pennypipe

Most of the time we are facing engineering completion challenges for timely delivery for EPC projects. The major issues are related to delay in vendor information, finalization of process conditions including equipment & pipe sizing, big package data simulation with plant, control parameters firming, plant layout finalization, plant constructability, operability, HSE & safety compliances.

The quality and skill-set of the people working for project team also play very important role in project successful completion. And each individual’s experience and knowledge found to be not as much as project pace requires. To counter the same issue “DATA –INFORMED DESIGN” concept works well. The data, decision, checks, limitations, cost-impacts, timing & special instructions related to specific task are fed to each member of the team employed with pre-formalized document in advance.

It also helps team member with low skill & experience to perform the task with high accuracy within stipulated time. That way this concept is helping an organization in improving its productivity!

Thanks

A member of Team Indionix

#201903

Dear All

Its great to share that the blog name has been revised as pennypipe from pipease. This is intended to put more focus on project cost accuracy and reduction.

In this new series first we are bringing detail about how to manage scope of interconnected piping in a EPC project. For the successful execution of the same it is important to issue the following deliverables with (+/-) 10% quantity accuracy –

• 1. General routing drawings of interconnecting piping of process, utility storage, packages & handling facilities.

  2. Planned piping routing drawing ( GAD/plot plan) of interconnecting piping.

  3. Specification of insulation, heat tracing, personnel protection & cold insulation, etc.

  4. Specification of painting & passivation etc.

  5. Position of piping in above ground and underground scope areas.

  6. List of interconnecting piping including PMS, VMS, size, class, fluid category, slope, free draining, supporting arrangement and connection plan ( cold/hot tapes).

  7. General arrangement drawing of primary piping support, secondary piping supports, expansion bellows, springs hangers, struts & snubbers.

  8. Reference, benchmarking scaling from previous project data base & references.

The above list works well for us. Wish the same for readers ahead!

Thanks

A member of Team Indionix

#201904

Often piping team found not so attentive while addressing piping support for small bore lines ( size <= 2 inch NB) in EPC projects. Due to schedule constarints, delayed vendor’s information and plant complexities these activities get comparatively less priority . During earlier days these were expected to be completed at site.

For quick design and planning of small bore piping support following checks can be more use –

• Carrying/supporting pipe from large diameter pipe ( >= 4 inch NB) can be planned subject to minimum thickness of header pipe 40 for Carbon Steel & 20S for Stainless Steel.

• For support on horizontal insulated pipe insulation of bottom half of pipe shall be cut 50 mm on either side of supporting member considering displacement.

• For support on vertical insulated pipe half pipe insulation towards supporting member shall be cut 50 mm on either side of supporting member considering displacement. The same need to be informed to process engineer.

• Pipes subject to vibrations, AIV, FIV, two phase flow, slug, plug, bubble, pulsation, heavy weight, concentrated loading shall be provided with two plane bracing. Avoid two plane bracing at tee & reducers.

Thanks

An Indionix Team Member

#201905

Dear All

In order to advance the project completion, following steps may will beneficial -

1. Jacking techniques for the fabrication of tankages

2. Bolted construction for furnaces

3. Modular construction

4. Piping spool fabrication at fabrication shop in place of fabrication at site.

5. Piping classes to a large extent should be minimized. It will help in procurement, pricing, substitution, interchange & streamlining of warehousing. Within the piping materials, exclusive standardization of hardware ( studs, nuts, fasteners, gaskets ) are highly effective. More number of piping classes will lead to problem in construction, pre-commissioning, commissioning of plants.

6. Contractibility study in advance.

7. Detail planning of underground piping headers, manhole & branch connections to be done.

8. Sleepers for offsite piping can be constructed on the pre-cast mode for fast track construction.

9. Compressor houses from grade level must be of structural steel.

10. Pre-cast concrete work at higher elevation.

11. Manholes and catch basins to be pre-casted.

12. All the electrical cables to be routed aboveground.

13. A separate tier of pipe rack to support the instrumentation ducts and the overhead electrical cables to be planned.

14. Maximize use of the steel structure in plant construction.

Thanks

An Indionix Engineers Team Member

#201906

During pre-bid engineering, clear definition of basis of Piping MTO estimation is important. These can be described in rather simplified way as-

• 1. Assumptions

  2. Piping Design Basis

  3. Piping Material specifications

  4. Valve material specification

  5. Piping Support, painting, insulation, testing, commissioning, waste treatment, fabrication, NDT & spares specification

  6. Plot plan

  7. P&ID for process plant and unities

  8. Packages P&IDs

  9. Battery limit scope , plan & isolation philosophy with plant units, packages, UG/treatment plants

  10. Tie-in location list , P&ID ( construct, destruct), site survey study plan drg within existing plant, its supporting arrangement as applicable

  11. PMS of existing plant ( for tie-ins material compatibility)

  12. Preliminary stress analysis routing for highly critical lines ( Line size>12” NB n rating= > 300#, Flare headers, HP, MP, LP steam headers, Fired Heater lines, Compressor lines & other as outlined in project specification.

  13. Placatory study of process lines > 6 “ NB .

  14. Vessel trims specification

  15. Specialty items data sheet

  16. MTO contingency for construction, testing, pre-commissioning & commissioning.

  17. List of free issue items

  18. List of UG services, plan & Tie-in list with location

  19. Transportation/ support specification for modular construction

  20. List of supply items to subcontractors

  21. Package suppliers specification, exclusion/special conditions

  22. Hot tapping/cold tapping plan, drg & mark-up P&IDs

  23. Exclusions

These handy items help in faster proposal piping MTO estimation with fair accuracy within stipulated time!

An Indionix Engineers Team Member

#201907

Dear All

Earlier we have written about the basis for Piping Bulk MTO calculation. Now it is time to discuss about Bulk Piping MTO check list. The same has been outlined in enclosed check list.

It covers all the applicable items and ensure the completeness of Piping bulk MTO calculation.

Piping Bulk MTO Check list.xlsx

Link-

https://drive.google.com/open?id=1gg9T01EvGritsq7XLxw1b6XVL0_1xiPD

Thanks

An Indionix Engineers Team Member

#201908

I noticed that the biggest barrier to better time management is that we generally “don't know where the time goes”. We need to understand ourselves better in terms of what time of day we tend to have maximum mental energy and when our minds are slower. Our job profile includes some amount of work that requires some thinking effort as referring project specification, reviewing 3D piping model, SPR/Navisworks review, vendor drawing reference and interpreting data. It also includes project management elements such as following up from site, shop, vendors and clients on timelines. It also includes servicing elements such as sitting through meetings, coordination & IDC. It is observed that the morning hours are our best time for work that involves some thinking, and the afternoon hours are when we are pretty lethargic. So it is very important to utilise morning hours wisely. Each of us has to work out what time planning suits our job requirements the best.

Working proactively on the similar line to enhance team productivity we have supplemented a tool (Piping EngineerV.xlsx) which is adding good value to piping engineers in understanding current project piping engineering status, getting information on future issues, piping span data, rest, guide & anchor loads . It is being widely used and popular among piping managers, piping, civil, structural, control systems, electrical, project lead engineers, project managers & shop/site construction team. It is also helping in striking a good speed with piping designer, area engineers, 3D PDS, PDMS, SP3D modellers, checkers, stress & material engineers. It is vital in accomplishing weekly Isometric IFC issue counts.

It uses status of piping engineering document status as input data, processes it and predicts competed work status and balance work.

Link of the tool -

https://drive.google.com/open?id=1cS0YUy9zBBuRRv8MWeqoFdOsV2yYNlF0

Hope reader will find it handy for their future work.

Thanks

An Indionix Engineers Team Member

#201909

Dear All,

Core values are the basic principles by which we live. They govern our productivity , attitude and behavior. These values helps to from our highest priorities into a set of value statements and give directions to our lives. These values are the driving force in our lives and they keep us focused on our tasks. Our values can include such ideals as: Financial securities, Talent, Hard work, Integrity, Physical and Mental health, Family & good friends. Core value should be identified because they used in goal setting to accelerate achievement and to help implement positive behavior changes. These three questions should be answered for each goals- what , why and how. Goals should be specific , achievable , result-oriented and time-limited. After all goal setting is key to successful living.

In order to achieve more we need to be better organized and utilize our time effectively. To make time works for us we must need to identify the time wasters and eliminate it as soon as possible. It also require to change the habits, values & goal setting. It will increase effectiveness and increase the amount of work we can comfortably accomplish before time.

In order to achieve the goal we need to identify the time wasters related to our daily life. We have prepared the list and an interactive worksheet to identify, quantify at scale of 10 , evaluate the present capability and the scope of improvement. It also suggests method to address the respective time waster issues as per the scope of possible improvement of individual. It includes major functional areas, perceptions towards daily work and socialization issues ( Face book, messaging, whatsapp, calling, chatting, twitting ).

Hope it will help reader for better self development.

The worksheet, (Self Organizer.xlsx ) is available at location -

https://drive.google.com/open?id=150C-rTHK4kRp-WgzEeGrg9_TikKs9N4J

Thanks

An Indionix Engineers Team Member

#201910

Dear All,

During piping routing in plant design, piping support planning plays important role. The selection of particular type of pipe support eg bare pipe rest, pipe shoe, pipe guide, trunnion support, pipe anchor, adjustable support, column clip bracket support, springs, struts, sway braces , snubbers , clamp, cold shoes & low-friction sliding pads ( Teflon, graphite, mirror finished SS plates) and its location are key to successful pipe supporting. Initially spring hangers dimension are not available. So planning of space below or above the pipe for spring hanger becomes difficult. To address the same issues we have estimated spring installed dimension for spring below pipe - Can type and above pipe - Spring hanger. It helps in planning the space for the same. Upon receipt of final vendor drawing of spring , the same get validated with minimum changes. It helps in IFC isometrics release comparatively easier. It also ensures the adequate planning of pipe supporting structure around.

Pipe size / Spring dimension below pipe ( estimated) / Spring hanger dimension above pipe ( estimated)

inch, NB / mm / mm

2" / 500 / 500

3" / 500 / 500

4" / 510 / 550

6" / 550 / 550

8" / 620 / 620

10" / 650 / 650

12" / 675 / 675

14" / 700 / 700

16" / 720 / 750

18" / 750 / 800

20" / 875 / 1000

Thanks

An Indionix Engineers Team Member

#201911

Dear All

Daily project activities are being treated as race against time ( sport) and expected to finish at Olympic level speed to meet the project target. You and me are part of this amazing lively world. We are connected with many network and great news are also being fed through it regularly. Sometimes weather also plays crucial role in happening around. Interestingly now professional life is full of adventure , risk & rewards.

Now we should focus on the topic of the day – Flare system piping design. Flare system design plays vital role in finalizing piping routing particularly at higher elevation on pipe racks.

Following consideration make things simpler for us. It provide basis for continuous input in live 3D model ( PDS, PDMS, SP3D, Auto plant ) .

• • Flare pipes shall have no pockets and shall slope continuously to the flare knock-out drum.

  • If a platform is installed for spading a part of the flare pipe whilst the main flare pipe is still in use, ensure that there is enough space to do the work. Ensure that there is a proper escape way from this platform.

  • Ensure that inlet pipes to relief valves are self-draining into process equipment. Relief valves should be located on the main process header.

  • Ensure that outlet pipes from relief valves are self-draining into the flare header. An exception may be made for liquid thermal relief valves which do not need to be self-draining on both sides if the pipes would become too long. Check that connections are made on top or on the side of the flare header.

  • Ensure the accessibility of relief valves sets for maintenance and inspection. Have relief valves been installed at proper elevations relative to the flare header. All relief valves should be accessible for removal.

  • Safety/relief valve piping as short as possible when discharging into a closed system. The orientation of PSV outlet pie to be kept perpendicular to axis of mail flare header enabling to provide enough flexibility.

  • Ensure relief valve outlet pipe arrangements such that supports can be provided to cope with reaction forces. Flare header are supported on slope shoe generally to cater required slope. Axial pipe stop to be provided at PSV outlet piping to counter PSV reaction force during pop up. PSV reaction calculator calculates the expected force during pop up.

  • Ensure that the spindles of flare main battery Limit block valves, if gate valves, are in a horizontal position. This prevents a blocked flare pipe if the wedge should fall down.

  • Ensure manhole vents are vented at stipulated height and distance from equipment’s and platforms.

  • Guidelines for finalizing the size of the PSV connections are another important area which is often un-addressed. This needs to be plugged in the initial stages for P&ID completeness. A good measure should be exercised to size PSVs & outlet pipe conservatively.

Hope you will find these guidelines handy. It will be surely help in securing your final flare berth booking on pipe rack!

Thanks

An Indionix Engineers Team Member

#201912

Dear All

I was amazed to see the player’s fitness level, weight control, personal attention and commitment to win every match during ICC cricket world cup 2019. It is so inspiring. How the physical education, daily workouts, self caring and health consciousness are becoming so relevant now!

The beginning of plant engineering piping activities in a project generally involves review of piping and instrumentation diagram (P&ID) with respect to piping information availability. Following checkpoints are handy for reviewing piping and instrumentation diagram (P&ID) from piping perspective-

• P & ID related to air Coolers are to be furnished with all header arrangements/cascading details. The other P&ID should have sufficient heat exchangers details of type, design conditions, stacking arrangement & TEMA type mention. The nozzle elevation/skirt height of column to be indicated in P&IDs. The minimum number of bends also to be mentioned for column-Reboiler circuit.

• General Arrangement of the furnaces along with coil arrangement is a necessary input for arranging the headers etc appropriately in P&IDs. Alongside standard inputs of snuffing steam, atomizing steam, decoking steam etc., are essential. Similarly number of burners and in-let and return to piping line sizes need to be indicated.

• Sizing of control valves and safety valves for reflection of the numbers and arrangement in the P&ID is another critical input to be indicated in P&ID.

• Ensure that no line remains un-sized/HOLD in the P&ID. Utility header sizes to be firmed and indicated in P&ID. Bypass line size also be indicated in P&ID.

• UG & AG interface with spec break should be indicated clearly. Line number, P&ID continuation, tie-in information , vendor drg battery limit are to be indicated on P&ID. Sometime expansion joint requirement are also indicated on P&ID.

• Spec break should be indicated clearly. Slope line, no pocket, vibration lines, slug lines note to be present on P&ID. Minimum straight run to be indicated where ever special requirements required.

Thanks

An Indionix Engineers Team Member

#201913

Recently there was so much emphasis on rain water harvesting. The source of drinking water is sinking day by day. Now people are becoming more conscious regarding use of water. As it is so important for life, it is on sale everywhere like other article. We should preserve it by applying all means n techniques.

We have faced a particular problem related to qualification of piping forces and moments on a vessel nozzle. The nozzle was self reinforced type and we need to carry out WRC analysis on stress analysis software. Software asks for input related to nozzle OD, thickness, corrosion allowance, material , reinforcement pad thickness, reinforcement pad outer diameter, vessel dimensions and design parameters, material & nozzle forces and moments in all three direction ( X, Y, Z).

But the in self reinforced nozzle drawing nozzle internal diameter, outer diameter, and material of construction differ from conventional nozzle pipe OD, ID, RF pad thickness and RF pad outer dia. And the input data can not be fed directly based on information available in drawing.

So we have found the way out for the same. First got the pipe thickness ( OD are standard for nominal bore pipe generally used in project) and established length of pipe section for pipe length = height of self reinforced nozzle. We calculated area of self reinforced nozzle as per data given in drg ( A1). Then we found the area of the nozzle for given pipe OD, ID and length( A2).We reduced area of pipe from area available in self reinforced nozzle ( A1-A2). We got the RF pad thickness after dividing area difference by 2xPipe OD.

Then we carried out WRC calculation for nozzle under consideration with pipe thickness, Pipe OD, Pipe material of construction ( same as of written in self reinforced drawing, generally forging material ), reinforcement pad thickness as calculated above, reinforcement pad OD = 2xPipe OD. The result was quite satisfactory. It was in same range with fair accuracy as of pressure vessel design software WRC nozzle analysis report with self reinforced dimensions!

An Indionix Engineers Team Member

#201914

Engineering design, analysis, result interpretations, failure prevention, plant operational challenges, its implications, recommendation, precautions and safety measures are now a day becoming much definitive in nature due to technological advancements. New avenues for design expert to justify their relevance are diminishing. Hence it is quite logical to look for individual’s participation in aligning, managing, compiling & customizing next generation advanced machines to get adequate & reliable results with minimum human interface at faster speed to match the business competition.

The relevance for pipe nominal diameter in indicating pipe support tag is interesting matter. Generally pipe nominal diameter are indicated with pipe support tag eg S1-10. It represents support type “ S1” for pipe diameter of 10” NB. It is due to the following reasons-

1. It provide information of line for which it has been planned.

2. It also provided basis for understand the likely support reaction for which it should be designed for transmitting.

3. Ease of fabrication of pipe support

4. Ease of dimensioning, fit –ups, construction, installation and associated structural member planning

Support tags on trunnion connected to pipe to be indicated carefully. And it should be indicated based on trunnion size and not as per pipe size. Because all the detailing and construction of support related to trunnnion will be as per trunnion pipe only . The member selection of the support ( on trunnion ) to be based on main pipe size and not as per trunnion size. Because the actual forces corresponding to main pipe will need to be transmitted through these support members ( installed on trunnion) to nearby structure/foundation.

An Indionix Engineers Team Member

#201915

On April 2 2017, PV Sindhu defeated Carolina Marin in straight games to win her maiden India Open title. During that match she was accompanied by her main coach and other Indonesian coaches. It was a curious case to see other coaches apart from P Gopichand. She recently won Gold medal in world badminton Championship 2019. She was accompanied with Korean coach. It shows that champions need battery of coaches to identify the weaker areas and get the required support/supervision to overcome it.

Plant engineering is also becoming more demanding carrier and we need to manage feedbacks from peers & seniors. It will helps in identifying the weaker area within ourselves. And then some experts related to those improvement areas to manage self transformation by learning/adaptation at the earliest. Trainee engineers, Job engineers, Area engineers, Lead engineers, Designers, Checker, Material engineers, Stress analysis engineers are required to identify the area of improvement related to their personal development and professional/technical advancement to secure better carrier future. Specific areas related to change management , application of advanced techniques, tools, software, calculation of quantum of bulk activities and micro monitoring are the most important features of future plant engineering job requirement. Our constant learning and rational approach to accomplish more can be of great help to achieve these special qualities. Our past blogs had well addressed these issues and supplemented the specifically customized worksheet. One can go & get it!

An Indionix Engineers Team Member