Piping Fundamentals

Piping System - What is that?

Concept Layout Development
Piping Components & their access requirement.
Straight length requirements.
Orientation of various tapings, components, etc.
Piping Drains & Vents
Insulation.
Material & Sizing
Critical piping system consideration.
Pipe Stress Analysis.
Pipe Supports
 Piping Fundamentals

Let us first Discuss about WHAT IS PIPE!

It is a Tubular item made of metal, plastic, glass etc.
meant for conveying Liquid, Gas or any thing that
flows.
It is a very important component for any industrial
plant. And it’s engineering plays a major part in overall
engineering of a Plant.
In next few pages we shall try to familiarize about pipe
and it’s components.
In any plant various fluids flow through pipes
from one end to other.
Now let us start with a plant where we see three
tanks.
Tank-1, Tank-2 and Tank-3
We have to transfer the content of Tank no. 1 to
the other two tanks.
We will need to connect pipes to transfer the
fluids from Tank-1 to Tank-2 and Tank-3
LET US BRING THE PIPES.
 We have just brought the pipes, now we
To solve these need to solve some more problems.
problems we need the
Pipes are all straight pieces.
pipe components, are
s
which are called p ipe s!
ome size
PIPE FITTINGS e n s rent
Ev diffe
of

We need some
branch
connections

We need some bend

connections
 These are the pipe fittings,
There are various types of fittings for various
purposes, some common types are -
Elbows/Bends, Tees/Branches,
Reducers/Expanders, Couplings, Olets, etc.

Anyway, the pipes and

fittings are in place, but the
ends are yet to be joined with
the Tank nozzles.

We now have to complete the

end connections.
These, in piping term, we call

TERMINAL CONNECTIONS.
 So far this is a nice arrangement.
But there is no control over the flow from Tank-1
to other tanks.
We need some arrangement to stop the
flow if needed

These are flanged joints

This is a welded joint

To control the flow in a pipe line we

need to fit a special component.

That is called - VALVE

There are many types of valves, categorized
based on their construction and functionality,
Those are - Gate, Globe, Check, Butterfly, etc.

Other than valves another important

line component of pipe line is a filter,
which cleans out debries from the
flowing fluid. This is called a
STRAINER
 Here we see a more or less functional piping
system, with valves and strainer installed.
Let us now investigate some aspects of pipe
flexibility.

If this tank nozzle

expands, when
the tank is hot.

In such case we need to fit a flexible

pipe component at that location,
which is called an EXPANSION
JOINT
 When some fluid is flowing in a pipe we may
also like know the parameters like, pressure,
temperature, flow rate etc. of the fluid.

To know these information we need

to install INSTRUMENTS in the
pipeline.
 There are various types instruments to measure various
Next we shall look parameters. Also there are specific criteria for installation
into how to of various pipe line instruments.
SUPPORT the
pipe/and it’s
components.
 Here are some of the pipe supporting arrangements.
There can be numerous variants. All depend on
piping designer’s preference and judgement.

Let us see some OTHER types of supports

 Pipe Wall Thickness Designations
• The Standard, Extra Strong (XS) and Double Extra
Strong(XXS) have been commercially used designation
for many years. All large size (NPS 8”to 36”) of XS have
½” wall thickness.
• The Schedule numbers were added as a convenient
designation. 5,10,20,30,40,80,100,120, 140 &160
Pipe Schedule No =1000 x Internal Pressure
Maximum Allowable Stress
 PIPE SCHEDULES METRIC
PIPE
PIPESCHEDULES
SCHEDULESIMPERIAL
METRIC

  DIMENSIONS OF SEAM LESS & WELDED STEEL PIPE ACCORDANCE WITH  

ANSI B36.10 & B36.19
NOM. OUT NOMINAL WALL THICKNESS
SIDE Sche. Sche. Sche. Sche. Sche. Standa Sche. Sche. Extra Sche. Sche. Sche. Sche. Sche. XX
PIPE DIAM.
SIZE 5*S 10*S 10 20 30 rd 40 60 Strong 80 100 120 140 160 Strong
20 mm 26.670 1.651 2.108 ----- ----- ----- 2.870 2.870 ----- 3.912 3.912 ----- ----- ----- 5.563 7.823
25 mm 33.401 1.651 2.769 ----- ----- ----- 3.378 3.378 ----- 4.547 4.547 ----- ----- ----- 6.350 9.093
32 mm 42.164 1.651 2.769 ----- ----- ----- 3.558 3.558 ----- 4.851 4.851 ----- ----- ----- 6.350 9.703
40 mm 48.260 1.651 2.769 ----- ----- ----- 3.683 3.683 ----- 5.080 5.080 ----- ----- ----- 7.137 10.160
50 mm 60.325 1.651 2.769 ----- ----- ----- 3.912 3.912 ----- 5.537 5.537 ----- ----- ----- 8.738 11.074
65 mm 73.025 2.108 3.048 ----- ----- ----- 5.158 5.158 ----- 7.010 7.010 ----- ----- ----- 9.525 14.021
80 mm 88.900 2.108 3.048 ----- ----- ----- 5.486 5.486 ----- 7.620 7.620 ----- ----- ----- 11.125 15.240
90 mm101.600 2.108 3.048 ----- ----- ----- 5.740 5.740 ----- 8.077 8.077 ----- ----- ----- ------ ------
100 114.300 2.108 3.048 ----- ----- ----- 6.020 6.020 ----- 8.560 8.560 ----- 11.125 ----- 13.487 17.12
mm
125 141.300 2.769 3.404 ----- ----- ----- 6.553 6.553 ----- 9.525 9.525 ----- 12.700 ----- 15.875 19.050
mm
150 168.275 2.769 3.404 ----- ----- ----- 7.112 7.112 ----- 10.973 10.973 ----- 14.275 ----- 18.263 21.946
mm
200 219.075 2.769 3.759   6.350 7.036 8.179 8.179 10312 12.700 12.700 15.088 18.263 20.625 23.012 22.225
mm
250 273.050 3.404 4.191 ----- 6.350 7.798 9.271 9.271 12.700 12.700 15.088 18.263 21.438 25.400 28.575 25.400
mm
300 323.850 3.962 4.572 ----- 6.350 8.382 9.525 10.312 14.275 12.700 17.475 21.438 25.400 28.575 33.325 25.400
mm
350 355.600 3.962 4.775 6.350 7.925 9.525 9.525 11.125 15.088 12.700 19.050 23.925 27.788 31.750 35.712 -----
mm
400 406.400 4.191 4.775 6.350 7.925 9.525 9.525 12.700 16.662 12.700 21.438 26.187 30.963 36.525 40.488 -----
mm
450 457.200 4.191 4.775 6.350 7.925 11.125 9.525 14.275 19.050 12.700 23.825 29.362 34.925 39.675 45.237 -----
mm
500 508.000 4.775 5.537 6.350 9.525 12.700 9.525 15.088 20.625 12.700 26.187 32.537 38.100 44.450 50.013 -----
mm
550 558.000 5.537 5.537 6.350 9.525 12.700 9.525 ----- 22.225 12.700 28.575 34.925 41.275 47.625 53.975 -----
mm
600 609.600 5.537 6.350 6.350 9.525 14.275 9.525 17.475 24.613 12.700 30.963 38.887 46.025 52.375 59.538 -----
mm
650 660.400 ----- ----- 7.925 12.700 ----- 9.525 ----- ----- 12.700 ----- ----- ----- ----- ----- -----
mm
 PIPE SCHEDULES IMPERIAL
  DIMENSIONS OF SEAM LESS & WELDED STEEL PIPE ACCORDANCE WITH  

ANSI B36.10 & B36.19

NOM. OUT SIDE NOMINAL WALL THICKNESS

PIPE Diameter Sche. Sche. Sche. Sche. Standar Sche. Sche. Extra Sche. Sche. Sche. Sche. Sche. XX
SIZE d
5 10 20 30 40 60 Strong 80 100 120 140 160 Strong
3/4
1.050 0.065 0.083 ----- ----- .0113 .0113 ----- 0.154 0.154 ----- ----- ----- 0.219 0.308
1 1.315 0.065 0.109 ----- ----- .0133 .0133 ----- 0.179 0.179 ----- ----- ----- 0.250 0.358
1 1/4
1.660 0.065 0.109 ----- ----- 0.140 0.140 ----- 0.191 0.191 ----- ----- ----- 0.250 0.382
1 1/2
1.900 0.065 0.109 ----- ----- 0.145 0.145 ----- 0.200 0.200 ----- ----- ----- 0.281 0.400
2 2.375 0.065 0.109 ----- ----- 0.154 0.154 ----- 0.218 0.218 ----- ----- ----- 0.343 0.436
2 1/2
2.875 0.083 0.120 ----- ----- 0.203 0.203 ----- 0.276 0.276 ----- ----- ----- 0.375 0.552
3 3.500 0.083 0.120 ----- ----- 0.216 0.216 ----- 0.300 0.300 ----- ----- ----- 0.438 0.600
3 1/2 4.000 0.083 0.120 ----- ----- 0.226 0.226 ----- 0.318 0.318 ----- ----- ----- ------ ------
4 4.500 0.083 0.120 ----- ----- 0.237 0.237 ----- 0.337 0.337 ----- 0.438 ----- 0.531 0.674
5 5.563 0.109 0.134 ----- ----- 0.258 0.258 ----- 0.375 0.375 ----- 0.500 ----- 0.625 0.750
6 6.625 0.109 0.134 ----- ----- 0.280 0.280 ----- 0.432 0.432 ----- 0.562 ----- 0.718 0.864
8 8.625 0.109 0.148 0.250 0.277 0.322 0.322 0.406 0.500 0.500 0.593 0.718 0.812 0.906 0.875
10 10.75 0.134 0.165 0.250 0.307 0.365 0.365 0.500 0.500 0.593 0.718 0.843 1.000 1.125 -----
12 12.75 0.156 0.180 0.250 0.330 0.375 0.406 0.562 0.500 0.750 0.843 1.000 1.125 1.312 -----
14 OD 14 ----- 0.250 0.312 0.375 0.375 0.438 0.593 0.500 0.750 0.937 1.093 1.250 1.406 -----
16 OD 16 ----- 0.250 0.312 0.375 0.375 0.500 0.656 0.500 0.843 1.031 1.218 1.438 1.593 -----
18 OD 18 ----- 0.250 0.312 0.438 0.375 0.562 0.750 0.500 0.937 1.156 1.375 1.562 1.781 -----
20 OD 20 ----- 0.250 0.375 0.500 0.375 0.593 0.812 0.500 1.031 1.281 1.500 1.750 1.968 -----
22 OD 22 ----- 0.250 ----- ---- 0.375 ----- ----- 0.500 ----- ----- ----- ----- ----- -----
24 OD 24 ----- 0.250 0.375 0.562 0.375 0.687 0.968 0.500 1.218 1.531 1.812 2.062 2.343 -----
26 OD 26 ----- ----- ----- ----- 0.375 ----- ----- 0.500 ----- ----- ----- ----- ----- -----
30 OD 30 ----- 0.312 0.500 0.625 0.375 ----- ----- 0.500 ----- ----- ----- ----- ----- -----
34 OD 34 ----- ----- ----- ----- 0.375 ----- ----- 0.500 ----- ----- ----- ----- ----- -----
36 OD 36 ----- ----- ----- ----- 0.375 ----- 19.050 0.500 ----- ----- ----- ----- ----- -----
Note:- All dimensions are given in decimals of and inch of the nominal pipe sizes. Thickness may vary        
due to mil tolerance.
Prepred By:- Syed Aftab Ahmed                        
 TYPES OF FLANGES

Blind Slip -On Lap joint Stub End

Threaded Weld Neck Socket weld

 TYPES OF FLANGES

Blind or Blank Flange:

The blind flange is a flange without an opening or bore. It is used to close off the ends of a
piping system and/or a pressure vessel opening. It also permits easy access to the interior
of a sealed pipe line or vessel if it need be reopened.

Slip-On Flanges:
The Slip-on flange has a low hub because the pipe slips into the flange prior to welding.
It is welded both inside and out to provide sufficient strength and prevent leakage.
Slip-on flanges are all bored slightly larger than the O.D. of the matching pipe. They are
preferred over welding neck flanges by many users due to their lower initial cost or
when space is a major consideration.
 TYPES OF FLANGES

Lap Joint Flanges with Stub end:

The lap joint flange or is practically identical to a slip-on flange except it has a larger radius at the intersection of
the bore and flange face. The bore diameter at the flange face is identical to that of the stub end to which it will
ultimately be mated. During construction, the flange is slipped over the pipe and a stub end is welded onto the end
of the pipe. The flange is then slipped over the stub end and bolted up. This design can be used to reduce the
amount of expensive material required to make a flange. An inexpensive steel ring is used in tandem with a stub
end that is made of a more exotic metal. The exotic metal will be at the fluid contact surfaces; while the outer steel
ring that is not in contact with the fluid contains the bolt holes.

Socket Welding Flanges

The socket welding flange is similar to a slip-on flange except it has a bore and a counter bore dimension.
The counter bore is slightly larger than the O.D. of the matching pipe, allowing the pipe to be inserted
into the flange similar to a slip-on flange. The diameter of the smaller bore is the same as the I.D. of the
matching pipe. During assembly, the pipe is inserted in the larger diameter bore and is welded in place.
This type of flange is often used with high pressure systems that use smaller diameter pipes (< 4 inches).
 TYPES OF FLANGES

Threaded (Screwed) Flanges:

The threaded flange is similar to the slip-on flange, but the bore is threaded, that it can be
assembled without welding, explaining its use in low pressure services at ambient temper-
atures, and in highly explosive areas where welding creates a hazard.

Welding Neck Flanges:

The Welding neck flange is normally referred to as the "high hub" flange. It is designed
to transfer stresses to the pipe, thereby reducing high stress concentrations at the base of
the flange. These flanges are also used when a butt weld is required. This means the end
of the beveled flange butts up against a piece of pipe that also has a beveled edge. This
joint provides a sound weld with no overlapping of parts. The welding neck flange is the
best designed butt-welded flange currently available. Due to its design, It is also one of
the most expensive flanges.
Flanges / Valves Classification ASME/ANSI B16.5
 TYPE OF GASKETS
• Sheet materials are used in low to medium pressure
services. With careful selection these gaskets are not only
suitable for general service but also for extreme chemical
services and temperatures.
Types: Non-asbestos Fiber Sheets, PTFE, PTFE Graphite
•Coated.
These are composite gaskets consisting of both metallic
and non-metallic materials. The metal provides the strength
and the resilience of the gasket and the non-metallic
component provides the conformable sealing material. These
gaskets are (Spiral Wound) suitable for low, high pressure
and temperature applications.
• These gaskets can be fabricated in a variety of shapes and
sizes recommended for use in high pressure/temperature
applications. Except for weld ring gaskets, high loads are
required to seat metallic gaskets, as they rely on the
deformation or coining of the material into the flange
surfaces. Types: Ring Type Joints, Weld Rings, Solid Metal
•Gaskets
Insulation Gasket kits are designed to the effects of
.
corrosion often found in flanged pipe systems. Galvanic
corrosion between dissimilar metal flanges (flow of currents)
, flange insulation associated with cathodic protection of
 Pipe & Pipe Fitting Material
  Specification       Minimum Nominal    
Sr No. & P UNS Nos Material Specfied Tensile Composition Product Form Used Location
  Garde No Nos   Strenght(KSI) (%)    
1 SA-106 Gr B 1 K03006 Carbon Steel 60 C-Si Seamless/ welded pipe Process gas line, vent line,
utility area piping.

2 SA-105 1 K03504 Carbon Steel 70 C-Si Pipe fitting / valve & Process gas line, vent line,
flanges utility area piping.

3 SA-516 Gr70 1 K02700 Carbon Steel 70 C-Mn-Si Plate Vessels ,Tanks , Heat
exchangers, Blinds & Spades.

4 SA-333 Gr 6 1 K03006 Carbon Steel 60 C-Mn-Si Seamless/ welded pipe Low Temperature Process gas
line, vent line, utility area
piping.
5 SA-350 Gr LF2 1 K03011 Carbon Steel 60 C-Mn-Si Pipe fitting / valve & Low Temperature Process gas
flanges line, vent line, utility area
piping.
6 SA-790 Gr 10H S31803 Duplex S.S 90 22Cr-5Ni-3Mo-N Seamless/ welded pipe Corrosion/ Erosion Resistance
S31803 pipelines.

7 SA 182 Gr F51 10H S31803 Duplex S.S 90 22Cr-5Ni-3Mo-N Valves, flanges& pipe Corrosion/Erosion Resistance
fitting. pipe fittings

8 SA 182 Gr F316 8 S31600 Stainless 75 16Cr-12Ni-2Mo Valves, flanges& pipe Methanol injection system/
Steel fitting. Corrosive system.

9 SA 312 Gr 8 S31600 Stainless 75 16Cr-12Ni-2Mo Seamless / welded pipe Methanol injection system/
TP316 Steel & Corrosive system.
Vessel.
10 B-466 34 C70600 Cupronickel 38 90Cu-10Ni Pipe lines Produced water/Freshwater

11 B-151 34 C70600 Cupronickel 38 90Cu-10Ni Valves, flanges & pipe Produced water /Freshwater
fitting.
  Prepared by:- Syed Aftab Ahmed
Here we carryout pipe routing / layout in Virtual 3D environment.

While development of piping layout we have to consider the following

➠ Piping from source to destination should be as short as possible with minimum
change in direction.
➠ Should not hinder any normal passage way. Also should not encroach any
equipment maintenance space.

Not Preferable

Preferable
While carrying out pipe routing we also need to consider the following
➠ Valves, strainers, instruments on the pipe should be easily accessible.
➠ If needed separate ACCESS PLATFORMS to be provided to facilitate these.
➠ Desired location and orientation of valves / instruments and other pipe
components are to be checked and maintained, like some valves or strainers
can only be installed in horizontal position.
➠ Specific requirements for instrument installation to be checked, like
temperature gauge can not be installed in pipe which is less than 4 inch in size.
➠ Specific requirements of STRAIGHT LENGTH of pipe for some components to
be maintained, like for flow orifice we need to provide 15 times diameter
straight pipe length at upstream of orifice and 5 times diameter straight at down
stream of orifice.

Example of Straight length requirement for Flow Orifice

⑥ For Pipeline which shall carry liquid, we have to make sure that all air is
allowed to vent out of the line when the line is filled with liquid.
⑥ To achieve this a VENT connection with Valve is provided at the top most point
of the pipeline.

⑥ Also arrangement is kept in the

pipeline so that liquid can be
drained out if required.
⑥ To achieve this a DRAIN
connection with Valve is provided
at the lowest point of the pipeline
⑥ Pipes are also slopped towards low
points.

Let us look
into typical
Vent and
Drain
arrangement
in a pipeline
INSULATION - When hot fluid flows through pipe then generally pipe is
insulated.
There are two primary reasons for insulating the pipe carrying hot fluid.
 Containing the heat inside the pipe. Insulation preserves the heat of the fluid. It
is called Hot Insulation
 Personnel safety, so that people do not get burn injury by touching hot surface
of pipe.
Cold pipesItare
is called Personnel Protection Insulation
also insulated
 Cold or chilled fluid carrying pipes are insulated to prevent heating of cold fluid
from outside. It is called Cold Insulation.
 Some times cold pipes are insulated to prevent condensation of atmospheric
water vapor on pipe surface. It is called Anti-Sweat Insulation.
Other types of Insulation
 When gas flows through pipes at high velocity, it creates noise. In such cases
pipes are insulated to reduce noise. It is called Acoustic Insulation.
 Some times pipe and it’s content are heated from outside, by heat tracing
element. In that case pipe along with heat tracing element are insulated to
conserve the heat of the tracer. It is called Heat Tracing Insulation.
INSULATION MATERIAL - The insulating material should be bad conductor of heat.
There are two basic categories
1) Fibrous Material, which has large voids full of air between fibers - Cork, Glass Wool,
Mineral Wool, Organic Fibers. Note stagnant air is a bad conductor.
2) Cellular Material, which has closed void cells full or air - Calcium Silicate, Cellular
Glass (Foam Glass), Polyurethane Foam (PUF), Polystyrene (Thermocol), etc.
Some times Cast material like Cement Plaster or Plaster of Paris are also used.
INSULATION CLADDING - Insulation materials are generally soft or fragile. So the
outer surface of insulation are protected with Aluminum sheet or GI sheet
cladding.

Have a look at how 
pipes are insulated, 
and general 
components of 
insulation
 Pipe Material Selection - to select appropriate pipe material based on flowing fluid property.

Find out type  Find out   Check Pipe  Select suitable  Check Mat.  YES Pipe 

of Fluid  Fluid Temp.  life  Material per  Listed in   Material 
flowing  & Pressure  Expectancy practice (Note-1) Design Code OK

NO
Note-1 : Material is selected per past experience with cost in
mind and per material listed in design code. If material is See Note-
not listed in code we may select next suitable material
listed.
1

Pipe Sizing Calculation - to select required pipe diameter based on velocity and pressure drop.

Find out  Check Velocity  Calc. flow area  Calc. Press.  Check Press.  YES Pipe 

Flow volume  Allowable per  required and  Drop for that  Drop meets  Size 
per second second Pipe size Pipe size Press. Budget OK

NO
Increase 
Pipe Size

Pipe Thickness Selection - to select appropriate pipe thickness based on flowing fluid property.

Select Mat.  Find out   Decide  on  Calc. Pipe 

& Diameter  Fluid Temp.  Corrosion  Thickness asper 
as above  & Pressure  allowance Code
 Types of Pipe Supports
In the beginning of this discussion we 
Constant Load Spring
talked about various types of pipe 
supports. Here is some elaboration
⑥ There are three general types
⑥ Rigid type (no flexibility in the
direction of restrain) Variable Spring

⑥ Spring type (Allows pipe

movement in direction of loading)
⑥ Dynamic Support (Degree of
restrain depends on acceleration
of load)

Rigid Support
Rigid Hanger
⑥ There are two types of spring
support
⑥ Variable load type, here support
load changes as the pipe moves.
⑥ Constant load support, the load
Dynamic Support,
remains constant within some Snubber
range of movement.
Rigid Support
 Some Special Considerations for Piping
When pipes are routed UNDER GROUND (Buried) following points to be kept in mind:
⑥ Minimum pipe size to be routed under ground shall be not less than1 inch.
⑥ Avoid flange joint in under ground piping.
⑥ Keep in mind if pipe leaks under ground, it will be difficult to detect, so avoid U/G routing of
pipe carrying hazardous fluid.
⑥ Pipe to be laid below Frost Zone at areas where ambient temperature goes below freezing.
⑥ U/G, Buried piping should be properly protected from corrosion.
⑥ Pipe may be properly wrapped and coated to prevent corrosion.
⑥ Sub surface piping be protected by using Cathodic protection.

Freeze Protection of outdoor Piping:

⑥ In the areas where the ambient temperature goes below freezing there is a possibility that
the liquid content of pipe may freeze while the plant is under shut down.
⑥ For similar case pipes are wrapped with heat tracing elements to maintain the content
temperature above freezing (around 4 deg. C) even when the ambient temp. is below
freezing.
⑥ Electric Heat tracing is done by wrapping electric coil around pipe, which turns on as the
ambient temperature goes down. Pipes are insulated over the heat tracing coils.
⑥ Heat tracing can also be done by winding Steam tubes around main pipes.
 We have come to the End of Session.

Hope you have gathered the fundamentals

on the subject of Piping& Fittings

Thank You