Beruflich Dokumente
Kultur Dokumente
1. General 2. Information Required 3. Evaluation of Information 4. Line Identification 5. Piperack Width 6. Piperack Elevation 7. Line Location in Piperacks 8. Piping Economy in Piperack and its Influence on Plant Layout 9. Piperack General Arrangement Checklist 10. Pipetracks 11. Trenched Piping (Civil Department) 12. Underground Piping (by Civil Department)
1. General
The pipeway conveys all main process lines connecting distant pieces of equipment, relief and blowdown 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 are usually routed in the pipeway. Pipeways are classified by their relative elevation to grade.
1.1 Piperack
Overhead piping supported on steel or concrete bents.
1.2 Pipetrack
Above ground piping supported on concrete sleepers at grade level. (Off site areas where equipment is well spaced out)
te a fire hazard through the length of the trench. For these reasons, only pump out lines, chemical sewers or chemical drain collection systems are sometimes placed in trenches and routed to a pit or underground collection tank.
Battery limit, valving and spade requirements. Catwalk, platform and ladder access to valves and relief valves in piperack. Minimum headroom and clearances under overhead piping or supporting steel within areas Pipeways and secondary access ways Main access roads Rail roads Standard to be used for minimum spacing of lines in paperacks Handling and headroom requirements for equipment positioned under piperacks Operating and safety requirements affecting piperack and structure design Location of cooling water lines underground or above ground Trenched piping, if any.
Pipe sizes. Pipe classes, and line number. Valving. Manifolding. All instrumentation. Equipment and lines requiring services, i.e. water steam, air, nitrogen etc.
And any additional services peculiar to the plant being worked on, e.g.:
3.2 Development
With the receipt of engineering flow diagrams and utility flow diagrams, a more complete and accurate assessment of rack space is possible. Utility headers generally run the whole length of the piperack, so should be taken into account when estimating additional space required. To assist Process Department in sizing utility headers in the pipeway a line routing on a repro of the plot plan, showing order of take-offs is required.
4. Line Identification
Certain types of piping require special consideration:
Products lines which run from vessels, exchangers or pump to battery / unit limits Crude or other charge lines entering the unit which run along piperack before connecting to process equipment, furnaces, exchangers, holding drums or booster pumps.
5. Piperack Width
The width of piperack is influenced by :
The number of lines Electrical/instrument cable trays. Space for future lines.
The width of a piperack 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 piperack.
W = ( f x N x S ) + A meters
Where f, safety factor = 1.5, if the lines have been laid out as described in initial evaluation.
Where f, safety factor = 1.2, if the lines have been laid out as described under development.
Usually - S = 300 mm
Lines larger than 18. Future lines. Instrument and electrical cable trays. Any slot for pump discharge lines 500 mm - 1 meter.
The total width is thus obtained. If W is bigger than 9M usually two piperack levels will be required.
Note : At the beginning of a job, `W` should usually include 30 - 40% of clear space for future lines.
The width of the piperack may be increased or determined by the space requirement, and/or access to equipment arranged under the piperack.
Below figure shows typical piperacks bents with tabulated dimensions. Total available piperack width of each type of support is included. This table can be used for selection. The most commonly used piperack supports are types 2, 3, 4 and 5.
Smaller lines which must be supported more frequently ( see Company design specification recommended span between pipe supports ) Liquid filled lines requiring shorter span than gas filled 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 Space requirements of equipment at grade can sometimes influence piperack bent spacing.
6. Piperack Elevation
Piperack elevation is determined by the highest requirement of the following :
Headroom over main road Headroom for access to equipment under the piperack Headroom under lines interconnecting the piperack and equipment located outside.
The size of steel or concrete beam supporting overhead piping must be taken into consideration. Headroom requirements for each job are detailed in Company specification no. C100 and coordination procedure.
Figure 2A illustrates this requirement. Choice of top elevation of lateral piperack midway between the top an bottom main piperack elevation allows turning up or down at the intersection.
Generally, lines running at right angles to main piperack are assigned elevations 500 mm to 1 meter higher or lower (depending on headroom requirements) than lines running in main piperack. 500 mm differential between pipe runs is the absolute minimum.
Figure 2B shows a piperack intersection where the respective main and lateral piperack elevations do not slot between each other. This design complicates routing of lines from piperack to the other, especially where lines run on the bottom levels of both piperacks. Avoid this design at all cost.
Where a single tier piperack turns through 90, and all lines can be kept in the same sequence in both directions, no elevation difference is necessary. When lines sequence changes, introduce an elevation change at the turn. See below figures.
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.
The central piperack portion is reserved for utility lines which may serve both right and left hand areas on the plant. However, utility lines serving one or two pieces of equipment should be on the same side of the piperack as the equipment to which they connect.
Process lines which interconnect equipment on both sides of the piperack should be placed close to utility lines, and can be on either side of piperack, 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 piperack.
If possible, a centrally placed section of the piperack is reserved for future lines. This section should run the whole length of the piperack. Should this be impracticable, a series of smaller sections, running the whole length of the piperack, are to be provided. (see below figure).
To determine expansion of hot lines, use Company engineering guide, Attachment thermal expansion of pipe materials.
8. Piping Economy in Piperack and its Influence on Plant Layout 8.1 Piperack Layout
Plant layout determines the main piperack piping runs. The shape of piperack is the result of plant arrangements, site conditions, Clients requirements and overall plant economy. See below figures.
Piping economy depends primarily on the length of lines routed in the piperack. Below figures shows critical dimensions which influence overall cost. These dimensions depend on overall plant layout and should be carefully considered when the plot is arranged.
Dimension A, (see below figures) is the total length of piperack and is governed by the number and size of equipment, structures and buildings arranged along both sides of the piperack. On average, 3 meters of piperack length are required per item of process equipment, good lay-out can reduce piperack length. (Thereby costs).
Equipment in pairs, stacked exchangers supported from towers, two vessels combined into one, closely located towers with common platforms, process equipment located - under piperack - are examples which help shorten piperack length. In a well arranged plant, average length of piperack per item of process equipment can be reduced to 2.1 meters to 2.4 meters.
Careful selection of dimensions B and C, below figure will minimize interconnection equipment on opposite sides of piperack. C is normally no more than 1.8 meters to 3 meters.
Dimensions D and E, (see below figure), minimize. Overgenerous dimensioning here will increase vertical pipe lengths. Maximize use of available platforms for access to valves. Where air fins are located above the piperack, use associated air fin maintenance platforms, modifying their extent if necessary. This method will be cheaper than adding special platforms in the piperack.
Steam (trap any pockets and dead ends) Slurry Blowdown (these lines must be self-draining) Caustic, acid and Phenol (all these services to be self draining) R.V.s both inlet and outlet Vapour to knock-out pots Heavy products, bitumen, wax Pump suctions Lethal and toxic substances
On hot lines, check shoe requirements and clearances at changes of direction (pipe expansion).
Provide steam traps at : low points, up-stream of loops and dead ends, via condensate drip legs.
On steam, air and condensate headers, take-offs to be from top of headers. RV headers high or low elevation. Before finalizing elevation of RV header consider elevation of all RV discharges and elevation of knock-out drum at flare.
Where lines change elevation bends may be used providing difference in elevation is adequate and specification permits Header take-offs in piperacks, use elbows Special piping: Catalyst lines 5D (minimum). Vibrating piping 5D. Small bore usually below 2 (Client preferred).
Pipe setting: to be avoided in large bore lines. Small bore lines to be set only where absolutely necessary.
Pipe Stress Department will advise which piping systems require formal stress analysis.
Steelwork clearances : check steelwork clearances for addition of fireproofing (lower elevation of piperack), brackets, gussets and thermal expansion of lines.
Concrete support clearances: check for local thickening of concrete columns due to method of fabrication adopted (i.e. corbels).
Valves: check clearances and accessibility. Make full of extending platforms for operation (i.e. air fin maintenance platforms).
Chain wheels: preferably do not use. However, if necessary, check chain clearances. Spading and valving at battery limit : check for accessibility if necessary, provide access platform.
10. Pipetracks
This type of pipeway is generally associated with offsite areas where equipment is well spaced out, and land space is not a premium.
Where small bore lines are few, sleeper spacing may be determined by the pipe span of large bore lines provided small bore lines are supported off the larger lines at adequate intervals. An angle with U bolts is sufficient (check with Pipe Support Section).
depending on line size and substance carried in pipes, (i.e. gas or liquid).
All lines must be supported. At changes of direction due to long overhangs, for narrow pipetracks a diagonal corner sleeper is recommended. On wide pipetracks, use alternative method of two short sleepers located near corner. See below figures.
As pipetracks are generally single tier, no change in elevation is necessary at changes of direction. This is effected by use of a flat turn. See below figures.
For individual line elevation above sleeper, use Company job specification no. C4 elevation of hot insulated lines.
10.8 Valves
Where possible, these should be grouped at the edge of an access platform for ease of operation. Drain valves where possible should be brought to outside of pipetrack for ease of operation. The same applies to steam trap assemblies.
Horizontally elevated expansion loops above pipetrack should be provided where necessary. Group all hot lines requiring expansion loops, hottest and largest line on the outside, on one side of pipetrack. (Generally, the side chosen is that side which has the highest number of take-offs serving equipment on that side).
Trenchers must be enough to allow sufficient clearance between trench wall and piping. 150 mm between outside of pipe and inside of wall is the minimum acceptable clearance. This will allow for installation of piping, painting and future maintenance. See below figures. Total width of trench required may be determined by using method detailed above. Piping Department will advise Civil Department of requirements.
Line location in a trench carrying a number of lines should be carefully chosen for maximum piping economy consistent with stress requirements, if any.
Open trenches require drains to stop accumulation of surface water. Trench bottom should be sloped towards drain points. In this case, pipe supporting is by means of angle steel or I beams set into the walls, allowing bottom for free drainage to nearest drain point.
This method allows drainage of a trench by a minimum of drain points between each pipe support as would be the case of solid concrete pipe supports built up from the trench. Before proceeding on trench drainage check with coordination procedure and Civil Department for water table level.
Where flammable liquids are carried in trenched lines, a fire break is provided at suitable intervals along a trench and at each intersection. This generally consists of two concrete walls 1 M - 1.25 M apart, with the space in between filled with sand. Where highly flammable gasses are carried, the whole trench, after installation of piping, is back filled with sand. Piping will advise Civil Department of requirements.
With future maintenance in mind, buried lines should be located well clear of foundations, and if running side by side, well spaced out. A minimum of 300 mm clearance is necessary between foundations and lines and between the lines themselves.
Above ground safe drain-tails will enter below ground drain line via a tundish (concentric reducer normally) or if a sealed system and cooling water lines by a flanged stub raised above ground.
Flanged connections should be a minimum of 300 mm above prevalent grade level. It is advantageous to set a common level for all these take offs at the outset of the job. When locating tie-in connections to underground systems, especially from elevated drain points, and adjacent to equipment plinths, ensure adequate clearance.
All buried steel pipes should have applied a corrosion resistant coating and wrapping.
Deep valve boxes for buried lines should be designed with ample room inside the box for a maintenance man to bend over and use wrenches for tightening flanges of re-packing valves. Consideration should be given to the use of concrete pipe in lieu of square boxes.
The criteria for a good underground piping design should be ease of maintenance. Piping should be so spaced as to allow easy digging out and replacement of faulty sections; for this reason, never run underground piping under or through foundations.
Figures - Table
TYPE
PIPERACK
CANTILEVER
NUMBER
No.
WITHOUT CANTILEVER
WITH CANTILEVER
WIDTH A
WIDTH B
OF ELEV.
3000
3000
6000 TO 7300
9150 TO 10400
6000 TO 7300
1500
8500 TO 9750
11600 TO 12800
8500 TO 9750
1500
11900 TO 14300
13700 TO 16150
6100 TO 7300
900 OR 1200
16800 TO 19200
18600 TO 21000
8500 TO 9750
900 OR 1200
8500 TO 10400
11000 TO 12800
6100 TO 7300
900 OR 1500
1.5
12200 TO 13400
14650 TO 15850
8500 TO 9750
900 OR 1500
1.5
EXPANSION LOOPS
TRENCHED PIPING