What is piping?

It is a tubular item made of metal, glass,

plastic etc. meant for conveying gas , liquid ,
mixture of fluid from one end to anther end.
piping also include piping supports, but does
not include structural supports.
What is pipe

A Pressure tight cylinder used to convey a

fluid under pressure or under gravity from
one end to other end.
What is the difference between pipe
& tube?

The fundamental difference between pipe and tube is

dimensional standard to which each is manufactured.
Pipe shall be only in round section and size in nominal
bore. However tube may be in round or any other
section and size in two dimensions shall be mentioned
like inner DIA , outer DIA or thickness not all three
dimensions.
What is nominal?

A numerical identification of dimension ,

capacity and rating or other
characteristics used as a designation, not
as an exact measurement.
 What is piping fabrication?

The preparation of piping assembly including cutting

,threading, grooving, forming, bending, jointing and
shop welding of components for subassembly. The
fabrication may be performed in the shop or in the
field.
In general “Inch Dia” Is used to monitor the progress
of welding.

Inch Dia = Dia of pipe in Inch X Number of joints

 What is piping erection?

The complete installation of the piping system at the

correct location with supporting , inspection and
testing of the system.
For erection of piping Inch meter, Running meter,
Ton in metric ton are in practice. But in general Inch
meter is used to monitor progress, billing purpose

Inch meter = Dia of pipe in Inches X Length of

pipeline in Running meter
Ref. piping codes
 Ref. Piping codes
List of the piping codes mentioned below
ASME b31.1B Power plant piping
ASME b31.3B Process piping
ASME b31.4B Piping system for liquid Hydrocarbons
ASME b31.5B Refrigeration piping
ASME b31.8B Gas transportation and distribution piping
ASME b31.9B Building service piping
ASME b31.11B Slurry transportation piping
BPV Boiler and pressure vessel
IBR Indian boiler regulation steam piping
ASME sec-ii part C Welding rods, electrodes and filler metals
ASME sec v Non destructive examination
ASME sec ix Welding and welders qualification
API STANDARDS
The generally referred API standards by the Piping
Engineers are :

API 5L - Specification for Line Pipe

API 6D - Pipe line Valves, End closures,
Connectors and Swivels.
API 6F - Recommended Practice for Fire Test for
valves.
API 593 - Ductile Iron Plug Valves – flanged ends.
API 59 - Valve Inspection and Test.
API 60 - Steel Gate Valves
API 601 - Metallic Gasket for Refinery piping
Piping material
 Piping materials
 API-5L –GRADE- A&B –carbon steel welded and seamless pipe.
 ASTM A-53 GRADE -A&B - Carbon steel.
 ASTM A-106 GRADE- A,B&C – Seamless pipe.
 ASTM A-672 GRADE-60&70- Carbon steel fusion welded.
 ASTM B- 672 NO6002 –HASTELLOY.
 ASTM A-312 GRADE –TP 304,304L,304H, 316,316L,316H –SS Seamless or
welded pipe.
 ASTM A-312 GRADE –TP 321,321H –SS Seamless and welded pipe.
 ASTM A-312 GRADE- TP 347,348,348H – SS Seamless or welded pipe.
 ASTM A-358 GRADE – 304,304L,304H – SS Fusion welded pipe.
 ASTM A -358 GRADE-316,316L,316H – SS Fusion welded pipe.
Piping material
grouping
 Metallic

Ferrous Materials Non-Ferrous Materials

Copper Aluminium Nickel

Lead
+ + +
Copper Aluminium Nickel
Alloys Alloys Alloys

Cast Carbon Alloy Stainless Special

Iron Steel Carbon Steel Alloys
Steel
Material grouping
 Steel &steel alloys – P.No.1 through P.No. 11 incl P.No. 5a,5b and
5c.
 Aluminum and aluminum base alloys – P.No. 21 through P.No.
25.
 Copper and copper base alloys- P.No.31 through P.No. 35.
 Nickel and nickel base alloys-P.No.41 through p-No.47
 Titanium and titanium base alloys- P.No.51 through P.No. 53
 Zirconium and zirconium base alloys- P.No. 61 through P. No 62
Parent metal/ base metal
P- Number
P.No.1-Carbon Steel 40 To 75 ksi. Uts min.
P.NO.2-Wrought Iron.
P.No.3-alloy steel with cr.>3/4% as with total alloy
content>2%.
P.No.4-alloy steel with cr.3/4% to 2% & and total
alloy content>2 3/4%.
P.NO.5- With total alloy content>10%.
Parent metal/ base metal
P.No.6-high alloy steel- martensitic.
P.No.7-high alloy steel-ferritic.
P.No.8- high alloy steel-austenic.
P.No.9-nickel alloy steel up to 5% ni.
P.No.11- Other alloy steel include 9% ni.steel.
P.No.21 TO 25-Al & Al base alloy.
P.No.31 TO 35- Cu &Cu base alloy.
P.No.41 TO 47- Ni & Ni base alloy.
P.No. 51 TO 53- Ti &Ti base alloy.
P.No. 61 TO 62- Zr & Zr base alloy.
Type of pipes
 Type of pipes
Electric resistance welded pipe.
Electric fusion welded pipe.
Seamless pipe.
Submerged arc welded pipe.
Cast pipe.
Double seam gas metal arc welded pipe.
Helical seam submerged arc welded pipe.
Piping components
What are the piping components?

Piping components include pipes ,fitting,

flanges, gaskets, bolting, valves, expansion
joints, flexible hoses, traps, strainers and in
line instruments.
ELBOW
90 SR ELBOW
The radius of the
SR elbow is1D
( D is the
diameter of the
pipe)

45 SR ELBOW
Miter

Two or more straight

section of pipe match
and joint
join s in a plane
bisecting the angle of
the junctions so as to
produce a change in
direction.
 TEE

EQUAL TEE

UN EQUAL TEE
Concentric REDUCER
Concentric reducers shall
be used in pump discharge
Eccentric REDUCER
Eccentric reducers shall
be used in suction line of
centrifugal pumps
LAP JOINT FLANGE
Blind flanges
Blind flanges are
used to blank off the
ends of piping,
valves, and pressure
vessel openings
THREADED FLANGE
Slip-on flanges
Slip-on flanges are
preferred to weld-neck
flanges because of their
initial low cost and ease of
installation. Their
calculated strength under
internal pressure is about
two-thirds of that of weld-
neck flanges. They are
typically used on low-
pressure, low-hazard
services such as fire water,
cooling water and other
Weld neck
The weld neck flange is a
preferred method of
jointing for use under high-
pressure, high-temperature, and
cyclic conditions
Gaskets
A gasket is a material or combination of materials designed
to clamp between the mating faces of a flange joint. The
primary function of gaskets is to seal the irregularities of
each face of the flange, preventing leakage of the service
fluid from inside the flange to the outside. The gasket must
be capable of maintaining a seal during the operating life of
the flange, provide resistance to the fluid being sealed, and
meet the temperatures and pressure requirements.
Gasket materials are selected for their chemical and
pressure resistance to the fluid in the pipe and their
resistance to deterioration by temperature.
Gasket materials may be either metallic or nonmetallic
Gate Valve
Gate valves are used as
isolation valves. In service,
these valves generally are
either fully open or fully
closed. When fully open,
the fluid or gas flows
through the valve in a
straight line with very little
resistance. Gate valves
should not be used in the
regulation or throttling of
flow. Gate valves are not
quick opening or closing
valves.
GLOBE VALVE
Globe valves may be
used for isolation and
throttling services
During installation
flow direction to be
checked

FLOW DIRECTION
 Needle valves
Needle valves generally are
used for instrument, gauge,
and meter line service.
Very accurate throttling is
possible
 BALL
VALVE
The ball valve is a
quarter-turn valve
suitable for clean gas,
compressed air, and
liquid service. They
provide leak-tight closure.
The valves exhibit
negligible resistance to
flow because of their
smooth body and port.
Plug valves
Plug valves are used for
the same full-flow service
as gate valves, where
quick shutoff is required.
They are used for steam,
water, oil, gas, and
chemical liquid service.
Plug valves are not
generally designed for the
regulation of flow
BUTTERFLY VALVE
Butterfly valves are used to control and regulate or throttle
the flow. They are characterized by quick operation and
low-pressure drop. They require only a quarter turn from
closed to full-open position
The compact design requires considerably less space,
compared to gate, globe, or other valves.
Light in weight.
BUTTERFLY VALVE
 SWING CHECK VALVE
 Check valves are
designed to pass
flow in one
direction with
minimum
resistance
 and to prevent
reverse or FLOW DIRECTION
backflow with
minimal leakage.
 During installation
flow direction to
be checked
PISTON TYPE CHECK VALVE
Safety Valves & Pressure-Relief Devices
Safety valves & pressure-
relief valves are automatic
pressure-relieving devices
used for overpressure
protection of piping and
equipment.
The valves protect the
system by releasing excess
pressure. Under normal
pressure, the valve disc is
held against the valve seat
by a preloaded spring.
STRAINER
Strainers are used in piping
systems to protect equipment
sensitive to dirt and other
particles that may be carried
by the fluid. During system
start-up and flushing,
strainers may be placed
upstream of pumps to protect
them from construction
debris that may have been left
in the pipe.
STRAINER
Steam Traps
The function of a steam trap is to discharge condensate
from steam piping or steam heating equipment without
permitting live steam to escape. Some principal types
of steam traps are
● Float
● Thermostatic
● Thermodynamic
● Inverted bucket
Float stream trap
Bi metallic steam trap
Ball type steam trap
Thermodynamic steam trap
Expansion joint
A flexible piping
component which
absorbs thermal
and/ or terminal
movement are
called expansion
joint.
Type of pipe joints
 Type of joints in piping.
Weld Joints
1) Butt joint 2) Socket Joints
Removable joints
1) Flange Joint 2) Coupling
3) Threaded Joint
 Chemical Bonding (Adhesive Type)
e.g. GRP, PVC, etc.
Butt joint
A joint between two members lying
approximately in the same plane are
called butt joint.
Advantages
a) Most practical way of joining big bore
piping
b) Reliable leak proof joint
c) Joint can be radiographed

Disadvantages
a) Weld intrusion will affect flow
b) End preparation is necessary
Socket Joints
Advantages
a) Easier Alignment than butt welding.
b) No weld metal intrusion into bore.
Disadvantages
a) The 1/16"(1.5 mm) recess pockets liquid.
b) Use not permitted by code if Severe
Erosion or Crevice Corrosion is anticipated.
Type of pipe
supports
Type of piping supports
Shoe supports welded with pipes
Clamp supports
Guide supports
Spring supports
Hangers
Anchor supports
Auxiliary piping supports
Purpose of pipe support
 To Support dead weight of Piping system
 To minimise Pipe Sagging
To take Expansion load in the Piping system
To absorb wind load and Seismic load
 To absorb Vibration in the Piping system
 To Suppress the Noise level in the Pulsating Piping
systems.
To absorb the Pressure Thrust of Bellow
To Support the system during Shut down/
Maintenance
Shoe supports welded with pipes
Guide supports
Clamp supports
Hangers
The rod hanger provides support
in the vertical direction and
allows limited
motion in the horizontal
direction. Adjustment in the
vertical direction can be
accomplished by threads or a
turnbuckle.
VARIABLE SPRING HANGER
The supporting force
varies with the spring
deflection. Movement
of
the pipe causes the
spring to extend or
compress. Since the
weight of the pipe is the
same in either the hot
or cold positions, the
variation in the spring
force results in pipe
weight transfer to
CONSTANT SPRING HANGER
Constant support
hangers provide a
constant supporting
force for the piping
system throughout its
full range of vertical
pipe movement. These
hangers are used on
systems and at locations
where the stresses are
considered critical.
Anchor support
A rigid restraint
providing
substantially full
fixation,
permitting
neither
translatory nor
rotational
displacement of
the pipe.
Construction
drawings &
documents
 Construction dwgs and documents
Technical specification and piping codes.
P& ID( Piping and instrument diagram)
GAD ( General arrangement dwgs)
dwgs
Isometrics.
LDS (line designation schedule)
Piping
Pip support dwgs.
Equipments vendor dwgs reviewed and approved by
consultant.
Quality control documents
PIPING & INSTRUMENTATION DIAGRAM
GENERAL ARRANGEMENT DRAWING
ISOMETRIC DRAWING
PIPE SUPPORT DRAWING
 QA/QC
 DOCUMENTATION
 Quality Control Plan review and approve the QA plan as
per the of project specification
 Inspection Test Plan review of ITP, based on
responsibilities of construction contractor, consultant and
client prescribed in contract document during execution
of piping fabrication and erection. In ITP, each and every
activity of piping and extend of inspection like random,
witness and hold point should be mentioned
 Welding Procedure Specification Review and approve
the welding procedure specification as per the parameters
prescribed in ASME Section IX, QW -482. Ensure that
the consumables selected are from consultant / Client
approved list of manufacturers
QUALITY

CONTROL
Procedure Qualification Record
 To qualify the approved WPS, PQR is to be
conducted. The parameters shall be inline with QW
– 483 of ASME Sec IX. Witness the PQR and
approve if the results are acceptable.
Welder’s Performance Qualification
 Review the work experience of welder furnished
by the Contractor and short-lists them for
Qualification Test. Witness Welder Qualification
Test as per QW – 484 of ASME-Section-IX.
Site activities
in piping
 Site activities in piping
Shifting of the pipes and components from
ware house to work location or painting yard
after checking the commodity code as per the
material specification.
Site inspection of the material and checking
of the vendor's test certificates.
Surface cleaning and painting as per the
technical specification/ standard in painting
yard.
 Fit up
Fit up of pipe to pipe and pipe to components.
 During fit-up Heat No. to be transferred to all cut pieces
from the main pipe for proper identification of material.
Points to be checked during fit-up inspection, like joint
No. to be punched near the joint, joint to be clean min
50mm on either side of the joint and groove profile to be
checked as per the approved WPS.
A typical FIT UP
Welding of the fit up joints to be done as per the
approved WPS, by the qualified welders and welder
No. to be punched after completion of the welding.
Post Weld Heat Treatment (PWHT) to be done as
per the specification and approved WPS.
Visual inspection of welded joints and released for
NDT as per codes.
Erection of the fabricated spools as per GAD and
Isometrics.
Field joints welding, supports including anchoring as
per the dwgs and to provide test drain and vents as per
site requirements .
Mechanical clearance and documentation prior to
hydro/pneumatic test.
Released for testing.
After successful testing the system shall be released for
painting / insulation.
Flushing / steam blowing of the system after
insulation.
Vents seal run welding to be done prior to steam
blowing for IBR lines.
All the spring supports shall remain in lock condition
(cold position) during hydro testing. Spring lock shall
be removed before steam blowing / operation.
Handing over the system to the commissioning team
after completion of flushing and steam blowing
Welding process at site
What is welding?
A localized coalescence of
material wherein
coalescence is produced
either by heating to
suitable temperatures with
or with out application of
pressure, or by application
of pressure alone, and with
or with out the use filler
material.
Butt weld
A joint between
two members
aligned
approximately in
the same plane.
FILLET WELD

A weld of approximately
triangular cross section
joining two surfaces
approximately at right
angle to each other in a
lap joint, tee joint or
corner joint.
Welding Procedure Specification (WPS)

The document which lists the parameters to

be used in production of weldments in
accordance with requirements of codes.
Procedure Qualification Record (PQR)

A document listing all pertinent data,

including the essential variables employed and
the test results, used in qualifying the
procedure specification.
Types of welding
 SMAW- Shielded Metal Arc Welding

Arc welding produces coalescence of metals by

heating them with an arc between a covered
metal electrode and the work piece. Shielding of
molten metal from oxidation due to contact with
atmosphere is obtained from decomposition of
the flux , no pressure is used and filler metal is
obtained from electrode.
 GTAW- Gas Tungsten Arc Welding

An arc welding process, which produces

coalescence metal by heating them with an
arc between a tungsten electrode ( non
consumable) and work piece with addition of
filler material. Shielding is obtained from
inert gas like Argon.
 SAW- Submerged arc welding

An arc welding process, which produces

coalescence of metals by heating with an arc
between a bare metal electrode and the
work piece. A blanket of granular fusible
flux on the work piece shield the arc and the
molten metal from atmosphere.
 GMAW- Gas me
m tal arc welding

An arc welding process, where in

coalescence is produces between a
continuous filler me
m tal and the base piece
, shielding is done by a gas mixture.
Welding Electrode

An electrode is a piece of wire or a rod of

metal or alloy, with or with out coating,
which carries current for welding. One
end of the electrode is gripped in a holder
and an arc is set up at the other end.
Type of Welding electrodes
Generally Welding Electrodes Are Two Types-
A) Consumable Welding Electrodes- These Are Two
Types .
1) Bare Electrodes
2) Flux coated Electrode
B) Non- consumable welding electrode.
 Tungsten Electrodes
STORAGE OF WELDING ELECTRODE
All consumables (Electrodes) should be stored in dried
conditions as per vendor’s recommendations.
Different types of electrodes to be stored separately.
AWS designation for manual arc
welding electrodes
The “E” designates arc welding electrodes.
The first two digits of four –digit numbers and the
three digits of five –digit number indicates minimum
tensile strength in thousand Psi.
The third digit indicate position.
The last digit indicate the type of electrode covering,
current (AC/DC) and polarity.
AWS welding electrodes & filler metal
SL. Pipe class P.No Coated electrode Bare
NO electrode
1 A 53, A106 1 E-6010 root, ER-70 S2,S3
E7018
2 A335 P-11 4 E-8018-B2 ER-80S – B2
3 A335 P-22 5 E-9018-B3 ER-90S-B3
4 A 312 TP 304 8 E-308 ER-308

5 A 312 TP 316 8 E-316 ER-316

6 A 312 TP 321 8 E- 347 ER-347

Checklist - Prior to Welding
 Review & approve WPS.
 Conduct PQR. After approval of PQR Conduct
WPQ.
 Material specification, Joint preparation,
dimension, alignment & cleanliness.
 Check the temperature of welding electrode in
Mother Oven.
 Punching of line No, joint No etc near the joint.
 Check the Pre-heat temperature as per
approved WPS.
Checklist - During Welding
 Temperature of baked welding electrode as per vendor’s
recommendation in portable oven.
 Working condition of portable oven.
 Proper Earthing connections.
 Proper pre-heating and inter pass temperature by
means of temperature crayons/ Digital thermometer.
Checklist - During Welding
Quality of root pass and succeeding passes
Welding sequence & inter-pass cleaning
Interruption of welding shall be as per specification.
Checklist

- After Welding
Punching of welder’s No near the joint.
Final weld appearance, size and surface defects.
Dimensional accuracy & distortion if any.
Post-weld heat treatment.( PWHT )
Review of PWHT chart.
NDT like RT, UT, MT, PT etc as per specification and
codes
PREHEATING
Preheating prior to cutting, tack welding and welding shall be
carried out as a means of crack prevention and improving the
weld reliability
Heating of parent material should be done by means of fuel
gas/air torches, burner systems high velocity gas/ oil burners,
electrical resistance or infrared elements
Austenitic stainless steel pipes need not be preheated during
welding.
Check the temperature readings by using temperature crayons
or thermo couples.
When welding two different P-number materials, the minimum
preheat temperature required should be the preheat
temperature for higher ‘P’ number
POST - WELD HEAT TREATMENT
Post Heating of weldment is to be carried out as per technical
specification or wherever applicable.
Post-Weld Heat treatment is used to avert or relieve the
detrimental effects of high temperature and severe
temperature gradients inherent in welding
The stress relieving temperature should be maintained for a
period of time proportional to one hour per 25 mm of wall
thickness of the thickest section at the joint, but in no case
less than one hour
Follow the rate of heating, soaking time & rate of cooling as
per specifications & procedure qualification
Check whether the thermocouple and temperature recorders
are connected properly and check for their calibration
validity
Weld Defects
 Welding defe
def cts
Excess Reinforcement
Weld Cracks at surface, subsurface and HAZ
( longitudinal and transverse)
Uneven Weld Bead
 Top surface and root under cut
Isolated Porosity
Cluster Porosity
Scattered Porosity
Elongated Or Wo W rm Hole
 Welding defe
def cts
Aligned Porosity
Slag- SMAW And SAW Welding Only
Lack of Penetration
Lack of Fusion
Burn through
Root cavity
Excess Penetration
Side Wall Lack of Fusion
NON DESTRUCTIVE
TESTING
Non Destructive Testing
Non Destructive Testing is a term used to
designate those inspection methods that allow
materials to be examined without changing or
destroying their usefulness. The commonly used
NDT methods that are applicable to the
inspection of weldments are as under
Liquid Penetrant Test
 This method is suitable for finding discontinuities that
are open to the solid surface (magnetic or nonmagnetic)
and essentially non- porous materials. Indication of the
flaw can be found regardless of size, configuration,
internal structure or chemical composition of the work
piece being inspected and regardless of flow orientation.
The process is well suited for the detection of all types of
surface defects such as cracks, laps, porosity, lamination,
slag & similar discontinuities that are open to the surface
of job under inspection.
 Acceptance Criteria of indication: This shall be as per
acceptance standard specified in piping specification
Magnetic Particle Test
 Magnetic particle examination is used to detect
cracks, laps, seams, cold shuts, and laminations
in ferromagnetic materials.
 This method of NDT is used to detect flaws on
and near the surfaces of materials.
 The principle of this method is magnetizing an
area to be examined and applying ferromagnetic
particles to the surface. The particles will form
patterns on the surface where discontinuities
cause distortions in the normal magnetic field
Radiographic Inspection
 Radiography is usually capable of revealing all-
important defects like porosity, slag inclusion,
incomplete root penetration, undercut,
incomplete fusion, cracks etc. Radiography has
to be carried out as per Section-V of ASME
Boiler Pressure Vessel Code.
 Acceptance Criteria of indication: This shall be
as per acceptance standard specified in piping
specifications and relevant codes
Ultrasonic Test
 Sound waves, which have a frequency above the
human hearing range, are called ultrasonic
waves. Like the light beam ultrasonic waves are
reflected at surface and refracted when crossing
an interface between two substances that have
different acoustic properties. With ultrasonic
inspection it is possible to find flaws in the raw
material, weldment, etc.
 Acceptance Criteria of indication: This shall be
as per acceptance standard specified in piping
specifications.
Testing procedure
 Hydro test procedure
A) Hydro testing- to be carried for liquid and water service
lines.
All welded joints should not be painted or insulated before
hydrotest.
Additional temporary supports to be provided if necessary.
All the control valves, traps, expansion bellows, check valves
and other inline instruments are to be removed and spool
piece to be provided prior to water filling.
Hydro test procedure
All the vents to be kept open during
water filling for venting the system.
Hydro test water should be cleaned and
shall be such quality as to minimize
corrosion of the material in the piping
system
Hydro test procedure
Test gauge limit shall be max- 4 times of test pressure
and min-1.5 times of test pressure.
Hydro test pressure shall be of 1.5 times the design
pressure or as per LDS.
Hydro test pressure should not be exceed from test
pressure of any components.
Test gauge to be installed at two locations minimum,
one at lowest point and one at highest point.
Hydro test procedure
Test pressure holding time 20 minutes
(minimum) as per ASME B31.3b , if
during holding time pressure is not
dropping than visual examination to be
carried out.
Visual examination of the joints to be
done at the design pressure.
Hydro test procedure
After successful visual examination, line
pressure to be released.
To depressurize the system, first open
the vent valve and after de- pressuring
the line then only the system shall be
drained.
Pneumatic Testing
 Pneumatic testing shall not be used in lieu of the
other means of leak testing except when one of
the following conditions exists.
 When the owner specifies or permits the use of
this test as an alternative.
 When piping systems are to be used in service
where trace of the testing media cannot be
tolerated.
 Instead of Air, Gases also can be used as a test
medium. In that case, testing medium should be
non-flammable and non- toxic.
Pneumatic Testing
 Pressure relief valve should be installed if not
shown in the general arrangement drawing. This
is required to release the pressure raise due to
atmospheric temperature or mal functioning of
compressor during stopping.
 Pneumatic test involves the hazard of released
energy stored in compressed gas. So care must be
taken to minimize the brittle fracture during
test.
Pneumatic Testing
 Pneumatic test pressure is to be increased
gradually until gage pressure which is the lesser
of one – half of test pressure or 170 Kpa (1.733
kg /cm2) at which time a preliminary check shall
be made.
 Pneumatic test pressure should be 110% of
design pressure The test pressure should not
exceed the maximum allowable test pressure of
any non-isolated component such as vessel,
pumps, and valves in the system.
Pneumatic Testing
Procedure for applying pressure: The pressure
should be gradually increased to not more than
50% the test pressure after which the pressure
shall be increased in steps of approx. 10% test
pressure until the required pressure is reached.
Holding time minimum shall be 10 minutes and
then reduce the pressure to 10% to conduct the
examination of leaks.
Pneumatic Testing
Leakage examination: The leakage can be detected
by soap solution or equivalent method for all the
joints, connections. The examination should be
preferred at the design pressure.
Reinstating of piping system
The following points shall be checked for pipe
line reinstatement and release of piping for
commissioning.
Drain the line completely by first opening the
vent and then the drain valves.
Flush the line to remove trash, debris etc.
After completion of testing, chemical cleaning (if
applicable), flushing and drying.
Ensure all temporary blinds and spools are
removed from the pipe line which are provided
for hydro test purpose.
Reinstating of piping system
 Ensure the installation of orifice plates with correct tag
no, flow indicators, spades, spacers, spectacle blinds,
pressure safety valves, control valves, check valves,
rupture discs, inline instruments etc.
 Ensure the removal of temporary hydro test gaskets
and installation of permanent gaskets.
 Ensure the bolt tensioning if required as per
specification.
 Removal of temporary strainers and installation of
permanent strainers when applicable.
 Ensure the locking device provided for the valves as
per the approved P&IDs and layouts.
Reinstating of piping system
 Release the piping for repairing paint damages,
final painting or insulation whichever is
applicable.
 For hanger supports unlock the cold setting lock.
 Verify that the piping connections with
equipment are tension free.
 Ensure the installation of extension stems
provided for the valves and operating condition
from the valve operating platform.
Painting
 Painting procedure
Introduction- Protective coating are one of the primary
means of controlling corrosion in industries . It is therefore
very essential to have a clear and concise technological
specification.
Non ferrous and galvanized metals shall not be generally
painted . the austenitic stainless steel surface should never be
painted.
Methods of surface preparation
Hand and power tool cleaning-This method normally
consists of use of manual and power tool cleaning such
as scraping , wire brushing , machine brushing and
grinding. The following quality grades are generally
applicable.
Quality grade st. 2

 This involves through scraping and brushing until

loose mill scale, rust and foreign material are removed.
Quality grade st.3

The surface shall be prepared according to st.2 but

much more thoroughly. When viewed with out
magnification it should be a clear free from oil ,
grease and dust.
 Blast cleaning
Blast cleaning shall be done using blast materials such as
steel grit or steel shots at a pressure of 7kg/sqcm. Sand
blasting is prohibited. The following grades are general used
Quality grade sa.2

This is thorough blast cleaning . when viewed with

out magnification, the surface shall be free from
visible oil , grease and dirt. It is also known as
commercial blasting.
Quality grade sa.2 ½

 This is very thorough blast cleaning. When viewed with

out magnification, the surface shall be free from visible
oil, grease, dirt and mill scale, rust and paint coating.
Appearance of the surface shall be near white metal.
 Quality grade sa.3
This is a blast cleaning to visually clean steel. When
viewed with out magnification , the steel shall be free
from oil, rust, paint coating. It should have uniform
metallic colour and appearance of the white metal.
Application of coating
In the epoxy based system, the primer and finish coats
for any particular class, shall be same manufacturer in
order to ensure compatibility.
Any painting work including surface preparation of
the piping shall be commenced only after the system
tests have been completed.
 Application of coating
The primer shall be applied with in 4 hours of the shot
blasting or 24 hours of hand/ power tool cleaning. The
over coating interval of min24 hours.
Colour of each coat of primer or paint shall be
different to clearly identify the number of coats
applied.
Painting shall not be done during fog or mist or when
it is raining weather.
Site inspection of painting
After completion of each coat , the surface shall be
checked for workmanship and dry film thickness
(DFT) by elco meter on completion of painting.
Final checking shall include measurement of paint dry
film thickness, check for finish and workmanship. The
thickness shall be measured at as many locations as
required and shall be with in +/- 10% of the total DFT
specified.
Insulation
When hot fluid flows through pipe then generally pipe is insulated.
There are two primary reasons for insulating the pipe carrying hot
fluid.
Containing the heat inside the pipe. Insulation preserves the heat
of the fluid. It is called Hot Insulation
Personnel safety, so that people do not get burn injury by touching
hot surface of pipe. It is called Personnel Protection Insulation
he purpose of insulation is to maintain the temperature of the
product inside the pipe
Before starting insulation work the pipe surface shall be free from
grease, loose scale, dirt and other foreign matter and shall be
thoroughly dry
Insulation
 Specified thickness of Mattresses (Single layer
thickness up to 75 mm and multiple layer
thereafter or as applicable, shall be fixed with
joints properly butted and laced together with 1
mm wire
 Insulation applied in to two or more layers shall
have staggered joints
 Final layer of insulation shall be further secured
by providing SS bands of size 19mmx 0.5mm
thick (SS 304) at every 300mm center duly tighten
Insulation
CLADDING
Aluminum or GI sheet shall be provided with
minimum over lap in the vertical joints will be 50
mm. For horizontal overlap will be minimum 50
mm, which shall be secured by using SS self
tapping screw with washer at 100 mm c/c
longitudinal and circumferentially .To prevent
water ingress on the cladding required sheet
metal sealant (Silicon Rubber Compound) has to
be applied manually at required locations
THANKS
ABHAY KUMAR
TATA Consulting Engineer Limited