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dedicated to a project from the bid stage until the design phase has been completed. He or she should also be available during construction and through to mechanical completion. The lead piping material engineer, the individual responsible for all piping engineering functions, usually reports directly to the project lead piping engineer, and depending on the size of the project, the lead piping material engineer may be assisted by a number of suitably qualified piping material engineers especially during the peak period of the project. This peak period is early in the job, while the piping classes are being developed and the first bulk inquiry requisitions are sent out to vendors.
1.5. Experience
There is no substitute for experience, and the piping material engineer should have strengths in several sectors and be confident with a number of others disciplines, to enable the individual to arrive at a suitable conclusion when selecting material for piping systems. Strong areas should include piping design layout and process requirements. Familiar areas should include the following: Corrosion. Welding. Piping stress. Static equipment. Rotating equipment. Instruments.
Both process and utility piping systems operate at various temperatures and pressures, and the following must be analyzed: Fluid typecorrosivity, toxicity, viscosity. Temperature range. Pressure range. Size range.
Method of joining. Corrosion allowance. After analyzing these characteristics, process and utility piping systems can be grouped into autonomous piping classes. This allows piping systems that share fundamental characteristics (pipe size range, pressure and temperature limits, and method of joining) to be classified together. This standardization or optimization has benefits in the procurement, inspection, and construction phases of the project. Too little optimization increases the number of piping classes, making the paperwork at all stages of the project difficult to handle and leading to confusion, resulting in mistakes. Too much optimization reduces the number of piping classes, however, as the piping class must satisfy the characteristics of the most severe service and use the most expensive material. This means that less-severe services are constructed using more-expensive material, because the piping class is "overspecified." It is the responsibility of the piping material engineer to fine-tune this optimization to the benefit the project. A typical oil and gas separation process plant may have 10 process piping classes and a similar number of utility piping classes. Morecomplex petrochemical facilities require a greater number of piping classes to cover the various process streams and their numerous temperature and pressure ranges. It is not uncommon for process plants such as these to have in excess of 50 process and piping classes.
2.2. Writing Specifications for Fabrication, Shop and Field Testing, Insulation, and Painting
It is pointless to specify the correct materials of construction if the pipes are fabricated and erected by poorly qualified labor, using bad construction methods and inadequate testing inspection, insulation, and painting. The piping material engineer is responsible for writing project-specific narratives covering these various activities to guarantee that they meet industry standards and satisfy the client's requirements. No two projects are the same; however, many projects are very similar and most EPC companies have corporate specifications that cover these subjects.
2.3. Creating All Data Sheets for Process and Utility Valves
All valves used within a process plant must have a dedicated valve data sheet (VDS). This document is, effectively, the passport for the component, and it must detail the size range, pressure rating, design temperature, materials of construction, testing and inspection procedures and quote all the necessary design codes relating to the valve. This VDS is essential for the efficient procurement and the possible future maintenance of the valve.
Pipe fittings (seamless and welded)carbon and stainless steel. Valves gate/globe/check (small bore, 1V2 m - and below)carbon and stainless steel. Valves gate/globe/check (2 in. and above)carbon and stainless steel. Ball valves (all sizes)carbon and stainless steel. Special valves (all sizes)non-slam-check valves, butterfly valves. Stud boltingall materials. Gasketsflat, spiral wound, ring type. Special piping items (SPs)strainers, hoses, hose couplings, sight glasses, interlocks, and the like. To get competitive bids, inquiries will go out to several manufacturers for each group of piping components, and they will be invited to offer their best price to satisfy the scope of supply for the requisition. This includes not only supplying the item but also testing, certification, marking, packing, and if required, shipment to the site.
2.6. Reviewing Offers from Vendors and Create a Technical Bid Evaluation
Many clients have an "approved bidders list," which is a selection of vendors considered suitable to supply material to the company. This bidders list is based on a track record on the client's previous projects and reliable recommendations. Prospective vendors are given a date by which they must submit a price that covers the scope of supplies laid out in the requisition. The number of vendors invited to tender a bid varies, based on the size and complexity of the specific requisition. To create a competitive environment, a short list of between three and six suitable vendors should be considered, and it is essential that these vendors think that, at all times, they are bidding against other competitors. Even if, sometimes, vendors drop out and it becomes a "one-horse race" for commercial and technical reasons, all vendors must think that they are not bidding alone. All vendors that deliver feasible bids should be evaluated, and it is the responsibility of the piping material engineer to bring all vendors to the same starting line and ensure that they are all offering material that meets the specifications and they are "technically acceptable," sometimes called "fit for purpose."
Some vendors will find it difficult, for commercial or technical reasons, to meet the requirements of the requisition. These vendors are deemed technically unacceptable and not considered further in the evaluation. The piping material engineer, during this evaluation, creates a bid tabulation spreadsheet to illustrate and technically evaluate all vendors invited to submit a bid for the requisition. The tabulation lists the complete technical requirements for each item on the requisition and evaluates each vendor to determine if it is technically acceptable. Technical requirements include not only the materials of construction and design codes but also testing, certification, and painting. Nontechnical areas also are covered by the piping material engineer, such as marking and packing. The delivery, required on site (ROS) date, is supplied by the Material Control Group as part of the final commercial negotiations. The Procurement Department is responsible for all commercial and logistical aspects of the requisition, and the Project Services Group determines the ROS date and the delivery location. It is pointless to award an order to a manufacturer that is technically acceptable and commercially the cheapest if its delivery dates do not meet the construction schedule. When this technical bid evaluation (TBE) or technical bid analysis (TBA) is complete, with all technically acceptable vendors identified, then it is turned over to the Procurement Department, which enters into negotiations with those vendors that can satisfy the project's technical and logistical requirements. After negotiations, a vendor is selected that is both technically acceptable and comes up with the most competitive commercial/logistical offer. The successful vendor is not necessarily the cheapest but the one that Procurement feels most confident with in all areas. What initially looks to be the cheapest might, at the end of the day, prove more expensive.
2.7. After Placement of a Purchase Order, Reviewing and Approving Documentation Related to All Piping Components
The importance of vendor documentation after placement of an order must not be underestimated. It is the vendor's responsibility to supply support documentation and drawings to back up the material it is supplying. This documentation includes an inspection and testing plan,
general arrangement drawings, material certification, test certificates, and production schedules. All this documentation must be reviewed by the piping material engineer, approved and signed off, before final payment can be released to the vendor for the supply of the material.
not be significant enough to support "on-premises" personnel during the manufacturing phase. Remember that if the wrong material arrives on site, then the replacement cost and the construction delay will be many times the cost of on-premises supervision. If the items concerned are custom-made for the project or they have long lead times (three months or more), then on-premises supervision should be seriously considered.