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Process Piping
Construction
Project Insight
FROM STRAIGHT LENGTH & WAREHOUSE ITEMS TO
PRESSURE ENVELOPE
Note – this presentation is an informative knowledge sharing attempt only.
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Piping takes – Pressure, Temperature,
Flow of fluids in different phases
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What we will discuss and what
will be left (other’s scope)
We will discuss – Only Piping Project / Piping Construction
We will not discuss – Engineering – Design Basis, Basic Design ,
Detailed Engineering Design & Development or WBS / System
grouping etc and billing on engineering progress.
We will not discuss – SCM / Procurements – MR / RFQ / PR / PO, LCs /
BGs / Project Management / expeditions, Mill certificates /MTCs /
Chem-test Lab Reports/ PMIs /RFI / AFI, TPI EN 10204 3.1/3.2
Inspections, Testing, TPI Sample / Check Test Piece selection, NDE at
Manufacturing shop/ MDCC / Invoicing /Waybills / back to back
documentation for MRC and subsequent billing against material
supply / or loading, unloading IMIR.
We will not discuss – RA billing at construction site work, we will not
go in details of Pre-commissioning and Commissioning, Livening Up /
Warming up & Startup etc.
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Straight lengths
Pipe can be of various metallurgy, Lining, Coating, Surface Prepared /
Painted, Wrap and of various type of ends / edge, many user specific
piping is also available with manufacturers. Majorly based on ASME
B36.10 & B 36.19. NPS or DN use are project specific.
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Pipe & Tubes
People use the words pipe and tube interchangeably, and they
think that both are the same. However, there are significant
differences between pipe and tube.
The short answer is: A PIPE is a round tubular to distribute fluids and gases,
designated by a nominal pipe size (NPS or DN) that represents a rough
indication of the pipe conveyance capacity; a TUBE is a round,
rectangular, squared or oval hollow section measured by outside diameter
(OD) and wall thickness (WT), expressed in inches or millimeters.
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Small Bore & Large Bore
In general, Pipes having size range ½” – 1 ½ ” are termed as small
bore. Pipes having size range 2” & above are termed as big bore.
This may slight vary depend on the company to company but at
most it is same
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Fitting & Flanges
Various type of Fittings and Flanges are manufactured as per process
requirement, small bore and large bore fittings and flanges are always
chosen to meet metallurgy of piping system. Flanges normally referred
from ASME B 16.5 / 16.47 for sizing, Welded fittings are referred with
ASME B16.9 27-03-2020
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O Lets
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Long Necks
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Swage Nipples
The manufacturing process of the reducer is the heat
pressing process or the cold pressing process for the
seamless reducer(the heat treatment is required for the
cold pressing process) and hot rolling process for the
other reducer. The manufacturing process of the swage
nipple is the forging process.
The swage nipple generally adopts the MSS SP-95 or the
BS3799 Standard.
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ASME SECTIONS
SECTION I - Rules for Construction of Power Boilers
SECTION II - Materials –
Part A Ferrous Materials
Part B Non-Ferrous Materials
Part C Welding Rods, Electrodes and Filler Metal
Part D Properties
SECTION III - Rules for Construction of Nuclear Facility Components
SECTION IV - Rules for Construction of Heating Boilers
SECTION V - Nondestructive Examination
SECTION VI - Recommended Rules for the Care and Operation of Heating Boilers
SECTION VII - Recommended Guidelines for the Care of Power Boilers
SECTION VIII - Rules for Construction of Pressure Vessels
SECTION IX - Welding and Brazing Qualifications
SECTION X - Fiber-Reinforced Plastic Pressure Vessels
SECTION XI - Rules for Inservice Inspection of Nuclear Power Plant Components
SECTION XII - Rules for the Construction and Continued Service of Transport Tanks
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ANSI / ASME & other societies
ANSI - American National Standards Institute
API - American Petroleum Institute
ASHRAE - American Society of Heating, Refrigerating and Air-Conditioning
Engineers
ASME - American Society of Mechanical Engineers
ASTM International - American Society for Testing and Materials
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Vessels – Tanks & Heat Transfer
Equipment
API American Petroleum Institute
ASME American Society of Mechanical Engineers
AWWA American Water Works Association
CTI Cooling Tower Institute
TEMA Tubular Exchanger Manufacturers Association
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Piping Material Procurement &
Spool Fabrication
API American Petroleum Institute
ASME American Society of Mechanical Engineers
MSS Manufacturers Standardization Society of the Valve and
Fittings Industry
ASTM American Society for Testing and Materials
NACE National Association of Corrosion Engineers
EJMA Expansion Joint Manufacturers Association
PFI Pipe Fabricators Institute
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Valves & Special items
Valves can be of many type and ends can be prepared according to the
process requirement. Flange end dimensions are referred with ASME
B16.10 – on service cryogenic or hot the valve have different design.
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Tag items - Control / Shut down
/ Valve
These items are specialties and designed Tag number items,
can not be randomly used.
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Tag items -Flow control items
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Tag items – RO Restriction
Orifice
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Gaskets
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Fasteners
A careful selection is made according to service / Line class –
majorly stud bolts one can see in process piping.
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Expansion Joints
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Sight Glass / Level Indicators
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Indicators & Transmitters
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Indicators & Transmitters
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Ejectors & Injectors
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Steam Traps
The working philosophy of a trap is decided by design engineers
on process requirements and suitable type of trap is used.
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Strainers
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Steam Vent Silencer
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Flame arrestors
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Thermowell
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Mono-block Flange / DBB
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Spectacle Blinds
In slang few people refer it as Figure 8 blind
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Venturi
Flanged or butt-welded is according to process
requirement
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PSV / PRV
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FW line
Sprinklers (of various kind)
Deluge Valves
Hose Reels
Items- industry specific
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Piping GADs
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P&ID
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Piping isometric drawing
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Important Documents
Piping Design Basis
Line Numbering Procedure
Process diagrams / PFD
P&IDS
GADS
Piping Line List
Equipment List
Instrument List
PMS & VMS
Isometric Drawing List
Specification, Standards & Method Statements
NDE Matrix & ITP
Line Class / System philosophy
3D model (Navis / smart Plant Review or else)
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ISOMETRIC Reading
Read Line No. and from Class check Material of Piping.
Find line size
Find line size reduction (if any)
What size is Reducer?
Is it Pump suction line / Discharge line?
Are eccentric reducers used ?– FSU/FSD to be carefully placed
Are Branchings there? Tee, Olets or LN Flanges, Direct Stab-on/in?
Are Elbows / Bends, Flanges, Tees, Reducers, etc MTO is clearly given?
Count against drawing before placing requisition.
Are Pipe Cut Piece length marked by PDS / PDMS produced drawings
or need to be calculated?
Read Which Service Iso is this. Is there a slope? Any other specific Note?
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ISOMETRIC Reading
Check if any Line cleaning requirements marked
Check for Design/Hydro/Operating Pressure
Check for Design & Operating Temperature
Check for NDE / NDT requirements
Check Hardness & PWHT requirements
Are Spool drawings separately prepared ? If yes, Check how
many spool drawings each ISO had.
Is line having pneumatic test?
Any Steam / Electrical Tracing?
Any Cold Pulling? (normally not is process piping)
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ISOMETRIC Reading
Any Tag items in MTO of the concerned Isometric?
Any Mono-Block Flange / Thermowell or Venturi?
Any Special Support or Spring Support / Hanger.
Any Support having Steel to be erected from Vessel / Column /
Pipe Rack above or Below?
Any Support having guide / Anchor / sliding plate requirement?
What is Paint Code?
What is Insulation Code?
Any Corrosion Protection?
Is it a nozzle piping for any equipment?
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ISOMETRIC Reading
Any check valve / Globe valve / Orifice Flange or Flow
elements?
Any other specialties such as RO, Sight glass or LI / LT & PI / PT?
Any wrapping, coating or lining?
Which N-E-EL line is? Or S-W-EL line location in this isometric?
Number of adjacent ISOs from – to ? Sheet nos?
Check for Field Weld Joints and Shop weld Joint Numbers.
Any Pre-Heat requirements ?
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Getting Fabrication of Spool
started
Are Good for Construction (GFC)/ Issued for Construction (IFC) drawing
issued? Let it be ISO or Spool drawing
Any HOLD on drawings ? Who is controlling HOLD – LIST and Change List ?
Is this the latest drawing? Who is controlling Revisions?
Are Piping NDE requirement INDEX / MATRIX Prepared against PMS/ LINE
List?
Are WPS and PQR prepared for each Material and sizes covered for
qualifying the range? Are those WPS/PQR approved?
Are WQT performed?
Are Shop Fabrication and Field Fabrication Procedure Approved.
Are purging requirements clearly identified?
Are welding Inter-pass temperature regulation made and approved?
Are Pre-Heat / PWHT procedures prepared, are those approved?
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Getting Fabrication of Spool
started
Is fabricator having pipe supporting tri-pods or Wheel-Trolley ?
Is fix pipe fitting bench being used?
What is provision for protecting SS – CS direct Contact?
How SS and CS fabrication is segregated to avoid carbon dust contamination?
How SS tools, Grinding wheels are differentiated from CS tools for crafts man? Are
Joint Gap gauge, gap wire, plumb, water level, spirit level, protectors, Right
angles, markers (SS use separately), measuring tapes, pipe clamps, jigs available?
Are Lifting tools/tackles tested and calibrated?
Are Purging gases / Dams available?
Is masking tapes available?
What is method for QC to mark Joint No. / Welder Details at welding Joint?
What is Spool Numbering Method? Is every flange or butt joint have fit-up
inspection or only few services?
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Getting Fabrication of Spool
started
Which method of weld is approved – is downhill acceptable?
Are Mother oven and quivers available?
Are Pre-Heat / PWHT coils or other provision available?
Pipe cutting method determined? Plasma or cutting wheel ? Or else
Is removing Japanese Black or other inside coat a requirement for
fittings before fit-up?
What is provision for welder to welder ARC protection (for eyes) –
temporary hut / tent etc type covering of welding?
Are approved filler material available and PMI done?
Are Fabricators / Fitters / Grinder man / Helpers/ Riggers / Tack-
welders / Production Welders available (Scaffolders also if at site)
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Piping Erection / Installation
(Pipe Rack / ISBL / OSBL)
Are North – East & Elevations marked on pipe rack steel / precast and
ISBL Pump / compressor foundations / nearby nozzle area steel?
Are sumps / UG vessels / Utility stations and other related identified &
located?
Is Accessibility checked for placing spool on rack? Are Crane
assessments done and availability checked?
If inside plant around equipment (static or rotating) piping, are
temporary supports arranged to take the weight of piping until actual
support placed?
Are Scaffolding team and Riggers also available with Piping Team?
Are all CIP critical interface point marked?
Are all contact point Corrosion places final painted before placing shoe
supports?
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Piping Erection / Installation
(Pipe Rack / ISBL / OSBL)
Is there any level difference due to difference in Tolerance acceptance of civil and
piping?
If level is showing back flow or as require? Do we need extra shimming or base plate
welding to maintain level?
Is this line (iso being referred to) have slope requirement? Is it flare line or process sewer line
or else?
Do we need to get each fit up checked? Each flange weld checked or we can proceed?
Are wind protection arrangement and spatter protection / spark fall protection fire
blankets available? Access OK?
Which welding will be done SMAW/GTAW? Or both?
Are pre/post weld, hardness check or inter-pass temperature checking equipment
available?
Is this a stress sensitive nozzle joint?
Is this a golden joint? Is CJP/FPJ/FJP or PJP specified?
FW Joint Number and Welder marking system developed?
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Completing a Hydro/
Pneumatic Test pack
Are test pack received approved? (Hydro or pneumatic) – containing marked P&ID
and ISOs, all TL, TR, HPV/LPD marked, is dummy spool required in place of any valve?
Do we have to rotate any Check/Globe or any other item? Are orifice / venture
flange nipples welded with isolation valves or to be plugged?
Is piping weld joint strength test / hydro test / pneumatic test procedure approved?
Have we completed the test limit to test limit welding? (TL) all drain lines vent line,
flanges, Instrument connections, branches? All required NDE?
Can we now make it an unit that can contain fluid for test? Water /Air
Are high point vent valves and PG / PRV location marked and is Pressure test
manifold fabricated complying to the highest pressure it has to handle plus safety ?
Is lowest point drain location marked and we have pressure injection manifold with
PG/PRV and shut off valves? Are Pumps ready?
What is management philosophy – can paint and insulation proceed leaving field
weld joints for test?
Is test medium/water requirement calculated?
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Minimum documents in a Test
Pack
An Index for listing below documents
Test pack involved Iso drawings Index & P&ID Index
marked drawings for test pack range with TL / TR / HPV / LPD, dummy spools / RS, direction
change valves marked, Keep Open, keep closed valves marked.
P&ID marked for TL / TR / HPV / LPD, dummy spools / RS, direction change valves marked, Keep
Open, keep closed valves marked.
List of Vent cap Seal weld or plug after test / Same list if drains have cap welds or hex plug.
Dummy Spool list with dummy spool weld and pipe material TCs and weld NDE records (Weld
maps). Same detailed drawings for Pressure Injection point manifold and HPV manifold
detailed drawings, weld map, NDE records
PG/PSV & Chart recorder calibration certificates (as per spec what % higher than test pressure
limit) – check if master PG or such requirement to be there or Two PG test or Two PSV.
QC Reports - Weld map and NDE records of test pack included piping (Piping Joint History, with
welders records, NDE matrix compliance to % NDE, Hardness Test Records, PWHT charts). All
weld joints welding correlation with an approved WPS/PQR and qualified welder number
allocation record.
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Minimum documents in a Test
Pack
All piping & fittings heat number correlation with MTCs / TCs / IMIR. Filler materials used TCs / PMI
reports
Reinstatement form / List
Tag items list
Punch List – Pre – Hydro/Pneumatic walk-down ( all A punch closed/ signed off)
Hydro-test / Pneumatic test Form stating step wise pressurizing sequence and draining method.
Permanent gasket holding flange joint list and the flange list marked for temporary joints.
All tensioned / Torqued Flanged Joint mapping.
If valves are not shop tested, which valves are put on test (normally not applicable)
Any RF pad included – Leak Test Report.
All direct weld support weld joint list / NDE records as per Line Class NDE Matrix / Spec.
Any pre-hydro flushing / Air blowing requirement signed off form.
Any carryover items (test at shop / tested earlier / to be tested later)
WEIL – Work Exemption Instrument List / DBB / TW etc.
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Testing -
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Pre-commissioning
Reinstatements as required other than very sensitive instruments / All
test Remove (TR items) to be final installed as per commissioning
team advice.
Flushing of piping system / subsystem (Multiple Hydro / pneumatic
test packs)
Air blowing, steam blowing and paper blasting
Oil flushing / chemical cleaning
Hot Air Blowing / Dry out / dew point check / Nitrogen blanketing.
System / subsystem boundary isolation (if required)
Solo runs / Loop test by other departments
DAC / PIMC Notice to the client.
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MDR / Dossier
journey from mill to process plant’s pressure envelope - All documents of
test pack is now collected subsystem by subsystem and a complete
manufacturing history is compiled for pipe, fittings, valves & specialties
e.g. expansion joints / sight glass.
MDR will have All ITP compliance report for material, coating / Painting /
Lining / Insulation / solo runs / function test etc.
MDR will have a complete check list against the client’s requirement.
When all subsystems documents collected together with complete
traceability records / test records / ITRs / PMI reports/ Signed Inspection
and Test Forms, Reinstatement verification forms, Flow direction check
forms / Orifice installation / TW / LI /LT installation reports, Blowing /Flushing
/Cleanliness records / Preservation records / and any other documents
such as NDE UT / RT Reports etc. this become MDR.
These MDRs will be part of completion team’s dossiers.
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Commissioning
All components of Pressure envelope installation for final
All flange leak test (with the client’s operations team)
All loop tests and other instrumentation check –final (Instruments
Team - MCR / DCS Team)
MC walks complete and all party sign off.
PSSR notice to the client.
Operations team and commissioning team work together for gas-in
or process fluid in activity
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System Completion
All ITRs signed off and Uploaded Scanned in Software such as INDRA
/TOSTR /TALISMAN / ICMS/PJCS or other ERP /SAP system.
MDRs collected and any commissioning punches closed and
marked system complete with operations.
NO COW – Carry Over Work Left
NO WEIL – Work Exemption Instrument Item Left
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complete Pressure Envelope
THANK YOU
Note – this presentation is an informative knowledge sharing attempt only.
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Appreciate that you reached here.
WORK SAFE – KEEP LEARNING
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