Fabrication and Inspection of Multi-Branch Industrial Piping Manifold Overview: This custom-fabricated multi-branch piping component was manufactured to be integrated into a high-pressure piping system. Its function is to distribute or collect fluid across multiple branches under controlled flow and pressure conditions. 1. Material Selection Material: Carbon Steel (ASTM A106 / A234 or equivalent) Selection based on design pressure, temperature, and fluid properties. All base materials were traceable with Mill Test Certificates (MTC). 2. Fabrication Steps a. Pipe Cutting and Beveling: Pipes were cut to precise angles using CNC plasma cutting. Bevels prepared for full penetration welds. b. Fit-up and Tack Welding: Each segment aligned using jigs and fixtures. Temporary tack welds applied to hold geometry. c. Final Welding: Welded manually or semi-automatically (SMAW/GTAW) by certified welders. Weld passes done in accordance with WPS (Welding Procedure Specification). Interpass cleaning and inspection between passes. d. Flange Installation: Flanges aligned using laser tools. Welded and checked for squareness and bolt circle accuracy. 3. Inspection and Quality Control a. Visual Inspection (VT): Performed after each weld pass. b. Non-Destructive Testing (NDT): Radiographic Testing (RT) for butt joints. Magnetic Particle Testing (MT) for surface cracks. All welds stamped and traceable. c. Dimensional Inspection: Ensured angular accuracy and internal alignment. Checked flange flatness and bolt hole symmetry. 4. Final Assembly and Integration The unit was hydro-tested at 1.5× design pressure. Painted and marked for identification. Integrated into a skid-mounted process module. 5. Inspection Plan Summary (ITP) Step Inspection Type Criteria Hold Point Material ID Visual/MTC Material spec Yes Fit-up Visual Alignment & bevels Yes Welding VT + NDT WPS compliance Yes Final Dim. Measuring tools Tolerances Yes Hydrotest Pressure test No leaks Yes Conclusion: Precision fabrication, stringent inspection, and material traceability ensured that the component meets both ASME B31.3 and project-specific specifications. This type of fabricated manifold is key to optimizing space and flow efficiency in compact industrial systems. This project is part of my professional portfolio. For more technical case studies, follow my page or visit my blog. Presented by Eng. Mohammed Ibrahim Member of the Arab Engineers Union & Professional Engineering Organizations Experience Shared – Knowledge Spread. Experience Shared – Knowledge Spread 🔗 Subscribe: https://www.youtube.com/@consud9033 #PipingEngineering #Welding #QualityControl #Fabrication #Inspection #ASME #EngineeringLeadership

 

Fabrication and Inspection of Multi-Branch Industrial Piping Manifold

Overview:

This custom-fabricated multi-branch piping component was manufactured to be integrated into a high-pressure piping system. Its function is to distribute or collect fluid across multiple branches under controlled flow and pressure conditions.

1. Material Selection

Material: Carbon Steel (ASTM A106 / A234 or equivalent)

Selection based on design pressure, temperature, and fluid properties.

All base materials were traceable with Mill Test Certificates (MTC).

2. Fabrication Steps

a. Pipe Cutting and Beveling:

Pipes were cut to precise angles using CNC plasma cutting.

Bevels prepared for full penetration welds.

b. Fit-up and Tack Welding:

Each segment aligned using jigs and fixtures.

Temporary tack welds applied to hold geometry.

c. Final Welding:

Welded manually or semi-automatically (SMAW/GTAW) by certified welders.

Weld passes done in accordance with WPS (Welding Procedure Specification).

Interpass cleaning and inspection between passes.

d. Flange Installation:

Flanges aligned using laser tools.

Welded and checked for squareness and bolt circle accuracy.

3. Inspection and Quality Control

a. Visual Inspection (VT):

Performed after each weld pass.

b. Non-Destructive Testing (NDT):

Radiographic Testing (RT) for butt joints.

Magnetic Particle Testing (MT) for surface cracks.

All welds stamped and traceable.

c. Dimensional Inspection:

Ensured angular accuracy and internal alignment.

Checked flange flatness and bolt hole symmetry.

4. Final Assembly and Integration

The unit was hydro-tested at 1.5× design pressure.

Painted and marked for identification.

Integrated into a skid-mounted process module.

5. Inspection Plan Summary (ITP)

Step Inspection Type Criteria Hold Point

Material ID Visual/MTC Material spec Yes

Fit-up Visual Alignment & bevels Yes

Welding VT + NDT WPS compliance Yes

Final Dim. Measuring tools Tolerances Yes

Hydrotest Pressure test No leaks Yes

Conclusion:

Precision fabrication, stringent inspection, and material traceability ensured that the component meets both ASME B31.3 and project-specific specifications. This type of fabricated manifold is key to optimizing space and flow efficiency in compact industrial systems.

This project is part of my professional portfolio. For more technical case studies, follow my page or visit my blog.

Presented by Eng. Mohammed Ibrahim

Member of the Arab Engineers Union & Professional Engineering Organizations

Experience Shared – Knowledge Spread.

 Experience Shared – Knowledge Spread

🔗 Subscribe: https://www.youtube.com/@consud9033

#PipingEngineering #Welding #QualityControl #Fabrication #Inspection #ASME #EngineeringLeadership