learnt on piping

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Lessons Learnt
Design & Engineering - Piping
MANIKANDAN BABU
Oct 22, 2022

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Title: Systemized for Steam Tracing Field routed piping
Details : Steam tracing drawings not received from LE.
Causes/Reason : It was difficult to monitor work progress.
Solution: Drawing prepared by LTEH & systemized in Ealps system as
Field routed piping to ease of As built documentation, Material
reconciliation & Erection sequence.
Learning: To be systemized to ease Erection sequence , Material reconciliation & Invoice.
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Victaulic coupling for Galvanized lines in Stick built piping
Details : Stick built drawings were issued as s spool with allowance.
Causes/Reason : Welding is not allowed on Galvanized lines as due to welding inner side of
pipe coating of galvanized removed due to temperature of welding
Solution: Proposed to use Victaulic coupling for Galvanized lines in Stick built piping
Learning: Where Green length has been specified on galvanized lines there Victaulic coupling shall be required at site as
field weld is forbidden in Pipe.
Impact: Victaulic pipe couplings can be installed faster than welding & flanging.
Remarks:
Positive / Negative

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Title: Support drawing prepared from LE Standard
Details : Individual support drawing not received from LE, Complication in
understanding the pipe support fabrication & Erection.
Causes/Reason : LE support standard details includes a combination of 3 to 4
standards of Each support. This leads to tedious to fabricate pipe supports.
Solution: Ident wise drawing prepared to ease of fabrication & Erection.
Learning: Ident wise drawing to be received from client
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Secondary support drawing Preparation
Details : Secondary support drawing not received from LE,
Causes/Reason : Complication in Fabrication & Installation of Sec.
support.
Solution: Snap was prepared from 3D model with combination of
Drg. no + Ident wise. Coordinates provided from near Colum
reference.
Learning: Secondary support drawing to be included in Structural
drawing.
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Piping GA drawing Preparation
Details : : Piping GA drawing not received from LE,
Causes/Reason : Complication in Erection of Piping.
Solution: GA drawing were prepared pancake wise from 3D model
with adequate details.
Learning: Piping GA drawing to be received from client
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Split of Piping Isometric Drawings
Details : Isometric drawings is being issued in smaller Length even for Straight line and Header line.
Causes/Reason : Isometric drawings received from client as splitted more drawings for Straight line / Header line.
Solution: Isometric drawings to be issued as single or minimum for Straight line / Header line
Learning: Drawings to be ensured before Issuing to minimize the field scope/ To be proposed to client to issue drawings as
single or min.
Impact: This leads to extra cost , Material & Delay in Schedule for Increasing field scope. Coordinates issue for branch
lines.
Remarks:
Positive / Negative

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Title: Piping Drawing Preparation - size below 2” lines
Details : Piping Isometric drawing is being issued as Spool drawing for size below 2” lines
Causes/Reason : lot of modification at site, damages of spool & Misplacement of spool
Solution: No spooling required, to be issued as loose item.
Learning: This leads to lot of modification at site, damages of spool & Misplacement of spool.
Impact: Extra cost , Material & Delay in Schedule
Remarks:
Positive / Negative

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Title: Piping Stick built – Welded valve scope
Details : Isometric drawing prepared, valve as erection item for Stick built drawings.
Causes/Reason : Communication mismatch with LE/LTEH
Solution: Scope to be freezed through proper communication from client.
Learning: Stick built welded scope to be finalized / Ensured before issuing drawing.
Impact: This leads lot of rework, extra cost & Delay in schedule.
Remarks:
Positive / Negative

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Title: Painting system & NDT Detail change in CLL
Details : Change in Painting system & NDT details due to frequent revision of Construction Line list by Client
Causes/Reason : Cross checking latest construction line list with older revision for Painting system and NDT details and
incorporating the changes in Isometric drawing and Ealps.
Solution: To be avoided certain time of revision from client. Revision shall be minimum not bulk.
Learning: Construction line list to be finalized from client. To be avoided frequent revision.
Impact: Spool wrongly painted due to discrepancy.
Remarks:
Positive / Negative

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Title: Valve handwheel orientation Missing
Details : Valve handwheel orientation detail missing in Piping Isometric drawing received from client
Causes/Reason : Misunderstanding in valve installation. valve handwheel not matching with Isometric orientation by
default received from vendor.
Solution: Proper valve handwheel orientation detail to be provided from client.
Learning: Valve handwheel orientation to be ensured before issuance of drawing.
Impact: This leads to lot of rework changing the valve handwheel orientation.
Remarks:
Positive / Negative

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Title: Steam tracing scope finalization
Details : Stick built coordination & Routing guidance not provided properly for Lead & tail of steam tracing.
Causes/Reason : Information are not clear from Steam tracing and jacketing schedule document and Specification
Solution: Proper details to be provided from client.
Learning: Lot of rework, Fouling with cable tray and other instrument connection.
Impact: Delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Steam Jacketing Inlet/outlet connection
Details : Steam Jacketing Inlet/outlet connection small bore pipe drawing issued as spool.
Causes/Reason : small bore coordinates & Orientation mismatch with connecting line
Solution: small bore pipe to be issued as loose item/ allowances shall be given in x, y and z directions
Learning: lot of CRW, material waste
Impact: delay in Schedule & cost
Remarks:
Positive / Negative

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Title: Valve orientation VOR & HOR
Details : Some of the welded valve, valve orientation has been mentioned as HOR and
VOR reference like STEM HOR -125 DEG VOR -45DEG
Causes/Reason : It is extremely difficult to understand from drawings
Solution: Orientation to be provided as easy of method for better understanding.
Learning: Wrongly welded valve based on wrong interpretation.
Impact: . Delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Cavity relief Gate Valve Flow direction missing
Details : Cavity relief Gate Valve Flow direction missing in Isometrics.
Causes/Reason : It was missed in LTHE spool isometrics and valves were wrongly welded.
Solution: Valve flow direction to be ensured before issuance of drawing
Learning: Special valve flow direction to be taken care in Isometrics.
Impact: delay in Schedule & cost.
Remarks:
Positive / Negative

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Title: Galvanized line support/ Shear plate welding
Details : Shear plate welding provided in Isometrics as Erection scope for GI pipe & Identified the issue & instructed to
weld shop itself.
Causes/Reason : Shear plate not welded on GI pipe in some of lines
Solution: All welding to be ensured before Galvanizing Drawing to be prepared properly.
Learning: Welding is not allowed on Galvanized lines. All welding to be ensured before Galvanizing
Impact: delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Cut length short in Modified flange connection – Jacketed piping
Details : Cut length short in Modified slip on flange connection - Jacketed piping, welding not met as per code
requirement.
Causes/Reason : Special part shall not be properly customized as per drawing.
Solution: It was identified during early stage of fabrication and resolved.
Learning: Drawing to be checked as per special item dimensional standard.
Impact: This leads to rework of spool & cost
Remarks:
Positive / Negative

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Title: Moment free anchor support at Elbow
Details : Moment free anchor support at elbow - LS 544-01
Causes/Reason : Insertion of pipe to pipe & weld as trunnion, 30deg tap in second
trunnion is too tedious task to complete welding of support
Solution: Result to avoid 2nd trunnion pipe, Extra sch pipe can be added in main pipe of trunnion support.
Learning: Type of support to be changed/ Proposed at Initial stage
Impact: Cost & Time
Remarks:
Positive / Negative

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Title: Piping secondary support drawing
Details : Piping secondary support drawing issued as snapshot for not received from client.
Causes/Reason : Separate secondary support drawing leads to separate erection
sequences.
Solution: secondary support details to be provided in structural drawing.
Learning: Lot of cut & weld activities at work at height lead to more scaffolding access, Erected in pancake itself same can
be completed.
Impact: Extra manhours to Install
Remarks:
Positive / Negative

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Title: Shear plate weld
Details : Shear plate to be welded as Equivalent parent material
Causes/Reason : usage of shear plate discrepancy w.r.t. support specification & Purchase specification. Support spec.
Material – A36/304, as per purchase spec. Equivalent parent material.
Solution: Shear plate to be welded as Parent material
Learning: scope & Procurement material qty to be listed & prior approval will save cost & time.
Impact: wrong welding w.r.t. shear plate & Parent pipe lead to delay in MC and get it approval.
Remarks:
Positive / Negative

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Title: Support shipping attachment
Details : Shipping attachment bolting connection to be done. LS 545-91
Causes/Reason : Drilling hinderance on beam.
Solution: Shipping attachment stich weld to be done with column & beam.
Learning: Drilling hole during erection found hard.
Impact: This leads to extra stich weld, cost & time.
Remarks:
Positive / Negative

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Title: Special item procurement - Support
Details : Delay in Procurement Special item scope confirmation - support
Causes/Reason : usage of special item in piping support consolidated procurement are needs to be done in prior. like SS
plate / PTFE, Puf & Graphite plate etc.
Solution: Pipe support special item MTO to be received from client
Learning: based on client support special item procurement to be finalized earlier.
Impact: delay in schedule
Remarks:
Positive / Negative

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Thank You