Process Plant Layout And Piping System Design

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PIPING SYSTEM DESIGN II – PROCESS PLANT LAYOUT AND PIPING SYSTEM DESIGN Presented By Alireza Niakani

REBIS ACADEMY OF TECHNOLOGY We are a top-level Canadian Engineering Training Center in Toronto. We offers more than 300 career-focused training courses form introductory to advanced in the key areas of engineering including Petroleum Engineering, Chemical Engineering, Piping Engineering, Instrumentation & Control Engineering, Mechanical Engineering, Electrical Engineering, Civil & Structural Engineering, Inspection & Maintenance Engineering, Safety Engineering and Project Management. Our training programs and courses are useful to university or college graduates, entry-level engineers, technologists or technicians, designers and drafters, experienced engineers and managers, who are willing to work in engineering consulting firms, construction and operation, technical support and sales companies in the different industrial sectors, including oil, gas and petrochemical companies, chemical and pharmaceutical plants, power, gas, water and waste water utilities, pulp and paper mills, food & beverage processors, mining, metals and minerals companies. We are constantly in touch with employers and strives to ensure that our training materials are consistent with what are required in the marketplace. Our training programs and courses either help universities’ graduates to be more marketable and competitive in the workforce or experienced engineers to update their professional skills to be as productive as possible in their work competitive environment. Our training programs and courses are delivered by instructors who have the knowledge and experience to understand your challenges, ensuring content is relevant, up to date and practice wherever possible and are highly respected professionals in their fields from all over the globe.

We are dedicated to preparing you to succeed in the global marketplace and business world. We are sure, you will leave REBIS ACADEMY with the knowledge and skills that employers want. 1

RESPONSIBILITIES OFPIPING GROUP • An Equipment Arrangement Drawing, usually termed the Plot Plan • Piping Design (Drawing or Model) • Piping Stress Analysis and Supporting • Piping Details for Design, Fabrication and Construction • Requisitions for Purchase of Piping Material

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ELECTRICAL

CLIENT

SAFTY

MATERIAL

INSTRUMENTS

PROCESS

PIPING  DESIGN MECHANICAL

INSPECTION CIVIL / STRUCTURAL REBIS ACADEMY Engineering and Management Solutions

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PROJECT DESIGN DATA •

Project Design Data-Is supplied by client or project engineering

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Vendor Data- Equipments and Special items

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Internally Generated Engineering Data

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PLANT LAYOUT AND PIPING DEPT. JOB FUNCTIONS • Plant Layout Eng. • Piping Design Eng. • Stress Analysis and Support Eng. • Material Eng.

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PLANT LAYOUT & PIPING DESIGNER PRINCIPLE FUNCTIONS • Development of Process Unit Plot Plan • Setting all Equipment Locations • Designing all Structures and Positioning the Associated Stairways and Ladders • Establishing all Equipment nozzle Locations • Locating all Safety Items

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PLANT LAYOUT & PIPING DESIGNER PRINCIPLE FUNCTIONS CONT. • Routing the above and below grade piping system • Isometrics Preparation • General Arrangement or Piping plan Preparation

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PLANT LAYOUT & PIPING DESIGNER SKILLS • Knowledge of what a particular plant is designed to. • Knowledge of Plant Process • A general understanding of how process equipment is maintained and operated. • The ability to generate a safe, comprehensive layout

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PLANT LAYOUT & PIPING DESIGNER SKILLS • Creativity • Knowledge of Flexibility and Support Basics • General Knowledge of Piping material • Knowledge of the principle roles of other design and engineering group

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MATERIAL ENGINEER PRINCIPLE FUNCTIONS • Develop the project piping classes for all process and utility services. • Write specifications for fabrication, shop and field testing, insulation, and painting. • Create and maintain all data sheets for process and utility valves. • Create a list of piping specials, such as hoses and hose couplings, steam traps, interlocks. REBIS ACADEMY Engineering and Management Solutions

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MATERIAL ENGINEER PRINCIPLE FUNCTIONS CONT. • Assemble a piping material requisition with all additional documents. • Review offers from vendors and create a technical bid evaluation. • Make a technical recommendation. • After placement of a purchase order, review and approve documentation from vendors related to piping components. • P&ID Mechanization and Line List prep. REBIS ACADEMY Engineering and Management Solutions

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MATERIAL ENGINEER SKILLS • Knowledge of what a particular plant is designed to. • Knowledge of Plant Process • Knowledge of the principle roles of other design and engineering group • Knowledge of Piping materials and Components Standards

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MATERIAL ENGINEER SKILLS • Knowledge of Corrosion characteristics of piping materials • Knowledge of welding processes necessary for fabrication of piping systems

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STRESS AND SUPPORT ENGINEER PRINCIPLE FUNCTIONS • Providing a Standard Specification and Drawings for Supports • Allocation pipe supports • Providing a specification stress Analysis • Creating a critical Line list • Checking the flexibility Level of piping Systems

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STRESS AND SUPPORT ENGINEER PRINCIPLE FUNCTIONS • Create and maintain all data sheets for Special Type of Supports such as Spring Hangers, Struts, … • Assemble a support material requisition with all additional documents. • Nozzle Load Calculation • Structural Load calculation

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Input: Project Scope, PFD, Client  Spec., Preliminary Size for Equip.  and Buildings

1St Design issue of P&IDs, Piping Spec. Preliminary Steel and Foundation Sizes, Instrument  sketches, Vendor Outline Dwgs. and equipments  Engineering Dwg. Input: Final Certified Vendor  Dwg.

Input: Preliminary PFD

Activity

Time/Phase

Conceptual Plot Plan Preliminary Plot Plan Major Lines Piping Study Minor Lines Piping Study Vendor Incorporation Isometrics Extraction

Conceptual Phase

•Detailed Equip. Locations,  •Structure Designs  Including All major piping Loads •Vessels Nozzles, Platform & Ladder Locations

Basic or Study phase

Detail Design

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Input: PFD, Stream Cod. List, Draft  P&ID from Process

1St Design issue of P&IDs, Piping Spec. Vendor Outline Dwgs. and equipments Engineering  Dwg. Input: Piping Studies, Vendor Offers,  Vendor Drawings,….

Input: Stream Condition List

Activity

Time/Phase

Piping Material Spec. P&ID Mechanization First MTO Material Requisition Prep. Second MTO Creating List and Data sheets Creating Specifications

Basic or Study phase •Piping Material Spec. (PMS),  •Special Item list, First MTO, •LDI Material Requisition, •Specifications for Fabrication and Installation •Line List

Detail Design

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1St Design issue of P&IDs, Piping Spec., Line List  Input: Stream Condition list, Client  Code and regulations, Process  Desc., …

Activity

Input: Piping Studies, Vendor Offers,  Vendor Drawings,….

Time/Phase

Stress Analysis Spec. Critical Line list Standard Supports Drawings Preliminary Analysis &Load Calculation (Major St.) Supports Alloc. Stress Analysis Special Supports Datasheet and DWG. MR. for Special supports and BULK Material Basic or Study phase REBIS ACADEMY Engineering and Management Solutions

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TERMINOLOGY • Maintenance • Operation • Safety • Cost-Effective • Constructability

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MAINTENANCE

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MAINTENANCE & OPERATION 70° 60° 50° 40° 30° 20° 10°

Elevation of 90° 80° center handwheel

prefered area

acceptable area for small valves

Valve stem vertical

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2000 for small valves 1900 hazardous 1800 area for headroom 1700 should be avoided 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100

prefered area

acceptable area

for small valves

Valve stem horicontal 21

MAINTENANCE & OPERATION

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MAINTENANCE & OPERATION

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SAFETY

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CONSTRUCTABILITY

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PLAN VIEW LAYOUT

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ELEVATION VIEW LAYOUT

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DIAGONAL PIPING RUN

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VALVE MANIFOLDS & USE OF FITTINGS

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SPACE USE

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PIPE RACK DESIGN (PIPE LOCATIONS) • Largest and Heaviest Lines to the OUTSIDE • Group Steam and Condensate Lines on TOP LEVEL • Small Bore Utility and Instrument Lines TOP LEVEL • Branches from Gas or Vapor Header from TOP • Branches from Liquid Header from BOTTOM • Short Distance process Lines LOWER Level • Long Distance process Lines MID/UPPER LEVEL • Group Lines of Cold Insulation Far from Hot Lines REBIS ACADEMY Engineering and Management Solutions

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PIPE RACK DESIGN

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PIPE RACK DESIGN (FLARE HEADER) • Flare line should be SLOPED in Direction of Knockout Drum • Locate Flare Header at the EDGE to accommodate any Flat Expansion Loops • Connection to Flare Header must be from TOP, Connections can be LATERALLY AT 45

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PIPE RACK DESIGN

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PIPE RACK DESIGN (PIPING FLEXIBILITY) • Lines of Extreme temp. HOT or COLD which travel Long Distance should be Checked for FLEXIBILITY • All branch lines that join to the header on Pipe Rack should be checked for adequate FLEXIBILITY • Line Spacing should be checked for expansion clearance at change of Direction Connections

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PIPE RACK DESIGN

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PIPE RACK DESIGN (BATTERY LIMITS)

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PIPE RACK DESIGN (BATTERY LIMITS)

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PIPE SPACING • Edge to edge space between to adjacent surface of pipe must be minimum 25 mm • Spacing must be increased to damp Lateral Movement due to Expansion • Consideration to be given to linear where pipe line changes direction • A clearance of 150 mm should be maintained between the edge of insulation and the edge of orifice piping • A clearance of at least 50 mm should be maintained between the edge of insulation and the edge of structure REBIS ACADEMY Engineering and Management Solutions

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PIPE SPACING

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PUMPS

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PUMPS TERMINOLOGY • Allowable Nozzle Load • Net Positive Suction head • Vapor Pressure • Available Net positive Suction Head • Cavitations

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NPSH REQUIREMENTS

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TYPES OF PUMPS • Centrifugal Pumps

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TYPES OF PUMPS • Positive Displacement Pumps

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TYPES OF PUMPS • Rotary Pumps

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TYPES OF PUMPS • Rotary Pumps

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PUMP LOCATIONS

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PUMP LOCATIONS

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PUMP LOCATIONS, Cont.

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PUMP DISCHARGE LOCATION

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PUMP PIPING

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TYPICAL TYPE OF STRAINERS

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PUMPS PIPING CONSIDERATIONS • Ensure that rear of the pump does not restrict access requirements • Ensure that maximum projection from pumps does not restrict minimum operating aisle. • Ensure that minimum clearance has been provided • Keep length of run and Number of fitting in suction line Minimum • The running of pipe over the motor is acceptable if the line is high enough for lifting equipment access REBIS ACADEMY Engineering and Management Solutions

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END SUCTION-TOP DISCHARGE

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END SUCTION-TOP DISCHARGE (ABOVE 8”)

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TOP SUCTION-DISCHARGE

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NOTE

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NOTE

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SIDE SUCTION-DISCHARGE

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NOTE

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THREE PUMP PIPING

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THREE PUMP PIPING (ABOVE 8”)

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HORIZONTAL VESSELS PIPING CONSIDERATIONS •

Elevation of Lower platform to be established for access to instruments and Man-ways

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Elevation of top platform to be approx. 150mm below face of all nozzles serviced from platform

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Bottom invert elevation of vessel to be fixed NPSH pump

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Platform required at man-way if centerline of drum is above 3m

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Minimum dimension above grade to be 450 mm B.O.P or insulation

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Relief valve discharge to be high enough to allow line to enter top of the flare

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VESSEL PIPING

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HORIZENTAL VESSEL PIPING

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HORIZENTAL VESSEL PIPING

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VERTICAL VESSELS PIPING CONSIDERATIONS • Use Minimum Headroom Elevation when vessel elevation is not governed by pump NPSH • Where possible, link platform to the adjacent Eq. platform or Structure • Proffered location for Manhole access platform El. is 900mm below man-hole centerline. • Pipe support should be located a minimum distance from the nozzle. • Provide a clearance of 150 mm from weld of elbow to the top of support REBIS ACADEMY Engineering and Management Solutions

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VERTICAL VESSELS PIPING CONSIDERATIONS • Guides may be located at 25 OD apart. • Lowest guide to be a minimum 25 OD above the lowest elbow • Safety Valve to Atmosphere: To be located at first platform under top manhole for good supporting of outlet pipe. • PSV outlet to the atmosphere should be a minimum 3000 mm above highest platform in vicinity of 8000mm. • Safety Valve to Closed System: To be located at a convenient platform above flare header. REBIS ACADEMY Engineering and Management Solutions

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VESSEL PIPING

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VESSEL PIPING

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VESSEL PIPING

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EXCHANGERS • Type of Heat Exchangers • Exchanger Locations and Support • Exchanger Piping • Exchanger Maintenance

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EXCHANGERS • Cooler • Exchanger • Reboiler • Heater • Condenser • Chiller

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TYPE OF HEAT EXCHANGERS • Shell and Tube Exchangers • Plate Exchangers • Spiral Exchangers • Double Pipe Exchangers • Air Cooler Exchangers

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SHELL AND TUBE EXCHANGERS

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SHELL AND TUBE EXCHANGERS

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PLATE EXCHANGERS

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SPIRAL EXCHANGERS

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DOUBLE PIPE EXCHANGERS

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AIR COOLER EXCHANGERS

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AIR COOLER EXCHANGERS • Forced – Draft Type

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AIR COOLER EXCHANGERS • Induced – Draft Type

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EXCHANGER LOCATIONS AND SUPPORT • Economic pipe Rune • Flexibility • Process Requirements • Operator and maintenance Access

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HORIZONTAL SHELL-TUBE EXCHANGERS LOCATION

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HORIZONTAL SHELL-TUBE EXCHANGERS LOCATION

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HORIZONTAL SHELL-TUBE EXCHANGERS LOCATION

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HORIZONTAL SHELL-TUBE EXCHANGERS LOCATION

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HORIZONTAL SHELL-TUBE EXCHANGERS SUPPORT

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VERTICAL SHELL-TUBE EXCHANGERS TOWER SUPPORTED

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VERTICAL SHELL-TUBE EXCHANGERS TOWER SUPPORTED

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SPIRAL EXCHANGERS LOCATION

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PLATE EXCHANGERS LOCATION

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COLUMN SUPPORTED AIR COOLER ARRANGEMENT

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LEG SUPPORTED AIR COOLER ARRANGEMENT

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FIXED PLATFORM AIR COOLER ARRANGEMENT

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TRAVELING PLATFORM AIR COOLER ARRANGEMENT

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT • Piping is Elevated a minimum distance from grade or platform to operator headroom, to offer ease of support, and to meet designated pipe rack elev. • The free space at the side of horizontal shells can be used for placement of controls. • 150 mm is the minimum clearance to allow any part of control valve and the piece of equipment including the foundation or insulation • Breakout flange are normally required on line that are routed over removable parts of equipments. REBIS ACADEMY Engineering and Management Solutions

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT • Small PSV is located between the inlet and outlet valves to protect the exchanger in case both valves accidentally closed, it should be piped locally to grade. • It must be considered that a medium that gets heated up should enter into the bottom and leave the top. • It must be considered that a medium that gets cooled down should enter into the top and leave at the bottom. • Large-diameter or more expensive piping can not be set to accommodate smaller or less expensive piping REBIS ACADEMY Engineering and Management Solutions

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT • Use 300 mm long filler added above valve to allow for adding miter cuts to match the misalignment between nozzle and underground connection • If a davit is fitted to the exchanger for removing the head ,piping must be routed well clear of its operating circle. • If Exchanger is located on the structure, Locate the piping beneath the platform for ease of support. REBIS ACADEMY Engineering and Management Solutions

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT

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SHELL AND TUBE EXCHANGERS PIPING ARRANGEMENT

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SPIRAL AND PLATE EXCHANGERS PIPING ARRANGEMENT • Piping is positioned to allow the opening of covers for spiral exchangers, and removal of plate for plate exchangers. • Controls at the spiral exchanger are located on the end of unit, clear of the cover plate swing area, and at the front and on one side for the plate exchangers. • Piping attached to the cover plate nozzles of the spiral unit is furnished with break flange. REBIS ACADEMY Engineering and Management Solutions

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SPIRAL EXCHANGERS PIPING ARRANGEMENT

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PLATE EXCHANGERS PIPING ARRANGEMENT

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EXCHANGERS MAINTENANCE

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EXCHANGERS MAINTENANCE

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EXCHANGERS MAINTENANCE

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EXCHANGERS MAINTENANCE

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EXCHANGERS MAINTENANCE

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EXCHANGERS MAINTENANCE

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SESSION SUMMARY

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QUESTIONS AND FEEDBACK

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