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
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.
Piping Fundamentals - For Fresher Engineers
In any pIant various fIuids fIow through pipes
from one end to other.
Now Iet us start with a pIant where we see three
tanks.
Tank-1, Tank-2 and Tank-3
We have to transfer the content of Tank no. 1 to
the other two tanks.
We wiII need to connect pipes to transfer the
fIuids from Tank-1 to Tank-2 and Tank-3
LET US BRING THE PIPES.
We have just brought the pipes, now we
need to soIve some more probIems.
Pipes are aII straight pieces.
We need some
branch
connections
We need some bend
connections
To soIve these
probIems we need the
pipe components,
which are caIIed
PIPE FITTINGS
These are the pipe fittings,
There are various types of fittings for various
purposes, some common types are -
EIbows/Bends, Tees/Branches,
Reducers/Expanders, CoupIings, OIets, etc.
Anyway, the pipes and
fittings are in pIace, but the
ends are yet to be joined with
the Tank nozzIes.
We now have to compIete the
end connections.
These, in piping term, we caII
TERMINAL CONNECTIONS.
These are fIanged joints
This is a weIded joint
So far this is a nice arrangement.
But there is no controI over the fIow from Tank-1
to other tanks.
We need some arrangement to stop the
fIow if needed
To controI the fIow in a pipe Iine we
need to fit a speciaI component.
That is caIIed - VALVE
There are many types of vaIves, categorized
based on their construction and functionaIity,
Those are - Gate, GIobe, Check, ButterfIy, etc.
Other than vaIves another important
Iine component of pipe Iine is a fiIter,
which cIeans out derbies from the
fIowing fIuid. This is caIIed a
STRAINER
Here we see a more or Iess functionaI piping
system, with vaIves and strainer instaIIed.
Let us now investigate some aspects of pipe
fIexibiIity.
If this tank nozzIe
expands, when
the tank is hot.
In such case we need to fit a fIexibIe
pipe component at that Iocation,
which is caIIed an EXPANSION
JOINT
When some fIuid is fIowing in a pipe we may
aIso Iike know the parameters Iike, pressure,
temperature, fIow rate etc. of the fIuid.
To know these information we need
to instaII INSTRUMENTS in the
pipeIine.
There are various types instruments to measure various
parameters. AIso there are specific criteria for instaIIation
of various pipe Iine instruments.
Next we shaII Iook
into how to
SUPPORT the
pipe/and it's
components.
Here are some of the pipe supporting arrangements.
There can be numerous variants. AII depend on
piping designer's preference and judgement.
Let us see some OTHER types of supports
We have just compIeted a pipe Iine design.
We shaII rewind and check how it is reaIIy done in practice.
First the fIow scheme is pIanned,
1) What, 2) From what point, 3) To which point
Pipe sizes are seIected, pipe materiaI and pipe waII thickness are seIected.
Types of VaIves are pIanned
AIso the types of instruments required are pIanned
We represent the whoIe thing in a drawing which is caIIed Piping and
Instrumentation Drawing, in short P&ID. For P&ID generation we use SPP&ID
software.
By this time you have aIready come to know that whiIe we prepare P&IDs in
SPP&ID, we enter aII the pipe Iines system information in the drawing.
So the SPP&ID drawing is an InteIIigent drawing which under it's surface carries aII
the information about a pipe Iike, Pipe size, FIowing FIuid, etc.
Let us see a P&ID prepared in SPP&ID
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 Iayout work.
Here we carryout pipe routing / Iayout in VirtuaI 3D environment.
PreferabIe
Not PreferabIe
We use PDS 3D software to route piping in the PIant virtuaI 3D space.
We caII this as piping modeIing or physicaI design.
WhiIe deveIopment of piping Iayout we have to consider the foIIowing
Piping from source to destination shouId be as short as possibIe with minimum
change in direction.
ShouId not hinder any normaI passage way. AIso shouId not encroach any
equipment maintenance space.
WhiIe carrying out pipe routing we aIso need to consider the foIIowing
VaIves, strainers, instruments on the pipe shouId be easiIy accessibIe.
If needed separate ACCESS PLATFORMS to be provided to faciIitate these.
Desired Iocation and orientation of vaIves / instruments and other pipe
components are to be checked and maintained, Iike some vaIves or strainers
can onIy be instaIIed in horizontaI position.
Specific requirements for instrument instaIIation to be checked, Iike
temperature gauge can not be instaIIed in pipe which is Iess than 4 inch in size.
Specific requirements of STRAIGHT LENGTH of pipe for some components to
be maintained, Iike for fIow orifice we need to provide 15 times diameter
straight pipe Iength at upstream of orifice and 5 times diameter straight at down
stream of orifice.
ExampIe of Straight Iength requirement for FIow Orifice
AIso arrangement is kept in the
pipeIine so that Iiquid can be
drained out if required.
To achieve this a DRAIN
connection with VaIve is provided
at the Iowest point of the pipeIine
Pipes are aIso sIopped towards Iow
points.
For PipeIine which shaII carry Iiquid, we have to make sure that aII air is aIIowed
to vent out of the Iine when the Iine is fiIIed with Iiquid.
To achieve this a VENT connection with VaIve is provided at the top most point
of the pipeIine.
Let us Iook
into typicaI
Vent and
Drain
arrangement
in a pipeIine
Let us have a Iook into a piping modeI done by PDS 3D
This is a 3D modeI
of Feed water Iine
aIong with pumps
and other
accessories
$&% - When hot fIuid fIows through pipe then generaIIy pipe is insuIated.
There are two primary reasons for insuIating the pipe carrying hot fIuid.
Containing the heat inside the pipe. InsuIation preserves the heat of the fIuid. It
is caIIed Hot InsuIation
PersonneI safety, so that peopIe do not get burn injury by touching hot surface
of pipe. It is caIIed PersonneI Protection InsuIation
CoId pipes are aIso insuIated
CoId or chiIIed fIuid carrying pipes are insuIated to prevent heating of coId fIuid
from outside. It is caIIed CoId InsuIation.
Some times coId pipes are insuIated to prevent condensation of atmospheric
water vapor on pipe surface. It is caIIed Anti-Sweat InsuIation.
Other types of InsuIation
When gas fIows through pipes at high veIocity, it creates noise. In such cases
pipes are insuIated to reduce noise. It is caIIed Acoustic InsuIation.
Some times pipe and it's content are heated from outside, by heat tracing
eIement. In that case pipe aIong with heat tracing eIement are insuIated to
conserve the heat of the tracer. It is caIIed Heat Tracing InsuIation.
INSULATION MATERIAL - The insuIating materiaI shouId be bad conductor of heat.
There are two basic categories
1) Fibrous MateriaI, which has Iarge voids fuII of air between fibers - Cork, GIass WooI,
MineraI WooI, Organic Fibers. Note stagnant air is a bad conductor.
2) CeIIuIar MateriaI, which has cIosed void ceIIs fuII or air - CaIcium SiIicate, CeIIuIar
GIass (Foam GIass), PoIyurethane Foam (PUF), PoIystyrene (ThermocoI), etc.
Some times Cast materiaI Iike Cement PIaster or PIaster of Paris are aIso used.
INSULATION CLADDING - InsuIation materiaIs are generaIIy soft or fragiIe. So the
outer surface of insuIation are protected with AIuminum sheet or GI sheet
cIadding.
Have a look at how
pipes are insulated,
and general
components of
insulation
Pipe Sizing CaIcuIation - to seIect required pipe diameter based on veIocity and pressure drop.
ind out
low volume
per second
Check Velocity
Allowable per
second
Calc. flow area
required and
Pipe size
Calc. Press.
Drop for that
Pipe size
Check Press.
Drop meets
Press. Budget
Pipe
Size
OK
YES
ncrease
Pipe Size
NO
Pipe MateriaI SeIection - to seIect appropriate pipe materiaI based on fIowing fIuid property.
ind out type
of luid
flowing
Check Pipe
life
Expectancy
Select suitable
Material per
practice (Note-1)
Check Mat.
Listed in
Design Code
Pipe
Material
OK
YES
See Note-
1
NO
Note-1 : MateriaI is seIected per past experience with cost in
mind and per materiaI Iisted in design code. If materiaI is
not Iisted in code we may seIect next suitabIe materiaI
Iisted.
ind out
luid Temp.
& Pressure
Pipe Thickness SeIection - to seIect appropriate pipe thickness based on fIowing fIuid property.
Select Mat.
& Diameter
as above
Decide on
Corrosion
allowance
Calc. Pipe
Thickness per
Code
ind out
luid Temp.
& Pressure
In Power pIant there are some piping which carries steam at high pressure and
temperature. And aIso there are piping which carries water at High pressure.
These pipes carries the main cycIe steam and water of the steam power pIant.
These pipeIines are caII the CRITICAL PIPING.
Very speciaI care are taken for design of these piping.
First the pipe materiaI seIection for such piping is very important as it has to
withstand the high pressure and may be aIso high temperature.
As these pipes carry the main system fIuid of the power pIant, they are given
the right of way, and routed at beginning of the overaII pIant Iayout.
Steam pipes run at very high temperature and the hot pipes expand. We have to
buiIt in fIexibiIity in the high temperature pipe routing so that the expansion
force is absorbed within the piping.
AIso there shouId be enough fIexibiIity in these pipe routing so that high Ioads
are not transferred to the nozzIes of Turbine or Pumps
There are many recognized internationaI codes which Iay down guide Iines and
mandatory requirements for design of such piping.
The most important codes used by power pIant piping engineers are
ASME ANSI B31.1- Power Piping Code & IBR - the Indian BoiIer ReguIation
Pipe Stress AnaIysis
We have aIready seen that some of the pipes are subjected to high pressure
and high temperature. AIso pipes carry the Ioad of the fIowing fIuid.
We need to check and confirm the pipe is not going to faiI with these Ioading.
This process of checking the stress deveIoped in the piping due to various
Ioading is caIIed Pipe Stress AnaIysis/FIexibiIity anaIysis.
In the process of AnaIysis we appIy various postuIated Ioading on the pipe and
find out the stress resuIted from these Ioading.
Then we check with governing codes if those stresses generated are
acceptabIe or not.
We check support Ioad & movement for various Ioading condition.
We aIso check out the terminaI point Ioading generated from pipe to the
equipment connected to the pipe. This Ioading are to be within acceptabIe
Iimits of the equipment suggested by the vendors.
We aIso find out the pipe growth due to change in temperature and need to
keep the movement of pipe within acceptabIe Iimits.
Pipe Stress AnaIysis is an Interactive and Iterative process. Each step is
checked
If a check faiIs we have to go back, modify the Iayout and restart the anaIysis.
PIPE STRESS ANALYSIS
Inputs
Geometric Iayout of Pipe
Pipe supporting configuration
Pipe Diameter and Thickness
Pressure inside Pipe
CoId and Hot temperatures of Pipe
Weight of Pipe and insuIation
Weight of carrying FIuid
Pipe materiaI Property (Young's ModuIus,
ThermaI Expansion Coefficient)
Thrust on pipe due to bIowing wind.
Thrust on pipe due to earthquake
Load of Snow on pipe
Any transient Ioading Iike Steam Hammer
Ioad
Any other Ioad on the piping
TooIs we use
PIPSYS - is an integrated pipe stress
anaIysis moduIe of PLADES 2000
CEASER - CommerciaI Piping anaIysis
software
There are many other commerciaI software
avaiIabIe
Outputs
Stress of the pipe at various Ioading
conditions
Load at various supports and restrains.
Movement of pipe at support Iocations
Pipe terminaI point Ioading.
Codes and Standards
In generaI Power PIant Piping have to
compIy stipuIations of ASME ANSI B31.1
In India Power cycIe Piping to compIy IBR
code requirements.
Types of Pipe Supports
n the beginning of this discussion we
talked about various types of pipe
supports. Here is some elaboration
There are three generaI types
Rigid type (no fIexibiIity in the
direction of restrain)
Spring type (AIIows pipe
movement in direction of
Ioading)
Dynamic Support (Degree of
restrain depends on acceIeration
of Ioad)
There are two types of spring
support
VariabIe Ioad type, here support
Ioad changes as the pipe moves.
Constant Ioad support, the Ioad
remains constant within some
range of movement.
Constant Load Spring
VariabIe Spring
R
i
g
i
d

H
a
n
g
e
r
R
i
g
i
d

S
u
p
p
o
r
t
Dynamic Support,
Snubber
Rigid Support
Some SpeciaI Considerations for Piping
When pipes are routed UNDER GROUND (Buried) foIIowing points to be kept in mind
Minimum pipe size to be routed under ground shaII be not Iess than1 inch.
Avoid fIange joint in U/G piping.
Keep in mind if pipe Ieaks U/G, it wiII be difficuIt to detect, so avoid U/G routing of pipe
carrying hazardous fIuid.
Pipe to be Iaid beIow Frost Zone at areas where ambient temperature goes beIow freezing.
U/G, Buried piping shouId be properIy protected from corrosion.
Pipe may be properIy wrapped and coated to prevent corrosion.
Or U/G piping be protected by using Cathodic protection.
Freeze Protection of outdoor Piping
In the areas where the ambient temperature goes beIow freezing there is a possibiIity that
the Iiquid content of pipe may freeze whiIe the pIant is under shut down.
For simiIar case pipes are wrapped with heat tracing eIements to maintain the content
temperature above freezing (around 4 deg. C) even when the ambient temp. is beIow
freezing.
EIectric Heat tracing is done by wrapping eIectric coiI around pipe, which turns on as the
ambient temperature goes down. Pipes are insuIated over the heat tracing coiIs.
Heat tracing can aIso 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.
For more info about Piping visit
http://piping-info.blogspot.com