Piping Study

When a fluid is required to be transferred from one location to other, pipe is required. A pipe is considered as a pressure tight cylinder which is used to convey fluids under pressure through materials of commercially available designation.
A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-section, used mainly to convey substances which can flow — liquids and gases (fluids), slurries, powders, masses of small solids. It can also be used for structural applications; hollow pipe is far stronger per unit weight than solid members.
Piping systems act like a nervous system for the flow of fluid in the huge network of any industry around the globe.

Piping is an assembly of pipe, pipe fittings, valves, instruments and specialty components.

Piping is divided into three major categories:
Large bore pipe generally includes piping which is greater than two inches in diameter.
Small bore pipe generally includes piping which is two inches and smaller in diameter.
Tubing is supplied in sizes up to four inches in diameter but has a wall thickness less than that of either large bore or small bore piping and is typically joined by compression fittings.

Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies for efficient transport of fluid is called Piping Engineering.

The most interesting branch of science in Mechanical Engineering is Piping .Piping engineering involves visualization ,creativity in design,detailing with established norms ,industry practices,procedures,codes,standards,dedication,risk taking ability and decipline.Piping is more often referred as ‘HALF SCIENCE & HALF ART’. Piping engineering is all about designing, fabricating and constructing lines for conveying fluids.

Importance of Piping Engineering:
To maintain pressure difference (Δp)
To maintain temperature difference (Δt)
To maintain flow rate (Δq)

APPLICATIONS:
Pipelines carry crude oil from oil wells to tank farms for storage or to refineries for processing.
The natural gas transportation and distribution lines convey natural gas from the source and storage tank forms to points of utilization, such as power plants, industrial facilities etc,
In chemical plants, paper mills, food processing plants, and other similar industrial establishments, the piping systems are utilized to carry liquids, chemicals, mixtures, gases, vapors, and solids from one location to another.
The fire protection piping networks in residential, commercial, industrial, and other buildings carry fire suppression fluids, such as water, gases, and chemicals to provide protection of life and property.
The piping systems in thermal power plants convey high-pressure and high temperature steam to generate electricity. Other piping systems in a power plant transport high- and low-pressure water, chemicals, low-pressure steam, and condensate.

Sophisticated piping systems are used to process and carry hazardous and toxic substances.
The piping systems in laboratories carry gases, chemicals, vapors, and other fluids that are critical for conducting research and development.

Process & Petroleum Industry
Chemical Process Industry
Petrochemical Industry
Pharmaceutical Industry
Power Plant
Long Distance LNG/LPG/CNG Piping System
Irrigation Project
Project & Construction Companies

A Piping Engineer plays an important role from start of a project concept ,assignment of contracts for design,detailing,erection to commissioning in all sector of process,power,chemical,petrochemical and all related industries. With increasing emphasis on process industry ,power,transportation of petroleum products, natural gas, corrosive & hazardous chemicals through undergoing and long distance pipelines, the requirement of skilled Piping Engineers increasing day by day.

Feasibility/Conceptual Studies

Conceptual Design & Feasibility Studies focus on evaluating the business opportunities and developing a project scope to meet identified needs. A key goal is to analyze and define how innovative design solutions can impact specific plant economics and provide a project justification. Conceptual Design & Feasibility Studies also establish a preliminary plan including scope of work and functional specifications to provide a well defined starting point for a project Front End Engineering

Design (FEED)

Participation in the FEED phase of a project lays the foundation for the development of a best of class solution for the project. The FEED phase has two basic elements: a technical aspect and a work process aspect.
Technical: Working in cooperation with the plant owner and process designer(s) the PMC organisation utilises its unique combination of technical expertise and product knowledge from thier own portfolio of products and that of alternative suppliers to provide the best technical concept definition, project standards, common functional design criteria and generic equipment specifications.
Work Processes: The FEED phase is also the period when the management systems and specific project plans to be employed during project execution are defined and developed into documented processes. Each organisation (owner, EPC contractor designers ) has its own internal standards and requirements for executing its work. These internal processes reflect the basic tenets of the respective organisation and are the foundation for how each approaches the various execution phases. A balance between the project specific requirements and the basic work processes of each of the participants must be achieved. Basic integration of the respective work processes must also be achieved to make transfer of critical engineering data and documentation possible. This integration of work processes and establishing a common approach to execution are key elements in achieving flawless execution.

Basic Engineering(front End Engineering Design, FEED)

As a minimum, basic engineering packages contain the following

Project Design Basis and Process Description
Process and Utility Flow Diagrams
Equipment List and Equipment Process Data Sheets
Catalyst, Chemicals and Effluent Plant Data
Hazard Study Data and Area Classification Diagram
Piping and Instrument Diagrams
Process Instrumentation Philosophy and Logic Diagram
Plant Layout and Battery Limit Schedule
Preliminary Process Operating Manual

It is not necessary that Basic Engineering Package may contain all documents mentioned above.
It is in Basic Engineering that all the real engineering work are done.

Detail Engineering

The range of activities in this phase are:
Detailed review of basic engineering and complete designing
Technical specifications for materials and equipment
Detailed engineering for all disciplines
Functional specifications
Dimensioning of conduit, piping and electrical installations
Lists of equipment, instrumentation, accessories , materials , Instrumentation Specifications, data sheets, logic diagrams
Electrical Equipment’s Sizing and specifications
Detailed installation drawings
Piping Layout
Conduit layout
Civil, Structural and architecture design details
Single-wire electrical drawings
Equipment layout drawings
Piping Routing / Design with support
Isometric drawings
Piping MTO
Supports drawings

Procurement

The process of obtaining goods and services from preparation and processing of a requisition through to receipt and approval of the invoice for payment. It commonly involves (1) purchase planning, (2) standards determination, (3) specifications development, (4) supplier research and selection, (5) value analysis, (6) financing, (7) price negotiation, (8) making the purchase, (9) supply contract administration, (10) inventory control and stores, and (11) disposals and other related functions.

Construction and Erection

This stage involves the real construction of the plant and related activities.
Erection and manufacturing of main supplier equipments.
Erection and installation of key piping systems and components.
Do the relevant test activities.
Report failures detected during tests and propose measures to prevent/correct

Commissioning & Inspection of the Plant

Inspection involves.
Initial audit of the facilities, the plant processes and quality procedures
Periodical inspections of main equipment manufacturers and subcontractors
Verification of documentation related to materials and components
Verification of calibration reports and measurements of the manufacturer
Welding procedures and welder certificates
Verification of instruments and certificates
Checklist revision and non conformity detection and monitoring
Verification of any incident that may occur during the plant erection.

Installation

Periodical inspections, including but not limited to:
Installation Manual revision
Civil works progress
Equipment delivery and installation
Issuance of an Installation Certificate (if applicable)
Specifications Verification
Verification of equipment and manufacturer:
Track record
Fitness for the site (related to site-specific external conditions)
Review of equipment design
Certification status

Commissioning

Commissioning surveys include verification of procedures for initial start-up and testing after installation, to confirm proper, safe and functional operation of all devices, controls and apparatus, e.g:
Safe start-up
Safe shutdown
Safe emergency shutdown
Functional tests
Proper records are kept for testing, commissioning, control parameters and results
Issuance of an Installation Certificate and Final Acceptance Certificate