Piping

Maintenance & Inspection of Piping in Hydrocarbon Industry
Haldia Refinery
Igniting Minds... Energizing Lives
PIPING SYSTEM
Haldia Refinery
PIPING TYPES
PIPING
UNDER GROUND
ABOVE GROUND
INSULATED
BARE
Haldia Refinery
PIPING MATERIALS
CS - SR AS PER SERVICE, THICK. > 19mm AS - POOR WELDABILITY, SR REQD.
SS - NO PRE-HEAT, SR
RUBBER LINED
CEMENT LINED
SS LINED
HDPE
Haldia Refinery
PIPING MATERIALS
CARBON STEEL ALLOY STEELS STAINLESS STEELS
PIPE SCHEDULES
PIPE SCHEDULES
PIPING DESIGN/ LAYOUT

OVERALL PLOT PLAN
P&IDs
GENERAL ARRANGEMENT DRAWINGS (GADs)
PIPING MATERIAL SPECIFICATION (PMS)
Haldia Refinery

PLOT PLAN

PIPING & INSTRUMENT DIAGRAM

GENERAL ARRANGEMENT DRAWINGS (GADs)
PIPING COMPONENTS
PIPE FLANGES / VALVES EXPANSION BELLOWS FITTINGS
HALF COUPLINGS MITRE BENDS REDUCER ELBOWS GASKETS
Haldia Refinery
PIPING COMPONENTS
SUPPORTS
GUIDE
FREE IN TWO DIRECTION
CROSS-GUIDE
FREE IN ONE DIRECTION
ANCHORS
NOT FREE FOR MOVEMENT
SPRING SUPPORTS
Haldia Refinery
PIPING WALL THICKNESS

BARLOWS FORMULA
t = PiD/ 2SA tn = t + allowance(s)
t= Minimum Wall Thickness (M) Pi= Maximum Allowable Operating Pr. (MPa) D= Outside Diameter (M) SA= Allowable Stress (MPa) tn = Nominal Wall Thickness(M)
Haldia Refinery
PIPING TEST PRESSURE
PT = 1.5P x ST/S
PT= Minimum Test Gage Pressure
P=Maximum Allowable Working Pressure

ST=Stress Value at Test Temperature S=Stress Value at Design Temperature
Haldia Refinery
PIPING FABRICATION
WELDING
SMAW GTAW PRE/ POST-WELD HEAT TREATMENT
HOT TAPPING
BRANCH CONNECTION WITHOUT INTERRUPTION TO THE FLOW OF FLUID
PIPE BENDING
Haldia Refinery
HOT TAPPING
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PIPE BENDING
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GENERAL GUIDELINES
Haldia Refinery
GENERAL GUIDELINES FOR PIPING
All small bore pipings and tracer lines, size and below should be welded by TIG process for all types of joints, e.g. butt, socket, tee, etc. to ensure proper quality of welding. Use of half coupling may be considered to increase reliability of small-bore connections. Minimum thickness of pipe for sizes up to 1 should be Sch.80 for CS and AS. Reinforcement pad shall be provided at support location. Steam drain points should be routed to a drain header and taken out of the unit area.
Haldia Refinery

Stiffener should be provided in small bore bleeder/ drain point connection welded to immediate upstream or downstream of safety valves. As far as possible, stub-in type branch connection are to be provided when branch size is less than one size than the main pipe. All the reinforcement pad telltale holes should be drilled and tapped properly. Gas cut holes should not be accepted. Wherever two phase flow in piping is expected, piping design including its support system should be checked w.r.t. most adverse conditions/ ratio of both the phases (slug flow) to avoid line vibration during operation.
Haldia Refinery

All the fittings like valves, flanges etc. in high temperature service (> = 300 0C) should also be fully insulated if they are in open area or the localized cooling can cause operational problems like coking etc. All SS piping should have chloride free insulation or preferably should have SS foil wrapped between pipe and insulation. Branch connections for fire hydrants along the roads should be totally above grounds. Hydrant connections also should remain above ground.
Firewater and cooling water lines emerging from underground should be wrapped coated beyond the ground level up to a length of 500mm.
Haldia Refinery

Hard surfacing with a proper slope towards open drain system is to be provided beneath the offsite pipe rack area with a clear space of 500mm from bottom of the pipe. Interspacing between the offsite piping on the support pedestal should be such that the lines should not touch each other even after insulation (at least 3 gap after insulation). Identification marks for location/ visibility of drain points of offsite piping should be provided. All drain points should be approachable and clearly visible.
Haldia Refinery

Piping insulation ends should be properly sealed to avoid water ingress. Hard surfacing under the piping bay in offsite areas should be done with proper slope & drainage facility.
Proper slope and gap should be provided in piping culverts to avoid water logging.
In fire water lines, the hydrant tapping should not be taken from the bottom side of pipe. Tapping should be taken from the top or from side.
Haldia Refinery

Any piping circuit if idle for more than six month shall be inspected or hydrotested before taking into service
Ensure adequate wrapping & coating and at least 0.5mtr wrapping & coating shall be visible externally at both ends on above ground portion of pipe. All piping route in off-site area shall be made grass & debris free. In Hydrocarbon service dia. 2 pipe shall be of minimum Schedule 80. Low point drain (LDP) shall be offset by 1 meter from the supports and shall not be embedded into soil.
Haldia Refinery
PIPING FABRICATION
Haldia Refinery
PIPING FABRICATION
FIT UPS
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PIPING FABRICATION
BRANCH CONNECTIONS
Haldia Refinery
PIPING FABRICATION
BRANCH CONNECTIONS
Haldia Refinery
PIPING FABRICATION
PREHEAT TEMPERATURES
PIPING FABRICATION
POST WELD HEAT TREATMENT
PIPING FABRICATION
TYPICAL WELD DEFECTS
DEGRADATION MECHANISMS IN PIPING SYSTEM
Haldia Refinery
DETERIORATION IN PIPING SYSTEM
INTERNAL CORROSION
UNIFORM CORROSION DUE TO LOW/ HIGH pH
Haldia Refinery
INTERNAL CORROSION
LOCALIZED CORROSION- IN CREVICES, BENDS ETC.
Haldia Refinery
INTERNAL CORROSION
CONDENSATION/ TWO PHASE SYSTEMS
Haldia Refinery

STAGNANT AREAS - IN DEAD ENDS ETC
INTERNAL CORROSION
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INTERNAL CORROSION
STRESS CORROSION CRACKING
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INTERNAL CORROSION
HYDROGEN ATTACK
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INTERNAL CORROSION
AREAS D/STREAM OF INJECTION POINTS
Haldia Refinery
INTERNAL CORROSION
IMPINGEMENT AREAS
Haldia Refinery
INTERNAL CORROSION
NAPHTHENIC ACID/ POLYTHIONIC ACID CORROSION
Haldia Refinery
INTERNAL CORROSION
FIRE WATER CORROSION
Haldia Refinery
INTERNAL CORROSION
COOLING WATER CORROSION
Haldia Refinery
EXTERNAL CORROSION
CORROSION UNDER INSULATION
Haldia Refinery
EXTERNAL CORROSION
SOIL SIDE CORROSION OF UNDER-GROUND LINES
Haldia Refinery
EXTERNAL CORROSION
EXTERNAL CORROSION DUE TO SOIL/ WEEDS
Haldia Refinery
EXTERNAL CORROSION
ATMOSPHERIC CORROSION - SULFUROUS / ACIDIC ENVIRONMENT
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WELD CORROSION
PREFERENTIAL ATTACK ON WELD
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EXTERNAL CORROSION
CORROSION AT SOIL / AIR INTERFACE
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STRESS RELATED
OVERPRESSURIZATION
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STRESS RELATED
VIBRATION- AS IN PUMP CONNECTED PIPING
Haldia Refinery

FAILURE OF WELD SEAM
STRESS RELATED
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THERMAL STRESSES
STRESS RELATED
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INSPECTION OF PIPING SYSTEM
Haldia Refinery
ROLE OF INSPECTION
To evaluate present physical condition of the pipeline. To keep the concerned operating and maintenance personal fully informed about the the condition of the lines. To determine causes of deterioration and advise suitable economical solution to the problem. To initiate procurement action of materials. To co-relate deterioration rate with design life for further run.
Haldia Refinery
FREQUENCY OF INSPECTION
The interval between inspections depend upon :
Degree of corrosiveness/ erosiveness of the fluid.
Remaining corrosion allowance.

Type of protective coating. Atmosphere prevailing around the piping. Potentially of fire /explosion in case of a leak or failure. Statutory requirements.
Importance of operations.
Haldia Refinery
Frequency of inspection for offsite piping (hydrocarbon):
Service Crude (sour)
LP/Natural gas Gasoline / naphtha ATF/ HSD/ LDO/ SKO FO/RCO/Bitumen/ VBO Fuel gas/ Flare gas Lube oil
External 3
2 2 3 3 3 5
Comprehensive 6
4 4 5 5 5 10
Haldia Refinery
Frequency of inspection for offsite piping (Utilities):
Service Fresh water
Fire water Air / steam Ammonia / caustic DEA/ MEA Furfural/ phenol Benzene/ toluene
External 2
3 (lined) / 1 (unlined) 3 2 3 2 2
Comprehensive 4
5 (lined) / 2 (unlined) 6 4 5 3 4
Haldia Refinery
INSPECTION PROCEDURE
Visual Inspection: For determining leaks, misalignment, supports, vibration, external corrosion, cracks, insulation damage. Ultrasonic Inspection: For ascertaining wall thickness, by scanning at least four spots (12 o clock, 3 o clock, 6 o clock and 09 o clock positions) on each circumferences for every 30 m of straight length and all bend locations.
Haldia Refinery
Radiographic Inspection: Critical spots which cannot be inspected by UT may be radio graphed during operation to determine internal fouling, pitting, scaling etc.
Shutdown Inspection: All piping which cannot be inspected during operation has to be inspected during shutdown.
Haldia Refinery
Hydrostatic Testing: Along with all NDTs hydro test has to be carried out to evaluate strength of existing and new joints of the line in addition to establishing overall integrity of the line.
For new lines hydro test is to be done at 1.5 times design pressure. For old lines or partially repaired or replaced line it is carried out at 1.5 times operating pressure. Coated or insulated lines are hydro tested before coating operation. Before using any line which has been idle for long time, hydro test is to be carried out. Portable water is to be used for CS or AS pipes and DM water is to be used for SS pipes. Water must be drained after the test.
Haldia Refinery
AREAS SUSCEPTABLE TO ACCELERATED CORROSION
In the presence of certain corrodants, corrosion rates are normally increased at areas of increased velocity and/or turbulence. Elbows, reducers, mixing tees, control valves, and orifices are examples of piping components where accelerated corrosion may occur because of increased velocity and/or turbulence. In the areas of no flow, such as dead legs, accelerated corrosion may occur. Such components are normally areas where an inspector would locate additional TMLs in a piping circuit.
Haldia Refinery
INSPECTION POINTS
Haldia Refinery
INSPECTION POINTS
Haldia Refinery
ON-LINE MONITORING OF PIPING

pH MONITORING
CORROSION PROBES
CORROSION COUPONS IN WATER LINES
Haldia Refinery
NDT IN PIPING SYSTEM

ULTRASONIC THICKNESS SURVEY DCVG / PEARSON SERVEY SPARK / HARDNESS TEST OF RUBBER LINED PIPES RADIOGRAPHY
Haldia Refinery

DCVG SURVEY
The Direct Current Voltage Gradient (DCVG) technique is a "newer" technique for coating surveys on buried pipelines. It has been used for not only locating but also sizing coating defects. The technique is fundamentally based on measuring the voltage gradients in the soil above a cathodically protected pipeline.
Haldia Refinery
DYE PENETRANT TESTING

CRACK DYE APPLIED
TRAPPED DYE ON CLEANED SURFACE
CRACK VISIBLE ON APPLYING DEVELOPER
Haldia Refinery
RADIOGRAPHY TESTING
RADIATION SOURCE DISCONTINUITY METAL
FILM
Haldia Refinery
RADIOGRAPHY TESTING
Sample Films :
Lack Of Penetration
Cluster Of Porosity
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RADIOGRAPHY TESTING
Sample Films :
Tungsten Inclusion Transverse Crack
Haldia Refinery
RADIOGRAPHY TESTING
Slag inclusions
Lack of fusion
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RADIOGRAPHY TESTING
Suck back
Root undercut
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RADIOGRAPHY TESTING
External undercut
Mismatch
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RADIOGRAPHY TESTING
Poor reinforcement
Excess reinforcement
Haldia Refinery
NDT IN PIPING SYSTEM LONG RANGE ULTRASONIC TESTING

This technique uses low
frequency
guided
ultrasonic
waves to detect a length of piping. It locates the affected area in terms of distance from transducer and serves as a screening tool to inspect large lengths of piping especially at
difficult to access locations.
Haldia Refinery
Haldia Refinery
Haldia Refinery
PHASED ARRAY ULTRASONICS

ELECTRONIC SCANNING
ELECTRONIC COMBINED WITH STEERING AND FOCUSING
DOCUMENTATION OF TMLs
Haldia Refinery
CORROSION PREVENTION IN PIPING SYSTEM
Haldia Refinery
CORROSION PREVENTION
PAINTING
ENAMEL, EPOXY, COAL TAR, CLORINATED RUBBER, BITUMENOUS

HIGH TEMPERATURE PAINTS TEMPERATURE INDICATIVE PAINTS TAPE COATING
Haldia Refinery
CATHODIC PROTECTION
PRINCIPLE OF CP
MOST NEGATIVE REGIONS ACTS AS ANODE
PRE-REQUISITE FOR CP
COATING / WRAPPING EFFECTIVENESS PIPE TO SOIL POTENTIAL SURVEY SOIL RESISTIVITY SURVEY INTERFERENCE WITH FOREIGN LINES
Haldia Refinery
CATHODIC PROTECTION
SACRIFICAIL ANODE TECHNIQUE
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CATHODIC PROTECTION
IMPRESSED CURRENT TECHNIQUE
Haldia Refinery
CAUSES OF PIPING FAILURES
Haldia Refinery
PIPING FAILURES
MAJOR REASONS OF PIPING FAILURES
MATERIAL NOT SUITABLE / MATERIAL MIX-UP
Carbon steel 5 Cr-1/2 Mo
Haldia Refinery
PIPING FAILURES
VIBRATION
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PIPING FAILURES
FLOW ACCLERATED CORROSION
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PIPING FAILURES
CATALYST EROSION
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PIPING FAILURES
THERMAL STRESSES
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PIPING FAILURES
COATING DAMAGE
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PIPING FAILURES
PROBLEMS WITH LOW POINT DRAINS
Haldia Refinery
PIPING FAILURES G MAJOR REASONS OF PIPING FAILURES

SEAM OPENING
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PIPING FAILURES
GRASS / WEED GROWTH & SOIL CONTAMINATION
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PIPING FAILURES
INTERNAL UNDER DEPOSIT / MICROBIAL CORROSION
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PIPING FAILURES
CORROSION AT SUPPORT LOCATIONS
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PIPING FAILURES
CORROSION UNDER INSULATION
Haldia Refinery
PIPING FAILURES
IMPROPER FABRICATION
Haldia Refinery
PIPING FAILURES
IMPROPER JOINT DESIGN
Standard Joint
Poor Penetration & Under cut
Improper Fit Up & Welding
Crack
Haldia Refinery
Haldia Refinery

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Maintenance & Inspection of Piping in Hydrocarbon Industry

PIPING DESIGN/ LAYOUT

PIPING MATERIAL SPECIFICATION (PMS)

PIPING DESIGN/ LAYOUT

PIPING DESIGN/ LAYOUT

PIPING DESIGN/ LAYOUT

PIPING WALL THICKNESS

PIPING TEST PRESSURE

P=Maximum Allowable Working Pressure

GENERAL GUIDELINES FOR PIPING

GENERAL GUIDELINES FOR PIPING

GENERAL GUIDELINES FOR PIPING

GENERAL GUIDELINES FOR PIPING

GENERAL GUIDELINES FOR PIPING

GENERAL GUIDELINES FOR PIPING

DEGRADATION MECHANISMS IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

DETERIORATION IN PIPING SYSTEM

INSPECTION OF PIPING SYSTEM

Remaining corrosion allowance.

ON-LINE MONITORING OF PIPING

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

DYE PENETRANT TESTING

TRAPPED DYE ON CLEANED SURFACE

CRACK VISIBLE ON APPLYING DEVELOPER

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

Tungsten Inclusion Transverse Crack

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM

NDT IN PIPING SYSTEM LONG RANGE ULTRASONIC TESTING

difficult to access locations.

NDT IN PIPING SYSTEM LONG RANGE ULTRASONIC TESTING

NDT IN PIPING SYSTEM LONG RANGE ULTRASONIC TESTING

PHASED ARRAY ULTRASONICS

ELECTRONIC COMBINED WITH STEERING AND FOCUSING

CORROSION PREVENTION IN PIPING SYSTEM

ENAMEL, EPOXY, COAL TAR, CLORINATED RUBBER, BITUMENOUS

CAUSES OF PIPING FAILURES

Carbon steel 5 Cr-1/2 Mo