PROCESS PIPING DESIGN HANDBOOK Volume 3 The Planning Guide to Piping Design Richard j. Beale, C.Tech Association of Science and Engineering Technology Professionals of Alberta (MET) Paul Bowers American Society of Mechanical Engineers (ASME) Society of Piping Engineers and Designers (SPED), co-president ~ k a v Peter Smith Gulf Publishing Company Houston, Texas The Pronning Guide to piping Design Copyright 0 20 I0 by Gulf Publishing Company, Houston, Texas. All rights reserved. No part of this publication may be reproduced or transmitted in any form without the prior written permission of the publisher. Gulf Publishing Company 2 Greenway Plaza, Suite I020 Houston. TX 77046 Library of Congress Cataloging-in-Publication Data Beale, Richard, 1955- The planning guide to piping design / Richard Beale, Paul Bowers, and Peter Smith. p. cm. Includes indexes. ISBN- I0 1-933762-37-3 (alk paper) ISBN- I3 : 978- I-933762-37- I (alk paper) I. Pipelines-Designa nd construction. I. Bowers, Paul (Paul Andrew), 1962- II. Smith, Peter, I95 I June 7- 111. Title. TA660.PSSB43 20 I0 62 I. 86724c22 20 I001 9043 ISBN: 978- I-933762-37- I Printed in the United States of America Printed on acid-free paper. 00 Editing, design and composition by TIPS Technical Publishing, Inc 1 0 9 8 7 6 5 4 3 2 1 List of Figures .............................................. Figure 1-1 Dummy Leg Standard 4 ............................................ Figure 1-2 Base Support Standard 5 .......................................................... Figure 1-3 Shoe Standard 6 .................... Figure 1-4 Single Block Vent and Drain Standard 7 ............................................... Figure 2-1 Stick File Flowchart 39 ......... Figure 2-2a Interdiscipline Drawing Review Flowchart 44 Figure 2-2b Interdiscipline Drawing Review Flowchart. ......... 45 ................ Figure 2-3 Interdiscipline Drawing Review Stamp 46 .................... Figure 2-4 Vendor Document Review Flowchart 49 Figure 2-5 Header with Line Reduction .................................. 52 . ......................................... Figure 2-6 Header with Spec Break 52 Figure 2-7 (a) Control Valve without Bypass or Spec. Break . . @) Control Valve with Bypass without Spec Break.. 52 . . Figure 2-8 (a) Control Valve without Bypass with Spec Break @) Control Valve with Bypass and Spec . Break ..... 53 Figure 2-9 (a) Single PSV without Bypass. (b) Single PSV ............................................................ with Bypass 54 . Figure 2-10 (a) Single PSV without Bypass on Vessel ..................... (b) Single PSV with Bypass on Vessel 55 Figure 2-1 1 (a) Multiple PSV without Bypass . @) Multiple PSV ............................................................ with Bypass 56 Figure 2-12 Inlet or Suction and Outlet or Discharge ................................ for Single Piece of Equipment 57 xix xx List of Figures Figure 2-13 Inlet or Suction and Outlet or Discharge ........................ for Multiple Equipment in Parallel 57 ........................ Figure 2-14 Inlet and Outlet for Aerial Coolers 58 Figure 2-15 Stress Analysis Method listed in LDT .................... 59 ................................................................ Figure 2-16 Stress Log 60 ....................................... Figure 2-17 Stress Analysis Flowchart 61 ....................................................... Figure 2-18 Stress Isometric 64 ....................................... Figure 2-19 Model Review Comment 72 ......................................................... Figure 2-20 Nozzle Re port 80 ....................................... Figure 2-21 Equipment Dialogue Box 81 ............................. Figure 2-22 Manhour Spreadsheet Example 99 Figure 2-23 Manhour Graph Example .................................... 100 ..................................................... Figure 3-1 Drawing Index 111 ............................................................... Figure 3-2 Plot Plan 112 .............................. Figure 3-3 Piping Arrangement Key Plan 113 ..................................... Figure 3-4 Area Piping Arrangement 117 ............................... Figure 3-5 Module Piping Arrangement 118 .............................................................. Figure 3-6 Isometric 120 ............................................................. Figure 3-7 Tie-In List 122 ............................................ Figure 3-8 Demolition Drawing 123 ..................................................... Figure 3-9 Heat Trace Log 125 ....................................................................... Figure 3-10 PFD 132 ..................................................................... Figure 3-11 P&ID 134 ....................................................................... Figure 3-12 LDT 135 .................................................. Figure 4-1 CWP Boundaries 140 ...................................... Figure 4-2 Study Model Boundaries 144 .................................. Figure 4-3 Detailed Model Boundaries 145 . Figure 4-4 (a) Single Level Module Numbering @) Multiple .................................... Level Module Numbering 158 .................... Figure 4-5a Piping Design Progress Spreadsheet 173 ................ Figure 4-5b Piping Checking Progress Spreadsheet 174 ............................. Figure 5-1 Photograph of Finished Spool 184 ........ Figure 5-2 Photograph of Spools Loaded for Shipment 184 Figure 5-3 Photograph of a Piperack Module being loaded ........................................................ for shipment 188 ListofFigures xxi Figure 5-4 Photograph of a piperack Module being shipped.. 188 Figure 5-5 Photograph of an Equipment Module ready .... ................................... ................ for shipment. 189 ............................................ Figure 5-6 Spool Sheet Example 193 ............................................ Figure 5-7 Spool Sheet Example 194 List of Tables .............. Table 1-la Branch Connections Instrument and Utility Air 8 ................................... Table 1-lb Branch Connections Process Lines 9 Table 1-2 Line Spacing Chart .......................................................... 10 ....................................................... Table 1-3 Line Spanning Chart 11 ...................................................... Table 1-4 Example Piping Class 17 .................................................... Table 1-5 Piping Class Identifiers 21 ..................................... Table 2-1 Discipline Mark-up Color Codes 40 ......................... Table 2-2 Inter-discipline Drawing Review Matrix 47 Table 2-3 Stress Analysis Inital Determination Matrix ................... 63 ...................................................... Table 2-4 Model Review Matrix 73 Table 2-5 Linear Thermal Expansion between 70°F/210C ............................................. and Indicated Temperature 86 ................. Table 4-1 Pipe Support Shop/Field Designation Chart 146 ............................... Table 4-2 Piping Material Purchasing Matrix 148 ........... Table 4-3 Equipment Coordinates and Elevations Matrix 153 xxiii Preface During the Christmas to New Year’s period of the years 2007 and 2008, Paul Bowers and I had the honor to peer review the book Advanced Piping Design by Rutger Botermans and Peter Smith. While we were corresponding with Peter Smith a discussion developed about the need for a book that would provide guidance in the set-up and management of the piping design- book for the project engi- neer or project manager who wishes to know more about the manage- ment of piping design and the piping designer who is new to the role of a piping lead. There are many fine books available on piping design and plant layout, but we shared a common observation that there is very little information available on how to manage the piping design. It was from these initial discussions and our observation that the making of a book was born, the final result of which is this book that you hold in your hands today. Essentially there are two components to the successful comple- tion of the piping design: the layout of the piping systems and the management of the activities that support the layout of the piping systems. Managing the piping design activities means being in control and organizing the planning, scheduling, manpower, progress moni- toring, and communications of the piping design. A piping designer begins his/her career after graduating from col- lege, whereas a piping lead can only begin his/her career after many years of further study and experience gained by working as a piping designer. The knowledge and the abilities required to manage the activities that support the layout of the piping systems from concep- tion through to construction can only be gained through years of xv xvi Preface exposure to piping design in organized companies with comprehen- sive procedures and through the guidance of experienced mentors. A book cannot substitute for an experienced mentor, but this book will assist the piping lead by explaining the management side of piping design with reference to documented procedures. Because pro- cedures provide direction to all team members and are integrally linked to the management of a successful piping design effort, they are the cornerstones of efficiency and teamwork. This book would have been incomplete without the inclusion of procedures. Until now documented procedures have only been available in company proce- dural manuals. Many of the procedures presented in this book have been used in industry for many years and are universally accepted because of the proven benefits, albeit with some differences to suit company specific requirements. For instance, a stick file procedure is an old concept used by many companies and has its origins going back many decades. The methods of management and the procedures outlined in this book are recommended practices. It is not expected that you will agree with everything that is written here; however, it is not an option for a piping lead to ignore the management of an activity. The only choice is to select one method of management over another. It is compulsory for a piping lead to manage all of the activities in one way or another. While the technologies used for piping design and drafting have changed from manual techniques to CAD over the last couple of decades, one thing has not changed: that of the need to consider all of the detail involved and manage accordingly. During my career I have had the good fortune to work for some very senior piping leads and well-organized companies. I am grateful to all for teaching me the importance of attention to detail in the management of the piping design. I must give special thanks and credit to the leads and management of Delta Projects, Calgary, Alberta, Canada (now Jacobs) who I had the privilege to work for in my early years: because they, above all, taught me the principles and values that I carry with me to this day. Many of these people are now retired and this book is my way of continuing their legacy and passing on the convictions that they instilled within me to the next generation. Credit and thanks are also due to the following individuals for their assistance and contributions to the writing of this book Ross Krill, P.Eng., Team Lead, and Bob Baker, Document Control Group Lead, for providing the approvals for needed materials. Without their ongoing support the task of writing this book would have been much heface xvii more difficult. Thanks also go to Xenia Beale, Intermediate Piping Designer; Mark Beauliua, Piping Lead; Madelaine Carrette, Contract Administrative Assistant; Gudrun Dahle, Senior Material Controller; Scott Maguire, Construction Coordinator; Rory McDougall, Manager of Pepco Pipe Services; Gord Mernickle, Construction Coordinator; Curtis Smith, Piping Lead; Alvin Winestock, P.Eng., PMP; and Sean Williams, CAD Administrator, for their willingness to give their time and expertise. Their assistance and advice has made a significant con- tribution. It is my hope that this book will communicate and promote the importance of the management of piping design and provide guid- ance on how to do so. -Richard J. Beale One unintended consequence of the adoption of CAD technology has often been the fragmentation of piping designers’ training, knowledge and experience into which software is being used. This is a natural outcome of the new tools being used and explored. Thirty years ago it did not matter if one used a Staedtler or Koh-I-Noor. Today’s CAD tools are remarkable in their ability to facilitate 3D visu- alization, import/export data for engineering, procurement and con- struction purposes and to replicate designs. But it is important to recognize that machines only do what you tell them to do, and understanding in more detail the purpose of what you are “drawing” helps to create better designs and better designers. It is my hope that this book will be of interest to new piping designers/draftsmen/engi- neers and anyone else wanting to learn about the process of designing a process piping facility. I wish to give thanks to the following people who helped me through my formative years: Glenn Fair, David Gencher, Robert Giu- bilei, Rene Inic, Bob Jacobs, Kim Levan, Steve Murton, Louis Parant, and Mike Schum. -Paul Bowers This book focuses on the management of the activities that support the piping design. It is our hope that it will prove to be a valuable resource to everyone interested in the role of a piping lead. The experienced reader will notice that the focus of this book is on Engineering, Procurement, and Construction (EPC) and detailed xviii Preface design. This is because a piping lead will spend eighty to eighty-five percent of his/her time in detailed design, fabrication, and construc- tion, where the true abilities of a piping lead are tested. The roles and responsibilities of the piping lead during Pre-FEED and FEED have not been discussed; however, it is emphasized many times in the book that one of the primary responsibilities of the piping lead is to know the project scope. Once a piping lead knows the project scope and his/her project deliverables it is a simple matter for him/her to extrap- olate the information and guidance provided in this book that are rel- evant to his/her own situation. The experienced reader will also notice the clear connection to the manual design and drafting world. This is because there are many small- to medium-size projects executed by small- to medium-size companies effectively utilizing manual procedures. Much of the work executed by these companies is somewhere between the realms of the manual and the automated due to the costs of software investment and/or clients who are not convinced of the benefits of using new technology on their projects. Often too, the larger projects and larger companies will fall somewhere in between the realms of the manual and automated depending on the software manufacturer of choice and the level of understanding of the available functionality of the software. A book that reaches out to the global piping community who work in a variety of industries and with a variety of software must draw lines somewhere. The lines in this book are drawn at the median approach to piping execution between manual and automation where the vast majority of projects lie today. A key point for all readers is that the piping lead's roles and responsibilities do not change with technology; it is merely the methods of piping execution that may change. An'understanding of where we have been, where we are currently, and where we are going is crucial for a piping lead to evaluate the effects of technological change and adjust accordingly. Undoubtedly the path forward is one toward more automation and will become the subject of future discussions within all industries that involve piping design and all technical institutions that teach piping design. For instance, there is software already available capable of auto- matic pipe routing that reduces the time required for piping layout study and material take-off, but as of now this is not mainstream. Your feedback will be appreciated so that we may make improve- ments. Feedback may be left with the Gulf Publishing Company at http:// www.gulfpub.com or on the authors' website http://pipingdesign.com/ planningguide-pipingdesign/.