N.

Todkar
9967479134 

Fig. 3.1.4a
  

Fig. 3.1.4b
Fig. 3.1.5
 DISCHARGE PIPING

SUCTION PIPING
ISOLATION VALVE

ISOLATION VALVE NON RETURN VALVE

PRESSURE
PI INDICATOR

CONCENTRIC
REDUCER

ECCENTRIC
'Y' TYPE REDUCER
STRAINER F.S.D

DRAIN

CL PUMP CASTING

COMPONENTS OF A TYPICAL PUMP SUCTION

AND DISCHARGE PIPING SYSTEM
 ECC. REDUCER

DRAIN

TYPICAL SUCTION LINE SUPPORT

 FCV

BYPASS LINE

BYPASS LINE
(ALT)

COOLER

ARRANGEMENT FOR MINIMUM FLOW FOR CENTRIFUGAL PUMP

 USE OF ECCENTRIC REDUCERS ALLOWS
LARGER FLANGES ON VALVES TO CLEAR

ECCENTRIC REDUCERS AT PUMP CONNECTIONS

The complexity of piping system design, maintenance,
and troubleshooting requires the process Engineers, the
Maintenance Engineers and the Piping Engineers on the
same Wavelength and work more closely together.
Fig. 3.1.6
 The following general concepts apply for locating the heat
exchangers.

a) Exchangers should be located adjacent to the related

equipment., e.g. Reboilers should be located attached/
next to their respective towers, condensers should be
located next to reflux drums close to tower.

b) Exchangers should be close to the other process

equipment e.g. in case of draw off flow
through an exchanger from a vessel/reactor
bottom, the exchanger should be close to and
under the vessel or reactor to have short pump
suction lines. Overhead condenser shall be
placed above the reactor to have minimum
horizontal piping.
 c) Exchangers connecting two equipment, one on shell
side and the other on the tube side, located at a
distance, should be placed where two streams meet,
and on that side of the yard where majority of related
equipment is placed.
d) Exchangers between process equipment and the
battery limit. e.g. product coolers, should be
located near the battery limit to reduce pipe
rum.
e) Stack those exchangers which can be grouped
together to simplify piping and save plot space.
f) Leave space and access around the exchanger flanges
and heads, and tube bundle cleaning/pulling space in
front and in line with the shell.
 g) While locating exchangers in a row, arrange the
saddle to have more economical overall (lined up or
combined) foundation / structure design. Further,
travelling gantry can be provided in such case to
handle a row of exchangers.
h) The heat exchanger shall be located in the equipment
layout with respect to the fixed saddle and the
same is located closer to the head
i) Outline the clearances and working space in the front
and around both ends of the exchanger to facilitate
shell cover and tube bundle removal as well as
maintenance and cleaning.
j) The channel end shall face the roadside for
convenience of tube removal and the shell
cover the rack side.
The various clearances shall be as indicated in Fig. 3.3.1.
 All Dimensions are in mm
Fig. 3.3.1a
  

Fig. 3.3.1b
 The basic principles adopted in the heat exchanger
piping are:
 
a) The working spaces should be kept clear of
any piping and accessories to facilitate
channel, shell- cover and tube bundle removal,
as well as maintenance and
cleaning.
b) Excessive piping strains on the exchanger
nozzles from the actual weight of pipe
and fittings and from forces of thermal
expansion should be avoided.
c) The piping shall be arranged in such a way that no
temporary support will be required for removing
the channel and tube bundle.
 d) Provide easily removable spool pieces, flanged
elbows, break flanges, or short pipe runs to provide
adequate clearances for the operation of tube
removal.
e) The pipe lines with valves and control valves should
run along with access aisle close to the exchanger.
f) Pipe line connecting the exchanger with adjacent
process equipment can run point to point just above
required head room.
g) Steam lines connecting the header on the rack can
be arranged on either side of the exchanger
h) Valve handles should be made accessible from the
grade and from access way. These access way
should be used for arranging manifolds, control
valves stations and instruments
 i) To avoid condensate drainage toward exchanger, the
preferred connection for steam lines is to the top of
the header. However, there is nothing wrong in having
a steam connection from the bottom of the header if
steam traps are placed at the low point
j) The standard dimensions related to exchanger
piping are given in sketch.
These details are illustrated in Fig. 3.3.2.
  

Fig. 3.3.2a
 

Fig. 3.3.2b
 The basic types used in the chemical process
industry are –
 
1)  Fixed tube-sheet Heat Exchange
 
2) `U’ Tube Heat Exchangers
 
3)  Floating Head type Exchangers
 
4)   Kettle type Heat Exchanger
 
 
 HEAT EXCHANGE NOMENCLATURE
N-2 NOMENCLATURE OF HEAT EXCHANGER
COMPONENTS

For the purpose of establishing standard terminology,

Figure N-2 illustrates types of heat exchangers. Typical part
and connections, for illustrative purposes only, are numbered
for identification table N-2
Table N-2
1.    Stationary Head –Channel
2.    Stationary Head – Bonnet
3.    Stationary Head Flange-Channel or Bonnet
4.    Channel Cover
5.   Stationary Head Nozzel
6.   Stationary Tubesheet
7.   Tubes
8.    Shell
9.    Shell Cover
10.  Shell Flange-Stationary Head End
11.  Shell Flange-Rear Head End
12.  Shell Nozzel
13.  Shell Cover Flange
14.  Expansion Joint
15.  Floating Tubesheet
16. Floating Head Cover
17.  Floating Head Cover Flange
18.    Floating Head Backing Device
19.    Split Shear Ring
20.    Slip-on Backing Flange
21.    Floating Head Cover External
22.    Floating Tubesheet
23.    Packing Box
24.    Packing Gland
25.    Packing Gland
26.   Klfjadlfkaj
27.    Tierods and Spacers
28.    Transverese Baffles or Support Plates
29.  Impingernent Plate
30.  Longitudinal Baffle
31.  Pass Partition
32.  Vent Connection
33.  Drain Connection
34.  Instrument Connection
35. Support Saddle
36.  Lifting Log
37. Support Bracket
38. Weir
39. Liquid Level Connection
 FRONT END REAR END
STATIONARY HEAD TYPES SHEEL TYPES HEAD TYPES

E L
A ONE PASS SHELL
FIXED TUBESHEET
LIKE "A" STATIONARY HEAD

CHANNEL
AND MOVABLE COVER
M
F
FIXED TUBESHEET
TWO PASS SHELL
LIKE "B" STATIONARY HEAD
WITH LONGITUDINAL BAFFLE

B N
G
FIXED TUBE SHEET
LIKE "N" STATIONARY HEAD
BONNET (INTEGRAL COVER) SPILT FLOW

P
H OUTSIDE PACKED FLOATING HEAD
REMOVABLE
C TUBE
BUNDLE DOUBLE SPLIT FLOW
ONLY

CHANNEL INTEGRAL WITH TUBE- S

SHEET AND REMOVABLE COVER
J FLOATING HEAD
WITH BACKING DEVICE

DIVIDED FLOW

N T
PULL THROUGH FLOATING HEAD

CHANNEL INTEGRAL WITH TUBE- K

SHEET AND REMOVABLE COVER

KETTLE TYPE REBOILER U

U-TUBE BUNBLE

D
X
W
SPECIAL HIGH PRESSURE CLOSURE DIVIDED FLOW EXTERNALLY SEALED
FLOATING TUBESHEET
32 2 3 6 32 8 1 37 27 29 14 12 34 2

5 34 12 37 33 6 3

BEM
36 4 3 5 31 34 12 1 30 21 27 1 32 9
34

1 34 5 6 10 12 34 35 35 33
CFU
Standards Of The Tubular Exchanger Manufacturers Association
36 4 3 5 34 31 12 34 23 27 28 8 7 32 15 23 24 25 22 36

1 34 5 6 10 33 35 35 34 12 19 20 21
3

AEP
36 34 5 3 10 1 2 28 12 34 27 23 24 26 24 23 15 1 36

4 3 1 6 34 12 35 35 34 12 34 5 3 4

Standards Of The Tubular Exchanger Manufacturers Association

36 4 3 5 34 31 6 31 12 25 7 8 27 28 18 36 37

36

15

18

1 5 34 35 12 11 13 12 33
3 10 35 34

Standard Of The Exchanger Manufactures Association

 8 34 12 35

36 4 3 34 5 31

15 17 36 34

16

1 5 34 3 6 38 34 12 35 27 28 7 35 12 34 39

AKT
 The following alterations can be suggested in order to
achieve optimum piping arrangement.
  a) Elbow nozzle permits lowering of heat exchanger to
grade to have better accessibility to valves and instruments.
(Refer Fig. 3.3.3)
  b) Angular nozzle can save one or two bends in the pipe
line.The maximum angle from the vertical centre line can be
about 300. (Refer Fig. 3.3.4) 
c) Horizontal exchanger can be turned vertical for
conserving floor space. Vertical exchangers can be changed
to horizontal when installation height is restricted
d) Exchanger saddle can also be relocated to adjust to a
line-up or combined foundation design. (Refer Fig. 3.3.2)
Fig. 3.3.3
Fig. 3.3.4a Fig. 3.3.4b
 Interchange flow media between tube side and shell side.
This can give the following advantages…
 
   If hotter liquid is allowed to flow through the tube,
this will minimize the heat loss and/or avoid
use of thicker shell insulation.
    If high pressure fluid flows on the tube side, only tubes,
tube sheets, channels and cover have to be designed for
high pressure. This reduces shell side thickness and the
cost.
    Corrosive liquid should pass through the tube so that
only the tubes and the channels have to be made of
corrosion resistant material.
 If one medium is dirty and the other is clean, passing
clean through the shell will result in easier tube bundle
removal and cleaning.
  Shell side volume is much more than the tube side
and hence vaporization or condensation of free
flowing fluid is more effective in shell.

   When hazardous chemicals are water cooled, the

water is passed through the shell. The tube leakage
will contaminate the cooling water. On the other
hand, the shell leakage can vent process material to
the atmosphere.

 
The piping associated with these vessels are simple.
Economy of piping and access to valves and instruments
depend on well-oriented nozzles. The nozzle and support
orientation can be evaluated as below. (Refer Fig. 3.4.1)

      Inlet/outlet nozzles

      Vents and Drains 
      Relief Valves/Rupture Disc 
      Level gauges 
      Pressure and Temperature tap-offs. 
      Manholes 
      Vessel saddles
Fig. 3.4.1
 
  
Fig. 3.4.2
 
  
Fig. 3.4.3
  

Fig. 3.4.4
Fig. 3.4.5
 Let us analyze the equipment layout and Piping design for a
distillation column, which is more of an integrated unit than the
individual equipment discussed earlier.
 
Interactions between hydraulic requirements and piping
configurations require close attention to many fluid and
mechanical details, in order to obtain the most efficient and
economical distillation units.
 

Fig. 3.5.1
 

Fig. 3.5.2
  

Fig. 3.5.3
 
Fig. 3.5.4
 The prime consideration in all these cases is the performance
to achieve the process requirements integrated with economy.
 
 
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