Main Equipment, System in Crude Oil and Product Pipelines

Schemes1.How schemes are conceived & formed 2.What are P& IDs and How are they formed 3.How Lay outs are formed 4.What Piping Area Diagrams and how are they prepared5.Tender and AFC drawings 6.CCOE drawings

Relevant codes and standards•ASME 31.4•OISD 118•OISD 117•OISD 141•Electrical Standards

Station Equipments – Mechanical, Electrical and T&I

Overall Project Activities

Execution / Monitoring Group

PMS 3

Costing Estimation

PMS 4

Detailed Engineering

PMS 4HR

Estimation

PMS 5DFR / Final

scheme transmission

Corporate Optimization Group Project Requirements

Options Scheme

PMS 1

Exploring Options

PMS 2

Scheme Development

Options

Scheme

Scheme

Past Project Reference Data base

Cost Estimation

HR Database

Engineering Details

CostingHR Estimate

Approval

Past P.O reference/B.O

Standard Spec. Database

COGPMS 1.1

Route Selection

PMS 1.2

Pipe Grade & Size Selection

PMS 1.4

Power requirement calculation

PMS 1.6

Compilation of data for each option

PMS 1.5

Instruction & Control

Selection

PMS 2

Pj Requirement

Route details

Land profile data soil survey

Pop. data

Govt. records

Pipe data specification

Engg. files

Power tariff & availability

Electrical database

Equipment details

PMS 1.3

Equipment Selection

Scheme Development

Controlrequirements

Options

FACILITIES

Pump Station Facilities•Pumping •Receipt•Delivery•Storage

•Scrapper Launch/Receipt•Surge tank/Others

•OWS•Fuel storage

•Metering•Controls•Electrical

•Instrumentation•Communication

•Switch Yard

MOTHER PUMP STATION WITH TANK FARM

Sl. No.

Equipment Applicable Code Remarks

1. Storage tanks API standard 650

2. Booster Pumping Units ANSI/API Standard 610

3. Crude Oil Blender

4. Basket Strainer BODY: ASME section VIIIWelding: ASME section IXFlanges: ANSI B 16.5 & MSS-SP-44Gasket: API 601

5. Mainline Pumping Units ANSI/API Standard 610

6. Scraper Launching Barrel BODY: ASME section VIIIQOC: BS EN 10222Flanges: ANSI B 16.5 & MSS-SP-44Gasket: API 601

7. Different Valves- Gate, Swing Check, Control etc.

API 6D, API 600/602, BS 1868, BS 1873

Main Equipments

MOTHER PUMP STATION WITH TANK FARMSl. No.


1. OWS

2. Sump Tank & Sump Pump

3. Drag Reducer

4. TRVs API standard 520, 526, 527ASME section VIII

Auxiliaries:

Fire Fighting Facilities:Sl. No.


1. Fire water pond/tank

2. Fire Fighting Pump & Jockey Pump

3. Fixed Foam Protection SystemC d DG

INTERMEDIATE PUMP STATION WITH TANK FARM

Sl. No.


1. Storage tanks API standard 650



4. Scraper Launching/Receiving Barrel

BODY: ASME section VIIIQOC: BS EN 10222Flanges: ANSI B 16.5 & MSS-SP-44Gasket: API 601

5. Different Valves- Gate, Swing Check, Control etc.

API 6D, API 600/602, BS 1868, BS 1873

Main Equipments

INTERMEDIATE PUMP STATION WITH TANK FARMSl. No.


1. OWS


3. Drag Reducer


Auxiliaries:





3. Fixed Foam Protection System

4 Compressors and DG

INTERMEDIATE PUMP STATION

Sl. No.




3. Scraper Launching/Receiving Barrel

BODY: ASME section VIIIQOC: BS EN 10222Flanges: ANSI B 16.5 & MSS-SP-44Gasket: API 601

4. Different Valves- Gate, Swing Check, etc.

API 6D, API 600/602, BS 1868

Main Equipments

INTERMEDIATE PUMP STATION

Sl. No.


1. OWS


3. Drag Reducer


Auxiliaries:





3. Compressors and DG

DELIVERY STATION

Sl. No.



2. Scraper Receiving Barrel BODY: ASME section VIIIQOC: BS EN 10222Flanges: ANSI B 16.5 & MSS-SP-44Gasket: API 601

3. Different Valves- Gate, Swing Check, etc.

API 6D, API 600/602, BS 1868

Main Equipments

DELIVERY STATION

Sl. No.


1. OWS


3. Drag Reducer


Auxiliaries:

Fire Fighting Facilities: Fire Water Network Hooked up with Refinery Fire water Network.

FACILITIES / EQUIPMENTS

TANK FARM

INTERMEDIATE PUMPING STATION

SCRAPPER STATION

STORAGE TANKS √ √ X

BOOSTER PUMPS √ XGENERATOR √ √ XCOMPRESSOR √ √ XMAINLINE PUMPS √ √ X

SCRAPPER BARREL √ √ √

SUMP TANK √ √ √

SUMP PUMP √ √ X

FACILITIES

FACILITIES / EQUIPMENTS

TANK FARM

INTERMEDIATE PUMPING

STATION

SCRAPPER STATION

FIRE PUMPS √ √ XFUEL TANK √ √ XFUEL UNLOADING PUMP √ √ XWATER SOFTENING PLANT

√ √ X

BASKET STRAINER √ √ X

TURBINE METER √ √ X

CONTROL VALVE √ √

FACILITIES

Induction Training - CTMPL IndianOil Pipelines 19/30

INSTRUMENTATION & CONTROL SYSTEM

A system of measuring process parameters, sensing status, logical decision making based on such analog / digital inputs, activation of corresponding controls in the process loop based on such logical decisions, initiating audible / visible alarms and providing a continuous, consistent, real time, accurate process feedback to the operator vide suitable MMI.

Induction Training - CTMPL IndianOil Pipelines 20/30


To ensure that the process runs in a safe, economical, efficient manner strictly in adherence to the operational philosophy by providing an easy, convenient and error free interface for the operator to monitor, maintain and record the process

IndianOil Pipelines 21/30


By measuring various parameters / physical states online and storing them w.r.to time to enable decision making / activation of various controls

Induction Training -C

TMP

LIndianO

ilPipelines

22/30

Process parameters

PressureIndicators (Bourdon type Gauges)Transmitters (LCR Bridge Transducer)

TemperatureIndicators (Bourdon type Gauges)Transmitters (Pt100 RTDs)


TMP

LIndianO

ilPipelines

23/30

DensityTransducer (Frequency sensors)

FlowThermally activated switches Turbine Flow Meters

LevelMagnetic float switchesRadar Tank Gauges

Process parameters

FILTERATION

TONEXT STATION

BOOSTERPUMPS

TANKFARM METERING

DENSITY MEAS.

METER PROVER

MA

NIF

OLD

SUMPTANK &

PUMP

MAINLINEPUMPS

FCV

S L B

MANIFOLD

BLOCK VALVES

S L B

S R B

FROM PREV. STN

SUMPTANK &

PUMP

DENSITY MEAS.

METERING

FCV

FILTERATIONTANKFARM

MA

NIFO

LD

S R VALVE


TMP

LIndianO

ilPipelines

26/30

SCADA

SCADA SOFTWARE

APPLICATION SOFTWARELEAK DETECTION & LOCATION WITH DRA MODULELINE / PRODUCT BALANCE (FLOW MEASUREMENT)METER PROVINGBATCH TRACKINGPIG TRACKINGOVER/UNDER PRESSURE PROTECTIONPREDICTIVE MODELPIPELINE EFFICIENCYOPERATOR TRAINER/PLANT SIMULATION SOFTWAREC.P. PERFORMANCEAUTOMATIC LOOK AHEADINSTRUMENT ANALYSIS

Design Considerations •Station Discharge Head•Rated Flow•Velocity of flow in the line •Piping Selection•Equipment Rating•Tankage Requirement •Effluent treatment•Fire & Safety Requirement•Offsite Facilities •Allied Facilities

Piping and Instrument Diagram

INTRODUCTION

Piping and Instrument Diagrams The P & I diagram (Engineering Line Diagram) allows the design to progress from the "Process Flow Sheet / System and Piping diagram" to the final system design and installation stage.

The P&ID are definitive and comprehensive diagrams showing all of the equipment, piping, valves and instrumentation. All items to be identified using a standard numbering systems.

This normally entails having a unique plant item number for eachitem of equipment, valve, instrument and line.

Ideally the line number should include a size, material and fluid contents identifier to enable the anyone reading the drawing to obtain this information without having to refer to other documents.

INTRODUCTION

An Engineering line should include

Mechanical equipment with names and numbers

Instruments with identification and necessary interfaces with

control loops

Interconnecting piping, sizes and identification

Valves with identifications

Vents, drains, special fittings, sampling lines, reducers and

increasers

Flow directions

Interface tags to other ELD's

Control interfaces, inputs and outputs.

Main plant interlocks.

Identification of symbols used

Reference list including identification of relevant PFD's

INTRODUCTION

The symbols used to be in accordance with identified standards and should clearly indicate the type of component, the method of connection (screwed, flanged etc) and and the status (Valves - Normally Closed, Normally Open). The method of operating equipment items should be clearly identified (electric motor, pneumatic actuator). It is not generally necessary to identify services and electrical supplies to the operators.

INTRODUCTION

P&I Diagrams includeProcess Flow Diagram

All equipments connected with piping

All pipe sizes and grades

All valves and sizes like Hand / Motor Operated Valves

All pipe fittings and flanges except LR bends

Two dimensional

All instrumentation

INTRODUCTION

P&I Diagrams exclude

X Piping Route

X Civil Facilities like buildings etc

X Co-ordinates for various facilities

X Distances between facilities

X Isometric Plant View

X Pipe Elevation

Codes & Standards being followed

Sl. No

Standard Description Usage

01 ANSI B31.4 Pipeline Transportation System for Liquid Hydrocarbons and other liquids

To Establish Requirement for safe Design

02 OISD 118 Layouts for Oil & Gas Installation

F/F Facility

03 OISD 117 Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline Installations and Lube Oil Installations

F/F Facility

04 API 5L Specification for Line Pipes M/L Pipe

05 ASTM A106 Gr.B

Station Pipes

06 ASTM A53 Gr.B

Station Pipes

07 IS 3589 Station Pipes

Sl. No

Standard Description Usages

08 API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

MLPU, BPU

09 API 650 Welded Steel Tanks for Oil Storage

Tanks

10 BS 5355 Reciprocating Internal Combustion Engines

Engines

11 API 6D Pipeline Transportation System -Pipeline Valves

Valves

12 API 600 Gate Valves

13 BS 1868 Swing Check Valves

Sl. No

Std. Description Usages

14 Design – ASME Section VIII,QOC- BS EN 10222Door Closure – BS PD 5500

Barrels

15 Design – ASME Section VIII Div-I Sump Tank

16 Material- ASTM A 234 WPB, MSS SP 75 WPHY 52,65Dimension- ANSI 16.25, MSS SP75Inspection – ANSI B16.9, MSS SP 75

Fittings

17 Material- ASTM A 105, Mfg/Dimension- ANSI B16. 5, MSS SP 44, API 605

Flanges

18 OWS19 API 1589, API 1581 Separator Filter

Elements20 Material- ASTM A 216 WCB,

Design- ANSI B16 104, ANSI B 16.5, Control Valves

Sl. No


21 API STANDARD 1104

Welding of Pipeline and related Facilities

Welding

22 Pump Design: IS 5120Engine Testing: BS 5514

Fire Fighting Pumping Units

23 Design – ASME Section VIII Div-I Insulating Coupling

24 API Standard 601

Metallic Gasket for Raised-Face Pipe Flanges and Flanged Connections (Double-Jacketed Corrugated and spiral-wound)

Gaskets

25 API Standard 526

Flanged Steel Pressure Relief valves

Relief Valves

26 ANSI/API Standard 602

Steel Gate, Globe and Check Valves for sizes DN 100 and smaller for the petroleum and Natural gas Industries

27 API Standard 2510

Design and Construction of LPG installations

Sl. No


28 OISD-STANDARD-214

Cross Country LPG Pipelines

29 ASME B 31.8-2003

Gas Transmission and Distribution Piping System

30 API standard 520, 526, 527ASME section VIII

TRVs

31 BS 1873 Globe Valves

FIRE PROTECTION SYSTEM FOR LIQUID LINE

Following fire protection system/ facilities shall be considered for all the liquid hydrocarbon lines as per OISD-141.Detection SystemFire Alarm SystemFire ExtinguishersFire Water System

a. Fire water storageb. Fire water Pumpsc. Fire water distribution piping networkd. Fire hydrant / Monitors

FIRE PROTECTION SYSTEM FOR LIQUID LINE

HOSES, NOZZLES AND ACCESSORIES AND SPARES

First Aid and Safety Equipment:

Windsock

Emergency Power supply

Communication System

Emergency Response Plan (ERP) / Disaster Management Plan (

DMP)

NOMENCLATURE

NOMENCLATUREA) LINE :- THE LINE NUMBER GIVES THE SIZE, LINE NUMBER

AND RATING AS FOLLOWS :

SIZE OF PIPE – P – LINE NUMBER – RATING

EXAMPLE

20” – P – 2033 – 31

LINE RATING

LINE NUMBER

LINE SIZE

NOMENCLATURE

B) FULL BORE VALVE :- THE VALVE NUMBER GIVES SIZE OF VALVE, STATION AND VALVE RATING AS FOLLOWS :

SIZE OF VALVE – STATION – VALVE RATING

EXAMPLE

24” – IMP – 20VALVE RATING

STATION

VALVE SIZE

NOMENCLATURE

C) REDUCED BORE VALVE :- THE VALVE NUMBER GIVES SIZE OF VALVE-FLANGE, SIZE OF VALVE BORE, NAME OF STATION AND VALVE RATING AS FOLLOWS :-

SIZE OF VALVE FLANGE X SIZE OF VALVE BORE – STATION –VALVE RATING

EXAMPLE

24” x 20” – IMP – 20

STATION

VALVE BORE SIZE

VALVE FLANGE SIZE

VALVE RATING

RATINGSRATING WORKING PRESSURE150 SR 275 PSI300 SR 720 PSI400 SR 960 PSI600 SR 1440 PSI800 SR 2160 PSI900 SR 2160 PSI1500 SR 3600 PSI

ANSI CODE RATING150 11300 21400 31600 41800 51900 61

LINE SPECIFICATION NUMBERS

VALVE RATINGS – GATE / BALL VALVE

ANSI CODE END CODE RATING150 W/W 1A300 W/W 2A400 W/W 3A600 W/W 4A800 W/W 5A900 W/W 6A


ANSI CODE END CODE RATING

150 W/F 01

300 W/F 02

400 W/F 03

600 W/F 04

800 W/F 05

900 W/F 06


ANSI CODE END CODE RATING150 F/F 00300 F/F 10400 F/F 20600 F/F 30800 F/F 40900 F/F 50

VALVE RATINGS – ALL CLEAR / NORMAL SWING CHECK VALVE


150 W/W 05

300 W/W 15

400 W/W 25

600 W/W 35

800 W/W 45

900 W/W 55



150 W/F 01

300 W/F 02

400 W/F 03

600 W/F 04

800 W/F 05

900 W/F 06



150 F/F 09

300 F/F 19

400 F/F 29

600 F/F 39

800 F/F 49

900 F/F 59

PIPING LEGEND

DIFFERENT GRADES SPECIFIED BY API 5L STANDARD

Grade Yield Strength (PSI)

Ultimate Tensile Strength (PSI)

A25 25000 45000 A 30000 48000 B 35000 60000

X42 42000 60000 X46 46000 63000 X52 52000 66000 X-56 56000 70000 X60 60000 75000 X65 65000 77000 X70 70000 82000 X80 80000 90600

YS/ UTS > 0.93

History

Upto X56 Developed upto 1960

X60 - X70 Developed in 1970s

X80 Developed in 1980s but commercially produced in India recently.

X90 to X120 are now also developed in the last twenty years but not in commercial use till date in India.

DIFFERENT GRADES SPECIFIED BY API 5L STANDARD

STANDARD LENGTH OF PIPES

Nominal Length

Minimum Avg. Length Max. Length

6 M 5.33 M 6.86 M 12 M 10.67 M 13.72 M 15 M 13.35 M 16.76 M 18 M 16.00 M 19.81 M 24 M 21.84 M 25.91 M

6 M length are termed as single random lengths.

12 M lengths are termed as double random lengths.

Based on pipe to pipe joints pipe ends are specified as

Beveled Ends Pipe to pipe/ fitting joints are butt welded

Plain Ends Pipe to pipe/ fitting joints are fillet welded

Screwed Ends For threaded connections

Flanged Ends For bolted connection

Spigot/ Socket Ends Cemented joints

END CONFIGURATION OF PIPES

ANSI 36.10 Carbon steel pipes

ANSI 36.19 Stainless steel pipes

ASTM A53 Welded and seamless pipes

ASTM A 106 Seamless CS pipes for high temp. service

ASTM A 120 Galvanized pipe for ordinary use

API 5L Line pipes for petroleum products

IS 3589 Steel pipe for general purpose

DIFFERENT CODES USED FOR PIPE SELECTION

Corrosion allowance is added depending on type of service

Design pressure is taken as 10% higher than anticipated MOP

Design temperature is taken as 250 C higher than anticipated MOT

When design temperature is 150 C and below consideration should be given for minimum temperature also.

Design should meet the requirements of relevant code

Material should be in accordance with the latest revision of standards.

DESIGN CONSIDERATIONS FOR PIPES

Mainline pipe is designed for 10% higher than the maximum operating pressure. Design factor of 72% SMYS is considered.

Station piping is designed for higher pressure than mainline to allow for the pump start-up against shut off and for throttling. In order to compensate for any un-calcubale expansion, mechanical, thermal or any residual stresses, generally 65% of SMYS is taken as the design factor.

For sizing of the piping a maximum velocity of 4.5 M/ Sec. is considered in the design.

CALCULATION OF PIPING WALL THICKNESS

Specified Minimum Yield Stress (SMYS) of pipe is known from the specification of the pipe.

Hoop stress (s) = 0.65 x SMYS x E

Where E = Weld joint factor = 1.0

Design pressure = 1.1 x Working Pressure

Design pressure = 2 x S x t / D

Where t = thickness of pipe in Inch.

D = Outside Dia of pipe in Inch.

CALCULATION OF PIPING WALL THICKNESS

M/s Jindal Saw Pipes M/s Wellspun Gujarat M/s PSL LimitedM/s Tubacero, Mexico (Plant at Monterry Pipe Mill, Mexico)M/s Hyundai Corporation, Korea (Plant at SEIIA Pipe, Korea)M/s ILVA, Italy (Plant at ILVA s.p.a. Taranto)M/s International Economics & Trading Co. (Baoji Petroleum Pipe Corporation, Wuhan)M/s Thyseen Krupp, Germany (Corinth Pipe Works s.a., Greece)M/s Daewoo Corporation, Korea (Shinho Steel Co., Korea)M/s Bao Steel, China (Shashi Steel, China) M/s Steel Authority of India Ltd. (Plant at Rourkela)M/s. Mitshubishi, Japan (NKK, Japan)M/s Sumitomo Corporation, Japan (Sumitomo Industries)M/s Marubeni Corporation, Japan

LIST OF SOME REPUTED API GRADE PIPE MANUFACTURERS

IndianOil

EQUIPMENTS IN PIPELINESEQUIPMENTS IN PIPELINES

ENGINE - FOUR STROKE DIESEL ENGINE (CRUDE/DIESEL)

PUMP - API 610 HORZONTAL CENTRIFUGAL PUMP

- API 610 VERTICAL TURBINE PUMP

GEAR BOX - SPEED INCREASING SINGLE STAGE GEAR BOX

VALVES -GATE VALVES

GLOBE VALVES

SWING CHECK VALVES

BALL VALVES – TOP ENTRY

CONTROL VALVES – PRESSURE/ FLOW,RELIEF VALVES – THERMAL / PRESSURE

/ SURGEBUTTERFLY VALVE/ TAPER PLUG VALVE 7

IndianOil

SPECIFICATION MAINLINE ENGINESPECIFICATION MAINLINE ENGINE••Mainline Engine being most critical equipment procured by Mainline Engine being most critical equipment procured by P/L Division, the Spec. has been prepared covering all the aP/L Division, the Spec. has been prepared covering all the aspect of a spect of a

Diesel engine. A comparison of various aspects covered in the Diesel engine. A comparison of various aspects covered in the spec.forspec.forengine, pump ,valves , pipe & pipe fitting are asengine, pump ,valves , pipe & pipe fitting are as

11

ENGINE PUMP VALVESCOPE SCOPE SCOPEENVOIRNMENT ENVOIRNMENT ENVOIRNMENTSPECIFIC REQUIREMENT SPECIFIC REQUIREMENT CODES AND STANDARDCODES AND STANDARD CODES AND STANDARD SPECIFIC REQUIREMENTLUB OIL SYSTEM DESIGN CHARACTERISTICS DESIGNSTARTING SYSTEM COMPONENTS MATERIAL OF COINSTRUCTIONCHARGE AIR SYSTEM DIRECTION OF ROTATION DIMENSIONSEXHAUST SYSTEM MATERIAL OF COINSTRUCTION TEST/INSPECTIONFUEL OIL SYSTEM TEST/INSPECTION PERFORMANCE GURANTEECOOLING SYSTEM CONTROL SYSTEM DOCUMENTATION GOVERNOR PERFORMANCE GURANTEEFLYWHEEL & FLYWHEEL GUARD DOCUMENTATION PUMP COUPLING GUARDDIRECTION OF ROTATIONMATERIAL OF COINSTRUCTIONCONTROL SYSTEMSERVICE TANKSTEST/INSPECTIONPERFORMANCE GURANTEEDOCUMENTATION

EngineEngine

CLOSE VIEW OF MAINLINE ENGINE

LUBE OIL FILTER ASSEMBLY

MAIN LINE ENGINE AUXILIARIES

OIL BATH FILTER

RADIATOR ASSEMBLY

EXHAUST SILENCER

MAINLINE ENGINE AUXILIARIES

FUEL OIL DAILY SERVICE TANK

RADIATOR ASSEMBLY

EXHAUST SILENCER

MAINLINE PUMPING UNIT

MAIN LINE PUMP WITH SUCTION / DISCHARGE ARMS

FIRE WALL

GEAR BOX M/L ENGINE

HAND OPERATED OVER HEAD TRACTION CRANE

HOT CRANE

CLOSE VIEW OF MAINLINE PUMP

MAINLINE PUMP WITH SUCTION AND DISCHARGE CONNECTION

PUMP DRAIN WITH FUNNEL ASSEMBLY

SCRAPPER LAUNCHING BARREL

SCRAPPER RECEIVING BARREL

SCRAPPER BARRELS

UNEQUAL TEE (X BAR)

SCRAPPER BARREL DOOR CLOSURE ASSEMBLY

TYPICAL PIPE CONNECTIONS

TRV

PIPS/PT

TYPICAL PIPE CONNECTIONS

PI

PS/PT

TRV

BASKET STRAINER WITH ISOLATING MOV’S

STRAINER BASKET

SUMP PUMP & MOTOR

UNDERGROUND SUMP TANK

LEVEL SWITCH

LEVEL TRANSMITTER

PRESSURE CONTROL VALVE

INSTALLATION OF TURBINE METER

U/S FLOW STRAIGHTENERU/S FLOW STRAIGHTENER

D/S FLOW STRAIGHTENER

‘Y’ TYPE STRAINER

BASKET STRAINER WITH ISOLATING MOV’S

STATION PIPING

INSTALLATION OF LR BENDS

INSTALLATION OF SEPARATOR FILTER

AIR COMPRESSORS

MOTOR DRIVEN

ENGINE DRIVEN

INSTALLATION OF AIR VESSELS

INSTALLATION OF DG SET

RADIATOR

EXHAUST PIPING

ALTERNATOR

INSTALLATION OF DIESEL U/L PUMP

INSTALLATION OF FIRE FIGHTING PUMPING UNIT

VERTICAL PUMP (MULTI STAGE)

ENGINE

FOAM FLOODING SYSTEM FOR M/L PUMP SHED

DELUGE VALVE

FOAM BLADDER TANK

VALVES IN PIPELINES INDUSTRY

TYPE OF VALVES COMMONLY USED

GATE VALVEGLOBE VALVEBALL VALVECHECK VALVEBUTTERFLY VALVE

GATE VALVEGATE VALVEGate valves are full flow valves normally used to start or stop flow.

A gate (sliding shut-off wedge) within the valve body is raised and lowered through a set of threads on the valve stem. The valve is operated by turning the valve stem counter clockwise to open the valve and clockwise to close the valve.

These valves are usually either fully open or fully closed during service.

GATE VALVE GATE VALVE

When fully open the gas or fluid flows through the valve in a straight line with very little resistance to flow.

A gate valve can normally be recognized by a long stem, by the number of turns of the valve stem that it takes to close the valve (more turns are needed for a gate as compared to a globe valve), and sometimes by the appearance of the outside of the valve body (more square when compared to a rounded globe valve).

GLOBE VALVEGLOBE VALVEGlobe valves are extensively used for the control of flow and where positive shut off is required.

A globe valve employs an internal seat within the valve body. Hand operated globe valves are operated by turning the valve stem counter clockwise to open the valve and clockwise to close the valve. Threads on the valve stem cause the seal on the valve stem to mate with or move away from the valve seat. Close control over flow is readily accomplished.

As the fluid or gas moves through this type of valve it must change direction. This results in increased resistance to flow.

GLOBE VALVEGLOBE VALVE

Globe valves are ideal for use on product and air lines where close control over flow is required. Globe valves have a positive shut off feature which can prevent leakage of air and product.

BALL VALVEBALL VALVEBall valves are quick opening, full flow valves, needing only a quarter of a turn to be fully open.

A ball with a non-restricting port rides in a valve body on plastic non-sticking seats. Ball valves can provide a bubble tight seal. The ball valve can be used for full flow (venting), and control (product and air supply) functions.

BUTTERFLY VALVE BUTTERFLY VALVE

Butterfly valves are quick opening, full flow valves which employ a metal disk which when rotated on a shaft seals against seats in the valve body.

Butterfly valves are normally used as throttling valves to control flow.

CHECK VALVEIn the functional grouping of the entire valve family, the check valve will be found in the group defined as valves designed to control the direction of flow.

Check valves differ considerably in their construction and operation from the other groups of valves, designed either to stop the flow entirely (gate, plug, and quick-opening valves), or throttle the flow to a desired degree (globe, angle, needle, Y, diaphragm, and butterfly valves).

CHECK VALVECheck valves are entirely automatic in their operation, and are activated internally by the flow of fluid or gases which they regulate.

Check valves permit the flow of fluids or gases in only one direction; if the flow stops or tries to reverse its direction, the check valve closes immediately and prevents a back-flow. As soon as the pressure in the line is re-established, the check valve opens and the flow is resumed in the same direction as before.

Swing check valvesSwing check valves

Swing check valves are the most popular of all check valves since they offer very little resistance to the flow when in wide open position.

They are generally used on all piping where the pressure drop is of prime importance.

Swing check valvesSwing check valves

Swing check valves are used for handling liquids, and can be installed in vertical or horizontal position without impairing their performance. However, these check valves are not recommended for such applications where the reversal of flow is frequent, since this causes the valve disk to fluctuate rapidly and result in "valve chatter."

PIPE-FITTINGSVARIOUS TYPES OF PIPE-FITTINGS ARE USED TO COMPLETE THE PIPING SYSTEM.

PIPE - FITTINGS ARE USED FOR :

CHANGING DIRECTION

CHANGING DIAMETER

FOR PROVIDING BRANCH-OFF FROM MAIN PIPE.

Contd/-

TYPES OF PIPE-FITTINGS(1) TEES

EQUAL TEE

UNEQUAL TEE

CROSS BAR TEE

(2) REDUCERSCONCENTRIC REDUCER

ECCENTRIC REDUCER

(3) BENDSLONG RADIUS BENDS (LR BENDS)

90 DEG. BENDS

45 DEG. BENDS

Material Forging WeldingPIPE FITTINGS MANUFACTURING PROCESS

Heat TreatmentMachining

Inspection

Finished product

TYPES OF PIPE-FITTINGS SHORT RADIUS BENDS(SR BENDS)

90 DEG. BENDS

45 DEG. BENDS

SPECIAL FITTINGS (1) WELD -O-

LETBUTT WELDED BRANCH CONNECTIONWHERE STANDARD TEE IS NOT AVAILABLE

(2) SOCK-O-LET

WHERE SOCKET WELDED BRANCHCONNECTIONS ARE REQUIRED

(3) THREAD-O-LET

FOR THREADED BRANCH CONNECTIONS

(4) ELBOW-LET

FOR BRANCH CONNECTIONS ON ELBOWS

(5) NIPPOLET FOR BRANCH CONNECTIONS ALONG WITHNIPPLES

(6) LATROLET FOR BRANCH CONNECTIONS AT AN ANGLE

DESIGN FEATURES OF LOW PRESSURE FITTINGS(ANSI - CLASS 150)

(1) ALL FITTINGS SHALL BE OUT OF ASTM-A-234 WPB MATERIAL.

(2) FITTINGS OF SIZE 18” NB AND ABOVE OF 150 CLASS PRESSURE RATING MAY BE OF TWO CUP, BUTT WELDED TYPE OUT OF SUITABLE CARBON PLATE MATERIAL.

(3) WELDING OF PIPE SHALL BE DOUBLE BUTT WELDED TYPE.

(4) ALL WELD JOINTS HAVE TO BE 100% RADIOGRAPHED AND HAVE TO BE STRESS RELIEVED.

DESIGN FEATURES OF HIGH PRESSURE FITTINGS

(ANSI - CLASS 400 & ABOVE ) (1) MATERIAL FOR FITTINGS UPTO 18” NB SIZE SHALL BE

CONFORMING TO WPHY-52 GRADE, WHILE CONSTRUCTION FOR THE SAME SHALL BE OF SEAMLESS TYPE.

(2) FITTINGS OF SIZE 20” NB AND ABOVE SHALL BE OF WELDED TYPE CONSTRUCTION.

(3) WELDING OF PIPE SHALL BE DOUBLE BUTT WELDED TYPE.

(4) ALL WELD JOINTS HAVE TO BE 100% RADIOGRAPHED AND HAVE TO BE STRESS RELIEVED.

H.K.SINGHDGM (PJ-Mech)

Main Equipment, System in Crude Oil and Product Pipelines

Documents

Transcript of Main Equipment, System in Crude Oil and Product Pipelines