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DOCKET FOR
ERA-IV ‘Q’ COURSE
DOCKYARD SPECIAL ENTRY SAILORS
TRADE: SHIP OUTFITTING (PLUMBING & PIPE FITTING)
SUB: SHIP PIPING SYSTEM AND VALVE REPAIR

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CONTENT
Chapter Topics Period Page

1 Piping System 1

2 Understand Piping System 11

3 Understand Expansion Arrangement Of Pipe 17

4 Understand trap 25

5 Understand Strainer And Filter 29

6 Valve 33

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CHAPTER-1

PIPING SYSTEM

0101. Bilge piping system: A piping system intended for disposing of water
that may accumulate in spaces within the vessel (holds, machinery spaces,
cofferdams) due to condensation, leakage, washing, fire fighting, etc. It is to
be capable of controlling flooding in the Engine Room as a result of limited
damage to piping systems. However, the bilge system is not able to cope with
flooding resulting from a large hull damage not protected in due time.

1. Bilge suctions: Drain pipes placed on each side at the after end of
the holds or compartments. The suction end is fitted with a strainer or mud
box. Bilge suctions in holds are to be connected to the bilge main by branch
lines.

2. Bilge system trials: All elements of the bilge system are to be

tested to demonstrate satisfactory pumping operation, including emergency
suctions and all controls. Upon completion of the trials, the bilge strainers are
to be opened, cleaned and closed up in good order. According to ABS.
3. Bilge water: The water that collects in the bilges of a vessel
which generally becomes foul and noxious. Bilge water also contains fluids
from machinery spaces, internal drainage systems, sludge tanks and various
other sources. This mixture is collected in the bilge water holding tank, which
generally is maintained at an elevated temperature. Regardless of its source
bilge water must be treated to reduce the oil content to levels meeting
international regulations for release into the environment.
0102. Sounding pipes: Sounding pipes are small-bore mild steel pipes used to
measure the quantity of fluid in a tank or a hold bilge. The pipe allows a tape
or sounding rod to pass through to the bottom of a tank or hold. Deck
sounding pipes pass through the weather deck and are fitted with screw-down
caps. Sounding pipes for engine room double-bottom tanks are fitted with self-
closing cocks.

0103. Air pipes: Air pipes allow an enclosed space to ‘breathe’. They prevent
over-or under-pressure by letting air in or out of the space when liquid is
pumped in or out, or when temperature changes cause air or fluids to expand
or contract. Cargo holds are ventilated by air pipes passing through the
weather deck and these are fitted with self-closing watertight covers
(headers). This is a Load Line requirement.

0104. Pipe materials: There are many kinds of pipe materials used, such as:
1. GI pipe
2. Copper pipe
3. SS pipe
4. MS pipe
5. Cuppro-nickel pipe
6. Aluminum pipe
7. Cast iron pipe
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8. PVC pipe
0105. Piping System: All shipboard piping is installed in such as a way that it
will not interfere with the operation of the ship’s machinery or with the
operation of doors, hatches, scuttles or openings covered by removal plates.
As far as possible, piping is installed so that it will not interfere with the
maintenance and repair of machinery or of the ship’s structure. If piping must
be installed in the way of machinery or equipment which requires periodic
dismantling for overhaul, or if it must be installed in the way of other piping
systems or electrical systems, the piping is designed for easy removal. Piping
that is vital to the propulsion of the ship is not installed where it would have to
be dismantled in order to permit routine maintenance on machinery or other
systems. Piping is not normally installed in such a way as to pass through
voids, fuel oil tanks, ballast tanks, feed tanks and similar spaces.

0106. Valve: A valve is a device that regulates, directs or controls the flow of
a fluid (gases, liquids, fluidized solids, or slurries) through pipelines by
opening, closing, or partially obstructing various passageways

Figure: Gate Valve

0107. Classification of valve: Mainly different types of valve are used to control
flow of fluid. The basic valve types can be divided into two groups. There are:

1. Screw down valve:

a. Gate valve
b. Globe valve
c. Needle valve etc.

2. Non-return valve:

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a. Strom valve
b. Flap valve
c. Cheek valve etc

0108. Valve Damages:

1. Valve Spine damage.

2. Seat damage.
3. Lead damage.
4. Valve body damage.
5. Gland damage.
6. Packing damage.

0109. Valve Repair Procedure:

1. At first need to marking between body and top cover by center punch.
2. Spindle dismantles from top cover.
3. Lead separate from spindle.
4. These parts are properly clean by diesel oil and examine condition/ defect.
5. If spindle damage, Need spindle to be made new.
6. If seat pitted lights, the seat need to be machining other hand seat deeply
pitted seat to be made new.
7. Valve lead to be machining. If required lead to be made new and lead
washer will be renewed.
8. Renewal gland packing.
9. If found valve body crack, valve body repair by welding or brazing
operation. But it is better that crack/ damage valve body replace with new
valve.
10. At last assemble all valve parts & carried out pressure test. If satisfied the
valve can use on Board Ship.

0110. Plumbing fittings: This section discusses fittings primarily used in

pressurized piping systems, though there is some overlap with fittings for low-
pressure or non-pressurized systems.

Elbow: An elbow is installed between two lengths of pipe (or tubing) to allow
a change of direction, usually a 90° or 45° angle. A 90º elbow, also known as
a "90 bend", "90 ell" or "quarter bend", attaches readily to plastic, copper, cast
iron, steel, and lead, and is attached to rubber with stainless-steel clamps. It is
primarily used to connect hoses to valves, water pumps and deck drains.
Elbows are also categorized by length. The radius of curvature of a long-
radius (LR) elbow is 1.5 times the pipe diameter, but a short-radius (SR)
elbow has a radius equal to the pipe diameter. Short elbows, widely available,
are typically used in pressurized systems and in physically tight locations.
Long elbows are used in low-pressure gravity-fed systems and other
applications where low turbulence and minimum deposition of entrained solids
are of concern. They are available in acrylonitrile butadiene styrene (ABS

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plastic), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), and

copper, and are used in DWV systems, sewage, and central vacuum systems.

Figure: Bend 45° Figure: Bend 90°

Coupling: A coupling connects two pipes. If their sizes differ, the fitting is
known as a reducing coupling, reducer, or an adapter. There are two types of
couplings: "regular" and "slip". A regular coupling has a small ridge or stop
internally, to prevent over-insertion of a pipe, and thus under-insertion of the
other pipe segment (which would result in an unreliable connection). A slip
coupling (sometimes also called a repair coupling) is deliberately made
without this internal stop, to allow it to be slipped into place in tight locations,
such as the repair of a pipe that has a small leak due to corrosion or freeze
bursting, or which had to be cut temporarily for some reason. Since the
alignment stop is missing, it is up to the installer to carefully measure the final
location of the slip coupling to ensure that it is located correctly.

Figure: Coupling

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Union: A union, similar to a coupling, allows the convenient future

disconnection of pipes for maintenance or fixture replacement. In contrast to a
coupling requiring solvent welding, soldering, or rotation (for threaded
couplings), a union allows easy connection and disconnection, multiple times
if needed. It consists of three parts: a nut, a female end and a male end.
When the female and male ends are joined, the nut seals the joint by pressing
the two ends tightly together. Unions are a type of very compact flange
connector.

Figure: Union

Nipple: A nipple is a short stub of pipe, usually male-threaded steel,

brass, chlorinated polyvinyl chloride (CPVC), or copper (occasionally
unthreaded copper), which connects two other fittings. A nipple with
continuous uninterrupted threading is known as a close nipple. Nipples are
commonly used with plumbing and hoses.

Figure: Nipple

Reducer: A reducer allows for a change in pipe size to meet hydraulic flow
requirements of the system or adapt to existing piping of a different size.
Although reducers are usually concentric, eccentric reducers are used as
needed to maintain the top- or bottom-of-pipe level.

Figure: Reducer
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Tee: A tee, the most common pipe fitting, is used to combine (or divide) fluid
flow. It is available with female thread sockets, solvent-weld sockets or
opposed solvent-weld sockets and a female-threaded side outlet. Tees can
connect pipes of different diameters or change the direction of a pipe run, or
both. Available in a variety of materials, sizes and finishes, they may also be
used to transport two-fluid mixtures. Tees may be equal or unequal in size of
their three connections, with equal tees the most common.

Figure: Tee

Cross: Crosses, also known as four-way fittings or cross branch

lines, have one inlet and three outlets (or vice versa), and often have solvent-
welded socket or female-threaded ends. Cross fittings may stress pipes as
temperatures change, because they are at the center of four connection
points. A tee is steadier than a cross; it behaves like a three-legged stool, and
a cross behaves like a four-legged stool. Geometrically, any three non-
collinear points can self-consistently define a plane; three legs are inherently
stable, whereas four points over determine a plane, and can be inconsistent,
resulting in physical stress on a fitting. Crosses are common in fire
sprinkler systems (where stress caused by thermal expansion is not
generally an issue) but are not common in plumbing. One cross fitting is more
expensive than two tees.

Figure: Cross

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Cap: Caps, usually liquid- or gas-tight, cover the otherwise open end of a
pipe. A cap attaches to the exterior of a pipe, and may have a solvent-weld
socket end or a female-threaded interior. The exterior of an industrial cap may
be round, square, rectangular, U- or I-shaped, or may have a handgrip. If a
solvent-weld cap is used to provide for a future connection point, several
inches of pipe must be left before the cap; when the cap is cut off for the
future connection, enough pipe must remain to allow a new fitting to be glued
onto it.

Figure: Cap

Plug: A plug fits inside the pipe segment or fitting to which to stop flow of
water.

Figure: Plug

Barb: A barb (or hose barb), which connects flexible hose or tubing to pipes,
typically has a male-threaded end which mates with female threads. The other
end of the fitting has a single- or multi-barbed tube a long tapered cone with
ridges, which is inserted into a flexible hose. An adjustable worm drive screw
clamp (or other type of clamp) is often added, to keep the hose from slipping
off the barbed tube. Barb fittings can be made of brass for hot-water
applications, and plastic may be used for cold water; brass is considered
more durable for heavy-duty use. The barb fitting may be elbow-shaped or
straight.

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Figure: Bard

0111. Friction: During flow of fluid in the pipe line effect the rate of flow of fluid.
That’s depending upon some factor. There are:

1. Friction factor due to surface roughness, F

2. Length, L
3. Velocity, V
4. Diameter, D

0112. Pipe Diameter and Tube Diameter: Tube is measured by outside diameter; the
pipe is measured by inside diameter.

There is often confusion as to which size die the customer actually needs -
Pipe Size or Tubing Size.

Keep in mind that pipe size refers to a nominal - not actual - inside pipe
diameter. Schedule refers to the pipe's wall thickness. The actual physical OD
is larger than it's nominal OD.

The dimensions provided for tubing, on the other hand, refer to the actual
outside diameter. In other words, the actual physical OD of a tube is just the
same as it's nominal OD. The size of a tube will keep the same OD no matter
what the wall thickness is.

For example: The actual outside diameter of 1¼″ pipe is 1.625″ - while 1¼″
tube has a true 1.25″ outside diameter.

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Figure: Pipe Figure: Tube

0113. Wall Thickness Difference: The wall thickness of pipes and tubes is an
important factor to tell difference. The thickness of tubing is often specified by
a gauge for thinner thicknesses and for thicker tubing it is indicated by
fractions of an inch or millimeters. The normal range for tubing is 20 gauges,
which measures .035 inch, up to a thickness of 2 inches. The wall thickness of
a pipe is referred to as a pipe schedule, which you can find the relevant
between pipe schedule and thickness in millimeter or inch in
specification ASME B36.10. The most common schedules are SCH 20,SCH
40 and SCH 80. Schedule 40 is the most common and 80 is extra heavy.
Which is needed to be noted, the pipe schedule is not set for all diameters; it
varies.

For example: Diameter 8inch/219.1 pipe, pipe schedule is SCH 40 = wall

thickness is 0.322inch/8.18mm,Diameter 12 inch /323.9 pipes, sch 40 refers
wall thickness of 0.406inch/10.31mm.There is no formula between the pipe
schedule and wall thickness, the only is to refer to the ASME B36.10 or
relevant standards.

0114. Pipes Tolerance & Tube Tolerance: Pipes are usually used for
transporting or distributing, then the properties of pressure or straightness,
roundness are strictly specified, the tolerance for pipes is more loose than
tubes comparatively. Here the tolerance refers to diameter tolerance, wall
thickness tolerance, straightness tolerance, roundness tolerance etc.

0115. Manufacturing Difference of pipes and tubes: As we mentioned

above, tubes will require higher level requirements, consequently, even from
the material producing to the pipe or tube manufacturing process will be
different. Tubes will require much more process, tests, inspection than pipes.
The delivery time will be longer, too. The yield of tubes are comparatively
much lower than pipes. Pipe manufacturing is easier compare to tubes and
it’s in mass production
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0116. Cost & Price: As per to the above, to manufacture tubes will take much
more labor, energy, material etc, so the production cost is surely higher than
pipes. And just because the high level requirement of tubes, the low yield of
tubes will also increase the cost and price. While the process of pipes is
easier. And pipes are manufactured in large lot and cut the cost.

0117. Use of Pipes and Tubes: Pipes are used for fluids and gases, such as
water, oil, gas or propane or as steam pipe, boiler pipe etc. Just because of
this, the outside & inside diameter is the key measurement — it indicates how
much can flow through the pipe. Also that’s the reason why the pressure
rating is so important, because the pressure must be under the transport or
distribute pressure range. Tubes, however, are often put to use in applications
that require precise outside diameters, like with medical tubes, weapon part,
industrial parts, cooler tubes, heat exchanger tubes and boiler tubes. Tubes
are usually used in medical area, construction, structure or load bearing etc.
This is why the outside diameter is important because it indicates how much it
can hold as a stability factor.

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CHAPTER-2

UNDERSTAND PIPING SYSTEM

0201. Define Piping System: All shipboard piping is installed in such as a way
that it will not interfere with the operation of the ship’s machinery or with the
operation of doors, hatches, scuttles or openings covered by removal plates.
As far as possible, piping is installed so that it will not interfere with the
maintenance and repair of machinery or of the ship’s structure. If piping must
be installed in the way of machinery or equipment which requires periodic
dismantling for overhaul, or if it must be installed in the way of other piping
systems or electrical systems, the piping is designed for easy removal. Piping
that is vital to the propulsion of the ship is not installed where it would have to
be dismantled in order to permit routine maintenance on machinery or other
systems. Piping is not normally installed in such a way as to pass through
voids, fuel oil tanks, ballast tanks, feed tanks and similar spaces.

Generally many kinds of piping system used in our ship. Such as:

1. Sea water piping system

2. Fuel piping system
3. Lub-oil piping system
4. Fresh water piping system
5. Bilge piping system
6. Drain line piping system
7. Garbage piping system
8. Hot water piping system
9. Sewage piping system

0202. Mention the different piping arrangement of ship: Generally many kinds
of piping arrangement used in our ship. Such as:

1. Sea water piping system

2. Fuel piping system
3. Lub-oil piping system
4. Fresh water piping system
5. Bilge piping system
6. Drain line piping system
7. Garbage piping system
8. Hot water piping system
9. Sewage piping system
10. Deck line piping system
11. Fire men piping system
12. Compressed Air piping system

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0203. Mention the material used in piping system: There are many kinds of pipe
materials used, such as:

1. GI pipe
2. Copper pipe
3. SS pipe
4. MS pipe
5. Cuppro-nickel pipe
6. Aluminum pipe
7. Cast iron pipe
8. PVC pipe
9. CPVC pipe
10. ABS pipe

0204. Pipeline Color:

1. Fireman line - Red

2. Sea water line - Green
3. Fresh water line - Blue
4. Fuel - Brown
5. Compressed Airline - Stone
6. Petrol - Orange
7. Discharge line - Black
8. Foam & Lub-oil line - Yellow
9. Air line - Blue

0205. Describe the cleaning procedure of pipe line: New construction of

piping systems requires some type of cleaning of debris or contaminants.
Debris can be defined as substances such as dirt, grease, construction
materials such as wood, wire, hard hats, tools, weld slag, rust and scale, and
any other small objects that could be misplaced inside the diameter of piping
systems. Proper cleaning is required dependent upon service requirements.
1. All piping systems shall be flushed with water. Water flush is accomplished
through hydro-testing of piping systems. If water being drained still has
evidence of debris, continue to flush with water until no evidence of debris
exists.
2. Lines that require cleaning should be identified on the Mechanical Flow
Diagrams. The Process Engineering Group (Process Department) shall
set the limits based on the service requirements and equipment being
protected from debris and contaminants generated during construction.
3. Certain process services require chemical cleaning. The process engineer
shall be responsible for identifying services that require chemical cleaning.
Typical examples of services requiring chemical cleaning are listed below:

a. Reciprocating Compressor suction piping

b. Super High Pressure Boiler Feed Water and High Pressure Steam

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4. Product Shipping Lines

a. Specialty Chemical /Catalyst lines
b. Oxygen
c. Hydrogen Peroxide

5. The designer should be responsible for verifying all steps to remove debris
that would be detrimental to the process fluid, including the provision of
any temporary facilities for carrying out the chemical cleaning procedures.

6. The cleaning method used should be selected based upon the facilities
available. Steam and detergent cleaning is much less costly than acid or
mechanical cleaning. Each project specification must indicate the type of
contamination/debris to be removed.

7. All systems shall be sealed after cleaning to keep out dirt and moisture.
Cleaning in place with chemical cleaning solutions shall be compatible with
all components of the piping system; otherwise, components that would be
adversely affected by the cleaning solution shall be temporarily removed.

8. Use and disposal of cleaning solutions must be in accordance with plant

policy or local regulations (or both).

0206. Types of Pipe Contamination for Stainless Steel:

1. Dirt
2. Iron contamination
3. Grease and loose weld spatter
4. Scale and tight weld spatter
5. Oil, paint, or grease
6. Rust

0207. Types of Pipe Contamination for Carbon Steel:

1. Dirt
2. Varnish or protective oil
3. Mill scale
4. Shop weld spatter and scale
5. Rust
6. Moisture (low-temp service)

0208. Various cleaning types:

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1. Mechanical Cleaning: Rotating shafts, brushes, compressed air, and flying

grit are hazards. Use protective equipment dictated by site.

2. Chemical Cleaning: Acids and other chemicals, heated solutions, steam

pressure hoses, spills, and sprays are hazards. Provide protective
clothing, eye protection, safety showers, and facilities to neutralize spills of
spent chemicals. Personnel should not breathe ferroxyl solution (or other
chemical) vapours that may be harmful. Adequate respiration must be
provided when testing or cleaning in enclosed areas with inadequate
ventilation.

3. Vapour Cleaning: Steam, condensate, and other hazards are associated

with chemical cleaning. Controlled discharge of vapours to the atmosphere
or condensate cooled by water sprays is essential to minimize personal
contact.

0209. Cleaning procedures:

1. Procedure for Water Flush:

a. Flush pipe with chloride-free clean water.
b. Thoroughly drain the pipe and dry if required. Drying can be done by
wiping or by blowing with clean, dry compressed air or inert gas.
2. Procedure for Air Blow:
a. Blow with clean, dry compressed air. Use sufficient volume of air to
create high velocity in pipe.
3. Procedure for Steam and Detergent Cleaning:
a. Steam-clean with a water solution of Pennwalt Corp. Cleaner MC-79,
Oakite Products, Inc. Oakite 33, or approved equal. (Mix 1 gal MC-79
with 9 gal clean water; mix 1 gal Oakite 33 with 6 gal clean water.)
b. Drain pipe thoroughly and flush with clean water.
c. Dry pipe by wiping or by blowing with clean, dry compressed air or inert
gas.
4. Procedure for Mechanical Cleaning for Stainless Steel:
a. Blast-clean inside of pipe and fittings with clean, iron-free sand or
alundum grit. Repeat if free iron is found. Use ferroxyl test if required.
Blast-cleaning of clad material should not be carried to the point of
seriously reducing the cladding thickness.
b. Walnut-shell blast provides very smooth interior surfaces. Blast inside
of pipe and fittings until desired results are obtained.

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c. For brush cleaning, use stainless steel wire

d. Note: Any one, or all, of the mechanical cleaning procedures may be
required to effectively clean stainless steel pipe and fittings when weld
spatter or scale (or both) have formed from welding.
5. Procedure for Mechanical Cleaning for Carbon Steel:
a. Blast clean inside of pipe and fittings. Wire brushing with power rotary
wire brushes is an alternate method. A rotary cutter followed by wire
brushing should be used on heavily rusted, pitted, and weld-spattered
pipe, and on pipe with tightly adhered scale.
b. Blow out residues with clean, dry compressed air.

6. Related Posts:
a. An article on “Internal Cleaning of Piping System”
b. Stress Analysis of Vertical Reboiler Piping using Caesar II: Part 3 of 3
c. Meaning of Pipe Schedule / Schedule Numbers?
d. An article on “APPLICATION OF ANTI-CORROSIVE LININGS &
COMPOSITES” : Part 1 of 2
e. An article on “APPLICATION OF ANTI-CORROSIVE LININGS &
COMPOSITES” : Part 2 of 2
f. A short presentation on Control Valve Sizing
g. A brief presentation on “DEHYDRATION : AN OVERVIEW”

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CHAPTER-3

Expansion arrangement of pipe:

All pipes will be installed at ambient temperature. Pipes carrying hot fluids
such as water or steam operate at higher temperatures.

It follows that they expand, especially in length, with an increase from ambient
to working temperatures. This will create stress upon certain areas within the
distribution system, such as pipe joints, which, in the extreme, could fracture.
The amount of the expansion is readily calculated using Equation 10.4.1, or
read from an appropriate chart such as Figure 10.4.1

Example 10.4.1
A 30 m length of carbon steel pipe is to be used to transport steam at 4 bar g
(152°C). If the pipe is installed at 10°C, determine the expansion using
Equation 10.4.1.

Alternatively, the chart in Figure 10.4.1 can be used for finding the
approximate expansion of a variety of steel pipe lengths - see Example 10.4.2
for explanation of use.

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Example 10.4.2
Using Figure 10.4.1. Find the approximate expansion from 15°C, of 100
metres of carbon steel pipework used to distribute steam at 265°C.
Temperature difference is 265 - 15°C = 250°C.
Where the diagonal temperature difference line of 250°C cuts the
horizontal pipe length line at 100 m, drop a vertical line down. For this
example an approximate expansion of 330 mm is indicated.

Pipework flexibility
The pipework system must be sufficiently flexible to accommodate the
movements of the components as they expand. In many cases the flexibility of
the pipework system, due to the length of the pipe and number of bends and
supports, means that no undue stresses are imposed. In other installations,
however, it will be necessary to incorporate some means of achieving this
required flexibility. An example on a typical steam system is the discharge of
condensate from a steam mains drain trap into the condensate return line that
runs along the steam line (Figure 10.4.2). Here, the difference between the
expansions of the two pipework systems must be taken into account. The
steam main will be operating at a higher temperature than that of the
condensate main, and the two connection points will move relative to each
other during system warm-up.

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The amount of movement to be taken up by the piping and any device

incorporated in it can be reduced by ‘cold draw’. The total amount of
expansion is first calculated for each section between fixed anchor points. The
pipes are left short by half of this amount, and stretched cold by pulling up
bolts at a flanged joint, so that at ambient temperature, the system is stressed
in one direction.
When warmed through half of the total temperature rise, the piping is
unstressed. At working temperature and having fully expanded, the piping is
stressed in the opposite direction. The effect is that instead of being stressed
from 0 F to +1 F units of force, the piping is stressed from -½ F to + ½ F units
of force.
In practical terms, the pipework is assembled cold with a spacer piece, of
length equal to half the expansion, between two flanges. When the pipework
is fully installed and anchored at both ends, the spacer is removed and the
joint pulled up tight (see Figure 10.4.3).

The remaining part of the expansion, if not accepted by the natural flexibility of
the pipework will call for the use of an expansion fitting.
In practice, pipework expansion and support can be classified into three areas
as shown in Figure 10.4.4.

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The fixed or ‘anchor’ points ‘A’ provide a datum position from which expansion
takes place.
The sliding support points ‘B’ allow free movement for expansion of the
pipework, while keeping the pipeline in alignment.
The expansion device at point ‘C’ is to accommodate the expansion and
contraction of the pipe.

Roller supports (Figure 10.4.5 and 10.4.6) are ideal methods for supporting
pipes, at the same time allowing them to move in two directions. For steel
pipework, the rollers should be manufactured from ferrous material. For
copper pipework, they should be manufactured from non-ferrous material. It is
good practice for pipework supported on rollers to be fitted with a pipe saddle
bolted to a support bracket at not more than distances of 6 metres to keep the
pipework in alignment during any expansion and contraction.
Where two pipes are to be supported one below the other, it is poor practice
to carry the bottom pipe from the top pipe using a pipe clip. This will cause
extra stress to be added to the top pipe whose thickness has been sized to
take only the stress of its working pressure.
All pipe supports should be specifically designed to suit the outside diameter
of the pipe concerned.

Expansion fittings
The expansion fitting (‘C’ Figure 10.4.4) is one method of accommodating the
expansion, without the total length of the line changing. They are commonly
called expansion bellows, due to the bellows construction of the expansion
sleeve.
Other expansion fittings can be made from the pipework itself. This can be a
cheaper way to solve the problem, but more space is needed to
accommodate the pipe.

Full loop
This is simply one complete turn of the pipe and, on steam pipework, should
preferably be fitted in a horizontal rather than a vertical position to prevent
condensate accumulating on the upstream side.
The downstream side passes below the upstream side and great care must
be taken that it is not fitted the wrong way round, as condensate can
accumulate in the bottom. When full loops are to be fitted in a confined space,
care must be taken to specify that wrong-handed loops are not supplied.
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The full loop does not produce a force in opposition to the expanding
pipework as in some other types, but with steam pressure inside the loop,
there is a slight tendency to unwind, which puts an additional stress on the
flanges.

This design is used rarely today due to the space taken up by the pipework,
and proprietary expansion bellows are now more readily available. However
large steam users such as power stations or establishments with large outside
distribution systems still tend to use full loop type expansion devices, as
space is usually available and the cost is relatively low.

Horseshoe or lyre loop:

When space is available this type is sometimes used. It is best fitted
horizontally so that the loop and the main are on the same plane. Pressure
does not tend to blow the ends of the loop apart, but there is a very slight
straightening out effect. This is due to the design but causes no misalignment
of the flanges.

If any of these arrangements are fitted with the loop vertically above the pipe t
hen a drain point must be provided on the upstream side as depicted in
Figure 10.4.8.

Expansion loops

The expansion loop can be fabricated from lengths of straight pipes and
elbows welded at the joints (Figure 10.4.9). An indication of the expansion of
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pipe that can be accommodated by these assemblies is shown in Figure

10.4.10.
It can be seen from Figure 10.4.9 that the depth of the loop should be twice
the width, and the width is determined from Figure 10.4.10, knowing the total
amount of expansion expected from the pipes either side of the loop.

Sliding joint:
These are sometimes used because they take up little room, but it is essential
hat the pipeline is rigidly anchored and guided in strict accordance with the
manufacturers’ instructions; otherwise steam pressure acting on the cross
sectional area of the sleeve part of the joint tends to blow the joint apart in
opposition to the forces produced by the expanding pipework (see Figure
10.4.11). Misalignment will cause the sliding sleeve to bend, while regular
maintenance of the gland packing may also be needed.

Expansion bellows
An expansion bellows, Figures 10.4.12, has the advantage that it requires no
packing (as does the sliding joint type). But it does have the same
disadvantages as the sliding joint in that pressure inside tends to extend the
fitting, consequently, anchors and guides must be able to withstand this force.

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Bellows may incorporate limit rods, which limit over-compression and over-
extension of the element. These may have little function under normal
operating conditions, as most simple bellows assemblies are able to withstand
small lateral and angular movement. However, in the event of anchor failure,
they behave as tie rods and contain the pressure thrust forces, preventing
damage to the unit whilst reducing the possibility of further damage to piping,
equipment and personnel (Figure 10.4.13 (b)).
Where larger forces are expected, some form of additional mechanical
reinforcement should be built into the device, such as hinged stay bars
(Figure 10.4.13 (c)).
There is invariably more than one way to accommodate the relative
movement between two laterally displaced pipes depending upon the relative
positions of bellows anchors and guides. In terms of preference, axial
displacement is better than angular, which in turn, is better than lateral.
Angular and lateral movement should be avoided wherever possible.
Figure 10.4.13 (a), (b), and (c) give a rough indication of the effects of these
movements, but, under all circumstances, it is highly recommended that
expert advice is sought from the bellows’ manufacturer regarding any
installation of expansion bellows.

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COMMON TYPES OF EXPANSION JOINTS ARE:

1. Simple Expansion Joint
2. Universal Expansion Joint
3. Pressure Balanced Expansion Joint
4. Hinged Expansion Joint
5. Gimbal Expansion Joint

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CHAPTER-4

UNDERSTAND TRAP

0401. Trap: trap is a type of curve pipe. It prevents spread out bad smell of
sewage line. Traps should be of the self-cleansing type. They should generate
enough velocity from the available flow to have a self-cleansing effect, a smooth
finish and a full uniform bore.

Figure: Trap

Some manufactured fixtures, e.g. water closets, bed pan washers and certain
models of urinals have integral traps built within the body of the fixture. Water
closets and in some cases urinals are provided with integral traps. All other
fixtures shall be provided with external traps with adequate water seal.
Diameter of the trap shall in no case be smaller than the diameter of the outlet
of the fixture to which it is connected.

0402. Different Types of Traps

a. Floor Trap or Nahni Trap: Floor trap or Nahni trap is provided into
the floor to collect waste water from bathroom, wash area, washbasin, and
kitchen sink etc.

Figure: Floor Trap

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b. Gully Trap: A gully trap is provided outside the building before

connecting it to external sewerage line. It also collects waste water from
the kitchen sink, wash basins, baths and wash area.

Figure: Gully Trap

c. P, Q and S-Trap: P, Q, and S traps are classified according to their shape.
They essentially consist of U – Tube which retains water acting as seal
between the foul gas and atmosphere.

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d. Intercepting Trap: Intercepting trap is provided into the Interceptor

Manhole (Interceptor Chamber). An Interceptor manhole is provided at the
intercept of building sewer and Public sewer. Intercepting trap is provided
to prevent the foul gases from public sewers entering into the building
sewer by providing water seal.

Figure: Intercepting Trap

e. Bottle Trap: A bottle trap is provided to receive waste from washbasin,

kitchen sinks and other appliances where the appliances do not have built-
in it trap.

Figure: Bottle Trap

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f. Grease Trap: Grease trap is installed in the waste pipe from one or
more fixtures for the purpose of separating grease from the liquid and
retaining the grease.

Grease Trap

g. Maintenance of traps: When water is not flowing on a regular basis inside

the drain pipe, a sink trap can dry out. When it does not contain water,
there is nothing to prevent sewage gas from entering your house, and this
is where the sink trap comes in. Sewer gas has a strong bad smell and it
may also contain dangerous substances that can be detrimental to ones
health. The main reason is that the gas is a byproduct of wastewater,
resulting from the decomposition of waste.

Gas naturally wants to rise and escape from its container; in this case your
drain lines. Without a sink trap, your house will be the first place for the
gas to visit. Every sink, shower, drain, toilet, and drain in your house
needs a p-trap. When one dries out from a lack of use, simply run some
water into it. That simple step will re-create the water seal, and stop the
escape of sewer gas.

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CHAPTER-5

UNDERSTAND STRAINER AND FILTER

0501. Strainers & Filters: Strainers are fitted in practically all piping lines to
prevent the passage of grit, scale, dirt and other foreign matter which could
obstruct pump suction valves, throttle valves or other machinery parts.

Figure : Strainers & Filters

Illustrates three common types of Strainers. Part ‘A’ shows bilge suction
strainer located in the bilge pump suction line between the suction manifold
and the pump. Any debris which enters the piping is collected in the strainer
basket. The basket can be removed for cleaning by loosening the strong back
screws, removing the cover and lifting the basket out by its handle. Part ‘B’ of
figure 14-9 shows a duplex oil strainer of the commonly used in fuel oil and
lubricating oil lines, where it is essential to maintain an uninterrupted flow of
oil. The flow may be diverted from one basket to the other, while one is being
cleaned. Part ‘C’ of figure 14-9 shows a manifold steam strainer. This type of
strainer is desirable where space is limited since it eliminates the use of
separate strainers and their fittings. The cover is located so that the strainer
basket can be removed for cleaning.

Metal-edge filters are used in the lubrication systems of many auxiliary units.
A metal-edge filter consists of a series of metal plates or disks. Turning a
handle moves the plates or disks across each other in such a way as to
remove any particles that have collected on the metal surfaces. Some metal-
edge type filters have magnets to aid in removing fine particles of magnetic
materials.

0502. Different between Filters and Strainers: The primary difference between
filters and strainers is in the size of the particulates they are removing. Filters
remove particulates that are smaller than 40 microns (often abbreviated 40
μm). Strainers remove particulates that are larger than 40 microns. A micron
is a unit of measurement equivalent to one one-thousandth of a millimeter. In
simpler terms the word “strainer” is typically used if the particulate being

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removed is visible to the naked eye; whereas, if the particulate is too small to
see with the naked eye the term “filter” is used.

Gulf Coast Filters is here to help. If you are ever in doubt about whether you
need a filter or a strainer our filtration experts are happy to discuss the
specifics of your application with you and make sure that you get the right
product. We can also advise you on filtration media, maintenance, and other
issues related to the performance of your system.

0503. Materials used for filter & strainer

1. Materials of strainer: Strainers can have a connection that is welded,

flanged, threaded, clamped or brazed or soldered. Materials of construction
include bronze, cast iron, nickel alloy, carbon or alloy steel, stainless steel,
titanium, polyvinyl chloride (PVC), polyethylene (PE), or polypropylene (PP,
PPL). Fiberglass strainers and rugged strainers made of reinforced plastics
and composite materials are also commonly available. Features common to
strainers include integral filters, magnetic inserts, steam jacketing, self-
cleaning, and sanitary construction.

2. Materials for Filter: Certain basic materials are required for the
purposes of filtration, especially biofiltration. In a filter reactor, granular
material is used to achieve both filtration and biochemical transformation of
contaminants.

Materials with rough surfaces have been found to produce the best results, as
bacteria can colonise such surfaces more easily. A form of bacterial biofilm
develops on the particles. It is these microorganisms that are responsible for
the breakdown of the contaminants in polluted water.

Various natural materials of volcanic origin can be used as filter materials, such as
lava stone, pumice, zeolite and basalt. Potential applications are drinking water and
waste water filtration, plant-based clarification systems, basin reactors, clarification
beds, ponds and aquaria, to name but a few. In each case, the basic principles are
the same.

0504. Cleaning & maintenance procedure of filter & strainer

1. Strainer:
a. Changeover to the standby sea chest filter and ensure all systems
running normally.
b. Shut the inlet and outlet valves of the sea chest filter to be
cleaned. Lock and tag them as closed so that nobody opens it
accidentally.
c. Open the vent valve and release any residual pressure as well as
check whether the inlet and outlet valves are holding. When no
further water or air escapes from the vent valve, it signifies that the
valves are holding.

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d. Drain the sea water from the sea chest through the drain valve at
the bottom.
e. Open the top cover of the filter and remove the mesh filter.
f. Clean the mesh filter thoroughly.
g. Place back the mesh filter and make sure to align any locking
notches on the filter body.
h. Clean the sealing surface on the filter body and filter cover.
i. Replace sealing gasket if need be and place back the filter cover
carefully.
j. Tighten the cover and shut the drain valve.
k. Keep the vent valve crack open and then open the inlet valve
slowly.
l. Purge the filter and check for leakages around the filter body.
m. Shut the vent valve after purging and then open the outlet valve.

2. Filter:

a. Proper use of a quality air filter restriction gauge and adherence to OEM
recommended air filter change guidelines will provide the maximum life out
of the air filter element and the engine/equipment that the filter is
protecting.
b. Cleaning air filters will reduce dust holding capacity compared to that of a
new air filter. Dust capacity can drop up to 25% after the first cleaning, with
additional loss after each subsequent cleaning. This leads to more
frequent servicing and potential complications such as mis-service or
accidental dust ingestion.
c. On-highway air filters should never be cleaned since the contamination
encountered over the road (fine particles and soot materials) is very
difficult to remove from the air filter media. The retained contaminant
causes discolouration, even after cleaning, and marked reductions in dust
capacity compared to a new air filter. Cleaning to a “like new” appearance
will most likely damage the air filter media.
d. Secondary air filters should never be cleaned since they are the last
barrier to contaminants before reaching your engine/equipment. A
secondary air filter should be replaced after three changes of the primary
air filter or one year of continuous service, whichever occurs first.
e. Extra handling of air filters could inadvertently cause damage.
f. Proper inspection of cleaned elements is of vital importance for the proper
operation of the air cleaner system.
g. Generally, the commercial air filter cleaning businesses do not want to
clean air filters that have been used to the OEM recommended change
point (20-30" H2O or 4.9 – 7.4 kPa filter restriction). This encourages more
frequent filter service and leads to the problems associated with too
frequent opening and closing of the air filtration system. Utilising the
maximum life of the air filter is your best practice for gaining the maximum,
cost-effective engine/equipment protection.

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CHAPTER-6

0601. Valve: A valve is a device that regulates, directs or controls the flow of
a fluid (gases, liquids, fluidized solids, or slurries) through pipelines by
opening, closing, or partially obstructing various passageways

0602. Function of valve:

1. To stop the fluid-flow or allow the flow to continue.

2. To “throttle” or control the quantity of flow.
3. To control the direction or flow.
4. Relieve the pressure to safeguard the system.
5. Reduce the pressure of the fluid.
6. Allow the flow only in one direction.

0603. List of valve use marine piping system: Mainly different types of valve
are used to control flow of fluid. The basic valve types can be divided into two
groups. There are;
1. Screw down valve:
a. Gate valve,
b. globe valve,
c. niddle valve
d. Ball valve,
e. Butterfly valve
f. Needle valve
g. Pinch valve,
h. Piston valve
j. Solenoid valve
k.Spool Valve

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2. Non-return valve:
a. Strom valve,
b. flap valve,
c. cheek valve
d. Flow control valve,
e. Poppet valve,
f. Pressure Reducing Valve
g. . Thermal expansion valve,
h. Safety valve or relief valve:

0604. Explain the working principle of valves: There are different types of
valves used on board in the various systems:

1. GLOBE VALVE:

a. It normally consists of a valve lid (circular disk).

b. The fluid enters the body from underneath the valve lid and passes
through from the top of the valve lid.
c. Hence the fluid has to make the change in the flow of direction, causing
energy waste or pressure drop and reduced flow rate.
d. Most Extensively used and gives fine control of Fluids/Gases.
e. The cost is reasonable and Maintenance is easy too.
f. Globe valves are normally used where it is necessary to throttle or
regulate the flow of fluid.
g. The valve lift in globe valve is about quarter of the lid diameter.(D/4)
h. can be used as:

1. Screw down: In SD valve the lid position is determined by the position of the
operating spindle.

2. Screw down non-return: In SDNR valve the lid remains seated, even when the
spindle is drawn up. The valve lid moves off its seat, only by fluid pressure
acting from below and remain open till the time pressure below the valve lid is
more than the pressure above.

GATE VALVE:

a. It is also known as sluice valve.

b. In this type, a wedge shaped valve disc is used as a closing device.The
valve disc fits into a wedge shaped opening in the valve body.
c. The main features of this valve are high flow rate, with minimum wastage
of energy and also allows flow in either direction.
d. These are costly valve and maintenance is a bit tricky.

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3. NON-RETURN VALVE:

a. The non-return valve is designed to allow the fluid flow only in one
direction. It is also called as a unidirectional valve.
b. The basic construction can be either disc or flap type.

4. BUTTERFLY VALVE:

a. This type has a valve disc, which swivels about a central axis in either
open or closed position.
b. These valves can be locked in any position once the desired flow rate is
achieved.
c. In overhauling of this type of valve, the renewal of valve lining and ‘O’ ring
rubber seals on the valve shaft are required.

5. BALL VALVE:

a. This valve has a hole in the stainless steel ball housed in internally Teflon
coated housing.
b. The access to the Fluid or Gas is through the Hole.

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