O©SooaotcQqoo COCO 0 VIT, Pune bes Piping Design, Engineering and Material of ConstructionO° emwooeccooo0o0o0000o oc ooo VIT, Pune Page 2 Contents 1 Piping and Instrumentation Diagram 3-3 2 Introduction to Piping System 4-8 3 Applicable ASME Codes for Piping System 9-11 4 Overview of Piping design in ASME B 31.3 12-16 5 Fundamentals of Pipe Stress Analysis 17-32 6 Selection of Material of Construction 33-44 7 Testing of Piping System 45 - 47 8 Illustrated Examples 48-50 Annexures A. Graphs and Tables B. Code Extracts C. Diagrams, Tables of Steel Metallurgy D. Selection of Gasket Material E. Guideline Tables for Piping Specification F. Drawings of Valves and Pipe FittingsoO cCoegneoo ooo oo ooo O OOO OOOO NDO09 009 VIT, Pune Page 3 CHAPTER 1 Piping And Instrumentation Diagram Drawing is a language of engineers. It is a very powerful tool developed by engineers to communicate the design of a future product’ plant, suggestive modifications, etc. which is in his mind. All the communications, instructions and direction for easy construction becomes very easy and handy if properly drawn. Piping and Instrumentation Diagram (P & ID or PID) is an engineering drawing and such a powerful too! which makes a sound foundation for entire down stream plant engineering. This drawing provides very vital information, such as equipment required, line sizes of process flow lines, utilities required, material of construction, automation philosophy, etc. Based on this information plant (piping) engineer further develops further constructional drawings. Information Provided by P & ID. (One may read / sense the following information from a given P & ID(s). Number of process flow streams Utilities required Line sizes of all Process streams as well all Uti Operational sequence, Fluid flow direction. Basic material of construction of pipes and Equipment Equipment required and their capacities! sizes Insulation requirement Sequence for process stream tapings ‘Automation philosophy Various process controls required and instruments used for those controls Electric / power requirement. ‘Specific requirements about equipment elevations ‘Special requirements of slopes in pipe lines, gravity flow pipe lines, etc Safety precautions considered/ Safety measures assured such as relief valves + Termination of scope, ie. battery limit ies required With all such information mentioned above a plant engineer can now work out the total area required for proposed plant. He may further finalizes the locations of all facilities is side the plant boundary. All the drawings required further for construction of plant, such as equipment layout, can now be developed further.oO BHO S952 545 65 COCSCERESESOSHESESCOOHS VIT, Pune Page 4 CHAPTER 2 Introduction To Piping System What is @ piping system? The piping network installed to convey the fluids required for chemical processes or otherwise between the various equipment and end users and consists of various components such as valves, fittings, online measuring instruments, etc is called as a ‘Piping System’. PIPING COMPONENTS: Mechanical elements suitable for joining or assembly into pressure-tight fluid containing piping systems. Components include pipe, fittings, flanges, gaskets, bolting, valves, and devices such as expansion joints, flexible joints, pressure hoses, traps, strainers, in-line portions of instruments, and separators. 1 Pipe A pipe or a tube is hollow, longitudinal product. °A tube’ is a general term used {for hollow product having circular, elliptical or square cross-section or for that matter cross-section of any closed perimeter. A pipe is tubular product of circular cross-section that has specific sizes and thickness govemed. by particular dimensional standard, Classification: Pipe can be classified based on methods of manufacture or based on their applications. Methods of Manutacture: Seamless pipes are manutactured by drawing or extrusion process. ERW pipes (Electric resistance welded pipes) are formed from a strip which is longitudinally welded along its length. Welding may be by Electric resistance, high frequency. or induction welding, ERW pipes can also be drawn for obtaining required dimensions and tolerances. Pipes in small quantities are manufactured by EFW (Electric fusion welding) process where in instead of electric resistance welding, the longitudinal seam is welded by manual or automatic electric arc process.9° 0 oC o © © o o oC oO eo VIT, Pune Page 6 For the Nominal size up to including 12”, there is one unique O.D. (different from nominal size) and |.D. would vary depending on schedule number. For Nominal sizes 14” and above, 0.D. is same as Nominal size. Schedule No. : Pipes are designated by schedule number or weight designation like Std. (S), Extra Strong (XS) and Double Extra Strong (XXS) Pipe schedule number $ is defined as: Sch. NO. S = 1000 P/S Where P = Internal Pressure (PS!) S = Allowable tensile strength of material used. Common pipe schedules are Sch 40, Sch 80, Sch 120, Sch 160, for larger pipe sizes intermediate schedule numbers (Sch20, Sch 30 etc.) are also employed (Ref. Pipe Dimension Chart) For Carbon steel, Pipe wall thickness tolerance is + 12 %% i.e. Pipe wall thickness can vary 12 %% from thickness obtained from dimension chart. For stainless stecls schedule numbers are designated by suffix S 80S etc. 108, 408, Length: - Pipes are manufactured in ‘random length’ which is + 20’ -0" and in double random length + 40" -0". 2 Fittings Pipe fittings are the components which tie together pipe lines, valves, and other parts of a piping system. They are used in “making up” a pipe line. Fittings may come in screwed, welded, soldered, or flanged varieties and are used to change the size of the line or its direction and to join together the various parte that make Up a piping system. The majority of pipe fittings are specified by the nominal pipe size, type, material and the riame of the fitting. Besides the end connections mentions above (screwed, welded, soldered, and flanged) it is also possible to order bell and spigot fittings, which are usually cast iron and used for low-pressure service© Go C6 oC > 6 c eo © VIT, Pune Page 7 In general, a fitting is any component in piping system that changes its direction, alters its function, or simply makes end connections. A fitting is joined to the system by bolting, welding or screwing, depending on many variables in the system, Butt-Welded Fittings (ASME 16.9): Welded fittings are used primarily in systems meant to be permanent. They have the same walll thickness as the mating pipe. Among the many advantages of butt welded systems are the following: 1, They have a smooth inner surface and offer gradual direction change with minimum turbulence. They require much less space for constructing and hanging the pipe system. They form leak-proof constructions. They are almost maintenance free. They have a higher temperature and pressure limit. They form a self-contained system ‘They are easy to insulate They offer a uniform wall thickness through-out the system. » eNom ee Ono of the major disadvantages of butt-welded systems is thal are nul easy to dismantle. Therefore, it is often advisable to provide the system with enough flanged joints so that it can be broken down at intervals. (One of the main uses of the butt-welded system is for steam lines, which are usually in high- temperature/ high-pressure service). Socket Welded Fittings (ASME B16.11): Socket welded fittings have certain advantages over butt-welded fittings. They ate easier to use on small-siza pipelines and the ends of the pipes need not be beveled since the pipe end slips into the socket of the joint. With socket-welded fittings there is no danger of the weld protruding into the pipeline and restricting flow or creating turbulence. Thus, the advantages of the socket welded system are: 1. The pipe does not need to be beveled. 2. No tack welding is necessary for alignment since joint and the pipe are self -allgning. 3. Welda material can not extend into the pipeline. 4. It can be used in place of threaded fittings, therefore, reducing the likelihood of leaks, which usually accompany the use of threaded fittings. 5. It is less expensive and easier to construct than other welded systems.