Process Plant Piping: Practical Guide to Fabrication, Installation, Inspection, Testing, and Commissioning

361 Pages·2023·13.495 MB·English

by  Sunil Pullarcot

Process Plant Piping
This book is designed as a complete guide to manufacturing, installation, inspec-
tion, testing and commissioning of process plant piping. It provides exhaustive cov-
erage of the entire piping spool fabrication, including receiving material inspection
at site, material traceability, installation of spools at site, inspection, testing and
pre- commissioning activities. In a nutshell, it serves as a complete guide to piping
fabrication and erection. In addition, typical formats for use in piping fabrication
for effective implementation of QA/QC requirements, inspection and test plans, and
typical procedures for all types of testing are included.
Features:
• Provides an overview of development of piping documentation in process
plant design with a number of illustrations
• Gives exposure to various codes used in piping and pipelines within its
jurisdiction
• Quick reference guide to various applicable sections of ASME B 31.3
provided
• Coverage of entire construction contractors’ scope of work with regard to
plant piping
• Written with special emphasis on practical aspects of construction and final
documentation of plant piping for later modifications/investigations
This book is aimed at mechanical, process and plant construction engineers/supervi-
sors, specifically as a guide to all novices in the above disciplines.

Process Plant Piping
Practical Guide to Fabrication,
Installation, Inspection, Testing,
and Commissioning
Sunil Pullarcot
Designed cover image: © Shutterstock
First edition published 2023
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
CRC Press is an imprint of Taylor & Francis Group, LLC
© 2023 Sunil Pullarcot
Reasonable efforts have been made to publish reliable data and information, but the author and
publisher cannot assume responsibility for the validity of all materials or the consequences of
their use. The authors and publishers have attempted to trace the copyright holders of all material
reproduced in this publication and apologize to copyright holders if permission to publish in this
form has not been obtained. If any copyright material has not been acknowledged please write and
let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known
or hereafter invented, including photocopying, microfilming, and recording, or in any information
storage or retrieval system, without written permission from the publishers.
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Trademark notice: Product or corporate names may be trademarks or registered trademarks and are
used only for identification and explanation without intent to infringe.
Library of Congress Cataloging‑in‑Publication Data
Names: Pullarcot, Sunil, 1957- author.
Title: Process plant piping : practical guide to fabrication, installation,
inspection, testing and commissioning / Sunil Pullarcot.
Description: First edition. | Boca Raton, FL : CRC Press, 2023. |
Includes bibliographical references and index. |
Identifiers: LCCN 2022036340 (print) | LCCN 2022036341 (ebook) |
ISBN 9781032357072 (hbk) | ISBN 9781032357089 (pbk) |
ISBN 9781003328124 (ebk)
Subjects: LCSH: Chemical plants–Piping.
Classification: LCC TP159.P5 P85 2023 (print) | LCC TP159.P5 (ebook) |
DDC 660/.28–dc23/eng/20221006
LC record available at https://lccn.loc.gov/2022036340
LC ebook record available at https://lccn.loc.gov/2022036341
ISBN: 9781032357072 (hbk)
ISBN: 9781032357089 (pbk)
ISBN: 9781003328124 (ebk)
DOI: 10.1201/9781003328124
Typeset in Times
by codeMantra
Contents
About the Author .....................................................................................................xv
Preface....................................................................................................................xvii
Chapter 1 Introduction ..........................................................................................1
1.1 General ......................................................................................1
1.2 Piping .........................................................................................3
1.3 Piping Engineering ....................................................................3
1.4 Piping Design ............................................................................4
1.4.1 Conceptual Layout Design ........................................5
1.4.2 Equipment Layout Design .........................................5
1.4.3 Piping Layout Design ................................................5
1.5 Design Basis ..............................................................................6
1.6 Design Codes .............................................................................6
1.6.1 American Society of Mechanical Engineers ............7
1.6.2 Editions and Addenda ...............................................7
1.6.3 Interpretations ...........................................................8
1.6.4 Code Cases ................................................................8
1.7 History of ASME Codes for Piping...........................................8
1.8 Loading Conditions for Piping ................................................13
1.8.1 Static Loading .........................................................13
1.8.2 Dynamic Loading ...................................................14
1.9 Equipment Requirements ........................................................14
1.10 Client/Project Requirements ...................................................15
1.11 Material Specifications ............................................................15
1.12 Failure Modes ..........................................................................15
1.13 Scope, Coverage and Layout of ASME Code B 31.3 –
Process Plant Piping ................................................................16
1.13.1 General ....................................................................16
1.13.2 Scope of ASME B 31.3 Process Plant Piping .........16
1.13.3 Exclusions from ASME B 31.3 ...............................17
1.13.4 Types of Fluid Services Covered ............................17
Chapter 2 Piping Documents Development Process ...........................................19
2.1 Key Documents .......................................................................19
2.2 Project Design Basis ................................................................19
2.3 Block Flow Diagram ...............................................................20
2.4 Process Flow Diagrams ...........................................................20
2.4.1 Purpose of PFD .......................................................22
2.4.2 Contents of PFD ......................................................22
2.5 Piping and Instrumentation Diagram ......................................23
v
vi Contents
2.5.1 Function and Purpose of P&IDs .............................24
2.5.2 When and Who Use P&IDs ....................................25
2.5.3 Difference between a PFD and a P&ID ..................25
2.5.4 Limitations of P&ID ...............................................25
2.5.5 P&ID and Associated Documents...........................25
2.5.6 Contents of P&ID ....................................................26
2.5.7 Specific Exclusions ..................................................26
2.5.8 Standards and Rules for Preparation of P&IDs ......27
2.5.9 Equipment Designation ...........................................27
2.5.10 Line Designation .....................................................27
2.5.11 Instrument Lines .....................................................28
2.5.12 Instrument Designation ...........................................28
2.5.13 Standard Symbols ...................................................30
2.6 Piping Engineering Deliverables .............................................33
2.7 Piping Key Plan .......................................................................36
2.8 Piping Isometric Drawings (Isometrics) ..................................37
2.9 Piping Material Specification ..................................................39
Chapter 3 Piping Isometric Drawings (Isometrics) ............................................41
3.1 Significance of Isometric Drawings ........................................41
3.2 Advantages of Isometric Drawings .........................................41
3.3 Comparison of Orthographic and Isometric Drawings ...........42
3.4 Isometric Views in More Than One Plane ..............................43
3.5 Piping Arrangement Symbols .................................................43
3.5.1 Piping Arrangement Symbol (Pipes) ......................43
3.5.2 Piping Arrangement Symbols (Fittings) .................46
3.5.3 Piping Arrangement Symbols (Flanges) .................46
3.5.4 Piping Arrangement Symbols (Valves) ...................46
3.5.5 Piping Arrangement Symbols (Miscellaneous
Fittings) ...................................................................47
3.6 Preparation of Piping Isometric Drawings or Isometrics ........49
3.7 Size of Piping Drawings ..........................................................49
3.8 Typical Drawings – Style/Presentation and Contents .............49
3.8.1 Piping Key Plan – Area Match Lines .....................49
3.8.2 Piping Key Plan .......................................................51
3.8.3 Piping Isometric Drawing .......................................52
3.8.4 Piping Isometric Drawing with BOM .....................53
Chapter 4 Piping Material Specification (PMS) and Material
Take-Off (MTO) ................................................................................55
4.1 Piping Material Specification ..................................................55
4.1.1 Contents of PMS .....................................................56
4.2 Piping Material Management ..................................................57
4.2.1 Material Take-Off ...................................................58
Contents vii
4.2.1.1 Bill of Materials .....................................58
4.2.1.2 Material Take-Off .................................58
4.2.1.3 Initial MTO ...........................................59
4.2.1.4 Manual MTO Preparation Overview ....59
4.2.1.5 Steps for Generating Manual MTO .......59
4.2.1.6 MTO for Special Items ..........................60
4.2.1.7 MTO for Non-Pickable Items ................60
4.2.1.8 Generation of Total MTO ......................60
4.2.1.9 Stages of MTO during Engineering ......60
4.3 Preparation of MR ...................................................................61
4.4 Purchase Enquiry ....................................................................62
4.5 Technical Bid Evaluation .........................................................62
4.6 Purchase Order ........................................................................62
4.7 Vendor Document Review/Approval .......................................62
4.7.1 Typical BOM in Isometric Drawing .......................63
4.7.2 Typical MTO ...........................................................63
Chapter 5 Pipes ...................................................................................................65
5.1 History of Pipe.........................................................................65
5.2 Pipe and Tube ..........................................................................65
5.3 Difference between Pipe and Tube ..........................................65
5.4 Material of Construction for Pipes ..........................................67
5.5 Manufacturing Processes ........................................................67
5.5.1 Seamless Pipes ........................................................67
5.5.2 Welded Pipes ...........................................................68
5.6 Strengths and Weaknesses of Manufacturing Processes ........69
5.7 Schematic Presentations of Various Manufacturing
Processes .................................................................................70
5.8 Size of Pipe ..............................................................................70
5.8.1 Nominal Pipe Size ...................................................70
5.8.2 Pipe Schedule ..........................................................72
5.8.3 Length of Pipe .........................................................72
5.9 Methods of Joining Pipes ........................................................72
Chapter 6 Pipe Fittings........................................................................................75
6.1 BW Pipe Fittings .....................................................................75
6.1.1 Bevelled Ends ..........................................................76
6.2 Material of Construction .........................................................77
6.3 Types of BW Fittings ...............................................................77
6.4 O’let Type Welded Branch Connections .................................77
6.4.1 Types of O’lets ........................................................77
6.4.2 Welding Requirements of O’let Fittings .................77
6.5 SW Fittings ..............................................................................83
6.5.1 Technical Details.....................................................84
viii Contents
6.5.2 Advantages/Disadvantages of Socket
Weld Fittings ...........................................................84
6.5.3 Typical SW Joint .....................................................85
6.5.4 Types of SW Fittings ...............................................85
6.6 THD Fittings............................................................................85
6.6.1 NPT Thread ............................................................87
6.6.2 Types of THD Fittings ............................................88
6.7 Mitered Elbows ........................................................................89
6.8 Header and Branch Connections .............................................90
6.8.1 Stub-in Connections ................................................90
6.8.2 Stub-in Reinforcements ...........................................91
Chapter 7 Flanges, Gaskets and Fasteners ..........................................................93
7.1 Flanges .....................................................................................93
7.1.1 Bolted Flange Connections .....................................94
7.1.2 Flange Rating ..........................................................94
7.1.3 Flange Facing ..........................................................95
7.1.4 Flange Types ...........................................................96
7.2 Fasteners for Flanged Connections .........................................96
7.2.1 Types of Bolts ..........................................................96
7.2.2 Hexagonal (Hex) Nuts .............................................99
7.2.3 Threads of Stud Bolts ............................................100
7.2.4 Standard Thread Pitches .......................................100
7.2.5 Coatings on Fasteners ...........................................101
7.2.6 Coating Thickness .................................................102
7.2.7 Life Expectancy of Coatings .................................102
7.3 Gaskets ..................................................................................102
7.3.1 Classification Based on Configuration ..................103
7.4 Gaskets for Flanged Connections ..........................................103
7.4.1 Types of Gaskets Based on Material of
Construction ..........................................................104
Chapter 8 Valves ...............................................................................................109
8.1 Classification of Valves .........................................................110
8.2 Class Ratings .........................................................................111
8.3 Common Types of Valves ......................................................111
Chapter 9 Sequence of Mechanical Works after Award of Work .....................115
9.1 Work Progression on Award of Contract ...............................115
9.2 Responsibility Matrix (Head Office and Site) .......................116
9.3 Organization Setup on Site ....................................................118
9.3.1 Introduction ...........................................................118
9.3.2 Organization Chart ...............................................119
Contents ix
9.4 Design, Drawings and Documents Approval ........................120
9.5 List of Documents .................................................................121
9.6 Preparation of MTO and CS..................................................124
9.7 Material Requisition ..............................................................125
9.8 Technical and Commercial Bid Evaluation ...........................125
9.9 Purchase Order ......................................................................125
9.10 Vendor Data and Its Approval ...............................................125
9.11 Materials Procured from Stockists or Traders ......................126
9.12 Work Contracts ......................................................................126
9.12.1 Sub-contract for NDT ...........................................127
9.12.2 Sub-contract for Scaffolding .................................127
9.12.3 Sub-contract for Surface Preparation and
External Painting ..................................................127
9.13 Local Contracts/Purchases at Site .........................................127
Chapter 10 Fabrication of Piping Spools ............................................................129
10.1 General ..................................................................................129
10.2 Linear Dimensional Tolerance for Piping .............................129
10.3 Workshop Requirements .......................................................129
10.4 Stainless and Other High-Alloy Steel ...................................130
10.5 Progress Control ....................................................................130
10.6 Spool Sizes ............................................................................131
10.7 Galvanized Piping .................................................................131
10.8 Painting of Spools ..................................................................131
10.9 Shop Fabrication of Spools ....................................................131
10.9.1 Release of ISOs in AFC Status .............................131
10.9.2 Material Release ....................................................131
10.9.3 Material Traceability .............................................132
10.9.4 Sizing of Pipe ........................................................132
10.9.5 Types of Weld Joints Required in Piping ..............132
10.9.6 Fit-Up of Butt and Socket Weld Joints ..................138
10.9.7 Threaded Connections ..........................................139
10.9.8 Flanged Connections .............................................139
10.9.9 Branch Connections ..............................................140
10.9.10 Cold Bending ........................................................141
10.9.11 Mitre Bends ...........................................................142
10.9.12 Misalignment Tolerance ........................................142
10.9.13 Preparation for Welding ........................................142
10.9.14 Cleaning ................................................................143
10.9.15 Preheating .............................................................143
10.9.16 Welding .................................................................144
10.9.17 Visual Inspection ..................................................150
10.9.18 Dimensional Tolerances for Pre-fabricated
Piping Assemblies .................................................152
10.9.19 Release for NDT of Completed Spools .................155