Piping Study

Group email: pipingstudy@googlegroups.com , Email : admin@pipingstudy.com : A one point destination for all the piping engineers,project engineers,designers,technicians related to process and power industry. A one point destination for industry oriented knowledge sharing and learning.Also who are looking for jobs or want to share job opportunities in this sector ,may apply to this group. Please feel free to share your knowledge with us.Email : admin@pipingstudy.com , Group email: pipingstudy@googlegroups.com

Commonly Used Piping Standards

Piping Standards

Reference Standard	Commonly Used Piping Standards for Piping Element
ASME B36.10	Pipe:Carbon Steel Welded & Seamless wrought
ASME B36.19	Pipe: Stainless steel welded and seamless
ASME B16.11	Fittings: Forged steel socket welding & threaded
ASME B16.9	Fittings: Wrought Steel butt welding fittings
ASME B16.5	Flange: flange & flanged fittings(Up to 24”)
ASME B16.47	Flange: Large Diameter steel flanges. (Above 24”)
ASME B16.25	Butt Weld Preparation Stanadard
ASME B16.10	Face to face & end to end dimension of valves
MSS SP 43	Olet Fittings
ASME B16.28	Short Radius Elbow
ASME B16.20	Metallic gaskets and Spiral wound
ASME B16.21	Non metallic gasket
ASME B 16.48	Spectacle Blind ,Spacer,Blank
ASME B16.34	Valves: End to End Dimention(Pressure &Temperature ratings)
API 602	Gate Valves:( Forged )Flanged, Threaded, Welding, and Extended-Body Ends
API 600	Gate Valve:(Castings)Bolted Bonnet Valves
BS 5352	Globe Valve - Forged
BS 1873	Globe Valve - Cast
BS 5352 (SB)	Check Valve: Lift Type
BS 1868	Check Valve: Swing Type
API 594	Check Valves: Flanged, Lug, Wafer and Butt-welding
API 608	Ball Valves - Flanged and Butt-Welding Ends
API 609	Butterfly Valves: Double Flanged, Lug- and Wafer-Type
API 599	Metal Plug Valves
BS 5352	Needle Valve
BS 5156	Diaphragm Valves
API 603	Corrosion-Resistant, Bolted Bonnet Gate Valves
API 598	Valve Inspection and Testing
API SPEC 6D	Specification for Pipeline Valves
BS 7244	Flame Arrestor
ASME Sec VIII	Rupture Disk

ASME B16 Dimentional Piping Standards

ASME B16 Standards

ASME B16	Dimentional Piping Component Standards
B16.1	Cast Iron Pipe Flanges and Flanged Fittings
B16.3	Malleable Iron Threaded Fittings, Class 150 and 300
B16.4	Cast Iron Threaded Fittings, Classes 125 and 250
B16.5	Pipe Flanges and Flanged Fittings
B16.9	Factory Made Wrought Steel Buttwelding Fittings
B16.10	Face to Face and End to End Dimensions of Valves
B16.11	Forged Fittings, Socket Welding and Threaded
B16.12	Cast Iron Threaded Drainage Fittings
B16.14	Ferrous Pipe Plugs, Bushings and Locknuts with Pipe Threads
B16.15	Cast Bronze Threaded Fittings Class 125 and 250
B16.18	Cast Copper Alloy Solder Joint Pressure Fittings
B16.20	Ring Joint Gaskets and Grooves for Steel Pipe Flanges
B16.21	Nonmetallic Flat Gaskets for Pipe Flanges
B16.22	Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
B16.23	Cast Copper Alloy Solder Joint Drainage Fittings – DWV
B16.24	Cast Copper Alloy Pipe Flanges and Flanged Fittings Class 150, 300,400,600,900,1500,2500
B16.25	Buttwelding Ends
B16.26	Cast Copper Alloy Fittings for Flared Copper Tubes
B16.28	Wrought Steel Buttwelding Short Radius Elbows and Returns
B16.29	Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittiings
B16.32	Cast Copper Alloy Solder Joint Fittings for Sovent Drainage Systems
B16.33	Manually Operated Metallic Gas Valves for Use in Gas Piping systems upto 125psig (sizes 1/2 through c)
B16.34	Valves – Flanged, Threaded and Welding End
B16.36	Orifice Flanges
B16.37	Hydrostatic Testing of Control Valves
B16.38	Large Metallic Valves for Gas Distribution (Manually Operated, NPS 2-1/2 to 12, 125psig maximum
B16.39	Malleable Iron Threaded Pipe Unions, Classes 1150, 250 and 300
B16.40	Manually Operated Thermoplastic Gs Shutoffs and Valves in Gas Distribution systems
B16.42	Ductile Iron Pipe Flanges and Flanged Fittings, Class 150 and 300
B16.47	Large Diameter Steel Flanges (NPS 26 through NPS 60)

Commoly Used Material Table for Process and Power Plants

	CARBON STEEL	STAINLESS STEEL	LOW ALLOY STEEL	LOW TEMP. CARBON STEEL
FORGINGS	A105	A182 Gr F 304	1 Cr 1/2 Moly A 182 Gr F12	A350 Gr LF-2
		A182 Gr F 316	1 -1/4 Cr 1/2 Moly A182 Gr F11
		A182 Gr F 321	5Cr 1/2 Moly A182 Gr F5
		A182 Gr F 347	9Cr 1 Moly A182 Gr F9

CASTINGS	A216 Gr WCB	A351 Gr CF8 (SS 304)	1 1/4 Cr 1/2 Moly A217 Gr WC6	A352 Gr LCB
		A351 Gr CF8 M(SS 316)	5 Cr 1/2 Moly A217 Gr C-5
		A351 Gr CF8 C(SS 321)	9 Cr 1 Moly A217 Gr C-12
		A351 Gr CF8 T(SS 347)

PIPE	A53 Gr B(WELDED/SEAMLESS)	A312 Gr TP 304 (WELDED &SEAMLESS)	1 Cr 1/2 Moly A335 Gr P-12	A333 Gr-6
	A106 Gr B(SEAMLESS ALWAYS)	A312 Gr TP 316 (WELDED &SEAMLESS)	1-1/2 Cr 1/2 Moly A 335 Gr P-11	A671
	API 5L Gr B (LINED PIPING)	A312 Gr TP 321 (WELDED &SEAMLESS)	5Cr 1/2 Moly A335 Gr-P5
	A672(ONLY FOR LARGE BORE)	A312 Gr TP 347 (WELDED &SEAMLESS)	9Cr 1 Moly A335 Gr-P9
		A409	1-1/4 Cr 1/2 Moly A691(ONLY WELDED)
		A358 Gr 304/316/321/347
		(Class 1 TO 6 depending on type of welding)

SMALL BORE FITTINGS	FORGINGS ARE USED FOR SMALL BORE FITTINGS
LARGE BORE FITTINGS	A234 Gr WPBS	A403 Gr WP 304	1 Cr 1/2 Moly A234 Gr WP-12	A420 Gr WPL-6
	A234 Gr WPBW	A403 Gr WP 316	1-1/2 Cr 1/2 Moly A 234 Gr WP-11
		A403 Gr WP 321	5Cr 1/2 Moly A234 Gr-WP5
		A403 Gr WP 347	9Cr 1 Moly A234 Gr-WP9

FLANGES	FORGINGS ARE USED FOR ALL FLANGES

BOLT/NUT	A193 Gr B7 / A194 Gr 2H	A193 Gr B8 CLASS II / A94 Gr 8	A193 Gr B16 / A194 Gr 8	A320 Gr L7 / A194 Gr-4
	A307 Gr B / A563 Gr A

SMALL BORE VALVES	FORGINGS ARE USED FOR SMALL BORE
LARGE BORE VALVES	CASTINGS ARE USED FOR BIG BORE

A Typical Process Plant or Oil & Gas Project

A typical process plant or oil and gas project comprise of many stages from concept to commissioning and production plant. A work flow diagram of an EPC project is shown.Click here
2-Project Execution
Project execution involves designing ,detailing and construction of the plant till final commissioning , start up and handover to the client. This phase is also called the detail engineering phase. A schematic block diagram of project execution and the activities involved is shown here.Click here

Detail Engineering Phase : PipingStudy

During detail engineering phase various engineering departments contribute to the study and design of the plant such as civil,mechanical,electrical,instrumentation,architecture,process and piping. Piping forms the backbone of the detail engineering phase. Piping Study is broadly divided in 4 major branches

Piping Layout
Piping Materials
Piping Stress Analysis
Piping Supports

Overview of Industry and Role of Piping Engineering

Collapse all | Expand all

Pipe

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

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.

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.

Scope for Piping Engineering

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.

Typical Work Flow in a Process Project :

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

Project Engineering

Piping Layout

Construction

Rigging and Lifting Plan

Welding

Piping is half art half sceince.