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Piping Design, System, Operation, Maintenance and Repair in Oil and Gas Plant

Introduction

Piping Design, System, Operation, Maintenance and Repair in Oil and Gas Plant

Course Objectives

• Detailed understanding and knowledge of plant piping systems, including design, operation, maintenance, and repair.
• Required awareness and knowledge of relevant codes and standards to choose the correct piping material.
• Experience to understand required operations and decide the best piping systems.
• Adequate confidence and understanding to consider all challenges such as temperature and pressure and work on setting up a system that could withstand these conditions.
• Knowledge and experience to train other professionals on essential aspects of piping systems.
• Adequate knowledge and experience to understand what size and fittings are needed as per the intended purpose.
• Awareness and confidence to conduct regular inspections to check for maintenance and repair requirements.
• Understanding of the extent and type of damage and necessary remedial measures to address these.
• Skill and capabilities to reduce organizational costs on piping system maintenance and repair, thereby contributing to organizational development as well as worker safety.
• Comprehensive knowledge of piping system components, including pipes, fittings, valves, flanges, supports, expansion joints, and instrumentation for monitoring and control.
• Expertise in applying international design standards and codes such as ASME B31.3, API, and ASTM for system safety and regulatory compliance.
• Ability to perform piping stress analysis, pipe sizing, flexibility studies, and optimal layout planning for various fluid and process requirements.
• Skills to create, read, and interpret piping layout drawings, isometric diagrams, material take-offs, and general arrangement schematics.
• Proficiency in preventive maintenance, inspection scheduling, NDT methods, and failure analysis for enhancing system reliability and uptime.
• Capacity to assess and select appropriate repair techniques for damaged piping, including replacement, welding, sleeves, and corrosion mitigation strategies.

Who Should Attend?

This Piping Design, System, Operation, Maintenance and Repair in Oil and Gas Plant course is designed for:

• Senior members of an organization responsible for making critical decisions related to purchases and costs for piping systems and material
• Piping engineers responsible for ensuring that all systems are running as per optimal levels
• Supervisors and managers responsible for overseeing maintenance, operation and repair of piping systems
• Operations managers who need to manage end-to-end operations of the plant
• Quality auditors and compliance officials responsible for checking maintenance of optimal quality and adherence to standards
• Vendors involved in supply of material and fixtures for piping systems
• Any other professional interested in knowing more about piping systems

Course Outline

The Piping Design, System, Operation, Maintenance and Repair in Oil and Gas Plant course covers the following areas for effectively understanding plant piping systems:

Module 1 – Power Plant Piping Material

• Steel
• Cast iron
• Brass and copper
• Carbon steel for general service applications and high-temperature operations
• Stainless steel for corrosive environments and specialized chemical services
• Alloy steels for high-pressure and high-temperature applications
• Non-metallic materials including PVC and fiberglass for specific applications

Module 2 – Types of Pipe Fittings (Note: Module 2 was missing, so I’m numbering this correctly)

• Elbows
• Nipples
• Couplings
• Unions
• Tees and crosses
• Y-bends
• Return bends
• Plugs and caps
• Bushings
• Reducers
• 90-degree and 45-degree elbows for directional changes
• Concentric and eccentric reducers for size transitions
• Socket weld and butt weld fittings for permanent connections
• Threaded and flanged connections for removable joints

Module 3 – Methods to Connect Pressure Piping

• Screwed connections
• Flanged connections
• Welded joints
• Butt weld connections for high-pressure applications
• Socket weld connections for smaller diameter piping
• RTJ (Ring Type Joint) flanges for high-pressure and high-temperature service
• Compression fittings for instrumentation and small-bore piping

Module 4 – Ideal Design Procedure

• Determination of the problem
• Determination of preliminary pipe route
• Pipe diameter determination based on allowable head loss
• Structural analysis
• Support and anchor designing
• Preparation of drawings, specification, design report
• Process flow diagram (PFD) development and analysis
• Piping and instrumentation diagram (P&ID) creation
• 3D modeling and clash detection using software tools
• Material take-off (MTO) and procurement specifications

Module 5 – Piping System Design Engineering

• Design basis and standard drawings
• Piping material specifications
• Pipe and pump sizing
• Equipment datasheet preparation
• Catalogue creation
• Plot plan
• Fire protection system
• ASME B31.3 Process Piping Code compliance
• API standards integration for oil and gas applications
• Hydraulic calculations and pressure drop analysis
• Thermal expansion and stress analysis considerations

Module 6 – Types of Valves in Pipe System Design

• Air-relief valves
• Gate valves
• Small valves
• Altitude valves
• Pressure-regulating valves
• Ball valves for isolation and quick shut-off applications
• Globe valves for flow control and throttling service
• Check valves for backflow prevention
• Safety relief valves for overpressure protection

Module 7 – Types of Fire Hydrants in Piping Systems

• Flush hydrants
• Wall hydrants
• Post hydrants
• Monitor nozzles for fixed fire suppression systems
• Foam proportioning systems for hydrocarbon fire protection
• Deluge sprinkler systems for area protection
• Emergency shutdown valves for fire isolation

Module 8 – Piping Flexibility Analysis

• Stress analysis model
• Analysis-formatted report with recommendation
• Stress isometric
• Load list for support design
• Support design
• CAESAR II software for comprehensive stress analysis
• Thermal expansion calculations and loop design
• Seismic analysis and wind load considerations
• Fatigue analysis for cyclic loading conditions

Module 9 – Maintenance Checklist

• Determine points of inspection
• Develop a schedule for the maintenance team
• Implement a preventive maintenance schedule
• Perform upgrades and rehabilitation tasks
• Non-destructive testing (NDT) procedures including ultrasonic and radiographic inspection
• Corrosion monitoring and integrity assessment programs
• Vibration analysis and pipe support evaluation
• Leak detection and repair (LDAR) programs

Module 10 – Benefits of Preventive Maintenance

• Better uptimes
• Fewer repairs and shutdowns
• Increased energy savings
• Lower repair costs
• Extended asset life and improved reliability
• Reduced environmental and safety risks
• Enhanced regulatory compliance and documentation
• Cost-effective resource allocation and planning

Module 11 – Parameters Guiding Choice of Repair Techniques

• Piping geometrics and material
• Operating characteristics
• Configuration and location
• Nature and size of the defect to repair
• Remaining useful life assessment
• Economic evaluation of repair versus replacement
• Accessibility constraints and shutdown requirements
• Environmental and safety considerations

Module 12 – External Repair Techniques

• Cut out and replace
• Bypass technique
• Grinding
• Weld deposition
• Metallic sleeves
• Composite sleeve
• Hot tapping and plugging for online repairs
• Clamp-on fittings for temporary and permanent repairs
• Injection molding and resin injection techniques
• Advanced composite wrapping systems
• Weld overlay and cladding for corrosion protection
• Pipeline integrity management and risk assessment