PIPE, PIPING SYSTEMS

&
PIPE FITTINGS

Malik Kamran Jahangir

Feb 05, 2005
 COURSE CONTENTS
ę Piping Philosophy
ę What is piping ?
ę Types of piping
ę Difference between pipe & tube
ę Difference between piping & pipeline
ę Piping Systems
ę Pipe Materials
ę Coding of pipes
ę Pipe Manufacturing
ę Piping drawings
 COURSE CONTENTS
ę Pipe size, schedule& thickness
ę Comparative Codes & Standards
ę Pipe manufacturing Processes
ę Pipe Design
ę Pipe Drawings
ę Piping Supports
ę Fittings
ę Flanges
ę Common definitions used in piping
ę Typical Questions & Answers
 WHAT IS PIPING ?
PIPING
Piping includes pipe, flanges, fittings, bolting, gaskets,
valves, and the pressure containing portions of other
piping components. It also includes pipe hangers and
supports and other items necessary to prevent over
pressurization and overstressing of the pressure-containing
components.
It is evident that pipe is one element or a part
of piping. Therefore, pipe sections when joined with
fittings, valves, and other mechanical equipment and
properly supported by hangers and supports, are called
piping.
Cost Analysis:

Piping in process units significantly affects the safety and

reliability of operations and also represents 25 to 50
percent of the capital investment of a process unit.
 PIPING CLASSIFICATION
Piping is divided into two classes mainly;
1. Metallic
2. Non-metallic
METALLIC PIPING

Metallic piping is further divided into two categories, Ferrous and

Non-Ferrous.
Ferrous : carbon steel, stainless steel, chrome steel, cast iron etc.
Non-Ferrous : aluminum.

NON-METALLIC PIPING
Most common in this category are asbestos-cemented, plastic
pipe, Polyvinyl chloride (PVC) Pipe, Clay pipe and Glass
reinforced plastic (GRP) pipe.
 PIPE & TUBING
Tubing:

Tube refers to cylindrical, square, rectangular or any shape of

hollow material of uniform thickness which is defined by the
outside diameter and wall thickness dimensions. (For example 4"
diameter x 0.562" wall.)
So, it is specified by its outer diameter. e.g. 4” tubing is 4” outer
diameter (OD).

Pipe:

Pipe is a tube with round cross section conforming to the dimensional

requirements of

● ASME B36.10M Welded and Seamless Wrought Steel Pipe

● ASME B36.19M Stainless Steel Pipe

4”pipe has 4.5” outer diameter (OD). It is specified by the nominal size.
 PIPING & PIPELINE
Piping :

It is the kind of piping that is used within the plant premises .

Pipeline :

It is the kind of piping that is used outside the plant premises e.g.
transportation of fluids between different cities.

In more simpler words the piping of water in your houses categorized in to

the piping and from your houses to disposal or from some water supply unit
to your home is categorized in to the Pipeline terminology.
 PIPE SIZE, SCHEDULE & THICKNESS
Piping :

Pipe sizes are given in NPS (Nominal Pipe Size). Some of the pipe sizes,
which are used today in almost all the industries, are as follows;
(In inches)
1/8, ¼ , 3/8 , ½ , ¾ , 1, 1 ¼ , 1 ½ , 2, 2 ½ , 3, 3 ½ , 4, 5, 6, 8 ,10, 12,
14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 42, 48 ………..

Pipe Schedule and Thickness :

It tells about the nominal wall thickness. It classifies the pipe size.
There are few letters in the schedule number column, which is source of
information to the designer. These symbols are as follows;
S Standard.
X Extra Strong.
XX Double Extra Strong.
LW Light Weight (lighter commercially standardize
pipe).
 COMPARATIVE CODES & STANDARDS
OF
PIPE
Piping :

Basic categorization of codes depend on two things i.e.

metallurgy and dimensional aspect.

Metallurgical Codes:

As the name indicates , it deals with the materials of the pipe.

The most common one in this category Is
‰ ASTM-American Standard of testing Materials

Dimensional or Structural Codes :

The most common in this category are
‰ ASME
‰ ANSI
‰ API
‰ UNS
 PIPE MANUFACTURE
The following types of pipe are used :

ƒ Seamless
ƒ Electric resistance welded
ƒ Arc (fusion) welded
ƒ Spiral Welded
ƒ Furnace welded

There are restrictions on the use of the pipe depending upon the
manufacturing process and maximum use temperature.
Table below summarizes restrictions for carbon steel pipe.
 PIPING DESIGN

General :

The design of a piping system consists of the design of pipe, flanges and
its bolting and gaskets ,valves , fittings , filters, steam traps and
expansion joints.
The design also include pipe supporting elements including
Shoes, Springs and hangers etc.
Usually the piping design is based on the ANSI B31. 3Code for
Chemical Plant.
 PIPING DESIGN (Contd…)
Piping Design Procedures :

The following are the steps which need to be completed in the mechanical
design of any piping system :

1. Establish design conditions:

a) pressure,
b) temperature
c) other conditions e.g. wind, earthquake, fluid shock, thermal gradients
and cycles .
d) Service
e) Philosophy (Flow diagram P&ID)
2. Selection of pipe materials based on corrosion, hydrogen
embitterment and strength.
3. Select flange and valve Class rating.
4. Calculate minimum pipe wall thickness for design temperature and
pressures .
5. Establish an acceptable layout between terminal points for the pipe .
6. Perform a flexibility and dead weight stress analysis .
7. Perform special analyses for earth quake, wind , thermal gradients or
fatigue as required.
 PIPING DESIGN (Contd…)
Design Conditions :

ƒ The setting of design temperature and pressure influences or establishes

material, component thickness, piping flexibility, layout supports,
insulation, fabrication and testing.

ƒ Time design basis ( Short time and intermediate time).

ƒ Design temperature and pressure should be set such that they are
adequate to cover all foreseeable operating conditions, including start –
up, shutdown, process up rates, planned increase in operating severity
etc.
 PIPING DESIGN (Contd…)
Design Temperature
ƒDesign temperature + 120°F and below

ƒConsider Critical Exposure Temperature ( CET).

ƒMaterial should be tough

ƒShock Chilling.

ƒDesign temperature above + 120°F

ƒFor insulated piping components :

ƒDesign Temp = Max. temperature of container fluid.

ƒFor uninsulated piping components.

ƒDesign Temp = Max temperature of container fluid (T) Less

5% T for pipe and welding fittings
10% T for flanged v/v`s and fittings.
 PIPING DESIGN (Contd…)
Design Pressure
ƒGenerally :
ƒ DP = 110% (O.P) max OR .
ƒDP = (O.P) max + 25psig whichever is greater
For Piping
Piping protected by a PR Device
ƒDP = ( Set Point )v/v + static head

Not protected by a PR Device

ƒDP = valve shut off contingency + static head .

e.g. Piping subject to centrifugal pump shut-off pressure and not protected by a PR
device, an acceptable estimate of design pressure is the greater of :

ƒNormal pump suction pressure + 120% of normal pump differential pressure .

ƒMaximum pump suction pressure + normal pump differential pressure .

 PIPING DRAWINGS

Drawing is the language of engineering. This statement holds true in

piping as well

ƒ P&ID (Process & instrumentation Diagram)

ƒ Civil plot Plan
ƒ Equipment layout
ƒ Piping & Support Plan
ƒ Details
ƒ Support Details
ƒ Isometrics
 PIPING DRAWINGS
ƒ P&ID (Process & instrumentation Diagram)

A P&ID is a detailed graphical representation of a process including the

hardware and software (e.g., piping, equipment, instrumentation)
necessary to design, construct and operate the facility. Common
synonyms for P&IDs include EFDs (Engineering Flow Diagrams), UFDs
(Utility Flow Diagrams) and MFDs (Mechanical Flow Diagrams ).

A Piping and Instrumentation Diagram - P&ID, is a schematic

illustration of functional relationship of piping, instrumentation and
system equipment components.

P&ID shows all of piping including the physical sequence of branches,

reducers, valves, equipment, instrumentation and control interlocks.

The P&ID are used to operate the process system.

 PIPING DRAWINGS
A P&ID should include:

ƒ Instrumentation and designations

ƒ Mechanical equipment with names and numbers
ƒ All valves and their identifications
ƒ Process piping, sizes and identification
ƒ Miscellaneous - vents, drains, special fittings, sampling lines, reducers
and increasers
ƒ Flow directions
ƒ Interconnections
ƒ Control inputs and outputs, interlocks
 PIPING DRAWINGS

This figure depict a very small and simplified P&ID:

 PIPING DRAWINGS
PFD - Process Flow Diagram
The Process Flow Diagram - PFD - is a schematic illustration of the
system.
A Process Flow Diagram - PFD - shows the relationships between the
major components in the system. PFD also tabulate process design
values for the components in different operating modes, typical
minimum, normal and maximum. A PFD does not show minor
components, piping systems, piping ratings and designations.

A PFD may include:

ƒ Process Piping
ƒ Major equipment symbols, names and identification numbers
ƒ Control, valves and valves that affect operation of the system
ƒ Interconnection with other systems
ƒ System ratings and operational values as minimum, normal and
maximum flow, temperature and pressure
ƒ Composition of fluids
 PIPING DRAWINGS
This figure depict a small and simplified PFD:
 PIPING DESIGN (Contd…)
Piping Design Loads :
Each piping system must be designed considering the most sever conditions of
coincident loadings. The following summarizes possible imposed loads which
need to be considered in a piping design :

ƒ Design Pressure and Design Temperature

ƒ Weight Loads

ƒ Dynamic Loads

ƒ Thermal Expansion/Contraction Effects

ƒ Effects of support , Anchor and terminal Movements

 PIPING DESIGN (Contd…)

Piping Design Criteria :

Loadings are divided for design purposes into two categories :

1. External loadings which, if excessive, might cause direct failure and

2. Strain effects attendant to temperature change.
 PIPING DESIGN (Contd…)

Types of Stresses :

Loadings are divided for design purposes into two categories :

ƒ Primary Stresses
ƒ Secondary Stresses
ƒ Peak ( Local Stresses )
ƒ Allowable Stresses
 PIPING DESIGN (Contd…)
Primary Stresses :

Primary stresses are the membrane, shear or bending stresses resulting

from imposed loadings which satisfy the simple laws of equilibrium of
internal and external forces and moments :

Types of Primary Stresses Due to Sustain loads

1. Circumferential Membrane Stress Pressure

2. Longitudinal Membrane Stress Pressure, Dead Weight
3. Primary Bending Stress Pressure, Dead Weight, Wind

The basic Characteristic of a primary Stress is that it is not self -limiting.

Primary stresses which considerably exceed the yield strength of the
piping material will result in gross distortion or failure.
 PIPING DESIGN (Contd…)
Secondary Stresses :

Secondary stresses are Self-equilibrating stresses which are necessary to

satisfy forces and moments within a structure :

Types of Secondary Stresses Due to

1. Bending and Torsional Thermal Loading ( Expansion or

Contraction)
2. Bending and Torsional Non–uniform Distribution of
Temperature within a Body.

Peak (Local ) Stresses:

Localized stresses diminish rapidly within a short distance from their

origin ,such as peak stresses developed at elbows, miters and tee
junctions. Localized stresses can be conservatively considered
equivalent in significance to secondary stresses.
 PIPING DESIGN (Contd…)
Allowable Stresses :
Piping Code ANSI B31. 3 stipulates two different allowable stresses
criteria for the design of piping.
1. Basic Allowable Stress
2. Allowable Stress range

Basic Allowable Stress:

Basic Allowable stress in tension at the design temperature.

Allowable Stress Range:

This is derived from the basic allowable stress and is used as the basis
for the thermal expansion and flexibility design.
The application of each criterion is as follows

For Sustained Loads Basic Allowable Stress

Circumferential Membrane
stress due to pressure must not exceed SE

Combined longitudinal stresses due to S

pressure, weight and other sustained
loads must not exceed
 PIPING DESIGN (Contd…)
Where :

S = Basic allowable design stress at temperature for selected ferrous

material is governed by lowest of following strength properties:
1. 1/3 minimum tensile strength
2. 2/3 minimum yield strength
3. Average stress to cause 1 % creep in 100,000 hours
4. 2/3 average stress to cause rupture in 100,000 hours.

E = Longitudinal weld joint factor or casting quality factor.

 PIPING DESIGN (Contd…)
Allowable Stresses (Contd…):
For Thermal Loads Allowable Stress Range
+ Expansion stresses must not exceed SA

Where the allowable stress range (SA) is :

SA = f (1.25 Sc + 0.25 Sh )

Where :
Sc=Basic allowable stress for the material at minimum (cold) metal temperature
expected during the displacement cycle.

Sh =Basic allowable stress for the material at maximum metal temperature during
displacement cycle under analysis.
f = stress range reduction factor for cyclic conditions for the total number of full
temperature cycles over expected life.

When Sh is greater than SL ( SL =combined longitudinal stresses)

SA = f ( 1.2 ( Sc + Sh ) - SL)
 PIPING DESIGN (Contd…)
GRAPH
 PIPE MATERIALS
Pipe material is selected on the basis of :

ƒ Design Temperature
ƒ Design Pressure
ƒ Service
ƒ Cost

Piping Specification cater for the above factors

If , however the piping specification is not available the usual method is then
to compare,

ƒ Corrosion Behavior of the fluid

ƒ Mechanical Properties of materials

ƒ Allowable Stress per dollar

 PIPE MATERIALS (Contd…)
Applicable Specifications:
Materials for piping should conform to the requirements of the ANSI B31 Code
and the additional requirements of the basic practices.

Pipe Specifications:
Table
 VALVE SELECTION
Valve are the flow controlling mechanisms of pipe line or as some might
term it, the muscles of the piping system.

They exists for a wide range of purposes :

ƒ Flow on & off services

ƒ Reducing and controlling flow by throttling

ƒ Stabilization of flow to meet conditions of temp, pressure and fluid level

ƒ Safety of the operator and of public and to protect plant

Cost Analysis :

Valves account for on an average ,some where in the region of 5-6% of the
total installed plant cost.
 VALVE SELECTION (Contd…)
Guide to Valve Selection :

The following factors affect the selection of valves

Type of service required

Flow on & off services Gate Valves, Plug Valves, etc.

For throttling services Globe Valves, Butterfly Valves etc.
Back flow prevention Check Valves,etc.
Pressure Control Control valves

Properties of the fluid to be conveyed

Considerations have to be given to the effects of

ƒ Corrosion
ƒ Erosion
ƒ Viscosity
ƒ Flash points of the liquid
ƒ Penetrating Properties of the liquid
ƒ Fire hazards
ƒ Toxic Hazards
 VALVE SELECTION (Contd…)
Operating Conditions

Selection of the valve class is based on the design pressure & temperature and
service which influences the choice of the material

Fluid friction Loss and Valve size

Pressure drop is related to the bore of the pipe line, valves and other fittings.
Since pressure drop considerations are significant and pressure drop in valve
account for a substantial portion of the friction losses, there its optimum size is
significant.
 VALVE SELECTION (Contd…)
Methods of construction
ƒ Castings :

Cast Iron
High duty cast iron
Cast steel
Stainless steel
Monel
Bronze
Nickel & Copper-Nickel alloys
ƒ Forgings in Steel
ƒ Machining from solid bar materials

ƒ Die casting in aluminum

ƒ Moulding in plastics and glass
Valve Class Rating
1- Select the required material group against the material of the valve from the
table1 ( ANSI B16.34) .
2- For the selected Design pressure and Temperature, identify the valve class
from table 2 (ANSI B 16.34) .
 PIPE WALL THICKNESS
Straight Pipe Wall Thickness:

ƒ Straight pipe under Internal Pressure

ƒ Straight pipe under External Pressure
ƒ Pipe Corrosion Allowance
ƒ Pipe minimum Thickness
 CALCULATION OF THE MINIMUNM PIPE
WALL THICKNESS
Thickness of the pipe is a function of ,
ƒ Allowable stress of the material
ƒ Pipe Diameter
ƒ Design Pressure
ƒ Corrosion and Erosion Rates
t = PD/2(SE +PY)
tm= t + c
Where,
tm= minimum required thickness satisfying requirements for pressure, mechanical
corrosion and erosion allowances, inches (mm)
t= pressure design thickness (PDT )for internal pressure only, inches (mm)
c=sum of mechanical allowances ( thread depth and the groove depth), corrosion
and erosion allowances, and manufacture mill tolerance (typically 12.5% of
nominal thickness ),inches (mm)
P=internal design pressure, psig (MPa)
D=Outside diameter of pipe ,inches (mm)
S=allowable stress of pipe material at design temperature. Given in ANSI
B31.3,Appendix A-1
Y=coefficient having values as given in ANSI B31.3,table 304.1.1
E=longitudinal weld joint factor. Given in ANSI B31.3,appendix A-1A and A-1B
 LAYOUT
Data required to begin layout and arrangement of piping

ƒ Approved Plot Plans

ƒ Flow diagrams from Process
ƒ Piping Specifications
ƒ Vessel Drawings
ƒ Vendor Prints
ƒ Instrument Location List
 LAYOUT CONSIDERATIONS
Data required to begin layout and arrangement of piping

ƒ Ease of Operation
The location of operating and control points , such as valves, flanges,
instruments, samples points, drains and vents shall be placed so that these
part of the system can be utilized with minimum difficulty.

ƒAccessibility for maintenance

Example,
Clearance must be provided off the end of shell and tube heat exchanger to
permit tube bundle removal.
Around rotating equipment to provide free access to cranes and lifting
equipment.

ƒEconomy
 LAYOUT CONSIDERATIONS

ƒSpecial Process Requirements

Example,
To cater for pressure head which is critical and thus minimize pipe bends.

ƒPotential Future Additions

ƒAppearance

ƒMinimize Dead ends

Example,
Low pockets in piping should be avoided, which may cause difficulty in
draining

ƒMaximize use of existing supports

ƒThermal Expansion Clearances

 GENERAL CHECKLIST FOR LAYOUT
ƒ Define the end to end location for the layout. Collaborate with equipment
designers to ensure that nozzle positions and orientations are convenient for pipe
layout.
ƒ Run pipes in North-South, East-West, and Up-Down directions where ever
possible.
ƒ Assign in advance, separate elevations for North-South and East-west piping.
This helps to prevent pipe fouls. The range of Clearances is 18” to 30”above,blow
or both.
ƒ When a pipe changes direction, change elevation, according to the above.
ƒ Route pipe groups (particularly containing large pipes ) along lines of main steel
work so that supports can be taken from main members.
ƒ Spacing of pipes within groups should be practical minima.
ƒ Make provisions for flexibility in hot or cold piping by use of loops, bellows or
expansion joints.
ƒ Allow for thickness of insulation (especially on high temperature pipes) in spacing
pipes.
ƒ Allow for runs of straight pipe needed for flow measuring devices.
 THERMAL FLEXIBILITY ANALYSIS

Definition
Any piping system should have flexibility to accommodate the effects
of thermal expansion, so that they,

Will not fail because of excessive thermal expansion stresses

Will not be overloaded and cause flange leakage, and
Will not produce excessive thrusts or moments at connected equipment .
 CRIETERIA FOR ANALYSIS (Contd…)
ANSI B31.3 Identifies certain conditions when flexibility analysis is not
required ,
Piping system is a duplicate of a successfully operating installation with
a satisfactory service record.
Line under consideration is judged adequate by comparison with
previously analyzed systems .
Piping system is of uniform size has no more than two points of fixation and
no intermediate restraints and satisfies the following formula .
DY/(L-U)2 < 0.03
D = NPS , inches
Y = Resultant of total thermal displacements to be absorbed by the piping
system , inches
U = Anchor distance ,straight line distance, between anchors, feet
L = Developed length of piping between anchors , feet
Precautions :
Caution should be exercised in applying it to abnormal configurations ,like,
L/U > 2 . 5,or near saw tooth configuration

D/t ratios having stress intensification factors of the order of 5 or more.

 PIPING DRAWINGS (Contd…)
Isometric Drawing :

There are many different types of 3-D drawings. One fairly simple way to
get started drawing in 3-D is to try an isometric drawing. An isometric
drawing of a cube looks like this:
 PIPING DRAWINGS (Contd…)
An easy way to draw objects in isometric is to use an isometric grid, as
shown below. On an isometric grid, there are 3 types of lines: vertical
lines, 30° lines to the right, and 30° lines to the left. The drawing below
on the left shows an isometric grid; the drawing on the right shows an
isometric grid with a cube drawn on it. In all of these drawings, the
faces are shaded to make it look more "solid."
 PIPING DRAWINGS (Contd…)
Examples of different geometric shapes drawn on isometric grids:

Sometimes in order to draw a particular shape you need to draw lines that
don't fall right on the grid, for example when drawing a pyramid with a
rectangular base, as shown below.
 GENERAL PROCEDURE FOR THE PIPING
FLEXIBILITY PROBLEM
Design Data inputs Required :
ƒ Line size
ƒ Wall thickness
ƒ Material
ƒ Number of anticipated temperature Cycles
ƒ Planned Layout
ƒ Greatest temperature differential, considering normal operating,
ƒ start up ,shut down, steam out ,abnormal conditions ,etc.
ƒ With regard to initial layout ,this is typically selected consistent with
pressure drop limitations, available space, equipment access, existing
structure for supporting, and “ rule of thumb” judgment as to its inherent
piping flexibility.
ƒ Conditions of end restraint have to be assessed. General practice in this
regard is to take the line terminations as fully fixed in the absence of
detailed analysis of the rotations deflections of vessel shells; pump,
compressor or turbine casing; or other pipe anchors to which the line
may be connected. equipment thermal expansion must however be
taken into account since they may cause increased forces ,moments, or
stresses.
 GENERAL PROCEDURE FOR THE PIPING
FLEXIBILITY PROBLEM ( Contd…)
ƒ The designer must then locate with reasonable accuracy all
intermediate points of restraint including supports, guides ,directional
stops and all significant branch line which effect piping flexibility.
Major restrictions to the free movement of the line due to guides, solid
hangers, or braces are usually taken into account in calculations or
other forms of analysis. Unbalanced forces of spring or counter weight
supports can usually be ignored for the thermal analysis of any system.

ƒ All support locations including springs or counter- weights should be

considered in evaluating sustained loads and stresses attributed to dead-
weight.
ƒ A method of analysis suitable to the importance of the system must
then be selected.
ƒ Finally, a comparison of the results have to be made with the applicable
allowable stress range ( SA) or load limit criteria designated for the piping
system or its connected equipment.
ƒ Finally, a comparison of the results have to be made with the applicable
allowable stress range ( SA) or load limit criteria designated for the piping
system or its connected equipment.
 GENERAL PROCEDURE FOR THE PIPING
FLEXIBILITY PROBLEM ( Contd…)

SA=f (1.25 Sc+0.25 Sh)

Where,

ƒ Sc = basic allowable stress for the material in the cold material in the
condition, psi (from Table A-1 ,ANSI B313.3)

ƒ Sh= Basic allowable stress for the material in the hot condition,psi
(from Table A-1,ANSI B31.3)

ƒ f= Stress range reduction factor for cyclic conditions for total number of
full temperature cycles over the expected life.
 PIPING SUPPORTS
ƒAnchors: It is used for the protection of weak links in system. In smaller branch
connections, overloads, excessive stiffness by expansion travel.

ƒ Stops or Guides: They are used for directing expansion away from the sensitive
equipment, such as pumps, turbines and prevent overstrain of casing or
misalignment of rotating parts.

ƒ Pipe Hangers & Sway Braces: Its design and type would be such to avoid
undue interference with free expansion movement between anchors. They are
neglected in flexibility analysis.

ƒ Rigid Hangers: They are limited to application where there is little vertical
movement. Roller hangers are same as rigid hangers but preferred for streamline.

ƒ Rigid Tie: They are beneficial for control of important junction where fix
anchors produces excessive stiffness .

ƒ Spring Hangers: They have the provision for adjustment, where vertical travel
is moderate.
 FITTINGS
Fittings allow pipe to be installed and joined where necessary and terminated in
the appropriate place. Each kind of pipe requires its own type of fitting, but all
fittings share some common features.

1. Fittings are either male or female

This refers to their orientation at the connecting point. Pipes, nipples, and
male fittings insert into female fittings. In threaded fittings, male threads are
on the outside and female threads are on the inside. Fittings that have one
male end and one female end are called street fittings.

2. When measuring the size of fittings, male threaded fittings are measured OD,
or to the outside edge, while female fittings are measured ID, or to the inside
edge of the inlet.
 FITTING CLASSIFICATION
Fittings that extend or terminate pipe runs

Couplings extend a run by connecting two lengths of pipe. They are available in
all standard pipe sizes and nearly all varieties of pipe.
They're called reducing couplings if they're connecting different sized pipe..

ƒ Adapters are similar to couplings, but they connect different types of pipe

ƒUnions are three-part mechanical fittings that connect any two standard size
pipe in such a way that they may be disconnected and reassembled with a pipe
wrench. Unions provide the easiest method for dismantling pressure pipe.

ƒCaps and Plugs end a run of pipe by closing it off with a watertight seal.
 FITTING CLASSIFICATION (Contd…)

Fittings that change a pipe's direction

Elbows (ells) change direction of pipe. Most common are 90° and 45° elbows, but
are also available in 22 ½ and 60. They are identified by their angle but number
ordinarily refers them to only. An elbow may be female at both ends, or in the
case of a street elbow, may be male on one end and female on the other. Some
are offered in a long-turn variety, some have side inlets; some have vent inlets.
 FITTING CLASSIFICATION (Contd…)
Fittings that Connect two or more pipes
Tees offer the most varieties of any type of fitting. Tees are fittings in the shape
of a "T" where the top of the "T" is the continuous pipe run, and the vertical
section is a branch connected to it. They may be reducing tees, where the branch
and or one end of the through section is a smaller diameter than the inlet.

ƒ Crows Feet Tees, which allow for a fourth pipe to join them. These may be left
or right handed depending on which side the inlet enters

If the branch line passes through the tee, the fitting becomes a Cross.
If the side inlet passes through the fitting, it would be a four-way tee.
If the cross has a side inlet, it could accommodate 5 different pipes. Tees can be
used with clean out plugs in a soil stack.
 FITTING CLASSIFICATION (Contd…)

Other tees in the soil stack are often sanitary tees, in which the branch line
connects in a curved manner, which reduces the friction in the pipe, thus less
likelihood of clogging.

ƒ Side-inlet Elbows have three-way outlets. They can be used as corner pieces
for railings, fences, etc. but are also used for pipe connections on corner
construction.

ƒWyes are similar to tees except that the branch line is angled to reduce friction
that could hamper the flow, and the connection is typically at a 45-degree angle
rather than a 90-degree angle. If a branch turns out at the end to be
perpendicular to the through line the fitting become a tee wye.
 FITTING CLASSIFICATION (Contd…)

Fittings that change pipe size

ƒ Reducers can be couplings, tees, ells, or wyes, where one end is smaller than the
other. This reduces the pipe's diameter between inlet and outlet. In the case of
fittings that connect more than two pipes, one of the outlets is of a smaller
diameter, (not counting side-inlets, which are always smaller). Some reduce pipe
only one size; others can reduce several sizes. Both ends are female.

ƒBushings serve the same purpose as reducers except that they have one male
and one female end. In steel pipe, they are threaded inside and out; instead of
screwing directly onto pipe threads, they screw into a coupling and pipe is
threaded into them. They are virtually invisible once installed.
 FITTING CLASSIFICATION (Contd…)

ƒCouplings connect pipe to pipe. Couplings with stops usually have tiny ridges or
"stops" on the inside to seat the pipe. When they don't, they're called "repair
couplings" that can be positioned anywhere along a length of pipe to repair a
leak. Both ends are female.

ƒ Flex couplings are rubber couplings and used to connect PVC to Clay or Cast
Iron above or below ground. Also used for repairs. They attach by used of steel
band clamps, or as underground adapters to connect PVC to Clay or Cast Iron
pipe. They are not suitable for pressure connections.
 FITTING CLASSIFICATION (Contd…)

ƒFitting reducers connect pipe to fittings. Fitting reducers look like couplings but
they're actually bushings used primarily with copper fittings to reduce the size of a
run. One end is female; the other male.

ƒAdapters connect dissimilar types of pipe. They may have either male or female
IPS threads on one end and the opposite gender on the other end to be soldered
or welded onto a smaller pipe. Flex couplings can act like adapters.
 FLANGES
A flange allows two pipes to be mechanically connected together, or a pipe to be
mechanically connected to a valve, tee, choke or other piece of equipment.
Types of Flange

ƒThreaded/Screwed Flanges - Threaded Flanges can be fitted to the pipe

without welding, though a seal weld can sometimes be used. They can be screwed
on to threaded pipes.

Use: They are suitable for small diameter high-pressure services. At larger
diameters, the difficulty in machining the thread on to both the flange and pipe
makes them unviable. They are also not suitable for areas having high external
loads, particularly torsion and involving thermal and bending stresses.

ƒWeld neck Flanges - Their long tapered hub recognizes them. The hub provides
an important reinforcement to the flange itself and acts to reduce rotation of the
flange at bolt up. It can stand repeated bending.

ƒUse: These are the most common types of flange used for high pressure/low or
high temperature applications. The smooth transition between the flange and the
hub combined with the strength of the butt weld joint allows the flange to be used
in extreme conditions of cyclic loading, bending and temperature fluctuations..
 FLANGES
Slip-On Flanges - Their ease of fitting and welding reduces fabrication costs. Less
time and skill needed to be spent ensuring the accuracy of the cut pipe and they
are somewhat easier to align. They do not have as much strength as a weld neck
flange and are not available in higher-pressure ratings and diameters.
Use: Slip-On Flanges are ideal for moderate or lower pressure applications and
when ease of assembly is required.
ƒSocket Weld Flanges - The fabrication of these items is similar to that of a
Slip-On Flange. However, their internal pocket allows for a smooth bore and
better fluid flow.
Use: They are ideal for small diameter high-pressure applications where leak
proof fittings are preferred to screwed attachment.

ƒLap Joint Flanges - Lap Joint Flanges must be used with their associated stub
end. The stub is welded to the pipe and the Lap Joint then works as a backing ring.
The main advantage of this type of flange is that the bolt holes can be aligned
with the matching flange after the welds have been completed.
Use: A Lap Joint Flange is not suitable for areas with high external or
dynamic loads and severe bending stresses. A Swivel Ring Flange should be
used for this type of application. Service requiring frequent dismantling for
inspection an cleaning. For large diameter pipe and other installation for which
ability to rotate flange is an advantage.
 FLANGES (Contd…)
ƒSwivel Ring Flanges - Swivel Ring Flanges are similar in principle to Lap Joint
Flanges. They have a hub, which is welded to the pipe and a rotating bolt ring. The
swivel inner hub profile and full thickness of the swivel outer can give the flange
the same strength and external load capabilities as a Weld neck Flange.

Use: Swivel Ring Flanges are used for sub seat installations. Swivel Ring
Flanges are not covered by International Standards and are designed by
Welding Units as proprietary items.
ƒBlind Flanges - Blind Flanges are used to blank off the ends of pipe, valves and
pressure vessel openings. They may often be supplied with NPT fittings to allow
pressure test connections to be fitted.
ƒOrifice Flanges - They are similar to Weld neck, Slip-On and Screwed Flanges,
except that they are modified to hold orifice plate carriers and have radial taped
holes for the fitting of meter connections.
Use: Orifice Flanges are used with orifice meters to measure the flow rate of
liquids and gases in a pipeline.

ƒAnchor/Hanger Flange - Anchor flanges are used to resist thrust loads in long
pipelines caused by thermal expansion and other environmental factors. The
Anchor Flange is normally buried in concrete. Hanger flanges are similar in profile
but are used to support the weight of a riser on an offshore pipeline.
 FLANGES (Contd…)
ƒFloor Flanges - connect pipe to a wall, floor or any flat surface. Flanges are
threaded onto pipe and tightened. This provides a flange rim with four screw
holes, making it easy to fasten pipe to a flat surface.

Flange Facing:
ƒRaised: Both flanges of a pair are identical. Gaskets are usually less in width
than the raised face. They are used for moderate services.
ƒRing-type: Most expensive and efficient flange facing. Not easily damaged in
assembling. It is used at high temperature and pressure services. It cannot be
damaged easily in assembling.
ƒ Male and Female: They are formed in small and large designs. Metal gaskets
can be used in small design because of high gasket compression. They are used for
special purposes requiring a retained gaskets.
ƒTongue and Groove: They too are found in large and small designs. Their inside
diameter does not extend to flange bore thus eliminating contact of gasket by
process fluid. Small design gives high joint efficiency with flat gaskets. They are
used in services requiring retained gaskets and lack of contact with process fluid.

ƒFlat Face: Raised portion of the flange is remove in this type of facing. They are
used for mating flanges for cast iron valves and fittings.
 COMMON DEFINITIONS USED IN PIPING
ƒAnchor: A point where piping is fixed.
ƒ Bleed: A small valve provided for drawing of liquid.
ƒBlind: A plate size to be inserted in a flange to isolate a portion of the system.

ƒBlock Valve: A valve furnished to shut off a system.

ƒB.O.P. : Bottom of outside of pipe.
ƒDirections: The plant north direction shown on plot plans and other drawings.

ƒDrip-Leg: A vertical section of pipe located in horizontal piping to deflect and

catch condensate.
ƒF.W.: Field weld.
ƒLine: A pipe run from one point to another.

ƒP.E. : It indicates plain-end.

ƒP.S. : It is used to indicate Pipe support.

ƒSpec: Line specification.

ƒSpool: A short piece of pipe provided with flanges. (normally of 20feet and
smaller).
 PUMP TYPES ORGANOGRAM

PUMP

Positive displacement
Dynamic Pump
Pump

Reciprocating Pumps Rotary Pumps Centrifugal Pumps

Plunger Pumps Gear Pumps Impeller Pumps

Diaphragm Pumps Screw Pumps

Propeller Pumps
Sliding vane Pumps
Turbine Pumps
Lobe Pumps
 PIPING FAILURE

Process industry have established an impressive safety record over the

years. However, failures have occurred for an assortment of reasons. Some
of the causes of failure are identified in this presentation.

. Pipe wall thicknesses are established on the pressure in

the line and on the allowable hoop stress levels for the material. The
allowable stress levels for piping vary based on the various things e.g.
location.

Piping are pressure tested in addition to nondestructive testing prior to being

put into service. Normally, pipelines are hydrostatically stressed to levels above
their working pressure and near their specified minimum yield strength. This
pressure is held for several hours to ensure that the pipeline does not have
defects that may cause failure in use. This proof test of pipelines provides an
additional level of confidence that is not found in many other structures .
 PIPING TROUBLESHOOTING
PIPING FAILURE

Probable Causes

• Mechanical damage
• Fatigue cracks
• Material defects
• Weld cracks
• Incomplete fusion
• Improper repair welds
• Incomplete penetration
• External or internal corrosion
• Hydrogen blistering
 TYPICAL QUESTIONS & ANSWERS

1. What is the difference between Pipe and Tube ?

2. What is the difference between Pipe & Pipeline?
3. Describe Classification of piping ?
4. Name three piping manufacturing processes ?
5. What is the difference between ERW and Arc welding manufacturing process ?
6. Define philosophy of the piping ?
7. What type of design data input required for the flexibility analysis ?
8. Define the type of stress that is not self limiting ?
9. Define critical exposure temperature ?
10. What could be the effects of excessive Vibration ?
 TYPICAL QUESTIONS & ANSWERS
11.Mathematically define the general relation between the design and operating
pressure ?
12. Briefly explain the isometric drawing & write down the immediate pre-requisite
of this drawing ?
13.For throttling services which type of valves are most suitable ?
14. Pipe material is selected on the basis of ?
15. Write down 3 important common synonyms of P&ID ?
16. What are the major areas for the development of the localized stresses in
piping ?
17. Write down 3 important differences between P&ID and the Process Flow
diagram ?
18. If the pipe is subject to severe conditions ,under which type of stress it fails first
longitudinal or circumferential (hoop stress) ?
19. Loadings are divided for design purposes in to how many categories ?
20. What is a Spool ?
21.Thickness of the pipe is a function of?
 TYPICAL QUESTIONS & ANSWERS
22.Mathematically define the general relation between the design and operating
pressure ?
23. Briefly explain the isometric drawing & write down the immediate pre-requisite
of this drawing ?