PIPING ELEMENTS

Piping elements is defined as any material

required install the piping system.

It includes specifications, material,

components, fabrication, inspection and testing.

PIPING ELEMENTS

PIPES
FITTINGS
FLANGES
GASKETS
BOLTING
VALVES
SPECIALITIES

PIPES

MANUFACTURING PROCESSES

MATERIAL SELECTION

MATERIALS

Classification Based on Manufacturing

Pipe

Seamless pipe

Ferrous pipe materials

Forged pipe

Forged and Bored PIpe

Welded pipe

Ferrous pipe materials

Hollow Forged Pipe

Hot Rotary Piercing

Furnace Welded Pipe

Pilger Mill Process

Fusion Welded Pipe

Push Bench (Cupping) Process

Resistance Welded Pipe

Cast Steel Pipe

Cast Iron Pipe

Centrifugally Cast Pipe

Vertical Pit Process

Cold-Wrought Pipe

Horizontal Process

Centrifugal casting in sand moulds

Centrifugal Casting in Metal moulds

Extrusion Process
High Frequency Induction

Aluminium and its alloy materials

High Frequency Resistance

Horizontal Extrusion Process

Arc Welding Process

Copper and Its alloy materials

Submerged Arc Welding

Hot Piercing Process

Extrusion Process
Cup and Draw Process
Tube Rolling Process
Nickel and its alloy materials

Extrusion Process
Cold Drawing

Titanium and its alloy materials

Extrusion Process

Inert Gas Welding

Spiral Welded Pipe

HOT ROTARY PIERCING

PIERCING MILL

PLUG ROLLING MILL

REELING MILL

SIZING MILL

PILGER MILL PROCESS

PUSH BENCH(CUPPING) PROCESS

EXTRUSION PROCESS

MATERIAL SELECTION CONSIDERATIONS

Piping system material selection considerations are discussed below.

A. Strength
Yield and Tensile Strength

Creep Strength
Fatigue Strength

B. Corrosion Resistance
C. Material Fracture Toughness
D. Fabricability
E. Availability And Cost

A. Strength
A material's strength is defined by its yield, tensile, creep, and fatigue strengths. Alloy content,
material grain size, and the steel production process are factors that affect material

1.0 Yield and Tensile Strength

A stress-strain diagram that is produced from a standard tensile test (Figure ) illustrates the yield and
tensile strengths. As the stress in a material increases, its deformation also increases. The yield
strength is the stress that is required to produce permanent deformation in the material (Point A in
Figure ).
If the stress is further increased, the permanent deformation continues to increase until the material fails. The
maximum stress that the material attains is the tensile strength (Point B in Figure ). If a large amount of strain
occurs in going from Point A to Point C, the rupture point, the material is said to be ductile. Steel is an
example of a ductile material. If the strain in going from Point A to Point C is small, the material is brittle.
Gray cast iron is an example of a brittle material.

SC

Typical Stress-Strain Diagram for Steel Figure 3.1

2.0 Creep Strength

Below about 750F for a given stress, the strain in most materials remains constant
with time. Above this temperature, even with constant stress, the strain in the material will
increase with time. This behavior is known as creep. The creep strength, like the yield and
tensile strengths, varies with temperature. For a particular temperature, the creep strength of a
material is the minimum stress that will rupture the material during a specified period of time.

The temperature at which creep strength begins to be a factor is a function of material chemistry.
For alloy materials (i.e., not carbon steel) creep strength becomes a consideration at
temperatures higher than 750F.

3.0 Fatigue Strength

The term fatigue refers to the situation where a specimen breaks under a load that it
has previously withstood for a length of time, or breaks during a load cycle that it has previously
withstood several times. The first type of fatigue is called static, and the second type is called
cyclic.
One analogy to cyclic fatigue is the bending of a paper clip. The initial bending beyond a
certain point causes the paper clip to yield (i.e., permanently deform) but not break. The clip could be
bent back and forth several more times and still not break. However after a sufficient number of
bending (i.e., load) cycles, the paper clip will break under this repetitive loading. Purely elastic
deformation (i.e., without yielding) cannot cause a cyclic fatigue failure.

The fatigue strength of a material under cyclic loading can then be defined as the ability
to withstand repetitive loading without failure. The number of cycles to failure of a material decreases
as the stress resulting from the applied load increases

B. Corrosion Resistance

Corrosion of materials involves deterioration of the metal by chemical or

electrochemical attack. Corrosion resistance is usually the single most important factor
that influences pipe material selection. Table below summarizes the typical types of
piping system corrosion.

For process plant piping systems in corrosive service, corrosion protection is

usually achieved by using alloys that resist corrosion. The most common alloys used
for this purpose are chromium and nickel. Low-alloy steels with a chromium content of
1% to 9% and stainless steels are used in corrosive environments.

Typical Types of Piping System Corrosion

General or Uniform
Corrosion

Characterized by uniform metal loss over entire surface of material.

May be combined with erosion if material is exposed to high-velocity
fluids, or moving fluids that contain abrasive materials.

Pitting Corrosion

Form of localized metal loss randomly located on material surface.

Occurs most often in stagnant areas or areas of low-flow velocity.

Galvanic Corrosion

Concentration Cell
Corrosion
Graphitic Corrosion

Occurs when two dissimilar metals contact each other in corrosive

electrolytic environment. The anodic metal develops deep pits or
grooves as a current flows from it to the cathode metal.

Occurs when different concentration of either corrosive fluid or

dissolved oxygen contacts areas of same metal. Usually associated
with stagnant fluid.
Occurs in cast iron exposed to salt water or weak acids. Reduces iron
in the cast iron and leaves the graphite in place. Result is extremely
soft material with no metal loss.

C. Material Fracture Toughness

One way to characterize the fracture behavior of a material is the amount of energy
necessary to initiate and propagate a crack at a given temperature. This is the material's fracture
toughness, which decreases as the temperature decreases. Tough materials require a relatively
large amount of energy to initiate and propagate a crack. The impact energy required to fracture a
material sample at a given temperature can be measured by standard V-notch tests.
Various factors other than temperature affect the fracture toughness of a material. These
include the following:
.
Chemical composition or alloying elements.
.
Heat treatment.
.
Grain size.

The major chemical elements that affect a material's fracture toughness are carbon,
manganese, nickel, oxygen, sulfur, and molybdenum. High carbon content, or excessive amounts of
oxygen, sulfur, or molybdenum, hurts fracture toughness. The addition of manganese or nickel
improves fracture toughness.

D. Fabricability
A material must be available in the shapes or forms that are required, and it typically must be
weldable. In piping systems, some common shapes and forms include the following:
.
Seamless pipe.
.
Plate that is used for welded pipe.
.
Wrought or forged elbows, tees, reducers, and crosses.
.
Forged flanges, couplings, and valves.
.
Cast valves.

E. Availability and Cost

The last factors that affect piping material selection are availability and cost. Where there is more than
one technically acceptable material, the final selection must consider what is readily available and
what are the relative costs of the acceptable options. For example, the use of carbon steel with a
large corrosion allowance could be more expensive than using a low-alloy material with a smaller
corrosion allowance.

PIPE FITTINGS
A. Fittings, Flanges, and Gaskets
1.0 Pipe Fittings
Fittings are used to make some change in the geometry of a piping system.
This change could include:
Modifying the flow direction.
Bringing two or more pipes together.
Altering the pipe diameter.
Terminating a pipe.

PIPETYPESFITTINGS
OF PIPE FITTINGS
ELBOWS

45 ELBOW

TEES

CAPS

UNIONS

COUPLINGS

CON.SWAGE

FULL

EQUAL TEE

SWAGE COUPLINGS

STUB ENDS

SPECIAL FITTINGS

REDUCERS

LONG STUB ENDS

OLETS

90 ELBOW

ECC.SWAGE

HALF

REDUCING TEE

EXPANSION BELLOW

SHORT STUB ENDS

STRAINERS

WELDOLET
THREDOLET
SOCKOLET
FLEXOLET
LATROLET
ELBOLET
SWEEPOLET
INSERT WELDOLET
NIPPOLET
BRAZOLET
COUPOLET

REDUCING

SHORT RADIUS LONG RADIUS

END CONNECTION

SOCKET WELD

SCREWED

BUTT WELD

FLANGED

SPIGOT/SOCKET

STEAM TRAPS

ELBOW

REDUCERS

TEES

Pipe Fittings-Standards

ASA B16b1: Cast Iron Pipe Flanges and Flanged Fittings for 800
Psig Hydraulic Pressure

ASA B16b2: Cast Iron Pipe Flanges and Flanged Fittings,25lb

ASA B16.1: Cast Iron Pipe Flanges and Flanged Fittings, Class
125(standard Includes Also Bolt,nut and Gasket Data)

ASA B16.2: Cast Iron Pipe Flanges and Flanged Fittings, Class 250
(Bolt,nut and Gasket Data are also included)

ASA B16.4: Cast Iron Screwed Fittings

ASA B 16.12: Cast Iron Screwed Drainage Fittings
WW-P-491: Pipe Fittings,cast Iron , Drainage
WW-P-501: Pipe Fittings,cast Iron,screwed 125 and 250 Pounds

FLANGES

FLANGES
A flange connects a pipe section to a piece of equipment,
valve, or another pipe such that relatively simple disassembly is possible.
Disassembly may be required for maintenance, inspection, or operational
reasons. Flanges are normally used for pipe sizes above NPS 1.

BASED ON PIPE ATTACHMENT

SLIP ON
SOCKET WELD
SCREWED
LAP JOINT
WELDING NECK
BLIND
INTEGRAL

BASED ON THE FACE OF THE FLANGE

FLANGE FACING
FLAT FACE
RAISED FACE
TONGUE AND GROOVE
MALE ANE FEMALE
RING TYPE JOINT

Flat Face Flanges

Cross section of Flat Face flange

Raised Face Flanges

Cross section of Raised Face flange

Ring Joint Face Flanges

Cross section of Ring Joint Face flange

Male & Female Joint

Cross section of Male & Female Joint

BASED ON PRESSURE-TEMPERATURE RATING

150#
300#
600#
900#
1500#
2500#

FACE FINISH
SMOOTH FINISH
SERRATED FINISH

FLANGE MATERIALS
ASTM A 105
ASTM A 181
ASTM A 182
ASTM A 350

Forged Carbon steel

Forged Carbon steel for general purpose
Forged alloy steel and stainless steel
Forged alloy steel for low temperature
services
ANSI B 16.47/API 605 Higher sizes(above 3)
IS 6392

SELECTION OF FLANGE
A flange type is specified by stating the type of attachment and the type
of face. The type of attachment defines how the flange is connected to a pipe
section or piece of equipment (e.g., welded). The type of flange face or facing
defines the geometry of the flange surface that contacts the gasket.

Flange Rating
ASME B16.5, Pipe Flanges and Flanged Fittings, provides steel flange
dimensional details for standard pipe sizes through NPS 24. Specification of an
ASME B16.5 flange involves selection of the correct material and flange "Class."

Flange Rating
STEPS INVOLVED IN FLANGE RATING

Refer to ASME B16.5 for material specifications and corresponding Material Group
Numbers. Table 1.1A

After the Material Group has been determined, the next step is to select the
appropriate Class. The Class is determined by using pressure/temperature rating
tables, the Material Group, design metal temperature, and design pressure.

Flange material specifications listed in Table 1A in ASME B16.5

SAMPLE PROBLEM 1 - DETERMINE FLANGE RATING

A new piping system will be installed at an existing plant. It is necessary to
determine the ASME class that is required for the flanges.

The following design

information is provided:
.

Pipe Material: 1 Cr Mo.

Design Temperature: 700F.

Design Pressure: 500 psig.

SOLUTION
Determine the Material Group Number for the flanges by referring to ASME
Table 1A. Find the 1 Cr Mo material in the Nominal Designation Steel column. The
material specification for forged flanges would be A182 Gr. F11, and the corresponding
material Group Number is 1.9.
Refer to Table 2 for Class 150. Read the allowable design pressure at the intersection of
the 700F design temperature and Material Group 1.9. This is only 110 psig and is not
enough for this service.
Now check Class 300 and do the same thing. The allowable pressure in this case is 570
psig, which is acceptable.
The required flange Class is 300.

FLANGE LEAKAGES

Uneven bolt stress

Poor flange alignment
Off-center gasket installation
Dirty & damaged flange faces
Thermal shock
Incorrect gasket size
High vibration

BOLTING

MATERIAL FOR CONSTRUCTION OF BOLTING

DIMENENSINAL STANDRADS FOR BOLTS

MATERIALS

ASTM A 307 - Low carbon steel bolting material

ASTM A 320 - Alloy steel bolting material for low
temperature
ASTM A 193 - Alloy steel bolting material for
high temperature
ASTM A 194 - Alloy steel nut material for high
temperature service
IS 1367
- Threaded steel fasteners

STANDARDS

ANSI B 18.2.1 - Square & Hex. Head bolts

ANSI B 18.2.2 - Square & Hex. Nuts
BS 916
- Black bolts & nuts
IS 1367
- Threaded steel fasteners

GASKETS
A gasket is a resilient material that is inserted between the flanges
and seated against the portion of the flanges called the face or facing.
The gasket provides the seal between the fluid in the pipe and the outside,
and thus prevents leakage. Bolts compress the gasket to achieve the seal
and hold the flanges together against pressure and other loadings.

GASKETS

1.
1.
2.
2.

3.
3.

SELECTION
Compatibility of gasket
material with the fluid
Ability to withstand pressure
and temperature of the
system
Corrosion of fluids flowing
through the flanges

CLASSIFICATIONS
Full face
Inside bolt circle
Spiral wound metallic
Ring type
Metal jacketed

MATERIAL STANDARDS

IS 2712,Gr W/1,W/2,W/3 :For steam alkali

general applications

IS 2712 ,Gr A/1

:For acid applications

IS 2712 Gr 0/1, 0/2,0/3

:For oil applications

DIMENSIONAL STANDARDS

API 601
:
API 3381
:
ANSI B 16.20:
ANSI B 16.21:

Metallic gaskets for refinery piping

Metallic spiral wound gaskets
Metallic gaskets for m pipe flanges
Non Metallic gaskets for pipe flanges

VALVES

Ball
Ball valves
valves

Butterfly
Butterfly
valves
valves

Gate
Gate valves
valves

ISOLATION VALVES

Plug
Plug valves
valves

Diaphragm
Diaphragm
valves
valves

Globe
Globe valves
valves

Needle
Needle valves
valves

REGULATION
VALVES

Diaphragm
Diaphragm
valves
valves

Butterfly
Butterfly
valves
valves

Non-return valve

Lift check valve

Swing check valve

Safety valve

Special purpose

Float valve

Foot valve

SPECIAL FITTING
OLETS
E XPANSION BELLOWS
STEAM STRAPS
STRAINER

OLETS
WELDOLET
THREDOLET
SOCKOLET
INSERT WELDOLET
FLEXOLET
BRAZOLET
NIPPOLET
COUPOLET
SWEEPOLET
ELBOLET & LATROLET

WELDOLET
They are economical
butt welded branch connections
with integral reinforcement

Weldolet, an economical
butt-weld branch
connection, is designed to
minimize stress
concentrations and
provide integral
reinforcement.

Thredolet utilizes the

basic Weldolet
configuration,
provides a threaded
outlet branch
connection.

Sockolet utilizes the basic

Weldolet design
configuration and
incorporates a socketweld outlet.

Flexolets Straight Thru Bore design allows for easy clean up of any base welding
penetrating into the I.D. bore by grinding, etc. Flexolet is available in threaded, butt-weld
and socket weld fittings.

Latrolet, used for 45 lateral connections, is available butt-weld to meet the specific
reinforcement requirements, and 3000# or 6000# classes for socket weld and
threaded applications.

Elbolet is used on 90 Long Radius Elbows (can be manufactured for Short Radius
Elbows) for thermowell and instrumentation connections. Available butt-weld to meet the
specific reinforcement requirements, and 3000# and 6000# classes for socket weld and
threaded applications.

Sweepolet is a contoured, integrally reinforced, butt-weld branch connection with a low

stress intensification factor for low stresses and long fatigue life. The attachment weld is
easily examined by radiography, ultrasound and other standard non-destructive
techniques.

Insert Weldolet is another contoured buttweld branch connection used in less

critical applications. Like the Sweepolet,
the attachment welds are easily examined
by radiography, ultrasound and other
standard non-destructive techniques.

Nipolet is a one piece fitting for valve

take-offs, drains and vents.
Manufactured for Extra Strong and
Double Extra Strong applications in 3
1/2" to 6 1/2" lengths. Available with
male-socket-weld or male threaded
outlets.

Brazolet is designed for use with brass or copper

tubing. Available with socket or threaded
connections.

Coupolet fittings are designed for use in fire protection sprinkler systems and
other low pressure piping applications. manufactured with NPT female threads
for 300# service

Exercise
Exercise 1 Determine Required Flange Rating
For the piping system described below, determine the required flange rating (or Class) in
accordance with ASME B16.5.
Pipe:

1 Cr Mo

Flanges:

A - 182 Gr. F11

Design Temperature:

900F

Design Pressure:

375 psig