PIPING OVERVIEW

ROLE OF PIPING ENGINEER IN BUILDING PLANT

Figure - 1
Concept
Chemistry
Basic Engineering

Conceptual PFD Heat & Material Balance Process Flow Diagram P&I Diagram Conceptual Plot Plan

Sizing , Costing & Optimization

Project Specification

Detail Engineering

Engineering Process
Piping

Electrical Instrument

Civil & structure

Mechanical Project Management

Procurement Inspection

Implemen-tation

Construction

Figure 2 Typical Contracting Office Man hour Break Down

Other Activities55% Other Departments 65% Design Engineering- 45%

Piping- 35%

Typical Material Cost

Civil 5% Foundation 3% Elect. 7% Instru. 4% Insulation 5% Painting 3%

Major Equipments 50%

Piping 23%

Typical Field Labor Cost

Civil 12% Instruments 5%

Electrical 6%

Piping 47%

Foundation 20%

Major Equipment 10%

Piping Design In Large Organization

Project Dept.
Process Dept. Mechanical Dept. Piping Design Dept.

Flow sheet Process Data Utilities, Auxiliary Equipment Data

Detailed Equip. Design

Pipe system specification selection

Line diagram basic design

Material Control section

Plant Lay out selection

Prod. drawing section

Line Diagram Pipe systems Specifications Key Plant Layout Drawings

Lay out studies Drawing or Model

Piping Isometric Details

Bill Of Material

Fabrication
Construction

DELIVERABLES FROM PIPING DEPARTMENT

DESIGN BASIS OF PIPING PIPING SPECIFICATION PLOT PLAN EQUIPMENT LAYOUT PIPING LAYOUT 3D MODEL ISOMETRIC DRAWING MATERIAL TAKE OFF STRESS ANALYSIS PIPING SUPPORTS CODES & STANDARDS

DESIGN BASIS OF PIPING

THIS DOCUMENT IS PREPARED IN THE BEGINNING OF THE PROJECT THIS DESCRIBES VARIOUS KEY REQUIREMENTS LIKE SPACING AND LAYOUT OF EQUIPMENT , PIPING ARRANGEMENT AND PRESSURE PIPING DESIGN EXHAUSTIVE LIST OF APPLICABLE CODES AND STANDARDS. IT PROVIDES PROJECT SPECIFIC REQUIREMENT FOR DEVELOPMENT OF MATERIAL SPECIFICATION. IT ALSO GIVES PROJECT SPECIFIC REQUIREMENT OF PLOT PLAN/ EQUIPMENT LAYOUT/PIPING LAYOUT / VALVING ETC.

MINIMUM DISTANCE BETWEEN FACILITIES.

DESIGN BASIS OF PIPING

MINIMUM HEADROOM REQUIREMENTS.

DESIGN BASIS OF PIPING

PIPING SPECIFICATION
THIS GIVES CONSOLIDATED INFORMATION ON MATERIAL USED FOR VARIOUS PIPING COMPONENTS DEPENDING ON PROCESS FLUID SERVICES . THIS LISTS FOLLOWING INFORMATION FOR PIPES/FLANGES/FITTINGS/VALVES /GASKET ETC FOR VARIOUS PIPE CLASSES. MATERIAL FOR PIPES/FLANGES/ FITTINGS /VALVES /GASKET AS PER ASME CODE. APPLICABLE CODE. DESIGN PRESSURE/TEMPERATURE. FLANGE RATING /FACING . CORROSION ALLOWANCE. WALL THICKNESS FOR VARIOUS SIZES OF ALL COMPONENTS. THIS ALSO GIVES TYPE OF BRANCH CHOSEN DEPENDING ON HEADER/ BRANCH SIZES. BRANCHES CAN BE IN THE FORM OF REDUCING TEE/ HALF COUPLING/ STUB ON /WELDOLET

TYPICAL PIPING SPECIFICATION

PLOT PLAN
IT GIVES THE OVERALL VIEW OF THE PLOT SHOWING RELATIVE LOCATION OF VARIOUS PROCESS UNITS , UTILITY UNITS, STORAGE AREAS, WASTE DISPOSAL AREAS, NON-PLANT BUILDING , SERVICE UNITS, PIPE RACKS, ROADS, RAILWAYS, OVERHEAD ELECTRICAL LINES AND PLANT BOUNDARY SCALE: 1:500 OR 1:1000 ON A0 SIZE SHEET

PLOT PLAN

INPUT FROM OTHER DISCIPLINE FOR PREPARATION OF PLOT PLAN BY PIPING

PROCESS: PROCESS UNIT SIZES,UTILITY/STORAGE AREA/FLUID CLASSIFICATION FOR STORAGE AREA INSTRUMENTATION: CONTROL ROOM,CABLE TRAY ELECTRICAL: SUB-STATION,MCCS,CABLE TRAYS/TRENCHES,OVERHEAD ELECTRICAL LINES PIPING: PIPE RACK, SLEEPERS,CULVERTS, FIREFIGHTING CIVIL: ROAD WIDTHS,SANITARY/STORM WATER DRAINS,FACTORY ACT REQUIREMENTS ERECTION: SPECIAL REQUIREMNTS FOR TRANSPORT OF LONG EQUIPMENT AND ITS ERECTION CLIENT: NON-PLANT BUILDINGS, SERVICE UNITS, PARKING FACILITIES,LAND SCAPING

EQUIPMENT LAYOUT
1) IT GIVES THE OVERALL VIEW OF THE UNIT PLOT SHOWING RELATIVE LOCATION FRACTIONATING COLUMN REACTORS / TANKS / VESSELS / DRUMS HEAT EXCHANGERS-REBOILERS PUMPS & COMPRESSORS FIRED HEATER RACK SHAPE OF THE UNIT WITH LOCATION OF WALL / COULMN / BEAM / PLATFORM / STAIRCASE / ERECTION CUTOUT / MONORAIL CUTOUTS FOR EQUIPMENT PASSING THROUGH FLOORS WITH APPROXIMATE SIZES MAINTENANCE AREAS/DROP OUT AREAS / HEAT EXCHANGER TUBE BUNDLE WITHDRAWAL AREA, AGITATOR AREA INTERNAL PIPERACK ARRANGEMENT WITH ITS SUPPORTING STRUCTURE INDICATING PIPING LOADS,CABLE TRAY LOADS PEDESTAL HEIGHTS FOR EACH EQUIPMENT FLOOR HIGH POINT AND DIRECTION OF SLOPE, LOCATION OF DRAIN GUTTER

2)
3) 4) 5) 6) 7)

EQUIPMENT LAYOUT

STUDY PIPING LAYOUT

THIS DRAWING GIVES GENERAL ARRNG. OF LARGE BORE/ CRITICAL PIPING WHICH ARE CONNECTED BETWEEN EQUIPMENTS AS PER P&ID. FOLLOWING POINTS ARE KEPT IN MIND WHILE PREPARING THIS DRAWING
1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) SUPPORTING ARRANGEMENT REGULAR SHAPE i.e NO CRIS CROSS NOZZLE LOAD WITHIN ACCEPTABLE LIMIT FOR PUMP/ COMPRESSOR VESSEL/FIRED HEATER WITH THE HELP OF STRESS ANALYSIS NO CLASH WITH EQUIPMENT / BEAM / OTHER PIPE HEAD ROOM CLEARANCE ACCESSABILITY FOR OPERATION & MAINTENANCE OF VARIOUS EQUIPMENTS PLATFORM AROUND VARIOUS EQUIP. FOR OPERATION / MAINTENANCE LOOP REQUIRED ON PIPE RACK SPECIAL REQUIREMENT LIKE GRAVITY FLOW / SLOPE / MINIMUM LENGTH / SYMMETRY PIPING FOR FIRED HEATER & AIRCOOLER AS PER P&ID ARRANGEMENT OF VARIOUS INSTR. LIKE ORIFICE / PRESSURE GAUGE / THERMOWELL AS PER RELEVANT STDS.

PIPING LAY OUT

3D MODEL
3D MODEL IS BUILT USING VARIOUS SOFTWARE LIKE PDMS,PDS ETC. THIS IS A JOINT EFFORT FROM PIPING / CIVIL /ELECTRICAL / INSTRUMENT ETC,HOWEVER OWNERSHIP LIES WITH PIPING INPUT REQUIRED : EQUIPMENT LAYOUT,PIPING LAYOUT &PIPING SPECIFICATION,LINE LIST,P&ID,PIPING STANDARDS ETC. THIS IS DONE FOR FOLLOWING PURPOSES 1) EASE OF ENGINEERING DESIGN 2) ACCURACY IN DESIGN 3) ACCURACY IN PROCUREMENT OF MATERIAL 4) CONSTRUCTABILITY / OPERATION & MAINTENANCE REQUIREMENT 5) GET ISO METRIC EXTRACT IN ACCURATE FORM TO FECILITATE EASE OF CONSTRUCTION

VARIOUS STAGES OF REVIEW & MINIMUM CONTENTS IN EACH STAGE

50% MODEL REVIEW 1) ALL MAJOR EQUIPMENTS 2) ALL PROCESS LINES 1 1/2SIZES & UTILITY LINES 3 & ABOVE 3) ALL CONTROL LOOPS 4) MAJOR STRUCTURE WITH PRELIMINARY SIZES 5) MAJOR CABLE TRAY ENVELOP/SPACE RESERVATION 6) OPERATING & MAINTENANCE PLATFORMS, LADDERS, STAIRS ETC 75% MODEL REVIEW 1) EQUIPMENTS AS PER VENDOR DRAWING 2) ALL LINES 3) ALL INLINE AND OFF LINE INSTRUMENTS WITH AVAILABLE DATA 4) MAJOR CIVIL&STRUCTURAL DESIGN 5) DATA CONSISTENCY & CLASH CHECKING DONE 6) MAJOR CABLE ROUTES

VARIOUS STAGES OF REVIEW & MINIMUM CONTENTS IN EACH STAGE

95% MODEL REVIEW 1) ALL THE EQUIPMENT AS PER FINAL VENDOR DRAWING MODELED & CHECKED 2) ALL PROCESS AND UTILITY LINES ARE DONE AFTER OBTAINING CLEARANCE FROM STRESS AND SUPPORT GROUP 3) PIPE SUPPORTS ARE MODELLED 4) JUNCTION BOX,LIGHT FITTING ,PUSH BUTTON ARE MODELLED AS PER THE PROJECT.

ISOMETRIC DRAWING
THIS IS A THREE DIMENSIONAL DRAWING (EXTRACT FROM 3D MODEL) BASED ON WHICH REAL LIFE FABRICATION/CONSTRUCTION WILL BE DONE. THIS SHALL BE COMPLETE IN ALL RESPECT WITH REFERENCE TO P&ID PIPING SPECIFIACTION MAINLY FOR CORRECT MTO ORIENTATION-CORRECTNESS AS PER 3D MODEL DIMENSION TO FACILITATE CONSTRUCTION ORIENTATION OF VALVE HAND WHEEL TO FACILITATE FOR OPENING/CLOSING INLINE ITEMS LIKE CONTROL VALVE,ORIFICE MARKING OF WELD SYMBOL FOR SPOOL PIECE TO FACILITATE SHOP FABRICATION

ISOMETRIC DRAWING

MATERIAL TAKE OFF

IT MEANS MATERIAL REQUIRED FOR THE PROJECT. THE REQUIREMENT IS GIVEN IN THE FORM OF LENGTH OF VARIOUS PIPES DEPENDING ON SIZE & MATERIAL. QUANTITY OF ELBOWS / TEES / REDUCERS / VALVES. QUANTITY OF SPECIAL MATERIAL LIKE TRAPS, STRAINERS,BELLOWS,SPRING SUPPORT AT AN EARLY STAGE OF THE PROJECT BULK MTO IS WORKED OUT TO GATHER QUOTATION FOR VARIOUS COMPONENTS BULK MTO IS CARRIED OUT BASED ON BASIC DOCUMENT LIKE P&ID,EQUIPMENT LAYOUT, PIPING SPECIFICATION, PLOT PLAN, LINE LIST INTERMEDIATE MTO : BASED ON DETAILED PIPING STUDY & APPROVED OR FROZEN DOCUMENT OR REVIEWED MODEL BASED ON THIS MTO ORDERING ACTIVITY IS STARTED FINAL MTO IS CARRIED OUT WHEN ISOMETRICS ARE RELEASED FOR CONSTRUCTION FOR PROCUREMENT OF BALANCE MATERIAL

STRESS ANALYSIS
ONCE PIPING LAYOUT IS FINALSED, THE SAME DESIGN IS CHECKED FOR CONFORMANCE AS PER APPLICABLE CODE/ DESIGN BASIS FOR VARIOUS LOADS SAY PRIMARY/ SECONDARY. PRIMARY LOADS IN THE FORM OF DESIGN PRESSURE/ SELF WEIGHT SECONADRY LOADS DUE TO FLUID TEMPERAURE IN SIDE THE PIPE OCCASIONAL LOADS DUE TO WIND/ EARTHQUAKE CODE PROVIDES VARIOUS FORMULAES/ ALLOWABLE STRESS / FACTOR OF SAFETY FOR ALL ABOVE TYPE OF LOADS. VARIOUS SOFTWARES LIKE CAESAR-II/CAEPIPE ARE USED FOR THIS DESIGN CALCULATION. THIS CALCULATION ALSO FORMS BASIS OF SUPPORT DESIGN

CODES AND STANDARDS

ASME B31.1 / ASME B31.3 / ASME B31.4 / ASME B31.8: PIPING DESIGN CODES ASME B16.5/ASME B16.34: FLANGE / VALVE DESIGN CODES ASME B36.10/ B36.19 : DIMENSIONAL STD OF CS & SS PIPE ASME B 16.9 / 16.11 : DIMENSIONAL STD OF BUTT WELDED / SOCKET WELDED FITTINGS

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