PIPING ELEMENTS

Piping elements is defined as any material required install the piping system. It includes specifications, material, components, fabrication, inspection and testing.

PIPING ELEMENTS

PIPES FITTINGS FLANGES GASKETS BOLTING VALVES SPECIALITIES

PIPES

MANUFACTURING PROCESSES MATERIAL SELECTION MATERIALS

Classification Based on Manufacturing

Pipe

Seamless pipe

Forged pipe

Welded pipe

Cast Steel Pipe

Cast Iron Pipe

Ferrous pipe materials

Forged and Bored PIpe

Ferrous pipe materials

Centrifugally Cast Pipe

Vertical Pit Process

Hollow Forged Pipe

Hot Rotary Piercing

Cold-Wrought Pipe

Horizontal Process

Furnace Welded Pipe

Centrifugal casting in sand moulds

Pilger Mill Process

Fusion Welded Pipe

Centrifugal Casting in Metal moulds

Push Bench (Cupping) Process

Resistance Welded Pipe

Extrusion Process
High Frequency Induction

Aluminium and its alloy materials

High Frequency Resistance

Horizontal Extrusion Process

Copper and Its alloy materials

Arc Welding Process

Submerged Arc Welding

Hot Piercing Process

Extrusion Process
Cup and Draw Process
Tube Rolling Process
Nickel and its alloy materials

Inert Gas Welding

Spiral Welded Pipe

Extrusion Process
Cold Drawing

Titanium and its alloy materials

Extrusion Process

HOT ROTARY PIERCING

PIERCING MILL

PLUG ROLLING MILL

REELING MILL

SIZING MILL

PILGER MILL PROCESS

PUSH BENCH(CUPPING) PROCESS

EXTRUSION PROCESS

MATERIAL SELECTION CONSIDERATIONS

Piping system material selection considerations are discussed below.

A. Strength
Yield and Tensile Strength

Creep Strength Fatigue Strength

B. Corrosion Resistance C. Material Fracture Toughness D. Fabricability E. Availability And Cost

A. Strength A material's strength is defined by its yield, tensile, creep, and fatigue strengths. Alloy content, material grain size, and the steel production process are factors that affect material

1.0 Yield and Tensile Strength A stress-strain diagram that is produced from a standard tensile test (Figure ) illustrates the yield and tensile strengths. As the stress in a material increases, its deformation also increases. The yield strength is the stress that is required to produce permanent deformation in the material (Point A in Figure ). If the stress is further increased, the permanent deformation continues to increase until the material fails. The maximum stress that the material attains is the tensile strength (Point B in Figure ). If a large amount of strain occurs in going from Point A to Point C, the rupture point, the material is said to be ductile. Steel is an example of a ductile material. If the strain in going from Point A to Point C is small, the material is brittle. Gray cast iron is an example of a brittle material.

SC

Typical Stress-Strain Diagram for Steel Figure 3.1

2.0 Creep Strength

Below about 750F for a given stress, the strain in most materials remains constant with time. Above this temperature, even with constant stress, the strain in the material will increase with time. This behavior is known as creep. The creep strength, like the yield and tensile strengths, varies with temperature. For a particular temperature, the creep strength of a material is the minimum stress that will rupture the material during a specified period of time.

The temperature at which creep strength begins to be a factor is a function of material chemistry. For alloy materials (i.e., not carbon steel) creep strength becomes a consideration at temperatures higher than 750F.

3.0 Fatigue Strength The term fatigue refers to the situation where a specimen breaks under a load that it has previously withstood for a length of time, or breaks during a load cycle that it has previously withstood several times. The first type of fatigue is called static, and the second type is called cyclic. One analogy to cyclic fatigue is the bending of a paper clip. The initial bending beyond a certain point causes the paper clip to yield (i.e., permanently deform) but not break. The clip could be bent back and forth several more times and still not break. However after a sufficient number of bending (i.e., load) cycles, the paper clip will break under this repetitive loading. Purely elastic deformation (i.e., without yielding) cannot cause a cyclic fatigue failure.

The fatigue strength of a material under cyclic loading can then be defined as the ability to withstand repetitive loading without failure. The number of cycles to failure of a material decreases as the stress resulting from the applied load increases

B. Corrosion Resistance

Corrosion of materials involves deterioration of the metal by chemical or electrochemical attack. Corrosion resistance is usually the single most important factor that influences pipe material selection. Table below summarizes the typical types of piping system corrosion.

For process plant piping systems in corrosive service, corrosion protection is usually achieved by using alloys that resist corrosion. The most common alloys used for this purpose are chromium and nickel. Low-alloy steels with a chromium content of 1% to 9% and stainless steels are used in corrosive environments.

Typical Types of Piping System Corrosion

General or Uniform Corrosion Characterized by uniform metal loss over entire surface of material. May be combined with erosion if material is exposed to high-velocity fluids, or moving fluids that contain abrasive materials. Form of localized metal loss randomly located on material surface. Occurs most often in stagnant areas or areas of low-flow velocity. Occurs when two dissimilar metals contact each other in corrosive electrolytic environment. The anodic metal develops deep pits or grooves as a current flows from it to the cathode metal.

Pitting Corrosion Galvanic Corrosion

Concentration Cell Corrosion Graphitic Corrosion

Occurs when different concentration of either corrosive fluid or dissolved oxygen contacts areas of same metal. Usually associated with stagnant fluid. Occurs in cast iron exposed to salt water or weak acids. Reduces iron in the cast iron and leaves the graphite in place. Result is extremely soft material with no metal loss.

C. Material Fracture Toughness One way to characterize the fracture behavior of a material is the amount of energy necessary to initiate and propagate a crack at a given temperature. This is the material's fracture toughness, which decreases as the temperature decreases. Tough materials require a relatively large amount of energy to initiate and propagate a crack. The impact energy required to fracture a material sample at a given temperature can be measured by standard V-notch tests. Various factors other than temperature affect the fracture toughness of a material. These include the following: . Chemical composition or alloying elements. . Heat treatment. . Grain size.

The major chemical elements that affect a material's fracture toughness are carbon, manganese, nickel, oxygen, sulfur, and molybdenum. High carbon content, or excessive amounts of oxygen, sulfur, or molybdenum, hurts fracture toughness. The addition of manganese or nickel improves fracture toughness.

D. Fabricability
A material must be available in the shapes or forms that are required, and it typically must be weldable. In piping systems, some common shapes and forms include the following: . Seamless pipe. . Plate that is used for welded pipe. . Wrought or forged elbows, tees, reducers, and crosses. . Forged flanges, couplings, and valves. . Cast valves.

E. Availability and Cost

The last factors that affect piping material selection are availability and cost. Where there is more than one technically acceptable material, the final selection must consider what is readily available and what are the relative costs of the acceptable options. For example, the use of carbon steel with a large corrosion allowance could be more expensive than using a low-alloy material with a smaller corrosion allowance.

PIPE FITTINGS
A. Fittings, Flanges, and Gaskets 1.0 Pipe Fittings Fittings are used to make some change in the geometry of a piping system. This change could include: Modifying the flow direction. Bringing two or more pipes together. Altering the pipe diameter. Terminating a pipe.

PIPE TYPESFITTINGS OF PIPE FITTINGS

ELBOWS
TEES
CAPS
COUPLINGS
UNIONS
SWAGE COUPLINGS
STUB ENDS

REDUCERS

SPECIAL FITTINGS

45 ELBOW
90 ELBOW

EQUAL TEE
REDUCING TEE

FULL
HALF

CON.SWAGE

LONG STUB ENDS

OLETS
EXPANSION BELLOW
STRAINERS

STEAM TRAPS

ECC.SWAGE

SHORT STUB ENDS

WELDOLET THREDOLET SOCKOLET FLEXOLET LATROLET ELBOLET SWEEPOLET INSERT WELDOLET NIPPOLET BRAZOLET COUPOLET

REDUCING

SHORT RADIUS LONG RADIUS

END CONNECTION

SOCKET WELD

SCREWED

BUTT WELD

FLANGED

SPIGOT/SOCKET

ELBOW

REDUCERS

TEES

Pipe Fittings-Standards

ASA B16b1: Cast Iron Pipe Flanges and Flanged Fittings for 800 Psig Hydraulic Pressure ASA B16b2: Cast Iron Pipe Flanges and Flanged Fittings,25lb ASA B16.1: Cast Iron Pipe Flanges and Flanged Fittings, Class 125(standard Includes Also Bolt,nut and Gasket Data) ASA B16.2: Cast Iron Pipe Flanges and Flanged Fittings, Class 250 (Bolt,nut and Gasket Data are also included) ASA B16.4: Cast Iron Screwed Fittings ASA B 16.12: Cast Iron Screwed Drainage Fittings WW-P-491: Pipe Fittings,cast Iron , Drainage WW-P-501: Pipe Fittings,cast Iron,screwed 125 and 250 Pounds

FLANGES

FLANGES
A flange connects a pipe section to a piece of equipment, valve, or another pipe such that relatively simple disassembly is possible. Disassembly may be required for maintenance, inspection, or operational reasons. Flanges are normally used for pipe sizes above NPS 1.

BASED ON PIPE ATTACHMENT

SLIP ON SOCKET WELD SCREWED LAP JOINT WELDING NECK BLIND INTEGRAL

BASED ON THE FACE OF THE FLANGE

FLANGE FACING FLAT FACE RAISED FACE TONGUE AND GROOVE MALE ANE FEMALE RING TYPE JOINT

Flat Face Flanges

Cross section of Flat Face flange

Raised Face Flanges

Cross section of Raised Face flange

Ring Joint Face Flanges

Cross section of Ring Joint Face flange

Male & Female Joint

Cross section of Male & Female Joint

BASED ON PRESSURE-TEMPERATURE RATING

150# 300# 600# 900# 1500# 2500#

FACE FINISH
SMOOTH FINISH SERRATED FINISH

FLANGE MATERIALS
ASTM A 105 ASTM A 181 ASTM A 182 ASTM A 350 Forged Carbon steel Forged Carbon steel for general purpose Forged alloy steel and stainless steel Forged alloy steel for low temperature services ANSI B 16.47/API 605 Higher sizes(above 3) IS 6392 -

SELECTION OF FLANGE
A flange type is specified by stating the type of attachment and the type of face. The type of attachment defines how the flange is connected to a pipe section or piece of equipment (e.g., welded). The type of flange face or facing defines the geometry of the flange surface that contacts the gasket.

Flange Rating
ASME B16.5, Pipe Flanges and Flanged Fittings, provides steel flange dimensional details for standard pipe sizes through NPS 24. Specification of an ASME B16.5 flange involves selection of the correct material and flange "Class."

Flange Rating
STEPS INVOLVED IN FLANGE RATING

Refer to ASME B16.5 for material specifications and corresponding Material Group Numbers. Table 1.1A

After the Material Group has been determined, the next step is to select the appropriate Class. The Class is determined by using pressure/temperature rating tables, the Material Group, design metal temperature, and design pressure.

Flange material specifications listed in Table 1A in ASME B16.5

SAMPLE PROBLEM 1 - DETERMINE FLANGE RATING A new piping system will be installed at an existing plant. It is necessary to determine the ASME class that is required for the flanges. information is provided: . . . Pipe Material: 1 Cr Mo. Design Temperature: 700F. Design Pressure: 500 psig. The following design

SOLUTION Determine the Material Group Number for the flanges by referring to ASME Table 1A. Find the 1 Cr Mo material in the Nominal Designation Steel column. The material specification for forged flanges would be A182 Gr. F11, and the corresponding material Group Number is 1.9. Refer to Table 2 for Class 150. Read the allowable design pressure at the intersection of the 700F design temperature and Material Group 1.9. This is only 110 psig and is not enough for this service. Now check Class 300 and do the same thing. The allowable pressure in this case is 570 psig, which is acceptable. The required flange Class is 300.

FLANGE LEAKAGES

Uneven bolt stress Poor flange alignment Off-center gasket installation Dirty & damaged flange faces Thermal shock Incorrect gasket size High vibration

BOLTING

MATERIAL FOR CONSTRUCTION OF BOLTING DIMENENSINAL STANDRADS FOR BOLTS

MATERIALS

ASTM A 307 ASTM A 320

ASTM A 193 ASTM A 194 IS 1367 -

Low carbon steel bolting material Alloy steel bolting material for low temperature Alloy steel bolting material for high temperature Alloy steel nut material for high temperature service Threaded steel fasteners

STANDARDS

ANSI B 18.2.1 - Square & Hex. Head bolts ANSI B 18.2.2 - Square & Hex. Nuts BS 916 - Black bolts & nuts IS 1367 - Threaded steel fasteners

GASKETS
A gasket is a resilient material that is inserted between the flanges and seated against the portion of the flanges called the face or facing. The gasket provides the seal between the fluid in the pipe and the outside, and thus prevents leakage. Bolts compress the gasket to achieve the seal and hold the flanges together against pressure and other loadings.

GASKETS
1. 1. 2. 2.

3. 3.

SELECTION Compatibility of gasket material with the fluid Ability to withstand pressure and temperature of the system Corrosion of fluids flowing through the flanges

CLASSIFICATIONS
Full face Inside bolt circle Spiral wound metallic Ring type Metal jacketed

MATERIAL STANDARDS

IS 2712,Gr W/1,W/2,W/3 :For steam alkali general applications IS 2712 ,Gr A/1 IS 2712 Gr 0/1, 0/2,0/3 :For acid applications :For oil applications

DIMENSIONAL STANDARDS

API 601 : API 3381 : ANSI B 16.20: ANSI B 16.21:

Metallic gaskets for refinery piping Metallic spiral wound gaskets Metallic gaskets for m pipe flanges Non Metallic gaskets for pipe flanges

VALVES

Ball Ball valves valves

Gate Gate valves valves

Butterfly Butterfly valves valves

ISOLATION VALVES

Plug Plug valves valves

Diaphragm Diaphragm valves valves

Globe Globe valves valves

Needle Needle valves valves

REGULATION VALVES

Butterfly Butterfly valves valves

Diaphragm Diaphragm valves valves

Non-return valve

Lift check valve

Swing check valve

Safety valve

Special purpose

Float valve

Foot valve

SPECIAL FITTING OLETS E XPANSION BELLOWS STEAM STRAPS STRAINER

OLETS
WELDOLET THREDOLET SOCKOLET INSERT WELDOLET FLEXOLET BRAZOLET NIPPOLET COUPOLET SWEEPOLET ELBOLET & LATROLET

WELDOLET
They are economical butt welded branch connections with integral reinforcement

Weldolet, an economical butt-weld branch connection, is designed to minimize stress concentrations and provide integral reinforcement.

Thredolet utilizes the basic Weldolet configuration, provides a threaded outlet branch connection.

Sockolet utilizes the basic Weldolet design configuration and incorporates a socketweld outlet.

Flexolets Straight Thru Bore design allows for easy clean up of any base welding penetrating into the I.D. bore by grinding, etc. Flexolet is available in threaded, butt-weld and socket weld fittings.

Latrolet, used for 45 lateral connections, is available butt-weld to meet the specific reinforcement requirements, and 3000# or 6000# classes for socket weld and threaded applications.

Elbolet is used on 90 Long Radius Elbows (can be manufactured for Short Radius Elbows) for thermowell and instrumentation connections. Available butt-weld to meet the specific reinforcement requirements, and 3000# and 6000# classes for socket weld and threaded applications.

Sweepolet is a contoured, integrally reinforced, butt-weld branch connection with a low stress intensification factor for low stresses and long fatigue life. The attachment weld is easily examined by radiography, ultrasound and other standard non-destructive techniques.

Insert Weldolet is another contoured buttweld branch connection used in less critical applications. Like the Sweepolet, the attachment welds are easily examined by radiography, ultrasound and other standard non-destructive techniques.

Nipolet is a one piece fitting for valve take-offs, drains and vents. Manufactured for Extra Strong and Double Extra Strong applications in 3 1/2" to 6 1/2" lengths. Available with male-socket-weld or male threaded outlets.

Brazolet is designed for use with brass or copper tubing. Available with socket or threaded connections.

Coupolet fittings are designed for use in fire protection sprinkler systems and other low pressure piping applications. manufactured with NPT female threads for 300# service

Exercise
Exercise 1 Determine Required Flange Rating
For the piping system described below, determine the required flange rating (or Class) in accordance with ASME B16.5. Pipe: Flanges: Design Temperature: Design Pressure: 1 Cr Mo A - 182 Gr. F11 900F 375 psig