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Vicent Carucci - Overview of Process Plant Piping System Design PDF
Vicent Carucci - Overview of Process Plant Piping System Design PDF
Participant’s Guide
CONTACT INFORMATION
ASME Headquarters
1-800-THE-ASME
Vincent A. Carucci
Carmagen Engineering, Inc.
Copyright © 2000 by
I. Introduction ....................................................................................................................... 73
II. General ............................................................................................................................. 73
A. What is a piping system .......................................................................................... 73
B. Scope of ASME B31.3............................................................................................. 73
III. Material selection considerations...................................................................................... 75
A. Strength................................................................................................................... 75
B. Corrosion Resistance .............................................................................................. 77
C. Material Fracture Toughness .................................................................................. 77
D. Fabricability ............................................................................................................. 78
E. Availability and Cost ................................................................................................ 78
IV. Piping Components........................................................................................................... 79
A. Fittings, Flanges, and Gaskets................................................................................ 79
B. Flange Rating .......................................................................................................... 85
Sample Problem 1 - Determine Flange Rating ................................................................. 88
Solution ............................................................................................................................. 88
V. Valves ............................................................................................................................... 89
A. Valve Functions....................................................................................................... 89
B. Primary Valve Types ............................................................................................... 90
C. Valve Selection Process ......................................................................................... 98
Exercise 1 – Determine Required Flange Rating ............................................................. 99
VI. 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
VII. 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
VIII. Fabrication, Assembly, and Erection .............................................................................. 140
A. Welding and Heat Treatment ................................................................................ 140
B. Assembly and Erection.......................................................................................... 144
IX. Quality Control ................................................................................................................ 151
A. Inspection .............................................................................................................. 151
B. Testing................................................................................................................... 154
X. Other Considerations ...................................................................................................... 156
A. Nonmetallic Piping................................................................................................. 156
B. Category M Fluid Service...................................................................................... 157
C. High Pressure Piping............................................................................................. 158
XI. Summary......................................................................................................................... 160
Part 1:
Participant Notes
3
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:
4
ASME B31.3
• Provides requirements for:
– Design – Erection
– Materials – Inspection
– Fabrication – Testing
Notes:
Notes:
5
Strength
• Yield and Tensile Strength
• Creep Strength
• Fatigue Strength
• Alloy Content
• Material Grain size
• Steel Production Process
Notes:
Notes:
6
Corrosion Resistance
• Deterioration of metal by chemical or
electrochemical action
• Most important factor to consider
• Corrosion allowance added thickness
• Alloying increases corrosion resistance
Notes:
Notes:
7
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:
8
Availability and Cost
• Consider economics
• Compare acceptable options based on:
– Availability
– Relative cost
11
Notes:
Pipe Fittings
• Produce change in geometry
– Modify flow direction
– Bring pipes together
– Alter pipe diameter
– Terminate pipe
12
Notes:
9
Elbow and Return
90° 45°
180° Return
13
Figure 4.1
Notes:
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
Enlarged Section
of Lap
18
Figure 4.6
Notes:
12
Typical Flange Assembly
Flange
Bolting
Gasket
19
Figure 4.7
Notes:
Types of Flange
Attachment and Facing
Flange Attachment Types Flange Facing Types
Socket-Welded Flanges
Slip-On Flanges
20
Table 4.1
Notes:
13
Flange Facing Types
21
Figure 4.8
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
Flange Rating Class
• Based on ASME B16.5
• Acceptable pressure/temperature
combinations
• Seven classes (150, 300, 400, 600, 900,
1,500, 2,500)
• Flange strength increases with class
number
• Material and design temperature
combinations without pressure indicated
not acceptable
23
Notes:
24
Table 4.2
Notes:
15
Pressure - Temperature Ratings
Material
1.8 1.9 1.10
Group No.
Classes 150 300 400 150 300 400 150 300 400
Temp., °F
-20 to 100 235 620 825 290 750 1000 290 750 1000
200 220 570 765 260 750 1000 260 750 1000
300 215 555 745 230 720 965 230 730 970
400 200 555 740 200 695 885 200 705 940
500 170 555 740 170 695 805 170 665 885
600 140 555 740 140 605 785 140 605 805
650 125 555 740 125 590 785 125 590 785
700 110 545 725 110 570 710 110 570 755
750 95 515 685 95 530 675 95 530 710
800 80 510 675 80 510 650 80 510 675
850 65 485 650 65 485 600 65 485 650
900 50 450 600 50 450 425 50 450 600
950 35 320 425 35 320 290 35 375 505
1000 20 215 290 20 215 190 20 260 345
25
Table 4.3
Notes:
Sample Problem 1
Flange Rating
New piping system to be installed at
existing plant.
Determine required flange class.
• Pipe Material: 1 1 Cr − 1 Mo
4 2
• Design Temperature: 700°F
• Design Pressure: 500 psig
26
Notes:
16
Sample Problem 1 Solution
• Determine Material Group Number (Fig. 4.2)
Group Number = 1.9
• Find allowable design pressure at
intersection of design temperature and Group
No. Check Class 150.
– Allowable pressure = 110 psig < design pressure
– Move to next higher class and repeat steps
• For Class 300, allowable pressure = 570 psig
• Required flange Class: 300
27
Notes:
Valves
• Functions
– Block flow
– Throttle flow
– Prevent flow reversal
28
Notes:
17
Full Port Gate Valve
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
10. Gland Lug Bolts and Nuts
11. Stem Packing
12. Plug
13. Lantern Ring
14. Backseat Bushing
15. Bonnet
16. Bonnet Gasket
17. Bonnet Bolts and Nuts
18. Gate
19. Seat Ring
20. Body
21. One-Piece Gland (Alternate)
22. Valve Port
29
Figure 5.1
Notes:
Globe Valve
• Most economic for throttling flow
• Can be hand-controlled
• Provides “tight” shutoff
• Not suitable for scraping or rodding
• Too costly for on/off block operations
30
Notes:
18
Check Valve
• Prevents flow reversal
• Does not completely shut off reverse flow
• Available in all sizes, ratings, materials
• Valve type selection determined by
– Size limitations
– Cost
– Availability
– Service
31
Notes:
Seat
Ring
Hinge
Flow
Direction
Disc
Body
32
Figure 5.2
Notes:
19
Ball Check Valve
33
Figure 5.3
Notes:
Seat
Ring
Piston
Flow
Direction
34
Figure 5.4
Notes:
20
Wafer Check Valve
35
Figure 5.5
Notes:
Ball Valve
No. Part Names
1 Body
2 Body Cap
3 Ball
4 Body Seal Gasket
5 Seat
6 Stem
7 Gland Flange
8 Stem Packing
9 Gland Follower
10 Thrust Bearing
11 Thrust Washer
12 Indicator Stop
13 Snap Ring
14 Gland Bolt
15 Stem Bearing
16 Body Stud Bolt & Nuts
17 Gland Cover
18 Gland Cover Bolts
19 Handle
36
Figure 5.6
Notes:
21
Plug Valve
Wedge
Sealing Slip
37
Figure 5.7
Notes:
Notes:
22
Valve Selection Process,
cont’d
3. Determine valve application requirements
(i.e., design or service limitations).
4. Finalize valve selection. Check factors to
consider if two or more valves are
suitable.
5. Provide full technical description
specifying type, material, flange rating,
etc.
39
Notes:
Exercise 1 - Determine
Required Flange Rating
• Pipe: 1 1 Cr − 1 Mo
4 2
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 900°F
41
Notes:
Design Conditions
• General
– Normal operating conditions
– Design conditions
• Design pressure and temperature
– Identify connected equipment and associated
design conditions
– Consider contingent conditions
– Consider flow direction
– Verify conditions with process engineer
42
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
• Thermal expansion loads
– Caused by thermal displacements
– Result from restrained movement
• Occasional loads
– Act for short portion of operating time
43
– Seismic and/or dynamic loading
Notes:
Stresses Produced By
Internal Pressure
Sl
Sc
P
t
Sl = Longitudinal Stress
t = Wall Thickness
P = Internal Pressure
44
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.
°°
Spec. No/Grade
Material 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Carbon Steel A 106 B 20.0 20.0 20.0 20.0 18.9 17.3 16.5 10.8 6.5 2.5 1.0
C - ½Mo A 335 P1 18.3 18.3 17.5 16.9 16.3 15.7 15.1 13.5 12.7 4. 2.4
1¼ - ½Mo 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 1.2
18Cr - 8Ni pipe 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 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
pipe
Table 6.1
48
Notes:
27
Pipe Thickness Required
For Internal Pressure
PD
t=
• 2 (SE + PY )
P = Design pressure, psig
D = Pipe outside diameter, in.
S = Allowable stress in tension, psi
E = Longitudinal-joint quality factor
Y = Wall thickness correction factor
• t m = t + CA
tm
• t nom =
0.875
49
Notes:
Carbon Steel
Stainless Steel
50
Table 6.2
Notes:
28
Temperature, °F
Materials 900 & lower 950 1000 1050 1100 1150 & up
Ferritic 0.4 0.5 0.7 0.7 0.7 0.7
Steels
Austenitic 0.4 0.4 0.4 0.4 0.5 0.7
Steels
Other 0.4 0.4 0.4 0.4 0.4 0.4
Ductile
Metals
Cast iron 0.0 ... ... ... ... ...
Table 6.3
51
Notes:
Notes:
29
Sample Problem 2 -
Determine Pipe Wall Thickness
Design temperature: 650°F
Design pressure: 1,380 psig.
Pipe outside diameter: 14 in.
Material: ASTM A335, Gr. P11 ( 1 14 Cr − 12 Mo ),
seamless
Corrosion allowance: 0.0625 in.
53
Notes:
PD
t=
2(SE + PY)
1,380 × 14
t=
2[(16,200 × 1) + (1,380 × 0.4 )]
t = 0.577 in.
54
Notes:
30
Sample Problem 2 -
Solution, cont’d
tm = t + c = 0.577 + 0.0625 = 0.6395 in.
0.6395
t nom = = 0.731 in.
0.875
55
Notes:
Nom. Reinforcement
Reinforcement tb c Zone Limits
Thk.
Zone Limits
Mill
Tol.
A3
A3
L4 A4
A4
A1
Tr
c th
Th
Dh d1
Mill A2 A2
Tol.
Nom. d2 d2
Thk.
β
Pipe C
56
Figure 6.2
Notes:
31
Reinforcement Area
Db − 2(Tb − c)
d1 =
sin β
Notes:
A 1 = t h d1(2 − sin β)
58
Notes:
32
Reinforcement Pad
• Provides additional reinforcement
• Usually more economical than increasing
wall thickness
• Selection variables
– Material
– Outside diameter
– Wall thickness
æ (D − Db ) ö
A 4 = çç p Tr
è sin β
59
Notes:
Sample Problem 3
60
Notes:
33
Sample Problem 3, cont’d
• Nominal Pipe Header: 0.562 in.
Thicknesses: Branch: 0.375 in.
61
Notes:
A1 = thd1(2 − sinβ)
Notes:
34
Sample Problem 3 -
Solution, cont’d
• Calculate excess area available in header, A2.
A 2 = (2d2−d1)(Th−th−c )
63
Notes:
Sample Problem 3 -
Solution, cont’d
• Calculate excess area available in branch,
• A3.
2L 4(Tb − tb−c )
A3 =
sinβ
L 4 = 2.5 (0.875 × 0.375 − 0.0625 ) = 0.664 in.
64
Notes:
35
Sample Problem 3 -
Solution, cont’d
• Calculate other excess area available, A4.
A4 = 0.
Notes:
Sample Problem 3 -
Solution, cont’d
• Reinforcement pad: A106, Gr. B, 0.562 in. thick
• Recalculate Available Reinforcement
L41 = 2.5 (Th - c) = 2.5 (0.875 × 0.562 - 0.0625) =
1.073 in.
L42 = 2.5 (Tb - c) + Tr
= 2.5 (0.875 × 0.375 - 0.0625) + 0.562 (0.875) =
1.16 in
66
Notes:
36
Sample Problem 3 -
Solution, cont’d
Therefore, L4 = 1.073 in.
2L 4 (Tb − t b − c)
A3 =
sin β
67
Notes:
Sample Problem 3 -
Solution, cont’d
• Calculate additional reinforcement required and
pad dimensions:
A4 = 6.11 - 0.535 = 5.575 in.2
Pad diameter, Dp is:
Tr = 0.562 (0.875) = 0.492 in.
A 4 Db 5.575
Dp = + = + 16 = 27.3
Tr sin β 0.492
Notes:
37
Exercise 2 - Determine
Required Pipe Wall Thickness
• Design Temperature: 260°F
• Design Pressure: 150 psig
• Pipe OD: 30 in.
• Pipe material: A 106, Gr. B seamless
• Corrosion allowance: 0.125
• Mill tolerance: 12.5%
• Thickness for internal pressure and
nominal 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:
PD 150 × 30
t= =
2(SE + PY ) 2[(20,000 × 1.0 ) + (150 × 0.04 )]
t = 0.112 in.
70
Notes:
38
Exercise 2 - Solution, cont’d
• Corrosion allowance calculation:
t m = t + CA = 0.112 + 0.125
t = 0.237 in.
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
Pipe Supports and Restraints
• Supports
– Absorb system weight
– Reduce:
+ longitudinal pipe stress
+ pipe sag
+ end point reaction loads
• Restraints
– Control or direct thermal movement due to:
+ thermal expansion
73 + imposed loads
Notes:
74
Notes:
40
Rigid Supports
75
Figure 7.1
Notes:
Hangers
76
Figure 7.2
Notes:
41
Flexible Supports
Load and Deflection Small Change in
Scale Effective Lever Arm
Large Change in
Effective Lever Arm
Relatively
Constant
Load
Typical Variable-Load Typical Constant-Load
Spring Support Spring Support Mechanism
77
Figure 7.3
Notes:
Restraints
• Control, limit, redirect thermal movement
– Reduce thermal stress
– Reduce loads on equipment connections
• Absorb imposed loads
– Wind
– Earthquake
– Slug flow
– Water hammer
– Flow induced-vibration
78
Notes:
42
Restraints, cont’d
• 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
81
Figure 7.4
Notes:
Restraints - Guides
Guide Guide
Guide
Vertical Guide
82
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:
– Elevated design temperatures
+ Increases pipe thermal stress and reaction
loads
+ Reduces material strength
– Pipe movement
84 – Supports and restraints
Notes:
45
Flexibility Analysis, cont’d
• Evaluates loads imposed on equipment
• Determines imposed loads on piping
system and associated structures
• Loads compared to industry standards
– Based on tables
– Calculated
85
Notes:
Design Factors
• Layout • Pipe diameter,
• Component thickness
design details • Design temperature
• Fluid service and pressure
• Connected • End-point movements
equipment type • Existing structural
• Operating steel locations
scenarios • Special design
considerations
86
Notes:
46
Equipment Nozzle Load
Standards and Parameters
Parameters Used
Equipment Item Industry Standard To Determine
Acceptable Loads
87
Table 7.1
Notes:
Computer Analysis
• Used to perform detailed piping stress
analysis
• Can perform numerous analyses
• Accurately completes unique and difficult
functions
– Time-history analyses
– Seismic and wind motion
– Support motion
– Finite element analysis
88 – Animation effects
Notes:
47
Computer Analysis Guidelines
Maximum Differential
Type Of Piping Pipe Size, NPS Flexibility Temp.
General piping ≥4 ≥ 400°F
≥8 ≥ 300°F
≥ 12 ≥ 200°F
≥ 20 any
For rotating equipment ≥3 Any
89
Table 7.2
Notes:
90
Notes:
48
Normal Temperature
Conditions To Consider
Temperature range expected for most of time plant is
Stable in operation. Margin above operating temperature
Operation (i.e., use of design temperature rather than operating
temperature) allows for process flexibility.
91
Table 7.3
Notes:
Abnormal Temperature
Conditions To Consider
Temperature changes due to loss of cooling medium
Loss of Cooling flow should be considered. Includes pipe that is
Medium Flow normally at ambient temperature but can be blocked
in, while subject to solar radiation.
92
Table 7.4
Notes:
49
Extent of Analysis
• Extent depends on situation
93
Notes:
Notes:
50
System Design Considerations
• Pump systems
– Operating vs. spared pumps
95
Notes:
System Design
Considerations, cont’d
• Atmospheric storage tank
– Movement at nozzles
– Tank settlement
• Friction loads at supports and restraints
– Can act as anchors or restraints
– May cause high pipe stresses or reaction loads
• Air-cooled heat exchangers
– Consider header box and bundle movement
96
Notes:
51
Tank Nozzle
SHELL
NOZZLE
BOTTOM
97
Figure 7.6
Notes:
Welding
• Welding is primary way of joining pipe
• Provides safety and reliability
• Qualified welding procedure and welders
• Butt welds used for:
– Pipe ends
– Butt-weld-type flanges or fittings to pipe ends
– Edges of formed plate
98
Notes:
52
Butt-Welded Joint Designs
Equal Thickness
99
Figure 8.1
Notes:
(d)
100
Figure 8.2
Notes:
53
Fillet Welds
101
Figure 8.3
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
Postweld Heat Treatment
(PWHT), cont’d
• Other reasons for PWHT to be specified
by user
– Process considerations
– Restore corrosion resistance of normal
grades of stainless steel
– Prevent caustic embrittlement of carbon steel
– Reduce weld hardness
105
Notes:
Notes:
56
Pipe Fitup and Tolerances
• Good fitup essential
– Sound weld
– Minimize loads
• 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
• Succeeding pipe sections bolted on
• Field welds to join piping located near
machine
108
Notes:
57
Load Sensitive Equipment,
cont’d
• Spring supports locked in cold position
during installation and adjusted in locked
position later
• Final bolt tensioning follows initial
alignment of nozzle flanges
• Final nozzle alignment and component
flange boltup should be completed after
replacing any sections removed
109
Notes:
110
Notes:
58
Flange Joint Assembly
• Primary factors
– Selection
– Design
– Preparation
– Inspection
– Installation
• Identify and control causes of leakage
111
Notes:
Flange Preparation,
Inspection, and Installation
• Redo damaged surfaces
• Clean faces
• Align flanges
• Lubricate threads and nuts
• Place gasket properly
• Use proper flange boltup procedure
112
Notes:
59
“Criss-Cross”
Bolt-tightening Sequence
113
Figure 8.4
Notes:
Notes:
60
Inspection
• Defect identification
• Weld inspection
– Technique
– Weld type
– Anticipated type of defect
– Location of weld
– Pipe material
115
Notes:
116
Figure 9.1
Notes:
61
Weld Inspection Guidelines
Type of Inspection Situation/Weld Type Defect
• Cracks.
• Slag inclusions.
• Surface defects.
• Subsurface flaws.
117
Table 9.1
Notes:
Testing
• Pressure test system to demonstrate
integrity
• Hydrostatic test unless pneumatic
approved for special cases
• Hydrostatic test pressure
– ≥ 1½ times design pressure
118
Notes:
62
Testing, cont’d
– For design temperature > test temperature:
1. 5 P S T
PT =
S
ST/S must be ≤ 6.5
PT = Minimum hydrostatic test pressure, psig
P = Internal design pressure, psig
ST = Allowable stress at test temperature, psi
S = Allowable stress at design temperature, psi
119
Notes:
Testing, cont’d
• 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
• Reinforced Thermosetting Resin Piping
(RTR)
– Fabricated from resin which can be treated to
become infusible or insoluble
121
Notes:
122
Notes:
64
Nonmetallic Piping, cont’d
• Designed to prevent movement from
causing:
– Failure at supports
– Leakage at joints
– Detrimental stresses or distortions
• Stress-strain relationship inapplicable
123
Notes:
Notes:
65
Nonmetallic Piping, cont’d
• Thermoplastics not used in flammable
service, and safeguarded in most fluid
services.
• Joined by bonding
125
Notes:
126
Notes:
66
Category M Fluid Service, cont’d
• Requirements same as for piping in
normal fluid service. In addition:
– Design, layout, and operation conducted with
minimal impact and shock loads.
– Detrimental vibration, pulsation, resonance
effects to be avoided or minimized.
– No pressure-temperature variation
allowances.
127
Notes:
128
Notes:
67
Category M Fluid Service, cont’d
• Following may not be used
– Miter bends not designated as fittings,
fabricated laps, nonmetallic fabricated branch
connections.
– Nonmetallic valves and specialty components.
– Threaded nonmetallic flanges.
– Expanded, threaded, caulked joints.
129
Notes:
130
Notes:
68
High Pressure Piping,
cont’d
• Other considerations
– Dynamic effects
– Weight effects
– Thermal expansion and contraction effects
– Support, anchor, and terminal movement
131
Notes:
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
OVERVIEW OF PROCESS PLANT PIPING SYSTEM DESIGN
Carmagen Engineering, Inc.
72
I. INTRODUCTION
II. GENERAL
• Pipe sections
• Fittings (e.g., elbows, reducers, branch connections, etc.)
• Flanges, gaskets, and bolting
• Valves
• Pipe supports and restraints
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:
74
III. MATERIAL SELECTION CONSIDERATIONS
A. Strength
S B
A C
75
2.0 Creep Strength
76
B. Corrosion Resistance
General or Uniform Characterized by uniform metal loss over entire surface of material.
Corrosion May be combined with erosion if material is exposed to high-velocity
fluids, or moving fluids that contain abrasive materials.
Galvanic Corrosion Occurs when two dissimilar metals contact each other in corrosive
electrolytic environment. The anodic metal develops deep pits or
grooves as a current flows from it to the cathodic metal.
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.
77
decreases as the temperature decreases. Tough materials require
a relatively large amount of energy to initiate and propagate a
crack. The impact energy required to fracture a material sample at
a given temperature can be measured by standard Charpy V-notch
tests.
D. Fabricability
• Seamless pipe.
• Plate that is used for welded pipe.
• Wrought or forged elbows, tees, reducers, and crosses.
• Forged flanges, couplings, and valves.
• Cast valves.
The last factors that affect piping material selection are availability
and cost. Where there is more than one technically acceptable
material, the final selection must consider what is readily available
and what are the relative costs of the acceptable options. For
example, the use of carbon steel with a large corrosion allowance
could be more expensive than using a low-alloy material with a
smaller corrosion allowance.
78
IV. PIPING COMPONENTS
90° 45°
180° Return
79
A tee (Figure 4.2) provides for the intersection of three
sections of pipe.
• A straight tee has equal diameters for both the run and
branch pipe connections.
• A reducing-outlet tee has a branch diameter which is
smaller in size than the run diameter.
• A cross permits the intersection of four sections of pipe
and is rarely seen in process plants.
Tee
Figure 4.2
Concentric Eccentric
Reducer
Figure 4.3
80
Typical Integrally Reinforced Branch Connection
Figure 4.4
A pipe cap (Figure 4.5) closes off the end of a pipe section.
The wall thickness of a butt-welded pipe cap will typically be
identical to that of the adjacent pipe section.
Cap
Figure 4.5
R
Enlarged Section
of Lap
81
2.0 Flanges
Flange
Bolting
Gasket
82
equipment (e.g., welded). The type of flange face or facing
defines the geometry of the flange surface that contacts the
gasket. Table 4.1 summarizes the types of flange
attachments and faces. Figure 4.8 illustrates flange facing
types.
Socket-Welded Flanges
Slip-On Flanges
83
Flange Facing Types
Figure 4.8
84
3.0 Gaskets
• Sheet.
• Spiral wound.
• Solid metal ring.
B. Flange Rating
85
ASME B16.5, Table 1A, Material Specification List (Excerpt)
Table 4.2
After the Material Group has been determined, the next step is to
select the appropriate Class. The Class is determined by using
pressure/temperature rating tables, the Material Group, design
metal temperature, and design pressure. Selecting the Class sets
all the detailed dimensions for flanges and flanged fittings. The
objective is to select the lowest Class that is appropriate for the
specified design conditions.
86
added to complete the flange selection process. Discussion of
these other factors is beyond the scope of this course.
Material Group
1.8 1.9 1.10
No.
Classes 150 300 400 150 300 400 150 300 400
Temp., °F
-20 to 100 235 620 825 290 750 1000 290 750 1000
200 220 570 765 260 750 1000 260 750 1000
300 215 555 745 230 720 965 230 730 970
400 200 555 740 200 695 885 200 705 940
500 170 555 740 170 695 805 170 665 885
600 140 555 740 140 605 785 140 605 805
650 125 555 740 125 590 785 125 590 785
700 110 545 725 110 570 710 110 570 755
750 95 515 685 95 530 675 95 530 710
800 80 510 675 80 510 650 80 510 675
850 65 485 650 65 485 600 65 485 650
900 50 450 600 50 450 425 50 450 600
950 35 320 425 35 320 290 35 375 505
1000 20 215 290 20 215 190 20 260 345
ASME B16.5, Pressure-Temperature Ratings (Excerpt)
Table 4.3
87
SAMPLE PROBLEM 1 - DETERMINE FLANGE RATING
SOLUTION
Determine the Material Group Number for the flanges by referring to ASME Table
1A (excerpted in Table 4.2). Find the 1¼ Cr – ½ 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 700°F 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.
88
V. VALVES
A. Valve Functions
89
B. Primary Valve Types
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
10. Gland Lug Bolts
and Nuts
11. Stem Packing
12. Plug
13. Lantern Ring
14. Backseat Bushing
15. Bonnet
16. Bonnet Gasket
17. Bonnet Bolts and
Nuts
18. Gate
19. Seat Ring
20. Body
21. One-Piece Gland
(Alternate)
22. Valve Port
91
typically used as hand-control valves. In larger sizes,
applications are limited primarily to bypasses at control valve
stations. They provide relatively tight shutoff in control valve
bypasses during normal operations; they serve as temporary
flow controllers when control valves must be taken out of
service.
92
Cap
Pin
Seat
Ring
Hinge
Flow
Direction
Disc
Body
93
Ball Check Valve
Figure 5.3
94
Seat
Ring
Piston
Flow
Direction
95
Figure 5.5
96
No. Part Names
1 Body
2 Body Cap
3 Ball
4 Body Seal Gasket
5 Seat
6 Stem
7 Gland Flange
8 Stem Packing
9 Gland Follower
10 Thrust Bearing
11 Thrust Washer
12 Indicator Stop
13 Snap Ring
14 Gland Bolt
15 Stem Bearing
16 Body Stud Bolt & Nuts
17 Gland Cover
18 Gland Cover Bolts
19 Handle
Ball Valve
Figure 5.6
97
Wedge
Sealing Slip
Plug Valve
Figure 5.7
98
Exercise 1 – Determine Required Flange Rating
For the piping system described below, determine the required flange rating (or
Class) in accordance with ASME B16.5.
Pipe: 1¼ Cr – ½ Mo
99
VI. DESIGN
A. Design Conditions
1.0 General
100
3. Considering contingent design conditions, such as upsets
not protected by pressure-relieving devices.
101
Sl
Sc
P
t
Sl = Longitudinal Stress
t = Wall Thickness
P = Internal Pressure
The weight refers to the total design weight load. The total
weight load includes the weight of the pipe, the fluid in the
pipe, fittings, insulation, internal lining, valves, valve
operators, flanges, supports and any other concentrated
loads. The weight loads produce a longitudinal stress in the
pipe wall.
102
pipe-to-equipment nozzle attachment points, causing
displacements in the piping system.
103
• Allowable stresses for sustained loads are established to
prevent general collapse or excessive distortion of the
piping system.
• Allowable stresses for thermal expansion loads are
established to prevent a localized fatigue failure.
• Allowable stresses for occasional loads are established
to prevent wind and earthquake type loads from
collapsing or distorting the piping system.
• Sustained loads
• Occasional loads
• Stress range due to differential thermal expansion
104
Basic Allowable Stress S, ksi. At Metal Temperature, °F.
Material Spec. No/Grade 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Carbon Steel A 106 B 20.0 20.0 20.0 20.0 18.9 17.3 16.5 10.8 6.5 2.5 1.0
C - ½Mo A 335 P1 18.3 18.3 17.5 16.9 16.3 15.7 15.1 13.5 12.7 4. 2.4
1¼ - ½Mo 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 1.2
18Cr - 8Ni pipe 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 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
pipe
1.0 General
PD
t=
2 (SE + PY )
Where:
105
S = Allowable stress in tension (Table 6.1), psi
106
Spec. Class (or Type) Description Ej
No.
Carbon Steel
Stainless Steel
107
Temperature, °F
Materials 900 & lower 950 1000 1050 1100 1150 & up
Ferritic 0.4 0.5 0.7 0.7 0.7 0.7
Steels
Austenitic 0.4 0.4 0.4 0.4 0.5 0.7
Steels
Other 0.4 0.4 0.4 0.4 0.4 0.4
Ductile
Metals
Cast iron 0.0 ... ... ... ... ...
tm = t + CA
Where:
108
tm
t nom =
0.875
Where:
109
SAMPLE PROBLEM 2 - DETERMINE PIPE WALL THICKNESS
A piping system must be modified to add a new, spare heat exchanger. You
have been assigned the responsibility to determine the required wall thickness
for the pipe from the heat exchanger to several pumps. The piping system will
have a design temperature of 650°F. The design pressure is 1,380 psig. The
pipe outside diameter is 14 in. The material is ASTM A335, Gr. P11 (1¼ Cr – ½
Mo), seamless. Corrosion allowance is 0.0625 in.
SOLUTION
PD
t=
2 (SE + PY )
P = 1,380 psig.
D = 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
t=
2 [(16,150 × 1) + (1,380 × 0.4)]
t = 0.577 in.
Therefore:
tm = t + c = 0.577 + 0.0625
tm = 0.6395 in.
0.6395
tnom = = 0.731 in.
0.875
111
4.1 Area Removed By Branch Connection
Db
Tb
Nom. Reinforcement
Reinforcement tb c Zone Limits
Thk.
Zone Limits
Mill
Tol.
A3
A3
L4 A4
A4
A1
Tr
c th
Th
Dh d1
Mill A2 A2
Tol.
Nom. d2 d2
Thk.
β
Pipe C
112
• Must be located reasonably close to the opening
to provide any practical benefit.
D b − 2(Tb − c )
d1 =
sin β
Where:
113
The required reinforcement area, A1, is then
calculated using :
A1 = t h d1(2 − sin β)
Where:
• Material
• Outside diameter
• Wall thickness
æ (D p − D b ) ö
A 4 = çç Tr
è sin β
Where:
114
The pad must be large enough to provide the
additional reinforcement needed and be within the
reinforcement zone. The pad material is generally
equivalent to that of the pipe.
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 - 700°F
• Design pressure - 550 psig
• Allowable stress - 16,500 psi.
• Corrosion allowance - 0.0625 in.
• Mill tolerance - 12.5%
• Nominal Pipe - Header: 0.562 in.
Thicknesses Branch: 0.375 in.
• Required Pipe - Header: 0.395 in.
Thicknesses for Pressure Branch: 0.263 in.
• The branch connection is made on top of the header at a 90° angle, and does
not penetrate a header weld.
SOLUTION
Db − 2(Tb − c )
d1 =
sin β
116
16 − 2(0.375 × 0.875 − 0.0625 )
d1 =
sin 90°
d1 = 15.469 in.
A1 = t h d1 (2 − sinβi
A1 = 6.11in.2
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 )
d1
(Tb−c ) + (Th−c ) +
2 , but less than the header diameter, Dh
A2 = 0.53 in.2
117
2L4(Tb − tb−c )
A3 =
sin β
L4 = 0.664 in.
A3 = 0.003 in.2
There is no reinforcing pad and the area contribution from the branch weld is
being disregarded. Therefore, A4 = 0.
AT = A2 + A3 + A4
AT = 0.53 + 0.003 + 0
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.
Now that a reinforcing pad is being used, the available reinforcement in the
branch must be recalculated since the height of the reinforcement zone in the
branch pipe will change slightly.
2L 4 (Tb − t b − c)
A3 =
sin β
The required reinforcement area is 6.11in.2, and the available area is 0.535
in.2. Therefore, the additional reinforcement area to be provided in the pad,
A4, is:
119
A4 = 6.11 - 0.535
A4 = 5.575 in.2
Db = 16 in.
A4 Db
Dp = +
Tr sin β
5.575
Dp = + 16
0.492
D p = 27.3 in.
The following approach of calculating the required pad width, Lr, may be used
as an alternative to calculating the pad diameter.
0.5 A4
Lr =
Tr
0.5 × 5.575
Lr =
0.492
L r = 5.66 in.
120
EXERCISE 2: DETERMINE REQUIRED PIPE WALL
THICKNESS
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 260°F. 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.
Use Table 6.1 along with Tables 6.2 and 6.3 for the necessary information.
121
VII. SYSTEM DESIGN
A. Layout Considerations
122
• Rotating equipment requires frequent monitoring and
maintenance.
123
1.0 Rigid Supports
Rigid Supports
Figure 7.1
124
one or more structural steel rods bolted to a pipe attachment and to
the overhead member. A hanger rod is designed to move freely
both parallel and perpendicular to the pipe axis, and not restrict
thermal expansion in these directions. A hanger will prevent
movement both down and up. See Figure 7.2.
Hangers
Figure 7.2
125
load. Since the spring is resilient, it permits vertical thermal
movement while still carrying the weight. This type of
support is used in situations where support must be provided
at a particular location, and vertical thermal expansion must
also be permitted.
Large Change in
Effective Lever Arm
Relatively
Constant
Load
Typical Variable-Load Typical Constant-Load
Spring Support Spring Support Mechanism
Flexible Supports
Figure 7.3
3.1 Restraints
126
• Restraints control, limit, or redirect the unrestricted
thermal movement of a pipe. They are used to
either reduce the thermal stress in the pipe or the
loads exerted by the pipe on equipment
connections.
3.2 Anchors
127
Anchor Anchor Partial Anchor
Restraints/Anchors
Figure 7.4
3.3 Guides
128
Guide Guide
Guide
Vertical Guide
Examples of Guides
Figure 7.5
C. Piping Flexibility
129
A structure that is subject to a change in temperature will change in
dimensions. If these thermal movements are allowed to occur
without any restraint whatsoever, no pipe stresses or reaction loads
result. However, in real systems, stresses are developed in the
pipe and moments and forces are imposed on the connected
equipment and at supports and restraints installed in the system.
The basic problem is to determine the internal pipe stresses and
the external loads, and then decide if they are acceptable. A
thermal flexibility analysis is done to ensure that the piping system
is laid out, supported, and restrained such that the thermal stresses
in the pipe and the loads on the end points are within allowable
limits.
130
2.0 Approaches to Design
131
D. Required Design Information for Piping Stress Analysis
132
type (e.g., pump or compressor) or stationary type (e.g., pressure
vessel or heat exchanger). Rotating equipment is the more
sensitive with respect to imposed piping loads because of the
moving parts and small clearances involved in its design.
Excessive piping loads imposed on rotating equipment can cause
damage, poor operation, and/or maintenance problems at levels
well below those that would cause pipe or equipment stress
concerns.
Parameters Used
Equipment Item Industry Standard To Determine
Acceptable Loads
Pressure Vessels, Shell- ASME Code Section Nozzle size, thickness, reinforcement
and-Tube Heat Exchanger VIII, WRC-107, details, vessel/exchanger diameter,
Nozzles WRC-297 and wall thickness. Stress analysis
required.
133
F. When Should A Computer Analysis Be Used
134
1.0 Piping Flexibility Temperature
Gives the temperature range expected for most of the time a plant is in
Stable operation. Some margin above equipment operating temperature (i.e.,
Operation use of the design temperature rather than operating temperature)
allows for process flexibility.
135
Temperature changes due to a loss of cooling medium flow
Loss of Cooling should be considered. This includes pipe that is normally at
Medium Flow ambient temperature but can be blocked in, while subject to
solar radiation.
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,
300°F is typically used for the metal temperature. Piping
connected to equipment which will be steamed out, especially
Steamout for Air
piping connected to the upper parts of towers, should be
or Gas Freeing
checked for the tower at 300°F and the piping at ambient plus
50°F. This situation may govern the flexibility of lines connected
to towers that operate at less than 300°F or that have a smaller
temperature variation from top to bottom.
136
2.0 Extent of Analysis
137
• Install expansion joints. However, this approach should
be the exception rather than the rule. Expansion joints
represent a "weak link" in a piping system. They may
affect the life of the system since they are more
susceptible to damage than pipe, and can create
maintenance and operational problems. Thus, the use of
expansion joints should only be considered as a last
resort. One situation where expansion joints must be
used is where pressure drop or other process
requirements dictate the use of relatively straight pipe
runs (e.g., fluidized solids transfer lines).
• Strategically locate restraints to minimize thermal and
friction loads at equipment. Restraints could also be
used to direct pipe thermal expansion into a section of
the system that has more inherent flexibility to absorb it.
• Use spring supports if large vertical thermal movements
are expected, or if thermal expansion causes pipe to lift
off fixed supports. Avoid fixed supports that result in
large thermal stresses.
• Use Teflon bearing pads at supports for large-diameter
pipe or other large weight loads if friction loads are
excessive on equipment connections or structural
members.
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.
NOZZLE SHELL
BOTTOM
Tank Nozzle
Figure 7.7
• It may be necessary to consider pipe frictional effects at
support points. If large enough, friction loads can restrict
pipe movement and cause unexpectedly high pipe
stresses or end point reaction loads. Typical situations
where it may be necessary to consider friction loads are
for long horizontal pipe runs, or where large concentrated
weight loads are supported near equipment nozzles.
• The most common configuration for air-cooled heat
exchanger piping uses short, straight sections of pipe to
connect the manifold to the exchanger nozzles. The
manifold is located directly above or below the exchanger
header box. The heat exchanger tube bundle is allowed
to move laterally to accommodate the thermal expansion
of the pipe manifold. The flexibility analysis should
include the restraining effect of friction from movement of
the exchanger bundle, which will resist lateral movement
of the bundle.
139
VIII. FABRICATION, ASSEMBLY, AND ERECTION
Individual sections of pipe must be fabricated into convenient sections (i.e., spool
pieces). Individual spool pieces are then assembled and erected in the field.
1.0 Butt-Welds
140
(a) Standard End Preparation (b) Standard End Preparation
of Pipe of Butt-Welding Fittings and
Optional End Preparation of (c) Suggested End Preparation,
Pipe 7/8 in. and Thinner Pipe and Fittings Over 7/8 in.
Thickness
(d)
141
attachments to piping components (e.g., reinforcing pads,
supports, etc.). See Figure 8.3.
Fillet Welds
Figure 8.3
142
3.0 Welding Preparation Steps
The following outlines the overall steps that are required for
welding.
4.0 Preheating
143
ASME B31.3 based on the pipe material and wall thickness
being joined.
144
• Pipe should not be stored directly on the ground to help
prevent rainwater accumulation around the pipe, which
could result in corrosion.
• Pipe should not be stacked so high that pipes or their
coatings may be damaged.
• Fittings and valves should be stored in shipping crates or
on racks to provide protection until used.
• End protectors should be firmly attached to prevent
damage to weld bevels, flange faces, threads, or socket-
weld ends.
• Lined and coated pipes and fittings should be lifted with
wide fabric or rubber-covered slings and padding to
prevent damage.
145
3.0 Alignment of Pipe Attached to Load-Sensitive
Equipment
146
specified for general piping systems. More stringent
limits are required to minimize the loads that are imposed
by flange boltup.
• Precautions should be taken to prevent ingress of debris
into machine internals during construction of connecting
pipework.
147
• Align flanges. Flanges at rest should be within the
alignment tolerances previously discussed, with the
flanges practically mating before the bolts are installed.
148
- Use a "criss-cross" pattern bolt-tightening sequence,
as is used when bolting a wheel onto a car. This
approach helps to achieve a uniform bolt load around
the flange. See Figure 8.4.
- Use at least three rounds of tightening around the
flange, increasing the applied load in each round,
with two rounds at the maximum load. This
approach helps achieve uniform bolt load around the
flange circumference.
- For the most critical high-temperature or high-
pressure 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.
149
force to align flanges, and improper location of supports
or restraints.
• Thermal Shock. Rapid temperature fluctuations can
cause flanges to deform temporarily and leak.
• Improper Gasket Size or Material. Using the wrong
gasket size or material can cause leakage.
• Improper Flange Facing. A rougher flange-surface finish
than specified for spiral-wound gaskets can result in
leakage.
150
IX. QUALITY CONTROL
A. Inspection
151
Typical Weld Imperfections
Figure 9.1
152
Type of Inspection Situation/Weld Type Defect
153
• At least 5% of all fabrication shall be visually examined.
• 100% of fabrication for longitudinal welds, except in
components made in accordance with a listed specification,
shall be visually inspected.
• Random visual examination of the assembly of threaded,
bolted, and other joints.
• Random visual examination during the erection of piping.
• Not less than 5% of circumferential butt- and miter-groove
welds shall be examined fully by random radiography or
random ultrasonic examination.
• Not less than 5% of all brazed joints shall be examined, by in-
process examination.
• Piping in severe cyclical service requires additional
examination.
B. Testing
1.5 PS T
PT =
S
154
Where:
155
X. OTHER CONSIDERATIONS
A. Nonmetallic Piping
156
- Nonmetallic piping shall be supported, guided, and
anchored to prevent damage to the piping.
- Point loads and narrow areas of contact between piping and
supports shall be avoided.
- Suitable padding shall be placed between piping and
supports where piping damage may occur.
- Valves and equipment that would transmit excessive loads
to the piping shall be independently supported.
• Thermoplastics shall not be used in flammable fluid service
above ground and shall be safeguarded when used in most fluid
services.
• Nonmetallic piping is joined by bonding. Bonding can be
achieved through many methods including adhesive, wrapping,
heat fusion, hot gas welding, and solvent cementing.
157
• The following may not be used:
- Miter bends not designated as fittings, fabricated laps, and
nonmetallic fabricated branch connections
- Nonmetallic valves and specialty components
- Threaded nonmetallic flanges
- Expanded, threaded, and caulked joints
158
In any case, the design must allow the system to either
withstand or provide some type of relief from the ambient
effects.
2.0 Examination
3.0 Testing
159
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.
160