WHAT IS PIPING ABOUT..

We can say PIPING is about designing, fabricating and constructing lines conveying
FLUIDS.

What is a FLUID?
It can be any of the following
a GAS
a LIQUID
a mixture of GAS and LIQUID
a SUSPENSION of small SOLID PARTICLES
inside a LIQUID.

Basic properties of conveyed FLUIDS
FLUID TYPE with particular attention to the CORROSION characteristics the
DANGER for HEALTH and the ENVIRONMENT
FLOW RATE
PRESSURE
TEMPERATURE

What is a PIPELINE?

A PIPELINE conveys a fluid from one given point of the plant usually called INLET
point of the line, to another part of the plant usually called OUTLET point of the line.
A PIPELINE can also connect one PIPELINE to another PIPELINE. PIPELINES can
also discharge the conveyed fluid into the environment (VENTS and DRAIN)

Basic characteristics of a PIPELINE
SIZE (or DIAMETER)
WALL THICKNESS
TYPE OF JOINTS BETWEEN PIECES welded joints (butt welding / socket
welding) threaded joints flanged joints
EXTERNAL FINISHING Painting Insulation
QUALITY CHECKS Hydraulic Testing Non Destructive Examination of Joints.

Other characteristics of a PIPELINE
ROUTING
The routing is how the Pipeline is developed into the space.
There are rules and regulations to route a Pipeline according the Good Engineering
Practice Cold Pipelines connecting static objects (something that does not move
like Tanks, Vessels, other Pipelines, Headers) can be straightly routed between the
inlet and the outlet point. Cold Pipelines connecting MACHINES that vibrate or
rotate may
need a flexible part between the inlet and the outlet point. Hot Pipelines must be flexible
enough to adsorb the thermal expansion of the Pipeline from cold to hot condition

SUPPORTING SYSTEM

Every Pipeline must be supported. Not all Pipelines are supported in the same way
Cold Pipelines can be supported everywhere with FIXED POINTS Hot Pipelines
cannot be supported only with fixed points, butcertain points must be only GUIDED,
meaning that in those points the Pipeline retains a certain numbers of degree of
freedom in certain directions, while are constrained in certain other directions

PIPING DESIGN
Specification of Lines
It is a document that summarizes all the characteristics of a PIPELINE. Starting
from the PROPERTIES of the CONVEYED FLUID, the document specifies all the
CHARACTERISTICS of the PIPELINE FLUID TYPE Choice of material

1. 1. Non corrosive fluids

Services where impurities are accepted industrial water lines (cooling water) steam lube oil
return / before filter lines air lines vents and drains
Carbon Steel, Low Alloy Steel (High T)

1. 2. Corrosive fluids

Services where impurities are not accepted demineralized water lube oil after filters
fuel gas / oil sea water (water containing Chlorine) Stainless Steel No Iron (Fe)
Copper/ Nickel Alloys (Cu- Ni)

1. 3. Aggressive Chemicals

Strong Acids / Bases
Plastic: PVC TEFLON PE
Rubber: NBR, Viton
Composites: RESIN GLASS

FLUID TYPE

Choice of CORROSION ALLOWANCE : Thickness increasing taking into account
CORROSION Typical corrosion allowance for water is 3 mm that affects THICKNESS
Choice of joints: DANGEROUS fluids are conveyed in fully welded pipes, were leaks
cannot occur. Choice of NDE : For Dangerous Fluids 100% of joints are likely to be
X- Ray examined

FLOW RATE Choice of Diameter

For a given flow rate
- SMALL DIAMETER means HIGHER VELOCITY of the conveyed fluid
- BIG DIAMETER means SLOWER VELOCITY of the conveyed fluid Velocity of fluids
in Pipelines affects
- Pressure Losses along the Pipeline Pressure Losses are PROPORTIONAL to the
square velocity (v 2 )
- Vibration of the Pipeline Usual Velocity of Fluids inside pipelines are:
Gas: 20 m/ s - max. 40 / 50 m/ sec
Liquid: 2 to 4 m/ s - max. 10 m/ sec

TEMPERATURE Choice of MATERIAL

-Steel for High Temperature (Low Alloy Steel Creep Resistant) Calculation of wall
THICKNESS Routing Design and calculation of SUPPORTS (STRESS ANALYSIS)
-Hot Lines must be routed properly. Provisions shall be taken so that when
temperature rises from ambient to Operating Temperature the thermal expansion of
Pipelines does not generate stresses too high for the pipes to withstand. Application
of Thermal Insulation -T> 60 C Insulation for Personnel Protection is mandatory
for all pipeline parts that can be reached by hands.

PRESSURE :

1. Calculation of Wall Thickness
2. Choice of the Joint
-Low pressure pipelines can be threaded or socket welded
-High Pressure pipelines are Butt Welded

1. 4. Extension of NDE of the joints

- Non process Pipelines (For Example Vents and drain lines) may
even have no tests at all
- Low Pressure Pipelines can undergo only the Hydraulic Test
-For intermediate pressures a 10% to 50% of joints must be
examined with X- rays
-High Pressure Pipelines are usually 100% X- ray examined.

AMERICAN STANDARDS FOR PIPING DESIGN
ANSI = AMERICAN NATIONAL STANDARDIZATION INSTITUTE
ASME = AMERICAN SOCIETY of MECHANICAL ENGINEERS

ANSI/ ASME B31.1: POWER PIPING
ANSI/ ASME B31.3: PROCESS PIPING

THESE STANDARDS GIVE TECHNICAL RECOMMENDATIONS FOR DESIGNING PIPING
SYSTEM FOR POWER PLANTS AND CHEMICAL PLANTS THEY CONTAINS FORMULAS
TO CALCULATE THE MINIMUM THICKNESS OF PIPELINES THEY CONTAINS
ORMULAS TO CALCULATE THE EXTRA THICKNESS THAT A PIPE MUST HAVE WHEN A
BRANCH IS CUT INTO IT. THEY CONTAINS REGULATIONS FOR STRESS ANALYSIS
THEY ONTAINS TABLES THAT GIVE MAXIMUM ALLOWABLE STRESS FOR METALLIC
MATERIALS ACCEPTED BY ANSI FOR PIPELINE CONSTRUCTION DEPENDING ON
TEMPERATURES.


STANDARD MATERIALS FOR PIPING

ASTM = AMERICAN SOCIETY for TESTING MATERIALS

ASTM developed a collection of documents called MATERIAL SPECIFICATIONS for standardizing
materials of large use in the INDUSTRY. Specifications starting with A are for STEEL.
Specifications starting with B are for non- ferrous alloys (Bronze, Brass, Copper Nickel alloys,
Aluminum alloys and so on). Specifications starting with D are for plastic material, as PVC. An
ASTM Specification does not only specify the basic CHEMICAL COMPOSITION of material, but
also the PROCESS through which the material is shaped into the final product. This is why for a
given base material SEAMLESS PIPE have a specification, WELDED PIPE have another
specification WROUGHT FITTINGS have another specification, FORGED FITTINGS have another
specification, large VALVE bodies (normally CAST) have another specification

CARBON STEEL

Steel is basically a solution of carbon (C) into iron (Fe). The presence of carbon into the crystal
structure of the iron improve very much the mechanical characteristics of the iron alone. Carbon
steel is a conventional denomination for steel that has almost no other metallic
elements added into it.
ASTM most employed carbon steel for pipes are ASTM A53 Grade A and B and ASTM
A106 Grade A and B. A53 used to be cheaper than A106 and Grade A cheaper than
Grade B. Today the difference is not so big, so that for small quantities ASTM A106
Gr. B is usually chosen. ASTM Specifications belonging to same family of Carbon
Steel
SEAMLESS PIPES ASTM A53 (Gr. A / B) or A106 (Gr. A / B)
WELDED PIPES ASTM A134 / A135 / A139
WROUGHT FITTINGS ASTM A234 (WPA / WPB)
FORGED FITTINGS A105
CAST PARTS A216 (WCB)

API Standards

For Oil and Gas Industry, another American Standardization Institute is common
and important. This Institute is
API = AMERICAN PETROLEUM INSTITUTE
Rules, Practices and Standards for Oil and Gas Industry are issued by this Institute
and followed by almost all Oil and Gas Companies in the world. Among the many
Standards issued by the Institute there is also a Standard for design of Pipelines:
API STANDARD 5L Within this Standard Materials for Oil and Gas transportation
pipelines are specified, with denomination API 5L This is a family of Carbon Steels
almost equivalent to ASTM A53 /A106.

LOW ALLOY STEEL

The introduction of other elements into steel can change very much its mechanical
characteristics. Steel is subject to a process called creep at high temperatures
(T > 540 C) Creep is a reduction of strength over time due to high temperature. It
means that if today the steel can withstand a certain pressure, after a long time at high
temperature same steel can withstand much lower pressures, since its resistance is decreasing
with time due to the high temperature. Steel becomes also particurarly fragile if submitted to
sudden impacts at low temperatures (< - 20 C).
The introduction of small percentages of chromium (Cr), nichel (Ni), magnesium
(Mg), manganese (Mn), molybdenum (Mo), proves to improve the strength of the
steel and its resistance to corrosion also at high temperatures (> 500 C) or at low
temperaturea (< -20 C). Low Alloy Steel is a conventional denomination for steels
where there are small percentages of elements, usually metallic, other than carbon
only. Alloy steels are usually identified with denominations that recall composition.
As for example following high temperature resistant steels: Denomination Alloy
percentage Grade Grade for Castings
5Cr- Mo (5% Cr 0.5% Mo ) P5 C5
1 Cr- Mo- Si (1.25% Cr 0.5% Mo Si) P11 (WC5)
1Cr- Mo (1% Cr 0.5 Mo) P12 (WC5)
2 Cr- 1Mo (2.25 Cr 1% Mo) P22 WC9
ASTM Specifications belonging to same families of Low Alloy Steels
SEAMLESS PIPE A335 (P5 P11 P12 P22)
WELDED PIPE ASTM A358
WROUGHT FITTINGS ASTM A234 (WP5 WP11 WP12 WP22)
FORGED FITTINGS A182 (F5 F11 F12 F 22)
CAST PARTS A217 (C5 WC5 WC9)

STAINLESS STEEL

One of most important problems with carbon and low alloy steels, is that the iron
exposed to air and water combines with oxygene (O 2 ) and generates rust (di- iron
tri- oxyde Fe 2 O 3 ) that peels out from the surface. High percentages of chromium
(Cr) and nichel (Ni) added into the steel stop this problem. Stainless Steel is
conventional generic denomination for steels with high percentages of chromium
(minimum 16%) and nichel (minimum 8 %). Traditional denomination for stainless
steel was given first from AISI (American Institute for Steel and Iron) and is still in
the tradition and retained in the Grade of ASTM Specifications. But as usual for alloy
steels, a more precise denomination can refer to composition. AISI Denomination
Alloy Percentage Grade for
Castings
304 / 304L 18Cr- 8Ni (18% Cr 8% Ni) CF3 / CF8
316 / 316L 16Cr- 12Ni- 2Mo (16% Cr 12% Ni 2% Mo) CF3M / CF8M
321 18Cr- 10Ni- Ti (18% Cr 10% Ni Ti) Not Available
The L suffix stands for Low Carbon. In fact the presence of high percentages of Cr and Ni
improves the resistance of steel against rust, but at one cost: stainless steel is very difficult to
weld. Welding of stainless steel can be improved by reducing the content of carbon in it. ASTM
Specifications belonging to same family of Stainless Steel
SEAMLESS PIPE A312 TP304 304L - 316 - 316L - 321
WELDED PIPE ASTM A249 TP304 - 304L - 316 - 316L - 321
WROUGHT FITTINGS ASTM A403 WP304 - 304L - 316 - 316L - 321
FORGED FITTINGS A182 F304 304L - 316 - 316L - 321
CAST PARTS A351 (CF3 CF3M / CF8 CF8M)

How Pipeline CHARACTERISTICS are defined by the Standards.

SIZE
NOMINAL PIPE SIZE : NPS It is a conventional size expressed solely in INCHES,
related to the cross section diameter of the pipeline. For smaller sizes the NPS is not
usually exactly equal to any real diameter, but bigger. This comes from the fact that for
uniformity, pipelines must have same Outside Diameter, and change Inside Diameter with
different thickness. But in fluid transportation the internal diameter is more significant, so if the
Outside Diameter is bigger of the NPS, taking away the thickness, the NPS gives more an idea
of the internal diameter. NOMINAL DIAMETER : DN Same as NPS, but in mm. It is the usual
denomination of Size in Europe where S. I. is adopted. All external diameters pipes according
EUROPEAN Standards (DIN - Germany, UNI - Italy, AFNOR France) are
exactly equal of the equivalent NPS Sizes according AMERICAN and
BRITISH Standars (BS) EXCEPT 5 (DN125)

WALL THICKNESS (1)1. For PIPES and WROUGHT BW FITTINGS, wall thickness is
given in INCHES or mm.
Some series of thicknesses are standardized. There are two series of systems of
standardized thicknesses. Carbon Steel
ANSI B16.10
5, 10, 20, 30, 40, 60, 80,
100, 120, 160. Schedule
Stainless Steel
ANSI B16.19
5S, 10S, 20S, 30S, 40S,
60S, 80S.

Std Standard

XS Extra Strong Weight Series
XXS Extra Extra Strong
It happens that for a given diameter the thickess of one Schedule is equal to the
thickness of one Weight Series. For example for small diameters, Sch. 40 is equal to
Std Weight. THIS IS NOT A RULE, and this idea is one of the most common mistakes
in piping design.

WALL THICKNESS (2)2. For FLANGES, VALVES and FORGED FITTINGS, a different
system of indicating the wall thickness is used. This is called PRESSURE RATING. It
is a NUMBER expressed in POUNDS per SQUARE INCH (PSI symbol #) that refers to
the maximum internal pressure acceptable for normal operation inside that part.
125# 150# 300# 400# 600# 800# Cast Iron Flanges & Valves (Not in NP
Standards) Fl. & Valves Forged Small Valves ( 2) 900# 1500# 2500# 3000# 6000#
9000# F l a n g e s & V a l v e s Forged Fittings This conventional number is not
exactly the actual maximum pressure acceptable inside the part. The maximum
pressure allowed for a given rating is tabulated in the ANSI standards and depends
on Temperature ASTM Material

TYPE OF JOINTS BETWEEN PIECES (1)

BUTT- WELDING ENDS The end is machined to allow head to head full penetrating
welding

TYPE OF JOINTS BETWEEN PIECES (2)

SOCKET WELDING ENDS A socket is provided where pipe can be inserted

TYPE OF JOINTS BETWEEN PIECES (3)
3. THREADED ENDS Parts to be connected are threaded. For services where leaks
are
strongly undesired, a light weld is carried out at the surface, this is called Seal
Weld. Seal weld

STANDARDIZED PIPING OBJECTS PIPES

FITTINGS
FLANGES
VALVES
GASKETS
BOLTS AND NUTS

PIPES: ANSI B36.10 CS / B36.19 SS
Seamless
Electric Resistance Welded No material is added during welding
process
Electric Fusion Welded Material (Filler Metal) is added during the
process of welding

HOW TO IDENTIFY A PIPE SIZE NPS 12 (DIAMETER) (DN 300)
WALL THICKNESS Sch. 40 MATERIAL ASTM A106 Gr. B
BW FITTINGS : ANSI B16.9
Bends 30 - 45 - 60 - 90
Long Radius R= 1.5 D
Short Radius R= D
Tees
Straight Full Tees .
Reducing Tees.
Reducers
Concentric Reducers.
Eccentric Reducers.
Caps
HOW TO IDENTIFY A BW FITTING
1. Straight Fittings TYPE BEND 90 LR SIZE NPS 12 (DIAMETER) (DN 300)
WALL THICKNESS Std MATERIAL ASTM A234 WPB

2. Reducing Fittings

TYPE REDUCING TEE SIZE NPS 12 x8 (DIAMETER) (DN 300x200)
WALL THICKNESS Sch. 30x20 MATERIAL ASTM A234 WPB FORGED FITTINGS ANSI
B16.11

HOW TO IDENTIFY A FORGED FITTING
TYPE ELBOW 90 SIZE NPS 1 (DIAMETER) (DN 25) WALL THICKNESS Rating 3000#
JOINT NPT MATERIAL ASTM A105

PIPE NIPPLES

They are standardized short pieces of pipe usually 50 mm or 100 mm long normally
used between two close fittings. They can come in straight size or in reducing size
and can have one end machined in a different way than the other. Such a variety of
combinations is summarized using abbreviations
B = Bevelled
P = Plain
T = Threaded
L = Large
S = Small E = End

Pipe nipples can be used to change among joint types.
For example a PExBE Pipe Nipple changes a Socket Welding Line into a Buttwelding
Line Beveled End Plain End BW SW FLANGES ANSI B16.5

1. 1. Pipe Connection
Welding Neck
Slip On
Lap Joint
Socket Welding
Threaded
2. Mating
Flat Face
Raised Face
Ring Joint

WELDING NECK

Used for all sizes, they allow full penetration weld between pipe and flange. For this
reason they are used for severe applications where failure of weld cannot be
accepted. This does not come free of cost, since the shape of the flange obliges to
start from a heavy forging and waste a lot of material from machining.

SLIP ON

Used for all sizes, they are very much economical because they are flat and can be
obtained from sheets or plates with minimum waste of material from machining.
But they do not allow full penetration weld, so that they are use for low ratings
(usually 150# only) and uncovered applications

THREADED

Can be used for all sized, but are preferably used for small sizes (< or equal to 2).
Cheap manufacturing, cheap installation (no weld is required) but limited to
threadel
lines, that means unsevere applications where leaks are not a major issue

LAP JOINT

A Stub End is welded on the pipe after the flange insertion of it. This solution is used
for Stainless Steel lines at low pressure, since the heavy flange does not come in
contact with the conveyed fluid and can be provided in much cheaper Carbon Steel
material. Moreover no weld is required, also a good thing for Stainless Steel lines.

SOCKET WELDING

Used for small sizes (< or equal to 2) for unsavory services on Socket Welding
lines.
Flat Face Gasket: Full Face Flat It covers the entire surface of the flange Raised Face
Gasket: Flat It covers the raised surface of the flange Spiral Wound Also known as
Spirometallic, or Spirotallic, its a wounded spiral of Stainless Steel and Graphite to
withstand high temperatures or severely aggressive fluids Ring Joint Gasket:
Metallic Ring It is normally made up of Steel. It deforms inside the ring joint
grooves
assuring sealing at very high pressures. Surface Finishing of Flanges To improve the
sealing effect of plane gaskets, the surface of a flange can be machined. A set of
circular scares is machined in the surface. When the gasket is tightly squeezed
etween the flanges, it penetrates into the scares improving sealing.

HOW TO IDENTIFY A FLANGE
JOINT TYPE -SLIP ON
SIZE -NPS 6
(DIAMETER) -(DN 150)
WALL THICKNESS -Rating 300#
MATING_FINISH - RF R9
MATERIAL- ASTM A105

ACTUATION OF VALVES

To open and close a valve, Hands, Electric Power, Compressed Air, High Pressure Oil
you can use in which case you need Hand wheel, Electric Actuator, Pneumatic
actuator, Hydraulic Actuator And is called Manual, Electric, Pneumatic, Hydraulic

CONTROL VALVES

These valves are used to CONTROL one or more of the PROPERTIES of the conveyed
fluid in order to mention the VALUES of the controlled property within a specific
ange.
The internal parts of these valves are specially designed tu suit the particular control task and
are non subject to particular Standards. Anyway, the majority of Control Valve Manufacturers
try to respect at least the end to end dimensions given in ANSIB16.25. Also connections follows
the recognized international standards.

SAFETY AND RELIEF VALVES

These valves are installed on pipelines where pressure can exceed by accident the DESIGN
PRESSURE of the pipeline. These valves are designed to open and discharge the conveyed fluid
when the pressure in the pipeline becomes greater than a pecified value called SET. RELIEF
The valve opens when the pressure goes over the SET, but close again when the pressure
returns under the SET SAFETY The valve opens when the pressure goes over the SET, but
never closes again. Personnel intervention is required on the pipeline to check the event and
the condition of the area, before re- arming the valve and starting operation again

TUBING

A TUBE is a circular section of given DIAMETER and THICKNESS. It is normally
specified giving the Ouside Diameter (OD) and the thickness. But it can also be
specified giving the Inside Diameter (ID) and the thickness. The given numbers
correspond exactly to the geometrical dimension they refer. So A 2 OD TUBE has
exactly a 2 Outside Diameters. Dimensionally, there are two big families of tubing

1. 1. FRACTIONAL TUBES

The INCH is the unit of measure, and since tubes for piping purpose (REMEMBER:
CONVEYING FLUIDS!) are small, usually less than 1, FRACTIONS of inch are used,
hence the name

FRACTIONALMETRIC TUBES

As per SI requirements, mm is the unit of measure. Again the value in mm is the actual ouside
diameter of the tube, so that a DN15 pipe has a rather different OD then a 15 mm tube.

TUBES in PIPING DESIGN.
Tubes are not usually used in PIPING DESIGN except for some very particular
services. In typical Oil and Gas Machinery installations, like Nuovo Pignones,
TUBES are basically used for: 1. Parts of HP Hydraulic Lines 2. Instrument
connecting Lines

Pneumatic Lines

These Lines are small size (usually less than 1).
COMPRESSION FITTINGS
Tubing is usually BENT.
A large variety of fittings are available for
1. detachment of BRANCHES (Tees)
2. Passing through steel walls (Bulk Unions)
3. Unite tube to tube (tubing is not welded)
4. Connecting Tubing to PIPES (Connectors)
5. Connecting Tubes to Flexible Hoses
Connection of TUBING with the fitting is
achieved through a particular locking system where a RING ( FERRULE) is forced
to COMPRESS the Tube walls for sealing and joining. These fittings are not
STANDARDIZED, but are branding based and patented. Most popular manufacturers
of compression fittings are PARKER, SWAGELOCK, GARILOCK.