PIPING SYSTEM

- Pankil J. Kapadia 1
 PIPING SYSTEM
• Piping system in a chemical plant are
comparable
p to the veins and arteries through g
which fluids, vapors, slurries, solids, etc. flow
under various conditions,, as imposed
p byy the
process design of the plant.

• Piping design becomes more complex due to

corrosion erosion,
corrosion, erosion toxic conditions and radio-
radio
activity.
2
 PIPING COSTS
Piping contributes to a major part in any
plant / industry investment.
investment
• Major equipment – 50%
• Piping – 23%
• Balance – 27% ((Building g and Structure,,
Foundation, Electrical, Instrumentation,
Painting & Insulation).
Insulation)

3
 PIPING COSTS
Piping contribution on office Man-hour
basis is a major part in any plant / industry
investment.

• Design Engineering – 45%

• Piping Engineering – 20%

4
 PIPING COSTS

Piping contribution on field labour cost basis:

• Piping – 47%
• Balance – 53% (Major equipment, Building
and Structure, Foundation, Electrical,
Instrumentation, Painting & Insulation).

5
 What a Piping Engineer should know ?
• Engineering
g g knowledgeg – Mechanical, electrical,
civil & instrumentation.
g
• Engineering g economics & costs.
• Metallurgy
• Methods of pipe fabrication and erection.
• Chemistry & chemical engineering.
• Communication skill.
skill
• Standards, codes & practices.
• Safety
S f t codes
d andd practices.
ti
• Drafting procedures and practices.
6
 Responsibility of a Piping Engineer

• ADEQUACY: Piping design must be adequate

to meet the process specification and physical
conditions in which the plant is to operate.

• ECONOMY: Adequate design must be

achieved
hi d att an economic i costt within
ithi budget.
b d t
Design costs must be minimized by maximizing
the
h use off standardized
d di d methods
h d off detailing
d ili
and data presentation.
7
 Responsibility of a Piping Engineer

• CLARITY: Piping data for design derived from

and used by other engineering dept.dept & other
sources must be clear, consistent and reliable.

• ACCURACY: Details of Piping p g must be

accurate and complete. Rectification of
g may
mistakes at a latter stage yp
prove to be very
y
costly and can delay project completion.

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Piping Design in an Organization

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PIPING CODES AND STANDARDS
For Scientific design of piping system, selection of
proper material of construction and to detail out
the material specifications, knowledge of codes and
standards are essential.

Each country has its own codes and standards. On

global basis,
basis American National Standards is most
widely used code and compliance with its
requirements is accepted all over. British Standards
and Indian Standards are also used for the design
and selection of piping systems.

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 CODES AND STANDARDS
CODE: A CODE IS A STANDARD THAT HAS BEEN
ADOPTED BY ONE OR MORE GOVERNMENTAL
BODIES AND HAS THE FORCE OF LAW. IT IS A SET OF
RULES BACKED UP BY PRINCIPLES OF SCIENCE AND
EXPERIENCE OF PAST SAFE AND SUCCESSFUL
USAGES.

STANDARD: A SET OF TECHNICAL DEFINITIONS AND

GUIDELINES, INSTRUCTIONS FOR DESIGNERS,
MANUFACTURERS & USERS.
USERS IT IS A SYSTEM /
DOCUMENT TO BE ADOPTED BY OR USED BY THE
PEOPLE
O WHOO ARE EXECUTING
CU G A PROJECT.
OJ C .
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 EFFECTIVENESS OF WORKING TO
CODES AND STDS.
• TO ESTABLISH COMMON AGREEMENT IN ENGINEERING
CRITERIA, TERMS, PRINCIPLES, PRACTICES, MATERIALS,
ITEMS,, PROCESSES,, ETC.
• TO FOLLOW ALREADY PROVEN WAY OF DOING THINGS
• SAFETY
• RELIABILITY
• TO FOLLOW CONTINUALLY
• AVOID MISMATCHING / INTERCHANGEABILITY
• USAGE OF EXISTING SYSTEM
• TO ECONOMISE THE SYSTEM
• TO REDUCE INVENTORY \ TO GET READYMAKE BACKUP
FROM MARKET
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BODIES FOR CODES & STANDARDS
• ASME AMERICAN SOCIETY OF MECHANICAL ENGINEERS
• ANSI AMERICAN NATIONAL STANDARDS INSTITUTE
• ASTM AMERICAN SOCIETY OF TESTING AND MATERIAL
• API AMERICAN PETROLEUM INSTITUTE
• AISI
S AMERICAN
C IRON
O AND STEEL
S INSTITUTE
S
• MSS-SP MFR. STD. SOCIETY OF VALVES & FITTINGS IND.
• BSI BRITISH STANDARDS INSTITION
• BIS BUREAU OF INDIAN STANDARDS
• AWS AMERICAN WELDING SOCIETY
• AWWA AMERICAN WATER WORKS ASSOCIATION
• DIN GERMEN STD.
• AFNOR FRENCH STD.
STD
• JIS JAPANESE STD.
• ISO INTERNATIONAL STANDARADS ORGANIZATION
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 PIPING
NG ELEMENTS
N S
In a process industry the transportation of materials in the fluid
form from one place to another takes place by forcing the fluid
through the piping system. The piping system not only involves
pipes but also the fittings, valves and other specialties. These items
are known as the piping components. Code specifies the piping
system as the mechanical elements suitable for joining or assembly
into pressure-tight fluid-containing piping.
These Piping Components are as under:

PIPES FITTINGS FLANGES GASKETS

BOLTING VALVES SPECIAL SAFETY

ITEMS ITEMS
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 PIPING ELEMENTS
PIPING ELEMENT:
IT IS DEFINED AS ANY MATERIAL OR WORK REQUIRED
TO PLAN AND INSTALL THE PIPING SYSTEM.
These elements include design specifications,
materials,
t i l components,t supports,
t f b i ti
fabrication,
inspection and testing.

PIPING SPECIFICATION:
IT IS A DOCUMENT SPECIFYING EACH OF THE
COMPONENTS USED IN A PIPING SYSTEM.

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 MATERIAL SELECTION OF
PIPING COMPONENTS
Basically the material is selected based on its service.
Thus the selection of piping g materials requires
knowledge of corrosion properties, strength and
engineering characteristics, relative cost and
availability.
il bilit

The main
Th i process considerations
id ti i MOC selection
in l ti are
fluid corrosion properties, pressure and temperature
conditions of the service and the nature of the service
(toxic, volatile, explosive, etc.)

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MATERIAL OF CONSTRUCTION

PTFE = Polyy Tetra Fluro Ethylene

y
PP = Poly Propylene
PVDF = Poly Vinylidene Flouride
FRP = Fibre Reinforced Plastic
HDPE = High Density Poly Ethylene
UHMW = Ultra High Molecular Weight
LDPE = Low Density Poly Ethylene
LLDPE = Low Linear Density Poly Ethylene
CPVC = Chlorinated Poly Vinyl Chloride

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 SPECIFICATION OF
PIPING COMPONENTS
Any piping component is specified by
• Item description
• Type of construction (welded or seamless)
• Material standard with grade
• Dimensional standard
• End connection
• End facing (if applicable)
• Datasheet reference (if applicable)
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 PIPE
A PIPE IS A TUBULAR ITEM MADE OF METAL, PLASTIC, GLASS
ETC. MEANT FOR CONVEYING LIQUID, GAS OR ANYTHING THAT
FLOWS.
BASED ON THE METHOD OF MANUFACTURE, PIPES CAN BE
CLASSIFIED AS UNDER:

SEAMLESS
WELDED Electric Resistance Welded (ERW)
Electric Fusion Welding (EFW)
Spiral Welded
Furnace Butt Welded
Double Submerged Arc Welded (SAW)

FORGED & BORED

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 PIPE
• PIPE is specified by its OD and thickness.
• p
Thickness is specified in schedule nos.
• Corrosion allowance is included in the thickness.
• Mill tolerance +/-
/ 12.5 %.
• Pipe thickness formula: t = _____P D_____ + C
2 (S E + P Y)

MOC & TYPE CS/AS/SS &

SMLS/WELDED
DIMN. STD. CS/AS: ANSI B36.10
SS: ANSI B36.19
END CONNECTION BE, PE, FLGD,
SCREWED, BUTRESS,
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SPIGOT/SOCKET
PIPE

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TYPES OF END CONNECTIONS

• SOCKET WELD PIPE JOINTS

• BUTT WELD PIPE JOINTS
• SCREWED PIPE JOINTS
• FLANGED END PIPE JOINTS
• BUTTRESS END PIPE JOINTS
• SPIGOT SOCKET END PIPE JOINTS

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SOCKET WELD END CONNECTION

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SOCKET WELD END CONNECTION

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 SOCKET WELD END CONNECTION
ADVANTAGES:
a)) Easier
E i alignment
li t than
th butt
b tt welding.
ldi
b) No weld metal intrusion into bore/hole.

DISADVANTAGES:
a) The 1/16” (1.6 MM) recess pockets liquid.
b) Use not permitted by code if Severe Erosion or
Crevice Corrosion is anticipated.
USE:
a) General utility & LP piping system.
b) NPS below 22” NB.
NB
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BUTT WELD END CONNECTION

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BUTT WELD END CONNECTION

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 BUTT WELD END CONNECTION
ADVANTAGES:
a)) Most
M t practical
ti l way off joining
j i i big
bi bore
b piping.
i i
b) Reliable leak proof joint.
c)) Joint
J i t can be
b radiographed.
di h d

DISADVANTAGES:
a) Weld intrusion will affect flow.
b) End preparation is necessary.
necessary

USE:
a) NPS 2” NB & above.
b) HP,
HP HT,
HT corrosive & erosive services
services.
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SCREWED END CONNECTION

29
SCREWED END CONNECTION

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 SCREWED END CONNECTION
ADVANTAGES:
a) Easily made at site.
b) Can be used for where welding is not permitted due to fire
hazard.
DISADVANTAGES:
a) Joint may leak when not properly sealed
b) Use not permitted by code if severe erosion, crevice
corrosion,
i shock
h k or vibration
ib i is i anticipated.
i i d
c) Strength of pipe is reduced as threads reduce wall
thickness.
thickness
d) Seal welding may be required.
e)) Code specified
p that seal weldingg shall not be considered to
contribute for strength of joint.
USE:
a) Non critical CW/utility system.
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FLANGED END CONNECTION

32
FLANGED END CONNECTION

33
 FLANGED END CONNECTION
ADVANTAGES:
a)) Used for all pprocess & utilityy ppiping
p g where
frequent bolting connections are required or the
jjoints need frequent
q dismantling.
g
b) Reliable leak proof joint when bolted properly.
DISADVANTAGES:
a) Gasket need to be inserted properly during bolting.
b) Prone to leakage if any dirt/dust is trapped
between flange and gasket seating surface.
USE:
Used at equipments, valves & special items where
maintenance is a regular feature,
feature breakout flanges are
provided at definite intervals on pipe lines. 34
 BUTTRESS END CONNECTION
Used in glass piping and are joined by bolting with
the use of backing flanges.
flanges (BS 2598)

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BUTTRESS END CONNECTION

36
 STUB END CONNECTION
Used in corrosive services where costlier piping mat.
like SS, Aluminum, Zirconium, etc. is required
q as pper
process req. This type of connection reduces cost.

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STUB END CONNECTION

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 SPIGOT SOCKET END CONNECTION
• Used when lead caulked/cement joints are provided
between pipes and between pipes and fittings. Generally
used for under ground sewer / water systems.
systems
• Used for low pressure services. This type of connection
has the advantage
g that it can take misalignment
g to a certain
extent.
IS 1538

39
SPIGOT SOCKET END CONNECTION

40
SPIGOT SOCKET END CONNECTION

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PIPE FITTINGS

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PIPE FITTINGS

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PIPE FITTINGS

44
PIPE FITTINGS

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PIPE FITTINGS – FORGED

SW ENDS

46
PIPE FITTINGS - WROUGHT

BW ENDS

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PIPE FITTINGS - WROUGHT

BUTT WELD ENDS

48
PIPE FITTINGS - FORGED

SCREWED
ENDS

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PIPE FITTINGS - FORGED

SCREWED
ENDS

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PIPE FITTINGS

Weldolet is used where tee is not

available due to size restriction and
the piping is of critical / high
pressure service. It is designed
p g to
minimize stress concentrations and
provide integral reinforcement.

Sweepolet
S l t is
i contoured,
t d integrally
i t ll
reinforced butt-weld branch
connection with low SIF (Stress
Intensification Factor)) for low
stresses and high fatigue life. The
weld is easily examined by
radiography, UT and other NDT
techniques
techniques.
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PIPE FITTINGS
Insert Weldolet is a contoured butt-
weld branch connection used in less
critical application. Other benefits
are same as Sweepolet.

Sockolet utilizes the basic Weldolet

design
g configuration
g and is used for
socket welding branch connection,
which require reinforcing pad.

Coupolet (threaded) fittings are

d i
designedd for
f use ini th
the fi
fire
protection sprinkler system and
other low pressure applications.

52
PIPE FITTINGS

Threadolet utilizes the basic

Weldolet design
g configuration
g and
provides a threaded outlet branch
connection.

Brazolet is designed for use with

brass or copper
pp p piping
p g or fittings.
g

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PIPE FITTINGS
Laterolet is used for branch
connection at an angle with butt
welding at branch thus providing
reinforcement on header pipe.

Elbowlet is used for branch

connection on elbow and have the
profiles made to suit the elbow.
Used for thermo well & other
instrument items.

Nipolet is one piece fitting for

various
i d i
drains and
d vents.
t Available
A il bl
with different end connections.

54
 PIPE FITTINGS

ELBOW:
• 22.5°
22 ° elbow
lb is also
l available
l bl in C.I.
C construction.

TEE:
• Branch off - Branch off with RF pad - Tee
• The mfg. Restrictions do not allow reducing tees of all size.
• Thumb rule: Size available is divide the major dia. By 2
and consider the next lower size. (4” x 1½”)

CROSS:
• Used
U d to
t reduce
d space. E.g.
E Marine
M i piping.
i i
• Generally tees are used in place of cross to reduce the
inventory
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 PIPE FITTINGS

REDUCERS: (Concentric & Eccentric)

• CR
C is usedd when
h centre line
l off larger
l & smaller
ll pipe is to
be maintained same.
• ER is used when the outside surface of the pipe lines are
to be maintained same.
• There are no ER in SW fittings
g and Swage g nipples
pp are used
for such service.

UNIONS:
O
• Used in low pressure piping where dismantling of the pipe
is required more often as an alternative to flange
flange. It can have
threaded end or SW ends.

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 PIPE FITTINGS

SWAGE NIPPLES:
• BS 3799
• Used to connect BW pipe to smaller screwed or SW pipe.
• Two types – Concentric & Eccentric.

COUPLINGS:
• Full Coupling
• Half Coupling
• Reducing Coupling

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 PIPE FITTINGS
STUB ENDS: To reduce the cost of piping, stub ends are used with
backing flanges for flange joints when exotic/costly materials are
used in piping.
piping

ANSI B16.9 MSS-SP-43

Long stubb ends
L d Di
Dimensions
i same as Short
Sh stub
b ends
d
Short stub ends
Type A:
T A With Radius
R di att the
th corner
Type B: Without Radius
Type C: Fabricated from plate
Used up to 40NB Used above 40 NB depending upon the
flange
g construction
Slip-on flange Class A: Chamfered backing flange
Class B: Slip
Slip-on
on flange
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 FLANGES
Classification of Flanges is done as under:
Based on pipe Slip-on, SW, Screwed, Lap joint,
attachment Welding Neck, Blind, Reducing
Based on P-T 125#,, 150#,, 300#,, 400#,, 600#,, 900#,,
rating 1500#, 2500#
Based on Flat Face (FF),
(FF) Raised Face (RF),
(RF)
Facing Tongue & Groove (T/G), Male &
Female (M/F),
(M/F) Ring Type Joint (RTJ)
Based on Face Smooth (for metallic gaskets)
Finish S
Serratedd (f
(for non-metallic
lli gaskets)
k )
Based on MOC Forgings
Plates – weldable quality 59
 FLANGE FACINGS

SMOOTH FINISH SERRATED FINISH

Specified when metallic Specified when non-
gaskets
gas e s are
a e used. metallic
e a c gaskets
gas e s are
a e used.
Gasket is comparatively Spiral or Concentric
softer than flange material
material. serrations
serrations.
Concentric – Low density
fl id
fluid
Specified by AARH Specified by AARH
(0-125 micron max.) (125-250 micron)

60
 FLANGES

SLIP-ON FLANGE:
• Forged with hub or fabricated from plate without hub
hub.
• Welded to pipe from inside & outside.

SOCKET WELD FLANGE:

• Welded only on outside.
• Not approvedd by
b IBR.
• Used for small bore pipes only (Below 2” NB)
• Thickness of pipe to be specified to ensure proper bore
dimension

SCREWED-ON FLANGE:
• Used where welding cannot be carried out.
• Used for water piping works.
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 FLANGES
WELDING-NECK FLANGE:
• BW to the pipe & hence can be radiographed.
• Used for critical services.
• Thickness of the welding end to be specified.

BLIND FLANGE:
• Used to close the pipe/equipment ends which need to be
re-opened later.

REDUCING FLANGE:
• Used to connect larger & smaller diameter pipes without
using a reducer.
• The thickness of the flange with smaller diameter shall be
the same as that of flange with larger diameter
diameter.
62
 FLANGES

INTERGRAL FLANGES:
• Cast along with the piping component or the equipment.
• Used
U d for
f critical
i i l services.
i
• Thickness of the welding end to be specified.
• Thickness of integrally cast flanges may differ from
standard forged flanges.

LONG WELDING-NECK FLANGE &

EXPANDER/REDUCER
/ FLANGE:
• Developed by the manufacturer to suit special
requirements.

63
 FLANGES

BASED ON PRESSURE-TEMPERATURE
PRESSURE TEMPERATURE RATINGS:
• In the standard ANSI B16.5, the P-T rating chart specify
the cold non-shock pressure to which the flange can be
subjected to at a particular temperature.
• ANSI B16.5 indicates the allowable pressures for various
MOC.
MOC
• Code does not recommend the use of class 150 # flanges
above 400 °F.
F.

64
FLANGES

65
FLANGES

66
FLANGES

67
FLANGES

68
FLANGE FACINGS

69
 GASKETS

SELECTION:
Selection of gasket depends upon the following factors:
• Compatibility of the gasket material with the fluid.
• Ability to withstand the pressure & temperature of the
system.

TYPE:
Gasket is classified based on the type
yp of construction:
• Full Face
• Inside Bolt Circle
• Spiral
S i l Wound
W d Metallic
M t lli
• Ring type
• Metal Jacketed
70
 GASKETS

MATERIAL:
Commonly used material is CAF (Compressed Asbestos
Fibre)

CAF Gasket standard: IS 2712 – Three grades:

• Gr. W/1, W/2 & W/3: Steam, alkali & general applications
• Gr.
Gr A/1: For Acid application
• Gr. O/1, O/2 & O/3: For Oil applications

• For corrosive services, asbestos free gaskets are used.

They are PTFE, CAF with PTFE envelop, GFT, Rubber, etc.

• For high temperature & high pressure applications, spiral

wound metallic gaskets are used.
used
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 GASKETS
SPIRAL WOUND GASKET:
• The selection of MOC for winding depends upon the
corrosive
i nature
t and
d concentration
t ti off fl
fluid,
id the
th operating
ti
temperature and the relative cost. Commonly used material
is SS304,
SS304 SS316 & SS321 with asbestos filler material
material.
• For very high temperature graphite filler is also used.
• Provided with CS external ring g which is called as centering
g
ring to position the gasket.
• For vacuum services, an internal gasket is also provided.
• Surface
S f roughness
h iis 125-250
125 250 AARH microns.
i

RING GASKET:
• For extremely high pressure & temperature.
• Oval (upto
( p 8” NB)) and Octagonal
g (Above
( 8” NB))
• Gasket material is soft as compared to flange material.72
FLANGE CONNECTION WITH CAF GASKETS

73
CAF GASKETS

74
SPIRAL WOUND GASKET

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SPIRAL WOUND GASKETS

76
RING GASKETS

77
OVAL & OCTAGONAL RINGS

OVAL OCTAGONAL

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