoe height of 100mm can be increased to up to 150mm where the insulation thickness is greater than 75mm. If required, shoes higher than 150mm will be designed by the stress engineer. Pipe shoes shall be installed centrally on the support steel unless noted otherwise on the piping fabrication isometric. When the design requires a continuously sloping line, this shall be achieved with the use of variable height shoes in combinations with adjustments of supporting steelwork. Lines having a design temperature above 120C shall be supported on shoes because of the temperature limitations of PTFE isolation pads used with uninsulated lines. Lines having a design temperature below minus 29C shall be supported on shoes to avoid cold temperature embritellment of the supporting structural steel.
Trunnions:
Use of trunnion supports will be minimised and approved by Stress Engineer. Trunnion supports on elbows will be avoided, particularly when a reinforcing pad is required. The use of the trunnion on an elbow with a reinforcing pad shall be approved by the Lead Piping Engineer.
Guides and Line Stops:
Guidesandlinestopswill be installed with the installation tolerance gap of maximum 3mm on each side of the support unless noted otherwise on the isometric. Hold down guides shall only be used when specified by Stress Engineer. Using these guides for guiding vertical pipes is not preferred. Alternative line stops of high load capacity shall only be used when approved by Stress Engineer. Guide span shall be as per CARBON STEEL & STAINLESS STEEL GUIDE SPACING
U-Bolts:
A U-bolt shall be installed in such a way that the dead weight of the piping is supported by the structure and not the U-bolt itself. U-bolts can be used on both horizontal and vertical lines.
Isolation Pads:
Isolation pad (PD-01) made of PTFE is used to support the line and reduce the risk of fretting corrosion to the underside of the pipe. Isolation pads shall be bonded directly to the structural steel. Bonding / fixing of the isolation pad to the structural steel shall be suitable for the required service life of the support. Pipe shoes shall be used instead of isolation pads if the temperature limit of the pad bonding adhesive or material has been exceeded. Isolation pads are not required under shoes, trunnions, reinforcing pads and on the facings of guides and line stops.
Reinforcing Pads:
Reinforcing pads are typically used to reduce stress level in the pipe wall from welded attachment or high bearing load. They can also be used to protect pipe wall from external corrosion.
Support Span:
Piping will be subject to internal and external loads during topside transportation and installation, environmental loads and operating and transient process loads. Piping movement shall be restrained on all three orthogonal directions allowing sufficient flexibility for thermal expansion and other imposed deflections, such as bridge and wellhead movements. Small size piping in 2 and below shall be restrained with U-bolts wherever possible. Larger piping shall use guides and line stops with guides installed on every second support on a straight run.
Welded Attachments:
Non-pressure retaining pipe attachments that are enclosed, such as reinforcing pads and trunnions, shall have a vent/test hole to release the gas build up during welding and to provide an inspection point for any pipe leak. The hole shall be tapped with an NPT thread
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Randomposts low pressure pneumatic testing after welding. Shareto allow Share Recent Translate L 3ink Menu
Special Applications:
Control valve sets will typically be anchored with a line stop and hold -down guide on one side and guided on the other side. Pig traps will typically be anchored with a line stop and hold-down guide at the pipeline end and guided at the closure end. Manifolds will typically have guides at each end and a centrally located line stop. Drain systems with rodding points shall be supported in such a way to withstand rodding loads. The free pipe ends on Utility Stations shall be securely fixed. That may be accomplished with U-bolts either as guides or anchors. For piping supported from a pressure vessel the pipe support details and loads will be issued to the Mechanical discipline for incorporation in the pressure vessel design by the vessel supplier.
SUPPORT MATERIAL:
Material for pipe supports can be generally divided into three categories: 1. Welded attachments to piping. The attachments shall be of the same material grade as the run pipe. 2. Pipe supports or pipe support parts not welded to piping. ASTM A36 or equivalent material can be used unless noted otherwise. 3. Structural pipe supports. Frames fabricated from ASTM A36 or equivalent structural steel sections and plates.
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may
TYPE OF WELD Branch connections (with or without reinforcing pads or olets) and Circumferential welds
Minimum Distance
Pipe Size
All Sizes
Tag: Weld distance, minimum weld distance, weld gap between fittings, minimum weld gap, pipe welding minimum gap, fittings weld gap, circumferential weld gap, longitudinal weld gap, weld gap thumb rule.
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16
may
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apr
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North arrow orientation. Line continuation - Iso index. Matching isometrics and elevation. Equipment location to grid. Equipment terminal details. Location to grid/equipment. Structural penetrations. Locations of item . Line content. Flow arrow. Pipeline number and elevations. Fabrication type. Dimensional completion. Valve orientation. Fabrication limits. Field weld locations. Make-up weld locations. Cut to fit dimensions. Spool number sequence. Pipe support locations. Hydrotest requirements. Flushing requirements. Insulation limits. Heat tracing limits. Piping bills of materials completeness. Piping insulation materials completeness. Specials list completeness. Assemblies list completeness. Tagged item list completeness. Fabrication requirements completeness.
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mar
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mar
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feb
VALVE OPERATING CLERANCE: Valves are best installed with the stem pointing staright-up (Vertical stem). Since this position greatly facilitates in-place maintenance (lubrication, inspection & repacking) Valves may be rotated as far as the horizontal position with no great decrease in maintenance convenience. But should not be installed with the stem downward since the bonnet acts as a trap for acrasive sediment and water wich may freeze under extreme climatic conditions. Safety (operation & maintenance ) requires that valves be placed over platforms, rather
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Randomposts Sharethan adjacent to them. Valves can be placed over access area if they comply with Share Recent Translate L 3ink Menu
horizontal stem limitations and area bove 2100 min head clearance.
MINIMUMCLEARANCEPASSAGE WAYS: Ergonomical requirements for minimum clearance of passage ways are illustrated in the following picture.
PERSONNEL CLEARANCE WORKING SPACE: Ergonomical Requirements for the personnel clearance for working space is illustrated in the following figure.
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feb
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M12 M14 M16 M20 M22 M24 M27 M30 M36 M42 M48 M56 M64 M72 M80 M90
2-Jan 16-Sep 8-May 4-Mar 8-Jul 1 1 1/8 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 1/4 3 1/2
14 16 18 22 24 27 30 34 40 46 53 62 70 76 86 95
M100 4 107 Technorati Tags: Useful Piping Info,English- Metric Conversion,selection of metric bolts
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DISTRIBUTION BEST ECONOMICAL PIPING Minimum Access Provisions-Process Unit and Offsite... Hydrocarbon Processings Refining Processes Handbo... What is the major difference between PDS course & ... COMPRESSED AIR PIPINGECONOMIC PIPING Senior Engineer, Piping & Layout Aibel Stavanger, ... PDMS COMMANDS TIPS & TRICKS 11/06 - 11/13 (5) 10/30 - 11/06 (6) 10/23 - 10/30 (5) 10/16 - 10/23 (2) 10/09 - 10/16 (5) 09/25 - 10/02 (2) 09/18 - 09/25 (1) 09/11 - 09/18 (1) 09/04 - 09/11 (4) 08/21 - 08/28 (1) 07/24 - 07/31 (2) 07/17 - 07/24 (2) 07/10 - 07/17 (1) 07/03 - 07/10 (1) 06/26 - 07/03 (1) 06/19 - 06/26 (3) 06/12 - 06/19 (4) 06/05 - 06/12 (5) 05/29 - 06/05 (6) 05/22 - 05/29 (2) 05/15 - 05/22 (1) 05/08 - 05/15 (2) 05/01 - 05/08 (2) 04/24 - 05/01 (2) 04/17 - 04/24 (3) 03/27 - 04/03 (1) 03/13 - 03/20 (3) 02/27 - 03/06 (6) 02/20 - 02/27 (6) 02/13 - 02/20 (5) 02/06 - 02/13 (6) 01/30 - 02/06 (4) 01/23 - 01/30 (1) 2010 (26) 2009 (44)
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