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Overview

This Certification Course on Process Piping Design & Engineering is integrated with Process Plant Layout & Equipments, per ASME B31.3 and ASME B31.1 , Piping Stress Analysis , Process Piping Drafting, Hydraulic Design of Piping Systems etc.

Process Piping is the piping that convey fluids under pressure or vaccum inside the boundaries of a Chemical plant, Petroleum refinery, Gas Processing plant, Petrochemical, Pharmaceutical, Textile, Paper, Semiconductor & Cryogenic Plants falls under the scope of ASME B 31.3

It is a complex arrangement of pipes, valves, support clamps, other related components and control instrumentation.

The Certification Course comprehensively focuses from fundamentals of Process Piping Systems , Layout of Piping Systems , Mechanical / Process Equipments , Flexibility Analysis , Stress Analysis to Industry Leading Pipe Stress Analysis CAESAR - II Software and Process Piping Drafting.

ASME B 31.3 Provides requirements for design, erection, materials, inspection, fabrication, testing for process piping in Petroleum refineries, chemical plants, pharmaceutical plants, textile plants, paper plants, Semiconductor Plants, Cryogenic Plants process plant.

Course Syllabus :

PART - 1
1. PIPING SYSTEMS DETAILED ENGINEERING
2. LAYOUT OF PIPING SYSTEMS & PIPING DRAFTING
3. MECHANICAL AND PROCESS EQUIPMENT

MODULE 1 – Fundamentals of Piping

Definition and Application of Piping
Pipe Manufacturing
Pipe Fabrication
Pipe Designations

MODULE 2 – ASME codes and standards

ASME Boiler and Pressure vessels Codes
ASME Pressure Piping Design Codes.
API Codes
Other Codes & Standards

MODULE 3 – Classification of pipe

Manufacturing Methods
Weight and Size – Standards STD , Extra Strong XS , Double Extra Strong XXS etc.
Applications or Uses
Pressure Temperature Rating System

MODULE 4 – Piping Material Specifications – ASME / ASTM

Ferrous Material Specifications
Non Ferrous Material Specifications

MODULE 5 – Calculation of Sandards Properties of Commercial Piping Materials

Several Examples of Calculation of Standards Properties of Commercial Piping Materials

MODULE 6 – Pipe Fittings

Types of Fitting - Butt Weld , Threaded and Socket Weld
_ Elbow – 90 degree (LR & SR), 45 degree, Reducing Ell. ,
_ Branch Connections – Straight & Out let Tees
Reducers – Concentric & Eccentric, Reducer Offsets.
Fabricated Branch Connections – Stub In & Stub On,
Branch Reinforcements – Reinforcing Pad, Welding Saddle Olets.
_ Olet Fittings – Weldolets, Sockolets, Threadolets, Latrolets, Elbolets

MODULE 7 – Types of Flanges

Definition of Flange.
Types of Flanges based on Face and Application,-. Forged Steel and Cast Iron Flanges.
Threaded Flanges, Slip-on Flanges, Socket-Welded Flanges, Welded-Neck Flanges, Blind Flanges
Gaskets – Types, Thickness, Bolts & Nuts.

MODULE 8 – Types of Valves

Definition & basic function
Valve Types – Gate, Globe, Ball, Check, Butterfly, Angle, PRV/PSV, & Plug, Automatic Control, Needle, Diaphragm, Safety ”Pop
Application of Check Valve
Valve Storage Procedure
Valve Testing
Control Valve Manifold. – Layout Representation & Requirements

MODULE 9 – Mechanical and Process Equipment

Static Equipment – Horizontal Vessels, Vertical Vessels, Storage Tanks, Heat Exchanger , Reboiler., Towers and Columns
Rotary Equipment – Pumps, Compressor, Fans, & Steam Turbines.

MODULE 10 – Flow Diagrams

Process Flow Diagram – PFD
Piping & Instrumentation Diagram – P & ID.
Utility Flow Diagram
Line Numbering
P& ID Requirements
Flow Diagram Exercises.
Symbols & Abbreviations.
Instrument Types & Symbols – Flow, Temp, and Pressure & Level.
Flow Plan arrangement etc.

MODULE 11 – Piping Isometric

Definition
Drawing Piping Isometrics
Isometric Dimensions, Notes & Callouts.
Isometric Offsets.
Exercises on Creation of Isometrics form Piping Plans and Sections.

MODULE 12 – Piping and Equipment Layout – (Plot Plan, Equipment Layout, & Piping GA Drawings)

Plot Plan Development & Requirements.
Equipment Layout Terminology, Control Point & Battery Limits
Preparation of Equipment Layout.
Piping GA Drawing Requirements and Layout Procedure.
Pump GA Drawing and Layout Consideration.
Tank & Vessel Layout Consideration .etc.

MODULE 13 – Pipe Supports

Types and Functions of Supports
Anchors
Pipe Guides
Limit Stops
Pipe Shoe
Dummy Leg / Trunion
Field Support / Base Support
Rigid Hangers
Flexible or Resilient Supports - Variable & Constant Load
Pipe Rack and Yard Piping Design

PART - 2
PIPING SYSTEMS DESIGN AND CALCULATIONS

MODULE 14 – Design of process piping requirements per ASME B31.3

Scope of ASME B 31.3, B31.1
Design Pressure & Design Temperature for Piping Systems.
Ratings of Flanges etc.
Reinforcement of Branch Connection

MODULE 15 – Design pressure integrity

Concept of Pressure Integrity
Pressure Design of Straight Pipe under Internal Pressure. – Wall thickness Calculations

Module 16 - Typical wall thickness calculation for Oil and Gas, Petrochemical, Refineries ( eg. Saudi Aramco )

Several Examples of wall thickness calculation for Oil and Gas, Petrochemical, Refineries (eg. Saudi Aramco)

Module 17 - Hydraulic Design of Piping Systems

Fluid Flow Sizing
Pipe Sizing
Recommended Velocities for Water and Steam Piping etc.
Reynolds Number
Types of Flow in Piping
Pressure Drop due to Friction / viscosity
Darcy Weisbach Equation
Friction Factor
Moody Diagram
Minor Losses in Piping – Equivalent Length Method & Loss Coefficient Method

Module 18 - Design Calculations of Piping sizing

Several Examples of Calculation of Pipe Sizing

Module 19 - Pump Calculations

Head
Section and Flooded Lift
Velocity Head
Total Dynamic Section Head, Total Dynamic Discharge Head, Total Systems Head
Cavitation in Pumps
NPSH Required & NPSH Available for Pumps.
Several Examples of Design of Pump Calculations

PART - 3
PIPE STRESS ANALYSIS

Module 20 - Introduction

Objectives & Definition of Stress Analysis
Critical Line List
Information Required for Stress Analysis
Piping Loads – Static & Dynamic
Requirements of ASME B 31.3 Code – Sustained Loads, ThermalExpansion & Occasional Loads.

Module 21 - Stresses due to Sustained Loads , Stresses due to Displacement Strainsand Stresses due to Occasional Loads

Longitudinal Stress,
Longitudinal Stress from Pressure
Longitudinal stress due to weight
Allowable Displacement Stress range
Basic Allowable Stress at maximum material temperature.

Module 22 - Pipe Flexibility Analysis per ASME B31.3

Pipe Stress Analysis Logic
Minimum Flexibility Requirements
Stress Range Reduction Factor - f
Piping Flexibility – General Consideration
Stress Analysis Flexibility Requirements
Stress Analysist’s Function
Scope of Code Requirements

Module 23 - Design Calculation of Pipe Stresses by Thermal Expansion Stress / Sustained Loads

Several Examples of Design Calculation of Pipe Stresses by Thermal Expansion Stress / Sustained Loads

Module 24 - Design Calculations of Occasional Loads

Several Examples of Design Calculation of Occasional Load

Module 25 - Design Calculations of Wind Load on a Piping Support in Open Terrain

Calculating Civil / Mechanical Load on Pipe Systems
Hydrostatic Test Weight
Wind Force
Wind Shielding
Several Examples of Calculations of Wind Load on a Piping Support in Open Terrain

Module 26 - Determination types of Pipe Support and Maximum Allowable Span

Maximum Support Spacing Based on Weight, Deflection Criteria and Design Loads
Suggested Pipe Support Spacing
Several Examples of Types of Support and Maximum Allowable Span
PART - 4

CAESAR II – STATIC ANALYSIS
Introduction
Nozzle Thermal Growth Calculations – pumps, vessels, heat exhangers.
Modelling of Piping elements & Isometrics – Bends, Reducers, Valves, Loops
Performing Static Analysis. / Modifying Load Cases.
Hanger Selection
Set up of Wind Load Cases.
Set up of SUS, OPE, EXP, HYD, HGR, & OCC loads.
Load Case Editor / Viewing Reports
Equipment Nozzle Load Qualifications
Coding technique of Vessel piping includes both piping and vessel
Local vessel flexibilities
Evaluation of local vessel stresses
Practical Examples – Input, Analysis & Results