piping system 1

8/10/2019 Piping System 1

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PIPING SYSTEM Piping system in a chemical plantarecomparable to the veins and arteriesthroughwhich fluids, vapors, slurries, solids,etc.flow under various conditions, asby the process design of the plant. Piping design becomes morecomplex dueto corrosion, erosion, toxic conditionsandradio-activity. 2


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PIPING COSTSPiping contributes to a major part in any plant/ industry investment. Major e uipment ! "#$ Piping ! %&$ 'alance ! %($ )'uilding and *tructure,+oundation, lectrical, nstrumentation,Painting nsulation .

PIPING COSTSPiping contribution on office Man-hour basisto a major part in any plant / industryinvestment. Design Engineering !" Piping Engineering #$"

PIPING COSTSPiping contribution on field labour cost basis% Piping &" 'alance !(" )Major e*uipment+ 'uildingand ,tructure+ oundation+ Electrical+


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nstrumentation+ Painting nsulation0. 3-5

What a Piping Engineershould no! " Engineering 1no2ledge Mechanical+ electrical+

civil instrumentation. Engineering economics costs. Metallurgy Methods of pipe fabrication anderection. 3hemistry chemicalengineering. 3ommunication s1ill. ,tandards+ codes practices. ,afety codes and practices. Drafting procedures andpractices #

$


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%esponsi&ilit' o( a Piping

Engineer 4DE56437% Piping design must be ade*uateto meet the process specification and physicalconditions in 2hich the plant is to operate. E3898M7% 4de*uate design must beachieved at an economic cost 2ithin budget.Design costs must be minimi:ed byma;imi:ing the use of standardi:ed methods of

detailing and data presentation .

%esponsi&ilit' o( a PipingEngineer

) 37% Piping data for design derivedfromand used by other engineering dept. othersources must be clear+ consistent and

reliable. 4336=437% Details of Piping must beaccurate and complete. =ectification of mista1es at a latter stage may prove to bevery


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costly and can delay project completion. &-?

PIPING CO*ES +N*ST+N*+%*SFor Scientific design of piping system, selection ofproper material of construction and to detail outthe material specifications, knowledge of codes and standards areessential.

Each country has its own codes and standards. Onglobal basis, American National Standards is mostwidely used code and compliance with itsrequirements is accepted all o er. !ritish Standardsand "ndian Standards are also used for the designand selection of piping systems.

CO*ES +N* ST+N*+%*SCODE: A CODE IS A STD. THAT HAS BEEN ADOPTEDBY ONE OR MORE GOVERNMENTAL BODIES ANDHAS THE FORCE OF LAW. A SET OF RULES BACKEDUP BY PRINCIPLES OF SCIENCE AND EXPERIENCEOF PAST SAFE AND SUCCESSFUL USAGESSTANDARD:

A SET OF TECHNICAL DEFINITIONS ANDGUIDELINES, INSTRUCTIONS FOR DESIGNERS,MFRS. & USERS. IT IS A SYSTEM/DOCUMENT TO BEADOPTED BY OR USED BY THE PEOPLE WHO AREEXECUTING A PROJECT.


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EFFECTIVENESS OF WORKING TOCODES AND STDS.

>8 E,>4'< ,@ 38MM89 4A=EEME9> 9 E9A 9EE= 9A3= >E= 4+ >E=M,+ P= 93 P 3E,+ M4>E= 4EM,+ P=83E,,E,+ E>3. >8 87 6,4AE 8 E ,> 9A ,7,>EM >8 E3898M ,E >@E ,7,>EM >8 =ED63E 9CE9>8=7 >8 AE> =E4D7M4FE '43F6Pfrom mar1et 14

BODIES FOR CODES & STANDARDS 4,ME % 4ME= 349 ,83 E>7 8 ME3@49 34< E9A 9EE=, 49, % 4ME= 349 94> 894< ,>49D4=D, 9,> >6>E 4,>M % 4ME= 349 ,83 E>7 8 >E,> 9A 49D M4>E= 4< 4P % 4ME= 349 PE>=8 >6>E 4 , % 4ME= 349 =89 49D ,>EE< 9,> >6>E M,,-,P % M =. ,>D. ,83 E>7 8 C4> 9A, 9D. ', % '= > ,@ ,>49D4=D, 9,> > 89 ' , % '6=E46 8 9D 49 ,>49D4=D,

4B, % 4ME= 349 BE7 4BB4 % 4ME= 349 B4>E= B8=F, 4,,83 4> 89 D 9 % AE=ME9 ,>D. 4 98= % =E93@ ,>D. G , % G4P49E,E ,>D. ,8 % 9>E=94> 894< ,>49D4=4D, 8=A49 H4> 89


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PIPING E,EMENTS"n a process industry the transportation of materials in the fluidform from one place to another takes place by forcing the fluidthrough the piping system. #he piping system not only in ol espipes but also the fittings, al es and other specialties. #heseitemsare known as the piping components. $ode specifies the pipingsystem as the mechanical elements suitable for %oining orassemblyinto pressure&tight fluid&containing piping.#hese 'iping $omponents are as under(

P P , >> 9A, ,'8 9A 4EM, ,4 E>7 >EM,

PIPING E,EMENTSPIPING ELEMENT:

"# "S )EF"NE) AS AN* +A#E "A- O O /E01" E)

#O '-AN AN) "NS#A-- #2E '"'"N3 S*S#E+.#hese elements include design specifications,materials, components, supports, fabrication,inspection and testing.PIPING SPECIFICATION:

"# "S A )O$1+EN# S'E$"F*"N3 EA$2 OF #2E


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$O+'ONEN#S.

MATERIAL SELECTION OFPIPING COMPONENTS

!asically the material is selected based on its

ser ice. #hus the selection of piping materialsrequires knowledge of corrosion properties,strengthand engineering characteristics, relati e costand

a ailability.#he main process considerations in +O$selectionare fluid corrosion properties, pressure andtemperature conditions of the ser ice and thenature of the ser ice 4to5ic, olatile,e5plosi e, etc.6

01


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SPECIFICATION OFPIPINGCOMPONENTS

Any piping component isspecified by Item description Type of construction (weldedor seamless)

Material standard with grade Dimensional standard End connection End facing (if applicable) Datasheet reference (ifapplicable)

20


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PIPE) PIPE is spe i.ed &' its O* and thi ness#

) Thi ness is spe i.ed in s hedule nos#) Corrosion allo!an e is in luded in thethi ness#) Mill toleran e /0- 12#5 #) Pipe thi ness (or ula4 t 66666P *66666 / C2 7S E / P Y8

MOC9TYPE CS0+S0SS 9SM,S0WE,*E*

*IMN #ST* CS4 +NSI:3$#1;SS4 +NSI:3$#1


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EN*CONNECTION

:E= PE= >,G*=SC%EWE*=:?T%ESS=SPIGOT0SOC@E

T

PIPE:+SE* ON TAE METAO* O>M+N?>+CT?%E= PIPESC+N :E C,+SSI>IE* +SSE+M,ESSWE,*E* Ele tri %esistan e

Welded 7E%W8

Ele tri >usion Welding7E>W8Spiral Welded>urna e :utt Welded*ou&le Su& erged +rWelded 7S+W8

>O%GE*9:O%E*


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TYPES OF ENDCONNECTIONS

) SOC@ET WE,* PIPE BOINTS) :?TT WE,* PIPE BOINTS) SC%EWE* PIPE BOINTS) >,+NGE* EN* PIPE BOINTS) :?TT%ESS EN* PIPE BOINTS) SPIGOT SOC@ET EN* PIPE BOINTS

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SOCKET WELD ENDCONNECTION

ADVANTAGES:

a8 Easier align ent than &utt!elding#

&8 No !eld eta intrusion into&ore0hole#DISADVANTAGES:


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a8 The 101$ 71#$ MM8 re esspo ets liDuid#&8 ?se not per itted &' odei( Se ere Erosion orCre i e Corrosion isanti ipated#USE:

a8 General utilit' 9 ,P pipings'ste #&8 NPS &elo! 2 N:#

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BUTT WELD ENDCONNECTION

ADVANTAGES:

a8 Most pra ti al !a' o( Foining &ig &ore piping#


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&8 %elia&le lea proo( Foint#8 Boint an &e radiographed #

DISADVANTAGES:a8 Weld intrusion !ill a e tHo!#&8 End preparation is

ne essar'#USE:a8 NPS 2 N: 9 a&o e#&8 AP= AT= orrosi e 9erosi e ser i es#

2

SCREWED ENDCONNECTIONADVANTAGES:

! E "#$% '( ) "#)(.


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*! C + *( "(' - 1( ( ($'#+ #" + ) 3( #))(' ' ( ) -# (

1 4 '.DISADVANTAGES:! J #+) % $( 5 1(+ + ) 3 3( $% "( $('

*! U"( + ) 3( #))(' *% 6 '( #- "(7( (( "# +, 6 (7#6(6 "# +, "1 65 7#* )# + #" +)#6#3 )('.

6! S) (+ )1 - 3#3( #" (' 6(' " )1 ( '"(' 6( $$

)1#65+("".'! S( $ ($'#+ % *( (8 # ('.(! C '( "3(6#-#(' )1 ) "( $ ($'#+ "1 $$ + )

*( 6 +"#'( (' )6 +) #* )( - ") (+ )1 - 9 #+).USE:

! N + 6 #)#6 $ CW/ )#$#)% "%")( .2


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FLANGED ENDCONNECTION

ADVANTA E!"a 2sed for all process utility pipingwherefre uent bolting connections arere uired or the

joints need fre uent dismantling.b 3eliable lea4 proof joint when boltedproperly.DI!ADVANTA E!"a 5as4et need to be inserted properlyduring bolting.

b Prone to lea4age if any dirt/dust istrappedbetween flange and gas4et seating surface.#!E" 2sed at e uipments, valves special items wheremaintenance is a regular feature,brea4out flangesare provided at definite intervals on pipelines.


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31

PIPE FITTINGSE


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is reDuired ore o(ten as an alternati e to Hange# Itan ha e

threaded end or SW ends#J3-JJ

PIPE FITTINGSSW+GE NIPP,ES4) :S 3


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eLoti 0 ostl' aterials are used in piping #

J5-J$

PIPE FITTINGS

6 7897 :; 2sed for '6 branchconnection wherestandard tee is not available andthe piping is of critical/high pressure service.*93 ?897 :; 2sed for threadedbranch connection.7'967 :; 2sed for branch

connection on elbows andhave the profiles made to suit the

elbow.7?: 397 :; 2sed for branchconnection at an angle.


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FLANGES + @ *> * 33?: 8 + @ *>

*pecified when metallicgas4ets are used.

*pecified when nonmetallicgas4ets are used.

5as4et is comparativelysofter than flange material.

*piral or


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*pecified by ??3>)#-0%" micron max.

*pecified by ??3>)0%"-%"# micron

FLANGESS,IP-ON >,+NGE4) >orged !ith hu& or (a&ri ated (ro plate !ithouthu) Welded to pipe (ro inside 9 outside#SOC@ET WE,* >,+NGE4) Welded onl' on outside#

) Not appro ed &' I:%#) ?sed (or s all &ore pipes onl' 7:el ! 2 N:8o) Thi ness o( pipe to &e spe i.ed to ensure proper&oredi ensionSC%EWE*-ON >,+NGE4) ?sed !here !elding annot &e arried out#) ?sed (or !ater piping !or s #FLANGESWE,*ING-NEC@ >,+NGE4) :W to the pipe 9 hen e an &e radiographed#) ?sed (or riti al ser i es#) Thi ness o( the !elding end to &e spe i.ed#:,IN* >,+NGE4) ?sed to lose the pipe0eDuip ent ends !hi h needto &e

re-opened later#%E*?CING >,+NGE4) ?sed to onne t larger 9 s aller dia eter pipes!ithoutusing a redu er#


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) The thi ness o( the Hange !ith s allerdia eter shall &ethe sa e as that o( Hange !ith larger dia eter#

FLANGES

INTE%G%+, >,+NGES4) Cast along !ith the piping o ponent or theeDuip ent#) ?sed (or riti al ser i es#) Thi ness o( the !elding end to &e spe i.ed#) Thi ness o( integrall' ast Hanges a' di er(rostandard (orged Hanges#,ONG WE,*ING-NEC@ >,+NGE 9E P+N*E%0%E*?CE% >,+NGE4) *e eloped &' the anu(a turer to suitspe ialreDuire ents#

FLANGES

:+SE* ON P%ESS?%E-TEMPE%+T?%E %+TINGS4) In the standard +NSI :1$#5= the P-T rating

hart spe i('

the old non-sho pressure to !hi h theHange an &esu&Fe ted to at a parti ular te perature#) +NSI :1$#5 indi ates the allo!a&le pressures(or arious


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MOC#) Code does not re o end the use o( lass15; Hanges

a&o e J;; >#

GASKETSSE,ECTION4

Sele tion o( gas et depends upon the (ollo!ing(a tors4) Co pati&ilit' o( the gas et aterial !ith theHuid#) +&ilit' to !ithstand the pressure 9te perature o( thes'ste #

TYPE4Gas et is lassi.ed &ased on the t'pe o(

onstru tion4) >ull >a e) Inside :olt Cir le) Spiral Wound Metalli) %ing t'pe) Metal Ba etedGASKETSM+TE%I+,4Co onl' used aterial is C+> 7Co pressed+s&estos>i&re8


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C+> Gas et standard4 IS 2 12 K Three grades4) Gr# W01= W02 9 W034 Stea = al ali 9 generalappli ations

) Gr# +014 >or + id appli ation) Gr# O01= O02 9 O034 >or Oil appli ations) >or orrosi e ser i es= as&estos (ree gas etsare used#

The' are PT>E= C+> !ith PT>E en elop= G>T=%u&&er= et #) >or high te perature 9 high pressureappli ations= spiral!ound etalli gas ets are used#

GASKETSSPI%+, WO?N* G+S@ET4) The sele tion o( MOC (or !inding dependsupon the

orrosi e nature and on entration o( Huid= theoperatingte perature and the relati e ost# Co onl'used aterialis SS3;J= SS31$ 9 SS321 !ith as&estos .ller

aterial#) >or er' high te perature graphite .ller is

also used#) Pro ided !ith CS eLternal ring !hi h is alledas enteringring to position the gas et#


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) >or a uu ser i es= an internal gas et isalso pro ided#) Sur(a e roughness is 125-25; ++%A i rons#

%ING G+S@ET4) >or eLtre el' high pressure 9 te perature#) O al 7upto N:8 and O tagonal 7+&o e N:8) Gas et aterial is so(t as o pared to Hange

aterial#

VALVESQal es ontri&ute to -1; o( the total

apitaleLpenditure o( an' proFe t#Qal es are installed on eDuip ent0piping toper(oran' one o( the (ollo!ing (un tions4) Isolation#) %egulation#) Non-%eturn) Spe ial purpose#

VALVES

Qal e lassi. ation &ased on (un tions4

Isolation %egulation Non-return Spe ialpupose

Gate Glo&e Che ulti-port:all Needle >lush

&otto


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Plug :utter(' >loatPiston *iaphrag >oot

*iaphrag Piston ,ine &lind:utterH' Pi h @ni(e gatePi h

VALVESQal e lassi. ation &ased on operation4) Operated Qal es) Sel(-operated Qal es 7Che al es8Qal e lassi. ation &ased on end

onne tions4) S re!ed ends) So et Weld ends) >langed ends) :utt Weld ends) Wa(er t'pe ends) :uttress ends 7in glass piping8Qal e lassi. ation &ased on MOC4

TIPS FOR PIPING) CS aterial shall &e used (or te p# up toJ25 C 7 ;; >8#


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) ,TCS aterial to &e used (or te p# &elo!K2< C 7-2; >8) +S aterial shall &e used (or te p#a&o e J25 C 7 ;;>8) SS shall &e used (or orrosi e ser i es#Pro ess ,i ensorspe i. ation shall &e re(erred#) GI piping shall &e used (or ser i es li edrin ing !ater=instru ent air= ,P nitrogen= et #) Sele tion o( non- etalli and non-(errous aterials shall&e as per the re o endations o( thePro ess ,i ensor#) +ll the pipes arr'ing toLi 0Ha a&le

Huids shall &esea less#) ?tilit' piping an &e E%W or sea !elded#) Stea piping shall pre(era&l' &esea less#

piping system 1

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