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SEM - 3069E
Piping Design
Compressor & Turbine Piping Design Standard
REV. : 3
DATE : 2004. 08. 20
ENGINEERING MANUAL
SEM - 3069E
REV. 3
DATE :
2004.08.20
PAGE
OF
Table of Contents
Page
1.
2.
3.
4.
5.
General
1.1
Purpose
1.2
Scope
------------------------------------------------- -----------------
---------------------------------------------------------------------
1.3
Reference
-----------------------------------------------------------------
COMPRESSOR General
2.1
--------------------------------------
2.2
Compressor Comparison
-----------------------------------------------------
------------------------------------------------------------
COMPRESSOR/TURBINE LAYOUT
3.1
Layout General
3.2
3.3
Installation Height
3.4
---------------------------------------------------
-------------------------------------------------------
---------------------------------------------------
------------------------------------------------
Piping LAYOUT
4.1
4.2
4.3
4.4
Strainer Installation
4.5
---------------------------------------------------
11
------------------------------------------------
12
------------------------------------------------------
12
----------------------------------------------
14
Standard
-------------------------------------------------------------------
5.2
5.3
Consideration
----------------------------------------------
--------------------------------------------------------------
14
14
15
ii
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PAGE
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PIPING SUPPORT
6.1
----------------------------------------
15
6.2
16
6.3
---------------------------------------------
16
6.4
---------------------------------------------
20
------------------------------ -------------------
21
---------------------------------------------------------------
22
7.
8.
Revision History
APPENDIX
. Compressor Pipe Fixed Point Selection Method
. Compressor Pipe Construction Method(SAMPLE)
. Reference Plot Plan (MOP, GSP-5, PEMEX-Tula, IOCL)
ii
ENGINEERING MANUAL
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OF
General
1.1
Purpose
This Manual aims to reinforce and standardize the Piping Layout (Incl Supports) for Compressor
/Turbine systems for oil refinery and Chemical Plants designed by SECL.
1.2
Scope
This Manual applies to large Compressor/Turbine Piping of all plants to be implemented by SECL.
For Any Disparity With The Client Spec, the latter shall prevail.
1.3
2.
Reference
1.3.1
SEM-2002E
1.3.2
SEM-3002E
1.3.3
SEM-3039E
1.3.4
SEM-3040E
"Pipe Support"
COMPRESSOR General
2.1
Centrifugal Compressor
It uses a rotating disk or impeller in a shaped housing to force the gas to the rim of
the impeller, increasing the velocity of the gas. It comes usually in Package Type,
and is composed of Inter-cooler, After-cooler, Lube Oil System, Seal Oil System,
Surface Condenser, Automatic Control,etc. Motor or Turbine is used as Driver and its
advantage is that Oil-free air/gas is supplied.
2.1.2
Reciprocating Compressor
The intake gas enters the suction manifold, then flows into the compression cylinder
where it gets compressed by a piston driven in a reciprocating motion, and is then
discharged. It is composed of Lubricated Type and Non-lubricated Type. Non-lubricated
Type is used for Instrument Air. It is used for capacity of Air below 30 N/min
and
Screw Compressor
It is a type of gas compressor which compresses gas in rotor cavity and achieves
ENGINEERING MANUAL
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pressure. It is capable of achieving pressure range around 7.0 ~ 8.5 Kgf/. It is not
suitable for high pressure.
2.2
Compressor Comparison
Screw Compressor
Reciprocating Compressor
Type
Consideration
screw
reciprocating
Efficiency
Capacity
Control
possible in
On-load/Off-load type
No effect on efficiency as
Mechanical Friction only in
Bearing
Operating Valve
No
Pulse
Less
More
Vibration
Less
More
Noise
Motor
size)
Base
Small
Installation
Space
Compact
Credibility
good
Durability
large
large
poor due to friction, damage of
operating valve
great care is to be taken due to noise,
Operation
Pressure Range
limited
3.
COMPRESSOR/TURBINE LAYOUT
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ENGINEERING MANUAL
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Installation General
3.1.1
Should be installed near Road for an easy access to Mobile Equipment for Maintenance.as
per requirements of layout.
3.2
3.1.2
Layout shall be as per Regulations of Oil, Noise, Fire Fighting & dangerous object, etc.
3.1.3
Type
Climate Condition
Outdoor Type
Warm Zone
Tropical Zone
Enclosure Type
Other Condition
Note
Layout Reference.
3.2.1
(2)
(3)
annexed device (Condenser, Cooler, Separator, Lube & Seal Oil System )
(4)
Cost would increase due to Width Extension of Traveling (or Overhead) Crane &
Architecture
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[Figure 3-1]
3.2.2
PAGE
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(2)
(3)
(4)
outside.
(5)
Architecture would result in a narrow and long shape so is susceptible to Area when
the overall Plant is set in place.
[Figure 3-2]
3.2.3
L-Shape Type
(1)
(2)
(3)
(4)
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[Figure 3-3]
3.3
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24
Installation Height
Generally Installation Height, Configuration, etc. is to be based on the requirements of
Compressor Vendor. But, Final Installation Height of Compressor is to be decided after review
thoroughly each Height of the below items required by Compressor Type.
3.3.1
Centrifugal Compressor
(1)
(2)
(3)
Slope Requirements of Lube Oil, Seal Oil System Location and Pipe
(4)
Maintenance Space Height of Annexed Device such as Condenser, Lube & Seal Oil System
(5)
Overhead Clearance
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[Figure 3-4]
3.3.2
PAGE
OF
Reciprocating Compressor
(1)
(2)
(3)
(4)
Minimum Distance between Beam Size & Dampener for Operating Platform
[figure 3-5]
24
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It is to be easy for Plant Operator to reach and operate Valves, Switches, Control
Panel instruments.
(2)
(3)
(4)
Bottom Style
Floor Arrangement Style around Compressor
Traveling Crane
(1)
(2)
(3)
Traveling Crane Installation Height is to be decided after review the below items
thoroughly.
1)
2)
3)
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(4)
Generally
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of its Height. But, decide based on item (4) and [Figure 3-7] & [Table 3-1] in case
Specific Information of (3) is not available.
[Figure 3-7]
[Table 3-1]
H1
H2
3.4.3
Small Compressor
4.0 m
Medium Compressor
5.0 m
Large Compressor
7.0 m
20 ton
2.6 m
30 ton
2.8 m
40 ton
3.0 m
Note
In case they are to be installed at the bottom of Compressor Deck, Make provision for
Installation & Removal.
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3.4.4
PAGE
(2)
(3)
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24
It has to be accessible from Road and, and it should be at convenient place to install
and load.
(2)
(3)
If Compressor House is closed type, Upper Floor (2nd F) of Oil System Installation
should be of removable type (Grating) for Maintenance.
(4)
Control Panel and Piping shall not to be installed in Grating Area of the above(3).
(5)
Oil Console to be installed such that Traveling Crane can be used in case of
Maintenance.
(6)
(7)
Pathway for Operation (Width Min. 800) is to be ensured enough around Oil Console.
(8)
Seal Oil Head Tank is to be installed in the place where it is not interfering with
Traveling Crane Operation.
(9)
Seal oil head tank are to be installed outside of Compressor House in case there is no
problem of Freezing or when the Capacity is above 2 ton.
(10) Installation Height of Seal Oil Head Tank is to be complied with Vendor's requirements.
(11) Installation Height of Oil Trap is to complied with Vendor's requirements.
3.4.5
Drop Area
(1)
It is to be the place where truck can have an easy access and direct unloading/loading
from Road.
3.4.6
(2)
(3)
Drop Area Section is to be based on the max. Size of the below items.
1)
Compressor or Turbine
2)
3)
4)
Control Panel
(1)
(2)
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Pipe LAYOUT
Pipe connecting to Compressor or Turbine is to be installed in order of High Temperature, Large Bore,
Heavy-wall. Detailed Standard by Pipe Type is be based on the below.
4.1
4.1.2
A Min. of
for even flow. But, if Vendor Requirement is available, then, this shall be taken up at
priority.
4.1.3
In case Tee is used instead of Elbow in Suction Nozzle, Min. 6D of Straight Run is to be
ensured. But, again Vendor Requirement shall govern.
4.1.4
In case Injection Nozzle is to be installed in Vertical Straight Run right before the
Suction Nozzle as per Straight Run
Suction/Discharge Lines.
4.1.6
4.1.7
In case By-pass Pipe for Minimum Flow connecting Suction and Discharge, install Pipe and
Support to minimize vibration generated by Pressure Difference.
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[Figure 4-2]
4.1.8
PAGE
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4.1.9
Check Valve (Non-slam, etc.) in Discharge should indicate Pressure Drop, P clearly in
Special Part Data Sheet.
4.1.10
4.1.11
4.1.12
In case Valve Body is Low Point according to overall Pipe Arrangement, Drain Valve is to be
installed to Valve Body.
4.1.13
In case Suction Pipe is branched from Main Header, branch shall be from top of Main Header
to prevent Condensate Flow to compressor/turbine.
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[Figure 4-3]
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4.1.14
4.1.15
Valve, Chest & Casing Drain Nozzle Connecting Pipe installed in Compressor is to be
connected to individual Drain Funnel.
4.2
4.1.16
Maintenance Area not to interfere with Strainer Screen Installation and Removal.
4.1.17
4.2.2
Main Valve of Suction Steam Pipe is to be installed adjacent to Turbine as close as possible
for access to instrument and equipment while operating.
4.2.3
4.2.4
4.2.5
Discuss with Process if Steam Trap is necessary in case Suction Pipe to Turbine Nozzle is
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Install Steam Trap right before Vertical Pipe to Turbine Nozzle (as shown in [Figure 4-4])
with Drip Pot to prevent Condensate flow.
[Figure 4-4]
4.2.7
See related Specification and SECL Pipe Hand Book(Sheet No.5-21) for Drip Pot
Configuration and Detailed Size.
4.2.8
4.2.9
Nozzle.
Design Steam Pipe connected to Turbine to prevent any problem in case of Steam Blow-out.
4.3.2
Be sure not to arrange Oil Pipe at top of Steam line or other high temperature Pipe to
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prevent Fire.
4.3.3
Be sure to check Temperature Maintenance Requirement by Steam Tracing in Lube & Seal Oil
System.
4.3.4
Be sure to design foreign matter not to pile up at welding part by using Butt Welding
Fitting in case of small bore Pipe.
4.3.5
4.3.6
Be sure to install Break Flange at an interval of every certain length in case of cleaning
Pipe by Wash Vessel.
4.4
Strainer Installation
Be sure to install near Suction Piping Nozzle for the purpose of damage prevention of Compressor,
Impeller or Blade of Turbine, and Branch Pipe, Temperature Indicator, Pressure Gauge, etc is not
to be installed in the lower part of Strainer.
4.4.1
Temporary Type
[Figure 4-5]
(1)
Temporary Type
Be sure to install spool piece with Flange as [Figure 4-5] for Installation and
Maintenance of Cone Type Strainer.
(2)
(3)
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4.4.2
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Low-Pressure T-Type
(1)
(2)
Make sure that it does not effect Compressor Alignment in case of Strainer
Maintenance.
[Figure 4-6]
4.4.3
(2)
(3)
Provide Drain Valve as Double Block in case of High Pressure(above 600LB) as per
Process Requirement.
[Figure 4-7]
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Expansion Joint can be used for inadequate Flexibility for large bore Pipe of Suction
Side. comply with Client's or Process Requirements.
4.5.2
Normally Expansion Joint is used with Transition Piece in Turbine and Condenser Connecting
Pipe.
4.5.3
B 31.3
Calculation.
5.2
Code Standard
Type
Stnadard
Note
Centrifugal Compressor
Turbine
NEMA SM-23
taken a priority.
N ozzle
S ize
2. 2.Nozzle
Size
Standard
(Ambient
Temperature,
( , )
3. N ozzle
3. Nozzle Movement
4. N ozzle ,
4. 5.Nozzle
Location,
Alignment
5. Other Spec.
Thermal
Stress Analysis
C om puter
by Computer
Review
Value
Yes
Reflection to
Design
No
1. ,
2.2.Review
R Pipe
oute Route
Change
3.3.Review
Equipment
Change
Layout
Layout
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Consideration
5.3.1
Base Temperature for Pipe Expansion Calculation is as below and Vendor should provide
Nozzle Thermal Movement.
(1)
(2)
5.3.2
5.3.3
Be sure not to use Cold Spring or Counter Weight in order to reduce reaction force of
Compressor, Turbine Nozzle, or adjust Support Load.
5.3.4
Measure
Support Distance around Nozzle & Balance
Use Teflon in
reduction)
Spring Hanger Variability
Settlement
6. PIPING SUPPORTS
6.1
Be sure to review by Computer from the basic Design Stage and not only Support Structure
Type, & Installation Method but also Civil/Architecture Information in detail at the same
time.
6.1.2
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6.1.3
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Be sure to consider Loading Data for Hydro Test, Insert Plate Configuration & Allowable
Deflection of Structure
for Support
6.1.4
6.1.5
reqd.)
6.1.6
Be sure to use Support of which structure is simple and fabrication and installation is
easy but do not to use Support Type as [Figure 6-1] in
[Figure 6-1]
6.2
Centrifugal Compressor
(1)
(2)
In case Compressor, Turbine Connecting Pipe is not connected by break-up Flange for
Alignment, Design Support to minimize deflection by Piping Weight.
(3)
(4)
6.2.2
Reciprocating Compressor
(1)
(2)
6.3
Consideration by Support
6.3.1
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Nozzle.
(2)
[Figure 6-2]
(3)
(4)
Use Variable Type as much as possible and use Constant Type in case movement is
large and influence on Nozzle is more.
(5)
Base Type is not usually used but be sure to reduce Friction by using Sliding Plate
like Teflon or Graphite Pad if necessary.
(6)
Use Hanger Type to reduce Horizontal Force & Moment which is transmitted to
Friction Force and Nozzle.
(7)
Sway Strut can also be used to reduce Nozzle Load by reducing Friction Force (See
Fig 6-3)
[Figure 6-3]
SEM - 3069E
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(8)
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Design as the structure of function and role identical to Input condition in case
Stress Analysis.
(2)
(3)
Guide
Turnbuckle Style
(Preferred)
[Figure 6-4]
(4)
Guide Style
Attachment to cause Elastic deformation by heat like Clamp can't be used for the
purpose of Direction Stop. Use only Lug Plate(or Rib Plate) is attached directly to
Piping as [Figure 6-5] and Reinforcing Ring is attached to Clamp in addition.
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(5)
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Wrong Installation
Right Installation
[Figure 6-6]
(6)
[Figure 6-7]
(7)
ENGINEERING MANUAL
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[Figure 6-8]
6.4
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below. Be sure
(2)
(3)
[Figure 6-9]
6.4.2
Support Structure should have enough strength, be sure to send information on Allowable
deflection within 1mm including Loading Data to person in charge of Civil/Architecture.
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6.4.3
Be sure to use Insert Plate, Anchor Bolt in case Support is to be fixed in Concrete.
6.4.4
and Quantity
charge of
7.
PAGE
24
Civil/Architecture.
Planning Study
(1) P&ID (AFP)
Requirements
(4) Compressor annexed
P&ID)
Equip. Arrangement,
(5) Electrical/Instrument,
Detail Design
Moments
(5) Nozzle movement
(6) Vendor Requirements
(7) Electrical/Instrument,
Requirements
Civil/Architecture
Information
(8) Each Information
Configuration Decision
(3) Information for
Planning
Phase
Decision
Analysis
Assembly, Dismantling
Method
Space
(5)
/Instrument Information
(7) Civil/Architecture
Information
Civil/Architecture
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Revision History
No.
Date
1981. 7. 30
Page
Establishment Process
The Standard of Piping Design around Large Compressor
was not available. It resulted in the the difficulty
to standardize the consistency when it comes to Job
execution. So SECL Manual is established according to
Japan
(2)
1998.5.10
Department
Piping Team
Prepared by
Supervised by
Cheong Young-keun
Revision Process
It is based on the Piping Team Manual Revision Plan.
1998.10. 26
Department
Piping Team
Prepared by
Lee Joo-sang
Reviewed by
Kim Ki-pil
Approved by
Lee Myung-hak
Revision Process
It was based on Piping Team '98 Major Execution Plan.
2004.08.20
Whole Page
Department
Piping Team
Prepared by
Reviewed by
Kim Ki-pil
Approved by
Lee Myung-hak
Revision Process
It revised errors and deleted general explanation from
the manual and it is revised and supplemented by
practical method of actual job
and contents
recommended by reference.
-
Department
Piping Team
Prepared by
No Hee-kwon
Reviewed by
Approved by
Kim Seok-ki
APPENDIX
Appendix :
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Piping Fixed Point Selection Method is as below to minimize Load and Moment to affect Compressor or
Turbine Nozzle by connecting Pipe. But, be sure to receive the final approval from a person in charge of
Stress Analysis in case it is to be applied to Actual Job Execution because the below is a simplified
method.
1.
here,
x :
2.
APPENDIX
Appendix :
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Great Care is to be taken in Piping Construction because Compressor piping is big comparing to other
equipment and so Compressor body can be moved by
inflict unreasonable force to Compressor body. Tips for Piping Construction in Site is described as below.
1.
In case Compressor location is not set up, be sure to leave 1 adjustment place in each direction and
weld from Point ~. ( SR is to be performed in case Welding is required to the part of Stress
Relieve(SR) )
2.
After Compressor Location is set up, connect Nozzle Flange and Pipe Flange by using the half of Bolt
quantity and weld Point , temporarily by adjustingS-135, S-136. If necessary, be sure not to put
unreasonable weight on the Compressor body by installing
Lock Pin of Spring Support as it is installed.
3.
Weld
Point ~ by adjusting each direction. Be sure not to add unreasonable weight in welding.
4.
5.
Be sure to set Nozzle Flange and Pipe Flange accurately (around half of the whole quantity of bolt),
and check if Piping Alignment Requirements and Flange Distance "T" complies with the below API RP 686
Chapter 6, Paragraph 4.6 standard and weld
Item
Standard
Note
Max. 1.5mm
Max. 10m/1)
Max. 750m
Remove Temporary Support installed in Spool No.301-10-01 ~ 06, and install Permanent Support(S-138, DS
-134, DS-133, S-136, S-135, DS-132).
7.
8.
Right before operating after Completion of Site Pressure Test and Flushing Work, be sure to adjust
balance by removing Lock Pin(S-134 S-135
installed in Spring from
9.
Compressor.
Be sure to perform after approval from SECL's Piping Supervisor in case executing Job from the above
No.2 to 8
Job Execution should be performed with the participation of person in charge of Piping or
(2)
Be sure to weld by 2 workers in the symmetrical location at the same time in principle.
(3)
(4)
Be sure to clean inside Pipe before connecting pipe, weld without foreign matters.
(5)
In case of piping installation, check centering by using Dial Gage between Coupling and connect
Pipe after checking the offset is below 3/100mm. But Vendor Requirements has to be taken a priority.
(6)
Install Cover in Pipe Flange of Spool No.301-10-01 and manage not to let foreign matters get in.
(7)
Be sure to get approval from SECL's Supervisor for other unclear item.
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