TRAINING MANUAL- PIPING
Uhde India Limited
INTRODUCTION TO PIPING ENGINEERING
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CONTENTS Page 0.0
Cover Sheet
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Introduction
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Knowledge Required for Piping Design
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Latest Developments in Piping Design Techniques
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Piping Design Function and Size of Organisation
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Annexure-1 Typical Material Cost Breakdown (Major Items)
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Annexure-2 Typ Typical Home Off Office Engineering ing Man-hour Breakdo kdown
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Annexure-3 Typical Field Labour Cost breakdown
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TRAINING MANUAL- PIPING
Uhde India Limited
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INTRODUCTION TO PIPING ENGINEERING
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INTRODUCTION:
Pipes and piping systems are the veins and arteries of chemical process plants used for transporting liquids, vapours, slurries, solids etc. under various conditions, as imposed by the process design of the plant. The network of pipes is subject to extremes of temperature, pressure, flow and combination of these. In addition, they are subject to corrosion, erosion, toxic condition and radioactivity, all of which calls for proper piping design enabling trouble free operation of the plant over a long period of time. Capital cost of piping forms a large portion of the investment in the plant exceeded only by that of major equipment. Pie Chart (Refer Annexure-1) shows the relative cost of various material components of a plant. As can be seen from the chart, piping accounts for nearly 15% of the overall material cost. Pie Chart (Refer Annexure-2) shows the man-hour effort that goes in to design engineering at home office for various engineering disciplines. Normally, out of the total engineering effort covering project management, detailed engineering, procurement, inspection and expediting, etc., 65% of the hours are required for detailed engineering. Out of this, 25% is required for piping engineering alone, the balance 40% accounting for civil, mechanical, electrical and instrumentation engineering. Progress in piping engineering being very much dependent upon the feed back of equipment data (static and rotating) as also on control valves and other inline instruments, a close monitoring of the schedule of orders for these equipment and follow up with vendors for data and drawings is required to finalise Piping Plans, generate Isometrics, order bulk Piping Material as well as Piping Speciality Items and release drawings to site for speedy construction and thus facilitate prompt start up.
TRAINING MANUAL- PIPING
Uhde India Limited
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INTRODUCTION TO PIPING ENGINEERING
DOC No. : 29040-PI-UFR-0001 Rev.
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LATEST DEVELOPMENTS IN PIPING DESIGN TECHNIQUES The trend in recent years has been to develop and employ better techniques in piping design to save time and also to improve accuracy. Computers are being extensively used to obtain speedy solutions to more complex problems of plant design and to solve problems of stresses in piping. Recent past has seen development of software for production of piping detail drawings, piping isometrics, bill of material, estimation and cost control. Piping Engineer has therefore the added responsibility in understanding and upgrading his / her knowledge on the application of a growing number of techniques of this nature helping speedy work execution. The most revolutionary advancement in the Piping Design in recent past had been the concept of 3D Modelling of the Plant by using sophisticated Software such as PDMS. This provides an opportunity to build the entire plant on soft media in a 3D environment to the last degree of detailing, to be able to identify and rectify practically every problem related to design and construction prior to actual commencement of erection activities at the Site.
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PIPING DESIGN FUNCTION AND SIZE OF ORGANISATION The size and scale of operations of a design engineering company does not affect either the piping design requirements or the underlying design principles and practices. As the volume and complexity of work and the number of projects executed increase, so does the degree of specialization increase. Piping layouts, piping specifications, detail drafting and material listing begin to emerge as functions handled by separate Specialist Groups within the department. There is little apparent similarity between piping design performed by a team of say ten engineers from a small office and by a large company having hundreds of piping design engineers. The job performed in both the cases is identical and has the same degree of relative importance to the whole project design organisation. The real difference lies in the number of projects handled by the design office. In a small office, the flow of work is such that each project is substantially completed before the succeeding project commences. This requires a flexible organization with a small group, who is responsible for all aspects of
Major equipments 60%
P a i n t i n g a t i o n I n s u l
2 % 2 %
Typical Material Costs of Major Equipment Com modities and Sub-Contracts
8 % s & g s s n i e r d l t u i o n i % u 8 B t r u c d a t S o u n s t l F a n c e i r m t p c i l e u E q E
ANNEXURE-1
% 5 s t n e m u s rt nI
Piping 15%
TYPICAL MATERIAL COST BREAKDOWN (MAJOR ITEMS) File: Annexure to C-1
Detailed En gineering 65%
i n g % p i P 2 5 n g i D e s
Typical Hom e Office Engineering Man-hour Breakdown
Implementation 35%
ANNEXURE-2 TYPICAL HOME OFFICE ENGINEERING MAN-HOUR BREAK DOWN File: Annexure to C-1
Piping 40%
Major Equipm ents 20%
Typical Field La bor Costs
Buildings Structures & 15 % Foundations
Instrum ents 10%
Electrical 15%
ANNEXURE-3 TYPICAL FIELD LABOUR COST BREAK DOWN File: Annexure to C-1
