PIPING LAYOUT

PHILOSOPHY OF YARD PIPING

The main artery of an outdoor process plant is the pipe rack. Because the rack is located
in the mid of an outdoor plant, the pipe rack must be erected first. Hence the development
of structural drawing becomes on of the early requirements in a plant. To pass on the data
to the civil/ structural group, a civil scope drawing showing the width, the column spacing
and the design load is prepared. This load data should include, in addition to the dead
weight specified per running meter, the thermal and occasional loading the piping will
impart on to the structure. The latter will include forces and moments depending on the
type of support provided. The structural designer reinforces such bays on the pipe rack to
overcome these forces and moments. Hence, a proper planning is required in the initial stages
of design itself.
So, the first step in the development of pipe rack is the generation of a line - routing
diagram. A line- routing diagram is a schematic representation of all process and utilitypiping systems drawn on a copy of plot plan or it could be Plano metric representation of the
utility and process line diagrams. Although it disregards the exact locations, elevations or
interferences, it locate the most congested area.
The pipe rack splits the area into convenient parts. The pipe rack takes various shapes
such as straight, L, T, and C or U. This configuration is based on the overall arrangement
and site conditions. Based on the incoming/ outgoing lines and locations, this pipe rack is laid.
Normally pipe rack width is limited to 6M. If the width worked out thus is more, then the
arrangement to be done in multiple layers. The space requirement of equipment along with
the access below influences the width of the rack. The arrangement adopted are;
a) single column rack T type
b) Double column rack with a single tier
c) Double column rack with a double tier
Depending upon the type of plant the rack could be of steel, concrete or a combination of both.
The spacing between the bent/ column of the pipe rack is normally 5 to 6 meters. Wide
spacing is necessary at road crossings or where loading and access space are needed.
The headroom clearance also depends upon the type of crossings.
The yard piping can also run on the sleepers. These are made of concrete and are mainly
used to run large diameter piping such as cooling water piping. Another way to run the
yard piping is in open trenches with the arrangement same as that of a single tier rack.
The road crossing are done by culverts Water logging in the trenches and draining of the same
are major problems to be handled in this case.
The expansion of the rack should also be thought while planning. It is normal practice to add
additional tier on the top. To accomplish the same, the space above the column should be kept
free of piping or conduit.

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VALVES LOCATION
Accessibility to valves instruments should be the primary concern while arranging the same on the
piping. Process isolation valves should be readily accessible, the valve-stem centerline
being at an elevation of 1200-1500 mm from the operating level. If at elevated level, they can
have chain operators. Valves located at low or high locations can have extended stems to reach
the access aisles.
Battery limit isolation valves can be provided with access platforms, valves being located on either
side of the platform to economize spacing. The valves are staggered on either side of the
catwalk. When a pipe rack enters a unit, the elevation changes may be required.
Control valves are located at grade, at about 500 mm height to provide convenient access
for operation and maintenance. Block and bypass valves also form the same criteria.
Isolation valves for level gauges and pressure gauges shall be made accessible. Access
and space for the removal of level controllers to be provided. All primary and secondary
indicators of pressure, temperature, flow level, petitioners etc. should be visible from the operating
area.

ELECTRICAL / INSTRUMENT TRAYTS

The electrical and instrument cable tray/ duct location is coordinated in the design-planning phase
it self and integrated in the overall arrangement.
Space for these trays are provided above the piping on the pipe rack. Future provision for
these is also taken care of while designing the pipe rack. Where the requirement of pipe rack
does not exist, cable rack is provided separately as required. Specific locations are allotted,
including the type of support so that electric and instrument hardware and their support do not
interfere with the operation and maintenance access.

MISCELLANEOUS
Space requirement of HVAC ducting, where applicable, shall be integrated into the layout at the
stage of development. The equipment for these will be housed separately and should include in
the overall plot plan. The dimensional requirements of ladders, stairways, trenches, platforms etc.
are to be considered while making equipment arrangement and planning access to valves and
instruments.

Distillation Units
Basics
Let us analyze the equipment layout and piping design for a distillation column, which is more of
an integrated unit than the individual equipment discussed earlier.

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Interactions between hydraulic requirements and piping configurations require close attention to
many fluid and mechanical details, in order to obtain the most efficient and economical distillation
units.
The PFD of a typical distillation column with bottom pump, themosyphon reboiler, overhead
condenser, reflux drum are shown in Fig. 3.5.1. During the normal operation, the pump transports
the liquid in equilibrium. The arrangements should be such that the NPSH requirements of the
pumps are satisfied. The pump normally has dual service. The pump head requirements should
be selected to suit both services. The pump can also have both services. The pump can also
have simultaneous operations. All alternatives should be investigated while selecting the reflux
pump.
The reboiler circuit could be either pumped or themosyphon. The design of pumped reboiler
circuit is similar to that of reflux pump system. The bottom pump transports the liquid through a
heat exchanger and return to distillation column. The possible two phase flow in the possible after
heater should be studied.
The reboilers could be shell and tube type, vertical or horizontal to kettle type. In large diameter
towers inserted type U tube bundles inserted directly into liquid space though tower nozzles, are
also used. Helical coils inside tower also can be used for small duties

EQUIPMENT LAYOUT:
The equipment components are located adjacent to each other in a process plant. The
arrangement of principal elements to integrate into the overall plant layout is as shown in fig 3.5.2
The tower is located adjacent to the rack so that the lines can drop directly on to the rack
and can turn left or right. The plan view, (Fig.3.5.2.) of the tower shows the segment of the
tower along its circumference allotted to various utilities. Manhole faces the access roads or
access aisles in case of indoor layout. Platform is provided below each manhole at a
distance of 750-1000mm below the centerline. This will facilitate maintenance as well as
access to instruments and valves. From layout point of view, it is preferable to have equal plant
form spacing, and orientation of bracket lined up along with the entire length of the tower. This
will minimize the interference with piping.
Most reboilers are at grade next to tower with centerline elevations 1.5m to 2m above
ground. This is to facilitate tube bundle removal, maintenance access to valve and
instruments. In this arrangement the static head is well determined between the exchanger
centerline and drew off and return nozzles of the tower. Vertical reboilers are supported on the
distillation column or adjacent to it at the same elevation. The details of support on the
skirt or on adjacent to it at the same elevation. The details of support on the skirt or on
adjacent structure are worked out considering the temperature of operation. Some
reboilers have condensate or liquid holding pot located after the tube side outlet as shown. When
high capacity steam traps are provided, the top of the condenser pot should not be higher than
the bottom of the exchanger shell to avid flooding on the tubes with condensate adversely
affecting the performance of the exchanger. Process conditions determine the precise
relationship between the exchanger and the vertical condensate control pot as shown in Fig. 3.5.3
Fig. 3.5.4 shows the part P&I diagram for a kettle type reboiler. This arrangement in the reboiler
is elevated to meet the NPSH requirement of the centrifugal pump. The elevated reboiler in turn,

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raises the tower because the minimum liquid level in the bottom of the tower must be higher than
the liquid level in the heat exchanger. The elevation difference marked as H in the Figure
provides static head for flow in reboiler circuit and overcomes friction losses in the exchanger
down comer and return lines. The pumps are located below the rack as per the details indicated
in section for pumps.

PIPING LAYOUT
BASIS OF PIPING
BASIS OF UNIT PIPING

Piping & Instrument diagram (P&ID)

Equipment layout/ Unit plot plan
Equipment data sheet & setting plan
Line list
Instrument data sheet
Structural & building drawing

The segment used to locate the access down comer from the column is as indicated in Fig. 3.5.2.
the area segment of piping going to equipment at grade a available between ladders and on both
sides of manholes. For economy and easy support, piping should drop immediately upon
leaving the tower nozzle and ran parallel and as close to the tower possible. The insulation
thickness of tower and that of any possible flange on the tower as well as line should be
considered while decided the distance. The vertical line can be a suitable location for the straight
run for an office.
The horizontal elevations after the lines leave the vertical run are governed by the
elevations of the main pipe rack. The lines to run further on the rack can approach the rack at
a higher elevation considering the size of other horizontal lines and be placed on the top tier.
These can turn left or right depending on the plant overall arrangement. Lines running directly to
equipment at grade, more or less in the direction of pipe rack, often have the same elevation as
the pipe bank.
Lines from tower nozzles below the pipe rack should approach the pipe bank below the
rack elevation the same elevations is used for lines that run for pumps located below rack.

PUMP PIPING
Pump drains shall have the clear access for operation point. All small bore piping connected to
pump drain to OSW & CDH; seat and gland leak drain shall have provision for break up flanges
for removal of pumps.
The pump suction lines should be as short as possible and run without any loops or
pockets. The steam lines to reboiler are tapped from the top of the main header to avoid
excessive condensate drainage to process equipment. This line can run at the same elevation as
those lines approaching the rack from the tower.

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On distillation column the largest lines are the overhead vapor lines and reboiler down
comer and return. These lines should have simplest and most direct configurations to
minimize pressure loss and cost.
The prime considerations in all these cases are the performances to achieve the process
requirements integrated with economy.
Suction lines to pumps shall be designed for supports in a manner to avoid traps and
pockets.
Horizontal suction lines shall be designed to avoid pockets resulting from thermal expansion. To
avoid cavitations in horizontal centrifugal pumps of the double suction type, the suction line shall
be arranged so, that equal flow distribution to both impeller entrances is warranted.
Vertical lines may be connected to an elbow directly fitted to the suction nozzle, provided this
elbow is perpendicular to the pump shaft of double suction type.
The line diameter shall be provided immediately upstream the suction nozzle of the pumps of
double suction type.
Valves in pump suction lines shall be line size.
Reduction in valve size, if desired, shall be shown on the flow diagram / P&ID.
The discharge line from centrifugal or rotary pumps shall be provided with a check valve
between the pump and the block valve as per the P&ID.
For vertical discharge pumps, the check valve shall be located in the vertical line whenever
practical.
Suction and discharge lines of pumps shall be drained through drains located at the low
point of the pump casing whenever possible.
Gland and sealing oil systems and cooling water piping shall be furnished in accordance with the
pump manufacturers recommendations. Before start up of the unit, screens shall be provided at
the largest flange between the pump suction nozzles and the first valve in the suction line.
Strainers for centrifugal preferably shall be in line welded Y or T type with flanged
cleanout nozzle.
The piping design shall provide spools to permit easy screen removal without cutting the line.
As per good engineering practice minimums 3D straight length for small pump suction nozzle
shall be considered.
Eccentric reducers immediately connected to the pump suction shall be eccentric type flat
side up to avoid the accumulation of gas pocket.
Manhole shall be kept on the road side of the column and approachable from the platform.
Platform width shall be such that minimum 900mm space is available beyond manhole for
movement.

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Piping shall be supported from the cleats welded on the vessel as for as possible.
Pipe guide to be provided for long vertical lines at proper interval
Unless specifically indicated in P&ID control valve shall preferably be kept at grade instead
of platform.
Piping support cleat shall be designed for safety valves considering impact loading during
discharging.
Access platforms / ladders shall be provided along the column for valves and instruments.
Minimum width of the platform shall be 750mm clear area.
Maximum height of the platform ladder shall be restricted to 5-6 m.
For up to two, safety valves on column top platform, davit is adequate for more than two,
safety valves, monorail with chain pulley blocks shall be provided.
Piping intended for vacuum services shall be routed as short as possible with minimum bends and
flanged joints.
Minimum clearance for towers between the first stage platform and ground level shall be a
minimum of 2.5 M.

EXCHANGER PIPING
Exchanger piping shall not run in the way of built in or mobile handling facilities.
Piping around exchangers shall be arranged so that enough space is provided for operation of
valves and instruments and for walkway as well.
Wrench clearance to be provided at exchanger flanges.
Piping shall be arranged so that they do not hinder removal of shell end and channel cover
and withdrawal of tube bundle. Space for maintenance works, such as removal of channel
cover, shell cover and tube bundle shall be considered.

COMPRESSOR PIPING
Suction line shall be short as possible.
Suction line shall have adequate flanged for ease of erection and maintenances.
Locate the lube oil cooler to facilitated tube bundle removal.
All operating valves on main suction and discharge piping shall be lined on one side as far as
possible.
A minimum straight length is to be provided as per the requirements of manufacturer.

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Compressor suction lines between knockout drum and compressor shall be as short as
practicable & shall be with out pocket.
Where the line between knockout drum and compressor cannot be routed without pocket, low
point in compressor line shall be provided with drain to remove any possible accumulation of
liquid.

STEAM AND CONDENSATE PIPING

All piping shall be designed as per ASME B31.3
Steam system shall be supplied to the extent shown on the steam flow diagrams and shall
normally include systems for the distribution of steam required for process operations, service
steam and steam tracing.
All branch connections from steam headers shall be taken off the top of the header.
Single block valves shall be provided in branches adjacent to the headers, to the extent shown in
the steam P&I diagrams.
Single block and check valves shall be provided adjacent to the point of injection of steam
into any process stream.
Steam relief valves shall discharge to atmosphere through discharge piping extending at
least 3m (10) above any platform or working area within 8m radius of the point of
discharge.
The low point of the relief valve outlet piping shall be provided with a 10mm (3/8)
minimum weep hole when discharging to the atmosphere may have to be piped to a safe
location where ever is necessary.
All steam lines shall be designed to avoid unnecessary traps.
Where traps cannot be avoided, steam traps with drains shall be designed into the piping to
remove condensate.
Process steam traps, which discharge to a low pressure condensate system shall generally be
provided with bypass requirements. However, block valves shall provide upstream and
downstream if trap discharges to a condensate system.
Before each process steam trap inlet, a drain valve (free blow) shall be installed in direction of
flow.
Traps inside battery units shall generally discharge to a condensate return system or sewer.
Outside battery limit, the trap shall discharge to a suitable location, such as ditch or as defined on
the P&I diagrams.
Steam traps discharging into a closed system shall be provided with a check valve unless the trap
is provided with an integral check valve.

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Steam traps discharging into a closed system shall be provided with a check valve unless the trap
is provided with an integral check valve.
Steam traps on steam mains or equipment shall be protected by a build-in strainer.
Steam tracing shall be provided in accordance with engineering specification Piping Steam
Tracing Specification.

UTILITY STATION
General Remarks
Fluids:
For maintenance and repair works, utility stations are to be installed within the plant.
The utility stations are connected with following fluids:
LP-Steam
Nitrogen
Utility Air/ Plant Air
Adequate clearance as per stress analysis to be provided for very long & high temperature
lines to avoid clashing at the bends.
Expansion loops for all line shall generally be kept at the same location. Vent shall be
provided at high point & drains to be provided at low points.
Drain valves shall be suitably located for ease of operation.

FLARE PIPING
Flare header shall be sloped as per P&ID towards flare knockout drum. Only horizontal
loops shall be provided as per requirement to accommodate thermal expansion. The
desired slope shall be ensured throughout including flat loop. Flare headers shall be
supported on shoe.
Flare piping to offsite shall be provided with guide on all around the pipe to prevent it falling
off from the flare trestles.

LINED PIPING
All lined piping shall be flanged with minimum spool length maintained as per the
manufacturers recommended length.
Necessary air pin holes shall be provided in the piping to release any entrapped gases.
All lined pipes branches shall be of flanged type fittings. Use of reducing flanges shall be
avoided.
Thickness of liner to suit the service conditions, all branch connections uses tees or
reducing tees to regular sizes only.

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UNDERGROUND PIPING
Under ground piping generally consists of the following services.
a) Cooling water Supply / return.
b) Process waste water system.
c) Sewer in unit area.
d) Potable water
e) Fire Water
f) Service Water

Location of Utility Stations

The utility stations are to be installed in such a position that area to be served within a reach
of 15m hose length.
The utility connection shall be grouped together as much as possible in the same sequence
namely N2, Air, Steam & Water.

Valves
All connections of utility are furnished with valves acc. to the relevant pipe class. P&ID
valves size shall be NPS 3/4.
Hose couplings have to be supplied separately acc. to purchaser specifications. Different
designs to hose coupling have to be used for each fluid.

Arrangement of utility station at steel columns

Utility stations are to be fitted preferably at pipe rack columns. In this case, the pipe routing
has to be performed acc. to the APPENDIX B.

Eye wash & shower

Eye wash and shower stations shall be installed at location conveniently accessible in case
of emergency. Water shall be tapped from DW system.

GENERAL ARRANGEMENT
All piping shall be routed for the shortest practical run and have minimum number of fittings
consistent with provision for expansion and flexibility.

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All lines inside battery limits, except acid and caustic lines and lines with pulsating
flow, shall preferably be run side by side on overhead pipe supports.
Lines that cannot be run overhead shall be run on sleepers.
Lines outside battery limits and all acid and caustic lines and lines with pulsating flow
shall preferably be laid on sleepers.
Large thin-walled lines in non-flammable service, such as cooling water lines, shall be
buried and continuously supported on sand cushions and suitably coated and
wrapped.
Piping insulated for hot service shall not be supported directly on structural steel
sections and shall be provided with pipe shoes with the bottom of the pipe minimum
100mm (4) above the top of supporting steel.
All lines, insulated or uninsulated, with operating temperatures of 121C (250F) and
over, which run on concrete members shall be provided with

REQUIREMENTS FOR PROCESS PIPING SYSTEMS

Sample connections and sample coolers shall be supplied to the extent shown on the P&I
diagrams.
All connections for sampling may normally be .
For pipe in a horizontal or inclined plane, the sample connection shall be located at the side
of the pipe unless otherwise indicated on the P&I diagrams.
Piping for pumping out towers and equipment shall be provided to the extent shown on the
P&I diagrams.
Such piping shall be a part of the regular process piping of the unit and shall be designed
with minimum possible additional piping not regularly required for normal startup and
operation of the units.
Relief valves shall be connected to a flare or other disposal system only when so
indicated on the applicable P&I diagrams.
Relief valves shall have a minimum of piping between the protected line or equipment and
the valve inlet.
The low point of the outlet piping when discharging to atmosphere shall be provided with a
10mm (3/8) minimum weep hole.

JOINTS AND CONNECTIONS

Jointing and all piping systems 2 and larger pipe size shall preferably be accomplished by
butt welding.
Jointing in piping 1 and smaller shall be accomplished by socket welding, butt welding or
threaded connections.

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Generally, flanged connections shall be used at connections to vessels and equipment

unless governed by P&ID and piping specification requirements.
Steel flanges used for the attachment to flat-faced cast iron flanges shall be flat faced.

BRANCH CONNECTIONS
Welded pipe-to-pipe connections shall be designed so that the angle of intersection between
the branch and the run shall not be less than 45.
The types of branch connections permitted are listed in the Piping Material Specification and
Piping Material Classifications.

VENTS AND DRAINS

In general, venting and draining shall be accomplished through vessel and / or equipment
connections.
Vessel vents and drains may be located in overhead or bottom piping provided that
no valves or blinds are located between vent or drain connections and vessels.
High-point vents on liquid lines should be valved. On gas lines the vent points may
be plugged / capped.
Low-point drains of all pipe lines should be valved.
Process vents and drains will be as per P&IDs.
Drains emptying into open receptacles shall terminate 50mm (2) above the top of the drain
receptacle and the discharge shall be visible from the location of the drain valve.
Unless otherwise noted on piping drawings or P&I diagrams, the minimum size of vent
and drain connection shall be .
The minimum vent and drain connection sizes for vessels shall be in accordance with
equipment data sheets.

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