Process Piping Designf AN. eOman: KK Gana(pi Ping On{ee) + Contents Preface Introduction 4 General Piping, 1 Piping Materials Methods of Manufacturing Pir Pipe Diameters, Thicknesses e=3 Schedules Fittings and Flanges Valves 2, Process Terms, 26 The Hydrocarbon Hydrocarbon Structures Fractionation Piping Equilibrium Liquids Two-Phase Flow Hot Vapor By-Pass Static Head Steam Data 3. Plant Arrangement and Storage Tanks, 37 Site Data Milly Terrain Block Plot Plan ‘The Process Block Storage Tanks Tank Dike Regulations Storage Tank Design A Refinery Exercise Dike Area Drainage Storage Tank Piping Foam Protection System 4 Process Unlt Plot Plans, 57 Equipment Plot Plan Preliminary Plot Plan Dimensios* Plot Plan Pxercise Foundation Location Plan Excavation Plan Flow Diagram Transportation Piping Drawing Index Equipment Settingontents, ontinued 5 Plping Systems and Details, 73 Underground Piping, Sewer System Terms Sewer Flow Di Cast Iron Soil Pipe and Fittings Designing Systems Student Exercise gram Design Guidelir Underground Pressurized Systems Fire Water Underground Cooling Water Pump-Out system Glycol Lines Steam Tracing Steam Tracing Design Practice Tail Pipe Cuts 6 Pipe Fabrication, 92 Welding Shop Details Pipe Bends Miter Welds Small Fittings The Triangle The Cutback 7 Vessels, 119 Definitions Horizontal Vessels Piping Arrangement for Elevated Vessels Maahold Davits and Hinges Vertical Vessels 8 Instrumentation, 149 Instrument Types Instrument Functions Dual Instruments Transmitters Thermowells Other Temperature Instruments Pressure Instruments Flow Instruments Orifice Flange Taps Level Instruments Level Gage Control Valves Appendix, 171 Conversions index, 209Preface This two-volume set on Process Piping Design has been written to supple- ment my first book, Process Piping Drafting. | have purposely used a very practical writing style for both of these efforts, a/:slying my personal practical experience rather than trying to present the technical aspects of piping. In Process Piping Design 1 have elected to have each chapter self-sustaining. £ have reproduced some charts and tables but only those required in learning the basics of piping design To become a competent piping designer requires many years of experience plus a talent for creative thinking. Piping designers must call on their knowledge for each design job but also must apply their owa ingenuity daily. I like to call that horse sense. Many piping designers have told me that their job is 25% knowledge, 25% experience and 50% horse sense, This book will try to deal with the first 25% and touch on the last 50% Fluor Corporation has been very. farsighted by sastigating piping drafting and piping design training classes and they have been very generous in allow- ing me to reproduce some of their instructional material. 1 wish to take this opportunity to thank Fluor for its assistance. T Powd= 0 342 leg FOsgalten 345 Gr]Introduction In a refining or petrochemical complex, piping constitutes the major expen diture of all the design disciplines. Piping consumes abaut SO% of the desiga engineering manhours, 35% of the material cost of the plant and about 30% of the labor cost in the field, Inept piping design in the office can increase the cost of @ plant. The design engineering department of a contractor designing refinery or petrochemical complexes consists of four main functions: piping, structural, electrical and vessels. The piping section encompasses flow diagrams, model making, insulation and painting. piping material take-off, piping material control, instrument design and piping design itself, Experienced piping designers know the functions of all of these groups. -They also must have a broad knowledge of the structural, electrical and vessel sections, And they must know the many pieces of equipment that they must pipe up, the numerous details of piping, the materials necessary for various services, piping flexibility basics and field construction practices. Then comes 4 general knowledge of plant operation and maintenance. When all of this is considered, it is easy to see why there is always a shortage of experienced, competent piping designers. Ironically, piping design is the one subject that has been neglected in the school systems. This is largely duc to the fact that adequate textbooks were not available. No book can teach a person to become a piping designer but it can teach the fundamentals and how to apply thems. lo become a designer1 General Piping The dictionary desciibes pipe as a Tong tube of clay, concrete, metal, wood, etc., for conveying water, gas, oil or other fluids. A fluid is defined as any substance that can flow-liquid or gas. Pipe has been with us for over S000 years Each year introduces new purposes for piping which create demands for new and improved mate- rial specifications and ingenuity on the part of the piping designer. Piping has advanced from its ear- lior function of transporting-water through wooden conduits from the mountains’ melting snow to the village below. Today piping can be found almost any place one looks, from the piping in an automo: bile to the complicated maze of piping in a process plant A piping designer is one who designs piping systems, Since piping is so widely used, the piping ers cannot learn the complete field of piping intly they have become more special: into the fields of pracess piping, pipe line piping, steam power plant piping or one of the many other eategories. Process piping design is, in the author's estima- tion, the most interesting specialization in the piping field. Each process piping unit presents 2 how challenge to the designer. Each plant is custom and while there is -some similarity be- nit of $0,000 barrels a day und one designed, tween a crude of 75,000 barrels a day, there is no duplication. A piping designer may work on two or three crude units in his entire carcer. These are fiterally hun- dreds of different types of units in a refinery or petrochemical complex. Each type of onit presents its own piping challenges. How, then, can one learn process pipin from a bork? It can’t be done. A book can present the basic similarities that exist in many’ types of units and introduce guidelines for competent de- From there on, the process piping designer adgment. design must ize his persdnal Piping Materials ‘The term piping means not only pipe but the fittings, flanges, valves and other ttems which form part of the overall piping system, Piping materia je classes. mictallic and wom Jat be glass, eeram= ain divided: ‘ous. Ferrous are divided ito two bi metallic, Nonmetallic piping mi ic, plastic. ete, The metallic pipi into two classes, ferrous and nonte materials are those of, containing. or derived from iron und are most commonly used in process is piping. Ferrous metals are carbon steel, stainless steel, chrome steel, east iron, ete. Nonferrous met- als include aluminum,Process Piping Design sole 1-1. Some Stet! Pipe Specifications Grae ‘Manufactured in welded aml seamless Grade B ts mast gonymonly ferred anal mostly used. hon size specified LAB | oo raven tperaues, Ione ; 1 spacial esting. For use to 50°F. | nm Carbon Moly Basically a carbon steel with 19% molybdenum. 1 Ce nding ee ate serie i mi Chrome Moly 18 chrome 1% motybdentm, Used in higher | semmperuture. corrosive services, | s Chrome Moly Hh, 7 mulvhdemot Used in higher orc po Cheam Moly 05 ehrame, UF rempasature highly cortosive sorvices. i asin 30m inless {Gad far tensporatties below 50°F and fa \ owas svsice at higher temperate, Widely | sel fr Food prodeet piping orci Stainless Used for high temperatuce. highly eorvosive service wen Used far sery hight tscive 2st Tasd in harsheconditjons than Type 321 stainless 2 Grd Nickel 3140; nickel, Used for temperatures fam -SO°F to SOF. \ | | \ | | aeeaeeatet rata I | | | | Fable I-L lists some of the many hundreds of - welded topether to form a longitudinal weld) The ie available for pipe. Those listed are longitudinal weld reduces the pressure-cop ising characteristics of pipe and the ANS] (American N: te--formerly ASAY Dipit ous me = most commonly used in process units. For splete Hsting sve the ASTM book. Ferrous Aare- tional Standanls_Institate 6 code reduces the allowable stress of this method of ‘anuluciure by imposing 2 “Joint efficiency” of Methods of Manufacturing Pipe fess than 10072 Geamless piping has a joint ef! cieney of 100% ig no longitud dhamoter, wall thickness, material speviti+ Welded pipe also can attain this TOO joint °F Tlelvery eequitements are deteriining —citney rating with special quality control. proce “hy gs stress relieving and Tall ray exami= S Steel piping i made by lapavelding, spinal nation. Wowever, these add (0 the cost and may pettwekding and._seamless —incthods, not be needed. In the smaller sizes, searnless pinvi Wed pine Typ aFe made from Cat ie quite often as economical as welded if 100% Tifie edges ave then joint efficiency is specified Pea ara lever method of manufacture is s THat Be added To the min Pips slow a ctors in the selection of the manufacturing prec dures s Found 3 Refer to ASTM Standard, Part 1: Steel Piping. To 1 Fittings, nam ed toTable 1-2 Conmerciat Wrought Stee! Pipe Date 3 “Nom=] Qutide /Sekedute) "Wall | Inide | Aree ] Weight] Weight xarnat Section seat | Gaal [NS] wha | Bisse | ASF Biel Seka, fie | "ater [Mier er Ne Pipe | Wite | ice | Dr | See | mm | | [natl2 | d) | Pounds | Pounds | Sq. Fe 1 wie | OL gaiee saune [BR etme aoe oe G5) fetes | inches inches [Inches | Thee _tnches | Feet [48 Pover! _feet_llof pipe ot pipe pee ae aa omy | Oe Ye | ems | | ME RT BS fons | on) Sul te | ie Seeed Seeger ry Sr oases ee ae A Lo | 301 | (oo030 | “oosrz) ‘sss | oar | ‘tal | ‘01395 eae a one aes aye ee He 0878 | 80x | 415 00098 | -oasez] 738/061 | 1178 ; ye SET or or 0 & | ag! | is) 1 F Ye | oso | | TE) a ee See Se 1 xx | | 282, OOO3S | 02424) 1.7141 lim) ui os) Re) oe i | i 1 ve | vo | BE) coset |e) S| L exe | asa | ‘oor | 05792) 2.440 ee eee vost iar Pee eee eee 3 oo i poise |B am ‘302 | a i La 599 00196 | 3.659 aa ie tea 1.660 | 160) 37st} ase | Sale | a8) 8 Tae ay ae Ms 10 | Be i) 8 | = Hel Ta piel eel 8 je es | 3a | ae | ae | ERT 768 | ae | Me ros | 8" | UE) ts i | es Ut \ 3) 3.00 | jeri | | 3 00 | 1 | 1 4 400 | | ! I | Lt : jee | 5) sess | ' 63 : ! | i 4 : 6 | ons \ H Hite a : 2 5 | sms ; rs i rans 17559 > os | | 162.0 iro | 2258 | i He5.9) 1380 [| dase 138.88 [Table 1-2 continued on fatiowing 592) Source: Crane Co. Note 1: The letters 5 x, ond xx nth Numbers indicate Standard Exira Strong Pipe, respectively fia Strong, and Dov Internal shown in sq Feet for the Transverse feprestnt the volume in cutie shamn of Soho.’ Nate 2: “the~ psec 4 (Table 1-2 continued} Ones Tage) [Tramnepe Moment, Weight Weight Extcrnal Section Near | Biss SP | agcract Arca [MSHS WGP MCP Sutiace Moguls ne ay |TEEEH ACS | a ciea| pine | Water (Dy ao ‘= Note 2 _ Pounds Lorie rave | Square | Rpt lhshes tol pee | pe ee toehes | Inches TERRES SRST WRG A |ne Sep sr ear) 7 | RF oo | aba | sei 0 | See | bos tbo | Fabs SH 10 | 40.750 ten | 3st aa Ba] Ou fea \ ion | 655 Bo ‘ fea | 608 hi | Hot SR Hee oan ae be | Hash BP 1S | tho BS iby | bias 58 134 | to ea ar | sas HS} foe; aa ; Hs | tor aa 5b ass | “Se | oe aa Mt) Se ao 1009 tas | S35 WH fos. Bat 63 ire 7 Toa Tarte 7 8 j eo 83 I | a3 I et uj 1400 i a3 | ' on ' | 18 } i as | hes ! tea 7 a BY 03 a3 ee 16 | 1600 we 1s | 1600 i i 20. | 20.00 | | i ' | 24 | 24.00 | i A, z | | | | i PeeRpmeeFe wpatael pips teluwence } a Gor Cie AES 3 Sas, 2. Seba Laapipe » ok le ey Je Kal) Lo General Pagheel (acho a tolerance of 0.01", Pipe made from plate (sit pipe with a-longitudinat seam) will have OT" sdided to its calculated minimum thickness for this nill tolerance, Seamless pipe is made by a process ihat requires a tolerance of 12/°%,1 Hee Seamless pipe is made from hot, round solid billets of steel. A mandrel is centered and pene= irates-the hot billet, expanding the solid piece to 2 hollow pipe. This method of manufacturing can cause :some possible, thin spots in the pipe wall; consequently, the 124% tolerance is imposed. Spécial mianufacturing of seamless pipe, such. a8 ntrifugally cast or special forging, is specified for ery thick requirements. This type is cast or forged fo a thicker wall and is precision machined, inside and out, and the folerance is usually nib. The piping engineer or designer must recognize the method of manufacture and its related mill tbl erance before calculating the minimum wall thick: ness required for his piping ‘The various methods of manufacture also de terinine the length of the delivered pipe. Com pipe is made in “random Jength" which \é in. “double random length whieh iy (/-0". Uniess double random Jength 3s specified, fhe Manufacturer will ship single rmdom. For Jong, straight runs of piping, considerable savings can made: by utilizing the longer pieces, saving butt welding Centrifugally_ cast _and_specisl foszed pipe wil be shipped in 6-12" lengths, Since these are ma Ghined juside and cuit. the lengths are very short ‘This adds humerows buttwelds to long runs of pipe, inereasing the system cost, Consequently. this method of manufacture is utilized only where the diher methods cannot produce the desired pipe more economically. And any economie evaluation myst consider the mon Pipe Diamaters, Thicknesses and Schedules Table 1-2 lists pipe data for most available sizes. Normally, sizes 144". 222 Sgre considered as noncommercially manufieer ured and are not specified by 3 Equipment manufacturers will employ these sizes fund the piping designer will have to attach 2 flange or reducer to this connection but should i-nedh ‘ately increase'to the next larger size for his pp! ~ Tubing is piping designer: are wat the same Sit talons Piping OD, 4” pipe is 4.5"OD. This is usually specified as 4" 1PS (Iron Pipe Size) for pipe and can also be defined by specifying 4” schedule 40. The schedule number defines the OD and the “Nominal” wall ‘thickness for IPS piping. Nomina} wall thickness is the average wall of the pipe-not the minimum wall, To ascertain the trinmurm wall, the mill tolerance must be Sub Fittings and Flanges Welding fittings are manufactured to match the companion pipeaHowever, it is not m: ry that {he fitting and the pipe have the sime thickness Wihile pipe of several schedules is available, Httings aie not stocked for all schedules. Fittings are usue ally specified as standard weight, extra strong, schedule 160 and double extra strong. It is usvally ndvantageous to specify the fitting thickness of the heat higher available weight if the pipe wall.thick- hess is not standard, extri sizong, etc. As an exam ple, with 14” schedule 10 (0.250" wall) the stand weight fitting would be specified, which is Wall. For 14” schedule 40 (0.438" wall) the extra strong fitting would be specified. which is 0.800" wall For pipe sizes 2” welding fittings ‘sal For low pressure, noncrit 2 is specified qwhile s ystems. tle OC employed te L-l describes Forged steel screwed it and Figure !-2 gives dimensional duta for tings them, Figuse 1-3 deseribes forged stecl socketwelding fittings and F 1-4 gives their dimensions. Starting in 1970, the 2000-pound series was dis: continued by. most manufacturers. The 3000. pound series would be used with schedule 40 sad schedule 80 pipe. Sockeiwelding seed iting T! eiwelded s Zand renin a Wak-fres win for y w Finire 1-5 describes steel buttweldin, nd Figure 16 gives their dimensions {ihe Hitings depicted in Figure 1-5 that may be specified by a piping des cz, due 10 uetivery and: cOst, facings se thie ones 1 practicalGros mem ole & fo, tose rend wo. g49, 200 ood ee doce ese Mocz43 20e0rend 00355: Joonreuss Na aes, e008 nae NS. Bsay 4o02.Faime s0) 3000-Pome Parts Ne, a61, 8900-Fs No bea, 6000-72 MEeSee ra y * feng te getShtecs mala aeaerd Neate 0Pons wo ate neebaeg Ne. eh atte we SB ae od hese are unusually eee habe ie * rene om oA 7 RS Oe ine and fo Carton Stee! and cas fick central power stations, and PR, Grade 3000 | 3000 | 6000 Dep Pound | Pound | Pound PE WOE. W.0.6.|W.0-6 and chemical slants yund W.O.L” Fittings, exceptionally and light in weight, are intended for vines beyond the temperature range of mal: ison fittings and for many relatively Tow Gare installations where the extra strength N afforded by'steel fittings are sesies Materials and design: Elbons, tees, crosses, Round Head Plu and Y.isends are forged solid: the caps, couplings, Wo, 208, 3099 P00 ans cers, plangs, and bushings are machined from, Said steel. Carbon stcel billets or har stock Seed in rhe manufacturing process are subject ta rigid specifications for strength, toughness. Bhd gesistance to temperatere and shock ‘The fittings feature ibe J sections through gue and have an ample fzetor of safety over the pecommended working pressures. Ail openings She drifles, on forged Aitangs, each opening is feinlorced with a wide and which completely ce ours the theead chamber, extending heyond the last thread. The design provides the apps and perms vmaintnttanin nae seceenmeeinen SRNR CSOSA Product used 8hi Biokis 1 Basst Bales. of tl Threads are accurately PES na Prtsaure Vessel Cod cut to gas 1 (rue alignment : “O eneranee of pipe. No, 602, 6000-Fo i peur st anat char swig opis niente 445g ratings: Worhing ? coi ty Pearce tae, EMRE aed or ah tee general eamposnion 1833 edition thereot ngs. N ase. io, 601, 6005-Feind Mo. 609, 4900:Po4"4 La, Fexged atest socketeaing Fittings 2309, 3000, 4000 end 6000 pound W.0.S Reprinted courtesy ofGeneral Piping 7 Reducer ait Coupling Coaningy, rece, ond eon ‘inandors af educing ize ore the wy 05 these of Sie mashined from ict ee Ie srighattecoreypending tothe lorses! cpeing MEW e | #42 | 34 | te Mae fT ae j % [8h] he | fave} a po dnt | | Liste | 2% | tie fie! ate | im) 1 [1% [Pep eT | S| Phe ate am fist ta (ata) = | we | 2s | Wis | Phe | Me! | he 3M | 249 | tthe L21842! 2 bathe oe Ts sisted 3 Yi] 3 Paw Me] YS [Oke A 12 Ue | Pate |e lant | | | hs | % | 386 ! i | | su | aig | sag tangs | 59 t ! 300)-Pound WO.G. Fittings 1h | 3% [iiss te | 1k Whe | Te [Ie |e te ng Lia de Ma Ma eal a Bat | tee 2 | Mir Ras! ia 2% Bie 1 He | 3% f : Mie Me Me B30) 13% Vhe ™% 1%6! 1% | 646 aA Bhat ha | anny 1 Mh6| Mm %e 3 es Figure 1-2. Forged steel serewed fittings {dimensions in inProcess Piping Design ho. indh igosgtounsWOG Nei 1242, 2000.PoundWOG No. 1243, 2000-Found WO No 12 gO Fe OG (Necta82, a000-tomsWOG Nv 1383, 2000-Fowd WOG eet eens WOG —Na.i462, 4090PownsWOG No. 1463, 4000,Fond WOG Noi 146), 6000.Paine WOS 3000.Peud WOS Fininas {000 Pound WOG Fitna t000.Peund WOS F Recommendations: These unusually rugged, durable fit= ings are ideal for small (up.to ana inchising's"} welded lines on relacively low pressure service, for high pressure hy- Graulic bnes -or for high pres sure-temperature service, Phe 2coo-Pound WOG Fit- tingsare lor use with Schedule 40 or Standard pipe... the 3009-Pound, with Schedule 80 or Extra Strong pipe... . the 4000-Pound, with Schedule Toe pipe... . and the 6000- Pound, with Double Extra Strong pipe Design: Elbows, tees, crosses, and Y-bends are forged solid: their openings are reinforced th a wide band which com- pletely surtounds the socket chamber, extends well beyond the back of the socket, and meets recognized requirements for socket-well dimensions. Reducer in- serts, couplings, ceducers, and caps are fnachined (ron solid steel. Openings of all Gittings are drilled and the ends are bored to slip over pipe. Materials: The fittings ace made from high grade carbon steel (ASTAI Atos, Grade 11) of unusual strength and toughness. It is particularly suit- able for fusion welding American Standard: These fittings conform to the American Standard for el Socket-Welding Fittings (B16.11- iaa6). This Standard inchides cltows, Finca 11% Fined steel socken 1eea, 6000 Fond WOS ose wih Soh wth Sebo for vee with Double Ere Suong “Material welding fittings (2 e68, 6000-Pouna OS: 0 = re Seng piPe Wor 1g Prossures* ros, or Ai ‘on-Shoek Temp. ind. |zo00 ~ Jo00 4000 T6000 Bound Sound: Pound, Pound Woo, 8G: Woo | WoC. aaa T2000 Foe, 6600 m7 3uH0 | S815 Bees 5830) 3803780 3730 3750 3700 1235, 1000 715. sees, crosses, and couplings in sices pinch and smaller for use with Schedule Jo, Schedule 80, and Sehedute rhs pipe Jote: When pipe is ratest in accordance with the Code for Pr cure Piping or any other Code, these nttings may be tised for the same pressures and temper- ures as the pipe even tho ratings exceed those in the table above The fittings, of course, must be made of a material having chemical and phys. ical properties comparable to the pipe. and must be of suitable weight, as indicated by the schedule numbers. 199, 3000, 4090 2nd €000 pound W.0.G.) 99 Elbow 1240, 2000,Pauna B06. U340, 3000.Pesns wos ‘80, £000-Foune WOS 35° Y-bond 1245, 2000.Feund WOS. 1305, 2000-Pouna wos, 1488, 4000 Pownd WES Ye6e, do00 Pound WOS Tee 1246, 2000-Pound WOS 386, 3000-Fosnd WOS 1466, 4000-Fara WOS 1866, 6006-PamnsWOG os 1247, 2000.2o.08 WOG 1347, 3000-Fowns WoC. Noor, e000 Pang WOS wp cor 9, 2008: Ped WOE Soo0-Founa wos 3469, 4000 fesna WOR 3669, 6009.Powns WOG15! thoow Generat Piping Dimensions of reducing sizes cre the some as those of the straight size corresponding to the fargest opening. PaTerere ele era a eee Tse Tes Te 2o00-Pound WOG Fittings, for ure with Schedule 40 or Standard Pipe The | Be [Pha he) | Hho | Ye | As Pia] Ma] 1 Bs thal the Whe) Wha] 3 | She | The [Phe Mia] Ths | 1. Pe te Me (ie! the! Ya tha | Tia Me! Mb Me Lhe 3 Me DE AV] 1 | Me | Me | THe Wha) Me | 1 [3Mhe Th | He DWI 1% | Me | Me He, Me) lhe 44 rife life l2vge ayy! 18h Mal Bh. Latpe 134 to i2%4s tated 3%4 2%! 17 TH | A PDI he Mh HH OTH hal BH Ba Se | aA] HL 3) 3 se Lo Lsthel 3 | 2% | Te PPh She | HK pglau| ae 3 [ate Te | os | 956 ae L2tme| 1M [tse] 65 sie |e a | (Me TA | ind [ae ae! 28 | 14] 1% | 456 | 336 [4 | 8 | | ah lintel sie sue Ls Lime [14 L534 ame te 98 3000- Pound WOG Fittings, for use with Schedule 89 or Extra [Pala BRT Fa] M4 | he | The | ha] Me] aT 1” 12 Biel ha] tas [242 3Ar| 3 | he | he [1YAa| Ma] The | APY UAL se | elie tsfel 4 1s | Me Mn | te | 4 Whe 3D 4 % Pe Ue a) Me MG Bae! Mie TM Sie Mae! 1A | | Ms TA ABE ete Me te Me Nhe HE | Be Me ABH | I Me 1 |e fe" 1A Lael he 2242 Tar Nhe Mie Bhs TM Phe el M4 12%: 11 TY Te 2 [TA | he Pisa Dhhe Me he Tha Bhe SH De he 2 FL PSR SP TS hel 3 aa! ih ie Othe) aa van Te 2m |S | 196 | 18% | 35 386 2s! MG Ac! 4 3M | | 14h Bake ant (a eae athe] BEIM ae 6H] EM 4 ja! 2% 12h! 544 534! 3m Las | 1s STA MMe Hig SH i a tia "4000-Pound WOG Fittings, for use with Schedule 160 Pipe is] We [LD] LR | ak ue he hs eee ita | ie Wee | oe | a [siete 14 | tie | the Pte Uae ths ai | 3. he! 1136 [the 134 [As Me 240 2%A6 Ie! he] Se |The M4 Nhe Phe aryl 3M (246, UA | He | 2M) TM 2M L ae Late athe I he ha Bg 2% Ihe Sh She hs We 4a! Mk Le SEPA) AY SUES 1 THigg Bisa 28 Ye PBATW AG 4 Tee 2 | | ST CREME |e Bia ean aig eae ate HT (athe | fn |B | te | ee SLM) TY a a He A Me] A [oobi eo alm 3a Lay La 44 24 | 1 Ye Late Lo iam ah Bee eee Vie Ve he i jay se Ms! yl HD TH Pee HE Ye ia 14 Ms TRIES aeetane ais 2 Patel aage 36 Th Ine emia ame [hel ea M% ) 2 be shalt ie ie TE tuange 3th btshg 2751 Wa Le ms the 1g eM TH Tipe Taky Poke Dae PAG DUay he | a DPMaa) 2 A 2 MW toege ashe Whe Tae Ar Se BAL [Me Le 3M 1M tm Cm ea ide 8 Me 43M Tay A ah te aus Ba TA Soy ah iy ‘ie ate 8 te tina fttinas (aimensions in tochesl10 Mo. 352 ‘ratght ond Reding Tenge i notices streigh end Reducing “ers X Process Piping Design ‘Thickness: Standard Atvings in sizes 12-inch and smaller are made cl pipe (the heaviest weigh on §, 80. Jresises sy-inch and larger. Standard fittings @ for use with O.D, pipe Sgineh thick Materials: Uniess otherwise’ specified, the fittings are Mode of carbon. stec! conforming. co requirements of BST Specification} 234; Grade B Fittings made of Grace A carbon st jzon, stainless steel, or other mater ‘Stich specified; information on reg ‘American Standarc: These fittings conform, in types at tees Included therein, to the American Standard for Stee) Butt-Welding Fittings, Bi6.9-1958 el, genatine wrought Is can be furnished The Standard does not include sizes smaller than eee see include go? elbows with 2 fong tangent, on ree eee) short radius Go* elbows, crosses, short radius Feturn bends, oF shaped nipples 90° elbow with long tangent: The No. 335 E are 0° dane radius elbows having a long tangent on one end to Serie welding on f slip-on welding flange. | Tre tangent Te nut beveled, the ether end is beveled, Cranelap stub ends: Cranelap stub, ends, mage of Crus Biccarnless steel pipe lapped to che full thickness Sees eige wall and. Gronelap flanges aford an ideal nethod of installing Aangec! equipment in a welded fine Tae saivel Range eliminares the difficulty of aligning felt ‘holes_and: permits installingthe equipment at any angle Shaped nipples: Shaped nipples eliminate the uss of Seblotes when seddling one pipe upon another: they sem Ofetion ume and ass" an accurate fit. Both encks are beveled for we When ordering, be sure to specify both the pine size and the aomtinal size of the Feeder on which the ripple will be used, hea Nhich the nipples are shaped ko fit are includes Upper table on. the Facing pare Prices: Prices are furnished on reques Ordering reducing tees and crosse: Mucing wees and crasses, specify the size of the lower case tions at the-left When ordering of openinus in Gp) shows oa thei Hiss Ne, 3506 os ecentie RedveorGeneral Pipi n t Standard, Ere Suong, Schedule 160, ih ‘oad. Double Extra rong. Fiingr ri hava the ome outise dimensions tat} reset American Standard: These fittings Reducing Toro conform, in sizes and types included therein, to the American Standard, Bib 9-958 Thickness: Scandard Ficsings 12-inch and smaller are ma.te for use with Standard pipe (heavicst weight on & to, and tmuinch sizes); sizes tacinch and cing Crate mL Jarger are made for use with O.D. pipe. refi (yee arse $8 Exera Strong Fitinas sainch and pee smaller are made for use with Extra vs | 7% Strong pipe; larger si are made for «S| 7Y use with OD. pipe Yeanch ehiek tet Schedule 160 Fittings are made for use ee sith Schedule 169 pipe 2 lt Double Extra Strong Fittings are made nigh ae for use with Double Extra Strong pipe. toe (1S eee 8: 1st Cencesire Essamtie Reaurer Bedreer 7 Schedles “bers for Sid. | Extra Fs_| Suis P31]. [ts “0 bm) 2 eas a0 3. | 1m 1 Bhs © 34 | Me | 24 0 Mi he | 3M 40 |e ahs | Phe 2 | rig sete! Sts a oa 6M 2 Peat © 2, 6% | 8% 40 18 | 74 108%6 #0 18 9h 125K 2 2 1i¢ 16 © 30158) | 20% 20 3 18% 2% en eM w wo! o mo RS 812 Welded flanged joints © illustrated here. The Cranelap flan Application: Any of fiange fases on all Crere Eerawed Hana. “Tavita hae ‘Wages Wea on tae aw, [ i. Type No.2 shp-on Wetting Fence Welded fron! und tact ond Resse oe a ranslap Flange with Figure 1-7, Flen be furnished in the (rcs Welding: | fanelap stub ends with is performed by Crane wekiers x leo ilkstraced, afford flanged connection for \elding. welded flanged joints Been at the right can 2 applied to straight pipe, pine sree Bends, the ends ans nozaies of welded headers PIES the flangeu ends of aclded assemblies. Special Shop equipment assures the perfect, aby Welded Flan: Process Piping Design 3d jounts under ape he shop weld nauxikary proved procedure control Special piping materials: These types of weldec Ranged joints can be furnished on many” special pining materials, including numerous alloy, steels. with facilities for heat-treating after fabricacion, ment of Complete information and prices will be furnished on a Joints. appheation Forged Steel Screwed Flange, Seal-Welded A Crane Forged Steet Screwed Flange is used in this joint, The pipe ndl the flange are accurately threacled, the flange Is made up tight on the pire; Scalsweloed, and then refaced. The joint is sealed by flet-welding-the back fof the flange to the pipe, thus assuring no teakuge through the threach The refscing assures perfect alignment o Sf the pipe is Hush with the face 6 e ding the large securely on the pipe hence there is no shearing. action Forged Steel Welding Neck Flange Crane Wekling Neck Elinges are of forged steel. They are machined with i beveled cs and bored to match the inside diameter of the pipe to-whichs they are applied. A bukt-weld is used to attach the welding neck flange:to the pipe, which is algo machine beveled Forged Steel Slip-On Welding Flange Crane Forged Steel Slip-On Welding Flanges are bored for @ snug fit on the pine and, when applied to fabricated! piping. are welded at the front and bach; Through the to methods defined below and illustrated at the right, Type No. 1: Type No, 1 is Crane standard for welded flanged joints usin Forged Stecl Slip-On Welding Flanges. Regular flanges are uulized with the nda the pipe set back from the face of the lange and the Mange welded he pipe Boch in front and back Type No. 2: Type No. 2 is furnished on special osder only with a special front groove for welding are used. The pip the fange face; this is accomplished by refacing, affer Bot ack of the flange are welded tothe pipe Conde tit for Pressure Piping or the ASN Fie TFOnt ari a. When piping must comply with the American Standard Cote Boiler and Pressure Vessel Code, the use fof the slip-on Hanged joint is permissible on all sizes of flanges listed under primary service pressure ratings up co and including the goo-pound class sinch and smaller of the 1sce-pound class, of the Americar {ASA U0 5-1937) Cranelap Stub Ends and Cranclap Flange The Cranelup stub end sith Cranelap flange can be applied to febrtcat pvping, Both the stub end and the pipe ase machine Beveted A bute This type of joint has all of the advantages of the regular Cranelap jn Tn moie conc ping can te fabricane a Cryrelap joins. pple Fprcee, winch chance the weld necessary foe the apalicatian OF eS areal ale s. tion_Ol Th Fanelap St08 TA Tange “| flanged joints. Reprinted courtesy of Crane CoGeneral Piping The Crane line of Forged Steel Flanges comprises he complete assortment of straight and reducing {nipes illustrated on this page. Made in seven different pressure classes “150, 300, 420, 600 03, 1309, and 2500-Pound they ate avail Une ina Variety of materials and with various Tange facings, providing a correct type for any service requirement Materials: Crane flanges are made of éarbon steel forgings having a highly refined grain ructure and generally excellent physical prop- erties well in excess of recognized minimum et Reducing Seremed Flange Nor $584, 130-Poond NS. 292 6) 00:Powne No 686 © 400-Pound No. 057 €,600.Pomnd No Ya4aé, 900.Posr No. 1558 €, 1500.Povnd feauirements 90 ¢) 300 Fores in the 150 and soo-pound pressure classes, the fat on fored flanges are regularly made of carbon a Sa io. t29s & 900.Fosea forming to ASTM S feation A No, 1595 E, )500-Pound ah specie onder they can DET treaed (normalized or annealed conform to ASTM Specification A 12), Gage In che goo-pound and higher pressure classes, the flanges are regulacly made of carton steel conforsing to ASTM, Specification A os, Grade 1] In addition, Ranges in 300-pound and higher pressure classes can be made to order of Crane No. 5 CinromerMolyty denum Forged Steel (ASTM A 182 Grade F sa) American Standard: The dimen: sions and dnilling of all Banges con form to the American Steel Flange Standard B16.5-1957, Tor theif respec tee pressure class. This Standard does not include slp: on welding Ranges of the r500-pound Class nor sizes j-inch and larger of the 1s02-cound elas; in such classes tandsives, Crane slip-on welding fisnges have the same dimensions as, Amer- Standard Steel Screwed Flanges being bored instead of threaded Flange facings: The 150 and» Bound Screwed, Slip-On_ Welding Welding Neck, and Blind Flanges a reguleriy’ furnished with an American Standard !g-inch raised fa: ‘The aforementioned Ranges, in pound and higher pressure classes. are Fegularly: furnished with an American Sta Npinch male face (large male) Oviier types of iacings such as sing joint, female, tongue, groove, ete Gan he furnished: see pages 532 to 135 for complete information In addition. flanges of any: pressure class ate available with 2 flat face {raised or male face removed). tHE Mat fee wh Ts ish , ge faces: The Sipinch raleed faves ard the 9 ,-inch large male faces are rezzlarly furnished ‘with @ serrated finish, A smooth finish can be fumished when specified Drilling: The flanges are regularly furnished faced, drilled, and spot faced to the corresponding pressure class of the Americen Standard. They’ con be furnished faced only, hen specifi. Reducing flanges: The Reducing Screwed and Reducing Slip-On Weld- ing Flanges. illustrated above, ace available io aay xction; prices gre based os the outside diameter of the flange Tor ordering information, see page 3) Redueing Welding Neck Flanges Eccentric Reducing Screwed or $I Gh Welding Flanges can be med fonder: information on request Reducing Cranelap Fis commended and, consequ manslacterd Another ty Figure 1-8, Forged stusl flanges, Reprinted courtesy of Crono Co. Ro. 1248 No. 1558 5 150.R0nd 300-Founs Eao-toune ee0-teune Soo-Roone 1'$00:Posnd Sip-On Walding Flasge Ne. $54, Ne. 694 €, Ro. e54 Rose. ‘s0-Poone 300-Foune Ze0.fomns 1500-Powe Wolcing Neck Flange No aes'e, Noose & 5, No. 1585 8 No. ave t. No. 664 € Ne, 662, No. 1242 &, Ne. 1362 © ae 1s0-tound aoostownd doo town 900:Found 1500-Pound 1s0stomne 300.Roord 100 Fours ‘0.Poune S00:Fowne \500-Rovee ind Fe Mo, S562, 150-foun No 297 €) 300-Pownd No. 657 € 400Pound No. ase e, S00-Pound Naar e, 900-Pewnd No. 1257 6, 1500.Pe0ne14 Process Piping Design Steam, Water, Oil, Oil Vaper, Gas, of Air Metal iTemp. __ Pouinds per Square inch, Non Shock soe [aaa aa 400 [0 Pee sees Sa 6 | 9801440 | 2160 3600 6000 rin | 945° 1470] 2130 | 3650 So1s 700 | 930, 1400 | 2100 | 3500. 5600 | 201380 | 3070 | 34505750 m0 1365 3001350 oD L370 1305 | 33150 70 Ko mo 10 90030 | 03s { tao | 2350 375 275 | 2125 | 3550 $90 aso" 25051 | 9458 | 15709 A880 ao | sans: | p70: ies Se Tr] bo aa" or ae 009 A sxe tase | nist 70 | spe) ao ise At syoperatures lowe thin 700 E_ ratings’ te 2 ame thowe for Cara Stel Plage SRT 9 To Hs ral 430 | 600 900 | 1330 | 2250 sis | 555! ans | 1250 | 2080 510705. | 1450 | 19 907735 | 1100-1830 _ Nos 465 | 700 | 1050 | 1730 Gargeiions: 33s) 435 | 65 | 1000 | 164s folsbeenum | ais | a0 635 | 950 | 1585 Flanges 308400 on 0 | 506 | sade te onder 380 | 335 S00) 750) 1250 | ns 385 430 | as | 1070 | 1788 sss | dae |e | a | as us| iss 290 | 435 |_730 | tats [150 HO | 865 [os : 98} 128 | 190 | 285 | a0 | yas 75 | 10 | 150 | nas | avs | 630 | 85 ns) im) ais} 530 so | 7 ws | iss | oss | 30 firore Tinaeat pe Oban st used within she juris not Seti I Att the ASME Pser ke sssare Wesel Cen It there Preduee usa withun the suns Cans? ASA and API Standards: Chine pressure-temperature ratings con form to those listed in che American Stee} Flange Standard. ASA Bros tos7.and inthe American Petrolexm Institute [API Stundard Neo: Foureh Edition, sass Cold service: For “temperatures Beeween minus 20 F and plus ree f the ratings shown in the table to? ice F with apply For temperatures below mines 29 sstecls ith suetable impuet strengeh, must. be used. pressuse ratings Tor such steels wii be the same as shown in the table for 10 F. Gaskets: “The use of these ratings equites gaskets conforming 10 re imtrements set forch in American Standard Bie.5-r95> ‘The user is responsiMe for selecting gaskers of dimensions and materiale Capable of withscandiey “he eequired hole loading without im jus erushy ing. aS well as_being suutable ior the servige vonhcons all other respects, Unless others ise Flange facings: sereweh Crane ordered, ship welding, welding neck. and Bling flanges of the 50 and jee-pound classes ure furnished witha Nreinch ratsed face. In the aoe-pound and higher pressure classes. these Hanes tare furnished with lyqinch lire mate Face Cranelap flanges and joints These ratings also apply to Cranelap Manges, the rating being depercient upon the type of facing applied cw the lupped pipe end Ratings for Cranelap joints are contingent upon the use of pipe of proper material having an equal or hi ‘Consideration should honet Secon | Boxer Ping of Be pivar-to The pees he ASN Cade for Prosurc Piping BGRCEP Sees esibuetio thyme te ht eaing n temperature lmitatane Nya Chantel hed up pining of the ane ghia Sect eee Fagen om Ta ta -Satnpcraries as ioe Figure 1-9. Forged stvél fisngis—working pressures. Reprinted coustesy of Crane Co,Screwed Flange 150 6nd 300:Pe0n8 400, i, $00, 1500, ond 2500-Povne Stip-On Welding Flange Tsa'end 200Pond ‘ . é “1 7. Rend eosp | eg Spoon Welding Flenge 1490, $09, 909, ond 1859. Poved Weiding Neck Flonge 130 end 300-Found Ghenclsp Flanae 150 ons $00.Peend 400, 600, 908 1360, ane 2990-F Fi Gin Te Oe) Los! 11 Me 2 ary al Tea Aco 1 150 | + u re (Wael 3 | 4501 1%e Pound | 5 Tl aig | See tthe poe 3 Lhe . 4 ead hel $4 112.78 ho Lay) $1400. 3h Bes [10.00 [3th Bihe. 5Y4 18.00 9 A8 1h 2p SiMe 2040 Yc Te 3 6 2400 | ae rs Ber aa 10s) EL oatig! athe! 1.32 | 1%e rel 1.68 | hs Bag Pig) 1907 Phe 238 he. 2381 1% 3.50 1 17M My wy oS a Pie be ree! so Pau 1841 1 a wis ae te eB : vr igure 116 Forged steel Manges (dimensions inchs Courtesy of Crane Co: skiqure 1-10-coninsed on fottosiing page?16 Regular Facing and jox-pound presser Closets. the. serened, shy-0% taioing. welding neck, "uo ling anges arc furnished ith Slipineh teised fice Irv goo-pound ane higher pees Sure. classes, the algreticn= oned. fanges-bave a taeinch mae face (are male) American Standerd The dimensions and dri'ling of anges conform vo the Amer Gn Steel Flange Standard Bho 5-1957, for there respective Presoure class. Ths. Searclard Spee not include sip-on wel ing flanges in the 2500-pound Gees noe sizes j-inch er! Jaeger of the 1s55-pound elas Phe flanges ofthis type base Some dimensions a3 Amer. tcon. Standard. Steal. Sereved anges, Being bored instead of chreaded Cranclap Flanges Cranelap als ae fecommended- for use 18. om Bination- with Cranelap stub ends flanges ch Cranelop Joints {300 sea 600-Posnal When j-inch 300 or e00-pound anges with ting joint facing are to be bolted (0 Granclap Joints, orders must <0 specify they require a groove of specs pitch diamet Galvanizing Galvanized flanges can be fur- ished to order Elpure 1-10 continued} Process Piping Design sions, in Inches — continued Pounes 8 16% Mine Be Me oa Blk sce 1 ing) — fe 20 | Ht 1734 Ai 0, % 5% [ier eine Sigh Baio, Poe fh wei tnt Ne 15M 12) 15h wo] ny te, 2 6! ay 27M ie 4 MMe | 1% a1 Ms siMe. 56 on Me 20.004 24.001 350 bie 83 74 1078 ™% 2 ay By, Tom 918.00 om | 2006 ui Ty Ost Di 1.05 | 2h | 1st! 2 66 3%, 4307 oie 535) 26% | 6:63 8% 8.63 10 | 1075 1% 51275, 14.00 Me) 08 3M | 1.05 34 | 132) ML tee! rc oh Te) 450 9 | 5.56) 1034 1 885, ny 36 16 1075 184 tL be 7M 2 Bh my By Me 8 “oY, te oa 104% Be 1% 1% 1% Ae Ae Me Me 36 ? 8% Ss ae Mie 1% BieteihSndia iat lasts oh Ri te agi “6 Process Piping Design Table 23 Tank Liquids Cassitication Class + Flimimuble Liquid Flash point below 100° and vapor pressure nor eveseding 40 psia at 100°F Class 18 Flammable Liguid —” Flash point below 73°F, bolting point below 100°F Class 1B. Flunmable Liquid, < Flash polat below 73°F. boiling point 10°F or above Class1C- “Flomnible Liquid Flash point 73°For shove but below 100°] Class. Flammable Liguid Flash point below 10°F but at or above OF + Chass 1 Combistbte Liquid Flash point above L40°F bet betow 200°F ; NoClass Uusicble Liquid’ Will poly mete, decompose, condense or E \ become sell:reactive under shock Lempotature oF pressuce Liquids with boilover cractorsties such wacrede il Table 34 Restritions for Conditions of Storage Condition 1 Class} through HH liquids stored below 2.5 psig oF equipped sith emergency venting which will Dat pernit pressure ta exceed 2.5 psi, Use ta ble 35, Conditio {Class 1 through IU quid stored above 2.3 pig bor equipped with emergency vending which will pormit pressure 1o exceed 2.5 psig. Use Table 3-6. Condition 3 Unstable liquids. Use Table 37 Condition 4 Liquids with boilover eharaceristes, Use Fable 3.8. 1. Three feet minimum distance between any grouped tankage (3 oF more rows or irres: two Maimmable or combustible liquid stor lar pattern)'to allow access For fre fis age tanks 6. LPG Containers CLiquified Petroleum 2. Minimuin distance between adacent tanks 6.120" minimum spacing to Aammable oF Gall senives except unstable tiquids and combustible liquid tank crude in production areas), Ifo the sum of 6.2. When adjacent Nammable or combus Ueie diameters; unless one tank is fess thaat ble liquid tanks are diked, LPG com Ys the diameter of the other tank, spacing tainers shall be a minimus of 10' shall be #2 th diameter of the smailer tank vital 3. Crude Petroleum in production areas. shall be taken to prevent accumu minimum spacing; capacity under 3000 ammable Liquid under LM barrels" capacity over 3000. barrels— grading diameter of smaller tank, 4° Unstable fnmmable or combustible liquid Tank Dike Regulations % the sum of tank diameters Local authorities (lire protection, insur The NEPA establishes minimum dike rexule ance, vtv.1 may iequire greater spacing fr dons in Volume F, paragraph 2170, Earthen di150 and ab0-tgund 400, 400, 900, 1500, ‘and 2900 Powe Clase oo vied ale tea | rion °F" dows vot eppty ap doles bee sunt 200 FO"e 30, hong By nc When ine 3000" 09: fovan ne be Dolled Ye Crevelon | Ree W] fhe Croan ig | Ren 20%) Se! ae hyo [R72 | Me hovng where fatorcovnd btto “Fre cree hovng Ret boom (or presen bre ihre ‘ie 4 |e MATS Mo] MG 3 Abe i Me 3 Tie, M4 | tas | 34 3 Mga! Ma | the | A 8a Ye Mal | Sha] 4 a AE LM Le SL %e tan Oe F Uijal Ma 8b 13 She Chass size % % Ring Ne: YR ‘Ris R ira Taga 1 F 50 400] 600 Hb Lb Lb, Lb. Lb. (aio. 660 Ub, Lb. bb, a4 2 | 2) R26 oo, HE 0. Rie and ae * wooo SRA ge Se Tt pound» © 838 gn Sie Th sR SH ig the he 1 RS ig, te ge The Re WME mel ae fie Te ROL 16M tae Mig Se Ta, fe Ma te ROS 18 The Me! Se Maa fie Toe HEE SIE MEE: etd Pye the The 2280 Os 3 OM TE Ree ee les amie NN ie eRe th a tie Bp tae Ma Me ton tg DADA Ve Figure V1, Rin joint facing and snes, Aeverican stance (dimensions in inches epringed courtesy of crane CoPlant Arrangement, Storage Tonks Fable 32 [Apr Standerd 650 Yanks for High Stress Dosign For Appendix D and Agpendix,G cig in Beands for 0.85 Preset Specific Gravity — hu aie Ht Hoton, Hc Root, ord Centleveeed Root Fe Capecty ah Indus 14" Botton, Ye" Real, end Com in 7 ‘append © Beslan Fag Sess Design favor occ Bienesor Hesghe Ho Corrosion wan ve No Covretion 2 ‘law Corrasion lalowonse Cone . (Sea Note 24 Kicwonce gee Note 9) Atowse 42,970, 60-0 43.0 278,200, 288,600 = 50,130 60-0 56-0 $21,000 334,000 7 7 67,140 100-0 40-0 412,200 427,200 78,230 100-0 56.0 479,000 496,400 = - 96,890 120-0 48-0 596,800 12,200 = 112,800 170-0] 56-0 693,200 710/000, 131,600 140-0" 48.0 300,200, 814,800 153,500, 140-0 56.0 931,500 946,400 174/900 140.0 28-0 1,037,000 1,051,000 - 200,500 160-0 56.0 43,209,000 2175500 180-0 48.0 17304,000 253/800 180.0) 56-0 1)520,000 17538,000 200 48.0 1,899,000 4,617,999 = 313,300 200-0 55.0 ¥,g67,000 “928,000, - . 325,000 220-0 48-0 11942.000 4,955,000 1,762,090 wwe 379,100 220° 56.0 2,268,000 2,279,000 2,013,009 387/090 240°. 43.0 2°30 1,000 2'316,000 2/086,000 451,209 240-0 560 (687,000 3,702,000 2,385,000 453,500 260-9 480 49) 009 2,705,000 2,438,000 : 526,000 200-0 45.0 3,117,000 5,124,000 2,792,000 7 529,500 260-0 56.0 See Note | ‘see Note 1 317991000 604,000 300-0 48.0 - 3,204,000 614,000 280-0 56.9 a - 3,499,000 672,500 293-0 560 S = 3,505,000 087,200 320.0 48.0 3,634,000 see 705,000 300-0 560 a - sea Note 1 ges 776,008 40:0 480 = - 4,092,000 + 769,200 343.0 28:0 7 - 4,163,000 See Nowe 1 gee 8e Saree coc nice site ea eer 4 7 sited by, WA maxima el 2) The dasign af Couiosian allowance b specie 2) tTyo2 of sec! applied for hop. D. design varias with design # ee ee EtG astm aL 3} Grate C. Nor ee Ganelpated saving Rois weight eeducion whom 4) Fer certain tankers 5) he Rigi Sn improved mote These The weigh) ot ies wind Teese Praaucts wits apes greviy of OY 2° be deci__aes high rangi stele Reviag a mvimor tonite scent of 70,000 Curses The woe of igh se Mortis melvdedin he Appendia G de ltemperesire specified: Buber ASTH A269 Grog erie ie aeghes eat o| the quelty see! “es fe on ABI Standard €50 shel deren nix D dsign bet are 1480" sum vied of $0.000 2 va mandatory by ars Basis a6 VCO erph wine din geal maken W HOH18 "Flex Gate” Valves support conventional tank ois borate pile fownsations, © cone foo! Links usually have columns to support the roofs with a raf Slope of "to 1-8 Since these roots are fixed, the spuve above the fiquid, These tanks must be vented re is always a spor to the atmosphere and quite often the loss of this vapor is 30 eXtensive that it wasranis specifying the more expensive Moating roof tink design: Floating Roof Design For storing volatile liquids, floatir roof ster age tumks have Uiree distinct advantages? ‘Theyre satly increase safety from jaune FS sho jue evaporttion Loss, ne how the fost reduces hresof Provess Piping Design ‘Avoid the use of the cross. Cost and deliv ery are undesirable Usecgecentric reducers only where absolute- ly necessary. ‘They cost almost twice 3 mitch as concentric reducers: 3. Reducing elbows are a cost saving (and are generally available} for sizes. 8 and below for the large end in varbon steel materials. Avoid their use in alloy materials. 4, Avoid the use of the 90° elbow with long tangent on one end. 5, The short-radius clbow causes additional pressure drop in a piping system. Use it only where close connections are needed 6. ‘Avoid the shaped nipples. Stub the pipe di- rectly into the header. Figure 1-7 shows how flanges ‘are joined with pipe Figure 1-8 describes the seven basic pressure Glasses. Figure 1-9 gives their allowable workin: pressures and Figuie 1-10 supplies flange dimen Sonal data. Figure “11 gives dimensions for ring joint facing and ring numbers. Valves “The three basie valve types are gate. globe and check. Figure 1-12 describes gate valves. Note that the stem rises up, raising the disc into the Bonnet and offering relatively smooth fluid flow through the valve body. Flow can enter either end of the gate body, “Figure 1-13 gives dimensions for gate valves When drawing valves always show the stem in the open position, dimension D. The handwhee! is lo- cated about one pipe size below the top of stem, Always show the handwheel diameter, dimension E, to scale. Gate vahe handwheels should not be ofiented below the horizontal, It is preferable that they be vertical, however horizontal installation will Keep the bonnet cavity relatively free of loose debris. It can easily be induced in the system and Mashing will start. Thesineter ran, C, cannot prop- erly measure two-phase flow: The control valve, D, cannot control properly. If this installation were fabricated and installed. it would have to be dis: i and rebuilt in the field, a costly pristake. Figure 23 is one corseet method of piphs equilibrium liquid. Liquid is drawn off through nozzle ol. stays horizontal through meter run B : and the control valve, then rises vertically at ¢ man ms rium piping hing occurs after the mew ng uml cons Shing aceurs. the flow, fia {rol functions and if excessive fs Tre size can be increased to Keep she velocity low Ge keeping both the meter sun sie yhe control waive belaw the liquid level in the rebeites, flashing & prevented in this 1 This reboiler liquid is often a predoct oi storage, It usually must be cooled b product tank, Cooling will drop 0 {te equilibrium point and condense ong Mashed vt seus. Then it is preferable to Tocats fh meter ron ‘Gnd the control valve downstyeam btre cooler The basic rule Tor piping eqsbibium or any fwid subject 10 Mashing is to kesy pressure drop dea minimum. gidd have no verted wsers before aecusuting or control deviees,ts Process Piping Design Table 22 Water Static Head Pressures Foet of cot Presiure Water ater sig 1 e3 26 1126 : 0.86 7 11.69 3 130 ® 02 4 13 1255 5 DAG 12.99 é 2.39) Baz 1 3.03 13.86 eee 3.46 14.29 1D 4.72 M10 6 u" 15.59 2 16.02 is 164 “4 16.89 15 17.32 16 1795 7 1829 Is 18.62 19 19.05 20 19.49 21 1992 2 20.35 B 20.79 4 21.22 is formed. Withr the small amount of differential pressure between points 4 and B. a pocket of lige viel head might not be overcome and the hot vapor by-pass would not work. There is generally less than 10 psig differential between these two points The pressure control valve is usually specified as a butterfly type to keep pressure drop to a minimum but this will consume 2-3 psig. Line loss due to friction may consume another 2-3 psig. This only Jeaves about 4 psig and that would not overcome muuch liquid head Static Head Hydraulics is the term used for the action of liquids in motion of at rest, Lucontined Hiquids seek the lowest possible level and a horizontal posi tion Prevture psig Feet of water 2 83 a 85 86 87 88 89 90 91 2 9 og 9s 9% 7 9 99 100 Liquids arrest cause a pressure equal in all ce rections and perpendicular to any surfaces in cow tact with the liquid. This pressure is caused by the weight of ihe liquid above the point in question phis the pressure at the top level of the liquis!. The liquid height is called static head, pressure hesd 01 quite often just head. tate the head pressure one must mult: ondyConsequently, @ colu Would exert I psig of pr would be called T pound of head. To this hes pressure one must add the pressure above the uid to get the actual presstire al the base of th liquid |PROPER — Figure 2-4. Propet 3-2 improper teiopphese pipingProcess Terms POINT ‘AG 7 ee Z —_———oooo k \ oo i TOWER. DESIGN sure 50" oa Eieteiete ON \ Nal ehranger. The condensed vapor fs then cirected 10 ectanbotor, To mraintain pressure OF iny-pass is installed ined in the most economical manner ond routed ee ape The endl. pass ifferemia) pressure overheat! Shop is 30 minor that i is of mo setval Fons the accumulator. 2 BO! SAP quence Hot overhead vapor is byrpassed around Ne cooker pressure conte salve, whi designer soos and is routed to the ‘Any time a competent piping symmetrical piping called for he shovld cree ualy, —alvows pressure to, enter Ine accumulator 95 7 question its need. especially HL 8 om a fred beater quited, outlet i ny-passes should pewsr he, pocketed, installed -pue pressure contro} valve shold Hot Vapor By-Pass ree ie tap of he accumulator aid INE Dby-pass riping should continuonsly drain FON point A te igure 76 is 2 hot vapor by-pass schemaus point 2. ‘rhe tower overhead vapor fine is routed Lo 40 aif Me this by-passed! vapor coals. de 16 sainfall ng Mhe Hine, comdenssat® Taser tfin-fan, This could be a shell and tbe es OP the fine or cool air cookinTwo-Phase Flow Next to adequate flexibility. tworphase Now fe flow occurs when both liquid and v .¢, flowing together. Since the pipe’s frietion seacts mare on the liquid portion, The vs problem oceurs When tvo-phase be routed to exchan; changer lta have Tess ps -ssure drop weed exchanger B to have mare when bath exchangers were de Process Terms y Figure 2.5. Piping at fired heaters same heat tra! the mest problems. Two: por are phase How will take most of it will A is getting the vapor tywo-phase Mow fedgeable enou! ned for the same pressure drop. nnsfer duty. Since A bas drop and the tiquid’s velocity int, The vapor © the path of Teast resi to exchanger A: Now s and B is gettin: another problem is exidet for if he knew he was Lo design the piping as wel) .; for the less pressure ‘io. he two- ace and chai ree Hiquid pore tend 10 flow al a greater velocity. The seal But ihe Wat ramsfer rate of both exchangers fs tare vaust be dt designed for equa Tow of liquid and ° 20) so vided equally into separate piping systems they will not transfer heal as dh and be Sf shows improper and proper Wo eakise these exehaneels welll not as de phase piping at exchanger infets, Ln the improper Sand. Whe process nit will not perfor: ad must the major portion oF the flow wowkl be slut down for corres ‘And this fs 2eause ee tyis would cause e\- piping designer did not recogniae eS piping + knowSasser ere 22 Process Piping Design OVERHEAD VAPOR LINE a FRACTIONATING TOWER Figure 26. Hot vapor by In the proper illustration, the two-phase flow ters the horizontal pipe midway between the 1 exchangers, The pressure drop is the same to her one so there is no path of least resistance 4 the flow of both liquid ane vapor will be equal oth exchangers. Figure 25 isa flow sketch of piping at a four- ss fired heater, ‘This is a very common piping rollation where the heater ialet is all fiquid Ho {U the outlet is two-phase flow, And in nine out ten cases this installation is completely unneces- y and excessively expensive! To analyze this statement, the liquid heater cx item 1, is divided into four streams to match w four passes of heater (ubes, Each stream has 2 be valve. item 2, for throttling and a flow ind- tor (orifice or meter run), items 3. Each he 6 outlet has a temperature indicator. Te operate fe heater, flow is regulated with the globe valves sure thut each pass has the same flow, while HOT VAPOR BY-PASS 7 AUB COOLER, Ai OVERHEAD ACCUMULATOR, the temperature indicator shows the desired outlet temperature, The piping is correct Co this pont Tho incorrect design occurs downstream of the TT located in each pass outlet, Someone has coined the magic term nve-phase flow and has decided that this means syrametrical piping. And symmetti cal piping means money and piping problems. ‘This can be doubly expensive if the heater outlet is al loy material Syonnetvice piping is necessary for 4wo-phase Now if there 45 no method of control, and distribue tion must be made, But in Figure 2-5 distribution jg made while the Muid is all liquid, controttedt by the globe valve and meteted by the flow indicator to insure that streams A, B, C and D are all equal flow. {f the flow is equal going into the heater it aust be equal coming out. Only in cases of very low pressure, such as a crude charge heater service, should symmetrical piping be considered. In higher pressure installations the cutlets should be com- Fa a a t 'Plant Arrangement, Storage Tanks a7 Table 35 “Yank Spacing Table—Condition 4 Miniunurn Distance (Feet) fron Powcton | Minoo Distance Tse tram Reet ide ot Ay bles Type of Tank | propery Line Which May’ Be Bit 1 ae Seo Publics \ Floating roof Protection for Ya times diameter of tank but | 146 times diameicr of task bet cnposues* need nv enes8 50 [sed nox enced 30" Repioactin | Dieter of tank “Tie ines ameter oF anh | exceed 175" need not exceed 30° Vente pnd oavor | mest f ik tecd| 146 tme aeer of an ot ed not exceed 90° not exceed 30° and not with ineting syste ni not weak than sa rool = to exceed 17 note shell a Ties Janet ok Bl iPS tes dame oe BM am No'proteciion not exited 350 toed not exesed 0 Horizont Approsed inesting | wd system on the aimee Table = su aot {gs imos Table 3.9 but Hot voi tank orapprosed ess tan 5 hss aan § with, Foam systems om { fnverggnay reer | wor wad tats venting to brat pressures te 2.5 palg } Protection for sn propor adjacent to tanks, »Prtection for exposures shall ti When acceptable to the wuthority havin iuisdiction ef any: public Hie department or (2) within or adjacen fire brigades shall be considered as hoving wWequate protection fe protection fur stiwerite jrsdiction, suck structates bosuted 1) within the te plants having private posure Table 36 Tank Spacing Table-Condition 2 T tininwun Distance ee Type of Tank} Peetection — | Property Line Which Mis Be at i Gn, Including the Oppose Sie of a Public Way fimargina Distinee (F200) Treny Nearest Silo of Any Public Way | Pootectin | ate ns Table S120 sad 2 nee Tobie 3 be Not Loto | test than 35 less ta 25 povenes Se tl a See eee au ereeted ' \ tion | 3 times Table 3.9 at wo fess tian 30 Lot tess than21. Define cone roof ¥s. floating roof tink sizsseseeseeseeseenen 22, What determines tank height? —________— 3, What are the advantages of the floating roof tank? —_______—— 34. There are____galtons per barrel of oil. of “foam and how does it work? 25, What is the purpos48 Table 37 Process Piping Design “Tank Spacing Table Condition 3 ‘Minin Di Property Lin Built On. b Opposite Si Protection type of Tank Tank protected with aay Hastizointal cone of the following: aid Approved water spray verticat Apptoved inerting tanks with and emerggney, ‘Approved insulatio reffigeration rehet Approved barricade to eee ee pevenit Protection for 2B times, T pressuze net exposures than 5 | No Protection S tues. of 25 psi, “Tank protected with any | one of the following | eokont | Approved watersmay | oid | Approve wrt flee Tah senticat | Xppioved insulation and | than 30 rks | cergeration sah Approved barres emergency ——— = reich Protecion fos exposures vent sha LOO to permit pressure er 5 peg No protection than) 150" are usually specified by the designer’ however, com crete wall dikes are sometimes used where plot Costs are high or where earth fijl materia! is esther expensive oF just not availuble. Dike requirements senevally specified by the eustomer, acu) regu cr, if neither of them have estab: the minimums noted below jatory bot lished. specifications may be used 1. ‘The'area surrounding a tank or group of tanks shall be provided with either drainage ‘or dikes to protect adjacent property and waterways (from a rupture: and/or spill) un- Jess the jurisdictional authority has waived this requirement (which never happens) 2. Drainage system shall comply with the fol. lowing: Table 2:9 butnot lesstian 25° Eee 4.times Table 39 but not less 8 times Table 3.9 bat not less jstuos (Feet) from, ne Which May Be fing the 2 oF a Public Way Minimunt Distance (Feet) tren ‘Nearest Sle of Any Pubic way Nut less than ri = 3.9 ut no ess put noctess | “Not less tan 30 Not less than 150" 2.1.Slope not less than 1% away from the tank toward the drainage system. 2.2. Drainage system shall tenminate in w cant land or impounding basin havi mininnum capacity of the largest tank served. ‘The terminating - cet and the route of the drainage systein shail be so located! that burning liquids in the systera will not seriously expose tanks oF adjacent property, The drainage system, including drainays pumps, shall not discharge to adjoivinz property, natural water courses, public sewers of public drains untess no hares is constituted or its design does not per7 Chapter 4 Review Test “This isa composite review of the fist Four chapters, The student shout be able to answer 20 of the questions in his own wo: js. without referting to the text 1. Ferrous metals differ from nonferrous because they = $$$ 2. Define ANSI. [A joint efficiency is applied to asset joint 4 Seamless piping has 110 _% joint efficiency 4, Pipe made from plate has 2 mill tolerance of —_——_—_—-- 5, Seamless pipe has a mill tolerance of 12k. % 6. Random length carbon steel pipe is + feet long. What is the difference between pipe and tubing? ———__—____—___-—_____-—_-——- Name the three basic types of valves, 9. Which valve is for throttling? Glebe. ueNere, «a 10. What type of check valve is specified for putsating flow? __ peo Kye 1. Define hydrocarbon ta 2. Define mercaptan, 13. Which is the lightest hydrocarbon? fet (C tha) 14. Define fractionation, 15, What js flashing? = 16. Define equilibrium, —__—______-____ 17. Define head) | 18. Define two-phase How Seer eee 19, What is hydrotesting and why is it done? 20. Define topographyeee ee ee Plant Arranger Tobie 32 Tank Spacing Table-Condition 4 sat, Storage Tanks | ‘Type of Tank | Protection Protection for i Flosting exposures: 4 goof i for inesting system i Fixed roof, Protection for exposutes Approvedsioam Minimnurs Distance (Feet) from Property Line Which May Be Built On, Including the Opposite Side of a Public Way Diametes of tank but need not ‘exceed 175° ‘Twice diemeter of tank but need not exceed 350" Diameter of tank but need not exceed 175" ‘Twice dinmeter of tank but need not exceed 350" 4 times diameter of tank but need noi exceed 350" Minimum Distence (Feet) from Nearest Side of Any Public Way 13 tithes diameter of tank but need not exceed 60" 1/3 times diameter of tank but need not exceed 60" 1/3 times diameter of tank but need not exceed 60° 2/3 times diameter of tank bat need not exceed 120° 243 times diameter of tank but 120" neoil not exc Capacity Tank IGallors} 378 Uh 4.05 ge or bess 76 t6 750 to 12,000 12,001 10 30.000 0.001 t0 30,000 50,001 10 100,000 100,001 10 $00,000 500,001 tw 1,000,000, 1,000,008 1 2,000,000 2,900,001 1» 3,000,000, 7.000.001 or mare Table 39 Tank Spacing Table Reference from Tables 3.5 through 38 Minimum Distance (Feet) from Proparty Line Which May Be Guilt Bq, Ineluding the Opposite Side of a Public Way 80. 100 135 165 175 Minimum Distance (Feet) trom Nearest Side of Any Public Wayto keep these lines short, Large ealso F7 ¢ short, Many times the LOST as cost tention ts neece, insuisted fi ifsutction is a expense Often Reboilers sto be Jocated next to the tower they serve except for pump-through type firec heateis, Kettle type reboiler elevation is dete mined by the tower liquid. Thermosiphon reboiiers are regular shell and tube Type exchangers, Hori Zoital thermosiphon exchangers are Tocaied at a FTAA CITTATION. Vertical thermosiphion types are ugually supported by the tower and ate located on the buck sid To the mannten- “anes equipm iypes may req Supporting str the vesseT engine See if the tower can support the reboiler or reboil ers. There may be more than one Reboilers « Compressors Compressors have two busic eatewories, contrite wal and, reciproca atte fas engine, gas fired turbine oF steam tur Tonite compressors (© Keep suction lines as et compressors are wsuully housed ina tropical type building with a drop-curtain wall extending to within 8° of the floor. In areus of severe winter. sich as Canuda, they are fully housed. Keep the building far enough away from the pipe ick to allow for the suction drum and the suction, and discharge headers on the sleepers. Large-niotordriven compressors may require room behind the bulging For transformers, Always allow room at one end of the building for parts drop and Compressor buildings must have pick-up area. truck access Centritus outside unless the customer requires a shelter. AL low a large ar the lube and seal oil console, usually: about LS v 20", Locate compressors should be mounted with truck access the building, if a building is the consale outsd quire eae eee ee eee ee from the pipe rack “Lotor-driver compressors may require © large tra.sform: turbine driven, IF the compressor is a harge surface condenser may be needed Wit is necessary. Ivete le surTice eon. denser above the compre Electrical Starter Rac Electrical starter racks and switehgear must be Jocated as early as possible, Consult the electrical department fo get the size and, with them, deter- mnine the location Maintenance Maintenance requirements must be considered early plot plan development. Shell and.tube exchangers should not be stacked over three units i wd then only ifthe centerline of the top unit iS hot over 13 of exchangers re b curi Trom grade ak stack them t four shells ‘wide, Bets cen two major processing units allow for s toad, it Space is available, and elearanee for a 25+ fom main plant ton crane, Provide accessways roads irst0 unit roads. Erection Erection of the new equipment must be con sidered. For large diameter and tong towers, con- sider how the field erew ca get them in the plant and where they can ly them for erection, For field-constructed equipment soeh as very large ve sels and reactors space must be allowed for field construction, Future Expansion Future expansion must always: be Furuse pumps, vessels and overlooked. Consult the pros: requirements, considered. exchangers are often engineer for theseine 3-7. Vypilcal dike design sniv Maynmable oF combustible igquids To be Feleaseds (Note: tis, plies Fequireinent of separator £2c/N1E5 % all spat the most remote Locations) spiked areas” shall comply with OS for Pika ae protection oF adeinine PT toe acconnplished by reusing IME Yiguid sound the tank with dikes: aroimor other than onde petrolem tanks rete fixed roots, the maimam caps ol to diked area shall Sea be_sufeased_from_the foes (unk. .(Dikedrarea. Eapectty ade capacity oF enctosed tanks (other Than the Jargest tank) below height of the dike.) rode petroteur tank, oF BFoUD Tras weit fixed Foafsy paininhart ike rey capacity-shat! be te full expects aa panko xanks onctosed: (DS oe reapaeity not to etude casey ret sand tanks bafow te heL EOF HE ike.) 4 pike construction requiremen BP vawimam average eight OF ° above interior gree ya. Farthen ails over 3° ish shall fhawe 2 avide ut seotion at the teh 5.3.3, Slope consistent with the angle of repose of the maton rains trom diked Treas to be to ated at nxost renmnore FOAL TOM sent, controlled to prevent annie 334 le of combustible materials [om enter adjacent property. waturtl venterways oF public drains avd se 4.4 biked ores comteining tee OF OME Tang shall be subdivided by drab veannels ar cues prevent SPITS HOM, caneering adjacent tanks whi INE kd area as FOLLOWS 3.4.1, Normally stable Higuids in a Cone rook tank with weak rool to shell seam. bp, Floating roof tanks 2 Crude petrokeswm it praduction areasany type inks T sabdivision for each tank iv Raeess of 10,000 barrel cur pacity 1 subdivision for each g908P fr tanks (no tank exceeds 10,000 burrel) having rte capacity not exceeding 15,000 barrel capacity 5.4.2, Normatly stable figeld ie tanks noi covered in 3.4.1 1 subdivision for each tank 18 eS ess of 160,000 zations capacity (2500 barrels) 4} subdivision for each group, of tanks (no tank exceeding 190,000 galtons) having, sere gate capacity ot exceed 759,000. gations (3520 wuss?69 oy xepu Suyeasp Culdig “Ly ONES, Piot Plans guiniy_sv.are sees Son TeaEon Naat Plant Arrangement, Storage Tanks 51 Figure 3:8, Truck access into diked area 7 3.4.3. Unstible liquid-any type tank-l subdivision each tank (exception tanks protected by water spray system per NPPA No, 15 require no additional subdivision) (Suhstivision by drainage channels is proterred) 344, Curbs shall be not less man 18" high. Figure 3-7 shows a typical earthera dike design tem A should be 2-0" minimum with 3-0" pre- erred for tall dikes, Item B is the freeboard and should be 1-0" minimum for crude oil for boilover wave. Tuaks holding other commodities require 20 freeboard. C is a V-0" layer of clay that prevents penetration of liquid through the bank. Top soit and grass should be applied above this clay blanket to prevent erosion Fhe slope of the dike wall showld march the of repose for the area's soil. A slope of 1¥ to Lis depicted as « design guide and may be used until actual soil data is bhown. Many authorities with demand truck access into the tank's diked areas for fire fighting, When Tat pumps are located within the diked area, truck ae~ Some custoniers require tiuck access for general maintenance. Figure 3-8 shows how to design the truck aceess. | is 10% maximum. or 1 to 10" goss also is necessary Storage Tank Design In snany companies the design of atmospheric storage tanks rests with the piping designer since it is 9 nonpsessure vessel. It Hhen becomes his task not only to orient the nozzles but to specify the tank materials and. sizes, To do this he must have more than a passing knowledge of tank design and matgrial specifications. Tank materials for hydrocarbon service are di- vided into three busic types: intermediate strength steels such as ASTM A285-C for general service (also ASTM A516 for atmospheric and low-temper ature service and ASTM ASUS for intermediate aad higher temperature service), high-yield strength slvels used for harger and taller tanks (0 keep shetl ihbeknesses 10 mininitum (ASTM ASI and A517) and the low-temperature steels used for pressure containing tak (ASTM AS37). Water tanks are specified usually as A283-C, a low grade stetlp Before specifying the mutterial, the designer must consider that the higher strength steels will cost move per pound, Freight avill be less but how uch fess will depend on the phant location. By utilizing the higher wllowable stresses. the shell wall thickness ig reduced, Buse plate, roof snd fram ate not affected, Any corrosion allowance specindex for his plot plan of, . light ends unit. Try to keep the piping areas no wider than 60-65 Equipment Setting The plot plan designer will come in contact with many different kinds of equipment, depend. ing on the type of unit he must lay out. Each subsequent chapter in this book will go into detil about most of these ites but, in general, the de- signer must Know how to locate equipment for plot plan purposes and the following is offered asa guide to this. Fractionating Towers | rectionating towers are located on a common centerline about 12-24" from the rack cokimas The fitst ludder from grade should be located on. the pipe tack side for easy aceess by the operators Towers over $0’ high are to have davits for hun ain ys. A clear drop area is to be pro vidal om the sil vessel Cra anvay from the rack. Exchangers Exchangers ‘set the “equipment fine." This is the location of the back head, usually set at 8! from the pipe rack column, Shell and tube type exchangers may have a removable shell cover, Mlanged head, Access must be provided for equip- nent to handle this cover, usually from under the rack, Tube pulling or rod clesning area mast be allowed ‘at the channel end, This should be the tube length plus 5’ from the tube sheet. Double pipe exchangers are tocated with the front end Tube removal space should be not manda intenanee toward -the rack allowed but, for one to four units, is tory_if_gsade fed, as _mobil_a equipment can pick up the entire unit and trans port it to the repair shop. Controf Buildings Control buildings sre to be centrally locuted becatise they afe home base for all the unit opera: tors, This also keeps instrument ieads shorter. Com ol buildings should have road access, Keep prov ess equipment 25" away, In the origin layou Keep hydrocarbon equipment 50’ away trol buildirss usually get larger than originally plesned To size control built .gs, get the instrument esi neer to size the control board and space needed for future board. Then consider requirements for of- fices. toilet facilities, tockers, tables and chairs for a lunch room, stoves, refrigerators, any electrical switchgear (consult the electrical engineer) or pos- sibly an air compressor and related equipment for the plant instrument air system. Allow space for the heating and/or air-conditioning unit. Some cus- tomers want a sinell ab area in the control building to test samples taken in the wnit. Fired Heaters Fired heaters are located a minimum from hydFocarbon-containing equipment; he FEI May be closer. The fired heaters must have ‘Toad access for equipment needed for tube repair or replacement, Vertical heater tubes (tubes a mounted vertically) are pulled up from the top with a crane, Horizontal box type heaters must have tube removal spuce allocated behind the heat er equal to the tube length plus 10". A lightly (rav- eled road can be utilized as part of this mainte Cooling Towers Cooting tuxers are to be located where the pre ig wind i divested fo the smal side._This at ant equal amount of circulating fresh ait, Many people focate cooling towers exactly opposite, directing the prevuiling wing © the slatted Jong side. This allows one-half tie tower to intuke fresh ait but the downwind side i starved. Locate cooling towers away fi fired heaters, flue stack OF any heat producing item, Air 19 the cooling tower must be as cool ss possible (6 do its duty. Supply road access to coul- 2 taers for muintenance of pumps, chemical aditixe equipment and for handling sereens. Pump pits may be located enywhere around the tower is not necessary to center them along 1 Many installations utilize the short pump pits to keep piping runs to a anit ide, Locat nt Piping Piping determines most equipment locations Alloy piping costs much more than varbon ste ve eaeProcess Piping Desist yin Geemany. Conresy of Chicago Bridge and Iron. Co, igure 3.9, Aerial view of British Petrateurn’s stresses of the lower strength metal, U: and fe of the more ist come out of the wall materials er 15 limited by he only considerat sity of operation. plant oss bt use or fire and the quanuty oF ome designers way road 0 pounds by. usitiy Oe hivlcs tank, but this may have wade stank must bs 1 powerful m: or the fire os xpenstis aportant sis a & Tas advan ed in de insights ths iPict Plans 67 Figure 4.6, Foundation location pian for Figura 4-1Figure 3:10, Crude tank dikes. A Refinery Figure’ 3-9 is an aerial view of British Petrole- uin’s Vohburg refinery in West Germany where Chicago Bridge and Iron’s German division built 161 tanks and vessels with an aggregate capacity of cover 6.5 million barrels of storage. The refinery has a capacity of 100,000 barrels per day These tanks range in size from a small 10° dia meter corrosion inhibitor tank to the large 168" in diameter Horton Floating Roof tanks used for cade oil storage. In this installation, 41 tanks are of the floating roof design, 112 are dome root ( cone roof)@nd eight are spheres. Spheres are used To store prope, Butane, propylene and butylene under pressure. wind, the farge crude tanks are nit with road access around the ting equipment. 1 rade tunks are diked separately. It is. usual pructive 10 imit a diked area to 250,000 barrels In the center of the tank farm are ss rerun and transfer storage tanks, unitized with like or located four toa unit for the fir Te rietey vat Yeates ae J dere notes) [pee deere f Jeo pee, crepe, oe similar commodities burched together is one diked arca, Farther in the beckground are the product storage tanks, again unitized, with the LPG spheres in the for background. Igcated near The prod Ioading area, the railroad eet “The process units, right center, utilize two common stacks for all the fired heuters in the plant with the waste heat exhausting almost S00" high Huge ducts, large enough to walk through, connect each heater to these stacks. (In most of Germany this type of design is required to try to keep the air as pollution free as possible.) Tne Vohburg installation is considered 3 large ry; however, there are many: over tice its size. Exercise A cnade storage sirea has six floating roof stor age tanks with a total storage capeeity 3.000,000 bartels, The soil bearing will allow a tank height of 56-0". What tik diameter is needed? (Tanks are the same diameter.)66 Bore EDP a eet Dimension TJ. Estabush pipe rack width, To do this accurately ly the pipe sizes ne For this purpose assume a 14-0" width, niension 12. Locate E-4 from pipe rack. Footings must clear and some accessway between rack columns and exchanger shduld be pi ovided. Assumig 6-0" “Dimension 13, Locate T-3 from E-4. 7-3 has 36 trays so_it_will_be taller than T-2, buf we_can assume ‘that the 200" octagon will_be large Shough. By using the same procedure used for de- termining dimension 9, dimension 13 13 also is 14-0". 7 0", same 1-0", Dimension 15.,Estimate width of air cooler. FF-4 js in overhead condensing service and the progess flow diagram indicates it is the largest of all the air coolers. “Assume tive cells, 5” Tive cells, 3” Wide plus 2-0" frame. or 27-0, ~Daens fou 16. Locate V-3_ from FF-4. Use nsion is 8-0" Srnce the tolal plot ength is 220-0 ue 43), V3 is, located 7-0" from the east battery limits.As. more frm information is developed s ioe Un Tensions may vy slightly. But if so there “wall have to agjst oth haps combining some foundations, Plot Pian Exercise The designer is now ready to draw the plot plan to soale. The student is to do this, assuming that the existing rack is 30°-0" wide and rack bents are spaced ut 20'-0" with the last bent at the east plot limit, 7-0" from V-3 centerline. Assuming no omman spare pumps, locate pumps under the rack with the centerline of discharge 2-0" out from the rack column centerline, Each pumping, service shown in Figure 4-2 hus two pumps, one operating and one spare, Locate pumps to keep suction lines short, Use equipment sizes and dimen- sions as estimated i this chapter. Fin-fans are 26-6" Jong. Draw all pumps 2-6" wide by 66" Tong. Use 1" = 100" scale, Remember, plot plins do not show dimensions ‘porTion is rads for the pro Faaund. on Location Plen ‘Figure 4-0 is the foundation location pla the ‘plot plan shown in Figure 4-17 This shows the Vocation of all unde ind concrete by coordinate and to scale, The underground portion of founda- tion is shown dotted while the conerete portion projecting above grade is shown with a solid line. Using Figure 4-6 us a guide, the student is to prepare ¢ foundation location plan for the equip- nent showa in Figure 4-3. Figure 4-3 supplies the two busic coordinates of the existing unit, called the ‘beach mark.” Bench marks also supply exist- ing elevation base, for Excavation Plan When the field construction crew moves onto the job site the first thing they want to do is exew vate, To do this they need a plot plan marked with the bottom of concrete elevations or an excavation plan, usually a transparency of the plot plan show- ing the exe, sation depth and periphery. Flow Diagrem Transposition “The How diagram transposition is the fst ef fori of layin Out The malar Sipiig Satems. It is made on a print or sepia of the plot plan. Piping sketched in from equipment to equipment, show- ing all meter runs and control valve locations, No_ ut the piping is shown goins to the towers. This oveslay. Tris best to develop this drawing after mechani gal ind Wiility flow diagrams ate prepared showing fine sizes and full instrumentation. Then one tra 2 for fines and one for after m: the utility Hines. Piping Drawing Index A piping drawing index is made for each pro ess unit to show the extent of urea covered by each piping draving and the daving nuinbers showing the piping details for that Figure 4-7 is a pip: ing drawing index for the plot pian shown jn Fig igre $1, The student is 10 prepare o piping drawingBA Process Piping Design \ oY ‘ i sore | 1 SLOBE ¥ I 17 L wa AR a Figure 3-11, Diked area dreinaye plan, Refer td Figinre 3-10 and supply the following: 1. Dimension A with 6°0" dike heig 2. Cubic yards of earth needed for dikes. 3. Dimension A with 5'-0" dike height. 4. Cubic yards of earth aeeded for dikes. 5. Squate feet of plot area saved with 67-0” dike, 6. If this oil has a specific gravity of 0.85, what is the head pressure on the tank’s base plate with the tank full, Express in pounds per square foot Diked Aree Drainage Each diked area must be drained to rid the area of rainwater. Figure 3-11 shows how to design this, drainage system. All gravity flow is directed toward, the catch basin. Note that surface water is sloped away from the tanks (see tank A, which is typical). This is done to keep the tink supporis as dry as possible, For very la sins may be required. diked areas, two cately bar Coming from the catch basin a line is rotited Uhrough the dike to a gate valve which is normally closed, This valve discharges to the storm water drain. system. The valve is kept closed to contain the oil within the diked areu in case of a rupture, After a rain, the valve is opened to drain off the surface water and is then etosed again. Storage Tank Piping ior ill have most of the Follow ing piping systems: inlet, outlet, overflow, manus! t, steam if tank heating is necessary anc foam system for fire fighting. The inlet es tO a “booster pump”, a low i-velixity pump that boosts the pressure To keep is SOF aF possible. locate tanks iF The pump. It is not necesPlot Plans Pot Limit. Figure 4:5, Preliminary plot pian diniensione,Plant Arrangement, Storage Tanks 55 Figure 3.12. Lap joint flange detail for tank settlement Sinee large diameter-tanks have a tendency to settle on their foundations. provisim must be made in the suction piping te take Gare of tank settlement. This may reguire the use of expansion joints, yictaulic. couplings or a lap joint Sfallation as shown in Figure he piping to the tank outlet nozzle has a.horozontal offset with two lap joint Manges instatled. The offser \would be several Teer, depending on the calvuluted tem report wil ply g00¢ ntusipated tank With the design of lap joint Ms the tank gradually settles, the lap joint stub end can rotate within the flange. maintaining its gasketed seal. Ht is good design to set the outlet nozzle higher than the line to the booster pump for z new installation This dimension should be equal to the anticipated settlement so that the piping is horizontal aft settlement occurs The API code for storage tanks gives detailed design data for nozzles such as projection. reine forcement, minimum dimension above buse ring and manhole requirements. Location is thy pipi designer's responsibility DUE must campy with the vode. Nozzles on the top head of cone root Ganks should be grouped together Tor case af access. Handrails av to be provided arour' the tink edge for the protection of personnel wis service th —) STORAGE TANK ANK OUTLET NOZZLE, LAP JOINT FLANGE LAP JOINT FLANGE, 4 WELD NECK FLANGE =TO BOOSTER PUMP nozzles but shall be located only in the nozzles’ vicinity, Shell nozzles are to be oriented to keep piping runs to a minimum. Manways at grade com be Jocated almost any pluee. The larget gage type level indicator must be located so it may be rend from the operating aisle or voudway if in a diked rea. Foam Protection System Many safety-vonseious companies have a fire fighting system called foam blanketing. This is ust ally specified oaly for’eone roof tanks. Foam is.» powder which, when mixed with the proper ratio stds Ta also Rots, p with Foant piped to thein Troi a ing unit. When activated, a blanket of foam about 6" thick will vover the taak liquid i a very few minutes and snuff the Mane. Koum connections are located at the ve anks. With all janks. pany Time rough is specified which Slopes TOR thebettem te-heep ihe Toum fonts) which might dm topNow that the designer “as an approved se- uence plot plan, he is ready to establish prelimi- say dimensions. Again, this ean be done with no pment sizes. A lot of progress is lost on design ‘esause people think they seed all the answers be- ce they can do anything Preliminary Plot Plan Dimemsions Figure 45 is a freshoud sketch made io estab prefiminary plot plan dimensions. Final dimen- EG done when equipment sizing is con ‘ed and piping layout is in the final stage. To stablish preliminary dimensions the designer wives certain assumptions based on his experience ‘af training. Assumptions and conclusions are (tol below. Dintension J, Locate E-1 from the plot limit ve; STO" clearance is maintained ,Assuming a “Skinny of 48” exchanger channel Manges, set cas diniension at "0" plus 2-0". of 70 Tocare Tet trom E-!. T-! is as- ~Dimemst med to be 72" diameter. Since there are pumps ing suction, the skirt will be about 20" high. low tray | there is a surge space of about 14’. ssume trays are spaced at 2'-6". Between tray 1 od tray 15 there are 14 spaces at 2'-6", or 35'-0". stween trays. 15 and 16 there is a cone section of sout 4-0". From trays 16 to 22, there are six aves at 2-6", or 15'-0". The vapor space above ay 22 is about 4'-0", Adding all of these, the ‘signer learns that the tower is about 82'-0" tall “th norm soil_ bearing, 2 Tower of this size will (jeite « foundation with a spread footing, bout fo be 470" wide. To keep spread foot vs. clear and to altow ample walkway. between, imension 2 is established as 9-0" (one-half of T-] vagon) plus 2-0" (onckal{ of E-1 footing) plus 0” Tor clearance to total 13°-0". Dimension 3. Locate E-2 trom T-l. E-2 isa eitla type reboiler and will be elevated a little nove grade. The liquid line fron T-1 will probably « low enough to block wal ki etween these two jeces of equipment, so E-2 is located so the back part will st on the Tel octagon. This makes _getagon @ Teombmed tooting™ thereto: F should be less thay 9-0" (one-halt the nor E:2 OD iy assumed to-he 31-0". Allowing, 10" clearance, dimension 3. comes. 31-0" plus 3 plus 1/-0" or 7-0" me es ew — Dimvisin three things to consider in estimating this dimen sion. The spread footings must clear (abuut 6/-0" ‘will accomplish this), The equipment must clear 16'-0" will clear Uns). Si there was no walkway west of E-2, access for maintenance and operation should be provided on the east side, The 2-6" ac: cess path'added ta one-half of E-2 OD of y” plus: one-half of E-3 diameter of 1'-6" makes dimension’ 4 total 7-0". —“Duivension 5. Lovate Vel from £3. V-l has pumps taking suetion Irom it so it will be clevated about 14'-0” or higher. The main consideration is to clear the spread foot ‘The V- footing is assumed to be 6-0" wide. E-3 footing is about 4'0" wide so 57-0" plus 1-0" clearance would suffice, Dimension 5 then becomes 6'0". Dimension 6. Locate V-2 from V-1. V-2 also has pumps taking suction from it so it will be cle- Fated abOUE the same ag V-L. Assuming 72” diene ter_for_both_vessels_and a common pliticiin between them with 6'-0" for working space, dimen- Sion 6 becomes 12-0" Dimeusion 7. Locate combined air cooter fiom V-2. Equipment cisaranee is all that is necessary since foundations will be relatively small, Dimea- sion 7 becomes 8-0". See Tinension © Estimate width of alr cooter Four separate coofing cells are located in one cool- ing frame. The product coolers, FP-1, 2 and 5, are generally smalkduty units and will require dxe or two cells per unit. FF-3 is an overhead condenser and has larger duty which may have three or four cells. Assume a total of eight cells 50" wide.or F Locare E-3 from E-2, There are pls fame ot 270" to total 42-0" for di: Dunensiont 9. Locate T-2 from air cooler, 12 thas 30 trays so it vail bs taller than T-1, The spread Samed to be wider than tie footing (oomeony S ng_and 2-0" for clear pus #0", « i i ma56 . Chapter 3 Review Test 1 Sonsite” and “offsite.” 7 ce st soil and why 2, Which of the above should be focated on the & 3. Give the two basic storage tank styles, Ee eee 4. Nae two items that determine maximum storage tank height. J‘ hree advantages of floating roof storage tanks, 6, Define LPG, # ee as 7, Msvimum height of tank dikes is fimited to___._________—. tand shell thickness. However ____—. 8) fig strength tank steel saves w ane ___are not affected. = pee 9. Spheres are used to store 10. Define “angle of repose.” —________—_——- i i i i | { {Plot Pians ie | ie él. — (Posey 5 . Grcbeoctasin EL . i Geter) __22 pS “68 pp Cesvmetatied yp | Comsest bs oD __ye3 Figure 4-4, Rough layout for light ens plot pln pote ed eames, Phat CET, Lutes hans, Labo EXISTING! RACK 6g EXISTING UNITThe purpose of any drawing i information to the construction petsonnel people, customers and other interested parties. The equipment plot plan of a process unit is the most carefully scrutinized drawing the piping depart. ment will make. t plot plans are made for (@) equipment 10 (6) foundation location ‘plan, (e) flow diasrs “tix compo: jodel is_uti- communicate office position and (7) Tor ne model plot board Equipment Piot Plan Equipment plot plans are drawn to seale, usta ‘= 20.0" or if possible on one sheet oF pape 1" = 101-0", Process usfit plot plans a to as large a seale as feasible and each item d wted is fo be drawn to scale, These plot plans should not have any dimensions, a8 all equipment will be located on the foundation location plar Many costly errors are committed by dimensioning the plot plan and duplicating equipment tocations on the foundation Location plan ly 7 re to be drawn, Piot plans showld show all equipment, main pipeways, buildings. major structures. housed el Tread gear and starter Fuck Location. rots, a6vess ips and any other item of imporkunee. Tue front and plant agsth areows are to be show A 87 bar graph scale should be drawn in above the title block to help viswlize distances if the reader viewing a reduced copy or microfilm. Pipeways are shown by centertines only simple outlines for ail equipment, st ‘and compressors, Indicate all equipment by item number but 2 not try to give equipment titles as this will clutter the drawing, Figure 4-1 is an example of a plot plan of new equipment in an existing Here a bar seale was not drawn and lative distances cannot be determined. To establish a preliminary plot plan the piping inst know basic maintenance and These are usually designated in the ications or the customer specir guidance: Indi ‘lly cate for pumps designer must layout general piping speci fications and are listed below for fh miain pipeway shalll To maintain this, nces beneat be minimum the bottom of pipe in the lower rack 38 to be about 15-0" above the high point of the finished surface. 2.0 Clearance of 7-0" will be maintained for all fines inside buildings. miscellancous lines in the pr 4.0 Clea ocess units sind Hines TU platforms. shall be 17-6" for so" 4 over aisles a ni 3.0 Roadway clearane imain tosis and t Tor secondary roads.62 Process Piping Design mprrrs oor! TT CE lek erie AN nL FREY AS TIT f at raeeeeeeeee aaa Lh \ Wy | ¥ il ical | gt tag | la \ V7 ian aS | \4 wt an | a 5] | |! eq | [te | B | eeroreen| Lo{fecarroam-| [ivacuur Z|iceune | |g Sy} ures }{S] fine own |) user), 97] oer a fal) * ' g fy | 2. rs i<} E i il 2 ol % i {| 1 wv) | pe x | ie Jo I . nh i a | ig a | E \y ut | \ 1 a u = | | ie C_| in | | eH a \ CONTROL. z | BLDG. | eas |} TRERTING COOLING ) UNIT TOWER— | : C MAINTENANCE ROAD | L Figure 4:3. Plot plan for multiple process unitsProcess P1 ping Des esign NoPlot Plans 61 diameter. Piping at reboiler heaters is usu- ally all carbon steel so assume no alloy piping in the unit The plot plan designer knows to Keep the fred hyeters at a minimum of 30%0" from any piece of guipment containing hydrocarbon, The only: ex- 2020 Trom heaters to Keep thé alloy lines shorter. This tnit has no reactors so this is not a considera- tion here, Figure 43 is a plot plan for multiple process units. The dotted spaces indicate the future light ends unit, the equipment shown in Figure 42 The pIOL is sized at OD" x 230" with the fired heater area hejiters to the outside away from the units but With ample, access. The units themselves have a conimon control building with easy access to all areas for the operators, The main pipeway with con- taiv all utility, feed and-product headeis. Figure 4-4 is a rough layout for the light ends tunit plot plan. {t is made freehand and to no seale The existing rack is drawn and equipment is sketched in according to flow of the process strcums. Note in Figure 4-2 that the first fed goes lo E-l 10 preheat the TH feed tiquid. So E-I is located is the first piece of equipment on the plot. The lew goes trom E-i to TL, the fractionating tower, so it is placed next to El some. and. Fron T-1 goes 10 E-2. usually ig walkthrough access, reboilers ure located close 6 towers and their back foundation usually rests on the tower octazon The acai sondtenser E is located next to fs plaged next to the’ wanda complete sistem trom ET to V’ guence The same philosophy is used for locating the other pices of equipment, The only itens sequence are and 5. The ': overhead iuently. its pipi be the most expensive, «ich governs its placement between T-2 and V-2. the air coolers (fin-fans) Wire net Tecate of the pipe rack becuuse (cre was no space left ¢-. the existing rack. ‘A small rack has beer, zdded to route process and utility lines to the two rebviter fired heatets, This rack will have the two liquid nes to the reboiler and the Teturn lines to the two to¥ers T-2 and T-3, plus fuel Oil, fuel gas, atomizing sigim, snuffing steam, instri- ‘tment air, utility station air. water and steam, and elec: trical conduits plus possibly the instrument tray. which carries the pneumatic signals to the conta Bua (uous ech cn dey e207) ¥ 20 my ‘The two heaters are vealed cfose tog deter su. that-one fader of stairs from grige can serve a platform common to bok heaters. The operator Gin then check both hescers without having to go Up al-down and bas pa THs design often overlooked but is 2a initial savings and an pperator “onvenience— Now ihe des s0r's approval of the nie) ady: to get the stiporvi- layout, With x criti gal eye the supervisor ses the plot plan and the flow diagiam. To him-it .oks good except for one piece of equipment. Cas. “te student find the exror Without reading on? Its -ctually # costly error in Judgment Large insulated fines -. insulated elbow is expe: pervisor’s eye tells hin ths most expensive fines in this_unit_are the hot lix.s to and from the fired heaters. Consequently, th.s2 lines should be routed Je straight as flexibility «i allow and with @ ania imum Tombs OF ABO The error is iu Joos ting ‘ostiy to install. Every e. The experience, Ramps shor saya TH eb oiler Fete te has an event greater id sith E-d as no fittings are involved. Some straight spe could be saved but this would be offset H feed to E-4 coming from (+ west Pump locations ares: vonsidered duri fay OUe Te FaANeT THAT UG T-3 is not exchang more pipe to the his preliar Wy Teeatedunder tiie rack bis their final position will aol effect thy length of th: groesss string“s ae le ' Pict Plans 4.0 Minimvam horizontal clearance berwe: equipment end/or piping shall be 2 Exception: clearance between exchanz flanges may be 1-6". 5,0 Main pipeway supports will be spac evenly and at 20°0" maximum. Pi supports shall be supplied for lines 3° and below, supporting them from 1: orver Hines. “6.0 For pipe racks supporting air coolers (fin-fans), 30°-0” width is desirable. As cooler tube length will be 32-0" 710 Locate pumps under the pipeway wis “Ste centerline of discharge 2-0" cur from under the pipe rack (240 fez: centerline of rack, columns). 8.0 There are two operating aisles, one un the pipe tack and one between 12 pumps and the equipment line. Coat: valve stations located 2-0" from ts rack’ column centerline shall have th: = handwheels tumed in under the rack, 9.0 Locate exchangers for adequate tebe removal space at the channet end (re sed to as the front end) and locate back head on a fine 8-0" from the py ruck column centerline. This is called equipment Line. 10.0 Locaze vertival vessels by locating est diameter vessel's OD on a T= 2-0" away from the equipment line 10-0" from the rack column center: Line up all other vertical vessels” cent lines with this one 10.1 Horizontal vessel heads will line -> with the equipment line. Laying Out the Piot Plan Most plot phins are first roughly sketched the back of an ld print to establish relative be. tions. Many designers use paper cut-outs, lap. them to a sealed drawing of the plot area. T easiest method is 10 use a 1/8" = 170" scale mew with » magnetized plot board. Once the plot y has been completed it is photographed for reo.2 purpows and for customer approvil Since a buok cannot utilize a magnetic! medel or paper cut-outs, the rough sketch pr 59 dure will be explained. The following data is need: ed but does not have to be complet 1, Process flow diagram for unit 2. Plot size, 3. Rough equipment sizes 4. Control building oration (of-plot or in unit); if in unit show 1. approximate size. 5. Location of off-plot msin pipeway (for unit connections). 6. Which lines are alloy. large carbon steel ‘oF other, Which must be kept as shart as pose sible. For item J, refer to Figure 4-2, This rough process flow diagram has bee sketched in a hurry by a process engineer to gine the piping designer some idea of the equipment and the major piping involved. It is incomplete ané subject to careful study Some items the piping desi: 1 y the designer laying out the plot plan, + will consider are: Pumps are shown as si units for P-1-P-6, but each unit is vetuatly two: pumps. the operating one aid _the spare. Common spares maybe utilized Jater, FP-1—-FF-S, air coolers, should be located ‘on the pipe rack. Ea iy be several cells, but the process engineer has given hint by. showing FF! os the largest one. This indicates that is larger than the othe Fs DUT not necessarily just two cells. Vessel sizes are not Known at this time. This is not important for relative locations of equipment but must be known to fina- lize equipment locations. A good rule of thumb is to consider all vessels as 96” dia otar Tor units with froushput_# FI" Ter sinaller units woul sizes 4 wm,~= = Exchanger sizes are boiler E-2 is guessed 7 shell: and tube diameter. Estima lengeli Tor ET. nit 0 nknown. The re " OD while other5 Piping Systems Every piping installation is resplendent with systems, each having something in common with— yet different fromthe last unit-:te designer fin ished. ‘The fractionation system «see Chapter 2) is the most common system since it is the basis of all process units. All offsite and «site units have draincige’ systems to handle surface or rain water ily drips and drains or special liquids such as eants- js. ete, Most process units have one or two Steam tracing systems are similar es, 2c Nare systems. and Details Underground Piping Underground piping is broken down into evo main cat ystems and utility sys. ems. process lines should be woided: however, there wre times where this i best installation and this will be discussed in other chapters. Underground utility systems dre classitied into two “divisions t systems - erecarti from job to job. This chapter will discuss these and other systems, Details are also similar from unit to wit. Many details should be standardized in the industry. but because they are not, countless millions of dollars are spent and man-hours are wasted developing way to do something that has already been done 50 times before by other designers. This chapter will present details showing ways lo solve problems which are not standardized but do the job. Piping fabrication is done on alt pipit process pipe is fabricated in x pipe shipped to the job site in “shop spools” to be as semibled by -the erection workers, Most piping srs know very little of a pipe fabricator’s prob: ts his work done. While his costs Most p and lems 0} ire high, the shop's streamlined efficiency and as sembly line techniques make ship Tubrisatjen cost Jess than Held fabrication. 73 Gravity Flow Systems Gravity Mow systems depend on the pull of gravity for Now. Consequently these lines mast have « constant slope from liquid o minus. Recommended minimum slog foot, or I" per 100" of ine, Piping is supplied for the followin lean water includes vue 1. Storm water 0 vyater, wash water anel fire wat This is usually collected from paved Gia catch basin and piped to z separsuor jil_or API separator, to separate any oils that may § “po to a creck, eeaporaTTOn pond, river OF DMPipe revneeues Table 62 Centerto-end (GE), Back Conter-tovond (B/CE) and Are Length for 45° Bends of Varying Radi and Pipe Sizes Re R Z ¢ S cE Y B/CE — TIGER ne See SasErEEES 5 5 @ ie % Bee we} 3 a yews [ie 7ae Fang inches Topane pisses [iaewne[oasene [pmo [75a [isin gsae i= fissan [asa |'s-sise 1 6ai8 Tame pa7e8_| 22a [izeaa [tosre [raore | r-esie | roeae iorse_ as 2asaia [1 staié pisesne fe bi=ran6 | 806 Fis pee we? 1 75 i imei ae a inriane imeane” [18700 | teeans ireene pr aaa a peers) 23 pia | ime. “Pe aane Pi sné teenie [iene . +1015 irene [rea [isin froré [11006 | saree | ners tape r-sae [i seve fowue [rote pro wiene sige = rae ~fresane [oii [rose [woe [re wiv) 1 10%8r6| irae [yw ane [aca sane prensa [2-096 werins} +197 fro ma i eye [1—aewa [20216 [705i inno] 03 | iotine [a= one Taare |? = oars Tessie [e976 area [4-107 roe [r= nane [y= joie] strane [1 Thane | fang) - tise] y= Thien tives [2-ova [2-03 2-0 7 - roe | ave = a [209716 21386 Stank [2s 136 Boose 21s triste 2-0 7 2igane [eae aos [2-778 Poa pane 2 anit pesaie | ao gigis [panne eine [2- hae3, Pragese-bewer, 50. mes called oily sewer or dirty water sewer, includes drips and drains from pumps, vessels, nection funnels and other dir gystent_is routed through at» the hydrocarbons are usually recovered 3, Combined sewer is the sewer that collects Foth storm and process sewers. utilizing only one piping system. “his amust_be routed through a large APL sep stor eapir ble oF handling the combined flow to sep: pre nyaragarbon’ fom water. While the combined system saves money on piping costs, the savings are usually offset by farger separation facilities costs. The com bined system is rarely used today. | 4. Sanitary sewerstare the systems that catty human waste, These are routed to a large ‘sanitary system or, if handled locally, 10 2 septic tank and its related field 5, Corrosive-sewer’ are designed as x separate sewer system within the unit. Thc includes acids, amines, curbonates and others, Some GF Tae circulate within the wnit, with all funnels draining to a separate header which js routed to a local sump, A sump pump. cither returns sewage to the _presufiz Sein or sends it ont of the anit for dis- posal posibty_ to # neutralizing pit (Some feids, such as sulphuric acid, are pumped fo Sforage HEH Shipped (6 @ reclaiming plant where the acid is FeoOwered, Tag gt ‘As these systems vary widely, the materials of construction will be somewhat different than nor fal and each selection must be thoroughly investi gated. If vitrified clay or cast iron soil pipe is se- jected, careTulattention must Be given to the mate rial selected to be used at the joints. Sewer terms are different and oft with terms applied to overhead systems, Inverts on all confused are used as a dimensional reference pain but carbon steel piping. Inverts ae the elevations of the inside bottom of the sewer line, In the larger sizes of vitrified clay pipe, the Urickness is very large and must be considered when calcula ing. clearances trom other tines or underground concrete. The use of a concentric reducer or in ‘creaser will change the invert elevation and must be calculated. Wher 7 systenis. ins pipe (BOP), expressed as an elevation, Inverts are carbon ste pipe is selected for se sioning is tu the bottom of also expressed as an & The fiquid ow is determined by the slope of « vity system which in turn iy inverts’ set. The designer must be concerned with the el sation. dveraedl by the inion of thy internal surface. the 58. A joint’s internal suy ne up even though the two wall thick The gravity systems" low must be as smooth ag possible, Without projections which would form weirs or dams. providing & point for solids to accumulate and block Row Tae must nesses diff Reducer Selection When reduetions in fine sizes for headers are required, special care must be taken in selecting the type of reducer. Because of inconsistent termi nology, there ig @ great dea) of confusion why defini tion in vither clay of east iron material Proper terminology is detined below. AH terns .¢ in the direction of flow line redu sare specifi 1. Vitrified ely: Concentric is all that is salable a. For increasing hue size use inereuscr swith bell on sina! end ih. For reducing line size use reducer with bell on large end Cast iron soil pipe wailable a. For increusing line size use reducer with bell on smal end be For reducing line size use inereaser with bell on large end 3. Cast iron pressuze pipe: Concentric and ec centric are avaiable Concentric only is i, For increasing or reducing line size use reducer, End types must be called out for both ends to match adjoining fit ting oF pipe b. Eecenttic reducers are available in Tim ited sizes und patterns but their use should be avoided. Before specify ine. ignet must be sure proper siz nercially available.Take BS : Gentee-t0-End (CE), Back Center ° End (B/CE) and Arch Lenatiy for 48° Bends of Varying Radil au Pipe Sizes 5 Time Teoma Re eer eee eee EEE ’ é = wT | vais 3 T fie"| ae | Gas | | Sens | ene | 319n8 | | Sine | am | aa | aie | | | 778 ave | 45 47/8 | | 358 aoe | sano |. S56 / I | | | vam} oso [ote faa 16 | i | Youre) sae | ere | cam | ane | | i nv’) Slane} cans | cone | ae | | \ tia | pane) ore | oasrie} rae | zn6 ‘ veoons | sea | rie | tae | rane | 704 | 1M5e | sane] zane | rans} 8 sare : li awe | rans) pine} sane | eae | sans | arane | | 1 aSse| tae) eae | an | atone| 0 oa | i-Suine| gate | sian | sane | ona | gone | nine | ' roa | guns sane | Sans | owe | orans | tome isia | sae | ose | ome | towne | toe | 1002 1-678 e156) wee} 10-111" 1078 TG 16/16 134 1 1-758 10.3/8 10778 je V5N6 az 194 |1- 03016 Vane | team} ota | tne | maine] nam |r-one [1 oane | {Gane | trans! ttatne} tntsne|s—ove [2 —osns /1—oon6 [1 —s i j 1-10 hee} 1—oue |t-o9s li-oans fi-oae [1-1 [1 t7n6 | toteva [reo |roore [y-oae fiona ts ve [i tee by ane {7 Mente] Dorms | 1 Detsne fra tans fro sae sans fy sans [yo aaie [yaar 2 o9s |1-o13e| 1-156 jr- 196 [1-4a4 fT 18S |i -2ar6 258 [1-316 aati [iowa ltrs fe to2ans {r-2a6 [1-258 Jr—aane [1-312 | i 2— tase |i saiie| 1-236 1-206 |h- 256 | peaue [1-342 |1— 318/06 | Pans [tlenme| tozene foarte fina ft Hla filaze |icasne | Ee aes Weameleh been laaanttl ; 2-aya |1—205ne) 1376 [1311s |r-37m |1-4ine |1~45i6 |1-aare [1-516 ; psa |ioasne | 1—aiate fais fi oave [tase [1 aig |1- sve [1 - 59/6 : 2 s98 jicsae [inave i—aie fr fig jioeve |t—sene fie i 3 esis [ise |1—see (i—are [1 sya_iosaa_|y— siete | 69 i us 2 Texas Pipe Bending Co., Inc., Houston, Texas,Piping Syste Sewer System Terms Fo discuss any sewer system, verbally 2F 08 the designer must know the terms that make up the system. These are: paper. ainsi Sewers for coliection from (80 OF OTE Yoterals: uswally located in roadway essemen’s Maing shall be sealed at regular intervals, with manholes, to prevent the spread of fire oF £25 backup. Laterals: Sewer lines collecting from two or more wrablaterals and discharging t© mains through & sealed manhole Sublarerals: Sewer lines connecting branches and Batch basins to laterals. Branches: Collect from vurious drain funnels oF atch basins and te into sublaterls Funnel: Liquids collection point, usually project ‘ing 2" above the finished surface. For carbon InsP igsteme, a 6?x4" concen sae 2B economical funnel. Lines from Tunnels should not be smaller than 4” to prevent oh ot sould b 4" should be the minimum size for the funnel Soeetion end. The swage is specified over te reducer ocmuse Tie swage Tanger and will © a deeper bowl area for splashing. ~ Catch Bastar Used to collect Surface drainage. Pave ing or other surface is stoped to the catch basin, Catch basin is usvally about 2 square by 1’ to 1s! deep and covered with grating. Manhole: A central collection box of a size that Fran san enter 40 chean the sewer tater. Coming. Tines are asually sexted to prevent packilow of fire oF gases. Sewer Materials Selection of sewer material depends om Pres sare, temperature. durability. cost fof material and Tabor), availability and the fuid, Carbon steel pipe properly coated. is quite often wed. WitTitied cts vad cast iron soit pipe are widely used. His very Gilficult to establish hurd and fast rules for mete Fiat geleetion. Experience with the particular spelt vation is the best asset. The plant sites soit cor rosiveness mast also be consideret ‘ar materials a 6"x4" reducer Could. bewsid.” rf - 1 Vitrified clay pipe 1s economical. I is used Forgrnmity systems handling surface drain gas and sentary sewers. Since this piping has joints mechanically asseuv bled. it should not be used under buildings oF 6" we picker concrete paving. If the com modity being handled is 150°F of hotter, special joint material may be necessa6y Gast iron_ soil pipe is used for erseity S Sw When vitrified clay is specitied. ust eet ion soil pipe under buildings ond thick paving. If the Muid is too hot (or sitgified clay, use cast iron soil pine for the vrecessary length to coo! the Muid Carbon stcel_piping is preferred by many Fesigners because it is exsily instatled. It is Subject to external corrosion and must Pe coated Tong He, THe ST SIA ce cating is TF and Tall paper, usually istered tO as Siar and teathers.” This is the cheapest coating bué has many disad- antages. It is easily damaged during ha fling and dumages are not always PrOPSEY repaired. ‘The author recommenss Comte iW such as “Scowh- vith, plate at Te te” oF “Fcotiss Fe anvest | “years in the gi oar iron water pipe.is sed for Brnity tigre he use of 12' of Longer see Toms makes a-more economical izstallation than the 4" 10 6' lengths of vitrified clay, OF cast iron soil pipe. Also specified fF Pres” Surized water systems Conorete pipe is generally used for surface Trainage houders for sizes 24" sod larser Investigate cost, freightand availsbiity Be fore specifying it Concrete-tined steel pipe is uses VOr PIES Grrogive service where presstires for east iron pit” same are greater than allowed Dupiran_pipe sometimes speed tor Thy corrosive special drains. Because of re awh siticon content it is vee brittle thee piassand fos fig. rewkge #400 I dime, which adds to its already #xPenSEE cost :Pipe Febricetion vee Tobie 62 Genter-to-end (CE), Back Centerto-end (B/CE) and Are | Length for 30° Bends of Varying Redii and Pipe Sizes CE, » aee| Qo Fear = inches Tee ocd Pe Ses ue we z spa 5 é wane | age | 12 Tosisne| sone Time [ae | tian6| ead) ou horns, O78 Tri oa’ Ji~ ose {ra one | ose | 6 (rk Hose [1 ors fy owene 1 sans he 15g : cossie}i— naa fr vo aans_ ro vane js 2ehe earrty 1a 2916, i reais] 208 ya aig iam i> sia yeanne rare [1-328 1 1 raise fi Trane [1-30 ia) ft vous |i iv jie ae ya sie [t- 3a fh v342 [yh Cerra ressaefisaia fp 130i Fane frogene [fs oae ft we ops 1a atin ieara. [rae f Poava |t 1 tise Tyisté|yceue [io esns ly —ere frag [rein] acess |t saa plans [reeae |reeone [r= sig |i ards |1 — 4asa6 {same [t- 61 sf tae fp LestasSare pos fr aeie pean facet rons tease frosnefs sie [t reese frou fiosaa [ree tow ficeane [yosas fr iisea [rosae [ie [ncesne Ps tlgas frien ficesa ficsae [iosre fimo jroera br saye (areas Woeung [rosae [tosnswelr—erss {1626 [este yon [1-678 Eng |g licane|ycbiine {ioe [ieeane [1 esne [rears [roams [Peas] 78 FELT [22 inane |p cassie [1 sure [rene fs eae fr sivas s -aae|y 7s we [no 138 plasm [iceve |rosens fiseas frsere [ror tare |izzae |i auie aioe [regia [tceumelioy fi-zve fromas [rarae, frazes [i Tees jlose [rogue [yorane fiozva fnzae fr-raa [yore ficaze fe Sltane fic ow fre oans [regia fisese |v- rae [1-20 [is v8 3 —vaie |i zane [1- 7678) |r - age [1 736 5 | 1 816 yeas [t- 876 Sdurce: Texas Pine Bersting Co., Ine., Houston, Texasoe Figure 6-1, Cast iron bell and spigot pipe det Joins for Gast tran Piping This might be river crossings wnni : water, supported by the bridge, or underground! are-equipped with where soll heaving is expected, The Gulf Cosst soi si iron pipz-and fittings sr gpigot ends. Figure S-b pictus the pipe calls for this joint detail rather often eto The foint cin be. stalsd_with teal aud Thee mechanical roll-on joint is a tow cow bakin, Cement or a rubber of neoprene fing fh mechanical joint with a round rubber gasket ove Tay iS The eroove shown. Lead and wate or the SPIRO tend. When the spigot is pulled into th Soha senda Fount material for surface water bell, the ring is seated in the bottom of the bell systeins, To ensure operational tightness the joint Outside the rubber Jed jute wedged ser rial mst be Kept moist, The conveyer! fiquid behind projected ridge. confines the gasket t ‘ny pressure in the piping system. A bituminous npound seals the mouth of the, bell, retainine avconiplishes this, re ce rarely used! in ges © Bell and spigot joint pressurize. systems. Pressures of up to 200 psig the IV gasket, Both bell and spigot aid Preset by the Joint for liquid service, For bigh mechanical Joint fittings can be used with this Frecsure water service such fie water systems. IDE Tolland spigot pipe and fittings are available with potting lugs to prevent joint separation. Toble 541 ‘Sewer Flow Diagram Symbols For pressurized systems, thst blocs afe ab: pied aC turns oF paints OF thrust to sestet joint 7 Oo Separation. THrst BIOKS, | [Manhole fe generally a muss of ete chanical joint, « modification of the GA cotcntasn | vat ny joint is used In HO peste 35 ala pie toms, However. the main use ofthe gain uel cegyanival joint is fox higher pressure fie seater | o-se Drain funnel with sea for rag Wap systems ope tina above 150 psig, The author rer | Stricts all cast iron piping to water and sewer sp se predveearbon gus service, wetted a] is recommended, eehanical Jock joint groove which is shown in Figure 5-1 is focated in the bell end. The awe yesommodates 3 rubber oF “RSC Tor installations where sogging is liksly (0 0 Tae the mechanical tock joint is recommended ae 5-H Catch basn with sete outlet‘atle 61 Terrie to-end (CED, Back Centgrtorend (RICE) and Ais Length for 30° Bonds of Vary Radi and Pips Stes Tre ~SIGEY Noninst Pipe Sizer Tins) aH 4 5. e | 2 | Dane 21S!6 BA5/i6 57/3 | 6316 eas | 612 jee 613/16 | eae 615116 | | 6 ala 72 “yaa “eis, 2) gone | 87/3 sian foe oasis Frowe bho Mose ef ean | joa 1012 sore | 10-9/76. | 10.12/38 | 20 yori | 10.13/16 | 1015/16 | AMES | 18S Si | 11-9016 rors | 194 | 1oas/ie| vs. ane Lt Gouree: Texes Pipe Bending Co., Ine., Houston, TextsTae L Figure 6-2. Typical process sever flow diagram. For special service conditions, the pit signer might employ the mechanical screw joint which will contain of, gas and water gt tr prewitres, the balland-socket joint which pro Chee ereat flexibility at the joints. ar the universal pipe joint which ist rather stiff joint “Tie Dresser coupling is a compressionstecee It is wsed with plain end cut pipe of ¢h irsteel in both underground and gas. water and coupli ther east ioe aboveground installations for sit. it, This type of joint fs quite often installed wile “nichors oF brucing and when the line 3s pressured it wil] come apart. Property in r ‘will have mchors or braces at turns on bot GL the jot, These joints are v fine econon! a Tor fines neceing a salt amount of 2 result in tot) owt proper Improperly installed they whos 1 spli-eoupling oie aT SCT Pup THis Fad To Tne pipe OF Hitting TEA ET ves cut near the nds. It is acceptable far use in hat aie expausion and a thi er vapor service, will take lows considerable angular displscentent ivemsily dastaligd and/or broken apart EXISTING CONTROL BLOG. it ‘ Piping Systems Sewer Flow Diagran! inn is the easiest Way 10 The sewer Tow di information gbout_the_draingss and the custou where communicate system to the layout desig Finaiaing ovations of desir, funn jiples ane in the systom, locations of seals ote much easier settled on a flow a gram than on te fhnished sewer drawing. Although most eompamics aeer prepare a sewer Mow dhugram, many RN jours would be saved if they did. Hl proper desig Mrormation is given to the fayout designer and HS ‘a better job un be done in about half the: ions checker expended manrhours Becmntse these flow di made, the symbols used are different in cach 6 pany that does make them. Table Se) depicts Symbols whielt are used ond could be standardized the industry. Figure 5-2 isa typical prgeess SS cer fhove divgtam. srams are not commonly Cast tron Soll Pipe and Fittings coil pipe and fitting standards the Cast tron Soit Pipe Wnstieale Cast its tabi *O8Pige Fabrication Dessriotion 160 Ib. SO AF Fi ‘all pipe to be ASTM A-108 Gr. B, Sms 0.375" Vall 1 12" qo 1a" 2PE | i 1 | Figure 65, Shop spool with bends. Courtesy of Tens ips inn Co Ine 99AKG LENGTH —+ 7 | Dourtecy of Cast tran Soil Pipe Institute f 2.12 5.3. Dimensions of service cast iron soil pipe and fittins Table 52 \ Dimensions of Hubs, Spigots, and ‘Serviee Cast Iron Soil Pipe an Size! of hub” ge of barra i : 3 y 6 33 width of , Spigot, end, pipe and a i size? Hob body _Over bead _fubhead?* bead fivinas? j aInmLLCHETE ~P Tina we ‘Nominal inside diameter 2£or tolerances sce Table 3, Cust dn if Pipe anc Mistings Mand tek Saying lee eth, all sizes—Single hub 570” less Y, for S-Foot 1b 10°0"; Double hub 10°0" less Y. for Leto | rai 4ifg bead s provides! on the spigot end. AT may be uy dian Hub ends snd spigot ends eam be made i draft, ord spig spigot ends cos be mune with ox without spixot bead bby made with or without draft, and |98 Material Uist size Desi auenity S28 n_ 7 fi Ft at pipe to be ASTHY A106 Gr. Sl, 0375" Bal + Tee yg = tear8” FE pool with rites, Courtsy of Texes Pipe ending Co., Ine Figure 6:4. Isometric s{ } Piping Systerns in mM 6B 1 1 Larne LENGTHY }—__y, (reuescornc LENGTH) igure 5. Diversions of extra heavy cast ron soil pine and fittings Courtesy of Cast Iron Soll Pipe Lasse Table 5:3 Dimensions of Hubs, Spigots, and Barrels for Extra Heavy Cast Iron Soil Pipe and Fittings 7 Dune ciamater inside ot ouside Invise diameter spigot?” diameter, Telescoping diameter, Thickness Size! of hub? Bead of barrel* tength® of barrel” of barrel’ A nm J y 2 r inches ‘nner inches inches inches 2 3.06 175 2.00 19 3 419 388 300 25 4 519 488 4.00 38 5 oo 588 5.00 35 6 TD HBR 6.00 23 8 9530 9.00 800 31 10 1162 13 16.00 3 2 1375 BB 3.00 3) 5 00 16.35 15.00 Es Distance from Thickness of Rub Wists of lead gioove to Depth of Iead groove wissh of , Splat eid, pine ano Size! Hub body Over bead _hub head? * bead? fittings? Simin) A tmind F ® P Cimin} __ G (man) inches inches Tnehesnehes «thes inches inches inches 2 on os O O28 010 O13 3 si 7 28 i 8 4 ss si 5 10 3 3 88 I 38 10 3 ‘ 88 3! e i B % 3 118 v2 & 5 9 0 20 119 me 38 5 19 2 40 iat 138 at 15 19 i 6 1a 138 a7 6 19 Source: Cost fran Soil Pipe Hnsttute, Cast deo Soi Pipe aon Hes Mal | Nominal inside diameter 2hortarantces see Table 3 ist fw Sl Peto Fits fle iok See ey ae, rotten engti sndl hub) 100": Dosate ub 1070" ess Y. for TOL leagih, all sies=Si Shut ends ad spigot ends ess be mule wit ‘witleat spisot bead. fon the spigot ead, May be ay Siamete ve seth deat 9 berweon J and M. ends fe mate with or withuwt dePipe Febrication Material List Quantity Sizo 3 6" 5 6” 1 wz All pipe to be ASTM A105 1 6 1 6 1 e 1 e 2 e 2 6 1 6 Total length 12° = 11" Description - 30 Std, Wi Std. we. Str Tee 2000 tb, Thd'd Half Cpa o - 3.3/4 o- 78" o - 103/18" vera" y—1eava’ 29158 BBE +, teomatrie pipe spool. Courtesy of Texas Pipe Bending Co. Ine 7K Street, NAW, Washir“*on, D.C. 20008, They have published an excelent pook on afl cast ron piping called Cust fron Soil Pipe and Fittings Hand- paok. which should be in every designer’s brary Cot iron soil pipe is available in sizes 15" Siaes are the nominal inside diameter of the pipe The wall thickness varies with the class specified, Which changes the outside diameter, Laying lengths Vary, but in gerseral will be ether 5 or 10", See Tables 3-2 and 5-3 and Figures 5.3 and 54 for details Fittings are ma pipe. Terms are dif sfactured in sizes to match the ent than the ones for carbon Niet and the designer must specify the correct term. For instance, the 90° ellis called 2.1/4 bend ‘The 45° ell is a 1/8 bend, Cast iron fittings also employ_bends of 1/5, 1/6 and 1/16. These terms. are devised according to what fraction of 360 aero eeeeeeeereeereSeeeC Fir janctions are made with fittings. Welding is not employed. Fittings sre available for Tine inter ection, clean-outs, etc. Flow is always directed into the barrel of the pipe or fitting (ee Figure 51). ‘Joints are usually made with twisted jute (oF akagaty a calmed WOT TSU Tue 1s 1 vet: ‘bre, Cotton and hemp are ‘algo sometimes used. These materials are ordered by the pound Lead be 12 ounces ments are calculated to be T aianeter. Tinis an 8” diameter pipe “F pounds of lead, lure estimated of the lead requirement by weight, The 8” at 10% pipe would need 0.6 pounds of jute. To order joint repferial, the piping designer must count all joints the total weight of joint ma- added to this total to allow by sizes and calculate terials, Ten precent 18 for waste Designing Systems To design a sewer system the designer must know thy depth of cover required, ‘The _highest poi satal piping must be below Tr frost lingo the liquids could fresze in the fine With @ slope of 1” per 100". the lowest point could be very deep. Lines are also located below frost lines to protect them from “heaving.” rising and falting caused by frozen earth thawing and Freez ing, Frost lines of euch area are designated in the teeneral specifications. In any event, underground Nines should-have a MINIDV paved areas for per cover Of 16" is the minimum under paved areas Student Exercise The plot plan, Figure 4-1, and the foundation location plan, Figure 4-6, comprise 2 unit for which the designer must preoure an underground piping plan and elevation. The stadent will make Five drawings as a class exercise, Figure 5-2 s-the process sewer. Assume a frost Tine of 3°, Use ear bon steel material and supply dimensions or coor dinates necessary for fabrication and installation. Locate funnels and fines by coordinates in plan ‘To design the storm sewer, the designer must divide the process area into drainage areas to facil tate the removal of Liquids as quickly as possible. If possible, drainage areas should be square, Paved Mrainage ateas should have a maximum of 2500 square feet of surface per catch basin. The student isto designate the surface drainage areas, locate the fateh basins and route the total flow to the tcxisting manhole. The cevierling coordinates of the existing manhole are W.610'-0" and _N.1090:0 High points of paving extremities are W.6) and W.658"-0", N. 9757-0": and N.1205*0" Drainage area slopes shall be fimited to & mini mam of 0.01" per foot and x maximum of 0.04" per foot. The maximum total drop allowed is 6” fram: the high point of paving to the lowest poin st the catch basin. ‘after completing the drawing, prepare a bill oF reatorial listing all material necessary to install the tivo sewer systems Refer to Figures 5-5, drain funnel installation and $6, typical clean-out detail, for design data Upon completion, students may drawings. checking one anothers work exchange Design Guidelines sles should be located at all major inter filing furns of major headers, Hie Tor sewer line sizes up to 24”, Tratiafes every 300” and for line sizes over 24 provide them every 500' for cleaning the syst Manholes may Be square Or roundMaterial List__ Quantity Size Description ‘Std. Wt, LR 90" Ett Std. Wr. 45° Et 180 Ib, SO RF Fig [All pipe to be ASTM A-108 Gr. 8 Smis. Sch 40 1 3 o-7a/e" IPE TRE 1 ca aes" BE i 3 1103/16 28E ‘Total lengih 18" — 7" Figure 6-2, Orthographic pipe spool, Cour sy of Texas Pipe Bending Co.. Inc.b Piping Systems E 83 HIGH POINT OF GRADE Ca" CONC. SWAGE MINIMUM 4° MINIMUM SIZE as ONE WELD MITRE” Sse IN WELD DIRE CT THE. FLOW IN GRAVITY SYSTEMS ANOID 90° TURNS: Figure 6-5, Drain funnel installation, Clean-outs shall be installed at dead ends off process sewers, or where the line turns a totul of 90° or at a 45° carn preceded by 50° of straight run pipe. Locate clean-outs so that cleaning may be accomplished in the tlow's direction. Drain funnels muy be considered as clean-outs if the line from the funnel is short and total turns do net exceed 135° When routing underground lines always check 1, Location of underground electrical ¢n- velopes, their sizes and elevations. + 2. Lines entering of leaving buildings routed by arehitect:ril of structural groups, Location and elevation of all foundations, whether they are spread faotings or grade beams. Sewer piping must clear 4. Angle of repose of the soil, Foundat must_not be underreamed by excavation for sewer piping. Any time a pipe is ran deeper than the foundatina if mot on pik ing) and within a few feet of it, check the structural group abut possible underreasn- ing. If there is no other route for the pipe, the structural group may have io lower their footing. Underground Pressurized Systems Fire water, cooling water, closed process drains, and pump-out systems arc the more common pics: Guised Underground ines, Carbon steel is the mest Srnvonly used. quaterial Tor these systems —Trausite. piping is often used in pressurized print aystems and some people specify it for fire: water service, ‘Transite is an asbestos material, Yer Jighs in weight Bi does not ust, itneeds no asternal protection when laid underground. 1s also used in some aboveground special service, The JohnsManville “Ring-tite™ joint is the author's selection of transite joints. It is easily Joined by the field peuple sind Keeps installed cos att minimum while furnishing an excellent pres: sore-containing closure, Jobns-Manvitle will be RePy fall de- coupli py 10 supply catalogs. ut request, show! tails of their transite pipe and Rings jointPe . cpus 6, conn tavon#o WELOING SIMBOLS fe P | coer ee r Fie IE i a be Fare So risscenes | FEDS i Wer] surtocing ee free i T Proc smnet | is - st ‘t ‘ot, ‘Nol Not, Nit, | We lara te, La] | Be ef a ka } ie Nol iF | a (274 Ae| RR ; | " = peia lel] |* is " eee 1 ot ot 1 ay | a me ee % | |i rane ng be) ag aT GereTaon Yat care Frajecion welding symbo) \ : of soos Tay OS seis Ba i [pet aeree — frsore ange ‘ sia Fae wg FT 5 te | eae | | Lp : sen ee eeeced \ a aa Se ad cane oy | ate i ni a Mo hl {~~ free sees ath a justia i Ms i 6 we ier : wean eed eal¢ FILL WITH &ITUMASTIC - PAVING OF GRADE RereefeeEeeeeeecos ING OF GRAD! SJE cnet amon reneyne IND BRASS PLUG - APS | as: Poon WELD MITRE Figure 56. Typical clean out derail Fittings of transite material are very (ITER toad intersections and one between roud intersee oot Fitting Com- tions if this distance exe ds 250’. Locate them eynd Johns-hlan- about $0" from an area OF building where special and limited in types. Corrosion pany mamafactures most, Ott vi ceils their fittings, ‘Tyler Pipe Indust fof protection is desired. Do ros locate them where Tyler, Texas, makes # east von fiting for wee Sn falling buildings or walls would injure the Gre TT transite pipe cus or possibly Knock over the fire plug results i Vyeoamicat jou east iron is also very popelat = Voss of system pressure when it is needed 1h for pressurized systems. The Clow Comparty © most. of tne larger manufacturers of this. WHER specify Fire headers are _ustaly 8", _while | vate 6” Valves should be iis beinst ng tiechtanical joint piping, either tie rods or branches to ‘plugs are 6”. Valves should procs must be used. Consult the Clow ea82 UNERAIS WUE Ha hea ated ar to make it possible jog tor details Te hut off small sections for repair or a new | + en thot Having to shes down the system, Fe, Fire Water a gaves £0 that no break or repair will shut down more than 1000" of the system | Every day people see fre plugs but wok NaN” rire water mains should be looped, allowine consider the design of the underground fe system + nydtantsjand MONTTOTS ‘bo Tad from two dine eee es and monitors are futmshed in pant prow. ns Een TERT WE BeSTBIS delivery of tection systems Ter without excessive friction loss, Flushing. © Monitors: are_usedl_to direct water to protect nections, 4” size Should be focated at the ends ov specific tisks hich may not Be aocessible Wi» far corners of the main. Fire water will freezeand | Gorrabte tose steeam er whete the Tae hazard is must be located under the ares frost line. For sale puch that prompt application of water IS pecexeary. ty. vacate it V" below, frost ine Minimum covet co need where the arca would be & sree be 3° except under tullroads where INS They are Tremely hazardous to occupy during an emesis ney ied tod, Ht the man i routed under 2 rai ests a culvert oF pipe sleeve FOF Memmiters may be fixed on one target, But usually road the author sti they ave leit free to rotate by the opers'ot They toad jrotection seer vnter as 2242” hose whic fede men tohandie. ae Underground Cooling Water PERE EIRRSTT Brass Mig. Co. of Ethier indi on producer of monitors. Figure 57 For_most installations, underground coobne Shows three «ypes of their monitors swatey supply and retum hes are utilized Tor BR se ast me eae pO ee second, they OE cheaper Some com94 Proves Fiping Vesig” Basie wale sy 90008 Tha tee losation significance He i co aimee ‘fhe sige Supplementary s7m BOs Tesh waitng_sy08 Spase[ tev [ore pee ena Bay wel 78 Oo e \ uatasanel Peeet any Sey we riesgo ae ora welding symbol ‘Supplementary wacateeoind synb3) symbols used een F farae| ov gree wldng aoe ynbols with welding 5 ye Basle jo Fins Tdeniificalion of gow side ond Figure 6-1. Welding Symbols. Cour sesy of Texes Pipe Bending Co. Inerial yin th Piping Systems Elkhart Monitor Nozzles Elkhart manufactures a complete Tine of Deck Pipes cr Monitor Nozzles. There are eight cifferent styles and three ilferent sizes to choose from, Elkhart monitor nozzles are the only ones manufactured with double row, full diameter rrylon bearings. These ““Kingrsized” bearings make. the rozzles extremely easy to operate et high pressures and ever need) 10 be lubricated. Even at high pressures, one man cen easily control any ot these nozzles. Nozzles are | normally supplied with # discharge tube and one tip, 600 {GP.i,, 1100 GPM. and hydrant Monitor nozzles are supplied with 2%" x 21" No, 282 discharge tube and No. | 181 tip. 2000 G.P.M, Monitor nozzles are supplies with = 34 x 3%" No. 284 discharge tube and No. 181-3 tip, All | 208 and 294 Monitors are available with a gauge and 92498 ued at extra cost, Frequently it is desirable to use a ‘combination straight stream and fog_nazzle on these | monitors such 25 the GF (500 G.P.M), CJN (2600 GP.) 3 (500 G.P.M,}, JN (1000-G.P.M.) or 1 Sky Chief nozzle. When those are used, tubes and tips are rot necessery and price of these can be epplied against the price of the fog nozzle. Monitors are available with either female TIPT or ASA flatfaced flanged bases tsee list of Ail discharge tubes ore equipped with double stream shapers, Bress body painted red — sre either polished brass or chromium plat remote camtrolied available bases 2 8:7. Fire monitor nozeles, Courtesy of Elkhert Brass Mia, Co. 292 Handle Operated Monitor Full 360° rotation with lock ~ Maximum elevation with iandle control ~ Has positive elevation lock, 292.6 for discharges from 200 to 600 GPM, 292-11 for discharges from 600 t0 1100 .P.M 792.20 for discharges from 1400 to 2000 G.P.M 298 Single Wheel Operated Monitor Full 360° rotation with lock - Maximum wheel operated worm gears which lock positively unless (he wheal is wormed. elevation bv 299.6 Yor discharges from 200 to 600 G.P.M, 303-11 for discharges from 600 to 1100 G.P.M. 293-20 for discharges from 1100 to 2000 GPM. ‘294 Double Whee! Operated Monitor Wwheel-ooerated worm gears contral both’ vertical and horizontal operation and lack automatically ~ full 360 rotation 294-11 for discharges from 600 to 1100 G.P.M. 294.20 for discharges from 1100 to 2000 GP. | | |f t f Ez Pipe Fabrication rough sketch of the shop spool, The sketch is checked by a “take-off checker.” Then itis passed to the detail draftsman who produces a finished drawing, the shop spool, Take-off men sometimes make a line isometric to pass on to draftsmen. When isometries ate furnished to the shop. the take-off man is usually by-passed and the line iso- metric goes to the draftsman. He makes the deci- sion of where to locste shop piece break points and completes the detail drawing. The drawing is then checked by a “break-down checker.” Some comr panies have spools checked twice to ensure acura vy. Shop spools are drawn orthographically and as isometrics. Some shops do single ine spools while some do double line. Texas Pipe Bending Co. in Houston has done all kinds and now does single line spools in isometric except for single plane spools, which are drawn orthographically Figure 6-2. orthographic pipe sposl, is drawn orthographically because the pipe is in one plane. Figure 6-3, isometric pipe spool, shows how shop spools are drawa to show more than one plane. Figure 6-4, isometric spool with miters, shows detail miter dimensioning, Note that the pipe’s to- tal length is shown in the material list Figure 6-5. shop spool with bends, is drawn orthographically bec: < it is in one plane, Alb bend date is shown in the boxes at the drawing’ top. The material list gives the total length of pipe needed to complete the spool Pipe Bends Pipe bends are used to make turns withou| Aiings., The pipe is usually filled with sand, Neate and hen toa radius and angle ws specived. diameters. For a 12" line this would-be 5”. Fabrication shops sive developed charts and tables to aid detail draftsmen. These charts arc use- ful to piping designers us well, Tables 6-1 and 6-2 30° bend data, supply dimensional data for 30° bends. Tables 6-3 and 6-4. 45" bend data. supply the same information for 45° bends. Tables 0-5 and 6-6, 60° bend data, supply dimensions for 60" bends. Table 6-7, 90° bend data, shows 90° bend dimensions. To read this table, for a 3'-6"" radius, see 370" ai the top und go down to 6" Lat the RID) 2 which would supply the are dimension of 5'6" Miter Welds Miter welds are often specified in low pressure services as elbow substitutes, In very Terge Ui Tings are unavailable and miter weld elbows are “Ged Where pressure drop must be held toa mini um, the four-weld miter is used. Two-weld 90° * miters are_used for maximam economy, but they cause the greatest pressure drop, The three-weld jniter is a compromise. Table 6-8, miter welding dimensions, gives Tull details on miters. For angles of 45° or less the one-weld miter is common. ‘Small Fittings . ‘The pipe fabricator is concesned with dimen- sions that affect the length of pipe he must supply. Table 6-9, screwed and socketweld fittings, gives dimensions of interest 10 pipe fabricators. Normal thread engagement is also shown. The Triangle Piping designers run pipe vertically, horizsvtal ly and at angles. The most common angles formed 30° and 45°. By construction, piping draftsinen make 90° triangles and apply their math back ground to solve triangles formed by these angles. Pipe shops have developed triangle tables to aid in quick solutions. Tables 6-10 and 6-11, 30° offsets, supply solutions for 30° triangles. Tables 6-12 and. 6-13. 45° offsets. show 45° triangle solutions ‘The Cutback A cutback is the dimension from the header centerline to The nomk's nearest point Cutback Gimensfons are needed t@ determine the exact length of the nozzle pipe, Table 6-154. 90° cutback for standard weight pipe and Table 6-15. 90° citback for extra heavy pipe, give the cutback dimensions when the nozzie's ID rests on the hiealer’s OD. Table 6-16, cuthack at elbows, supplies dimen- sions for cutbacks occurring at 90° elbows Th formula shown can be applied for sizes not listed84 Process Fly fon cooling water in overhead pipeways, but This fasans that their racks will be larger and laterals £0 cechangers Will be longer and corisume more fit tings. ‘Fhe most economical system will employ wy dempound headers outed, outside of the charac! Gnd of exchangers, causing very short Lateral lines, If possible during plot plan development, focste a exchangers using cooling water on one side of the “init pipeway. This would elirninate having 1Wo se St supply and return headers. IP one oF two sinall ater users must be Located on the opposite side, & Subheader could be run across the writ from the main header to feed them [Locating the cooling water headers at the chan aol end of the exchangers leaves the area under the tinit pipe rack clear for underground drains and dlectrical distribution envelopes. 1¢ simplifies maine tenance when needed and Keeps these big headers free and clear of foundations. : SoS peer ree ‘ed to Feep heat from being conducied thous gh tie earth from the hotter return header tothe OETA reader Branches are 10 have 1-6" ‘poter_ supply Wesdet_E cleat Tor shovel room only. Pump-Out System The closed process pump-out system is usually focated underground. [t is a pressurized carbon Steel pipe connecting to the unit's vessels. 0 Changers and some pumps, routed to a pump mane Telded so TE ean be used as a pump-out pum, which pumps the unit down discharging to & S10 Me tunk in the tank farm. This system is run with 90° elbows; clean-outs and manholes are not pro” vied Glycol Lines Glycol lines in_cold_process_gusoline_ plants shold abiaws be a These ave routed ior inlet fap calles and ae dsebarged rom, e displocement pnp. This pump raises the prosure from 50 psig to over 1000 psig and due to fae pump design the small elyoe! line 1s Tpject fo Waukee paTeATION Tom eaely Oust oT the pumps see This ine Wy Tose over end 1 HAS # sood change or staking, rattling inthe rack, and Tracing Tracin fer of heut from ucforeign Sour 10 piping syste JERI IS Waally accomplished by a steam tre sine, bat sometimes this gives way to eleettle ts ing where au electrical wire transmits heal to Pipe Ferree eee “Figure 5-8 shows how steam tracers stalled inside insulated lines, Steam traced Kites sulation for steam traced lines must be sized on, size larger than line size to accommodate the irs er. For example, 8" insulation would be-ordyied for 6" lines, ete. Since electrical tracing employs flat tape, oversized Insulation is not necessary. Steam acing is used to -keéb liquids Jasin rece in cold climate 16 Heep a viscous Last! From setting up or solid ing nd fo wagons form in-a vapor Service. Onehali Teh per tubing, with lara’ Be tings, 38 the most common and least Experts method of steam) tracing, Properly installs), ll fared joints will {located outside the iasulsiin where any leak can be observed and repaired. He liso will prevent damage to insulation should « fe Sceur, Steam of 100 to 150 psig is usually, econ ically available for tracin Steam Tracing Design Practice ‘The “Low Jsnuary Average” is available Iw the US. Weather. Bureau office for any porticuls rea, The Weather Burest calculates this by ss" faging the low temperatures for the entire me’ “Tic Low January Average is used as the design temperature for determining extent of trl winterizing.” For 2 Low January Average of 30°F or b winterizing is specitied only where a sustalts! reading below 30°F is recorded severat days of month, lasting 24 hours o: longer. For » Low January Average of O°F t0 274 water must be protected from freezing. 1"! water To maintain a temperature of Appron! “SF, Hydrocarbons containing water must he freeing applied to “dead Teg” arensy whens S= Twhich is heavier) can settle out_and bees’ ffeezing hazard. eee.6 Pipe Fabrication Robrication is the assembling and attaching of compondeT piewes 10 make a completed item. Fab- rieation OF piping, the joming together of weldable pipe and fittings, is done by field personnel at the Job site and by “shop fabricators,” a shop located dt a metropolitan area with access to qualified pe sonnel and all materials on a lage scale, Shop fabsi- cation is Usually less costly than field fabrication. ae TO MMOMETT awEMby Tine Techniques and access Tatest fabrication equipment, This savings crage 10-15%. over the usual field fabrica ~Becanse SOPs have tastant communication F steel mills and large suppliers, they can locate cia) materials ot fittings for their customers’ heeds. And as they buy huge quantities of piping materials yearly, they can get the best possible prices, Shop Fabrication thus saves money on both Jabor and ina 7 Most pipe shops employ all union personnel The national union agreement calls for all pipe 2” and smaller to b* fabricated in, the field. By ar nent with the local union, smaller pipe may be shop fabricated, They usually agree to this if they cannot supply snough people to field fabri cate the work Normally, pipe 3” and Larger is shop fabricated Long stsight-quns are mot supplied by shops Hine is sent din the field, Underground pipe i5 field fabricated. ~ Shops fabricate pipe for all companies company’s drawings and specifica the shop in sp F uh, ions are sent (© many different kinds of forms. Half of their drawings are supplied as fully dimensioned The other half are fine isome ree, seferred to as “spools” by ce: tractors, Sheps ce not call isometries spools. Shops prepury_ drawing of a piece that is shippable and they cali this GOO! A Tine isometric may produce” dozen shop spools plans and elevations. aS Welding Shops have welders and engineers fully quali fied to make almost any type of weld necessary Most large contractors, such as Fluor, heve com plete welding specifications and procedures which shops use. However, for customers who do not fur nish welding specifications, shops have their ov specifications Welding symbols have been standardized t AWS, the American. Society. Figure 6-1 uelding Smbols, shows these standur Shop Details he shop's drafting room prepares drawings © shop spools. showir dimension shop piece drawing th every piece and every det for tabric with ‘alist ot materia! is shown cut fe Ho" wh take-oft” for each piece of pipe te pluns and elevations are supplied job of preparing an is given thwo PINSULAT ION ‘All Muids with pour poi s at or above the low ambient design temperature should be traced to een a. emnperatuie-approximately 100°E- {ove thelr pour point. Pow point tempos of all fluids are avs ‘lable from chemicalenginectitis, femdbooks. Fora Low January Average below OF Winterizing is cequired for water and aqueous $9" aoe rmace to muaintin temperate of approxiatly IS°F. vias with pout points at ot above the low ambient sign temperature should be traced fo maintains erature approximately 100° above their pour Poi evi} consideration is given tothe following: buried lines, because of the deep frost fine ‘Air intakes to boilers and other heating equipment Couling towers and air evokes. Equipment Winte' Pompe are preerbly wiateriznd ith eompalion PP onipressrs, blowers an ott ametamica av re are apeeiied for operation at tow umbient desist temperature Suoroge tanks sn vessels have wintericed (ype OHS RO PI SUPPORT SHOE PE BEING TRACED Water draw off seetions of vessels ad botort of Alt Watton mveivers: where water can coHesk SE neat traced ‘Materials for Steam Tracing racers shall be 0.D. robin, Sott anneal Tirana be used whexexempasate- 1 acing, steam does vol Temperature dead “soit anneal ‘garbon seamless steel ‘shal ie quality. Jo Fo stissstebincs_ she uacel ma ron. stéel, Stainless steel I Graze with copper DIE: For aluininusn pipe nes. te Saimlescstee! sacer, materiel shall b&_ For conditions where the tsgcer could Seg act, cause, aR, PED “eral tation spaces les Sevwacerand ach tracer shall ove its own trap, Traces 1050 shall recharge to sewer, Hf condense must PE collected, ved tracer size is derennined piping por gud tases sucuun peessite 1S dio uot (Figure 59)