Recent Posts

Recent changes in ASME B31.3 and their implementation in CAESAR II

Written by Anup Kumar Dey in Caesar II,Piping Stress Analysis,Piping Stress Basics

This presentation is prepared by Mr. Deepak Sethia (working in Imagegrafix software) who has extensive experience in using Caesar II software and troubleshooting. The points that will be covered in this article are:

  • Allowable Displacement Stress Range
  • Expansion Allowable Stress Change
  • Longitudinal stress due to sustained loads
  • Appendix P
  • B31J

Allowable Displacement Stress Range (SA)

  • SA is defined in equations (1a) & (1b) of ASME B 31.3 (Reproduced below)
  • SA is a function of the cyclic factor f
Allowable Displacement Stress Range

The definition of f has changed over the years.

Stress Range Reduction Factor

Sc and Sh are each limited to 20 ksi when calculating SA allowable displacement stress range.

Sc-Sh

Expansion Allowable Stress Change

Process Piping

CAESAR II Has Always Determined & Used the “Maximum Value”.

But What Does “Considering All Support Conditions” Mean?

Alt Sustained (formerly Hot Sustained approach)

nonlinear stress

“… All Support Conditions (Positions) of The Pipe …”

  • Each Operating Load Case (For a Particular Support Condition) Could Produce a Different Sustained Stress Distribution.
  • The Expansion Allowable Must Be Based on The Maximum Sustained Stress, Considering All of These Operating Load Cases.
  • Consider the following Example:
  • Only 2 of The Branch Lines are Hot.
  • One Branch Line is Cold.

The system Has Three “Real” Operating Conditions, All Producing a Different Primary (Sustained) Stress State Due to Different Nonlinear Support Conditions.

How Can This Be Achieved, Automatically In The Software?

New Load Case Template Recommendations

Load case
load case changes

ASME B31J

  • Standard Test Method for Determining Stress Intensification Factors (i & k Factors) for Metallic Piping Components
  • The scope of this standard has recently been revised to add the ability to update new i & k Factor information as it becomes available
  • B31J provides a set of calculations for revised SIFs and flexibility factors, as defined in the revision to ASME B31J. By using these revised SIFs and flexibilities, your stress analyses produce more accurate results. B31J provides the “more applicable data” referenced in recent editions of the piping codes.

What 319.3.6 is saying……

load condition

i-factor requirement as per the Latest Code

As shown in Figure the previous code (Appendix D) you had SIF(i) and SIF(o) which were valid for both Expansion Stress and Sustained Stress. Now you can find the following. Not only the SIF are different for the primary and secondary stress but in addition, you have to consider SIF for Tortion and axial effect!

  • SIF is valid for Expansion Stress (SIF)and Index(SSI) is valid for Sustained Stress.
SIF entries

Do you know that the i & k factors from ASME B31.3/ASME B31.1 can be calculated according to B31J and it is freeware available with CAESAR-II software?

B 31J calculations in CAESAR II…..

B 31J result for Flexibility (k) & SIF (i)…..

CAESAR-II model with “more applicable data”….

We open the translated model in CAESAR II using B31J option

Top 15 Piping Books for a Piping Engineer

Written by Anup Kumar Dey in Piping Design Basics,Piping Stress Analysis

This post is solely for beginners in the piping industry. If you want to learn the basics from books or literature, then try the following 15 listed books. Most experienced piping professionals will be aware of these piping books.  Most of the piping books and literature mentioned below are available for free downloading over the internet. Simply search with the book name along with the term pdf, and you will get it. All these piping engineering books are also available in the Amazon online portal, from where you can easily buy them. Additionally, simply do an exclusive search on the internet, and you will find some links to download these piping books for free. 

1. PIPE STRESS ENGINEERING by L C Peng and T L Peng:

This is the best book on piping stress engineering. If you are planning a career in piping stress analysis, then you must collect this book and read it effectively to build solid basics. This book explains the ideas so nicely that it will provide effective results to you.

It delves deeply into the principles and methodologies of pipe stress analysis. The book offers an extensive exploration of stress analysis techniques, focusing on the mechanical behavior of pipes under various loads and conditions. It covers critical topics such as thermal expansion, pipe supports, and the impacts of different loading scenarios on pipe integrity. Detailed explanations are provided on methods for calculating stress, evaluating pipe supports, and designing systems to manage stress-related issues. The inclusion of practical case studies and real-world examples further enriches the content, illustrating how theoretical principles are applied in practice.

What sets Peng’s book apart as a premier resource for pipe stress engineers is its comprehensive and practical approach to a complex subject. The authors’ ability to break down intricate concepts into understandable segments makes this book invaluable for both seasoned professionals and those new to the field. The practical guidance on managing stress-related issues and the integration of case studies provide actionable insights that are directly applicable to everyday engineering challenges. The book’s focus on real-world applications and problem-solving ensures that it remains a crucial reference for engineers aiming to enhance their expertise in pipe stress engineering and ensure the reliability and safety of their piping systems.

2. DESIGN OF PIPING SYSTEMS by M W Kellogg Company:

This is the second-best book on piping stress analysis. Even though the language used is quite difficult to comprehend and the contents are not interesting, this book shares a great place for describing the topics effectively and was the best book earlier before the Peng book.

M. W. Kellogg’s “Design of Piping Systems” is a classic text that provides a detailed examination of the principles and practices involved in designing piping systems. The book covers a range of topics including pipe sizing, stress analysis, and material selection. Kellogg’s text is known for its depth of coverage and its methodical approach to addressing the various challenges encountered in piping system design. It also includes practical examples and case studies to illustrate key concepts.

The enduring relevance of Kellogg’s book lies in its thorough and systematic approach to piping system design. The book’s detailed explanations and comprehensive coverage make it a valuable reference for engineers seeking a deep understanding of piping design principles. Its combination of theoretical knowledge and practical examples ensures that it remains a key resource for both learning and applying piping design techniques.

3. INTRODUCTION TO PIPE STRESS ANALYSIS by Sam Kannapan:

One of the best books on piping stress analysis and is easy to understand. “Introduction to Pipe Stress Analysis” by Sam Kannapan is an accessible yet thorough guide designed to introduce engineers to the principles and practices of pipe stress analysis. This book covers fundamental concepts such as the behavior of pipes under various loading conditions, stress calculation methods, and the importance of proper pipe support and restraint systems. Kannapan provides a clear explanation of key topics including thermal expansion, pipe flexibility, and the impact of different types of loads on pipe systems. The book is structured to build a solid foundation in pipe stress analysis through clear illustrations, examples, and straightforward explanations.

The strength of Kannapan’s book lies in its approachability and clarity, making it an ideal resource for both newcomers and seasoned engineers seeking a refresher. The practical focus and structured presentation of complex concepts makes it easier for readers to grasp and apply pipe stress analysis principles in real-world scenarios. The book’s emphasis on fundamental techniques, combined with practical examples and problem-solving strategies, ensures that it serves as an excellent reference for engineers aiming to understand and address stress-related challenges in piping systems effectively.

Piping Stress Analysis Best Books

4. COADE STRESS ANALYSIS SEMINAR NOTES by COADE:

Must have a tutorial guide for every piping stress engineer using CAESAR II. Explains in detail all the basics of Caesar II’s application. The guidebook is developed by Hexagon (COADE) and explains all the basic concepts that are used for the development of the Caesar II software program.

5. PIPING HANDBOOK by M L Nayyar:

One good book for both stress and layout engineers with the huge important databases on piping engineering. Refer to this book for any data you require during your day-to-day piping work. The “Piping Handbook” by Mohinder L. Nayyar is a definitive resource that encompasses a wide array of topics essential for piping engineers. This book covers everything from basic piping design principles to advanced topics such as pipe stress analysis, hydraulic calculations, and material properties. Nayyar’s handbook is renowned for its detailed tables, charts, and formulas that aid in the design and analysis of piping systems. It also addresses various industry codes and standards, providing a thorough grounding in compliance and best practices.

What makes Nayyar’s Piping Handbook an excellent reference is its broad scope and depth of coverage. The book’s extensive collection of practical data and guidance makes it a useful tool for engineers working in diverse industries, from oil and gas to chemical processing. Its emphasis on real-world applications and problem-solving, combined with its comprehensive coverage of standards and regulations, ensures that it remains a critical resource for professionals seeking reliable and detailed information.

6. PIPE DRAFTING AND DESIGN by Rhea and Perisher:

The best book for a beginner. Covers the basics in simple language. Very easy to understand. “Pipe Drafting and Design” by Rhea and Perisher is a comprehensive guide that provides a detailed overview of the principles and practices involved in drafting and designing piping systems. The book covers a wide range of basic topics, including the fundamentals of pipe drafting, design standards, and the various types of piping systems used in different industries. Rhea and Perisher delve into the technical aspects of piping design, such as pipe layout, the selection of materials, and the application of industry codes and standards. The text also emphasizes the use of drafting software and tools, making it relevant for modern design practices.

This book is highly regarded for its practical approach and its ability to bridge the gap between theoretical knowledge and real-world drafting application. Rhea and Perisher’s clear explanations and step-by-step guidance make complex design concepts more accessible, helping both novice and experienced engineers enhance their drafting and design skills. The inclusion of detailed illustrations, case studies, and practical examples provides valuable insights into the design process, making it a valuable reference for anyone involved in the drafting and design of piping systems. Its focus on both traditional techniques and modern tools ensures that it remains relevant in today’s evolving engineering landscape.

7. PROCESS PLANT LAYOUT AND PIPING DESIGN by Hunt and Bausbacher:

The best book for a piping layout engineer. Covers the basics of the piping layout. Most of the preliminary layout ideas connected to any equipment evolve from this book. So read this book attentively for effective layout knowledge.

“Process Plant Layout and Piping Design” by Ed Bausbacher and Roger Hunt is a highly regarded text that provides an in-depth exploration of the principles and practices involved in the layout and design of piping systems in process plants. The book covers a wide range of topics essential for effective process plant design, including the fundamentals of layout planning, equipment arrangement, and the integration of piping systems with plant processes. Bausbacher and Hunt address critical considerations such as safety, accessibility, and efficiency in piping design, offering practical guidelines for optimizing plant layout and ensuring operational effectiveness.

The value of this book lies in its comprehensive and practical approach to process plant layout and piping design. Bausbacher and Hunt’s expertise is evident in their detailed explanations and real-world examples, which help readers understand complex design concepts and apply them to practical situations. The book’s focus on optimizing plant layouts for safety and efficiency makes it an essential resource for engineers involved in the design and operation of process plants. Its combination of theoretical knowledge and practical application ensures that it remains a crucial reference for achieving effective and efficient process plant design.

Piping Layout Engineering Best Books

8. PROCESS PIPING DESIGN HANDBOOK by John Mcketta:

One of the good books. The “Process Piping Design Handbook” by John J. McKetta Jr. focuses on the detailed aspects of designing piping systems specifically for process industries. McKetta’s handbook covers various design considerations such as flow dynamics, material selection, and the integration of piping with process equipment. It provides in-depth guidance on designing for safety, reliability, and efficiency, addressing issues such as thermal and mechanical stresses, as well as corrosion control.

McKetta’s handbook is highly valued for its targeted focus on process piping, making it an essential resource for engineers working in process industries. The book’s detailed coverage of design principles and its emphasis on practical design considerations ensure that it provides relevant and applicable knowledge for engineers looking to optimize their process piping systems. Its thorough exploration of industry-specific challenges and solutions enhances its utility as a reference for both design and troubleshooting.

9. THE FUNDAMENTALS OF PIPING DESIGN by Peter Smith

Peter Smith’s “Fundamentals of Piping Design” is an accessible yet comprehensive introduction to the principles and practices of piping design. The book covers fundamental topics such as system layout, pipe sizing, and material selection. Smith’s approach is designed to build a solid foundation in piping design, making complex concepts understandable for newcomers while providing enough depth to be valuable to experienced engineers. It also includes practical design examples and problems to reinforce the learning experience.

The strength of Smith’s book lies in its clear and methodical approach to piping design fundamentals. It provides a structured pathway for learning the basics of piping design, making it an excellent resource for engineers new to the field or those seeking to refresh their knowledge. Its emphasis on practical examples and clear explanations makes it a valuable tool for developing a strong understanding of piping design principles and practices.

10. “PIPING AND PIPELINE ENGINEERING” by George A. Antaki

“Piping and Pipeline Engineering” by George A. Antaki is a comprehensive guide that covers all critical aspects of piping and pipeline design and maintenance. The book delves into the fundamental principles of fluid dynamics, materials selection, and the mechanical aspects of pipeline systems. Antaki’s text is structured to provide both theoretical knowledge and practical insights, making it an invaluable resource for understanding the lifecycle of piping systems from design through construction and maintenance. It includes detailed coverage of pipe stress analysis, corrosion, and inspection techniques.

This book stands out as a top reference for piping engineers due to its extensive scope and clarity. Antaki’s approach integrates real-world scenarios with theoretical concepts, offering practical solutions to common issues encountered in the field. The inclusion of case studies and practical examples helps bridge the gap between theory and practice, making it a go-to resource for both novice and experienced engineers seeking to deepen their understanding of piping systems.

Piping Books

Other Notable Piping Books

Some other notable piping books that readers can keep as a reference book are:

  • 11. PROCESS PIPING DRAFTING By Rip Weaver: A very nice book in simple, easy-to-understandable language.
  • 12. THE PLANNING GUIDE TO PIPING DESIGN by  Richard Beale
  • 13. One must-have book for piping materials engineers is PIPING MATERIALS GUIDE by Peter Smith
  • 14. PIPING SYSTEMS MANUAL by Brian Silowash
  • 15. PIPING DESIGN FOR PROCESS PLANTS by Rase Howard F

In addition to all the above-mentioned piping books, you must remember that you have to read the latest applicable piping codes as well.

All of You are already aware that books are our best friends. It helps us without charging us. So enjoy reading. 

Cooling Tower Water Treatment Basics

Written by Anup Kumar Dey in Maintenance,Mechanical

We all know that Cooling towers are essential components in various industrial processes and HVAC systems. They play a crucial role in dissipating excess heat generated during these processes. However, for cooling towers to function smoothly, efficiently, and sustainably, proper water treatment is paramount. Proper water treatment Increases Energy Efficiency, Reduces the water-consumption, and Extends Equipment Life. In this blog post, we’ll explore the importance of cooling tower water treatment, its key components, and the benefits it offers. Additionally, we will learn about the cooling tower water treatment chemicals.

Why Should You Treat Cooling Tower Water?

Cooling towers rely on the evaporation of water to remove heat from processes, making them susceptible to various water-related issues such as scaling, corrosion, and biological growth. Without adequate water treatment, these problems can lead to reduced efficiency, increased maintenance costs, and even system failure. Therefore, cooling tower water treatment is essential for several reasons:

  • Prevent Scaling: Scaling occurs when minerals in the water, such as calcium and magnesium, precipitate and form deposits on heat exchange surfaces. These deposits insulate the heat exchangers, reducing their efficiency and potentially causing equipment damage.
  • Corrosion Control: Cooling tower components, including pipes, pumps, and heat exchangers, are often made of metal. Corrosion can lead to the deterioration of these components, compromising the system’s reliability and lifespan.
  • Microbial Growth Prevention: Cooling towers provide an ideal environment for the growth of bacteria, algae, and fungi. These organisms can clog water distribution systems, degrade water quality, and pose health risks to workers.
  • To control the water pH.

Effect of Changes in Water Composition

Cooling water operation changes water composition radically causing the circulating water composition really affect the system’s operation and life

Factors affecting physical and chemical properties of water

  • Temperature change
  • Evaporation
  • Air contact
  • Product contamination

Cooling Tower Water Treatment

Scaling and Fouling of Cooling Tower

Main causes:

  • Scaling – Due to salts that deposit on high-temperature surfaces due to retrograde solubility
  • General fouling – Due to insoluble suspended particles forming deposits on the surface
  • Biological fouling -This results from abundant growth of Algae, Fungi, or Bacteria on the surface

Scale Control in Cooling Tower

  • Blowdown control
  • Increased Blow-down limits cycles of concentration.
  • Treatment is required to keep the dissolved solids in the non-scale forming state.
  • Scale inhibitors do this permitting operation at supersaturated conditions
  • Acid Dosing- Sulfuric Acid
  • Relatively inexpensive method
  • The acid treatment removes the bicarbonate acidity by converting HCO3- to SO4 and CO2
  • CO2 is released to the atmosphere and Sulfate remains as by product
  • Caution – Overdosing causes corrosion

Fouling Control in Cooling Towers

  • Fouling occurs when insoluble suspended particles like iron, mud, silt, and other debris deposit on the surfaces.
  • Removal of suspended matter from make-up water, re-circulating water, basin by use of Side-stream filters (filtering 1-5% of the total circulation)
  • High Water Velocities- A design stage measure for deposit control. This is always not possible ( Shell side)
  • Dispersants-Keep the particulates in suspended form
  • Surfactants-Keep the Hydrocarbons in emulsified form

Controlling Corrosion in Cooling Tower

  • Achieved by dosing a Corrosion inhibitor. This primarily works by forming a protective film on the surface.
  • Different types of treatments:
  • Chromate based program
  • Phosphate/ Phosphonate Programs
  • Di-anodic
  • Alkaline Zinc
  • Alkaline Phosphate Program
  • All Organic
  • Molybdate based

Micro-Biological Control in Cooling Tower

  • Microorganisms enter through wind, dust, and make-up water
  • Results in Slime and algae growth
  • Important to minimize slime and algae growth as they reduce
  • heat transfer
  • decrease cooling water flow
  • localize corrosion
  • serve as a mortar for the rapid buildup of deposits
  • Control is done by dosing chemicals
  • Biostatic agents: Chemicals that inhibit the growth of microbes
  • Biocides: Chemicals that kill the microorganisms
  • Advisable to use biocides in the cooling water treatment – two classes :
  • Oxidizing Biocides: Chlorine, bromine, Hypochlorite, Chlorine dioxide, Ozone
  • Non-Oxidizing Biocides: Methylene-bis-thiocyanate (MBT), Organotin compounds, Aldehydes, Chlorophenols, Sulphones and Thiones, Carbamates, Isothiazoline
  • Biofouling – accumulation of deposits of microorganisms forming films
  • Biodispersants are used for dislodging the biofilms and preventing their formation
  • Followed by the addition of biocide which kills the released bacteria

pH Control in Cooling Tower

  • Important to minimize the rate of corrosion in a heat transfer/cooling system
  • To avoid corrosion problems, controlling the pH in an alkaline range of between 8 and 9 is important
  • Alkaline pH has a greater tendency towards scaling from dissolved solids
  • Conductivity measurement measures the level of TDS in water.

Cooling Tower Water Treatment Chemicals

For cooling towers to remain effective and reliable in a variety of industrial and commercial applications, cooling tower water treatment chemicals are crucial. Specific water-related problems like scale, corrosion, and microbiological development are addressed using these compounds. The following are some of the main compounds used in cooling tower water treatment and what they do:

Biocides:

Biocides are those chemicals that are used to control microbial growth in cooling tower water. Various microorganisms like bacteria, algae, and fungi can thrive in the warm and nutrient-rich environment of cooling towers, leading to biofilm formation and clogging. Biocides help eliminate or prevent the growth of these microorganisms, ensuring the water remains clean and free from biological fouling.

  • Oxidizing Biocides: Examples include chlorine and bromine-based compounds. These chemicals are effective at killing existing microorganisms.
  • Non-Oxidizing Biocides: Compounds like quaternary ammonium compounds (quats) and isothiazolinones are non-oxidizing biocides used to prevent the regrowth of microorganisms.

Scale Inhibitors:

Scaling occurs when minerals in the cooling water, such as calcium and magnesium, precipitate and form deposits on heat exchange surfaces. Scale inhibitors, often referred to as antiscalants, work by sequestering these minerals, preventing them from forming scale deposits. Common types of scale inhibitors include polyphosphates and phosphonates.

Corrosion Inhibitors:

Cooling tower components are typically made of metal, making them susceptible to corrosion. Corrosion inhibitors are chemicals that create a protective film on metal surfaces, preventing corrosion and extending the life of equipment. Common corrosion inhibitors include orthophosphates, molybdates, and filming amines.

pH Adjusting Chemicals:

Maintaining the proper pH level in cooling tower water is essential to prevent both scaling and corrosion. Chemicals such as sulfuric acid and caustic soda are used to adjust and control the pH of the water within the desired range.

Dispersants and Surfactants:

Dispersants are used to keep suspended particles and solids in the water from settling and forming deposits. Surfactants can improve the wetting ability of the water, enhancing its contact with surfaces and facilitating the removal of deposits.

Anti-Foaming Agents:

Foaming in cooling towers can reduce their efficiency by interfering with the heat transfer process. Anti-foaming agents are added to control and minimize foam formation.

Scale and Deposit Removers:

In cases where scaling or deposits have already formed, specialized chemicals may be used to dissolve and remove these accumulations. Acid-based descaling chemicals are often employed for this purpose.

Oxygen Scavengers:

Oxygen in the cooling water can promote corrosion. Oxygen scavengers, such as sodium sulfite or hydrazine, are used to remove dissolved oxygen from the water, reducing the risk of corrosion.

Dissolved Solids Control:

Cooling towers can concentrate impurities as water evaporates. To prevent the buildup of excessive dissolved solids, chemicals like phosphates and polymers are used to control their levels.

Air Cooler Piping Design

Written by Anup Kumar Dey in Piping Design Basics

Air Cooled Heat Exchangers are used in the plants to utilize the atmospheric air to cool the hydrocarbon, process, and utility fluids by means of direct heat transfer from the fluid (within the tube) to be cooled by air circulated by means of forced/induced draft fan.

In Order to increase the heat transfer area, fins are also attached periphery of tubes. These heat exchangers are generally designed, inspected, and tested as per EN-ISO 13706.

The purpose of this article is to provide guidelines for the Piping Design/Layout connected to Air Cooled Heat Exchanger (Fig. 1) or Air Fin Fan Coolers. Click here to have a brief idea of Air Cooled Heat Exchangers.

Types of Air Cooled Heat Exchangers / Air Cooler Types

There are three types of Air cooled heat exchangers

  • Forced Draft: The bundle is located on the discharge side of the fan. The fan is below the finned tube bundle.
  • Induced draft: The tube bundle is located on the suction side of the fan, that is, the fan is above the tube bundle and sucks the air from the bottom.
  • Natural Draft (Used only for applications like transformer Oil Cooling)

Depending on the position of the inlet and outlet nozzle air coolers, are of the following types:

  • EVEN PASS ARRANGEMENT: Inlet nozzle of the air cooler is at the top side of the header and the outlet nozzle is on the same side but at bottom of that header.
  • ODD PASS ARRANGEMENT: Inlet is at the top of the header and the outlet nozzle of the air cooler is at the opposite header side but at bottom of the header.
  • SPLIT HEADER TYPE: When the differential temperature between inlet and outlet nozzles exceeds 111 degrees Celsius then a split header arrangement is used.

Different Types of Construction Air-cooled Heat Exchangers

  • Single Pass Cooler
  • Multipass Cooler
  • U Tube Cooler
A typical Air Cooled Heat Exchanger
Fig. 1: A typical Air Cooled Heat Exchanger

Air Cooler Equipment Layout Design

As this equipment needs a good flow of air for the purpose of better cooling, the location of the air fin fan cooler has to be such that it is not directly crowded or surrounded by other structures or equipment which blocks the path of plenty of airflows.

This static equipment is generally installed on the top of the pipe rack or other structure so that there is no difficulty or obstruction which can reduce proper airflow. Again by installing the air-cooled heat exchangers on top of the rack, huge space on the ground can be saved and the plant will become more compact.

Based on the width of the pipe rack or structure, normally the tube bundle length is fixed. Thus supporting legs of the air cooler bundle comes on the main civil or structural beams, which simplifies the pipe rack design. At the same time, it is desirable to adjust the pipe rack or the structure’s longitudinal column spacing based on the width of the air cooler bundle such that bundle legs straight away sit on top of the columns. Sometimes, This may not be possible to adjust as each tube bundle might have varied widths depending on service conditions, and adjusting pipe rack columns for different widths may not be feasible from a structural design and detailing point of view.

Walkways between two sets of air coolers are desired, which means if one cooler consists of ten bundles and the other of five bundles then walkways have to be provided in between, after the 10th bundle and before of next five bundles. This dimension of this walkway has to be a minimum of 1.5 to 2.0 m wide as this will be the only place at such elevation to keep tools and parts during maintenance.

The air Fin Fan coolers on the pipe rack shall be located in such a way that the bundles are accessible with a crane at least from one side.

Air Fin Fan coolers must have access platforms mounted on the air-cooled heat exchanger structure at least on the operating side.  An all-around platform is a better provision for maintenance.

Air Fin coolers have motors hanging at the bottom of the coolers. Hence, It is required to give access platforms underneath the cooler for maintenance of the motors. The localized platform can also be used.

A regular staircase needs to be provided for accessing the air fin cooler platforms or motor maintenance platforms.

Normally Inlet piping of air cooler requires a symmetrical distribution and loops. The piping needs to be supported so either air cooler structural columns or pipe rack structure columns need to be extended upwards to properly support the piping. Such data has to be given at a very early stage in the project as this needs to be considered during pipe rack design.

If the Air cooler is grade mounted then the area beneath the air cooler shall be paved to avoid the flow of sand/ dust on tubes.

Typical Layout of Air Cooled Heat Exchanger Piping
Fig. 2: Typical Layout of Air Cooled Heat Exchanger Piping

For two fans per bay, the height of the underside of the fan inlet bell (on forced draft units) or of the underside of the bundle (on induced draft units) shall be at least 2 m or one fan diameter (whichever is the greater) above the ground level, elevated floor or pipe bridge. For three or more fans per bay, the height of the underside of the bundle shall be agreed upon with the Principal.

Air Cooler Piping Design Considerations

Air coolers are normally used when a large quantity of vapor is required for condensation or a huge quantity of gas or liquid needs to be cooled. Such an application is common in the case of column overhead vapor condensation. The major points which need to be taken care of while pipe routing or laying air fin cooler connected piping (Refer Fig. 2, Fig. 3, Fig. 4, and Fig. 5) are as follows:

From the center line of the complete air cooler assembly, the piping distribution to the air cooler should be symmetrical.

If the supply line has very low pressure, care needs to be taken to keep no. of bends or elbows to a minimum. But functionality and stress requirements have to be considered. Line sizing during the distribution has to be proper if required the same has to be checked with the process or operations department.

Air Cooler Inlet Piping Arrangements
Fig. 3: Typical Air Cooler Inlet Piping Arrangements

The length of all branch pipes for all tube bundles from its header has to be more or less similar to keep pressure drop the same and this will ensure equal distribution of fluids to all bundles.

Normally inlet side header box is considered fixed for piping connection and the other header is floating. But the bundle can move in the transverse direction of tubes = 6 mm or if it is fixed at one edge then it can move by 13 mm in the other direction (as per API 661). This displacement is required for piping header expansion compensation. However the same has to be checked with the air cooler vendor as they may provide other displacement provisions.

Air Cooler Outlet Piping Arrangements
Fig. 4: Air Cooler Outlet Piping Arrangements

The movement of tube bundles in a transverse direction could occur only when the piping connected to equipment nozzles generates enough force to overcome the friction at the bundle supports that is why it is a common practice to provide SS or PTFE plate at the support point (but this must be consulted with the vendor) to ease the movement.

The loads due to thermal expansion, pipe, insulation & fluid weight, and an inside pressure of piping created on the bundle nozzle shall be less than the limits given by EN-ISO 13706. Sometimes vendor allows a more allowable load (normally 2 times the code given allowable nozzle loads). So it is required to discuss the same with the vendor at the initial stage of the project. The stress analysis of air cooler-connected piping systems is covered here.

Air Cooler Inlet and outlet Piping
Fig. 5: Typical Layout of Air Cooler Inlet and outlet Piping

List of Piping Design Companies in India

Written by Anup Kumar Dey in Mechanical,Piping Design Basics

Due to the recession in the Oil and Gas Industry/Market, Many of you may be trying to find some good jobs in good organizations. There are many organizations in India that recruit Piping Engineers and Piping Designers. But most of us are aware of only a few of them.

In this post, I will list down the names of a few of the organizations which I know. I request all the readers to add more company names with location (and if possible email id or contact number of the recruiter) in the comments section which I will include in the main list from time to time. This way we will be able to know the names of the other organizations.

Top Engineering Design Companies in INDIA for Piping Jobs

In the next step, by searching the internet we can get the contact information of the required company and apply for it. This way we will be able to apply in many organizations. And who knows that this endeavor may bring some results too as many times if the requirement of the organization is very less they may not advertise in newspapers or job sites. Wherever possible I will provide the email ids of the concerned HR. But many a time those contacts change frequently. If you know the email ids of the HR (As many of you might be working in the listed organizations) then please share that mail id in the comments section for the benefit of the job seeker.

Top Piping Design Companies in India

Piping Engineering companies are distributed all over India. For ease of finding, I will list them according to the city.

Piping Engineering Companies in Mumbai

Sr NoCompany NameOffice AddressHR Email ID
1WorleyLodha i-Think Techno Campus, B Wing, 5th Floor, Off Pokhran Road No. 2, Majiwada, Thane West, Thane, Maharashtra 400601, India; Phone: +91 22 6781 8000 Priyanka.Chourasia@worley.com
Tapaswi.Chandra@Worley.com
2Petrofac7th Floor, Ventura Central Avenue, Hiranandani Business Park, Hiranandani Gardens, Powai, Mumbai, Maharashtra 400076, India: Phone: +91 22 3051 3100
3Technip EnergiesB1 – 701/701A, Boomerang Building, Chandivali Farm Road, Andheri East, Yadav Nagar, Chandivali, Powai, Mumbai, Maharashtra 400072, India; Phone: +91 22 6700 2000Hiring_India@technipenergies.com
4GS Engineering2nd floor, D wing, Jolly Board Tower, I Think Techno Campus,, Kanjurmarg Station Rd, Kanjurmarg East, Mumbai, Maharashtra 400042, India; Phone: +91 22 4138 5000
5Technimont 504,Tecnimont House, Link Rd, Chincholi Bunder, Malad West, Mumbai, Maharashtra 400064, India; Phone: +91 22 6694 5555
6Toyo EngineeringVillage Road, Toyo Technology Centre, 71, Kanjur Village Rd, Kanjurmarg East, Mumbai, Maharashtra 400042, India; Phone: +91 22 2573 5000 in.placement@toyo-eng.com
7Udhe IndiaUhde India Private Limited,Uhde House,Lal Bahadur Shastri Marg,Vikhroli (West),Mumbai 400 083, India,Tel : 91 22 6796 8000
8SNC Lavalin2nd Floor, Tradestar, J.B.Nagar, Andheri-Kurla Road, Andheri East, Mumbai, Maharashtra 400059, India; Phone: +91 22 6789 2600
9NELUnit No.1101-1108, 11th Floor Windfall Sahara Plaza Complex, Andheri Kurla Rd, J.B.Nagar, Andheri (East), Mumbai, Maharashtra 400059, India; Phone: +91 22 4039 0505 hr@nel-india.com
10Mott MacdonaldWinchester Building, South Avenue, Road, Hiranandani Gardens, Powai, Mumbai, Maharashtra 400076, India; Phone: +91 22 4908 0100 Swati.Prabhu@mottmac.com/ miloni.mehta@mottmac.com
11Burns & Mcdonnell400 079, Block A, Sixth Floor, Godrej IT Park – P2 Godrej & Boyce Complex, Pirojsha Nagar Vikhroli, W, Mumbai, 400079, India; Phone: +91 22 2519 6600 careers@burnsmcd.in
12Rolta IndiaRolta Tower A MIDC, Rolta Technology Park, Andheri East, Mumbai, Maharashtra 400093, India; Phone: +91 22 2926 6666
13Techint5th Floor, iThink Techno Campus, Pokhran Road No. 2, Off Eastern Express Highway, Behind TCS, Thane, Maharashtra 400607, India; Phone: +91 22 6113 3500Contact HR Manager Mr. Jogendraa Nakhawa on 022-61133500 (Mail Id: jogendra.nakhawa@techint.in)
14Aker SolutionsBeta building, i-Think Techno Campus, Aker Powergas Pvt Ltd, Nehru Nagar, Kanjurmarg East, Mumbai, Maharashtra 400042, India; Phone: +91 22 6691 5901
15Reliance Engineering31, Narayan Plaza Ind. Estate, Chandivali Road, Andheri East, Mumbai, Maharashtra 400072, India; Phone: +91 22 2847 4646
16Essar EngineeringF/41 Palm Acres CHSL,Mahatma Phule Road,Mulund East,Mumbai, 400081, near Gawanpada, Mumbai, Maharashtra 400081, India; Phone: +91 99677 95973
17TCE (Tata Consulting Engineers Ltd)Unit No NB 1502 & SB -1501, 15th floor, Empire Tower, Cloud City Campus, GUT NO 31, Village Elthan, Kalwa Industrial Estate, Thane Belapur Road Airoli, Navi Mumbai, Maharashtra 400708, India; Phone: +91 22 6114 8181 tceconnect@tce.co.in
www.tce.co.in/careers
18Citec EngineeringMindspace, Building no.1, 4th Floor, Plot No Gen 2/1/F TTC Industrial Area, MIDC, Shiravane, Juinagar, Navi Mumbai, Maharashtra 400706, India; Phone: +91 22 6768 0200shilpa.deshmukh@citec.com
19Chemtex
20Indian Oil TankingIOT Infrastructure & Energy Services Ltd. Plot No. Y2, Near Nahur Railway Station, Off CEAT Tyre Road, Nahur (W), Mumbai – 400078.Tel: (+91) 22 6152 4500/600
21Aarvi EnconB1-603, Innova, Marathon NextGen G.K. Road, Opp. Peninsula Park, Lower Parel West, Mumbai, Maharashtra 400013, India; Phone: +91 22 6662 6890
22Pyramid E&C6th Floor, B Wing, I-Think Techno Campus,Behind Viviana Mall,, Pokhran Road No.2,Off,Eastern Express Highway,, Thane West, Maharashtra 400607, India; Phone: +91 22 6212 1000
23Atec India
24Ausenco
25Kepples
26L&T-Hydrocarbontalent.offshore@larsentoubro.com
27Hector & Streak Consulting Pvt. Ltd. hr17@hectorandstreak.com
28Tauraus Contractors jobs@tauruscontractors.com
29Manav Corporate Consultants info@manavconsultants.com
30Innovsource services Private Limited meghnab@innovsource.com
31AtkinsVikhroli, MumbaiRecruitment.GTC@atkinsglobal.com
32United Youepcindia@unitedyou.com
33Pyramid E&CThanehr@pyramidenc.com

Piping Design Companies in Gurgaon/ Gurugram

Sr NoCompany NameOffice AddressHR Email ID
1Bechtel
2Fluor Daniel
3Lahmeyer
4GS Engineering
5GE (General Electric)
6Mcdermott
7Punj Lloyd
8KBR
9Siemens
10Toshiba
11Honeywell
12Doosan
13Alstom India
14IOTL
15Katzstroy
16The BIM Engineershr@thebimengineers.com
Ph No: +91-8810360478

Piping Companies in Pune

Sr NoCompany nameOffice AddressHR Email ID
1Black & Veatch
2Udhe India
3Praj IndustriesPraj Industries Ltd; Praj Tower, 274 & 275, Bhumkar Chowk, Hinjewadi Road, Hinjewadi, Pune-411057poojaingale@praj.net
Ph No-+91-20-71802000
4Air Productsmohantm1@airproducts.com
5Neilsoft
6Chandan Tech
7Arya System
8Equinox
9Plantech
10Transtech
11Delta Group
12Aquatech
13Va Tech Wabag Limited
14Citec EngineeringMidas Tower, 6th Floor part B, Plot No. 44, Rajiv Gandhi Infotech Park, 411057 Hinjawadi Phase I, Pune, Maharashtra; Phone: +91 20 6656 1313
15Frames Indiamkulkarni@plugpower.com

Piping Engineering Companies in Chennai

Sr NoCompany NameOffice AddressHR Email ID
1TechnipFMC
2Petrofac
3Mcdermott
4Exterron Energy
5SaipemSaipem India Projects Pvt Ltd, Perugundi, Chennai-600096sipcareers@saipem.com
6Dow Chemical
7Petrocil Engineers & Consultants Pvt Ltdprakash@petrocil.com

Piping Design Companies in Noida

Sr NoCompany Name Office AddressHR Email ID
1Samsung Engineeringrecruitment.sei@samsung.com
2TechnipFMC
3S&B-Valdel
4CH2M Hill
5CTCI
6ISGECA-4, Sector 24; Noida – 201 301, U.P., India

Piping Design Companies in Vadodara (Baroda)

Sr NoCompany NameOffice AddressHR Email ID
1LindeLinde House, Vasna – Bhayli Main Rd, near Nilamber Circle, Saiyed Vasna, Vadodara, Gujarat 391410, India; Phone: +91 265 305 6789
2L&T-SNLL&T- Knowledge City, L&T Service Rd, Madhavpura, Vadodara, Gujarat 390019, India; Phone: +91 265 245 6000 recruitment@lntsnl.com
3L&T-Chiyoda5th L&T Knowledge City, West Block 1 N.H. 8 Ajwa-Waghodia Crossing Gate no. 1, Gujarat 390019, India; Phone: +91 265 244 2000jobs@lntchiyoda.com,
+91 265 2442020
4WorleyWorley India Pvt Ltd, Vadodara, 4th Floor, Notus Pride – IT Park, Sarabhai Campus, Genda Cir, Vadodara, Gujarat 390023, IndiaTapaswi.Chandra@Worley.com
Perumal.Raj@Worley.com
Chaitali.Shah@Worley.com
5Zeppelin Systems India Pvt LtdZeppelin Systems India Pvt Ltd. Level 4, ADM Building, Alembic Campus, Alembic Road, Vadodara – 390003. INDIA. Phone:+91-265-2291710 info@zeppelin-india.com
6Shiva Engineering Service1st floor, ABS towers, Old Padra Road, Vadodara, Gujarat, India; Tel : +91-265-2357316, 2357318, 2357319 info@shiva-engineering.com
7L&T Technology ServicesL&T Technology Services Limited, Ashish Complex, Revenue Sur. No. 370/2(Part) VI, Opposite Geb Substation, N.H.No.8, Chhani, Chhani Road. Vadodara, Gujarat, India india.careers@ltts.com
8Lisega
9Air Productsmohantm1@airproducts.com
10Bechtel
11VCare Engineering Pvt Ltdhr@vcare-global.com
12Tech Mahindra (KBR)
13Petroexcel Technology services
14Thyssenkrupp Group
15Nuberg Engineering
16Quanta Process Solutions Pvt Ltd
17Libra

Piping Companies in Delhi

Sr NoCompany NameOffice AddressHR Email ID
1Air Liquide
2Triune
3EIL
4L&T-Faridabad
5Honeywell

Piping Design Companies in Kolkata

Sr NoCompany nameOffice AddressHR Email ID
1Wood (AMEC FW)
2Development Consultants Pvt LtdDevelopment Consultant House, Block: DG-IV, Sector-II, Salt Lake, Kolkata-700091hrrecruit@in.dclgroup.com
3Richard Design Services
4Paharpur Cooling Tower
5Worley
6L&T-SNL

Piping Engineering Companies in Bangalore / Bengaluru

Sr NoCompany NameOffice AddressHR Email ID
1TaalTechrecruitment@taaltech.com
swathisavanth@taaltech.com
2TCE
3GE
4L&T Valdel
5Suez Water Technologies
6Quest Global Engineering Services
7Veolia
8Sidvin Energy Engineeringcareers@sidvincoretech.com

Other Piping Engineering Companies from India

  • DGS: Hyderabad: careers@dgsts.com
  • Padink Engineering: Bengaluru: hr@padink.in

Few more Resources for you..

Top EPC companies of UAE (Abu Dhabi, Dubai, and Sharjah) to try for employment opportunities

If anyone of you knows the HR Email ids of any of the listed companies please share them in the comments section in Company Name-Email ID format as this database will be helpful for all of us. Thanks in Advance.

Examples of Hazards of Pressure Testing

Written by Anup Kumar Dey in Mechanical,Piping Design Basics,Process

What is Pressure Testing?

Pressure testing is a process of verifying the strength, integrity, and safety of a pressurized system or component. It involves pressurizing the system or component with a fluid or gas, usually water or air, to a predetermined level and monitoring the pressure to ensure that it remains stable over a specified period of time.

The purpose of pressure testing is to identify any leaks or weaknesses in the system or component that could lead to failure under normal operating conditions. By subjecting the system or component to a higher pressure than it would normally experience, any weaknesses or defects in the material or construction can be detected.

There are several types of pressure tests, including hydrostatic testing, pneumatic testing, and vacuum testing. Each type of test is designed to assess different aspects of the system or component, such as its ability to withstand pressure, its resistance to leaks, and its overall integrity.

Pressure testing is commonly used in a wide range of industries, including oil and gas, manufacturing, construction, and aerospace. It is a critical step in ensuring the safety and reliability of pressurized systems and components.

Hazards of Pressure Testing

Everybody knows that Pressure Testing (Hydro test, Pneumatic Test, or Pressure Test) is a highly hazardous activity and there are many examples of incidents that had already happened. So the utmost care must be exercised to manage safety during pressure testing.

While pressure testing is an important safety measure to ensure the integrity of pressurized systems, it also involves certain hazards that should be taken into account to prevent accidents and injuries. Some of the hazards associated with pressure testing include:

  • Explosion or rupture: If the system or component being tested is unable to withstand the pressure, it may explode or rupture, causing damage to the equipment and potential injury or death to anyone nearby.
  • Projectile hazards: If a component fails during the test, it may release fragments or debris at high velocity, which can cause serious injury or damage to equipment and structures.
  • Chemical hazards: The fluid or gas used to pressurize the system may be hazardous if it leaks or is released, potentially causing chemical burns or respiratory problems.
  • Noise hazards: The noise generated during pressure testing can be very loud, potentially causing hearing damage if proper hearing protection is not used.
  • Thermal hazards: The pressurized fluid or gas may generate heat during the test, potentially causing burns or other thermal injuries.

To prevent these hydro testing hazards, proper safety measures should be taken, including wearing appropriate personal protective equipment (PPE), maintaining a safe distance from the test area, using proper containment and ventilation measures, and following established safety procedures and protocols. It is also important to ensure that the equipment used for pressure testing is properly maintained and calibrated to prevent accidents and ensure accurate results.

In the below paragraphs, We will provide examples of five such incidents that can be used to understand the hazards and dangers involved during pressure testing.

Hydro-test of a new vertical vessel

Explosion of a vertical vessel during hydrotesting
Fig. 1: Explosion of a vertical vessel during hydro testing

Refer to Fig. 1. The image shows an exploded vessel that happened during hydro testing of a new vessel. The root cause of the incident is not known fully. But there was some brainstorming and people thought that hydro-testing with “very cold” water could be a contributing factor. The good news is that no injuries occurred.

Learning from the Incident

It is learned that water temperature during hydro testing is critical. It is suggested to maintain the metal and water temperature at least at 16°C or at least 10°C above the impact test temperature of the metal during pressure testing.

Filling of a vertical tank

This incident happened while filling the tank (Refer to Fig. 2) with water from a fire hydrant. As the relief valve could not displace the air fast enough for the volume of water that was being pumped in, The top of the tank blew off suddenly.

Fortunately, no injury happened, but an operator was on top of the tank a few seconds before.

Top of tank blew off during hydrotesting
Fig. 2: The top of the tank blew off during hydro testing

Lessons Learned from the Incident

Before filling and emptying operations, drain and venting systems must be thoroughly inspected and checked.

Emptying a vertical tank

Refer to Fig. 3. While the tank was being emptied, it suddenly collapsed. Root cause analysis shows that a plastic sheet that was protecting the roof was trapped in the vent which created a vacuum. So it is a must to inspect the venting systems before filling and emptying operations.

There was no injury. It should be noted that this type of incident is not that unusual.

Collapse of tank during hydrotesting
Fig. 3: Collapse of a tank during hydro testing

Sphere collapse

During the filling of a 2000 m3 LPG sphere (Fig. 4), Its legs suddenly collapsed. One nearby person was killed and one was seriously injured.

The research found that the sphere was approximately 80% full of fresh water. The vessel’s last hydro-test was 10 years ago and the last inspection of its legs was done 5 years ago.

The main cause was the Severe corrosion of the legs under the concrete fire protection. The corrosion occurred due to water ingress between the concrete and the steel legs. The water protective cap that was located over the concrete was not sufficient to keep the water out. It was verified later that the steel legs had their thickness reduced by up to 8 mm, with pitting holes of up to 10 cm2.

Sphere Collapsed during hydrotesting
Fig. 4: Sphere Collapsed during hydro testing

Thorough investigation and tests confirmed that the following factors contributed to the sphere collapse:

  • The poor design of the water caps over the fire-proofing concrete was allowing the water to penetrate the steel beams and the concrete.
  • Vertical cracks in the concrete let water in.
  • Poor workmanship during Repairs had been done to the concrete.
  • The new concrete had not adhered to the old concrete, again letting water in.
  • The deluge system had been tested with saltwater, increasing the possibility of corrosion.

Learning from the incident

A complete inspection must be performed visually and if required with NDT before pressure testing of an old vessel. This inspection must include the vessel, nozzles, appurtenances, and supporting structures.

Emptying of a gearbox

To speed up the removal of 250 liters of oil from a gearbox (Fig. 5), the gauge hole was plugged and the breather was connected to the 6-bar air network. The gearbox exploded and threw missiles around seriously damaging surrounding piping and structure. Fortunately, there was no injury.

Gear box explosion
Fig. 5: Gear-box explosion

Even though a gearbox is not a pressure vessel, its productivity may lead to a risky attitude.

Recommended Actions for Pressure Testing

Tests may be a routine operation pressure but do not forget that in fact, pressurization is energy storage. Its instantaneous release works like a bomb and may cause severe damage to persons and equipment.

Good preparation is always essential to avoid incidents. It is recommended to use the following checklist:

  • Based on relevant standards and specifications, A detailed checklist procedure must be prepared which shall cover the testing operation from filling up to emptying the vessel.
  • Good coordination is of utmost importance to avoid performing the hydro-test at the same time as other operations. Most reputed companies use work permit procedure / Job Hazard Analysis methodology.
  • The equipment must be in good condition and adequately maintained and certified.
  • Testing equipment shall be kept as far as practicable from the recording and pumping station.
  • New Testing equipment must be checked before using it.
  • The test area must be roped off,
  • During the test, from filling up until the end of depressurization, all non-essential people must be out of the test area,
  • The test crew must attend a toolbox talk,
  • Wearing PPE must be made mandatory for all personnel involved in testing.
  • Leak inspection must be performed at least 15 minutes after the test pressure has been reached and this has to be inspected only by designated personnel.
  • While under pressure or during pressure-up stages, never tamper with, or tighten any fittings (i.e. connections, bolts, hoses, etc).

Few more useful resources for you…

What is Engineering Process Safety?
Safety Rules during A Field Visit By A Design Engineer
An article on Crane safety during Construction
HAZOP (Hazard and Operability) Study: A brief introduction
An article on Excavation Hazards at Construction Sites
Hazardous Area- Theory, Classification and Equipment selection: A short presentation