Process-Piping-Pipeline Engg PDP_Ray R10copies

8/11/2019 Process-Piping-Pipeline Engg PDP_Ray R10copies

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Member, Mapua Alumni Association

Alberta Chapter

RAY ALVARADO, P.E.

PROCESS ENGINEERINGPIPING ENGINEERINGPIPELINE ENGINEERING


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Acronyms

CAE Computer Aided EngineeringCAD Computer Aided DesignHMB Heat and Mass Balance, a Process activity

CFD Computational Fluid DynamicsFEA Finite Element AnalysisPFD Process Flow DiagramP&ID Piping and Instrumentation Diagram

LDT Line Designation TableROW Right of Way, for pipeline routingHDD Horizontal Directional Drilling, for pipelinecrossing

HVAC/R Heating, Ventilation, Air Conditioning &Refrigeration


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PROCESS ENGINEERING


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PROCESS ENGINEERING

PROCESS ENGINEERING - an early project activity for analysis ofphysical separation or chemical conversion. It follows project definitionand early financial studies. System-wide Process simulation nowadays iscomputer-aided e.g. heat-and-mass balances, logical block flows, controlphilosophies, and equipment selection.

Important Deliverables:

Process Flow Diagrams(PFDs) - schematic showing major processequipment, main fluid flows, and basic stream characteristics (pressure,

level, temp., flow).Piping and Instrumentation Diagrams(P&IDs) - schematics with muchmore detail and confirmed data. Shown here are process conditionlimitations, major machinery specifications, minor equipment data, pipesize/details, instrumentation types, and more precise

controls/automation.-


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PROCESS ENGINEERING

Usual entry-level positions:Chemical Process EngineerMechanical Process Engineer

Process Simulation Specialist

Minimum Skill Sets for a Junior Process Engineer:Undergraduate degree in Chemical Engineering,Mechanical Engineering, or Chemistry-relatedacademic programs.Basic knowledge of Fluid Statics/Dynamics,Thermodynamics, Heat Transfer, and Chemical Unit

Operations.


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PROCESS ENGINEERING CHEMCAD Process Simulation, Screen Images


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PROCESS ENGINEERINGHeat and Mass Balance (HMB) Study, Selexol Process


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PROCESS ENGINEERING Early concept of an oil refinery


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PROCESS ENGINEERINGExample of Process Flow Diagram (PFD)


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PROCESS ENGINEERINGExample of Piping & Instrumentation Diagram(P&ID)


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PROCESS ENGINEERING

Process Engineering and Beyond:Next-Generation Process Simulators ..higherprocessing speeds, capable of more simultaneous

calculations, broader chemical database.Multi-Physics Tools to the Mainstream thesesoftware can now be fully integrated with existingProcess Simulators.Intelligent 2D Diagrams embedded data onPFDs and P&IDs will pop up once a particularelement is clicked or highlighted on the drawing.


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PIPING ENGINEERING


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PIPING ENGINEERING

Screen shots of CAEPIPE , a widely-used pipestress analysis software, showing the InputGeometry :

Piping layoutimported fromCAD 3D Model, ormanually re-created


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PIPING ENGINEERING

Stress Output .watch for the Reds!

RED areas havehigher calculatedstresses(needs re-work)


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PIPING ENGINEERING

Animation features ...it moves!

Shows areas of

excessive movemendirection of thermalgrowth, lift-off atsupport points, etc.


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PIPING ENGINEERING If not analysed properly, pipes may..

deform and collapse

.or lift -off from


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PIPING ENGINEERING

PIPING ENGINEERING - a Mechanical sub-disciplinemainly to validate Piping Design s pipe -fittings layout,inside enclosed industrial areas, by computational analysisor technical reasoning.Such activities follow right after critical and major piping arecompletely laid out and supported.

PIPE - a closed cylindrical conduit for moving fluid (liquid,gas, solid particles) from one location to another, either bygravity or applied pressure.FITTINGS - are transition elements for connecting pipesinto an assembly or conduit network. Elbows, tees,flanges, reducers, and couplings are examples.


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PIPING ENGINEERING

Important Deliverables:Static & Dynamic Pipe Stress Analysis, Reports -computer- aided, hand calculations, and by -inspection

judgement.Finite Element Analysis (FEA) - on equipment nozzles,header branches, and support attachments. General Pressure Calculations wall thickness, branchreinforcement, leak-strength testing, and hot-tapcalculations. Sizing of Engineered Restraints - for spring supports,rollers, sway braces, sway struts, seismic snubbers, etc.

Detailing of Special Pipe Supports - as required bystress analysis results or vendor special requests.


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PIPING ENGINEERINGPlant Piping

3D layout ofpipingand pressurevessels

Offshore platformpiping


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PIPING ENGINEERING

Usual entry-level positions:Piping Design EngineerPipe Stress EngineerPiping Materials Engineer

Minimum Skill Sets for a Junior Piping Engineer:Undergraduate degree in Mechanical Engineering,Chemical Engineering, or related sub-discipline.

Basic knowledge of Structural Mechanics, Strength ofMaterials, Fluid Dynamics, Machine Elements Design,Materials Science, and Welding Technology.Supplemental knowledge in Chemical Processes, HeatTransfer, Thermodynamics, and Stationary/Rotating

Mechanical Equipment.


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PIPING ENGINEERINGExamples of Engineered Restraints

Constant spring can

Variable spring hangers

Sway strut assembly

Seismicsnubber

Sway brace assembly


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PIPING ENGINEERINGExample of Custom-Ordered Supports

Support clamp withfabric lining, for

vibrating lines

Rigid hanger clamp,for pre-insulated line

Pipe clamp and shoe,pre-insulated cold line


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PIPING ENGINEERING

Piping Engineering and Beyond: Full Integration of computational Analysis Softwarewith 3D CAD Model seamless and bi -directional compatibility of both CAD and CAEactivities, thus substantial savings of time andresources.FEA/CFD Multi-Physics to theMainstream complex analysis and engineering

calculations can now be simultaneouslyperformed e.g. structural mechanics, fluid flow,vibration, and heat transfer.Opportunities in Oilfield Frontier Areas .morecomplex piping needs for fixed offshore platforms,floating FPSOs, marine tanker, and Arctic process


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PIPING ENGINEERING FEA & Multi-Physics Analysis Tools

Multi-Physics Analy(thermal + structuralof vessel

FEA of stab-inbranch

FEA of

crimped pipe


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PIPING ENGINEERINGCFD & Multi-Physics Analysis Tools

ANSYS 3D Multi-Physics (wind +thermal + struct.) around reactors

ABAQUS 2D Multi-Physics (fluid flow +thermal)

COMSOL 3D Multi-Physics(fluid


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PIPELINE ENGINEERING


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PIPELINE ENGINEERING - a Mechanical sub-discipline mainly tovalidate Pipeline Design s overland or seafloor routing, bycomputational analysis or technical reasoning, outside the fencedindustrial area.

Such activities usually start after initial project development, geodetic(land) or bathymetric (ocean) surveys, and preliminary right-of-wayrouting.

Pipelines are generally classified into:

Land Pipelines, Underground (Buried)

Land Pipelines, AbovegroundUnderwater Pipelines

Important Deliverables/Involvement:

Hydraulic Analysis , Steady-State and/or Transient (Surge)

Pipeline Stress Analysis


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Usual entry-level positions:Pipeline Design EngineerPipeline Stress Engineer

Pipeline Hydraulics Engineer

Minimum Skill Sets for a Junior Pipeline Engineer:Undergraduate degree in Mechanical or Civil

Engineering.Basic knowledge of Engineering Surveying, StructuralMechanics, Strength of Materials, Fluid Dynamics,Machine Elements Design, Materials Science, andWelding Technology.Supplemental knowledge of Heat Transfer,


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PIPELINE ENGINEERINGLand Pipeline Routing

Natural gas pipelineright-of-way Rout ing S tudytaken from terrain survey

Plan-and-Profi le Drawin g ,with data from routing study

and terrain survey


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PIPELINE ENGINEERINGPipeline Analysis

Rivercrossing..suspension

bridge and cable stay

Seismic analysis.andmitigation measures for Trans- A lask a Pipel ine while crossingthe Denali fault line


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PIPELINE ENGINEERINGEngineered Pipeline Supports

Detail of H-Supportand side bumpers

Trans -A laska Pipeline ammonia-filledH-Support , with cooling fins, piledriven through permafrost


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PIPELINE ENGINEERINGUnderwater Pipelines

Underwater gas pipelineon uneven seafloor, withfree-spanned sections

Underwater pipelines, foroil-



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PIPELINE ENGINEERING Seafloor Routing Study of underwater oilpipeline


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PIPELINE ENGINEERING Pipeline Stability Analysis & FEA

Overstress at seabed touchdownarea, due to excessive bending

from pipelay surface vessel


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Pipeline Engineering and Beyond:Integration of Pipeline Surveys with RoutingSelection in intelligent 3D format, these

related activities will be fully synchronized foraccuracy and cost savings.Pipeline 3D Models Imported Into Multi-PhysicsSimulation ..like stress analysis, hydraulic

surge, flow assurance, global buckling, or icegouging hazards.Deeper, Colder in search for oil and gas, theindustry is pushing the limits of pipelinetechnology beyond the worlds Continental Shelf



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PIPELINE ENGINEERING Arctic Pipelines, Ice Gouge Hazard Analysis &FEA

Burial depth iscritical, to preventpipeline damage

Gouged seafloor imaginBerg gouging

Sea ice gouging


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PIPELINE ENGINEERINGCFD & Multi-Physics Analysis Tools (ANSYS)

3D CFD (fluid flow +thermal) at junction

3D CFD (fluid flow +structural) through valve

3D CFD (fluid flowonly) through blades


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Trivia Question:

Whats the differencebetweenPIPING andPIPELINES?

Other than spelling of course


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Answers:

PIPINGInside the enclosed industrial area or fenced plot limits.Physical configuration can be very complex.Mostly of short length, specified in feet or meters.

Uses lower grade steel, thus pipe wall is thicker.Can operate at very high temperatures and pressures, orconversely at cryogenic temperatures and partial vacuum.

PIPELINES

Outside the enclosed industrial area or fenced plot limits.Physical configuration is usually simple, from point A topoint B.

Almost always very long, specified in miles or kilometres.Uses higher grade steel, thus pipe wall is thinner.

Process-Piping-Pipeline Engg PDP_Ray R10copies

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