JITENDRA SURVE

PIPING GUIDE BASIC STEPS

12/10/2005

Estimation of quantities from drawings. Addition of various contingencies, segregation of site fabricated items and procurement. 3. Grouping the items to place requisition for materials. 4. Receipt of bids, Technical and commercial evaluation. 5. Placement of order. 6. Vendor drawing checking and approval. 7. Material control and receipt at site. 8. Substitution and 9. Material reconciliation. 1. 2. ESTIMATION OF QUANTITIES FROM DRAWINGS Successful completion of a project depends on correct estimation of piping quantities. Following documents are required for different stages of MTO. For preliminary MTO: 1. PIDs 2. Line list. 3. Piping specification. 4. Equipment layout/piping studies. For intermediate MTO: 1. PIDs. 2. Line list. 3. Piping specification and 4. Piping GADs. For final MTO: 1. Piping isometrics drawings in addition to the above documents. REASONS FOR THREE STAGES 1. 2. 3. 4. To complete the project in minimum possible time. Order the long delivery materials in advance. Cater for additions and deletions during engineering, and Match the vendor drawing requirements.

With PIDs and equipment layouts, piping items can be estimated. Valves and flanges are estimated from PIDs. Pipe lengths and fittings like elbows are estimated by experienced piping engineer, visualizing the actual routine of pipe line on equipment layout. With the flanged joints requirements, gaskets and bolt estimation could be done. Other specilities like steam traps, strainers, hoses and hose couplings, eye wash and safety shower, etc, could also be estimated from PIDs. To account for the material line number wise, lines are designated with a unique number for each connection. For example: MEG 4003 B1A Ih 1. 2 = Size 2. MEG = Fluid code. 3. 4003 = Line serial number. 4. B1A = Piping class /spec. 5. Ih = Type of insulation. In addition to this, the area of the plant in which this line runs, the design temperature of this line can be designated. Once the linewise material take off is coded in ASCII form the bill of material sheets, with the help of computer programmes, all the piping material can be compiled and various reports generated.

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JITENDRA SURVE

PIPING GUIDE

12/10/2005

Different types of reports are generated using computer: 1. Bulk summary. 2. Line wise MTO. 3. Zone wise MTO. 4. Item wise MTO. 5. Service wise MTO. 6. Piping class wise MTO. 7. Line index. 8. Item break up. 9. Insulation statement. 10. Painting statement. REQUISITION AND TECHNICAL EVALUATION.

With the quantity known for procuring, the requisition for all items with various vendors are placed. The vendor documents are evaluated technically and commercially to place the orders. After that the vendor drawings for each item are checked for compliance with the requirements and are approved, with deviations and corrections if any, if they are within the tolerance limit. If deviations are far away from the requirements, the vendor can be asked to submit the revised drawing as per the specifications and finally all the vendor drawings are approved and the items thus procured are transported to site for construction.

SELECTION OF MATERIALS Involves selection of material for the entire piping system. Piping system is termed as Pipe Grade or Pipe Class. Piping system is selected for the following set of Service Parameters: 1. Fluid. 2. Temperature. 3. Pressure. 4. Environment.

CRITERIA FOR SELECTION OF MATERIALS FOR PIPING SYTEMS Corrosion :

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JITENDRA SURVE

PIPING GUIDE

12/10/2005

1. Due to fluid inside pipes. 2. Due to external environment. 3. Galvanic. Design pressure. Design Temperature. Availability. Ease of Fabrication. Ease or Erection. Maintainability. Special Requirements, if any. Economics. PIPING SYSTEM : MATERIALS OF CONSTRUCTION

Usual Metals : 1. Carbon steels: Black and galvanized. 2. Cast iron. 3. Low alloy steels. 4. Stainless steels. Special metals: 1. Aluminium. 2. Copper and alloys. 3. Nickel alloys. Plastics: 1. PVC. : Polyvinyl chloride. 2. HDPE : High density polyethylene. 3. PP : Polypropylene. 4. PVDF : Polyvinyldene fluoride. 5. PTFE : Polytetrafluoroethylene. 6. FRP: Fibre reinforced plastic. Glass: Lined Pipes: 1. PP lined, HDPE lined, PTFE lined, PVDF lined, Rubber lined, Glass lined, Concrete lined. SPECIFICATION OF PIPES AND FITTINGS

For pipes and fittings following specifications are required: 1. Size range. 2. Material specification. 3. Dimensional standard. 4. Thickness schedule, class. 5. Corrosion allowance. 6. End condition BW, SW, flanged. 7. Flange type and facing. 8. Special requirements IBR etc. SPECIFICATION FOR VALVES AND SPECILITIES

For valves and specialities, following specifications are required: 1. Size range. 2. Material specification for body. 3. Material specification for trim. 4. Pressure class. 5. Dimensional standard. 6. End conditions. 7. Tag number. 8. Special requirements Fire safe design etc.

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JITENDRA SURVE

PIPING GUIDE

12/10/2005

TIPS FOR THE PREPARATION OF PIPING SPECIFICATONS The approach should be to minimize the number of different elements and thus simplify and rationalize stock facilities. Materials 1. 2. 3. 4. Carbon steel shall be used for temperature upto 425 C (800 F) only. Low temperature steel shall be used for temperature below 29 C ( -20 F). Alloy steel shall be used for temperature above 426 C (801 F). Stainless steel shall be used for corrosive fluids. Basic material of construction specified by process licensor to be referred for the type. 5. Galvanised steel piping shall be used for services such as drinking water, instrument air, nitrogen (LP) etc. 6. Selection of non-ferrous and non-metallic piping shallb e as per the recommendation form the process licensor. Piping Joints 1. Buttwelded connection shall normally be used for all alloy/carbon steel piping 2 NB and larger. 2. Alloy/Carbon steel piping 11/2 NB and below shall be socket welded. 3. Threaded connection shall be avoided except in galvanized piping. 4. Flanged joints shall be minimized as it is a point of potential leakage. It may be used to connect piping to equipment or valves, connecting pipe lines of dissimilar materials and where spool pieces are required to permit removal or servicing of equipment. Piping Components Pipes: 1. All pipe lines carrying toxic/flammable fluids shall be seamless. 2. Utility piping can be ERW or Seam Welded. 3. Steam pipe lines shall be preferably be seamless. Fittings: 1. Fittings shall be preferably be seamless. 2. Butt weld fittings shall be used for pipe sizes 2 NB and above for all alloy/carbon steel piping. 3. For stainless steel piping where thickness is less all fittings could be butt welding type. 4. Welding tees shall be used for full size branch connections and for reduced branch sizes upto 2 steps less than run diameter it can be fabricated. 5. For smaller sizes, half coupling shall be used. 6. Full size unreinforced branch welding can be done where pressure temperature condition are low. Flanges: 1. Rating shall be based on the pressure temperature conditions. However 150# flanges are not permitted beyond 200C(400F). 2. Socket welding flanges may be used for all pressure ratings upto 11/2 NB size except on steam lines subjected to IBR regulations. 3. Screwed flanges shall be used for galanised steel/cast iron piping. 4. Slip on flanges are used in 150# and 300# rating upto a maximum of 200C. Welding neck flanges shall be used for higher pressure ratings. 5. Raised face is used for flanges upto 600# rating. 6. For flanges 900# rating and above RTJ is recommended. 7. Tongue and groove facing shall be used selectively. 8. Depending on pressure and temperature gasket shall be either CAF or spiral wound metallic for raised face flanges. 9. Use flat face flanges to mate with cast iron valves and equipments.

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