PIPING SYSTEM

Piping system in a chemical plant

are
comparable to the veins and arteries
through
which fluids, vapors, slurries, solids,
etc.
flow under various conditions, as
by the process design of the plant.
Piping design becomes more
complex due
to corrosion, erosion, toxic conditions
and
radio-activity.
2

PIPING COSTS
Piping contributes to a major part in any plant
/ industry investment.
Major equipment 50%
Piping 23%
Balance 27% (Building and Structure,
Foundation, Electrical, Instrumentation,
Painting & Insulation).

PIPING COSTS
Piping contribution on office Man-hour basis
to a major part in any plant / industry
investment.
Design Engineering 45%
Piping Engineering 20%

PIPING COSTS
Piping contribution on field labour cost basis:
Piping 47%
Balance 53% (Major equipment, Building
and Structure, Foundation, Electrical,

Instrumentation, Painting & Insulation).

3-5

What a Piping Engineer

should know ?
Engineering knowledge
Mechanical, electrical,
civil & instrumentation.
Engineering economics & costs.
Metallurgy
Methods of pipe fabrication and
erection.
Chemistry & chemical
engineering.
Communication skill.
Standards, codes & practices.
Safety codes and practices.
Drafting procedures and
practices.
6

Responsibility of a Piping
Engineer
ADEQUACY: Piping design must be adequate
to meet the process specification and physical
conditions in which the plant is to operate.
ECONOMY: Adequate design must be
achieved at an economic cost within budget.
Design costs must be minimized by
maximizing the use of standardized methods of
detailing and data presentation.

Responsibility of a Piping
Engineer

CLARITY: Piping data for design derived

from
and used by other engineering dept. &
other
sources must be clear, consistent and
reliable.
ACCURACY: Details of Piping must be
accurate and complete. Rectification of
mistakes at a latter stage may prove to be
very

costly and can delay project completion.

7-8

PIPING CODES AND

STANDARDS
For Scientific design of piping system, selection of
proper material of construction and to detail out
the material specifications, knowledge of codes and standards are
essential.
Each country has its own codes and standards. On
global basis, American National Standards is most
widely used code and compliance with its
requirements is accepted all over. British Standards
and Indian Standards are also used for the design
and selection of piping systems.

CODES AND STANDARDS

CODE:
A CODE IS A STD. THAT HAS BEEN ADOPTED
BY ONE OR MORE GOVERNMENTAL BODIES AND
HAS THE FORCE OF LAW. A SET OF RULES BACKED
UP BY PRINCIPLES OF SCIENCE AND EXPERIENCE
OF PAST SAFE AND SUCCESSFUL USAGES
STANDARD:
A SET OF TECHNICAL DEFINITIONS AND
GUIDELINES, INSTRUCTIONS FOR DESIGNERS,
MFRS. & USERS. IT IS A SYSTEM/DOCUMENT TO BE
ADOPTED BY OR USED BY THE PEOPLE WHO ARE
EXECUTING A PROJECT.

12-13

EFFECTIVENESS OF WORKING TO
CODES AND STDS.
TO ESTABLISH COMMON AGREEMENT IN ENGINEERING
CRITERIA, TERMS, PRINCIPLES, PRACTICES, MATERIALS,
ITEMS, PROCESSES, ETC.
TO FOLLOW ALREADY PROVEN WAY OF DOING THINGS
SAFETY
RELIABILITY
TO FOLLOW CONTINUALLY
MISMATCH/INTERCHANGEABILITY
USAGE OF EXISTING SYSTEM
TO ECONOMISE THE SYSTEM
TO REDUCE INVENTORY \ TO GET READYMAKE BACKUP
from market

14

BODIES FOR CODES & STANDARDS

ASME : AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ANSI : AMERICAN NATIONAL STANDARDS INSTITUTE
ASTM : AMERICAN SOCIETY OF TESTING AND MATERIAL
API : AMERICAN PETROLEUM INSTITUTE
AISI : AMERICAN IRON AND STEEL INSTITUTE
MSS-SP : MFR. STD. SOCIETY OF VALVES & FITTINGS IND.
BSI : BRITISH STANDARDS INSTITION
BIS : BUREAU OF INDIAN STANDARDS
AWS : AMERICAN WELDING SOCIETY
AWWA : AMERICAN WATER WORKS ASSOCIATION
DIN : GERMEN STD.
AFNOR : FRENCH STD.
JIS : JAPANESE STD.
ISO : INTERNATIONAL STANDARADS ORGANIZATION

15

PIPING ELEMENTS
In a process industry the transportation of materials in the fluid
form from one place to another takes place by forcing the fluid
through the piping system. The piping system not only involves
pipes but also the fittings, valves and other specialties. These
items
are known as the piping components. Code specifies the piping
system as the mechanical elements suitable for joining or
assembly
into pressure-tight fluid-containing piping.
These Piping Components are as under:
PIPIS
BOLTING

FITTINGS
FALVES

FLANGES
SPECIAL ITEMS

PIPING ELEMENTS

GASKETS
SAFETY ITEMS

PIPING ELEMENT:
IT IS DEFINED AS ANY MATERIAL OR WORK
REQUIRED
TO PLAN AND INSTALL THE PIPING SYSTEM.
These elements include design specifications,
materials, components, supports, fabrication,
inspection and testing.
PIPING SPECIFICATION:
IT IS A DOCUMENT SPECIFYING EACH OF THE

COMPONENTS.

MATERIAL SELECTION OF
PIPING COMPONENTS
Basically the material is selected based on its
service. Thus the selection of piping materials
requires knowledge of corrosion properties,
strength
and engineering characteristics, relative cost
and
availability.
The main process considerations in MOC
selection
are fluid corrosion properties, pressure and
temperature conditions of the service and the
nature of the service (toxic, volatile,
explosive, etc.)
18

SPECIFICATION OF
PIPING
COMPONENTS
Any piping component is
specified by
Item description
Type of construction (welded
or seamless)
Material standard with grade
Dimensional standard
End connection
End facing (if applicable)
Datasheet reference (if
applicable)
20

PIPE
PIPE is specified by its OD and thickness.
Thickness is specified in schedule nos.
Corrosion allowance is included in the
thickness.
Mill tolerance +/- 12.5 %.
Pipe thickness formula: t = _____P D_____
+C
2 (S E + P Y)
MOC&TYPE

CS/AS/SS &
SMLS/WELDED

DIMN .STD

CS: ANSI
B36.10
SS: ANSI
B36.19

END
CONNECTIO
N

BE, PE, FLGD,

SCREWED,
BUTRESS,
SPIGOT/SOCKE
T

PIPE
BASED ON THE METHOD OF
MANUFACTURE, PIPES
CAN BE CLASSIFIED AS
SEAMLESS
WELDED
Electric Resistance
Welded (ERW)
Electric Fusion Welding
(EFW)
Spiral Welded
Furnace Butt Welded
Double Submerged Arc
Welded (SAW)
FORGED&BORE
D

TYPES OF END
CONNECTIONS

SOCKET WELD PIPE JOINTS

BUTT WELD PIPE JOINTS
SCREWED PIPE JOINTS
FLANGED END PIPE JOINTS
BUTTRESS END PIPE JOINTS
SPIGOT SOCKET END PIPE JOINTS
22-2

SOCKET WELD END

CONNECTION
ADVANTAGES:
a) Easier alignment than butt
welding.
b) No weld meta intrusion into
bore/hole.
DISADVANTAGES:

a) The 1/16 (1.6 MM) recess

pockets liquid.
b) Use not permitted by code
if Severe Erosion or
Crevice Corrosion is
anticipated.
USE:
a) General utility & LP piping
system.
b) NPS below 2 NB.
25

BUTT WELD END

CONNECTION
ADVANTAGES:
a) Most practical way of
joining big bore piping.

b) Reliable leak proof joint.

c) Joint can be radiographed.
DISADVANTAGES:
a) Weld intrusion will affect
flow.
b) End preparation is
necessary.
USE:
a) NPS 2 NB & above.
b) HP, HT, corrosive &
erosive services.
27

SCREWED END
CONNECTION
ADVANTAGES:

a) Easily made at site.

b) Can be used for where welding is not

permitted due to fire
hazard.
DISADVANTAGES:

a) Joint may leak when not properly sealed

b) Use not permitted by code if severe
erosion, crevice
corrosion, shock or vibration is anticipated.
c) Strength of pipe is reduced as threads
reduce wall
thickness.
d) Seal welding may be required.
e) Code specified that seal welding shall not
be considered to
contribute for strength of joint.
USE:

a) Non critical CW/utility system.

29

FLANGED END
CONNECTION
ADVANTAGES:

a) Used for all process & utility piping

where
frequent bolting connections are
required or the
joints need frequent dismantling.
b) Reliable leak proof joint when bolted
properly.
DISADVANTAGES:

a) Gasket need to be inserted properly

during bolting.
b) Prone to leakage if any dirt/dust is
trapped
between flange and gasket seating surface.
USE:Used at equipments, valves &

special items where

maintenance is a regular feature,
breakout flanges
are provided at definite intervals on pipe
lines.

31

PIPE FITTINGS
ELBOW:
22.5 elbow is also available in C.I. construction.
TEE:
Branch off - Branch off with RF pad - Tee
The mfg. Restrictions do not allow reducing tees of
all size.
Thumb rule: Size available is divide the major dia.
By 2
and consider the next lower size. (4 x 1)
CROSS:
Used to reduce space. E.g. Marine piping.
Generally tees are used in place of cross to reduce
the
inventory

PIPE FITTINGS

REDUCERS: (Concentric & Eccentric)

CR is used when centre line of larger & smaller pipe
is to
be maintained same.
ER is used when the outside surface of the pipe
lines are
to be maintained same.
There are no ER in SW fittings and Swage nipples
are used
for such service.
UNIONS:
Used in low pressure piping where dismantling of
the pipe

is required more often as an alternative to flange. It

can have
threaded end or SW ends.
43-44

PIPE FITTINGS
SWAGE NIPPLES:
BS 3799
Used to connect BW pipe to smaller screwed
or SW pipe.
Two types Concentric & Eccentric.
COUPLINGS:
Full Coupling
Half Coupling
Reducing Coupling

PIPE FITTINGS
STUB ENDS: To reduce the cost of piping, stub ends
are
used with backing flanges for flange joints when
exotic/costly materials are used in piping.
ANSI B16.9

ANSI B16.9

Long stub ends

Short stub ends

Dimensions same as Short stub

ends
Class A: With Radius
Class B: Without Radius

Used up to 40NB Used above 40 NB depending upon

the
flange construction
Slip-on flange

Class A: Chamfered backing flange

Class B: Slip-on flange

exotic/costly materials are used in piping.

45-46

PIPE FITTINGS

WELDOLET: Used for BW branch

connection where
standard tee is not available and
the piping is of
critical/high pressure service.
SOCKOLET: Used for SW branch
connection which
requires reinforcement pad.
THREADOLET: Used for threaded
branch connection.
ELBOWLET: Used for branch
connection on elbows and
have the profiles made to suit the
elbow.
LATEROLET: Used for branch
connection at an angle.

FLANGES
Classification of Flanges is done as under:
Based on pipe
Slip-on, SW, Screwed, Lap joint,
attachment
Welding Neck, Blind, Reducing
Based on P-T
rating

125#, 150#, 300#, 400#, 600#,

900#,
1500#, 2500#

Based on
Facing

Flat Face (FF), Raised Face (RF),

Tongue & Groove (T/G), Male &
Female (M/F), Ring Type Joint
(RTJ)

Based on Face
Finish

Smooth (for metallic gaskets)

Serrated (for non-metallic
gaskets)

Based on MOC

Forgings
Plates weldable quality

FLANGE FACINGS
SMOOTH FINISH
Specified when metallic
gaskets are used.

SERRATED FINISH
Specified when nonmetallic
gaskets are used.

Gasket is comparatively
Spiral or Concentric
softer than flange material. serrations.
Concentric Low density
fluid

Specified by AARH
(0-125 micron max.)

Specified by AARH
(125-250 micron)

FLANGES
SLIP-ON FLANGE:
Forged with hub or fabricated from plate without
hub.
Welded to pipe from inside & outside.
SOCKET WELD FLANGE:
Welded only on outside.
Not approved by IBR.
Used for small bore pipes only (Bel w 2 NB)o
Thickness of pipe to be specified to ensure proper
bore
dimension
SCREWED-ON FLANGE:
Used where welding cannot be carried out.
Used for water piping works.

FLANGES
WELDING-NECK FLANGE:
BW to the pipe & hence can be radiographed.
Used for critical services.
Thickness of the welding end to be specified.
BLIND FLANGE:
Used to close the pipe/equipment ends which need
to be
re-opened later.

REDUCING FLANGE:
Used to connect larger & smaller diameter pipes
without
using a reducer.

 The thickness of the flange with smaller

diameter shall be
the same as that of flange with larger diameter.

FLANGES
INTERGRAL FLANGES:
Cast along with the piping component or the
equipment.
Used for critical services.
Thickness of the welding end to be specified.
Thickness of integrally cast flanges may differ
from
standard forged flanges.
LONG WELDING-NECK FLANGE &
EXPANDER/REDUCER FLANGE:
Developed by the manufacturer to suit
special
requirements.
FLANGES
BASED ON PRESSURE-TEMPERATURE RATINGS:
In the standard ANSI B16.5, the P-T rating
chart specify
the cold non-shock pressure to which the
flange can be
subjected to at a particular temperature.
ANSI B16.5 indicates the allowable pressures
for various

MOC.
Code does not recommend the use of class
150 # flanges
above 400 F.

GASKETS
SELECTION:
Selection of gasket depends upon the following
factors:
Compatibility of the gasket material with the
fluid.
Ability to withstand the pressure &
temperature of the
system.
TYPE:
Gasket is classified based on the type of
construction:
Full Face
Inside Bolt Circle
Spiral Wound Metallic
Ring type
Metal Jacketed

GASKETS

MATERIAL:
Commonly used material is CAF (Compressed
Asbestos
Fibre)

CAF Gasket standard: IS 2712 Three grades:

Gr. W/1, W/2 & W/3: Steam, alkali & general
applications
Gr. A/1: For Acid application
Gr. O/1, O/2 & O/3: For Oil applications
For corrosive services, asbestos free gaskets
are used.
They are PTFE, CAF with PTFE envelop, GFT,
Rubber, etc.
For high temperature & high pressure
applications, spiral
wound metallic gaskets are used.

GASKETS
SPIRAL WOUND GASKET:
The selection of MOC for winding depends
upon the
corrosive nature and concentration of fluid, the
operating
temperature and the relative cost. Commonly
used material
is SS304, SS316 & SS321 with asbestos filler
material.
For very high temperature graphite filler is
also used.
Provided with CS external ring which is called
as centering
ring to position the gasket.

 For vacuum services, an internal gasket is

also provided.
Surface roughness is 125-250 AARH microns.
RING GASKET:
For extremely high pressure & temperature.
Oval (upto 8 NB) and Octagonal (Above 8
NB)
Gasket material is soft as compared to flange
material.

VALVES

Valves contribute to 8%-10% of the total

capital
expenditure of any project.
Valves are installed on equipment/piping to
perform
any one of the following functions:
Isolation.
Regulation.
Non-Return
Special purpose.

VALVES

Valve classification based on functions:

Isolation

Regulation Non-return

Gate
Ball

Globe
Needle

Check

Special
pupose
multi-port
Flush
bottom

Plug
Piston
Diaphrag
m
Butterfly
Pich

Butterfy
Diaphrag
m
Piston

Float
Foot

Pich

Knife gate

Line blind

VALVES
Valve classification based on operation:
Operated Valves
Self-operated Valves (Check valves)
Valve classification based on end
connections:
Screwed ends
Socket Weld ends
Flanged ends
Butt Weld ends
Wafer type ends
Buttress ends (in glass piping)
Valve classification based on MOC:

TIPS FOR PIPING

CS material shall be used for temp. up to
425 C (800 F).

 LTCS material to be used for temp. below

29 C (-20 F)
AS material shall be used for temp.
above 425 C (800
F)
SS shall be used for corrosive services.
Process Licensor
specification shall be referred.
GI piping shall be used for services like
drinking water,
instrument air, LP nitrogen, etc.
Selection of non-metallic and nonferrous materials shall
be as per the recommendations of the
Process Licensor.
All the pipes carrying toxic/flammable
fluids shall be
seamless.
Utility piping can be ERW or seam
welded.
Steam piping shall preferably be
seamless.