The document discusses maintenance and inspection of piping systems in hydrocarbon industries. It covers topics such as types of piping, materials used, design considerations, fabrication methods, degradation mechanisms, and inspection procedures. The key aspects are underground and above ground piping, various piping materials like carbon steel, testing and fabrication techniques like welding and bending, corrosion issues, and the role of inspections in evaluating piping condition and determining causes of deterioration.
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The document discusses maintenance and inspection of piping systems in hydrocarbon industries. It covers topics such as types of piping, materials used, design considerations, fabrication methods, degradation mechanisms, and inspection procedures. The key aspects are underground and above ground piping, various piping materials like carbon steel, testing and fabrication techniques like welding and bending, corrosion issues, and the role of inspections in evaluating piping condition and determining causes of deterioration.
The document discusses maintenance and inspection of piping systems in hydrocarbon industries. It covers topics such as types of piping, materials used, design considerations, fabrication methods, degradation mechanisms, and inspection procedures. The key aspects are underground and above ground piping, various piping materials like carbon steel, testing and fabrication techniques like welding and bending, corrosion issues, and the role of inspections in evaluating piping condition and determining causes of deterioration.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online from Scribd
The document discusses maintenance and inspection of piping systems in hydrocarbon industries. It covers topics such as types of piping, materials used, design considerations, fabrication methods, degradation mechanisms, and inspection procedures. The key aspects are underground and above ground piping, various piping materials like carbon steel, testing and fabrication techniques like welding and bending, corrosion issues, and the role of inspections in evaluating piping condition and determining causes of deterioration.
Copyright:
Attribution Non-Commercial (BY-NC)
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Download as PPTX, PDF, TXT or read online from Scribd
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Maintenance & Inspection of Piping in Hydrocarbon Industry
All small bore pipings and tracer lines, size and below should be welded by TIG process for all types of joints, e.g. butt, socket, tee, etc. to ensure proper quality of welding. Use of half coupling may be considered to increase reliability of small-bore connections. Minimum thickness of pipe for sizes up to 1 should be Sch.80 for CS and AS. Reinforcement pad shall be provided at support location. Steam drain points should be routed to a drain header and taken out of the unit area.
Stiffener should be provided in small bore bleeder/ drain point connection welded to immediate upstream or downstream of safety valves. As far as possible, stub-in type branch connection are to be provided when branch size is less than one size than the main pipe. All the reinforcement pad telltale holes should be drilled and tapped properly. Gas cut holes should not be accepted. Wherever two phase flow in piping is expected, piping design including its support system should be checked w.r.t. most adverse conditions/ ratio of both the phases (slug flow) to avoid line vibration during operation.
All the fittings like valves, flanges etc. in high temperature service (> = 300 0C) should also be fully insulated if they are in open area or the localized cooling can cause operational problems like coking etc. All SS piping should have chloride free insulation or preferably should have SS foil wrapped between pipe and insulation. Branch connections for fire hydrants along the roads should be totally above grounds. Hydrant connections also should remain above ground.
Firewater and cooling water lines emerging from underground should be wrapped coated beyond the ground level up to a length of 500mm.
Hard surfacing with a proper slope towards open drain system is to be provided beneath the offsite pipe rack area with a clear space of 500mm from bottom of the pipe. Interspacing between the offsite piping on the support pedestal should be such that the lines should not touch each other even after insulation (at least 3 gap after insulation). Identification marks for location/ visibility of drain points of offsite piping should be provided. All drain points should be approachable and clearly visible.
Piping insulation ends should be properly sealed to avoid water ingress. Hard surfacing under the piping bay in offsite areas should be done with proper slope & drainage facility.
Proper slope and gap should be provided in piping culverts to avoid water logging. In fire water lines, the hydrant tapping should not be taken from the bottom side of pipe. Tapping should be taken from the top or from side.
Any piping circuit if idle for more than six month shall be inspected or hydrotested before taking into service Ensure adequate wrapping & coating and at least 0.5mtr wrapping & coating shall be visible externally at both ends on above ground portion of pipe. All piping route in off-site area shall be made grass & debris free. In Hydrocarbon service dia. 2 pipe shall be of minimum Schedule 80. Low point drain (LDP) shall be offset by 1 meter from the supports and shall not be embedded into soil.
ROLE OF INSPECTION To evaluate present physical condition of the pipeline. To keep the concerned operating and maintenance personal fully informed about the the condition of the lines. To determine causes of deterioration and advise suitable economical solution to the problem. To initiate procurement action of materials. To co-relate deterioration rate with design life for further run.
FREQUENCY OF INSPECTION The interval between inspections depend upon : Degree of corrosiveness/ erosiveness of the fluid.
Remaining corrosion allowance.
Type of protective coating. Atmosphere prevailing around the piping. Potentially of fire /explosion in case of a leak or failure. Statutory requirements.
Importance of operations. Haldia Refinery Igniting Minds... Energizing Lives
FREQUENCY OF INSPECTION Frequency of inspection for offsite piping (hydrocarbon): Service Crude (sour) LP/Natural gas Gasoline / naphtha ATF/ HSD/ LDO/ SKO FO/RCO/Bitumen/ VBO Fuel gas/ Flare gas Lube oil
FREQUENCY OF INSPECTION Frequency of inspection for offsite piping (Utilities): Service Fresh water Fire water Air / steam Ammonia / caustic DEA/ MEA Furfural/ phenol Benzene/ toluene
INSPECTION PROCEDURE Visual Inspection: For determining leaks, misalignment, supports, vibration, external corrosion, cracks, insulation damage. Ultrasonic Inspection: For ascertaining wall thickness, by scanning at least four spots (12 o clock, 3 o clock, 6 o clock and 09 o clock positions) on each circumferences for every 30 m of straight length and all bend locations. Haldia Refinery Igniting Minds... Energizing Lives
INSPECTION PROCEDURE Radiographic Inspection: Critical spots which cannot be inspected by UT may be radio graphed during operation to determine internal fouling, pitting, scaling etc.
Shutdown Inspection: All piping which cannot be inspected during operation has to be inspected during shutdown.
INSPECTION PROCEDURE Hydrostatic Testing: Along with all NDTs hydro test has to be carried out to evaluate strength of existing and new joints of the line in addition to establishing overall integrity of the line. For new lines hydro test is to be done at 1.5 times design pressure. For old lines or partially repaired or replaced line it is carried out at 1.5 times operating pressure. Coated or insulated lines are hydro tested before coating operation. Before using any line which has been idle for long time, hydro test is to be carried out. Portable water is to be used for CS or AS pipes and DM water is to be used for SS pipes. Water must be drained after the test.
INSPECTION PROCEDURE AREAS SUSCEPTABLE TO ACCELERATED CORROSION
In the presence of certain corrodants, corrosion rates are normally increased at areas of increased velocity and/or turbulence. Elbows, reducers, mixing tees, control valves, and orifices are examples of piping components where accelerated corrosion may occur because of increased velocity and/or turbulence. In the areas of no flow, such as dead legs, accelerated corrosion may occur. Such components are normally areas where an inspector would locate additional TMLs in a piping circuit. Haldia Refinery Igniting Minds... Energizing Lives
DCVG SURVEY The Direct Current Voltage Gradient (DCVG) technique is a "newer" technique for coating surveys on buried pipelines. It has been used for not only locating but also sizing coating defects. The technique is fundamentally based on measuring the voltage gradients in the soil above a cathodically protected pipeline.
NDT IN PIPING SYSTEM LONG RANGE ULTRASONIC TESTING
This technique uses low
frequency
guided
ultrasonic
waves to detect a length of piping. It locates the affected area in terms of distance from transducer and serves as a screening tool to inspect large lengths of piping especially at
