Unit Description and General Aims

The objective in presenting this unit is to impart to students the fundamental principles and concepts used in process plant layout and piping and pipeline design.

The subject matter covered in this unit will include the many considerations and requirements that are integral to the process of plant layout such as specifications; equipment arrangements; plot plans; Process and Instrumentation Diagrams (P&IDs); and, design documentation. Applicable codes and standards, issues related to design and construction practices, and the assessment of optimum routing and layout techniques will also be examined. Case studies and practical exercises are employed throughout this unit to assist students’ assimilation of unit contents, particularly piping concepts.

At the conclusion of this unit, students will have been imparted with the requisite knowledge and skills to prepare plant layout specifications, plot plans, and P&IDs; evaluate pipeline design principles and procedures; and, recognise the underlying causes behind piping degradation, assess damage, and undertake repairs.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Examine the basics of process plant layout and design. 
   Bloom's Level 4

2. Develop plant layout specifications, plot plans, and P & IDs. 
   Bloom's Level 6

3. Identify piping system components. 
   Bloom's Level 3

4. Evaluate pipeline design principles and procedures. 
   Bloom's Level 5

5. Apply the relevant data and tools for pipeline routing. 
   Bloom's Level 3

6. Calculate forces and stresses in pipelines. 
   Bloom's Level 3

7. Assess pipelines for damage / degradation and undertake repairs. 
   Bloom's Level 5

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam, and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Textbook

Fundamentals of Process Plant Layout and Piping Design, IDC Technologies, Perth 
Pipeline Systems: Design, Construction, Maintenance and Asset Management, IDC Technologies, Perth

Reference

Bausbacher, E & Hunt, R 1993, Process Plant Layout and Piping Design, 1st edn, Prentice Hall, ISBN-13: 978-0131386297

Journal, website

piping-info.blogspot.com/.../process-plant-layout-and-piping-design.htm

Notes and Reference Texts

IDC Technologies 
Other material advised during the lectures

Unit Content

Topic 1

Fundamentals

1. Plant layout fundamentals 
2. Procedures and workflow methods 
3. Physical quantities and units 
4. Process Flow Diagrams (PFDs) 
5. Equipment used in process plants 
6. Equipment drawings and specifications

Topic 2

Plant Layout and Plot Plans

1. Plant layout specifications 
2. Guidelines and codes for plant layout 
3. Safety considerations 
4. Plot plans 
5. Equipment arrangement drawings

Topic 3

Process and Instrumentation Diagrams (P&IDs)

1. Fundamentals of P&IDs 
2. Instruments and instrument symbols 
3. Layout and components of control valve manifolds 
4. Layout and components of meter runs

Topic 4

Plant Layout and Piping Design Documentation and Tools

1. Equipment arrangement drawings 
2. Equipment lists 
3. Piping line lists 
4. Piping specifications and codes 
5. Piping isometrics 
6. Bills of Material 
7. 3D models

Topic 5

Piping Fundamentals, System Components, and Materials

1. Basics of piping 
2. Fittings 
3. Flanges 
4. Valves 
5. Material classification system and specifications 
6. Piping specifications 
7. Material selection

Topic 6

Overview of Pipeline Systems

1. Pipeline basics 
2. Factors influencing pipeline design 
3. Pipeline construction fundamentals 
4. Pipeline design principles – hydraulics, mechanical design, and materials of construction 
5. Pipeline economics

Topic 7

Pipeline Design Standards

1. Standards development 
2. International and local codes applicable to pipelines 
3. Changes to regulations 
4. Pipeline design steps 
5. Fluids and gases transported

Topic 8

Routing Techniques and Environmental Considerations

1. Factors influencing piping routing 
2. Investigation of pipeline routing techniques 
3. Tools and data used in pipeline routing 
4. Environmental issues to consider during planning 
5. Design considerations with respect to the environment

Topic 9

Mechanical Design of Pipelines, Components, and Materials (Part 1)

1. Forces and stresses in pipelines 
2. Specified minimum yield strength of pipeline materials 
3. Mechanical design equations: calculations of Maximum Allowable Pressure (MAP) and minimum required wall thickness of pipelines 
4. Sustained loads in pipelines 
5. Thermal expansion/contraction of materials 
6. Optimal pipeline construction material

Topic 10

Mechanical Design of Pipelines, Components, and Materials (Part 2)

1. Pumps
2. Compressors 
3. Optimal pipe size vs. location of pump/compressor stations 

Topic 11

Corrosion, Assessment, Repairs, and Maintenance

1. Practical corrosion 
2. Classification of corrosion mechanisms 
3. Internal corrosion – chemical treatment, inhibitors and biocides 
4. External corrosion – coatings and cathodic protection 
5. Pipeline Integrity Programs

Topic 12

 Unit Review

In the final week, students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Software/Hardware Used

Software

• Software: PASS Start-Prof - It is a comprehensive software for pipe stress, flexibility, and fatigue strength analysis. It is crucial for mechanical engineers as it enhances design accuracy, reduces development time, and ensures compliance with international standards. Applications include analyzing piping systems in industries such as oil and gas, power, and chemical processing. 
• Version: 4.84 R5
• Instructions: Go to Remote Labs 
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback