The following shall be considered in piping lay out around the Loading and Unloading Areas

1. Category of loading and unloading facilities

a. Loading and Unloading Facilities for Marine Transportation

a1. Loading and Unloading Facilities at Buoyed Moorings: These facilities are used for loading or unloading of crude oil from large sized tankers moored offshore, through piping installed on the sea bed

a2. Loading and Unloading Facilities on Stationary Jetty: These facilities are used for loading or unloading of oil from a tanker directly moored to a berth constructed offshore, through the use of loading arm or hose

b. Loading and Unloading Facilities for Railway Transportation

-These facilities are used for loading tank carriages through the use of loading arm or hose and used for transportation to an area where pipelines, etc. are not available

c. Loading and Unloading Facilities for Road Transportation

-These facilities are also used for loading the tank lorries by the use of loading arm or hose and used for transporting small amount of products

2. Arrangement

-The general arrangement of the major equipment to be provided within the respective facilities based on the general plot plan

3. Piping Plan

a. Piping Classification

-Piping Classification is dependent on the facilities involved
-Understanding offsite piping concepts
-Understanding items to note in piping planning
-Determine arrangement and configuration

b. Piping Route

Piping routes shall be planned with consideration given to the following items:

-Loading Facility for Marine Transportation
-Loading and Unloading Facilities for Railway and Road Transportation

General matters related to piping arrangement are described in the following:

1. Piping Plan

a. Routing

Basically, yard piping is desirable to be assembled in one area on sleepers, for economic efficiency, safety, ease of construction, operability, and maintenance and inspection, and to be planned in the shortest possible route by also preventing pies from crossing each other. Following are the general notes with respect to the routing

-Yard piping shall have its routing laid out along the oil dikes or roads as much as possible
-An overall routing plan shall be made in consideration of spacing for electrical instrumentation ducts, trenches and fire fighting piping, etc.
-Piping other than those connected to tanks shall not have its routing pass through the area surrounded by oil dikes
-Routing shall be planned by keeping the road crossing areas as least as possible
-Pump suction lines shall be routed to minimize pressure drop caused by piping configuration
-Lines having process requirements (requirements for the gravity flow and slope of lines such as for flare, blow-down, and condensate) shall be planned at a higher priority
-A minimum distance of 0.5 m shall be secured from the dike or the fence to the  support or the piping

b. Support Planning

-Types of support: Sleeper type, Rack type
-It shall be determined by considering the following items: Width, Spacing, Elevation and Locations of supports for guide and stopper

2. Detailed Arrangement

a.Type of Yard Piping: Process Piping, Drain Oil, Off-Gas Piping, Utility Piping and Others
b.Arrangement:

-Piping arrangement shall be planned by grouping process and utilitiy respectively
-Small diameter piping shall be arranged in one area to allow easier support
-Electrical and instrumentation ducts shall be arranged at the end of supports to allow easier check and maintenance
-When horizontal loop is required in gravity flow piping such as flare, condensate lines, etc., such piping shall be arranged at the end of supports

c. Others:

The following shall be considered in Detailed Arrangement

-Road Crossing, Drain Piping, Piping at Sloped Site, Measures to Thermal Expansion, Walkway Plan and Piping Support

Study of piping lay out around the Heater

The piping around heaters are consist of the following:

1. Types of Heaters

a.Typical Heater Types

-Vertical, Cylindrical Type
-Cabin Type (Horizontal Tube Arrangement)
-Box Type (Vertical Tube Arrangement)

b. Typical Burner Types and Arrangements

-Gas Burner
-Oil Burner
-Oil-Gas Burner

Generally, burners are located on the floor and on the side wall (end or side burner).

2. Layout

-Since heaters will handle flames, a sufficient safe distance must be provided between each heater and equipment designed to handle flammable fluids
-The collocation of heaters and related equipment (to which the heater outlet piping is to be connected) shall be determined after measures against thermal stress and vibration are reviewed
-As heaters play a major role in their process units and their accident may directly lead to plant shut-down in many cases, it is desired that they would be located in areas where their operation can be monitored at all times
-Space for the maintenance of the heating tubes shall be provided

3. Structure Planning

-Check the dimensions, locations and elevations of the platforms. Make necessary additions, if any
-Check the types and locations of ladders and stairways and make additions if necessary
-Determine the pipe supports which can be designed better as a part of the heater structure than as a part of the piping

4. Piping Plan

1. Process Piping

-Heater Inlet Piping
-Heater Outlet Piping

2. Utility Piping

a. Fuel Piping

-Fuel Oil Supply Piping
-Fuel Oil Return Piping
-Fuel Gas Piping
-Pilot Gas Piping
-Atomizing Steam Piping

b. Snuffing Steam Piping
c. Decoking Piping
d. Soot blower Piping
e. Steam Generation Piping

-Heater Inlet Piping
-Heater Outlet Piping

5. Design Work Flow

-Advance Check
-Preparation of General Piping Arrangement
-Preparation of detailed Piping Arrangement
-Preparation of Auxiliary Piping Arrangement

a. STEP 1

-Checking the required documents
-Understanding the contents of basic documents
-Checking of Heater itself and relevant items

b. STEP 2

-Preparation of conceptual routing drawing
-Studying for the necessity of operation platform and pipe support
-Studying of basic piping plan

c. STEP 3

-Preparation of Process Piping Arrangement
-Preparation of Utility Piping Arrangement
-Preparation of Decoking Piping Arrangement
-Support Plan

Piping BM and BQ estimation

1.What is Piping Bill of Materials (BM)?

-Is the total list of material that will be used for procurement purposes
-The list consist of the following items:

a.Piping Bulk Materials (pipes, fittings, etc.)
b.Special Piping Materials (strainer, expansion joints, etc.)

2.What is Piping Bill of Quantity (BQ)?

-Is the total list of piping material and inch-diameter (ID) that will be used for piping construction purposes.
-It pertains to the data that indicates the volume of piping construction work

Note:  Inch-diameter (ID) is equal to pipe nominal size x number of welding area

The items to be studied are as follows:

1. Layout

-As the furnace handles direct fire, a safety distance should be maintained between this furnace and equipment handling flammable liquid.
-The interrelated layout between the furnace and equipment (equipment to which the furnace outlet piping is connected) should be decided after studying measures against the thermal expansion and vibration of the piping.
-A space should be secured for the maintenance work of heater coils.
-Care should be taken to arrange the furnace upwind of the average wind direction. Then, the furnace should not be arranged to avoid the suction of light hydrocarbon.
-If a duct is connected to the centralized stack, the layout of the furnace and the duct should be studied after discussions with a furnace engineer in charge.

2. Piping arrangement

Piping around the furnace is as follows:

a. Process piping

-Furnace inlet piping
-Furnace outlet piping

b. Utility piping: Piping associated with fuel

-Fuel oil feed piping
-Fuel oil return piping
-Fuel oil gas piping
-Pilot gas
-Atomizing steam piping

c. Snuffing steam piping

d. Soot blower piping

e. Decoking piping

3. Piping detailed arrangement

1. Furnace inlet and outlet piping

-It is necessary to make piping symmetrical to allow the flow rate of each outlet and inlet piping to be uniform.
-The symmetrical piping is arranged to allow the configurations of lines to be quite the same, symmetrical and also to permit the same and symmetrical shapes to be mixed, to make the flow rate of each branch to be constant, if one line is branched into a number of lines.
-Piping arrangement considering thermal expansion and vibration

4. Utility piping

Fuel piping, snuffing steam piping and steam piping for the soot blower are installed as the utility piping around the furnace.

-Fuel piping

Basically, it is necessary plan the piping arrangement considering the operability of burners, valves, etc.

-Burner piping: Piping around the gas burner, oil burner. The burner line must not cross a sightglass, etc., and must not interfere with the open and close of the window glass.
-The piping should be arranged to allow the valve to be close to the sightglass, in order to operate this valve while monitoring the combustion condition of the burner.
-The valve for the pilot burner (the first valve from the burner nozzle) should be installed near the burner to facilitate the ignition operation of the pilot burner.
-Piping detailed arrangement around Snuffing steam piping, Soot blower piping and Decoking piping

5. Support plan

-The supports should have enough rigidity to withstand vibration, and should be structures independent from the furnace considering the frame strength of the furnace proper.
-The construction of the supports should be planned considering the installation points and orientation of the oil damper, friction-proofing device and spring-type vibrationproofing, as vibration-proofing supports.

The following studies are conducted in the planning to establish piping around compressor

1. Layout

a. Layout philosophy

-The compressor should be laid out to minimize the pressure loss of the system on the suction side.
-The compressor should be laid out to facilitate maintenance work.
-As electrical and instrumentation cables are used for the compressor, this compressor should be laid out close to the control room and substation.

b. Basic layout

-A number of electric and instrumentation cables are used for the compressor. Also, the distance between this compressor and the control room/substation
should be as close as possible, in consideration of the operation of the compressor in case of an emergency.
-In particular, care should be taken to prevent the compressor and other items of equipment, building, etc. from coming closer, and each foundation from combining, in order to avoid the transmission and effect of the vibration from the compressor.
-Basically, sleeper piping should be adopted and the area for this piping should be secured, to provide measures for piping vibration-proofing.

c. Sleeper

-A compressor suction line and a discharge line are liable to suffer vibration. Therefore, these lines are arranged on the sleeper to facilitate the fixing of these lines.
-The layout of sleepers should be studied to prevent vibration from directly transmitting the surrounding building, structure and equipment. The sleeper should be as close to the compressor as possible, considering the vibration of piping between the sleeper and compressor (a long line is liable to suffer vibration).

d. Installation height

The items to be studied in determining the installation height are as follows:

-The distance between the drain piping and operating floor level for the compressor snubber should be 150mm or larger.
-The compressor should be installed at such a height that a pocket portion should not be produced in the process piping between the sleeper and compressor.

2. Piping arrangement

a. General items

-As piping handles gaseous liquid, a free drain line should be adopted to prevent the accumulation of gas condensate in the line. If a drain pocket should be produced in the piping system, measures should be provided to allow drain to be completely drawn off.
-The route of each line should be shortest. However, compressor outlet piping and steam piping connected to the turbine driver should be flexible enough not to cause a problem due to thermal expansion (effect on equipment nozzle).
-The valves, instruments, etc. of the piping connected to the compressor should be installed to facilitate the operation of the switch-off operation of the
compressor.
-Piping supports should preferably be provided on the ground to facilitate vibration measures. Therefore, lines should be arranged on the sleeper as far as possible.
-If trench piping is adopted around the compressor, studies should be done on whether or not gas (especially propane gas which is heavier than air) accumulate within the trench and involves risk.
-The piping route should be planned not to hinder the compressor operation and maintenance.

b. Detailed piping arrangement

After piping engineers understand the line flow, satisfy process requirements and know which line requires measures against vibration and thermal stress, in advance, they should arrange lines in detail and plan piping supports.

b1. Nozzle orientation

-As in the case of other rotary machinery, the installation point of each nozzle is automatically fixed from type and constructional viewpoints. Therefore, the manufacturer fixes the nozzle orientation, unless otherwise instructed.

b2. Suction piping

-Piping arrangement on the sleeper facilitates the installation of supports from the ground, which becomes advantageous for vibration-proofing measures. Also, the installation point of valves, instruments, etc. is not high, and these items can be operated from the access way for inspection, thereby allowing the
economic design of the structure. This arrangement method is generally more used. In this method, the gas liquid handled does not condense with steam trace heating.
-Valve layout: A suction valve is operated in connection with the operation of the startup and shutdown of the compressor. It is therefore preferable to lay out the valve as close to the compressor as possible.
-Strainer: Fine mesh screens are generally used for the suction-line strainers in the process compressor during the initial startup operation. Also, it is preferable to install the strainer as close to the compressor nozzle as possible.

b3. Discharge piping

The discharge-piping route should be planned after studying the following items, bearing in mind the concurrent action of piping vibration due to liquid pulsation and piping stress due to piping thermal expansion arising from compressed heat.

-Piping arrangement aiming mainly at vibration-proofing. Unless there is no problem in the access, it is preferable to install ground piping (support) in view of vibration-proofing measure.
-Valve layout: The basic valve layout of the discharge line should be as in the case of the foregoing “Layout of Suction Valves”.

3. Support Plan

In order to satisfy these two contradictory conditions, support measures must be provided by fully considering these conditions. Piping supports must basically be planned, designed and selected according to the following pertinent standards. The following covers the considerations, etc. of layout and installation of support types (typical) for vibrating lines around the compressor.

a. Support type

-The types of supports can be identified by the difference in the hardware to be fixed to the top surface of the foundation. The major objective of the sleeper around the compressor is to arrange lines in a group, as in the case of normal sleepers.
-Vibration-proofing supports are used as supports used exclusively for vibration proofing of piping, which vibrates along with thermal expansion.

b. Support installation clearance

The proper supporting clearance of supports is determined based on the vibration analysis results of the piping system.

c. Considerations in support installation

• U-bolts should not be used as far as possible. Instead, U-bands or straps should be used. (As U-bolts are in linear contact with the pipe in the axial direction,
satisfactory constraint cannot be expected. Therefore, U-bolts should not used for large vibration load lines.).
-Vibration-proofing supports of bolting construction should be of double-nut types.
-If piping supports are installed directly from buildings, etc., the vibration of buildings, etc. should be studied.

The following shall be considered in piping arrangement around Air Fin Cooler (AFC)

1. Arrangement

a. Determination of Arrangement

-Air-fin cooler shall principally be installed near related equipment
-Space shall be secured between column or structure
-Layout for stairs, ladder, etc. to access air-fin cooler shall be studied confirming to customer’s specification at the planning of Plot Plan

b. Determination of Installation

-Air-fin cooler installation height shall be determined by adding the minimum (shortest) height between the air-fin cooler and the receiver to the receiver

installation height.
-When located on pipe rack, installation height shall be determined considering above mentioned, height and number of stages of pipe rack

2. Structure Planning

-The legs of air-fin cooler shall be aligned as much as possible, to the columns of the structure.
-For air-fin coolers plugging there tubes, the use of mobile crane shall be considered.
-For piping support, principally support shall independently be attached to the structure.
-Platform planning for maintenance

3. Piping Plan

-Plan for Manifold

a. Types of manifold

-U-type
-MU-type
-T-type

b. Selection of Manifold

-Piping Plan

4. Design Work Flow

-Advance Check
-Preparation of Conceptual Drawing
-Preparation of Piping Arrangement
-Preparation of Auxiliary Piping Arrangement of Air Fin Cooler such as drain/vent

a. STEP 1

-Checking the required documents
-Understanding the contents of basic documents
-Checking of Air Fin Cooler itself and relevant items

b. STEP 2

-Preparation of conceptual routing drawing
-Studying for the necessity of operation platform and pipe support
-Studying of basic piping plan

c. STEP 3

-Planning of AFC positioning
-Planning for Steel Structure
-Preparation for detailed piping arrangement

Piping Arrangement Around Tank

1.Types of Tank

a.Cylindrical tanks

-Fixed roof tanks
-Floating roof tanks
-Floating roof tanks with fixed roof

b.Spherical tanks

c.Tank Farm Divisions

-Crude tank area
-Intermediated product tank area
-Product tank area

2.Strength analysis considerations:

-Expansion and contraction
-Tank nozzle displacement
-Tank displacement
-Piping flotation

3.Tanks-Dikes-Sleepers-Pumps considerations:

-Pits required to discharge rain water and oily drain water from the dikes shall be located at the corners of the dikes.
-The elevation of pumps shall be determined not to have the pump suction nozzle raised above the suction nozzle of the tank.

4.Piping Layout

-Determination of Piping Route
-Process piping should not cross any other pipes if possible.
-Formation of vent pockets
-Piping from and to the tanks should run through the shortest routes.
-A minimum distance of 500mm shall be secured between the dike and pipe support.
-Tank block valves shall be provided with platforms which can also be used as a walkway
-Valves shall be arranged by aligning the flange surfaces
-Space between two crossing pipes shall be  at least 300 mm.
-Valve accessories should be considered in determining spaces between closely arranged valves
-Attention shall be paid to the following on the area where platform is necessary

Piping Arrangement Around Column

1.Data gathering

-Check necessary information
-Check/grasp contents of the basic information
-General specification
-Material specification
-Standard drawing
-Reference material
-P & ID
-Line index
-Plot plan

2.Assumption of platform position (Attention shall be paid to the following on the area where platform is necessary)

-Location, Elevation and Size
-Determine the installation height by checking the items required for the process
-Describe the elevation by preparing drawing of each nozzle and manhole

a.Jobs that are performed on the platform

-Reading the meters
-Collecting samples
-Opening and closing the valves
-Access to manholes during maintenance

b.Platform elevation

-Space between platforms shall be 8 meters maximum and 2.1 meters minimum
-Height of lowest platform shall be a minimum of 3 meters from the floor

c.Size of platform

-Space for passing shall be considered
-When manhole is located at the top of the column,a platform that goes all the way shall be installed.
-Shall have no problem in valve handle and its operability and accessibility
-Shall provide working space for installing and removing safety valve

d.Access and piping area

-In general, nozzles for manholes/ instruments and platforms shall be arranged at access area

3.Study of nozzle orientation (Basic considerations)

-Process requirements
-Operability
-Maintainability
-Cost

a.Size of platform

-Width shall be normally set as follows
-Rectangular platform-1000mm
-Platform with manhole-1500mm

b.Platform at the top of column

-A platform that goes all the way shall be installed
-Space given for path shall be a minimum of 600 mm

4.Piping arrangement (main piping)

-Must meet process requirements
-Determination of Piping Route
-Route of each line shall be as short as possible
-Consideration shall also be given to appearance.In some cases,each pipe is arranged individually or by group
-Installation of Piping Support
-Adjustment with the Result of Strength analysis
-Operable and safe