Fig. 3.1.

4a

Fig. 3.1.4b

Fig. 3.1.5

DISCHARGE PIPING

SUCTION PIPING
ISOLATION VALVE

ISOLATION VALVE

NON RETURN VALVE

PI
CONCENTRIC REDUCER

PRESSURE INDICATOR

'Y' TYPE STRAINER

ECCENTRIC REDUCER F.S.D

DRAIN PUMP CASTING C L

COMPONENTS OF A TYPICAL PUMP SUCTION AND DISCHARGE PIPING SYSTEM

ECC. REDUCER

DRAIN

TYPICAL SUCTION LINE SUPPORT

FCV BYPASS LINE

BYPASS LINE (ALT)

COOLER

ARRANGEMENT FOR MINIMUM FLOW FOR CENTRIFUGAL PUMP

USE OF ECCENTRIC REDUCERS ALLOWS LARGER FLANGES ON VALVES TO CLEAR

ECCENTRIC REDUCERS AT PUMP CONNECTIONS

The complexity of piping system design, maintenance, and troubleshooting requires the process Engineers, the Maintenance Engineers and the Piping Engineers on the same Wavelength and work more closely together.

Fig. 3.1.6

The following general concepts apply for locating the heat exchangers.

a) Exchangers should be located adjacent to the related equipment., e.g. Reboilers should be located attached/ next to their respective towers, condensers should be located next to reflux drums close to tower.
Exchangers should be close to the other process equipment e.g. in case of draw off flow through an exchanger from a vessel/reactor bottom, the exchanger should be close to and under the vessel or reactor to have short pump suction lines. Overhead condenser shall be placed above the reactor to have minimum horizontal piping. b)

c) Exchangers connecting two equipment, one on shell side and the other on the tube side, located at a distance, should be placed where two streams meet, and on that side of the yard where majority of related equipment is placed. d) Exchangers between process equipment and the battery limit. e.g. product coolers, should be located near the battery limit to reduce pipe rum. e) Stack those exchangers which can be grouped together to simplify piping and save plot space. f) Leave space and access around the exchanger flanges and heads, and tube bundle cleaning/pulling space in front and in line with the shell.

While locating exchangers in a row, arrange the saddle to have more economical overall (lined up or combined) foundation / structure design. Further, travelling gantry can be provided in such case to handle a row of exchangers. h) The heat exchanger shall be located in the equipment layout with respect to the fixed saddle and the same is located closer to the head i) Outline the clearances and working space in the front and around both ends of the exchanger to facilitate shell cover and tube bundle removal as well as maintenance and cleaning. j) The channel end shall face the roadside for convenience of tube removal and the shell cover the rack side.

g)

The various clearances shall be as indicated in Fig. 3.3.1. All Dimensions are in mm Fig. 3.3.1a

Fig. 3.3.1b

The basic principles adopted in the heat exchanger piping are:

a) The working spaces should be kept clear of any piping and accessories to facilitate channel, shellcover and tube bundle removal, as well as maintenance and cleaning. b) Excessive piping strains on the exchanger nozzles from the actual weight of pipe and fittings and from forces of thermal expansion should be avoided. c) The piping shall be arranged in such a way that no temporary support will be required for removing the channel and tube bundle.

d) Provide easily removable spool pieces, flanged elbows, break flanges, or short pipe runs to provide adequate clearances for the operation of tube removal. e) The pipe lines with valves and control valves should run along with access aisle close to the exchanger. f) Pipe line connecting the exchanger with adjacent process equipment can run point to point just above required head room. g) Steam lines connecting the header on the rack can be arranged on either side of the exchanger h) Valve handles should be made accessible from the grade and from access way. These access way should be used for arranging manifolds, control valves stations and instruments

i) To avoid condensate drainage toward exchanger, the preferred connection for steam lines is to the top of the header. However, there is nothing wrong in having a steam connection from the bottom of the header if steam traps are placed at the low point j) The standard dimensions related to exchanger piping are given in sketch. These details are illustrated in Fig. 3.3.2.

Fig. 3.3.2a

Fig. 3.3.2b

The basic types used in the chemical process industry are

1) Fixed tube-sheet Heat Exchange

2) `U Tube Heat Exchangers

3) Floating Head type Exchangers

4) Kettle type Heat Exchanger

HEAT EXCHANGE NOMENCLATURE N-2 NOMENCLATURE OF HEAT EXCHANGER COMPONENTS For the purpose of establishing standard terminology, Figure N-2 illustrates types of heat exchangers. Typical part and connections, for illustrative purposes only, are numbered for identification table N-2 Table N-2 1. Stationary Head Channel 2. Stationary Head Bonnet 3. Stationary Head Flange-Channel or Bonnet 4. Channel Cover

5. Stationary Head Nozzel 6. Stationary Tubesheet 7. Tubes 8. Shell 9. Shell Cover 10. Shell Flange-Stationary Head End 11. Shell Flange-Rear Head End 12. Shell Nozzel 13. Shell Cover Flange 14. Expansion Joint 15. Floating Tubesheet 16. Floating Head Cover 17. Floating Head Cover Flange

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Floating Head Backing Device Split Shear Ring Slip-on Backing Flange Floating Head Cover External Floating Tubesheet Packing Box Packing Gland Packing Gland Klfjadlfkaj Tierods and Spacers Transverese Baffles or Support Plates

29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

Impingernent Plate Longitudinal Baffle Pass Partition Vent Connection Drain Connection Instrument Connection Support Saddle Lifting Log Support Bracket Weir Liquid Level Connection

FRONT END STATIONARY HEAD TYPES

SHEEL TYPES

REAR END HEAD TYPES

E A
CHANNEL AND MOVABLE COVER ONE PASS SHELL

L
FIXED TUBESHEET LIKE "A" STATIONARY HEAD

F
TWO PASS SHELL WITH LONGITUDINAL BAFFLE

M
FIXED TUBESHEET LIKE "B" STATIONARY HEAD

G
BONNET (INTEGRAL COVER) SPILT FLOW

N
FIXED TUBE SHEET LIKE "N" STATIONARY HEAD

P H C
REMOVABLE TUBE BUNDLE ONLY OUTSIDE PACKED FLOATING HEAD

DOUBLE SPLIT FLOW

CHANNEL INTEGRAL WITH TUBESHEET AND REMOVABLE COVER

S J
DIVIDED FLOW FLOATING HEAD WITH BACKING DEVICE

N
CHANNEL INTEGRAL WITH TUBESHEET AND REMOVABLE COVER

T
PULL THROUGH FLOATING HEAD

K
KETTLE TYPE REBOILER

U
U-TUBE BUNBLE

D X
SPECIAL HIGH PRESSURE CLOSURE DIVIDED FLOW

W
EXTERNALLY SEALED FLOATING TUBESHEET

32

32

37

27

29

14

12

34

34

12

37

33

BEM

36

34

31

34

12

30

21

27

32

34

10

12 34

35

35

33

CFU

Standards Of The Tubular Exchanger Manufacturers Association

36

34

31

12

34

23

27

28

32

15

23

24

25

22

36

34

10 33

35

35

34

12

19

20

21

AEP

36

34

10

28

12 34

27

23

24 26 24 23 15 1

36

34 12

35

35

34

12

34

Standards Of The Tubular Exchanger Manufacturers Association

36

5 34

31

31 12

25

27

28

18 36

37 36

15

18 1 5 34

10

35

35

12

34

11

13

12

33

Standard Of The Exchanger Manufactures Association

34

12

35 9

36

34

31

15

17

36

34

16

34

38

34 12

35

27

28

35

12

34

39

AKT

The following alterations can be suggested in order to achieve optimum piping arrangement. a) Elbow nozzle permits lowering of heat exchanger to grade to have better accessibility to valves and instruments. (Refer Fig. 3.3.3) b) Angular nozzle can save one or two bends in the pipe line.The maximum angle from the vertical centre line can be about 300. (Refer Fig. 3.3.4) c) Horizontal exchanger can be turned vertical for conserving floor space. Vertical exchangers can be changed to horizontal when installation height is restricted d) Exchanger saddle can also be relocated to adjust to a line-up or combined foundation design. (Refer Fig. 3.3.2)

Fig. 3.3.3

Fig. 3.3.4a

Fig. 3.3.4b

Interchange flow media between tube side and shell side. This can give the following advantages
If hotter liquid is allowed to flow through the tube, this will minimize the heat loss and/or avoid use of thicker shell insulation. If high pressure fluid flows on the tube side, only tubes, tube sheets, channels and cover have to be designed for high pressure. This reduces shell side thickness and the cost. Corrosive liquid should pass through the tube so that only the tubes and the channels have to be made of corrosion resistant material. If one medium is dirty and the other is clean, passing clean through the shell will result in easier tube bundle removal and cleaning.

Shell side volume is much more than the tube side and hence vaporization or condensation of free flowing fluid is more effective in shell.

When hazardous chemicals are water cooled, the water is passed through the shell. The tube leakage will contaminate the cooling water. On the other hand, the shell leakage can vent process material to the atmosphere.

Fig. 3.3.5

The piping associated with these vessels are simple. Economy of piping and access to valves and instruments depend on well-oriented nozzles. The nozzle and support orientation can be evaluated as below. (Refer Fig. 3.4.1)
Inlet/outlet nozzles Vents and Drains Relief Valves/Rupture Disc Level gauges Pressure and Temperature tap-offs. Manholes Vessel saddles

Fig. 3.4.1

Fig. 3.4.2

Fig. 3.4.3

Fig. 3.4.4

Fig. 3.4.5

Let us analyze the equipment layout and Piping design for a distillation column, which is more of an integrated unit than the individual equipment discussed earlier. Interactions between hydraulic requirements and piping configurations require close attention to many fluid and mechanical details, in order to obtain the most efficient and economical distillation units.

Fig. 3.5.1

Fig. 3.5.2

Fig. 3.5.3

Fig. 3.5.4

The prime consideration in all these cases is the performance to achieve the process requirements integrated with economy.

*********