Week 1 Presentation

Topics
 Valves
 Pipes
 Fittings
 Gaskets
 Flanges
Valves
What is a valve…

 A valve is a device that regulates, directs or controls the flow of a

fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or
partially obstructing various passageways. Valves are
technically fittings, but are usually discussed as a separate category.
In an open valve, fluid flows in a direction from higher pressure to
lower pressure. The word is derived from the Latin valva, the moving
part of a door, in turn from volvere, to turn, roll.
What are their applications…

 Valves are found in virtually every industrial process, including water

and sewage processing, mining, power generation, processing of
oil, gas and petroleum, food manufacturing, chemical and plastic
manufacturing and many other fields.
 People in developed nations use valves in their daily lives,
including plumbing valves, such as taps for tap water, gas control
valves on cookers, small valves fitted to washing
machines and dishwashers, safety devices fitted to hot water
systems, and poppet valves in car engines.
What are their types…
There are different types of valves used in industries based on their
applications , advantages and disadvantages. Mostly the valves which
are used in industry are
 Ball Valve
 Globe Valve
 Gate Valve
 Choke valve
 Butterfly valve
 Non-return valve
 Safety valve
 Check valve
 Needle valve
 Ball Valve
 A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball to control flow
through it. It is open when the ball's hole is in line with the flow and closed when it is pivoted 90-degrees by
the valve handle. The handle lies flat in alignment with the flow when open, and is perpendicular to it when
closed, making for easy visual confirmation of the valve's status.

Advantages Disadvantages Applications

Efficiency: Ball valves don’t need
any lubrication, and offer a bubble-
tight seal with low torque.
Poor throttling characteristics: In a Ball Valves are used for flow and
throttling position, the partially pressure control and shut off for
exposed seat may be prone to corrosive fluids, slurries, normal
erosion as a result of high velocity liquid and gases.
flows. They’re therefore not
recommended for sustained
throttling applications.

Affordability: They can often be
purchased at a considerably lower
cost than comparable products for
the same job.
Wear and tear: When used to
regulate the wrong types of fluids,
such as slurries, ball valves can stick
in position and become jammed
due to suspended particles being
trapped. This can cause the valve
to wear, or to become damaged
or stuck.
They are used in the oil and natural
gas industry, but also find a place in
many manufacturing sectors,
chemical storage, and even
residential uses.

Easy to use: Ball valves are

relatively quick and easy to install,
and plastic ball valves are light and
easy to handle.
Strong: Ball valves can maintain
and regulate high pressure, high
volume and a high flow of
temperature.
 Globe Valve
 Globe Valves are among the most popular type of valves used in various applications. These valves
are similar to gate valves and use linear motion to throttle flow. They are used to control the flow in a
pipeline and they regulate by the position of a movable disk (or plug) in relation to the stationary ring
seat. The major advantage of a globe valve is, it does not leak as much as other valves.

Advantages Disadvantages Applications

Throttling: Globe valves throttling,
the full-closing characteristic is
good.
Pressure loss: pressure loss is
higher
Global valves are used primarily
for throttling purposes. They may
be considered as general purpose
flow control valves that are used
for high-temperature applications.

Short action time: The opening- Torque: To close under high

closing time is shorter. pressure, globe valves require a
larger amount of force or an
actuator with a large torque

Positive shut-off: They contain

positive shut-off
 Gate Valve
 Gate Valves are designed to serve as isolation valves. These valves help to control the flow of liquid
through the pipes. To start or stop the water flow or any other kind of liquid, these valves are affixed
to the pipelines. Gate valves are used for various purposes and they can be seen commonly in
homes and commercial centers. Different materials such as stainless steel, cast iron, alloy steel,
forged steel etc. are used to manufacture these valves.

Advantages Disadvantages Applications

Friction loss: Gate valves Opening and closing :Gate Gate valves are suitable to use
contain very low friction loss valves cannot be opened & in high temperature and
closed quickly pressure conditions.

Pressure loss: They provide Vibrations: They cause vibrations They are used for on-off
laminar flow, a pressure loss is applications
minimum

Energy Saver: Gate valves help Leakage: In systems where high-

to save energy and reduce total
cost of ownership
Dual usage: They can be used
both ways in the circuit
temperature changes irregularly,
due to the load in pipe at the
valve end, leakages in gate
valves occur.
Repair & maintenance: The
operation, maintenance, and
repair of gate valves seating
 Choke Valve:
 Choke valve is a type of control valves, mostly used in oil and gas production wells to control the flow
of well fluids being produced. Another purpose that the choke valves serve is to kill the pressure from
reservoir and to regulate the downstream pressure in the flow lines. Choke valves allow fluid flow
through a very small opening, designed to kill the reservoir pressure while regulating the well
production. The reservoir fluids can contain sand particles. Hence the choke valves are usually
designed to handle an erosive service.

Advantages Disadvantages Applications

Pressure: Choke valve can be It has limited usage In oil and gas industry choke
used to control high pressure valve is used with Christmas tree
to regulate the flow of well

Installation: Choke valves are In motor vehicles choke valve is

easy to install used for mixture of air and fuel
 Butterfly Valve
 Butterfly Valves are designed to regulate flow, but with limited control capability. Butterfly valves are
easily operated by rotating a handle 90 degrees. It consists of a metal disc in the body of the valve
which is positioned perpendicular to the flow in the closed position. Regulation of liquid flow can be
allowed through intermediate rotations. Butterfly valves are configured to operate electronically,
manually or pneumatically.

Advantages Disadvantages Applications

Accuracy: Butterfly valves are very Shut-off: Butterfly valves have no tight Butterfly valves can be used in
accurate, which makes them shut offs pharmaceutical, chemical, and food
advanta- geous in industrial processing services.
applications.

Maintenance: They are quite reliable Always Open: Some portion of the They are used for corrosive liquids at
and require very little maintenance. disc is always presented to the flow, low temp and pressure.
even when fully opened.

Throttle: They have the capability to

throttle flow.

Installation: They can be installed or

removed without pipe system
dislocation
 Non-Return / Check Valve:
 Check Valves are also known as Non Return Valve (NRV). They allow liquid to flow in one direction only
and prevents back flow of media in the reverse direction. The purpose of check valves is to prevent
process flow from reversing in the system which could damage equipment or upset the process.

Advantages Disadvantages Applications

Back Flow: Check valves prevent Pulsating Systems: They cannot be Check valves are used in a variety of
backflow used with pulsating systems markets and applications as they
contain simple design and versatile
material options.

Pressure: They can sustain pressure Damage: Closing element may crash They help to prevent backflow and
causing damage and excessive wear maintain pressure.

Backup: Check valves serve as Check valves can be seen in industries

backup system such as refining, petrochemical,
chemical, etc

They are also commonly found in

waste-water management systems
and in manufacturing
 Safety Valve
 A safety valve is a valve that acts as a fail-safe. An example of safety valve is a pressure relief
valve (PRV), which automatically releases a substance from a boiler, pressure vessel, or other system,
when the pressure or temperature exceeds preset limits. Pilot-operated relief valves are a specialized
type of pressure safety valve. A leak tight, lower cost, single emergency use option would be
a rupture disk.

Advantages Disadvantages Application

Reliable: Most reliable type if
properly sized and operated
Pressure: Relieving pressure
affected by back pressure
Safety valves should be installed
wherever the maximum allowable
working pressure (MAWP) of a
system or pressure-containing
vessel is likely to be exceeded.

Versatile: can be used in many Back Pressure: Susceptible to safety valves are also used in
services chatter if built-up back pressure is process operations to prevent
too high product damage due to excess
pressure
 Needle Valve:
 A needle valve is a type of valve with a small port and a threaded,
needle-shaped plunger. It allows precise regulation of flow, although it is
generally only capable of relatively low flow rates.

Advantages Disadvantages Application

Flow Rate : Need valves usually
allows very good flowrate.
Clogging: Needle valve has a
higher risk of clogging because of
entrained solids.
Needle valves are usually used in
flow-metering applications,
especially when a constant,
calibrated, low flow rate must be
maintained for some time, such
as the idle fuel flow in a
carburetor.

Pressure Rating: Needle valve

comes in high pressure rating also
so there is a lot of variety
Pipes
What are pipes…

 A pipe is a tubular section or hollow cylinder, usually but not

necessarily of circular cross-section, used mainly to convey
substances which can flow — liquids and gases (fluids), slurries,
powders and masses of small solids. It can also be used for structural
applications; hollow pipe is far stiffer per unit weight than solid
members.
 Pipe is made out of many materials such as metals , plastic ,
ceramic , concrete , fiber glass etc. In oil & gas sector usually steel
pipes are used and most common of them are MS (Mild steel) , CS
(Carbon Steel) , SS (Stainless Steel).
What are MS , CS & SS…
 Mild Steel (MS):
Mild steel (iron containing a small percentage of carbon, strong and tough but not readily
tempered), also known as plain-carbon steel and low-carbon steel, is now the most common form of steel
because its price is relatively low while it provides material properties that are acceptable for many
applications. Mild steel contains approximately 0.05–0.30% carbon making it malleable and ductile. Mild
steel has a relatively low tensile strength, but it is cheap and easy to form; surface hardness can be
increased through carburizing. In applications where large cross-sections are used to minimize deflection,
failure by yield is not a risk so low-carbon steels are the best choice, for example as structural steel. The
density of mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3) and the Young's modulus is
200 GPa (29,000 ksi).

 Carbon Steel (CS):

Carbon steel is differentiated from mild steel on the basis of amount of carbon . Mild Steel have small
amount of carbon as discussed above usually up to 0.3%. Carbon steel has more carbon i.e up to 2& and
this allows it to be hardened an tempered. Hardness increases as carbon content increases. Normally mild
steel are forged and fabricated into steel plates, while carbon steel are made into pulleys and drive shafts.

 Stainless Steel (SS):

In metallurgy, stainless steel, also known as inox steel or inox from French inoxydable (inoxidizable), is
a steel alloy, with a minimum of 11% chromium content by mass and a maximum of 1.2% carbon by mass.
Stainless steels are most notable for their corrosion resistance, which increases with increasing chromium
content. Additions of molybdenum increases corrosion resistance in reducing acids and against pitting
attack in chloride solutions.
Pipe Tests
Once a pipe or system of pipes are installed there need to be some test
performed for maintenance purpose . Intensity of test depend upon the
environment in which pipeline is installed. Usually following tests are
performed in oil & gas sector.
 Hydraulic Test
 Ultrasonic Test
 Liquid Penetration Control
 Magnetic Particle Control
 Radiographic test
 Destructive Examinations
 Contact-less Inspection
Hydraulic test
A Hydraulic/Hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas
cylinders, boilers and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or
pipe system with a liquid, usually water, which may be dyed to aid in visual leak detection, and
pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the
supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified
more easily if the water contains a colorant
Dimensional Test
Dimension inspection of the pipe is carried out based on the Dimension Standard, final dimension of the
pipe must confirm the following standard or it should be as specified in purchaser’s specification.
 For Welded and Seamless Wrought Steel Pipe dimensional requirements are cover in ASME B36.10
 For Stainless Steel Pipe dimensional requirements are cover in ASME B36.19
During dimensional inspection, following to be confirmed with standard
 Diameter
 Length
 Thickness
 Straightness
 Ovality
 Weight
Ultrasonic Inspection
Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation
of ultrasonic waves in the object or material tested. In most common UT applications, very short ultrasonic
pulse-waves with center frequencies ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are
transmitted into materials to detect internal flaws or to characterize materials. A common example
is ultrasonic thickness measurement, which tests the thickness of the test object, for example, to monitor
pipework corrosion.
Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be used
on concrete, wood and composites, albeit with less resolution. It is used in many industries including steel
and aluminum construction, metallurgy, manufacturing, aerospace, automotive and
other transportation sectors.
Liquid Penetration Control
Dye penetrant inspection (DP), also called liquid penetrate inspection (LPI) or penetrant testing (PT), is a
widely applied and low-cost inspection method used to check surface-breaking defects in all non-
porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-ferrous materials
and ferrous materials, although for ferrous components magnetic-particle inspection is often used instead
for its subsurface detection capability. LPI is used to detect casting, forging and welding surface defects
such as hairline cracks, surface porosity, leaks in new products, and fatigue cracks on in-service
components.
Magnetic Particle Control:
Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and
shallow subsurface discontinuities in ferromagnetic materials such as iron, nickel, cobalt, and some of
their alloys. The process puts a magnetic field into the part. The piece can be magnetized by direct or
indirect magnetization. Direct magnetization occurs when the electric current is passed through the test
object and a magnetic field is formed in the material. Indirect magnetization occurs when no electric
current is passed through the test object, but a magnetic field is applied from an outside source. The
magnetic lines of force are perpendicular to the direction of the electric current, which may be
either alternating current (AC) or some form of direct current (DC) (rectified AC).
Radiographic Inspection:
Radiographic Testing (RT) is a nondestructive examination (NDE) technique that involves the use of either
x-rays or gamma rays to view the internal structure of a component. In the petrochemical industry, RT is
often used to inspect machinery, such as pressure vessels and valves, to detect for flaws. RT is also used
to inspect weld repairs.
Destructive Testing
The mechanical / Destructive test type of pipe inspection confirms the mechanical requirements of pipe
are as per the material standard. In Destructive Testing- a sample from the pipe is cut to performed tests
 The tensile test is done to check yield and ultimate tensile of the pipe. If required by the purchaser or by
standard high or low-temperature tensile test are also performed.
 Bend test / Guided bend test are used to check integrity of weld joint
 Flattening test examines ability of plastic deformation in pipe
 Impact test / Charpy V-Notch Test, check the ability of material to withstand under low-temperature
conditions
 Creep test is done to check long term effect of temperature under constant load.
Contactless Inspection
Contactless inspection is usually carried out for buried pipes and are of two types
 For outer inspection of pipe - Magnetic Field Inspection
 For Inner Inspection of pipe – Pigging
Fittings & Gaskets
What are fittings…
A fitting or adapter is used in pipe systems to connect straight sections of pipe or tube, adapt to different
sizes or shapes, and for other purposes such as regulating (or measuring) fluid flow. These fittings are used
in plumbing to manipulate the conveyance of water, gas, or liquid waste in domestic or commercial
environments, within a system of pipes or tubes.
Most common types of fittings usually used are
 Reducer
 Adapter
 Tee
 Bend
 Elbow
Reducer
A pipe reducer changes the size of the pipe. There are two types of reducer used in piping Concentric &
Eccentric.
 Concentric Pipe Reducer or Conical Reducer
In Concentric reducer which is also known as a conical reducer, the center of both the ends is on the same
axis. It maintains the centerline elevation of the pipeline. When the center lines of the larger pipe and
smaller pipe are to be maintained same, then concentric reducers are used.
 Eccentric Reducer
In Eccentric reducer, the center of both the ends is on different axis as shown in the image. It maintains
BOP (bottom of pipe) elevation of the pipeline. When one of the outside surfaces of the pipeline is to be
maintained same, eccentric reducers are required.
Tee
Pipe Tee is a type of pipe fitting which is T-shaped having two outlets, at 90° to the connection to the main
line. It is a short piece of pipe with a lateral outlet. Pipe Tee is used to connect pipelines with a pipe at a
right angle with the line. Pipe Tees are widely used as pipe fittings. They are made of various materials and
available in various sizes and finishes.
Applicable Standards
· ASME B 16.9 for large bore
· ASME B 16.11 for small bore
Bend
Long radius pipeline bends are used in fluid transportation line which required pigging. Due to their long
radius and smooth change of direction, pipe bend has very less pressure drop, and smooth flow of fluid &
pig is possible. 3D and 5D Pipe bends are commonly available. Here, D is the pipe size.
There are generally two types of bend

 Miter Bend
Miter bends are not standard pipe fittings they are fabricated from pipes. Usually, they are preferred for size
10” & above because large size elbow is expensive. Use of miter bend is restricted to the low-pressure
water line. Miter bend can be fabricated in 2, 3, & 5 pieces.

 Returns – 180 Degree Elbow

Returning elbows are used to make a 180º change in direction. Available in short & long pattern. Returns
are used in the heating coil, heat exchanger, tank vent etc.
Elbow
The Elbow is used more than any other pipe fittings. It Provides flexibility to change the pipe direction. Elbow
mainly available in two standard types 90° and 45°. However, it Can be cut to any other degree. Elbows
are available in two radius types, Short radius (1D) and Long radius (1.5D). Elbows are usually of following
types

 90 Degree Elbow Pipe

90 Degree elbow is installed between the pipe to change the direction of the pipe by 90 Degree.
Available in long and short radius form.

 45 Degree Elbow
45 Degree elbow is installed between the pipe to change the direction of the pipe by 45 Degree.

 Long Radius Elbow

In long radius elbow, centerline radius is 1.5 times the nominal size of the pipe or you can say 1.5 times the
diameter of the pipe. Normally long radius elbows are used in piping as pressure loss is less as compared to
short radius elbow. It required more space than short radius elbow.

 Short Radius Elbow

In short radius elbow, centerline radius is same as the nominal size of the pipe or you can say one
times the diameter of the pipe. Short radius elbows are used under limited space application.
However, it has a high-pressure drop due to a sudden change in the direction of flow.
Gaskets
A gasket is a mechanical seal which fills the space between two or more mating surfaces, generally to
prevent leakage from or into the joined objects while under compression. Gaskets allow for "less-than-
perfect" mating surfaces on machine parts where they can fill irregularities. Gaskets are commonly
produced by cutting from sheet material
Gaskets usually are of Rubber , Non-Asbestos , Cork Material
The most common types of gaskets are:
 Gaskets used in piping (flange gaskets)
 Gaskets used in vehicles (cars, boats, planes, trains)
 Gaskets with certain material properties (cork, rubber paper etc.)
 Gaskets used for a particular function (for pressure, temperature, or chemical resistance)
 Bespoke or custom made gaskets
Flanges
What are flanges…
A flange is an external or internal ridge, or rim (lip), for strength, as the flange of an iron beam such as an I-
beam or a T-beam; or for attachment to another object, as the flange on the end of a pipe, steam
cylinder, etc., or on the lens mount of a camera; or for a flange of a rail car or tram wheel. Thus flanged
wheels are wheels with a flange on one side to keep the wheels from running off the rails. The term "flange"
is also used for a kind of tool used to form flanges. Pipes with flanges can be assembled and disassembled
easily.
There are many different flange standards to be found worldwide. To allow easy functionality and
interchangeability, these are designed to have standardized dimensions. Common world standards
include ASA/ASME (USA), PN/DIN (European), BS10 (British/Australian), and JIS/KS (Japanese/Korean). In the
USA, ANSI stopped publishing B16.5 in 1996, and the standard is ASME B16.5.
Types of flanges commonly used are
 Weld neck
 Slip-on
 Socket weld
 Lap joint
 Threaded & Blind
 Weldo / Nippo
 Elbow
 Orifice
Weld Neck Flange
A welding neck flange (“WN”)features a long tapered hub that can be welded with a pipe. This
flange type is used, normally, in high-pressure and high/low temperatures applications that require
an unrestricted flow of the fluid conveyed by the piping system (the bore of the flange matches
with the bore of the pipe). The absence of pressure drops prevents negative effects as turbulence
and erosion/corrosion of the metals in the proximity of the flanged joints.
The tapered hub allows a smooth distribution of the mechanical stress between the pipe and the
weld neck flange and facilitates the execution of radiographic inspections to detect possible
leakages and welding defects. The dimension of the flange (NPS and the pipe schedule) shall
match the dimension of the connecting pipe. A welding neck flange is connected to a pipe by a
single full penetration V-shaped butt weld. The dimension and weights of ASME weld neck
flanges are shown in this article.
Slip-on Flange
A slip-on flange is connected to the pipe or the fittings by two fillet welds, one executed inside and one
outside the cavity of the flange. The bore size of a slip-on flange is larger than the outside diameter of the
connecting pipe, as the pipe has to slide inside the flange to be connected by the execution of a fillet
weld. Slip-on flanges are also defined “Hubbed Flanges” and they are easy to recognize due to their slim
and compact shape.
Socket Weld Flange
Socket weld flanges are connected to pipes using a single fillet weld executed on the outer side of the
flange (different from the slip-on flange type that requires two welds). According to ASME B31.1, to
execute a flanged connection using a socket weld flange, the pipe shall be at first inserted in the socket
of the flange until it reaches the bottom of the flange, then it should be lifted by 1.6 mm and finally
welded.
This gap shall be left to allow proper positioning of the pipe inside the flange socket after the solidification
of the weld. Socket Weld Flanges are used for small-size and high-pressure piping that do not transfer
highly corrosive fluids. This due to the fact that these flange types are subject to corrosion in the gap area
between the end of the pipe and the shoulder of the socket. Their static strength of socket weld flanges is
similar to slip-on flanges’, but their fatigue strength is higher due to the presence of a single, instead of
double, fillet weld.
Lap joint Flange
Lap joint flanges feature a flat face and are always used in conjunction with a stub end. Lap joint flanges
resemble, in shape, slip-on flanges except for the radius at the crossing of the flange face and the bore to
accommodate the flanged portion of the stub end.
A lap joint flange slips over the pipe and seats on the back of the stub end and the two are kept together
by the pressure of the bolts. The use of lap joint flanges in combination with stub ends is a cost-effective
solution for stainless steel or nickel alloy pipelines, as the material of the lap joint flange can be of a lower
grade (generally carbon steel) than the material of the stub end (which has to match the pipe grade, as in
contact with the conveyed fluid).
Threaded & Blind Flange
Threaded flanges are joined to pipes by screwing the pipe (which has a male thread, generally NPT
per ASME B1.20.1) onto the flange, without seam welds (in certain cases, though, small welds are applied
to increase the strength of the connection).
Threaded flanges are available in sizes up to 4 inches and multiple pressure ratings, however, they are
used, mostly, small size piping in low pressure and low-temperature applications, like water and air utility
services. Threaded flanges are also a mandatory requirement in explosive areas, such as gas stations and
plants, as the execution of welded connections in such environments would be dangerous.
Blind Flanges do not have a center hole, and are used to blind or seal a pipeline, a valve/pressure vessel
and block the flow of the fluid. Blind flanges have to withstand remarkable mechanical stress due to the
system pressure and the required bolting forces. Blind flanges allow easy access to the pipeline, as they
can be easily unbolted to let the operator execute activities inside the terminal end of the pipe (this is also
the reason why the blind flange type is used as manhole for pressure vessels, at times).
Nippo & Weldo Flange
A Nipoflange is used for branch pipelines at 90 degrees and is a product manufactured by combining a
welding neck flange with a forged Nipolet. However, a Nipoflange is a solid single piece of forged steel
and not two different products welded together. To install a Nipoflange, the piping staff has to weld the
Nipolet part of the device on the run pipe and bolt the flanged part on the flange of the branched pipe.
Nipoflanges are available in different materials, such as carbon steel ASTM A105 (high-temperature
service), ASTM A350 (low-temperature carbon steel), ASTM A182 (stainless steel grades, including duplex
and super duplex) and nickel alloys (Inconel, Incoloy, Hastelloy, etc). Nipoflanges are also manufactured in
the reinforced variant, which has additional mechanical strength compared to a standard Nipoflange.
Weldoflange is conceptually similar to a Nipoflange, as that they are a combination of a weld neck flange
and a branch fitting connection (a Weldolet in this case). Weldoflanges are made out of a single piece of
solid forged steel, not by welding separate parts together.
ElboFlange
Other less common types of flange Olets is the so-called Elboflange (a combination of a flange and an
Elbolet) and “Latroflange” (combination of a flange with a Latrolet). Elboflanges are used to branch a
pipeline at 45 degrees.
Orifice Flange
An orifice flange is used to measure the flow of the fluid conveyed by the pipeline via a flow nozzle
positioned on the flange itself. Pairs of pressure tappings are machined onto the orifice flange, making
separate tappings on the pipe wall unnecessary. The traditional orifice flange assembly consists of a pair of
flanges, orifice plate, bolts, nuts, gaskets, jacking screws and plugs. Jacking screws ensure the easy
removal of the primary flow element.
The End