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Table of Contents 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)
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2.2 Process Flow Diagrams Process flow diagrams show main process lines and lines interconnecting process equipment. 2.3 Engineering Flow Diagrams Engineering flow diagrams are developed from process flow diagrams and show: Pipe sizes. Pipe classes, and line number. Valving. Manifolding. All instrumentation. Equipment and lines requiring services, i.e. water steam, air, nitrogen etc.
2.4 Utility Flow Diagrams Utility flow diagrams show the required services: Steam Condensate Water Air Gas
And any additional services peculiar to the plant being worked on, e.g.: Caustic Acid And refrigeration lines, etc.
3. Evaluation of Information 3.1 Initial Evaluation Use plot plan and process flow diagrams to make a preliminary assessment of which portion of process lines will be located in piperack and which lines will interconnect directly to nozzles on adjacent items of equipment. Draw lines to be located on piperacks on print of plot plan. Some idea of utility piping required must be established and included coordinate with Instrument and Electrical Section to assess what additional rack space may be required
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4.2 Relief Headers Individual relief lines, blowdown lines and flare lines should be self draining from all relief valve outlets to knock-out drum, flare stack or to a point at the plant limit. To achieve this, lines will connect into the top of the header and at 45 degrees in direction of flow. To eliminate pockets, and obtain required slope to knock-out drum some relief headers must be placed above the main piperack. 4.3 Instrument and Electrical Cable Trays Often instrument and electrical cable trays are supported on the piperack track. Space must be allocated to accommodate them from the outset. Due to the possibility of induced current interference instrument and communication cable trays must be located away from electrical and power cable trays. Consult with Instrument /Electrical Department for separation requirements. 5. Piperack Width The width of piperack is influenced by : The number of lines Electrical/instrument cable trays. Space for future lines.
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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. 5.1 Spacing between Piperack Bents Normal spacing between piperack bents varies between 4.6M to 6M. This may be increased to a maximum of 8M consideration must be given to : Smaller lines which must be supported more frequently ( see Company design specification recommended span between pipe supports )
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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. 6.1 Elevation at Piperack Intersection Where two two-tier piperacks meet, it is essential that elevations of lateral piperacks slot between elevations of main piperack. 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. 7. Line Location in Piperacks 7.1 One Tier Piperacks Below figure shows a cross section of a single level piperack. Heavy lines (very large diameter lines, large bore lines full of liquid) regardless of service are placed over or near the piperack columns. This simplifies steelwork or concrete piperack design. Centrally Compiled By: Laxmikant Sawleshwarkar
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Low point pockets to be avoided in the following lines : Steam (trap any pockets and dead ends) Compiled By: Laxmikant Sawleshwarkar CH-2 Page 8 of 25
High point pockets to be avoided in the following lines : Pump suctions Light ends Vapour/liquid mixes (hot tower bottoms - reflux lines) Crude lines
On hot lines, check shoe requirements and clearances at changes of direction (pipe expansion). Provide vents at high points. Provide drains at low points. 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. Bends, if used : (check with job specification). 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.
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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). For recommended pipe support spans, use Company standard. On an average minimum span = 3 meters maximum span = 6 meters 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. 10.3 Pipetrack Elevation Pipetrack elevation is set by maintenance access to piping items located underneath the pipetrack, i.e. drains and steam traps. A minimum of 12/300 mm clearance between
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Where trenchers are used to route lines such as: Pump out lines Chemical sewers Chemical drains
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. 11.1 Line Spacing Use Company job specification C100. recommended piperack spacing. 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. 11.2 Safety Precautions Most trenches have either a cover of concrete slabs or a grating. 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.
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Figures - Table
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No.
WIDTH A
WIDTH B
OF ELEV.
1 2 3
1500 1500
1 1 1
6100 TO 7300
900 OR 1200
8500 TO 9750
900 OR 1200
6100 TO 7300
900 OR 1500
1.5
8500 TO 9750
900 OR 1500
1.5
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EXPANSION LOOPS
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TRENCHED PIPING
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