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