Piping Design & Applications Workshop Rev 9-04-03 Piping Design & Applications Workshop Part A Piping Design & Applications Workshop Part A Don Frikken – Becht Engineering Company A-2 Scope Scope This workshop covers above ground industrial piping as practiced in the USA. I do not intend to cover: Pipelines Plumbing Nuclear plant piping
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Piping Design & Applications Workshop
Rev 9-04-03
Piping Design & Applications Workshop
Part A
Piping Design & Applications Workshop
Part A
Don Frikken – Becht Engineering Company
A-2
ScopeScope
This workshop covers above ground industrial piping as practiced in the USA.I do not intend to cover:
Introduction to Piping Flexibility AnalysisDesigning with Expansion JointsWater HammerLiquid Thermal ExpansionFabrication, Examination and TestingIntroduction to Line Sizing and Pressure Drop
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Definitions:Definitions:
piping: assemblies of piping components used…[for] fluid flows. Piping also includes pipe supporting elements, but does not include support structures…or equipment…
piping system: interconnected piping subject to the same design conditions
A-6
More Definitions:More Definitions:
piping components: mechanical elements suitable for joining or assembly into pressure-tight fluid-containing piping systems…pipe, tubing, fittings, flanges, gaskets, bolting, valves and devices such as expansion joints…
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& More Definitions:& More Definitions:
design pressure: the pressure at the most severe condition of internal or external pressure and temperature expected during service
design temperature: the temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required
A-8
Piping StandardsPiping Standards
Provide a set of requirements for obtaining a safe, reliable and economical installation (system standards or codes)
Provide consistent dimensions and ratings so that components will fit together and can be used interchangeably (component standards)
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Piping System Standards - ASMEPiping System Standards - ASMEB31.1 Power PipingB31.3 Process PipingB31.4 Liquid Transportation PipelinesB31.5 Refrigeration PipingB31.8 Gas Transportation PipelinesB31.9 Building Services PipingB31.11 Slurry Transportation PipelinesBPE-1 Bioprocessing EquipmentPVHO-1 Pressure Vessels for Human OccupancyHPS High Pressure Systems
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Piping System Standards - OtherPiping System Standards - OtherNFPA 13 – Installation of Sprinkler SystemsNFPA 24 – Installation of Private MainsNFPA 50 – Bulk Oxygen Systems NFPA 54 – National Fuel Gas Code CGA – Handling of Anhydrous Ammonia (K61.1)Chlorine Institute #6 – Piping Systems for Chlorine
Many piping systems, especially nonmetallic systems, are proprietary products and rated by the manufacturer.
Ratings for above ground metallic systems are generally governed by their joints. Frequently these are flanged joints manufactured in accordance with ASME B16.1 (iron flanges) and ASME B16.5 (other metallic flanges).
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P-T Ratings for Flanges – Gray Iron P-T Ratings for Flanges – Gray Iron
0
10
20
30
40
0 50 100 150 200
Temperature (C)
Pres
sure
(bar
g)
Class 125,NPS 1-12
Class 125,NPS 14-24
Class 125,NPS 30-48
Class 250,NPS 1-12
Class 250,NPS 14-24
Class 250,NPS 30-48
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P-T Ratings for Flanges – Carbon SteelP-T Ratings for Flanges – Carbon Steel
0
50
100
150
200
250
300
350
400
450
0 100 200 300 400 500
Temperature (C)
Pres
sure
(bar
g) Class 150Class 300Class 600Class 900Class 1500Class 2500
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Class 300 Ratings for Flanges – Several MaterialsClass 300 Ratings for Flanges – Several Materials
0.0
10.0
20.0
30.0
40.0
50.0
60.0
0 100 200 300 400 500 600 700 800
Temperature (C)
Pres
sure
(bar
g)
Carbon Steel(B16.5)
316StainlessSteel (B16.5)Nickel Alloy400 (B16.5)
Coper AlloyB61 (B16.24)
AluminumAlloy 6061-T6 (B31.3)
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Classifying Componentsby Reliability
Classifying Componentsby Reliability
RobustnessFire ResistanceBlow-out ResistanceTendencies to Leak
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RobustnessRobustnessAble to withstand exposure to loads such as:
Being stepped onDropped toolDropped tool boxForklift trafficTruck trafficCrane booms
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Fire ResistanceFire Resistance
Components able to maintain piping system integrity if subjected to approximately 1200 F (650 C) for 30 minutes. The intent is to
prevent the exposure of fire fighters to danger due to leaking fluids
prevent adding fuel to the fire
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Blow-out ResistanceBlow-out ResistanceGaskets and seals able to withstand high pressure without failing by extrusion or fracture. A short-term leak could be resealed by tightening the bolting. The intent is to avoid large leaks
when a flanged joint is not tightened properlywhen the piping system is subjected topressures much higher than designwhen large bending moments areapplied to the flanges
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Blow-out ResistanceBlow-out Resistance
Failure by Extrusion Failure by Fracture
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Tendencies to LeakTendencies to LeakSome joints are more leak prone than others. These are usually a strong function of the construction and maintenance practices at a particular site. Examples:
Threaded jointsUnionsElastomeric seals such as o-rings
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Pipe and Fitting SelectionPipe and Fitting SelectionWhat is a Fluid Service?What is a piping system failure?Bases for selectionIndividual components (metallic):
What distinguishes one fluid service from another?
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Piping System FailurePiping System Failure
How can you recognize a failure in a piping system?
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Bases for SelectionBases for SelectionPressure ClassReliability
RobustnessFire ResistanceBlow-out ResistanceTendencies to leak
Corrosion ResistanceMaterial ToughnessCost
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Corrosion ResistanceCorrosion ResistanceWhere corrosion is more or less uniform, extra pipe wall material can be provided in the form of a “corrosion allowance”.
Where material degradation is localized, either preventive measures must be used or a more resistant material must be provided. Examples of localized material problems:- Erosion - Pitting - Intergranular- Stress-Corrosion Cracking - Microbiological- Hydrogen Embrittlement
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Material ToughnessMaterial Toughness
Measured by energy necessary to suddenly propagate a crack to failureMostly of concern for carbon steelsGenerally decreases as temperature decreasesFactors affecting fracture toughness include:
Chemical composition or alloying elementsHeat treatmentGrain size
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Example of Brittle FractureExample of Brittle Fracture
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Example of Ductile DeformationExample of Ductile Deformation
Fiberglass or carbon fiber reinforcementPolyester, vinylester or epoxy resin
Thermoplastic Lined Metals
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Non-Metallic Pipe and FittingsNon-Metallic Pipe and Fittings
CharacteristicsLess expensive than metallic alternativesCannot be made fire resistantMore sensitive to abuseMore supports are generally requiredFlanged joint make-up requires more care
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Thermoplastic Pipe and FittingsThermoplastic Pipe and Fittings
(Charlotte Pipe)
(Durapipe)
(Durapipe)
• Pipe is extruded• Fittings are usually injection
molded, but sometimes fabricated
• Valve parts are usually injection molded
• Requires warm, dry and clean environment for fabrication
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Thermoplastic Pipe and FittingsThermoplastic Pipe and Fittings
(Asahi)
Butt fusion fittings are joined to the pipe using a butt fusion welding process.
(Asahi)
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Thermoplastic Pipe and FittingsThermoplastic Pipe and Fittings
(Spears)
Socket fittings are joined to the pipe using a socket fusion welding process or solvent cement.
(Asahi)
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RTR Pipe and FittingsRTR Pipe and Fittings• Pipe is filament wound
or centrifugally cast• Fittings are molded,
filament wound or fabricated
• Few RTR valves are available
• Requires warm, dry and clean environment for fabrication
(Smith Fibercast)
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Butt fittings are joined to the pipe using a butt wrapping process.
RTR Pipe and FittingsRTR Pipe and Fittings
(Smith Fibercast)
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Socket fittings are joined to the pipe using an adhesive.
RTR Pipe and FittingsRTR Pipe and Fittings
(Conley)
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RTR Pipe and FittingsRTR Pipe and FittingsA leak at an elbow requires1. Cutting out the elbow
and adjacent pipe2. Fabricating a piece with
an elbow and two couplings
3. And installing it, hoping none of the six new joints leak
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Lined Pipe and FittingsLined Pipe and Fittings• Common liners are
fluoropolymer, polypropylene, and PVDF
• Liners can be “locked-in” or loose
• PTFE and FEP lined systems require vent holes
• Pipe and fittings are usually ductile iron and steel
• Systems usually have many flanged joints
(Resistoflex)
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Lined Pipe and FittingsLined Pipe and FittingsTypical Fittings
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Lined Pipe and FittingsLined Pipe and Fittings
Untypical Fittings
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Pipe & Fitting SelectionPipe & Fitting Selection
Workshop: What basic piping system characteristics would you provide for the following services:
Steam condensateSulfuric acidGasoline650 psig (45 bar) SteamHeat transfer oil
See Supplement page 21 for details.
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B31.3 Fluid Service DefinitionsB31.3 Fluid Service Definitions
Category DCategory MHigh PressureNormal
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B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsCategory D: The fluid handled is
nonflammable, nontoxic and not damaging to human tissue. The design pressure does not exceed 150 psig (1035 kPa). The design temperature is greater than -20°F (-29°C) and does not exceed 366 °F (186°C).
Often characterized as “utility”
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B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsCategory M: A fluid service in which the potential
for personnel exposure is judged to be significant and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to persons upon breathing or on bodily contact, even when prompt restorative measures are taken.
Often characterized as “lethal”
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B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsHigh Pressure: A service for which the owner
specifies the use of Chapter IX [of B31.3] for piping design and construction… considered to be in excess of Class 2500 (PN 420).
Characterized as “high pressure”
Normal: Everything else.Often characterized as “process”
See Table in Supplement.
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Fluid Service SelectionFluid Service Selection
Workshop: What B31.3 fluid service definition is most nearly applicable for the following services:
Steam condensateSulfuric acidGasoline650 psig ( ) SteamHeat transfer oil