WASTE WATER TREATMENT PROJECT (WWTP)

Starting new Project, which is Waste Water Treatment Plant Project (WWTP), meanwhile Pipe Rack Line 5 project is not finish yet, and that's a big challenge for me as a Coordinator for the project. On WWTP Project also has Piping and Fabrication, Equipment such as Clarifier, Tank, etc, and tomorrow the schedule of meeting for this WWTP Project. When I have to prepare all the requirements for that project, me and my teams start to estimate the Inch Dia for the PIPING jobs and all of that Piping ID is about 12000 InchDia.

Also with the Equipment jobs, it's about 50 Tons, and the schedule of WWTP Project about 3 months, and we still waiting when we have to start this project until the result of tomorrow meeting with the users.

We also have to prepare all the tools such as Grinding Machine, Gas Cutting, Welding Machine, etc. If the stock is available for the project, we just have to start that project without have to think about the tools, or we don't have or less of any tools.

The drawing is also already hand over to us and we hope we ready for this WWTP Project. I think is enough for now, and I hope in the next post I can provide more useful post to all of us, not only tell about the project I've been working on. Thanks for visiting and if there is any question, you can post on comment box.

RENEWAL ISO CERTIFICATE

Yesterday my company on Site Project has an audit for Renewal ISO Certificate for ISO 9001 : 2008, and me is one of the employee who involve directly with that audit. and with our work which is Piping and Fabrication, there is so many thing that we have to check and audit. Start from Safety, JRA, PPE, Documentation, Process and Computerize.

I have to admitted there is few minor in our Site Project and that's make me has to move fast to correct all that minor. with all the jobs that we have to finish by the end of June, so we have to move very fast. I have to increase more man power to catch all the progress that has been left behind about 10%.

I hope with those action we can get the new project which is WWTP Project, inside of that project is all about PIPING and we think we already learn from this Pipe Rack Project, what is the important thing we can do first before start the project.

So, I hope we can get better and better, because our ISO now already Renew and that mean something. Thanks!

How to Make a Ducting Elbow

Sometimes I don't understand why they can't calculate how to make a ducting elbow, and this is really happen in our workshop. And for this one I think this is one of the basic knowledge that every Fitter has to know. And because of that, now Piping and Fabrication will post about How to Make Ducting Elbow and how to calculate it (shown in the picture below).

To find out the Radius of a Long Radius Elbow, this is how to do it. Radius = 1 1/2 x Nominal Size, and that's really simple when we want to learn. And from that calculation we know what is the requirements for the materials, and how many plate we will use to make a ducting elbow.

I think may be this post will enough to them know how to make a Ducting Elbow, and hope they will learn much about Piping.

Sand Blast and Painting

For almost few weeks, Piping and Fabrication can't post this blog, because there is too many problems that I have to solve for Pipe Rack Line 5 Project, and one of them is Sandblast and Painting. We already told to our Sub contractor that all the Steam Line Pipe has to paint with Heat Resistance Paint, including all the support such as shoe and etc. But, when we inspect to the field, they don't do paint as we told. They do the painting without Heat Resistance Paint and that's make our progress delay, because they have to do reworks.

Not mention all the weather problem such as rain, because we can not avoid it, when the rain falls, almost every activity on the Pipe Rack is stop to avoid accident. Now our progress is almost 15% left behind and that's make me have to think, how do I have to cover all those 15%?

This is Piping and Fabrication, I hope this project will finish soon and all the problems will disappear. Thanks for visiting and if you have a suggestion, please comment!

Piping on Pipe Rack

It's been almost the end of April, but our progress on the Pipe Rack Line 5 at South Pacific Viscose still far far away from the target. The target should be 60% in the end of this month, but we only reach 48.98% for over all job on the Pipe Rack. I know there is so many problem on the field when we doing Piping and Fabrication for this job. For example, there is too many Pipe Rack doesn't suit to with the drawing, or too small support, so it's not possible if we put 24" Inch Pipe on that Pipe Rack and also the other problem such as unfinished pipe rack and support. Because all the Pipe Rack and support is doing by Civil.

We can't joint straight because the limitation of pipe rack

We who doing the Piping Job, it's really face the hard situation here, because only one week left but we have to chase 10% delay from the target. We hope everything will be fine as our planning. By the way, today Piping and Fabrication only post about this, because this is very important to me to catch everything on time.

Thanks for visiting and Good Luck.

Cutting, Bending, Welding, Heat Treatment, and Examination

Cutting, Bending, Welding, Heat Treatment, and Examination

Cutting, bending, and welding operations in the field parallel those used in the shop. See the section ‘‘Fabrication’’ in this Piping and Fabrication blog in the older post. and also Mechanical and oxyfuel gas cutting are most commonly used in the field. Plasma cutting may occasionally be used in Piping. 

Bending, if used at all, is limited to small-diameter piping using relatively simple bending equipment at ambient temperatures. Occasionally in order to correct for misalignment, larger-diameter ferritic piping is bent at temperatures below the lower critical. Please note that this procedure is limited to ferritic materials. Any application of heat to austenitic materials will result in sensitization and loss of corrosion properties. See the section ‘‘Bending.’’ For smaller pipe sizes, torches may be used to supply heat, but for larger, heavier-wall materials and where better temperature control is warranted, heat may be applied by induction or resistance heating units in the same manner as local stress relieving. See the section ‘‘Local Heat Treatment.’’ The heating units are applied to the section of the pipe to be bent. The section of the line upstream of the area to be bent should be anchored to preclude translation or rotation of the installed portion of the line. The anchor should preferably be not more than one or two pipe diameters from the area to be heated. Once the bend area has attained the required temperature, a bending force can be applied on the downstream leg of the pipe until the required bend arc has been obtained. Since most ferritic materials still have reasonably high

yield strengths even at lower critical temperatures, care should be exercised. Large bending forces may damage the building structure or crack the line being bent.

Apply a reasonable force for the conditions and allow the imposed stress in the bend arc to be relieved by the heat. Then repeat. Progress in this fashion until the required bend is accomplished. Some small amount of overbending may be required to offset the deflection which will occur in the unheated section of pipe between the heated arc and the pulling device. When the bend is completed and allowed to cool, all restraints may then be removed. Little if any force should be needed to align the downstream joint; otherwise additional bending may be needed to further correct the situation. No further heat treatment of the bend arc is needed since the temperatures applied in this bending method are below the lower critical temperature. Corrections to lines with large section modulus or where the required bend arc is large should preferably be made in a shop since better controls can be exercised.

Field welding is more often than not in a fixed position. Welders should be qualified in the 6G position since this qualifies for all positions. Welding will be done using SMAW,GMAW,FCAW, and GTAW. Somewelding processes can be automated using orbital welding techniques. Such practice can result in fewer repairs, provided the bevels and alignment are within tolerance and the welding parameters are carefully selected.

Field postweld heat treatment also follows the practices outlined in the section ‘‘Heat Treatment’’ for local stress-relieving of ferritic materials. This usually involves induction or resistance heating units with recording devices. For small pipe welds, torch heating using temperature-sensitive crayons to control temperature is sometimes used. Exothermic heating to stress-relieve welds is still used on occasion for outdoor applications where heating rates are not required to be controlled.

Exothermic materials are preformed to pipe contour and sized to reflect the wall thickness and desired stress-relieving temperature. They are placed around the weld and ignited, attaining temperature in 5 or 10 min. The actual maximum temperature attained may vary. NDE in the field will follow the practices outlined in the section ‘‘Verification Activities.’’ Radiography is usually limited to radioactive isotopes, although occasionally X-ray equipment may find a use. Most surface examination is conducted using liquid-penetrant methods, since magnetic particle equipment is not as convenient in the field. Ultrasonics are used for thickness verification and in certain situations as an alternative to radiography of welds when permitted by the governing code.

Mechanical Joints

Threaded joints probably represent the oldest method of joining piping systems. The dimensional standards for taper pipe threads are given in ASME B1.20.1. This document gives all required dimensions including number of threads per inch, pitch diameter, and normal engagement lengths for all pipe diameters. Thread cutting should be regarded as a precise machining operation. For steel pipe the lip angle should be about 25,

but for brass it should be much smaller. Improper lip angle results in rough or torn threads. Since pipe threads are not perfect, joint compounds are used to provide leak tightness. The compounds selected, of course, should be compatible with the fluid carried and should be evaluated for possible detrimental effects on system components. Manufacturers’ recommendations should be followed.

Threading Die

Where the presence of a joint compound is undesirable, dryseal pipe threads in accordance with ASME B1.20.3 may be employed. These are primarily found in hydraulic and pneumatic control lines and instruments. Flanged joints are most often used where disassembly for maintenance is desired. Agreat deal of information regarding the selection of flange types, flange tolerances, facings and gasketing, and bolting is found in B16.5. The limitations regarding castiron-to-steel flanges, as well as gasket and bolting selection, should be carefully observed. The governing code will usually have further requirements. Gasket surfaces should be carefully cleaned and inspected prior to making up the joint. Damaged or pitted surfaces may leak. Appropriate gaskets and bolting must be used. The flange contact surfaces should be aligned perfectly parallel to each other. Attempting to correct any angular deviation perpendicular to the flange faces while making up the joint may result in overstressing a portion of the bolts and subsequent leakage. The proper gasket should be inserted making sure that it is centered properly on the contact surfaces. Bolts should be tightened hand-tight.

Compression sleeve (Dresser) coupling for plainend cast-iron or steel pipe

If necessary for alignment elsewhere, advantage may be taken of the bolt hole tolerances to translate or rotate in the plane of the flanges. In no case should rotation perpendicular to the flange faces be attempted. When the assembly is in its final location, bolts should be made up wrench-tight in a staggered sequence. The bolt loading should exert a compressive force of about twice that generated by the internal pressure to compensate not only for internal pressure but for any bending loads which may be imposed on the flange pair during operation. For a greater guarantee against leakage, torque wrenches may be employed to load each bolt or stud to some predetermined value. Care should be exercised to preclude loading beyond the yield point of the bolting. In other cases, special studs that have had the ends ground to permit micrometer measurement of stud elongation may be used. Flange pairs which are to be insulated should be carefully selected since the effective length of the stud or bolt will expand to a greater degree than the flange thicknesses, and leakage will occur. Thread lubricants should be used, particularly in high-temperature service to permit easier assembly and disassembly for maintenance. There are a great variety of mechanical joints used primarily for buried castiron pipelines carrying water or low-pressure gas. They are primarily of the bell and spigot type with variations involving the use of bolted glands, screw-type glands, and various types of gasketing. The reader is referred to AWWA Standards C 111, C 150, and C 600, and to catalogs for proprietary types. For reinforced concrete pipe,AWWAStandards C 300, C 301,51 and C 302, should be consulted. Compression-sleeve couplings such as the Dresser coupling and the Victualic coupling are widely used for above- and below-ground services, both with cast-iron and steel pipe. Consult the manufacturers’ catalogs for more information. 

INSTALLATION PROCESS ON PIPING AND FABRICATION

INSTALLATION ON PIPING AND FABRICATION

I think everyone who work and involved in the Piping, Maintenance, Fabrication and Mechanical on Piping and Fabrication must know about the whole process from the beginning what the piping system is and here we will talk start from drawing, erection, cold spring, joint alignment and etc.

Drawings

Drawings used for piping system installation may vary greatly. Often orthographic projections of the building showing several systems or single systems, depending on complexity, are used. In many cases single or multiple isometric drawings of a single system are used. These of course are not to scale but are convenient for planning, progress recording, or record keeping when required by quality programs. In all cases where prefabricated subassemblies are being erected, these drawings will have been marked up to show the locations and mark numbers of the individual subassemblies, the location and designations of field welds, and the locations and markings of hangers.

Erection Planning

Planning is vitally important in installing a piping system. Many factors must be considered, among them accessibility to the building location, coordination with other work, availability and accessibility of suitable welding and heat treatment equipment, availability and qualification of welders and welding procedures, rigging, scaffolding, and availability of terminal equipment. Each of the system components should also be carefully checked to assure correctness. Valves and other specialty items in particular should be checked to assure they are marked with flow arrows, that the handwheels or motor operators are properly oriented, and that the material to be welded is compatible with the material of the piping. Special valves for use in carbon steel systems are sometimes furnished as 5 percent chrome material, and thermowells are often not of the same chemical composition as the pipe. This may not be apparent from the drawings Such a preliminary check will indicate the need for alternate welding procedures and preclude problems later.

The location of the work and accessibility to it should be viewed. It may not be possible to install an overly long subassembly after other equipment or building structure is in place. A common practice in the power field is to have large, heavy assemblies often found in the main steam and reheat lines of large central stations erected with the structure. In other cases, a preliminary review may show interferences from an existing structure, cable trays, ducts, or other piping which are not apparent from the drawings. The locations of the terminal points on equipment should be checked to assure that they are correct. The type, size, rating, or weld preparation of the connection should be checked to assure that it will match the piping. Solutions to any problems can be devised with the designer before work starts.

The ideal way to begin erection is to start at some major piece of equipment or at a header with multiple outlets. Install the permanent hangers if possible. If these are to be welded to the structure, some prudence should be exercised, since the final location of the line may warrant some small relocation to assure that the hanger is properly oriented relative to the piping in its final position. Obviously a certain number of temporary supports will be needed. Welding of temporary supports to the building structure or to the piping itself should be avoided or used only with the approval of the responsible engineers. Variable spring and constantsupport type hangers should normally be installed with locking pins in place, assuring that they function as a rigid support during the erection cycle. Where welded attachments to the pipe are involved, it is preferred that they be installed in the shop as part of the subassembly. If possible, the major components of the system should be erected in their approximate final position prior to the start of any welding. This will reveal any unusually large discrepancies which may result from equipment mislocation, fabrication error, or tolerance accumulations. Adjustments or corrections can then be decided upon. Long, multiplane systems can absorb considerable tolerance accumulation without the need to modify any part. Short, rigid systems may not be able to accommodate any tolerance accumulation, and it may be necessary to rework one or more parts.

Cold Spring

Both the B31.1 and B31.3 Codes address cold springing in detail. Cold spring is the intentional stressing and elastic deformation of the piping system during the erection cycle to permit the system to attain more favorable reactions and stresses in the operating condition. The usual procedure is to fabricate the system dimensions short by an amount equal to some percentage of the calculated expansion value in each direction. The system is then erected with a gap at some final closure weld, equal to the ‘‘cut shorts’’ in each direction. Forces and moments are then applied to both ends as necessary to bring the final joint into alignment. Once this is done, it is usually necessary to provide anchors on both sides of the joint to preserve alignment during welding, postweld heat treatment, and final examination. When the weld is completed and the restraining forces are removed, the resulting reactions are absorbed by the terminal points, and the line is in a state of stress. During start-up the line expands as the temperature increases, and the levels of stress and terminal reactions resulting from the initial cold spring will decrease. For the 100 percent cold sprung condition, the reactions and stress will be maximum in the cold condition and theoretically zero in the hot condition. It should be borne in mind that it is very difficult to assure that a perfect cold spring has been attained and for this reason the codes do not permit full credit in the flexibility calculations. Also remember that lines operating in the creep range will ultimately attain the fully relaxed condition. Cold spring merely helps it get there faster. Cold spring was historically applied to high-temperature systems such as main steam and hot reheat lines in central power stations, but this practice is not as prevalent anymore.

For those involved with the repair of lines which have been cold sprung, or which have achieved some degree of creep, caution should be exercised when cutting into such lines since the line will be in a state of stress when cold. The line should be anchored on either side of the proposed cut to prevent a possible accident.

Joint Alignment

In aligning weld joints for field welding it may be necessary to compromise between a perfect weld fit-up and the location of the opposite (downstream) end of the assembly. The weld bevel may not be perfectly square with the longitudinal axis of the assembly. Even a 1/32-in (0.8 mm) deviation across the face of the weld bevel can result in an unacceptable deviation from the required downstream location if the joint is aligned as perfectly as possible. Often such a small gap can be tolerated in the welding. If, in order to maintain the downstream location, the gap at the joint is excessive, the joint should be disassembled, and the land filed or ground as needed to attain the required alignment of the weld joint while still maintaining the required downstream position. Flanged connections should be made up handtight so that advantage can be taken of the bolt-hole clearances to translate or rotate the assembly for better alignment of downstream connections.

Weld shrinkage of field welds may or may not be important in field assembly. In long flexible systems, they may be ignored. For more closely coupled systems, particularly those using GTAW root-pass welding, this factor should be considered. The degree of longitudinal shrinkage across a weld varies with welding process, heat input, thickness, and weld joint detail. See the section ‘‘Layout, Assembly, and Preparation for Welding.’’ In extreme cases closure pieces may be used. Here, the system is completed except for the final piece. A dummy assembly is then fabricated in place and the closure assembly is fabricated to match the dimensions of the dummy assembly with weld shrinkage of the final welds taken into account.

Just to remembering, that what we explain here is according to the ASME Standard.