【Common Issues in Haichuan Pipeline Design】Selection of hoses and valves at the utility material hose station, as well as details regarding piping and installation
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During the design, installation, and inspection of pipelines, various minor issues that have been overlooked or not taken into consideration are often identified. These issues are compiled into a series; this list is being updated continuously. Everyone is welcome to actively participate in discussions. This is a compilation post on common problems in Haichuan pipeline design – it’s still being updated, and discussions are welcome: https://bbs.hcbbs.com/thread-5705828-1-1.html ------------------------------------------------------------------ Selection of hoses and valves for public material hose stations, as well as details regarding piping and installation. “Public material hose stations are essential ‘service units’ in chemical and petrochemical plant areas, providing nitrogen, steam, compressed air, and water for operations such as equipment purging, cleaning, displacement, and pressure testing.” Whether its design is reasonable or not directly affects operational convenience and safety. This article provides a comprehensive overview of the design requirements for hose stations, covering installation principles, the sequence of material arrangement, valve selection and installation height, floor and frame layout plans, as well as the choice of hoses and supports. It includes key schematic diagrams and serves as a practical design guide for engineers involved in piping, process, and plant planning. 1. Overall layout principles — Where to locate it? How much to set? 1.1 The location of the public material hose station shall meet the requirements for process operation and maintenance. 1.2 At least one common material hose station shall be provided in each unit of the plant area. 1.3 The service range of each common material hose station should be the area that can be covered by a 20m long hose, enabling it to serve all equipment on the ground in that area. 1.4 For multi-story buildings and frames, a common material hose station should be provided on each floor. 1.5 On the operating platform of the container type, common material hose stations should be installed as needed. 1.6 Where the process has special requirements, a common material hose station should be installed.
II. Detailed Explanation of the Piping Design for Public Utility Hose Stations —— How to Design It? How to install it? 2.1 Types of common materials at the hose station 1) Common materials: A hose station typically has common materials such as nitrogen, compressed air, water vapor, and water (tap water and pure water). 2) From the operational perspective, the order of the types of utility materials from left to right is: nitrogen, compressed air, steam, and water (with pipe diameters ranging from DN15 to DN50). See Figure 2.1 for a schematic of the hose station on the ground. 2.2 The valve installations are equipped with DN20 quick-connect hoses at the end; for valves used for nitrogen, air, and water, ball valves are generally suitable, while globe valves are required for steam applications. Dual valves should be installed for nitrogen pipelines. The valve material is determined in accordance with the pipeline material grade specifications. The installation height of valves on compressed air, steam, and water pipelines (the distance from the center of the valve handle to the operating surface) should be 0.8~1.2 m, while the installation height of valves on nitrogen pipelines should be 1.3 m. 2.3 Layout of the common material hose stations within the unit 2.3.1 The common material hose stations can be installed on the ground or on elevated platforms. When there are no special requirements for the process, compressed air, steam, and water pipelines should be installed on the floor and the first operating platform; steam and compressed air pipelines are advisable to be installed on the second and higher operating platforms. Nitrogen pipelines shall be installed in accordance with process requirements. When installing a hose station on the ground, a steam condensate pipe should be provided near the quick connector on the steam pipeline, so that the steam condensate can return to the system or be discharged on-site, as shown in Figure 2.1, which illustrates the hose station on the ground. 2.3.2 The hose connections on the equipment platform shall not prevent the opening of the manhole cover ； Moreover, the hose station should have proper support. The minimum clear distance between the hose station and the hose rack is 600 mm, while the minimum clear distance between the hose station and pipes, equipment, manhole covers on the equipment, as well as ladders is 1000 mm. Refer to Figure 2.3-1 for a schematic illustration of the hose station on the frame, and Figure 2.3-2 for a schematic illustration of the hose station on the tower platform.
.3.3 Public material hose stations can be installed indoors and outdoors. In cold regions, when the hose station is located outdoors, measures must be taken to prevent the water pipes from freezing; generally, the water pipes and steam pipes above the ground level are insulated together. 2.4 Installation of hoses and hose racks 2.4.1 Unless otherwise specified, one common material hose station can be equipped with two hoses: one is a steel-wired rubber hose, used for steam and nitrogen ； The other one is a fabric-clad rubber hose, used for compressed air and water. 2.4.2 For the connections of hard and soft pipes in various systems at the common material station, quick connectors are generally used; for rubber pipes, pyramid-shaped pipe fittings can be employed. 2.4.3 Each common material hose station shall be equipped with 1 to 2 hose racks at appropriate locations for hanging hoses; the type of hose rack is shown in Figure 2.4 Hose Rack. Summary: The design of the common material hose station is an important reflection of the level of humanization, standardization, and safety in the installation. Its core lies in proper coverage, standard arrangement, safe isolation, convenient operation, and neat storage. By following the above principles, not only can the daily operational needs be met, but safety accidents caused by misconnections, trips, freezing, blockages, and similar issues can also be effectively prevented. Regarding the hose station design in the devices you have designed and worked on, are there any other details or lessons learned from mistakes that you would like to share? Feel free to leave a message in the comments section.
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