Two Weeks Job Oriented Certificate Course

on

Piping Design
(20th – 31 May 2011)

Organised
By

Department of Mechanical Engineering

(Under Continuing Education Program- CEP)
G. H. Raisoni College of Engineering, Nagpur

In collaboration
With
ELIXIR Institute of Piping Engg. & Technology, Pune
Contents:

I. INTRODUCTION
II. Syllabus:
i. line sizing and optimization
ii. materials for piping systems
iii. piping system design
iv. piping design code
v. piping layouts
vi. corrosion protection for piping
vii. pipe supports and stress analysis
viii. MTO / BOO for piping
ix. statutory regulations

INTRODUCTION:

Design, Engineering, Construction and Testing of Piping System for Chemical

Plants, Power Stations, Refineries, Petrochemicals and Fertilizers Plants, Food and
Pharma Industries, etc. Including (cross country) Piping for Oil and Gas sector.
Software Knowledge :
stress Analysis and Caeser – II will be taught as a part of STTP

SYLLABUS:

I. LINE SIZING AND OPTIMISATION

A brief revision covering friction factor, pressure drop for flow of non- compressible
and compressible fluids ( Newtonian Fluids), pipe line sizing, economic velocity.

Pipeline network and their analysis for flow in branches, restriction orifice sizing.

Non- Newtonian fluids – types with examples, pressure drop calculations for Non-
Newtonian Fluids.

Assignment : Numerical exercise in line sizing.

II. MATERIALS FOR PIPING SYSTEMS

Desirable properties of piping materials, materials for law, normal and high temperature
service, materials for corrosion resistance.
Common ASTM and IS specifications for :
Seamless/ ERW pipes, pipefitting, flanges, and fasteners, materials for valves.

Gaskets : Functions and properties, types of gaskets and their selection.

Polymeric materials (Plastics), important considerations, for plastic pipelines (HDPE, PP,
PVC etc.)

Joining methods for plastic pipes and fittings, Valves made out of plastics, constructional
features, and limitations.

III. PIPING SYSTEM DESIGN

Two phase flow, types of two phase flow, two phase flow as encountered in piping for
steam, distillation column, related aspects of two phase flow such as pressure drop,
vibrations.

Types of valves excluding safety valves, constructional features , criteria for selections
codes relevant to valves- ― Construction & Testing.‖

Safety valves and other pressure relieving devices constructional features, selections
criteria, sizing of these devices.

Role of Piping Engineering and needs of Various Process Industries. Scope of piping
engineering, inputs and output documents, interaction with other departments etc.

Introduction to P & I Diagrams, process flow diagrams, standard symbols and notations.
Preliminary bill of material based on PID.

Introduction to various facilities required, guidelines for plot plan/ plant layout,
recommended practices and statutory regulations for facilities spacing.
Important system characteristics and design principles related to stream flow at high and
low pressures. Calculations for line sizing, steam traps, P.R.V. & condensate systems.

Design principles and line sizing for vaccum pipelines, slurry pipelines, surge drums and
flarestacks, vaccum devices including ejector system.

Classifications of pumps, compressors, fans and blowers. Considerations governing pump

selection, analysis of system and pump selection, analysis of system and pump
characteristics in connection with series, parallel flow, minimum flow and equalizing
lines, NPSH, allowable nozzle loads in various codes.

Design principles and line sizing of pneumatic conveying of solids, components of

conveying systems, dust and fume extraction systems principles.

Long distance and cross- country pipelines with specific emphasize on sizing and routing
techniques.

Hygienic piping systems.

PRACTICALS :

1. Pressure drop across pipeline systems including valves and other fittings using
monograms and tables, summary write- up on same.
2. Study of constructional features of valves.
3. Determination of characteristic curves for a centrifugal pumps and valves.
4. Determination of chrematistic curves for a centrifugal pumps and valves.
5. Study of manufacturer’s catalogues on pumps and valves etc.

IV. PIPING DESIGN CODE

National and international codes of piping design, basic principles, distinguishing

features and applicability of various codes, coded design of piping components, case
studies illustrating use of code rules. Pipe schedule number, its significance and
dimensional standards.
V. PIPING LAYOUTS

Introduction to equipment layout.

1. Typical piping systems layout considerations for following various systems.

i) Distillation systems and heat exchange systems.

ii) Cooling water, process water, chilled water/ brine systems.
iii) Pumps, air compressor suction/ discharge piping.
iv) Condensate recycle, steam distribution.
v) Gas / steam turbines, vaccum system and flare lines.
vi) Yard piping jacketed and traced lines.
vii) Petroleum products, class A, B, C, including LPG.
viii) Fire fighting system.

2. Selection and design considerations for hoses, strainers, sight glasses,

TSVs, rubber and metallic expansion bellows.

3. Information to and from piping departments with other engineering

departments in reference to layouts preparation. Do’s and Don’ts for routing of

pipelines in consideration with operating feasibility.

4. Preparation of process plant layouts, piping layouts CAD’s, aesthetics in

plant layouts, project piping specifications, line list etc,

Practicals :
a. Preparations of following sheets

i. P & ID symbols and a typical P & ID, piping specification.

 ii. Plot plan.

iii. Process plant layout

iv. Piping layout

b. Study of typical drawings as listed in item (a).

c. Use of computer software packages in preparation of P & I D, Piping layouts etc.

VI. CORROSION PROTECTION FOR PIPING

Corrosion : Types of corrosion, methods of preventing corrosion, coating of pipelines for

underground and long distance services, cathodic protection of pipelines.

Painting of Pipelines : Common paints for corrosion protection ,abrasive cleaning and
painting of pipelines. Pickling for passivation of S.S. Piping.

VII. PIPE SUPPORTS AND STRESS ANALYSIS

Design of pipe wall thickenss, thermal stresses due to thermal expansion of pipelines and
dissimilar materials, design of mitre bends, contraction of pipelines, reinforcement of
branches, flexibility analysis, pipe stress analysis with reference to pipe layout.

Design code ANSI B 31.1/ B31.3 req uirements for thermal stresses, imposed loading on
equipment nozzles and structares, concept of cold — pull and self springing, pipe stress
analysis with and without expansion joints, design and selection of expansion joints
bellows.

Stress analysis for different configurations of pipe layout. Use of computer aided
packages for stress analysis, transfer of vibration from machine, different types of pipe
supports, span calculations, gravity lines, pipe rack sizing and loading data for pipe-rack.

Some assignments for stress / force calculations using tables / monograms / charts.

Interfacing of piping and instruments scope of work. Pneumatic tubing and cabling for
instrumentation.
SCADA, Telemetry, fibre optics with reference to cross country pipelines.

VIII. MTO / BOO FOR PIPING

Piping isometrics and phases of material take off (MTO)

Practical:
1. Preparation of following sheets
i. Piping isometrics
ii. M.T.O
2. Case studies in material take - offs.
IX. STATUTORY REGULATIONS

Principles, guidelines and statutory requirements such as factory's act, safety and health
directorate, petroleum rules, SMPV rules, gas cylinder storage rules, TAG, IBR etc.

Considerations of above statutory regulations on plant layout equipment layout and piping,
colour identification code for pipelines.

Factory inspector approval drawings, CCOE approval drawings, boiler inspector isometric
approval drawings etc.

Introduction to environmental protection and waste management. Brief reference for hazardous
area classification.

Specific precautions for handling flammable and hazardous substance and liquefied gases,
introduction to HAZOP methodology.

ISO / QA requirements.

Assignment:

Preparation of equipment layout for a given size of plot using petroleum rules.