Piping System Installation

 

Introduction

Welcome to Piping Knowledge! In this video, we will explore different types of pipe welds. Pipe welding is the process of joining pipes, fittings, flanges, or valves to create a functional piping system. This is a fundamental aspect of pipe fabrication.

Before diving into the types of welds, let’s understand the piping system installation process, which typically follows fabrication.

Piping System Installation

Installation Methods:

  1. Shop Fabricated and Field Installed:
    • Piping components are welded into spools in a controlled shop environment.
    • Spools are transported to the site for assembly.
  2. Field Fabricated and Installed:
    • Pipes are fabricated and installed directly at the job site.

Common Practices:

  • Butt-welded piping is typically used for NPS 2” and above.
  • Shop fabrication minimizes field welding, which is costlier and more time-consuming.
  • Prefabricated piping systems cannot always be transported as a single piece due to size and logistical constraints.

Shop Fabrication

Key Features:

  • Spools are pre-assembled in a controlled environment.
  • Each spool is labelled with a unique identification No. or Spool no. for efficient installation.
  • Fabrication includes pipe, fittings, flanges, and sometimes valves.
  • Quality control, equipment, and documentation are better managed.

Advantages:

  • Controlled environment ensures consistent weld quality.
  • Easier inspection and use of advanced tools.
  • Reduced risks from weather and site-specific challenges.

Shipping Constraints:

  • Spool pieces must fit within standardized dimensions (e.g., 3m x 3m x 12m).
  • Proper labeling and handling reduce damage during transportation.

Field Fabrication

Key Features:

  • Piping is fabricated on-site, often to accommodate project-specific constraints.

Advantages:

  • Raw materials are easier to handle and store.
  • Reduces transport-related risks.
  • Allows adjustments to site-specific obstacles (e.g., structural steel, ducts).

Disadvantages:

  • Weather conditions (rain, snow, wind) can impact safety and efficiency.
  • Pre-heating may be required in extremely cold conditions.
  • Less cost-effective and efficient compared to shop fabrication.

Comparison: Shop vs Field Welding

Aspect

Shop Welding

Field Welding

Environment

Controlled

Variable (weather impact)

Inspection

Easier and consistent

More challenging

Cost

Lower

Higher

Flexibility

Limited

High (site adjustments)

 

Types of Welds in EPC Projects

  1. Shop Welds:
    • Performed in a fabrication shop.
    • Includes butt welds for NPS 2” and above.
    • Spools are pre-assembled and hydrotested before transport.
  2. Field Welds (FW):
    • Conducted on-site, often requiring additional measures like scaffolding or protective shelters.
    • Placement of welds considers ease of installation and safety.
  3. Field Fit-Up Welds (FFW):
    • Includes an additional allowance (e.g., 150mm) for site adjustments.
    • Used when precise dimensions are unavailable during design.
  4. Tack Welds:
    • Temporary welds used for holding components together during transport or initial assembly.
    • Removed or incorporated into final welds during installation.

Key Considerations for Weld Placement

  • Accessibility: Ensure welds are placed where welders can work safely and comfortably.
  • Avoid Obstacles: Place welds to minimize interference from structural elements or equipment.
  • Ease of Transport: Design spool pieces to fit within shipping constraints.
  • Inspection Requirements: Include NDT (e.g., X-ray, ultrasonic) for quality assurance.

Best Practices

  • Shop welds are preferred for better quality and cost-efficiency.
  • Avoid horizontal field welds on vertical pipes to reduce welding difficulties.
  • Strategically use FFWs for areas requiring precise adjustments (e.g., connections to pumps or vessels).
  • Always adhere to project-specific standards and dimensions for spools.

Conclusion

Thank you for watching this video! We’ve covered the types of pipe welds and their applications in piping projects. Understanding the distinctions between shop and field fabrication, as well as the types of welds, helps in optimizing project efficiency and quality.

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Dear Reader,

I am writing to express my interest in the Piping Engineer / Mechanical Engineer / Site Engineer / Field Engineer / Static & Rotary Installation Engineer position at your organization. With over 8 years of experience in the oil and gas industry, including roles at Equilibrium Engineering Consultancy (UAE) and major projects like the Dangote and Reliance Refineries, I offer expertise in piping installation, hydrotesting, fabrication, and project management.

I hold a B.Tech in Mechanical Engineering and am NDT level-2 certified, with a strong background in installation, alignment, and testing of mechanical equipment. I am confident that my skills align with your needs.

Thank you for your time and consideration.

Sincerely,
Afzal Danish
+971 542797928
Email. afzalpipingknowledge@gmail.com

 

YouTube channel: - @pipingknowledge5360
Afzal Danish
+974 52099408
afzalpipingknowledge@gmail.com

With my best wishes.......... regard and respect to all.

                                                   Afzal Danish

 


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