PIPE WAYS DESIGN PIPE WAYS The pipe way carries: All main process lines connecting distant

pieces of equipment. Relief and blow down headers. All lines leaving and entering the plant. Utility lines supplying steam, air, cooling water and inert gas to the plant. Electrical and instrument cable trays

PIPE WAYS DESIGN Pipe rack: Overhead piping supported on steel or concrete

PIPE WAYS DESIGN Pipe track: Above ground piping supported on concrete sleepers

PIPE WAYS DESIGN

Importance of rack in Layout.

In order to arrange the piping within a process unit and interconnecting piping between units, inevitably a number of lines are most conveniently grouped at the same elevation on a common structure. Interconnection piping between process areas and offsite areas Effective utilization of plot plan area

PIPE WAYS DESIGN

Configuration: The pipe rack splits the plant into convenient parts. It takes various shapes such as straight, L,T,C, or even U. This configuration is based on the overall plant arrangement.

PIPE WAYS DESIGN

L configuration

T configuration

PIPE WAYS DESIGN

U configuration

Combination of shapes

PIPE WAYS DESIGN

An example

PIPE WAYS DESIGN Development of the pipe racks:

First step is the generation of the line routing diagram. Its a schematic representation of the all process line, utility piping systems.

PIPE WAYS DESIGN Inputs required:1. 2. 3. 4. 5. 6. 7. Job Specification PFD P&ID Utility Flow Diagrams Plot plan Interface details Anchor points

PIPE WAYS DESIGN Inputs required cont. 1. Job Specification

Battery limit, valving and spade requirements. Isolation valves and relief valves in pipe rack. Secondary access ways Main access roads Railway siding facility Standard to be used for minimum spacing of lines in pipe racks Operating and safety requirements affecting pipe rack and structure design

2. PFD
Process flow diagrams show main process scheme and interconnecting process equipment. Engineering flow diagrams are developed from process flow diagrams and show: Pipe sizes. Pipe classes, and line number. Valves. Manifold. All instrumentation. Equipment and lines requiring services, i.e. water steam, air, nitrogen etc.

3. P&ID

PIPE WAYS DESIGN Inputs required cont 4. Utility Flow Diagrams

Steam Condensate Water Air Gas Nitrogen

5. Plot plan 6. Interface details 7. Anchor points

PIPE WAYS DESIGN Pipe rack Width:

The width of pipe rack is influenced by : The number of lines Space for future lines. Interdistances b/w lines.

The width of a pipe rack may be calculated using the following method : First estimate number of lines as described. Add up the number of lines up to 18 diameter in the most dense section of the pipe rack. The total width in meters (W) will be :

PIPE WAYS DESIGN

Typical example

PIPE WAYS DESIGN Pipe rack Elevation:

Headroom clearance at battery limit. Main road access clearance. Secondary road access clearance. Maintenance equipment access clearance. Process requirements. Safety concepts. Construction feasibility. Project specifications.

PIPE WAYS DESIGN

PIPE WAYS DESIGN Elevation at Pipe rack Intersection:

Where two-tier pipe racks meet, it is essential that elevations of lateral pipe racks shall be between elevations of main pipe rack.

PIPE WAYS DESIGN

Change in direction in same elevation (Optional)

Change in direction in different elevation (Recomended)

Note: BOP shall be maintained

PIPE WAYS DESIGN

PIPE WAYS DESIGN Column spacing in Pipe Rack:

Following points to be considered:
Deflection of pipe at mid-span. Size of the majority lines. Hot lines which span shorter distances than cold lines of the same size and wall thickness Insulated lines; small bore, cold - insulated lines due to weight of insulation must be supported at relatively short intervals However normal span of pipe rack sections varies between 4.6M to 6M. In special case ,this may be increased to a maximum of 8M.

PIPE WAYS DESIGN

PIPE WAYS DESIGN Grouping of lines:

1.

Process Lines
Products lines which run from vessels, exchangers or pump to battery / unit limits Crude or other charge lines entering the unit which run along pipe rack before connecting to process equipment, furnaces, exchangers, holding drums or booster pumps. Lines interconnecting nozzles on process equipment more than 6M apart (closer spaced equipment may be directly interconnecting inside piping areas).

2. 3. 4.

Relief Headers Utility Headers Small & large bore lines.

PIPE WAYS DESIGN

PIPE WAYS DESIGN

PIPE WAYS DESIGN

PIPE WAYS DESIGN Piping layout on Pipe racks:

1.

One Tier Pipe racks

Heavy lines regardless of service are placed over or near the pipe rack columns. Place process and relief lines next to these. Lines serving left hand areas of plant on left, lines serving right hand areas on the right. central pipe rack portion is reserved for utility lines Process lines which interconnect equipment on both sides of the pipe rack should be placed close to utility lines, and can be on either side of pipe rack, depending upon location of equipment they serve. The position of product lines is influenced by their routing after leaving the unit, right, (left) turning lines should be on the right (left) hand side of the pipe rack.

PIPE WAYS DESIGN

PIPE WAYS DESIGN Piping layout on Pipe racks:

2. Two Tier Pipe racks
Utility lines are placed on the top level and process lines on the bottom level. This is not a rigid rule and where piping economy dictates certain process lines may be routed on the top level.

PIPE WAYS DESIGN

PIPE WAYS DESIGN Design of the pipe tracks: 1. Pipe track Width
Pipe track width may be estimated using the method detailed previously for pipe rack

2. Spacing of Pipe track Sleepers:

Depending on line size and substance carried in pipes, (i.e. gas or liquid). On an average minimum span = 3 meters, maximum span = 6 meters

3. Pipe track Elevation :

Pipe track elevation is set by maintenance access to piping items located underneath the pipe track, i.e. drains and steam traps. Minimum of 300mm,can be even 500mm.

4. Line Location
Line location with reference to bore and weight is unnecessary, as all pipes are supported on sleepers which rest directly on the ground All lines interconnecting process equipment and/or storage tanks located on left-hand side of pipe track are placed to the left-hand side. Similarly, all lines interconnecting equipment located on right-hand side of pipe track are placed to the right of pipe track. Lines interconnecting equipment located on either side of pipe track are placed near the center of pipe track.

PIPE WAYS DESIGN Design of the pipe tracks cont

5. 6. 7. 8. 9.

Line Spacing Road Crossings Access Ways Valves Expansion Loops

SAFETY CONCEPTS Safety concepts:

Heat radiation factors. Thermal radiation from the line/equipments should not affect the personnel involved in operations. Equipments (like furnace, flare stack etc) shall be located down stream of the prevailing wind direction.
Escape ways. Dead ends must be considered max of 7M. Max travel distance to a ladder/stair on a working platform must be 25M. Intermediate platform on the vertical ladder must be at 6M interval. primary & sec escape route to be considered. All main escape routes must be directed towards the road. Clearances. Head room must be considered a min of 2.2M.

SAFETY CONCEPTS Safety concepts cont.

Ergonomics & human factors. To prevent human errors and/or its consequences (reliability). To protect the users safety & health (integrity) Other Benifits: 1.To enhance productivity by human performance improvements (efficiency). 2.To enforce ease & comfort of operations (usability).
Fire fighting. Plant fire fighting facilities to be designed in such way that all the fire prone equipments & also the plant area fire can be covered at any point of time. Care should be taken care for the movement of emergency fire tender inside the plant.

Environment & Pollution factors.