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Creating The Plant Pipe Code
Creating The Plant Pipe Code
W.N. Weaver, PE
1.
INTRODUCTION
Pipes codes are used to standardize piping practices in a facility, to ensure each fluid is
conveyed in the appropriate materials, to control piping costs and to ensure plant safety.
There are multiple pipe codes in use in the various industries involved with pipe; some
are listed below:
ASME BPE
ASME B31
Most process plants have pipe codes in place which are used for bidding, construction,
new design planning, and repairs. Several points will indicate some of the benefits of
internal pipe codes.
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Pressure safety
Ensures proper wall thickness, connection types and gasketing to hold the
required pressure
Consistency of connection types
Ensures proper joint efficiencies, gaskets and flange types to maintain design
conditions
Consistency in materials of construction for specific fluids
Ensures corrosion is controlled
Pre use testing of new and or repaired pipe lines
Provides standardized testing for all pipe codes
Proper gasket materials selection
Ensures gaskets reflect corrosion research and pressure requirements
Proper structural support for pipe lines
Provides pipe span details for each pipe size and schedule
Control of fugitive emissions from the piping system
Reduces fugitive emissions by reducing leaks from improperly selected
connections
Reduction or elimination of contamination of raw materials and products
Reduces corrosion contamination by ensuring proper materials for each fluid
Reduction in leakage which results in money saved in raw materials and finished
product, reduces environmental problems, reduces fire and injury hazards
Maximizes control of leakage by ensuring proper gaskets and joint types
Some cities and counties have had individual disaster experiences, which have caused
them to institute pipe codes for specific materials within their political jurisdictions.
These may well be more restrictive than the recognized national codes.
Certain areas of the country exposed to hazards specific to their locations have added
requirements to piping systems which, are more restrictive than those in other areas. As
an example you would expect California to have more requirements for pipe supports on
hazardous materials than non earthquake prone areas.
Individual facility pipe codes can generally be more restrictive than nationally recognized
codes. Great care and consultation with the company legal and insurance departments are
called for if the developed pipe code is less restrictive than the national standard.
3.
Why not just use an existing nationally recognized code? Lets look at various materials
in pipes and see if we can find justification for facility specific pipe codes.
Compressed Air
Over the years I have seen or installed compressed air piping systems using the following
types of pipe:
Carbon steel, schedules 40 and 80
Stainless steel, schedules 5, 10, 20 and 40 using 304 and 316
Copper, K, L and M
2008 W.N. Weaver, PE
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Page 4 of 19
It is not necessary that all pipe codes contain all of the above items, later well see how to
determine what is needed for your facility and how the facility can benefit by using a
home grown pipe code.
5.
Invariably pipes must be connected to other pipes, valves, instruments and equipment.
How these connections are made is critical to the longevity of the piping system and the
cost of maintenance. Additionally these connections frequently limit the allowable
pressure of the system.
Piping connections need to offer some or all of the following characteristics:
Pressure tightness
Fluid tightness
Material compatibility
Temperature capability
Corrosion resistance
Connection rigidity
Connection longevity
Relative ease of use
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6.
POINTS TO CONSIDER
Most pipes have several mechanical properties to be considered when being selected for a
specific task. Lets look at the two characteristics most often considered; Pressure Rating
and Allowable Temperature.
PRESSURE
Pipes have four pressures of importance.
TEMPERATURE
We also have several temperatures to consider.
Note that metal pipe (actually almost all pipe) has a temperature / pressure curve which
means that Design Pressure and Design Temperature must be considered together. As a
general rule metal pipe will withstand less pressure at higher temperature and in some
cases at lower temperatures as well. This tells us we must know the maximum expected
Operating Temperature before we can actually select a suitable material of construction
2008 W.N. Weaver, PE
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for the pipe. We must combine this information with the Design Pressure and potential
for corrosive attack in order to select the proper material.
This should be clearer if we look at some actual pipe ratings verses temperatures. First
lets see what happens to the allowable stress, S, for A106 steel verses temperature. A106
is a common steel specification for pipe.
TEMPERATURE, F
ALLOWABLE STRESS, S, psi
150
12,000
250
11,520
350
11,040
400
10,800
500
10,320
TEMPERATURE, F
ALLOWABLE STRESS, S, psi
600
9,840
700
9,100
800
7,250
900
4,400
950
2,600
Note that the Allowable Stress decreases with rising temperature, this means we must
reduce the Operating Pressure as the temperature climbs, we must also reduce the Design
Pressure as the temperature rises. For some carbon steel alloys we also have a lower
acceptable operating temperature. Although not simply a pressure problem some carbon
steel alloy pipes become brittle below certain temperatures. For A105 that temperature is
about 20 F.
Therefore our Design Pressure / Design Temperature numbers need to take into account
both the reduction in Allowable Stress and the increase in low temperature shock
sensitivity for carbon steel pipe. Most pipe materials will experience a range of
temperatures below and above which they should not be used. Polymeric piping materials
have a relatively narrow temperature range between too brittle for use and too weak for
use because of loss of tensile strength caused by an increase in temperature.
The following shows what happens to Maximum Allowable Pressure, psig, for 2 inch
A106 Grade B schedule 40 steel pipe as the temperature rises. Reference ASME B31.1.
TEMPERATURE, F
ALLOWABLE PRESSURE, psi
100
1,783
200
1,783
300
1,783
400
1,783
TEMPERATURE, F
ALLOWABLE PRESSURE, psi
600
1,783
650
1,783
700
1,712
750
1545
500
1,783
Notice that the Allowable Pressure remains constant until we reach over 650 F. This
reflects the decrease in strength for carbon steel as the temperature rises; up to about 650
F the change in allowable stress per 100 degrees temperature rise is around -4%, at 650
the change jumps to -7.5% and continues to rise from there on.
Pipe burst strength and design pressures relate directly to allowable stress. The following
is the burst pressure for various sizes of schedule 40 wrought carbon steel pipe at
constant temperature. The decrease in burst strength is related to the decrease in hoop
strength. Allowable stress remains constant at constant temperature. Hoop strength
calculations incorporate Allowable Stress, diameter and wall thickness. This combination
2008 W.N. Weaver, PE
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causes the burst strength to decrease as diameter increases. Burst Pressure P = 2tS/D
where t = thickness, S = Allowable Stress and D = diameter.
SIZE, INCHES
BURST PRESSURE, PSI
10,380
8,610
1
8,090
1 &
6,745
1 &
6,100
2
5,185
Were only interested in burst pressure in that it reflects on our safety factor; we would
never knowingly design or operate at or even near the burst pressure. ASME, other codes,
various government agencies and insurance companies dictate how closely we may
approach the burst pressure for a piece of pipe.
Following all this verbiage we need to select our design pressures based on a variety of
physical properties; most of the time it is easier and safer to accept allowable pressures
from someone like ASME and keep our design pressures at or below these values.
7.
Generally all piping systems should be included in the plant pipe codes. These codes are
a tool for engineering, estimating, maintenance, construction and purchasing to use to
ensure proper piping installation in the plant therefore the maximum number of piping
systems should have specific codes created for them.
The field of pipe codes can be broad so to limit the topic we will concentrate on standard
pipe materials and common connection approaches. Understanding the necessary steps to
be used to develop one pipe code applies to all other codes. Most process facilities have
some or all of the following piping systems in use:
Utilities
Steam
Condensate
Tower Water
Compressed Air
Fuel Gas
Potable Water
Fuel Oil
Waste Water
Nitrogen
Rain Water (from building roof)
Storm Water (underground)
Hot Oil
Chilled Water
Brine Systems
Refrigerant
Vacuum
Engine Exhaust Piping
Dust Collection Systems
Lubricant Systems
2008 W.N. Weaver, PE
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Process
Liquid Raw Materials (solvents, acids, caustics, other chemicals)
Finished Products
Heat Traced Pipe
Jacketed Pipe (heating or cooling)
Pneumatic Conveying Systems
Safety Systems
Sprinkler Piping
Safety Shower / Eyewash Stations
Pressure Relief Device Discharge Piping
Fire Lines
8.
A complete pipe code will contain significant information on the requirements the pipes
must meet during operation. Or stated differently, the pipe codes give us the acceptable
ranges of temperatures and pressures under which our facility has agreed a particular type
of pipe can be used. Notice that the authority in this case is our facility; it is no less an
authority than ASME or a local code and a violation of this code puts facility insurance
coverage in jeopardy. In the event of a failure of a piping system which results in lawsuits
the violation of a plant standard pipe code generally can be expected to have negative
effects in court.
The first activities in developing the code require we establish three process related
criteria:
Corrosion Resistance
For example this process requirement determines if we can
use carbon steel pipe or need a stainless alloy to resist the
effects of the fluids.
Operating Temperature This criteria separates polymeric materials from most
metallic piping materials and is the expected normal or
maximum temperature the system will experience.
Operating Pressure
This criteria with the first two provides the data necessary
to determine the required wall thickness for the pipe and is
the expected normal or maximum pressure the system will
see.
Corrosion resistance can be determined from a variety of corrosion tables (Perrys
Handbook, pipe manufacturers web sites, etc.), facility chemists and historical data from
the maintenance department. In addition to normal corrosion concerns maintenance
records, industry experience and insurance records may indicate problems with threaded
connections with some raw materials, utilities or finished products.
Design Temperature is selected based on Operating Temperature plus some tolerance to
allow for system deviation from normal operating conditions. Determining the tolerance
required can be complicated and needs to incorporate consideration of items like the
following:
2008 W.N. Weaver, PE
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Only a complete analysis of the system and its range of operations can lead to a
determination of the required tolerance for Design Temperature; for this reason facility
chemists, maintenance, R&D, Operations and engineering should all be involved in this
criteria development.
Design Pressure is selected based on Operating Pressure plus some tolerance to allow for
system deviation from normal operating conditions. Determining the tolerance required
can be complicated and needs to incorporate consideration of items similar to the
following:
Possible deadheading of pumps
Possible loss of temperature controls causing a rise in pressure
A change in reaction kinetics which could cause pressure rises.
System pressurization using inert gas
Thermal expansion of some fluids
Decisions about these three items will allow us to select the pipe and establish some
boundaries within which it must operate.
9.
EXAMPLE:
For our real life example let us assume that the plant has a 150 psig steam system fed
directly from the boiler through a reducing station and protected by a properly set and
sized relief device.
Corrosion Potential for Steam Piping System
Operating Pressure
Operating Temperature
Pipe Material
Carbon Steel
304 Stainless Steel
316 Stainless Steel
Galvanized Steel
Copper
Cast Iron
PVC
150 psig
365.9 F
Comments
Corrosion Potential
LOW
INDUSTRY STANDARD
NONE
EXPENSIVE
NONE
EXPENSIVE
PLATING PROBLEMS GALVANIZING MAY
FLAKE OFF UNDER
CONTINOUS USE
VERY EXPENSIVE
NONE
DOESNT MEET SOME
LOW
CODES
NONE
ABOVE TEMPERATURE
USE LIMITS
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From the table we can see that carbon steel is probably the least expensive choice and has
a long history in this fluid service.
From earlier data we can safely use carbon steel at 650 F, well above our Operating
Temperature.
Now all that is left is to select the applicable wall thickness, or schedule number. There
are multiple sources of allowable pressures, and calculation methods to determine
schedule numbers and burst pressures. So many sources that it sometimes becomes
difficult to select the appropriate data source. See the References section for some
additional sources.
Well use a commonly available source, the ASME table in B31.1 for A106 carbon steel
pipe. The selection of a commonly used national standard as an allowable pressure
reference usually provides adequate liability protection for the engineer. The following
table for our 2 inch pipe gives us the data we need.
TEMPERATURE, F
ALLOWABLE PRESSURE, psig
100
1,783
200
1,783
300
1,783
400
1,783
TEMPERATURE, F
ALLOWABLE PRESSURE, psig
600
1,783
650
1,783
700
1,712
750
1545
500
1,783
We can now establish the basics for the pipe code for 150 psig steam at 365.9 F to be:
Schedule 40 Carbon Steel Pipe
10.
CONNECTIONS
Each pipe code needs to tell the user what method of connection between sections of
pipe, fittings, valves, instruments and equipment is acceptable. We can look at the most
common pipe connections for our steam line with some subjective comments. All of the
following connections provide adequate pressure capability when properly applied.
CONNECTION Ease of
Installation
THREADED
Easy
WELDED
Easy
FLANGED
Most Involved
Longevity
Fair
Excellent
Excellent
Maintenance
Concerns
High
None
Moderate
Cost
Structural
Integrity
Low
Fair
Low
Excellent
Moderate Excellent
Properly butt welded or socket welded pipe produces joints at least as strong as the pipe.
Threaded couplings and other fittings are rated by their pressure class and produce some
concern where flexing of the pipe might occur. The table below lists pressure verses
temperature rating for 150# and 300# threaded fittings.
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Temperature, F
200
300
500
150# Class
psig
All Sizes
265
150
to 1
1785
1360
510
300# Class
psig
1& to 2
1350
1050
450
2 & to 3
910
735
385
Pipe flanges also have their own set of classes including 125, 150, 300, 400, 600, 900,
1500 and 2500 # classes. Frequently individuals make the assumption that a 150#
flange is only good for 150 psig and end up spending extra dollars for heavier than
necessary flanges.
A 150# flange has the following temperature / pressure curve
TEMPERATURE
F
-20 to
100
ALLOWABLE
PRESSURE, psig
285
80
20
A second curve provides additional information necessary for pipe code creation. This
table details Allowable Pressure verses Flange Class at 300 F.
FLANGE CLASS, #
150
300 400
600
900
1500 2500
ALLOWABLE
PRESSURE, psig
230
NOTES
A facility may create pipe codes allowing for multiple methods of
connection; pipe codes allowing both welding and flanges are common.
A single pipe code usually covers a range of pipe sizes and may allow for
threads on small pipe, socket weld on some pipe and flanges only above a certain
size.
A single material of construction, pipe size and schedule number may
occur in several different pipe codes having different design pressures and
temperatures.
A pipe code is a Facility Tool and as such needs to be created to match the facilitys
needs and help the facility maintain piping system integrity.
Pipe flanges come in a variety of styles which need to be included in the pipe code:
Connection Type
Weld neck
Socket weld
Back up
Threaded
2008 W.N. Weaver, PE
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12.
Carbon Steel
Schedule 40 pipe is acceptable being rated at 1783
psig at 400 F
150 # flanges or welded
(a 150# flange is acceptable for 200 psig for an
operating temperature of 400 F which gives us a 50
psi and about 40 F tolerance)
300# threaded connections are good up to 280 psig
(interpolated from table data to 365.9 F)
WHAT IS LEFT?
Determining the extent of the pipe code contents is influenced by the fluid contents of the
pipe, system pressure, temperature, installation environment, facility needs and available
engineering time.
The following provides guidance for the remaining items which can be beneficial if
incorporated into a pipe code.
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13.
VALVES
14.
BRANCH
SIZE, in.
1
1 &
2
2
S
S
W
W
T
1 &
R
R
W
T
1
R
R
T
R
T
The selection of how branch connections are made belongs to the facility and is
influenced by pressure, temperature, fluid and pipe sizes involved. The goal is to produce
branch connections, which maintain the pipe code pressure rating. The sample table
above is interpreted as follows:
A Branch is connected to a 2 Header using Sock-O-Let (S)
A Branch is connected to a Header using a Reducing Tee (R)
A Branch is connected to a Header using a Tee (T)
15.
16.
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18.
Schedule #
40
80
Allowable Span
190
200
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19.
20.
21.
HEAT TRACING Depending on the type of heat tracing in use there may be a
need for a Heat Trace Pipe Code. Generally heat tracing is
accomplished using hot water, hot oil, steam or electric heat wire.
Most fluid trace system use copper or stainless steel tubing as the
trace piping and details on how it should be specified and installed
should be incorporated into a pipe code.
22.
HEAT OR COOLING JACKETING Pipe jackets are a separate pipe code and
require sketches and considerable detail for a pipe code. Jacket
pipe codes contain two sections: one for the core or inner pipe and
one for the jacketing pipe. This is generally a stand alone code
rather than a portion of another code and incorporates a variety of
information:
Pipe to be jacketed
Desired temperature within core pipe
Pressure in core pipe
Materials of construction of core pipe
Connection details for branches in core pipe
Jacketing pipe with sizes related to the core pipe
Jacketing pipe schedule
Jacketing termination at valves, fittings and equipment
Jacket connections and flow patterns
Jacket spacers designed to hold the jacket off the core pipe
This can quickly become very complicated and it may be necessary
to develop a jacketing standard independent of the pipe codes in
order to put in all the necessary details.
23.
ANCHORING All pipe requires support (see section on allowable spans) and
how the supporting is accomplished is a critical detail. Supports
include the following items:
Rigid anchors
Guides (to allow for thermal expansion or other movement)
Thrust
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TESTING
Page 17 of 19
When dealing with low pressure systems carrying non toxic, non environmentally
damaging fluids which offer no hazards to life testing may, at the engineers discretion
consist of a tightness test only. Basically a static liquid filled line with no pressure
applied.
The choice of testing fluids (water or air, etc) belongs to some extent to the engineer, to
recognized national standards and codes, the insurance company and local or national
authorities. Research in creating the pipe code usually will provide sufficient information
to guide the engineer in selecting the proper test procedure. Incorporating the test
procedure into the pipe code eliminates confusion and problems later.
CAUTION 1: It is generally not a good idea to pressurize equipment connected to piping
systems during pressure testing.
CAUTION 2: Using air for pressure testing must be considered very carefully. Pipe
failure under liquid pressure generally results in a short spurt of water whereas with air
the failure may well become explosive.
CAUTION 3: Frequently instrumentation is removed or valved off during hydrostatic
testing.
25.
PIPE FABRICATION
Metallic pipe can be fabricated in several ways and is classified in such as way as to
define the manufacturing technique.
Cast Iron Cast in a foundry and generally not part of a process industry except for some
CONCLUSION
Properly prepared pipe codes provide a variety of services to the facility engineer
including:
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The effort required may seem significant but by utilizing existing codes as a starting point
the task is simplified and the result worth the effort in future time saved and problems
avoided. A completed pipe code standard relieves the engineer of having to re-invent the
code each time a piping project is approved.
27.
REFERENCES
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