Professional Documents
Culture Documents
Creating The Plant Pipe Code PDF
Creating The Plant Pipe Code PDF
W.N. Weaver, PE
1. INTRODUCTION
Pipes codes are used to standardize piping practices in a facility, to ensure each fluid is
conveyed in the appropriate materials, to control piping costs and to ensure plant safety.
There are multiple pipe codes in use in the various industries involved with pipe; some
are listed below:
Creating proper pipe codes for your facility is generally a combined effort between
engineering, operations and maintenance. Where available piping, corrosion and welding
engineers should be included in the design group.
It is not necessary to start the creation process with a blank sheet of paper; starting from
an existing national code simplifies the process and gives everyone a view of what the
finished product should look like and contain.
Before we go further let us see why we even need a pipe code. It’s generally easier to
produce an appropriate document if we understand the reason we need the document in
the first place.
Most process plants have pipe codes in place which are used for bidding, construction,
new design planning, and repairs. Several points will indicate some of the benefits of
internal pipe codes.
Some cities and counties have had individual disaster experiences, which have caused
them to institute pipe codes for specific materials within their political jurisdictions.
These may well be more restrictive than the recognized national codes.
Certain areas of the country exposed to hazards specific to their locations have added
requirements to piping systems which, are more restrictive than those in other areas. As
an example you would expect California to have more requirements for pipe supports on
hazardous materials than non earthquake prone areas.
Individual facility pipe codes can generally be more restrictive than nationally recognized
codes. Great care and consultation with the company legal and insurance departments are
called for if the developed pipe code is less restrictive than the national standard.
Why not just use an existing nationally recognized code? Let’s look at various materials
in pipes and see if we can find justification for facility specific pipe codes.
Compressed Air
Over the years I have seen or installed compressed air piping systems using the following
types of pipe:
Carbon steel, schedules 40 and 80
Stainless steel, schedules 5, 10, 20 and 40 using 304 and 316
Copper, K, L and M
Common to almost all facilities is Potable Water (City Water and Well Water in some
companies)
Types of pipe encountered in use
Carbon steel
Stainless steel, schedules 5, 10, 20 and 40 using 304 and 316
Copper, K, L and M
Galvanized steel
PVC, schedules 40 and 80
CPVC
Glass
Fiber glass
Cast iron
Cement lined steel
Rubber lined steel
From these two examples it is obvious there are multiple codes for some fluids. More
importantly each of these codes does the job and is considered as a correct application for
the fluid by someone.
Invariably pipes must be connected to other pipes, valves, instruments and equipment.
How these connections are made is critical to the longevity of the piping system and the
cost of maintenance. Additionally these connections frequently limit the allowable
pressure of the system.
Piping connections need to offer some or all of the following characteristics:
• Pressure tightness
• Fluid tightness
• Material compatibility
• Temperature capability
• Corrosion resistance
• Connection rigidity
• Connection longevity
• Relative ease of use
1. Socket welded
2. Butt welded
3. Threaded
4. Flanged
5. Grooved
6. Soldered
7. Brazed
8. Flare fittings
9. Silver soldered
10. Compression fittings
11. Adhesives
12. “O” ring fittings
13. Sheet metal couplings (ex. Morris Coupling)
The acceptable connection systems for each pipe code should be included in the codes
you create.
Most pipes have several mechanical properties to be considered when being selected for a
specific task. Let’s look at the two characteristics most often considered; Pressure Rating
and Allowable Temperature.
PRESSURE
TEMPERATURE
Note that metal pipe (actually almost all pipe) has a temperature / pressure curve which
means that Design Pressure and Design Temperature must be considered together. As a
general rule metal pipe will withstand less pressure at higher temperature and in some
cases at lower temperatures as well. This tells us we must know the maximum expected
Operating Temperature before we can actually select a suitable material of construction
This should be clearer if we look at some actual pipe ratings verses temperatures. First
let’s see what happens to the allowable stress, S, for A106 steel verses temperature. A106
is a common steel specification for pipe.
Note that the Allowable Stress decreases with rising temperature, this means we must
reduce the Operating Pressure as the temperature climbs, we must also reduce the Design
Pressure as the temperature rises. For some carbon steel alloys we also have a lower
acceptable operating temperature. Although not simply a pressure problem some carbon
steel alloy pipes become brittle below certain temperatures. For A105 that temperature is
about –20 ºF.
Therefore our Design Pressure / Design Temperature numbers need to take into account
both the reduction in Allowable Stress and the increase in low temperature shock
sensitivity for carbon steel pipe. Most pipe materials will experience a range of
temperatures below and above which they should not be used. Polymeric piping materials
have a relatively narrow temperature range between too brittle for use and too weak for
use because of loss of tensile strength caused by an increase in temperature.
The following shows what happens to Maximum Allowable Pressure, psig, for 2 inch
A106 Grade B schedule 40 steel pipe as the temperature rises. Reference ASME B31.1.
Notice that the Allowable Pressure remains constant until we reach over 650 ºF. This
reflects the decrease in strength for carbon steel as the temperature rises; up to about 650
ºF the change in allowable stress per 100 degrees temperature rise is around -4%, at 650
the change jumps to -7.5% and continues to rise from there on.
Pipe burst strength and design pressures relate directly to allowable stress. The following
is the burst pressure for various sizes of schedule 40 wrought carbon steel pipe at
constant temperature. The decrease in burst strength is related to the decrease in hoop
strength. Allowable stress remains constant at constant temperature. Hoop strength
calculations incorporate Allowable Stress, diameter and wall thickness. This combination
We’re only interested in burst pressure in that it reflects on our safety factor; we would
never knowingly design or operate at or even near the burst pressure. ASME, other codes,
various government agencies and insurance companies dictate how closely we may
approach the burst pressure for a piece of pipe.
Following all this verbiage we need to select our design pressures based on a variety of
physical properties; most of the time it is easier and safer to accept allowable pressures
from someone like ASME and keep our design pressures at or below these values.
Generally all piping systems should be included in the plant pipe codes. These codes are
a tool for engineering, estimating, maintenance, construction and purchasing to use to
ensure proper piping installation in the plant therefore the maximum number of piping
systems should have specific codes created for them.
The field of pipe codes can be broad so to limit the topic we will concentrate on standard
pipe materials and common connection approaches. Understanding the necessary steps to
be used to develop one pipe code applies to all other codes. Most process facilities have
some or all of the following piping systems in use:
Utilities
Steam
Condensate
Tower Water
Compressed Air
Fuel Gas
Potable Water
Fuel Oil
Waste Water
Nitrogen
Rain Water (from building roof)
Storm Water (underground)
Hot Oil
Chilled Water
Brine Systems
Refrigerant
Vacuum
Engine Exhaust Piping
Dust Collection Systems
Lubricant Systems
A complete pipe code will contain significant information on the requirements the pipes
must meet during operation. Or stated differently, the pipe codes give us the acceptable
ranges of temperatures and pressures under which our facility has agreed a particular type
of pipe can be used. Notice that the authority in this case is “our facility”; it is no less an
authority than ASME or a local code and a violation of this code puts facility insurance
coverage in jeopardy. In the event of a failure of a piping system which results in lawsuits
the violation of a “plant standard” pipe code generally can be expected to have negative
effects in court.
The first activities in developing the code require we establish three process related
criteria:
• Corrosion Resistance For example this process requirement determines if we can
use carbon steel pipe or need a stainless alloy to resist the
effects of the fluids.
• Operating Temperature This criteria separates polymeric materials from most
metallic piping materials and is the expected normal or
maximum temperature the system will experience.
• Operating Pressure This criteria with the first two provides the data necessary
to determine the required wall thickness for the pipe and is
the expected normal or maximum pressure the system will
see.
Only a complete analysis of the system and its range of operations can lead to a
determination of the required tolerance for Design Temperature; for this reason facility
chemists, maintenance, R&D, Operations and engineering should all be involved in this
criteria development.
Design Pressure is selected based on Operating Pressure plus some tolerance to allow for
system deviation from normal operating conditions. Determining the tolerance required
can be complicated and needs to incorporate consideration of items similar to the
following:
• Possible deadheading of pumps
• Possible loss of temperature controls causing a rise in pressure
• A change in reaction kinetics which could cause pressure rises.
• System pressurization using inert gas
• Thermal expansion of some fluids
Decisions about these three items will allow us to select the pipe and establish some
boundaries within which it must operate.
For our real life example let us assume that the plant has a 150 psig steam system fed
directly from the boiler through a reducing station and protected by a properly set and
sized relief device.
From earlier data we can safely use carbon steel at 650 ºF, well above our Operating
Temperature.
Now all that is left is to select the applicable wall thickness, or schedule number. There
are multiple sources of allowable pressures, and calculation methods to determine
schedule numbers and burst pressures. So many sources that it sometimes becomes
difficult to select the appropriate data source. See the References section for some
additional sources.
We’ll use a commonly available source, the ASME table in B31.1 for A106 carbon steel
pipe. The selection of a commonly used national standard as an allowable pressure
reference usually provides adequate liability protection for the engineer. The following
table for our 2 inch pipe gives us the data we need.
We can now establish the basics for the pipe code for 150 psig steam at 365.9 ºF to be:
10. CONNECTIONS
Each pipe code needs to tell the user what method of connection between sections of
pipe, fittings, valves, instruments and equipment is acceptable. We can look at the most
common pipe connections for our steam line with some subjective comments. All of the
following connections provide adequate pressure capability when properly applied.
Properly butt welded or socket welded pipe produces joints at least as strong as the pipe.
Threaded couplings and other fittings are rated by their pressure class and produce some
concern where flexing of the pipe might occur. The table below lists pressure verses
temperature rating for 150# and 300# threaded fittings.
Pipe flanges also have their own set of classes including 125, 150, 300, 400, 600, 900,
1500 and 2500 # classes. Frequently individuals make the assumption that a “150#”
flange is only good for 150 psig and end up spending extra dollars for heavier than
necessary flanges.
TEMPERATURE -20 to
ºF 100 200 300 400 500 600 650 700 800 1000
ALLOWABLE 285 260 230 200 170 140 125 110 80 20
PRESSURE, psig
A second curve provides additional information necessary for pipe code creation. This
table details Allowable Pressure verses Flange Class at 300 ºF.
NOTES
• A facility may create pipe codes allowing for multiple methods of
connection; pipe codes allowing both welding and flanges are common.
• A single pipe code usually covers a range of pipe sizes and may allow for
threads on small pipe, socket weld on some pipe and flanges only above a certain
size.
• A single material of construction, pipe size and schedule number may
occur in several different pipe codes having different design pressures and
temperatures.
• A pipe code is a Facility Tool and as such needs to be created to match the facility’s
needs and help the facility maintain piping system integrity.
• Pipe flanges come in a variety of styles which need to be included in the pipe code:
Connection Type
• Weld neck
• Socket weld
• Back up
• Threaded
For the flange to hold the design pressure several things must be correct:
• Gasket surfaces must be flat and in good condition
• The proper gasket must be specified
• The proper bolts torqued to the proper amount must be installed
For welded joints to perform up to the design conditions the welds must be proper and the
pipe fit up correct.
For threaded fittings the threads must be clean, properly cut, have the proper pipe dope
and have the proper amount of thread engagement.
Determining the extent of the pipe code contents is influenced by the fluid contents of the
pipe, system pressure, temperature, installation environment, facility needs and available
engineering time.
The following provides guidance for the remaining items which can be beneficial if
incorporated into a pipe code.
¾” S R R T
1” W W T
1 & ½” W T
2” T
The selection of how branch connections are made belongs to the facility and is
influenced by pressure, temperature, fluid and pipe sizes involved. The goal is to produce
branch connections, which maintain the pipe code pressure rating. The sample table
above is interpreted as follows:
15. BOLTING FOR FLANGES All flanges have a specified number of bolts, a
specific bolt size, a specific bolt torque value and a tightening pattern. It is critical
that these values are followed in order to obtain the stated flange pressure rating.
21. HEAT TRACING Depending on the type of heat tracing in use there may be a
need for a Heat Trace Pipe Code. Generally heat tracing is
accomplished using hot water, hot oil, steam or electric heat wire.
Most fluid trace system use copper or stainless steel tubing as the
trace piping and details on how it should be specified and installed
should be incorporated into a pipe code.
22. HEAT OR COOLING JACKETING Pipe jackets are a separate pipe code and
require sketches and considerable detail for a pipe code. Jacket
pipe codes contain two sections: one for the core or inner pipe and
one for the jacketing pipe. This is generally a stand alone code
rather than a portion of another code and incorporates a variety of
information:
Pipe to be jacketed
Desired temperature within core pipe
Pressure in core pipe
Materials of construction of core pipe
Connection details for branches in core pipe
Jacketing pipe with sizes related to the core pipe
Jacketing pipe schedule
Jacketing termination at valves, fittings and equipment
Jacket connections and flow patterns
Jacket spacers designed to hold the jacket off the core pipe
This can quickly become very complicated and it may be necessary
to develop a jacketing standard independent of the pipe codes in
order to put in all the necessary details.
23. ANCHORING All pipe requires support (see section on allowable spans) and
how the supporting is accomplished is a critical detail. Supports
include the following items:
Rigid anchors
Guides (to allow for thermal expansion or other movement)
Thrust
24. TESTING
For systems handling hot oil, chemicals which might react with water and create
corrosive conditions or when the pipe line must be dry or when there might be damage to
a lining or freezing using water then fluids other than water may be considered. For
example pressurization might be carried out with non flammable liquids, antifreeze
solutions, or some other compatible liquid.
When the design temperature is higher than the test temperature the following calculation
can be used to establish a minimum test pressure.
Care must be taken using this calculation and it is critical to review ASME B31.3 during
the calculation phase whenever this testing situation occurs.
The choice of testing fluids (water or air, etc) belongs to some extent to the engineer, to
recognized national standards and codes, the insurance company and local or national
authorities. Research in creating the pipe code usually will provide sufficient information
to guide the engineer in selecting the proper test procedure. Incorporating the test
procedure into the pipe code eliminates confusion and problems later.
Metallic pipe can be fabricated in several ways and is classified in such as way as to
define the manufacturing technique.
Cast Iron Cast in a foundry and generally not part of a process industry except for some
utilities and drainage.
Seamless Essentially extruded in some fashion around a mandrel. Considered to be the
best pipe since there is no seam to offer a weak spot or allow corrosion to
begin..
ERW Electric Resistance Welded in an automatic machine as the formed pipe exits
a forming machine.
This becomes a team decision as ERW is usually somewhat less expensive than seamless.
26. CONCLUSION
Properly prepared pipe codes provide a variety of services to the facility engineer
including:
27. REFERENCES