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Equipment Layout:
Equipment layout is an extension of
the conceptual layout in a more detailed
manner. In the same way as the P & I
diagrams are the basic documents of
chemical engineering design, equipment
layout is the basic document of
mechanical engineering design. This is a
composite mechanical engineering design,
coordinating the design information to
produce construction drawings.
Generally all equipment and facilities
that need floor space are shown. Access,
removal space, cleaning area, storage
space and handling facilities are outlined.
Good layout design minimizes the cost of
operation and maintenance. Access is the
most important feature to be considered
Constructibility is another factor, which
have equal importance. Equipment layout
of large outdoor plant is sometimes
referred as plot plan. This document is the
basis for the development of construction
drawings by all disciplines.
iv) Underground
facilities:
Piping
Engineer should investigate the
facilities such as storm water drain,
effluent drain, fire water, cooling water
to be placed underground
before
deciding the equipment position.
Depending upon the soil condition, the
foundation will be either piled or
spread footings. Spread footing
foundation will require more space and
equipment should be spaced to suit. In
certain cases multiple equipment could
be placed on a common foundation. In
such cases vibrating equipment shall
be segregated from static equipment.
v) Climatic
conditions:
Weather
condition influences the type of
enclosures and location of equipment.
Wind influence the location of
furnaces, cooling towers and stacks
a)
Grade
arrangement
mounted
Horizontal
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Fig. 2.2.6a
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Fig. 2.2.6b
2.3 Piping Layout
2.3.1 PHILOSOPHY
OF
YARD
PIPING
The main artery of an outdoor process
plant is the pipe rack. Because the rack is
located in the mid of an outdoor plant, the
pipe rack must be erected first. Hence the
development of structural drawing
becomes one of the early requirements in a
plant. To pass on the data to the
civil/structural group, a civil scope
drawing showing the width, the column
spacing and the design load is prepared.
This load data should include, in addition
to the dead weight specified per running
meter or per sq.meter the thermal and
occasional loading the piping will impart
on to the structure. The latter will include
forces and moments depending on the type
of support provided. The structural
designer reinforces such bays on the pipe
rack to overcome these forces and
moments. Hence, a proper planning is
required in the initial stages of design
itself.
So, the first step in the development of
pipe rack is the generation of a line
routing diagram. A line routing diagram/
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Fig. 2.3.10
Fig. 2.3.11
Although the final stress analysis will be
done after the routing are finalized,
preliminary check from monogram is
required to establish the requirement and
size of expansion loops. The flexibility
temperature can be obtained from the line
list. The lines requiring expansion loops is
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away.
Fig 2.3.20
Fig 2.3.19
Fig 2.3.21a
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Fig 2.3.21b
Fig 2.3.22
2.3.4 ELECTRICAL/INSTRUMENT
TRAYS
The Electrical and Instrument cable
tray/duct location is coordinated in the
design-planning phase itself and integrated
in the overall arrangement.
Space for these trays is provided above
the piping on the pipe rack. Future
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Fig. 2.3.24
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3.1 Pumps
Pumps rarely influence the plant layout
except where a common standby for two
services or multiple duty pumps might
dictate
the
process
equipment
arrangement. But the pumps can never be
treated as an independent entity, but to be
treated as part of the piping system, which
affects the performance even if the basic
selection is faultless.
2.3.10
CRITICAL
EXAMINATION
TECHINIQUE
The quality of the equipment and piping
layout can be established by the Critical
Examination Technique where you ensure
that all the following parameters are well
addressed
a) It is process adequate?
b) It is operator friendly?
c)It is construction clear?
Types of pumps
Before looking into the layout and
piping details of pumps, we will review
the pertinent details of the equipment that
affect the plant layout and piping design.
Basically there are two types of pumps,
the centrifugal type and the positive
displacement type.
The centrifugal type could be a single
stage or a multistage. The single stage
pump has one impeller and multistage
pump has two or more impellers in series.
The discharge of one impeller is the
suction of the next one and the head
developed in all the stages are totaled.
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Fig. 3.1.1a
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Fig. 3.1.1b
arranged under the pipe rack in a refinery
or an outdoor process plant, keeping motor
end towards the access space and
suction/discharge faces towards the
process vessels (Refer Fig. 3.1.1). Single
pump should have access all around, a
minimum of 900mm. When space is
restricted, or the pumps are small, two
pumps can be placed on common
foundations with the orientation of the
motor terminal modified if required.
(Refer Fig. 3.1.2)
Fig. 3.1.2
Fig. 3.1.3
For safety and operators' convenience,
pumps
for
tanks
containing
inflammable/corrosive liquids should be
located outside the dykes. (Refer
Fig.3.1.3)
3.1.2 PIPING ARRANGEMENT
The
primary
goal
in
piping
arrangement is to satisfy the performance
and the flexibility requirements. Suction
piping should be designed without loops
or pockets. The eccentric reducers are
placed close to the suction nozzle either
FSU or FSD depending on the line
configuration (Refer Fig. 3.1.4). These
lines shall be drainable near the pumps.
The suction line is generally one or two
sizes larger than the pump suction nozzle
for centrifugal pumps. NPSH requirement
has to be checked while locating the
pumps and routing the suction lines.
Accordingly saturated liquid, steam
condensate and vacuum conditions need
elevated suction vessels. The horizontal
runs should be kept minimum in all
suction piping. The thermal expansion
requirement should be taken care of in
such a way that the pump nozzles are not
loaded. The suction as well as the
discharge piping shall be supported
adequate enough not to impose excess
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FIG. 3.1.4a
FIG. 3.1.4b
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3.2 Compressors
Basically there are two types of
compressors used in the chemical process
industry. They are the centrifugal type and
the reciprocating type.
Layout and piping considerations for the
centrifugal compressors do not differ in
concepts from arrangement of centrifugal
pumps. However pipe sizes are much
larger because of the large volume
handled. These have horizontally split
casing. Those having bottom connections
are elevated. Concrete columns and
tabletop arrangements are provided with
surrounding access platform.
Compressor
foundations
are
kept
independent of building foundations. A
hand operated travelling crane located at
compressor centre line is to be provided
overhead. Lay down space also has to be
planned for. Knockout drums and inter
stage exchangers are so arranged as to
have short and simple piping. Long radius
elbows should be used immediately before
the compressor suction. A straight length
of 5D at the suction is normally provided.
For air compressors, strainer has to be
provided at the open-air inlet.
Lubricating oil and seal oil consoles are
also to be located which occupy large area
near or under the compressors.
Manufacturer's recommendation should be
followed in this case.
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Fig. 3.3.1a
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Fig. 3.3.1b
3.3.2 PIPING ARRANGEMENT
The piping engineer is responsible for
the physical arrangement of piping. Most
often the piping engineer will have no
influence in the selection of exchangers,
he can only modify the nozzle
arrangements to have an economical
piping. For this, the basic knowledge of
the type of exchangers and its construction
details are required. TEMA (Tubular
Exchanger Manufacturers Association)
specifies the various combinations
possible.
The basic types used in the chemical
process industry are
a) Fixed tube-sheet Heat Exchangers:
Exchangers with complete enclosed tubes
are mainly used in clean services.
Cleaning can be done by flushing through
the tube side and shell side. Clean out
connections are provided in the piping
between the exchanger nozzle and block
valve. The bolted cover and channel
facilitate inspection and physical cleaning
of the tubes. When used in high
temperature services, an expansion joint is
built into the shell to take care of the
differential expansion between the shell
and the tube.
b) U tube Heat Exchangers:
In this type, the tube bundle is hairpin
shaped and can freely expand. The bundle
is removable from the shell and provision
in layout has to be made for the same this
Equipment and Piping Layout
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Fig. 3.3.4a
FIG.3.3.4b
c) Horizontal exchanger can be turned
vertical for conserving floor space.
Vertical exchangers can be changed to
horizontal when installation height is
restricted.
d) Exchanger saddle can also be relocated
to adjust to a line-up or combined
foundation design. (Refer Fig. 3.3.2)
e) Interchange flow media between tube
side and shell side. This can give the
following advantages.
i) If hotter liquid is allowed to flow
through the tube, this will minimize the
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g) Vessel saddles
Ideally, saddles are located at 1/5 of
the drum length from each tangent line.
The vertical vessel can be supported on
skirt, on half skirt, on legs or on lugs as
the case may be. The analysis of the
support attachment shall be done
accordingly.
Location of associated equipment around
the vessel also influences the nozzle
orientation. The liquid outlet should be
located towards the nearby pump suction.
The elevation of the vessel should be such
as to provide the required NPSH. In a
reactor, the manhole should be oriented
towards the access aisle to facilitate
manual feed if required. The utility
manifold and the process inlet manifold
should be placed at the operating level
irrespective of the nozzle attached to the
vessel.
The piping should run overhead as short
and as simple as possible. Pipe rack shall
be arranged which will support electric
and instrument trays along with pipelines.
Piping should not transmit vibrations and
should be isolated from vibrating
equipment with the help of expansion
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Fig. 3.4.4
Equipment and Piping Layout
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