Process piping systems within manufacturing industries are vital to the productivity and maintenance needs of plants. In manufacturing, various industrial processes are integrated and controlled to achieve end products suitable for use.
These processes are either manual or automated depending on the end product or stage of production. Process piping is essential in automated manufacturing processes, such as the secure conveyance of materials.
What Is Industrial Process Piping?
Process piping is distinct from utility piping, which is plumbing for clean and wastewater. Plumbing involves conveying water for general use, such as drinking and washing, as well as plumbing drains, waste lines, and venting.
Process piping, on the other hand, conveys material including water and other pressurized fluids that are directly involved in an industrial process. There is standard type (no toxicity), type D (low toxicity), type M (high toxicity), and the piping can feature caustic, chilled, and much more fluid types.
Industrial Process piping involves the installation of pipes, fittings, and all other components essential for transporting material from one point to another. Without proper installation for moving gas, liquid, and solid materials, there can be many risks and failures.
Process Piping Structure: Components of Process Piping
Process piping requires various components to come together according to engineering principles. The number, size, and shape of materials depend on the intent and purpose of the process piping. Below are some common components of process piping.
- Pipes: Pipes are the main components of process piping. The type and material of pipes used depend on what is being conveyed. In every process you will find pipes color-coded to match the temperature and type of material it transports. For durability, most pipes in process piping are metallic. Different metals, including aluminum and stainless steel pipes, are in use depending on the temperature and toxicity levels of the materials within.
- Fittings: Fittings refer to connections between pipes in process piping. Fittings depend on the pipe material and type. They need to be able to withstand pressures, temperature, and toxicity levels similar to the pipes on which they fit to. Common fittings include sockets, bends, and elbows. Bends and elbows connect pipes at turning points while sockets connect pipes at straight sections.
- Valves: Valves control the flow of fluids. They ensure fluids flow in the correct direction at the necessary speed and volume. There are different types of valves; your choice of a valve depends on the purpose. Common types of valves include pressure-regulating valves and isolating valves. Pressure regulating valves (PRV) control the amount of fluid through a section of the process piping. Isolating valves are useful to separate certain sections of the system, especially for maintenance.
- Pumps: Pumps are the main component of pressurized process piping systems. They generate a force that conveys fluids to intended destinations. Pumps exist in different sizes and types. They are classifiable according to their power rating, application method, and volume they can supply at an instance. Submersible pumps meet design standards for fluid immersion and operation within those fluids.
Almost all components of piping systems must meet specific installation needs. For instance, insulators and heat exchangers are suitable in high-temperature systems, but not cryogenics ones.
Building a Process Piping System: What You Need
Process piping systems are complex to set up — they require specialized skills and standardization for safety and efficiency. When building a system, the following aspects will guide you in making the best decision.
Functionality: What Makes Process Piping Useful
Process piping systems should sufficiently meet the need for which they are installed. Whether the system is functional or not depends on the engineering designs and considerations. Various codes and standards guide the design process.
Pipes and material selection should be in line with regulations for the safety of the system and personnel interacting with it. For instance, selected pipe diameters should transport the required fluid volumes without straining the system.
Personnel, Environmental, and Equipment Safety
Safety is a top consideration for all industrial processes. There are different levels of safety, these are checked against industry standards for compliance. Process piping systems should guarantee safety for personnel working nearby. Personnel safety includes protection from exposure to toxins, heat, or injury from broken pipe systems.
System components handling toxic materials should be resistant to damage that might lead to exposure. Environmental conservation agencies inspect process piping systems to ensure they pose no risk to the environment.
Maintenance and Operation Costs of the System
Running industrial processes could be expensive — having a high-maintenance process piping system worsens the case. Process piping should be affordable depending on the intended purpose and scale. Using high-quality components prevents frequent breakdowns, lowering the cost of maintenance.
Regularly cleaning the system prevents the risk of blockages and corrosion of inner pipe walls. The system design should use shorter pipe sections with minimal bends for fast and effective cleaning.
Process piping plays an essential role in the safety and quality of manufactured items. However, you need a properly designed and built system to achieve the intended purpose fully. Consulting professionals in your industry provide insight into what is needed for your process piping system.
With JDI Industrial, you can access high-quality construction and maintenance services for functional, safe, and cost-effective process piping. Thanks to technological advancements, automation of process piping systems minimizes human interference which might compromise safety and increase maintenance costs.
To find out how we can help you with your project, contact us today.
