PIPING DESIGN AND STRESS

ANALYSIS

Welcome
to
CADD CENTRE 1
TOPICS COVERED

1. Introduction T o Piping System

2. Piping Components
3. Testing Of Piping Systems
4. STRESS ANALYSIS

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 PIPING SYSTEM
o It convey the fluids, between the various equipment and end users.
o It consists of various components such as pipes, valves, fittings,
online measuring instruments, etc.

DIFFERENCE BETWEEN PIPE AND TUBE

PIPE
o It is a tubular product of circular cross section that has specific sizes
and thickness governed by particular dimensional standards.
TUBE
o It is a hollow product having circular, elliptical or square cross section or
cross section of any closed perimeter. Tubes are also used for heat transfer purpose.
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CLASSIFICATION BASED ON END
USEPIPE
LINE
o It is mainly used for conveying fluids over long distances and are subjected to
fluid pressure. It is usually not subjected to high temperature.
PRESSURE PIPE
o These are subjected to fluid pressure and /or temperature. Fluid pressure in generally
internal pressure or may be external pressure (e.g. Jacketed piping
)and are mainly used as plant piping.
STRUCTURAL PIPE
o These are not used for conveying fluids and not subjected to fluid pressures or
temperature. They are used as structural components (e.g. handrails, columns, sleeves etc.)
and are subjected to static loads only.
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 NOMINAL PIPE SIZE (NPS)
o Pipes are designated by nominal size, starting from 1/8” nominal size, and
increasing in steps.
o For the nominal size up to including 12” there is one unique OD (different from
nominal size) and ID would vary depending on schedule number.
o For nominal sizes 14” and above O.D is same as nominal size.
WHY PIPE SIZE IS MORE IMPORTANT
o According to American Survey 30 % of the total cost of a chemical process plant
goes for piping elements and valves. Take optimum pipe size while designing the
pipe size.
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AVAILABILTY OF PIPE SIZES
1. Sizes in steps of 1/8” from 1/8”to ½”
2. Sizes in steps of ¼”from ½” to 1 ½”
3. Sizes in steps of ½” from 1 ½” to 4”
4. Sizes in steps of 1” from 4” to 6”
5. Sizes in steps of 2” from 6” to 36”

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SCHEDULE NUMBER
Pipes are designated by schedule number .
Schedule number is represented by the pressure carrying capacity of the
pipe.
Schedule = 1000 P/S where
P = service pressure (psi) - (Internal pressure)
S = allowable stress (psi) - (Allowable tensile strength of material)
Irrespective of pipe dia., equal schedules have equal pressure carrying capacity. For stainless steels
schedule number are designated by suffix S i.e. 5S, 10S, 40S, 80S etc.
For pipes of all dimensions the outside diameter (O.D.) remains relatively constant. The variation in wall
thickness affects only the inside diameters (I.D.). The higher the schedule number is, the thicker the pipe is.

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PIPING SCHEDULE

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PIPING SCHEDULE

Velmurugan Sivaraman

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COMPONENTS OF PIPING SYSTEM
1. Pipe
2. Fittings (Elbows, Tees, Reducers, Couplings, Unions, Olets)
3. Flanges
4. Gaskets
5. Fasteners
6. Valves
7. Special fittings
8. Specialty items (strainers, traps, bellows etc.)
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FITTINGS
o Pipe fittings are the components which tie together pipelines, valves, and other
parts of a piping system.
o Fittings may come in butt Welded, Socket welded, Screwed and flanged
connections.
o They are used to change the size of the line or its direction.

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COMMON PIPE FITTINGS

90° Elbow Equal Tee

Concentric Eccentric
Reducer Reducer
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 TEES
STRAIGHT TEE / EQUAL TEE
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It is used when the branch and header are the same.
REDUCING TEE
It is used when the branch size is smaller than the header size.
POINT TO REMEMBER
It is expensive and requires three butt welds. Alternatively for low pressure services
, branching off is done by direct welding of pipe to pipe instead of standard Tee.
 ELBOWS
They are used to change direction of pipe.
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1. LONG RADIUS (LR) AND
2. SHORT RADIUS (SR)ELBOWS.
90 degree elbow comes in LR and SR.
45 degree elbow comes in LR only.
The LR elbows radius is 1.5 times the nominal size. The SR elbows radius is 1 times the
nominal size.
Normally elbows are butt-welded, socket welded or sometimes bolted connections are also available.
Reducing elbows are available on 90 degree only and the radius is 1.5 times of the larger end

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 MITRE BENDS
These are fabricated bends for larger
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diameter piping, low pressure less) (50 psi are
pressure applications.
It is made out of two, three, four segments of
pipe pieces. These are normally used for non
critical services. (water, drainage, and wend
piping )

Velmurugan Sivaraman
 COUPLINGS & UNIONS
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COUPLINGS
FULL COUPLING
It is used to connect small bore pipes as
projection of welding inside the pipe bore
reduce the flow area
HALF COUPLING
It is used for branch connection

UNIONS
It is used where dismantling of the pipe is
required more often. It can be with threaded
end or socket weld ends.
 REDUCERS
It makes reduction in line size
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ECCENTRIC REDUCER
It is used to pump suction to avoid cavitation with top surface
being flat.
To maintain elevation bottom of pipe (BOP) in rack.
Offset dimension is ½ the difference of the two inside
diameters. Eccentric reducer are costlier than concentric reducer.
Designer to optimize the requirement
 REDUCERS
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CONCENTRIC REDUCER
It is used on pump discharge, vertical pipe line etc.
SWAGE NIPPLE
It is also like a reducer, it connect butt welded pipe
to smaller screwed or welded pipe .
concentric and eccentric swage nipples are also
available.
 FLANGES
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BLIND SLIP ON SOCKET WELDING

FLANGES FLANGES FLANGE

LAP-JOINT WELDING
THREADED
FLANGE NECK
FLANGES
FLANGES
 FLANGES
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Flanges can be classified based on the

attachment to the piping
SLIP ON
These flanges are attached by fillet welding
inside as well as outside. Used where quick
assembly, saving in cost and where extreme
load condition are not present .
SOCKET WELD
These flanges are welded only one side. Is is
used for small bore only.
 FLANGES
21 SCREWED
These flanges are used on pipe lines where low pressure
and temperature are envisaged. Generally used in
galvanized lines.
BLIND FLANGE
These flanges are used to close the ends which need to be
reopened later, also used for blanking the dead end during hydro
test.
22 FLANGES

LAP JOINT
These flanges are used with stub ends when piping is of a exotic
material. Stub ends will be butt welded to the piping and the
flanges are keep loose over the same.
WELDING NECK
These flanges are generally butt welded to the pipes where
excessive direct bending stress on the flanged joint or supporting
heavy equipment are envisaged.
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BUTT WELDED FITTINGS (ASME B16.9)

ADVANTAGES
Higher pressure and temperature conditions. Leak proof joints and
almost maintenance free.
DISADVANTAGE
Weld projection will affect flow. Edge preparation is necessary.
 SOCKET WELDED FITTINGS (ASME
24 B16.11)
ADVANTAGES
Fast production, No need to bevel the edges. Can be used
in lieu of thread fittings. Weldment can not extend in to the pipe
line.
DISADVANTAGE
The 1/16” recess pocket liquid. Use not permitted by code if
severe erosion or crevice corrosion anticipated.

Velmurugan Sivaraman
25

FLANGED
FITTINGS
(ASME B16.1 AND B16.5)

ADVANTAGE
Easy to dismantle and assemble.

DISAVANTAGE
Costlier than equally rated butt welded fitting.
Occupy more space, and more weight load.
 REINFORCED
26 FITTINGS
 REINFORCED
27 FITTINGS
WELDOLET
An economical butt -weld branch connection, is
designed to minimize stress concentration and provide
integral reinforcement.
SOCKOLET
Utilizes the basic weldolet design configuration and
incorporates a sockolet -weld outlet.
 REINFORCED
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FITTINGS
ELBOWOLET
utilizes the basic weldolet configuration, provides at
branch connection on elbow.

LATROLET
Used for 45 degree lateral connections.
Similarly, elbolet, sweepolet etc are available
29 THERMAL EXPANSION OF
PIPE
Each material has its own coefficient of thermal expansion.
If the pipe is of carbon steel or low alloy steel, it will expand at the rate of 6 to
7mm every meter length as the temperature raises to 500 degree C.
To accommodate the thermal expansion, these joints are provided.
 EXPANSION
30 JOINTS
Expansion joints are used to accommodate certain degree of linear expansion
and torsional misalignments in the piping system
BELLOW TYPE
Metallic bellows of compatible materials (usually stainless steels) are used to
compensate the thermal expansion. Thickness of bellows normally 1 to
2mm.
 EXPANSION LOOPS
31 Expansion loops are widely used for high temperatures & high pressures
applications. Ideally suitable for longitudinal movements and certain degree
of torsional movement.
TELESCOPIC TYPE
These joints ideally suitable for low temperature & low pressure application.
Suitable only for axial expansion

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 VALVES
32 valves are installed in between the pipes / equipment to perform
following functions :
Isolation (gate valve, ball valve, butterfly valves etc.)
Regulation (globe valve etc.) (check
Non return valve, SDNR etc.)
Special purpose (foot valve etc.)
 BALL VALVE
33 Ball valve is normally used for positive shut off. Operation by a quarter turn
of operating handle. The ball valve offers minimum resistance to flow. Widely
used on onshore/offshore and petrochemicals.
 GATE VALVE
34 Flow is axial piping. Lower pressure drop. It is not recommended for
throttling the flow.
 BUTTERFLY
VALVE
It is widely used on low pressure application . It may be used to
control and regulate the flow.

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 CHECK VALVE / NON RETURN VALVE
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Swing Check Valve

This valve allows flow in one direction only. Return flow
will automatically close the valve, thus preventing flow in reverse direction.
37
TESTING OF PIPING
SYSTEM
(AS PER ANSI B 31.3)
Piping system can be tested for leak tightness and pressure integrity by
hydro test / pneumatic test methods.
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HYDROSTATIC
TEST
TEST PRESSURE =(1.5 X Design Pressure X stress value at test temp) /
stress value at design temperature
TEST DURATION
A leak test shall be maintained for at least 10 minutes, and all joints
may be examined for leaks.
TEST MEDIUM
Water at ambient temperature is the test medium. Incase of possibility
of freezing exists, other fluids may be used.
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PNEUMATIC
TEST
TEST PRESSURE
(1.1 x Design Pressure x stress value at test Temperature) / stress value
at design temperature
TEST DURATION
A leak test shall be maintained for at least 10 minutes, and all joints
may be examined for leaks.

TEST MEDIUM
Air at ambient temperature is the test medium.
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CHECK LIST FOR HYDRO
TEST
1. COMPLETION OF WELDING ON PRESSURE PARTS.
2. ALL LONG SEAMS & CIRC. SEAMS ARE MADE VISIBLE
FOR INSPECTION.
3. COMPLETION OF ALL NDT.
4. GASKETS & GASKET SEATINGS ARE CHECKED FOR ANY
DAMAGE.
5. EQUIPMENT WHICH IS NOT TO BE TESTED SHALL BE
EITHER
DISCONNECTED OR ISOLATED.
5. RAISE THE PRESSURE TILL 50% OF TEST PRESSURE.
6. INCREASE THE PRESSURE IN INCREMENTS OF 10% OF TEST
41 CHECK LIST FOR HYDRO
TEST
7. STOP PUMPING FOR 5 MINUTES AFTER EACH INCREMENT OF
10% OF RISE IN PRESSURE.
8. IF ANY LEAKAGE IS OBSERVED THROUGH GASKET
CONNECTION,
REPEAT THE TEST AFTER DEPRESSURISING THE SYSTEM.
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PIPING FABRICATION
• Cutting
• Bending
• Forming
• welding
Cutting and beveling of the edges by Mechanical Methods (lathes, grinding
Wheels / Thermal methods (oxy – fuel gas cutting, Arc cutting.)
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PIPING
THINNING
Bending results in the thinning of the outer surface (extrados ) and
thickening of the inner surface (intrados ) of the pipe.
It can be approximated by multiplying the thickness of the pipe before
bending by
R/(R+ r)
Where R - Radius of Bend &
r-

Pipe radius. ( Half of

the O.D )
 Ovality
44 The pipe while being bent assumes a oval shape with the major axis
perpendicular to the plane of the bend
Acceptable normally 8% for internal pressure & 3% for external
pressure.
BENDING
45 COLD BENDING
Where sufficient quantities of repetitive bends are required, ferrous pipes and
tubes up to NPS 10 or 12 with wall thickness of ½ in or less are most often
bent at ambient temperature using some type of bending machine.

Velmurugan Sivaraman
 HOT BENDING
46 Carried out in the temperature range of 1036*c to 1121*c by induction
bending. Where suitable cold bending equipment is unavailable
Pipes of size NPS 3 ½ to NPS 64, radius of 8 to 400 inch and
wall
thickness 4” can be bend by Induction Bender .
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CADD
CENTRE
THANKING YOU

Velmurugan Sivaraman
THURAIYUR