ASME B31.3 Piping Design - Part A

Piping Design & Applications Workshop

Part A
Don Frikken Becht Engineering Company
Scope
This workshop covers above ground industrial piping as practiced in the USA. I do not intend to cover:
Pipelines Plumbing Nuclear plant piping
A-2
Rev 9-04-03
Topics Covered
Definitions Piping Standards Classifying Components Pipe & Fitting Selection Valve Selection
A-3
More Topics Covered

Introduction to Piping Flexibility Analysis Designing with Expansion Joints Water Hammer Liquid Thermal Expansion Fabrication, Examination and Testing Introduction to Line Sizing and Pressure Drop
A-4
Rev 9-04-03
Definitions:
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
A-5
More Definitions:
piping components: mechanical elements suitable for joining or assembly into pressuretight fluid-containing piping systemspipe, tubing, fittings, flanges, gaskets, bolting, valves and devices such as expansion joints
A-6
Rev 9-04-03
& More Definitions:

design pressure: the pressure at the most severe condition of internal or external pressure and temperature expected during service design temperature: the temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required
A-7
Piping Standards
Provide a set of requirements for obtaining a safe, reliable and economical installation (system standards or codes) Provide consistent dimensions and ratings so that components will fit together and can be used interchangeably (component standards)
A-8
Rev 9-04-03
Piping System Standards - ASME

B31.1 B31.3 B31.4 B31.5 B31.8 B31.9 B31.11 BPE-1 PVHO-1 HPS Power Piping Process Piping Liquid Transportation Pipelines Refrigeration Piping Gas Transportation Pipelines Building Services Piping Slurry Transportation Pipelines Bioprocessing Equipment Pressure Vessels for Human Occupancy High Pressure Systems
A-9
Piping System Standards - Other

NFPA 13 Installation of Sprinkler Systems NFPA 24 Installation of Private Mains NFPA 50 Bulk Oxygen Systems NFPA 54 National Fuel Gas Code CGA Handling of Anhydrous Ammonia (K61.1) Chlorine Institute #6 Piping Systems for Chlorine
See the longer list in the supplement.

A-10
Rev 9-04-03
Piping Component Standards - ASME

B16.3 Malleable Iron Threaded Fittings B16.5 Pipe Flanges and Flanged Fittings B16.9 Wrought Steel Buttweld Fittings B16.20 Metallic Gaskets B16.22 Wrought Copper Solder Joint Fittings B16.33 Metallic Gas Valves B16.34 Valves Flanged, Threaded and Welded See the longer list in the supplement.
A-11
Piping Component Standards - Other

MSS SP-80 Bronze Valves MSS SP-97 Branch Outlet Fittings API 602 Compact Steel Gate Valves API 608 Metal Ball Valves ASTM A53 Steel Pipe ASTM A312 Stainless Steel Pipe AWWA C110 Ductile & Gray Iron Fittings AWWA C151 Ductile Iron Pipe See the longer list in the supplement.
A-12
Rev 9-04-03
Classifying Components
By Pressure-Temperature Ratings By Reliability
A-13
by Pressure-Temperature Ratings
Many piping systems, especially nonmetallic systems, are proprietary products and rated by the manufacturer. Ratings for above ground metallic systems are generally governed by their joints. Frequently these are flanged joints manufactured in accordance with ASME B16.1 (iron flanges) and ASME B16.5 (other metallic flanges).
A-14
Rev 9-04-03
P-T Ratings for Flanges Gray Iron

40
Class 125, NPS 1-12
Pressure (barg)
30
Class 125, NPS 14-24 Class 125, NPS 30-48 Class 250, NPS 1-12
20
10
Class 250, NPS 14-24 Class 250, NPS 30-48 0 50 100 150 200
0 Temperature (C)
A-15
P-T Ratings for Flanges Carbon Steel

450 400 350
Pressure (barg)
300 250 200 150 100 50 0 0 100 200 300 400 500
Class 150 Class 300 Class 600 Class 900 Class 1500 Class 2500
Temperature (C)
A-16
Rev 9-04-03
Class 300 Ratings for Flanges Several Materials

60.0 50.0
Carbon Steel (B16.5) 316 Stainless Steel (B16.5) Nickel Alloy 400 (B16.5) Coper Alloy B61 (B16.24) Aluminum Alloy 6061T6 (B31.3)
0 100 200 300 400 500 600 700 800
Pressure (barg)
40.0
30.0
20.0
10.0
0.0
Temperature (C)
A-17
by Reliability
Robustness Fire Resistance Blow-out Resistance Tendencies to Leak
A-18
Rev 9-04-03
Robustness
Able to withstand exposure to loads such as: Being stepped on Dropped tool Dropped tool box Forklift traffic Truck traffic Crane booms
A-19
Fire Resistance
Components able to maintain piping system integrity if subjected to approximately 1200 F (650 C) for 30 minutes. The intent is to prevent the exposure of fire fighters to danger due to leaking fluids prevent adding fuel to the fire
A-20
Rev 9-04-03
Blow-out Resistance
Gaskets and seals able to withstand high pressure without failing by extrusion or fracture. A short-term leak could be resealed by tightening the bolting. The intent is to avoid large leaks when a flanged joint is not tightened properly when the piping system is subjected to pressures much higher than design when large bending moments are applied to the flanges
A-21
Blow-out Resistance
Failure by Extrusion
Failure by Fracture
A-22
Rev 9-04-03
Tendencies to Leak
Some joints are more leak prone than others. These are usually a strong function of the construction and maintenance practices at a particular site. Examples: Threaded joints Unions Elastomeric seals such as o-rings
A-23
Pipe and Fitting Selection

What is a Fluid Service? What is a piping system failure? Bases for selection Individual components (metallic): Pipe Fittings Flanges Branch Construction Bolting Gaskets Nonmetallic piping
A-24
Rev 9-04-03
Fluid Service
What distinguishes one fluid service from another?
A-25
Piping System Failure
How can you recognize a failure in a piping system?
A-26
Rev 9-04-03
Bases for Selection

Pressure Class Reliability
Robustness Fire Resistance Blow-out Resistance Tendencies to leak
Corrosion Resistance Material Toughness Cost

A-27
Corrosion Resistance
Where corrosion is more or less uniform, extra pipe wall material can be provided in the form of a corrosion allowance. Where material degradation is localized, either preventive measures must be used or a more resistant material must be provided. Examples of localized material problems: - Erosion - Pitting - Intergranular - Stress-Corrosion Cracking - Microbiological - Hydrogen Embrittlement
A-28
Rev 9-04-03
Material Toughness
Measured by energy necessary to suddenly propagate a crack to failure 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
A-29
Example of Brittle Fracture
A-30
Rev 9-04-03
Example of Ductile Deformation
A-31
Cost
CPVC, Sch 80 Carbon Steel, Sch 40 Stainless Steel, 304, Sch 10S Stainless Steel, 316, Sch 10S Aluminum, 6061 T6, Sch 40 Fiberglass - Vinyl Ester Polypropylene Lined Steel Fluoropolymer Lined Steel Alloy 20, Sch 10S Alloy 400, Sch 10S Alloy C276, Sch 10 Zirconium, Sch 10
10
Relative Installed Cost - NPS 4 Complex System
A-32
Rev 9-04-03
Pipe and Fitting Selection (Metallic)

Pipe Joining Method Fittings Branch Connections Flanges Gaskets Bolting
A-33
Pipe - seamless
Strand Caster
Billet Heating
Rotary Piercing Mill
Elongator
Reheat
Pug Rolling Mill

A-34
Rev 9-04-03
Pipe - seamless
Reheat
Sizing Mill
Finishing
NDT
Facing & Beveling
Hydrotesting
A-35
Pipe ERW
Coil Feed
First Forming
Fin Pass
Welding
NDT
Seam Normalizer
A-36
Rev 9-04-03
Pipe - ERW
Sizing Mill
Flying Cut-Off
Hydrotesting
Straightening
NDT
Facing & Beveling

A-37
Pipe Wall Thickness

t =PD / [2 (SE + PY)]
Where: t = pressure design thickness P = design pressure D = outside diameter of pipe S = allowable stress value from piping code E = weld quality factor Y = coefficient (function of material) = 0.4 for ductile metals up to 900F (480C) = 0.0 for gray cast iron
A-38
Rev 9-04-03
Pipe Wall Thickness

Total thickness required is the sum of
1. Pressure design thickness 2. Manufacturing tolerance (usually 12.5% of the nominal wall thickness) 3. Corrosion (or erosion) allowance 4. Threading allowance
A-39
Pipe Wall Thickness

Workshop: What is the required nominal pipe wall thickness for the following case:
NPS 4 ERW carbon steel pipe Design pressure = 150 psig (1035 kPa) Design temperature = 200F (95C) S = 20,000 psi (138 MPa) Corrosion allowance = 1/16 (1.6 mm) Buttwelded system (no threading allowance) See Supplement starting on page 13.
A-40
Rev 9-04-03
Fittings
Fittings are selected primarily by the way they are joined to the pipe. Threading Socket Welding Buttwelding OD Tubing (Compression fitting, Flare) Water Tubing (Solder, Braze) Others
A-41
Fittings: Threaded
Common materials
Gray iron (ASME B16.4) Malleable iron (ASME B16.3) Steel (ASME B16.11)
Size frequently limited to ~NPS 2

Potential injury for installers Ability to get a good seal
Generally not used where leaks cannot be tolerated A-42
Rev 9-04-03
Fittings: Socket Welding

Common materials (ASME B16.11)
Carbon Steel Stainless Steel
Size frequently limited to ~NPS 1-1/2 Not used in severe cyclic conditions Not use in services where corrosion is accelerated in crevices
A-43
Fittings: Buttwelding
Common materials (ASME B16.9)
Carbon Steel Stainless Steel Nickel alloys
Used in most piping systems ~NPS 2 and larger Use generally not restricted Difficult in small sizes, especially for thin wall
A-44
Rev 9-04-03
Fittings: OD Tubing
Common materials
Copper Carbon steel Stainless steel Nickel alloys
Compression Fittings Flared Fittings (ASME B16.26) Generally not used in most severe services because of leak potential
A-45
Fittings: Water Tube

Common material: copper Solder joint (ASME B16.18 & B16.22) Braze joint (ASME B16.50) Not fire resistant
A-46
Rev 9-04-03
Fittings: Grooved
Fittings that use grooves in pipe elastomeric seal required
A-47
Fittings: Compression for Pipe
Pressfit by Victaullic (B16.51 draft for copper)
Lokring (metal-to-metal seal)

A-48
Rev 9-04-03
Fittings: Hygienic
Clamp
(Waukesha Cherry-Burrell)
Buttweld
(HPS Products)
A-49
Fittings: Hygienic Clamp

Clamps, hubs and gaskets are not the same from manufacturer to manufacturer Gaskets are intended to be flush with the inside Those with metal-tometal contact are more resistant to gasket over compression
(Waukesha Cherry-Burrell)
A-50
Rev 9-04-03
Fittings: Hygienic Buttweld

Fittings have long tangents to allow space for automatic orbital welder.
(ASME BPE)
(Arc Machines, Inc.)

A-51
Branches
Generally many choices NPS 3 and larger Choices include:
Tee Unreinforced Fabricated Tee Reinforced Fabricated Tee Branch Connection Fitting
A-52
Rev 9-04-03
Branches
Tee
Unreinforced Fabricated Tee

(Capable of less than full pressure)
Reinforced Fabricated Tee

A-53
Branches Branch Connection Fittings
A-54
Rev 9-04-03
Branches
Basis for selection: Cost: depends on material, sizes & fabricator Resistance to external moment Ability to examine fabrication See table in supplement.
A-55
Flanges (ASME B16.5)

Flange types designated by joining method
Threaded
Socket welding
Welding Neck (buttweld)
These flanges have the same advantages and restrictions as fittings with the same joining method
A-56
Rev 9-04-03

Other types of flanges - Slip-on Has no crevice if installed with two welds Easier to get good alignment Unable to seat metal gaskets as well as WN & LJ
A-57

Other types of flanges - Lapped joint Flange can be made from cheaper material Easier to fabricate and install than WN
A-58
Rev 9-04-03
Flanges Facings (ASME B16.5)

Raised normal choice Flat
* Standard for gray iron flanges * More gasket has to be compressed, so only softer gaskets can be used * Less likely to break flange when bolting (applicable to brittle materials like gray iron)
A-59
Gaskets
Important Gasket Characteristics Resists deterioration in normal service
Chemical resistance Temperature resistance
Low enough leak rate Blowout resistance Fire resistance

A-60
Rev 9-04-03
Gaskets Rubber
Chemical OK for most Resistant Approximate 200F Max. Temp. (95C) Leak Best Performance Blowout No Resistant Fire Resistant No Bolt Strength Low
A-61
(Thermoseal)
Gaskets Reinforced Rubber

Chemical OK for most Resistant Approximate 325F (160C) Max. Temp. Leak Fair Performance Blowout No Resistant Fire Resistant No Bolt Strength Low
A-62
(Garlock)
Rev 9-04-03
Gaskets Fluoropolymer
Chemical Resistant Approximate Max. Temp. Leak Performance Blowout Resistant Fire Resistant Bolt Strength OK for almost all 350F (180C) Good No No Low
(Gore)
(Teadit)
(Garlock)
A-63
Gaskets Flexible Graphite

Chemical OK for almost Resistant all Approximate 900 or 625F (480 or 330C) Max. Temp. Leak Good Performance Blowout Not without Resistant heavier insert Fire Resistant Yes Bolt Strength Medium
Natural Graphite Flake
Thermally Decomposed (Worms)
Worms Compressed Into Foils (SGL Carbon Group)

A-64
Rev 9-04-03

Foil Inserted Insert is usually 0.002 (0.05 mm) type 316 stainless steel Adhesive bonded
(Teadit)
Tang Inserted Insert is usually 0.004 (0.10 mm) type 316 stainless steel Mechanically bonded
(Teadit)
A-65

Corrugated Insert Insert is usually 0.018 (0.46 mm) type 316 stainless steel Adhesive bonded Blowout resistant Lower hand cutting potential Lower sealing stress Cannot be cut from sheet
A-66
(Garlock)
Rev 9-04-03
Gaskets Spiral Wound

Chemical Resistant Approximate Max. Temp. Leak Performance Blowout Resistant Fire Resistant Bolt Strength
Both metal winding & filler must be OK
1500F (820C) Good

(Garlock)
Yes Depends on Filler High
(Flexitallic)
A-67
(NE Seal)
A-68
Rev 9-04-03

Winding Material 304 SS 316L SS Nickel 200 Alloy C276 Alloy 400 Ring Edge Color Code Yellow Green Red Beige Orange
A-69

Filler Material Ring Stripe Color Code None Asbestos Gray Flexible Graphite Mica Graphite Pink White PTFE Vermiculite No standard Fire Resistant Yes Yes No No Yes Maximum Temp F/ C 1500 / 820 900 / 480 325 / 160 350 / 180 1500 / 820
A-70
Rev 9-04-03
Gaskets - Kammprofile
Chemical Resistant
Both metal & sealing material must be OK
Approximate 1500F (820C) Max. Temp. Leak Good Performance Blowout Resistant Yes Fire Resistant Bolt Strength Depends on sealing material High
(Garlock)
A-71
Gaskets Ring Joint

Chemical Resistant Approximate Max. Temp. Leak Performance Blowout Resistant Fire Resistant Bolt Strength Metal must be OK 1500F (820C) Very Good Yes Yes High
Octagonal
(NE Seal)
Oval
A-72
Rev 9-04-03
Bolting
Has to be strong enough to seat the gasket Consider need to be corrosion resistant to process fluid Studs versus bolts
A-73
Non-Metallic Pipe and Fittings

Types Thermoplastic Reinforced Thermosetting Resin (RTR)
Fiberglass or carbon fiber reinforcement Polyester, vinylester or epoxy resin
Thermoplastic Lined Metals

A-74
Rev 9-04-03
Non-Metallic Pipe and Fittings

Characteristics Less expensive than metallic alternatives Cannot be made fire resistant More sensitive to abuse More supports are generally required Flanged joint make-up requires more care
A-75
Thermoplastic Pipe and Fittings

Pipe is extruded Fittings are usually injection molded, but sometimes fabricated Valve parts are usually injection molded Requires warm, dry and clean environment for fabrication
(Durapipe)
(Charlotte Pipe)
(Durapipe) A-76
Rev 9-04-03

Butt fusion fittings are joined to the pipe using a butt fusion welding process.
(Asahi) (Asahi) A-77

Socket fittings are joined to the pipe using a socket fusion welding process or solvent cement.
(Spears)
(Asahi) A-78
Rev 9-04-03
RTR Pipe and Fittings

Pipe is filament wound or centrifugally cast Fittings are molded, filament wound or fabricated Few RTR valves are available Requires warm, dry and clean environment for fabrication
(Smith Fibercast)
A-79

Butt fittings are joined to the pipe using a butt wrapping process. (Smith Fibercast)
A-80
Rev 9-04-03

Socket fittings are joined to the pipe using an adhesive. (Conley)
A-81

A leak at an elbow requires 1. Cutting out the elbow and adjacent pipe 2. Fabricating a piece with an elbow and two couplings 3. And installing it, hoping none of the six new joints leak
A-82
Rev 9-04-03
Lined Pipe and Fittings

Common liners are fluoropolymer, polypropylene, and PVDF Liners can be locked-in or loose PTFE and FEP lined systems require vent holes Pipe and fittings are usually (Resistoflex) ductile iron and steel Systems usually have many flanged joints
A-83

Typical Fittings
A-84
Rev 9-04-03

Untypical Fittings
A-85
Pipe & Fitting Selection

Workshop: What basic piping system characteristics would you provide for the following services: Steam condensate Sulfuric acid Gasoline 650 psig (45 bar) Steam Heat transfer oil See Supplement page 21 for details.
A-86
Rev 9-04-03
B31.3 Fluid Service Definitions

Category D Category M High Pressure Normal
A-87

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
A-88
Rev 9-04-03

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
A-89

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 See Table in Supplement.
A-90
Rev 9-04-03
Fluid Service Selection

Workshop: What B31.3 fluid service definition is most nearly applicable for the following services: Steam condensate Sulfuric acid Gasoline 650 psig ( ) Steam Heat transfer oil See Supplement page 21 for details.
A-91
Rev 9-04-03

ASME B31.3 Piping Design - Part A

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Piping Design & Applications Workshop

Piping Design & Applications Workshop

Don Frikken Becht Engineering Company

Piping Design & Applications Workshop

More Topics Covered

Piping Design & Applications Workshop

Piping Design & Applications Workshop

& More Definitions:

Piping Design & Applications Workshop

Piping System Standards - ASME

Piping System Standards - Other

See the longer list in the supplement.

Piping Design & Applications Workshop

Piping Component Standards - ASME

Piping Component Standards - Other

Piping Design & Applications Workshop

Piping Design & Applications Workshop

P-T Ratings for Flanges Gray Iron

P-T Ratings for Flanges Carbon Steel

Piping Design & Applications Workshop

Class 300 Ratings for Flanges Several Materials

Robustness Fire Resistance Blow-out Resistance Tendencies to Leak

Piping Design & Applications Workshop

Piping Design & Applications Workshop

Piping Design & Applications Workshop

Pipe and Fitting Selection

Piping Design & Applications Workshop

What distinguishes one fluid service from another?

Piping System Failure

How can you recognize a failure in a piping system?

Piping Design & Applications Workshop

Bases for Selection

Corrosion Resistance Material Toughness Cost

Piping Design & Applications Workshop

Example of Brittle Fracture

Piping Design & Applications Workshop

Example of Ductile Deformation

Relative Installed Cost - NPS 4 Complex System

Piping Design & Applications Workshop

Pipe and Fitting Selection (Metallic)

Rotary Piercing Mill

Pug Rolling Mill

Piping Design & Applications Workshop

Facing & Beveling

Piping Design & Applications Workshop

Facing & Beveling

Pipe Wall Thickness

Piping Design & Applications Workshop

Pipe Wall Thickness

Pipe Wall Thickness

Piping Design & Applications Workshop

Size frequently limited to ~NPS 2

Generally not used where leaks cannot be tolerated A-42

Piping Design & Applications Workshop

Fittings: Socket Welding

Piping Design & Applications Workshop

Fittings: Water Tube

Piping Design & Applications Workshop

Fittings: Compression for Pipe

Pressfit by Victaullic (B16.51 draft for copper)

Lokring (metal-to-metal seal)

Piping Design & Applications Workshop

Fittings: Hygienic Clamp