Piping system.pptx important for engineering
- 1. Definition PIPE: It is a Tubular item made of metal, plastic, glass etc. meant for conveying Liquid, Gas or any thing that flows PIPING: The term Piping means not only pipe but includes components like fittings, flanges, valves, bolts, gaskets, bellows etc Cdr Tasnuva 1
- 2. Definition PIPING ARRANGEMENT: The piping arrangement drawing evolves from the foundation location and equipment location drawings. It shows all pieces of mechanical equipment, including vessels in the unit and the pipes connecting them, including manholes, ladders, platforms, cages, and davits. The pipes leading from the cargo tanks to the pumps are termed as bottom lines, from the pump-room up to deck are called risers. The lines on deck are termed as deck lines. The lines which lead from the deck to the tanks are called drop lines. Cdr Tasnuva 2
- 3. Selection of Piping Materials • Materials selection for achievement of metallurgical stability shall be made on the basis of design condition and to resist possible exposures against fire, corrosion, operating condition, service etc • The designer is confronted with the following concerns regarding the material of construction : Resistance to Stress Resistance to Wear Resistance to Corrosion etc Cdr Tasnuva 3
- 4. Selection of Piping Materials Piping Materials (1) METALLIC (2) NON-METALLIC (3)COMPOSITES (i) FERROUS (i) ORGANIC (i) GRP (ii)NON-FERROUS (ii) INORGANIC (ii) FRP (Fibre reinforced polymers) Examples: FERROUS NON-FERROUS ORGANIC INORGANIC Carbon Steel Nickel Plastics Ceramics Cdr Tasnuva 4
- 5. Most Commonly Used Materials Carbon Steel : This is the most common and cheapest material used in process plants. Carbon steels are used in most general refinery applications. It is routinely used for most organic chemicals and neutral or basic aqueous solutions at moderate temperatures. Carbon steels are extensively used in temperature range of (-) 29 deg cent to 427 deg cent... Low Carbon steel (LTCS) can be used to a low temperature of (- 46) deg cent Alloy Steels : Low Alloy Steels contain one or more alloying elements to improve mechanical or corrosion resisting properties of carbon steel. Nickel increases toughness and improves low temperature properties & corrosion resistance Cdr Tasnuva 5
- 6. Most Commonly Used Materials Alloy Steels : Chromium and silicon improve hardness, abrasion resistance, corrosion resistance and resistance to oxidation. Molybdenum provides strength at elevated temperatures. Stainless Steels : They are heat & corrosion resistant, non- contaminating and easily fabricated into complex shapes. There are three groups of Stainless steels, viz, Martensitic, Ferritic & Austenitic Cdr Tasnuva 6
- 10. Pipe and Fittings Full forms PVC : Polyvinyl Chloride UPVC: Unplasticized Polyvinyl Chloride CPVC: Chlorinated Polyvinyl Chloride PE-RT: Polyethylene of Raised Temperature Resistance GI : Galvanized Iron FTA: Female Threaded Adapter MTA: Male Threaded Adapter Cdr Tasnuva 10
- 11. Pipe Manufacturing It consists all about material details, dimension details, type of ends, schedules/thicknesses, branch offs, NDT requirements, various codes/standards being followed for all Piping items. Main Piping items are listed below: • Pipes • Fitting • Flanges • Misc items (Steam traps/Strainers) etc • Bolts • Gaskets • Valves Various codes, symbols in piping design and manufacturing are: • ASME - American Society of Mechanical Engg • API - American Petroleum Institute • ANSI - American National Standards Institute • ASTM -American Society for Testing and Materials Cdr Tasnuva 11
- 12. Pipe fittings Cdr Tasnuva 12 FTA – Female Threaded Adapter
- 13. We have just brought the pipes, now we need to solve some more problems. Pipes are all straight pieces. We need some branch connections We need some bend connections Even some pipes are of different sizes! To solve these problems we need the pipe components, which are called PIPE FITTINGS Cdr Tasnuva 13
- 14. There are various types of fittings for various purposes, some common types are - Elbows/Bends, Tees/Branches, Reducers/Expanders, Couplings, Olets, etc. Anyway, the pipes and fittings are in place, but the ends are yet to be joined with the Tank nozzles. We now have to complete the end connections. These, in piping term, we call TERMINAL CONNECTIONS. Cdr Tasnuva 14
- 15. These are flanged joints This is a welded joint But if we want to control the flow from Tank-1 to other tanks. We need some arrangement to stop the flow if needed Cdr Tasnuva 15
- 16. FLANGES • Flanges provide a bolted, separable joint in piping. The most of valves have flanged ends and must have a companion or matching flange attached. A gasket is then inserted between them, and the bolts are tightened to form a flanged joint When to use Flanges? • Where there is a clear need for removal of valves or equipment, for access of maintenance, or for blinding. As all flanged connections are potential leak source, their use should be kept to the minimum needed for safe and reasonably convenient operation and maintenance Cdr Tasnuva 16
- 17. Types of Flanges • Neck Weld (NW):The welding neck flanges are attached by butt-welding to the pipes. • Socket Weld (SW):The socket weld flanges are welded only on one side and are not recommended for severe services. These are used for small-bore lines only. • Slip-on (SO):The slips on flanges are attached by welding inside as well as outside. • Lap-Joint (LJ):The lap joint flanges are used with the stub ends when piping is of a costly material. Cdr Tasnuva 17
- 18. Slip-on Flange Neck weld Flange Socket weld Flange Cdr Tasnuva 18
- 19. Slip-on Flange Lap Joint Flange Cdr Tasnuva 19
- 20. Flange Material • Flanges are made of carbon steel forging having a highly refined grain structure and generally excellent physical properties well in excess of recognized minimum requirements • In addition, flanges in 300 psi and higher-pressure classes can be made of Chrome-Molybdenum Forged steel (ASTM A182 GRADE F5A) Cdr Tasnuva 20
- 21. Bolts & Gaskets • Choice of bolting material is governed by service fluid and its temperature • The most commonly used bolts for flanges in piping are the ASTM A193 Gr.B7 Stud bolts which fall into the high strength group. The temperature range is from –29°C to 454°C. ASTM stands for American Society for Testing and Materials • A gasket is a thin circular disc, made up of soft compressive material. The most of valves have flanged ends and must have a companion or matching flange attached • A gasket is then inserted between them, and the bolts are Cdr Tasnuva 21
- 22. These are flanged joints This is a welded joint But if we want to control the flow from Tank-1 to other tanks. We need some arrangement to stop the flow if needed To control the flow in a pipe line we need to fit a special component. That is called - VALVE Cdr Tasnuva 22
- 23. VALVES Valves stop or open and regulate flow. Some of the basic valve types are gate, globe, check, Ball, Plug, etc. GATE VALVE: It is usually manually operated and is designed for open or shut operation. Flow can enter either end of the gate body GLOBE VALVE: is for throttling. Good examples of globe valves are the faucets on washbasin which throttle or adjust the flow to suit a person’s needs. Flow must enter the valve and flow up, against the seat, and change the direction again to the outlet CHECK VALVE: “checks” flow. It lets flow go one way and will not let it reverse. When you have a check valve in a line, you have made a one-way street. The flow can go one way Cdr Tasnuva 23
- 24. VALVES In piping systems, valves are used to stop or open and regulate the flow. Some of the basic valve types are gate, globe, check, Ball, Plug, etc. Type of vales: Cdr Tasnuva 24
- 25. Type of valves Isolation Valves: • Gate Valve • Ball Valve • Plug Valve • Piston Valve • Diaphragm Valve • Butterfly Valve • Pinch Valve Cdr Tasnuva 25 Regulation Valves: •Globe Valve •Needle Valve •Butterfly Valve •Diaphragm Valve •Piston Valve •Pinch Valve
- 26. Type of valves Non return Valve: Check Valve Special Purpose Valves: Multi-port Valve Flush Bottom Valve Float Valve Foot Valve Line Blind Valve Pressure / Vacuum Relief Valve Cdr Tasnuva 26
- 27. Type of valves Cdr Tasnuva 27 globe valve
- 28. Type of valves Cdr Tasnuva 28 Butterfly valve
- 29. Type of valves Cdr Tasnuva 29 Butterfly valve • Butterfly valves are used where space is limited • Unlike gate valves, butterfly valves can be used for throttling or regulating flow as well as in the full open and fully closed position • The pressure loss through a butterfly valve is small in comparison with the gate valve
- 30. Type of valves Cdr Tasnuva 30 Check valve • Check valves are generally installed in pipelines to prevent backflow • A check valve is basically a one-way valve, in which the flow can run freely one way, but if the flow turns the valve will close to protect the piping, other valves, pumps etc
- 31. Type of valves Cdr Tasnuva 31 Check valve
- 32. Type of valves Cdr Tasnuva 32 Screw down valve Storm valves, also known as scupper valves are used in sanitary discharge pipelines which have a ship side exit, preventing seawater from entering the system during heavy sea
- 33. Type of valves Cdr Tasnuva 33 Fire hydrant valve Throttle valve
- 34. There are many types of valves, categorized based on their construction and functionality, Those are - Gate, Globe, Check, etc. Other than valves another important line component of pipeline is a filter, which cleans out derbies from the flowing fluid. This is called a STRAINER Cdr Tasnuva 34
- 35. When some fluid is flowing in a pipe, we may also like know the parameters like, pressure, temperature, flow rate etc. of the fluid. Cdr Tasnuva 35
- 36. Here are some of the pipe supporting arrangements. There can be numerous variants. All depend on piping designer’s preference and judgement. Cdr Tasnuva 36
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- 39. Piping Flexibility All piping must be designed for thermal expansion under start up, operating and shut down conditions without over stressing the piping, valves or equipment. Adequate flexibility for the steam out conditions at temp of 120 deg c provisions for expansion or contraction shall normally be made with bends, off-sets etc. DESIGN CONDITIONS: Operating conditions: - normal design conditions of pressure & temperature are expected to co-exist. These usual operations include all manipulations & control functions such as throttling, blowing, and bypassing Transient conditions: - such as those incidentals to start up, steam out, abnormal load, etc Cdr Tasnuva 39
- 40. Piping Layout Detailed equipment layout including key plan. Preparation of piping studies. Fixing the orientation. Piping supports. Line isometric & vessel trims. Model preparations & field engineering. BASIS OF EQUIPMENT LAYOUT: Equipment layout shall be developed based on the following data: P&IDs ( Piping & instrumentation diagram ) Overall plot plan Equipment data sheets Indicative equipment layoutCdr Tasnuva 40
- 41. Piping Layout Pipe sizes are selected. Then pipe material and pipe wall thickness are selected. Types of Valves are planned Also, the types of instruments required are planned We represent the whole thing in a drawing which is called Piping and Instrumentation Drawing, in short P&ID. For P&ID generation we may use suitable software such as AutoCAD, Edraw, Smartplant etc. All the pipelines system information in the drawing has to enter for P&ID The P&ID drawing is an Intelligent drawing which carries all the information about Pipe size, Pipe Material, Fittings, Valves, Strainer, Flowing Fluid, etc. Cdr Tasnuva 41
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- 43. Cdr Tasnuva 43 This is screen picture of P&ID made by SPP&ID If we click on any line it will show the Data embedded.
- 44. Pipe Coating and Colour No internal coating is done for pipes to carry air, fuel and lubricants. MS pipes are galvanized for water. But SS or copper -nickel pipes do not require galvanization. External coatings are required to identify each system. Sometimes, bands are used for identification instead of coatings Cdr Tasnuva 44
- 45. Pipe Stress Analysis To check and confirm the pipe is not going to fail due to various loading. In the process of analysis, we apply various postulated loading on the pipe and find out the stress resulted from these loading. Then we check with governing codes if those stresses generated are acceptable or not. We check support load & movement for various loading condition. We also check out the terminal point loading generated from pipe to the equipment connected to the pipe. This loading are to be within acceptable limits of the equipment suggested by the vendors. Cdr Tasnuva 45
- 46. Pipe Stress Analysis To check and confirm the pipe is not going to fail due to various loading. We also find out the pipe growth due to change in temperature and need to keep the movement of pipe within acceptable limits. Pipe Stress Analysis is an Interactive and Iterative process. Each step is checked If a check fails, we have to go back, modify the layout and restart the analysis. Cdr Tasnuva 46
- 47. PIPE STRESS ANALYSIS Inputs Geometric layout of Pipe Pipe supporting configuration Pipe Diameter and Thickness Pressure inside Pipe Cold and Hot temperatures of Pipe Weight of Pipe and insulation Weight of carrying Fluid Pipe material Property (Young’s Modulus, Thermal Expansion Coefficient) Tools we can use PIPSYS - is an integrated pipe stress analysis module of PLADES 2000 CEASER - Commercial Piping analysis software Outputs Stress of the pipe at various loading conditions Load at various supports and restrains. Movement of pipe at support locations Pipe terminal point loading. Cdr Tasnuva 47