Professional Documents
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Piping System
Piping system: conveys fluid between
locations
Piping system includes:
Pipe
Fittings (e.g. elbows, reducers, branch
connections, etc.)
Flanges, gaskets, bolting
Valves
Pipe supports
2
ASME B31.3
Provides requirements for:
Design
Materials
Fabrication
Erection
Inspection
Testing
Petroleum refineries
Chemical plants
Pharmaceutical plants
Textile plants
Paper plants
Semiconductor
plants
Cryogenic plants
Strength
S
A
Corrosion Resistance
Deterioration of metal by chemical or
electrochemical action
Most important factor to consider
Corrosion allowance
added thickness
Alloying increases corrosion resistance
Pitting
Corrosion
Galvanic
Corrosion
Concentration
Cell Corrosion
Graphitic
Corrosion
Material Toughness
Energy necessary to initiate and
propagate a crack
Decreases as temperature decreases
Factors affecting fracture toughness
include:
Chemical composition or alloying elements
Heat treatment
Grain size
9
Fabricability
Ease of construction
Material must be weldable
Common shapes and forms include:
Seamless pipe
Plate welded pipe
Wrought or forged elbows, tees, reducers,
crosses
Forged flanges, couplings, valves
Cast valves
10
11
Pipe Fittings
Produce change in geometry
12
90
45
180 Return
13
Figure 4.1
Tee
Cross Tee
Figure 4.2
14
Reducer
Concentric
Eccentric
Figure 4.3
15
16
Figure 4.4
Cap
Figure 4.5
17
R
R
Enlarged Section
of Lap
18
Figure 4.6
Bolting
Gasket
19
Figure 4.7
Types of Flange
Attachment and Facing
Flange Attachment Types
Threaded Flanges
Flat Faced
Socket-Welded Flanges
Blind Flanges
Raised Face
Slip-On Flanges
Lapped Flanges
Ring Joint
20
Table 4.1
21
Figure 4.8
Gaskets
Resilient material
Inserted between flanges
Compressed by bolts to create seal
Commonly used types
Sheet
Spiral wound
Solid metal ring
22
24
Table 4.2
25
1.9
1.8
150
235
220
215
200
170
140
125
110
95
80
65
50
35
20
300
620
570
555
555
555
555
555
545
515
510
485
450
320
215
400
825
765
745
740
740
740
740
725
685
675
650
600
425
290
150
290
260
230
200
170
140
125
110
95
80
65
50
35
20
300
750
750
720
695
695
605
590
570
530
510
485
450
320
215
Table 4.3
1.10
400
1000
1000
965
885
805
785
785
710
675
650
600
425
290
190
150
290
260
230
200
170
140
125
110
95
80
65
50
35
20
300
750
750
730
705
665
605
590
570
530
510
485
450
375
260
400
1000
1000
970
940
885
805
785
755
710
675
650
600
505
345
Sample Problem 1
Flange Rating
New piping system to be installed at
existing plant.
Determine required flange class.
Pipe Material:
Design Temperature:
Design Pressure:
26
1 1 Cr 1 Mo
4
2
700F
500 psig
Valves
Functions
Block flow
Throttle flow
Prevent flow reversal
28
29
Handwheel Nut
Handwheel
Stem Nut
Yoke
Yoke Bolting
Stem
Gland Flange
Gland
Gland Bolts or
Gland Eye-bolts and nuts
Gland Lug Bolts and Nuts
Stem Packing
Plug
Lantern Ring
Backseat Bushing
Bonnet
Bonnet Gasket
Bonnet Bolts and Nuts
Gate
Seat Ring
Body
One-Piece Gland (Alternate)
Valve Port
Figure 5.1
Globe Valve
30
Check Valve
31
Seat
Ring
Hinge
Flow
Direction
Disc
Body
32
Figure 5.2
33
Figure 5.3
34
Figure 5.4
35
Figure 5.5
Ball Valve
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
36
Part Names
Body
Body Cap
Ball
Body Seal Gasket
Seat
Stem
Gland Flange
Stem Packing
Gland Follower
Thrust Bearing
Thrust Washer
Indicator Stop
Snap Ring
Gland Bolt
Stem Bearing
Body Stud Bolt & Nuts
Gland Cover
Gland Cover Bolts
Handle
Figure 5.6
Plug Valve
Wedge
Sealing Slip
37
Figure 5.7
Exercise 1 - Determine
Required Flange Rating
Pipe:
1 1 Cr 1 Mo
4
2
Flanges:
Design Temperature:
Design Pressure:
40
Exercise 1 - Solution
1. Identify material specification of flange
A-182 Gr, F11
2. Determine Material Group No. (Table 4.2)
Group 1.9
3. Determine class using Table 4.3 with design
temperature and Material Group No.
The lowest Class for design pressure of 375
psig is Class 300.
Class 300 has 450 psig maximum pressure
at 900F
41
Design Conditions
General
Normal operating conditions
Design conditions
Loading Conditions
Principal pipe load types
Sustained loads
Act on system all or most of time
Consist of pressure and total weight load
Occasional loads
43
Stresses Produced By
Internal Pressure
Sl
Sc
P
t
44
Sl
Longitudinal Stress
Sc
Wall Thickness
Internal Pressure
Figure 6.1
Stress Categorization
Primary Stresses
Direct
Shear
Bending
Secondary stresses
Act across pipe wall thickness
Cause local yielding and minor distortions
Not a source of direct failure
45
46
Allowable Stresses
Function of
Material properties
Temperature
Safety factors
Established to avoid:
General collapse or excessive distortion from
sustained loads
Localized fatigue failure from thermal
expansion loads
Collapse or distortion from occasional loads
47
B31.3 Allowable
Stresses in Tension
Basic Allowable Stress S, ksi. At Metal Temperature, F.
Material
Spec. No/Grade
100
200
300
400
500
600
700
800
900
1200
1300 1400
1500
Carbon Steel
A 106
20.0
20.0
20.0
20.0
18.9
17.3
16.5
10.8
6.5
2.5
1.0
C - Mo
A 335
P1
18.3
18.3
17.5
16.9
16.3
15.7
15.1
13.5
12.7
4.
2.4
1 - Mo
A 335
P11
20.0
18.7
18.0
17.5
17.2
16.7
15.6
15.0
12.8
6.3
2.8
1.2
A 312
TP304 20.0
20.0
20.0
18.7
17.5
16.4
16.0
15.2
14.6
13.8
9.7
6.0
3.7
2.3
1.4
16Cr - 12Ni-2Mo
pipe
A 312
TP316 20.0
20.0
20.0
19.3
17.9
17.0
16.3
15.9
15.5
15.3
12.4
7.4
4.1
2.3
1.3
Table 6.1
48
1000 1100
PD
t=
2 (SE + PY )
49
t m = t + CA
t nom =
tm
0.875
Spec.
No.
Description
Ej
Carbon Steel
API
5L
...
...
...
Seamless pipe
Electric resistance welded pipe
Electric fusion welded pipe, double butt, straight or
spiral seam
Furnace butt welded
1.00
0.85
0.95
A 53
Type S
Type E
Type F
Seamless pipe
Electric resistance welded pipe
Furnace butt welded pipe
1.00
0.85
0.60
A 106
...
Seamless pipe
1.00
...
...
Seamless pipe
Electric resistance welded pipe
1.00
0.85
A 335
...
Seamless pipe
1.00
Stainless Steel
A 312
...
...
...
Seamless pipe
Electric fusion welded pipe, double butt seam
Electric fusion welded pipe, single butt seam
1.00
0.85
0.80
A 358
1, 3, 4
5
2
1.00
0.90
0.85
50
B 161
...
1.00
B 514
...
Welded pipe
0.80
B 675
All
Welded pipe
0.80
Table 6.2
Temperature, F
Materials
950
1000
1050
1100
1150 & up
Ferritic
Steels
0.4
0.5
0.7
0.7
0.7
0.7
Austenitic
Steels
0.4
0.4
0.4
0.4
0.5
0.7
Other
Ductile
Metals
0.4
0.4
0.4
0.4
0.4
0.4
Cast iron
0.0
...
...
...
...
...
Table 6.3
51
Mitered bend
Straight pipe sections welded together
Often used in large diameter pipe
May require larger thickness
Function of number of welds, conditions, size
52
54
55
Tb
Reinforcement
Zone Limits
Nom.
Thk.
tb
Mill
Tol.
A3
A3
L4
A4
A4
A1
Tr
Th
Dh
Nom.
Thk.
th
Mill
Tol.
d1
A2
A2
d2
d2
Pipe C
56
Reinforcement
Zone Limits
Figure 6.2
Reinforcement Area
Db 2(Tb c)
d1 =
sin
d1 = Effective length removed from run pipe, in.
Db = Branch outside diameter, in.
Tb = Minimum branch thickness, in.
c = Corrosion allowance, in.
==
===
== Acute angle between branch and header
57
58
Reinforcement Pad
Provides additional reinforcement
Usually more economical than increasing
wall thickness
Selection variables
Material
Outside diameter
Wall thickness
(Dp Db )
Tr
A 4 =
sin
59
Sample Problem 3
Pipe material: Seamless, A 106/Gr. B for
branch and header, S = 16,500 psi
Design conditions: 550 psig @ 700F
c = 0.0625 in.
Mill tolerance: 12.5%
60
Required Pipe
Thicknesses:
A1 = thd1(2 sin)
A1 = 0.395 15.469 (2 sin90) = 6.11 in.2
62
A 2 = (2d2d1)(Ththc )
d2 = d1 = 15.469 in. < Dh = 24 in.
A2 = (2 15.469 - 15.469) (0.875 0.562 0.395 - 0.0625)
A2 = 0.53 in.2
63
2L 4 (Tb tbc )
A3 =
sin
Pad needed
65
66
67
Exercise 2 - Determine
Required Pipe Wall Thickness
69
Exercise 2 - Solution
From Tables 6.1, 6.2, and 6.3 obtain values:
S = 20,000 psi
E = 1.0
Y = 0.4
Thickness calculation:
PD
150 30
t=
=
2(SE + PY ) 2[(20,000 1.0 ) + (150 0.04 )]
t = 0.112 in.
70
tm
0.237
=
=
0.875 0.875
= 0.271 in.
Layout Considerations
Operational
Operating and control points easily reached
Maintenance
Ample clearance for maintenance equipment
Room for equipment removal
Sufficient space for access to supports
Safety
Consider personnel safety
Access to fire fighting equipment
72
Restraints
73
74
Weight load
Available attachment clearance
Availability of structural steel
Direction of loads and/or movement
Design temperature
Vertical thermal movement at supports
Rigid Supports
Shoe
Dummy Support
75
Base Adjustable
Support
Saddle
Figure 7.1
Trunnion
Hangers
76
Figure 7.2
Flexible Supports
Load and Deflection
Scale
Small Change in
Effective Lever Arm
Large Change in
Effective Lever Arm
Relatively
Constant
Load
Typical Constant-Load
Spring Support Mechanism
Typical Variable-Load
Spring Support
77
Figure 7.3
Restraints
Control, limit, redirect thermal movement
Reduce thermal stress
Reduce loads on equipment connections
Restraints, contd
Restraint Selection
Direction of pipe movement
Location of restraint point
Magnitude of load
79
Guide
Permits movement along pipe axis
Prevents lateral movement
May permit pipe rotation
80
Restraints - Anchors
Anchor
81
Anchor
Figure 7.4
Partial Anchor
Restraints - Guides
Guide
Guide
Vertical Guide
82
Guide
Figure 7.5
Piping Flexibility
Inadequate flexibility
Leaky flanges
Fatigue failure
Excessive maintenance
Operations problems
Damaged equipment
Flexibility Analysis
Considers layout, support, restraint
Ensures thermal stresses and reaction
loads are within allowable limits
Anticipates stresses due to:
84
85
Design Factors
Layout
Component
design details
Fluid service
Connected
equipment type
Operating
scenarios
86
Pipe diameter,
thickness
Design temperature
and pressure
End-point movements
Existing structural
steel locations
Special design
considerations
87
Parameters Used
To Determine
Acceptable Loads
Industry Standard
Centrifugal Pumps
API 610
Nozzle size
Centrifugal
Compressors
Air-Cooled Heat
Exchangers
API 661
NEMA SM-23
allowable
Nozzle size
Tank Nozzles
API 650
Steam Turbines
NEMA SM-23
Nozzle size
Table 7.1
Computer Analysis
Used to perform detailed piping stress
analysis
Can perform numerous analyses
Accurately completes unique and difficult
functions
88
Time-history analyses
Seismic and wind motion
Support motion
Finite element analysis
Animation effects
Maximum Differential
Flexibility Temp.
400F
300F
12
200F
20
any
Any
Any
For tankage
12
Any
Type Of Piping
General piping
89
Table 7.2
Normal Temperature
Conditions To Consider
Stable
Operation
Startup and
Shutdown
Regeneration
and Decoking
Piping
Spared
Equipment
91
Table 7.3
Abnormal Temperature
Conditions To Consider
Loss of Cooling
Medium Flow
92
Table 7.4
Extent of Analysis
Extent depends on situation
Analyze right combination of conditions
Not necessary to include system sections
that are irrelevant to analysis results
93
System Design
Considerations, contd
Atmospheric storage tank
Movement at nozzles
Tank settlement
Tank Nozzle
SHELL
NOZZLE
BOTTOM
97
Figure 7.6
Welding
98
99
Figure 8.1
(b)
(d)
100
Figure 8.2
(c)
Fillet Welds
101
Figure 8.3
Weld Preparation
Welder and equipment must be qualified
Internal and external surfaces must be
clean and free of paint, oil, rust, scale, etc.
Ends must be:
Suitably shaped for material, wall thickness,
welding process
Smooth with no slag from oxygen or arc
cutting
102
Preheating
Minimizes detrimental effects of:
High temperature
Severe thermal gradients
Benefits include:
Dries metal and removes surface moisture
Reduces temperature difference between
base metal and weld
Helps maintain molten weld pool
Helps drive off absorbed gases
103
105
Dimensional tolerances
Flange tolerances
107
Pipe Alignment
Load Sensitive Equipment
Special care and tighter tolerances needed
Piping should start at nozzle flange
Initial section loosely bolted
Gaskets used during fabrication to be replaced
110
111
Flange Preparation,
Inspection, and Installation
112
Criss-Cross
Bolt-tightening Sequence
113
Figure 8.4
114
Inspection
Defect identification
Weld inspection
Technique
Weld type
Anticipated type of defect
Location of weld
Pipe material
115
d) Incomplete Penetration of
Weld Groove
External Undercut
Internal Undercut
116
Figure 9.1
f) Undercut
Radiography
Magnetic Particle
Liquid Penetrant
Ultrasonic
117
Situation/Weld Type
All welds.
Defect
Cracks.
Slag inclusions.
Butt welds.
Gas pockets.
Girth welds.
Slag inclusions.
Incomplete penetration.
Ferromagnetic
materials.
Cracks.
For flaws up to 6 mm
(1/4 in.) beneath the
surface.
Porosity.
Lack of fusion.
Ferrous and
nonferrous materials.
Cracks.
Intermediate weld
passes.
Seams.
Porosity.
Folds.
Simple and
inexpensive.
Inclusions.
Shrinkage.
Surface defects.
Laminations.
Subsurface flaws.
Table 9.1
Testing
Pressure test system to demonstrate
integrity
Hydrostatic test unless pneumatic
approved for special cases
Hydrostatic test pressure
1 times design pressure
118
Testing, contd
For design temperature > test temperature:
1 .5 P S T
PT =
S
ST/S must be 6.5
PT
P
ST
S
119
Testing, contd
Pneumatic test at 1.1P
Instrument take-off piping and sampling
piping strength tested with connected
equipment
120
Nonmetallic Piping
Thermoplastic Piping
Can be repeatedly softened and hardened by
increasing and decreasing temperature
121
122
123
125
127
128
129
130
131
Examination
132
Summary
Process plant piping much more than just
pipe
ASME B31.3 covers process plant piping
Covers design, materials, fabrication,
erection, inspection, and testing
Course provided overview of requirements
133