What is a Process Datasheet? A Comprehensive Guide to Process Datasheets

Written by Anup Kumar Dey in Process

In the world of industrial processes, efficient and accurate information management is vital for smooth operations and optimal productivity. Process Datasheet is one such essential tool for all oil and gas projects. From engineering and manufacturing to oil and gas, process datasheets play a crucial role in ensuring seamless communication, facilitating equipment procurement, and driving effective decision-making. In this article, we will learn about the significance of process datasheets, their structure, and how they streamline operations in various industries.

Process datasheets are one of the important process deliverables generated during the detailed design phase of a project. Defining every piece of equipment is essential for every project and process datasheets quantify the equipment before procurement. Once the Process team prepares the P&ID (Piping and Instrumentation Diagram), the next phase is to create process data sheets for each piece of equipment. these process datasheets can be sent to suppliers or vendors to obtain pricing.

What Is a Process Data Sheet?

A Process Datasheet summarises the performance of equipment or a system. The technical characteristics of the equipment/system are specified in the process datasheet for initiating the detailed design. They are also known as Design Datasheets or Process Equipment Datasheets. All the fundamental technical requirements (Design Data) to specify equipment (technical specification) are provided in the process datasheet.

Process datasheets serve as a consolidated source of information about a specific component or equipment within an industrial process. These documents provide a standardized format for capturing key technical details, specifications, and operational requirements. Process datasheets act as a bridge between engineering and procurement teams, enabling effective collaboration and reducing the risk of miscommunication.

Understanding Process Datasheets

Structure and Components of Process Datasheets

Process datasheets for oil and gas industries typically contain the following sections:

General Information:

This section includes the equipment name, tag number, and a brief description of its function. It provides an overview of the equipment’s purpose and its integration within the overall process.

Process Parameters:

Here, critical process parameters are documented, including temperature, pressure, flow rates, and any other relevant operational variables. These parameters help in determining the equipment’s suitability for a specific process.

Design and Construction:

This section outlines the equipment’s design specifications, construction materials, dimensions, and installation requirements. It ensures that the procurement team can select the right equipment that aligns with the process needs and meets industry standards.

Performance and Efficiency:

Process datasheets highlight the performance characteristics and efficiency metrics of the equipment. This information assists in evaluating the equipment’s capability to meet production targets, energy efficiency goals, and overall process optimization.

Overall each process datasheet usually includes:

Overall size of the equipment
Number of equipment,
Approximate geometry (Diameter, length, etc)
Identification of the nozzle and tie-in point connections,
Material of construction of the equipment (Material, Corrosion allowance, cladding requirement, lining requirement, etc)
Full range of operating conditions (Design Pressure, Design and Operating temperature, Test Pressure, Fluid Type, etc).
Specific notes and remarks.

The Process Datasheet sometimes includes a simple diagram to easily communicate the technical specifications to the vendor, supplier, or clients. Mechanical datasheets for a piece of equipment are often prepared using the process datasheets as a reference. Fig. 1 below shows an example of a typical process datasheet template.

**Fig. 1: Typical Process Datasheet Template**

Significance and Benefits of Process Datasheets

Process datasheets offer numerous benefits as mentioned below:

Standardized Communication:

By providing a uniform format for technical information, process datasheets facilitate clear and concise communication between engineering, procurement, and maintenance teams. This reduces misunderstandings, accelerates decision-making processes, and minimizes project delays.

Streamlined Procurement:

Process datasheets play a vital role in equipment procurement by enabling precise specification and selection. Procurement teams can refer to these datasheets to identify vendors that provide equipment meeting the required specifications, reducing the risk of purchasing incompatible equipment.

Enhanced Safety and Compliance:

Process datasheets include crucial safety considerations, such as hazardous area classifications, electrical ratings, and necessary safety features. Adhering to these specifications ensures compliance with industry regulations and minimizes safety risks in the workplace.

Improved Equipment Reliability and Performance:

Process datasheets provide comprehensive information on equipment design, performance, and maintenance requirements. This knowledge enables better equipment selection and facilitates proactive maintenance planning, leading to enhanced reliability and performance.

Efficient Project Management:

Process datasheets are invaluable during the project management phase. They serve as a reference for design reviews, equipment installation, and commissioning activities, ensuring that projects progress smoothly and efficiently.

Applications of Process Datasheets

Process datasheets find applications across various industries. Some of the typical examples are:

Chemical and Petrochemical Industry:

In the chemical and petrochemical industry, process datasheets are extensively used for equipment procurement, such as pumps, reactors, heat exchangers, and distillation columns. These datasheets help in specifying material compatibility, corrosion resistance, pressure ratings, and other critical factors specific to chemical processes.

Oil and Gas Industry:

In the oil and gas sector, process datasheets play a vital role in the procurement and selection of equipment for exploration, production, refining, and transportation. Datasheets for equipment like compressors, separators, pipelines, and storage tanks provide crucial details about pressure ratings, materials, safety features, and environmental considerations.

Pharmaceutical and Biotechnology Industry:

Process datasheets are essential in the pharmaceutical and biotechnology sector, where strict compliance with regulatory standards is paramount. Datasheets for equipment like sterilizers, bioreactors, filtration systems, and cleanrooms outline critical parameters, such as sterility requirements, temperature control, agitation systems, and documentation protocols.

Power Generation Industry:

In the power generation industry, process datasheets are used for various equipment, including turbines, generators, boilers, and control systems. These datasheets provide specifications related to power output, efficiency, fuel requirements, emissions control, and safety features.

Manufacturing Industry:

Process datasheets find applications in the manufacturing sector for equipment such as conveyors, robotics, CNC machines, and industrial ovens. Datasheets in this industry specify parameters like speed, load capacity, precision, control systems, and energy consumption.

Generation of Process Datasheets

Even though the responsible engineer for preparing a process datasheet is a process engineer, it is jointly prepared by a process engineer and a mechanical engineer. Sometimes other disciplines like electrical and instrumentation may also help the process engineer in the process datasheet creation process.

Most design companies have their own standard process datasheet template for each type of equipment. So, while preparing the process datasheet for specific equipment, process engineers fill out the process data in those standard templates of process datasheets. Data like flow, temperature, pressure, capacity requirements, etc are obtained from the Process Flow Diagram (PFD), or process engineers calculate and fill the process datasheet. Equipment information like design code, loading information, flange and nozzle requirements, etc are usually provided by the responsible mechanical engineer.

Process datasheets vary from one piece of equipment to another. For static equipment, the data required will be different from rotating equipment. So, depending on the number of equipment in any project, different process datasheets need to be prepared. As the data from the process datasheet is used for the equipment design by the manufacturer, the data must be thoroughly checked and verified before sending to the equipment vendor. Process datasheet usually provides data for critical items in the equipment or system skipping the insignificant items.

The following documents are required for preparing a process datasheet:

Process P&ID
PFD
Equipment Design Codes
Process Design Basis
Industry Guidelines and Best Practices
Supplier datasheets, etc

Final Thoughts

Process datasheets are indispensable tools for efficient and streamlined industrial operations. By providing standardized and detailed information about equipment specifications, process parameters, and operational requirements, these datasheets enhance communication, aid procurement processes, improve safety, and optimize performance. Whether in the chemical, oil and gas, pharmaceutical, power generation, or manufacturing industry, process datasheets play a crucial role in facilitating informed decision-making, ensuring compliance with regulations, and driving operational excellence. Embracing the use of process datasheets not only enhances efficiency but also contributes to overall productivity and profitability in a rapidly changing industrial landscape.

Meaning of Slope, Free Draining, Gravity Flow, and No Pocket in P&ID

Written by Nupur Mukherjee in Process

Process P&ID is the most important multidisciplinary document produced for any oil and gas project. The majority of the piping design information is taken from the piping and instrumentation diagram while laying a piping system. Every P&ID contains lots of piping information and hence P&ID is the piping designer’s roadmap for laying out the piping system. Some of the terms used in P&IDs are quite confusing to piping engineers and designers. Four such widely used terms are:

No Pockets
Free Draining
Slope
Gravity flow

In this article, we will explain the meaning and requirements for No Pockets, Free Draining, Slope, and Gravity flow in piping system design. Let’s have a quick walkthrough of all the above requirements with examples.

No Pocket

Definition of No Pocket

The term “NO POCKET” means no liquid pocket in the line. When it’s necessary to prevent vapor pockets, the note will read “NO VAPOR POCKETS”.

For “NO POCKET” lines elevation changes are either vertically up or vertically down, but not both. Refer to Figure 1A.

What is Pipe Pocket?

A section of the pipe that will not self-drain due to pipe layout/orientation is considered a “pipe pocket” (refer to Figure 1B).

Examples of Pocket and No-Pockets — **Fig. 1: Examples of Pockets and No-Pockets**

Why Do Pockets Appear?

During piping layout, pipes may encounter many obstructions (Such as Structure, Equipment, other piping, etc) and may need to change elevation.
Valve accessibility
Expansion loop

P&ID representation of No Pocket

In P&ID, the no pocket is indicated with an arrow as shown in Fig. 2A below.

Typical applications of No-Pocket

Two-phase lines,
Compressor suction line,
Column overhead vapor lines,
Vapor balancing lines, etc.

Examples of No-Pocket Lines

The column overhead vapor line going to the overhead condenser, should not have a liquid pocket, this is the minimum requirement. If the column overhead vapor carries entrained liquid it may accumulate in this liquid pocket and prevent the free vapor flow by plugging the flow path. This liquid accumulation may not be apparent until upset (flooding, product quality deviation, etc) occurs. So, rather than depending upon signals and low point draining, piping can be routed in such a way that prevents any liquid accumulation. That’s why we indicate “NO POCKET” for the column overhead vapor line in P&ID (refer to Figure 2B).

**Fig. 2: No Pocket Symbol & No-Pocket at Column Overhead Line**

For a Two-phase flow line, Process engineers typically indicate a note “Provide support for two-phase flow”. Typically, they try to minimize the slug flow regime in the two-phase flow because that can lead to serious pressure fluctuation and vibration. A two-phase flow line should not have a pocket, because liquid will accumulate and promote unstable flow.

The pump suction line should not have any high point vapor pocket (NO VAPOR POCKET). However, this is typically not specified on P&ID.

Free Draining

Definition of Free Draining

The term “FREE DRAINING” means elevation changes are downward only for the unwanted liquid to drain out from the line (process motive fluid may have a different flow direction). No pockets (no liquid and gas pockets in the line) are permitted. A free draining line may or may not be sloped (Refer to Figure: 3A)

The line does not need to be sloped, but it must not be pocketed. Any line with a “FREE DRAINING” note towards any equipment or low point indicates undesirable liquid flowing towards the lower point. “FREE DRAINING” with directions towards equipment is covered with no pocket requirement also. “FREE DRAINING” with direction is typically to empty out or clean the line from undesirable liquid accumulation. The direction of the main process fluid flow may or may not match the direction of “FREE DRAINING”.

For example, Compressor Kickback lines. To prevent liquid from obstructing kickback operation, the vapor kickback line (vapor mainly flows from the compressor discharge side to the suction side) upstream of the control valve should be free draining to the inlet line of suction KOD and downstream of control valve free draining to a low point at discharge line. This can be achieved by elevating the kickback valve above the drum’s maximum liquid level (refer to Figure: 3B).

P&ID representation

The P&ID symbol for free draining is similar to the No pocket P&ID symbol. Here also the term No Pocket is mentioned above the arrow.

Typical applications:

PSV inlet/outlet line, Dead leg, Compressor suction line should be free draining towards suction KOD, Compressor kickback line, etc.

Examples of Free Draining Lines

The relief valve inlet line shall be free draining towards the protected equipment or Pipe header where it’s installed. Relieving fluid flow goes upward and relief through PSV, but any liquid at this line will be free draining towards protecting equipment to ensure no liquid accumulation that can hinder relief operation.

The relief valve outlet line (tail pipe) should be free draining towards the Flare header or Flare KOD. Refer to Figure 4A.

**Fig. 4: Examples of Free Draining Requirements**

A line can have two sections free draining to either side as shown in Fig. 4B. Compressor suction pipe should be free draining towards suction KOD or low point in the suction line.

Slope

Definition of Slope

The slope indicates a change in the elevation of the line. In general, slope indicates elevation changes that are constantly downward. Slope requirements are specifically mentioned in the P&ID using symbols.

P&ID Symbol for Slope

**Fig. 5: P&ID representation for Slope**

In the piping and instrumentation diagram, the slope is represented as shown in Fig. 5. In this Figure, X has a unit the same as 1. In general, they are given as (SLOPE is mm: mm)

Typically, a minimum 1:500 slope is required for Flare main header and 1:200 is required for Flare sub-headers.

More details about the piping slope can be found here.

Typical Applications of Slope

Typically, the following lines are provided with slope:

Flare main header,
Flare sub-header,
Drain header,
Stormwater channel, etc.

Gravity Flow

Definition of Gravity Flow

Gravity flow means that the elevation downstream never exceeds inlet elevations. The line may contain pockets.

P&ID Symbol for Gravity Flow

In P&ID the gravity flow requirement is represented by using a symbol to the Free draining requirement symbol. This means here also, the term Gravity flow is mentioned above the arrow.

Typical Applications of Gravity Flow

Sometimes we have a stacked design in such a way that column will be at the bottom section, Exchanger (Reflux condenser) will be at the top, and the reflux drum in between the column and exchanger. For those configurations typically we don’t use the pump for reflux going to a column. We making sure that the reflux will flow by gravity to the drum because of the elevation difference. And from the drum, it flows to the column using gravity. There we typically indicate gravity flow. Because of the elevation difference between source and destination, process fluid flow by gravity, there we are not using any pump. The gravity flow line is not the same as free draining.

Free draining is typically for cleaning lines purposes whereas Gravity flow (direction of process motive fluid has the same direction) occurs because of elevation difference.

Fig. 6 (Image Courtesy: https://www.linkedin.com/pulse/slope-free-draining-gravity-flow-pocket-jargon-saeid-rahimi-mofrad/) below depicts some of the acceptable piping arrangements that can be used by piping designers for the correct interpretation of P&ID piping requirements into the 3D model.

**Fig. 6: Possible Modelling Configuration for lines with different piping requirements**

Overview of Nitrogen Tanks and Cylinders

Written by Anup Kumar Dey in Mechanical

Nitrogen tanks, also known as nitrogen cylinders or nitrogen bottles, are containers specifically designed to store and transport nitrogen gas in its compressed form. Nitrogen is an odorless, colorless, and inert gas that is widely used in various industries and applications for a quite long time.

Nitrogen tanks are typically made of high-strength steel or aluminum alloy to withstand the high pressure generated when the gas is compressed. These tanks come in different sizes and capacities, ranging from small portable cylinders to large stationary tanks. The size and design of the tanks depend on the intended use and the amount of nitrogen required.

Nitrogen gas is often used in industries such as manufacturing, electronics, rubber, healthcare, food processing, mining, automotive, chemical, and aerospace. It is utilized for a variety of purposes, including purging, inerting, blanketing, and pressurizing. For example, nitrogen is commonly used to displace oxygen and moisture in sensitive manufacturing processes or to prevent the oxidation and spoilage of food products.

When using nitrogen from a tank, a regulator or pressure-reducing valve is attached to control the flow and pressure of the gas. This ensures that the nitrogen can be safely and accurately released for the intended application. It’s important to handle nitrogen tanks with care and follow proper safety guidelines, as they contain highly pressurized gas. Regular inspections, maintenance, and adherence to safety procedures are crucial to prevent accidents and ensure the safe handling of nitrogen. Various codes and standards including AMME, NFPA, CGA, ISO, DOT, etc provide guidelines for nitrogen tanks.

Why Store Nitrogen?

Storing nitrogen serves several important purposes across various industries and applications. Here are some common reasons for the storage of nitrogen:

Inerting: Nitrogen is an inert gas, meaning it does not easily react with other substances. This property makes it useful for inerting applications, where it is used to displace or reduce the presence of oxygen. By introducing nitrogen into a storage or processing environment, oxygen levels can be lowered, reducing the risk of oxidation, combustion, or degradation. Inerting is often employed in industries such as oil and gas, chemical manufacturing, and pharmaceuticals.

Blanketing: Nitrogen is used to create a protective atmosphere or nitrogen blanket over sensitive materials or substances. By filling a storage container or vessel with nitrogen, it can act as a barrier between the material and the surrounding air, preventing contact with oxygen and moisture. This is commonly done to protect perishable goods, such as food products, chemicals, and pharmaceuticals, from degradation, spoilage, or contamination.

Pressurizing: Some applications require the use of pressurized nitrogen gas. Nitrogen tanks provide a convenient and portable solution for storing and delivering compressed nitrogen. Pressurized nitrogen is used in various industrial processes, such as pneumatic tools, gas-assisted injection molding, and as a propellant in aerosol cans.

Laboratory and research applications: Nitrogen is extensively used in laboratories for a wide range of applications. It is often needed for sample storage, preservation, or as a carrier gas in gas chromatography. Storing nitrogen in tanks ensures a readily available and reliable source of this gas for laboratory operations.

Emergency backup: In critical systems or facilities where the interruption of gas supply can have serious consequences, storing nitrogen provides a backup or contingency plan. For example, in hospitals, nitrogen is often stored in tanks to support medical gas systems, ensuring a continuous supply of essential equipment such as ventilators or cryogenic storage.

In general, nitrogen is stored in its liquid form which calls for cryogenic needs. Fig. 1 below shows some typical nitrogen tanks.

Liquid Nitrogen Tank

A liquid nitrogen tank, also known as a cryogenic tank or dewar, is a specialized container designed for the storage and transportation of liquid nitrogen. Unlike nitrogen gas stored in compressed gas cylinders, liquid nitrogen is extremely cold and maintained at a temperature of -196 degrees Celsius (-320.8 degrees Fahrenheit) at atmospheric pressure.

Liquid nitrogen tanks are constructed with materials that can withstand extremely low temperatures and prevent heat transfer from the environment. The tanks are typically double-walled or vacuum-insulated, which creates a thermal barrier to minimize heat exchange and maintain the low temperature of the liquid nitrogen inside.

Components of a Liquid Nitrogen Tank

The main components of a liquid nitrogen tank include:

Inner Vessel: This is the innermost chamber that holds the liquid nitrogen. It is usually made of stainless steel or aluminum alloy and is designed to safely contain extremely cold liquid.
Vacuum Space: Surrounding the inner vessel is a vacuum space that acts as insulation to minimize heat transfer. It prevents the entry of external heat and reduces heat conduction, convection, and radiation.
Outer Jacket: The outer jacket is the outermost layer of the tank, made of a durable material such as steel or aluminum. It provides structural support and additional insulation to maintain the low temperature inside the tank.
Pressure-Building Valve: Liquid nitrogen tanks are equipped with a pressure-building valve to allow controlled venting of gas that evaporates from the liquid nitrogen. This valve helps maintain the appropriate pressure within the tank.

Liquid nitrogen tanks are commonly used in various applications, including scientific research, cryogenic storage, medical facilities, and industrial processes. They provide a reliable and efficient method for storing and accessing liquid nitrogen, which is utilized in areas such as cryopreservation, cryosurgery, cryogenic cooling, and cryogenic testing.

Safety precautions must be followed when handling liquid nitrogen tanks, as the extremely cold temperature can cause frostbite and pose other hazards. Proper training and protective equipment are necessary to ensure safe operation and prevent accidents. If the liquid nitrogen is not handled and stored properly, it can cause cold burns or can cause explosions due to pressure built up.

Liquid nitrogen tanks provide several advantages including:

Easy Accessibility for Medical Purposes
Ease of Transportation and Loading Process
No contamination
Efficient operation
Temperature preservation

Nitrogen Tank Sizes

Nitrogen tanks come in various sizes and capacities to cater to different needs and applications. The size of a nitrogen tank is typically determined by its capacity to hold compressed nitrogen gas, which is measured in cubic feet (ft³) or liters (L). Here are some common nitrogen tank sizes:

Small Portable Tanks:

These tanks are typically lightweight and easy to transport. They are often used for smaller-scale applications or for portable nitrogen supply. Common sizes include:

20 cubic feet (ft³) or 580 liters (L)
40 cubic feet (ft³) or 1,160 liters (L)
80 cubic feet (ft³) or 2,270 liters (L)

Intermediate Tanks:

Intermediate-sized tanks are suitable for moderate nitrogen requirements or for situations where a larger supply is needed but portability is not a major concern. Examples include:

125 cubic feet (ft³) or 3,540 liters (L)
180 cubic feet (ft³) or 5,090 liters (L)
250 cubic feet (ft³) or 7,080 liters (L)

Large Stationary Tanks:

These tanks are designed for stationary applications where a substantial nitrogen supply is required. They are commonly used in industrial settings or facilities with high nitrogen consumption. Sizes can range from a few hundred cubic feet to several thousand cubic feet.

500 cubic feet (ft³) or 14,160 liters (L)
1,000 cubic feet (ft³) or 28,320 liters (L)
3,000 cubic feet (ft³) or 84,960 liters (L)

It’s important to note that the specific sizes and capacities of nitrogen tanks may vary depending on the manufacturer and regional standards. When selecting a nitrogen tank, it’s essential to consider factors such as the required nitrogen volume, available space, portability needs, and the intended application to ensure the right size is chosen for the task at hand.

Materials for Nitrogen Tanks

Nitrogen tanks are typically made from materials that possess high strength and can withstand the high pressure generated by compressed nitrogen gas. The two most common materials used for nitrogen tanks are:

Steel: Steel tanks are widely used for nitrogen storage due to their strength, durability, and ability to handle high-pressure applications. The steel used is often a high-strength alloy, such as chrome-molybdenum steel or aluminum-lined steel, which provides excellent resistance to rupture or deformation. Steel tanks are suitable for both portable and stationary nitrogen storage.
Stainless Steel: Stainless steel is a commonly used material for the construction of liquid nitrogen tanks. It offers excellent strength, durability, and resistance to corrosion. The stainless steel used for cryogenic applications is typically low-temperature grades, such as 304 or 316 stainless steel, which can maintain their mechanical properties and integrity at very low temperatures. Stainless steel tanks provide reliable storage for liquid nitrogen and are often used in laboratory, medical, and industrial settings.
Aluminum Alloy: Aluminum alloy tanks are another popular choice for nitrogen storage, particularly in applications where weight is a concern. Aluminum is lightweight and corrosion-resistant, making it suitable for portable nitrogen cylinders. Aluminum alloy tanks are commonly used for smaller-sized nitrogen cylinders, such as those used in laboratories or for portable nitrogen supply.

Both steel and aluminum alloy tanks undergo rigorous testing and certification processes to ensure their safety and compliance with industry standards. These tanks are designed to withstand high-pressure conditions and are equipped with safety features, such as pressure relief valves, to prevent over-pressurization.

It’s worth noting that the choice of material for a nitrogen tank may depend on factors such as the required capacity, portability needs, regulatory requirements, and specific industry standards. Manufacturers and suppliers can provide detailed information on the material composition and specifications of their nitrogen tanks to help customers select the appropriate option for their intended application.

Nitrogen Tank Price

The price of a nitrogen tank can vary depending on several factors, including the tank size, material, manufacturer, region, and any additional features or accessories included. Here are some approximate price ranges for nitrogen tanks:

Small Portable Tanks: Smaller nitrogen tanks with capacities ranging from 20 cubic feet (ft³) to 80 ft³ can cost between $50 and $200.
Intermediate Tanks: Intermediate-sized nitrogen tanks with capacities between 125 ft³ and 250 ft³ may range in price from $200 to $500.
Large Stationary Tanks: Larger stationary nitrogen tanks with capacities of 500 ft³ or more can cost several thousand dollars, depending on the size and specifications. Prices can range from $1,000 to $10,000 or more.

It’s important to note that these price ranges are estimates and can vary significantly based on market conditions, location, and other factors. Additionally, prices may differ between different suppliers or manufacturers.

What is a Pre Insulated Pipe? Its Applications and Advantages

Written by Anup Kumar Dey in Piping Design Basics

Pre-insulated pipes are a type of piping system that consists of a carrier pipe (also known as the service pipe or inner pipe), insulation material, and an outer casing. These pipes are designed to transport fluids, such as hot water, steam, or chilled liquids while providing excellent thermal insulation. The insulation bonds the carrier pipe and the casing together. Preinsulated pipes are also known as bonded pipes or insulated pipes.

The service pipe is typically made of materials like steel, copper, or plastic, depending on the specific application and requirements. It carries the fluid being transported through the pipe. The common fluid is hot water and is used widely for district heating networks.

The insulation material surrounds the carrier pipe and is responsible for minimizing heat transfer. Due to this minimum heat transfer, the temperature inside the service pipe is maintained. Common insulation materials used in pre-insulated pipes include polyurethane foam, polyisocyanurate foam, or mineral wool. These materials have excellent thermal properties, ensuring minimal heat loss or gain from the fluid inside the pipe. Such materials usually have a thermal conductivity of around 0.024–0.033 W/(m·K)

The outer jacket or casing encloses the insulation material, providing protection and mechanical strength to the pipe assembly. It is usually made of materials like high-density polyethylene (HDPE), polyvinyl chloride (PVC), or steel, depending on the application and environmental conditions. Fig. 1 below shows some typical pre-insulated pipes.

**Fig. 1: Examples of Pre-insulated pipes**

Advantages of Pre-Insulated Pipes

Pre-insulated pipes are commonly used in various industries, including district heating and cooling systems, oil and gas pipelines, and industrial process piping. They offer several advantages, such as:

Energy Efficiency: The insulation layer minimizes heat loss or gain, resulting in improved energy efficiency and reduced operational costs.
Reduced Heat Transfer: Pre-insulated pipes provide excellent thermal insulation, preventing the formation of condensation on the outer surface and maintaining a consistent temperature of the transported fluid.
Corrosion Protection: The outer jacket protects the carrier pipe from corrosion, extending its lifespan and reducing maintenance requirements.
Easy Installation: Pre-insulated pipes are typically supplied in long lengths, which simplifies installation and reduces the number of joints, minimizing potential leakage points.
Environmentally Friendly: By reducing energy consumption and heat loss, pre-insulated pipes contribute to environmental sustainability and reduced greenhouse gas emissions.

These pipes are available in various sizes, insulation thicknesses, and configurations to suit specific project requirements.

Codes and Standards for Pre-Insulated Pipes

European standards EN 253 and EN 15698-1 describe the pre-insulated pipes for district heating systems. EN 253 provides guidelines for Bonded single pipe systems for directly buried hot water networks having assembly of steel service pipe, polyurethane thermal insulation, and a casing of polyethylene. On the other hand, EN 15698-1 provides guidelines for bonded twin pipe systems for directly buried hot water networks with a twin pipe assembly of steel service pipes, polyurethane thermal insulation, and one casing of polyethylene”.

Applications of Pre-Insulated Pipes

Even though pre-insulated pipes are widely used for district heating and cooling networks, they are found to be used in various other industries including

Oil and Gas
Food processing
Water Treatment
Wineries
Chemical industries
Infrastructure and utility
Pharmaceutical, etc

As per market research, the pre-insulated pipe market is projected to grow at a CAGR (Compounded Annual Growth Rate) of 9.8% over the next few years. The growth will mainly happen due to strict regulations to reduce carbon footprint and improve energy efficiency.

Specification of Pre-insulated Pipes

When specifying pre-insulated pipes for a project, it’s important to provide clear and detailed information to ensure that the product meets the required specifications. Here are some key factors to consider when specifying pre-insulated pipes:

Fluid Type and Temperature: Specify the type of fluid (e.g., hot water, steam, chilled water) that will be transported through the pipe, along with the desired operating temperature range. This information helps determine the appropriate insulation material and thickness.
Pipe Diameter and Material: Specify the required pipe diameter and material for the carrier pipe. Common options include steel, copper, or plastic (such as high-density polyethylene – HDPE). The selection depends on factors like pressure rating, corrosion resistance, and project-specific requirements.
Insulation Thickness: Determine the necessary insulation thickness based on factors such as the desired heat loss/gain, ambient temperature, and energy efficiency goals. This will depend on the thermal conductivity of the insulation material and the required thermal resistance (R-value).
Casing Material: Specify the outer jacket material based on factors like environmental conditions, UV resistance, and mechanical strength requirements. Options may include HDPE, PVC, or steel.
Pipe Length: Specify the required lengths of pre-insulated pipe sections or coils. Longer lengths may reduce the number of joints and facilitate faster installation. Insulated pipelines are usually assembled from pipes of 6 meters, 12 meters, or 16 meters in length, directly buried in soil in depths of commonly 0.6–1.2 meters.
Standards and Certifications: Identify any specific standards or certifications that the pre-insulated pipes need to meet. For example, in certain industries or regions, there may be specific codes or regulations governing the materials, insulation properties, or safety requirements.
Accessories and Additional Requirements: Determine if any additional accessories are needed, such as fittings, valves, expansion joints, or heat tracing elements. Specify any special requirements for pipe connections or insulation joints.
Project-Specific Considerations: Provide any project-specific requirements or considerations, such as seismic resistance, fire resistance, or special insulation properties.

Preinsulated Pipe Manufacturers

There are several reputed pre-insulated pipe manufacturers around the world. Here are some well-known companies in this field:

Uponor Corporation (Finland)
Logstor (Denmark)
Perma-Pipe International Holdings, Inc. (United States)
Georg Fischer Piping Systems Ltd. (Switzerland)
Isoplus Fernwärmetechnik GmbH (Germany)
Aquatherm GmbH (Germany)
BRUGG Rohrsysteme GmbH (Switzerland)
Thermaflex International (Netherlands)
Huntsman Corporation (United States)
Kooltherm Pipe Insulation (United Kingdom)
Microflex Preinsulated Systems (Italy)
CPV Ltd. (United Kingdom)
Flexalen by Thermaflex (Netherlands)
SIMONA AG (Germany)
Rovanco Piping Systems (United States)

These manufacturers specialize in producing pre-insulated pipes and offer a wide range of products to meet various industrial and commercial needs. It’s important to note that availability may vary depending on the region, and it’s always recommended to research and consult local suppliers for specific project requirements.

What is a Clevis Hanger? Its Features and Applications

Written by Anup Kumar Dey in Piping Supports

A clevis hanger is a type of mechanical support device widely used in the piping and plumbing industries. This pipe attachment is specifically designed to support and suspend piping systems, such as pipes, tubes, and conduits, from overhead structures or beams. Clevis hanger provides vertical adjustments and is quite flexible for supporting pipes. They are in general preferred for non-insulated piping systems. However, clevis hangers can be used for insulated piping systems, as well.

Components of a Clevis Hanger

The clevis hanger consists of two main components: a U-shaped clevis and a threaded rod. The clevis is a metal bracket or yoke with two holes that are used to attach the hanger to the supporting structure. One hole is for connecting the hanger to the threaded rod, while the other hole is used to fasten the hanger to the structure using bolts or other suitable means.

The threaded rod, often referred to as a hanger rod or hanger bolt, extends vertically downwards from the clevis. It provides the means to adjust the height of the suspended piping system by turning the rod clockwise or counterclockwise.

Applications of Clevis Hangers

Clevis hangers are commonly used in applications where there is a need to support pipes, ducts, or conduits while allowing for some degree of movement or adjustment. They are often used in HVAC (Heating, Ventilation, and Air Conditioning) systems, plumbing installations, fire sprinkler systems, and industrial piping systems. Clevis hangers are commonly used for the following systems:

HVAC (Heating, Ventilation, and Air Conditioning): Clevis hangers are extensively used in HVAC systems to support ductwork, air handling units, and ventilation pipes.
Plumbing Systems: Clevis hangers provide support for pipes and conduits in plumbing installations, including water supply lines, drainage systems, and sewage pipes.
Fire Sprinkler Systems: Clevis hangers are used to suspend fire sprinkler pipes and ensure proper alignment and support for the sprinkler system.
Industrial Piping: Clevis hangers are employed in industrial settings to support various types of pipes, including process piping, chemical lines, steam lines, and hydraulic systems.
Commercial Buildings: Clevis hangers are utilized in commercial structures such as office buildings, hospitals, schools, and shopping centers to support plumbing and HVAC systems.
Power Plants: Clevis hangers are used in power generation facilities to support piping systems for steam, water, fuel, and other fluids.
Oil and Gas Industry: Clevis hangers find applications in the oil and gas sector for supporting pipelines, including offshore platforms, refineries, and pipelines.
Petrochemical Plants: Clevis hangers are used in petrochemical facilities to support various piping systems involved in the transportation and processing of chemicals.
Water Treatment Plants: Clevis hangers provide support for pipes used in water treatment facilities, including filtration systems, pump stations, and distribution networks.
Industrial Process Systems: Clevis hangers are employed in a wide range of industrial processes, including food processing, pharmaceutical manufacturing, chemical production, and pulp and paper mills.

The design of clevis hangers allows for easy installation and adjustment, making them versatile and convenient for various pipe support requirements. They provide stability and help distribute the weight of the suspended pipes or conduits evenly, reducing stress and potential damage to the piping system and the supporting structure.

Materials for Clevis Hangers

Clevis hangers are typically made from various durable and corrosion-resistant materials to ensure their strength and longevity. The choice of material depends on the specific application and environmental factors. Here are some common materials used in the design of clevis hangers:

Carbon Steel: Carbon Steel is a popular choice due to its high strength and durability. However, carbon steel is prone to corrosion and hence suitable measures must be exercised to reduce corrosion.
Stainless Steel: Stainless steel provides high corrosion resistance along with the required strength. But, stainless steel is costly as compared to carbon steel.
Galvanized Carbon Steel: Galvanized carbon steel is a good choice which helps in protecting corrosion as well.
Cast Iron: Cast iron clevis hangers are known for their exceptional strength and load-bearing capacity. They are often used in heavy-duty applications.
Malleable Iron: Malleable iron combines the strength of cast iron with improved malleability and ductility, making it easier to shape and manipulate during manufacturing.
Aluminum: Aluminum clevis hangers offer lightweight properties, making them suitable for applications where weight reduction is desired. They also exhibit good corrosion resistance.
Galvanized Steel: Galvanized steel clevis hangers are coated with a layer of zinc, providing enhanced corrosion resistance. They are commonly used in outdoor or high-moisture environments.
PVC (Polyvinyl Chloride): PVC clevis hangers are used for supporting plastic piping systems. They are lightweight, non-corrosive, and resistant to chemicals, making them suitable for certain applications.

Clevis Hanger Sizes

In general, clevis hangers are manufactured to support pipes from 1/2 inch through 24 inches. However, custom-designed clevis hanger sizes can be produced when required. The dimensions of each component may vary from one manufacturer to another. Accordingly, the load-carrying capability of the clevis hanger also varies. The following image from Carpenter and Paterson catalog is reproduced below to provide a reference about how much weight a clevis hanger can carry.

**Fig. 1: Clevis Hanger Details from C&P Catalog**

Clevis Hanger Specification

The following information needs to be mentioned to specify a clevis hanger for ordering.

Material of Construction
Figure Number as per the specific manufacturer (For example, Fig. 100 as per C&P catalog)
Nominal pipe size

Clevis Hanger Manufacturers

Some of the well-established and popular manufacturers of clevis hanger support are listed below:

Anvil International
Piping Technology and Products
Carpenter & Paterson
Taylor Pipe Supports
Globe Pipe Hanger Products
Oatey
Hilti
Buckaroos, Inc.
ERICO (nVent)
Empire Industries
Fischer International

Difference between Clevis Hanger and Pipe Clamp

While both clevis hangers and pipe clamps serve the purpose of supporting and suspending piping systems, there are notable differences between the two in terms of their design, functionality, and applications. Here are some key distinctions:

Clevis Hanger	Pipe Clamp
A clevis hanger consists of a U-shaped clevis and a threaded rod. The clevis has two holes, one for attaching the hanger to the supporting structure and the other for connecting the hanger to the threaded rod	A pipe clamp typically consists of a metal band or strap that wraps around the pipe and is secured using bolts or other fasteners. It may also have a cushioning material or lining to protect the pipe surface
Clevis hangers are typically attached to the supporting structure using bolts or other suitable means. They provide vertical support and allow for adjustment of the suspended pipe’s height	Pipe clamps directly wrap around the pipe and are fastened using bolts or other fasteners. They provide lateral support and are used to secure pipes to walls, beams, or other structural elements.
Clevis hangers primarily provide vertical support and suspension for pipes. They allow for some degree of movement and adjustment to accommodate thermal expansion, contraction, or system adjustments.	Pipe clamps are designed to secure pipes in place, preventing movement or vibration. They provide lateral support and help distribute the load along the pipe’s length.

Clevis Hanger vs Pipe Clamp

Vibration Measurement: Instruments, Units, and Applications Explained

Written by Anup Kumar Dey in Mechanical

Vibration measurement is the process of quantifying the magnitude, frequency, and direction of oscillatory motion in a physical system. This can be done using various sensors, such as accelerometers, to measure the vibrations in a particular object or structure.

Vibration measurements are important in a variety of industries, including automotive, aerospace, and civil engineering, as excessive vibration can cause damage to machinery and structures over time. By measuring vibrations, engineers and technicians can identify potential problems early on and take corrective actions to prevent further damage or failure.

Vibration measurements are typically analyzed using tools such as signal processing and spectral analysis to identify the root cause of the vibrations and develop solutions to mitigate them.

Requirements for Vibration Measurement

There are several reasons why we need to measure vibration:

Prevent damage: Excessive vibration can cause damage to machinery and structures over time. By measuring vibrations, engineers and technicians can identify potential problems early on and take corrective actions to prevent further damage or failure.
Improve performance: Vibration measurements can help engineers and technicians identify opportunities to improve the performance of a system. For example, by identifying the source of unwanted vibrations, they can make design changes or adjustments to reduce or eliminate those vibrations, which can lead to improved performance and efficiency.
Ensure safety: Vibrations can be hazardous to human health, and in some cases, can cause injury or even death. By measuring vibrations, engineers and technicians can ensure that structures and equipment are safe for people to use and operate.
Meet regulatory requirements: In some industries, there are regulatory requirements for vibration levels in equipment and structures. By measuring vibrations, engineers and technicians can ensure that they meet these requirements and avoid any legal or financial penalties.

Overall, vibration measurement is essential in many industries to ensure the safe, reliable, and efficient operation of machinery and structures

How is Vibration Measured?

Vibration can be measured using a variety of techniques, but the most common method is through the use of sensors called accelerometers. Accelerometers are devices that measure the acceleration of a vibrating object, which can then be used to calculate the vibration amplitude and frequency.

Accelerometers are typically attached to the surface of the object being measured using adhesive or mounting screws. They can be designed to measure vibration in one, two, or three dimensions, depending on the nature of the vibration being measured.

Once the accelerometer is attached to the object, it produces an electrical signal that is proportional to the acceleration of the object. This signal is then amplified and filtered to remove any noise or interference and then recorded or displayed on a computer or other data acquisition system.

Vibration measurements can be analyzed using various tools and techniques, including time-domain analysis, frequency-domain analysis, and statistical analysis. These techniques help engineers and technicians identify the characteristics of the vibration, such as the frequency, amplitude, and direction, and develop appropriate solutions to address any issues.

Measured vibration data can be used in several ways depending on the application and the specific parameters being measured. Here are some common ways to use vibration data:

Maintenance and monitoring: Vibration data can be used to monitor the condition of machinery and equipment (Learn more about vibration monitoring by clicking here) and to detect any changes in vibration that may indicate equipment failure or performance degradation. This helps to minimize downtime, improve equipment reliability, and optimize maintenance schedules.
Design and testing: Vibration data can be used in the design and testing of mechanical systems and structures to ensure that they are safe, durable, and reliable under various environmental and load conditions.
Performance optimization: Vibration data can be used to optimize the performance of machinery and equipment by identifying areas where vibration levels are high and implementing changes to reduce or eliminate the sources of vibration.
Quality control: Vibration data can be used in quality control processes to ensure that products meet the required specifications and do not have any defects or issues related to vibration.
Research and development: Vibration data can be used in research and development projects to better understand the behavior and performance of mechanical systems and structures under various conditions.

Unit of Vibration Measurement

The unit of vibration measurement depends on the specific parameter being measured. The most common unit of vibration measurement is acceleration, which is typically measured in meters per second squared (m/s²) or g’s (where 1 g = 9.81 m/s²).

Other common units of vibration measurement include:

Velocity: measured in meters per second (m/s) or inches per second (in/s)
Displacement: measured in meters (m) or inches (in)
Frequency: measured in Hertz (Hz) or cycles per second (CPS)

Each of these units represents a different aspect of the vibration being measured. Acceleration measures the rate of change of velocity, velocity measures the rate of change of displacement, and displacement measures the amount of movement from a stationary position. Frequency represents the number of oscillations or cycles per unit of time.

It’s important to note that the unit of vibration measurement will depend on the specific application and the parameters being measured. Engineers and technicians will choose the appropriate unit of measurement based on the requirements of their particular application.

How to Quantify Vibration?

There are several ways to quantify vibration, depending on the specific application and the parameters being measured. Here are some common methods:

Amplitude: Amplitude is the measure of the maximum displacement, velocity, or acceleration of a vibrating object from its equilibrium position. It is typically measured in units such as meters (for displacement), meters per second (for velocity), or meters per second squared (for acceleration).
Frequency: Frequency is the number of oscillations or cycles per unit of time. It is typically measured in units such as Hertz (Hz) or cycles per second (CPS).
Power Spectral Density (PSD): PSD is a measure of the distribution of energy across different frequencies in a vibration signal. It is typically expressed in units such as g^2/Hz, where g is the acceleration due to gravity.
Root Mean Square (RMS): RMS is a measure of the average energy of a vibration signal over time. It is typically expressed in units such as g (for acceleration) or mm/s (for velocity).
Crest Factor: The crest factor is the ratio of the peak amplitude of a vibration signal to its RMS value. It is typically used to assess the severity of high-frequency vibration signals.
Kurtosis: Kurtosis is a measure of the peakedness of a vibration signal. It is typically used to assess the presence of high-frequency or impulsive vibration signals.

Vibration Measurement Instruments

There are several types of instruments used to measure vibration. Each vibration measuring tool has its own limitations and so it must be carefully selected. The most common instruments include:

Accelerometers: Accelerometers are the most commonly used instruments for measuring vibration. They measure the acceleration of a vibrating object, which can then be used to calculate the vibration amplitude and frequency.
Velometers: Velometers measure the velocity of a vibrating object. They are typically used to measure low-frequency vibrations.
Displacement probes: Displacement probes measure the displacement of a vibrating object. They are typically used to measure high-frequency vibrations.
Proximity probes: Proximity probes measure the distance between a vibrating object and a stationary surface. They are typically used to measure the vibration of rotating machinery.
Laser vibrometers: Laser vibrometers use laser beams to measure the vibrations of an object without physical contact. They are typically used to measure vibrations in delicate or hard-to-reach objects.
Tachometers: Tachometers measure the rotational speed of a shaft or motor. They are typically used to measure the vibration of rotating machinery.
Spectrum analyzers: Spectrum analyzers are used to analyze the frequency content of a vibration signal. They are typically used to identify the source of unwanted vibrations and develop appropriate solutions.

Applications of Vibration Measurement

Vibration measurement has a wide range of applications across various industries. Here are some examples:

Industrial machinery: Vibration measurement is commonly used in the maintenance and monitoring of industrial machinery to detect any changes in vibration that may indicate equipment failure or performance degradation. This helps to minimize downtime, improve equipment reliability, and optimize maintenance schedules.
Aerospace: Vibration measurement is critical in aerospace applications, where it is used to monitor the structural integrity of aircraft components and ensure that they remain within safe limits during operation.
Automotive: Vibration measurement is used in the design and testing of automobiles, where it is used to evaluate the ride comfort of the vehicle and to detect any potential issues with the suspension or steering systems.
Civil engineering: Vibration measurement is used in civil engineering applications, such as bridge and building design, to ensure that structures are safe and stable under various environmental and load conditions.
Medical devices: Vibration measurement is used in the development and testing of medical devices, such as surgical instruments and implantable devices, to ensure that they operate within safe limits and do not cause harm to patients.
Consumer electronics: Vibration measurement is used in the design and testing of consumer electronics, such as smartphones and laptops, to ensure that they are durable and reliable under various usage conditions.
Oil and Gas Industries

Industry Standards for Oil and Gas Vibration Measurement

There are several industry standards for piping vibration measurement, including:

API 618/API 674 – This standard specifies the vibration limits for reciprocating compressors and pumps used in the petroleum, petrochemical, and natural gas industries.
ISO 10816 – this standard provides guidelines for the measurement and evaluation of vibration in industrial machinery. It specifies the allowable vibration levels for various types of machines, including pumps, fans, and compressors.
ASME PTC 19.3 – this standard provides guidelines for the measurement of vibration in piping systems. It includes procedures for measuring vibration levels, identifying the sources of vibration, and evaluating the severity of vibration.
ANSI/HI 9.6.4 – this standard provides guidelines for the measurement and evaluation of vibration in centrifugal pumps. It specifies the allowable vibration levels for different pump types and operating conditions.
NEMA MG 1-2018 – this standard provides guidelines for the measurement and evaluation of vibration in electric motors. It specifies the allowable vibration levels for different motor types and operating conditions.
Energy Institute Guidelines

Overall, these industry standards provide guidelines for measuring and evaluating vibration in various types of machinery and equipment, including piping systems. They help to ensure that equipment is operating safely and reliably and that any potential issues related to vibration are identified and addressed in a timely manner

Vibration Meter

A vibration meter is a portable device that is used to measure the vibration of a mechanical system or structure. It typically consists of a sensor, display unit, and software for analyzing the vibration data.

The sensor is usually an accelerometer that is attached to the surface of the object being measured. It measures the acceleration of the object, which can then be used to calculate the vibration amplitude and frequency. Some vibration meters may also include other sensors, such as velocity sensors or displacement probes, to provide additional information about the vibration characteristics.

The display unit of a vibration meter typically shows the vibration measurement in real-time, allowing the operator to monitor the vibration levels and make any necessary adjustments. Some vibration meters may also include additional features, such as the ability to store and analyze vibration data over time, or the ability to connect to a computer or other data acquisition system for more detailed analysis.

Vibration meters are commonly used in the maintenance and monitoring of industrial machinery, where they are used to detect any changes in vibration that may indicate equipment failure or performance degradation. They are also used in various other industries, including aerospace, automotive, and civil engineering, to measure and analyze vibrations in machinery and structures.

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