CHAPTER: 1

INTRODUCTION

DEFINITION:
Piping engineering is all about designing, fabricating and constructing lines for conveying
fluids.

IMPORTANCE OF PIPING ENGINEERING:
To maintain pressure difference (p)
To maintain temperature difference (t)
To maintain flow rate (q)


APPLICATIONS:
Pipelines carry crude oil from oil wells to tank farms for storage or to refineries
for processing.
The natural gas transportation and distribution lines convey natural gas from the
source and storage tank forms to points of utilization, such as power plants,
industrial facilities etc,
In chemical plants, paper mills, food processing plants, and other similar
industrial establishments, the piping systems are utilized to carry liquids,
chemicals, mixtures, gases, vapors, and solids from one location to another.
The fire protection piping networks in residential, commercial, industrial, and
other buildings carry fire suppression fluids, such as water, gases, and chemicals to
provide protection of life and property.
The piping systems in thermal power plants convey high-pressure and high
temperature steam to generate electricity. Other piping systems in a power plant
transport high- and low-pressure water, chemicals, low-pressure steam, and
condensate.
Sophisticated piping systems are used to process and carry hazardous and toxic
substances.
The piping systems in laboratories carry gases, chemicals, vapors, and other
fluids that are critical for conducting research and development.

DEFINE PIPING
Piping is an assembly of pipe, fittings, valves, instruments and specialty components.
Piping is divided into three major categories:

Large bore pipe generally includes piping which is greater than two inches in
diameter.
Small bore pipe generally includes piping which is two inches and smaller in
diameter.
Tubing is supplied in sizes up to four inches in diameter but has a wall thickness less
than that of either large bore or small bore piping and is typically joined by
compression fittings.
Piping system includes:
Pipe
Fittings (e.g. elbows, reducers, branch connections, etc.)
Flanges, gaskets, bolting
Valves
Pipe supports

ASSOCIATION INVOLVED IN GENERATING CODES FOR PIPING DESIGN
ENGINEERING:

ASME
-American Society of Mechanical Engineers

ANSI
-American National Standardization Institute

These standards give technical recommendations for designing piping system for power plants
and chemical plants

They contain formulas to calculate the minimum thickness of pipelines
They contain formulas to calculate the extra thickness that a pipe must have when a branch
is cut into it.
They contain regulations for stress analysis
They contain tables that give maximum allowable stress for metallic materials accepted by
ANSI for pipeline construction depending on temperatures.


PIPING CODES:

ASME B31.1 - Power Piping
ASME B31.2 - Fuel Gas .Piping
ASME B31.3 - Process Piping
ASME B31.4 - Liquid Piping
ASME B31.5 - Refrigeration Piping
ASME B31.8 - Gas Distribution and Transportation
ASME B31.9 - Building Service Piping
ASME B31.11 - Slurry Piping


ASSOCIATION INVOLVED IN GENERATING MATERIAL SPECIFICATION FOR
PIPING:

ASTM
-American Society for Testing Materials

ASTM developed a collection of documents called material specifications for
standardising 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, aluminium 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

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.
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CHAPTER 2

PIPE

INTRODUCTION:

A pressure tight cylinder used to convey fluids under pressure through materials of
commercially available designation.
Pipe is always designated through nominal bore size(NBS) also called as nominal pipe
size(NPS)
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.

NOMINAL PIPE SIZE (NPS):
Pipe size is specified with two non-dimensional numbers: a Nominal Pipe Size (NPS) and a
schedule (SCH). The relationship of these numbers to the actual pipe dimensions is a bit
strange.

The NPS is very loosely related to the inside diameter in inches, but only for NPS 1/8 to NPS
12.

For NPS 14 and larger, the NPS is equal to the outside diameter (OD) in inches. For a given
NPS, the OD stays constant and the wall thickness increases with larger SCH. For a given
SCH, the OD increases with increasing NPS while the wall thickness increases or stays
constant.

NOMINAL DIAMETER (DN):
It is same as nominal pipe size, but in mm.

SCHEDULE (WALL THICKNESS):
Schedule:
Carbon steel : 5, 10, 20, 30, 40, 60, 80, 100, 120, 160.
Stainless steel : 5S, 10S, 20S, 30S, 40S, 60S, 80S.

Weight series:
STD : Standard
XS : Extra Strong
XXS : Double Extra Strong

Wall thickness is designated by schedule number or descriptive classification, rather than the
actual wall thickness. The original thicknesses were referred to as standard (STD), extra
strong (XS) and double extra strong (XXS).

Wall thickness for the schedule 40 and STD are same for sizes to [Link] 80 and XS
also have the same wall thickness for to 8 diameter pipe.

CODES:
ASME B36.10 - CARBON STEEL

ASME B36.19 - STAINLESS STEEL
MATERIAL:

Carbon steel:
Steel is basically a solution of carbon (C) into iron (Fe). The presences 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.

Carbon steel material specification ASTM A106 is available in grades A, B
and C. These refer to the tensile strength of the steel, with grade C having the highest
strength.
Common practice is to manufacture the pipe as A106 grade B

ASTM A53 is also commonly specified for galvanized or lined pipe or as an
alternate to [Link] testing requirement for A53 are less stringent(rigorous or tight) than for
A106. Three types of carbon steel pipe are covered by A53. These are type E or Electric
resistance welded, type F or Furnace-butt welded, and type S or Seamless. Type E and S are
available in grade A and B, comparable to grades A and B of A106.
Stainless steel:
Austenitic stainless steel pipe commonly referred to as Stainless Steel is
virtually non-magnetic. Stainless steel is manufactured in accordance with
ASTM A312 when 8 or smaller sizes are needed. There are eighteen different grades, of
which type 304L is the most widely used.

Grade 316L has high resistance to chemical and salt water corrosion and is
best suited for welding. Large sizes (8 and up) of stainless steel pipe are covered by ASTM
A358. Extra light wall thickness (schedule 5S) and light wall thickness (schedule 10S)
stainless steel pipe is covered byASTM A409.

PIPE MANUFACTURING METHOD:
Seamless
Hot rolled, cold drawn etc

Electric resistance welding
No material is added during welding process

Electric fusion welding
Filler material is added during welding process

CHARACTERISTICS OF A PIPELINE:
Nominal pipe size(NPS)
Wall thickness
Type of joint between pieces

Welded joints
Butt welded
Socket welded
Threaded joints
Flanged joints
External finishing
Painting
Insulation

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, and 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, but certain
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.




TYPE OF JOINT BETWEEN PIECES:

1. Butt welded joint:
The end is machined to allow head to head full penetrating welding


2. Socket welded joint:
A socket is provided where pipe can be inserted

3. Threaded joint:
Parts to be connected are threaded.


PIPE ENDS:
Pipe may be obtained with

Plain ends are cut square and reamed to remove burns. This
type of end is needed when being joined by mechanical couplings, socket weld
fittings, or slip-on flange.

Bevelled ends are required for most butt weld application.
Threaded ends are used with screwed joints and are ordered
noting threaded on both ends or one end.

Various combination of pipe end:
POE: Plain one end
PBE: Plain both end
BOE: Bevelled one end
BBE: Bevelled both end
TOE: Threaded one end
TBE: Threaded both end

PIPE REPRESENTATION:
Up to 12 inch




Above 14 inch




SPECIFICATION OF A PIPE:

Example:
Size : NPS 12

Diameter : DN 300

Wall thickness: Sch. 40

Material : ASTM A106 Gr. B
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CHAPTER-3
FLUID

INTRODUCTION:
It can be
A gas
A liquid
A mixture of gas or liquid
A suspension of small solid particles inside a liquid.

BASIC PROPERTIES OF CONVEYED FLUIDS:
Fluid type
Flow rate
Pressure
Temperature


FACTORS DEPENDING UPON FLUID TYPE:

1. MATERIAL:
a. Non corrosive fluids: Services where impurities are accepted
Example:
Industrial water lines (cooling water)
Steam
Lube oil return / before filter lines
Air lines
Vents and drains
Material:
Carbon Steel
Low Alloy Steel (High T)
b. Corrosive fluids: Services where impurities are not accepted
Example:
Demineralized water
Lube oil after filters
Fuel gas / oil
Sea water (water containing Chlorine)
Material:
Stainless Steel
No Iron (Fe)
Copper/Nickel Alloys (Cu-Ni)
c. Aggressive Chemicals
Example
Strong Acids / Bases
Material:
Plastic: PVC TEFLON PE
Rubber: NBR, Viton
Composites: RESIN GLASS
2. CORROSION ALLOWANCES:
Thickness of the pipe increases with respect to corrosion. Typical corrosion allowance
for water is 3mm.

3. TYPE OF JOINT:
Dangerous fluids are conveyed in fully welded pipes, were leaks are not accepted.

4. TESTING AND EXAMINATION:
For Dangerous Fluids 100% of joints are likely to be X-Ray examined


FACTORS DEPENDING UPON FLOWRATE:
1. 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 (v2).
Vibration of the pipeline.

Usual velocities of fluids inside pipelines are:
Gas: 20 m/s - max. 40 / 50 m/sec.
Liquid: 2 to 4 m/s - max. 10 m/sec.


FACTORS DEPENDING UPON PRESSURE:
1. WALL THICKNESS CALCULATION
2. TYPE OF JOINT
Low pressure pipelines can be threaded or socket welded
High Pressure pipelines are Butt Welded
3. TESTING AND EXAMINATION:
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.

FACTORS DEPENDING UPON TEMPERATURE:
1. MATERIAL:
Steel for High Temperature (Low Alloy Steel Creep Resistant)
2. WALL THICKNESS CALCULATION
3. THERMAL INSULATION:
T>60C Insulation for Personnel Protection is mandatory for all pipeline parts
that can be reached by hands.
4. 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.



FLUID SERVICE CATEGORIES:
B31.3 recognizes the following fluid service categories and a special design consideration
based on pressure. It is the owners responsibility to specify the fluid service category for
each piping system. With the fluid service category known, then the designer can make
material and component selection, as well as employ the code required fabrication and
inspection requirements based on the selected fluid category. These fluid categories and
pressure concern are:

1. Normal fluid service
2. Category D fluid service
3. Category M fluid service
4. High pressure piping
5. Severe cyclic conditions

Category D Fluid Service is defined as all fluid services that are:
Nonflammable
Nontoxic
Not damaging to human tissues
The design gage pressure does not exceed 150 psig
The design temperature is from -20 f to 366 f is the saturated temperature of
steam at 150psig

Category M Fluid Service is defined as a service in which a single exposure to a very small
quantity of toxic fluid can produce serious irreversible harm to person on breathing or bodily
contact, even when prompt restorative are taken.

The Normal Fluid Service is defined as all other fluid services that are not category D and
category M

High Pressure Piping Service is defined as that in which the pressure is in excess of that
allowed by the ASME B16.5 2500 flange class ratings.

PIPING SYSTEM CORROSION:

General or Uniform Corrosion:
Uniform metal loss. May be combined with erosion if high velocity fluids, or moving fluids
containing abrasives.

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

Galvanic Corrosion:
Occurs when two dissimilar metals contacts each other in corrosive electrolytic
environment.

Concentration Cell Corrosion:
Occurs when different concentration of either a corrosive fluid or dissolved oxygen contacts
areas of same metal.

Crevice Corrosion:
Localized corrosion similar to pitting.
Occurs at places such as gaskets, lap joint, and bolts where crevice exists.
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