Steamline Piping Brochure

8/6/2019 Steamline Piping Brochure

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You make delicious

chocolateswe weld pipes at heights

You manufacture life-savingdrugs

we wire complex control loops

You make incrediblecars

we take on turnkey responsibility with erection and insulation

You design world-classbreweries

we supply steam at the correct pressure every time



We worked tirelessly together, toaugment your Steam System at your Pune plant.

Obviously, you liked what we did, sinceyou entrusted the turnkey Design,

Erection and Comissioning of your new plant in Uttaranchal to us.

Your brief: “The Ideal Boiler House”.

We helped you build just that, with a central Boiler MonitoringSystem for all 5 boilers in the plant.

And....while executing the project, we also saved an additionalRs. 100 Lakhs / year from Condensate Recovery!!

DYNAMIX DAIRY

COCA-COLA

FRESENIUS

KABI

A high pressure boiler,

HP steam piping,

turbine outlet piping,

a 100 -loop Boiler Control System,

Pressure Reducing &De-superheatingStations,

a bullet-proof Condensate RecoverySystem....

Need we say more? ?

TATA-ACSI

INTERVET

You wanted to quadruple production.

Together, we re-designed your existing plant.

Then, we installed and commissioned the entire steam systemfrom the new Boiler, Chimney, FWT, DOT, Piping, PRSs, valves,flanges, down to the nuts & bolts....all in record time.

PRAJ

Your brief: Utility piping for a world-class R&D facility.

We helped your scientists get.......

steam, cooling water, chilled water, compressed air, process

water, etc. to their pilot plants and laboratories.

You called us for asimple job and we weresuddenly opening up an

entire machine,and rebuilding part of it,

all because of a smallheat balance equation...

Industrial Process Piping & Insulation



Engineering

ideas taking shape

Need evaluation. From turnkey Design Build solutions, SteamTM

Products, Energy Audits and Piping and Insulation, Steamlineprovides a full menu of services that you can count on. We firstunderstand your project goals, budget, and schedule. We thencombine new-generation estimating, scheduling andmanagement systems, with qualified construction personnel -ensuring that your project is well planned and executed in amanner that promotes trust and confidence.

Engineering Standards. To steamline and standardize quality to arepeatable level, the adoption of proper Engineering Standardsis critical. Standards also help to introduce and guaranteequality, reduce inventory, shorten project execution and providea baseline for validation of installed equipment.

Applicable Codes and Standards. Equipment and materials used in

the entire project, including all systems, sub-systems, products,piping, etc. conform to one or more of the following Codes andStandards, or equivalent.

IBR Indian Boiler Act (1923) and regulations(1950) and subsequent revisions

ASME Sec II Material specifications

ASTM SA516 Materia l speci ficat ions for Steel Plate

BS 3059/320/360 Material specifications for BQ ERW tubes

IS 2002/2062 Material specifications

ASME Sec V Standards for Non-Destructive Testing

ANSI B 31.1 &3 Piping Standards (American)

ASTM A 106 Specifications for Carbon Steel PipesSeamless and Welded

ANSI B 16.5 Steel Pipe Flanges and Flanged Fittings

ANSI B 16.10 Face-to-face and End-to-end dimensions of Ferrous valves

ANSI B 16.11 Threaded Pipe Fittings

ASTM A 216 Speci fications for Cast Carbon Steel Valvesand Fittings

ASTM A 105 Speci fications for Forged Steel Valves andFittings

ASTM A 234 Cast Steel Steel Pipe Fitting

ASTM A 182 Forged Carbon Steel Pipe Fittings

ASTM A 193/4 Fasteners for HP / MP Service

IS 1367 Fasteners for LP Service

IS 2712 Gaskets for Fluid Flow Piping

IS 6533 Design Codes for Steel Stacks (Chimneys)

IS 14164 Insulation of Process Piping

Code/ Standard Description

Table 1: Applicable Codes and Standards

SERVICE/ APPLICATION VELOCITY (m/s)

Raw or treated water 1 - 5

Boiler feed pump suction 1 - 1.5Boiler feed pump discharge 2.5 - 3.5

Saturated steam - HP 25 - 40

Saturated steam - LP 15 - 30

Superheated steam 30 - 50

Flash steam 5 - 15

Condensate 0.5 - 1.5

Recommended Velocities For Piping Systems.

Table 2: Recommended Velocities

RELIABILITY

Top corporations nationwide rely on their infrastructure for day-to-day operations. In industry, stability and reliability arekey. Equipment must function dependably, communicationlines must remain open, workflow must be efficient.

TM

At Steamline we understand the demands facing your company. We work to optimize your performance. We focuson completing projects that meet or exceed our clients’expectations, while minimizing construction impacts anddelivering the highest quality work.

So, while you focus on growing and developing your business, we focus on making sure your infrastructure isready to handle new challenges.

TM

Materials. Steamline maintains welding procedures coveringcarbon steel, low alloy, aluminum, Inconel, Hastelloy andothers. Joining dissimilar materials is also in our repetoire. Allpipe welding is performed by welders certified to ASME IX andeach qualification is additionally certified by the Indian Boiler Regulations (IBR).

Documentation. Through the use of detailed engineering drawings,TM

Steamline provides customers with an accurate and permanentrecord of their project. Our design tools are used to combineideas, specifications, and concepts into a blueprint for your pipingprocess.

Isometric drawings give craft personnel a single three-dimensional reference document from which to build, spendingmore time in the building process and less in consulting referencedrawings. They also give the customer the opportunity to see eachstep of the job, in detail, before fabrication begins.

Revisions can be made and incorporated at any phase of a projectwith minimal delays in the work schedule. Specialized procedurescan also be integrated into the drawings, including weldingoperations, NDE examinations, or torque operations.

Each phase of a project, down to the smallest detail, is recorded,documented, and retained as an accurate reference for thecustomer's future use.

Sizing & Routing. No matter how well a pipe is fabricated, it willfail if it is not sized correctly. The selection of the correct sizedepends on flowrate, but also on velocity, allowable pressuredrops and design life of the plant. Too small a pipe and you willget process starvation, high pressure drops, noisy operationand accelerated wear. Too big, and you lose energy as well asmoney.Steamline uses a variety of tools including the Moody charts,the Darcy-Weisbach method, Unwins formula and our ownproprietary pipe-sizing software.



QUALITY

Whether threaded, flanged or welded or brazed, from theTM

ferrous to alloy, Steamline can provide experienced pipingfabricators and installers for every type of process pipingsystem.

Regardless of the material specification, the serviceclassification, or the examination requirements, each systemis installed in accordance with ANSI regulations. Materialcertifications are maintained, hydrostatic or pneumatictesting is documented, and the torquing of flangedconnections is verified. Our stellar performance in the arena

TMof process piping has established Steamline as thecontractor of choice when "close enough" really isn't.

Process Piping & Utilities Projects

maintaining the arteries of the Process Industry

Responsibility.

Competence.

You are at the centre of all our business decisions.

Established to streamline the traditional method of deliveringconstruction performance, Steamline provides a single sourceof responsibility for total project execution. Whether your projectdemands a particular skill or a full range of disciplines, our services are tailored to the task at hand.

Our workforce includes pipe-fitters, riggers,welders, and mechanics - each with a diverse background of practical experience.

Experience has taught us that satisfied customers don't justreturn, but actively market our business by word-of-mouth.

Tools of the trade. Our on-site team has been equipped with the best

possible tools.

Our German welding machines, for example, are packed withpower and yet have extremely compact dimensions. In fact,they weigh only 6.0 kg !! These features make them the idealcompanion for arduous outdoor work on building sites.

TMSpecialization in Steam. Steamline

TM As a leading piping and industrial contractor Steamline is

first in safety, quality and performance. Process SafetyManagement, Responsible Care, and OSHA-Compliance are

TMterms that are heard on a daily basis at Steamline jobsites.

Safety is not a thread running through our operation, but the fabricfrom which it is woven. Whether it is entering a permit-requiredconfined space, or climbing over the six-foot fall protectionthreshold, all our work is performed by employees with safetytraining under the direction of competent supervision. No work isperformed without every employee being aware of the hazards of his workplace and having received the proper training to deal withthose hazards.

Typically, our site teams are fully equipped with boilersuits, safetyshoes, protective eyewear, helmets, safety slings and harnesses,ear-muffs, etc.

has been in the business of steam for a decade.

Steam Distribution systems pose certain special challenges.Sizing must be done keeping in mind the typical high turndowns of a steam load. The removal of moisture by correctly spaced pipeloops and automatic drain traps is critical. Installing a flow meter correctly makes the difference between accurate readings andmoney wasted. The expansion of pipes when steam passes

through them presents special challenges for pipe supports.

We have been doing exactly this for really long and it would be awonderful opportunity to share this knowledge with you.

Safety.

TMProjects. Steamline takes pride in the ability to do precisionmachinery installation and equipment relocation. Whether it is theclose-tolerance placement of manufacturing lines and conveyors

TMor the setting of an entire tank farm,Steamline can be called uponto do the job.

We have years of experience serving a wide range of market

sectors, including food and beverage manufacturing, healthcare,chemical and pharmaceuticals, paper and chemical, power generators, vegetable oils, and more.

SAVINGS

Savings come from competent implementation.

One contact at one phone call puts you in touch with everyfacet of your project. The engineers, planners, designers,site managers and other experts at Steamline are talkingto each other, making sure that your needs and concernsare always at the forefront.What does this mean for you?

It means that your projects cure headaches instead of causing them.

It also means that you save time.



Insulation

TMSteamline's in-house ability to provide painting, insulating andcladding services keeps "critical path" activities under the sameroof. By reducing specialty contractors whenever possible,

TMSteamline maintains the forward momentum of its projects.

Whether a red oxide primer or a three-part paint system, our coatings department can deliver. Surface blasting to maintain aspecific profile and mill thickness testing are all services providedby our coatings personnel.

Insulation can be attached concurrently with fabrication andassembly when it is applied by our insulators. Pipe spools can beinsulated in the shop, eliminating time-consuming fieldwork.Vessels can have lagging installed prior to installation, eliminatingelaborate scaffolding and consequent delays.

We do all Insulation as per IS 14164.

Thickness Charts. Table 3 to the right, gives recommendedinsulation thickness in mm required for different pipe sizes anddifferent operating temperatures.

Insulation material assumed is Mineral wool with a thermalconductivity of 0.035-0.04 kcal/m hr ºC and average density of about 100-200 kg/m³.

Payback. Given the rising cost and availibility of energy, an un-insulated hot or chilled line is a crime. The cost of insulation isrecovered within 3-9 months, depending on the size and thetemperature of the pipe. This is illustrated below in easy to readRupee terms.

boosting plant Efficiency

Table 4: Annual Loss in Rupees for uninsulated pipe

A microscopic view of mineral fibres

Table 3: Recommended thickness

90 150 200 260 315 375

25 25 40 65 65 75 90

40 25 40 65 65 75 90

50 25 40 65 65 75 90

80 25 40 65 65 75 90

100 25 50 75 75 100 100

150 40 50 75 75 100 115

200 40 50 75 75 100 115

250 40 65 90 90 100 125

300 40 65 90 90 100 125

Flat 40 65 90 90 100 125

Pipe dia

(NB) mm

Operating/ Fluid temp in deg C

Ó Steamline, 2008. All rights reserved.

Head Office & WorksSteamline, S. No. 32/3/14, Kondhwa Budruk, PuneMaharashtra, India 411 048.

Phone: + 91 20 2693 2213Fax: + 91 20 2693 2214Email: [email protected]: www.steamline.com

Rs Loss/yr for every 100 m of Pipe Length

NB

15

20

25

40

50

65

80

100

125

150

200

250

300

3 5 7 10 3 5 7 10 3 5 7 10

138872 166912 191555 222949 64501 77525 88970 103552 49144 59066 67787 78897

173909 209023 239883 279198 80774 97084 111417 129678 61542 73968 84889 98802

217864 261853 300513 349765 101190 121621 139577 162453 77097 92664 106345 123774

273285 328464 376959 438740 126931 152560 175084 203779 96710 116236 133397 155260

310870 373638 428802 499079 144388 173541 199163 231805 110010 132222 151743 176613

487964 586489 673078 783391 226642 272403 312621 363857 172680 207545 238187 277224

387314 465516 534245 621804 179893 216215 248138 288806 137062 164736 189057 220042

570141 685258 786429 915320 264810 318278 365268 425133 201760 242497 278300 323911

732583 880499 1010496 1176109 340259 408960 469339 546261 259245 311589 357592 416199

1060653 1274809 1463022 1702801 492636 592103 679521 790890 375341 451126 517731 602583

1395731 1677541 1925214 2240744 648267 779158 894193 1040745 493918 593644 681290 792949

1739089 2090227 2398829 2791981 807745 970836 1114170 1296775 615425 739685 848892 988019

2063337 2479944 2846083 3312537 958346 1151845 1321904 1538555 730169 877596 1007165 1172232

Fuel - Coal

Steam Pressure in kg/cm2 g

Fuel - FO Fuel - Bagasse

Steam Pressure in kg/cm2 g Steam Pressure in kg/cm2 g

Steamline Piping Brochure

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