Академический Документы
Профессиональный Документы
Культура Документы
Table of Contents
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 1 of 150
Machinery Installation
Chapter One
Introduction
Machinery Installation
Enppi Copyright © Enppi 2016 Page 2 of 150
Machinery Installation
There are Process Piping, against Utility Piping, there are Fire Water
Piping, Pneumatic Piping, Gas Piping, Hydrocarbon Liquid piping, chemical
services, etc.,
Two or three phase piping need very special design procedure,
Slugging Flow Piping take place when the Gas Phase volume Flow to
the Liquid Phase Volume Flow is within a certain ratio range. If Slugging
Flow takes Place, it has to be treated by a special piping design, and it is
Machinery Installation
Enppi Copyright © Enppi 2016 Page 3 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 4 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 5 of 150
Machinery Installation
The type of Process through the Piping can be defined as ideal with
some losses. Some internal turbulence, friction, eddies, heat, etc., are
associated with the flow through pipes; causing a loss in the pre-described
total fluid enthalpy or energy.
Reasonably sized piping system with acceptable velocities normally
cause less than a meter of head losses each 100 meter equivalent pipe
run. This is for liquids; however, for gases the loss per one kilometre of
pipe length is around a fraction of a Bar (0.1 Bard). The above Frictional
losses imply some power losses to transport the fluids through the piping
system; which is inevitable everyday energy losses. It represents the
Machinery Installation
Enppi Copyright © Enppi 2016 Page 6 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 7 of 150
Machinery Installation
It is a fact of life that piping system has to cause pressure drop per
meter run along the passage; as straight run or an equivalent straight run
like elbows, reducers, or other types of fittings,
from vessels or tanks, etc., can cause the flow stream reluctant to
follow exactly the ideal theoretical pipe walls tending to flow
separation and local circulation and eddies,
For very slow velocities and pipe runs tending to form low elevation
traps, sludge or dust can drop and left to accumulate causing
further reduction in flow area. In straight long piping Velocities
below 0.3 to 0.5 m/sec can be a cause of a solid particle loss of
buoyancy leaving it to drop on the lower pipe wall (bottom of pipe).
This phenomenon is attributed to Stock’s Law.
Sludge flow should be gravity flow to enhance motion of the heavier
density solid particles.
Per the above analyses two phase flow generation from liquid phase
transportation is common.
As well, if gas transportation is associated with liquid condensation,
two phase flow is the result.
New twin screw Positive Displacement Pumps are intentionally
applied to pump two phase natural well production through a
relatively long flow line or pipeline.
Two phase piping needs to be designed for different criteria than
the single flow piping.
Pipe fittings, isolation valves, control valves, pipe wall thickness due
to erosion, corrosion, liquid hammer, possible formation of slugs,
pipe supports, fatigue consideration due to continuous change of
acting forces, etc., have to be rated for higher strength and with
additional material as corrosion allowance.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 10 of 150
Machinery Installation
a small time period followed by a gas bubble flow filling the entire
pipe section, ten by a different fluid lump, then repeating this
unsteady pattern.
Slugs or fluid lumps normally move at higher than the average flow
Velocity. The intermediate gas is a varying volume bubble
compensating for the unsteady flow velocity of the surrounding
Slugs. Gas bubble expansion means less pressure, and its
compression means a little higher pressure. The result is a
continuously rippling static pressure at all locations of the pipe
along its center line.
Liquid Slug momentum is very large value compared to gas portion
momentum; resulting in rapid change of pipe bend/elbows acting
forces along the continuous operation; which is a continuous fatigue
due to impacts on all pipe portions.
Slug Flow can be from the original source of Liquid Flow; such as
two Phase Well Production; at initial phase, or after wells have been
depleted.
Slug Flow can be due to poor piping design causing successive
vapor generation, collection, accumulation, then releasing, with the
main liquid flow.
- Flow Surge,
- Liquid Hammer,
Surge and Hammer are two Synonyms for the same phenomenon.
- Flow Lamination,
- Solidification,
- Chemical Reaction,
- Erosion,
- Corrosion,
Corrosive agents like CO2, HCL, H2SO4, etc., need water solution
to be active chemical consuming most piping material.
Lower internal velocities or complete stagnation promotes corrosion
process,
Free Oxygen increases rate of corrosion,
Presence of air medium on top of liquids moving within pipe
increases corrosion rate,
- Heat transfer,
- Thermal Growth,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 12 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 13 of 150
Machinery Installation
High Density Polyethylene provides light weight and easy to weld by fusion
heating, achieving low cost material and installation. It is suitable for
underground sewage system, potable water system, buried hydrocarbon
service.
The State of the Art of all types of Buildings nowadays is the application of
polypropylene flexible piping to all plumbing work. It is connected by fusion
(heat) welding, it has standardized fittings with built-in threaded ends (Copper
alloy), light weight, short time to erect. It is available at lower cost than
galvanized piping (tubing).
Machinery Installation
Enppi Copyright © Enppi 2016 Page 15 of 150
Machinery Installation
The case is similar to Duplex piping and fittings, available for higher degree of
resistance to corrosion, at higher temperatures, and higher strength.
It provides less material and lower budgets for challenging services such as
Deep Water Installations with long piping, umbilical transmission pipeline,
submerged equipment. It is available subject to thorough techno-economic
study to prove its feasibility.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 16 of 150
Machinery Installation
Chapter Two
General Requirements for Piping Lay Out
Machinery Installation
Enppi Copyright © Enppi 2016 Page 17 of 150
Machinery Installation
- Simplicity
The piping designer in most cases has a wide space to rout and
laydown his piping. Except for offshore facilities and brown field facilities
the above statement can be true. Simplicity may contradict with other
important criteria; however, if kept in the Piping Designer mind, it can be
achieved to a very Practical Degree.
Why would a pipe turn to the right or left, to up or down, if it can be left
straight. In other words, turn only if you need to turn for a good
mandatory reason.
- Flexibility,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 19 of 150
Machinery Installation
- Accessibility
The meaning is automatic system filling with the process liquid is a basic
criterion rather than the need to drain and vent from several locations to
ensure system filling.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 21 of 150
Machinery Installation
This can be achieved by gravity flowing from the starting vessel to various
parts of the system as long as there are no pockets, traps, and ther are
proper sloping of all pipe runs in the system.
- Drop Areas
All types of equipment need a nearby small size area to contain maximum
maintenance object or part in the life cycle of the equipment. It is
normally termed Drop Area. It has to be nearest to access side by roads,
recommended to be upwind of the equipment served, having clear line of
sight to equipment.
Piping Leader has the Knowledge of Piping System and the Technical Rules
and data base for all related parts; he is the decision maker about many
details. He has to approach every equipment originator explaining to him
the details of the design, and the constraints he has to abide with; then
hear from the specialist the clear design requirements and conditions
coming from the equipment manufacturer and Enppi previous similar
installation practices.
Mutual interchange of knowledge in a transparent way is deemed required
between all project leaders. The objective is not that certain specialist has
to rule out the options and make the decisions; but to have clear mutual
understanding of all concerns.
The final target is trouble-free operation of the equipment and its
neighborhood equipment, valves, controls, and instrumentations.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 23 of 150
Machinery Installation
It has to take sufficient time for discipline to see all hidden details. Senior
(old of long experience personnel) specialists from outside project task
force have to be involved in the review.
All issues need to be scrutinized and explained to all participants then left
to the concerned discipline leader to make a report about various feasible
courses of action to be the road map for the discussion in the next
session.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 25 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 26 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 27 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 28 of 150
Machinery Installation
Top vent valved and bottom drain valved connection are obvious
requirements, with the necessity to be able to execute full venting and
Machinery Installation
Enppi Copyright © Enppi 2016 Page 29 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 31 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 32 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 33 of 150
Machinery Installation
The main objective shall be the trouble free and reliable operation of
Machinery per its intended design details. Suppose the piping lay out
provided the easier maintainability of yard valves, the optimum
flexibility of the piping system, and the least pump flange loads; but the
pump loses suction and trip most of the time! The installation then has
failed!
Machinery Installation
Enppi Copyright © Enppi 2016 Page 34 of 150
Machinery Installation
Pumps and Compressors, and the Fatigue stresses acting throughout the
life time of the Equipment. Schedule 30/30s, 20/20s, 10/10s are
absolutely prohibited.
Chapter Three:
Pumps Piping Arrangements
Machinery Installation
Enppi Copyright © Enppi 2016 Page 35 of 150
Machinery Installation
- Introduction
Pumping system is the concern of this document and API RP 686. Health of the
pump alone, piping mechanical design, control valves, suction vessel, or any
individual portions of the system is a necessary but not sufficient for the health of the
integrated system. Health of the integrated pumping system means normal and upset
operation without undue transients which if repeated would break any part of the
system.
Pumping system is the suction vessel or tank, the suction piping, the discharge
piping, minimum flow piping, suction and discharge valves, check valves, control
system, and safeguarding system, pipe supports belong to the piping system, Pump
driver, Electric or Fuel Supply, Equipment Base Plate, Concrete Foundation and
Grouting for equipment and Piping Supports.
All the rules surveyed in previous chapter have to be respected. Compromises have
to be decided by Equipment Originator, Piping Designer, Process Specialist, Civil
Engineer, Electric and Instrument Engineers; as Applicable.
The following example of an overhung type (end Suction) pump seems to have
satisfied all the dreams of the Piping Designer; valves are put near the ground, pump
is not very far from the suction tank, sufficient flexibility of both suction and discharge
piping has been achieved, plot area is not exaggerated, etc. the pump will be
automatically filled when both manual suction and discharge valves are opened!
However, if there is an automatic air release valve (in case of handling potable or
process water to ensure that pumpage spray is not harmful to the Operators), or a
small top piping of small bore and a restriction orifice (3.0 mm opening orifice in a ½”
or ¾” pipe) returning back to the vapor space of the tank, would have achieved the
complete self-priming condition of the system.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 36 of 150
Machinery Installation
Note that the remainder of the discharge piping is not evaluated as it is unknown in
the photo!
Eccentric reducer in the suction can be either to or bottom flat because vapors and
air can go either way; back to the tank or to be pumped by the pump!
Suction piping must be sloping downwards (1:100 up to 1000) from the tank to the
pump.
If the discharge piping are elevated after few meters, why it was elevated once it left
the pump from the first beginning? Discharge Isolation Valve and Check Valves could
be installed either in the vertical rising pipe or on the high horizontal pipe afterwards.
The suction pipe support could have been at the elbow where the larger size pipe is
still there, to have better mass balance and least nozzle load because its thermal
growth or retraction or moment will be less as it is far from the nozzle.
This support is supposed to be sliding not Fixed (Bolted) as it is apparently made!
The next example is for vertical type pumps, it is operating with the following
which could have been optimized:
Machinery Installation
Enppi Copyright © Enppi 2016 Page 37 of 150
Machinery Installation
Automating venting from the top manifold by a small pipe and restriction
orifice, back to the suction sump,
Sliding supports for each pump discharge pipe to allow for thermal movement
of the elbows away or towads the pump nozzle,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 38 of 150
Machinery Installation
The above piping for three vertical pumps is providing better flexibility for the
individual pump discharge pipe. It does not provide automatic priming of the piping
system!
The following case is for a top/top Pump nozzle configuration where piping flexibility,
access to all valves and strainers from grade, and pipe designer dreamed of criteria
have been satisfied; however, the pump hydraulics were not part of the objectives of
design! The Pump failed to continuously operate until the fatal error(s) was/were
removed.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 39 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 40 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 41 of 150
Machinery Installation
The optimum pipe flexibility was made by introducing the reducer at grade level
downstream the suction strainer which is optimally supported and accessed from
grade level, the entire inverted U connected to suction nozzle is made of same
suction nozzle size.
The superfluous straight run condition was made excluding any portion of the elbow
or the pump nozzle; per the rules of the book!
Per Piping Leader Convictions; the created suction pipe pocket was safe because it
was below the liquid level in the three phase separator being the suction vessel!
The inverted U or the perfect pocket created plus the perfect straight run upstream
suction, made the pump capable of strong suction of crude in case there is any liquid
in the suction pipe; leading to creating sufficient transient vacuum to release gases
from crude liquid; leading to hammering of the discharge pipe because of intermittent
high frequency of building pressure due to successful suction of flow followed by
losing suction due to vacuum which in turn drops the discharge pressure suddenly.
Add to this the flow control was based on a pressure control valve about 600 meters
away of pump discharge nozzle, causing the pump to operate outside its end of
curve, demanding higher NPSHR which could not be achieved by the Perfect Pocket.
Add to this the pump was over rated for very high viscosity value (about 1200 CP)
while the actual crude viscosity was not reaching 200 CP.
The pump Electric Motor Driver was overrated for the actual site conditions!
Machinery Installation
Enppi Copyright © Enppi 2016 Page 42 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 43 of 150
Machinery Installation
The red suction piping was executed to remove the Perfect Pocket and try to
operate the pump after a long series of trials to live with it; which could not
override the rules of Nature or physics.
Service platforms are superfuous as the height of serviced valves is below 3.5
meters.
The suction pipe of individual pumps is not taken below the manifold to avoid
trapping of vapors!
The control system was not corrected!
It was very difficult again to push the button to start the pumps in a simple
way!
The five D straight run is maintained although it is superfuous for a top/top
pump configuration. Enppi had many of this type runing with less the two D
straight runs, and some of them just make a large radius elbow to fit the pump
nozzle; operating trouble free eversince.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 44 of 150
Machinery Installation
This is a straight forward application of Vertical Can Pump Type for crude
shipping; manifold from two sides of the separator sloping down to pumps. It
meets most of the piping design criteria presented so far.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 45 of 150
Machinery Installation
The above two photos for El-Quasr Condensate Pumps where the perfect
pocket has been repeated again. The top of pocket can be vented to
Machinery Installation
Enppi Copyright © Enppi 2016 Page 46 of 150
Machinery Installation
separator liquid with a large pipe. This is a sort of flooded vent working as an
auxiliary or supplementary suction pipe not passing through a strainer or an
isolation valve. Apparently this made the pumps work as pumps.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 47 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 48 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 49 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 50 of 150
Machinery Installation
Suction lift pumps must have an elbow at suction nozzle receiving vertical
pipe from the sump. No runs horizontally, no isolation valves, no common
suction headers, no air pockets, etc. the original design as shown in the
coming photos was completely wrong. No reducers should be used;
suction pipe has to be of the same size of the suction nozzle. The last
photo shows one pump after correcting the situation.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 51 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 52 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 53 of 150
Machinery Installation
- Reciprocating Pumps
Machinery Installation
Enppi Copyright © Enppi 2016 Page 54 of 150
Machinery Installation
- Safety Valves
- Check Valves
Hydraulic Oil Systems are very sensitive to Dirt’s or any deviation from
installation recommendations of the Original Manufacturer. Diaphragms
when double must be adhering to each other, to the degree that some
manufacturers recommend using a sort of vacuum pump to do that.
Diaphragm Failure Detection Device monitors the pressure rise between
the two Diaphragms by a simple pressure indicator or a pressure
Transmittal (switch if Project specifications allow). We do not wait for
Process Fluid to attack the Hydraulic Reservoir to declare Pump
Diaphragm failure, or wait to lose hydraulic oil leaking into the Process
Medium.
Hydraulic Systems always require a Higher Caliber of Operating and
Maintenance Crew, or special attention with a degree of education of the
pump Theory and Construction.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 56 of 150
Machinery Installation
This pump is used for intermittent filling of clean liquids such as lubricating oils,
chemicals, potable water, or emptying dirty sumps, oil reservoirs, storm water
collection pits, etc. they sometimes are stationary installation or fixed on a mobile
trolley. A discharge pulsation damper is recommended to reduce the shaking forces
to ensure long life time expectancy.
The same rules for a self-priming type pump apply when the pump sucks liquids from
a sump or a pit. Each pump must have its own suction hose or pipe which has to be
reinforced to resist collapse.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 57 of 150
Machinery Installation
Their purpose is to elevate sludge to be introduced from the top of the downstream
transfer piping to resume their motion by gravity.
Sludge flow cannot be forced by differential pressure because sludge itself shall
accumulate in the inlet transfer pipe.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 58 of 150
Machinery Installation
No check valves, no isolation valves, but rather intermediate transit sump with
another lifting sludge pump is needed every reasonable sloped horizontal run
dictated by the code of practice.
Pumping against upward sloped grade has to obey the same above rules.
This type of pumps needs to be treated similar to a control valve being a part of
piping system, floating in most installations with piping, having upstream and
downstream piping supports and sliding on a special fixed Soleplate. The mounting
bolts, if deemed necessary to keep the pump standing alone after disconnecting of
Machinery Installation
Enppi Copyright © Enppi 2016 Page 59 of 150
Machinery Installation
suction and discharge flanges, would be allowing pump horizontal displacement bur
preventing the pump from tilting over causing damage or accidents.
One fixed baseplate to pump sliding on another soleplate fixed to concrete
foundation can be the mounting way for many pumps. For flexible piping design,
pumps may have to be tightened to the concrete foundations.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 60 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 61 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 62 of 150
Machinery Installation
Pumping Liquid Fuel Into a Pipeline is different from pump application in a refinery,
gas plant, or a petrochemical plant. To demonstrate the main features of liquid
pipeline service, consider the example of pumping Jet A1 Fuel to an Airport for a
distance of 20 Kilometer across a high elevation terrane reaching 200 meter above
sea level where the initial location of the pumping station and final location of
receiving station are at low elevation; about 5.0 meters above sea level.
- The pump should be capable of covering the frictional losses in the pipeline
length; reaching for example about 10 Bard,
- The pump must be capable to pump liquid uphill requiring 20 Bard,
- The terminal pressure must not exceed 2.0 Barg to be able to bet introduced
to storage tanks without any troubles,
- The liquid fuel pressure midway on top of elevation must not be allowed to get
below 3.0 Barg to prevent liquid vaporization and initiation of severe
hammering condition both ways of the pipeline,
- To reach midway of the pipeline the required pumping head shall be 50% of
the total pipeline friction (0.5*10.0)+ Static Head (20.0)+ Margin (3.0)= 28.0
Bard,
- To complete the second portion of the pipeline the available Head (23 Barg)
shall be reduced by the friction (5.0) and 2.0 Barg to e remaining at terminal
station; resulting in 16.0 Bard remaining and not required; which would cause
damage and can increase when flow is reduced by the amount of friction
spared; i.e. can reach 26.0 Bard,
- A Back Pressure Control Valve has to be installed at terminal location to
maintain the top elevation pressure at 3.0 Barg or above; but not exceeding
5.0 Barg,
- Pipeline system needs to be 300# flange rating to maintain a margin above
the minimum allowable working pressure of 33.0 Barg, unless further surge
scenarios prove higher pressure is possible,
- Possible surge scenarios are not limited to: sudden closure of Terminal
Receiving Station, Sudden Pumping Station Tripping, Vacuum Taking Place
in the top Elevation midpoint.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 63 of 150
Machinery Installation
Chapter Four:
Piping Acoustics and Noise
Machinery Installation
Enppi Copyright © Enppi 2016 Page 64 of 150
Machinery Installation
ASME section VIII sets rules for investigating the nature of the applied loads on a
vessel (or a Piping System as analogous to Vessels, as a first guess) to determine if
fatigue analyses is due or not.
Changes such as: Pressure, temperature, thermal expansion cycles, day and night
effects, process flow rate changes, mechanical vibration loads, wind loads, etc., are
investigates to estimate the range of change of the associated load/stresses, as a
percent of the normal operating condition mean (or Average) Load. When this ratio
exceeds a certain value then Dynamic Fatigue Analyses has to be executed.
When the load is a transient one, acting in a very limited number of cycles, such as
starting load of an electric motor (normally large motors are started every few
months), or seismic load, or short circuit loads, or similar type of a load, sometimes
seasonal thermal expansion load is treated as one of these transient loads, then the
Machinery Installation
Enppi Copyright © Enppi 2016 Page 65 of 150
Machinery Installation
concept of equivalent static can be applied. The peak load is multiplied by a factor
(normally equal to 2) then is introduced as a static load.
Repeated cyclic loads of a frequency several times per hour, day, weak, month, and
sometimes per year but a sizable value of load range, have to be inspected
according to the criteria set up by the applied Code Charts of S-N curves.
As a rule, it is better to apply the S-N charts criteria in few minutes (up to couple of
hours) than to decide without pre-calculation to go to static load design criteria, or to
equivalent Static Load Criteria.
Process Loading Data for Instrument Design was 110% of Normal Flow; although per
API 617 Standard Compressor Performance Charts are covering up to 130 % of the
rated flow as such higher flows are experienced at start up, over capacity operation,
and transient change of number of operating units. Thermo-well natural frequency
was excited for a long time causing fatigue failure.
The same process loading data were used to purchase a replacement of the
Thermo-wells, resulting in a subsequent short time failure!
Three phase flow of crude, water, and associated gas at a Gas to Liquid Ratio known
to promote slugging Condition to be handled by Enppi Piping and Three Phase
Separator. On-Spec as a third party made an Olga Soft-Ware calculation with clear
severe Slugging Conditions,
Piping isometric showed a very pronounced rise of pipe elevation, from 2.0 meter
from grade up to 14.0 meter from grade, followed by a drop of elevation about 7.0
meters to get into the three phase separator vessel after several sharp elbows then
to go through double elbows inside the separator vessel.
Velocity of average mixture of the three phases was selected higher than 6.0 m/sec!
Actual slugging liquid velocities reached 20 m/sec, per On-Spec Calculation Results,
Process did not declare a state of Danger to other disciplines,
Piping used the Equivalent Static Load Approach for the design; passing very low
loads to Civil to design the supporting Structure,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 66 of 150
Machinery Installation
Civil applied a steel structure of elevation higher than 12.0 meters at a lateral width of
3.0 Meters!
The result is obvious; severe vibration, clear failure of pipe supports and anchor point
support, steel structure failure,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 67 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 68 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 69 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 70 of 150
Machinery Installation
Chapter Five
Piping Dynamics
Machinery Installation
Enppi Copyright © Enppi 2016 Page 71 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 72 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 73 of 150
Machinery Installation
Unbalance from any rotating parts is the first and most influential
source of vibration, acting at running speed of any machinery
equipment,
Misalignment at synchronous and twice synchronous speed and
mainly acting in the axial direction, is the second of importance,
Blade Passing Frequency at Running RPM multiplied by the number
of blades,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 74 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 75 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 76 of 150
Machinery Installation
Chapter Six
Supports
Machinery Installation
Enppi Copyright © Enppi 2016 Page 77 of 150
Machinery Installation
Spring elements
To compensate for slight vertical displacements in the piping, spring components are
used as supports. The functioning of these components is based on preset helical coil
springs which exert a variable supporting load over the whole range of movement
corresponding to the given spring characteristics.
Load variations resulting from this are limited through corresponding specifications based
on stress calculations for the piping - this depends on the sensitivity of the system.
The fundamental principles relevant for the function of the spring components are found
in the MSS SP 58 and VGB R 510 L guidelines.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 78 of 150
Machinery Installation
additional
damping
effect is
obtained at
the same
time. The
connection
parts
correspond
with those of
Product
Group 3.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 80 of 150
Machinery Installation
Spring hangers and supports should be set in such a way that the spring load and the
piping weight correspond with the cold load position. The corresponding hot load position
results from the theoretically determined pipe movement (travel) and the spring rate. The
load difference between the cold and hot positions acts on the piping as a reaction force
and is limited by the relevant design specifications. Generally, the max. permissible load
deviation amounts to 25% of the operating load.
- Clamped Supports,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 81 of 150
Machinery Installation
- U-Bolts
Machinery Installation
Enppi Copyright © Enppi 2016 Page 82 of 150
Machinery Installation
- Cryogenic Supports
Machinery Installation
Enppi Copyright © Enppi 2016 Page 83 of 150
Machinery Installation
Part CS01
Part CG02 G0
Machinery Installation
Enppi Copyright © Enppi 2016 Page 84 of 150
Machinery Installation
Manufacture of High-
Density Polyurethane
Foam (HD PUF) on
high-pressure foam
injection machine
HD PUF segments
Machinery Installation
Enppi Copyright © Enppi 2016 Page 85 of 150
Machinery Installation
Part-assembled cryogenic
anchor support with fitted
spool
Hot
H
Machinery Installation
Enppi Copyright © Enppi 2016 Page 86 of 150
Machinery Installation
- Hot Pipe Supports,
Hot Shoe
- Slide Supports,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 87 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 88 of 150
Machinery Installation
- Support Stiffness,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 89 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 90 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 91 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 92 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 93 of 150
Machinery Installation
Chapter Seven
Machinery Installation
Enppi Copyright © Enppi 2016 Page 94 of 150
Machinery Installation
- Introduction
Machinery Installation
Enppi Copyright © Enppi 2016 Page 95 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 96 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 97 of 150
Machinery Installation
merge point to ensure no back flow upstream and that all recycled
flow is introduced into suction scrubber,
- Recirculation line take off has to be from the top of discharge piping
close to discharge cooler to achieve fast response in emergency
cases,
- Recirculation line take off must be followed by a check valve to
ensure that only gases coming through the compressor casing is
that gas being recycled,
- Hot gas bypass valve to avoid surging during fast stop has to be
from the compressor discharge upstream any cooler to compressor
suction upstream scrubber if not mandated to be downstream
scrubber,
- The recycle valve (Anti-Surge Control Valve for a Centrifugal
Compressor must be axially supported to mitigate the sudden
momentum force upon sudden opening of the valve in emergency
condition,
- Compressor manual and shutdown discharge valves must be
installed downstream a check valve to prevent back flow when they
are open and the compressor is still unloaded to the discharge
manifold prevailing pressure,
- All tie-ins to flare or closed drain system must be provided with a
check valve,
- All Nitrogen inlet tie-ins must be fitted with a check valve to
prevent back pressure to flood the Nitrogen system; hazardous gas
and over pressure condition,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 98 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 99 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 100 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 101 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 102 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 103 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 104 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 105 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 106 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 107 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 108 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 109 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 110 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 111 of 150
Machinery Installation
Chapter Eight
Grouting of Baseplates, Soleplates and Pipe
Supports
Machinery Installation
Enppi Copyright © Enppi 2016 Page 112 of 150
Machinery Installation
pipe supports, higher support loads, and better resistance to oil or liquid
spills. Most important characteristic is that it is non-shrinking upon curing
to keep filling voids and adhering to internal steel surfaces.
Epoxy grout is the best from all above respects, and most
expensive; optimum chemical resistance, compressive strength, bearing
strength, adhesion capacity to steel surfaces, resistance to heat and direct
solar radiation, heat/temperature variations, tolerance to impact or
dynamic loads, easier for the applications of any type or configuration;
thin spaces, be injected into thin cracks, etc.,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 114 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 115 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 116 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 117 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 118 of 150
Machinery Installation
Chapter Nine
Steam Turbine Piping
Machinery Installation
Enppi Copyright © Enppi 2016 Page 119 of 150
Machinery Installation
- Steam trap
- Basic operation
The simplest form of steam trap is a disc or short solid pipe nipple with a small
hole drilled through it installed at the lowest point of the equipment. Since
steam condensate will collect at the lowest point and live steam is about 1200
times greater in volume than this hot liquid, condensate is effectively removed
and steam is blocked. However, the vast majority of steam traps in current
operation are of the mechanical or thermostatically operated design.
Mechanical and thermostatic steam traps basically open when condensate
and inert gases need to be removed, and close when all the condensate is
removed. The process repeats when new steam is condensed again and
ready to be drained.
Steam traps work best when sized specifically for the application they are
used on. Generally, it is better to oversize, as they will still discharge
condensate when present and close or obstruct for live steam. However an
over-sized steam trap may wear quickly, waste energy (use steam), and if
drastically over-sized can cause process issues.
- Types
1. Mechanical traps.
They have a float that rises and falls in relation to condensate level
and this usually has a mechanical linkage attached that opens and
closes the valve. Mechanical traps operate in direct relationship to
condensate levels present in the body of the steam trap. Mechanical
steam traps have a typical service of life of 3 years. Inverted
bucket and float traps are examples of mechanical traps.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 120 of 150
Machinery Installation
2. Temperature traps.
They have a valve that is driven on / off the seat by either expansion /
contraction caused by temperature differ from mechanical traps in that
their design requires them to hold back some condensate waiting for it
to cool sufficiently to allow the valve to open. In most circumstances
Machinery Installation
Enppi Copyright © Enppi 2016 Page 121 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 122 of 150
Machinery Installation
Venturi Nozzle steam traps work by utilizing the basic physics of two-
phase flow for the effective removal of condensate from steam
systems. Steam and condensate pass through the Venturi nozzle
steam traps by a series of staged steps. "The denser liquid
(condensate) throttles the Venturi nozzle, which keeps the steam from
escaping. Erosive eddy currents are eliminated and any contamination
is carried away with the condensate. Because condensate is created
continuously in a working steam system, the condensate continuously
chokes the nozzle from losing steam as condensate is removed
continuously". Venturi Nozzle traps require expert engineering and
precise sizing in steam systems.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 123 of 150
Machinery Installation
All steam piping up to steam traps and condensate drain piping need
insulation for either heat conservation or personnel protection. Even for steam
jacketed piping transferring other heated process fluid, they need to be
Machinery Installation
Enppi Copyright © Enppi 2016 Page 124 of 150
Machinery Installation
insulated to keep steam and process fluid above a certain temperature and for
heat conservation. Jackets do need hot insulation.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 125 of 150
Machinery Installation
Chapter Ten
Piping Elements Maintenance, Reliability and
Availability
Machinery Installation
Enppi Copyright © Enppi 2016 Page 126 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 127 of 150
Machinery Installation
Consider the two gas turbine driving Centrifugal Pumps where failure of
one unit shall leave the other unit handling only 50% of the Plant
Throughput. Then calculation of the Reliability of the plant shall be as
follows:
- Failure of one unit has a percentage happening of 3.5% associated
with 50% loss of the production,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 128 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 129 of 150
Machinery Installation
Piping system for clean fluids is assumed to be 100% of the time available
for Operation.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 130 of 150
Machinery Installation
times, maximizing profitability of the Pumping Station; i.e. Total Life Cycle
Cost minimization versus Commercial Production time.
Equipment monitoring implies automatically piping system monitoring; as
cleanliness, health condition of supporting system, valves and strainers
are in good sustainable condition, etc.,
Erosion and corrosion of piping system wall thickness and internal parts
can be monitored visually during facility maintenance, or externally by
periodic Ultra-Sonic Inspections, for instance.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 131 of 150
Machinery Installation
Standard Tools are available in the local Market and in the Manufacturer
Catalogues. They must be availed at site as basic requirements for
undertaking a maintenance job. Special Tools made by the Manufacturer
Machinery Installation
Enppi Copyright © Enppi 2016 Page 132 of 150
Machinery Installation
of the valve; for instance, to enable working on the valve; such as and not
limited to: valve seat Removal Kit, valve packing Disassembly/assembly
tools, Inner parts Removal/assembly Tool, etc.,
Some special Electric, Electronic and Calibration Tools can be standard or
special type based on the specialty of the design or assembly; they need
to be available in the hands of the Maintenance Crew to do their
diagnostics and checking jobs. Paint Thickness Meter, Electric Resistance
Tester at High Voltage, Specialized Analyser Calibration Kit, etc.,
Monorail and Overhead Cranes Hydraulic Jack Carts, Fork Lift, Hydraulic
Cranes for Passengers, Temporary Scaffolding, Hydro-Test Pump Kit,
Pneumatic Hoses, Hydraulic Hoses, Hydrostatic Test Hoses, Vacuum
Pumps, Drying heaters, Industrial Large size Ventilation Blowers suitable
for classified areas, Sunshade tents, etc., available as per Company
Policy!
Machinery Installation
Enppi Copyright © Enppi 2016 Page 133 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 134 of 150
Machinery Installation
10.13.1 Alignment,
Putting all piping flanges on the same straight line when reaching their
operating temperature at full load, is the target of making alignment. No
soft foot should be left after alignment, i.e. piping on its supports should
not be distorted by tightening of any anchor or mounting bolts. There are
Alignment Indicators to be mounted on coupling hubs by special rigid
brackets, there are Laser Alignment Kits, there are Optical Alignment
measurement tools to measure the thermal growth due to
equipment/machine/piping heating up from cold condition up to stabilized
warm operating conditions.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 135 of 150
Machinery Installation
- Third is to look for higher order causes of the trouble, which may
need extra inspections, testing, small scale disassembly of parts,
then exclude or confirm the reason.
- Fourth step is to look for the root cause which originated and
initiated the cause of the breakdown.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 136 of 150
Machinery Installation
- Conclusive Report: Did one solve the root cause of the problem? Is
there a mandatory modification or upgrade of the Equipment to
avoid the occurrence of the same trouble?
Example:
Machinery Installation
Enppi Copyright © Enppi 2016 Page 137 of 150
Machinery Installation
- Step Three: the control system and suction piping seem to be the
root cause of the problem.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 138 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 139 of 150
Machinery Installation
Chapter Eleven
Overview of API Standard 686 Requirements
Machinery Installation
Enppi Copyright © Enppi 2016 Page 140 of 150
Machinery Installation
Other examples of Codes are not limited to ASME, ANSI, BS, DIN, JIS,
API, AGMA, AFBMA, ASHREA, etc., they are very generic and containing
thousands of more specific Standard Publications.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 141 of 150
Machinery Installation
For some few Commodities, API has set some rules to enable certification
of Fabrication Facilities, and of its Products, and to have a Monogram
Symbol attached to the Product Nameplate to Certify the Product. This is
applied to quite a few Equipment such as Pedestal Cranes, similar to ASME
qualified Vessel Fabrication Shops and ASME Nameplate, and ASME U- or
R- Stamps.
This is not the case for most of other Products. API 610 Standard
Requirements for Heavy Duty Centrifugal Pumps sets guidelines for
Design, Inspection, Testing, Material Selection, etc., however API
Committee does not have an inspector to qualify the factory, attend the
inspections or testing, or evaluate the Product Deviations from API strict
Requirements.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 142 of 150
Machinery Installation
This is left to the Fabrication Shop Own Quality Standards and to the
Purchaser or its Representative. Previous Experience List and
Manufacturer Reputation are of prime Role in this Context.
Every Paragraph in the API standard targets stronger, More Rigid, Higher
Strength Margin, Higher Speed or Power Margin to achieve robust
equipment and ancillaries to tolerate excursions in operating conditions
and errors in maintenance and sometimes negligence of the Maintenance
or Operating Crew.
Some API standard Pumps have been running in Egypt for the last 35 to
50 years and still having excellent reliable and operational Availability
running Performance.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 143 of 150
Machinery Installation
Some Engineering Companies seek low budget fit for the Purpose Heavy
Duty Pump Design but not fully complying with the strict Requirements of
API standard Specifications.
Such conditions puts the API Standard to be used only as a guideline for
reference to know the deviations and evaluate them.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 144 of 150
Machinery Installation
Chapter Twelve
Local Fabrication
Machinery Installation
Enppi Copyright © Enppi 2016 Page 145 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 146 of 150
Machinery Installation
Valve Factory and Pipe Factory in Egypt for fabrication of Coded Valves
and Seamless Piping per ANSI standard are in business for over few
decades.
Machinery Installation
Enppi Copyright © Enppi 2016 Page 147 of 150
Machinery Installation
from the mating new discs, from the remaining parts and components of
the valve or equipment.
It is similar to repairing an ancient monument based on good technical
guessing!
For a knowledgeable maintenance designer or leader, it is better to set his
target to make a stem that can achieve the valve job, rather than creating
an identical to original stem! Simply the latter objective is almost
impossible as the details cannot be compiled!
Fabrication drawings with detailed dimensions and tolerances can then be
made!
However; in Egypt it is better to provide the old piece with a responsible
person to supervise and lead the fabrication job. For instance; having a
new sleeve in hand is the only way to machine the stem to fit to this
sleeve!
Anyway, fabrication of the stem is yet a more straightforward than the
other pieces of the valve!
Machinery Installation
Enppi Copyright © Enppi 2016 Page 148 of 150
Machinery Installation
It seems simpler than the procedure for the casing; however, it is the
moving part, requiring more exact dimensions, thinner sections, better
cast-able alloys, better surface finish, special NDT,
Machinery Installation
Enppi Copyright © Enppi 2016 Page 149 of 150
Machinery Installation
Machinery Installation
Enppi Copyright © Enppi 2016 Page 150 of 150