PIPING MANUAL FOR STAINLESS STEEL PIPES FOR BUILDINGS N° 12 008 JAPAN STAINLESS STEEL ASSOCIATION and NiDI NICKEL DEVELOPMENT INSTITUTEThe material presented in this publication has been prepared for the general information of the reader and should not be used or relied on for specific applications without first securing competent advice. The Nickel Development Institute, its members, staff and consultants do not represent or warrant its suitability for any general or specific use and assume no liability or responsibility of any kind in connection with the information hereinPiping Manual for Stainless Steel Pipes for Buildings JAPAN STAINLESS STEEL ASSOCIATION and NICKEL DEVELOPMENT INSTITUTEForeword hee the first edition of the "Construction Stainless Steel '983. Following its publication, this manual served as a Steel Piping Design and Work Workshop held by the jnber 30, 1983, at which nearly 90 participants actively fic paricans snd many sens, nd thee were committee have decided to come out with a fuller, rporating those valuable views and the results of the | and writing staff has been newly constituted, and the assume direct responsibility for this undertaking. laken a fresh look at the entire manual and have finally |ted lively discussions in a number of editorial meetings ited. Although the printing, proofreading, and other edition has finally been published, and | would like to ‘nmittee members who participated in the planning and re} A Ss0%;ation for their efforts, about this revised edition is that difficult points and 2ught to light in the workshop have been made clearer naterial has been added. ) may not meet your every need, but we think you will ‘ecessor, and we hope that you find it of value. Chairman inless Steel Piping Manual Committee isociation lish translation of completely updated contents of the Manual for Stainless Steel Pipes for Buildings. Wwimmittee td.) td.) itd.) id.) takes precedence over rinciples. yy defined in Japanese for ordinary piping” ture is used only when ther types of pipe. ping” is abbreviated to work for piping, etc., Y “stainless steel piping Jd to adopt them as the(3) The main formal terms for piping that occur in this text and their corresponding abbreviated terms are as follows. © Light gauge stainless steel pipe for ordinary piping (the formal term, JIS G 3448): stainless steel pipe, stainless steel piping, stainless steel pipe for construction, stainless steel piping for construction © Carbon steel pipe for ordinary piping (the formal term, JIS G 3452) steel pipe, carbon steel pipe, etc. © Copper and copper alloy seamless pipe (formal term, JIS H 3300): copper pipe, etc. © Stainless steel pipe for piping (formal term, JIS G 3459): schedule pipe, stainless steel pipe, etc. (iii)14 1d 1.4.2 12 1.2.1 1.2.2 1.23 13 134 1.3.2 133 1.3.4 214 245 21.6 22 224 2.22 23 234 23.2 24 2.441 Contents 1. THE BASICS Definition and Classification of Stainless Steel .... Definition of stainlesssteel ..... Classification of stainless steel. , Properties of Stainless Steel. . Physical properties of stainless steels Mechanical properties of stainless stee! Corrosion properties of stainless steel . Comparison with Other Pipe Materials Dimensions and weight Physical properties of pipe materials Mechanical properties of pipe materials Corrosion resistance of stainless steel and other metals 2. DESIGN Scope of Use of Stainless Steel Piping .... : Range of use of stainless steel pipe for ordinary piping, classified by application ceeseee ‘Temperature, pressure and flow volume ranges for light gauge stainless steel pipe for ordinary piping Design allowable sress and maximum allowable pressure of stainless steel pipe for general service ........6..00000+ a Dimension designations for stainless steel pipe for general services Selection conditions The economics of st less steel pipe for ordinary piping Piping Planning . . Characteristic of and points tonote in piping planning Joining methods and their characteristics Pipe Diameter for Piping Flow velocity standards Flow rate chart and local loss equivalent length ‘Supports and Anchors General considerations (1) Load on piping and support and anchor points (2) Support and anchoringmethods. ....... (3) Allowable stress in stainless steel piping 24 24, 29 31 33 34, 38 42 42 45 49 49 53 57 57 87 58 5959 59 62 acceleration 62 63 67 67 67 68 nm n n 73 73 74, 74, 74 75 75 76 76 84, ceesees : 84 construction work - 84 stem . 86 87 87 88 se 89 89 89 a1 133 34 35 351 3.5.2 353 35.4 355 35.6 35.7 (2) Standards-compliance . 1 Cutting Pipe ... - 92 (1) Cutting tools 92 (2) Cutting methods 92 {@) Points to note concerning the cutting method 93 PipeBending .. (1) Bending tools (2) Bending methods (8) Points to note when bending 96 Pipe Junctions Welding junction (1) Welding process ceseeeeeeee : (2) Welding machines and jigs and tools . 98 (3) Welding operator .. ; ce 101 (4) Welding work procedures 101 (5) Inspection of welds ...... 104 (6) Points to note in the welding work 108 Flange junction .. 110 (1) Joints, 110 (2) Joiningmethod .......... wt {8) Points to note inthe joining operation wt Press type junction wt (1) Couplings .. 112 2) Joining method 113 (3) Points to note in the j 113 Compression joint 113 (1) Couplings .. 113 (2) Joining method : 114 {8) Points to note in the joining operation 115 Dresser and Snap Ring type joint 115 (1) Couplings 115 (2) Joining method 116 {8) Points to note in the joining operation 7 Grip Type joint 7 (1) Coupling Wy (2) Joining method 7 (8) Points to heed inthe joining operation 118 Pipe Enlarging Type joint 119 (1) Coupling 119 (2) Joining method 120 (3) Points to note inthe joining operation ...........226eeceeereeessees 1203.5.8 Other joining methods 120 (1) Victaulic Type Coupling connection 120 2) High flexibility type coupling junctions... 122 3.6 _Joints with Other Kinds of Pipe se 124 3.6.1 Withsteel pipe 124 3.6.2 With copper pipe 125 3.6.3 Withlead pipe cee 128 3.6.4 With unplasticized polyvinyl chloride pipe 128 3.7 Connection with Accessories 127 3.7.1 Withvalves . 127 3.7.2. With faucets, etc. 127 3.7.3 With pumpsor other equipment 127 3.7.4 Withflexiblejoints .... 128 3.8 Member Processing (Prefabrication) for Piping cee 128 (1) Work procedure 128 (2) Points toheed in the operation 128 (3) Inspection 128 3.9 Pipe Care eens 129 3.10 _ Embedding Pipe 129 3.10.1. Inthe ground . 129 3.10.2 Inconcrete ... 130 3.11. Supporting and Anchoring the Piping . 132 (1) Support fixtures 2... cece ceceetseeseeeseeeseseeeeteteetetes 132 (2) Supporting and anchoring methods : cesetteerees 133 (3) Vibration resistasnce for pipe and supports . 133 3.12 Compression and Expansion Treatment 135 3.13 Preventing Water Hammer 136 3.14 Preventing Corrosion : oe 136 (1) Pitting corrosion and crevice corrosion 137 (2) Stress corrosion cracking 137 (3) Intergranular corrosion 138 (4) Givanic corrosion 138 3.15 Condensationproofing and Heat insulation ..... 138 (1) Antisweating and heat insulation materials ceceteeteeeees 138 (2) Antisweating and heat insulation construction 138 3.16 Coating and Identification se. 140 (1) Coating cee 140 (2) Identification and color coding ceeeeeeee 1403.17 Testing and Inspection 141 3.17.1 Testing 141 (1) Water pressure 141 (2) Water flow ; 141 (3) Measurement of residual chloride 141 (4) Treatment after testing 141 3.17.2. Inspection 142 4. MAINTENANCE MANAGEMENT 4.1 Inspection and Maintenance Management 146 4.1.1 Methods of maintenance . , 5 . 146 (1) Preventing pitting corrosion 146 (2) Preventing corrosion ofthe outer surface of the pipe (heat-insulated piping) . 147 (8) Preventing atmospheric corrosion exposed piping) 147 (4) Preventing galvanic corrosion with other metals 147 4.1.2. Items to inspect and maintain : Penne 148 (1) Inairconditioning piping systems... cee 148 (2) Inwater supply and hot-water supply piping systems 148, (3) Checklist of items to inspect and maintain 148 4.2 Water Quality Control cece cee cece 148 421 Coolingwater systems .........2.+ ceseeeeeees 151 (1) The Ryznar's index (R.1.) 151 (2) Chlorine ion concentration 154 4.2.2. Hotand cold water systems 155 (1) Inclosed circuit 156 (2) Witha thermal storage tank 156 4.2.3 Steam systems 1987 42.4 Boilers ...... 187 42.5 Hotwatersupply and water supply systems 158 5. REFERENCE MATERIAL 5.1 Standards for Stainless Steel Pipe and Couplings 162 5.1.1. Standards for stainless steel pipe 162 5.1.2 Standards fr pipe couplings fr stainless steel pipe 168 5.2 Corrosion Characteristics of Stainless Steel .... 180 5.2.1. Soil corrosion .... ceeeeeee 180 (1) Soil corrosion . 180 (2) Soil corrosion data for stainless ste! 180 5.2.2 Corrosion by waterworks water 1825.2.3 Effect of cold working 183 5.2.4 Effect of welding cee 185 5.3 Various Experiment and Investigation Research Reports (Excerpts) 186 5.3.1 Corrosion resistance of couplings for stainless steel pipe ceseeese 186 (1) Resistance to galvanic corrosion with other metals 186 (2) Crevice corrosion when joined to other metals cesses 187 (3) Soldered couplings 188 (4) Compression type couplings 190 5.3.2 _ Indoor piping corrosion field tests 190 (1) Buildings and water used : s-. 190 2) Overview of the tests ene 190 (3) Results of the tests oo... sce cceseeeeeeeereeeteeeeeees secre 190 5.33 Soll corrosion testing of stainless steel pipe (Murayama, Yamagata Prefecture) .......0.0.ccceceeeeeeeeereeeeeees 195 (1) Outline of the corrosion tests voceeeeeeteees 195 (2) Results of the study 195, (3) Comments 196 5.3.4 Soll corrosion testing of stainless steel pipe (Kushiro, Hokkaido) ..--...--. 199 (1) Overview of the burial tests 199 (2) Results of the study cee 200 5.35 Corrosion resistance of stainlesssteelinsoll environment ....--..csssse+-+ 200 (1) Onsite corrosion tests 201 (2) Laboratory corrosion tests, 202 5.4 Examples of Problems with St au 5.4.1. Views expressed in questionnaire survey and measures taken by manufacturers 211 (1) Weld junctions 212 (2) Press type junctions 212 (3) Compression type junctions 212 5.42 Examplesof problems ...... a 212 (1) Presstype junctions problems (Table 5.21) 212 (2) Compression type junctions problems Table 5.22) ...... cesses 214 3) Soldered joints problems 215 (4) Gaskets problems (Table 5.23) 215 (5) Other problems (Table 5.24) 215 5.5 Actual Experience with Stainless Stee! Piping 217 5.6 Example of Installation of Stainless Stee! Piping ceeeeeeeeeees 220 5.6.1 KResearchCenter ....... 220 (1) Purpose and background of using stainles steel piping ...ss--se-s-s+ 221 (2) Impressions and problems during construction and after completion, and topics for the future .... 223,5.6.2 TSecurities Exchange Building (1) Why stainless steel piping was adopted (2) Example of use of stainless stee! piping (3) Problems in the design and installation of stainless steel piping (4) Future topics and suggestions concerning stainless steel pipe for piping 225 226 226 227 2291. THE BASICS1 THE BASICS 41.1 Definition and Classification of Stainless Steel wa Definition of stainless steel Stainless steel is considered to be rustless or rust- resistant steel, but there is no explicit definition, and in general any alloy of iron that contains at least 12% chromium may be thought of as stainless steel. By its composition, stainless steel is classified into Cr stainless steel and Cr-Ni stainless steel. The first stainless steel put into practical application was 12-13% Cr steel (in 1912, for edged tools), and about ten years later steel containing 18% Cr and 8% Ni appeared on the market. This 18 Cr-8 Ni steel has an austenitic structure and it is today most widely used in shapes such as sheet, strip, pipe, and wire because it has excellent corrosion resistance, workability, and weldability. The superior corrosion resistance of stainless steel is explained by its passivity Iron-nickel-chromium is known as an alloy that exhibits passive characteristics. There is strong support today for the “oxide film theory” as an explanation for the essential nature of passivity. This view holds that reaction products such as thin metal 0) jes cover the surface of the metal with a “passive coating,” forming a barrier to diffusion, preventing the exposure of the metal to the environment and significantly slowing down its rate of corrosion Classification of stainless steel Stainless steel is broadly classified by its composition into Cr stainless steel and Cr-Ni stainless steel. Alternatively, when classified by its metallography structure, stainless steel is broadly classified into the three categories of ferritic stainless steel, martensitic stainless steel, and austenitic stainless steel. In addition, as special categories, there are two-phase stainless steels and precipitation hardening. Ferritic stainless steel is a class of Cr stainless steel often used for the purpose of oxidation resistance at high temperatures. Martensitic stainless steel is another class of Cr stainless steel offering high hardness and high strength. Two-phase stainless steel or duplex is a class of austenite-ferrite stainless steel providing enhanced strength and corrosion resistance. The precipitation hardening type is a class of stainless steel in which intermetallic compounds are precipitated in order to increase its strength at high temperatures. Table 1.1 lists examples of stainless steels classified by the structure of the metal, with their main components other than iron.Table 1.1. Classification of stainless steel by structure of the metal Example of this, Structure of the metal class of stee! Main components Ferritic class SUS 430 18% Cr Martensitic class sus 4202 | 13% cr Austenitic class sus 304 18% Cr-8% Ni Austenite-ferrite class duplex SUS 329)1 | 25% Cr-5% Ni-2% Nb Precipitation hardening type SUS 630 16% Cr-4% Ni~4% Cu-Nb 1.2 Properti 1.2.1 1.2.2 Table 1.2 (a) to Table 1.2 (e) lists the chemical composition of various classes of stainless steel according to JIS. As JIS G 3448, "Light Gauge Stainless Steel Pipe for Ordinary Piping," only the two stainless steel types SUS 304 and SUS 316 are designated. of Stainless Steel Physical properties of stainless steels. Table 1.3 lists the physical properties of typical stainless steels.” in comparison with the physical properties of ordinary steel, austenitic stainless steels used for building piping have higher coefficients of thermal expansion, lower thermal conductivities, higher electric resistivities, and they are usally nonmagnetic. These properties, it should be noted, are very important in work that involves heat and electricity, such as welding. In addition, because they have a lower modulus of elasticity than ordinary steel, under the same load it tends to have a greater deflection than ordinary steel. For calculating the weight of piping in the design and planning of stainless steel piping, one may use the basic weight values set forth in JIS G 4310, "How to Calculate the Weight of Stainless Steel Plate.” Mechanical properties of stainless steel Table 1.4 lists the mechanical properties of typical stainless steels, including tensile strength, proof stress (0.2%), elongation, strength, and impact value.”” Austenitic stainless steels, used in stainless steel piping for ordinary piping, have high strength over a wide temperature range from low temperatures to high ‘temperatures and have excellent ductilities. Because the crystalline structure is a face-centered cubic lattice, even if the material is put under a tensile load, there is none of the clear breakdown phenomenon that is seen in the stress-strain curve ofordinary steel (see Figures 1.1 and 1.2), Therefore for austenitic stainless steels the stress value that corresponds to the yield point is usually defined to be the stress at which 0.2% permanent strain remains when the load is removed; this value is known as the proof stress. Their proof stresses are lower than those of ferritic stainless steels, and the proof stress/tensile strength ratios are low as well, being 40- 50%. These values, along with its high elongation value, show that austenite stainless steels are easy to work. SUS 304, SUS 316, and other "18 Cr-8 Ni" stainless steels have a fully austenitic structure in the solution treated state, but their structure, being in the borders of the austenite range, unstable, and when for example they are cold- worked, @ structure called work-induced martensite occurs and hardens the material. 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Stress-strain curve of ordinary {carbon or low alloy) stee! stress 6: Gauge length (50 mm) 02%6 strain Fig, 1.2. Stress-strain curve of austenitic stainless stee! 101.23 Corrosion properties of stainless stee! 0) 2 Passivity The corrosion resistance of stainless steel is attributed to its passivity. A strict definition of passivity would be quite complicated, so here we will define it very generally as “the phenomenon whereby when a thin, stable oxide film is formed on the surface of a metal or alloy that is highly active (that is, is highly reactive) and easily forms oxides by reacting with oxygen, the metal becomes unreactive with the environment and its corrosion resistance improves.” So too with stainless steel, the surface is coated with a thin, fine-grained ‘oxide film (passive film) that immediately repairs itself if it should get scratched or otherwise damaged in air. The existence of this film has been confirmed in various experiments, along with measurements of its thickness, and the composition of its oxides has been confirmed through precise analysis. The passive film on stainless steel can be damaged locally by chloride, bromide, and rhodan ions in aqueous solution, especially at stagnant condition, and the result is local corrosion such as pitting corrosion, cervice corrosion, and stress corrosion cracking. Pitting corrosion If the surface of stainless steel is freely in contact with an aqueous solution that includes chloride ions and oxidising agents such as oxygen, pitting corrosion as shown in Photo 1 may occur depending on the concentration, ‘temperature, and flow velocity. Fine pitting often occurs in the surface of stainless steel exposed to the atmosphere in maritime regions. According to the local cell theory of corrosion, pits form anodes, and the following anode dissolution reactions occur: Fe > Fe + 2e cr > cre + 3e Ni > NP* + 20 The area around an anode is a cathode, and for example a cathode reduction reaction of the oxygen in sol n takes place. 120, + H20 + 2e > 20H ‘The explanation given for the effect of the chloride ions is that they replace ‘the oxygen in the film (oxides) at the defects of the passive film, thereby promoting the destruction of the film. "It is necessary for the progress of the above anode dissolution reactions that, there are cathode reactions associated with the consumption of the same number of electrons (e), and thus oxidising agents such as oxygen are needed for pitting to proceed. For example, in the ferric chloride solution which is used a8 a pitting testing solution, the ferric ions constitute the oxidising agent and are cathodically reduced. Fe + e@ > Fel Electrochemically, the pitting potential Vc of stainless steel is important. This value varies depending on the type of stainless steel and the environment and is useful for comparing the pitting resistance of stainless steels. Vc is higher with higher chromium and molybdenum content of the stainless steel, lower chloride ion concentration in the solution, and lower temperature. How fast the liquid flows is one of the important environmental factors. In general, the faster the flow, the less pitting occurs. Pitting is prone to occur where the flow stagnates. Why this is so is not entirely clear but is explained as having something to do with how easily oxygen is supplied to the passive film. ‘One obvious way to prevent pitting is to select a high grade stainless steel that has a high chromium and molybdenum content. Other very effective methods are to lower the buildup of chloride ions in the environment, to give heed to the state of flow and eliminate areas where the liquid stagnates, and to apply cathodic protection so that the potential of the stainless stee! falls below Ve. 3) Crevice corrosion Crevice corrosion such as that pictured in Photo 2 occurs on the surface of the metal inside crevices when a metal or nonmetal piece is attached tightly to the surface of stainless steel leaving a gap, and the object is immersed in an aggressive medium such an aqueous solution containing chloride ions. ‘The cause of the corrosion in this case is similar to that which causes pittiny defects in the passive film on the surface of the stainless steel. The surface within the crevice acts as an anode, the part outside the crevices acts as a cathode, and crevice corrosion proceeds. The factors associated with the ing: the concentration of chloride ions, the concentration of oxidising agents, and ‘occurrence and growth of crevice corrosion are also similar to those for pit the temperature are important environmental factors, while chromium and molybdenum are important as alloy components. 12Crevice corrosion in general occurs and grows more easily than pitting corrosion. This is because in crevice corrosion the anode portion is masked from the easy entry of oxygen from outside, At the same time, the dispersion of the corrosion products to the outside is hampered, so that the hydrogen ions produced by their hydrolysis build up signi antly, lowering the pH inside the crevices and making it difficult for the anode portion to become passive again. Electrochemically, there is the repassivation potential Ea as the reproducible characteristic voltage. At this potential, crevice corrosion that has occurred and begun to grow is rendered passive again. Thus crevice corrosion can be prevented by maintaining a potential less than Eq. In other words, this is the cathodic protection potential for crevice corrosion. There are many precedents of the successful application of cathodic protection to crevice corrosion using sacrificial anodes. A typical case in which crevice corrosion is prone to occur is the combination of a stainless steel flange and an asbestos gasket, especially a graphited asbestos gasket. For the latter gasket the problem is the galvanic effect of the graphite, and for the white asbestos, the salt content in the asbestos gasket. In response, recent anticorrosive asbestos joint sheets have been blended with synthetic rubber, with the salt content reduced as much as possible and a corrosion inhibitor added. (4) Intergranular corrosion Selective corrosion near the boundary of grains in metal is called intergranular corrosion. When austenitic stainless steel is cooled through 400- 850°C, chromium carbide (CrC,) may precipitate on the grain boundaries, creating a low-chromium region that is selectively corroded. This thermal effect is called sensitization. During welding or brazing a sensitized heat affected zone is created in a narrow band adjacent to the joint. ‘An example is shown in Photo 3. When intergranular corrosion becomes far advanced, the strength of the material declines because crystal grains then fall out. Intergranular corrosion in stainless steel is linked with the amount of carbon that is available for the precipitation of chromium carbide onto the grain boundary. This has prompted the development and wide use of ELC grades having a final Lin their stainless steel designation, such as SUS3O4L and 3161, in which the carbon content is limited to no more than 0.030%, or SUS347 and 13,321, in which a small amount of Nb or Ti is added in so that carbon will combine to form Nbe or Tic compounds rather than CrC compound and grain Cr depletion. (5) Stress corrosion cracking Stress corrosion is a phenomenon that is characterised by the need from tensile stress, temperature above 60°C and a corrosive medium. It always appears as by transgranular cracking. It does not occur unless both of these factors, tensile stress and a corrosive environment, are present, but with industrial products itis very difficult to reduce tensile stress to a negligible level For stainless steel, chloride ions constitute the characteristic corrosive environment. That is why a boiling high-concentration solution of chlorides is often used as a test solution for stress corrosion cracking susceptibility of stainless steel. But in practice stress corrosion cracking often occurs under conditions of concentration by corporation (for example, at the gas-liquid interface), even when the chloride ion concentration is at the very low level of pure water. Stress corrosion cracking in stainless steel tubes is said to be a factor in many of the cases of cooling water leakage reported in nuclear power plants. Stress corrosion cracking in stainless steel is transgranular in nature (Photo 4), and not related to sensitization of the grain boundaries. Since the latter kind of stress corrosion cracking can be solved by avoiding sensitization, in general transgranular cracking is harder to deal with. ‘Stress relief annealing (SR treatment) reduces the level of stress on stainless steel, and this method for reducing the risk of stress corrosion is considered important as a prevention method. Many experimental results have suggested that air-cooling from heat treatment at 870°C for 1/2 hour produces the necessary stress releif. But, since this air cooling is liable to sensitize standard grades of 304 and 316, this SR treatment should be limited to the low carbon (304L, 3161) and stabilized (347, 321) grades. Stress corrosion cracking requires tensile stress and does not occur with compressive stress. So one method for preventing this kind of cracking is to make st less steel products in such a way that some compression stress remains in th surface, such as by shot-peening. The effectiveness of this ‘technique has been reported. Also, there have been many reports from the laboratory on prevention 14methods by cathodic protection. But the limit potential below which cracking does not occur cannot be said to be a characteristic value, because it is affected by the stress level and other environmental conditions of the test. Photo 1. Pitting corrosion in SUS304 Courtesy of Nippon Metal industry Co., Ltd. Photo 2. Crevice corrosion in SUS316L Courtesy of Nippon Metal industry Co., Ltd. 15Photo 3. Intergranular corrosion in SUS304 Courtesy of Nippon Metal Industry Co., Ltd, Photo 4. Stress corrosion cracking in SUS304 Courtesy of Nippon Metal Industry Co., Ltd. 16ve os eso se ow | et ry sow | (wey ‘sae | ep + sab | pha See tui eum 0) eos i apo a vRie3 {esta uoponaien soy e609 ‘on ups ope Hod permasesun SIeHaIeW adid se4,0 YIM UosuedWOD 1yBIEM pue UOISUaUIIG °S"L BIEL 741.3 Comparison with Other Pipe Materials 1.3.1. Dimensions and weight Table 1.5 lists the dimensions and weights of stainless steel pipe for ordinary piping and of representative pipe materials. In terms of dimensions, the outside diameter of the stainless steel pipe is the same as for copper pipe up to a nominal bore size of 25 Su. For 30 Su and above the dimensions are the same as for carbon steel pipe for general service. It weighs almost the same as steel pipe and is lighter than carbon steel pipe for general service, having about a third of the weight in thin walled pipes and about half the weight in thick wall pipes. Since stainless steel! pipe is thinner, its inside diameter is greater than that of other types of pipe having the same nominal bore size, and its smooth surface allows a greater flow of water fora given head. 1.3.2 Physical properties of pipe materials Table 1.6 lists the physical properties of stainless steel and other pipe materials. It is readily apparent that in comparison with copper pipe, stainless steel pipe has about the same coefficient of thermal expansion, a much lower thermal conductivity, a much higher electrical resistivity, and about the same specific heat. Table 1.6. Physical properties of pipe materials (reference values) Average egeffcent | thermal | specific | _ electric Stenermal | conductuty | “Rest | eesstvty | Youngs specite | ‘enlrgin Younes | sagnetiem gravity | Grt0878, | (cauemseeo (oem _| poets, | Mao (oro0rg | 00% | (0-100°O | tenor Carbon et Pipetorordinary | 706 | 116 | oxae ous | 142 | 21000 | yes Boing Phosphorons seondaed | asc | 178 | osae oosz | 171 | 11000 | no pie Unplastczed polyinyt 14a | 70 | onzx102 | 0035 | stox10# | - no Phi pipe Fesereniant unplsticze 156 | 70 | oarx1? | 025 | sox | - 0 Enis pipe Stanteeste Bipes tor 793 | 173 | oo39 on rn | 1970 | 10 Erainary piping 18133 Mechanical properties of pipe materials Table 1.7 lists the mechanical properties of various pipe materials. It is evident that stainless steel pipe has a much higher tensile strength than pipe made of other materials. The properties of stainless steel bars and plates are referred to for its hardness and other mechanical properties as a pipe material. Table 1.7. Mechanical properties of pipe materials (reference values)” Tensile strength | Elongation {kg/mm2) (%) Carbon steel pipe for ordinary piping 35.5 (530) | 46.4 ($30) Phosphorous deoxidized seamless copper pipe 247(S21) | 53 Unplasticized polyvinyl chloride pipe 53 100 Heat-resistant unplasticized polyvinyl chloride pipe 53 30 Stainless steel pipes for ordinary piping 73.6 ($53) | 47.5 (535) Note: Figures within parentheses () denote JIS values. 134 Corrosion resistance of stainless steel and other metals ‘As mentioned above, the stainless steels designated in JIS as being most suitable for building piping are the two grades SUS 304 and SUS 316. SUS 316 is made by increasing Ni adding Mo to 18 Cr-8 Ni stainless steel to achieve better resistance to pitting, cre corrosion, with acids (non-oxidizing acids) than is given by SUS 304. recent times that stainless steel! pipe has been used for building piping. Figure 1.3 shows how the velocity of tap water affects corrosion of various It is only metallic materials for water pipes.” With some exceptions, it shows a quite high corrosion rate, For example, with mild steel a flow rate of 3 m/sec produces a corrosion rate of about 0.42 mm/y. Under such conditions the corrosion loss of stainless steel would be almost undetectable. The Stainless Steel Association's subcommittee on corrosion testing methods conducted immersion tests on stainless steel and other materials in hot water. Table 1.8 is an excerpt from the data in its report. The dissolution of stainless steel is very small, and in both dissolved ion concentration and corrosion weight loss we have the relationship SUS 304 < SUS 430 < copper < galvanized sheet. For example, the quantity of dissolved iron ions is 107 times greater, and the corrosion rate is 77 times greater, with galvanized sheet than with SUS 304. But because, as mentioned above, stainless steel can be susceptible to local corrosion such as pitting, crevice corrosion, and stress corrosion, 19sufficient attention must be given to these types of corrosion when one uses water of 60°C or hotter and water that contains many chloride ions. Hot water is sometimes handled successfully in stainless steel piping. Failures from SCC. frequently arise on the hot tank walls just above the water line where water evaporates readily concentrating chlorides in the salt deposit left. Table 1.8. Results of (5-week) immersion tests in tap water (80°C) ” Concentration of dissolved metallicions Maximum corrosion Material rate for the five weeks ton | Maximum in each (g/m?-hr) week, (mg/l) 304 Fe 4 0.0003 430 Fe 09 0.0006 Copper cu 3.0 0.003 Galvanized sheet | Fe 43 0.0231 0.0030 0.0025 40160 brass 0.0020 001s o.0010 Corrosion rate (g/cm day: mild steel 0.0005 6 Gunmetal 0.0001 1 Tooy 300 St 700 m/sec Flow rate (rpm) Fig. 1.3. Effect of flow speed on corrosion of metallic materials by tap water (rotary vane test) (Shimodaira, Sawada) 20References 1) AISI Steel Product Manual, Stainless and Heat Resisting Steel 2) Saburo Shimodaira: Corrosion prevention technology, 16-2, (Feb. 1967), p.54 3) Stainless Steel Association: Hot water immersion corrosion test joint experiment report (1974). 22. DESIGN2 DESIGN 2.1 Scope of Use of Stainless Steel 2a ing Range of use of stainless steel pipe for ordinary piping, classified by application Many different kinds of pipe are used in construction, including pipe made of steel, cast iron, copper, plastic, lead, and cement. Through many years of experience, the right kind of pipe is chosen to fit the particular application and construction site, Light gauge stainless ste! pipe for ordinary piping (JIS G 3448), covered in this manual, does not as yet have the volume of field experience as conventional pipe. For example, when it is used for steam pipe or sewage pipe, problems remain to be ident ied there being an insufficiency of data on how well the anticorrosive film is maintained or resistance to stress, pitting, and crevice corrosion. Result of experiments confirm to date, that stainless steel pipe for ordinary piping is applicable to cold water supply, hot water supply, cooling water, and chilled/hot water. These experiments carried out by the Tokyo municipal sanitation laboratory and independently by the Stainless Steel Association include the elution of metals such as chromium and nickel in water pipes, carrying water at room temperature and hot water (80-100°C). Other applications await further research and will be added from time to time. Table 2.1 summarizes the categories of use for various pipe materials, and Table 2.2 lists for reference their specifications. As the standard for usable water quality one may take the waterworks water quality standards of the Ministry of Health and Welfare and water quality standards for makeup cooling water for freezing and air conditioning equipment put out by the Japan Air Conditioning and Freezing Industry Association (see Tables 2.3 and 2.4). When used for water supply pipes, the dissolution of chromium and other metals into the waterworks water could be a problem, but from the results of the experiments referred to above, no hexavalent chromium is detected, and even the total chromium is sufficiently below the water quality standard values for waterworks water that it is thought to present no problem. 24coolo e000 se ona open Manse perpen, 0° 0° ° °° orzi3 020021210879 ‘ars oye nsdn po oo) ‘eomsiems0} dn qe pe ad mayne oe noo pur 068) ° edhe Foal oe ‘anmjintosbevsn 090m per) ‘osensmen.ojeispert © colo ofo ofo © © ofo ofo ofo © 0 ofo ofo ofo reds ode Sia vos seu eaounmn 00 0° lower enon weebals (one 405 (oxen a5 mass (oessompnng as (outs arene oars fxd apo 0 as oa “essay eno poeeae ‘mapeassens ‘trio sos enemy abne en H}[oooo 0 of 0 o EF ]oo i 0000 0 [Jp [ocoe © o | veowls ocean ‘adid so sadha saxo 4o pue Burdid Asourpio 40} adic jaays ssajurers yo asn yosauobaye> “1-Z aIqeL 25wu one-9 od te 0 2 snes oe Tonmarvoreoree | ares wee eck | seen. tenses ‘nam a0 eee uted edad bre vn ss.abum wu ono toe 269 Ssueboe woereant 268 | wap, ° ee) Crabs wuooese se oa a en osenrmcion ati siabin wastes eg pe reese, woos: von | wmase-se | socovnwr yrs cane SS ‘abun pur won eee wae; weonareoe Hq |S asen uoseest seg sso goupeurpernso — | Spat: wecorse vee bint TE SE) pean munsoynsavonses| ‘abn eoe et wevnson wwoorsc soe | umes . cetupuenngscd| ww oosi-t2 ~ Raed eet ato vy oleae ssomtttsbesrcsmneet | Sebo aarp =a wssutineteppons| ewes ou reertoctes! | ~opsunmmeniosnoa Sth aS oe si wt wee eeeeasi | SR es em Fue fe] = Cs BEE FEE] nnn oon SS Tso | weesabon ac preps | ours pertain sod 2s | ee AEREERERTES | toe one ee ee Sitbaens mapa 1 va on me a ‘mioepuraigenmatsmsneson | amatunonunumen | eddyoedty ey tone, yeuarew Buidid snouea yo suoneryneds 72 alge 26sd ren weve “soe oe wesw (eted eu) guasouoo panvoquies ebnjuaUe>| enw ese poets yee . {ood urna) man yo ans commenrne| oT — ene vonierrr hs Tuber ot = | a oolgrmant seosenuano Mewss mse rumtyoe oss | oh “faaie Spuon asa senten ee Sonmanay aaa ou se tobe 5 _scnd ssouves word 290800 | = vos “vee { |” mpm cpm gstg ones 8 “game res ete a ssseoescrnn| a St = lS mca Bees Fag 5 net wnerses woes Tecperand it nn emsosiere RS eES| commence — mao in wtp wontons | SR, ui Burdid snouenjo suoneaypeds 77 a1qe1 27Table 2.3, Water quality standards for waterworks water (ordinance of, Ministry of Health and Welfare) vem Woter quality tandard for waterworks water TNigicadd nitrogen ondvivousaca Nica nivoge must notexced 10 mg Horie fos muntnot exceed 200 ngf Organic matter, ete (quantity of ptasium permanganate must notexceed 10 mgit General bacteria ‘umber of aggregates formedin | mioftestwater mut novexceed 168. Coliform groups must notbe detected Ganions ‘must not be detected Mercury ‘must not be detected ‘Organic phosphorus must notbe detected Hexavalent chromium Copper Tustnotexceed 1Omgh Tron mustnotexceed 0.3 nah ‘Manganese mustnotexceed 0.3 nah Zine Tmustnotexceed 1Omgh ead mustnotexceed0.1 mgt mustnotexceed 0.05mi Cadmium mustnotexceed 0.01 magi ‘Arsenic Tustnotexceed 005mgi Fluorine mustnaotexceed 0.8 ngf Calin pegnedur ic Grardnessy must notexceed 300 mg/ Heat-generating residues must not exceed 500 mgi Phenol must not exceed 0.005 mg/las phenols Negative on surface active agents mustnot exceed 0.5 ng pa value mustexceed 5B and must not exceed 86 ‘odor Tmustnot be abnormal Taste ‘must not be abnormal Color must not exceed °C Turbidity must not exceed 2 28Table 2.4. Water quality standards for cooling water for freezing and air conditioning equipment (JRA 9001") ten Water quality standard | Water quality standard valueforcoolingwater | value for makeup water pH asl 6080 6080 Conductivity [25%] (tem) 5 500 5 200 Chlorineions cmp) 5.200 550 Sulfurieacidions S07 (mgfh 200 550 Tota iron Fe (mai 51005) 503 Malalinty 200) (mg) = 100 50 Totathardness CaCO, (mg 200 = 50 ‘Sulfur ions * (mg!) must not be detected must not be detected Ammoniumions NH (mai | mustnotbedetected | mustnotbe detected stica 80, (mah 50 <3 212 Notes: ("), Cooling water means water that passes through a condenser, whether one-pass or circulating type. (@), JRA: Japan Refrigernation and Air Conditioning Industrial Associaiton ‘Temperature, pressure and flow volume ranges for light gauge stainless steel pipe for ordinary piping ‘The choice of a material for piping is made on the basis of the type of fluid and its temperature, pressure, and flow speed. The permissible temperature and pressure are directly related to the mechanical properties of the material, such as its tensile strength value. The flow speed affects the system design and is also related to the mechanical properties of the pipe material, taking into account the hydraulic pressure increase during water hammer. Figure 2.1 shows the recommended range of application for light gauge stainless steel pipe for general service with respect to temperature and pressure with that for carbon steel pipe for piping to SGP (JIS G 3452) and stainless stee! pipe for piping to SUS-TP (JIS G 3459). In general, if the ‘temperature is low, the pressure can be high and the diagram is toward the lower left, but like SGP it has been made rectangular. The basis for selection of the range of application is the official gazette (extra edition No. 63, dated October 15, 1979). First, SGP is set to 10 kg/cm’, 350°C, and then SUS-TP, which can be used in a range from low temperatures to high temperatures and at high pressure, is partitioned at 350°C, the same as SGP, and at a presure of 30 kg/cm’, which is used rarely with 29steam. And for the stainless steel pipe for ordinary piping, which is discussed in this manual, because of its thinness and in view of systems that include various kinds of couplings, the pressure is set to 10 kg/ cm?, the same as SGP (by calculation from the thickness of the pipe and the permissible pressure, it can withstand several times ‘the pressure), and the upper limit for the temperature is set to 100°C, as far as ‘temperature is concerned its applications for now are hot-water supply and chilled water. Regarding flow speed, the range shown in the solid lines in Figure 2.5 is generally applied, but for stainless steel pipes for general service, because of their superior resistance to cavitation and corrosion, it is possible to adopt a flow rate that is higher than for steel pipe, and the upper limit has been set to 3.5 m/s, as shown by the dotted line 350 — Stainless tee! pipe for 300 geggrtoewie O86 Carbon stee pipe for jeneral service SGP UISG 452) 200 Stainless steel pipe SUS- Temper- TPUIsG 3459) ature co) 100 ' ° 5 20 Pressure (kalem?) 50 - ~ 100 Fig. 2.1. Recommended temperature and pressure applicability ranges for stainless steel pipe for ordinary piping in building services 30Design allowable stress and maximum allowable pressure of stainless steel pipe for ce general se Design standards for strength members made of austenite stainless steel, which has excellent properties for high- temperature and low-temperature members, have been set forth by ASME (the American Society of Mechanical Engineers), mainly in connection with nuclear power. But since there are no explicit data for pipe, the provisional value for the allowable stress is set for now at 13 kg/mm?. This is one-fourth of the 53 kg/mm? tensile strength of SUS 304 as set forth in JIS and was decided upon partly because it is less than the JIS 0.2% proof stress* of 21 kg/mm? Using this allowable stress of 13 kg/mm, the maximum allowable pressure (the maximum allowable pressure for each pipe diameter corresponding to the allowable stress) is given by formula (2.1), for temperatures up to and including 100°C. pn 2oxSaey xt on wherer P: maximum allowable pressure (kg/cm) S: designs allowable stress (13 kg/mm?) 1 weld efficiency (0.85) t: wall thickness of pipe (mm) D: outsidediameter of pipe (mm) Note: With a material that does not clearly exhibit a yield point, such as austenite stainless steel, the stress that gives rise to a permanent strain of a certain size (generally 0.2%) is taken as the yield stress, and this is called the proof stress. 31Table 25 lists the maximum allowable pressure calculated for various outside diameters and thicknesses of stainless steel pipe for general service. The 10 kg/cm? design internal pressure for pipe mentioned in paragraph 2.1.2 is a value set as an upper limit for the proof stress during design and should be considered separately from the calculated values listed in Table 2.5. Table 2.5. Maximum allowable pressure for stainless steel pipe for general service ‘Alowable difference Vaximym ominat | ousise | imootisestomcter tolerance | Uritmasstigim) | alowable Semele | ameter iam) thicknes | 8 ° (mm) (mm) | Outside | Circum- (mm) vckness sus 304 | sus3i6 2) (om) | dtameter | ference tm) | SHB | SDS | tegen’ @ | os o7 ore | ones | 123 10 | 1270 os os | as | 1392 +0 |r fe | = | oe ose: | 002 | ana 20 | 2222 10 | gay | 0529 | ose | 994 as | 2058 10 ossr | oss: | 774 x0 | x40 | z0ae 12 oso | oss | 780 £020 wo | ar | 09 12 rae | sas es so | ass | oso 2 va | vas sas t0as co | cos | 060 15 220 | 2ar sas sors vs | 763 1s axa | 2st a co | oss 20 ase | aar 8 too | nas 20 | soso | 539 | se 288 1a | 190 20 cor | sat as sim | t0a% 150 | 652 30 rr | 2 wo 2e0 | 2163 20 | ayy [189 | 150 206 aso | 2674 30 18 | 199 nas zoo | ates 30 ae | ae 208 Remarks Outside diameter by Grcumference means the value ofthe circumference divided by cercular constant 32Dimension designations for stainless steel pipe for general services ‘The standards for stainless steel pipe for general service are given in section 5.1 of 5, Reference Materials. This gives the designations (Su designations) for stainless steel pipe for general service. Table 1.5 (in section 1.3 of 1, The Basics) compares their dimensions and weights with other pipe materials, but there are subtle differences with the nominal bone designs and the outside diameter designations. The nominal bore size of piping has been treated as an “indication.” For example, itis convenient to remember them by integers such as 25A, SOA, or 100A. This makes them easy to deal with, and thus these designations are still in use ions, A for steel pipe, B for copper pipe, today. But none of these nominal bore size dimensions agree with the actual outside diameter or inside diameters. In actual design or construction, the inside diameter is taken as the standard for calculating the flow volume that determines the piping pipe diameter, and the outside diameter is taken as the standard for construction. The nominal bore size of stainless steel pipe for ordinary piping is derived to a great extent from their history as products. A product is an “outside diameter standard” product that agrees copper pipe or steel pipe, but because copper pipe couplings used to be misused all its dimensions with the outside diameter of when couplings were not as well organized as they are today, pipes of 25 Su or less igned with the outside (corresponding to 25A for steel pipe) or greater are aligned with the outside or jameter of copper pipes, and pipes of 30 Su diameter of steel pipes. Thus the designations of stainless steel pipe for ordinary piping do not agree with the conventional nominal bore sizes A of steel pipes and from 30 Su to 75 Su are completely different from the nominal bore sizes A of steel pipes. For example, if one specifies 40 Su for stainless steel pipe for ordinary piping with the intention of getting 40A steel pipe, the outside diameter is equivalent to 32A steel pipe. These points require close attention, because they also affect the choice of valves, couplings, and heat insulating materials. 33Selection conditions It is quite difficult to determine the ba: on which to adopt stainless steel pipe for general service. As discussed in section 2.2, an evalution is made and a decision is arrived at after studying the various items from the decision criteria for and the points to consider in piping design. Here we consider the economics of corrosion resistance that must be considered as part of that decision process. Stainless steel pipe for general service is usually considered following corrosion problems with other pipe materials, and in deciding whether to adopt stainless steel, a balance must be struck between its anticipated effectiveness against corrosion and the amount of investment required. With stainless steel pipe one considers corrosion resistance, which is virtually never considered when one uses a conventional pipe material, particularly steel pipe. The general corrosion found in steel pipe does not occur in stainless steel pipe, but one must take into account the kinds of corrosion that can occur with stainless steel, such as stress corrosion, crevice corrosion, and intergranular corrosion, and one must specify installation methods to prevent such corrosion. One corrosion-related decision criterion is the number of years of useful lifetime of the pipe. Recently, “expected number of years of use” has been proposed as a measure of pipe lifetime. According to the literature,” this is defined as "the number of years of useful lifetime expected considering such conditions as the equipment system and external forces of degradation." We will attempt to set this parameter explicitly and rationally for various applications and piping materials. “External forces causing degradation” refers to all factors that cause stress, including the quality (water quality), temperature, and flow speed of the fluid, and corrosion and scaling caused by the soil quality in the case of buried pipes. This “expected number of years of use” has become a performance requirement for how long the pipe will last (useful lifetime), that is, the number of years until corrosion causes holes in the equipment piping or rust and scale clog the piping so that it no longer functions and the degradation cannot be remedied. Tables 2.6 through 2.9 list the expected number of years of use of pipe materials and joining methods classified by application, and of piping classified by type of system, as proposed in the literature® (reference examples). The decision criterion to be considered after one has understood the corrosion resistance discussed here, is the “economics” of pipe, which is discussed in the next section, 34Table 2.6. Expected number of years of useful lifetime and grade? Expected number of years of Cop useful lifetime A © 60 years 8 = 40 years c & 30 years D © 20 years E = 15 years 35“sem 0909 943 Jo saunas jo apes ays Wo Bupuadsp paramo) s 9pesb oR "weRrsI0s (e roune aa uo Bupuadap pasomo,s opesB an seem Bu}00> 0} edi en0w 104 a | e . @ rT ‘ v ® s s_|en ¥ ¥ a eta v > > ® > > a > | ‘aid sdo03 > > > s > > > >| sns_| bucks Arup soy ais oan sores > > > | aw | edidjenspouriopmad everinohog > > e_| an 2046 ome pour spon > a 3 a 3 3 as > o o 2 ® > > o | as o e ° a _| aos | syomseemsos ac one pamueneD abe ¥ v v lo ue Asdnsseiem 0} a6 ut Q Qe Qe Qe rows, pom yeuanew oie omar weeurep Tides Sunes amempe>| yee | von fans ‘asnsyo | Saupe’, | “Stes’ | sonsa | smemaon | empie>| 220 sottmaon | RE ‘pueson | Bure | -eimuon | STO now | “mem unsicbuae weno. ujorypuooany aqyovosecy ‘(s2}dwexe 22u19421) suoneoyjdde snousen Jo} pasn sjeyavew add yo awnayt| jnjasn yo sse0K 30 sequinu parradxe 0} sepes6 jo ajaeL “LZ 3IGeL 36‘ute edivemyouume bad pte aN ie “ogg. yomeunvesno we Burcu von puE perunne puRppune one ax use eunes joo} puns’ ave ese CRM Ce snspners guy re vanes 704 # Jo neng ne pow uauounens meyn pve am pedeD sim pne> Kn pue > MsbuyEre VRDAUIOHMDS ( "to,owo>Hoomsaaduomnio eon mon pens) eM mud 370) 5 RP HNL.) “werrsncynsnenasnmmemmnnonnanariatanmpencancemetrretertonmventnmes =m > > Fi Ls > 7 Te] Saran nip 3[, ‘ 2h | Sencar 5 a a eet ‘ a concn ee TS a 2 easel 3 1. > ee 2 F 7 | eateries 3 ‘ : | errors ae > ra erry ola eel ° > > > 3 (495 | pedo a0y) Burded 20; 200 joes voase | 2 2 a 40s _BuoMmuayem 20) dic ads PaNUENIeD, o om rots eminneca censoupe | Sento! | 6 ‘ ‘supa | ssuny | 3805 | sic | staenc> | ah | Ete |store] owe | Seem | Sap | fen | aie, | ER | oe | “EEE =a ooo ro — ee ee ‘o(saidurexe o2u019}0u) sjeuareui adid snowen 10} poyraw Buruio! hq auinays| jnjesn 40 sueak yo soquinu papedxe so; sopes6 40 9/9EL “BZ BIGEL 37Table2.9. Reference examples for expected number of years of useful lifetime of piping, classified by type of system” Residential including muttipe- ees Non-residential buildings Equipment piping by remarks ‘ypectsystem | at « Durabiltyot | Durabiity of rvateuse | Common-use min 28 | system in 12- person portion | "Reuruse” | “houruie Water supply pipe © c ° ° “0 Hot water supply 5 a 5 re “ty Pipe Drainage pipe c B B A 2) Cold water pipe - - c c *e) Cooling water pipe = 5 > c *e) steam pipe = = © c oe) Condensate return _ . : : pipe Fee extinguishing _ ° A a 4 Pipe +*(}) For waterworks water, itis assumed that as a general rule no water quality control including anticorrosives. is caried out, and inspection and diagnosis ofthe pipe interior and exterior is done as needed +0) For systems in which kitchen drainage water is mixed in, itis assumed that the inside of the pipe is cleaned coutat least oncea year +2) Forsystems with no water quality control, the grade is one rank lower. 44) wet-ype fie extinguishing pips are assumed tobe for systems with no water flow. 2.1.6 The economics of stainless steel pipe for ordinary piping It is very difficult to decide what criteria to adopt in considering the economics Of stainless steel pipe, that is, its life cycle costs of money to be expended versus its expected useful lifetime. This decision is made mostly in comparison with other types of pipe one by one. In estimating the useful lifetime of stainless steel pipe for general service, one would refer to the above-described expected number of years of use, because pipe of this type has only been in use for about ten years, so actual experience does not provide answers. In the following we consider a number of examples. Figure 2.2 is an example comparing the direct construction costs, item by item, for the air conditioning piping in a certain building, as between carbon steel pipe 38for ordinary piping (galvanized) and stainless steel pipe for general service. The items and percentages show that the piping construction costs for galvanized steel for general service show that for stainless steel pipe they are divided into the cost of processing members at the factory and the cost of on site installation. The percentage of the two added together is quite large, and the percentage accounted for by couplings is very large. Of course, there is a considerable difference in the total amount; the ratio of the total cost between carbon steel pipe for general service (galvanized) and stainless steel pipe for ordinary piping is 1:1.4. Figure 2.3 presents a comparison of total construction costs for two systems with different piping extensions, both including pipe for air conditioning piping, cooling water and chilled/hot water. Here 150A galvanized steel pipe for general service is changed to the case of 100A stainless steel pipe for general service. In this trial calculation example, a system planned with galvanized steel pipe for general service having a maximum pipe diameter of 150A is changed to stainless steel pipe for general service having a maximum pipe diameter of 100A, reflecting its improved characteristics, namely, its larger inside diameter and its higher flow speed. In this example the total costs of the two cases are quite close, being in a ratio of 1:1.2, indicating that t conversion is worth serious consideration Figure 2.4 presents an example of member processing costs for the cooling water piping (designations 300-25 Su) in a certain public building in Tokyo. The joining methods used were TIG welding and lap joints for designations of 50 Su and above, and compression joint type couplings for designations of 40 Su and below. Thus the economics, which are the prime consideration in selecting a pipe material, dictate that today a large amount must be expended for steel pipe, but a more profitable base is being approached as experience is built up, the number of couplings used is reduced, and efforts are made toward rationalization of member processing. Even today, steel pipe is full competitive with copper pipe. 39Sleeve inserts, ete Sleeve inserts, ete Bare pipe 20.2%, (14-436) Painting costs 16.5% Bare pipe {nsulation and painting costs 19.99% Zouplings 8.7% biackers frre, couplings Suspension] eM etOM yo go> 21.6% my (14-296) Suspension Piping costs brackets 11.1% incidental Vawes 25.6% —materais’ (ember procesing costs | 7 11% 15.0% (197886) 7" incidental raters Carbon steel pipe for ordinary Stainless steel pipe for ordinary piping piping (galvanized) (Above total 100%) (Above total 140% (100%)) * The numerical values for stainless steel pipe for ordinary piping have been adjusted so that the total values 14086 of the standard (100%) for carbon steel pipe for ordinary piping (galvanized). But the ‘igures in the parentheses () give the breakdown forthe stainless steel pipe for ordinary piping soas to total 100%. Fig. 2.2. Example of percentages of various piping construction costs (direct construction costs) 4020 -— (2) costs (5) Hot and cold water (main) B ESaing wae (eUsysen)| L &} Hocand coldwater main) (6) Hotand cold water (branch) (at system) (Usysem) (4) Hotandeold water branch) (7) Inmathine room r (anu sytem) flo 20 c ” 4 @ Eaaution cont (inden) a my ® 0 10 ° @ E @ @ . To To a O r @ | ts ef L 7 o Of © -[ L o 7 o ” o ° Carvonteel Sines Carbonstes! —_stines ive for Seelppe spe for Seelppe ordinary forordimary Erdinary forordinary ‘In ‘pi pon Pn (avanizes) pene (Gsivanizes) * (eample 1) (example) Note: ‘The maximum pipe diameter of the galvanized steel pipe for general service's 150A, but the maximum pipe diameter ofthe stainless steel pipe for general service Isat to 100A because ofthe difference inthe inside diameter and the difference in permissible flow speed. Fig. 2.3. Comparison example of piping construction costs (total construction costs) aFransport costs Cost of supplies. (1.5%). (1.5%) Application Cooling water piping Piping dimensions 300-25 Su Pipingweight —11.5ton Stainless steel pipe for ordinary piping Pretab processing 300~25S0 Processing costs about 2,400,000 yenvton costs a5 596) (30.9%) Note: Onsiteinstallation costs are not included. ‘Welded couplings (41.626) Fig. 2.4. Example of percentages of member processing costs 2.2 Piping Planning 2.2.1. Characteristics of and points to note in piping planning 19 planning involves the style and structure of the building as well as the equipment system, and these are all considered as one proceeds from basic planning to actual design. Here we will venture to discuss how stainless steel pipe for ordinary piping is characterized from the standpoint of design. Table 2.10 is a kind of checklist of what needs to be decided piping planning.” Among the items in this table, those that have particular relevance to stainless steel pipe for ordinary piping are the quality of the pipe material, the pipe diameter, the wall thickness of the pipe, the shape of the couplings and where they are used, how the thermal expansion and contraction of the pipe is absorbed and the pipes are supported, the thermal insulation specifications, and the gasket specifications. 42Table 2.10. Decision criteria and points to heed in piping design Decision crite Characteristic asstainles steel pipe Point toheed Cannot be bent witha radius smaller Has superior corrosion resistance. Butif | than × the diameter. Hand mater acenomnay" [wadingronircert: navenely (0 Quattyotte nine | ee eeearatensenarorang. | stectopnsegce ns nrg, reterial crevice corrosion, and stress corrosion. _| care is required for use in sea water or regres srtwatetersdongerotcreson caused by its components). ‘Su designation. Large inside diameter. Smooth inside surface. Occasionally the pipe diameter is decreased by one ot Care is required when matching steel 2) Pipe diameter ‘and copper pipe. Maximum flow speed twosizes 3.5m ‘When handling, be careful not to cause @) Pipethickness | Thin. Light. any deformation (8) Piping route ‘Aswith conventional pipe. (6) Arrangement of with conventional pi Re ‘Aswith conventional pipe. (©) Method of branchingané | Aswith conventional pipe. confluence Dissimilar metals: insulate surely to avoid galvanic effects. Welding: form adequate inner surface (7) Shape of couplings | Press ype, compression type, dresser ‘and where they are | and snapring type, clip type, expansion ed Pipe type, welds. ‘gasket shield and control heat input. (8) Support method ‘Could be galvanic corrosion. Insulation support. (9) Shape of valves and Sine they oe | swith convenonapipe ee Measrevareakentocoreay (ro abserstonct | xpanesidslacementisiage. __ seer inedeyee af exponionaré Bipesthermal | Expandsandcontacstoaboutthe | contraction andabsoro i Becaetlof exparsonand | en scone pie ‘Seaway erpesoncouings tose of 305 Crimson ___|stanesststadveneatiecedby | Teremustberoscuton of chorine specifications halogen ions. specially’ condensation), (12) Method of drain removaland air | Aswith conventional pipe. removal Crevice corrosion can occur with {gaskets that have ahigh halogen ion content, (13) Gasket specifications Use those which ae intended for use with tainiss steel 43Regarding the steel pipe material, if one simply decides to accept “stainless steel pipe,” one falls into the one-sided interpretation that it is "a completely problem-free pi material,” and a victory is achieved. This has been referred to in ‘the chapter on the basics, but the main characteristics are that, because it is austenite stainless steel, there is work hardening rather than quench hardening. These facts mean that although it is easily welded, care must be taken that the welding is done in a sufficiently inactive atmosphere. One must also be careful about the allowable bend radius (it must not be less than 4D). Properly speaking, after welding the areas reaching a temperature of 1000-1100°C, should be given a 19, but as long as the above-described precaution is taken, this step may be dispensed with for the subsequent solution anneal with quick cool 1d of piping covered by this manual. The thermal conductivity of stainless steel is low and this is associated with reduced heat loss from the piping. Howerer, since heat insulation is generally provided, this factor may be ignored, and in this respect stainless steel ical property of stainless steel pipe is that it has about the same coefficient of thermal pipe may be thought of as about the same as copper pipe. A characteristic ph ‘expansion as copper pipe and expands a great deal. This fact is of relevance for deciding upon piping routes and support methods. A characteristic mechanical property of stainless steel is that it is very hard. For example, its Brinell hardness is about twice that of mild steel, and it has superior anti-cavitation properties. ‘What might be mentioned concerning pipe diameter and pipe thickness is that the aforementioned “size designations" correspond to the outside diameter of copper pipe and steel pipe, that one must be aware that the designations do not mean exactly what they mean for conventional steel pipe, and that the pipe is thin. The thinness of stainless steel pipe means that it is lighter and easier to transport, and for deciding on the piping size, its larger inside diameter than copper pipe of ‘the same outside diameter, along with its smoother inside surface, means, in terms of design, that stainless steel pipe provides a greater flow volume than copper pipe of the same outside diameter and pressure loss. Standards for seven types of couplings have been enacted by the Stainless Stee! Association, each having its own characteristics: soldered type, press type, compression type, butt welded type, dresser and Snap Ring type, clip type, and enlarging pipe type (for the particular characteristics, see the next section and 3, Construction). Which type to select depends on what characteristics are desired, and this will involve consideration of the following points. First, as corrosion- 4a2.22 related characteristics, couplings should not have crevices, they should not have parts having excessive residual stress, during construction they should not be exposed for long periods to a temperature range that would induce intergranular corrosion, and there should be no galvanic corrosion with constituent members. Second, to facilitate construction work, they should not require a high degree of skill to install, their performance should be stable, and hand repair and reinstallation should be possible. Because of the high coefficient of thermal expansion of the pipe, a larger amount is required for displacement absorption than with copper pipe, and as a result one must consider the position of the expansion joints as well as the position of anchors (fixed supports) and restraints (supports that bind at right angles to the axis) Regarding heat insulation and gaskets, there should be no solution of halogen ions (especially chloride ions) from the material at parts where there is dew condensation or contact with the liquid. But with actual heat insulation materials this need not be thought of as a fatal problem, and during design it suffices to cursorily confirm this point (in consultation with the manufacturer of the heat insulation material and gasket material). In selecting the gasket material, as stated above, it should not have a structure that includes crevices. Joining methods and their characteristics, No screw-in connection is used for the stainless steel pipe for ordinary piping dealt with in this manual, because it is much thinner than conventional steel pipe (see Table 1.5 in section 1.3 of 1, The Basics). Various joining methods have been proposed for stainless steel piping, and there are ten methods to choose from. Seven have been enacted as Stainless Steel Association standards. These apply to pipe having a pipe diameter of no greater than 80 Su and use pipe fitttings of soldered type, press type, compression type, butt welded type, dresser and Snap Ring type, clip type, and enlarging pipe type. The other three joining methods, which have not been adopted as association standards and which are used for pipe of 30 Su or greater, are flange joints, welding joints, and victaulic joints. In recent years, however, soldering has fallen into disuse because of the high degree of skill it requires. These joining methods differ in how they form a joint, and each has unique characteristics. Table 2.11 lists the characteristics of each joining method from the standpoint of construction, 45including whether it uses heat, whether the joints are removable, the degree of skill required, the tools needed, and ease of on-site installation. Table 2.12 lists the pipe diameters for which each joining method is appropriate (for the joining mechanism of each joining method, see 3, Construction). From the construction standpoint, the joining methods can be broadly classified into hot joints and cold joints. It can be said that hot joints require skill and cold joints do not, and thus special tools are used for hot joints. Here and in the chapter on the basics we have said that stainless steel piping requires attention to corrosion. Needless to say, the same sort of attention must be paid to couplings and joining methods. Since corrosion often starts at joints, how well a kind of coupling or joining method resists corrosion is an important element is deciding whether to adopt produce susceptibility to a cert In the strict sense, each joining method may type of corrosion. For example, press-type and dresser-and-Snap Ring-type pipe couplings and flange joints might allow crevice corrosion to occur because of their structure, with includes crevices; press- type, clip-type, compression-type, and enlarging-pipe-type pipe couplings leave some room for concern about stress corrosion; and intergranular corrosion in parts affected by heat is a concern in butt welded and welded joints. But these are only mentioned as possi ities that do not necessarily occur, and verification testing by the various manufacturers indicates that at normal operating temperatures below 60°C there are no problems with stress corrosion 46Table 2.11. Characteristics of various couplings and joining methods Water ne tweot T oitare | 282! | ook | omste | bees | stander reat removable i installation | (mm) ange pipe wpacaed ae co | eranary_ | 86 cay | cosa | sasase Comoresion saoenie | = | ame | ontmay | ey | on | sasass couplings eae wees | somewhat pre [wns | me Jaana] amcor | aint | san | sane a or manual) orewer ‘snapring s ordinary el eas) 1 me a dinay [2 y | oose | sasass copings cinae soa pine ~ | m0 | ontinany |29Rese4 | oan, | cose | sasase tountingt Beersion eee synced ee = |e | cxtinay [20 cay | ose | sasasr couplings Fangejoins | =| ver [oatresuina | - | eon | 000 | Te Welding weiter | somewhat e no _| iraqi : joints a ° ao {automatic difficult 300-30 ermanva) vital fe - | yee | oie |= ey | a0] - #Weldingis done in the factory. ** ‘++ Tungsten inactive gas arcwelder ‘Stainless Steel Association Randards 47“sbus soars joomjo.asnessq uoanosiamouop eqrowes uaynsaibuepieg| | | ©} O| Oo] Oo} o} o| o| of o| o uoloneonn \y “nuvedseyimauop 0g e> 330m au ‘psinbes | Bupem Buudons ‘anys womDerd ssavoneiadoyenvew suming Ajeoneworne pueAyeruew ace suoa| O}| O| O| o| 0] 0] o| o| o} of o| o aut 5upIom, ‘asm hyensn = Buipiom oi. “hxaesnp pue aBvensBuyane 0g ou "posn ere Bucs pnussuessojnayeb eceds penn ensetunypespuenucten| | ©] ©] O}] O] 0] O} O} of oO] of o porous: pu wo and oq Ue PodBoar ha pve pique saci (pus ad aun Bubse40109) pas axe 003 e805 Oo} Oo} Of OF © Ose aai-ecivonveces o| of of of o © | sseanos aa oth supa ©} O} OJ OF CO] OF O ©] 20 Buudeuspuesossaig “Boyne jowah pm women uipemorearenuoiée aaeisepsitupemoneuan| o| Oo] 0] 0] 0] o| o| o| of} of o| o sSigyone> 9016 popjonane -pesn Anan Supram ou, *fneeinp ue wabvens Buyéne> sso ou “Gnu eum oh un os porno nao au ‘Bueno xpueum 0 sued yim porous: 40 uo and Aye 9 Ue) eo} of © O} wx adte-vorar8i0> “sBupzoqgnjo om jo eseseq uORNO um ouop eg OBUED “awn 104s # u PoUIor y002 Saud e Bulsn paxay-sseud axe sSuNdno> Oo} Of oO} CO} © (©) Benson ects octvars woneubep one sasumnen coe | ose | oz | os: | s2i | oo: | o€ | se | os | os | or | oe | sz a sreoeg mn | ‘20 yu9s je10U96 10} adid joars ssa]UIEIs 10} spornow BuILIOT “Z1-Z aIGeL 482.3 Pipe Diameter for Piping 234 Flow velocity standards In deciding upon the pipe diameter for piping, the equal friction loss method is often used. This is a method whereby the pipe diameter for a flow volume is selected by setting the unit loss of friction head to a constant value. By this method, 1s the flow volume increases, the flow velocity increases as well. Here methods are also used to set a limit on the flow velocity and minimize its effects on erosion and water hammer. ‘Where to set the flow velocity standard is a difficult problem. For example, as shown in Figure 2.5, it has been taken for each pipe diameter or for the location of +the piping, or (not shown in the diagram) the flow velocity standard has been made ‘to correspond to the number of hours of operation per year. Today all these factors are considered in deciding the matter. But, as is evident from Figure 2.5, it can be seen that the smaller the pipe diameter is, the lower the flow velocity must be in order that the unit loss of head due to friction does not increase, and from the fact that naturally the smaller the pipe diameter, the lower the flow velocity that can be selected, by the above- described method of combining the equal friction loss method with an upper value for the flow velocity, itis evident that this is a practical method. Figure 2.6 shows, in a flow rate chart, the applicable ranges for the flow velocity standards that are set. The portion labeled "normal range of application” is set as ‘the normal design level allowing the same handling as with conventional pipe, with reference to Figure 2.5. The portion labeled "maximum range of application” is set for a higher flow velocity, based on the fact that stainless steel pipe for ordinary piping is very resistant to cavitation; this is the provisional range for use when the highest priority is to be given to economy. The use of stainless steel pipe for general service sometimes allows one to select a smaller pipe diameter for a given flow volume than the pipe diameter that would be required with carbon steel pipe for the same service, because the stainless steel pipe has a greater inside diameter for a given nominal bore size and has a wider range of application on the flow rate chart. As an example, Table 2.13 shows the flow volume for various pipe materials as calculated by the Hazen Williams formula. A flow velocity standard of 2.0 mvs (1.4 mis for copper pipe) and a unit loss of head due to friction of 45 mmAgim were used, in conformity with the normal range of application, but for stainless steel pipe for general service, 3.5 mis was also added. 49Asis clear from Table 2.13, the pipe size falls off mare in the range where the flow volume is determined by the flow velocity standard. For example, what corresponds to 200 A for v=3.5, 7000 min for stainless steel pipe for general service is 300 A at v=2.0, 7000 limin for carbon steel pipe for general service, a difference of two sizes. Also, if, as in water supply piping, the pipe diameter is set according to the loss grade determined from the potential head between an elevated tank and the equipment and from the pressure needed for the equipment, then the flow velocity standard cannot always be followed, and in such cases the above examples cannot be applied. Flow speedwithin pipe (nh) Type 1 2 3 «os ‘Steel pipe 2 asa 2128 50-1008, f2_ ie a so gle eonditionn Senetioning Pumpintake pipe aaa oper pipe aay Staines tel pipe for 06 Srdinary pom _ Steel pipe Ordinary piping ep Pumpintakenipe | 95 1 wate Pump discharge pipe 13 20 Steel pipe ety Stainless see ppe for en as Ky ol * The dottedtne portions determined in consideration of nose, vibration, water hammer, pressure-transport power Fig. 2.5. Flow velocity standard for various pipe materials 50Flow volume (min) A 50100, Loss of head due to friction (mmAaim) Fig.2.6. Standard (upper limit) for flow velocity and loss of head due to friction for stainless steel pipe for general service 51suapyjacn moj 1 ‘(w/ovwl) peoy vonDu 40550) un u"{Snu) pecs MOY :A ANON (oes +2) s0000 oc: =>) aie roms peuy epuen (anton ary (os =>) somos TFEWAE] 210u06.0jsoKf oonerarues soy alse os 5508 seat yoah, [ae | ne {och s068e9 mos somo) edi ans pau epvon Kunsjod“soisoses0u96 10} 6s poss boars mor eppnueoiur feu 40} 2d aan s2]uEAs mo 6n) 91 4109 eUIWON ‘eJnusoy sweyjan-uezeH aun Aq ‘adic jo sed Jatno pue a>yuas /es0Ua6 40) add jaars ss9]UIErs UaaMIag (UI) BwINIOR MOY JoUOsUEdWOD “EL'Z 9191 82232 Flow rate chart and local loss equivalent length Flow rate charts for stainless steel pipe are shown in Figures 2.8 and 2.9, which were both prepared using the Darcy-Weisbach formula* following the flowchart given in Figure 2.7 (verification tests were also conducted). Figure 2.8 applies to ambient-temperature fluids in water supply pipes, cold water pipes, and cooling water pipes, while Figure 2.9 applies to hot-water-supply pipes and hot-water pipes. These flow rate charts yield about the same values as the results of the Hazen. 50. Regarding the local loss equivalent length for couplings and valves, since no jams formula** with the flow coefficient: data characteristic of stainless steel pipe for ordinary piping are available, we use the “Local loss equivalent length of couplings for copper pipe’ listed in Table 2.14. *Darcy-Weisbach formula **Hazen Williams formula: v = 0.35464cD°1* where : flow coefficient unit loss of head due to friction lossgrade(mAgim) (mmaqm) D: inside diameter of the pipe (m) average flow speed ihp (m/s) gravitational acceleration (mv/s’) inside diameter of the pipe (m) specific gravity of the water (kg/m?) friction factor (see below) surface roughness (mm) dynamic coefficient of viscosity (m/s) friction factor in the transition zone friction factor in the laminar flow zone friction factor in the critical zone friction factor in the complete turbulence zone Reynold's number Reynold's number for which ais constant 53ree ves No n0.0055(1 (20000 = + 10° x8 a * Re Grist nia value) oe T 7 eee 28 os (2tog¢ EL ¢ cae ReVaT 3.7d No ves | ee 204 pa Rege= Re ve uo Re = Regr - . T° cotbrook’s formula 1 ang 22 a ep Cranks ee re ies a ceimtion v 1 {(2og( +114 ‘ Re < Laminar flow zone > Re a ¥ og 7 Fig. 2.7. Flowchart for preparation of flow rate chart for stainless steel pipe for general service 54Flow volume (min) 0.009 HOC. 7 850g? v= 1.207XI0-HF fe. =8.8 m/e 100,000 ; 1 0,000 2,000 40,000 30,000 20,000 10,000 000 5,000 4,000 3,00 2.000 ‘0 | | 1 r Ft 4 SE A 1 a 20 W590 BO T0O a0) a0) LOOTED OH Friction Loss (mmAg/m) Fig. 2.8. Flow rate chart for stainless steel pipe for ordinary piping (10°C) Prepared by Makino and Miyata in 1975 55Lfle/a? + =0.96210% w/e, 9m TT +4 we a0 200 300400600 tO 1,000 vim sipe for general service (80°C) Prepared by Makino and Miyata in 1975Table 2.14, Local loss equivalent length of fittings for copper pipe” Nominal bore Equivalent pipe length (m) oo | ax | gorr | gore | Seenote | Seenote | foctiae.” 5u | 4 | aiow | eibow | 28, | “aight | date | clobe | smingcheck | Socket valve | Save | vale: se va] 13 | 030 | ore | os | 009 | o06 | 227 | 24 | 009 20 | 20| 038 | 023 | os | o12 | oo8 | 303 | 36 | onz as | 2s| oas | 030 | o76 | or | oop | 379 | as | one x | os | o3 | 091 | ors | or | sas | sa | os so| «| o76 | o#s | 106 | oz | ors | cor | ca | oz co | so| 106 | os | 152 | 030 | oa: | sas | 4 | 030 7s | 65 | 121 | 076 | saz | o39 | 028 | 100 | 2 | 039 so | 20 | 152 | om | 227 | oas | o30 | 1212 | 120 | os too | 100 | 212 | 121 | ase | os | oa2 | 1909 | 16s | oo ras | ras | 273 | 152 | 290 | ore | oso | arr | aro | o76 s50 | 150 | 302 | 192 | 455 | os | ost | 2545 | 210 | om 200 | 200 330 250 | 250 30 Note (1): made of bronze casting }: made of bronze casting of SOA or les, cast iron of 65A or greater, 2.4 Supports and Anchors The issue of supports and anchors is pertinent not just to stainless steel pipe for general service, but we discuss them here, including general considerations, because stainless steel pipes are thinner and lighter than pipes made of other materials. 2.4.1 General considerations (1) Load on piping and support and anchor points The load on piping is broadly classified as follows. (a) Stress in the axial direction () Stress due to internal pressure (ii) Stress due to own weight, water, thermal insulation material, valves, etc. (including stress due to bending moment) (ii) Thermal stress (including thermal stress due to bending moment) (iv) Earthquake force (including earthquake force due to bending moment) 87(b) Stress in the circumferential direction () Hoop stress (stress in the circumferential direction due to internal pressure) In general the pipe wall is subject to a number of the above stresses in combination, but the supports and anchors must be such that the combined stress is no greater than the allowable stress value. The following is a presentation, in summary form, of what should be considered with regard to supports and anchors. (a) Weight of the piping (b) Vibration and shock from outside (©) However of pipes due to thermal stress (d) Mutual vibration of pipes and structure (e) Support spacing with respect to deflection of the pipes (2) Support and anchoring methods Support and anchoring methods are classified as follows from various standpoints. (2) Classified by direction of the piping (Vertical anchoring Gi) Horizontal anchoring (iii) Anchoring in the axial direction (b) Classification by flexibility (i)_ Rigid anchoring (no displacement at all) (ii) Flexible anchoring a) Consideration of displacement in the direction of the pipe’s axis b) Consideration of displacement in the direction perpendicular to the pipe’s axis Vibration isolation support such as springs, rubber, etc. (©) Classified by pressure (Under normal load @ (6) Classified by number of pipes ())_ Support of a single pipes only Not under normal load, only constraint (ii) Support of multiple pipes together Examples of these are pictured in Figures 2.10 through 2.17. Earthquakeproofing measures for piping supports must be considered 58individually, but the literature” basically indicates that it is by “no-displacement methods.” Figures 2.18 through 2.22 are examples taken from the literature.” (3) Allowable stress in stainless steel piping Based on a 0.2% permanent strain stress of 21 kg/mm, a repeated stress (test value) of 20 kg/mm?, and values such as one-fourth of the 53-kg/mm2 tensile strength of SUS 304 steel, and allowing some margin, the allowable stress for stainless steel piping is set at 13 kg/mm? 2.4.2 Horizontal piping (1) Spacing between supports Calculation formulas for a beam anchored at both ends and bearing an evenly distributed load are used for determining the spacing between supports for horizontal piping. There are calculation formulas for simple beams and for continuous beams, and when the calculation is made for the same spacing between supports, the deflection (6) of the former is about five times that of the latter, as is clear from the formulas in Table 2.15. Therefore if safety is the top priority, there will be no problems if one considers the allowable stress by the simple- beam formula and sets the minimum slope of the piping to eliminate standing water caused by deflection. But it can be said that the shape cof most piping can be construed as a continuous beam, and that during use the water is not drained from pipes for water supply, hot-water supply, or cooling water, and as a practical matter there will be no major problems even if the calculation is made with the continuous beam formula. Also, the support spacing for stainless steel pipes and copper pipes is sometimes determined in conformity with a continuous beam, and we have treated it as if dealing with a continuous beam. Based on the foregoing, we have set the following two principles for determining horizontal support spacing: (2) The stress on the piping must be no greater than the allowable stress. (b) There must be no standing water caused by the deflection (8) of the piping asin Figure 2.23 (the piping must slope). 59™ AL a «© Fig. 2.10. Fixed anchor (fixed support platform) w ig. 2.11. Guide anchor (sliding support platform) Jam nut Turnbuckle va Suspension bar Band / Fig. 2.12. Bar hanger (pipe suspension) Fig. 2.13. Vibration Hanger vibration isolation rubber lation support for integral horizontal pipe ver suspension steel barsare Supportangle Vibration isolation support for multiple horizontal pipes Vibration isolation rubber tion isolation support for multiple vertical pipesSliding lock rubber A Fig.2.16. Vibration isolation support {for integral vertical pipe ‘Vibration isolation material Piping (thermal insulation) Fig. 2.17. Simple vibration isolation & d Vv] Fig.2.18. Through-the-wall portion” Suspension member Fig. 2.19. Example of using a wall” Fig.220. Bracket support? Use of both suspension member ‘and diagonal brace Fig. 2.21. Bracket support from a wall (or pillar)” Suspension member Duiagonal brace Pipe Pipe clamp. Fig. 2.22. Method of suspension from a slab” 61Table 2.16 lists the support spacing calculated on the basis of a continuous beam, with may be used for design purposes, as well as the gradient of the piping required for this (for the calculation formula, see Table 2.16). According to the calculation, the stress that arises in piping having this support spacing is about one-tenth of the allowed stress, so there is no problem at all. Table 2.20 gives the maximum spacing between anchors to avoid buckling when subjected to earthquake forces of 0.5 G in the horizontal direction, (2) Vibration The natural frequency (f) of horizontal piping supported or anchored at a given spacing can be calculated from the formula in Table 2.18 using the coefficients in Table 2.17, which are determined by the form of the support or anchoring. The value of the natural frequency is frequently an issue when fif = 1V(2) (where fp is the frequency of a building during an earthquake) and the resonance point is to be avoided, or when, for example, greater than 20 Hz and the resistance to vibration is to be improved. Table 2.18 shows the results of calculations for simple support and band anchoring, Although in principle fo is calculated by the designer of the structure, in general itis given by formulas (2.2) and (2.3). . 1 Steel structures: fossa (He) (2.2) RCstructuresand structures inwhich 1 different types are mixed: fo fo=—om (Ha) ae where fg: frequency of the building (Hz) H: above-ground height of the building (m) (3) Spacing between anchor points with respect to acceleration in the horizontal direction When horizontal piping is long and is supported by suspension bolts, then even if the spacing conforms to Table 2.16, the piping is relatively free with respect to forces in the horizontal direction, and long spans between two points spaced farther apart than the hanger spacing act as beams anchored at both ‘ends and are subject to a large bending moment. Formulae for the bending moment for beams supported at both ends and for cantilevers are given in Table 2.19. The bending stress that then arises is given by formula (2.4). This 62bending stress should be no greater than the allowable stress. Table 2.20 gives the maximum spacing between anchors when the acceleration in the horizontal direction is 0.5 G. Thus buckling will occur unless the spacing between anchors is less than the values in this table. 2.43 Vertical piping ‘The spacing between supports or anchors of vertical piping is often determined by whether it will withstand the bending moment caused by the displacement between strata (Figure 2.24) and whether there will be no buckling due to its own weight. Thus a long spacing between supports is adopted in flexible- structure buildings that have a large displacement between strata. In that case buckling may generally be disregarded, although there is a greater risk of twist buckling. If the spacing between supports is long then, as in the case of vertical piping discussed above, it must be no greater than the maximum spacing between supports that withstands the bending moment caused by loads in the horizontal direction (Figure 2.25), such as the acceleration that occurs during earthquakes. The calculation formulas in Table 2.21 give the minimum spacing between supports to withstand displacement between strata in flexible-structure buildings and rigid-structure buildings, and the maximum spacing between supports to withstand the bending moment caused by loads in the horizontal direction. Actually, spacing between the two is permitted, but as a practical matter one support on each floor suffices. Table 2.15. Maximum bending stress and deflection in horizontal piping made of stainless steel pipe for general service” ‘Type otsupport | Maximumstresse(kgiem’) | Locationofe | Maximum deflection (cm) | Location of Simple beam | —(624w12+12.6w)0_ | Inthemidate | _12,880wL++20,600w13_| inthe middle aa T of the span zi of the span continuous | _(.23012+630WI0 | oe ine |_2870ites.t60wL2 | Inthe middle beam T port poi tr of the span W: evenly distributed load (kg/m) (weight ofthe pipe itself + water + covering) W: concentrated load acting on the middle of beam (kg) E: Young's modulus (kg/em*) geometrical moment of inertia?) Li length ofthe piping (m) ‘outside diameter of the piping (em) 63= Tht lh Fig. 2.23. Deflection in horizontal piping Table 2.16. Spacing between supports and required piping gradient in horizontal piping made of stainless steel pipe for general service Required Spacing between Even) Spacin Loadon fiominal | gutibuted | between | Support pining | cateuation formula, | #90" forethe types eee | Nica supports | ‘pointes | gradient, conditions Pipe ‘(kgim) (mm) (ko) value) ‘Steel pipe | Copper pipe 10 057 043 1 1s se ane 3 nz 062 Ee ee xia | s10 2 TH yo He 7 Le spacing between 25 17 1 mo ‘a/ 5 a s 290 7 & aateaionoriem) | | cas “0 357 448 < 30 432 648 1 1 ® sa 30 a7 He [te nan =20 5 89: 1 30 80 ANZ an 2424 1 G: piping gradient S25 100 1757 35.14 000 125 2421 so 6053 1 | conditions: 540 180 35.20 88.10 1250) (1) own weight when full Stwaterand thermal <30 200 sare 168.16 1 insulted 250 7024 60 nan ee |) detlectiond = tomm | =50 300 | 10582 2746 + According to HASS (Heating, Ai Conditioning and Sanitary Standards) 107,206. copper pipe isthe Su equivalent. However, the pipe diameter forsteel pipe and Table 2.17. Value of the coefficient a of the natural frequency of piping” Form 1. Cantilever 176 2. Simple support 492 3. Anchored atone end 763 4. Anchored at both ends m2 5. Bandanchored experimentalvaivey ES a) ea 64Table 2.18. Natural frequency of supported or anchored horizontal piping (stainless steel pipe for general service) Caleulation formula, conditions Tominal | __ Natural frequency a) °°Sa)* [Simplesuppor | Band anchor 10 93 159 2 na 189 20 a4 186 25 ns 203 20 93 159 0 107 183 50 82 man 60 107 183 8 127 az 20 89 152 100 108 18s 125 80 17 150 104 79 200 87 us 250 108 v2 300 13 193 f-aVEWB 1 + natural frequency 2: coetfcient depending on form of support(Table 218) + Young's modulus 1.97108 (kalem’) 1 + geometrical moment of inertia em) W.: weightof piping between suppor points (kg) Wet LA: spacing between support points (mem) (able 2.17is used forw) Table2.19. Bending moment due to acceleration in the horizontal direction in anchored horizontal piping Maximum bending | Point where maximum Type of support moment bending moment occurs Beam anchored at both y bal awl/8 Support point Cantilever awl Support point where a: acceleration (mis?) w: evenly distributed load ( —*2- L: spacing between anchors (m) 65Table 2.20. Maximum spacing between anchors (m) for which there isno buckling in horizontal piping subject to a horizontal load (stainless steel pipe for general service) Nominal bore size Maximum spacing between (su) anchors 10 58 13 65 20 8.0 25, 89 30 99 40 103 50 10.7 60 12.2 75 129 80 147 100 15.6 125 16.3 150 19.3 200 20.3 250 21.0 300 21.6 ‘The values are taken to be acceleration a = 0.56, allowable stress a» = 13 kgimm?, “ifs ZI Fig. 2.24. Support of vertical piping _—Fig. 2.25. If vertical piping is subjected to acceleration 66Table 2.21. Spacing between supports (m) in vertical piping (stainless steel pipe for ordinary piping) Nominal bore | Maison depaeamentbetmeenscats” | Yerwnichihere Gnobuckingwren ve ‘subjected to a horizontal load (su) Flexible structure Rigid structure im 10 oa os 58 3 09 os 65 20 19 o7 80 2s 12 os as 20 13 09 99 ‘0 “4 19 103 0 1s " 107 «0 7 12 12 8 19 14 ne 0 21 15 waz 100 2a 7 156 125 26 18 163 150 28 20 193 200 32 23 203 250 a5 25 20 300 38 27 26 Galevation |# = VEER |e = VIET 4 2 VEEAIOSH) formule -09535Viz =06782VTZ_ VER where _f: spacing between supprts (m), Z: section modulus (cm*), acceleration = 0.5G, «7 allowable stress 1300 kg/cm?, E: Young's modulus 1.97 x 10® kg/em?, w: evenly distributed load (kgm). 2: displacement between strata flexible = 2em, rigid = tem 2.5 Handling the Expansion and Contraction of Piping 2.5.1. Expansion and contraction of piping (1) Coefficient of linear expansion and the amount of expansion or contraction ‘The expansion or contraction of piping caused by heat occurs in the piping as thermal stress and can bring about rupture of the support points, buckling of the pipes itself, or breakage of the equipment connected to the piping. This is an important consideration in stainless steel pipes for ordinary piping, which expands and contracts more than other materials. Table 2.22 lists the average 67252 coefficient of linear expansion for various materials. The value for 18-8 stainless steel, which is used in stainless steel pipes for ordinary piping, is normally 16.7 x 10%, which is about 50% greater than that for carbon steel. Table 2.23 calculates the expansion per 10 m of pipes length at various temperatures, taking 0°C as the base. (2) Thermal stress and reaction ‘Thermal stress occurs when a piping system is heated, and as a result there is a reaction on support and anchor points and on the equipment. For example, in straight pipe that is anchored at both ends and has no displacement, the compression stress given by formula (2.5) arises, and its support points are subjected to the reaction given by formula (2.6). a= Eadt (2.5) where o: compression stress (kg/mm?) ‘Young's modulus 1.97 x 10* (kg/mm’) a: coefficient of linear expansion (mmnir ‘At: temperature difference (°C) Fok (26) where F: reaction (kg) ‘A: cross-sectional area of the piping (mm’) The literature” gives detailed figures and tables for calculating the reaction in bent pipes such as those shown in Figures 2.26 and 2.27, and these are used for the calculations. Also the reaction on the connected equipment must be no greater than the allowed value for the equipment, but the data is avi lable from the manufacturer. Table 2.24 is an example for a pump. ‘What to do about expansion and contraction There are two basic ways to absorb the change in dimensions caused by the ‘thermal expansion of piping. One is to absorb it by the flexibility of the pipes, and the other is to insert expansion joints. In the flexibility method, one calculates the reaction, bending moment, and angular moment on the piping, its support and anchor points, and the connected equipment of the contemplated piping system and compares each with its permissible value. But this involves an enormous amount of calculation and requires a computer. We will not deal with this here except to make some remarks about a simple judgment method. 68This simple judgment method, known colloquially as “the ASA judgment method," is an empirical formula that says that the flexibility of piping can absorb its expansion if itis less than the value gi through (c) holds. 2n in formula (2.7), where constraints (a) — saz 27 nominal bore size of the pipe (in) total expansion to be absorbed (mm) piping extension (m) }: Spacing between anchor points (m) Y = V@X+EXY + (y+ by) + (ze azy ‘4x, dy, Az: amount of thermal expansion in the x, y, and z directions (mm) Ax, Ay’, Az’: displacement of the anchor point in the x, y, and z directions (mm) (The direction opposite to the expansion of the pipe is taken tobe positive, and in the same direction is taken to be negative.) Constraints: (2) The piping system has no branches. (b) Along its entire length there are no changes in pipe diameter, thickness, material quality, temperature, etc. (0) The anchor points are the two ends. If the displacement cannot be completely absorbed by the flexibility of the piping, expansion joints, flexible joints, or ball joints are used. Consideration of the adoption of such joints involves a stress analysis by computer, as for steel pipes. It is a characteristic of stainless steel, however, that for general service the distance between the expansion joints will be short because of its greater expansion and contraction. Table 2.22. Average coefficient of expansion for various materials (mm/mm°C x 10°)? Temperature range) 100-0 | 0-100 | 0-200 | 0-300 | 0-400 | 0-500 | 0-600 | 0-700 Materials “Alumimun 210 | 240 | 267 | 255 | 261 | 266 | 279 | 203 Brass 166 | 175 | 180 | 195 | 189 | 193 | 200 | 206 Copper 157 | 6s | t69 | 173 | 178 | 182 | 185 | 189 Castiron 33 | oa | nofrz]re] - | - | - Carbon steel (03-0.40) sos | 115 | 119 | 126 | 133 | 140 | 142 | 145 12.Crstainlessstee! 97 | ito | tts | 21 | 12a | azo | 132 | 133 18Cr-BNistainiess steel s62 | 167 | 172 | 176 | ter | 195 | 188 | 191 69Table 2.23. Expansion per 10-m length of pipe (mm/10 m) (set to 0 at 0°C) Temperaturec | -10 0 10 20 30 40 50 60 70 8 90 100 Stainless stee! pipe forgeneralservice | -16 0 17 33 50 67 84 100 117 134 150 167 (65308) oma 11 0 12 23 35 46 58 69 81 92 104 115 Copper pipe 16 0 17 33 50 66 83 100 116 133 149 166 ‘AE : expansion of the pipe (mm) + coefficient of linear expansion (mmimen alevlation formula 8: total length of pipe (mm) At : temperature difference (©) 70me Pe A 4 4 P« Ln UM fe A y ry |. 2.26. Bent pipe ina plane Fig. 2.27. Bent pipe in three dimensions 2.6 Preventing Water Hammer in Piping It is a rather difficult problem to determine whether the proof stress of stainless steel pipes for general service is better than that of carbon steel pipes when water hammer occurs. Because the 73.6-kg/mm? tensile strength of stainless steel is about ‘twice that of carbon steel, stainless steel pipe has thinner walls, and therefore it cannot be deemed to be superior to carbon steel pipes with respect to the increase in internal pressure in the pipes during water hammer when one considers the entire piping system including the couplings and takes into account the fact that stainless steel piping designs allow greater velocity withi the pipes. Therefore stainless steel pipes must be treated the same as carbon steel pipes when it comes to understanding the phenomenon of water hammer, calculating the increase in pressure that it causes, and preventing it. 2.6.1 Water hammer (1) The phenomenon and the governing basic equations "Water hammer” means the phenomenon whereby the pipes walls and connected equipment are subjected to water impact when the pump that is part of the piping system is stopped or when the valves are suddenly shut, the pressure in the piping suddenly increases, and a pressure wave travels back and forth in the closed-off portion of the piping system. Figure 2.28 pictures a situation in which a pipeline L meters long having uniform pipe diameter and thickness is connected to an infinitely large water tank, the valve is suddenly closed when the water is flowi 1g at flow speed Vo, and a pressure wave travels nback and forth. The basic formulas for determining the pressure increase in this phenomenon at arbitrary time are formulas (2.8) and (2.9). H-Hg = Fe )+ftts Sy (2.8) Vevo = 2 pir pttt+ @) where H pressure head at arbitrary time after valve closing (mAq) Ho : pressure head in steady state prior to valve closing (mAq) v flow velocity at arbitrary time after valve closing (m/s) Vo : flow velocity in steady state prior to valve closing (m/s) F function of t-x/a, pressure forward wave advancing in the positive direction of x f function of t-x/a, pressure backward wave advancing in the negative direction of x x distance from the valve measured along the pipeline (m) t time since the valve began to move (arbitrary time) (s) 9: acceleration due to gravity Also, a represents the propagation speed of the wave motion; formula 2.10. given by (2.10) bulk modulus of water = 2.07 x 10° (kg/m?) inside diameter of the pipe (m) modulus of longitudinal elasticity of the pipe material 1.97 10" (kg/m?) pipe thickness (m) 72Iner when the valve is closed suddenly closing refers to the situation in which the valve closing time (T) is time it takes for a pressure wave to traverse the length of the pipes irections; this is expressed by formula (2.11). (2.11) where T: valve closing time (s) vow (2.12) (2.12) is a variation of the basic formulae obtained from the basic 8) and (2.9). The increased pressure AHmax in the event of sudden letermined by formula (2.13), which is formula (2.12) when V= [presents the results of formula (2.13) in graph form. The flow speed ‘ts the pressure head: as between a flow speed of 2.0 mis and 3.0 a difference in pressure head of 100 m. But in an actual system it 1ed never to increase this much, because actual systems have some Ives are not fully shut off instantaneously, and the branches and lof the system provide a cushion. a L2 yy, (2.1 a Vo (2.13) e valve closing time (1) is in the range T < 2Ua and is rather long, prtion that experiences the internal pressure at maximum pressure In the valve to the middle of the piping, and the portion from the ‘ance aT/2 from the water tank to the water tank is the range of ease. This s expressed graphically in Figure 2.30. 1er when the valve is closed gradually closing refers to the situation in which the valve closing time (1) > 2U/a. When this is the case, the value of the maximum pressure sed by water hammer (AHmax) is given by formula (2.14) and frula (2.14) kaTHo) (2.15) ax: maximum pressure increase value (m) 73ee pipes lown in ration jolumn lonce it Ind the jer and heavy harge t keeps ce and Increase tion by jake all quality ple the sphere, teel or es withpolyvinyl chloride or some other substance, or by injecting a chemical to form an anticorrosive coating on the inner surface of the pipes. Inner-surface corrosion prevention is ordinarily not needed for stainless steel pipes for general service, because this type of steel has a passive chromium oxide coating. As for outer-surface corrosion, although it is not the case that stainless steel pipes for ordinary piping never gets damaged, burial experiments performed in Japan by the Stainless Steel Association have yielded quite good results, and it can be said that stainless steel pipe presents no problems as long as it is used, as it generally is used, as construction equipment. But it is advisable to examine the soil and take appropriate measures in regions near the seashore, on reclaimed land, and in areas where there is much upwelling ground water in the soil. In the following we list design anticorrosion measures related to the particular nature of stainless steel: (2) Use heat insulation mat ‘that does not include halogen ions, especially chloride ions (consult with the manufacturer). (b) When using water treatment agents, exercise care, including water quality control, because some of them contain chlorides. (©) In gaskets, use materials that are intended especially for stainless steel piping. (@) Take care to ascertain whether insulation treatment is needed for joining different metals (especially for connection with steel pipes) (@) Ifa bender is used, the bend radius of the pipes should be at least 4D, where D is the outside diameter of the pipes. (8 Inusing a chloride sterilizer or the like, be careful of the concentration or detention of free chloride or Cl. (g) Make sure that extreme concentrations of stress do not occur in parts of the piping, (h) Do not form front guard frame or reverse front guard frame piping that allows detention of the fluid in the pipes. If unavoidable, install a drain valve and do periodic cleaning and flushing 2.8 Sweatproofing and heat-insulation 2.8.1 Heat loss from stainless steel piping Calculations show that the heat loss from st less steel pipes is very slightly less than that from steel pipes (due to differences in the thermal conductivity), and as a matter of practice they may be taken as equal. Thus there is no need to perform new calculations, and the previous data for steel pipes can be used. 75Jous types of insulation materials, al conductivity, and flammability. dluble halogen ions are preferable. is recommended for chloride ions se of the heat insulation materials 1-free, but sometimes glass wool r storage tanks, and the matter jal should be determined by the economics into account, but in Lain conditions and are listed in a }, “Standard Specifications for Air ," without performing the for which the stainless steel Su results are given in Table 2.26. valve closingarbon steel pipe for ordinary pipin y 4 cromnmaorrmotne a Lhe amanil ms TO Fi 1340 mis per pipe 100A.8 = 1,088 mis Flow speed inside the pipe (mis) Fig. 2.29. Pressure increase when valve is closed suddenly (a: propagation speed of ‘the pressure wave) Presureincrenseg {Hux 8h Ms standard pressure Fig. 2.30. Distribution of pressure increase values when the valve is closed suddenly 7Portion where water ressure during operation -= Column separation Pressure during operation-= p‘olumn sep: Elevated tank Atmospheric pressure. re Pressure immediately «after pump shutoff Wate’ column separation will not occur if the piping is modified like this, Fig. 2.31. Water column separation Table 2.24, values for pump nozzle reaction force and moment (see Wolsewick) ; Pump support material | 4 ooint support | 2-point support Reaction force Reaction force in direction of shaft [kg] 110 D 130 D (1,800) (1,200) Reaction force perpendicular to shaft [kg] 45D 38D (680) (400) Bending moment in longitudinal direction 370 D 230 D kgm] (5,500) (1,300) Bending moment in circumferential 370 D 230 D direction [kg m] (5,500) (3,000) Torsion moment [kgm] 370 D 230 D (5,500) (2,400) D: nominal diameter of pipe (in); number in parentheses () represents maximum, value 78So) gf RR) eee oot oe ‘ even pe SNIETS cay | rote | erasers 33 one iSsG | SEAolees RES fF SE oro & BE ESSE | sonmatlesa | "Ssagaseaetes irae Ges oe S50 oe SE ESSE | venGticaldeed | Mate’ smoot “ireriee ore ee Ey BE coe un sn nirBaBung : we se is : evo or oc = Tet {soasaqse ayysowe) 55940 5005 - ugrauoaeines! | yogeynsui sea, aS ERTES move ‘es | Sat porpon Baseynuey prowens ~ {yu>. wus wet, | woltstSny | enaspeoune fm "20 neater woe oe (L056 v Sir) srevarew uoneynsuy xe9y 404 spuepuers uoRDe|as “Sz'Z 219° 7910,000 1,000 Chlorine ions (mgm 10 100 1,000 10,000 100,000 Sodium + silicate ions (maf) Fig. 2.32. Allowable range of use for stainless steel with respect to thermal insulation material components (chloride ions and sodium silicate ions) (data from Nichias Corporation) References 1) Japan Construction Center: Guidelines for earthquake- resistant design and construction in buildings and equipment (1982 edition), p.63, 64, 66 2) U, Ogawa: Piping Engineering (1964), p.112-122, 134-136, Engineering Library 3) M. Naruse: Course in Piping Design (1966), p.283, Japan Industrial Publishing 4) Overall Technology Development Project for Fiscal 1984, Development of technology for improving the durability of structures, Report of the subcommittee on construction equipment piping (March 1985) 5) Copper Brass Bronze Product Handbook 6) TFF Copper Pipes Research Association, ‘opper Pipes Manual for Construction Piping” 80Table 2.26. iping covering thickness (1) Covering thickness to prevent moisture condensation: The following table lists the standards for thermal insulation materials and covering thicknesses for preventing moisture condensation on water supply pipes (drainage pipes), etc. (2) General case (conditions: water temperature in pipe 15°C, ambient temperature 30°C, relative humidity 85%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | 40 | so | 60 | 75 | 80 ]100 [125 [150 [200 ]as0 |200 Covering thicknessimm) | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 2s [25 [2s [25 | 20 | ao [so |s0 rock woo! heat insulation tubing, glass woot heat insulation tubing, foam polystyrene heat insulation Heat insulation material ‘tubing No.3 (b) For high-humidity locations (conditions: water temperature in pipe 15°C, ambient temperature 30°C, relative humidity 90%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | 40 | 50 | 60 | 75 | 80 |100 [125 [150 ]200 ]as0 ]300 Covering thickness(mm) | 25 | 25 | 25 | 25 | 30 | 30 | 30 | 30 | 30 | as | ao | ao | a0 | a0 | ao | 50 |50 rock wool heat insulation tubing, glass woo! heat insulation tubing, foam polystyrene heat insulation Heat insulation material aes (2) Heat insulation covering thickness: The following table lists the standards for heat insulation materials and covering thicknesses for heat insulation of hot-water-supply pipes, etc. (conditions: temperature in pipe 100°C, ambient temperature 20°C) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | 40 | so | 60 | 75 | 80 |100 |125 |150 200 J2s0 |300 Covering ticknessmm) | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 2s | 25 [2s [25 [30 [ao [so |so rock woo! heat insulation tubing, glass woo! heat insulation tubing, calcium silicate heat insulation Heat insulation material tubing No. 2, pearlte heat insulation tubing No. 1 (3) Covering thickness for cold preservation: The following table lists the standards for covering materials and covering thicknesses to keep in the cold in beverage cold water pipes, etc. (a) General case (conditions: water temperature in pipe 5°C, ambient temperature 30°C, relative humidity 85%) Pipe diameter (Su) 3 | 10] 13 | 20 | 25 | 30 | a0 | s0 | 60 | 75 | 60 ]100 [125 |150 ]200 Jas ]200 Covering thickness(mm) | 30 | 30 | 30 | 30 | 30 | 30 | 30 | ao | a0 | a0 | a0 | a0 | 40 | a0 | a0 | 50 |s0 rock wool heat insulation tubing, glass woo! heat insulation tubing, foam polystyrene heat insulation Heat insulation material tubing No.3 (b) For high-humidity locations (conditions: water temperature in pipe 5°C, ambient temperature 30°C, relative humidity 90%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | 40 | 50 | 60 | 75 | 80 [100 |125 |150 |200 250 |300 Coveringthickness(mm) | a0 | a0 | a0 | a0 | 40 | a0 | s0 | s0 [50 [so | 50 [os fos [os [os [os [os rock woo! heat insulation tubing, glass wool heat insulation tubing, foam polystyrene heat insulation leatinsulation material Heatinsulation mat tubing No.3 81(4) The following table lists the heat insulation materials and heat insulation covering thicknesses for hot- water pipes (oil pipes, steam pipes). (a) Under the conditions of temperature in pipe 100°C, ambient temperature 20°C Pipe diameter (Su) 8 | 10] 13 | 20 [25 | 30 [40 [so [60 | 75 | 80 ]100 [125 [150 [200 Jaso ]300 Covering thickness(mm) | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 20 | 25 | 25 | 25 [2s | 30 [a0 |s0 |so rock wool heat insulation material, glass wool heat insulation material, calcium silicate heat insulation Heat insulation material material No.2, pearite heat insulation material No. 1 (b) Under the conditions of temperature in pipe 150°C, ambient temperature 20°C Pipe diameter (su) 8 | 10 | 13 | 20 | 2s | 30 | 40 | so | 60 | 75 | 80 |100 |125 |150 }200 Jas0 |300 Covering thickness(mm) | 20 | 20 | 20 | 20 | 25 | 25 | 25 | 25 [25 | 25 | 30 | 30 [30 | a0 | a0 |s0 |so rock wool heat insulation material, glass wool heat insulation mater ‘material No.2, pearlite heat insulation material No. 1 Heat insulation material calcium silicate heat insulation (5) The thicknesses of insulating coverings of cold and hot tubing conform to the table below. The same apply for value insulating coverings. (2) General case (conditions: water temperature in pipe 5° ambient temperature 30°C, relative humidity 85%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | a0 [50 | 60 | 75 | 80 [100 [125 ]150 [200 ]2s0 |300 Covering thickness(mm) | 30 | 30 | 30 | 30 | 30 | 30 | 30 | 40 | 40 | 40 | a0 | 40 | a0 | 40 | 40 | so |s0 ‘rock woo! heat insulation tubing, glass woo! heat insulation tubing, foam polystyrene heat insulation tubing No.3 Heat insulation material (b) General case (conditions: water temperature in pipe 10°C, ambient temperature 30°C, relative humidity 85%) Pipe diameter (Su) 8 | 10 | 13 | 20 | as [30 | a | 50 [60 | 75 | 20 [100 ]r25 [150 |200 [250 ]s00 Covering thicknessimm) | 25 | 25 | 25 | 25 | 25 | 25 | 25 | 25 [30 [30 [30 [30 [30 [30 [40 |s0 [50 rock wool heat insulation tubing, glass wool heat insulation tubing, foam polystyrene heat insulation Heat insulation material sree (0) For high-humidity locations (conditions: water temperature in pipe 5°C, ambient temperature 30°C, relative humidity 90%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | a0 [50 [60 | 75 | 80 | 100 [125 [150 ]200 Jaso ]200 Covering thickness(mm) | a0 | a0 | 20 | 40 | 40 | 40 | 50 | 50 [50 | so | so [os [os [os [os [es [es rock woo! heat insulation tubing, glass woo! heat insulation tubing, foam polystyrene heat insulation Heat insulation material aaa (d) For high-humidity locations (conditions: water temperature in pipe 10°C, ambient temperature 30°C, relative humidity 90%) Pipe diameter (Su) 8 | 10 | 13 | 20 | 25 | 30 | a0 | 50 | 60 | 75 | 80 ]100 [125 ]150 [200 Jaso ]200 Covering thickness(mm) | 30 | 30 | 30 | 40 | 40 | 40 | 40 | a0 [a0 | a0 | a0 [50 [50 |s0 |s0 [so |so rock wool heat insulation tubing, glass woo! heat insulation tubing, foam polystyrene heat insulation Heat insulation material ‘tubing No.3 823. CONSTRUCTION3 CONSTRUCTION 34 BAA ping Construction Planning Construction planning flow (1) Understanding and planning the content of the construction work Pipe laying, like all construction work, must be carried out according to an orderly plan. Generally, when laying piping, because one is dealing with materials in common use, one is apt to proceed with the actual job without careful consideration beforehand, and sometimes one sees examples in which the expected performance, including durability, is not obtained. Today, when various kinds of pipe materials and joints are being used for maximum durability and ease of construction work, it is necessary to instill the habit of doing the right kind of construction planning and faithfully executing it. Table 3.1 summarizes the procedures that should be considered and the items that should be studied at various stages when planning piping construction. One must have a thorough familiarity with the characteristics both of the fluid to be transported through the piping system and the system's parts, because the fluid could be a factor in causing the constant deterioration of the materials that make up the system. (2) Need for working drawings Design drawings for the systems we deal with generally set forth the rough route of the pipe, the pipe diameter, and the specifications of the materials to be used. But this is not sufficient for laying the pipe; its detailed position and shape and the required auxiliary equipment must be determined according to working drawings. The most important job in ensuring the quality of the piping is to determine the optimum measures to take for maintenance so as to obtain all the desired characteristics of the piping system, subject to such constraints as its complex interrelationships and the finished height of the ceiling. One point to be careful of in preparing working drawings is the shape of bends and branches. Their shape must be chosen with regard to the properties of the fluid that will move through the pipe and the pipe material to be used in such a way that the resistance is minimized and the pipe itself is not damaged. 84Table 3.1. Verification and study of the ‘content ofthe construction Detailed decisions concerning the piping system {preparation of working drawings) SN Decide upon the constituent. parts (calculation of capacity and strength) SN Deciding upon construction methods Preparation of construction control plan Construction planning flow Verify the applications ofthe piping system Verity the design policy (flow volume, flow speed) Consider the characteristics ofthe piping materials and auxiliary equipment Verity the characteristics of the fluid to be transported Decide upon the position and shape ofthe piping Decide where the necessary auxiliary equipment isto be installed Consider the piping's strength performance Consider how itil be maintained Decide how it willbe heat-insulated Decide upon anticorrosion methods for buried pipe Vibration-resistant joints, expansion joints ‘Support and anchoring fixtures and anchors Specially fabricated part (air chambers, etc) Air bends, safety valves, gauges Strainers, drain valves ‘Water hammer prevention, shock absorbers Cleaning, inspection holes, monitor pieces Decide upon the kinds of joints Select the construction methods and processing machinery Decide upon work procedures Decide upon precision checking methods and judgment criteria Prepare documents for promulgating policies 2. Setinspection items and inspection points "Make clear the division of responsibilities Decide what to doifstandards are not met 85Most fluids that move through pipe contain dissolved gases that separate ‘out when the temperature and pressure change. These separated-out gases increase the resistance as the fluid moves through the pipe and can cause Vibration and noise. In addition they can destroy the oxide film that protects the pipe material from corrosion. All these factors shorten the useful lifetime of the pipe, so attention must be given to the smooth discharge of gases. In such piping systems, strainers and dirt pockets must be installed as necessary at the right locations so as to keep the inside of the system clean. The temperature of the fluid as well as changes in the ambient temperature during the year cause thermal stress on piping systems. Thermal stress can be absorbed by the proper pipe shape and expansion joints, but to be effective, care must be taken that they are installed in the right place and anchored correctly. Thus the main purpose for preparing working drawings, besides making clear just where the pipe will be laid, is to confirm the position of the equipment needed to ensure, maintain, and preserve the functions of the piping, including (1) the shape of the pipe, (2) where dissolved gases will be exhausted, (3) where mixed-in substances will be discharged, (4) where the thermal stress will be absorbed, (5) where the inspection peepholes needed for maintenance will be positioned, and (6) where the monitoring pieces will be inserted. (3) Deciding upon the parts and members of the system Besides the valves, measuring struments, traps, and other auxiliary ‘equipment shown in the design drawings, the working drawings list additional needed auxiliary equipment and prescribe specifications including the capacity of each based on comprehensive judgment. The pieces of auxiliary equipment are often made of different kinds of metals, so if they are used unthinkingly the functions of the piping could be hampered by local damage caused by galvanic corrosion, dezincification, or scale buildup. Measures must be taken to avoid this. Support and anchor fixtures and specially fabricated parts are checked as need for their strength against outside forces such as thermal stress, water hammer stress, and earthquake stress. Particularly for support fixtures used in common in multiple systems, their strength and the strength of their members, 86including floor anchors, is considered, and antivibration measures are considered for systems in which vibration and noise is a factor. (4) Deciding upon the construction method Here “construction” is the series of jobs determined up to the preceding section, namely, the processing, assembly, installation, and testing of pipe material, parts, and members. The goals of construction are to obtain full advantage of the properties of the materials that make up the system, to improve operating efficiency, and to ensure uniform precision. Junctions are important in piping construction. They must ensure long-term strength and be resistant to the damaging effects caused by the nature and temperature of the fluid in the pipe. The expected lifet 1 of pipe material or junctions might vary depending on their location within the building where the piping is installed. This is a judgment based on their exchange performance. ‘The judgment standards are based on life cycle costs, taking into consideration a long lifetime for buried piping and a shorter lifetime for exposed piping, ‘The method of joining is decided upon based on the above conditions. The construction method determines what processing machinery and construction procedures to use. At the same time, one must be able to measure the precision of the finished work. (5) Deciding upon the construction control method To ensure quality in piping equipment, it is necessary to decide upon a control method for monitoring the above procedures and for checking how well the work is carried out. At each stage of design, construction planning, construction, and work flow, each person in charge must, besides carrying out ‘own duties, exercise means of control by preparing documents that clearly set forth the work results required of those responsible under him and the method by which it will be verified that the intended results have been achieved, and must show them to his responsible superiors and subordinates and obtain their confirmation. These procedures are set forth in Table 3.2, The column at the left of the table lists, in the sequence of the flow, the control document for the job, while the row across the top lists the matters to be decided. The content of each document is listed in the box where its row intersects with each relevant column. jlarly, each working drawing should clearly state the purpose of the 87work, the sequence in which itis to be done, what it will be like when it is done, how it will be inspected and the criteria by which it will be judged, and what to do if the standards set by the person in charge are not met. (On the workman's level, both “work procedures” and "work standards” documents are listed. The former cover matters requiring particular attention in construction and must be prepared anew every time. The latter have the nature of normal equipment and technology data that all workers should be familiar with. Since these control documents serve to communicate intentions from upstream in the work flow, it is most important for construction control that in going ahead with the work the responsible person listed in the right-hand column in the table be consulted. Matters to note when using stainless steel pipe Stainless steel pipe for ordinary piping (JIS G 3448) is manufactured in order to apply the corrosion-resistant properties of stainless steel to general municipal water works facilities and building facilities. Light gauges are adopted both to satisfy cost requirements and to improve work efficiency by reducing the weight of the pipe. Pipe is specified by its outside diameter; 25 Su and less matches copper pipe, while 30 Su and above matches gas pipe. Also, conformity is sought with valves and other auxiliary equipment for piping. ‘As mentioned in the previous section with reference to planning, in using stainless steel pipe, everyone including the workers on the site should be aware of the properties of the material and of the characteristics of the shapes of the products. These are explained in detail in this manual, including the physical and mechanical properties of stainless steel (1, The Basics), its applicable range, flow speed standards, and the expansion and contraction of piping (2, Design), and the corrosion-resistant characteristics of stainless steel (1, The Basics and 5, Reference Material). Broadly, the matters that should be kept in mind in construction are as follows. @ Heating processing: heating temperature, atmosphere, and quality of the material used for welding @ Coldworking: —_ elimination of residual stress, bend radius @ Parts: prevent couplings n of galvanic corrosion, dissimilar metal 88® Assembly: revention of crevice corrosion and deposit attack, insulation of support fixtures (cold-water systems) © Storage: deformation (ensurance of roundness) © Halogenions: _ heat insulation material, gaskets for joints ® Pipe cutting: maintenance of roundness, elimination of flash (prevention of damage to gaskets, etc.), avoidance of overheating ® Buried pipe: ground wet with sea water, areas of hot-water springs in volcanic regions, concrete including chlorides in high concentration ‘Specific measures to take are discussed in the next chapter. 3.2 Transport, Handling, Storage, and Inspection of Pipe 3.2.1. Transport, handling, and storage of pipe (1) Transport and handling Stainless steel pipe is lightweight, but because it is thin it must be transported and handled with care. (2) When transporting it, take care that it is not damaged or crushed by contact with other objects, and when necessary protect it with a covering so that no grease or other foreign substances adhere to it and cause trouble when the pipe is fitted together. (b) Use rubber, wood, plastic, or the like to protect those parts that come into contact with fixtures or wires when the pipe is lifted or set down, so that the pipe does not get scratched by a crane's hooks or wires. (© When transporting or handling the pipe (shock caused by load collapse, etc.), protect the pipe ends so that they do not get crushed or acquire burr. (2) Storage Steel pipe must be cared for in such a way that it does not come into contact with other metals and is not subject to dirt, grease, sewage, soot, or other foreign matter gets into it. If necessary, the pipe ends should be sealed. The place chosen for storage must have low humidity and must avoid the danger of objects falling from above. If the pipe is stored in a warehouse, it should be fully enclosed and have a concrete floor. 89Conseasu poe ned sonen soverssesqen| suuesp-eonceaw tones Set sueusy Seomtnaen SGomespuegsny | __auctvonveds — Pay puneeg | ues: "ripeere on aa “ott veuryomenoy auhyosonenybess ueseco | “e=Hna0e ssuntes seuaneu one ond ous pownou| ponewuonseds | ugun8tlett!| suméuon Suppo roposnon reat | yoqssdeu pur sind puctaneny | _ggSumeseipue | ‘Srl en vost Sapo =e sncoit ives teumee| seam vorsuntan soos win se py an vod buns ee bwonanusuen Sane sbumesp wuonisod adeus oid pu et sSumep| “Burom sions a 1a pus vonred | suoneyroe> nbvens um envodnSusea | sipjovonensoeds| 20 pusoaiiod sok Poxpeuuogonssuco siepues veoussuon | y ‘4 40 voneayiDads uoje}jeasu} 2249265 | yownsop sosnsodns ad eran a ‘nai stumeo] uy sued but id Touewioped jones 4 ro inbesBumen voneojuoneieisu | powewsuuer | “Aiguginde Arty | _Jojsaineeaw | an jouoneinbyuo> = ‘uonjpuo> uononasuos axa uodn Bulppag worshs Burdid ayy dn 9y2u ep sioquiow ay uodn BuIprag sJom uonnasuoD Buldid yo yuauo> ayp BuUIEIEG “Z'E aIGEL 90322 Inspection of the pipe Pipe inspection includes appearance inspection, in which the inside and outside of the pipe and its ends are visually checked for defects, and standards-compliance pection, i delivered pipe are verified. (1) Appearance The pipe is visually checked for bending, uniform outside diameter, and which the labeling, outside diameter, thickness, and length of defects or scratches on the finish of its inner and outer surfaces. The pipe is rejected if any scratches, cracks, scale, or defects are found. For scratches caused during the transport or delivery of the pipe, shallow scratches may be accepted as long as the outside diameter and thickness are within allowed dimension limits after they are eliminated by polishing, but for deep scratches, the affected parts should be cut off. Any scratches or burr on the pipe ends should be cut off before the pipe is used. (2) Standards-compliance Labeling on the outer surface of the pipe as well as the pipe diameter, thickness, and length are checked as follows: (@) Labeling There must be clearly displayed on each pipe its type symbol, indicating its method of manufacture, its designation and dimensions, and the name or abbreviation of the manufacturer. For stainless steel pipe for general service there are two grades, SUS 304 TPD and SUS 316 TPD (TPD stands for "Tube Piping for Domestic water"). (b) Outside diameter, thickness Outside diameter, thickness, and tolerance for the designation must conform to requirements in Table 2.5 in 2. Design. (9 Length The standard length of pipe is 4 meters. But inspection is done upon delivery if the length is specified with constraints as to the on-site crane, entrance groove, containers, etc. when the pipes are worked at the factory asmembers. 13.3 Cutting Pipe When pipe is cut, a cut surface that is usable for pipe junction is required. As necessary conditions, the cut surface must be perpendicular to the axis of the pipe, there must be no shear drop or flash, and the cut surface must not be elliptical (1) Cutting tools ‘The types of cutting tools generally used and their ranges of applicability are presented in summary form in Table 3.3. The cutting tools must all use blades made of stainless steel. (2) Cutting methods (2) Fixed-pipe rotary cutter (hand tube cutter) ‘As shown in Figure 3.1, the pipe is placed in a receiving roller, a handle {knob) is turned, and the cutter is aligned on the cutting line, then the rotary cutter is made to revolve once and, after verifying that the cutter has not strayed from the cutting line, the rotary cutter is turned and the pipe is cut. In doing so, it is easier to fix the pipe in a pipe vise rather than try to hold it by hand. (b) Pipe-turning rotary cutter ‘As shown in Figure 3.2, the pipe is set onto a receiving roller and is made to revolve by turning the receiving roller, thereby holding the rotating cutter against the pipe and cutting it. Stainless steel pipe is sometimes cut at the construction site using a threader for carbon steel pipe. (©) Gircular-saw cutter The pipe is cut by turning a circular saw. In doing so, care must be taken that the circular saw is held tightly against the pipe and that the pipe is not turned too fast. For butt welding the cut surface of the pipe must be at right angles and in the same plane; a circular-saw cutter is ideal for this (d) Metal saw The pipe is held in a pipe vise or the like and is cut either manually or automatically. (€) Abrasive cutter (high-speed cutter) The pipe is held fast or revolved, and i cutting wheel. Care is taken that the pipe is not deformed by holding the cut by turning a disk-shaped cutting wheel too firmly against it 92(3) Points to note concerning the cutting method When cutting pipe, care must be taken concerning the following basic matters. (2) The cutting blades suitable for stainless steel must 2777? high-speed tool steel since stainless steel has poor heat conductivity, and the blade tip gets very hot consequently, the cutting speed must be slow enough so that the blade tip temperature is controlled. With carbon steel, the cutting tip gets dull and is prone to seizure. {b) The pipe must be held rigidly to ensure a proper cut surface. Care must be taken to avoid deformation. (0) Avoid coating pipe with cutting lubricating oil otherwise pipe must be degreased and rinsed after cutting. (d) Die wear and contamination on the cut surface should be meticulously removed to avoid gasket damage. {e) The spot at which the pipe is to be cut must be inspected before cutting. Since ‘many methods require that there be a tight fit between the outer surface of the pipe and the inner surface of the joint, one must check carefully whether there is any deformation, depression, or scratching at the spot where the cut is to be made. Rotary cutter Stainless steel pipe (blade after cutting through) Receiving rollers Fig. 3.1. xed: pipe rotary cutter 93Table 3.3. Types of cutting tools and range of application Type of cutting tool Range of application ‘manual type, used for small pipe diameter Pipe-fixed type | Oreo su cress Rotary cutter automatic type, used for medium and Pipe-rotating type | ore pipe diameters Little burr, good for butt welding; for Circular saw Pipe-fixed type small and medium pipe diameters cutter Pipe-rotating type _| (same as above), for small pipe diameters Manual type Little burr, for small pipe diameters Metal-cutting re ce Electic ype {game a above, for mec pipe 5 Much burr, but easy to work with; for Abrasive wheel Pipe-fixed type ‘small and medium pipe diameters cutter (high- speed cutter) (same as above), for medium and large Piperotating type | oiee diameters Rotation Rotary tube cutter—__ Blade Stainless steel pipe (ITT) necering tes Fig. 3.2. Pipe-rotating type rotary cutter 943.4 Pipe Bending In bending pipe change in thickness, wrinkling, or out-of-roundness must be avoided. Wrinkling is a particular problem. Wrinkling occurs on the inner side of the bent portion when the bend radius is less than a certain value with respect to the taken as, ‘outside diameter of the pipe. Four times the outside diameter of the pips the standard value for the mi imum bend radius with respect to a stainless steel designation. Stress corrosion cracking is more likely occur with a bend radius that is smaller than this standard value. (1) Bending tools When classified by size, the bending tools are as follows. Hydraulic electric type Stationary type ae { Electric type Hydraulic electric type Portable type Hydraulic manual type Manual type (a) Stationary type ‘These pipe bending tools are large and are used mainly for bending pipe of medium and large diameter of 25 Su and greater. Since the bending machine itself is heavy and difficult to transport to the site and install, itis generally kept at the processing plant, where it is used for working piping members. (b) Portable type These pipe bending tools are lightweight and used for bending small- diameter pipe (13-25 Su). Their power source can be hydraulic electric, hydraulic manual, or manual, and generally the manual type is used in combination with a worm gear. For bending, either a bending die or a side plate (they are replaceable) is selected, depending on the pipe diameter. An example of a manual type is pictured in Figure 3.3. (2) Bending methods In general when pipe is bent naturally, the inside radius with respect to the pipe axis is compressed while the outside radius is stretched. In the draw bending technique, bending can be done while strongly stretching the compressed portion Manual pipe benders having a mechanism for this bending with inner-radius 95stretching have been developed and are commercially available, but their range of application is 13-25 Su. (a) Bending methods using manual pipe benders ‘As shown in Figure 3.4, the work procedure for bending pipe with a manual pipe bender is to hold the pipe securely with a clamp, put the side plate between the pipe and the clamp roller, then with the clamp roller anchor the side plate to the bending mold. When the ratchet handle is turned, the pipe is bent by the rotational motion of the rotating arm. For a 90° bend the rotating arm is moved to the R or L line marked on the surface of the bending mold, (3) Points to note when bending In manual operation, ensure that attachment bolts are tight and that the pipe is held securely. To attain the prescribed direction and angle of bend, and avoid wrinkling. Fig. 3.3. Pipe Bender 96Pipe Side plate Rotating arm N ’ clamprolier Bending mold \ Pipe clamp Fig. 3.4. The bending process using a pipe bender 3.5 Pipe Junctions ‘The methods for connecting stainless steel pipe include press type, compression type, dresser and snapring type, grip type and others. Which joining method to use is. determined by pipe size, intended application, and the piping conditions. 3.5.1. Welding junction (1) Welding process Welding is the most reliable kind of pipe junction, because the strength of the weld is near that of the base metal, forming the most secure junction. Welding can be done either manually or automatically, but the manual technique requires a high degree of skill. The kind of welding most often used for stainless steel pipe is TIG (tungsten inert gas) welding, because stainless steel pipe is relatively thin. In TIG welding, 8 shown in Figure 3.5, tungsten is used for the electrode and the welding is 97done while blocking out the air with argon gas. It can be done either with or without a filler metal. In general, a filler metal is used if the pipe wall is thick Filler metals are commonly Y308, Y309, and Y316 as set forth in JIS Z 3321 (Stainless Steel Welding Rods and Wires) For joints, SAS 354 (Butt Welding Pipe Fittings for Light Gauge Stainless Steel Pipes for Ordinary Piping) are used. Electrode rod Argon gas ‘Argon gas Nozzle -—— Filler metal Base metal ‘Argon gas Welding metal ‘Molten poo! Fig.3.5. TIGwelding (2) Welding machines and jigs and tools Wel 1g machines include those used for manual welding and those used for automatic welding (a) Manual welding (i) Besides the welding machine itself, one needs two gas tanks for the argon gas (one for the torch and one for the inner surface shield), as well as jigs and tools for the welding torch and the inner surface shield. The makeup of a welder is shown in Figure 3.6. (i) Welding machine characteristics In welding stainless steel the pipe is relatively thin and uniform penetration bead is required, so the welder must have the following features.: a) Positive and stable arc start Since weld defects are prone to occur when welding begi the arc start is stable, the arc must be initiated smoothly, b) Constant electric current It must not exhibit fluctuations in the arc length and fluctuations in the power source voltage during welding. 98Q) Itmust be able to do crater treatment When the arc is interrupted at the end of (or during) welding, watering can occur, creating pinholes which could cause water leakage. ‘Thus the welder that is used should have a crater treatment function. d) Pr je shield gas preflow and afterflow In order to protect the weld and the electrode, it should be possible to have preflow and afterflow of the shield gas. © Welding torch @ Welding switch @ Welding powersource__@ Argon gas ank forthe torch © Argon gastank for the inner surfaceshield @ Jig forthe innersurfaceshield @ Base metal cable © Earth wire Fig. 3.6. Makeup of a welder (ii) Accessory jigs and tools a) Jigs and tools for pipe inner surface gas shield When providing gas shi Iding of the inner surface of the pipe active weld area, sealing ‘argon gas need only achieved using appropriate Jigs in the local pipe weld area. b) Jigs and tools for correcting pipe ends Because stainless steel pipe is relatively thin, its ends are sometimes deformed during transport or handling. If such damaged pipes are welded as is, weld defects could occur where the distortion is great. Before welding, therefore, the pipe ends should be corrected in the following ways.: 1) Medium- and small-diameter pipe Correct the out-of-roundness of the pipe end by inserting into it 99a punch whose outside diameter is about the same as the inside diameter of the pipe and which has a narrow tapered tip, then strike it with a wooden mallet or the like around the outer surface of the pipe. 2) Large-diameter pipe Tack weld, either while correcting with a wooden mallet or while using a jig for out-of-roundness. Rotation jigs To accomplish uniform penetration bead welding, the torch must move at a constant speed during welding. Uniform welding can be done without any interruption of the arc by welding while the pipe is rotated at the required wel 19 speed, using a turning roll or positioner. (b) Automatic welding Automatic welding includes the type where the welding torch of a TIG circumferential automatic welder is rotated, and the type whereby the torch is fixed and the pipe is rotated. In the former type the welding torch is generally called a rotating head, and is changed to fit the size of the pipe. There is also a type whereby a filler rod is supplied if the outside diameter and thickness of the pipe are large. As shown in Figure 3.7, the welding equipment consists of a welding power supply, welding control device, a welding torch, an argon gas tank, and a gas regulator. The welding machine should have the same characteristics as for manual welding machines. In the latter type, in which the torch is held fixed and the pipe is rotated, alized equipment is needed, and the apparatus can be fabricated 100Input, three-phase, 200 V ne i 200 Argon gas hose fe————— (Control cable) ‘argon gas hose ase metal cable(+) tC___ Input, single phase, 100 V af ES ™ staintess steel pipe Hand switeh © Rotatinghead __@ Automaticwelding control device @ Welding powersource @ Argon gastank © Argon gas regulator Fig. 3.7. Makeup of an automatic welding machine (3) Welding operator In manual welding, special care is needed where thin pipe is used. The welding operator must have enough the same level of experience and skill in welding stainless steel! pipe one skilled in TIG welding to JIS Z 3821 (Standard Qualification Procedure for Welding Technique of Stainless Steel). (4) Welding work procedures Work procedures are shown mainly for manual welding. Even for automatic welding there are many point: ‘common with manual welding, but the work procedures set by the manufacturer of the automatic welder should be followed. (2) Welding conditions Welding is done with reference to Table 3.4 101wu os ae oz08 ve z 20 a ot sae ve 0 a ezi-00r z zo i on sz ozroe z = a ot vise ose or x ezi-008 z 2 7 on a ozr-0e z 2 a ot esz ooz u on x ozi-a00 z zo 7 uw or sz oze-oe ve z e0 n ot reo st i ry se e200 Fe z zo 7 i 9) 325 7 1 2 A oz weet set or sev 1 ‘ 7 on sea st 1 A oz ev cot or rom 1 1 ri ore seo 1 1 A oz vee oe te ors seo a 1 a uw = 1 7 1 A st es su u a st i i oy v1 i A st soo ° * v1 1 1 1 ‘ a zr se os * 1 i 4 w = eov-o8 o i 7 zr cw or 1 * azi-oor 7 i 3 u 7 1 001-08 s i A zm ove 0 u * st ozo a i ri seyowelp: MA we suake| sw pu a ‘Do aslo | opoasooon | Ue | WO) | voneuauc | allt, | srowerp ah gusum | sponzsiow | jovequnn 3 soupu. | “2UEP | uoneibise0 we usb (e2uas0j04) adhd aes ssajuteys 404 sun !pUo> BuIpjemang OIL “y'E 2191 102(i), Groove It should be square as shown in Figure 3.8(a), or, if the thickness is 3 mm or greater, V single groove as shown in Figure 3.8(b). (ii) Filler rod When a filler rod is used, itis as set forth in Table 35. 60"~70" JEST | Thickness] (a Outside diameter Outside diameter (o Fig. 3.8. Shape of Groove Table 3.5. Typesof filler rod Base metal Filler rod Color code for the filer rod ‘308 VIS 2.3321, Stainless Stee! Bar a susa0a rep | 2nd Wire for Welding) ‘¥309 ame as above) black SUs316 PD 316 (same as above) white (b) Procedure (i) Table 3.6 describes the procedure for butt welding between pipe and pipe and between pipe and joint. (ii) Welding other than butt welding In stainless steel pipe for construction, sometimes welding other than the aforementioned butt welding is done. In this case it is the same as butt welding, the welding method is TIG welding, and back shielding is done. a) When welding branch pipes (air vents, instrumental ete) n installation, When making a hole in the main pipe, take care that no spatters, shaving, grease, or other foreign matter get onto the inside surface of the pipe, and open the hole with a grinder or the like. 103When inserting a branch pipe into a main pipe, take care that the branch pipe does not jut out into the main pipe as shown in Figure 3.9, and make sure that there is enough free penetration bead, When a branch pipe is welded onto a main pipe, do groove processing on the branch pipe and produce enough free penetration bead, as shown in Figure 3.10. b) When welding a stainless steel flange When a stainless steel flange is welded on as shown in Figure 3.11, fillet weld is made between a thick flange (thickness about 14-24 m) and a thin stainless steel pipe (thickness 1.2-3.0 mm). In doing so, the wel 19 conditions are set to match thin pipe, and the depth of fusion is set so that there is no burn-through. If the welding current is too high, one too much heat gets into the pipe, whi \ishes corrosion resistance and sometimes causes burn- through. (5) Inspection of welds (@) (b) Welds are inspected for appearance and leakage. Appearance inspection In appearance inspection, a visual inspection is made of the following items each time a weld is completed. (The weld must have no harmful defects such as lack of fusion, crack, or blow holes. (ii) The weld must have no harmful undercut or overlap. (iii) There must be sufficient penetration bead. (iv) The height of the weld overlay must be 0-2.5 mm, except that a smooth depression of about 0.5 mm is acceptable if in an | groove no filler rod is used. (¥) There must be no harmful cracks or pinholes, etc. in the crater portion. (vi) There must be no oxide scale on the inner surface of the pipe. (vii)In the welding of flanges, rings, and pipe support fixtures there must be no burn-through, Leakage inspection Leakage inspection is according to the inspection and testing standards given in 3.17.1, Table 3.15. 104Table 3.6. Welding work procedure Type of work Method of the work Remarks 1. Pipe cutting ‘Asa general rule, a pipe iscut perpendicular toits axis with a metal-cuting saw ora high-speed cutter. Any dle wear or flash should be removed. The degree of perpendicularity i checked with a right- angle scale 2. Pretreatment ofthe weld Toclean the butt surface and around it any rust, ol, paint, steel, or other adhering substances harmful to the fluid should be removed with an organic solvent (thinner, trichlene, etc) ora stainless steel wire brush (5Us300), sandpaper, etc H the thicknessis 3 mm, there should be Vsingle groove in order to achieve the right penetration bead shape. 3.Tack welding ‘Tack welding is done by a qualified operator by the “TiG welding method, as for the main welding, by the following procedure. © The piping members precisely centered. @ Tack welding is done in the sequence @ >® >© + pictured below while minimizing the displacement by using a pipe end correction jg, et. Tacking should be done in atleast four spots, with ‘more depending on the pipe diameter and the extent. of the displacement. weld Weld Misalignment ‘isalignment 105Type of work ‘Method of the work Remarks 2. Tackwelding @ The appropriate penetration depth for tack ‘welding is about one-half of the thickness. ‘Whether the tack welding was done wellor badly arn? {TT} (There might be misalignment when the main welding isdone.) (The penetration bead could become oxidized, ‘causing defects when the main welding is done.) Good Bad Bad 4, Main welding ‘The main welding is done by TIG welding Using horizontal anchoring or vertial anchoring, depending on the place and position. (2) Horizontal 0 (e)Verticat |— Horizontal Vertical @ Mainwelding ‘The welding is done with reference tothe welding conditions listed in Table 35, and in order to-achieve the good bead shape pictured in the remarks column, care istaken with the work environment footing, vibration, wind, ete). If rmult-layer welding is done, the welds in each layer arecleaned, Note: The weld overlay height ofthe penetration bead isset to up to one-half the wall thickness of the pipe ‘Shape of the welding | Judgm- pe of te welding | Mucor Reason Optimum (WEY J 00 | sonction Theresa lepression, but Good | trengthisnot Seriously affected Insufficient Bed | penetration Weld center Bad | misalignment Bad | undercut Bad | overtap Bad | Lack of fusion Too much weld S| overlay Bad | Blowholes Bad | crater (a L aq | Verticaterack Horizontal crack 106Type of work Method of the work 4, Main welding © Crater treatment Crater treatmentisalwaysdone upon completion of the main welding, The treatments For back shielding, both ends are sealed with urethane or thick paper, et. Weld Argon Urethane Pinholes and cracking could result unless appropriate crater treatmentisdone, Ifthe back shielding isnot right, there could be insufficient penetration of the penetration bead, ‘oxidation, or push-up. Branch pipe made _— of stainless tee! Stainless steel pipe (Good) Fig. 3: 107 Crevice portion] (ad) ‘When a branch pipe is inserted into a main pipe|, —— Stainesssteet pipe —_ 4] Stainless steel pipe —— oo oS Gaps | (Good) (ead) Fig. 3.10. Ifa branch pipe is put onto a main pipe Flange made of stainiess steel 8 lesssteel pipe ‘About the thickness of the pine Fig. 3.11. Ifa flangeis welded on (6) Points to heed in the welding work @O 2 The welding must be done by TIG welding. Since stainless steel pipe for construction is relatively thin, the welding operator, even if having qualifications, should have ample experience. Depending on the butting method, it is important to do adequate gas shielding of the inner surface, to have adequate weld penetration, and to have no gaps. Examples of failures are shown in Figure 3.12. When the welding is done, in particular the inner surface bead should penetrate completely (the bead must be smooth too). Along with giving adequate attention to crater treatment, there must be no defects such as blow holes or undercuts. 108Pipe must be cut at right angles to its axis and after cutting the die wear, flash, and cutting dust or shavings must be removed. To prevent deformation caused by the welding, jigs and anchoring tools must be used as much as possible. Any foreign matter or contamination that adheres to the parts to be connected must be removed prior to welding. The same care must be taken for tacking as for the main welding. Centering must be done so as to minimize dislocation, and heat input must be kept to aminimum. The argon gas used for inner-surface shielding must have a purity of 99.9% or greater. Ifa filler rod is used, then Y308 of JIS Z 3321 (Stainless Steel Bar and Welding) must be used if the pipe is SUS 304 TPD, and Y 316 must be used if the pipe is SUS 316 TPD. The filler rod must be dry and have no adhering foreign matter or contamination. for For the grounding of the welder itself, its grounding wire must be properly connected, and the stainless steel piping, etc. must not be used as a grounding wire. If joints ha conform to JIS G 3448. An example is pictured in Figure 3.13. 19 designation SAS 354 or above are used, their bevel must ‘Any spattering (metal particles) or contamination produced during welding must be removed. No welding oxide scale is produced if adequate back shielding is done on inner-surface welds, but if black oxidation occurs, the welding oxide scale must be removed by a method such as acid washing or polishing. Substandard welds, such as those having weld defects, must be hand repaired, or if this is impossible, they must be refabricated. 109Creviees Must be butt welded (must be done 10 there arena gaps or crevices) — B83 oi surface must be x x see - Ceo Fig. 3.12. Examples of bad welding 7 Thickness Y 1 Thickness somes tore Outside diameter | Fig. 3.13. Example of groove 3.5.2. Flangejunction Generally, many flange junctions are used with stainless steel pipe. One method is that shown in section 3.5.1, Figure 3.11, but this is a special case. More usual is the loose flange type shown in Figure 3.14, in which a lap joint (stub end) made of stainless steel is welded to the pipe and a flange made of steel is used. This type can be applied to improve work efficiency at the site if the members are processed at the factory. (1) Joints The kind of lap joint used for this type of junction is SAS 354. The flange used is made of either electroplated zinc or hot galvanized steel 110(2) Joining method its is done by the methods Welding of stainless steel pipe and lap j described in section 3.5.1. (3) Points to note in the joining operation The points to heed in welding junction that are listed in section 3.5.1 must. be fully complied with. The gaskets used are usually made of Teflon. Rubber gaskets can also be used in low-temperature environments such as for water supply. The asbestos gaskets used for steel pipe must not be used; they contain chloride that concentrates in welded stainless steel lap joints, causing crevice corrosion in the lap joints. Flange made of ordinary steel ‘Adaptor for lange junction (ap joint) weld }— staintess tee! pipe Fig. 3.14. Flange junction 3.5.3 Presstype junction A press-type junction uses a special tightening tool (press tool) allowing quick junction without a great degree of skill. A certain amount of space is needed to operate the special tightening tool, but since no heating apparatus is used, it has the advantage of being usable even in places where combustibility is a problem. ‘The specifications of press tools are listed in Table 3.7. The junction is made by inserting the stainless steel pipe into the press-type pipe coupling and pressing the coupling with a special tightening tool (press tool). The special tightening tool consists of a portable electric hydraulic pump and a press tool(1) Couplings With press-type pipe couplings, the end of the junction part of the coupling is filled with a special synthetic rubber ring and the pipe is inserted into the coupling and pressed with a special tightening tool (press tool). The area from the middle of the inserted portion to its ent compressed in diameter, and the pipe and coupling are joined. Thus the use range is a designation of 13-60 Su (see Figure 3.15). Table 3.7. Specifications of press tools Portable electric hydraulic pump Presstoo! ingle phase Hydravlicqjlinder weight | about 3.4kg Rated voltage ‘aternating current foov Rated power 150w Crimp jaw weight about22kg about 115k9 hose length 5 m Remarks: 1. The appropriate designation is 13-60 Su. 2. The crimp jaw sreplaced to match the designation. Rubber ring Stainless steel pipe Before tightening ptical diameter compression portion Hexagonal diameter After tightening Fig. 3.15. Junction by press-type coupling 112354 (2) Joining method After cutting the pipe to the prescribed length, the part to be joined is cleaned and any die wear or flash is removed. Using a line marker, the position where the joint will be when it is inserted is marked with a line, and the coupling is inserted until its end comes to the line. The junction is made with a special tightening tool (press tool). The joining operation must be carried out in accordance with the instruction manual of the tool manufacturer. (3) Points to note in the joining operation (2) A special tighter 19 tool must be used. (b) Before it is inserted into the joint, the surface of the part to be joined is checked, any grease, dirt, or other adhering matter is removed, and any die wear or flash is removed. In particular, care must be taken that the rubber ring does not get scratched or damaged. (The junction points are pressed and tightened again, because they can become loose if after pressing a coupling having an adaptor is used, if during screwing-in a force is imparted to the pipe to turn it, or if some force isimparted to the parts to be joined. (d) The amount of insertion is verified. If when the pipe is fully inserted into the coupling there is a gap between the line marked on the pipe and the ‘end of the coupling, the insertion is insufficient, and the pipe is reinserted. After press joining, a collar splay may be put on the fastening part. (e) The fastening groove of the special tightening tool must be inspected once a year, because when it is used many times it could make an incomplete junction. Compression joint Although the couplings are rather expensive, this type of jun advantage that it can be done with two wrenches. Like press-type junction, this n has the type of junction can be used even in places where fire cannot be used. (1) Couplings With a compression-type pipe coupling, a sleeve-bearing pipe is inserted into the junction portion of the coupling itself and a cap nut is tightened, pressing the sleeve to the pipe. The range of use for this type of pipe coupling is designations 13-40 Su (see Figure 3.16). 113(2) Joining method The pipe is cut to the prescribed length, then the portion to be joined is cleaned and any die wear or flash is removed. The pipe is inserted fully until it will go in no further, and the cap nut is tightened by hand until it will turn no more. With a magic marker, alignment marks are drawn on the cap nut and on ‘the coupling itself, and the position of the end of the coupling is marked on the pipe. Then the junction is made by putting a spanner or the like on the coupling and cap nut and tightening by turning one-sixth turn from the alignment mark position for a 13-25 Su pipe, or one full turn for a 30-40 Su pipe. ‘The mark on the pipe serves to confirm whether the pipe has come out when the tightening is done. The size of the spanner or monkey wrench used to tighten the coupling and nut differs depending on the pipe designation (see Table 3.8). Sleeve Thecouplingitself—Capnut Stainless steel pipe Fig. 3.16. Example of the structure of a compression coupling Table 3.8. Sizes for spanners used for compression couplings Designation | For the coupling itself | For the cap nut B 22 24 20 30 32 25 36 a 30 46 50 40 55. 60 14355 () Points to note in the joining operation (a) Before inserting the pipe into the coupling, the surface of the portion to be joined is inspected, any oil, dust, or adhering matter is removed, and a check ismade for any dents or scratches. (b) The coupling must be tightened slowly and carefully. Any pipe pull-out or the turning of the pipe and coupling together could lead to an incomplete junction and cause leakage. A pipe wrench or the like must not be used for tightening the coupling, as this could cause deformation or scratching. (When the piping is extended in a straight line, the pipe and coupling sometimes revolve in tandem and the joined tightened parts get loose. ‘When this happens the couplings and cap nuts should be slowly tightened with a spanner or the like. Dresser and Snap Ring type joint The pipe must be grooved, but the junction can be done simply using a pipe wrench. Even after itis tightened it can be removed. It is flexible and is superior in preventing pull-out. (1) Couplings With Dresser and Snap Ring type pipe coupling, the snapring fits into a groove previously provided in the pipe, preventing pipe pull-out. By tightening the cap nut, a pressurized fluid is hermetically sealed with the rubber packing of the receptacle portion, and the pipe and coupling are joined. The range of use isa designation of 13-80 Su (see Figure 3.17). @ snap ring @Wesher .@ Rubber packing ®cepmut © The coupling tse Fig. 3.17. Example of the structure of Dresser and Snap Ring coupling 1152) Joining method After the pipe is cut to the prescribed length, the part to be joined is cleaned and any die wear or flash is removed, Next, the pipe is held in a pipe vise, the A dimension of the pipe’s grooving position is marked with a magic marker or the like, and a plug for grooving is inserted into the pipe. In doing so, it must be inserted until the collar of the plug hits the end of the pipe (see Figure 3.18). ‘The blade of the pipe cutter is fitted onto the grooving roll, the tip of the roll is placed against the A-dimension position of the pipe, and the operation proceeds as in pipe cutting, that is, a groove is made around the entire circumference while moving the cutter in a pendulum motion (about 30°-90°). This is done to the depth at which the shaft of the roll comes into contact with the pipe. The cap nut, snapring (inserted into the groove on the pipe), washer, and rubber packing are fitted onto the pipe in that order, then the pipe is inserted into the pipe coupling itself and the nut is tightened. The nut is tightened with a pipe wrench until its torque increases suddenly and resistance is felt. — Grooving core Grooving is done to 2 depth (1.4 min) such that this surface comes into contact with the surface of the pipe (outside circumference) Pine surface Fig. 3.18. Grooving 11635.6 (3) Points to note in the joining operation (a) Check that there are no vertical scratches on the pipe end, (b) The pipe must be grooved to the prescribed depth (©) The parts must be put on in the correct sequence. (d) The rubber packing must be fitted on in the right direction, not upside- down. Grip Type joint Because a special tightening tool (Grip tool) is used, a high degree of ski required. Moreover, the joining can be accomplished in a short time. A certain is not amount of space is needed in order to operate the special tightening tool, but since no heating apparatus is used, there is the advantage that it can be used even where combustible articles are present. (1) Coupling In Grip Type pipe coupling, the pipe is inserted into the groove of the coupling, which is packed with a rubber ring and a bite ring, and the joint is tightened with a special grip tool (see Table 3.9). This causes the bite ring to bite into the pipe and prevent it from slipping out, while watertightness is maintained by compression of the rubber ring. This method of joining the coupling and the pipe is diagramed in Figure 3.19. The range of use includes designations 13-60 Su. (2) Joining method (a) As with the press type, the pipe is cut to the prescribed length, then the part to be joined is cleaned and any die wear or flash is removed. {b) Using a line gauge, a line is marked on the pipe indicating the position of the coupling when the pipe is inserted, and then the pipe is inserted into the coupling. In doing so, the pipe is inserted straight into the coupling until it hits the other end of the coupling, and one verifies whether the marked line aligns with the end of the coupling. (©) Aarip connection is made using the special grip tool. The joining operation is done in accordance with the tool manufacturer's instruction manual.Table 3.9. Grip tool specifications Portable electric hydraulic pump Giptool weigh) Fowersoureeused | A(100V50-60 #2) 32581 [aocosu Output sw Tyrac cyinderandvoo! | bout Teg | about rg Weight abot tg Procesing de Gresiypes) [08K geach | VOKg each Tyiaulchore [5m Remark: Used with nterchangeabe procestng dies chosen to fit the sizeof each coupling kupring The coupling self Rubber rng Bie rog Bite portion Staintesstetpipe a porton, iY ate), (Before tightening) (after tightening) Fig.3.19. J ing by Grip Type coupling (3) Points to heed in the joining operation (a) The special tightening tool must be used. (b) As with the press type, before inserting the pipe into the coupling, any soiling on the surface of the part to be joined must be removed, and care must be taken to ensure the rubber ring is not scratched. (c) The extent of the insertion is checked. When the pips fully inserted into the coupling, the li 1e marked on the pipe should be just visible from the end of the coupling. If one first uses a magic marker or the like to make a line all around the pipe where the end of the coupling should be, it can be verified whether the pipe has slipped out when the clip is attached. (2) Piping support fixtures must be attached prior to gripping. If they are attached afterwards, the piping might get bent by the caulking force of the caulking tool. 1183.5.7 Pipe Enlarging Type joint ‘The part of the pipe to be joined is expanded using a special tool, and the junction can be made simply, with a cap nut. Even after tightening, it can be removed. ‘Aswith the other types of couplings, it can be used where heat cannot be used. (1) Coupling With an pipe enlarging type pipe coupling the pipe and coupling are joined by using a special tool (Table 3.10) to expand the pipe near its end, into which a cap nut is inserted as shown in Figure 3.20, then inserting this part into the junction portion of the coupling, which is filled with a rubber packing, and tightening the cap nut. Its range of use includes designations 13-60 Su. Table 3.10. Specification of the pipe enlarging tool Powersourceused | AC 100V 50-60 Hz Capacity 320W(7 A) Discharge pressure | 700 kg/cm? max Weight Main unit pump base 23kg Weight Setofattachments _11.3kg Thecounlingttelt FE, packing Copmut Stanlessstectpipe S28, Yoke. papnvt Suigerod Pipe, Stainlesssteet! \ au \ pipe. subber Fig. 3.20. Joining by pipe enlarging type Fig. 3.21. Pipe enlarging operation coupling 119@) Joining method (2) After cutting the pipe to the prescribed length, the portion to be joined is cleaned, and any die wear or flash is removed. (b) As shown in Figure 3.21, the cap nut is attached to the yoke of the pipe enlarging tool and the pipe, fitted with a guide lock, is inserted into the tool (0 When the hydraulic pump is started, the enlarging pipe rubber expands and the pipe is expanded. The expansion of the pipe continues until the lamp on the hydraulic pump comes on and the pump stops. (d) The cap nut is loosened and the pipe is removed from the pipe enlarging tool. (@) After the coupling itself is filled with rubber packing, the expanded pipe, fitted with the cap nut, tightened. (f) tis tightened until the colored surface on the flush washer on the coupling iserted into the coupling itself and the cap nut is isno longer visible. (3) Points to note in the joining operation (2) Any die wear or flash on the pipe end must be completely removed. (b) The special pipe enlarging tool must be used. (©) The attachment of parts on the pipe enlarging tool and its insertion into the pipe must be done securely. (d) Once every 50 operations, the amount of expansion must be verified with a gauge. (e) Do not forget the rubber packing. 3.5.8 Otherjoining methods (1) Vietaulic Type Coupling connection ‘The couplings are expensive, but they are flexible and absorb expansion well. If pre-fabricated, on-site work efficiency is improved, (@) Coupling The couplings used are victaulic type coupling conforming to HASS 007- 1986, "Mechanical Displacement-Absorbing Pipe Fittings." As shown in Figure 3.22, this kind of coupling consists of a rubber ring, stainless steel ring, housing, bolt, and nut. The kind with a shoulder on the connection end of the pipe is known as the shoulder type, and the kind with a ring is 120known as the headless pipe type. In a victaulic type coupling, a short pipe made of SUS 316 to which a shoulder or ring is welded is welded to the stainless steel pipe, rubber rings are fitted on both ends of the short pipe, a housing is put on top of them, and the junction is made by tightening the bolt and nut. The quality of the rubber ring varies depending on the fluid used and the temperature, so is necessary to consult with the manufacturer beforehand. The range of application of this type of coupling includes designations 30 Su and greater. (b) Joining method The joining method follows the procedure given in Table 3.11 Rubber ring Housing Rubber ring Housing shoulder Headless pipe type Shoulder type Fig. 3.22. Victaulic Type Coupling 121Table 3.11. Joining procedure for victaulic type coupling No, ‘procedure Content ofthe operation Precautions Be careful thatthe rabber uring onthe | Spreadoutthe rubber ring by hand and ft 1 | fubbeesing Wino the endothe pipes fing doesnot get scratched insert the pipe tobe connected, make he 2 |apadjusrment | preserbedspecing, and move the rusber Fing tothe Center boson, Coating with oat the outer surface of the rubber in 3 [fibrcane with castor olor soapy water * Place on the housing from above and Coupling on the A 4 below ang uniform ughtan etn the housing bolt and nut. ae (2) High flexibility type coupling junctions This type was developed for buried pipes. The couplings have been given high flexibility to be able to withstand shifting of the ground in which the pipes arelaid. (a) Coupling in a high flexibi ity-type coupling, by tightening a cap nut a gasket is pressed against a tapering portion at the end of the coupling, maintaining airtightness, a bite ring is pressed against the pipe, preventing the pipe from slipping out, and a rubber ring (A) at the end of the cap nut keeps ground water from seeping in. The range of use is designations 13-50 Su (see Figure 3.23). (b) Joining method Any die wear or flash on the portion of the pipe to be joined is removed, is cleaned. It is checked how far the pipe will be inserted when joined, and four lines are marked on the pipe for setting the gasket, etc. and The four lines are for the position at which the gasket is to be set, a line for where the bite ring will be set, a covering line for the cap nut, and a line for verifying the tightening. The set positions, which correspond to the pipe diameter, are listed in Table 3.12. It is convenient to use a special gauge. ‘The procedure is that a bite ring groove about 0.7 mm deep is made with a special roller along the bite ring set line, the cap nut, rubber rings ((A) and (8), retainer, bite ring, and washer are put onto the pipe, and then the gasket is set on along the marked line, the pipe is inserted into the coupling itself, and the cap nut is tightened by hand first and then with a spanner or 122the like until the threaded portion of the coupling i covered by the cap nut. (©) Points to heed in the joining operation The cap nut of the coupling should be tightened slowly, taking care that the pipe does not slip out and that the pipe and coupling do not rotate in tandem. ‘washer Rubber ring (8) Gasket Bite ring Retainer Rubberring (A) Stainless steel pipe The coupling tell pins Capnut Fig. 3.23. High flexi lity type coupling Table 3.12. Setting positions for gasket, etc. of high flexibility type couplings Designation P 8 Q R 3 39 6 20 30 cy GJ 3 Ey 6 5 30 5 35 0 37 56 76 cy 30 76 Gl Pipeendtobejoines Bitering P: gasket setting position S: ite ring setting position Q: cap nut covering ine (position) tightening verification tine 1233.6 Joints with Other Kinds of Pipe Joining stainless steel pipe directly to some other kind of pipe could cause galvanic corrosion, so some care is called for. Table 3.13 lists whether various kinds of pipe can be directly joined to stainless steel pipe. Special couplings are used, including press type, compression type, dresser and snap ring type, and grip type. Table 3.13. Whether stainless steel pipe can be joined to other kinds of pipe With respect to stainless stee! pipe Remarks ‘Other kind of pipe material | Yesino Lead pipe © _ | Containslead inthe solder components Copper pipe © [Asapicicamater no protien, because the cece Unplasticized polyvinyl chloride ‘No problem, because plasticis a poor conductor of pipe a O | credit’ Ps ‘Mustbe electrically insulated, because there ia big Galvanized steel i X | diference in etecttic potential with gaivanizedstee! pipe Note: Omeansyes, x meansno. 3.6.1 Withsteel pipe For joining stainless steel pipe to steel pipe, a flange junction is generally used, as shown in Figures 3.24 and 3.25, and an insulating bolt is utilized. Figure 3.26 pictures a junction using an insulating union. Y Insulating bolt Lop joint made of stainless see! Stainless steel pipe Galvanized stee! pipe Ordinary steel loose flange Fig. 3.24. Junction with galvanized steel pipe 124Insulating union made of steet Loose flange Gasket Flat washer Insulating washer 7 Bo ean eee nen VY Stainless steel pipe Insulating washer Insulating washer Insulating sleeve Fig. 3.25. Insulating bolt, Fig. 3.26. Insulating union 3.6.2. With copper pipe Small-diameter copper pipe (diameter of 28.58 mm or less), since it has the same pipe diameter as stainless steel pipe, can be joined directly with a soldered coupling. But medium- and large-diameter copper pipe is joined as shown in Figures 3.27 and 3.28 because the pipe diameters differ somewhat. 3.6.3 Withlead pipe There are two ways to join lead pipe to stainless steel pipe: direct soldering junction, and mechanical junction. The procedure for a direct soldering junction is as follows. © The part of the lead pipe to be joined is expanded somewhat, its inner surface is scoured with a wire brush or the like and its surface coating is removed. @ The inner surface of the portion of the lead pipe to be joined is coated with type 4 solder for lead pipe, then it is heated and pre-tinned. @ The outer surface of the stainless steel pipe is polished and coated with cream, then it is heated and pre-tinned. ® The part to be joined on both pipes is coated with type 4 solder for lead pipe, then the stainless steel pipe is inserted into the lead pipe, and the junction is made while heating the inserted portion and heating type 1 solder (see Figure 3.29) 3.6.4 With unplasticized polyvinyl chloride pipe Junctions with unplasticized polyvinyl chloride pipe are made by solder junction 125using a union made of a bronze casting (BC6) for copper pipe and lead pipe (see Figure 3.30) Flange je Sate Welding Soldering Copper pipe Stainless steel pipe f zat ‘ Cyt Lap joint made of steel Lapjoint made of stainless steel Fig. 3.27. Flange junction with copper pipe Stainless steel pipe () Threaded adaptor made of stainless steel (There are male junctions too) Copper pipe Threaded adaptor made of copper Fig. 3.28. Union junction with copper pipe Stainless steel pipe Lead pipe Soldering Stainless steel pipe Union Fig. 3.29. Junction with lead pipe Fig. 3.30. Junction with unplasticized polyvinyl pipe 1263.7 Connection with Accessories Pipe couplings for the various types of junctions (weld type, press type, compression type, dresser and snap ring type, grip type) are used for connecting accessories and stainless steel pipe. But with accessories made of iron or the like, insulating bolts are used for flange connections, and insulating unions are used for threaded connections. Also, the points to be heeded in the various junction operations described above must be fully observed if accessories are connected using screwed type adaptor couplings (see Figure 3.31) Valve (made of bronze) Pr threading Stainless stee! pipe / P* screwed type adaptor made of stainless steel Fig. 3.31. Screwed type adaptor made of stainless stee! 3.7.1 Withvalves There are screwed type valves and flange type valves. For the screwed type, male adaptor couplings for the various types of junctions are used. For the flange type, a flange connection adaptor is welded onto the stainless steel pipe. 3.7.2 With faucets, ete. For connections between stainless steel pipe and faucets or the like, various types of socket couplings for water supply faucets or elbow couplings for water supply faucets are used. 3.7.3 With pumps or other equipment Connections between stainless steel pipe and equipment such as pumps may be either of the flange type or the screwed type. For the flange type, a flange connection adaptor is welded to the stainless steel pipe. For the screwed type, the conne n is made using male adaptor and female adaptor couplings for the various types of junctions. 1273.7.4 With flexible joints Connections between stainless steel pipe and flexible joints made of stainless steel may be either of the flange type or of the screwed type, and the connection is made using flange connection and male and female adaptors for couplings for stainless steel pipe. If a flange connection is made between a stainless steel pipe and a flexible joint made of rubber, a gasket is inserted between the rubber seal and the stainless steel seal, because otherwise corrosion could cause leakage. 3.8 Member Processing (Prefabrication) for Piping As has been discussed, various types of couplings such as press type or compression type are used for joining stainless steel pipe. But these couplings are generally intended for small-diameter pipe; for large-diameter pipe of 60 Su or greater, a welded junction is normally used. Joints can be welded at the construction site, but welding requires skill and presents considerable difficulties because the pipe is thin and the work environment is not always very good. That is why the welding is generally done at the factory. As illustrated by Photo 3.1, in this method member processed parts (prefabricated parts) in which tees, elbows, flange-junction lap joints, and victualic joint rings, etc. are welded to the pipe are fabricated, they are brought to the site, and there they are connected by tightening bolts, thereby completing the joining operation. It is advantageous to use SAS 371 ("Module Pipes of Light Gauge Stainless Steel Pipe for Ordinary Piping"), which has been enacted in order to standardize member processing. (1) Work procedure First, isometric drawings are prepared, and based on them, pipe is cut to the prescribed lengths. Next, various couplings are welded on, following the notes for weld junctions given in section 3.5.1 (2) Points to heed in the operation Follow the points to heed for the joining operation that are given in section 3.5.16) (3) Inspection Follow the inspection procedures given in section 3.5.1(5). 3.9 Pipe Care Care must be exercised in the handling, working, and piping of stainless steel pipe because itis lighter and thinner than, say, carbon steel for piping. In the factory where members are pre-processed, stainless steel pipe must be kept in order and kept clean, 128Photo 3.1. Prefabricated parts and during storage finished members must be protected from damage from falling objects or other causes and from soiling by oil, mud, dust, or other foreign substances. In particular, iron objects must not come in contact with the stored stainless steel pipe, because this could cause corr n. Also, since the pipe ends could get crushed or acquire flash if they come in contact with other materials, they should be capped when doing so is thought advisable. When pre-processed members are installed into their prescribed location on site, the pipe must also be protected. Antisweating and heat insulation should be put on horizontal ceiling pipe or vertical pipe as soon as possible. If piping is located in places that form traffic corridors, they must be protected by laying down boards or the like to keep other materials or machinery from touching or striking them. While the piping is being laid out, open pipe ends should be covered as necessary to prevent foreign material from adhering or getting into the pipe. Even after the pi is completed, care must be taken that it is not distorted by placing heavy objects on it or suspending objects from it. 3.10 Embedding Pipe 3.10.1 Inthe ground In many places in Japan, the soil has a resistivity of 1000 Q-cm or more and a Cl’ concentr of 100 mg or less. In such soils, stainless steel pipe exhibits excellent resistance to corrosion and can be buried as is, without treating the outer surface of the pipe. But if underground piping is laid in such areas as wet coastal regions where sea water wells up or volcanic hot springs regions where gas comes out of the ground, stainless steel pipe must always be protected, such as with Petratum 129corrosion protective tape. If an anti-rust treatment is given, first any adhering dirt, or other substances are removed, then Petratum paste is smeared on, then Petratum corrosion protective tape is wound around once with a one-half overlap. In addition, anticorrosion vinyl tape (JIS Z 1901, 0.4 mm thick) is wound around once with a one-half overlap. But couplings and other such parts are wrapped with Petratum corrosion protective sheet and then wound with anticorrosion vinyl adhesive tape. Normally SUS 304 used, but the adoption of other types, such as less the more corrosion-resistant SUS 316, should also be considered. Because stai steel pipe is so thin, backfilling must be done carefully. Such means as the double- pipe method, waterproof coverings, or packing in sand are used when backfilling is. done. Embedding stainless steel pipe in soil should be avoided if temperature fluctuations would cause expansion and contraction, but when the pipe simply must be buried, it should be as short as possible. To protect piping from ground subsidence, flexible joints or high flexibility-type couplings are used between the piping and the building (see Figure 3.32). For corrosion prevention, insulating joints are used to insulate piping inside the building and underground pipe (see Figure 3.33(a)). Figure 3.33(b) shows the details of the insulating sleeve in Figure 3.33(a). Fig. 3.32. How to use high flexibility-type couplings 3.10.2 Inconcrete Stainless steel pipe generally exhibits corrosion resistance with respect to concrete and therefore it may be used in concrete-embedded piping, but contact with the steel reinforcement in buildings must be avoided, and insulation measures 130