Process Plant Piping: Practical Guide to Fabrication, Installation, Inspection, Testing, and Commissioning

Cover
Half Title
Title Page
Copyright Page
Table of Contents
About the Author
Preface
Chapter 1 Introduction
1.1 General
1.2 Piping
1.3 Piping Engineering
1.4 Piping Design
1.4.1 Conceptual Layout Design
1.4.2 Equipment Layout Design
1.4.3 Piping Layout Design
1.5 Design Basis
1.6 Design Codes
1.6.1 American Society of Mechanical Engineers
1.6.2 Editions and Addenda
1.6.3 Interpretations
1.6.4 Code Cases
1.7 History of ASME Codes for Piping
1.8 Loading Conditions for Piping
1.8.1 Static Loading
1.8.2 Dynamic Loading
1.9 Equipment Requirements
1.10 Client/Project Requirements
1.11 Material Specifications
1.12 Failure Modes
1.13 Scope, Coverage and Layout of ASME Code B 31.3 – Process Plant Piping
1.13.1 General
1.13.2 Scope of ASME B 31.3 Process Plant Piping
1.13.3 Exclusions From ASME B 31.3
1.13.4 Types of Fluid Services Covered
Chapter 2 Piping Documents Development Process
2.1 Key Documents
2.2 Project Design Basis
2.3 Block Flow Diagram
2.4 Process Flow Diagrams
2.4.1 Purpose of PFD
2.4.2 Contents of PFD
2.5 Piping and Instrumentation Diagram
2.5.1 Function and Purpose of P&IDs
2.5.2 When and Who Use P&IDs
2.5.3 Difference Between a PFD and a P&ID
2.5.4 Limitations of P&ID
2.5.5 P&ID and Associated Documents
2.5.6 Contents of P&ID
2.5.7 Specific Exclusions
2.5.8 Standards and Rules for Preparation of P&IDs
2.5.9 Equipment Designation
2.5.10 Line Designation
2.5.11 Instrument Lines
2.5.12 Instrument Designation
2.5.13 Standard Symbols
2.6 Piping Engineering Deliverables
2.7 Piping Key Plan
2.8 Piping Isometric Drawings (Isometrics)
2.9 Piping Material Specification
Chapter 3 Piping Isometric Drawings (Isometrics)
3.1 Significance of Isometric Drawings
3.2 Advantages of Isometric Drawings
3.3 Comparison of Orthographic and Isometric Drawings
3.4 Isometric Views in More Than One Plane
3.5 Piping Arrangement Symbols
3.5.1 Piping Arrangement Symbol (Pipes)
3.5.2 Piping Arrangement Symbols (Fittings)
3.5.3 Piping Arrangement Symbols (Flanges)
3.5.4 Piping Arrangement Symbols (Valves)
3.5.5 Piping Arrangement Symbols (Miscellaneous Fittings)
3.6 Preparation of Piping Isometric Drawings or Isometrics
3.7 Size of Piping Drawings
3.8 Typical Drawings – Style/Presentation and Contents
3.8.1 Piping Key Plan – Area Match Lines
3.8.2 Piping Key Plan
3.8.3 Piping Isometric Drawing
3.8.4 Piping Isometric Drawing with BOM
Chapter 4 Piping Material Specification (PMS) and Material Take-Off (MTO)
4.1 Piping Material Specification
4.1.1 Contents of PMS
4.2 Piping Material Management
4.2.1 Material Take-Off
4.2.1.1 Bill of Materials
4.2.1.2 Material Take-Off
4.2.1.3 Initial MTO
4.2.1.4 Manual MTO Preparation Overview
4.2.1.5 Steps for Generating Manual MTO
4.2.1.6 MTO for Special Items
4.2.1.7 MTO for Non-Pickable Items
4.2.1.8 Generation of Total MTO
4.2.1.9 Stages of MTO During Engineering
4.3 Preparation of MR
4.4 Purchase Enquiry
4.5 Technical Bid Evaluation
4.6 Purchase Order
4.7 Vendor Document Review/Approval
4.7.1 Typical BOM in Isometric Drawing
4.7.2 Typical MTO
Chapter 5 Pipes
5.1 History of Pipe
5.2 Pipe and Tube
5.3 Difference Between Pipe and Tube
5.4 Material of Construction for Pipes
5.5 Manufacturing Processes
5.5.1 Seamless Pipes
5.5.2 Welded Pipes
5.6 Strengths and Weaknesses of Manufacturing Processes
5.7 Schematic Presentations of Various Manufacturing Processes
5.8 Size of Pipe
5.8.1 Nominal Pipe Size
5.8.2 Pipe Schedule
5.8.3 Length of Pipe
5.9 Methods of Joining Pipes
Chapter 6 Pipe Fittings
6.1 BW Pipe Fittings
6.1.1 Bevelled Ends
6.2 Material of Construction
6.3 Types of BW Fittings
6.4 O'Let Type Welded Branch Connections
6.4.1 Types of O'Lets
6.4.2 Welding Requirements of O'Let Fittings
6.5 SW Fittings
6.5.1 Technical Details
6.5.2 Advantages/Disadvantages of Socket Weld Fittings
6.5.3 Typical SW Joint
6.5.4 Types of SW Fittings
6.6 THD Fittings
6.6.1 NPT Thread
6.6.2 Types of THD Fittings
6.7 Mitered Elbows
6.8 Header and Branch Connections
6.8.1 Stub-in Connections
6.8.2 Stub-in Reinforcements
Chapter 7 Flanges, Gaskets and Fasteners
7.1 Flanges
7.1.1 Bolted Flange Connections
7.1.2 Flange Rating
7.1.3 Flange Facing
7.1.4 Flange Types
7.2 Fasteners for Flanged Connections
7.2.1 Types of Bolts
7.2.2 Hexagonal (Hex) Nuts
7.2.3 Threads of Stud Bolts
7.2.4 Standard Thread Pitches
7.2.5 Coatings on Fasteners
7.2.6 Coating Thickness
7.2.7 Life Expectancy of Coatings
7.3 Gaskets
7.3.1 Classification Based on Configuration
7.4 Gaskets for Flanged Connections
7.4.1 Types of Gaskets Based on Material of Construction
Chapter 8 Valves
8.1 Classification of Valves
8.2 Class Ratings
8.3 Common Types of Valves
Chapter 9 Sequence of Mechanical Works After Award of Work
9.1 Work Progression on Award of Contract
9.2 Responsibility Matrix (Head Office and Site)
9.3 Organization Setup on Site
9.3.1 Introduction
9.3.2 Organization Chart
9.4 Design, Drawings and Documents Approval
9.5 List of Documents
9.6 Preparation of MTO and CS
9.7 Material Requisition
9.8 Technical and Commercial Bid Evaluation
9.9 Purchase Order
9.10 Vendor Data and its Approval
9.11 Materials Procured From Stockists or Traders
9.12 Work Contracts
9.12.1 Sub-Contract for NDT
9.12.2 Sub-Contract for Scaffolding
9.12.3 Sub-Contract for Surface Preparation and External Painting
9.13 Local Contracts/Purchases at Site
Chapter 10 Fabrication of Piping Spools
10.1 General
10.2 Linear Dimensional Tolerance for Piping
10.3 Workshop Requirements
10.4 Stainless and Other High-Alloy Steel
10.5 Progress Control
10.6 Spool Sizes
10.7 Galvanized Piping
10.8 Painting of Spools
10.9 Shop Fabrication of Spools
10.9.1 Release of ISOs in AFC Status
10.9.2 Material Release
10.9.3 Material Traceability
10.9.4 Sizing of Pipe
10.9.5 Types of Weld Joints Required in Piping
10.9.6 Fit-Up of Butt and Socket Weld Joints
10.9.7 Threaded Connections
10.9.8 Flanged Connections
10.9.9 Branch Connections
10.9.10 Cold Bending
10.9.11 Mitre Bends
10.9.12 Misalignment Tolerance
10.9.13 Preparation for Welding
10.9.14 Cleaning
10.9.15 Preheating
10.9.16 Welding
10.9.17 Visual Inspection
10.9.18 Dimensional Tolerances for Pre-Fabricated Piping Assemblies
10.9.19 Release for NDT of Completed Spools
10.9.20 Repair of Defects
10.9.21 Verification of Completion of Spool and Release for Post-Weld Heat Treatment (PWHT)
10.9.22 Pipe Spool PWHT
10.9.23 Hardness Test of Welds (if Required)
10.9.24 Hydrostatic Test of Spool (as Applicable)
10.10 Surface Preparation and Painting
10.10.1 Inspection During and After Completion of Surface Preparation and Painting
10.11 Release of Pipe Spools and Tagging
10.11.1 Tagging and Numbering
10.12 Temporary Storage of Pipe Spools
10.12.1 General Storage Requirements
10.12.2 Stainless Steel Materials
10.12.3 Lined Steel Pipes
Chapter 11 Non-Destructive Testing (NDT) of Piping
11.1 Introduction
11.2 Basic ASME 31.3 NDT Requirement
11.3 Enhanced NDT Requirements for Piping
11.4 Progressive Radiographic Examination
Chapter 12 Preheat and Post-Weld Heat Treatment (PWHT) of Piping
12.1 Preheating
12.1.1 Preheat Requirements
12.1.2 Verification of Preheat
12.1.3 Other Aspects of Preheating
12.2 Post-Weld Heat Treatment
12.2.1 General Requirements
12.2.2 Governing Thickness for Determining PWHT Temperature and Soaking Time
12.2.3 Heating and Cooling Methods
12.2.4 Heating Rate
12.2.5 Soak Temperature
12.2.6 Soak Time
12.2.7 Cooling Rate
12.2.8 Temperature Verification
12.2.9 Hardness Tests
12.2.10 PWHT of Weld Joints Between Dissimilar Materials
12.2.11 Delayed Heat Treatment
12.2.12 Heat Treatment in Parts
12.2.13 Local Heat Treatment
Chapter 13 Installation, Welding, Inspection and Testing of Piping Spools
13.1 Completed Piping Spools
13.2 Other Miscellaneous Components to Be Installed, Welded or Bolted
13.3 Cleaning of Piping Spools Before Installation or Erection
13.4 Piping Routing
13.5 Slopes
13.6 Fit-Up and Welding of Field Weld Joints
13.7 Flange Connections
13.8 Vents and Drains
13.9 Valves
13.10 Instruments
13.11 Line-Mounted Equipment/Items
13.12 Bolts and Nuts
13.13 Pipe Supports
13.14 Installation and Interconnection of Piping Spools and Other Inline Equipment
13.14.1 General Requirements
13.14.2 Installation of Valves
13.14.3 Piping for Rotating Equipment
13.14.4 Field Welding and Tests
13.15 Flanged Joint Bolting
13.15.1 Flanged Joint Bolting Torque
13.15.2 Flange Bolt-Up Procedure
13.15.3 Bolt Tightening Sequence
13.15.4 Recommended Torque Value Chart
13.16 Causes of Flange Leakage
13.16.1 Uneven Bolt Stress
13.16.2 Improper Flange Alignment
13.16.3 Improper Gasket Centring
13.16.4 Dirty or Damaged Flange Faces
13.16.5 Excessive Loads in Piping System at Flange Locations
13.16.6 Thermal Shock
13.16.7 Improper Gasket Size or Material
13.16.8 Improper Flange Facing
13.17 Safety of Flange Joint Assembly
13.18 Insulated Piping
13.19 Stainless Steel Piping
13.20 Plastic Piping
13.21 Lined Piping (Rubber, Polyurethane and PTFE Lining)
13.22 Underground Piping
13.23 Galvanized Piping
13.24 Mining Hose
13.25 Pressure Testing
13.25.1 Test Requirements
13.25.2 Test Pack Systems
13.25.3 Test Pack Preparation
13.25.4 Test Pack Limits
13.25.5 Test Pack Documentation
13.25.6 Special Notes on Test Pack Documentation
13.25.7 Test Media
13.25.8 Test Pressure
13.25.9 Hydrostatic Testing of Piping Designed for External Pressure (Jacketed Lines)
13.25.10 Pneumatic Testing
13.25.11 Test Duration
13.25.12 Preparation for Testing
13.25.13 Blinds for Pressure Test
13.25.14 Test Equipment
13.25.15 Completion of Testing
13.25.16 Test Records
13.26 Cleaning and Reinstatement
13.26.1 Cleaning
13.26.2 Reinstatement
13.27 Inspection of Valve Installation
13.28 Pipe Supports
13.28.1 General Guidelines for Supporting
13.28.2 Inspection of Supports and Restraints
13.29 Types of Supports
13.29.1 Rigid Supports
13.29.2 Pipe Hangers
13.29.3 Flexible or Resilient Supports
13.29.3.1 Variable Load Flexible Support
13.29.3.2 Constant Load Flexible Support
13.30 Restraints
13.31 Surface Preparation and Coating of Field Welds and Repair of Coating Damages
13.32 Surface Preparation and Painting of Piping After Installation
13.33 Punch Listing
13.33.1 Category A Punch Items
13.33.2 Category B Punch Items
13.33.3 Category C Punch Items
13.33.4 The Punch Listing Procedure
13.34 Release for Commissioning
Chapter 14 Construction Documentation for Plant Piping (Mechanical)
14.1 General
14.2 Project Record Book
14.3 Documentation Mode for PRB
14.4 PRB Preparation and Review Responsibility
14.5 Construction Record Book
14.6 Documents Specific to Piping
14.6.1 Material Summary
14.6.2 Weld Summary
14.6.3 NDE Reports
14.6.4 Weld Joint NDT Summary
14.6.5 Heat Treatment Records and Charts
14.6.6 Weld Joint PWHT Summary
14.6.7 Pad Air Test Summary Reports
14.6.8 BOM Check Report (Test Pack Wise)
14.6.9 Test Pack Documentation
14.6.10 Punch List
14.6.11 Mechanical Completion and Handing Over Report
14.7 General Requirement for Contents of CRB
14.8 Records and Reports of Inspections, Tests and Calibrations
14.9 Certification for Materials
14.9.1 Components Requiring "Material Certification" in Piping
14.9.2 Contents of "Certification Dossier" for Bought Out Items (as Applicable)
Chapter 15 Formats for Plant Piping Documentation
15.1 General
15.2 Formats for Spool Fabrication and Installation
Appendix A: Inspection and Test Plan (ITP) for Piping
Appendix B: Welding Procedure Specification (WPS),
Procedure Qualification Record (PQR) and Welder
Qualification Record (WQR)
Appendix C: Piping Progress Monitoring Based on Standard Point Factor
Appendix D: Radiographic Acceptance Criteria for Rounded Indication
Appendix E: Preheat and Post-Weld Heat Treatment Requirements as
per ASME B 31.3
Appendix F: Quality Audit of Piping Girth Welds Based on Radiography
References
Index