HERVE Engineering Training

BARON

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Piping

Engineering discipline.

Comments are most welcome (herve.baron@gmail.com),

which I will incorporate for the benefit of all.

Please download this file so that you can see my trainers

notes in the top left corner latest Acrobat Pro feature.

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Herv
HERVE Engineering disciplines: activities and deliverables
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PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

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INSTRUMENTATION

ELECTRICAL
HERVE
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Process design

PFDs P&IDs We are

here
H&M balance
Piping
Instrumentation

Equipment specification
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Fired equipment Civil

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Heat exchangers
Electrical
Packages etc.
HERVE Piping discipline
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Plant Layout &

Piping discipline

Piping Piping Piping stress

Plant Layout
installation materials analysis

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HERVE Piping installation
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Unit Plot Plan Line diagram
HERVE Piping study & layouts
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Piping layout
Line diagram
HERVE Piping study
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HERVE Piping study
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Requirements from Process

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HERVE Piping routing/provision for flexibility
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HERVE Piping layout
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Important considerations
for piping layouts:

Operator access to:

Valves
Instruments

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HERVE Piping Routing
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HERVE Piping Routing
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HERVE Piping layout
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Important considerations
for piping layouts:

Operator access to:

Valves
Instruments

Straight pipe lengths

upstream & downstream
flow meters

Straight pipe lengths

upstream & downstream
control valves

PSVs and BDVs located at

high points with slopes on

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both side lines

Safe location of vents

HERVE Piping design basis
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The Piping design basis, also called Job specification for design Piping, modifies and
supplements to design code (AME B31.3)

Contents include

Provisions for future

Clearance
Valve accessibility

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HERVE Piping design basis
BARON

The Piping design basis, also called Job specification for design Piping, modifies and
supplements to design code (AME B31.3)

Contents include

Provisions for future

Clearance
Valve accessibility

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HERVE Piping design basis
BARON

The Piping design basis, also called Job specification for design Piping, modifies and
supplements to design code (AME B31.3)

Contents include

Provisions for future, e.g., spare space on pipe-racks and sleeper ways
Clearance
Valve accessibility

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HERVE Piping design basis
BARON

The Piping design basis, also called Job specification for design Piping, modifies and
supplements to design code (AME B31.3)

Contents include

Provisions for future

Clearance
Valve accessibility

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HERVE Piping design basis
BARON

The Piping design basis, also called Job specification for design Piping, modifies and
supplements to design code (AME B31.3)

Contents include

Provisions for future

Clearance
Valve accessibility

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HERVE Piping Layout/3D model
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Piping layout
HERVE Piping modelling in 3D model
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HERVE 3D model reviews
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Second model review:

When 60% of the piping is modelled, i.e., all 4 and larger indicated on P&IDs

Aspects reviewed: location of individual items (valves, instruments, junction boxes, panels),
arrangement around all equipment, location of fire fighting equipment, confirm space around
equipment for maintenance based on vendor requirements, handling equipment (hoist/davit),
platforms for all accesses required for operation

Third model review:

When 90% of Piping is modelled, i.e., all 2" and larger as indicated on P&IDs

Allows to start ISOs production after implementation of comments raised.

Aspects reviewed: accesses to all remaining items (flanged joints etc.), location of remaining items
(utility stations etc.).

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HERVE Piping drawing extraction
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HERVE Isometric drawings
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HERVE Isometric drawings
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HERVE Isometric drawings
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What checks would you

do before issuing an
isometric drawing?

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HERVE Isometric drawings
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HERVE Piping Isometric
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HERVE Piping Isometric
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HERVE Piping design iso vs Shop iso
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HERVE Post weld heat treatment
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HERVE Post weld heat treatment
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When is PWHT
applied?

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HERVE Post weld heat treatment
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When is PWHT
applied?

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For sour service
(NACE) and above
19mm w.t. (B31.3)
HERVE Piping inspection and testing
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How is the % of welds
to be RT defined?

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HERVE Piping NDE
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ANSI B31.3 Requirements:

Extent of RT/US (for circumferential welds) shall be as follows, or

to any greater extent specified in the engineering design:
Normal Fluid Service 5%, random selection to cover work of
each welder
Category D fluid Visual only
Severe Cyclic Conditions 100%

States that supplementary examinations and any acceptance

criteria that differs shall be specified in the engineering design
Therefore ASME B31.3 gives minimum requirements and
Client shall include in Design Basis a specification for higher

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inspection requirements (see example that follows)
HERVE Piping NDE
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ANSI B31.3 Requirements:

Extent of RT/US (for circumferential welds) shall be as follows, or

to any greater extent specified in the engineering design:
Normal Fluid Service 5%, random selection to cover work of
each welder
Category D fluid Visual only
Severe Cyclic Conditions 100%

States that supplementary examinations and any acceptance

criteria that differs shall be specified in the engineering design
Therefore ASME B31.3 gives minimum requirements and
Client shall include in Design Basis a specification for higher

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inspection requirements (see example that follows).

On what criteria will they be based?

HERVE Piping NDE
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ANSI B31.3 Requirements:

Extent of RT/US (for circumferential welds) shall be as follows, or

to any greater extent specified in the engineering design:
Normal Fluid Service 5%, random selection to cover work of
each welder
Category D fluid Visual only
Severe Cyclic Conditions 100%

States that supplementary examinations and any acceptance

criteria that differs shall be specified in the engineering design
Therefore ASME B31.3 gives minimum requirements and
Client shall include in Design Basis a specification for higher

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inspection requirements (see example that follows).

On what criteria will they be based? Service + pressure class

HERVE Piping NDE
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HERVE Piping general arrangement drawing
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HERVE Piping Hydrotest
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HERVE Piping Hydrotest
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ASME B31.3 requires:

Hydrostatic leak test at 1.5 times the design pressure

If Owner considers that hydrostatic leak test is impracticable, a

pneumatic test may be substituted

At the Owners option, a service test can be done in lieu of

hydrostatic leak test for category D fluids, i.e.,
Nonflammable, non toxic
and
Design Pressure < 10 barg

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For which fluids is it common to do a service test?
HERVE Piping Hydrotest
BARON

ASME B31.3 requires:

Hydrostatic leak test at 1.5 times the design pressure

If Owner considers that hydrostatic leak test is impracticable, a

pneumatic test may be substituted

At the Owners option, a service test can be done in lieu of

hydrostatic leak test for category D fluids, i.e.,
Nonflammable, non toxic
Design Pressure < 10 barg

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What does ASME B31.3 says about golden welds?
HERVE Piping Hydrotest
BARON

ASME B31.3 requires:

Hydrostatic leak test at 1.5 times the design pressure

If Owner considers that hydrostatic leak test is impracticable, a

pneumatic test may be substituted

At the Owners option, a service test can be done in lieu of

hydrostatic leak test for category D fluids, i.e.,
Nonflammable, non toxic
Design Pressure < 10 barg

Closure welds. The final weld connecting piping systems which

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have been successfully tested need not be tested provided the
weld passes with 100% RT or US.
HERVE Piping installation work process
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Line Piping Isometric

Plot Plan 3D model
Diagram Layout drawing

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HERVE Piping discipline
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Plant Layout &

Piping discipline

Piping Piping Piping stress

Plant Layout
installation materials analysis

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HERVE Piping stress analysis
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HERVE Piping stress analysis
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Which calculations are done

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for Piping?
HERVE Piping stress analysis
BARON

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By how much does a 10 meter long
carbon steel line expand when its
temperature increases by 100C?
HERVE Piping Flexibility and Stress Analysis Criteria
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Not all lines are subject to calculation for stress.

This is defined in the Piping Flexibility and Stress Analysis Criteria.

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HERVE Piping Flexibility and Stress Analysis Criteria
BARON

Not all lines are subject to calculation for stress.

This is defined in the Piping Flexibility and Stress Analysis Criteria.

Level 1 : Visual Analysis

No stress analysis is required. The piping lines are routed and supported
by piping designers as per usual practice.

Level 2: Simplified Analysis

This method includes the use of charts, cantilever method or simplified
formulae.

Level 3: Detailed analysis

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Detailed analysis by computer program shall be carried out.
HERVE Piping Flexibility and Stress Analysis Criteria
BARON

Not all lines are subject to calculation for stress.

This is defined in the Piping Flexibility and Stress Analysis Criteria.

Level 1 : Visual Analysis

No stress analysis is required. The piping lines are routed and supported
by piping designers as per usual practice.

Level 2: Simplified Analysis

This method includes the use of charts, cantilever method or simplified
formulae.

Level 3: Detailed analysis

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Detailed analysis by computer program shall be carried out.

On which basis is the category of a line decided?

HERVE Piping Flexibility and Stress Analysis Criteria
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Line temperature Level 1 : Visual Analysis

Line diameter Level 2: Simplified Analysis
Level 3: Detailed analysis

FAT: FLEXIBILITY ANALYSIS TEMPERATURE (C) (Note 9)

PIPING LINE TYPE Amb Tref: 20C
PIPE SIZE (INCHES)
CONNECTION TYPE (Note 9)
FAT (C)
2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"
400

Non-fragile equipment and/or 300

low movements (<600#)
Level 2 Level 3
A
Carbon steel 200
(Note 7)
100 Level 1
0

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HERVE Piping Flexibility and Stress Analysis Criteria
BARON

Line temperature Level 1 : Visual Analysis

Line diameter Level 2: Simplified Analysis
Criticality of equipment Level 3: Detailed analysis

FAT: FLEXIBILITY ANALYSIS TEMPERATURE (C) (Note 9)

PIPING LINE TYPE Amb Tref: 20C
PIPE SIZE (INCHES)
CONNECTION TYPE (Note 9)
FAT (C)
2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"
400

Non-fragile equipment and/or 300

low movements (<600#)
Level 2 Level 3
A
Carbon steel 200
(Note 7)
100 Level 1
0

2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"
Rotating machines

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400
Plate exchangers
300
D Cold boxes - Air cooler Level 3
200
Turbine -Furnace
100
(Note 10) Level 1 Level 2
0
HERVE Piping Flexibility and Stress Analysis Criteria
BARON

Line temperature Level 1 : Visual Analysis

Line diameter Level 2: Simplified Analysis
Criticality of equipment Level 3: Detailed analysis
Material
FAT: FLEXIBILITY ANALYSIS TEMPERATURE (C) (Note 9)
PIPING LINE TYPE Amb Tref: 20C
PIPE SIZE (INCHES)
CONNECTION TYPE (Note 9)
FAT (C)
2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"
400

Non-fragile equipment and/or 300

low movements (<600#)
Level 2 Level 3
A
Carbon steel 200
(Note 7)
100 Level 1
0

2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 > 28"
400

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Non-fragile equipment and/or 300 Level 3
low movements (<600#)
B
Stainless steel 200
Level 1 Level 2
(Note 7) - (Note 10)
100

0
HERVE Piping stress analysis Calculation note
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HERVE Piping loads studies
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HERVE Piping Supports
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HERVE Pipe support book
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HERVE Piping Support Book
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HERVE Pipe support standard
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HERVE Piping Support Book
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HERVE Special supports
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HERVE Spring supports
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HERVE Spring supports
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HERVE Design of line supports
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Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

Lines subject to 2 phase flow

Lines subject to flow or accoustic vibration

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HERVE Design of line supports
BARON

Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

What type of lines are subject to water hammer?

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HERVE Design of line supports
BARON

Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

What type of lines are subject to water hammer?

What is the work process for such lines?

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HERVE Design of line supports
BARON

Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

Lines subject to 2 phase flow

How and by whom are 2 phase flow lines identified?

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HERVE Design of line supports
BARON

Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

Lines subject to 2 phase flow

Lines subject to flow or accoustic vibration

What type of lines are subject to accoustic vibration?

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HERVE Design of line supports
BARON

Besides critical lines, the support of some other lines has to be studied.

This is the case for:

Lines subject to water hammer (also called surge)

Lines subject to 2 phase flow

Lines subject to flow or accoustic vibration

What type of lines are subject to accoustic vibration?

What special design features are incorporated for these lines?

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 HERVE Piping installation work process
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Plot Piping Piping Piping 3D Piping Piping

Plan line studies isometric Stress isometric
modelling
diagram & layout drawing OK? drawing IFC

Sometimes, another check is

done. Which one?

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Piping stress analysis
 HERVE Piping installation work process
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Plot Piping Piping Piping 3D Piping Piping

Plan line studies isometric Stress Process isometric
modelling
diagram & layout drawing OK? OK? drawing IFC

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Piping stress analysis
HERVE Piping discipline
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Plant Layout &

Piping discipline

Piping Piping Piping stress

Plant Layout
installation materials analysis

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HERVE Piping discipline
BARON

Plant Layout &

Piping discipline

Piping Piping Piping stress

Plant Layout
installation materials analysis

Materials/corrosion,

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insulation, painting
HERVE Piping Material: line pipe, fittings
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 HERVE Material selection
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Selection of steel based on design temperature
STEEL TEMPERATURE RANGE Based on ASME B31.3 edition 2004
- 254C - 198 - 101 - 73 - 46 - 40 - 29 37,8 343 371 427 538 593 650 732 816C

- 425F - 325 - 150 - 100 - 50 - 40 - 20 100 650 700 800 1000 1100 1200 1350 1500F

Low temperature

down to -29C CS
-29C to -46C LTCS
-59C to -101C 3 Nickel
-101C to -195C 9 Nickel
-195C to -254C SS 304, 316, 321, 304L, 316L

High temperature
up to 427C CS

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up to 593C Cr-Mo (typ. 1.25-0.5) Alloy CS
up to 816C SS 304H, 316H, 321H
HERVE Material selection
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Case study: Oil & Gas production facility

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HERVE Material selection
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Case study: Oil & Gas production facility

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HERVE Material selection
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Case study: Oil & Gas production facility

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HERVE Material selection
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Case study: Oil & Gas production facility

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HERVE Material Selection
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Corrosion and Material Selection Report

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HERVE Material Selection
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Corrosion and Material Selection Report

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HERVE Material Selection
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Corrosion and Material Selection Report

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HERVE Material Selection and corrosion control specification
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(pipes)

STREA
Op.
M COMPOSITI Des. T Op. P Des. P
FLUID TYPE T. MATERIAL SELECTION COMMENT
NUMBE ON (C) (barg) (barg)
(C)
R
5-15g/L The design temperature of 80C is
K41,
Barren H2SO4 47 only expected when the line is
AA01, 35 5.9 9.8 HDPE / GRP
Solution 0.9 g/L Cl- (80) empty; in presence of flowing liquid
AA02
pH 1 the design temperature is 47C.

Concentrat
AM05, Refer to 9806J-0000-JSD-2400-003
ed 98.5wt%
AA03, 35 80 5.4 9.3 High Silicon SS For safety consideration High Silicon
Sulphuric H2SO4
AA04 SS selection preferred to CS.
Acid

The design temperature of 80C is

V23,
Process Process 47 only expected when the line is
AA08, 35 0 0 HDPE
Water Water (80) empty; in presence of flowing liquid
AA09
the design temperature is 47C.

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Air
- 35 80 Atm. Atm. CS + 1.5mm CA To filtration
Air + Ore dust
- Air 35 80 Atm. Atm. CS + 1.5mm CA To atmosphere
HERVE Material Selection and corrosion control specification
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(equipment)

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HERVE Material selection
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Material Selection Diagrams

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HERVE Sour service
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What is Sour service?

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HERVE Sour service
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What is Sour service?

Fluids containing water + a certain amount of H2S

The concentration of H2S above which the service is considered

sour is specified in NACE MR0175 for Upstream (oil & gas
production) applications and in NACE MR0103 for Downstream
(Refinery) applications.

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HERVE Sour service
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What happens to materials subject to Sour service?

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HERVE Sour service
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What happens to materials subject to Sour service?

Phenomenon: Presence of H2S in the aqueous solution causes the

steel to absorb a large amount of H2. The steel is subject to
cracking above a critical concentration of hydrogen absorbed.
This cracking is called Sulfide Stress Cracking (SSC).

The possible loss of containment resulting from this cracking

causes a particularly severe hazard as H2S is fatal in minutes.

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HERVE Sour service
BARON

What happens to materials subject to Sour service?

Phenomenon: Presence of H2S in the aqueous solution causes the

steel to absorb a large amount of H2. The steel is subject to
cracking above a critical concentration of hydrogen absorbed.
This cracking is called Sulfide Stress Cracking (SSC).

The possible loss of containment resulting from this cracking

causes a particularly severe hazard as H2S is fatal in minutes.

How to avoid this?

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HERVE Sour service
BARON

What happens to materials subject to Sour service?

Phenomenon: Presence of H2S in the aqueous solution causes the

steel to absorb a large amount of H2. The steel is subject to
cracking above a critical concentration of hydrogen absorbed.
This cracking is called Sulfide Stress Cracking (SSC).

The possible loss of containment resulting from this cracking

causes a particularly severe hazard as H2S is fatal in minutes.

How to avoid this?

Apply requirements of NACE:

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Base materials: chemical composition, max hardness, heat
treatment
Welds: limit hardness by PWHT
HERVE Piping discipline
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Plant Layout &

Piping discipline

Piping Piping Piping stress

Plant Layout
installation materials analysis

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HERVE Piping Material Classes Specification
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Piping fluids list

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HERVE Piping material class specification
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HERVE Piping material
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Wall thickness calculation
Design code for Process plants: ASME B31.3

P*D
t=
(2SWE + PY)

P design pressure
D (outside) diameter
S stress value for material as per table in ASME B31.3
W weld joint reduction factor for long term strength of weld at elevated temperature
E quality factor, from table in ASME B31.3 (1 for seamless, 0.85 for ER welded pipe, etc.)
Y coefficient from table in ASME B31.3 (from 0.4 to 0.7 depending on material and temperature)

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To the above calculated thickness shall be added:
- The corrosion allowance, e.g., 3 mm
- The manufacturing tolerance: 12.5%
HERVE Piping material class specification
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HERVE Piping material class specification
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HERVE Piping material class specification
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HERVE Piping material class specification
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ASME B16.5 Flanges

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HERVE Piping material class specification
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HERVE Piping material class specification
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HERVE Piping material requisition
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The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

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HERVE Piping material requisition
BARON

The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO:

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HERVE Piping material requisition
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The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)

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HERVE Piping material requisition
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The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)
2nd MTO

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HERVE Piping material requisition
BARON

The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)
2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part)

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How are Quantities to purchase (BOM) obtained
from the MTO quantities?
HERVE Material Take-Offs
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Piping material

Piping
specifications

Piping installation MTO quantities

- Uncertain items
Bill of Material
P&IDs Materials Requisition
+ Allowances for
cut & losses
MTO
+ Estimates of
Piping what is not
routing / taken-off
layout

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+ Allowances for
design
development
HERVE Piping material requisition
BARON

The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)
2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part)
3rd and subsequent MTOs

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HERVE Piping material requisition
BARON

The Piping MTO is issued 3 times as a minimum:

1st MTO: issued for Inquiry, to get the Unit prices

2nd MTO: issued for Order
3rd and subsequent MTOs: to top-up

On the basis of which document(s) are the 1st, 2nd and 3rd piping MTO
prepared?

1st MTO: P&IDs 1st issue + Plot Plan or Line diagram (if available)
2nd MTO: IFD P&IDs + Piping studies/layouts or 3D model (part)
3rd and subsequent MTO: (IFC P&IDs) + isometrics (3D model)

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HERVE Piping Material Management
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Above ground Piping

P&ID IFR IFD IFC

Piping
1st MTO 2nd MTO 3rd MTO
Material
(for order) (top-ups)
Take-Offs (for inquiry)

Drawing Piping Piping layout Piping

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routing drawings isometric
drawings drawings
HERVE Piping Material Management
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Above ground Piping

RFQ 1st PO Final

qties

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Line Piping Isometric
Plot Plan 3D model
Diagram Layout drawing
HERVE Piping Bill Of Materials
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Final qties (from IFC isos)

- Ordered qties (MTO 2)

= additional qties to supply

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HERVE Material Requisition
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 HERVE The Oil & Gas Engineering Guide
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A unique synthetic overveiw of Engineering...

2015 Herv Baron

HERVE The Oil & Gas Engineering Guide - 2nd edition
BARON
Table of Contents

2015 Herv Baron

HERVE The Oil & Gas Engineering Guide - 2nd edition
BARON
Table of Contents

This suite of training modules

covered the discipline
chapters of the book...

2015 Herv Baron

HERVE The Oil & Gas Engineering Guide - 2nd edition
BARON
Table of Contents

The Guide contains much more:

The overall picture, interfaces,

methods & tools, etc.

2015 Herv Baron

HERVE The Oil & Gas Engineering Guide
BARON
2nd edition

Order direct from the publisher:

http://www.editionstechnip.com/en/catalogu
e-detail/1111/oil-gas-engineering-guide-
the.html

2015 Herv Baron