LESSON

5
LECTURE
MAINTENANCE & TROUBLESHOOTING OF
PIPING SYSTEM
SUB-OBJECTIVE
At the end of th! Le!!on the T"#nee $%% &e #&%e to de'on!t"#te #n (nde"!t#ndn) of
M#nten#n*e & T"o(&%e!hootn) of P+n) S,!te'-
.-/ MAINTENANCE CONSI0ERATIONS
The maintenance of piping systems involves more than making repairs when a
breakdown in the system occurs. It is true that accidents can happen, and do, and
that unexpected component failures can take place at any time without warning. The
real secret of successful maintenance of a piping system lies in knowing what parts it
is made of, and where the various parts of the system are located. Preventive
maintenance is the key to keeping any piping network operating smoothly and
efficiently. By knowing the system, and making routine, scheduled inspections, you
will find that your job is much easier and far more satisfying. ou will be heading
trouble off before it happens.
1-/ MAJOR PROBLEMS
The major problems in piping systems are caused by leakage and corrosion. !ne
may cause the other. The nature of the materials being carried has an influence, of
course, but you will usually find that the system has been designed to prove
maximum precautions, including ample safety margins for excessive pressures and
dangerous fluid leakage.
The following list includes the points with which you, as a maintenance crafts man
whose responsibility is the maintenance of piping systems, will be concerned.
I. "hecking for corrosion and leakage
II. "hecking to be sure that valves are in working order
III. #epacking valves, maintaining and replacing gaskets $"overed in a later
lesson%
I&. "hecking insulation and possibly installing it as needed
&. Installing new sections of piping, tubing and hose.
&I. Installing, inspecting, and replacing fittings as needed.
&II. "hecking hangers and pipe supports.
&III. Testing and maintaining the steam traps $cover in valve maintenance%
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
.(''!- 1 P,0( 2 PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/IP*(-T
I5. "leaning piping as re6uired
5. (xtending existing systems as needed
5I. #eporting anything of an unusual nature
5II /sing special piping maintenance tools and e6uipment. 7ell designed piping
systems have various features to minimi8e maintenance and wear9and9tear.
!n such protective feature there are many techni6ues of piping protection
and maintenance.
2-/ BLO3 OFF VALVES
The valve can be opened to blow out any foreign material in the line. That can be
included in routine maintenance as system re6uirement .
CLEAN OUT PLUGS AN0 MANHOLES
These are e6uipped in the pipe line at intervals. By removing these pipe can clean
up to some distance. -ormally these openings are used to clean or inspect the pipe
in shutdown.
4-/ PIPE CLEAINING
The piping could have been cleaned by either running chemical solvents through the
lines or using mechanical clean9out devices. The solvents dissolve the sludge and
corrosion, thus freeing the line so that it can once again supply the needed :;
pounds of pressure. The clean9out devices do the same job mechanically. !ne type
of clean9out devices do the same job mechanically. !ne type of clean9out device has
steel scrapers which clean the sludge out as the tool is drawn through the section of
pipe. #ubber s6ueegee discs at the end of the tool wipe the material out of the pipe
after it has been freed by the scrapers.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/P*(-T .(''!- 1 P,0( <
F)- 5-.- P+e C%e#nn) Lne-
)ig. 192 shows the schematic flow diagram of this acid cleaning system. In order to
soften the corrosive strength of the acid, a reagent called an inhibitor is added to the
dilute acid solution.
In acid cleaning, any scale in the pipe will be dissolved into the solution and all
surfaces of the pipe will be cleaned inside.
To stop the further corrosion by the acid, neutrali8ation using a caustic soda solution
must be carried out. Though washing with clean water is the next step, followed by
blowing with air to remove the humidity in the pipes. This blowing will be repeated
until a visual inspection shows that the pipes are clean.
4-. CLEANING BEFORE REPAIR 3OR5 6AFTER PLANT STOPPAGE7
,ll pipe lines are filled with operational fluid. This fluid can be purged by operation of
function. 'ome fluids must be recovered for storage. !ther fluids will be disposed
into a sewer, if it contains no contamination. Treatment is sometimes necessary
before disposal.
The person repairing the pipe line should confirm its status before beginning
disassembly= i.e., permission to disassemble must be obtained before work
commences.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
.(''!- 1 P,0( > PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/IP*(-T
If the fluid is a dangerous li6uid of gas, the repair person shall consider the following?
a. 7ear protection coat, glasses, gloves, boots or mask as necessary.
b. 7orkers must be coordinated.
$for emergency, rescue, communication, etc.%
c. 'afety preparation must be done ?
Preparation of receiver for leaked li6uid,
Preparation of blowing fan,
Preparation of fire extinguisher
Preparation of water hose
d. #emoval of flammable substances
,ll necessary fluid purges must be carefully completed.
4-1 CLEANING AFTER REPAIR 3OR5
,ny foreign matter in the pipe line from the repair work must be removed as part of
the repairing function. "onsideration must be given to the operational function of the
line when choosing the cleaning method.
4-2 BALL CLEANING SYSTEM
This system uses some appropriate balls made of a soft material such as sponge, in
order to clean pipe inside or any other e6uipment inside where the fluid passes
through.
Inside of heat exchanger, for an instance, scale is apt to grow.
Ball cleaning system is useful for suspension of the growth of scale, therefore it is
adopted for brine heaters and heat recovery sections of evaporator in this plant.
The advantage of this system is to be able to clean inside of tubes without stopping
of the apparatus.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/P*(-T .(''!- 1 P,0( @
5-/ TEMPORARY ACTIONS TO STOP LEA5AGE
0eneral principle are listed below.
2. ,sk operation shift supervisor to stop the pressure source.
<. "ontact the operation superintendent or supervisor and consult with him
about the treatment.
>. Take appropriate safety measures.
@. "onfirm the cause of the leakage.
1. If the problem is serious, report it to your supervisor or superintendent.
A. 'upervision will result in one or more of the following?
a. "ut off the leakage line
b. Possible use of another line
c. #apid change of the part
d. #apid repair of the parts.
8-/ ASSEMBLY OF PIPE LINE
,fter repair, all pipe lines must be reassembled with careful consideration of safety,
inside cleaning, and necessary record taking, including photo graphs. Inspection
before reassembling must be attended by operation section people.
.eakage tests such as pressure test must be done as legislated. Blowing for final
cleaning will be executed if re6uired.
,fter completion of the above, final field cleaning must be checked and the related
function supervisor informed.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
.(''!- 1 P,0( 1 PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/IP*(-T
9-/ SPECIAL PIPING SYSTEM MAINTENANCE E:UIPMENTS AN0 THEIR USE
9-. TAPPING MACHINE 6FIG- 5-17
This machine is often used. Its function is to drill an opening in the wall of an active
pipeline, even under a high pressure, without interrupting the service. The machine
essentially consists of a sleeve, inside which is mounted a drill9carrying shaft, driven
by a mechanism situated outside the sleeve, to drill an opening in the pipe wall. The
mechanism is protected from contact with the product by a stuffing box through which
passes the shaft. The assembly is affixed on the outside of the pipe to be drilled by a
flange joint or a filleted joint on a pre9welded T9piece. ,ccordingly, the drilling
operation consists in pre9welding the T9piece with a full9opening valve, after which the
following operations are performed.
a. The machine is affixed to the flanged or the filleted joint or valve, and the
valve is opened.
b. The drill is lowered to the contact of the pipe wall and the drill engine is
started.
c. +aving made the hole, the drill is lifted through the fully9opened valve, after
which the valve is closed.
d. The machine is dismantled.
The tap is then ready to receive the e6uipment intended for it. *achines of this kind
are available in many si8es, for making holes of < to @ in, : to 2; in. etc. The function
in all positions, hori8ontal, vertical or obli6ue.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/P*(-T .(''!- 1 P,0( A
F)- 5-1- P+e-t#++n) '#*hne-
9-1 STOPPLE
The stopple can be mounted on a branch connection made by the tapping machine
to plug the pipeline and isolate a section for work. There are many types of stopple.
!ne 19> which is fre6uently used is a rubber plug mounted between metal jaws and
fixed on a jointed parallelogram frame, by means of which it can be lowered into the
conduit and put into place to form a seal capable of withstanding pressures of up to
B; kgCcm
<
.
In gas pipe lines, the pressure can sometimes be reduced before working on the line
if the section does not present problems of static pressure or of counter pressure to
be maintained. Blown9up balloons are often inserted in the pipeline to isolate such
sections= bladders are inserted into the pipe through specially prepared taps, after
what they are blown up to form a plug.
The use of these various machines and methods make it possible to isolate a section
of the pipeline, which can then be cut to change route, install valves, etc. without
having to drain large amounts of product, and while working under satisfactory safety
conditions.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
.(''!- 1 P,0( B PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/IP*(-T
F)- 5-2- Sto++%e de;*e (!ed on # t#+ to !o%#te # !e*ton of the %ne-
9-2 VARIOUS SPECIAL TOOLS
&arious special tools have been developed to deal with situations that sometimes
develop during the operation of gas or li6uid pipeline. !f these, we may mention?
a. ,ttachment sleeves, by means of which two pipes can be joined without
welding. 'ealing is usually effected by means of !9rings $)ig. 19@%, which are
sufficiently pressure tight to permit to resume pumping, after which the final welding
operation can be performed.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/P*(-T .(''!- 1 P,0( :
F)- 5-4- J(n*ton !%ee;e fo" <onn) ++e end!-
b. &arious clamps $)ig. 191% are used for the temporary repair of leaks prior to
welding which will constitute the permanent repair but can only be made when the
soil around the leak is sufficiently freed from ha8ardous li6uids or vapors so that the
operation can be implemented safely. In all cases the seal is made with -eoprene,
either as a plug $fig. 191% for small leaks, or as discs compressed under clamped steel
saddles.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
.(''!- 1 P,0( D PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/IP*(-T
F)- 5-5- A %e#= "e+#" *%#'+-
.eaks can be plugged or welded without stopping flow. , neoprene cone is
compressed to fill the cavity. The collar is applied by pressing apart and slipping over
the pipe. ,fter the plug has been inserted, the collar is screwed.
'P("I)I" *("+,-I",. "!/#'( )!# (-0I-((#'
PIP( "!*P!-(-T ,-3 ,-"I.I,# (4/P*(-T .(''!- 1 P,0( 2;