2.1 INTRODUCTION Piping 29 PIPE:- pipes can be defined as a pressure tight cylinder used to transfer fluid. SMALL BORE :- Pipes having size range 1 are termed as small bore. BIG BORE :- Pipes having size range 2 above are termed as big bore. SINGLE RANDOM LENGTH :- !traight pipe in !"# is $ meters. DOUBLE RANDOM LENGTH :- !traight pipe in %"# is 11 meters. COMMONLY USED PIPE SIZE NPS NB OD 1&2 1' 21.( (&) 2* 2$.+ 1 2' ((.) 1 )* ),.( 2 '* $*.( ( ,* ,,.- ) 1** 11) $ 1'* 1$, , 2** 21- 1* 2'* 2+( 12 (** (2) .able 2.1 Pipe size NOT COMMONLY USED PIPE SIZE:- 1 / 0 2 0 ( ' SCHEDULE:- .he pipe thic1ness is designated by schedule no: and the corresponding thic1ness is specified in the 2!34 5 ($.1* for carbon steel pipe 2!34 5 ($.1- for stainless steel pipes. !tainless steel pipe are available in schedule 5S, 10S, 40S, 0S 6arbon steel pipes are available in schedule 10,20,!0,40,"0,0,100,120,140,1"0,STD,#S,##S PIPE & TUBES S$N PIPES TUBES 1 Pipes is specified by 7ominal 5ore 8759 .ubes are specified by outside diameter 2 :all thic1ness is e;pressed in schedule :all thic1ness is e;pressed in 5:< 8 5irmingham =ire gauge.9 ( 2vailable in small bore as =ell as big bore. 2vailable in small bore only. ) >sed in all process utilities line <enerally used in tracing lines0 tubes for e;changer in instrument connection. ' .he outside dia of pipe up to size 12 ?utside dia of tubes are numerically Piping 30 are numerically larger than corresponding size e@ual to the corresponding size. 2.2 CLASSIFICATION OF PIPES BASED ON METHOD OF MANUFACTURING PIPES SEAMLESS %ELDED ELECTRIC RESISTANCE %ELDED ELECTRIC FUSION %ELDED &ER%' 8EF%' CLASSIFICATION OF PIPES BASED ON MATERIAL OF CONSTRUCTION PIPES CARBON STEEL STAINLESS STEEL LO% TEMP CARBON STEEL LO% ALLOY STEEL &CS' &SS' <CS' &LAS' A used up to )2'B6C Aused for corrosive fluidC A used for temp D 8-2-B69C A used for tempE 8)2'B69C 2.! COMMENLY USED MATERIALS MATERIALS Piping 31 PIPES & COMPONE NT CARBON STEEL STAINLESS STEEL LO% ALLOY STEEL LO% TEMP CARBON STEEL PIPES 2'( <r 5 8:elded& !3#!9 21*$ <r 5 8!3#!9 2PF '# <r 5 8:elded& !3#!9 2$+2 <r 5$*0 81$ above9 2(12 <r .P(*) 2(12 <r .P(1$ 2(12 <r .P(21 2(', <r (*) 2(', <r (1$ 2(', <r (21 2)*- 81) (*9 6r-3o- 2((' <r P2 16r-3o- 2((' <r P12 1 1&)6r-3o-2((' <r P11 2 1&)6r-13o-2((' <r P22 (6r-13o-2((' <r P21 '6r-1&23o-2((' <r P' -6r-13o-2((' <r P- 2$-1 <r GG84H: high .-.. 1$ above9 82dd 6r I in blan1 space9 2((( <r.$ 8=elded&! 3#!9 2$+1 <r.66$* 84H:01$ 2bove9 FORGING 8Hlanges0 JoKlet fittings0 small bore valve0 fittings special parts.9 21*' 21,2<r.H(*)81,6r -,7i9 21,2<r.H(1$81$6r -127i-23o9 21,2<r.H(2181,6r -1*7i-.i9 6r-3o- 21,2 <r H2 16r-3o- 21,2 <r H12 1 / 6r-3o- 21,2 <r H11 2 / 6r-13o- 21,2 <r H22 ( 6r-13o- 21,2 <r H21 ' 6r-3o- 21,2 <r H' -6r-13o- 21,2 <r H- 2('* <r.#H2 6lass 1 2 . %ROUGHT FITTINGS 2((( <r.$ 8:elded& !3#!9 2)*(<r.:P(*) 2)*(<r.:P(1$ 2)*(<r.:P(21 16r-3o- 22() <r.:P12 1 / 6r-3o- 22() <r.:P11 2 / 6r-3o- 22() <r.:P22 ' 6r-3o- 22() <r.:P' - 6r-13o- 22() <r.:P- 2)2* <r.:P#-$ CASTINGS 8#arge bore valve special parts.9 221$ <r.:65 2('1<r.6H, 8!! (*)9 2('1<r.6H,3 8!! (1$9 2('1<r.6H,6 8!! (219 1 / 6r-3o- 221+ <r.:6$ 2 / 6r-13o- 221+ <r.:6- ' 6r-3o- 221+ <r.6-' - 6r-13o- 221+ <r.6-12 2('2 <r.#65 PLATES 2'1' <r.$* 22)* <r.(*) 22)* <r.(1$ 22)* <r.(21 6r-3o- 2(,+ <r.26#.1 16r-3o- 2(,+ 2'1$ <r.$* Piping 32 <r.126#.1 1 / 6r-3o- 2(,+ <r.116#.1 2 / 6r-13o- 2(,+ <r.226#.1 ( 6r-13o- 2(,+ <r.216#.1 ' 6r-3o- 2(,+ <r.'6#.1 -6r-13o- 2(,+ <r.-6#.1 BOLTS$NU T 21-( <r.5+ 21-) <r.2L 5 o l t 21-( <r.5, 6lass FF 21-) <r., 21-( <r.51$ 21-) <r.) 2(*+ <r.5 2'$( <r.2 7 u t .able 2.2 3aterials for pipes 7ote: - Lighlighted one are seldom used 2.4 METHOD OF (OINING PIPES Pipes can have follo=ing end section: PIPE ENDS 5eveled ends. Plain ends. !cre=ed ends. Hlanged ends. !oc1et ends. ). BUTT %ELDED:-
Higure 2.1 5utt =eld Piping 33 AD*ANTAGES 3ost economical method of Moining big bore lines. Noint is lea1 proof. Noint can be radio graphed. DISAD*ANTAGES :eld intrusion =ill affect the flo=. 4nd preparation is necessary. )). SOC+ET %ELDED:- Higure 2.2 !oc1et =eld AD*ANTAGES 2lignment is easier than butt =elded. 7o intrusion of =eld metal inside the pipe. #ea1 proof Moint. <enerally used to connect small bore lines. DISAD*ANTAGES .he 1 1&1$ recess poc1et . 7ot suitable =hen service fluid is corrosive in nature. 7ot suitable =hen vibration is anticipated. ))). SCRE%ED:- Piping 34 Higure 2.( !cre=ed Moint AD*ANTAGES 4asy to made it at site. 6an be used =here =elding is prohibited due to fire hazard. <enerally used to connect small bore lines. DISAD*ANTAGES #ea1 proof Moint cannot be guaranteed. . 7ot suitable =hen service fluid is corrosive in nature. 7ot suitable =hen vibration is anticipated. 7ot suitable =hen operating temperature is above -2' H. .hread reduces the =all thic1ness0 conse@uently reducing the strength. ),. FLANGED:- Higure 2.) Hlanged Moint AD*ANTAGES 4asy to made it at site. 6an be used =here =elding is prohibited due to fire hazard. %ismantling is very easy. DISAD*ANTAGES #ea1 proof Moint cannot be guaranteed. . Fts an e;pensive method of Moining pipes.. 7ot suitable =hen high bending moment is anticipated. Piping 35 2.5 PIPE FITTINGS: S-./0.10 P)23 4)--)/56. 2.5.1 ELBO%S:- B.630 7/ 3/0 87//38-)7/ 39:7;6 .13 74 47997;)/5 -<236. B=---;39030 39:7;. S78>3- 39:7;. T?13.030 39:7;. A,.)9.:93 )/ @0A& 45A 39:7;6. A,.)9.:93 )/ 6?71- 1.0)=6 & L7/5 1.0)=6 2.--31/. A,.)9.:93 .6 130=8)/5 39:7;.
Higure 2.' 4lbo=s
2.5.2 MITER BEND:- 3iter bends are not standard fittings they are fabricated from pipes. >sually they are preferred for size 1* above because large size elbo= is e;pensive not easily available in the mar1et. >se of miter bend is restricted to lo= pressure.. 3iter bend can be fabricated in 2 0 ( 0 ' piece. Piping 36 Higure 2.$ 3iter 5end Piping 37 2.5.! RETURNS:- "educing elbo=s are used to ma1e 1,*B change in direction. 2vailable in short long pattern. 3ainly used in heating coil0 heat e;changer etc.
Higure 2.+ "eturns 2.5.4 REDUCER:- "educers are used to connect larger dia pipe to smaller dia pipes vice versa. .here are t=o types of reducers CONCENTRIC REDUCERS:- It maintains the center line elevation of pipe line. Higure 2., "educers ECCENTRIC REDUCERS:- It maintains BO ! "ottom of pipe# elevation of pipe line.Offset is e$%al to & ' !lar(er ID min%s smaller ID#. Higure 2.- 4ccentric "educers Piping 38 2.5.5 S%AGE:- !=age is li1e reducers used to connect butt =elded pipes to smaller scre=ed or soc1et =elded pipes. #i1e reducers they are concentric eccentric type..they are covered under the regulatory code 5! (+--.
Higure 2.1* s=age 2.5." UNION:- >nion is used to connect small bore pipes. Ft can be soc1et end or threaded end Piping 39 Higure 2.11 >nions 2.5.B HALF COUPLING:- <enerally used for branching or for vessel connections. Ft can be threaded or soc1et type. Piping 40 Higure 2.12 Lalf 6oupling 2.5. FULL COUPLING:- <enerally used for connecting pipes or items =ith either threaded or soc1et ends. Higure 2.1( Hull 6oupling 2.5.@ TEES :- .ees are used for ma1ing -*B branch from main run of pipe .5ranch size may be of same size or less than the main header size. Piping 41 Higure 2.1) .ee 2.5.10 CROSS :- !traight cross are usually stoc1 items. "educing cross may not be readily available hence it is proffered to use .44 instead of reducing 6ross-e;cept =here space is restricted. Higure 2.1' 6ross 2.5.11 LATERALS: - Ft permit entry of branch to a main header at )'B angle. Ft is used =here lo= resistance to flo= is re@uired especially in flare lines. 5ranch size may be of e@ual size or reducing. 5ranch angle other than )'B angle is possible only to special order. Piping 42 Higure 2.1$ #aterals 2.5.12 STUB-IN :- !tub in is not any standard fittings ..his term is used for branch pipe directly =elded to main pipe run. Ff re@uired it may be re-inforced. .his is the most common least e;pensive method to branch full size or reducing size from main header0 Higure 2.1+ !tub-in 2.5.1! COD LET FITTINGS: - .hese are the special fittings available readymade in the mar1et. Ft does not re@uire any reinforcement. .hey are preshaped to the curvature of the run pipe end preparation is pre done. T?3 )-3E6 9)6-30 )/ COD 93- 4)--)/56 .13 Piping 43 )E*DO*ET SOC+O*ET Threa,olet Piping 44 S)EEO*ET E*BO)*ET NIO*ET Piping 45 *-TERO*ET CAP :- 6ap is used to seal end of pipe. Higure 2.1, Oarious J?K let fittings 2." FLANGES Hlanges are used to connect Pipe to pipe0 =hich re@uire fre@uent dismantling. Piping 46 Pipe to e@uipment. Pipe to valves. Pipe to special items. 2 flanged Moints consist of three integral parts namely 49./536, 5.6>3-, B79- & N=-. .he design standard for Hlanges is 2!34 5 1$.'. B.630 7/ P-T 1.-)/56 49./536 .13 89.66)4)30 .6 1'*P (**P )**P $**P -**P 1'**P 2'**P B.630 7/ .--.8?E3/- 49./536 .13 89.66)4)30 .6 i. !lip-on ii. !oc1et =eld. iii. !cre=ed. iv. :eld 7ec1 v. "educing vi. #ap Moint. vii. 5lind. 2.".1 SLIP-ON FLANGE Piping 47 Higure 2.1- !lip on Hlange Hlange is attached by =elding inside as =ell as outside. Pipe is set bac1 1&1$ Qfrom the face of flange. Fnternal =eld is subMected to corrosion0 hence not preferred for corrosive service. Poor resistant to shoc1 vibration. 6heaper to buy but costlier to assemble. 4asier to align. .he strength is about 1&( that of the corresponding =eld nec1 flange. 2.".2 SOC+ET %ELD FLANGE :elded only on one side0 hence not recommended for severe service. >sed only for small bore pipes 7ot recommended for service above 2'*B6 belo= -)'B6 SCRE%ED FLANGES >sed to connect scre=ed pipe to flanged items. Piping 48 >sed only for small bore pipes 7ot recommended for service above 2'*B6 belo= -)'B6 >sed =here =elding can not be used for hazardous reasons. Higure 2.2* !cre=ed Hlange %ELD NEC+ FLANGE Hlanges are attached by butt-=elding to pipes. !uitable =here e;treme temperature0 shear0 impact vibratory stress apply. :elding can be radia-graphed. 6ostly. Higure 2.21 :eld 7ec1 Hlange REDUCING FLANGE >sed to connect bigger pipe to smaller pipes. 2vailable in slip-on or =eld nec1 type. Piping 49 !hould not be used if abrupt transition =ould create undesirable turbulence. !pecified by the line size of smaller pipe ?% of the flange to be mated. Higure 2.22 "educing Hlange LAP (OINT FLANGE Ft is used to connect pipe of costlier material li1e stainless steel. .his is used along =ith stub-end. 3aterial of stub-end =ill be as pipe flange =ill be of cheaper material li1e carbon steel. !tub-end =ill be butt =elded to the pipe flange is 1ept loose over it. Ft is also useful =here alignment of bolt is difficult. Piping 50 Higure 2.2( #ap Moint Hlange BLIND FLANGE <enerally used to close the pipe end =hich need to be reopened later.. 2.B C9.66)4)8.-)7/ 74 49.536: 5ased on Hacing flanges are classified as Piping 51 i. Hlat face. 8HH9 ii. "aised face. 8"H9 iii. "ing .ype Noint. 8".N9 iv. .ongue groove Noints. v. 3ale&female Noints.
FLAT FACE RAISED FACE
RING (OINT TONGUE & GROO*E (OINT Hig 2.2) Hlange Hacing
2. MALE $ FEMALE (OINT GAS+ET. Piping 52 <as1ets are used to provide fluid resistant seal bet=een the flanges. Ft can be metallic or non metallic type metallic gas1et is referred to 2!34 5 1$.2* non metallic gas1et is referred to 1$.21 . 3etallic gas1et is further categorized as !piral =ound0 corrugated metallic ring type Moint. S3938-)7/ 74 G.6>3- 0323/06 7/ 47997;)/5 4.8-71. P-. of the fluid service. 6orrosive nature of the fluid service. 6ode re@uirement. 6ost Higure 2.2, <as1et Noint .ables 2.( <as1et 3aterial Piping 53 BOLTS & NUTS. .=o types of bolt are generally used in the industry 3achine bolt !tud bolt %esign standard for bolt nut is 2!34 5 1$.' Hor lo= P-. machine bolt is preferred other=ise studs 5olts are provided =ith he;agonal head 0 he;agonal nuts =asher. Higure 2.2$ 7ut-5olt Piping 54 2.@ SPECIAL PARTS: 2.@.1 S-1.)/316 !trainers are used in a piping system to protect the e@uipment sensitive to dirt or other solid particle that may be carried by fluids. %uring start-up temporary strainers are placed upstream of pumps to protect from construction debris0 =hich may be left over during construction these are called S-.1--=2 $T3E271.1< 6-1.)/316. Higure 2.2+ 6onical !tart-up temporary !trainer P31E./3/- 6-1.)/316 are installed upstream of control valves0 stream trap instrument to protect it from solid particle. .here are t=o type of permanent strainer. R- type strainer. 5as1et strainer. .-t/pe strainer. Higure 2.2, R-type strainer Bas0et strainer. Piping 55 Higure 2.2- 5as1et strainer 2.@.2 STEAM TRAPS: .he function of stream trap is to discharge condensate from the steam piping =ithout releasing steam. 6ommonly used steam traps are i. Hloat ii. .hermostatic iii. .hermodynamic iv. Fnverted buc1et. FLOAT Hloat type consist of a chamber0 containing float arm mechanism0 =hich modulates the position of discharge valve. :hen the level of condensate increases0 the float lifts ups causing the valve to open discharge condensate. .his has got venting system to discharge air carbon dio;ide. Higure 2.(* Hloat type !team trap F3.-=13 6an be used in process0 utility as =ell as LO26 system <enerally used for high capacity. 7ot suitable =hen there is a fluid hammering in the system. 7ot suitable for very lo= temperature service. 2vailable in size 1'0 2*0 2'0 )*0 '* 75. 2vailable in scre=ed0 soc1et =eld flanged ends. Piping 56 THERMOSTATIC .his system employs a thermostatic 85i-metallic9 elements0 =hich opens closes the valve. .he valve gets open by cooler condensate gets closed =hen steam comes in contact =ith the thermostatic elements. Higure 2.(1 .hermostatic type steam trap F3.-=13 6an be used =here fluid hammering is anticipated in the piping system. Ft can handle =ide range of condensate load over a =ide range of pressure. .he application include drip legs0 heating coil0 steam tracer etc. Ft re@uires a straight pipe run of 2 1, on upstream side. 2vailable in size 1' 2* 75. 2vailable in scre=ed soc1et =eld ends. THERMODYNAMIC .he basic principle behind this trap is that the e;panded volume of steam compared to condensate has a throttling effect at the orifice. :ith the a properly sized orifice0 condensate at lo=er specific volume =ill pass through the opening at comparatively slo=er velocity. 2s steam begin to reach orifice plate the condensate =ill begin to e;pand. 2s the condensate e;pand0 the velocity through the orifice =ill increase throttling action =ill start to ta1e place. Piping 57 Higure 2.(2 .hermodynamic steam trap F3.-=13 #imited capacity. Potential for steam lea1age. Ff steam is allo=ed to pass through the orifice for e;tended period0 it =ill cause erosion of orifice. 2vailable in size 1' 2* 75. 2vailable in scre=ed butt =elded ends. IN*ERTED BUC+ET Ft consists of a chamber containing an inverted buc1et0 =hich actuates the discharge valve through lin1age. .he valve is open =hen buc1et rest at the bottom of trap. .his allo=s air to escape until the bottom of buc1et is seal by rising condensate. .he valve remains open as long as condensate is flo=ing0 and trapped air bleeds out through a small vent in the top of the buc1et. :hen steam enters the trap0 it fills the buc1et0 causing the buc1et to float0 so it rises close the valve. Piping 58 Higure 2.(( Fnverted 5uc1et steam trap F3.-=13 6an be used over =ide range of pressure temperature.. 2vailable in size 1'02* 2' 75. 2vailable in scre=ed ends. 2.@.! FLAME ARRESTOR: 2 flame arrestor is a device that is fitted into0 or at the end of0 a pipeline or vessel =here flammable gases or vapors are flo=ing. Ft prevents the transmission of accidentally ignited flames or e;plosions =hile permitting the process gas to flo=. Hlame arrestors may be installed on their o=n or as part of a more comprehensive flame and e;plosion safety system. 3ore than one flame arrestor may be re@uired to ensure complete protection.
2.@.4 E#PANSION BELLO%S: Piping 59 Higure 2.() 4;pansion 5ello= 2n e;pansion bello=s is a device used to allo= movement in a piping system =hile containing pressure the medium running through it. .he 5ello=s are generally employed in a piping system in one of the follo=ing situations: :hen the space constraints do not permit providing ade@uate fle;ibility by conventional methods 8e. g. e;pansion loops etc.9 for maintaining the system stresses =ithin acceptable limits. :hen conventional solutions 8e.g. e;pansion loops etc.9 create unacceptable process conditions 8e.g. e;cessive pressure drop9. :hen it is not practical to limit the piping induced loads on the terminal nozzles of the connected e@uipment =ithin admissible limits by conventional methods. :hen the e@uipment such as 6ompressors0 .urbines0 Pumps etc. necessitate isolating the mechanical vibrations from being transmitted to the connected piping. Piping 60