Piping Engineering – Process Outline

What is Piping Engineering

Front-End Engineering Design (FEED)

The objective of FEED is to define the project’s technical requirements and establish a foundation for
detailed design and execution.

Key Activities:

1. Project Scope Definition:

o Outline the project’s objectives, deliverables, and constraints.

o Outcome: A clear understanding of project objectives and boundaries.

2. Basis of Design (BOD):

o Develop the Basis of Design document. This document outlines the fundamental criteria
and assumptions that guide the design process, including project-specific requirements,
design codes and standards, operational parameters, and environmental considerations.

o Outcome: The BOD document provides a comprehensive framework for the design and
ensures that all subsequent activities align with the project’s requirements.

3. Process Flow Diagrams (PFDs):

o Develop PFDs to provide a high-level overview of the process, showing major equipment
and the flow of materials.

o Outcome: PFDs that outline the main process flow, helping to visualize the overall system.

4. Hydraulic Calculations:

o Perform preliminary hydraulic calculations to determine pressure drops, flow rates, and
pump requirements. These calculations are essential for sizing pipes and equipment.

o Outcome: Hydraulic calculation report detailing required flow rates, pressures, and
equipment specifications.

5. Piping and Instrumentation Diagrams (P&IDs):

o Create P&IDs that provide detailed information about the piping system, including the
arrangement of piping, instrumentation, and control devices. P&IDs are more detailed than
PFDs and are informed by hydraulic calculations.

o Outcome: Detailed P&IDs that guide the development of piping layouts and material
selection.

6. Preliminary Piping Layouts:

Piping Engineering – Process Outline

o Develop initial piping layouts based on PFDs and P&IDs. The results of hydraulic calculations
inform the layout and sizing of pipes.

o Outcome: Preliminary piping layouts integrated with PFDs and P&IDs.

7. Material Selection:

o Select appropriate materials for pipes, fittings, valves, and other components based on
process requirements, environmental conditions, and hydraulic calculations.

o Outcome: Material selection report specifying types and grades of materials for pipes,
valves, and fittings.

8. Preliminary Stress Analysis:

o Perform initial stress analysis to identify potential issues and optimize pipe routing.

o Outcome: Initial stress analysis report highlighting potential stress points and mitigation
strategies.

9. Cost Estimation:

o Provide preliminary cost estimates for piping materials, labor, and associated equipment.

o Outcome: Cost estimate report providing a budgetary overview for the piping system.

10. Specifications and Standards:

o Define project-specific piping specifications and standards to be followed during detailed

design.

o Outcome: Documented project specifications and standards to guide detailed design and
construction.

Deliverables:

1. FEED report 6. Material selection report

2. Process Flow Diagrams 7. Initial stress analysis report

3. Preliminary hydraulic calculation report 8. Cost estimates

4. P&IDs 9. Project specifications and standards

5. Preliminary piping layouts

Piping Engineering – Process Outline

2. Detailed Engineering Design

Develop comprehensive and detailed designs for the piping system based on FEED data.

Key Activities:

1. Detailed Piping Layouts:

o Create detailed isometric drawings and layouts for all piping systems.

o Outcome: Detailed piping layout drawings and isometric drawings for fabrication and
installation.

2. 3D Modeling:

o Develop 3D models to visualize the piping system and ensure proper integration with other
systems and structures.

o Outcome: 3D piping models to identify and resolve clashes and optimize space utilization.

3. Stress Analysis:

o Conduct detailed stress analysis to ensure piping integrity under various operating
conditions.

o Outcome: Comprehensive stress analysis report with recommendations for mitigation.

4. Supports and Hangers Design:

o Design supports and hangers to ensure proper alignment and support of piping.

o Outcome: Detailed design of supports and hangers with installation drawings.

5. Valve and Instrumentation Selection:

o Specify and select valves, instrumentation, and control devices.

o Outcome: Specifications and datasheets for valves, instrumentation, and control devices.

6. Hydraulic Calculations:

o Perform detailed hydraulic calculations to determine pressure drops, flow rates, and pump
requirements.

o Outcome: Detailed hydraulic calculation report for final design validation.

Deliverables:

1. Detailed P&IDs 4. Stress analysis reports

2. Isometric drawings 5. Support and hanger designs

3. 3D piping models
Piping Engineering – Process Outline

6. Valve and instrumentation 7. Hydraulic calculation reports

specifications

3. Procurement
Acquire the necessary materials, equipment, and services for the piping system.

Key Activities:

1. Material Requisition:

o Prepare and issue material requisition documents.

o Outcome: Material requisition documents specifying quantities, specifications, and delivery

requirements.

2. Vendor Evaluation:

o Evaluate and select vendors based on quality, cost, and delivery timelines.

o Outcome: Vendor evaluation reports with recommendations for selection.

3. Purchase Orders:

o Issue purchase orders to selected vendors.

o Outcome: Purchase orders for all required materials and equipment.

4. Expediting:

o Monitor and expedite orders to ensure timely delivery of materials and equipment.

o Outcome: Expediting reports to track and manage delivery schedules.

5. Inspection and Testing:

o Inspect and test materials and equipment upon delivery to ensure they meet project
specifications.

o Outcome: Inspection and test reports confirming quality and compliance.

Deliverables:

1. Material requisition documents

2. Vendor evaluation reports

3. Purchase orders

4. Expediting reports

5. Inspection and test reports

Piping Engineering – Process Outline

4. Construction and Installation

Physically construct and install the piping system as per the detailed engineering design.

Key Activities:

1. Site Preparation:

o Prepare the site for construction activities, including clearing, leveling, and setting up
temporary facilities.

o Outcome: Site prepared for construction with necessary temporary facilities in place.

2. Piping Fabrication:

o Fabricate piping spools in accordance with isometric drawings and specifications.

o Outcome: Fabricated piping spools ready for installation.

3. Piping Installation:

o Install piping spools, fittings, valves, and instrumentation at the project site.

o Outcome: Piping system installed as per design specifications.

4. Welding and Joining:

o Perform welding and other joining methods to connect piping components.

o Outcome: Welded and joined piping system with quality assurance.

5. Nondestructive Testing (NDT):

o Conduct NDT on welds to ensure quality and integrity.

o Outcome: NDT reports confirming the quality and integrity of welds.

6. Supports and Hangers Installation:

o Install supports and hangers as designed.

o Outcome: Properly supported and aligned piping system.

7. Insulation and Painting:

o Apply insulation and protective coatings to piping as required.

o Outcome: Insulated and painted piping system for protection and efficiency.

Deliverables:

 Fabrication and installation records

 Welding and NDT reports

 As-built drawings

 Insulation and painting records

Piping Engineering – Process Outline

5. Testing and Commissioning

Verify the functionality and integrity of the piping system and ensure it operates as intended.

Key Activities:

1. Hydrostatic Testing:

o Conduct hydrostatic tests to check for leaks and ensure piping integrity under pressure.

o Outcome: Hydrostatic test reports confirming system integrity.

2. Pneumatic Testing:

o Perform pneumatic tests where applicable.

o Outcome: Pneumatic test reports confirming system integrity.

3. System Flushing:

o Flush the piping system to remove debris and contaminants.

o Outcome: Clean and debris-free piping system ready for operation.

4. Pressure Testing:

o Verify the pressure ratings and ensure there are no leaks.

o Outcome: Pressure test reports confirming system integrity.

5. Instrumentation Calibration:

o Calibrate and test instrumentation and control devices.

o Outcome: Calibration records ensuring accurate instrumentation.

6. Functional Testing:

o Perform functional tests to ensure the piping system operates correctly within the overall
process.

o Outcome: Functional test reports confirming system performance.

7. Punch List:

o Develop and address punch list items to resolve any issues identified during testing.

o Outcome: Completed punch list with all issues resolved.

Deliverables:

 Hydrostatic /pneumatic test reports  Pressure test reports

 Flushing records  Calibration records

 Functional test reports

 Punch list and resolution records

Piping Engineering – Process Outline

6. Commissioning and Start-Up

Objective:

Bring the piping system into operational service and ensure it integrates with the overall plant
operations.

Key Activities:

1. Commissioning Plan:

o Develop a detailed commissioning plan outlining the steps and procedures for start-up.

o Outcome: Comprehensive commissioning plan.

2. System Integration:

o Integrate the piping system with other plant systems and processes.

o Outcome: Integrated system ready for start-up.

3. Operator Training:

o Train plant operators on the operation and maintenance of the piping system.

o Outcome: Trained operators capable of managing the piping system.

4. Operational Testing:

o Conduct operational tests to ensure the system performs as expected under real operating
conditions.

o Outcome: Operational test reports confirming system performance.

5. Performance Monitoring:

o Monitor system performance during initial operation and make necessary adjustments.

o Outcome: Performance monitoring records ensuring optimal operation.

6. Documentation:

o Compile all documentation, including test reports, as-built drawings, and operation
manuals.

o Outcome: Complete set of final documentation.

Deliverables:

 Commissioning plan

 Operator training records

 Operational test reports

 Performance
Piping Engineering – Process Outline

The piping engineering process involves a variety of engineers, each specializing in different
aspects of the project to ensure a successful outcome. Below is a list of key engineers
involved in the process, along with their roles and responsibilities:

1. Project Engineer
Role:

 Oversee the entire project from FEED to commissioning.

 Coordinate activities between different engineering disciplines.
 Ensure that the project stays on schedule and within budget.

Responsibilities:

 Define project scope and objectives.

 Manage project timelines and resources.
 Communicate with stakeholders.
 Ensure compliance with standards and regulations.
 Prepare and review project documentation.

2. Process Engineer
Role:

 Develop process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).
 Perform process simulations and calculations.

Responsibilities:

 Define process requirements and design criteria.

 Develop and optimize process flows.
 Perform hydraulic calculations.
 Ensure process safety and operability.
 Provide input for material and equipment selection.

3. Piping Engineer
Role:

 Design and develop piping layouts and systems.

 Ensure proper integration of piping systems with other plant systems.

Responsibilities:

 Create detailed piping layouts and isometric drawings.

 Develop 3D models of piping systems.
 Select appropriate materials and components.
 Ensure compliance with design codes and standards.
 Collaborate with other disciplines to resolve design issues.
Piping Engineering – Process Outline

4. Piping Stress Engineer

Role:

 Analyze and ensure the structural integrity of piping systems under various conditions.

Responsibilities:

 Perform stress analysis using software tools.

 Identify and mitigate stress-related issues.
 Design supports and hangers.
 Ensure compliance with stress analysis codes and standards.
 Provide input for layout optimization.

5. Instrumentation and Control Engineer

Role:

 Design and specify instrumentation and control systems for the piping network.

Responsibilities:

 Develop instrumentation and control schematics.

 Select and specify control valves, sensors, and other instruments.
 Ensure proper integration with the overall control system.
 Perform calibration and functional testing of instruments.
 Provide input for P&IDs.

6. Mechanical Engineer
Role:

 Design and specify mechanical equipment associated with the piping system, such as pumps
and compressors.

Responsibilities:

 Select and size mechanical equipment.

 Perform mechanical calculations and simulations.
 Ensure proper integration of mechanical equipment with piping systems.
 Develop equipment datasheets and specifications.
 Perform equipment layout and support design.

7. Civil/Structural Engineer
Role:

 Design and ensure the structural integrity of supports, foundations, and other civil structures
related to the piping system.
Piping Engineering – Process Outline

Responsibilities:

 Design pipe supports and foundations.

 Ensure compliance with structural design codes.
 Perform structural analysis and calculations.
 Collaborate with piping engineers to optimize support design.
 Review and approve structural drawings and specifications.

8. Electrical Engineer
Role:

 Design and specify electrical systems associated with the piping network.

Responsibilities:

 Develop electrical schematics and layouts.

 Specify electrical components and equipment.
 Ensure proper integration of electrical systems with instrumentation and control systems.
 Perform electrical load calculations and safety analysis.
 Provide input for equipment power requirements.

9. Safety Engineer
Role:

 Ensure the safety of the piping system throughout its design and operation.

Responsibilities:

 Conduct hazard and operability (HAZOP) studies.

 Perform risk assessments and safety audits.
 Develop safety procedures and guidelines.
 Ensure compliance with safety regulations and standards.
 Provide input for emergency response plans.

10. Procurement Engineer

Role:

 Manage the procurement of materials, equipment, and services required for the piping
system.

Responsibilities:

 Prepare material requisition documents.

 Evaluate and select vendors.
 Issue purchase orders and manage vendor contracts.
 Expedite orders to ensure timely delivery.
 Inspect and test materials and equipment upon delivery.
Piping Engineering – Process Outline

11. Construction Engineer

Role:

 Oversee the construction and installation of the piping system.

Responsibilities:

 Plan and schedule construction activities.

 Supervise piping fabrication and installation.
 Ensure compliance with design drawings and specifications.
 Coordinate with subcontractors and construction crews.
 Conduct quality assurance and quality control (QA/QC) inspections.

12. Commissioning Engineer

Role:

 Manage the commissioning and start-up of the piping system.

Responsibilities:

 Develop commissioning plans and procedures.

 Conduct functional and operational tests.
 Perform system integration and start-up activities.
 Train plant operators on system operation and maintenance.
 Prepare commissioning reports and documentation.

These engineers work collaboratively throughout the piping engineering process to ensure
that the design, construction, and operation of the piping system meet the project’s objectives
and comply with industry standards and regulations. Each engineer’s expertise and
contributions are essential for the successful completion of the project.