PIPING SYSTEM

CODES

A code gives guidelines about the subject.It tells rejection and acceptance part of it. EX: ASME SEC VIII DIV 1

Standards is for specific product and gives guarantee for quality of that product. EX: ANSI B 16.5

Regulations are government imposed rules.EX:IBR

PRESSURE PIPING CODES B 31 B 31.1 POWER PIPING.

Piping typical found in electric power generation stations, in industrial and institutional plants, geothermal heating systems, and central and district heating and cooling systems,

B 31.3 PROCESS PIPING.

Piping typically found in petroleum refineries chemical, pharmaceutical , textile , paper semiconductor , and cryogenic plants, and related processing plant and terminals,

B 31.4 PIPELINE TRANSPORTATION SYSTEMS FOR LIQUID HYDROCARBONS AND OTHER LIQUID .

Transporting products, which are predominately liquid between plants and terminal and within terminals, pumping ,and metering stations.

B 31.5 REFRIGERATION PIPING.

Piping for refrigeration and secondary coolants.

B 31.8 GAS TRANSPORTATION AND DISTRIBUTION PIPING SYSTEMS.

Piping transporting product which are predominately gas between sources and terminals.including compressor, regulating,and metering station, and gas gathering pipelines,

B 31.9 BUILDING SERVICES PIPING.

Piping typically found in industrial ,institutional,commercials,and public building and in multi-unit residences

B 31.11 SLURRY TRANSPORTATION PIPING SYSTEM

Piping transporting aqueous slurries between plants and terminal,and within terminal and within terminal, pumping, and regulating stations.

SCOPE OF B31.3a) This Code prescribes requirements for Materials and

components, design, fabrication, assembly, erection, examination, inspection, and testing of piping.

b) This code applies to piping for all fluids, including:

1) Raw, intermediate, and finished chemicals;

2) Petroleum products;

3) Gas, steam, air, and water;

4) Fluidized solids;

5) Refrigerants;

6) Cryogenic fluids (-151o to –425oF).

EXCLUSIONS OF B31.3This code excludes following:• Piping systems design for internal gauge pressures at or above

zero but less than 105kPa (15psi), provided the fluid handled is nonflammable, nontoxic, and not damaging to human tissue and its design temperature is from –29oC (-20oF) through 186oC (366oF);

• Power boiler s in accordance with BPV code Section-I and boiler external piping which is required to confirm to B31.1

• Tubes, tube headers, crossovers, and manifolds of fired heaters, which are internal to the heater enclosure; and

• Pressure vessels, heat exchangers, pumps, compressors, and other fluid handling or processing equipment, including internal piping and connections for external piping.

DESIGN PRESSUREThe design pressure of each component in a piping system shall be not less than the pressure at the most severe condition of coincident internal or external pressure (Minimum or Maximum) expected during service

DESIGN TEMPERATURE The design temperature or each component in a piping system is the coincident temperature,under the coincident pressure, the greatest thickness or highest component rating is required.

MINIMUM TEMPERATURE

The design minimum temperature is the lowest component temperature expected in service.

FLUID CATEGORY ON B 31.3CATEGORY D

A) The fluid handled is non flammable,non toxic ,and not damaging to human tissues.

B) The design gauge pressure does not exceed 150 Psi and temperature is from –29 c to 186 c.

C) Example water,air.(testing of the system not stringent.)

CATEGORY M

A fluid service in which the potential for personnel exposure is judged to be significant and in which a single exposure to a very small quantity of a toxic fluid,caused by leakage,can produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken.

Example .H2 SO4, CL2 Gas (Thread flanges are not recommended. Low pressure testing is also one of the requirement.

HIGH PRESSURE FLUID SERVICE –K CATEGORY

If the pressure is in excess of 2500 rating for specified design temperature and material group.

NORMAL FLUID SERVICE.

A fluid service pertaining to most piping covered by this code ie not subject to the rules for category D,category M or high pressure fluid service.

PIPE UNDER INTERNAL PRESSURE

• For t<D/6, the internal pressure design thickness for straight pipe shall be not less than that calculated belowt = PD 2(SE + PY)

• The minimum thickness T for the pipe selected, considering manufacturer’s minus tolerance, shall be not less than tm..

tm = t + cWhere,tm = minimum required thickness including mechanical, corrosion, and erosion allowances.t = pressure design thickness

PIPE UNDER INTERNAL PRESSURE

c = the sum of the mechanical allowance plus corrosion and erosion allowances.

T = Pipe wall thicknessP = internal design gauge pressureD = outside diameter of the pipeE = quality factor from Table A-1A or A-1BS = stress value for material form Table A-1Y = Coefficient from Table 304.1.1, valid for t < D/6 and for

material shown. The value of Y may be interpolated for intermediated temperatures.

THICKNESS OF PIPE BENDThe minimum required thickness tm of a bend, after bending, in its finished form, shall be determined in accordance with Eq.(3c) :

t = PD (3c) 2[(SE/I) + (PY)]

Where at the intrados (inside the bend radius)I = 4(R1/D) – 1 (3d)

4(R1/D) – 2

and at the extrados (outside bend radius)I = 4(R1/D) + 1 (3e)

4(R1/D) + 2

and at sidewall on the bend centerline radius, I = 1.0R1 = bend radius of welding elbow or pipe bend .

THICKNESS OF BLIND FLANGEThe minimum required thickness of a permanent blank shall

be calculated in accordance with Eq. (15). tm = dg√(3P/16SE) + c (15)

Where,dg = inside diameter of gasket for raised or flat face flanges, or the gasket pitch diameter for ring joint and fully retained gasketed flangesE = quality factor from Table A-1A or A-1BP = design gauge pressureS = stress value of material from Table A-1c = sum of allowances

IMPACT TESTING

For carbon steels, impact testing exemption is given in fig 323.2.2a of B31.3.If a design minimum metal temperature-thickness combination is on or above the curve, impact testing is not required.

NPS- A dimension less designator of pipe .It indicates standard pipe size when followed by the specific size designation number with out an inch symbol (eg NPS 2, NPS 12)

NORMALISING- A process in which a ferrous metal is heated to a suitable temperature above the transformation range and is subsequently cooled in still air at room temperature.

POST HEATING- The application of heat to a fabricated or welded section subsequent to a fabrication, welding or cutting operation. Post heating ,or the entire assembly may be post heated in a furnace.

POST WELD HEAT TREATMENT- Any heat treatment subsequent to welding.

PREHEATING- The application of heat to a base metal immediately prior to a welding or cutting operation.

Galvanizing – A process by which the surface of iron or steel is covered with a layer of zinc

PREHEATINGPreheating is used, along with heat treatment, to

minimize the detrimental effects of high temperature and severer thermal gradients inherent in welding.Requirement and recommendations : Required and recommended minimum preheat temperatures for materials of various P-Numbers are given in table. If the ambient temperature is below 0oC (32oF), the recommendation become requirements.Preheat Zone : Preheat zone shall extend at least 25mm (1in.) beyond each edge of the weld.

HEAT TREATMENT

Heat treatment is used to avert or relieve the detrimental effects of high temperature and severe temperature gradients inherent in welding, and to relieve residual stresses created by bending and forming.Governing thickness : When components are joined by welding, the thickness to be used in applying the heat treatment provisions of Table 331.1.1 shall be that of the thicker component measured at the joint.

BLOCK DIAGRAM OF DETAILED ENGINEERINGBID DOCUMENT

EQUIPMENT LAYOUT

PIPING GENERAL ARRANGEMENT MATERIAL TAKE OFF

PURCHASE SPECIFICATION

PIPE SUPPORTGAD

PIPE SUPPORT

PRE-CONSTRUCTION SURVEY

INSTALLATION

ISOMETRIC DRAWINGS

FABRICATION DRAWINGS

FABRICATION DRAWINGS

PRE-ENGINEERING SURVEY

PROCESS FLOW DIAGRAM (PFD)

- BLOCK DIAGRAM SHOWS UNIT OPERATIONS AND

UNIT PROCESSES INVOLVED.

-SHOWS ALL MAJOR EQUIPMENT AND MAIN PIPING

AND ITS FLOW. BASED ON THIS PROCESS FLOW

DIAGRAM ENGINEER PREPARES PIPING &

INSTRUMENTION DIAGRAM.

PIG

•Device that moves through the inside of a pipeline for the purpose of cleaning .

NEED OF PIG A PIPELINE:

• Remove any debris left in the line from the new construction

• To maintain line efficiency

•Types of pigs1) cleaning pigs:equipped with wire brushes or blades to do the cleaning2) sealing pigs:used during hydrostatic testing of pipelines

LAUNCHER & RECIEVER

•Pig launchers are used to launch the pig into the pipeline & receiver to receive pigs after they have made successful run

•Shall be installed horizontally with 5° slope in the direction of flow

•Internal dia of launcher/receiver shall be atleast 2” higher than the pipe dia

•F.B valves on launcher/receiver must be round•All distribution/collection header shall have their

dead ends blind flange

SCRAPPER TEE

•Purpose of scrapper tee is not to allow passage of pipe scrapper / pig on to the branch pipe.

•Consists of concentric barrel tees•Suitable for pigging operation with process hydrocarbon/raw sea water•Inside dia shall be same as that of inside dia of riser to

maintain smooth pigging operation.•Maximum opening shall be provided through slots to

limit the pressure drop.•Total opening shall be 1 to 1.5 times branch pipe area

FLANGE

PIG DETECTOR

SCRAPPER TEE

SOCKOLETBRANCHPIPE

TYPICAL SCHEMATIC OF PROCESS LINE.

PIPING & INSTRUMENTATION DIAGRAM

THIS IS A DETAILED DIAGRAM WHICH IS DEVELOPED BASED ON PROCESS FLOW DIAGRAM. IN THIS DIAGRAM ONE WILL COME TO KNOW ABOUT THE EXACT NUMBER OF FLUID SERVICES INVOLVED APART FROM MAIN PROCESS FLUID. ALSO THIS DIAGRAM WILL HELP PIPING ENGINEER IN DEVELOPING HIS PIPING ARRANGEMENT.

THE INFORMATION WHICH THIS DIAGRAM WILL PROVIDE TO PIPING IS

- CONNECTING POINTS OF THE PIPE

-SIZE OF PIPE

- MATERIAL CLASS OF PIPE

- FLUID SERVICE OF THE PIPE - UNIQUE LINE IDENTIFICATION NUMBER

- INSULATION

- CONNECTING POINTS OF A PIPE

-VALVES, INSTRUMENTS AND SPECIALITIES INVOLVED IN THE PIPELINE.

- PRESSURE, TEMPERATURE FOR THE EQUIPMENTS.

-ALWAYS A P&ID IS ACCOMPANIED WITH LEGEND P&ID IN WHICH ALL SYMBOLS (USED IN P&ID) ARE EXPLAINED.

LINE NUMBER DESIGNATION –

1.5”-DH-A1N-1129-

SIZE LINE NUMBER

FLUID SERVICE

MATERIAL CLASS

LINE LISTPROVIDES SUMMARY OF ALL PROCESS PARAMETERS OF SYSTEM. IT IS PREPARED FROM P&ID.

PROVIDES INFORMATION ON :

- LINE NUMBER - FLUID IN SYSTEM -- SERVICE CLASS - HEAT TRACING- PAINTING - LINE SIZE- FLUID PHASE- OPERATING & DESIGN PRESSURE , TEMPERATURES- STRESS RELIEVING REQUIREMENT- RADIOGRAPHY REQUIREMENT- PWHT REQUIREMENT- TEST FLUID & TEST PRESSURE- INSULATION REQUIREMENT

LINE LIST

EQUIPMENT LAYOUT

THIS DIAGRAM INDICATES THE POSITION OF EQUIPMENT IN THE PLANT. ALL EQUIPMENTS ARE LOCATED WITH THEIR CO-ORDINATES OR THEY ARE LOCATED FROM GRID REFERENCE POINTS. FOR EACH EQUIPMENT ITS TAG NUMBER IS ATTACHED. THIS DRAWING IS PREPARED BY PIPING ENGINEER WITH THE HELP OF PROCESS ENGINEER

PIPING ENGINEER FURTHER DEVELOPS HIS GENERAL ARRANGMENT DIAGRAM BASED ON THIS.

PIPING GENERAL ARRANGEMENT DIAGRAM

THIS DIAGRAM SHOWS THE ROUTING OF PIPE AS PER THE P&ID WITH RESPECT TO EQUIPMENT AND EXISTING STRUCTURE.

INFORMATION PROVIDED :

- EQUIPMENT LOCATION & ORIENTATION

- LINES WITH LINE NUMBERS

- INSTRUMENT TAG

- ROUTING OF PIPE BETWEEN EQUIPMENTS

- LOCATION OF EXISTING EQUIPMENT & INTERCONNECTING PIPING

- ELEVATION OF PIPE LINES

PIPING SUPPORT GAD

- SHOWS TYPES OF SUPPORT AND THEIR LOCATIONS IN THE PIPE LINE

- REFER STANDARD PIPE SUPPORT SKETCHES - GIVEN BY CONSULTANT

- THERE CAN BE SPECIAL TYPE OF SUPPORTS ALSO.

ISOMETRIC DRAWING LINE DIAGRAM OF PIPING, SHOWS FOLLOWING :

- Operating and Design temperature

- Operating and Design pressure

- Insulation required - Thermal tracing

- Hydro test pressure - Bill of material

- Inch-dia, Inch Meter - Piping Class

- Pipe support locations - Service of fluid

- Points of weld, its marking - Pipe support type

1) Numbering of shop joint & offshore joints in successive numbers2) Numbering of spool according to the individual spools3) Check the BOM according to the item no.,inch,schedule&description 4) According to the pipe size,the no.of shop,offshore joints are added in the table inside the isometric.5) Inch meter,inch dia is calculated6) Inch meter =pipe length in meter x pipe size in inch7) Inch dia =pipe size in inch x no.of joints8) No.of spools are noted in the table9) For the continuing sheets,the numbering of shop joints,offshore & spool numbers will also be continuous.

Activities in ISO’S

PIPE SUPPORTS- PROVIDE SUPPPORT SO THAT, PIPE DOES

NOT SAG OR BEND

- SUPPORT LOCATIONS ARE IDENTIFIED AND STRESS ANALYSIS OF PIPE IS UNDERTAKEN

- SUPPORT LOCATION DEPENDS ON PIPE DIAMETER AND THICKNESS

- EXPANSION BELLOW FOR PIPE FOR WHICH OPERATING TEMPERATURE IS HIGH

- VARIOUS STANDARD SUPPORTS ARE AVAILABLE

- THERE ARE SPECIAL SUPPORTS ALSO

MATERIAL TAKE OFF- THIS DOCUMENTS GIVE THE TOTAL MATERIAL

REQUIREMENT FOR THE JOB WHICH INCLUDES PIPES,

FITTING, FLANGES, GASKETS, FASTENERS, VALVES,

SPECIALITY ITEMS, STRUCTURES ETC.

- MAIN MTO FOR TOTAL JOB REQUIREMENT

- HYDRO - TEST MTO ( AT YARD, AT OFFSHORE )

- SPARES MTO (WHEN CLIENT REQUIRES)

- CONTINGENCIES CONSIDERED (DIFFERENT FOR NEW BUILDING or REVAMP JOBS)

PRE – ENGG SURVEY - FINALISE DATE OF SURVEY, TAKE CLIENT

PERMISSION & MAKE OFFSHORE PASS

- FORM THE TEAM WITH : INSTALLATION CONTRACTOR, DESIGN CONSULTANT, MFF MEMBERS

- CARRY OFFSHORE SCOPE OF WORK, DESIGN STANDARD, CHECK LIST – FOR SURVEY

- CARRY OUT SURVEY & COLLECT ALL RELEVANT DATA

- CHECK LIFTING CAPACITY OF EXISTING DECK CRANE & MONO RAIL

- CHECK IF EXISTING EQUIPMENT HAS TO BE DISMANTLED TO TAKE OUT

PRE – ENGG SURVEY - CHECK, IF BREAK – DOWN AREA IS NEEDED

- CHECK, IF ANY STRUCTURAL MEMBER IS TO BE CUT TO TAKE OUT AN EUQIPMENT

- CHECK IF TUGGER LINE / PAD EYE IS NEEDED TO BE USED TO LIFT OR SHIFT WEIGHT

- CONSIDER APPROACH OF BARGE OR SUPPLY VESSEL TO REQUIRED LOCATION WITH LOAD

- ON COMPLETION OF SURVEY, INSTALLATION CONTRACTOR / DESIGN CONSULTANT IS TO MAKE A PRE- ENGG SURVEY REPORT

PRE – ENGG SURVEY - SUBMIT REPORT TO CLIENT FOR INFORMATION

AND TO SHOW MISMATCH, IF ANY, BETWEEN ACTUAL & BID – PACKAGE DATA.

- NEGOTIATE WITH CLIENT FOR EXTRA COST & TIME (IF SOME WORK IS TO BE DONE OUT OF SCOPE)

- DECIDE THE ACTIVITIES FOR PRE-SHUT-DOWN, SHUT-DOWN AND POST-SHUT-DOWN PERIOD, IN DISCUSSION WITH INSTALLATION CONTRACTOR AND ONGC PLATFORM PEOPLE.

PRELIMINARY DATA FROM DESIGN CONSULTANT

- IN GENERAL, A DESIGN CONSULTANT IS EMPLOYED FOR BASIC & DETAILED ENGINEERING

- CONSULTANT REVISES P & ID (REFER NEXT SHEET) & GAD, MAKES ISOMETRICS, PREPARES STRESS ANALYSIS REPROT, PIPE SUPPORT DRAWINGS & STRUCTURAL DRAWINGS BASED ON SURVEY DATA

- ALL DOCUMENTS ARE SUBMITTED TO CLIENT / CLIENT’S CONSULTANT FOR THEIR APPROVAL

- FIRST MTO IS MADE & CHECKED BY MFF ENGG PERSONNEL, USE THIS MTO FOR ORDERING.

PRE – INSTALLATION SURVEY

- DURING THIS SURVEY, REVISED DRAWINGS ARE CHECKED WITH EXISTING CONDITION ON PLATFORM ONCE AGAIN.

- CHECK FOLLOWING :- DIMENSIONS- FEASIBILITY OF CONSTRUCTION- HOOK- UP POINTS- EASE OF INSTALLATION - ANY OTHER POINTS - MISSED EARLIER

PRE – INSTALLATION SURVEY

- A PRE - INSTALLATION REPORT IS MADE BY INSTALLATION CONTRACTOR

- ISSUES LIKE SHUT-DOWN REQUIREMENT AND MARINE SPREAD ARE HIGHLIGHTED

- REPORT IS SUBMITTED TO CLIENT FOR APPROVAL

- IF NECESSARY, MTO IS REVISED AGAIN

MARKING OF SHOP JOINTS

Shop joints are the welding joint done at shop. For joining pipe to pipe, pipe to fittings, pipe to flanges shop joints are marked. Shop joints are done to minimize the erection joints. ( Normally joints after rolling of pipe or joints connecting to existing flange of equipment should be avoided at shop ).

MARKING OF ERECTION OR FIELD JOINT

Erection or field joints are the welding joint done during erection. The following points to be followed for deciding erection joint

1. The spool length shall be such a way decided that there is no damage to other pipes while erecting ( Normally upto 6 mtr. ).

2. The spool length shall be decided so that it is easily transportable.

3. To avoid distortion in spools more shop joints shall be avoided ( Straightness after welding shall be checked by fabricator ).

4. If there is branch connection and there are chances of damage to it, then branch connection shall be erection joint.

5. One field joint in x, y and z direction shall be kept so that length adjustment can be made.

MARKING OF OFFSHORE JOINTS

1. Joints made at offshore are known as offshore joints.2. Piping Hook up connection between deck and bridge shall

be offshore joint.3. Piping connection in between new erected equipment at

offshore with existing deck piping.4. Some piping work is kept under hold at Onshore because

of equipment installation at Offshore.5. Some piping below Cellar Deck may be avoided at Onshore

to avoid problem during deck installation.6. If the instrument to be connected is of long delivery and to

be erected at Offshore then the joint shall be Offshore joint.

th = Header thickness

tf = Fillet size ( 0.7 x th or 6mm whichever is less)

t = Full penetration weld size = (th)

tw = Minimum total weld size = (t + tf)

th

tf

t

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