ashwin-udhe-1-Introduction-to-Piping-Engineering.pdf

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TRAINING MANUAL- PIPING

INTRODUCTION TO PIPINGENGINEERING

Uhde India Limited

DOC No. : 29040-PI-UFR-0001

Rev. : R0

Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

1.0 Introduction 2

2.0 Knowledge Required for Piping Design 2

3.0 Latest Developments in Piping Design Techniques 34.0 Piping Design Function and Size of Organisation 3

Annexure-1 Typical Material Cost Breakdown (Major Items) 1 Sheet

Annexure-2 Typical Home Office Engineering Man-hour Breakdown 1 Sheet

Annexure-3 Typical Field Labour Cost breakdown 1 Sheet

App li cable Rev is io n:Prepared: Checked: App roved :


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Uhde India Limited

DOC No. : 29040-PI-UFR-0001

Rev. : R0

Page : 2

1.0 INTRODUCTION:

Pipes and piping systems are the veins and arteries of chemical process plants used for transporting liquids, vapours, slurries, solids etc. under various conditions, as imposed by theprocess design of the plant. The network of pipes is subject to extremes of temperature,pressure, flow and combination of these. In addition, they are subject to corrosion, erosion,toxic condition and radioactivity, all of which calls for proper piping design enabling troublefree operation of the plant over a long period of time.

Capital cost of piping forms a large portion of the investment in the plant exceeded only bythat of major equipment. Pie Chart (Refer Annexure-1) shows the relative cost of variousmaterial components of a plant. As can be seen from the chart, piping accounts for nearly15% of the overall material cost. Pie Chart (Refer Annexure-2) shows the man-hour effortthat goes in to design engineering at home office for various engineering disciplines.Normally, out of the total engineering effort covering project management, detailedengineering, procurement, inspection and expediting, etc., 65% of the hours are required for detailed engineering. Out of this, 25% is required for piping engineering alone, the balance

40% accounting for civil, mechanical, electrical and instrumentation engineering.

Progress in piping engineering being very much dependent upon the feed back of equipmentdata (static and rotating) as also on control valves and other inline instruments, a closemonitoring of the schedule of orders for these equipment and follow up with vendors for dataand drawings is required to finalise Piping Plans, generate Isometrics, order bulk PipingMaterial as well as Piping Speciality Items and release drawings to site for speedyconstruction and thus facilitate prompt start up.

2.0 KNOWL EDGE REQUIRED FOR PIPING DESIGN:

Apart from having in-depth knowledge of piping design one should have understanding of material costs, metallurgy, piping fabrication methods and related costs to be able to providethe most economical design. Piping design being central to detailed engineering effort,working knowledge of other disciplines like civil, mechanical, electrical, instruments andprocess engineering is required appreciate their problems / requirements and to be able toseek the right information from them to proceed with his / her own work of piping design.

Pipes and pipelines are always subject to fluid pressures at varying temperatures. This resultsin expansion and contraction of the pipes inducing stresses which get transferred toequipment like pumps / compressors and other static equipment or rotating equipmentresulting in breakdowns. A good knowledge of structural engineering is therefore necessaryfor analysing and solving such problems. Needless to say that a thorough understanding /


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Uhde India Limited

DOC No. : 29040-PI-UFR-0001

Rev. : R0

Page : 3

3.0 LATEST DEVELOPMENTS IN PIPING DESIGN TECHNIQUES

The trend in recent years has been to develop and employ better techniques in piping designto save time and also to improve accuracy. Computers are being extensively used to obtainspeedy solutions to more complex problems of plant design and to solve problems of stressesin piping. Recent past has seen development of software for production of piping detaildrawings, piping isometrics, bill of material, estimation and cost control. Piping Engineer hastherefore the added responsibility in understanding and upgrading his / her knowledge on theapplication of a growing number of techniques of this nature helping speedy work execution.

The most revolutionary advancement in the Piping Design in recent past had been theconcept of 3D Modelling of the Plant by using sophisticated Software such as PDMS. Thisprovides an opportunity to build the entire plant on soft media in a 3D environment to the lastdegree of detailing, to be able to identify and rectify practically every problem related to designand construction prior to actual commencement of erection activities at the Site.

4.0 PIPING DESIGN FUNCTION AND SIZE OF ORGANISATION

The size and scale of operations of a design engineering company does not affect either thepiping design requirements or the underlying design principles and practices. As the volumeand complexity of work and the number of projects executed increase, so does the degree of specialization increase. Piping layouts, piping specifications, detail drafting and material listingbegin to emerge as functions handled by separate Specialist Groups within the department.There is little apparent similarity between piping design performed by a team of say tenengineers from a small office and by a large company having hundreds of piping designengineers. The job performed in both the cases is identical and has the same degree of relative importance to the whole project design organisation. The real difference lies in the

number of projects handled by the design office. In a small office, the flow of work is such thateach project is substantially completed before the succeeding project commences. Thisrequires a flexible organization with a small group, who is responsible for all aspects of design. In a large organisation, however, not only a large number of projects are executedsimultaneously but the size of the projects also vary. This requires different group of peoplewith a high degree of specialization for economic and administrative reasons.

In either case, piping design is the most lengthy and complex part of the whole design workand almost would be on critical path of the project engineering schedule.


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File: Annexure to C-1

TYPICAL MATERIAL COST BREAKDOWN (MAJOR ITEMS)

Major equipments 60%

TypicalMaterial Costs of Major EquipmentCom modities and

Sub-Contracts

B u i l d i n g

s

S t r u c t

u r e s & 8 %

F o u n d a

t i o n s

E l e c t r i c a l

E q u i p m

e n t s

8 %

I n s u l a t i o n

2 % P a i n t i n g 2%

Piping 15%

I n s t r u m e n t s

5 %

ANNEXURE-1


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TypicalHom e OfficeEngineering

Man-hourBreakdown

DetailedEngineering 65%

P i p i n g

D e s i g n

2 5 %

Implementation 35%

ANNEXURE-2

TYPICAL HOME OFFICE ENGINEERING MAN-HOUR

BREAK DOWN


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Piping 40%

TypicalField La bor

Costs

Electrical 15%

Instrum ents 10%

BuildingsStructures & 15 %Foundations

MajorEquipm ents 20%

TYPICAL FIELD LABOUR COST BREAK DOWN

ANNEXURE-3

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ashwin-udhe-1-Introduction-to-Piping-Engineering.pdf