WELCOME TO THE SESSION

ON

PIPING
 PIPING

DESIGN & ENGINEERING

PROCUREMENT
FABRICATION

ERECTION & ALIGNMENT

HYDROTESTING & DRYING

PRE-COMMISSIONING
 PIPING
DESIGN & ENGINEERING

1. FLOW DIAGRAMS
2. P & ID

3. PIPING LAYOUT

4. ISOMETRIC DRAWING

5. PIPING SUPPORT DRAWING

 PIPING

FLOW DIAGRAMS

1. Schematic Flow Diagrams

A. Block Diagram

B. Process Flow Diagram

C. Graphic Flow Diagram

 PIPING
1. Schematic Flow Diagrams

Individualistic in Nature

Explains the process

 PIPING
A. Block Diagrams
Used in early stages of process studies.

Working pattern for process put down with rectangular

boxes inserting physical or chemical operation
 PIPING
B. Process Flow Diagrams
Process and operations are apparent

Shows Equipment's selected to carry out the process.

Only Essential instrumentation is shown.

Temperature, Pressure, Flow and concentration at significant

points shown.

Starting point for Design Engineer to Design

 PIPING
C. Graphic Flow Diagrams.
Frequently used for advertising and Technical reports.
Emphasis on certain features in eye catching manner.
 PIPING
Engineering Flow Diagram (EFD)

Preplanned in advanced stage of Design

A. Detailed Equipment Flow Diagram.

B. Instrumentation Diagram

C. Piping & Instrumentation Diagram

 PIPING
Engineering Flow Diagram (EFD)

A. Detailed Equipment Flow Diagram includes

1. Process Piping.

2. Valves

3. By passes

4. Vents & drains

5. Process Equipment's Including Stand by

 PIPING

Equipment resembles actual shape.

Simple elevation views with all connections shown.

Nozzles with approximate locations shown but not to scale

Vessels - Major Dimensions & Special features included

Heat exchangers
Service
Duty

Heat transfer area

Temperature at Inlet & Outlet

Design conditions
Pumps
Service
Size & Type

Design flow & Head

NPSH (Net Positive Suction Head)

Operating Temperature

Power Requirement

Type of power
Piping & Valves:-

All process line and utility lines serving process equipment's.

Main Process lines are shown thick.

Utility lines drawn of different thickness.

Lines crossing shown by a break or bridge

Valves identification by No & symbol.

Instrumentation Diagram:-
Determines the requirement of process control instruments.

Clearly shows instruments for controlling, recording and indicating

plant operations.

Standard instrument symbols used for representing instruments.

Piping & Instrumentation Diagram:-
Combination of detailed equipment Flow diagram and
instrumentation Diagram.

Central source of information to design group.

All important information are included

Numbering schemes adopted for identification of equipment &

Piping

It also shows various instruments, valves etc used in the system

P - Pumps

K,e - Compressors.
E, Hx - Heat Exchangers
C - Condensers
RB - Reboilers
R - Reactors.

T,St - Storage Tanks

T - Towers
V - Vessels
Pipe Lines:-
From one equipment to another is identified by different number.

Line No. changes whenever specification/ size changes

Number of deleted lines are never assigned to other lines

Line No. includes :- Size, System or utility, area/section it is located.

Valves:- Type, Size, Specification shown

Instruments:- System, utility, nomenclature of instrument shown.

 TYPES OF VALVES

1. Gate Valve

2. Globe Valve

3. Plug Valve

4. Diaphragm Valve

5. Check valve

6. Reheat Valve

7. Ball Valve
 GATE VALVES
• Gate valves are also known as knife valves or slide valves.
• Are linear motion valves in which a flat closure element slides into the flow stream to provide shut-off.
• The valves are designed to minimize pressure drop across the valve in the fully opened position and stop
the flow of fluid completely. 
• The direction of fluid flow does not change, and the diameter through which the process fluid passes is
essentially equal to that of the pipe.
• Hence, they tend to have minimal pressure drop when opened fully.
• Gate valves are usually divided into two types: parallel and wedge-shaped.
•The parallel gate valve uses a flat disc gate between two parallel seats, upstream and downstream.
• Wedge-shaped gate valves and knife valves use two inclined seats and a slightly mismatched
inclined gate allowing for tight shut-off

USES:
• Gate valves are advantageous in applications involving slurries, as their “gates” can cut right through the
slurry.
•  They are also used in applications that involve viscous liquids such as heavy oils, light grease,etc.& other
non-flammable viscous liquids.
•  They are available in large sizes to better handle thick flow.  
• However, gate valves do have low-pressure limitations, and are not optimal in applications that require
cleanliness or sanitary conditions.
•  They are excellent for use anywhere a shutoff valve is needed.
• They can also be used where throttling capabilities are desired, although this is not generally
recommended as erosion of the seat and disc occurs due to the vibrations of the disk in throttling
applications.

 
. 
 GLOBE VALVES
• Globe valves are linear motion valves with rounded bodies, from which their name is derived.
•. Globe valves consist of the following moving parts – the disk, the valve stem, and the handwheel. The stem
connects the handwheel and the disk. It is threaded and fits into the threads in the valve bonnet. 
• The location of the valve disk in relation to the valve seat allows or restricts flow. 
• The direction of fluid flow through the valve changes several times, which increases the pressure drop across
the valve.
• In most cases, globe valves are installed with the stem vertical and the higher-pressure fluid stream connected
to the pipe side above the disk, which helps to maintain a tight seal when the valve is fully closed.
• When globe valves are open, the fluid flows through the space between the edge of the disk and the seat.
• Globe valves are available in three main body types: angle design, Y-design and multi-piece design.
•  Angle valves are designed so that the inlet and outlet are perpendicular, for transferring flow from vertical
to horizontal.
•  Y-design valves derive linear action from the incline between the axis of the inlet and outlet ports. 
• The bodies of multi-piece design valves are bolted together.  The inlet and outlet are not of single piece
construction. 

USES:
• They are widely used in industry to regulate fluid flow in both on/off and throttling service
• These valves are commonly used as a fully open or fully closed on/off valves.
• They may be used for throttling as long as fine adjustments are not required.
• These linear motion valves can be used in a variety of applications as long as the pressure and temperature
limits are not exceeded.
• Globe valves provide the following advantages: they offer precise throttling and control and have high-pressure
limits.
• Conversely, they offer a low coefficient of flow and are not good selections in applications that require
cleanliness or sterility.
BALL VALVE
 BALL VALVES

• Ball valves are quarter-turn, straight through flow valves that have a round
closure element with matching rounded seats that permit uniform sealing
stress.
• The type of seat can vary with the valve pressure rating and materials of
construction.
•  Some valve seats are composed of single molded forms, while other seats
with higher-pressure ratings often incorporate a trunnion design where each
face of the ball is separately sealed. 
• Ball valves are available in a variety of body styles, including one-piece,
two-piece, three-piece and flanged body construction. 
• Each of these ball valve forms offers specific advantages depending upon
the requirements of the given application. 
• Similarly, they are designed using a wide variety of materials, as required
by their application. 
• Common ball valve materials include brass, bronze, copper, cast iron,
ductile iron, stainless and other steel types, metal alloys and plastics
including PVC and CPVC.
 BALL VALVES

USES
• Ball valves are used in situations where tight shut-off is required.
• They are wide duty valves, able to transfer gases, liquids and liquids with
suspended solids (slurries).
• In general, ball valves offer many advantages when contrasted with other
valve types.
• They provide superior ease of operation and can maintain and regulate
high volume, high pressure and high temperature flow.
•  Most ball valves offer rugged construction providing for a long service life,
and a comparably low cost. 
• The design of the regulating element allows the valve to function without
the complications of side loads, typical of butterfly or globe valves, and the
valve design permits inspection and repair of seats and seals without
removing the valves’ body from the line.

 
Standards & specifications for Pipes,
Pipe Fittings and Flanges

ASME
ANSI

ASTM

API

DIN

TEMA

BS
IS
 PLANT LAYOUT

1. Space requirements to be known for products & by products

Raw material, Process equipment's.

2. Schematic Flow Pattern

3. Future Expansion Program

4. Weather condition

5. Building code requirement

6. Waste disposal

7. Govt.. Regulations
 PLANT LAYOUT

Equipment Layout

Civil Foundations & Buildings

Piping Layout

Electrical Drawings

Instrumentation drawing
 PIPING LAYOUT

A. P & ID

B. Project Piping Specification

C. Equipment outline drawing

D. Project general arrangement / equipment locations

 PIPING GENERAL ARRANGEMENT

- Provides Routing Of Pipe With Respect To Equipments

And Existing Structure.
- Information Provided :
- * Equipment Location & Orientation.
- * Lines With Line Numbers.
- * Instrument Tag.
- * Routing Of Pipe Between Euiqpments.
- * Location Of Existing Equipment & Interconnecting
Piping.
- * Routing Of Pipe Between Equipments.
 RELATIONSHIP BETWEEN
P & ID AND GADs

- P & ID shows the start & the end point of a line.

- GAD provides exact location of equipment & routing of pipe
between them.
 General consideration in Piping Layout

1. Positive pressure head

2. Frictional loss

3. Viscosity

4. Slurries

5. Vapour Lock

6. Flashing

7. Process Requirement
 Piping Routing Considerations

1. Size of lines

2. Temperature

3. Hazardous material

4. Direction & Elevations

5. Expansion & Contraction provision

Avoid straight run of pipe between two anchor point

 Pump Connections

A. Suction & Discharge of pumps to be supported independently

to avoid load transmission to pump casing
B. No air pockets in suction line, preferred is flooded suction

C. Eccentric reducer in suction to reduce the size

D. Suction to be provided with strainer.

 Valves

A. Valves to be installed stems vertical or between vertical &

horizontal for liquid service
B. Valves should not be installed up side down

C. 3 Diameter straight run for control valves in upstream &

down stream
D. 5 Diameter straight run for Butter fly valves in upstream
 Pipe Supports

Keep stresses with in limit

Limit deflections and pocket formation

Control Natural frequency to avoid vibration

Support location depends on pipe diameter and
thickness
Expansion bellow for pipe for which operating
temperature is high
Various standard supports are available
There are special supports also
 Piping Support GAD

- Shows types of support & their locations in the pipeline.

- Refer standard pipe support sketches - given by
consultants.
- There can be special type of supports also.
 Support Types

1. Resting supports

2. Guided supports

3. Anchor support
 ISOMETRIC DRAWING
1. Three dimensional representations
2. Used for fabrication & erection
3. Stress Analysis models
LINE DIAGRAM OF PIPING, SHOWS FOLLOWING :
- Operating and Design temperature
- Operating and Design pressure
- Insulation required - Thermal tracing
- Hydro test pressure - Bill of material
- Inch-dia, Inch Meter - Piping Class
- Pipe support locations - Service of fluid
- Points of weld, its marking - Pipe support type
 FEATURES OF ISOMETRIC

1. Need not be drawn to scale

2. Dimensions given relative to center line of pipe

3. Mostly indicates pipe supports, type & locations.

4. Cleaner presentation of piping configuration than in plans &

elevation
 SOME SPECIFIC REQUIREMENETS

- POST-WELD HEAT TREATMENT :

-Normally when the pipe thickness is above 19 mm, after the
weld, the stress developed needs to be released by controlled
heating and cooling as per PWHT cycle given in ASME code
- STRESS RELIEVEING
-Due to bending or forming also, stress may develop in the
material, which is to be released by controlled heating.
- USE OF EXPANSION BELLOWS
-When hot fluid passes through pipe, it expands. To take care of
this Expand Bellows are provided at pipe line end, to absorb the
expansion.
 MATERIAL TAKE OFF

* This documents give the total material requirement for the

job which includes
pipes,fitting,flanges,gaskets,fasteners,valves,speciality ,structure
etc.
* Main mto for total job requirement
* Hydro - test mto (at yard at offshore)
* Spares mto (when client requires)
* Contingencies considered (different for new building or
revamp jobs)
 PIPING

FABRICATION
- cutting
- bending
- forming
- welding
* Fabrication generally done in Fabrication shops.

* Generally Pre-Fabrication is done for dia. 2”- and above.

* Most commonly used code for welding is ASME.

* Progress of pre-fab. Measured in terms of In-Dia.

 PIPING
* Piping systems are divided into sub assemblies called “spools”.

* Number of field welds are minimized.

* Field adjustment length 75 mm provided for field welds.

* 3-axis freedom to be considered for any system while

identifying spools.

* Equipment connection flanges to be left free for adjustment.

* Deviation from conventional x,y,z axis will be shown as

hatched triangles.
PIPING
 PIPING
* BENDING

1) Hot bending
2) Cold Bending.
Limitation for Bending

1. Thinning

% of Thinning = R x 100
R+ r
Where R - Radius of Bend &
r - Pipe radius
Preferred value for thinning < 10

2. Ovality.
Acceptable normally 8% for internal pressure & 3%
for external pressure.
 PIPING

* MITRE BENDS

Fabricated From Pipe.

 PIPING

WELDING

* Normally applicable code- ASME Section IX.

* Consumable code ASME Section II . Part C.

Flame heating.
* Preheating
Coil Heating.

Furnace
*Post Weld Heat Treatment
Local by coil heating.
 PIPE CONNECTIONS

- Butt Welding.
- Socket Welding.
- Brazing.
- Threaded Joints.
 BRANCH CONNECTIONS

- Equal or Reducing T
- Weldo - let.
- Socko - let.
- Elbow-let.
- Threado-let.
 N.D.T

- Butt welds are radio-graphed.

- Socket welds are die penetration tested.
 PIPING
ERECTION

* As per General Arrangement.

* Availability of Termination Point to start with.

* Scaffolding and rigging facilities.

* Painting of spools to be completed.

* Valves and online equipment availability.

* Availability of permanent pipe supports.

* Spring supports to be installed with lock in position.

 PIPING
HYDROTESTING-LOOPS

1) Mechanical completion.

2) P & ID Check.

3) NDT clearance.

4) Support checking.

5) Flushing.

6) Removal of Control valves,rupture disc etc.

Hydrotest Loop
 PIPING
DRYING

1) Draining.

2) Air Blowing.

3) Gasket blasting if required.

4) Boxing Up.

5) Final painting.

6) Purging.
BALL VALVE IN OPEN CONDITION
ELBOW LET BRANCHING
SIMPLE BRACKET SUPPORT
SHOE SUPPORT
DRAIN CUP’S FOR DECK DRAIN
PRODUCTION MANIFOLD VALVE IN SAME LINE
SOCKET WELD CONNECTION
TRUNION SUPPORT
LINES IN SAME ELEVATION
HYDRO TESTING ARRANGEMENT
HYDRO TESTING ARRANGEMENT
INSULATED PIPES
RESTING TRUNION SUPPORT
TRUNIONS ON ELBOW
GLOBE VALAVE IN POSITION
GATE VALVE
CONTROL VALVE
PROPOSAL
ENGINEERING
 MAJOR STEPS OF PROCESS
- DATA (BID PACKAGE, DRAWINGS, SPECIFI-
CATIONS, DATA SHEETS ETC) RECEIVED
FROM MARKETING DEPT
- STUDY BID PACKAGE : UNDERSTAND SCOPE
- CONDUCT PRE - BID SURVEY
- PREPARE MATERIAL TAKE OFF (MTO)
- PREPARE PURCHASE SPECIFICATION &
PROVIDE TO PURCHASE DEPT TO GET
VENDOR QUOTATION
- EVALUATE VENDOR & HIS OFFER
- COMMERCIAL & TECHNICAL BID ARE
EVALUATED AND ORDER IS PLACED.
 DATA FROM MARKETING
DEPT
- BID PACKAGE
- P & ID
- PIPING GAD AND LINE LIST
- EQUIPMENT LIST AND EQUIPMENT LAYOUT
- SPECIFICATION OF PIPING MATERIAL,
VALVES, EQUIPMENT
- SCOPE OF WORK
- DESIGN BASIS
- ALL APPLICABLE STANDARDS
 UNDERSTANDING SCOPE OF
WORK
- STUDY BID DOCUMENT (PARTICULARLY
SCOPE OF WORK)
- STUDY THE SPECIFICATIONS
- DECIDE IF MFF IS CAPABLE TO
UNDERTAKE JOB, DECIDE MARINE
SPREAD NEEDED
- ENGG DEPT MAY RAISE TECHNICAL
QUERIES, WHOSE ANSWERS ARE TO BE
OBTAINED FROM CLIENT
- PRE – BID SURVEY ALSO HELPS TO
UNDERSTAND SCOPE
 PRE – BID SURVEY
- INFORMATION PROVIDED IN THE BID
PACKAGE MAY NOT BE SUFFICIENT TO
MAKE A PROPER QUOTATION.

- A SURVEY ON THE PLATFORM MAY BE

CONDUCTED TO COLLECT MORE DATA

- LOOK FOR CHANGES IN PIPE LINE, CRANE

REQUIREMENT, BARGE APPROACH,
STRUCTURAL ADEQUACY, STRUCTURAL
OBSTACLE ETC
 CLARIFICATION FROM CLIENT

- TECHNICAL QUERIES WILL BE PREPARED

BY ENGG. DEPT ON BID PACKAGE OR WHEN
SURVEY SHOWS DIFFERENCE WITH BID
PACKAGE DATA.

- THESE QUERIES ARE RESOLVED IN THE

PRE-BID MEETING WITH CLIENT
 PREPARATION OF MTO

- BASED ON BID PACKAGE DATA AND ON

DATA COLLECTED DURING SURVEY, A
M.T.O IS MADE
- MTO IS MADE FOR BULK PIPING ITEMS
- MTO IS MADE FOR STEEL STRUCTURAL
MATERIAL
- MTO IS MADE FOR VALVES &
SPECIALITY ITEMS ALSO
 VENDOR DATA
- DATA SHEETS AND QUANTITY OF VARIOUS
EQUIPMENT ARE SENT TO PURCHASE
DEPT FOR COLLECTION OF QUOTATION
FROM VARIOUS VENDORS
- QUERIES RAISED BY VENDORS ARE
ANSWERED
- DEVIATIONS RAISED BY VENDORS ARE
EXAMINED AND DECISION PROVIDED TO
PURCHASE DEPT
 QUOTATION ESTIMATION
- BASED ON MTO PRICE IS ESTIMATED BY
MARKETING DEPT WITH SUITABLE
MARGIN
- QUOTATION OF SUPPLIERS OF
EQUIPMENTS ARE CONSIDERED FOR
PRICE ESTIMATION
- CONSULTANTS’ FEES ARE CONSIDERED
- INSTALLATION CONTRACTOR’S PRICE
CONSIDERED
- COST FOR MARINE SPREAD IS
CONSIDERED
- CONSUMABLE COSTS ARE CONSIDERED
 QUOTATION SUBMISSION

- MARKETING DEPT CONSIDERS ALL THE

PRICES AND ESTIMATE TOTAL PRICE OF
JOB TO BE QUOTED TO CLIENT
- INFORMATION ON TECHNICAL CAPABILITY
OF MFF IS PROVIDED
- BOTH COMMERCIAL AND TECHNICAL BID IS
SUBMITTED
- TECHNICAL CUM COMMERCIAL BID
(WITHOUT PRICE) IS OPENDED ON SPECIFIC
DATE IN FRONT OF ALL BIDDERS
 QUOTATION SUBMISSION

- QUERIES OF BIDDERS ARE ANSWERED BY

CLIENT IN THE MEETING
- CONTRACTOR IS EVALUATED IN TERMS OF :
PAYMENT TERMS, EXPERIENCE OF CARRYING
OUT SIMILAR JOBS, LD CLAUSE ETC
- ON GENUINE GROUND BIDDER MAY
RESUBMIT A NEW QUOTATION IN SEALED
COVER
- PRICE BID IS OPENED AT A LATER DATE
- ONE CONTRACTOR IS SELECTED
THANK YOU
Thank You