PIPING & PIPING

MATAERIALS

UNDER GUIDENCE OF

PROF .S.P.MANKANI

BY:

KOTAMKAR SAMIKSHA

PAWAR AKANSHA

PREFACE

INTRODUCTION

CLASSIFICATION OF PIPES

PIPING MATERIAL

FACTORS AFFECTING SELECTION OF PIPING MATERIALS

FLANGES

BOLTS & GASKETS

VALVES

INSULATION

PIPING

The term Piping means not only pipe but includes components like fittings,

flanges, valves, bolts, gaskets, bellows etc.

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.

CLASSIFICATION OF PIPES

PIPE

MATERIALMETHOD OF

MANUFACTURINGAPPLICATION

Engineering materials

Metallic

Ferrous Non ferrous

Non metallic

organic In organic

Composite

As per Materials

Ferr

ou

s Carbon steel

Low alloy steel

Stainless steel

No

n f

erro

us Nickel

Monel

Brasses

Org

anic

Plastic

Thermo setting

Thermo plastic

In o

rgan

ic Ceramic

Glass

Graphite

As per method of Manufacturing

Met

ho

d o

f m

anu

fact

uri

ng

Seamless

Wield

Electric resistance wielding (ERW)

Electric fusion wielding

(EFW)

Electric fusion wielding(EFW)

Seamless This process is used to make smaller sizes of seamless

pipe, typically 1 to 6 inches (25 to 150 mm) diameter.

The ingot of steel is heated to 2,370 °F (1,300 °C) and

pierced.

A mandrel is inserted into the tube and the assembly is

passed through a rolling (mandrel) mill. the mandrel mill reduces wall thickness continuously with a

series of pairs of curved rollers set at 90° angles to each other.

After reheating, the pipe is passed through a multi -stand stretch-reducing mill to reduce the diameter to the finished diameter.

The pipe is then cut to length before heat treatment, final straightening, inspection, and hydrostatic testing.

ERW (Electric resistance

wielding)

– Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920s until 1970. In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.

– Over time, the welds of low frequency ERW pipe was found to be susceptible to selective seam corrosion, hook cracks, and inadequate bonding of the seams, so low frequency ERW is no longer used to manufacture pipe. The high frequency process is still being used to manufacture pipe for use in new pipeline construction.

EFW (Electric fusion wielding)

– EFW-Electric Fusion Welded is of again two types :

i. Longitudinal SAW Pipe

ii. Spiral SAW Pipe

– Working is same of ERW.

Based on application

Pressure pipe

Line pipe

Structural pipe

As per Application

Pressure pipe

Pressure pipe

Mettalic

Concrete pressure pipe

Bar wrapped pipe C303

Pressure pipe are used where a large amount of pressure is there like water , sewage etc. Metallic pipe are usually of 3 types :• Cast iron pipe• Ductile iron pipe• Steel pipe

• Refrence : https://www.puretechltd.com/types-of-pipe

Line pipe

– A Line Pipe is a high strength carbon steel pipe used for transporting crude oil,

petroleum products, natural gas and water. It is a pipeline which carries only

one type of fuel. These pipes are made as per metallurgical specifications

developed by API (American Petroleum Institute). Line pipes are manufactured

in a wide range of pipeline diameter size ranging from 2 inches to 48 inches.

Structural pipe

– Structural steel is a category of steel used as a construction material for making

structural steel shapes. A structural steel shape is a profile, formed with a

specific cross section and following certain standards for chemical

composition and mechanical properties.

Materials Used for Piping.

– The manufacturing of pipe uses many different materials including ceramics,

fiberglass, concrete, plastics and metals.

– Concrete and ceramic

– Plastic

– Metals

– special piping materials such as glass or lined pipe

Selection of Piping Materials

– Materials selection for achievement of metallurgical

stability shall be made on the basis of design condition

and to resist possible exposures against fire, corrosion,

operating condition, service etc.

– The following are the main points which every designer

consider while selecting a material for piping

Resistance to stress

Resistance to wear

Design Life

Resistance to corrosion

Strength & pressure

Ductility & formability stress

Temperatur

Fatigue etc..

In any plant various fluids flow through pipes

from one end to other.

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

We have just brought the pipes, now we

need to solve some more problems.

Pipes are all straight pieces.

We need some

branch

connections

We need some bend

connections

To solve these

problems we need the

pipe components,

which are called

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.

These are flanged joints

This is a welded joint

But if we want to control the flow from Tank-1 to

other tanks.

We need some arrangement to stop the

flow if needed

To control the flow in a pipe line we

need to fit a special component.

That is called - VALVE

FLANGES

– Flanges provide a bolted, separable joint in piping. The most of valves have flanged ends and must have a companion or matching flange attached. A gasket is then inserted between them, and the bolts are tightened to form a flanged joint.

When to use Flanges?

– Where there is a clear need for removal of valves or equipment, for access of maintenance, or for blinding.

– Because all flanged connections are potential leak source, their use should be kept to the minimum needed for safe and reasonably convenient operation and maintenance.

Types of flanges

Flange

Weld neck

Socket weld

Slip on

Lap joint

Weld Neck

– The welding neck flanges are attached by butt-welding to the pipes.

Socket weld

– The socket weld flanges are welded only on one side and are not recommended

for severe services. These are used for small-bore lines only.

Slip on

– The slips on flanges are attached by welding inside as well as outside.

The lap joint flanges are used with the stub ends when

piping is of a costly material.

Lap Joint

MATERIAL:– Flanges are made of carbon steel forging having a highly refined grain

structure and generally excellent physical properties well in excess of

recognized minimum requirements. In addition to this, flanges in 300

pound and higher pressure classes can be made of Chrome-Molybdenum

Forged steel (ASTM A182 GRADE F5A).

BOLTS & GASKETS

– Choice of bolting material is governed by service fluid and its temperature.

– The most commonly used bolts for flanges in refinery piping are the ASTM A193

Gr.B7 Stud bolts which fall into the high strength group. The temperature range

is from –29°C to 454°C.

– A gasket is a thin circular disc, made up of soft compressive material. The most

of valves have flanged ends and must have a companion or matching flange

attached. A gasket is then inserted between them, and the bolts are tightened

to form a flanged joint.

There are many types of valves, categorized

based on their construction and functionality,

Those are - Gate, Globe, Check, etc.

Other than valves another important

line component of pipe line is a filter,

which cleans out derbies from the

flowing fluid. This is called a

STRAINER

VALVES

– Valves stop or open and regulate flow. Some of the basic valve types are gate, globe, check, Ball, Plug, etc.

– GATE VALVE: It is usually manually operated and is designed for open or shut operation. Flow can enter either end of the gate body.

– GLOBE VALVE: is for throttling. Good examples of globe valves are the faucets on washbasin which throttle or adjust the flow to suit a person’s needs. Flow must enter the valve and flow up, against the seat, and change the direction again to the outlet.

– CHECK VALVE: “checks” flow. It lets flow go one way and will not let it reverse. When you have a check valve in a line, you have made a one-way street. The flow can go one way , it restricts the back flow of fluid.

Gate valve

Globe valve

Check valve

When some fluid is flowing in a pipe we may

also like know the parameters like, pressure,

temperature, flow rate etc. of the fluid.

Here are some of the pipe supporting arrangements.

There can be numerous variants. All depend on

piping designer’s preference and judgement.

INSULATION

Insulation of piping & fitting is required for the following purpose:

– Heat conservation.

– Process stabilization to assist process control.

– Steam tracing.

– Steam jacketing.

– Fire hazard protection to prevent fast boil- off of liquid.

Basic Requirement & Type of

Insulation :

HOT INSULATION

– High quality & good appearance.

– Low chloride content.

– Chemically inert.

– Impervious to hot water & steam.

– Non corrosive to steel & aluminum.

COLD INSULATION

– All materials used for insulation, fixing, sealing, etc. shall be used as under:

– Operating temp range Insulation material

– -195 to +85 deg.c PUF or Polystyrene

– -195 to +120 deg.c PUF

– -30 to +120 deg.c PUF or polystyrene

– Rest are same as for hot insulation.

Advantages

– Additional securty is ensured.

– Increase in efficiency.

– Life of equipment is increased .

– Working atmosphere is easily maintained at desired parameters.

– Quality work is achieved.

Limitations

– Piping materials ensure additional safety only upto certain limit.

– Cost is increased.

– Maintaenance is complicated.

– No. of parts become large.

– Skilled labour is required.

– Maintaenance in proper interval of time is essential.

THANK YOU