PIPING EXECUTION PROCEDURE

 Basic Knowledge of Piping Execution Engineer

This article is written with my personal experience for improve Knowledge for G.E.T Engineers piping execution planning.

In this Article I  will try to  give you a basic detail of how to plan for a piping job execution and try to explain short and Best techinic.

Piping execution planning includes piping fabrication planning and piping erection planning as well which starts with data preparation for its various parameters like the total number of joints, Running meter scope of piping, scope of IM, Scope of ID, type of material, scope of the valve, and special critical components. 

INDEX:-

1. Activities to be done before starting work
2. Before Starting Pipe Fabrication work
3. Office planning work for Piping.
4. Fabrication work for Piping.
5. Pipe Erection work.

1. Activities to be done before starting work

Collect the following documents:-

•  Plot Plan – IFC
•  P & ID (Process & Utility) – IFC
•  G.A.D for all Areas
•  Isometric drawings
•  Drawing Index (P & ID, G.A.D, ISO)
•  Line detail schedule (L.D.S)
•  Pipe Rack support details
•  Support standard
•  Equipment drawings for erection purpose
•  Tapping point list
•  Piping related civil drawings (Man Hole, Catch Basin etc)
•  M.T.O (U.G & A.G) piping
•  U.G piping drawings

From Plot Plan: 

The plot plan is basically explain  an arrangement drawing that shows the static or Rotatory equipment and supporting facilities (pipe racks, structures, buildings, roads) that are required for the process facility within a battery limit area, which will be designed for independent  operation, Maintenance  and shutdown.

•  Preparing equipment list with all the necessary details.
•  Approach of crane placement for Heavy Lift/Static & Rotary equipment.

From G.A.D: -

General Arrangement drawings for piping systems and equipments are developed by piping designers. 

These drawings indicate the locations of main equipments in the plant. The main piping items, valves, and fittings are also indicated in the General Arrangement or GA drawings. 

• Compare with ISO & P&ID.

•  Line routing & nozzle orientation with ISO.

•  Check the Instrument tapping,  identify type & number of valves, orifice flanges,

• location of supports with ISO & P&ID.

•  Prepare list of small bore lines system wise.

•  Prepare the small bore isometric Bill of Material, Inch Meter (I.M) & Inch
• Diameter (I.D).

•  List out the types of supports.

•   Prepare the list of U-bolts & anchor fasteners.

From P & ID: -

A piping and instrumentation diagram, or P&ID, shows the piping and related components of a physical process flow. It's most commonly used in the engineering field.

• Prepare Nozzle analysis sheet.
•  Prepare piping specification sheet.
•  Prepare scope of work (I.M/I.D) for unit/rack.

From M.T.O (Material Take off): -

Piping Material Take Off (MTO) is a list generated by analysis of a blueprint or other design document in Engineering and Construction industry related projects. It enlists all the material that can be used in the project that includes their quantity, quality, source, elements etc.

•  Compare isometric B.O.M with main M.T.O.
• Prepare total scope Spec wise for preparing requisition for contract.
•  Material uploads in I.M.M.S system.

From Isometric Drawings: -

Isometric drawing, also called isometric projection, method of graphic representation of three-dimensional objects, used by engineers, technical illustrators, and, occasionally, architects.

Isometric drawings are commonly used in technical drawing to show an item in 3D on a 2D page. Isometric drawings, sometimes called isometric projections, are a good way of showing measurements and how components fit together. Unlike perspective drawings, they don't get smaller as the lines go into the distance.

Isometric piping drawings are not scale drawings; they are dimensioned drawings. They are not realistic, pipes are shown as single lines, and symbols are used to represent pipe fittings, valves, pipe gradients, welds, etc. Lines, valves, etc.

• List total number of ISO system wise, with Revision numbers.

•  If required mark scope of I.M, S.W (Shop weld), and F.W (Filed weld) spool numbers in each ISO.

•  Prepare total scope S.W, F.W number of spools I.M. from all isometrics.

•  Prepare a list of types of supports.

•  Prepare B.O.M for steel structure.

Drawing Index: - 

• A Drawing index is a list of Drawings on a project. It is also commonly referred to as a Drawing Register or a Master Drawing Register.

• The piping drawing index is developed from the plot plan. This drawing divides the plot plan into smaller drawing areas using match lines

• Check with index whether we received all the Drawing’s or not.

U.G. piping Drawing: -

Underground piping means piping that is buried {underground}in the ground that is in direct contact with soil and connected to an aboveground petroleum storage tank.
 * Check if any line crosses the road.
 * Identify scope of work
 * Prepare contract requisition.

2. Before Starting Pipe Fabrication work activity.

• Check the availability of material.

•  Collect marked up ISO, GAD, MTO.

•  Finalize the total scope of fabrication in I.D. & number of spools in System wise & Spec wise.

•  Locate space & location of fabrication yard.

•  Required power connection

• Finalize the contractor & mobilization

•  Arrange trailer, hydra, crane etc. for material handling.

•  Prepare spec wise material storage yard

•  Collect the required material from warehouse

•  Make fabrication schedule I.D per day/ required man power.

•  Required machinery as per main schedule.

•  Prepare temporary spool for Fabrication.

•  Prepare fabricated spool yard & Sand Blasting yard, dark room.

•  Prepare standard format for inspection of fit-up, weld, weld visuals, D.P. Daily progress report & man power report.

•  Record daily, material received from warehouse & issued to site isometric drawing wise.

•  Prepare WPS (welding procedure specification)/ PQR (performance qualification record) with pipe specifications & welder test for fabrication (QA/QC).

•  Pipe & fitting sand blasting.

3. Office planning work

• Mark the system number in P&ID & list out the total number of system.

•  Mark the loop number in each system.

•  Prepare list of system with loop number.

•  Prepare list of lines/ Isometric in each loop.

•  Prepare list of loop files with all related documents.

•  Make separate list for utility & process.

•  Collect daily progress report from contractor.

•  Make weekly progress report & give to planning department.

•  Record of MTO & material availability in warehouse & issue material to contractor (all records required).

•  Record all the latest drawings/documents & give to concern engg .

•  Record the total scope & daily progress report, unit wise.

•  Arrange the shortage material.

4. Fabrication work in Piping.

Pipe fabrication is the process of cutting, bevelling, and welding piping components like pipes, tees, elbows, flanges, reducers, etc. Piping fabrication is a highly critical activity requiring high precision and involving hundreds of components and thousands of steps.

Some important point during Febrication

• Fabrication starts from pipe rack & then unit.

• During fabrication, make daily fit-up report & signature. Check the following

• Punching/painting the joint number, line number, spool number.

•  Pipe schedule/class & dimensions as per drawing.

•  After signature of fit-up, spool will be released for welding

•  Put the welder number in each joint after welding

•  Grinding, cleaning of joints.

•  Prepare the welding report.

•  Offer the spool for weld visual & signature from QA/QC.

•  Send the spool for radiography.

•  Send the fabricated spool to the spool yard.

• Colour coding in isometric drawings fit-up/weld/weld visual.

• During fabrication if any shortage of fittings/pipe inform to planning department & record in isometric drawings.

Some Important point during Febrication.

• Data preparation for Spool-wise fittings requirement.

• Tracking for required and available fitting for fabrication.

• Deciding priority of spools required as per erection sequence and physical front going to available.

• Issuing drawings as per material availability and work front.

• Deciding priority of spools required as per erection sequence and physical front going to available.

• Painting of spool as per required Dry film thickness (DFT).

• Preparing spool clearance note and Dispatch to the site for erection activities.

5. Pipe Erection work

Piping Installation or Erection refers to the laying of the piping system and its related accessories to make it ready for fluid transfer. 

• Mobilize the contractor at site with office, tools & machineries.

•  Power connection for erection work as per requirement.

•  Prepare area for spool unloading & F.W. fittings & valves.

•  Arrange transportation for shifting the spools, F.W. fittings at erection site.

•  Collect one set of drawings, MTO, support details etc. at site.

•  Mark the line number on the pipe rack tire beams as per drawing/dimensions

•  Collect the pipe rack support details & schedule & start fabrication of support (only pipe rack).

•  Start the erection work from the pipe rack.

•  After release of front from equipment, start unit piping.

•  * Make daily erection progress report, ID, IM (unit wise).

•  Make proper erection schedule & increase man power & machinery to achieve the schedule.

• During the erection of spools parallels support work can be started.

• Radiography, Stress Reliving, NDT as per requirement.

• Start the utility line erection as per schedule.

• After completion of some lines, start Mechanical Clearance (MC) of loop.

• After MC, loop file handed over to QA/QC department.

• QA/QC will check NDT part, Radiography, DP, UT etc. & release for Hydro-test.

•  After completing hydro-test of a system, release the system for format – I to operation/ maintenance.

•  Operation/maintenance will give format – II with punch points.

•  Clear the punch points & release the format – III.