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TABLE OF CONTENTS
1.
INTRODUCTION TO PIPING
03
2.
PIPING SHAPES
04
3.
PIPING MATERIALS..
05
4.
08
5.
09
6.
PIPING INSULATION
10
7.
11
8.
PIPE FITTINGS..
12
9.
FLANGES.
14
10. VALVES .
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31
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35
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1. INTRODUCTION TO PIPING
Pipe is a pressure tight cylinder used to convey a fluid or to transmit a fluid pressure,
ordinarily designated pipe in applicable material specifications. Materials designated
tube or tubing in the specifications are treated as pipe when intended for pressure
service.
Piping is an assembly of piping components used to convey, distribute, mix, separate,
discharge, meter, control or snub fluid flows. Piping also includes pipe-supporting
elements but does not include support structures, such as building frames, bents,
foundations, or any equipment excluded from Code definitions.
Piping components are mechanical elements suitable for joining or assembly into
pressure-tight fluid containing piping systems. Components include pipe, tubing, fittings,
flanges, gaskets, bolting, valves and devices such as expansion joints, flexible joints,
pressure hoses, traps, strainers, in-line portions of instruments and separators.
Piping is used in industry for conveying fluids and heat transfer. Pipes are generally
hollow cylindrical in shape.
Pipes
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Tubes
ID = OD (2 x
Wall thickness)
2. PIPING SHAPES
The shape of pipe is hollow-cylindrical. Hollow cylindrical shape leads to economic
design. Hollow square pipes are used in cases where space restriction is predominant.
The pipes used for structural application are usually hollow rectangular. The thickness
required for hollow cylindrical shape is the minimum among various shapes. As per
ASME sec I, thickness of more than one half of the internal radius is considered as a thick
cylinder.
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3. PIPING MATERIALS
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PD
+ A
2 ( SE + PY )
tm = t + A
tm =
= 3000 psig
= 85C = 185 F
= 12
= API 5L Gr B Seamless
= 3mm = 0.1181099 inch
= 12.5 %
= (1- Mill Tolerance)
= (1-0.125)
= 0.875
= 60Ksi = 60000Psi
= 35Ksi = 35000Psi
Allowable Stress
@ Design Temperature (S)
Longitudinal weld joints (E)
Values of Co-efficient (Y)
= 20000 Psi
= 1.0 for Seamless pipe.
= 0.4 (Below 900 F)
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tm =
Design Formula:
t
=
=
=
tm
=
=
=
t+C
0.849056 + 0.1181099
0.96716 inch
t nom
=
=
0.96716 / 0.875
1.1053 inch
t nom
5. PRESSURE DROP
The piping can carry a single phase fluid or two phase fluid or three phase fluid. The
following fluids are conveyed by the piping,
1. Liquid
2. Gas
3. Liquid-Solid slurry
4. Gas-solid mixture
5. Liquid-gas mixture
6. Gas-Liquid-solid mixture
In a maze of piping, flow distribution plays a major role in piping design. The following
formulas are commonly used to calculate the Pressure drop and the pumping power
required for a hollow cylindrical horizontal pipe carrying a liquid.
The following formula we have been used to find out the pressure drop,
Pressure Drop P (Kg/m2)
Where,
W
- Mean Specific weight of the fluid (Kg/m3)
V
- Mean Velocity of the fluid (m/Sec)
g
- Gravitational constant (Friction factor)
f
- co-efficient of friction
L
- Sum of straight pipe Lengths of same size (m)
D
- Bore of pipe (m)
Z
- Sum of Co-efficient of fluid resistance of each fitting such as bend,
elbow, tee, reducer, valve, etc.
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Reynoldss number
It is a dimensionless number representing the ration of inertial and viscous forces
governing a flow
Re
=
(103 x x V x d) /
Where,
V
- Mean Velocity of the fluid (m/Sec)
D
- Bore of pipe (m)
6. PIPING INSULATION
Insulation is the material, which resist the heat flow from one medium to other.
List of insulation material:
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SOCKET
WELDED
CONNECTION:
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8. PIPE FITTINGS
BENDS
Bends are used to change the direction of flow of fluid in pipes. Bends are usually made,
using a bending machine, from straight pipes.
ELBOWS
Elbows are made using a pressing machine or a forging machine, from a straight pipe.
Elbows are of the following types:
45 elbow, 90 elbow and 180 elbow.
Elbows of the following types are also available:
22.5 elbow and 11.25 elbow.
REDUCER
The purpose of the reducer is to reduce the diameter of straight run of pipe.
There are about two types of reducers. They are:
Concentric reducer
Eccentric reducer.
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CONCENTRIC REDUCER
Concentric reducer will be having common Centre line.
Concentric reducer will be used for vertical and Pump Discharge Piping.
ECCENTRIC REDUCER
Eccentric reducer will be having offset centerline between inlet pipe and exit pipe.
Eccentric reducer will be used for horizontal and Pump Suction Piping.
For horizontal piping, flat on Bottom for maintaining the elevation in the Rack Piping.
For Pump Suction, flat on top to avoid the cavitation.
TEES
Tees are used to distribute to collect flow. Tees are of the following types: formed
tees, forged and machined tees, unequal tees and pregnant tees.
BRANCHES
Branches are similar to tees. Branches are made from straight pipes by machining
and welding.
Y-PIECES
Y-pieces are rarely used. The y are used to collect and distribute flow. The pressure
drop in a y-piece is less than that of a comparable tee.
END COVERS
End covers are of the following types: flat end cover, hemi-spherical end cover,
tori-spherical end cover, semi -ellipsoidal end cover and tori-conical end cover.
SAFETY VALVE STUBS
Safety valve stubs are used to attach safety valves to the pipes. Safety valve stubs are
designed to with stand the bending moments imposed on them by safety valve
blowing jet reaction, over and above the internal pressure load.
RADIOGRAPHIC PLUG
Radiographic plugs are used to facilitate insertion of radioactive substance for doing
radiographic test of butt weld on the pipes.
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END CONNECTIONS
The following end connections are popularly used butt welding, flanged
connection ,screwed connection, screwed and flanged connection ,socket welded
connection, slip-on type of connection, thrust block connection and mechanical type
of connection.
VALVES, FLOW MEASURING DEVICES AND INSTRUMENTS
Valves, flow measuring devices and instruments are used to stop, direct, check,
measure and control flow, temperature, pressure, level and quality of fluid in the
piping.
9. FLANGES:
A flange will be consisting of 2 flanges with gasket in between them.
FLANGE RATING AND CLASS
TYPES OF FLANGES
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Weld Neck Flange This flange is designed to be joined to a piping system by butt
welding.
It is relatively expensive because of its long neck, but is preferred for high stress
applications.
The neck, or hub, transmits stresses to the pipe, reducing stress concentrations at
the base of the flange.
The gradual transition of thickness from the base of the hub to the wall thickness
at the butt weld provides important reinforcement of the flange.
SLIP ON FLANGE
Slip on Weld Flange The flange is slipped over the pipe and
Welded (usually both inside and outside) to provide strength and prevent
leakage.
These flanges are at the low cost end of the scale, and do not require high
accuracy when cutting the pipe to length.
They can sometimes have a boss or hub, and can be made with a bore to suit
either pipe or tube.
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Lap Joint Flange This is again similar to a slip-on flange, but it has a radius at the
intersection of the bore and the flange face, and no raised face, to accommodate
a lap joint stub end.
The face on the stub end forms the gasket face of the flange.
This type of flange is used in applications where sections of piping systems need
to be dismantled quickly and easily for inspection or replacement, because the
stub end is welded to the pipe, not the flange.
THREADED FLANGE
Threaded Flange this is similar to a slip-on flange in outline, but the bore is
threaded, thus enabling assembly without welding.
This obviously limits its application to relatively low pressure piping systems.
The joint after assembly, but this is not considered a satisfactory method of
increasing its pressure applications.
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SOCKET-WELD FLANGE
BLIND FLANGE
ORIFICE FLANGE
The function of orifice flange is to measure the rate of flow of commodity through
piping system.
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Flat face flange has flat, level connecting surface. There will be two flanges with
gasket in between them. The external or mating surface for two flanges will be flat
face.
Using a flat face flange will assure full surface contact, thereby reducing the
possibility of cracking the softer cast iron.
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This flange face has raised surface. With shallow grooves attached into raised
surface, this flange face assures a positive grip with the gasket.
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GASKETS
10. VALVES
A Valve is a device that controls flow of a fluid.
Valves can Control not Only the flow but also the rate, the Volume, the Pressure and the
direction of a fluid within a pipe.
STEM
Stem can be moved manually (or) to be driven hydraulically, pneumatically (or)
electrically under remote or) Automatic control (or) mechanically by weighted lever,
Spring etc.
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Valve Action
Explanation
ON / OFF
Regulating
Checking
Switching
Discharging
SELECTION OF VALVE
Fluid properties
Service
Valve size design
Pressure losses/friction losses
Temperature and pressure
End connection
Flanged
Butt
Socket
Threaded
Medium pressure
High pressure
Commercial
END CONNECTIONS
FLANGED
WELDED
SCREWED
long service
Dismantling then for maintenance
Purpose is frequent
FUNCTION OF VALVE
ISOLATION
Gate valve
Ball valve
Plug valve
Piston valve
Butterfly valve
REGULATING
Globe valve
Needle valve
Butterfly valve
Piston valve
NON-RETURN
Multi-port valve
Float valve
Line blind valve
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VALVE SYMBOLS
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STRESS STRAIN CURVE: It is a curve in which unit load or stress is plotted against
unit elongation, technically known as strain.
O A represents the stress is directly proportional to strain, and point A is known
proportional limit.
Point B represents elastic limit beyond which the material will not return to its
original shape when unloaded but will retain a permanent deformation called
permanent set.
Point C is called yield point and is the point at which there is an appreciable
elongation or yielding of the material without any corresponding increases of
load.
Point D is ultimate stress or ultimate strength of material.
Point E is the stress at failure known as rupture strength.
WHAT IS STRESS ANALYSIS?
Piping Stress analysis is a term applied to calculations, which address the static and
dynamic loading resulting from the effects of gravity, temperature changes, internal
and external pressures, changes in fluid flow rate and seismic activity. Codes and
standards establish the minimum requirements of stress analysis.
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STRESS CATEGORIES
The major stress categories are primary, Secondary and peak.
PRIMARY STRESSES:
These are developed by the imposed loading and are necessary to satisfy the
equilibrium between external and internal forces and moments of the piping
system. Primary stresses are not self-limiting.
SECONDARY STRESSES:
These are developed by the constraint of displacements of a structure. These
displacements can be caused either by thermal expansion or by outwardly
imposed restraint and anchor point movements. Secondary stresses are
self-limiting.
PEAK STRESSES:
Unlike loading condition of secondary stress which causes distortion, peak
stresses cause no significant distortion. Peak stresses are the highest stresses in
the region under consideration and are responsible for causing fatigue failure.
LONGITUDINAL STRESS
Longitudinal stress or axial stress is the normal stress acting parallel to the
longitudinal axis of the pipe.
SL = (Fa / A) + (P A i / A) + (M b C / I)
There are a total of three components that make up the longitudinal stress:
I. The stress caused by an internal force axially within the pipe
SL = Fa / A
Where:
SL = longitudinal stress (Pa)
Fa= internal axial force (N)
A = metal cross sectional area of pipe (m2)
II. The longitudinal stress due to internal pressure.
SL = P A i / A
Where:
P = design pressure (Pa)
A i = internal area of pipe (m2)
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BENDING STRESS
Bending stress is the third component of the axial stress. Bending stress is zero at
the neutral axis of the pipe.
SL = M b C / I
Where:
M b = Bending moment (N-m)
C = distance of point of interest from neutral axis of cross section (m)
I = moment of inertia of cross section (m4)
HOOP STRESS
This stress is mainly caused by internal pressure, the hoop stress acts in a
direction parallel to the pipe circumference in a way such that the pipe is split
into two halves. The hoop stress varies throughout the pipe wall.
SH = P do / 2 t
Where:
SH = hoop stress due to pressure (Pa)
P = pressure force (Pa)
do = pipe outer diameter (m)
t = pipe wall thickness (m)
RADIAL STRESS
Radial stresses which are caused by internal pressure at the pipes inner surface.
SR = P (ri2 ri2 ro2 / r2 ) / ( ro2 -
ri2 )
Where:
SR = radial stress due to pressure (Pa)
ri = inner radius of pipe (m)
ro = outer radius of pipe (m)
SHEAR STRESS
Shear stresses are applied in a direction parallel to the face of the plane of the
pipe. Shear Stresses tend to cause adjacent planes of the pipe slip against each
other.
Ssh = MT C / R
Where:
Ssh = maximum shear stress (Pa)
MR = torsion resistance of cross section (m4)
R = torsion resistance of cross section (m4)
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CLASSCIFICATION OF LOADS
PRIMARY LOADS: These can be divided into two categories based on the
duration of loading.
o Sustained loads: These loads are expected to be present throughout the
plant operation. E.g. pressure and weight.
o Occasional loads: These loads are present at infrequent intervals during plant
operation. E.g. earthquake, wind, etc.
EXPANSION LOADS: These are loads due to displacements of piping. e,g .thermal
expansion, seismic anchor movements, and building settlement.
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Weight load
Design temperature
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ANCHOR
This is an anchor type support; it restricts the pipes movements in all six degrees of
freedom.
GUIDE
This is a guide type support. Even though, it allows the horizontally mounted pipe to
move vertically, it prevents the vertically and horizontally mounted pipe from any side
movements.
REST
This is a support in the vertical direction only (upwards), it represents the support
under the Flanges and valves.
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SPRING HANGERS
These are used to support a piping system that is subjected to vertical thermal
movements. Variable effort spring hangers are usually incorporated for vertical
thermal movements up to approximately 50 mm, the variation between the preset
and operating loads should be no more than 25% of the operating load. Constant
effort spring hangers are usually incorporated for vertical thermal movements in
excess of 50mm.
Variable Load Hanger is special type of hanger, which accommodate the vertical
thermal movements, while carrying the vertical load. Usually variable load
hangers are made of helical springs. The load varies from cold condition to hot
condition.
Constant Load Hanger is a special type of hanger, similar to the variable load
hanger. There are several types of constant load hangers. The load variation in
the constant load hanger from cold to hot is limited to 0 %.
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TEN DON'TS
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Location of equipment
Tag numbers of equipment
Tag number of lines
Tag number of valves
Tag number of instruments
Tag number of motors
Location of vents and drains
Type of valves
Type of Instruments
Purpose of Instruments
Output signal from instruments
Flow measuring devices
Level Indicating devices
Equipment interfaces
Scope of suppliers
The intelligent P & ID used in process industry indicates the complete particulars of
different components and piping. A Piping and Instrumentation Diagram P & ID, is a
schematic illustration of functional relationship of piping, instrumentation and system
equipment components P & ID shows all of piping including the physical sequence of
branches, reducers, valves, equipment, instrumentation and control interlocks.
The P&ID are used to operate the process system.
A P & ID should include: Instrumentation and designations
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The P & I diagram (Engineering Line Diagram) allows the design to progress from the
Process Flow Sheet / System and Piping diagram to the final system design and
installation stage. The P & ID are definitive and comprehensive diagrams showing all of
the equipment, piping, valves and instrumentation. All items to be identified using
standard numbering systems. This normally entails having a unique plant item number
for each item of equipment, valve, instrument and line. Ideally the line number should
include a size, material and fluid contents identifier to enable the anyone reading the
drawing to obtain this information without having to refer to other documents.
An Engineering line should include
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The symbols used to be in accordance with identified standards and should clearly
indicate the type of component, the method of connection (screwed, flanged etc.) and
the status (Valves Normally Closed, Normally Open). The method of operating
equipment items should be clearly identified (electric motor, pneumatic actuator). It is
not generally necessary to identify services and electrical supplies to the operators.
A piping and instrumentation diagram / drawing (P & ID) is defined by the Institute of
Instrumentation and Control as follows:
A diagram which shows the interconnection of process equipment and the
instrumentation used to control the process. In the process industry, a standard set of
symbols is used to prepare drawings of processes.
The primary schematic drawing used for laying out a process control installation
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Flowing fluid
Fluid temperature
Fluid pressure
Fluid mass flow rate
Direction of fluid flow
Process piping
Major equipment symbols, names and identification numbers
Control, valves and valves that affect operation of the system
Interconnection with other systems
Major bypass and recirculation lines
System ratings and operational values as minimum, normal and
maximum flow, temperature and pressure
Composition of fluids
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Pipe class
Pipe line numbers
Minor bypass lines
Isolation and shut off valves
Maintenance vents and drains
Relief and safety valve
Code class information
Seismic class information
The flow diagram shows all the essential parts pf the process and items of equipment in
sufficient detail to enable the analysis and calculation of the physical characteristics of
the system to be undertaken.
A process flow diagram is a diagram of a fluid flow system showing the equipment items
connected by the major process pipes and containing data on the essential process
control circuits or major process requirements. The drawing is not to scale and the
equipment items are represented by symbols. The main equipment items and flow
streams should be identified and included in tables which identify process requirements
in sufficient detail to enable production of Piping and Instrumentation Diagrams
(Engineering Line Drawings)
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