Piping Engineering

Manilal A M
Assist. Prof. in Chemical Engineering
Contents
Scope Of Piping Engineering
Pipe Sizing Techniques
Mechanical Design Of Pipes
Codes and Standards
Piping Elements
Stress Analysis of Piping Systems

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Various Stresses in Pipes
Pipe Support Selection and Design
Stress Analysis of Piping Systems
Expansion Joints
Jacketed Piping
Basics of Piping Drawings
Plot Plan Fundamentals
Equipment and Piping Layout
Dynamic Analysis of Pipes

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Scope Of Piping Engineering
Life of a Chemical Process





Knowledge Base Required
Chemical Engineering
Mechanical Engineering
Metallurgical Engineering
Civil Engineering


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Commissioning
Concept Beyond
Piping
Engineering
Major Phases

Techno-Economic Feasibility
Design Phase
Construction Phase
Commissioning Phase
Operation/Production Phase
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Techno-Economic Feasibility
Economics- guiding principle
Risk factor and pollution consideration
For new plants
Chemical Path Feasibility
Thermodynamic feasibility
Kinetic feasibility
Reaction Path Synthesis Algorithms( Organic
Synthesis)
BFD
Engineering/Technological Feasibility
Batch or Continuous or Combination of both
Detailed processes involved
Unit operations
Unit processes

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Process Synthesis
BFD
Decision on Unit Operations
Choices of Equipment
Plant Cost
Operating Cost
Scope of Optimization
Cost Optimal Flow sheet Configuration
Selection of other equipments
Utilities


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End results


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Conceptual Design
Equipments and their
Capacities (Roughly)
Capital cost and
Operating Cost
Raw material availability and Cost and
Market prizes of products and by products
Techno-Economically feasible process
Design Phase
Rigorous Engineering Calculations
Essentially two components
Process Design & Mechanical Design
Process Design
Operating Conditions
Equipment Sizes
Simulation Software
Steady State Simulators
Dynamic Simulators

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BFD PFD
PFD
Father drawing
Instead of blocks symbols
Max Possible information about the process
Stream specifications
Unique numbering, stream table
Inspection and review of PFD
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Control System Synthesis and Design(CSSD)
Control System Design
System Identification
Manipulated/Controlled variable selection
Controller selection
HAZOP
Identify deviation from expected steady state
Identify hazard
Monitoring instruments
Stand by
Mitigation measures
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Many more to do with the PFD
Hydraulic Calculations
Pressure drop
Compressible/ Incompressible
Single Phase/ Multi phase
Available correlations
Pipe Sizing
Operating Cost
Capital cost
Batch/ Semi batch
Storage tanks
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P&ID
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PFD
P&ID
Stand-by
Equipments
Storage
Tanks
Pipe Sizes
Instrumentation
&
Control
Valves
Other
Fittings
P&ID
Is the Mother Drawing shows
Relative elevations of equipments
Number of Trays, feed tray location (Distillation
Column)
Cardinal Drawing for various section
Stored and updated for the entire life cycle
Basic drawing for
subsequent equipment design
Plant layout
Piping layout
Insulation calculations
Bill of material (BOM)

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Bible for Piping Engineer
Details of pipe lines
Material of Construction
Service
Mechanical Design
Pressure vessels
Closures
Flanges
Gaskets
Bolts
Man holes and Hand holes
Reinforcing pads
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Mechanical Design
Stiffening rings
Internally/Externally
Tall vessels
Wind loads
Supports
Seismic effects
Eccentric loads

Considering all these fabrication drawings are issued
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Piping (preliminary )
Pipe wall thickness design
Fix nominal diameter and schedule
for first BoM for pipe length requirement


Design Phase is Over
7/17/2013 17
Construction Phase
Choice of Plant location
Politico-socio-economic considerations
Plant Layout
Unit layout/ Equipment Layout
Directly influence Piping layout
Piping (veins and arteries)
Routing
Stress Analysis
Supports
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Use of softwares
Civil structures/ Foundations
Software model of 3-D layout
Has all the details
BoM for pipes and piping elements
Can monitor project implementation
Can act as Complete database



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Commissioning
Not at all a smooth affair
Adhoc decisions need to be taken on field
Fabrication errors
Late or non delivery of items
Design errors
Steady state design
Evolve a good start up policy using dynamic
simulators

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Normal Operation Phase
Properly designed smooth run
Need debottlenecking
Minor/major changes
Installation of additional equipment
Bypassing existing equipment
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PIPE HYDRAULICS & SIZING
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PIPING
Pipe sections when joined with fittings, valves, and
other mechanical equipment and properly
supported by hangers and supports, are called
piping.
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Why Pipe Sizing Is Important?
30% of total cost of process plant

Significant amount of operating cost

Significant amount of maintenance cost

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Pipe Sizing involves
Lots of experience
Engineering foresight and judgment
Not mere theory
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Pipe Sizing Procedures
1. Velocity considerations
2. Available pressure drop considerations
3. Economic considerations

Degree of difficulty: 3>2>1
P calculation is an integral part of 2 & 3
For (1) it is needed to quantify energy requirements


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Pressure drop calculations
Types of flow
Phase
Horizontal, Inclined
Through straight run pipes/ complex routings
Isothermal/ Non-isothermal
Incompressible/ compressible
Laminar/Turbulent
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BERNOULLIS EQUATION
Statement of Law of Conservation of Energy




Sum of the pressure head, velocity head and
elevation head is constant everywhere along the
flow path.
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2
2
2
2 2
1
2
2
1 1
Z
g
v
g
P
Z
g
v
g
P
+ + = + +

g
P

1
g
P

2
g
v
2
2
1
g
v
2
2
2
1
Z
2
Z
Fig. 1
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Frictional Pressure drop
BE need to be modify
Skin friction
Form friction
7/17/2013 30

P
Z
g
v
g
P
Z
g
v
g
P
A
+ + + = + +
2
2
2
2 2
1
2
2
1 1
Single Phase Pressure Drop Calculation
Single Phase Flow
Laminar
Transient
Turbulent
Reynolds Number

R
e
< 2000 - Laminar
2000<R
e
<4000 - Transition
R
e
>4000 - Turbulent

D - diameter for circular c/s
- 4x Hydraulic radius, for non- circular c/s



7/17/2013 31

Dv
R
e
=
Alternate definitions


G = linear mass velocity



W = mass flow rate in lb/h,
D = pipe ID in inches


7/17/2013 32

DG
R
e
=
D
W
R
e
31 . 6 =
Darcys Equation
7/17/2013 33
gD
v f P
D
2
) (
2
=
A

For turbulent flow region, use friction factor chart -

) , (
Factor Friction s Darcy
Roughness Pipe R f f
f
e D
D
=

ratio D different for R vs f

e D
) (c
Fanning's Equation
7/17/2013 34
gD
v f P
F
2
) 4 (
2
=
A

F D
F
f f
anning f
4
Factor Friction s F
=

Another friction factor used in pressure drop

calculation is the Churchill friction factor
C F D
f f f 8 4 = =
Be sure which chart you are using!!!
Linear region of for Laminar flow


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e
R vs f
e
C
e
F
e
D
R
f
R
f
R
f
8
16
64
=
=
=
Mathematical correlations
All equations are based on

7/17/2013 36
) ( Factor Friction s Darcy
D
f
3400000
e
R pipe, Smooth
50000
e
R pipes, commercial Rough
2
1
2 10
126 . 1
ln 656 . 19
10 8 . 56
Region Turbulent
64
Region Laminar
<
<
(
(

=
=
=

f
R
f
R f
R
f
e
e
e
D
Mathematical correlations
Blazius Equation, for fully developed flow

7/17/2013 37
(
(
(
(

+
=
<
=
=

2 1
2 . 0
25 . 0
888 . 0
27 . 0
1
656 . 19
, 3400000
046 , 0
3164 . 0
f R D
f
flow turbulent developing R with pipe rough or smooth for
R f
equation Blasius Another
R f
e
e
e
e
c
Mathematical correlations
Colebrook- White Equation
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mm pipe steel commercial
f R
f
pipes smooth For
f R
d
f
D e
D
D e D
05 . 0
51 . 2
log 2
1
51 . 2
71 . 3
log 2
1
=
(
(

=
(
(

+ =
c
c
Roughness Factor

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Calculation of Actual Pressure Drop

Use this in BE to get actual pressure drop
If Piping contains valves and fitting
Equivalent pipe length of fittings
Equivalent pipe length for entrance and exit effect
Add all these and use in BE
Temp and Pressure Effects?
7/17/2013 40
length Effective P calculated P frictional Net A = A
Over Design
Recommend next higher size than calculated
Design for 30%extra flow rate
Design for 30% less pressure drop
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Two Phase Calculations
Depend on flow regimes
7 flow regimes are identified
Bakers procedure
Bakers parameters
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P A
Y X
B and B
| |
5 . 0
3 1 5 . 0
) (
16 . 2
3 2
) (
) ( 531
v l
v
Y
l
l
l
v l
v l X
A
W
B
W W B

o

=
(

=
7/17/2013 43
dyne/cm liquid, of tension Surface
cP liquid, of Viscosity
, sec
lb/ft density, Liquid
lb/ft density, Vapour
lb/h rate, flow Liquid
lb/h rate, flow Vapour
2
3
3

l
l
l
v
l
v
ft area tional cross Internal A
W
W
o

Flow regimes
7/17/2013 44
Bakers Chart
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Correlations for
Lockhart Martinelli Method
Lockhart Martinelli modulus (X)


From fig obtain Y
L
and Y
V

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P A
( ) ( )
V L
P P X A A = /
2
two the of largest the take
) ( ) (
) ( ) (
L L LV
L L LV
P Y P
P Y P
A = A
A = A

7/17/2013 47
Pipe Sizing
Based on Velocity Considerations
Simplest approach

Liquid - 1-3 m/s
Gases/Vapour - 10-30 m/s



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ocities) linear vel Recomanded rate, Flow ( f D=
Based on Available Pressure Drop
Most involved/important method
Sized to meet process requirement
Acceptable maximum hydraulic pressure drop
A minimum pipe size, which causes at the most
this pressure drop is recommended
Trial and error procedure
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Assume a commercial pipe size (NB)
Fix the schedule number (pressure design decides it)
Obtain the ID
Calculate hydraulic P
If P> acceptable level
Take a higher pipe size and repeat the calculations
Recommend, minimum pipe size meeting the P
requirement
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Situations demanding this method
Suction pipe sizing for a pump
Flow of volatile liquid through pipes
Feed to distillation column
Lines having control valves
Lines from thermo-siphon reboiler
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Economic Pipe Sizing
Least Annual Cost Approach
If the previous two constraints are not stringent
Go for Economic pipe sizing
Economics is governed by
Capital cost
Operating Cost

Figures given below shows the Amortized cost,
Annual operating cost and Total cost, each vs NPS

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Optimum Pipe Dia
The cost of unit length of run pipe of diameter
D is calculated as

Let F be the fraction of cost of accessories per
unit length
The Total Capital cost =
Annualized Capital cost =
Where A
M
is the amortization factor


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5 . 1
353 . 0 XD C
D
=
D
C F) 1 ( +
D M
C F A ) 1 ( +
If annual maintenance cost if a fraction G of
the capital cost,
Total pipe cost is
Annualized capital + maintenance cost, C
P
,


Operating Cost


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D M
C F G A ) 1 )( ( + +
5 . 1
) 1 )( ( 353 . 0 XD F G A C
M P
+ + =
(

A
=
E
PYK W
C
F
0000542 . 0
7/17/2013 55
pumping of cost Annual C
kW.h) (per power, electric of cost
year per operation of hours
efficiency pump
lb/ft density,
lb/h , rate flow
psi drop, pressure hydraulic
F
3
=
=
=
=
=
=
= A
K
Y
E
W
P

The P can be calculated as



So, the cost of moving the fluid per year is



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84 . 4
16 . 0 84 . 1
1325 . 0
D
W
P

= A
(

=
E D
YK W
C
F
2 84 . 4
16 . 0 84 . 2
2840000

Total Annual cost of unit pipe length is

So,





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(

+ + + =
E D
YK W
XD F G A C
M T
2 84 . 4
16 . 0 84 . 2
5 . 1
2840000
) 1 )( ( 353 . 0

0 )
dD
dC
@( D of value
as obtained be can C minimizes which
T
T
= =
Optimum
Optimum
D
D
On solving


Most of the quantities in the above expression
are project specific.
The expression is further simplified with
representative values of A
M
,G,F,E,X,Y and K
as

7/17/2013 58
( )( )
169 . 0
337 . 0
027 . 0 479 . 0
1
0657 . 0
(

+ +
(

=
F G A
YK W
D
M
opti

027 . 0 142 . 0 479 . 0
027 . 0 142 . 0 479 . 0
276 . 0
717 . 1

S Q D
or
S Q D
LAC
LAC
=
=
7/17/2013 59
kWh K
year h Y
ft X
E
F
G
A
M
/ $ 0218 . 0
/ 7880
/ $ 32 . 1
55 . 0
75 . 6
01 . 0
143 . 0
=
=
=
=
=
=
=
169 . 0
D
169 . 0
D
) 01 . 0 /( 728 . 0 F
2196 , 0 F
factors Correction
+ =
=
a
Y
Given optimum Dia how to select commercial
size?
Concept of cross over diameter


If, D
LAC
>D
C
D
H
If, D
LAC
<D
C
D
L
7/17/2013 60
4 . 0 6 . 0
H L C
D D D =
But.
It is an industrial practice to
recommend a pipe of one size
higher than what is arrived at by
any of the above procedures.
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Thank You
7/17/2013 62