1. MEP201 Mechanical Engineering Drawing 1 st semester 2005-2006 S R Kale Lecture : Schematics 1 Flow/Schematic/Process Flow Drawings: Lines, Equipment & Fittings

2. Schematics 12 Schematic / PFD / Flow diagrams Applications: Power plants, Cogeneration, Oil and Natural gas Paper and pulp Plastics and chemicals Food processing Building air conditioning and ventilation Mineral processing Utilities (water, steam, N 2, O 2, …)

3. Schematics 13 Schematics – Lines (1) Line denotes pipes, tubes, ducts carrying the working fluid that Connects equipment, fittings, instruments & controls in a scientific / technical manner to put together the Process sequence that meets the process objectives in normal system and takes care of Operating requirements e.g. maintenance, stand-by, start-up, shut-down, vents, drains, safety, … -- “abnormal” situations

4. Schematics 14 Schematics – Lines (2) This information + Information on Layout & G.A. drawings  Pipe routing as 3-D drawings  Specifications of piping Fluid, pressure, temperature,  Material, OD, thickness, insulation  Civil drawings  Power, instrument & control cable routing  Bill of materials (& specs.) – pipes, fittings, instruments, equipment, construction, pipe support, cable trays,.... THEN purchase & construction commence !

5. Schematics 15 Schematics – Lines (3) Working fluids : Water, steam, air, gas, oil, fuel, refrigerants, blood, chemicals (Cl 2, O 2, CO 2, H 2, H 2 SO 4, …), food, coal,.. Working fluid sub-classification Water (liquid): Tap, filtered, soft, DM, fire fighting, river, sea, potable. OR Warm, cold, chilled, tap Steam: S/H, low pressure, high pressure, wet, Oil: Lube (!), HSD, crude, kerosene, thermic fluid, Gas: NG, LPG, Biogas, flue gas, CO 2, H 2, Air (compressed) Refrigerant: R-??, Sub-cooled, S/H, wet,

6. Schematics 16 Line types – for clarity, one type per fluid (/state) Schematics – Lines (4) ooooo xxxxx

7. Schematics 17 Schematics – Lines (5) Steam tracing Heavy oil, … Steam line Electric tracing Electric heater Insulated

8. Schematics 18 Schematics – Lines (6) Connected linesCross-over (no connection) Continuation fromContinuation to Termination FlangedPlugged From ‘B’ on drawing no. 12 To ‘A’ on drawing no. 89

9. Schematics 19 Schematics – Lines (7) Types of connections Termination FlangedPlugged ThreadedFlangedWelded

10. Schematics 110 Schematics – Lines (8) Header – “Large” diameter pipe/duct, distributor More than one inflows and/or outflows  Ensures uniform distribution amongst tappings Fitted with vent and drain Tapping – “Small” diameter pipe/duct that branch-off

11. Schematics 111 Schematics – Lines (9) Lines connect equipment and fittings as per process scheme/requirement. Direction of flow with arrows Example Eqpt #1 Eqpt. 2 Continued to ‘A’, on same/other drwg A

12. Schematics 112 Schematics – Equipment (typ.) Tank Pump, fan, blower Turbine Compressor Heat exchanger, boiler Chimney Conveyor Air blown heat exchanger

13. Schematics 113 Schematics – Equipment (1) Tanks - storage

14. Schematics 114 Schematics – Equipment (2) Pumps – liquid flow Centrifugal Gear (positive displacement) Relief/safety valve integral

15. Schematics 115 Schematics – Equipment (3) Blowers, fans – gas, air flow Centrifugal

16. Schematics 116 Schematics – Equipment (4) Heat exchanger – heat transfer between two fluids without mixing

17. Schematics 117 Schematics – Equipment (5) Heat exchanger – air blown (air cooler, air heater typ.) Desuperheater – steam

18. Schematics 118 Schematics – Equipment (6) Compressor – gas, air Turbine – steam, gas, hydro Compressor – with bleed Turbine – steam with extraction

19. Schematics 119 Schematics – Equipment (7) Hopper – store & feed Mill, crusher – crush g Feeder – metered Conveyor – belt, Granular materials

20. Schematics 120 Schematics – Equipment (8) Cooling tower forced draft Cooling tower natural draft

21. Schematics 121 Schematics – Equipment (9) Chimney, stack

22. Schematics 122 Schematics – Equipment (10) Electric motor, generator (usually A.C.) M ~ G

23. Schematics 123 Schematics – Equipment (11) Process specific – create with resemblance to equipment Tyre making machine Paper machine Machine tool Tanker truck, truck Railway tanker, freight wagon Ship, boat Furnace Boiler Digester Stack of granular material Steel mill, non-ferrous…. + + +

24. Schematics 124 Schematics – Fittings (1) Expansion joint Reducer/ expander Blind flange, Plug Drain funnel Vent (with goose neck) Silencer Y-strainer, T-strainer, Basket strainer Sight glass Steam trap

25. Schematics 125 Schematics – Fittings (2) Expansion Joint Diesel engine exhaust

26. Schematics 126 Schematics – Fittings (3) Expansion Joint Application Allow relative movement – thermal expansion, pressure, machine vibration Symbol

27. Schematics 127 Schematics – Fittings (4) Flexible hose HSDO line at boiler burner Lube oil, HSDO & water lines on diesel engine

28. Schematics 128 Schematics – Fittings (5) Flexible hose Application Allow flexibility in placement and connectivity of different equipment and fittings Symbol

29. Schematics 129 Schematics – Fittings (6) Y-strainer Water from cooling tower to pump (DG set) HSDO from tank to burner (boiler)

30. Schematics 130 Schematics – Fittings (7) Y-strainer Application Metal wire mesh removes ‘large” particles Mesh can be removed, cleaned & reassembled without disturbing piping Symbol

31. Schematics 131 Schematics – Fittings (8) Basket strainer HSDO filter on diesel engine (DG set) HSDO from tank to burner (boiler)

32. Schematics 132 Schematics – Fittings (9) Basket strainer Application Fine wire mesh or fabric filter removes ‘small” particles Mesh/filter element can be removed replaced without disturbing piping Symbol

33. Schematics 133 Schematics – Fittings (10) Filter Intake air filter on diesel engine (DG set) Air filter in HVAC system (CSC A.C.)

34. Schematics 134 Schematics – Fittings (11) Filter Application Fine opening fabric removes ‘small’ & ‘very small’ particles Mesh/filter element can be removed replaced without disturbing assembly Symbol

35. Schematics 135 Schematics – Fittings (12) Drains Applications Drain liquid from pipes & equipment to enable maintenance Connection at lowest point of equipment and piping On-Off valve – normally closed Outlet to nearest drain (channel…) Symbols

36. Schematics 136 Schematics – Fittings (13) Vents Vent on boiler shell

37. Schematics 137 Schematics – Fittings (14) Vents Applications Open at start-up to vent out air from pipes & equipment Open while draining pipes & equipment to let air in Connection at highest point of equipment and piping On-Off valve – normally closed OR no valve Outlet led to safe point or locally at gooseneck Symbols

38. Schematics 138 Schematics – Fittings (15) Silencer Application Reduce noise due to sudden expansion Engine exhaust, safety valve outlet, compressor inlet,… Symbol

39. Schematics 139 Schematics – Stand-by capacity Application System operates if one equipment / fitting is out of service Extra investment  plant operates at full or part load without complete shut-down ($$$). Equipment/fittings connected in parallel. Too many equipment/fittings  Maintenance , space , cost ,  Compromise, optimize – philosophy, experience Notation 100 %  Provides the full required process capacity. 50 %  Provides half the required process capacity, so on.. Examples 1 x 100%. 2 x 100%, 3 x 10 % (  ) 1 x 50% , 2 x 50 %. 3 x 50%, 4 x 50% (  ), 5 x 50% (  ) 3 x 33%, 4 x 33% (  ) 4 x 25%, 5 x 25% (  ), 11 x 10% (  ),

40. Schematics 140 Example – Gas turbine power plant ~

41. Schematics 141 Example - Lubricating Oil System BEARING LUBE OIL TANK M

42. Schematics 142 Francis Turbine – Lube Oil System Drawing given in class

43. Schematics 143 Francis Turbine – Lube Oil System

44. Schematics 144 Lecture #2 - Summary Schematic drawings show: line connections between equipment and fittings so that process logic is realized; symbolic arrangements, not to scale; Bill of Materials – pipes, equipment & fittings; NEXT STEP: Add valves, instrumentation and control details.