Professional Documents
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ASME Piping System Design
ASME Piping System Design
Participants Guide
CONTACT INFORMATION
ASME Headquarters
1-800-THE-ASME
Copyright 2000 by
TABLE OF CONTENTS
PART 1:
PART 2:
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
Introduction ....................................................................................................................... 73
General ............................................................................................................................. 73
A.
What is a piping system .......................................................................................... 73
B.
Scope of ASME B31.3............................................................................................. 73
Material selection considerations...................................................................................... 75
A.
Strength................................................................................................................... 75
B.
Corrosion Resistance .............................................................................................. 77
C.
Material Fracture Toughness .................................................................................. 77
D.
Fabricability ............................................................................................................. 78
E.
Availability and Cost ................................................................................................ 78
Piping Components........................................................................................................... 79
A.
Fittings, Flanges, and Gaskets................................................................................ 79
B.
Flange Rating .......................................................................................................... 85
Sample Problem 1 - Determine Flange Rating ................................................................. 88
Solution ............................................................................................................................. 88
Valves ............................................................................................................................... 89
A.
Valve Functions....................................................................................................... 89
B.
Primary Valve Types ............................................................................................... 90
C.
Valve Selection Process ......................................................................................... 98
Exercise 1 Determine Required Flange Rating ............................................................. 99
Design ............................................................................................................................. 100
A.
Design Conditions ................................................................................................. 100
B.
Loads and Stresses............................................................................................... 101
C.
Pressure Design of Components .......................................................................... 105
Sample Problem 2 - Determine Pipe wall thickness ....................................................... 110
Sample Problem 3 .......................................................................................................... 116
Exercise 2: Determine Required Pipe Wall Thickness .................................................. 121
System Design ................................................................................................................ 122
A.
Layout Considerations .......................................................................................... 122
B.
Pipe Supports and Restraints ............................................................................... 123
C.
Piping Flexibility..................................................................................................... 129
D.
Required Design Information for Piping Stress Analysis ...................................... 132
E.
Criteria for Allowable Equipment Nozzle Loads .................................................... 132
F.
When Should A Computer Analysis Be Used ....................................................... 134
G.
Design Considerations for Piping System Stress Analysis ................................... 134
Fabrication, Assembly, and Erection .............................................................................. 140
A.
Welding and Heat Treatment ................................................................................ 140
B.
Assembly and Erection.......................................................................................... 144
Quality Control ................................................................................................................ 151
A.
Inspection .............................................................................................................. 151
B.
Testing................................................................................................................... 154
Other Considerations ...................................................................................................... 156
A.
Nonmetallic Piping................................................................................................. 156
B.
Category M Fluid Service...................................................................................... 157
C.
High Pressure Piping............................................................................................. 158
Summary......................................................................................................................... 160
Part 1:
Participant Notes
OVERVIEW OF
PROCESS PLANT PIPING
SYSTEM DESIGN
By: Vincent A. Carucci
Carmagen Engineering, Inc.
Notes:
Piping System
Piping system: conveys fluid between
locations
Piping system includes:
Pipe
Fittings (e.g. elbows, reducers, branch
connections, etc.)
Flanges, gaskets, bolting
Valves
Pipe supports
2
Notes:
ASME B31.3
Provides requirements for:
Design
Materials
Fabrication
Erection
Inspection
Testing
Petroleum refineries
Chemical plants
Pharmaceutical plants
Textile plants
Paper plants
Semiconductor
plants
Cryogenic plants
Notes:
Notes:
Strength
Notes:
S
A
Notes:
Corrosion Resistance
Deterioration of metal by chemical or
electrochemical action
Most important factor to consider
Corrosion allowance
added thickness
Alloying increases corrosion resistance
Notes:
Pitting
Corrosion
Galvanic
Corrosion
Graphitic
Corrosion
Notes:
Material Toughness
Energy necessary to initiate and
propagate a crack
Decreases as temperature decreases
Factors affecting fracture toughness
include:
Chemical composition or alloying elements
Heat treatment
Grain size
9
Notes:
Fabricability
Ease of construction
Material must be weldable
Common shapes and forms include:
Seamless pipe
Plate welded pipe
Wrought or forged elbows, tees, reducers,
crosses
Forged flanges, couplings, valves
Cast valves
10
Notes:
11
Notes:
Pipe Fittings
Produce change in geometry
12
Notes:
90
45
180 Return
Figure 4.1
13
Notes:
Tee
Cross Tee
Figure 4.2
14
Notes:
10
Reducer
Concentric
Eccentric
Figure 4.3
15
Notes:
16
Figure 4.4
Notes:
11
Cap
Figure 4.5
17
Notes:
R
R
Enlarged Section
of Lap
18
Figure 4.6
Notes:
12
Bolting
Gasket
Figure 4.7
19
Notes:
Types of Flange
Attachment and Facing
Flange Attachment Types
Threaded Flanges
Flat Faced
Socket-Welded Flanges
Blind Flanges
Raised Face
Slip-On Flanges
Lapped Flanges
Ring Joint
20
Table 4.1
Notes:
13
Figure 4.8
21
Notes:
Gaskets
Resilient material
Inserted between flanges
Compressed by bolts to create seal
Commonly used types
Sheet
Spiral wound
Solid metal ring
22
Notes:
14
Notes:
24
Table 4.2
Notes:
15
1.9
1.8
150
235
220
215
200
170
140
125
110
95
80
65
50
35
20
300
620
570
555
555
555
555
555
545
515
510
485
450
320
215
400
825
765
745
740
740
740
740
725
685
675
650
600
425
290
150
290
260
230
200
170
140
125
110
95
80
65
50
35
20
300
750
750
720
695
695
605
590
570
530
510
485
450
320
215
1.10
400
1000
1000
965
885
805
785
785
710
675
650
600
425
290
190
150
290
260
230
200
170
140
125
110
95
80
65
50
35
20
300
750
750
730
705
665
605
590
570
530
510
485
450
375
260
400
1000
1000
970
940
885
805
785
755
710
675
650
600
505
345
Table 4.3
25
Notes:
Sample Problem 1
Flange Rating
New piping system to be installed at
existing plant.
Determine required flange class.
Pipe Material:
Design Temperature:
Design Pressure:
1 1 Cr 1 Mo
4
2
700F
500 psig
26
Notes:
16
Notes:
Valves
Functions
Block flow
Throttle flow
Prevent flow reversal
28
Notes:
17
Handwheel Nut
Handwheel
Stem Nut
Yoke
Yoke Bolting
Stem
Gland Flange
Gland
Gland Bolts or
Gland Eye-bolts and nuts
Gland Lug Bolts and Nuts
Stem Packing
Plug
Lantern Ring
Backseat Bushing
Bonnet
Bonnet Gasket
Bonnet Bolts and Nuts
Gate
Seat Ring
Body
One-Piece Gland (Alternate)
Valve Port
Figure 5.1
29
Notes:
Globe Valve
30
Notes:
18
Check Valve
31
Notes:
Seat
Ring
Hinge
Flow
Direction
Disc
Body
32
Figure 5.2
Notes:
19
Figure 5.3
33
Notes:
34
Figure 5.4
Notes:
20
Figure 5.5
35
Notes:
Ball Valve
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
36
Part Names
Body
Body Cap
Ball
Body Seal Gasket
Seat
Stem
Gland Flange
Stem Packing
Gland Follower
Thrust Bearing
Thrust Washer
Indicator Stop
Snap Ring
Gland Bolt
Stem Bearing
Body Stud Bolt & Nuts
Gland Cover
Gland Cover Bolts
Handle
Figure 5.6
Notes:
21
Plug Valve
Wedge
Sealing Slip
Figure 5.7
37
Notes:
Notes:
22
Notes:
Exercise 1 - Determine
Required Flange Rating
Pipe:
1 1 Cr 1 Mo
4
2
Flanges:
Design Temperature:
Design Pressure:
40
Notes:
23
Exercise 1 - Solution
1. Identify material specification of flange
A-182 Gr, F11
2. Determine Material Group No. (Table 4.2)
Group 1.9
3. Determine class using Table 4.3 with design
temperature and Material Group No.
The lowest Class for design pressure of 375
psig is Class 300.
Class 300 has 450 psig maximum pressure
at 900F
41
Notes:
Design Conditions
General
Normal operating conditions
Design conditions
Notes:
24
Loading Conditions
Principal pipe load types
Sustained loads
Act on system all or most of time
Consist of pressure and total weight load
Occasional loads
43
Notes:
Stresses Produced By
Internal Pressure
Sl
Sc
P
t
44
Sl
Longitudinal Stress
Sc
Wall Thickness
Internal Pressure
Figure 6.1
Notes:
25
Stress Categorization
Primary Stresses
Direct
Shear
Bending
Secondary stresses
Act across pipe wall thickness
Cause local yielding and minor distortions
Not a source of direct failure
45
Notes:
46
Notes:
26
Allowable Stresses
Function of
Material properties
Temperature
Safety factors
Established to avoid:
General collapse or excessive distortion from
sustained loads
Localized fatigue failure from thermal
expansion loads
Collapse or distortion from occasional loads
47
Notes:
B31.3 Allowable
Stresses in Tension
Basic Allowable Stress S, ksi. At Metal Temperature, F.
Material
Spec. No/Grade
100
200
300
400
500
Carbon Steel
A 106
20.0
20.0
20.0
20.0
18.9
17.3
16.5
10.8
6.5
2.5
1.0
C - Mo
A 335
P1
18.3
18.3
17.5
16.9
16.3
15.7
15.1
13.5
12.7
4.
2.4
P11
20.0
1 - Mo
A 335
600
700
800
900
1000 1100
1200
1300
1400
1500
18.7
18.0
17.5
17.2
16.7
15.6
15.0
12.8
6.3
2.8
1.2
A 312
TP304 20.0
20.0
20.0
18.7
17.5
16.4
16.0
15.2
14.6
13.8
9.7
6.0
3.7
2.3
1.4
16Cr - 12Ni-2Mo
pipe
A 312
TP316 20.0
20.0
20.0
19.3
17.9
17.0
16.3
15.9
15.5
15.3
12.4
7.4
4.1
2.3
1.3
Table 6.1
48
Notes:
27
t=
PD
2 (SE + PY )
t m = t + CA
t nom =
tm
0.875
49
Notes:
Spec.
No.
Description
Ej
Carbon Steel
API
5L
...
...
...
A 53
Type S
Type E
Type F
A 106
...
Seamless pipe
Electric resistance welded pipe
Electric fusion welded pipe, double butt, straight or
spiral seam
Furnace butt welded
1.00
0.85
0.95
Seamless pipe
Electric resistance welded pipe
Furnace butt welded pipe
1.00
0.85
0.60
Seamless pipe
1.00
...
...
Seamless pipe
Electric resistance welded pipe
1.00
0.85
A 335
...
Seamless pipe
A 312
...
...
...
Seamless pipe
Electric fusion welded pipe, double butt seam
Electric fusion welded pipe, single butt seam
1.00
0.85
0.80
1.00
1.00
0.90
0.85
Stainless Steel
A 358
1, 3, 4
5
2
B 161
...
B 514
...
Welded pipe
0.80
B 675
All
Welded pipe
0.80
50
1.00
Table 6.2
Notes:
28
Temperature, F
950
1000
1050
1100
1150 & up
Ferritic
Steels
0.4
0.5
0.7
0.7
0.7
0.7
Austenitic
Steels
0.4
0.4
0.4
0.4
0.5
0.7
Other
Ductile
Metals
0.4
0.4
0.4
0.4
0.4
0.4
Cast iron
0.0
...
...
...
...
...
Materials
Table 6.3
51
Notes:
Mitered bend
Straight pipe sections welded together
Often used in large diameter pipe
May require larger thickness
Function of number of welds, conditions, size
52
Notes:
29
Notes:
PD
2(SE + PY)
t=
1,380 14
2[(16,200 1) + (1,380 0.4 )]
t = 0.577 in.
54
Notes:
30
0.6395
= 0.731 in.
0.875
55
Notes:
Tb
Reinforcement
Zone Limits
Nom.
Thk.
tb
A3
A3
L4
Reinforcement
Zone Limits
Mill
Tol.
A4
A4
A1
Tr
Th
Dh
Nom.
Thk.
th
Mill
Tol.
d1
A2
A2
d2
d2
Pipe C
56
Figure 6.2
Notes:
31
Reinforcement Area
d1 =
Db 2(Tb c)
sin
Notes:
58
Notes:
32
Reinforcement Pad
Provides additional reinforcement
Usually more economical than increasing
wall thickness
Selection variables
Material
Outside diameter
Wall thickness
(D Db )
A 4 = p
Tr
sin
59
Notes:
Sample Problem 3
Pipe material: Seamless, A 106/Gr. B for
branch and header, S = 16,500 psi
Design conditions: 550 psig @ 700F
c = 0.0625 in.
Mill tolerance: 12.5%
60
Notes:
33
Required Pipe
Thicknesses:
Notes:
Db 2(Tb c)
sin
A1 = thd1(2 sin)
A1 = 0.395 15.469 (2 sin90) = 6.11in.2
62
Notes:
34
A 2 = (2d2d1)(Ththc )
d2 = d1 = 15.469 in. < Dh = 24 in.
A2 = (2 15.469 - 15.469) (0.875 0.562 0.395 - 0.0625)
A2 = 0.53 in.2
63
Notes:
A3.
A3 =
2L 4(Tb tbc )
sin
64
Notes:
35
Pad needed
65
Notes:
66
Notes:
36
2L 4 (Tb t b c)
sin
A3 =
67
Notes:
A 4 Db
5.575
+
=
+ 16 = 27.3
Tr sin 0.492
Notes:
37
Exercise 2 - Determine
Required Pipe Wall Thickness
69
Notes:
Exercise 2 - Solution
From Tables 6.1, 6.2, and 6.3 obtain values:
S = 20,000 psi
E = 1.0
Y = 0.4
Thickness calculation:
t=
PD
150 30
=
2(SE + PY ) 2[(20,000 1.0 ) + (150 0.04 )]
t = 0.112 in.
70
Notes:
38
t nom =
t nom
71
Notes:
Layout Considerations
Operational
Operating and control points easily reached
Maintenance
Ample clearance for maintenance equipment
Room for equipment removal
Sufficient space for access to supports
Safety
Consider personnel safety
Access to fire fighting equipment
72
Notes:
39
Restraints
Control or direct thermal movement due to:
+ thermal expansion
+ imposed loads
73
Notes:
Weight load
Available attachment clearance
Availability of structural steel
Direction of loads and/or movement
Design temperature
Vertical thermal movement at supports
74
Notes:
40
Rigid Supports
Shoe
Dummy Support
75
Base Adjustable
Support
Saddle
Trunnion
Figure 7.1
Notes:
Hangers
76
Figure 7.2
Notes:
41
Flexible Supports
Load and Deflection
Scale
Small Change in
Effective Lever Arm
Large Change in
Effective Lever Arm
Relatively
Constant
Load
Typical Variable-Load
Spring Support
Typical Constant-Load
Spring Support Mechanism
Figure 7.3
77
Notes:
Restraints
Control, limit, redirect thermal movement
Reduce thermal stress
Reduce loads on equipment connections
Notes:
42
Restraints, contd
Restraint Selection
Direction of pipe movement
Location of restraint point
Magnitude of load
79
Notes:
Guide
Permits movement along pipe axis
Prevents lateral movement
May permit pipe rotation
80
Notes:
43
Restraints - Anchors
Anchor
Anchor
Partial Anchor
Figure 7.4
81
Notes:
Restraints - Guides
Guide
Guide
Vertical Guide
82
Guide
Figure 7.5
Notes:
44
Piping Flexibility
Inadequate flexibility
Leaky flanges
Fatigue failure
Excessive maintenance
Operations problems
Damaged equipment
Notes:
Flexibility Analysis
Considers layout, support, restraint
Ensures thermal stresses and reaction
loads are within allowable limits
Anticipates stresses due to:
84
Notes:
45
85
Notes:
Design Factors
Layout
Component
design details
Fluid service
Connected
equipment type
Operating
scenarios
Pipe diameter,
thickness
Design temperature
and pressure
End-point movements
Existing structural
steel locations
Special design
considerations
86
Notes:
46
Parameters Used
To Determine
Acceptable Loads
Industry Standard
Centrifugal Pumps
API 610
Nozzle size
Centrifugal
Compressors
Air-Cooled Heat
Exchangers
API 661
NEMA SM-23
allowable
Nozzle size
Tank Nozzles
API 650
Steam Turbines
NEMA SM-23
Nozzle size
Table 7.1
87
Notes:
Computer Analysis
Used to perform detailed piping stress
analysis
Can perform numerous analyses
Accurately completes unique and difficult
functions
88
Time-history analyses
Seismic and wind motion
Support motion
Finite element analysis
Animation effects
Notes:
47
Maximum Differential
Flexibility Temp.
400F
300F
12
200F
20
any
Any
Any
For tankage
12
Any
Table 7.2
89
Notes:
Notes:
48
Normal Temperature
Conditions To Consider
Stable
Operation
Startup and
Shutdown
Regeneration
and Decoking
Piping
Spared
Equipment
Table 7.3
91
Notes:
Abnormal Temperature
Conditions To Consider
Loss of Cooling
Medium Flow
92
Table 7.4
Notes:
49
Extent of Analysis
Extent depends on situation
Analyze right combination of conditions
Not necessary to include system sections
that are irrelevant to analysis results
93
Notes:
Notes:
50
Notes:
System Design
Considerations, contd
Atmospheric storage tank
Movement at nozzles
Tank settlement
Notes:
51
Tank Nozzle
SHELL
NOZZLE
BOTTOM
Figure 7.6
97
Notes:
Welding
98
Notes:
52
Figure 8.1
99
Notes:
(b)
(c)
(d)
100
Figure 8.2
Notes:
53
Fillet Welds
Figure 8.3
101
Notes:
Weld Preparation
Welder and equipment must be qualified
Internal and external surfaces must be
clean and free of paint, oil, rust, scale, etc.
Ends must be:
Suitably shaped for material, wall thickness,
welding process
Smooth with no slag from oxygen or arc
cutting
102
Notes:
54
Preheating
Minimizes detrimental effects of:
High temperature
Severe thermal gradients
Benefits include:
Dries metal and removes surface moisture
Reduces temperature difference between
base metal and weld
Helps maintain molten weld pool
Helps drive off absorbed gases
103
Notes:
Notes:
55
105
Notes:
Notes:
56
Dimensional tolerances
Flange tolerances
107
Notes:
Pipe Alignment
Load Sensitive Equipment
Special care and tighter tolerances needed
Piping should start at nozzle flange
Initial section loosely bolted
Gaskets used during fabrication to be replaced
Notes:
57
Notes:
110
Notes:
58
111
Notes:
Flange Preparation,
Inspection, and Installation
112
Notes:
59
Criss-Cross
Bolt-tightening Sequence
Figure 8.4
113
Notes:
114
Notes:
60
Inspection
Defect identification
Weld inspection
Technique
Weld type
Anticipated type of defect
Location of weld
Pipe material
115
Notes:
d) Incomplete Penetration of
Weld Groove
External Undercut
Internal Undercut
f) Undercut
116
Figure 9.1
Notes:
61
Radiography
Magnetic Particle
Liquid Penetrant
Ultrasonic
Situation/Weld Type
All welds.
Defect
Cracks.
Slag inclusions.
Butt welds.
Gas pockets.
Girth welds.
Slag inclusions.
Incomplete penetration.
Ferromagnetic
materials.
Cracks.
For flaws up to 6 mm
(1/4 in.) beneath the
surface.
Porosity.
Lack of fusion.
Ferrous and
nonferrous materials.
Cracks.
Seams.
Intermediate weld
passes.
Porosity.
Folds.
Simple and
inexpensive.
Inclusions.
Shrinkage.
Surface defects.
Laminations.
Subsurface flaws.
Table 9.1
117
Notes:
Testing
Pressure test system to demonstrate
integrity
Hydrostatic test unless pneumatic
approved for special cases
Hydrostatic test pressure
1 times design pressure
118
Notes:
62
Testing, contd
For design temperature > test temperature:
PT =
1. 5 P S T
S
119
Notes:
Testing, contd
Pneumatic test at 1.1P
Instrument take-off piping and sampling
piping strength tested with connected
equipment
120
Notes:
63
Nonmetallic Piping
Thermoplastic Piping
Can be repeatedly softened and hardened by
increasing and decreasing temperature
121
Notes:
122
Notes:
64
123
Notes:
Notes:
65
125
Notes:
Notes:
66
127
Notes:
128
Notes:
67
129
Notes:
130
Notes:
68
131
Notes:
Examination
132
Notes:
69
Summary
Process plant piping much more than just
pipe
ASME B31.3 covers process plant piping
Covers design, materials, fabrication,
erection, inspection, and testing
Course provided overview of requirements
133
Notes:
70
Part 2:
Background Material
71
72
I.
INTRODUCTION
II.
GENERAL
A.
Pipe sections
Valves
73
ASME B31.3 applies to piping and piping components that are used
for all fluid services, not just hydrocarbon services. These include
the following:
Petroleum products.
Fluidized solids.
Refrigerants.
Cryogenic fluids.
74
III.
Strength
A material's strength is defined by its yield, tensile, creep, and
fatigue strengths. Alloy content, material grain size, and the steel
production process are factors that affect material strength.
1.0
S
A
E
Typical Stress-Strain Diagram for Steel
Figure 3.1
75
2.0
Creep Strength
Below about 750F for a given stress, the strain in most
materials remains constant with time. Above this
temperature, even with constant stress, the strain in the
material will increase with time. This behavior is known as
creep. The creep strength, like the yield and tensile
strengths, varies with temperature. For a particular
temperature, the creep strength of a material is the minimum
stress that will rupture the material during a specified period
of time.
The temperature at which creep strength begins to be a
factor is a function of material chemistry. For alloy materials
(i.e., not carbon steel) creep strength becomes a
consideration at temperatures higher than 750F.
3.0
Fatigue Strength
The term fatigue refers to the situation where a specimen
breaks under a load that it has previously withstood for a
length of time, or breaks during a load cycle that it has
previously withstood several times. The first type of fatigue
is called static, and the second type is called cyclic.
Examples of static fatigue are: creep fracture and stress
corrosion cracking. Static fatigue will not be discussed
further in this course.
One analogy to cyclic fatigue is the bending of a paper clip.
The initial bending beyond a certain point causes the paper
clip to yield (i.e., permanently deform) but not break. The
clip could be bent back and forth several more times and still
not break. However after a sufficient number of bending
(i.e., load) cycles, the paper clip will break under this
repetitive loading. Purely elastic deformation (i.e., without
yielding) cannot cause a cyclic fatigue failure.
The fatigue strength of a material under cyclic loading can
then be defined as the ability to withstand repetitive loading
without failure. The number of cycles to failure of a material
decreases as the stress resulting from the applied load
increases.
76
B.
Corrosion Resistance
Corrosion of materials involves deterioration of the metal by
chemical or electrochemical attack. Corrosion resistance is usually
the single most important factor that influences pipe material
selection. Table 3.1 summarizes the typical types of piping system
corrosion.
General or Uniform
Corrosion
Pitting
Corrosion
Galvanic Corrosion
Crevice Corrosion
Concentration Cell
Corrosion
Graphitic Corrosion Occurs in cast iron exposed to salt water or weak acids. Reduces
iron in the cast iron and leaves the graphite in place. Result is
extremely soft material with no metal loss.
Heat treatment.
Grain size.
Fabricability
A material must be available in the shapes or forms that are
required, and it typically must be weldable. In piping systems,
some common shapes and forms include the following:
E.
Seamless pipe.
Cast valves.
78
IV.
PIPING COMPONENTS
A.
Pipe Fittings
Fittings are used to make some change in the geometry of a
piping system. This change could include:
Terminating a pipe.
90
45
180 Return
Elbow and Return
Figure 4.1
79
A straight tee has equal diameters for both the run and
branch pipe connections.
Tee
Figure 4.2
A reducer (illustrated in Figure 4.3) changes the diameter in
a straight section of pipe. The centerlines of the large and
small diameter ends coincide in a concentric reducer,
whereas they are offset in an eccentric type.
Concentric
Eccentric
Reducer
Figure 4.3
80
Cap
Figure 4.5
A lap-joint stub end (Figure 4.6) is used in conjunction with
lap-joint flanges.
R
R
Enlarged Section
of Lap
Lap-Joint Stub End
Figure 4.6
81
2.0
Flanges
A flange connects a pipe section to a piece of equipment,
valve, or another pipe such that relatively simple
disassembly is possible. Disassembly may be required for
maintenance, inspection, or operational reasons. Figure 4.7
shows a typical flange assembly. Flanges are normally used
for pipe sizes above NPS 1.
Flange
Bolting
Gasket
82
Threaded Flanges
Flat Faced
Socket-Welded Flanges
Blind Flanges
Raised Face
Slip-On Flanges
Lapped Flanges
Ring Joint
83
84
3.0
Gaskets
A gasket is a resilient material that is inserted between the
flanges and seated against the portion of the flanges called
the face or facing. The gasket provides the seal between
the fluid in the pipe and the outside, and thus prevents
leakage. Bolts compress the gasket to achieve the seal and
hold the flanges together against pressure and other
loadings.
The three gasket types typically used in pipe flanges for
process plant applications are:
B.
Sheet.
Spiral wound.
Flange Rating
ASME B16.5, Pipe Flanges and Flanged Fittings, provides steel
flange dimensional details for standard pipe sizes through NPS 24.
Specification of an ASME B16.5 flange involves selection of the
correct material and flange "Class." The paragraphs that follow
discuss the flange class specification process in general terms.
Flange material specifications are listed in Table 1A in ASME B16.5
(excerpted in Table 4.2). The material specifications are grouped
within Material Group Numbers. For example, if the piping is
fabricated from carbon steel, the ASTM A105 material specification
is often used. ASTM A105 material is in Material Group No. 1.1.
Refer to ASME B16.5 for additional acceptable material
specifications and corresponding Material Group Numbers.
85
86
Material Group
No.
Classes
Temp., F
-20 to 100
200
300
400
500
600
650
700
750
800
850
900
950
1000
1.8
150
235
220
215
200
170
140
125
110
95
80
65
50
35
20
300
620
570
555
555
555
555
555
545
515
510
485
450
320
215
1.9
400
150
825
765
745
740
740
740
740
725
685
675
650
600
425
290
300
290
260
230
200
170
140
125
110
95
80
65
50
35
20
750
750
720
695
695
605
590
570
530
510
485
450
320
215
1.10
400
1000
1000
965
885
805
785
785
710
675
650
600
425
290
190
150
290
260
230
200
170
140
125
110
95
80
65
50
35
20
300
750
750
730
705
665
605
590
570
530
510
485
450
375
260
400
1000
1000
970
940
885
805
785
755
710
675
650
600
505
345
87
SOLUTION
Determine the Material Group Number for the flanges by referring to ASME Table
1A (excerpted in Table 4.2). Find the 1 Cr Mo material in the Nominal
Designation Steel column. The material specification for forged flanges would be
A182 Gr. F11, and the corresponding material Group Number is 1.9.
Refer to Table 2 for Class 150 (excerpted in Table 4.3). Read the allowable
design pressure at the intersection of the 700F design temperature and Material
Group 1.9. This is only 110 psig and is not enough for this service.
Now check Class 300 and do the same thing. The allowable pressure in this
case is 570 psig, which is acceptable.
The required flange Class is 300.
88
V.
VALVES
A.
Valve Functions
The possible valve functions must be known before being able to
select the appropriate valve type for a particular application. Fluid
flows through a pipe, and valves are used to control the flow. A
valve may be used to block flow, throttle flow, or prevent flow
reversal.
1.0
Blocking Flow
The block-flow function provides completely on or completely
off flow control of a fluid, generally without throttling or
variable control capability. It might be necessary to block
flow to take equipment out of service for maintenance while
the rest of the unit remains in operation, or to separate two
portions of a single system to accommodate various
operating scenarios.
2.0
Throttling Flow
Throttling may increase or decrease the amount of fluid
flowing in the system and can also help control pressure
within the system. It might be necessary to throttle flow to
regulate the filling rate of a pressure vessel, or to control unit
operating pressure levels.
3.0
89
B.
Gate Valve
Most valves in process plants function as block valves.
About 75% of all valves in process plants are gate valves.
The gate valve is an optimum engineering and economic
choice for on or off service. The gate valve is not suitable to
throttle flow because it will pass the maximum possible flow
while it is only partially open. Figure 5.1 illustrates a typical
full-port gate valve.
90
1.
Handwheel Nut
2.
Handwheel
3.
Stem Nut
4.
Yoke
5.
Yoke Bolting
6.
Stem
7.
Gland Flange
8.
Gland
9.
Gland Bolts or
Gland-Eye Bolts
and Nuts
Globe Valve
The globe valve is the type most commonly used to throttle
flow in a process plant. In the smaller sizes, they are
91
Check Valve
Check valves prevent flow reversal. Typical check valve
applications are in pump and compressor discharge piping
and other systems that require protection against backflow.
Valves which contain a disc or discs that swing out of the
flow passage area usually create a lower pressure drop in
the system than those which contain a ball or piston
element. These latter elements remain in the flowstream
and the port configurations frequently include an angular
change in flow direction. For all process designs, the
intended purpose of check valves is to prevent gross flow
reversal, not to effect complete leakage-free, pressure-tight
shutoff of reverse flow.
The selection of a particular check valve type generally
depends on size, cost, availability, and service. Ball and lift
check valves are usually the choice for sizes NPS 2 and
smaller, while swing check and plate check valves are used
in the larger sizes.
3.1
Cap
Pin
Seat
Ring
Hinge
Flow
Direction
Disc
Body
93
94
Seat
Ring
Piston
Flow
Direction
95
Figure 5.5
3.5
Ball Valve
Ball valves (Figure 5.6) usually function as block
valves. Ball valves are well suited for conditions
where quick on/off and/or bubble-tight shut-off is
required. The pressure/temperature ratings for ball
valve soft seats above ambient temperatures are
usually lower than the ASME ratings for steel valves.
This is because of the lower physical properties of the
soft-seat materials. Soft-sealed ball valves are not
normally used for throttling service because the softseats are subject to erosion or distortion/displacement
caused by fluid flow when the valve is in the partially
open position.
96
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part Names
Body
Body Cap
Ball
Body Seal Gasket
Seat
Stem
Gland Flange
Stem Packing
Gland Follower
Thrust Bearing
Thrust Washer
Indicator Stop
Snap Ring
Gland Bolt
Stem Bearing
Body Stud Bolt & Nuts
Gland Cover
Gland Cover Bolts
Handle
Ball Valve
Figure 5.6
3.6
Plug Valve
Plug valves (Figure 5.7) usually function as block
valves. They are well suited for conditions where
quick on/off and/or bubble-tight shutoff is required.
The soft-seal-types may have lower
temperature/pressure ratings than the ASME ratings
for steel valves because of the lesser physical
properties of the soft-seat materials. Soft-seal plug
valves are not normally used for throttling service
since the soft seals are subject to erosion or
distortion/displacement caused by fluid flow when the
valve is partially open.
97
Wedge
Sealing Slip
Plug Valve
Figure 5.7
C.
1 Cr Mo
Flanges:
Design Temperature:
900F
Design Pressure:
375 psig
99
VI.
DESIGN
A.
Design Conditions
1.0
General
Normal operating conditions are those expected to occur
during normal operation, excluding failure of any operating
device, operator error, and the occasional, short-term
variations stated in the applicable code. Startup and
controlled shutdown of plants and similar foreseeable
events are included within normal operation.
Design conditions are those which govern the design and
selection of piping components, and are based on the most
severe conditions expected to occur in service. A suitable
margin is used between the normal operating and design
conditions to account for normal operating variations.
ASME B31.3 does not specify what margins should be used
between operating and design conditions; suitable margins
are determined by the user based on his experience.
2.0
100
101
Sl
Sc
P
t
Sl
Longitudinal Stress
Sc
Wall Thickness
Internal Pressure
Stress Categorization
To evaluate the stresses in a piping system, it is necessary
to distinguish among primary, secondary, and peak stresses.
3.0
Allowable Stresses
The basic allowable stress is a function of material
properties, temperature, and safety factors. The basic
allowable stress provides an upper limit for the actual
stresses.
103
Sustained loads
Occasional loads
104
Spec. No/Grade
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
Carbon Steel
A 106
20.0
20.0
20.0
20.0
18.9
17.3
16.5
10.8
6.5
2.5
1.0
C - Mo
A 335
P1
18.3
18.3
17.5
16.9
16.3
15.7
15.1
13.5
12.7
4.
2.4
1 - Mo
A 335
P11
20.0
18.7
18.0
17.5
17.2
16.7
15.6
15.0
12.8
6.3
2.8
A 312
TP304
20.0
20.0
20.0
18.7
17.5
16.4
16.0
15.2
14.6
13.8
9.7
6.0
3.7
2.3
1.4
16Cr - 12Ni-2Mo
pipe
A 312
TP316
20.0
20.0
20.0
19.3
17.9
17.0
16.3
15.9
15.5
15.3
12.4
7.4
4.1
2.3
1.3
1.2
General
Two different types of pressure may be imposed on a piping
system: external or internal. Most piping systems need only
be designed for internal pressure. Some piping systems
may be subject to a negative pressure or vacuum condition
during operation (e.g., process vacuum conditions, steamout, underwater lines, etc.) and must be designed for
external pressure. This section only discusses the internal
pressure design of straight sections of pipe. Refer to ASME
B31.3 for design requirements for external pressure.
2.0
1500
PD
2 (SE + PY )
Where:
t
105
106
Spec.
No.
Description
Ej
Carbon Steel
API
5L
...
...
...
Seamless pipe
Electric resistance welded pipe
Electric fusion welded pipe, double butt, straight or
spiral seam
Furnace butt welded
1.00
0.85
0.95
A 53
Type S
Type E
Type F
Seamless pipe
Electric resistance welded pipe
Furnace butt welded pipe
1.00
0.85
0.60
A 106
...
Seamless pipe
1.00
...
...
Seamless pipe
Electric resistance welded pipe
1.00
0.85
A 335
...
Seamless pipe
1.00
Stainless Steel
A 312
...
...
...
Seamless pipe
Electric fusion welded pipe, double butt seam
Electric fusion welded pipe, single butt seam
1.00
0.85
0.80
A 358
1, 3, 4
5
2
1.00
0.90
0.85
...
1.00
B 514
...
Welded pipe
0.80
B 675
All
Welded pipe
0.80
107
Temperature, F
Materials
950
1000
1050
1100
1150 & up
Ferritic
Steels
0.4
0.5
0.7
0.7
0.7
0.7
Austenitic
Steels
0.4
0.4
0.4
0.4
0.5
0.7
Other
Ductile
Metals
0.4
0.4
0.4
0.4
0.4
0.4
Cast iron
0.0
...
...
...
...
...
108
t nom =
tm
0.875
Where:
tnom = Minimum required nominal pipe wall thickness, in.
Each pipe size has several standard nominal thicknesses
that are available. The nominal pipe thickness that is
specified for a system must be selected from those readily
available and be at least equal to tnom.
3.0
109
SOLUTION
The following equation applies:
t=
PD
2 (SE + PY )
1,380 psig.
14 in.
Since all the required parameters have now been determined, the required
internal pressure thickness may be calculated as follows:
110
1,380 14
2 [(16,150 1) + (1,380 0.4)]
t = 0.577 in.
t=
4.0
tm
t + c = 0.577 + 0.0625
tm
0.6395 in.
tnom =
0.6395
= 0.731 in.
0.875
111
4.1
Tb
Reinforcement
Zone Limits
Nom.
Thk.
tb
Mill
Tol.
A3
A3
L4
Reinforcement
Zone Limits
A4
A4
A1
Tr
Th
Dh
Nom.
Thk.
th
d1
A2
Mill
Tol.
A2
d2
d2
Pipe C
112
Reinforcement Area
The required reinforcement area is based on the
metal area removed. This is calculated using:
d1 =
D b 2(Tb c )
sin
Where:
d1
Db
Tb
113
Where:
th
4.5
Reinforcement Pad
Additional branch reinforcement is needed when the
required area exceeds the available area, and may be
provided by locally increasing the thickness of either
the header or branch pipe. However, it is usually
more economical to provide a reinforcement pad to
supply the additional reinforcement.
There are three variables to select in designing the
reinforcement pad:
Material
Outside diameter
Wall thickness
(D p D b )
A 4 =
Tr
sin
Where:
D01p = Outside diameter of the pad, in.
Db =
Tr =
114
115
SAMPLE PROBLEM 3
A new steam turbine is being installed within a process plant. This will require a
new NPS 16 steam supply line to be connected to an existing NPS 24 distribution
header. The following design information has been determined:
Pipe material - Seamless, A 106/Gr. B for both the branch and header.
Design temperature
700F
Design pressure
550 psig
Allowable stress
16,500 psi.
Corrosion allowance
0.0625 in.
Mill tolerance
12.5%
Nominal Pipe
Thicknesses
Required Pipe
Thicknesses for Pressure
The branch connection is made on top of the header at a 90 angle, and does
not penetrate a header weld.
SOLUTION
See Figure 6.2 for the relevant nomenclature.
Next, the value for the effective length removed from the run pipe, d1, must be
calculated. This equals the corroded inside diameter of the branch
connection after accounting for mill tolerance (i.e., the actual pipe wall
thickness may be up to 12.5% less than the nominal thickness).
d1 =
Db 2(Tb c )
sin
116
d1 =
d1 = 15.469 in.
The available reinforcement areas in the header and branch pipe are now
calculated. This is determined using any excess thickness available in the
header and branch that is not necessary to withstand the pressure (or other)
loads. Disregard any contribution from nozzle attachment welds since this is
minimal.
A2 = (2d2 d1)(Th th c )
First determine d2 which is the greater of d1, or,
(Tbc ) + (Thc ) +
d1
2 , but less than the header diameter, Dh
= 8.43 in.
117
A3 =
2L4(Tb tbc )
sin
L4 =
0.664 in.
A3 =
A3 = 0.003 in.2
A2 + A3 + A4
AT =
0.53 + 0.003 + 0
AT =
The available total reinforcement of 0.533 in.2 is obviously much less than the
required reinforcement area of 6.11 in.2. Therefore, a reinforcing pad is
required. The reinforcement pad will now be sized.
118
A106, Gr. B material will be used for the reinforcement pad. Its thickness is
set to be equal to the header nominal thickness of 0.562 in.
2.5 (Th - c)
L41 =
L41 =
1.073 in.
L42 =
2.5 (Tb - c) + Tr
L42 =
L42 =
1.16 in.
2L 4 (Tb t b c)
sin
A3 =
119
A4 =
6.11 - 0.535
A4 =
5.575 in.2
A4
Db
+
Tr sin
5.575
+ 16
0.492
D p = 27.3 in.
Dp =
120
EXERCISE 2:
A new project is being considered to transport 48 API crude oil in a carbon steel
pipe between two areas within a tank farm. The fluid being transported will have
a design temperature of 260F. The system design pressure is 150 psig, the
pipe outside diameter is 30 in., and the pipe being used is A 106, Gr. B seamless
pipe. A corrosion allowance of 1/8 in. has been specified for the pipe. All piping
within the tank farm is designed in accordance with ASME B31.3. Assume there
is a 12.5% mill tolerance.
a.
b.
Use Table 6.1 along with Tables 6.2 and 6.3 for the necessary information.
121
VII.
SYSTEM DESIGN
A.
Layout Considerations
Operational, maintenance, and safety considerations influence the
layout of a piping system. These factors must be recognized when
designing the layout and spacing of piping and equipment. This
section discusses how these factors influence piping layout.
1.0
Operations Requirements
Operating and control points (e.g., valves, flanges,
instruments, sample points, drains, and vents) should be
located so that they can be used safely and easily. For
example, valves must be located so that they can be
reached.
There must be enough clearance above and below the pipe
to perform basic operations on valves and flanges.
There must also be enough lateral space to access valves,
sample points, vessel flanges, and other equipment that may
require operator attention.
2.0
Maintenance Requirements
The piping system must be laid out so that its components
can be inspected, repaired, or replaced with minimum
difficulty. There must be ample clearance for maintenance
equipment (e.g., cranes) and for vehicles (e.g., trucks).
Access must be provided so supports can be maintained.
There must be enough space to access and remove large
pieces of equipment if they require maintenance.
122
3.0
Safety Considerations
Piping layout must consider the safety of personnel near the
pipe. This specifically includes access for fire fighting
equipment and fire prevention. Fire fighting equipment
needs clearance to access major pieces of equipment (e.g.,
heat exchangers, vessels, and tankage). Pipeways must be
routed and designed to provide the necessary clearances.
There must be enough space beneath pipeways for people
to walk and work. Firewater piping must be routed so that it
would not be damaged by piping containing hazardous fluids
that could rupture.
B.
Design temperature.
123
1.0
Rigid Supports
Rigid supports are used in situations where weight support is
needed and no provision to permit vertical thermal
displacement is required. A rigid support always will prevent
vertical movement downward, will sometimes prevent
vertical thermal movement upward, and will permit lateral
movement and rotation. See Figure 7.1.
Shoe
Base Adjustable
Support
Saddle
Dummy Support
Trunnion
Rigid Supports
Figure 7.1
Hangers are a type of rigid support. They support pipe from
structural steel or other facilities that are located above the pipe
and carry piping weight loads in tension. Pipe hangers are typically
124
Hangers
Figure 7.2
2.0
Flexible Supports
Flexible or resilient supports allow the piping system to move
in all three directions while still supporting the required
weight load. Weight is supported by the use of a coil spring
having an appropriate stiffness to carry the applied weight
125
Small Change in
Effective Lever Arm
Large Change in
Effective Lever Arm
Relatively
Constant
Load
Typical Variable-Load
Spring Support
Typical Constant-Load
Spring Support Mechanism
Flexible Supports
Figure 7.3
3.0
Restraints
Restraints have two primary purposes in a piping
system.
126
Anchors
An anchor is a special type of restraint that stops
movement in all three directions. Anchors provide full
fixation of the pipe, permitting very limited, if any,
translation or rotation. An anchor is used in situations
where it is necessary to totally isolate one section of a
piping system from another from the standpoint of
load and deflection. A total anchor that eliminates all
translation and rotation at one location is not used as
commonly as one or more restraints that act at a
single location. A directional anchor which restrains
the line only in its axial direction is more commonly
used. Figure 7.4 provides several examples of
anchors.
127
Anchor
Anchor
Partial Anchor
Restraints/Anchors
Figure 7.4
3.3
Guides
A guide is a particular type of restraint that permits
movement along the pipe axis while preventing lateral
movement. Depending on the particular guide details
employed, pipe rotation may or may not be restricted.
Common situations where guides are used are in long
pipe runs on a pipe rack to control thermal movement
and prevent buckling, and in straight pipe runs down
the side of a tower to prevent wind-induced
movement and control thermal expansion. See
Figure 7.5.
128
Guide
Guide
Guide
Vertical Guide
Examples of Guides
Figure 7.5
C.
Piping Flexibility
Piping must have sufficient flexibility to accommodate thermal
expansion (or contraction) effects. Piping systems must be
designed to ensure that they do not fail because of thermal
stresses or produce excessive forces and moments at connected
equipment. If a system does not provide adequate flexibility, the
results can be leaky flanges, fatigue failure of the pipe, excessive
maintenance, operations problems, and damaged equipment.
129
130
2.0
Approaches to Design
Due to the complexity of the piping flexibility and support
design process, there is no single procedure or design
method applicable for all situations. The following is one
way to approach the problem.
Layout geometry.
End-point movements.
131
D.
End-point movements.
132
Equipment Item
Industry Standard
Parameters Used
To Determine
Acceptable Loads
Centrifugal Pumps
API-610
Nozzle size
Centrifugal Compressors
API-661
Nozzle size
Tank Nozzles
API-650
Steam Turbines
NEMA SM-23
Nozzle size
133
F.
Type Of Piping
General piping
4
8
12
20
3
4
12
Maximum Differential
Flexibility Temp.
400F
300F
200F
any
Any
Any
Any
134
1.0
Stable
Operation
Startup and
Shutdown
Gives the temperature range expected for most of the time a plant is in
operation. Some margin above equipment operating temperature (i.e.,
use of the design temperature rather than operating temperature)
allows for process flexibility.
Must be examined to determine if the heating or cooling cycles pose
flexibility problems. For example, if a tower is heated while some
attached piping remains cold, the piping flexibility should be checked
for that case.
Regeneration
and Decoking
Piping
Spared
Equipment
135
Loss of Cooling
Medium Flow
Most on-site equipment and lines, and many off-site lines, are
freed of gas or air by the use of steam. For 125 psig steam,
300F is typically used for the metal temperature. Piping
connected to equipment which will be steamed out, especially
piping connected to the upper parts of towers, should be
checked for the tower at 300F and the piping at ambient plus
50F. This situation may govern the flexibility of lines connected
to towers that operate at less than 300F or that have a smaller
temperature variation from top to bottom.
No Process Flow
While Heating
Continues
136
2.0
Extent of Analysis
The extent of a piping system analysis depends on the
situation. The overall purpose of the analysis is to provide
enough flexibility for the system. The engineer must analyze
the right combination of operating conditions to determine
where, and if, additional flexibility is needed to reduce pipe
stresses or loads at end points. The engineer must also
decide if it is desirable and acceptable to not include portions
of a large, complex system in the analysis to simplify the
modeling. For example, including an NPS 4 branch run in
the model of a NPS 24 main system may not be necessary.
Judicious installation of anchors or other restraints in a large
system could also help simplify the modeling by separating
the system into sections.
Use the following steps to develop the piping design:
3.0
137
4.0
138
the tank nozzle. When the tank is filled with liquid, the
shell will bulge outward and the nozzle will rotate down
due to this shell bulging (see Figure 7.7). Over a period
of time, the tank may also settle down into its foundation
with respect to the pipe. Because of these expected tank
movements, it is often necessary to use a flexible-type
pipe support located near the tank nozzle to ensure that
the tank nozzle is not overloaded.
SHELL
NOZZLE
BOTTOM
Tank Nozzle
Figure 7.7
139
Butt-Welds
Butt-welds are made between two components whose edges
are in close proximity. Butt-welded joints in piping systems
are primarily of the single-V configuration and are welded
from the pipe outside surface. The joint preparation and the
procedure that is used ensure that there is complete fusion
between the edges of the components being joined. Joint
designs shown in Figure 8.1 are typically used for ends of
equal thickness. The transition between ends of unequal
thickness may be accomplished by taper grinding the thicker
pipe to match the thinner, or by using weld metal to provide
a smooth transition as shown in Figure 8.2. Butt-welds are
always used to weld pipe ends together, to weld butt-weldtype flanges or fittings to pipe ends, or to weld the edges of
formed plate together when plate is used to manufacture
pipe.
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(b)
(c)
(d)
Butt-Welded Joint Design
Unequal Thickness
Figure 8.2
2.0
Fillet Weld
The fillet weld generally requires no special joint preparation.
It is an angular weld bead that joins components normally
positioned at a 90 angle to each other. The size of a fillet
weld is stated as a leg length of the largest inscribed right
isosceles triangle. In piping systems, fillet welds are only
used for slip-on flanges, socket welds, and for welding
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Fillet Welds
Figure 8.3
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3.0
4.0
Preheating
Preheating is used, along with heat treatment, to minimize
the detrimental effects of high temperature and severe
thermal gradients that are inherent in welding. The following
identifies the benefits of preheating:
5.0
143
B.
144
2.0
The tolerance for axial dimensions, face-to-face, centerto-face, and location of attachments should be 1/8 in.
maximum.
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3.0
146
147
148
6.0
For the most critical high-temperature or highpressure flanges, use a method that permits
measuring the applied load (i.e., torque wrench or
stud tensioner). In this way, there is greater
assurance that uniform bolt load is achieved. For
such applications, a maximum stud stress during
boltup of 40-50,000 psi is the normal target.
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150
IX.
QUALITY CONTROL
A.
Inspection
Prior to initial operation, each piping installation, including individual
components and overall workmanship, shall be examined. The
following requirements are based on ASME B31.3.
Defects must be identified before a piping system can be tested or
go into operation. Defect identification is especially important in
welded areas. A good weld starts with a proper design and is
executed using a qualified procedure and welder. However, the
quality that is achieved in a particular instance may not be
acceptable for a variety of reasons. The method of weld
examination needed to ensure that welds of acceptable quality are
achieved must be specified. Not all welds are inspected in the
same manner. Determining the proper type of weld inspection is a
function of technique, weld type, anticipated type of defect, location
of weld, and pipe material.
The following are common weld defects (illustrated in Figure 9.1):
Undercut.
Cracks.
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152
Type of Inspection
Visual
Situation/Weld Type
All welds
Radiography
Magnetic Particle
Liquid Penetrant
Ultrasonic
Defect
Cracks
Slag inclusions
Butt welds
Gas pockets
Girth welds
Slag inclusions
Incomplete penetration
Ferromagnetic materials
Cracks
Porosity
Lack of fusion
Cracks
Seams
Porosity
Folds
Inclusions
Shrinkage
Surface defects
Laminations
Subsurface flaws
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B.
Not less than 5% of all brazed joints shall be examined, by inprocess examination.
Testing
The piping system must be pressure tested after it has been
completely fabricated, erected, and inspected. The pressure test
demonstrates the mechanical integrity of the system before it is
placed into operation. The following highlights several test
requirements.
1.5 PS T
S
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Where:
c)
PT
ST
155
X.
OTHER CONSIDERATIONS
A.
Nonmetallic Piping
The following highlights several aspects of nonmetallic piping
design. Refer to ASME B31.3 for additional details.
Examples of nonmetallic piping include:
Leakage at joints.
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B.
157
C.
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2.0
Allowable stresses.
Examination
While the examination of High Pressure Piping is very similar
to that of piping in normal fluid service, it must be more
extensive. For example, in normal fluid service, a sample
selected at random per the inspector's judgement is
sufficient to make a determination as to the acceptability of
the material. In high pressure piping, 100% of the material
and components must be examined. Also, only 5% of the
fabrication must be examined for normal fluid service,
whereas 100% of fabrication must be examined in high
pressure piping.
3.0
Testing
Prior to initial operation, each piping system shall be either
hydrostatically or pneumatically leak tested. Each weld and
each piping component (except bolting and individual
gaskets to be used during final assembly) shall be tested. If
the testing is done on the equipment prior to installation, an
additional test of the installed piping system shall be
conducted at a pressure not less than 110% of the design
pressure. If the initial testing is done on the installed piping,
then the additional test is not necessary.
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XI.
SUMMARY
A process plant piping system includes much more than just straight sections of
pipe. It also includes fittings, flange assemblies, valves, pipe supports, and
restraints. ASME B31.3 specifies the design, materials, fabrication, erection,
inspection, and testing requirements for process plant piping systems. This
course provided an overview of process plant piping system requirements,
including items that are not explicitly included in B31.3 (e.g., valve selection and
design, flexibility analysis guidelines, equipment nozzle load requirements, etc.).
Participants can use this information on their jobs, and are prepared to take more
extensive courses if appropriate.
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