Академический Документы
Профессиональный Документы
Культура Документы
Fig. 1.1a, 1.1b 2.0 STEPS IN PLANT DESIGN The mechanical design and development of the plant has three major steps viz. 2.1 Conceptual layout design 2.2 Equipment layout design 2.3 Piping layout design These are not sharply divided areas. Though equipment arrangement can be made along with the piping layouts, it is normally dealt with separately in large plants. The plant layout can be the biggest cost saver in chemical plant design next to the Process and Equipment design. Money wasted or saved can be substantial
b) Similar equipment grouping Operating or maintenance convenience and safety considerations can dictate the grouping of equipment. Grouped exchangers and lined up channel ends make possible the use of a common gantry crane moving on rails in the front for bundle removal. Columns can be lined up to have a common platform for manholes and valve operations. Reactors or agitated kettles can be grouped to have common
2.2.5 EQUIPMENT LAYOUT/UNIT PLOT PLAN DRAWING GUIDE LINES The following are the guidelines generally followed while making an Equipment layout/Unit Plot Plan drawing. a) Equipment layout/Unit Plot Plan shall be drawn in 1:50 or 1:100 scale. b) A0 size drawing sheet should generally be used for equipment layout. If the area to be covered is small, A1 size can be used. c) Place north arrow at the top right hand corner of the sheet to indicate Plant North. d) The area above title block to be kept free for general notes, legends, reference drawings etc. i) One of the general notes should establish how to ascertain the datum level.
ii) The legends normally adopted are; a) TOS Top of Steel b) TOC Top of Concrete c) TOG Top of Grout d) FGL Finished Ground Level e) FFL Finished Floor Level f) FS Fixed Support g) SS Sliding Support h) BOS Bottom of Steel i) HPP High Point of Paving
iii) Floor finish or floor treatment required should also be explained with symbols such as; a) AR Tiling b) Grating c) Chequered Plate e) All equipments are marked with its equipment no. as appearing in
iv) Underground facilities: Piping Engineer should investigate the facilities such as storm water drain, effluent drain, fire water, cooling water to be placed underground before deciding the equipment position. Depending upon the soil condition, the foundation will be either piled or spread footings. Spread footing foundation will require more space and equipment should be spaced to suit. In certain cases multiple equipment could be placed on a common foundation. In such cases vibrating equipment shall be segregated from static equipment. v) Climatic conditions: Weather condition influences the type of enclosures and location of equipment. Wind influence the location of furnaces, cooling towers and stacks
a) Grade arrangement
mounted
Horizontal
In the grade-mounted horizontal in the line unit, the equipments are placed on either side of the central pipe rack with auxiliary roads. The main advantage of this arrangement is that the equipments are located at grade level, which makes it easier to construct, operate and maintain. The disadvantage is that it takes a lot of ground area. The typical layout of a grade mounted outdoor petrochemical plant is illustrated in Fig. 2.2.1. The cross section of such units is shown in the sketches 2.2.2 to 2.2.5. In principle all these variations of the layout shown therein are same. One or two lines of process equipments are placed along the pipe rack. Maintenance roads are provided parallel to the pipe rack and process equipments. Central pipe rack is economical as shown in Fig. 2.2.2 and
10
Fig. 2.2.6a
11
Fig. 2.2.6b 2.3 Piping Layout 2.3.1 PHILOSOPHY OF YARD PIPING The main artery of an outdoor process plant is the pipe rack. Because the rack is located in the mid of an outdoor plant, the pipe rack must be erected first. Hence the development of structural drawing becomes one of the early requirements in a plant. To pass on the data to the civil/structural group, a civil scope drawing showing the width, the column spacing and the design load is prepared. This load data should include, in addition to the dead weight specified per running meter or per sq.meter the thermal and occasional loading the piping will impart on to the structure. The latter will include forces and moments depending on the type of support provided. The structural designer reinforces such bays on the pipe rack to overcome these forces and moments. Hence, a proper planning is required in the initial stages of design itself. So, the first step in the development of pipe rack is the generation of a line routing diagram. A line routing diagram/
12
In larger plants, yard piping will be more complicated as shown in Fig. 2.3.4, 2.3.5 and 2.3.6. Fig. 2.3.4 shows a T shaped yard. Process and utility lines can Equipment and Piping Layout 13
Depending upon the type of plant the rack could be of steel, concrete or a combination of both. The spacing between the bent/column of the pipe rack is normally 5 to 6 meters. Wide spacing is necessary at road crossings or where loading and access space are needed. The headroom clearance also depends upon the type of crossings.
14
15
2.3.2 PIPING ARRANGEMNT P & I diagram, equipment layout, piping specifications, equipment drawing and the vendor requirement for proprietary equipment form the basis of a piping layout. In areas where piping is critical, the equipment locations are fixed only after a piping study is made. This will facilitate access to equipment after piping is in place and also to have the most economical pipe routing. Fig. 2.3.9 shows typical cross section of pipe rack for a petrochemical plant.
Fig. 2.3.10
Piping shall be arranged in an orderly manner and routed as directly as is practical in established pipe racks. As far as practical, piping should run at different elevations along north-south and east-west directions. The basic principle to be followed in such cases is change in direction, change in elevation. Combined change in direction and change in 0 elevation is effected by 90 elbows. To achieve minimum change in elevation, 0 0 combination of 90 and 45 elbows may be used. (see Fig.2.3.10 and 2.3.11)
Fig. 2.3.11 Although the final stress analysis will be done after the routing are finalized, preliminary check from monogram is required to establish the requirement and size of expansion loops. The flexibility temperature can be obtained from the line list. The lines requiring expansion loops is
16
rack and also provide additional flexibility (see Fig. 2.3.12) Proper drip leg and steam traps shall be provided for steam lines to avoid the condensate collection at these points (see Fig. 2.3.13). The expansion of the rack should also be thought while planning. It is normal practice to add additional tier on the top. To accomplish the same, the space above the column should be kept free of piping or conduit. The preferred location of relief header is as shown in Fig. 2.3.15. Header growth can create problem of interference, which is often overlooked. The spacing on the rack should account for these. The line, which expands also, should be properly guided to ensure maximum effectiveness of expansion loops. Most of the lines leaving or entering the rack perpendicular to it need support. This is affected by the provision of the structural members, known as spandrels, connecting between the columns at the required elevation. These spandrels could
Alternative to the expansion above the rack could be planned for expansion outside which not preferred. This keeps 17
The typical arrangement of hose station along the rack is as shown in Fig. 2.3.17.
The overall pipe rack design must meet the current needs as well as expansion plans without major modifications. Heavy large diameter piping may be laid below ground or on sleepers as established by economics and location. 2.3.3 VALVES-LOCATION Accessibility to valves and instruments should be the primary concern while
Utility lines have two groups of valves. One group is closely related to process and should be located having accessibility just like process valves. The other groups contain all isolating valves such as block valves on headers, root valves on sub headers and valves for future connections. These valves are seldom used and are located overhead. Temporary ladder accessibility is acceptable for such valves (see Fig. 2.3.19). Battery limit isolation valves can be provided with access 18
Fig 2.3.20
Fig 2.3.19
Fig 2.3.21a
19
Fig 2.3.21b
Fig 2.3.22
2.3.4 ELECTRICAL/INSTRUMENT TRAYS The Electrical and Instrument cable tray/duct location is coordinated in the design-planning phase itself and integrated in the overall arrangement. Space for these trays is provided above the piping on the pipe rack. Future
20
21
Figure 2.3.24 shows cross section of a typical yard piping for petrochemical plant. The various structural elevations are determined by the guidelines for the requirement of headroom given earlier.
Fig. 2.3.24
22
23
Fig. 3.1.1a
24
Fig. 3.1.1b arranged under the pipe rack in a refinery or an outdoor process plant, keeping motor end towards the access space and suction/discharge faces towards the process vessels (Refer Fig. 3.1.1). Single pump should have access all around, a minimum of 900mm. When space is restricted, or the pumps are small, two pumps can be placed on common foundations with the orientation of the motor terminal modified if required. (Refer Fig. 3.1.2)
Fig. 3.1.3 For safety and operators' convenience, pumps for tanks containing inflammable/corrosive liquids should be located outside the dykes. (Refer Fig.3.1.3) 3.1.2 PIPING ARRANGEMENT The primary goal in piping arrangement is to satisfy the performance and the flexibility requirements. Suction piping should be designed without loops or pockets. The eccentric reducers are placed close to the suction nozzle either FSU or FSD depending on the line configuration (Refer Fig. 3.1.4). These lines shall be drainable near the pumps. The suction line is generally one or two sizes larger than the pump suction nozzle for centrifugal pumps. NPSH requirement has to be checked while locating the pumps and routing the suction lines. Accordingly saturated liquid, steam condensate and vacuum conditions need elevated suction vessels. The horizontal runs should be kept minimum in all suction piping. The thermal expansion requirement should be taken care of in such a way that the pump nozzles are not loaded. The suction as well as the discharge piping shall be supported adequate enough not to impose excess 25
Fig. 3.1.2
FIG. 3.1.4a
Streamlined piping is desirable at suction and discharge piping of reciprocating pumps. Use long radius bends and angular branch connection to avoid sudden change of direction and opposing flows (Refer Fig. 3.1.6). Spool pieces shall be provided to facilitate pump removal because the
FIG. 3.1.4b
The check valves are placed on the discharge piping to arrest the back flow and the reverse run of the impeller due to it. If the check valve is piston lift type, the piping should be arranged horizontally and if it is swing type it can be placed vertically (Refer Fig. 3.1.5).
26
3.2 Compressors Basically there are two types of compressors used in the chemical process industry. They are the centrifugal type and the reciprocating type. Layout and piping considerations for the centrifugal compressors do not differ in concepts from arrangement of centrifugal pumps. However pipe sizes are much larger because of the large volume handled. These have horizontally split casing. Those having bottom connections are elevated. Concrete columns and tabletop arrangements are provided with surrounding access platform. Compressor foundations are kept independent of building foundations. A hand operated travelling crane located at compressor centre line is to be provided overhead. Lay down space also has to be planned for. Knockout drums and inter stage exchangers are so arranged as to have short and simple piping. Long radius elbows should be used immediately before the compressor suction. A straight length of 5D at the suction is normally provided. For air compressors, strainer has to be provided at the open-air inlet. Lubricating oil and seal oil consoles are also to be located which occupy large area near or under the compressors. Manufacturer's recommendation should be followed in this case.
The reciprocating compressors are located on concrete foundation at grade level and not on a concrete tabletop. The basis of lay down area, foundation and the roof above are identical to that of a centrifugal machine. The piping interconnecting the pulsation dampeners, intercoolers, after coolers etc. should be short and simple to reduce the vibration. It is advisable to provide a vibration dampener (expansion bellow) at the outlet of the compressor. Sufficient straight length shall be provided after the discharge to avoid backpressure. To avoid vibration due to pulsating flow the customary piping details are modified as follows. a) Use bends instead of elbows b) Use angular inlets instead of laterals c) Use smooth junction instead of head on opposing flow. d) Use streamlined end-of-header arrangement instead of dead end header (Refer Fig 3.1.6). Components having large pressure drops should be avoided. Types of valves should also be selected accordingly. Support the piping at directional changes and at valves. Support should also restrict the pipe movements. High pressure and high-speed compressors must have pulsation dampeners to eliminate pulsation in suction and discharge piping. If pulsating flow is transmitted to piping, structures and process equipment, material fatigue can occur. Dampeners design is highly
27
Fig. 3.3.1a
28
Fig. 3.3.1b 3.3.2 PIPING ARRANGEMENT The piping engineer is responsible for the physical arrangement of piping. Most often the piping engineer will have no influence in the selection of exchangers, he can only modify the nozzle arrangements to have an economical piping. For this, the basic knowledge of the type of exchangers and its construction details are required. TEMA (Tubular Exchanger Manufacturers Association) specifies the various combinations possible. The basic types used in the chemical process industry are a) Fixed tube-sheet Heat Exchangers: Exchangers with complete enclosed tubes are mainly used in clean services. Cleaning can be done by flushing through the tube side and shell side. Clean out connections are provided in the piping between the exchanger nozzle and block valve. The bolted cover and channel facilitate inspection and physical cleaning of the tubes. When used in high temperature services, an expansion joint is built into the shell to take care of the differential expansion between the shell and the tube. b) U tube Heat Exchangers: In this type, the tube bundle is hairpin shaped and can freely expand. The bundle is removable from the shell and provision in layout has to be made for the same this Equipment and Piping Layout
29
30
The following alterations can be suggested in order to achieve an optimum piping arrangement. Consent from the process group is required to ensure that these will not affect the thermal design of the exchanger. The cost increase in modification can be more than offset by the cost effective piping. These factors influence the decision on piping routing as well. 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 pipeline. The maximum angle from the vertical centre line can be about 0 30 . (Refer Fig. 3.3.4)
Fig. 3.3.4a
FIG.3.3.4b 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) e) Interchange flow media between tube side and shell side. This can give the following advantages. i) If hotter liquid is allowed to flow through the tube, this will minimize the
31
32
33
Vessels are sloped towards drain point. If the vessel has a top manhole, the vent can be located on the manhole cover. The drain valve can also be located at the low point of the outlet piping instead of vessel. c) Relief Valves/Rupture Disc Located anywhere on the top of the drum, preferably at accessible location from the platform provided for valve operation. d) Level gauges The gauge glass shall be located at the least agitated liquid section. If the vessel is horizontal, the location is best at the centre of inlet and outlet nozzle. e) Pressure and Temperature tap-offs. Pressure connection at the vapor space at the top of the vessels will make it visible from the platform. The temperature connection shall be near the outlet pointing towards the platform. f) Manholes These can be positioned on the top, to the side or at one end of the vessel. Depending upon the vessel size, there can be two manholes, one located on top and the other is located on the shell accessible from the grade.
g) Vessel saddles Ideally, saddles are located at 1/5 of the drum length from each tangent line. The vertical vessel can be supported on skirt, on half skirt, on legs or on lugs as the case may be. The analysis of the support attachment shall be done accordingly. Location of associated equipment around the vessel also influences the nozzle orientation. The liquid outlet should be located towards the nearby pump suction. The elevation of the vessel should be such as to provide the required NPSH. In a reactor, the manhole should be oriented towards the access aisle to facilitate manual feed if required. The utility manifold and the process inlet manifold should be placed at the operating level irrespective of the nozzle attached to the vessel. The piping should run overhead as short and as simple as possible. Pipe rack shall be arranged which will support electric and instrument trays along with pipelines. Piping should not transmit vibrations and should be isolated from vibrating equipment with the help of expansion
34
The reboiler circuit could be either pumped or thermosyphon. The design of pumped reboiler circuit is similar to that of reflux pump system. The bottom pump transports the liquid through a heat exchanger and return to distillation column. The possible two phase flow in the pipeline after heater should be studied. The reboilers could be shell and tube type, vertical or horizontal to kettle type. In large diameter towers inserted type U tube bundles inserted directly into liquid space through tower nozzles, are also used. Helical coils inside tower also can be used for small duties.
36
The tower is located adjacent to the rack so that the lines can drop directly on to the rack and can turn left or right. The plan view (Fig. 3.5.2) of the tower shows the segments of the tower along its circumference allotted to various utilities. Manhole faces the access roads or access aisles in case of indoor layout. Platform is provided below each manhole at a distance of 750 1000 mm below the centerline. This will facilitate maintenance as well as access to instruments and valves. The side entry with cat ladder, except for the top platform, shall be arranged. From layout
37
Lines from tower nozzles below the pipe rack should approach the pipe bank below the rack elevation. The same elevation is used for lines that run for pumps located below rack. The pump suction lines should be as short as possible and run without any loops or pockets. The steam lines to reboiler are tapped from the top of the main header to avoid excessive condensate drainage to process equipment. This line can run at the same elevation as those lines approaching the rack from the tower.
38
*********
39