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Piping Systems in the Chemical Process Industries

March, 2009
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Introduction Basis for Design Piping Codes and Standards Design of Process Piping Systems

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

Earliest piping systems: Aqueducts Hollow-Log Piping Facilitated growth of ancient civilizations.

So, it was the ChemEs!

Not the MEs!

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Piping Systems include:

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

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Primary Design Consideration is Safety y Evaluate Process Conditions

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

y Evaluate the Effects of a Leak y Evaluate Performance in a Fire Situation

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Secondary Considerations
y Evaluate any Special Requirements { Sanitary requirements Cleanability { Serviceability ease of maintenance of equipment { Possible contamination of process fluid by piping materials, sealants, or gasketing { Earthquake, Hurricane, Lightening, Permafrost y Lowest Cost over the Lifetime

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Piping System Routing and Layout The unwritten #1 rule:

Serviceability/Operability

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Piping System Design Criteria 4 areas to consider:

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

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Codes and Standards simplify design, manufacturing, installation process

y Standards provide design criteria for

components
standard sizes for pipe { dimensions for fittings or valves
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y Codes specific design/fabrication

methodologies
Incorporated into local/regional statute { Its the LAW
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y ASME Boiler and Pressure Vessel Code y ASME B31: Code for Pressure Piping y ANSI Standards dimensions for valves,

piping, fittings, nuts/washers, etc. y ASTM Standards for piping and tube y API Specs for pipe and pipelines y AWS, ASHRAE, NFPA, PPI, UL, etc.

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ASME B31 Pertinent sections y B31.1 Power plant boilers y B31.3 Chemical plant and refinery piping y B31.4 Liquid petroleum transport y B31.7 Nuclear power plant radioactive fluids

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ASME B31.3 Chemical Plant and Refinery Piping Code Includes piping systems in: y Chemical and refinery plants y Pharmaceutical and food processing y Textile and paper plants y Boilers

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ASME B31.3 covers: y Materials of construction y Piping design process y Fabrication, Erection, Assembly y Design of supports y Examination, inspection, and testing

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Piping Design Process a three step approach

1. Design for Flow { Find min. diameter to achieve desired flow velocity 2. Design for Pressure Integrity { Find min. wall thickness for process and external conditions { Find appropriate rating of in-line components 3. Re-check for Flow Criteria

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Standard Pipe Sizes

Diameters are Nominal

Sizes 12 and less, nominal size < OD { Sizes 14 and over, nominal size = OD
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Wall thickness inferred thru Schedule

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

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What is Pipe Schedule?

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Schedule = P/S * 1000

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

What is max. working pressure for Schedule 40 Carbon Steel pipe?

40 * 36,000 P= = 1440 psig 1000

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Standard Tubing Sizes

y Steel tubing { Diameters are Actual OD { Wall thickness is specified y Refrigeration Tubing { Single wall thickness available for each size { Actual OD y Copper Tubing Nominal sizes { Type K, L, M

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Criteria for Design for Flow

y Economics Serviceable over Design Life Smallest diameter usually is lowest cost y Performance Minimum entrainment velocity Prevent erosion or cavitation

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Design Rules of Thumb when sizing for velocity...

Water lines: 3-10 ft/sec Pump discharge: 3-12 ft/sec Pump suction: (1/3 x discharge velocity) Steam: low pressure (25 psig or less) 50-100 ft/sec high pressure (>100 psig) 100-200 ft/sec Slurries: > min. entrainment velocity
from Peters and Timmerhaus, Plant Design and Economics for Chemical Engineers, 4th ed., McGraw-Hill, 1991.

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Determine min. reqd wall thickness:

Pressure Integrity Design Method ASME B31.3,

PD tm = +A 2(SE + Py )
tm=min. wall thickness P=design pressure, psig D=O.D. of pipe, in. S=allowable stress, psi E=weld joint efficiency y=factor to adjust for temp A= addl thickness for corrosion, external loads, etc.

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After determining wall thickness:

Re-check ID for velocity; Select in-line components; Determine insulation, coverings, coatings; Design and locate supports and hangers.

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Inline Components:
Fittings Valves Gaskets, Seals, and Thread Sealants Connection Hardware Bolts, studs, nuts, washers

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Pipe Fittings - Steel

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Forged Cast Malleable Iron

Select Class of Fittings

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150 lb., 300 lb., 600 lb., etc. Need a look-up table to determine max. allowable P at the design temperature

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Ratings for flanged steel pipe fittings, ANSI B16.5 - 1988.

Maximum Allowable non-shock Pressure (psig)
Pressure Class Rating for Flanged Fittings (lb) Temperature (oF) 150 300 400 600 900 1500 2500

Hydrostatic Test Pressure (psig) 450 1125 740 675 655 635 600 550 535 535 505 410 270 170 105 50 1500 990 900 875 845 800 730 715 710 670 550 355 230 140 70 2225 1480 1350 1315 1270 1200 1095 1075 1065 1010 825 535 345 205 105 3350 2220 2025 1970 1900 1795 1640 1610 1600 1510 1235 805 515 310 155 5575 3705 3375 3280 3170 2995 2735 2685 2665 2520 2060 1340 860 515 260 9275 6170 5625 5470 5280 4990 4560 4475 4440 4200 3430 2230 1430 860 430

-20 to 100 200 300 400 500 600 650 700 750 800 850 900 950 1000

285 260 230 200 170 140 125 110 95 80 65 50 35 20

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

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Design Checklist:
Re-check ID for velocity; Select in-line components; Determine insulation, coverings, coatings; Design and locate supports and hangers.

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Piping Insulation
y Prevent heat loss/ gain y Prevent condensation below ambient y Personnel protection over 125oF y Freeze protection outdoor cold climates y Fire protection y Noise control

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Recommended minimum Thickness of Insulation (inches)*
Temperature Range (oC) 50 - 90 Nominal Pipe Size NPS (inches) 90 - 120 120 - 150 150 - 230

Temperature Range (oF) 120 - 200 Hot Water 201 - 250 Low Pressure Steam 1.5 1.5 2.0 2.0 2.0 251 - 305 Medium Pressure Steam 2.0 2.5 2.5 3.0 3.0 306 - 450 High Pressure Steam 2.5 2.5 3.0 3.5 3.5

< 1" 1 1/4" - 2" 2 1/2" - 4" 5" - 6" > 8"

1.0 1.0 1.5 1.5 1.5

* based on insulation with thermal resistivity in the range 4 - 4.6 ft2 hr oF/ Btu in Source:EngineeringToolbox,http://www.engineeringtoolbox.com/pipesinsulationthicknessd_16.html,3262009

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Common Types of Insulation

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

Polymeric closed cell foams

Flexible polyethylene Rigid foam polystyrene, polyurethanes

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Fiberglass Insulation w/ Asbestos-plastered fitting coverings

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Metal Jacketed insulation covering

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After determining wall thickness:

Re-check ID for velocity; Select in-line components; Determine insulation, coverings, coatings; Design and locate supports and hangers.

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Piping Supports

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

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

Horizontal Run

Vertical Run

1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4

4.5 7.5 7.5 7.5 7.5 7.5 10 10 10

10 10 10 12 12 15 15 15 18

Source:EngineeringToolbox,http://www.engineeringtoolbox.com/steelpipesupportsd_1071.html,22609

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Inadequate support

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Effect of Thermal Expansion on piping and supports Example 1: Calculate the expansion per 20 length of 2, schedule 40 carbon steel steam line at boiler startup for a 100 psig steam service. =thermal expansion coefficient for mild steel, =6.6x10-6 in/inoF

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Temp of pipe at amb. cond. =70oF Temp of 100 psig sat. steam =338oF T=268oF L=20=240 expansion due to temperature increase is *L* T =(6.6x10-6in/inoF)*(240in)*(268oF) =0.42 in per 20 of pipe

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Example 2: What force is exerted on the end restraints of that 20 pipe if it is rigidly installed (end restraints cant move)? =internal stress due to T, and = *(T)*E E is the material property called Modulus of Elasticity, relationship between stress and strain E=30x106 psi for low carbon steel

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= *(T)*E =(6.6x10-6 in/inoF)*(268oF)*(30x106lbf/in2) =53,000 lbf/in2 since =F/A, The force on the end restraints is F=*A where: F=force in lbf A=cross sec. area of 2, sched 40 pipe in sq. inches

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A=(OD2-ID2)/4 = (2.3752-2.0672)/4 =1.07 sq.in F= *A =(53,000 lbf/in2)*(1.07 in2) Force on the end restraints = 57,000 lbf or 28.5 tons

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Results of inadequate support: Flixborough, England

May, 1974 Leaking reactor #5 removed from train of 6 reactors and temporarily replaced with a section of 20 pipe. Pipe is supported by scaffolding. June 1, 1974 Supports collapse, pipe breaks 28 dead, 89 injured, 1800 houses damaged, 160 shops and factories damaged, large crater where plant stood

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Heat Tracing
y Prevents flow problems in cold climates { Freeze protection { Loss of flow due to viscosity increase y Prevent condensation in vapor lines y Methods { Electric { Hot Fluids

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References:
y Piping Handbook, 7th ed., Nayyar, McGraw-Hill, New y y y y

York, 2000. Plant Design and Economics for Chemical Engineers, 4th ed., Peters and Timmerhaus, McGraw-Hill, 1991. Valve Handbook, Skousen, McGraw-Hill, New York, 1998 www.flowserve.com, Flowserve Corp., Sept. 2004. www.engineeringtoolbox.com, The Engineering Toolbox, Sept. 2004.

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Materials Metallic piping

Carbon and low alloy steel

Ductile { Inexpensive and available { Easy to machine, weld, cut { Some drawbacks
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Materials Metallic piping

Alloy Steels including Stainless Steels

Good corrosion resistance { More difficult to machine, weld, cut { Some drawbacks
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Materials Metallic piping

Nickel, Titanium, Copper, etc.

Copper is used in residential and commercial applications and is widely available { Other materials are expensive and difficult to machine, weld, join { Some incompatibilities with each
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Materials Non-Metallic piping

Thermoplastics

Wide range of chemical compatibility { Light weight { Easily cut and joined { Low temperature limits { Need extra supports
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Materials Non-Metallic piping

Fiberglass Reinforced Pipe

Wide range of chemical compatibility { Easily cut and joined { Wider temperature limits than thermoplastics { Thermal expansion similar to carbon steel { Similar structural performance as carbon steel
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Materials Others
Glass Concrete Lined or coated
Glass Rubber Cement Teflon Zinc (galvanized pipe)

Double Containment piping systems

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

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Threaded joints

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Soldered joints

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Welded joints

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Compression joints

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Mechanical joints shown on glass drain piping system

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

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Fittings for changing directions in pipe: 45o Ell 90o Ell Street Ell

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Fittings for adding a branch in a run of piping: Tee Cross

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Fittings for blocking the end of a run of piping: Pipe plug Pipe cap Blind Flange

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Misc. pipe fittings: Nipple Reducing bushing

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

Sliding gate on knife-gate valve

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Globe Valve: Used to regulate flow

Cut-away shows stem seal plug and seat

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Ball Valve: Typically used as block valve

Quarter-turn valve Cut-away shows ball and seat

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Butterfly Valve: Can be used for flow control or on/off

Valve actuator/ positioner for accurate flow control

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Check Valves: Used to prevent backflow

Piston check Swing check