OVERVIEW OF

PROCESS PLANT PIPING

SYSTEM

Reza Manafi
Definition
Piping component
Piping drawing
Design
Pipe work
Codes & Standards
Piping components: summary
Prepared by Reza Manafi
Definition
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piping:
assemblies of piping components
used[for] fluid flows. Piping also
includes pipe supporting elements, but
does not include support structuresor
equipment

piping system:
interconnected piping subject to the
same design conditions

Definition:
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piping components:
mechanical elements suitable for joining
or assembly into pressure tight fluid-
containing piping systems include
Definition:
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Piping component
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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

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Pipe & Tube
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Seamless Show

Welded:
Longitudinal seam
Single seam
Double seam (NPS 36)

Helical (spiral) seam Show
NPS 4
0.8 OD Skelp width 3.0 OD
Submerged arc welding


Piping components: Pipe & tube manufacturing
Prepared by Reza Manafi
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
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Billet preparing
visual control
Billet chopping
Billet heating
in annular furnace
Rough tube
piercing
Tube rolling in
continuous mandrel mill
Mandrel removing
Piping components: Pipe & tube manufacturing : Seamless pipe
Prepared by Reza Manafi
Tube heating in
cell induction furnace
Sizing and reduction Stalk ends cutting,
tubes cutting with flying shears
Tubes cooling Tubes leveling Tubes cutting in ready
sizes, tubes facing
Piping components: Pipe & tube manufacturing : Seamless pipe
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Geometry measuring,
mechanical tests,
chemical composition control
Tube ends sizing
(by OD and ID)
Heating for quenching
Quenching in sprayer Tempering Tubes cooling
Piping components: Pipe & tube manufacturing : Seamless pipe
Prepared by Reza Manafi
Tubes etching Ultrasonic or
electromagnetic test
Hydraulic test
Sweeping-up (if required)
, visual control
Preservative coating Weighing, marking,
packing, storing
Piping components: Pipe & tube manufacturing : Seamless pipe
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Tube end upset Thermal treatment Leveling
Sweeping-up and
grading by length
Threading, thread
quality monitoring
Couplings screwing-on
Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)
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Hydraulic test Tubes inspection,
rings and nipple
screwing-on, marking
Painting (if required))
Packing, storing
Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)
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Piping components: Pipe & tube manufacturing : other pipe
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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
Piping components: pipe & tube classification
Prepared by Reza Manafi
Pipe:
NPS:
1/8, , 3/8, , , 1, 1 , 2, 3, 4, 6, 8, 10,
12, 14, 16, 18, 20, 24, 28, 30, 32, 36, 40,
44, 48 52, 56, 60

NPS 1 , 2 , 3 , 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

Piping components: pipe & tube classification
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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 & tube classification
Prepared by Reza Manafi
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 53 Electric-weldedand seamless
steel pipes, black or hot-dip galvanized
ASTM A 106 Seamless carbon steel pipes for high
temperature performance
Piping components: pipe standards
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Piping components: Fitting
Fitting
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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)

Piping components: Fitting
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Method of joining pipe:
Butt weld
Socket weld
Threaded
Quick coupling
Flange
Special item
Piping components: Fitting
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ASME B16.9
Used in most piping systems NPS 2
Use generally not restricted
Difficult in small sizes, especially for thin wall

Piping components: Fitting (butt-weld)
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Backing ring
Piping components: Fitting (butt-weld)
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Elbow (90, 45)
Long reduce
Curvature = 1 NPS
Long tangent: straight
extension at one end
Short reduce
curvature = NPS

Reducing elbow:
90
curvature = 1 NPS larger end
Piping components: Fitting (butt-weld)
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Return:
Curvature = 1 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



Piping components: Fitting (butt-weld)
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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

Piping components: Fitting (butt-weld)
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Reducer
Eccentric
Suction & discharge of pump
support
concentric
Piping components: Fitting (butt-weld)
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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
Piping components: Fitting (butt-weld)
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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

Piping components: Fitting (butt-weld)
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Cross
Straight (branch to the same size as the run)
Reducing (rarely used)
Piping components: Fitting (butt-weld)
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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

45
Piping components: Fitting (butt-weld)
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Stub-in
Welded directly in the side of the main pipe run
Least expensive
NPS 2
Cab be reinforced
Piping components: Fitting (butt-weld)
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Weldolet
Make a closer manifold that Tee
Full size
Reducing
Flat
Are available for connecting to pipe caps and
pressure vessel
Piping components: Fitting (butt-weld)
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Elbolet: reducing tangent branch on elbow
Latrolet : reducing, 45
Sweepolet
Good flow pattern and optimum stress
distribution
90 reducing from the main pipe
Piping components: Fitting (butt-weld)
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Closure
Cap
Flat closure

Piping components: Fitting (butt-weld)
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Size frequently limited to NPS 1 (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

Piping components: Fitting (socket)
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Elbow (90, 45)

Piping components: Fitting (socket)
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Return:

Piping components: Fitting (socket)
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Reducer
Reducer insert
Piping components: Fitting (socket)
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Sewage :
Abrupt change of line size in butt-weld
Piping components: Fitting (socket)
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Full coupling
Half coupling
Piping components: Fitting (socket)
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Union
Piping components: Fitting (socket)
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Tee

Piping components: Fitting (socket)
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Cross
Piping components: Fitting (socket)
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Lateral
Piping components: Fitting (socket)
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Sockolet
Piping components: Fitting (socket)
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Socket welding Elbolet
Socket welding latrolet
Nippolet
Piping components: Fitting (socket)
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Cap

Piping components: Fitting (socket)
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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 , pressure rating < 600, temperature < 625

Piping components: Fitting (threaded =screwed)
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Elbow (90, 45)
Reducing elbow
Piping components: Fitting (thread)
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Reducer
Reducer insert
Piping components: Fitting (thread)
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Sewage nipple
Piping components: Fitting (thread)
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Full coupling
Half coupling
Piping components: Fitting (thread)
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Tee
Piping components: Fitting (thread)
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Nipple
Piping components: Fitting (thread)
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cross
Piping components: Fitting (thread)
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lateral
Piping components: Fitting (thread)
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Union
Piping components: Fitting (thread)
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Hexagon bushing
Piping components: Fitting (thread)
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Threadolet

Piping components: Fitting (thread)
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Threaded elbolet
Threaded latrolet
Threaded nippolet
Piping components: Fitting (thread)
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Closure
Cap
plug
Piping components: Fitting (thread)
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Piping components: Fitting
Flange used for
Mate to equipment, vessels, valve,
When need periodic cleaning
Flanges are normally used for pipe sizes above
NPS 1.


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Piping components: Fitting
Type of flanges:
Threaded Flanges
Socket-Welded Flanges
Blind Flanges
Slip-On Flanges
Lapped Flanges
Weld Neck Flanges
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Welding neck flange
Regular
Long (used for vessel & equipment nozzle, rarely for
pipe
Suitable where
Extreme temperature
Shear
Impact and vibration
Stress apply
Piping components: Fitting (flange)
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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



Piping components: Fitting (flange)
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Socket welding flange
Piping components: Fitting (flange)
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Threaded flange
Piping components: Fitting (flange)
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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

Piping components: Fitting (flange)
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Expander flange
Reducer + welding neck flange
Increase pipe size to first or second large size
Piping components: Fitting (flange)
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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

Piping components: Fitting (flange)
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Blind flange
Piping components: Fitting (flange)
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Flageolet
Piping components: Fitting (flange)
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Flange Facing Types
Flat Faced
Raised Face
Ring Joint

Piping components: Fitting (flange)
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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.

Piping components: Fitting (flange)
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Material Specification List
Piping components: Fitting (flange)
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Material and design temperature combinations
that do not have a pressure indicated are not
acceptable.

Pressure - Temperature Ratings
Piping components: Fitting (flange)
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Flange Rating Class
Piping components: Fitting (flange)
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Flange Rating Class
Piping components: Fitting (flange)
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Flange Rating Class
Piping components: Fitting (flange)
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Equipment Nozzle Load standards and Parameters
Piping components: Fitting (flange)
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Flange with jack screw
Piping components: Fitting (flange)
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Piping components: Fitting (piping specification)
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Piping components: Fitting (gasket)
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Piping components: Fitting (branch connection chart)
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Gasket:
Resilient material
Inserted between flanges
Compressed by bolts to create seal
Commonly used types
Sheet
Spiral wound
Solid metal ring
Insulation gasket
Piping components: Fitting (gasket)
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Sheet
Piping components: Fitting (gasket)
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Sheet
Piping components: Fitting (gasket)
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Spiral wound
Piping components: Fitting (gasket)
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Spiral wound

Piping components: Fitting (gasket)
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Spiral wound

Piping components: Fitting (gasket)
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Solid metal ring
Piping components: Fitting (gasket)
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Insulation gasket
Piping components: Fitting (gasket)
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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)
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Tightening arrangement
Piping components: Fitting (bolt)
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ASME B16.5, Pipe Flanges and Flanged Fittings
(NPS 24)


Piping components: Fitting
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Quick coupling
Piping components: Fitting (special item)
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Piping components: Fitting (special item)
Flange coupling adaptor
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Piping components: Fitting (special item)
Expansion joint (Bellows)
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Piping components: Fitting (special item)
Expansion joint
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Piping components: Fitting (special item)
Flexible joint
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Piping components: Fitting (special item)
Flexible joint
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Piping components: Fitting (special item)
Double block & bleed
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strainer
Piping components: Fitting (special item)
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Spectacle blind
Piping components: Fitting (special item)
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Piping components: Fitting (special item)
Thermal sleeve & Queel
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Piping components: Fitting Piping components: Fitting (special item)
Bird screen
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Piping components: Fitting Piping components: Fitting (special item)
Tundish
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Piping components: Fitting Piping components: Fitting (special item)
Pigging Tee
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RUPTURE DISKS OR BURST DIAPHRAGMS:
must be replaced after opening

Piping components: Fitting (special item)
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Valves
Piping components: valve
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Valve are use 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
Piping components: valve
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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

Piping components: valve
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Piping components: valve
Type of valves:
Ball valves
Gate valves
Globe valves
Check Valves
Plug valve
Butterfly valves
Pinch valve
Needle valves
Relief Valve
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Ball Valve
Piping components: valve
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Piping components: valve (ball valve)
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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
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Gate Valve
Piping components: valve
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Piping components: valve (gate valve)
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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

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Piping components: valve (gate valve)
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Globe Valve
Piping components: valve
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Piping components: valve (globe valve)
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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.)

Piping components: valve (globe valve)
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Piping components: valve (globe valve)
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Check Valve
Piping components: valve
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Piping components: (check valve / swing check valve)
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Simple design
Allows flow in one direction
Can not be used as an isolation valve
Piping components: (check valve / swing check valve)
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Piping components: (check valve / ball check valve)
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Their low cost usually makes them the first choice
valves sized NPS 2 and smaller (available in
sizes NPS 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 / ball check valve)
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Piping components: (check valve)
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are available in sizes from NPS 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.

Piping components: (check valve / lift check valve)
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Wafer Check Valve
Piping components: (check valve)
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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.

Piping components: (check valve / wafer check valve)
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Stop Check Valve
Piping components: (check valve)
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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



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Piping components: (check valve)
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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
Piping components: (check valve)
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Plug Valve
Piping components: valve
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Plug Valve
Piping components: valve (plug valve)
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Similar to ball valve
Piping components: valve (plug valve)
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Butterfly Valve
Piping components: valve
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Butterfly Valve
Piping components: valve (butterfly valve)
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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
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Pinch Valve
Piping components: valve
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Pinch Valve
Piping components: valve (pinch valve)
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Needle Valve
Piping components: valve
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Needle Valve
Piping components: valve (needle valve)
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Relive Valve
Piping components: valve
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Relive Valve
Piping components: valve
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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
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Interlock sequence
Piping components: valve (interlock)
close
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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 (parts)
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Piping components: valve (result)
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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).
Piping components: valve (valve selection process)
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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.

Piping components: valve (valve selection process)
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V
a
l
v
e

d
a
t
a

s
h
e
e
t

Piping components: valve (valve selection process)
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According to ANSI, leakage classify by class
(I, II, III, IV, VI)
Piping components: valve (leakage classification)
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Pipe Supports and Restraints
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Function of supports and restraints:
To carry load
To ensure that material is not stressed beyond a
safe limit
Holdup of liquid can occurred due to pipe sagging
(allow draining)
To permit thermal expansion
To withstand and dampen vibrational forces applied
to the piping
Piping components: pipe supports and restraints
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Supports:
Absorb system weight
Reduce:
longitudinal pipe stress
pipe sag
end point reaction loads

Piping components: pipe supports and restraints
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Restraints
Control, limit, redirect thermal movement
Reduce thermal stress
Reduce loads on equipment connections
Absorb imposed loads
Wind
Earthquake
Slug flow
Water hammer
Flow induced-vibration

Piping components: pipe supports and restraints
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Support and Restraint Selection Factors:
Weight load
Available attachment clearance
Availability of structural steel
Direction of loads and/or movement
Design temperature
Vertical thermal movement at supports

Piping components: pipe supports and restraints
Prepared by Reza Manafi
Piping components: pipe supports and restraints (rigid support)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (hanger support)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (flexible support)
Rigid hangers are normally used at locations where no vertical
movement of the piping occurs.

Prepared by Reza Manafi
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Flexible Supports
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Flexible Supports
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Flexible Supports
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (flexible support)
Prepared by Reza Manafi
Anchor
Full fixation
Permits very limited (if any) translation or
rotation
Guide
Permits movement along pipe axis
Prevents lateral movement
May permit pipe rotation

Piping components: pipe supports and restraints (anchor, guide)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (Restraints - Anchors)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (Restraints - Guide)
Prepared by Reza Manafi
Piping can be arranged
On piperacks

Near grade on sleeper

In trench

Near steelwork or equipment

Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Pipeway:
Is the space allocated for routing several parallel
adjacent lines
Group lines in pipeway

Piperack
Is a structure in the pipeway for carrying pipes and
is usually fabricated from Steel, Concrete & steel,
also provide protected location for ancillary
equipment (pump, utility station, )

Piperack shape termed tee-head support
Piping components: pipe supports and restraints (Piping and support arrangement / support definition)
Prepared by Reza Manafi
Piperack consist:
Bent:
Connected shape frame
Stanchion:
The vertical member of bents are
termed stanchion

Piperack arrangement:
Single deck
Double deck,
Piping components: pipe supports and restraints (Piping and support arrangement / support definition)
Prepared by Reza Manafi
Arrangement of pipe on support:
Usually 2 < NPS < 12 mounted on piperack and
larger pipes are mounted on sleeper




Mounted large diameter pipe near stanchion for
uniform distribution of load









Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Hot pipe usually insulated and mounted on shoes




Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Other type of shoes




Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Use bracket or outrigger for
Installation of electrical and instrument tray
Pipes with slope

Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Group requiring expansion loop at one side of
the pipe rack






Design hanger for 2 and larger pipe
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
For better stress distribution in the pipe wall,
saddle used on large line and used for lines that
twist over when moving

Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Provide guide for long straight pipes subject to
thermal movement

Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
The smallest size of pipe run on a piperack 2

If necessary, suspend pipe smaller 2 from 4 and
larger

For making horizontal branch, change height of pipe



Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
The most economic beam section desired for the
piperack












If more room is needed, make double or triple piperack
Piping components: pipe supports and restraints (Piping and support arrangement)
20 -25 ft
> 6 ft
Prepared by Reza Manafi
Categorize piperack, for example if using double deck,
place utility service piping on the upper level of the
piperack












Piping components: pipe supports and restraints (Piping and support arrangement)
Utility service
process
Determine by lifting equipment required access
Prepared by Reza Manafi
Dont install pipe on stanchion, this will prevent
adding another deck






Consider sufficient space beside piperack






Piping components: pipe supports and restraints (Piping and support arrangement)
10 ft
Prepared by Reza Manafi
Ensure that nozzles on equipment are free from
transmitted by the piping
Equipment suppliers will state max. loading
permissible at nozzles
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Dummy leg length
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
For line smaller than 2 and non-critical arrange
supports in the field
Pocketing of liquid due to sagging can be eliminated
by sloping the line so that the difference in height
between adjacent supports is at least equal to triple
deflection at the midpoint





As a rule of thumb, spans for insulated lines should
be reduced by approximately %30 from those for
uninsulated pipes
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Support piping from overhead, in preference to
underneath





Install flange, with 12 minimum clearance from
supporting steel





>12
Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Keep weld joints at least 3 from supporting steel or
other obstruction








To carry the weight of the piping use a FOS = 3

In general, one hanger or other support should be
specified for each side of a valve.



Piping components: pipe supports and restraints (Piping and support arrangement)
>3
Prepared by Reza Manafi
Field support
For line smaller than 2 and non-critical, arrange
supports in the field

Finding location of support

Piping components: pipe supports and restraints (Piping and support arrangement)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (piping support document)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (piping support document)
Prepared by Reza Manafi
Piping components: pipe supports and restraints (piping support drawing)
Prepared by Reza Manafi
Piping Drawing
Prepared by Reza Manafi
The main purpose of a drawing is to communicate information
in a simple and explicit way for construction apart from
specification

Pipe represent by
Single line:
Only centerline of the pipe is drawn
Double line:
Very time-consuming
Difficult to read
Piping drawings:
Prepared by Reza Manafi
Three type of drawing that developed from schematic (Block
Flow Diagram (BFD)) diagram are:

Process Flow Diagram (PFD)

Piping & Instrument Diagram (P&ID)

Piping drawing

Piping drawings:
Prepared by Reza Manafi
Block Flow Diagram
BFD
Prepared by Reza Manafi
Piping drawings: block flow diagram
Prepared by Reza Manafi
A Block Flow Diagram - BFD, is a
schematic illustration of the major
process.The block or rectangles used
represent a unit operation. The blocks are
connected by straight lines which represent
the process flow streams which flow
between the units. These process flow
streams may be mixtures of liquids, gases
and solids flowing in pipes or ducts, or
solids.

Piping drawings: block flow diagram
Prepared by Reza Manafi
In order to prepare block flow diagrams a number of rules
should be followed:
unit operations such as mixers, separators, reactors,
distillation columns and heat exchangers are usually
denoted by a simple block or rectangle.
groups of unit operations may be noted by a single block
or rectangle.
process flow streams flowing into and out of the blocks are
represented by neatly drawn straight lines. These lines
should either be horizontal or vertical.
the direction of flow of each of the process flow streams
must be clearly indicated by arrows.
flow streams should be numbered sequentially in a logical
order.
unit operations (i.e., blocks) should be labeled.
where possible the diagram should be arranged so that the
process material flows from left to right, with upstream
units on the left and downstream units on the right.

Piping drawings: block flow diagram
Prepared by Reza Manafi
Process Flow Diagram
PFD
Prepared by Reza Manafi
Piping drawings: process flow diagram
Prepared by Reza Manafi
Piping drawings: process flow diagram
Prepared by Reza Manafi
A Process Flow Diagram - PFD, is a
schematic illustration of the system.PFD's
shows the relationships between the major
components in the system. PFD also tabulate
process design values for the components in
different operating modes, typical minimum,
normal and maximum. PFD's do not show
minor components, piping systems, piping
ratings, standby equipment
It is advisable to draw equipment that is
operated cyclically
Piping drawings: process flow diagram
Prepared by Reza Manafi
A PFD should include:
Process Piping
Major equipment symbols, names and identification
numbers
Control, valves and valves that affect operation of
the system
Interconnection with other systems
System ratings and operational values as
minimum, normal and maximum flow, temperature
and pressure
Composition of fluids
This figure depict a small and simplified PFD:
Piping drawings: process flow diagram
Prepared by Reza Manafi
Each item of equipment should bear the same number on all
drawings.
Standby or identical equipment if in the same service, may be
identified by adding letters A, B, C
Process material balance can be tabulated on separate 8 * 11
Use of arrowhead at all junction and corners aids the rapid
reading of the diagram, keep parallel line at least 3/8 apart
Process & service stream entering or leaving the process are
noted by hollow arrow with
Piping drawings: process flow diagram
Prepared by Reza Manafi
Piping and Instrumentation Diagram
P&ID
Prepared by Reza Manafi
Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
A Piping and Instrumentation Diagram -
P&ID, is a schematic illustration of functional
relationship of piping, instrumentation and
system equipment components.P&ID shows
all of piping including the physical sequence
of branches, reducers, valves, equipment,
instrumentation and control interlocks. The
P&ID are used to operate the process
system.
Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
A P&ID should include:
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings,
sampling lines, reducers and increasers
Flow directions
Interconnections
Control inputs and outputs, interlocks
Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Preferably draw all valves with the same size
long

Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Draw instrument identification balloons 7/16
diameter









Draw square with 3/8 width

Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Allocate new number to branch
A typical note may be used to describe multiple piece
of identical equipment in the same service
Special point for design and operation procedure are
noted such as line which need to be sloped for
gravity flow, line which need careful cleaning,

Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Terminate the number at major number of a
equipment such as tank, pressure vessel, mixer
or any equipment carrying an individual
equipment number
Show and tag process and service valve with size
and identification number
Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Flow direction





Piping drawings: line number
Prepared by Reza Manafi
Standby and parallel equipment are shown
Dripleg are not shown but steam trap are
shown
vent and drain to be used for hydrostatic
testing are not shown
Insulation, insulation thickness and tracing
are shown
Piping drawings: piping and instrumentation diagram
Prepared by Reza Manafi
Drawing component
Prepared by Reza Manafi
Drawing components include:
Title block
Revision
Key plan
Reference drawings
Legend
Important notes
Graphic reference point
line number
Flow directions
connections

Piping drawings: drawing component
Prepared by Reza Manafi
Title block
Piping drawings: drawing component (title block)
Prepared by Reza Manafi
Space for revision
Piping drawings: drawing component (space for revision)
Prepared by Reza Manafi
Key plan
Piping drawings: drawing component (key plan)
Prepared by Reza Manafi
reference drawing
Piping drawings: drawing component (reference drawing)
Prepared by Reza Manafi
legend
Piping drawings: drawing component (legend)
Prepared by Reza Manafi
Important note
Piping drawings: drawing component (important note)
Prepared by Reza Manafi
Graphic reference point
Piping drawings: drawing component (Graphic reference point)
Prepared by Reza Manafi
Piping drawings: drawing component (Graphic reference point)
Graphic reference point
Graphic reference point

Ex Ny
y
x
True north

Plant north

Prepared by Reza Manafi
Line number shall be labeled to show the area of
project, conveyed fluid, line size, piping material or
specification code number and number of line
Allocate new number to branch
Piping drawings: line number
Prepared by Reza Manafi
Flow direction & connection





Piping drawings: flow direction & connection
3/8
Prepared by Reza Manafi
Line list
Prepared by Reza Manafi
Line list (line designation sheet or table)
include:
The number of the line
Line size
Material of construction
Conveyed fluid
Pressure, temperature, flow rate
Test pressure
Insulation and jacketing
Connected line (which will usually branch)

Piping drawings: line list
Prepared by Reza Manafi
Piping drawings: line list
Prepared by Reza Manafi
Piping drawings: line list
Prepared by Reza Manafi
Drawing view
Prepared by Reza Manafi
Two type of view are used for piping drawing:
Orthographic
Plans
Elevation

Pictorial:
in complex piping system where orthographic
view may not easily illustrate the design
Isometric
Oblique

Piping drawings: drawing view
Prepared by Reza Manafi
Piping drawings: drawing view
Prepared by Reza Manafi
Piping drawings: drawing view
Prepared by Reza Manafi
Piping drawing
Prepared by Reza Manafi
Piping drawing include:
Site plan
Key plan
Equipment layout
Piping layout (plan)
Isometric
Support drawing


Piping drawings: piping drawings
Prepared by Reza Manafi
Piping drawings: piping drawings (site plan)
Prepared by Reza Manafi
Piping drawings: piping drawings (key plan)
Prepared by Reza Manafi
Piping drawings: piping drawings (key plan)
Prepared by Reza Manafi
Piping drawings: piping drawings (Equipment arrangement drawing)
Prepared by Reza Manafi
Piping drawings: piping drawings (Equipment arrangement drawing)
Prepared by Reza Manafi
piping symbols for fittings, flanges,
special items
Prepared by Reza Manafi
Piping abbreviation
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings
(piping symbols for fittings, flanges, special items)
Prepared by Reza Manafi
Piping drawings: piping drawings (piping layout = plan)
Prepared by Reza Manafi
Piping drawings: piping drawings (piping layout = plan)
Prepared by Reza Manafi
Piping drawing
isometric
Piping drawings: piping drawings (Isometric)
Prepared by Reza Manafi
Piping take off material (bill of material, material list)

Project :
Platform/Unit :
Date : 19/06/01
Platform/ Line Number/ Sht. Rev. Piping Short Tag Stock Code End Nominal Diameter
Unit Location No. Spec. Code Number Size 1 Size 2
SPP1 AA 2490 D1C1 *90E 8 WAAAAAWASA BW 6 IN
SPP1 AA 2490 D1C1 *FLG 10 FAAAIAWAAA RF 6 IN
SPP1 AA 2490 D1C1 *PIP 208 PAAAAAKABT BE 10 IN
SPP1 AA 2490 D1C1 *90E 209 WAAAAAWASA BW 10 IN
SPP1 AA 2490 D1C1 *FLG 210 FAAAIAWAAA RF 10 IN
SPP1 AA 2490 D1C1 *BOL 1209 BTFB72HBA RF 7/8 120
SPP1 AA 2490 D1C1 *GAS 1261 XWAANZZTGS RF 6 IN
SPP1 AA 2490 D1C1 *GAS 1788 XWAANZZTGS RF 10 IN
Piping drawings: piping drawings (Isometric / take off material)
Prepared by Reza Manafi
Piping material take off
Rating
Thicknes
s Qty. Weight Description
SCH/MM (kg/ps)
80 1 15.35 90 DEG. LR ELBOW, A234 GR.WPB SS SEAMLESS, B16.9
150 80 1 10.6 WELDING NECK FLANGE, ASTM A105N SS, B16.5.
80 4.8 95.74 SEAMLESS PIPE, API 5L GR.B SS
80 1 59.8 90 DEG. LR ELBOW, A234 GR.WPB SS SEAMLESS, B16.9
150 80 2 23.9 WELDING NECK FLANGE, ASTM A105N SS, B16.5.
12 0 STUD BOLT, A193 GR.B7, WITH 2 HEAVY HEX.NUTS, A194 GR.2H, PTFE COATED
150 1 0 FLAT GASKET, TANGED GRAPHITE/AISI 316 INSERT,ANSI B16.21 (B16.5), THK = 1.5MM
150 1 0 FLAT GASKET, TANGED GRAPHITE/AISI 316 INSERT,ANSI B16.21 (B16.5), THK = 1.5MM
Piping drawings: piping drawings (Isometric / take off material)
Prepared by Reza Manafi
Welding
Prepared by Reza Manafi
What is Welding?
Welding is a joining process in which metals are
heated, melted and mixed to produce a joint with
properties similar to those of the materials being
joined.


Welding
Penetration Depth
Weld Reinforcement
Heat Affected
Zone (HAZ)
Weld Pool Parent Metal
Weld Root
Prepared by Reza Manafi
Pass Name:
Root Pass
Hot Pass
Fill Pass
Cover Pass (capping pass)


Welding
Prepared by Reza Manafi
Weld type:
Fillet
Used when joining two pieces of metal
without preparing the surface of the metal
first.
Groove
used when preparing the metal before
welding it into place, include:
Square
Bevel
Single or double V
Single or double U
Single or double J


Welding
Prepared by Reza Manafi
Fillet
Approximately triangular
Most common weld in structural work



Welding
Prepared by Reza Manafi
groove
Square

Penetration difficult with single; double
used to ensure strength
Sometimes root is opened and a backing
bar is used



Welding
Prepared by Reza Manafi
groove
Bevel
Single bevel is widely used
Double preferred if metal thickness >3/4

Welding
Prepared by Reza Manafi
groove
Single V
Both members beveled
Butt joints for plate thickness greater than
1/4 inch



Double V:
welds reduce distortion
Welding
Prepared by Reza Manafi
groove
Single and double U:
Rounded base allows larger electrodes
for narrower groove angles
Machined or carbon arc gouged
preparation


Welding
Prepared by Reza Manafi
groove
Single or double J
Single well suited for butted corner and T
joints
Machined or carbon arc gouged
preparation


Welding
Prepared by Reza Manafi
Type of joints:
Butt joint

T joint

Lap joint

Corner joint

Edge joint
Welding
Butt Joint

T Joint

Lap Joint

Corner Joint

Edge Joint

Prepared by Reza Manafi
Type of joints:
Butt joint

Welding
Prepared by Reza Manafi
Type of joints:
T joint

Welding
Prepared by Reza Manafi
Type of joints:
Lap joint

Welding
Prepared by Reza Manafi
Type of joints:
Corner joint

Welding
Prepared by Reza Manafi
Type of joints:
Edge joint

Welding
Prepared by Reza Manafi
Pipe welding position
Prepared by Reza Manafi
Position:
Flat
Horizontal
Vertical
Overhead
Welding
Prepared by Reza Manafi
Position according to standards:
1G
2G
5G
6G

1F
2F
2FR
4F
5F



Welding
Prepared by Reza Manafi
Position:
1G
Pipe rotated, Electrode is always at the top
Either a split bead or weave technique may be
used

Welding
Prepared by Reza Manafi
Position:
2G
Pipe Axis Vertical, Weld is Horizontal, Pipe is
considered in a fixed position.
Always use a split bead technique
Always work from the bottom up.


Welding
Prepared by Reza Manafi
Position:
5G
Axis of the Pipe is Horizontal, The weld in vertical.
Progression may be up or down.
A weave bead is best used.




Welding
Prepared by Reza Manafi
Position:
6G
Pipe axis is fixed in position at a 45 degree
incline. The position includes flat, horizontal,
vertical, and overhead welds.
A split bead technique is best used.


Welding
Prepared by Reza Manafi
Position:
1F
Pipe is rotated. The pipe axis is at a 45
degree incline. Welding is to occur at the
top of the pipe.
Split bead or weave technique may be
used.

Welding
Prepared by Reza Manafi
Position:
2F
Fixed Position
Best to use a split bead technique

Welding
Prepared by Reza Manafi
Position:
2FR
Rotated
A split bead technique is best used.


Welding
Prepared by Reza Manafi
Position:
4F
A split bead technique is best used




Welding
Prepared by Reza Manafi
Position:
5F
Not Rotated. Progression may be up or
down.
Split beads or weaves can be used on
5F-up welds, split beads are best used on
5F-down welds.




Welding
Prepared by Reza Manafi
Type of welding:
Oxy-fuel gas welding

Arc welding
SMAW
GTAW
Welding
Prepared by Reza Manafi
Oxy-fuel gas welding
Welding
Prepared by Reza Manafi
Basic Oxy-fuel Gas Welding Equipment

Welding
Prepared by Reza Manafi
Pressure Regulators
Welding
Prepared by Reza Manafi
Acetylene and oxygen cylinder
Welding
Prepared by Reza Manafi
Carburizing, Neutral, and Oxidizing Flames
Welding
Prepared by Reza Manafi
Applications of Oxy-fuel Gas Welding
Recommended for material up to 3.2mm (1/8in)
Most steels, rolled, wrought or cast

Root opening
Up to 4.8mm (3/16in) square butt O.K.
Up to 6.8mm (1/4in) root opening and filler
Above 6.8mm parts must be beveled
Welding
Prepared by Reza Manafi
Applications of Oxy-fuel Gas Welding
Most steels, rolled, wrought or cast
Aluminum and copper

No reactive metals
titanium, zirconium, hafnium

No refractory metals
tungsten, molybdenum, tantalum,
niobium

Welding
Prepared by Reza Manafi
Advantages of Oxy-fuel Gas Welding
Very portable
Low cost
Gentle flame

Disadvantages of Oxy-fuel Gas Weld.
Poor air protection
Low heat input
Safety issues
Welding
Prepared by Reza Manafi
Shielded Metal-Arc Welding
( MMAW, SMAW, Stick welding)
Welding
Prepared by Reza Manafi
Work
Lead
+
-
Electrode
lead
Power Source
DCEP Shown
Base material
Electrode
Coating
Core
wire
Weld pool
Slag
Weld metal
Welding
SMAW process:

Prepared by Reza Manafi
Welding
electrode
Prepared by Reza Manafi
E xx y z n H
m
R
positions (y)
1=all positions
2=flat + horizontal
4=vertical down
Tensile strength
41 = 410 MPa min
48 = 480 MPa min
Flux type (z)
0, 1 = cellulosic
2, 3, 4 = rutile
5, 6, 8 = low hydrogen
7 = iron powder + iron oxide
Impact properties (n)
0 = 47J at 0C
2 = 47J at -20C
3 = 47J at -30C
4 = 47J at -40C
Hydrogen level (H
m
R)
H
5
= 5 ml / 100g of WM
R = low moisture
Welding
Electrode numbering:
Prepared by Reza Manafi
Advantages
Equipment simple, inexpensive, and
portable
Process can be used in any position
Shop repairs, pipelines, building
construction
Disadvantages
Limited deposition rate relative to other
welding processes due to stubs and slag
Weld not well protected form the
atmosphere
Welds have more inclusions than welds
made with other processes
Welding
Prepared by Reza Manafi
SMAW usually restricted to metals between 3 to
19mm (1/8 to 3/4 in) thick.
Typical pass 3mm (1/8 in) thick.

Welding
Prepared by Reza Manafi
Gas Tungsten Arc Welding
Welding
Prepared by Reza Manafi
Ceramic
shroud
Torch
Gas lens
(optional)
Inert
gas
Power
source
Torch
lead (-)
Work
lead (+)
Filler
Arc
Weld metal
Weld pool
Collet
Tungsten
electrode
Welding
GTAW process:

Prepared by Reza Manafi
Gas Tungsten Arc Welding
Welding
SMAW process:

Prepared by Reza Manafi
Welding
Shielding gases:
Pure argon, Argon-helium, Argon-2%
hydrogen
Torch gas must not contain oxygen or CO
2
Backing (or purge) gas
Used for all single-sided welds except in
carbon steel
Supplementary shielding
Reactive metals: Ti, etc
Prepared by Reza Manafi
Welding
TIG Process features :
can also be used to weld dissimilar metals
(but not very well)
Slower and more costly than consumable
welding
Independently added filler
Used for root, pass runs in pipe or thin
sheet
High quality, Clean process, no slag
Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single
sided welds

Prepared by Reza Manafi
Welding
Filler metals:
Filler wire or rod of matching composition
C-Mn & low alloy steel
Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler replaced in joint

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Welding Symbols

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The welding symbols devised by the AWS has 8
elements
Reference line
Arrow
Basic weld symbols
Dimensions and other data
Supplementary symbols
Finish symbols
Tail
Specification or others reference


Welding symbols:
Prepared by Reza Manafi
Reference line and arrow pointing to the joint
the reference line has two sides:
Other side, above the line
Arrow side, below the side
Welding symbols:
ARROW SIDE
OTHER SIDE Arrow
ARROW SIDE
OTHER SIDE
ARROW SIDE
OTHER SIDE
ARROW SIDE
OTHER SIDE
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Basic welding symbols
Welding symbols:
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If a bevel groove is required the use broken arrow
Welding symbols:
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Dimensions and other data
Welding symbols:
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Dimensions and other data
Welding symbols:
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Dimensions and other data
Welding symbols:
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Welding symbols:
Supplementary symbols
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Welding symbols:
A circle at the tangent of the arrow and the reference
line means welding to be all around.
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Welding symbols:
A flag at the tangent of the reference line and arrow
means Field Weld.
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Tail
Welding symbols:
The tail of the welding symbol is used to indicate the
welding or cutting processes, as well as the welding
specification, procedures, or the supplementary
information to be used in making the weld
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Welding symbols:
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Arrangement
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Design flexible arrangement for piping to reduce
thermal stress (induce stress in piping, support and
attachment equipment)
settlement strain (foundation of large tanks and
heavy equipment may settle or tilt slightly in course
of time)


Arrangement: Flexibility
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Arrangement: Flexibility
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Avoid cold spring of pipe
Cold spring used in to manner
To reduce stress
To avoid an interference


Arrangement: Flexibility
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Flexible pipe connection should have a length of
6 to 10 NPS

Arrangement: Flexibility
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Take gas and vapor branch lines from tops of header
where it is necessary to reduce the chance of
drawing off condensate or sediment which may
damage rotating equipment

Arrangement:
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Allow room for the joint to be made

Arrangement:
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Establish sufficient headroom for ductwork, electrical run
Consider vertical clearance (dont route piping) over pump
compressor to permit removal for servicing (maintenance),
consider headroom for mobile crane

Arrangement:
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Centrifugal Pump arrangement:
Suction: eccentric reducer are used in 2 line and larger

Arrangement:
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Centrifugal Pump arrangement:
Suction (socket weld)


Arrangement:
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Centrifugal Pump arrangement:
Suction arrangement


Arrangement:
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Dont use globe valves at suction and discharge for
isolating pump
Route suction line as directly as possible Dont route
piping over the pump, as this interferes with
maintenance
If pump positioned close to supply tanks and are on
separate foundations, avoid rigid piping arrangement,
for settle of tank in course of time
Locate the pump as closely as practicable to source of
liquid to be pumped from storage tank


Arrangement:
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Centrifugal Pump arrangement:
Discharge: Concentric reducers are used in 2 line and smaller


Arrangement:
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Centrifugal Pump arrangement:
Discharge (socket)


Arrangement:
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Centrifugal Pump arrangement:
Discharge (manifold)


Arrangement:
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Provide to drain between ball valve and check
valve at discharge of pump to drain
Drain can be provided on above disk of check valve


Arrangement:
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The outlet pipe for pump is chosen to be of large bore
than the discharge port in order to reduce velocity and
equipment pressure drop
Concentric reducers are used in 2 line and smaller

Arrangement:
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Each pump is usually provided with a drain hub
4 to 6 positioned about 9 in front of the pump
Arrangement:
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Positive displacement Pump arrangement:
Install PRV at discharge line befor isolating valve
pump PDP dont change velocity so, reducer at
discharge and suction not used


Arrangement:
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PDP have pulsation discharge, so used standpipe
(reservoir to damp vibration)

Arrangement:
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Compressor arrangement:
Arrangement:
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Compressor arrangement
suction
Arrangement:
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Compressor arrangement
discharge
Arrangement:
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Turbine piping arrangement
Arrangement:
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Piping may have thru concrete floor as walls, inform
the civil and architectural to avoid cutting exciting
reinforcement
Dont run piping under foundation
If there is no possibility of future road or site
development, lay piping such as
Line to outside storage
Loading and receiving facilities
At grade on pipe sleeper
Avoiding burying steam line that pocket, due the
difficulty to collecting condensate
Burying line (water, gas, drain) bellow the frost line to
avoid freezing water and solutions, save the expense
of tracing long horizontal parts of the line

Arrangement:
Prepared by Reza Manafi
Vent all high point and drain all low point on lines,
place vent and drain valve to permit easily drained or
purged during shutdown period (important for reducing
cost of winterizing)
Avoid pocketing lines. Arrange piping lines to drain
back into equipment or into lines that can to be
drained
Run piping beneath of platforms, rather than over
them.
If need removing equipment, cleaning line provide
Union
Flanged
Removable spool
Cross instead elbows to permit removing solid

Arrangement:
Prepared by Reza Manafi
Dont obstruct access ways (doorways, escape road, )
Consider vertical clearance (dont route piping) over
pump to permit removal for servicing (maintenance),
consider headroom for mobile crane


Arrangement:
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Nearly all valve will be line size, one exception is
control valve, which are usually one or two size
smaller than line size
Arrangement:
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Provide isolating valve
in all small lines branching from header, place valve in
horizontal rather than vertical run, so that lines can drain when
the valve are closed
At all instrument point for removal of instrument
Arrangement:
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Utility station
Steam line NPS > , use globe valve
Air and water > 1 , use gate valve
Terminate with house connection
3
Arrangement:
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Arrange valve so that support will not be on removable spools
In critical application, use two pressure relive valve with interlock
Arrangement:
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A relive valve that discharged to into a header should be placed
higher than the header in order to drain into it
Arrangement:
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Required space between pipes
Arrangement:
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Pipe Work
Material work:
Fabricate, test, certificate
Test (spectrograph), marking

Storing
SS shall be separated from other steels and
without any contact to zinc material





Pipe work
Prepared by Reza Manafi
Person who are engaged for
Tack welding
Welding
Shall be qualified according to ASME SEC. IX

Pipe fitting
Assembling
Erection
Control weld temperature
fully trained and have certificate (license, pass) of
employer
Pipe work
Prepared by Reza Manafi
Cutting method:
Shear
Milling
Planer
Flame cutting
Flame gouging
Arc gouging
Pipe work
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Cutting:
In the case of thermal cutting
Cutting surface shall be ground to remove any
edge and roughness (dross, scale, .. At HAZ)
and to be made flush and smooth
Cutting slag stuck to the inside of the pipe shall
be completely removed
After thermal cutting
Machining for C.S, SS not require
for other material required (3 mm of HAZ)
In the abrasive disk case
Abrasive disk for SS shall not be used for C.S
or vise verse
Plasma jet cutting may be applied for SS, etc
Pipe work
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End preparation:
According to WPS

Pipe work
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Trimming:
When having unequal wall thickness (the difference is
more than 3 mm for outer surface and/or 1.5 mm in inner
surface

Pipe work
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Trimming for making branch connection
Shall be inserted at least as far as the inside
surface of pipe run

Pipe work
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Alignment:
When a pipe having a longitudinal seam is used
in a horizontal line, the pipe shall be laid so that
the longitudinal weld seam is not on bottom or
top of the pipe

Pipe work
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Pipe work
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Pipe work
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To measure root opening use taper gauge

Pipe work
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To measure internal misalignment of joint use hi-low
mismatch gauge
T > 19 mm, 2.5 mm
T < 19 mm, 1.6 mm

Pipe work
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Tolerance:
Pipe work
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cleaning:
The bevel shall be fully clean so that there is no rust, oil,
grease, (50 mm from bevel edge)
Solvent:
Non-injurious to the material
Halide free

Material of wire brush shall be properly selected for
working CS and SS respectively
Iron free
Grinding wheel (or disk) shall be organic resin bond



Pipe work
Prepared by Reza Manafi
Preheating:
Shall be performed by propane prior to tack welding and
welding
Valve shall be open during preheating,
Where the ambient temperature is below 5C, preheating
temperature = 40 (except Cu-Ni, Ti)

Pipe work
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Preheating:
Extend 50 mm or 4T beyond each edge





Temperature measure by surface thermometer or crayons

Pipe work
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Preheating:
Preheat temperature shall be measured based on 2
minutes per 25 mm thickness


Pipe work
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Tack weld
Use internal or external clamps before tack weld


Pipe work
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Pipe work
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Tack weld
Ensure the contact surface of the clamps are made of
same base metal
Before welding of the root, both ends of the root tack weld
bead shall be prepared with a grinder as shown in the
following illustration

Type of tack weld
Root
Bridge (Bridge tack shall never be hammered,
removed by grinding or gas cutting)
Pipe work
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Welding:
WPS, PQR shall be approved
Welder shall be qualified according to ASME SEC. IX
All welding processes shall be protected from adverse
weather (use shelter)
All welding equipment shall be calibrated
When preheat is applied, welding shall not be interrupted
or stopped until 30% of the final weld has been completed
Bolts hole:
symmetrically from a vertical center line
Symmetrically from plant north




Pipe work
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Welding:
Consumable:
Consumable manufacture shall be approved by third party
Shall be close matching with base metal
Control the storage, handling, conditioning
Electrode:
Low hydrogen electrode stored in oven and dont re-dried
more than twice
Pipe work
Prepared by Reza Manafi
Welding:
Consumable:
Purge gas, shielding gas:
Check Mixture tolerance, Purity, Dew point
moisture < 10 PPM
Nitrogen not used for SS
Before tack weld and root pass welding monitoring the
oxygen content < 5000 PPM
Use purge gas for
Thin wall tubing or piping T < 5.5 mm
Root pass without backing, single sided for all weld metal

Pipe work
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Use following fitting format:


Pipe work
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Use following fitting format:
Perform at least 2 layer weld and end point of weld at each
layer shall change


Pipe work
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Post Weld Heat Treatment
Pipe work
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Weld Test include:
Tensile
Bending
Impacting
Hardness





Pipe work
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Material is sectioned and edges rounded of to
prevent cracking. Punch marks are made to see
elongation.




Pipe work: Tensile
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Pipe work: Tensile
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Shows physical condition of the weld and
Determine welds efficiency
Tensile strength
Ductility
Fusion and penetration





Pipe work: Bend test
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Bend through 180
O
the specimen should be a minimum of 30mm wide
The fulcrums diameter is 3x thickness of the plate
The bottom rollers have a distance of the diameter
of the former + 2.2 times the thickness of the plate
Upper and lower surfaces ground or filed flat and
edges rounded off.
the tests should be one against the root -another
against the face ,and in some cases a side bend.




Pipe work: Bend test
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Pipe work: Bend test
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Pipe work: Bend test: face bend
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CHARPY AND IZOD:
Gives the toughness and shock loading of
the material and weld at varying
temperatures with a notch such as under cut

The measurement is the energy required to
break a specimen with a given notch

2mm depth at a 45
o
bevel or a U notch.




Pipe work: Impact
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Pipe work: Impact: charpy
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Pipe work: Impact: charpy
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Pipe work: Impact: Izod
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This gives the metals ability to show resistance
to indentation which show its resistance to
wear and abrasion.



Pipe work: Hardness tests
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Design
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ASME B31.3 provides requirements for:
Design
Materials
Fabrication
Erection
Inspection
Testing

process plants including
Petroleum refineries
Chemical plants
Pharmaceutical plants
Textile plants
Paper plants
Semiconductor
plants
Cryogenic plants
ASME B31.3
Prepared by Reza Manafi
ASME B31.3 applied to piping and piping components
of all fluid services:
Raw, intermediate, and finished chemicals
Petroleum products
Gas, steam, air, and water
Fluidized solids
Refrigerants
Cryogenic fluids

ASME B31.3: Scope of ASME B31.3
Prepared by Reza Manafi
The following are excluded from the scope of
ASME B31.3
Piping system that design according to BPV
and other B31
.





This item not exclude vacuum system

Tube, inside a fire heater
Fire protection system (NFPA )
Plumbing, sanitary sewer (AWWA)

ASME B31.3: Scope exclusions specified
Prepared by Reza Manafi
The factors that affect piping material selection are:
Strength
Yield & Tensile strength
Creep strength
Fatigue strength

Corrosion resistance
Material fracture toughness
Fabricability
Availability & cost

ASME B31.3: Material
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ASME B31.3: Material: Stress - Strain Diagram
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ASME B31.3: Material: Variation of strength with temperature
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ASME B31.3: Material: Variation of strength with temperature
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ASME B31.3: Material: Variation of strength with temperature
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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.

ASME B31.3: Material: creep
Prepared by Reza Manafi
The type of fatigue are:
Static:
specimen breaks under a load that it has
previously withstood for a length of time.
Examples of static fatigue are: creep
fracture and stress corrosion cracking.

Cyclic:
specimen breaks during a load cycle that it
has previously withstood several times.
ASME B31.3: Material: fatigue
Prepared by Reza Manafi
Corrosion of materials involves deterioration of the
metal by chemical or electrochemical attack and
include:
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.

Pitting Corrosion:
Form of localized metal loss randomly located on
material surface. Occurs most often in stagnant
areas or areas of low-flow velocity.




ASME B31.3: Material: Corrosion resistance
Prepared by Reza Manafi
Galvanic Corrosion:
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 cathodic metal.


ASME B31.3: Material: Corrosion resistance
Crevice Corrosion:
Localized corrosion similar to pitting. Occurs at
places such as gaskets, lap joints, and bolts, where
a crevice can exist.





Prepared by Reza Manafi
Concentration Cell Corrosion:
Occurs when different concentration of either
corrosive fluid or dissolved oxygen contacts
areas of same metal. Usually associated with
stagnant fluid.

Graphitic Corrosion:
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.

ASME B31.3: Material: Corrosion resistance
Prepared by Reza Manafi
It is the amount of energy necessary to initiate and
propagate a crack at a given temperature.
The addition of manganese or nickel improves
fracture toughness.
Mostly of concern for carbon steels
Generally decreases as temperature decreases
Factors affecting fracture toughness include:
Chemical composition or alloying elements
Heat treatment
Grain size

The impact energy required to fracture a material
sample at a given temperature can be measured
by standard Charpy V-notch tests.



ASME B31.3: Material: Material fracture toughness
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ASME B31.3: Material: Material fracture toughness
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ASME B31.3: Material: Cost
Prepared by Reza Manafi
FAILURE BY GERNRAL YIELDING: Failure is due to
excessive plastic deformation.
Yielding at Sub Elevated temperature: Body
undergoes plastic deformation under slip action of
grains.

Yielding at Elevated temperature: After slippage,
material re-crystallizes and hence yielding continues
without increasing load. This phenomenon is known as
creep.

FAILURE BY FRACTURE: Body fails without undergoing
yielding.
Brittle fracture: Occurs in brittle materials.

Fatigue: Due to cyclic loading initially a small crack is
developed which grows after each cycle and results in
sudden failure.
ASME B31.3: Material: Modes of failures
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ASME B31.3: Material: Modes of failures: Ductile Deformation
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ASME B31.3: Material: Modes of failures: Brittle Fracture
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Category D
Category M
High Pressure
Normal

ASME B31.3: B31.3 Fluid Service Definitions
Prepared by Reza Manafi
Category D:
The fluid handled is nonflammable,
nontoxic and not damaging to human
tissue. The design pressure does not
exceed 150 psig (1035 kPa). The design
temperature is greater than -20F (-29C)
and does not exceed 366 F (186C).

Often characterized as utility

ASME B31.3: B31.3 Fluid Service Definitions
Prepared by Reza Manafi
Category M:
A fluid service in which the potential
for personnel exposure is judged to be
significant and in which a single
exposure to a very small quantity of a
toxic fluid, caused by leakage, can
produce serious irreversible harm to
persons upon breathing or on bodily
contact, even when prompt restorative
measures are taken.

Often characterized as lethal

ASME B31.3: B31.3 Fluid Service Definitions
Prepared by Reza Manafi
High Pressure:
A service for which the owner
specifies the use of Chapter IX [of
B31.3] for piping design and
construction considered to be in
excess of Class 2500 (PN 420).
Characterized as high pressure

Normal: Everything else.
Often characterized as process

ASME B31.3: B31.3 Fluid Service Definitions
Prepared by Reza Manafi
Normal operating conditions:
Are those expected to occur during normal
operation, excluding failure of any operating device,
operator error, and the occasional, short-term
variations stated in the applicable code.

Design conditions:
Are those which govern the design and selection of
piping components, and are based on the most
severe conditions expected to occur in service.

ASME B31.3: B31.3 Definitions
Prepared by Reza Manafi
Loading classification
Primary loads: These can be divided into two categories based
on the duration of loading.
Sustained loads: These loads are expected to be present
through out the plant operation. e.g.
internal & external pressure
weight of system (piping material and operating
pressure).

Occasional loads: These loads are present at infrequent
intervals during plant operation. e.g.
Wind, ice and snow load
seismic load
Dynamic load (pressure surge, water hammer, energy
release by pressure relief valve,
Hydrostatic leak test load
Wheel load (traffic load)


ASME B31.3: B31.3 Definitions
Prepared by Reza Manafi
Expansion loads: These are loads due to
displacements of piping. e.g.
thermal expansion:
are created when the free expansion and
contraction of the piping is prevented at
its end points by connected equipment,
or prevented at intermediate points by
supports and/or restraints that are
installed. pipe thermal loads can be from
the thermal expansion of equipment at
pipe-to-equipment nozzle attachment
points, causing displacements in the
piping system.
seismic anchor movements
building settlement.

ASME B31.3: B31.3 Definitions
Prepared by Reza Manafi
Principal pipe load types
Sustained loads
Act on system all or most of time
Consist of pressure and total weight load

Occasional loads
Act for short portion of operating time
Seismic and/or dynamic loading

Thermal expansion loads
Caused by thermal displacements
Result from restrained movement

ASME B31.3: B31.3 Definitions: result
Prepared by Reza Manafi
Primary Stresses: These are developed by the imposed
loading and are necessary to satisfy the equilibrium between
external and internal forces and moments of the piping
system. Primary stresses are not self-limiting.
Direct
Shear
Bending

Secondary stresses: These are developed by the constraint
of displacements of a structure. These displacements can be
caused either by thermal expansion or by outwardly imposed
restraint and anchor point movements. Secondary stresses
are self-limiting.
Act across pipe wall thickness
Cause local yielding and minor distortions
Not a source of direct failure

ASME B31.3: B31.3 Definitions: Stress Categorization
Prepared by Reza Manafi
Peak stresses: Unlike loading condition of
secondary stress which cause distortion, peak
stresses cause no significant distortion. Peak
stresses are responsible for causing fatigue failure.
More localized
Rapidly decrease within short distance of origin
Occur where stress concentrations and fatigue
failure might occur
Significance equivalent to secondary stresses
Do not cause significant distortion

ASME B31.3: B31.3 Definitions: Stress Categorization
Prepared by Reza Manafi
t = Required thickness for internal pressure, in.
P = Internal design pressure, psig
S = Allowable stress in tension, psi
E = Longitudinal-joint quality factor
Y = Wall thickness correction factor
tm = Total minimum required wall thickness, in.
tnom = Minimum required nominal pipe wall
thickness, in.
ASME B31.3:
Required Wall Thickness for Internal Pressure of Straight Pipe

Prepared by Reza Manafi
Function of
Material properties
Temperature
Safety factors
ASME B31.3: Allowable Stresses
Prepared by Reza Manafi
ASME B31.3: Wall thickness correction factor
Prepared by Reza Manafi
ASME B31.3: Wall thickness correction factor
Prepared by Reza Manafi
Uninsulated component:
T < 150F:
the metal design temperature of the pipe and component
taken as the fluid temperature unless solar radiation or
other effects result in higher temperature
T > 150F
pipe = 0.95 FT (Fluid Temperature)
Flange = 0.9 FT
Lap joint = 0.85 FT
Bolt = 0.8 FT
Externally Insulated:
Metal design temperature = FT
Where piping is heated or cooled by heat tracing or jacketing,
the effect shall be included in the determination of the metal
design temperature.
Internally insulated:
Require heat transfer calculation
ASME B31.3: Design temperature
Prepared by Reza Manafi
The design pressure of a piping system is the pressure at the
most severe condition of coincident internal or external pressure
and temperature expected during service. unless all of the
following criteria are met.

The piping system have no pressure containing components
of cast iron or other non ductile metal.

Nominal pressure stresses shall not exceed the yield
strength, Sy data in [ASME] BPV Code, Section II, Part D,
Table Y-1).


The total number of pressure-temperature variations shall not
exceed 1000 during the life of the piping system.

Increased pressure shall not exceed the test pressure



ASME B31.3: Design pressure
Prepared by Reza Manafi
Occasional variations above design conditions shall remain
within one of the following limits for pressure design.
Subject to the owner's approval, it is permissible to
exceed the pressure rating or the allowable stress for
pressure design at the temperature of the increased
condition by not more than:
33% for no more than 10 hour at any one time and
no more than 100 hour per year; or
20% for no more than 50 hour at any one time and
no more than 500 hour per year.

When the variation is self-limiting (e.g., due to a
pressure relieving event), 20% for no more than 50
hour at any one time and no more than 500 hour per
year.

ASME B31.3: Design pressure
Prepared by Reza Manafi

The combined effects of the sustained and cyclic
variations shall have been evaluated.

Temperature variations below the minimum
temperature shown in Appendix A [of ASME B31.3]
are not permitted.

The application of pressures exceeding pressure-
temperature ratings of valves may cause loss of
seat tightness or difficulty of operation. The
differential pressure on the valve closure element
should not exceed the maximum differential
pressure rating established by the valve
manufacturer.
ASME B31.3: Design pressure
Prepared by Reza Manafi
For buried piping, dead weight is not a factor.
However, a sustained load that is analyzed is the
load from the earth above the buried piping. The
earth load on rigid piping may be calculated using
the following formula.


ASME B31.3: Load: Weight
Prepared by Reza Manafi

Wheel load




ASME B31.3: Load
Prepared by Reza Manafi
Wind load:
Wind load can cause other loads, such as
vibratory loads, due to reaction from a deflection
caused by the wind. The design wind speed is
determined from ASCE 7

ASME B31.3: Load
Prepared by Reza Manafi
Snow load (ANSI A58.1)
Assuming that snow laying on a pipe will take the
approximate shape of an equilateral triangle with
the base equal to the pipe diameter.

For most heavy snow climates, a minimum snow
load of 1.2 kpa (25 psf) is used in the design.

ASME B31.3: Load
Prepared by Reza Manafi
Ice load:
Unless local or regional data suggests
assumption of 50 to 75 mm (2 to 3 in) maximum
ice accumulation to calculate an ice loading
ASME B31.3: Load
Prepared by Reza Manafi