Course programme
The Course is divided in 5 Modules.Module -1:
Basic Piping Design & LayoutProject phase & development concepts· Hydrocarbon sector project· Project location on global· Phases of project / asset lifecycle· Greenfield development· Brownfield optimization· Procurement services· Inspection services· Project productsPiping Engineering Scope· Design engineering· Field engineering3ASME Codes & Standards• Introduction to ASME Pressure Piping Design Codes.• ASME Standards for Common Piping Elements.• API Codes• Other Codes & StandardsFlow Diagrams• Process Flow Diagram – PFD• Piping & Instrumentation Diagram – P & ID.· Line Numbering· P& ID Requirements· Print Reading Exercise· Line Number· Flow Diagram Exercises.· Symbols & Abbreviations.• Instrument Types & Symbols – Flow, Temp, and Pressure & Level.• Utility Flow Diagram – UFDPiping Fundamentals· Introduction to Process Plants· Scope of Piping in Projects.· Plant Piping Systems and Transportation Pipelines.· Definition & Application of Pipe· Pipe Designators – NPS , IPS , NB, Pipe Wall Thickness & Schedule, Pipe· Weights, Lengths, Grades, Ends, Joining Methods,· Methods of Manufacture, Pipe Ratings, Pipe Symbols.Pipe Fittings• ASME Standards, Selection, Application, Drawing Symbols & Dimensioning.• Types of Fittings – Butt Weld, Screwed & Socket Weld.• Elbow – 90 degree (LR & SR), 45 degree, Reducing Ell. ,• Pipe Bends – Miter Bends, 180 degree Return.• Branch Connections – Weld Straight & Reducing Tee, Cross & Lateral.• Fabricated Branch Connections – Stub In & Stub On, Welding Minimums for Stub In,• Branch Reinforcements – Reinforcing Pad, Welding Saddle & Olets.• Olet Fittings – Weldolets, Sockolets, Threadolets, Latrolets, Elbolets & Sweepolets.• Reducers – Concentric & Eccentric, Reducer Offsets.4• Types of Couplings, Weld Cap.• Fitting Makeup – Dimensioning, Minimum Pipe Length Requirements, Placement of Dimensions.• Screwed & Socket Weld Fittings – Union, Plug, Coupling, Types of Swages.• Dimensioning ExercisesPipe Flanges• ASME Standards, Symbols, Selection & Application.• Definition of Flange.• Types of Flanges based on Face and Application, P-T. Ratings.• Forged Steel and Cast Iron Flanges.• Flange Facings – Flat Face, Raised Face, RTJ, & Male - Female, Tongue & Groove. Flange FaceFinish.• Weld Neck, Slip On, Threaded, Socket Weld, Lap-Joint, Reducing, Blind & Orifice Flanges.• Gaskets – Types, Thickness, Bolts & Nuts.• Dimensioning Exercises.Valves• ASME/API Standards, Symbols, Selection & Application• Valve Functions, Locations & End Connections.• Valve Types – Gate, Globe, Ball, Check, Butterfly, Angle, PRV/PSV, & Plug etc.• Control Valve Manifold. – Layout Representation & Requirements.• Valve Operators.• Valve Layout Considerations.• Valve Data Sheets• Valve Selection• Dimensioning Exercises.Piping Special Elements• Strainers• Bellows/Expansion Joints• Rupture Disc• Spray Nozzles• Steam Traps• Flame Arrestor• Hose• Pig detector• Barred tee/scapper tee• Hinged closure• Corrosion/biological /scale coupons• 5D bends5Process Mechanical Equipments• API Standards, Symbols, & Application.• Static – Horizontal Vessels, Pig Launcher & Receiver, Separators, Heat Exchanger & Reboiler.• Rotary – Pumps, Compressor, Fans, & Gas Turbines., Emergency Diesel generators, IACompressor,• Fire Water pumps, Injection Pumps• Material handling EquipmentPlot Plan, Equipment Layout, & Piping GA Drawings.· Plot Plan Development & Requirements.· Equipment Layout Terminology, Control Point & Battery Limits.· Preparation of Equipment Layout.· Piping GA Drawing Requirements and Layout Procedure.· Pump GA Drawing and Layout Consideration.· Tank & Vessel Layout Consideration.· GA - Print Reading Exercise.Piping Isometrics· Definition· Drawing Piping Isometrics· Isometric Dimensions, Notes & Callouts.· Isometric Offsets.· Print Reading Exercises.· Exercises on Creation of Isometrics form Piping Plans and Sections.Piping Systems Design· Pressure Design of Process Piping Systems – ASME B 31.3· Scope of ASME B31.4 & B 31.8 and Pipeline Wall thickness Calculations· ASME B 31.3 Fluid Service Categories· Design Pressure & Design Temperature for Piping Systems.· P-T Ratings of Flanges, Butt-weld Fittings & Socket Weld Fittings· Pressure Design of Straight Pipe under Internal Pressure. – Wall thickness Calculations· Branch Reinforcements – Reinforcement Pad Calculations· Pressure Design of Miter Bends – Single & Multiple Miters.· Pressure Design of Blanks.· Piping Material Selection per ASME Code.6· Severe Cyclic Conditions.
Module -2: Material Selection·
Material Fundamentals· Corrosion Aspects· Classification of Piping Material· Ferrous & Non Ferrous Material· Non Metallic such as PVC, GRE, FRP· Alloy material in piping· Piping Material Specifications
Module-3: Stress analysis & Support DesignPipe Stress Analysis· Objectives & Definition of Stress Analysis· Critical Line List· Information Required for Stress Analysis· Piping Loads – Static & Dynamic· Static & Dynamic Analysis· Forces, Moment & Stress Calculations.· Requirements of ASME B 31.3 Code – Sustained Loads, ThermalExpansion & Occasional Loads.· Classification of Loads· Solutions for Piping Loads.Pipe Span Calculations· Span limitations based on Stress, Deflection & Natural Frequency.· Allowable Pipe Span Calculations· Suggested Pipe Support Spacing· Pipe Span Reduction Factor for Elbows, Concentrated Loads etc.· Selection of Supports.· Location of Supports and Restraints.Flexibility Analysis – Expansion Loops & Expansion Joints· Concept of Thermal Expansion.· Providing Flexibility in Piping· Minimum Leg Required to Absorb Thermal Expansion· Types of Expansion Loops· Expansion Loop Sizing for Hot Piping· Expansion Joints – Types, Application & Selection.· Bellow Materials, Hydrostatic Test Pressure for Bellows7· Guide Spacing for Expansion Joints.· Layout Solutions for Weight, Thermal, Vibration & Wind Loads.· Causes of Pipe Stress· Layout Solution for Weight Stress – Continuously Supported &· Branch Pipe Allowable Spans· Solving Concentrated Loads and Reducing Loads on Equipment Nozzles.· Equipment Nozzle Load Qualifications.· Layout Solutions for Thermal Load using force & Stress· Checking Piping Layout in Pipe Racks.· Checking Piping Layout for Reciprocating Equipment· Checking Piping Layout for Wind Load.Flexibility Analysis using ASME B 31.3 Code Equations· Thermal Expansion Stress - Se and Code Allowable Thermal Displacement· Stress Range Sa.· Stress Range Reduction Factors - f· Bending & Torsional Stress· Formal Analysis Requirements· In plane & Out plane Bending Moments· Stress Intensification Factors – SIF· Calculation of Thermal Expansion Stress.· Cold Spring.· Sustained Loads - Internal Pressure & Longitudinal stresses· Theories of Failure· Stresses acting in Pipe due to internal Pressure· Sustained Loads QualificationOccasional Load Stresses· Wind Load· Seismic Load· Pressure Relief LoadDynamic AnalysisCAESAR – II – Pipe Stress Analysis Software· Introduction· Nozzle Thermal Growth Calculations – pumps, vessels, heat exchangers.· Piping Input Spreadsheet.· Modeling of Piping Isometrics – Bends, Reducers, Valves, Loops etc.· Performing Static Analysis.· Modifying Load Cases.· Hanger Selection.· Set up of Wind Load Cases.· Set up of SUS, OPE, EXP, HYD, HGR, & OCC loads.· Load Case Editor8· Viewing Reports· Evaluating API 610 Pump Nozzle Loads· Practical Examples – Input, Analysis & Redesign.Pipe Supports· Classification of Supports· Primary & Secondary· Anchors· Pipe Guides· Limit Stops· Pipe Shoe· Dummy Leg / Trunion· Field Support / Base Support· Rigid Hangers – Rod & Clevis, Trapeze.· Flexible Hangers – Variable & Constant.· Pipe Rack Design – Types, Height & Width Calculations, Pipe Arrangements· Control Station & Utility Station on Pipe Racks
Module-4: 2D/3D modeling Concepts & Practical
· Plot plan development· Equipment layout· Piping GA Drawing· 3D Review Procedure· Generation of Isometrics· MTO extraction· Support modelingModule-5 Field Engineering for Fabrication, Erection & Commissioning· Material Identification· Fabrication Procedure / drawings—Spool drawing, welding etc· Erection Procedure· Hydro testing Procedure· Painting Procedure· Color Coding· Erection Clash Resolution· Commissioning