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PART 1

SELF ASSESSMENT (results not included in grade)

Algebra
Geometry
Physics
Chemistry
Descriptive Geometry
CAD Basics
INTRODUCTION TO PROCESS PLANT DESIGN
Stakeholders
Roles and Results
Project Life Cycle
DESIGN PHASES AND INFORMATION
Design Phases
Information Flow
Process Documents
Piping Documents
PART 2

PIPE MANUFACTURING AND FABRICATION

Manufacturing Processes
Pipe Sizes
Marking and Coating
Fittings and Components
Pipe Fabrication
Shop Welding
Branch Connections
Heat Treat and Shipping
PIPE ASSEMBLY
Cranes and Lifts
Scaffolding
Pipe Field Assembly
Pipe Rigging and Lifts
Hydrotest Insulation Labeling
Finding CG of Spool
TYPICAL FABRICATION ISOs
PIPE AND WELD MATERIALS
Pipe Materials and Properties
Welding and Welder qualifications
Weld Defects and Inspection
PART 3

VALVE TYPES AND APPLICATIONS

Valve Parts
Isolation Valves
Gate Valves
Butterfly Valves
Isolation Applications
Throttling Valves
Valve Actuators
SELF-ADJUSTING VALVES
Check Valves
Regulator and Relief Valves
Steam Traps
VALVE SELECTION AND USE

Valve Symbols and Loops

Valve Selection
Station Layout
INSTRUMENTATION
Control Loop Elements
Pressure Measurement
Flow Measurement
Temperature Measurement
Level Measurement
Installation Concepts
More Installation Concepts
PART 4

PUMP SELECTION
Centrifugal Pump Configurations
Centrifugal Pump Cavitation and NPSH
Centrifugal Pump System Design
Positive Displacement Pumps
Motive Power for Pumps
PLUMP LAYOUT
Configuration and Elevation
Pump Piping Layout
Temporary Strainers
Pump Access
Pump Loading and Reducdancy
Pump installation Examples
PIPE ROUTING
Piping Layout Data
Pipe Routing Considerations
Piping Component Use
PIPE RACKS
Pipe Rack Terminology
Rack and Bent Layout
Rack Pipe Layout
Rack Pipe Expansion
Construction and Details
Other Uses
PIPE LAYOUT SPECIFICATION
PART 5

PRESSURE VESSELS
Overview and Terminology
Head Shapes and Attachments
Vessel Layouts and Nozzles
Introduction to ASME Section VIII
Vessel Fabrication and Erection
PIPE SUPPORTS AND HANGERS
Span Types and Terminology
Spans and Characteristics
Spring Hanger Placement
Spring Design
PIPE STRESS AND B31.3
Component Class
Pipe Stress Overview
Weight Solutions for Rack Piping
Thermal Expansion
Simplified Pump Nozzle Load Check

Simplified Vessel Pipe Stress Check

Simplified Expansion Loop Design
Intro to B31-3
CAD
Data Structures
Rendering from Data
Database Issues
Database integrity Capture and Reuse

PART 1

INTRODUCTION TO PROCESS PLANT DESIGN

Stakeholders
Rules and Results
Project Life Cycle
DESIGN PHASES AND INFORMATION
Design Phases
Information Flow
Process Documents
Piping Documents
GENERAL LAYOUT CONSIDERATIONS
Stakeholders and Information
Layout Techniques and Methods
Layout Considerations
Example - Madden Methodology
PLANT LAYOUT SPECIFICATIONS
Equipment Spacing
Equipment Elevation and Clearance
Operations and Maintenance Clearances
Plot Plan Development
PART 2

INSTRUMENTATION
Control Loop Elements
Pressure Measurement
Flow Measurement
Temperature Measurement
Level Measurement
Installation Concepts
More Installation Concepts
PUMP SELECTION
Centrifugal Pump Configurations
Centrifugal Pump Cavitation and NPSH
Centrifugal Pump System Design
Positive Displacement Pumps
Motive power for Pumps
PUMP LAYOUT
Configuration and Elevation
Pump Piping Layout
Temporary Strainers
Pump Access
Pump Loading and Redundancy
Pump Installation Examples
COMPRESSORS
Centrifugal
Reciprocating and Rotary
Drives
Auxiliary Equipment
Pulsation Control
Lube-Seal Oil and Condensate
Maintenance Requirements
Supports and Foundations
Combining Requirements on Layout
PART 3

HEAT EXCHANGERS
Heat Exchange Concepts
Shell and Tube
Plate
Spiral Hairpin Air Cooler
Applications
Exchanger Arrangements
Nozzle and Piping Arrangements
Construction and Maintenance
DRUMS
Drums Introduction and Internals

*****************************************************

I) Piping Systems Detailed Engineering /Plant & Piping Layout Engineering / Piping
Drafting.

Module

- 1 Piping Fundamentals
o Introduction to Process Plants
o Difference between Code and Standards
o Scope of Piping in Projects.
o Plant Piping Systems and Transportation Pipelines.
o Definition & Application of Pipe
o Difference between pipes and tubes,
o Pipe Designators NPS , IPS , NB, Pipe Wall Thickness & Schedule, Pipe Weights, Lengths, Grades, Ends, Joining
Methods, Methods of Manufacture, Pipe Ratings, Pipe Symbols.
o ASTM Specifications of pipes.
Module - 2 Pipe Fittings ASME Standards, Selection, Application, Drawing Symbols & Dimensioning.
o Types of Fittings Butt Weld, Screwed & Socket Weld.
o Elbow 90 degree (LR & SR), 45 degree, Reducing Ell, Elbow Representations on drawings, different views,
drawing call outs .
o Pipe Bends Miter Bends, Miter types, Miter angle determination, Miter stress requirements, 180 degree Return,
Representations on drawings.
o Branch Connections Weld Straight & Reducing Tee, Cross & Lateral. Representations on drawings, drawing call
outs.
o Reducers Concentric & Eccentric, Reducer Offsets Representations on drawings, Drawing call outs.
o Eccentric reducer applications, offset calculation.
o Stub Ends, Stub end types: Long, Short, Class A, Class B Representations on drawings, Application of Stub Ends.
o Fabricated Branch Connections Stub In & Stub On, Representations on drawings, Welding Minimums for Stub
In.
o Branch Reinforcements Reinforcing Pad, Welding Saddle, Representations on drawings, Drawing call outs.
o O let Fittings Weldolets, Sockolets, Threadolets, Latrolets, Elbolets & Sweepolets, Nipolet, Flangolet
Representations on drawings.
o Types of Couplings: Full coupling, Reducing coupling, Half coupling, Representations on drawings, Drawing call
outs.
o Weld Cap, Plug, Representations on drawings, Drawing call outs.
o Fitting Makeup Dimensioning, Placement of Dimensions.

o Minimum Pipe length requirements.

o Screwed & Socket Weld Fittings Union, Plug, Coupling, Types of couplings, coupling applications. Types of
Swages, Swage end configurations. Swage applications.
o Classes of Screwed & Socket Weld Fittings
o Dimensioning Exercises
Module - 3 Pipe Flanges ASME Standards, Symbols, Selection & Application.
o Definition of Flange.
o Types of Flanges and Application, P-T. Ratings. Forged Steel and Cast Iron Flanges.
o Flange Facings Flat Face, Raised Face, RTJ, & Male - Female, Tongue & Groove. Flange Face Finish types,
application.
o Weld Neck, Slip On, Threaded, Socket Weld, Lap-Joint, Reducing, Blind & Orifice Flanges.
o Flange considerations by a Piping Engineer and by Code. Bolt hole requirements. Bolts & Nuts types.
o Gaskets Types, Thickness, selection requirements
o Flange selection exercise.
o Dimensioning Exercises.
Module - 4 Valves ASME/API Standards, Symbols, Selection & Application.
o Definition.
o Valve Functions, P-T Ratings, Difference in Valve and flange Ratings, Valve Tag numbers, Locations & End
Connections.
o Valve Types Gate, Globe, Ball, Check, Butterfly, Angle, PRV/PSV, Plug, Control Valve, Diaphragm, Needle,
Piston, Flush bottom, 3-Way, 4-Way, etc.
o Control Valve Manifold: Types, Function, Layout types, Representation & Requirements on flow Diagrams and
Layouts.
o Valve Operators.
o Valve Data Sheet preparation and understanding.
o Valve Trim.
o Valve Selection.
o Valve Layout Considerations.
o Dimensioning Exercises.

Module
o
o
o
o

- 5 ASME Codes & Standards

Introduction to ASME Pressure Piping Design Codes.
ASME Standards for Common Piping Elements.
API Codes.
Other Codes & Standards.

Module - 6 Piping Special Elements.

o Strainers
o
o
o
o
o
o
o
o

Bellows/Expansion Joints.
Rupture Disc.
Spectacle Blind.
Blanks.
Spacers.
Steam Traps.
Flame Arrestor.
Vortex Breaker.

Module - 7 Process Mechanical Equipments API Standards, Symbols, & Application.

o Static Horizontal Vessels, Distillation columns, Storage Tanks, Heat Exchanger & Re boiler, Fired Heaters,
Reactors, Cooling Towers.
o Rotary Pumps, Compressor, Fans.
o Vessel trim.
Module - 8 Flow Diagrams.
o Block flow Diagrams-BFD,
o Process Flow Diagram PFD.
o Utility Flow Diagram- UFD,
o Piping & Instrumentation Diagram P & ID.

o Line Numbering,
o Line Number requirements,
o
o
o
o
o
o
o

Piping Tracing(Jacket Piping ,Steam/Electric tracing).

P& ID Requirements,
Line Designation table/ Line list creation from P & ID.
Print Reading Exercise,
Flow Diagram Exercises,
Symbols & Abbreviations.
Equipment vendor data/PDS,

o Instrument Types & Symbols Flow, Temp, Pressure & Level.

o Instrument Hook-up Drawing
Module - 9 Piping Material Specification (PMS)/ Piping class
o PMS and its requirements,
o Piping Specifications / Material Selection / P-T ratings / Valve Data / Branch table / Abbrevation details.
o PMS Application/Use by various departments.
Module - 10 Plot Plan, Equipment Layout, & Piping GA Drawings.
o Plot Plan Development & Requirements.
o Layout Terminology & call outs,
o Control Point & Plant north, Battery Limits.
o Equipment Layout: Types, Guidelines for preparation based on type,
o Guidelines for Building layout types.
o
o
o
o
o
o

Piping GA Drawing Requirements and Layout Procedure.

Pipe routing requirements
Pump GA Drawing and Layout Consideration.
Tank & Vessel Layout Consideration.
GA - Print Reading Exercise.
Inputs(Drawings/Documents) for piping G A drawings.

Module - 11 Piping Isometrics

o Isometric requirements
o Drawing Piping Isometrics
o Isometric Dimensions, Notes & Callouts.
o Isometric Offsets.
o Print Reading Exercises.
o Exercises on Creation of Isometrics form Piping Plans and Sections.
o Inputs (Drawings/Documents) for piping Isometric drawings.
Module - 12 Piping Spools
o Definition
o Types of Spool Drawings.
o Guidelines to Prepare Spool Drawings.
o Print Reading Exercises.
o Exercises on Creation of Piping Spool from Piping Isometrics.
o MTO (Material Take Off): Types, and applications.
Module - 13 Pipe Supports
o Classification of Supports.
o Primary supports
o Secondary supports
o Rest supports
o Anchor supports
o Standard supports
o Standard support details required
o Non Standard supports/Special pipe supports(SPS)
o SPS requirements.
o Anchors.
o Pipe Guides.
o Limit Stops.

o
o
o
o

Pipe Shoe.
Shoe Guides / Hold down guides,
Dummy Leg / Trunion.
Field Support / Base Support.

o Rigid Hangers Rod & Clevis, Trapeze.

o Pick up supports,
o Flexible/Spring supports Variable & Constant.
o Control valve manifold supports.
o Piping support Engineer work procedure.
o Pipe Rack Design Types, Height & Width Calculations, Pipe Arrangements.
o Control Station & Utility Station on Pipe Racks.

II) Piping Systems Design

Module - 1 Pressure Design of Process Piping Systems ASME B 31.3.

o Scope of ASME B 31.3, B31.4 & B 31.8
o ASME B 31.3 Fluid Service Categories.
o Design Pressure & Design Temperature for Piping Systems.
o P-T Rating Determination of Flanges, Threaded & Socket Weld Fittings.
o Pressure Design of Straight Pipe under Internal Pressure. Wall thickness Calculations.
o MDP Maximum Design Pressure for Piping S.ystems
o Branch Reinforcements Reinforcement Pad Calculations.
o Pressure Design of Miter Bends Single & Multiple Miters.
o Pressure Design of Blanks.
o Pipeline Wall thickness Calculations B 31.4 / B 31.8.
o MAOP Maximum Allowable Operating Pressure for Pipelines.
o Piping Material Selection per ASME Code.
Module - 2 Hydraulic Design of Liquid Piping Systems & Pipelines.
A. Pressure Drop Due to Friction
o
o
o
o
o
o
o
o
o

Velocity Variation in Pipes

Typical Velocities for Water Piping & Other Liquids
Pipe Sizing
Hazen Williams Equation
Darcy Weisbach Equation
Friction Factor
Reynolds Number
Colebrook White Equation
Moody Diagram

o Minor Losses in Pipe Fittings Equivalent Length Method & K-Factor method.
B. Pressure & Horse Power Required
o Total Pressure Required to Transport Friction Head, Elevation Head, And Minimum Delivery Pressure.
o
o
o
o

Elements of Total Dynamic Head Static Head, Pressure Head, Velocity Head, Friction Head.
Pump Horse Power Required.
Cavitation in Pumps.
NPSH Required & NPSH Available for Pumps.

III) Pipe Stress Analysis

Module - 1 Introduction

o Objectives & Definition of Stress Analysis

o Piping Loads Primary, Secondary, Sustained Loads, Occasional Loads, Static & Dynamic Loads.
o Piping Stresses- Primary, Secondary.
o Stresses acting in Pipe due to internal Pressure.
o Stresses acting in Pipe due to pipe weight.
o Critical Line List & its criteria.
o Information Required for Stress Analysis.
o Occasional Loads

o
o
o
o

Wind Load.
Seismic Load.
Water Hammer Load.
Theories of Failure.

o Requirements of ASME B 31.3 Code Sustained Loads, Thermal Expansion & Occasional Loads.
Module - 2 Pipe Span Calculations
o Span limitations based on Stress, Deflection & Natural Frequency.
o Allowable Pipe Span Calculations.
o Suggested Pipe Support Spacing.
o Pipe Span Reduction Factor for Elbows, Concentrated Loads etc.
Module - 3 Flexibility Analysis Expansion Loops & Expansion Joints.
o Concept of Thermal Expansion.
o Providing Flexibility in Piping.
o Minimum Leg Required to Absorb Thermal Expansion.
o Stress Nomographs for Pump and Vessel Piping.
o Types of Expansion Loops.
o Expansion Loop Sizing for Hot Piping.
o Expansion Loops requirements on pipe racks.
o Nozzle Thermal Growth Calculations pumps, vessels, heat exchangers.
o
o
o
o

Expansion Joints Types, Application & Selection.

Bellow Materials, Hydrostatic Test Pressure for Bellows.
Guide Spacing for Expansion Joints.
Severe Cyclic Conditions.

Module - 4 Layout Solutions for Weight, Thermal, Vibration & Wind Loads.
o Causes of Pipe Stress.
o Solving Concentrated Loads and Reducing Loads on Equipment Nozzles.
o Checking Piping Layout in Pipe Racks.
o Checking Piping Layout for Reciprocating Equipment.
o Checking Piping Layout for Wind Load.
o Solutions for piping loads.
o Selection of Supports, Location of Supports and Restraints on a Pump Piping Layout.
Module
5 Flexibility Analysis using ASME B 31.3 Code Equations.
o Thermal Expansion Stress Se, Code Allowable Thermal Displacement Stress Range Sa.
o Stress Range Reduction Factors f.
o Bending & Torsion Stress.
o Formal Analysis Requirements.
o Inplane & Outplane Bending Moments
o Stress Intensification Factors SIF.
o Calculation of Thermal Expansion Stress
o Cold Spring.
IV) CAESAR II Pipe Stress Analysis Software
o Introduction.
o Piping Input Spreadsheet.
o
o
o
o
o

Modelling of Piping Isometrics Bends, Returns, Reducers, Valves, Loops etc.

Performing Static Analysis.
Load case explanations
Modifying Load Cases.
Hanger Selection.

o
o
o
o
o

Set up of SUS, OPE, EXP, HYD, HGR Load cases.

Set up of Wind Load cases.
Set up of Uniform Load cases.
WRC Nozzle load calculations.
Viewing Reports.

o Word/Excel file conversion of reports.

o Making/Reviewing unit files.

o Importing Lines for stress analysis.

o 10 Practical Examples Input, Analysis & Redesign

**************************

I) Plumbing Systems Design

Module 1) Introduction
Introduction, History, Scope, Objective, Building Services
Plumbing Codes & Standards -UPC, SPC, NPC, BOCA & IPC
Plumbing Scope in a building
Role of Plumbing Practitioners
Plumbing Fixtures & Appliances Definitions, Symbols, Supply
Installation & Fixture Clearances
Water Closet, Lavatory, Bath Tub, Shower Head, Bidet, Urinal
Floor Drain, Kitchen Sink, Dish Washer, Waste Food Grinder
Drinking Fountain, Laundry Tray, Hose Bib
Flushing Systems
Water Consumption
Module 2) Piping Systems
Fundamentals-Pipe, Tube
Pipe Designators NPS, IPS, NB
Pipe Wall Thickness, Schedule, Pipe Weight, Lengths, Grades, Ends
Connections in Piping System
Pipe Joining Methods (Threaded, Socket-Weld, Butt-Weld, Flanged)
Pipe Fittings Elbows (90 - Long Radius, Short Radius, 45 Bends, Reducing, Mitre)
Tee Equal, Reducing
Fabricated Stub-In, Stub-On
Reducers Concentric, Eccentric, FOT, FOB
Couplings, Unions, Plug, Swage
Flanges, Configurations, Types
Valves Introduction, Functions, Components, Locations
Gate, Globe, Butterfly, Ball, Angle, Check, PRV, Drain, Air Vent, Control Valves
Valve Operators, Valve Layout Considerations
Basics of Heat transfer in a building envelop.
Understanding of Outdoor & Indoor Conditions.
Indoor Conditions requirements
Exposure of Wall, Latitude of Location, Daily Range etc
Factors affecting the loads estimate.
Module 3) Water Supply Cold & Potable Water Systems

Introduction, Water, Sources of Water Supply, Requirements

Estimating the Total Demand for Water Supply System
Water Meter, Types, Sizing, Pressure Drop
Water Supply Systems in Buildings Direct, Over-Head Tank
Underground-Overhead, Direct Pumping Systems
Water Distribution System in Building-Up-Feed, Down-Feed
Types, Sizing Underground & Overhead Tank
Booster Pump Requirement
Estimation of Number of Plumbing Fixtures
Fixture Units/Demand Units/Loading Units
Estimation of Fixture Units, Simultaneous Demand
Hunter Curves, Max. Probable Flow
Sizing Water Supply Piping - Pressure Drop & Velocity Limitation
Pressure Needed in Different Fixtures
Excessive Water Pressure, Water Hamme
Module 4) Hot Water Supply System
Introduction, Hot Water Requirement
Hot Water Temperature for Various Services
Components of Hot Water Supply System
Water Heaters, Types, Storage Tanks
Hot Water Distribution Piping System
Individual Geysers
Centralized Hot-Water Systems
Hot Water Circulation Systems Up-Feed, Down-Feed, Combined, Inverted
Design Average Hot Water Demand
Water Heater Coil Capacity, Storage Tank Capacity
Module - 5) Hydraulics and Pumping Systems
Introduction, Density, Viscosity
Pressure-Vapor, Atmospheric ,Absolute and Gauge
Static Head, Dynamic Head
Flow under Gravity Conditions Pipes
Open Channels, Flow under Pressure
Coefficient of Roughness, Frictional Loss, Nomo graph
Need for Pumping
Pump Types Centrifugal, Rotary, Positive Reciprocating
Pump Application Booster, Circulation, Submersible, Sewage and Sump Pump
Pumping Systems Direct Boosting, Break-Pressure Tank, Hydro-Pneumatic
Pump Characteristics Capacity, Total Dynamic Head, Efficiency, Power Required
Suction, Cavitation, Net Positive Suction Head
Module 6) Sanitary Drainage System
Introduction, Waste Water-Black Water, Gray Water
Planning Layouts, Pipes, Fittings
Grouping of Drainage System-Above Ground, Basement, In Ground
Parts -Traps, Vents, Drainage Pipe, Building Drain Pipe, Sewer
System Types One-pipe, Two-pipe, Single Stack, Soil Stack, Waste Stack
Drainage Fixture Units, Estimation
Sizing-Horizontal Fixture Branches, Stacks
Branch Intervals, Maximum Capacities, Grading(sloping) of Horizontal Pipes
Vent System, Role of Atmospheric Pressure
Types Wet, Waste Stack, Back-Back, Circuit, Loop, Individual Vent
Sizing and Length
Sewage Basin, Sewage Pump
Types-Submersible, Vertical Lift, Self Priming, Simplex, Duplex
Drawdown Capacity, Circular Basin Capacity, Basin Sizing
Sewage Pump Head Calculations

Module 7) Storm Water Management

Introduction, Collection, Catchment Areas
Design Considerations- Rain Water Area, Amount of Rainfall
Type of Roof System- Flat Roofs, Sloped Roofs
Catchment Area, Roof Drains
Screening, Gutters, Leader, Horizontal Storm Drain
Sizing, Sloping, Connections
II) Fire Fighting Systems Module 1) Introduction
Requirement, Absolute Safety
Classification of Fire Safety Systems
Passive Fire Safety, Active Fire Safety
Fire Detection & Alarm System
Fire Suppression System
Foam, Chemical, Gaseous Systems
Water-Based Systems
Codes & Standards, Organizations
Design and steps for protection
Module 2) Fire Dynamics
Fire Dynamics, Fire Tetrahedron
Fire Extinguishing Methods, Fire Extinguishing Agents
Fire Classes, Comparison of Classes
Fire Class & Extinguishing Agent
Types of Extinguishing Agents
Module 3) Fire Sprinkler Systems - NFPA 13
Introduction
Water Based Fire Suppression Systems
Fire Extinguishing Properties, Disadvantages
Building Occupancy Classification
NFPA Standards Related to Fire
Sprinkler Head Construction, Temperature Ratings, Configurations, Types
Sprinkler System Description, Types, Components
Module 4) Design & Layout
Description, Riser, Feed Main, Cross Main, Branch Line
Typical Piping Layouts Grid, Loop, Tree
Hazard Classification- Light, Ordinary, Extra, Special
Floor Area Limitation
Protection Area of Sprinkler
Spacing, Location
Sprinkler Pipe Sizing Pipe Schedule Method
Module 5) Fire Sprinkler Hydraulics-NFPA 20
Sprinkler Piping pressure, Material, Piping Joints, Wall thickness
Sprinkler Head K-Factor
Basic Design Circuit
Sprinkler Density Requirement
Hydraulic Analysis, Design Density
Area/Density Curves, Flow Adjustments
Riser Detail
Hazen-Williams Formula for Friction Loss
Sprinkler System Water Supplies
Module 6) Standpipe Systems-NFPA 14
Introduction- Hose Connection, Valve, Nozzle
Hose Storage Devices, Hose Station
Combined Standpipe and Sprinkler System

Standpipe Classes Class I, Class II, Class III

Fire Department Connection
Standpipe Classification Automatic, Semi-Automatic, Manual
Standpipe Types Dry, Wet
Requirements, System Zoning, System Demand
System Design Location, Number, Interconnection, Minimum Size
Pressure Limitation, Supply and Flow Rates
Fire Tank Sizing
Hydraulic Calculation Procedure
Drains and Test Riser
Module 7) Private Hydrant and Hose Systems-NFPA 14
Introduction
Types Wall, Wet Barrel, Frost-proof, Monitor Nozzle Hydrant
System Design - Number, Size, Arrangement, Location
Flow Indicators, Body Color