Pipe is a hollow tube with round cross section for the conveyance of products. The products include fluids, gas, pellets, powders and more. The word pipe is used as distinguished from tube to apply to tubular products of dimensions commonly used for pipeline and piping systems. On this website, pipes conforming to the dimensional requirements of: ASME B36.10 Welded and Seamless Wrought Steel Pipe and ASME B36.19 Stainless Steel Pipe will be discussed.
PIPE OR TUBE?
In the world of piping, the terms pipe and tube will be used. Pipe is customarily identified by "Nominal Pipe Size" (NPS), with wall thickness defined by "Schedule number" (SCH). Tube is customarily specified by its outside diameter (O.D.) and wall thickness (WT), expressed either in Birmingham wire gage (BWG) or in thousandths of an inch. Pipe: NPS 1/2- SCH 40 is even to outside diameter 21,3 mm with a wall thickness of 2,77 mm. Tube: 1/2" x 1,5 is even to outside diameter 12,7 mm with a wall thickness of 1,5 mm. The principal uses for tube are in Heat Exchangers, instrument lines and small interconnections on equipment such as compressors, boilers etc..
MATERIALS FOR PIPES
Engineering companies have materials engineers to determine materials to be used in piping systems. Most pipe are of carbon steel (depending on service) and are manufactured to different ASTM standards. Carbon-steel pipe is strong, ductile, weldable, machinable, reasonably durable and is nearly always cheaper than pipe made from other materials. If carbon-steel pipe can meet the requirements of pressure, temperature, corrosion resistance and hygiene, it is the natural choice.
Iron pipe is made from cast-iron and ductile-iron. The principal uses are for water, gas and sewage lines.
Plastic pipe may be used to convey actively corrosive fluids, and is especially useful for handling corrosive or hazardous gases and dilute mineral acids.
Other Metals and Alloys pipe made from copper, lead, nickel, brass, aluminium and various stainless steels can be readily obtained. These materials are relatively expensive and are selected usually either because of their particular corrosion resistance to the process chemical, their good Heat Transfer, or for their tensile strength at high temperatures. Copper and copper alloys are traditional for instrument lines, food processing and Heat Transfer equipment. Stainless steels are increasingly being used for these.
LINED PIPES Some materials described above, have been combined to form lined pipe systems.
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For example, a carbon steel pipe can be internally lined with material able to withstand chemical attack permits its use to carry corrosive fluids. Linings (Teflon, for example) can be applied after fabricating the piping, so it is possible to fabricate whole pipe spools before lining. Other internal layers can be: glass, various plastics, concrete etc., also coatings, like Epoxy, Bituminous Asphalt, Zink etc. can help to protect the inner pipe. Many things are important in determining the right material. The most important of these are pressure, temperature, product type, dimensions, costs etc..
NOMINAL PIPE SIZE
Nominal Pipe Size (NPS) is a North American set of standard sizes for pipes used for high or low pressures and temperatures. The name NPS is based on the earlier "Iron Pipe Size" (IPS) system. That IPS system was established to designate the pipe size. The size represented the approximate inside diameter of the pipe in inches. An IPS 6" pipe is one whose inside diameter is approximately 6 inches. Users started to call the pipe as 2inch, 4inch, 6inch pipe and so on. To begin, each pipe size was produced to have one thickness, which later was termed as standard (STD) or standard weight (STD.WT.). The outside diameter of the pipe was standardized. As the industrial requirements handling higher pressure fluids, pipes were manufactured with thicker walls, which has become known as an extra strong (XS) or extra heavy (XH). The higher pressure requirements increased further, with thicker wall pipes. Accordingly, pipes were made with double extra strong (XXS) or double extra heavy (XXH) walls, while the standardized outside diameters are unchanged. Note that on this website only terms XS and XXS are used.
PIPE SCHEDULE
So, at the IPS time only three walltickness were in use. In March 1927, the American Standards Association surveyed industry and created a system that designated wall thicknesses based on smaller steps between sizes. The designation known as nominal pipe size replaced iron pipe size, and the term schedule (SCH) was invented to specify the nominal wall thickness of pipe. By adding schedule numbers to the IPS standards, today we know a range of wall thicknesses, namely: SCH 5, 5S, 10, 10S, 20, 30, 40, 40S, 60, 80, 80S, 100, 120, 140, 160, STD, XS and XXS. 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. For example, NPS 6 indicates a pipe whose outside diameter is 168.3 mm. The NPS is very loosely related to the inside diameter in inches, and NPS 12 and smaller pipe has outside diameter greater than the size designator. For NPS 14 and larger, the NPS is equal to 14inch.
For a given NPS, the outside diameter stays constant and the wall thickness increases with larger schedule number. The inside diameter will depend upon the pipe wall thickness specified by the schedule number. Summary: Pipe size is specified with two non-dimensional numbers, nominal pipe size (NPS) schedule number (SCH) and the relationship between these numbers determine the inside diameter of a pipe.
Stainless Steel Pipe dimensions determined by ASME B36.19 covering the outside diameter and the Schedule wall thickness. Note that stainless wall thicknesses to ASME B36.19 all have an "S" suffix. Sizes without an "S" suffix are to ASME B36.10 which is intended for carbon steel pipes. The International Standards Organization (ISO) also employs a system with a dimensionless designator. Diameter nominal (DN) is used in the metric unit system. It indicates standard pipe size when followed by the specific size designation number without a millimeter symbol. For example, DN 80 is the equivalent designation of NPS 3. Below a table with equivalents for NPS and DN pipe sizes.
Note: For NPS ! 4, the related DN = 25 multiplied by the NPS number.
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EXAMPLES INSIDE/OUTSIDE ACTUAL
Actual outside diameters NPS 1 actual O.D. = 1.5/16" (33.4 mm) NPS 2 actual O.D. = 2.3/8" (60.3 mm) NPS 3 actual O.D. = 3!" (88.9 mm) NPS 4 actual O.D. = 4.1/2" (114.3 mm) NPS 12 actual O.D. = 12.3/4" (323.9 mm) NPS 14 actual O.D. = 14" (355.6 mm) Below you will find an example of the true inside diameters of a 1 inch pipe. NPS 1-SCH 40 = O.D.33,4 mm - WT 3,38 mm - I.D. 26,64 mm NPS 1-SCH 80 = O.D.33,4 mm - WT. 4,55 mm - I.D. 24,30 mm NPS 1-SCH 160 = O.D.33,4 mm - WT 6,35 mm - I.D. 20,70 mm Such as above defined, no inside diameter corresponds to the truth 1" (25,4 mm). The inside diameter is determined by the wall thickness (WT).
FACTS YOU NEED TO KNOW!
Schedule 40 and 80 approaching the STD and XS and are in many cases the same. From NPS 12 and above the wall thickness between schedule 40 and STD are different, from NPS 10 and above the wall thickness between schedule 80 and XS are different. Schedule 10, 40 and 80 are in many cases the same as schedule 10S, 40S and 80S. But watch out, from NPS 12 - NPS 22 the wall thicknesses in some cases are different. Pipes with suffix "S" have in that range thinner wall ticknesses. ASME B36.19 does not cover all pipe sizes. Therefore, the dimensional requirements of ASME B36.10 apply to stainless steel pipe of the sizes and schedules not covered by ASME B36.19.
TYPES, LENGHTS AND ENDS OF PIPES
Pipe manufacturing refers to how the individual pieces of pipe are made in a pipe mill; it does not refer to how the pieces are connected in the field to form a continuous pipeline. Each piece of pipe produced by a pipe mill is called a joint or a length (regardless of its measured length). In some cases, pipe is shipped to the pipeline construction site as "double joints", where two pieces of pipe are pre-welded together to save time. Most of the pipe used for oil and gas pipelines is seamless or longitudinally welded, although spirally welded pipe is common for larger diameters. Steel Pipes are manufactured in 4 versions:
Longitudinally Welded SAW Spiral Welded Electric Resistance Welded (ERW)
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Seamless
Welded Pipes Welded pipe (pipe manufactured with a weld) is a tubular product made out of flat plates, known as skelp, that are formed, bent and prepared for welding. The most popular process for large diameter pipe uses a longitudinal seam weld. Spiral welded pipe is an alternative process, spiral weld construction allows large diameter pipe to be produced from narrower plates or skelp. The defects that occur in spiral welded pipe are mainly those associated with the SAW weld, and are similar in nature to those for longitudinally welded SAW pipe. Electric Resistance Welded (ERW) and High Frequency Induction (HFI) Welded Pipe, originally this type of pipe, which contains a solid phase butt weld, was produced using resistance heating to make the longitudinal weld (ERW). But most pipe mills now use high frequency induction heating (HFI) for better control and consistency. However, the product is still often referred to as ERW pipe, even though the weld may have been produced by the HFI process.
Seamless Pipe Plug Mill Process
This process is used to make larger sizes of seamless pipe, typically 6 to 16 inches (150 to 400 mm) diameter. An ingot of steel weighing up to two tons is heated to 2,370F (1,300C) and pierced. The hole in the hollow shell is enlarged on a rotary elongator, resulting in a short thick-walled tube known as a bloom. An internal plug approximately the same diameter as the finished diameter of the pipe is then forced through the bloom. The bloom containing the plug is then passed between the rolls of the plug mill. Rotation of the rolls reduces the wall thickness. The tube is rotated through 90 for each pass through the plug mill to ensure roundness. The tube is then passed through a reeling mill and reducing mill to even out the wall thickness and produce the finished dimensions. The tube is then cut to length before heat treatment, final straightening, inspection, and hydrostatic testing.
Seamless Pipe Mandrell Mill Process
This process is used to make smaller sizes of seamless pipe, typically 1 to 6 inches (25 to 150 mm) diameter. The ingot of steel is heated to 2,370F (1,300C) and pierced. A mandrel is inserted into the tube and the assembly is passed through a rolling (mandrel) mill. Unlike the plug mill, the mandrel mill reduces wall thickness continuously with a series of pairs of curved rollers set at 90 angles to each other. After reheating, the pipe is passed through a multi-stand stretch-reducing mill to reduce the diameter to the finished diameter. The pipe is then cut to length before heat treatment, final straightening, inspection, and hydrostatic testing.
Seamless Pipe Extrusion Process
This process is used for small diameter tubes only. The bar stock is cut to length and heated to 2,280F (1,250C) before being sized and descaled. The billet is then extruded through a steel die. After extrusion, the final tube dimensions and surface quality are obtained with a multi-stand reducing mill.
Electric Resistance Welded (ERW) and High Frequency Induction (HFI) Welded Pipe
Originally this type of pipe, which contains a solid phase butt weld, was produced using resistance heating to make the longitudinal weld (ERW), but most pipe mills now use high frequency induction heating (HFI) for better control and consistency. However, the product is still often referred to as ERW pipe, even though the weld may have been produced by the HFI process. The defects that can occur in ERW/HFI pipe are those associated with strip production, such as laminations and defects at the narrow weld line. Lack of fusion due to insufficient heat and pressure is the principal defect, although hook cracks can also form due to realignment of non metallic inclusions at the weld interface. Because the weld line is not visible after trimming, and the nature of the solid phase welding
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process, considerable lengths of weld with poor fusion can be produced if the welding parameters fall outside the set limits. In addition, early ERW pipe was subject to pressure reversals, a problem that results in failure in service at a lower stress than that seen in the pre-service pressure test. This problem is caused by crack growth during the pressure test hold period, which in the case of early ERW pipe was due to a combination of low weld line toughness and lack of fusion defects.
A note about the lack of fusion in ERW weld
As a result of these early problems, ERW pipe was generally regarded as a second-grade pipe suitable only for low pressure applications. However, prompted by a shortage of seamless pipe and the lower cost of ERW pipe, suppliers and end users directed a major effort toward improving the pipe mill quality in the 1980s. In particular, accurate tracking of the weld line by the automatic ultrasonic inspection equipment was found to be crucial, since the weld line can rotate slightly as the pipe leaves the welding station. In addition, the standard of heat treatment of the weld line, which is necessary to ensure good toughness, was found to be important and some specifications call for local weld line heat treatment using induction coils followed by full body normalizing of the whole pipe in a furnace. As a result of these improvements, modern ERW/HFI pipe has much better performance than the traditional product and has been accepted by a number of operators for high pressure gas transmission. Text about types of welded and seamless pipe for this page are coming from: General Electric Company
LENGHT OF PIPES
Piping lengths from the factory not exactly cut to length but are normally delivered as: Single random length has a length of around 5-7 meter Double random length has a length of around 11-13 meter Shorter and longer lengths are available, but for a calculation, it is wise, to use this standard lengths; other sizes are probably more expensive.
ENDS OF PIPES
For the ends of pipes are 3 standard versions available. Plain Ends (PE) Threaded Ends (TE) Beveled Ends (BE) The PE pipes will generally be used for the smaller diameters pipe systems and in combination with Slip On
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flanges and Socket Weld fittings and flanges.
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The TE implementation speaks for itself, this performance will generally used for small diameters pipe systems, and the connections will be made with threaded flanges and threaded fittings.
The BE implementation is applied to all diameters of buttweld flanges or buttweld fittings, and will be directly welded (with a small gap 3-4 mm) to each other or to the pipe. Ends are mostly be beveled to angle 30 (+ 5 / -0) with a root face of 1.6 mm ( 0.8 mm).
STEEL PIPES MANUFACTURING PROCESSES
Introduction
The advent of rolling mill technology and its development during the first half of the nineteenth century also heralded in the industrial manufacture of tube and pipe. Initially, rolled strips of sheet were formed into a circular cross section by funnel arrangements or rolls, and then butt or lap welded in the same heat (forge welding process). Toward the end of the century, various processes became available for the manufacture of seamless tube and pipe, with production volumes rapidly increasing over a relatively short period. In spite of the application of other welding processes, the ongoing development and further improvement of the seamless techniques led to welded tube being almost completely pushed out of the market, with the result that seamless tube and pipe dominated until the Second World War. During the subsequent period, the results of research into welding technology led to an upturn in the fortunes of the welded tube, with burgeoning development work ensuing and wide propagation of numerous tube welding processes. Currently, around two thirds of steel tube production in the world are accounted for by welding processes. Of this figure, however, about one quarter takes the form of so-called large-diameter line pipe in size ranges outside those which are economically viable in seamless tube and pipe manufacturing.
Seamless Tube and Pipe
The main seamless tube manufacturing processes came into being toward the end of the nineteenth century. As patent and proprietary rights expired, the various parallel developments initially pursued became less distinct and their individual forming stages were merged into new processes. Today, the state of the art has developed to the point where preference is given to the following modern high-performance processes: The continuous mandrel rolling process and the push bench process in the size range from approx. 21 to 178 mm outside diameter. The multi-stand plug mill (MPM) with controlled (constrained) floating mandrel bar and the plug mill process in the size range from approx. 140 to 406 mm outside diameter. The cross roll piercing and pilger rolling process in the size range from approx. 250 to 660 mm outside diameter.
Mandrel Mill Process
In the Mandrel Mill Process, a solid round (billet) is used. It is heated in a rotary hearth heating furnace and then pierced by a piercer. The pierced billet or hollow shell is rolled by a mandrel mill to reduce the outside diameter and wall thickness which forms a multiple length mother tube. The mother tube is reheated and further reduced to specified dimensions by the stretch reducer. The tube is then cooled, cut, straightened and subjected to finishing and inspection processes befor shipment.
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* Note: Processes marked by an asterisk are conducted specification and/or customer requirements
Mannesmann plug mill process
In the Plug Mill Process, a solid round (billet) is used. It is uniformly heated in the rotary hearth heating furnace and then pierced by a Mannesmann piercer. The pierced billet or hollow shell is rollreduced in outside diameter and wall thickness. The rolled tube simultaneously burnished inside and outside by a reeling machine. The reeled tube is then sized by a sizing mill to the specified dimensions. From this step the tube goes through the straightener. This process completes the hot working of the tube. The tube (referred to as a mother tube) after finishing and inspection, becomes a finished product.
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Welded Tube and Pipe
Ever since it became possible to manufacture strip and plate, people have constantly tried to bend the material and connect its edges in order to manufacture tube and pipe. This led to the development of the oldest welding process, that of forge-welding, which goes back over 150 years. In 1825, the British ironware merchant James Whitehouse was granted a patent for the manufacture of welded pipe. The process consisted of forging individual metal plates over a mandrel to produce an open- seam pipe, and then heating the mating edges of the open seam and welding them by pressing them together mechanically in a draw bench. The technology evolved to the point where strip could be formed and welded in one pass in a welding furnace. The development of this butt-welding concept culminated in 1931 in the Fretz-Moon process devised by J. Moon, an American, and his German colleague Fretz. Welding lines employing this process are still operating successfully today in the manufacture of tube up to outside diameters of approx. 114 mm. Aside from this hot pressure welding technique, in which the strip is heated in a furnace to welding temperature, several other processes were devised by the American E. Thomson between the years 1886 and 1890 enabling metals to be electrically welded. The basis for this was the property discovered by James P. Joule whereby passing an electric current through a conductor causes it to heat up due to its electrical resistance. In 1898, the Standard Tool Company, USA, was granted a patent covering the application of electric resistance welding for tube and pipe manufacture. The production of electric resistance welded tube and pipe received a considerable boost in the United States, and much later in Germany, following the establishment of continuous hot strip rolling mills for the production of the bulk starting material necessary for large-scale manufacture. During the Second World War, an argon arc welding process was invented - again in the United States - which enabled the efficient welding of magnesium in aircraft construction. As a consequence of this development, various gas-shielded welding processes were developed, predominantly for the production of stainless steel tube.Following the far-reaching developments which have occurred in the energy sector in the last 30 years, and the resultant construction of large-capacity long- distance pipelines, the
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submerged-arc welding process has gained a position of pre-eminence for the welding of line pipe of diameters upward of approx. 500 mm.
Seridium AG SWITZERLAND Piping Products and Systems, Engineering and EPC Contracting D-U-N-S (Dun & Bradstreet): 485622430 www.seridium.com - email: info@seridium.com 11 Electric Weld Pipe Mill
Steel strip in coil, which has been slit into the required width from wide strip, is shaped by a series of forming rolls into a multiple length shell. The longitudinal edges are continously joined by high frequency resistance/induction welding. The weld of multiple length shell is then head treated electrically, sized and cut to specified lengths by a flying cut-off machine. The cut pipe is straightened and squared at both ends. These operations are followed by ultrasonic inspection or hydrostatic testing.
PIPES MATERIALS
ASTM Grades
Dimensions from carbon steel pipes are defined in the ASME B36.10 standard, dimensions for stainless steel pipe are defined in the ASME B36.19 standard. The material qualities for these pipes are defined in the ASTM standards. These ASTM standards, define the specific manufacturing process of the material and determine the exact chemical composition of pipes, fittings and flanges, through percentages of the permitted quantities of carbon, magnesium, nickel, etc., and are indicated by "Grade". For example, a carbon steel pipe can be identified with Grade A or B, a stainless-steel pipe with Grade TP304 or Grade TP321 etc.. Below you will find as an example a table with chemical requirements for fittings ASTM A403 Grade WP304, WP304L, WP316L and a table with frequent Grades, arranged on pipe and pipe-components, which belong together As you may be have noted, in the table below, ASTM A105 has no Grade. Sometimes ASTM A105N is described; "N" stands not for Grade, but for normalized. Normalizing is a type of heat treatment, applicable to ferrous metals only. The
Seridium AG SWITZERLAND Piping Products and Systems, Engineering and EPC Contracting D-U-N-S (Dun & Bradstreet): 485622430 www.seridium.com - email: info@seridium.com 12 purpose of normalizing is to remove the internal stresses induced by heat treating, casting, forming etc..
(A) Carbon 0.040% max. is necessary where many drawing passes are required, as with outside diameter <0.5 inch (12.7 mm), or nominal wall thickness <0.049 inch (1.2 mm). (B) On pierced tube, Nickel may be 11 - 16.00%.
ASTM Grades
Material Pipes
A106 Gr A Fittings
A234 Gr WPA Flanges
A105 Valves
A216 Gr WCB Bolts & Nuts Carbon Steel A106 Gr B A234 Gr WPB A105 A216 Gr WCB
A193 Gr B7 A194 Gr 2H
A106 Gr C A234 Gr WPC A105 A216 Gr WCB
A335 Gr P1
A234 Gr WP1
A182 Gr F1
A217 Gr WC1
A335 Gr P11 A234 Gr WP11 A182 Gr F11 A217 Gr WC6
Carbon Steel Alloy A335 Gr P12 A234 Gr WP12 A182 Gr F12 A217 Gr WC6 A193 Gr B7 High-Temp A335 Gr P22 A234 Gr WP22 A182 Gr F22 A217 Gr WC9 A194 Gr 2H
A335 Gr P5 A234 Gr WP5 A182 Gr F5 A217 Gr C5
A335 Gr P9 A234 Gr WP9 A182 Gr F9 A217 Gr C12
Carbon Steel
A333 GR 6
A420 Gr WPL6
A350 Gr LF2
A352 Gr LCB
A320 Gr L7
Alloy Low-Temp A333 Gr 3 A420 Gr WPL3 A350 Gr LF3 A352 Gr LC3 A194 Gr 7
A312 Gr TP304
A403 Gr WP304
A182 Gr F304
A182 Gr F304
Austenitic Stainless Steel A312 Gr TP316 A312 Gr TP321 A403 Gr WP316 A403 Gr WP321 A182 Gr F316 A182 Gr F321 A182 Gr F316 A182 Gr F321 A193 Gr B8 A194 Gr 8
A312 Gr TP347 A403 Gr WP347 A182 Gr F347 A182 Gr F347
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ASTM Materials Pipes A106 = This specification covers carbon steel pipe for high-temperature service. A335 = This specification covers seamless ferritic alloy-steel pipe for high-temperature service. A333 = This specification covers wall seamless and welded carbon and alloy steel pipe intended for use at low temperatures. A312 = Standard specification for seamless, straight-seam welded, and cold worked welded austenitic stainless steel pipe intended for high-temperature and general corrosive service.
Fittings
A234 = This specification covers wrought carbon steel and alloy steel fittings of seamless and welded construction. A420 = Standard specification for piping fittings of wrought carbon steel and alloy steel for low- temperature service. A403 = Standard specification for wrought austenitic stainless steel piping fittings.
Flanges
A105 = This specification covers standards for forged carbon steel piping components, that is, flanges, fittings, Valves, and similar parts, for use in pressure systems at ambient and higher- temperature service conditions. A182 = This specification covers forged or rolled alloy and stainless steel pipe flanges, forged fittings, and Valves and parts for high-temperature service. A350 = This specification covers several grades of carbon and low alloy steel forged or ring-rolled flanges, forged fittings and Valves for low-temperature service.
Valves
A216 = This specification covers carbon steel castings for Valves, flanges, fittings, or other pressure- containing parts for high-temperature service and of quality suitable for assembly with other castings or wrought-steel parts by fusion welding. A217 = This specification covers steel castings, martensitic stainless steel and alloys steel castings for Valves, flanges, fittings, and other pressure-containing parts intended primarily for high- temperature and corrosive service. A352 = This specification covers steel castings for Valves, flanges, fittings, and other pressure- containing parts intended primarily for low-temperature service. A182 = This specification covers forged or rolled alloy and stainless steel pipe flanges, forged fittings, and Valves and parts for high-temperature service.
Bolts & Nuts
A193 = This specification covers alloy and stainless steel bolting material for pressure vessels, Valves, flanges, and fittings for high temperature or high pressure service, or other special purpose applications. A320 = Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for Low- Temperature Service. A194 = Standard specification for nuts in many different material types