CM4120

Unit Operations Lab

Piping Systems

Piping Systems in the Chemical

Process Industries
March, 2009

Introduction
Basis for Design
Piping Codes and Standards
Design of Process Piping Systems
Joints and Fittings
Valves
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Piping Systems

Piping Systems include:

Pipe, Flanges, Fittings

Bolting, Gaskets
Valves
Hangers and Supports
Insulations, Coverings,
Coatings
Heat Tracing

CM4120
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Piping Systems

Piping systems are like arteries and

veins. They carry the lifeblood of
modern civilization.
Mohinder Nayyar, P.E.
Piping Handbook, 7th ed.
McGraw-Hill, 2000

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Primary Design Consideration is

Safety
Evaluate Process Conditions

Temperature
Pressure
Chemical compatibility/Corrosion allowances
Vibration, flexing, bending
Expansion/Contraction due to temperature
change
Environmental conditions

Evaluate the Effects of a Leak

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Piping Systems

Secondary Considerations
Evaluate any Special Requirements

Sanitary requirements Cleanability

Serviceability ease of maintenance of
equipment
Possible contamination of process fluid by
piping materials, sealants, or gasketing
Earthquake, Hurricane, Lightening,
Permafrost

Lowest Cost over the Lifetime

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Piping System Routing and Layout

The unwritten #1 rule:

Serviceability/Operability
UO Lab

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Piping System Design Criteria

4 areas to consider:

Physical Attributes
Loading and Service Conditions
Environmental Factors
Materials-Related Considerations

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Codes and Standards simplify

design, manufacturing, installation
process
Standards provide design criteria for
components

standard sizes for pipe

dimensions for fittings or valves

Codes specific design/fabrication

methodologies

Incorporated into local/regional statute

8
Its the LAW

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ASME Boiler and Pressure Vessel Code
ASME B31: Code for Pressure Piping
ANSI Standards dimensions for valves,
piping, fittings, nuts/washers, etc.
ASTM Standards for piping and tube
API Specs for pipe and pipelines
AWS, ASHRAE, NFPA, PPI, UL, etc.

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Piping Systems

ASME B31 Pertinent sections

B31.1
B31.3
piping
B31.4
B31.7
fluids

Power plant boilers

Chemical plant and refinery
Liquid petroleum transport
Nuclear power plant radioactive

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ASME B31.3 Chemical Plant and

Refinery Piping Code
Includes piping systems in:
Chemical and refinery plants
Pharmaceutical and food processing
Textile and paper plants
Boilers

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ASME B31.3 covers:

Materials of construction
Piping design process
Fabrication, Erection, Assembly
Design of supports
Examination, inspection, and testing

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Piping Design Process a three step

approach
1. Design for Flow

Find min. diameter to achieve desired flow

velocity

2. Design for Pressure Integrity

Find min. wall thickness for process and

external conditions
Find appropriate rating of in-line
components

3. Re-check for Flow Criteria

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Standard Pipe Sizes

Diameters are Nominal

Sizes 12 and less, nominal size < OD

Sizes 14 and over, nominal size = OD

Wall thickness inferred thru Schedule

Defined Schedules:
5, 10, 20, 30, 40, 60, 80, 100, 120, 140,
160

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Standard Tubing Sizes

Steel tubing

Diameters are Actual OD

Wall thickness is specified

Refrigeration Tubing

Single wall thickness available for each size

Actual OD

Copper Tubing Nominal sizes

Type K, L, M
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Criteria for Design for Flow

Economics
Serviceable over Design Life
Smallest diameter usually is lowest cost

Performance
Minimum entrainment velocity
Prevent erosion or cavitation

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Design Rules of Thumb when sizing for
velocity...
Water lines: 3-10 ft/sec
Pump discharge: 3-12 ft/sec
Pump suction: (1/3 x discharge velocity)
Steam: low pressure (25 psig or less) 50-100
ft/sec
high pressure (>100 psig) 100-200
ft/sec
Slurries: > min. entrainment velocity
from Peters and Timmerhaus, Plant Design17and
th

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Piping Systems

Selecting appropriate pipe Schedule

Schedule = P/S * 1000

P = max. working pressure of pipe, psig
S = allowable stress in piping material, psi
For carbon steel pipe, S = 36,000 psi

What is max. working pressure for

Schedule 40 Carbon Steel pipe?

40 * 36,000
P
1440 psig
1000
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Piping Systems

Determine min. reqd wall thickness:

Pressure Integrity Design Method
ASME B31.3,

PD
tm
A
2 SE Py
tm=min. wall thickness
P=design pressure, psig
D=O.D. of pipe, in.
S=allowable stress, psi

E=weld joint efficiency

y=factor to adjust for temp
A= addl thickness for
corrosion, external loads,
etc.
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After determining wall thickness:
Re-check ID for velocity;
Select in-line components;
Determine insulation, coverings,
coatings;
Design and locate supports and
hangers.
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Inline Components:
Fittings
Valves
Gaskets, Seals, and Thread Sealants
Connection Hardware Bolts, studs,
nuts, washers

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Pipe Fittings - Steel

Forged
Cast
Malleable Iron

Select Class of Fittings

150 lb., 300 lb., 600 lb., etc.

Need a look-up table to determine
max. allowable P at the design
temperature
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Ratings for flanged steel pipe fittings, ANSI B16.5
- Maximum
1988.
Allowable non-shock Pressure (psig)
Pressure Class Rating for Flanged Fittings (lb)
Temperature
(oF)

150

300

400

600

900

1500

2500

Hydrostatic Test Pressure (psig)

450

1125

1500

2225

3350

5575

9275

-20 to 100

285

740

990

1480

2220

3705

6170

200

260

675

900

1350

2025

3375

5625

300

230

655

875

1315

1970

3280

5470

400

200

635

845

1270

1900

3170

5280

500

170

600

800

1200

1795

2995

4990

600

140

550

730

1095

1640

2735

4560

650

125

535

715

1075

1610

2685

4475

700

110

535

710

1065

1600

2665

4440

750

95

505

670

1010

1510

2520

4200

800

80

410

550

825

1235

2060

3430

850

65

270

355

535

805

1340

2230

900

50

170

230

345

515

860

1430

950

35

105

140

205

310

515

860

1000

20

50

70

105

155

260

430

http://www.engineeringtoolbox.com/ansi-flanges-pressure-temperature23
d_342.html

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Piping Systems
Design Checklist:
Re-check ID for velocity;
Select in-line components;
Determine insulation, coverings,
coatings;
Design and locate supports and
hangers.
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Piping Insulation
Prevent heat loss/ gain
Prevent condensation below ambient
Personnel protection over 125oF
Freeze protection outdoor cold
climates
Fire protection
Noise control
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Recommended minimum Thickness of Insulation (inches)*
Temperature Range (oC)
50 - 90
Nominal Pipe Size
NPS
(inches)

90 - 120

120 - 150

150 - 230

Temperature Range (oF)

120 - 200

201 - 250

251 - 305

306 - 450

Hot Water

Low Pressure
Steam

Medium Pressure
Steam

High Pressure
Steam

< 1"

1.0

1.5

2.0

2.5

1 1/4" - 2"

1.0

1.5

2.5

2.5

2 1/2" - 4"

1.5

2.0

2.5

3.0

5" - 6"

1.5

2.0

3.0

3.5

> 8"

1.5

2.0

3.0

3.5

* based on insulation with thermal resistivity in the range 4 - 4.6 ft2 hr oF/ Btu in
Source: Engineering Toolbox,
http://www.engineeringtoolbox.com/pipes-insulation-thickness-d_16.html, 3-26-2009

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Common Types of Insulation

Mineral Fiber

Fiberglas
Rock wool
Cellular glass
(Asbestos or Asbestos-containing)

Polymeric closed cell foams

Flexible polyethylene
Rigid foam polystyrene, polyurethanes
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Fiberglass Insulation w/ Asbestosplastered fitting coverings

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Piping Systems
Metal Jacketed
insulation
covering

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Piping Systems
After determining wall thickness:
Re-check ID for velocity;
Select in-line components;
Determine insulation, coverings,
coatings;
Design and locate supports and
hangers.
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Piping Systems

Piping
Supports

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Piping Systems

Supports
Prevent strain at connections
Prevent sag
Allow for expansion/contraction
Design for wind, snow/ice, earthquake
Provide clearance for plant
traffic/equipment

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Piping Systems
Steel Pipe - Distance between Supports (ft)
Outside Diameter
(in)

Horizontal Run

Vertical Run

1/2

4.5

10

3/4

7.5

10

7.5

10

1 1/4

7.5

12

1 1/2

7.5

12

7.5

15

2 1/2

10

15

10

15

10

18

Source: Engineering Toolbox,

http://www.engineeringtoolbox.com/steel-pipe-supports-d_1071.html, 2-26-09

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Piping Systems
Inadequate support

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Effect of Thermal Expansion on

piping and supports
Example 1:
Calculate the expansion per 20 length of
2, schedule 40 carbon steel steam line
at boiler startup for a 100 psig steam
service.
=thermal expansion coefficient
for mild steel, =6.6x10-6 in/inoF
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Temp of pipe at amb. cond. =70oF
Temp of 100 psig sat. steam =338oF
T=268oF
L=20=240
expansion due to temperature
increase is *L* T
=(6.6x10-6in/inoF)*(240in)*(268oF)
=0.42 in per 20 of pipe

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Example 2:
What force is exerted on the end
restraints of that 20 pipe if it is rigidly
installed (end restraints cant move)?
=internal stress due to T, and
= *(T)*E
E is the material property called Modulus
of Elasticity, relationship between stress
and strain
E=30x106 psi for low carbon steel
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= *(T)*E
=(6.6x10-6 in/inoF)*(268oF)*(30x106lbf/in2)
=53,000 lbf/in2
since =F/A,
The force on the end restraints is F=*A
where: F=force in lbf
A=cross sec. area of 2, sched 40
pipe in sq. inches
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A=(OD2-ID2)/4
= (2.3752-2.0672)/4
=1.07 sq.in
F= *A
=(53,000 lbf/in2)*(1.07 in2)

Force on the end restraints =

57,000 lbf
or 28.5 tons
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Piping Systems
Results of inadequate support:
Flixborough, England
May, 1974 Leaking reactor #5 removed from
train of 6 reactors and temporarily replaced
with a section of 20 pipe. Pipe is supported
by scaffolding.
June 1, 1974 Supports collapse, pipe breaks
28 dead, 89 injured, 1800 houses damaged,
160 shops and factories damaged, large
crater where plant stood
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Heat Tracing

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Heat Tracing
Prevents flow problems in cold climates

Freeze protection
Loss of flow due to viscosity increase

Prevent condensation in vapor lines

Methods

Electric
Hot Fluids

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References:
Piping Handbook, 7th ed., Nayyar, McGraw-Hill,
New York, 2000.
Plant Desing and Economics for Chemical
Engineers, 4th ed., Peters and Timmerhaus,
McGraw-Hill, 1991.
Valve Handbook, Skousen, McGraw-Hill, New
York, 1998
www.flowserve.com, Flowserve Corp., Sept.
2004.
www.engineeringtoolbox.com, The Engineering
Toolbox, Sept. 2004.
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Materials Metallic piping

Carbon and low alloy steel

Ductile
Inexpensive and available
Easy to machine, weld, cut
Some drawbacks

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Materials Metallic piping

Alloy Steels including Stainless Steels

Good corrosion resistance

More difficult to machine, weld, cut
Some drawbacks

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Materials Metallic piping

Nickel, Titanium, Copper, etc.

Copper is used in residential and

commercial applications and is widely
available
Other materials are expensive and difficult
to machine, weld, join
Some incompatibilities with each

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Materials Non-Metallic piping

Thermoplastics

Wide range of chemical compatibility

Light weight
Easily cut and joined
Low temperature limits
Need extra supports

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Piping Systems

Materials Non-Metallic piping

Fiberglass Reinforced Pipe

Wide range of chemical compatibility

Easily cut and joined
Wider temperature limits than thermoplastics
Thermal expansion similar to carbon steel
Similar structural performance as carbon steel

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Materials Others
Glass
Concrete
Lined or coated

Glass
Rubber
Cement
Teflon
Zinc (galvanized pipe)

Double Containment piping systems

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Piping Systems

Pipe Joints

Threaded
Welded
Soldered/ Brazed
Glued
Compression
Bell and spigot
Upset or expanded

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Threaded joints

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Soldered joints

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Welded joints

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Compression joints

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Mechanical joints
shown on glass drain piping system

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Piping Systems
Fittings for joining 2
sections of pipe:
Coupling
Reducing
Coupling
Union
Flange

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Piping Systems
Fittings for
changing
directions in pipe:
45o Ell
90o Ell
Street Ell
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Piping Systems
Fittings for
adding a
branch in a run
of piping:
Tee
Cross

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Piping Systems
Fittings for blocking
the end of a run
of piping:
Pipe plug
Pipe cap
Blind Flange
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Misc. pipe fittings:
Nipple
Reducing bushing

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Piping Systems
Gate Valve:
Used to block
flow (on/off
service)

Sliding gate
on knife-gate
valve
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Globe Valve:
Used to
regulate flow
Cut-away shows
stem seal
plug
and seat

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Ball Valve:
Typically used
as block
valve
Quarter-turn
valve
Cut-away shows
ball and seat
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Butterfly
Valve:
Can be used for
flow control or
on/off
Valve actuator/
positioner for
accurate flow
control
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Check Valves:
Used to prevent
backflow
Piston check
Swing check

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