GENERAL PIPING
SYSTEMS AND LAYOUTS OF
INDUSTRIAL PLANTS
GROUP 2
Introduction to Piping
Systems
A pipe can be defined as a tube made of metal,
plastic, wood, concrete or fiberglass. Pipes are
used to carry liquids, gases, slurries, or fine
particles. A piping system is generally considered
to include the complete interconnection of pipes,
including in-line components such as pipe fittings
and flanges. Pumps, heat exchanges, valves and
tanks are also considered part of piping system.
Piping systems are the arteries of our industrial
processes and the contribution of piping systems
are essential in an industrialized society.
Piping Material
The material to be used for pipe
manufacture must be chosen to suit
the operating conditions of the piping
system. Guidance of selecting the
correct material can be obtained from
standard piping codes. As an example,
the ASME Code for Pressure Piping
contains sections on Power Piping,
Industrial Gas and Air Piping, Refinery
and Oil Piping, and Refrigeration.
THE MOST COMMON POWER PLANT PIPES
Steel – Steel is the most frequently used material
for piping. Forged steel is extensively used for
fittings while cast steel is primarily used for
special applications. Pipe is manufactured in two
main categories – seamless and welded.
Cast Iron – Cast iron has a high resistance to
corrosion and to abrasion and is used for ash
handling systems, sewage lines and underground
water lines. It is, however, very brittle and is not
suitable for most power plant services. It is made
in different grades such as gray cast iron,
malleable cast iron and ductile cast iron.
Brass and Copper – Non-ferrous material
such as copper and copper alloys are used in
power plants in instrumentation and water Steel Cast Iron Copper and Brass
services where temperature is not a prime factor.
PIPE FITTINGS
A fitting is used in pipe systems to connect straight
pipe sections, adapt to different sizes or shapes
and for other purposes, such as regulating (or
measuring) fluid flow. Pipe Fittings (especially
uncommon types) require money, time, materials
and tools to install, and are an important part of
piping and plumbing systems. Valves are
technically fittings, but are usually discussed
separately.
Pipe Fittings
Elbows Nipples Couplings
for making angle turns in piping for making close connections. They are for connecting two pieces of pipe of the
threaded on both ends with the close same size in a straight line.
nipple threaded for its entire length.
Unions Bushings Y - Bends
for providing an easy method for for connecting pipes of different sizes. The for making branch line connections at 45º.
dismantling piping. male end fits into a coupling and the
smaller pipe is then screwed into the
female end. The smaller connection may
be tapped eccentrically to permit free
Return Bends drainage of water. Tees and Crosses
for reversing direction of a pipe run. for making branch line connections at 90º.
Plugs and Caps
for closing off open pipe ends or fittings.
Methods of Connecting Pipe
Screwed Connections
In this method, threads are cut on each end of
the pipe and screwed fittings such as unions,
couplings, and elbows are used to join the
lengths. This method is generally used for pipe
sizes less than 101.6 mm (4 inch) for low and
moderate pressures. It has the advantage that
the piping can be easily disassembled or
assembled. However, the threaded connections
are subject to leakage and the strength of the
pipe is reduced when threads are cut in the
pipe wall.
Methods of Connecting Pipe
Flanged Connections
This method uses flanges at the pipe ends
which are bolted together, face to face, usually
with a gasket between the two faces. Flanged
connections have the advantage over welded
connections of permitting disassembly and are
more convenient to assemble and disassemble
than the screwed connections. Gaskets are
usually used between flange faces. Gaskets are
made of a comparatively soft material which,
when the flanged connection is tightened, will
fill in any small depressions in the flange faces
and thus prevent leakage.
Methods of Connecting Pipe
Welded Connections
In this method, the pipe lengths are welded
directly to one another and directly to any
valves or fittings that may be required. The use
of these welded joints for piping has several
advantages over the use of screwed
connections or flanged connections and the
main disadvantage of using welded joints for
piping is the necessity of obtaining a skilled
welder whenever a connection is to be made.
Methods of Connecting Pipe
Piping Supports
Piping must be supported in such a way as to
prevent its weight from being carried by the
equipment to which it is attached.
Piping Drainage
In the case of steam piping, it is necessary to
constantly drain any condensate from the lines.
If this is not done then the condensate will be
carried along with the steam and may produce
water hammer and possibly rupture pipes or
fittings. In addition, the admission of moisture
carrying steam to turbines or engines is most
undesirable. Various devices are used to
remove this condensate and moisture from the
lines and these are discussed in the following
sections.
Steam Separators
Steam separators, sometimes called steam
purifiers are devices which, when installed in
the steam line, will remove moisture droplets
and other suspended impurities from the
steam. To do this, the separator either causes
the steam to suddenly change its direction of
flow or else it imparts a whirling motion to the
steam. Both of these causes the moisture and
other particles to be thrown out of the steam
stream.
Steam Traps
The purpose of the steam trap is to discharge
the water of condensation from steam lines,
separators and other equipment without
permitting steam to escape. In addition, most
traps are designed to discharge any air present
in the lines or equipment. Steam traps should
be installed in lines wherever condensate must
be drained as rapidly as it accumulates, and
wherever condensate must be recovered for
heating, for hot water needs, or for return to
boilers. They are a “must” for steam piping,
separators, and all steam heated or steam
operated equipment.
Piping Insulation
Most piping systems are used to convey
substances that are at temperatures much
higher than that of the surrounding air.
Examples would include the main steam piping
and feedwater piping. In order to reduce the
amount of heat lost to the surrounding air from
the hot substance, the piping is covered with
insulation. The insulation not only retains the
heat in the hot lines but also prevents the
temperature inside the process plant building
from becoming uncomfortably high. In
addition, insulation of hot pipe lines will
prevent injury to personnel due to contact with
the bare surfaces of the pipe.
In the case of piping which carries substances at a lower
temperature than that of the surrounding air, insulating
the piping will prevent sweating of the pipe and
consequent dripping and corrosion. Some of the more
common materials used for piping insulating are the
following :
➢ Diatomaceous Silica – This material is bonded with clay and asbestos and is used
for temperatures up to 1030ºC.
➢ Asbestos – Pipe covering sections are molded from asbestos fibre and are used
for temperatures up to 650ºC.
➢ Calcium Silicate –This insulation is made from silica and lime and is suitable for
temperatures up to 650ºC.
➢ Cellular Glass – This material is glass which has been melted and foamed and
then molded into pipe covering forms. It can be used for temperatures up to 430ºC
Some of the more common materials used for piping
insulating are the following :
➢Magnesia (85%) – This material is composed of magnesium carbonate with
asbestos fibre. It is available in molded form for pipe covering and also is supplied
in powdered form to be mixed with water to form an insulating cement which is
used to cover pipe fittings. Magnesia pipe covering is suitable for service up to
315ºC.
➢Glass Fibre – This is glass that has been processed into fibres and then formed
into pipe covering sections which are suitable for temperatures up to 190ºC.
➢Plastic Foams – These are plastics that have been processed into a foam during
manufacture and then formed into pipe covering sections. They are available for
temper atures as low as -170ºC and as high as 120ºC.
Industrial Plant Layout
Plant layout is the most effective
physical arrangement, either existing
or in plans of industrial facilities i.e.
arrangement of machines, processing
equipment and service departments
to achieve greatest coordination and
efficiency of 4 M’s (Men, Materials,
Machines and Methods) in a plant.
Industrial Plant Layout
Layout problems are fundamental to every type of organization/enterprise and are
experienced in all kinds of concerns/undertakings. The adequacy of layout affects the
efficiency of subsequent operations.
Following points should be considered in designing a layout:
➢ It should follow minimum material handling and minimum in process inventory.
➢ It should be designed such way that it should utilize space properly.
➢ It should provide employee safety and comfort.
➢ It should be flexible to change according to future product requirement.
➢ Minimize production time.
Types of Plant Layout
PRODUCT LAYOUT
In this layout all machines, equipment and work stations are arranged according to sequence of
operation of products and closer to each other. It is also called as Line Layout. In Product Layout Raw
Material is fed at one end and Finished Product is Came Out at another end from last workstation
Types of Plant Layout
PROCESS LAYOUT
In this layout, machines or equipment grouped and installed in one area, according to their function. For
example, lathes are installed in one area and grinding machines are grouped in one area. It also called
as functional Layout. In this layout, machines are not arranged according to the operation sequence of a
product. Product or products will move in between these work stations according to their operation
sequence. This will result in zig zag movement of material and higher material movement compared to
product layout.
Types of Plant Layout
COMBINATION LAYOUT
Combination layout is the combination of process layout and product layout. In this layout advantages
of both product and Process layout are obtained.
Types of Plant Layout
FIXED LAYOUT
In fixed Layout the Product is fixed or it remains Stationary at specific location and all Machines, Men
and Material is moved around it to manufacture it. We can follow this layout when the product is huge.
Layout by fixed position of the product is inherent in ship building, aircraft manufacture and big
pressure vessels fabrication. In other types of layouts discussed earlier, the product moves past
stationary production equipment, whereas in this case the reverse applies; men and equipment are
moved to the material, which remains at one place and the product is completed at that place where the
material lies.
Factors Influencing Industrial Plant Layout
➢ Man Factor – Safety & working conditions, skill levels, and number of
workers.
➢Material Factor - It includes the various input materials like raw materials, semi-finished
parts and materials in process scrap, finished products, packing materials, tools and other
services.
➢Machinery Factor - The operating machinery is also one of the most important
factors therefore all the information’s regarding equipment and the tools are
necessary for inspection, processing and maintenance etc.
Factors Influencing Industrial Plant Layout
➢ Movement Factor - A good layout should ensure short moves and should always tend
towards completion of product. It also includes interdepartmental movements and
material handling equipment.
➢ Waiting Factor - Whenever material or men is stopped, waiting occurs which costs
money. Waiting includes handling cost in waiting area, money tied up with idle material etc.
Waiting may occur at the receiving point, materials in process, between the operations etc.
➢ Service Factor - It includes the activities and facilities for personnel such as fire
protection, lighting, heating and ventilation etc. Services for material such as quality
control, production control, services for machinery such as repair and maintenance and
utilities liked power, fuel/gas and water supply etc.
THANK YOU
GENERAL PIPING
SYSTEMS AND LAYOUTS OF INDUSTRIAL PLANTS
