Piping Training Course - Part - 1

 Piping Training Course
OVERVIEW OF
PROCESS PLANT PIPING
SYSTEM
Piping components: summary
 Definition
 Piping component
 Piping drawing
 Design
 Pipe work
 Codes & Standards
Definition
Definition:
 Piping:
Assemblies of piping components
used…[for] fluid flows.
Piping also includes pipe supporting
elements, but does not include support
structures…or equipment…
 Piping system:
Interconnected piping subject to the
same design conditions.
Definition:
 Piping components:
Mechanical elements suitable for joining
or assembly into pressure tight fluid-
containing piping systems include
Piping Component
Piping components:
 Piping components includes:

 Pipe & tube
 Fittings (e.g. elbows, reducers, branch,
connections, flanges, etc.)
 gaskets, bolting
 valves
 Pipe support
 Special items such as expansion
joints…
Pipe & Tube
Piping components: Pipe & tube manufacturing
 Seamless Show
 Welded:
─ Longitudinal seam
• Single seam
• Double seam (NPS ≥ 36”)
─ Helical (spiral) seam Show

• NPS ≥ 4 ½”
• 0.8 OD ≤ Skelp width ≤ 3.0 OD
• Submerged arc welding
Piping components: Pipe & tube manufacturing
 Welding process:
─ Without filler metal
• Electric welding Show
• Continuous welding Show
– With filler metal

• Sub-merged arc welding
• Gas metal arc welding
Piping components: Pipe & tube manufacturing : Seamless pipe
Billet preparing Billet heating

Billet chopping
visual control in annular furnace
Rough tube Tube rolling in Mandrel removing

piercing continuous mandrel mill
Tube heating in Sizing and reduction Stalk ends cutting,

cell induction furnace tubes cutting with flying shears
Tubes cooling Tubes leveling Tubes cutting in ready

sizes, tubes facing
Geometry measuring, Tube ends sizing Heating for quenching

mechanical tests, (by OD and ID)
chemical composition control
Quenching in sprayer Tempering Tubes cooling

Tubes etching Ultrasonic or Hydraulic test

electromagnetic test
Sweeping-up (if required) Preservative coating Weighing, marking,

, visual control packing, storing
Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)
Tube end upset Thermal treatment Leveling
Sweeping-up and Threading, thread Couplings screwing-on

grading by length quality monitoring
Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)
Hydraulic test Tubes inspection, Painting (if required))

rings and nipple
screwing-on, marking
Packing, storing
Piping components: Pipe & tube manufacturing : other pipe
Piping components: pipe & tube classification
 Pipe classification:
─ Iron pipe size (approximate internal dia.)
─ Manufacturers’ weight: NPS +
• STD
• XS
• XXS
─ Schedule number: NPS +
• 5, 5s, 10, 10s, 20, 20s, 30, 40, 40s, 60, 80, 80s, 100, 120,
140, 160 Show
• SCH ≈ 1000 P/S
• NPS ≤ 12, OD ≥ NPS
• NPS ≥ 14, OD = NPS
• NPS ≤ 10, SCH 40 = STD
• NPS ≤ 8, SCH 80 = XS
• Light wall = light gage = 5, 5s, 10, 10s
– API designation
• A25, A, B, X42, X46, X52, X60, X65, X70
• X(AA), AA = Allowable stress
– Pressure-Temperature Ratings
• 150, 300, 400, 600, 900, 1500, 2500
 Pipe:
─ NPS:
1/8”, ¼”, 3/8”, ½”, ¾”, 1”, 1 ½”, 2”, 3”, 4”, 6”, 8”, 10”,
12”, 14”, 16”, 18”, 20”, 24”, 28”, 30”, 32”, 36”, 40”,
44”, 48” 52”, 56”, 60”
─ NPS 1 ¼”, 2 ½”, 3 ½”, 5” not used
─ Pipe is supplied in
─ Random length (17 to 25 ft)
─ Double random length (38 to 48 ft)
─ Pipe end:
─ BE (bevel end)
─ PE (plain end)
─ T& C (treaded and coupled, rating of coupling shall
be specified
 Tube:
– Specify by two of
• Outside diameter
• Inside diameter
• Wall thickness:
– Thousandths of inch
– Gauge number
» American wire gauge
» Steel wire gauge
» Birmingham wire gauge
»…
– When gauge numbers are given without reference to a

system (BWG) is implied
Piping components: pipe standards
 ASTM A53 – Steel Pipe

 ASTM A312 – Stainless Steel Pipe
 AWWA C151 – Ductile Iron Pipe
 API 5L – Line pipes
 ISO 11960, API 5CT – tubing
 ASTM A 53/A 53М Electric-weldedand seamless
steel pipes, black or hot-dip galvanized
 ASTM A 106 Seamless carbon steel pipes for high
temperature performance
Piping components: Fitting
Fitting
 Fitting produce change in geometry and include:
– Change in direction of piping
– Alter pipe diameter
– Terminate pipe
– Bring pipes together

(made branch from main pipe run)
 Method of joining pipe:

─ Butt weld
─ Socket weld
─ Threaded
─ Quick coupling
─ Flange
─ Special item
Piping components: Fitting (butt-weld)
 ASME B16.9
 Used in most piping systems NPS ≥ 2”
 Use generally not restricted
 Difficult in small sizes, especially for thin wall
Backing ring
 Elbow (90, 45)

– Long reduce
• Curvature = 1 ½ NPS
• Long tangent: straight
extension at one end
– Short reduce
• curvature = NPS
 Reducing elbow:
– 90
– curvature = 1 ½ NPS larger end
 Return:
– Curvature = 1 ½ NPS
– Uses in:
• Vent on tanks
 Bend:
– Curvature = 4 - 6 NPS
– Made from seamless and ERW straight
pipe
– Two methods used to making bend
• Hot
• Cold
 Miter
– 2 piece (pressure drop ≈ 4-6 LR elbow)
– 3 piece (pressure drop ≈ 2 LR elbow)
– Low pressure line, NPS > 10” & pressure drop not important
– 90
 Reducer
– Eccentric
• Suction & discharge of pump
• support
– concentric
 Sewage :
– connect butt-welded piping to smaller socket-weld or
screwed
– Abrupt change of line size in butt-weld Type:
• Eccentric
• Concentric
• Venturi: Allows smoother flow
 Tee
– Straight (branch to the same size as the run)
– Reducing
• Branch smaller than the run
– Bullhead tee have branch larger than run &
seldom used and made to special order
 Cross
– Straight (branch to the same size as the run)
– Reducing (rarely used)
 Lateral (manufacture in factory)

– Run inlet × run outlet × branch × angle respect
to outlet (6 × 6 × 4 × 45)
 Shape nipple (use template)

– Manufacture at shop
– Rarely use
– 90, 45
 Stub-in
– Welded directly in the side of the main pipe run
– Least expensive
– NPS ≥ 2”
– Cab be reinforced
 Weldolet
– Make a closer manifold that Tee
– Full size
– Reducing
– Flat
• Are available for connecting to pipe caps and
pressure vessel
 Elbolet: reducing tangent branch on elbow

 Latrolet : reducing, 45
 Sweepolet
– Good flow pattern and optimum stress
distribution
– 90 reducing from the main pipe
 Closure
– Cap
– Flat closure
Piping components: Fitting (socket)
 Size frequently limited to NPS≤ 1 ½” (ASME B16.11)

 Not used in “severe cyclic conditions” and in
services where corrosion is accelerated in crevices
 No weld metal can enter bore, easier alignment on
small line than butt-weld
 Tack is unnecessary
 Have not any leakage
 Elbow (90, 45)

 Return:
 Reducer
 Reducer insert
 Sewage :
– Abrupt change of line size in butt-weld
 Full coupling
 Half coupling
 Union
 Tee
 Cross
 Lateral
 Sockolet
 Socket welding Elbolet

 Socket welding latrolet
 Nippolet
 Cap
Piping components: Fitting (threaded = screwed)
 Common materials
– Gray iron (ASME B16.4)
– Malleable iron (ASME B16.3)
– Steel (ASME B16.11)
─ Non-toxic, non-flammable, Generally not used where leaks
cannot be tolerated
─ NPS ≤ 1 ½” , pressure rating < 600, temperature < 625
Piping components: Fitting (thread)
 Elbow (90, 45)

 Reducing elbow
 Reducer
 Reducer insert
 Sewage nipple
 Full coupling
 Half coupling
 Tee
 Nipple
 cross
 lateral
 Union
 Hexagon bushing
 Threadolet
 Threaded elbolet
 Threaded latrolet
 Threaded nippolet
 Closure
– Cap
– plug
 Flange used for

– Mate to equipment, vessels, valve, …
– When need periodic cleaning
– Flanges are normally used for pipe sizes above
NPS 1½”.
 Type of flanges:
– Threaded Flanges
– Socket-Welded Flanges
– Blind Flanges
– Slip-On Flanges
– Lapped Flanges
– Weld Neck Flanges
Piping components: Fitting (flange)
 Welding neck flange

– Regular
– Long (used for vessel & equipment nozzle, rarely for
pipe
 Suitable where
– Extreme temperature
– Shear
– Impact and vibration
Stress apply
 Slip-on flange
– Internal welds is slightly more subject to corrosion
than the butt-weld (0 – 1/16”)
– Poor resistance to shock and vibration
– Cheaper to buy, costlier to assemble
– Strength under internal pressure 1/3 of corresponding
welding neck flange
– Easier to align than the welding neck flange
 Socket welding flange

 Threaded flange
 Reducing flange
– Specify by size of smaller pipe and outside diameter
of flange to be mate
• Ex/ RED FLG 4” × 11”
– Should not be used if abrupt transition would create
undesirable turbulence as at pump
 Expander flange
– Reducer + welding neck flange
– Increase pipe size to first or second large size
 Lap joint (van stone) flange

– If stub and flange are of the same material they will
be more expensive than a welding neck flange
– Economical for different material of stub and flange
 Blind flange
 Flangeolet
 Flange Facing Types

 Flat Faced
 Raised Face
 Ring Joint
 Flange Rating Class:

– pressure/temperature combinations
– Seven classes (150, 300, 400, 600, 900, 1,500,
2,500)
– Flange strength increases with class number
– The material specifications are grouped within
Material Group Numbers.
 Material Specification List

 Pressure - Temperature Ratings
 Material and design temperature combinations

that do not have a pressure indicated are not
acceptable.
 Flange Rating Class



 Equipment Nozzle Load standards and Parameters

 Flange with jack screw

Piping components: Fitting (piping specification)
Piping components: Fitting (piping specification)
Piping components: Fitting (branch connection chart)
Piping components: Fitting (gasket)
 Gasket:
– Resilient material
– Inserted between flanges
– Compressed by bolts to create seal
– Commonly used types
• Sheet
• Spiral wound
• Solid metal ring
• Insulation gasket
 Sheet
 Sheet
 Spiral wound
 Spiral wound
 Spiral wound
 Solid metal ring

 Insulation gasket
Piping components: Fitting (bolt)
 Bolt type:
– Stud bolt
• Easily remove if corroded
• Material can be readily made
– Machine bolt
 Has to be strong enough to seat the gasket
Piping components: Fitting (bolt)
 Tightening arrangement
 ASME B16.5, Pipe Flanges and Flanged Fittings

(NPS ≤ 24”)
Piping components: Fitting (special item)
 Quick coupling
 Flange coupling adaptor

 Expansion joint (Bellows)

 Expansion joint
 Flexible joint
 Flexible joint
 Double block & bleed

 strainer
 Spectacle blind
 Thermal sleeve & Queel

 Bird screen
 Tundish
 Pigging Tee
• RUPTURE DISKS OR BURST DIAPHRAGMS:

• must be replaced after opening
Piping components: valve
Valves
 Valve are used for

– Controlling process and utility service
– Isolating equipment or instrument for
maintenances
– Discharge gas, vapor or liquid
– Draining piping and equipment on
shutdown
– Emergency shutdown
 Classify valves according to functions:

– Block flow (On / Off)
– Regulating (Throttle flow)
– Checking (Prevent flow reversal)
– Switching
– Discharging (pressure relive valve)
 Classify valves according to operating device:

– Manual
– Hydraulic
– Motor (electric and air operated)
– Solenoid
 Type of valves:
– Ball valves
– Gate valves
– Globe valves
– Check Valves
– Plug valve
– Butterfly valves
– Pinch valve
– Needle valves
– Relief Valve
Ball Valve
Piping components: valve (ball valve)
Piping components: valve (ball valve)
 Used for isolation (quick on / off)

 Soft-sealed ball valves are not normally used for
throttling service because the soft-seats are subject
to erosion or distortion/displacement caused by fluid
flow when the valve is in the partially open position.
 ADV: Low pressure drop, fast operating, bubble-tight
shut off, can be throttled Check Valves
 DISADV: Expensive, heavy, poor throttling
Gate Valve
Piping components: valve (gate valve)
 About 75% of all valves in process plants

 an optimum engineering and economic choice for on
or off service. (cutout or isolation valves)
 ADV: small pressure drop across valve
 DISADV: poor throttling characteristics
Globe Valve
Piping components: valve (globe valve)
 Most economic for throttling flow and used for flow

control
 Can be hand-controlled
 Provides “tight” shutoff
 Not suitable for scraping or rodding
 Too costly for on/off block operations
 ADV: excellent throttling characteristics
 DISADV: large pressure drop across the valve due to
the flow restriction (thus more pumping power is
required to move the fluid through the system.)
Check Valve
Piping components: (check valve / swing check valve)
Piping components: (check valve / swing check valve)
 Simple design
 Allows flow in one direction
 Can not be used as an isolation valve
Piping components: (check valve / ball check valve)
Piping components: (check valve / ball check valve)
 Their low cost usually makes them the first choice

valves sized NPS 2 and smaller (available in
sizes NPS ½ through 2)
 Used when pressure drop is not a concern.
 The basic types are the straight-through- and
globe-type (90 change in direction)
Piping components: (check valve)
Piping components: (check valve / lift check valve)
 are available in sizes from NPS ½ through 2 plants.

 They are most commonly used in the higher ASME
B16.5 ratings (Class 300 and greater) where tighter
shutoff is required.
 Valves of this type should only be used in clean
services.
Wafer Check Valve

Piping components: (check valve / wafer check valve)
 Valves of this type are placed between pipe flanges

and held in place by the compressive force between
the flanges and transmitted through the gaskets.
Stop Check Valve

Piping components: (check valve / stop check valve)
 Internals similar to a globe valve

 Disc is not attached to the stem
 Valve stem - long enough to hold the disc firmly against
the seat
 Stem raised - the disc can be opened by pressure on the
inlet side
 Can be used as an isolation valve as well as a check
valve
 Function of check valve:

– Prevents flow reversal
– Does not completely shut off reverse flow
– Available in all sizes, ratings, materials
– Valve type selection determined by
• Size limitations
• Cost
• Availability
• Service
Plug Valve
Piping components: valve (plug valve)
Plug Valve
Piping components: valve (plug valve)
 Similar to ball valve

Butterfly Valve
Piping components: valve (butterfly valve)
Butterfly Valve
Piping components: valve (butterfly valve)
 used as cutout/isolation valves

 ADV: quick-acting low pressure drop across the valve,
has adequate throttling characteristics
 DISADV: only used for low press/low temp systems
due to force involved in valve operation
Pinch Valve
Piping components: valve (pinch valve)
Pinch Valve
Needle Valve
Piping components: valve (needle valve)
Needle Valve
Relive Valve
Relive Valve
Piping components: valve (relive valve)
 special type of valve designed to operate automatically

(self actuating) in a system overpressure condition (a
protective feature in most systems)
 most relief valves use an adjustable spring to determine lift
pressure. System pressure opposes spring pressure, and
when pressure is high enough, the valve will open against
spring pressure and port the fluid to another location
(typically, overboard for „safe‟ fluids)
 Type of relive valve:
– Relief Valve - liquid systems
– Safety Valve - gas and vapor systems
– Safety Relief Valve - liquid and/or vapor systems
Piping components: valve (interlock)
Interlock sequence
Piping components: valve (parts)
 Parts of valves:
– disk:
• The moving part directly affecting the flow
– seat:
• Non-moving part that disk bear on it
– Metallic
– Non-metallic (elastomer)
– port:
• Maximum internal opening for flow when the
valve is fully open
– Stem:
• Move the disk
– Handwheel:
• Rise with the stem
• Stem rise thru the handwheel
Piping components: valve (result)
Piping components: valve (valve selection process)
 General procedure for valve selection.

– Identify design information including
pressure and temperature, valve function,
material, etc.
– Identify potentially appropriate valve types

and components based on application and
function (i.e., block, throttle, or reverse flow
prevention).
– Determine valve application requirements

(i.e., design or service limitations).
– Finalize valve selection. Check factors to

consider if two or more valves are
suitable.
– Provide full technical description

specifying type, material, flange rating,
etc.
Valve data sheet

Piping components: valve (leakage classification)
 According to ANSI, leakage classify by class

(I, II, III, IV, VI)

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What are the main components of a piping system?

What are the main components of a piping system?

What are the main types of pipes used in piping systems?

What are the main types of pipes used in piping systems?

 Piping Training Course

 Piping components includes:

─ Helical (spiral) seam Show

• Continuous welding Show

– With filler metal

Billet preparing Billet heating

Rough tube Tube rolling in Mandrel removing

Tube heating in Sizing and reduction Stalk ends cutting,

Tubes cooling Tubes leveling Tubes cutting in ready

Geometry measuring, Tube ends sizing Heating for quenching

Quenching in sprayer Tempering Tubes cooling

Tubes etching Ultrasonic or Hydraulic test

Sweeping-up (if required) Preservative coating Weighing, marking,

Tube end upset Thermal treatment Leveling

Sweeping-up and Threading, thread Couplings screwing-on

Hydraulic test Tubes inspection, Painting (if required))

─ NPS 1 ¼”, 2 ½”, 3 ½”, 5” not used

– When gauge numbers are given without reference to a

 ASTM A53 – Steel Pipe

 Fitting produce change in geometry and include:

– Change in direction of piping

– Alter pipe diameter

– Bring pipes together

 Method of joining pipe:

 Elbow (90, 45)

 Lateral (manufacture in factory)

 Shape nipple (use template)

 Elbolet: reducing tangent branch on elbow

 Size frequently limited to NPS≤ 1 ½” (ASME B16.11)

 Elbow (90, 45)

 Socket welding Elbolet

 Elbow (90, 45)

 Flange used for

 Welding neck flange

 Socket welding flange

 Lap joint (van stone) flange

 Flange Facing Types

 Flange Rating Class:

 Material Specification List

 Pressure - Temperature Ratings

 Material and design temperature combinations

 Flange Rating Class

 Flange Rating Class

 Flange Rating Class

 Equipment Nozzle Load standards and Parameters

 Flange with jack screw

 Solid metal ring

 ASME B16.5, Pipe Flanges and Flanged Fittings

 Flange coupling adaptor

 Expansion joint (Bellows)

 Double block & bleed

 Thermal sleeve & Queel

• RUPTURE DISKS OR BURST DIAPHRAGMS:

 Valve are used for

 Classify valves according to functions: