PIPING DESIGN ENGINEERING

COURSE DURATION:

4.0 Months [Part Time Batch]

2.0 Months [Full Time Batch]

COURSE ELIGIBILITY:

B. Tech / B.E in Mechanical/Chemical Engineering .
Diploma in Mechanical/ Chemical Engineering.
M .Tech / M.E in Mechanical/ Chemical Engineering.

[Module A] Piping Systems Detailed Engineering /Plant & Piping Layout Engineering / Piping Drafting.

Module 1 - Piping Fundamentals

• Introduction to Process Plants.

• Difference between Code and Standards.

• Scope of Piping in Projects.

• Plant Piping Systems and Transportation Pipelines.

• Definition & Application of Pipe. Difference between pipes and tubes.

• Pipe Designators – NPS , IPS , NB, Pipe Wall Thickness & Schedule, Pipe Weights, Lengths, Grades, Ends, Joining Methods, Methods of Manufacture, Pipe Ratings, Pipe Symbols.

• ASTM Specifications of pipes.

Module 2 -  Pipe Fittings – ASME Standards, Selection, Application, Drawing Symbols & Dimensioning.

• Types of Fittings – Butt Weld, Screwed & Socket Weld.

• Elbow – 90 degree (LR & SR), 45 degree, Reducing Ell, Elbow Representations on drawings, different views, drawing call outs.

• Pipe Bends – Miter Bends, Miter types, Miter angle determination, Miter stress requirements, 180 degree Return, Representations on drawings.

• Branch Connections – Weld Straight & Reducing Tee, Cross & Lateral. Representations on drawings, drawing call outs.

• Reducers – Concentric & Eccentric, Reducer Offsets Representations on drawings, Drawing call outs.

• Eccentric reducer applications, offset calculation.

• Stub Ends, Stub end types: Long, Short, Class A, Class B Representations on drawings, Application of Stub Ends.

• Fabricated Branch Connections – Stub In & Stub On, Representations on drawings, Welding Minimums for Stub In.

• Branch Reinforcements – Reinforcing Pad, Welding Saddle, Representations on drawings, Drawing call outs.

• O let Fittings – Weldolets, Sockolets, Threadolets, Latrolets, Elbolets & Sweepolets, Nipolet, Flangolet Representations on drawings.

• Types of Couplings: Full coupling, Reducing coupling, Half coupling, Representations on drawings, Drawing call outs.

• Weld Cap, Plug, Representations on drawings, Drawing call outs.

• Fitting Makeup – Dimensioning, Placement of Dimensions.

• Minimum Pipe length requirements.

• Screwed & Socket Weld Fittings – Union, Plug, Coupling, Types of couplings, coupling applications. Types of Swages, Swage end configurations. Swage applications.

• Classes of Screwed & Socket Weld Fittings

• Dimensioning Exercises

Module 3 -  Pipe Flanges – ASME Standards, Symbols, Selection & Application.

• Definition of Flange.

• Types of Flanges and Application, P-T. Ratings. – Forged Steel and Cast Iron Flanges.

• Flange Facings – Flat Face, Raised Face, RTJ, & Male - Female, Tongue & Groove. Flange Face Finish types, application.

• Weld Neck, Slip On, Threaded, Socket Weld, Lap-Joint, Reducing, Blind & Orifice Flanges.

• Flange considerations by a Piping Engineer and by Code. Bolt hole requirements. Bolts & Nuts types.

• Gaskets – Types, Thickness, selection requirements

• Flange selection exercise.

• Dimensioning Exercises.

Module 4 -  Valves – ASME/API Standards, Symbols, Selection & Application.

• Definition.

• Valve Functions, P-T Ratings, Difference in Valve and flange Ratings, Valve Tag numbers, Locations & End Connections.

• Valve Types – Gate, Globe, Ball, Check, Butterfly, Angle, PRV/PSV, Plug, Control Valve, Diaphragm, Needle, Piston, Flush bottom, 3-Way, 4-Way, etc.

• Control Valve Manifold: Types, Function, Layout types, Representation & Requirements on flow Diagrams and Layouts.

• Valve Operators.

• Valve Data Sheet preparation and understanding.

• Valve Trim. 

• Valve Selection.

• Valve Layout Considerations.

• Dimensioning Exercises.

Module 5 -  ASME Codes & Standards

• Introduction to ASME Pressure Piping Design Codes.

• ASME Standards for Common Piping Elements.

• API Codes.

• Other Codes & Standards.

Module 6 - Piping Special Elements.

• Strainers

• Bellows/Expansion Joints.

• Rupture Disc.

• Spectacle Blind.

• Blanks.

• Spacers.

• Steam Traps.

• Flame Arrestor.

• Vortex Breaker.

Module 7 -  Process Mechanical Equipments – API Standards, Symbols, & Application.

• Static – Horizontal Vessels, Distillation columns, Storage Tanks, Heat Exchanger & Re boiler, Fired Heaters, Reactors, Cooling Towers.

• Rotary – Pumps, Compressor, Fans.

• Vessel trim.

Module 8 - Flow Diagrams.

• Block flow Diagrams-BFD,

• Process Flow Diagram – PFD.

• Utility Flow Diagram- UFD,

• Piping & Instrumentation Diagram – P & ID.

• Line Numbering,

• Line Number requirements,

• Piping Tracing (Jacket Piping ,Steam/Electric tracing).

• P& ID Requirements,

• Line Designation table/ Line list creation from P & ID.

• Print Reading Exercise,

• Flow Diagram Exercises,

• Symbols & Abbreviations.

• Equipment vendor data/PDS,

• Instrument Types & Symbols – Flow, Temp, Pressure & Level.

• Instrument Hook-up Drawing

Module 9 -  Piping Material Specification (PMS)/ Piping class

• PMS and its requirements,

• Piping Specifications / Material Selection / P-T ratings / Valve Data / Branch table / Abbreviation details.

• PMS Application/Use by various departments. 

Module 10 -  Plot Plan, Equipment Layout, & Piping GA Drawings.

• Plot Plan Development & Requirements.

• Layout Terminology & call outs,

• Control Point & Plant north, Battery Limits.

• Equipment Layout: Types, Guidelines for preparation based on type,

• Guidelines for Building layout types.

• Piping GA Drawing Requirements and Layout Procedure.

• Pipe routing requirements

• Pump GA Drawing and Layout Consideration.

• Tank & Vessel Layout Consideration.

• GA - Print Reading Exercise.

• Inputs (Drawings/Documents) for piping G A drawings.

Module 11 - Piping Isometrics

• Isometric requirements

• Drawing Piping Isometrics

• Isometric Dimensions, Notes & Callouts.

• Isometric Offsets.

• Print Reading Exercises.

• Exercises on Creation of Isometrics form Piping Plans and Sections.

• Inputs (Drawings/Documents) for piping Isometric drawings.

Module 12 - Piping Spools

• Definition

• Types of Spool Drawings.

• Guidelines to Prepare Spool Drawings.

• Print Reading Exercises.

• Exercises on Creation of Piping Spool from Piping Isometrics.

• MTO (Material Take Off): Types, and applications.

Module 13 - Pipe Supports

• Classification of Supports.

• Primary supports

• Secondary supports

• Rest supports

• Anchor supports

• Standard supports

• Standard support details required

• Non Standard supports/Special pipe supports(SPS)

• SPS requirements.

• Anchors.

• Pipe Guides.

• Limit Stops.

• Pipe Shoe.

• Shoe Guides / Hold down guides,

• Dummy Leg / Trunion.

• Field Support / Base Support.

• Rigid Hangers – Rod & Clevis, Trapeze.

• Pick up supports,

• Flexible/Spring supports – Variable & Constant.

• Control valve manifold supports.

• Piping support Engineer work procedure.

• Pipe Rack Design – Types, Height & Width Calculations, Pipe Arrangements.

• Control Station & Utility Station on Pipe Racks. 

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[Module B] Pipe Stress Analysis - Add-on Learning Module

Module 1 -  Introduction to Objectives & Definition of Stress Analysis

• Piping Loads – Primary, Secondary, Sustained Loads, Occasional Loads, Static & Dynamic Loads.

• Piping Stresses- Primary, Secondary.

• Stresses acting in Pipe due to internal Pressure.

• Stresses acting in Pipe due to pipe weight.

• Critical Line List & its criteria.

• Information Required for Stress Analysis.

• Occasional Loads

• Wind Load.

• Seismic Load.

• Water Hammer Load.

• Theories of Failure.

• Requirements of ASME B 31.3 Code – Sustained Loads, Thermal Expansion & Occasional Loads.

Module 2 - Pipe Span Calculations

• Span limitations based on Stress, Deflection & Natural Frequency.

• Allowable Pipe Span Calculations.

• Suggested Pipe Support Spacing.

• Pipe Span Reduction Factor for Elbows, Concentrated Loads etc.

Module 3 -  Flexibility Analysis – Expansion Loops & Expansion Joints.

• Concept of Thermal Expansion.

• Providing Flexibility in Piping.

• Minimum Leg Required to Absorb Thermal Expansion.

• Stress Nomographs for Pump and Vessel Piping.

• Types of Expansion Loops.

• Expansion Loop Sizing for Hot Piping.

• Expansion Loops requirements on pipe racks.

• Nozzle Thermal Growth Calculations – pumps, vessels, heat exchangers.

• Expansion Joints – Types, Application & Selection.

• Bellow Materials, Hydrostatic Test Pressure for Bellows.

• Guide Spacing for Expansion Joints.

• Severe Cyclic Conditions.

Module 4 -  Layout Solutions for Weight, Thermal, Vibration & Wind Loads.

• Causes of Pipe Stress.

• Solving Concentrated Loads and Reducing Loads on Equipment Nozzles.

• Checking Piping Layout in Pipe Racks.

• Checking Piping Layout for Reciprocating Equipment.

• Checking Piping Layout for Wind Load.

• Solutions for piping loads.

• Selection of Supports, Location of Supports and Restraints on a Pump Piping Layout.

Module 5 -  Flexibility Analysis using ASME B 31.3 Code Equations.

• Thermal Expansion Stress – Se, Code Allowable Thermal Displacement Stress Range Sa.

• Stress Range Reduction Factors – f.

• Bending & Torsion Stress.

• Formal Analysis Requirements.

• Inplane & Outplane Bending Moments

• Stress Intensification Factors – SIF.

• Calculation of Thermal Expansion Stress

• Cold Spring.            

[Module C] Pipe Stress Analysis Software

• Introduction.

• Piping Input Spreadsheet.

• Modelling of Piping Isometrics – Bends, Returns, Reducers, Valves, Loops etc.

• Performing Static Analysis.

• Load case explanations

• Modifying Load Cases.

• Hanger Selection.

• Set up of SUS, OPE, EXP, HYD, HGR Load cases.

• Set up of Wind Load cases.

• Set up of Uniform Load cases.

• Load Case Editor.

• Evaluating API 610 Pump Nozzle Loads.