QUALITY DEPARTMENT Sep - 2014
PIPING INSTRUCTION
* SHIPBUILDING
CONTENTS: 1. INTRODUCTION Page 2. PIPING THEORY and INTRODUCTION TO P&IDs P &IDs 2.1 Piping basic Page 5 2.1.2. Materials 2.1.2. Standards 2.1.4. Pipe system classes by DNV 2.1.3. System Diagrams – P&IDs 2.1.4. Piping drawings 2.1.5. SFI System 2.2. System Diagram Introduction – P&ID Page 8 2.2.1. Going through one typical P&ID 2.2.2. Pipeline components 2.2.3. Introduction to main system diagrams - System by system 2.2.3.1. Cargo systems 2.2.3.2 Machinery Systems & Other Systems 2.2.4. S ecial e ui ment and Ex ressions 2.2.5. Corrosion rotection 3. PIPING ON BOARD 3.1. Fabrication of PT-pipes Page 30 3.1.1 Planning 3.1.2. Measuring of the pipes 3.1.3. Make an ISO drawing of your pipe (hand sketch) 3.1.4. 3.1.4. Bendi Bendin n with with the the bendi bendin n mach machin ine e 3.1.4.1. Installing of the sealing 3.1.5. Cleaning of the pipe 3.1.6. Installation of supports 3.1. 3.1.7. 7. Wor Worki kin n on boar board d 3.2. Fabrication of Steel pipes Page 39 3.2.1. Planning 3.2.2. Building of ISO pipes 3.2.3. Pipe building on board 3.2. 3.2.4 4. Ma Make ke an ISO ISO draw drawin in of our our i e 3.2.5. Calculation 3.2.6. Buildin of i es 3.2.7. Preparing 3.2.8. Start the work 3.2.9. Tag welding of flanges 3.2.10 3.2.10.. Work Workin in on board board 3.2.11. Site run of last spool before equipment
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PIPING INSTRUCTION
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CONTENTS: 3. PIPING ON BOARD 3.1. Fabrication of PT-pipes 3.2. Fabrication of Steel pipes 3.3. Some common routing problems to be aware of (for all pipe fitters) 3.4. Pipe erection by block Page 48 3.4.1. Pre-outfitting 3.4.2. Pipe erection by module 3.4.3. Pipe erection with isometric drawing (ISO) and P&ID drawing 3.4.4. Setting of supports 3.5. Cleaning, Cleaning, testing testing and and coating coating of piping piping systems systems Page 58 3.5.1. Pipe cleaning inside 3.5.2. Pipe coating/preservation 3.5.3. Pressure testing 3.5.4. NDT testing (Non Destructive Testing) 3.5.5. Flow coding 3.6. Yard standard for i in com onents Pa e 60 3.6.1. Bulkhead and deck enetration 3.6.2. Overboard pipes 3.6.2.1. Overboard pipes and sleeves 3.6.3. Bended pipes and Elbows 3.6.4. Branch line connection with "saddle" or "T-pipe" 3.6.5. Reducers 3.6.6. Drains 3.6.6.1. External drains 3.6.6.2. Internal drains 3.6.7. Pipe supports / Clamps 3.6. 3.6.8. 8. Pi e oint oint meth method odss 3.6.8.1. Pipe to flange with slip-on flange 3.6.8.2. Pipe to flange with welding neck flange 3.6.8.3. Pipe to flange with welding collar in combination 3.6.8.4. Pipe to pipe joint with Straub Grip coupling 3.7. Tank accessories Pa e 68 3.7.1. Tank sounding 3.7.2. Level alarm 3.7.3. Heating coils 3.7.4. 3.7.4. Steam Steam in in ection 3.7.5. Temperature sensor 3.7.6. Sampling point Page 74 4. TYPICAL DRAWING SYMBOL
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PIPING INSTRUCTION
* SHIPBUILDING
1. General introduction - This handbook is developed with the aim to be a support for the worker/pipe fitter, for the foreman and also for the engineer. The handbook is on the whole fairly elementary, being a reference guide with methods, solutions, key points and alternatives. - It is the base handbook for a training program for pipe fitters and alternatively for the engineers. - Not many standards, etc. are included in the manual, although there are some in the appendix. To include all common standards for the pipe fitter the handbook would be quite comprehensive. Please refer to the catalogue from Brodrene Dahl or other relevant
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.1 Piping basic 2.1.2. Materials • Piping material to be used is decided in the building specification for the ship. • Piping material with information about standards and dimensions are given on the different Pipe system diagrams. • The common types are as follows: - Steel, St. 37, Seamless. Galvanized or not galvanized. + Main cargo systems + Fresh water cooling + Bilge system + Fire system + Drain system + And others…. - Stainless steel, type Blucher + Sanitary discharge - Copper Nickel, CuNi10Fe + For SW cooling - Copper, plastic coated + Sanitary supply pipes (small dimensions) - Stainless steel, AISI 316 + For methanol system + For remote sounding inside tanks + For hydraulic system wet area SW exposed (=
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.1 Piping basic 2.1.2. Standards • A pipe standard is a fixed specification for pipes describing in detail diameter, wall thickness, strength, material specification, fabrication method and so on. • The normal standards used in VARD Group are as follows: - NS Norwegian Standard - DIN Deutsches Institut for Normung = German National Standard - EN European Standard - ISO International Organization for Standardization - NS 2501 (DIN 17177) Normal steel pipes - DIN 2391 Precision steel tubes - Traditionally in VARD Norway Offshore the NS and DIN standards have been dominating. It is a natural development to change more over to the international ISO standard, specially for VARD Vietnam as an international yard. ISO and NS have a lot of similarities but for some areas the NS standard is somewhat stricter. - It has also been developed an International Shipbuilding Standard. For now this is not a standard that we take into consideration when building a ship in VARD Vietnam. It is possible that this will be a more important standard in the future. 2.1.3. Pipe system classes by DNV • For the purpose of testing, type of joint to be adopted, heat treatment and welding procedures, piping is subdivided into three classes by DNV, class I, class II and class III. Criteria are pressure, temperature and flow media. • Ref. DNV Pt. 4, Ch. 6, Sec. 1B, Table B1. • Ref. chapter 3.5 and appendix 4.2, Drawings, "Pipe systems, Test, Cleaning and Coating" for a closer description. 2.1.4. System Diagrams – P&IDs • P&ID is short for "Piping and Instrumentation Diagram" • A P&ID is designed for each system onboard the ship and is the central drawing in the whole process from designing the piping system/routing, building the pipes and testing, until delivery. • P&ID is defined by the "Institute of Instrumentation and Control" as follows: 1. A diagram which shows the interconnection of process equipment and the instrumentation used to control the process. In the process industry, a standard set of symbols is used to prepare drawings of processes. The instrument symbols used in these drawings are generally based on "Instrumentation, Systems, and Automation Society" (ISA) Standard S5. 1. 2. The primary schematic drawing used for laying out a process control installation. • The set of P&IDs are checked very carefully at the beginning of each project. Page 5
PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.1 Piping basic 2.1.5. Piping drawings • 3D model of ship including equipment and piping - All steel pipes in the ship are drawn in 3D. The program used for 3D modelling in VARD Vietnam for the first 6 vessels is Nupas Cad Matic - To model the ship piping system in a 3D program gives the designer good control and overview of the piping system. In the building process, easy to see and modify, where necessary because of changes or conflicts. - With a 3D picture it is easy to understand how the piping shall be conducted for the pipe fitter. - Also data as pipe length or pipe weight can easily be taken out from the 3D program. - 3D model is a tool for the designer. • ISO drawings are generated directly from the 3D program. ISO drawings are describing in detail how every pipe shall be built and where it shall be mounted. Issued for use in the production. • Piping arrangement drawing is a 2D drawing of a room or a section showing all pipes in this area with notification of pipe reference (pipe number) for each pipe. Issued for use in the production. (Piping arrangement can also be a 3D drawing.) • 3D view or isometric view of each system is a 3D drawing of all piping belonging to one system. Issued for use in the production. (Optional) 2.1.6. SFI system • SFI System (SFI – Skipsteknisk Forsknings Institutt – Ship Research Institute of Norway) - SFI system is an international acknowledged code system for overview and filing of information which is widely used in the maritime industry. Main activities often organized according to SIF system are: + Procurement + Production plan + Drawings (drawing numbers) + Component identification + Documentation. • Example of SFI use on drawings: - Drawing number example: + 001-357-060 - Liquid Mud System (vessel no. 1 – VARD Vietnam) • First number is vessel no. 001 • Second number is main SFI group. Main group 352 stands for "Loading/discharging systems for liquid cargo". • Third number is drawing no. 60 within this main group
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.1 Piping basic 2.1.6. SFI system • Example of SFI use on drawings: - Component number example (on this drawing): + 357.013.10 - Liquid mud pump no. 1 • The first number is the main SFI group for this component. • The second number is component number 13 for this system • The third number is used to identify for example: o If there are identical components, 10, 20, 30, 40, etc. o Can be used for identifying minor parts belonging to a bigger part, such as 01, 02, 03, 04, etc, for throwing nozzles to FiFi system. o Various use for these numbers on various shipyards. Can identify starter cabinets belonging to the main components, 351.013.11 (ref. Liq. mud pump) - Line number example (on this drawing): + 357-614-125 • First number is the main SFI group • Second number is line number 614 for this system • Third number is the nominal dimension of the pipe, ND125. - Valve number example (on this drawing): + 357.6361 • First number is the main SFI group • Second number is valve number within this system • Component identification - There is a huge number of components on board the ship. It is essential to have a system for numbering and identifying of these. - All components on board are identified and marked according to the SFI system. • It is very important that the components are marked and labeled correctly on board the ship. For example are all valves belonging to the SW cooling system starting with 721.xxxx. When the crew is operating the ship they are operating valves based on the SFI number marked on the valve, which shall of course correspond to the P & ID system. If this is not correct, the system will not work correctly. • The correct marking of any part on board will immediately give information to crew what system the component is belonging to. • A piping system is not complete before the marking of all components are complete and checked to be correct.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.1 Going through one typical P&ID • Ref. Liquid Mud System for STX Vietnam b. no. 1. (see appendix 1 for drawing) • It is very important that the system drawing is followed accurately. Although a lot of effort is put into producing the system drawings and checking them at the beginning of each project it is possible that a system drawing has some errors. If there is reason to believe so a person in charge and/or the technical coordinator has to be informed 2.2.2 Pi eline com onents • Pumps - Electrical driven - Hydraulic driven - Centrifugal pumps - Screw pumps + 2-spindle or 3-spindle screw pump + Eccentric screw pump
2-spindle or 3-spindle screw pump
Centrifugal pump
Eccentric screw pump
• Ejectors - Same function as a pump + Creates a vacuum pressure + Cheap and simple construction + Powered by waterflow or by airflow. + Used for emptying cofferdams for water + Used for emptying BHS tanks
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Cooler - A cooler is cooling down the hot water from engines and other heat producing components. - There are different types of coolers: + Plate coolers + Tube coolers + Box coolers (no SW cooling pipe system needed) - Ref. explanation further down regarding FW and SW cooling systems - The hot and cold water have opposite flow direction in the cooler. Check drawings and instrucons carefully before connecng. Plate type cooler
Box cooler
• Heat exchanger - A heat exchanger is transferring heat from one medium to another. - In principle the same as a cooler. • Filters - Threaded or flanged? + Basic rule is to use flanged for sizes from ND50 and up + Threaded connection for sizes below ND50 + For fuel oil it is restriction from class to use threaded connection - Y-filters + Used for fluids which requires fine filtering such as FW water, fuel oil, compressed air and more. + Normally to be mounted in horizontal pipeline with filter/bonnet down + Important to prepare space below for filter changing and access to the filter.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Filters - Mudbox + Used for fluids and media which requires more coarse filtering such as mud, brine, SW cooling intake, bilge water and more. + Advantage that filter basket is taken upwards, leads to easier maintenance and less spill. + Fine mesh on filter basket is available upon request. + Comes in straight and angular version + Special types of mudboxes are often made by shipyard
Mudbox Bilge Straight type
Mudbox Bilge Angle type
Mudbox for Mud, Brine system
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves In the following overview of valves, be aware of that there are a lot of different types of valves on the market and it is only the most common types used on STX ships that are mentioned below. - Ball valve + Open/close valve. Simple and practical. + Mostly used for dimensions below ND40. Threaded type. - Butterfly valve + Open/close valve. + Mostly used for dimensions from ND40 and up. Flanged type. + LUG type. Bolted to flanges on both sides of the valve. • Very common valve on cargo systems • Can be used as dead-end flange. + Wafer type. To be mounted between flanges.
Butterfly valve, LUG type
Butterfly valve, Wafer type
- Non Return valve (NR valve): + Non Return valve is permanently open in flow direction of pipe and blocking any flow in the opposite direction. + Some of the NR valves have to be mounted in vertical or horizontal direction. + Most types requires a small pressure to open. Despite of this they are sometimes used in drain system causing some problems
NR valve, Swing check valve
NR valve, Check valve
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NR valve, Duo check valve
PIPING INSTRUCTION 2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Blind flange valve: This is normally mounted in a piping system where it is necessary to segregate two different media. Many of the tanks are combined tanks, f. ex. for fuel oil and brine. When the tank is filled with fuel oil, the blind flange valve is closed against the brine piping system. It is very important that different tank media are not mixed and a blind flange valve is a very safe valve for 100% blocking which is approved by the main classification societies for this purpose. - 3-way valve thermostatic: + Valve having 1 inlet and 2 outlets or 2 inlets and 1 outlet. + Thermostatic type automatic and self regulating. The temperature control power is created by the expansion of a wax/copper mixture which is highly sensitive to temperature changes. No external power source is needed.
- 3-way valve temperature control valve: + Valve having 1 inlet and 2 outlets or 2 inlets and 1 outlet. + External temp. sensor on the pipeline + Electric or pneumatic actuator is opening/closing the valve - 3-way valve lever operated + Valve having 1 inlet and 2 outlets or 2 inlets and 1 outlet.
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* SHIPBUILDING
PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Ventilation valve + Tank vent valve type Aero • Ventilation of tanks. Air can come out, water can not come in. • To be mounted outside in open air
• On tanks containing fuel oil, base oil or lub oil and is ventilated directly to open air, a vent valve with flame screen is required. Flame screen is a perforated steel plate designed to prevent fire to pass through the screen. • On ventilation of mud and brine tanks a special type of vent. valve is necessary to use. If mud is overflowing in the tank, a normal vent. valve does not have enough opening for mud to escape and the tank can be deformed because of high pressure, and eventually start leaking.
+ P/V valve – High velocity valve • Used for methanol and special products tanks (LFL tanks) • Valve preventing pressure or vacuum to build up in the tank • Preventing passage of flames through the valve • The air out from tank is blowing in high velocity, straight up. This is done because the gas is LFL (Low Flammable Limit) and it is important to get this away Page 13
PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Safety relief valve: + Limiting max. pressure in a system according to a preset limit. + Works on any media - Volume regulating valve: + The types shown below are regulating and measuring the flow, and are designed for use in sanitary supply systems and heating and cooling systems. + Flow direction is recommended to follow. + Globe valve can also be used as volume reg. valve.
TA valve, Incl. Shut-off function
TACO Setter valve
- Globe valve: + Open/close valve but normally used where there is need for some regulating of the flow. + If fine regulating is necessary, a conical shape of the "plug" can be used. + Not suitable where full opening is - Gate valve: + Open/close valve that is suitable where full opening is necessary.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Storm flap valve + Is used as "overboard" valve for grey water applications. + Is preventing seawater flow back into the pipes. + Closeable
- Fire valve / Fire hydrant: + A type of globe valve developed for fire valve purpose. Is prepared for direct connecon of re hoses.
- Pressure regulating valve: + Output pressure can be adjusted. + Normally a manometer is to be mounted in combination with this valve. The manometer can be mounted on the valve itself, or on pipeline near the valve - Quick closing valve + All fuel pipes on tank bulkheads/TT in engine room (or penetrating from pump room) must have a quick closing valve mounted on or as near the bulkhead as possible. This is a DNV requirement. In an emergency situation it shall be possible to close off all fuel lines to and from the engine room from a osition outside the en ine room.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Combination valve: + One valve can have the function of two valves. + Non Return Stop valve (NR Stop valve),has the function of a NR valve - Self closing valve: + A valve that requires that a handle is operated manually to be open. + When operator is not present, the valve is always closed. + Spring operated.
- Sounding valve: + A type of self closing valve developed for use on manual sounding pipes. + Normally delivered with a pedal so that the valve can be opened with the foot. + A counterweight is closing the valve. - Solenoid valve: + A magnet operated valve. An electrical signal is activating a magnet that is opening or closing the solenoid valve. + Used f. ex. on all valve actuators.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Valves - Bilge chest: + A bilge chest is a valve central for several bilge points. Some bilge wells can be almost inaccessible. + Be aware of that the dimensioning of a bilge chest is according to the smaller cell inlets and not according to the greater main bilge line.
• Safety components: - Pressure alarm and Temperature alarm + This is constantly feeling the pressure or temperature in a piping system and giving an alarm signal when preset limit (high or low) is exceeded. Alarm signal is normally to ship's alarm and monitoring system - An overflow pot can be mounted to an overflow system (on FO and LO system). When one of the tanks connected to this system goes in overflow, fl uid will go through the overflow piping and overflow pot, and create an alarm signal. - High level alarm is mounted on most of the tanks. • Components for measuring and controlling: - Temperature sensors + Thermometer • Thermometer is a device for local indication of the temperature. • Normally mounted before and after a cooler or heat exchanger. + Digital temp. sensor • Sensor that gives an electric signal when reaching a set limit. Signal can be used for alarm, for autostart of other equipment or other. + Analog temp. sensor • Sensor for accurate temp. reading. Normally 4-20 mA signal for remote reading/controlling.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • Components for measuring and controlling: - Pressure sensors: + Manometer: • Manometer is a device for local reading of the pressure. • It is recommended to mount a small ball valve before the manometer to make mounting/demounting easier. • Normally mounted before and after a pump. + Presostat = Pressure switch = Digital pressure sensor: • Sensor that gives an electric signal when reaching a set limit. Signal can be used for alarm, for autostart of other equipment or other. + Analog pressure sensor • Sensor for accurate pressure reading. Normally 4-20 mA signal for remote reading/controlling. • Working pressure range. EX: WP of system = 5 bar => Range of gaugse = 0 bar ÷ 6 bar • Actuator: - An actuator is mounted on a valve for remote operation of the valve. - All actuators are connected to the ships control and monitoring system so that the operator in Engine Control Room can see the position of all valves connected to the system and can open/close them remotely. - Pneumatic or Electric type
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.2 Pipeline components • See glass or control glass: - Control glass mounted on the pipeline so that a person can see visually if media is flowing through the pipe. - Be aware of that the glass is not mounted face down because this makes it very difficult to see if media is flowing through. Ok to mount horizontally as shown or with see-glass in vertical position. - Normally used on FO supply system.
• Couplings: - Very often a standard type of coupling is described to be mounted on the end of a pipe. - All cargo systems have specified couplings prepared on pipe ends in cargorail/outside which will fit directly to the hose coupling standard on platforms/rigs. - There is a large variety of different couplings.
Non spill coupling, MannTek
Quick coupling, Hammer Lug Union
• Sockets / muffs: - Equipment mounted to the pipeline such as pressure sensors, temperature sensors, etc. need a socket/muff (f. ex. ½" with internal threads) on the main line to be mounted to. - It is important that the sockets are included in the ISO drawings from the beginning so that it is ready for the outfitter onboard to mount the sensor. If not it will be welding on the pipe after mounting onboard. Specially on galvanized pipes this shall
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system • The following introduction and key points for each system is not complete and should only be used for reference. When designing a system the ships building specification and rules and regulations are important guidelines to f ollow. • There are different variations of the system diagrams (P&ID). The following introduction is based on the first 6 newbuildings at VARD Vietnam, with some extra systems and info. • For the builder it is always advisable to read the building specification for ea ch system before building. 2.2.3.1 Cargo system • Bulk Handling System – BHS System (SFI: 326) - The BHS system consists of BHS tanks, BHS compressors, coolers, air dryers and an ejector. - BHS is dry bulk like cement and barite. - Barite is used as weighting material and a barite plug is placed at the bottom of the wellbore which puts pressure on the drillbit. The alternative would be to apply more pressure from top which would require stronger, bigger and mo re expensive drilling equipment. - Cement is used to seal the drillhole or to plug a well so that it may be abandoned or similar. - The BHS compressor is pressurizing the BHS tanks and forcing the cargo to flow through the pipes. To empty the last part from the tanks the ejector is used. • Fresh Water Cargo System (SFI: 352) - The FW cargo system consists of FW cargo tanks and 2 pumps, arranged for transfer between tanks and discharge to deck. - The purpose of the system is to supply fresh water to oil rigs and platforms. Also FW to ships internal FW system is taken from these tanks. • Fuel Oil Cargo System (SFI: 351 ) - The FO cargo system consists of FO cargo tanks, pump and backup pump. Backup pump can be combined with base oil pump. System also includes a FO flowmeter to control how much fuel is received and delivered. - The purpose of the system is to supply fuel oil to oil rigs and platforms. Also FO for own consumpon is taken from these tanks.
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PIPING INSTRUCTION
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2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.1 Cargo system • Base Oil System: (SFI: 359 ) - The BO cargo system consists of BO cargo tanks, pump and backup pump. Backup pump can be combined with FO cargo pump. - The purpose of the system is to supply base oil to oil rigs and platforms. - Base oil is used as a component in oil-based drilling fluid consisting of an emulsion of water and base oil. This is resulting in less environmental impact. - Mineral base oil is a result of a long and complex distillation and refining process. • Ballast/Drillwater System: (SFI: 801) - The main components of the ballast/drillwater system are pump, backup pump and BW/DW tanks. - The purpose of the ballast water system is to trim the boat when cargo is loaded/offloaded. - Ballast water is normally seawater. - Drillwater is used as lubrication water for the drilling process and is transported from land facilities to offshore sites in the BW/DW tanks. No problem that SW and DW is mixed. - New rules are in the process of being implemented that requires a BW treatment unit to be installed in the ship. Purpose of this is to hinder that microbes and small living organisms are moved from their normal habitat to other places in the world where they may disturb the normal microbiology, by means of BW water exchange. BW treatment unit is killing nearly 100% of living organisms in the BW water, f. ex. by means of UV radiation. • Brine System: (SFI: 358 ) - The main components of the brine system are brine tanks, pump and backup pump. - The purpose of the brine system is to supply brine to oil rigs and platforms. - Brine is saline water containing more dissolved inorganic salt than typical seawater. - Brine is used as a well control fluid in completion and workover phases of well operations. It is used because it has higher density than fresh water and it has no solid particles that might damage producible formations. - Brine is very corrosive and it must be avoided to spill brine in the ship.
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PIPING INSTRUCTION
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2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.1 Cargo system • Liquid Mud System: (SFI: 357 ) - Main components are pump and backup pump together with liquid mud tanks and mud agitators. - Liquid mud is a water/mud solution used for lubricating the drill bit, stabilize and cooling the well bore, carry the cuttings to the surface and to control subsurface pressures. • ORO System: (SFI: 489 ) - Oil Recovery Operation (ORO) is the class nomination for a vessel that is outfitted to collect oil spill from the surface of the sea. This is in case of an oil pollution incident. - If boat is assigned to go in ORO operation it will be outfitted with oil skimmer and transrec and prepared by the crew within 48 hours to be ready. + Oil skimmer is equipment for pumping oil from the sea surface. + Transrec is handling equipment for hose and skimmer. - The regulations for this system are quite comprehensive such as: + Extended gas zones and stricter regulations for ventilating of tanks and rooms. + All areas where equipment for pumping oil are located and deck above tanks, are defined as EX area – Explosion hazardous area. All electrical components and sensors in this area must be EX proof. + Heating of ORO tanks with steam which makes it necessary to install a steam generator/steam system. + Reg. for crane, MOB, radar, tanks, blindflange valves, steam outlet, etc. • Methanol System: (SFI: 355 ) - Methanol System consists of 1 pump for each methanol tank, methanol tanks, cofferdam around methanol tanks and inert gas system for safety/purging. - Pipes and tanks are to be produced in acidproof steel, AISI316. - Methanol is extremely flammable and is defined as LFL – Low Flashpoint Liquid by DNV. - LFL is a class notation by DNV. LFL has flashpoint 60°C and LFL* has flashpoint 43°C. - Pumps are normally hydraulically operated and seal and lubricating tanks for the pumps will be needed on main deck. - Special P/V valves (pressure/vacuum valves) are needed for ventilation. • Tank Washing System: (SFI: 382 ) - System consists of pump, tankwashing machines for each tank, duplex filter, small tank for soap/chemicals, chemical dosing pump and hot water tank. - Purpose is to clean typ. mud and brine tanks. Page 22
PIPING INSTRUCTION
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2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • AHT Winch Servo System: ( SFI: 437 ) - Anchor Handling / Towing Winch Servo System. - High pressure servo system (up to above 300 bar) for having control with AHT Winches. - Including lever controls for winches, brake controls, tension controls and couplings. • LP Hydraulic System for AHT Winches: (SFI: 438 ) - Low Pressure Hydraulic System for AHT Winches. - Low pressure (up to about 60 bar) hydraulic system for operating the AHT winches. - Including AHT winches, windlass/mooring winches, tugger winches, hydr. oil storage tanks, hydr. oil expansion tanks and pumps. • Sanitary Water Supply & Hydrophore System: ( SFI: 581 ) - Fresh water supply system used for sanitary purposes and other. • Hot Water Boiler System: ( SFI: 648 ) - Provides hot water for the ship. For sanitary purposes, for AC units (heating), for high pressure washer, etc. - Including hot water boiler, circulation pump and expansion tank. - Most often the main heating source for hot water boiler is fuel oil burning. In addition there are electrical heating coils. - If there is a steam generator on the ship, then steam is normally used as heating source for the hot water boiler. In addition there are electrical heating coils. • Steam System: (SFI: 641 ) - For offshore supply ships with ORO system according to NOFO (national authorities) it is required to have steam heating of ORO tanks. This is to keep the collected oil hot and liquefied so it can be pumped out to land facility quite easily. - Steam system consists of steam generator, hotwell tank, boosterpumps, waterpump, steam collector, condensate cooler, etc. - When dividing the steam system in main parts the system consists of a steam art a condensate art and a feedwater art.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • Wheelhouse Windows Washing System: ( SFI: 581 ) - This is the water circuit for washing of wheelhouse windows. - Supply water normally from the hydrophore system. - Including water spray nozzles for windows. • Sanitary Water Discharge System (incl. sewage system): (SFI: 582 ) - This is the sanitary water discharge system incl. sewage system. - Including toilets, sinks and grease trap. - The sewage system is including sewage tank, sewage treatment plant and sewage transfer pump. • Fuel Oil Supply System (domestic system): ( SFI: 703 ) - This is the fuel oil system for engines and all fuel consumers on the ship. - Includes FO service tanks, FO settling tank, FO transfer pumps (main/backup), duplex filters, FO separators, separator feeder pumps and additional FO feeder pumps if necessary • Lub Oil Systems: ( SFI: 711 ) - Lubrication system for engines and separators - Lubrication system for gears and propulsion - Lubrication system for thrusters, winches and steering gear - Including lub oil tanks, LO separators, LO transfer pumps, gravity tanks, etc. • SW Cooling System: ( SFI: 721 ) - SW Cooling System is taking cold water from the sea to the main coolers and heated water back to overboard. Transporting heat away from the machinery systems. - Including sea chests, crossover tank, SW pumps, (SW/FW coolers,) main mudboxes/filters on inlet side and chemical dosing system. - Normally CuNi pipes (Copper/Nickel) because this is very resistant to seawater. - The cooler is an essential part of this system. The cooler can be mounted inside the vessel as plate type cooler or tube cooler. An interesting alternative is the box cooler where the cooling part is an open seachest. There will always be plenty of cold and fresh water and no SW cooling pipe system is necessary.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • FW Cooling System: (SFI: 722 ) - FW cooling systems are transporting cold water around to all machinery parts that need to be cooled and hot water back to the main SW/FW coolers. - Including main SW/FW coolers, smaller coolers, pumps, FW expansion tanks and 3-way valves. • Compressed Air System (Starting air and Instrument air): ( SFI: 731 ) - Compressed air system is generating compressed air and distributing air at 30 bar or less to consumers. - Main consumers for starting air (30 bar) are starting air for m ain engines, typhoons, quick closing valves and purge system for wheelhouse windows washing system. - Main consumers for instrument air (7 bar) are instrument air for main engines, separators for FO/LO/bilge, pneumatic actuators (for valves), expansion tanks and tank sounding system. - Instrument air must be dried in air dryers otherwise fine consumers can be damaged from moisture. - Main components are starting air compressors, starting air receivers (bottles), air dryers, instrument air receiver and pressure reduction station. • Working Air System: ( SFI: 732 ) - Working Air System is generating air and distributing air at 7 bar to consumers. - Main consumers are many working air outlets, air ejectors for pumps, blowing air in sea chest, incinerator and possibly others. - Main components are working air compressor and working air receiver, • Exhaust Pipe System: ( SFI: 740 ) - Exhaust Pipe System is the exhaust pipeline from the engines to top of funnel with components. - Main components are silencers. Pipeline is including flexible rubber compensators for minimizing vibration and noise. Spark arrestor is mounted if recommended by subsupplier. • HVAC System: ( SFI: 570 ) - Heating, Ventilating and Air Conditioning System - HVAC System is a description of the entire HVAC system for all roo ms in the vessel. Also it shows the specific gas zones. - Including AC units, coolers, fans, louvers and goose necks. Page 25
PIPING INSTRUCTION
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2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • UREA System: ( SFI: 746 ) - UREA system is a system for cleaning the exhaust gases, to reduce the NOx emissions, in a Selective Catalytic Reaction, SCR. - Main components for UREA System is UREA tank, catalyzers, pump/filter unit, UREA injection unit, injection air distribution unit, control metering unit, gas washer, NO-analyzer and more. - UREA used on vessels is produced from ammoniac and carbon dioxide. Natural UREA is an ingredient of urine. • Bilge System incl. Oily Bilge and Sludge system: ( SFI: 803 ) - The main components of the bilge system consists of main pump and backup pump, bilge wells, mud boxes and oily water/bilge water separator - This system is pumping bilge water overboard from bilge wells around the ship. - The system is automatic with float switches in each bilge well. - Oily water and sludge water is being filtered and separated in the bilge water separator. "Clean" water is going overboard, the rest is either burned in an incinerator or being delivered to land as special disposal. - System is often connected to Fire System. • Fire System: ( SFI: 813 ) - Fire system consists of main fire pump, backup pump and emergency fire pump, valves and fire hydrants. Fire water is taken from seachest forward and seachest aft. - Fire pump no. 2 (backup) is often used as backup pump also for bilge system. - Included in the complete fire system is also: (see below) + Overall fire extinction system for engine room + Local Application Fire Fighting - LAFF + If required foam fire extinction system for main deck if boat is carrying LFL. + FiFi system, if specified by the ship owner. • Fire Extinguishing System - Total flooding based on CO2 ( SFI: 815 ) - It is a requirement from authorities to have a fixed fire extinguishing system for engine room and some other crucial areas like switchboard room and casing. - CO2 system is a fire extinguishing system based on decreasing the level of oxygen gas (O2) in the burning area to a level where the fire is suppressed and extinguished. This is done by spraying CO2 into the area until it reaches minimum 30% of the net volume. - When O2 content is reduced to this level, there is not enough O2 for human beings to survive. - Main components are CO2 cylinders, CO2 nozzles and release panel. - System can not be released before ensuring that area is evacuated. Page 26
PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • Fire Extinguishing System - Local Application Fire Fighting system based on watermist: ( SFI: 815 ) - It is a requirement from authorities to have Local Application Fire Fighting (L AFF) system on main components like main engines, generator, FO & LO separators, incinerator, boiler and steam generator. - Watermist system is a fire extinguishing system that is reducing the heat on the fire and burning objects until the fire is extinguished. - Watermist system can be high pressure type or low pressure type. - System consists of FW and/or SW supply, pump, watermist nozzles and control system. - System can be released as soon as fire is discovered. • FiFi system: ( SFI: 814 ) - FiFi system consists of 2 big fire pumps and water monitors (canons) normally on top of wheelhouse and control system. The pumps require very high effect and it is normal to have extra PTO (Power Take Out) on the main engines for this purpose. - Water spray system for self protection of ship, deluge system. - FiFi is a DNV class notation. + FiFi 1 requires 2 x 1500 m3/h pumps (or equivalent) + FiFi 2 requires 2 x 2400 m3/h pumps (or equivalent) + Throwing length 120 m and 150 m from ship front • Drain Pipe System: ( SFI: 804 ) - Drain pipe system is a description of the drain system in the ship. One part for external drains and one part for internal drains. • Vent Pipe System: ( SFI: 821 ) - Each tank has tank vent valve ventilated to open air. - There are different heights of vent valves (type Aero) from deck based on the rules. - FO tanks often have their own ventilation system, see below. • FO Overflow System: ( SFI: 821 ) - There are restrictions on venting of FO tanks and it is quite common to create a FO overflow system. Leads to less ventilation valves on main deck. - The fuel tanks connected to the system have a common ring pipe, normally 2 drain/storage tanks for fuel oil and normal ventilation of these t anks. FO overflow pots are giving alarm if any of the tanks goe s in overflow.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.3 Introduction to main system diagrams - System by system 2.2.3.2 Machinery Systems & Other Systems • Tank Sounding System: (SFI: 821 ) - A system describing type of tank sounding outfitting on each tank. - Different types of tank sounding equipment are for manual sounding, local reading and remote reading. • Dispersant System: ( SFI: 489 ) - The purpose of this system is to clean up oil spill at sea. - The operation is by spraying a dispersant on oil spill in order to dissipate oil slicks. There is a chemical process and oil is broken up into smaller parts and finally diluted with water. - The system consists of dispersant tank, spraying booms, dispersant pump, dispersant transfer pump (to platforms) and flowmeter. 2.2.4 S ecial e ui ment and Ex ressions • EX: Explosion hazardous area • ORO: Oil Recovery Operation • LFL: Low Flammable Liquid - See further description under ORO System, Methanol System and Steam System. • Mud agitator: - Mud agitator is agitating, stirring the mud so it is in constant movement inside the tanks. If not the mud can become stiff and hard inside the tank and there will be problems when pumping out. - Mud agitator is mounted inside each mud tank and can be hydraulically or electrically driven. • Hydraulic Powerpack: - Hydraulic Powerpack, often called HPU, is a pump central producing the necessary hydraulic power to operate hydraulic driven pumps, cranes and other equipment. • Incinerator: - Burning of waste oil, sludge and garbage is carried out using the incinerator. Incinerator can be powered by fuel oil or electrical type. • Sampling: - Expression for taking a sample from any tank or media. To prepare for sampling normally includes to prepare a 1" socket with a ball valve.
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PIPING INSTRUCTION
* SHIPBUILDING
2. PIPING THEORY and INTRODUCTION TO P&IDs 2.2 System Diagram Introduction – P&ID 2.2.4 Special equipment and Expressions • Purging: - Purging is an expression used f. ex. for methanol system. Methanol is extremely fire hazardous. After methanol has been pumped through the pipes it is necessary to empty the pipes for methanol damp. Then an inert gas is used, normally nitrogen, to blow the pipes clean. When pipes are filled with nitrogen gas it is safe. • E0 list: - E0 is a DNV class notation meaning unattended machinery space. - E0 list is a listing of all alarms, surveillances, requirements, etc. necessary to have to be able to operate the ship with unattended machinery space. • Torsional vibration calculations: - When having a classical propulsion arrangement with engine, propeller shaft, sterntube, propeller and perhaps intermediate shaft and gearbox, a complex calculation is necessary to hinder that any part in the system is coming into its own natural frequency vibration. If this is not done it is a high possibility that a part in the propulsion system will vibrate to a level that is not acceptable. Vibration, noise, excessive wear and breakdown of parts will be the result. - The calculation can be done by engine supplier or supplier of the elastic coupling (between engine and gearbox). - The calculation has to be checked and approved by DNV. • Pressure drop calculations: - When a liquid is pumped through a pipeline, there is resistance to the flow from the friction inside the pipe, from each bend and if the liquid is lifted to a higher elevation. The longer and thinner the pipe is, the more pressure drop. - A pressure drop calculation is a calculation of how much pressure is lost through the pipe. From tanktop level up to cargo station on main deck, the pressure can easily drop 2-3 bar. • See also DNV Rules Part. 5 Ch. 3 Sec. 1 B100 for useful definitions.
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.1 Planing • Check the drawings and plan where you want to erect the pipes • PT pipes do not have ISO drawings, all routing must be planned by yourself • Planning of routing for many or all systems is recommended • Check what is recommended for this system (size, material, routing, pressure) EXAMPLE: FW cooling System -all pipes in steel -pipes to be cleaned by blowing with air -all valves to have easy access -de-airing to have a upward gradient to the expansion tank and no air pocket -Work pressure = 6bar -test medium = air or water
• Check also how many pipes you will run in this area and take it into the planning DO NOT
GOOD
Pipes blocking ventilation
pipe routing acceptable
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.1 Planing • Check that you are not blocking main entrance, valve handles or further DO NOT
GOOD
Pipes blocking handle
Pipe are routed away from the handle
DO NOT
GOOD
Pipes blocking ventilation
pipe routing acceptable
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.2 Measuring of the pipes • Pipes have to be routed straight and close together other pipes NOT GOOD
OK
The pipe left from the pillar is not together with the other pipes
Here are all pipes in a block
• Take a good measuring • Use a minimum of fittings • Do not lay coupling side by side DO NOT
GOOD
Coupling are side by side and can not be reached with a key
Couplings can be easily reached with tools
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.2 Measuring of the pipes • The supports are to be planned in the same time • It is always easier to bend a pipe instead of building long and difficult supports PT Standard for supports Pt8-12 between 600 - 800mm Pt15-18 between 1000-1200mm Pt20-25 between 1200-1400mm Pt28-42 between 1500-1700mm • Use this standard for setting of supports • Also should every bend have a support • Check the pipe on vibrating if the pipe vibrates too much, install an extra support
3.1.3 Make an ISO drawing of your pipe ( hand sketch )
3.1.4 Bending with the bending machine
- make a small iso with a wire
Note! this pipe can only be bended with the start from one side!! Try to find out.
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PIPING INSTRUCTION 3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.4 Bending with the bending machine • Control the pipe of cuts and dents • Calculate the length of the pipe - 439+1355+500+1200+ ~500 = 3994mm - You need a pipe over 4 m. • Try to use rest pipes • The pipe have to be burr free, inside and outside • Use the burr removing machine not the grinding machine
• Change the parts from the machine to the size of your pipe • Take the pipe inside and measure the first length
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* SHIPBUILDING
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.4 Bending with the bending machine • Set on the bending radius on the digital pad (90) +the extra radius (2.3) (list from the
• Measure the second bend and take the pipe on level
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.4 Bending with the bending machine 3.1.4.1 Installin of the sealin ! Before you go to this step, the ends of the pipes must be clean and • There are two different types of connections at STX Vietnam Offshore: 1. Cutting ring The ring is pressed on the pipe with big pressure and must be pressed on with the Bending machine
et on pressure o cutt ng r ng press
n s e p pe
2. Walform A machine form a ring on the pipe with very high pressure must be pressed on with the Walform machine.
Pipe is ready for be pressed
Finished pipe
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.5 Cleaning of the pipe. • Every pipe must be cleaned by air and oily pipes additional by a sponge (see 000-
blow air in 10s and do not forget to wear safety glasses
• Tighten so much fitting you can in the workshop and mark them with a cross
•
n ng every p pe w a ape a er cleaning and remove it only on board before you connect the
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.1 Fabrication of PT-pipes 3.1.6 Installation of supports. • Support always together if possible • Small pipes can be supported on big pipes (not reverse) DO NOT
GOOD
Too many double supports and pipes are not in a straight block
The pipes have a clean design
3.1.6 Workin on board. • Never leave a pipe open !!! • Tightening always every fitting/support immediately after installation • Mark the tightened fitting with a cross • Stainless steel and copper pipes have to be covered with fire blanket after and during installation and welding • Check your work one more time • Clean always your working space after you are finished and keep it clean!!
Before
After Page
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.1 Planning • Check the drawings and plan the erecting of the pipes • Check what is recommended for this system (size, material, routing, pressure) EXAMPLE: a) Planning: - check the drawings and plan the erecting of the pipes - Check what is recommended for this system (size, material, routing, pressure)
EXAMPLE: Fire System (example from 003-813-001)
PIPES SPECIFICATION. PIPING SYSTEM CLASS: ||| PIPE PRESSURE CLASS: PN16. DESIGN WORKING PRESSURE: 7 BAR TEST PRESSURE: 10, 5 BAR. PIPE TYPE ACC. PIPE DIM.: ND < 40: DIN 2391 PRECISION STEEL TUBES. St. 37.4 (On weather deck to be of stainless steel). ND =<150:`` DIN 2501 SEAMLESS STEEL PIPES St. 37.0/St. 35.8.1 (w/3.1 B. cert,) ND =>200: DIN 2501 SEAMLESS STEEL PIPES St. 37.0/St. 35.8.1 (w/3.1 B. cert,) DNV product certificate for all overboard valves and valves on collision bulkhead according to DNV Pt.4 Ch.6 Sec 2 and Pt.4 Ch.6 Sec. 6 C300. FLANGES/THREADS SPECIFICATION. FLANGE CONNECTIONS TO BE USED FOR PIPE DIMENSION DN >= 40 AND UPWARDS, FITTINGS WITH THREADS, PRESS OR CUT RING TO BE USED FOR PIPES LESS THAN ND < 40.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.1 Planning • Check the drawings and plan the erecting of the pipes • Check what is recommended for this system (size, material, routing, pressure) EXAMPLE: NOTES. 1. RECIRCULATION LINE TO BE POSITIONED AS CLOSE AS POSSIBLE TO THE TOP OF THE TANK AND TO END AGAINST THE BULKHEAD. 2. FILLING/DISCHARGE STATIONS TO BE EQUIPPED WITH 5" COUPLINGS, WECO / BEST. 3. HORIZONTAL PUMP SUCTION LINE. 4. THE GALVANIZING OF THE PIPING ARE TO BE EXECUTED AFTER ALL FABRICATION (WORKING UP AND WELDING) ARE FINISHED. 5.TANKS ABOVE SHELL TO BE FITTED WITH SUCTION BILGE WELLS (see "SUCTION IN WELLS" detail). SUCTION PIPE IN SHELL TANKS TO BE ENDED WITH SUCTION BELLMOUTH. 6. ALL VALVES, COCKS AND CONNECTIONS SHALL BE READILY ACCESSIBLE FOR MAINTENANCE AND OPERATION. PIPES RUNS SHALL BE DESIGNED FOR EASY REMOVAL. 7. CARGO PIPELINES ABOVE MAIN DECK TO BE ARRANGED IN A WAY TO ACHIEVE AS GOOD DRAINAGE AS PRACTICABLE BACK TO TANK. THE HOSE CONNECTION END SHALL NOT HAVE ITS FACING DOWNWARDS. 8. PIPELINES GENERALLY TO HAVE SUFFICIENT DRAIN PLUGS. 9. PUMPS TO HAVE LIQUID FILLED PRESSURE GAUGES ON SUCTION AND DISCHARGE. 10. THE CARGO SYSTEMS TO BE REMOTE OPERATED AND CONTROLLED FROM BRIDGE AND CONTROL ROOM.
In case you have a DN 50 pipe to build: -pipe is 60.3mm x 4.5mm -pressure rating is PN 16 -the pipe must be send to galvanizing -when the pipe have a water trap on weather deck, a drain socket have to be installed -all valves should have easy access
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.2 Building of ISO pipes How to calculate the correct cutting length of pipe from spool length on the ISO • You will find all information in the drawing Example: Pipe Nr. 3001_8131_125004 In the right upper corner are the part and quantity In the lower right corner are information about vessel no., coating, galvanizing and the pipe no.
Spool No.1 The Spool is 3135mm long from middle of the gasket to middle of the gasket 3135mm – 3mm = 3132mm pipe = 3125 – 3mm = 3122mm So, you have to cut a pipe of 3122mm
Spool No. 3 The first length is 400mm from the middle of gasket to middle of elbow Elbow = 18* the pipe is 383mm – 1.5mm for the half gasket and 2mm for the welding gap = 379,5mm You have to cut a pipe of 380mm - Do not forget to subtract the welding gap and the gasket A normal gasket at STX Vietnam Offshore is 3mm!!! ………….(please calculate the rest by your own)
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.3 Pipe biulding on board Some times you have to reroute pipes because of pipe touching or to erect the last spool before equipment (pump). • Measure the pipe on board • Take a good measuring • Use a minimum of elbows • Do not block valve handles • Be aware for pipe touching
3.2.4 Make an ISO drawing of your pipe 3.2.5 Calculation • The first pipe is 100mm from end of the flange on board to the 90* elbow 100mm – 5mm (flange) – 3mm (gasket) – 76mm (elbow), Check relevant table to find the building length of an elbow DN 50 = 76mm – 2mm (welding) = 14mm 60.3mm pipe
• The second length is 1000mm from the middle of flange to middle of the elbow You calculate the elbow radius for a 60mm (see appendix 4.4 "bending pipe chart" ) = 36* The building length you must measure by your self 1000mm -106mm (building length of elbow +36* elbow -2mm (welding gap) -2mm (welding gap) -76mm (elbow)
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= 81mm
= 814mm
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.5 Calculation • The third length is 600mm from middle of the bend, to end of the offset The offset can be calculated (see appendix 4.5 "Bends offset chart" ). = 48* so you need 2 elbows of 48* The building length must be measured and is = 113mm 600mm - 113mm - 2mm (welding gap) - 2mm (welding gap) - 76mm (elbow) = 407mm • The last length is 500mm 500mm - 2mm(welding gap) - 5mm(flange) - 3mm (gasket)
=490mm
To build this pipe we will need:
2 flanges DN 50 PN 16 1 2 2 1 1 1 1
elbow 36* elbow 48* elbow 90* pipe = 14mm pipe =814mm pipe =407mm pipe =490mm
60.3mmx4,5mm 60.3mmx4,5mm 60.3mmx4,5mm 60.3mmx4,5mm
Note: By building a pipe to connect equipment, the flanges must be point welded on board.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.6 Building of pipes • Build all pipes in the workshop • All hot work should be done in the workshop • Work clean and safety All fitting must be cut before you start to built the pipe
3.2.7 Preparing
A parts must e cut exact y
E ows ave to e cut wit t e e ow
3.2.8 Start the work Prepare a clean working condition
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PIPING INSTRUCTION 3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.8 Start the working Grind the pipe and elbows, also the first 25mm By the side of the welding it must be oil and rust free
* SHIPBUILDING
Start to weld the offset together
• Always use a wire for the welding gap. • Use always a water level and check often. • The pipe must always be tag welded with minimum 3 points.
the other Offset
now the two pipes on the second offset
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.8 Start of working • Be always as precise as you can
The 90* elbow
The first offset with pipe 1 and 2
• Keep your working place clean • Check our tools every time before you start the work • When grinding and welding be sure not to harm other workers
3.2.9 Tag welding of flanges
The finished pipe
Take the pipe in level, then use a water level to get the flange holes
Note!!:
Check always all sides with a water level and flange angle tool.
To build a pipe that is connecting to equipment,
• After measuring, control and cleaning of the pipe, the pipe can be sent to welding and galvanizing (painting)
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.2 Fabrication of steel pipes 3.2.10 Working on board
NOTE!! NEVER LEAVE A PIPE OPEN!!!! • Tightening always every bolt/support immediately after installation • Mark the tightened bolts with a cross • Check your work one more time • Clean always your working place after you are finished and, keep it clean!! • Take only the material on board which you will install on the same day! • Take care of other workers
After
Before
3.2.11 Site run of last spool before equipment • The last spool of pipe before equipment shall not be produced according to ISO drawing in the workshop, but be made on site after that the equipment is mounted. There are always building tolerances on board the ship and if pipes are prefabricated according to ISO drawing (with theoretical dimensions) this will not fit precisely to the flange on the pump etc. • If pipes are prefabricated and forced in place, high stress will be present in the system, with high risk for breakage some place and problems with
Page 47
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.3 Some common routing problems to be aware of (for all pipe fitters) Although the steel pipes are built according to ISO drawings and the routing is by that decided, the piping erector should always bear in mind some important areas: • There shall be sufficient space around the pipe: - Below the pipe there shall perhaps be a drip tray. Is there space for this? - Remember to keep sufficient distance to points where the pipe shall be clamped. - Shall the pipe be insulated? This requires extra space around the pipe. - In general the pipes routed along a bulkhead/deck have flanges and the distance between the flange and the bulkhead should be 1-2 cm. Enough space so that it is possible to paint underneath. • To keep in mind and allow space for operation of valve handles. This is important for the pipe being built and also for pipes located below or behind. Some types of valve handles have a movement. • To keep in mind and allow space for mounting of valve actuators. Be conscious to find the best rotation position for the valve. • There shall be adequate access to flanges located behind or below the pipe being built. It must be possible to connect and disconnect all flanges on board after all the pipes are built. • The pipe shall not block the way through manholes, hatches or ladders. • The pipe shall not block the opening of cabinet doors (electro or other). • Care should be taken if pipes are routed in service spaces for components. It can be accepted in some cases provided that essential areas are not blocked. • If a pipe is obviously routed in passage way or escape way, this should be fixed or reported to a person in charge. • Any other point that an experienced pipe fitter can think of will be a problem, should be taken care of or reported to a person in charge. • It is always better to rectify such bad piping practices in an early stage than to build the pipe and wait for that somebody else is taking responsibility.
3.4 Pipe erection by block 3.4.1 Pre-outfitting • The vessels are constructed as blocks/units in Hull Factory. Pre-outfitting for piping is to install pipes and the system components belonging to the block at the block fabrication stage. • The benefit of Pre-outfitting is that we can save many man-hours in comparison with erecting pipes in a closed area when the blocks have been connected together. • The blocks are numbered from B1 to B7 in example drawing below. Page 48
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.1 Pre-outfitting • 3D zone concept is 3D area on the vessel where all piping of designed systems go through. • In order to erect pipes with pre-outfitting, the below steps are being followed to define which spools are erected on what block: - Define the limit of the block by Frame to Frame with Block/Unit Arrangement Drawings. - Define the block containing which 3D zones with Arrangement Drawings. - Use Piping arrangement drawings of defined 3D zones to know which pipes located in that 3D zones. - Take the Isometric drawings of defined spools for construction.
Block/Unit Arrangement Drawing
Piping Arrangement Drawing Page 49
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.1 Pre-outfitting
Block under pre-outfitting stage 3.4.2 Pipe erection by module • Piping Module is a group of pipes and components which can be fitted together in the workshop and the whole piping group (assembled together), is lifted onboard the vessel and fitted. This is more effective than erecting one by one spool on the
Module of piping in Upper cement room Page 50
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.2 Pipe erection by module • The benefit of piping erection by module is saving many man-hours and lifting equipment. We also can save time for scaffolding building and manual piping transportation means as using chain block. • In order to erect piping by module, the below steps are followed: - Study Piping arrangement drawing of each 3D zone to know how the pipe spools are arranged at completion of that zone/area. - Study Room layout drawing to know how the equipments are arranged in that zone/area. - Define which piping spools and components can be built as module. - Define which spools and components belonging to that module as per spool number. - Collect spools and components to erect the module on the ground. Some supports can be attached to the module at this stage. - When the area is ready with hull condition, we board the piping module on vessel at the correct co-ordinate location. - Install sufficiently pipe supports and complete tightening. - Have focus on proper alignment of the pipes, flanges should be parallel to each other before tightening with bolts, minimum stress between the flanges is
002 – 352 – 253 Piping arrangement in Upper Cement Room Page 51
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing • Before erecting spools, make sure that you follow the below steps: - Prepare all ISO drawings of the 3D zone or area of the system you are going to erect. - Put all those ISOs together, connect them together following drawing, then you know the complete line you are going to erect. - Make a list for all components on that line (valves, pressure indicator, thermometer …) following the ISO drawings. - Study the P&ID drawing to define where that line is located in P&ID. - Compare your component list with P&ID to make sure there is not any component missing in your list. For pressure indicator and thermometer, you don’t need to install them at the beginning, but the sockets for them have to be on the spools. - Prepare all spools following these ISOs. - Prepare all valves and other components (if any) according to the component list. To remind, all sockets for pressure indicators and thermometer have to be on spools. If you find any sockets missing, please make it just after mounting the spool on vessel. - All the sockets and other open ends always to be blinded during and after being
• Example of ISO preparation: 2002 – 3524 – 401002 (Base Oil system): - At the end of the spool in this drawing, you see the connection to ISO 2002 – 3524 – 404002 - Take ISO 2002 – 3524 – 404002 you see the connection back to 2002 – 3524 – 401002 and another connecting point to 2002 – 3524 – 404003 - On the ISO 2002 – 3524 – 404002 at below sketch, you see that we have 02 valves numbered 352.4041 and 352.4042. We have to prepare these two valves before erecting the spools.
2002 – 3524 – 401002 Page 52
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• Example of ISO preparation: 2002 – 3524 – 401002 (Base Oil system): - At the other end of ISO 2002 – 3524 – 404002, we see one socket ½” and a connecting point to the components numbered 351.009.10. - This socket has to be on the spool before erecting and plugged properly. If not, you make it, either making a socket or plugging it. - By learning P&ID drawing of Base Oil system, we will know that 351.009.10 is the Pump. FW (eld weld)
2002 – 3524 – 404002
will be only welded when the spool is properly aligned and connected to the pump.
2002 – 3524 – 404002
Base Oil system
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• During erecting piping spools and components: - Make sure that you erect the spool exactly with the co-ordinate location and direction showing on ISO. Ex: Fr45 – 130, CL –> PS 1254, Base + 1880 is the coordinate location on 2002 – 3524 – 404002. - Make sure that there is not any spools and pipes collision.
Not like this
After repair - a small gap => OK
• For flange connection, make sure that all gaskets have to be greased to prevent leaking before tightening flanges together. - Make sure that all the bolts of each flange connection are fitted sufficiently and properly tightened before you leave this spool to other ones.
Not like this
Like this
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• For valves mounting, the below notes have to be followed: - Make sure that the valve handles can be operated properly. Any collisions are not acceptable. - Make sure that the valve handles are not sticking out to the walkway - All bolts have to be fitted sufficiently and properly tightened. - After finish mounting a valve, make sure that you try to open and close that valve one time. All valves have to be 100% opened/closed before you move to other locations.
Before repair - Not like this
After repair - OK
Before repair - Not like this
After repair - OK
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.4 Setting of support Supports "supporting" the pipes and taking vibration and stress from the pipe. All support must be welded complete You can find a list of minimum distances for steeel pipes in the appendix 4.4 Also every bend should have a support.
Be aware to not build support with a water pot/trap
like this the water can flow away
Always cut angels or grind them smooth:
The upper support is good/ the lower is not grinded
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The support is grinded smooth
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.4 Pipe erection by block 3.4.4 Setting of support
By welding on a bulkhead outside or tank a doubling must be used. Do not weld to the outside or under the floor use other solutions.
-Two holes (or more) in the angle bar by the use of the stamping machine
3.5 Cleaning, testing and coating of piping systems • Ref. diagram "PIPE SYSTEMS, TEST, CLEANING AND COATING", diagram no. 000104-004 (attached in appendix 4.2) for information and details about the following: 3.5.1 Pipe cleaning inside • It is important that the pipes are treated correctly in the cleaning and preparation process in order to prevent corrosion and dirt in the piping systems. 3.5.2 Pipe coating/preservation • It is very important that the pipes are protected in the best possible way in order to withstand corrosion and wear from weather and cargo/chemicals. • Always refer to the System Diagram for the specific system or to the drawing "Pipe Systems, Test and Inspections". Ship owner can have special requests that are varying from yard standard. • Fuel oil, base oil and lub. oil are reacting with the zinc in the galvanizing and these pipes are in general not to be galvanized. The parts of these pipes that are located outside exposed to seawater, are not well protected against corrosion. A proper solution is to galvanize only on the outside, the parts that are in wet area. An alternave is to metallize these pipes on the outside.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.5 Cleaning, testing and coating of piping systems 3.5.3 Pressure testing • Class (DNV or other) has requirements for pressure testing of each piping systems. This is to verify the quality of the materials, welding and work of the shipyard in order to ensure that there are no leakages in the piping systems. • Always refer to the System Diagram for the specific system or to the drawing "Pipe Systems, Test and Inspections". Test levels can differ from the levels given in this diagram, from project to project. • See drawing No: xxx - 104 - 001 / "Piping system, test & inspection". 3.5.4 NDT testing (Non Destructive Testing) • Class (DNV or other) has requirements for NDT / X-ray testing of a group of welds belonging to pipe classes I and II. This is to verify the quality of the welding work done by the shipyard in order to hinder leakages or fractures in the welds. 3.5.5 Flow coding • Colour flow code marking for the cargo pipes and main machinery pipes gives information about the flow direction and which system it is. This is for all pipes over DN 40. Makes it much easier for the crew to get the overview and have • The main rule is a distance of about 3 meters between the markings which have to be in the correct colour. The pipe must be cleaned before gluing the name tag to the pipe. After this the colour flow tape must
The tape must always have a overlap The arrow must be shown in the right direction (flow direction).
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.5 Cleaning, testing and coating of piping systems 3.5.5 Flow coding Flow code colours (possible with some variations in colours from one ship to the next, depending on the ship operator): Steam Bulk handling Bilge Purge Air Fresh Water Sea Water Fire Sanitary discharge Fuel Oil Liquid Mud Ballast drill water Oro Brine
= silver = black = green = blue = blue = green = red = black = Brown = brown = green = brown = green
3.6 Yard standard for piping components 3.6.1 Bulkhead and deck penetration • The 2 main penetration methods are by using a sleeve or using a bulkhead flange. • To use a sleeve penetration is less expensive and safer regarding leakage from the pipe.
Single side sleeve
Connecting sleeve
Penetration sleeve Page 59
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.1 Bulkhead and deck penetration • To use a bulkhead flange leaves the pipes demountable, which normally is an advantage. • Single bulkhead flange (set-on flange) is used when needed to have flange connection on one side of bkhd and not on the other side (f. ex. with demountable pipe connection to a tank)
• Double bulkhead flange is used when needed to have flange connection on both sides of a bkhd or deck, with demountable pipe connections on both sides.
• For higher pressure flanges above 40 bar ( f.ex. hydraulic pipes) MFAS flange (single or double bulkhead flange) with o-ring sealing is used. The o-ring (rubber gasket) is allowing for higher pressure.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.1 Bulkhead and deck penetration • Roxtec sealings are DNV accepted for ues in penetration through the deck and bulkheads that requires watertight or gastight penetration. Roxtec is also used on chilled water system for thermal insulation between pipe and bulkhead. Note: Roxtec parts are expensive, so avoid using water - or gastight penetration throught the beams/deck which is not require water or gastight 3.6.2 Overboard pipes • Special attention is necessary for overboard pipes. This is the pipe going from the (DNV) classified overboard valve to overboard. • It is very serious if this pipe is breaking because then seawater can enter uncontrolled into the vessel. • The overboard pipe is continuously exposed to a harsh corrosive environment because: - Seawater is a salt and corrosive fluid - The water in the overboard pipe can remain in the pipe for a long time and not being refreshed with new water, which makes it more acid and corrosive. - When sleeves are used it is a risk for that seawater is coming into very small gaps/spaces between pipe and sleeve and becoming more aggressive regarding corrosion. • Overboard pipes to have a thickness of min. 11 mm according to DNV. • After finished welding the overboard pipes, MPI (magnetic particle inspection) testing should be applied. • Overboard pipes to be galvanized unless otherwise is specified. • Su ortin brackets to be used between overboard i e and hull. 3.6.2.1 Overboard pipes and sleeves • Only penetration sleeves to be used, no connecting sleeves. To connect an overboard pipe inside a sleeve is not accepted by class. • Overboard pipe to be built completely, including sleeve, before sending to galvanizing. • Thickness of sleeves to be about 10mm. Page 61
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.3 Bended pipes and elbows • Elbow standard (commercial type) - Standard elbow with bending rad. = 1,5 x dia. is the standard method used for bending a pipe at STX Vietnam. - Are delivered in 22,5 / 45 / 90 / 180 degrees and other angles can be made out from these. • Elbow short radius: - Elbow short radius with rad. = 1 x dia. is available from supplier. - Can be used when necessary for making installation easier, etc.
• Elbow big radius: - Elbow big radius with rad. = 5 x dia. is available from supplier. - For BHS system it is a requirement from owner to use such big radius for making loading/offloading of BHS cargo smoother. • Bended pipe: - To use bended pipe method a special bending machine for pipes is necessary. - STX Vietnam has a bending machine for small pipes (precision steel tubes) but not for the bigger cargo pipes. 3.6.4 Branch line connection with "saddle" or "T-pipe" • Saddle connection - To make a branch line from a main pipeline with "saddle" connection is the normal method used in STX Vietnam. - The diameter of the branch line can be equal to or smaller than the main line.
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.4 Branch line connection with "saddle" or "T-pipe" • T-pipe connection - An alternative method of making a branch line is with a "T-pipe" connection. - The diameter of the branch line can be equal to or smaller than the main line. - This connection can be used when necessary for making installation easier, etc.
3.6.5 Reducers • Reducers are used when making a diameter change on a pipeline. Normally delivered in to 1, 2 or 3 steps below main diameter. • The 2 types used are concentric type and eccentric type, where concentric is the most normal. 3.6.6 Drains • Drain pipes shall not be routed horizontally, always with inclination (min. 2%). 3.6.6.1 External drains • The function of the external drain system is to lead away water (or oily water or equivalent) from outside decks and areas where otherwise will have some level of water when raining, in rough sea, etc. All drains are described on the external drain pipe system drawing. • Drain can be placed in 4 corners to ensure that all water from this area is drained away. Alternatively drains are placed in forward end, if the boat normally has forward trim, or the opposite. • There are drains from each deck to deck below, to overboard or connected to another drain line. Page 63
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.6 Drains 3.6.6.1 External drains • Where possible, external drains from one deck to be routed directly above the drain down to next level. • All drain pipes to be hot galvanized
3.6.6.1 External drains • It is also necessary to have an internal drain system because of water from condensation and washing/flushing. All internal drains are described on the internal drain pipe system. • If a drainpipe is going from one watertight area to another it is required to have a selfclosing valve on the outlet. Otherwise the 2 sections are not watertight and can be a possible risk in an emergency situation. • To make a gutter is quite normal in order to collect all condensation water from the inner side of bulkhead and to make a drain pipe system from the gutters to bilge tank or to overboard. See drawings beside:
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.7 Pipe supports / Clamps • There is a lot of vibration on board the ship and pipes need to be supported. If this job is not done properly it is a high risk of that fractures in the piping system will occur. Pipes that are vibrating are also creating excessive noise. • All pipes must be evaluated if they need to be clamped. Thick pipes over a short distance do not need extra support, but most pipes onboard have to be clamped. Below are shown the most common types of clamps to be used. - Flat bar pipe clamps (NS 5553):
- U-bolt clamps (NS 5550):
- Clamp support (NS 6007 A):
- Clamps with insulation (because of heat or coldness :
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.7 Pipe supports / Clamps • The piping designer should always do the routing so that clamping is possible. To route the pipe in the middle of a room is not good. The pipe fitter will sometimes have to build extra support for the pipe clamp. • The pipe should not be routed in close proximity to bulkhead or deck in order to allow adequate space for the pipe support. • When pipes are insulated, the pipe support should be in contact only with the insulation, if possible. Ref. illustration above. 3.6.8 Pipe joint methods • There are many ways how to joint a pipe to a flange or to another pipe. Some of the methods used in STX are shown below. 3.6.8.1 Pipe to flange with slip-on flange • A very common way is to weld a pipe to a slip-on flange. The pipe is welded 2 places to the flange. Distance from pipe end to flange end should be 10 mm as a standard (the same for all pipe thicknesses. See appendix 4.6 for length adjustments on cutting length for spool, valid for vessel 03 – 06 on STX Vietnam.
• For PN40 a variation of this slipon flange is used;
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.8 Pipe joint methods 3.6.8.2 Pipe to flange with welding neck flange • To butt-weld a pipe to a welding neck flange is similar to the connection above but this flange connection is stronger and more solid. The strength ratio is about 2/3 in favour of the welding neck flange. • Also recommended for dimensions less than DN40 instead of slip-on flanges.
3.6.8.3 Pipe to flange with welding collar in combination with a sli p-on flange • On SW cooling system there are CuNi pipes in combination with steel flanges, two different materials which can not be welded together. The way to solve this is to weld the CuNi pipe on to a prefabricated welding collar of CuNi. A loose flange of steel, a "slip-on" flange is combined with the collar. Then the pipe end with flange is ready to be connected to a pump flange or similar.
Welding collar
Slip-on flange
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PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.6 Yard standard for piping components 3.6.8 Pipe joint methods 3.6.8.4 Pipe to pipe joint with Straub Grip coupling • It is a method for quick and easy connection and disconnection. • Can be used for black steel and galvanized steel without damaging the galvanizing layer. • Is normally used on the BHS system. Can also be used on other systems.
3.7 Tank accessories 3.7.1 Tank sounding • For almost all structural tanks on board it is required by class to have 2 independent possibilities of checking the tank level. The exception is for a CD which is not intended to carry any media. • Tank sounding devices are divided in 3 main types: - Remote sounding + For most of the tanks on board it is required by class to have sounding sensorsgiving a continuous signal/information to the alarm and monitoring system for the ship. + There are different types of remote sounding of the level in a tank, The main types used for STX ships are: • The level sensor is a float with electric signal transmittal. • Hydrostatic level transmitter is measuring the gravitational pressure of the liquid in the tank using a capacitive ceramic sensor. Electric signal transmittal. Page 68
PIPING INSTRUCTION
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3. PIPING ON BOARD 3.7 Tank accessories 3.7.1 Tank sounding + There are different types of remote sounding of the level in a tank, The main types used for STX ships are: • A pneumatic type with pneumatic signal transmittal is measuring the gravitational pressure in the bottom of the tank. • An electric sensor with electric signal transmittal. o Example below is from a mud tank. 2 sensors are installed at 1000mm distance in between. This type is measuring variations in density of mud and can because of this give a more correct level indicating at any time.
- Local sounding: + This is based on a local system for reading of the level in the tank. The main types are: • Sight glasses mounted on outside bulkhead of the tank.
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PIPING INSTRUCTION 3. PIPING ON BOARD 3.7 Tank accessories 3.7.1 Tank sounding - Local sounding + This is based on a local system for reading of the level in the tank. The main types are: • Sounding clock mounted on outside bulkhead of the tank based on the gravitational pressure from the media.
- Manual sounding This is based on that a sounding pipe/dipstick or similar is dipped manually directly down in the tank and the reading is done when pulling the dipstick out. A cap has to be removed from the tank. The 2 types alternatives • Manual screwed cap. • Sounding cock/valve with pedal. This is a type of self
3.7.2 Level alarm • For many of the tanks on board the ship it is required to have level alarm. It can be alarm on high level, on low level or for both high and low level. • Type of level alarms are: - Float switch. A float is giving signal when liquid level is reaching the float. See different installation alternatives below.
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* SHIPBUILDING
PIPING INSTRUCTION
* SHIPBUILDING
3. PIPING ON BOARD 3.7 Tank accessories 3.7.2 Level alarm • Type of level alarms are: - Electric sensor that is sensing when liquid is coming into contact.
Lidec L20D Typ. mud tanks
Lidec L20-70 DW Typ. mud tanks Encl. by other tanks
- An alarm signal can be taken from the analog signal from the level indicator. But in many cases class is requirement an signal from an independent sensor/switch.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.7 Tank accessories 3.7.2 Level alarm • Below is a list of the normal requirements for level alarms for the most common tanks. The list below is added only for reference, do always check the system drawings or IO/E0 list for the specific project. SFI 326 352 352 352 352 352 352 352
System Bulk Handling tanks BW/DW tanks FW cargor tanks FO cargo tanks BO Cargo tanlks Brine tanks Liquid Mud Tanks
Alarm No requirement No requirement No requirement High High High High
Remarks Ref. supplier P&ID
When Clean notation When Clean notation
Alarm also on surrounding CD, if liquid is entering.
Methanol tanks
High
Hot water tanks for tankwash Sewage tank
No requirement High
FO settling tank
High and low
Conn. to overflow system
FO service tank
Low
Conn. to overflow system Also LCH and LCL
701 711
FO drain tank
High
803 803 803
Dirty oil tank Bilge tank Sludge tank
382 581 701 701
Conn. to overflow system
LO tank High High High
3.7.3 Heating coil • For some tanks it is needed to have heating. This is done by means of heating coils where hot water or hot steam is flowing in pipes inside the tank to be 3.7.4 Steam injection • For ORO tanks it can be a requirement to have steam injection directly into the tank for heating the collected oil. This is to keep the oil hot and liquefied so that it will be possible to pump the oil out from the tanks.
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PIPING INSTRUCTION
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3. PIPING ON BOARD 3.7 Tank accessories 3.7.5 Temperature sensor • For some tanks a temperature sensor is mounted. This is normally done first mounting a temp. pocket in the tank. Then the temp. sensor is mounted in this. Advantage with this solution is that it is possible to change sensor without emptying the tank.
3.7.6 Sampling point • For some tanks it shall be prepared a possibility to take a sample of the media from a position outside of the tank. • This can be done by mounting a 1" socket in the tank near the bottom and mounting a ball valve directly to this. • The bulkhead penetration can for some reason be higher up from tank bottom, then a small pipe on the inside of the tank (to near the bottom) should be mounted.
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4.TYPICAL DRAWING SYMBOL
Centrifugal pump W/EL. Pump
Screw pump W/EL. Pump
Gear pump W/EL. Pump
Propeller pump W/EL. Pump
Diaphragm Diaphragm pump air driven
Flow meter
Heat exchanger
Bucket
Box cooler
Ejector
2-cell, double valve chest, remote operation w/Pneumatic actuator
2-cell, NR. Bilge chest
Butterfly valve
Butterfly valve w/EL actuator
Butterfly valve w/Pneum. Actuator
Butterfly valve w/Hydr. Actuator
Globe valve
NR check valve
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Butterfly valve w/Pneum. Actuator&spring
NR Globe valve
Solenoid valve
PIPING INSTRUCTION
* SHIPBUILDING
4.TYPICAL DRAWING SYMBOL
Stor Storm m Fla Flap valv valve e
NR reli relief ef valv alve
Relie elieff valve lve
Spectacle blind Spectacle blind - Blind flange valve open (Blind flange) close (Blind flange) NC
Temp. reg. valve pilot operated
3-way thermostat valve, WAX type
3-way thermostat mixing valve
Relief valve angle type
Self closing valve
Blind flange valve NO
3-way motor operated valve
3-way valve
Ball valve
Ball valve Ball valve W/Hydr. Solenoi Solenoid d ball ball valve valve 3-way 3-way valve valve L-type L-type 3-way 3-way valve valve T-type T-type W/Pneu. Actuator Actuator
3-way solenoid valve (L-type)
Regu Regula lati ting ng valv valve e
Quic Quick k clos closing ing valv valve e
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Quick openning valve
Flow regulating valve
PIPING INSTRUCTION
* SHIPBUILDING
4.TYPICAL DRAWING SYMBOL
Pressure reduction valve
Self-regulating valve
Diaphragm valve
Fire valve (Hydrant)
Gate valve
Orifice
Orifice adjustable
Flexible coupling
Rubber compensator
Filter
Mud box
Sight glass
Liquid seperator
Steam trap
Hose coupling
Cargo hose coupling
Break away coupling
Amature number
Hand pump
Deaerator
Funnel
Suction piece ( Bell mounth )
Reducer
Blind cover
Agitator
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PIPING INSTRUCTION
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4.TYPICAL DRAWING SYMBOL
Low level Alarm tag ( Test by pin down)
Tank washing
Pressure indicator
Temp. Indicator
1/4" socket for DPIinstrumentation
Pipe up
Orifice adjustable
Flexible coupling
Insulation for pipe
Ball valve for instrument
Corrosion piece
Hose
Bilge well
Scupper
Flow direction arrow
Exhaust fan
Spark arrestor
Flue gas damper
Expansion joint
Air vent valve
Air vent valve W/flame screen
Air vent valve venting through ship side
Blind cover
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High level Alarm tag ( Test by pin up)
Agitator
