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%20FITTINGS.htm
PROCESS PIPING & PIPING FITTINGS
In any Petrochemical, Chemical, Fertilizers or Power generation plant, one
can see kilometers of various piping carrying various process fluids from
one end to other. The process piping acts as blood carriers in our body. It
plays very important role as any minor failure of process piping or pipe
fitting of critical service in continuous process plant means shutdown of
the plant. The role of the maintenance engineers is to design and select
appropriate piping material and rating to avoid such failures.
Piping
design
includes
selection
of
applicable
codes/standards,
various
pressure piping
system,
Material
Allowable stresses
Maximum deflection
Seismic loads
Thermal expansion
Corrosion allowance
Factor of safety
Codes for piping pipe fittings and valves are separate. But all the
details shall be specified in the construction isometrics. Construction
isometrics shall contain following informations:
Pipe Number
Pipe Class
Insulation Class
Support class
Pipe Size
Main dimensions for assembly
Deatil dimensions for valves & spool pieces
Point of reference
Instruments
Pipe supports
Part List
For process piping design ASME B31.3 includes selection of material,
design, fabrication, assembly, erection, examination, inspection and
testing.
Welding joints of pipes and fittings also plays an important role. For any
process
piping,
PQR
(procedure
qualification
record),
WPS(Welding
Procedure Specifications) and QAP (Quality assurance plan) are made with
reference to the standards. These documents gives the details of type of
welding, type of electrodes, qualification of welder, preheat and post weld
heat treatment cycles, inspection and testing to be done etc for any
piping.
Quality assurance plan and Procedure qualification records are generally
developed in workshops anf for this many destructive tests are also
performed along with Non-destructive tests. Based on these recorded
documents, NDT (Non Destructive Test) which consists of
Penetrating Test) Radiography/ X-Ray , Ultrasonic(UT)
DPT (Dye
MP(Magnetic
B16.50
standards
covers
pressure
&
temperature
ratings,
Weldolet: Weldolets are used for making branches in the piping system.
The size of the weldolet specifies the size of the main line, size of the
branch line, schedule of the main line and schedule of the branch line
along with MOC.
Nippolet: Nippolets are also used for making branches in the piping system
but for small sizes and in particular for making drains and vents. The
rating of the Nippolet shall confirm to rating of the main line, along with
MOC.
Threadolet: Threadolets are also used for making branches in the piping
system but for small sizes and in particular for making openings for fixing
Thermo-well etc. The rating of the Threadolet shall confirm to rating of the
main line, along with MOC.
Letrolet: Lettrolets are used for making branches in the piping system at
the Elbows for small sizes and in particular for fixing thermo well etc threaded
letrolets are used. The rating of the letrolet shall confirm to rating of the main line,
along with MOC. Butwelded letrolets are also known as elbolets.
Sweepolet Sweepolet are used for making branches in the piping system
without reinforncing. The size of the sweepolet specifies the size of the
main line, size of the branch line, schedule of the main line and schedule
of the branch line along with MOC. Both joints are Butt Weld joints
VALVES:
Valves are basically used to allow or restrict flow of fluid in the piping as
per process requirement. There are various type of valves which are used
for specific services in industries. End connection of these valves may be
with flanges or welded end. Welding end may be Butt weld type or socket
weld type. For socket weld valves the min. class for any type of valves is
800lb. However for flanged valves the classes are based on the flange
classes. E.g. 150#, 300#, 600#, 900#, 1500# and 2500# etc.
GATE VALVE:-Gate Valves are specifically intended for use as isolation
applications. These valves creating minimum pressure drops across them
and they are used for ON and OFF applications. Although they can be used
for throttling but the service life gets reduced due to wear out seats.
GLOBE VALVE :-
the disc only needs to move a small distance from its seat to allow full
flow but due to change in direction in flow, resistance to flow increases
and this also generates turbulence in the flow. This results in a higher
pressure drop across globe valves than gate valve. These valves are used
to control the flow in the process lines.
Specification
1 Body
ASTM A105
2 Bonnet/Cap
ASTM A105
3 Stem
AISI 410
4 Gate/Disc
5 Body Seat
Ring*
6 Stem Packing
Graphite
7 Handwheel
8 Bolts/Studs
9 Gasket
International standards & codes followed for design of valve AP1-600 &
API-602 for valve design, ASME B16.10 for face to face dimension of
flange valves, API 598 for pressure testing of valves etc.
For any valve following are the main parts which plays important roll in its
performance.
1.
2.
3.
4.
5.
Seat
6.
7.
Gland Bush
8.
Yoke
9.
10.
Gland Flange
The material of construction of the above parts varies with the service
class of the valves and is generally standardized by the manufacturers.
The word TRIM in case of Valves means combination of seat and disc
(wetted portion) of valve and the gland packing. Trim number specify the
particular combination of disc/stem/and seat with gland packing will be
used. These are the most vulnerable parts of the valve and this defines
the performance of valve.
CHECK VALVES :-
NRV
DISC CHECHK VALVES :- The disc type check valve mainly use a spring
loaded disc which is seated on a seat due to spring force. The differential
pressure required to open the check valve is determined by the type of
the spring used. Where the differential pressure across the valve is small
no spring is used simply a disc with a stem works as check valve.
otherwise spring or Heavy duty spring are used.
STEM SEALING :-
and along the Stem of the valve, a barrier must be placed around the
stem for sealing. Stem sealing is generally achieved by providing gland