LEARN BASIC OF PIPING ENGINEERING

CHAPTER: 1
INTRODUCTION
DEFINITION:
Piping engineering is all about designing, fabricating and constructing lines for
conveying fluids.
IMPORTANCE OF PIPING ENGINEERING:
To maintain pressure difference (p)
To maintain temperature difference (t)
To maintain flow rate (q)

APPLICATIONS:
Pipelines carry crude oil from oil wells to tank farms for storage or to refineries for
processing.
The natural gas transportation and distribution lines convey natural gas from the
source and storage tank forms to points of utilization, such as power plants, industrial
facilities etc,
In chemical plants, paper mills, food processing plants, and other similar industrial
establishments, the piping systems are utilized to carry liquids, chemicals, mixtures,
gases, vapors, and solids from one location to another.
The fire protection piping networks in residential, commercial, industrial, and other
buildings carry fire suppression fluids, such as water, gases, and chemicals to provide
protection of life and property.
The piping systems in thermal power plants convey high-pressure and high
temperature steam to generate electricity. Other piping systems in a power plant
transport high- and low-pressure water, chemicals, low-pressure steam, and
condensate.
Sophisticated piping systems are used to process and carry hazardous and toxic
substances.
The piping systems in laboratories carry gases, chemicals, vapors, and other fluids
that are critical for conducting research and development.
DEFINE PIPING
Piping is an assembly of pipe, fittings, valves, instruments and specialty components.
Piping is divided into three major categories:

Large bore pipe generally includes piping which is greater than two inches in
diameter.

Small bore pipe generally includes piping which is two inches and smaller in

diameter.
Tubing is supplied in sizes up to four inches in diameter but has a wall thickness
less than that of either large bore or small bore piping and is typically joined by
compression fittings.

Piping system includes:

Pipe
Fittings (e.g. elbows, reducers, branch connections, etc.)
Flanges, gaskets, bolting
Valves
Pipe supports
ASSOCIATION INVOLVED IN GENERATING CODES FOR PIPING DESIGN
ENGINEERING:
ASME
-American Society of Mechanical Engineers
ANSI
-American National Standardization Institute
These standards give technical recommendations for designing piping system for power
plants and chemical plants
They contain formulas to calculate the minimum thickness of pipelines
They contain formulas to calculate the extra thickness that a pipe must have when a
branch is cut into it.
They contain regulations for stress analysis
They contain tables that give maximum allowable stress for metallic materials
accepted by ANSI for pipeline construction depending on temperatures.

PIPING CODES:
ASME B31.1 - Power Piping
ASME B31.2 - Fuel Gas .Piping
ASME B31.3 - Process Piping
ASME B31.4 - Liquid Piping
ASME B31.5 - Refrigeration Piping
ASME B31.8 - Gas Distribution and Transportation
ASME B31.9 - Building Service Piping
ASME B31.11 - Slurry Piping

ASSOCIATION INVOLVED IN GENERATING MATERIAL SPECIFICATION FOR

PIPING:
ASTM
-American Society for Testing Materials
ASTM developed a collection of documents called material specifications for
standardising materials of large use in the industry. Specifications starting with a are
for steel. Specifications starting with b are for non-ferrous alloys (bronze, brass,
copper nickel alloys, aluminium alloys and so on). Specifications starting with d are for
plastic material, as PVC.
An ASTM specification does not only specify the basic chemical composition of
material, but also the process through which the material is shaped into the final
product.
This is why for a given base material seamless pipe have a specification, welded pipe
have another specification wrought fittings have another specification, forged fittings
have another specification, large valve bodies (normally cast) have another specification
API
-American Petroleum Institute
Rules, practices and standards for oil and gas industry are issued by this institute and
followed by almost all oil and gas companies in the world.
Among the many standards issued by the institute there is also a standard for design
of pipelines: API STANDARD 5l
Within this standard materials for oil and gas transportation pipelines are specified,
with denomination API 5l
This is a family of carbon steels almost equivalent to ASTM A53 / A106.

CHAPTER 2
PIPE
INTRODUCTION:
A pressure tight cylinder used to convey fluids under pressure through materials of
commercially available designation.
Pipe is always designated through nominal bore size(NBS) also called as nominal
pipe
size(NPS)
A pipeline conveys a fluid from one given point of the plant usually called inlet
point of the line, to another part of the plant usually called outlet point of the line.
NOMINAL PIPE SIZE (NPS):
Pipe size is specified with two non-dimensional numbers: a Nominal Pipe Size (NPS)
and a schedule (SCH). The relationship of these numbers to the actual pipe dimensions
is a bit strange.
The NPS is very loosely related to the inside diameter in inches, but only for NPS 1/8 to
NPS 12.
For NPS 14 and larger, the NPS is equal to the outside diameter (OD) in inches. For a
given NPS, the OD stays constant and the wall thickness increases with larger SCH.
For a given SCH, the OD increases with increasing NPS while the wall thickness
increases or stays constant.
NOMINAL DIAMETER (DN):
It is same as nominal pipe size, but in mm.
SCHEDULE (WALL THICKNESS):
Schedule:
Carbon steel : 5, 10, 20, 30, 40, 60, 80, 100, 120, 160.
Stainless steel : 5S, 10S, 20S, 30S, 40S, 60S, 80S.

Weight series:
STD : Standard
XS : Extra Strong
XXS : Double Extra Strong

Wall thickness is designated by schedule number or descriptive classification, rather

than the actual wall thickness. The original thicknesses were referred to as standard
(STD), extra strong (XS) and double extra strong (XXS).
Wall thickness for the schedule 40 and STD are same for sizes to 10.schedule 80
and XS also have the same wall thickness for to 8 diameter pipe.
CODES:
ASME B36.10 - CARBON STEEL
ASME B36.19 - STAINLESS STEEL
MATERIAL:
Carbon steel:
Steel is basically a solution of carbon (C) into iron (Fe). The presences of
carbon into the crystal structure of the iron improve very much the mechanical
characteristics of the iron alone. Carbon steel is a conventional denomination for steel
that has almost no other metallic elements added into it.
Carbon steel material specification ASTM A106 is available in grades A, B
and C. These refer to the tensile strength of the steel, with grade C having the highest
strength.
Common practice is to manufacture the pipe as A106 grade B
ASTM A53 is also commonly specified for galvanized or lined pipe or as an
alternate to A106.the testing requirement for A53 are less stringent(rigorous or tight)
than for A106. Three types of carbon steel pipe are covered by A53. These are type E or
Electric resistance welded, type F or Furnace-butt welded, and type S or Seamless.
Type E and S are available in grade A and B, comparable to grades A and B of A106.
Stainless steel:
Austenitic stainless steel pipe commonly referred to as Stainless Steel is
virtually non-magnetic. Stainless steel is manufactured in accordance with
ASTM A312 when 8 or smaller sizes are needed. There are eighteen different grades,
of which type 304L is the most widely used.
Grade 316L has high resistance to chemical and salt water corrosion and is
best suited for welding. Large sizes (8 and up) of stainless steel pipe are covered
by ASTM A358. Extra light wall thickness (schedule 5S) and light wall thickness
(schedule 10S) stainless steel pipe is covered byASTM A409.
PIPE MANUFACTURING METHOD:
Seamless
Hot rolled, cold drawn etc
Electric resistance welding

No material is added during welding process

Electric fusion welding
Filler material is added during welding process
CHARACTERISTICS OF A PIPELINE:
Nominal pipe size(NPS)
Wall thickness
Type of joint between pieces
WELDED JOINTS
Butt welded
Socket welded
Threaded joints
Flanged joints
External finishing
Painting
Insulation
OTHER CHARACTERISTICS OF A PIPELINE:
ROUTING:
The routing is how the Pipeline is developed into the space.
There are rules and regulations to route a Pipeline according the
Good Engineering Practice
Cold Pipelines connecting static objects (something that does not move
like Tanks, Vessels, other Pipelines, and Headers) can be straightly
routed between the inlet and the outlet point.
Cold Pipelines connecting machines that vibrate or rotate may need a
flexible part between the inlet and the outlet point.
Hot Pipelines must be flexible enough to adsorb the thermal expansion
of the Pipeline from cold to hot condition
SUPPORTING SYSTEM:
Every Pipeline must be supported. Not all Pipelines are supported in
the same way.
Cold Pipelines can be supported everywhere with fixed points
Hot Pipelines cannot be supported only with fixed points, but certain
points must be only guided, meaning that in those points the Pipeline
retains a certain numbers of degree of freedom in certain directions,
while are constrained in certain other directions.

TYPE OF JOINT BETWEEN PIECES:

1. BUTT WELDED JOINT:
The end is machined to allow head to head full penetrating welding

2. SOCKET WELDED JOINT:

A socket is provided where pipe can be inserted

3. THREADED JOINT:
Parts to be connected are threaded.

PIPE ENDS:
Pipe may be obtained with
Plain ends are cut square and reamed to remove burns. This
type of end is needed when being joined by mechanical couplings, socket weld fittings,
or slip-on flange.

 Bevelled ends are required for most butt weld application.

Threaded ends are used with screwed joints and are ordered
noting threaded on both ends or one end.
Various combination of pipe end:

POE: Plain one end

PBE: Plain both end
BOE: Bevelled one end
BBE: Bevelled both end
TOE: Threaded one end
TBE: Threaded both end

PIPE REPRESENTATION:
UP TO 12 INCH

ABOVE 14 INCH

SPECIFICATION OF A PIPE:
Example:
Size : NPS 12
Diameter : DN 300
Wall thickness: Sch. 40

Material : ASTM A106 Gr. B

CHAPTER-3
FLUID

INTRODUCTION:
It can be
A gas
A liquid
A mixture of gas or liquid
A suspension of small solid particles inside a liquid.
BASIC PROPERTIES OF CONVEYED FLUIDS:
Fluid type
Flow rate
Pressure
Temperature
FACTORS DEPENDING UPON FLUID TYPE:
1. MATERIAL:
a. Non corrosive fluids: Services where impurities are accepted
Example:
Industrial water lines (cooling water)
Steam
Lube oil return / before filter lines
Air lines
Vents and drains
Material:
Carbon Steel
Low Alloy Steel (High T)
b. Corrosive fluids: Services where impurities are not accepted
Example:
Demineralized water
Lube oil after filters
Fuel gas / oil
Sea water (water containing Chlorine)
Material:
Stainless Steel
No Iron (Fe)
Copper/Nickel Alloys (Cu-Ni)
c. Aggressive Chemicals

Example
Strong Acids / Bases
Material:
Plastic: PVC TEFLON PE
Rubber: NBR, Viton
Composites: RESIN GLASS
2. CORROSION ALLOWANCES:
Thickness of the pipe increases with respect to corrosion. Typical corrosion allowance
for water is 3mm.
3. TYPE OF JOINT:
Dangerous fluids are conveyed in fully welded pipes, were leaks are not
accepted.
4. TESTING AND EXAMINATION:
For Dangerous Fluids 100% of joints are likely to be X-Ray examined
FACTORS DEPENDING UPON FLOWRATE:
1. DIAMETER:
For a given flow rate:
Small diameter means higher velocity of the conveyed fluid.
Big diameter means slower velocity of the conveyed fluid.
Velocity of fluids in pipelines affects:
Pressure losses along the pipeline.
Pressure losses are proportional to the square velocity (v2).
Vibration of the pipeline.
Usual velocities of fluids inside pipelines are:
Gas: 20 m/s - max. 40 / 50 m/sec.
Liquid: 2 to 4 m/s - max. 10 m/sec.
FACTORS DEPENDING UPON PRESSURE:
1. WALL THICKNESS CALCULATION
2. TYPE OF JOINT
Low pressure pipelines can be threaded or socket welded
High Pressure pipelines are Butt Welded
3. TESTING AND EXAMINATION:
Non process Pipelines (For Example Vents and drain lines) may even have no tests at
all Low Pressure Pipelines can undergo only the Hydraulic Test For intermediate
pressures a 10% to 50% of joints must be examined with X-rays High Pressure
Pipelines are usually 100% X-ray examined.
FACTORS DEPENDING UPON TEMPERATURE:

1. MATERIAL:
Steel for High Temperature (Low Alloy Steel Creep Resistant)
2. WALL THICKNESS CALCULATION
3. THERMAL INSULATION:
T>60C Insulation for Personnel Protection is mandatory for all pipeline parts that can
be reached by hands.
4. STRESS ANALYSIS:
Hot Lines must be routed properly. Provisions shall be taken so that when temperature
rises from ambient to Operating Temperature the thermal expansion of Pipelines does
not generate stresses too high for the pipes to withstand.
FLUID SERVICE CATEGORIES:
B31.3 recognizes the following fluid service categories and a special design
consideration based on pressure. It is the owners responsibility to specify the fluid
service category for each piping system. With the fluid service category known, then the
designer can make material and component selection, as well as employ the code
required fabrication and inspection requirements based on the selected fluid category.
These fluid categories and pressure concern are:
1. Normal fluid service
2. Category D fluid service
3. Category M fluid service
4. High pressure piping
5. Severe cyclic conditions
Category D Fluid Service is defined as all fluid services that are:
Nonflammable
Nontoxic
Not damaging to human tissues
The design gage pressure does not exceed 150 psig
The design temperature is from -20 f to 366 f is the saturated temperature of steam
at 150psig
Category M Fluid Service is defined as a service in which a single exposure to a very
small quantity of toxic fluid can produce serious irreversible harm to person on breathing
or bodily contact, even when prompt restorative are taken.
The Normal Fluid Service is defined as all other fluid services that are not category D
and category M
High Pressure Piping Service is defined as that in which the pressure is in excess of
that allowed by the ASME B16.5 2500 flange class ratings.
PIPING SYSTEM CORROSION:
General or Uniform Corrosion:

Uniform metal loss. May be combined with erosion if high velocity fluids, or moving
fluids containing abrasives.
Pitting Corrosion:
Localized metal loss randomly located on material surface.
Occurs most often in stagnant areas or areas of low flow velocity.
Galvanic Corrosion:
Occurs when two dissimilar metals contacts each other in corrosive electrolytic
environment.
Concentration Cell Corrosion:
Occurs when different concentration of either a corrosive fluid or dissolved oxygen
contacts areas of same metal.
Crevice Corrosion:
Localized corrosion similar to pitting.
Occurs at places such as gaskets, lap joint, and bolts where crevice exists.
PROCESS PLANT TERMINOLOGY

Process Plant Terms

Refinery

A refinery is a plant that takes crude oil as its feed or charge stock and converts it into
the many petroleum products that people use; Some of these are gasoline, jet-fuel,
kerosene, butane, propane, fuel oil and asphalt.

Hydrocarbon

The hydrocarbon compound contains hydrogen and carbon. Hydrocarbon compounds

are numerous and form the basis for petroleum products. They exist mostly as vapors
and liquids but may also be solid. In general, piping systems refineries and gasoline
plants transport hydrocarbons or utilities.

Gasoline Plant

The gasoline plant takes natural gas (a vapor) as its charge stock and separates the

vapors heavier products out and re-injects the lighter gas (methane) into a pipeline or
perhaps into the gas field it came from. Again gasoline, propane and butane are
extracted as products. But, since a gasoline plant starts with a vapor, the heavier
hydrocarbons do not exist in its charge stock; so heavier products cannot be made.
Asphalt s one of the products that is classified as a heavy hydrocarbon and is not
produced in a gasoline plant.

Chemical Plant

The chemical plant takes semi-refined products from refineries and gasoline plants and
reprocess them, in this case it is also act as a Petrochemical plant. Sometimes blending
in other products and converts them into certain chemicals which may be sold as a
finished consumer product. One such product widely demanded today is plastic.
Chemical plants make many ingredients in modern medicines.

Tank Farm

The tank farm is the area that contains the huge storage tanks of the refinery and
gasoline or chemical plants. The tanks are usually isolated from the main processing
units in case of fire. They may be 200 or more in diameter and will contain the plants
charge stock for several days. The tanks also store the plants products, until the
shipment goes to the consumer.

Flare Systems

The flare system transports vapors (via a piping system) to a flare stack which is very
tall and has a flame burning at the top. This system burns waste gases and also collects
and burns relief valve discharges. At night the flare stack usually stands out -sending
flames high into the air. This is waste gas burning. if it did not burr, it would pollute the
air.

Instruments

Instruments tell the operator what is happening inside a vessel or pipe. There are four
basic groups of instruments, namely temperature, pressure, flow and level.

Fluid

Most students may think of fluid as liquid, but it can also be a vapor. Fluid means

something that will flow-something not solid. Piping directs fluid flow.

Process Plant Utilities:

The utility is a refinerys service portion. While a home has water, gas and electricity, a
refinery or other plant has many more, some of which are below.

Steam

Steam services many plant items. Heat generates steam in fired boilers or heater which
will make many different steam pressures and temperatures. They apply heat and
convert condensate (pure water) to steam (a vapor). The steam then goes to the
different plant units in the piping systems which use the steam.
Many students think they have seen steam, but they havent. They cannot actually see
steam: it is invisible. What they have seen is the condensate condensing out of the
steam. That is where the term condensate comes from.

Condensate

As the energy in steam is used, the steam turns to condensate. Another piping system
collects this condensate, which is returned under a row pressure to a collection point
and is pumped through the boiler tubing and converted to steam again. So the
condensate is in a constant cycle from steam to condensate to steam.

Fuel Oil

Fuel oil is another utility that refineries make and partially consume. It is also sold as a
product to heat homes and fires furnaces in private business.

Instrument Air

A utility that operates the plant instruments is instrument air. A piping system distributes
this air, which has been compressed and dried to remove, all its moisture, as the
moisture would harm the instruments.

Utility Air

Utility air drives air motors and blow air on objects to clean them, such as some barbers
blow cut hair off customers with air hoses.

Cooling Water

Cooling water cool various streams in a plant. The water starts at a cooling tower and is
pumped through a piping system to exchangers, which exchange heat. it comes out
boner-much like water from a hot water heater in a home. This water then returns to the
cooling tower, which cools the water. and then is ready for more circulation into the unit.
Like the steam and condensate system above, this is a constantly c system.

Drains

An underground utility collects drains from funnels or catch basins and, in a separate
piping system, transports them to a disposal point. Since no pressure is in this drain
piping, the pipes must slope to cause flow. This slope is usually 1 foot per 100 feet of
tine or greater.
It can be very difficult to design drain systems. Since they run underground, they must
miss all other underground items. The drainage system must twist and turn to miss all
the process equipment foundations.
Most plants also have more than one drain system. They may have an oily water sewer
a storm water sewer and an acid sewer. The oily water sewer handles the oily drips and
drains. The storm water sewer collects surface runoffs from rains. The acid sewer
collects acid drains and drips. There may be many other types of separate drain
systems.

Questions Answers Related to Codes & standard:

1. Q:-What is the ASME code followed for design of piping systems in Process piping
(Refineries
& Chemical Industries)?
(i) B 31.1
(ii) B 31.3
(iii) B 31.5
(iv) B 31.9

Answer (II)
2. Q:-Which American institute standard does piping engineer refer?
Answer:
A. The American Petroleum institute (API).
B. The American Iron & Steel institute (AISI).
C. The American Society for Testing and materials (ASTM).
D. The American National standard institute (AISI).
E. The American welding society (AWS).
F. The American Water Works Association (AWWA).
G. The American Society for Mechanical Engineers (ASME).
3. Q:-What is the different ASME 31 code for pressure piping?
Answer:
A. ASME B31.1 Power piping.
B. ASME B31.2 Fuel Gas Piping.
C. ASME B31.3 Process piping.
D. ASME B31.4 Pipeline Transportation system for liquid hydrocarbon & other liquid.
E. ASME B31.5 Refrigeration Piping.
F. ASME B31.8 Gas transmission & distribution piping system.
G. ASME B31.9 Building services piping.
H. ASME B31.11 Slurry transportation piping system.
4. Q:-What are the different sections of ASME code? Where these sections are referred?
Answer:
A. ASME section I : Rules for construction of power boiler.
B. ASME Section II : Materials.
Part A Ferrous materials.
Part B Non-Ferrous materials.
Part C Specification for electrodes & filler wire.
Part D Properties.

C. ASME Section IV : Rules for construction of Heating Boiler.

D. ASME Section V : Non- destructive Examination.
E. ASME Section VI : Recommended rules for care & operation of heating boiler.
F. ASME Section VII : Recommended guidelines for care of power boiler.
H. ASME Section VIII : Rules for construction of pressure vessels. (Division I & II)
I. ASME Section IX : Welding & Brazing qualification.
5. Q:-Which American standard is reffered for selection of following piping element?
A. Flanges B. Butt Welded fittings C. Gasket D. Socket & Threaded fittings
E. Valves F. Pipes.
Answer:
A. Flanges :I. ASME B16.1 : Cast iron pipes flanges & flanged fittings.
II. ASME B16.5 : Carbon steel pipes flanges & flanged fittings. (Up to 24)
III. ASME B16.47 : Large Diameter steel flanges. (Above 24)
B. Butt welded fittings :I. ASME B16.9 : Steel butt welding fittings.
II. ASME B16.28 : Butt-welded short radius elbows & returns bends.
C. Gasket :I. ASME B16.20 / API -601: Metallic gaskets for pipe flanges- Spiral wound,
Octagonal ring Joint & Jacketed flanges.
II. ASME B16.21 : Non metallic gasket.
D. Socket & Threaded fittings :
I. ASME B16.11 : Forged steel socket welding & threaded fittings.
E. Valves :I. ASME B16.10 : Face to face & end to end dimension of valves.
II. ASME B16.34 : Flanged & butt-welded ends steel valves (Pressure &Temperature
ratings)
except Ball, Plug & Butter fly Valves.
F. Pipes :I. ASME B36.10 : Welded & Seamless wrought iron pipes.
II. ASME B36.19 : Stainless steel pipes.

Piping Stress Critical Lines: Procedure Defining the Basis for Piping Critical Line List

Below procedure defines the basis to establish piping critical line list from line list, P & I
Diagrams and Piping Specification.
What is Piping Critical Line:
A piping critical line is a line for which a flexibility review is required to be carried out by a
Piping Stress Engineer due to temperature, weight, supporting arrangement, external
loading, lines connection to strain sensitive equipment, vibrations, etc.
Line 50 mm (2) NB and smaller are not considered critical. Therefore, in the following
definitions the word lines means lines 65 mm (2 1/2) NB and above, unless otherwise
stated.
CATEGORY 1: Stress Critical Lines
CATEGORY 2: Equipment Critical Lines
CATEGORY 3: Support Critical Lines
CATEGORY 4: Relief Critical Lines
CATEGORY 5: Category M Fluid Service Lines
CATEGORY 1: Stress Critical Lines
These lines are identified based on the temperature to which line is subjected Normal basis
for temperature is maximum operating / design temperature. In absence of maximum
operating temperature, design temperature shall be considered. Operating temperature
shall be considered only if client ask for.
Following are the criteria to establish critical lines under this category:
1.

Lines 80 mm (3) NB to 125 mm (5) NB at temperature 260 0 C and above or at (-)

200 C and below.
Lines 150 mm (6) NB to 600 mm (24) NB at temperature 1200 C and above or at
(-) 1000 C and below.
Lines 650 mm (26) NB and above at temperature 600 C and above or at (-) 400 C
and below.
Non-ferrous lines operating above 1000 C.
Jacketed Lines All sizes.
Lines for which a probable requirement for an expansion joint (e.g. bellows) has
been pre-determined by process group, and shown on the P&ID, as a result of their
experience on a similar plant for accommodating thermal expansion. Bellows shall not be
used unless approved by stress department.
Any line for which formal calculations are specified, either by client or local
authorities. For example IBR-370 calls for flexibility analysis of IBR controlled piping.
However same temperature criteria shall be followed as highlighted in a, b, c. IBR lines
analysis shall be done using ANSI B31.1 code.
Lines that although not in themselves critical, tie-in to critical lines and have a
significant effect on their flexibility.As a general rule such lines are added to the Critical
Line List at the initial review stage if their nominal size exceeds one-third of that of the
0

2.
3.
4.
5.
6.

7.

8.

critical line (and they exceed 50 mm NB). The remainder shall be established, and added
to the critical line list, during the design stage of the contract.
These lines cease to be considered critical beyond the nearest anchor to the tie-in-point.
1.

Lines having very long straight run and are subjected to harsh solar temperature
(above 500 C).
2.
Any other lines that the Piping Engineer and/or Lead Stress Engineer consider
Critical. Formal computer Analysis shall be carried out for a,b,c,d,e,f,g,h.

CATEGORY 2: Equipment Critical Lines

Lines connected to strain sensitive equipment fall under this category:
1.

Piping connected with centrifugal pumps having size 65 mm (2-1/2) NB and above
with maximum operating temperature of 1200 C and above or minimum operating
temperature of (-) 1000 C and below and 150mm (6) NB and above size with maximum
operating temperature of 600 C and above or minimum operating temperature (-) 400 C
and below.
2.
Rotating machinery, other than centrifugal pumps, e.g. steam turbines, centrifugal
compressors and fans.
3.
Fired heaters and reforming furnaces.
4.
Reciprocating compressor.
5.
Air cooled exchanger.
6.
Vessels fabricated from fragile construction such as graphite, glass etc.
7.
Vessels with linings of a brittle nature, e.g. glass, brick or refractory materials or nonmetallic material shall have piping connection based on vendors recommendation.
8.
Special items of equipment for the manufacturer specifies low nozzle loadings.
These shall be added at a later
9.
Lines connected to any vessel or tanks which may undergo settlement in course of
its working life are also classified critical in this category.
Lines that are classified as critical solely because they are connected to strain sensitive
equipment cease to be considered critical beyond the anchor nearest to the equipment
concerned.
Nozzle loading for such equipment shall be generally as per following codes. However,
Lead Engineer in the beginning of the project should ascertain that the equipment is going
to be bought as per what code ?
Steam Turbine

NEMA SM23

Centrifugal Pumps

API 610

Centrifugal Compressor

API 617

Air Fan Coolers

API 661

Fired heaters

API 560

Formal computer analysis shall be carried out for lines under a, b, c, d, e, h only.

CATEGORY 3: Support Critical Lines

Lines which requires special care and consideration during supporting falls under this
category.
Following are the criteria to establish support critical lines:
1.

Lines to which field welding is prohibited such as stainless steel, alloy steel or thick
carbon steel which require stress relieving after welding.
2.
Lines subject to two-phase flow.
3.
Lines connected to reciprocating compressor.
4.
Non-ferrous lines.
5.
Non Metallic lines shall be supported as per vendors recommendation.
6.
Lines with wall thickness schedule 160 or greater.
7.
Lines 500 mm (20) NB and larger thickness less than Standard Weight wall
thickness.
8.
Lines having coating of lining of a brittle nature e.g. glass, concrete.
Computer analysis need not be carried out for lines under this category.

CATEGORY 4: Relief Critical Lines

Lines upstream and downstream of pressure relieving devices such as relief valve,
blowdown valve etc. fall under this category.
Following are the criteria to establish relief critical lines:
1.

Relief valve / control valve having: Inlet lines 65 mm (2-1.2) NB and above having
set pressure 5.0 kg/cm2 g and above.
2.
Lines downstream of bursting discs having pressure and size criteria as per above
norms of relief valves.
CATEGORY 5: Category M Fluid Service Lines
These are lines 40 mm (1 1/2) NB and larger, at any temperature, with piping spec. Codes
identified in the Contract Piping Specification as ANSI B 31.3 Category M Fluid Service

Minimum Access Provisions-Process Unit

andOffsites Layout
Guide
Minimum

Type of

Access

Item to be Accessed

Platform
- Items Located
Over Platform

Elevated
heat exchangers
Elevated
control valves (all sizes)
Manholes
(higher than 3658 mm (12 ft.) above grade)
Relief
valves (NPS 102 mm (4) inlet and larger on
vertical vessel)
Process
blinds (higher than 3658 mm (12 ft.) above grade)
Furnace
soot blowers
Furnace
burners (when not accessible from grade)
Furnace
observation doors and sample ports (higher than
3658 mm
(12
ft.) above grade)
Elevated cleanouts

Platform
- Items Located
at Edge of Platform

NPS
102 mm (4) and larger gate and globe valves at
vessels
Battery
limit valves in elevated pipe racks
Elevated
motor operated valves
Relief
valves - NPS 77 mm (3) inlet and smaller on
vertical vessels
Relief
valves - All sizes on horizontal vessels
Level
controllers (higher than 3658 mm (12 ft.) above
grade)
Sampling
devices on vessels (higher than 3658 mm (12 ft.)
above
grade)

Permanent Ladder

All
sizes of check valves at vessels
NPS
77 mm (3) and smaller gate and globe valves at
vessels
Level
controllers between 2134-3658 mm (7-12 ft.) above
grade
Level
gauges and valves
Furnace

observation ports between 2134-3658 mm (7-12 ft.)

above grade
Instruments
requiring routine access
Handholes
Elevated electrical
substations and equipment
Mobile Stair

All
servicing between 2134-3658 mm (7-12 ft.) above
grade except as
noted in this Table

No Permanent Access

Block
valves in pipe racks (except at battery limit)
Elevated
orifices or meter runs
Nozzles
on vessels (without process blinds or valves)
Check
valves not at vessels
Temperature
connections in piping
Pressure
connections in piping
Silencers
or exhaust heads
Metal
temperature measuring points on vessels
Instrument
connections on furnaces

CHECK VALVE (NON RETURN VALVE-NRV)

Check valve is used to stop back flow in a piping system. This is also called Non
return Valve (NRV)
Check valves are available in the following designs:
Swing Check Valves
Tilting Disk Check Valves
Wafer Check Valves
Disk Check
Piston Check
Ball Check
Duo-Check Valves

 Non-Slam Check Valves

SWING CHECK VALVE:

Swing Check Valves are available in straight body design and y-pattern design.
The disk is suspended from the body by means of a hinge pin and seals against the
seat which is integral with the body. These valves are typically used in sizes 2
inches and over. Swing check valves can be installed in both horizontal and vertical
position. They are not suitable for pulsating flow.
Closure response of swing check valve is slower compared to lift check valve due to
longer disc travel and inertia of disk.

Industry Codes and Standards

Valve Design:

Pressure Testing:

Face To Face:

BS 1868 / API 6D
BS 6755-I

ANSI B 16.10

Flange Drilling: ANSI B 16.5 / BS 10 Table / DIN / IS / JIS Std.

Butt Weld End: ANSI B 16.25

Face to Face: ANSI B 16.10

Socket Weld End: ANSI B 16.11

Screwed End: ANSI B 1.20.1(BSP/NPT)

TILTING DISK CHECK VALVE

Tilting Disk Check Valves fit between two flanges and provide a compact
installation for large diameter applications. These valves can be installed in
horizontal and vertical lines. They provide a quick closing response and are
particularly suited for pulsating flows with compressible fluids.
Face to Face: ANSI B 16.10
WAFER TYPE CHECK VALVE

Wafer Type Check Valve has short face-to-face dimensions and low weight allows a simple
space saving installation between the companion flanges. The valves are suitable to mounting
between weld neck or slip on type companion flanges of different standards.
They are specially developed for applications where a low-pressure loss is essential. Opening
and closing of the valve will take place at an extremely low-pressure difference over the valve
disc. The eccentric disc shaft combination with the disc seat guarantees a positive shut off
returning media. Wafer check valves are becoming the preferred type of check valve for most
applications, due to their compact design and relatively low cost.
Face to Face: ANSI B 16.10
DISC CHECK VALVE

The Single Disc Check Valve (Wafer Type Disc Check Valve) consists of four main components:
the body, a disc, a star guide and a spring. The Disc check valves are opened by the pressure
of fluid and closed through compression spring as soon as flow stops thus preventing reverse
flow.
The design of Wafer Design, Sandwich Type Single Disc Spring Loaded Check Valves allows
them to be installed between any flanges of different standard and in any position; including
vertical pipelines where the fluid flows downwards.
PISTON CHECK VALVE

Piston Check valves are generally used to protect pumps or similar equipment, allowing the flow
only in one direction and preventing flow reversal due to back pressure. The piston check valves
are designed with globe valve bodies, producing an increased drop pressure in the pipeline.
This design provides a tight seal as well as a fast reaction to the closure impulse. Metal seated
check valves may not provide drop tight sealing when used in gas system or fluid system with
low back flow pressure or fluids containing particles.
Face to Face: ANSI B 16.10
BALL CHECK VALVE

The ball check valve is one of the few check valves that works well in both water and
wastewater applications. Ball check valves are simple in operation and commonly used on small
pumps and in low head systems. Consider adding an optional roll-bar to the piping system for
safety; ball check valves have the highest tendency to slam due to the ball's high inertia long
stroke. When ball check valves encounter high pressures and dynamics, severe slamming may
result.
Face to Face: ANSI B 16.10
DUAL PLATE WAFER CHECK VALVE

The Dual Plate, Wafer Check Valve employs two-spring-loaded plates hinged on a central hinge
pin. When the flow decreases, the plates close by the action of torsion spring before flow
reversal takes place. All features put together make the Dual Plate Check Valve as the most
efficient & versatile design. It is also referred to asSILENT CHECK VALVE. It is much easier to
install between standard gaskets and line flanges, and therefore is more cost effective to install
and to maintain. Its design complies with API 594 and API 6D, testing with API 598. It is also
called as Butterfly Check Valve.
NON-SLAM CHECK VALVE
It is essential to see the closing characteristic of the valve with the dynamics of the pumping system.

The swing check valve closes abruptly because of gravity, and causes pressure surge
resulting in shock waves. These high pressure waves causes sever stress on the piping
system. This problem can be minimized by installing a Non-Slam type check valve.
Non-Slam check valve do not rely on gravity. As the upstream velocity of the fluid slows
the spring assist on the valve start to close the disc. By the time the upstream velocity
comes to 0, the disc is completely closed. With the reverse flow eliminated, the force
necessary to produce water hammer on either side of the valve are substantially
reduced.

SPACING REQUIRED BETWEEN UNITS & EQUIPMENTS

Consider the following when determining the layout and the separation required:
High hazard operations
Grouped operations
Critical operations
Number of personnel at risk
Concentration of property and business interruption values
Equipment replacement and installation time
Interdependency of facilities
Critical customer or supplier relationships
Market share concerns
Fire and explosion exposures
Corrosive or incompatible materials exposures
Vapor cloud explosions

 Sources of ignition
Maintenance and emergency accessibility
Drainage and grade sloping
Prevailing wind conditions
Natural hazards and climate
Future expansions
External exposures
Review the various hazards and loss potentials to establish the degree of separation
required
between units and equipment. Consult Tables 1, 2 and 3 in this guide for minimum
spacing guidelines
based on fire and vessel explosion hazards. Increase spacing where appropriate.

Inter-Unit Spacing Recommendations For Oil And Chemical Plants

Intra-Unit Spacing Recommendations For Oil And Chemical Plants

Storage Tank Spacing Recommendations For Oil And Chemical Plants

Calculate the vapor cloud explosion overpressure circles. Where applicable, base the minimum spacing
required between units upon the following criteria:
Do not locate critical equipment of adjacent units within the 3 psi (0.21 bar) overpressure circle.
Design equipment or structures of adjacent units within the 1 psi (0.07 bar) overpressure circle to
withstand the calculated vapor cloud overpressure.
If the minimum spacing requirements based on a vapor cloud explosion differ from the minimum
spacing required by the spacing tables, use the greater of the two.
REFERENCES
1. Hazard Survey of the Chemical and Allied Industries, Technical Survey No. 3, 1968, American Insurance
Association, New York, NY.
An Engineers Guide To Process-Plant Layout, F.F. House, July 28, 1969, Chemical Engineering, McGraw Hill,
New York,NY.

Process Plant Layout, by J.C. Mecklenburgh, John Wiley & Sons, New York, NY.
Loss Prevention In The Process Industries, F. P. Lees, Volumes 1 & 2, Butterworths, Boston, MA.
Loss Prevention Fundamentals For The Process Industry, O. M. Slye Jr., Loss Prevention Symposium, March
1988,
American Institute of Chemical Engineers, New York, NY.
NFPA 30-2000, Flammable And Combustible Liquids Code, National Fire Protection Association, Quincy, MA.
NFPA 58-2001, Liquefied Natural Gas, National Fire Protection Association, Quincy, MA.
2. OVERVIEW, GE Global Asset Protection Services.
3. NFPA 496-1998, Purged And Pressurized Enclosures For Electrical Equipment In Hazardous (Classified)
Locations,
National Fire Protection Association, Quincy, MA.
4. API RP 521-1982: Guide For Pressure-Relieving And Depressurizing Systems, American Petroleum Institute,
Washington, DC.
5. Center for Chemical Process Safety, American Institute of Chemical Engineers, New York, NY.
6. Fire & Explosion Index, Hazard Classification Guide, Dow Chemical Company, Sixth edition, available from
the American Institute of Chemical Engineers, New York, NY.
7. API RP 752-1995: Management of Hazards Associated with Location of Process Plant Buildings, American
Petroleum Institute, Washington, DC.

PIPING JOINTS

Joint design and selection can have a major impact on the initial installed cost, the
long-range operating and maintenance cost, and the performance of the piping
system. Factors that must be considered in the joint selection phase of the project
design include material cost, installation labor cost, degree of leakage integrity
required, periodic maintenance requirements, and specific performance requirements.
In addition, since codes do impose some limitations on joint applications,
joint selection must meet the applicable code requirements. In the paragraphs that
follow, the above-mentioned considerations will be briefly discussed for a number
of common pipe joint configurations.

Butt-welded Joints

Butt Welded Joint

Butt-welding is the most common method of joining piping used in large commercial,
institutional, and industrial piping systems. Material costs are low, but labor costs
are moderate to high due to the need for specialized welders and fitters. Long term
leakage integrity is extremely good, as is structural and mechanical strength.
The interior surface of a butt-welded piping system is smooth and continuous which
results in low pressure drop. The system can be assembled with internal weld
backing rings to reduce fit-up and welding costs, but backing rings create internal
crevices, which can trap corrosion products. In the case of nuclear piping systems,
these crevices can cause a concentration of radioactive solids at the joints, which
can lead to operating and maintenance problems. Backing rings can also lead to
stress concentration effects, which may promote fatigue cracks under vibratory or
other cyclic loading conditions. Butt-welded joints made up without backing rings
are more expensive to construct, but the absence of interior crevices will effectively
minimize crud buildup and will also enhance the piping systems resistance to
fatigue failures. Most butt-welded piping installations are limited to NPS 21 (DN
65) or larger. There is no practical upper size limit in butt-welded construction.
Butt-welding fittings and pipe system accessories are available down to NPS 1 (DN
15). However, economic penalties associated with pipe end preparation and fit-up,
and special weld procedure qualifications normally preclude the use of butt-welded

construction in sizes NPS 2 (DN 50) and under, except for those special cases where
interior surface smoothness and the elimination of internal crevices are of paramount
importance. Smooth external surfaces give butt-welded construction high aesthetic
appeal.

Socket-welded Joints

Socket Welded Joint

Socket-welded construction is a good choice wherever the benefits of high leakage

integrity and great structural strength are important design considerations. Construction
costs are somewhat lower than with butt-welded joints due to the lack of
exacting fit-up requirements and elimination of special machining for butt weld end
preparation. The internal crevices left in socket-welded systems make them less
suitable for corrosive or radioactive applications where solids buildup at the joints
may cause operating or maintenance problems. Fatigue resistance is lower than
that in butt-welded construction due to the use of fillet welds and abrupt fitting
geometry, but it is still better than that of most mechanical joining methods. Aesthetic
appeal is good.

Brazed and Soldered Joints

Soldered Piping Joint

Brazing and soldering are most often used to join copper and copper-alloy piping
systems, although brazing of steel and aluminum pipe and tubing is possible. Brazing
and soldering both involve the addition of molten filler metal to a close-fitting
annular joint. The molten metal is drawn into the joint by capillary action and
solidifies to fuse the parts together. The parent metal does not melt in brazed or
soldered construction. The advantages of these joining methods are high leakage
integrity and installation productivity. Brazed and soldered joints can be made up
with a minimum of internal deposits. Pipe and tubing used for brazed and soldered
construction can be purchased with the interior surfaces cleaned and the ends
capped, making this joining method popular for medical gases and high-purity
pneumatic control installations.
Soldered joints are normally limited to near-ambient temperature systems and
domestic water supply. Brazed joints can be used at moderately elevated
temperatures.
Most brazed and soldered installations are constructed using light-wall tubing;
consequently the mechanical strength of these systems is low.

Threaded or Screwed Joints

Threaded or screwed piping is commonly used in low-cost, noncritical applications

such as domestic water, fire protection, and industrial cooling water systems.
Installation
productivity is moderately high, and specialized installation skill requirements

are not extensive. Leakage integrity is good for low-pressure, low-temperature

installations where vibration is not encountered. Rapid temperature changes may
lead to leaks due to differential thermal expansion between the pipe and fittings.
Vibration can result in fatigue failures of screwed pipe joints due to the high stress
intensification effects caused by the sharp notches at the base of the threads. Screwed
fittings are normally made of cast gray or malleable iron, cast brass or bronze, or
forged alloy and carbon steel. Screwed construction is commonly used with galvanized
pipe and fittings for domestic water and drainage applications. While certain
types of screwed fittings are available in up to NPS 12 (DN300), economic
considerations
normally limit industrial applications to NPS 3 (DN 80). Screwed piping
systems are useful where disassembly and reassembly are necessary to accommodate
maintenance needs or process changes. Threaded or screwed joints must be used
within the limitations imposed by the rules and requirements of the applicable code.

Grooved Joints

The main advantages of the grooved joints are their ease of assembly, which results
in low labor cost, and generally good leakage integrity. They allow a moderate
amount of axial movement due to thermal expansion, and they can accommodate
some axial misalignment. The grooved construction prevents the joint from separating
under pressure. Among their disadvantages are the use of an elastomer seal,
which limits their high-temperature service, and their lack of resistance to torsional
loading. While typical applications involve machining the groove in standard wall
pipe, light wall pipe with rolled-in grooves may also be used. Grooved joints are
used extensively for fire protection, ambient temperature service water, and low
pressure
drainage applications such as floor and equipment drain systems and roof
drainage conductors. They are a good choice where the piping system must be
disassembled and reassembled frequently for maintenance or process changes.

Flanged Joints

Flanged connections are used extensively in modern piping systems due to their
ease of assembly and disassembly; however, they are costly. Contributing to the
high cost are the material costs of the flanges themselves and the labor costs for
attaching the flanges to the pipe and then bolting the flanges to each other. Flanges
are normally attached to the pipe by threading or welding, although in some special
cases a flange-type joint known as a lap joint may be made by forging and machining
the pipe end. Flanged joints are prone to leakage in services that experience rapid
temperature fluctuations. These fluctuations cause high-temperature differentials

between the flange body and bolting, which eventually causes the bolt stress to
relax, allowing the joint to open up. Leakage is also a concern in high-temperature
installations where bolt stress relaxation due to creep is experienced. Periodic
retorquing of the bolted connections to reestablish the required seating pressure
on the gasket face can minimize these problems. Creep-damaged bolts in
hightemperature
installations must be periodically replaced to reestablish the required
gasket seating pressure. Flanged joints are commonly used to join dissimilar materials,
e.g., steel pipe to cast-iron valves and in systems that require frequent maintenance
disassembly and reassembly. Flanged construction is also used extensively
in lined piping systems.

Compression Joints

Compression sleeve-type joints are used to join plain end pipe without special end
preparations. These joints require very little installation labor and as such result
in an economical overall installation. Advantages include the ability to absorb a
limited amount of thermal expansion and angular misalignment and the ability to
join dissimilar piping materials, even if their outside diameters are slightly different.
Disadvantages include the use of rubber or other elastomer seals, which limits their
high-temperature application, and the need for a separate external thrust-resisting
system at all turns and dead ends to keep the line from separating under pressure.
Compression joints are frequently used for temporary piping systems or systems
that must be dismantled frequently for maintenance. When equipped with the

proper gaskets and seals, they may be used for piping systems containing air, other
gases, water, and oil; in both aboveground and underground service. Small-diameter
compression fittings with all-metal sleeves may be used at elevated temperatures
and pressures, when permitted by the rules and requirements of the applicable
code. They are common in instrument and control tubing installations and other
applications where high seal integrity and easy assembly and disassembly are
desirable attributes.
Minimum Distance between welds

TYPE OF WELD

Minimum Distance

Branch
connections (with or without reinforcing
pads or olets)

The
larger of

and Circumferential welds

50mm (or) 4xT

Pipe Size

All Sizes

The larger of
B

Two
circumferential welds

Two
adjacent fillet welds

50mm (or) 4xT

<=6" Pipes

100mm (or) 4xT

8" to 12" Pipes

150mm (or) 4xT

14" and above

Smaller of
40mm (or) 3xT

All Sizes

Tag: Weld distance, minimum weld distance, weld gap between fittings, minimum weld
gap, pipe welding minimum gap, fittings weld gap, circumferential weld gap, longitudinal
weld gap, weld gap thumb rule.