UNIT 5

Introduction to Piping System

A pipe can be defined as a tube made of metal, plastic, wood, concrete or fiberglass. Pipes are used
to carry liquids, gases, slurries, or fine particles. A piping system is generally considered to include
the complete interconnection of pipes, including in-line components such as pipe fittings and
flanges. Pumps, heat exchanges, valves and tanks are also considered part of piping system. Piping
systems are the arteries of our industrial processes and the contribution of piping systems are
essential in an industrialized society.

Fig. 1 illustrates the magnitude of piping required in a typical chemical process plant. Piping
systems accounts for a significant portion of the total plant cost, at times as much as one-third of
the total investment. Piping systems arranged within a very confined area can be a added challenge
to piping and support engineers.

Figure 1

The initial design of a piping system is established by the functional requirements of piping a fluid
from one point to another. The detailed design is decided by criteria such as type of fluid being
transported, allowable pressure drop or energy loss, desired velocity, space limitations, process
requirements like free drain or requirement of straight run, stress analysis, temperature of fluid,
etc. The supporting of piping systems requires a significant engineering, design, fabrication and
erection effort. In some cases, special structures (like structural T or inverted L, cantilevers, U
portals, pedestals, etc) must be built solely for the purpose of supporting piping systems.

Piping Material

The material to be used for pipe manufacture must be chosen to suit the operating conditions of
the piping system. Guidance of selecting the correct material can be obtained from standard piping
codes. As an example, the ASME Code for Pressure Piping contains sections on Power Piping,
Industrial Gas and Air Piping, Refinery and Oil Piping, and Refrigeration
Piping Systems. The objective being to ensure that the material used is entirely safe under
the operating conditions of pressure, temperature, corrosion, and erosion expected. Some of the
materials most commonly used for power plant piping are discussed in the following sections.

 Steel – Steel is the most frequently used material for piping. Forged steel is extensively used
for fittings while cast steel is primarily used for special applications. Pipe is manufactured in
two main categories – seamless and welded.
 Cast Iron – Cast iron has a high resistance to corrosion and to abrasion and is used for ash
handling systems, sewage lines and underground water lines. It is, however, very brittle and
is not suitable for most power plant services. It is made in different grades such as gray cast
iron, malleable cast iron and ductile cast iron.
 Brass and Copper – Non-ferrous material such as copper and copper alloys are used in power
plants in instrumentation and water services where temperature is not a prime factor.

Commercial Pipe Sizes

Commercial pipe is made in standard sizes each having several different wall thicknesses
or weights. Up to and including 304.8 mm (12 inch) pipe, the size is expressed as nominal
(approximate) inside diameter. Above 304.8 mm, the size is given as the actual outside
diameter. All classes of pipe of a given size have the same outside diameter, with the extra
thickness
for different weights on the inside. For example, if a pipe was designated as 152.4 mm size this
would mean that it has a nominal or approximate inside diameter of 152.4 mm. The outside
diameter is 168.28 mm. This is a constant value no matter what the wall thickness is. The actual
inside diameter of the pipe will depend upon its wall thickness. For a standard wall
thickness, the actual inside diameter of 152.4 mm pipe is 154.06 mm. For an extra strong
wall thickness, the actual inside diameter is 146.34 mm.

There are two systems used to designate the various wall thicknesses of different sizes of pipe. The
older method lists pipe as standard (S), extra strong (XS) and double extra strong (XXS). The
newer method, which is superseding the older method, uses schedule numbers to designate wall
thickness. These numbers are 10, 20, 30, 40, 60, 80, 100, 120, 140 and 160. In most sizes of pipe,
schedule 40 corresponds to standard and schedule 80 corresponds to extra strong.

Dimensions and the mass in kg/m of different sizes of steel pipe with varying wall thicknesses is
shown in Fig. 2 .

Figure 2
Pipe Fittings

A fitting is used in pipe systems to connect straight pipe sections, adapt to different sizes or shapes
and for other purposes, such as regulating (or measuring) fluid flow. Pipe Fittings (especially
uncommon types) require money, time, materials and tools to install, and are an important part of
piping and plumbing systems. Valves are technically fittings, but are usually discussed
separately. The purposes of the fittings, shown in Fig. 3 may be generally stated as follows:
 Elbows – for making angle turns in piping.
 Nipples – for making close connections. They are threaded on both ends with the close nipple
threaded for its entire length.
 Couplings – for connecting two pieces of pipe of the same size in a straight line.
 Unions – for providing an easy method for dismantling piping.
 Tees and Crosses – for making branch line connections at 90º.
 Y-bends – for making branch line connections at 45º.
 Return Bends – for reversing direction of a pipe run.
 Plugs and Caps – for closing off open pipe ends or fittings.
 Bushings – for connecting pipes of different sizes. The male end fits into a coupling and the
smaller pipe is then screwed into the female end. The smaller connection may be tapped
eccentrically to permit free drainage of water.
 Reducers – for reducing pipe size. Has two female connections into which the different sized
pipes fit. May also be made with one connection eccentric for free drainage of water.
Figure 3
Methods of Connecting Pipe

There are three general methods used to join or connect lengths of pressure piping. These are:

1. Screwed Connections.
2. Flanged Connections.
3. Welded Joints.
Each of these methods has certain advantages and disadvantages and each will be discussed in the
following sections.

Screwed Connections

In this method, threads are cut on each end of the pipe and screwed fittings such as unions,
couplings, and elbows are used to join the lengths. This method is generally used for pipe sizes
less than 101.6 mm (4 inch) for low and moderate pressures. It has the advantage that the piping
can be easily disassembled or assembled. However, the threaded connections are
subject to leakage and the strength of the pipe is reduced when threads are cut in the pipe wall.

Flanged Connections

This method uses flanges at the pipe ends which are bolted together, face to face, usually with a
gasket between the two faces. Flanged connections have the advantage over welded connections
of permitting disassembly and are more convenient to assemble and disassemble than the screwed
connections. In order to prevent leakage at flanged connections, the flange faces, which butt
together, would have to be absolutely flat and smooth. While it is theoretically possible to grind
the faces to this condition, it is a time consuming and expensive proposition. Therefore gaskets are
usually used between flange faces. Gaskets are made of a comparatively soft material which, when
the flanged connection is tightened, will fill in any small depressions in the flange faces and thus
prevent leakage.

For more on Flanged Connections, check out:

 Introduction to Flanges.
 Introduction to Gaskets.

Welded Connections

In this method, the pipe lengths are welded directly to one another and directly to any valves or
fittings that may be required. The use of these welded joints for piping has several advantages over
the use of screwed connections or flanged connections:

1. The possibility of leakage is removed with the elimination of screwed or flanged joints.
2. The weight of the piping system is reduced due to the elimination of connecting flanges or
fittings.
3. The cost of material and the need for maintenance are reduced with the elimination of flanges
and fittings.
4. The piping looks neater and is easier to insulate with the elimination of bulky flanges and
fittings.
5. Welded joints give more flexibility to the piping design as the pipes may be joined
at practically any angle to each other.
The main disadvantage of using welded joints for piping is the necessity of obtaining a
skilled welder whenever a connection is to be made.

Piping Supports

Piping must be supported in such a way as to prevent its weight from being carried by
the equipment to which it is attached. The supports used must prevent excessive sagging of the pipe
and at the same time must allow free movement of the pipe due to expansion or contraction. The
supporting arrangement must be designed to carry the weight of the pipe, valves, fittings and
insulation plus the weight of the fluid contained within the pipe. Various types of piping support
are shown in Fig. 4.

Figure 4

Piping Drainage

In the case of steam piping, it is necessary to constantly drain any condensate from the lines. If
this is not done then the condensate will be carried along with the steam and may produce water
hammer and possibly rupture pipes or fittings. In addition, the admission of moisture carrying
steam to turbines or engines is most undesirable. Various devices are used to remove this
condensate and moisture from the lines and these are discussed in the following sections.
Steam Separators

Steam separators, sometimes called steam purifiers are devices which, when installed in the steam
line, will remove moisture droplets and other suspended impurities from the steam. To do this, the
separator either causes the steam to suddenly change its direction of flow or else it imparts a
whirling motion to the steam. Both of these cause the moisture and other particles to be thrown
out of the steam stream.

Steam Traps

The purpose of the steam trap is to discharge the water of condensation from steam lines, separators
and other equipment without permitting steam to escape. In addition, most traps are designed to
discharge any air present in the lines or equipment. Steam traps should be installed in lines
wherever condensate must be drained as rapidly as it accumulates, and wherever condensate must
be recovered for heating, for hot water needs, or for return to boilers. They are a “must” for steam
piping, separators, and all steam heated or steam operated equipment.

Piping Insulation

Most piping systems are used to convey substances that are at temperatures much higher than that
of the surrounding air. Examples would include the main steam piping and feedwater piping. In
order to reduce the amount of heat lost to the surrounding air from the hot substance, the piping is
covered with insulation. The insulation not only retains the heat in the hot lines but also prevents
the temperature inside the process plant building from becoming uncomfortably high. In addition,
insulation of hot pipe lines will prevent injury to personnel due to contact with the bare surfaces
of the pipe.

In the case of piping which carries substances at a lower temperature than that of the surrounding
air, insulating the piping will prevent sweating of the pipe and consequent dripping and corrosion.

A material suitable for use as an insulation should have the following characteristics.

 High insulating value.

 Long life.
 Vermin proof.
 Non corrosive.
 Ability to retain its shape and insulating value when wet.
  Ease of application and installation.
Some of the more common materials used for piping insulating are discussed in the
following sections.

 Diatomaceous Silica – This material is bonded with clay and asbestos and is used for
temperatures up to 1030ºC.
 Asbestos – Pipe covering sections are molded from asbestos fibre and are used for
temperatures up to 650ºC.
 Calcium Silicate – This insulation is made from silica and lime and is suitable for
temperatures up to 650ºC.
 Cellular Glass – This material is glass which has been melted and foamed and then molded
into pipe covering forms. It can be used for temperatures up to 430ºC.
 Magnesia (85%) – This material is composed of magnesium carbonate with asbestos fibre.
It is available in molded form for pipe covering and also is supplied in powdered form to be
mixed with water to form an insulating cement which is used to cover pipe fittings. Magnesia
pipe covering is suitable for service up to 315ºC.
 Glass Fibre – This is glass that has been processed into fibres and then formed into pipe
covering sections which are suitable for temperatures up to 190ºC.
 Plastic Foams – These are plastics that have been processed into a foam during manufacture
and then formed into pipe covering sections. They are available for temperatures as low as -
170ºC and as high as 120ºC.

What is Piping Engineering and Design

Piping Engineering is a specialized discipline of Mechanical Engineering which covers the design
of piping and layout of equipments and process units in chemical, petrochemical or hydrocarbon
facilities. Piping Engineers are responsible for the layout of overall plant facilities, the location of
equipments and process units in the plot and the design of the connected piping as per the
applicable codes and standards to ensure safe operation of the facilities for the design life.

Piping can be defined as an assembly of piping components used to convey or distribute process
fluid from one item of equipment to another in a process plant. The piping components that form
a part of this assembly are pipes, fittings, flanges, valves, piping specials, bolts and gaskets. This
definition also includes pipe-supporting elements such as pipe shoes but does not include support
structures such as pipe racks, pipe sleepers and foundations. As per ASME B31.3, the piping
designer is responsible to the owner for assurance that the engineering design of the piping
complies with the requirements of this code and any additonal requirements established by the
owner. Piping Engineering is a very important aspect of plant facility design and extends way
beyond designing piping as per ASME Codes. There are various ASME codes used for piping.
Most of the plant facilities in the petrochemical and hydrocarbon industry will use ASME B31.3
code for design of process piping.

What does the ASME B31.3 Piping Code cover

It may be noted that ASME B31.3 code is not a design handbook. The code does not serve as a
substitute for sound engineering judgements by the owner and designer. Many decisions that must
be made to produce a sound piping installation are not specified in detail within the code. The
introduction section of the code clarifies this aspect of ASME B31.3 code.

ASME 31.3 provides ample guidance and set of rules on the following aspects of piping design:

References to applicable material specifications and component standards, including dimensional

requirements and pressure-temperature ratings.
Requirements for design of component and assemblies including pipe supports.
Requirements and data for evaluation and limitation of stresses, reactions associated with pressure,
temperature changes and other forces.
Guidance and limitations on selection and application of materials, components and joining
methods.
Requirements for the fabrication, assembly and erection of piping.
Requirements for examination, inspection and testing of piping.
Piping Engineering and Design Competencies
Piping Engineering broadly involves the following competencies:

Plant Layout
Equipment Layout
Piping Layout
Piping Materials
Piping Supports
Piping Stress Analysis
CAD or 3D Modeling
Typical Piping Engineering Organization set-up
In many engineering organizations a piping discipline is organized into two groups, namely piping
engineering and piping design. The engineering group is mainly involved with piping material
specifications, pipng materials and stress analysis whereas the design group is involved with plant
layout, equipment layout and piping layout. The lead piping engineer on the project assumes full
responsibility for piping engineering and design on the project. The lead designer who is
responsible for plant, equipment and piping layout reports to the lead piping engineer. This
organizational set-up works successfully in most organizations because it eliminates any conflicts
through a single point responsibility, and ensures that a high level of coordination and interface is
maintained between the engineering and design group.

In the early stages of your career as a piping engineer or a designer, you may not get immediate
exposure to all the required competencies. In very large organizations your role as a piping
engineer may be limited to one of the core competencies. It may be a good idea to work in a smaller
set-up where the piping engineer engages with almost all activities related to piping engineering
and design. On a large project, the Lead Piping Engineer is responsible for overall design of the
piping and is supported by the Piping Department Manager and the following piping sub-groups:

Piping Materials Engineering Group

Piping Layout and Design Group
Piping Stress Engineering Group
Piping Support Engineering Group

Piping Engineering Organization

Typical Piping Engineering Organization
Responsibilities of Lead Piping Engineer
The Lead Engineer is required to have the knowledge in all areas of piping engineering along with
good managerial skills. He is responsible for day-to-day planning and delegating the tasks to the
team members to be able to issue the piping deliverables in a timely manner and meet the project
objectives. Following are the key activities and responsibilities of Lead Piping Engineer:

Managing the piping engineering activities and deliverables on the project.

Ensuring adherence to industry codes and standards as well as department work instructions,
specifications, and standards for the assigned project.
Participating in developing overall schedule for piping engineering as well as assessing the
progress of the piping engineering effort and managing the budget.
Coordinating the review of vendor drawings and data used for the project.
Coordinating and interfacing with discipline lead engineers to ensure the smooth flow of all
information on the project task force, and to ensure alignment with project requirements.
Reviewing piping valves and speciality vendor drawings and data.
Preparing piping construction scope of work.
Participating in the development of P&ID's, package specifications, construction specifications,
project schedules, project budgets and construction planning.
Performing quality reviews like discipline and inter-discipline checks for detailed engineering
documents and specifications.
Planning and participating in any inspection/testing activities associated with their respective
piping and equipment packages.
Organizing and leading design, layout, constructability and 3D model reviews.
Overseeing and assisting in the preparation of reports for feasibility studies.
Supporting the Project Manager on piping technical and schedule issues related to the project.
Responsibilities of Piping Stress and Support Engineer
The Piping Stress Engineer is responsible for performing stress analysis of piping systems and
ensuring that the piping stresses and loads on equipments are within the allowable limits. The
piping stress engineer is responsible for locating the supports and transferring the load information
to the structural group to design the support members. To perform these activites he is required to
continually coordinate with the layout group as well as the structural group. Following are the key
activities and responsibilities of piping stress engineer:

Prepare piping stress critical line list.

Prepare project stress design criteria or basis.
Peform piping stress analysis of piping systems using validated software and prepare stress
analysis reports.
Select the type of supports and support location and issue support loads to structural group.
Prepare specifications and data sheets for stress specific special items such as spring supports,
expansion joints and perform technical evaluation.
Coordinate with other disciplines such as process group to confirm various operating scenarios to
decide the stress load cases, two phase flows etc. or with structural group to confirm support
locations and loads.
Prepare stress isometrics mark-ups and issue the same to layout group. Ensure that the stress
recommendations are incorporated in piping design by signing and stamping on stress critical
isometrics.
Responsibilities of Piping Material Engineer
The Piping Material Engineer is responsible for preparing piping material classes, piping material
specifications and other material procurement related requisitions, technical bid evaluations and
purchase requistions. The bill of material for piping is usually prepared by the layout group or
extracted from the 3D model in an advanced stage of the project. Following are the key activities
and responsibilities of piping material engineer:

Prepare piping material classes.

Prepare piping specifications including material procurement specification.
Preparing piping speciality list and data sheets for special items.
Preparing valves specifications and data sheets.
Checking bill of material for correctness of descriptions.
Prepare piping material enquiry requisitions.
Prepare technical bid evaluation.
Review of Vendor drawings.
Prepare piping purchase requisitions.
Piping Engineering Deliverables
The piping engineering disciplines is responsible for the following deliverables. Different
organizations and different regions of the world may use alternate terminologies or prepare
additional deliverables depending on the scale of the project which are inlcluded in the brackets:

Plot Plans (Overall Plot Plan and Unit Plot Plans)

Equipment Layouts
Piping General Arrangement Drawings (Piping Plans or Piping GADs)
Piping Section and Details (Usually included as part of Piping Plans)
Conceptual Piping Layouts or Study Piping Layouts
Piping Isometrics
Line Designation Table (Line List or Line schedule)
Tie-in Schedule (Tie-in Index)
Nozzle Orientation Drawings
Piping Demolition Drawings
Pipe Support Details
Material Take Off (Bill of Material or MTO in short)
Piping Material Classes
Piping Specifications
Speciality Items List
Data Sheets for Valves
Data Sheets for Piping Specials
Technical Bid Evaluation
Piping Stress Analysis Report
3D Piping Model