Piping Systems and Piping Circuits

The following sections describe the process of defining systems and circuits. Piping
systems are defined first and then subdivided into circuits.

Defining Piping Systems

An Inspection Engineer defines piping systems. A Piping System is defined as an
assembly of interconnected piping built to the same design code and containing the same
or similar process stream. Piping systems include the piping associated with multiple
pieces of fixed process equipment. Piping systems start and stop at pieces of fixed
equipment that affect the chemical composition of the process stream. Process piping is
defined and identified on PFDs and P&IDs to organise piping into manageable segments
as an initial step in the development of a criticality based inspection program.

Basic information needed to define piping systems includes:

 One copy each of the P&IDs and PFDs
 The battery limits/boundaries of the process unit
 The list of covered processes to be included in the work scope
 Material balance sheets that include the list of the chemical composition of
various process streams within the unit.
 Unit process description

Steps to Define Piping Systems:

1. Obtain a current copy of the PFDs, P&IDs, and Material Balance Sheet for
the unit you are working on. If material balance sheets are not available,
obtain a process description from the process engineer or operations. The
process description can be verbal if a written description is unavailable. If
the process description is verbal, information should be recorded and
maintained for reference.
2. Using the material balance sheet or process description as a reference,
select a particular process stream and determine if it is included in the P-
RBI program’s scope of work.
3. Once you have resolved that a process stream is included in the scope of
work, review the PFD to determine the extent of the piping on that PFD.
Process streams, and consequently piping systems, usually start and stop at
major pieces of equipment such as towers, columns, and reactors, etc.
4. Highlight the piping that includes the process stream on the PFD using
unique colour schemes or cross-hatching to distinguish that process stream
from other process streams within the same unit. Some process streams
originate in one unit and terminate in a different unit. As a rule, piping
systems will “belong” to the unit where the piping system originates.
5. Record each System ID on the piping System/Circuit Identification Log
listing a unique identifier, the system ID number, and the system
description. The unique identifier is the representative colour scheme or
cross-hatching used to identify the system on the P&ID. The system ID
 number is the number that will identify the system separately from the
other piping systems in the database and on reports. Define the system ID
using the format XXYY where XX is a unique identifier for the process
unit and YY is a sequential number identifying different process systems.
Example: 1301 (The first piping system within Unit
13)
6. Enter a system description on the Piping System Identification Log. The
system description is a short narrative description of the system that
includes the name of the process stream, the starting point of the system,
and the termination point of the system. Example: Treated Ethane from
(V-1) Contactor to (V-2) Scrubber
7. Record the System ID on the PFD.
8. Repeat steps 2 through 7 until all process piping within the unit and
included in the scope of work is uniquely identified on the PFD and
recorded on the system ID Log.
9. Using the PFD as a reference, select a specific piping system. Locate the
initiation point on the P&IDs. Identify the piping system on the P&IDs
with the same unique identifier used on the PFDs. Keep in mind that
P&IDs usually have more piping lines on them than those indicated on the
PFDs (i.e., bypass lines, small bore branch connections, etc.). When
identifying these additional lines, always stop the system at a piece of
equipment or at a block valve if the system ties into another piping system.
Record the System ID on the P&IDs and record the starting P&ID number
for the piping system on the Piping System/Circuit Identification Log.
10. Repeat step 9 until all process piping within the unit and included in the
scope of work is uniquely identified on the P&ID. In some cases, there
will still be piping represented on the P&IDs that has not been identified
as belonging to a piping system. Review these lines to determine if they
connect piping systems that have already been identified. All piping
included in the scope of work should be uniquely identified. Highlight
these lines appropriately and break the system at a valve or other piece of
equipment.
11. Evaluate the remaining lines that have not been identified to determine if
the process fluids that they contain are included in the P-RBI scope of
work. Assistance from operations or process engineering may be required
to determine what the process streams contain. If additional process
streams within the project scope of work are found, identify these
additional systems using the instructions outlined above.
12. Review the P&IDs one final time to ensure that all-applicable process
piping has been identified in a piping system.
13. File and maintain these P&IDs in the piping section of the appropriate unit
equipment files.

Defining Piping Circuits

An Inspection Engineer defines piping circuits. Piping circuits are defined as sections of
continuous piping exposed to an environment of similar internal corrosivity, similar
operating conditions, and similar materials of construction. Piping circuits are defined
and identified on P&IDs to organise the piping into manageable segments as an
intermediate step in the development of a criticality based inspection program.

The piping circuit ID will be used as a reference for all P-RBI related activities associated
with the piping included in the piping circuit (i.e., the Circuit ID becomes the equipment
ID).
The information needed to define piping circuits includes:
 A set of P&IDs or flow diagrams identifying the individual piping systems
 Operating temperatures and pressures for the fixed equipment included in the
piping systems
 Piping specifications which identify materials of construction for the piping in the
unit

Steps to Define Piping Circuits:

1. Obtain the systemized P&IDs and the System Identification Log for the
unit you are working on. All piping highlighted on the systemized P&IDs
will eventually be included in a piping circuit.
2. From the System Identification Log, select one piping system to work on
and note how it is identified on the systemized P&IDs. Review the piping
system on the systemized P&IDs to determine its extent, specifically
noting the fixed equipment included in the piping system, any changes in
piping specification, and any potential injection point locations. Piping
circuits start and stop at the following locations:
 Fixed equipment including towers, columns, reactors, tanks,
drums, heat exchangers, air coolers, furnaces, and filters
 Rotating equipment including pumps, turbines, and compressors
 Locations where the material of construction changes
 Injection points
 Block valves where the piping system ties into another piping
system
 Control valves where the pressure differential is greater than 50
psig.
Note: Flare and drain systems may be started and stopped at different
header’s to subdivide them into manageable circuits.
3. With a red pen on a clean set of P&IDs draw a line perpendicular to the
pipeline at each spec break where there is a change in the material of
construction. You will have to review the customer’s piping specification
to determine where these materials of construction changes occur. A
change in pipe specs without a material change, (i.e., going from Schedule
40 Carbon Steel to Schedule 80 Carbon Steel), does not constitute a circuit
change and should not be marked on the P&IDs.
4. Review the piping system and circle in red ink on the clean set of P&IDs,
any injection points that are included in the system. Occasionally,
injection points are not identified on the P&IDs. Under these
 circumstances, consult with the process engineer or operations
representative to determine where injection points are located within the
unit.
5. Determine the starting point of the piping system on the systemized
P&IDs. This will also become the starting point for the first piping circuit.
Highlight the piping on the clean set of P&IDs from the starting point of
the system to the next piece of fixed equipment, material of construction
change, or injection point location using unique colour schemes or cross-
hatching to distinguish that piping circuit from other piping circuits within
the same piping system. This highlighted line will represent the basic
extent of the piping circuit.
6. Review the highlighted piping circuit to determine if any branch
connections are attached. Highlight all branch connections with the same
unique identifier it is attached to until you reach the next block valve fixed
equipment item, material of construction change, or injection point. Note:
If a circuit terminates at a valve, the valve is included with the “upstream”
circuit.
7. The System ID/Circuit ID is a five-character alphanumeric that will
identify the circuit separately from other piping circuits, and essentially
serve as the equipment ID. Define the System ID/Circuit ID using the
format XXYYZ where XXYY is the System ID that has already by
defined, and Z is a letter from A to Z which differentiates it from other
piping circuits within the same facility. Confirm the System/Circuit ID
convention with the client to ensure that it fits with the way they do their
business. Note: Do not use the letters “i” and “o” for Circuit ID because
they are easily confused with numbers.
8. Record the System ID and Circuit ID on the P&IDs at the starting point,
ending points, and any other point in between that will make it easy to
identify. Note: Also record any connecting System IDs on the Circuit
P&IDs.
9. Record the Circuit ID on the Piping Circuit Data Sheet along with the
System ID and the Unit Name.
10. Label injection point circuits with: ‘Injection Point Circuit” on the P&IDs,
as they can occasionally appear to start and stop at unidentifiable locations
on the P&ID. API 570 specifically identifies the minimum upstream and
downstream limits of injection point circuits. The upstream limits of an
injection point circuit are 12 inches or 3 pipe diameters upstream,
whichever is greater. The downstream limits of an injection point circuit
are at the second change in flow direction past the injection point, or 25
feet beyond the first change in flow direction, whichever is less. The
individual identifying an injection point circuit in the field on an isometric
field sketch should be familiar with these limits so that the circuit limits
are established properly.
11. Starting at the termination point of the previous circuit, repeat steps 5.0
through 9.0 until all process piping included in the system as defined on
the systemized P&IDs in included in a piping circuit. In some cases, there
 will still be piping represented within a piping system on the systemized
P&IDs that has not been identified as being a part of a piping circuit.
Review these lines on the systemized P&IDs to determine if they connect
to other piping circuits or other piping systems and highlight these lines
appropriately. All piping highlighted on the piping system should be
included in a piping circuit.
12. After identifying all of the piping circuits included in a specific piping
system, record all of the applicable circuit designations (A-Z) for that
system under the Circuit ID column on the Piping System/Circuit
Identification Log.
13. Repeat steps 2 to 12 until all process piping highlighted on the systemized
P&IDs is included in a piping circuit. Each time you begin a new piping
system; a clean set of P&IDs should be used.
14. Upon completion of the unit, compare the Circuit P&IDs for each piping
system with the systemized P&IDs to verify that all applicable process
piping in each piping system is included in a piping circuit.
15. If the client has authorized piping visuals, then field verification will be
done at the same time as the visuals. If visual inspection will not be
performed, then field verify the piping circuits before completing the
tracking list.
16. File and maintain the Circuit P&IDs in the piping section of the
appropriate unit equipment files.

Developing Tracking Lists

Tracking lists are developed to:
 Identify equipment items included in the project scope
 Provide a quick reference identifying tasks to be performed, tasks
completed and incomplete tasks for planning/organizing on-site
work and for progress reporting.