플랜트 배관 설계 (제2판) (양장)

박철수,김병식,공진성

저자:박철수

현SvPlantEngineering대표

삼성엔지니어링(주),SK건설(주),대우조선(주)등에서34년근무

서울산업대학교대학원졸업(산업안전공학전공)



저자:김병식

전케이앤알엔지니어링대표,현대엔지니어링(주),SK건설(주)상무등으로36년근무

연세대학교기계공학과졸업



저자:공진성

현SvPlantEngineering전무,현대엔지니어링(주),SK건설(주)전문위원등으로36년근무

인하대학교기계공학과졸업

머리말/iii

01IntroductionofEngineering1

1.1General3
1.2EPCBusiness소개3
1.2.1FeasibilityStudy단계3
1.2.2Execution단계:EPC(엔지니어링,조달,건설)4
1.2.3O&M단계8
1.3EPCProjectExecution8
1.3.1ProjectLifeCycle8
1.3.2EPCProjectExecutionOrganization9
1.4IntroductionofPipingEngineering11
1.4.1EPCTypicalPipingEngineeringOrganization(SupportEngineerGroupbyProjectSize)11
1.4.2EPCPipingWork상호관계12
1.5엔지니어링기술의전망13
1.5.1엔지니어링산업의동향/EngineeringIndustryTrends13
1.5.2엔지니어링산업관련중점사항/EngineeringIndustryKeywords18
1.5.3엔지니어링산업에대한결론적의견28

02Code&Standard에대한이해와역사29

2.1General31
2.2Code&Standard사용32
2.2.1코드(Code)32
2.2.2표준공업규격및단위계(Standard&UnitSystem)32
2.2.3Code&Standards가필요한이유33
2.2.4Project에적용하는EngineeringRuleSystem정의33
2.3ASMECode발전과현재33
2.3.1ASME(AmericanSocietyforMechanicalEngineers)CodeBook구성34
2.3.2UnderstandingofPressurePipingB31구성35
2.4FutureDirectionofCode활용37
2.4.1정성적평가(PlantLayoutEvaluationbyQualitativeEvaluation)38
2.4.2정량적평가(PlantLayoutEvaluationbyQuantitativeEvaluation)38
2.4.3정량적해석ALARP(AsLowAsReasonablyPractice)이해39
Example사례연구:정량적평가(PlantLayoutEvaluationbyQuantitativeEvaluation)42
사례1.EthyleneTankPSV용TankFlare설치여부검토42
사례2.GuideforHazardAnalysis적용사례43

03PipingDesignRole&Responsibility45

3.1General47
3.1.1ProcessEthylenePlant전경47
3.2PipingEngineering&Design소개47
3.2.1PipingEngineering의중요성47
3.2.2PipingWorkFlow상호관계48
3.2.3PipingBasicDesign이해48
3.2.4DetailDesign55
3.3배관엔지니어의역할과책임(RoleandResponsibility)57
3.3.1General57
3.3.2PipingEngineer의역할과책임57
3.4PipingDesignInput&OutputControl66
3.5PipingGroup별WorkActivity67
3.5.1PipingLeaderEngineering67
3.5.2PipingDesignGroup69
3.5.3PipingMaterialEngineering69
3.5.4PipingMaterialControlEngineering69
3.5.5PipingStressEngineering70
3.6PipingEngineering성과품(Deliverables)의종류70
3.73DGraphicSoftware(S/W)71
3.8계산용S/W71

04PlantLayout73

4.1General75
4.2PlantLayout기초75
4.2.1PlantLayoutEngineer&Designer75
4.2.2Engineer&Designer의역할과책임76
4.2.3ProjectInputData77
4.2.4PlantLayoutStep77
4.3PlantLayoutSpecification78
4.4PlantLayout원칙79
4.5Plotplan작성FlowChart79
4.6PlantLayout시고려사항80
4.6.1최우선고려사항및주요역할80
4.6.2Reference82
4.7PlantLayout결론83
4.8근원적안전공학개념이해83
4.8.1InherentlySaferDesign84
4.8.2ISD(InherentlySaferDesign)의목표84
4.8.3Plant기기이격거리준수85
4.8.4Utility(저위험지역)와Process(고위험지역)분리85
4.8.5PlotPlanPlanning의예86
4.9PlantLayoutStudy88
사례연구:EthyleneProjectPlotLayoutStudies88
4.9.1GeneralInformation88
4.9.2SafetyFactor/PrevailingWind에대한Data검토89
4.9.3PlotArea선정의우선순위결정90
4.9.4ProcessSystemGroup단계에의한PlantLayout91
4.9.5풍향과ProcessSystemGroup을고려한상세Layout91
4.9.6기타부속건물배치/Substation,ControlRoom92
4.9.7각Area의넓이의제한92
4.9.8Code및Local규정에따른PlotPlan상의Area구분93
4.9.9Road계획검토94
4.9.10EquipmentErection검토95
4.9.11Maintenance95
4.9.12Underground에배치해야할Items검토96
4.9.13ProjectFinalPlotPlan96

05PipingDrawing99

5.1General101
5.2PipingDrawing종류101
5.2.1PlotPlanDrawing(전체공장배치도)101
5.2.2PipingArrangementDrawing101
5.2.3PipingIsometricDrawing/SpoolDrawing101
5.2.4PipingSupportDrawing101
5.3DrawingIssuebyStage102
5.4PipingDrawing(Sample)103
5.4.1PlotPlanDrawing:구상도면,공장의기계배치도103
5.4.2GeneralArrangementDrawing(PlanDrawing):PipingPlan104
5.4.3ISODrawing(ForConstruction도면)105
5.4.4PipingSupportDrawing106
5.4.5배관설계산출물을위한관련도면107
5.5As-BuiltDrawing111
5.5.1제출도면111
5.5.2AS-Built반영방법111
5.6도면이해와활용112

06PipingSystemDesign115

6.1General117
6.2PipingSystemDesign117
6.2.1배관의정의117
6.2.2프로세스(Process)정의/ASMEB31.3117
6.2.3유틸리티(Utility)정의118
6.3UtilityPipingSystemDesign118
6.3.1UtilitySystem종류118
6.3.2공업용수Sources및처리118
6.3.3스팀(SteamSystem)120
6.3.4공기(AirSystem)122
6.3.5질소시스템(N2)123
6.3.6화학물질시스템123
6.3.7기타시스템124
6.3.8UtilityPipingLinesDesignBasis124
6.3.9UtilitySystem배치및전반적인레이아웃설계124
6.4ProcessPipingSystemDesign125
6.4.1ProcessPipingLinesDesignBasis125
6.4.2ProcessArea내UtilitiesLinesDesignBasis126
6.4.3ProcessPipingLineRoute검토시고려사항126
6.4.4ProcessEquipment별일반적고려사항126
6.5ProcessRequirement146
6.5.1Slope146
6.5.2FreeDraining148
6.5.3GravityFlowLine148
6.5.4TwoPhaseFlow148
6.6배관진동에대한이해149
6.6.1배관진동의종류149
6.6.2배관진동의설계기준150
6.6.3진동해석평가152
6.6.4배관진동에대한고려사항154
6.7주요배관시스템문제유형및대책155
6.7.1배관에서TwoPhase흐름에대한문제점을최소화하는방안155
6.7.2공동현상(Cavitation)157
6.7.3주요진동현상에대한이해와대책158
6.7.4ValvesProblems158
6.7.5PumpAlignment159
6.8PipingSystemDesignStudies163
사례연구:CompressorSystemPipingStudiesinCompressorArea163
6.8.1MainCompressor의사전특성파악163
6.8.2MainCompressor의ProcessSystem검토164
6.8.3PlantLayout의기기의Location을ProcessFlow측면에서이해하기164
6.8.4CompressorSystemPipingStudiesinCompressorArea165

07PipingMaterial167

7.1General169
7.2PipeandTube169
7.2.1Pipe와Tube의차이점169
7.2.2MarkingsonPipeandTube170
7.2.3배관재질/제작방식에의한분류170
7.2.4NonDestructiveTestsforPipeandTube172
7.2.5MaterialTraceability173
7.2.6주요Metal/NonMetalPipes174
7.2.7중동Project수행시가장많이사용되는NonMetalPipes(GRP)상세이해176
7.3Fitting&MainComponents183
7.3.1Fitting이란183
7.3.2Fitting의분류184
7.3.3Fitting의종류와용도184
7.3.4MainComponents186
7.4배관관경선정199
7.5배관공칭Size&두께계산201
7.5.1IntroductiontoPipeSizes201
7.5.2공칭(Nominal)파이프크기및공칭직경202
7.5.3InternationalStandardsforPipeSizes202
7.5.4PipeSizesforOtherMaterials203
7.5.5PressureRatingsforPipeandTube203
7.5.6WallThicknessCalculationsforStraightPipeUnderInternalPressure203
7.6배관자재선정205
7.6.1PhysicalPropertiesofPipingMaterials206
7.6.2유체에따른배관자재선정기준:공정조건은재료선택에가장많은영향을미침207
7.6.3일반적인배관자재선정기준(Pipe&FittingSelection)207
7.6.4배관재료의성질(ASTM내용)207
7.6.5ASTM재료시험특성을고려한선택209
7.6.6ASTM재질의운전온도및용도에따른분류210
7.7MaterialSpecification211
7.7.1StandardMaterialSpecification에포함해야할사항211
7.7.2MaterialSpecification(EthyleneProjectSample)212
7.8유지관리/부식213
7.8.1부식이란213
7.8.2부식의종류213
7.8.3부식대책219
7.8.4배관의부식측정방법220
7.8.5매설배관의부식방지221
7.9배관Material선정예제223
7.9.1배관자재선정예제223
7.9.2사례검토결과/배관재질선정에대한해설224
7.10Paint&Insulation225
7.10.1Paint225
7.10.2Insulation227

08BasicConceptofPipingStressAnalysis233

8.1General235
8.2배관응력해석의정의235
8.3적용범위235
8.4배관응력해석의개념235
8.4.1Pipe에작용하는Stress종류이해236
8.4.2BasicConceptofPipingStressAnalysis237
8.4.3ASMEB31.3Code배관응력해석의개념238
8.4.4용어의정의240
8.5배관응력해석의주목적251
8.6배관응력해석시고려되어야할하중251
8.6.1배관에작용하는하중의종류251
8.6.2ASMEB31.3의TypeofLoadonPiping(Design,Normal,Up-set,Emergency,Test등)252
8.7배관응력해석시필요한자료252
8.8열응력해석의필요성에대한판단기준253
8.9배관응력해석절차256
8.10배관응력평가기준256
8.10.1ASMEB31.3Code응력평가이해256
8.10.2ASMEB31.3CodePIPE의열팽창Stress계산방식이해와평가258
8.10.3Flexibility&StressIntensificationFactor의상세개념259
8.10.4StressRangeFactor이해261
8.10.5AllowableStressRange해석261
8.10.6허용응력범위에추가할수있는응력(ADDITIVESTRESS)262
8.11배관응력해석의평가263
8.11.1Static응력해석검토(StaticLoad종류)263
8.11.2Dynamic응력해석검토(DynamicLoad종류)263
8.11.3PipingStressAnalysisResult고려사항/PipingStressAnalysis결과에의한평가264
8.11.4배관응력해석후검토해야할사항265
8.11.5열응력해소방안265
8.12배관응력해석보고서265
8.13배관응력해석관련CODES266
8.14배관설계GuidedCantileverBeamMethod적용266
8.15InformationFlowforStressAnalysis&PipingStressEngineeringSoftware269
8.15.1InformationFlowforStressAnalysis269
8.15.2PipingStressEngineeringSoftware269
사례연구:고온,고압기기에연결되는배관해석진행271

09PipingSupports275

9.1General277
9.2PipeSupports의정의277
9.3PipingSupport의역할277
9.4PipingSupportMaterial선정278
9.4.1SupportMaterial적용온도범위278
9.4.2ReinforcingPad설치기준278
9.4.3기기에대한Reaction검증279
9.5Function에의한TypeofSupport분류기준279
9.6TypeofSupport280
9.6.1RestingType:Y-Direction(1DOFRestraint)*DOF:DegreeofFreedom280
9.6.2GuideType:XorZ-Direction(2DOFRestraint)281
9.6.3DirectionalStopType:XorZ(2,3Restraint)282
9.6.4AnchorType:6DirectionConstraint(6DOFRestraint)283
9.6.5SpecialType284
9.7열팽창,지진에사용되는SpecialTypeSupport285
9.7.1VariableSpring286
9.7.2ConstantSpring286
9.7.3SnubberSupport287
9.8PipeSupportsCode&Standards287
9.9PipingSupportSpan의이해288
9.9.1PipingSupportSpan288
9.9.2AllowablePipeSpanCalculation289
9.10TypicalSmallBore(11/2"&Lower)Installations291

10EthylenePipingSystemStudies295

10.1General297
10.1.1EthylenePlant일반사항297
10.2ConceptualEthyleneProcess298
10.2.1ConceptualEthylenePlant298
10.3DualEthyleneProcessPlant300
10.3.1GeneralInformation300
10.3.2EthyleneMajorEquipmentLocation&PipingSystemDesign301
10.3.3EquipmentLocation&PipingEngineering&Design중요고려사항302
10.4EthyleneLargeBorePipingHeaderStudies303
10.4.1열분해공정(CrackingHeater)PipingSystemDesign&Configuration303
10.4.2냉각공정(CrackedGasQuench)PipingSystemDesign&Configuration315
10.4.3압축공정(CrackedGasCompressor)PipingSystemDesign&Configuration317
사례연구:CrackedCompressorNozzleA/B,66"-150#(GasketMaintenance)3DModelvsActualViews326
10.4.4정제공정(ColdExchanger)PipingSystemDesign&Configuration327
10.5LargeBorePipingSystemConsideration(EthyleneProjectCase)337
10.5.1DefinitionofLargeDiameterPiping338
10.5.2Cost/Issues338
10.5.3ProductionTechnologicalProblems338
10.5.4A/GPipingDesign&ConstructionTechnologicalProblems339
10.5.5U/GPipingDesign&ConstructionTechnologicalProblems340
10.6EthyleneProjectSpecialConsideration343
10.6.1EthyleneProject에적용된GRPPiping344
10.6.2DissimilarWeldingMethod357
10.6.3AcousticInducedVibration-AIVinPipingSystems358
10.6.4GussetSupportwork365
10.6.5CryogenicValve366
10.6.6Roads,AccessWaysAndPaving368
10.6.7Locationofsilencer,FlamearrestorandLinesOpentoAtmosphere369

11ProjectPipingExecution371

11.1General373
11.2ProjectPipingDesignExecution이해373
11.2.1Project수행3StageCycle373
11.2.2ProjectExecutionStage별Management(by*PMI)374
11.3PipingEngineeringWorkMilestone관리375
11.3.1PipingEngineeringOverallSchedulefor33Month(forGeneralView)376
11.3.23DModeling&Review376
11.3.3MajorMilestonefor3DModeling378
11.3.4MajorMilestoneforMaterialTake-Off381
사례연구382
11.3.5MajorMilestoneforQualityControl382
11.3.6PipingEngineeringWork의주요관리항목383
11.4InterfaceControl385
11.5KeyFactorforSuccessofPipingEngineeringWork387
11.5.1사례연구:대형EthyleneProjectPipingEngineering&Design초기성공요인도출/Cost,Schedule,Quality388
11.6ProjectManagement업무범위정의/ReferenceDatabyPMP389

12PipingDesignCloseoutPhase399

12.1General401
12.2FieldEngineering401
12.2.1Responsibilities(현장설계의책무)402
12.2.2ActivitiesofFieldEngineeringTeam(현장설계팀의업무)402
12.3Lessons&Learned405
12.3.1Purpose405
12.3.2Scope405
12.3.3GeneralRequirements405
12.3.4Application405
12.3.5Responsibilities405
12.3.6PreparationProcedures406
12.3.7Preparation406
12.3.8ChangingandNewCreationofADEPandPEP(DesignEngineeringProcedure,ProjectEngineeringProcedure)407
12.3.9References407
12.4PipingCloseoutReport408
12.4.1전체PipingDesign&Construction(EPC)성과평가409
12.4.2DocumentActualProjectCost409
12.4.3DocumentActualProjectSchedule410
12.4.4DocumentScopeChanges410
12.4.5RecordPost-ImplementationReview410
12.4.6IdentifyOpenIssues410
12.4.7ArchiveProjectDocuments411
사례자료:SampleReport412

마무리하면서421
Glossary정리425
References446

우리나라는상대적으로뒤처진분야가상존하고있는게현실이지만,선진적이고도고도화된산업분야의경쟁력에힘입어현재세계제일의자리를확보하고있는분야도있습니다.오늘날의한국의위상에는반세기전부터의산업화과정을비롯하여1970년대의중동건설붐시기를거치며익힌각종플랜트분야의건설기술경험과해외건설공사수주에의한경제적기여가일정부분역할을했습니다.뿐만아니라,우리가해외여행을통해세계도처에서한국기업이건설한각종시설들을보면서건설한국의자부심을가지게하는분야도있습니다.
플랜트건설사업(EPC)은첫째,사업수행과정의신속한의사결정및강한추진력,둘째,정해진규칙이나데이터의부족에도불구하고창의적인결과를도출해내는자세의유연성,셋째,구성원상호간에마음을열고합심하여역경을극복해내는역동성이절대적으로필요한산업분야이며이런특성은우리한국인의자랑할만한민족성이자장점이기도합니다.

반세기전우리나라가중동의석유화학플랜트공사현장에뛰어들던초창기에는우리내부에축적된기술과데이터도없이선진국의관리에전적으로의존하여국제건설시장에뛰어들었습니다.이런과정을슬기롭게극복하면서우리는구미선진기술진이제공하는자료와외국의기술서적에의존하여기술을익히고경험을쌓으며국제사회의강자로성장해왔습니다.
플랜트건설사업분야는학문/학술이아닌경험에의해축적한기술이가장중요한부분입니다.그러나경험의노하우와기술데이터를축적하지못하고살아온세대로서할일을못한것같은아쉬움을늘가져오던차에여러경험과지식을정리하고자료를모아이분야에종사하는사람은물론새로이도전하는사람들에게길잡이가되기를바라는뜻을담아책으로펴내게되었습니다.
이미해외에서는GPC(GulfPublishingCompany)를비롯한몇몇출판사에서많은배관기술서적을출간했으나,국내에서는위생배관이나일반유틸리티배관을대상으로하는제한된책을제외하면한글로제대로출간된플랜트관련전문기술서적을찾기가쉽지않아아쉬움이컸습니다.외국어로된자료를익히고활용하기에불편을느끼는기술자들에게이책이친근한벗이되어업무수행이나기술습득에많은도움이되기를기원합니다.
배관설계는배관만의기술이론만으로완성되기보다는플랜트를구성하고있는연관분야와의정보교환을통한유기적인조합과협업을통해이루어지고있습니다.이런환경에서배관설계를담당하고있는자신을둘러싼이해관계자들과의관계와그사이에서형성된역할과책임을설명하는장을마련하여배관설계에한정된지식뿐아니라프로젝트의진행과정에서필연적으로만나야할상대에대한이해를돕도록하였습니다.
또한프로젝트의생성과관리및수행조직에대한설명을제공함으로써개략적이나마프로젝트업무흐름을이해함과동시에배관설계관리자로서관리역량신장에도도움이되도록하였습니다.

아울러,프로세스플랜트의배관분야의실질적업무실행을위하여대표적인주요기기주변의배관기본유형과예시를통해배관구성의아이디어를얻을수있게하였고실제설계경험을바탕으로에틸렌플랜트의적용예를마련하여의사결정에참고가되도록하였습니다.
마지막으로배관설계과정을거쳐건설현장에서시공하는중현장의여건변화또는조달자재의정보오류등필연적으로발생하는설계의변경사항을관리하기위한실제현장설계관리기법과변경내용을반영한사례중심의종결보고서를제시하여경험을자료화할수있도록아이디어를제시하였습니다.시행착오를거치며시간을들여만들어진경험과지식을축적하고숙성시킬수있을때비로소확보되는역량이우리의힘입니다.
플랜트산업은과학의영역이라기보다산업적경험의축적이경쟁력의원천인분야이며배관설계역시기술연마를위한각고의노력뿐만아니라숱한시행착오와경험을바탕으로한리더십이더해져서빛을낼수있는분야입니다.이책에서설명한부분의내용과관련하여각사의공유방식에따라서설계된공통사항과실제프로젝트에서사용되는실행방법등은사업주,프로젝트유형,프로젝트특성에따라달라집니다.여기에쓰인내용이만능일수는없으며일부상황에는적합하지않을수도있으므로,모든경우에예외없이적용될내용만을담아낼수는없을것입니다.책이언제어디에서도움이되는지를결정하는것은각개인의지식과경험을응용하고자하는노력에달려있습니다.

보다다양한자료와경험들을이책에담아내고자하였으나여기저기매끄럽지못한부분도없지않아아쉬움도있습니다.그러나누구나배우고익히며항상준비하는마음을갖추고있으면낯설고예상하지못한상황이발생해도어디서건부족한부분을채워주는스승이나타나곤하던것을선후배동료와함께한오랜경험으로알고있습니다.아무쪼록이책이독자여러분의앞날에작으나마자양분이되어유능한기술자로성장하는데도움이되기를기대합니다.

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