Piping systems manual

Piping Systems Manual

About the Author

Brian Silowash, PE, CEM, LEED AP, is president of

Innovative Design Engineering of America, LLC, a

Pittsburgh-based engineering consulting firm special￾izing in facilities engineering, energy management, in￾surance consulting, and building inspections. He has

worked as a maintenance foreman, a plant engineer,

and an engineering consultant. Mr. Silowash has ex￾tensive experience in design, construction, and com￾missioning.

Piping Systems Manual

Brian Silowash

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In memory of my parents, George and Juliana Silowash

“Deep waters cannot quench love, nor floods sweep it away.”

—Song of Songs 8:7

This page intentionally left blank

vii

Contents

Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

Chapter 1 Introduction 1

Some Miscellaneous Thoughts on Piping . . . . . . . . . 2

Chapter 2 Terminology 3

Chapter 3 Reference Materials 15

Chapter 4 Piping Codes 17

ASME B31.1 Power Piping . . . . . . . . . . . . . . . . . . . . . 21

100.1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

100.1.3 Not in Scope . . . . . . . . . . . . . . . . . . . . . . . 22

102.3.2 Limits for Sustained and

Displacement Stresses . . . . . . . . . . . . . . . . . . . 22

104.1 Pressure Design of Straight Pipe . . . . . . . 22

104.3 Branch Connections . . . . . . . . . . . . . . . . . . 25

104.3.3 Miters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

119 Expansion and Flexibility . . . . . . . . . . . . . . . 35

137 Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . 37

137.4 Hydrostatic Testing . . . . . . . . . . . . . . . . . . . 38

137.5 Pneumatic Testing . . . . . . . . . . . . . . . . . . . . 38

ASME B31.3 Process Piping . . . . . . . . . . . . . . . . . . . . 38

300.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

300.2 Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . 39

301 Design Conditions . . . . . . . . . . . . . . . . . . . . . 40

301.3.2 Uninsulated Components . . . . . . . . . . . . 40

302 Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . 40

302.2.4 Allowances for Pressure and

Temperature Variations . . . . . . . . . . . . . . . . . . 40

304.1.1 Pressure Design of Straight Pipe . . . . . . 41

304.3 Branch Connections . . . . . . . . . . . . . . . . . . 43

305.2 Specifi c Requirements . . . . . . . . . . . . . . . . 50

319.4 Flexibility Analysis . . . . . . . . . . . . . . . . . . . 51

345 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

ASME B31.9 Building Services Piping . . . . . . . . . . . . 53

904 Pressure Design of Components . . . . . . . . . 53

Summary of Code Comparisons . . . . . . . . . . . . . . . . 54

Chapter 5 Specifi cations and Standards 55

viii Contents

Chapter 6 Materials of Construction 83

Casting versus Forging . . . . . . . . . . . . . . . . . . . . 84

Cast Iron Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 85

Manufacture of Cast Iron Pipe . . . . . . . . . . . . . . 86

Ductile Iron Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 92

Manufacture of DI Pipe . . . . . . . . . . . . . . . . . . . . 93

Fabrication and Assembly of Ductile

Iron Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Carbon Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . 97

Manufacture of Carbon Steel Pipe . . . . . . . . . . . 100

Wall Thicknesses of Carbon Steel Pipe . . . . . . . 101

Sizes of Carbon Steel Pipe . . . . . . . . . . . . . . . . . . 102

Fabrication and Assembly of Carbon Steel

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Stainless Steel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 104

Manufacture of Stainless Steel Pipe . . . . . . . . . . 105

Fabrication and Assembly of Stainless

Steel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 108

Manufacture of Copper Tubing . . . . . . . . . . . . . 109

Fabrication and Assembly of Copper Tubing . . 109

Brass Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 114

Titanium Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 114

Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fabrication and Assembly of Titanium Pipe . . . 115

Aluminum Piping and Tubing . . . . . . . . . . . . . . . . . . 115

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 115

Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Fabrication and Assembly of Aluminum Pipe . 116

PVC (Polyvinyl Chloride) Piping . . . . . . . . . . . . . . . . 116

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 117

Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Fabrication and Assembly of PVC Pipe . . . . . . . 120

CPVC (Chlorinated PolyVinyl Chloride) Piping . . . 122

Contents ix

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 122

Manufacture of CPVC Pipe . . . . . . . . . . . . . . . . . 123

Fabrication and Assembly of CPVC Pipe . . . . . 123

Polybutylene (PB) Piping . . . . . . . . . . . . . . . . . . . . . . 124

Polyethylene (PE) and High-Density Polyethylene

(HDPE) Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 125

Manufacture of PE pipe . . . . . . . . . . . . . . . . . . . . 128

Fabrication and Assembly of PE Pipe . . . . . . . . 130

Acrylonitrile-Butadiene-Styrene (ABS) Piping . . . . 132

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 132

Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Fabrication and Assembly of ABS Pipe . . . . . . . 133

Cross-Linked Polyethylene (PEX) Piping . . . . . . . . . 133

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 134

Manufacture of PEX Tubing . . . . . . . . . . . . . . . . 135

Fabrication and Assembly of PEX Tubing . . . . . 135

Fiberglass Reinforced Plastic (FRP) Piping . . . . . . . . 136

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 137

Manufacture of FRP . . . . . . . . . . . . . . . . . . . . . . . 137

Fabrication and Assembly of FRP Pipe . . . . . . . 137

Concrete Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . 138

Manufacture of Concrete Pipe . . . . . . . . . . . . . . 138

Fabrication and Assembly of Concrete Pipe . . . 139

Asbestos Cement Pipe . . . . . . . . . . . . . . . . . . . . . . . . . 139

Other Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Centrifugally Cast Glass-Fiber Reinforced, Polymer

Mortar Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Lined Piping Systems . . . . . . . . . . . . . . . . . . . . . . 145

Elastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Polyvinylidene Fluoride (PVDF) . . . . . . . . . . . . 145

Polytetrafl uoroethylene (PTFE) . . . . . . . . . . . . . 145

Nitrile Rubber, or Buna-N . . . . . . . . . . . . . . . . . . 145

Ethylene Propylene Diene Monomer (EPDM)

Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Polychloroprene . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Fluoropolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Polyetheretherketone (PEEK) or

Polyketones . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Insulating Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Fiberglass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Calcium Silicate . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

x Contents

Cellular Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Foam Synthetic Rubber . . . . . . . . . . . . . . . . . . . . 147

Polyisocyanurate . . . . . . . . . . . . . . . . . . . . . . . . . 147

Mineral Wool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Extruded Polystyrene . . . . . . . . . . . . . . . . . . . . . . 148

Chapter 7 Fittings 149

Applicable Specifi cations . . . . . . . . . . . . . . . . . . . . . . 151

Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Flange Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Flange Facings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Types of Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Dielectric Connections . . . . . . . . . . . . . . . . . . . . . 166

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Other Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Cleanouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Laterals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Threaded Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 172

Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Caps and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Bull Plugs and Swaged Nipples . . . . . . . . . . . . . 180

Couplings and Half-Couplings . . . . . . . . . . . . . 180

Integrally Reinforced Forged Branch Outlet

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Wyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Ratings of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Chapter 8 Valves and Appurtenances 183

Valve Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Gate Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Globe Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Swing Check Valves . . . . . . . . . . . . . . . . . . . . . . . 188

Lift Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . 189

Ball Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . 189

Silent Check Valves . . . . . . . . . . . . . . . . . . . . . . . . 189

Foot Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Butterfl y Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Wafer-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Lug-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

High-Performance Butterfl y Valves (HPBV) . . 194

Fluid Velocities through Control Valves . . . . . . . . . . 194

Needle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Pressure Regulating Valves . . . . . . . . . . . . . . . . . . . . . 195

Pressure Relief Valves (PRVs) . . . . . . . . . . . . . . . . . . . 196

Contents xi

ASME Boiler and Pressure Vessel Code –

Section I Requirements . . . . . . . . . . . . . . . . . . 198

ASME Boiler and Pressure Vessel Code –

Section VIII Requirements . . . . . . . . . . . . . . . 198

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Pilot-Operated Valves . . . . . . . . . . . . . . . . . . . . . 199

Design Considerations . . . . . . . . . . . . . . . . . . . . . 201

Temperature and Pressure (T&P) Valves . . . . . . 202

Rupture Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

ASME Requirements for Rupture Disks . . . . . . 205

Design Considerations . . . . . . . . . . . . . . . . . . . . . 205

Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Plug Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Diaphragm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Triple-Duty Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Backfl ow Preventers . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

ASSE Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

ASSE 1016 Control Valves . . . . . . . . . . . . . . . . . . 212

ASSE 1017 Control Valves . . . . . . . . . . . . . . . . . . 212

ASSE 1062 Temperature Actuated Flow Reduction

(TAFR) Valves . . . . . . . . . . . . . . . . . . . . . . . . . 212

ASSE 1066 Pressure Balancing In-Line

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

ASSE 1070 Water Temperature Limiting

Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Steam Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Float Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Inverted Bucket Traps . . . . . . . . . . . . . . . . . . . . . 213

Liquid Expansion Trap . . . . . . . . . . . . . . . . . . . . . 213

Balanced Pressure Trap . . . . . . . . . . . . . . . . . . . . 214

Bimetallic Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Thermodynamic Traps . . . . . . . . . . . . . . . . . . . . . 215

Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Temperature Elements and Indicators . . . . . . . . 217

Pressure Transmitters and Indicators . . . . . . . . 217

Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Annubar® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Turbine Flow Meters . . . . . . . . . . . . . . . . . . . . . . 218

Magnetic Flow Meter . . . . . . . . . . . . . . . . . . . . . . 218

Ultrasonic Flow Meters . . . . . . . . . . . . . . . . . . . . 219

Hoses and Expansion Joints . . . . . . . . . . . . . . . . . . . . 219

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Expansion Joints . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Chapter 9 Pipe Supports 221

Reference Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Pipe Routings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Support Considerations . . . . . . . . . . . . . . . . . . . . . . . 222

Degrees-of-Freedom . . . . . . . . . . . . . . . . . . . . . . . 223

Types of Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Rack Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

xii Contents

Structural Supports . . . . . . . . . . . . . . . . . . . . . . . 226

Support Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Trapezes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Spring Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Stress Analysis Software . . . . . . . . . . . . . . . . . . . 235

Chapter 10 Drafting Practice 245

The Purpose of Piping Drawings . . . . . . . . . . . . . . . . 245

The Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Drawing Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Drawing Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Symbology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Valves and Piping . . . . . . . . . . . . . . . . . . . . . . . . 250

Process Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Drafting Practices for Piping . . . . . . . . . . . . . . . . . . . 255

Piping Plans and Elevations . . . . . . . . . . . . . . . . 255

Piping Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Chapter 11 Pressure Drop Calculations 261

Concepts Involved in Pressure Drop . . . . . . . . . . . . . 262

Bernoulli’s Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Pressure Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Velocity Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Elevation Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Friction Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Major Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Darcy Weisbach Equation . . . . . . . . . . . . . . . . . . 271

Hazen-Williams Formula . . . . . . . . . . . . . . . . . . . 278

Fanning Friction Factor . . . . . . . . . . . . . . . . . . . . 280

Tabulated or Graphic Solutions . . . . . . . . . . . . . 280

Minor Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Resistance Coeffi cient K . . . . . . . . . . . . . . . . . . . . 281

Equivalent Length Method . . . . . . . . . . . . . . . . . 281

Flow Coeffi cient Cv

. . . . . . . . . . . . . . . . . . . . . . . . 282

Pump Head Terminology . . . . . . . . . . . . . . . . . . . . . . 285

Total Suction Head . . . . . . . . . . . . . . . . . . . . . . . . 285

Static Discharge Head . . . . . . . . . . . . . . . . . . . . . 286

Total Static Head . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Total Discharge Head . . . . . . . . . . . . . . . . . . . . . . 286

Total Dynamic Head . . . . . . . . . . . . . . . . . . . . . . . 286

Contents xiii

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Suction Piping and Cavitation . . . . . . . . . . . . . . . . . . 293

Chapter 12 Piping Project Anatomy 297

An Archetypical Project . . . . . . . . . . . . . . . . . . . . . . . . 297

Utility Consumption Table . . . . . . . . . . . . . . . . . . . . . 298

Diversity Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Utility Quality Spreadsheets . . . . . . . . . . . . . . . . . . . . 300

Block Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 301

P&IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Design Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Recommended Data . . . . . . . . . . . . . . . . . . . . . . . 306

Optional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Inappropriate Data . . . . . . . . . . . . . . . . . . . . . . . . 307

General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . 307

Design and Construction Schedules . . . . . . . . . . . . . 308

Flow Maps or Utility Distribution Diagrams . . . . . . 308

Equipment Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Piping Plans, Sections, and Details . . . . . . . . . . . . . . 309

Pipe Support Plans and Instrument Location Plans 309

Isometrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Document Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

After IFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Field Engineering . . . . . . . . . . . . . . . . . . . . . . . . . 312

Chapter 13 Specifi cations 315

Types of Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . 315

Specifi cation Formats . . . . . . . . . . . . . . . . . . . . . . 315

Equipment Specifi cations . . . . . . . . . . . . . . . . . . . . . . 316

Sample Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

Bid Tabulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Pipe Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

CSI Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Outlined Narrative . . . . . . . . . . . . . . . . . . . . . . . . 322

Tabulated Piping Specifi cations . . . . . . . . . . . . . 324

Chapter 14 Field Work and Start-up 329

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Walkdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Pipe Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Sample Bearing Lube Oil System Cleaning

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Sample Hydraulic Oil System Cleaning

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

xiv Contents

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Steam Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

Chapter 15 What Goes Wrong 337

Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Floods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Earthquakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Unanticipated Thermal Growth . . . . . . . . . . . . . . . . . 339

Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Damage to Underground Utilities . . . . . . . . . . . . . . . 339

One Call and 811 . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Underground Markers . . . . . . . . . . . . . . . . . . . . . 340

Legionella . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Cooling Towers . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Hot Water Systems . . . . . . . . . . . . . . . . . . . . . . . . 341

Operator Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Protection from Physical Damage . . . . . . . . . . . 343

Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Design and Construction Errors . . . . . . . . . . . . . . . . . 345

Drawing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Interferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Contractor Errors . . . . . . . . . . . . . . . . . . . . . . . . . 346

Chapter 16 Special Services 347

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Capacity of Natural Gas Pipelines . . . . . . . . . . . 348

Sealing Natural Gas Threaded Connections . . . 348

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Instrument Air . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Oxy-Fuel Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Hydrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Pigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Chapter 17 Infrastructure 355

Infrastructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Rehabilitation and Replacement of Pipelines . . 357

Energy Considerations . . . . . . . . . . . . . . . . . . . . . . . . 359

Centrifugal Machines . . . . . . . . . . . . . . . . . . . . . . 359

Compressed Air Systems . . . . . . . . . . . . . . . . . . . 359

Water Conservation . . . . . . . . . . . . . . . . . . . . . . . 360