valve & piping

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INSTUTE TECHNOLOGY PETROLEUM PETRONASINSTUTE TECHNOLOGY PETROLEUM PETRONASPETRONAS MANAGEMENT TRAINING SDN BHD

VALVE VALVE && PIPINGPIPING

PART B

PIPINGPIPING

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Part AIntroductionPiping materials:

Metallic & Non-metallicMetallic piping manufacturing processPipes specification:

Pipe size :Dimensions & Schedule NumbersPipe fittings:

Types & functions of fittingsPipe connections:

Threading, welding, flangesGasketPiping symbols & drawingHydrostatic testing

VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGContentsContents

Piping coating & insulationPipe Supports & restraintsMaintenance of piping system

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGIntroductionIntroduction

Piping constitutes the major expenditure of all the design disciplines in a refining or petrochemical plant.Piping consumes:-

50% of the design engineering man-hours35% of the materials cost30% of the labour cost

Term PIPING is not only the pipes but including all fittings, flanges, valves, gauges and other items which form part of the overall piping system.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGIntroduction Introduction ……. cont. cont’’

Is a long tube with round cross section used for conveying fluid from one location to another.Can be classified generally under 3 broad groups:

Process (between processing unit)Services (support/utility services)Transportation (from one location/station to another)

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGFluidFluid

Is any substances like a liquid and gas that flow. e.g.: water, steam, oil, air etc.

ANYTHING THAT FLOW – FLUIDS

Fluid travel through a system at various:-TemperaturePressureSpeed

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping MaterialsMaterials

Not Contain IronBrass (Cu + Zn)Bronze (Cu + Tn)Aluminum

PIPING MATERIAL

Non-Metallic Metallic

Non-Ferrous FerrousClayRubberGlassCeramicPVCBamboo

# Civil work

Contain IronCarbon SteelStainless Steel

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials ……. cont. cont’’

Pipe materials are divided into 2 categories:-Non-Metallic materials.

Materials other than metal and include natural substances such as wood and manufactured or synthetic substances such as plastics.

Metallic materials :-Ferrous metals.

Main constituent of the metals is iron. e.g. wrought iron, cast iron and steel.

Non-Ferrous metals.Not contain iron as a main constituent.

Weaker than ferrous metals but have other important properties such as corrosion resistance and high electrical conductivity.

e.g. copper, aluminum, zinc, tin, lead and their alloys.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– Non MetallicNon Metallic

e.g. Glass, clay, wood, bamboo, ceramic, rubber, plastic, etc.

Plastic pipe materialsPlastic pipe materials

Polyvinyl Chloride (PVC) - 1st plastic produces in 1838 by Victor Regnau.UPVC – unplasticised, higher strength & stiffness 65°C.Chlorinated polyvinyl Chloride (CPVC)

Increase operating temp. up to 93°CPolypropylene (PP).Polyethylene (PE) – cannot exposed, underground pipe.Polybutylene (PB).Fluoroplastics (PTFE) – excellent resistance to chemical & solvents.Reinforced Thermosetting Resin (RTHP) or Fiber Glass

Corrosive products.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– Ferrous Metals (contain Iron)Ferrous Metals (contain Iron)

Wrought IronWrought Iron

Iron that has had most of the carbon removed.Tough and bends easily whether it is cold or heated.Rust very slowly and is readily welded.Used in ornamental ironwork, furnace stacks and oil pipelines.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– Ferrous Metals (contain Iron) Ferrous Metals (contain Iron) ……. cont. cont’’

Plain Carbon SteelsPlain Carbon Steels

Steel is an alloy of iron and carbon or some other alloying elements.Carbon steel are classified by the % of carbon in "point" or hundredths of 1% they contain.Low Carbon Steels contain < 0.3% carbon.

Easy to work, can be welded, but cannot be hardened.Available as black iron sheet, bars and rods.

Medium Carbon Steels contain 0.3 to 0.6% carbon.Hammer heads, clamps, etc.

High Carbon Steels contains 0.6 to 1.5% carbon.Many products that must be heat treated are manufactured from HCS.

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Alloy SteelsAlloy Steels

Plain carbon steels to which other metals (alloying elements) have been added in sufficient quantities to materially alter the properties of the steel.Most common alloying elements added to steel:-

Nickel – to refine the grain and strengthen the steel. Nickel steel does not rust easily.Chromium – to improve the response of the steel to heat treatment and corrosion resistance of the steel.

Basis of stainless steel and extensively used for automobile and aircraft parts.

Molybdenum – reduces temper brittleness and enables operate continuously at high temperatures without becoming brittle.Manganese – purifies steel and adds strength and toughness.

Used for parts that must stand shock and hard wear such as bulldozer and plough blades.

Tungsten – added in the proper amount makes steel self-hardening.Used extensively for making cutting tools.

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Tool SteelsTool Steels

Contain either a high % of carbon or a high alloy contain or a combination of both.Tough and made into tools that must hold a cutting edge.High carbon steels rapidly lose their hardness at cutting temperatures > 250°C which makes them unsuitable for use at high cutting speeds.

Good hardness at lower temperatures combines with strength and toughnessUseful cutting materials for applications where high cutting speeds are not required.

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High Speed Steels (HSS)High Speed Steels (HSS)

Name given to a range of alloy steels which have been developed as cutting tool materials capable of operating at high cutting speeds.Various alloying elements, such as tungsten and vanadium.

Used in high speeds steel make it more expensive material than high carbon steel but having greatly improved properties of red hardness.

HSS is generally less hard than HCS at room temperature but has the ability to retain a high proportion of its hardness at temperature would cause softening and breakdown of the cutting edge of HCS tools.

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Cast Irons (CI)Cast Irons (CI)

Produced by remelting crude pig iron with certain adjustments to its composition (removing impurities, reducing the carbon content and improving the fluidity of the iron) while in the molten state.Widely used for cast components which are not required to withstand impact or shock loads.Advantages over steel as a casting metal:-

Lower melting temperatures (CI !1200°C & Steel !1380°C).High fluidity and low shrinkage on cooling, enabling intricate shapes to be cast with high definition and accuracy.

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Cast Irons (C I) Cast Irons (C I) ……. cont. cont’’

Advantages …. cont’Contains free graphite which acts as a lubricant to reduce friction between sliding surfaces

Suitable as a material for machine tool slide ways.Ability to damp down vibrations occurring in running machinery (undamped vibration in a machine tool can result in poor surface finish on the work piece).Once the hard skin of the casting has been removed, it easy to machine and finish with hand tools such as files and scrapers.

Better corrosion resistance than steel.Because pig iron is cheap, CI is an inexpensive material.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– NonNon--Ferrous MetalsFerrous Metals

Not containing iron such as copper, lead, zinc, aluminum, tin, brass and bronze.Precious metal such as gold, platinum and silver and radioactive metals such as uranium and radium.

In the pure state, it is softer and much weaker than steel.Used in engineering for their high values of other properties such as electrical conductivity and corrosion resistance.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– NonNon--Ferrous Metals Ferrous Metals ……. cont. cont’’

LeadLead

Lead is a soft, malleable metal of very high density.Low strength but possesses high resistance to corrosion and good conductor of heat and electricity.Surface is usually covered by an oxide film giving a dull grey appearance, but a newly cut surface appears bright blue-silver.Easy to cut, cast, cold work and extrude.Typical uses :- extruded piping, cable, sheathing, linings for chemical vessels, roof and weather protection, balance weight, radiation shielding for x-ray equipment and nuclear plant, low strength die castings such as battery plates and terminals.

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TinTin

Expensive metal and used mainly as an alloying element or for coating steel sheet.Pure metal is soft, malleable and ductile but has low strength. Good conductor of heat and electricity and has excellent corrosion resistance.Silver-white in appearance and produces a smooth, shinny finish when used as a coating in the hot-dip process.Easy to cut, cast and cold work.

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Tin Tin ……. cont. cont’’

Typical uses :-, food industry for coating cans and for tin-based die-casting fittings because tin is non-toxic.

Low melting temperature and alloyed with lead to form soft solders.White-metal tin-based bearing alloys are more expensive than lead-based but widely used in the aircraft and automobile industries for high-performance bearings.

Tin is alloyed with copper to produce bronze bearing and corrosion-resistant valves and fittings.

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ZincZinc

Soft, weak metal having low ductility but possesses high resistance to corrosion.Used mainly as an alloying element, die-casting alloy or as protective coating on steel sheet.Silver appearance with blue-green sheen.Fracture of cast zinc reveals a very large crystal size.Low melting point and easily cast and bent or hammered to shape.Typical uses :- used to provide a corrosion-resistance protective coating for steel and may be applied by hot-dip galvanizing, electro galvanizing or metal spraying techniques.Zinc is alloyed with copper to give wrought and casting brasses for bearings and corrosion-resistance parts.

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CopperCopper

Most important and widely used in engineering.In pure form it has moderate strength and low hardness but excellent properties of ductility and corrosion resistance.Excellent conductor of heat and electrical and is widely used.Surface is usually covered by an oxide film giving a reddish- brown appearance but newly cut surface will appear reddish-pink.Important alloying element and used as the base metal with zinc to form brasses and with tin to form bronzes.

Both these alloys retain the corrosion-resisting properties of copper.

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Copper Copper ……. cont. cont’’

Rapidly hardens when cold worked but can be softened by annealing.Easy metal joint by soldering, brazing and welding.Typical uses :- electrical and telephone cable, radio and television equipment, bus bars, switchgear, washers and gasket, water pipes and fittings, soldering iron bits, wire, sheet, domestic boilers, cooking vessels and pans, roofing, gas tubing, radiators, chemical plate and marine parts.

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AluminumAluminum

Soft, ductile metal of very low density.In pure state, the metal is too weak and soft for most engineering applications but its strength and hardness are greatly increased when alloyed with small amounts of copper and other metals.High resistance to corrosion and excellent conductor of heat and electricity.Covered by a thin oxide film giving a light grey appearance but newly cut surface appears polished silver.

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Aluminum Aluminum ……. cont. cont’’

Can be cast and hot or cold worked, easy to machine and can be cut at high cutting speeds to give a fine polished finish.Typical uses :- a few engineering uses of pure aluminum because of its low strength and hardness.

Useful as a cladding to protect other metals.Commercially pure aluminum (99%) is used to produce wrapping or reflective foil, decorative parts, kitchen utensils and low-stressed sheet metal parts.

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Materials Materials –– Metallic Pipe Manufacturing MethodsMetallic Pipe Manufacturing Methods

Wrought Seamless PipeForged Seamless PipeWelded Pipe

Butt Welded PipeLap Welded PipeElectric Fusion Welded Pipe (EFW)Electric Resistance Welded Pipe (ERW)Spiral Welded Pipe

Cast Pipe

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping SpecificationSpecification

SpecificationSpecification

Earlier Designation:Standard (Std)Extra Strong (XS)Double Extra Strong (XXS)

Now - ANSI B36.10Nominal Pipe Size (NPS)Schedule Number (Sch. No.)

Sch. No. 5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160.

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PIPES & VALVESPIPES & VALVESPiping Materials Piping Materials ––MetallicMetallicPipe Specification Pipe Specification ……. cont. cont’’

PIPE SIZE AND PRESSURE RATING

371316260-29 to 204

1 6072 6623 7175 310

1 6832 7863 8965 666

1 8413 0484 2626 090

1 9453 2274 5516 448

596.500590.550584.200574.650

6.3509.52517.70017.475

1020-

40

-sx-

609.624 in

2 1493 5594 9799 972

2 2483 7315 22110 455

2 4624 0765 67511 366

2 6004 3106 041

12 096

444.500438.150431.800409.550

6.3509.52512.70023.825

10--

80

-sx-

457.218 in

5 0347 08218 49021 028

5 2837 42719 39322 048

5 7728 11721 18624 090

6 1108 58622 41425 462

304.800298.450273.050257.200

9.52512.70025.40033.325

4080-

160

sxxx-

323.8512 in

6 85511 73121 38626 510

7 18612 29622 42027 793

7 85513 43424 49630 365

8 31014 22025 92432 131

154.051146.329131.749124.384

7.11210.97318.23721.949

4080-

160

sxxx-

168.2756 in

11 96514 73114 731

12 54420 68920 689

13 71022 60022600

14 50323 91723 917

26.64524.30824.308

3.3784.5474.547

4080-

sxxx

33.4011 in

WORKING PRESSURE IN kPa for OC TEMPERATURE

INSIDE DIAMETER

mm

WALL THICKNESSWEIGHT SCHEDULE

mm

PIPE SIZE OUTSIDE

DIAMETER mm

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48------0.500--0.7500.375-0.625-0.312--40.00048.0004846------0.500--0.7500.375-0.625-0.312--46.00046.0004644------0.500--0.7500.375-0.625-0.312--44.00044.0004442------0.500--0.7500.375-0.625-0.312--42.00042.0004240------0.500--0.7500.375-0.625-0.312--40.00040.0004038------0.500--0.7500.375-0.625-0.312--38.00038.0003836------0.500--0.7500.375-0.6250.5000.312--36.00036.0003634------0.500--0.6880.375-0.6250.5000.312--34.00034.0003432------0.500--0.6880.375-0.6250.5000.312--32.00032.0003230------0.500---0.375-0.6250.5000.3120.3120.25030.00030.0003028------0.500---0.375-0.6250.5000.312--28.00028.0002826------0.500---0.375--0.5000.312--26.00026.0002624-2.3442.0621.8121.5311.2190.500-0.9690.6880.375-0.5620.3750.2500.2500.21824.00024.0002422-2.1251.8751.6251.3751.1250.500-0.8750.6250.375-0.5000.3750.2500.2180.18822.00022.0002220-1.9691.7501.5001.2811.0310.500-0.8120.5940.375-0.5000.3750.2500.2180.18820.00020.0002018-1.7811.5621.3751.1560.9380.500-0.7500.5620.375-0.4380.3120.2500.1880.16518.00018.0001816-1.5941.4381.2191.0310.8440.500-0.6560.5000.375-0.3750.3120.2500.1880.16516.00016.0001614-1.4061.2501.0940.9380.7500.500-0.5940.4380.375-0.3750.3120.2500.1880.15614.00014.00014121.0001.3121.1251.0000.8440.6880.5000.5000.5620.4060.3750.3750.3300.250-0.1800.15612.53912.75012101.0001.1251.0000.8440.7190.5940.5000.5000.5000.3650.3650.3650.3070.250-0.1650.13410.52810.7501080.8750.9060.8120.7190.5940.5000.5000.5000.4060.3220.3220.3220.2770.250-0.1480.1098.5168.625860.8640.719-0.562-0.4320.4320.432-0.2800.2800.280---0.1340.1096.5046.625650.7500.625-0.500-0.3750.3750.375-0.2580.2580.258---0.1340.1095.5045.563540.6740.531-0.438-0.3370.3370.337-0.2370.2370.237---0.1200.0834.5004.5004

3 1/2-0.500---0.3180.3180.318-0.2260.2260.226---0.1200.0834.0004.0003 1/230.6000.438---0.3000.3000.300-0.2160.2160.216---0.1200.0833.5083.5003

2 1/20.5520.375---0.2760.2760.276-0.2030.2030.203---0.1200.0833.0042.8752 1/220.4360.344---0.2180.2180.218-0.1540.1540.154---0.1090.0652.3822.3752

1 1/20.4000.281---0.2000.2000.200-0.1450.1450.145---0.1090.0651.9131.9001 1/21 1/40.3820.250---0.1910.1910.191-0.1400.1400.140---0.1090.0651.6811.6601 1/4

10.3580.250---0.1790.1790.179-0.1330.1330.133---0.1090.0651.3391.31513/40.3080.219---0.1540.1540.154-0.1130.1130.113---0.0830.0651.0711.0503/41/20.2940.188---0.1470.1470.147-0.1090.1090.109---0.0830.0650.8540.8401/2

XXSSch.160

Sch.140

Sch.120

Sch.100

Sch.80

XSSch.80S

Sch.60

Sch.40

STDSch.40S

Sch.30

Sch.20

Sch.10

Sch.10S

Sch.5 S

JISANSINom ina lPipe Size

Nominal Wall ThicknessOutside DiameterNomina lPipe Size

Standard Wall Thickness All Dimension in InchesCARBON, ALLOY AND STAINLESS STEEL

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Standard Wall Thickness All Dimension in MIllimetersCARBON, ALLOY AND STAINLESS STEEL

48------12.7--19.09.5-15.9-7.9--1219.21219.24846------12.7--19.09.5-15.9-7.9--1168.41168.44644------12.7--19.09.5-15.9-7.9--1117.61117.64442------12.7--19.09.5-15.9-7.9--1066.81066.84240------12.7--19.09.5-15.9-7.9--1016.01016.04038------12.7--19.09.5-15.9-7.9--965.2965.23836------12.7--19.09.5-15.912.77.9--914.4914.43634------12.7--17.59.5-15.912.77.9--863.6863.63432------12.7--17.59.5-15.912.77.9--812.8812.83230------12.7---9.5-15.912.77.97.96.4762.0762.03028------12.7---9.5-15.912.77.9--711.2711.22826------12.7---9.5--12.77.9--660.4660.42624-59.552.446.038.931.012.7-24.617.59.5-14.39.56.46.45.5609.6609.62422-54.047.641.334.928.612.7-22.215.99.5-12.79.56.45.54.8558.855.92220-50.044.438.132.526.212.7-20.615.19.5-12.79.56.45.54.8508.0508.02018-45.239.734.929.423.812.7-19.014.39.5-11.17.96.44.84.2457.2457.21816-40.536.531.026.221.412.7-16.712.79.5-9.57.96.44.84.2406.4406.41614-35.731.827.823.819.012.7-15.111.19.5-9.57.96.44.84.0355.6355.6141225.433.328.625.421.417.512.712.714.310.39.59.58.46.4-4.64.0318.5323.8121025.428.625.421.418.315.112.712.712.79.39.39.37.86.4-4.23.4267.4273.010822.223.020.618.315.112.712.712.710.38.28.28.27.06.4-3.82.8216.3219.18621.918.3-14.3-11.011.011.0-7.17.17.1---3.42.8165.2168.36519.015.9-12.7-9.59.59.5-6.66.66.6---3.42.8139.8141.35417.113.5-11.1-8.68.68.6-6.06.06.0---3.02.1114.3114.34

3 1/2-12.7---8.18.18.1-5.75.75.7---3.02.1101.6101.63 1/2315.211.1---7.67.67.6-5.55.55.5---3.02.189.188.93

2 1/214.09.5---7.07.07.0-5.25.25.2---3.02.176.373.02 1/2211.18.7---5.55.55.5-3.93.93.9---2.81.760.560.32

1 1/210.27.1---5.15.15.1-3.73.73.7---2.81.748.648.31 1/21 1/49.76.4---4.94.94.9-3.63.63.6---2.81.742.742.21 1/4

19.16.4---4.54.54.5-3.43.43.4---2.81.734.033.413/47.85.6---3.93.93.9-2.92.92.9---2.11.727.226.73/41/27.54.8---3.73.73.7-2.82.82.8---2.11.721.721.31/2

XXSSch.160

Sch.140

Sch.120

Sch.100

Sch.80

XSSch.80S

Sch.60

Sch.40

STDSch.40S

Sch.30

Sch.20

Sch.10

Sch.10S

Sch.5 S

JISANSINominalPipe Size

Nominal Wall ThicknessOutside DiameterNominalPipe Size

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VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGPipingPiping Specification Specification ……. cont. cont’’

Schedule Number (SCH NO)Schedule Number (SCH NO)

Sch. No . + 1000 times the Pressure/Stress Ratio

Sch. No. = 1000 x PS

where P = internal pressure (psi)S = allowable fiber stress (psi)

ANSI = American National Standard InstituteASTM = American Society for Testing MaterialsAPI = American Petroleum Institute

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Pipe SizingPipe Sizing

Outside Diameter (OD) – constant Inside Diameter (ID) – varies, depend on Sch. No

NPS < 12" - Nominal Bore (NB)NPS > 14" - Outside Diameter (OD)


Sch No Wall Thickness ID OD

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Pipe Sizing Pipe Sizing ……. cont. cont’’


Schedule No Inside Diameter

NPS 4 Sch. 40 NPS 4 Sch. 80

OD=4.50"

0.337"0.237"

ID = 3.826"ID = 4.026"

ID = OD - 2 (wall thickness)

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Steel PipeSteel Pipe

ANSI B36.10 Welded and seamless wrought-steel pipeANSI/ASTM A 53 Welded and seamless steel pipeANSI/ASTM A 106 Seamless carbon steel pipe for high-temperature serviceANSI/ASTM A 120 Black and hot-dipped zinc-coated (galvanized) welded

and seamless steel pipe for ordinary usesANSI/ASTM A 134 Electric-fusion (arc)-welded steel-plate pipe

(sizes 16" and over)ANSI/ASTM A 135 Electric-resistance-welded steel pipeANSI/ASTM A 139 Electric-fusion (arc)-welded steel pipe (sizes 4" and

over)ANSI/ASTM A 155 Electric-fusion-welded steel pipe for high- pressure

serviceANSI/ASTM A 211 Spiral-welded steel or iron pipeANSI/ASTM A 381 Metal-arc-welded steel pipe for high-pressure

transmission systems

VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGANSI and API Piping StandardANSI and API Piping Standard

34

Steel Pipe Steel Pipe ……. cont. cont’’

ANSI/ASTM A 524 Seamless carbon steel pipe for processANSI/ASTM A 530 General requirements for specialized carbon and alloy

steel pipeANSI/ASTM A 587 Electric-welded low-carbon steel pipe for the chemical

industryANSI/ASTM A 589 Seamless and welded carbon steel water- well pipeANSI/ASTM A 660 Centrifugally cast carbon steel pipe for high-

temperature serviceANSI/ASTM A 672 Electric-fusion-welded steel pipe for high- pressure

service at moderate temperaturesAPI 5 L Line pipeAPI 5 LS Spiral-weld line pipeAPI 5 LU Ultrahigh test heat-treated line pipeAPI 5 LX High-test line pipe

VALVE AND PIPING VALVE AND PIPING PIPINGPIPINGANSI and API Piping Standard ANSI and API Piping Standard ……. cont. cont’’

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Cast Iron and Ductile Cast Iron and Ductile –– Iron PipeIron Pipe

ANSI A 21.52 Ductile-iron pipe, centrifugally cast, in metal molds or sand-lined molds for gas

ANSI A 40.5 Treated cast-iron pipe for drainage, vent and waste services

ANSI/ASTM A 74 Cast-iron soil pipe and fittingsANSI/ASTM A 142 Cast-iron culvert pipeANSI/ASTM A 716 Ductile-iron culvert pipeANSI/AWWA C 101 Thickness design of cast-iron pipeANSI/AWWA C 150 Thickness design of ductile-iron pipeANSI/AWWA C 106 Cast-iron pipe centrifugally cast in metal molds for

water or other liquidsANSI/AWWA C 108 Cast-iron pipe centrifugally cast in sand- lined molds

for water or other liquidsANSI/AWWA C 112 2" and 2 ¼" cast-iron pipe, centrifugally cast for water

or other liquids


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Cast Iron and Ductile Cast Iron and Ductile –– Iron Pipe Iron Pipe ……. cont. cont’’

ANSI/AWWA C 115 Flanged cast-iron and ductile-iron pipe with threaded flanges

ANSI/AWWA C 151 Ductile-iron pipe, centrifugally cast in metal molds or sand-lined molds for water or other liquids

Steel Pipe For Low Temperature ServiceSteel Pipe For Low Temperature Service

ANSI/ASTM A 333 Seamless and welded steel pipe for low- temperature service

ANSI/ASTM A 671 Electric-fusion welded pipe for atmospheric and lower temperatures


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FerriticFerritic Alloy Piping and TubingAlloy Piping and Tubing

ANSI/ASTM A 268 Seamless and welded ferritic stainless-steel tubing

ANSI/ASTM A 335 Seamless ferritic-alloy steel pipe for high-temperature service

ANSI/ASTM A 369 Ferritic-alloy steel-forged and bored pipe for high-temperature service

ANSI/ASTM A 405 Seamless ferritic-alloy steel pipe specially heat-treated for high-temperature service

ANSI/ASTM A 426 Centrifugally cast ferritic-alloy steel pipe for high temperature service

ANSI/ASTM A 669 Seamless ferritic-austenitic alloy steel tubes


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Nickel and Nickel Alloy Pipe and TubingNickel and Nickel Alloy Pipe and Tubing

ANSI/ASTM B 161 Nickel seamless pipe and tube.ANSI/ASTM B 165 Nickel-copper alloy seamless pipe and tube.ANSI/ASTM B 167 Nickel-chromium-iron alloy seamless pipe and tube.ANSI/ASTM B 407 Nickel-iron-chromium alloy seamless pipe and tube.ANSI/ASTM B 423 Nickel-iron-chromium-molybdenum-copper alloy

seamless pipe and tube.ANSI/ASTM B 444 Nickel-chromium-molybdenum-columbium alloy

seamless pipe and tube.ANSI/ASTM B 445 Nickel-chromium-iron-columbium-molybdenum

tungsten alloy seamless pipe and tube. ANSI/ASTM B 513 Supplementary requirements for nickel- alloy seamless

pipe and tube for nuclear applications.


39

Nickel and Nickel Alloy Pipe and Tubing Nickel and Nickel Alloy Pipe and Tubing ……. cont. cont’’

ANSI/ASTM B 514 Welded nickel-iron-chromium alloy pipe.ANSI/ASTM B 517 Welded nickel-chromium-iron alloy pipe.

Aluminum and Aluminum Pipe and TubingAluminum and Aluminum Pipe and Tubing

ANSI/ASTM B 210 Aluminum-alloy drawn seamless tubes.ANSI/ASTM B 221 Aluminum-alloy extruded bars, rods, wire

shapes and tubes.ANSI/ASTM B 241 Aluminum-alloy seamless pipe and seamless extruded

tubes.ANSI/ASTM B 313 Aluminum-alloy round welded tubes.


40

Aluminum and Aluminum Pipe and Tubing Aluminum and Aluminum Pipe and Tubing ……. cont. cont’’

ANSI/ASTM B 345 Aluminum-alloy seamless extruded tube and seamless pipe for gas and oil transmission and distribution piping systems.

ANSI/ASTM B 483 Aluminum-alloy drawn tubes for general purpose applications.

ANSI/ASTM B 547 Aluminum-alloy formed and arc-welded round tube.

PIPES & VALVESPIPES & VALVESPiping Materials Piping Materials –– MetallicMetallicANSI & API Piping Standards ANSI & API Piping Standards ……. cont. cont’’

41

Copper and Copper Alloy Pipe and TubingCopper and Copper Alloy Pipe and Tubing

ANSI/ASTM B 42 Seamless copper pipe, standard sizes, hard drawn.

ANSI/ASTM B 43 Seamless red brass pipe, standard sizes, annealed.ANSI/ASTM B 68 Seamless copper tube, bright annealed.ANSI/ASTM B 75 Seamless copper tube, annealed or drawn.ANSI/ASTM B 88 Seamless copper water tube.ANSI/ASTM B 135 Seamless brass tube.ANSI/ASTM B 165 Nickel-copper-alloy seamless pipe and tube.ANSI/ASTM B 251 General requirements for wrought seamless copper and

copper-alloy tube.ANSI/ASTM B 280 Seamless copper tube for refrigeration field service.ANSI/ASTM B 302 Threadless copper pipe.ANSI/ASTM B 306 Copper drainage tube (DWV).


42

Copper and Copper Alloy Pipe and Tubing Copper and Copper Alloy Pipe and Tubing ……. cont. cont’’

ANSI/ASTM B 315 Copper-silicon-alloy seamless pipe and tube.ANSI/ASTM B 447 Welded copper tubeANSI/ASTM B 466 Seamless copper-nickel pipe and tube.ANSI/ASTM B 467 Welded copper-nickel pipe and tube.ANSI/ASTM B 469 Copper-iron alloy tubes for pressure applications.ANSI/ASTM B 543 Welded copper and copper-alloy tube.ANSI/ASTM B 552 Seamless and welded copper-nickel tubes for water

desalting plants.


43



PART B

FITTINGFITTING

44

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)IntroductionIntroduction

Components used in a piping system to connect sections and change the direction of flow.

Specified by :-

Type (pattern)

Material

Nominal pipe (size)

Name of the fitting

Fitting connections :-

Screwed/Threaded

Welded/Soldered

Flanged

Bell and Spigot (Cast Iron and low-pressure)

45

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)FunctionFunction

Change the flow directione.g. Elbow, Return

Provide branch connectionse.g. ' T ' , ' Y ', Cross

Change line sizese.g. Reducer

Close linese.g. Plug, Cap, Blind

Pipe connectionse.g. Coupling, Union, Nipple

46

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)Function Function ……. cont. cont’’

Change the flow directionElbow – 45° or 90° turn and other angles.

Short radius – centre to face = diameterLong radius – centre to face = 1½ diameter

Return or Bend – 180°e.g. heater coils and heat exchanger tube

Provide branch connectionsSystem need more than single lines running.Have a number of intersections, like a city street system.Tee "T" – 3 lines (90° angle)Y-fitting "Y" – 3 lines joints (45° or 60° angle)

47

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)Function Function ……. cont. cont’’

Change line sizesReducer – to reduce a line to a smaller line, reason is to :-

increase the flow pressure.reduce the volume of fluid.

Close linesCaps – close or seal the pipe or tube end.Plugs – close opening in fitting.Blind – close flange.

Pipe connectionsUnion or coupling – to connect 2 lengths of pipe together.

union – easy to connect or disconnect pipes without disturbing the position of the pipe.

48

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)Type of Fitting ConnectionType of Fitting Connection

Threaded Pipe FittingWelded FittingWelded Elbow

CROSS

PLUG

UNION

GATEVALVE

CAPREDUCINGBUSHING

900 ELBOW

450 ELBOW

TEE

REDUCING COUPLING

Y - BRANCH

49

TEE 900 ELBOW PLUG" Y "

REDUCING TEE LONG SCREW

STREET ELBOW

450 STREETELBOW

SIDE OUTLETELBOW EXTENSION PIECE REDUCER LOCK NUT

UNION CAP SIDE OUTLETTEE

FLANGE HEXAGON BUSHING NIPPLE

450 ELBOWCOUPLING CROSS REDUCING ELBOW WASTE NUT

ALL-THREAD NIPPLE

VALVE AND PIPINGVALVE AND PIPINGPipe Fittings (ANSI B16.9)Pipe Fittings (ANSI B16.9)Type of Fitting Connection Type of Fitting Connection ……. cont. cont’’

Threaded Pipe FittingThreaded Pipe Fitting

50

900 ELBOWSLONG RADIUS

900 REDUCING ELBOWLONG RADIUS

900 ELBOWSHORT RADIUS

450 ELBOWLONG RADIUS

1800 RETURNLONG RADIUS

1800 RETURN SHORT RADIUS TEE

CROSS STRAIGHT& REDUCING OUTLET

CONCENTRIC REDUCER

ECCENTRICREDUCER

CAP LAP JOINTSTUB END

LATERAL STRAIGHT& REDUCING OUTLET

SHAPED NIPPLES

SLEEVE SADDLE FULL ENCIRCLEMENTSADDLE


Welded Pipe FittingWelded Pipe Fitting

51


Welded ElbowWelded Elbow

90° elbows, long & short radius

90° reducing elbow, long radius

TUBE TURNS IDENTIFICATIONNOMINAL PIPE SIZE

WALL THICKNESSMATERIAL or TYPE NUMBER

LABORATORYCONTROL NUMBER

52


Elbow or Elbow or ‘‘ELLSELLS’’

900 LONG - RADIUS

900 SHORT - RADIUS

1 1/2 x NPSNPS

1 1/2 x NPS

450 LONG - RADIUS

1 1/2 x NPS(Of Larger Pipe)

=

REDUCING ELBOW

53


Return or 180Return or 180ºº ElbowElbow

LONG - RADIUS RETURN

SHORT - RADIUS RETURN

3 X NPS 2 X NPS

54



PART B

PIPE CONNECTIONSPIPE CONNECTIONS

55

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGPipingPiping ConnectionConnection

Screw/ThreadedSmall line and low pressure

WeldedSmall line – socket welded> 2" – butt welded

FlangedMost common methods of joining pipe to equipmentJoint to pipe by threading or welding

56

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGType of Joint/ConnectionType of Joint/Connection

THREAD ENGAGEMENT

PIPE

SCREWED JOINTSOCKET WELDED JOINT

WELD

PLAIN END

PIPE

1/16" EXPANSION GAP

BORE

WELD

PIPEBEVEL

LAND

BEVEL - ENDED ITEMSUCH AS PIPE, VALVE,EQUIPMENT, ETC.

BUTT - WELDED JOINT

57

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGType of Joint/Connection Type of Joint/Connection ……. cont. cont’’

Screwed/ThreadedScrewed/Threaded

Used in low-pressure, small bore and non-flammable services.For quality joints, it is essential to have a smooth and clean thread (threading die) because of cut-thread surfaces are somewhat imperfect.

Imperfect threads may require white lead or plumber's tape to provide a good seal.

Thread sealant (pipe dope) and lubricants are often used to ensure a leak-tight joint.In high-pressure piping where leakage cannot be tolerated, the threaded joints may be seal-welded and all exposed threads should be covered to prevent crackling in the weld.

58

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGThreading MachineThreading Machine

Main ComponentsMain Components

59

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGThreading Machine Threading Machine ……. cont. cont’’

Checking Thread LengthChecking Thread Length

Thread is cut to proper length when end of pipe is flush with edge of dies.Die head is adjustable to obtain proper thread diameter.

If possible, threads should be checked with a thread ring gage.Proper thread is cut when end of pipe is plus or minus one turn of being flush with face of ring gage.

NOTE ! If a ring gage is not available, a fitting can be used. This fitting should be representative of those being used on the job. The pipe thread should be cut to obtain 2 to 3 turns hand tight engagement with fitting. If pipe thread is not proper diameter the index line should be moved in the direction of the OVERor UNDER size mark on size bar.

60

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGThreading Machine Threading Machine ……. cont. cont’’

Checking Thread Length :Checking Thread Length :

61

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGWelding ConnectionWelding Connection

Welding processWelding process

2 components are being fused together with or without the supplement of additional filler materials.Heat generated during welding process is so intense (strong) that all affected material combine into one single material of equal strength.

Methods of Welding ProcessMethods of Welding Process

Oxy-acetylene Welding (Gas Welding)Shielded Metal-Arc Welding (SMAW)Gas Metal-Arc Welding (GMAW/MIG)Gas Tungsten-Arc Welding (GTAW/TIG)

62

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGWelding ConnectionWelding Connection ……. cont. cont’’

Methods of Welding Process:Oxy-acetylene Welding (Gas Welding):

Use oxygen and acetylene to produce a strong flame to melt the adjoining metal.Welding by using a filler rod.Now change to electric arc welding but oxy-acetylene flame is still used for cutting metal.

Shielded Metal-Arc Welding (SMAW):Commonly used for welding steel pipes and in construction works.Process – both the flux coated electrode and the material are heated simultaneous then the filler metal from the electrode is deposited.Need to remove the slag first before overlapping layers of welding is carried out .

63


Methods of Welding Process …. cont’Gas Metal-Arc Welding (GMAW/MIG):

Extensively used in fabrication facilities because of its easy application for automatic use.Bare electrode is automatically feed from a wire feeder apparatus.Arc is shielded by helium, argon or a mixture of the two inert gases and welding gun is protected from overheating through a continuous flow of cooling water.

Gas Tungsten-Arc Welding (GTAW/TIG):Welding heat is produce from an arc between a non consumable tungsten electrode and the weld area.Arc is shielded by an envelope of inert gas.Uncoated filler rod is provided separately manually.Often used in a critical root pass because less chance of a burn through.

64


Methods of Welding Process …. cont’Shielded Metal-Arc Welding (SMAW):

FLUX COATING

ARC STREAM

SLAGCOVERING

MOLTEN WELD PUDDLE

ELECTRODECORE WIRE

SHIELDING GASATMOSPHERE

COMPONENTS OF A SHIELDED METAL-ARC WELDING CIRCUIT

ELECTRODEHOLDER

ELECTRODEWELDING MACHINE

ARC

WORK

GROUND(WORK)CLAMP

GROUND (WORK) CABLE

ELECTRODECABLE

65

PIPES & VALVESPIPES & VALVESPIPINGPIPINGWelding Connections Welding Connections ……. cont. cont’’

Methods of Welding Process …. cont’

Gas Metal-Arc Welding (GMAW/MIG):

WELDING GUNWIRE FEED UNITGAS

CYLINDERS

WHEELED CARTFOR PORTABILITY

WELDING POWER SUPPLY

GUN NOZZLE

ELECTRODE WIRE

GAS SHIELD

STREAM OFMETAL SPRAYDROPLETS

SPRAY TRANSFER OF METAL

BASE METAL

GUN NOZZLE

ELECTRODEWIRE

GASSHIELD

DROP OFMOLTENMETAL

GUN NOZZLE

GLOBULAR TRANSFER OF METAL

BASE METAL

66


Methods of Welding Process …. cont’Gas Tungsten-Arc Welding (GTAW/TIG):

TUNGSTENELECTRODE

GTAW TORCH SHIELDING GAS

FILLER RODARC

MOLTEN WELD PUDDLE

BASE METAL

67


Preparation of fittings for weldingPreparation of fittings for welding

Unless otherwise specified, the angle of bevel on fittings ⅛" thick and over shall comply with the Figure below:-

Welding ends having a thickness less than ⅛" shall be square unless otherwise agreed between purchaser and manufacturer.Attention is drawn to the importance of careful matching of ends for welding.

37 ½ 0

+ 2 ½ 0

1/16"+ 1/32"

Weld preparation

68


Welding End PreparationWelding End Preparation

(i) PLAIN BEVEL (ii) COMPOUND BEVEL

Compound bevel as in sketch “b” aboveMore than ⅞"

X = 3/16 for carbon steel, ferritic alloy steel or wrought iron; ⅛ for austenitic alloy steel

Plain bevel at in sketch “a” aboveX"to ⅞"

Cut square or slightly chamfer, at mfr’s optionLess than X"

End PreparationNominal Pipe WallThickness (t)

69

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGFlange ConnectionFlange Connection

Flange MarkingFlange Marking

MANUFACTURERNOMINALSIZE

PRESSURERATING

FACE DESIGNATION

WALL THICKNESSOF MATCHING PIPE

MATERIALDESIGNATION

HEAT CODE

70

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPINGFlange Connection Flange Connection ……. cont. cont’’

Flange TypesFlange Types

Slip-onLap jointSocket typeThreadedReducingBlindWelding Neck

71


Flange Types Flange Types ……. cont. cont’’

SLIP - ON THREADED

LAP JOINT BLIND

SOCKET TYPE REDUCING

WELDING NECK

72


Type of Flange FacesType of Flange Faces

Flat/Full Face (FF)Raised Faced (RF)Ring Type Joint (RTJ/RJ)Tongue and Groove (T&G) (Large/Small)Male and Female (M&F) (Large/Small)Lap Joint

73


Type of Flange Faces Type of Flange Faces ……. cont. cont’’

RAISED FACE FLAT FACE

RING JOINTLAP JOINT

TONGUE & GROOVE

GASKET

74


Flange Bolt PatternsFlange Bolt Patterns

90O

45O

4 BOLT PATTERN 8 BOLT PATTERN 16 BOLT PATTERN

22 1/2O

11 1/4O

45O

45O

22 1/2O

75


Contact Face of FlangeContact Face of Flange

FLAT FACE 0.06" RF 0.25" RF RING JOINT

SMALL M / F LARGE M / F SMALL T / G LARGE T / G

76


Flange InstallationFlange Installation

RAISED FACE

PIPELAP

LARGE M & F SMALL M & F LARGE T & G

Align flange to avoid troubleCareful aligning before bolting prevents excessive bolting stresses in valves, fittings and pipe flanges.

Use of thread lubricant cuts friction, protects thread and makes joints easier to break for necessary repair

SMALL T & G

77



PART B

GASKETSGASKETS

78

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETIntroductionIntroduction

To make a tight leak proof seal between 2 joint surfacesType of gaskets:-

Non-metallicCompressed Asbestos Fiber (CAF)Rubber & etc

Semi-metallicAsbestos Filled Metal / Spiral Wound (SW)

Solid Metal GasketCarbon SteelStainless Steel

79

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETMaterial SelectionMaterial Selection

1000Steam or waterMonel, corrugated or plain

1000Steam or waterStainless steel, 12 - 14% chromium, corrugated

1000Steam or waterHydrogen-annnealed furniture iron

600Steam or waterCopper, corrugated or plain1000Steam or waterSteel, corrugated or plain

200OilFiber and paper200OilSynthetic rubber

750Steam, water, oilAsbestos composition250Steam, air, waterRed rubber

1000Steam, water or oilIngot iron, special gasket for ring-type joint

Usual MaxTemp ºF

FluidGasket Material

80

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETFace TypeFace Type

Non-metallic Flat Gasket For Pipe Flange (ANSI B 16.2 - 1978)

Flat FaceFull FaceRaised FaceFlat RingMale & FemaleMale & FemaleTongue & GrooveTongue & Groove

Flange FacingGasket Type

81

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETFace Type Face Type ……. cont. cont’’

Non-metallic Flat Gasket For Pipe Flange (ANSI B 16.2 - 1978)

RAISED FACE GASKET(FLAT RING)

FULL FACE GASKET

TONGUE & GROOVE GASKET MALE & FEMALE GASKET

82

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETDimensionsDimensions

Flat Ring Gasket :-Self centering O.D = BCD – Bolt diameterSmall O.D = O.D of RFI.D = Nominal O.D of Steel Pipe

Full Face Gasket :-O.D = O.D of the FlangesI.D = Nominal O.D of Steel Pipe

Male and Female Gasket :-O.D = O.D of Male FaceI.D = Nominal O.D of Steel Pipe

Tongue and Groove Gasket :-O.D = O.D of TongueI.D = I.D of Tongue

87

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETSemi Metallic Semi Metallic –– Spiral Wound GasketSpiral Wound Gasket

Narrow strip of V-shape metal hoop is spirally wound under tension with a filler cushion between the lamination of the metal and spot-welded at both ends.Provides excellent characteristics:-

Resistance to high temperature & pressureGreat resilience which allows the gasket to adjust automatically to changes in operating conditions

e.g. pressure, temperature, thermal shocks, vibration etc.Excellent sealability in maintained with comparatively small gasket area.Good tolerance for flange surface finish irregularitiesCan designed to any dimensionsAvailability to satisfy specific operating conditions.

88

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETSemi Metallic Semi Metallic –– Spiral Wound Gasket Spiral Wound Gasket ……. cont. cont’’

Gasket Thickness : 4.5mmFiller Material : Asbestos PaperHoop Material : Stainless Steel, SUS 304 or 316.

(3.2mm thickness is also available on request with the hoop material of SUS 304, 316 or Titanium.Maximum gasket O.D is 600mm)

Rings : 3.2mm for Low Carbon Steel & 3.0mm for Stainless Steel (Can be supplied with SUS 304 & 316 in the thickness of 3.0mm)

Function of Rings:Function of Rings:Outer Ring works as:-

Centering gasket portion between flangesLimiting bolt load at proper compressionPreventing external expansion of the gasket when compressed

Inner RingPrevents internal extrusion of the gasket when compressed.

89


Standard Type for General Used :Standard Type for General Used :

Standard Type (Without anything attached) :-For Male and Female & Tongue and Groove flange.

With Inner Ring Attached :-For Male and Female flange.

With Outer Guide Ring Attached :-For Raised Face & Flat Face flange.

With Outer Guide Ring and Inner Ring Attached :-For Raised Face & Flat Face flange.

90


STUDBOLT OUTERRING

FLANGE FACES

ASBESTOS FILLING

METALCOIL

91


CONSTRUCTION HOOP MATERIAL FOR FLANGE OF COMPLIANCE WITH STANDARD

Stainless SteelSUS 304


as specified

Standard type(Without anything attached)

Gasket Thickness : 4.5 mmFiller Material: Asbestos paper

Male & FemaleTongue & Groove specified byANSI B16.5JIS B2210

B2220

JIS B 2404

TOMBO NO:

1804

1806

18081804

With Inner ring attached

Inner Ring: Low Carbon Steel 3.2mmStainless Steel 3.0mm

Gasket Thickness: 4.5mmFiller Material: Asbestos paper

Male & Female

With outer guide ring attached

Outer Ring: Low Carbon Steel 3.2mmstainless Steel 3.0mm

Gasket Thickness: 4.5mmFiller Material: Asbestos paper

Raised FaceFlat Face specified byANSI B16.5API 605JIS B2210

B2220JPI 7S-15 & 7S-43

JIS B 2404

Same as above

With outer guide ring andinner ring attached

Outer and Inner Ring:Low Carbon Steel 3.2mmStainless Steel 3.0mmGasket Thickness: 4.5mmFiller Material: Asbestos paper



as specified



as specified



as specified

1804-R

1806-R

1808-R1804-R

1834

1836

18381834

1834-R

1836-R

1838-R1834-R

JIS F 7102 450SUJIS F 7102 510SUJIS F 7102 520SUAPI-601JIS B 2404JPI-7S-41

JIS F 7102 450SUJIS F 7102 510SUJIS F 7102 520SUAPI-601JIS B 2404JPI-7S-41

92

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETSolid Metal GasketSolid Metal Gasket

Ring Joint Gasket Ring Joint Gasket –– ANSI B 16.20 ANSI B 16.20 –– 19731973

Machine from solid metals in a variety of shapes and designed fro high pressure, high temperature or highly corrosive applications by selecting the most suitable:

Material and shapeHigh pressure up to 250 psi @ 500°C

Type:Oval ▪ PlainOctagonal ▪ Lens ringRX ▪ BX (pressure from 5000 psi to

15000 psi)Material – suitable for service condition. Hardness equal or lower than flange materialDesign by letter “R”

93

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETSolid Metal Gasket Solid Metal Gasket ……. cont. cont’’

Ring Joint Gasket Ring Joint Gasket –– ANSI B 16.20 ANSI B 16.20 –– 19731973

The outer surface of each gasket shall carry the manufacturer's trademark, gasket number prefixed by the letter "R" or "RX" and followed by the material identification.The application of marking shall be done so as not to injured the contact faces nor to harmfully distort the gasket.Material identification shall conform to the following standards unless otherwise specified on the purchase order.

94

VALVE AND PIPINGVALVE AND PIPINGGASKETGASKETSolid Metal Gasket Solid Metal Gasket ……. cont. cont’’

RING GASKET MATERIAL

IDENTIFICATION MARKING EXAMPLE

Soft IronLow-Carbon Steel

4 - 6 Percent Chrome1/2 Percent Molyb. Steel

Type 410 SteelType 304 SteelType 316 SteelType 247 Steel

DS

*F5S410S304S316S347

@ R51D@ R51S

@ R51F5@ R51S410@ R51S304@ R51S316@ R51S347

@ Denotes manufacturer's trademark.*F5 – Identification designates ASTM Specification A 182-72 chemical composition requirements only.

95

PIPES & VALVESGASKETSolid Metal Gasket …. cont’

96

PIPES & VALVESPIPES & VALVESGASKETGASKETSolid Metal Gasket Solid Metal Gasket ……. cont. cont’’

Designed to DIN2696.

Bolt load will be comparative small because its contact surface with flange face is spherical/

1850-L

Lens Ring

More economical to make and more accurate in dimensions and surface finish than oval type because it consists of straight surfaces only. But more torque load is required to flow the gasket material into imperfections on the flange facings. Reuse is possible. Complies with the same standards as above.

1850-C

Ring Joint

Octagonal

Type

Designed to API 6A for use with grooved flanges on special applications involving high pressures from 5,000 to 15,000 psi.

1850-BX

Ring Joint

BX Type

Designed to API 6A. Interchangeable with the oval and octagonal series of identical reference numbers and used in the same flange grooves.

1850-RX

Ring Joint

RX Type

Flat Ring punched or lathed from comparatively soft metal such as aluminum, copper etc. Relatively inexpensive to make.

1850-P

Plain

This type is the original joint design. Contacts flange face at the curved surface and provides a high reliability seal. But due to its shape, it is harder to achieve accuracy of dimensions and surface finish in oval type than in octagonal one and also more expansive to make. Reuse is not possible. Complies with ANSI B16.20, API 6A, JIS F 7102, JPI-7S-23-63.

1850-V

Ring Joint

Oval Type

97

AMERICAN NATIONAL STANDARD (ANSI B 16.21 - 1978) NONMETALLIC FLAT GASKETS FOR PIPE FLANGES

GASKET DIMENSIONS FOR ANSI B16.5 CLASS 150 STEEL PIPE FLANGES & FLANGED FITTINGS

DIMENSIONS ARE IN INCHES

1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

1.001.311.501.882.122.883.384.254.755.196.317.509.33

11.2513.5014.2516.7519.2521.0025.25

1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

2.382.753.123.503.884.755.506.007.007.508.509.50

11.7514.2517.0018.7521.2522.7525.0029.50

0.620.620.620.620.620.750.750.750.750.750.880.880.881.001.001.121.121.251.251.25

4444444488888

12121216161818

3.503.884.254.635.006.007.007.508.509.00

10.0011.0013.5016.0019.0021.0023.5025.0027.5032.00

1.882.252.623.003.384.124.885.386.386.887.758.75

11.0013.3816.1317.7520.2521.6223.8828.25

0.841.061.311.661.912.382.883.504.004.505.566.628.62

10.7512.7514.0016.0018.0020.0024.00

½¾1

1¼1½

22½

33½

4568

10121416182024

O.DI.DO.DBolt Circle Diameter

Hole Diameter

No of HolesO.D

Large Tongue and Groove

Large Male and FemaleFull Face Gasket

Flat Ring O.D

Gasket I.D

Nominal Pipe Size

98




1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

1.001.311.501.882.122.883.384.254.755.196.317.509.33

11.2513.5014.2516.7519.2521.0025.25

1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

2.122.622.883.253.754.385.125.886.507.128.509.86

12.1214.2516.6219.1221.2523.5025.7530.50

0.841.061.311.661.912.382.883.504.004.505.566.628.62

10.7512.7514.0016.0018.0020.0024.00

½¾1

1¼1½

22½

33½

4568

10121416182024

O.DI.D

Large Tongue and GrooveLarge Male and Female

O.D

Flat RingO.D

GasketI.DNominal Pipe Size

99


1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

1.001.311.501.882.122.883.384.254.755.196.317.509.33

11.2513.5014.2516.7519.2521.0025.25

1.381.692.002.502.883.624.125.005.506.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

2.122.622.883.253.754.385.125.886.387.629.50

10.5012.6215.7518.0019.3822.2524.1226.8831.12

0.841.061.311.661.912.382.883.504.004.505.566.628.62

10.7512.7514.0016.0018.0020.0024.00

½¾1

1¼1½

22½

33½

4568

10121416182024

O.DI.D

Large Tongue and GrooveLarge Maleand Female

O.D

Flat RingO.D




100


1.381.692.002.502.883.624.125.006.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

1.001.311.501.882.122.883.384.255.196.317.509.33

11.2513.5014.2516.7519.2521.0025.25

1.381.692.002.502.883.624.125.006.197.318.50

10.6212.7515.0016.2518.5021.0023.0027.25

2.502.753.123.503.885.626.506.628.129.75

11.3814.1217.1319.6220.5022.6225.1227.5033.00

0.841.061.311.661.912.382.883.504.505.566.628.62

10.7512.7514.0016.0018.0020.0024.00

½¾1

1¼1½

22½

34568

10121416182024

O.DI.D

Large Tongue and GrooveLarge Maleand Female

O.D

Flat RingO.D




101



PART B

PIPE SYMBOLS & DRAWINGPIPE SYMBOLS & DRAWING

102

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGIntroductionIntroduction

Process Flow DiagramBasic blueprint of the process, function & equipment for a job (1st drawing to be completed).Provide data to begin the design & layout of the system.

Piping & Instrumentation Diagram (P&ID)Line Symbol & Abbreviation – easier to read.Instrumentation – indicates all four major categories of Instruments

Temperature, Pressure, Flow & Level.

103

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGPiping SymbolsPiping Symbols

WELDED FLANGED SCREWED SOLDERED BELL & SPIGOT----X---- -----||---- ----|----- ----O---- -------(-------

WELDED FLANGED

CONNECTING PIPE

ELBOW

45 DEGREE

90 DEGREE

TURNED DOWN

TURNED UPTEESTRAIGHT SIZEOUTLET UP

OUTLET DOWNCROSSSTRAIGHT SIZE

REDUCERCONCENTRIC

ECCENTRIC

GATE VALVE

GLOBE VALVE

PLUG VALVE

CHECK VALVE

ANGLE VALVEGLOBE(ELEVATION)

GLOBE(PLAN)

DIAPHRAGMVALVE

MOTOR-OPERATED

104

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGPiping Symbols Piping Symbols ……. cont. cont’’

105


106


107

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGPiping Identification System (Line Number)Piping Identification System (Line Number)

Has 5 basic parts (combination of letters, numbers & symbols):-Line Size – NPSConveyed Fluid (Fluid code)Line Number - e.g. 1006, the first 2 digit (10) is the unit area code (unit/area 10) & the second 2 digit (06) means the line number (line 06)Piping Classification – material classificationInsulation Type – insulation code and thickness, e.g.:

1st - Insulation for Steam tracingIns - Insulation for Heat ConservationPP - Insulation for Personal Protection

3" - KE - 10 06 - CD 121 - (1st 25)LINE SIZE

CONVEYED FLUID(KEROSENED) UNIT AREA CODE

LINE INDEX

MATERIALCLASSIFICATION

LINE WITH STEAN TRACING & INSULATION OF 25mm THICK

108

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGColourColour CodingCoding

COLOUR BANDS BLACK ARROW

FLOW DIRECTION

50 mm

FLOW ARROW LOCATION

FLOW ARROW DIMENSIONS

A B

CDPipe size A mm B mm C mm D mm

1" & 2" 25 15 20 10

3" Thru. 6" 75 50 65 40 8" & Over 125 75 115 65

109

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGColourColour Coding Coding ……. cont. cont’’

Pipes are coded with coloured bands (striping) to show function and with arrows to show direction of flow.Bands can be a single colour or a combination of 2 colours.Bands are 50mm wide and completely circle the pipe wherever possible. Band spacing is 50 mm.All striping is applied within 700 mm of the line starting and termination wherever possible.

110

VALVE AND PIPINGVALVE AND PIPINGPIPE SYMBOL & DRAWINGPIPE SYMBOL & DRAWINGColourColour Coding Coding ……. cont. cont’’

2 Pink BandsHydraulic1 Pink bandCompressed Air2 Blue BandsHP Water Injection1 Blue BandDrain System3 Red BandsFire Water DelugeRed (Fully Painted)Fire Water1 Orange between 2 BlackFuel Gas2 Orange BandInjection Gas1 Orange BandHP Gas1 Green BandCrude Oil

COLOUR STRIPINGSERVICES

Piping Piping ColourColour CodesCodes

111



PART B

HYDROSTATIC TESTINGHYDROSTATIC TESTING

112

VALVE AND PIPINGVALVE AND PIPINGHYDROTESTINGHYDROTESTINGIntroductionIntroduction

Pressure Test is performed or conducted when there are NEW or OLD operating equipment like Boilers, Heat Exchangers, Pipe Connections and other pressure vessels installed.All pressure vessels must go through the pressure test before they are permitted to operate.In Malaysia, there are the regulation enforced by Malaysian Authority under theDepartment of Occupational Safety and Health (DOSH).There are 2 pressure tests performed :-

Pressure Leak TestPressure Strength Test – commonly known as Hydrostatic Test.

113

VALVE AND PIPING VALVE AND PIPING HYDROTESTINGHYDROTESTINGDefinitionDefinition

Design PressureDesign Pressure

The pressure used in the design of a vessel.Manufacturer recommended design pressure on each equipment.Design pressure is higher than operating pressure and it will satisfy the requirement of the pressure of the fluid and other content of the vessel standard.

Operating PressureOperating Pressure

Pressure which pressure vessel can work safely or operate normally.

114

VALVE AND PIPING VALVE AND PIPING HYDROTESTINGHYDROTESTINGDefinition Definition ……. cont. cont’’

Maximum Allowable Working Pressure (MAWP)Maximum Allowable Working Pressure (MAWP)

Internal pressure at which the weakest element of the vessel is loaded to the ultimate permissible point when the vessel is assumed to be :-

Corroded conditionUnder the effect of a designed temperatureNormal operating conditionUnder the effect of other loading, like wind, external pressureMAWP is higher than operating pressure.

Test PressureTest Pressure

Manufacturer recommended hydrostatic pressure test when the vessel or equipment is new as appeared on the equipment name plate.

115

VALVE AND PIPING VALVE AND PIPING HYDROTESTINGHYDROTESTINGObjectiveObjective

Fired and Unfired pressure vessels are under government regulation, their objectives are to prevent :-

Accidents that could cause undue risk to the personnel working at or near the plant equipment,Accidents that could cause several severe material damage and consequently substantial economic losses,Accidents that could cause risk of pollution to the environment,Downtime in plant production.

116

VALVE AND PIPING VALVE AND PIPING HYDROTESTINGHYDROTESTINGHydrostatic TestingHydrostatic Testing

Pressure Leak Test (1.10 x MAWP)Pressure Leak Test (1.10 x MAWP)

Purpose is to detect leaking paths through the "pressure envelope" in either direction.Methods used may be straightforward using water or gas, like air or inner search gases.Leakage detection may be visual or measurement of pressure drop, pressure vacuum decay rate, trace gas or water respond to detection instrument, audible or ultrasonic devices, fluorescent dyes, etc.Pressure applied in the case of trace gas techniques should be of a very low order and for audible or visual technique it should be equal to the working pressure of the vessel with small multiplying factor but it should not in any circumstances exceed 110% of the MAWP.

117

VALVE AND PIPING VALVE AND PIPING HYDROTESTINGHYDROTESTINGHydrostatic Testing Hydrostatic Testing ……. cont. cont’’

Hydrostatic Test (1.50 x MAWP)Hydrostatic Test (1.50 x MAWP)

Statutory requirement of pressure vessel in order to verify and demonstrate the continued fitness for services.Pressure applied may approach up to original design pressure with a suitable correction factor applied for the ambient design temperature differential and deviation from the new and old condition.In practice, the standard hydrostatic pressure test is equal to 150% of the MAWP.

Hydrostatic should also be applied when repairs or modifications have been carried out which affect the structural integrity of the pressure shell and foundation.

118


Hydrostatic Test (1.50 x MAWP) Hydrostatic Test (1.50 x MAWP) ……. Cont. Cont

Also hydrostatic test is conducted after all fabrication work has been completed.Hydrostatic Test Pressure = 1.5 (MAWP) (stress value at test temp ºF)

(stress value at design temp ºF)

NOTE : All hydrostatic Test shall be witnessed by Inspector. However, the Senior Inspector may approve the following person to witness the mentioned test during off-hours.

Pressure Rating (psi) 150 300 400 600 900 1500 2500

Hydrostatic Test (psi) 450 1100 1450 2175 3250 5400 9000

119


Hydrostatic Test Procedure on PipesHydrostatic Test Procedure on Pipes

For pipelines, the test pressure shall be governed by the line flange rating, unless the line is for a non-critical services when inspections will advice the test pressure.During the testing process, temporary gaskets may be used.The steps below are typical procedures while other may have added requirements :-

Bolts together the 2 pipes.Connect the elbow casting simplifies the end of the pipelines. The fitting of the elbow casting simplifies the process of filling the pipeline with water.Bolt a flange fitted with a shut off cock to the other end of the pipe.Close the shut off cock and fill the pipeline with water until the water start to flow through the elbow.

120


Hydrostatic Test Procedure on PipesHydrostatic Test Procedure on Pipes …. Cont’

Bolt a flange with a pressure gauge connection to the elbow casting.Connect the test pump to the shut off cock.Open the shut off cock and operate the test pump until water overflows from the pressure gauge connection (BLEEDING PROCESS).Fit the pressure gauge.Operate the test pump until the pressure gauge indicates the specified test pressure.Inspect for leaks in the pipeline at the flange joint, as well as the pipe system in general.Release the pressure from the pipeline through the test pump discharge cock.Disconnect the test pump and drain the pipeline through the shut off cock.Remove the blank flanges and dismantle the pipe joints.

121


Hydrostatic Test Procedure on PipesHydrostatic Test Procedure on Pipes …. Cont’

A

C

B

122


Pipe Work CriticalPipe Work Critical

Marking, cutting, threading installation and pressure testing

PUMP

300300

400

450

450350

Pipe Material : Galvanized IronPipe Size : 3/4 "Test Pressure : 150 psigAll Dimensions in MM

123


Safety RequirementSafety Requirement

Depressurising the equipment after inspection and the test has been approved must be done by releasing the pressure slowly through the vent and drain valves.Vent valve needs to be opened to release pressure when draining to prevent collapsing of the system by pulling a vacuum.Never leave equipment an attended at any time when it is under pressure.Always wear safety gear when conducting hydrostatic test.

124


Safety Requirement Safety Requirement ……. cont. cont’’

Record and inspection report are to be kept properly according to the requirements of inspection manual of pressure vessels.It is necessary to keep a record of all inspection result of each vessel from the initial inspection to the latest inspection, so that comparison and analysis can be made from these inspection result.Plan and report are to be submitted for evaluation before issuance of inspection certificate by Malaysian Authority (DOSH).

125



PART B

PIPE COATING & INSULATIONPIPE COATING & INSULATION

126

VALVE AND PIPINGVALVE AND PIPINGPIPING COATING & INSULATIONPIPING COATING & INSULATIONCoatingCoating

Pipe External coatingPipe External coating

Purpose – to prevent external corrosionTypical coating – Asphalts enamel (for corrosion protection) and concrete (for weight)Coating application is carried out at a pipe coating yard

Riser external coatingRiser external coating

Purpose – to prevent external corrosionTypical coating – Splashtron (rubber) or tide guard on risers(40 ft) in splash zone3 coat paint system for above splash zone

127

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPING COATING & INSULATIONCOATING & INSULATIONInsulationInsulation

Piping is frequently covered by layers of insulation.Pipe insulation amounts to wrapping the pipe in a blanket of insulation material.The thickness of the blanket of insulation depends on the application.It is a natural law that heat passes from a warm surface to a cold or colder one.Insulation helps prevent hot fluid from cooling as it passes through the system.If the piping is carrying a cold fluid, insulation helps keep the fluid cold.

e.g. if a steam pipe were not insulated, lower temperatures would cause the steam to condense.

128

VALVE AND PIPINGVALVE AND PIPINGPIPINGPIPING COATING & INSULATIONCOATING & INSULATIONInsulationInsulation ……. cont. cont’’

Barrier or wall against the flow of thermal energy to conserve energyAs a safety devices to prevent accidents such as anti-sweat and cryogenic service.Function of insulation is to prevent heat loss and temperature loss.An outer wrapping may be used to protect the insulating material against the effects of water, chemicals, and mold or other damaging conditions (cladding or metal jacketing).Insulation also protects piping against possible rusting and corrosion caused by exposure to water and chemicals in the soil.For additional protection, the outer sheathing is usually covered with a layer of a waterproofing or cement-like material called "mastic".For underground piping, usually wrapping or coating with epoxy paint or bitumen.Always put on "safety gears" while working with installation/dismantling of insulation.If possible, wet it down before remove insulation to prevent dust from flying.

129


Materials for insulation (lagging) depends on the requirements of the application, such as:-

Polystyrene foamFiberglassHair-feltPolyurethane foam (PUF)Calcium silicate – inorganic insulating materialsMineral wool – fibrous and glassy in naturePolyisocyanurate foam – a thermosetting polymer which forms a rigid foam once a constituents parts are mixedFoam glass – a non standard insulating materialAsbestos – in existing system onlyPaper & wood fibresFoam rubberWiremesh

130


Foams of thermal insulationLoose fill – poured and packed in place.

e.g. asbestos powder, cork granules, powdered gypsum and mineralwool pellets

Flexible insulation is in the form of blankets sheet or felt. Installed by wrapping, nailing or using adhesives

e.g. Asbestos felt, cotton, fiber glass, mineral wool, foam rubber.Rigid insulation – available in block, hard boards, brick, sheet, asbestos cork, fine clay, foam rubber, paper and wood.

131


SpecificallySpecifically

Heat conservation – steam from condense.Cold conservation – pipe carrying cold fluids causes water droplet to form on the pipe.Sound proofing.Protect underground pipe from rusting, corrosion.Personnel protection

132


INSULATION(LAGGING)

PIPE

METAL JACKETING(CLADDING)

CROSS-SECTION OF AN INSULATED PIPECROSS-SECTION OF AN INSULATED PIPE WITH MULTIPLE LAYERS

133



PART B

PIPE SUPPORTSPIPE SUPPORTS

134

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORTPIPE SUPPORTIntroductionIntroduction

Supporting element must ;-Avoid excessive interference with thermal expansion and contraction of pipeNot contribute to leakage at jointsNot contribute to excessive sag in piping requiring drainagePrevent overstress, resonance or disengagement due to vibrationWithstand jet effect produced by discharging relief valves

PurposeSupport the load of the piping system.Prevent the pipe making direct contact with the ground which cause severe corrosion problems.

135

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORTPIPE SUPPORTIntroduction Introduction ……. cont. cont’’

Pipe supports and supporting structures need to be properly designed to ensure safe long term operation.Liaison between the piping design authority and the civil design authority is important.Pipe supports are an important part of any piping system and should be considered as an integral part of piping design.Piping systems should be properly supported.Incorrect supporting can lead to water hammer, leaking flanged joints and valves and unacceptable loads on equipment and structure.Method of supporting (plastic piping may need continuous supports), the location and type should be selected when the piping is being routed.

136

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORTPIPE SUPPORTIntroduction Introduction ……. cont. cont’’

Many factors to be considered, including :-Weight of piping, insulation and contents (some fluids are heavier than water).Weight of tests fluids.Wind, snow and ice loading.Thermal movement and settlement.Spans between supports.Strength of equipment, supporting structures and plinths.Discharge reactions due to letdown (venting) or pressure relief.

137

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTSPIPE SUPPORT & RESTRAINTSIntroduction Introduction ……. cont. cont’’

Piping must be support to kept the line straight and prevent sagging.Rigid pipe that sags excessively will strain it’s connection fittings which will probably cause leakage.Pipeline may be designed to run at a slight angle and will be supported at suitable intervals.In a long run pipeline, rigid piping must be supported and fastened to the floor, wall, ceiling or pillars.

Spring hangers help absorb vibration.The roll types permit the pipe to move as it expands or shrinks in length because of temperature variations.

Temperature effects – nearly all materials and metals expand as the temperature increases and contracts or become smaller size as the temperature decreases.To allow this expansion and contraction in piping system, expansion joints must be installed in the line between sections of rigid pipe which will eliminates train on the pipes.

138

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTSPIPE SUPPORT & RESTRAINTSIntroduction Introduction ……. cont. cont’’

Great variety of pipe supports and hangers are available.Some of the pipe supports can be very simple and fabricated at the time of installation by either using standard components or structural steel shape.Other supports are very sophisticated and through a lengthy design, layout and manufacturing process.Pipe support will be fitted to pipe before pipe is installed (spool piece)Pipe rack

To carry numerous pipelines for interconnection of various plant process area.Fabricated from structural steel and consists of H-Frames.Sufficient height from ground (8’ to 10’)

139

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Introduction Introduction ……. cont. cont’’

Support – The term 'support' refers to any device used to carry the weight of the pipework. Supports are usually made from structural steel.Hanger – A hanger is a particular type of support by which pipework is suspended from a structure. Hangers are usually adjustable for height.Anchor – An anchor is a rigid support which prevents transmission of movement along pipework.Tie – An arrangement of rods, bars, etc. to restrict movement of pipework. Dummy Leg – An extension piece of pipe or steel section welded to an elbow.Guide or Shoe – A means of allowing a pipe to move along its length whilst restricting its lateral movement.

140

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Type of Pipe SupportType of Pipe Support

Type of pipe supportsType of pipe supports

Wall BracketDummy LegSaddleBent Flat BarAngle ‘L’ Bar‘L’ Section‘T’ SectionPiping

141

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Type of Pipe Support Type of Pipe Support ……. cont. cont’’

142

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Type of Pipe SupportType of Pipe Support

U - Bolt

Angle(L-Section)

Weld' I ' Section

Dummy Leg

Weld

Channel or' T ' or ' L 'Section

Rod

Vent

Pipe

Rod

Trapeze

Rod

U - Bolt

Pipe Attachments

143

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Type of Pipe HangerType of Pipe Hanger

Device that suspends piping from structural steel or concrete.Type of pipe hangers ;-

Beam Clamp3 design – top, bottom & side

Clevis Hanger3 parts – pipe cradle, top bracket & bolts/nuts

Pipe RingsTrapeze Hanger

Carry several pipesSpring Hanger

144

VALVE AND PIPINGVALVE AND PIPINGPIPE SUPPORT & RESTRAINTS PIPE SUPPORT & RESTRAINTS Type of Pipe Hanger Type of Pipe Hanger ……. cont. cont’’

Type of pipe hangers …. cont’Pipe ClampU-BoltAnchor

Rigid support which prevent transmission of movementTie

Arrangement of rods, bars, etc to restrict movementGuide/Shoe

Restricting a lateral movement

145


146


UPPER SUPPORTS

MIDSECTIONS

PIPE ATTACHMENTS

Section: Section:

INSULATIONINSULATION

INSULATION

INSULATION

FLAT BAR ROD

'U' BOLT

SPRING HANGERTURNBUCKLE

EYEROD ORFLAT BARROD

ROD

NUT

CLEVIS

TRAPEZE

ROD

RODNUT

LUGCLEVIS

FLAT BAR

RODBOLT

LUGWELD

WELD

CHANNELor 'T' or 'L'SECTION

ROD EYEROD ORFLAT BAR

SPRING HANGERCLEVIS

WELD

147


Hangers (A,B,C,D) generally permit vertical adjustment (1) to permit piping alignment to be maintained and to allow for proper division of load among supports. Pivoted hangers (E,F) may permit universal movement (2) or may permit one-way movement as shown at (3). Multiple supports (G,H,I,J) for banks of small pipe may be grooved for axial movement only (4) or may have a flat surface (5) to allow a certain amount of sidewise movement.

11 11 1

AB C

D

EF

GH

I

J

2 3

4

5

148



PART B

PIPING MAINTENANCEPIPING MAINTENANCE

149

VALVE AND PIPINGVALVE AND PIPINGMAINTENANCE OF PIPING SYSTEMMAINTENANCE OF PIPING SYSTEMIntroductionIntroduction

Major problem in Piping System are :-LeakingCorrosion

Failures or accidents can take place at any time without warning/notice2 types of Maintenance :-

Preventive Maintenance – regularly scheduled interval, finding and correcting minor defectsRepair Maintenance – correcting conditions, immediate action

150

VALVE AND PIPINGVALVE AND PIPINGMAINTENANCE OF PIPING SYSTEMMAINTENANCE OF PIPING SYSTEMIntroduction Introduction ……. cont. cont’’

The following list includes the points will be concerned for the maintenance of piping system:-

Checking for corrosion and leakageChecking to be sure that valves are in working orderRepacking valves, maintaining & replacing gasketsChecking insulation & possibly installing it as neededInstalling new sections of piping, tubing & hoseInstalling, inspecting & replacing fittings as neededChecking hangers & pipe supportsCleaning piping as requiredExtending existing systems as neededReporting anything of an unusual nature

151

VALVE AND PIPINGVALVE AND PIPINGMAINTENANCE OF PIPING SYSTEMMAINTENANCE OF PIPING SYSTEMInspection Inspection

Checking during operation ;-Operation of a Piping System is dictated by the operation of the equipment which it connects.Care must be taken at all times to ensure that :-

Piping is not operated beyond its design range of pressure and temperatureAll joints are checked regularly for leaks and any leaks discovered are reported immediatelyPiping is correctly isolated and purged, if necessary, before any maintenance work is performed on itLine markings are clearly visible and remade if notAny abnormal vibration, damage, missing supports, etc. are reported immediately

valve & piping

Engineering