TRAINING MANUAL- PIPING

PIPING DESIGN IN DETAILED ENGINEERING

DOC No. : 29040-PI-UFR-0002 Rev. Page : R0 : 1

Uhde India Limited

CONTENTS Page 0.0 1.0 2.0 3.0 Cover Sheet Introduction Major Inputs for Piping Design Interface with other Design Groups 1 2 2 24

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TRAINING MANUAL- PIPING

PIPING DESIGN IN DETAILED ENGINEERING

DOC No. : 29040-PI-UFR-0002 Rev. Page : R0 : 2

Uhde India Limited

1.0

INTRODUCTION:

Any process can be divided into a number of unit operations. In a chemical process, unit operations could include mixing, reaction, distillation, evaporation, drying, etc. In a mechanical process, unit operations would include cutting, machining, milling, grinding, fitting, welding, etc. Similar divisions can be done in other branches of the engineering/ manufacturing. Piping forms major portion of Chemical Process Plants including petroleum refineries, petrochemicals, pharmaceuticals involving both process piping and utility piping. In other processes, piping requirement may be limited to utilities only and the Piping Engineer will be involved only to that extent. Piping engineering, as already mentioned, is central to detail engineering activity in a project. Right from the inception of a project till the plant is commissioned, engineering activities centre around the Piping Engineering. Basic information from various disciplines is to be received by them and they in turn provide detailed engineering information to those departments for executing their part of the job. In short, it may not be wrong to say that Piping department is the chief co-ordinating agency for executing detailed engineering work.

2.0

MAJOR INPUTS FOR PIPING DESIGN:

The first document that will be required by the piping engineer to kick off his work would be the Process Flow Diagram (PFD) along with approximate size of the process equipment and utility packages. These are to be provided by the process engineer. Armed with this information, piping department prepares a rough plant layout indicating the position of units and utility packages. This becomes the basic document for developing the overall site plan. In the meantime, the process department develops the piping and instrumentation diagram (P&ID). The P&ID contains all the critical information required for piping and instrumentation design. Piping department is required to use this along with the PFD and make study layouts so that equipment, control stations and all other major items can be located properly. Process department also prepares process data sheets for equipment and provides them to Mechanical department. Mechanical department works out the load of each and every equipment static, dynamic, empty, full of fluid, operating weight etc. and indicates the type of support required for each and every item. This data is provided by Mechanical department to Piping department.

3.0

INTERFACE WITH OTHER DESIGN GROUPS: Conventional (2D) Design Approach: Piping department prepares plot plans indicating the load of each equipment and also the piping load. Equipment loading is provided by Mechanical department while the piping loads are worked out by the Piping department themselves. Piping department also collects information from Electrical and Instruments departments regarding the loads of their equipment. Civil engineering department prepares all the civil information / scope drawings as well as detailed construction drawings. Piping department has to indicate the size and position of pedestals, insert plates, floor openings and other requirements on the civil information drawings. Civil information drawing would thus indicate all the requirement of piping and equipment erection. Many a time, a wall is required to be constructed after the erection of an equipment.

TRAINING MANUAL- PIPING

PIPING DESIGN IN DETAILED ENGINEERING

DOC No. : 29040-PI-UFR-0002 Rev. Page : R0 : 3

Uhde India Limited

Piping department is required to furnish the clear height required between each and every floor in order to enable Civil department to design columns and beams. Civil drawings are to be checked once again by Piping department in order to ensure that no loose ends are left and all the requirements are met. The civil construction drawings are issued only after Piping gives clearance. It may be noted that each and every activity is sequential and is centred around piping. The next activity of the Piping department is to issue the nozzle orientation to Mechanical department. This activity requires close co-ordination by the Piping department with Process and Instrumentation departments. Nozzle orientation and elevation, support location, insulation, cleat orientation, ladder, platform are some of the items to be covered in the nozzle orientation sheet. Once nozzle orientation is provided, Mechanical part is complete and the vessel is cleared in all respects for fabrication. One of the most important areas of interaction with instruments department is on the hook-up points. The battery limits concerning the scope of Instruments and Piping is to be clearly marked in the drawing. This is to avoid either duplication or short ordering of material by the Piping and Instrument departments. Piping plan has to incorporate all the civil structures as well as electrical and instrument cable trays in order to clearly show the non-interference with pipes and pipe supports. The other important area is the rack piping. Rack distribution diagrams are made and loading of pipes and cables are provided to the Civil department. Road crossings, change of direction of pipes in the racks, movement of cranes are some of the important issues to be considered. Quite often the data would be required from various departments at the same time and the Piping engineer has to be well aware of this so that design does not proceed with incomplete information. Piping plans are to be issued to Process department for them to check and confirm that all the requirements P&ID are met in these piping drawings. Piping engineers prepare piping specifications based on the fluid list data provided by the Process department. Piping specification and Bill of Material are issued to Procurement department for procurement purposes. Piping department prepares isometrics, which are to be provided to the fabricator for pipe fabrication. Piping plans, isometrics, Bill of Material are issued to the Erection department to facilitate fabrication and erection through erection contractors. 3D Design Approach: As per the new concept of 3D Design the Plant is modelled on the Electronic Platform (by using modern software such as PDMS) to the last degree of detailing prior to actual commencement of erection at site. This provides a unique opportunity to eliminate every possible interface problem amongst various Groups involved in the design activities. In order to avoid communication gaps every Group participates in building/ updating the model (portion related to their scope of work). For instance the static equipment by Mechanical Group, structures and civil foundations by Civil Group etc. PI Group naturally plays a central role in ensuring a proper co-ordination amongst various groups during the progress of detailed engineering which, is incorporated in the above 3D Plant Model on regular basis. The changes/ additions as a result of design progress, are jointly reviewed by various Groups on the 3D Model to identify the consequential effects of these changes on their part of engineering.

TRAINING MANUAL- PIPING

PIPING DESIGN IN DETAILED ENGINEERING

DOC No. : 29040-PI-UFR-0002 Rev. Page : R0 : 4

Uhde India Limited

The final design is reviewed by all groups together (i.e. Process, Instrument, Electrical, Civil and Piping) on the Completed model. Owing to the unique 3D Space simulation it becomes possible to anticipate various problems (maintenance/ operation/ erection) much before the commencement of actual Plant installation at site. The solutions thus obtained are error free in totality.