GENERAL PIPING SYSTEM

AND LAY-OUT FOR INDUSTRIAL PLANTS

1. Piping Materials Selection Criteria:

? Process condition will impact selection of material

- ServiceFluids
�Corrosive- Sea Water, H2S, Ammonia, Acids etc..
�Non-Corrosive�Lube oil, Air, Nitrogen etc.
-Temperature
�Cryogenic
�Low temperature
�Medium temperature
�High temperature

? Processconditionwillimpactselectionofmaterial
- High or Low Pressure

? Other factors that also considered

-Cost
-Availability
-Weldability
-Manufacturability

? Material property that considered before selection

-Ultimate Tensile Strength
-Yield Strength
-Elasticity
-%Elongation
-Hardness
-Toughness
-Creepresistance
-FatigueResistance

2. Classification of Piping Material

3. Pipe
�A straight pressure tight cylindrical hallow, used in piping system
�Different types of pipes used in different design conditions, considering
technical and commercial parameters
�Pipes are mainly classified as follow ;
*SAW - Submerged arc welding
*ERW - Electric resistance welding
*EFW - Electric Fusion Welding

? Pipe Size
�Pipe size are mentioned as nominal pipe size (NPS),also mentioned as Diameter
nominal (DN)
�It is in-between of outer and inner diameter of pipe
�For NPS 14� and above NPS is same as outer diameter
? Pipe length
�Pipe are available in following lengths
-Single random
�4.8 m to 6.7 m with 5% of lengths 3.7 to 4.8 m
-Double random
�minimum average of 10.7 m and a minimum length of 4.8 m with 5 % 4.8m to
10.7m
-Fixed length as per purchase order

? Pipe Thickness
�Thickness are expressed in Schedule number (5, 10, 20, 30, 40, 60, 80, 100, 120,
140, 160)
�Also in STD, extra strong-XS, double extra strong-XXS
�Higher the schedule higher the thickness

? Pipe ends
�Pipe can be
-Plain end
-Beveled end
-Threaded end
-Special end such as socket & spigot with o-ringtype gaskets
4. Fittings
? Fittings are Piping component which helps in
-Changes the direction of the flow
�elbows, tee
-Changes the size of the pipe
�reducers, reducing tees, reducing couplings, reducing flanges
-Joins together pipe
�flanges, couplings

? Fittings ends
�Socket weld & Threaded end
-ASME B16.11 -Forged steel socket welding & threaded fittings

? Fitting material

Commonly used material for wrought fittings

�Carbon Steel :-ASTM A234Gr.WPA/B, ASTM A420 Gr.WPL6
�Alloy Steel :-ASTM A234 WP1 /WP5 /WP7 /WP9 /WP11 /WP12 /WP22
�Stainless Steel :-ASTM A403 WP304 /WP304L /WP304H /WP316 / WP316L/ WP321/ WP347

Commonly used material for forge fittings

�Carbon Steel :-ASTM A181, ASTM A105, ASTM A350 LF1/2
�Alloy Steel :-ASTM A182F1 /F2 /F5 /F7 /F9/ F11 /F12 /F22
�Stainless Steel :-ASTM A182F6 /F304 /F304L /F304H /F316 /F316L/ F321/ F347/
F348

5. Flange

�Second most used joining method after welding

�Connect pipe with various equipment
�Provide flexibility in maintenance
�Cannot use in underground piping
�Most common source of leak
�Variety of flanges available to suit requirements

? Flange Attachments Types

�Threaded Flanges
�Socket-Welded Flanges
�Slip-On Flanges
�Lapped Flanges
�Weld Neck Flanges
�Blind Flanges

? Flange Facing Types

�Flat Faced (FF)
�Raised Face (RF)
�Ring Joint (RTJ)
�Tongue and groove (T&G)
�Male and Female
�These face can be smooth or serrated type

? Flange Material

�Standard Flanges are made by forgematerials

�Carbon steel
�Low alloy steel
�Stainless steel
�Combination of Exotic martials(Stub) and other materials
6. Branch Connection

�Reinforced branch Pipe to pipe

-Site fabricated branch connections
�Self reinforced branch
-Specially design branch connection which can be use without reinforcing pad
-Well-known as �Olets�

? Branch Connection Material

�Standard branch connection are made by forge materials
-Carbon steel
-Low alloy steel
-Stainless steel
�ASMEB31.3 provide list of acceptable forge material used in process piping

7. Gasket

�Gasket is sealing material placed between connecting Flanges

�create a static seal
�Maintain leakage proof sealing in all operating conditions
? Gasket Material
Non-Metallic Gasket
�Resilient or pliable material
�Commonly used materials
-Compressed Non-Asbestos fiber
-PTFE
-Rubber
-Mica
-Ceramic fiber

8. Bolting

�Bolting is a term that includes stud, bolts, nuts, and washers

�Also Known as fastener

Washers
�Conical or Belleville Springs washers
-Keep bolted joints tight
-High spring loads with small deflections
-Used in area where vibration,differential thermal expansion,and bolt creep present

? Bolting Material
�Carbon steel
�Low alloy steel
�Stainless steel
�Exotic material,such as Monel, Inconel, Nickel alloy
�These material further divide in
-High Strength
-Intermediate strength
-Low Strength
�List of ASTM Material grade used for manufacturing stud are listed in ASME
B16.5
�Coating
Bolting are also coated with different materials to improve its corrosion
resistance and reduce maintenance
-Chrome plated
-Galvanized
-Xylan coated
-PTFE coated

9. VALVES
valves are installed in between the pipes / equipment to perform following
functions :
1. Isolation (gate valve, ball valve, butterfly valves etc)
2. Regulation (globe valve etc)
3. Non return (check valve, SDNR etc)
4. Special purpose (foot valve etc)
? Piping Layout Considerations:
1. Operation
2. Maintenance
3. Constuctability
4. Economics
5. Safety
6. Aesthetics

? Design for Constructibility

Ten Commandments:

1. Keep It Straight and Simple

2. Keep Its Structures Simple
3. Keep Its Specification Simple
4. Keep It Shop Standard
5. Keep Its Standard Simple
6. Keep It Same Size
7. Keep It Square and Squatty
8. Keep Its Support Simple
9. Keep Its Schedule Sacred
10. Keep Its Site Suitable

Example: