= 5 hE Tei mauncep we Mpl a7 HE. is Lé0 ma 7 FAUI PERTILIZER COMPANY LIMITED PLANTSITE ~ GOTH MACHU jCONTENT: WHAT IS STEAM? WHY STEAM IS REQUIRED IN AN INDUSTRY? HOW STEAM IS GENERATED? WHAT IS CONDENSATE? HOW IS CONDENSATE FORMED? PROBLEMS DUE TO CONDENSATE IN PIPES. HOW IS THE CONDENSATE REMOVED? TYPES OF STEAM TRAPS. MAINTENANCE.Mh FEC WHAT IS STEAM? [As we have studies in PHYSICS that every MATTER exists in three basics forms, namely SOLID, 1IOUID and GAS. The presence of each state is due to certain conditions of PRESSURE and TEMPERATURE, If we alter any of these condition, the states will change 2.9. If we heat water to 100°C, it starts to boil end on further heating will cause steam formation, which is the gaseous state of water. WHY STEAM IS REQUIRED IN AN INDUSTRY? Approximately every industry requires and has steam production. There are many usages of steam in an industry. 1. tis 2 source of power for steam turbines, etc. 2, tis used far heating / cooling of afferent fluids. 3. Miscellaneous utilities such as line jacketing, instrumentation, oil spill cleaning etc. HOW STEAM Is GENERATED: In an industry steam is gonerated in pressure vessels called BOILERS. The essential parts of a boiler are TUBE, PRESSURE SHELL, IGNITION SOURCE. BLOWER, SAFETY VALVES. a esters ‘These are normally of diameters 4, %, Vinches. 37325” These ore made of carson st SHELL: It ig made of carbon steel plates and its thickness is dasigned to with stand TECHNICAL TRAINING CENTRE ~ crIGNITION SOURCE: In ease of gos fired boilers this is # burner which uses natural gas. tn case of coal fred boilers coal is used. (Normally the decession of type of ignition source required depends upon the availabilty of fuel. In Pakistan natural gas is abundant therefore natural gas is used). Lowen: Blower is used for forcing the hot gases into the tubes, in case water is in shell side and in shell in case water is in tube side. ‘SAFETY VALVE: Safety valves are fitted or the-sholl-to let the stiuim pass if TE pressure increases the design pressure of the boiler. f safety valves are not provided on the shell then the steam pressure exceeding the design pressure of the boiler wil exert 9 tremendous pressure on the shell, which might burst TECHNICAL TRAINING CENTRE2PRG WHAT IS CONDENSATE? When steam is cooled down it changes back to its liquid form called the CONDENSATE, HOW IS.CONDENSATE FORMED?— When stoam is generated it has to pass through pipes to reach where it ie required, e.g. steam turbines. As the temperature of steam is much greater then the pipes, therefore heat energy from steam will be transferred to the pipes (we know from physics that heat flows from high temperature to lower temperature.) This loss of heat energy will cause a temperature drop in steam which is in contact with the pipe, and hence drops of will be formed and will collect at the bottom of the pipe, called the condensate. ‘CONDENSATE Formation of condensate depends largely on; 1) Rate of heat transfer 2} Insulated / Non-Insulated pipes 3) Ambient temper FTRETINIGAC TRA ENTAE oaBee HOW IS THE CONDENSATE REMOVED? provide drain valve at Hocations where the condensate (2 Ore likely to accumulate. As the steam cuit is usually very long, which includes pipes gone UP and va at mast ofthe places. Therefore the best facaton t9 provide Hse valves vee thowe portions of piping cuit which are at lowest elevations then others. te the above figure, portions a,b, ¢ & J are more Tkely 1 accumulate condensate, therefore if wo provide valves at these lacations then He amount of condensate accumulated in the ctcuit can be removed aut by providing valves, it will be uneconomical, bacwuse for ope/a8NG these aves we wil have to depute operators for each valve and ie removal of voveneate wilt putely depends upon eeir experiance and practice, oxhenwise will cause steam leakages. ine selection of steam traps is by no means staighforward, A wap TNSE be veucted to carry out a given function unger given conditions, THese TY sve variations in operating pressure Yad oF ack pressure: Taps TY Pe pieced to extemes of temperature oF water nammer, wie cOrosion OF eet ave other common hazards Ti GAIGAL TRAINING CENTRE oy otes PROBLEMS DUE TO CONDENSATE IN PIPES: [see aL WATER HAMMERING. ‘When condensate collects at the bottom of the pipe it starts to move with the steam and when it reaches any restriction such as ELBOWS, VALVES, EQUIPMENT OR. MACHINERY like Steam turbine, it creates sound and vibration upon impact, This vibration can cause the pipe to dislodge from its supports: or ‘can make pipe joints weaker. b) STEAM! ‘The condensate due to its heavy STARVATION: weight collects at the lowest portion of the piping circuit such as a vertical U-bend. This condensate restricts the flow of steam to an extant that the amount of steam required does not reach, causing steam starvation, IRREGULAR EXPANSION OF PIPES: ‘The portion of pipe which isin contact with steam exp corresponding to the ste temperature where as the port of the pipe in contact with condensate expands corresponding to condensate temperature. This iregular expansion of pipe causes th pine to bend thus weakening the pipe joints oF stressing the machinery J equiprnent connection with pipe wo bod jen - — shonin CcunncAl sRanic CentER ~ usMK @Q STEAM TRAPS THE FUNCTION OF STEAM TRAPS It ig extremely important that steam distribution system always be properly drained, Steam traps are the key to optimum steam / condensate system operation, and as such, have three basic functions: (1) Remove condensate: Condensate must be allowed (0 pass through the trap quickly and completely, keeping the heat ansfer equipment and piping free of condensate to maximize heat transfer. (2) Remové air and other noncondensible gases: Air and gases In the system reduce heat transfer area, and lower the overall heat transfer temperature. In addition, 07’ and COz are corrosive in the presence of condensate. (3) _ Prevent steam loss: The trap must minimize live steam loss while it passes condensate, air ana_noncondensibies. TYPES OF STEAM TRAI ‘There are three basic types of steam traps, operating on three basic physical principles to distinguish between steam and condensate: (1) Thermostatic (temperature difference}: The thermostatic, trap senses temperature, and operates on @ wemperaiure difference between steam and condensate. The steam not only has a higher temperature than the condensate. but also has a higher neat transfer coefficient, ané can have an immodiate effect on the thermostatic sensor. The sansor cools ee SHNIGAL TRAINING CENTREZi ZERG Ine presence of condansate, and opens a vale to clooge i but upon contact with live steam the valve is closed to prevent steam loss. KS Lig (2) Mechanical (density difference): This tap relies on the Gitference in density between steam and condensate for its volicot : eperation. A fost or bucket ses in the presence of condensate, and fall when only steam is present. This mechanical movement causes @ vale to open in the presence of condensate, and close in the presence of steam. @ Trermodynamic (change of stato: This third tye of wap tot so easy recognized as such and encompasses 2 group of spparentyunelted devices. These include ‘thermodynamic, impulse and labyrinth traps, and even the simple oc pate. Al ry on the fet that hot condensate released under pressure, can "flash off” to give a mixture of ‘steam and water. THERMODYNAMIC TRAPS * ‘Thermodynamic traps are phase detectors, ie. they can differentiate between liquids and gases. But they cannot differentiate between steam and air or other non-condensible gases. i, Disc Traps- Disc Traps utilize the heat energy mn hot condensate ‘and the kinetic energy in steam to open and close a valve disc, They are phase detectors, sensing the difference between liquid and gas or vapor Fig. 3-4 helps 10 explain how the trap operates. Oise: A ss caisedt Irom die seat € by incoming, pressure, allowing aie and condeusata to pass rarkally TECHNICA TRAINING CENTRE a 2ZRERe ZlsG to steam. Flash steam flows round the end of the disc resulting in pressure build up in the control chamber O. wet Por (8) {enset Chamber (D7 Seating Sutace oy Wales Die (AD When The steam pressure in chamber D acting over the full area of the disc exceeds the incoming condensate pressure acting on the much ‘smaller inlet area, the disc snaps shut-covering the inlet orifice, This snap action is important, Disc traps are most frequently used in light condensate load applications and are known as “hot” wraps ie. quickly discharging very hot condensate immediately after it forms. Strainers are installed at the inlet to ensure dirt free condensate / steam TECHNICAL TRAINING CENTRE aN\ Ga] os) @ Advantages: © Simple construction, © ~ Small size and light weight. © Can be mounted in any position. © Rugged, withstands water hammer. Disadvantages: © Marginal air handling capability. © Condensate discharge temperature cannot be adjusted. © Excessive back pressure in return systems can prevent trap from closing. - © High discharge noise level. Piston Traps - Fig. 3-8 shows piston trap and its internals. During initial start-up pressure created by. the-cold- condensate lifts the piston vaive, allowing discharge of condensate. When the temperature of the discharging condensate is very close to steam temperature, the condensate, experiencing the lower pressure of the control chamber, wil change into flash steam. This increased pressure, acting on a larger effective area of the piston valve than the inlet pressure, causes it to snap shut-preventing steam flow through the trap. When cooler condensate reaches the trap, causing the control chamber pressure 10 drop. wap reopens to repeat the cycle. ‘The contol orifice provides @ continuous discharge which is helpful in passing air or other non-condensable gases during start-up. Steam toss through the control orifice is minimal TECHNICAL TRAINING CENTRE agFst Once Second Once (Centro! Cafes) Seat Paton Vale Fig. 3-8 Advantages © Suitable fer high pressure © Can be meunted in any position, © Good response to changing condensate load conditions. © Ruggéd, withstands water hammer. : © Good air handling capabiity © Small size and light weight. Disadvantages © Excessive back pressure in retun system can prevent trap fiom closing, © Condensate discharge temperature follows the saturation curve over 2 limited range. ‘GHINIGAL TRAINING CENTRE 12ZEEG i. Lever Traps - Typical lever trap is shown in Fig. 3:C. Incoming condensate pushes the lever upward with a titing motion and full flow 005 under it and out the discharge port. Condensate flowing past the inlet seat (a restriction) experiences a pressure drop and it will flash into steam when the condensate temperature is very close to steam temperature. The localized lower pressure under the lever causes the lever and inlet valve to snap shut. This prevents steam flow through the trap. When condensate with its cooler temperature again reaches the trap, it will reopen, repeating the cycle. Lever traps are designed for applications “having especially large condensate loads and that benefit from the very rapid discharge of condensate after its formation. het Seat FustOree Inet Valve ischange Fig. 3-C TECHNICAL TRAINING CENTREN\ te) ay @ Advantages © Suitable for high pressure applications. © Good response to changing condensate load conditions ©, Rugged, withstands water hamme © Good ait handing capability © Small, Gompact, easy to install and service. Disadvantages © Excessive back pressure in return systems can prevent trap from closing. © Can only be mounted in one position. Impulse - The impulse trap is shown diagrammatically in Fig. 3-D. It consists-of 2 hollow piston A with a piston disc 8 working inside 2 tapered piston C which acts 2s a guide. At start up the main vale rests on the seat leaving a passage of flow through the clearance between piston and cylinder and the hole & at the C top of the piston. Increasing flow of air and condensate will act on the piston dise @ and lift the main valve off its seat to give increased flow. Some condensate will also flow through the gap between piston and disc. through E and eway to the trap outlet TECHNICAL TRAINING CENTRE rs‘As the condensate approaches steam temperature some of it flashes to steam as it passes through the gap. Although this is bled away through hole E it does create an intermediate pressure over the piston, which effectively positions the main valve to meet the load. perise) c(erenoee) 4 Advantages Can handle substantial condensate capacity as compared to their ‘Suitable for high pressure applications. Good air venting capabilities. ‘Small, compact, easy to install. Disadvantages Cannot give a dead shut off and will blow steam on very low loads Easily affected by any dirt and plug small clearance between piston and cylinder and of course the control orifice. Trap will not work against @ back pressure which exceeds 40 percent of the inlet pressure. INIGAL TRAINING CENTRE\\ ZREC ZEEG ve Labyrinth - This type hardly qvlfies 2s a0 “automatic dain ap but is shown in Fig. 3-£. It consists of a series of battles which can be adjusted by means of a hand whoe!, BAFFLES Fig. 3-E Hot condensate passing between the first baffle and the trap body is subject to 8 drop in presse nd soma off Hshes to steam. The space around: the ext bale has.40 cope with ncossed wokine of Hot condensate and flash steam. "Tlie result is a'restriction along the length of . the wap wtih slows down the How of contensate and peers the On scape of ive steam. C The device is fairly crude and requires frequent adjustment to cope with varying conditions. Advantages © Can handle condensate in targe capacity a5 compared to its size. 9 No mechanical failure since there are na moving parts TECHNICAL TRAINING CENTRE TGOs oO ZPrG Disadvantages © Manual adjustinent i required with the variation in either steam pressure or condensate load. If the adjustment is not done. Steam wastage or water logging of the steam space will occur. Orifice Traps - This device consists of one or more successive orifices. Where two or more orifices are used (as shown in Fig. 3-F), condensate passes through @ number of | successive chambers where flashing ee oceurs. This, in tum, creates @ restricting or choking L effect and allows the use of larger and loss dirt sensitive orifices» for a. given] Ze condensate capacity. In Second Ost some. design executions ‘these orifices are adjustable valves, Fig. 3-F Advantages © No moving pars. © Suitable for high pressure application © Rugged, withstands water hammer. © Can be mounted in any position Disadvantages © Orifice size must be carefully selected for each instattation © Can not respond to varying condensate loads. © Inetticient if oversized © Dir particles readily impair portormance. SHINIGAL, TRAINING GENTRY© Diliult to field check because of continuous discharge. © Inthe absence of condensate, the trap passes live steam. MECHANICAL TRAPS Mechanical traps, are also phase detectors. These devices respond to changes in condensate level only, independent of temperature-or pressure. ‘They respond rapidly to changing conditions. Condensate discharae temperatures follow closely the saturation curve and they have @ modulating type of discharge. They are extromoly energy efficient. All mectianical traps are position-sensitive. i. Closed Float Traps - Although it is one of the oldest in the market, the closed float trap is still in widespread use: The opening and closing of the valve is caused by changes of the condensate level within the trap shell. Fig. 3-G shows float and float thermostatic traps. When the i of the float closes the valve. As-condensate trap is empty, the wei centers the trap, the float rises and opens the valve, allowing condensate to be discharged. = ‘An inherent disadvantage of 2 simple float trap is that it cannot discharge air or non: condensible gases. It is therefore necessary to install an auxiliary thermostaticelly activated air vent. For this reason, these aps are known as float and thermostatic or F & T taps. Fig. 3-6 TECHNICAL TRAINING CENTRE €Advantages © Unaffected by sudden or wide pressure changes. © Responds very quickly to condensate load changes. © Continuous discharge. © Condensate discharge temperature closely follows the saturation © Simple construction. . Disadvantages © Relatively large and heavy. © Float easily damaged by water hammer. © Can be mounted only in one position. © Suitable only for relatively low pressures, © Requires auxiliary air vent which is an additional source of failure. ji, Inverted Bucket Traps - Inverted bucket traps are members of the mechanical trap family, using an open “inverted bucket” as‘a float. The trapping principle utilizes the difference in density between steam and water. The construction of the trap is such that the (rap inlet leads into the bottom and open end of the inverted bucket. Discharge is through an outlet valve above the inverted bucket as shown in Fig 3-H, TECHNICAL TRAININGSteam entering the inverted ‘and submerged bucket, ‘causes it to float and close the outlet valve, preventing discharge of steam. Steam in the bucket both condenses and leaks through the vent, allowing the bucket to sink ‘and open the valve to discharge condensate. Inverted bucket traps. discharge condensate intermittently. very near saturation temperature. ‘Any air o nen-condensible gases entering the trap will aiso cause the bucket to float and the valve to close. In order to overcome this problem, the bucket has a hole to vent air and steam. Advaritages © Simple construction. © Rugged. 0 Condensate discharge temperature closely follows the saturation curve. © Fast response to changing condensate loads. Disadvantages © Marginal air handling during startup 08 Can tose prime, and is not self-priming, 9 Can be mounted only in a single position.iii, Open Bucket Trap - Open bucket traps are rarely used today. When condensate first enters the trap, it fils the trap body and causes the bucket to rise and close the vale at the top of the trap. Condensate will continue to enter the trap, finally spilling over into the bucket. This causes i to sink and open the valve allowing discharge of condensate. When ‘steam arrives, it pushes the condensate out of the bucket through the siphon tube, which in turn refloats the bucket and closes the valve. ‘As the steam in the trap condenses, additional condensate enters the trap and the cycle is repeated, Fig. 3 This type of trap requires an auxiliary thermostatically activated air vent. Typical open bucket trap is shown in Fig. 3-1 Advantages © Simple construction. © Condensate discharge temperature closely follows the saturation © Fast response to changing condensate loads, Disadvantages, Can tose prime, not selt-priming © Can be mounted only in a single position, TECHNICAL TRAINING CENTRE 5ZeeG — © Requires auxiliary air vent which is an additional source of failure. © Suitable only for ralatively low pressures. © Relatively large and heavy. THERMOSTATIC TRAPS = sone, @rlerdves thermostatic traps respond to changes in temperature and therefore differentiate very well between steam and cooler non-condensible gases. ‘They can rapidly purge air from a system, especially on 2 cold start-up, and can be installed in various positions. cooling leg atleast three feet in length is recommended for better response. Of : « Bimetallic - \etalic steam traps utilize the serisible heat in the Condensate in conjunction with line pressure to open and close a valve. ‘The bimetalic elements are in. the form of small discs and are arranged to yroduce a closing force with increasing temperature as shown in Fig. 3-J. | eimeratiic ‘sreirs= = |_eeoy 29 Siar Fig. 3-4 Some bimetallic traps use a single leaf element rather than the stacked disc elements.As the condensate cools, the line pressure becomes the dominant torce, causing the valve to open and allowing the discharge of condensate, Gack pressure in @ closed rotum system provides an TECHINICATZFC Unfortunately the replacement seats of some thermodynamic weps are more complicated. Two separate gasketed joints may have to be made or 2 single gasket has t0 cope with twa or more steam / condensete passages. The "weakest point is in fact the joint between trap body and seat, Particularly if this has been allowed to blow steam, remaking it become impossible. {A lot will depend on site conditions. The small float and inverted bucket taps. fas shown in figure, are designed so that the cover with the internals attached can be taken to the workshop for atiention without disturbing the pipe work. “This is far preferable to renewing the seats of inaccessible traps, welded into pipe work. REPLAt “TRaps: ‘On some sites the high cost of labour will rule out the repai of all but'the largest traps. In these cases it is essential that the traps themselves can be ‘changed easily. Flanged connections provide one: solution. Unfortunately the ftariged trap is ‘more expensive than the equivalent screwed trap, while the meting flanges are an additionet expense. The trap chown in Figure was designed for easy removal from welded systems. Two large. unions with generous faces ensure adequate joints which can be broken quickly to facilitate trap removal. ‘STRAPS2,DOC/hmZePG additional closing force resulting in a lower opening temperature than the same wap distharging to atmosphere. The discharge temperature, therefore, is affected by back pressure, © Rugged. © Withstands waterchammer. © Capobie of discharge temperature adjustment, © Can be mounted in several positions. Disadvantages © Dirt particles can prevent tight valve closing. © condeasate discharge temperature is made lower as backpressure Increases. . ° © Relatively slow response to changing condensate loads. ©. Bimetallic elements are relatively susceptible to corrosion, “Bellows traps (Balanced pressure) -° --Bellows~traps: are thermostatic traps that respond to the changes in the temperature and Pressure of the steam supply to open and close a valve. The valve actuator is 3 capsule or bellow filled with a vapourizing fiquid. Typical construction of bellows type steam trap is shown Fig. 3-K {In the cold conditions which exist at start up the element is contracted, ‘The valve is off its seat and is wide open, allowing removal of aut. TECHNICAL TRAINING CENTRE 0Batiows Element wer Fig. 3-K {As condensate passes through the trap, heat is transmitted to the liquid in the element, Before steam reaches the trap this liquid boils. The vapour pressure within the element causes it to expand and the trap shuts, Heat loss from the trap cools the water surrounding the element and the filing condenses. The element contracts to open the vélve and releases condensate until it again approaches steam temperature when the cycle is, fepeated. ‘The temperature below steam temperature at which the tap operates is governed by the filling. At the same time the fact that the element is thin walled means that the boiling effectively takes place at the operating pressure. Advantages © Excellent air handling capability. © Energy efficient 6 Various condensate discharge temperatures available depending on bellows cesign. AL TRAINING CENTREZZIRER Z ZFEFG © Condensate discharge tomperture follows the saturation curve © Can be mounted in several positions © Simp constustion. © Small size and weight. Disadvantages © Bellows elements tend to be failure prone, especially when subjected to water hammer. © Generally not suited for high pressure applications. Liquid Expansion Traps - is one of the simplest thermostatic trap-as shown in Fig. 3:4. An ci led element expands (when hor + condensate pass through the trap) and close the valve against the seat ‘The adjustment allows the element to be moved relative to the seat which effectively alters the temperature of the trap discharge. This type of trap operates at 4 fix temperature what so ever be the condensate tempsrature. caenon ree Fig 3-L TECHNICAL TRAINING CENTREoajuey Suraresy, peorryoe LO roma y-sA-POOSEN £44 PAMOEAOY SWALSAS ONIdId- INTRODUCTION - MANUFACTURING - PIPING MATERIAL - PIPE SIZING - - PIPE FITTINGS - PIPING PROBLEMS & THEIR REMEDY - PIPING SPECIFICATION - OFF SETS ~ PIPING EXPANSION JOINTS - LINEAR EXPANSION OF PIPINGe PPG recuucat anno cenmae page IPING Aa essential part of @ power plant is the piping used to convey steams, water, gas oll Compressed ait, chemicals, etc. This piping must be properly designed so that it will be of sufficient size and strength to adequately handle tne service for which it is required, It must be installed in the proper mannar with the neceszery valves end fittings end With provision mage for expansion and contraction, drainage, support end insulation ‘These considerations are discussed in this lesson, DEFINITION: 66 Pipe is mechanical component pf round shape, and Hollow, tram inside which used to transfer liuid/vepors gas trom one point to snotnet,ike house water pipes. Normally available from 1/8 inches, Diometer to 40 Og ines dometr + Large size than 40 inches are also avoitable on request. CQy sheen sizes normaly used ore He Me het-¥/2, 25-4 58,10,12,14,16,18.20, 24 she 1-1/4, 2.112, 3-1/2 & 8 are seldom used. 1/8, 1-1/4, 3/8 & % pipe is usually restricted {0 instrument lines. J" pipe is extensively used for steam tracing of lines Straightpipe is, supplied in random lengths (20 ft - 36 ft). The ends of these length 2re normally beveled for welding (BE], Plain (PE) or threaded and supplied with one coupling.per length (T & C} MaNuracTURING: Pines are manufactured to mest various conditions and requirements of services. Following are some methods of manufacturing Seamless Stee! Pine ‘Seamless steel pipe is made from e solid billet of stesl, which is pierced and rolled {0 obtain the required diameter and wall thickness. Although this is a most expensive method to manufacture pipe, seamless pipe is stronger than welded pipe and suitable for higher pressure and temperature service. When a piping system is subjected to pressures above 600 psi the pipe should be ot seamless construction Seam / Welded Steel Pi Welded stee! pipe is made from flat steot plates thet ar¢ rolled into" tubular shape ‘and the edges then welded together by ans of three methods (al. Butt welded. the edges are not beveled bit pareilel to each.other Ine filler mets! sede "Lap welded, che edgos are bevalad and overlaped at the joint. Prior 19 rolling and the a:cove formed filled over 8° Gia ded the asiges oe bev: 2. “hus method is used is pip Fusion v» — = BIPAG secmcat raamme centre Weided pipe is lass costly than the seamless type but can only be used, due to its Inherent weakness, for relative low pressure applications A} Welding a bended metal plate ina straight ine Parallel ta the axis. B) Welding a spiral bended plate. S| ~mny BR Gosted: One of the oldest pipe material cast iron is stil in use today. They ere cested from cast iron, used for low pressure and corrosive service such 88 spwyer pipe. Po oO. All above three types of pipes are usod at our plant, PIPING MATERIAL: The material to be used for pipe manufacture must be chosen to suit the operating conditions of the piping system. Guidance in selecting the correct material can be obtained from standard piping codes. The objact being to ensure that the material used is entirely safe under the operating conditions of pressure temperature corro- sion anc erosion expected. ‘The most frequently used materials for power piping systems are: - ow earbon steels alloy steels ‘austenitic stainless steels oC CLASSIFICATION OF PIPE: Many kinds of pipe are manufactured to meet the varied and requirements of service. The major classifications aie according to the material used, the process of manufacture, and the type of Joint used. 1 Wrought irons . Wrought iron pipe is identified by +9 paintéd or knurled spiral marking on each section. tis made of about 97% iron and 3% slag. This composition makes. it more resistant 10 certain types of corrosion than ordinary steel pipe, and it is therefore sometimes spacified for heating systems Ik is not as strong es wrought steel pipe and yet costs mora because it is menufactured in small quantities Very little wrought iron pipe is ssen in the refinery and it should never be used for any process pioingZFFC ZIPIPG sccumeas ranma cenree : 2, Wrought Steel: Mer This is the common cerbon steel pipe that is so widely used. It contains about 99- iron. While normally used black (that is, without any coating), stee! pipe for srinking water lines is purchased with a bright zine coating called galvanizing which ives added protection against rusting This pipe is used in low-prescure steer, la. Ud, and gas line service at temperatures ranging upto 780 to 1100°F, 3. Carbon-moty: Carbon steel pipe thet contains a very small percentage of metal molybdenum is referred to as carbon-moly pipe It is stronger than common steel pipe at high tem. Peratures. A preheat is generally necessary whan wolding this type of material P1 4. Chrome Stee! Chromium added to steel adds strength and incraases its resistence to corrosion Pipe ‘in this classification is usually identified by the amount of chromium involved, such 88 1%, 2%, 4 to 696 oF 6 to 8%, (These alloys all require preheating and stress Felieving when welded construction is used). P-11 1% 9% cromium and %% molybedenium. P12 1% cromium and 14% molybedenivm. P-22 2% % cromium and 1% molybedeniun. 5. . This is @ broad classification Thermoplastics euch as PVC, PE, PP & ABS (Acrylonitiite ~styrene) are mostly used for low pressure, corrosive service. Asbestos cement pipes are used for water lines. It is corrosion sesistant with smeoth inner. Selt water, corrosive soils will not hermit Epexy, polystyrene and phenolic resins with glass reinforcement are also widely used they are generally called fiberglass or ATAP]. Materaials Used in FFC CARBON STEEL Moterial Specs. + [Normal Composition Product een Carbon Stee! Fos fr paleo ahd Fe ASTM ASS Carbon Ste Pipe for General use. ASTM AOS Carbon Stee! Fipas for high tom. service ASTM A-105 Carbon Steel Forged CS flanges and fing ASTM A234 Gr. WPB, Carbon Stee! Seamless and welded fittings. [astwat7e arbor Steal Cold drawn heat exch. & __ } condenser tubes [ASIN ASSES GT _7 [Riles carbon sieei mi [Klied carbon sige) ~~ T Flanges itings for tow temo i j Seviee. | ASTM A.350 Gr. LFI/LF2LOW ALLOY STEEL ASIN ASES GPT [Site (PH) "Tipe TorRigh emp: sevice] | (ASTM AS3E GPT TSG Silo (IIT Pips fori tmp. sevice | [ASTM A336 GrPIs 1C-0.6Mo (P12)_—| Pipe for igh temp- service [ASTM AB35 GeP22 J 2.25Ci-1Mo (P22) | Pipe Tor vary high temp carvice ] ASTM ABD G.WPIN TED For PY, PIT & P22| Fitting for high temp. Service ‘respectively ASTM A2I7 Gr WETTED ae: Castings for high temp. service ‘| [ASTM A208 THAT Equiv. to Pi and PTT Tubes for Figh temp. Service AINLESS STE ASTW A312 TPS0aBOaL | TaGraN [Austenitic SS Pipes [ASTM A312 TP3i6/316L | TaGreniaMo ‘Austenitic SS Fipas ASTM ASI2 TST BIN | BCT aT Austenitic SS Fipes ASTM A-SI2 TP347Ra7H T8CrENI +CbFTa | Austenitic SS Pipes” ASTM ADI9 TP0aaTe SS-304/8S-316 Aust. SS tubes for heat exch, are A182 F-304/F-316 [ASTM ASST CrBICrS’ cra IOFSMICFBC 4 TuCFEC (SS Uree Grade L [Fiberglass pine vt [REC Pipe Claas 5 VE ASTM AOS GW sORRIE] | NON-METALLIC [RIRP—Tighiy cowoaive ous) } ‘SR Rasist coment + Austenitic 53 forging/fittings and valves | Weldedt or Seamiess fittings | Castings and cast vaives SS-30HSS- TE [Ss30asS-316~ ‘or S8-308 730017 ~ 916 /3161/321/947 respectively 25 Cr-B2Ni ~2Mo | For Highly corrosive Urea and” carbamate soliton, ee Pressure service, a ‘inking water and [plant waste ines ‘or moderate temp. and | pressure Service Asbestos Polyvinyl chibaide i | iPAU UW rechnicat TRAINING CENTRE PAGE-6 CENTRE —____PAGE:6 JOMINAL Si Fine is usualy called by its nominal size which means that it is not exactly that size, but that it is sufficient for identification. For instance, when we say 6° pipe we are ‘actually referring to pipe which has an 1D. of 6.065" in the standard wall *hicknece Pipe 12" and smaller is known by its nominal inside dlamater, while pipe 14" onal larger is known by its outside diameter. Tubing and boller tubes are always knows by their outside diameters. Nominal Pips Size 6” op = 6.625" ID = 6.065” SC ° Example; From this table No. 1 you will see that Outside diameter of a pipe remains édnstant but inside diameter changes according to well thickness of pipe schedule TABLE NO. 01 10" Sch. 80 10" Sch. 40 OD= 10.75" 0D= 10.75" Wwr= 594" wr 365" ID = 10.75-2x,598 © = 1075-2x.366 = 9.562" = 10.02" “a “vi | g| S| g NOMINAL PIPE SIZE = 10 PipingBIPIE vecumcat teaming cewtne WALL THICKNESS: For any given size of pipe there is @ choice of wall thickness. The thickness of metal required for a particular service is determined by the job engineer after consideration vf the temperature, pressure, and possible corrosion allowance invoived. The differ- {ences in wall thickness for a given size pipe are always made by changing the inside iameter (1.D.). The reason for this, of course, is that the outside diamoter (0.0.) ‘must be @ standard size for threading and for matching all :ypes of fittings. Thus, the 0.0 is usually measured to identify the size of the pips. |n the past, wall thickness has been specified by the terms standard, extra strong, ‘and double extra strong, which are usually written as Std., XS end XXS. To meet Industriat requirements in recent years, manufacturers of pipes have been supplying ‘meny additional wall thicknesses that could not be specified by these three terms. A system of using schedule number to specify wall thickness was developed and is, ow in use by practically all industries. The schedule is @ number that is actually folated to the strength of the pipe. The numbers were arranged to match the old system as much as possibie, and in IPS iron pipe size) upto and including 10", Schedule 40 has the same dimensions as the old standard wall. The same is true of ‘schedule 80 and XS upto and including 8” IPS. Thera is no relationship between the old XXS end any schedule number. MEASURING PIPE: {is important to be able to measure pipe property and identity tin terms of nominal size and weight (wall thickness or schedule). When pipe is received for 9 job it should bbe messured to make sure it is the same as the drawing calls for. To find the wall thickness of schedule numbor of piece of pipe, one must take two. accurate dimensions, the O,D and L.D of the specimen. By subtracting the |.D from the 0.D and dividing by 2, you will have an approximation of the wall thickness. ‘After you find the wall thickngss, convert it to @ decimal and then look at the pipe size indicated by the O.D and fi the closest number for that size pipe in one of the schedule columns. pire9 DIMENSIONS OF SEAMLESS AND WELDED STEEL PIPES 3 ZIPIRG secrnicat raamine crnrne APA ASA, ASTM, eB ew Be. ce. ch. cs Cor , Ch, va. come, Mae Cone. Conn Coup. Diem, es ABBREVY = American Petroloun Institut. American Standards Association. = American Society for ‘Testing Materials ~ Bottes Bonnet ~ Bectic Fusion Welded = Elecic Resistance Welded ~ Bolt Cirle = Conter to Center + Cast kon ~ Cast Steot = Conter to Face + Check Valve Colé Working Pressure Male & Female + Concentric ~ Connection ~ Counting - Dismeter Iron Pipe Size ay PIperirrens tor End to Face FSS Forged Stainioss Stee! Exty. —- Ext Heavy aw - Butt-Wela Fro. ~ Flange | Bik, ~ Blank : FS. Forged Stee! FtoC Face to Center FoF -Face to Face F&D Faced & Dries FW. Fels Wola Fi. = Figure FAS Forged Alov Steat Fw ~ Field Weta Gav. Galvanice Horie, < Horizontal tn “Inches to. ~ inside Diameter 188M. ton Body Bronze {or Brass Mounted)ZIPFG secucar manne cerns Fee 8 Ewe Nas. No. on. os.8y. PSA Press PG. R Re Fed. Rev. ik RTA Sera. Ser. 8.0. Fig RAD Saft ste. Eccentric - Elevation = End to Center = Non-Fising Stem Number = Outside Diometer ~ Outside Sérew and Yoke = Pounds Per Sa. Inche = Pressure - Pressure Gauge = Radius - Raised Face Reducer + Reversible Blank Ring Type Joint - Screwed Series « Slip On FiangeStrong, = Radius - Square Foot - Standard, Psa sm sTAe. NPs. Tomo. sw Tk. Tee Tw. TOE ver. W.0.G, ~ oR Fw WAN. Fg. XH 2X Hy, XX St0. st. Sa.in - Pressur Seal Bonnet - Stoo! Strong Nominal Pipe Size - Temperature - Socket Weald ~Tank Thread Both Ends = Theead - Thread One End - Vertical = Water,Oil or Gas ~ Header - Field Wels Wold Neck Flange - Extra Heavy = Double Extra Heavy © (same a8 XXsir0n9) = Double Extra - Extra Strong - Sdvare InchZIMAG recunont ream cevrne PIPE FITTINGS DEFINITI Pipe fittings are devices used to connect pipe to each ather or to equipment. IDENTIFICATION OF PIPE FITTINGS Its extremely important that the proper type of fitting is used for a particular service. Accidents have frequently occurred when a fitting of the wrong material hes becy Instalad in a pipe line. Therefore, al fittings must be properly identified as to the material and service con- ditions, All fittings not properly or clearly identified should be rejected. All markings, which shall be legible, must indicate thé following minimum require ments 1. Manufacturer’s name or trade mark. 2 Service designation, e.g. pressure-temperature for which the fitting is desig nated. 3. Material designation, e.g. steel or cast iron, ASTM No. ete Following are different fittings: 1. Counting Coupling is used to join two pines. A coupling may be used ta join {wo pipes of same size or different sizes when a coupling Is used to connect two pipes of different sizes, it is known as reducer cou. pling 2 Half coupling: A coupling with one end for pipe and the other énd welded to # pipe fF equipments is called a half coupling,5 BIPPO room 3 Union: Union is also used to joint pipe. But it differs from coupling. Pipe tines connected by coupling must be dismantled befare removing the f ‘but pine line connected with union fitting do not have to be removed in order to change the fitting. 4 Nipple: For making close connection a nipple is @ short length of pipe 12” and shorter with a variety of end connections. It is also used to join two straight pipes. Such as; BET Both end thread oer Gre cd tend Fired moines cemnr yng eroemins, CL two pipes of different sizes is called a reducer. Reducer fittings are of wo general types called concentric and eccentric reducers, a) Concentric Reducer: The reicr m whch the coal othe smal and oir ne is f=} same. [4 b) — Eecenttic Reducor: “The reducer in which the central ling of the two pipas is not same. It ‘should be noted thet concentric reducers are used on vertical pipe lines only while eccentric reducers are used on non vertical pipe lines. There may be reducer couplings, reducer union, raducor elbow. o u 6) Bushing A fitting used to connect threaded pipe or fittings of different sizes is called bushing. The male end fits into a coupling and the smaller pipe is then screwed in to the female end, 7) Cap: A cop is used to close the end of a pipe. 8) Plua: A fitting used to close female pipe openings is called 6 re] plug. The plug may be square nead solid plug, counter sunk plug, Hex-Head plug. Pic.ZFC Zz TECHNICAL TRAINING CENTRE PAGE-13 =Ebow: a, = Elbows are used to change directions of 2 pipe line. a} 90° Elbow It tums @ pipe S0° 45. Elbow It tums a pipe 45°. b) Reducing Elbow: Elbows with different size outlets are called reducing elbows. ©) Street Elbow: > An elbow with one male and one fomale threaded end is called @ street elbow. 2) Short Radius Elbow: The radius of short radius is equal to the elbows N.P.S. For example, 6° short radius 90 butt welding elbow has a 6" radius. ©) Long.Radius Elbow: A long radius elbow hes a radius 1.6 times the elbow’s N.P.S. For ‘example A 6" butt welding 80° elbow’s radius is 9". > - \ 11. Tee: A fitting with three end connections, shaped like the letter called 2 “toe”. They are different types such as; a) Straight tee b) Reducing vee 3 Beate es 12. ouoss A fing with four openings in the same pan» at 90° anges to eae fT Goneray used two types of ross: £ Tak @) Straight Cross12. Lateral A three way fitting shaped like the fitting “Y is called a Y-branch or lateral for making branch fine connection it 45° 14. Saddle: ‘A welding fitting used to reinforce a pipe oF fiting already welded {at 8 right angle (90°) to another pipe is called a welding saddle, 15- Weldatet A waldolet is @ fitting used for branch fcom header. These are available in different sizes and both ends are BUTT WELDED, 16- _ Sockolat: A sockolet is differ from weldolet. Its one end (branch side) is ‘socket weld and the other end Is BUTT WELD (Header side). 17 Threadoter: A threadolet is differ from both. Its one end (branch side) is, threaded and the other end is BUTT WELDED (Header Side) FLANGES This method uses flanges at the pipe ends which are bolted together, face to fa Types of flanges; BLIND FLANGE: A blind flange is @ sold flange that is driled to match the flange bolting and is used to blank off the piping, valves and vessel by bolting to another flange face, ‘REDUCING FLANG 4 reducing flange is used to connect a smaller to @ large flan face. The flange has the same outside diameter, bolt hole and Spacing as ihe larger flange. The connection may be welding rae Cferfeamecel PIPING CRese ReducingZane BIPIPG secimicar teanine cenrae ‘mice Fane Orifice lange consist of a pair of special flanges are widely used in conjunction with orifice mater for measuring the rote of thee Of liquids and gases. They are basically the same os standard welding neck, slip on and screwed flanges except for the provi, sion of radial tapped holes in the flange ring for meter connection and additional bolts to act as jack screws to facilitate separsting the flanges for inspection or replacement of the orifice plate WELDING NECK FLANGE: Welding neck flanges are afferent fram other types by thei long {tapered hub. The tong tapered hub provides an important rein forcement ofthe flange. This type of flange is preferred for every severe service conditions, whether this results from high prec ‘sure and temperature ‘SLIP ON FLANGE: Slip on flange to-be preferred to welding neck flanges by many users on account of their initially lower cost, the reduced aren, ‘2ey required in cutting the pipes to length end the somewhat greater ease of alignment of the assembly; however, thelt final installed cost is probably not much, if any, less than that of welding nesk flanges. Their calculated strength under intern! Pressure is ofthe order of two-third that of welding neck flanoce or these ceasons slip on flanges or limited to sizes 1/2 to 2 1/5 5 the class 7800 standard and not shown in the class 2500 ston dard. LAP JOINT FLANGES: Lap joint flanges are primarily employed with fap joint stubs, the Combined intial cost of the two items being approximately one, third higher than that of comparable welding neck flanges thet: Pressure holding ability is little, if any better than that of slip on flanges and the fatigue life of the assembly is only one-tenth anor of welding neck flanges. Tho chiof use of lap joint tlanges in ‘arbon or low alloy steel piping system isin services necessitan ing frequent dismantling for inspection and cleaning and where the ability to swivel flanges and to align bolt holes material simpliies the erection of large diameter or usually sti piping Their use at point where severe bending stress occurs should oe avoided, SOCKET WELD FLANGE: Socket weld flanges were initially developed for use on smal! size high pr initial cost is about 10% greater than that of slip on sure pin ic Orifice FlangeZIFIC secmens rman cevrne ante THREADED FLANGE: ded flanges made of steel, are confined to special applica- FLANGE FACES: rieededl Flanges are made with various types of faces, but the most corm ‘mon in use are the flat face, reised face and ring type. GASKETS: All flanged joints have @ gasket betwean the flange. The service dotermines the gasket material, 1) BULL FACED: ‘This gasket has the same outside diameter as the flange and use always flat face. — 2) LATING: UN SIDE BOLT CIRCLEX: a 2 AEN EOL setcomane Ce, ‘3 face ofthe flange fo the Inside edge ofthe Both s 3) ‘TYPE (METALLIC i “This gasket is used in aig type face. Te gasket is ccule and Pa ‘comes in two different cross sections one being oval and the ‘ther octagonal and flange face Is matched to the corresponding contour. PIPING. SIGNIFICANCE: ‘The components of Piping system have two purposes. 1) One to help keep the fluid moving freely and smoothly through the system, 2} To help keep the system and fluids in good condition. ‘The steam trap is one example and filters are another. eet PIPINGZIPIEG secmiont reamme cenrne OD OF JOWINS BPE ‘The three most common types of piping connections are: 1. THREADED OR SCREWED JOINTS 2. FLANGED JOINT 3. WELDED JOINTS 1. : ‘With this method, the ends of the pipe ere threaded and then served into threaded fittings. Threaded connector are usually used for small dia meter 2” or less. In gen- eral, threaded connectors are to be avoided as difficuty is ususlly encounter in preventing leaks around the thread and seal weld is required for many services. However for general maintenance work these are not as practical as threaded cou. pling that have beon seat walded. NOTE: All threads on piping components shall be taper pipe threads. 2. ELANGED JOINT: ‘The flanged joint involves the use of flanges at the pipe ends which are bolted together, face to face, usually with a gaskat between the two faces, This type of joint is suitable for modulates pressures and is frequently used on low pressure line larger than 8” dia. itis stronger and more convenient to assemble and disassemble than the screwed connection. Where pipe must be removed for inspection, cleaning or maintenance itis customary to use flanged connection. The majarity of our glant willbe welded line with flanged fiting, it is however, prone to leak if the flanges are ot accurately line up and if the proper gasket is not used, 3. Where piping does not have to be disconnected and where other condition permit, welded connection are the best solution also joint is achieved as strange as the pipe and there is litle possiblity of leaks. For small piping butt welding of pipe is very. ‘edous and socket weld fitting are often used. The overall cost for socket welding fitting is greater than threaded connection. — SCREWED (THREADED) werpeo £ { a : FLANGEDZIFIPG secnca nme cnr vast , FITTINGS, FLANGES. BOLTS, AND_ GASKETS i ‘The Engineering and Technical Divisions must make very careful calculations before selecting the pipe and fittings that are to be used in the construction of a new unit or for repair work that will be done, 5 ‘There ure several factors to be considered in the selection of fittings for any: piping system 1. "The temperature at which the proposed system will operate, 2. The maximum pressure the system may be called upon to withstand. 3. The derrosive cha‘acteristics of the fluid (gas or liquid) to be handled bC ) ws the piping syatem> 4, Process difficulties in the event of leakage or failure of fittings. i 5. Safety of operating personnel wherever failures of fittings could cause: 6. Cost, both original and maintenance. 2} He therefore follows that iis justy important to know thot the materials us installed, , for replacements are the same or equal to the same 5 were originally tig substitution is mede 2nd the improper material is used, your own life and the lives of other persons in the plant mey 8 endangered To help avoid errors of this nature, everyoe should become more familiar with > the ways and means’of identifying pipe and fittings. PIPING _Fre TecHivoAL TRAINING CENTRE . STANDARD STEEL FLANGES AND BOLTS (For working pressure 150 pounds} Tie a Sizia of | Bolin | ots in | of cies Bote_| Ickes | Becher | suds % 4 % we [an : + “ Pie [2m th + % 2 lame nt 7 & 2 PP 2 ‘ te a 4/3 m° 4 % | we dow 3 4 & | me [oe 3% 5 mz | mh Te : + ® ‘ 3 bs é 2 nf ate |e On = s mm | ae fe Oy re B % | Ph Lan 2 B hm | me fae i 2 r ae 1s % 6 : se [5mZIPPC scouons mania ceae WELDING PIPE pri HON FOR im Most of our pipes for welding will be cut to line for cutting will be marked uséd a wrap a round (or sometimes called @ run ‘a round). The wrap 8 round can be any type of flexible material thet will retain strength edges. We have purchased some for the tool room, but they cah be made from comprassed asbestos gasket material. Agth usitig 2 cutting torch. The ‘They should be about 10 cm. wide and must be at least 1-1/2 times the circumference of the pipe to assure that the line is “square” around the pipe A sharp piece of soap stone is used to mark the line around the pipe. In cutting the pipe to Length an allowance must be made for the gap required for weld Where pipe is being welded to a fitting, all of the allowance must be mad_3i the pipe. Some shops allowance total of 1/8" for this gap to assure penetration, however, full penetration can be obtained with a 1/16” gap. In cutting the pipe, the operator should cut along the center of the line using a radial cut After the pipe is cut to length, the pipe is beveled using a miter cut et 8 37-1/2 angle and leaving a 1/16 inch land. If work is being performed in the shop where air grinders ere available, the burrs should be removed with a grinder before fitting up for welding. If a grindét is not available 3 chipping hammer should be used to remove all burrs. In fitting up the pipe for welding ‘care must be taken to assure that the two sections of pipe are in alignment and so that no part of the pipe is offset with respect to the adjacent part. The epds of the pipe must be cleaned of all rust gid scale for @ distance of 1 inch fhurf the edge of the welding groove. After the pipe is aligned the pipe is tacked together using three tack welds for small pipe and 4 tack welds for larger pipe up to 12" above 12" (6 to 8) tack welds will be required. In making the weld it Is desicable to roll the weld to permit down hand welding if possible.ANSI STANDARD AMERICAN NATIONAL STANDARD (ANSI-816.9) Erne: “ we 7 . NY" 48", BEVELING STANDARDSZIPING recumicar rramine cewrne Paae:22 ‘PIPE ALIGNMENT . Proper alignment is one of the most important tasks performed by the pipe fitter. If done correctly, welding will be much easier and the piping system will be properly fabricated. If alignment Is poor, however, welding will be difficult and the piping system may not function properly. Many devices are available to aid alignment. Tube Turns manufactures thrae types of welding rings which not only make alignment easier but also provide the correct gap for welding. ‘There is no best The procedures Methods of alignment vary widely throughout the trad syetam.-any number of methods hava proven successful =tagered yt anil poplar wth any snemen andi onal to quleWly obtein good alignment. PtpE-TO-PIP= Move pipe lengths together until bevels are nearly abutted, allowing space for welding gap. Center squares on top of both pipes and move pipe up and down ntl aquaces re aged. Tack weld tsp end bottom, Repest procedure y placing aquares on side of pipe. Correct alignment by mioving pipe left or right, Tack weld each side. pe: ELBOW-TO-PIFE Place fitting bevel in line with bevel of pipe, allowing for welding gap. Tack weld on top. Center square or top of pipe. Center second square on elbow's alternate face. Move elbow until squares are aligned. Piping| NX 45° ELBOW-TO-PIPE Follow procedure described above except squares will cross. To obtain correct 45° angle, align the seme numbers on the inside scale of the tilted square (note: The numbers 4 and 7 are used in the illustration.) Alternate Method Use same procedure to a butt pipe and fitting. Center spirit level on pipe. Next, center 45° spirit level on face of elbow and move elbow until 45° bubble is, tered, TEE-TO-PIFE A butt bevels, lowing for welding gap. Tack weld on top. Center square en top of pipe. Place second square on centre of branch ou squares are alignePAGE-24 N Oe Om G TECHNICAL TRAINING CENTRE Alternate Method Follow same procedure to 2 butt pipe and fitting. Place square on tee 2s illustrated. Center rule on top of pipe. Blade of square should be parallel wi pipe. Check by measuring with rule at severdl points slong the pipe. > i) FLANGE-TO-PIPE oa STEP3 A butt flange to pipe. Align top two holes of flange with spirit level, Move flange until bubble Is centered. Make one tack weld on top. o ©, ste Center square on face of flange. Center rule on top of pipe. Mave flange until square and pipe are parallel. Tack weld bottom. e of flange. Center rule on side of pipe ang align as in step- Center square on faci 2. Tack both sides. piPING“9 ZIPIFG secuont re z ING CENTRE SAFETY RULES FOR wort AND ACCESSORY EQUIPMENT 1. WORK PERMITS: Work Permits, when necessary, must be secured before work is started. With this permit you have the assurance that the equipment is safe to work on. However, regardiess of the fact that your permit is signed, your job must be checked by yourself before starting. (See Section on Work Permits in Setety ‘Manual. 2 Toots: a) Always use tools that are in good condition and ef the proper type. When tools become detective, they shall be returned to the tool roam. +b) Use box type wrenches instead of open end wrenches whenever practical when working at elevated locations ©) Never add leverage to your wrenches. Get the proper size wrench. 0} When driving wedges or drift pins, stand to one side of the flange to avoid being struck if these tools are sprung from the flange. e) When using chisels, gouges, grinders - wear your goggles. £1 Agood mechanic can always be identified by the condition of his tools and the manner by which he uses them. 3. FLANGED TYPE PIPING: a} Whon unbolting a flanged type joint always loosén bolts farthest from you, but do not remove, Wedge flanges open, slacking top bolts if necessary. When certain line is eimpty, remove all bolts, b) Always stand to the windward sida of the flanges while unbolting. ©) Always keep the joint under control until you are sure line is empty.ZIPIPG secinmicar teams centne ® PAGE-26 Do notuse your fingers to center gaskets. Keep vour fingers out of flange holes. #8) When inserting or removing blanks or unbolting tlanges on an ammonia, ‘acid, chamical, or steam line, goggles and gloves (rubber for acid and ‘ammania and other chemicals) shall be worn by the mechanic doing the unbolting. He shall keep himself in the clear in respect to the flange in ease the line is not entirely empty. NOTE: When making up a flanged joint it is important that flange and gasket surfaces be clean and free from any foreign particles. The flanges must be carefully aligned so that the flange faces fit together properly. ‘The gasket should be lightly coated with 8 lubricant to permit easy removal during future disassembly. The bolts threads also should be lubricated and then tha nuts screwed on by hand as far as possible. When pulling up with a wrench, the bolts should not be tightened in rotation, but. the cross-over method should be used where opposite bolts, around the flange are tightened gradually and evenly. 4. BLANKING PIPELINES: a ») a o a ses, in accordance with Blanks must be-of the proper thick’ Engineering Standards. c All blanking of pipe connections to vessels must be done as close~ to the vessel ae convenient, All types of lines must be closed, blanked, plugged or made up before leaving the job. 09 not remove blanks until operator in charge has Inspected lines ‘and approved the work. When blanking lines or equipment that has contained toxic chemical or gas, 2 fresh air mask or approved canister type gas masks shail be used.© BIFIRG scunons vine ene — job is near or above them, 2) Never leave the welder alone while he is welding in a confined or dangerous place. oO “c}RemeDy oF prostem: The maintenance of piping system Involves more than repairs when a breakdown in the system occurs. It is. true that accidents can happen and do and that unex- ected component failures can take place at any time without warning. ‘The resi Secret of successful maintenance of e piping system lies in knowing what parts it made, and where the various parts of the system are located. Preventive mainte- nance is the key to keeping any piping network operating smoothly and efficiently. By the , and routine, scheduled inspection, you will find that your job is much easier ‘and for more . You will be heading trouble off before it happens. ‘The major problems in piping systems ere caused by leakage and corrosion, one may cause the other. The nature of the materials being carried has an infivence, of course but you will usually find that system has been designed to provide maximum precautions, including safety for excessive pressures and dangerous fluid leakage. ‘The following ist includes the points with which you, as @ maintenance craftsmen, whose responsibilty is the maintenance of piping system, will be concemed. 1) Checking for corrosion and leakage 2). Checking to be sure that valves are in working order. 3} Repack valves maintaining and replacing gaskets. 4) Checking insulation and possibly installing it 6s needed. 5) Installing new sections of piping, tubing and hose. 6) Instaling, inspecting and replacing fistings #8 needed 71 Checking hangers snd pipe suppresZIPEG sommen manne cevne 8) Clean piping as required 9) Extending existing systems as needed, 10) Reporting any thing of an unusual nature. Inshort, it will be upto you to help that’ the vital pipelines. you are concerned ‘with will continue to function smoothly and well. Yours can be one of the most critically important jobs in whole plant. And that’s only one ofits advantages. You will also have the personal satisfaction which comes from knowing your job, and doing it wel PIPING AND TUBING: Nearly all industrial equipment now in service makes some of tui fines. From an economic point of view the best fluid lines system is that which is easiest to pin~ {ain at the lowest original cost, The use of tubing and tube fitting on lines up 2 (6.08 om) diameter is almost in veriable more economical than the use of pipe an! pipe fittings. in modern installations. few of the more important reasons follow ‘A.common question is just what is the difference between pipe and tubing ? Many of the differences in physical characteristics methods of instalation, 9s well 1as the advantages and disadvantages of tubing will be come clebr. s ‘An exampie from the standardized codes for piping and tubing ilustratos the differ fence between pipe and tubing. The wall thickness of two types of B-inches iron pipe {one light and one heavy) fe 0.250" light) and 0.408" theavy). A ight wall 8 inch copper tube has a wall thickness of 0.170" and a heavy wall 8" inches tube has 1 wall thekness of 0.277" When you compare these figures, tis cea that tubing hes @ thinner wall then ofthe Same general diameter . 0 Size for size, tubing is lighter weight, easier to handle and can be bent more easily than ion pipe. © The bendabilty of tubing reduces the number of connections, requires, thus reducing material and labour costs. 0 Fewer joints means lower costs and fewer points of potential leakage. © The use of tube fittings makes every joint a union, permitting, easier, faster maintenance and repair work. 0 Modern flared and flare tess tube fittings eliminate the need for threading, soldering, or welding. PipingO ZPrC Z TECHNICAL TRAINING CENTRE Page-ze PIPE HANGERS AND SUPPORTS: Piping must be supported in such a way as to prevent its weight from being carried by the equipmant to which itis attached. The supports used must prevent excessive ‘sagging af the pipe and at the same time must allow free movement of the pipe due to expansion of contraction, The supporting arrangement must be designed to carry the weight of the pipe, valves, fittings and insulation plus the weight of the fluid contained within the pipe Spring hangers help absorb vibration. The roll types permit the pipe to move as It ‘arows or shrinks in length because of temperature variations. Routine preventive maintenance includes checking to be sure that hangers and sup. ports remain properly fastened. Such inspections are especially important in pipe lines affected by vibration caused by the activity of the fluids being carried, or by machinery to which the pipes are attached. Adjustable ‘Swival pipe roll Single hook Adjustable and hanger stander tng Jochen” Aalusaba Snlbonnanger neh Pine astaIPPC secomcar reawwe cevrne HOT TAPING DEFINITION: ‘At various time we desire to make piping connection in operating equipment without ‘shut down the plant. The reasons for making such connection are varied: 1) To by pass 2 partially plugged tine. 2) To add a by pass line to increase flow volume. 3) To provide connection for adding equipment without a shut down. Dring Machines Hot Type Ovn Machine Adapter 3 ng ‘O° ZIPIPC sccunroar reamno eenrnt eases a a All piping off sets ute based on right triangles. The trigonometry in this suction deals with the solution of problems involving right triangles, FUNCTION OF ANGLE: In computing piping off sets with trigonometry, the trades man will employ the six functions. (Technically called trigonometric functions are ratios of the angle of fit ting. These function are: Travel Sine Cosecent = Cosine Secant = , wravel at { sot tt Tangent = — cotangent = Finding set, run and travel Formulas: set travel x _ sine of angle of fitting also rus x tangent of angle of iting. Run = Travel x cosine of angle of fitting, also set x cotangent of angle of fiting. Travel = set X — cosecant of angle of fiting also, run x secant of angle of fitting, Example: What is the length of run and travel for a 45°off set with @ set of 15 in? Run Set x cotangent of angle of fiting Run = 15 1.000 = 15 in {length of run center to center. Travel= set x cosecant of engle oF fitting Travel= 15 x 1.414 = 21.21 in length of travel piece center to center. the burts should be removed with # grinder before fiting up for welding. if @ grinderZEFC ZIPIFC secumea rama cewrne EINDING ANGLES WITH TRIGONOMETRY: ‘The following information is careful for finding the angle of fitting for welded off set. To find one of the acute angle, two sides of the right triangle must be known. iPS Po nvre —4t When the set and run are known the angle of iting A is found by determining *he tangent ofthe angle and obtaining the angle fom the tigonomotry casi Example: When the set is 18 in, and the run is 24 In, What is the angle of fitting for a welded off set? Tangent of angle of fitting = 18 Tangent of angle of fitting — 24 Angle of fitting = 37 SIMPLE OFFSET: Oo All piping off set are based on the right triangle, Simple off sets may be calculate use’. of the table given below; SIMPLE Ore Ser.ZIPIPG secnnioar vane cenrae MULTIPLIES cs TH TO FIND KNOWN MULTIPLY FOR 60° SIDE SIDE'S SIDE ELBOW BY ELBOW BY ELBOW ay 1.155 0-866 0577 4.732 2,000 0'500 Dione Amnode set R = SIMPLE OFF SETS For 45° FoR 30° 1.414 2,000 0.707 0'500 1.000 1.732 1.000 0.577 vale 1.185 0.707 0.886 run T For 22 ELBOW BY ELBOW BY 2.613 0.383 2414 oata 1.082 osza © FoR 1K 5.125 0.185 5.027 0.198 1.017 0.980 rave! ‘USE OF TABLE: Find the sie of the triangle that is needed in the fst column. Find the known glde in ‘the second column. Continue across in that row to Of fitting to be usad and read the constant. Multiph and the answer will be the lenath of the side needed, Example: What is the length of side T for 9 30° off set if side is.15 inch? 1. The side needed T, and the si and second column, the column headed with thd angle 'y the constant by the known side 2. Continuing across in the same row to the 30%lbow column the constant is found to be 2. in cantre to centre, Multiplying the constant 2 by 18 {the known side Stside T is found to be 30_ ‘ROLLING OFF SET: Finding trevel and run for a rolling off set. Formula: a For Travel = A x cosecant of angle of fiting (see trigonometry table) un = A.x cotangent of angle of fitting (see trigonometry table). Example: ‘The roll of a 45°%off set is 8 in and the set is 18 in. Find the length of travel and run. » = + eer . a < [eae = 289 = 17 inch Travel= A x cosecant of angle of fitting Trovel = 171.414 = 24 1/92 in contre to contre un = Ax-cotengent of angle of fitting Run 17x 1.000 = 17 in centre to-centve ooZIPIPG secmicarreanmie cenrae PIPING EXPANSION AND EXPANSION JOINTS A pipe line will expand and contract due to alternate heating and cooling. Expansion control in pipelines which carry hot or cold fluids, or which are exposed to large Variations in ambient temperature, can be a major problem, As the metal temperature of the pipe increases or decreases, its langth also varies cue to thermal expansion or Contraction. Therefore, unless provision is made for these changes in length, excessive stresses will be induced in the piping and large forces will be transmitted th-ough the systom to anchors and connected equipment. Several different methods are available for controlling pipeline expansion. ‘Two of the most commen are expansion bends and expansion joints. 1. EXPANSION BENDS; With this method, the pipe is fabricated with special bends or loops and the increase in the length of pipe due to expansion is taken up by flexing or springing of the bends (or loops. »ZFFG = TECHNICAL TRAINING CENTRE PAGE-39 The expansion bend is the most trouble-free method as there is no maintenance involved end leakage is unlikely. Any temperature, pressure or fluid can be handled by proper selection of material and thickness. However, expansion bends require a larger amount of space and produce a higher pressure drop and n, they produce heat loss end are more costly than expansion joints. in addit higher end thrusts which can present probiems when connecting to equipment such as turbines and pumps. The use of expansion bend is usually preferred for high pressure work 2. EXPANSION JOINTS. Two types of expansion joints in general use ae th aip expansion Joint the corrugated expansion joint. SLIP EXPANSION JOINT: This type, which is illustrated in figure, features a slip pipe which is welded to he main body of the joint which is an adjoining pipe. The slip pine fits into fasteneato the end of the other adjoining pipe. When the pipe line expaids the slip pipe moves within the joint body. To prevent leakage between the slip pipe and the joint body, packing is used around the outside of the slip pipe and the slip pipe moves within the packing. Pu a0 : PA seauna pains 7 erunoee usr mca, unr sre «sesua pacaes, > Cone on BRICATION FTNZIPIPG secunscar reame cevrne Slip expansion joints are simple and rugged and are capable of handling 2 large amount of expansion. Their space requirements are’ a minimum and they produce little pressure drop and heat loss. However, they must be located where the packing can be given attention. Also, problems may arise if the joint, Is poorly aligned or if it becomes corroded and therefore the joint should be Installed and maintained according to manufacturer's instructions. The proper packing must be used and this should b¢ lubricated two or three times a year unless self lubricating packing is used. The slip expansion joint is suitable for medium and low pressure. CORRUGATED EXPANSION JOINT: ‘This type of expansion joint consists of a flexible corrugated section which is able to absorb @ certain amount of endwise movement of the pipe. LOW PRESSURE CORRUGATED EXPANSION JOINT A simple design suitable for only low pressures is illustrated in figure and is, available with either flanges or welding ends. For higher pressures the corrugated joint uses contiol or reinforcing rings which surround the corrugations as illustrated in figure REINFORCED CORRUGATED EXPANSION JOINTAIPIFW secrmucar tame cenrae Stainless Stee! matsDise Bellows Compression End Dise Extension Eni tim External Sleeve Anchor Base Le BELLOWS TYPE CORRUGATED EXPANSION JOINT The bellows type corrugated expansion joint shown in figure is suitable for Pressures up to 2070 KP. It is equipped with an internal safety sleeve having 8 limit stop to prevent undue extension or compression. Alsé, as this sloave is closely fitted it will prevent excessive leakage if failure of the bellows section occurs. This type may be supplied with or without anchor bases Prine.5 AIFIPG secumcar name cewrne ‘AR EXPANSION OF PI FORMULA: E = Expansion in inches per 100 ft. of pips F = Starting temperature (F°) r Final temperature (F°) E = Constant x (FI EXAMPLE: 6 Matte the expansion of a 965 fet seam heat 75, pounds pressure if he =~ starting temperature is 60° Fahrenheit? @ ° e Constant X (T-F) Constant - table) 5 t = 320%(se8 table for boling point of water at 75 pounds pressure) e = 00804 x (320-60) = .00804 X 260 = 2.09 in, Expansion for 365 ft. line = 2.09 X 3.65 = 7.628 in METAL CONSTANT Steel 00804 Wrought ron - 00816 Cast iron 00780 Copper & Brass 01140ZFC ZIPPG recuucar raamino cewrne 1 Vacuum in Inches of Botting F° Mercury Point 29 76.62 28 99.93 27 114.22 26 124.77 25 133.22 24. 140.31 23 146.45 22 151.87 21 ~ 156.75 20, 461.19 19 165.24 18 169.00 ow 172.51 16 175.80 16 178.91 14 181.82 13 184.61 2 187.21 " 189.75 10 192.19 9 194.50 8 196.73 PipDL Panett Nowe 20, 189 pueeee Vacuum, in Inches of ‘Mercury 100 125 200 Bolling F* Point. 199.87 200.96 202.25 204.95 206.70 C 208.50 c © 210.25 Gauge Lbs 212 2156 218.5” pana 229.8 224.5 2209.4 249.8 206.8 297.7 (y- 320.1 Ce 3379 352.9 387.9Tae eae yaa orein [aT fest “foamed a : 2s 1 | PIPING- — ZIPIFG secuwoas-rnammocenrie pagan | o toe stot capa TUL Ya AT ST ye PrpinG1h a, a 7 ; — == aya a im) RET ty od BsTYPES OF FLANGE ait ‘Threaded Flange MALE & FEMALE FLANGE&Snamprogetti Materials Standardisation TB.5801 hows company smpoL — SP ~ Snamprogeres Guanactenrsrics : Thee alpha-numeric syubols to be vsed to ‘AND HATERTALS dezine STEXECUTION (To be indicated with « punter from 1 to 9 or one of the following 1et~ fers: BC-D-P-GHASK-LM-P RT REL) + NODY/BOWWET MATERIAL. (To be indicated a wich one of the following letests” A-BC-DrESP-GAH-LeM-WeP RS T-O-Z-K-¥) + TRIM (To be inducaced with « muaher from Teo 9) VALVE ENDS BE to be bute-welded Fr - flanged: fiat face GR | Flanged: raised face Fe 2 ANST flanged: fiat face RF = ANSI flanged: raised face Ry + ANSE flanged: ring Joint RF suoora "ANSE Elanged RF 'E23 ana RF 250 ARH - ANSI flanged: RF-250 AAR RF 500 4ARH < ANSI flanged: RF-300 AAR : THD) * BS./ DIN'/ ete, threaded NPT - aus 82.1 eT threeded + SH + ANSL 816.11 sockee-welded ‘su/tHop * one end socker-velded end the other end. threaded sspressed in am for FP and OR ends To be exapreased An inches for the other NOTE: Requirenance indicated in the table below can be and when appropriate to the quleesents shall be indicated in the relevant ocders acuatoretopeci tid by toe Toe fe] fee [sso texte bef fete tebe [escent inpetton Reet ECEiy & o mst | [pes'ivaw | song 7 i | | a | se i a | Tes) weney [ree EREmma Dee wat ete bao esl mal ras te eta [outeme tse. Tae fares StS mister} mes] ws]Fons iby eovstaveriey aici stisoaas,ouer- | & ssieunion | ane roesemnies | yn ci sramuaoeast. | 2 | : avaes | B/E] 1 Ble fhe eben eI Far et pase fe [Gree teres isa] Bie TE asi see ea] RAISED FACE T- T= = 1 i= SSO uso re (oe ise be hes Fur ats ‘usen Face (Graal 6a] = lum 279 T=v000! 20 Q ) (om-atae ‘oR wr FONE | = | UF al 8 1A peek ‘ad eetal ie) emma ere =| Ia Sie L- we aie wo-TORE [= Tan 22s eae Hee [owe merce | | swear aren frees SS aatinaceone | ar sre —ree roweve ano cacove To | - lum 2226 hs EEE usa race rsum| - freom|i see fvesapee | = wero |= | ow fires - fee msone |- |= lerswer frwiec comer sect | GRR te SER au rns (wie) ise pee ‘ROE AEH : a [ame |= | [esr ees Fen tL = 5 | 1 om hm SEAT muro | aro pense Fusrie ewer z ist € 16.21 wd Vasa | ae haa 1 ste | miso x | fou pepe | @ swan [= fa frwrereee- foods] =| era AR 1) ue un =| a [ust erez0 _rmasfies : 2) se = 2] sen ne oir ~ | m fusisaea [ea five sg five oust ~ fiw ferswer fenton: