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They are frequently operating under high pressure, high temperature and in
corrosive atmosphere.
• The cut edges should be free of cracks, notches, to remove adherent slag etc.
• Piping designed for vapor or gas shall be provided with additional temporary
supports, if necessary to support the weight of the liquid.
• If a pressure test is to be maintained for a period of time and the test liquid in the
system is subjected to thermal expansion, precautions should be taken to avoid
excessive pressure.
• Pressure shall be increased gradually in steps providing sufficient time to allow the
piping to equalize strains during test and then check the leaks.
• These can be done with help of ISO metric drawing ( ISO drawing
).
• These pipe lines are generally carrying feed stock to the plant, final product
from the plant to the storage area and utility lines such as Steam, Water, Air,
Nitrogen etc.
• Number of joints are less when compare to unit piping since straight length and
less tapping.
In plant piping about 60% of the joints can be welded at shop balance 40% to be
assembled and welded at site during erection, while doing this we may keep some
allowances in lengths for adjustment. Field joints are to be determined prior to shop
fabrication.
Now follow the norms(Refer Sheet No 25 to 30) and find out the number of joints in
each categories and the Labour required for the job.
We now have got a fairly good idea about the work volume and Labour strength
required for the job. These data's are good enough to find out the consumables
required, P&M to be deployed and the staff requirement.
Now based on the front availability, which can be obtained from the material delivery
schedule, we can make out an overall construction plan in consultation with client’s
engineer.
Friday, April 26, 2019
Major activities involved in Piping
• Pre-Fabrication
• Erection
• Alignment & Supporting
• Mechanical Clearance
• NDT Clearance
• Hydraulic Test / Pressure Testing
• Drying and Box-Up
Friday, April 26, 2019
Pre-Fabrication
• This can be generally at a pre-fabrication shop.
• We may have to fabricate some pipe specials also at Fab-Shop. These are
Miter Bends, Reducer, Tee branches etc.
• We have to keep erection allowances for field joints.
• As per as possible, flanges which are to be hooked up to equipment's, are not
to be welded. They can be kept on tacked condition.
• After the fabrication, keep the fabricated spools properly numbered and store
in place where it can be easily located for erection. These spools properly
stacked area wise or plant wise.
• Always keep the ends covered to avoid dirt and other particles to go inside.
• Field joints are to be selected in such a way to have easy accessibility for
welding.
• Cost is classified as direct cost and indirect cost, direct cost comprises of direct
Labour, consumables, supervision and P&M and is related to quantum of work
included.
• Indirect cost is related to volume of work and time span.
• In normal case, direct cost is directly proportional to the work quantum. Due to site
conditions the Labour, supervision cost shall increase, but consumable cost cab be
controlled by monitoring.
Friday, April 26, 2019
Cost Control - Tips
• Prior to start the actual execution of the job, the total cost must be calculated.
• Labour details are to be worked out.
• Right type of the plant and machinery's required for piping quantity and the
period at which these are to be deployed are to be decided.
• Consumable required for the job are to be established. The monthly requirement
of consumable can be detailed out.
• Proper persons to be earmarked for key posts like planning, materials, billing,
quality control & site supervision. The roll of each staff is to be clearly
identified.
• The quantity to be pre-fabricated is to be established. Welding expenses at shop
will be always less, so we should try to do maximum shop fabrication.
• Productivity of Welders
AB X BC
= AB - CE Z
Let AD = Y
2 2
Y= Complete Height Radius X
of Cone + of Base Y
E
C
Top
2 2 Z
=
BD + AB
CE X AD
= AB Z
QUALITY ASSURANCE :
- Ascertain degree of quality required by the application.
- Standard to be established based on service needs and
considering.
* Engineering Performance.
* Safety Factor.
• What is ISO ?
A set of guidelines to effectively manage the
important activities in an Organization.
• ISO 9000 :
Quality management and Quality Assurance
standards guidelines for use.
Friday, April 26, 2019
ISO Series
• ISO 9001 :
Quality Assurance in design, development, production, installation &
servicing.
• ISO 9002 :
Quality Assurance in Production and installation.
• ISO 9003 :
Quality Assurance in final inspection and testing.
• ISO 9004 :
Quality Management and Quality system elements guidelines.
Friday, April 26, 2019
ISO Series
• “ Steam Pipe ” means any pipe through which steam passes from a boiler to a
prime-mover or other user of both if
L X-Y X
L1 = X + C
W X
L Y L2
L2 = X + C
W X Toe Side
Size of Weld Shop Site Weld
6 mm 0.462 T/Cm 0.369 T/Cm
8 mm 0.616 T/Cm 0.492 T/Cm
10 mm 0.770 T/Cm 0.616 T/Cm
12 mm 0.924 T/Cm -
Friday, April 26, 2019
No. of Electrodes / Kg.
Sr. Electrodes Size No. of Sr. Electrodes Size No. of
No. Pieces/Kg. No. Pieces/Kg.