OVERVIEW OF

PROCESS PLANT PIPING

SYSTEM

Reza Manafi

Piping components: summary

Definition
Piping component
Piping drawing
Design
Pipe work
Codes & Standards

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Definition

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Definition:

piping:
assemblies of piping components
used[for] fluid flows. Piping also
includes pipe supporting elements, but
does not include support structuresor
equipment

piping system:
interconnected piping subject to the
same design conditions
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Definition:

piping components:
mechanical elements suitable for joining
or assembly into pressure tight fluidcontaining piping systems include

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Piping component

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Piping components:

piping components includes:

Pipe & tube
Fittings (e.g. elbows, reducers, branch,
connections, flanges, etc.)
gaskets, bolting
valves
Pipe support
Special items such as expansion
joints

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Pipe & Tube

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Piping components: Pipe & tube manufacturing

Seamless

Welded:

Show

Longitudinal seam
Single seam
Double seam (NPS 36)
Helical (spiral) seam
NPS 4
0.8 OD Skelp width 3.0 OD
Submerged arc welding

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Show

Piping components: Pipe & tube manufacturing

Welding process:
Without filler metal
Electric welding
Continuous welding
With filler metal
Sub-merged arc welding
Gas metal arc welding

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Show
Show

Piping components: Pipe & tube manufacturing : Seamless pipe

Billet preparing
visual control

Rough tube
piercing

Billet chopping

Tube rolling in
continuous mandrel mill

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Billet heating
in annular furnace

Mandrel removing

Piping components: Pipe & tube manufacturing : Seamless pipe

Tube heating in
Sizing and reduction
Stalk ends cutting,
cell induction furnace
tubes cutting with flying shears

Tubes cooling

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Tubes leveling

Tubes cutting in ready

sizes, tubes facing

Piping components: Pipe & tube manufacturing : Seamless pipe

Geometry measuring,
Tube ends sizing
mechanical tests,
(by OD and ID)
chemical composition control

Quenching in sprayer

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Tempering

Heating for quenching

Tubes cooling

Piping components: Pipe & tube manufacturing : Seamless pipe

Tubes etching

Ultrasonic or
electromagnetic test

Sweeping-up (if required)Preservative coating

, visual control
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Hydraulic test

Weighing, marking,
packing, storing

Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)

Tube end upset

Thermal treatment

Leveling

Sweeping-up and
grading by length

Threading, thread
quality monitoring

Couplings screwing-on

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Piping components: Pipe & tube manufacturing : Seamless pipe (threaded)

Hydraulic test

Packing, storing

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Painting (if required))

Tubes inspection,
rings and nipple
screwing-on, marking

Piping components: Pipe & tube manufacturing : other pipe

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Piping components: pipe & tube classification

Pipe classification:
Iron pipe size (approximate internal dia.)
Manufacturers weight: NPS +
STD
XS
XXS
Schedule number: NPS +
5, 5s, 10, 10s, 20, 20s, 30, 40, 40s, 60, 80, 80s, 100, 120,
140, 160
Show
SCH 1000 P/S
NPS 12, OD NPS
NPS 14, OD = NPS
NPS 10, SCH 40 = STD
NPS 8, SCH 80 = XS
Light wall = light gage = 5, 5s, 10, 10s
API designation
A25, A, B, X42, X46, X52, X60, X65, X70
X(AA), AA = Allowable stress
Pressure-Temperature Ratings
150, 300, 400, 600, 900, 1500, 2500

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Piping components: pipe & tube classification

Pipe:
NPS:
1/8, , 3/8, , , 1, 1 , 2, 3, 4, 6, 8, 10,
12, 14, 16, 18, 20, 24, 28, 30, 32, 36, 40,
44, 48 52, 56, 60
NPS 1 , 2 , 3 , 5 not used
Pipe is supplied in
Random length (17 to 25 ft)
Double random length (38 to 48 ft)
Pipe end:
BE (bevel end)
PE (plain end)
T& C (treaded and coupled, rating of coupling shall
be specified

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Piping components: pipe & tube classification

Tube:
Specify by two of
Outside diameter
Inside diameter
Wall thickness:
Thousandths of inch
Gauge number
American wire gauge
Steel wire gauge
Birmingham wire gauge

When gauge numbers are given without reference to a

system (BWG) is implied

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Piping components: pipe standards

ASTM A53 Steel Pipe

ASTM A312 Stainless Steel Pipe

AWWA C151 Ductile Iron Pipe

API 5L Line pipes

ISO 11960, API 5CT tubing

ASTM A 53/A 53 Electric-weldedand seamless

steel pipes, black or hot-dip galvanized

ASTM A 106 Seamless carbon steel pipes for high

temperature performance

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Piping components: Fitting

Fitting

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Piping components: Fitting

Fitting produce change in geometry and include:

Change in direction of piping
Alter pipe diameter
Terminate pipe
Bring pipes together
(made branch from main pipe run)

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Piping components: Fitting

Method of joining pipe:

Butt weld
Socket weld
Threaded
Quick coupling
Flange
Special item

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Piping components: Fitting (butt-weld)

ASME B16.9

Used in most piping systems NPS 2

Use generally not restricted

Difficult in small sizes, especially for thin wall

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Piping components: Fitting (butt-weld)

Backing ring

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Piping components: Fitting (butt-weld)

Elbow (90, 45)

Long reduce
Curvature = 1 NPS
Long tangent: straight
extension at one end
Short reduce
curvature = NPS

Reducing elbow:
90
curvature = 1 NPS larger end

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Piping components: Fitting (butt-weld)

Return:
Curvature = 1 NPS
Uses in:
Vent on tanks

Bend:
Curvature = 4 - 6 NPS
Made from seamless and ERW straight
pipe
Two methods used to making bend
Hot
Cold

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Piping components: Fitting (butt-weld)

Miter

2 piece (pressure drop 4-6 LR elbow)

3 piece (pressure drop 2 LR elbow)
Low pressure line, NPS > 10 & pressure drop not important
90

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Piping components: Fitting (butt-weld)

Reducer
Eccentric
Suction & discharge of pump
support
concentric

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Piping components: Fitting (butt-weld)

Sewage :
connect butt-welded piping to smaller socket-weld or
screwed
Abrupt change of line size in butt-weld Type:
Eccentric
Concentric
Venturi: Allows smoother flow

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Piping components: Fitting (butt-weld)

Tee
Straight (branch to the same size as the run)
Reducing
Branch smaller than the run
Bullhead tee have branch larger than run &
seldom used and made to special order

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Piping components: Fitting (butt-weld)

Cross
Straight (branch to the same size as the run)
Reducing (rarely used)

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Piping components: Fitting (butt-weld)

Lateral (manufacture in factory)

Run inlet run outlet branch angle respect
to outlet (6 6 4 45)

Shape nipple (use template)

Manufacture at shop
Rarely use
90, 45

45

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Piping components: Fitting (butt-weld)

Stub-in

Welded directly in the side of the main pipe run

Least expensive
NPS 2
Cab be reinforced

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Piping components: Fitting (butt-weld)

Weldolet

Make a closer manifold that Tee

Full size
Reducing
Flat
Are available for connecting to pipe caps and pressure
vessel

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Piping components: Fitting (butt-weld)

Elbolet: reducing tangent branch on elbow

Latrolet : reducing, 45

Sweepolet
Good flow pattern and optimum stress
distribution
90 reducing from the main pipe

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Piping components: Fitting (butt-weld)

Closure
Cap
Flat closure

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Piping components: Fitting (socket)

Size frequently limited to NPS 1 (ASME B16.11)

Not used in severe cyclic conditions and in

services where corrosion is accelerated in crevices

No weld metal can enter bore, easier alignment on

small line than butt-weld

Tack is unnecessary

Have not any leakage

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Piping components: Fitting (socket)

Elbow (90, 45)

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Piping components: Fitting (socket)

Return:

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Piping components: Fitting (socket)

Reducer

Reducer insert

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Piping components: Fitting (socket)

Sewage :
Abrupt change of line size in butt-weld

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Piping components: Fitting (socket)

Full coupling

Half coupling

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Piping components: Fitting (socket)

Union

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Piping components: Fitting (socket)

Tee

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Piping components: Fitting (socket)

Cross

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Piping components: Fitting (socket)

Lateral

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Piping components: Fitting (socket)

Sockolet

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Piping components: Fitting (socket)

Socket welding Elbolet

Socket welding latrolet

Nippolet

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Piping components: Fitting (socket)

Cap

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Piping components: Fitting (threaded = screwed)

Common materials
Gray iron (ASME B16.4)
Malleable iron (ASME B16.3)
Steel (ASME B16.11)
Non-toxic, non-flammable, Generally not used where leaks
cannot be tolerated
NPS 1 , pressure rating < 600, temperature < 625

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Piping components: Fitting (thread)

Elbow (90, 45)

Reducing elbow

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Piping components: Fitting (thread)

Reducer

Reducer insert

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Piping components: Fitting (thread)

Sewage nipple

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Piping components: Fitting (thread)

Full coupling

Half coupling

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Piping components: Fitting (thread)

Tee

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Piping components: Fitting (thread)

Nipple

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Piping components: Fitting (thread)

cross

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Piping components: Fitting (thread)

lateral

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Piping components: Fitting (thread)

Union

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Piping components: Fitting (thread)

Hexagon bushing

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Piping components: Fitting (thread)

Threadolet

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Piping components: Fitting (thread)

Threaded elbolet

Threaded latrolet

Threaded nippolet

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Piping components: Fitting (thread)

Closure
Cap
plug

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Piping components: Fitting

Flange used for

Mate to equipment, vessels, valve,
When need periodic cleaning
Flanges are normally used for pipe sizes above
NPS 1.

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Piping components: Fitting

Type of flanges:

Threaded Flanges
Socket-Welded Flanges
Blind Flanges
Slip-On Flanges
Lapped Flanges
Weld Neck Flanges

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Piping components: Fitting (flange)

Welding neck flange

Regular
Long (used for vessel & equipment nozzle, rarely for
pipe
Suitable where
Extreme temperature
Shear
Impact and vibration
Stress apply

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Piping components: Fitting (flange)

Slip-on flange
Internal welds is slightly more subject to corrosion
than the butt-weld (0 1/16)
Poor resistance to shock and vibration
Cheaper to buy, costlier to assemble
Strength under internal pressure 1/3 of corresponding
welding neck flange
Easier to align than the welding neck flange

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Piping components: Fitting (flange)

Socket welding flange

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Piping components: Fitting (flange)

Threaded flange

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Piping components: Fitting (flange)

Reducing flange
Specify by size of smaller pipe and outside diameter
of flange to be mate
Ex/
RED FLG 4 11
Should not be used if abrupt transition would create
undesirable turbulence as at pump

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Piping components: Fitting (flange)

Expander flange
Reducer + welding neck flange
Increase pipe size to first or second large size

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Piping components: Fitting (flange)

Lap joint (van stone) flange

If stub and flange are of the same material they will
be more expensive than a welding neck flange
Economical for different material of stub and flange

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Piping components: Fitting (flange)

Blind flange

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Piping components: Fitting (flange)

Flageolet

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Piping components: Fitting (flange)

Flange Facing Types

Flat Faced
Raised Face
Ring Joint

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Piping components: Fitting (flange)

Flange Rating Class:

pressure/temperature combinations
Seven classes (150, 300, 400, 600, 900, 1,500,
2,500)
Flange strength increases with class number
The material specifications are grouped within
Material Group Numbers.

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Piping components: Fitting (flange)

Material Specification List

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Piping components: Fitting (flange)

Pressure - Temperature Ratings

Material and design temperature combinations

that do not have a pressure indicated are not
acceptable.

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Piping components: Fitting (flange)

Flange Rating Class

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Piping components: Fitting (flange)

Flange Rating Class

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Piping components: Fitting (flange)

Flange Rating Class

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Piping components: Fitting (flange)

Equipment Nozzle Load standards and Parameters

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Piping components: Fitting (flange)

Flange with jack screw

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Piping components: Fitting (piping specification)

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Piping components: Fitting (gasket)

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Piping components: Fitting (branch connection chart)

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Piping components: Fitting (gasket)

Gasket:

Resilient material
Inserted between flanges
Compressed by bolts to create seal
Commonly used types
Sheet
Spiral wound
Solid metal ring
Insulation gasket

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Piping components: Fitting (gasket)

Sheet

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Piping components: Fitting (gasket)

Sheet

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Piping components: Fitting (gasket)

Spiral wound

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Piping components: Fitting (gasket)

Spiral wound

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Piping components: Fitting (gasket)

Spiral wound

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Piping components: Fitting (gasket)

Solid metal ring

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Piping components: Fitting (gasket)

Insulation gasket

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Piping components: Fitting (bolt)

Bolt type:

Stud bolt
Easily remove if corroded
Material can be readily made
Machine bolt
Has to be strong enough to seat the gasket

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Piping components: Fitting (bolt)

Tightening arrangement

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Piping components: Fitting

ASME B16.5, Pipe Flanges and Flanged Fittings

(NPS 24)

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Piping components: Fitting (special item)

Quick coupling

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Piping components: Fitting (special item)

Flange coupling adaptor

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Piping components: Fitting (special item)

Expansion joint (Bellows)

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Piping components: Fitting (special item)

Expansion joint

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Piping components: Fitting (special item)

Flexible joint

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Piping components: Fitting (special item)

Flexible joint

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Piping components: Fitting (special item)

Double block & bleed

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Piping components: Fitting (special item)

strainer

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Piping components: Fitting (special item)

Spectacle blind

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Piping components: Fitting (special item)

Thermal sleeve & Queel

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Piping components: Fitting (special item)

Bird screen

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Piping components: Fitting (special item)

Tundish

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Piping components: Fitting (special item)

Pigging Tee

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Piping components: Fitting (special item)

RUPTURE DISKS OR BURST DIAPHRAGMS:

must be replaced after opening

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Piping components: valve

Valves

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Piping components: valve

Valve are use for

Controlling process and utility service
Isolating equipment or instrument for
maintenances
Discharge gas, vapor or liquid
Draining piping and equipment on
shutdown
Emergency shutdown

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Piping components: valve

Classify valves according to functions:

Block flow (On / Off)

Regulating (Throttle flow)
Checking (Prevent flow reversal)
Switching
Discharging (pressure relive valve)

Classify valves according to operating device:

Manual
Hydraulic
Motor (electric and air operated)
Solenoid

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Piping components: valve

Type of valves:

Ball valves
Gate valves
Globe valves
Check Valves
Plug valve
Butterfly valves
Pinch valve
Needle valves
Relief Valve

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Piping components: valve

Ball Valve

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Piping components: valve (ball valve)

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Piping components: valve (ball valve)

Used for isolation (quick on / off)

Soft-sealed ball valves are not normally used for

throttling service because the soft-seats are subject
to erosion or distortion/displacement caused by fluid
flow when the valve is in the partially open position.

ADV: Low pressure drop, fast operating, bubble-tight

shut off, can be throttled Check Valves

DISADV: Expensive, heavy, poor throttling

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Piping components: valve

Gate Valve

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Piping components: valve (gate valve)

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Piping components: valve (gate valve)

About 75% of all valves in process plants

an optimum engineering and economic choice for on

or off service. (cutout or isolation valves)

ADV: small pressure drop across valve

DISADV: poor throttling characteristics

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Piping components: valve (gate valve)

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Piping components: valve

Globe Valve

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Piping components: valve (globe valve)

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Piping components: valve (globe valve)

Most economic for throttling flow and used for flow control

Can be hand-controlled

Provides tight shutoff

Not suitable for scraping or rodding

Too costly for on/off block operations

ADV: excellent throttling characteristics

DISADV: large pressure drop across the valve due to the flow
restriction (thus more pumping power is required to move the
fluid through the system.)

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Piping components: valve (globe valve)

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Piping components: valve

Check Valve

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Piping components: (check valve / swing check valve)

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Piping components: (check valve / swing check valve)

Simple design

Allows flow in one direction

Can not be used as an isolation valve

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Piping components: (check valve / ball check valve)

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Piping components: (check valve / ball check valve)

Their low cost usually makes them the first

choice valves sized NPS 2 and smaller (available
in sizes NPS through 2)

Used when pressure drop is not a concern.

The basic types are the straight-through- and

globe-type (90 change in direction)

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Piping components: (check valve)

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Piping components: (check valve / lift check valve)

are available in sizes from NPS through 2 plants.

They are most commonly used in the higher ASME

B16.5 ratings (Class 300 and greater) where tighter
shutoff is required.

Valves of this type should only be used in clean

services.

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Piping components: (check valve)

Wafer Check Valve

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Piping components: (check valve / wafer check valve)

Valves of this type are placed between pipe flanges

and held in place by the compressive force between
the flanges and transmitted through the gaskets.

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Piping components: (check valve)

Stop Check Valve

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Piping components: (check valve / stop check valve)

Internals similar to a globe valve

Disc is not attached to the stem

Valve stem - long enough to hold the disc firmly against

the seat

Stem raised - the disc can be opened by pressure on the

inlet side

Can be used as an isolation valve as well as a check

valve

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Piping components: (check valve)

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Piping components: (check valve)

Function of check valve:

Prevents flow reversal

Does not completely shut off reverse flow
Available in all sizes, ratings, materials
Valve type selection determined by
Size limitations
Cost
Availability
Service

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Piping components: valve

Plug Valve

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Piping components: valve (plug valve)

Plug Valve

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Piping components: valve (plug valve)

Similar to ball valve

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Piping components: valve

Butterfly Valve

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Piping components: valve (butterfly valve)

Butterfly Valve

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Piping components: valve (butterfly valve)

used as cutout/isolation valves

ADV: quick-acting low pressure drop across the valve,

has adequate throttling characteristics

DISADV: only used for low press/low temp systems

due to force involved in valve operation

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Piping components: valve

Pinch Valve

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Piping components: valve (pinch valve)

Pinch Valve

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Piping components: valve

Needle Valve

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Piping components: valve (needle valve)

Needle Valve

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Piping components: valve

Relive Valve

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Piping components: valve

Relive Valve

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Piping components: valve (relive valve)

special type of valve designed to operate automatically

(self actuating) in a system overpressure condition (a
protective feature in most systems)

most relief valves use an adjustable spring to determine lift

pressure. System pressure opposes spring pressure, and
when pressure is high enough, the valve will open against
spring pressure and port the fluid to another location
(typically, overboard for safe fluids)

Type of relive valve:

Relief Valve - liquid systems
Safety Valve - gas and vapor systems
Safety Relief Valve - liquid and/or vapor systems

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Piping components: valve (interlock)

Interlock sequence

close

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Piping components: valve (parts)

Parts of valves:
disk:
The moving part directly affecting the flow
seat:
Non-moving part that disk bear on it
Metallic
Non-metallic (elastomer)
port:
Maximum internal opening for flow when the valve is fully
open
Stem:
Move the disk
Handwheel:
Rise with the stem
Stem rise thru the handwheel

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Piping components: valve (result)

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Piping components: valve (valve selection process)

General procedure for valve selection.

Identify design information including
pressure and temperature, valve function,
material, etc.
Identify potentially appropriate valve types
and components based on application and
function (i.e., block, throttle, or reverse flow
prevention).

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Piping components: valve (valve selection process)

Determine valve application requirements

(i.e., design or service limitations).
Finalize valve selection. Check factors to
consider if two or more valves are
suitable.
Provide full technical description
specifying type, material, flange rating,
etc.

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Valve data sheet

Piping components: valve (valve selection process)

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Piping components: valve (leakage classification)

According to ANSI, leakage classify by class

(I, II, III, IV, VI)

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Pipe Supports and Restraints

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Piping components: pipe supports and restraints

Function of supports and restraints:

To carry load
To ensure that material is not stressed beyond a
safe limit
Holdup of liquid can occurred due to pipe sagging
(allow draining)
To permit thermal expansion
To withstand and dampen vibrational forces applied
to the piping

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Piping components: pipe supports and restraints

Supports:
Absorb system weight
Reduce:
longitudinal pipe stress
pipe sag
end point reaction loads

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Piping components: pipe supports and restraints

Restraints
Control, limit, redirect thermal movement
Reduce thermal stress
Reduce loads on equipment connections
Absorb imposed loads
Wind
Earthquake
Slug flow
Water hammer
Flow induced-vibration

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Piping components: pipe supports and restraints

Support and Restraint Selection Factors:

Weight load
Available attachment clearance
Availability of structural steel
Direction of loads and/or movement
Design temperature
Vertical thermal movement at supports

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Piping components: pipe supports and restraints (rigid support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (hanger support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Rigid hangers are normally used at locations where no vertical

movement of the piping occurs.

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Flexible Supports

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Flexible Supports

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Flexible Supports

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (flexible support)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (anchor, guide)

Anchor

Full fixation
Permits very limited (if any) translation or
rotation
Guide
Permits movement along pipe axis
Prevents lateral movement
May permit pipe rotation

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Restraints - Anchors)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Restraints - Guide)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Piping can be arranged

On piperacks
Near grade on sleeper
In trench
Near steelwork or equipment

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement / support definition)

Pipeway:
Is the space allocated for routing several parallel
adjacent lines
Group lines in pipeway

Piperack
Is a structure in the pipeway for carrying pipes and
is usually fabricated from Steel, Concrete & steel,
also provide protected location for ancillary
equipment (pump, utility station, )
Piperack

shape termed tee-head support

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement / support definition)

Piperack consist:
Bent:
Connected
shape frame
Stanchion:
The vertical member of bents are
termed stanchion

Piperack arrangement:
Single deck
Double deck,

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Arrangement of pipe on support:

Usually 2 < NPS < 12 mounted on piperack and
larger pipes are mounted on sleeper

Mounted large diameter pipe near stanchion for

uniform distribution of load

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Hot pipe usually insulated and mounted on shoes

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Other type of shoes

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Use bracket or outrigger for

Installation of electrical and instrument tray
Pipes with slope

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Group requiring expansion loop at one side of

the pipe rack

Design hanger for 2 and larger pipe

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

For better stress distribution in the pipe wall,

saddle used on large line and used for lines that
twist over when moving

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Provide guide for long straight pipes subject to

thermal movement

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

The smallest size of pipe run on a piperack 2

If necessary, suspend pipe smaller 2 from 4 and
larger
For making horizontal branch, change height of pipe

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)
The most economic beam section desired for the piperack

> 6 ft

If more room is needed, make double or triple piperack

20 -25 ft

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Categorize piperack, for example if using double deck,

place utility service piping on the upper level of the
piperack
Utility
service

process

Determine by lifting equipment required

access

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Dont install pipe on stanchion, this will prevent

adding another deck

Consider sufficient space beside piperack

10 ft

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Ensure that nozzles on equipment are free from

transmitted by the piping
Equipment suppliers will state max. loading
permissible at nozzles

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Dummy leg length

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

For line smaller than 2 and non-critical arrange

supports in the field
Pocketing of liquid due to sagging can be eliminated
by sloping the line so that the difference in height
between adjacent supports is at least equal to triple
deflection at the midpoint

As a rule of thumb, spans for insulated lines should

be reduced by approximately %30 from those for
uninsulated pipes
Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Support piping from overhead, in preference to

underneath

Install flange, with 12 minimum clearance from

supporting steel

>12
Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Keep weld joints at least 3 from supporting steel or other

obstruction

>3
To carry the weight of the piping use a FOS = 3
In general, one hanger or other support should be specified for
each side of a valve.

Prepared by Reza Manaf

Piping components: pipe supports and restraints (Piping and support arrangement)

Field support
For line smaller than 2 and non-critical, arrange
supports in the field
Finding location of support

Prepared by Reza Manaf

Piping components: pipe supports and restraints (piping support document)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (piping support document)

Prepared by Reza Manaf

Piping components: pipe supports and restraints (piping support drawing)

Prepared by Reza Manaf

Piping Drawing

Prepared by Reza Manaf

Piping drawings:

The main purpose of a drawing is to communicate information

in a simple and explicit way for construction apart from
specification

Pipe represent by
Single line:
Only centerline of the pipe is drawn
Double line:
Very time-consuming
Difficult to read

Prepared by Reza Manaf

Piping drawings:

Three type of drawing that developed from schematic (Block

Flow Diagram (BFD)) diagram are:
Process Flow Diagram (PFD)
Piping & Instrument Diagram (P&ID)
Piping drawing

Prepared by Reza Manaf

Block Flow Diagram

BFD

Prepared by Reza Manaf

Piping drawings: block flow diagram

Prepared by Reza Manaf

Piping drawings: block flow diagram

A Block Flow Diagram - BFD, is a

schematic illustration of the major
process.The block or rectangles used
represent a unit operation. The blocks are
connected by straight lines which represent
the process flow streams which flow
between the units. These process flow
streams may be mixtures of liquids, gases
and solids flowing in pipes or ducts, or
solids.

Prepared by Reza Manaf

Piping drawings: block flow diagram

In order to prepare block flow diagrams a number of rules

should be followed:
unit operations such as mixers, separators, reactors,
distillation columns and heat exchangers are usually
denoted by a simple block or rectangle.
groups of unit operations may be noted by a single block
or rectangle.
process flow streams flowing into and out of the blocks are
represented by neatly drawn straight lines. These lines
should either be horizontal or vertical.
the direction of flow of each of the process flow streams
must be clearly indicated by arrows.
flow streams should be numbered sequentially in a logical
order.
unit operations (i.e., blocks) should be labeled.
where possible the diagram should be arranged so that
the process material flows from left to right, with upstream
units on the left and downstream units on the right.

Prepared by Reza Manaf

Process Flow Diagram

PFD

Prepared by Reza Manaf

Piping drawings: process flow diagram

Prepared by Reza Manaf

Piping drawings: process flow diagram

Prepared by Reza Manaf

Piping drawings: process flow diagram

A Process Flow Diagram - PFD, is a

schematic illustration of the system.PFD's
shows the relationships between the major
components in the system. PFD also tabulate
process design values for the components in
different operating modes, typical minimum,
normal and maximum. PFD's do not show
minor components, piping systems, piping
ratings, standby equipment
It is advisable to draw equipment that is
operated cyclically

Prepared by Reza Manaf

Piping drawings: process flow diagram

A PFD should include:

Process Piping
Major equipment symbols, names and identification
numbers
Control, valves and valves that affect operation of
the system
Interconnection with other systems
System ratings and operational values as
minimum, normal and maximum flow, temperature
and pressure
Composition of fluids
This figure depict a small and simplified PFD:

Prepared by Reza Manaf

Piping drawings: process flow diagram

Each item of equipment should bear the same number on all

drawings.

Standby or identical equipment if in the same service, may be

identified by adding letters A, B, C

Process material balance can be tabulated on separate 8 * 11

Use of arrowhead at all junction and corners aids the rapid

reading of the diagram, keep parallel line at least 3/8 apart

Process & service stream entering or leaving the process are

noted by hollow arrow with

Prepared by Reza Manaf

Piping and Instrumentation Diagram

P&ID

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

A Piping and Instrumentation Diagram P&ID, is a schematic illustration of functional

relationship of piping, instrumentation and
system equipment components.P&ID shows
all of piping including the physical sequence
of branches, reducers, valves, equipment,
instrumentation and control interlocks. The
P&ID are used to operate the process
system.

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

A P&ID should include:

Instrumentation and designations

Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings,
sampling lines, reducers and increasers
Flow directions
Interconnections
Control inputs and outputs, interlocks

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Preferably draw all valves with the same size

long

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Draw instrument identification balloons 7/16

diameter

Draw square with 3/8 width

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Allocate new number to branch

A typical note may be used to describe multiple piece

of identical equipment in the same service

Special point for design and operation procedure are

noted such as line which need to be sloped for
gravity flow, line which need careful cleaning,

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Terminate the number at major number of a

equipment such as tank, pressure vessel, mixer
or any equipment carrying an individual
equipment number

Show and tag process and service valve with size

and identification number

Prepared by Reza Manaf

Piping drawings: line number

Flow direction

Prepared by Reza Manaf

Piping drawings: piping and instrumentation diagram

Standby and parallel equipment are shown

Dripleg are not shown but steam trap are

shown

vent and drain to be used for hydrostatic

testing are not shown

Insulation, insulation thickness and tracing

are shown

Prepared by Reza Manaf

Drawing component

Prepared by Reza Manaf

Piping drawings: drawing component

Drawing components include:

Title block
Revision
Key plan
Reference drawings
Legend
Important notes
Graphic reference point
line number
Flow directions
connections

Prepared by Reza Manaf

Piping drawings: drawing component (title block)

Title block

Prepared by Reza Manaf

Piping drawings: drawing component (space for revision)

Space for revision

Prepared by Reza Manaf

Piping drawings: drawing component (key plan)

Key plan

Prepared by Reza Manaf

Piping drawings: drawing component (reference drawing)

reference drawing

Prepared by Reza Manaf

Piping drawings: drawing component (legend)

legend

Prepared by Reza Manaf

Piping drawings: drawing component (important note)

Important note

Prepared by Reza Manaf

Piping drawings: drawing component (Graphic reference point)

Graphic reference point

Prepared by Reza Manaf

Piping drawings: drawing component (Graphic reference point)

Graphic reference point

True north

Ex Ny
y
Plant north

Graphic reference point

Prepared by Reza Manaf

Piping drawings: line number

Line number shall be labeled to show the area of

project, conveyed fluid, line size, piping material or
specification code number and number of line

Allocate new number to branch

Prepared by Reza Manaf

Piping drawings: flow direction & connection

Flow direction & connection

3/8

Prepared by Reza Manaf

Line list

Prepared by Reza Manaf

Piping drawings: line list

Line list (line designation sheet or table)

include:

The number of the line

Line size
Material of construction
Conveyed fluid
Pressure, temperature, flow rate
Test pressure
Insulation and jacketing
Connected line (which will usually branch)

Prepared by Reza Manaf

Piping drawings: line list

Prepared by Reza Manaf

Piping drawings: line list

Prepared by Reza Manaf

Drawing view

Prepared by Reza Manaf

Piping drawings: drawing view

Two type of view are used for piping drawing:

Orthographic
Plans
Elevation
Pictorial:
in complex piping system where orthographic
view may not easily illustrate the design
Isometric
Oblique

Prepared by Reza Manaf

Piping drawings: drawing view

Prepared by Reza Manaf

Piping drawings: drawing view

Prepared by Reza Manaf

Piping drawing

Prepared by Reza Manaf

Piping drawings: piping drawings

Piping drawing include:

Site plan
Key plan
Equipment layout
Piping layout (plan)
Isometric
Support drawing

Prepared by Reza Manaf

Piping drawings: piping drawings (site plan)

Prepared by Reza Manaf

Piping drawings: piping drawings (key plan)

Prepared by Reza Manaf

Piping drawings: piping drawings (key plan)

Prepared by Reza Manaf

Piping drawings: piping drawings (Equipment arrangement drawing)

Prepared by Reza Manaf

Piping drawings: piping drawings (Equipment arrangement drawing)

Prepared by Reza Manaf

piping symbols for fittings, flanges,

special items

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Piping abbreviation

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings

(piping symbols for fittings, flanges, special items)

Prepared by Reza Manaf

Piping drawings: piping drawings (piping layout = plan)

Prepared by Reza Manaf

Piping drawings: piping drawings (piping layout = plan)

Prepared by Reza Manaf

Piping drawings: piping drawings (Isometric)

Piping drawing

isometric

Prepared by Reza Manaf

Piping drawings: piping drawings (Isometric / take off material)

Piping take off material (bill of material, material list)

Project

Platform/Unit

Date

Platform/

Line Number/

Sht.

Unit

Location

No.

SPP1

AA 2490

SPP1

19/06/01
Rev.

Piping

Short

Tag

Spec.

Code

Number

D1C1

*90E

WAAAAAWASA

BW

IN

AA 2490

D1C1

*FLG

10

FAAAIAWAAA

RF

IN

SPP1

AA 2490

D1C1

*PIP

208

PAAAAAKABT

BE

10

IN

SPP1

AA 2490

D1C1

*90E

209

WAAAAAWASA

BW

10

IN

SPP1

AA 2490

D1C1

*FLG

210

FAAAIAWAAA

RF

10

IN

SPP1

AA 2490

D1C1

*BOL

1209

BTFB72HBA

RF

7/8

SPP1

AA 2490

D1C1

*GAS

1261

XWAANZZTGS

RF

IN

SPP1

AA 2490

D1C1

*GAS

1788

XWAANZZTGS

RF

10

IN

Prepared by Reza Manaf

Stock Code

End

Nominal Diameter
Size 1

Size 2

120

Piping drawings: piping drawings (Isometric / take off material)

Piping material take off

Rating

Thicknes
s

Qty.

SCH/MM

Weight

Description

(kg/ps)

80

15.35

90 DEG. LR ELBOW, A234 GR.WPB SS SEAMLESS, B16.9

80

10.6

WELDING NECK FLANGE, ASTM A105N SS, B16.5.

80

4.8

95.74

SEAMLESS PIPE, API 5L GR.B SS

80

59.8

90 DEG. LR ELBOW, A234 GR.WPB SS SEAMLESS, B16.9

80

23.9

WELDING NECK FLANGE, ASTM A105N SS, B16.5.

12

STUD BOLT, A193 GR.B7, WITH 2 HEAVY HEX.NUTS, A194 GR.2H, PTFE COATED

150

FLAT GASKET, TANGED GRAPHITE/AISI 316 INSERT,ANSI B16.21 (B16.5), THK = 1.5MM

150

FLAT GASKET, TANGED GRAPHITE/AISI 316 INSERT,ANSI B16.21 (B16.5), THK = 1.5MM

150

150

Prepared by Reza Manaf

Welding

Prepared by Reza Manaf

Welding

What is Welding?
Welding is a joining process in which metals are
heated, melted and mixed to produce a joint with
properties similar to those of the materials being
joined.
Parent Metal

Weld Pool
Weld Reinforcement

Heat Affected
Zone (HAZ)

Penetration Depth

Weld Root

Prepared by Reza Manaf

Welding

Pass Name:

Root Pass
Hot Pass
Fill Pass
Cover Pass (capping pass)

Prepared by Reza Manaf

Welding

Weld type:
Fillet
Used when joining two pieces of metal
without preparing the surface of the metal
first.
Groove
used when preparing the metal before
welding it into place, include:
Square
Bevel
Single or double V
Single or double U
Single or double J

Prepared by Reza Manaf

Welding

Fillet
Approximately triangular
Most common weld in structural work

Prepared by Reza Manaf

Welding

groove

Square

Penetration difficult with single; double

used to ensure strength
Sometimes root is opened and a backing
bar is used

Prepared by Reza Manaf

Welding

groove
Bevel
Single bevel is widely used
Double preferred if metal thickness >3/4

Prepared by Reza Manaf

Welding

groove
Single V
Both members beveled
Butt joints for plate thickness greater than
1/4 inch

Double V:
welds reduce distortion

Prepared by Reza Manaf

Welding

groove
Single and double U:
Rounded base allows larger electrodes
for narrower groove angles
Machined or carbon arc gouged
preparation

Prepared by Reza Manaf

Welding

groove
Single or double J
Single well suited for butted corner and T
joints
Machined or carbon arc gouged
preparation

Prepared by Reza Manaf

Welding

Type of joints:
Butt joint
T joint
Lap joint
Corner joint
Edge joint

Prepared by Reza Manaf

Lap
Butt
TJoint
Joint
Edge
Joint
Corner
Joint

Welding

Type of joints:
Butt joint

Prepared by Reza Manaf

Welding

Type of joints:
T joint

Prepared by Reza Manaf

Welding

Type of joints:
Lap joint

Prepared by Reza Manaf

Welding

Type of joints:
Corner joint

Prepared by Reza Manaf

Welding

Type of joints:
Edge joint

Prepared by Reza Manaf

Pipe welding position

Prepared by Reza Manaf

Welding

Position:

Flat
Horizontal
Vertical
Overhead

Prepared by Reza Manaf

Welding

Position according to standards:

1G
2G
5G
6G

1F
2F
2FR
4F
5F

Prepared by Reza Manaf

Welding

Position:
1G
Pipe rotated, Electrode is always at the top
Either a split bead or weave technique may be
used

Prepared by Reza Manaf

Welding

Position:
2G
Pipe Axis Vertical, Weld is Horizontal, Pipe is
considered in a fixed position.
Always use a split bead technique
Always work from the bottom up.

Prepared by Reza Manaf

Welding

Position:

5G
Axis of the Pipe is Horizontal, The weld in vertical.
Progression may be up or down.
A weave bead is best used.

Prepared by Reza Manaf

Welding

Position:
6G
Pipe axis is fixed in position at a 45 degree
incline. The position includes flat, horizontal,
vertical, and overhead welds.
A split bead technique is best used.

Prepared by Reza Manaf

Welding

Position:
1F
Pipe is rotated. The pipe axis is at a 45
degree incline. Welding is to occur at the
top of the pipe.
Split bead or weave technique may be
used.

Prepared by Reza Manaf

Welding

Position:
2F
Fixed Position
Best to use a split bead technique

Prepared by Reza Manaf

Welding

Position:
2FR
Rotated
A split bead technique is best used.

Prepared by Reza Manaf

Welding

Position:
4F
A split bead technique is best used

Prepared by Reza Manaf

Welding

Position:
5F
Not Rotated. Progression may be up or
down.
Split beads or weaves can be used on
5F-up welds, split beads are best used on
5F-down welds.

Prepared by Reza Manaf

Welding

Type of welding:
Oxy-fuel gas welding
Arc welding
SMAW
GTAW

Prepared by Reza Manaf

Welding

Oxy-fuel gas welding

Prepared by Reza Manaf

Welding

Basic Oxy-fuel Gas Welding Equipment

Prepared by Reza Manaf

Welding

Pressure Regulators

Prepared by Reza Manaf

Welding

Acetylene and oxygen cylinder

Prepared by Reza Manaf

Welding

Carburizing, Neutral, and Oxidizing Flames

Prepared by Reza Manaf

Welding

Applications of Oxy-fuel Gas Welding

Recommended for material up to 3.2mm (1/8in)
Most steels, rolled, wrought or cast
Root opening
Up to 4.8mm (3/16in) square butt O.K.
Up to 6.8mm (1/4in) root opening and filler
Above 6.8mm parts must be beveled

Prepared by Reza Manaf

Welding

Applications of Oxy-fuel Gas Welding

Most steels, rolled, wrought or cast
Aluminum and copper
No reactive metals
titanium, zirconium, hafnium
No refractory metals
tungsten, molybdenum, tantalum,
niobium

Prepared by Reza Manaf

Welding

Advantages of Oxy-fuel Gas Welding

Very portable
Low cost
Gentle flame

Disadvantages of Oxy-fuel Gas Weld.

Poor air protection
Low heat input
Safety issues

Prepared by Reza Manaf

Welding

Shielded Metal-Arc Welding

( MMAW, SMAW, Stick welding)

Prepared by Reza Manaf

Welding

SMAW process:

Electrode
lead
Electrode
Coating

Slag

Core
wire

Weld metal

Base material

Prepared by Reza Manaf

Power Source
DCEP Shown
Work
Lead

Weld pool

Welding

electrode

Prepared by Reza Manaf

Welding

Electrode numbering:
Impact properties (n)
0 = 47J at 0C
2 = 47J at -20C
3 = 47J at -30C
4 = 47J at -40C

Tensile strength
41 = 410 MPa min
48 = 480 MPa min

positions (y)

Hydrogen level (HmR)

H5 = 5 ml / 100g of WM
R = low moisture

E xx y z n HmR

1=all positions
2=flat + horizontal
4=vertical down

Flux type (z)

0, 1 = cellulosic
2, 3, 4 = rutile
5, 6, 8 = low hydrogen
7 = iron powder + iron oxide
Prepared by Reza Manaf

Welding

Advantages

Equipment simple, inexpensive, and

portable
Process can be used in any position
Shop repairs, pipelines, building
construction
Disadvantages
Limited deposition rate relative to other
welding processes due to stubs and slag
Weld not well protected form the
atmosphere
Welds have more inclusions than welds
made with other processes

Prepared by Reza Manaf

Welding

SMAW usually restricted to metals between 3 to

19mm (1/8 to 3/4 in) thick.

Typical pass 3mm (1/8 in) thick.

Prepared by Reza Manaf

Welding

Gas Tungsten Arc Welding

Prepared by Reza Manaf

Welding

GTAW process:

Tungsten
electrode

Torch

Collet

Ceramic
shroud

Gas lens
(optional)

Torch
lead (-)

Power
source

Arc

Filler
Weld metal
Weld pool

Prepared by Reza Manaf

Inert
gas

Work
lead (+)

Welding

SMAW process:

Gas Tungsten Arc Welding

Prepared by Reza Manaf

Welding

Shielding gases:
Pure argon, Argon-helium, Argon-2%
hydrogen
Torch gas must not contain oxygen or CO2

Backing (or purge) gas

Used for all single-sided welds except in

carbon steel
Supplementary shielding
Reactive metals: Ti, etc

Prepared by Reza Manaf

Welding

TIG Process features :

can also be used to weld dissimilar metals

(but not very well)
Slower and more costly than consumable
welding
Independently added filler
Used for root, pass runs in pipe or thin
sheet
High quality, Clean process, no slag
Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single
sided welds

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Welding

Filler metals:
Filler wire or rod of matching composition
C-Mn & low alloy steel
Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler replaced in joint

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Welding Symbols

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Welding symbols:

The welding symbols devised by the AWS has 8

elements

Reference line
Arrow
Basic weld symbols
Dimensions and other data
Supplementary symbols
Finish symbols
Tail
Specification or others reference

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Welding symbols:

Reference line and arrow pointing to the joint

the reference line has two sides:

Other side, above the line
Arrow side, below the side
OTHER SIDE
ARROW SIDE

OTHER SIDE
ARROW SIDE
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Arrow

OTHER SIDE
ARROW SIDE

OTHER SIDE
ARROW SIDE

Welding symbols:

Basic welding symbols

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Welding symbols:

If a bevel groove is required the use broken arrow

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Welding symbols:

Dimensions and other data

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Welding symbols:

Dimensions and other data

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Welding symbols:

Dimensions and other data

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Welding symbols:

Supplementary symbols

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Welding symbols:

A circle at the tangent of the arrow and the reference

line means welding to be all around.

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Welding symbols:

A flag at the tangent of the reference line and arrow

means Field Weld.

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Welding symbols:

Tail

The tail of the welding symbol is used to indicate the

welding or cutting processes, as well as the welding
specification, procedures, or the supplementary
information to be used in making the weld

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Welding symbols:

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Arrangement

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Arrangement: Flexibility

Design flexible arrangement for piping to reduce

thermal stress (induce stress in piping, support and
attachment equipment)
settlement strain (foundation of large tanks and
heavy equipment may settle or tilt slightly in course
of time)

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Arrangement: Flexibility

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Arrangement: Flexibility

Avoid cold spring of pipe

Cold spring used in to manner
To reduce stress
To avoid an interference

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Arrangement: Flexibility

Flexible pipe connection should have a length of

6 to 10 NPS

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Arrangement:

Take gas and vapor branch lines from tops of header

where it is necessary to reduce the chance of
drawing off condensate or sediment which may
damage rotating equipment

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Arrangement:

Allow room for the joint to be made

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Arrangement:

Establish sufficient headroom for ductwork, electrical run

Consider vertical clearance (dont route piping) over pump

compressor to permit removal for servicing (maintenance),
consider headroom for mobile crane

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Arrangement:

Centrifugal Pump arrangement:

Suction: eccentric reducer are used in 2 line and larger

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Arrangement:

Centrifugal Pump arrangement:

Suction (socket weld)

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Arrangement:

Centrifugal Pump arrangement:

Suction arrangement

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Arrangement:

Dont use globe valves at suction and discharge for

isolating pump

Route suction line as directly as possible Dont route

piping over the pump, as this interferes with
maintenance

If pump positioned close to supply tanks and are on

separate foundations, avoid rigid piping arrangement,
for settle of tank in course of time

Locate the pump as closely as practicable to source of

liquid to be pumped from storage tank

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Arrangement:

Centrifugal Pump arrangement:

Discharge: Concentric reducers are used in 2 line and smaller

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Arrangement:

Centrifugal Pump arrangement:

Discharge (socket)

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Arrangement:

Centrifugal Pump arrangement:

Discharge (manifold)

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Arrangement:

Provide to drain between ball valve and check

valve at discharge of pump to drain

Drain can be provided on above disk of check valve

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Arrangement:

The outlet pipe for pump is chosen to be of large bore

than the discharge port in order to reduce velocity and
equipment pressure drop

Concentric reducers are used in 2 line and smaller

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Arrangement:

Each pump is usually provided with a drain hub

4 to 6 positioned about 9 in front of the pump

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Arrangement:

Positive displacement Pump arrangement:

Install PRV at discharge line befor isolating valve
pump PDP dont change velocity so, reducer at
discharge and suction not used

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Arrangement:

PDP have pulsation discharge, so used standpipe

(reservoir to damp vibration)

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Arrangement:

Compressor arrangement:

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Arrangement:

Compressor arrangement
suction

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Arrangement:

Compressor arrangement
discharge

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Arrangement:

Turbine piping arrangement

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Arrangement:

Piping may have thru concrete floor as walls, inform

the civil and architectural to avoid cutting exciting
reinforcement

Dont run piping under foundation

If there is no possibility of future road or site

development, lay piping such as

Line to outside storage

Loading and receiving facilities
At grade on pipe sleeper
Avoiding burying steam line that pocket, due the
difficulty to collecting condensate
Burying line (water, gas, drain) bellow the frost line to
avoid freezing water and solutions, save the expense
of tracing long horizontal parts of the line

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Arrangement:

Vent all high point and drain all low point on lines,
place vent and drain valve to permit easily drained or
purged during shutdown period (important for reducing
cost of winterizing)

Avoid pocketing lines. Arrange piping lines to drain

back into equipment or into lines that can to be
drained

Run piping beneath of platforms, rather than over

them.

If need removing equipment, cleaning line provide

Union
Flanged
Removable spool
Cross instead elbows to permit removing solid

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Arrangement:

Dont obstruct access ways (doorways, escape road, )

Consider vertical clearance (dont route piping) over

pump to permit removal for servicing (maintenance),
consider headroom for mobile crane

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Arrangement:

Nearly all valve will be line size, one exception is

control valve, which are usually one or two size
smaller than line size

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Arrangement:

Provide isolating valve

in all small lines branching from header, place valve in
horizontal rather than vertical run, so that lines can drain when
the valve are closed
At all instrument point for removal of instrument

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Arrangement:

Utility station
Steam line NPS > , use globe valve
Air and water > 1 , use gate valve
Terminate with house connection

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Arrangement:

Arrange valve so that support will not be on removable spools

In critical application, use two pressure relive valve with interlock

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Arrangement:

A relive valve that discharged to into a header should be placed

higher than the header in order to drain into it

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Arrangement:

Required space between pipes

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Pipe Work

Pipe work

Material work:
Fabricate, test, certificate
Test (spectrograph), marking

Storing
SS shall be separated from other steels and
without any contact to zinc material

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Pipe work

Person who are engaged for

Tack welding
Welding
Shall be qualified according to ASME SEC. IX

Pipe fitting
Assembling
Erection
Control weld temperature
fully trained and have certificate (license, pass) of employer

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Pipe work

Cutting method:

Shear
Milling
Planer
Flame cutting
Flame gouging
Arc gouging

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Pipe work

Cutting:
In the case of thermal cutting
Cutting surface shall be ground to remove any
edge and roughness (dross, scale, .. At HAZ)
and to be made flush and smooth
Cutting slag stuck to the inside of the pipe shall
be completely removed
After thermal cutting
Machining for C.S, SS not require
for other material required (3 mm of HAZ)
In the abrasive disk case
Abrasive disk for SS shall not be used for C.S
or vise verse
Plasma jet cutting may be applied for SS, etc

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Pipe work

End preparation:
According to WPS

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Pipe work

Trimming:
When having unequal wall thickness (the difference is
more than 3 mm for outer surface and/or 1.5 mm in inner
surface

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Pipe work

Trimming for making branch connection

Shall be inserted at least as far as the inside
surface of pipe run

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Pipe work

Alignment:
When a pipe having a longitudinal seam is used
in a horizontal line, the pipe shall be laid so that
the longitudinal weld seam is not on bottom or
top of the pipe

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Pipe work

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Pipe work

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Pipe work

To measure root opening use taper gauge

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Pipe work

To measure internal misalignment of joint use hi-low

mismatch gauge
T > 19 mm, 2.5 mm
T < 19 mm, 1.6 mm

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Pipe work

Tolerance:

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Pipe work

cleaning:
The bevel shall be fully clean so that there is no rust, oil,
grease, (50 mm from bevel edge)
Solvent:
Non-injurious to the material
Halide free
Material of wire brush shall be properly selected for
working CS and SS respectively
Iron free
Grinding wheel (or disk) shall be organic resin bond

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Pipe work

Preheating:
Shall be performed by propane prior to tack welding and
welding
Valve shall be open during preheating,
Where the ambient temperature is below 5C, preheating
temperature = 40 (except Cu-Ni, Ti)

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Pipe work

Preheating:
Extend 50 mm or 4T beyond each edge

Temperature measure by surface thermometer or crayons

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Pipe work

Preheating:
Preheat temperature shall be measured based on 2
minutes per 25 mm thickness

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Pipe work

Tack weld
Use internal or external clamps before tack weld

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Pipe work

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Pipe work

Tack weld
Ensure the contact surface of the clamps are made of
same base metal
Before welding of the root, both ends of the root tack weld
bead shall be prepared with a grinder as shown in the
following illustration

Type of tack weld

Root
Bridge (Bridge tack shall never be hammered,
removed by grinding or gas cutting)
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Pipe work

Welding:
WPS, PQR shall be approved
Welder shall be qualified according to ASME SEC. IX
All welding processes shall be protected from adverse
weather (use shelter)
All welding equipment shall be calibrated
When preheat is applied, welding shall not be interrupted
or stopped until 30% of the final weld has been completed
Bolts hole:
symmetrically from a vertical center line
Symmetrically from plant north

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Pipe work

Welding:
Consumable:
Consumable manufacture shall be approved by third party
Shall be close matching with base metal
Control the storage, handling, conditioning
Electrode:
Low hydrogen electrode stored in oven and dont re-dried
more than twice

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Pipe work

Welding:
Consumable:
Purge gas, shielding gas:
Check Mixture tolerance, Purity, Dew point
moisture < 10 PPM
Nitrogen not used for SS
Before tack weld and root pass welding monitoring the
oxygen content < 5000 PPM
Use purge gas for
Thin wall tubing or piping T < 5.5 mm
Root pass without backing, single sided for all weld metal

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Pipe work

Use following fitting format:

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Pipe work

Use following fitting format:

Perform at least 2 layer weld and end point of weld at each
layer shall change

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Pipe work

Post Weld Heat Treatment

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Pipe work

Weld Test include:

Tensile
Bending
Impacting
Hardness

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Pipe work: Tensile

Material is sectioned and edges rounded of to

prevent cracking. Punch marks are made to see
elongation.

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Pipe work: Tensile

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Pipe work: Bend test

Shows physical condition of the weld and

Determine welds efficiency
Tensile strength
Ductility
Fusion and penetration

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Pipe work: Bend test

O

Bend through 180

the specimen should be a minimum of 30mm wide

The fulcrums diameter is 3x thickness of the plate

The bottom rollers have a distance of the diameter

of the former + 2.2 times the thickness of the plate

Upper and lower surfaces ground or filed flat and

edges rounded off.

the tests should be one against the root -another

against the face ,and in some cases a side bend.

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Pipe work: Bend test

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Pipe work: Bend test: face bend

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Pipe work: Impact

CHARPY AND IZOD:

Gives the toughness and shock loading of
the material and weld at varying
temperatures with a notch such as under cut
The measurement is the energy required to
break a specimen with a given notch
o

2mm depth at a 45 bevel or a U notch.

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Pipe work: Impact: charpy

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Pipe work: Impact: charpy

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Pipe work: Impact: Izod

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Pipe work: Hardness tests

This gives the metals ability to show resistance

to indentation which show its resistance to
wear and abrasion.

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Design

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ASME B31.3

ASME B31.3 provides requirements for:

Design
Materials
Fabrication
Erection
Inspection
Testing

process plants including

Petroleum refineries
Chemical plants
Pharmaceutical plants
Textile plants
Paper plants
Semiconductor
plants
Cryogenic plants

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ASME B31.3: Scope of ASME B31.3

ASME B31.3 applied to piping and piping components

of all fluid services:

Raw, intermediate, and finished chemicals

Petroleum products
Gas, steam, air, and water
Fluidized solids
Refrigerants
Cryogenic fluids

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ASME B31.3: Scope exclusions specified

The following are excluded from the scope of ASME B31.3

Piping system that design according to BPV and other B31
.

0 Pg 15 psi
nonflammable & nontoxic

This item not exclude

vacuum
0
0 system

20 F T 366 F

Tube, inside a fire heater

Fire protection system (NFPA )
Plumbing, sanitary sewer (AWWA)

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ASME B31.3: Material

The factors that affect piping material selection are:

Strength
Yield & Tensile strength
Creep strength
Fatigue strength

Corrosion resistance
Material fracture toughness
Fabricability
Availability & cost

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ASME B31.3: Material: Stress - Strain Diagram

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ASME B31.3: Material: Variation of strength with temperature

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ASME B31.3: Material: Variation of strength with temperature

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ASME B31.3: Material: Variation of strength with temperature

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ASME B31.3: Material: creep

Below about 750F for a given stress, the strain in

most materials remains constant with time. Above this
temperature, even with constant stress, the strain in
the material will increase with time. This behavior is
known as creep.

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ASME B31.3: Material: fatigue

The type of fatigue are:

Static:
specimen breaks under a load that it has
previously withstood for a length of time.
Examples of static fatigue are: creep
fracture and stress corrosion cracking.
Cyclic:
specimen breaks during a load cycle that it
has previously withstood several times.

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ASME B31.3: Material: Corrosion resistance

Corrosion of materials involves deterioration of the

metal by chemical or electrochemical attack and
include:
General or Uniform Corrosion:
Characterized by uniform metal loss over entire
surface of material. May be combined with erosion
if material is exposed to high-velocity fluids, or
moving fluids that contain abrasive materials.
Pitting Corrosion:
Form of localized metal loss randomly located on
material surface. Occurs most often in stagnant
areas or areas of low-flow velocity.

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ASME B31.3: Material: Corrosion resistance

Galvanic Corrosion:
Occurs when two dissimilar metals contact each other in
corrosive electrolytic environment. The anodic metal
develops deep pits or grooves as a current flows from it to
the cathodic metal.

Crevice Corrosion:
Localized corrosion similar to pitting. Occurs at
places such as gaskets, lap joints, and bolts, where
a crevice can exist.
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ASME B31.3: Material: Corrosion resistance

Concentration Cell Corrosion:

Occurs when different concentration of either
corrosive fluid or dissolved oxygen contacts
areas of same metal. Usually associated with
stagnant fluid.
Graphitic Corrosion:
Occurs in cast iron exposed to salt water or
weak acids. Reduces iron in the cast iron and
leaves the graphite in place. Result is extremely
soft material with no metal loss.

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ASME B31.3: Material: Material fracture toughness

It is the amount of energy necessary to initiate and

propagate a crack at a given temperature.
The addition of manganese or nickel improves fracture
toughness.
Mostly of concern for carbon steels
Generally decreases as temperature decreases
Factors affecting fracture toughness include:
Chemical composition or alloying elements
Heat treatment
Grain size
The impact energy required to fracture a material
sample at a given temperature can be measured by
standard Charpy V-notch tests.

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ASME B31.3: Material: Material fracture toughness

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ASME B31.3: Material: Cost

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ASME B31.3: Material: Modes of failures

FAILURE BY GERNRAL YIELDING: Failure is due to excessive

plastic deformation.
Yielding at Sub Elevated temperature: Body undergoes
plastic deformation under slip action of grains.
Yielding at Elevated temperature: After slippage, material
re-crystallizes and hence yielding continues without
increasing load. This phenomenon is known as creep.

FAILURE BY FRACTURE: Body fails without undergoing

yielding.
Brittle fracture: Occurs in brittle materials.
Fatigue: Due to cyclic loading initially a small crack is
developed which grows after each cycle and results in
sudden failure.

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ASME B31.3: Material: Modes of failures: Ductile Deformation

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ASME B31.3: Material: Modes of failures: Brittle Fracture

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ASME B31.3: B31.3 Fluid Service Definitions

Category D

Category M

High Pressure

Normal

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ASME B31.3: B31.3 Fluid Service Definitions

Category 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 -20F (-29C)
and does not exceed 366 F (186C).
Often characterized as utility

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ASME B31.3: B31.3 Fluid Service Definitions

Category 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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ASME B31.3: B31.3 Fluid Service Definitions

High 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

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ASME B31.3: B31.3 Definitions

Normal operating conditions:

Are those expected to occur during normal
operation, excluding failure of any operating device,
operator error, and the occasional, short-term
variations stated in the applicable code.

Design conditions:
Are those which govern the design and selection of
piping components, and are based on the most
severe conditions expected to occur in service.

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ASME B31.3: B31.3 Definitions

Loading classification
Primary loads: These can be divided into two categories based
on the duration of loading.
Sustained loads: These loads are expected to be present
through out the plant operation. e.g.
internal & external pressure
weight of system (piping material and operating
pressure).
Occasional loads: These loads are present at infrequent
intervals during plant operation. e.g.
Wind, ice and snow load
seismic load
Dynamic load (pressure surge, water hammer, energy
release by pressure relief valve,
Hydrostatic leak test load
Wheel load (traffic load)

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ASME B31.3: B31.3 Definitions

Expansion loads: These are loads due to

displacements of piping. e.g.
thermal expansion:
are created when the free expansion and
contraction of the piping is prevented at
its end points by connected equipment,
or prevented at intermediate points by
supports and/or restraints that are
installed. pipe thermal loads can be from
the thermal expansion of equipment at
pipe-to-equipment nozzle attachment
points, causing displacements in the
piping system.
seismic anchor movements
building settlement.
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ASME B31.3: B31.3 Definitions: result

Principal pipe load types

Sustained loads
Act on system all or most of time
Consist of pressure and total weight load
Occasional loads
Act for short portion of operating time
Seismic and/or dynamic loading
Thermal expansion loads
Caused by thermal displacements
Result from restrained movement

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ASME B31.3: B31.3 Definitions: Stress Categorization

Primary Stresses: These are developed by the imposed

loading and are necessary to satisfy the equilibrium between
external and internal forces and moments of the piping
system. Primary stresses are not self-limiting.
Direct
Shear
Bending

Secondary stresses: These are developed by the constraint

of displacements of a structure. These displacements can be
caused either by thermal expansion or by outwardly imposed
restraint and anchor point movements. Secondary stresses
are self-limiting.
Act across pipe wall thickness
Cause local yielding and minor distortions
Not a source of direct failure

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ASME B31.3: B31.3 Definitions: Stress Categorization

Peak stresses: Unlike loading condition of

secondary stress which cause distortion, peak
stresses cause no significant distortion. Peak
stresses are responsible for causing fatigue failure.
More localized
Rapidly decrease within short distance of origin
Occur where stress concentrations and fatigue
failure might occur
Significance equivalent to secondary stresses
Do not cause significant distortion

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ASME B31.3:
Required Wall Thickness for Internal Pressure of Straight Pipe

t = Required thickness for internal pressure, in.

P = Internal design pressure, psig
S = Allowable stress in tension, psi
E = Longitudinal-joint quality factor
Y = Wall thickness correction factor
tm = Total minimum required wall thickness, in.
tnom = Minimum required nominal pipe wall
thickness, in.

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ASME B31.3: Allowable Stresses

Function of
Material properties
Temperature
Safety factors

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ASME B31.3: Wall thickness correction factor

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ASME B31.3: Wall thickness correction factor

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ASME B31.3: Design temperature

Uninsulated component:

T < 150F:
the metal design temperature of the pipe and component
taken as the fluid temperature unless solar radiation or
other effects result in higher temperature
T > 150F
pipe = 0.95 FT (Fluid Temperature)
Flange = 0.9 FT
Lap joint = 0.85 FT
Bolt = 0.8 FT
Externally Insulated:

Metal design temperature = FT

Where piping is heated or cooled by heat tracing or jacketing,
the effect shall be included in the determination of the metal
design temperature.
Internally insulated:
Require heat transfer calculation

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ASME B31.3: Design pressure

The design pressure of a piping system is the pressure at the

most severe condition of coincident internal or external pressure
and temperature expected during service. unless all of the
following criteria are met.
The piping system have no pressure containing components
of cast iron or other non ductile metal.
Nominal pressure stresses shall not exceed the yield
strength, Sy data in [ASME] BPV Code, Section II, Part D,
Table Y-1).

The total number of pressure-temperature variations shall not

exceed 1000 during the life of the piping system.
Increased pressure shall not exceed the test pressure

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ASME B31.3: Design pressure

Occasional variations above design conditions shall remain

within one of the following limits for pressure design.
Subject to the owner's approval, it is permissible to
exceed the pressure rating or the allowable stress for
pressure design at the temperature of the increased
condition by not more than:
33% for no more than 10 hour at any one time and
no more than 100 hour per year; or
20% for no more than 50 hour at any one time and
no more than 500 hour per year.
When the variation is self-limiting (e.g., due to a
pressure relieving event), 20% for no more than 50
hour at any one time and no more than 500 hour per
year.

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ASME B31.3: Design pressure

The combined effects of the sustained and cyclic

variations shall have been evaluated.
Temperature variations below the minimum
temperature shown in Appendix A [of ASME B31.3]
are not permitted.
The application of pressures exceeding pressuretemperature ratings of valves may cause loss of
seat tightness or difficulty of operation. The
differential pressure on the valve closure element
should not exceed the maximum differential
pressure rating established by the valve
manufacturer.

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ASME B31.3: Load: Weight

For buried piping, dead weight is not a factor.

However, a sustained load that is analyzed is the
load from the earth above the buried piping. The
earth load on rigid piping may be calculated using
the following formula.

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ASME B31.3: Load

Wheel load

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ASME B31.3: Load

Wind load:
Wind load can cause other loads, such as
vibratory loads, due to reaction from a deflection
caused by the wind. The design wind speed is
determined from ASCE 7

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ASME B31.3: Load

Snow load (ANSI A58.1)

Assuming that snow laying on a pipe will take the

approximate shape of an equilateral triangle with
the base equal to the pipe diameter.
For most heavy snow climates, a minimum snow
load of 1.2 kpa (25 psf) is used in the design.

Prepared by Reza Manaf

ASME B31.3: Load

Ice load:

Unless local or regional data suggests

assumption of 50 to 75 mm (2 to 3 in) maximum
ice accumulation to calculate an ice loading

Prepared by Reza Manaf