REPORT

INTERNSHIP

[Type the document subtitle]

DAWOOD HERCULES CHEMICALS LTD
AHMAD SAEED

1. Piping Systems
Definition:
A complete network of pipes, valves and other parts(components) designed to do a specific job
i.e. transfer of fluid from one place to another or a system which connect the whole plant
operations as piping or valve breakdown in one part of the plant can bring harm in another
sections.
The system can carry:

Fuel oils to heating plants

Steam to steam turbine
Lubricants for equipment
Plants water supply and for the removal of liquefied wastes etc.

The components of piping systems are made of different materials depending upon the
application, for example, be made of brass, stainless steel, plastic, glass, lead, cast iron, and steel.

2. Components of Piping Systems

i) Valves:
These are the devices which control the flow of fluid and pressure in the piping systems.
These include:

Protective devices (relief valve) that automatically open to vent fluid out of the pipe when

the pressure in the lines gets too high and

Control devices like gate valves and globe valves which are operated by hand

ii) Fittings

Fittings are the components used in a piping system to connect sections and change the direction
of flow.

iii) Pipe Hangers and Supports

Pipes are supported to keep the line straight and to prevent sagging. Rigid pipes sags excessively
will strain its connecting fitting which will cause leakage. To some extend is self-supporting
because it has a certain amount of mechanical strength but in a long run rigid pipes are fastened
to floor, walls, ceiling, or pillars.

3. Temperature Effects :
All materials and metals in particular expand as the temperature increases and contact or become
smaller in size as the temperature decreases. To allow for this expansion and contraction in
piping systems, expansion joints must be included in the line between sections of rigid pipe.
Expansion joints have three functions:

To compensate for expansion and contraction of the pipes

To allow pipe motion either to the side or along the length of the pipe
To help dampen vibration and sounds carried along the pipe from distant pumps or other
equipment

4. Piping insulation:
Piping is covered by layers of insulation. Insulation helps prevent hot fluid from cooling as it
passes through the system. And if piping is carrying a cold fluid, insulation helps keep the fluid
cold. Insulation also protects piping against rusting and corrosion caused by exposure to water
and chemicals in soil. Typical insulating materials are polystyrene foam, fiberglass, hair-felt, and
mineral wool.

5. Maintenance considerations

Preventive maintenance is the key to keeping any piping network operating smoothly and
efficient
The major problem in piping systems are caused by leakage and corrosion
Some points:

Checking for corrosion and leakage

Checking to be sure that valves are in working order
Checking hangers and pipe supports
Cleaning piping as required
Reporting anything of an unusual nature.
Installing, inspecting, and replacing fittings.

5. Pipes
Pipe sizes are expressed in inches () or fractions of inches. As a rule, the size of the pipe is
given in terms of the outer diameter (O.D.) or inside diameter (I.D.).
The principle dimensions are as follow:

Outside diameter (O.D.)

Inside diameter (I.D.)
Wall thickness
Length

The pipe sizes are designated by diameter. Commercial sizes 12 inches and less are known by
their nominal or approximate inside diameters.
Above 12 inches, a pipe is designated by its outside diameter. For example a 4 diameter pipe is
actually 4 inches in diameter while a 10 or 12 pipe is of an inch greater than the size
used.

5.1 Pipe Schedules

Pipes are classified according to SCHEDULE the most common schedule numbers are 40,
80,120,and 160. The schedule numbers ranges from 10 to 160, the difference being the wall

thickness. For example, a Schedule 40 3 diameter pipe, whose actual O.D. is 3.500 has a wall
thickness of 0.216. The same pipe in schedule 80 would have a wall thickness of 0.300. when
the wall thickness of any given size of pipe is increased, the inside diameter will decrease.
Piping is referred to either in terms of its diameter or schedule number.

5.2 Pipe manufacturing methods:

Metal piping is made by different processes. The four methods are:
i.
ii.
iii.
iv.

Wrought seamless pipe

Forged seamless pipe
Welded pipe
Cast pipe

In first method billet or block is heated and hole is driven through it. In second method steel
billet is heated and then is lengthened by forging hammers until it is stretched out to a diameter
about one inch greater than that of the finished pipe. In third method a flat strip of steel is
converted into a tube after successive rolling operations. Cast piping is made by pouring molten
metal into a mold where it is allowed to cool.

5.3 Piping Applications

Welded or seamless pipe is used for plumbing, heating, water, gas and air lines.
Cast iron pipe is used for water and gas distribution land sewage lines because it has long life
due to heavy wall and good resistance to both internal and external corrosion. Cast iron is
more corrosion resistant than steel.
Reactive solutions are carried in nonferrous type pipes. And relatively more expensive. For
example brass and copper pipes.

5.4 Joining pipe

The five methods are given as:
i.

Bell and spigot

ii.
iii.
iv.
v.

Welded
Soldered or brazed
Screwed
Flanged

Bell and spigot joints are used for connecting lengths of cast iron water pipe. The enlarged
section at one end of pipe is the bell, the plain end is the spigot. Welding is the process of heating
materials to high temperature that the section to be joined melt and blend together. i) butt weld ii)
socket or fillet weld iii) sleeve weld are the three methods of welding.
Soldered or brazed joints are used for joining nonferrous metals. Brazing is done at lower
temperature than welding. Screwed joints are used to join sections of smaller diameter pipe
which carries fluids at low pressure and normal temperature. Diameter range is 1/8 up to 4and
8.

6. Tubing
The term tubing refers to tabular products made either to an outside or inside diameter expressed
in even inches or fractions of an inch.
Birmingham Wire Gage (BWG) system is used for tube sizing.

i)

Difference between pipe and tubing

Tube wall thickness is much thinner than those of pipes.

The wall thickness increases slightly as the diameter of the tubing increases while in pipes it
decreases.
Tubes can be more suitable where vibration is problem because these are flexible.
Tubing eliminates fittings due to which:
a) Cost of fittings eliminates
b) Time required to cut thread and join separate sections of pipe is saved.

c) Tubing become much lighter in weight

d) Possibility of leakage decreases
Another advantage of tubing is that it has smoother inner wall surface so fluid in a tube is
LAMINAR. While in iron pipe flow is irregular.
Tubing has chemical advantages over pipe as it is more corrosion resistant to corrosive fluids.

7. Fittings
Fittings are the components used in a piping system to connect sections and change the direction
of flow. The function of fittings is the same for both pipes and tubes. And both are similar in
shape and type but pipe fittings are little heavier than tube fittings.

7.1. Functions of fittings:

Change the direction of flow

Provide branch connections
Change the sizes of lines
Close lines

7.2. Changing the direction of flow

An elbow is used to change the direction of flow. It may be in 45degree 90 degree angle. Elbows
are most common fittings. Two types of elbow fittings are used
Long radius
Short radius
Long radius has more curve. The dimension is taken as center to face distance. In long radius
elbow the center to face distance is 1-1/2 times the diameter of the fittings C/F=1-1/2 where C is
center and F is face.this is used for service where rate of flow is critical and space no problem.

In short radius elbow, the center to face measurement equals the pipe diameter. If the line is long
and have many change in direction short radius elbow is used.

7.3. Branch connections

When pipe and tube have more than single lines from one point to another following fittings are
mostly used :
TEE (connect three lines)
CROSS (connect four lines)
LATERAL OR Y FITTINGS (connect three lines)
These fittings offer straight run of fluid and branch run too. If outlet size is changed than the inlet
than these fittings have reducing effect too.

7.4. Changing line sizes

The function of a reducer is to reduce a line to a smaller pipe size. This increases the flow
pressure in a piping system. And reduce the volume of fluid.

7.5. Caps, plugs and Couplings

Pipe caps are used to close the end of a pipe or tube.
Plugs are used to close openings in fittings. Suppose a three pipe connection is required and
fourth pipe is to be connected latter a CROSS is used and unused outlet is fitted plug.
To connect the two lengths of pipes a UNION is used.
The fittings can be connected through welding, by using threading or by flange.

Internship Report

dh
Dawood Hercules Chemicals LTD

Submitted by:
AHMAD SAEED
STUDENT OF MECHANICAL ENGINEERING (UET TAXILA)