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PIPINGLAYOUT|PIPINGGUIDE

PIPINGLAYOUT
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Piping is a major expenditure in the design and construction of industrial,

refinery, petrochemical, or powergenerating plants when one considers
engineering costs, material costs, and fabrication and field labor costs.
Properplanningandexecutionofthedesignandroutingofpipecanhavea
majorimpactoncontrollingthetotalinstalledcost(TIC).
Piping design and equipment arrangement are interrelated subjects that
cannot be well taught in the classroom. Most good designers throughout
history have learned their profession by a combination of academic and
practical work. Field and design office plus a little shop experience is good
preparation for designing or teaching. This topic is very broadbased and
reliesonasoundmechanicalengineeringbackgroundandalotofcommon
sense.Theuseofpreviousdesignsanddrawingsisagoodwaytolearnandimproveoncurrentdesigns.

Theexperiencedpipingdesignerneedstohaveaworkingknowledgeofplantlayout,equipmentarrangement,andsystem
functionality associated with one or more fields of endeavor, such as commercial, industrial, refinery, petrochemical, or
power. In addition, the designer must have an understanding of the practical application of piping materials, valves,
pumps,tanks,pressurevessels,heatexchangers,powerboilers,vendorsuppliedskidassemblies,steamturbinedrivers,and
othermachineryandequipment.

CODESANDSTANDARDS
Thesecodesandstandardswerewrittentoestablishminimumrequirementsforsafedesignandconstructionwithverylittle
referencetothephysicalroutingofpiping.However,thepipingdesignershouldbefamiliarwiththemastheyapplytohis
orherwork.Thereareafewspecificreferencestophysicalpipingdesignofsafetyreliefvalvearrangements:
TheASMEBoilerandPressureCode,SectionI,PowerBoilers,specifiesthatthereistobenointerveningpipe,valves,or
fittings between the safety relief valves and the vessel or piping to which they are attached. This means that they must be
fittingbound.
The ASME B31.1, Power Piping Code, Appendix II, NonMandatory Rules for the Design of Safety Valve Installation,
providesguidelinesforthephysicalarrangementofsafetyvalvepiping,themostsignificantbeingthatthedistancebetween
the centerline of the valve and the centerline of the discharge elbow must not exceed 4 times the nominal pipe size of the
reliefvalveoutlet.
The Pipe Fabrication Institute has a series of engineering standards (ES) covering the fabrication, design, cleaning, and
inspectionofpiping.Threeofthesestandards,listedbelow,specificallyrelatetothephysicalpipingdesign:
ES2,MethodofDimensioningWeldedAssemblies
ES3,LinearTolerances,BendingRadii,MinimumTangents
ES7,MinimumLengthandSpacingforWeldedNozzles

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For piping and valve drawing symbols, refer to ANSI/ASME Y32.2.3, Graphical Symbols for Piping Fittings, Valves and
Piping. It is essential that designers read and understand applicable codes and standards prior to developing fabrication
pipingdesigns.

PIPINGLAYOUTCONSIDERATIONS

ProjectClientandOwnerRequirements
Most projects have projectspecific requirements imposed by the owner. These usually include additional requirements
above the codes and standards which may have direct impact on both pipe layout and equipment location. Most of these
requirements derive from operations feedback which the owner contractually invokes on future projects. Owners may not
have a thorough understanding of all the levels of detail required to produce a piping design, but they know the finished
product.Itisveryimportantthatallprojectpersonnelanddesignersknowandunderstandtheserequirements.

HierarchyofReferenceDesignInformation
In the everexpanding electronic engineering environment, the documents identified can and will be replaced with
databases,buttheflowofrequiredinformationtodesignthepipingsystemswillremainthesame.

SystemPipingandInstrumentationDiagrams(P&ID)
Thesearetheschematicsinglelineprocessdiagramswhichdefinethesequenceofequipment,valves,inline
components, pipeline sizes, and overall system arrangement required for proper system function. Computeraided P&IDs
that link the schematic diagrams to electronic design data are preferred in order to perform computerized P&ID
compliancechecks.

P&IDImplementationandPhysicalization
Pipingandinstrumentationdiagramsarethepipingdesignersroadmapforlayingoutpipingsystems.Thedesignershould
understand the P&ID and the specific system characteristics. With this knowledge the designer is required to develop the
P&IDandarrangeconnectionsandbranchesasrequiredtobestsuittheprocesstoactualphysicaldesign.

ProjectPipingSpecifications
These documents or databases define the following essential information: the system design and operating pressures and
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temperaturespipingmaterialspipewallthicknessorschedulestypesoffittingstobeused,e.g.,buttweld,socketweld,or
screwedandthevalveandflangepressureratingandinsulationrequirements.Inaddition,thepipingspecificationdefines
the fabrication, examination, testing, inspection, and installation requirements, including the requirements for seismic
installations,whereapplicable.

EquipmentOutlines
Thesedocumentscanbeeitherimportedcomputeraideddesignanddrafting(CADD)filesorprintsoftheequipmentbeing
piped.Theyincludeoveralldimensionsandthepipesize,wallthickness,flangepressurerating,andlocatingdimensionsof
allpipenozzlesandotherconnections.

GeneralArrangementsorEquipmentLocationDrawings
Thesedrawingswillindicatethelocationofallmajorpiecesofequipmentintheplantwhichthedesignerwilleitherverify
orrelocate,asrequired,toaccommodatethephysicalpiperoutingasdesignedorredesignthepipingtoaccommodatethe
particularpieceofequipment.
Generallyequipmentlocationdrawingsaredevelopedbyseniorlevelpipingdesignersduringtheproposalpreparationand
aretakenoverbytheprojectteamuponawardofthecontract.Fromthispointontheyarerevisedandupdatedaspartof
the normal process of design development. Equipment should be arranged with the piping layout in mind. Equipment
locations and relational arrangements should be evaluated during the piping layout design process. Adjustments and
occasionally major changes to equipment arrangement are required to solve major piping arrangement problems. Piping
systemdesignisdependentontheinputfromnumerousreferencesourcespriortothestartofpipingdesign.

CollectionofAsBuiltInformation
CADD and electronic surveying capabilities have changed and are continuously changing. Photogrametry (photographs
that are input into threedimensional CADD models) and laser mapping (laser scanning using a time of flight laser
connected to a computer that translates the scanned points to a threedimensional CADD model) are applications that
enable the designer to collect existing conditions which can be imported into the designersCADDfiles. Total Station
Surveyingisthecomputerizedsurveyingsystemwhichengineeringshouldrequestforthecollectionofsurveydatapoints
withtheelectronictransferofinformationbeingabletobetranslateddirectlyintotheCADDenvironment.

PipingLayoutConsiderationsandPlanningStudiesforImprovedPipingEconomics
Proper planning is an important activity performed by the piping designer in the early stages of a project. Space
conservationandasymmetricpipingarrangementareachievedwhenallthesystemsareevaluatedinthepreliminarystages
ofdesign.Thisstudywillbecomethefinaldesign.Itisimportanttoconsiderthecostofthepipingmaterialatthistimefor
the expensive lines. These lines should be kept as short as possible, while maintaining proper piping flexibility even if this
requireschangingtheequipmentarrangement.
Detaileddesignshouldnotstartuntiltheplanningstudiesarecomplete.Expendingengineeringworkhoursondetailsthat
aresubjecttochangependingthecompletionoftheplanningstudyisnotrecommended.
Pipinglayoutthenbecomesamatterofdesigningdimensionedroutingsfromonepointtoanotherpointwiththebranches,
valves,pipingspecialties,andinstrumentationasindicatedontheP&ID.Thisstatement,however,isanoversimplification
of the process, since many other factors must be considered, such as interference, piping flexibility, material costs, pipe
supports,operationandmaintenance,andsafetyandconstructionrequirements.
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An example would be moving a pump 3 in (75 mm) to avoid a compound elbow offset in order to connect to the top
dischargenozzle.Perhapstheequipmentwasarrangedwhileplanningonasidesuctionanddischarge.

FIG:Nozzlealignmentdrawing.

PipeBending
Pipe bending has become increasingly widespread due to a desire for a decrease in fabrication costs. If bending is to be
used, the designer should consider special requirements imposed by the process (i.e., tail ends and clamp dimensions are
requiredbythebendingmachine,andincreaseddistancesandspacearerequiredbecausebendshaveagreatercenterto
facedimensionthanconventionalfittingdimensions).

Interferences
Oneofthemostimportantaspectsofpipinglayoutistheavoidanceofinterferenceswithotherfacilitiesintheplantsuchas
other piping systems structural steel and concrete heating, ventilating, and airconditioning (HVAC) ductwork and
electric cable trays and conduit. For engineering firms using 2D CADD (twodimensional computeraided design and
drafting)ormanualdraftinganddesign,thesearchforinterferencesisverytediousandtimeconsumingsincethedesigner
mustmentallyandvisuallylookforinterferencesbetweenthesystemscurrentlybeingdesignedandpreviouslydesignedor
the existing system or facilities, not to mention those systems or facilities in design concurrently. This process is extremely
complexatbest.Traditionally,thishasbeenaccomplishedbytheuseofareacompositedrawingsandplasticscalemodels.
Thecompositedrawingsandplasticmodelsshowallplantfacilitiesdesignedtodateandareusedbythedesignerstoselect
aninterferencefreerouteforthesystemcurrentlyunderdesignhowever,thedesignerstillmustsearchoutthosesystems
orfacilitiesindesignconcurrently.Oncethedesignerissatisfiedthatthecurrentsystemlayoutisinterferencefree,itwillbe
addedtotheareacompositedrawingandtheplasticmodel.
An alternative to composite piping drawings and plastic models for interference detection is the use of computeraided
design(CAD).Specifically,threedimensional(3D)computermodelingcanprovideanefficient,accurate,andcosteffective
alternativetothetraditionalmanualmethodsforinterferencedetection.ThisandotherCADapplicationsforpipinglayout
areaddressedinthesectionApplicationofComputerAidedDesigntoPipingLayout.

PipingFlexibility
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The effects of the thermal expansion of pipe and fittings as a result of system operating temperature changes cannot be
overlookedduringthelayoutandroutingofanypipingsystem.Thefunctionofpipingflexibilityorstressanalysishas,for
themostpart,beendelegatedtothecomputerparticularlyinthecaseofhightemperature,highpressurepipingsystems.
Thepipingstressanalysttranslatesandentersthepipingdesigndataintothecomputer,reviewstheoutputdata,andifthe
systemistoorigid,maysuggestappropriatecorrectiveredesigns.However,itisthepipingdesignersresponsibilitytoensure
that the final stress analysis results are incorporated into the final pipe support and pipe routing design. In the past, a
computerstressanalysis,includingthedevelopmentofinputdataandtheinterpretationoftheoutput,couldbeexpensive
and timeconsuming if numerous iterations of computer runs were needed to arrive at an acceptable system design. The
experiencedpipingdesigner,withtheknowledgeandcapabilityof

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FIGURE:Areapipingcomposite.

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FIGUREB3.2(Continued)Areapipingcomposite.

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FIGURE:A3DCADmodelusedforinterferences,equipmentlayout,andpiperouting.
designing piping systems that are inherently flexible, was relied on to keep the number of computer iterations to a
minimum.Today,thisismuchlessofaproblemwiththeadventofthepersonalcomputerandmanycomputerprograms
forcalculatingstressesinpipingsystemsduetothermalexpansionandotherstaticanddynamicloads.However,thepiping
designermustintegratepipingflexibilityconsiderationsintothepipinglayout.
Thepipingdesignershouldroutepipingwithflexibilitydesignedintoit,usingtheminimumamountofpipe,fittings,and
expansionloopsbyconsideringthefollowing:
Avoidtheuseofastraightrunofpipebetweentwopiecesofequipmentorbetweentwoanchorpoints.
Apipingsystembetweentwoanchorpointsinasingleplaneshould,asaminimum,beLshaped,consistingoftworunsof
pipeandasingleelbow.Thistypeofarrangementshouldbesubjectedtoaquickcheckanalysistodetermineifaformal
computerstressanalysisisrequired.ApreferredsolutioninthiscasemaybeaseriesoftwoormoreLshapedrunsofpipe.
ApipingsystembetweentwoanchorpointswiththepipingintwoplanesmayconsistoftwoLshapedrunsofpipe,e.g.,
oneLshapedruninthehorizontalplaneandanotherintheverticalplane.Thisarrangementshouldalsobesubjectedtoa
quickcheckanalysis.
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AthreeplaneconfigurationmayconsistofaseriesofLshapedrunsand/orUshapedexpansionloopsdesignedintothe
normalroutingofthesystem.
When the expected thermal expansion in any given run of pipe is high, consider the use of an anchor at or near the
centeroftherun,therebydistributingtheexpansionintwodirections.
Forsystemsconsistingofalargediametermainandnumeroussmallerbranchlines,thedesignermustascertainthatthe
branchesareflexibleenoughtowithstandtheexpansioninthemainheader.
Systems which are to be purged by steam or hot gas must be reviewed to ensure that they will be flexible during the
purgingoperation.
System or equipment bypass lines may be cold due to lack of flow while the main runs are at operating design
temperature,resultinginexcessivestresses.
Temperaturesduringinitialstartupandtestingareoftengreaterthanthoseatoperatingconditions.
Closedreliefvalveandhotblowdownsystemsshouldbegivenspecialattentionduetorapidtransientsintemperature.
Inaddition,thepipingdesignermayuseavarietyofsingleandmultiplanepipingarrangements,suchastheLshaped,the
Ushaped,andtheZshapedconfigurations,inthenormalroutingofanysystem,asshowninFigs.B3.4throughB3.9.

Valves
Thepipingdesignermustbefamiliarwithproperapplicationofalltypesofvalvesincludinggate,globe,plug,butterfly,ball,
angle,diaphragm,check,pressurerelief,andcontrolvalvesandtheirmethodsofoperationincludingmanual,chain,gear,
air,hydraulic,ormotor.Thefollowinggeneralguidelinesshouldbeappliedwhenlocatingvalvesinanypipingsystem:
Valvesshouldbeinstalledwiththestemsbetweentheverticallyupwardandhorizontalpositionswithparticularattention
giventoavoidingheadandkneeknockers,trippinghazards,andvalvestemsinthehorizontalplaneateyelevelthatmaybe
asafetyhazard.Largemotoroperatedvalvesshouldbeinstalledintheverticaluprightpositionwherepossibletofacilitate
supportandmaintenance.
Valves in acid and caustic services should be located below the plant operators eye level or in such a manner as to not
presentasafetyhazard.
Thelocationofvalves,withconsiderationforoperatingaccessibility,shouldbeaccomplishedinthenaturalroutingofthe
systemfrompointtopoint,avoidingtheuseofverticalloopsandpockets.
Valves in overhead piping with their stems in the horizontal position should be located such that the bottom of the
handwheel is not more than 6.5 ft (2 m) above the floor or platform. Only infrequently operated valves should be located
abovethiselevation,andthenthedesignershouldconsidertheuseofachainoperatororaplatformforaccess.
Wherechainoperatorsareused,thevalvesshouldbelocatedsuchthatthechaindoesnotpresentasafetyhazardtothe
operatingpersonnel.
Aminimumof4in(100mm)ofknuckleclearanceshouldbeprovidedaroundallvalvehandwheels.
Valvesshouldnotbeinstalledupsidedown.
Spaceshouldbeprovidedfortheremovalofallvalveinternals.
Improperapplicationandplacementofvalvesinthepipingsystemcanbedetrimentaltosystemfunction.Thiscanresultin
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malfunctionofthevalveandinwaterhammer,andthiscancausethevalvestoliterallyselfdestruct.Whatfollowsaresome
specificrecommendationsandmethodsofavoidingtheseproblemsforsomespecifictypesofvalves.

ControlValves
All control valve stations should be designed with the valve stem in the vertical upright position and a minimum of three
diametersofstraightpipebothupstreamanddownstreamofthecontrolvalve,inordertoreducetheturbulenceentering
andleavingthevalveandtoprovidespaceforremovaloftheflangestudsorbolts.Whereapplicable,thisstraightpipewill
includetheusualreductioninpipesizerequiredtomatchthecontrolvalvesize.Spacemustbeprovidedforflangestudbolt
removalwherecontrolvalvebodiesaredesignedforthroughboltinstallation.

ButterflyValves
Butterfly valves should be provided with a minimum of five diameters of straight pipe upstream of the valve and if this
requirement has been met, the valve stem and operator may be oriented in the position best suited for operation and
maintenance.Whenabutterflyvalveisprecededbyanelbowandthisstraightpiperequirementcannotbemet,thevalve
stemmustbeorientedinthesameplaneastheelbow.Thatis,iftheelbowisintheverticalplane,thevalvestemmustalso
beintheverticalplane.Thisrecommendationisbasedonthefactthatthevelocityprofileofthedischargeofanelbowisnot
symmetric.Theresultcanbefluiddynamictorquethatistwicethemagnitudeofthatfoundforavalvewithastraightrun
of pipe upstream. The resultant eccentric forces applied to valve disk produces excessive vibration and disk flutter which
eventuallymaycompletelydestroythevalve.

CheckValves
The preferred installation of any check valve is in a horizontal, continuously flooded run of pipe with cap up however,
swingcheckvalveswillfunctionproperlyinverticalrunsofpipewiththeflowup.However,thevelocityandtherateofflow
mustbeadequatetomovethevalvediskawayfromtheseatandtomaintainthevalveintheopenposition,asrequired.
Experience has indicated that check valves are highly susceptible to chattering due to upstream turbulence caused by
elbows and branches. Therefore the designer should provide upstream straight pipe in accordance with the valve
manufacturersrecommendations.However,wherethisinformationisnotavailable,thepreliminarydesignshouldinclude
aminimumoffivediametersofstraightpipeupstreamofall
check valves. In addition, the designer should be aware that this requirement can be as much as 10 diameters of straight
pipedependingonthetypeofvalveandthemanufacturer.

SafetyReliefValves
Thearrangementforinstallationofsafetyandreliefvalvesisverycriticalandinvolvestheactuallocationofthevalveitself,
the design of the vent stack, and the design of any associated drain piping. The designer should adhere to the valve
manufacturersrecommendationsandthefollowingguidelineshowever,theseguidelinesrelatetothepowerindustryand
maybeusedelsewhere,asapplicable.

ValveLocation
All relief valves must be in the vertical upright position and fittingbound to the top of a horizontal run of pipe, the
pressuresource,andmustnotbelocatedlessthanonenominalheaderdiameterfromanybuttweld.

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