A PIPING TUTORIAL ©

1. 1. Introduction
1.1. 1.1. Definition of Piping
2
1.2. 1.2. Piping Nomenclature & Components 3
1.3. 1.3. Regulatory Acts, Codes & Standards 5
1.4. 1.4. Line Designation Tables 7

Problem Set 1 8

2. 2. Codes & Standards

2.1. 2.1. ASME 9
2.2. 2.2. NEPA / NFPA 11
2.3. 2.3. CSA 12
2.4. 2.4. MSS 13
2.5. 2.5. API 14
2.6. 2.6. ASTM 16

Problem Set 2 17

3. 3. Supplemental Documents
3.1. 3.1. Owner’s Specifications & Documents 25
3.2. 3.2. Contractor’s Standards & Documents 26

Problem Set 3 27

4. 4. Piping Design
4.1. 4.1. Failure Mechanisms 28
4.2. 4.2. Code Considerations for Design 29
4.3. 4.3. Material Selection
40
4.4. 4.4. Fabricated Tees & Area Reinforcement 54
4.5. 4.5. Piping Flexibility Analysis
58

Exam

© EDA Ltd. 2002

1.0 Introduction

1.1 1.1 Definition of 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 typically round.

1.2 1.2 Piping Nomenclature, Components

Graphic of piping system illustrating

• • header
• • branch connection
• • valve
• • flange
• • expansion joint
• • expansion loop
• • pipe support
• • reducer
• • elbow
Pipe system essentials:

Header • • Main run of piping

Take off • • Branch run

Stub in • • Branch fitting connection made to header by direct attachment of branch

• •
Branch • • Material added in the vicinity of a branch opening to restore the
reinforcement mechanical integrity of the pipe

NPS • • Nominal pipe size

Pipe support • • Support elements which serve to maintain the structural integrity of the
piping system, these are typically non-linear elements

Spring support • • Support provided by an element composed of a spring assembly, these are
linear support elements

Snubber • • Support provided by an element composed of a non-linear, damping

element

Category D • • Within reference of B31.3, a service classification

Category M • • Within reference of B31.3, a service classification

Expansible fluid • • Any vapour or gaseous substance, any liquid under such pressure and
temperature such that when pressure is reduced to atmospheric, will change to a
gas

Hydro test • • Test pressure = 1.5 x MAWP (some of the time)

MAWP • • Maximum allowable working pressure

MDMT • • Minimum design metal temperature

Fracture • • Typically measured by CVN (Charpy V Number) at MDMT

toughness
1.3 1.3 Regulatory Acts, Codes & Standards

Codes

Codes are rules for the design of prescribed systems which are given the force of law through provincial,
state and federal legislation. In Canada, provincial governments have the responsibility for public safety
that includes these facilities, among others:

• • Pressure piping
• • Pressure vessels
• • Boilers
• • Pipelines
• • Plumbing systems
• • Gas piping

Alberta Safety Codes Acts and Codes of Practice

The following are applicable to the first four facilities listed above.

Boilers and Pressure Vessels Regulation

• • Prescribes requirements for registration of pressure vessels, boilers, pressure piping and
fittings

Design, Construction and Installation of Boilers and Pressure Vessels Regulations

• • Cites the codes and “bodies of rules” that form part of the regulations
• • CSA B51 Boiler, Pressure Vessel and Pressure Piping Code
• • CSA B52 Mechanical Refrigeration Code
• • CAN/CSA Z184 Gas Pipeline Systems
• • ASME Boiler & Pressure Vessel Code
• • ASME B31 Pressure Piping Codes
• • B31.1 Power Piping
• • B31.3 Process Piping
• • B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia and Alcohols
• • B31.5 Refrigeration Piping
• • ANSI K61.1 Safety Requirements for the Storage and Handling of Anhydrous Ammonia
• • NFPA 58 Standard for the Storage and Handling of Liquefied Petroleum Gases
• • DOT Regulations of the Department of Transportation Governing the Transportation of
Hazardous Materials in Tank Motor Vehicles
• • MSS Standard Practice SP 25 Standard Marking System for Valves, Fittings, Flanges
and Unions
• • TEMA Standards of Tubular Exchanger Manufacturers Association
Pipeline Act

Cites the “minimum requirements for the design, construction, testing, operation, maintenance
and repair of pipelines”:

• • CAN/CSA Z183 Oil Pipeline Systems

• • CAN/CSA Z184 Gas Pipeline Systems
• • CSA Z169 Aluminum Pipe and Pressure Piping Systems
• • Canadian Petroleum Association Recommended Practice for Liquid Petroleum Pipeline Leak
Prevention and Detection in the Province of Alberta

Currently, CSA Z662 Oil and Gas Pipeline Systems

(This standard supercedes Z183 & Z184)

In the US:

As in Canada, some facilities are governed by federal regulations. Interstate pipeline facilities are
defined by the:

• • Code of Federal Regulations, Title 49

• • Part 192 Transportation of Natural and Other Gas by Pipeline – Minimum
Federal Safety Standards
• • Part 193 Liquefied Natural Gas Facilities
• • Part 195 Transportation of Hazardous Liquids by Pipeline

Other pipeline pressure piping codes include:

• • ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and

Other Liquids
• • ASME B31.8 Gas Transmission and Distribution Systems
1.4 Line Designation Tables

The Province of Alberta Safety Codes Act "Design, Construction and Installation of Boilers & Pressure
Vessels Regulations" par 7(2) requires that construction of a pressure piping system must include
submission of drawings, specifications and other information and include:

(a) flow or line diagrams showing the general arrangement of all boilers, pressure vessels, pressure piping
systems and fittings (2 copies)

(b) pipeline identification lists showing the maximum pressures and temperatures for each pressure piping
system (2 copies)

(c) a list of pressure relief devices, including the set pressure (2 copies)

(d) material specifications, size, schedule and primary service rating of all pressure piping and fittings (2
copies)

(e) the welding procedure registration number

(f) the pressure pipe test procedure outlining the type, method, test media , test pressure, test temperature,
duration and safety precautions (1 copy)

(g) a form, provided by the Administrator, completed by the engineering designer or contractor which
relates to the general engineering requirements for design and field construction of pressure piping systems
(AB 96)

(h) such other information as is necessary for a safety codes officer to survey the design and determine
whether it is suitable for approval and registration
Problem Set 1

1 1 Which Act governs the design of plant pressure piping systems in Alberta?

2 2 Are process plant water lines considered pressure piping systems?

3 3 For what fluid service category may a hydrotest be waived per B31.3?

4 What is the difference between a pipe elbow and a bend?

2.0 Codes and Standards

The following codes are used for the design, construction and inspection of piping systems in
North America.

2.1 The ASME B31 Piping Codes

Piping codes developed by the American Society of Mechanical Engineers:

B31.1 Power Piping

Piping typically found in electric power generating stations, in industrial and institutional
plants, geothermal heating systems and central and district heating and cooling plants.

B31.3 Process Piping

Piping typically found in petroleum refineries, chemical, pharmaceutical, textile, per,

semiconductor and cryogenic plants and related processing plants and terminals.

B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

Piping transporting products which are predominately quid between plants and terminals
and within terminals, pumping, regulating, and metering stations.

B31.5 Refrigeration Piping

Piping for refrigerants and secondary coolants.

B31.8 Gas Transportation and Distribution Piping Systems

Piping transporting products which are predominately gas between sources and terminals
including compressor, regulating and metering stations, gas gathering pipelines.

B31.9 Building Services Piping

Piping typically found in industrial, institutional, commercial and public buildings and in
multi-unit residences which does not require the range of sizes, pressures and
temperatures covered in B311.1

B31.11 Slurry Transportation Piping Systems

Piping transporting aqueous slurries between plants and terminals within terminals,
pumping and regulating stations.
The following codes are used to specify the geometric, material and strength of piping and components:

ASME B16 Dimensional Codes

The ASME B16 Piping Component Standards

Piping component standard developed by the American Society of Mechanical Engineers or the
American National Standards Institute (ANSI)

B16.1 Cast Iron Pipe Flanges and Flanged Fittings

B16.3 Malleable Iron Threaded Fittings, Class 150 and 300
B16.4 Cast Iron Threaded Fittings, Classes 125 and 250
B16.5 Pipe Flanges and Flanged Fittings
B16.9 Factory Made Wrought Steel Buttwelding Fittings
B16.10 Face to Face and End to End Dimensions of Valves
B16.11 Forged Fittings, Socket Welding and Threaded
B16.12 Cast Iron Threaded Drainage Fittings
B16.14 Ferrous Pipe Plugs, Bushings and Locknuts with Pipe Threads
B16.15 Cast Bronze Threaded Fittings Class 125 and 250
B16.18 Cast Copper Alloy Solder Joint Pressure Fittings
B16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges
B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
B16.23 Cast Copper Alloy Solder Joint Drainage Fittings – DWV
B16.24 Cast Copper Alloy Pipe Flanges and Flanged Fittings Class 150, 300, 400,600,
900, 1500 and 2500
B16.25 Buttwelding Ends
B16.26 Cast Copper Alloy Fittings for Flared Copper Tubes
B16.28 Wrought Steel Buttwelding Short Radius Elbows and Returns
B16.29 Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings –
DWV
B16.32 Cast Copper Alloy Solder Joint Fittings for Sovent Drainage Systems
B16.33 Manually Operated Metallic Gas Valves for Use in Gas Piping systems Up to 125
psig (sizes ½ through 2)
B16.34 Valves – Flanged, Threaded and Welding End
B16.36 Orifice Flanges
B16.37 Hydrostatic Testing of Control Valves
B16.38 Large Metallic Valves for Gas Distribution (Manually Operated, NPS 2 ½ to 12,
125 psig maximum)
B16.39 Malleable Iron Threaded Pipe Unions, Classes 1150, 250 and 300
B16.40 Manually Operated Thermoplastic Gs Shutoffs and Valves in Gas Distribution
Systems
B16.42 Ductile Iron Pipe Flanges and Flanged Fittings, Class 150 and 300
B16.47 Large Diameter Steel Flanges (NPS 26 through NPS 60)
 ASME B36 Piping Component Standards

Piping standards developed by the American Society of Mechanical Engineers / American

National Standards Institute:

B36.10 Welded and Seamless Wrought Steel Pipe

B36.19 Stainless Steel Pipe

Other ASME or ANSI

B73.1 Horizontal, End Suction Centrifugal Pumps

B73.2 Vertical In-line Centrifugal Pumps
B133.2 Basic Gas Turbine

2.2 NEPA Codes

National Electrical Protection Association

Piping covering fire protection systems using water, carbon dioxide, halon, foam, dry
chemical and wet chemicals.

NFC - NFPA Codes

National Fire Code / National Fire Protection Association

NFPA 99 Health Care Facilities

Piping for medical and laboratory gas systems.

2.3 CSA Standards

Canadian Standards Association

CSA Z662 - 94 Oil & Gas Pipeline Systems

This standard supercedes these standards:

• • CAN/CSA Z183 Oil Pipeline Systems

• • CAN/CSA Z184 Gas Pipeline Systems
• • CAN/CSA Z187 Offshore Pipelines

Other CSA Piping and Component Codes:

B 51 Boilers and Pressure Vessels

B 53 Identification of Piping Systems
B 52 Mechanical Refrigeration Code
B 63 Welded and Seamless Steel Pipe
B 137.3 Rigid Poly-Vinyl Chloride (PVC) Pipe
B 137.4 Polyethylene Piping Systems for Gas Service
W 48.1 Mild Steel Covered Arc-Welding Electrodes
W 48.3 Low-Alloy Steel Arc-Welding Electrodes
Z 245.1 Steel Line Pipe
Z 245.11 Steel Fittings
Z 245.12 Steel Flanges
Z 245.15 Steel Valves
Z 245.20 External Fusion Bond Epoxy Coating for Steel Pipe
Z 245.21 External Polyethylene Coating for Pipe
Z 276 LNG - Production, Storage and Handling
2.4 MSS Standard Practices
Piping and related component standards developed by the Manufacturer’s Standardization
Society. The MSS standards are directed at general industrial applications. The pipeline industry
makes extensive use of these piping component and quality acceptance standards.

SP-6 Standard Finishes for Contact Faces Pipe Flanges and Connecting End Flanges of Valves
and Fittings
SP-25 Standard Marking System for Valves, Fittings, Flanges and Union
SP-44 Steel Pipeline Flanges
SP-53 Quality Standards for Steel Castings and Forgings for Valves, Flanges and Fittings and
Other Piping Components - Magnetic Particle
SP-54 Quality Standards for Steel Castings and for Valves, Flanges and Fittings and Other
Piping Components - Radiographic
SP-55 Quality Standards for Steel Castings and for Valves, Flanges and Fittings and Other
Piping Components - Visual
SP-58 Pipe Hangers and Supports - Material, Design and Manufacture
SP-61 Pressure Testing of Steel Valves
SP-69 Pipe Hangers and Supports - Selection and Application
SP-75 High Test Wrought Butt Welding Fittings
SP-82 Valve Pressure Testing Methods
SP-89 Pipe Hangers and Supports - Fabrication and Installation Practices
2.5 API

American Petroleum Institute

The API standards are focused on oil production, refinery and product distribution services.
Equipment specified to these standards are typically more robust than general industrial
applications.

Spec. 5L Line Pipe

Spec. 6D Pipeline Valves
Spec. 6FA Fire Test for Valves
Spec. 12D Field Welded Tanks for Storage of Production Liquids
Spec. 12F Shop Welded Tanks for Storage of Production Liquids
Spec. 12J Oil and Gas Separators
Spec. 12K Indirect Type Oil Field Heaters

Std. 594Wafer and Wafer-Lug Check Valves

Std. 598Valve Inspection and Testing
Std. 599Metal Plug Valves - Flanged and Butt-Welding Ends
Std. 600 Steel Gate Valves-Flanged and Butt-Welding Ends
Std. 602 Compact Steel Gate Valves-Flanged Threaded, Welding, and Extended-Body Ends
Std. 603 Class 150, Cast, Corrosion-Resistant, Flanged-End Gate Valves
Std. 607Fire Test for Soft-Seated Quarter-Turn Valves
Std. 608Metal Ball Valves-Flanged and Butt-Welding Ends
Std. 609Lug-and Wafer-Type Butterfly Valves
Std. 610 Centrifugal Pumps For Petroleum, Heavy Duty Chemical and Gas Industry Services
Std. 611General Purpose Steam Turbines for Refinery Services
Std. 612Special Purpose Steam Turbines for Refinery Services
Std. 613Special Purpose Gear Units for Refinery Services
Std. 614 Lubrication, Shaft-Sealing and Control Oil Systems for Special Purpose Application
Std. 615Sound Control of Mechanical Equipment for Refinery Services
Std. 616Gas Turbines for Refinery Services
Std. 617Centrifugal Compressors for General Refinery Services
Std. 618Reciprocating Compressors for General Refinery Services
Std. 619 Rotary-Type Positive Displacement Compressors for General Refinery Services
Std. 620 Design and Construction of Large, Welded, Low Pressure Storage Tanks
Std. 630 Tube and Header Dimensions for Fired Heaters for Refinery Service
Std. 650Welded Steel Tanks for Oil Storage
Std. 660Heat Exchangers for General Refinery Service
Std. 661Air-Cooled Heat Exchangers for General Refinery Service
Std. 670 Vibrations, Axial Position, and Bearing-Temperature Monitoring Systems
Std. 671Special Purpose Couplings for Refinery Service
Std. 674Positive Displacement Pumps-Reciprocating
Std. 675Positive Displacement Pumps-Controlled Volume
Std. 676Positive Displacement Pumps-Rotary
Std. 677General Purpose Gear Units for Refineries Services
Std. 678Accelerometer-Base Vibration Monitoring System
Std. 1104 Welding Pipelines and Related Facilities
Std. 2000 Venting Atmospheric and Low-Pressure Storage Tanks - Non-Refrigerated and
Refrigerated

RP 530 Calculation for Heater Tube Thickness in Petroleum Refineries

RP 560 Fired Heater for General Refinery Services
RP 682 Shaft Sealing System for Centrifugal and Rotary Pumps
RP 1110 Pressure Testing of Liquid Petroleum Pipelines

Publ. 941 Steel for Hydrogen Service at Elevated Temperature and Pressures in Petroleum
Refineries and Petrochemical Plants
Publ. 2009 Safe Welding and Cutting Practices in Refineries
Publ. 2015 Safe Entry and Cleaning of Petroleum Storage Tanks
2.6 ASTM

There are numerous American Society for Testing and Materials designations cover the
specification of wrought materials, forgings and castings used for plate, fittings, pipe and valves.
The ASTM standards are directed to dimensional standards, materials and strength
considerations.

Some of the more material standards referenced are:

A 36 Specification for Structural Steel

A 53 Specification for Pipe, Steel, Black and Hot –Dipped, Zinc Coated Welded and
Seamless

A 105 Specification for Forgings, Carbon Steel, for Piping Components

A 106 Specification for Seamless Carbon Steel Pipe for High Temperature Service

A 181 Specification for Forgings, Carbon Steel for General Purpose Piping

A 182 Specification for Forged or Rolled Alloy Steel Pipe Flanges, Forged Fittings, and
Valves and Parts for High Temperature Service

A 193 Specification for Alloy Steel and Stainless Steel Bolting Materials for High
Temperature Service

A 194 Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure and
High Temperature Service

A 234 Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures

A 333 Specification for Seamless and Welded Steel Pipe for Low Temperature Service

A 350 Specification for Forgings, Carbon and Low Alloy Steel Requiring Notch
Toughness Testing for Piping Components

A 352 Specification for Steel Castings, Ferritic and Martensitic for Pressure Containing
Parts Suitable for Low Temperature Service

A 420 Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low
Temperature Service

A 694 Specification for Forgings, carbon and Alloy Steel for Pipe Flanges, Fittings,
Valves and Parts for High Pressure Transmission Service

A 707 Specification for Flanges, Forged, Carbon and Alloy Steel for Low Temperature
Service
Problem Set 2

1. 1. A project award has been made. At the kick off meeting, the PM advises that piping design will
be to B31.4. The facility is steam piping in a refinery extending from the boiler to the tank farm.
What do you do or say and why?

2. 2. A liquid pipeline is to be built to Z184. You raise an issue. Why?

3. 3. What flange specification would you expect to reference for a gas pipeline facility?

Show the development of your answers.

Section 1 – References

Due to copyright laws, the following figures have not been published here. We leave as an exercise for the
user to retrieve these for reference.

Fig 100.1.2(B) of ASME B31.1

Fig 300.1.1 of ASME B31.3 1996
Fig 300.1.1 of ASME B31.3 1999
Fig 400.1.1 of ASME B31.4
Fig 400.1.2 of ASME B31.4
Fig 1.1 of CSA Z 662
Fig 1.2 of CSA Z 662
Table of Contents CSA Z 662
3.0 Supplemental Documents

3.1 Owner’s Specifications & Documents

Many of the Owners in the industries we service are technically sophisticated and will often have
supplementary specifications, standards or practices. It is the intent of these documents to clarify
and provide interpretation of the legislated Codes and industry-accepted standards specific to the
Owner’s facilities.

These specifications typically go beyond the requirements of Codes and without exception do not
contravene a Code requirement.

3.2 Contractor’s Specifications & Documents

Engineering contractors may be called upon to provide the engineering specifications for a project
if an Owner does not have his own standards or if required by terms of the contract.
Problem Set 3

1 1 What is the typical precedence of documents for engineering standards?

2 2 Can the Owner’s engineering standard override a Code provision?

3 3 Under what conditions can the Owner’s standard override a Code provision?

4 4 How would you deviate from an Owner’s engineering specification?

4.0 Piping Design

Piping design deals with the:

• • analytical design
• • material selection
• • geometric layout
• • fabrication
• • inspection specification
• • component specification

of piping and piping components.

4.1 Failure Mechanisms

Piping and piping components may fail if inadequately designed, by a number of different
mechanisms. These failures, in the majority of cases are either load controlled or displacement
controlled failures.

• • Pipe rupture due to overpressure

• • Bending failure in pipe span
• • Elbow cracking after 10 years of service, 5000 cycles of heat up to 500 F
• • On heat up, a line comes into contact with adjacent header which is at ambient
temperature
• • During startup on a cold winter day in Grande Prairie, an outdoor gas line located above
grade and constructed to Z662 is suddenly subjected to full line pressure and ruptures.
• • A 12” Sch.40 header, bottom supported, 40 feet long runs vertically up a tower and
connects to a nozzle. On steam out of the vessel, a 1’ deflection is observed in the pipe and
remains after the steam out procedure is completed and the pipe returns to ambient
temperature.
• • A header of a reciprocating compressor has been stressed checked; during operation
vibration is observed in the line. During the unit turnaround, cracking is found at midspan in
the wrought piping material.
• • A stress check determines that a hot, high alloy line does not pass the flexibility
requirements per B31.3. Twenty-five cycles are expected over the lifetime of the line.
4.2 Code Considerations for Design

Design of piping systems is governed by Codes. All codes have a common theme, they are intended to set
forth engineering requirements deemed necessary for safe design and construction of piping installations.

The Codes are not intended to apply to the operation, examination, inspection, testing, maintenance or
repair of piping that has been placed in service. The Codes do not prevent the User from applying the
provisions of the Codes for those purposes.

Engineering requirements of the Codes, while considered necessary and adequate for safe design, generally
use a simplified approach. A designer capable of applying a more rigorous analysis shall have the latitude
to do so, but must be able to demonstrate the validity of such analysis.

Design Conditions

Design conditions refer to the operating and design temperature and pressure that the piping
system will operate at over the course of its design life.
Code Design Temperature & Design Pressure
Code Design Temperature
B31.1 The piping shall be designed for a metal temperature representing the
maximum sustained condition expected. The design temperature
shall be assumed to be the same as the fluid temperature unless
calculations or tests support the use of other data, in which case the
design temperature shall not be less than the average of the fluid
temperature and the outside wall temperature.
B31.3 The design temperature of each component in a piping system is the
temperature at which, under the coincident pressure, the greatest
thickness or highest component rating is required in accordance with
par. 301.2
B31.4 The design temperature is the metal temperature expected in normal
operation. It is not necessary to vary the design stress for metal
temperatures between –20 °F and 250 °F.
B31.8 No design temperature. The Code mentions only ambient
temperature and ground temperature. (1975)
Z662 For restrained piping, the temperature differential shall be the
difference between the maximum flowing fluid temperature and the
metal temperature at the time of restraint.
For unrestrained piping, the thermal expansion range to be used in
the flexibility analysis shall be the difference between the maximum
and minimum operating temperatures.
Design Pressure
The internal design pressure shall be not less than the
maximum sustained operating pressure (MSOP) within the
piping system including the effects of static head.
The design pressure of each component in a piping system
shall be not less than the pressure at the most severe
condition of coincident internal or external pressure and
temperature expected during service, except as provided in
par. 302.2.4.
The piping component at any point in the piping system
shall be designed for an internal design pressure which
shall not be less than the maximum steady state operating
pressure at that point, or less than the static head pressure at
that point with the line in a static condition. The maximum
steady state operating pressure shall be the sum of the static
head pressure, pressure required to overcome friction losses
and any required back pressure.
Design pressure is the maximum operating pressure
permitted by the Code, as determined by the design
procedures applicable to the materials and locations
involved.
The design pressure at any specific location shall be
specified by the designer, shall not be less than the
intended maximum operating pressure at any location, and
shall include static head, pressure required to overcome
friction loss and any required back pressure.
Design of Piping – B31.1

B31.1 essentially limits the pressure design consideration to three items:

Minimum thickness for pressure:

(P ∗ Do )
tmin = 2( SE + PY ) + A , or

P ∗ d + 2 SE + 2 yPA
t= 2( SE + Py − P)

The limit is based on the limit stress being less than the basic allowable stress at temperature. This limit is
based on the static yield strength of the material.

Maximum longitudinal stress due to sustained loadings (SL ):

SL ≤ Sh ; stress due to sustained loadings shall be less than the basic allowable stress at temperature.
Sustained loadings are those due to pressure, self weight of contents & piping and other sustained loadings
particular to the situation. The limit is based on the static yield strength of the material.

P ∗ Do
Slp= 4 ∗ tn

The computed displacement stress range SE :

SE ≤ SA = f(1.25 Sc + 0.25 Sh). SE stresses arise from the constraint of the thermal strain displacements
associated with the expansion of pipe due to temperature. The limit is based on fatigue considerations.

Where the sum of the longitudinal stresses is less than Sh, the difference may be used as an
additional thermal expansion allowance.

2 2
Sb + 4∗ St
SE =

2 2
ii M i + io M
o
Sb = Z
B31.1 (cont’d)

The computed displacement stress range SE:

The factor “f” is a stress range reduction factor:

Cycles, N Factor, f

7,000 and less 1.0

> 7,000 to 14,000 0.9
>14,000 to 22,000 0.8
> 22,000 to 45,000 0.7
> 45,000 to 100,000 0.6
> 100,000 to 200,000 0.5
> 200,000 to 700,000 0.4
> 700,000 to 2,000,000 0.3
Design of Piping – B31.3

B31.3 essentially limits the pressure design consideration to three items:

Minimum thickness for pressure:

P∗D  SE − P 
P∗D D ∗  (1 − 
 SE + P 
t = 2( SE + PY ) or t = 2 SE or t = 2   (Lamé Equation)

The limit is based on the limit stress being less than the basic allowable stress at temperature. This limit is
based on the static yield strength of the material.

Maximum longitudinal stress due to sustained loadings (SL ):

SL ≤ Sh ; stress due to sustained loadings shall be less than the basic allowable stress at temperature.
Sustained loadings are those due to pressure, self weight of contents & piping and other sustained loadings
particular to the situation. The limit is based on the static yield strength of the material.

The computed displacement stress range SE :

SE ≤ SA = f(1.25 Sc + 0.25 Sh). SE stresses arise from the constraint of the thermal strain displacements
associated with the expansion of pipe due to temperature. The limit is based on fatigue considerations.

Where the sum of the longitudinal stresses is less than Sh, the difference may be used as an
additional thermal expansion allowance.
Design of Piping – B31.4

B31.4 essentially limits the pressure design consideration to three items:

Minimum thickness for pressure:

Pi ∗ D
t = 2S

The limit is based on the limit stress being less than the basic allowable stress at temperature. This limit is
based on the static yield strength of the material.

S = 0.72 ∗ E ∗ SMYS ,

where SMYS is the specified minimum yield strength of the material

Maximum longitudinal stress due to sustained loadings (SL ):

SL ≤ 0.75 • SA

where SA = 0.72 ∗ SMYS

SL, the stress due to sustained loadings shall be less than 0.75 x the allowable stress range, SA at
temperature. Sustained loadings are those due to pressure, self weight of contents & piping and other
sustained loadings particular to the situation.

The computed displacement stress range SE :

For restrained lines:

SL = E ∗ a ∗ ∆Τ − v ⋅ ∗Sh ≤ 0.9SMYS

For unrestrained lines:

SE ≤ SA
Design of Piping – B31.8

B31.8 (1975) essentially limits the pressure design consideration to three items:

Design pressure:

2∗ S ∗t
P= D F•E•T

F = design factor for construction type (includes a location factor)

E = longitudinal joint factor
T = temperature derating factor

S = SMYS ,

where SMYS is the specified minimum yield strength of the material

Total combined stress:

The total of the following shall not exceed S:

a) a) Combined stress due to expansion

b) b) Longitudinal pressure stress
c) c) Longitudinal bending stress due to internal + external loads

Further,

The sum of (b) + (c) ≤ 0.75 • S • F • T

The computed displacement stress range SE :

B31.8 applies itself to the above ground piping in discussing expansion and flexibility to a temperature of
450 °F.

For these “unrestrained” lines:

SE ≤ 0.72 • S
Design of Piping – CSA Z662

Z662 essentially limits the pressure design consideration to three items:

Pressure Design:

2S ∗ t × 10 × F × L × J × T
3

P= D ; units are metric

F = design factor = 0.8

L = location factor per Table 4.1 (appear to be safety factors)
J = longitudinal joint factor
T = temperature derating factor
S = Specified Minimum Yield Strength (SMYS)

Maximum longitudinal stress due to sustained loadings (SL ):

For restrained lines (below ground):

Sh - SL + SB ≤ 0.90 • S • T ; where, SL = v ⋅ ∗Sh − E ∗ a ∗ ∆Τ (below ground)

* note conservatism with respect to definition of ∆T, Code requires use of temperature at time of
restraint

Sh - SL + SB ≤ S • T ; (above ground, freely spanning segments)

The computed displacement stress range SE :

For unrestrained lines (above ground):

SE ≤ 0.72 • S • T
Design of Piping

The Design Effort Continuum

Code Code +

Calculation Method

Simple

Complex

Answer Quality

Conservative

Accurate

Effort

Least

Most
Design Loads

The Codes prescribe minimum rules for stress conditions and alert the designer explicitly to some
of the loadings likely to act on a system. In addition to the previous listing, most of the Codes
specify design rules for:

• • Occasional loads such as wind & earthquake

• • External pressure

The Codes caution the designer to consider the effect of other loadings and their impact on the
stress state of the system:

• • impact events (hydraulic shock, liquid & solid

slugging, flashing, transients)
• •
• •
• •
• •
• •
auto- refrigeration, seasonal temperature variations
vibration
discharge reactions
temperature gradients
bi-metallic connections

• • effects of support & restraint movements

• • cyclic effects

The Codes do not explicitly alert the designer to other loadings which may cause failure in the
piping system, including:

• • buckling (shell & column)

• • nozzle loadings on attached equipment, such as
• • pumps, compressors, engines
• • pressure vessels
• • steam generating equipment
• • fired heaters
• • heat exchangers
• • loadings on in-line equipment such as flanges, valves, filters, strainers
4.3 Material Selection

Key Considerations

• • Material specification
• • Chemical Composition
• • Mechanical Properties
• • Brittle fracture toughness
• • Carbon equivalent
• • Inspection
• • Repair Welding Procedure

Let’s discuss a couple of these considerations at this time.

Material Selection – Common Specifications for Carbon Steel Systems

Commodity B31.1 B31.3 B31.4

Pipe ASTM A 106 ASTM A 53 ASTM A 53

API 5L API 5L
API 5LU
Pipe – Low Temp ASTM A 333 Gr.6 ASTM A 333 Gr.6 ASTM A 333 Gr.6
Pipe – High Temp ASTM A 106 ASTM A 106 ASTM A 106
Bolting ASTM A 193 B7 ASTM A 193 B7 ASTM A 193 B7
ASTM A 320 ASTM A 320
Nut ASTM A 194 2H ASTM A 194 2H ASTM A 194 2H
Fittings ASTM A 234 WPB ASTM A 234 WPB

Fittings – Low Temp ASTM A 420 WPL6 ASTM A 420 WPL6 ASTM A 420 WPL6
Fittings – High Temp ASTM A 234 WPB ASTM A 234 WPB ASTM A 234 WPB
ASTM A 216 WCB ASTM A 216 WCB
Flanges ASTM A 105 ASTM A 105 ASTM A 105
ASTM A 181 ASTM A 181 ASTM A 181
ASME B16.5 ASME B16.5 ASME B16.5
Flanges – Low Temp ASTM A 350 LF2 ASTM A 350 LF2 ASTM A 350 LF2
ASTM A 352 LCB ASTM A 352 LCB
Flanges – High Temp ASTM A 105 ASTM A 105 ASTM A 105
ASTM A 181 ASTM A 181 ASTM A 216 WCB
ASTM A 216 WCB ASTM A 216 WCB
Valves ASTM A 105 ASTM A 105 API 6D
ASME B16.34 API 600 API 600
Valves – Low Temp ASTM A 350 LF2 ASTM A 350 LF2
ASTM A 352 LCB ASTM A 352 LCB
Valves – High Temp ASTM A 216 WCB ASTM A 216 WCB

As can be seen from the Table, material selection can be made from available national standards
such as ASTM and API.
Material Selection – Common Specifications for Carbon Steel Systems (cont’d)

Commodity B31.8 CSA Z662

Pipe ASTM A 53 CSA Z 245.1

API 5L
Pipe – Low Temp ASTM A 333 Gr.6 CSA Z 245.1

Pipe – High Temp ASTM A 106

Bolting ASTM A 193 B7 CSA Z 245.

ASTM A 354
ASTM A 449
Nut ASTM A 194 2H

Fittings MSS SP-75 CSA Z 245.11

Fittings – Low Temp CSA Z 245.11

Fittings – High Temp

Flanges ASTM A 105 CSA Z 245.12

ASTM A 372
MSS SP-44
Flanges – Low Temp CSA Z 245.12

Flanges – High Temp

Valves ASTM A 105 CSA Z 245.15

API 6D
ASME B16.34
ASME B16.38
Valves – Low Temp CSA Z 245.15

Valves – High Temp

Brittle Fracture

Brittle fracture refers to the often catastrophic failure of materials when subjected to
stresses at a lower temperature which the materially would normally be able to
withstand at higher temperatures.

A “transition temperature” can be defined at the 13.5, 20, 27 J (10, 15, 20 ft-lb)
energy level.

Charpy test results for steel plate obtained from failures of Liberty ships revealed that
plate failure never occurred at temperatures greater than the 20-J (15 ft-lb) transition
temperature.

This transition temperature varies with the material and is not used as a criterion.

Transition Temperatures

The transition temperature establishes the temperature at which a material “goes

brittle”. It’s major shortcoming is it’s imprecision and non-repeatability.

Charpy Testing

Impact testing provides a repeatable means to establish the impact toughness

capability of a material under temperature. The more common method is the Charpy
drop test measurement which determines the energy absorbing capacity of a
standard specimen.

Minimum Required Charpy V Notch Impact Values (B31.3-1999)

Energy

Fully Other than

Deoxidized Fully
Number of Specimens Steels Deoxidized
Specified Minimum
Tensile Strength Steels
Joules Ft-lbf Joules Ft-
lbf
(a) Carbon & Low
Alloy Steels
SMTS ≤ 65 ksi 18 13 14 10
Average for 3 16 10 10 7
65 ksi < SMTS ≤ 75 specimens 20 15 18 13
ksi Minimum for 1 16 12 14 10
specimen
75 ksi > SMTS < 95 27 20 … …
ksi 20 15 … …
Lateral Expansion

96 ksi < SMTS Minimum for 3 0.015 in

specimen
(b) Steels in P-Nos. Minimum for 3 0.015 in
6, 7, 8 specimen
Impact Testing Exemption Temperatures – B31.3

Refer to Figure 323.2.2 in the Code.

This figure provides a correlation between material group, reference thickness and
exemption temperature.

Material group is defined in Table A-1. For example, SA 106 B is given a Min Temp
rating of “B”. Entering Figure 323.2.2A, this material is impact testing exempt up to a
thickness of 0.5” down to a minimum temperature of –20 F. Curve B rises to a
minimum temperature of 75 F for a material thickness of 3”.

Minimum Required Charpy V Notch Impact Values (CSA Z 662-1999)

Table 5.1 provides a toughness category matrix. This matrix is somewhat

cumbersome to apply as it requires cross referencing to CSA Z 245 and makes use
of toughness categories I, II & III. It is not intuitively obvious what these categories
represent.

This Table also inherently provides for a risk based approach by bringing in service
fluid, test fluid and pipe design operating stress parameters.
Case Study:

On the next page, the Material Requisition Form has certain boxes marked off to
indicated inspection needs. Not all marked boxes are appropriate! Do you know
which?
 INSPECTION REQUIREMENTS
Project No. Project Name Requisition No. Page 1 of 1

Equipment / Material Rev. No.

La rge Bore Fla nge s & Fittings 0
DOCUMENTATION: In addition to the c opies required in Section III, one c opy of the Documents marked (X) must b
provided by the V endor to the Inspector w hen he/she visits the Shop.
A SME Code Report X Burst Test
X Material Certif ic ates (Mech. and Chem. Test Reports)
X Charpy Impact Tests
Postw eld Heat Treatment
Hardness Test
Perf ormanc e Test Curves
Nameplate Rubbings or Fascimile
Certif icate of Compliance
Certif icate of Compliance (Batch Tests)
Union Label (Des cribe)
V alve Manuf acturer's Certif icate
Surf ac e Preparation and Coating Reports
Calibration Certif icates f or Manuf ac turer's Equipment
PROCEDURES : The proc edures and qualif ications c hec ked below are s ubjec t to approval by
engineering prior to f abrication.
High Pot Test Procedures Tube Rolling Procedures
Motor Tes t Procedures Tube Cleaning and Installation Procedure
Mac hining Procedures Quality Control Proc edures
X Welding Procedures (WPS and PQR) Surf ac e Preparation, Painting & Coating Proc edures
X Welding Repair Procedures (WPS and PQR) Preparation f or Shipment Proc edure
Noise Tes t Procedures Perf ormanc e Test Procedure
Routine Electrical Procedures Material Hardness Test Procedures
X NDT Procedures X QC Inspection and Test Plan
X Heat Treatment Procedure Calibration Procedure
Casting Repair Proc edure
Hydrotest Proc edure

INSPECTION CHECKLIST: The Ins pector may c hec k (C), review (R), approve (A ) and/or w itness (W) the
f ollow ing items marked (X) below .
Welder's Qualif ications (R) Sandblast, Painting, Coating and Galvanizing (A )
Draw ing and Proc edures (R) Mechanical/Electrical/Pneumatic Run Test (W & A )
X Material Test Reports (C, R, & A ) X Nameplates , Tagging (C); Marking
Hydrotest (C) X Mac hining Tolerances (C)
Perf ormanc e Test (W on one pump per model) Tube Cleaning and Installation Procedure (R)
Complete Train Test (W & A ) Tube Bundle Ins ertion (W & A )
NPSH Tes t ( A ) One per pump model Shop Fit Up Prior to A ssembly (W)
Sound Level Test X Compliance w ith Specif ic ations (C)
X Dimens ional Chec k (C ) X Cleanliness Prior to Shipment (C)
X NDT (R) Elec tric al and Mec hanic al Runout (C)
Charts (C) Wiring Continuity/High Pot Test (C)
Rotor Balancing (R) X Flange Face Finish (C)
Compliance w ith Dimensional Outline Draw ing (C) Final Equipment Inspection (A )
Compliance w ith V endor's P&ID (C) Final Pac kaging Inspection (W & A )
Coupling Ty pe and Size (R) Seal Pres sure Test (C)
Coupling Hub Contac t
Note s: 1) The Contractor's ins pec tor or des ignate shall hav e ac ces s to V endor's premises f or the purpos e of documentatio
auditing or source inspection.

Note: Mark all revisions in c olumn "R" w ith revision number

4.4 Fabricated Tees & Area Reinforcement

Paragraph 304.3.2 of the Code provides explicit direction on the proper design of branch connections.
In summary, this paragraph states that branch connections must be made using fittings that are inherently
reinforced such those listed in Table 326.1 or fabricated and sufficiently reinforced using design criteria
based on area reinforcement principles. This presumes that a branch connection opening weakens the pipe
wall and requires reinforcement by replacement of the removed area to the extent it is in excess to that
required for pressure containment. The Code is fully detailed in the necessary calculations. These
calculations can be very tedious, time consuming prone to error if done by hand. A computer program is
advised for productivity; a spreadsheet based program is more than adequate.

No calculation is required for branch connections made by welding a threaded or socket weld coupling or
half coupling if the branch does not exceed 2 NPS nor ¼ the nominal size of the run line. The coupling
cannot be rated for less than 2000 CWP.

Multiple openings are addressed by the Code.

The area reinforcement rule can be at times, be overly conservative; in other

instances, this approach can be deficient even within the limits of applicability defined
in the Code. Code users must be aware of the limits of applicability of the Code rules
which are given in paragraph 304.3.1. Jurisdictions such as the Alberta Boiler Safety
Association (ABSA) have defined additional limits. WRC publications also have
guidance on this issue.
4.5 Flexibility Analysis

Stress Analysis Criteria:

This stress analysis criteria establishes the procedure, lists critical lines and piping
stress/design liaison flow sheet to be followed.
Lines to be analyzed:
• • all lines attached to pumps, compressors, turbines and other rotating equipment
• • all lines attached to reciprocating compressors
• • all pressure relief valve piping
• • all category M piping
• • all lines on racks (with discretion)
• • all lines which the piping designer is uncomfortable with
• • all vacuum lines
• • all jacketed piping
• • all tie-ins to existing piping
• • all non metallic piping
• • all steam out, decoking and regeneration lines
• • all lines 16” and larger
• • all lines 6” and larger over 500 F
• • all lines over 750 F
• • all lines specifically requested by the stress department.
• • all lines specifically requested by the Client.

The above list is actually very conservative and discretion is required in applying these rules
to ensure economical approach to piping analysis.

Paragraph 319.4.1 lists the conditions under which flexibility analysis may be waived.

If formal analysis is deemed necessary, follow the requirements of paragraph 319.4.2.

The other Codes will have similar provisions.

 Exam

There is no exam; take a break!

Stanford University
Facilities Design & Construction Standards

SECTION 02551
UNDERGROUND STEAM AND CONDENSATE SYSTEM
SPECIFICATIONS

(Revised: January, 1999)

PART 1 GENERAL

1.01 RELATED WORK

A. Section 02315: Excavation and Fill

B. Section 02950: Site Restoration and Rehabilitation

1.02 SYSTEM DESCRIPTION

A. Steam Distribution System: Steam is the primary heat source for a variety of
heating functions throughout the University. Saturated steam is generated at the
Central Energy Facility and distributed via a loop piping system which operates at
125 psig (353F). (Design conditions for piping are 135 psig and 400F. The
distribution system serves all sections of the Campus as well as the Hospital, Medical
School and Hoover Pavilion.

B. Condensate Return System: The condensate return system operates with 180oF
condensate at 20 psig. Design conditions for piping are 100 psig and 212 F.

1.03 CODE COMPLIANCE AND STANDARDS: Use current edition in effect at

time of design and construction.

A. American Society of Mechanical Engineers (ASME) - Boiler and Pressure Vessel

Code.

B. American National Standards Institute (ANSI)- B31.1 Power Piping

C. Expansion Joint Manufacturers Association (EJMA) - Standards

D. California Department of Transportation - Standards

1.04 QUALITY ASSURANCE

A. All materials shall be certified new from factory. Pipe, fittings, and valves shall be
made in the USA or Canada to ANSI/ASME standards and suitably stamped. Piping
components made in other countries shall mot be used unless specifically approved by
the Project Manager.

B. Welder Qualifications: Welder(s) shall be qualified in accordance with ASME

Section VIII, Pressure Vessels; ASME Section IX, Welding and Brazing
Qualifications. Welders shall be thoroughly familiar with ANSI B31.1 requirements.

C. The Contractor shall furnish to the Project Manager all applicable welding
procedures and welder certification and procedure qualification records. All
documentation shall be signed and dated by the appropriate Contractor personnel.

1.05 SUBMITTALS

A. Manufacturer's Data: Manufacturer's standard drawings, catalog cuts,

specifications, and data sheets for all materials and equipment (piping, valves,
expansion joints, insulation, etc.) shall be submitted to the Project Manager for
approval.

B. Shop Drawings: Manufacturer's shop drawings for underground piping or conduit

systems, including anchors, guides, supports, vault penetrations and trenches shall be
submitted to the Project Manager for approval.

C. Welder's Performance Qualifications: Welder's performance qualification records

shall be submitted to the Project Manager for approval prior to beginning work.

1.06 DELIVERY, STORAGE, AND HANDLING

A. Delivery and Storage:

1. Contractor shall be responsible for inspecting materials delivered to site for

damage.

2. Materials shall be stored on-site in enclosures or under protective coverings.

Materials shall not be stored directly on ground.

3. Insulation, expansion joints, joint materials, fittings, valves, and gaskets shall be
stored under cover out of direct sunlight.

B. Handling:

1. Pipe, conduit sections, fittings, valves and other accessories shall be handled in
such a manner as to ensure delivery to the trench in sound, undamaged condition.

2. Special care shall be taken to avoid injury to coatings and linings on pipe and
fittings. Damaged coatings and linings shall be repaired by the Contractor to the
satisfaction of the Project Manager.
PART 2 PRODUCTS

2.01 PIPE AND FITTINGS

A. Pipe:

1. ASTM A-106 (seamless), Grade B, black carbon steel

2. Condensate lines: all sizes to be Schedule 80.

3. Steam lines:

a. 2 inch and smaller: Schedule 80,

b. 2.5 inch through 10 inch: Schedule 40,

c. 12 inch through 14-inch, 0.375 inch wall,

B. Fittings:

1. Threaded or socket weld (2 inch and smaller): ANSI B16.11 forged carbon steel,
ASTM A105, 2000# class.

2. Butt-Welded (2.5 inch and larger): ANSI B16.9, ASTM A234 WPB, schedule to
match pipe.

3. Flanged (2.5 inch and larger): ANSI B16.5, ASTM A105 forged steel, 150 or 300
pound class, weld-neck flanges shall be used to match equipment.

4. Unions (2 inch and smaller): ANSI B16.11 forged carbon steel, 800 # class.

5. Dielectric flange sets shall be rated for the service intended.

6. All buried pipe fittings shall be butt welded for all sizes.

2.02 VALVES

A. General: Valves shall be threaded for 2 inch and smaller piping, flanged for 2.5
inch and larger. Socket weld or butt weld valves shall only be used if specifed on the
Contract Drawings. Acceptable valve manufacturers for steam or condensate service
are provided below; no substitutions unless approved by the Project Manager.

B. Gate Valves:

1. Threaded (2 inch and smaller): ANSI B16.34, 800 pound class, forged steel, bolted
bonnet, OS&Y, conventional port gate valve Walworth, Vogt, or Edwards.

2. Flanged (2.5 inch and larger): ANSI B16.34, 150 pound class, A216 WCB cast
steel body, bolted bonnet, OS&Y., stainless steel trim; Walworth or Stockham.
3. Butt weld (2.5 inch and larger): ANSI B16.34, 150 pound class, A216 WCB cast
steel body, bolted bonnet, OS&Y; stainless steel trim, Walworth or Stockham.

4. Warmup lines: All gate valves 4 inch and larger shall have bypass lines with
appropriately sized warmup valves.

C. Globe Valves:

1. Threaded (2 inch and smaller): ANSI B16.34, 800 pound class, forged steel body,
stainless steel seat ring and plug, bolted bonnet, rising steam; Walworth, Vogt, or
Edwards.

2. Flanged (2.5 inch and larger): ANSI B16.34, 150 pound class, A216 WCB cast
steel body, OS&Y; stainless steel trim, Walworth or Stockham.

D. Ball Valves:

1. Threaded (2 inch and smaller): 150 pound class, steam-rated, cast steel/stainless
steel, Nibco or Walworth.

E. Check Valves (condensate systems only):

1. Threaded (for steam trap discharge): 800 pound class, forged steel, stainless steel
disc, swing check; Vogt, Edwards, or Walworth.

2. Flanged (2.5 inch and larger): ANSI B16.34, 150 pound class, A216 WCB cast
steel body, bolted flange cover, swing check; Walworth or Stockham.

3. Vertical lift check valves: threaded, 150/200 pound class, bronze body, for steam
powered condensate pump, Stockham or Walworth. (reference Standard Drawing
MS-59).

F. Rotary Valves: 1. 150 pound class, carbon steel, flanged, Adams or Keystone
Vanessa.

2.03 PIPING SPECIALTIES

A. Gaskets: Non-asbestos containing ring gaskets, flexitallic type "cg" grafoil/304ss

or equal, suitable for the fluids and temperatures encountered.

B. Bolting: ASTM A193, Grade B7, for bolts and studs, and ASTM A194, Grade 2H
for nuts.

C. Sleeves: Sleeves for foundation wall penetrations shall be fabricated of one-eighth

inch (1/8") thick steel, with two inch (2") wide collar welded in place, and the
assembly hot-dip galvanized.

D. Wall Penetration Seals: High temperature elastomeric link type mechanical seals
compressed with corrosion-protected bolts and compression plates; Thunderline Link-
Seal, no substitution. (Reference Standard Drawing MS-52)
E. Expansion Joints:

1. Expansion joints shall be slip tube type or extenally pressurized bellows type as
designed for the specific location. They shall be 150 psig steam rating, flanged, and
shall conform with the Standards of the Expansion Joint Manufacturers Association.

2. Bellows type joints shall have 316 ss bellows, and may be single or double bellows
style as required for the intended service: Hyspan, Pathway or Senior Flexonics.

3. Slip-tube type shall have external and internal high performance guides rated for
500oF and designed for packing under pressure; Yarway or Hyspan.

4. Slip-tube joints shall be single or double type with center take-off taps as required
for the given service. See Standard Drawing MS-54 for typical installation.

F. Steam Traps for main line or building PRV assembly (see Standard Drawing MS-
55): Steel body, 3/4 inch diameter, thermodynamic disc type, Nicholson TD 301,
Yarway #721, or Spirax Sarco TD. Install 3-way forged steel trap test valve
downstream of trap and before check valve.

G. Automatic Air Vents (for high points on condensate systems): 3/4 inch threadolet
with 3/4 inch gate isolation valve is required upstream of air vent. Air vent shall be
3/4 inch 150 # rating, Sarco 13W or approved equal. Discharge of condensate air
vents in vaults shall be routed to the floor.

H. Strainers (for use on steam trap stations): Y-type with cast or forged steel body,
1/16 inch mesh monel strainer elements, threaded for 2 inch and smaller piping; C.M.
Bailey or Spirax Sarco IT.

I. Pipe Hangers and Supports: Pipe hangers and supports shall be designed, and
located per the requirements of B31.1 and the recommendations of the powder
insulation or prefabricated conduit system vendor.

J. Pressure guages: 4.5 inch dial, bourdon tube, 0 to 200 psig on steam mains, 0 to 50
psig on condensate mains, Ashcroft or equal. Include isolation valve and pigtail coil
on steam guages.

K. Steam main high point vents: Install isolation valve and thermostatic vent on steam
main high points, Spirax Sarcp V-204 or equal. Vent discharge to floor.

L. Insulation:

1. In manholes, pipe 2.5 inch and greater shall be insulated with ASTM C533, Type I,
calcium silicate; 2.5 to 6 inch steam (3 inches thick), 8 to 12 inch steam (4 inches
thick), 2.5 to 6 inch condensate (2 inches thick).

2. In manholes, tunnels, and exterior installations: pipe and fitting insulation shall be
covered with 0.016 inch smooth aluminum jackets with integral moisture barrier.
Stainless steel band on 12 inch center shall hold the insulation to the pipe.
3. Valves and equipment shall be insulated with removable shop-fabricated fiberglass
padding rated for 500oF, with thin wire mesh lining, and covered with 18 ounce high-
temperature fiberglass cloth with velcro straps.

2.04 MANHOLES

A. General (see Standard Drawing CS-301):

1. All structures shall be of reinforced concrete. Main line junctions and service
connections shall be in vaults, which require two openings. Minor assemblies such as
drip legs, can be in pits, which require only one opening.

2. Prefabricated or field-constructed manholes shall be provided with walls, floors,

and roofs not less than 8 inches thick and reinforced with steel bars. Floors shall drain
to sump hole (see Standard Drawing CS-301).

3. Prefabricated concrete manholes shall conform with CDT Standard Specifications,

Section 70.

4. Concrete shall be 2500 psi minimum compressive strength after twenty-eight (28)
days, for both prefabricated and field-constructed manholes.

5. Waterproofing shall be provided according to CDT Standard Specifications,

Section 54.

6. Ladders shall be provided according to CDT Standard Specifications, Section 70.

7. Covers and openings shall be vehicular traffic rated (H-20). 38-1/2 inch Neenah
1792 frames with one 40 inch solid lid and one 40 inch grate lid, both marked
STEAM.

2.05 STEEL PIPE AND POWDER INSULATION SYSTEM

A. The powder insulation system shall provide for minimizing heat loss, corrosion
protection, and unrestricted thermal movement between anchors.

B. Powder insulation shall be Dri-Therm, or Gilsulate. Thickness of the insulation

shall be defined by the Engineer and shown on the Contract Drawings

C. Expansion Loops and L- Bends: In addition to the powder insulation thickness,

bends shall be preinsulated with ASTM C547, Class 1, mineral fiber to allow for
thermal expansion of the piping. The mineral fiber thickness at bends should be
approximately 200% of the calculated thermal growth.

D. Pipe Supports: Anchors shall be located outside vaults, typically at five to ten feet
from the vault wall. Expansion loops shall use guides and vertical supports as
required.

2.06 BURIED CONDUIT SYSTEMS

A. Fiberglass Conduit Casing: Conduit casing shall be manufacturer's standard
drainable, ventable, and pressure-testable fiberglass system with an annular air space.
Fiberglass casing systems shall be spiral wound fiberglass-reinforced isopthalic
polyester resin.

B. Conduit End Seals: Conduit end seals shall be fixed type where there is no thermal
pipe expansion through the end seal, and shall be slip type where there is thermal pipe
expansion through the end seal. One-half inch (1/2") threaded pipe ports at top and
bottom of each end seal shall be provided for draining, venting, and pressure testing
of conduit casings.

C. Insulation: ASTM C533, Type I, calcium silicate, mineral fiber, or C552 cellular
glass three inch (3") for steam, and two inch (2") for condensate shall be used on the
steel pipe within the casing.

D. Expansion Loops and L-Bends:

1. ANSI B31.1, factory fabricated, with weld testing per design. Casing, couplings,
insulation, and piping shall be identical to those used for straight runs and designed to
ensure complete drainage. Fabricated materials shall be shipped to the job site in
maximum feasible size sections to minimize number of field joints.

2. Loop casings shall be sized to contain pipe movement without crushing the
insulation or causing other damage. Eccentric reducers and increasers or welding
collars designed to serve the same purpose shall be used to allow free drainage
through the loop.

3. Pipe supports shall be slotted to permit unrestricted lateral movement of piping, and
shall be otherwise identical to pipe supports specified for straight runs.

E. Pipe Supports: Anchors shall be located outside vaults as shown in Standard

Drawing MS-51. Inside vaults, vent and drain holes shall be provided at the top and
bottom of casing closure plates.

PART 3 EXECUTION

3.01 TRENCHING, BACKFILLING, AND COMPACTING

A. Refer also to Section 02315: Excavation and Fill.

B. Trenching: Stanford may limit the amount of trench to be opened at any time.

C. Bedding:

1. Pre-insulated conduit systems: Ditch bedding shall be accurately graded with a

minimum of six inches (6") of sand. Sand shall pass a 1/4 inch screen with not more
than fifteen percent (15%) passing a No.200 sieve. Sand shall be backfilled to a
minimum of six inches (6") above the pipe casing. Bedding shall be laid to firmly
support the piping along its entire length.
2. Steel pipe and powder insulation system: The steel pipes shall be top hung or
bottom supported to allow a bedding of powder insulation underneath (in accordance
with manufacturer's specifications). The powder insulation shall be placed to the
minimum thickness shown on the Contract Drawings. The insulation shall be installed
and compacted (per the manufacturer specifications) to firmly support the piping
along its entire length.

D. Backfilling: Backfilling of trenches shall progress as rapidly as construction,

testing, and acceptance of work permits.

E. Damage Repair: Utilities, walls, piping, and other improvements damaged during
the course of work shall be repaired to their original condition or replaced by the
Contractor.

F. Excess Material: Excess material and debris shall be removed and disposed of, at
an approved disposal site, within one week after final approval of installation.

3.02 PIPING INSTALLATION

A. General:

1. Piping and pipe systems shall be fabricated, assembled, welded, installed and tested
in accordance with ANSI B31.1.

2. Piping shall be cut accurately to field measurements and worked into place without
springing or forcing, except where cold-springing is specified. Piping shall not be
buried, concealed, or insulated until it has been inspected, tested, and approved in
accordance with Article 3.07, Field Quality Control (below).

3. Materials and equipment shall be protected from the weather during construction.

4. Pipe runs underground between vaults shall be welded. Flanged and threaded joints
shall not be buried.

5. Gaskets, packing, and thread compounds shall be suitable for the service. Joint
compound or thread tape shall be applied to male threads only.

6. Arrangement of all piping shall be shown on the drawings. During installation, care
shall be taken to avoid interference with other piping, conduit, and equipment. Lines
shall be trapped only where shown on the drawings.

7. Reducing fittings shall be used for changes in pipe sizes. Bushings shall not be
used.

8. In horizontal lines two inches (2") and larger, reducing fittings of the eccentric type
shall be used to maintain the bottoms of the lines in the same plane for steam, and the
tops of the lines in the same plane for condensate.

9. Pipe shall be adequately supported and anchored so that strain from weight and
thermal movement of piping is not imposed on piping, equipment, or structures.
B. Cleaning:

1. Each section of pipe, fittings, and valves shall be thoroughly cleaned free of all
foreign matter before erection. Interior of piping shall be cleaned thoroughly as
described in Article 3.07 (below) before final connections are made.

2. Open ends of mains shall be plugged or capped during shutdown periods. Lines
shall not be left open at any place where foreign matter might accidentally enter pipe.

C. Pipe Expansion: Expansion of pipes shall be accommodated by expansion loops,

L-bends, Z-bends in buried locations, or by slip or bellows expansion joints in
manholes, tunnels and buildings. Expansion joints shall be set to ensure proper
function and movement during system operation.

D. Connections: Locations of capped or plugged outlets for future connections shall

be shown on the Drawings. Weldolets or welding fittings shall be used for tapping
existing systems.

E. Steam Line Drainage: Steam lines shall be pitched to allow for condensate drainage
to the low point steam pots. For steam pipes in tunnels sloped down down in the
direction of steam flow, a minimum of three inches per one-hundred feet (3" per 100')
of length is required. Where counterflow of condensate must be accommodated in
steam tunnels, lines shall be pitched up in the direction of steam flow six inches per
one-hundred (6" per 100') feet of length. Buried steam lines shall be pitched to
accommodate the worst case of 6" per 100 feet. Steam lines may be peaked with lines
pitched as above. Final pipe elevations must be recorded on the as-built drawings.

F. Welding:

1. Responsibilities of Contractor for Electric Fusion Welding:

a. Contractor shall be responsible for the quality of all welding.

b. Contractor shall be capable of performing all welding operations

required for construction of the steam distribution and condensate return systems.

c. Contractor shall determine the suitability of welding procedures used to ensure that
welds meet the requirements specified herein.

2. Beveling: Field bevels and shop bevels shall be done by mechanical means or by
flame cutting. Where beveling is done after flame cutting, surfaces shall be ground
and thoroughly cleaned of scale and oxidation just prior to welding. Beveling shall
conform with ANSI standards.

3. Butt welds: All butt welds shall be open root, multi-pass welds, 6010 or 6011 root
with 7018 filler caps (SMAW welding process).
3. Electrodes shall be stored in a dry, warm area and kept free of moisture during
fabrication operations. Electrodes that have lost part of their coatings shall be
discarded.

4. Welds shall be inspected in accordance with ANSI B31.1 requirements. The Owner
will radiograph 5 to 10% of the welds.

5. If any welds are found to be defective, the Contractor is responsible for full 100%
radiograph testing of all the welds. Repair of defective welds by adding weld material
over the defect, or by peening shall not be permitted. Welders responsible for
defective welds shall be re-qualified before performing more welding on the job.

6. All finished weld joints shall be painted with high temperature black paint.

G. Anchor Blocks:

1. Anchor Blocks: Concrete anchor blocks shall be provided for pipe anchorage not
less than five feet (5') from building or manhole walls (except where metal anchor at
the vault wall is shown on the Contract Drawings). Size and position of anchor blocks
shall be as shown on Standard Drawings MS-51 and MS-52. Anchor blocks shall be
cast against undisturbed earth using concrete that conforms to ASTM C-94 and has a
minimum compressive strength of 2,500 psi at twenty-eight (28) days.

2. Fabricated Structural Anchors: Fabricated structural anchors shall be provided if

necessary in vaults, tunnels, and mechanical rooms as described in the Contract
Drawings.

H. Wall Penetrations: Galvanized steel sleeves shall be provided for penetrations in

concrete walls six inches (6") or less in thickness, and masonry walls. Existing
concrete walls thicker than six inches (6") shall be core drilled or equipped with
galvanized steel sleeves. High temperature elastomeric link type seals shall be
acceptable for use in all locations. Reference Standard Drawings MS-51 and MS-52.

I. Insulation and Jackets:

1. Insulation shall be continuous through pipe hangers with calcium silicate inserts to
prevent crushing of insulation.

2. Steam and condensate valves and equipment in manholes and buildings shall be
insulated and covered with removable jackets. Insulation shall stop short of
bolts/studs at flanges to allow their removal without damage of permanent insulation.

3. Trap sections between unions in steam trap manifolds shall not be insulated.

4. No exposed insulation will be permitted. Aluminum or PVC end caps that match
the insulation jackets shall be used to cover the ends of insulation runs.

5. Steam and condensate lines in manholes, tunnels, and buildings shall be color
coded as follows, or as otherwise directed by the Project Manager:
High pressure steam - RED (darker shade)
Reduced pressure steam - RED (lighter shade)
Condensate Return (building) - Orange (lighter shade)
Condensate Return (steam system traps) - Orange (darker shade)

3.03 VALVE INSTALLATION

A. Valves shall be installed in accordance with ANSI B31.1 and ASME Section VIII.

B. Valves shall be installed as shown on the drawings and as required for proper
functioning of the system.

C. Valve handwheels shall be installed in locations accessible from floor level,

preferrably with vertical stems, for operation and repair.

D. All flange bolts shall be lubricated with a high temperature bolt lubricant approved
by the Project Manager. Flanged bolt torquing shall be in a incremental staggered
patternto assure even compression of the gasket.

3.04 PIPING SPECIALTIES INSTALLATION

A. Traps and Manifolds: Steam drip and mud legs, guard and blowdown valves, and
piping shall be as shown on Standard Drawing MS-55. Dual traps stations shall be
installed at all mud legs unless otherwise indicated on the drawings. Multiple trap
manifolds at one location shall be in the same horizontal plane.

B. Hangers and Supports:

1. Hangers shall be sized to allow for continuous pipe insulation through the hangers.
Hangers shall not be permitted to touch steam pipe.

2. Expansion bolts shall be acceptable for use in wall or ceiling construction.

3.05 POWDER INSULATION SYSTEM INSTALLATION

A. Installation as per Manufacturer's specifications.

3.06 BURIED CONDUIT INSTALLATION

A. Conduit Field Joints:

1. Conduit sections shall be joined after leak testing of carrier pipe. Conduit joining
materials provided or specified by the system manufacturer shall be used.

2. Pipe shall be insulated and casing joined to provide field joint equal to factory
fabricated section on conduit system. Connections to existing conduit systems of a
different manufacturer or type shall be made only in manholes or buildings and never
in buried locations.
B. Conduit End Seals: Conduit end seals in manholes or tunnels shall be provided
with gooseneck vents on the top and drain valves on the bottom. In buildings, conduit
end seals shall be provided with threaded brass plugs. Refer also to Standard Drawing
MS-51.

3.07 FIELD QUALITY CONTROL

A. General: The Project Manager or his representative will conduct field inspections
and shall witness all field tests specified in this Section. The Contractor shall perform
field tests and provide labor, equipment, and incidentals required for testing. The
Contractor shall produce evidence, when required by the Project Manager, that any
item of work has been constructed properly in accordance with the Contract Drawings
and Specifications.

B. Field Tests:

1. General: All anchor blocks and restraints shall be complete prior to testing.
Concrete supports shall be fully cured.

2. Piping Initial Air Leak Tests: Before insulation is applied at field joints, piping
shall be pressurized to twenty-five (25) psig air pressure and tested for leaks with soap
solution. Leaks shall be repaired and test repeated.

3. Piping Hydrostatic Pressure Tests:

a. Test pressure gauges for a specific test shall have dials indicating not less than one
and one-half (1-1/2) times nor more than two (2) times the test pressure.

b. After installation of insulation, anchor blocks, and backfill, hydrostatic pressure

shall be applied to 200 psig and allowed to stabilize to ground temperature while
maintaining 200 psig, +/- 10 psi. After stabilization, pressure source shall be removed.
Piping must hold 200 psig, +/- 10 psi, for at least four (4) hours. Leaks shall be
repaired and the test repeated if the pressure does not hold.

4. Conduit Casing Pressure Tests: Before backfilling, conduit casing shall be

pressurized to fifteen (15) psig air pressure and allowed to stabilize. After
stabilization the pressure source shall be removed. Casing must hold fifteen (15) psig
air pressure, +/- 2 psi, for at least four (4) hours. Pressure test shall be repeated after
backfilling. Leaks shall be repaired and the test repeated if the pressure does not hold.

5. Cleaning: After pressure and hydrostatic testing, the pipe system shall be flushed
with a water/chemical solution. The procedure, cleaning solutions, and disposal shall
be approved by the Project Manager.

6. Operational Tests: After completion of the work, the system shall be operated for
not less than six (6) hours at operational temperatures and pressures to demonstrate
satisfactory function. The movement of each expansion joint shall be checked, and
each valve shall be operated in both cold and hot conditions.

END OF SECTION