Piping

Engineering
Lecture 3
Dr. Trupti Dharmarao

© Dr. Trupti Dharmarao

 Learning objectives

• To understand role of piping engineer in details

• To classify pipes into different categories
• To analyse different methods of pipe
manufacturing

© Dr. Trupti Dharmarao

What is the role of a Piping
Engineer in a Process industry ?

1) Review of Process Package

2) Preparation of plot plan, equipment

layouts, piping studies, piping specification
and giving inputs to civil, process, electrical /
instrumentation groups for various purposes

© Dr. Trupti Dharmarao

Role of piping engineer
1. Review of Process Package
• Process data required converting P & ID’s to piping
layouts like a proper identification of valves,
strainers, In- line instruments.
• Utility summery giving utility consumption for each
equipment with duty conditions like pressure,
temperature etc.,
• Conceptual equipment layout drawings for process
plant reflecting the process constraints.
• Process data sheets for equipments.
• Hazardous area classification etc
© Dr. Trupti Dharmarao
Role of piping engineer
2. Preparation of plot plan, equipment layouts, piping
studies, piping specification and giving inputs to civil,
process , electrical / instrumentation groups for various
purposes.
• Preparation of piping layouts, isometrics, support
Drawings;
• Stress analysis
• Procurement assistance;
• Preparation of drawings for statutory approvals;
• Preview of vendor drawings;
• Coordination with various engineering groups & site
• And ends with completion & commissioning of plant. © Dr. Trupti Dharmarao
Classifications of pipes
• Pipes are classified on different basis:
1. Based on material
2. Based on the industry where they are used
3. Based on the fluid they transport
4. Based on the manufacturing method

© Dr. Trupti Dharmarao

 Pipe Types based on Material
• Pipes are normally classified based on the material
which is used to produce the pipe during
manufacturing.
• In general, there are two types of pipes:
1. Metallic Pipes and
2. Non-metallic Pipes

© Dr. Trupti Dharmarao

Metallic Pipes
• The pipes made of metal are known as metallic
pipes. They can be grouped into two categories:
1. Pipes made from ferrous materials
2. Pipes made from non-ferrous materials

© Dr. Trupti Dharmarao

Type of Pipes made from ferrous materials:
• These types of pipes are stronger and heavier. These pipes have
iron as their main constituent element.
• Common examples of pipes made from ferrous materials are
1. Galvanised iron pipe
2. Cast Iron pipes
3. Carbon steel pipes
4. Stainless steel pipes
5. Alloy steel pipes
6. Ductile iron pipe etc
• This category of pipes is suitable for higher temperature and
pressure applications
• Most of the pipes used in the oil and gas, refinery, chemical,
petrochemical, power plants, etc are made of ferrous materials
Galvanised iron pipe (GI pipes)
• These are the mild steel or wrought iron pipes,
provided with a protective coating of zinc on both
inner and outer surfaces.
• These pipes are commonly used in house plumbing or
after-service connection.
• These are cheap, light, easy to join, easy to transport
and handle.
• The life span of these pipes is around 20 years
Cast iron pipes (CI)
• These pipes are widely used for the conveyance of
water in the water supply scheme.
• These pipes are corrosion resistant and possess
other desirable properties like durability, easy to make
joint, long life, strong and can resist maximum
pressure likely to develop.
• Cast iron pipes are expensive and heavy hence
difficult to transport.
Steel pipe
• These are fabricated by rolling the mild steel
plates to proper diameter and can be joined
by riveting or welding.
• These pipes are strong, cheaper, light in
weight can resist high pressure
• The welded steel pipes are made up to 2.4 m
in diameter and up to 12 m lengths.
• These pipes are costlier, liable to corrosion,
and can’t resist pressure due to external load
during vacuum inside.
• Advantages of Steel pipes
• 1. Numbers of joints are less because these are available in
long lengths.
• 2. The pipes are cheap at the first cost.
• 3. The pipes are durable and strong enough to resist high.
• 4. The pipes are flexible to some extent laid on curves. and they
can therefore 5. Transportation is easy because of lightweight.
• Disadvantages of Steel pipes
• 1 Maintenance cost is high.
• 2. The pipes are likely to be rusted by acidic or alkaline water.
• 3. The pipes require more time for repairs during breakdown
and hence are not suitable for distribution pipes.
Application of steel pipes
• Process pipes
• Water main
• Sewage system pipes
• Industrial water pipes
• Casing pipes
• Pipes for natural gas
Type of Pipes made from Non-ferrous materials:
• Iron is not the main constituent element.
• They are usually made of copper, aluminum, brass, etc.
• Common pipes made from non-ferrous materials are:
1. Aluminum and Aluminum alloy pipes.
2. Copper and copper alloy pipes.
3. Nickel and Nickel alloy pipes.
4. Titanium and titanium alloy pipes.
5. Zirconium and Zirconium alloy pipes.

© Dr. Trupti Dharmarao

Copper pipes
• Because of tendency of steel pipe to
corrode over the time for copper pipes are
used in plumbing industry
• Advantages
• Copper Plumbing Pipes Are Durable
• Copper Piping Does Not Contaminate Water
• Copper Pipes Are Lightweight
• Copper Piping is Less Harmful For the
Environment
• Copper Plumbing Pipes Are Fire Resistant
 Non-metallic Pipes
• Non-metallic pipes are widely used for services where the
temperature is not significant.
• Non-critical services like water industries and drainage systems
make use of most of the non-metallic pipes.
• Common non-metallic and widely used pipes are:
1. PE/HDPE Pipes
2. uPVC/PVC/CPVC Pipes
3. PP pipes
4. Reinforced thermoplastic pipes or RTPs
5. ABS Pipes
6. Composite pipes like FRP Pipes
7. Cement and Asbestos Cement Pipes
8. Vitrified clay pipes © Dr. Trupti Dharmarao
PVC Pipes
• PVC pipes are made of a combination of plastic
and vinyl.
• These plastic pipes are highly rigid, easy to join,
strong in resisting pressure, light in weight hence
transportable can resist acids, alkalis, salts, and
organic chemicals, cheaper so commonly used.
• This pipe requires support closer due to flexibility
so that can break or crack if miss-handled.
• PVC pipes can resist temperature up to 60 °C.
• Minimal skills and tools are required to install
PVC pipes.
• As they do not rust, rot, or wear over time, these
pipes are commonly used in water systems.
• Advantages of PVC pipes
• 1. Pipes are cheap.
• 2. The pipes are durable.
• 3. The pipes are flexible.
• 4, The pipes are free from corrosion.
• 5. The pipes are good electrical insulators.
• 6. The pipes are light in weight and they can easy to
mold any shape.
• Disadvantages of PVC pipes
• 1. The co-efficient of expansion for plastic is high.
• 2. It is difficult to obtain plastic pipes of uniform composition.
• 3. The pipes are less resistant to heat.
• 4. Some pipes of plastic impart taste to the water.
Applications of PVC pipes
• For water plumbing and water transport
• For waste water handling and contr
• For rain water management
• For agriculture
• For fire sprinkler
• For coating and cable insulation
• For building infrastructure and structural material
PPR pipes
• Polypropylene random copolymers are
thermoplastic resins produced through the
polymerization of propylene, with ethylene
links introduced in the polymer chain.
• Nowadays PPR pipes and fittings are popular
in plumbing and water supply plants due to
ease in the joint, perfect seal-tight system, no
calcification problem, durable and long life
expectancy, recyclable, good chemical
resistance, etc.
• Advantages of PPR Pipes
1.Light in weight and easy to handle.
2. eco-friendly and durable.
3. high resistivity against heat.
4. good resistivity to chemicals.
5. These pipes are
6. Life expectancy is of more than 50 years.

• Disadvantages of PPR Pipes

1. Joining and repairing PPR pipes is possible by the use of a
fusion-welding tool.
2. As PPR pipes are plastic products exposed to direct sunlight
may dry out the oil content present in all plastics.
Concrete pipes
• Cement concrete pipe pipes may be either
plain cement or reinforced cement concrete.
• PCC pipes can be used up to 15 m head
whereas RCC pipes can be used up to the
head of 60 in and for higher head pre-
stressed concrete can be used.
• RCC pipes are non-corrosive and longer Life.
• The maintenance cost of cement concrete
pipe is less and joints are very simple.
• However, concrete pipes are inconvenient as
they are heavy, less resistant to withstand
impact and shock.
• Advantages of concrete pipes
1. most durable with usual life of about 75 years.
2. can be cast at site work and thus reduction in transport
charges.
3. Maintenance cost is less.
4. Inside surface of the pipe can be made smooth.
5. No danger of rusting.
• Disadvantages of concrete pipes
1. Transportation is difficult.
2. Repair work is difficult.
3. Initial cost is high.
4. These pipes are affected by acids, alkalies, and salty waters.
Types of Pipes depending on the industry
they are used
• Depending on the type of industry there are
three types of pipes
1. Pipes for Chemical and Power industries
2. Pipes for Plumbing industry
3. Pipes for Pipeline industry

© Dr. Trupti Dharmarao

Continued
1. Types of Pipes for Chemical and Power Piping
Industries
• These types of pipes are suitable for high-
temperature and pressure applications.
• Mainly pipes made from ferrous materials are used
in chemical, power, petrochemical, steel, oil, and gas
industries.
• They are usually designed following codes like ASME
B31.3, ASME B31.1, and various other international
codes.
• They are usually selected based on their ability to
sustain pressure, temperature, corrosion resistance,
etc. © Dr. Trupti Dharmarao
Continued

2. Types of Pipes for the Plumbing industry

• Common plumbing pipes are PVC pipes, PEX pipes,
Copper pipes, ABS pipes, Cast Iron and galvanized
steel pipes, etc. They are mainly used for water
distribution purposes.

© Dr. Trupti Dharmarao

 Continued
3. Pipes for the Pipeline industry
• Pipes used in pipeline industries are usually known as
line pipes and designed by API 5L standard. All types
of five are available in many materials and grades and
they are used to convey oil, gas, or water through
pipelines.

© Dr. Trupti Dharmarao

Continued

• Carbon steel in grades such as ASTM A106, A333, A53, and API 5L .
• Chrome-moly alloy steel seamless pipes in grades like ASTM A335
Grades P5 to P91 for high temperature and pressure applications.
• Stainless steel pipes in ASTM A312 Series of 300 and 400 such as
304, 316, 321, and 347.
• Duplex and super duplex Seamless pipes in ASTM A790/ A928 with
double ferritic and austenitic structure.
• Seamless Pipes are available in different nickel alloys such as
Inconel, Hastelloy, Cupronickel, Monel, and Nickel.
Types of Pipes based on the manufacturing
method
• Pipes can also be classified based on the method of
manufacture.
• These are again sub-categorized depending on the
material of the pipe.
• For example, Metallic pipes can be categorized as:
1. Seamless pipe
2. Welded pipe
• ERW pipes
• SAW pipes

© Dr. Trupti Dharmarao

Pipe Manufactureing processes
• Seamless pipes
• Welded pipe
Seamless Pipe Manufacturing Process
• Seamless pipe is strongest amongst all pipes type as it has
a homogeneous structure throughout pipe length.
• Seamless pipes are manufactured in a verity of Size and
schedule
• However, there is a restriction on the manufacturing of
large diameter pipe.
• Seamless pipes are widely used in the manufacturing
of pipe fittings such as bends, elbows, and tees.
 Methods of seamless pipe manufacturing
1. Mandrel (Pilger) Mill Process
2. Mannesmann Plug Mill Pipe Manufacturing Process
3. Forged Seamless Pipe Manufacturing Process
4. Extrusion Processes
Mandrel (Pilger) Mill Process
• A steel billet is heated to forging temperature and placed between the rolls of a hot
rotary piercing mill.
• A piercing point is placed at the center of the billet, and the rotating rolls are designed
to advance the billet over the piercing point, thereby forming a hole through the
center of the billet along its entire length as it advances into the tilted rolls.
• A mandrel of outside diameter approximately that of the inside finished pipe diameter
is pressed into the pierced hole of the billet.
• A combination of mandrel and billet is placed between rolls of a pilger-mill having a
cam-shaped contour revolving counter to the direction in which the billet is being
forced by means of a hydraulic and pneumatic ram mechanism.
 Mannesmann Plug Mill Pipe Manufacturing
Process
• The only difference between the Plug mill process and the Mandrel mill
process is that in the mandrel method inside diameter is achieved in a
single pass whereas in Mannesmann multi-stage reduction is possible.
• In this process, the billet may be pierced in two hot rotary piercers because
of the greater reduction needed for medium- size pipe and tube.
• Following the piercing process, the pierced billet is placed in a plug-mill,
which reduces the diameter by rotating the tube over a mandrel.
• Having some ovality, the tube is next inserted between the rolls of reelers
which provide for dimensional correction and burnish the inside and
outside diameters of the tube.
• Finally, after reheating, the tube reenters a reeler and sizing rollers to
provide for greater dimensional uniformity.
• The Mannesmann plug-mill process is a standard process for making large
quantities of thin-wall stainless steel tube or pipe of uniform size and
round- ness throughout its entire length
Forged Seamless Pipe Manufacturing Process

• In a Forging pipe manufacturing process, a heated billet is

placed in forging die that has a diameter slightly larger than
the finished pipe.
• A hydraulic press of forging hammer with matching inside
diameter is used to create cylindrical forging.
• Once this forging is done pipe is machined to achieve the
final dimension.
• Forging pipe manufacturing process is used to manufactured
large diameter seamless pipes that cannot be manufactured
using traditional methods.
• Forged pipes are normally used for the steam header.
 Extrusion Processes
• In an extrusion pipe manufacturing, a heated
billet is placed inside the die.
• A hydraulic ram pushes the billet against the
piercing mandrel, material flows from the
cylindrical cavity between die and mandrel.
• This action produces the pipe from the billet.
• Sometimes pipe manufactured produce pipe
with a high thickness which is known as mother
hollow.
• Many secondary pipes manufactured used this
mother hollow to produce pipes with different
dimensions.
Welded Pipe Manufacturing Process
• Welded Pipes are manufactured from Plate or continues
Coil or strips.
• To manufacture a welded pipe, the first plate or coil is
rolled in the circular section with the help of a plate
bending machine or by a roller in the case of a continues
process.
• Once the circular section is rolled from the plate, the pipe
can be welded with or without filler material.
• A welded pipe can be manufactured in large sizes without
any upper restriction. Welded pipe with filler material can
be used in the manufacturing of long radius bends and
elbow.
• Welded pipes are cheaper with compared to the seamless
pipe and also Weak due to the weld
Types of welding methods

• There are different welding methods used

to weld the pipe.
1. ERW- Electric Resistance Welding
2. EFW- Electric Fusion Welding
3. HFW- High-frequency welding
4. SAW- Submerged Arc Welding (Long
seam & Spiral Seam)
ERW Steel Pipe Manufacturing Process
• In the ERW / EFW / HFW pipe process, the first plate is formed in a cylindrical
shape and the longitudinal edges of the cylinder formed are welded by flash-
welding, low-frequency resistance-welding, high-frequency induction welding, or
high-frequency resistance welding.
 SAW Pipe Manufacturing Process
• In the SAW welding process, external filler metal
(wire electrodes) are used to join the formed
plates. SAW pipes can have a single longitudinal
seam or double longitudinal seam depend on the
size of the pipe.
• SAW pipes are also available in the spiral seam,
which is continually rolled from the single plate
coil.
• The production rate of the spiral SAW pipe is very
high as compared to the Straight SAW pipe.
• However, Spiral SAW pipes are only used in low-
pressure services such as water, non-critical
process services, etc.
 Question 1
Which type of pipe is preferred for pressure
applications?
 Question 2
Name few constituents used for making non-
ferrous pipes
 Question 3
PVC/PEX/ABS pipes are preferred in ….
 Question 4
A mandrel of outside diameter approximately
equal to that of the …….. pipe diameter
 Question 5
In pipe manufacturing by welding process, which process
uses external filler metal (wire electrodes) to join the
formed plates
 Question 6
Name Four different basis for classification of pipes
 Question 7
Based on pipe material, pipes are classified as ….
 Question 8
Copper pipes are preferred in ….
Thank you
Videos shown
• https://www.youtube.com/watch?v=ztcEyel47Kg
• https://www.youtube.com/watch?v=0x1uRR9Jb34