Process Piping Design, Construction, Inspection, Maintenance & Mechanical Integrity (ASME B31.3 & API 570)

Introduction

This course is designed to provide participants with a detailed and up-to-date overview of Process Piping Design, Construction, Inspection, Maintenance & Mechanical Integrity (ASME B31.3 & API 570). It covers the ASME B31.3 piping code, ASME piping system standards and other piping system standards; the ASME B31.1, ASME B31.3, ASME B31.4, ASME B31.5, ASME B31.8, ASME B31.9, ASME B31.11 and design and construction code selection; the furnace butt welded pipe, electric-fusion welded pipe, double submerged-arc welded pipe, seamless pipe and spiral welded pipe; and the piping components, piping elements, piping installation, pipe-supporting elements, fixtures and structural attachments. Further, the course will also discuss the metallic pipe, fitting selection and material selection, materials, strength, fatigue and toughness; the requirements for low temperature toughness tests and carbon steel lower temperature limits; the pressure design, valve selection and layout and support; the thermal expansion and contraction effects, effects of support, anchor, piping flexibility, preheat zone, post weld heat treatment and heat treatment requirements; and the types of expansion joints, pressure thrust, installation of expansion joints, bellows movement, universal expansion joint, hinged expansion joint and other types of expansion joints. During this interactive course, participants will learn the fabrication and installation, welding procedure specification (WPS), welding processes, shielded metal arc welding and other welding techniques; inspecting, examining and testing various requirements and criteria and methods used in ASMI B31.3 including instrument piping and pressure relieving systems; the API 570 repairs and alterations, welding repairs, hot tapping, pressure tests and pneumatic and combination tests; the high pressure piping and implement proper inspection, repair, alteration and rerating of in-service piping; the external inspection checklist including leaks, misalignment and vibration; the various types of inspection like internal visual, thickness measurement and external visual; the inspections practices including frequency and extent of inspection, extent of CUI inspections, extent of small bore piping inspection and maximum allowable working pressure; the piping calculations and corrosion rate determination; and the design requirements, fabrication requirements, examination requirements, metallic leak test requirements in category M fluid service.

Objectives

Upon the successful completion of this course, each participant will be able to: -

• Apply the latest revision of process piping design, construction, inspection, maintenance and mechanical integrity (ASME B31.3 & API 570)
• Discuss ASME B31.3 piping code, ASME piping system standards and other piping system standards
• Explain ASME B31.1, ASME B31.3, ASME B31.4, ASME B31.5, ASME B31.8, ASME B31.9, ASME B31.11 and design and construction code selection
• Recognize furnace butt welded pipe, electric-fusion welded pipe, double submerged arc welded pipe, seamless pipe and spiral welded pipe
• Identify piping components, piping elements, piping installation, pipe-supporting elements, fixtures and structural attachments
• Conduct metallic pipe, fitting selection and material selection, as well as discuss materials, strength, fatigue and toughness
• Recognize the requirements for low temperature toughness tests and carbon steel lower temperature limits
• Illustrate pressure design, valve selection and layout and support
• Identify thermal expansion and contraction effects, effects of support, anchor, piping flexibility, preheat zone, post weld heat treatment and heat treatment requirements
• Recognize the types of expansion joints, pressure thrust, installation of expansion joints, bellows movement, universal expansion joint, hinged expansion joint and other types of expansion joints
• Carryout fabrication and installation, welding procedure specification (WPS), welding processes, shielded metal arc welding and other welding techniques
• Inspect, examine and test various requirements and discuss criteria and methods used in ASMI B31.3 including instrument piping and pressure relieving systems
• Carryout API 570 repairs and alterations, welding repairs, hot tapping, pressure tests and pneumatic and combination tests
• Discuss high pressure piping and implement proper inspection, repair, alteration and rerating of in-service piping
• Review the external inspection checklist including leaks, misalignment and vibration • Apply various types of inspection like internal visual, thickness measurement and external visual
• Carryout inspections practices including frequency and extent of inspection, extent of CUI inspections, extent of small bore piping inspection and maximum allowable working pressure
• Employ piping calculations and corrosion rate determination as well as recognize design requirements, fabrication requirements, examination requirements, metallic leak test requirements in category M fluid service

Training Methodology

This training course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes stimulating presentations supporting each of the topics together with interactive trainer lead sessions of discussion.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of process piping design, construction, inspection, maintenance and mechanical integrity (ASME B31.3 & API 570) for those who are involved in the design, analysis, fabrication, installation, maintenance or ownership of piping systems. engineers, senior draftsmen, maintenance, quality assurance, and manufacturing personnel who work in the chemical, petroleum, utility, plastic processing, pulp and paper, and manufacturing, fields will find it a time-saving means to broaden and update their knowledge of piping. Those who must comply with code requirements will benefit from the practical approach presented in this course in obtaining satisfactory and economical piping systems.

Course Outline

Introduction ASME B31.3 Process Piping Code

ASME/ANSI • ASME B31 Code • Piping System Standards • ASME Piping System Standards • More ASME Piping System Standards • Other Piping System Standards • ASME B31.1 • ASME B31.3 • ASME B31.4 • ASME B31.5 • ASME B31.8 • ASME B31.9 • ASME B31.11 • Design & Construction Code Selection • Other Design / Construction Codes

ASME B31.3 (Scope & Definition)

Scope • Content and Coverage • Exclusions • Definitions • Category D Fluid Service • Category M Fluid Service • High Pressure Fluid Service • Elevated Temperature Fluid Service • High Purity Fluid Service • Normal Fluid Service • Definition • Flexibility Stresses (SE) • Allowable Displacement Stress (SA) • Packaged Equipment • Pipe • Electric Resistance-welded Pipe Furnace Butt Welded Pipe • Electric-fusion Welded Pipe • Double Submerged Arc Welded Pipe • Seamless Pipe & Spiral Welded Pipe • Piping • Piping Components • Piping Elements • Piping Installation • Pipe-supporting Elements • Fixtures • Structural Attachments • Stress Terms • Design • Piping Development Process • Responsibilities

Metallic Pipe & Fitting Selection

Bases for Material Selection • Fire Resistance • Material Toughness • Example of Brittle Fracture • Material Cost • Material Selection of Piping • Elevated Temperature Fluid Service • Pipe Components – ASME • Other Listed Components • Weld Joint Quality Factor Ej • Fittings • Solder & Brazed Joint Fluid Service Requirements • Branches • Flanges (ASME B16.5) • Gaskets (ASME B16.20) • Bolting • Flanged Joints

Materials

Materials • Metal Properties • Strength of Materials • Fatigue • Toughness • Charpy Specimen • Toughness Test • Transition Temperature Samples

Pressure Design

Straight Piping Under Internal Pressure B31.3 304.1B • Stainless Steel Piping Schedules • New Piping • Required Thickness of Permanent Blanks

Valve Selection

Pipe Line Valves ( API-6D ) • Bolted Bonnet Gate Valve (API 600) • Type of Gate Valve Bonnet • Type of Gate Valve Stems • Gate Valve Stem Pull Test • Type of Gate Valve Trim • Type of Gate Valve Discs • Extended Body Gate Valve – API-606 • Knife Gate Valves • Globe Valve • Check Valve • Types vs. P-T Ratings • Types vs. Attributes • Butterfly Valve - Low Pressure • Butterfly Valve - High Pressure • Ball Valve • Plug Valve • Diaphragm Valve

Flanged Fitting (ASME B16.5)

Scope •Markings/Materials • Pressure Testing • Pressure Tests • ASME B16.5 Pressure Testing • ASME B31.3 Flange Selection • Slip on Flange • ASME B16.5 Flange Selection • ASME B16.5 Flange PT Rating Selection • ASME B31.3 Bolt Selection• General Consideration for Bolting Selection • ASME B16.5 Bolts Selection • Bolt Lengths • ASME B31.3 Gaskets • F308.4 Gaskets • ASME B16.5 Gaskets • F312 Flanged Joints • Factors Affecting Flange Joint Performance

Layout & Support

General Considerations • Support Spacing • Sagging Due to Creep (12 Years) •Support Locations • Simple Support • Guide • Spring Hangers • Special Purpose Supports • Support Element Selection • The Sustained Load Analysis • Fixing Problems

Thermal Expansion & Contraction

Thermal Expansion & Contraction Effects • Effects of Support, Anchor • Piping Flexibility • Properties for Flexibility Analysis • Thermal Expansion & Contraction • Piping Support • Sliding Supports

Preheat & PWHT

Preheating • Requirements and Recommendations • Temperature Verification • Preheat Zone • Post Weld Heat Treatment • Heat Treatment Requirements • Governing Thickness • Heating & Cooling • Temperature Verification • Hardness Tests • Specific Requirements • Alternative Heat Treatment • Exceptions to Basic Requirements • Dissimilar Materials • Delayed Heat Treatment • Local Heat Treatment

Designing with Expansion Joints

Types of Expansion Joints • Pressure Thrust • Pressure Thrust Workshop • Installation of Expansion Joints • Bellows Movement • Universal Expansion Joint • Hinged Expansion Joint • Gimbal Expansion Joint • Pressure Balanced Expansion Joint • Bellows Expansion Joint Types • Metal Bellows Expansion Joints • Bellows Shapes (EJMA) • Metal Bellows Failure Modes • Flixborough Disaster • Metal Bellows Fatigue • Special Designs • Designer Responsibilities • Metal Bellows Design Conditions • Piping Design for Metal Bellows • Installation & Testing • Manufacturer Responsibilities • Other Considerations • Problems to Avoid

Fabrication & Installation

Welder Qualification • Welding Procedure Specification (WPS) • Welding Processes • Shielded Metal Arc Welding • Gas Metal Arc Welding • Flux Cored Arc Welding • Gas Tungsten Arc Welding • Welding Processes • Welding Processes Accepted • Weld Preparation • Typical Welds • Preheating • Heat Treatment • Bending & Forming • Installation • Flanged Joints Alignment • Tighten Procedure for Flange Joints • Threaded Joints

Inspection, Examination & Testing

Inspection • Examination Requirements • Acceptance Criteria • Ultrasonic Examination • Examination Methods • Examination Requirements • Examination —Normal Fluid Service • Examination - Severe Cyclic Conditions • Testing• Leak Test Methods

Repairs, Alterations & Rerating of Piping Systems

API 570 Repairs and Alterations • Welding Repairs (Including on-Stream) • Welding & Hot Tapping • Re-rating • Case Study: Marcus Oil

Pressure Tests Hydrostatic, Pneumatic & Combination Tests

API 570 Pressure Testing, Requirements • ASME B31.3 Calculation of Test Pressures • Pressure Tests • Initial Service Leak Test

In-Service: Piping API 570 – Inspection, Repair, Alteration & Rerating of In-Service

In-Service Piping • API 570 Piping Inspection Code • Responsibilities

External Inspection

Checklist Leaks • Misalignment • Vibration • Supports • Corrosion • Insulation

Existing Piping Calculations (API-570)

Piping Calculations (API-570) • Injection Point Limits (API-570 5.10) • Existing Piping Calculations • Corrosion Rate Determination • Short Term (S.T.) Corrosion Rate • Maximum Allowable Working Pressure (Half Life) • Pressure Design Thickness (API-574- 11.1) • Structural Minimum Thickness • Minimum Required Thickness • Determination of Retirement Thickness for Valves