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What is Importance of Piping Engineering ?

Organization

About Department

Department Strength
Head of Dept. 1 Dy. Head of Dept. 2
Managers 17Sr. Engineers 32
Engineers 53
Designers 34
Sub Total 139
Contract - 62
Total - 201

What is
Piping

In any plant various fluids flow through


pipes from one end to other.
Now let us start with a plant where we see
three tanks.
Tank-1, Tank-2 and Tank-3
We have to transfer the content of Tank no. 1
to the other two tanks.
We will need to connect pipes to transfer the
fluids from Tank-1 to Tank-2 and Tank-3

LET US BRING THE PIPES.

To solve these
problems we need
the pipe
components, which
are called
PIPE FITTINGS

We have just brought the pipes, now


we need to solve some more
problems.
Pipes are all straight pieces. es
ip
p
e
t
om eren
s
iff
en
Ev of d
are es!
siz

We need some
branch
connections

We need some
bend connections

These are the pipe fittings,


There are various types of fittings for
various purposes, some common types are Elbows/Bends, Tees/Branches,
Reducers/Expanders, Couplings, Olets, etc.

Anyway, the pipes and


fittings are in place, but
the ends are yet to be
joined with the Tank
nozzles.

We now have to complete the


end connections.
These, in piping term, we call

TERMINAL
CONNECTIONS.

So far this is a nice arrangement.


But there is no control over the flow from
Tank-1 to other tanks.
We need some arrangement to stop the
flow if needed

These are flanged


joints
This is a welded joint

To control the flow in a pipe line


we need to fit a special
component.
That is called - VALVE

There are many types of valves, categorized


based on their construction and functionality,
Those are - Gate, Globe, Check, Butterfly, etc.

Other than valves another


important line component of pipe
line is a filter, which cleans out
derbies from the flowing fluid.
This is called a STRAINER

Here we see a more or less functional


piping system, with valves and strainer
installed.
Let us now investigate some aspects of
pipe flexibility.

If this tank
nozzle expands,
when the tank is
hot.
In such case we need to fit a
flexible pipe component at that
location, which is called an

EXPANSION JOINT

When some fluid is flowing in a pipe we


may also like know the parameters like,
pressure, temperature, flow rate etc. of
the fluid.

To know these information we


need to install INSTRUMENTS
in the pipeline.

Next we shall
look into how to
SUPPORT the
pipe/and its
components.

There are various types instruments to measure


various parameters. Also there are specific criteria
for installation of various pipe line instruments.

Here are some of the pipe supporting


arrangements. There can be numerous variants.
All depend on piping designers preference and
judgement.

Let us see some OTHER types of supports

Interfacing with other departments

Interfacing with other departments

Interfacing with Civil

Interfacing with other departments

What will be the Skirt Height ?

Interfacing with Process

Interfacing with other departments

Interfacing with
Static Equipment

Interfacing with other departments

Interfacing with Civil


Interfacing with
Static Equipment

Interfacing with other departments

Interfacing with
Rotating Machinery

Interfacing with other departments


Interfacing with Instrumentation

Interfacing with Stress Group

Interfacing with Support Group

Interfacing with U/G

Interfacing with other departments


Interfacing with Instrumentation

Interfacing Stress Group

Interfacing with
Static Equipment

Interfacing with Civil

Interfacing with Support Group

Interfacing with UG

Interfacing with Process

Interfacing with
Rotating Machinery

PROJECTS

PROCESS

CIVIL

BID
DOCUMENT
S
SCHEDULE,
MANHOURS
ETC.

P&ID, PFD,
LINE LIST,
EQUIPT.
LIST, BASIC
PLOT PLAN

CIVIL / STR.
DRAWINGS,
FOUNDATIO
N DWGS.,
CRWS
LAYOUT

ELECTRICAL INSTRUMET. EQUIPMENT MACHINERY


ELE. CABLE
TRAY DWG,
HAZARDOUS
AREA
CLASS.,JB
LOCATIONS

LEVEL
SKETCH,
INST.
CABLE /
DUCT
LAYOUT,
INSTR. ITEM
DWGS

ENGG.
PUMPS /
DWGS,
COMPR. /
VENDOR
PACKAGE
DRAWINGS, DRAWINGS
PACKAGED HANDLED BY
ITEMS LIKE MACHINERY
HEATERS

PLANT AND PIPING ENGG. INTERFACING

PROJECTS
ALL
DOCUMENT
S/ DWGS. AS
PER
DOCUMENT
MASTER

PROCESS

CIVIL

CIVIL INFO
PSV
DWGS. FOR
ROUTING,
P/R, T.S., OP.
UHD
PLTFS.,
PLANNING,
PMS, EQPT. INSERT PL.,
SUPPORTS
LAYOUT

ELECTRICAL INSTRUMET. EQUIPMENT MACHINERY


EQPT.
EQPT.
NOZZLE
EQPT.
LAYOUT,
LAYOUT,
ORIENTATIO
LAYOUT,
NOZZLE
NOZZLE
N, SUPPORT PMS, VMS,
ORIENTATIO ORIENTATIO
CLEAT
INPUTS FOR
N, G.A.
N, G.A.
DWGS..EQPT PACKAGE
DWGS
DWGS, PMS,
. LAYOUT
ITEMS
VMS

Flowchart of Piping Department


Process & Flow Diagrams
General Layout
Equipment Datasheet
Datasheets of Streams

Equipment Layout

Piping Study

Classes & Specifications


of Components for Piping

3D Model

Definition of the Quantity


to be erected: Piping,
insulation, Painting

Isometric &
Material Lists

Technical Documentation
As per Contract agreement
Mechanical
Insulation Work
Painting Work

Civil, Electrical &


Instrumentation
Engineering

Stress Analysis

3-4 MTO

Materials
Requisitions (MR)

Proposal Engineering

Basic / Detail Engineering

What are the functions of Department ?


Construction Assistance

Procurement Assistance

Proposal Engineering
Technical Requirement From Client/ PMC/
Licensors
Basic
Layouts and Data from Client/PMC
Preliminary Design / Layout
MTO Estimation & Construction Work Volume

Construction Assistance
Const. Activity Planning , Warehouse
Management
Erection
Pre-Commissioning

Basic / Detail Engg


Interpretation of Technical Requirement
Final Design / Layout/ Specification
Integrated PDS modeling & Const. Drawings
MTO, MR/PR, Construction Work Volume

Procurement
Procurement

Requirements:
PR, MR Specifications
Quantity

PO

Commissioning

Inquiry

Start-up & Handover


Engineering
Bid

Negotiation Deviation
Vendor Drg./Data

Technical
Evaluation

Commercial
Evaluation

Proposal Engineering
Technical Requirement From Client/ PMC/
Licensors
Basic
Layouts and Data from Client/PMC

Technical Requirement From Client/ PMC/ Licensors

Preliminary Design / Layout

Basic Layouts and Data from Client/PMC

MTO Estimation & Construction Work Volume

Preliminary Design / Layout


MTO Estimation & Construction Work Volume

Work Flow for Proposal Engineering


Receiptofoftenders
tenders&&
Receipt
biddocuments
documents
bid

Bidreview,
review,
Bid
raisetechnical
technical
raise
queries &&
queries
clarifications
clarifications

Reviewofofequipment
equipment
Review
layoutand
andissue
issueto
to
layout
internaldepartments
departments
internal

Technicallyevaluate
evaluate
Technically
vendoroffers
offersof
of
vendor
pipingitems.
items.
piping

Issuematerial
materialtake
take
Issue
offsfor
forall
allpiping
piping
offs
itemsand
and
items
requisitionsififasked
asked
requisitions
for.
for.

Issuecivil
civil
Issue
information
information
drawings,loading
loading
drawings,
data
data

Issueconstruction
construction
Issue
workvolumes
volumeslike
like
work
Inch-Dia,Inch-Mtr,
Inch-Mtr,
Inch-Dia,
PWHT,radiography,
radiography,
PWHT,
LP/DP,insulation,
insulation,
LP/DP,
painting.
painting.

SiteSurvey
Surveyifif
Site
required
required

Interfacingwith
with
Interfacing
otherdisciplines
disciplinesfor
for
other
accurateestimation
estimation
accurate
ofquantities
quantities
of

Proposal Engineering
Technical Requirement From Client/ PMC/
Licensors
Basic
Layouts and Data from Client/PMC
Preliminary Design / Layout
MTO Estimation & Construction Work Volume

Construction Assistance
Const. Activity Planning , Warehouse
Management
Erection
Pre-Commissioning

Basic / Detail Engg


Interpretation of Technical Requirement
Final Design / Layout/ Specification
Integrated PDS modeling & Const. Drawings
MTO, MR/PR, Construction Work Volume

Procurement
Procurement

Requirements:
PR, MR Specifications
Quantity

PO

Commissioning

Inquiry

Start-up & Handover


Engineering
Bid

Negotiation Deviation
Vendor Drg./Data

Technical
Evaluation

Commercial
Evaluation

Basic / Detail Engg


Interpretation of Technical Requirement

Interpretation of TechnicalFinal
Requirement
Design / Layout/ Specification

Integrated PDS modeling & Const. Drawings

Final Design / Layout/ Specification


MTO, MR/PR, Construction Work Volume

Integrated PDS modeling & Const. Drawings


MTO, MR/PR, Construction Work Volume

How do We build 3D Model ?


And What does it delivers ?

Proposal Engineering
Technical Requirement From Client/ PMC/
Licensors
Basic
Layouts and Data from Client/PMC
Preliminary Design / Layout
MTO Estimation & Construction Work Volume

Construction Assistance
Const. Activity Planning , Warehouse
Management
Erection
Pre-Commissioning

Basic / Detail Engg


Interpretation of Technical Requirement
Final Design / Layout/ Specification
Integrated PDS modeling & Const. Drawings
MTO, MR/PR, Construction Work Volume

Procurement
Procurement

Requirements:
PR, MR Specifications
Quantity

PO

Commissioning

Inquiry

Start-up & Handover


Engineering
Bid

Negotiation Deviation
Vendor Drg./Data

Technical
Evaluation

Commercial
Evaluation

Work Flow for Procurement Engineering


Procurement

Requirements:
PR, MR Specifications
Quantity

PO
Inquiry

Engineering

Procurement

Bid
Negotiation
Deviation
Vendor Drg./Data

Requirements:

Procurement

PR, MR Specifications
Quantity

Engineering

PO

Inquiry

Supplier
Bid

Negotiation Deviation

Technical
Evaluation

Commercial
Evaluation

Vendor Drg./Data

Technical
Evaluation

Commercial
Evaluation

Proposal Engineering
Technical Requirement From Client/ PMC/
Licensors
Basic
Layouts and Data from Client/PMC
Preliminary Design / Layout
MTO Estimation & Construction Work Volume

Construction Assistance
Const. Activity Planning , Warehouse
Management
Erection
Pre-Commissioning

Basic / Detail Engg


Interpretation of Technical Requirement
Final Design / Layout/ Specification
Integrated PDS modeling & Const. Drawings
MTO, MR/PR, Construction Work Volume

Procurement
Procurement

Requirements:
PR, MR Specifications
Quantity

PO

Commissioning

Inquiry

Start-up & Handover


Engineering
Bid

Negotiation Deviation
Vendor Drg./Data

Technical
Evaluation

Commercial
Evaluation

USING

AS

PLANT ENGINEERING TOOL

TO ASCERTAIN
HIGH QUALITY DESIGN
THROUGH
VIRTUAL PLANT CONSTRUCTION

Work Flow for 3D Modeling


P&ID, PDS 2D

CONSTRUCTIO
N

PLOT PLAN

REVISION

EQ / ME.
DATA SHEET

REVISION

STRUCTURE /
FOUNDATION DRG

REVISION

CONSTRUCTION DRG
ERECTION QTY/ WORK VOLUME

EL CABLE TRENCH
& IN DUCT LAYOUT
PIPING SERVICE
CLASSES

MTO

CUSTOMISATION

3D MODELING
PRELIMINARY

3D MODEL
UPDATE
CHECK

1. DESIGN REVIEW
2. PRE CHECK
3. GROUP
DISCUSSION

CHECK BY
LE/SE

CONST DRG.

STUDY ON PAPER
STUDY AROUND
EQUIPMENT
REFERENCE DRG.
FROM
OWNER/PMC

3D MODEL
UPDATE

DESIGN REVIEW
SESSIONS WITH
CLIENT / PMC

PROCUREMENT

3D MODEL
UPDATE

COMMENTS MARKED
ON PRE ISO OR CONST.
DRAWING

3D PLANT MODEL APPROACH


A CASE STUDY

Equipment Layout

Structural
Modeling

Equipment Modeling

Piping Modeling

Accessibilit
y

Intelligence

Operability

Constructibility

Monorail

Maintenance

Extent of 3D Modelling
All piping within the units & offsite, above ground and underground,
Jacketing, big bore and small bore, and including package items
All inline instruments like control valve, safety valves, flow instrument,
level instrument,etc. with near exact geometry
All piping specialty like MOV, steam traps, strainers, funnel, hose
coupling etc. with near exact geometry
All pipe physical supports using structural steel members with complete
details
Access envelop for strainer element removal, temperature element
removal, etc. for interference detection
All Equipments , Structure, Electrical / Instrument Cable duct, Lighting
Fixtures

Cable Route North Utility CCB

3D Model v/s Reality


Project SIPChem Methanol Complex
Location Al-Jubail, Saudi Arabia

In PDS Model

Actual at Site

Feed Gas Saturator

In PDS Model

Actual at Site

Deliverables Using PDS


PIPING GENERAL ARRANGEMENT DRAWINGS
ISOMETRICS FOR CONSTRUCTION
BILL OF MATERIAL
NOZZLE ORIENTATION DRAWINGS
CLASH CHECK REPORT
DIFFERENT TYPE OF REPORTS FROM MODELLED DATA
DESIGN REVIEW FILES

Advantages of 3D Modelling in EPC


Design
Consistency
Checks
Interface checks
with other
disciplines

Integrated model
of all disciplines

3D Model

Minimize Manual
Errors

Reduction
of rework during
design & at site

Accurate MTO
Better Space
Planning

Parallel
Design
Review

Customized
Report on work
volume etc

Switch to Stress Analysis

Simultaneous Multidisciplinary Engineering between various


Engineering Offices, while ensuring application of same set of
Design Rules throughout.

PIPING

EQUIPMENT

INSTRUMENT

PDS 3D
MODEL

INTERNAL
WEEKLY DESIGN
REVIEWS

- Design
- PDS Setup
- Procedures
- Formats
Partly.
MILESTONE
DESIGN REVIEWS
& COMMENTS

PROCESS
P&IDS
PLOT PLAN
PROCESS
REQUIREMENTS
OPERABILITY
CONSTRUCTABILITY

HOME OFFICE

How does Department execute the jobs ?


DESIGN
OFFICE

CIVIL AND
STRUCTURAL
FIRE
FIGHTING

Design Changes

ELECTRICAL

Output Documents
(Iso,GAD,MTO)
PROJECT SITE
OFFICE

INCORPORATION
OF REVIEW
COMMENTS

Execution Models (Domestic Job)


VSAT

Construction
site

Design
Office

FTP /
Email
Tele
Conferencing

Procurement
Office

Scanne
r

Execution Model (International Job)


On-line Discussions
Concepts, Changes

Video Conferencing and Web


Collaboration

Concepts, changes
Status reports
Schedules, escalation
Inputs,. deliveries

FTP/ Email
Tele Conferencing

Site Office
Scanner

Home
Office

Design
Office

Sketches for concepts, Changes,


Design Guidelines, Standards.

SOFTWARES being Used in Department


3D MODELLING SOFTWARE
PDS 3D - Intergraph Plant Design System
AUTO PLANT For smaller plants
SSPipe
STRESS ANALYSIS SOFTWARE
CAESAR-II for stress analysis
AUTOPIPE for stress analysis
CAD SOFTWARE
MICROSTATION for 2D applications
AUTOCAD 2006, 2007
SMART SKETCH
REVIEW SOFTWARE
Intergraphs Smart Plant Review & Design Review
Navis Work

SOFTWARES being Used in Department


PC COOK FOR CALCULATIONS RELATED TO PIPING COMPONENTS.
DRAW-IZ FOR GAD ANNOTATION
IGS & IRIS FOR ISOMETRIC EXTRACTION & CONTROL
PDS SUPPORTING SOFTWARE ( In house developed )
LTCSUPPORT ( for special support placement)
MTO Processing software
Model Progress Controller (MPC) & Online Project Documentation
Clash report in the form of Design review tag file
CEof software for Caesar II output to get maximum restraint value

QUALITY LIST OF PROCESSES FOR PP


SR.
NO

PROCESS

TARGET

Preparation
of Material
Requisition

Receipt of Bid from


vendor without any
comments on specified
Data. Approval of the
document within 3
revisions.

Preparation
of
Equipment
Layout

Approval of the
document within 7
revisions.

Preparation
of Plant 3D
Model

Approval of the output


documents from PDS
within 3 revisions, on
average.

Flexibility
Analysis

Approval of the
documents within 3
revisions on average.

QUALITY
OBJECTIVE

TARGET

QUALITY
Rework at site

NOT TO EXCEED
2%

ECONOMICAL
DESIGN Bulk
material and
work volume

TARGET
TOLERANCE :
+0/-10% of
Proposed
Quantities (LTC)

ECONOMICAL
DESIGN ManHours

TARGET
TOLERANCE : +/10% of Budgeted
Man-Hours

SCHEDULE

TARGET
TOLERANCE : 0%
from Agreed
Schedule

Virtual Effect of Plant Maintenance


Virtual Effect of Plant Tour

May all be Happy,


May all be Healthy,
May all Experience what is good and let no one suffer !!!

Thank You !!!

Jacketed Piping Details

Customized Instruments

Customized Piping Specialty Items

Customized Pipe Supports

Soft Envelope Modeling


Strainer Removal Soft Envelope

Manhole Soft Envelope

Equipment - Typical Model

Civil - Structural Modeling

Electrical /Instrument Modelling

Sample Isometric Drawing

Sample G.A. Drawing