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Piping Layout Engineering -
Basic Concepts
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Piping Layout Considerations:
OperationMaintenance
Constuctability
Economics
Safety
Aesthetics
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Design for Constructibility Ten Commandments:
K eep I t Straight and Simple K eep I ts Structures Simple K eep I ts S pecification Simple K eep I t Shop Standard K eep I ts Standard Simple K eep I t Same Size
K eep I t S uare and S uatty K eep I ts Support Simple K eep I ts Schedule Sacred K eep I ts Site Suitable
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Ma!or steps before Piping Layout "esign:
#"e$elopment of Plot Plan
#E uipment layout design
#Conceptual Piping layout design
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EQUIPMEN L!"#U $UNI PL# PL!ND%!&IN' 'UIDE LINES
The follo%ing are the guidelines generally follo%ed %hile ma&ing an E uipment layout'unit plotplan dra%ing(
a) E uipment layout shall be dra%n in *:+, or *:*,,
scale(
b) A, size dra%ing sheet should generally be used for
e uipment layout( -f the area to be co$ered is small. A*
size can be used(
c) Place north arro% at the top right hand corner of the
sheet to indicate plant north(
d) The area abo$e title bloc& to be &ept free for general
notes and reference dra%ings(
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e) All e uipments are mar&ed %ith its e uipment no( as appearing in E uipment list / dimensions
0diameter. height'length etc()f) All e uipments center line are located in plant
building %(r(t( the column grid( 1or layout ofoutdoor plant ' offsite facility. the e uipment shall be located by co2ordinates(
g) Conceptual layout. P / -". $endor'fabricatede uipment dra%ings are to be used as basicdocument for preparing e uipment layout
dra%ing(h) 3al&%ays. cutouts. piperac&s. floor drains. gutter.
trenches. ramp etc( if applicable should be clearly mar&ed in the dra%ing (
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i) 1or in house plant layout. the location of staircases. lift /
other utility areas should be clearly sho%n(
!) -n e uipment layout sectional dra%ing. for each e uipment
its top most or bottom most ele$ations should be mar&ed(
&) Orientation of e uipment shall be clearly mar&ed for all
the
e uipments by orienting one of the ma!or nozzles(
l) -n case of reactors ' tan&s. the location of manhole '
handhole.
S4'L4.L- etc( shall be at accessible position(
m) E uipment lifting cutout shall be mar&ed clearly in the
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n) E uipment planned to be installed in future shall be
sho%n dotted(
o) 1or heat e5changers. tube remo$al ' cleaning space
shall be mar&ed(
p) 3hile locating the pumps care shall be ta&en to ensure
that the 6PS7 re uirement is met(
) 4eneral notes are %ritten on one of the dra%ings 0first)
and shall not be repeated on all layouts but reference
shall be gi$en( r) "irection of north shall be maintained same for all the
plans for the same plant ' pro!ect(
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s) -f more than one dra%ing is re uired to co$er a
specified area. then the match line shall be indicated clearly%ith the reference dra%ings(
t) One of the general notes should specify the
absolute le$el of the area co$ered %ith respect to the plot(
u) The e uipment load. operating or test load
%hiche$er is ma5imum shall be considered for design and the
layout should indicate this along %ith the dynamic factor
%here$er applicable( This could also be co$ered in table as
%ell(
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$) 1or reactors %ith agitators. lifting beam shall be pro$ided for
agitator remo$al(
%) 1or $endor e uipments maintenance space as recommended by
them for maintenance shall be pro$ided(
5) E uipment layout shall also indicated the positions of utility
stations. safety sho%er and eye %ash(
y) E uipment ele$ation shall be so arranged to ensure gra$ity
flo%
%here specified(
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-rrespecti$e of the type of arrangement. there are certain basic principles to be follo%ed %hile locating the e uipment(
# Economic piping# Process re uirements
# Common Operation
# 8nderground facilities# Climatic conditions
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!CCESS PL! )#%MS
The follo%ing guidelines shall be follo%ed for pro$iding access platforms in the layout(
a) 1or all Manholes %ith centre line ele$ation abo$e 9+,,
mm( b) 1or instrument $ision( The L4 should be $ie%ed %hile
operating the bypass of the control $al$e(c) At ,, mm 2 *+,, mm belo% the Manhole(
d) A minimum height of ;(+ m to be considered bet%een platforms to ta&e care of the headroom(
e) The platform at the top of the to%er shall be at ;+, to 9,,mm abo$e the top dish(
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P*IL#S#P*" #) IN-PL!N PIPIN'
o
o
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=A>" P-P-64
P / - diagram. e uipment layout. piping specifications.e uipment dra%ing and the $endor re uirement for proprietarye uipment form the basis of a piping layout( -n areas %here
piping is critical. the e uipment locations are fi5ed only after a?piping study@ is made(
The first step in the de$elopment of pipe rac& is the generationof a line routing diagram( A line routing diagram is aschematic representation of all process and utility piping systems
dra%n on a copy of plot plan or it could be planometricrepresentation of the utility and process line diagrams( Althoughit disregards the e5act locations. ele$ations or interferences. itlocates the most congested area(
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1.5 TO 2M
TYPE 1
5 TO 6M 1TO 1.2M
TYPE 2
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5 TO 6M
TYPE 3
/ * 0 1 1 ll 2i0 0 i b l 3(
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/e *ea0roo1 nor1ally pro2i0e0 is as belo3(Sr( "escription 7eadroom
6o( 0mm)*( Clear head room under ;;,,
Structures'pipe linesinside operating area(
;( 7ead room o$er rail B,,,0from top of rails)
9( Clear headroom abo$e B,,,crest of road for cranemo$ement(
( Clear headroom abo$e D,,,crest of road for truc& mo$ement(
+( Clear headroom abo$e +,,crest of road bet%een
process units(
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8al2e !ccessibility
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+(,(9 PIPIN' )#% INS %UMEN S
-nstruments.%hen located on piping .%ill need certainspecific re uirement for it to perform the duty for %hich it is pro$ided( Piping Engineer should be a%are of thesere uirements and should ta&e care of the same %hile routingthese pipe lines(a) 1lo% measurement instrument need certain straight lengthupstream and do%nstream of the instrument(This is normally*+" on the upstream and +" on the do%nstream(
b) The pipe lines in %hich flo% meters such as magneticflo%meters .$orte5 meters .turbinemeters etc are located should
be routed in such a %ay that the line %ill be full %ith li uid allthe time(The pipe line should be supported on both sides ofmeter(
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c) Control $al$es are located at grade. at about +,,mm height to pro$ide con$enient access for operation and maintenance( loc&and bypass $al$e also form the same criteria( The standard
arrangements follo%ed are as per 1ig ;(9(;9 ( -f poc&eting the process line is unacceptable. then a permanent or mobile platformshould be planned. as access is $ery important( Locating control$alues on the $ertical line should be a$oided(-f is una$oidableF theshould actuator should be supported properly(The bypass should
be selected for easy operation(
d) -solation $al$es for le$el gauges and pressure gauges shall bemade accessible( Access and space for the remo$al of le$elcontrollers temperature probes .conducti$ity probes.bottom flagsof the control $alues etc shall be pro$ided( All primary andsecondary indicators of pressure. temperature. flo%. le$el.
positioners etc( should be $isible from the operating area(
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e) >otameters shall be placed on $ertical line and the inletshould be from the bottom of the instrument(
f) Thermo%ell shall be located on the pipe line of re uiredsize(-nstrument hoo& up shall be reffered for the re uirement(
g) Enough operating and maintance access shall be considered%hile locating any instrument(
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The Considerations to arri$e at an economical rac& desgingare
*(
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/e re;uire1ent as per t/e follo3ing s/all bea0/ere0 to
a) The 1actories Act * G(
b) The Petroleum Act * 9 / The Petroleumrules * BD(
c) The Static and Mobile Pressure ules * G*(
d) The 4as Cylinders >ules * G*(
e) The -ndian oiler >egulations * +*( f) "e$elopment control rules by the State
-ndustrial "e$elopment Corporation (
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B F W
TA N K
E C O N O M IS E R
B F W
H P D O S IN G
B O IL E R F E E DW A TE R P U M P
D O S IN G TA N K D O S IN G P U M P
P I
M A N I F O L D
C O N S U M E R
S T
Y
S T
TO A TM O S .( T Y P )
L G L G L G L G
B L O W D O W ND R A I N
B LO W D O W N TA N
N O TE :
P IP E L IN E S T H E P U R ! I E W O F IB R S H O W N W ITH T H IC H L IN E S .
IB R S C O P E
IB R S C O P E
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+(,(. C%I IC!L E
The uality of the e uipment and piping layout can beestablished by the Critical E5amination Techni ue %here youensure that all the follo%ing parameters are %ell addresseda) -t is process ade uateH
b) -t is operator friendlyHc)-t is construction clearHd)7as ade uate maintenance access pro$idedHe)7o% to e$acuate in case of emergencyHf)7as safe fire fighting access pro$idedH
g)Standard practices %here applicable has been adoptedHh)-s the piping arrangement aesthetic Hi)-s supporting arrangement ade uate and aesthetic H
!) -s piping ade uately fle5ible H
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EQUIPMEN !ND PIPIN' L!"#U - PUMPS
Pumps rarely influences the plant layout e5cept %here a
common standby for t%o ser$ices or multiple duty pumps
might dictate the process e uipment arrangement( ut the
pumps can ne$er be treated as an independent entity. but to be
treated as part of the piping system %hich affects the
performance e$en if the basic selection is faultless(
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The design of e uipment and piping configuration
affect the energy used and capital cost of pumps( 7ence.
economy of piping and structures along %ith ease of
operation and maintenance are the principal aim %hile
arranging the pumps (
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The primary goal in locating the pump is to minimize the
piping configuration %hile satisfying the performance and
fle5ibility re uirements as %ell as allo%able loads that may
be sub!ected to the nozzles(
Mechanical or Chemical Engineers can no longer
consider the pump as an independent entity. but to be treatedas a part of the Piping System(
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