Basics of Piping PDF

Introduction to Process Piping
Piping in a process plant is just like blood veins in human body

NationalInstituteofDesign&Analysis,Lahore
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Basics of Piping
Interaction Between Piping and Other Departments
Basics of piping
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Broad Responsibilities of Piping Engineer

Receive / Study basic engineering package Receive / Study equipment plan, P&ID, Specification Prepare General Plot Plan of all facilities Prepare Layouts of each individual Units Prepare underground coordination plan Prepare Piping study Drawings Prepare Piping Plans /Layouts Prepare Piping Specifications Prepare Piping design / stress Analysis / support systems. Prepare M.T.O. (B.O.M.) for pipes / pipe fittings /Valves etc. Prepare Piping ISO-Metrics
Basics of piping
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Piping Fundamentals
Let us first Discuss about WHAT IS PIPE! It is a Tubular item made of metal, plastic, glass etc. meant for conveying Liquid, Gas or any thing that flows. It is a very important component for any industrial plant. And its engineering plays a major part in overall engineering of a Plant. In next few pages we shall try to familiarize about pipe and its components.
Basics of Piping
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Piping Fundamentals
In any plant various fluids flow through pipes from one end to other. Now let us start with a plant where we see three tanks. Tank-1, Tank-2 and Tank-3 We have to transfer the content of Tank no. 1 to the other two tanks. We will need to connect pipes to transfer the fluids from Tank-1 to Tank-2 and Tank-3
LET US BRING THE PIPES.
Basics of Piping
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Piping Fundamentals
To solve these problems we need the pipe components, which are called PIPE FITTINGS Basics of Piping
We need some branch connections We need some bend connections We have just brought the pipes, now we need to solve some more problems. Pipes are all straight pieces.
Piping Fundamentals
These are the pipe fittings, There are various types of fittings for various purposes, some common types are Elbows/Bends, Tees/Branches, Reducers/Expanders, Couplings, Olets, etc.
Anyway, the pipes and fittings are in place, but the ends are yet to be joined with the Tank nozzles.
We now have to complete the end connections. These, in piping term, we call
TERMINAL CONNECTIONS.
Basics of Piping
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Piping Fundamentals
So far this is a nice arrangement. But there is no control over the flow from Tank-1 to other tanks. We need some arrangement to stop the flow if needed
These are flanged joints This is a welded joint
To control the flow in a pipe line we need to fit a special component. That is called - VALVE
Basics of piping
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Piping Fundamentals
There are many types of valves, categorized based on their construction and functionality, Those are - Gate, Globe, Check, Butterfly, etc.
Other than valves another important line component of pipe line is a filter, which cleans out derbies from the flowing fluid. This is called a STRAINER
Basics of piping
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Piping Fundamentals
Here we see a more or less functional piping system, with valves and strainer installed. Let us now investigate some aspects of pipe flexibility.
If this tank nozzle expands, when the tank is hot. In such case we need to fit a flexible pipe component at that location, which is called an
EXPANSION JOINT
Basics of piping
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Piping Fundamentals
When some fluid is flowing in a pipe we may also like know the parameters like, pressure, temperature, flow rate etc. of the fluid.
To know these information we need to install INSTRUMENTS in the pipeline.
Basics of piping
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Piping Fundamentals
Next we shall look into how to SUPPORT the pipe/and its components. There are various types instruments to measure various parameters. Also there are specific criteria for installation of various pipe line instruments.
Basics of piping
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Piping Fundamentals
Here are some of the pipe supporting arrangements. There can be numerous variants. All depend on piping designers preference and judgement.
Let us see some OTHER types of supports
Basics of piping
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Piping Fundamentals
Basics of piping
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Piping Fundamentals
Basics of piping
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Piping Fundamentals
We have just completed a pipe line design. We shall rewind and check how it is really done in practice. First the flow scheme is planned, 1) What, 2) From what point, 3) To which point
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Pipe sizes are selected, pipe material and pipe wall thickness are selected. Types of Valves are planned Also the types of instruments required are planned We represent the whole thing in a drawing which is called Piping and Instrumentation Drawing, in short P&ID
Piping Fundamentals
After the P&ID is ready we start the layout work. Here we carryout pipe routing / layout in Virtual 3D environment. We use 3D Modeling software to route piping in the Plant virtual 3D space. We call this as piping modeling or physical design. While development of piping layout we have to consider the following
Should not hinder any normal passage way. Also should not encroach any equipment maintenance space.
Not Preferable
Preferable
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Piping from source to destination should be as short as possible with minimum change in direction.
Piping Fundamentals
While carrying out pipe routing we also need to consider the following Valves, strainers, instruments on the pipe should be easily accessible. If needed separate ACCESS PLATFORMS to be provided to facilitate these. Desired location and orientation of valves / instruments and other pipe components are to be checked and maintained, like some valves or strainers can only be installed in horizontal position.
Specific requirements of STRAIGHT LENGTH of pipe for some components to be maintained, like for flow orifice we need to provide 15 times diameter straight pipe length at upstream of orifice and 5 times diameter straight at down stream of orifice.
Example of Straight length requirement for Flow Orifice
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Specific requirements for instrument installation to be checked, like temperature gauge can not be installed in pipe which is less than 4 inch in size.
Piping Fundamentals
For Pipeline which shall carry liquid, we have to make sure that all air is allowed to vent out of the line when the line is filled with liquid. To achieve this a VENT connection with Valve is provided at the top most point of the pipeline. Also arrangement is kept in the pipeline so that liquid can be drained out if required.
Pipes are also slopped towards low points.
Let us look into typical Vent and Drain arrangeme nt in a pipeline
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To achieve this a DRAIN connection with Valve is provided at the lowest point of the pipeline
Piping system components
Pipe Fittings ( elbows, reducers, flanges, etc) Gaskets, bolts Valves Pipe support Special items ( e.g. expansion joints)
Basics of piping
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Pipe
Pipe is a tube with round cross section conforming to the dimensional requirements of
Basics of piping
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ASME B36.10M Welded and Seamless Wrought Steel Pipe ASME B36.19M Stainless Steel Pipe
Pipe Selection
How a pipe is selected?

Size Material Thickness Schedule
Basics of piping
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Pipe Calculation
Pipe Material Selection - to select appropriate pipe material based on flowing fluid property. Find out type of Fluid flowing Find out Fluid Temp. & Pressure Check Pipe life Expectancy Select suitable Material per practice (Note1) Check Mat. YES Pipe Listed in Material Design Code OK NO See Note-1
Note-1 : Material is selected per past experience with cost in mind and per material listed in design code. If material is not listed in code we may select next suitable material listed.
Find out Flow volume per second
Check Velocity Allowable per second
Calc. flow area required and Pipe size
Calc. Press. Drop for that Pipe size
Check Press. YES Drop meets Press. Budget NO Increase Pipe Size
Pipe Size OK
Pipe Thickness Selection - to select appropriate pipe thickness based on flowing fluid property. Select Mat. & Diameter as above Find out Fluid Temp. & Pressure Decide on Corrosion allowance Calc. Pipe Thickness per Code Add corrosion allowance & select pipe schedule having thickness >required
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Pipe Sizing Calculation - to select required pipe diameter based on velocity and pressure drop.
Pipe Specification
Pipe Classification Iron pipe size ( approximate internal dia.) Manufacturers weight : NPS +
Schedule Number: NPS+
o
o
5,5S,10,10S,20,20S,30,40,40S,60,80,80S,100,120,140, 160 o A25,A,B,X42,X46,X52,X60,X65,X70
API Designation
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STD XS XXS
Pipe Specification
Pipe:
NPS:
1/8,1/4,3/8,1/2,3/4,1,1,2,3,4,6,8,10, 12,14,16,18,20,24,30,32,36,40,44,48, 52,56,60
NPS 1 ,2 3 ,5 are not used. Pipe is supplied in

Random length ( 17 to 25 ft) Double random length (38 to 48 ft)
Pipe End:
BE (bevel end) PE ( Plain end) Thrd ( Threaded end)
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Common Material Standards
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ASTM A53- Carbon Steel Pipe ASTM A106- Seamless carbon steel ASTM A312- Stainless Steel Pipe API 5L- Line Pipes ASTM A333- Low Temp Carbon Steel.
Fittings Produce change in geometry

Modify flow direction Bring pipes together Alter pipe diameter Terminate pipe Elbow Tee O-Let Weld-O-Let Socket-O-Let Thread-O-Let Flanges Gasket Special Items
Fittings
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Common Fittings include:
Elbows
Elbow:
Used to change direction of pipe.
Types
Forged Elbows : 90 Elbow socket weld 90 Elbows threaded 45 Elbow threaded 45 Elbows socket weld
Fittings
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Elbow
Welded Elbows : 90 Elbows long 45 Elbow long 90 Elbows short 45 Elbows short
Fitting
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Elbow Specification
Size: Same size as that of Pipe Thickness: Same schedule as that of pipe for welded elbow For forged elbow , available ratings are as 2000,3000,6000,9000. Note: forged elbows are used for NPS<2
Fittings
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Branch Connection
Branch connection can be obtained by using
Tee Tee Straight Tee Reducing O-Let Weld-O-Let Socket-O-Let Thread-O-Let
Fittings
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Branch standard connection
Fittings
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Tee
Tee Straight Used when branch size is equal to header size Tee Reducing: Used when branch size is smaller than that of header. Forged tee
Fitting
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Socket welded tee Threaded tee
Welded tee
Specification of tee
Specification of tee are same as that of Elbow. Size of tee is same as that of pipes connected to it Schedule and rating are selected on basis of pipe schedule.
Fitting
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O-Lets
Used when branch size is much smaller compared to header size.
Weld-O-Let: Used when branch connection is butt welded to header. Normally branch NPS 2
Fittings
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Socket-O-Let & Thread-O-Let

Used when branch size is much smaller compared to header size. Used when branch connection is Threaded or socket welded to header. Normally branch NPS < 2
Fitting
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Reducers
Changes the diameter of Pipe. Types
Concentric Reducer
Eccentric reducer
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Specification of Reducer
Size (NPS of Larger end x NPS of Smaller end) Schedule Material
Fittings
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Caps
Used to closed the pipe.
Welded Forged
Fittings
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Flange
A Flange is a method of connecting pipes, valves, pumps and other equipment to form a piping system. It also provides easy access for cleaning, inspection or modification. Flanges are usually welded or screwed into such systems and then joined with bolts.
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Types of Flange
Weld neck flange Socket Weld flange Threaded flange
Flange
Slip On Blind Lap joint Ring type joint
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Flange rating
flange
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Gasket
Sheet Spiral wound Solid metal ring
Fittings
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Resilient material Inserted between flanges Compressed by bolts to create seal Commonly used types
Material Specification List
Material
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Valves
Functions
Block flow Throttle flow Prevent flow reversal Controlling process & Utility service
Valves
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Valves Classification
Valves are classified according to function:
Block Flow (on/off) Regulating ( throttle flow) Checking ( prevent flow reversal) Switching Discharging Manual Hydraulic Motor solenoid
Valves
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Classification according to operating device:
Valves
Ball Valve Gate Valve Glove valve Check Valve Plug Valve Butterfly Valve Needle Valve Relief Valve
Valves
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Ball Valve
Used for On/Off purpose. Advantages:
Low pressure drop, fast operating, bubble-tight shut off.
Disadvantages:
Expensive, heavy, poor throttling
Valve
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Globe Valve
valves
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Globe Valve
Most economic for throttling flow Can be hand-controlled Provides tight shutoff Too costly for on/off block operations Disadvantage: Large pressure drop.
Valves
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Gate Valve
Valves
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Gate Valve
About 75% of all valves in process plant An optimum engineering and economic choice for on/off service. ( isolation valve) Advantage
Small pressure drop across valve
Disadvantage
Poor throttling characteristics
Valves
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Check Valve
Prevent flow reversal Doest not completely shut off reverse flow Available in all sizes, rating, materials Valve type selection determined by
Size limitations Cost Availability service
Valves
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Types of check valve

Swing check valve
valves
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Types of Check Valves
Ball check valve
Valves
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Types of Check Valves
Lift check valve
Valves
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Plug Valve
Used for on/off purpose Required 90Deg turn to operate.
Valves
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Butterfly Valve
Valves
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Butterfly Valve
Used as cutout/isolation valves Advantage:
Quick acting Low pressure drop
Disadvantage
Valve
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Can be used only for low press/ low temp systems due to force involved in valve operation.
Needle Valve
Valve
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Relief Valve
Valves
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Relief Valve
Special type of valve designed to operate automatically ( Self-actuating) in a system overpressure condition. Also called safety valve
valves
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Pipe Supports and restraints

Function of supports and restraints
Transfer load of piping to structure and then ground To ensure that material is not stressed beyond a safe limit Prevent pipe sagging To permit thermal expansion To minimize load on equipment nozzles
Pipe Supports
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Support Selection
Support and restraints selection factors are:
Weight Available attachment clearance Availability of structure steel Direction of loads and/or movement Design temperature Vertical thermal movement at support
Pipe Supports
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Common support types

Anchor Guide Stopper Vertical support
Pipe Supports
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Common support types
Piping Supports
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Pipe Rack
Pipe Supports
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Piping SPEC
It is final guide line for piping engineer All piping component material & type enlisted in it Process data range is given Welding type mentioned.
Piping SPEC
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Piping SPEC
Piping SPEC
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Piping SPEC
Piping SPEC
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Piping Drawing
Piping Drawing
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Piping Drawing
The main purpose of drawing is to communicate information in a simple way for construction apart from specification Three type of drawing are developed from schematic (block flow diagram)
Process flow diagram (PFD) Piping & instrumentation diagram (P&ID) Piping Drawing
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Piping Drawings
Block Flow Diagram

A BFD is a schematic illustration of major process. Block used, represent a unit operation.
BFD
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Process flow diagram
PFD
Process flow diagram

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Process Flow Diagram
PFD
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Piping & Instrumentation diagram
P&ID
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Piping Drawings
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Piping Drawings
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Piping Drawing
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Piping Drawings
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Piping Drawings
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Piping Drawings
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Design
Design
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ASME B31.3
Fluid Service
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ASME B31.3
ASME B31.3
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ASME B31.3
Material
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ASME B31.3
Strength & Temp

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ASME B31.3
Fatigue
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ASME B31.3
Fluid Service
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ASME B31.3
Fluid Service
90
ASME B31.3
Fluid Service
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ASME B31.3
Fluid Service
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ASME B31.3
Operating condition
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ASME B31.3
Load types
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ASME B31.3
Load types
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ASME B31.3
Load types
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ASME B31.3
Stress categorization
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ASME B31.3
Stress categorization
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ASME B31.3
Allowable stress
99
ASME B31.3
Wall thickness correction factor

100
ASME B31.3
Design Pressure
101
ASME B31.3
Design Pressure
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Introduction to Process Piping

Piping in a process plant is just like blood veins in human body

Interaction Between Piping and Other Departments

Broad Responsibilities of Piping Engineer

LET US BRING THE PIPES.

These are flanged joints This is a welded joint

To know these information we need to install INSTRUMENTS in the pipeline.

Let us see some OTHER types of supports

Example of Straight length requirement for Flow Orifice

Pipes are also slopped towards low points.

Let us look into typical Vent and Drain arrangeme nt in a pipeline

Piping system components

How a pipe is selected?

Find out Flow volume per second

Check Velocity Allowable per second

Calc. flow area required and Pipe size

Calc. Press. Drop for that Pipe size

Schedule Number: NPS+

5,5S,10,10S,20,20S,30,40,40S,60,80,80S,100,120,140, 160 o A25,A,B,X42,X46,X52,X60,X65,X70

NPS 1 ,2 3 ,5 are not used. Pipe is supplied in

Common Material Standards

Fittings Produce change in geometry

Common Fittings include:

Branch standard connection

Socket welded tee Threaded tee

Socket-O-Let & Thread-O-Let

Slip On Blind Lap joint Ring type joint

Sheet Spiral wound Solid metal ring

Material Specification List

Classification according to operating device:

Types of check valve

Types of Check Valves

Ball check valve

Types of Check Valves

Lift check valve

Used for on/off purpose Required 90Deg turn to operate.

Pipe Supports and restraints

Common support types

Common support types

Block Flow Diagram

Process flow diagram

Process flow diagram

Process Flow Diagram

Piping & Instrumentation diagram

Strength & Temp

Wall thickness correction factor

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