Piping Engineering Tutorial

© 2015 – Hervé Baron

HERVE BARON

Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Piping Engineering discipline.

Comments are most welcome ([email protected]), which I will incorporate for the benefit of all.

Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.

Hervé


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Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION

ELECTRICAL


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Process design

PFDs

H&M balance

Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

P&IDs

Piping

Instrumentation

Layout

Civil

Electrical

Process data sheet

Equipment specification

Vendor drawings

We are here


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Piping discipline

Plant Layout & Piping discipline

Plant Layout Piping installation

Piping materials

Piping stress analysis


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Piping installation

Unit Plot Plan Line diagram

Presenter

Presentation Notes

Piping line diagrams show line routes. They allow to comfort/revise the plot plan, size the pipe-racks.


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Piping study & layouts

Line diagram

Piping layout

Presenter

Presentation Notes

Piping line diagrams are split in zone. A designer is assigned to perform piping studies for each zone. These are 1:50 scale drawings showing routing of main lines, typ. 8 inch and above. They also yield guide drawings for vessels.�Once these studies are completed 3D modeling starts.


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Piping study

Presenter

Presentation Notes

Also called Planning study Largest pipes are located on the sides of pipe-racks, smaller ones in the middle Pipes exit the pipe-rack by changing level to allow for future pipes to be added on the pipe-rack


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Piping study Requirements from Process

Presenter

Presentation Notes

In particular PSVs and BDVs shall be located at high points, with line sloped towards vessel and towards Flare KO drum.


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Piping routing/provision for flexibility


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Piping layout

Important considerations for piping layouts: Operator access to: • Valves • Instruments


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Piping Routing


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Piping layout

Important considerations for piping layouts: Operator access to: • Valves • Instruments

Straight pipe lengths upstream & downstream flow meters Straight pipe lengths upstream & downstream control valves PSVs and BDVs located at high points with slopes on both side lines Safe location of vents

Presenter

Presentation Notes

Minimum straight pipe lengths Flow meter: 15D mini upstream – 5D mini downstream Control valves: 5 D mini upstream / 5D mini downstream Continuous vents discharging hazardous materials must be located at elevation of min. 3 meter above any platform located within 20 meters. For intermittent vents discharging hazardous materials this is reduced to 10 meters. Vents discharging non-hazardous materials must be directed away from personnel. PSVs and BDVs shall be located at high points, with line sloped towards vessel and towards Flare KO drum.


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Piping design basis

The Piping design basis, also called “Job specification for design – Piping”, modifies and supplements to design code (AME B31.3) Contents include • Provisions for future • Clearance • Valve accessibility


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Piping design basis

The Piping design basis, also called “Job specification for design – Piping”, modifies and supplements to design code (AME B31.3) Contents include • Provisions for future, e.g., spare space on pipe-racks and sleeper ways • Clearance • Valve accessibility


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Piping design basis

The Piping design basis, also called “Job specification for design – Piping”, modifies and supplements to design code (AME B31.3) Contents include • Provisions for future • Clearance • Valve accessibility


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Piping Layout/3D model

Piping layout

Presenter

Presentation Notes

Notes on P&ID like no pocket/free draining determine the routing Also, instr rqts such as 7d/3d upstream/downstream lengths


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Piping modelling in 3D model


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Second model review: When 60% of the piping is modelled, i.e., all 4 ̋ and larger indicated on P&IDs Aspects reviewed: location of individual items (valves, instruments, junction boxes, panels), arrangement around all equipment, location of fire fighting equipment, confirm space around equipment for maintenance based on vendor requirements, handling equipment (hoist/davit), platforms for all accesses required for operation Third model review: When 90% of Piping is modelled, i.e., all 2" and larger as indicated on P&IDs Allows to start ISOs production after implementation of comments raised. Aspects reviewed: accesses to all remaining items (flanged joints etc.), location of remaining items (utility stations etc.).

3D model reviews


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Piping drawing extraction


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Isometric drawings

Presenter

Presentation Notes

The Iso contains the bill of materials


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Isometric drawings

Presenter

Presentation Notes

Each item is identified by means of short identification code


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Isometric drawings

What checks would you do before issuing an isometric drawing?


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Isometric drawings

Presenter

Presentation Notes

Each item is identified by means of short identification code


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Piping Isometric


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Piping design iso vs Shop iso


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Post weld heat treatment

Presenter

Presentation Notes

Required above 19mm as per ASME B31.3, and for wet H2S service


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When is PWHT applied?

Presenter

Presentation Notes



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When is PWHT applied? For sour service (NACE) and above 19mm w.t. (B31.3)

Presenter

Presentation Notes



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Piping inspection and testing

How is the % of welds to be RT defined?


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Piping NDE

ANSI B31.3 Requirements:

Extent of RT/US (for circumferential welds) shall be as follows, or to any greater extent specified in the engineering design: • Normal Fluid Service – 5%, random selection to cover work of

each welder • Category D fluid – Visual only • Severe Cyclic Conditions – 100%

States that supplementary examinations and any acceptance criteria that differs shall be specified in the engineering design

Therefore ASME B31.3 gives minimum requirements and Client shall include in Design Basis a specification for higher inspection requirements (see example that follows)


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Piping NDE





Therefore ASME B31.3 gives minimum requirements and Client shall include in Design Basis a specification for higher inspection requirements (see example that follows). On what criteria will they be based?

Presenter

Presentation Notes

Service: Process > Utility Pressure level: =< 600 lbs, > 600lbs


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Piping NDE





Therefore ASME B31.3 gives minimum requirements and Client shall include in Design Basis a specification for higher inspection requirements (see example that follows). On what criteria will they be based? Service + pressure class

Presenter

Presentation Notes

Service: Process > Utility Pressure level: =< 600 lbs, > 600lbs


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Piping NDE

Presenter

Presentation Notes

JSM – Piping NDE


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Piping general arrangement drawing


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Piping Hydrotest


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Piping Hydrotest

ASME B31.3 requires:

Hydrostatic leak test at 1.5 times the design pressure

If Owner considers that hydrostatic leak test is impracticable, a pneumatic test may be substituted

At the Owner’s option, a service test can be done in lieu of hydrostatic leak test for category D fluids, i.e., • Nonflammable, non toxic and • Design Pressure < 10 barg

For which fluids is it common to do a service test?

Presenter

Presentation Notes

Air, fuel gas, nitrogen


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Piping Hydrotest




At the Owner’s option, a service test can be done in lieu of hydrostatic leak test for category D fluids, i.e., • Nonflammable, non toxic • Design Pressure < 10 barg

What does ASME B31.3 says about « golden » welds?

Presenter

Presentation Notes

345.2.3 Special provisions for testing (c) Closure welds. The final weld connecting piping systems which have been successfully tested need not be tested provided the weld passes with 100% RT or US.


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Piping Hydrotest




At the Owner’s option, a service test can be done in lieu of hydrostatic leak test for category D fluids, i.e., • Nonflammable, non toxic • Design Pressure < 10 barg

Closure welds. The final weld connecting piping systems which have been successfully tested need not be tested provided the weld passes with 100% RT or US.

Presenter

Presentation Notes

345.2.3 Special provisions for testing (c) Closure welds. The final weld connecting piping systems which have been successfully tested need not be tested provided the weld passes with 100% RT or US.


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Piping installation work process

Plot Plan Line Diagram

Piping Layout 3D model Isometric

drawing


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Piping discipline



Piping materials



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Which calculations are done for Piping?

Presenter

Presentation Notes

Internal pressure: determination of the wall thickness Internal pressure (end effect) + thermal expansion: confirmation of the routing


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By how much does a 10 meter long carbon steel line expand when its temperature increases by 100°C?

Presenter

Presentation Notes

1cm


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Piping Flexibility and Stress Analysis Criteria

Not all lines are subject to calculation for stress. This is defined in the “Piping Flexibility and Stress Analysis Criteria”.


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Not all lines are subject to calculation for stress. This is defined in the “Piping Flexibility and Stress Analysis Criteria”. Level 1 : Visual Analysis No stress analysis is required. The piping lines are routed and supported by piping designers as per usual practice. Level 2: Simplified Analysis This method includes the use of charts, cantilever method or simplified formulae. Level 3: Detailed analysis Detailed analysis by computer program shall be carried out.


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Not all lines are subject to calculation for stress. This is defined in the “Piping Flexibility and Stress Analysis Criteria”. Level 1 : Visual Analysis No stress analysis is required. The piping lines are routed and supported by piping designers as per usual practice. Level 2: Simplified Analysis This method includes the use of charts, cantilever method or simplified formulae. Level 3: Detailed analysis Detailed analysis by computer program shall be carried out. On which basis is the category of a line decided?


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• Line temperature • Line diameter

Level 1 : Visual Analysis Level 2: Simplified Analysis Level 3: Detailed analysis

PIPING LINE TYPECONNECTION TYPE

A

FAT: FLEXIBILITY ANALYSIS TEMPERATURE (°C) (Note 9)Amb Tref: 20°C

(Note 9)FAT (°C)

PIPE SIZE (INCHES)

Non-fragile equipment and/or low movements (<600#)

Carbon steel(Note 7)

0

100

200

300

4002 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"

Level 3Level 2

Level 1


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• Line temperature • Line diameter • Criticality of equipment


D

Rotating machinesPlate exchangers

Cold boxes - Air coolerTurbine -Furnace

(Note 10)

0100200300400

2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"

Level 3

Level 2Level 1


A


(Note 9)FAT (°C)

PIPE SIZE (INCHES)



0

100

200

300

4002 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"

Level 3Level 2

Level 1


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A


(Note 9)FAT (°C)

PIPE SIZE (INCHES)



0

100

200

300

4002 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"

Level 3Level 2

Level 1

• Line temperature • Line diameter • Criticality of equipment • Material


B


Stainless steel(Note 7) - (Note 10)

0

100

200

300

4002 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"

Level 3

Level 2Level 1


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Piping stress analysis Calculation note


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Piping loads studies


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Piping Supports


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Pipe support book


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Piping Support Book


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Pipe support standard


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Piping Support Book


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Special supports


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Spring supports


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Design of line supports

Besides critical lines, the support of some other lines has to be studied. This is the case for: • Lines subject to water hammer (also called surge)

• Lines subject to 2 phase flow

• Lines subject to flow or accoustic vibration


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What type of lines are subject to water hammer?

Presenter

Presentation Notes

Lines identified by Process: list of lines subject to hammer + loads


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What type of lines are subject to water hammer? What is the work process for such lines?

Presenter

Presentation Notes

Process identifies the lines subject to water hammer and pressure/time curves to Stress for detailed pipe stress analysis


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How and by whom are 2 phase flow lines identified?

Presenter

Presentation Notes

Identified by Process and indicated on P&IDs


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What type of lines are subject to accoustic vibration?

Presenter

Presentation Notes

Lines downstream of pressure relieving devices.


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What type of lines are subject to accoustic vibration? What special design features are incorporated for these lines?

Presenter

Presentation Notes

Increase line thickness in special areas, such as at welded tees etc. to prevent failure.


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Piping line diagram

Plot Plan

Piping studies & layout

Piping 3D modelling


Piping isometric drawing

Stress OK?

Piping isometric drawing IFC

Sometimes, another check is done. Which one?


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Piping line diagram

Plot Plan

Piping studies & layout

Piping 3D modelling

Piping isometric drawing

Stress OK?

Piping isometric drawing IFC

Process OK?


Presenter

Presentation Notes

This check is a hydraulic check. It is done for lines whose pressure drop must be checked, e.g., PSV impulse lines, line at suction of pumps.


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Piping discipline



Piping materials



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Piping discipline



Piping materials


Materials/corrosion, insulation, painting


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Piping Material: line pipe, fittings


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Material selection Selection of steel based on design temperature

Low temperature

» down to -29°C CS » -29°C to -46°C LTCS » -59°C to -101°C 3 ½ Nickel » -101°C to -195°C 9 Nickel » -195°C to -254°C SS 304, 316, 321, 304L, 316L

High temperature

» up to 427°C CS » up to 593°C Cr-Mo (typ. 1.25-0.5) Alloy CS » up to 816°C SS 304H, 316H, 321H

1100- 425°F - 20- 40- 100- 150- 325 100

STEEL TEMPERATURE RANGE Based on ASME B31.3 edition 2004

- 50 1000800700650 1500°F13501200

- 254°C

- 198 - 101 - 73 - 46 - 40 - 29 37,8 343 650 732 816°C371 427 538 593

Presenter

Presentation Notes

304: 18 Cr 8 Ni 316: 16 Cr 12 Ni 2 Mo 321: 18 Cr 11 Ni 2 Mn Ti 0.15. Titanium-bearing, austenitic, chromium-nickel steel.


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Material selection Case study: Oil & Gas production facility


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Material Selection Corrosion and Material Selection Report


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Material Selection and corrosion control specification (pipes)

FLUID TYPE

STREAM NUMBER

COMPOSITION

Op. T.

(°C)

Des. T (°C)

Op. P (barg)

Des. P (barg) MATERIAL SELECTION COMMENT

Barren Solution

K41, AA01, AA02

5-15g/L H2SO4 0.9 g/L Cl- pH ≤ 1

35 47 (80) 5.9 9.8 HDPE / GRP

The design temperature of 80°C is only expected when the line is empty; in presence of flowing liquid the design temperature is 47°C.

Concentrated Sulphuric Acid

AM05, AA03, AA04

98.5wt% H2SO4 35 80 5.4 9.3 High Silicon SS

Refer to 9806J-0000-JSD-2400-003 For safety consideration High Silicon SS selection preferred to CS.

Process Water

V23, AA08, AA09

Process Water 35 47

(80) 0 0 HDPE

The design temperature of 80°C is only expected when the line is empty; in presence of flowing liquid the design temperature is 47°C.

Air - Air + Ore dust 35 80 Atm. Atm. CS + 1.5mm CA To filtration

- Air 35 80 Atm. Atm. CS + 1.5mm CA To atmosphere


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Material Selection and corrosion control specification (equipment)


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Material selection Material Selection Diagrams


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Sour service

What is Sour service?


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Sour service

What is Sour service?

Fluids containing water + a certain amount of H2S

The concentration of H2S above which the service is considered sour is specified in NACE MR0175 for Upstream (oil & gas production) applications and in NACE MR0103 for Downstream (Refinery) applications.

Presenter

Presentation Notes

Sour service: Equipment/piping is considered in sour service when it handles fluids containing water with H2S present or wet gas where H2S is present. Sour service occurs above a certain concentration of H2S in presence of liquid water. The concentration of H2S above which the service is considered sour is specified in NACE MR0175 for Upstream (oil & gas production) applications and in NACE MR0103 for Downstream (Refinery) applications. Sour service conditions start at lower concentration of H2S in Downstream facilities due to the presence of constituents in the aqueous phase which increases the pH, H2S solubility and corrosivity. Upstream sour service conditions start from 0.05 PSIA H2S partial pressure AND total pressure above 65 PSIA (for gas) resp. 265 PSIA for mixed phase. Downstream sour services conditions start from 0.05 PSIA H2S partial pressure whatever the total pressure.


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Sour service

What happens to materials subject to Sour service?


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Sour service


Phenomenon: Presence of H2S in the aqueous solution causes the steel to absorb a large amount of H2. The steel is subject to cracking above a critical concentration of hydrogen absorbed. This cracking is called Sulfide Stress Cracking (SSC).

The possible loss of containment resulting from this cracking causes a particularly severe hazard as H2S is fatal in minutes.


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Sour service




How to avoid this?


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Sour service




How to avoid this?

Apply requirements of NACE: Base materials: chemical composition, max hardness, heat

treatment Welds: limit hardness by PWHT

Presenter

Presentation Notes

Note that cracking is not, like corrosion, a phenomenon that develops over time. Hence sour service shall be specified for materials event if they are only subject to sour servcie during upset conditions.


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Piping discipline



Piping materials



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Piping Material Classes Specification

Piping fluids list


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Piping material class specification


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Piping material Wall thickness calculation

Design code for Process plants: ASME B31.3

)(

PY 2SWED * Pt+

=

P design pressure D (outside) diameter S stress value for material as per table in ASME B31.3 W weld joint reduction factor – for long term strength of weld at elevated temperature E quality factor, from table in ASME B31.3 (1 for seamless, 0.85 for ER welded pipe, etc.) Y coefficient from table in ASME B31.3 (from 0.4 to 0.7 depending on material and temperature)

To the above calculated thickness shall be added: - The corrosion allowance, e.g., 3 mm - The manufacturing tolerance: 12.5%

Presenter

Presentation Notes

T and D of same unit P and S of same unit


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Piping material class specification ASME B16.5 Flanges


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Piping material requisition

The Piping MTO is issued 3 times as a minimum: 1st MTO: issued for Inquiry, to get the Unit prices 2nd MTO: issued for Order 3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared?


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO:


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available) 2nd MTO


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available) 2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part)

How are Quantities to purchase (BOM) obtained from the MTO quantities?


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Material Take-Off’s

Piping installation

Piping material

MTO

Material Requisition P&IDs

Piping routing /

layout

Bill of Materials

+ Estimates of what is not taken-off

+ Allowances for cut & losses

MTO quantities

- Uncertain items

+ Allowances for design development

Piping specifications

Presenter

Presentation Notes

The quantities to be supplied – called the Bill Of Materials - are derived from the MTO by taking into account commercially available lengths, e.g., pipe straight length of 6 meters by adding allowances for extra length for adjustments, losses, etc.


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available) 2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part) 3rd and subsequent MTOs


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On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO prepared? 1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available) 2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part) 3rd and subsequent MTO: (IFC P&IDs) + isometrics (3D model)


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Piping Material Management Above ground Piping

2nd MTO (for order)

1st MTO

(for inquiry)

3rd MTO (top-up’s)

Piping Material Take-Off’s

IFR IFD IFC P&ID

Piping routing drawings

Piping layout drawings

Piping isometric drawings

Drawing


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Piping Material Management Above ground Piping

Plot Plan Line Diagram

Piping Layout 3D model Isometric

drawing

1st PO RFQ Final qties


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Piping Bill Of Materials

- Ordered qties (MTO 2)

Final qties (from IFC isos)

= additional qties to supply

Presenter

Presentation Notes

The MR is revised with final qties


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Material Requisition

Presenter

Presentation Notes

Each piping item is assigned an identification code « Sigma code » in the Piping manterial management system. The same codes may be used for different projects by an EPC contractor in order to re-use surplus material from one to the other.


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Piping Engineering Tutorial

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