Piping

Maintenance & Inspection of Piping
in Hydrocarbon Industry

Igniting Minds... Energizing Lives
Haldia Refinery

PIPING SYSTEM

Haldia Refinery

Haldia Refinery
PIPING TYPES
PIPING
UNDER GROUND ABOVE GROUND
INSULATED
BARE

Haldia Refinery
PIPING MATERIALS
CS - SR AS PER SERVICE, THICK. > 19mm
AS - POOR WELDABILITY, SR REQD.
SS - NO PRE-HEAT, SR
RUBBER LINED
CEMENT LINED
SS LINED
HDPE

PIPING MATERIALS
CARBON STEEL ALLOY STEELS STAINLESS STEELS

PIPE SCHEDULES

PIPE SCHEDULES

Haldia Refinery
PIPING DESIGN/ LAYOUT
OVERALL PLOT PLAN
P&IDs
GENERAL ARRANGEMENT DRAWINGS (GADs)
PIPING MATERIAL SPECIFICATION (PMS)

PLOT PLAN

PIPING & INSTRUMENT DIAGRAM

GENERAL ARRANGEMENT DRAWINGS (GADs)

Haldia Refinery
PIPING COMPONENTS
PIPE
FLANGES / VALVES
EXPANSION BELLOWS
FITTINGS
HALF COUPLINGS
MITRE BENDS
REDUCER
ELBOWS
GASKETS

Haldia Refinery
PIPING COMPONENTS
SUPPORTS
GUIDE
FREE IN TWO DIRECTION
CROSS-GUIDE
FREE IN ONE DIRECTION
ANCHORS
NOT FREE FOR MOVEMENT
SPRING SUPPORTS

Haldia Refinery
PIPING WALL THICKNESS
BARLOWS FORMULA

t = P
i
D/ 2S
A

t
n
=

t + allowance(s)

t= Minimum Wall Thickness (M)
P
i
= Maximum Allowable Operating Pr. (MPa)
D= Outside Diameter (M)
S
A
= Allowable Stress (MPa)
t
n
= Nominal Wall Thickness(M)

Haldia Refinery
PIPING TEST PRESSURE

P
T
= 1.5P x S
T
/S

P
T
= Minimum Test Gage Pressure
P=Maximum Allowable Working Pressure
S
T
=Stress Value at Test Temperature
S=Stress Value at Design Temperature

Haldia Refinery
PIPING FABRICATION
WELDING
SMAW
GTAW
PRE/ POST-WELD HEAT TREATMENT

HOT TAPPING
BRANCH CONNECTION WITHOUT
INTERRUPTION TO THE FLOW OF FLUID

PIPE BENDING

Haldia Refinery
HOT TAPPING

Haldia Refinery
PIPE BENDING

GENERAL GUIDELINES

Haldia Refinery
Haldia Refinery
All small bore pipings and tracer lines, size and below should be
welded by TIG process for all types of joints, e.g. butt, socket, tee,
etc. to ensure proper quality of welding. Use of half coupling may
be considered to increase reliability of small-bore connections.
Minimum thickness of pipe for sizes up to 1 should be Sch.80 for
CS and AS.
Reinforcement pad shall be provided at support location.
Steam drain points should be routed to a drain header and taken out
of the unit area.

GENERAL GUIDELINES FOR PIPING
Haldia Refinery
Stiffener should be provided in small bore bleeder/ drain point
connection welded to immediate upstream or downstream of safety
valves.
As far as possible, stub-in type branch connection are to be
provided when branch size is less than one size than the main pipe.
All the reinforcement pad telltale holes should be drilled and tapped
properly. Gas cut holes should not be accepted.
Wherever two phase flow in piping is expected, piping design
including its support system should be checked w.r.t. most adverse
conditions/ ratio of both the phases (slug flow) to avoid line vibration
during operation.

Haldia Refinery
All the fittings like valves, flanges etc. in high temperature service (>
= 300
0
C) should also be fully insulated if they are in open area or the
localized cooling can cause operational problems like coking etc.

All SS piping should have chloride free insulation or preferably should
have SS foil wrapped between pipe and insulation.

Branch connections for fire hydrants along the roads should be totally
above grounds. Hydrant connections also should remain above
ground.

Firewater and cooling water lines emerging from underground should
be wrapped coated beyond the ground level up to a length of 500mm.

Haldia Refinery

Hard surfacing with a proper slope towards open drain system is to
be provided beneath the offsite pipe rack area with a clear space of
500mm from bottom of the pipe.

Interspacing between the offsite piping on the support pedestal
should be such that the lines should not touch each other even after
insulation (at least 3 gap after insulation).

Identification marks for location/ visibility of drain points of offsite
piping should be provided. All drain points should be approachable
and clearly visible.

Haldia Refinery

Piping insulation ends should be properly sealed to avoid water
ingress.

Hard surfacing under the piping bay in offsite areas should be done
with proper slope & drainage facility.

Proper slope and gap should be provided in piping culverts to avoid
water logging.

In fire water lines, the hydrant tapping should not be taken from the
bottom side of pipe. Tapping should be taken from the top or from
side.

Haldia Refinery
Any piping circuit if idle for more than six month shall be inspected or
hydrotested before taking into service

Ensure adequate wrapping & coating and at least 0.5mtr wrapping &
coating shall be visible externally at both ends on above ground
portion of pipe.

All piping route in off-site area shall be made grass & debris free.

In Hydrocarbon service dia. 2 pipe shall be of minimum Schedule 80.

Low point drain (LDP) shall be offset by 1 meter from the supports
and shall not be embedded into soil.


PIPING FABRICATION

Haldia Refinery
Haldia Refinery

PIPING FABRICATION
FIT UPS
Haldia Refinery

PIPING FABRICATION
BRANCH CONNECTIONS
Haldia Refinery

PIPING FABRICATION
BRANCH CONNECTIONS

PIPING FABRICATION
PREHEAT TEMPERATURES

PIPING FABRICATION
POST WELD HEAT TREATMENT

PIPING FABRICATION
TYPICAL WELD DEFECTS

DEGRADATION MECHANISMS
IN
PIPING SYSTEM

Haldia Refinery

Haldia Refinery
DETERIORATION IN PIPING SYSTEM
INTERNAL CORROSION
UNIFORM CORROSION DUE TO LOW/ HIGH pH

Haldia Refinery
INTERNAL CORROSION
LOCALIZED CORROSION- IN CREVICES, BENDS ETC.

Haldia Refinery
INTERNAL CORROSION
CONDENSATION/ TWO PHASE SYSTEMS

Haldia Refinery
INTERNAL CORROSION
STAGNANT AREAS - IN DEAD ENDS ETC

Haldia Refinery
INTERNAL CORROSION
STRESS CORROSION CRACKING

Haldia Refinery
INTERNAL CORROSION
HYDROGEN ATTACK

Haldia Refinery
INTERNAL CORROSION
AREAS D/STREAM OF INJECTION POINTS

Haldia Refinery
INTERNAL CORROSION
IMPINGEMENT AREAS

Haldia Refinery
INTERNAL CORROSION
NAPHTHENIC ACID/ POLYTHIONIC ACID CORROSION

Haldia Refinery
INTERNAL CORROSION
FIRE WATER CORROSION

Haldia Refinery
INTERNAL CORROSION
COOLING WATER CORROSION

Haldia Refinery
EXTERNAL CORROSION
CORROSION UNDER INSULATION

Haldia Refinery
EXTERNAL CORROSION
SOIL SIDE CORROSION OF UNDER-GROUND LINES

Haldia Refinery
EXTERNAL CORROSION
EXTERNAL CORROSION DUE TO SOIL/ WEEDS

Haldia Refinery
EXTERNAL CORROSION
ATMOSPHERIC CORROSION - SULFUROUS /
ACIDIC ENVIRONMENT

Haldia Refinery
WELD CORROSION
PREFERENTIAL ATTACK ON WELD

Haldia Refinery
EXTERNAL CORROSION
CORROSION AT SOIL / AIR INTERFACE

Haldia Refinery
STRESS RELATED
OVERPRESSURIZATION

Haldia Refinery
STRESS RELATED
VIBRATION- AS IN PUMP CONNECTED PIPING

Haldia Refinery
STRESS RELATED
FAILURE OF WELD SEAM

Haldia Refinery
STRESS RELATED
THERMAL STRESSES

INSPECTION OF PIPING SYSTEM

Haldia Refinery

Haldia Refinery
ROLE OF INSPECTION
To evaluate present physical condition of the pipeline.
To keep the concerned operating and maintenance
personal fully informed about the the condition of the
lines.
To determine causes of deterioration and advise
suitable economical solution to the problem.
To initiate procurement action of materials.
To co-relate deterioration rate with design life for
further run.

Haldia Refinery
FREQUENCY OF INSPECTION
The interval between inspections depend upon :
Degree of corrosiveness/ erosiveness of the fluid.
Remaining corrosion allowance.
Type of protective coating.
Atmosphere prevailing around the piping.
Potentially of fire /explosion in case of a leak or failure.
Statutory requirements.
Importance of operations.

Haldia Refinery
Service External Comprehensive
Crude (sour) 3 6
LP/Natural gas 2 4
Gasoline / naphtha 2 4
ATF/ HSD/ LDO/ SKO 3 5
FO/RCO/Bitumen/ VBO 3 5
Fuel gas/ Flare gas 3 5
Lube oil 5 10
Frequency of inspection for offsite piping (hydrocarbon):

Haldia Refinery
Frequency of inspection for offsite piping (Utilities):
Service External Comprehensive
Fresh water 2 4
Fire water 3 (lined) / 1 (unlined) 5 (lined) / 2 (unlined)
Air / steam 3 6
Ammonia / caustic 2 4
DEA/ MEA 3 5
Furfural/ phenol 2 3
Benzene/ toluene 2 4

Haldia Refinery
INSPECTION PROCEDURE
Visual Inspection: For determining leaks,
misalignment, supports, vibration, external
corrosion, cracks, insulation damage.

Ultrasonic Inspection: For ascertaining wall
thickness, by scanning at least four spots (12 o
clock, 3 o clock, 6 o clock and 09 o clock
positions) on each circumferences for every 30 m
of straight length and all bend locations.

Haldia Refinery
Radiographic Inspection: Critical spots which
cannot be inspected by UT may be radio graphed
during operation to determine internal fouling,
pitting, scaling etc.

Shutdown Inspection: All piping which cannot be
inspected during operation has to be inspected
during shutdown.

Haldia Refinery
Hydrostatic Testing:

Along with all NDTs hydro test has to be carried out to
evaluate strength of existing and new joints of the line in
addition to establishing overall integrity of the line.

For new lines hydro test is to be done at 1.5 times design
pressure.
For old lines or partially repaired or replaced line it is carried out
at 1.5 times operating pressure.
Coated or insulated lines are hydro tested before coating
operation.
Before using any line which has been idle for long time, hydro test
is to be carried out.
Portable water is to be used for CS or AS pipes and DM water is to
be used for SS pipes. Water must be drained after the test.

Haldia Refinery
In the presence of certain corrodants, corrosion rates
are normally increased at areas of increased velocity
and/or turbulence.
Elbows, reducers, mixing tees, control valves, and
orifices are examples of piping components where
accelerated corrosion may occur because of increased
velocity and/or turbulence.
In the areas of no flow, such as dead legs, accelerated
corrosion may occur.
Such components are normally areas where an
inspector would locate additional TMLs in a piping
circuit.
AREAS SUSCEPTABLE TO ACCELERATED CORROSION

Haldia Refinery
INSPECTION POINTS

Haldia Refinery
INSPECTION POINTS

Haldia Refinery
ON-LINE MONITORING OF PIPING
pH MONITORING
CORROSION PROBES
CORROSION COUPONS IN WATER LINES

Haldia Refinery
NDT IN PIPING SYSTEM
ULTRASONIC THICKNESS SURVEY
DCVG / PEARSON SERVEY
SPARK / HARDNESS TEST OF RUBBER LINED
PIPES
RADIOGRAPHY

Haldia Refinery
DCVG SURVEY

The Direct Current Voltage
Gradient (DCVG) technique is a
"newer" technique for coating
surveys on buried pipelines.

It has been used for not only
locating but also sizing coating
defects.

The technique is fundamentally
based on measuring the voltage
gradients in the soil above a
cathodically protected pipeline.

Haldia Refinery
CRACK
DYE APPLIED
TRAPPED DYE
ON CLEANED
SURFACE
CRACK
VISIBLE
ON APPLYING
DEVELOPER
DYE PENETRANT TESTING
Haldia Refinery
DISCONTINUITY
METAL
RADIATION SOURCE
FILM

RADIOGRAPHY TESTING
Haldia Refinery
Sample Films :
Lack
Of
Penetration
Cluster
Of
Porosity

RADIOGRAPHY TESTING
Haldia Refinery
Sample Films :
Tungsten
Inclusion
Transverse
Crack

RADIOGRAPHY TESTING
Haldia Refinery
Slag inclusions

RADIOGRAPHY TESTING
Lack of fusion
Haldia Refinery
Suck back

RADIOGRAPHY TESTING
Root undercut
Haldia Refinery
External
undercut

RADIOGRAPHY TESTING
Mismatch
Haldia Refinery
Poor
reinforcement

RADIOGRAPHY TESTING
Excess
reinforcement
Haldia Refinery

LONG RANGE ULTRASONIC TESTING
This technique uses low
frequency guided ultrasonic
waves to detect a length of
piping. It locates the affected
area in terms of distance from
transducer and serves as a
screening tool to inspect large
lengths of piping especially at
difficult to access locations.
Haldia Refinery

Haldia Refinery

ELECTRONIC SCANNING
ELECTRONIC COMBINED WITH
STEERING AND FOCUSING

PHASED ARRAY ULTRASONICS
Haldia Refinery

DOCUMENTATION OF TMLs

CORROSION PREVENTION
IN
PIPING SYSTEM

Haldia Refinery

Haldia Refinery
PAINTING
ENAMEL, EPOXY, COAL TAR,
CLORINATED RUBBER, BITUMENOUS
HIGH TEMPERATURE PAINTS
TEMPERATURE INDICATIVE PAINTS
TAPE COATING

Haldia Refinery
CATHODIC PROTECTION
PRINCIPLE OF CP
MOST NEGATIVE REGIONS ACTS AS ANODE

PRE-REQUISITE FOR CP
COATING / WRAPPING EFFECTIVENESS
PIPE TO SOIL POTENTIAL SURVEY
SOIL RESISTIVITY SURVEY
INTERFERENCE WITH FOREIGN LINES

Haldia Refinery
CATHODIC PROTECTION
SACRIFICAIL ANODE TECHNIQUE

Haldia Refinery
CATHODIC PROTECTION
IMPRESSED CURRENT TECHNIQUE

CAUSES OF PIPING FAILURES

Haldia Refinery

Haldia Refinery
PIPING FAILURES
MAJOR REASONS OF PIPING FAILURES
MATERIAL NOT SUITABLE / MATERIAL MIX-UP
5 Cr-1/2 Mo
Carbon steel

Haldia Refinery
PIPING FAILURES
VIBRATION

Haldia Refinery
PIPING FAILURES
FLOW ACCLERATED CORROSION

Haldia Refinery
PIPING FAILURES
CATALYST EROSION

Haldia Refinery
PIPING FAILURES
THERMAL STRESSES

Haldia Refinery
PIPING FAILURES
COATING DAMAGE

Haldia Refinery
PIPING FAILURES
PROBLEMS WITH LOW POINT DRAINS

Haldia Refinery
PIPING FAILURES
G
SEAM OPENING

Haldia Refinery
PIPING FAILURES
GRASS / WEED GROWTH & SOIL CONTAMINATION

Haldia Refinery
PIPING FAILURES
INTERNAL UNDER DEPOSIT / MICROBIAL CORROSION

Haldia Refinery
PIPING FAILURES
CORROSION AT SUPPORT LOCATIONS

Haldia Refinery
PIPING FAILURES
CORROSION UNDER INSULATION

Haldia Refinery
PIPING FAILURES
IMPROPER FABRICATION

Haldia Refinery
PIPING FAILURES
IMPROPER JOINT DESIGN
Standard Joint
Improper Fit Up
& Welding
Poor Penetration
& Under cut
Crack
Haldia Refinery

Piping

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