BASIC CONCEPT OF PIPING ENGINEERING

PIPING DESIGN FUCTION IN ORGANIZATION

The size and scale of company or design office do not change either the basic piping design requirements or the underlying design principles and practices.
As the volume of piping design work and the number of projects executed increases, so also does the degree of specialization increase.

Functions such as Piping layout, Piping Specifications, Detail Drafting, 3D Modeling and Material Take Off (MTO) emerges as separate departments within the design office.

PROCESS PROJECT CONSTRUCTION CIVIL

QUALITY

INSPEC

PIPING

ELECT

FIELD ENG.

EQUIP/VESSEL

MATERIAL CLIENT

INST.

PIPING

PIPING includes pipe, flanges, fittings, bolting, gasket, valves and the pressure containing portion of other piping components. It also includes Pipe hangers and supports and other items necessary to prevent over-pressurization and over stressing of the pressure-containing components. When the pipe sections joined with fittings, valves and other mechanical equipment and properly supported by supports are called PIPING. Pipe having round cross section confirming to the dimensional requirement according to

PIPE

ASME B 36.10 Welded and Seamless Wrought Steel Pipe ASME B 36.19 Stainless Steel Pipe PIPE SIZE
Initially a system known as Iron Pipe Size (IPS) was established to designate the pipe size. Size represents the approx. inside dia. Of pipe in inches. In the beginning each pipe size was produced to have one thickness, which later was termed as Standard (STD) or Standard Weight(STD WT.)

As the industrial requirements demanded the handling of higher-pressure fluids, pipes were produced having thicker wall, which came to be known as Extra Strong (XS), double extra strong (XXS) walls while the standardized out side diameters are unchanged

PIPE SIZE

Con.

With the development, stronger and corrosion-resistance piping materials, the need for thinner wall pipe resulted in new method of specifying pipe size and wall thickness. The designation known as Nominal pipe Size (NPS) replaced IPS term schedule (SCH) was invented to specify the nominal wall thickness of pipe. Nominal pipe Size (NPS) is a dimensionless designator of pipe size. It indicates standard pipe size when followed by the specific size designation number without an inch symbol. The NPS 12 and small pipe has out side diameter greater than the size designator. However, the outside diameter of NPS14 and large pipe is the same as the size designator in inch.

Diameter Nominal (DN) is also a dimensionless designator of pipe size in the metric unit system, developed by the International Standards Organization (ISO). It indicates standard pipe size when followed by the specific size designation number.

PIPE SIZE Cont.

Pipe Size Designators NPS and DN
NPS 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 DN 6 8 10 15 20 25 32 40 50 65 80 NPS 3 1/2 4 5 6 8 10 12 14 16 18 20 DN 90 100 125 150 200 250 300 350 400 450 500 NPS 22 24 26 28 30 32 34 36 38 40 42 DN 550 600 650 700 750 800 850 900 950 1000 1050 NPS 44 48 52 56 60 64 68 72 76 80 DN 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

For sizes larger than NPS 3, determine the DN equivalent by multiplying NPS by 25

 Components include
1. Pipes 2. Fittings 3. Flanges 4. Gaskets 5. Bolting 6.Valves

CODE
A group of general rules or systematic procedures for design, fabrication, installation and inspection prepared in such a manner that it can be adopted by legal jurisdiction and made into law.

STANDARDS
Documents prepared by a professional group or committee which are believed to be good and proper engineering practice and which contain mandatory requirements.

RECOMMENDED PRACTICES
Documents prepared by professional group or committee indicating good engineering practices but which are optional. Companies also develop Guides in order to have consistency in the documentation. These cover various engineering methods which are considered good practices, without specific recommendation or requirements. Codes and standards as well as being regulations, might be considered as design aids since they provide guidance from experts. Each country has its own Codes and Standards. On global basis, American National Standards are undoubtedly the most widely used and compliance with those requirements are accepted world over. In India, other than American Standards, British Standards and Indian Standards are also used for the design and selection of equipment and piping systems.

MAJOR ORGANIZATION FOR STANDARDS

Sr. No.
1.
2. 3. 4. 5.

Country
USA
Canada France United Europe

Organization
American National Standards Institute
Standards Council of Canada Association Francaise British Standards Institute Kingdom Committee of European Normalization

Abbreviation
ANSI
SCC AFNOR BSI CEN

6.
7. 8.

Germany
Japan India

Deutsches Institute fur Normung

Japanese Industrial Standards Committee Bureau of Indian Standards

DIN
JISC BIS

9.

Worldwide

International Organization for Standards

ISO

ISO is a worldwide federation of national standards bodies from some 100 countries, one from each country.

The American National Standards Institutes standards used in the design of the Piping System are as listed. ASME B 31. Code for Pressure piping is at present a non-mandatory code in USA, though they are adopted as legal requirement. 1)ASME B 31.1 2)ASME B 31.2 Power Piping Fuel Gas Piping

3)ASME B 31.3
4)ASME B 31.4 5)ASME B 31.5

Process Piping
Pipeline Transportation System for liquid hydrocarbon and other Liquids Refrigeration Piping

6)ASME B 31.8

7)ASME B 31.9

8)ASME B 31.11
9)ASME B 31.G

Gas Transmission and Distribution Piping Systems. Building Services Piping Slurry Transportation Piping Systems Manual for determining the remaining strength of corroded piping -A supplement to ASME B31.

Of the above, the most commonly used code is ASME B31.3. Refineries and chemical plants are designed based on the same. All power plants are designed as per ASME B31.1.

Metallic

Non-Metallic

Lined
MS PP Lined MS PVDF Lined MS MS Cement Lead Lined Lined MS FRP Ceramic PP Lined Lined

Ferrous Materials

Non-Ferrous Materials

MSGL MSRL

MS PTFE Lined

Copper + Copper Alloys

Aluminium + Aluminium Alloys

Nickel + Nickel Alloys

Lead

Cast Iron

Carbon Steel

Alloy Carbon Steel

Stainless Steel

Special Alloys

PVC CPVC

PP

HDPE UHMW-HDPE FRP PTFE LDPE

LLDPE Glass Ceramic

Cement

FIGURE 1.1
PIPING ELEMENTS CLASSIFICATION BASED ON MATERIAL OF CONSTRUCTION

Metallic

Ferrous Materials

Non-Ferrous Materials

Copper + Copper Alloys

Aluminium + Aluminium Alloys

Nickel + Nickel Alloys

Lead

Cast Iron

Carbon Steel

Alloy Carbon Steel

Stainless Steel

Special Alloys

Pipe Ends Based on the material of construction and the pipe to pipe joint, the ends of the pipes are specified as follows. Bevelled ends Plain ends Screwed ends Flanged ends Spigot/Socket ends

Buttress ends

Types Of Pipes Based on the method of manufacture pipes could be classified as; Seamless Welded o o o o o Electric Resistance Welded (ERW) Electric Fusion Welded (EFW) Spiral Welded Furnace Butt welded Double Submerged Arc Welded

Forged and Bored

1. 2. 3.

4. 5. 6.

7.

Pipe Materials ASTM A53 : Welded and Seamless Steel Pipe Black and Galvanized ASTM A106 : Seamless CS Pipe for High Temp. Services ASTM A120 : Black and Hot Dipped Zinc coated (Galvanized) welded and seamless pipe for ordinary use ASTM A134 : Electric fusion welded steel plate pipe (Sizes 16 NB) ASTM A135 : Electric resistance welded pipe ASTM A155 : Electric fusion welded steel pipe for high temperature service ASTM A312 : Seamless and welded Austenitic stainless steel pipes

8.

9.

10.

11.

12.

ASTM A333 :Seamless and welded steel pipe for low temperature service ASTM A335 :Seamless ferric alloy steel pipe for high temperature service ASTM A358 : Electric fusion welded Austenitic chrome-nickel steel pipe for high temperature service ASTM A369 : Carbon and ferric alloy steel forged and bored for high temperature service ASTM A376 : Seamless austenitic steel pipe for high temperature central station service

13. ASTM A409 :

14. ASTM A426 :

15. ASTM A430 :

16. ASTM A451 :

17. ASTM A452 :

18. ASTM A524 :

Welded large diameter Austenitic steel pipe for corrosive or high temperature service Centrifugally cast ferric alloy steel pipe for high temperature service Austenitic steel forged and bored pipe for high temperature service Centrifugally cast austenitic steel pipe for high temperature service Centrifugally cast austenitic steel cold wrought pipe for high temperature service Seamless carbon steel pipe for atmospheric and low temperature services

1. IS 1239

2. IS 1536 3. IS 1537 4. IS 1978 5. IS 1979 6. IS 3589 7. IS 4984 8. IS 4985

: : : : : : :

Steel pipes for general purposes (Sizes 6" NB) Centrifugally cast iron pipe Vertically cast iron pipe Line pipe High test line pipe Steel pipe for general services HDPE pipe PVC pipe

END CONNECTIONS
SOCKETWELD SCREWED BUTTWELD FLANGED SPIGOT/SOCKET BUTTRESS

Type

ELBOWS

180o RETURNS

TEES

CROSS

CAPS

REDUCERS STUBENDS COUPLINGS SWAGE NIPPLE UNIONS

SPECIAL FITTINGS

45o

90o

SR.

LR.

EQUAL CROSS

REDUCING CROSS

LONG SHORT STUBENDS STUBENDS

CONCENTRIC ECCENTRIC

ELBOWS ELBOWS

EQUAL TEES

REDUCING TEES

CONCENTRIC REDUCERS

ECCENTRIC REDUCERS

FULL COUPLINGS

HALF COUPLINGS

REDUCING COUPLINGS

LR ELBOWS

SR ELBOWS

WELDOLET

SOCKOLET

THREADOLET

ELBOWLET

SWEEPOLET NIPOLET

LATROLET

FIGURE 2.1 STANDARD PIPE FITTING

PIPE FITTINGS DIMENSIONAL STANDARDS 1. ASME B 16.1 - Cast Iron Pipe Flanges and Flanged Fittings 2. ASME B 16.3 - Malleable-Iron Threaded Fittings 3. ASME B 16.4 - Grey Iron Threaded fittings 4. ASME B 16.5 - Pipe Flanges and Flanged Fittings 5. ASME B 16.9 - Factory-Made Wrought Steel Butt welding Fittings 6. ASME B 16.11 - Forged Fittings, Socket welding and Threaded 7. ASME B 16.28 - Wrought Steel Butt welding Short Radius Elbows and Returns

8.

9. 10. 11. 12.

13.
14.

ASME B 16.42 - Ductile Iron Pipe Flanges and Flanged Fittings BS 1640 - Butt weld Fittings BS 3799 - Socket weld and Screwed end fittings BS 2598 - Glass Pipelines and Fittings IS 1239 Part-II - M.S. Fittings IS 1538 - Cast Iron Fittings MSS-SP-43 - Stainless Steel Fittings

PIPE FITTINGS CLASSIFICATION BASED ON END CONNECTIONS - SOCKET WELD/SCREWED FITTINGS (DIMN STD ASME B16.11/BS 37 99) Classification based on the maximum Cold non-shock Working pressure. a. b. c. d. 2000 # Class only for SCRD fittings 3000 # Class 6000 # Class 9000 # Class only for SW fittings

Class Type of fitting Designation of fitting

Pipe used - Rating based SCH No Wall Designation 80 160 -80 160 -XS -XXS XS -XXS

2000 3000 6000 3000 6000 9000

Threaded Threaded Threaded Socket Welding Socket Welding Socket Welding

Class Type of fitting Designation of fitting

Pipe used - Rating based SCH No Wall Designation 80 160 -80 160 -XS -XXS XS -XXS

2000 3000 6000 3000 6000 9000

Threaded Threaded Threaded Socket Welding Socket Welding Socket Welding

Beveled end fittings are covered under ASME B 16.9, B16-28 and BS 1640. Thickness to suit pipe thickness.

BW FITTING MATERIALS
1. ASTM A 234 - Carbon Steel and Alloy steel pipe fittings

2.
3.

ASTM A 403 - Austenitic Stainless Steel fittings

ASTM A 420 - Alloy Steel for low temperature Services

Flanged fittings are covered under ASME B 16.5 and BS 1650 for carbon and alloy steel piping and ASME B 16.1 for cast iron fittings. FLANGED END FITTING MATERIALS 1. ASTM A 216 - Carbon Steel Castings

2.
3. 4. 5.

ASTM A 351 - Stainless Steel Castings

ASTM A 352 - Alloy Steel Castings ASTM F 1545 - Plastic Lined Fittings IS 1538 - CI Fittings

ELBOWS

45o

90o

Long Radius Return

ELBOWS

ELBOWS

Short Radius 90 degree Elbow (R=1D)

LR ELBOWS

SR ELBOWS

Mitre Bend 90o

90 deg Elbows Socket weld

Elbows - 45o

TEES

EQUAL TEES

REDUCING TEES

Tees Butt weld

CROSS

Tees Socket weld

EQUAL CROSS REDUCING CROSS

Cross

REDUCERS

CONCENTRIC REDUCERS

ECCENTRIC REDUCERS

Concentric Reducer

Eccentric Reducer

STUBENDS

LONG
STUBENDS

SHORT
STUBENDS

CLASS A

CLASS B

Stub End Class A

Stub End Class B

COUPLINGS

FULL COUPLINGS

HALF COUPLINGS

REDUCING COUPLINGS

SWAGE NIPPLE

CONCENTRIC

ECCENTRIC

Concentric Swage Nipple Eccentric Swage Nipple

SPECIAL FITTINGS

WELDOLET

SOCKOLET

THREADOLET ELBOWLET

SWEEPOLET NIPOLET LATROLET

Weldolet

Sweepolet

Sockolet

Thredolet

Latrolet

Elbolet

Nipolet

3.0 FLANGES CLASSIFICATION - BASED ON

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6

BASED ON ATTACHMENT TO PIPE SLIP-ON SOCKET WELD SCREWED ON LAP JOINT WELDING NECK BLIND

Slip-on Raised Face Flange

Socket Welded Raised Face Flange Threaded Raised Face Flange

Lap Joint Flange with Stub End

Welding Neck Raised Face Flange Reducing Slip-on Flange Expander or Reducer Flange

3.2 Based On Pressure-temperature Rating

The flanges are also classified by the pressure temperature rating in ASME B 16.5 as below :
3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 150 # 300 # 400 # 600 # 900 # 1500 # 2500 #

3.3
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

BASED ON FACING
FLAT FACE RAISED FACE RING TYPE JOINT TONGUE AND GROOVE MALE AND FEMALE

Flat Face

Raised Face

Ring Joint

Tongue and Groove Joint

Male / Female Joint

3.4 Based On Face Finish Smooth finish Serrated finish.

The serrations are specified by the number which is the Arithmetic Average Roughness Height (AARH).

3.5 Based On Material Of Construction

Flange Materials :
3.5.1 ASTM A105 - Forged Carbon Steel 3.5.2 ASTM A181 - Forged Carbon Steel for General Purpose 3.5.3 ASTM A182 - Forged Alloy Steel and Stainless Steel 3.5.4 ASTM A350 - Forged Alloy Steel for low temperature services

PARAMETERS FOR SPECIFICATION

1 2 3 4 5 6 7 8 9 BORE/INSIDE DIAMETER - ID - B OUTSIDE DIAMETER - OD - O BOLT CIRCLE/PITCH CIRCLE DIAMETER BCD/PCD No OF BOLT HOLES - N BOLT HOLE DIAMETR - RAISED FACE DIAMETER HUB DIAMETER - X LENGTH THROUGH HUB - Y THICKNESS OF FLANGE - C

10

THICKNESS OF RAISED FACE

GASKETS Proper selection of gasket depends upon following factors. Compatibility of the gasket material with the fluid. Ability to withstand the pressure-temperature of the system. Based on the type of construction, gaskets are classified as: Full Face Inside bolt circle Spiral wound metallic Ring type Metal jacketed

The material which is most commonly used is the Compressed Asbestos Fibre. Indian Standard IS 2712 specifies three different materials at three different grades. IS 2712 Gr W/1, W/2 and W/3 - for Steam, Alkali and general applications. IS 2712 Gr A/1 - for Acid applications. IS 2712 Gr O/1, O/2, O/3 - for Oil applications. Asbestos free gaskets are also available for above applications. For very corrosive applications, PTFE or PTFE enveloped gaskets are used.

For high temperature and high pressure applications, spiral wound metallic gaskets are used. ASME B 16.5 does not recommend the use of 150# rating gaskets on flanges other than welding neck and lapped joint type. The spiral wound gasket will perform when the flange face is 125-250 AARH finish.

Dimensional Standards

API 601

- Metallic Gasket for Refinery Piping

- Metallic Spiral Wound Gaskets

BS 3381

ASME B16.20 - Metallic Gaskets for pipe flanges

ASME B16.21 - Non-metallic Gaskets for pipe flanges

GASKET APPLICATION Based on Manufacturers Technical Publication the following Rule of Thumb is used for selection of Gasket material.
MATERIAL MAXIMUM PxT (PSI x 0F)
15,000 1,25,000 2,50,000 2,50,000

MAXIMUM TEMP (T) (0F)

300 400 850 Depends on type

Rubber Sheet Woven AsbRubberized Sheet Compressed Asbestos sheet Metal Gasket

This Table does not imply that none of these materials listed have ever been used above the Pressure Temp. value shown. The designer should refer Manf. Cat. for the recommended upper temp. limits. The thickness normally selected by piping engineers 2mm for rubber. 2mm for CAF. For 150 & 300 lb flanges. The installation bolt force must seat the gasket properly to withstand the effect of internal pressure. Bolt stress value depend upon the material of constn. of bolt Flange finish could be suitable for the gasket selected. Please find herewith given below cost comparison of various ring gaskets used. As 11/2 size is the most used size, it has been considered for comparison. Sr. No. 1. 2. 3. 4. 5. 6. 7. Type Cost/No.

Acid proof gasket Rs. 13.00 Permanite gasket Rs. 13.00 Ammonia gasket Rs. 10.00 Virgin Teflon gasket Rs. 161.00 Spiral wound (asb.) gasket Rs. 14.00 Spiral wound (grph) gasket Rs. 38.00 Teflon envelope gasket Rs. 110.00

Rate excludes taxes (15.3% ST and 4% octroi)

BOLTING For low pressure, low temperature services, machine bolts are used and studs are used otherwise. Flanged joints using low strength carbon steel bolts shall not be used above 200 oC or below 29 oC Material Of Construction For Bolting Bolting materials normally used are ASTM A 307 - Low Carbon Steel Bolting Material ASTM A 320 - Alloy Steel Bolting material for low temperature service ASTM A 563 - Carbon and alloy steel nuts ASTM A 193 - Alloy Steel Bolting Material for high temperature service ASTM A 194 - Alloy Steel nut material for high temperature service IS 1367 - Threaded steel fasteners