Piping Basics

Mechanical Engineering – Piping.
By. Pornlert W. / Mechanical Engineer.

Date : 30 June 2012
Time : 10:00 – 12:00
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MECHANICAL ENGINEERING – PIPING.
• CONTENT;
– BASIC OF PIPING AND PIPING COMPONENTS.

– PIPING DESIGN.
– PIPE STRESS ANALYSIS AND PIPE SUPPORT DESIGN.
– FABRICATION,WELDING AND TESTING.
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• BASIC OF PIPING AND PIPING COMPONENTS.

What is PIPING SYSTEM ?
Pipe sections when joined with fittings, valves, and other mechanical
equipment and properly supported by hangers and supports, are called piping
Piping refers to the overall network of pipes, fittings, flanges, valves and
other components that comprise a conduit system used to convey fluids.
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• BASIC OF PIPING AND PIPING COMPONENTS

Piping system is used to simply convey fluids from one point to another or
to process and condition the fluid, piping components serve an important role in the
composition and operation of the system.
Simple piping components

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GENERAL USES OF PIPING
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- Plumbing (Commercial piping)
These are installed in commercial buildings, schools, hospitals, residences,
house, etc for distributing water and fuel gases, for collecting waste water, and for
other purposes.
- Civil piping
This is used to distribute public utilities (water, fuel gases) and to collect
rainwater and industrial waste waters. Most piping of this type is placed underground.
- Transportation piping
Normally large-diameter piping is used to convey liquids, slurries and gas,
sometimes over hundreds of kilometers. Crude oils, petroleum products and etc are
transported thru pipeline.
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- Marine piping
For ships is often extensive. Much of it is fabricated from welded and screwed
carbon steel piping.
Piping is used to transfer the liquid to/from the ship (loading/unloading). It is
also use to convey liquid from/to one compartment to another.
- Process and Utility (Industrial piping)
Piping is used in industrial (Oil refinery Plant Petrochemical Plant , Power Plant,
etc). Process piping is used to transport fluids in processing units. Utility piping is used to
convey stream, air, water, etc. for processing units.
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What is the difference between PIPE and TUBE ?
Tube
is customarily specified by Outside Diameter (OD) and wall thickness, expressed either
in BWG (Birmingham wire gage) or in thousandths of an inch.
The principal uses for tube are in heat exchangers, instrument lines, and small
interconnections on equipment such as compressors, boilers, and refrigerators.
Pipe
is customarily identified by Nominal Pipe Size (NPS) with wall thickness defined by
Manufacturers’ Weight, Schedule number, or API designation.
1. ASME - Manufacturers’ Weight (STD, XS, XXS)
2. ANSI - Schedule number (Sch.40, Sch.10S, etc)
3. API - API designation (API 5L Grade: B, X42, etc.)
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Tube
BWG
Outside 22 20 18 16 14 12 10
diameter Wall thickness mm
0.71 0.89 1.24 1.65 2.11 2.77 3.40
mm inches Weight kg/m
9.53 3/8 0.157 0.193 0.257
12.7 1/2 0.214 0.263 0.356 0.457
15.88 5/8 0.271 0.334 0.455 0.588
19.05 3/4 0.327 0.405 0.553 0.729 0.895
25.4 1 0.44 0.546 0.75 0.981 1.234 1.574
31.75 1 1/4 0.554 0.688 0.947 1.244 1.574 2.014
Pipe
38.1 1 1/2 0.667 0.832 1.144 1.514 1.904 2.454
44.5 1 3/4 1.342 1.774 2.244 2.894 3.5
50.8 2 1.549 2.034 2.574 3.334 4.03
63.5 2 1/2 1.949 2.554 3.244 4.214 5.13
76.2 3 2.345 3.084 3.914 5.094 6.19
88.9 3 1/2 2.729 3.609 4.584 5.974 7.27
101.6 4 4.134 5.254 6.854 8.35
114.3 4 1/2 4.654 5.924 7.734 9.43
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PIPE  Pipe Size
Pipe size is determined by the design requirements of flow rate and head loss.
Nominal pipe size (NPS) is a dimensionless designator of pipe size. It indicates
standard pipe size when followed by the specific size designation number without an inch
symbol.
Diameter nominal (DN) is also a dimensionless designator of pipe size in the metric
unit system, developed by the International Standards Organization (ISO).
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PIPE  Pipe Wall Thickness
Schedule is expressed in numbers (5, 5S, 10, 10S, 20, 20S, 30, 40, 40S, 60, 80,
80S, 100, 120, 140, 160). The higher the schedule number, the thicker the pipe is. The outside
diameter of each pipe size is standardized. But inside diameter depending upon the schedule
number specified.
NPS 10 and smaller  SCH 40 same as STD
NPS 8 and smaller  SCH 80 same as XS
Carbon Steel Pipe
SCH without S  ASME B36.10
Ex. SCH 5, SCH 10, SCH 40 …
Stainless Steel Pipe
SCH letter S  ASME B36.19
Ex. SCH 5S, SCH 10S, SCH 40S …
Note. Letter S may or may not be the same as that specified
by a schedule number without the letter S.
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PIPE  Example Pipe Size and Pipe Wall Thickness
ID = 4.026”
OD = 4.5”
ID = 3.826”
Ex.1 NPS 4 SCH40 Ex.2 NPS 4 SCH80
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PIPE  Size, Lengths and Connections
Pipe size normally stocked include : 1/2, 3/4, 1, 1-1/4, 1-1/2, 2, 2-1/2, 3, 3-1/2, 4,
6, 8, 10, 12, 14, 16, 20, 24 inch
Straight pipe is supplied in ‘Random’ length 17-25 ft (6 m.) ‘Double random’
length 38-48 ft (12 m.)
Thread End (TE) Plain End (PE) Bevel End (BE)

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PIPE  Manufacturer
Steel piping is classified according to the manufacturing method as follow
Steel and malleable iron*
- Seamless (SMLS)*
- Electric resistance welded (ERW)*
- Submerged arc-welded (SAW)*
- Gas metal arc-welded (GMAW)*
- Double submerged are-welded*
- Furnace butt-welded
- Electric fusion arc-welded
- Spiral welded
- Electric flash-welded
- Furnace lap-welded
Cast iron pipe
- Centrifugally cast
- Concentric mold
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PIPE  Manufacturer – Seamless (SMLS)
Cast Round Billets Round Reheating Rotary Piercing Mill Mandrel Mill
Batch Saws Cooling Bed Stretch Reducing Mill Shell Reheating
If req.
Heat Treating
Finishing
NDT Inspection In-Process Storage

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PIPE  Manufacturer – Seamless (SMLS)
Straightening NDT Inspection End Finishing
Final Inspection Hydrostatic Testing
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PIPE  Manufacturer – Electric Resistance Welded (ERW)
Coil Feed Ramp First Forming Section Fin Pass Section
Seam Normalizer Non-Destructive Inspection High Frequency Welder
Hydrostatic Testing
Sizing Mill Flying Cut-Off
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PIPE  Manufacturer – Electric Resistance Welded (ERW)
Straightening Non-Destructive Inspection Cut-Off Facilities
Final Inspection Facing and Beveling
Stock
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PIPE  Manufacturer – Seamless Pipe
Seamless
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PIPE  Manufacturer – Seam Welded Pipe
Electric resistance welded (ERW)
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PIPE  Manufacturer – Seam Welded Pipe
Spiral welded
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PIPE  Material
Pipes are made in a number of materials, the particular one chosen being
dependent upon pressure, temperature, resistance to corrosion, cost etc.
The most commonly used is carbon steel and for process work, this is normally
of seamless construction.
Other metals and alloys are sometimes used although they tend to be more
expensive. Traditionally, corer and copper alloys were used for instrument lines although
they have largely been replaced by stainless steel. They are still used for heat transfer
equipment because of their high thermal conductivity.
Pipe can be lined or coated with materials such as vitreous substances, to

provide resistance to chemical attack, corrosion, etc.
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PIPE  Material (most commonly used)
- A53
- A106
- API 5L
Carbon steel
- A333 (Low Temp.)
- A671 (Large Dia.)
- A672 (Large Dia.)
- A312
- A358 (Large Dia.)
Stainless steel
- A409 (Large Dia.)
- A790 (Duplex)
- A335
Alloy steel
- A691 (Large Dia.)
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What is FITTINGS ?
Fitting permit a change in direction of piping, change in diameter of pipe, joint
pipe, branch to made from the main run of pipe and end closure.
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FITTING  Change in Direction
Elbow Make 90 degree or 45 degree change in direction of the run of pipe.
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Elbow
90 Long Radius Elbow (LR) 90 Short Radius Elbow (SR)
Provide a change in direction Uses when space limitations do
with a reasonably priced fitting that has a not allow use of long radius
relatively low pressure loss.
R = 1.0xNPS
R = 1.5xNPS
R = 1.0x4
R = 1.5x4
R = 4 inch
R = 6 inch
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Reducing Elbow
90 degree change in direction with a change in line size. Have a centreline
radius of curvature 1.5 times NPS to be attached to the larger end.
Reducing Elbow Degree Elbow
30o
Degree of Elbow
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Bends
Made from straight pipe. Common bending radii 3 and 5 times NPS (3D bend /
5D bend). Only seamless or electric resistance welded pipe is suitable for bending and
prefer hot bending to make larger radius bends. Often used for pipeline which require
pigging operation
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FITTING  Change in Diameter
Reducer
Joins a larger pipe to a smaller pipe. The two available types, concentric
and eccentric. The eccentric used when it is necessary to keep the top or the bottom
of the line level.
Concentric reducer Eccentric reducer
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Reducer - Example
Concentric reducer (Vertical line) Eccentric reducer – Top Flat (TF)
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Reducer - Example
Eccentric reducer – Bottom Flat (BF) on Piperack Eccentric reducer at Control Valve
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Reducer - Example
Eccentric reducer in Suction Line.

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Swage
Used to connect butt welded piping to smaller screwed or socket welded
piping. Used as an alternative to the reducer when greater reductions in line size
required. Regular swages in concentric or eccentric form give an abrupt change in line
size, as do reducers.
Swage
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Swage
Large End Small End
Both End Large End Small End

TBE : Threaded Both End TLE : Threaded Large End TSE : Threaded Small End
PBE : Plain Both End PLE : Plain Large End PSE : Plain Small End
BBE : Bevel Both End BLE : Bevel Large End BSE : Bevel Small End
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FITTING  Joint pipe
Coupling
Couplings extend a run by joining two lengths of pipe (Full Coupling). They
are known as Reduced Coupling if they are used to connect pipes of different sizes.
Coupling
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Coupling - Example
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Union
Union is a type of fitting equipment designed in such a way to unite two pipes
which can be detached without causing any deformation to the pipes. Any kind of small
diameter piping connections requiring a positive seal and easy assembly as well as
disassembly are made with the help of union.
Union (Assembly) Union (Disassembly)

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FITTING  Branch
Stub-In / Stub-On
Team for a branch pipe welded directly into the side of the main pipe run – it
is not a fitting. This is the commonest and least expensive method of welding a full size
or reducing branch for pipe 2 inch and larger.
Stub-On Stub-In
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FITTING  Branch
Stub-In / Stub-On Example
Vent and Test Hole
Without Reinforcement Pad With Reinforcement Pad
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FITTING  Branch
Tee
Make 90 degree branches from the main run of pipe. Straight (Equal) tees
have branch the same size as the run . Reducing tees have branch smaller than the run.
Straight (Equal) Tee (BW) Reducing Tee Straight Tee (SW) Reducing Tee (Thrd.)
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FITTING  Branch
Olet
These fittings offer an alternative means of connecting into the main run pipe, and do not
require reinforcement. Forged fitting shaped to provide a bevelled end prepared for
welding to a larger diameter pipe.
Weldolet Sockolet Threadolet

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FITTING  Branch
Olet
Elbolet - Make a reducing tangent branch on long radius and short radius elbows.
Latrolet - Make a 45 degree reducing branch on straight pipe.
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FITTING  Branch
Olet Nipolet a variant of the sockolet or threadolet, having integral plain nipple
(For sockolet) or threaded (For threadolet) nipple. Primarily developed for small valve
connection.
PE TE
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FITTING  Branch
Olet (Example)
Threadolet
Weldolet
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FITTING  Branch
Half Coupling
The full-coupling is not used for branching or for vessel connections, as the
haft-coupling is the same length and is stronger. The haft-coupling permits 90 degree
entry into a larger pipe or vessel wall.
Full Coupling Haft Coupling

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FITTING  Branch
Lateral
Permits odd-angled entry into the pipe run where low resistance to flow is
importance. Straight laterals with branch bore equal to run bore are available in STD and
XS weight.
Lateral
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FITTING  End Closure
Cap
Is used to seal the end of pipe. Ellipsoidal Heads are used to close pipe of
large diameter, and are similar to those used for constructing vessels.
Cap (BW) Cap (THRD) Cap (SW)

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Plug
Seals the threaded end of a fitting, valve, etc. These pipe plugs come in one
piece body design and the easy to replace plug assembly make these industrial pipe
fittings very easy to maintain and clean.
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Plug (Example)
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What is FLANGES ?
Used to connect with piping component that are flange type, for example
valve, orifice flanges, inline-instruments, fitting, pumps and other equipment etc.
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FLANGE  Advantageous / Disadvantageous
Advantageous
- The components cannot be serviced in line.
- The components being joined are not capable of being welded.
- Quick field assembly is required.
- The component or pipe section must be frequently removed for service.
Disadvantageous
- Very expensive when compare with other connection.
- Heavy Weight.
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FLANGE  Flange Description
“A”
Bolt Circle
Flange End Flange Facing
“A” View “A-A”

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FLANGE  Flange Facings & Finishes
Many facings for flanges are offered by flange manufacturers, including
“tongue-and-groove” type which must be used in pairs. However only four types of facing
are widely used.
Raised Face Flat Face
Ring Joint
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FLANGE  Flange Facings : Raised Face (RF)
The raised face is used for about 80% of all flanges. The
Raised Face (RF) is 1/16 inch high for Ctasses 150 and 300
flanges, and 1/4 inch high for all other classes.
FLANGE  Flange Facings : Flat Face (FF)

Most common uses are for mating with non-steel
flange on bodies of pumps, etc. and for mating with Class
125 cast-iron valves and fittings.
The Flat Faced (FF) are used with a gasket
whose outer diameter equals that of the flange
This reduces the danger of cracking a cast
iron, bronze or plastic flange when the assembly is
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FLANGE  Flange Facing : Ring Type Joint (RTJ)
More expensive facing, and considered the most

efficient for high temperature and high pressure service.
Facing is not pore to damage in handling as the
surfaces in contact with the gasket are recessed.
FLANGE  Flange Facings : Lap Joint (LJ)
Shaped to accommodate the stub end. Lap joint

(LJ) combination of flange and stub end presents similar
geometry to the raised face flange and can be used where
severe bending will not occur.
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FLANGE  Flange Finishes
The term ‘finish’ refers to the type of surface produced by machining the
flange face which contacts the gasket. Two principal types of finish are produced, the
‘stock’ and ‘smooth’.
Stock finish : spiral groove generated by 1.6 or 3.2mm. Radius round-nosed tool at feed
rate of 0.8 or 1.2 mm per revolution with depth 0.06 to 0.1 mm. The roughness between
125 – 500 microinch
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FLANGE  Flange Types
Flanges differ in method of attachment to the pipe, i.e., whether they are screwed, welded,
or lapped.
Welding Neck (WN) Socket Welding (SW) Slip-On (SO)
Threaded (THRD) Lap joint (LJ) Long Welding Neck (LWN)
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FLANGE  Flange Types : Welding Neck (WN) Flange
Flange that have a hub that is gradually tapered down as it
approaches the corresponding pipe wall at the small end.
Most commonly used weld-on flange and is preferred for severe

service conditions such as high pressure, hot/cold temp. and
where shock or vibration may be encountered.
FLANGE  Flange Types : Socket Weld (SW) Flange
Use where socket-weld fittings are specified, and are generally

limited to 2 inches and smaller sizes.
Some service, the crevice at the pipe base of the socket may
promote contamination of product and can also encourage
corrosion.
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FLANGE  Flange Types : Slip-On (SO) Flange
Require double fillet welds, front (internal) and back (external) and
are favoured by some designer because the pipe doesn’t have to
be cut very accurately.
It is weaker than a welding neck flange and is not to be used on
services with frequent thermal cycling.
Pocket formed between the pipe and the flange which can be
objectionable when liquid or sediment settle out of the fluid.
Never use slip on flange in hydrogen or hydrogen sulfide service
because hydrogen will accumulate in the cavity between welds and
may contribute to weld failure.
Note.
Class 150 – Max. flange size NPS 12
Class 300 – Max. flange size NPS 8
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FLANGE  Flange Types : Thread (THRD) Flange
Restricted to small sizes and to the low pressure and temperatures.

Cast iron screwed flanges are limited to non-pressurized water
services.
Usually installed where a transition from welded to screw end pipe
is necessary.
FLANGE  Flange Types : Lap Joint (LJ) Flange
Flange have a lap equal to the pipe wall thickness and are among
the weakest of the standard types of flange.
Sometime used in jointing expensive non-ferrous piping.
Economical if costly pipe such as stainless steel is used, as the
flange can be carbon steel and only the stub end need be of the line
material.
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FLANGE  Flange Types : Reducing Flange
Reducing screw flange

Are designated by the size of the pipe tapping required
for the screwed end pipe or tube.
Reducing slip-on flange

Are preferable to reduce screwed flange for a
permanent leak proof joint.
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FLANGE  Flange Types : Blind Flange
May be installed on access openings, such as manholes, or on

pipe ends provided for inspection or future tie-in. And also used to
blank off connection.
FLANGE  Flange Types : Long Weld Neck (LWN) Flange

Used for connection on pressure vessels and heat exchangers.
Lengths are generally 9 to 12 inches and the standard bore is
equal to the nominal pipe size.
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FLANGE  Flange Types : Orifice Flange
Orifice
Are manufactured for mounting an
Tapped
Flange orifice plate between the welding neck
Connection
flanges.
To provide these flanges with a
sufficient thickness for a ½ inch tapped
meter connection they are supplied with
a minimum 300 ANSI class rating.
Stud bolt
with Nut Orifice
Plate
Jack Screw Gasket
Orifice Flange Set (Disassembly)
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Reducing Screw Flange
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Blind Flange
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Welding Neck (WN) Flange

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Orifice Flange
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FLANGE  Material (most commonly used)
- A105
Carbon steel - A694
- A350 (Low Temp.)
Stainless steel - A182
Alloy steel - A182
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What is GASKET used for ?
Used to make a fluid-resistant seal between two surfaces while under
compression.
Gasket selection
1.Temperature, pressure and corrosive nature of the conveyed fluid
2.Whether maintenance or operation requires repeated uncoupling
3.Code requirements that may apply
4.Cost
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GASKET  Soft Cut
Sheet materials are used in low to medium pressure service. With carefully selection
these gaskets are not only suitable for general service but also for extreme chemical
services and temperatures.
Type: Non asbestos-fibre sheet, PTFE, Graphite, Insulating gaskets.
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GASKET  Semi Metallic
There are composite gasket consisting of both metallic and non-metallic materials. The
metal provides the strength and the resilience of the gasket and the non-metallic
component provide the conformable sealing materials. These gasket are suitable for low
and high pressure and temperature applications. Design based on ASME B16.20
Type: Spiral wound gasket, metal jacket gasket, etc.
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GASKET  Metallic
These gaskets can be fabricated in a variety of shapes and sizes recommended for use
in high pressure/temperature applications. Design based on ASME B16.20.
Type R : Oval and Octagonal
Type RX : Octogonal.
Type: Ring type joint, etc.
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GASKET  Insulation Gasket
Used to protect the galvanic corrosion between dissimilar material
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BOLT  Bolted Joints
The use of bolted joints is advantageous in the following circumstances:
- The components cannot be serviced in line.
- The components being joined are not capable of being welded.
- Quick field assembly is required.
- The component or pipe section must be frequently removed for service.
BOLT  Bolt selection
Proper bolt selection depends on many factors
- Application
- Type and design of joint
- Loads
- Fatigue considerations
- Temperature, chemical exposure
- Preload required
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BOLT  Types of Bolting
Two types of bolting are available
- Stud bolt (Using two nuts)
- Machine bolts (Using one nut)
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BOLT  Common surface treatment to resist corrosion
Zinc-plated / bichromate-treated
- Suitable for both carbon steel and alloy steel bolts
- Limited useful service temperature at 250°F
Cadmium-plated / bichromate-treated
- Suitable for both carbon steel and alloy steel bolts
- Limited useful service temperature at 450°F
Fluoropolymer (PTFE) coated
- Not used in service grater than 400°F (204 °C)
- No Galvanic Corrosion
NOTE. No protective coating for stainless steel bolts
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BOLT  Most commonly used for Stud bolts C/W hex nuts
- General service
A193 Gr.B7 / A194 Gr.2H - Used on SS. Pipe but must undergo surface treatment
- Insulated pipe
A193 Gr.B7M / A194 Gr.2HM - CS. at low temp. service (below 29°C)
A193 Gr.B16 / A194 Gr.4 - Alloy steel at high temp service
A320 Gr.L7 / A194 Gr.4 - CS. at low temp. service (below 0°C (Cryogenic Temp.))
A193 Gr.B8 Cl.2 / A194 Gr.8MA - SS. General service

A193 Gr.B8M Cl.2 / A194 - SS. General service
Gr.8MA - SS. At low temp. service (below 0°C (Cryogenic Temp.))
- SS. General service
A320 Gr.8 Cl.2 / A194 Gr.8 - SS. At low temp. service (below 0°C (Cryogenic Temp.))
A193 Gr.B8M Cl.2 / A194 Gr.8M - Plastic pipe
A453 Gr. 660 - Duplex SS.
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VALVE
Valves are an essential part of any piping system that conveys liquids, gases,
vapors, slurries and mixtures of liquid, and gaseous phases of various flow media.
A valve is a device that regulates the flow of fluids (either gases, fluidised
solids, slurries or liquids) by opening, closing, or partially obstructing various
passageways.
Different types of valves include: gate, globe, check, ball, plug, butterfly,
diaphragm, pinch, pressure relief, and control valves.
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VALVE  Valve Specification
API Standard
API 6A ; Describes flange standards
API 6B ; Extends data to include 30,000 PSI wellhead equipment
API 6D ; Cover pipeline valves
API 6F ; Covers test procedures for classifying a valve “fire safe”
API 593 through 609 ; Provides standards for the manufacture of valves for use in refinery services
ANSI Standard
ANSI B16.5 ; Provides dimensional standards for flanges
ANSI B16.10 ; Covers face-to-face and end-to-end standard dimension
ANSI B16.34 ; Covers flanged, threaded and welded-end flanges
MSS Standard
MSS SP72 ; Covers ball valve with flanged or butt welded ends for general service
MSS SP99 ; Covers non-code compliant instrument valves
MSS SP105 ; Covers code compliant instrument valves (needle valves)
MSS SP110 ; Covers ball valves – threaded, socket weld, solder joint, grooved or flange end
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VALVE  End Connections
Screw end valves
Require less labour for connections and thus cost less
than others types.
Socket weld and butt weld valve

End must be machined within established tolerances
and are more expensive than screw end valves.
Flanged valves
Require more metal and extensive machining of the
ends which results in a much higher cost.
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VALVE  Component
Body
-Major part of the valve.
-Pressure containing case for the operating parts and
provides connections to the piping.
Bonnet
-Joins the moving parts of the valve to the body.
-Can either be bolted, screwed or welded to the body.
Trim
-Consists of the moving parts of the valve and the seat.
-Includes the stem, stem packing and seal elements.
-Can either be bolted, screwed or welded to the body.
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VALVE  GATE VALVE
General Considerations
Gate valves are designed to operate fully open or

fully closed. When fully opened, there is very little pressure
drop across the valve, and when fully closed there is good
sealing against pressure. With the proper mating of a disk to
the seat ring, very little or no leakage occurs across the disk
when the gate valve is closed.
Gate valve open or close slowly, which prevents
fluid hammer and subsequent damage to the piping system.
Gate valves are usually classified by the type of
disk used, and a variety of disk type are available, such as
solid wedge, split wedge or parallel disk.
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Advantages of a Gate Valve
1.They have good shutoff characteristics.
2.They are bidirectional.
3.The pressure loss through the valve is minimal.
Disadvantages of a Gate Valve

1.Gate valves are not quick opening or closing valves. Full-stem travel to open or close a
gate valve requires many turns of its handwheel or an actuator.
2.Gate valves require large space envelope for installation, operation, and maintenance.
3.The slow movement of the disc near the full-closed position results in high-fluid velocities,
causing scoring of seating surfaces.
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Disadvantages of a Gate Valve
4. Some designs of gate valves are susceptible to thermal or pressure binding, depending
upon the application.
5. In systems experiencing high-temperature fluctuations, wedge-gate valves may have

excessive leakage past the seats due to changes in the angular relationship between the
wedge and the valve seats caused by piping loads on the valve ends.
6. Repair or machining of valve seats in place is difficult.
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VALVE  BALL VALVE
This rotational-motion valve uses a ball-shaped disk with

a hole bored through to stop or start fluid flow.
Because the ball moves across the seats with a wiping
motion, ball valves can handle fluids with suspended solids.
Ball valves are available in venturi, reduced and full port
patterns. The full port pattern has a ball with a bore equal to
the inside diameter of pipe.
Most ball valves instead have a reduced bore with a
venturi shaped flow passage of about three quarters the
nominal valve size.
ADP 2012 87

Advantages of a Ball Valve
1.Quick to open and close.

2.Smaller in size than a gate valve.
3.Lighter in weight than a gate valve.
4.Multiport design offers versatility not available with gate or globe valves. It reduces the
number of valves required.
5.Can be used in clean and slurry applications.
6.High-quality ball valves provide reliable service in high-pressure and high-temperature
applications.
7.Force required to actuate the valve is smaller than that required for a gate or a globe valve.
ADP 2012 88

Disadvantages of a Ball Valve
1.They are not suitable for sustained throttling applications.
2.In slurry or other applications, the suspended particles can settle and become trapped in
body cavities causing wear, leakage, or valve failure.
ADP 2012 89

VALVE PORT
Full port
Required in applications such as hot-tapping operation or in line subject to pigging or pressure
release (Pressure safety valve).
ADP 2012 90

VALVE PORT
Reduced port
Most ball valve have a reduced port with a venturi-shaped flow passage that is generally one
pipe size smaller than the nominal valve size. Pressure drop through a reduced port valve is
generally low enough that the additional cost of a full port valve is not justified.
ADP 2012 91

Floating Ball
Ball is free to move in the lateral direction.
Fluid pressure acting on the ball forces the ball into the seat,
giving a tight seal.
Not used in high pressure and large sizes for two reasons
- High force of the ball against the seats can deform the
seats and affect the low pressure sealing characteristics of the
valve.
- The same force makes the valve difficult to operate,
thus requiring a high torque to overcome the seating force at
high pressure differentials.
Floating ball
ADP 2012 92

Trunnion-mounted Ball Ball rotates in a fixed position.
Ball cannot move in the lateral direction because it is held in place
by a shaft on the top and the bottom of the ball.
Valve creates a seal by either
- Fluid pressure forcing a floating seat ring against the ball.
- Pre-stressing the seats and the ball.
Pre-stress can occur as a result of an interference fit between the
ball and seal or as a result of a spring-type mechanism.
Easier to operate than the floating ball valve and is available in

larger sizes and higher pressure classes.
Trunnion-mounted
ADP 2012 93

Body Styles
ADP 2012 94

VALVE  GLOBE VALVE
The basic principle of globe valve operation is the perpendicular
movement of the disk toward, or away from, the seat.
This causes the annular space between the disk and seat ring to
gradually close as the valve is closed. It is this characteristic that
gives the globe valve good throttling ability.
When the valve is closed, a globe valve has much less leakage
around the seat.
ADP 2012 95

Advantages of a Globe Valve
1.Moderate to good throttling capability.
2.Shorter stroke (compared to a gate valve).
3.Available in tee, wye, and angle patterns, each offering unique capabilities.
4.Easy to machine or resurface the seats.
Disadvantages of a Globe Valve
1.Higher pressure drop (compared to a gate valve).

2.Requires greater force or a larger actuator to seat the valve (with pressure under the seat).
3.Throttling flow under the seat and shutoff flow over the seat.
ADP 2012 96

Pattern
Tee-Pattern
Globe valves have the lowest coefficient of flow and higher pressure drop. They
are used in severe throttling services, such as in bypass lines around a control valve. Tee-
pattern globe valves may also be used in applications where pressure drop is not a concern
and throttling is required.
ADP 2012 97

Pattern
Wye-Pattern
Globe valves, among globe valves, offer the least resistance to flow. They can
be cracked open for long periods without severe erosion. They are extensively used for
throttling during seasonal or start-up operations. They can be rod through to remove debris
when used in drain lines that are normally closed.
ADP 2012 98

Pattern
Angle-Pattern
Globe valves turns the flow direction by 90 degrees without the use of an elbow
and one extra weld. They have a slightly lower coefficient of flow than wye-pattern globe
valves. They are used in applications that have periods of pulsating flow because of their
capability to handle the slugging effect of this type of flow.
ADP 2012 99

VALVE  BUTTERFLY VALVE
Butterfly valves get their name from the wing like action of
the flow controlling disk that opens and close at right angles to
the flow path.
Butterfly valves were introduced to counteract the
problems associated with linear valve designs (especially gate
valves), such as the relatively large size and weight, the high
operating force required, and the tendency to leak.
Instead of a long stroke, the butterfly valve requires a
quarter turn to cycle from the fully open to fully closed
position.
Butterfly valves can be used for both on/off and throttling
applications.
ADP 2012 100


Advantages of a Butterfly Valve
1.The compact design requires considerably less space, compared to gate, globe, or other
valves.
2.Light in weight.
3.Quick acting; as a quarter-turn valve, it requires less time to open or close.
4.It is available in large sizes, ranging from NPS 1-1/2 (DN 40) to over NPS 200 (DN 5000).
5.They have low-pressure drop and high-pressure recovery.
6.Provide bubble-tight service.
ADP 2012 101


Disadvantages of a Butterfly Valve
1.Throttling service is limited to low differential pressure.

2.Throttling is restricted to a 30- to 80-degree disc opening. Location of valve, pipe
routing, free, and closed discharge are to be considered while using a butterfly valve in a
throttling application.
3.Cavitation and choked flow are two potential concerns.
4.The disc movement is unguided and affected by flow turbulence.
ADP 2012 102


Connection Types
Wafer-type
Wafer style is the more common of the two and is less
expensive than the lug style. The wafer style butterfly valve is just
about the standard.
It is so common that no one even bothers to use the word
"wafer" when ordering a butterfly valve. They take it for granted that
if they order a butterfly valve, they will get a wafer style one.
The wafer style butterfly valve is installed between two flanges.
The valve is kept in place by using bolts or studs and nuts from
flange to flange.
This type of installation, of course, makes it impossible to
disconnect just one side of the piping system from the valve. That is
where the lug style valve comes in.
ADP 2012 103

Connection Types
Lug-type
Lug style valves have threaded inserts at both sides of the valve
body.
This allows them to be installed into a system using two sets of
bolts and NO nuts. The valve is installed between two flanges using
a separate set of bolts for each flange.
This setup permits either side of the piping system to be
disconnected without disturbing the other side.
ADP 2012 104


VALVE  PLUG VALVE
Plug valves have a cylindrical or tapered plug with a hole

bored through, as with ball valves, fluid flows when the hole
in the plug is aligned with the pipe, and a quarter turn of the
plug stops the flow.
Plug valves often have fluorocarbon seating materials
and in some cases are fully lined with fluorocarbons, which
provide excellent protection for corrosive applications that
require bubble tight shutoff.
There are several different types of plug valves
commonly used in the CPI, including lubricated, non-
lubricated and eccentric types.
ADP 2012 105


VALVE  PLUG VALVE
Advantages of a Plug Valve
1.Simple design with few parts.
2.Quick to open or close.
3.Can be serviced in place.
4.Offers minimal resistance to flow.
5.Provides reliable leak tight service. Seal can be maintained by injection of sealant or by
replacement of sleeve, in addition to utilizing the wedging action of a tapered plug.
6. Multiple port design.
Disadvantages of a Plug Valve

1.Requires greater force to actuate, due to high friction.
2.NPS 4 (DN 100) and larger valves require use of actuators.
3.Reduced port, due to tapered plug.
4.Typically, plug valves may cost more than ball valves.
ADP 2012 106

VALVE  DIAPHRAGM VALVE
The flow passage in diaphragm valves is free of crevices

and is unobstructed by moving parts, making them suitable
for applications where cleanliness, bubble-tight shut off and
chemical compatibility are important.
The diaphragm valve is considered to be the valve least
likely to cause contamination. For this reason, it is popular in
high-purity applications. It is available in two general designs,
weir and straightway. The weir style diaphragm valve is
utilized for higher pressure applications. The straightway
diaphragm valve, having no flow path obstructions, is well
suited for higher flow and slurry applications.
ADP 2012 107


Advantages of a Plug Valve
1.Can be used as on-off and throttling service valves.
2.Offer good chemical resistance due to variety of linings available.
3.Stem leakage is eliminated.
4.Provides bubble-tight service.
5.Does not have pockets to trap solids, slurries, and other impurities. It is suitable for slurries
and viscous fluids.
6.These valves are particularly suitable for hazardous chemicals and radioactive fluids.
7.These valves do not permit contamination of flow medium, thus they are used extensively in
food processing, pharmaceutical, brewing, and other.
ADP 2012 108


Disadvantages of a Plug Valve
1.The weir may prevent full drainage of piping.
2.Working temperatures and pressures are limited by the diaphragm material. Generally the
pressures are limited to 200 psi (1380 kPa) and temperatures up to 400 F (204 C).
3.The diaphragm may also limit the hydrostatic pressure.
4.The diaphragm may experience erosion when used extensively in severe throttling service
containing impurities.
5.Diaphragm valves are available in limited sizes, usually NPS 1/2 to 12 (DN 15 to 300).
ADP 2012 109


ADP 2012 110


VALVE  NEEDLE VALVE
Generally used on instrumentation because of its excellent

control of flow. The stem is a tapered needle and the flow pattern is
offset
Used specifically for accurately controlling the flow of fluids at
low flows.
The valve is basically a globe valve without the disc.
ADP 2012 111


VALVE  NEEDLE VALVE
ADP 2012 112


VALVE  CHECK VALVE
The purpose of a check (or non-return) valves is to allow

fluid flow in one preferred direction and to prevent back flow, or
flow in the opposite direction.
Ideally, a check valve will begin to close as the pressure
drops in a pipeline and the fluid momentum slows.
When the flow direction reverses, the check valve should
close completely.
Check valves can be of the following type: swing, lift and
tilling disk.
ADP 2012 113


Types of Check Valve
Swing Lift Check Valve Tilting Disc Check

Check Valve Valve
Disc Check Valve Diaphragm Check Split Disc

ADP 2012 114
Valve Check Valve

Types of Check Valve – Swing Check Valve
1.Seating element swings about a hinge which is mounted outside
the seat.
2.Disc swings freely in an arc with the flow area varying with the
flow rate.
3.The effect of gravity combined with the reversal of flow causes the
disc to seat.
4.As the size of the valve increases

- Weight and travel of the disc become excessive for satisfactory
valve operation.
- Valve larger than 24 inches are designed with multiple discs.
ADP 2012 115

Types of Check Valve – Swing Check Valve
5.Causes very little pressure drop and is best suited for low velocity
flow service where flow changes are infrequent.
6.If used where high frequency flow reversals are encountered

(such as reciprocating compressor and pump service) the disc will
have a tendency to chatter which may damage the valve seats.
7.Furnished in both regular and full-opening pattern.
8.Can be installed in line which horizontal or upward vertical flow.

.
ADP 2012 116


Types of Check Valve – Lift Check Valve
1.Seating element travels in the direction normal to the plane of the

seat.
2.Flow follows a turning course through the valve.
3.Disc is equipped with a short guide.
4.Black flow and gravity contribute to seating of the disc and ball
that rise and fall depending on the pressure.
.
ADP 2012 117


Types of Check Valve – Lift Check Valve
5.Because the travel lift check valves is shorter than other types of
check valves, lift check valve are fast closing.
6.Create a larger pressure drop than swing check valves.
7.Suitable for service where

-Frequent changes in flow direction area encountered.
-High pressure differential can occur, and
-Low flow rates are involved.
.
ADP 2012 118


Types of Check Valve – Tilting Disc Check Valve
1.Seating element tilts about a hinge which is mounted near, but

above, the centre of the seat.
2.Disc drops on the seat upon closing and lifts out upon opening.
3.Quicker acting than swing check valves because the centre of

gravity of the disc halves describes only a short path between the
fully open and the closed positions.
.
ADP 2012 119


Types of Check Valve – Tilting Disc Check Valve
4.More expensive and more difficult to repair than swing check

valves.
5.Normally restricted to applications of low pressure and high flow

rates and which cannot be met by the use of a swing check valves.
6.Cannot be used in lines that must be fully open.

.
ADP 2012 120


Types of Check Valve – Disc Check Valve
1.The disc check valve consists of four main components: the body,
a disc, a spring and a spring retainer.
2.The disc moves in a plane at right angles to the flow of the fluid,
resisted by the spring that is held in place by the retainer.
3.Disc check valves are smaller and lighter than lift and standard
swing check valves and sub-sequently cost less.
.
ADP 2012 121


Types of Check Valve – Disc Check Valve
4.Standard disc check valves should not be used on applications

where there is heavily pulsating flow, for example, on the outlet of a
reciprocating air compressor, as the repeated impact of the disc can
lead to failure of the spring retainer and high levels of stress in the
spring.
5.The design of disc check valves allows them to be installed in any

position, including vertical pipe-lines where the fluid flows
downwards.
.
ADP 2012 122


Types of Check Valve – Split Disc Check Valve
1.Split disc wafer check or dual plate check or butterfly check.
2.Consists of two spring loaded D-shaped sealing elements

mounted on a rib across the valve bore.
3.Design reduces the weight of the disc by about 50%, compared

with single disc swing check valve.
4.Coupled with spring loading, this valve closes very rapidly.
5.Suitable for operation even with vertical downflow.

.
ADP 2012 123

Best practice valve installation

ADP 2012 124


ADP 2012 125


ADP 2012 126

VALVE  Operators
Manual Operators
1.Installed on valve so that they can be operated by hand.
2.Chain operator allows the operation of a valve that is installed

more than six feet above grade.
3.Gear operator has a mechanical advantage which makes the

valve easier to open and close
4.Manually operated valves do not change position due to a

change in the mode of system operation or an accident. As such,
a manually operated valve remains in the last position it was
placed in.
5.Manually operated quarter-turn valves, such as a ball, plug, or

ADP 2012 butterfly valve, is provided with a lever to actuate the valve.127

VALVE  Operators
Power Operators 1.Large valves and valves required to be operated
against high-fluid pressure.
2.When the time required to open, close, throttle, or

regulate the valve manually is longer than that required
by system-design criteria.
3.When the valve is required to be operated from a

remote location.
4.When the valve must attain a position (open or close)

in the event of an accident or in a particular mode of
system operation.
ADP 2012 128


VALVE  Operators
Power Operators The valves to be furnished with an actuator utilizing
external source of energy, such as elec-tricity,
pneumatics, hydraulics, mechanical springs, or a
combination of one or more of these energies, are called
actuated valves.
Upon failure of the external source of energy, a

valve may not be in the required position for
accomplishing the design function. One must be aware
of failure modes prior to selecting a valve actuator.
ADP 2012 129


VALVE  Operators
Power Operators - Failure Modes
1.Fail-As-Is (FAI): The valve remains in its last position
following upon an external power failure.
2.Fail-Closed: The valve is provided with external source

of energy to place it in the closed position, regardless of
valve position before power failure.
3.Fail-Opened: The valve is provided with external source
of energy to place it in the open position, regardless of
valve position before power failure.
4.Fail-Locked: Air or inert gas actuators may be provided
with a device or devices to seal in actuator pressure upon
the loss of normal pneumatic source control.
ADP 2012 130

VALVE  Operators
Power Operators - Diaphragm Operator
1.Uses low pressure air or gas to operate the valve.
2.Advantages of this operator are
-It requires low pressure air or gas to operate.
-It is easy to maintain.
-It has a low cost.
3.Disadvantages include
-Inability to provide the large force required to open
some valves.
-Slow operating speed.
4.Can employ a spring that opposes the force of the
air or gas so that the valve will fail closed or open
when the air or gas signal is lost.
ADP 2012 131


VALVE  Operators
Power Operators - Piston Operator
1.Uses high pressure air or gas or hydraulic oil to operate

the valve.
2Advantages of this operator are

-Ability to provide the large force to operate some large
valves.
-Fast operating speed.
3.Disadvantages are
-Required high pressure air, gas or hydraulic fluid.
-Is more difficult to maintain than the diaphragm type.
4.Can have the force of the air, gas or hydraulic fluid
opposed by a spring so that the valve will either fail opened
or closed upon loss of the fluid pressure.
ADP 2012 132

VALVE  Operators
ADP 2012 133

• PIPING DESIGN.
– P&ID Reading and Interpretation
• What is the P&ID??
P&ID : Process and Instrument Diagram. This is the most important document which
developed from process simulation. The process plant design begin from this
diagram. Therefore, the interpretation of this diagram is very important.
At the beginning of piping design, in order to interpret P&ID, the following documents
shall be accompanied with P&ID.
• Process line list.
• Piping specification.
• Plot plan,
• Preliminary dimension of equipment, valve and instrument.
ADP 2012 134

– P&ID Process and Instrument Diagram.
ADP 2012 135

– Process line list.
• Process data such as pipe size, line no., origin, destination, CA. ,Piping class,
Insulation type and thickness, operating and design temperature and pressure.
Testing requirement,
ADP 2012 136

– Piping Class or Piping Specification.
• Indicate material of flange, valve, fitting and gasket., corrosion allowance.
ADP 2012 137

– Piping Class or Piping Specification
• Indicate max. and min. temperature and pressure, pressure rating and branch
table.
ADP 2012 138

High potential to ignition
• PIPING DESIGN.
– Plant Lay-out.
• Good example.. Occupied area.
. High risk of gas leakage
ADP 2012 139

– Plant Lay-out.
• Equipment location shall be complied with following requirement;
– Plant layout specification. : safety, operation and maintenance
– Economic piping.: Cost of plant.
– Process requirement. : No pocket, gravity flow
– Equipment size
– Real estate availability : Land. Tall building and vertical installation is an alternative.
– Common operator. : common crane requirement, common building requirement,
common upstream or downtream equipments.
ADP 2012 140

– Plant Lay-out.
• Equipment location shall be complied with following requirement;
– Can be accessed, operation and maintenance.
– Underground facilities.
ADP 2012 141

– Plant Lay-out.
• Equipment Spacing.
Minimum spacing between

equipment. This dimension
is depended on hazard
analysis by specialist.
ADP 2012 142

– Plant Lay-out.
• Road and platform dimension.
(For info only).
ADP 2012 143

– Plant Lay-out.
• Recommended clearance for Onshore.- Offshore(Vehicle / Pedestrains)
– Main access way (including equipment removal
» Headroom for primary access ways (under pipe racks), equipment
inside modules. = 2100 mm. – 4500 mm. / 2100 mm.
» Width = 750 mm. – 5000 mm. / 1200 mm.
» Mobile lifting equipment in operating area = 2400 mm.
– Access for maintenance of equipment.

» Headroom for maintenance access ways = 2100 mm. – 4500 mm.
/ 2100 mm.
» Width = 750 mm. – 5000 mm. / 1200 mm.
– Escape route
» Headroom = 2100 mm. - 2100 mm
» Primary escape route width = 1000 mm. – 1000 mm.
» Secondary escape route width = 750 mm – 750 mm.
ADP 2012 Note : Ref. PEGS-0710-PIP-001 144

• PIPING DESIGN.
– General Piping Design:
• Pipe routing has to be followed the specific requirements as indicated in P&ID.
such as No Pocket, Gravity flow, Slope line, minimum bend, minimum length.
• Pipe routing should not be too much flexibility or too many bend due to it impact to
cost of material.
• Straight length should be strictly complied with requirement of each instrument of
equipment. (5D / 3D).
• BOP. should be in grouped in common elevation.
• The main pipe rack mainly consist of all welded piping. Flange connection shall be
limited.
• The minimum height of concrete pier or sleeper shall be 300 mm.
• Pipe rack for firewater system should be separated from process fluid.
ADP 2012 145

• PIPING DESIGN.
• Equipment drain, vent and pressure safety valve shall be connected to piping
systems as appropriate. Minimum size of equipment drain shall be 2”.
• Piping at equipment shall be sufficiently flexible and adequately supported.
• Minimum size of by-pass valve related to main principle valves as follow;
Size of Principal Valve Size of Bypass
4” ½”
6”- 8” ¾”
10”- 20” 1”
24” and larger (per Equipment
Specification)
• Pump suction lines shall be sloped not less than 20 mm.per m. downward to
pump. The eccentric reducer (top flat) is required. 3D or 5D straight length for
horizontal end suction centrifugal pumps is required. (to prevent cavitation).
• For discharge nozzles, the concentric reducer shall be installed.
ADP 2012 146

• PIPING DESIGN.
• If common header is required in pump or compressor piping system, the spectacle
blind shall be installed at upstream side and downstream side of block valve at
discharge and suction line respectively. This is to facilitate positive isolation.
• Temporary strainer is required at pump suction line to remove foreign object during
startup. The opening area shall be 300% of cross section pipe area.
• Permanent strainer shall be Y (limit to 6”-300#, T (for all size and classes) or
Basket type.
• Check valve is required at discharge line of pump to protect pump damage due to
back pressure.
• The pulsation dampeners shall be utilized to prevent piping vibration.
• Underneath of Air cooled heat exchanger shall be free of petroleum containers
which operated at high temperature (300 C and above).
• Piping around heat exchanger shall be designed to permit removal of tube/bundle.
ADP 2012 147
• PIPING DESIGN.
– Pipe routing:
ADP 2012 148

• PIPING DESIGN.
– Pipe routing:
ADP 2012 149

• PIPING DESIGN.
– Pipe routing:
ADP 2012 150

• PIPING DESIGN.
– Pipe routing:
• Gravity flow
ADP 2012 151

– Piping drawing : 3D Modelling
ADP 2012 152

– Piping drawing : Plot plan.
ADP 2012 153

– Piping drawing : Piping GA. (General Arrangement, Top view).
ADP 2012 154

– Piping drawing : Piping GA. (General Arrangement, Elevation View).
ADP 2012 155

– Piping drawing : Piping Isometrics.
ADP 2012 156

– Piping drawing : Piping Standard.
ADP 2012 157

– Piping drawing : Piping Standard.
ADP 2012 158

– Piping drawing : Pipe Support Drawing.
ADP 2012 159

– Piping drawing : Pipe Support Location Plan.
ADP 2012 160

– Piping drawing : Others Documents and drawings;
• Piping MTO (Material Take Off).
• Piping Special Item Datasheet.
• Pipe Stress Analysis Report.
• Technical Bid Evaluation.
ADP 2012 161

– Sample of Piping design.
ADP 2012 162

ADP 2012 163

Access
ADP 2012 164

ADP 2012 165

ADP 2012 166

ADP 2012 167

ADP 2012 168

• Flexibility Analysis or Pipe Stress Analysis.

– Purpose of Flexibility analysis is to review pipe routing, pipe support and
equipment due to
• Thermal expansion, Internal pressure, Weight
• External load such as wind, wave, external force.
• Vibration.
• Movement of equipment’s nozzle.
– Analysis is performed based on ASME code such as
• Power Plant Piping : ASME B31.1
• Process Piping (Topside Piping, Onshore) : ASME B31.3
• Pipeline Transportation systems for liquid Hydrocarbons and other liquids: ASME
B31.4
• Gas Transmission and distribution piping system : ASME B31.8.
ADP 2012 169


– Pipe stress analysis procedure.
• Define all criteria of pipe stress analysis.
• Define stress Level.
– Level 1 Visual check.
– Level 2 Approximately check.
– Level 3 Comprehensive or program check. (the most stringent).
• Main factor is temperature, pipe size, piping material, equipment, type of fluid.
ADP 2012 170


ADP 2012 171


ADP 2012 172

– Flexibility Analysis.
• Currently, there are several FEA software developed by many software developers.
However, the most favorite and practical used is Caesar II. Autopipe is an effective
software as well. ROHR2 is new coming.
ADP 2012 173

• Caesar II Input Window.
Graphic 3D.
Input Window.
- Node no.
- Piping Material.
- Temperature.
- Pressure.
- Fluid condition.
ADP 2012 174

• Stress review for overall piping system.
ADP 2012 175

• To determine the load of piping components, thermal load, fluid load during any
occasion such as operating condition, empty pipe, hydrostatic test. And include
load due to other occasional case such as wind, earthquake and wave.
Node 90
Node 250
Node 90
Node 150
ADP 2012 176

• To study the piping deflection due to weight and thermal expansion.
Initial Condition Expanded Condition
ADP 2012 177

• To verify the integrality of flange connection (ASME BPV Sec VIII), weld
connection between pipe to equipment (WRC107/297).
• Vibration analysis.
– Modal analysis.
– Surge analysis or water hammer.
– Time history analysis.
– Harmonic analysis.
• Equipment nozzle load review.
– Centrifugal pump (API610)
– Centrifugal compressor (API617)
– Turbine (NEMA 23)
– Pressure vessel (WRC107/297)
– Air-cooled heat exchanger (API661)
– Fire heater (API 560)
– Welded steel tank for oil storage (API650)
ADP 2012 178
ADP 2012 179

ADP 2012 180

– .
ADP 2012 181

ADP 2012 182

– Pipe Support Design.
• Pipe support design can be started after pipe routing has been studied.
• Pipe support design will be reviewed by performing flexibility analysis.
ADP 2012 183

– Pipe Support Design
ADP 2012 184

• Expansion Joint.
ADP 2012 185

– Pipe Support Design
ADP 2012 186

• Resting Support.
– Bare pipe support,
– Pipe shoe,
– Wear pad
ADP 2012 187

• Guide Support.
– U-Bolts
– Steel Guide.
ADP 2012 188

• Line Stop Support.
ADP 2012 189

• Spring Support.
– Variable Spring Support
– Constant Spring Support
ADP 2012 190

• Hanging Rod.
ADP 2012 191

– Fabrication and Welding.
ADP 2012 192

– Fabrication requirement.
General Requirement.
• All piping and valves material shall be supplied by Vendor and all have to be
complied with material specification.
• Material certificate BS EN 10204 type 3.1 or 3.2.
• If painting is required, it also complied with painting specification.
• Fabrication can be commenced after all engineering deliverables already issued
and approved by Client. Fabrication procedure provided by Contractor has to be
approved by Client prior to fabricate.
ADP 2012 193

• Minimum spacing of circumferential welds between center lines shall be minimum
1D or 2” whichever is greater unless otherwise specified.
Note : In case of restriction zone, the minimum spacing shall be not less than 4t or 1”
whichever is greater.
ADP 2012 194

• Small bore pipe (1 ½” and smaller) galvanized pipe shall be joined together by
socket welding. For larger pipe size can be joined with threaded connection.
– The threaded pipe of process service shall be at least sch. 80 thk. and 1 ½” max.
diameter. For thinner pipe or larger pipe , flange connection shall be used.
• Seal weld for threaded connection is permitted after testing. The thread connection
shall be cleaned, free from moisture, dust and grease before seal welding. The
seal welding shall be performed by Qualified Welder.
ADP 2012 195

• Caps and plugs on vents and drains shall not be seal welded incase of normal use
purpose. But incase of hydrostatic tests, seal weld after testing is required.
• Welding of small bore branch fitting shall be performed by Gas Tungsten Arc
Welding (GTAW) or Tungsten Inert Gas (TIG) only.
Note: GTAW or TIG have less heat effect zone, no slag, weld can be visible (little smoke),
good welding for thin material.
ADP 2012 196

• Welding of small bore branch fitting shall be performed by Gas Tungsten Arc
Welding (GTAW) or Tungsten Inert Gas (TIG) only.
Note: GTAW or TIG have less heat effect zone, no slag, weld can be visible (little smoke),
good welding for thin material.
ADP 2012 197

• Cleaning of pipe after fabrication and heat treatment shall be performed on both
external and internal pipe.
• Pipe bend for pigging process shall be at least 3D radius bends unless otherwise
specified.
ADP 2012 198

• The pipe wall thickness at thinnest point after bending (minus with corrosion
allowance) shall not be less than the calculated thickness.
• Pipe bend shall be free from cracks, wrinkles and bulges after bending and heat
treatment. Weld repair of cracks is not acceptable.
• Galvanized pipe shall not be bended or welded.
• All pipe spools shall be tagged as indicated in the piping isometrics.
ADP 2012 199

• Fabrication Tolerance.
ADP 2012 200

– Welding.
• Welding process
– Manual metal arc welding (MMA). This method is the most wildly used arc welding
processes. It requires considerable skill to produce good quality welds.
Advantage :
- Low capital cost.
- Freedom movement.
- Mobility
Disadvantage.
- Quality is depended on Welder.
- Overall cost is depended on
Labor Cost.
ADP 2012 201

– Welding.
• Welding process
– Metal Active Gas (MAG) Welding. This method is sometime call Metal Inert Gas (MIG)
Welding (Once shied gas is Pure Argon). This is semi-automatic process.
The shield gas is CO2 or Ar+CO2
ADP 2012 202

– Welding.
• Welding process
– Submerged arc welding (SAW).. Fully automatic process.
Advantage :
- High productivity.
Disadvantage.
- High capital cost.
- Be able to weld on flat plate only
ADP 2012 203

– Welding.
• Welding procedure specification (WPS).

• Procedure qualification record (PQR).
• Welder Performance Qualifications. (WPQ).
• Filler metal
– Filler metal shall match the physical properties of the base material when similar metals are
welded.
– For dissimilar material are to be welded, filler metal should be properly selected.
• Permanent backing ring and consumable inserts shall not be used.

• Peening is not permitted.
• If the multi-pass welding is required, the welding shall be done by semi-automatic and
fully automatic process.
• Minimum of 2 passes is required for all types of fillet welded on pressure containment
components.
ADP 2012 204

– Welding.
• Gas Metal Arc Welding (GMAW) shall be only performed under sheltered
environmental and inside enclosed fabrication shop
• No welding after heat treatment and NDE is acceptable.
• Arc burns shall be removed by grinding or b cutting out a cylindrical section of pipe
and replacing with undamaged spool. Grinding is permitted only if there is sufficient
pipe wall thickness remaining after grinding. Repairing part shall be inspected by
Magnetic particle inspection (MPI).
ADP 2012 205

– Welding.
• 1.6 mm. gap between the end of pipe and the shoulder of the socket should be
provided.
ADP 2012 206

– Heat treatment
• Preheating will be complied with ASME B31.3.
ADP 2012 207

– Heat treatment
• Post-weld heat treatment will be complied with ASME B31.3.
ADP 2012 208

– NDT (Non Destructive Testing)
• All Nondestructive testing will be carried out in full compliance with requirement of
ASME 31.3.
• Weld examination shall be performed in accordance with following standards
– Visual : ASME Section V, article 9
– Radiographic : ASME Section V, article 2
– Magnetic Particle : ASME Section V, article 7
– Liquid Penetrant or Dye Penetrant : ASME Section V, article 6
– Ultrasonic : ASME Section V, article 4
ADP 2012 209

Note :
1) 100 %RT for lines subject to pneumatic tests unless otherwise 10 %RT (minimum) is
– NDT (Non Destructive Testing) required
2) 5 %RT (minimum) is required.
Severe Category M
Service Hydrocarbons (liquid
Utilities lines Cryogenic Service Cyclic services
Conditions or gas)
Conditions
600 and 900 and 300 and 600 and 150 and 300 and 150 and All
Pressure class
below above below above below above above
Longitudinal welds 100% RT 100% RT 100% RT 100% RT 100% RT 100% RT 100% RT 20% RT
(Note 2) 100% RT 100% RT 100% RT 100% RT 100% RT 100% RT 20% RT
Girth welds (Note 1) (Note 1)
None 10 %MPI 10 %MPI 100 %MPI 10 %MPI 10 %MPI (Note 3) 20% UT

Socket welds or or or 100 % or or
10 %DPI 10 %DPI DPI 10 %DPI 10 %DPI
Pressure- 5 % MPI 10 %MPI 10 %MPI 100 %MPI 10 %MPI 10 %MPI 100 %MPI 20% UT
containing Tee or or or or or or or
welds, pipe-to-pipe 5 % DPI 10 %DPI 10 %DPI 100 % DPI 10 % DPI 10 %DPI 100 % DPI
branch or or or or or or or
connections, 5 % UT 10 %UT 10 %UT 100 % UT 10 %UT 10 %UT 100 % UT
branches made
with “O-let” fittings,
slip-on flange
welds, pipe
couplings, etc.
Non pressure- None 5 % MPI or 5 % MPI 10 %MPI 5% MPI 10 %MPI 100 %MPI or 20% UT
containing fillet 5 % DPI or or or or 100 % DPI
welds (attachments or 5 % DPI 10 %DPI 5 % DPI 10 %DPI or
welds to pressure- 5 % UT or or or or 100 % UT
containing parts) 5 %UT 10 %UT 5 %UT 10 %UT
ADP 2012 210
• Radiographic Testing.
– This module presents information on the NDT method of radiographic inspection or
radiography.
– Radiography uses penetrating radiation that is directed towards a component.
– The component stops some of the radiation. The amount that is stopped or absorbed is
affected by material density and thickness differences.
– These differences in “absorption” can be recorded on film, or electronically.
ADP 2012 211

• Radiographic Testing.
The part is placed between the radiation source and a piece of

film. The part will stop some of the radiation. Thicker and
more dense area will stop more of the radiation.
The film darkness (density) will vary with the amount of

radiation reaching the film through the test object.
X-ray film
= less exposure
= more exposure
Top view of developed film 0o 20o

ADP 2012 212
• Magnetic Particle.
– Magnetic particle inspection can detect both production discontinuities (seams, laps,
grinding cracks and quenching cracks) and in-service damage (fatigue and overload
cracks).
– Basic Procedure and Important Considerations
1. Component pre-cleaning
2. Introduction of magnetic field
3. Application of magnetic media (wet or dry)
4. Interpretation of magnetic particle indications
ADP 2012 213

– How does it work??
A ferromagnetic test specimen is magnetized with a strong magnetic field created by a
magnet or special equipment. If the specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the specimen and a leakage field will occur.
Finely milled iron particles coated with a dye pigment are applied to the test specimen.
These particles are attracted to leakage fields and will cluster to form an indication
directly over the discontinuity. This indication can be visually detected under proper
lighting conditions
ADP 2012 214

• Yoke or magnetic generator.
• Magnetic media (wet or dry.)
ADP 2012 215

• Sample of defect part.
ADP 2012 216

– Advantage.
» Fast method of inspection and indications are visible directly on the specimen
surface.
» Considered low cost compared to many other NDT methods.
» Is a very portable inspection method especially when used with battery powered
equipment.
» Can inspect parts with irregular shapes easily.
– Limitation.
» Cannot inspect non-ferrous materials such as aluminum, magnesium or most
stainless steels.
» Some parts may require removal of coating or plating to achieve desired
inspection sensitivity.
» Limited subsurface discontinuity detection capabilities. Maximum depth sensitivity
is approximately 0.6” (under ideal conditions).
» Post cleaning, and post demagnetization is often necessary.
» Alignment between magnetic flux and defect is important.
ADP 2012 217

• Dye and Liquid Penetrant Inspection
• To inspect the defect, crack from machining, grinding or welding by using
penetrants.
• This can be applied for both metal and non-metal materials such as Metals
(aluminum, copper, steel, titanium, etc.), Glass, Many ceramic materials , Rubber,
Plastics
– The penetrant must;
» spread easily over the surface of the material being inspected to provide
complete and even coverage
» be drawn into surface breaking defects by capillary action.
» remain in the defect but remove easily from the surface of the part.
» remain fluid so it can be drawn back to the surface of the part through the drying
and developing steps.
» be highly visible or fluorescent brightly to produce easy to see indications.
» not be harmful to the material being tested or the inspector
ADP 2012 218

ADP 2012 219

– Penetrant materials come in two basic types. These types are listed below
» Type 1 - Fluorescent Penetrants. Fluorescent penetrants contain a dye or several
dyes that fluorescent when exposed to ultraviolet radiation.
» Type 2 - Visible Penetrants. Visible penetrants contain a red dye that provides high
contrast against the white developer background.
– Penetrants are then classified by the method used to remove the excess penetrant from the
part. The four methods are listed below:
» Method A - Water Washable : penetrants can be removed from the part by rinsing with
water alone.
» Method B - Post-Emulsifiable, Lipophilic : the penetrant is oil soluble and interacts
with the oil-based emulsifier to make removal possible
» Method C - Solvent Removable : Solvent removable penetrants require the use of a
solvent to remove the penetrant from the part.
» Method D - Post-Emulsifiable, Hydrophilic : use an emulsifier that is a water soluble
detergent which lifts the excess penetrant from the surface of the part with a water
wash
ADP 2012 220

– Penetrant materials can classified based on strength or detectability
» Level ½ - Ultra Low Sensitivity
» Level 1 - Low Sensitivity
» Level 2 - Medium Sensitivity
» Level 3 - High Sensitivity
» Level 4 - Ultra-High Sensitivity
ADP 2012 221

– Advantage
» The method has high sensitivity to small surface discontinuities.
» The method has few material limitations, i.e. metallic and nonmetallic, magnetic
and nonmagnetic, and conductive and nonconductive materials may be
inspected.
» Large areas and large volumes of parts/materials can be inspected rapidly and at
low cost.
» Parts with complex geometric shapes are routinely inspected.
» Indications are produced directly on the surface of the part and constitute a visual
representation of the flaw.
» Aerosol spray cans make penetrant materials very portable.
» Penetrant materials and associated equipment are relatively inexpensive.
ADP 2012 222

– Disadvantage
» Only surface breaking defects can be detected.
» Only materials with a relatively nonporous surface can be inspected.
» Precleaning is critical since contaminants can mask defects.
» Metal smearing from machining, grinding, and grit or vapor blasting must be
removed prior to LPI.
» The inspector must have direct access to the surface being inspected.
» Surface finish and roughness can affect inspection sensitivity.
» Multiple process operations must be performed and controlled.
» Post cleaning of acceptable parts or materials is required.
» Chemical handling and proper disposal is required.
ADP 2012 223

• Ultrasonic inspection
– Ultrasonic testing uses high frequency sound energy to conduct examinations and
make measurements.
– Ultrasonic examinations can be conducted on a wide variety of material forms including
castings, forgings, welds, and composites
– A considerable amount of information about the part being examined can be collected,
such as the presence of discontinuities, part or coating thickness; and acoustical
properties can often be correlated to certain properties of the material.
ADP 2012 224

– The ultrasonic generated by transducer.
A piezoelectric element in the transducer

converts electrical energy into mechanical
vibrations (sound), and vice versa.
The transducer is capable of both transmitting

and receiving sound energy.
ADP 2012 225

– Ultrasonic waves are introduced into a material where they travel in a straight line and
at a constant speed until they encounter a surface.
– At surface interfaces some of the wave energy is reflected and some is transmitted.
– The amount of reflected or transmitted energy can be detected and provides
information about the size of the reflector.
– The travel time of the sound can be measured and this provides information on the
distance that the sound has traveled.
– Ultrasonic inspection techniques are commonly divided into three primary
classifications.
» Pulse-echo and Through Transmission
(Relates to whether reflected or transmitted energy is used)
» Normal Beam and Angle Beam
(Relates to the angle that the sound energy enters the test article)
» Contact and Immersion
(Relates to the method of coupling the transducer to the test article)
ADP 2012 226

– Pulse-echo inspection techniques.
In pulse-echo testing, a transducer sends out a pulse of energy and the same
or a second transducer listens for reflected energy (an echo).
crack
plate
0 2 4 6 8 10
ADP 2012 227

– Pulse-echo inspection techniques.
ADP 2012 228

– Through Transmission techniques.
In pulse-echo testing, a transducer sends out a pulse of energy and the same
or a second transducer listens for reflected energy (an echo).
1. No defect
11 2. Defected
0 2 4 6 8 10
ADP 2012 229

– Normal and Angle Beam
» In normal beam testing, the sound beam is introduced into the test article at
90 degree to the surface.
» In angle beam testing, the sound beam is introduced into the test article at
some angle other than 90.
ADP 2012 230

– Angle Beam
ADP 2012 231

– Contact or Immerge.
» In contact testing (shown on the previous slides) a couplant such as water,
oil or a gel is applied between the transducer and the part.
» In immersion testing, the part and the transducer are place in a water bath.
This arrangement allows better movement of the transducer while
maintaining consistent coupling.
1 2
IP 1 IP 2 IP = Initial Pulse
FWE FWE FWE = Front Wall Echo
DE = Defect Echo
BWE BWE BWE = Back Wall Echo
DE
Defect
0 2 4 6 8 10 0 2 4 6 8 10
ADP 2012 232

Q/A
ADP 2012 233

Piping Basics

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Mechanical Engineering – Piping.

By. Pornlert W. / Mechanical Engineer.

– BASIC OF PIPING AND PIPING COMPONENTS.

• BASIC OF PIPING AND PIPING COMPONENTS.

• BASIC OF PIPING AND PIPING COMPONENTS

Simple piping components

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Thread End (TE) Plain End (PE) Bevel End (BE)

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Batch Saws Cooling Bed Stretch Reducing Mill Shell Reheating

NDT Inspection In-Process Storage

• BASIC OF PIPING AND PIPING COMPONENTS

Straightening NDT Inspection End Finishing

Final Inspection Hydrostatic Testing

ADP 2012 Stock 16

• BASIC OF PIPING AND PIPING COMPONENTS

Coil Feed Ramp First Forming Section Fin Pass Section

Seam Normalizer Non-Destructive Inspection High Frequency Welder

• BASIC OF PIPING AND PIPING COMPONENTS

Straightening Non-Destructive Inspection Cut-Off Facilities

Final Inspection Facing and Beveling

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Electric resistance welded (ERW)

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Pipe can be lined or coated with materials such as vitreous substances, to

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Elbow Make 90 degree or 45 degree change in direction of the run of pipe.

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Concentric reducer Eccentric reducer

• BASIC OF PIPING AND PIPING COMPONENTS

Concentric reducer (Vertical line) Eccentric reducer – Top Flat (TF)

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Eccentric reducer in Suction Line.

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

Large End Small End

Both End Large End Small End

• BASIC OF PIPING AND PIPING COMPONENTS

• BASIC OF PIPING AND PIPING COMPONENTS

ADP 2012 Full Coupling 36

• BASIC OF PIPING AND PIPING COMPONENTS