The Engineer's Guide to Plant Layout and Piping Design for the Oil and Gas Industries

By Geoff B. Barker

The Engineer’s Guide to Plant Layout and Piping Design for the Oil and Gas Industries gives pipeline engineers and plant managers a critical real-world reference to design, manage, and implement safe and effective plants and piping systems for today’s operations. This book fills a training void with complete and practical understanding of the requirements and procedures for producing a safe, economical, operable and maintainable process facility. Easy to understand for the novice, this guide includes critical standards, newer designs, practical checklists and rules of thumb.

Due to a lack of structured training in academic and technical institutions, engineers and pipe designers today may understand various computer software programs but lack the fundamental understanding and implementation of how to lay out process plants and run piping correctly in the oil and gas industry. Starting with basic terms, codes and basis for selection, the book focuses on each piece of equipment, such as pumps, towers, underground piping, pipe sizes and supports, then goes on to cover piping stress analysis and the daily needed calculations to use on the job.

• Delivers a practical guide to pipe supports, structures and hangers available in one go-to source
• Includes information on stress analysis basics, quick checks, pipe sizing and pressure drop
• Ensures compliance with the latest piping and plant layout codes and complies with worldwide risk management legislation and HSE
• Focuses on each piece of equipment, such as pumps, towers, underground piping, pipe sizes and supports
• Covers piping stress analysis and the daily needed calculations to use on the job

• Language: English
• Publisher: Elsevier Science
• Release date: Nov 25, 2017
• ISBN: 9780128146545

Geoff B. Barker

Geoff Barker is a Professional Engineer and Principal Consultant at Independent Oil and Gas Consultants in the USA and United KIngdom. He received his Higher National Certificate in Mechanical Engineering from Leeds Polytechnic Institute in the United Kingdom. He also studied at the George Brown College of Applied Arts and Technology in Toronto, Canada, where he received qualifications in Process Plant Piping Design and Calculation. Continuing his education, he studied Natural Gas Processing and Gas Plant Operations at The Southern Alberta Institute of Technology in Canada. Geoff also received accreditation from ASME in ASME B31.3 Process Piping Design, ASME BPV Code, Section V111, Division 1, and API 579-1/ASME FFS-1 Fitness for Service. He has more than 40 years of industrial and consultancy experience in the oil and gas onshore and offshore industries, as well as petrochemical, mining, pharmaceutical and food processing industries. Geoff has held engineering, supervisory and management positions at various companies including Fluor BV, CBI, MW Kellogg, Brown and Root, Bechel, Technip, Kvaerner, Aker Engineering, Shell, Exxon, and Wood Group. He has served as a consultant to numerous EPC, engineering and industrial companies as well as professional organizations worldwide. Geoff is a member of the American Society of Mechanical Engineers, The Energy Institute (UK and USA), and a former member of The Institution of Plant Engineers (UK), The Society of Operations Engineers (UK), and The Institute of Mechanical Incorporated Engineers (The Institute of Engineering Technology-UK).

Book preview

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Introduction

This book is aimed at not only being an introduction, but an extension and further enhancement of advanced explanations covering the many facets of detail engineering and layout of plant and piping systems. The material progresses through each of the major design processes, starting with the basics of plant layout design, equipment sizing and layout, pumps and exchanger layouts, maintenance requirements, process and utility piping, pipe supports and ending with pipe sizing, and pipe stress analysis. The book concentrates not only on the design aspects, but also on the practical aspects of plant and piping layout, using design examples to illustrate the points of design, and show the maintenance, operational, and safety aspects required in designing and building a process plant facility.

The objective of this book is to focus on how to design and build a process plant and its associated piping, that is safe, operable, maintainable, and economical.

Detail engineering of process piping plants consists of the engineering, design, detail and layout of process and utility equipment, piping, and instrumentation. The objective is to enhance the understanding of detail engineering and layout of piping systems, for people employed in any area that process piping is present, be it refinery, chemical, power, pulp and paper, mining, pharmaceutical or utilities, etc. It will enhance the knowledge of engineers, designers and construction personnel in the various procedures involved in the development and engineering of Piping and Instrumentation Diagrams (P&IDs), Equipment Plot Plans, Piping Arrangements and Fabrication Drawings.

The design practices that have been incorporated into the course are in compliance with procedures developed in the petroleum industry and that comply with ASME B31.3 Code.

This will include pipe sizing, pressure drop calculations, pump and equipment sizing and selection, preparation of equipment specifications and drawings, piping specifications, instrumentation and process control, as well as piping component familiarization including valves and fittings, piping hangers, and supports.

This book will bring a greater understanding to engineers, designers, operations, and construction personnel with regard to layout, design procedures, and practices involved in the location of equipment and layout of piping systems for industrial and oil and gas facilities.

In the past, there was very little formal training in the area of plant design and process piping design. Decisions were made based on practical considerations without formulae or code reinforcement.

This has now changed with the introduction of industry codes and practices mainly implemented by ASME (American Society of Mechanical Engineers) in the United States, and by PED (Pressure Equipment Directive) in Europe, and by organizations such as the Energy Institute in the UK, API (American Petroleum Institute), NACE (National Association of Corrosion Engineers), and NFPA (National Fire Protection Association) in the USA.

The production of piping arrangement drawings and piping isometrics, takes up the majority of man-hours in the design of a process plant and the engineer is required to apply acceptable safe, maintainable, operable, and economic layout procedures to achieve this.

This book will give engineers the background required to produce the necessary detail engineering documents required to design and layout process plants including plot plans, equipment and piping drawings, and the necessary calculations required to achieve this.

Chapter 1

Engineers and designers—Career paths—Institutes

Abstract

This chapter deals with the responsibilities of an engineer and designer. It also shows the guidelines to the routes and registration to become a professional engineer and technician.

Keywords

Engineers; Designers; American Society of Mechanical Engineers; Institution of Plant Engineers; Society of Operations Engineers; Institute of Mechanical Engineers; Energy Institute; Institute of Engineering and Technology

The terminology dimensional, temperature, pressure, etc. used throughout this book is shown in both metric and imperial (English units) notations. There are however some instances where the notation might be shown only in metric, and in other instances where it might be only shown in imperial (English units). This was done for the clarity of the particular calculation, and the fact that the book would be read by engineers in countries using both or either metric or imperial systems.

1.1 What is a Piping/Plant Layout Designer and Engineer

Engineer

The engineer is the person in charge of the engineering design of a plant and/or of a piping system. He or she shall be experienced in the design principles of piping and plant layout design, stress analysis, materials, and pipe support design, along with a thorough understanding of the ASME B31.3 code for pressure piping. The engineer shall also be responsible for the checking and approval of all design work produced by the designer.

Designer

The designer is the person responsible for the piping design and layout of a plant and/or piping system with emphasis on the detailed design. He or she shall be responsible for the ownership and lead of a design area or areas on a project, along with the detailed design and layout of equipment and piping general arrangement drawings, piping isometric drawings, and pipe support details.

Engineers

Engineers need the completion of (minimum) a bachelor's degree in mechanical engineering or an HNC/HND (Higher National Certificate/Diploma) followed by an extra year of learning, to bring up to degree status. Engineers require a minimum 4 years of study, plus 10 years of experience in the design of related pressure piping.

To gain Professional Engineer registration in the United Kingdom and its territories, the following are the requirements:

Chartered Engineer (CEng)—requires a master's degree in mechanical engineering and appropriate years of experience, plus the membership of a professional institution such as but not limited to:

• The Institution of Mechanical Engineers

• The Institute of Engineering Technology

• The Institution of Plant Engineers

• The Energy Institute

Incorporated Engineer (IEng)—requires a bachelor's degree or an HNC/HND (with an additional year of study) in mechanical engineering, and appropriate years of experience, plus the membership of a professional institution such as but not limited to:

• The Institution of Mechanical Engineers

• The Institute of Engineering Technology

• The Institution of Plant Engineers

• The Energy Institute

To gain Professional Engineer registration in the United States an accredited 4-year degree in mechanical engineering, plus study for the engineer in training exams which must be passed to satisfy the requirements of the professional engineering board depending on the state that the engineer is to practice in.

To gain Professional Engineer registration in any other country you must consult the relevant Board of Engineering for the country you live in.

Designers

Require the completion of an accredited engineering technician or associates degree, or an ONC/OND (Ordinary National Certificate/Diploma, NVQ qualification or equivalent), requiring at least 2 years of study, plus a minimum of 10 years of experience in the design of related pressure piping.

To gain Engineering Technician registration in the United Kingdom and its territories, the following are the requirements:

Engineering Technician (EngTech)—an ONC/OND (Ordinary National Certificate or Diploma) in Mechanical Engineering and appropriate years of experience, plus the membership of a professional institution such as but not limited to:

• The Institution of Mechanical Engineers

• The Institute of Engineering Technology

• The Institution of Plant Engineers

• The Energy Institute

To gain Engineering Technician registration in any other country you must consult the relevant Board of Engineering Technicians for the country you live in.

Fig. 1.1 Timeline to gain Incorporated or Chartered Engineer status.

Fig. 1.2 Timeline to gain Engineering Technician status.

1.2 Engineering Institutions and Engineering Societies

American Society of Mechanical Engineers (ASME)

The ASME was founded in 1880 to provide a setting for engineers to discuss the concerns brought about by industrialization and mechanization. ASME is the leading international developer of codes and standards associated with the art, science, and practice of mechanical engineering. ASME started with the first issuance of its legendary Boiler and Pressure Code in 1914. These codes have now grown to nearly 600 offerings currently in print.

A major benefit of being an ASME member is to further your professional career, and to connect with the best minds in engineering, advance your career, and make a difference by getting involved. Joining ASME's community of engineers enables you to learn new technologies, keep your skills up to date, explore solutions to technical problems, and to advance your career. As an ASME member, you can take advantage of extensive professional and student benefits, most of which are available at no additional cost or at a substantial discount. ASME membership gives you the tools, professional training, information, and connections you need to succeed at every step of your career. Joining ASME is one of the most important connections a mechanical engineer can make. Members enjoy a host of valuable benefits, plus the opportunity to have a direct impact on the engineering field.

The Institution of Plant Engineers (IPlantE), the Society of Operations Engineers (SOE)

The IPlantE (Institution of Plant Engineers) was founded in 1946 and is the professional sector for people whose engineering skills are typically used in industrial, manufacturing, military, and utility processes for ensuring machinery and equipment can be operated safely, efficiently, and in an environmentally sustainable way.

The institution helps its members develop their skills, share best practices, and demonstrate their professional competence—for current and prospective employers, engineering service providers, plant and equipment owners, or the community at large.

It also owns www.plantengineer.org.uk, a definitive online resource for plant engineers and technicians containing the latest industry news, jobs, and a comprehensive supplier directory. The SOE along with IPlantE runs a variety of seminars on current legislations.

The Institute of Mechanical Engineers (IMechE)

The IMechE was started in 1847, holding its first meetings in Birmingham, UK.

The present headquarters of the IMechE, 1 Birdcage Walk in London was completed in 1899.

Two of IMechE's famous past presidents.

Fig. 1.3 George Stephenson. From The Project Gutenberg eBook, Great Britain and Her Queen, by Anne E. Keeling http://www.gutenberg.org/etext/13103. Taken from https://en.wikipedia.org/wiki/George_Stephenson#/media/File:George_Stephenson_Project_Gutenberg_etext_13103.jpg.

Fig. 1.4 Joseph Whitworth. Photograph of a portrait of Joseph Whitworth, engineer. Taken from https://commons.wikimedia.org/wiki/File:Joseph_Whitworth.jpg.

The Institute of Mechanical Engineers (IMechE)

The IMechE supports product innovation, developing a nation's economic growth and increasing its global trade. Through government campaigns such as Engineered in Britain, this institute shows that a growing and thriving manufacturing sector will provide future economic growth, wealth, and prosperity.

The institute promotes safe, efficient transport systems to ensure less congestion and emissions. To advance, travel must be made cleaner, safer, and easier, which means creating a better understanding of global transport supply and demand, while keeping a sharp focus on the implications on carbon emissions.

The IMechE promotes sustainable energy use and engineering sustainable supply. The institutes need to share knowledge, changes the way we behave and drives advances in technology to reduce the strain on the world's resources, and champions the development of more sustainable sources of energy which will also help reduce emissions.

The IMechE inspires, prepares, and supports tomorrow's engineers so that they can respond to society's challenges.

The Energy Institute (EI) (Formerly the Institute of Petroleum)

The purpose of the Energy Institute is to develop and disseminate knowledge about energy in all its forms and applications, and to enhance public understanding of energy resources and their role in society.

The institute publishes magazines and technical publications to promote knowledge and good practice across the whole spectrum of energy supply and use.

Energy professionals can keep themselves up to date with the latest developments within the industry through its programs or events providing access to the latest thinking from industry leaders and fellow energy specialists.

The EI provides a wide range of industry information through its lbrary services providing access to e-publications and journals, in-depth statistics as well as a physical stock of 15,000 books held at its premises, and has an education portal covering all aspects of energy, which also provides career advice for students and professional development guidance for existing employees within the

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