introduction to process plant layout & piping design
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INTRODUCTION TO PROCESS PLANT
LAYOUT & PIPING DESIGNThe objective of plant design is to define the equipment,
piping, instrumentation and process requirements neededto build and operate a process plant.
By equipment, we mean vessels, pumps, heat exchangers, etc.These are the most common type of equipment in chemicaland petrochemical plants, where most of the processstreams are gases or liquids. Other industries that deal withsolids use equipment like conveyors, Cyclones, and others
that will not be dealt with here. Vessels can be of manytypes, such as drums, tanks, reactors, phase separators,and distillation columns.
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PIPING DESIGN FUNDAMENTALSPiping is the physical elements that interconnect the equipment and in which the
process streams flow. Piping comes in different sizes and materials. It is the duty of the
process engineer to specify the size and materials of the piping and also the thermalinsulation, if required. The term piping also includes accessories such as elbows, tees,
valves, flanges, etc.The most common material is carbon steel. Other materials, such as varies grades of
stainless steel, and plastic materials, such as PVC, Teflon, are also used.Instrumentation are devices used to measure, control, and monitor the process
variables.These variables can be flow, temperature, pressure liquid levels, viscosity, and others.Control valves and relief valves are also an important part of the instrumentation.Plant design normally starts with a process scheme that is a known series of physio-
chemical operations that must be performed to go from the feed stocks to the desired
products. These operations are established during the process development stage,
normally in pilot plants, which are a small scale versions of the industrial plant.The most common operations are:Mixing two or more streams to obtain a homogeneous mixture.Splitting a stream in two or more streams of same composition.
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Heating or cooling stream to a given temperature.Vaporizing a liquid stream partially or totally.Condensing a vapor stream partially or totally.Adiabatically flashing a stream to a given pressure.
Exchanging heat between two streams.
Pumping a liquid stream.Compressing a vapor stream.Separating a stream into 2 or more streams in a series of vapor- liquid equilibrium (VLE).Reacting certain components of a mixed stream according to a predefined stoichiometry.
PIPING DESIGNPiping plant design is an essential part of successful plant operation. Many decisions must be made in
the design phase to achieve this successful operation, including:
Required fluid quantity to or from a process
The optimum pressure- temperature for the process
Piping material selection
Stress and nozzle load determination
Pipe support scheme
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PRINCIPALS OF PROCESS PLANT LAYOUT
PLOT PLAN Roads
Access
Storage
Admin
Utilities
PROCESS PLANT Roads
Access
Units
Buildings
PROCESS UNIT Access
Equipment
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PROCESS EQUIPMENT Spacing
Arrangement
IMPORTANT ISSUES IN LAYOUT General terrain
Safety and environment
Regulations, Native,
Flammable /non-flammable materials
High /Low pressure units
Wet / Dry systems Maintenance, Utilities
IMPORTANT SAFETY ISSUESIN PLANT LAYOUT Accident containment and avoidance of Domino effects
High hazard operations
Segregation of different risks Exposure to possible explosion over pressure
Exposure to fire radiation
Minimizing vulnerable piping
Drainage and grade sloping
Prevailing wind directions
Provisions for future expansion
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OVERALL PHILOSOPHY
Arrange units to provide:
Economical plant
Safe and easy to operate and maintain
Compactness in arrangement
Integrated in flow sequenceSpace provided for convenient operation and maintenance access
Planed expansion
HOUSED PLANTMultilevel
Vertical and horizontal arrangements important
Gravity flow possible Mobile crane-use in central aisle
Pipe rack locations and main access
Piping runs to change elevation on direction change
Ability to extend plant
Offices and control room
EQUIPMENT LAYOUT ISSUESPumps (NPSH, suction line, motor location)
Instrumentation(CVs accessible)
Heat exchangers(bundles, fin-fan vs. water)
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Flares(radiation levels, alternatives)
Solids (use gravity flow, Containment)
Expensive piping (Run lengths)
Reactors (catalyst dump)
Maintenance (access, removal)
MODULAR SYSTEMS Major savings in construction costs( 50%)
Require more detailed engineering design
Extra structural steel (30%)
Transportation costs (1-2% of module cost)
Small footprints possible
Ideal for small-scale plants
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We have just brought the pipes now we need to solve some more problems.
Pipes are all straight pieces.
Even some Pipes are of different sizes
We need some branch connections.
We need some bend connections.
Anyway, the pipes and fittings are in place, but the ends are yet to joined with the Tank nozzles.
We now have to complete the end connections
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
Other than valves another important line component of pipe line is a filter, which cleans out
debris from flowing fluid. This is called strainer
When some fluid is flowing in a pipe we may also like know the parameters like, pressure,
temperature, flow rate etc. of the fluid.
To know these information we need to Install INSTRUMENTS in the pipeline
Here are some of the pipe supporting arrangements. There can be numerous variants. All
depend on piping designers preference and judgment.
PROCEDURE & WORK FLOW PHYSICAL QUANTITIES & UNITS
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PROCESS UNIT
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Access
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Equipment
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PROCESS EQUIPMENT
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Spacing
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Arrangement
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IMPORTANT ISSUES IN LAYOUT
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General terrain
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Safety and environment
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Regulations, Native,
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Flammable /non-flammable materials
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High /Low pressure units
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Wet / Dry systems
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Maintenance, Utilities
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Important Safety Issues in Plant layout
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Accident containment and avoidance
of Domino effects
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High hazard operations
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Segregation of different risks
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Exposure to possible explosion over
pressure
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Exposure to fire radiation
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Minimizing vulnerable piping
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Drainage and grade sloping
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Prevailing wind directions
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Overall Philosophy
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Arrange units to provide:
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Economical plant
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Safe and easy to operate and maintain
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Compactness in arrangement
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Integrated in flow sequence
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Space provided for convenient
operation and maintenance access
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Planed expansion
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Housed Plant
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Multilevel
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Vertical and horizontal arrangements
important
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Gravity flow possible
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Mobile crane-use in central aisle
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Pipe rack locations and main access
h l
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Piping runs to change elevation on
direction change
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Ability to extend plant
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Offices and control room
P (NPSH i li
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Pumps (NPSH, suction line, motor
location)
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Instrumentation(CVs accessible)
H t h (b dl fi f
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Heat exchangers(bundles, fin-fan vs
water)
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Flares(radiation levels, alternatives)
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Solids (use gravity flow, Containment)
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Expensive piping (Run lengths)
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Reactors (catalyst dump)
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Maintenance (access, removal)
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& Piping Design Fundamentals
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Piping is the physical elements that
interconnect the equipment and in
which the process streams flow. Piping
comes in different sizes and materials.
It is the duty of the process engineerto specify the size and materials of the
piping and also the thermal insulation,
if required. The term piping alsoincludes accessories such as elbows,
tees, valves, flanges, etc.
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The most common material is carbon
steel. Other materials, such as varies
grades of stainless steel, and plastic
materials, such as PVC, Teflon, are also
used.
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Instrumentation are devices used to
measure, control, and monitor theprocess variables.
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These variables can be flow,temperature, pressure liquid levels,
viscosity, and others. Control valves
and relief valves are also an important
part of the instrumentation.
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Plant design normally stars with a
process scheme that is a known series
of physic-chemical operations that
must be performed to go from the
feed stocks to the desired products.These operations are established
during the process development stage,
normally in pilot plants, which are asmall scale versions of the industrial
plant.
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The most common operations are:
Mixing two or more streams to obtain
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Mixing two or more streams to obtain
a homogeneous mixture.
Splitting a stream in two or more
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Splitting a stream in two or more
streams of same composition.
Heating or cooling stream to a given
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Heating or cooling stream to a given
temperature.
Vaporizing a liquid stream partially or
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Vaporizing a liquid stream partially or
totally.
Condensing a vapor stream partially or
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Condensing a vapor stream partially or
totally.
Adiabatically flashing a stream to a
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Adiabatically flashing a stream to a
given pressure.
Exchanging heat between two
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Exchanging heat between two
streams.
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Pumping a liquid stream.
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Compressing a vapor stream.
Separating a stream into 2 or more
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streams in a series of vapor- liquid
equilibrium (VLE).
Reacting certain components of a
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mixed stream according to a
predefined stoichiometry.
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Piping code
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In 1926 the American standardsinstitute initiated Project B31 develop
a piping code. ASME was the sole
administrative sponsor. A number ofseparate sections have been prepared,
most of which have been published.
The various sections designations
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The various sections designations
follow.
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B31.1 Power Piping
B31.2 Fuel Gas Piping (Withdrawn in
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B31.2 Fuel Gas Piping (Withdrawn in
1988)
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B31.3 Process piping.
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B31.4 Liquid Transportation System for
Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols.
B31 5 R f i i Pi i
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B31.5 Refrigeration Piping.
B31.6 Chemical Plant Piping (never
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B31.6 Chemical Plant Piping (never
published).
B31.7 Nuclear Piping(Moved to B&PV
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B31.7 Nuclear Piping(Moved to B&PV
Code Section III).
B31.8 GAS Transmission and
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3 .8 GAS Transmission and
Distribution piping Systems.
B31 9 B ildi S i Pi i
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B31.9 Building Service Piping.
B31.10 Cryogenic Piping (Never
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y g p g (
published).
B31 11 Sl Pi i
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B31.11 Slurry Piping.
B31.12 Hydrogen Piping (project
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y g p g (p j
started in 20004)
Plant Capacity in MTPY(metric ton per
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p y ( p
year)
Product specification in terms ofit i t t f t i
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purity maximum content of certain
inpurities,