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Comprehensive Cost Estimates for Plant Auxiliary Systems and Piping Design Guidelines

This document outlines fixed cost estimates for various auxiliary facilities and specific components essential to plant utility systems, including steam, water, air, and power distribution. It details estimate factors influenced by facility types, auxiliary processes, and piping system designs. It also covers crucial aspects of piping installation, choosing materials, maintaining constant velocities, and meeting safety codes. The resource provides illustrative examples, diagrams, and links to enhance understanding of piping design criteria and related costs.

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Comprehensive Cost Estimates for Plant Auxiliary Systems and Piping Design Guidelines

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  1. DIRECT FIXED COST ESTIMATES ESTIMATE METHODS FOR AUXILIARIES AND SPECIFIC COMPONENTS

  2. AUXILIARY FACTILITIES • AS LISTED IN THE TEXT:

  3. GENERAL CATEGORIES • PLANT UTILITY SYSTEMS • STEAM • WATER • AIR • POWER • NATURAL GAS • MINOR UTILITIES • FIRE SYSTEMS • INERT GASES • WASTE DISPOSAL • SEWERS • HAZARDOUS MATERIAL TREATMENT SYSTEMS • DISTRIBUTION & TRANSPORTATION SYSTEMS • ROADS • RAILS • DOCKS http://www.syska.com/Energy/images/St-Joes-Boiler-plnt.jpg http://www.smvrhm.org/2misc/unk-boxcar-loading.jpg

  4. ESTIMATE FACTORS • DEPEND ON TYPE OF FACILITY

  5. AUXILIARY PROCESSES CAN BE COMPLICATED • EXAMPLE OF WASTE TREATMENT PROCESS http://www.uscentrifuge.com/images/process-operation2-lg.jpg

  6. PIPING SYSTEM COST ESTIMATES • ESTIMATES DEPEND ON FOLLOWING FACTORS • TYPE OF SYSTEM • WELDED • SCREWED • SWAGED FLANGES • WELDED FLANGES • MATERIALS OF CONSTRUCTION • SEE TABLE 12-2 FOR ALTERNATE TYPES http://www.welcoservices.com/pic3b.jpg

  7. PIPING DESIGN CRITERIA • MAXIMUM VELOCITIES • DIAMETER IS GENERALLY SET TO MEET PROJECT CRITERIA • SEE TABLE 12.3 AND NOTE LIMITS AS A FUNCTION OF VISCOSITY • SPECIFIED PRESSURE DROP (SEE MEMO CTA-02) • USE SPECIFIC EQUATIONS FOR LAMINAR, TURBULENT, COMPRESSIBLE AND INCOMPRESSIBLE FLOW. • CHOOSE MORE CONSERVATIVE (LARGER DIAMETER) WHEN COMPARING RESULTS FROM VARIOUS MODELS • AVOID SONIC VELOCITY (VALVES ARE PRIMARY SOURCES)

  8. OTHER CONSTRAINTS • CODES • ASME B31.3 – PROCESS PLANT PIPING • ASME B31.1 – STEAM PIPING http://www.fluidh.com/images/imgCalcPumpHead2.gif

  9. SYSTEM CURVES • PRESSURE DROP IN FLUID FLOW LINES (TOTAL HEAD) • USING EQUIVALENT LENGTHS REQUIRE SOME IDEA OF THE ROUTING. • FACTORS IN CRANE OR CAMERON. www.fluidedesign.com/download-free/chapter4-extract.pdf

  10. PIPING INSTALLATION OPTIONS • OVERHEAD PIPING SYSTEMS ARE EASIER TO MAINTAIN • RUN PIPING IN RACKS • MINIMUM SIZE IS GENERALLY 2"(NOM) TO ALLOW REASONABLE SPAN OF ABOUT 25 FT • RACK PIPING LAYOUT SHOULD ISOLATE INCOMPATIBALE MATERIALS • USE STRUCTURAL STEEL IN BUILDINGS http://www.sococo.co.uk/petro-chemical.htm

  11. SUBSURFACE PIPING • GENERALY LOCATED IN TRENCHES • DOES NOT INTERFERE WITH MOST SURFACE OPTIONS • CAN LIMIT SPREAD OF LEAKS WHEN FLUIDS FLOW INTO TRENCHES • TRENCHES MUST BE PERIODICALLY DRAINED • HAVE MIXED EFFECTS IN FIRES • MANY PLANTS HAVE A COMBINATION OF OVERHEAD AND SUBSURFACE PIPING http://www.nasm.si.edu/udvarhazy/bts/good_place/hazy_4.jpg

  12. DETAILED PIPING DESIGN FACTORS • ATTEMPT TO MAINTAIN CONSTANT VELOCITIES THROUGH SYSTEMS FOR PURPOSES OF EFFICIENCY • USE WELDED WHERE LEAKS OF HAZARDOUS MATERIALS WOULD BE POSSIBLE • FLANGED FITTINGS ARE USED WHERE LINES MIGHT BE FREQUENTLY OPENED FOR MAINTENANCE • LINES 2-3"(NOM) IN DIAMETER MAY BE RUN IN THE FIELD. LARGER SHOULD BE FABRICATED IN SHOP.

  13. PIPING QUALITY CHECKS • RADIOGRAPHY REQUIREMENTS • RANGE FROM 0% ON LOW RISK SYSTEMS TO 100% ON HIGH RISK • 5% RANDOM A TYPICAL INTERMEDIATE VALUE. • THERMAL AND MECHANICAL STRESS CONSIDERATIONS • EXPANSION MUST BE CONSIDERED AND SYSTEMS DESIGNED TO HAVE ZERO STRESS ON EQUIPMENT NOZZLES • NPSH MAY BE A FACTOR WHEN DESIGN FOR PUMP INLETS. SEE PERRY'S FOR GUIDELINES • AVOID VAPOR TRAPS IN EQUIPMENT PIPING • CONTROL VALVES SHOULD BE ISOLATED TO ALLOW REMOVAL FOR MAINTENANCE WITHOUT SHUTTING DOWN THE SYSTEM

  14. VALVE DESIGN CRITERIA • DEPEND ON MEDIA AND SERVICE • POSITIVE SHUTOFF - GATES, PLUG, BALL • GASES - GATES FOR SHUTOFF, BUTTERFLYS FOR THROTTLING • CHECK VALVES - PREVENT BACKFLOW AND SHOULD BE INSTALLED AFTER ROTATING EQUIPMENT http://www.valvediagnostics.com/media/pictures/gate.gif http://www.offshore247.com/news/article.asp?Id=3226 http://www.valvediagnostics.com/media/pictures/check.gif

  15. RELATIVE COSTS FOR PIPING • SEE FIGURES 12-4 THROUGH 12-12 • PIPING COSTS ARE LOWEST FOR SCREWED PIPING, BUT THIS IS GENERALLY LIMITED TO 6” DIAMETER OR LESS • STRAIGHT RUN PIPE IS GENERALLY FIELD FABRICATED IN 20 FT SECTIONS • AUTOMATIC WELDING MACHINES FOR FIELD INSTALLATIONS ARE AVAILABLE FOR STRAIGHT RUNS • SCREWED CONNECTIONS CAN ALSO BE INSTALLED IN LONGER SECTIONS

  16. OTHER PIPING COST FACTORS • PIPE WITH BENDS, FITTINGS, VALVES, MULTIPLE CONNECTIONS IS TYPICALLY FABRICATED IN A SHOP • THE SHOP CAN BE LOCATED IN THE FIELD FOR PIPE UNDER 1 FT IN DIAMETER • LARGE PIPE FABRICATIONS ARE COMPLETE IN A SHOP WITH AUTOMATED WELDERS http://home.iprimus.com.au/jackdog/lockseam22.jpg http://www.alibaba.com/catalog/11115924/Quality_Pipe_Fittings_Elbow_Bend_Tee_Flange_Reducer.html

  17. SPECIFIC EXAMPLE Cl2 PLANTS DATA FROM T. PAVONE

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