CM4120

Piping Systems
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Piping Systems in the Chemical Process

Industries part 1
March, 2009
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Introduction
Basis for Design
Piping Codes and Standards
Design of Process Piping Systems

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Piping systems are like arteries and veins. They

carry the lifeblood of modern civilization.
Mohinder Nayyar, P.E.
Piping Handbook, 7th ed.
McGraw-Hill, 2000

Earliest piping systems:

Aqueducts
Hollow-Log Piping
Facilitated growth of ancient
civilizations.

So, it was the ChemEs!

Not the
MEs!

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Piping Systems include:

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Pipe, Flanges, Fittings

Bolting, Gaskets
Valves
Hangers and Supports
Insulations, Coverings, Coatings
Heat Tracing

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Primary Design Consideration is Safety

y Evaluate Process Conditions
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Temperature
Pressure
Chemical compatibility/Corrosion allowances
Vibration, flexing, bending
Expansion/Contraction due to temperature change
Environmental conditions

y Evaluate the Effects of a Leak

y Evaluate Performance in a Fire Situation

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Secondary Considerations
y Evaluate any Special Requirements
{ Sanitary requirements Cleanability
{ Serviceability ease of maintenance of equipment
{ Possible contamination of process fluid by piping
materials, sealants, or gasketing
{ Earthquake, Hurricane, Lightening, Permafrost
y Lowest Cost over the Lifetime

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Piping System Routing and Layout

The unwritten #1 rule:

Serviceability/Operability

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Piping System Design Criteria

4 areas to consider:
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Physical Attributes
Loading and Service Conditions
Environmental Factors
Materials-Related Considerations

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Codes and Standards simplify design,

manufacturing, installation process
y Standards provide design criteria for

components
standard sizes for pipe
{ dimensions for fittings or valves
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y Codes specific design/fabrication

methodologies
Incorporated into local/regional statute
{ Its the LAW
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y ASME Boiler and Pressure Vessel Code

y ASME B31: Code for Pressure Piping
y ANSI Standards dimensions for valves,

piping, fittings, nuts/washers, etc.

y ASTM Standards for piping and tube
y API Specs for pipe and pipelines
y AWS, ASHRAE, NFPA, PPI, UL, etc.

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ASME B31 Pertinent sections

y B31.1 Power plant boilers
y B31.3 Chemical plant and refinery piping
y B31.4 Liquid petroleum transport
y B31.7 Nuclear power plant radioactive fluids

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ASME B31.3 Chemical Plant and Refinery

Piping Code
Includes piping systems in:
y Chemical and refinery plants
y Pharmaceutical and food processing
y Textile and paper plants
y Boilers

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ASME B31.3 covers:

y Materials of construction
y Piping design process
y Fabrication, Erection, Assembly
y Design of supports
y Examination, inspection, and testing

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Piping Design Process a three step approach

1. Design for Flow
{ Find min. diameter to achieve desired flow velocity
2. Design for Pressure Integrity
{ Find min. wall thickness for process and external
conditions
{ Find appropriate rating of in-line components
3. Re-check for Flow Criteria

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Standard Pipe Sizes

Diameters are Nominal

Sizes 12 and less, nominal size < OD

{ Sizes 14 and over, nominal size = OD
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Wall thickness inferred thru Schedule

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Defined Schedules:
5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160

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What is Pipe Schedule?

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Schedule = P/S * 1000

P = max. working pressure of pipe, psig
S = allowable stress in piping material, psi
For carbon steel pipe, S = 36,000 psi

What is max. working pressure for Schedule 40 Carbon Steel

pipe?

40 * 36,000
P=
= 1440 psig
1000

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Standard Tubing Sizes

y Steel tubing
{ Diameters are Actual OD
{ Wall thickness is specified
y Refrigeration Tubing
{ Single wall thickness available for each size
{ Actual OD
y Copper Tubing Nominal sizes
{ Type K, L, M

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Criteria for Design for Flow

y Economics
Serviceable over Design Life
Smallest diameter usually is lowest cost
y Performance
Minimum entrainment velocity
Prevent erosion or cavitation

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Design Rules of Thumb when sizing for velocity...

Water lines: 3-10 ft/sec
Pump discharge: 3-12 ft/sec
Pump suction: (1/3 x discharge velocity)
Steam: low pressure (25 psig or less) 50-100 ft/sec
high pressure (>100 psig) 100-200 ft/sec
Slurries: > min. entrainment velocity
from Peters and Timmerhaus, Plant Design and Economics for
Chemical Engineers, 4th ed., McGraw-Hill, 1991.

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Materials Metallic piping

Carbon and low alloy steel

Ductile
{ Inexpensive and available
{ Easy to machine, weld, cut
{ Some drawbacks
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Materials Metallic piping

Alloy Steels including Stainless Steels

Good corrosion resistance

{ More difficult to machine, weld, cut
{ Some drawbacks
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Materials Metallic piping

Nickel, Titanium, Copper, etc.

Copper is used in residential and commercial

applications and is widely available
{ Other materials are expensive and difficult to
machine, weld, join
{ Some incompatibilities with each
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Materials Non-Metallic piping

Thermoplastics

Wide range of chemical compatibility

{ Light weight
{ Easily cut and joined
{ Low temperature limits
{ Need extra supports
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Materials Non-Metallic piping

Fiberglass Reinforced Pipe

Wide range of chemical compatibility

{ Easily cut and joined
{ Wider temperature limits than thermoplastics
{ Thermal expansion similar to carbon steel
{ Similar structural performance as carbon steel
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Materials Others
Glass
Concrete
Lined or coated
Glass
Rubber
Cement
Teflon
Zinc (galvanized pipe)

Double Containment piping systems

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Pipe Joints
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Threaded
Welded
Soldered/ Brazed
Glued
Compression
Bell and spigot
Upset or expanded

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Threaded joints

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Soldered joints

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Welded joints

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Compression joints

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Mechanical joints
shown on glass drain piping system

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Fittings for joining 2

sections of pipe:
Coupling
Reducing Coupling
Union
Flange

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Fittings for changing

directions in pipe:
45o Ell
90o Ell
Street Ell

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Fittings for adding

a branch in a run
of piping:
Tee
Cross

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Fittings for blocking

the end of a run of
piping:
Pipe plug
Pipe cap
Blind Flange

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Misc. pipe fittings:

Nipple
Reducing bushing

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Gate Valve:
Used to block flow
(on/off service)

Sliding gate
on knife-gate
valve

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Globe Valve:
Used to regulate
flow
Cut-away shows
stem seal
plug
and seat

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Ball Valve:
Typically used as
block valve
Quarter-turn valve
Cut-away shows ball
and seat

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Butterfly Valve:
Can be used for
flow control or
on/off
Valve actuator/
positioner for
accurate flow
control

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Check Valves:
Used to prevent
backflow
Piston check
Swing check