PIPING ENGINEERING
Miss. Ishani
Prof. M.B. Mandake
B.V.C.O.E. NAVI MUMBAI
WHAT PIPING ENGINEERING SHOULD KNOW ABOUT.
A piping engineer
A piping engineer A piping engineer Piping engineer
should have good
should have good should have good should be well
understanding of
knowledge of knowledge of conversant with
engineering economics
industrial international drafting
& cost of method of
processes and codes & procedures &
pipe fabrication &
materials. standards. practices.
erection.
Role of a piping engineer
SYLLABUS
MODULE 1
1 2 3 4
INTRODUCTION CLASSIFICATION BASIC DUTIES AND
AND DEFINITIONS RESPONSIBILITIES
FUNDAMENTALS OF A PIPING
ENGINEER
What is Piping &Piping design?
– 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.
– It is a system used for moving fluids from one
location to another.
– Piping design is required for doing transportation of
fluid in an efficient manner
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.
DIFFERENCE BETWEEN PIPES AND TUBES
IMPORTANCE OF PIPING ENGINEERING
To maintain To maintain To maintain
pressure temperature flow rate
difference (∆p) difference (∆t) (∆q)
Piping system includes:
• Pipe
• Fittings (e.g. elbows, reducers,
branch connections, etc.)
• Flanges, gaskets, bolting
• Valves
• Pipe supports
PIPE REPRESENTATION
UPTO 12 INCH
ABOVE 14 INCH
PIPE SIZES
Pipe sizes are designated by two numbers: Diameter and Thickness.
Pipe size is designated by two non-dimensional numbers: Nominal Pipe
Size (NPS) and schedule (SCH)
• Nominal pipe size (NPS) is used to describe a pipe by name only.
Nominal pipe size (NPS) is generally associated with the inside diameter
(ID) for sizes 1/8” to 12”. For sizes 14” and beyond, the NPS is equal to
the outside diameter (OD) in inches.
• Outside diameter (OD) and inside diameter (ID), as their names imply,
refer to pipe by their actual outside and inside measurements. Outside
diameter (OD) remains same for a given size irrespective of pipe
thickness.
IRON PIPE SIZE (IPS)
STANDARD For Low Pressure Services
(STD) ASME Class 150 & 300
EXTRA
For Mid Pressure Services
STRONG
ASME Class 600
(XS OR XH)
DOUBLE For High Pressure Service
EXTRA ASME Class 900 and Above
STRONG
(XXS OR XXH)
• Schedule refers to the pipe wall thickness. As the
schedule number increases, the wall thickness increases,
and the inside diameter (ID) is reduced.
• Nominal Bore (NB) along with schedule (wall thickness)
is used in British standards classification.
Important
In process piping, the method of sizing pipe maintains a
uniform outside diameter while varying the inside diameter.
This method achieves the desired strength necessary for
pipe to perform its intended function while operating under
various temperatures and pressures. It is also important to
maintain certain interchangeability of pipe fittings.
PIPE SCHEDULES (SCH)
• The Schedule of pipe refers to the wall thickness of pipe in the
American system.
• Eleven schedule numbers are available for Carbon Steel Pipes: 5,
10, 20, 30, 40, 60, 80, 100, 120, 140, & 160
• The most popular schedule, by far, is 40.
• Schedules 5, 60, 100, 120, & 140 have rarely been used.
• Thickness of the pipe increases with the schedule number.
PIPE SCHEDULES (SCH)
This means that:
• Schedule 80 steel pipes will be heavier and stronger than schedule
40 pipe.
• Schedule 80 pipe will provide greater factor of safety allowing it to
handle much higher design pressures.
• Schedule 80 pipe will
use more material and
therefore costlier to make
and install.
How to calculate Schedule?
A simple rule of thumb expression is:
Schedule Number = (1,000) (P/S)
Where,
• P = the internal working pressure, psig
• S = the allowable stress (psi) for the material of construction
at the conditions of use.
How to calculate Schedule?
Example Calculate allowable internal pressure P for Schedule 40
mild steel pipe having ultimate tensile strength (S value) of 65,300
psi.
Ans)Rearrange the schedule equation: P = SCH x S/1,000
Therefore, P = 40 x 65,300/1,000 = 2,612 psi.
This is reasonable, based on a current-day published value of
2,849-psi for 1-inch Schedule 40 steel pipe.
INTERNAL DIAMETER (ID) OF PIPE
For process engineers, the most important parameter for hydraulic
sizing is the pipe Internal Diameter (ID). The ID can then easily be
calculated as: ID = OD - 2t
Example) A 4 inches Schedule 40 pipe has an outside diameter of
4.500 inches, a wall thickness of 0.237 inches.
Therefore, Pipe ID = 4.5 inches – 2 x 0.237 inches = 4.026 inches
A 4 inches Schedule 80 pipe has an outside diameter of 4.500
inches, a wall thickness of 0.337 inches.
Therefore, Pipe ID = 4.5 inches – 2 x 0.337 inches = 3.826 inches
NOTES
PRESSURE RATINGS
The pressure rating of the pipe is associated to the maximum
allowable working pressure. It is the ability of the pipe material to
resist the internal pressure and pressure surges. It is defined by pipe
schedule or thickness. Minimum wall thickness of pipe is calculated
by ASME B31.3 code (hoop stress) formula:
PRESSURE RATINGS
Where,
• t = required wall thickness, inches
• tm = minimum required wall thickness, inches
• P = Design pressure, psi
• D = Pipe outside diameter, inches.
• A = Corrosion allowance, inches
• S = Allowable Stress @ Design Temperature, psi
• E = Longitudinal-joint quality factor
• Y = Wall thickness correction factor
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
OTHER CHARACTERISTICS OF A PIPELINE:
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
Supporting elements of piping
CLASSIFICATION OF PIPES ( ON BASIS OF)
MATERIAL APPLICATION SIZE COATING
MANUFACTURING PRESSURE CONNECTION
PROCESS RATING METHOD
ON THE BASIS OF MATERIAL
Carbon Steel, Nickel Thermosetting Ceramic
Low Alloy Steel, Monel plastic Glass
Stainless Steel Brasses Thermoplastic Graphite
Based on Application
PRESSURE STRUCTURAL
LINE PIPE
PIPE PIPE
• High strength carbon steel
•Used for high-pressure pipes for transporting crude Used in
applications like water and oil , natural gas , or water. construction,
sewage • It is a pipeline which formed with
•Types include Cast Iron, carries only one type of specific
Ductile Iron, Steel, and fuel. mechanical and
Concrete Pipes • diameter size ranging from chemical standards
2 inches to 48 inches.
Based on Pressure Rating
Low-Pressure Pipes: For non-critical applications like drainage.
Medium-Pressure Pipes: Used in industries for moderate pressure
fluids.
High-Pressure Pipes: For high-pressure systems in oil, gas, and
chemical industries.
Based on Size
Small-Diameter Pipes: For household and small-scale
applications.
Large-Diameter Pipes: Used in water mains and industrial
pipelines.
Based on Lining/Coating
Lined Pipes: Pipes with internal linings like rubber or PTFE for
corrosion resistance.
Coated Pipes: External coatings like epoxy or polyethylene for
protection.
PIPE CONSTRUCTION METHODS
ELECTRIC
RESISTANCE
WELDING (ERW)
SUBMERGED ARC
WELDING (SAW)
SEAMLESS (SMLS)
Electric Resistance Welding (ERW)
− Electric Resistance Welding (ERW) pipe is manufactured by
rolling metal and then welding it longitudinally across its length.
The weld zone can also be heat treated, so the seam is less visible.
− Welded pipe often has tighter dimensional tolerances than
seamless, and can be cheaper if manufactured in large quantities.
These can be manufactured up to 24” OD in a variety of lengths to
over 100 feet.
− It is mainly used for low/ medium pressure applications such as
transportation of water / oil.
Electric Resistance Welding (ERW)
• Other welding technique for pipe fabrication is fusion weld (FW)
sometimes called “continuous weld” or spiral weld (SW) pipe.
The basic difference between ERW and FW is:
−No material is added during welding process in ERW.
− Filler material is added during welding process in FW.
− Large diameter pipe (about 10” or greater) may be ERW, or
Submerged Arc Welded (SAW) pipe.
Submerged Arc Welded (SAW)
• Submerged Arc Welding (SAW) is an arc welding process
where an arc is established between one or more
continuous bare-solid or cored-metal electrodes and the
work.
• The welding arc or arcs and molten puddle are shielded by
a blanket of granular, fusible material.
• Filler metal is obtained from the electrodes, and on
occasion, from a supplementary welding wire.
Seamless (SMLS)
− Seamless (SMLS) pipe is manufactured by piercing a billet
followed by rolling or drawing, or both to the desired length;
therefore, a seamless pipe does not have a welded joint in its cross-
section.
− Seamless pipe is finished to dimensional and wall thickness
specifications in sizes from 1/8 inch to 26 inch OD. Seamless pipe
is produced in single and double random lengths. Single random
lengths vary from 16'-0" to 20'-0" long. Pipes that are 2" and below
are found in double random lengths measuring 35'-0" to 40'-0"
long.
− Seamless pipe is generally more expensive to manufacture but
provides higher pressure ratings.
Seamless Steps OF
1. Cutting
2. Tempering in Furnace
3. Circular Section
4. Mandrel
5. Cold Forming
6. Length Cutting
7. Hydrostatic Test
8. End Preparation
9. Polish
10.Marketing
IMPORTANT
• Generally, wider wall thicknesses are produced by the
seamless method.
• Seamless pipe is usually preferred over seam welded pipe
for reliability and safety. Seamless pipes cannot be
substituted for others.
• Only ERW and SAW pipes can be substituted. Seam
welded pipe should not be specified for installation in
which it will be operating in the material’s creep range
[700°F (370°C) for carbon/low alloy steels and from 800°F
(430°C) for high alloy and stainless steels].
• However, for the many low pressure uses of pipe, the
continuous welded method is the most economical.
How to Identify Seamless or ERW Stainless Steel pipes?
To identify that a pipe supply is seamless or ERW, simply
read the stencil on the side of the pipe
• If it is ASTM A53,
− Type S means seamless.
− Type F is furnace but welded.
− Type E is Electrical resistance welded.
That’s how it is the easiest way to identify whether pipe is
seamless or ERW.
Recommended Guidelines
• All pipe lines carrying toxic
inflammable fluids shall be
seamless.
• Utility piping can be ERW or
Seam welded.
• Steam pipe lines shall preferably
be seamless.
GENERAL DEFINITIONS
Pipe
A pipe is a hollow cylindrical structure used to transport fluids
(liquids, gases, or slurries) from one location to another. Pipes are
classified based on material, size, and pressure rating.
Pipeline
A pipeline is a system of pipes, often with associated infrastructure
like pumps, valves, and fittings, designed to transport fluids or gases
over long distances.
Piping System
A piping system refers to a network of pipes, fittings, valves, and
equipment designed for a specific purpose, such as carrying water,
gas, oil, or chemicals in industrial or commercial settings.
PIPE
PIPELINE
PIPING SYSTEM
Fittings
Fittings are components used to connect, change direction, or
terminate pipes. Common fittings include:
Elbows: Change the direction of flow (e.g., 90°, 45°).
Tee: Distributes flow into two directions.
Reducers: Change the size of the pipe.
Couplings: Join two pipes together.
Valve
A valve is a device used to control, regulate, or stop the flow of fluid
in a piping system. Types include:
Gate Valve: Used to fully open or close the flow.
Globe Valve: For throttling and regulating flow.
Ball Valve: Quick on-off control using a rotating ball.
Check Valve: Allows flow in one direction only.
TYPES OF VALVES
Flange
A flange is a disc-like component used to connect pipes, valves, or other
equipment in a piping system. Flanges are bolted together and often
sealed with gaskets to ensure no leakage.
Gasket
A gasket is a sealing material placed between two mating surfaces to
prevent leakage of fluid. It is commonly used in flanged connections.
Pipe Schedule (SCH)
The pipe schedule indicates the wall thickness of a pipe. A higher
schedule number means a thicker wall, which can withstand higher
pressure. Common schedules include SCH 40, SCH 80, and SCH 160.
FLANGES IN A PIPE
GASKETS IN A PIPE
Pipe Support
Pipe supports are structures or devices used to hold a pipe in position
and carry its load. Types include:
Hangers: Suspend pipes from above.
Saddles: Provide support beneath the pipe.
Anchors: Fix pipes in place to prevent movement.
Pressure Drop
Pressure drop refers to the reduction in pressure as fluid flows through a
piping system, caused by friction, fittings, valves, and other restrictions.
Pigging
Pigging is a maintenance operation where a "pig" (a cleaning or
inspection device) is sent through the pipeline to clean or inspect its
condition.
P&ID (Piping and Instrumentation Diagram)
A P&ID is a schematic representation of a piping system that includes
details about pipes, valves, instruments, and control loops.
Expansion Joints
Expansion joints are flexible connectors used to absorb thermal
expansion or contraction in a piping system.
**The definition of the Equivalent Length of a pipe fitting is the
length of pipe of the same size as the fitting that would give rise to the
same pressure drop as the fitting.
Nominal Pipe Size (NPS)
Nominal Pipe Size refers to the standard way of sizing pipes in North
America. It is based on diameter, but the actual dimensions (inner and
outer) vary depending on the pipe schedule.
EXPANSION JOINT
Concept of high point vent and low point drain.
In piping systems, high point vents and low point drains are critical components
used for managing fluids, gases, and ensuring operational efficiency. They are integral
to maintaining the safety, functionality, and integrity of the system.
High Point Vent (HPV)
Definition
A high point vent is a valve or fitting installed at the highest point in a piping system
to allow the release of trapped air or gases.
Purpose
• Air Removal: Trapped air or gases in a pipeline can form air pockets, leading to
reduced flow efficiency and potential pressure surges (water hammer).
• Startup and Commissioning: During system filling, air must be vented to ensure
the pipeline is fully charged with fluid.
• System Maintenance: Vents facilitate periodic removal of gases to prevent
blockages.
Applications
• Hydronic Systems: Removal of air from water systems in heating or cooling
circuits.
• Chemical and Process Piping: Ensures gas pockets do not hinder fluid flow or
chemical reactions.
• Steam Systems: Prevents air entrapment that can reduce heat transfer efficiency.
Placement
High point vents are located at:
• The highest elevation in the piping network.
• Points where gases are likely to accumulate (e.g., near vertical rises).
Types of Vents
• Manual Vents: Operated manually to release trapped air.
• Automatic Vents: Self-operating, designed to expel air automatically as it
accumulates.
Low Point Drain (LPD)
Definition
A low point drain is a valve or fitting installed at the lowest point in a piping system
to allow the removal of liquid, sediment, or debris.
Purpose
• Liquid Removal: Ensures complete drainage of liquids, especially during
maintenance or shutdown.
• Sediment Removal: Prevents sediment buildup that can cause blockages or
corrosion.
• Prevent Freezing: Draining water from pipes in cold climates avoids freezing
and damage.
• Hydrostatic Testing: Used to drain water post-testing to prevent corrosion.
Applications
• Process Piping: Draining liquids after processing or cleaning cycles.
• Oil and Gas Pipelines: Removal of water and condensates to maintain
flow efficiency.
• Utility Piping: Drains in HVAC systems, water supply networks, and fire
protection systems.
Placement
Low point drains are located at:
• The lowest elevation in the piping network.
• Locations where liquids are likely to collect (e.g., bends or depressions in
the pipe).
Types of Drains
• Manual Drains: Operated manually to discharge collected liquid.
• Automatic Drains: Activated by pressure or liquid levels to self-drain.
Advantages
High Point Vent
• Prevents air-lock conditions.
• Enhances system efficiency by maintaining uninterrupted fluid flow.
Low Point Drain
• Reduces risk of corrosion by removing stagnant water.
• Ensures proper maintenance and prolongs pipeline lifespan.
Challenges
• Improper Placement: Ineffective venting or drainage due to incorrect
positioning.
• Valve Failure: Manual or automatic vents and drains can fail, leading to
leaks or blockages.
• Corrosion or Fouling: Continuous exposure to fluid or sediment may
degrade components.
METHOD OF JOINING PIPES.
1 2 3 4
BUTT SOCKET SCREWED FLANGED
WELDED WELDED
1 2 3 4
BUTT SOCKET SCREWED FLANGED
WELDED WELDED
BUTT WELDED
The end is machined to allow head to head full penetrating welding
ADVANTAGES
• Most economical method of joining big bore lines.
• Joint is leak proof.
• Joint can be radio graphed.
DISADVANTAGES
• Weld intrusion will affect the flow.
• End preparation is necessary.
SOCKET WELDED
A socket is provided where pipe can be inserted
ADVANTAGES
• Alignment is easier than butt welded.
• No intrusion of weld metal inside the pipe.
• Leak proof joint.
• Generally used to connect small bore lines.
DISADVANTAGES
• The 1 1/16 recess pocket .
• Not suitable when service fluid is corrosive in nature.
• Not suitable when vibration is anticipated.
SCREWED
ADVANTAGES
• Easy to made it at site.
• Can be used where welding is prohibited due to fire hazard. •
Generally used to connect small bore lines.
DISADVANTAGES
• Leak proof joint cannot be guaranteed.
• Not suitable when service fluid is corrosive in nature.
• Not suitable when vibration is anticipated.
• Not suitable when operating temperature is above 925 F.
• Thread reduces the wall thickness, consequently reducing the
strength.
FLANGED
ADVANTAGES
• Easy to made it at site.
• Can be used where welding is prohibited due to fire hazard.
• Dismantling is very easy.
DISADVANTAGES
• Leak proof joint cannot be guaranteed.
• Its an expensive method of joining pipes.
• Not suitable when high bending moment is anticipated.
PIPE ENDS
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.
Beveled 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.
Plain Ends (PE)
- A plain end pipe is a pipe that has been cut at 90° perpendicular
to the pipe run.
- This type of end is needed when being joined by mechanical
couplings, socket weld fittings, or slip on flange.
Bevel Ends (BE)
- A bevel is a surface that is not at a right angle (perpendicular)
to another surface. The standard angle on a pipe bevel is 37.5°
but other non-standard angles can be produced.
- Beveling of pipe or tubing is to prepare the ends for Butt
welding.
Threaded Ends (TE)
- Typically used on pipe 3" and smaller, threaded connections are
referred to as screwed pipe. With tapered grooves cut into the
ends of a run of pipe, screwed pipe and screwed fittings can
easily be assembled without welding or other permanent means
of attachment.
- In the United States, the standard pipe thread is National (not
nominal) Pipe Thread (NPT).
- The reason for this is that as NPT connections are assembled,
they become increasingly more difficult for the process to leak.
The standard taper for NPT pipe is 3/4" for every foot.
Various combination of pipe end:
POE: Plain one end
PBE: Plain both end
BOE: Beveled one end
BBE: Beveled both end
TOE: Threaded one end
TBE: Threaded both end
DUTIES AND RESPONSIBILITY OF PIPING ENGINEER.
• Piping engineer is responsible for accurate
design
• Piping design must satisfy the P&ID &
specification constraints.
• Standardization of engineering design
method.
• To achieve adequate design at an economic
cost.
• To co-ordinate with other departments.
• Co-ordination with the site.
Piping Design Engineer or Layout Engineer
Piping Design Engineer/layout Engineers deal with pipe routing with the
help of various 3D tools & software.
1.Role and Responsibilities of a Piping Design Engineer:
1. What Does a Piping Design Engineer Do? A piping design
engineer is responsible for creating and developing the layout and
design of piping systems used to transport fluids, gases, or other
materials in industrial facilities. These systems are essential in
sectors like oil & gas, power generation, chemical processing, and
manufacturing.
2. Core Responsibilities:
1.Layout and Design: Piping design engineers develop detailed
layouts for piping systems, considering factors such as pipe
size, flow rate, pressure, and material compatibility. They create
2D and 3D models using specialized design software like
AutoCAD, PDMS, or Smart Plant.
3. Coordination with Other Disciplines: Collaboration with other
engineering disciplines, such as mechanical, civil, and electrical
engineering, is crucial to ensure the piping design integrates seamlessly
with the overall project. This includes coordinating with structural engineers
to ensure support for the piping system and with process engineers to
understand the requirements of the fluids being transported.
4. Compliance with Codes and Standards: Piping design engineers
must ensure that all designs comply with industry standards and codes,
such as ASME B31.3, API standards, and local regulations. This ensures
the safety, reliability, and efficiency of the piping systems.
5. Stress Analysis and Material Selection: They also conduct stress
analysis to ensure that the piping can withstand operational loads, thermal
expansion, and other forces. Material selection is another critical aspect,
where the engineer chooses appropriate materials based on the fluid type,
temperature, pressure, and environmental conditions.
● Piping engineering is a crucial part of every process plant. It is a specialized field in
mechanical engineering dealing with piping and layout of equipment in various
petrochemical, chemical, and hydrocarbon facilities.
● As a piping engineer, you will be responsible for accomplishing many tasks in their
respective departments.
● What Does Piping Engineering Do?
● As mentioned earlier, being a piping engineer comes with a lot of tasks, the primary
responsibilities being to create the layout of overall plant facilities, place equipment and
process unit in the plot, and ensure the connected piping design is as per the applicable
regulations and standards for the safe operation of the design life. Some of the essential
design competencies in piping engineering are as follows:
● Plant Setup and Layout
● Equipment Layout
● Piping placement and Layout
● Piping Materials
● Piping Supports
● Piping Stress Analysis
● CAD or 3D Modeling
● Piping engineers skills
● Piping engineering involves mainly technical jobs and to
become an efficient piping engineer, you need to possess
specific skills. Let us now look into the skills required for
piping engineers:
● Observation Skills
● Effective Analysis Skills
● Project Management Skills
● Drafting Skills
● Communication Skills Both Verbal and Written
