Professional Documents
Culture Documents
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PROCESS PLANT
LAYOUT AND
PIPING DESIGN
D
Ed Bausbacher
Roger Hunt
•
P T R Prentice Hall, Englewood Cliffs, New Jersey 07632
Library of Congress Cataloging·in-Publication Data
Bausbacher, Ed..
Process plant layout and piping design I Ed Bausbacher, Roger
Hunt.
p. em.
.Includes index.
ISBN 0-13-138629·8
1. Chemical plants-Design and construction. 2. Plant layout.
3. Chemical plants-Piping. I. Hunt, Roger (Roger W.) II. Title.
TP155.5.B38 1993
660-<1c20 93·9725
CIP
The publisher offers discounts on this book when ordered in bulk quantities.
For more information, contact:
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PTR Prentice Hall
113 Sylvan Avenue
Englewood Cliffs) NJ 07632
Phone: 201-592·2863
FAX: 201·592-2249
10 9 8 7 6 54 3 2 1
0-13-138629-8
3 Plot Plans
6 Exchangers
rhe Plot Plan in the Process Unit 27
)efinition . . . . . . . 27 Exchanger Construction . . . . . 110
'lot Plan Development 28 Exchanger Location and Support 114
"ypes of Plol Plans 31 Nozzle Orientation .. 125
Exchanger Piping .. . . 127
~quipment Location . . 33
Exchanger Maintenance 135
'ipe Racks . . . . . . . 42
toads, Access Ways, and Paving 44
~uildings
:quipment Spacing . . . . . .
' 44
44
7 Furnaces
ample plot Plan Arrangement. . Sl Basic Operation and Primary Pans of a Fumace 141
Types of Furnaces 141
1/ ' Terminology. . . . . . . . . . . . . 144
'C Compressors
Burners . . . . . . . . . . . . . . . 147
uXiliary Equipment . . . . . . . . . . . . .. 5S Combustion Air Preheating Systems 148
entrifugal Compressors: Nozzle Orientations. 61 General Arrangement of Furnaces . 149
ypes of Compressor Drives . 61 Piping Layout for a Furnace . . . . 165
Jbe Oil System . . . . . . . . . . . . . .. 64 Tail Gas Incinerator and Waste Heat Unit 177
~al Oil. System . . . . . . . . . . . . . . .. 64
Jrface Condensers and AUxiliary Equipment.
ompressor Maintenance .. " . . . .
66
69
8 Pumps
:)filpressor Arrangement and Location 75 Pump Terminology 181
.evations of Machines 79 NPSH Requirements 182
vii
viii
)uring the 43 years of my career, it was extremely am convinced it provides an excellent tool to enhance
lifficul( and time.-eonsuming for an individual to be~ the education of individuals who aspire to such a ca·
ome knowledgeable and competent in the field of reef. In addition, 1believe it should attraa widespread
.iping design and plant layout Little was wrinen in a use as a textbook and reference manual by refinery
:)rmat that would provide the designer with educa~ and petrochemical companies, engineering and con~
lonal or reference material. About the only ways struetion companies, and technical schools and col·
nowledge and techniques were absorbed were by leges.
edious, repetitious design functions and through I commend the authors on their remarkable effon
vorking with experienced peers. in accumulating and developing this data, and present~
Today, the learning cycle is even more constricted, ing it in such a practical and commonsense· maiiner.
educing exposure to me design basics that are so
VINCEl'41 L. Sl"RDI
:ssential to the development of me plant layout de~
Piping Design and' Plant Layout
igner.
Engineer and Manager
I have spent considerable time in reviewing and
itudying Process Plant Layout and Piping Design and
"
Preface
Whether one is entering the employment ranks in the within the process unit plot plan. Chapters' 4 through
process industry for the first lime or is well estab- 15 deal.with specific pieces of process equipment, or
lished in the design field, it is imperative to under- components of a plant such as piperacks, structures,
stand the true nature of today's marketplace. underground piping, instrumentation and their most
Competition formerly limited to cities, states, prov- efficient layout in the overall· plant design configura·
inces, or country. must now be considered in the tion. Chapter 16 deals with stress analysis by step ap·
world marketplace. A sustained level of success can proach to basic stress analysis. which is a must for
only come about as a result of Hmeeting or exceeding" designers and engineers. The last chapter in this book
dient requirements. Introduction of automated tech- is dedicated to the computerization tools that are now
nology has added another dimension to the already available to help plant layout and piping designers in
dynamic process industty. Formal education of design- the execution of their work. During the past decade or
ers and engineers has become a necessity. Rapid t\Vo, the way these designers learned their craft has
changes in process technology. environmental and changed dramatically. Historically, secondary school
safety laws, along with work execution methodology, as.well as two-year technical college graduates entered
place a constant demand for education in this industry. the profession and spent many years learning the busi..
The intent of this. boo.k is to help train, on an ac· ness. Novices were trained through such manual ex~
celerated basis, the young engineers and technicians . ercises as revising draWings, draWing single·line
entering the field of process plant layout and piping isometrics. and preparing material takeoff" sheets;
design. It also updates equipment spacing require- . eventually they were given an opportunity to do sim v
ments and addresses the latest feature of electronic pIe deSign work. Today's computers vastly alter iliis
data transfer for the experienced layout designer. learning process. One designer at a computer graph~
Process Piant Layout and Piping Design represeil~ ics terminal can route a line and extract the Single line
the accumulated, practical experience of two plant isometric, which includes a complete bill of material.
layout designers who, through more than 70 years of Thi~ information may then be electronically transmit·
trial and error, hav~ devised workable methods and ted to a shop or field fabricator. .
rules of thumb for plant layout and piping design. Such rapid changes in technology demand tha~ in·
Illustrations that make up the heart of this book are dustry adopt a more formal means of educating future
its key aspect, because plant layout and piping design designers, because new trainees today must learn in a
is visual by nature, reqUiring the designer to make in few shon years what our talented predecessors spent
essence the conceptual leap from a two·dimensional a lifetime learning by repeated manual exercise. Al~
process flow diagram, to a three·dimensionaJ, phy. though the aVailability of the computer vastly facilitates
sicaJ process facility that comprises extensive networks the design of process plants, the tool itself does not
of process and piping equipment. . confer the knowledge of fundamental principles of
This book has been arranged into 17 chapters. 11le plant layout and piping design that are the basis of any
first three deal with general concepts and principles of creditable effort at such design work. The computer
plant layout from basic technology and input require- remains, at best, a tool for learning and execution.
ments to actual deliverables. plant layout specifications A plant layout designer is primarily skilled in the
have been included for spacing, clearances, and safety development of equipment arrangements and piping
requirements leading to equipment arrangement layouts found in process plants. The position offers a
xiii
xiv
unique opportunity to demonstrate technical ability entailed in each individual job. .And although the tool~
and creative talent as well as a commonsense approach we now use to achieve these goals have changed froIT
to problem solving. The world economy today de· pencil and paper to computer graphics terminal. the
mands that the design and engineering or" process responsibilities and challenges of the plant layout de·
plants be accomplished on extremely shon schedules signer remain the same. It is hoped that, through thE:
while optimizing operations, maintenance, safetyt combined practical experience of both authors, thi~
quality, construetibility, and economics. This demand- book can help designers meet those challenges suc-
ing position offers great rewards for those willing to cessfully.
work to solve the countless complex layout problems
Preface
PROCESS PLANT
LAYOUT AND
PIPING DESIGN
------------C-'-H-A-P-· T-E-R-l---
The Basics of
Plant Layout
Design
Plant layout design plays an important part in the deM o Creativity.
sign and engineering phases of any industrial facility. • Sufficient experience to avoid reinventing the
This chapter discusses the role and responsibilities of wheel.
the plant layout designer provides advice on how to
I
• Knowledge of the principal roles of other design
use project data, describes the timing of various activi- and engineering groups and the ability to use input
ties, offers an approach to a basic piping design layout, from these other disciplines.
and lists abbreviations and common terminology. Sub-
{I The ability to resolve unclear or questionable data.
sequent chapters cover plant layout speCifications, ma-
jor equipment layouts comrnonly found in such facili· • Willingness to compromise in the best interest of
. the project. "
ties, pipe rack layout, underground design, and
instrumentation. Gl The ability to generate clear and concise documenrs.
• The ability to defend designs when challenged.
mE PLANT LAYOUT DESIGNER The Designer's Role
The plant layout designer is skilledprimariJy in the Exhibit 1·) shows the factors , departments, and per~
development of equipment arrangements and piping sonnel with which the plant layout designer can ex·
layouts for process industries. The position offers an peel to work throughout the engineering phase of a
opportunity to demonstrate technical ability along project. The principal activities of the plot plan devel-
with a creative talent and common-sense approach to opment, equipment layout and piping design) which
t
problem solving. Process facilities must be designed often aCCOunt for a significant portion of project engi-
and engineered within extremely short schedules neering costs, become a focal point for clients, projeCt
while adhering to maintenance, safety, and quality management, construction, engineering, and suppOrt·
standards; moreover. the design must take constructi- ing disciplines. The designer must realize that time
bilityt economics t and operations into account. Al- and care spent during engineering help shorten con~
though the tools to achieve these goals are changing struetion schedules and thereby lower overall project
from pencil a~d paper to computer graphics termi- costs. The designer must be c01)scious of the construc-
nals, the responsibilities of the plant layout design re- tit>i1ity of every layout.
main' the same.
The plant layout designer must develop layout doc- Principal Fun~tions
uments during the conceptual and study phases of a
The principal functions of the plant layout designer
project. The skills needed include:
include the conceptual and preliminary developm.ent
of process unit plo~ plans, sometimes referred to as
• Common sense and the ability to reason.
equipment arrange~ents; the routing of major above-
~ Knowledge of what a particular plant is designed to and below-grade piping systems; and the layout of
do. equipment and its associated infrastructure. Plot plans
• A general understanding of how process equipment show the positions of major units and equipment
is maintained and operateq.. within units and their associated infrastructure. Creat·
e The ability to generate a safe t comprehensive layout ing a well·designed facility involves meeting all dient
within a specified time and with consideration to· specifications and local government codes and regula-
ward constructibility and cost-effectiveness. tions and adhering [0 design engineering practices.
1
2
EXHmIT I-I Plant Layout Interface
With the planning plm plan ~ a basis, the following • Establishing all equipment nozzle locations that
functions are a standard part of the plant layout de- satisfy all process, utility, and instrument require-
signer's activities: ments.
• Locating aU safety items (e.g., fire hydrants, moni·
• Setting all equipment locations-This activity in- tors, and safety shower stations).
cludes input from construction on ereCtion se-
quences or on special problems associated with set· • Locating all miscellaneous items (e.g., filters, si-
lencers, and analyzer houses).
ting large pieces of equipment. Choosing equip-
ment locations includes setting coordinates in two These activities must be closely coordinated among
directions and finalizing equipment elevations, all the plant design and construction participants in-
whether they are centerline, tangent line, or bottom. volved in the engineering and construction phases of a
of baseplate. project to reduce costly rework and enable the plant
G Designing all structures and positioning the associ· layout de~igner to generate the optimum design on
ated stairways, ladders, and platforms-In general, schedule.
the designer makes provisions to satisfy all opera·
tional, maintenance, and safety requirements for ac-
cess to and clearance around equipment. PROJECT INPUT DATA
• Planning unobstructed areas for- necessary steel
members or stroaures that facilitate all plant main- Although there is a vast amount of input data through-
tenance requirements. out the life of a project, the data basically falls into
3
EXHIBIT 1-2
loternally Generated
Engineering Data
'l'I- ,
f
I -
- -i
r - "
t.e-]VIT("
• ~PTIJtJ.. ppt P4N
• pt2~UMlt-.Jel2'( r;il~ fttJ-J
• ZILJP( LAyOJr
during the study phase of a project. The diagram BASIC LAYOUT PHILOSOPHY
shown in Exhibit 1-3 oudines the sequence of these
activities, along with the principal input required and Each plant layout designer develops an individual lay-
output generated. Although project schedules often out philosophy. Although conditions (e.g., client speci-
dictate variations in this approach, it is intended to be fications, schedule constraints, and aVailability of infor-
an optimum condition for the most effective use of mation) may change significantly among projectS, the
staff time. The study phase can make or break a proj- designer's style remains consistent. One.basic rule to
.ea. Working out of sequence is acceptable within rea- remember is to avoid designing one line at a time-
son, but if it is overdone, a project will never recover that is, routing a line from one piece of equipment to
during the detail phase. The ideal situation for speed another before thinking about the next one. Although
and quality is to do the job right the first time. it is possible to complete an area design using this
A J2.C
~;~ -. ~ -....
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,
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~ 1'!'~
~ ~ 1-10- t-i- T
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are on the outside of the pipe rack and peel off first though it is not always necessary to plan for future
with flat piping turns. The lines to exchangers A, B, expanSion, it can often be done with ver.y little addi-
and C are located to the center of the rack and can· also tional effort and cost. Each area should be thought
peel off in most cases. through on a case-by-case basis.
This approach saves finings and requires a shorter
steel beam to support the piping. It should be noted
Elevation Layout
that the use of flat turns in piping is not recommended
if there is a likelihood of future expansion in an area. Exhibit 1·5 shows two workable piping layouts. The
The alternative to accommodate future piping ronning key difference is that the arrangement on the left
north at the same elevation is to change elevation for shows piping running at too many elevations. With a
the piping running east and west to the drums. AJ· little effort, this can be corrected, as shown in the
EXHIBIT 1-6
11
,l...
X"
-l, I_~__II
,
+-"--1 Diagonal Piping Runs
I
/
I 1'0"
"ight·hand view. Adding support steel for this prefer- ferent elevation, as shown. There is no absolute rule,
"ed. design would require only minimal effort. The except that judgment should be used to produce a
rjew on the left, however, would require additional neat and orderly layout as well as to occasionally save
~ngineering time and additional steel cost. pipe fittings when possible.
!N~~~
e~IVe: I:!:CP~
II
6J
Vd')CaZ '
~
~~A"
.---,,--
.. ,,--------------------------- EXHIBIT 1-8
Space Use
~ I
~.\
~
0
::J:
ht:Jl~
m~
.~r~LJhI~
W
1W'7J~eN
y-z.ll ILlelM~
Heat tracing In many processes, equipment, instru- points in a plant. An example of a header arrangement
ments, and piping systems require externally applied is shown in Exhibit 1-12.
heat. This heat may be applied by electrical tracing
leads attached to the item or line or through a small Branch 1he individual piping leads between head-
bore pipe or tubing that carries steam or other heating ers and users are also illustrated in Exhibit 1-12.
media (e.g., hot oil). An example of a steam-traced line
is shown in Exhibit 1-10. Maintenance Equipment and its components re-
quire routine maintenance for continued reliability
Inline ThiS term refers to a component that is placed and safe operation. A plant layout designer must pro-
either inside or between a pair of flanges as opposed vide unobstructed space for service equipment and
to one anached to a piece of pipe or equipment, An personnel to access and remove components without
example of inline instrumentation is shown in Exhibit removing unrelated equipment and piping.
1-11.
Operation Valves, instruments, and many types of
Header block valves These valves isolate branch equipment require frequent attention for operation.
lines that are not usually prOVided with permanent These items must be accessible without impairing the
access for plant operations personnel. safety of plant personnel.
Header This line is the primary source of a commod- Safety The layout of any facility must enable plant
ity used by numerous pieces of equipment or setvice personnel to exit a potentially hazardous area without
,
Process plant Layout and Piping Destgn
13
EXHmlTl~l1
lnline Instrumentation
IBk
EXHIBIT 1~12 \"
Header-Branch-Header
Block Valve
injury. Planning for safety includes adding roadways to the result of a balanced consideration of initial COSt,
provide access for nre fighters and equipment; strate· safety, and the long-term effects of a design on opera-
gically placing fire detectors and hydrants around the tions and maintenance. •
process unit; adding sufficient ladders and Stairways at An example of cost-effectiveness is the layout of
structures to meet OSHA requirements; locating fur- steam-driven gas compressors. Although a grade-
naces with fired burners away from potential sources mounted installation is initially less expensive to io-
of gas leaks; and setting the height and location of stall, maintenance on such arrangements often re-
Vents to prevent injury to operating personnel. quires the dismantling of all major piping systems.
This can prolong plant downtime and translates into
Cost-effective Developing the most inexpensive lay- lost revenue for the client. Careful consideration
Out may not translate into the most cost-effective de- should be given to aU factors before the initially low-
sign for the life of the plant. A cost-effective design is est-cost solution is chosen.
Gravity flow When pockets must be avoided in a Flexibility Every piping arrangement must be suffi-
given piping system, the line is labeled "gravity flow" ciently flexible to allow each line to thermally expand
on the piping and instrumentation diagram. This often or contract without overstressing the pipe or equip-
results in locating equipment in elevated struCtures ment. Exhibit 1-15 illustrates several methods to meet
instead of at grade, as shown in Exhibit 1-13. this flexibility requirement, induding:
Open systems An open system is one in which the • Relocating equipment to build flexibility-'into the
coments of a line are discharged and not recovered. inherent design of the line.
Examples of this include a relief valve discharging into • Adding an expansion loop.
the atmosphere and a steam trap discharging onto the
• Adding an expansion joint (but only if a loop will not
ground or into an open drain.
suffice).
Closed systems A dosed system is one in which the • Reducing the schedule (I.e., wall thickness) of the
contents of relief systems or steam trap condensates pipe if possible.
are recovered. Examples of open and dosed systems
are shown in Exhibit 1-14. The designer should thoroughly review an possible
-----~¥~
D~\Mzr;t? 'F A~f:ee
---~
~ /~
- +-1 / ?2'bH,.) MU'2
~
EXHIBIT 1-15
tine Flexibility
16
EXHIBIT 1-16
Typical Pipe Supports
...
I
~ I 1
solutions with the project stress engineer before pro- • Spring supports~ These lines move at the poim of
ceeding with any of these methods. support as a result of thermal expansion or contrac-
tion and are generally supported by springs. De-
Pipe supports These steel members are attached to a signed for specific pipe loads and movements, they
pipe to hold it in place during operation. Supports are maintain a support under a line throughout its range
available in many shapes and sizes and rJ.nge from of movement
those that hold a line firm enough to permit no move- • Trunnions and dummy legs-These supports are
ment to those that allow movemem in any direction. used for many applications and are welded to the
Some typical pipe supportS are shown in Exhibit 1-16 outside of the pipe without cutting a hole into it.
and include; • Brackets-ThiS type of support may be welded to
structural members or certain pieces of equipment
• Pipe shoes-These insulated lines are usually sup- It may have a cantilever design or knee bracing for
ported on shoes fabricated from structural shapes supporting heavy loads. Lines may be U-bolted,
(e.g., T·sections or Wide flanges). A standard shoe gUided, or hung by rod hangers from the bracket or
height is 4 in (100 mm). may rest on shoes.
lam layout designer should make every effort to pump. Although the piping configuration is basically
w and understand the pipe support requirements correct, it ignores the constructibility of the overall
le area being worked on so that an optimum lay- layout Adding a spool piece to pump B permits any
from a piping and a pipe support point of view can adjustment that construction may require.
leveloped. The fitting-ro·fitting arrangement at the air cooler
inlet header poses a similar problem. Installation of
structibility Spending additional time and effort large air coolers often makes it impossible for a pre·
og me engineering phase of a project is often justi- fabricated piping configuration to be bolted to the
if it reduces initial construction staff time or de- nozzles, unless a spool piece of reasonable length is
ses the potential for costly rework on piping lay- included in the layout. Heat may be applied to the
. Two examples of constructibility are shown in problem branch lines so they can be recentered on
ibit 1-17. The suction piping of pump A is arranged the nozzles. The fitting-to-fitting configuration does
Ig to fitting and does not allow the construction not permit this flexibility to the constructor. Once
racrer any way to make an adjustment to a mis- again, the constructibility factor should be conSidered.
lrnent between the centerline of the vessel and the
Plant Layout
Specification
ecification, as used in industrial terminology, means equipment in place or to remove the unit equipment
: constraints under which a component should be or portions of eqUipment for off·site repair.
signed and manufactured. Almost everything that is Equipment includes every component associated
rchased, constructed, or designed is governed by with the process plant (e.g., pumps, towers, heat ex-
~cification5. Specific.uions encourage uniformity changers, and compressors).
j improve quality throughout all industries. For the
.ot layout designer, specification is an essential tool
~he trade. Ignorance of or failure to comply with the
Equipment Arrangement
.defines set in the project specification could be General plant arrangement rtlust be consistent With
;t1y and could affect the quality of the design. Specifi- prevailing atmospheric and site conditions as well as·
ions set the requirements for plant equipment ar- with local codes and regulations. EqUipment must be
Igement, operation, maintenance, and satet)' in the grouped within common process areas to suit inde-
lcess plant layout and detail the fequi~ements for pendent operation and shutdown. Equipment within
npliance with national codes and regulations. process and off-Site areas must be arranged to accom-
modate operational and maintenance access and to
meet the safety requirements listed in Exhibit 2-1. Un-
IE COMPONENTS OF SPECIFICATION less required for common operation or safeey, equip-
ment is to be located in process sequence to minimize
s chapter defines what is induded in the specifica- interconnecting piping.
1. The plant layout designer must be aware of all Process units, buildings, and groups of off-site areas
specification components and how to work effec- (e.g., tank farms) are serviced by auxiliary roads for 1
-Iy with the specification. maintenance and fire fighting. EqUipment .Iocation
must facilitate in-place maintenance by mobile equip-
ment. Process equipment must be enclosed in shelters
difications
only when required by extreme climatic conditions or
.revisions, exceptions, or addenda to the specifica- client preferences.
I should be highlighted in the project documenta- In general, piping, power, and instrument cables
l. Except for small skid-mounted units, all dear- are to be carried on overhead pipe racks in process
es and accesses for operation and maintenance on units and utility plants and in grade sleepers in off·site
of
ipment furnished as a regular part a proprietary areas.
<age should be in accordance with the require-
lts of the specification. .'
Equipment Elevations
EqUipment should generally be elevated a minimum
ms height from grade to suit process, operational, and
~rator access is the space required between com- maintenance requirements. Horizontal drums, shell
eots or pairs of components to permit walking, and tube exchangers, and furnaces must be supported
rating valves, viewing instruments, climbing lad- from grade by concrete piers. Vertical vessels (e.g.,
. or stairs. and safely exiting the unit in an emer- lowers and reactors with attached skirts) and baseplate
:yo eqUipment with pumps should be supported at grade
laintenance aocess is the space required to selVice by concrete foundations.
19
20
EXHIBIT 2-1 Equipment Spacing
_.ro Key:
W~.-\\ ~t
selected to protect spedfic items of
equipment
~ , § ~ $611 ~ 1'0:-
D Greater than 500· F
e>l't'-"'.". ~_"'-LL E Less than 500· F
1
f §ir:~~
1M
~ '~~
i J~ ~J \!JJ1 ~~ \,)),1
loPc-1Ul1..;? LJlIJrr
F The diameter of the largest tank
G Double the diameter of the largest
tank
~ M "A ~~ r~ J~ :Z6J ~1 g:~ 0 ~ H Maximum 250'; minimum will vary
4-
;. ~"'M
"'. 1?G> M
"5~lt~j~f!~
t
'li>,{C)
~ I~ l} ~ ~
J Blast resistam
M Minimum to suit operator or
1~Ia?Ia:'1a1M I~~ ~~
., ''''74>''''''' ~
"",..,.~~ jh ~~ 1;1!
g I~~ ~~ ~
maintenance access
~ 'z:1:-k1l I NA Nor applicable
f!,
'} !70 3«;a
?lSo Z"" Z'!C 1:0:;.:
~c;o ;11<> ~ ~olz'.? G! :1" ~ l\ ~I~ r:tt
~ ··~.~~e.~Ft1~~~ ~
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10
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~ .;;~. t" ,,)I ~ ~
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, M ""." ... . , "" ''''' ''''' '''' N' I.
11_
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'Z> ~So Ic:o IIJb Ic:c H H H ? S M i2tl.. :a p~
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I... ,"",.".,,., "" ,.< 3;::
"'" ,,,IV! leo""...~Q NA INA II ~ t
I; "M ......, 1M l.x>
I~ J 4::to 170 ~O<:) It;ro 100 100
30
",0 ~ M ?o ':l..;:>c 1<:>0 ~ '1
I, ";l M M '?o Ill%:' 1170 ICO 2a:> 1Do!'7a:;> M 1&r:' r;c!v NA NA NA ~
l~ ~ ~ ; ':l!'
i~ ~ ~ 'Z. ~
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~ ;
~(p tao 170 1tIO ~ 10C I~ 14::> 14> '7q, 10 tao II;c> 1M NA t-lA I , Il;. Ie;. If? tv! M I ~ Ie' M NA 1),(
'Z1 1M 117" ~ 1P::> l..o 100 1.:.0 ~ *0 M 1Qo 113t::> &? NA NA M 1lX>?o I~ ~ iC70 170 170 170 Ie; 1M n:: 7 ~ ~~
'Zb 1Ba I~ 1ro "Uv ~ ''''''' ~ ~ 'Z~ll:10 1Dc» ~ ~ !\lA NA ~ ~ ~ "Zl7 170·;0 ;'017.;> C}o,z;;. c.b lvl r,5 ,.,.
"l8' NA I;.. w 'Z0 be 1.:>0 !~ ~ .1;:;. M NA INt:. 'Zc:; S::::> ?t:o ltV ex> 'So St;> '70 ~ 1M !"lc;. ?o tv! f-!~
~ 1'5>l? M M ?l::'> t..A tv! ~ 10 ~ ~ Iv1 NA t-JA M M IV! M M 1M M ~/I t--tl I-J1 N1 t.I1 M I..."
Notes:
Exhibit 2·1 highlight!> the recommended safety distances Fixed fire water sprays should be provided over equipment that
between eqUipment associated with· refinery, chemical, and handles flammable materials and operates at temperatures
peuocllemical plants. greater than 500· F (2600 C) and over equipment that handles
1bis exhibit should be read in conjunction with national and light hydrocarbons with a vapor pressure greater than 65 pst
local codes and regulations. Exceptions to this exhibit should be (;~.S kg/em) at 100· F (:S8° C) Or a discharge pressur~ greater
by client specification only. than 500 psi (35 kg/em) that is located directly beneath
air·cooled exchangers.
Dimensions shown are to the face of eqUipment and are
minimum.
Large vacuum or crude towers with swagged bot- overhead pipe racks. Equipment elevations must be in
tom sections and compressors that are to be elevated accordance with Exhibit 2-2.
for operational needs must be supported from con:"
crete structures. Equipment that must be elevated for
Roads, Paving, and Railroads
process requiremenr.s (e.g., shell and tube overhead
condensers) must be supported in structures. When Process plants are to be serviced by roads adjacent to
practical, air coolers should also be supported from process units, utility planr.s, materials-handling and
Key:
[A) A Can be reduced to a minimum of
l'~
~~~
61 m by increasing heighr of flare
B Boilers, power generators, air
tt-~J'~, C
compressors
Monitor iocations should be
1U£{~ ~~~@ selected to protect specific items 0 f
I jt [~t ~~~
!l.1<S2~I~~)~!6- ~.. !>I:" r?I7.... ~
D
E
F
equipment
Greater chan 2600 C
Less than 2600 C
The diameter of the largest tank
tI k ~~~ Wf'
~. _ lY J I~ \V I"( ~~ t;X ~rr,::.?
\})J ~
tJN'T G Double rhe diameter of the largest
t;,- 4"-' 'U> :;.. "'" 1-'\ I"~~ RJ \'l~ ' ~~~ ~ P4 maintenance access
NA Not applicable
i
f:>
A7 ~ ~ ci:o A r;,
'17'S, 10&''7.'':;'1'3> F
I;' ;q
~~"ll ~"'i:\l
j~ ~
ill ~~
t
~ d', ~
~ ~c r;o Gt? ~ 50 ~ .a:::> ~ 1'7
~ ~ <I.s. '!>
WI ~ :7 ~
&~~~~
si $:v P7 , Nil. NA I=? M M 4. r, M M M ~~
1; «0 I:!o "0 00 ko I!? GO 1'7 MNA NA ''''' kl.;. <l.t; <l.t; ?> M pK 11
~ r;;o 4' ~ Go ~ ~ c:x:> ~ C::o ~ ~ II;:. M Nl\ NA :t.?' ~.; tl,;. A.'7 M ~ M ; M NA 1.\., -~ ~ii
1 t-/l 4? (tCJ (0 ~ i?o 1; 1t; fo;lM lAo It;. "l NA Nll. M I? It;.. 1'7 15 I? Ie;, I~ 1~4.? tJA u: ~)J~
:; 117fd.t7 ta:? ~ ?o 3obo Cd:' i1C; ?t:> ~ 1'7 It? Nfl. NA I!? ISo IS h'7 (7 I~ IS 17 IS> '.? ISo M 15 ::;~
~ NA At? V::o C:o &:> ~Ico ~ ~ ;. t&o IC7tvlNi NA h.c, 1710 IS 17 IS IS lr; '3> M 1.r; 1'9 M ~~
~ A? M tv'! Ie; M M C:.o (J:P 0;) ~ 17 ,;- tJ1 NA NA tA M M M M M tv! N'I M M M tv! M
b. Metric Measurement
"""
lding areas, and groups of off~site equipment that extend to auxiliary roads.
~uire access for maintenance and fire fighting. An Off-site area paving must be provided at groups of
equate road network an9 parking facility should be eqUipment (e.g., pump slabs and metering stations)
~vided at administration buildings, the main plant but not at· tank farms, inside diked areas, under pipe
mrol room, firehouses, and warehouses. Access racks, or in areas alongside roads, except when re-
ys or secondary roads must be prOVided within pro- qUired for maintenance. These unpaved areas are not
;5 units and utility plants so that eqUipment can be surfaced. Unpaved areas within the battery limits of
noved for off-unit repair and chemicals and cata· process units and utility plants must be graded and
ts can be loaded and unloaded. Roads must be surfaced with crushed stone or a Similar materiaL Ex~
oped over piping at intersections with grade-level cept for floors in control and switchgear buildings, aU
epers. indoor and outdoor paving must be sloped for drain-
Paving within process units and utility plants should age.
) encompass all eqUipment, unit control room ar- Curbs and walls are to be used in process units and
and the area beneath the main pipe rack. Unless utility plants to contain spills from equipment- using
IUired for maintenance reasons, paving need not acid and other dangerous chemicals. Earthen dikes
For ease of height reference and calculations, all elevations refer to 100 ft
for projectS using English measurements and 100,000 mm for projectS
using metric measurements. These datums correspond to the Site elevation
highlighted in the project design data specification,
Dimensions shown in b COlfSile) are heights above high point of grade.
All concrete support elevations shown (or equipment include an allowance
for grout.
All dimensions shown are minimum.
must be built in off~5ite areas to retain spills from Railroad systems that are designed for in~plant op~
storage tanks. Dikes} curbs, and walls used to contain eratioh and that intersect or form part of the main line
tank spills must be able to accommodate the volume are to conform with standards and practices of the
of the largest tank in the area. When calculating the main~1ine railroad or appropriate authority. Road, pav-
size of enclosure, the designer must consider the dis- ing, and railroad dimensions and clearances should be
placement volume of all other tanks (i.e., to the height in accordance with the minimum dimensions sho"WTl
of the dike) as well as an allowance for freeboard. in Exhibit 2·3.
<0"--' .•
Platfonn Fixed
Ladde...
,
Item or Grade
Maintenance access
Level controls
Yes
Yes
No
No
,I
Motor-operated valves Yes No tf
I
Sample connections Yes No I
Blinds and figure-8s Yes No
Observation doors Yes No
Relief valves Yes No
Control valves Yes No
Battery limit valves Yes No
Valves, 3 In and larger Yes No
Hand holes Yes Yes
Valves, smaller than 3 in Yes Yes
level gauges Yes Yes
Pressure instruments Yes Yes
Temperature instruments Yes Yes
Vessel nozzles No No
Check valves No No
Header block valves No No
~ifice flanges No No
Plot Plans
.
The plot plan is one of the key documents produced limit area. usually designed for independent operation
during the engineering phase in any processing facil· and shutdown. The final plot plan identifies all the
ity. It is used (0 locate equipment and supporting in- components by deSignated numbers and shows, to
frastructure and to establish the sequence of major scale. the basic shapes of the equipment and'support-
engineering and construction activities. Plot plans are ing faCilities, locating them in both the vertical and the
used by almost every engineering group within a proj· horizontal planes. Generally. the arrangement is
ect task force from estimating and scheduling through shown in the plan with elevated views furnished only
construction. The plot plan is developed by the plant for clarity (e.g" in the vertically structured plant). Plot
layout designer, usually at the proposal stage of the plans developed with three-dimensional CAD l)'iodel-
project, and remains the responsibility of the designer iog have the advamage of producing multiple plans,
throughout construction. Similar process units engi- elevations, and isometric views with no additional ef·
neered for two clients may look vastly different for fon. The plot plan is used for the functions discussed
various reasons. including available real estate, soil in the follOWing sections.
md climate conditions, and client philosophy on op-
:ration, maintenance. and safety. For these reasons, Piping design The plot plan is used to produce
;tandardization of process unit plot plans is difficult. eqUipment arrangement studies that faCilitate the in·
'1evenheless, as most operating facilities use common terconnection of above· and below-ground process
~quipment (e.g., shell and tube heat exchangers, pres- and utility piping systems and to. estimate piping mate-
;ure vessels. pumps, and compressors), it is possible rial quantities.
o apply a few basic rules that suit most clients and
)rocesses and that enable the plant layout designer to Civil engineering The plot plan is used to develop
tpproach the task of arranging the eqUipment and grading and drainage plans. holding ponds, diked ar-
upporting facilities in an orderly manner. eas. foundation and structural designs, and all
bulk
material estimates.
I1IE PLOT PLAN IN THE PROCESS UNIT Electrical engineering The plot plan is used to pro-
duce area classification drawings, to locate SWitchgear
hiS chapter highlights the general requirements for and the incoming substation and motor COntrol cen-
,recess unit plot plan arrangement. It identifies the ter, to route cables, and to estimate bulk materials.
uormation reqUired to locate operating eqUipment
nd supporting facilities to suit operator and mainre- Instrument engineering TI'le plot plan is used to lo-
ance access, constructibUiry, process operation, cate analyzer houses and cable trays, assist in the loca-
uety, and cost-effective design. tion of the main control house, and estimate bulk ma-
terials.
27
28
EXHIBIT 3·1
Sample Proposal Plot
Plan
Construction The plot plan is used to schedule the arrangement be recognized and eliminated during the
erection sequence of all plant equipment, which in- plot plan development phase of the projecl because
cludes rigging studies for large lifts, constructibility they can be costly to correct once the plant is in opera-
reviews, marshaling, and lay-down areas throughout tion.
the entire construction phase. Plot plans are generally developed in stages, from
the initial concept to the fully dimensioned document
Estimating The plOl plan is used to estimate the at the construction issue stage.
overall cost of the plant. The proposal plot plan, shown in Exhibit 3·1, is
developed during the estimate phase of the project
Client use The plot plan is used for safety, operator, and is used to estimate bulk materials. It is also in-
and maintenance reviews and to develop an as-built cluded in the proposal as a representation of the unit
record of the plant arrangement. arrangement to the prospective client. The proposal
plot plan is based on limited information and gener-
ally indicates only the principal items of equipment,
PLOT PlAN DEVELOPMENT main supporting facilities, and overall dimensions.
After contract award, the proposal plot plan is up-
Developing a plot plan is not an exact science, because dated to suit the latest information and is reviewed
the arrangement of the plant must be set at the begin- and approved by the client. This document becomes
ning of the projecl before all eqUipment requirements the basis for the plant layout phase of the project and
and configurations are finalized and before all of the is called the planning plot plan. A sample planning
mechanical problems associated with the design are plot plan is shown in Exhibit 3-2. On completion of
solved. Plot plan arrangement is a reflection of the the plant layout phase-when all the equipment has
designer's ability to anticipate mechanical problems been sized and is in the best position to suit the proj-
and provide the necessary access for operation and ect requirements and when all access roads, buildings,
maintenance as well as the designer's general experi- and pipe racks have been located-the plot plan is
ence with plant layout requirements. The intended finally issued for construction. This is illustrated in
goal is to produce a safe, cost-effecrive operational Exhibit 3-3 as the construction plot plan.
plant, which will probably remain in use for at least 25 To develop a plot plan, the designer must assemble
years. Therefore, it is important that any errors in the information discussed in the follOWing sections.
!
Process Plant Layout and PiPing Destgn
29
a:
EXHIBIT ~2 Sample Planning Plot Plan
10 ~ ,,"WIOE
¥oo
•I A"-t='>S WAX
The equipment list This document lists all the items The block flow diagram The block flow diagram
of equipment and buildings by number and descrip- shows all primary interconnecting lines between pro-
tion to be included within the unit battery limits. A cess units, utility plants, and storage facilities. Although
sample equipment list is given in Exhibit 3-4. not absolutely essential, it is a useful document for
eqUipment location:
The process flow diagram The process flow diagram
is one of the most important documents required by Specifications Similar to the plant layout specifica-
!he designer to position equipment. It indicates flow tion discussed in Chapter 2, thiS document highlights
rates, temperatures, and pressures and how the vari- maintenance, operator access, clearances, and eqUip-
ous pieces of equipment are interconnected. The pro- ment spacing.
"
PlotPlatl$
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33
.,.._....
me and cabling usually enter and exit the structure at one .
EXHWIT 3.. 6 Floor Space Sizes level and gain access to each floor by chases or are
supported from the outside members. Operators usu-
Item
Exchangel"S
BWld1e Diameter length
--'-- ally gain access to each level by stairs or by ele~atof.
Equipment maintenance is usually accomplished
lOl·E 36 in (9] 5 mm) 20 It (6.100 mm) through the use of hitch points, tfolley beams, or trav-
lO2·E 30 in (750 mm) 20 ft (6,100 mm) eling cranes. An adequate area must he prOVided
103-E 30 in (750 mm) 20 ft (6,100 mm) around each item along with a clear drop zone at
104-E 24 in (610 mm) 20 ft (6,100 rom) grade for equipment removal. The structure,. is ser·
10S·E (NC) 30 ft (9,150 rom) 40 ft (12,:WO mm) viced by access roads.
106-£ (AlC) 30 ft (9,150 mm) 20 ft (6,100 mm) The advantages of this type of arrangement are the
107·E (8 shells) 36 in (9]5 rom) 24 (t (7,300 mm) small amount of real estate required for the plant and
lO8·E 60 in (1,500 rom) IS ft (4,600 mm) the ability to house the facility to suit proces.~ require-
109·E 30 in (750 mrn) 20 ft (6,100 rom) ments or climate conditions. The disadvantages are in
the operator and maintenance access and in the con-
Pumps
struction of the plant. Exhibit 3~8 shows a typical struc-
Item Length Width
ture-mounted vertical plot plan arrangement.
101-Palb 5 ft (1500 mm) 2 ft 6 in (750 mm)
lO2·P 2 ft 6 in (750 mm) 1 ft 3 in (380 mm)
103·Pa/b 4 ft 6 in (1,370 mm) 2 ft (610 rom) EQUIPMENT LOCATION
l04·Pa/b 4 it (1,220 mm) 1 ft 6 io (450 mm)
105-Pa/b (vertical) 1 ft 6 in (450 mm) 1 it 6 in (450 rom) Various requirements dictate the location of equip-
ment and supponing facilities within the conventional
operating plant) and many factors must be considered
when the designer is locating equipment. They are
The principal advantage of this arrangement is that the
discussed in the following sections.
equipment is generally located at grade, which makes
this type of plant easier to construct and more accessi·
PlantLayoutSpec~cation
ble for maintenance and operation. The disadvantages
are the amount of real estate required and the long This document highlights spacing requ irements for
runs of. cabling, utility, feed) and product piping re~ equipment-and access widths and elevation clearances
qUired to service the unit. Exhibit 3-7 shows a typical for operator and maintenance access. A typical plant
horizontal inline plot plan arrangement. layout specification can be found in Chapter 2. The
sample specification shown in Exhibit 3-9 highlights
The Stroeture..Mounted Vertical the safety spacing req~irements around a process fur·
Arrangement nace.
The structure~mounted vertical arrangement has
Economic Piping
equipment located in a rectangular multilevel steel or
concrete structure. The structure can be several bays The major portion of the piping within most process
long and either open-sided or fully enclosed, to suit units is used to interconnect equipment and support
either client preference or climate conditions. Piping controls between equipment. To minimize the cost of
Plot Plo.ns
34
~ .$?e:.AQ _
-<. gpA.R _
this bulk material, equipment should be located in of related equipment and controls that function as a
process sequence and close enough to suit safety subsystem within the main process unit. The compo-
needs, access requirementS, and piping flexibility. The nents within the subsystem should be arranged to suit
sequential interconnection of the unit is shown on the the most economic piping runs, and the whole assem-
process flow diagram. The first step is to identify the bly should be positioned within the plot area to pro-
alloy or heavy wall piping. The diagram should then vide the most economic interconnection between reo
be subdivided into smaller grouns of process-related lated process subsystems. Exhibit 3·10 shows a
equipment. These groups should contain an assembly process flow diagram divided into subsystems, an ar-
35
EXHIBIT 3·8 Structure-Mounted Vertical Arrangement
-++
l-++-'
-E3-
-B- 1
$ m
EXHIBIT 3·9
~IlLA""O Sample Plant Layout
i~
Plot Plans
36
EXHIBIT 3~10 Planning Piping with a Process Flow Diagram
r;:;----,
t@ I f@----./ r=---i
I I I I I
..-- .... I' I
J
I
I ,
I ---,.--: :
I ,
r ----®l I I I
I J I I I
I I ----..--L ~ .@!.J
I I
r--+--+-~
I
I I
I
L \-"
I \ TYPI<:::..6..L 5U~X~T~"'!.
I
5J
~
I I MO' :
Lr-rtJ
_..J
.:: : J
- - - f....-!- - - - -,
_
I I I I I . I
I I I
I
~
I I
I
I
L_~_~ I@
~5 ~
I '@
~c JI
b. Subsystem Arrangement
c. Interconnection of Subsystems
'angemem of a subsystem, and the interconnection of cost. Exhibit 3-12 shows a typical compressor area ar-
I group of subsystems. rangement.
Plot Plans
38
EXHmIT 3-12
Typical Compressor Area
Arrangement
.i
39
5trugglesto place a large, cumbersome piece of equip- first and plan the remainder of the unit around them.
ment into an area while retaining the aesthetics of the Whether the planned plant is an inUne arrangement
unit Generally, most plants are dominated by conven- or housed in a structure, the plant layout deSigner
tional rectangular and circular equipment of a reason- must make provisions for operator and maintenance
able size. Some processes, however, require much access. The designer must review the items of eqUip·
larger and more awkwardly shaped items (e.g., an ment that are included in the process and plan for
:>rthotlow converter and expander train in a fluid cata· their operation and maintenance requirements. For
lYtic cracking unit, as displayed in Exhibit 3-14, are· example, towers must be located in a position to allow
former furnace in an ammonia unit, or a waste heat for the removal of internals, reactors require space for
recovery system in ~ large cogeneration plant). In catalyst loading and unloading, shell and tube ex-
these situations, the designer should place these items changers require space for bundle removal, and rotat-
Plot Plans
40
ing equipment needs space for drive and casing reo soil conditions, the foundations for the equipment are
moval. either piled or spread footings. Spread footing founda-
All these aspects of the equipment design add to tions require more space than piled applications, and
the tloor space requirementS of the plant. Equipment care should be taken to locate equipment so that
that requires servicing during regular operation or enough space exists between equipment for the foun-
planned shutdown periods should be accessible from dations of larger items. In certain cases, equipment
the auxiliary roads or internal access ways. From the can be supported on a common foundation. Depend·
project specification, the plant layout designer should ing on the project specification, instrument and elec-
determine operator access requirementS and the de· trical cabling can be located above or below grade. If
vices to be used for servicing before proceeding with located below grade, adequate space should be desig·
the plant arrangement. Exhibit 3-15 shows typical ac- nated during the plot plan development stage. Under-
cess requirements in a venicaI arrangement, and Ex· ground piping is another factor that the designer must
hibit 3·16 displays an inUne arrangement. consider when locapng equipment. Most process \lnits
are serviced by an underground oily water sewer,
storm sewer, and fire water system and a chemical
Underground Fadlities drainage system if required. In addition, the unit cool-
There are a variety of underground facilities that could ing system could be positioned below ground. All of
affect the positioning of equipment. Depending on these facilities require plot space, and it is recom-
41
EXHIBIT 3~16
Typical Access
Requirements in an
Inline Arrangement
mended that the plant layout designer investigate what the whole unit, as depiaed in Exhibit 3·18, or by in-
facilities are to be pOSitioned below ground before dividually housing groups of equipment (e.g., cpm-
proceeding with the equipment arrangement. Exhibit pressors or pumps), as illustrated in Exhibit 3-19. For
3-17 shows a typical elevation through a unit below individual housing, consideration must be given to
ground. locating equipment out of process sequence to mini-
mize cost.
The wind can influence the location of such eqUip-
Climate Conditions ment as furnaces, compressors, control houses, cool-
Weather conditions could influence the location of ing towers, and stacks. Furnaces or other fired equip-
equipment. In a severely cold climate, equipment ment should be located so as not to allow flammable
should be housed; this can be done by encasing vapors to constantly drift. Smoke from stacks or vapors
PlotPlam;
42
EXHIBIT 3·17
Typical Underground
Elevations
eLe.:::.rlZ.lt.Ab
c6.ft\.e. Du.::;.T?
EXHIBIT 3·18
Total Uoil Encasement
from cooling towers should not be in the direct path sion), the equipment and access way located beneath
of main operating areas (e.g., compressor houses, con- the pipe rack, or the equipment (if any) supported
trol rooms, and structures). above the pipe rack. The layout that results in the most
economical design should be chosen.
At the estimate stage, when most plot plans are
PIPE RACKS developed, the pipe rack width is specified on the
basis of limited information; process flow diagrams
Generally, most inline plant arrangements are fur- usually are not available 10 accurately work out the
nished with a central pipe rack system that acts as the exact requirements. Using the process flow diagram,
main artery of the unit supporting process intercon- the designer can prepare a line routing diagram on a
nection, feeds, product and utility piping, instrument print of the preliminary plot plan, similar to Ihe in-
and electrical cables, and, sometimes,air coolers and structions given in Chapter 11. This establishes the
drums. Usually, the pipe rack is made of structural main process lines supported in the pipe rack for
steel, either single level or multilevel, to suit the width equipment interconnection, feed, and production. An
and capacity of the unit it is serving. The pipe rack bays allowance of 20% of the main lines should be added
are usually spaced at 20-ft (6,OOO-mm) centers. The to the total for unknowns. The pipe rack width can
width is determined by such factors as the quantity of be adequately sized on the basis of approximate line
piping and cabling to be carried on the main run of sizing, utility piping, and insulation requirements
the pipe rack (with an allowance for future expan· by the process system engineer; cable tray reqUire-
.'
PrrH:ess Plant Layout and Piping Design
43
EXHIBIT 3·19
Individual Equipment
I-louses
flrzE' WATER
_..-1. _~
mems by the electrical and instrument engineers; and The bottom sUPPOr[ elevation of the main pipe rack
a 20% future piping allowance. Most typical units re- is dictated by the maintenance and piping c1eanlnce
quire a two-level pipe rack with a width of 20 ft (6,000 beneath the pipe rack, with additional levels space<! at
mm) to 40 ft (12,000 mm). If the total requirements 6-ft (I.800-mm) intervals. On projects with very large
exceed 80 ft (24,000 mm), an extra level should be diameter piping, increasing this dimension to suit
introduced. clearance requirements should be considered when
After establishing the pipe rack width to suit the pipe direction is changed. External clearances (e.g. I
)iping and cable requirements, the designer must over main roads Or intersections with off-Site pipe
:heck the design for the accommodation of air cooler racks) need close attention. Exhibit 3-20 shows a typi-
;uppon, if specified, and pumps and access ways be- cal pipe rack elevation.
leath the pipe rack. The air cooler is specified by tube Pipe rack configurations are dictated by the equip-
}undle length and is established at the estimate stage ment layout, site conditions, client requirements, and
)f me project. It can overhang the rack width equally plant economy. The ideal situation would be a
m either side. An air cooler with a 40-ft (l2,OOO-mm) straight-through arrangement, with process feeds and
ube bundle length can be adequately supported on a utilities entering one end of the unit and products and
lipe rack that is 35 ft (10,500 mm) wide. Pumps may disposals exiting the other end. The final layout of the
Ie located beneath pipe racks on either side of an pipe rack to meet the specific requirements of the
ccess way that is 10 ft 0,000 mm) wide. project could result in a variety of configurations (e.g.,
Plot Plans
44
EXHIBIT 3·20
Typical Pipe Rack
al.I~"~QII Elevation
I~i .~'2.f:;p>
q---ti~~~~-
let" 2.p LO "
IQ~·t''51
aT, L, or U shape), as shown in Exhibit 3-21. Changes cess ways for mobile equipment acce~s. Most clients
of direction in pipe racks must be accommodated by require that the equipment areas, the area beneath
changes in elevation and are usually equally spaced the pipe rack, and the areas around buildings be
about the midpoint of the main pipe rack elevations to paved with concrete for housekeeping. Exhibit 3-23
suit required clearances. illustrates a typical process unit road and paving ar-
Pipe racks within vertically structured or housed rangement.
facilities cannot be· defined as easily as for inline ar-
rangements, because the equipment is usually located
on several levels. The vertical units are usually fed by BUILDINGS
conventional pipe racks at established elevations en-
tering the structure at a designated area. Once inside Apart from buildings that house equipment (e.g., com-
the structure, piping should be routed in an orderly pressor houses), it is often necessary to position con-
manner according to economic, constructibility, and trol houses, substations, analyzer houses, and operator
suppOrt requirements. Exhibit 3·22 displays a typical shelters within the process unit battery limits. Admin-
process structure. istration buildings and warehouses are generally lo-
cated away from process unit areas. Control houses
and substations are usually located at the edge of the
ROADS, ACCESS WAYS, AND unit adjacent to a plant road, 50 ft (15,000 rnm) from
PAVING the operating eqUipment. As seen in Exhibit 3-24, ana-
lyzer houses and operator shelters should be located
For maintenance and safety, the principal access to next to the equipment that they service.
and from most process units is by auxiliary roads. Ide-
ally, the unit banery limits should be positioned SO
ft (15,000 rom) from the centerline of the main plant EQUIPMENT SPACING
roads. This allows adequate space for ditch drainage
and firefightfng faCilities and avoids obstructing roads The previous sections have outlined the information
when such items as heat exchanger tube bundles are required to locate equipment and the general coment
removed. Access ways or spur roads should be pro- of the typical process unit. At this stage, the plant lay-
vided within the unit for access to items that require out designer should prepare a sketch of the unit con-
servicing or for components that require removal figuration and a line run to confirm that the equip-
for off-site repair, Clearance according to project ment is positioned for the most favorable piping
specification should be prOVided over roads and ac- interconnection. The line run can be prepared by dia-
!
Process Plant Layout and nping Destgn
EXHIBIT 3--21 Pipe Rack Configurations EXHIBIT 3·22 Typical Pipe Rack in a Vertical
Arrangement
-----.1
I
L- 'S~APf;D
-~
space equipment and supporting facilities for operator
and maintenance access, safery, piping fleXibility and
support, and platforming requirements. At this stage,
the layout designer must rely on experience because
the final information is not available for calculating
Plot Plans
46
exact distances between equipmem or solving unfore- should review the sketched arrangement of the unit to
seen mechanical problems. The spacing of the compo- confirm the exact requirements needed for safe and
nents within the unit is an jinportam exercise-it fi· orderly operation of the plant. Consultation with pro-
nalizes real estate requirements for the facility and cess engineers is recommended to obtain general line
assists in the pricing of the plant. It is also used as the sizing requirements for control spacing allowances. At
basis for the plant layout design, this stage, the designer should be completely familiar
Before spacing the equipment, the layout designer with the project specification requirements for safety
EXHWIT 3-24
Building Locations
.'
PIotP/ans
EXHIBIT 3·25
Typical Tower Area
Spacing
~I·O" 1.C;ePO
'0'_0" ~.Q~
1/'2. 'c>1A.ME.Telit E:xGMAI'Jc:. E.2. FLAW c!:aE~ +1 e>"J.4?o
8 1-0"/ '2.400 TO loLd 3.000
l
.
¥'1. 02UM D,AMETe.~'!lt+ 4'.011 / I.~oo
1/2. DlZwM PIAMETefiC. + Ih. ~AN",eft DIAMe.T£~
+ a.1_O~/~'IS (:)p~A"'R:>~ .Aae~~ + ~'-O~91"
fCt2 p, F'lto.16 A .....P e.t!:J"""Tl'i:Ol.. ~
G::: MIN,Mi-JM Fo£ FL.e..)(I~Ir..ITj'
A<.e:-f<::~
'STA.(:.I'&t:;.> E.l<G+\A..N6 fC'::>
11.~cl/~.liltoc
M4.X-IMuM
P~J:E.lC.R&.O
and should be located as close to the condenser as compressor and suction drum. Adequate space should
possible to suit flexibility in the piping and vertical be prOVided around the compressor and turbine for
removal space. The lube oil console should be located the installation of a platform and staircase. If the facil-
as close to the compressor as possible with operator ity is housed, a drop area must be provided. Exhibit
access on all sides of the skid, with space to remove 3-26 illustrates a typical compressor area arrangement.
the cooler tube bundle, filters, and pumps. Interstage Air coolers, shown in Exhibit 3-27, are generally
coolers, if needed, should be located adjacent to the . supported from the central pipe rack adjacent to their
EXHmlT 3·26
Typical Compressor Area
Spacing
C::;"4.'~PE:j;;'
~Mc>"'A.1.
AJZ.e:.A
1-----./
A~ MINIMuM
8:: 6I.oll/~Aoo
c:: : C"l' U"-lpE.f? I2e..Mo\}A.L+ lattJ~QO
D.: ",'_Oil I.BC)O MJt-JItv'!UVl
~ '2 x C + !e,~ /.470
lated equipment and are serviced by platforms at the located directly beneath air coolers. Space should be
:ader boxes and beneath the air coolers for motor available on the plot plan for maintenance access by
aintenance. Care should be taken to position air mobile cranes for removal of air cooler tube bundles.
'DIers to allow tlexibHiry for interconnecting piping. Furnaces should be located at a safe distance and
poorly positioned overhead condenser could result upwind from unrelated equipment containing hydro-
additional large overall diameter piping and expen· carbons. Steam drums or deaerators can be located as
'e supports, Unless furnished with fixed fire water reqUired for operation and maintenance. Reactors can
rays, pumps comaining hydrocarbons and operat- be located closer to furnaces than other equipment
~ higher than autoignition conditions should not be containing hydrocarbons, as long as adequate space is
Plat Plans
50
EXHmrr 3~27
Typical Air Cooler
~tJMP~ Af2oVe. Spacing
AuTo 16""..,.'0....
Po..AM~ e~w
A.....T C I(;:aNITIO....
OR WIT'" FI)t lii-e>
FIFaE. Wb..,... " "!IP2A."(~
0'"
I
EXHmlT 3~28
Typical Furnace Area
Spacing
A'S lZ~~lJlrze;.D
-r-i"'t--
IZELATEO EGlIJIPMI<N"
.i
Process Plant LaJlt'ut and Plptng Design
51
;
EXlJIBIT 3-29 Subsystems Within the Process Flow Diagram
rovided for catalyst loading and unloading. Exhibit sketch of the unit (Exhibit 3-30), the line run check
28 shows a typical furnace area. (Exhibit 3-31), and the final plot plan arrangement
(Exhibit 3-32).
This chapter has highlighted some of the principal
t\MPLE PLOT PLAN ARRANGEMENT features involved in the arrangement of process
equipment with regard to operation, maintenance,
1e following illustrated examples show the various constructibility, safety, and economics. Subsequen't
eps in arranging a naphtha hydrotreater unit and chapters deal with the needs of each equipment item
entify the process subsystems within the process in more detail, thereby offering greater insight to
)W diagram (Exhibit 3-29), the initial arrangement proper equipment location on a plot plan.
Plot Plans
52
~--- --
N+-
+,
lfJi
lol-F
<4l;lMMotJ ~,=f'!M'S9~
~~e. ~'e-T fZf!Qul~6M~T
- -.,
,•
lol-~
- --------- - - ---
GcC'A".Trr
-~2
a.e."A.,.£
i"K~4ect.S
PkJtPlans
54
p\'(eIJAll.n..l&
~
I
IL.
I I
""0
.Q -'
~
t-JA.PHTMA HrpliZ<:>"'2'E:ATE:~
PI.o..IoJt-.lI....,6 P£.CT PL.;A""
/
ProceS$ Plant LayOut and Piping Design
CHAPTER
Compressors
Compressor machines are used to increase the pres- ing compressors are available in many sizes and physi-
sure of a gas by mechanically reducing its volume cal configurations. These machines, which can be used
within itS case. Air is most frequently compressed, but with a variety of auxiliary equipment, are usually
natural gas, oxygen, and nitrogen are also com- driven by steam or gas [urbines or by electric motors.
pressed. Positive-displacement, centrifugal. and axial Exhibit 4-] shows a surface condenser mounted
compressors are the three most common types used directly below the turbine. This arrangement is used
in process facilities and pipeline stations, They can when the condenser is designed to service only one
handle large volumes of gas in relatively small equip- s[eam turbine. The arrangement shown in Exhibit 4-2
ment and may have a variety of drives (e.g., electric is generally used when several turbines are exhausting
motors and sleam or gas turbines). into one condenser. Exhibit 4-3 shows thi various
This chapter focuses on the two mOSt common compressor systems and their reciprocals.
types of compressors-centrifugal and positive dis-
placement, also known as reciprocating. Centrifugal
machines can be single stage or multistage. High- AUXILIARY EQUIPMENT
speed impellers increase the kinetic energy of the gas,
converting this energy into higher pressures in a di- Centrifugal and reciprocating compressors and their
vergent outlet passage called a diffuser. Large volumes drives require a varieey of auxiliary equipment to sup-
of gas are compressed to moderate pressures in cen- port their operation. The equipment for these com·
trifugal machines. Positive-displacement, or recipro- pressors is described in the follOWing sections,
cating, compressors can also be Single stage or multi-
stage. They are usually of the reciprocating piston-type Lube oll consoles Compressor bearings receive ,lu-
and are the only compressors that can compress gas to bricating oil from the lube oil console (Exhibit 4-4),
extremely high pressures. Centrifugal and reciprocat- These consoles may either stand alone or be mounted
n
EXHmIT4~1
Elevated Centrifugal
Compressor with a Single
Condensing Steam
Turbine Drive
-==1
55
56
EXHIBIT 4-2
Elevated Centrifugal
Compressor with
Multiple Condensing
Steam Turbine Drives
~
•.....
.to";;
EXHIBIT 4·3
Types of Compressor
Systems
b. Grade~MountedCentrifugal Compressor
with Gas Turbine Drive
directly onto the compressor frame. Condensate pump The condensate pump (Exhibit
4-7), which is usually venica1, removes the condensate
Seal oil consoles The hydraulic seals, located at the from the hot well in the surface condenser. Conden-
outer ends of the compressor shaft, receive oil from sate forms during liquefaction in the condenser and is
the seal oil console (Exhibit 4-5), The seal oil equip- collected in the hoc well.
ment may be configured as a console or may be de-
signed as individual pieces of eqUipment. Air blowers Usually motor driven, these centrifugal
fan machines (Exhibit 4·8) deliver fresh air to cool the
Surface condensers Surface condensers (Exhibit internally housed electric motors. Although this air is
4·6) reduce gas or vapor to a liquid by removing heat. delivered to the motor through ducts, its exhaust may
Once sufficient heat is eliminated, liquefaction occurs. be sent directly into the compressor house or to the
Compressors
58 a a
EXHmlT 4-4
Lube Oil Console
~
e~rei-wmr~
z
EXHIBIT 4-5
Seal Oil Console
EXHlB1T4.6
Surface Condenser
.'
59
Zt
EXHIBIT 4·7
Vertical Condensate
Pump
~ ~~~~~~
!
v
tside in similar ducts. Not all electric motors within If other air inlet duct schemes (e.g., B, C, 0, or E) in
uses require this cooling facility. Exhibit 4·10 are considered, a brief study should be
conducted to obtain an agreement by all principals,
et air filters Gas turbines require large amounts induding the equipment engineer, the engineering
clean filtered air for operation. The filters (Exhibit manager, the vendor, and the client. The exhaust gas
) can be extremely large. When positioning a gas duct ha'i a theoretical 180° discharge orientation range
bine-drlven compressor, the plant layout designer but is usually set at the left, tOp, or right side, shown as
,uld be aware of the possible variations in orienta· F, G, and H in Exhibit 4·10.
1 of the inlet and outlet dueting, as shown in Exhibit
D.
rhe optimum inlet ducting arrangement shown in
Waste heat system Waste heat systems (Exhibit 4·11)
take hOI exhaust gas from gas turbines and put high
I
I
libit 4·10 is in a parallel plane with the gas turbine, outlet temperatures, ranging from 8000 to 1,200° F I
.ch is at point A in the exhibit. Sometimes, how-
0 0
(426 to 650 C), to use in various ways. Through con- I
l', the available space adjacent to the gas turbine vection, it may be used to generate steam or to heat I
air filter does not permit this optimum arrange· oil, which may be used as a heating medium.
1t, and alternative layouts must be considered. Ad-
)nal turns and length [Q the inlet ducring can de· Compressor suction drum/knockout pot Because
le the machine's efficiency and overall economics. compressors require dry gas that is free of foreign
Compressors
,.
EXHIBIT 4.,
Inlet Air Filter
EXHIBIT 4·10
Variations in Inlet and
Outlet Dueting
EXHIBIT 4·11
'! j Waste Heat System
j
- 61
Compressors
62
a
EXHIBIT 4·13
Pulsation Dampeners/
Volume Bottles
EXHmIT4.t4
Single-Stage or Multistage
Horizontal Split-Case
Compressor
~Prz~t¥TtJrz~'lJe- €p - 1
I
EXHIBIT 4·21
LUbe Oil Console Piping
r and Instrumentation
Diagram '
I
I [ tpMegE7fOI? ~~ 1UlZ~tJE-
V m €6
I 1
I I f.@
I
~-
(tYPo)
I
I I
I - -- I
I i&:~~ j
I ~~~~-..,
-=~ , I
I ~~:'=:..l:::I::!!ioo I I
L-1 ~..r:.:t-7\ I
I
J
I
Compressors
66
.....' EXHmIT4·22
Lube Oil Ocain Routing
~
AUXILIARY EQUIPMENT
~ Surface condensers are used in conjunction with con-
densing steam turbines that drive large centrifugal
compressors. As depieted in Exhibit 4-25 the exhaust
steam enters the top of the condenser and passes
as with the lube oil console. On some compressor through the shell, which is filled with tubes. Cold wa-
systems, a gland condenser is required; it should be ter is pumped through the tubes while hot exhaust
located close to the compressor. Systems engineering steam passes around the outside. Hot water, called
supplies information regarding the elevation and condensate, results and collects in the hot well at the
other requirements of a seal oil loop. Seal oil facilities bottom of the condenser.
are not required for reciprocating compressors. Ex- Exhibit 4·26 shows a piping arrangement typicaI1y
a
67
EXHIBIT 4-24
Scal Oil Console Piping
and Instrumentation
Diagram
5:
- --
r
.......
r
§~
r-"r- &otv1~
r-'-
1--;,-,
I
I
-
- __ J
-- --,- -- ---~----....,
Basic Condenser
OperatiOn
~~~
(4.,t;..L TUeg;. NDr*~)
~a-.J P~~1J:
(J-@~&1)
Compressors
• EXRIBIT 4·26
Surface Condenser and
Auxiliary Equipment
found around surface condensers. The condensate the atmosphere through a safely valve. Condensate is
that collects in the hot well is pumped out and used in piped downstream of the valve and creates a water
the generation of steam elsewhere in the plant. A level seal on the valve to maintain the vacuum pressure in
controller, which is mounted on the side of the hot the system. Ejectors pull additional wet vapor from the .
well, activates the control valve downstream of the condenser. As steam is fed into the end of the ejectOr,
pumps when the condensate reaches a specific level in the low-pressure wet vapor is sent to the inter-after
the hot well. A wet vapor vent is run from the pump condenser, where additional liquefaction takes place
casing back to the condenser shell to be liquefied. A through convection with cold water. When the steam
line connected to the exhaust system inlet is vented to .. trap is filled with condensate, it opens and the higher
69
pressure on the inter-after condenser sends the con- nance and economic factors must also be considered
densate back to the hot well in the surface condenser. when in a compressor area plan. When dealing with a
horizontal split·case centrifugal compressor, the plant
designer nlust determine whether the compressor
Equipment Location and Elevation should be elevated or grade mounted. Although a
Exhibit 4-27 illustrates how primary process consider- grade-mounted machine sits on a relatively low con-
ations govern the elevation of the surface condenser crete pad, with its lube oil console close by, this ar~
and some of its auxiliary equipment Because a pump rangemem also has irs price. Suction and discharge
is needed to remove the condensate from the hot well, piping enters and exits the compressor case frqrn the
the pump net positive suction head (NPSH) must be top, which means that piping must be removed to
satisfied to operate satisfactorily. Venical pumps are perform general maintenance on horizontal split-case
generally used in this application because the NPSH machines. When a condensing turbine is used as the
requirement is calculated from the bottom of the driver for such a machine, the exhaust piping, which is
lower impeller for vertical pumps, compared with the also run overhead, must be removed. The support
centerline of the inlet nozzle for horizontal pumps. steel required for top-connected compressors is gen-
Setting the elevation of the inter-after condenser, usu- erally more extensive, and it must be placed so that
ally located to the side of the surface condenser, can maintenance of the machine is not hindered.
be done with fewer restrictions. The bottom of the For an elevated compressor with condensing tur-
inter·after condenser shell must not be more than 3 ft bine drive, the compressor suction and discharge
(900 mm) below the condensate return nozzle on (he (with single stage or multistage) and the exhaust out·
side of the hot well. The plant layout designer is then let on the turbine remain in place during generpl
free to set the elevation as high as necessary. maintenance. Although an elevated structure requires
a greater initial capital expenditure, [he on·stream
time over the life of the plant will be greater because
COMPRESSOR MAINTENANCE ofshorter maintenance turnaround and shoner down·
time.
Compressor installations and most other equipment
may be located either in open areas of the plant or in
Maintenance Impact on Shelter or
structures that have a roof only or a curtain wall or are
Structure Size
completely enclosed. For the plant layout designer,
client preference and climate conditions are the two Exhibit 4·28 illustrates how compressor maintenance
primary considerations that determine the inclusion affects the size of the shelter or structure. Although
of compressor shelters. The fact that machines may be operational access often determines floor space're-
either elevated or grade mounted creates a variety of quirements, the height of a compressor house is
maintenance problems for the plant layout designer. strictly a function of maintenance. ConsequentlYt the
size of the maintenance area must permit the largest
single item £0 pass unobstructed from one end of the
Compressor Maintenance Versus building to the other and should be set as close to the
Economics operating level as possible. The centerline elevation of
Although operation and safety are important and must the hook that allows all items to pass through the
be incorporated in the design of any facility t mainte- maintenance area must be set. The hook elevation,
Compressors
70
EXHIBIT 4·27
Surface Condenser
Elevation
'11
EXHIBIT 4·28
Elevated Compressor
p'H----t
A curtain wall is usually a four-sided structure with all four sides open 8 ft (2.6 m)
above the operating floor.
Totally enclosed structures usually have siding on all four sides from grade level up. This
generally is done in severe climates.
All maintenance is handled by a traveling crane. A clear area is reserved during the
layout stage to allow the largest piece 10 be removed without dismantling any piping
system, if at all possible.
EXHWIT4·29
Grade-Mounted
Centrifugal Compressor:
No Shelter
us the maximum lifted load, determines the depth of tractor should be informed of the type of mobile
e trolley beam, The elevation of the building's eave equipment the client will use, as well as its lifting
then set by allowing sufficient space for the traveling capacity, to develop the optimum compressor layout.
ane to traverse the length of the building as well as For top-connected horizontal split-case compressors,
r its routine maintenance. break flanges must be provided in the piping to allow
the removal of the top half of the compressor case.
The installation in Exhibit 4·30 is an open-sided
[aintenance Considerations fof'
structure with a roof. Component removal may be ac-
'0 Shelter
complished by mobile equipment or a traveling crane.
hen developing a compressor layout that does not Adequate room must be planned for removing the
~quire a structure or shelter, the designer must allow largest component both in the level I (grade-
Jequate room for mobile handling equipment to lift mounted) and level II (elevated) installations.
1 item, raise it to dear all obstructions (including fire The compressor arrangement in Exhibit 4-31 is a
{drams, monitors, and light poles), and back away or curtain wall struCture with four sides, open from the
\fing it to where it can be placed on another vehicle. operating level to a height of 8 ft (2,400 mm). This
mibit 4-29 illustrates a grade-mounted centrifugal arrangement is often found in temperate climates.
)mpressor with no shelter. Maintenance is accomplished With a traveling crane.
This installation is usually the easiest to maintain The _drop zone for the equipment may be within or
ecause all the components may be removed with outside the shelter; if the drop zone is outside the
lobile equipment. If possible, the engineering con- shelter, removable panels must be furnished and ideo-
Compressor:;
72
BlIlD
EXHIBIT 4-30
Grade-Mounted or
Elevated Centrifugal
Compressor:
Open-Sided Structure
CD
(i)
'\-1 r-"""') I
J 1__ I I _!I _ .r-
CDcs;;~ ~~
@~Areo
tified on the layout drawings. The arrangement illustrated in Exhibit 4-28 is fur an
The arrangement in Exhibit 4·32 is an open ele- elevated multicompressor strueturcj it can be
vated installation. Component removal may be accom- equipped with a curtain wall or totally enclosed. A
plished with mobile equipment or a traveling gantry, dear area must be planned early in the layout stage to
which rides on two rails .along either side of the ma- permit any machine to be maintained without disturb-
chine. A struct~re must be provided to carry the rails ing the piping or components of the other c:ompres-
out to the equipment drop zone. sors. The maintenance sequence for a multicompres-
73
., EXHIBIT 4·31
Grade·Mounted
Compressor:
Curtain Wall Shelter
:::::;;et::=;j\J
L f f l - - - - - - f f - - - - - - - l U - - 1Tt
I
~~j~l~l
I (r"'l-t/;,.:..)
, arrangement is shown in Exhibit 4-33 and is • The item is lowered to grade, where maintenance
:ailed as follows: may be performed, or set on a flatbed truck for
removal.
'he component is lifted by the traveling crane and is
• The clear area allows the mobile equipment to tra·
lassed through the dear maintenance area. vel to and fcom the drop zone.
t is brought to the drop zone above the operating
lcor level. If the diem prefers to maintain the component on the
74
EXHIBIT 4·32
Elevated Centrifugal
Compressor: No Shelter
6
...
..(',
:.:
...
.' .
~': WOP Le:
TlZAveLlt-J§ §A"-lTI2¥
!
COMPRESSOR ARRANGEMENT
AND LOCATION
No Shelter
Because many acceptable variations of a centrifugal
compressor area are possible, the version presented
in Exhibit 4·36 must be explained. Briefly, the area
l. Piece to be maintained is lifted and passed through this area. ' includes three centrifugal machines with separate
n. It is then brought to the drop zone area. lube oil consoles (driven by condensing steam tur-
III. The piece is lowered to grade or onlO a vehicle for removal bines), twO imer-coolers. three suction drums, a sur-
from the compressor structure., face condenser. and two vertical condensate pumps.
IV. The clear area allows the vehicle to pass free of any Because there are three condensing steam turbtnes
obstruction (c.g., equipment, piping. lite monitors. and light
poles).
operating at low steam pressure, minimizing the
Some maintenance may be done on the operating Roor, but the
length of the exhaust Iloe to the surface condenser
floor must be designed accordingly. should be one of the firSt goals a layout designer con-
siders. The surface condenser is located just to the
south of the compressor operating platform. The lube
oil console for compressor 1 is located to the west of
the surface condenser] which permits the return line
to drain to the oil reservoir without obstruction. Con-
sequently, the area directly east of the surface con·
Compressors
76
EXHIBIT 4·34
R.eciprocating
Compressor: Open
Installation/Enclosed
Structure
EXHIBIT 4·35
Planning for Cylinder
Removal
!".-
k':_
1""."'
~: ....... 11_....
au
EXHIDIT4-36
Centrifugal Compressor
Area: No Shelter
denser can be used to pull the tube bundle. south for tube removal. The lube oil console for com-
The vertical condensate pumps are located just to press 2 is located just to the east of tbe compressor at
the south of the condenser and should straddle the grade level below the operating platform. If there is
centerline of the hot well outlet nozzle. The distance insufficient room to maintain the console, removable
between the condenser and the pumps is dictated by grating must be provided at the operating platform
pump operation and maintenance requirements as level, which prohibits any other use for this area.
well as piping flexibility. Compressor 3 has an inter-cooler mounted directly
The suction drums for compressors 1 and 2 are below the machine, which is supplied by the vendor.
located along the equipment line just to the west of Again, ample access must be proVided for tube re-
the operating platform. Often, the outlet line of the moval. The lube oil console for compressor 3 is lo-
suction drum to the compressor suction nozzle re- cated just outside and clear of the operating platform
quires a flow meter with straight run lengths upstream to the east. Again, a free-draining oil return line to the
and downstream. This arrangement permits the natu- console must be provided. The suction drum for com-
ral configuration of the line to Satisfy the meter flow pressor 3 is on the equipment line to the east of the
requirements. operating platform.
The intercooler for compressor 1 is located at Access to the operating platform is by two stairways
grade below the platform, with clear access to the at opposite ends of the area, allowing emergency exit.
Compressors
78
EXHIBIT 4-37
..
Reciprocating
CompceS50r Area: Totally
Enclosed Structure
Each machine has a control panel that is placed along whether it runs directly below the operating platform
the north edge of the operating platform. Because or below grade.
there is no shelter over this particular area, all major Compressor 1 has three cylinders with a separate
maintenance is handled by mobile equipment. lube oil console that is located directly to the north,
below the operating platform. A removable section of
the platform should be provided for maintenance
Enclosed Stmctui"e
above the unit. This area must be kept clear of any
The arrangement shown in Exhibit 4-37 consists of obstf\1ction.
three electric motor-driven-reciprocating compres- Compressors 2 and 3 are identical {our-cylinder
sors as well as air blowers, suction drums, inter-cool- machines that have integral lube oil consoles moumed
ers, control panels, and one lube oil console. Because directly ontO the compressor frame. Each compressor
the compressors are two different sizes, the electric has a control panel located along the north wall
motors have been lined up to permit the power-supply An area along the nonh compressor wall is re-
conduit to run straight east and west, regardless of served for the valve stems, which are located below
:: floor and extend to a distance of approximately 3 ft sor inlet piping are the major factors that set the final
,000 mm) above the platform floor. A sleeper runs elevation of the machines. Exhibits 4-38 and 4-39 illus-
st and west outside the north wall for all compressor trate the follOWing:
Jing, which vibrates a great deal because of recipro-
ting compressor operation and therefore must be • Arrangement A shows bottom-mounted nozzles.
n as close to grade as possible. If the operating .. Arrangement B shows top-mounted nozzles.
[yes are located outside the building, a catwalk • Arrangement C shows a surface condenser mounted
auld be proYided to allow access during operation. directly below the turbine, which is common when
Ie suction drums and imer-coolers are located only one turbine is being serviced.
ross from the sleeper area. • Arrangement D shows a top nozzle that allows the
In a totally enclosed building, all compressor main- exhaust steam line to run to a surface condenser
lance is handled by traveling crane. The operating servicing multiple turbines, as shown in Exhibit 4-2.
or stops one bay before the east wall, which allows
: a drop zone for maintenance. Mobile equipment By selecting compressor arrangement A or Band
Jst be brought into this area from the south or east. placing its match line against the turbine match-line
III-up doors are generally provided for this purpose. arrangement C or D, a designer can review the gov-
Each of the three electric motors requires air from erning criteria for setting machine elevations (see Ex-
~ outside to cool the motors. Electric motors within hibit 4-40). In addition, consideration must be given to
ildings do not always require this type of cooling. miscellaneous equipment (e.g., as shown in arrange-
Access to the operating area of this structure is ac- ment A of Exhibit 4-38).
mplished by stairway and doors along the north
~l both at the west end and dose to the east end and
the south waH at the west end. An additional stair- Reciprocating Compressors
tyat the east end permits operators or'maintenance Reciprocating machines are located as close to grade
rsonnel to enter the drop zone or to access the area as possible because of the extreme vibration in the
der the operating floor. piping system. This minimum elevation is established
by the follOWing steps that describe Exhibit 4-41:
EXHIBIT 4·38
Setting Elevations of
Centrifugal Compressors
,·r
".
"..,..
,. ~.
r-
0--
I
l..-_ _--1't>;? '
",.;"
I
I
82
tu t!
7. Dimension from the centerline of the dampener to should be located as dose to the compressor as prac-
the face of the nozzle-Set by vendor. tical. In some reciprocating compressor arrangements,
8. Bottom of the compressor baseplate to the cen- the coolers may be mounted on and directly over the
terline of the compressor shaft-Set by the vendor. compressor by the vendor, but they are u~uaHy lo-
cated by the engineering contractor dose to the rna·
chine or stage suction drum. Exhibit 4-42 shows a
INTER- AND AFfER..COOLERS centrifugal compressor with its inter-cooler and inter-
connecting piping between stages as supplied by the
Inter-coolers Coolers are primarily used to reduce vendor. Exhibit 4-43 shows a reciprocation compres·
the operating temperature within a compressor cir- SOl' with all components, including the inter-cooler.
cuit, which allows the use of a smaller machine with supplied separately by the contractor. Further refer-
fewer cylinders. These coolers may vary in size and ence [0 this can be seen in Exhibit 4·36, where the
type (e.g., shell and tube, air coolers, and U-tube) and intercooler to compressor 1 is mounted separately at
83
(110"'-- •
... - -
a centrifugal gas compressor. The elements to be sized Building elevation The elevation of the building is
are discussed in the following sections. further established by determining the size of the dear
maintenance area (shown as X by Y). This area must
Floor elevation TIle operating floor elevation is es- accommodate the largest single piece to be maintained
tablished by making all standard allowances around at a minimum elevation above all operating floor re-
and above equipment and providing the usual head- quirements, shown as clearance A The alternative
room below all horizontal piping runs and conduits, maintenance area may be used if this area. is dear
as shown by blocks E and F and Exhibit 4-45. throughout the length of the building.
Building width The width of the building is estab- Hook centerline elevation The layout designer de-
lished by first allowing space for the largest compres- termines the centerline elevation of the hook. The
sor train. There must be adequate room between the maximum lifted load must be supplied to the struc-
steam turbine, lube oil drain piping, and any miscella- tural engineer or building contractor to furnish the
neous piping that may· be arranged along the adjacent correct traveling crane. The eave elevation is then set
wall, as shown by block C in Exhibit 4-45. At the com- on the basis of the clearance of the crane selected.
.'
Process Plant lAyout and PiPing Design
85
EXHIBIT 445
Compressor Shelter:
Sizing Criteria
GENERAl COMPRESSOR lAYOUT by the various layouts. Another factor that could influ-
ence straight run requirements is the need to inject
fhis section highlightS additional features to consider wash water into the gas stream to dean compressor
in the design of a centrifugal or reciprocating com- blades, as shown in Exhibi[ 4-47.
~ressor layout. There are many ways to develop a
:ompressor layout, but certain aspects of these ma-
:hines dictate how best to approach a design that opti-
Suction Line Strainers
nizes operation, maintenance. and safety while adher- Compressor suction Jines must be free of any foreigl1
ng to economic requirements. panicles [hat could damage the internals of the ma~
chine. Strainers are installed in the inlet line between
the block valve and the compressor inlet nozzle. After
:entrifugal Compressors:'InJet Piping
the unit has been on stream for some time. the strain-
X/ith higher compressor velocities and rotating ers:ire normally removed. Should the strainer be the
peeds, the plant layout designer must give greater permanent type, a clean-out connection must be
:onsideration to the compressor inlet line. The ASME added to remove any trapped foreign matter during a
lower test code requires a minimum of three diame- shutdown of the compressor. Exhibit 4-48 illustrates
ers of straight run piping between the elbow and the two such applications.
nlet nozzle. Often, however, such factors as gas veloc-
ties, molecular weight, and temperature must be con-
Break-Out Flanges
idered for the optimum layout. An equipment engi o
leer should be consulted at the outset to develop a All lines to a compressor that must be removed for
lase·case layout requirement. The preferred design is maintenance of the compressor or strainer removal
,ne in which the horizontal run is parallel to the com- must have a set of flanges in the line in addition to the
,ressor shaft, as sho'WIl in arrangement A of Exhibit set at the compressor nozzle. Exhibit 4·49 shows one
-46. (In these examples. it is assumed that the com- line with a built-in extra set of flanges at the shut-off
ressor inlet size is 12 in and that the required L· valve and another line for which flanges must be
imension for this particular gas compressor is four add~d because there are no other flanges near the
iameters.) The compressor elevation can be affected compressor case.
ComjJreS$on
86
EXllmIT 4-46
Compressor Suction
Configurations
I ~
lot
~~~ A~MF¥f~ ~~
87
&
EXH1B114-47
Wash·Water Injection
::
iscellaneous Piping Connections accessible through extension stems or chain opera- ,..
tors, Exhibit 4-50 shows some of these variations.
Ie plant layout designer must review both the engi-
~ering contractor and the vendor piping and instru-
entation diagrams to ensure that all connections High-Pressure Steam Inlet Piping
ve been piped up by one or the other.
To streamline the high-pressure. high·temperature
imary operating valve accessibility AU operat- steam inlet piping to the turbine, the plant layout de-
~ valves must be accessible to the operator from signer should review the compressor outline drawing
ade or the operating platform around the machine. to locate the neutral axis. At this point, the turbine is
Ives that are physically out of reach may be made anchored to the steel frame. As depicted in Exhibit
Compressors
88
EXHIBIT 4-48
Inlet Line Strainers
I
I
t t
L
EXHWIT 4-49 Maintenance Break·Out Flanges EXHIBIT 4·51 High-Pressure Steam Inlet Piping
Straightening Vanes
, I
G,!·lpll'" I ' When the straight run on the inlet piping is less than
QWO~ d desired, a straightening vane may be installed to
.smooth the flows and improve the compressor perfor-
mance. These vanes must be in accordance with ASME
or American Gas Association standards. If use of vanes
can be tolerated, the length for any arrangement (a.c;
illustrated in Exhibit 4-46) can be divided by four,
EXHWIT4·53
Compressor Supports
lendor or an independent testing laboratory. Simu- located on the top of the piping to minimize any po·
,ated by electrical circuits, this analog study identifies tential liquid carry·over. Exhibit 4-52 shows typical
)otentially damaging accoustic or pulsation problems branch connections.
juring the design phase of the project, eliminating
1igher repair and redesign costs at a later date.
Compressor Pipe Supports
Exhibit 4·53 illustrates how to minimize the transmis-
Line Branches
sion of damaging vibrations by isolating the line sup-
\11 branches should be located close to a line support portS from adjacent compressor or building founda-
N'henever possible. Any such connections should be tions, operating floor steel, or building framing.
Compt-essors
90
Generally, drums are cylindrical hollow steel vessels drum, and Exhibit 5-2 shows a horizontal reflux drum.
used in process plants as intermediate containers that When specified, steam drums and deaerators are
receive liquid from distillation and condensing equip- usually furnished as a. proprietary item. Layout is lim-
ment. Drums also collect liquid from vapor circuits ited to confirmation of nozzle and support locations to
and pump it to other process groups, disposal, or suit piping and structural configurations and platform·
product storage. They are also used for chemical and ing for operator and maintenance access. Exhibit 5-3
catalyst storage, steam generation, and deaeration of illustrates a typical deaerator arrangement.
boiler feed water. This chapter highlights the general
requirements for drum plant layout and provides in- .;'
TYPES OF DRUMS
EXHIBITS·2
L.IGlUIO IN Typical Horizontal Reflux
Drum
-LE..VE.1.
' '''?tt..JM e.... T~
1.IGUIO CuT
91
92
:zt
EXHIBIT 5·3 Typical Oeaerator Arrangement EXHmIT 5-4 Drum Location in a Tower Re1Iux System
-.$-_ "To,",U
LOCATION OF DRUMS EXHmIT 5·5 Locations for Feed Surge and Compressor
Suction Drums
Drums are located within a process unit either adja-
cent to related equipment (e.g., the reflux drum) or as
a standalone operation (e.g., a condensate collection
drum). When operating within process sequence of
related items (e.g., pumps, condensers, and towers),
the drum should be positioned to facilitate an orderly
and economic piping interconnection between itself
and those items.
Within the conventional inUne process unit, drums
and their related items are generally located on either
+N
!
Process Plant Layout and Piping Design
93
~II.
f -0/ ·31X>
I
Elevation and Support ability. Drums for chemical collection systems are gen-
erally located below ground in concrete pits, as shown
Similar to towers, drum elevations are dictated by the in Exhibit 5·8.
NPSH, as illustrated in Exhibit 5-7, minimum dear- Methods of support are influenced by the size and
ance. common platforming. and maintenance and op- location of the drum. Similar to towers, large vertical
eratOr access. Within structures, especially chemical drums are supported by skirts. If size permits, small
facilities, drums could be elevated above the mini- vertical drums may be supported by legs, as shown in
mum requirementS of accommodate floor space avail- Exhibit 5·9, or by lugs if elevated within a structure, as
94 ta
EXHIBIT 5·7 Net Positive Suction Head Elevation EXHIBIT 5·8 Elevation Requirements for an
Requirements for a Horizontal Drum Underground Drum
EXHIBIT 5·9 Sample Leg-Supported Drum EXHIBIT 5·10 Sample Lug-Supported Drum
EXHIBIT 5-11
Sample Saddle-Supported
Drum
(ZE;ltoJFc~I"'6
~
-
95
EXHIBIT 5-12 Drum Elevation Sketch EXHIBIT 5-13 Typical Process Vessel Sketch for a
Horizontal Drum
shown in Exhibit 5-10. Horizontal drums are usually loJ<:>:n.LE SLa..,.... A.Il:.'/'
&1'Mktl. $P1'Z.1iI .e.~VlC:.1a
supported by saddles from concrete piers or steel A "I1II~gtlZ4" VAA::>lZ o:>UT
frames if elevated within a structure, as illustrated in e- Go' LIGh~IO ,...
• Type of heads.
• Support details.
• NPSH requirements of pump. release package. Exhibit 5-13. shows a typical process
• Bottom outlet size. vessel sketch for a horizontal drum. The following
o Minimum clearances. information is reqUired in order to position drum
nozzles:
• Location.
The centerline elevation of the drum, as illustrated • Process vessel sketch. .'
in Exhibit 5-12, was set using the following listed infor- • Instrument vessel sketch.
mation (it is recommended that a freehand sketch be • Piping and instrumentation diagrams.
used for this exercise): ., Plant layout specification.
., Nozzle summary.
• Drum dimensions-4·ft (l,220-mm) diameter by lO-
ft (3,050-mm) length. ., Insulation reqUirements.
• Support details-Saddles and concrete piers. OJ Plot plan.
• NPSH-9 ft (2,700 mm).
Exhibit 5·14 depicts the preferred nozzle locations for
• Bottom outJet-4 in. horizontal drums.
t Location-Freestanding. The preferred location for level instruments is away
• Minimum c1earance-7 ft (2,100 mm). from the turbulence at the liqUid outlet nozzle. Al-
though the vessel is provided with a vortex breaker,
instruments should be set in the quiet zone of the
NOZZLE LOCATIONS vessel-for example, on the opposite side of the weir
or baffle or near the vapor outlet end. Process nozzles
I?rum dimensions, nozzle sizes, and, if required, inter- should be located a minimum from the tangent line.
nals are shown on the process vessel sketch furnished Steam-out connections should be located at the end
by process engineering and included in the process opposite the maintenance access and vent in the bot-
96
EXHIBIT 5-14
Preferred Nozzle
Locations for a
Horizontal Drum
-:
internal components, as is the case for the distillation
.~' -.. - tower. More information on vertical drums is available
'.: " in Chapter 10, Towers,
The nozzles shown in Exhibit 5·16 were positioned
97
EXHIBIT 5·16
Sample Nozzle Locations
and Elevations
2~O"1 I~d'
.&10 1.8~o .610
Q'-<0 II
:ISo
IE1ll- I
g----
using the guidlines discussed in this chapter as wen as .. Piping and Instrumentation Diagram (P&ID)-Ex-
other jnformation contained in this book. The jnfor- hibit 5-28,
mation required can be located as follows: • Nozzle summary-Exhibit 5-13.
_" Plant layout specification-Chapter 2.
.. Process vessel sketch-Exhibit 5-13, .. Insulation-No requirements.
.. Instrument vessel sketch-Exhibit 5-29. .. Plot plan-Exhibit 5-4.
Drums
98
EXHIBIT 5-17
Platfonn Arrangement at
a Horizontal Drum
TOPt-'CAp ~
t:ouPFb~T6.C' FiZOM
TIZI.lp.,J~IO""~
c. StrUcture·Located Drum
d. Common Platform
100
EXHIBIT S·20
Horizontal Drum
Platfonn and ladder
-
Elevation ReqUirements
[IOIIMIN •
.2S0
:: ,.oP o~ '::C'N'I4ETE
0 PII:.~
-'( ) MAl"" Tlh.lA....<:. E:
\'(\ .
1 ~ Ac.e.. E<$ ~ I VAI.Vt?:, I;I.IND
al
:J
1 I-AODCf< ..
~7.,.~ u.~S""",. Au.~~
~
III
au 11IIT£I<ME.O,ATe P\.ATFoRM
~
4
0
rio 1b ~IT MAl<.lwhJ!IA
~
LApp 8':2 IQJt-J
installations. For tall vertical drums, platforms should drums' location to related equipment. Piping should
be arranged using the tower subject as a guide; this is . be positioned to facilitate the installation of supports,
covered in Chapter 10. with sufficient flexibility to absorb any excessive
Exhibit 5-23 depicts a horizontal drum platform ar- stresses during operation. Piping at taU vertical drums
rangement that was designed using the guidelines in should be arranged in accordance with the guidelines
this chapter. This information can be found as follows: given in Chapter 10.
If required, piping at horizontal freestanding
.. Process vessel sketch~Exhibit 5·13. drums should be supported from the sh,elJ of the
.. Drum elevation-Exhibit 5-12. drum, the platform steel, or the concrete piers sup-
.. Plot plan-Exhibit 5-4. porting the drum. Piping associated with drums lo-
.. Type of support-Saddles and concrete piers. cated within structures should be supponed from the
structural steel. Exhibit 5-24 shows typical pipe sup-
pons at a horizontal drum, and Exhibit 5·25 shows a
PIPING ARRANGEMENTS typical pump suction arrangement
Relief valves that are open to the atmosphere on
Piping at drums should be arranged in conjunction ~ low elevated horizontal or vertical drums should be
with nozzle locations, platform arrangements, and the positioned to allow the discharge piping to be routed
lfi
VENI EXHIBIT '.21
Horizontal Drum
.7f1o Platfonn Floor Space
Area Requirements
i£':IbIlP~"ATu£,'f:
I ~ ;-r~~MF ....-r
O""i'T
L.E'J~l..
IN~T(lLJM~T.,
MAI..... TENAN"e;
A"e.~~
tl ... A A"
EXHIBIT 5-22 Vertical Drum Platform Floor Space Area EXHIBIT S-23 Horizontal Drum Platform Arrangement
Requirements
st!R fJ'.t}
.~~ :!&;e>
TEl>ip~eAr<.JR&
P\'i?a;1:uB.e
ItI/!>TIOWMe...lT$
"'.t.I NTEN.v.!(.l:
AGc::.e~~
EXHmITS·24
Horizontal Drum Pipe
Supports
""·.·H
1':. '.
.. ..' ~,. t-::=t::;J
'.
.. ' ",...' ...
;.
~PPCl2'" R<DM
S.UPPD"~ ~OM ~N~e.j"=' PlE:.~
PI,..~T~2.M e~Ac:..l'.f!.T
103
EXHIBIT 5-25 Pump Suction Arrangement EXHIBIT 5·26 Relief Valve Systems
~T'''''60 !"';PI<:
"01:> tTIO...aA l.
I=Le."" e> 11..1" 'f
<::ol.D':Pep !"f'!o'TEM
2llo.1.!I;'" VAL\I~ ~"Il'r.l
'I' C'l2iJ"I P\.A'T1"c:> la.M
I*LoW Ii!EWEF'I6.LII6
I"
IolIll.ADEB
IX&l.liSF IJAJ.,V6
H&.b>C>B/lt
DRUM INSTRUMENTATION
EXHIBIT 5·27
Sample Drum Piping
Arrangement
~l
Pl..ATf'Q~M El..
I09"411/102,8~
- EXHIBIT 5·28
Sample Pipin~ and
105
lnstnunentation Diagram
e-~o
oVfUZ.W£/o.P ~O.IWSl!;ft
To
4'M) "lJl{TyP.)
P·201 "'JAl& !'- ~CCJ J--L&
9oT!o,,",,<f, F'UIoI'IP1J fl.E.Fl..I.J)( PI...U"'P~
EXHIBIT S..29
Sample Instrument Vessel
Sketch
Drums
106
3'
EXHIBIT 5-30
Instrument Arrangement
EXHIBIT 5-31 Sample Horizontal Drum Davit EXHIBIT 5·32 Drum with Mixer
Arrangement
MAINTENANCE
EXHIBIT 5-34
Sample Sloping Drum
required, they should be arranged in accordance with given to the arrangement of additional pliltforming for
those in Exhibit 5-31. access to the instrumentation on the boot. Exhibit 5-33
Removal space should be prOVided above drums shows a typical drum boot layout.
furnished with mixers. If the drum is located within a In certain cases, drums must slope, as shown in
structure, a removable section of the floor above Exhibit 5-34. If the nozzles are not perpendicular to
should be provided. Exhibit 5-32 illustrates a drum the horizontal plane, all vertical .piping runs from
with a mixer. these nozzles must be calculated because they will be
offset at an angle.
'The dimensions, clearances, and gUidelines high-
FURmER CONSIDERATIONS lighted in this chapter are an example ,of what can be
used for drum arrangement. The plant layout designer
For various process reasons, horizontal drums often should be familiar with company and client standards,
are furnished with what appears to be a smaUvertical however, before proceeding with drum layout and
drum, called a boot, attached to the underside of the should coordinate the effon with such supporting
vessel. Because the boot is inaccessible to the main groups as vessel, systems, process, and instrument en-
drum platforming, special consideration must be gineering.
CHAPTER
Exchangers
Heat exchangers are similar to pumps and vessels in mation reqUired by the plant layout designer to locate,
that they are widely used in most process plants. The elevate, operate, and maintain the most common ex-
control of heat within any facility is an important part changers and to position the piping and controls asso-
of plant operation, whether by direct application (e.g., ciated with these items. The most common applica-
in a furnace) or by heat interchange (e.g., in a shell tions for heat exchangers, illustrated on a process flow
and tube exchanger). The principal application of a diagram in Exhibit 6-1, are:
heat exchanger is to maintain a heat balance through
the addition or removal of heat by exchange with out- • Cooler-Cools process streams by transferring heat
side sources or between streams of two different oper- to cooling water, atmosphere, and other 111edia.
ating temperatures. o Exchanger-Exchanges heat from a hot/to a cold
EXHIBIT 6-1
Exchanger Applications
Shown on a Process Flow
Diagram
~L.E?!
GMILL.e.~
~~eI6e..~A"'T
109
110
EXHIBIT 6-2 Common Heat Exchangers
ing steam, hot oil, or a hot process stream as the aNres by evaporating a refrigerant.
heating medium.
" Heater-Heats a process stream by condensing EXCHANGER. CONSTRUCTION
steam.
e Condenser-Condenses vapors by transferring heat 1be most common heat exchangers used in process-
to cooling water, atmospheric air, or other media. ing facilities are illustrated in Exhibit 6-2 and dis-
e Chiller-Cools a process stream to very low temper- cussed in the following sections.
SiDE.
EXHIBIT 6-4 Key Items for a Typical Shell and Tube Exchanger
'&l-lcl..t. Fl..OA,..ltooJ6
~-e=AD cove.~.
$"f:L.L. SlOG.
~UPPQa.-r
~AI/Pl-E
Shell and Tube Exchangers welded steel plates for the larger sizes. Tube bundle
sizes can vary from 8 to 96 in (200 mm to 2,400 mm) in
Shell and tube exchangers are elongated steel cylin- diameter and from 6 to 50 ft (l,800 mm to 15,000 mm)
drical vessels containing bundles of parallel tubes. liq- in length. The ends of the shell can be designed to
uid passes through the inside of the shell over the accommodate welded, dished, or flanged shell covers
exterior side of the tubes, with another liquid passing as well as flanged or welded heads. Both the tube side
through the interior of the tubes. causing the neces- and the shell side of the exchangers have inlet and
sary interchange of heat between the two liqUids. The outlet nozzles positioned to provide the required flow
heads at the ends of the exchanger can be designed to through the exchanger. The unit is supported at dle
accommodate several passes on the tube side. Multi- shell by attached saddles for horizontal installations
ple passes on the shell Side can be achieved by install- and by lugs for venical arrangements. Tube bundles
ing baffles parallel to the tubes. Baffles may also be are made up of many small-diameter tubes that are
installed inside the shell, perpendicular to the tubes, expanded into tube sheets at each end of the bundle.
to direct the liquid in the shell against the lubes. Multi- One end is usually fixed; the other is allowed to float
ple passes are used to increase the fluid velocity or to for expansion. For the more Simplified U-tube ar-
improve the flowpaili. causing increased heat recov- rangement, only one tube sheet is used, which is inte-
ery. Exhibit 6-3 shows an exchanger with two passes grated with the channel head. Exhibit 6-4 shows a typi-
on the tube side and one on the shell side. cal shell and tube exchanger identifying the key items
The shells of most heat exchangers are constructed of construction.
of seamless pipe for small diameters and shaped With many shells, shell covers, and head covers
112
001""-'" •
d
available, exchangers can be arranged in various com-
EXHmIT 6-5 Typical Shell and Tube Exchanger
binations to provide a wide range of services. The U·
Arrangements
tube, fixed tube, and kettle arrangements are illus-
trated in Exhibit 6,5.
Plate Exchangers
Plate exchangers, shown in Exhibit 6-6, are generally
used in low-pressure, low-temperature applications
and are made up of end covers, carrying bars, inlet
and outlet nozzles, plates, and gaskets. The exchanger
a. V-Tube plates have spacing between them for liqUid flow. A
gasket, set into channels on the periphery of each
plate, directs and contains the liquid flow distribution.
Pons for inlet and outlet of both hot and cold liqUids
are stamped into the corners of each plate. When
aligned, they form four distribution headers through
the plate pack Distribution of hot and cold liqUids to
alternate plate flow channels is achieved by the gasket-
ing pattern around each port. When the liquid is in-
tended to flow through to the next plate, the gasket is
left intact around the port. Alignment is achieved by
b. Fixed Tube top and bottom carrying bars and slots in each plate.
When completely assembled, the plate pack and gas-
kets are compressed by bolts between the cwo covers.
Support is provided by the fixed end cover and carry·
ing bar. The plate exchanger requires less installation
and servicing space than do shell and tube arrange·
ments of equivalent surface.
EXHWIT 6-6
Plate Exchanger
Construction
Exchangers
114
PINNe.D INtJe", EXHIBIT 6-s
~
Double Pipe Exchanger
Construction
EXHIBIT 6·9
Air Cooler Exchanger
Construction
MOTc::>~ AG:Ge=?S
Pl..ATF02:M
rached to a foundation or to the side of other equip- installed and located side by side.
ment suppOrts. Air is circulated by multiblade propeller-type fans
that proVide forced or induced drafts. Fans can be
supplied with either adjustable-speed or variable-pitch
AU: Cooler :Exchangers
blades. The fan blade pitch can be changed to vary the
Air cooler units are entirely different from the previ- air-flow fate to compensate for rising or falling air
ously mentioned arrangements in that the cooling temperatures. Air coolers supplied with multiple fans
agent used is circulating air instead of a liquid. As seen may be operated with some of the fans shut down.
in Exhibit 6·9, an air cooler unit consists of fin-tube Dampers, baffles, and bypasses can also be used to
bundles with a header box attached to each end, sup- further control liquid outlet temperature. For elevated
ported horizontally by a steel frame or structure. For installations, platforms are generally furnished for ac-
the single-pass arrangement, the inlet nozzles are cess to header boxes and motors.
moumed on the top of the header box; the outlet
nozzles are at the opposite end and mounted on the
bottom of the header box. For the double-pass ar- EXCHANGER LOCATION AND SUPPORT
rangement, the outlet nozzles are located at the same
end as the inlet nozzles. For additional surface area, Heat exchangers are located within the conventional
more passes can be added or additional units can be process unit plot area, dose to related equipmen~, to
·PISii':.A.1.
~)f,.C;.H~6e~~ --+-!H-
Exchangers
116
£
EXHIBIT 6-12 Sample Single and Paired Exchanger EXHIBIT 6-14 Sample Structure-Mounted Exchanger
1I1$tallation Installation
TOW~
.... ./
SINa.Le
E:1(C;HA"''''e.~
DI'Y.>oIMII.AIZ. '"
$Es.:.\lIC.~,
bonnet flanges and fixed handling devices.
Horizontal shell and tube exchangers may be lo-
cated at grade or elevated in steel or concrete struc-
tures when process requirements or space availability
dictate. Support of horizontal exchangers, as shown in
Exhibit 6-16, is by saddles attached to concrete piers
XHIBIT 6-16 Typical Horizontal Exchanger Supports for grade-mounted installations and by saddles at-
tached to steel frames in elevated installations. When
D,to..YI"T
possible, supportS should be inline for common foun-
dation design.
If process requirements permit, shell and tube ex-
changers can also be mounted in a vertical position,
supported by lugs and tower nozzles in a toweHUp-
ported installation (as shown in Exhibit 6-17), within
concrete or steel structures (as shown il) Exhibit 6-18),
and by concrete piers (as shown in Exhibit 6-19). The
same considerations for maintenance, control, and op-
~Il 1., GL~ioJG.E.
-..,j~/!:. OIJTt>IDE: of' erator access should be given for vertical installations
FLA...JC:tE 01<: as are for horizontal installations.
.!."'!:oUL.A..'TICN
An important feature to remember when working
with tower-supponed vertical reboilers. not requiring
~u f>L.t: PI p'e springs, is highlighted in Exhibit 6·17A.
t1:X~b.r-J6e.sc.?
1. The layout designer must set the reboiler sup-
POrt lug elevation 1 inI.025 above the platform
steel. and not at the steel elevation.
2.. Before maintenance, the 1-iol.025 gap will be
.. ; "
... shimmed, thereby enabling the reboilee load to
118
• EXHIBIT 6.17
II
Tower-Supported Vertical
Installation
i
I-!IT"'j.\ POlo.JT~ ~
~ovec;: IZEMOVAI..
121'011/~fgoo
MA\(IM..J~
WIT"¢UT
F'I.A1"F=Ol<:o.A
EXHIBIT CJ.17A
Tube Bundle
'j Maintenance
;t~w
ii (
~
CD
1~>~ / 1?Ef:1?\{E;
Q.!AIJNe-k
~
EXHWIT 6-18
Structure-Supported
Vertical Installation
MIt-JIMuM
4'-o'YI. 'ZQO
(Typ,)
L1.l6~
~LO'0bOO
MAKIU\WV\
PLATf:<OQ:M
be carried by the platform steel during mainte- rangements for control and operator access, with
nance turnaround. enough room allowed at the spiral exchanger to swing
3. The nozzle and channel flange will be unbolted the cover plates open, as shown in Exhibit 6-20, and at
and the channel section removed. the plate exchanger to remove the individual plates, as
4. The tube bundle is then ready to be removed. shown in Exhibit 6-21.
Air coolers are located adjacent to the equipment
Spiral and plate exchangers can operate in series or that they serve for piping flexibility and maintenance.
parallel, but, because of their configuration and main- They can be supponed from grade, at the top level of
tenenace requirements. it is preferable to position structures, or above pipe racks, which is the most
them as single items. Space is provided at both ar· common installation. The tube bundle bank can be
120
EXHIBIT 6-19
Pier·Mounted Vertical
Installation.
M'~'MUM
4I..o~I.200
(p1ot~.800
M~IMUM
J.:
"
..
.~
EXHIBIT 6·20
Control and Operator
Access in a Spiral
Arrangement
COVEiii'::. PLATE
S,WIe.J6 AC<E.A (TyPo)
CCH.,j'Tr:a.o L.
$pA.G.e (Typ.1
,r
H~A.De."
&o~ PI.b.'TFoRM
j
I
..::l
AODITIONAL P1.ATFo~twt
~!)PE:"Z_ ~u...., I'
LO.... GE.I< -rH-AN
~ot..oll/9.1'50
122
sa
R:>12.c:..e.t> Ds<A-FT EXHIBIT 6.23
AIt2.. GOO l.e. 2 Typical Leg-Supported
Air Cooler Arrangement
supported by steel legs from the air cooler vendor or platform arrangements.
by extending the pipe rack or structure columns to the When designing the air cooler configuration, the
underside of the bank. Generally, the air cooler ven· plant layout designer must consider the source of the
dor furnishes header box and motor access platforms. supporting column. As seen in Exhibit 6-26, arrange-
Ladders are provided for exit to grade to suit maxi- ment A, developed by the contractor, allows changes
mum ladder runs and safety requirements. Exhibits to platforming and pipe support loading late in a proj-
6-22 through 6-25 show various air cooler support and eCt without affecting the air cooler vendor's scheduled
platform configurations, which include column-sup- delivery dates to the job site. In arrangement B, any
ported, leg-supported, fixed-platform, and traveling- such late changes would cause the air cooler vendor
123
£ d IBm
EXHIBIT 6-24
Typical Fixed-Platform
Air Cooler Arrangement
lA\:>062 To
MlI.lo..ITE:.lJ~tJc:.E
P\.A'TFoll""
(T.,..P.)
~'TEP-OFF
Pl-ATFo12M
LADDE-Ii? To
I4E:.AOU t>C"~
PL.ATFCi~M
.'
125
EXHffi1T6·26
Considerations for
Vendor- or
Contractor·Suppfied
Supporting Columns
to redesign the support legs or platforming, causing improved arrangement by relocating exchanger noz·
delays in delivery and extra costs. zles. Exhibit 6·28 shows allowable nozzle configura-
tions.
NOZZLE ORIENTATION Elbow or gooseneck nozzles are especially useful
in redUcing the height of large stacked exchangers.
Nozzle orientation and location can affect the piping Exhibit 6-29 highlights the effects of using elbow noz-
:;onfigurations at mosl exchanger arrangements. A de- zles on stacked exchangers.
:lsion by the piping designer to relocate the ex- Air cooler nozzle locations can also affect piping
~hanger nozzles can often produce a neat and cost· configurations. A single-pass arrangement can make
~ffective arrangemem. Although the piping designer the return piping on an overhead condenser very long
:ioes not have the freedom to independently relocate and can also increase the height of the air cooler.
~xchanger nozzles, suggested alternate nozzle loca- Reorienting the air cooler or making the unit a dou-
ions can be made to the exchanger engineer in the ble-pass arrangement can improve the piping configu-
merest of improving external piping arrangements- rations. Exhibit 6-30 shows alternative nozzle configu-
or example, alternative B in Exhibit 6·27 highlights an rations for air cooler piping.
126
EXHIBIT 6·27
Alternative Arrangements
for Locating Exchanger
Nozzles
ALTe.~~ATI\lE '\6"
'\\ I,
ALTEl2tJAi'VE A
au
EXHIBIT 6·28
et---~
Allowable Nozzle
Configurations
a !II i ~[}
1:
?I~l{:-~* ~e:LL
7l$lNl I?QlQ#
AI..TE.r.(,NAT\ VE 'ti.' AL TE.l2.tJAT I \I E 1'6"
EXHIBIT 6·30
Alternative Air Cooler
Nozzle Configurations
Ooub~e-p~s a~TL~T
,",,01.'%..L5 L.oG.ATION
/S:--
...iI-
\J;
I
XCHANGER PIPING
"changer piping must be routed in such a manner lions. Large-diameter or more expensive piping call"
lat it meets economy, flexibility, support, and opera- not be set to accommodate smaller or less expensive
on and maintenance access requirements. Piping at piping. Piping connected to channel head nozzles
leU and tube exchangers is positioned to allow ade- should be furnished with break flanges to facilitate the
uate space for removal of channel heads and shell removal of the channel head.
:)vers. The free space at the side of horizontal shells Piping at spiral and plate exchangers is also posi.
an be used for placement of controls. Piping is ele- tioned to allow the opening of covers and the removal
ated a minimum distance from grade or platform to of plates. Controls at me spiral exchanger are located
mvide operator headroom clearances, to offer ease on the ends of the unit, clear of the cover plate swing
,f support, and to meet designated pipe rack eleva- area, and at the front and on one side for the plate
128
a
EXHIBIT 6-31
Piping Arrangement fol"
Horizontal Shell and
Tube Exchangers
c:.U&'O:::I( GI.CACZ4f<>JGe
.e:."T '$>uPFbli:T$
exchanger. Piping is elevated in a fashion similar to over tube banks or fans and should be kept dear of
the shell and tube arrangements. Piping attached to the designated space for motor maintenance. Exhibits
the cover plate nozzles of the spiral units is furnished -6-31 through 644 show various piping configurations
with break flanges. Piping at air coolers is not routed for hea,t exchangers.
E.l.EVAiION 0(:
c.<:>j"JDe~$ATE PeT
'$oaT ~ Ptl.o,e'2~
c:<':'...., 0 \ "TIC N ~
h«:bangers
1,30
EXHIBIT 6·34
Sample of Piping
Economy Arrangement
',-
12 11 4' ALLo
Cb II tP cA(i:. et?t.J ';'/eEL
EXHIBIT 6·35 Supports for a Piping Arrangement EXHffiJT 6-36 Piping Arrangement for Horizontal
Reboiler
lo..rrE1o?M£-PIA"TE s"'ef'o~:r
~e;c:oluI2e.1;l F.c:>g PIP,,,,,61
-r~Ao'T .0, C:W1<1i:'!kPboNloJE.P
~'TWe-E~ P.P1;, 14,\,'-1(. .."'"
E:.'\(GIoIA....... 6E~-;
i.
III
lOT
~
r'mt.
... -
I
..
~
".1
..- ..... ., ..
• ,~
}Jt-
.• I
O...M"'I"" UU:r/
T~'-JN 1Ot-.j ,
, : A
;
--- .- . .I
"-
i
I I
I
.:1 I'
n!
i
,
!Il'I'
I 11
I'
I I I
~i I
I
j
! I I
f
,.
"t,
J
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I
!
' ;
1
.i
~ I :,
I
I,
I I
:
r .. r - ,..-
I
-
~
,
~
.l
I
I I r , ,B
.. "~ :11
-u "' '\J -n J I'
.....
I' '-
$F.a~
I
P((bVq,e.
'''' PIPING
Loo P'"
r-Otc::
f'i2.0 VI DE.
~wppoeT AT C6NT£R
FLE; >' I e, 11..1TY E XC ~tJ~t iC: Ci-lLw-.J t.J f:L.
EtooJl' ONLY
I\."J
ALlER-NAT IVE
" II
'A ALT~NAil\JE t>
~~T E:.FFf::G.T\\JE
Excbangen
132
•
LOc:..A'i'E PlPIt...sG ~e.b.T,", EXHIBIT 6-39
PI..A."1"'t=c:>~M ~'2 e:.A"i;lre Piping Arrangement for
Feed Exchangers
OF ,,;,wP'~t<:.T
'.'
PW
COVclZ P~AT6 EXHmrr6-4o
~WI""'6 ARS-A. Piping Arrangement for
Spiral Exchangers
RE:MOvA~L.E
~r ., ~I II
J r ...
//~/~
ELENA.,.' ON
U&IFF
Exchangers
134
'11I
EXHIBIT 643
Overhead Piping
Arrangements for :Ii
Condensing Air Cooler
....
tXTe~Q S~'~~=~~=:::5i:j>
~L.~ :;up~",. CD~· &.FFf!G.-r'VE
~Tce..1.. To ~Pf'O£."T' A l TE£wA"I\le. J<c::>UTIN(:,
eVe:J'~EAD LINE IF PIPIIoJC::! ,~ FLe:'XIf,U=
Al-JI) c:..AN '5oPAhJ OI':fJ"A""CE
W\T~O&-lT I"I"T&R Me. O'A'TE
$uPPoR,
EXHIBIT 6·44
Inlet and Outlet Piping
Arrangement tor a
Product Air Cooler
11= iZe:Qu,k:E: D
:::>~ OUTl..cI PIPINU SUPPola.'T c.oc>LII..ICl
AI .c..114 CO:::n.E: iZ. IloJL.E.T PIP INc::,
~CHANGER MAINTENANCE dling devices for removal of rube bundles, Minor re-
pairs (e.g., tube plugging) are usually accomplished
.ike an automobile radiator, the internals of heat ex- with the air cooler in place; for major repairs, air
hangers require periodic cleaning and repair. It is cooler sections are removed by mobile cranes, as
mponant for exchangers and related components to shown in Exhibit 6-49. Internal servicing at plate ex·
>e positioned to facilitate access to their internal pans. changers can be done manually. In the event of a tube
For the shell and tube heat exchangers, the tubes failure, individual tubes are dosed by inserting a plug
Ind the interior of the shell can be cleaned in place through the end of the header box and hammering it
\lith high-pressure steam or water and rodding de· into place, as shown in Exhibit 6-50.
'ices. If the design of the exchanger permits, the lube The use of tube bundle extractors eliminates the
>undle can also be removed for repair or cleaning. need for permanent tube bundle removal structures,
tube bundles and head and shell covers can be reo with considerable saving to the plant. These mecha·
noved by built-in fixed handling devices (e.g., davits, nisms weigh seven tons and are capable of pull forces
litch poims, pulling posts), fixed structures with trol· greater than 500,000 lbs. The extractor is lifted into
ey beams and traveling gantry cranes, or by mobile position by crane and damped to the shell flange of
~uipmem (e.g., cranes and hydraulic bundle extrac· the exchanger, which is stripped for bundle removal.
ors). Exhibits 6-45 through 6-48 provide examples of Held in pOSition by the crane and balanced by the
ube bundle removal eqUipment. Considerable saving extractor's leveling cradle, die bundle is pulled out of
~ be achieved if the plant is selViced by mobile its shell with pull rod attachments that use hydraulic
~quipment. force. The whole unit is then lowered to grade and can
Air cooler units are not furnished with fixed han- be relifted OOlO a truck for off-Site repair or cleaning.
':.
~._,.
EXHIBIT 6-45
Bundle Pulling Post
~~llldJ1/
~e.Mo"Abl.E
Pu L.L.I""e::. e.cA.M
EXHIBIT 6-47
Fixed Structure with a
Traveling Gantry
f\JI.LINC:i
SeAM AIooaO
";;'Ao.~L.1i
EXHIBIT 648 Removal of a Tube Bundle by Crane EXHIBIT 649 Removal of Air Cooler sections with a,
Mobile Crane
• I
, I
I Iil\~=~
1
!
i
I
I
~,L LJJJl~~L
138
'.~.
mrnWIT6·S0
U~t2%'t-
EXHWIT6·51
Bundle Removal Using an
Extractor and a Mobile
Crane
EX1UBIT 6-52
Tube Bundle Extractor
Details
Item No.
3
9
Mllift supef$tM:t1H'll
f1Ilnp clllmp ,
8 Drive elllin
f1INIIe c"mp
19 H)'dnlulk IIMllcn 10 Sibil cytlncklrs
21 Tanchmll\llllllll 11 HydmlIIc; controlllalyfl
23 A1rmotOf 15 salam. qflnder5
J MOllftfr-. I. R~I.
".
Furnaces
Furnaces, also referred to as heaters, are one of the perature increases, the hot flue gas rises out of the
main pieces of equipment in a process complex. A stack and begins to exert a negative pressure within
furnace may raise the temperature of a gas or hydro- . the radiant and convection sections. For optimum op-
carbon liquid to meet specific processing needs or, in eration, there should be a pressure of approximately
the case of pyrolysis and reformer furnaces, cause a -0.35 in of water columns just inside the air register
chemical or physical change to the medium. A circular of the burner. There should be a pressure of -0.2 in
or box-type configuration is primarily used; variations of water columns at the furnace floor, with a further
to each design are covered throughout this chapter. In drop (0 -0.5 in at the top of the radiant section, and
addition, because of the various types of furnaces, this -0.7 in at the base of the stack. MaintainilJg these
chapter covers some basics of furnace design and dis- levels ensures adequate air flow to the burner. Peep
cusses how to approach a piping layoul as it relates to doors are provided along the radiant walls {Q allow
maintenance, operation, and safety. plant operations personnel to view the burners while
making fuel flow adjustments.
A product is introduced into the radiam tubes and
BASIC OPERATION AND PRIMARY is heated to the maximum operating temperatures. It
PARTS OF A FURNACE then exits the furnace. Steam emers the convection
section tubes and is raised to a superheated tempera·
Exhibit 7-1 illustrates the basic makeup of a furnace. A'i ture by the hot flue gases.
shown in this exhibit, the basic parts of a furnace in- The damper, which is used to control me draft in
clude: the furnace, is located in the Slack. Adjusting the
damper controls the pressure balance within the mr-
e The radiant section-Houses rows of horizontal or nace. The stack height is determined by the draft re-
vertical tubes that carry the product £0 be heated. quirements of the furnace but may be adjusted. Draft
e Burners-These are primarily fired by oil or gas and gauges are used to check pressure levels.
are located in the radiant section. . It should be understood that there are many vari-
e The convection section-Located above or down- ables to this description. Burners may be located in
stream from the radiant section. It houses rows of the side walls or roof of the radiant section. Insulation
horizontal tubes that are heated by the hot flue may be refractory brick, ceramic fibers, or a mineral
gases. wool blanket The product may flow into the convec·
e The slack-This is usually located above the convec- tion section tubes, exit that section through crossover
tion section and carries the flue gases to the atmo- piping, and flow mrough the radiant section. Multiple
sphere. furnaces may be tied to one common Slack by breech·
ing.
• Insulation-Lines the waIled surfaces of the radiant
and convection sections.
TYPES OF FURNACES
The furnace operates in the following manner. Fuel
is fed to the burners located along the furnace floor. It
The principal types of furnaces are box, circular, pyro·
is then ignited by a pilot gas line located in the burner. lysis, and reformer.
The combustion air flow is regulated by adjustment of
the air registers. For proper operation within a fur- Box-type Exhibit 7·2 shows a box-type furnace that
nace, a natural draft must be maintained. .As the tern- houses rows of horizontal or vertical tubes in the radi-
141
142
EXHIBIT 7.1
Basic Furnace Operation
__t;;;"
o----~~-i
BEATW
~
!?\J!2NEg ---11-1----./
EXHIBIT 7·2 Typical Box-Type Furnace EXHIDIT 7·3 Typical Circular Furnace
ant sectioo. The convection section is located down· the product being heated, and are located at one end
stream from the radiant section, where flue gas may of the convection section.
pass in an upward or downward flow. Rows of burners
are located in the radiant section; rhis is the primary Pyrolysis Exhibit 7-4 illustrates a pyrolysis furnace
source of product heating. whose product tubes are placed in the center of the
radiant section because of a relatively short residence
Circular Exhibit 7-3 illustrates a circular furnace that time, high heat transfer rate, and need for even tem-
houses tubes mounted vertically or helically in the perature distribution in the tubes. An integral waste
radiant section. These furnaces are generally used for heat recovery system that employs the use of a steam
such smaller duties as start-up heaters or rebollers. drum and a transfer line exchanger (11.X) is also
Inlet and outlet connections are usually located at the shown. Steam decoking is reqUired to clean the inter-
top orme bottom of the radiant section, depending on nal walls of the process tubes.
144
8118'1
EXHIBIT 7-4
Typical Pyrolysis Furnace
Reformer In a reformer furnace, shown in Exhibit system used to carry waste away from piping or tubes
7-5, preheated process fluid flows through catalyst- for disposal.
fiiJed tubes, which are usually located in the center of
the radiant section. This type of furnace may have sin- Breeching Breeching refers to the duct work that
gle or multiple compartmems; burners may be collects flue gases along the furnace box outlet for
mounted in the roof, wall, or floor. Heat recovery sys- transmission to the stack.
tems may also be employed through the use of waste
heat boilers or the convection section's steam genera- Burners Supplied with air and fuel necessary for
tion coils. combustion, burners heat the product in the tubes in
the radiant section of the furnace. The most common
types of burners are gas; air and gas; air and oil or
TERMINOLOGY gas; and oil, which requires air, oil, and atomizing
steam,
The following sections liSt common furnace terms,
Burner management package This device is de-
Blowdown steam Blowdown steam is used for tube signed to control such burner operations as monitor-
cleaning or removal Df products from the inlet piping ing purge sequence, igniter and main fuel Start-up,
in the event of fire, pilot flame, main flame, and heater conditions. Limit-
ing devices are built into the package that shut down
Blowdown system A blowdown system is the piping the furnace if unsafe operating conditions arise.
::lean-out access doors Access is provided to the in- usually flat plates that rotate on a shaft resting on pil-
erior of the furnace for maintenance personnel. low blocks set in the steel shell, similar to a butterfly
valve.
:;onvection section This companment houses rows
)f primarily horizontal tubes located downstream Decoking The coke built up in many hydrocarbon
rom the radiant section that are used for additional furnace tubes during operation is removed by inject·
leating in a process unit. Passing the hot flue gases ing steam and air into the tubes.
lver these tubes can provide additional duty. Exam-
lies include preheating process streams, steam super-
Draft: gauge This instrument is used to check pres-
leating, and additional steam generation. Provisions
sure in a furnace.
I"JUSI be made to remove these tubes for inspection,
epair, or replacement.
Explosion doors In the event of an explosion in a
:rossover piping This piping interconnects the radi- furnace, doors speCifically designed to blowout and
nt and convection sections and is usually furnished protect against a major structural failure are provided;
y the furnace vendor. they act like safety valves in a piping system.
lamper Located in the stack or duct, this device is Header A header is the fitting that connects two
sed to control drafts in the furnace. Dampers are tubes in a flow pattern.
Furnaces
146
EXH18IT7·6
Pigtail Detail
EXHIBIT 7-7
Typical Radiant Coil
Header boxes Most ends of tubes are connected by on natural drafts. If the height of the Slack is increased
U-bends that make inspection difficult. Therefore, spe- to suit safety conditions, a fan must be added, If emis·
cial return fittings with plugged connections are pro- sion probes are needed in a stack, ladders aoCi plat·
vided that permit inspection and cleaning. Because the forms are added as required. .
removable plugs are subject to leal·dng, all headers
must be completely enclosed in header boxes. Snuff- Snuffing steam This is steam that is injected into the
ing steam is used to suppress fire in thiS area. combustion chambers or header box of a furnace to
suppress a fire.
Peep doors Small doors are provided in the wall or
~oor of the radiant section to permit visual inspection
Transfer line The oudet of the process tubes are tied
)f burners during stan-up or operation, imo a piping header called a transfer line, which feeds
the main process tower.
:JigtaiJs .Small-bore flexible piping configurations
·Tubes Piping within the furnace carries the medium
:onnect the radiant tubes to the inlet and outlet head-
to be heated. A typical radiant coil is shown in Exhibjt
~rs, as illustrated in Exhibit 7-6.
7-7.
ladiant section The main companment of a furnace
5 the radiant section, in which process streams are BURNERS
Icated, usuaUy in venical tubes, by heat from burners
nounted in the wal1s, roof, or floor. Furnace structure and heat-release requirements are
the determining factors in the selection of the correct
~efractory The refractory is made up of insulating burner design. Burners are fired by a wide range of
,ricks capable of withstanding high temperatures in gaseous and liquid fuels, and a variety of configura-
Jrnaces. tions are used throughout the industry. It is recom·
mended that the deSigner take fuJI advantage of all
DOt blowers SoOt blowers are mechanical devices burner data avail~bje from vendors to gain a greater
lat clean residue build-up on the exterior of the con- understanding of the operation and maintenance re-
ection tubes. They are usually furnished when oil- quirements of each design.
red burners are used. The combination oil and gas burner is shown in
Exhibit 7-8. Some of the features of this burner in-
:ack Located downstream from the convection sec- clude:
:m, the stack is designed to carry flue gases directly to
Ie atmosphere or to diven them through secondary o It i.s designed to fire horizontally or vertically.
letS to an air preheating system. Stack elevations are • Oil spillage in the radiant section cannot cause
mally established by a furnace designer to operate burner plugging.
Furmu:es
148
EXHIBIT 7-9 Maintenance Area for a Combination Oil EXHIBIT 7"10 Windproof Gas Burner
and Gas Burner
~ .:-r-
.:L --_-::f t--~~~~
7
I
I t:1 1?CE?:tz tre?t
IV£..
EXHIBIT 7~11
Sample Burner Locations
.,·f
....,
.
ems are regenerative systems and recuperative sys· tank and pump is far less complex than the regenera-
ems. tive system.
A typical regenerative system is shown in Exhibit
7-12. HOt flue gas exiting the convection section is
:livened through a duct to a heat exchanger called an GENERAL ARRANGEMENT OF
lir preheater. Incoming fresh air is heated and sent by FURNACES
I forced draft fan to the burner plenum, where it en-
ers the burner through the air register for combus- This section describes the general arrangement of var·
ion. An induced draft fan draws the flue gas through ious types of furnaces and discusses how operation
he preheater and sends the cooled gas back into the and maintenance affect furnace elevation, how to plan
Itmosphere through the stack. all necessary access, and platform requirements, asso·
A conventional recuperative (dosed-loop) system ciated equipment, and stack design. Exhibit 7-)4
5 illustrated in Exhibit 7-13. Oil is circulated through shows a typical arrangemem of a circular furnace.
he convection section tubes, heated, and scnt through
he inlet air duct, where it releases its heat. The hot air
Setting Furnace Elevation
:ten enters the burner for combustion, and the hot oil
> recirculated to a storage tank for recycling. From a The location of burners and the possible need for air
lYOut standpoint, the hot oil system with a storage preheating duCts are twO primary factors to be consid-
150
'."
EXH1B1T7·U
'l)'pical Regenerative
System
,1
~II
I
151
EXHIBIT 7·13
Conventional
Recuperative System
teUM~
L-t--:---~~~~+-- f~ al FZ.
C:::Ot L. IZE=L~~ u~,
To CoM@§j5at-J .o.ui j-
152
EXHffiIT 7-14
Typical Arrangement of a
Circular Furnace
t'fj-..
~-11
- +-+-.f--I.-";""-«=J:l
~~~Ym~~77/,~~e
.E:.LE.VATIO"J
ered when the elevation of a furnace is established. If, valves is on the firing platform at the peep doors, not
as shown in Exhibit 7-15, the burners are floor beneath the furnace. When wall~mounted burners are
mounted, the elevation should be set high enough to used, the elevation of the furnace can be lower be-
allow an operator to walk freely under the furnace or cause there are no major maintenance or operational
dUeling but not necessarily under all the burner requirements beneath the furnace to be addressed.
piping. Access for operation and maintenance is a major
The preferred location of the burner operating consideration in the development of a furnace layout.
EXHm1T7·15
Setting a Furnace
Elevation
Access requirements are reviewed for tube removal, tube removal in a circular furnace is accomplished by
soot blowers, damper control, header boxes, burners, pulling the tubes through an access door located in
and burner management skids and control panels. the tOp of the radiant section. This is performed by
Because furnace tubes must be periodically re- using a hoist attached to the circular trolley beam on
placed, clear areas are provided directly in line with top of the stack. Once the tubes are lifted out of the
the tubes. The removal mechanism may be a trolley radiant compartment, they are pulled away from the
beam located on the stack of a circular furnace, a furnace and lowered to grade. The convection section
a
crane, or cherry picker. If only one or two tubes tubes are removed in a manner similar to the one
require removal, a tube extractor, similar to the type shown for the box-type furnace in Exhibit 7-17. Here
used for extracting shell and tube exchanger bundles, again, the access area must allow the tubes to be
may be used. As can be seen in Exhibit 7-16, radiant pulled clear of the furnace, permitting the crane to
Furnaces
154
• EXHIBIT 7~16
Radiant Tube Removal in
a Circular Furnace
f'r~---
155
2 I
EXHIBIT 7·17
Convection Section Tube
Removal in a Box-Type
Furnace
'1'1
't
\
Jl
156
1 EXHIBIT 7 IS
M
Damper Mechanism
EXHIBIT 7·19
Header Box Detail
-IE~ J-------'"*""-
.,'
FUnul.ces
158
EXHIBIT 7·22
Circular Furnace Platform
Requirements
·r
.'
EXHIBIT 7·23
Miscellaneous Platform
Requirements for a
Circular Furnace
from any other large piece of equipment that needs A circular furnace platform layout is shown in Ex-
operator and maintenance attention. Because each hibit 7-22. The firing platform, which is usually a full
heater is designed to meet specific process needs, may 3600 circle, can be reached by a variety of stairway
fire with different fuels and require air preheating or configurations and ladders, as illustrated on the lower
soot blowers, and is ~ubjeet to client needs, each de- plan in this exhibit. Each scheme shown may be set to
sign should be approached as a unique layout, follow- accommodate the layout as reqUired. Stairway varia-
ing basic guidelines. tions shown here are:
II Stairway A-Perpendicular, which can be set to ei- form and viewed from the peep door on the end wall.
ther side of the landing. The floor-mounted burners can be operated from
'" Stairway B-Radial. grade at the edge of the furnace or from an optional
II Stairway C-Tangential.
lower firing platform. Additional platforming is re-
qUired for access to draft gauges, peep doors, and the
Access to all other platforms on this type of furnace is convection section. Because the primary operator
by ladder, indicated on the exhibit as fol1ows: level is at the burners, stairways are used for access
and ladders are provided for all other levels.
'" Ladders 0 and E-Limited to a 30-ft (9150-mm) max-
A reformer furnace, shown in Exhibit 7·25, has a
imum ladder run per Occupational Safety and Health
penthouse and roof-mounted burners. In addition to
Administration (OSHA). An intermediate platform is
platforms and a stairway for regular maintenance and
required.
operation, ladders are proVided in case of an emer·
II Ladder F-Enables plant personnel to gain access to
gency. Other platforms are for access to peep doors,
both sides of the upper furnace by the convection draft gauges, and piping, as required.
section platform.
Additional platform requirements-for example,
Auxiliary Equipment
for access to soot blowers or interconnecting plat~
forms between groups of similar heaters-are shown A SOOt blower mechanically cleans soot build-up on
in Exhibit 7-23. Catwalks are planned for the firing convection section tubes in fuel-oil-fired heaters. A
platform and tOp of the radiant section for operator SOOt blower essentially consists of a lance (j.e., pipe)
convenience. with nozzles specifically located for the tube section to
Apyrolysis furnace, shown in Exhibit 7-24, has both be cleaned and a connection for the blowing medium,
wall- and floor-mounted burners. The wall-mounted which is steam or air. There are two types of blowers:
burner piping can be operated from the firing plat- fixed and retractable.
160
II
EXHIBIT 7-2S
Reformer Furnace
Platforms
EXHmlT7-26
Fixed Soot Blower
5!X1eii ~
~"~/?'fEAM I~~
EXHIBIT 7-28
1
Soot Blower in Operation
1 ..._F
r-""'l- - 1--
p _
I 1-,
A fixed soot blower, shown in Exhibit 7·26, is in Exhibit 7-29. Platforms designed specifically for
mounted directly on the convection section wall and is each fan configuration should be adequate for mainte-
hard-piped as shown. A retractable soot blower, illus- nance and operation of the drive and fan mechanism.
trated in Exhibit 7·27, allows the lance to be removed Exhibit 7·30 shows a typical arrangement of a sin-
from the convection section during operation. Some gle-zone pyrolySis furnace wIth an integral waste heat
of the principal components are the support channel, system, which requires a steam drum and a heat ex-
the gear·driven carriage, the poppet valve (used to changer (often called a transfer line exchanger). Be-
control the flow of the cleaning medium), and the . cause the preheater and ducting on an average-sized
lance with nozzles. Exhibit 7-28 depicts a soot blower combustion air preheating system are somewhat large,
in operation. As the lance enters the heater. the blow- the plant layout designer should pay extra attention. to
ing medium cuts a path through the deposits until the the amount of space that is finally used for this equip-
lance reaches its apex. The lance then reverses rota· ment, After enough room is allotted for maintenance
tion and is indexed so that on the retraction path it and operation of the forced and induced draft fans and
cleans surfaces not covered on insenion. The reversed blowers, the distance from the outer edge of the pre·
rotation and indexing allow the soot blower to peel heater to the centerline of the furnace should be kept
md strip all deposits efficiently and with less chance of to a minimum, as shown in Exhibit 7-31.
ileater tube erosion. Whenever furnaces are arranged in groups on a
An induced draft fan may be reqUired for furnace plot plan, the plant layout designer should consider
)peration, as shown on top of the convection section USing a common stack, as depicted in Exhibit 7-32.
FunUICes
162
EXHIBIT 7·29
Induced Draft Fan
EXHIBIT 7·30
Steam Drum and Transfer
line Exchanger
163
EXHIBIT 7·31
Combustion Air
Preheating System
EXHIBIT 7·32
Common Stack {or
Multiple Furnaces
164
jill
EXHIBIT 7·33
Piping and
Instrumentation Diagram
for a Circular Furnace
@> ~6/)U6!:
@~~
® +"f"=AM 11ZAP
t:;;;.. ~sze
~~=
III
165
EXmBIT7~34
Piping and
Instrumentation Diagram
for a Combination Burner
ODD
Fo·'2.?c:>·~1
II
F~~J2-'l" Ij
:'
F<Sl.-ZOI~~~ .
-TO ,",l-ACZC:-
Economic constraints usually determine the feasibility convection section. The furnace plan and elevation for
of this design feature; all furnace configurations can the upper level of thiS furnace are shown in Exhibits
use this breeching concept. 7-35 and 7-36, respectively. The stack shown in Exhibit
7-36 is equipped with a trolley beam (an optional fea-
ture) that pulls the radiant tube bundles during main-
PIPING lAYOUT FOR A FURNACE
tenance. The need for platforms depends on the in-
strument requirements. The damper selting is
This section details the piping layout of circular and
regulated from grade by a cable-operated mechanism
box-type furnaces. Although such special features as
supplied by the furnace vendor. .
snuffing steam are actually required for both heaters,
In the convection section, three stationary soot
they are explained for one application only.
blowers are fed by l.5·in leads from the fire steam
header located below them. This piping is kept close
Circular Furnace Piping
to the convection section wall to maximize the avail·
Exhibits 7·33 and 7·34 present simplified piping and able work area for plant personnel. The four 3·in
instrumentation diagrams for a circular furnace. The product inlet lines have manual control valves and
furnace has 6·in inlet and outlet lines, with control local flow indicators that must be visible when person·
valves, combination burners, and soot blowers in the nel are operating the valves. They are located at the
Furnaces
166
EXHm1T7~35
Plan for the Upper Level
of a Circular Furnace
TU~4
tl~AW~
1if!uEe!~
F~1-Z!?~-!L---~7H-+Yl
_ _~....l
167
EXHIBIT 7-36
Furnace ElevatiOn for the
Upper I.evel of a Circular
Furnace
1*l.1·~
VAI.VE-e-
Y"'Lve~:-:
,.I-1-L-~..&.U.I.Il_--I-_41.~~~
168
EXHIBIT 7-37
Lower PIan for a Circular
Fumace
''''''~ ~ f~
$k~
\XlAI tJ Hut> "'"
HE'AOE:l2 ~ t't?AIt-J
~Il..c>r GlNll>
l--I"UIl:t-~
----",IZE:~
p~uer DUTL.e:T
. . - - - - - - - - - - f I J S L . c:olL
upper platform for economic reasons-placing them port when praCtical, as shown in Exhibit 7-38.
at grade would require running four individual lines Snuffing steam, which is used to suppress a fire in
up the entire furnace. The snuffing steam lines are the header box in the convection or radiant sections,
grouped together for common support until they is supplied through local and remote manifolds. The
reach the tOP of the radiant section. The line to the remote manifold shoulA be no closer than SO ft
header box on the opposite side is run radially around (15,000 mm) from the furnace. In Exhibit 7-37, the
the heater. Bending smallll.nes is generally not a prob· local manifold is located at grade, next to the interme-
lem and saves fittings and welds. Platforms are de- diate pipe support column. If the local area is unreach·
signed to permit plant operations and maintenance able in an emergency, steam would be supplied from
personnel dear access to aU valves, instruments, and the remote manifold. The inlet and outlet control sta"
soot blow~rs, dons are located along the pipe rack adjacent to the
The lower level of the circular furnace is shown in furnace. This particular furnace uses manually con-
Exhibits 7-37 through 7-39. In the radiant section, all trolled valves for each burner. The burner supply
piping should be grouped together for common sup- headers-fuel gas, fire steam, and fuel oil-are run
EXHIBIT 7·39
Burner Piping Detail
t~ FUi:L ~~ - - - -
;Iz~9\eAM----.......-l1-roJ
~ II FUa. 0' L ---I-...;..a....I
Funuaces
170
EXHIBIT 7-40
Piping and
@-- Instmmentation Diagram
for a Box-Type Furnace
---e9
radially over one another to keep the ladder close to should have a drip leg to remove any condensate
the furnace wall. This positioning also allows the indi- . build-up by piping it to the flare system. The fire steam
vidual burner piping leads to run adjacent to me peep line that atomizes steam must be run and insulated
doors, creating access to the valves during operation, with the fuel oil line to decrease oil Viscosity. Atomiz-
as shown in Exhibit 7·39. The pHO[ gas valve is located ing steam is injected into the burner with the fuel oil
below the furnace, providing operator access during to obtain effective combustion.
ignition. It should be noted that although most new The header-box drain must have a seal loop and
furnace installations use burner management systems, clean-mit plug for inspection just above the drain hub
this design approach is acceptable if manual control (see Exhibit 7-37). Removal of this plug permits in-
and ignition is required. spection for small leaks in the tube headers in the
The fueloH, fuel gas, and pilot gas control valves header box.
are located at the pipe rack. The fuel gas is run sym- The 360" firing platform allows full access around
metrically to provide an even gas flow to each burner. the radiant section to the burner valves (at the peep
This system must be kept dry by the elimination of low doors) and instruments. The intermediate platform is
points where condensate may collect. The header furnished to meet OSHA reqUirements, which state
f
,<
that any single ladder run must not exceed 30 ft (9,150 is set for regular operation. With the swing ell bolted
moo). The plant layout designer must ensure that tube to the steam and air line, the tube cleaning' process
removal areas remain clear of any obstruction. may begin. Each coil is drained and blown out with
steam. Header plugs are removed-the removable
header-box panels are illustrated in Exhibit 7-43. A
Box-Type Furnace Piping
cleaning tool is used to remove coke deposits from
Exhibit 7-40 is a sample piping and instrumentation the inner wall of each tube. Once this iscomplelcd,
diagram for a box-type furnace. This heater has 6-io the plugs are replaced and the burners are fired.
product inlet and ourlet leads, a swing ell used for Steam Is introduced to remove any remaining coke
decoking, a convection steam coil, and a burner mao- deposits. The steam flow rate must be suffiCient to
agement system. Exhibit 7-41 pfOvides an overall view prevent overheating of the tube walls; air is then
of the furnace in this example and indicates the major added to burn off any remaining coke depOSits. Steam
parts of me furnace. and air discharge to the stack above the damper
Exhibit 7-42 shows the decoking operation. Product through the vent line. Stearn is introduced one final
inlet line A is shown in the decoking mode, and inlet B time to flush the tubes clean. All decoking flows are
172
EXHmIT743
Product Outlet and
Decoking Piping
,r
Furnaces
EXHIBIT 7-44
Convection section
Steam Piping with
Miscellaneous StruCtural
Details
EXHIBIT 7-45
Piping and
Instrumentation Diagram
for a Burner Management
Skid
T r
_ _ _ _ _ .J I I I
_ _ _ _ _ _ ...J
_______==-J
downflow operations, except the vent line to the stack Exhibit 7·43 also shows the product oudet line and
The swing ell is pOSitioned to be accessible to mainte- its decoking hook-up. Line A is set up in its usual
nance personnel. The steam and air manual comrol operation configuration; line B is set in the decoking
valves and their local flow indicators must be located mode. As the steam and air are blown through the
at the peep doors to allow the tubes to be Viewed radiant tubes, any waste is carried to the sewer or, if
during this operation because overheating can cause preferred, to a drum for removal. The vent line is run
damage to furnace tubes. to the stack. Once again, the plant layout designer
~ ~
EXHIBIT 7-46
£i Burner Piping
i, JJ.J i,
~
-'t'
t:'UI2t-Je-tZ ~~'P
~loN"A-A'
"~
flJEt. ~ L,we;:
must avoid blocking access to the header boxes when hazard to plant operations and maintenance person-
developing the piping layout in this area of the nel. The structural feature highlighted here is the ab-
furnace. sence of handrails to permit access to the decoking
piping. The plant layout designer must notify the fur-
nace vendor of this requirement on a mark-up of the
Convection Section Piping platform arrangement drawing,
Exhibit 7-44 illustrates the convection section steam
coil piping along with some miscellaneous structural
Bumer Management System Piping
details. The steam inlet line can be run horizontally to
the inlet nozzles because the elevation is above head- Exhibit 7-45 is a sample piping and instrumentation
room. The superheated steam outlet piping can be diagram of a burner management system supplied by
routed below the platform so that it will not pose a the burner vendor. The engineering contractor sup-
176 m
EXHIBIT 1-41 Transfer Line Layout EXHmlT 148 Stcam-Generation Thermosiphon Circuit
, !, I I,
L-l-l-.~~-
&NO vieW
convection section, exits the coil into the crossover TAIL GAS INCINERATOR AND
piping, and then enters the radiant tubes through the WASTE HEAT UNIT
top of the heater~ The heated product outlet from the
two rows of radiant tubes enters the transfer line ex- Waste gases containing liquids that must be disposed
changer from the bonom, transferring its excess heat of and that for environmental or safety reasons canner
energy to the steam piping, and exits at the top of the be directed to the flare system arc burned in a tail gas
exchanger. incinerator, shown in Exhibit 7·50. The horizontal in·
Furnaces
178
Sf
EXHIBIT 7-50
Tail Gas Incinerator
cinerator is bolted directly to the stack. The waste continued heat source for steam generation. Because
product enters the top inlet and is disposed of by a the physical makeup of these waste heat units varies in
burner firing directly imo the chamber. Piping usually size and overall configuration, a derailed pipip.g layout
associated with this equipment includes fuel gas, pilot is not shown.
gas, steam, nitrogen, and a liquid drain outlet located Because the configuration of equipment and associ·
in the stack. ated items covered in this chapter may vary signifi-
The waste heat recovery unit, illustrated in Exhibit cantly among vendors, the plant layout designer
0 0
7.51, uses the waste gases of 800 to 1,200 F (425 to
0
should study the principles outlined and adjust each
650 C) from a gas turbine to generate high. and low-
0 layout accordingly. Consideration for maintenance,
pressure steam for plant use. As can be seen in this operation, safety, and economics, as well as the use of
exhibit, duct burners located in the inlet of this unit common sense, resu){s in an effective overall furnace
can be used if the turbine is shut down, providing' a design.
,~
,>
I:!I6H-ffle.=::6U~S if.~161;l~ge
l}oell..G:fZ. ~
Funuu:es
CHAPTER
Pumps
This chapter highlights the types of pumps commonly reqUired. Dimensions of nozzle locations or baseplate
found in industrial plants, along with maintenance and sizes may change slightly, but revisions to phYSical
operation considerations for a cenrrifugal pump pip- nozzle locations (i.e., from (OP to side or side to front)
ing layour. do not usually occur when the data is finalized. Work·
Exhibit 8·1 shows :m electric motor-driven hori· ing dosely with the eqUipment and system engineers
zontal pump that is familiar to plant layout designers. acquaints the principal parties with the exact design
The two primary piping connenions are the suction conditions and minin1izes rework.
and discharge nozzles (i.e., liqUid inlet and outlet).
The impellttr within the pump case draws the liquid ,r
into the pump and sends it out at a high velocity. The PUMP TERMINOLOGY
impeller shaft is sealed with a Sluffing box where the
shaft exits the case lO prevent the pump fluid from This section highlights some of the most common
leaking. Drips from wearing seals are picked up in the terms that the plam layout designer encounterS wh~n
SlUffing hox drain. The pump shan is connected to the creating a pump layout.
drive shaft by a coupling, which is enclosed within
protective housing. Both pump and driver are Allowable nozzle loading The allow'lble nozzle
mounted on a common baseplate. Miscellaneous loading is the maximum amount of stress thm the pip-
pump leaks that collect within the baseplme during ing configuration may impose on the pump suction
operation are drained through a connection at the and discharge no:r.zles, as set by rhe vendor, client, Of
from of the pump. code. The pipe stress engineer is respollsible for
Pump size and configuration vary for the folloWing working within this tolerance by coordinating the pip-
reasons: ing design early in a project and rechecking all calcula-
tions before formal fabrication L'iSUeS of piping dmw-
.. The commodity being pumped. ings are made.
.. The viscosity of the liquid.
.. Capacity. Net positive suction head NPSH is one of rhe most
important terms a plant layout designer needs to un-
.. Pressure.
derstand when developing an eqUipment layout thm
.. Temperature. includes pumps and vessels. The reqUired nel positive
.. Available head requirements. suction head is a measure of the pressure drop of the
.. Physical limitations. liquid as it moves from the inlet of the pump to the
eye of the impeller. It is a dluraCleristic of the pump
Initial pump piping layouts are done with prelimi- (hat is generally determined by testing and is ex-
nary information. The eqUipment engineer supplies pressed in "feet of water" by the pump manufacturer.
the plant layout designer with a catalog cut of the
pump that most closely represents the one to he pur- Vapor pressure When the pressure in the pump suc-
chased. In many cases. this data does not change sig- tion line falls below the vapor pressure of a liquid, the
nlfiC',mtly if the engineer has made the correct selec- liqUid flashes, or changes to V'Jpor. Becuuse no ordi-
tion. Piping layouts are started early ill the study phase; nary liquid pump C'JI1 pump only vapor; liqUid flow to
when the certified vendor dwwings become llvailable the pump falls off and the unit is said to be vapor
later in the project, minor adjustments are made as bound.
181
182
EXHIBIT 8-1
Centrifugal Pump
4?k!pl..INei! 4tUAlZ'2
'\
~~l.Are ~l-J
b1 Uff:I!:k2 ee)( !?CZAI tJ
Available net positive suction head The availablt: vice" is used to specify pumps f()r purchase. To a plant
NPSH is the net prc:ssure :Jvailable in a given system, layout designer, an API pump is a large, refinery-type
based on vessel pressure and static head, minus the pump.
liquid vapor pressure and functional losses in the sys-.
tern. The goal is to maintain equipment heights and AVS (American Voluntary Standard) pumps This
minimi:le pump suction piping to ensure that the standard, issued by the Hydraulic In:>tftute, outlines
available NPSH is greater than the required NPSH. In- several pumps with standard dimensions. They are in-
sufficient NPSH can reduce pump capacity and effi- terchangeable for a given size, regardless of who
ciency and lead ro cavitation damage. builds the pump, with no effect on foundation, piping
design, or type of electric motor used.
Cavitation The rapid collapse of vapor hubbies that
can produce noise, result in a loss of head and capac-
ity, and create a severe erosion of the impeller and NPSH REQUIREMENTS
<.:a.c;ing surfaces in the adjacent inlet areas.
An example of how to deal with a typical NPSH prob-
API (American Petroleum Institute) pumps This lem is shown in Exhibit 8-2. The reqUired NPSH in this
term refers to the horizontal, single-stage pumps example is 22 ft (6,700 mm). If a horizontal pump is
found in the petroleum industry. The standard devel· used, the bonom tangent line of vessel A must be a
oped by vendors, comractors, and users entitled "API-- minimum of 22 ft (6,700 mm) above the centerline
610-Centrifugal Pumps for General Refinery Ser- elevation of the shaft. If a vertical pump is used, the
181.
...-
..... _.. ~
EXHIBIT 8·2
NPSH Example
vessel B tangent line is located closer to grade heGllIse temperature. They are usually driven by electric mo-
NIJSH is calculated from the bottom impeller of the tors or steam turhines. They may he single stage or
pump located below grade. Although venical pumps multistage, depending on pressure requirements in
require less of a vessel support structure ~lIld possihly the system, and can be horizontal or vertiC'<i1. Centrifu-
less piping, they are more expensive to huy and main- gal pumps, unlike reciprocating and rotary pumps, op-
win. Therefore, a horizontal pump applicmion is tl erate at constant speed and· can deliver any C'Jpacity
more desirable solution in this instance. Venical from zero to maximum, depending on the head de-
pumps are better used to draw suction from large sign and suction conditions. Exhibit 8-3 depicts some
surface coodensors that service large compressors. of the more common variations of centrifugal pumps.
Pumps
184
EXHIBIT 8-3 Examples of Centrifugal Pumps
EXHIBIT 8-5
Examples of Rotary
Pumps
Rotary Pumps the length of the suction piping while satjs~'il1g the
piping fleXibility requirements as well as allowable
These pumps are generally ulled for viscous liquids
loads that may be subjected to the nozzles. Exhihit ~·6
that are free of hard and abrasive solids. Rotary pumps
de~lIs with pumps along and under main pipe racks m
push the liquid within the casing by gears, vanes, and
various IOC"Jtions. Exhibit 8-7 dispbys the typical pump
cams. The liquid is then discharged in a smooth !low,
elevations.
unlike With the reciprocating pump. These pumps ~tn.:
In Exhihit 8·6, pumps lA, lB. 2A, ,I\)d 213 ~tre located
also characterized by the absence of suction w1d dis-
under [he main overhead pipe rack. This is a common
charge valves. One :tdvanwge of rotary pumps is their
locmion within m:my plants with a minimal powntial
ability (0 send out :l constant volume ag,tinsr V".triahle
for hydrocarbon leaks to the electric motors. (Hydro-
discharge pressures. Some variations of rmary pump
carbon-bearing air coolers located over pipe r'lcks arc
design are illustrmed in Exhibit 8-5.
a concern for many diems.) This location provides an
effective means for ~ldding support steel from the pipe
rack.
PUMP LOCATIONS Pumps 3A, 38, 4A, and 413 are partiaJly locmed UIl-
der the pipe rack, with the c'L<;ing set outside the
The location of pumps may vary for many reasons. The c(-}Iumn line. In tllis ar.mngemem, the (.lisch~IQ~e piping
primary goal in setting pump location is to minimize can rise imo the vertical l'ilm that is usu:tlly proVided
Pumps
186
F
EXHIBIT 8·6
Typical Pump Locations:
Plan
EXHIBITS-7
Typical Pump Locations:
Elevation
for lines entering or leaving the pipe rack, as shown in ported in the structure above. Drums and shell and
Exhibit 8-8. tube exchangers are less associated with dangerous
Pumps SA, 5B, 6A, and 6B in Exhibit 8·6 are located spills and therefore may have pumps loc-.ned directly
outside the confines of the pipe rack. This is the usual beneath them. Supporting pump piping is also facili-
arrangement when hydrocarbon spills are more likely. tated by the proximity of the steel.
Pumps 7A, 78, 8A, and 88 are located directly under Pumps 9A, B, and C and lOA, H, and Care inline and
the process equipment that they serve, which is sup- are treated basically as a piping item (e.g., a control
j
&
187
EXHIBIT 8·8 Pump Discharge Location EXHIBIT 8·9 Vertical Condensate Pump
EXIIIBIT 8·10
Sump Pump
v-.alve). Adequate access must he planned to the pump shows a typical condensate pump that is located adja-
and drive, which may be removed for maintenance. cent to the surface condenser it serves.
Exhibit 8-10 depicts a sump pump that is generally
used to remove waste material collected in a concrete
Locating Boiler Feed Pumps or steel pit A screen at the bottom of the pump suc-
Because boiler feed pumps take water from a deaera- tion connection reduces the possibility that the pump
tor and generally operate dose to the vapor pressure will foul during operation. The discharge connection
of the liquid, they must be located as dose to the may be piped to another holding vessel, a pond, or a
deaerator as possible. waste-removal vehicle.
Centrifugal pumps in vacuum service are shown in
Exhibit 8-11. Because the system operates at a negative
locating Vertical Pumps
pressure and extremely high temperatures, the loca-
Vertical pumps are used when NPSH requirements tion of these pumps must be either directly under the
make using horizontal pumps impractical. Exhibit 8·9 tower or JUSt outside the support columns. When [he
188
t:tf.'l2l::; -~utJTeD . EXHmIT8·11
Centrifugal Pumps in
1lOflr. $fUU}y1TOWE:12 Vacuum Service
_--""t---.!
EXIIIBIT., 8·12
Spring-Mounted Pump
pumps are located directly under the tower, it may be in most of the exhibits, the arrangements are typical
necessary to support the pumps with springs, as for all types O{, pump applications. Exhibit 8·13 illus-
shown in Exhibit 8-12. This essentially consists of a trates the components that are usually foulld in pump
st{."el frame with four spring supports attached to the suction and discharge piping.
sides. The pump is then set into the steel frame and The suction line has a positive shut·offvalvc; in this
secured. During operation, the pump is free to move example, it is a gate valve. The temporary tee-type
within the design limits ()f the four springs, reducing strainer (shown in Exhibit 8-14) catches any foreign
the stress imposed on the nozzles by high tempera- matter that may have collected in the piping during
tures. construction. After the suction and discharge valves
have been shut off, the blind flange is unbolted and
put aside and the strainer is pulled out. This strainer i:i
PUMP PIPING generally used only for start-up. Exhibit 8-15 shows <l
basket strainer that may aL'lo be used in a pump suc-
This section highlights some common pump piping tion line.
configurations. Although horizontal pumps are shown Although thi,; particular strainer does not need ad-
/
189
• u
EXHWIT8-13
Components of a Typical
~mp Suction and
Discharge Piping System
""'''''''''' "'ZOolN_N~>/
~~"
EXHIBIT 8-14
Typical Temporaty
Tee-Type Strainer
EXHIBIT 8-1S
Typical Basket Strainer
~N9'< \.'
190
ddl
ditional fittings for its removal and c::le-Jning if rew,ed,
EXHIBIT 8-16 Eccentric Reducers it does require additional maintenance becau5c of the
downstream !lange,.; of (he valve. The pump l1oz:de
and possibly the base support under the elbow must
be unbolted to pull the spool piece and remove the:
str;liner. The next common litting is a reducer; this
should he an l:ccenlric type as shown in Exhibit 8-16.
with the tIm side on top 10 reduce the possibili[)' of
cavitation in the pump.
EXHIBIT 8-18
Standardi:lcd Pump
blyOlit
flexibility loop thm w<IS ha~ed on a 3-in line operating project. If the pumps in the designer's area fell into the
at 2300 F. Thi~ layout was duplicated for 76 pairs of 3·in, 2300 F operating temperature category, the design
pumps, or 152 total. Although the piping as designed was copied exactly. The 152 pumps were designed
'Was conservative and slightly more costly for the II/l- and supported once and in an identical manner.
in and 2-in pumps, engineering, fahrication, and con- Uniformity of design in piping, supports, and steel
struction time could be reduced through standardiza- were the result'i of thinking ahead. This is what a client
tion. A fullv dimensioned sketch of this particular pays for when hiring an engineering contractor.
standard d~sign was given to each designer on the Spending more on engineering may reduce construe-
192 u
IE
EXHIBIT 8.19 Maintenance and Operational Access EXHIBIT 8·21 Block Valve Handwheel Elevations
Requirements
T
:rI
I
I a. Preferred b. Alternative
I Arrangement Arrangement
I
I
r ..
I tion COSts, or sp<mding morc on materi'lls may save
1,.JooI.-l-...IooA,
hoth engineering and construction costs. A pump lay-
out should he viewed not on ,ll) item-by-iwm basis but
as a whole area. Exhibit 8·18 shows an example of a
st:ll1dardized pump layout. The designer must also be
aware of all operation and maimen<U1l'C concerns with
all pump hlyouts. Maimen.lI1ce and operational access
EXHIBIT 8·20 Primary and Standby Pump Arrangement needs are iIIustraK..u in Exhihit H-19.
When developing an equipment ammgcment ill
pllmp areas, the layout designer must envision poten-
thll ohstruction:-; around the pumps (e.g., large hlock
valves, steam turhine piping, :md tce-Type pipe sup-
ports from grade). Four feel (1,200 mill) is a genemlly
accepted distance between pumps or :tssocimed
piping.
When expansion loops are reqt,ired between
pumps, it is necessary to p<lrtinlly run the lines over
the pump ::md driver. Every effort must he 11l::lde to
minimize maintenance obstructions by running rhe
piping either outside the -area directly over the pumps,
or at:t high enough elevation to permit the remov::11 of
the pump or driver.
Orientmion of block valves must minimize the plm
area required. Elevation of the v<llve:-; should gencr:llly
be m; low as possible and common in both lines when
praclkal.
EXHIBIT 8·25 Primary and Standby Pump with EXHIBIT 8·26 Spool Piece Removal
Below·Grade: Suction
EXHIBIT 8-27
Be>i1er Feed Pumps
distributes the liquid evenly because the flow is com- steam condensate into the turbine case, which could
ing in perpendicular to the impeller. Exhibit 8·29 dis- damage the blades. A typical turbine arrangement is
plays this configuration for a centrifugal pump. shown in Exhibit 8-30.
The steam supply comes off (he top of the supply
header and reduces condensate carry-over into the
Steam Turbine Piping
turbine. The block valve isolates the turbine when it is
Arrangements not in use. A drip leg is prOVided at the low point of
When a steam turbine piping arrangement is being the system to remove any condensate. A control valve
developed, it is important to avoid the introduction of is placed adjacent to the turbine. The steam exhaust
196
jj
EXHIBIT 8-28
CO2 Medium Pumps
'. • MUJIMUk! H ~
.I
Process PlanllAlJO'" and Piping D~
197
EXHIBIT 8·29
Side-Suction Nm:zks Oil a
Centrifugal Pump
Pumps
198
EXHWIT8..30
::. ~-:--. ~tJ Nt? ~ Typical Steam Turbine
. ~-f<l"4?H e:= Piping Arrangement .
~~M~~
w--- ..
~L vALve-----I1--'
EXHIBIT 8..31
Improper Valve and
Steam Trap Location
line block vaJ"e is provided fDr isolation. A rdicf valve and may he: run to rhe pump support pedestal for
is also pnwitkd as :J protection <.levin? should the c;\- high-temperature services.
h~ltJSl valve be: dosed before culting off the steam sup- PLlnlp vendors usually ~upply [he auxiliary piping
ply. This line must vent to a safe location away from to the Inechanical ~eals through a harness. When
plant personnel. Additional consideration mUSf be pump fluid is used, a lin~ is attached to the vent con-
given to ;lCces.'i to the turhine for mail1len~tnce or in+ nection on the pump case. The circulated seal fluid
spe<:tion of lube oil connections, packing gl~U1dsl and must he senc hack to the pump strean1 Of returned
{he governor. through the seal to pump internal dearance~. In vis~
Exhibit 8·31 shows an improper steam supply line cous or high-temperature hydrocarbon liqUids, the
arr~ngemem; the ~[eam trap <Joes not come off the low seal fluid medium circulates from an external source
point in (he system. The condensate that builds up through connections on the pump seal. This medium
aho\'c the block valve enters the turbine when [he may he a dean ga:-; oil. In all cases of auxiliary PUhlP
valve is opened, damaging the hh.lues. This configura- piping, the plant layout designer must carefully review
tion must be avoided. the vendor drawing and piping and instrumentation
Remova.l of condensate at multistage turhines is an- diagram:') to ensure that all requiremems for cooling
other serious concern because if the water :-)Jugs, the or seal~ have been covered hy one of these docu-
thrust hearings can fail. A typical method of safely reo ments. Exhibit 8~33 shows a typical auxiliary pump
moving excess condensate without endangering the piping arrangement. The cooling water in and out of
operator who drains the line is shown in Exhihit 8·32. this particular punlp is from above grade; however)
A temperature indicator, which is visible from the many cooling water systems are helow grade, and the
blowdown valve, indicates the presence of water in plant layout designer must find 4J suitable location for
the sys«:~rn. Opening the valve releases the hot con- this connection.
densate into the exhaust stack The hot steam can then
Vent safely overhead, and the condensate is dumped to
grade or direcEly to a drain system. PUMP PIPING SUPPORTS
A plant layout designer must have some basic knowl-
Auxiliary Pump Piping Arrangements
edge of stress and pipe supports to generate a sound
Many pumps have auxiliary piping that is supplied by pump piping arrangement that will not be radically
the vendor or the engineering contractor. This piping redesigned by a stress/$uppon engineer. Some simple
delivers cooling water [0 mechanical seals, bearings, rules, if followed) enable the designer to satisfy two of
Stuffing boxes, gland quench, and lantern ring flush the most important considerations illustrated in Ex~
Pumps
"200
EXHIBIT 8-33
Auxiliary Pump Piping
hibit 8·34: supporting the suction line under the eJ· diameters of that elbow. Pump nozzle loading falls
bow and supporting the discharge line within five di- under (he APl"610 code. There are two ways of sup-
ameters of [he top elbow. porting the discharge Hne. One is to sit the spring
The suction line is commonly supported under the suPPOrt on the steel with a rod hanger and clamp; the
elbow adjacent to the pump nozzle. This may be a other version is to place a base spring on the steel with
hard support (Le., pipe or a structural steel member), the discharge line resting directly on the load flange of
adjustable type, or spring support for high-tempera- the spring. Because rhehanger rod could pose a dan-
ture pumps. If pumps are located in POOf soil areas or' ger during a fire, each project should be reviewed for
where differential settlement may occur, extending such concerns. Loading on steam turbine nozzles falls
(he pump block foundation may be necessary to pick under the NEl\1A-SM-21 code, which is different from
up the base support The stress/support en~ineer and the allowable nozzle loads on pumps.
civil engineer need to be part of this decision. Inlioe pumps do not require a direct support hut
The discharge line should be supported as dose to are held in place by the suction and discharge line
the top elhow as possible and should be within five supports) as shown in Exhibit 8-35.
i
Process Plant lAyout and PIping Design
201
EXHWIT 8·34
Typical Pump and
Turbine Support
Considerations
.,.J'
EXHIBIT 8-35
TypicallnIine Pump
Support
"
Pumps
CHAPTER
Reactors
Reactors are used in processing facilities to conwin • Some of the nitrogen is converted to ammonia.
cawlysts that promote chemical transformation of • Any metals entrained in the oil are deposited on the
feeds or as agems to remove unrequired materials catalyst.
from feeds. Reactors are genemJly vertical steel hollow • Some of the olefins. aromatics, and naphthenes be-
vessels and often operme under very high tempera- come hydrogen saturated and some cracking wkes
tures and pressures. One of the principal layout fea-
place, Glusing the formation of but~mes, propane.
tures of the reactor is rhe requirement for cawlyst and lighter gases, Exhihit 9-2 shows a typical hydro.
loading and unloading. Tile use of catalyst·ch~lrged treater process arrangement,
vessels are essemial to modern processes and have T
found wide:;pread applicmiol1 in the production of .'
DESIGN CONSIDERA1·IONS
PROCESS OPERATION FOR REACTORS
There are many catalyst-charged vessels within the Glt- Although some reactors (e.g., those used in methanol
egoty of reactors, mainly because their chawcteristics and catalytiC: reforming units) are spherica!, most are
and layout requirements are similar, Examples ,of vertically mounted vessels with elliptical heads. There
chese are desulfurizers, methanators, and guard cham· are fewer connections for the plant layout designer to
hers. The desuJfurizer, which usually operates with a he concerned with than there are with the distillation
twin vessel, is responsible for che removal of sulfur tower. Generally, connections are limited to inlet and
from feedstock by absorbing the sulfur on the inter- outlet. maintenance access, unloading, sample, and
nally loaded catalyst When rhe catalyst hecomes satu- temperature, Internally. reactors are furnished with
rated with sulfur, regeneration takes place and the bed supports, screens, inlet baffles, outlet collectors,
spent catalySt becomes refurbished. Exhibit 9-1 shows catalysts, and inert materials, Exhibit 9-3 depicts a typi-
a typical desulfurizer process arran~ement. cal reactor and its principal components,
The reactor used in a typical hydrotremer unit is Nozzle requiremems and overaU dimensions of. the
more versatile. In the hydrotreating process, the reactor are highlighted on the process vessel sketch
treated stream is mixed with hydrogen and he-.lted to furnished by process engineering and are included in
between 500° and 8000 F (260° to 427" C). The hydro- the process release package, If the reactor operates in
gen-oj) mixture is then charged to a reactor filled with a high-pressure service, it is recommended, for dear-
a pelJeted catalyst, and the follOWing reactiOns take ance purposes, that the piam layout designer obtain
place: the shell thickness of the vessel before proceeding
with layout arrangements. Exhibit 9-4 shows a typical
• The hydrogen combines with sulfur to form hydro· reactor process vessel sketch, and Exhibit 9-5 shows a
gen sulfide. high·pressure reactor.
203
204
EXHm1T9·1
Desulfurizer Process
I
I
I
I I I
L...J.J
It-JDuc:.E:O
PIl!"I='T
~
FIIle.O GrIZAoTII:J(.
'Soo::-2.IUS.N
LOCATION OF REACTORS
N02.2LE. ~MMA.2"""
~""'M~L size $IERVIGE
A e
1/ <,,00'# Iiii:F INLE.T
e e ll 60lP £F OuTLeT
~ 5"6Do-2F ~AMPLe
EXHIBIT 9-5 High-Pressure Reactor EXHIBIT 9-6 Partial Plot Plan for a Hydrotrealer Unit
t-I-r-
~"~GrE
Fu~"'A(.e
-l I
4.~7 c::..ATA\.yfpT I
lDADlt.JGl
UN
~~EA
~.l'>1""'6.
4-
I
...._-----
Reactors
206
LU6-:'
.:
.'
"'.,
';
.i
~ess Plant lAyout and PIPIng Design
207
EXHIBIT9 8ft
Minimum Reactor
Elevatiun Requirements
MI...,IMI.JM To ~"oUT
riPe- 'Sl.4PPOIZ:T
0(2 \.oW-FbI"""'" O"A.tJ
, Reactor dimensions.
, Type of heads.
, Support details.
I BoHom outlet size.
o Unloading nozzle size.
I Client preference for catalyst handling.
RetU:tor$
208
EXHIBIT 9-10
Top-Head Nozzle
Arrangements
E.LE.VATIOfoJ
nomic ~1I)(1 orderly interconnection of piping bt:tween zie are located on the bottom head of the reactor. If
the reactor and reluted equipment. The following in- the reactor is skirt supported, the outlet is arranged
formmion is required to locate and elevate reactor like a lower bottoms outler. If supported by lugs or hy
nonles: a ring girder, the nozzle is vertical on the centerline of
the vessel that terminatcl'i at the nozzle flange. The
.. Process vessel sketch. catalyst unloading nozzle is angled from the bottom
.. lnstrumem vessel sketch. head to clear the skirt and is positioned between the
.. Piping and instrumentation diagram. piers on lug-supported reactors and below the table
top on ring girder-supported reactors. Exhihit 9·11
.. Piping line list.
depicts lYpical bottom-head arrdngement1'i. In certain
e Nozzle summary. casel'i, especially with stacked reactors, catalyst unload-
.. Pl:.tm layout specification. ing nozzles are located in the side shell of the reactor,
.. lnsulmioll requirements. as shown in Exhibit 9·12.
Temperature instrumem:; are usualiy required HI
The process inlet i~ located at the top head of the reactors; they are used to" me'.lsure the temperature at
reactor along with maintenance acccsl'i, which is used different levels of tht: catalyst bed. These instruments
for catalyst loading. On smull-diameter reactors whose can be individual nozzles located at V'<lrious levels on
space is limited, the inlet no:a!e can be integral with the shell of the reactor or, to minimize multiple con·
l11uintenance access. Exhibit 9-10 shows typical top- nections, immersed in a well from the top of the reac-
head arrangements. tor, either on an individual nozzle or through the
The process outlet and the caralyst unloading 1l0Z- maintenance access. Instrument requirements for re-
/
Process Plant Layout and Piping Design
209
z
EXHIBIT 9·11
Bouom-Head Nozzle
D..ae ~()'tZL~
Arrangements
Dlb.McT&l
M I""I MUM
RAOlu"S
TAil>J61!."""
~
.•·f
~ATALY..L.L_ _&-V~
U~\.OAOuJu
t..,j(;l':l. 2. L_IS
eL.~vb.,.IO"-J PLAN
Lf:6 Sl.JPPOlZTJ!.P
:Ion; are usually highlighted on a vessel instrumcm unloading. Platform elevations art' determined by the
,etch that is furnished by the instrument engineer. items that require operation and maintenance; on tall
IChioU 9-13 illustrates side shell-mounted tempera- reactOrs, pJmform elevation:-; are set to a<xomlllotlme
Ife instruments, and Exhibit 9-14 shows the top·head a maximum ladder run length of 30 ft (9,150 mm).
~rtical arrangement. Exhibit 9·]6 shows platform and lac.kler e1~v;l(i()n r~
Sample prohe connections, which are sometimes quiremenrs.
lecified, are usually located on the side shell of the Reac(()rs taller than 30 fi (9,1 '50 mm) should be
~ssel as shown in Exhibit 9-1 S. tremed much Jike towers (see Chapter 10) for pla[·
form requiremerits except that, for reactors, imermc-
diate platforms and ladders are required only for ac·
LAnORM ARRANGEMENTS cess to temperature instruments, :;ample probes,
catalyst unloading nozzles at stacked vessels, and max·
atforms are required at reactors for access to "'.lIves, imum ladder runs. Because of the economics of phil-
struments, blinds, maintenance accesses, and ('aw· form bracket welding or client preference, however,
it loading as well as at stacked reactors for catalyst reactors must sometimes· be surrounde<.l hy steel
210 II
EXHIBIT 9·12 Side Shell-Moumed Catalyst Unloading EXHIBIT 9·14 Vertically Mounted Temperature
Nozzles Connection
~12\20jo,j"o.l.
NOz,2..LE:
\
GATA.L"f:::.~T.:--r
SuPPOlZi
\)r . • • . . •
II
EXHIBIT 9-1; Sample Probe Connection
PIPING ARRANGEMENTS
,
.'
211
rSMpel2.A. Tul2.E
/'IJ~M~T ~
'by L.A!2Q=~ ~
P\ATFol""""
~All,.IMUM ~J}E2
/ ~e:~~ FIieOM
. C::rlZA.QE:. &i'f' P~TFO~
Reack>rs
212
EXHIBIT 9-17 Vessel-Supported Platfonn Arrangement EXHIBIT 9-19 Structure-Supported Platform
Arrangement
TeMPe.l'l"'1'w~f,.
tlJ;rJQ.)MI!'.o..6T~
i>~ol .~I?
Mltollt.llUllJ\
('TYPICAL ~geE $o12e.~)· ~y~rr
L~Plto..r()
NQZ:z:J,.e.
.pJ.,.A.J
/
Process plant Layout and Piping Design
213
EXHIBIT 9 20
0
Top Platform
Arrangements
Reactors
214
EXHIBIT 9-21
Multiple-Reactor
Arrangement
EXHmIT9·22
Single-Reactor Piping
Arrangement
--t- ---±-+-
215
EXHIBIT 9~23
Reactors in Series:
Manually Operated Valve
Manifold
t h lit 0->1
,:::>pe@.TC:>~
~~~
PLAN
EXHIBIT 9·24
Reactors in Series; .,\
Remotely Operated Valve
Manifold
PL.AN E:.LeV.ATlo~
luipment Because reactors often operate at very be routed directly between related equipment to suit
gh temperatures, piping must he arranged with suffi- economics, flexihility, and support';, as shown in Ex-
~m flexibility to ahsorh excessive stress under usual hihit 9-22. If the facility operates in a series, the piping
lerating conditions. s.ystem is designed to accommodate regeneration of a
Piping at reactors or other similar aualyst operating catalyst in one reactor while the other is still on
luipment can be relatively simple in configuration, stream, as shown in Exhibit 9-23. To do this, the sys-
shown in the process flow diagram in Exhibit 9-2, or tem is furnished with controls and crossover bypasses.
)re sophisticated, as shown in the flow diagram in For ease of operation, the valve manifolds for regener-
hibit 9-1. In the single-reactor arrangement, which ation should be located at grade. If these valves are
s no comrols to influence the design, the piping can controlled remotely, however, the overhead manifold
216
MAl""" TE..,JANc.e
INL.E.T A."e?~
BAFFl.f: FL.OATINc.
TE:.M pelZATloJrlE
We:u.~
~AiA.L."'~T
t:i'12t:>p. ~
t.Jo 2.2.L.e
(;')UTL.e ,..
~LLe~TOl<
~k:l~'"
EXHIBIT 9-28
Horizontal Reactor
l1e unloading nozzle, the catalyst can be allowed to lighted in this chapter are examples of reactor ar·
ree fall to a 'temporary containment area or he re- rangements. The plant layout designer, however,
noved using an industrial vacuum, or a temporary should be familiar with company and c1iem standards
alve may be used to control the unloading rates. Ex- before proceeding with reactor layout and should «).
lihiLS 9-27 through 9·30 are examples of less common ordinate this effort with such supporting groups as
eactor arrangements. vessel, systems, process, civil, and instrument engi·
The dimensions, clearances, and guidelines high- neering.
Reactors
218
GA'TA.L:'3'~
~OA!?It.,lu
No2:Z.L.e
h&:+--,--~GA=T.!.:"::.::Lr.~1' e,a 9
(TYP\'A~)
OUTLET
No2.'Z.l-E::
~J-f-....¥
~""~T
~~
J..~"" c::IeE.~I'" 6
T
(;:.6o"'I>./..
~D.I""'Cir
/oo,JO'1'Z.LE:-
Towers
Towers, also referred to as columns, are one of the • The fractional distillation process.
principal pieces of equipment of any processing facil-
ity. Towers are cylindrical steel vessels that are used
Batch Shell
for distilling raw materials in the production of such
products as gasoline, diesel, and heating oil. The plant In the hatch shell stiII process, the still is panially filled
layout designer must undersrand the internal structure with a set feed called a batch. The feed is then heated
of a tower and how it operates to produce a satisfac- to the temperature required to produce a specific
tory design... product from the overhead vapors. This process is
This chapter highlights the general requirements repeated each time for each product until the? batch
for tower plant layout design. It describes the internal reaches the maximum temperature for the range of
workings of towers and provides the information re- products specified. The feed remaining in the still is
qUired to orient nozzles; locate instruments, piping, then pumped out, and the still is allowed to cool. It is
and controls; and prOVide platforms and ladders for then refilled, and the whole process is repeated. Not
operator and maintenance access. only is this process time consuming, but the product is
not always of high quality. Exhibit 10-2 shows the
batch shell still process, which was one of the earliest
THE DISTILLATION PROCESS used for liquid mixture separation.
219
220
EXHIBIT 10·1 Crude Distillation of Products Across EXHIBIT 10-2 Batch Shell Still Distillation Pl:ocess
Temperature Range
EXHIBIT 10·3
Continuous Shell Still
Distillation Process
c.oNDEflJ$E.f::
Sr!;GOMD
~
~~~
EXHIBIT 10-4
Multiunit Fractional
Distillation Process
Fe-aD
P2.0puc;..T
15t"F (he~)
pors rise, travel through the overhead line, and come still. As vapors rise in the first still, they meet the it
into contact with the liquid in the second still. Because coming liqUid from the second still. This causes vapOl
the temperature of the liquid in the second still is ization of the incoming liqUid from the second sti;
lower than the incoming vapors from the first still, the and condensation of the rising vapors in the first stU
vapors partially condense. At the same time, liqUid The same reaction takes place in all the downstrear:
from the second still enters near the top of the first stiUs. This process improves on previous operations il
j
221
sa
EXHIBIT 10·5 Fractionator Tower EXHmlT 10·6 Vapor Liquid Flow
Towers
222
EXHIBIT 10-' Vacuum Tower and Stripper EXHIBIT 10-8 Trayed Tower
OV£lZ""E.to. 0
/
MAl"'" "~AN~Jr:=::4-4
A""e.i~
VAcwwM
~#-=-El-~ !: rL MAINiiiNANG&:
I:: ~~ :; ~ • Au..e..io~
I.--
... FEE.Q
~~ j:: 1
LeVIS L.
!viA I~Tb.lMlc:.e 1"'~"'YMe-,..'2
14"--1:,.,
~TiOM2 I
vacuum pressure. Exhibit 10-7 shows a typical vacuum of irs associated components.
tOwer and stripper. In a packed tower, instead of having trays, the units
From the outside, tower configurations are similar are packed with beds of metal rings. On e.ntering the
in appearance, varying only in dimension; some tow- tower, the liqUid passes through a distributor that
ers have swaged top and bottom sections. The princi- routes the liquid evenly down through the packed
pal difference among towers is the type and layout of beds of metal rings. Rising vapors passing through the
the internal components that control the vapor-liquid beds come into contact with the descending liqUid. In
contact. a manner similar to trayed tower operation, the liquid
This chapter describes the internal and external is partially vaporized by the heat from the vapors and
plant layout requirements for the two most common the vapors are condensed by the cooler liquid. Exhibit
types of tower: the trayed and packed arrangements. 10-9 illustrates a typical gas-liqUid packed tower and
Exhibit 10-8 depicts a typical teayed tower with some irs principal components.
/
223
~ESIGN
CONSIDERATIONS
OR TOWERS A skirt is the most frequently used and most satis-
factory means of suppon for vertical vessels. It is at·
owers are not a standalone operation; they are usu- tached by continuous welding to the bottom head of
.ly located within a process unit adjacent to related the vessel and is furnished with a base ring, which is
~uipmem and in a suitable position for operator and secured to a concrete foundation or structural frame
laintenance access. A tower operates dose to such by means of anchor bolts. In most cases, the skirt is
~lated items as pumps, reboilers, drums, and con- straight, but on tall, small-diameter towers, the skirt
ensers and should be positioned to facilitate an or- could be flared. Access openings are reqUired in ves-
edy and economic interconnection between itself sel skirts for inspectiOn and, when possible, should be
ld that equipment. oriented toward the main access way. Exhibit 10-18
Within the conventional inline process unit, towers shows a typical skirt arrangement.
224
EXHIBIT 10-10 Tower Area
~·r!;;
..q:;:::::;:. ==t.
+=-
I
PU.1oI Ako"a.
I -=-1.1!Gt<S
,~.,--.....-j\l---...
UWIl. PI.l
, .
.:;
c. ~levation
.'"
225
.. ...._ _. . .
2 .7 I11III _
EXHIBIT 10-11 Considerations for Tower Elevation EXHIBIT 10-13 Operator Access
and Suppon
TAN6£:NT "-INc
- ~Pe.2ATcJ2
A<::c::.e,s ,
I
:
EXHmn 10·12 Net Positive Suction Head EXHIBIT 10-14 Maintenance Access
T<?Wf=l2
- ~
-,
-f----,
. _..J
I
I
flJe.,.. P~IT\\IE
Slit-TIO..., ~lIUtt.J)
~"".
.. 10 ""'l -- .
,
....
226
~
~
~~M
t1t:
II /,
!>Tt>.~OAAo Sl\'.I~T 1=...6.££.0 -s.II:IIiZT
J \
If/WII
.'
227
EXHIBIT 10-18
Tower Skirt
11
'1 " 1&";' ?::oc>><At;o
MlIoJIMWM-
I
_-1--+' c,;a." \~ L AaS-SS
oPe. N'..... G
et e.1...+'2I~(&,I;7S0
&oLI'
~Le.$
EXHIBIT 10-19
Tower Elevation Sketch
I
I ~~~ PD~~T Or ~Ppc~T
101Lo '
.-l:==:::::81==::'_~1~:
~_"J:..:;l......:f--~,*
AA 100.000
a::>Pe.~J.e..~
~.e;2~
228
EXHIBIT 10·20
Process Vessel Sketch
o
o
S!.
~9 NO'Z.'ZI..E: ·~._u"'MA~V
-~ mJ ~Y""'6QL ~12.1!. $£litv~e:
""0
@)
'"
"
-'c:-4
i
A 1e.·ISC"~F ..YAPo!'-_,.--
f:)
c.
21- I$~ ~':L,",)(
~ I~G~F FEE.t>
td'I~1trtF
~t-
() D ~e:&~IL. E:~
I ~. E 10" ,s8 £F
D~W Of=F
f<eec:;lll.e~
I 0.1" ~ :6-
fQ
() -en
!.'
':
~
~
ffil
@J
~ F
p
fl 1t3i!fl.F
til ISo«'ItF
r<'e::T4JIZ.f'J
e.eTTo",~
06o&TL.E:T
F'lZ&~~~l4e
= () "2
T III 15d*~F T~MF'E€;'T\JfE
0
_I
-'~
~ ~
~
~
L. 1," 16fl ~F L.&VEl.
.s ~ 5 JII It;o* ftf: ~"TEAM ouT
:~
~
~ M '24 IrJ~F
11
M~~c.E.
Gr ~Il 1~.IaF ~ .........
:#
ITE.M T-too
EXHIBIT 10·2]
Tray Details
1
III/t:n~
OUTL.-E.T
we. Il2.
t
.._'1
2~1~'86 -
'). io~o- -1---... D
"1°2S - - - -11
'-I- -........
~ til
.!>oo
4
230
EXHIBIT 10.22. Examples of Downcomer Trays
Ibih
EXHIBIT 10·23 Tower Transition Section EXHIBIT 1().2S Opposing Downcome.rs ,\.
li:."l! tJ·...,....&e.lZ....D
t:lc:l w~ tU> M EUl:.S
\l.IQUID DoW~M~
b. liquid Distributor c. Packing Support Grid
especially those with enlarged sections, could change vessel sketch (Exhibit 10.20) shows that the reboiler
from single-pass to double-pass tray configurations. draw-off nozzle is located directly below the down·
Exhibit 10-23 shows a typical arrangement at a tower comer of tray 27, and the plan arrangement (Exhibit
transition section. The chimney tray, if specified, is 10-1Ob) indicates that the rebailer is located on the
another device that could change the tfay configura- west side of the tower and that the maintenance road
tion. The chimney lfay is a solid plate with a central is south of the tower. Therefore, because the tower
chimney section and is usually used at draw-off sec- reboiler nozzle is generally on the same side as the
tions of the tower. Exhibit 10-24 identifies a typical reboiler and the maintenance access way is best .lo-
chimney tray arrangement. cated on the maintenance side, the trays are automati-
The plant layout designer must· orient the trays cally positioned about a north/south centerline. Ex-
along with the tower nozzles to suit the best exterior hibit 10-26 illustrates a plan view of the arrangement.
arrangement. The trays can be at any angle as long as The principal difference between trayed and
the downcomers directly oppose each other. Exhibit packed towers is that the packed tower uses metal
10-25 shows a typical example of opposing down- rings instead of trays for vapor.liquid contact. The
comers. metal rings are dumped or packed into specific sec-
Two main items that influence tray orientation are tions of the tower, called beds, and supported by cross
maintenance access ways and reboilers. The process grid bars spaced to prevent the rings from falling
Towers
232
•
EXHIBIT 10·28
Elevation and Orientation
Requirements for
Maintenance Accesses
'T.L.
N02::z.1-E
CIAl'AE.T~e.%t'22 '-'1"..1.
J
il<:.b.')'SP "'owe~
through. The supports are designed to allow vapor to operational needs. Their position must also facilitate
rise and liquid to flow down. Liquid is fee! into the economic and orderly interconnection of piping be·
vessel at the top of each bed through a liquid distribu- tween the tower and related equipment.
tor. Unlike the trayed tower, mere are no special con- A maintenance access is usually located in the bot-
siderations for orientation oCthe beds, the distributor, tom; top, and intermediate sections of the tower and is
or the packing supports. Exhibit 10-27 shows these used to gain entry to the tower during shutdowns for
three packed tower components. internal inspection and component removal. Mainte-
nance accesses muSt not be located at downcomer
sections of the tower. Care must be taken at sections of
NOZZLE ELEVATION AND the tOwer that contain internal piping [0 avoid block-
ORIENTATION ing the maintenance. access entrance. Exhibit 10-28
shows typical elevation and orientation requirements
Nozzles must be elevated to meet the internal require- for maintenance accesses.
mentS of the tower and oriented for maintenance and Feed connections to trayed towers usually must be
i
233
EXHIBIT 10·29
Reflux: Alternative
Arrangements
No'Z.Z.\..E DIAMETER
+51t1I.I~t:;. MINIMLJM
___ +--_n+·~
234
~
economic exterior arrangement. Internal feed piping
to packed towers is piped directly to the distributOf
and can be oriented at any angle. Exhibits 10-29
and 10·30 illustrate several options fOf internal feed
I piping. .
If specified, reboHer connections ·~re usually lo-
I
...I,. .J.. cated at the bottom section of the tower. For the hor-
ALl£lZt-&A-rIV6\/
izontally mounted thermosiphon reboiler, the draw-
o12I1:...,TA'TI()f'o.l off nozzle is located just below the bottom tray. For
DoubL.c NoZ'2.L£: OIi:IE-~TATIO""
Two OPTION'S.
me vertically mounted recirculating thermosiphon re-
boiler, the draw-off nozzle is located at the bottom
head. For both systems, the return nozzles are located
just above the liquid level. Exhibit 10-31 shows both of
these arrangements.
The vapor outlet is usually a vertical nozzle located
on the top head of the tower. Jt is usually a single
nozzle, but in certain cases (e.g., towers with very
large diameters), more than one nozzle is specified.
On large-diameter vapor lines, the vessel connection
""- could be butt-welded instead of flanged. In addition,
J.lTCfll-JATI~ the vent and relief valve could be located on the top
C:>21~ ..Tollq'ION
'SINGl.E NO'Z,';Z.LE. O~IE-"'TA"IO'" head instead of anached to the overhead piping. Ex-
"TWO 0 PTlo,"" 5 hibit 10-32 shows a typical top head arrangement.
The liqUid outlet is located on the bottom head of
the tower. If the tower is supported by a skirt, the
nozzle is routed outSide the skirt. As with the vapor
oudet, more than one nozzle may be specified. The
elevation of the nozzle is dictated by the ~onstraints
discussed previously in this chapter. The orientation
can be at any angle, but generally it is dictated by
pump suction piping flexibility. Exhibit 10·33 shows a
, , typical bottom head arrangement.
.~ Temperature- and pressure-instrumen~ connec·
tions are located mroughout the tower. The tempera-
e,'N~I.e. ~t:'~%J"e; OlitlfOfo&TATlolJ
ture probe must be located in a liqUid space, and the
MUI.'T,Pj,.!'. OPTIC'N;'
pressure connection in a vapor space. Exhibit 10·34
shows the preferred location for both connections.
235
EXHIBIT 10·31
Reboiler Connections
~Te.""...,AT'V&
~eTloI12.N
L.OCATIO"-l?
iowel'lC: 14eeoILE~
a. Horizontal Reboiler
1116M U<!hJlp
,"Q.VE..~
\Y ALTe.~""AT
~eT"""'...J
IV£:
Loc:;A..,..e,,", ~
b. Vertical Reboller
236
EXHIBIT lO~32
Top Head Arrangement
REL1E..F VALVE
1(p.,J ue..I'l-E: gADIU'$>
TA."-JC:r~' F'<;::)1~T
ALTE.~~A" VIS:
VA. f\;?~ 0 unf:.T I--~.£..r"--t----+-I ALT~g""ATIVc
l.~~M1:.l::o::.",-;.;~~V I'.E;.LIl:F_ VA.I.VE
Loc.Ai"IC'N
\
L.A.~6E DIA.METi:ft 1.1Ne~
IA.2 NoT r2e'aU1~ R.At.l6E~
I lJOZ'Z.I.E$
I
m
EXHIBIT 10·33
Bottom Head
Arrangement
TA....<:rE.lo..JT LINEr;
:::&1::1: HEAD
+..-.--lL--_ _- - I _ OIt",ie,.toJ ~ 10",","$
""
Re. ,j,ta~
f;:eio.JlZN
p12.eFE.IiCRe.D L..eVE\..
HLI.. '= ~16~ L1GuID L.e.V€J, J~.~'T2.l-lMF:h1'T ~TIO.~.1>
~u.= t-JoRMtl.L. L.ltAl..JlP LE.Ve.L
II
Towers
238
S,TAr-JDO....,'T S"A~Dou,. fZATltJ6 EXHIBIT 10·37
ell/~~D 1'ILJSo . 1$0*. eo,,:tt Nozzle Standouts
v2N.?J ()(;> t;) 1I /.2?Jo ~o""
I~JI/.~'L~ [ 1~IY:fJOO ~~O""
~IUSIDe. ,,\o2'2.\,E'S
ANO FI.AI01:.E.P
-;.e:.::.'T1 0"" S
Pl.A"'FO~""1
P~foJ G.TrzA'T'O'-J S
EXHIBIT 10·38
'2.: I ElLIPil 'A.l. Head Dimensions
HE:.AD
Level instruments are located in the liquid section of flange. To set top- and bottom·head nozzle elevations,
the tower, usually at the bottom. The elevation of the the type of head must be specified. This information is
nozzles is dictated by the amount of liquid being con- highlighted in the process vessel data, The two most
trolled or measured and by standard controller and commonly used are flanged·and-dished and 2 ;1 ellip-
gauge glass lengths. This information is furnished on tical heads. Exhibit 10·38 shows approximate dimen·
the instrument vessel sketch. Exhibit 10-35 illu~trates sions for these heads.
level instrument requirements. As an example, the nozzle elevations shown in Ex-
When nozzles, especially those with internal pip- hibit 10·39 have been set using the following guide·
ing, are positioned, the plant layout designer must lines:
allow adequate clearance at tray support steel. Exhibit
10-36 illustrates approximate tray suppon beam sizes. • Process vessel sketch (Exhibit 10·20):
Standouts, shown in Exhibit 10·37, are measured from • Tray details (Exhibit 10-21).
the internal diameter of the vessel to the face of the • Type of heads-2; 1 elliptical.
A EXHQJIT 10·39
Nozzle Elevations
PLATi=o2M liL.
Ib9 1-0"
121.o~o
m Ei..I4-~1_9"
1l~.~~S
4.El...14'2~4'1 §l
[j]] ,*,E:1..14t'-$~ .
11'2."Q~
fl2b2~
04-~L"~-0· I t---:-..:...:....I PLA'TF02M I&L.
1I'2.?14S f~9 -t::'1t
111.6'0
Uo e.~
$1'121 A.4-=e.~_-JIl
~U.I"1ZI... ~l1
'"',It;D
I DO. j,I:J"
Po~ EL.IQ!I.. QIl_
EXHiBIT 10-40
Typical Platfonn
Arrangement
MA.IIoJTe.~ AtJc.E
~"ce.~~
• Bottom tangent line elevation (Exhibit 10-19). attached to the side of the tower. Generally, access to
• Nozzle summary (Exhibit 10-20). platforms is by ladder. Exhibit lQ.40 depicts a typical
o Instrument vessel sketch (Exhibit 10-58).
platform arrangement.
Platform elevations for towers are set by the items
• Piping and instrumentation diagram (Exhibit 10·56). that require operation and maintenance and by a max-
• Plant layout specification-Chapter 2. imum ladder run of 30 ft (9,150 mm). Exhibit 10-41
e Insulation-None required. shows platform and ladder elevation requirements.
Platform widths are dictated by operator access. For
intermediate platforms with no controls required and
PlATFORM ARRANGEMENTS platforms with controls located to the side or the edge
of the platform, the width must be a minimum of 3 ft
Platforms are required on towers for access to valves, (915 mm). At congested platforms with controls lo-
instrumenlS, blinds, and maintenance accesses. Plat- cated oyer the platform, the width must be a minimum
forms are usually circular and supported by brackelS of 3 ft (915 mm) plus the w,idth of the controls or
i
Process Plant Layout and Piping Design
241
EXHIBIT 1041
Tower Platform and
ladder Elevation
Requirements
MA.I...rrE.W~E+ l?L.IJJQ
/ kG E:~~
TeN! peIZAT""l<E
P2e'$~~.,u~e POII"JI
Aa~~ E!:»y L"'.op.Ee
~ct P!.A'TFQ"M
'1=.1&11 T~ re.'-g-
:4So T~ 'Z. ~?Q
,!t;.1.. rf:'l""ATav& V/)J..yE
~e.~s WI.'"
WI.,.~uT &KTF+ol"?'O,,",
~
'liS>Tfi....
12 11&300 M1NIM4N1
e
'NTEIC: ....i:OIA
PIA'TFQ~M 'i;:;l
~I T M.A)l1 MuM
I.."-DPE£ "..,.."
pQAI...... VA"'VE At:(;E~S
I..~"et. GlAuGrE ~e: ~ <!7f2A,QE:
&r LA.OD£:" Ql(. F\.A.,.t:"D~
242 ..
EXHIBIT 10-42 Platform Width Requirements EXHIBIT 10-43 Maintenance A<:cess Arrangements
V~T
12 1.0W./,'t,IO
Mlto.llMuM
~'W'~~~"M
1!-d'
MINIMUM
.,=,tc;J
.?~
TOWER PIPING
Tower piping is located in conjunction with tf'dY, noz-
zle, and platform orientation. When possible, the pip-
quirement. Ladders at tower transition sections and at ing is grouped for ease of suppon and positioned'to
~ared skirts may be sloped, if required, to a maximum accommodate interconnection with related equip-
mgle of 15° from the vertical. Offsets in ladders ment and the pipe rack. Exhibit 10-51 shows the pre-
;hould be avoided. Exhibit 10-48 shows a typical slop- ferred areas of division for piping, platforming, and
:ng ladder arrangement. ladders.
On very wide platforms or those that support heavy Adequate space must be provided between piping
)iping loads, knee bracing is reqUired in addition to and between the back of piping and the tower shell to
he usual platform steel, as illustrated in Exhibit 10-49. facilitate the installation of pipe supports, which are
[he potential obstruction immediately under the knee attached to the tower. Exhibit 10-52 displays some typ-
>race must be kept in mind during platform design. ical supports for tower piping.
244-
I
EXHIBIT t()..46 Bracket Spacing EXHIBIT 10-48 Sloping Ladder
V~~eJ..
1~e2N~ P1AMETe.i2 X '(
17'_0 11 To t211'-ol/
6.180 1.~'Jo
1I'jt fJ.~1;
,---
.,.
. - PU.TF(:)~M EL.I$ ,)1.
111.2>')0
~
zUl _ .B-A."~M Et,. I ~L
UI 1
jil1l 109,140
~
:!
Pl-A.'TFe>f2M Et..Il~.
L,.,...... •
- lo~,790
UPoE$Z I
i
_ •.fl,A'T.~ e~.lIol.
l0'a~
N EXHmrr 10-50
Platform Orientation
LADOE~
l4~e
tT'(F' ,GoA L}
t
-~
/"
I~.I"O
.. t-tllJIM.I.lM
1
INf>lJ~"T,g:)f4
I Rb"PIAL locATEp
____ PIP'IWG
I I
j 1 ! J
Vf!:fZTl"~1.. PIP' ...."
*,~e.A 1:.0 f' .. &Ac:..lt. 0(: PIPe.
,,~
- - . . . . Cll'lo.Ilo.It.'oJ
LocATeQ PIPING
!
Proc:ess Pima Layout and PIPing Design
247
EXHIBIT 10·5~
Overhead Arrangement
Oyt=J:Z.~e.AP ........-:::
l-t.... e
N EXHmrr lO-S4
t
Pump Suction
Arrangement
PUN VIE.k:/
249
EXHmrr 16-55
.
L.t:> c.ATI ON &
r Relief Valve Systems
"'Jr I-
~F'ETy
PI',.... tJc,..e.
liT'
-to .......
ATMo~Pl-le~lc:. R.&I.IE:F \lAWE
2 o!
F'2eS=EIZR.£.D .... OCA'TION
OIJE:.~'Hi:;"'D liNe
r
'I
I{ t~~
I I
PIPE RAc.K
I
I
I ~~
EXHIBIT lO-S6 Preliminary Piping and Instrumentation Diagram
TD ~LAtz.e. ~EJ,.\i:.F
VbLVI! "'eAP E.ft
1000-e
OVEIZ.\o\EA P
Gt::>NpEtJ~e
lo'S>-el.fE~
1&2 \M GOOL62'i.
c:. _68
FeED
@~
~-T'
I
lID: .,
$lT2A\N Ee(T=rp.)
G
4-'"I\(Y,J ?;If('l',,v,)
1~3-I='A/St ~~~-PA/6
eQ'TTO""f~ Pu""P~ JZai=l..u)( PWMP"$
251
EXHmn 10-57
Tower Piping
Arrangement
,,~ AI~ +~e4M
IolTlI,.IT'I" L'N~
_ •<0
~!>
©f-.__--!:P...!l_~h-_J
EXHIBIT 10-58
Instrument Vessel Sketch
T 1 rrE\
t-L-.!....t+-';...;....---~
r'~~F
~7 101
l.t
....
_.-
lft ~
mounted indicators are available in a variety of styles, • Platform arrangement (Exhibit 10-50).
with straight or swivel heads that can be positioned for • Piping arrangement (Exhibit 10-57). ,
clear dial visibility, Exhibit 10-60 shows typical tern· • Level instrument locations (Exhibit 10·35).
perature and pressure connections.
The instrument arrangement shown in Exhibit
10-61 has been designed using the folloWing informa- MAINTENANCE
tion and the guidelines in this chapter:
Tower maintenance is usually limited to removal of
• Nozzle elevations (Exhibit 10-39). exterior items (e.g.• relief or control valves) and inte-
• Instrument vessel sketch (Exhibit 10-58). rior components (e.g.• trays or packing rings). Han·
253
EXHIBIT to.S9
Arrangements for Level
Instruments
C>~""laoJ %"
Et..EVATIQt.J
:
3. Siogle~MountedLevel Controller
·t
PLA......
iling of these items is achieved by fixed devices (e.g., the back of the tower that is accessible from the plant
iavits or trolley beams) or by mobile equipment (e.g., auxiliary road. Exhibit 10-62 depicts a typical davit ar-
:canes). When davits or beams are used, they are 10· rangement, Exhibit 10-63 shows a typical troUeY beam
::ated at the top of the tower, accessible from a plat· arrangement, Exhibit 10-64 portrays a planned drop
'orm, and designed to lower the heaviest removable zone, and Exhibit 10-65 shows mobile equipment.
tern to a designated drop area at grade. When mobile In certain cases, stiffening rings are specified as
~quipment is used, a clear space must be provided at additional strengthening for the tower shell, especially
Towers
254
T-100
PL.ATF'Q~M
EL. JOgl.C d
IC;74c
.I
255
a t
_~lo'l'!>~o ,.
4" To ell
DAvIT SWppCI2.T
FIC:o M Ve.~~EL.
"
Ptt.."'i
J
EXHIBIT 10-63
Typical Tower Trolley
Beam Arrangement
256
EXHIBIT 10-64
Planned Drop Zone
T~u.ey
e.~ F::=;S;~==:::;I
.,1
~
I
;
257
EXIImlT 10.65
Mobile Equipment
TDWE.fi: _
for towers in vacuum service. Care must he taken in ings show the location of weld seams; Exhibit 10·67
positioning the rings to allow adequate clearance at illustrates typical weld seams.
nozzIes~ platforms, ladders, and clips. A tpwer section Utility stations are reqUired at tower platforms that
with stiffening rings is shown in Exhibif 10-66. Be· have maint~nance accesses. Steam and air risers are
cause of size~ Jowers can be shop fabricated in twO or ~e two services' required ~d must be positioned dur-
more sections for shipment in one piece 0,," in sections ing the tower layout stage so Wat adequate clips can be
for field welding. As with stiff~nin8 rings, allowances furnished for support. Exhibit 10-68 shows utility sta·
for clearances must be made between weld st':aJTIS and tion requirements. Such towers as demethanizers op-
attached fittings. The vendor's vessel fabrication draw- erate under extremely cold coqditions and sometimes
258
!'Jo:z.'Z,I,.E
EXHmIT 10·69
Cold-Service Tower
Requirements
.'200
~E=tt---rl2l.o If
.~oo
t-
V
t-.-J-_ _........._
:C?d\4f:~
CHAPTER 11
Pipe Racks
A pipe rack is the main artery of a process unit. It mentation diagram issues covers onlycommodity, Hne
connects aU equipment with lines that cannot run number, and preliminary sizes.
through adjacent areas. Because it is located in the Process flow diagrams provide insight to operating
middle of most plants, the pipe rack must be erected temperatures and identify the need for insulation.
first, before it becomes obstructed by rows of equip- Once the routing diagram is complete, the develop~
n\('nt. The corresponding piping drawings are also re- ment of rack width, bent spacing, and numbers of
qUired early for the same reason. Pipe racks ...:arry levels and elevations may proceed. .
process and utility piping and may also include instru-
ment and electrical cable trays as well as equipment
Bent Spacing
mounted over ~i of these. This vital area requires
considerable planning and coordination with other A pipe bent consists of a vertical column or columns
technology groups regarding construction because and a ~orizontal structural member or members that
costs are so high. carry piping systems, usually above headroom. The
This chapter explains what is required to finalize line sizes that are installed in the rack establish the
the pipe rack width, number of levels and elevations, bent spacing. Exhibit 11-2 is· a typical pipe span chart
and bent spacing and addresses pipe flexibility and and shows how far a panicular line C'dn span on the
access and maintenance concerns for each item 10· basis of size, schedule, liquid or vapor, and insulated
cated wIthin the pipe rack area. or bare pipe. Pipe racks are tailored to a specific plant;
The primary data required for the detailed develop- pipe sizes in chemical plants are smaller than those
ment of a pipe rack includes the following: found in refinery units. If a plant requires a 16-ft
(4,900-mm) spacing. the variation in Exhibit 11·3 al-
• Plot plan. lows for a 32·ft (9}OO~mm) spacing by adding inter~
e Piping and instrumentation diagrams. mediate bents supported from spandrels. Spandrels
are horizontal structural members located along the
• Plant layout specification.
longitudinal centerline that are used for structural sta·
• Client specification.
bility, pipe support, or intermediate pipe bents. Dou-
• Construction materials. bling the column spacing as shown in 2A of Exhibit
• Fireproofing requirements. 11-3 may be required to cross roadways or avoid un~
derground obstructions. The civil and structural engi-
neers should be consulted to review the economics of
ESTABLISHING WIDTH, BENT SPACING, the approach.
AND ELEVATIONS Setting the width of the pipe rack may then pro·
ceed. With the routing diagram, a dimensioned cross
The first step in the development of any pipe rack is section is developed at the bent that will carry the
the generation of a line-routing diagram, shown in most piping, which is bent No 12 in the example
E~ibit 11-]. A line-routing diagram is a schematic rep- shown in Exhibit 11-4. Usually, pipe racks carry pro~
resentation of all process piping systems drawn on a cess Hnes on the lower level or levels, and the utility
copy of the plot plan. Although it disregards exact lines on the top level. Instrument and electrical trays
locations, elevationss or interferences, it locates the are integrated on the utility level if space permits or
most congested piping bent in the pipe rack. Usually) on a separate level above all pipe levels. Any pipe rack
the information available on early piping and instru- design should prOVide for 20% future growth. When
261
262
EXHIBIT 11·1 Line-Routing Diagram
J'l.:j..O~
I
P-104-.-
I
-E::.2~.
~=Z36. _ _ _ _ ..L"'lDf
(?,o'
Q-21'='
...r-~O~
..,t ..22td- - - - , • b- ZI 7. I
" .. 2q ~"-I-_ --+4:r1- _ e..'l~ ,
I
t"'to1....
I ~T"1.!>J.
263
....
EXHmITl1·4
A Pipe Rack Cross Section
(at Column 12)
!
Process Plant Layout and Piping IhJslgn
265
~,.
EXHIBIT 11·S
Pipe Rack Composite
IH:z@J~~ ~lZIAi.
t-":'J---r-llo!ol--------I--: - ......
It:'l2X'.F» UNP".&
.-Hrr~
,---L-.-..-+-o--:---:--YdL-
rp'Nt
~--~~~
,
I
!)\ i
/ . I
j
t
the electrical conduit trays are located on the top level ft (6,100 mm) rather than 19 ft 3 in (5,850 mm). 'To
and a row of motor-driven pumps is located beneath illustrate, if the pipe requires a much greater area in
the rack at grade, a 6·in (lSO-mm) slot should be pro- the rack, the designer would work with the structural
vided to allow the conduit to run in the most direct engineers to determine whether the pipe rack should
manner and avoid running to the outside of the rack be [wo 30-ft (9,lSO-mm) wide levels or three 20·ft
and back to the pumps. This feature is illustrated in (6,IOO·mm) wide levels. This decision affects the COSt
Exhibit 11-5. Once future rack growth and conduit of the structure and pipe and must be made carefully.
have been allowed fOr in the plan, the spacing may be After the bem spacing, rack width, and number of
set with the line spacing chart in Exhibit 11-6. levels are established, the elevation of the leveis must
When flanges or flanged valves are required on twO be set. As discussed in Chapter 2, the plant layout
adjacent lines, the flanges are staggered as depicted in designer must know the minimum clearances to set
Exhibit 11-7. Thermal expansion or contraction must the elevations. Plant roads, type of mobile equipmenr,
be accommodated, as shown in Exhibit 11-8. When all and equipment located beneath the pipe rack can in-
the distances have been established between all lines fluence the pipe rack elevation. Usu~lly, space is al·
on each level, induding allowances for future growth lowed below the pipe rack for eqUipment, with a mini-
and condUit, the only remaining dimension to be set is mum clearance of 10 ft (3.050 mm).
the distance from the first line in the rack to the verti- The next· factor to consider is the dimension be-
cal column centerline. Column sizes are furnished by tween the boltom of a line in the rack and the bottom
the civil/structural engineers. of a branch as it leaves the rack. For example, if a
The last step is to add up all the dimensions and review of the largest lines in the entire pipe rack
round off to the next whole number-for example, 20 indicates that there are twO or three large-diameter
266
EXHIBIT 11.6 line Spacing Chart
tX 1 1 1
'l ,1
1 ~ ~ Ie 1'Z. I~ 14 'r:. l(p 12l
1 e ~ II 1'2. I:? 14 l~ I~
'1 1 ~
/3 ~I., , ..,
1o II
10 II
,~
l~ !4 I, '1
14 IS.
,,,
I~ II!> to
Ie tl
b ~ 10 II I=? 14 I~ I~ 11 I~ 1 e e:,
W 4
~ i
a ~ 10 1'2 I? 14 It;. l~ 11 lu ~
,,, IIII I'Z. ~
t"l. ,4
I~
I~
,,, 111& I~
I~
1.1
11.
N
I~ 14- It; 11 11 'ZI II I~
"
I'") ,~
~ ~ 10 I~ ,'-' 11 14!> ~ -z.;
81l
:z e 11- 14- 17 Ij¢ l~ 1& I~ '2.t I? 14 ltd '1 lb 1# tot 114
I, 1" ,'"
.3 10 I~ I~ Ii '2' 1~ Ie;. 11 It> ,~ ~, 1.1- ~
'tz I~
I~ 1'2 18 '2.0 z.::, I~ I~ ~ <Z1 1:; ~
Z4
tc;
'f4,.
'Z5' 1t1
Z,
t'Z 't~ 'Z.7 1.1
~ 1(:,
Z1
~
2~
-?I
EXHmlT 11·7
line Spacing
i
1'rYKess Plant Loyout and Piping Dealgn
267
EXHIBIT 11·8
Planning for Line Growth
I:.• ·1
.~
'i.
...
~. ~'.
. ..
:t'~
~Yi'/P':'~
I.Il~N+-
EXHIBIT 11-9/
Large-Diameter Lines
r:I:1~I:I:Jr::~~ e:-LWAT~
.tlUl.- +"I1IlI~
END VIEW
E:LEVAIIO"" I
268
Process P;Z;:t,:
ant:Layout
- ; - - -and
- - -Pi
--- - -
rping Design
269
EXHIBIT 11"11
Pipe Rack Meter Runs
lines (e.g., 18,20, or 24 in) and the remaining lines are is an example of a typical layout.
12 in, the exit level above and below the rack can be 3 A common arrangement of a standard process unit
ft (915 mm). The dimension from the end of a 90° pipe rack is one in which the process lines are on the
bun-weld elbow to the centerline of a 12-in line is 18 lower level or levels. The utility piping is on the top
in (457 mm). Exhibit 11·9 illustrates how to handle the level, which carries piping Electrical and instrument
large-diameter lines by using a 45° elbow or trimming cable trays are located on the top level with the utility
an elbow to a more shallow angle. If the instrument piping or on a separate level above the utility piping,
and electrical conduit are installed on a separate level, depending on the extent of cable tray area reqUired.
the estimated dimensions of each tray must be ob- The plant layout designer must consult the electrical
tained from the instrument and electrical engineers to and instrument engineers early in the pipe rack layout
ensure that adequate space is prOVided. to establish these reqUirements. '
The design of the pipe rack is now complete with When locating lines in the rack, the plant layout
the exception of installing equipment over the rack. designer should run the largest lines near the outside
where POSSible to reduce the overall load on the sup-
pOrting beams. Meter runs should be installed directly
SETnNG LINE, VALVE, AND next to the columns so that access is available by porta-
INSTRUMENT LOCATIONS ble ladder or mobile platform, as shown in Exhibit
ll-lI. Meter runs are located in the pipe rack only
Many factors must be consjdered when locating each when absolutely necessary.
line, valve, and instrument in a pipe rack. Exhibit 11-10 Many relief headers must be located above the top
EXHIBIT n-12
Relief Header Location
EXHIBIT 11·13 Alternative Pipe Rack Expansion EXHIBIT 11-14 Hose Station at a Pipe Rack Column
" ~, eo
!
Process Plont Layout and Piping Design
271
....-......
maintain such units (e.g., providing a hitch point over
the channel end to facilitate its removal). Once agaio, EXHIBIT 11.15 Battery Limit Valving: Single-Level Rack
it is extremely important to know exactly what kind of (ProcesS/Off·Site Common Elevation)
mobile handling equipment the plant will use.
The vertical drop of lines outside the rack, although
usually 2 ft (610 mm), is once again set by the average
line size in the unit. If the average line size is 2 io, a 12-
in (300-mm) drop may be sufficient. This view also
shows how the electrical conduit can he run directly
to the pump starter switch.
Exhibit 11-14 shows a typical arrangement for a
hose station. Battery limit valving for a single-level
pipe rack is shown in Exhibit 11-15. The valves are
staggered on either side of the catwalk, and hand·
wheel extension stems are furnished when necessary
to facilitate operation. Exhibit 11-16 also displays a
single-level rack. Here, however, an elevation change
is required between the process unit and the off-Site pLAI'-J
pipe rack. This design has the block valves installed in
the vertical portion of the line, which allows for rela-
tive ease of operation.
Exhibit 11-17 illustrates a two-level process unit
pipe rack; the elevation change to the off-site area is
either above or below the process unit pipe rack.
EXHIBIT 11-16
Battery limit Valving:
Single-Level Rack
(Proces..../OO·Site
Elevation Change)
i
Process Phi,., Layout and .PiPing Design
273
EXHmITU-17
Battery Limit Valving:
Two-Level Rack
( Process/Off·SiEe
Elevation Change)
A
i \ i
I
LJl.j
274
EXHIBIT 11~18
Flexibility Check Steps
.J I I III I I I IT
\!E')" .wc.laz. IN ~ i'$ lJNt:;
.... - .
275
LW
EXHIBIT 11-19
Pipe Rack Anchor Bent
/ Plr:ol!'J~ H ~, I
l..IHZf!o
. .-- - \ .
- - -
Lj-! f·
""-
'ri
termining line gro'Wth The growth of such utility two anchor points approximately one-quarter of the
lders should be determined by multiplying the co- distance from each end of the header should be tried.
cient of expansion by the length of the line. The Using the nomograms, the designer can calculate the
~fficient of expansion is based on a particular mate· amount of expansion leg reqUired to satisfy all flexibil~
I operating at a specific temperature. Upset temper- ity requirements.
res take precedence over operating temperatures.
Arranging Hnes in proper sequence The line that
tel:mining whether one anchor point wiD suffice requires the largest leg must be located on the outside
uming that an anchor is located in the center of the of the loop. Placing the headers along one side of the
Ider, the deSigner should calculate the growth of pipe rack allows the expansion loops to sit with a
ious branches to determine whether they have slight_ overhang along the adjacent side of the pipe
)ugh fleXibility to absorb the header growth. If not, rad<. Exhibit 11-19 shows such an arrangement. As a
276
• • EXHIBIT 11·20
Steam Line Dtlp Legs
EXHIBIT 11·21
Proper line Support
II I biJ
EXHIBIT 11-24
Pipe Rack Spandrel
Variations
support, and it may be better to use another line for member for the spandrel suppon. The spandrel al:;o
this application. has an embedded steel member that is bolted to the
column and eventually grouted in. An installation se·
quence for a precast pipe rack is also shown in Exhibj(
STRUCTURAL CONSIDERATIONS 11-25.
Such equipment as drums and deaerators is often
Most lines require support when leaving or entering a located above pipe rack columns. To avoid wasting
pipe rack. Struc£ural members called spandrels are the valuable rack space with the large support columns,
most common means of satisfying thiS requirement. the inside face of the pipe rack column must line up
After all the lines have been fun in the pipe rack. the With the inside face of the equipment support column,
plant layout designer must begin to locate the span- as shown in Exhibit 11-26. This approach also allows
drels necessary to support all of these lines. Exhibit the feed-water outlet piping to run vertically down to
1] -23 shows how the requirement can be handled. If the pump before the expansion loop is added. •
the structural engineers require additional spandrels Fireproofing of pipe rack columns is shown in Ex·
for stability of the pipe rack, they should bring this hibit 11-27. If hydrocarbons are prevalent. it is com·
requirement to the attention of the plant layout de· man to fireproof the columns to a level just below the
signer. Exhibit ] 1·24 shows some variations of span- lower. rack suppOrt beam. If air coolers or other
::Irel design. equipment is located above a pipe rack, the fireproof-
The plant layout designer should be aware that pre- ing is extended to the equipment support beam. This
~ast concrete pipe racks require structural members issue must be reviewed with the client; allowances
:hat are much larger than most designs. Exhibit 11-25 may need to be made for as much as 4 in (loo mm) of
llustrates a precast column With an embedded steel fireproofing.
PtpeRacks
278
EXHmlT 11·25
Precast Concrete Pipe
Rack Considerations
. I
"., ~
.. .
~ ..
:' ..t-.,
/~ r;'IZeC.6hI ~NT
f4l'3T 1iJ
b. InstalJation Sequence .
279
EXHIBIT 11u2:6
Equipment Support
Column Location
EXHIBIT 11·27
Fireproofing
Requirements
280
EXHIBIT 11·28
90" Pipe Rack Turns
- EXHIBIT 11-29
Rack Intersection
OTHER CONSIDERATIONS on the left side of the rack must remain constant as
long as flat turns are used. A different elevation must
Occasionally, a situation arises in which a flat-turn be used at a 90° turn in the rack if the sequence must
pipe rack may be employed. This often happens near a change, as shown on the right side of the diagram.
dead-end area where the potential for problems is This approach must be well thought out before it is
minimal. As shown in Exhibit 11-28, the line sequence used.
281
.- EXHIBIT 11·29
Ra~ Intersection (COni)
I
1----ffi-+--.4 - -f--+-4--I-~- - - - - - - ~fB_-----_.../
r--/-+-t--eJ~t-H-+--_..tI)----4-----J1
I ,
/ I /
'L;J:.,.I---t----$-t-++-H----+f--.....---r'~..-;:_.
J f
f , I
Structures
285
286
EXHIBIT 12..1
Typical Ladder Detail
____ J~
, I
Pipe load Pipe load refers to the weight of all piping, Dynamic loading This is the response of structures
valves, finings, and insuJa(ion~ including the weight of and their components to the cyclical loading pro·
contents during test or regular operation, whichever is duced by rotating or reciprocating equipment.
greater.
Earthquake load This is the specific seismic data for STRUCTURAL DETAILS
a particular site.
A typical ladder detail is shown in Exhibit 12~ 1. lad-
Wind load Measured in miles per hour, wind load is
ders with elevations of a maximum of 20 ft (6,100 mm)
the force applied to a structure at a given site.
above grade do not require a safety cage. An B-in (200-
Exchanger bundle removal load This is half the mm) open area behind the ladder shouJd be main~
weight of the tube bundle. ~ined for toe clearance. Any obstruction within this
distance is a potential tripping hazard. ,
Thermal expansion loadThe effects of thermal ex- The preferred positions for ladders~ stairways, and
pansion must be accommodated by equipment sup· ramps are illustrated in Exhibit 12~2. It is recom-
pon structures and elements. mended that ladders be run vertically to a maximum
angle of 15°. Stairways should be limited to a maxi-
Pipe anchor load The force calculated to resist load~ mum angle of 500 off the horizontal plane, but they
ing in anchored piping systems, the pipe anchor load should not be used for less than a 150 incline. Ramps
is added to the thermal expansion loads of the equip- should be limited to a 15° maximum incline. A stair-
ment. way dimensional detail is shown in Exhibit 12~3. The
288
T
location of the steps are usually set by the structural
EXHIBIT 12-4 Traveling Belt Lift engineer.
Exhibit 12~4 shows a traveling belt lift. This device
consists of an electric drive belt with steps and hand
grips. It is constantly in motion at a slow rate. The lift
provides rapid access to a large structure without the
need for a standard elevator.
A grating platform is depicted in Exhibit 12~5. When
, this type of platform is used, the platform top-of-steel
elevation does not include the thickness of the grating.
I :[ Moderate pipe SUPPOI1 loads can be imposed on this
design; holes for piping should be banded for rein-
~IBIT12.. 6
Deck Plate Platform
Structures
290
as
r-- '------, EXHIBIT 12-7
~o:=~: .:J , ..... Fireproofed Steel
:6"'~':
~-: ,::t~
~f'Frzn~ p!r~) ~'.
" ..-j'- - '
EXHIBIT 12-8
Bracing
JII1li
EXHmIT 12..9
Concrete Platform
~ ....
~\;
~ ...
. ':?:;' .. ' .• ;j',
",:'.. '.
mrnmrr 12..10
Concrete Platform for
Acid Service
291
EXHIBIT 12-11
Acid-Bearing Equipment
-$-
I
EXlUBIT 12-12
Structural Siding
II
I
!.
.\
i
I
II
iI
'I
il
il
j,
Struaures
292
EXHIBIT 12..13
Equipment Supports
340
EXHIBIT 13-43
Sewer Box with Line
Cleanout
&
EXHIBIT 13..44
Buried Insulated Piping
_~. . ~.t'l
~E-L~l~·
Exhibit 13-44 shows one way to bury a hot line slope or impossible to tie into existing plant facilities
underground. The line should be backfilled with a without the installation of a pump in the system. A lift
mixture that is equal parts sand and vermiculite, allow- station is shown in Exhibit 13~46. It basically consists
ing for a thickness of at least 4 in (l00 mm) around the of a concrete sump (sized by systems engineering)
entire line. The line is anchored as required by the and a vertical pump. The discharge line of the pump is
stress engineer, through the use of concrete thrust run as desired because it is now a pressure system.
blocks. This insulating mixture of sand and vermicu-
lite allows [he line to expand as necessary.
A diked area drain is shown in Exhibit 13~45. Be- DOUBLE CONTAlNMENT-
cause dikes are designed to hold the coments of a UNDERGROUND SYSTEMS
storage vessel in the event of a rupture, area drains
must be kept closed at all times. A drain valve operates New and more stringent environmental laws through~
just outside the dike wall so that plant personnel can out most of the world are impacting many operating
see when the contents have been drained and the an
process plant underground systems. As example, in
valve may be reclosed. the United States, the Environment Protection Agency
When gravity flow drain systems are developed, it has promulgated several standards applicable to the
may be impractical to continue with the required transfer of waste operations in refineries. The NESHAP
EXHIBIT 13..42
\ ....
jl i ----L" 4Y,,,,,,
~. 4 T
GIVIl,...
fittings is different from that used for fittings above depending on the traffic anticipated in the area or
grade. A 90° change in direction is not a 90° elbow but particular process concerns. The width of the trench
a quarter bend, indicated a~ 1/4 B on a piping plan should allow adequate clearance to valves and drains
drawing. A lateral is called a Y branch. as required. Miscellaneous details are displayed in Ex-
Concrete pipe, which is commonly used in oily and hibit 13-25.
storm water sewer systems in sizes of 15 in and larger, A typical sewer box is displayed in Exhibit 13-42. As
is illustrated in Exhibit 13AO. Use of cast iron pipe mentioned preViously, all pertinent information for
smaller than 15 in is determined by economics. each sewer box must be recorded on the sewer box
Trench piping is shown in Exhibit 13~41. Occasion- schedule, shown in Exhibit 13~15) for transmission to
ally, drain piping or process piping must be run below the construction contractor. Exhibit 13~43 illustrates a
grade but not buried. The example shows two insu- variation to the inlet piping at a sewer box where
lated lines, A and B, running below grade to a drain provisions are made to rod the Hne near the sewer
tank. The top of the trench is covered with grating but box. The systems engineer should be consulted as to
could be covered with deck plate or concrete slabs, whether this feature is reqUired.
Underground PIping
338
EXHIBIT 13·40
Concrete Pipe
~It
"e,U L ~~
I~'I.. e:t... 97~llf'
~(j~
(p
-J8&
~1~"A.A't
q. Double Y
f·-=:-
w. Double Hub
u. P Trap
v. Running Tlt"ap
with Hub Vent
~-----
equipment on the north half of the plm, where best to locate the pull boxes. (There may not be
e Monitors 6E and BE are elevated and can cover the a box per se, but it is the point at which the conduit
air coolers over the pipe rack as well as the pipe exits the underground and serves all other users.) It is 11
rack itself. important that this space be left free of piping, equip-
ment, or associated maintenance access. The conduit
Although each plant must conform to local firefight~ in Exhibit 13~38 is encased in red concrete for protec-
iog rules and regulations, client interpretation of those tion and located under the main pipe rack, between
regulations can produce vastly different fire water sys- the two rows of pumps. Both the electrical and the
tem layouts. Early consultation with each client is instrument engineers. are responsible for prOViding
strongly suggested before a complete systems layout is the estimated size of the duct, and the plant layottt
developed. designer sets the elevation to best suit the gravity flow
drain systems throughout the unit.
~t the outset of a project J a decision must be made on Variations of pipe fittings, catch basins, sewer boxes,
;vhere the major electrical and instrument conduits trenches, sumps, and lift stations are only a sample of
;viIl run-above ground· in the pipe rack or buried what a plant layout designer encounters in the devel·
)elow grade. If the underground route is selected, the opment of an underground piping system. Available
)lam layout designer must confer with the electrical vendor data for fittings, catch basins, and sewer boxes
lnd instrument engineers about the optimum layout must be used as a reference. Typical cast iron fiuings
)f the duets, where the conduits enter the unit, and are shown in Exhibit 13~39. The list of labels for these
Underground Piping
336
1
EXHmIT 13..39
t9 A reproducible copy of the plot plan is used to pre~ through vendor data or the chart in Exhibit 13~30~
pare the initial layout, as depicted in Exhibit 13~37, If a compass is set to the maximum effective range,
8 A complete loop is drawn around the unit, with the monitor 1 can be positioned showing its full cover~
line run along (he edge of the plant road. a~a~. '
a! To prOVide a margin of safety in the fire water sys. • Monitor 2 is located east of monitor 1 to cover aU
tern, the fire water loop is fed from opposite ends of equipment not protected by monitor 1, and moniror
the unit-Enough block valves are p.rOvided to en- 3 is located to cover equipment nor protected by
sure the overall firefighting capabilities of the sys~ monitor 2.
tern in the event of a rupture in the fire water loop. o Monitor 4E is an elevated monitor that is trained on
The number ofvalves placed in the header is subjec- the air cooler over the pipe rack, the large process
tive and is submitted to the client for approval. tower, or furnaces.
(l The effective fire water range is then eStablished • Monitors 5 and 7 adequately cover the remaining
11 ~. ' m [DJ]'
L----- --1.!~t ---+-----tldo'I~_ ___.~~.
EXHIBIT 13.. 38
~(AJfT Jt.:) PjHa2 U~i Underground Cable Duct
~r:LL~
?
334
EXHIBIT 13..36
Typical Deluge and Spray
Systems-
.1"
t:L£YAfION
ME----.:~~:::::::::.~~~----. - ...
.I.::/~--;;;;:;:;::;=:::;:=
~
Deluge and Spray Systems connections that flood the sphere in the event of fire;
the other has a horizontal 3600 ring header and verti-
Deluge and spray systems are generally used when
cal leads that are approximately 6 in (150 min) from
process equipment cannot be reached by fire moni-
the sphere shell, all with equally spaced spray nozzles.
tors or requires a great quantity of water to protect it
This type of fire protection is often subcontracted to
from a fire in the local area. Typical dell;Jge and spray
companies that specialize in this panicular service.
systems are shown in Exhibit 13-36. The storage bullet
is protected by a ring header around the vessel, with
Fire Water System Layout
spray nozzles equally spaced to provide appropriate
coverage. Two storage sphere arrangements are _The layout of a fire water system in a process unit is
shown in the exhibit. One has twO open-ended pipe usually accomplished in the following way: .
M~M~~
~
EXHIBIT 13..35
Grade-Mounted and
Elevated Monitors
332
EXHIBIT 13..32
Typical Elevated Monitor
13-33.
/
Process Plant Layout and Piping Design
331
EXHWIT 13.. 30
Monitor Range Chart
liA
EXHIBIT 13·..31
Typical Grade-Mounled
Fire Monitor
I
' - - _ _ ....l
ALTla2t.JATIVE: @f1!i32T
Undergt'Ound PipIng
330
EXHIBIT 13..29
Hydrant and Monitor
Installations
MotJliP~g~-- ...----..____
HWtZAWT
EXHWIT 13..28
Hydrant Installation-
gineer should be consulted before this detail is pre~ tank farms or truck loading areas), hydrants are lo-
pared. If the soil conditions prohibit the proper drain- cated every 300 ft (90.5 m).
age around the hydrant, a drain [Q the nearest clean Fire monitors are used to direct streams of water to
water or drainage ditch must be provided, burning pieces of equipment in a plant. Before moni-
Exhibit 13~29 illustrates some additional features tors are selected and located, several factors must be
that the plant layout designer should consider when considered, Fire monitors are lever operated, have a
selecting and planning the instaJlation of fire hydrants full 3600 range) and may be locked in any desired
and monitors, induding: position. They may be located at grade, approximately
4 ft (1,200 rom) above (he ground, elevated to heights
• Protecting the valve bonnet and extension stem with of 100 ft (30 m) or more, or mounted on a hydrant.
a buffalo box, which is a piece of pipe that sits on the The spray pattern of fire monitors depends on water
valve and extends approximately 9 in (230 mm) pressure and flow rate. If vendor data is not available
above grade. when preliminal)'. fire water layouts are made, the
$ When required, orienting the pumper connection chart in Exhibit 13·30 can be used to determine the
nozzle toward the fire truck access way. effective fire water monitor range. This chart is based
• ]f hydrants are vulnerable to damage, providing on a water pressure of 150 psi and a flow rate at the
guard posts for protection. nozzle of 500 gpm.
~ Coating and wrapping the buried ponion of the hy~ Typical monitor.s are shown in Exhibits 13-31
dranl. through 13-33. The grade-mounted monitor shown in
Exhibit 13·31 has the block valve located above grade,
If not specified by the client, a typical hydrant has a but it would be buried below grade in a freeZing cli-
6-in inlet line size with two 2V2-in hose connections. mate. The method of supponing an installation of this
Hydrant locations must permit clear access during a type is determined by the civil engineer.
fire and be no more than 25 ft (7.5 m) from where 3 A typical elevated monitor is displayed in Exhibit
pumper may be required to hook up a suction hose. lJ-32. When grade-mounted monitors cannot direct
In remOle areas of an industrial plant (e.g., around water to all pieces of process equipment because of
Underground Piping
328
EXHffiIT 13..26
Emergency Eyewash and
Shower
f&:lONt:t:Z E.~
?I~ta~
1f2 .
t..~o~ I2~U!t2f:O
v~Lv~
~1·X'2.Ii,un 'New
/
t(::)~\C. lZeou~et2.
~ ~'y~~~e-
.~:': ~.~ "Of: o~ .,j,
Yz ClJ:P
~-..-l..N-~
Ii! G~LJ~i=4;Qe><::>.I<>O
.~
~:.~' ..~
'Y''' I·.......
"J =;q:jL
t? .
'~potJI-J
.o.-P0t-J7
-
k-p~"; ~~~~
':?,)'"
{. /
J..?J)
<toC/~tq!\~.c.~U~qt)o
t IJt:> 2eQU'~C>
t
Notes:
1. Typical equipment dram, with the top of the cast iron hub set at an
elevation of 100 ft 4 in (100.1 m). Lines draining into this hub would
terminate at a plain end elevation of 100 ft 3l/~ in (100.085 m).
~ 2. Similar drain hub tying into another drain line.
S'
~ 3. Cleanout connection in a cast iron piping system.
4. Catch basin in a paved area.
5. Inline sewer box or catch basin in which flow passes directly
through the box.
6. Catch basin in an unpaved area.
7. Sump with a lead plug drain valve. Turning a handle allows the plug
to fit into the seat, closing off the sump to its drain system.
S. A hydrant valve, which is commonly used for water in freezing
climates.
9. Chemical drain hub~ whose size is determined by the number of lines
entering the hub as well as by its flow requirements. "'!.r.
~
......
-?2lV11lS>;
~It~-
I
4:t~1.,i
~~-B
r EXHIBIT 13..24
Cooling Water at Pumps
J
.1'
the bottom of the exchanger channel, the inlet header agreed to by both the above·ground and the under-
must be located directly under this nozzle, as illus- ground plant layout designers.
trated in Exhibit 13-23. This arrangement aJIows for
the most direct hookup. The underground portion of
the fabricated pipe includes the flange to be bolted to FIRE WATER SYSTEM
the block valve; the hot water outlet line should termi-
nate 12 in (300 mm) above grade with a bevel end. Every industrial plant is protected by a fire water sys·
The above-ground piping takes over from this point, rem that provides water to each piece of equipment
If the water users are located in a structure, the through hydrants, monitors, or deluge spray systems.
underground portion of the lines should terminate Each process unit has its own underground piping
with bevel ends 12 in (300 mm) above grade. Cooling loop system, which is adequately valved to protect the
and hot water headers to the pumps are run under the. system from a failure in any part ofthe line or isolation
pipe rack, between the rows of pumps, as Exhibit 13· because of maintenance. Although each piece. of
24 shows. A self-draining hydrant valve is used if the equipment must be protected by one hydrant or mon-
installation is in a freezing climate; this detail is dis- itor, client specific.ations often override this rule and
played in item 8 of Exhibit 13·25. require two sources of fire water for each piece of
The potable water line also enters the unit at the equipment Basic fire protection equipment consists
west battery limit and is run to the emergency eye~ of fire hydrants, hydrants with monitors, grade-level
. wash and shower installation. A typical arrangement of and elevated monitors, hose reels, and deluge and
this facility is illustrated in Exhibit 13-26. The under· spray systems.
ground ponion of this line should terminate at a point All hydrants and monitors and their shut-off valves
Underground Plp~ng
324
i t5
EXHIBIT 13..21 Process Cooling Water and Potable Water System
~ tl ~,~
l l --.
4>
EXHIBIT 13~19
Closed Drain System:
Cross Section
EXHIBIT 13 20
D
Potable or drinking water is used by plant personnel not be set above the frost line as determined by the
and also is supplied to emergency eyewash and project design data.
shower installations. Parallel cooling water and hot water return headers
The layout of a comprehensive pressurized water must be kept a minimum of 12 in (300 rom) from the
system follows some basic guidelines. In freezing cJi~ outside of the pipe diameters. Running these two
mates, the centerline elevation of a water line should headers too dose together may affect the temperamre
U,ulerground Piping
322
tE,~w' ~ \V
t o.
9
cess water include the following: • -Cooling water for pump and compressor seals.
321
:EXHIBIT 13--16 Sewer Box Sizes
,~I
. a. 900 Entry
limit, and at the point at which the header enters the neer. A typical sump is depicted in Exhibit 13-20. The
sump. Exhibit 13-19 illustrates a typical cross section civil engineer sizes the sump on the basis of the quan-
of what a dosed or' chemical drain system consists of. tity expected to be collected, as supplied by the sys-
The large end of the hub, or reducer, is sized to suit tems engineer. The discharge of the sump pump is
the number of drain leads entering the hub. The re~ piped to an on-site storage tank or to a truck that is
mainder of the system is sized by the systems engi- brought in periodically to remove the contents.
320
Sewer Main Outlet Auxiliary Sewer EXHmlT 13-015
Main Inlet
BOl Inlet Top Bottom Box Sewer Box Schedule
No. Sile Invert fl. Size Invert n. Elevation Elevatioh Elevation Diameter
I %- ~?'..S:' 4614 ~'. zos ~1!.~·· ~",,::;' ... d· ~'-d h~
£, 1.0" ~'... ;'iJ :;,ott ~?l~. ~(;r .. 4" ~~''''H'' ~' ..."Z" tf::;tt::;lf
~ t&;:· ~,-I ..e:>· ~. ~ir.. ,'9 <f!)6\...0 ~ ,oo'_cJ1 ~~~o" ~~t1
across the chart from left to right at the flow fate previ-
EXHIBIT 13..14 Calculation Chart ously calculated, 2.56 cfs. As can be seen on the chart,
several line sizes could handle the flow in the desired
velocity range of 3 to 5 ft per second. A 12~in line
would flow at 3 ft per second if the slope were set at
Al:z.E:.A ~Pf G"M/t=~ rzE6,.,.1~? 0.42 ft per 100 ftj a lO-in line would flow at 4 ft per
, ~ot> 1t!>'Z: /4t:J second at a slope of 1 ft per 100 ft; and an 8-in line
'2 ~ '24~ /.~ would flow at 5 ft per second if the slope were set at
~ ~oQ ~/ .~'Z 2.1 ft per 100 [t. Higher velocities are attainable but at
4- 4~ 'ZIO / .11 much greater slopes, which may not be prattical.
;. ~r,.o t1~/.~ Therefore, the actual line-size selection must be made
~ ~/I.c;.;. ~~~
"
1
!l!>
wATt:IjZ. on the available slope within the system (from the
farthest catch basin to the final invert elevation at the
battery limit) and on the desired flow rate. It must be
~ relnembered that, in this example, the flow rate can-
10 not be set at less than 3 ft per second.
tl The runoff rate calculated in each area of the unit
t'2 must be recorded on a chart similar to the one shown
~
in Exhibit 13-14. Because each section of sewer main
\4 is sized to handle the total accumulation that could
1&
possibly enter the Hne, it is important that all total.
flow-rate quantities are recorded not only for Hne siz-
ing but for use dUring a mechanical check or audit·of
the system. SiZing gravity flow drain systems is a give~
and-:-take situation. As the west battery limit is ap-
proached, it may be necessary to readjust some previ-
ously selected line sizes, flow rates, or slopes to avoid
gpm. To convert 430 gpm to cubic ft per second (efs), an underground obstruction or other gravity flow
it is multiplied by O.00223 t yielding 0.959 cfs. drain system within the unit. There are no absolutes,
To calculate the total amount of water that would just many alternatives that must be explored before
result if the pipes were running 75% full t 0,959 efs is the line sizing of the oily and storm water drain system
multiplied by 1.1, for a resulrof 1.05 efs. The com- is finalized. ,
bined fire water and process water is: As the invert elevations of the main at the sewer
1,000 gpm + 150 gpm = 1,150 gpm or 2,56 ~s boxes are confirmed, the actual elevations are re~
t
corded on the orthographic piping plan drawing,
The larger total of the two, 2.56 cfs, would be used for which is shown in Exhibit 13-7.
sizing. As the details for each sewer box become available
Now that a flow rate of 2.56 cfs has been estab- (e.g., main inlet and outlet sizes and inven elevations,
lished, the actual line calculations can be developed auxiliary inlet elevation, cop and bottom elevations,
through the use of graphs based on the Manning for- and -the diameter)) the information is recorded on a
mula, illustrated in Exhibit 13-13. First, a line is drawn sewer box schedule, as depicted in Exhibit 13-15. This
Underground Piping
318
l~-ib"EEm~~~~~~m~gJEi~ij~
.at:
.6 J--1-+./....,.¥~I-M-A+-+-b~.?:.+H-H-H+--+--f--t-+++-H+f
.5 / ...-
'\,./ /'/' t
A~ / 1
_··+-t--+-*I-H++H-.-+-iI-t--t--1+H-H
'~1
r--
.02.03,04.05 .1 .2.3 .4.5.6.8 1 2 3 456 810
SLOPE OF PIPE (FT PER 100 FT) •
. 42/IOO'.. tt U"'E- .!ty'6EC,~ I '2.. 1;100 .. altutJE- J7F%l:G
1.0/100'-10" 1..11.JIb1.'Y:sec' I ...j
Eventually, the sewer line must be sized for a com· The runoff rate for each area, as initially outlined in
bination of rainfall and fire water. Sewers comaining Exhibit 13·5, may now be calculated by using the mod·
combined rainfall and process water are designed to ified rational formula:
run 75% full, which allows additional capacity for .i
I
Q=KlCA
shon but heavy rainfalls. This amount is calculated by
multiplying the actual runoff rate by a factor of ].1. For where:
example, if the actual runoff rate were 1,s00 gpm, that Q == the runoff rate in gpm (converting to cubic
figure would be multiplied by 1.] and the resulting feet per second can be done by multiplying
1,650 gpm would be used in the line·sizing calcula- gpm by 0.00223)
tion. Sewers containing combined fire water and pro- K = the conversion constant (0.01039 for flow in
cess water are designed to fun full. The follOWing co· gpm)
effidents are used for surface drainage runoff: I := rainfall intensity for the storm duration in
inches (or decimals of an inch) per hour, as
III Rainwater, paved area-90% (0.9). shown in Exhibit 13-12
• Rainwater, unpaved area- 50% (0.5). C = the runoff coefficient
• Fire water, all areas-lOO% (1.0). A = the area of surface to be drained in square '
feet
Sewers running at the maximum flow rate are de- For example, the runoff rate for a paved area can be
signed with a maximum velocity of9 ft (2,700 mm) per calculated with the follOWing data:
second and a minimum velocity of 3 ft (900 mm) per
second. The size of pipe depend') on the coefficient of • Area = 80 ft 75 ft (6,000 sq ft).
X
roughness, n, when run at a given slope. Although it is • Rainfall = 5 in per hour.
preferable to stay at the lower values of n for the most .. Fire water = 1,000 gpm.
economical sizing, it is important to select the proper • Process water :::;:; 150 gpm.
n value on the line·sizing chart. Based on these pipe • Pipe material:::;:; 4 in to 15 in, cast iron; 18 in and
types, the design value n is as follows: larger, concrete.
Gl Velocity =:; 3 to 5 ft per second.
o Clean, coated cast iron-O.012.
e Clean, uncoated cast iron-O.013. Therefore, K = 0.01039, I = 5 in per hOUf, C = 0.9
e Concrete-O.013. (data was supplied), and A = 6,000 sq ft. The runoff
rate· in gpm (Q) is calculated as follows:
o Painted steel-O.013
e Vitrified clay tile-O.013. 0.01039 x 5 in x 0.9 x 6 tOOO :::; 280 gpm
III Galvanized iron-O.015. The· total area runoff is the total process water (150
o Corrugated steel-O.02S. gpm) plus the total rainfall runoff (280 gpm), or 430
Underground Piping
\
314
'ateral Detail
~~~L ~t;i7
~ ~ '2Oa/fb_foo lZ\.J.,J :: 4" LnJe-E:AZE-
J
~U~ ~ ~()tz.eJU~ ~'Lt;, . IOO ~ : <i:J"LJ~F:-~ZC
r ,t..J'I: ::.1 ~V~
inlet and below. Under no conditions should any sys~ Line Sizing
tern run flooded, unless approved by the client. Eleva-
.Hons for sewer systems are shown only at key intersec- This section outlines the criteria and formulas that are
tions, sewer boxes, and the starting and termination commonly used for developing line sizing for oily and
points of lines. storm water sewer systems.
When all mains, laterals, and sublaterals have been Oily water and storm water sewers are sized to
routed, the line-sizing calculations can proceed. The handle the calculated rainfall plus process water drain-
system must be checked for excessive quantities of age or the fire water plus process drainage t whichever
hydrocarbons that may suddenly discharge into the results in the greater quantity. Rainfall rates are ob-
oily or storm water drain system as well as for any tained from the project design data, and process water
continuous discharge that exceeds 100 gallons (378.5 drainage quantities are obtained from the systems en-
liters) per minute (gpm). (For simplicity's sake, the gineer. When client input on fire water quantities is
remainder of this chapter deals only with gallons.) unavailable} a decision is made jointly by the systems
These quantities are added into the line-sizing calcula- and project engineers. When specific considerations
tions and are furnished by the systems engineer. If (e.g., a deluge system) are not required) the fire water
excessive discharges are expected, it may be advanta- flow rate for each area is set at 1,000 gpm. The maxi..
geous to run a separate branch line directly to me mum fire water figured into line*sizing calculations for
nearest sewer box. The outlet line of a sewer box is a process unit should not exceed 2,000 gpm. Local
sized based on the total effluent into the sewer box rainfall charts are reviewed before any line sizes are
from all sources. calculated.
41'
~~ ~ ~~
~uTiOt ~1Tf:12Y Ct"AlT
value as displayed in Exhibit 13-] 1. before cleanouts are i.qscalled. All laterals entering
The piping designer should locate the oily water sewer boxes are sealed.
drain hubs using the above-ground piping studies, set- Oily or chemical lines should not be routed over
ting each invert elevation and routing sublaterals, fat" the top of potable water lines. Local plumbing codes
erals, and headers. Each fining (e.g., Y branches, 1/s should be used for actual requirements. When oily
bends, and 1/4 bends) must be identified. Headers and and process systems drain to a sump or storage can·
laterals should be reduced, when possible, to 4 in tainment, the storage capacity is determined from the
Underground Plpln8
314
EXHIBIT 13·9
Minimum Cover for
Buried Piping
.. IS
C', I J(5J
~Ab
::;lQT7
~II
q>"
l~~ t.dA'"
j
Process Plant Layout and PIPing Design
313
EXHIBIT 13·7
Sewer Box Detail
+ EXHIBIT 13 8u
Cleanout Connection
Underground Plptng
312
r1---r------7~~---+--"'--.--+--~~-H--~_+_____I~
------.l.,o~~~~~_---I~
all
t7...??t---;-=-f~~;n;t'77T""-H-~:-::::~~~~::-::t~P'77/;"77T~~+-r~;----rhm
(j) ~~
f& At the beginning and at the end of each main. Sewer boxes should be made of precast reinforced
1& At the intersection at which a branch line must be concrete pipe a minimum of 48 in (1)220 rom) in
sealed from the header. . diameter. The system engineer establishes the need
for sealed sewer boxes. Those containing dean storm
o At any change in direction or elevation in the main.
or fire water do not require sealing) but toxic hydro-
e Every 300 ft (91 m) for lines of 15 in and larger. _. carbon-bearing run-off requires a sealed sewer box
• Every 200 ft (61 m) for lines of 12 in and smaller. _ that is vented to a safe location, as shown in Exhibit
EXHIBIT 13..5
Catch Basin
..t
by a single catch basin. The area under the pipe rack When possible, catch basins are located near the cen·
{award the center of the high point is included in each rer of the drainage area, preferably not under stair-
area run-off calculation. The suggested maximum area ways, structures, or eqUipment. A typical catch basin is
per catch basin is 5,500 sq ft (510 sq m) for paved illustrated in Exhibit 13~5, and the extent of these areas
areas and 3,500 sq ft (325 sq m) for unpaved areas. is shown in Exhibit 13~6.
Cricket lines are drawn around each area to indi- A tentative location and invert elevation of the drain
cate the high point of paving or grade. The diagonal system is established at the unit battery limit from the
cricket Hnes from the corners of the area [0 the catch site data supplied by the client. If the information is
basin must slope at a rate of 1 in per 120 in; the unavailable, the end of the unit that the system exits
maximum aIJowable drop should not exceed 6 in (150 should be obtained from the client. The west battery
mm). The maximum length of this diagonal cricket limit and an invert elevation of 94 ft 6 in (99.850 mm)
must not exceed 60 ft (18.25 m). Its length and eleva- is used as an example. The two sewer mains running
tion difference is calculated point to point and does east and west through the unit are located in the mQst
not account for such obstructions as equipment foun- direct route possible, with the depth of all under~
dations. ground obstructions on the way taken into consider-
In paved areas with a high concentration of equip- ation. The designer must avoid locating any line below
ment, the allowable area per catch basin should not the angle of repose of a foundation. Another concern
exceed 3,000 sq ft (270 sq m). When practical, these is possible interference at the point at which any two
areas are arranged to collect drainage from common underground lines intersect It may not be obvious
equipment. Catch basins are located as required, pro· what the exact elevation of each graVity drain line is at
vided that the difference between the long and the the point of intersection. The follOWing criteria deter-
shon diagonal cricket line is no greater than 2 to 1. mine the need for sewer boxes:
Underground Piping
piping is routed underground.
EXHmlT 13..4 Below-Grade Obstructions
o Fire water requirements.
• The type of system required (e.g., separate or com-
bined oily and storm water system).
• The invert elevation of lines at the process unit bat-
tery limit, as preferred by the client.
• The extent of paving.
• The extent of pipe trenches that carry heatvtraced
drain systems. :.
• Preliminary foundation sizes and depths.
• Continuous process discharge that enters the sys~
tern.
m~
ing equipment and structure foundations, proposed
row
f?Zrf.rg!t4t{~fWW//Z1
routing of major electrical and instrument ducts as
developed by the electrical and instrument engineers,
or any existing underground piping, trenches, and
light pole stanchions. A typical example is shown in
Exhibit 13~4.
A decision must be made on whether to route the
flAhl oily and storm water drains as separate systems or
combine them. A combined system is the most com-
mon. It requires seals to prevent the spread of hydro-
carbon vapors or fire throughout the unit. Acombined
As with any piping layout, information for an under v
system must pass through a treatment facility outside
ground gravity· flow drain system is often less than the process unit before entering any outside body of
what is required at the outset of a project. A list of the water. Because the sewer must be run paCit the cooling
most preferred information includes: water system,· under the pipe rack, along- with some
electrical dueting and the major portion of the cooling
~ The underground specification. system run outside the equipment, the combined oily
e The plot plan. and storm water sewer system is routed between the
e Above-ground piping studies.
pipe rack columns and the eqUipment. The extent of
all paving, curbed and diked areas, roadways, access
• Local codes and regulations. ways. and eqUipment layAdown areas should be
• The location of potential site obstructions. shown.
• Local site data. including topographic information, A high point of paving of 100 ft 1 in (100.025 mm) is
maximum design rainfall, and frost depth. set down the center of the area directly below the pipe
• Electrical and instrument conduit locations if the rack before the unit is subdivided into areas serviced
out liries are covered with a mixture of sand and ver- o Stainless steel-For closed chemical drains.
miculite. e Cast iron (or grey iron)-Often used in handling
storm and oily water drains. Cast iron is very resis-
Solvent Collection System tant to corrosion. The hub and spigot deSign is fabri~
cated in 5- and 10~ft lengths, which may be modified
Many solvents are used to remove C02 from gas with a special cutting tool.
streams. These solvents are reclaimed in a separate • Ductile iron-Has a higher stress value than cast
drainage system and are also shown on the piping and iron. It is also used for hub and spigot as,well as
instrumentation diagrams. The pipe is usually made of process water service. ;'
carbon steel and is run to an underground sumpt
e Concrete pipe-Used for surface drainage and for
where it is eventually pumped out.
] 5·in and larger pipes. Although it is available in
smaller sizes, economics may limit its use.
Cooling Water • Fiberglass reinforced pipe-Used in corrosive s"er~
This system supplies water to such process equipment vice. It is limited to lowwpressure and low-tempera-
as surface condensers, coolers, and pumps through an ture systems. When fabricated t it is designed to meet
underground header system. very specific needs. For example, it may need to be
able to withstand outdoor exposure or burying or
may need to be sun retardant or made to project-
Fire Water specific dimensions.
This system consists of a loop around a process unit or • PVC pipe-Commonly used for corrosive service.
equipment, with branches as required for hydrants or • Vitrified clay pipe-Used in gravity drain systems
monitors, to protect the unit in case of fire. that handle sanitary or surface drainage. It cannot be
subjected to any significant loads (e.g., under build-
ings, paved areas or roadways). It generally has a
t
Potable Water maximum operating temperature of 2000 F (93 0 C).
: {";t:; water is used for drinking, emergency eyewashes, e Glass pipe-Used for floor drains in processing
and shower facilities. plants, especially for acid service.
Underground Piping
308
EXHm1Tl3a3
Pile-Supported
Foundations
...t.' ~;
. ~. ~.
a 0 •
~~.f4Itt'---:;/),.VO'!2 TH 17
~ILpr;z
Sanitary Sewer drainage from a furnace. This sewer box has an air-
tight cover and vents to the atmosphere if located
This system collects raw waste from lavatories. If not within a minimum distance of SO ft (15 m) from a fired
discharged to the unit limit or lift station for disposal, heater.
it is routed to a septic tank or leeching field.
Pump..Out System
BlowdolVll System This system is shown on the piping and instrumenta g
This system picks up drains around boilers and steam don diagrams. Although it does not need to slope,
drums and is run as a separate system, preferably to pockets must be avoided. Because it is common to
the battery limit. It is permissible to tie into a sewer pump out hot piping systems, adequate means must
box in the oily water sewer system as long as it is be provided to allow for line expansion or growth.
located downstream from any sewer box that collects Although trenches are generally used, buried pump"
.I
Process Plant Layout and Piping Design
307
EXHIBIT 13·2
Angle of Repose
whichever is greater. In most cases/ the latter will gov- fuliy identify aU such equipment and provide a drain
ern the line~sizing criteria. hub at each item.
Underground Piping
306
Underground
Piping
Underground piping applies to any piping system lo- TERMINOLOGY
cated below grade. Buried or in trenches, under··
ground piping systems within a processing complex Terms used in underground piping systems are de-
consist of gravity flow drainage systems that carry pro- fined in the following section.
cess waste, spiBs, hydrocarbons to be reclaimed, and
sanitary and storm water, along with pressurized water Invert elevation This term, usually associated with
systems for process, fire, and drinking to meet (he any underground Hne, refers to the elevation of the
operational needs of the facjJity. inside bottom of the sewer line, as shown in Exhibit
This chapter highl ightS the general srep-by-step 13~ 1. Because of the wide range of materials u.sed in
procedures to follow for each system when an under- drainage piping systems with varying wall thickOesses,
ground piping layout is being developed. Local codes it is the constant that is used to set the elevation on
and regulations and specifk diem requirements gov- construction drawings.
ern the design of any underground piping system.
Sewer main This is the primary drain line in a sys~
tern; it is separated into sections for safety reasons by
INDUSTRY STANDARDS sewer boxes.
The following list represents the most commonly used Laterals Laterals are drain lines collecting from two
industry standards for developing underground pip- or more sublaterals. They discharge into the sewer
ing systems: main through a seal.
o ASTM A74-Cast iron soil piping and fittings. SUblaterals These collect branch Jines and sealed
• ASTM A120-Steel, black and hot~dipped, zinc- sewer boxes into laterals.
coated (galvanized), welded and seamless pipe, for
ordinary use. . Branches Branches collect all the various drain
o ASTM A746-Ductile iron gravity sewer. pipe. points within a plant (e.g., from catch basins and drain
• AS1M C425-Compression joints for vitrified day hubs) and tie into sublateraJs.
pipe and fittings.
Lift station This is an underground structure (e.g., a
• ASTM C700-Vitrified day pipe (extra strength, stan-
sump) used to pump effluent to a higher elevation.
dard strength, and perforated).
which may be in a gravity sewer system t or to the
(6 ASTM Di785-Polyvinyl chloride (PVC) plastic pipe
battery limit.
(schedules 40, 80 and 120)..
1
305
304
OPERATIONS PLATFORMS
EXHmIT 12·27
Structures in a Coker
Unit
t?l2J LL ~12C
J~~~~
.302
EXHIBIT 12~26
Stair Structure
'f
.; .·0
.0.
0"
:. •
.I
Process Plant Layout and Piping Destin
301
EXHIBIT 12..2S
Setting Heavy Equipment
in a. Large Structure
installed, the vessel is moved laterally into place; the need to route lines and suppOrt them from their re-
beams are then installed. This is one method for set· spective towers. The structure should be looked at as a
ting large or heavy equipment in structures, vertical pipe rack and used to its maximum advantage
to allow sufficient flexibility in the piping systems
between the stationary structure and the movable
STAIR STRUCnJRES towers.
~
\ I
~l
~
'\ Ii/l
~v::+--+--tl
111111
11\\ i l - - - r - - - !l - - a lIB
==r--- 1- 111-/-----
Cb
c':)
e A dear access way is needed for equipment mainte~ structural engineer's information. Main pipe routing
nance or removal. elevations must be established early. Flat piping turns
o Adequate clearance should be provided around all should be used with caution. The use of pipe chases
equipment for operation, maintenance, and safety. for grouped piping configurations should be consid-
$ Adequate stairways and escape ladders are needed ered for structures that have concrete tloor6 to mini-
to meet OSHA requirements. mize individual holes through the floor.
When designing a large structure, the plant layout
Open-sided and enclosed structures fall under differ- designer must observe how various pieces of equip-
ent governing codes. ment are erected during construction. Exhibit 12·25
Hitch points and trolley beams are also required to shows one such sequence. The lift structure is erected
facilitate maintenance. The lifted load requirement adjacent to the process structure, and a temporary
should be indicated on the layout drawing (as shown track is run between them. The vessel is brought into
in the structure cross section in Exhibit 12-24) to show place and lifted off the rail. It is then raised to the
the maximum weight to be lifted at (har point for the desired elevation. With the outside beams yet to be
1r:::::1:~t==~~~~::l-~
(1YPI~~ .'
1 ~a'ACA;
I 11/
! ..(:)/. 3C30
Structures
298
EXHIBIT 12..22
Vertical Arrangement
E:L. ,~r;,.~~
1""'===F==b:c..1
GI2ADc
the vertical layout is significantly smaller than for the gravity·flow systems and a great deal of small piping
horizontal one. If a traveling crane is used in the hori- need the natural support that a large structure can
zontal arrangement, a slightly larger drop zone is offer. Exhibit 12-23 illustrates a large structure. Factors
needed. If individual trolley beams are used over each that must be considered during the development of an
exchanger, the area required at grade is significantly equipment arrangement and piping layout in a pro-
increased and can become a costly real estate prob- cess plant include:
lem. Solving it requires the participation of the struc·
tural engineer and the exchanger engineer. o Finished grade within a structure should be 12 in
(300 rom) higher than grade outside to avoid drain-
age problems.
lARGE STRUCTURES $ Pipe racks and electrical and instrument cable trays
should be located in the same general area, prefera-
Many process plants have equipment located in large bly down the middle of the structure.
structures. The reason these structures are preferred • Freestanding process towers should be located adja-
over grade-mounted installations is that a significant cent to the structure to facilitate operator access
number of small pieces of equipment are used. Many from the tower platforms to the structure.
/
Process PkBnt Layout and PipIng Design
297
EXlImlT 12~20
Two-Level Small
Structure
EXHIBIT 12-21
HQrizontal Arrangement
Structures
296
EXHIDIT 12..19
SingleMLevel, Two-Bay
Small Structure
+
'\~lPMe-Nt LiNer:
HI? V1evY:
dIes are located on main structural beams whenever must project out to allow mobile equipment (0 pick
possible to minimize the need for additional steel. At up the bundle and lower it to grade.
grade, equipment is lined up along a regular equipM
ment line; however, equipment in structures must fol~
low an equipment line that accommodates the main MEDIUM..SIZED STRUCTURES
support location, which may vary. Removable hand-
rails must be provided in front of shell and tube ex- When designing a structure, a plant layout designer
changers when tube bundles must be removed. must often satisfy restrictive process conditions (e.g., a
A rwo·level structure is shown in Exhibit 12 20. The
M
minimal pressure drop within a system). Exhibits
exchanger tube bundle maintenance on level I is the 12~21 and 12·22 show how one equipment arrange-
focal point of this exhibit. Th~ size of the exchanger to ment may satisfy that requirement. Prefer:ab1y, the
. be maintained determines the need for a tube removal shell and tube exchangers (El through E6 in Exhibit
structure. If such a structure is required, it should have 12-22) are set venically in the structure, which uses
a beam directly opposite the exchanger from which the least amOunt of platform and may significantly re-
the bundle can be pulled. The structure must also duce the area needed for the maintenance of the ex~
have a trolley beam acroSS the top of the upper level changers. Although the tube bundle removal structure
and directly over the exchangers. If a tube removal is higher for the vertical configuration, the drop zone
structure is not used, a tfOney beam located directly at grade is at its absolute minimum.
over the channel end of the exchangers on level I As illustrated in Exhibit 12~22, the platform area for
DRUM UpPE:tZ
.
294
EXHmlT 12·1S
Pipe Chase Detail
I .
~ceFq~rkPg~~~~;.~~!_
I\,i
'. J
;\i
I:
i ,
"II
I/\!
r ~
I
~-\-----~~------LL
~N
Exhibit 12~13 provides three variations of equip- load to be maintained by the monorail.
ment suppon. Detail A is a kettle supported on lugs at A pipe chase, shown in Exhibit 12-15, is usually
floor level; the major portion of the vessel sits below found within a building or structure with concrete
the supponing floor. Detail B illustrates an exchanger floors. The chase on each floor is lined up free of any
supported by lugs below the floor) with a steel frame obstructions and allows utility and process piping to
hung above the equipment to secure it at the required run between all floors with minimal changes in direc-
elevation. Detail C shows a common method of sup- tion. Individual lines should penetrate the floor at the
porting horizontal equipment. In this applicatioI1 the
J desired locations and do not use a pipe chase.
main structural steel members must be located under
the saddles. Additional steel may be reqUired between
the supporting beam and the saddle to achieve the SMALL STRUCTURES
desired elevation, or the exchanger saddle may sit di~
rect1yon the structural beam. Exhibits 12-16 through 12~20 show variations of sfuall.
A monorail layout is depicted in Exhibit 12~14. structure design. The physical size of any structure
When equipment requires constant maintenance, a should be strictly limited to the space required for
monorail is often used to service it not necessarily in a
J equipment operation and maintenance. The first
straight line. Client input is required before this fea~ small-structure scheme) in Exhibit 12-16) illustrates a
tore is added) because mobile handling equipment common approach, in which one piece of equipment
may be an alternative to this approach. When a mono- is set above another to accommodate a graVity-flow
rail is planned, the plant layout deSigner highlights the system. Although the design appears reasonable, there
lifted load on the drawing to signify the maximum may be an alternative to consider.
Structures
£
341
1 EXHIBIT 13·45
, IW'?\/f- Diked Area Drain
~----
i Dl~f;-
I
I
EXHIBIT 13..46
Lift Station
Process drains normally run below grade may he ing with vendors who specialize in providing this ser~
~ssured to remote treatment facilities through vice. FRP, lined, and PVC pipe are just a few examples
)ve~ground piping. Another solution is possibly to of available prefabricated double-containment piping
uble~contain the gravity flow drain system carrying systems. Primary drain lines, sometimes called carrier
, contaminant. It is suggested all local environmen· pipes} come fully fabricated with supports within the
laws be thoroughly reviewed by the operating com· secondary pipe or containment line. This service
ly before any decision is made on this vital matter. greatly reduces field installation time that can translate
)uld double-containment be the selected means of into significant cost savings.
sfying such regulations, the following exhibits are Exhibit 13-47 is a composite schematic sketch of the
1e suggested ways of dealing with the layout. various containment features covered in the followiing
Underground Piping
342
EXHIBIT 1347 Double·Containment-Systems Sketch
L_
Key:
tD leak dt!t<:!'ction
exhibits. Exhibit 13~48 is a drain hub with a P"Tcap. Because it is possible to suck the water se~ out of
The secondary containment Hne should be sealed to a P-Trap caused by the introduction of variable flow
the drain line approximately 1 ftl300 below finished rates downstream, it is important to vent underground
grade because it is not likely that any liquid entering drain systems properly. Exhibit 13-49 shows how the
the drain pipe would ever reach this elevation. As with vent is branched off the dean-out line. The vent line
many aspectS of underground systems, it is important may discharge into the aunosphere or closed system
to understand client philosophy on providing a vapor for disposal.
seal. Solutions may include use of a P·Trap, Running Exhibit 13·50t a commercially available component,
Trap, Sewer Box seal, or insertion of a commercially is a suggested means of effectively providing a seal to
available seal into the effected drain hub. new or existing underground systems. It comes in
'arying sizes and is inserted into a hub and sealed with spilled liquids or vapors that may have entered the
.caulking compound. A clean~out plug is provided to secondary containment pipe. An internal dip collec~
lush out any debris that may collect in the system. [ion line is precast into the sewer box, and should be
Exhibit 13-51 highlights a number of features for a large enough to permit cleaning if required. A 1~in
lesigner to consider. A prefabricated section of pipe is vapor leak detector line should be run from the top'of
nbedded into the concrete wall. A ¥2 in/OIS-thick me effluent carrier pipe, through the top of the sewer
Ilate is welded to the secondary line to act as a water box. A pomble leak detection device can routinely be
eal. A I-in drain line is provided to remove any leaked attached to check the integrity of the system. Perma-
:laterial from the containment line. The exterior wall nent detection devices are also available.
f the sewer box is covered with a polyethylene mem~ These few sketches are juSt some examples of how
'rane liner that acts as a condary containment bader. the new and changing environmental laws may impact
Exhibit 13-52 shows one means of dealing with any the design of underground piping systems.
Underground Piping
344
UNDERGROUND COMPOSITE
Exhibit 13-47 is a composite of the various under~ '~All spread footing sizes and elevations to ensure that
ground piping systems discussed in previous sections ~ foundation has not been undermined by entering
of this chapter. The circled numbers refer to details the angle of repose.
shown in Exhibit 13-25. Shop-fabricated piping sys~ $ SpaCing prOVided between lines and cover.
terns are the only underground lines assigned line .. The data transferred from the draWing to the sewer
numbers. All other piping is fabricated and installed box schedule to be used by the cons~ructjon con·
from informatiOn supplied on this drawing. When pre- tractor.
paring this drawing, the plant layout designer should
• All line-size calculations from the data recorded in
double-check the following:
Exhibit ] 3-14.
• All above-ground piping layouts to ensure that al1 • All piping interface points between the new facility
drain points have been picked up. and any existing piping at the site.
It Coordination of the locating dimensions, interface $ The issued construction piping and instrumentation
point, flange size, rating and elevation, and bevel diagrams to ensure that all Jines have been ac-
end schedules and elevations. counted for on the underground piping plan.
Instrumentation
Instruments play an important part in the operation from a panel within the control room. This is achieved
and control of modern process plants. Instruments by a mechanical, pneumatic, or electrical connection
indicate, record, and control such process and utility from the instrument-sensing element. These arrange-
flows as liquid volume, temperature, and pressure ments are referred to as local and distributed control
conditions within equipment and piping systems. Al- systems. Exhibits 14-1, 14·2, and 14¥3 show typical pip-
though the instrument engineer is responsible for de- ing and instrumentation diagram arrangements for
signing the instrumentation to operate and control the these syStems.
plant, the plant layout designer must understand the
system to position the associated controls.
This chapter highlights the general requirements TYPES OF INSTRUMENTS
for the layout of instruments. It also discusses what
information is reqUired· to locale, operate, and main- Most process plants have many instrument compo-
tain the most common types of instruments associated nents that must be incorporated into the design by the
with these facilities. plant layout designer. The most common are vessel
Instruments give information about the internal level instruments, pressure and temperature indica p
conditions of piping and vessels and, when required, tors, control valves, and flow elements.
about control temperatures, pressures l liquid levels, Control valves are installed in piping systems to
and process flow. Temperature, pressure, and level automatically control the flow of process and utility
gauges are regarded as locally mounted systems and gases and liqUids. This control is achieved by com-
are placed in piping systems and on vessels to facilitate mands from the sensing elements through transmit.
visual readout. Instruments can also be monitored ting and controlling devices, The body of the val~e is
from a control panel adjacent to the components or similar in design to the conventional globe valve and
IJ
EXlIWIT 14..1 Locally Mounted System EXHIBIT 14..2 local Control System
PI
003 ,
W
/TEMP'I!fU,..,..... sz.E
Grlr..uGtE
PrlE. ..a12E
"AuGe.
345
346
EXHmlT 14~3
Distributed Control
y O~IFIc.e
I.Ao-l (:) E; ~
System
,, .... ,
t
I
t I
~----~
"V. ~
v~Lv
.1
347
EXHIBIT 14-5
Flow Instruments
TAP:>
a. Orifice Flanges
attachment
Pressure measurement for piping and vessels is
achieved by the installation of dial indicators or by
distributed control systems. The piping and vessels are
tapped at the required location and furnished with a
3/4-in threaded or flanged connection and a block
valve. The dial indicator is screwed into the block
valvej if a remote readout system is required) the valve
a. Pressure Gauge becomes the sensing connection. Like the thermocou·
pIe) the dial can be either fixed or swivel-headed to
facilitate readout. A dual local indicator and transmit-
ter system needs only one tapping point Exhibit 14-9
depicts a typical pressure gauge and a dual'pressure
systenl hookup.
Level gauges are installed at vessels to check the
liquid level visually. They consist of metallic box seg-
ments with heavy-duty glass insertions and l/2-in
threaded end connections. A 3/4~in-by·1j2-in threaded
angle valve is used for the connection between the
gauge glass assembly and the vessel. Generally, a 3/4~in
block valve is required betvleen the angle valve and
b.. Dual Pressure System the vessel; the vessel connection is threaded or
EXHmlT 14-10
Level Gauge Assemblies
NoTE:
~
l.£."eL MA" e.S;
v,e.we.o ~M 8o"'flo\
~\l)e~.
I I
•
,J
I
I
Ii
b. Reflective Glass
350
SENSING
UNIT
---DISPLACEA
_ _ _ EXTEANAL
CAGE
351
EXHIBIT 14..12
ExternaJ-Cage Level
Switch
ENCLOSING TUBe - - - - l J - - - f
TUBING r--- --
I
---'\
I
I I
I I
I I
I I
MAGNETIC SLEEVE .
I
I
:
I
I
I
l.~ .J•
.'\'
"
ENCLOSING TUBE - - - - - -
MOUNTING NUT
fLOAT STEM
FLOAT _-.....wILl
FLOAT CHAMBER
langed. Exhibit 14~ lOa shows a typical level gauge the sensing. device. This device is connected to the
lSSembly. It should be noted that if reflective glass is control valve actuator directly for local control or to
pecified, it can only be viewed from one side, as the control room for remote recording and contrql.
ihown in Exhibit 14~ lOb. The liquid flows through the chamber to the vessel by
Aside from the level gauge) which is a local visual two flanged or screwed connections that are mounted
'eadout instrument, many devices are installed at ves- on the vessel's side or on its top and bottom (or both).
iels to control and record liquid levels. The displacer~ The size of the connections usually ranges from 1 in to
ype level controller or transmitter and SWitches are 2 in; a block valve is installed between the vessel and
he most common. Basically, these operate by a float the chamber to suit maintenance requirements.
)r displacer in a chamber that reacts to the changing Another type of level control instrument is based
evels of the liquid in the vessel and, in turn, operates on 'an internal ball, which is generally used in vessels
352 L
EXHmlT 14-13
Side-Mounted Internal
Level Switch and
Transmitter
a. Switch b. Transmitter
T
hibits 14-11 through 14-15 display typical examples of
EXHIBIT 14..14 Top~Mounted Internal Level Switch these applications.
and Transmitter Exhibit 14-16 illustrates the level control operating
principle. A directly acting proportional controller is
illustrated. A decrease in vessel outfloyv causes the
liquid level to rise. Buoyant force on d'isplacer C in-
creases, unloading range spring E, which causes the
displacer to rise. Attraction ball J rises inside the en-
closing tube G. Magnet H follows and rotates cam L
clockwise. Flapper M moves closer to pilot nozzle K,
increasing pressure in chamber Aof relay B. The pres-
sure increase opens check valve S, increasing output
pressure to the control valve) which throttles, decreas-
ing flow into the vessel. Simultaneously, feedback bel~
lows D senses the increased pressure and expands
against proportional band spring N, ending pressure
buildup in chamber A by driving pilot nozzle K away
from flapper M. As a result, the liquid level is stabilized
at a high point within the proponional band and ves-
sel outflow again' equals inflow. The reverse cycle
takes place on a falling liquid level.
INSTRUMENT LOCATIONS
~
SUPPL Y PRESSURE
_----f-r-----.'" ..........
FILTER REGULATOR
OUTPUT PRESSURE
REMOTE MOUNTED
ReCEIVER RECORDER
----:H--...... (OR INDICATOR)
uaUID
LEVEL
CONTROL
VALVE
D1SPlACER
VA L.V e
i2uNNION
f>A?e
SUPPoK!T
....,ltJ.
TRUNl'J'ON
E>I..OWOFF
VAt-V£:,
1. Multiple fittings may be considered as single bend,; there is an interference between the valve and the •
when aU but one line is usually blocked off. measuring device I the minimum distance between the
2. The length of run upstream from the orifice must be intermediate interference and the measuring device is
equal to or greater than the number of diameters required by the applicable det;lil-that is, the
reqUired by any fitting upstream from pipe segment x. . measurement of material flowing inside a pipe should
be made downstream from the interference. The
3. If a control or other throttling valve must be installed
remainder of the 39 diameters is between the valve
upstream from a flow measuring instrument, the
and the intermediate interference.
minimum straight run requirement is as. shown. If
Instrumentation
356 F i
EXHIBIT 14-23
Pressure Tap Locations
P\
i20!
.'1'
.'
PI T'
'01 to~
Tl
n
~I j
I I
~
Process liquid
Storage Tanks
Steel containers are w.,ed for storing liquids in a pro~ All NFPA codes are recommended as a oasis for
cess plant. Although many such ve~sels are found legal regulations. They are intended to reduce poten-
within the confines of a process unit. most vessels ~md tial h;Jzard~ to puhlic safety, but compliance does not
tanks arc located in arc:.lS commonly referred (0 ;IS off eliminate such hu/'..ards as those that occur when Ibm-
,ite~ or tank farms. Tht' tv..'o most important factors m3bk and comoustihle liquids ore stored in process
~overning these r~I}'outs are safety ;Jnu c(:onomics. Any facilities.
~-ompn:hcnsive design must consider Jocal codes ~lJ)d
regulations. dient spccitications. [opography, 3dj~ct'l1£
The Occupational Safety
xoccss unit"s, and neighhoring commercial or resi-
and Health Act
jentiaI property as well ~ls m<limenance, operation.
md construct iOWIY. This chaptcr discusses the most The main considerations in the layout of sloragt· facili¥
:ommon types of S(Of:.tge vessels, plot plan :lrr~1J)ge· tie~ that fall under OccupalionaJ Safety and Health A<:t
nems. safety considerations. spill containment. pump- (OSHA) regulations :.1re personnel, access ladders. and
ng, ~tnd general piping layout stairways and catwalks.
359
360
"O!""- •• ,
DiSUlbution system This comprises equipment. pip- keeps the foot valve open, When the pump is re~
ing mains, and services that carry and control gas sup· moved, the spring-operated foot valve closes the riser
plies, pipe.
Diversion channel A diversion channel directs dan· Heaters These are heat exchangers used inside .large
gerous produCt spills away from primary diked areas storage tanks. They hear viscous materials using steam.
(0 remote holding ponds. hot water, or other heating fluids.
Diversion dike This is a barrier designed (0 divert Hortonsphere This spherical \'esseJ is used (0 store
spills from other srorage tanks: it uses natural terrain liquids and gases at high pressure, ;
to direct liquids to a sump area.
Intermediate holding tank This tank is used for tem-
DoubJe·wall storage tank A douhle·waU storage tank porarily storing a liquid until it reaches a specified
has an inner wall to contain a liquid. an annulus space state. at which time it is pumped downstream in a
usually filled with insulation, and an outer \'\'all for process.
spill containment
Remote impounding basin Used for temporary stor~
Fixed roof This is a JOVit-pressure tank With a foof age of pOtentially dangerous liqUid'). a remote im-
that is welded to the shell regardless of roof design or pounding bac;in is a containment area located away
method of supp~rt. from a process or off-Site facility,
Flame arrester In the evem of lightning or another Sediment This sludge accumulates in tanks and pip-
source of \'apor ignition, aflame arrester in the vent ing. It consists of dirt, \vax. and mill scale and must be
. line of a storage tank prevents flames from flac;hing {() disposed of periodicalh',
the vapor inside the tank.
Sleeper Sleepers are steel or concrete supports usu-
Flame snuffer This is a device in a tank vent line that· ally located within 18 in (4;0 mm) of grade for piping
can be operated manually (0 snuff out ;.l t1~me at the systems commonly found in off sites.
open end of the vent.
Sump This is (he lo~v point within an area used to
Floating"roof tank A tloating~nx)f tank is designed to collect liqUids for remo\'al.
conserve vapor loss and minimi:le fire h~rd,
Tank fann A location with many storage tankr; is of·
Foam This is a solution with ~ density lower than th~u ten c-.A1led :1 tank farm.
of oil and water. It is used to form a hlanket over
dangerous vapors and therehy reduce the risk of ex·
pJosion. TYPES OF TANKS
Foot valve This valve is found at the hottom of a riser Storage tanks come in many shapes and sizes, accord·
in a tank, where .a suhmersibJe pump can he housed, ing to the t)pe of product to be stored, its potential for
During regular operation, the weight of the pump fire~ and the amount to be held. This section discusses
the most (001n10n iype,o.; of vessels t{)Und in most pro- por Joss and minimizing nre hazard. It b commonly
cess facilities. found in oil refineries.
EXHIBIT 15..7
Concrete Dike
IWS &
EXHIBIT 15..8
Double Containment
Diking Method
r
EXHIBIT 15..9
Earthen and Concrete
Combination Dike
364
£ a
EXHIBIT 15...10
Natural Terrain Diking
EXHIBIT 15-11 NaruraJ Terrain Diking with Tanks Containing Highly Volatile Uquids
- trz
.
K
~·.,.' ""'-"'~' --=~"~~- EXHIBIT 15·12
Plant Topography
EXHIBIT 15..13
Earthen and Concrete
Containment fQr Buried
Low-Temperature Tank
I'
of a tire spreading from one sphere to tht: other. A~ a ing facility. Therefore, extreme ~afety measures ,are
result of (he natural terrain, the spill is directed to its employed, as shown in Exhihit 1';-13. The inner tank is
safest poim within the dike. heavily insulated from the outer concrete containment
When the overaU plot plan for a process facility is and is huried in an earthen containment.
developed, offwsite storage should be set at a lower Developing a layout for huried storage tanks in an
elevation than the process unit whenever possible. ex"isting chemical plam often poses special prohlems.
This approach (see Exhibit 15~12) provides an addi- It may not he possible or practical to move existing
tional margin of safety in the event of a olajor rupture. underground obstructions in the area in which the
Containment of potentially dangerous liquefied tank must be located. One solution to this problem is
natural gas spiJIs is a significant concern to any operat- to hury the tank ahove grade in u concrete c.:onwin-
EXHIBIT 15..14
Tank Buried Above
Grade
ment. as shown in Exhibit 15-]4. Pumps. maintenance nance vehicle ram p should have a maximum grade of
access, and all appurtenances must be instalJed in the 15%. It should be located on the side opposite the
roof of the tank pump area. Personnel access should be by stairways
Spills that pose a high-risk to adjacent facilities must designed according to OSHA standards. A single stair-
be diverted to a remote holding area. One method way located at the pump area provides access to a
would be to erect a concrete diversion canal (see Ex- catwalk located on top of the dike. Two other stairways
hibit 15·15). Drain valves that are located outside the provide service access to the dikes, as sho\\n in Ex-
diked area usually would be dosed but would be hibit 15-16.
opened in the event of a critical spill. Sump drain lines When a layout of a tank farm must be developed at
discharge into the concrete diversion canal and flow an existing facility, unmovable objeas or structures
downward to a holding basin. may obstruct the dike area. Exhibit 15-17 shows how a
dike may be designed to accommodate obstructions.
Such designs are routine, but the spacing between the
DIKE ACCESS outside sheIl of the tank and the obstruaion must
meet NFPA or other governing regulations.
Consideration must be given to providing vehicular When inhiaUy trying to establish a tank farm layout,
and personnel access into diked areas. A typical ar· . the designer should consulc NrPA codes and local
rangement is shown in Exhibit 15-16. The mainte· ~ codes and regulations. Rules for spacing between
367
EXHIBIT 15 15
M
EXHIBIT 15..16
Vehicular and Personnel
Access
I ~!ZW~_
~
368
2& ft. Next) the designer reads to the right until the de-
EXHIBIT 15..18 Tank Berm Volume sired capacity (861 724 f(3) is found and then reads
1
TANK DETAILS
--- - - -- -_ .
;
4ZSI " - .
$~O' ~I=-=:-=::.l::::==::j=~~~=:::::~~~-t--
3~t 1--~-4----+-~~~:~
:?~
U1
aU
iL
(/) 15
ill
~
5
LL
0
:r 8
K
3
:I:
.....
\!J
Z
ill ~
..............
~ ~
_ • • _ .... L •••
~ ~,:
...J ',' : • •• _ ..... ..... : :: .. 1 •• : ••
2.5
7 8 9
1.5 2.5 6 '1 8 9 1
l
Process Plant Layout and PIping Design
371a
2
EXHmlT 15..20 Tank Details
e·.. . ·,-..1JI'"lo.c ••
Ii
EXHIBIT 15..21
Tank Maintenance
Accesses
~. ..'
. ..:.~
"," ',...
<W-"._ . •
EXHmrr 15--22
Valve Access Carwalks
VALVE:
~TENSlot...1.
~IEM
18
EXHIBIT 15..23
Tank Mixers
nat heaters. The layout designer must keep the area Cltion must be given to (he elevation of all valve hand u
inlmedi:,ltely around access openings free of such ()h~ ""heels in relation to the cam'alk Adding extension
slructions ~s large pipe ~uppons. piping. and light seems to smaHer valves will facilitate opening or dos-
poles. ing such valves.
Valve aCcess cat\\-alk,;; can he seen in Exhihit 1';-22.
h is of utmost importance to give operarions person~ Tank mixers A tank mixer. shown in Exhihit 15-23, is
net adequate access to primary tank valves. Consider- -- another auxiliary piece of equipment found in tanks
--_..
~ ...
.- . . . - - ...... _,.
~.-
CO~I-ISb::r-e
. ~ ::'::a~-:..~Il?""I
'jth highly viscous fluids. Adequate area must be pro- tanks) consideration should be given to designing in-
ded for removal of tank mixers. terconnecting catwalks for operator convenience. The
limiting factor is catwalk length, as shown in Exhibit
mk heaters Tank heaters come in various sizes and 15-26. Travel distance to exits in high-hazard industrial
lapes, as shown in Exhibit 15-24. Sufficient unob- occupancies shan not exceed 75 ft (23 m). Additional
rueted space must be provided outside access open- length can be accommodated by adding ladders or
gs to permit removal of heaters. stairways.
Because of the need to avoid imposing heavy loads
oating-roof tank access Access to floating-roof on the external tank or containment walls of most low-
1k() is shown in Exhibit 15-25. The strJight stairway temperature tanks) consideration should be given to
l the left of the diagram can be used for tanks of all using access lowers (see Exhibit 15-27). The rectangu-
lJUeters. Each stairway must have a landing outside lar tower on the left of the diagram supports all piping
~ tank wall that allows adequate space for the stair- and a conventional stairway; the circular tower on the
ly) provided by the tank vendor) down to the floating right ~arries all piping inside with a spiral stairway on
:Jf. the outside. Both provide access to the operations
For Storage areas with many small or medium-sized platform at the top of the tank Economics and client
preference usually diaate design selection. tions. Layout designers should understand the funda-
Another approach to accessing lank roofs is shown mental nature of each design to optimize piping, stair-
in Exhibit 15-28. In this design. the interior dike eleva- way, and ladder locations without creating problems
tion is lower than the outside grade, and all tank con- for construction or plant personnel.
nections are on the roof. Therefore. consideration A concrete ring wall is shown in Exhibit 15-29. The
should be given (0 adding a catwalk over the dike tank is supported by Class I compacted struaural fill as
parallel to the piping. Plant personnel use a stairway well as a ring wall that is 12 in (0.300 m) thick.
on the dike'5 outSide wall to reach the catwalk, which Compacted granular fill support is shown in Exhibit
connects (0 a ladder to the operations platform on top 15-30. The tOP of the tank berm is 3 ft (0.900 m) wide,
of [he tank. slightly sloped away from the tank wall,' and coated
with asphaltic concrete for weather protection.
A low-temperature tank foundation design is shown
TANK SUPPORTS in Exhibit 1;·31. This particular design employs a con~
crete slab supported by columns, providing an air
Four common tank support designs are shown in space under the slab. This air space helps raise the
ExhibitS 15-29 through 15-32. The civil engineer is temperature of the slab during a failure in the primary
responsible for determining the most cost -effective tank.
design, on the basis of available data about soil condi· A more conventional low-temperature tank founda-
375
EXHIBIT 15..27
Piping and Personnel
Access 1'ower
--...,.---.~TloN2 r.:U:q:.COfZlv1
CYLlt-..JD~\C.6L
·VT~
.2fA1t2w.c.y
P1~~~
/~C&e~
~t--~t-~~~~i§~~~~~~~~~--t.~--t.~
EXHIBIT 15-28
Elevated Pipe Way
and Catwalk
'"fl»Jk=:~
~~~~.~- =t~)Il;&>±
Gi~U~ cJ-A~ I.
~p¥Teo #{EUC[LJ¢A!..
FILL "
EXHIBIT 15..30
---.::;:::~.. "~ ..
Compacted Fill Tank Pad
- - ~~~
t'~"T"H-ICK
ASP"'lALTIC- .,t
~cae=Te:
EXHIBIT 15~31
low-Temperature
Tank Foundation with
Elevated Concrete Base
/
c;oLUM~
don i~ shown in Exhihit 1:;·32. This design has an diem preference, Exhibit 1;-33 shows the pump 10·
emheuded heating element for use during pos~ihly cared in the eanhen diked area. surrounded by a
damaging spills. C{"msultalion with cl\'iJ engineers h~ curbed wall that is I S to 18 in (0,380 to 0.460 m) high.
fore any tank layout is undertaken is necessa~· to ef- This design protects the pump from minor spills
fectiveh'" use each design. within the dike and enables the discharge piping to
To t:~whlish the optimum location for pumps. con· exit the dike. over the v.,oaU. thereby eliminating the
sideration must he given to potential hazards and to l1eed for dike-penetration seals. Piping outside the
EXHIBIT 15-33
Pumps Inside Diked Area
A~
rifE ~K ~ 7LeEpe~S
EXHIBIT 15-34
DI~ Pumps Outside Diked
An,'a
rr=--
II
II
II
ike may run on a pipe rack or sleepers. maintenance philosophy. Sleepers permit unob-
Pumps located outside the dike are shown in Ex~ structed pump access when located hetween tile
ibit 15~34. Tank outlet piping can either penetrme the pump and the dike waH. Pumps located under pipe
[ke or pass over, as shown in this exhibit. The latter racks support discharge piping hut limit access to
)proach would usually be considered if the maxi- pumps during maintenance. Prime conSideration
lum dike height were 6 ft (1.83 m) and if the mini~ should be given to prOViding an ample nlainten311ce
lum liquid level in the tank would not cause damag- area· around and above pumps.
19 cavitation in the pump. The designer must Locating pUITIpS inside a concrete <.liked wall is
lrefully examine each layout before enlploying this common in many process p}ant~. The approach shown
~sign. The location of an elevated pipe rack or in Exhihit 15-3') shows the pump block set at the same
~eper relative to the pumps should account f<)r planr elevation as the dike. With this configuration, the
BSIi
EXHIBIT 15-35
Pumps Inside Concrete
Diked Area
EXHIBIT 15.. ~
AL~~~L ~r: .... N Buried Produc[·Transfcr
Piping
7.:~~~;: ~
pump would not be submersed during a spill inside
EXHIBIT 15..37 Dike-Penetration Seal the clike. This configuration enables a dose·coupled
piping arrangement. Providing for differential settle-
ment allows the discharge line to be run to the pipe
~ .. rack over the dike wall. This approach should be ap-
~ 111
/
379
EXHIBIT 15 38 q
~pe=~eEVE:
IN'2lJ LA1ION
EXHIBIT ] S~39
Differential SC'ttlc:ment
pipe sleeve that must be sealed on the inside of the settlement (distance A) yields the differential settle·
-iike. This design permits minor line movement. A ment between the two. By figuring line size, wall thick-
"::xess or suppon engineer should be consulted when ness, and allowable stresses. distance C can be estab·
>~?e designer is planning its application. lished. Differential settlement can also be caused bv
tilting of the tank, by out~of·plane settlement, or by
)ifferential settlement This concern must be ad· dishing of the tank bottom (which is a result ofgreater
',ressed early in the layout of any process unit or tank settlement at the center of the tank than at the edge),'
f~rm. Exhibit 15-39 illustrates differential settlement. The optimum piping arrangement in a tank farm. as
the foundation of any process faciliry will eventually elsewhere in a process facility. is the most direcr route
.dttle or sink to some extent, depending on the weight between two points, allowing for normal line expan-
'>carries and the condition of the soil. To determine sion and stresses. Exhibit 15·40 illustrates piping be-
where pipes may be supported safely without impos- tween tank,; and pumps.. Anchor points, or places
INg excessive stress on equipment nozzles, a civil engi- where piping movement is restricted, must be esrab-
_}~r and soils experts must work together to deter- lished._Tank nozzles are one such anchor point. The
. '~:ine how much the foundation is likely to settle. second anchor point may be the pump nozzle if line
~"~btracting sleeper settlement (distance B) from tank growth is permitted through the dike, or it may be
ExumIT 15-40
Alternative Piping
Layouts
:J-~tZlJ61Mk
B:'MF'N9
an~where along the piping within the dike or m {he under the road. making allov.:ances for vehicular loads
point of dike penetration. To minimi:!e the potential imposed on the pipe. or by placing them over the road
for tank spiIJs, expansion joints should nor be used. on a pipe hridge. Client preference should he consid-
Exhihit 1:;-41 shows how to accommodate line ex- ered in this design. Adequate access 10 pumps on the
pansion oetween tJok no%zJes and a manifoJd header. side of the pipe way opPosite the road must also he
Expansion loops may he 3dded at the sleeper level. as provided.
shown for lines A and B. Expansion may also he al· A bulJet~tank piping layout is shown in E~hibit 1s~
lowed (Dr hy running line C direccJy over the header. 43. Tanks are set at the lowest possible elevation to
perpendicular to the portion of the line cJusing (he satisfy pump head requirements. A catwalk is located
expansion. across all four tank~ to provide sufficient access to
Exhioit }-}-42 illustrates :.t crOss section of piping. operating valves and instruments. Liquid outlet piping
pumps. dikes, and a primary pipe way that is typical of to (he pumps should allow for differential settlement
what might he found in a tank farm. Because the prj· and Hne flexibility. A fire water spray protection Sy5~
nlary pipe way is Jocated to the left of the roadway. tern for bullet-; is shown in Exhibit 13-36.
pump-discharge line:-; across the road must be routed A typical piping arrangement for a high~pressure
(0 the headers in one of two way~: by hurying them _ Hononsphere is shown in Exhibit 1544. Layout factors
I
I
EXHIBIT 1541
Tank Piping Layout
DIKe
Er 11
E-AEqH~N Me-DNKMC:N}
~~I#H
)r spheres include: the operations phnfonn and tank roof. Additional Iad~
dens are provided from the circular acce~s road
T~nk elevation should be kept low hut not less than around the tank (0 the catwalk. This platform provide~
5 ft (1.525 m) above grade. access to relief valves, vacuum breakers, maintenance
Ideally, each wnk should have its own swif\\,(ly- access openings and instrument~.
1
Exhibit 15-44 shows an acceptable alternative ar· If an above"grade, more conventional layout is pre-
rangement. ferred for liquefied natural gas tanks. a Javout similar
Valves should be installed as dose as possible to aU to that shown in Exhibit 15·47 may be ~sed. NPSH,.,
requirements usually necessitate locating the pumps
nozzles.
in a pit when the tank is above grade. A submersible
Typical layouts of liquefied natural gas tanks in an pump and its motor are located within a containment
lrthen embankment are shown in Exhibits 15·45 and vessel and supported on lugs. An adequate dear area
)·46. Features of this arrangement include: directly over the pumps must be maintained to allow
pump removal for maintenance. Motor-operated
The secondary contaloment is a steel·lined concrete header valves are located at grade. and made accessi~
structure. ble by platforms. Individual suction and discharge
valves are located near the nozzle connections in the
There is heavy cryogenic insulation between the pri-
pit. Safety requires that a water·deluge fire-fighting
mary and secondary containers.
system be induded in this layout as well as a sump and
The earthen embankment provides an acceptable sump pump to remove unwanted water. '
margin of safety in the event of tank failure. When high-pressure bullet tanks are located close
Submersible pumps are located at the bottom of the to a process unit, a protection berm is often used (see
pump shaft. Exhibit 1548). Berm length .is slightly longer than the
The roof is steel domed. width of the tank area, and the berm height is roughly
The operations platform, piping, and jib crane are equal to the height of the tanks. These berms offer
~upported from the concrete containment wall. some prOtection in the event of an explosion.
Although foam fire-fighting systems. are often sup-
The staiIWay on the pipe trestle provides access to plied by companies specializing in fire protection! a
384 F ., .._ .
=
385
Dlk!. EXHIBIT 15*47
Ahove·Gradt, Liquefied
Natural Gas Tank l.ayout
EXHIBIT 15-48
Protection Berm
Ft2'o~
:€OlJ~~ Of f"OAl0 COt..JCE:~:p;:.
basic understanding of such systems is beneficial to a age tank through a permanent line especially for that
layout specialist. Exhibit 15-49 sho~rs an arrdogemem purpose.
in which foam concentrate is pumped with water from An alternative to mobile fire-fighting equipment.
a truck to a storage tank. The piping usuaJly has quick- permanent hydrants and monitors may be used for
<'Onnea coupling located outside the dike. The line is fighting fires in storage tank areas. Local codes and
routed to the tank wall. A foam maker-which essen· regulations as well as the latest issue of NFPA mUSt be
tially consists of a pressure gauge. an air strainer. and a consulted to establish the appropriate coverage of wa-
check valve-is located in the vertical riser. The foam ter for a given layout. Exhibit 1;-51 shows hQw fire
solution enters a foam chamber located at the edge of hydrants and mon,itors may be arranged in a tank farm.
the tank roof and then discharges across the top of the The fire water piping around thiS area must come
liqUid in me tank. from two supply sources should any pan of the. system
Another way of injecting foam into a tank is shown fail.
in Exhibit 15-;0. Foam concentrate from a truck or Exhibit 15-52 illustrates an effective overall layout
tank is supplied to a foam maker located outside the of a process and off~site plot plan. The administration
dike wall. The foam may be injected into the regular area is immediately inside me plant's main entrance.
product transfer piping ~r routed directly to the stor- as are maintenance and fire-fighting equipment. Pro-
?bY
387
EXHIBIT ]5~50
Semiporrabk Foam
NO~Md.- Fl?ooucq: SyscL'm
J~N5fEl< LI~E:
EXHIBIT 15·51
t2oAO Tank Fire Water System
i!
I
*- FIl2:E
+ t?1~e
M~'T~
~"(ORAN:r:
F,rze
-fr f46H1'....,~ fJQLJI~M
-------,
j
~D~I~ro::."l ~ 11ot-J M.A It·.J'1''l3-J~Gf; / F
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r+- ao [3--
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...
_~
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f~ru~~111
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LV '-- I /. f\1I ~\~~ LVA'~'~
r $
I >__ • ! . ~! l./Ui1J~:
. . ·1 L \j ~---~
I / I S1!3Q:
$ t
~
I
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.~Il...ITY
______:.::.::=:JI, ~ __ .. _ _ .... ~=====
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$ I $~
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-$ ~ 4-
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:r I. . . . . I -$-$- __.m
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f\7 ~ / '\. /
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cess units ;md rht' utility plant are ]oC'~lted in the cen- the cooling [ower, across the Storage tank,;. and av..~y
tral and eastern section of the pJot, and a]Jowances for from busy process units.
future expansion are made. Storage wnk'i are located Tank farms can occupy vac;t area') of valuable real
in the western and southern sections of the plot. Truck estate within a process facility. Development of the
~lld raiJ loading und unloading areas are located to- optimum design. considering all applicable codes and
gether in the south and southwest corners of the plot. regulations. is achieved only through dose attention
A tlare swck. 3 cooling (ower. and tre-.lting ponds are in t~) safety and economics. Although many solutions to
the ~()u{h~Js( corner. layout problems are possible, a mixture of proven
Process unit'l are loCated ~s f:tr away as is practical methods-along with the commonsense lessons of
from the swragt' tanks and product-loading ::treas. In trial and error-will produce the optimum design.
cold climates, the wind will carry e,,;hausl g:tses from
CHAPTER
Stress Analysis
INTRODUCTION TO PIPING STRESS tors. Some aHowable stresses expressed in this chap-
ter are not addressed or defined by the code. Rather,
The impact of high piping stresses on operating piping we chose some of these lower limits to assure a high-
systems can be dramatic and costly. Yet for many pipft quality, cost-effective, piping layout.
iog designers. piping stress analysis is the Jeast- Before going funher with stress analysis itself, let us
understood area of piping knowledge. A thoroughly first address the work proce:)s.
analyzed plant will last longer and be more cOSt~
effective. Neglecting the impacr of the weight of pipe
and the thermal expansion of hot pipe can cause sig- PIPE STRESS ANALYSIS WORKP~OCESS
nificant maintenance problems. Some examples of typ~
ical maintenance problems due to high piping stress There are many steps in understanding how to layout
are the following: a plant with minimal piping stress revisions. The first
step is lO understand the work process on a project.
e Pump bearings wearing out. The steps the designer takes to assure quality stress
analysis during the design of a petrochemical plant
• Hairline cracks developing in vessel and nozzle junc-
may vary. The steps vary with the size and complexity
tures.
of the plant. Client requirements also can affect the
o Flanges leaking flammable liquids.
work process. The process described in the foHowing
• Pipe permanently deforming. steps is a typical process for a plant design resulting in
3,000 isometrics. Other processes may work equally
The piping layout designer and the stress engineer well. ,.
must work together as a team during the design cycle.
This team is critical to successful stress analysis. It is
Critical Lines List
critical because the solution to many pipe stress prob-
lems is an adjustment of the pipe layout. Exhibit 16~1 shows that the first step in the stress anal~
This chapter's purpose is toreduce the cycle time ysis work process is to identify the Jines on the critical
between the layout designer's proposed layout and lines list. The critical lines list is a list of line numbers
the stress engineer~s approved layout. This section will that are likely to receive formal calculations by the
accomplish this goal by prOViding stress background stress engineer. This list of lines is important to the
and easily used stress analysis tools to the designer. designer. It identifies those lines that have the most
Using these tools will assure the designer that his or potential for layout revision requests. The revision
her proposed layout will need little or no revision requesrs typically come from the stress engineer- on
because of a stress engineer's comments. the project. The designer will usually apply the tech~
We define pipe stress as the force per unit area ap· niques described later to the lines in the critical lines
plied to the cross~section of a piping component. En- list.
gineers typically express stress in pounds per square The stress engineer normally supplies the critical
inch (psi). Many of the codes limit the design stress on lines list. At times the critical lines list is not available.
carbon steel pipe to 20,000 psi or less. This limit is The designer can then use the following tables as a
associated with stress due to pressure and weight. This gUideline. There are twO tables used for determining
allowable can change based on attached. equipment, the critical lines. The designer uses the first table for
temperatures, load applications, and many other fac.. lines attached to rotating equipment, such as pumpsl
389
390
R.m.the
~lkD----l1llll ptplng layout
"'dl.~
Review 30
Model end
s.uppoft
Sc:homo
as shown in Exhibit 16-2. He uses the second table for work process that requires most of the designer's
all other lines as indicated in Exhibit 16~3. Because stress knowledge. A good layout at this stage reduces
pumps are more sensitive to pipe loading than other turnaround time between the stress group and the
equipment, pump lines are often more difficult to lay design group.
out. Many of the lines on a critk.-al lines list will be
pump suction and discharge lines. Analysis and Revision
To read the chart, the designer aligns the pipe size
(not the nozzle size) and the upset line temperature. The stress engineer will usually analyze critical lines
If the intersection of the two lines is not in the shaded with a computer. Over the last decade, the piping in-
area then the Hne is critical. dustry has made significant progress in computer·
aided engineering (CAE) programs. The CAE
programs have resulted in stress engineers analyzing
Stress Isometrics increasing amounts of linear footage. Stress engineers
The stress engineer uses the stress isonletrics to seIVe are also performing more iterations of analysis on the
as the basis for a formal calculation. The piping layout same stress isometric. Lower costs in computer equip-
designer draws the preliminary isometrics as shown in ment and increasing hardware performance are the
exhibit 16.4. . primary reasons for this increased level of analysis.
The creation of these isometrics is the step in the What is the impact to the designer? The impact is more
.I
Process Plant Layout and Plptng Design
391
EXHmlT 16-2
Pipe Stress Review
Criteria Rotating
::>eroting Temperature . Equipment Piping
00 r==------.-----------------,
00
Comp"Ier AnQIy~'l
Of
[Nlo~ed MonuOI Anolym
00
VdlJolAnolyslS ,.,..
Of
Jud(l'ement
00
10 12 I~ 16 III 20 22 2. ~Vii
visions to his or her original design as the stress only the critical lines. The conceptual study contains/-
Igineer attempts to improve the computer results. layouts for noncritical as well as critical lines. There-
lis step in the work process requires dose teamwork fore, the layout designer may receive a stress engi·
:tween the designer and the responsible area stress neer's feedback on the noncritical lines at this stage.
gineer. The authors designed the tools given in this chapter to
reduce this feedback to a minimum.
>nceptual Studies
TIlree..Dimensional (3..D) Modeling
Ie piping layout designer will generate conceptual
mographic drawings (planning studies) based on The 3~D designer builds the 3-D models based on the
ad layout practice and the recommendations of the approved conceptual studies. The designer includes
)e stress engineer. The plant. design supervisor cir- the pipe supports in the model. At this point revisions
I
lates these documentS to the other disciplines. The to layout due to stress problems are unusual. .
ess engineer will often write requests on this doc·
lent for additional steel, additional nozzle reinforce-
Isometric Extraction and Approval
~nt, critical pipe support locations, and other items.
fer to Exhibit 1~9 for an example of a "planning Plant design extracts the isometrics from the 3-D elec-
!dy. n Feedback from the different engineering de- tronic model automatically. The isometric checker re-
n groups concerning stress analysis requests may views each isometric. The· stress engineer then signs
mge the designer's piping layout. off on the isometric. The extracted isometric also in-
Up to this point the stress engineer has reviewed cludes pipe supports.
rnanently deforms (yields) but does not break. Re· thermal causes. These two causes are also the most
peated· bending of the paper clip will eventually crack common reason for loads on equipment nozzles.
and break it.
Weight
bnpacting Mechanical Equipment
Weight causes the pipe to sag, which put.;; stress into
For this section, we will define mechanical equipment the piping material and forces onto equipment noz~
as equipment that rotates or reciprocates. The most zIes. Proper spacing and design of suppor:ts, and care~
co.nm'on example of this type of equipment on petro- ful attention to concentrated loads can 'take care of
chemical projects is a centrifugal pump. The stress most weight problems.
engineer's goal is to Jitnit the amount of force the pipe
pushes on the mechanical equipment nozzle. When a
piping systen1 pushes a pump nozzle, the force de- Thennal
flects the linkage between the pump and the pump
motor. Excessive deflection (misalignment) of this When a piece of pipe gets hot, it grows. The pipe itself
linkage causes rapid wear of the bearings and other physically becomes longer as the temperature of the
parts of the pump. This extra wear results in extra pipe material gets hotter. As the pipe grows it pushes
maintenance effort on the pump. against the nozzles and supports that restrain it from
Who defines what an excessive force on a mechan- moving. With an improperly stress-analyzed system,
ical equipment nozzle really is? Typically, the manu- this "pushing" will cause pump bearings to wear out
facturer lists allowable loads for his piece of quicker, vessel nozzles to leak and perhaps even the
equipment. In some cases, the vendors build the pipe or vessels themselves to rupture. Also, the re~
equipment to a standard specification. An example is straint of this grovvth causes the pipe to deflect in
the API610 specification for centrifugal pumps. In directions different from an unrestrained pipe. This
these cases, the standard specification defines the al· "unnatural" deflection causes additional stress in the
lowables. pipe.
These allowable forces on mechanical equipment
nozzles often result in an equivalent pipe stress that is
Other
small. This eqUivalent pipe stress is typically a snlall
ponico of the allowable stress for the pipe. Therefore, The first two types of pipe stress problems cause most
it is sometimes difficult to achieve a piping layout that of the pipe stress effon. However, there are other
will satisfy the manufacturer's maximum allowable causes. The following paragraphs list some of these.
forces on a nozzle. The stress engineer on a typical Wind pushing on a pipe can exert large forces on a
Petrochemical project spends much of his time on piping system. Exhibit 16~5 shows the approximate
solving this type of problem. forces exerted on different pipe sizes 100 ft above
ground during a hurricane force wind of 75 miles per
hour (mph).
CAUSES OF PIPE STRESS These loads increase with higher elevations of pipe
and with insulated pipe. The Code requires that the
There are many causes of pipe stress in a piping sys- designer considers the wind in the design of piping
tem. The two most common causes are weight and systems. Wind loading that reaches 70 mph is not Ufl-
i8IIII
~OM]NAL DIAMETER 2 3 4 6 8 10 12 14 16 J8 20 24
VJNO FORCE LBfLJN IN 0.08 0.12 0.16 0.22 0.29 0.36 0.43 0.47 0.55 0.60 0.68 0.81
Isua!. Piping guides and anchors resist the wind Joad- routing of the piping system. Layout problems due to
19 on the piping system. weight stress typically arise for piping systems that the
The petrochemical piping codes require that the de- designer has elevated. The pipe stress engineer can
igner considers the loads due to earthquakes. The easily support systems that are dose to the ground by
:ode allows a simplified version of seismic analysis for using foundations or paving. When the piping layout is
etrochemical plants, otherwise known as a static anal~ higher than 6 ft, the stress engineer usually supports
5is. For areas of high earthquake activity, static analysis from existing structures. Therefore, the layout de~
sually results in latera] loads that are about a third of signer must route the piping system dose to these
Ie piping system weight. Pipe support engineers de- structures. Except piperacks, a designer will want to
gn pipe anchors and guides to resist these forces. avoid a situation in which construction would have to
There are some dynamic loads that a petrochemical build a structure to support one or two lines.
ress engineer encounters regularly. Pulsation load- So, how often does a designer have to provide pipe"
18 due to reciprocating compressors is a common support access to an existing structure? What is the
ress concern. The back~andoforth motion of the com~ allowable span for piping systems? The answers to
~essor pistons compresses the gas. The compressor these questions depend on the way the designer
lshes the gas into the piping system in pulses. The routes the system, the size of the pipe, the contents of
Jlses usually happen around six times a second. This the pipe, the pipe material, the temperature of the
eans that the pulsing frequency is six pulses per pipe, the insulation on the pipe, what the pipe con~
condo As a tuning fork has a natural vibrating Ere- nects to, and several other factors.
leney, every piping system has a natural vibrating For our purposes here, we will make conservative
~quency. If the piping system natural frequency is assumptions about many of these variables. Let us fo~
e same as the compressor pulsing frequency, large cus on the different types of pipe routing and the im~
ping detleaions occur. The stress engineer strives to pact different pipe sizes have on dle span. The
Ike the piping system frequency different from the designer will use different piping spans for each size'
mpressor pulsing frequency by adding and subtract- of pipe for three basic types of pipe routing. These
~ supports. three types of routing are piperack spans, branch
spans, and unsupported overhang spans.
lYOUT SOLUTIONS FOR WEIGHT
~RESS
Piperack Pipe Allowable Spans
le stress engineers can resolve most weight stress The first type of pipe routing typically encountered is
1I
>blems by the addition of pipe supports. For the pipe that is "continuously supported. This is the type
ling layout designer, this solution may change the of routing associated with pipes in a piperack. By con·
.....
tinuously supported, we mean there are at least two smallest diameter of piping typically allowed in a rack,
identically supported spans on either side of the span which is 2 inches.
in question as shown in Exhibit 16-6. For example for a 6·inch diameter pipe that fits
1
This type of routing provides a balance in loading within the parameters defined in notes 1 and 2 in
on either side of the suppOrt point. This allows a Exhibit 16-7, the allowable span is 44 ft.
greater span than what the designer will observe with
"free·to·rotate" end conditions. Exhibit 16·7 gives the Branch Pipe AUo~ble Spans
allowable spans for the continuously supported pipe
The second type of pipe routing that affects the allow-
routing situation. We should note here that although
able span is pipe that is "simply supporte).'i.lI This is the
we have. used the piperAck routing as a typical exam~
type of routing associated with branch lines coming out
pie, the designer usually spaces piperacks at 20 ft or 2S
of a piperack. What this means is that either end of the
ft between bents. This is partly to accommodate the
span in question is free enough to rotate slightly about
the support point. There is no span on the other side of
the support to hold the end afthe span from rotating.
u This situation makes the end conditions of the span
EXHIBIT 16-6 Continuously Supported Spans Hfree. Therefore, it makes the allowable span for
It
.I
Process Plant Layout and PtptnR DesIgn
ca
EXHIBIT 16-7 Allowable Spans for Continuously
Supported Pipe Routing
PIPE SIZE 2 3 -4 6 8 10 12 14 16 18 20 24
;PAN (FT) 25 30 36 44 48 55 56 57 59 61 66 70
NOTE: Normal spans for general pipewa:y design shall be within 20' (0 2$'.
he overhang is free to rorate and deflect. This type of Once the designer has identified the system as a col-
outing is acceptable, but the allowable span for each lection of one or more of these three types of routing,
lverhang is smaller than both the simply and contin~ then it is a simple matter for him or her to apply the
iously supported spans described earlier. correct table and determine the location of the suppOrt
The designer will use a graph to determine the points. Once the designer has the support points de~
lIowable span for unsupported overhangs. This is be- termined, he or she has the responsibility to make sure
ause the allowable span for one overhang changes that there is a structure available for the support to use.
rith the span of the attached overhang. The two over·
angs impaCt each other.
Other Weight Stress Problems
For example, for a 6~in diameter pipe that fits within
Ie parameters defined in the notes in Exhibit 16~ 11, So far when determining the span, we have only coo"
le allowable A span is 18 ft when the allowable B sidered the pipe stress due to the pipe weight. There
)an is 13 ft. A clB" span greater than 13 1 would re- are two other points a designer also should consider:
uire additional support. first, the significant effect concentrated weights such as
valves and pipe risers can have on auxiliaty steel lo-
cations; and, second, the imp~et of large weight loads
reaking Up a System into Its Spans
on equipment nozzles.
le designer can break up most piping systems into
le of the three different span types. Exhibit 16-12 Solving concentrated weight problems A common
ves an example of this. problem facing a stress analyst is how to support con·
398
/
Process Plant Layout and Piping Design
399
24
,~.: ):!~~~~(I~MIT(QTO~'15-0~-P,$, '~" .:
, 'D('f((C'rliH'~ -HM~lfD'
'~T~ l~·i. ~f: T:Il~ I~ D~ : I I • I I l
22
. , .
:
:
I
.
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..
. . .. ~-~.:.
20 -+- - . • • , • • •.• _. - .- - - - -~ ,~
I
*.
...... ~ ~
~- ...... +.
;
--..,....~~-r--r-r----+-
... .... . ~ ...
........-i-*H-~-+-*'"'-r--+--i-~-+----t'-t
*., l !
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14 ~-~-......-~-+-~-t---..,----
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. ,. J. ..• :1 t
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4 6 a 10 12 14 16 1a 20
II A" 0 VE It HA If G- f T
!!ll
tUViS .,,( TIl •• U8UM aUO"UlE
OVERRAN& Of Aft UNS8"O.T(~ 'IPE IfH'
flun W. HI tUTU A WITIII 1 ItF r
nSlUllO••
BI
EXIImrr 16--12
Piping System Showing
Three Different Span
Types
!,I...o'Y~to
~MUM
Step 1.0
Calculate the allowable force on the pump.
(10~in pump nozzle) X (200) == 2,000 Ib maximum
force allowed
Step 2.0
Calculate the expansion in the north-south direction.
The 15 ft 6 in leg is the only run in the norm-south
the nozzle allowable loads. Once the designer knows direction. (Reference Exhibit 16~15 for thermal growth
the rotating equipment allowable loads, he can enter a table.)
nomograph and determine the amount of leg needed
to satisfy the loads. (15 ft 6 in) x (0.046) = 0.713 in expansion
Rotating Equipment Nozzle Allowable Loads .M dis- Step 3.0
cussed earlier, the designer should use the equipment
Calculate the total absorbing legs that are 900 to the 15
manufactUrer's published allowable loads. However, ft 6 in leg. These legs are the east~west leg (11 ft) plus
these loads may not be available at the planning"
14
the vertical leg (7 ft 3 in). Due to the rigid valves and
stage of piping layout. For this example, we will make
nozzles in the system, neglect the 6'-8' venical leg.
the folloWing assumption. The maximum allowable
force on steel rotating equipment nozzles is (200 Ib) total available absorbing legs = (11 ft) + (7 ft 3 in)
x (the nominal nozzle size). The maximum limit for ;;;; 18 ft 3 in
the allowable load is 2,000 lb.
Step 4.0
Example ofAllowables Calculation
Apply the chan shown in exhibit 16-17 to determine if
2..in, 300# RF, CS nozzle 200 x 2 == 400 lb the absorbing leg reqUired is less than the total avail-
18..in, 150# RF, CS nozzle 200 x 18 == 3,600Ib) able absorbing legs determined earlier. Refer to the
exceeds the allowable limit. Use 2,000 lb. -circled numbers on the chan.
403
EXHIBIT 16.14
Pump Piping
Step 4.1
On the Force scale locate the maximum allowed
force on pump nozzle: 2,000 lb. (point 4.1) n
EXHmlT 16..15 Thennal Growth Chart Table
Step 4.2 Notes:
On the Total Thermal Expansion scale locate expan- L Carbon steel (C.S.) == Carbon·moly steels (through 3% Cr.)
sion in inches: 0.713 in. (point 4.2) 2. Low chrome (L.er.) = Intermediate alloy steels (5% Cr. Mo.
through 9% Cr. Mo.)
~tep 4.3 .3. High chrome (H.Cr.) == Straight chromium stainless steels;
Draw a line from point 4.1 to point 4.2. Where this 12% Cr., 17% Cr., and 27% Cr.
line crosses the Pivot Line, locate point 4.3.
~tep 4.4 Of CoS. L.Cr. B.u. Of COS. L.Cr. H.O.
)n the Nominal Pipe Diameter scale, locate the line 100 0.003 0.003 0.003 800 0.067 0.061 0.056
;ize 12 in. When the schedule of the pipe is other 200 0.010 0.009 0.009 900 0.078 0.071 0.065
han the standard weight, use the Pipe Moment of 300 0.018 0.017 0.016 1.000 0.089 0.081 0.074
nertia scale. 400 ·0.027 0.025 0.023 1,100 0.100 0.091 0.083
500 0.036 0.034 0.031 1,200 0.111 0.100 0.092
:tep 4.5 600 0.046 0.042 0.039 1,300 0.122 0.111 0.101
)rawa line from Point 4.3 on the Pivot Line to pOint 700 0.056 0.051 0.047 1)400 0.133 0.121 0.110
~.4 on the Nominal Pipe Diameter scale. This locates
Inches of growth per linear fool.
loint 4.5 on the Pipe Length scale. Read 23 it on the
'ipe Length scale as the minimum required absorb..
19 pipe length.
404
EXHmlT 16-16
Example Thermal
Calculation for Pump
Piping
~ oI:lr".!' ..... ~ ~~
l
407
EXHIBIT 16-18
Example Thcnnal
Ca.Iculation for Vessel
Piping
~
l'
,~)
f
fJ,O ~
~
I
ft}
1/ I~;
/'
Step 5.0 (20 ft) x (0.046) + (30 ft) x (0.027) + (25 fty X
Follow the procedure describe in step 3.0 to deter v
(0.0065) - (80 ft + 4 ft) x (0.003) - (6 ft) X
mine that the minimum required absorbing pipe (0.0065) = 1.601S-in expansion
length is 13 ft.
Follow the procedure described in step 3.0. The
Step 60 m~nimum required absorbing pipe length is 52 ft. The
The last step is to determine the vertical expansion available absorbing leg is (20 ft) + (25 ft) + 5 ft == 50
and its impact on the vessel nozzles. ft. These absorbing legs are smaller than the minimum
408
EXHmIT 16--19
Nomograph for Absorbing Leg on Vessel Piping
\
~ \
\
\
\
\
!
409
~quired pipe length. Therefore, add at least 2 ft in the The designer should locate anchors such mat the
)rth-south or east-west direction to be within the max- expansion going into the loop does not exceed 12
lum allowable stress on steel equipment nozzles. in. Also, the total unbalanced forces at the anchors
will be within the limiting criteria. Locate anchors at
hecking the Piping Layout in Piperacks 125 ft from points A and B.
lis section wiIt describe how to size a piperack loop. Step 1.3
le first step is to determine the location of the an- . Calculate the expansion going into the loop. Refer·
lors and loops in the line. Once the designer locates ence Exhibit 16·15 for the thermal growth chan.
,-
.e anchors, he or she will design. preliminary loop {(500 ft) - (2 x (125 ft))} x (0.036) ::= 9.00/in
zes and locations. Once he places the loopsl the de-
gnercan check the stress in the pipe. Step 2.0
Determine the minimum size of the loop based on the
,perack allowable loads There are different types of allowable stress.
lowables for each phase of the piperack design. For
,e location of the anchors, the allowable movement is Step 2.1'
in maximum pipe movement at the loops and 5·in Determine the amount of expansion in each leg of
the loop perpendicular to the direction of pipe ex·
,aximum movement at changes of direction.
For the sizing of the pipe loops in a rack, the de-
pansion:
gner uses a maximum pipe stress allowable. The A = Total expansion iry.to the loop
laximum primary stress in a loop is 20,000 psi for 2
lost. temperatures encountered (reference ANSI
31.3, Appendix A for more detailed information). A = 9I 2 = 4.5 in
Step 2.2
lperack loop example calculation The folloWing Enter the table "DETERMINING LENGTH OF LEG IN
cample describes how to size a piping loop in a pip~ A PIPERACK LOOP" listed as Exhibit 16.21. Locate
~ack. Reference Exhibit 16-20 for a diagram of the the expansion of 4.5" on the X~Axis.
mmple.
Step 2.3
'ep 1.0 Draw an imaginary line vertically from the 4.5" mark
etermine the location of the anchors and loops for to the Hne labelled (412" nominal diameter. Next
lis 5000 F carbon steel line. draw a horizontal imaginary line from this intersec,
tion point to the vertical axis. R~"d the loop leg
Step 1.1 length as 24 ft.
Calculate the total expansion in the east·west direc·
tion. Step 2.4
(500 ft) x (0.0362) = 18.1 in Try to make the width of the loop approximately 20
feet wide for pipe sizes between 3 in. and 20 in. For
Step 1.2 pipe sizes above 20 in. make the loop 30 ft wide.
Locate a preliminary location for the loops and an" Note that the leg length is dependent on the as-
chors based on inspection. sumption that the pipe is standard wall and the al-
EXHmIT 16..20
Piperack Loop Sizing
lowabJe stress is 20000 psi. Consult the Stress erly a cold~sprung system. This is also why we do not
Engineer for exceptions. recommend cold springing as a piping layout solution
for thermal loads. Another reason is the difficulty of
Cold Springing the Piping System to maintaining accurate coldAspring records over the op-
Reduce the Loads on Equipment Nozzles . erating life of the plant. Future maintenance efforts
may not consider the original cold spring when dis-
Cold springing a pipe js the act of cutting short a
connecting the piping system.
section of a piping system and then "pulling" the two
On petrochemical projects, cold springing is very
ends together to make dle final weld. This places a
rare. However, if the piping designer is considering
prestress in the piping system that is opposite to the
this option, we recommend the client approves the
stress imposed on the system when it is hot. Per the
procedure before proceeding with the final piping lay-
B31 Code, the stress engineer can take no credit for out design. '
cold spring when he considers the maximum stress in
the system. However, the piping code does allow the
stress engineer to apply two-thirds of the calculated LAYOUT SOLUTIONS FOR OTHER
reduction in nozzle loads to the impacted nozzles. STRESS
Therefore, the benefit to cold spring is some reduc-
tion in nozzle loads on critical equipment. I..ayouc solutions for stress problems due to recipro-
Why does the code only allow the stress engineer to cating equipment, wind, or earthquake are similar in
consider two-thirds of the calculated benefit of cold nature to the solutions prOVided for weight stress
spring? The reason is it is very difficult to install prop- problems. Thus, most solutions revolve around rout~
EXHmlT 16.. 21
~'
I-JOMIt-...JAL.
PIFE-71~E.
ng a piping system such that there is existing steel or makes the system looser, and therefore lowers the
:oncrete within reach of the support scheme. This system stress. However, on reciprocating systems
;ection primarily addresses the spacing of anchors and there is an additional problem. The pipe can vibrate
~ides so that these other types of stress do not ad- with the compressor pulsations. To resist this vibra-
Tersely impact the piping system. tion, stress engineers often ask for stiffer systems with
more guides and anchors. These opposite types of
solutions for different problems provide the challenge
for. a stress engineer. The resolution to this routing
Checking the Piping Layout for
challenge is first to rout to satisfy the thermal problem
[{eciprocating Equipment
(using the methods described earlier) and then solve
\.s described earlier, routing pipe to satisfy thermal the_ vibration problems. Normally, the stress engineer
:riteria usually involves adding more absorbing legs will go through a series of iterations working the two
md reducing the number of guides and anchors. This types of stress concerns.
EXHmlT 16-22
Piperack Loop Sizing
Once a line is routed for access and thermal con~ span for a typical reciprocating compressor piping
siderations the piping layout designer considers the
t system.
vibration problem. The designer will determine the
forcing frequency of the compressor. With the forcing
Step 1.0
frequency known, the designer will use a nomograph
.Determine the reciprocating compressor forcing fre~
that will show the allowable spacing for the vibration
quenC}'. Often, the motor speed is around 360 rpm. If
restraints. He can then rout the piping to assure that
we use this value in our example, then we get the
the needed restraints will be accessible to structural
following:
steel and concrete.
4 x (360 rpm I 60) ::::: 24 cycles per second
Allowable natural frequencies in a reciprocating com-
pressor piping system For initial routing on a typical Step 2.0
multistage reciprocating compressor) the designer can Determine the allowable span for a llclamped endtt
use the following formula for an aUowable natural condition using exhibit 16~23..
frequency of the piping system.
allowable natural frequency =4 x (motor rpm / Step 2.1
60) Draw a line from the lamda(A.) frequency factor
(equal to approximately 14 for clamped end condi~
Reciprocating equipment piping example calculation tions) to the allowable frequency of 24 cps. Extend
The following example will calculate the appropriate - this line through the Reference Une.
L
rolooo f
8,000
6,000
4.000
3.0
2.000
"'' °0
".000
' ..... 8
16"
1.000
L JO
5
""OJ
t5.;'''' 14 t1
I-
40
600 .
600 f t 9
t2.IU)
13.2'0
12.000 12"
II."'~O
1AJ 400 ;'
W 8
u... 5.0 UJ
~
J
..J ...J 200 1 'O"J
ID.O~O
'.?e.o
10
to
0
...:
•
6.0 W
"
W
..J 10
(,)
Z
tOO~
80
G W
N
(i)
lL.
0 8.0
IJJ
n:
W
IJ..
60
40
5 :5
.'''')
- 7.n,
7.8n
0" W
a..
:r 9.0 W 0..
..... Ck:
(!) to 4
20
Z
W
i--L-
....J
to "") .
~,n7 6
~ ~~
e :5 lUll
6
L IL 2
4
L / ~,.
20 2
:JL OUT _
f
30
LEGEND
K = RADIUS OF GYRATION, rN.
A =: FREQUENCY FACTOR
40 L = LEG LENGTH, FT.
L f ;:: NATURAL FREQUENCY, HZ
K
1'< = PIPE CLAMP
(~,,>O.«>O('(o«( ~2..~o\'\VN'o.
.. .__~. .o>cce.l cac¢cC«<¢oO"'QO , ; '~,."".'-..o"ICCC:ClalCllelceH :"IOQCCCHICI.J,ccllIClcc:m, t
EXHIBIT 16~24.
Guide Spacing for Vertical and Horizontal Pipe
Step 2.2 must place gUides on the pipe at intervals smaller than
Draw a line from the pipe size (assume 6~in pipe) the guide spacing for horizontal pipe.
on me Radius of Gyration (K) line through (he in-
tersection on the Reference Line. Extend this Hne layout suggestions for reducing wind stress A1~
through the Length of Leg (L) line. Read the L di- though most wind guides placed in a system have little
mension of 16 ft. This is the allowable span for a impact on proposed piping routing, vertical pipe on
steel pipe with no concentrated weights. columns requires some special consideration. Guides
on vertical pipe are physically larger than guides on
horizontal pipe. Also, the guide spacing is smaller on
Step 2.3 vertical pipe than on horizontal pipe. Therefore, the
Similarly, check each of the portions of the pipe piping layout designer must carefully consider where
routing for the correct span. the support designer will place the gUides. Some col-
umn piping such as overhead vapor lines are large,
therefore generating large lateral loads. These loads
Checking the.Piping Layout for Wind
can result in very large structural guides that may im-
Stress .
pede access on column platforms.
Depending on the location of the plant, the designer Exhibit 16-24 is a suggested spacing chart for guides
can design piping systems to withstand more than 100- on vertical column piping. Also provided for corppar-
mph winds. The designer must place guides on the . ison 1s the spacing chart for horizontal Hnes. The pip-
pipe at regular intervals to help brace the piping sys- ing layout designer should consult with the pipe
tem. Piping systems that travel down vertical columns support designer to confirm the guide locations. This
are particularly susceptible to vibrations because of should happen during the preliminary layout phase of
high winds. To prevent this vibration, the designer me piping design.
i- CHAPTER
1
Computer-Aided Design
Todais rapid changes in computer technology de~ needs. Even existing drawings may be easily regener·
mand that industry adopt formal means of educat~ ated with revised symbols.
iog future designers. Many engineering contractors
as well as operating companies are now committed
Standard Drawings
to establishing a position in this rapidly develop-
ing technology. Computer-aided design (CAD) sup- Extensive libraries of standard drawings and details
ports the entire engineering work flow from process have also been developed. These range from electrical
simulation to mechanical design. This chapter lighting fixtures and pipe suppon details to commonly
provides an overview of the tools used and how used process flow diagrams or comraclorproprietary
they benefit the engineering and construction con- vessel assemblies. Each represents the cumuhttive ex..
tractor. perience of many contractors over decades of engi·
ApplicatiOns range from the basic use of standard neering design. They conform to major industry codes
symbols and details to sophisticated 3·D graphics mod- as well as the contractor's own design practices.
eling with associated data bases, extracted reports, and Exhibit 17..2 shows an example of a CAD-generated
draWing generation. The use of these· tools results in a drawing.
higher-quality engineering design at lower overall The most important benefit of standard draWings is
cost. The enhanced quality results from improved ac~ quality. Each detail for each project initially reflects the
curacy, greater consistency, improved constructibility, latest engineering· design technology and is custom·
and enhanced operability and maintainability; lower ized to meet particular client needs as well as special
costs are a result of fewer engineering staff hours, less code or material reqUirements. Drawings are laid out
field rework, lower material surpluses and shaner
l well, and because CAD is used lines and text are dear
1
Layering
BASIC CAD APPLICATIONS
Computerization also takes practical advantage of
graphics layering (the placement of different elements
Graphics Symbols of a drawing on different layers) and overlays in a
Each engineering technology group has designed eXA single drawing file as well as overlays, or referencing,
haustive libraries of standard graphics symbols. These of entirely separate files. For example, piping layout
range from simple arrowheads to entire mechanical draWings are referred to by various downstream func-
assemblies, from schematic equipment symbols to tions that develop pipe support location plans, eJe~tri
draWing title blocks and borders. cal and instrument cable and conduit routing plans,
The most significant immediate benefit of using steam tracing plans) and others,. as Exhibit 17-3 dem~
standard symbols is the lower engineering costs as a onstrates. Reproducible copies of piping draWings
result of reduced designer time and better overall effi~ were often used in the past. If equipment was moved,
ciency. The other major benefit is consistency. Sym~ new draWings were made and overlay drafting redone t
bois appear exactly the same every time, as shown In or each downstream function revised its draWing. With
Exhibit 17 1. Overall draWing presentation is dramati-
A CAD t these groups may begin work much earlier.
cally improved. An indirect advantage is the ability to When changes are made, they need only reference the
customize these symbols easily for particular project latest revisions.
415
416
EXHffiIT 17..1
Standard Symbols for
Foundations Detail
Drawings
lID
1-0 eel
R
!
I
I
I
._._._._._.~._._._¥-.
i
,! • ,
I
. t
~ \
(lVl')
ElEVATION
/
417
"limIT 17-2 Standard Vessel Clip Details EXHIBIT 17-3 Portion of Pipe Support Location Plan
Using a Referenced Piping Layout Drawing
PLATE (T) THICK
ORIENT. LINE
o
~ @
o
I en
o
I
o
Computer-Aided Design
418
EXHIBIT 17..4
~I Scanning Comparison
,
., '~-6" ( "'6)
I.P. 'aq1'. Ya$.
1
. i
i i
I ~ j
i........ i .
11:lr1'. "1(' I
1- _.....-~ ........-+-_-"""o:&ll-.:z::;
q~ ...,.
l~t"4
I~ ~ "*""
[!j't .,.. ...." " eft
~.",'tlI'
YO$)lh,.
Pt.AN Vf~W O~
iII'JIIIIIil5
EXTERNAL VE~~IL..
a. Manually Drafted
t.D. T. \'£5.
)·'tL.2
a. OR
G
.ra.... ">.,.
e ~
tNTEfl04~ ,
tXP.rto'Sl(h JOINT NOt'
tlr 8.4SlCt't 01 VESSEL
F F'ASAfCATOf
PLAN ytEW OE
EXTERNAL VESSEL
SpeCial graphics data files, and applications were writ~ nace mechanical drawings, foundation detail' draw-
ten to format these drawings. They also select and ings, and structural pipe support schedule drawings.
place appropriate graphics symbols, add dimensions Exhibit 17·5 shows an example of such a plan.
and text, perform material scheduling and takeHoff cal- The advantages of automated draWing systems are
culations, and execute plOts. significant. The drafting effort is radically reduced or
Automated programs are now available for many entirely eliminated in terms of design staff hours and
heat exchanger setting plans and tube layout sketches, graphics terminal time. Engineering cost reduCtions
electrical one-line and control wiring diagrams, fur- are substantial, and valuable schedule time is saved.
419
EXHIBIT 17--5 Automatically Generated Heat Exchanger Setting Plan
,··r·
"H]
r·J lit-
till .....
. !"....UH 1/4' IIMI
'IU. "'1.lllT
lI,fl'-'no
SI,U.lIlO.O
• Il.lIC n.ss
S1 I ,..~' •• 11 I I ~. li» . II QIll£I
,,·/'O-fU···
II' 7'. SO> • III I. I 1(1' .lDO" • .,
IUJlllllll
NUL :H[OUl: ."J .1-1
Errors are reduced through direct electronic data SYSTEMS ENGINEERING AND
transfer and automated materials scheduling and take- INSTRUMENT DESIGN
off. Drawing formars are consistent and engineered to
ensure excellent layout using standard graphics sym- Many computer vendor data base systems are initial-
bols. Flexibility is maintained through the capability to ized during the system engineering design of the pip-
~asily customize referenced graphics symbol libraries ing. and instrumentation diagrams. Line or nomencla~
md, in some cases, drawing arrangements. ture lists and other reports can be extracted from this
data. Dam consisten<..y checks are made throughout to
ensure that the information is complete and accurate.
lNTEGRATED MODELING The data base is further expanded by instrument
SYSTEMS engineers and can then support the generation of in-
strument line liste; and data sheets, It can be used to
file applications discussed in the previous section pri- assign and track cabling between individual insu~u
narily use the basic graphics capabilities of CAD. Inte~ ments, field junction boxes t and control room mar~
~rated modeling systems, however, make extensive shalling racks and can reference appropriate graphics
lse of graphics data bases. They are structured so that element,; for the generation of instrument loop dia-
nost of the data is collected in the process of con~ grams. Exhibit 17-6 illustrates this process. This pro~
itruding 3-D elecrronic plant models. Most of the en~ cess requires about half the staff hours and much less
~ineering documents (e.g., drawings and data sheets) graphics terminal time than previously expended by
lre extracted from the graphics models or automati" manual development of CAD drawings. Moreover,
:ally generated from the data bases. loop drawings may now denote additional component
Computer-Aided Design
420
EXHmJT 17..6 Typical Plant Design System-Generated Insttument Loop Diagram
CONTROL ROOM
~,
IDUBI'. ,lilt
c.........
8Iltll • I
lila
am t'
••
&o.-_...,6I)lll1l1B1,. ,
......,
IlGlICnJl'
~.
a~
'11.&
trw. fUll
Q..CId
lIS1•.,.,
«a"",. no 1lIQ8~
eta .,
G .l
e..-_ _ UI ••
C8lIIlllll. • t
_.
information (e.g.. calibration data. manufacture and and dimensions are kept to a minimum. It is easy for
model number. cross references to installation details the designer to relocate, copy, or revise equipment in
and original purchase orders, and input and output the plot. Both two-dimensional (2-D) and 3-D plots
signals) from the data base: which is useful for plant are developed simultaneously on separate graphics
maintenance. layers of the same file, as Exhibit 17-8 illustrates.
There are three consecutive phases-conceptU31 The conceptual plot plan is simply extracted by
planning, detailed planning, and detailed engineer- viewing the model from the tOP and turning off the
ing-for which different modeling tools are used. 3-D layer. Plot model development is very fast, and the
3-D rendering is vastly superior to the purely 2-D plot
approach. As Exhibit 17-9 shows, the issue document
Conceptual Planning
becomes a repon that accurately reflects the model.
Conceptual planning is the process of optimizing Extraction of a complete equipment list is a useful by-
equipment layout relative to the a'v'ailable real estate product.
and overall construction and operating costs. Many
CAD users write their own modeling sofr«.-are specifi-
Detailed Planning
cally for conceptuaJ modeling. An example of such a
program is an advanced layout and design interface, in The detailea planning phase basically expands the
which plot modeling is built around the basic graphics equipment plot model by the addition of major pip..
system. It provides the plant layout designer 'with the ing. An efficiently advanced layout and deSign inter..
ability to create and locate equipment, pipe racks. and face system can be used for pipe routing. Piping is
Simple struCtures using specially designed menus at placed in a single-line representation for simplicity,
an alphanumeric terminal. This supportS the designer but dimensional data is included for batch process--
in building a 3-D equipment plot model, illustrated in ing double-line shaded renderings later on, as de..
Exhibit 17-7. Input parameters, basic equipment types, pieted in Exhibit 17-10. If equipment is moved, asso-
421
EXHIBI1' 17..'
Equipment PJot Model
Using Plot Modeling
Software
Detailed Engineering
XHIBIT 17-8 3-0 Equipment Plot ModeJ with 2-D and
-0 Layers During the derailed engineering phase, exhaustive
analysis and designs are performed. The resulting doc-
~-\? (1J!I~L) uments are those actually used to requisition, fabri~
cate, and construct the plant.
'2,9 (!J!'IUL) Equipment is modeled in more detail, followed by
the piping layout. This process is expedited in the
plant design system by the fact that routing informa-
tion may be transferred directly from the planning
model. Piping parameters are downloaded from th~
system data base, which also ensures that all piping
specified in the piping and instrumentation diagrams
is accurately accounted for; even small bore lines are
run.
At this point, an exhaustive piping component cata-
ated piping is automatically rerouted with the same log and specification data base are used. Only compo·
lSk configurations. Complex piping assemblies nents approved for the project may be entered. The
.g., piping control stations) that are used more than software automatically checks for compatibility be-
lee are easily duplicated as a unit through macros. tween adjacent components-for example, to ensure
Ie piping model geometry is interfaced with a pipe that a flange piece is not placed against a nontlanged
"ess analysis program to ensure adequate piping component. Parts are placed to dimensional toler-
~xibility. ances of less than a millimeter on the basis of catalog
The major advantages of this system include: values. Materials (e.g., piping, flanges, gaskets, nuts,
bolts, washers, and insulation) are tracked per specifi-
rhe simplicity of pipe routing. cation.
\utomated rerouting with equipment changes. Steel structures are modeled initially by centerline
rhe ability (0 extract preliminary piping material representation, then with preliminary member sizes.
luantities to support defined estimates and early An electronic interface to finite element structural
>rders. analysis programs allows the project to proceed to
'he ability to extract the detailed layout drawings detailed design.
lirecdy from the model. Structural component catalogs of steel shapes are
Computer-Aided Design
422
:'.
EXHmlT 17...9
Partial Conceptual Plot
Plan (Extracted from Plot
Model)
423
EXHWIT 17~10
Partial Planning Model
referenced for final member sizing in compliance piping. In addition, the automated system is a ffiltch
with engineering specifications and design codes. A more valuable tool for plant maintenance and future
return interface is then made to upgrade [he graphics expansion because, unlike the above-ground struc-
layout model to that of the final design, as shown in tures, the aaual installation cannot be seen except by
Exhibit 17-11. Foundations and concrete structures computer once it is in place.
can be added as designs are completed through the Each engineering function (e.g., civil) structural,
use of a foundation modeling system. Piles are placed and piping design) builds its ponieD of the model
in a 2-0 model at grade for subsequent drawing ex- with the ability to view but not change the other func~
traction. The entire underground can be modeled, in- lions' work. An example· of this detailed engineering
cluding electrical and instrument conduits as well as model is depicted in Exhibit 17~12.
Interference Checking
Once completed. a batch process is run to identify all
component interferences for the entire model, as
shown in Exhibit 17~13. It also checks for such inter·
ferences as pipes that cross a designated clear space
(e.g., a walkway or equipment maintenance area). Be·
cause these problems can be resolved before docu·
ments are extraaed, an extrernelv small number of
interference reports during cons~aion are now gen·
Computer-Aided Destgn
426
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erated, significantly lowering fixed field and refabrica- quence to better reflect a project's critical path. Mate~
tion costs and enhancing the ability £0 adhere to crit~ rial quantities may be extracted at any stage for .
ical schedules. estimates or early orders. As soon as the model is
comple[ed, piping isometrics and other fabrication
drawings are extracted, followed by orthographic
Issue Documents
views for construction. (Manual drafting methods re~
The rea) return on investing resources to construct an quire the reverse order.)
electronic model is the ability to generate issue docu~ Finally, materials reports may be directly interfaced
ments quickly and accurately. Plot plans and piping lay~ with the comractor's materials control sy,Stem, which
out drawings are taken directly from the model by automates much of the requisitioning, tracking, field
specifYing plan and vertical boundaries, as shown in Ex~ inventory control, and cost reporting.
hibit 17~15. Elevation views are produced in the same
way. These are often augmented with isometric views ELECTRONIC SPOOL SHEETS
of especially complex piping configurations to aid in
visualization and construction, as illustrated in Exhibit Electronic spooling is the term used for automatically
17-14. Such downstream disciplines as electrical, in~ generating spool sheets, complete with bills of mate·
srrument, and piping engineering then refer~ence rial (BOM), for pipe spool fabrication. Pipe fabrication
these drawings to generate their own data and reports. . shops have traditionally hand drafted these sheets us·
The largest benefit of the system is the ability to iog isometrics as a reference, but are now developing
automatically generate piping isometrics complete computer programs to interface with contractors iso-
with detailed bills of materials, as Exhibit 17~16 shows. metric data files directly.
The designer merely indicates breakpoints for each . The programs used for this system are capable of
sheet. Process plans require thousands of isometric reading input data generated from a CAD 3-D model
drawings, and the system cross checks the model (0 using interface software provided with the 3-D model.
ensure that sections of pipe are neither omitted nor The first step in generating a spool sheet is to conven
duplicated. Structural steel erection drawings, plans, the input data into a standard format for processing. The
and elevations are extracted and annotated, and mate~ 3-D model is then restored with all of the branches and
rial summaries are automatically produced. Founda- connectivity established. The model is then transversed
tion and pile location plans are extracted in much the and broken into sheets to suit prelocated field welds or
same way the equipment plot plans are. Pile counts by natural material breaks. Finally, the material require-
type are automatically created, and foundation and pile mentsforeachsheetarematchedwiththepipefabricators
data sheets are generated for internal checking. computerizedwarehouse or material information.
Automating take·off material quantities offers a great The geometry of the sheet is then evaluated, and a
productivity gain. The material quantities are com~ best view is determined. Scaling and drawing compo~
pletely specification driven, which ensures conform- sition requirements are automatically considered and
ance with project requirements and precise assembly appropriately set. Using the necessary software, the
breakdowns. Because quantities are computed directly spool-sheet design file is then created with compo-
from the model data base, accuracy has improved; this nents, piece mark numbers, dimensions, title block,
has allowed some standard surplus order rates to be and a BOM. The spool sheet can then be automatically
reduced. _ plotted, checked, and issued to the shop floor for fab-
Graphics modeling also allows the schedule se- rication, illustrated in Exhibit 17-17.
1
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430
431
432
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433
Construction (cont) Deluge and spray systems 334 Drill structures 301-304
plot plan 28 Design Drums
Construction materials reactors 203 boo! layout 106
underground piping 309 struCtUres 285 elevation sketch 95
Comaminated storm water 307 towers 223 feed surge and compressor suction
Continuous shell Desulfurizer process 204 drum locations 92
still process 219, 220 Diagonal piping runs 7 in an enclosed chemi~l plam
(omraaor-supplied supporting columns Dike access structure 93
125 building around obstructions instrumentation 103, 105';'106...
Comrol and operator access 366-368,368 in tower reflux syslems 92 ;
in a plate arrangement 121 tanks and 3.66-368 loquion of 92-95
in a spiral arrangemem 120 > vehicular and personnel 366, 367 maintenance 106-]07
Control valv~s and accessories 346 Diked area drain 341 nozzle locations 95-97
Control valve station Dikes, types of piping arrangements 100-103, 104
elevated 355 buried low-temperature tank 365, platform arrangements 98-100
single 354 365 process vessel sketch 95
standard 354 buried low-temperature tank above type~ of 91
steam 355 grade 365-366, 366 Dynamic loading
Conveaion section 145 concrete 362,363 definition of 287
ConveCtion section piping 174, ]75 diversion canals and 366, 367
Convection section tube removal double containment method 362, E
in box-type furnace 155 363 Earthquake 395
Cooling water 309 earthen 362, 363 Earthquake load
Cost-effectiveness earthen and concrete combination definition of 287
definition of 13 362,363 Eccentric red~cers 190
Critical lines list 389 natural terrain 362, 364 Economic piping
Crossover piping 14; natural terrain witl1 volatile liquids
equipment location 33-37
362-365) 364 .
Crude distillation of productS across Elbow nozzles
temperature range 220 plant topography and 365, 365
effect on stacked exchangers 127
Distillation process
Electrical engineering
D towers 219.-221
plOl plan 27
Double pipe exchangers 113-114
Damper 145 Electric motors 63
Downcomer trays 230
mechanism 156 compressor drives 61-63
DOlJrostream dimensional requirements
Davit Elevated centrifugal q)mpressor
356
ar~gemen{ 216
Draft gauge 145 no sh~lter 74
hori~ontal drum 106
Drainage areas 312 open-sided structure 72
Dead Joad Elevation
Drain hub
definition of 286 furnace 149-159
definition of 306
Deaerator 92 pipe racks 261-269
Drain piping
Deck plate platform 289 reaCtors 204-207
compressor layout 90
Decoking 145 19wers 223-232
434
'.'
Elevation layout 6-7 definition of 287 fire water system layom 334-337
Emergency eyewash and shower 328 Exchanger installation Flexibility
Engineering parallel and series 116 check steps 274
systems engineering and instrument single and paired 116 definition of 14-16
design 421-423 Slacked 117 pipe racks 271-rn
Engineering model structure~moumed 1J 6 Floating-roof tank 361
detail 425 Exchanger orientation 115 Floor elevation
Equipment arrangement Exchangers compressor housing 84
plant layout specification 19 construction 110-114 Floor space
Equipment elevations location and support 114-125 comparison 38
plant layout specifications 19-20,22 maintenance 135-140 sizes 33
Equipment houses· 43 nozzle orientation 125-127 Flow instruments 347
Equipment list 31 piping 127-134 Fluid catalytic cracking unit plot plan 39
definition of 10 Explosion doors 145 Foundation detail drawings
plOl plan development 29 Extemal-cage level controller and standards symbols 416
Equipment load transmitter 350 Fracrional distillation 219-221
definition of 286 Extemal-cage level switch 351 Fraaionator tower 221
EqUipment location Furnace elevation 153
climate condirions 41-42 F Furnace operation 142
common operation 37 Feeds Furnaces
economic piping 33-37 alternative arrangements 234 basic operation 141
equipment sizes 37-40 Fire fighting, foam system burners 147-148
plant layout specification 33 foam injection into tanks 383-386, combustion air preheating systems
process requirements 37 386 148-149
real estate availability 37 semiportable foam system general arrangement of 149-165
underground facilities 40-41 386,387 piping layout for 165-177
Equipment plot model Fire fighting water system 386, 387 spacing 50
plot modeling software 421 Fire hydrant 328 tail gas incinerator 177-179
Equipment sizes details 330 terminology 144-147
equipment location 37-40 installation 329 types of 141-144
plot plan development 31 with monitor 332 waste heat unit 177-179
Equipment spacing 20,21 Fire monitor 330
plot plans 44-51 elevated 332, 333 G
EqUipment suppon 292 grade-mounted 331,333 Gas turbine
column locations 279 range chart 331 compressor drive 63-64
Estimating selecting 333 Grade-mounted centrifugal compressor,
plot plan 28 Fire water 309 no shelter 71
Exchange nozzles Fireproofed steel 290 . Grade-mounted compressor, cunain wall
alternative locations 126 Fireproofing requirements 279 shelter 73
Exchanger applications 109 Fire water system 325-337 Grade-mounted horizontal inline
Exchanger bundle removal load deluge and spray syStems 334 arrangement
.I
435
plOI pJans 31-33,34 Hononsphere piping layout 380-383, Inter- and after-coolers
Grade-mounted or elevated centrifugal 382 compressors 82-83
compressor, open-sided structure Hose station at pipe rack column 270 Interference checking
72 Housing and platform requirements system engineering and instrument
Graphics symbols compressors 83-84 design 424-428
O\D applicarions 415 HydrOtreater process 204 Internal clearance 356
Grating platform 289 Hydrotreater unit plot plan 205 Imernallevel switch and transminer
Gravity feed 37 side-mounted 352
Gravity flow I top-mounted 352 ..
definition of 14 Induced draft fan 162 Inrernally generated engineering data 3
Guide spacing 414 Industry standards Invert elevation
underground piping 305 definition of 305
H Initial arrangemem sketch 52 Issue documems
Head dimensions 238 Inlet air filters 60 system engineering and instrument
Header 145 compressors S9 design 428
definition of 12 Inlet dUCl 60
Head block valves Inlet line strainers 88 K
definition of 12 Inlet piping Knee brace 244
Header box derail 156 centrifugal compressors 85
Header boxes ]47 Inline
Header-bronch-Ieader block valve 13 definition of 12 L
Heat exchangers 110 instrumentation 13 Ladder
Heat exchanger setting Inline pump SUPPOl1 201 detail 286
automaticall~' generated 419 Instrumentation plam layout specification 23
Heat tracing drums 103 preferred poSition 286
definition of 12 locations 352-357 rung spacing 244
High-pressure reaCtor 205 types of 345-352 sloping 244
High-pressure steam inlet piping Instrument details l.arge~iameter lines 267
compressor layout 87-88 alternative 356 Large structures 298-301
Hillside noule96 Instrument engineering setting heavy equipment in 301
Hook centerline elevation plot plan 27 Latcr'dl and sublateral detail 316
compressor housing 84 Instrument locations Laterals
Horizontal exchanger suppon 117 pipe racks 269-271 definition of 305
Horizontal pressure tank (bullet) Instruments Layering
361 distributed control system 346 CAD applications 415
bullet-tank piping layout 380, 382 local control system 345. Layout draining
protection berm and 383, 385 locally mounted systems 345 definition of 1O~ 11
Horizontal reactor 217 towers 246-252 Layout philosophy
Horizontal reflex drum 91 Instrument vessel sketch 25? diagonal piping runs 7
Horizontal spHt<ase compressor 61,62 Integrate modeling systems elevation layout 6-7
Hortonsphere pressure tank 362 computer-aided design 419 plan view layout 5-6
Index
436
i
437
NPSH requirements Pier·mounted vertical instaJJation 120 Piping and instrumentation diagrams
pumps 182-183 Pigtails 146, 147 definition of 10
Pile-supported foundations 308 Piping arrangements
o Pipe anchor load
definition of 287
drums 1OD-l03
economy 130
Oil and gas burner 147 Pipe chase detail 294 feed exchangers 132
maintenance area 148 Pipe elevations 306 for horizontal shell and tube
Oily water sewer 307 Pipe load exchangers 128
Oily water syslems 315 definition of 287 for steam and condensare syst~m 129
line sizing "316-320 Pipe racks 261-283 for underground cooling water
underground piping 309-320 addilions 281 system 129
Open systems 15 . high·temperature, high-pressure feed
alternative pipe rack expansion 270
definition of ]4 anchor bent 275 exchangers 131
Operating valve accessibility 88 column spacing 264 horizontal reboiler 130
Operation composite 265 inlet and outlet for product air cooler
definition of 12 configurations 45 135
Operations platforms structure cross section 264 overhead for condensing air cooler
304 elevation 44 134
Operations structure 304 plate exchangers 133
intersection 280
Operator access reactors 210-216
layout 268
pipe racks 283 spiral exchangers 132
90 0 turns 280
to controls 25 supports for 130
plot plan development 42-44
towers 225 spandrel location 277
vertical reboifer 130
Opposing downcomers 230 Piping connections
spandrel variations 277
Outlet duct 60 compressor layout 87
vertical arrangement 45
Overhe'dd arrangement Piping design
Piperack 396
lowers 247
Pipe span table 263
plot plan 27
Overloading 394 Piping isometric draWing 427
Pipe stress 389
Overstress 392 Piping layout
Pipe stress work process 390
Pipe support location plan furnaces 165-1 n
p reference piping layout drawing 417
Piping layoU( model
Pipe supports
auxiliary isometric view 425
Packed tower 223
Piping specification
Packed (ower components 231 compressor 89
definition of 10
Partial conceptual plOt plan 422 definition of 16-17
intermediate 276
Plan
Partial piping layout drawing 426
view favour 5-6
Partial planning model 423 Piping
Planning ,
Paving 23 buried, insulated 344
systems engineering and insrrument
arrangement 46 cover for buried 314
design 420-42]
plant layout specification 20-22 exchanger 127-134
Planning study
plot plans 44 pumps 188-]97
definition of 10-11
Peep doors 147 towers 243-246
Index
438
Plant design system planning 29 Product outlet and decoking piping 173
CAD generated 420 proposal 28 Projea design data 3
plant layout design roads, access ways, and paving 44 Project input data
basics of ]-] 7 sample arrangement 51 in plant layout design 2-4
philosophy 4-8 types of 31-33 Pulsations 395
projea inptn data 2-4 Positive displacement pumps 185 Pulsation dampener/volume bottle 61 t 62
role and funaions of designer 1-2 Positive displacement (reciprocating) Pump
terminology and 5tandard~ 8-17 pumps 183 and turbine suppon 201
Plant layout designer Potable water system 309 324
1 discharge location 187
funaion of 1-2 Precast concrete pipe 278 layout 191
role of 1 Preliminary piping and instrumentation suction and discharge piping system
Plant layout interface 2 diagram 189
Plant layout specification towers 250 Pump locations
componems of 19-25 Pressure measurement plan 186
equipment location 33 instruments 348 elevation 186
Plant operation Pressure tap locations 356 Pump-oU( system 308-309
plant layout specificatiOn 24 Primary and standby pump Pumps
Plate exchanger construction 113 arrangement 192 locations 185-188
Plate exchangers ·112 for hot slurry service 194 NPSH requirements 182-183
Platform and ladder elevation requirements with below-grade suction 194 piping 188-197
towers 241 Probe connection 210 terminology 181-182
Platform arrangements Process and potable water 322-325 types of 183-185
drums 98-100 Process (dosed) sewers 320-321 Pump suction arrangement 248
reactors 209-210 Process cooling water system 324 Pyrolysis furnace 143, 144
towers 240-243 at exchangers 325 ladder and platform requirements 159
Platform orientation 245 at pumps 325
Platforms crossover piping 324 R
plant layout specification 23 Process design data Radiant coil 146
Platform width requirements plot plan development 29-31 Radiant section 147
towers 242 Process drains: dosed system 321 Radiant tube removal
Plot plans Process flow diagram 32 in a circular furnace 154
buildings 44 definition of 10 Railroads 23
construction 30 planning piping with 36 plam layout specification 20--22
definition of 27-28 plot plant developmem 29 Rainfall calculation chart 319
development of 28-31 Process operation Rainfall intensity and frequency 317
equipment location 33-42 reactors 203 Ramps
equipment spacing 44-51 Process requiremenrs preferred position 286
exchanger applications 115 equipment location 37 ReaCtOrs 204
final arrangement 54 Process unit road 46 design considerations for 203
in the process unit 27 Process vessel sketch 205 elevation requirements 207
pipe racks 42-44 towers 228 location of 204
/
Index
439
Reactors (cont)
maintenance 216-218
s dimensions, square dike 369
volume of rank berm 368-369,369
Saddle-supported drum 94
nozzle locations and elev~{ions Skin temperature attachment 348
Safety
207~209 Sloping drum 106
definition of 12-13
piping arrangements 210-215 Small structure 293-296
spacing requirements 35
platform arrangements 209-210, alternative design 295
211 Sanitary sewer 308
single-Ievel,one·bav 295
Scanning and translation
process operation 203 single-level [Wo-ba~' 296
suppon and elevation 204-207 CAD applications 416-417 t
two-level 297 .
unloading 207 Scanning comparison 4] 8
Snuffing steam 147
Reactors in series Scheduling
Solvent colleaion system 309 '
manually opera red \'alve manifold 215 pJO[ plan 27
Soot blower 147
remotely operated valve manifold 215 Seal oil console 58
fixed 160
Real estate availability compressors 56
in operation 161
equipment location 37 piping and instrumem3lion diagram
67 retractable 161
Reboiler Space
Seal oil system
arrangement 230 use of 18
compressors 64-66
conneaions 235 Specifications
Seal oil tank location 66
Reciprocating compressor piping pIol plan development 29
Seals
compressor layout 88-89 Sphericai reaaor 217
definition of 306
1eciprocating equipment piping lavout Spill containment) see also Dikes, types of .
411 . Sewer box 339
definition of 306
tanks and, 362-366
{eciprocating compressors 79-82 Spiral exchanger construction 113
tecuperative system 151 derail 313
schedule 320 Spiral heat exchangers 112-113
~eflux Spool piece removal 194
alternative arrangements 233 sizes 321
wjth line deanout 340
Spring-mounted' pump 188
teformer furnace 144 Stalrin reboiler 140
platforms 160 Sewer main
Stack 147
tefraetory 147 definirion of 305
Shell and tube exchangers 111-1]2 Stacked reactors 218
~egenerative system 150 Stairs
~eJief header location 270
arrangements 112
Side shell-mounted catalyst unloading plam layout specification 23
:elief valve systems 249 Stair structures 301,302
nozzles 210
jgid frames Stairway
Side shell-mounted temperature
definition of 285-286 dimensional detail 287
conneaions 210
oads 23 preferred position 286
Side-suction nozzles on centrifugal' pump
plant layout specification 20-22 197 Standard drawings
. plOt plans 44 Single platform arrangement 212 CAD applicants 415
otary pumps 185 Single-reactor piping arrangement 214 Steam drum and transfer line exchange
3tating equipment layout 401 Sizing tanks and dikes 368-369 162
Jtating equipment nozzle allowable dimensions, chan for square dike Steam-generation thermosiphon circuit
loads 402 370 176
Index
440
.I
;Tanks and piping (conI) dike 359 davit arrangement 255
buried product-transfer piping 378, distribution system 360 design considerations 223
378 diversion channel 360 distillation process 219-221
differential settlement and piping 379, double-wall storage tank 360 drop zone 256
379 fixed-roof lank 360 elevation and support 223-232
dike-penetratiOn seal 378,378 flame arrester 360 elevation sketch 227
flexible dike seal 378-379,379 flame snuffer 360 intervals 228~232
Horronsphere piping layout 380-383, floating-roof tank 360 maintenance 252-259
382 foam 360 nozzle elera[ion and oriemalion .:'
liquefied natural ga.~ pump and piping fOOt valve 360 232-240
layout 383,383, 384, 385 heaters 360 piping 243-246
pipe way and pumping cross seaion Hononsphere 360 piping arrangement 251
380,381 intermediate holding tank 360 piping supports 246
piping layout 380, 381 remote impounding basin 360 platform arrangements 240-252
:Tanks and pumps 376-378,377, 378 sediment 360 skirt 227
pipe way and pumping cross section sleeper 360 spacing 48
380,381 sump 360 tower instrumenrs 246-252
pumps inside concrete dike 377-378, transition section 230
tank farm 360
378 tfolley beam arrangement 255
Tee-type strainer 189
pumps inside diked area 376-377, types of 221--222
Temperature measurement instrument')
377
348 weld seams 258
pumps outside diked area 377,377
Temperature and pressure instrumentS Tower-supported vertical installation
':fanks, types of 360-362 118
arrangement for 254
cone-roof tank 36], 361
Temperature and pressure locations 237 Transfer line 147
floating-roof tank 361,361 Transfer Hne layout 176
Terminology
horizontal pressure tank (bullet)
in plant layout design 10-17 Transfer line piping 176-177
361-362, 361
of structures 285-287 Traveling gantry 137
Hortonsphere pressure tank 362,
underground piping 305-306 Tray details 229
362
Thermal 394 Trayed tower 222
low-temperature storage tank 361,
361 Thermal expansion load Tray support beam sizes 237
Tank suppons 374-376 definition of 287 Trench
compacted fill tank pad 374,376 Thermal growth 399 definition of 305
elevated concrete base 374,376 Thermal stress solutions 398 Trench piping 338
embedded heating element 374-376, 3·D equipment plot model 421 Trolley beam 136
377 Top head arrangement 236 arrangement 216
ring wall 374,376 To head nozzle arrangement 208 Tube and shell exchanger passes 111
Tank terminology Top platform arrangement 213 Tube bundle extractor details 139
atmospheric tank 359 Tower·mounted air cooler 140 Tube bundle removal
barrel 359 Towers by crane 137
bullet 359 area 224 Tube exchangers 111-] 12
cone-roof tank 359 areas of division 246 Tubes ]47
442
.I
Index
I
[ CHEMICA~ENGINEERIN~ I
PROCESSP~
LAYOUTAND
PIPING DESIGN
Ed Bausbacher · Roger Hunt
Ed Bausbacher and Roger Hunt draw on more than 70 years of experience as
plant layout designers to offer readers tried-and-true methods and rules of thumb
for plant layout and piping design. Because plant layout and piping designers ,,:'f
must translate a two-dimensional process flow diagram into a physical plant in
three dimensions, this Indispensable reference will help designers in the crucial
task of equipment and piping configurations.
Abundantly illustrated with more than 640 draWings, Process Plant layout
and Piping Design:
PRENTICE HALL
Englewood Cliffs, NJ 07632