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Lessons Learned

from Husky Sunrise Project

Piping Material Engineering


Needle Valve MALE- FEMALE issue
10745: VALVE, NEEDLE, 6000 PSIG W.O.G., (?)SOCKET WELDING END X FEMALE
THREADED END, STAINLESS STEEL ASTM A479 GRADE 316L BODY, 316 SS SEAT,
GRAPHOIL PACKING WITH CORROSION INHIBITOR, INSPECTION CATEGORY A PER
PROJECT SPECIFICATION, BARSTOCK BODY, INTEGRAL SEAT, 3/16 INCH ORIFICE, TEE
HANDLE, TYCO H7 OR EQUAL, AS PER MANUFACTURER STANDARDS.

FTHD X FSW (wrong valve) MSW X FTHD

MALE or FEMALE end must be specified for valves in the piping specification.
Valve Bolt-Nut info issue
5928: VALVE, GATE, CLASS 150, RAISED FACE(S) WITH FINISH TO MSS SP6,
STAINLESS STEEL ASTM A351 GRADE CF8M BODY AND BONNET, TRIM 12,
STAINLESS STEEL ASTM A193 GRADE B8M CLASS 2 BOLTS WITH ASTM A194 GRADE
8M NUTS, FLEXIBLE GRAPHITE PACKING WITH CORROSION INHIBITOR, BRAIDED END RINGS AND DIE FORMED INNER RINGS,
316 SS SPIRAL WOUND WITH GRAPHITE FILLER BONNET GASKET, INSPECTION CATEGORY B PER PROJECT SPECIFICATION, BOLTED
FLEXIBLE WEDGE, STANDARD SEAT, FULL PORT, HANDWHEEL OPERATOR,
BONNET, OS&Y,
ASME B16.34, FOR ASME B16.5 FLANGES.

Valve manufacturer KITs BOM Spec. asked for

Bolt-Nut will be as per valve manufacturer standard in the piping spec.


Check Valve with cover gasket
Hydrotest require opening of the cover to
remove internals from the check valve that
ruin cover gasket when to be tested. A new
cover gasket shall be installed after the
completion of the Hydrotest.

Purchasing one extra


cover gasket with each
Check valve would
solve the issue.
Plug Valve
Plug valve usually are internally lined with
PFA/PTFE. PTFE (non-metallic) gasket should
be used at flanges.
1) Lined pipe+ lined valve= No gasket
2) Lined pipe+ valve= Non-metallic gasket
3) Pipe+ Lined valve= Non-metallic gasket

Lined valve part


destroyed due to
wrong metallic
(spiral wound)
gasket use

For lined plug valve, PTFE (Non-metallic) gasket.


Avoid adding Valve in Sour Process Line
It is not a good practice to add valve as Hydrotest
vent/drain in a sour service to avoid closure weld.

Ask process before adding any valves to vent and drain.


Y- strainer with different drain size
STRAINER, Y, CLASS 600, SOCKET WELDING, CARBON STEEL ASTM A216 GRADE
WCB BODY, 304 STAINLESS STEEL SCREEN, MUELLER 582 OR EQUAL, AS PER
MANUFACTURER STANDARDS.

Drain size SHALL be specified.


Example: Same Y-strainer from different manufacturer has & 3/8 drains
where a gate valve is to be added to the drain point.
Items sandwiched between Flange
Injection quill
More attention is required for designing SPECIAL ITEMS that sandwiched
between flange to avoid construction delay

Injection quills header of 100m was incorrect for 3 flanges.

Simple solution is to take corresponding class+size


gasket outside dia as the sandwiched part diameter.
Items sandwiched between Flange
Temporary Strainer
More attention is required for MANUFACTURER STANDARD drawings item that will be sandwiched
between flange to avoid installation issue

16 STRAINER, CONE TEMPORARY, 14 GAUGE CONE, CLASS 300, RAISED FACE(S) WITH FINISH TO MSS SP6, 304L STAINLESS
STEEL WITH 1/4 INCH THICK INTERNAL CROSS BRACING, 1/8 INCH DIAMETER HOLES, 150% OPEN AREA, FOR ASME B16.5
FLANGES, AS PER MANUFACTURER STANDARDS.

Simple solution is to take corresponding class+size


gasket outside dia as the sandwiched part diameter.
Gasket- SPIRAL WOUND
with or without Inner Ring
Without inner ring gasket has a tendency to buckle which is the main source
of leaking. Inner ring buckle cannot be detected during installation so it is
not possible to be sure that leaking did not occur during operation.

Source: Flexitallic

Purchasing all gaskets with inner ring is the best solution.


OR
Gasket with inner ring shall have a BLUE color on the
circumference with 4 stripes 90 apart.
Bolts with different length
BOLT, STUD, ALLOY STEEL ASTM A193 GRADE B7 WITH ASTM A194 GRADE 2H
NUTS, 2 HEAVY HEXAGONAL NUTS. LENGTH IS IN mm.

Vendor supplied Bolts are in IMPERIAL UNITS (in) which differ from the length
asked for in metric system (mm).

In line class, stating stud bolt length in imperial units


can solve this issue.
Gaskets & Bolts
All gaskets should be bought with Inner ring.
This helps to avoid 1000s man-hours only for answering or
finding the correct gasket to install.

For all CS bolts can be BOLT, STUD, ALLOY STEEL


ASTM A193 GRADE B7M WITH ASTM A194 GRADE
2HM NUTS, 2 HEAVY HEXAGONAL NUTS. This helps to
avoid 1000s man-hours answering or finding correct bolts to
install.
B8 > B7M > B7= $2.5x > $1.1-1.2x > $1.0
Item price has no major impact or even less if considered the
time it can save.
Some Numbers for Piping
Valves: 21502 (21207- Calgary + 295- site)
Flange: 20733 pcs (20516- Calgary + 217- site)
Gaskets: 87, 658 pcs (84174- Calgary + 3484- site)
Pipes: 155,683 meter (153975- Calgary + 1708- Site)
Stud-Bolts & Nuts: 185034 pcs (177278- Calgary +
7756- site)
Specialty Items: 677 CPF + 49 SRU
Valves#- 21502
Valves used in Husky Sunrise Project

Gate valves: 17565+229=17794 (83%)


Globe valves: 572+3=575 (3%)
Check valves: 1037+6=1043 (5%)
Ball valves: 1694+20=1714 (8%)
Bolts- B7 with 2H or B7M with 2HM
Total project purchase:
Bolts -Stud & Nuts B7/ 2H: 84114
Bolts -Stud & Nuts B7M/ 2HM: 86594
Bolts -Stud & Nuts B8M CL 1-2/ 8M: 6424
A307 GR.B GALV / ASTM A563 GALV : 464

Site purchase: 7756 (mostly B7M)


NGC bolts & washer supply for PTFE lined pipe
Project requirement vs. Purchased
Items Project Purchased Unit Remarks
requirement
Valves 15802 21502 pcs Purchased
Flange 15760 20733 pcs items
include SRU
Gaskets 15760 87658 pcs Items does
Pipes 117549 155683 meter not show
Studs & Bolts 99818 185034 pcs the quantity
required for
Specialty Item 726 726 pcs FDN

Updated
June 20, 2014
Important Notes
Bolt torquing value: Document for bolt
torquing value needs to be added in VDR for
gaskets other than Spiral Wound type (i.e.
PTFE, Neoprene, Buna-N gaskets etc.)

Each GeMaPi voucher would be individually


marked for easy search in future i.e. PCV 1399
[Piping Collecting Voucher], PEWV 3236
[Piping Extra Withdrawal Voucher]
Why issuing so many vouchers for lost items?
Important Notes
Valves should come with PO# and Tag# in one SS tag.
Inspection department should implement this. Piping
informed inspection. However, adding a quick cheat
sheet like below can help everyone involved in
material purchasing.

Before asking any question, please read the project specification.


Hydrostatic Test
Criteria should be set for issuing FDN. No FDN for those
ISO info which does not affect hydrostatic tests activities:
Operating temp.
Insulation type
Insulation thickness
Tracing type, stress system
Cosmetic typo on line number
Flow direction etc.

These info can be updated as red mark on


master copy ISO.