Equipment Design - 4th year Chapter Two By: Lec.

Ihsan Habib

2-1 Piping and Instrument Diagram (PID)

The P and I diagram shows the arrangement of the process equipment, piping,
pumps, instruments, valves, and other fittings. It should include:
1- Prepared by chemical engineer with the aid of mechanical and control
Engineers.
2- All process equipment, identified by an equipment number. The equipment
should be drawn roughly in proportion and the location of nozzles shown.
3- All pipes, identified by a line number. The pipe size and material of
construction should be shown. The material may be included as part of the
line identification number.
4- All valves, control and block valves, with an identification number. The type
and size should be shown.
5- Ancillary fittings that are part of the piping system, such as inline sight-
glasses, strainers, and steam traps, with an identification number.
6- Pumps, identified by a suitable code number.
7- All control loops and instruments, with an identification number.

2.2 Basic Symbols

The symbols illustrated below are those given in ISA-5.1-1984 (R1992).

2.2.1 Control Valves

There are different types of valves:

2.2.2 Failure Mode

The direction of the arrow shows the position of the valve on failure of the
power supply.

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

2.2.3 General Instrument and Controller Symbols

Locally mounted means that the controller and display are located out on the
plant near to the sensing instrument location. Main panel means that they are
located on a panel in the control room. Except on small plants, most controllers
would be mounted in the control room.

2.2.4 Other Common Symbols

2.3 Type of Instrument

This is indicated on the circle representing the instrument-controller by a
letter code as table below:

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

The first letter indicates the property measured; for example, F = flow.
Subsequent letters indicate the function; for example,
I = indicating
RC = recorder controller

A typical control loop

2.4 Valve Selection

The valves used for a chemical process plant can be divided into two broad
classes, depending on their primary function:
1. Shut-off valves (block valves or isolation valves), whose purpose is to close off
the flow.
2. Control valves, both manual and automatic, used to regulate flow.

The main types of valves used are:

1-Gate valve 2- Plug valve 3- Ball valve 4- Globe valve
5- Diaphragm valve 6- Butterfly valve 7- Non-return valve

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

(a) Gate valve (slide valve). (b) Plug valve. (c) Ball valve. (d) Globe valve.
(e) Diaphragm valve.

(f ) Butterfly valve. (g) Non-return valve, check valve.

Characteristics of selected Valves:

(1) Gate valve: primarily designed to serve as isolation valves. These valves
generally are fully open or fully closed.

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

(2) Butterfly valve: It used to control and regulate or throttle the flow. It required
only a quarter-turn from closed to fully-open position. Butterfly valves are
often used for the control of gas and vapor flows.
(3) Non-return valves: It used to prevent backflow of fluid in a process line. The
valve is kept open by forward flow of fluid and quickly closed by reverse flow.
The careful selection and design of control valves is important; good flow
control must be achieved, while keeping the pressure drop as low as possible. The
valve must also be sized to avoid the flashing of hot liquids and the supercritical
flow of gases and vapors.
Control valves have basically four interactive components : (1) valve body,
(2) actuating device (usually a spring diaphragm type), (3) valve positioner (an
instrument that converts an electric control signal into air signal to control the
position of the valve)m and (4) an airset to supply air pressure to the positioner.

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

2.5 Mechanical Design of Piping Systems

2.5.1. Wall thickness, pipe schedule:
The pipe wall thickness is selected to resist the internal pressure, with an
allowance for corrosion. Processes pipes can normally be considered as thin
cylinders; only high pressure pipes, such as high-pressure steam lines, are likely to
be classified as thick cylinders and must be given special consideration, the
following formula used for calculate pipe thickness:

…(2.1)

where P = internal pressure, bar.

d = pipe OD, mm.
σd = design stress at working temperature, N/mm.

Pipes are often specified by a schedule number which is defined by:

…(2.2)

where Ps = safe working pressure, lb/in2 (or N /mm2).

σs = safe working stress, lb/in2 (or N /mm2).
Schedule 40 pipe is commonly used for general purposes.

Example 2.1
Estimate the safe working pressure for a 4 in. (100 mm) dia., schedule 40
pipe, carbon steel, butt welded, working temperature 100 oC. The safe working
stress for butt welded steel pipe up to 120 oC is 6000 Ib/in2 (41.4 N/mm2).

Solution:

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

2.6 Economic Pipe Diameter

The capital cost of a pipe run increases with diameter, whereas the pumping
costs decrease with increasing diameter. The most economic pipe diameter will be
the one which gives the lowest annual operating cost. The following equations for
the optimum diameter, for turbulent flow:
Carbon steel pipe:

… (2.3)

Stainless steel pipe:

… (2.4)
where d = pipe inside diameter, mm.
G = mass flow rate, kg/s.
ρ = liquid density, kg/m3.
Equations (2.3) and (2.4) can be used to make an approximate estimate of the
economic pipe diameter for normal pipe runs for turbulent flow

Example 2.2
Estimate the optimum pipe diameter for a water flow rate of 10 kg/s, at 20 oC.
Carbon steel pipe will be used. Density of water 1000 kg/m.
Solution:

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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Equipment Design - 4th year Chapter Two By: Lec. Ihsan Habib

Example 2.3
Estimate the optimum pipe diameter for a flow of gaseous HCl of 7000 kg/h a t 5
bar, 15oC, stainless steel pipe. Molar volume 22.4 m3/kmol, at 1 bar and 0oC.
Solution:

2.7 Flanged Joints

Flanged joints are used for connecting pipes and instruments to vessels, for
manhole covers, and for removable vessel heads when ease of access is required.
Flanges may also be used on the vessel body, when it is necessary to divide the
vessel into sections for transport or maintenance. Flanged joints are also used to
connect pipes to other equipment, such as pumps and valves. Flanges range in size
from a few millimeters diameter f or small pipes, to several meters diameter for
those used as body or head flanges on vessels.

‫ أحسان حبيب داخل‬. ‫م‬ ‫املرحةل الرابعه‬/ ‫ تصممي معدات‬/ ‫ لكية الهندسة‬/‫جامعة املثىن‬
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‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪21‬‬
‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪22‬‬
‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪23‬‬
‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪24‬‬
‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪25‬‬
‫‪Equipment Design - 4th year‬‬ ‫‪Chapter Two‬‬ ‫‪By: Lec. Ihsan Habib‬‬

‫م ‪ .‬أحسان حبيب داخل‬ ‫جامعة املثىن‪ /‬لكية الهندسة ‪ /‬تصممي معدات ‪/‬املرحةل الرابعه‬
‫‪26‬‬