A TECHNICAL REPORT ON
STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
UNDERTAKEN AT
DATUMENERGY NIGERIA LIMITED (DNL)
AVIATION ESTATE, IKEJA, LAGOS STATE.
BY
AKINRINADE, OPEYEMI DANIEL
MATRIC NO: EES/16/17/0127
SIWES REPORT SUBMITTED TO THE
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF ENGINEERING
OLABISI ONABANJO UNIVERSITY
IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF
BACHELOR OF SCIENCE (B.Sc.) IN MECHANICAL ENGINEERING
FROM
MARCH 2020 TO FEBRUARY 2021
CERTIFICATION
This is to certify that the Student Industrial Work Experience Scheme (SIWES) was carried
out by Akinrinade Opeyemi Daniel with Matric Number - EES/16/17/0127 of Mechanical
Engineering Department, Faculty of Engineering, Olabisi Onabanjo University, Ago – Iwoye
, under my coordination.
____________________
Dr. Olatunde
SIWES Co-ordinator
____________________
Date
____________________
Dr. H. O. Adeyemi
Head of Department
____________________
Date
DEDICATION
This report is dedicated to my Fathers: God the Father who through the Holy Spirit guided
me in choosing this career path and my earthly Father who has been supportive and also of
guidance.
ii
ACKNOWLEDGEMENT
My sincere and ultimate thanksgiving goes to the Almighty God, the one who sustain me
throughout the course of my Industrial Training.
I also appreciate and thank the Managing Director of DATUMNERGY Nigeria Limited
Engr. Daniel Olaoluwa for giving me the opportunity to be trained under his establishment
and supporting me throughout the training.
My regards also goes to my Industrial Based Supervisor Mr. Adebayo Olubaye and all my
lecturers in the department for their necessary supervision and useful information provided,
Engr. Nwaokocha Collins for the advising that we should learn the use of CAD software’s,
the Head of Department Dr. Adeyemi Hezekiah for taking is time and energy in teaching the
Computer-Aided-Design course practically and SIWES coordinator Dr. Olatunde for the
guidance.
I cannot forget my loving and caring family, and all my brothers and sister for their support
both spiritually and financially during my SIWES programme, may God bless you all.
Time and space will not permit me to mention all the Individuals that contributed to the
success of my SIWES in one way or other. I sincerely appreciate you all.
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ABSTRACT
This report will take you through the journey of my SIWES which I did at Datumenergy
Nigeria Limited, Ikeja, Lagos State.
My training was on the design, fabrication and testing of different piping system ranging
from fire hydrant piping, natural gas reticulation system and Air compressor piping with use
of different pipe materials.
During this period, I acquired practical knowledge on how to install and replace piping
components like Pressure gauges, valves, gas filters and also providing the needed assistance
to site supervisor, Non-Destructive Testing (NDT) inspectors, fitters and welders with the
functionality they need.
This report discussed the technical skills gained during the training period and justifying the
relevance of the scheme in equipping students with needed technical competence to thrive in
the real world.
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Contents
TITLE PAGE
CERTIFICATION ………………………………………………………………………………………………………………………………… i
DEDICATION …………………………………………………………………………………………………………………………………… ii
ACKNOWLEDGEMENT ……………………………………………………………………………………………………………………. iii
ABSTRACT ……………………………………………………………………………………………………………………………………… iv
TABLE OF CONTENT …………………………………………………………………………………………………………………….. v-vi
CHAPTER ONE ......................................................................................................................................... 1
INTRODUCTION ................................................................................................................................... 1
OBJECTIVES OF SIWES ......................................................................................................................... 1
ABOUT INDUSTRIAL TRAINING I.T.F. ................................................................................................... 2
CHAPTER TWO ........................................................................................................................................ 3
COMPANY OVERVIEW ......................................................................................................................... 3
DNL SERVICES ...................................................................................................................................... 3
VISION STATEMENT ............................................................................................................................ 4
MISSION STATEMENT ......................................................................................................................... 4
QUALITY POLICY AND OBJECTIVES ...................................................................................................... 4
QUALITY POLICY .............................................................................................................................. 4
QUALITY OBJECTIVES ...................................................................................................................... 5
HEALTH SAFETY AND ENVIRONMENT ................................................................................................. 5
CHAPTER THREE ...................................................................................................................................... 6
INDUSTRIAL TRAINING EXPERIENCE ....................................................................................................... 6
PIPING SYSTEM ................................................................................................................................... 7
COMPONENTS OF PIPING SYSTEM ..................................................................................................... 8
PIPES................................................................................................................................................ 8
PIPE FITTINGS ................................................................................................................................ 10
Flanges Gaskets and Bolting ......................................................................................................... 14
Types of flanges based on flange facing ....................................................................................... 17
Types of Flange based on Pressure-Temperature Class (Service Rating) ..................................... 18
Types of Flange based on Material ............................................................................................... 18
GASKET .............................................................................................................................................. 18
Types of Gasket ............................................................................................................................. 19
BOLTS ................................................................................................................................................ 20
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PROCEDURE FOR APPLICATION OF BOLT TORQUE ON FLANGED JOINTS .................................... 21
VALVES .......................................................................................................................................... 22
PRESSURE GAUGE ......................................................................................................................... 26
NON-DESTRUCTIVE TESTING (NDT) OF PIPING SYSTEM ................................................................... 27
HYDROSTATIC TESTING OF PRESSURE PIPING SYSTEM ................................................................ 27
FABRICATION AND INSTALLATION OF PIPING SYSTEM .................................................................... 30
Types of Pipe-Weld Joint............................................................................................................... 30
DRAWING .......................................................................................................................................... 32
PAINTING OF FABRICATED PIPING .................................................................................................... 37
CHAPTER FOUR ..................................................................................................................................... 38
NEW SKILLS ACQUIRED AND CHALLENGES ENCOUNTERED ................................................................. 38
CHAPTER FIVE ....................................................................................................................................... 40
CONCLUSION AND RECOMMENDATIONS............................................................................................. 40
REFERENCES .......................................................................................................................................... 41
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CHAPTER ONE
INTRODUCTION
The Student Industrial Work Experience Scheme (SIWES) was initiated in October 8, 1973
by the Industrial Training Fund (ITF), the Student Industrial Work Experience (SIWES)
gives opportunity for students to go on a Skill Acquisition or Work Experience program in an
Industry that relate to their field of study in order to update practical knowledge of students in
the Universities, Polytechnics and Colleges of Technology. It was aimed at bridging the gap
between the theoretical knowledge acquired in classes and technical knowledge in the
industry by providing students with the opportunities to apply their educational knowledge in
real work situations.
With the primary purpose of gaining relevant skills required from an engineering graduate
and to secondary purpose of fulfilling the major requirement for the award of Bachelor of
Science degree, I undertook my SIWES at Datumenergy Nigeria Limited which is located at
Aviation Estate, Ikeja, Lagos from MARCH 2020 to FEBRUARY 2021.
OBJECTIVES OF SIWES
The Industrial Training Fund’s Policy Document No. 1 of 1973 which established SIWES
outlined the objectives of the scheme. The objectives of the Students Industrial Work
Experience Scheme (SIWES) are:

Provide an avenue for students in institutions of higher learning to acquire industrial
skills and experience during their courses of study;

Prepare students for industrial work situations that they are likely to meet after
graduation;

Expose students to work methods and techniques in handling equipment and
machinery that may not be available in their institutions;

Make the transition from school to the world of work easier and enhance students’
contacts for later job placements;

Provide students with the opportunities to apply their educational knowledge in real
work situations, thereby bridging the gap between theory and practice;
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Enlist and strengthen employers’ involvement in the entire educational process through
SIWES.
ABOUT INDUSTRIAL TRAINING I.T.F.
The objective for which the Fund was established has been pursued vigorously and
efficaciously. In the four decades of its existence, the ITF has not only raised training
consciousness in the economy, but has also helped in generating a corps of skilled indigenous
manpower which has been manning and managing various sectors of the national economy.
Over the years, pursuant to its statutory responsibility, the ITF has expanded its structures,
developed training programmes, reviewed its strategies, operations and services in order to
meet the expanding, and changing demands for skilled manpower in the economy
As part of its responsibilities, the ITF provides Direct Training, Vocational and Apprentice
Training, Research and Consultancy Service, Reimbursement of up to 50% Levy paid by
employers of labour registered with it, and administers the Students Industrial Work
Experience Scheme (SIWES). It also provides human resource development information and
training technology service to industry and commerce to enhance their manpower capacity
and in-house training delivery effort.
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CHAPTER TWO
COMPANY OVERVIEW
DATUMENERGY LIMITED (DNL) is a wholly indigenous engineering company
incorporated since 2003 to provide needed engineering services for Industrial and Oil & Gas
Companies
The company is comprised of highly experienced indigenous engineers of different
engineering disciplines. Experienced gained over the years of active engineering practice in
various companies is being put together to form a formidable corporate body to the best
advantage of our various clients. The merging of the expertise in their various fields has
allowed the development of an innovative Engineering culture providing our firm with
interesting areas of operation.
The company over the years has been very successful in possessing various types of
machinery’s in its workshop for use on various projects.
The permanent office located at 116, Ewu Road, Aviation Estate Lagos State. This office in
Lagos is presently the control center for all our activities Nationwide. While the workshop is
located within the perimeter-fenced office. It is at the back of administrative building. This
workshop in Lagos is presently the fabrication yard for all our activities. The workshop is
equipped to meet all fabrication, welding and insulation fabrication works.
DNL SERVICES

Oil & Gas and industrial pipes welding

Non Destructive Testing (NDT )

Insulation and cladding of industrial pipes and fittings

Cement Kiln installation and welding

Fire hydrant installation and pump sizing

TIG (argon) welding for stainless steel pipes

PRMS assembling and installation

Structural design, welding and construction

Civil work ( insitu casting, pre-casting and reinforcement)

Plant/storage Tank erection
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
Detailed engineering and front end design

Procurement (gas flow metre, diesel flow metre , regulators, filters, valves, PRMS, pipes,
etc.)

Pipeline Maintenance Services

Liquefied Petroleum Gas (LPG)

Compressed gas (nitrogen gas, acetylene, oxygen, argon gas, etc.)
VISION STATEMENT
“To be a leading operator in project management, engineering consulting services in the
industrial environment. We draw our strength from our experience, integrity, unique
packaging of service and excellence of the people we engage. We shall demonstrate our our
leadership position with great passion, rigour and total commitment to providing our
customers with concise solutions to their problems always meeting and exceeding, where
possible, customer’s need and expectations. ”
MISSION STATEMENT
To passionately provide engineering solutions that exceeds customers’ expectations. We shall
this through:



Building and developing well trained professionals that are proud of their work and
working environment and committed to continuous improvement.
Ensure that all employees are treated well, working as an “intelligent army”
Give future to our employees towards individual actualization.
QUALITY POLICY AND OBJECTIVES
QUALITY POLICY
DNL shall operate a quality Assurance system. We are keen on excellence to our
customer’s service deliverables which must consistently be of the highest quality
obtainable. We ensure that our customers’ needs are met and exceeded, where
possible demonstrating our professionalism and experience in our areas of operations.
We shall achieve this through:

Prompt provision of information

Priority attention to customers’ satisfaction, through articulated consideration
and customers’ needs and expectation.
4

Making everyone committed to attainable, define quality requirements.
Therefore, management shall create a conducive working environment for employees through
mutual trust, respect and love, teamwork, continuous improvement, compliance with national
and international standards recognition and celebration of individual or team achievements.
We will measure the efficiency of our activities and ability to meet our customer’s
requirements and expectations. Identify shortcomings and take necessary actions promptly.
Adequate communication interface with customers to identify complaints before they become
problems and most importantly, DATUMENERGY will treat our customers as partners in
our business.
QUALITY OBJECTIVES

Provide a service that consistently meets the needs and expectations of our customers
and indeed exceed them. Targets shall be compliance to regulatory and contractual
requirements.

To be seen and perceived by our customers as being better than the competition.

Achieving an optional level of employee satisfaction and competence and cooperation.

Targets shall be defined through periodic evaluation process

Delivering service with improved results as evident of continuous process
improvement activities

Ensure that all works are performed correctly at the first time for cost effectiveness
and efficiency.
HEALTH SAFETY AND ENVIRONMENT
Successfully managing HSE issues is an essential component of our business strategy through
the encouragement of our HSE policy and program. Our goal is to minimize impact to the
environment and prevent harm to those who could be affected by our operations. DNL is
solely committed to personnel safety; environmental safety, equipment safety, quality and
when these concerns are met objectives can be focused on profit. We take safety as our
priority.
…Safety first and safety always
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CHAPTER THREE
INDUSTRIAL TRAINING EXPERIENCE
During my industrial I worked in several departments/sections in the company where I was
trained, assisted and carried out several duties and assignments.
Basic Work activities and job assigned to me in the office and workshop:
 Preparation of waybills and moving materials to site
 Design and drafting of piping isometric drawings
 Acknowledgement of waybill and invoice from suppliers
 Taking inventory of materials and tools
 Assisting in office activities such as printing, photocopying and editing document
such as work permits, invoices and waybills
 Maintenance of workshop tools and machines
 Observation of all engineering related work going-on in the workshop.
 Identification and training on how to use different tools and equipment like wrench,
steel square, spirit level, grinding and cutting machines
 Carry out routine inspection of materials, tools and equipment.
I also visited and worked on different sites during my industrial training which include;
Josefdam Port Services,Apapa
VIK industries Ajao Estate
Reco plastics Ajao Estate
National Salt Company (NASCON) Allied Industries Plc. Apapa
NASCON Oregun Ikeja
Pardee Foods Nigeria Limited Sango-Otta
Fareast Mercantile Company Limited (FMCL) Mushin
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Ro-Manrong Nigeria Limited Amuwo Odofin Industrial Estate
Basic work activities in various site:
 Participated in site survey and drafting of piping isometric drawings piping
plan drawings and Piping and Instrumentation Diagrams(P&ID)

Moving of working tools and equipment’s(welding machine, extension box,
grinding machine measuring tape) on and off site

Delivery of materials to the site

Collection of site PTW( Permit-To-Work)

Participation in Nitrogen purging of pipelines

Installation of equipment like pressure gauges, gas filters, ball valves and
bolting of valves to flanges

Pneumatic pressure testing

Leakage test(bubble test)
I also worked on two different residential building acting as the supervisor and ensure all
plumbing works are done to standard.
PIPING SYSTEM
Piping includes pipe, flanges, fittings, bolting, gaskets, valves, and the pressure containing
portions of other piping components. It also includes pipe hangers and supports and other
items necessary to prevent over-pressurization and overstressing of the pressure-containing
components. It is evident that pipe is one element or a part of piping. Therefore, pipe sections
when joined with fittings, valves, and other mechanical equipment and properly supported by
hangers and supports, are called piping. Piping covers very large part of any process plant. If
you look at Oil Exploration platform, Refinery and Petrochemical complex one thing that
catches the attention is a complex network of piping. Piping is used to transport various
process materials from one equipment to another.
During my industrial training we fabricated different piping system like
 Water system(fire hydrant piping)
 natural gas piping system of different working pressure and pipe sizes
 Air compressor system piping system(stainless steel pipe and socket weld joint)
 Domestic plumbing.
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COMPONENTS OF PIPING SYSTEM
Piping components are mechanical elements suitable for joining or assembly into pressuretight fluid containing piping system.
Piping system components include:
 Pipes
 Fittings (e.g. elbows, reducers, branch connections, etc.)
 Flanges, gaskets and bolting
 Valves
 Instruments for pressure temperature and flow measurement
 Pipe supports
PIPES
Pipe is a straight pressure tight cylindrical hollow, used in the piping system to transport
liquid, gas and sometimes solids. A pipeline conveys a fluid from one given point of the plant
called inlet point of the line, to another part of the plant called outlets point of the line.
TYPES OF PIPES
Different types of pipes used in different design conditions, considering technical and
commercial parameters. Types of pipes include:
1. Seamless Pipe: Seamless pipe is Strongest amongst all pipes type as it has a
Homogenous structure throughout pipe length. It is manufactured in variety of size.
However, there is a Restriction on the manufacturing of large diameter pipe.
Throughout my Industrial training seamless pipe was used for the piping system I
worked with due to the working pressure of these piping systems. Different
manufacturing processes used for producing seamless pipes are milling, forging and
extrusion
2. Welded Pipe: Welded Pipes are manufactured from Plate or continues Coil or strips.
To manufactured welded pipe, first plate or coil is rolled in the circular section with
the help of plate bending machine or by a roller in the case of continues process. Once
the circular section is rolled from the plate, the pipe can be welded with or without
filler material. Welded pipe can be manufactured in large size without any upper
restriction. Welded pipe with filler material can be used in the manufacturing of long
radius bends and elbow. Welded pipes are cheaper with compared to the seamless
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pipe and also Weak due to the weld joint. There are different methods used to weld
pipes. Which are:
• ERW- Electric Resistance Welding
• EFW- Electric Fusion Welding
• HFW- High-frequency welding
• SAW- Submerged Arc Welding (Long seam & Spiral Seam)
PIPE SIZE AND DIMENSION
Pipe Dimensions are covered in following Standard


ASME B36.10 – Welded and Seamless Wrought Steel Pipe (Carbon & Alloy Steel)
ASME B36.19 – Stainless Steel Pipe
Three different terms are commonly used to define the size of the pipe.
1. NPS – Nominal Pipe Size: All American standard used NPS designation to define
pipe size. This is a modern derivation of earlier IPS – Iron Pipe Size. NPS is not
an OD or ID of the pipe it is in-between of the outer and the inner diameter of the
pipe. For example, NPS 2 size pipe outside diameter is 60 mm or 2.375 inches. In
general, NPS 12 and the smaller pipe has outside diameter greater than the size
and for NPS 14 and above size pipe outside diameter is the same as the size in
inches.
2. NB – Nominal Bore: This is the European equivalent of NPS. In this standard pipe
sizes are mentioned in millimeter
3. DN – Diameter nominal: This is the German equivalent of NPS. In this standard
also, pipe sizes are mentioned in millimeter
In the Table 1, you can see the correlation of size and OD (outside diameter).
Table 1: Correlation of size and outside diameter (OD)
PIPE THICKNESS - SCHEDULE NUMBER
Pipe Thickness are expressed in Schedule number. A schedule number is an approximate
value of the equation = 1000 P/S
Where; − P is the service pressure in (psi)
− S is the allowable stress in (psi)
9
Common carbon steel pipe schedule numbers are 5, 10, 20, 30, 40, 60, 80, 100, 120, 140,
160.Pipe Thickness are also expressed as STD, extra strong-XS, double extra strong-XXS.
Higher the schedule number, Higher the thickness of the pipe and smaller the inside diameter
of the pipe as outside diameter of each pipe size is standardized.
The thickness of stainless steel pipe is also expressed in Schedule number. Schedule number
with S suffix is as per ASME B36.19, and it is used with stainless steel pipe. There is only
four schedules are mentioned in ASME code which are 5S, 10S, 40S, 80S. So, please
remember schedule number 10 and 10S do not have the same thickness.
PIPE ENDS
Pipe comes in following 4 end types
1. Plain End – This kind of end used when socket type weld fittings are used.
2. Beveled End – This kind of end used when butt type weld fittings are used.
3. Threaded End – This kind of end used with threaded connections in piping system
4. Socket & Spigot – This type of end generally used in ductile iron pipeline and non-metallic
piping pipeline such as PVC, GRE/GRP.
PIPE FITTINGS
It is used to connect straight pipe or tubing sections, to adapt to different sizes or shapes, to
branch or re-direct the piping system and if necessary to provide a jointing method if two
dissimilar piping materials are used in the one system. Fittings for pipe and tubing are most
often made from the same base material as the pipe or tubing being connected, e.g., stainless
steel, steel, copper or plastic.
The images below show some common fittings that are used in piping systems.
Figure 1:Screwed stainless steel and Butt weld mild steel fittings
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Fittings are piping component which helps in changing the direction of the flow such as
elbows, tee, changing the size of the pipe such as reducers, reducing tees, Connect to
components together such as couplings and stop the flows such as Caps and plugs. The most
common type of pipe fittings are:
Elbow
A pipe fitting installed between two lengths of pipe or tube allowing a change of direction,
usually 90° or 45°. The ends may be machined for butt welding, threaded (usually female), or
socketed, etc. When the two ends differ in size, it is called a reducing or reducer elbow. Most
elbows are available in short radius or long radius of types. The short radius elbows have a
center to end distance equal to the nominal diameter, while the long radius is 1.5 times the
nominal diameter. Elbows used on powder transfer systems have a much longer radius
(radius of bend can be 10 times the nominal diameter of the pipe) to ensure smooth flow,
reduce wear to both product and piping and to reduce the chance of getting blockages. When
fluids are transported to long distances or go frequent directional changes, short radius
elbows are not recommended because of their greater friction loss, which may require
installation of larger pump or compressor.
Figure 2: 90° short radius and 45° Elbows
Tees
A Tee is used to either combine or split a fluid flow. There are different types of Tee used in
piping,
• Equal/Straight Tee– in this type of Tee, Diameter of Branch is same as the Diameter of the
Run Pipe
• In Reducing Tee – Diameter of the Branch size is smaller than the Diameter of the Run Pipe
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Figure 3: Reducing and Straight (Equal) Tees
Cross
A cross has one inlet and three outlets, or vice versa and like tees come in equal and reducing
forms and are also known as four-way fittings. A cross is more expensive than two tees but
has the advantage of reduced space and requires less labour to install. Generally, crosses are
not used in process piping to transport fluid. But forged crosses are common in fire water
sprinkler line.
Figure 4: Cross or Four ways fittings
Reducer
Reducers are used to join two different pipe sizes together. They can be either concentric or
eccentric which refers to the relative position of the center lines of the outlet and inlet. In
Concentric reducer, center of the both the ends are on same axis. It maintains the center line
elevation of pipe line. Whereas in Eccentric reducer, center of the both the ends are on
different axis as shown in image. It maintains BOP (bottom of pipe) elevation of pipe line.
Special attention must be given when using reducers in a horizontal orientation as the slope
will prevent free draining of a system if not installed correctly.
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Figure 5: Eccentric and Concentric Reducers
Pipe Caps
A type of pipe fitting which is liquid or gas tight, and is used to cover the end of a pipe. A cap
has a similar function to a plug. For screwed systems the cap would have female threads
where a plug would have male threads. Pipe caps are used at the dead end of the piping
system. It is also used in piping headers for future connections.
Figure 6: Pipe Cap and Hexagonal Head Plug
Stub ends
Stub ends are used with lap joint flange. In this type of flange, stub is butt welded with pipe,
whereas flange is freely move over the stub end.
Figure 7: Stub Ends
Unions
A union is similar to a coupling, except it is designed to allow quick and convenient
disconnection of pipes for maintenance or fixture replacement. While a coupling is usually a
permanent joint or requires the ability of being able to rotate all the pipe to one side of it to
unscrew it, a union provides a simple nut transition, allowing easy release at any time. When
using unions with dissimilar metals (such as copper and galvanized steel) a dielectric union
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should be used. This breaks the electric current with a plastic liner between two halves of the
union, thus limiting galvanic corrosion.
Figure 8: NPS 2 Union
Flanges Gaskets and Bolting
The flange is second most used joining method after welding. Flanges are used when joints
need dismantling. It provides flexibility for maintenance. Flange connects the pipe with
various equipment and valves. Breakup flanges are added in the pipeline system if regular
maintenance in required during plant operation. A flanged joint is composed of three separate
and independent although interrelated components; the flanges, the gaskets, and the bolting;
which are assembled by yet another influence, the fitter.
However, it is not advisable to used flange connection in underground piping when it
supposed to be buried. The flange is also a most common source of leak and fire in a process
plant. There are variety of flanges available to suit the standards and requirements. Flanges
can be classified in several alternate ways as follows:
1. Based on Types of Connection
2. Based on Flange facing Types
3. Based on Pressure Temperature Ratings
4. Based on Material Types
Types of Flange based on connection
Threaded Flanges
Threaded Flanges are also known as screwed flange, and it is having a thread inside the
flange bore which fits on the pipe with matching male thread on the pipe. This type of joint
connection is Speedy and simple but not suitable for high presser and temperature
applications. A screwed or threaded flange requires no welding and is used to connect other
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threaded components in low pressure non-critical applications and is mostly used in utility
services such as air and water.
Figure 9: Threaded Flanges
Socket-weld Flanges
Socket-Weld Flanges has a female socket in which pipe is fitted. A socket flange is counterbored to accept the pipe, then fillet welding is done from outside on the pipe. Generally, it is
used in small bore piping and only suitable for low pressure and temperature application.
Figure 10: Socket-Weld Flange
Slip-On Flanges
Slip-On flange has a hole with matching outside diameter of pipe from which pipe can “slip
in” (can pass). The flange is placed on pipe and fillet welded from both inside and outside.
Slip-On Flange is suitable for low pressure and temperature application. This type of flange is
available in large size also to connect big bore piping with storage tank nozzles. Normally,
these flanges are of forged construction and are provided with the hub. Sometimes, these
flanges are fabricated from plates and are not provided with the hub.
15
Figure 11: Slip-On Flange
Weld Neck Flange
Weld neck flanges are used in critical applications. These are circumferentially welded onto
the system at their necks which means that the integrity of the butt-welded area can easily be
examined by X-ray radiography. The bores of both pipe and flange match thus reducing
turbulence and erosion.
Lap Joint Flanges
Lap flange is having two components, a stub end, and a loose backing flange. Stub end is butt
welded to the pipe and Backing flange freely move over the pipe. This type of joint is easily
assembled and aligned, and it is favoured in low pressure applications. The backing flange
can be of different material than stub material and normally of the carbon steel to save the
cost. Lap flange is used where frequent dismantling is required, and space is constrained.
Figure 12: Lap Joint and Weld-Neck Flanges
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Blind Flanges
The blind flange is a blank disc with bolt hole. These types of flanges are used with another
type of flange to isolate the piping system or to terminate the piping as an end. Blind flanges
are also used as a manhole cover in the vessel. It is sometimes called a blanking flange; also
used for blanking off pipelines, valves and pumps and as an inspection cover.
Figure 13: Blind Flange
Types of flanges based on flange facing
Based on flange facing it can be further classified as:
Flat Face
As name suggest, flat face flange has a flat face. Flat face flanges are used when the counter
flanges are flat face. This condition occurs mainly on connection to Cast Iron equipment’s,
valves and specialties. Full face gasket is used when flat face flange is used.
Raised Face
Raised face flange has small portion around the bore is raised from the face. The gasket seat
on this raised face. The height of the raised face depends on the flange pressure temperature
rating that is known as a class of the flange. For 150# & 300# height of the raised face is 1/6”
and above 300# it is 1/4”. The inside bore circle type of gasket is used with raised face
flange.
RTJ Face
Ring joint type face flange has a specially designed grove in which metal gasket seat. This
type of flange is used in high pressure and temperature services.
17
Figure 14: Different Flange faces
Types of Flange based on Pressure-Temperature Class (Service Rating)
Flanges are classified as per their pressure-temperature ratings which are designated as 150#,
300#, 400#, 600#, 900#, 1500# and 2500#. Large diameter flanges that are 24” to 60” are
available up to 900# class. Pressure-temperature ratings are maximum allowable working
gage pressures in the bar & the temperatures in degrees Celsius. Higher the rating, heavier the
flange and can withstand higher pressure and temperature. When the temperature goes up, the
pressure goes down, and vice versa. Please note that different material has different pressure
ratings.
Types of Flange based on Material
Flanges are manufactured from
•Carbon steel
•Low alloy steel
•Stainless steel
•Or Combination of Exotic materials (Stub) and other backing materials
GASKET
A Gasket is sealing material placed between connecting Flanges to create a static seal, which
will maintain the leak-proof sealing in all operating conditions. Criteria for selecting gasket
depend on the piping system service condition and the fluid parameters which include:
• Temperature
• Pressure
• Corrosion resistance
• Types of fluid
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• Robustness
• Availability
• Cost
Types of Gasket
There are three types of gasket used in piping:
Non-Metallic
Metallic
Composite
Non-Metallic Gasket
These gaskets are also known as a Soft gasket, most common materials used for this type of
gaskets are Rubber, Teflon and Compressed Non-Asbestos Fiber (CNAF).Non-Metallic
gaskets can easily compress with low tension bolting and these types of gaskets are used with
low-pressure class flanged such as 150 or 300 Class and in low-temperature services. They
are not used in hydrocarbon services but are cheapest and easily available.
Metal Gasket
• Metal gaskets are manufactured from material such as Soft iron, Low Carbon steel,
Stainless Steel, Monel and Inconel
• These gaskets are also known as ring gasket or RTJ gaskets
• Metallic gaskets are used in high-pressure class flanges, normally above 900 Class, they can
also be used for high-temperature services.
• High tension bolting is required when we used metallic gaskets.
• They are Very robust &most costly
Composite Gasket
Composite gaskets are Combination of metal and non-metal material. Different types of
combination of materials are possible based on service requirement. Spiral wound, Metal
Jacketed, and cam-profile gasket are well known in composite gasket category. They can be
used in wide range of pressure and temperature services. These gaskets are cost effective with
compare to metal gaskets but careful handling is required.
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Figure 15: Gasket of different made of Materials
BOLTS
Bolts are used to assemble the piping system through the flanges. They are graded for tensile
strength which is affected by temperature and pressure ratings of the piping system.
Flange bolts
Two types of bolts are available for the assembly and tightening of flanges:
1. The machine bolt, which uses one nut
2. The stud bolt, which uses two nuts
Stud bolts have become the preferred method of bolting flanges. They offer the following
advantages.
● They can be removed easily (especially when corroded).
● They are not easily confused with other bolts used on site.
● They can be made from round stock.
● The bolt sizes required for flanged joints are readily available from manufacturers’ tables.
Figure 16: Machine Bolt, Stud and Nuts
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PROCEDURE FOR APPLICATION OF BOLT TORQUE ON FLANGED JOINTS
During my Industrial training I participate in connecting of flange joints; both flange to
flange joint and flange to valve or equipment joint. These are the following steps for the
application of bolt torque on flanged joints:
Step 1
Component parts must be aligned and clamped together with the hold down.
Step 2
Stud (or bolt) threads in area of nut (or forged ring) engagement should be lubricated. The
face of nuts (or bolt heads) should also be lubricated using a suitable lubricant.
Step 3
All bolts should be installed so that torqueing requirements can be followed.
Step 4
All bolts should be numbered so that torqueing requirements can be followed.
Step 5
Torque should be applied in 20% (1/5) steps of required final torque, with all bolts loaded at
each step before the next step is undertaken.
Step 6
Bolts should be tightened in sequential order: 0°–180°, 90°–225° and 135°–315° at each step
until final torque is reached. (See Figures on the next page.)
Step 7
Rotational tightening should be used until all bolts are stable at final torque level; two
complete times around are usually required.
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Figure 17: Bolt Torque Procedure
VALVES
Valves are mechanical devices that control the flow and pressure of fluid within a system or
process. Fluids do not just flow freely through piping systems. They must be regulated and at
certain points stopped. Valves may be operated manually, either by a hand wheel, or a lever
or operated automatically by a pneumatic actuator or electrical drive motor. Complex control
systems will use feedback from an instrument to control these types of valves to regulate
pressure, temperature or flowrate depending on the control parameters required.
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Types of Valves
Based on the mechanical or cyclical motion of the valve closure member, valves are
classified as follows:
Linear Motion Valves: The valves in which the closure member, as in gate, globe,
diaphragm, pinch, safety, relief and lift check valves, moves in a straight line to allow, stop,
or throttle the flow.
Rotary Motion Valves: When the valve-closure member travels along an angular or circular
path, as in butterfly, ball, plug, eccentric- and swing check valves, the valves are called rotary
motion valves.
Quarter Turn Valves: Some rotary motion valves require approximately a quarter turn,
0degree through 90 degree, motion of the stem to go to fully open from a fully closed
position or vice versa.
Some of the valves I participated in its procurement and installation are:
Gate Valves
Gate valves are primarily designed to serve as isolation valves. In service, these valves
generally are either fully open or fully closed. When fully open, the fluid or gas flows
through the valve in a straight line with very little resistance. Gate valves should not be used
in the regulation or throttling of flow because accurate control is not possible. Furthermore,
high-flow velocity in partially opened valves may cause erosion of the discs and seating
surfaces. Vibration may also result in chattering of the partially opened valve disc.
Advantages of Gate Valves
1. They have good shutoff characteristics.
2. They are bidirectional.
3. The pressure loss through the valve is minimal.
Disadvantages of Gate Valves
The following are some of the disadvantages of gate valves that must be considered when
selecting a gate valve for an application:
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1. Gate valves are not quick opening or closing valves. Full-stem travel to open or close a
gate valve requires many turns of its hand wheel or an actuator.
2. Gate valves require large space envelope for installation, operation, and maintenance.
3. Repair or machining of valve seats in place is difficult.
Ball Valve
A ball valve is a valve with a spherical centre which controls the flow through it. The sphere
has a hole, or port, through the middle so that when the port is in line with both ends of the
valve, flow will occur. When the valve is closed, the hole is perpendicular to the ends of the
valve, and flow is blocked. The handle or lever is also in-line with the port through the sphere
which allows the operator to know whether the valve is opened or closed. The ball valve is a
quarter-turn valve suitable for clean gas, compressed air, and liquid service.
Ball valves do not offer the fine control that may be necessary in throttling applications;
however they are durable and usually work to achieve perfect shutoff even after years of
disuse and are suitable for high pressures and temperatures.
Figure 18: NPS 1and NPS 2 Ball Valve
Butterfly Valve
The butterfly valve like the ball valve is part of the family of quarter turn valves, i.e. they
only require a quarter turn to achieve their fully open position. The butterfly valve can be
used for isolating or regulating flow. The closing mechanism takes the form of a disc whose
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position is again indicated by the position of the opening lever. Butterfly valves are generally
favored because they are lower in cost to other valve designs as well as being lighter in
weight, meaning less support is required. The disc is positioned in the center of the pipe, but
unlike a ball valve, the disc is always present within the flow, therefore a pressure drop is
always induced in the flow, regardless of valve position.
Figure 19: Butterfly Valve
Relief valve
Relief valves are used to prevent build-up of excessive pressure of gas or liquid in lines or
vessels. They usually operate against a pre-set spring loading. Relief valves for gas are
designed to permit a large flow; a small flow which will rapidly decrease pressure is usually
all that is required for liquids.
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PRESSURE GAUGE
Most pressure gauges in piping systems are based on the Bourdon gauge which was patented
in France in 1849 by Eugene Bourdon. The bourdon tube, which is a hollow metallic tube
sealed at one end, flexes when pressure is applied. It flexes because it naturally wants to
straighten out, but cannot because it is linked to a geared movement. As it tries to flex, this
linear movement is changed to a rotational one by means of small gears, this in-turn cause the
pointer to indicate the measured pressure. Gauges like this are designed for clean, nonclogging liquids and gases.
Figure 20: 0-40 bar Pressure Gauge
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NON-DESTRUCTIVE TESTING (NDT) OF PIPING SYSTEM
Non-Destructive Testing (NDT) is the process of inspecting, testing and evaluating materials,
components without destroying the serviceability of the part or system.NDT is concerned
with revealing flaws in the structure of a product. It, however, cannot predict where flaws
will develop due to the design itself.
All NDT methods have the following common characteristics:
(a) The application of a testing medium to the product to be tested.
(b) The changes in the testing medium due to the defects in the structure of the product.
(c) A means by which it detects these changes.
(d) Interpretation of these changes to obtain information about the flaws in the structure of
the product. The following are the NDT methods performed and participated during my
industrial training:
1. Hydrostatic Testing (Hydro-test)
2. Pneumatic Testing
3. Bubble Test
HYDROSTATIC TESTING OF PRESSURE PIPING SYSTEM
Hydrostatic testing of pressure piping is a mandatory activity before commissioning of any
new or modified piping system. It is the final check of mechanical integrity of the whole
system and should be followed religiously as after this activity the piping system has to be
commissioned. This test is carried out at a pressure 1.5 times higher than the design pressure
of a system regardless of the services condition of a piping system.
Test Procedure
1. All equipment and piping to be pressure tested should be thoroughly cleaned of all dirt,
welding slag, construction debris.
2. Equipment such as pressure gauges, Hydrotest pump, dead weight tester and other
connections like flanges, temporary spades and blank installed properly on the piping system.
3. Connections which serve as vent should be open during filling so that all air is completely
evacuated and tightened after filling.
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4. Drain point for fluid (water) disposal after testing should be provided.
5. Hydrostatic pump is then used to pump water, maintain pressure for 10 minutes and then
gradually increase pressure in the steps for one tenth of the pressure until the test pressure is
attained.
6. Recommended inspector walks into the whole pipe system and check for leaks. Every
single length of piping, welds, bolted, connection should be visually examined for any
leakage.
7. Although span for Hydrotest varies for layer piping system, the minimum allowable time
taken should be one hour for standard practice.
8. Any leakage from weld joint, piping base metal or other connections which requires repair
should be allowed after depressurizing the piping under test.
Pneumatic Leak Testing
The fluid normally used for a pneumatic test is compressed air, or nitrogen if the source is
bottled gas. Pneumatic tests are potentially more dangerous than hydrostatic because of the
higher level of potential energy.
Pneumatic tests may be performed only when at least one of the following conditions exists:

When pressure systems are so designed that they cannot be filled
with water.

When pressure systems are to be used in services where traces of
the testing medium cannot be tolerated.
Test Procedure
1. Ensures that the test gauge has a current calibration sticker. (A pressure relief valve or
non-reclosing relief device may be installed in the test medium supply line to ensure
that this limit is not exceeded.)
2. Verifies that the pressure is continually monitored to ensure that pressure never
exceeds the designated test pressure of the system
3. Pressurizes the system, raising pressure in the system gradually until not more than
half of the test pressure is achieved
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4. Increases the pressure slowly in steps of approximately 1/10 of the test pressure until
the required test pressure has been reached
5. Reduces the pressure to the maximum operating pressure before proceeding with the
inspection; holds the pressure for a sufficient period of time to permit inspection of
the system
6. Checks the pressure gauge periodically for indications of leakage
7. Applies a soap solution to accessible welds, screwed pipe joints, flanges, et cetera
where leakage is suspected
8. If there is evidence of structural distortion, either rejects the system or repairs as
advised by the inspector
9. If there is leakage in the system, performs the following as appropriate; Ensures repair
is performed and return to Step 3 or Rejects the system
10. When the test is completed, vents the test medium to approved discharge
vicinity/atmosphere
11. Completes pressure test record and submits copy to the pressure systems project
manager
Figure 21: The images above shows a session during pneumatic leakage test and piping
schematic for pneumatic testing
Bubble Test
Inspection for a leak is done with a soapy-water mixture that is applied to the joints and
which produces bubbles when air is escaping.
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FABRICATION AND INSTALLATION OF PIPING SYSTEM
Fabrication is the cutting, bending, forming, and welding of individual pipe components to
each other and their subsequent heat treatment and nondestructive examination (NDE) to
form a unit (piping subassembly) for installation.
Installation refers to the physical placement of piping subassemblies, valves, and other
specialty items in their required final location relative to pumps, heat exchangers, turbines,
generator, boilers, and other equipment; assembly thereto by welding or mechanical methods;
final NDE; heat treatment; leak testing; and cleaning and flushing of the completed
installation.
Pipe fabrication
Pipe fabrication involves assembling pieces such as elbows, tees and flanges into sections
which, along with the pipe and all other equipment, can be accurately fitted together into the
plant. Because of the cost and importance of such lines, pipe fabricators (fitters and welders)
must assemble and weld pipes together with a high degree of precision. This requires careful
thought and planning, accurate layout of work and control of welding operations as well as
the competent use of jigs, templates and other precision tools.
Fabricators (Fitters and Welders) Tools
During my industrial training I was able to use and maintain some fabricators tools such as
pipe wrench, welding machine, spirit level, chalk line, steel tape steel square grinder and pipe
cutter
Types of Pipe-Weld Joint
Butt Welds: The most common type of joint employed in the fabrication of welded pipe
systems is the circumferential butt joint. It is the most satisfactory joint from the standpoint of
stress distribution. Its general field of application is pipe to pipe, pipe to flange, pipe to valve,
and pipe to fitting joints. Butt joints may be used for all sizes, but fillet-welded joints can
often be used to advantage for pipe NPS 2 (DN 50) and smaller.
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Figure 22: Butt-Welded Joints
Fillet Welds: Circumferential fillet-welded joints are generally used for joining pipe to
socket joints in sizes NPS 2 (DN 50) and smaller. Figure A2.29 illustrates three typical filletwelded joints. These types of welds are subjected to shearing and bending stresses, and
adequate penetration of the pieces being joined is essential. This is particularly important
with the socket joint, since the danger of washing down the end of the hub may obscure, by
reason of fair appearance, the lack of a full and sound fillet weld. This condition is one which
cannot be detected in the finished weld by the usual visual inspection. Additionally, a 1/16-in
(1.5-mm) gap (before welding) must be maintained between the pipe end and the base of the
fitting to allow for differential expansion of the mating elements.
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Figure 23: Fillet Weld Joints of Air Compressor piping system
DRAWING
The main purpose of a technical drawing is to communicate fabrication requirements clearly
and simply. Before execution of project, there should be proper planning for the success of
the project. I participated in site survey and drafting of different drawing which are used for
fabrication and field erection.
To design process piping, five types of drawings are developed in sequence. These drawings
are developed from the schematics and specifications for process piping prepared by the
process engineer. In order of development, the sequence is as follows:
1. General Arrangement (GA)
2. Process Flow Diagram (PFD)
3. Piping and Instrumentation Diagram (P&ID)
4. Plot plan layout
5. Isometric drawings.
General Arrangement
The piping plan or general arrangement (GA) drawing shows all major equipment to scale, its
north/south and east/west orientation and all piping leading to and from the equipment. All
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instrumentation, access ladders and platforms are shown. The GA will usually show a plan
view (top) with elevations (side) and section elevations, as well as all pipe dimensions and
piping details including line numbers, size and specifications with the direction of flow noted
for all lines, so that the draftsperson will have all necessary information to create the final
fabrication drawings or isometrics.
Process Flow Diagram (PFD)
A process flow diagram (PFD) is an unscaled drawing or schematic which describes the
process of transferring material by piping.
It will:
● State, for example, the materials (fluid) to be conveyed by the piping
● Specify the rates of flow
● List the pumps required
● Provide information such as pressure or temperature. At this point the pipe sizes, types of
valves, etc., have not been determined. The PFD and specifications are then transferred to a
piping and instrumentation (P&ID) diagram, plot plan or isometric drawing.
Piping and Instrumentation Diagram (P&ID)
The P&ID is similar to, but more detailed than, a PFD. It is a single-line schematic drawing
that includes all major equipment items, instruments and controls, major valves and line
sizes, It contains all the data necessary for the various design groups involved in the project
to proceed to the next step in the design of the plant.
Plot plan
A plot plan or site plan is produced by the piping designer which shows schematic of the
whole site with boundaries, roads, buildings, plant areas, equipment layouts, utility runs, and
other constructions of the existing project, etc. at a properly defined scale. So it gives an
overview of the entire plant. This allows the piping engineer to arrange equipment to
optimize the design to reduce cost.
Piping Isometric Drawing
Piping Isometric drawings represent the pipe routing with proper dimensions including all
piping items and equipment. They are not to the scale, single line diagram with symbols for
pipe components, weld points, and supports. Isometric drawings are used:
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
By fabricator to fabricate the line.

By piping material group for purchasing materials

By the Construction team to erect the piping items in the site following proper
routing.
BELOW ARE SOME OF MY DRAWINGS I DRAFTED ON AUTOCAD
Figure 24: Piping Isometric Drawing
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Figure 25: Piping Isometric Drawing
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Figure 26: General Arrangement showing position of Fire Hose Box and Hose Reel in a
Production Floor
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PAINTING OF FABRICATED PIPING
Painting of piping and equipment’s as well as structures, is essential to avoid corrosion. It
helps ensure long life of a constructed plant and low maintenance costs. Painting involves not
only total surface cover but also markings of various types such as line numbers, fluid codes,
flow arrows, equipment numbers etc. I participated in painting of different piping system
such as natural gas piping and fire hydrant piping system.
Painting Workflow
1. Ensure all tests are performed on piping system before starting painting work.
2. Clean painting surface to remove oils, grease, dirt.
3. Ensure proper room temperature and humidity levels.
4. Use hand tools, scrapper, wire brush etc. to clean surface as per relevant standards and
project requirements.
5. Apply primer within 4 hours of surface preparation.
6. Apply paint coats after previous coats have dried up.
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CHAPTER FOUR
NEW SKILLS ACQUIRED AND CHALLENGES ENCOUNTERED
During my Industrial training I acquired new skills in different skill such as:
1. Safety (HSE) skills
2. Piping fabrication and Installation skills
3. Project management and Supervision skills
4. Tool maintenance
Safety (HSE) Skills: this include how to use a fire extinguisher, where a formal ‘Permit To
Work’ system is in force it must be complied with. Where there is no such system, it is
recommended that a responsible person should know what work is going on and, where
necessary, arrange to have an assistant whose primary responsibility is safety and proper
handling of fabrication tools to achieve zero hazards.
Piping fabrication and Installation skills: I can now tack weld, bolt flange Joint, assembly
and installation of equipment’s such as filters, pressure gauge, gas regulator and valve,
assembly of threaded fittings and valves.
Project management and Supervision Skills: The main function of the project management
includes effective communication, involvement of team in decision making and effective
information distribution. Also, the project management makes sure that things happen on
time and keeping the project on schedule.
The stages of managing a Project are:

Initiating the project

Planning the project

Executing the project

Monitoring and controlling the project

Closing the project
Tool maintenance: during my Industrial training I maintained some tools but limited to tools
such as grinding machine welding machine cutting machine etc. To maintain proper working
condition of tools, Good House Keeping is required by:
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
Clean the store tools properly.

Fix or report broken tools.

Store materials properly.

Clean and maintain machine properly.

Keep work place clean.
Maintain adequate lightening.
Challenges Encountered
During my Industrial Training, I experienced some challenges, which are;
a. Accommodation was a major challenge for me after securing an Industrial training
placement and caused me much inconvenience.
b. I also faced a major challenge in transporting myself to and fro office, I had to travel
over eighty kilometres and beat heavy gridlock which was stressful but I was
supported by the company which lessen the financial problem.
c. I was forced to stop work during the pandemic lockdown and I was home for two
months.
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CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS
In conclusion, I was offered an opportunity for industrial experience at Datumenergy Nigeria
Limited where I engaged in industrial activities that help shape my career development.
Beyond gaining industrial experience, I got adapted to the industrial work environment,
acquired both working and professional ethics and socialization.
Before and after completing my training experience, I realized that Datumenergy Nigeria
Limited is the best place for industrial training, especially for engineering undergraduates
who wishes to specialize as process and piping engineers, maintenance of pipelines and major
construction works including civil works (silo and concrete platforms construction)
fabrication and installation. I realized that I learnt lot new things that one would never be able
to learn at our universities academic environment. Also I was able to practice and understand
most things I learnt at the university as theory.
Equally, I was not left out during the inspection of piping system, Non-Destructive Testing
and bubble leakage testing of threaded joints and commissioning of piping system.
Finally, I can say I completed my Industrial Training successfully; I got lots of experience
and guidance of my future career.
RECOMMENDATION

I strongly recommend that there should be an improvement in the teaching of the
workshop practices courses where student will be allowed to use all the workshop
tools and machines.

The School authorities should set up a well-tailored programme towards developing
students’ career.

All Engineering students should be encouraged on the use of CAD software’s before
going on Industrial training.
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REFERENCES
https://siwesbeginner.com/siwes-introduction/
www.wikipedia.com
www.whatispiping.com
www.pipingdesigners.com
http://www.datumergy.ng
Piping Engineering Handbook –Mohinder L. Nayyar, P.E
Hardhat Piping Engineering Handbook –Varun Patel
Pipe Fabrication –Department of Training and workforce Development Australia
http://www-group.slac.stanford.edu/esh/eshmanual/references/pressureProcedTest.pdf
Trade of Pipefitting – Finbar Smith
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