1 Process Piping Construction Project Insight FROM STRAIGHT LENGTH & WAREHOUSE ITEMS TO PRESSURE ENVELOPE Note – this presentation is an informative knowledge sharing attempt only. Piping takes – Pressure, Temperature, Flow of fluids in different phases Courtesy - Lalit Mohan Nainwal 2 27-03-2020 What we will discuss and what will be left (other’s scope) 3 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 4 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 5 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 6 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 7 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 Courtesy - Lalit Mohan Nainwal 8 O Lets Courtesy - Lalit Mohan Nainwal 27-03-2020 9 Long Necks Courtesy - Lalit Mohan Nainwal 27-03-2020 10 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 11 ASME SECTIONS SECTION I - Rules for Construction of Power Boilers SECTION II - Materials – Part A Part B Part C Part D Ferrous Materials Non-Ferrous Materials Welding Rods, Electrodes and Filler Metal 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 12 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 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 Courtesy - Lalit Mohan Nainwal 13 27-03-2020 Piping Material Procurement & Spool Fabrication 14 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 15 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 Tag items - Control / Shut down / Valve 16 These items are specialties and designed Tag number items, can not be randomly used. Courtesy - Lalit Mohan Nainwal 27-03-2020 17 Tag items -Flow control items Courtesy - Lalit Mohan Nainwal 27-03-2020 Tag items – RO Restriction Orifice Courtesy - Lalit Mohan Nainwal 18 27-03-2020 19 Gaskets Courtesy - Lalit Mohan Nainwal 27-03-2020 20 Fasteners A careful selection is made according to service / Line class – majorly stud bolts one can see in process piping. Courtesy - Lalit Mohan Nainwal 27-03-2020 21 Expansion Joints Courtesy - Lalit Mohan Nainwal 27-03-2020 22 Sight Glass / Level Indicators Courtesy - Lalit Mohan Nainwal 27-03-2020 23 Indicators & Transmitters Courtesy - Lalit Mohan Nainwal 27-03-2020 24 Indicators & Transmitters Courtesy - Lalit Mohan Nainwal 27-03-2020 25 Ejectors & Injectors Courtesy - Lalit Mohan Nainwal 27-03-2020 26 Steam Traps The working philosophy of a trap is decided by design engineers on process requirements and suitable type of trap is used. Courtesy - Lalit Mohan Nainwal 27-03-2020 Strainers Courtesy - Lalit Mohan Nainwal 27 27-03-2020 28 Steam Vent Silencer Courtesy - Lalit Mohan Nainwal 27-03-2020 29 Flame arrestors Courtesy - Lalit Mohan Nainwal 27-03-2020 30 Thermowell Courtesy - Lalit Mohan Nainwal 27-03-2020 31 Mono-block Flange / DBB Courtesy - Lalit Mohan Nainwal 27-03-2020 32 Spectacle Blinds In slang few people refer it as Figure 8 blind Courtesy - Lalit Mohan Nainwal 27-03-2020 33 Venturi Flanged or butt-welded is according to process requirement Courtesy - Lalit Mohan Nainwal 27-03-2020 34 PSV / PRV Courtesy - Lalit Mohan Nainwal 27-03-2020 35 FW line Sprinklers (of various kind) Deluge Valves Hose Reels Items- industry specific Courtesy - Lalit Mohan Nainwal 27-03-2020 36 Piping GADs Courtesy - Lalit Mohan Nainwal 27-03-2020 37 P&ID Courtesy - Lalit Mohan Nainwal 27-03-2020 38 Piping isometric drawing Courtesy - Lalit Mohan Nainwal 27-03-2020 39 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) Courtesy - Lalit Mohan Nainwal 27-03-2020 40 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 41 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) Courtesy - Lalit Mohan Nainwal 27-03-2020 42 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 43 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 ? Courtesy - Lalit Mohan Nainwal 27-03-2020 Getting Fabrication of Spool started 44 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 Getting Fabrication of Spool started 45 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 Getting Fabrication of Spool started 46 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 / Tackwelders / Production Welders available (Scaffolders also if at site) Courtesy - Lalit Mohan Nainwal 27-03-2020 Piping Erection / Installation (Pipe Rack / ISBL / OSBL) 47 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 Piping Erection / Installation (Pipe Rack / ISBL / OSBL) 48 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 Completing a Hydro/ Pneumatic Test pack 49 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? Courtesy - Lalit Mohan Nainwal 27-03-2020 Minimum documents in a Test Pack 50 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 Minimum documents in a Test Pack 51 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 52 Testing - Courtesy - Lalit Mohan Nainwal 27-03-2020 53 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 54 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. Courtesy - Lalit Mohan Nainwal 27-03-2020 55 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 56 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 Courtesy - Lalit Mohan Nainwal 27-03-2020 All the above now is called complete Pressure Envelope THANK YOU 57 Note – this presentation is an informative knowledge sharing attempt only. Courtesy - Lalit Mohan Nainwal 27-03-2020 Appreciate that you reached here. WORK SAFE – KEEP LEARNING Courtesy - Lalit Mohan Nainwal 58 27-03-2020
0
advertisement
Download
advertisement
Add this document to collection(s)
You can add this document to your study collection(s)
Sign in Available only to authorized usersAdd this document to saved
You can add this document to your saved list
Sign in Available only to authorized users