Small Bore Piping & Fittings

Taras N Jha
6th July 2021
 Overview
• Safety Topic
• Introduction to piping system
• Pipe Fittings
• Small Bore piping
• Small bore piping design take away(observations)
• Q & A…

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 Tips to Avoid Work-Related Injuries While Working from Home

TIPS TO AVOID WORK-RELATED INJURIES

WHILE WORKING FROM HOME
Tips to Avoid Work-Related Injuries While Working from Home

1. Set up an ergonomic work station:

• Use a rolling chair equipped with back support and ample padding.
• Position monitors 20-30 inches from your face, centered straight ahead. Our eye
level should fall at the top third of the screen.
• Sit with your back and shoulders straight, with a few inches separating the backs
of your knees from the edge of the chair.
• Follow the 20/20/20 Rule: Every 20 minutes, look at an object 20 feet away or
more for at least 20 seconds.

2. Get up, stretch and stay active:

We should take special care to stretch our neck, shoulders, back and feet.

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 Tips to Avoid Work-Related Injuries While Working from Home
3. Prevent slips, trips and falls:
• Prevent slips by wearing proper footwear, even inside your home – avoid slippery
socks.
• To prevent trips, keep the walkways in your home clear of clutter. Should Keep
our house well-lit and make sure cords are safely secured. Avoid distractions, like
your phone, while walking.
• Prevent falls down stairs by always turning on the lights and using a handrail
when going up or down stairs. Avoid trying to carry too much – leave one hand
free to catch yourself if you stumble.

4. Pay attention to your surroundings:

• Prevent electrical hazards by keeping desks clear of open liquid containers, like
coffee or tea.
• Dispose of trash at the end of each day.

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5. Keep lines of communication open :
• Working from home can create a sense of isolation for us. Others may find it
challenging to share a workspace with family, pets, or roommates. Encourage
team to sit down and talk with their families.

6. Put safety first at work – or at home:

• We can build a safety culture even if our team’s not in the office. Communicate
and share resources that will help them improve their safety while working from
home.

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 INTRODUCTION TO PIPING SYSTEM
The piping network is installed to convey the fluids required for chemical processes
or between the various equipment and end users and consist of various components
such as valves fitting , online measuring instruments , etc is called as a piping system.

In the refining and chemical processing industries, Small Bore Piping (SBP) is
generally process/utility piping that is two inches or less in diameter.

• Piping Components
1. Pipe: Small bore piping are seamless. Seamless pipes are derived from solid steel
that is in sheet or bar form.

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• Schedule No.
-is a standard that measures the nominal wall thickness of a pipe, given by the
ASME B36.10/19 .

-Pipes are designated by schedule number like Std(S), Extra Strong(XS) and Double
Extra Strong( XXS).

- Common pipe schedules are Sch 80, Sch 120, Sch 160.

- For stainless steel schedule numbers are designated by suffix S i.e. 40S, 80S etc.

- Pipes are manufactured in single random length( 20’-0”) and in double

random length(40’-0”) .

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 Material of Constructions:
• Generally , process piping is designed for a certain minimum service life under
specific operating conditions like 20 years, 10-15 years, 5-10 years.

• CS materials shall be used for temperature up to 425degC.

• Alloy Steels shall be used for temperature above 426degC.

• Stainless steel shall be used for corrosive fluids.

• Galvanized steels shall be used for Drinking Water, Instrument Air & Low pressure
Nitrogen lines.

• Most of the Utility lines come under small bore piping categories.

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 PIPE FITTINGS
• Pipe fittings are the components which tie together pipe lines, valves, and other
parts of a piping system.

• helps in Changes the direction of the flow such as elbows, tees.

• Changes the size of the pipe such as reducers(swages), reducing tees.

• Connect different components such as couplings & unions.

• stop the flows such as Caps.

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 Butt-Welded Fittings (ASME B16.9)
• used primarily in systems meant to be permanent.

• They form leak proof constructions.

• have a higher temperature & pressure limit.

• easy to insulate but not easy to dismantle.

• Minimum space required for attachment of such fittings.

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 Socket welded fittings ( ASME B 16.11)
• are easier to use on small size pipelines .

• pipes does not need to be beveled.

• less expensive & easier to construct than other welded systems.

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 Screwed/Threaded Fittings(ASME B 16.11)
• are used for the connections of pipe with small diameters (piping whose nominal
diameter is NPS 2 or smaller).

• is commonly used in low-cost, noncritical applications such as domestic water,

fire protection, and industrial cooling water systems.

• are available in three pressure ratings: 2000lbs, 3000lbs and 6000lbs.

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 Flanged Fittings( ASME B16.1/B16.5)
• are found on piping systems throughout the petrochemical & power generation
fields on pipelines having minimum 2” diameter.

• Used in the system which are subjected to shock or high temperature/pressure .

• Flanged systems can be easily dismantled & assembled.

• Considerably costlier than an equally rated butt welded system.

• Pipe attachment based flanges are classified as Slip On, Socket Weld, Screwed,
Lap Joint, Welding Neck, Blinds etc.

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 Screwed & Socket weld fittings :
• Screwed and socket-weld fittings perform the same basic functions as butt-weld
fittings.

• reserved for installations where the nominal pipe size is 2″ and smaller.

• are available in cast iron, malleable iron, or forged steel.

• Low pressure and temperature lines, such as air, water, or condensate, are
fabricated using either cast or malleable iron fittings.

• Pipe lines containing high pressure and temperature commodities, which are
subject to substantial amounts of movement and vibration, mandate fittings
made of forged steel.
• Forged steel screwed and socket-weld fittings are manufactured in two pressure
classes—3000# and 6000#.
• Mostly Forged steels are used in our OGC projects.

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• Forged steel screwed and socket-weld fittings are manufactured in two pressure
classes—3000# and 6000#.

• Mostly Forged steels are used in our OGC projects.

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• Thread Engagement(TE)
A particular concern to the pipe designer is the amount of pipe length lost during
the assembly of screwed fitting configurations.

Formula for AL=CE1+CE2+PL-(TE1+TE2)

The length of this engagement varies depending upon the nominal pipe size and
pound rating of the fitting.
It is already taken care by S3D software so no manual calculation needed.
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Types:
 Elbow (ASME B 16.11):
 The Elbow is used more than any other pipe fittings.

 It provides flexibility to change the pipe direction.

 Elbow mainly available in two standard types 90°and 45°.

 90° elbows are not available as long-radius or short-radius, and their center-to-
end dimension must be found on a dimensioning chart, as no formula is available
for calculating their radius length.

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 Tee (ASME B 16.11):
 Tee makes 90°branch from the Main run of pipe.

 available as equal or reducing tee.

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 Union(MSS SP-83):
• Union is a fitting placed within a piping configuration that will allow the assembly
to be disassembled for inspection, repair, or replacement.

• These are unique to the screwed and socket-weld family of fittings.

• Unions should be positioned in locations that will facilitate the easy removal of
critical pieces of equipment.

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 Full Coupling(ASME B 16.11):
• Couplings are unique to the screwed and socket-weld family of fittings.
• full Coupling is used to connect lengths of screwed and socket-weld pipe
together.
• It used to connect pipe to pipe or pipe to swage or nipple.

• full coupling has both ends of threaded or socket welded connection.

• A socket weld full coupling is used to join small bore plain end pipes where the
pipe spec requirement is socket weld.

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 Half Coupling:
• this fitting is used in butt-welding applications as a branch connection.

• Half coupling is only threaded or socket weld at one end, and the other end is
welded type.
• The Half Coupling can be directly welded to the run pipe, to make a branch.
• Mostly we do not use half coupling for BMcD projects.

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 O’let Branch connection(MSS SP 97):
 Branch Connection fittings (also known as O'lets) are fittings which provide an
outlet from a larger pipe to a smaller one (or one of the same size).

• WELDOLET is the most common of all branch connections, and is welded onto the
outlet pipe. The ends are bevelled to facilitate this process, and therefore the
weldolet is considered a butt-weld fitting only.

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• SOCKOLET is the basic Weldolet however the branch affixes by way of a socket
inside the olet.
- is considered a socket fitting, and manufactured in 3000#, 6000# and 9000#
classes.

• THREDOLET utilizes the basic Weldolet however the branch affixes by way of a
thread just inside the top of the olet .
• The bore matches the outlet bore, and the existence of this threading facilitates
installation, as no welding is necessary.
-is considered a threaded fitting, and manufactured in 3000# and 6000# classes.

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• LATROLET used for 45° lateral connections.
- is available butt-weld to meet specific reinforcement requirements .
- available in 3000# or 6000# classes for Socket Weld and threaded applications.

• ELBOLET is used on 90° Long Radius Elbows (can be manufactured for Short
Radius Elbows) for thermowell and instrumentation connections.
-available butt-weld to meet specific reinforcement requirements
-available 3000# and 6000# classes for Socket Weld and threaded applications.

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• NIPOLET is a one piece fitting for valve take-offs, drains and vents.
-manufactured for Extra Strong and Double Extra Strong applications in 3½in to
6½in lengths.
-available with male-socket weld or male threaded outlets.

• FLANGED PIPET offer a simplified installation and provide more exacting

tolerances where multiple flanges of constant height are required.

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  Plug :

-Seals the threaded end of fitting.

-are manufactured for screwed fittings with male threads and are screwed into
the end of a pipe to create a seal.

Square Head Hex Head Round head plugs(mostly used)

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 Cap (ASME B16.11):
-Seals the threaded & plain end of pipe.

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 Bush: a pipe fitting which is threaded on both the inside and the outside so that it
can be used to connect two pipes (or other fittings) of different sizes
-Can be used to reduce a threaded fitting.

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• Swage Nipple: A swage nipple is something similar to that of a reducer but it is
used to join the butt welded pipe with a socket welded or screwed pipe.
-Concentric & Eccentric swage nipples are available as per requirement.

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 SMALL BORE PIPINGS
Areas :
1. High Point Vent/Low point drains, Pressure gauges, Pressure Transmitters.
2. Vent & Drains in piping, Drain Headers, Closed/open drain, closed /open drain
on rack.
3. Utility Stations.
4. Sample stations.
5. Steam Trap Assembly, Drip leg drains.
6. Chemical Injection/dozing
7. Utility headers(IA, CWS, CWR) & branching, Instrument air piping.
8. Eye wash & Safety shower.
9. Standpipes(Level Bridle).
10. Vessel Trims
11. Pump casing drain & vent lines, pump seal plans.

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 Basis of Design
 Minimum pipe size shall be ½”, except for connections to equipment as noted on
P&ID.

 The use of nipples shall only be used at branch connections for vents, drains, PI’s
etc.

 Do not use nipples inline on small bore piping because the wall thickness can be
different for nipples and pipe.

 Piping shall be permanently supported. Piping shall be supported adequately to

eliminate deflection and swaying during operation.

 The maximum cantilevered length of piping shall be limited to 12 inch.

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 Use of U-bolts and clamps for small pipe (NPS 1-1/2 inch and smaller) is allowed
provided a coating (elastomeric wrap or otherwise coated, CSG) is applied
between the clamp and the pipe.

 A 3-inch finger clearance shall be maintained around valve handwheels and

levers, except for valves with small handwheels or levers, i.e., 1 1/2-inch and
smaller valves where operation is by hand or wrist motion. In these cases,
minimum finger clearance shall be 1 1/2 inches.

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• A standard vertical drain under the pipe is preferred for safety reasons.

• Elbow type drain connections under pipes are potential tripping hazards and
should be avoided if possible.

 If elbow type of drain is used, it should be located under or on the backside of

the pipe maintaining accessibility.

 Y-strainers and drains should be oriented in the down and vertical plane from
horizontal run piping.

 When setting the line elevation, ensure adequate clearance is provided between
the underside of the line and the deck, to prevent rolling of Y-strainers or drains
into the safe access area.

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• Liquid pockets shall be avoided. Designs having pocketed piping require special
attention/client approval.

• Piping layouts in all services shall be designed to eliminate dead legs.

• PI root valve shall be ¾” SW x FT. All nipples shall be 3” min. All PI nipples and
valves shall be coded as Shop Material. For insulation thickness more than 2” use
a 6” nipple length.

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 Valve levers and handwheels, or equipment operated from a fixed ladder shall be
located as below

No further than a 24-inch reach, measured as a radius from the ladder

stringer.

Valve levers shall not rotate away from the ladder.

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Vents in Piping :
1. High point vent are provided in piping for removing Air during Hydro Test .

2. For all piping less than 6” in size Vent size shall be ¾” & for piping above 6” ,
vent size shall be 1”(follow Job Notes).

3. Valved vents open to atmosphere in hydrocarbon, hydrogen, steam, or chemical

service shall have a plug or blind flange on the atmospheric side of valve.

4. All vent nipples and valves shall be coded as Shop Material.

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5. Vent connections shall be located in accessible locations(if possible) adjacent to
operating platforms or structural members.

6. Threaded vent connections shall be seal welded. General note: “SEAL WELD
THREADED PIPE CAP AFTER HYDROTEST “

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Drains in Piping
1. Low point drains are for draining water after conducting Hydrotest.
2. Piping systems shall have drain valves at low points. If there are multiple loops in
single line, then vent should be at every high point and drain should be at every low
point. (Each high & low point requires individual vent and drain)

3. For all piping less than 6” in size Drain size shall be ¾” & for piping above 6” ,
Drain size shall be 1”. OR minimum allowable pipe size as per the piping material line
class.
4. Pipe rack with Low point Drains shall be preferred with all drains in the same bay
@ same location for accessibility through common scaffolding.

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5. All drain nipples and valves shall be coded as Shop Material.

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 Utility stations Piping:
• A Utility station is a place in a Process Plant (Refinery, Petrochemical Plant,
Chemical Plant, Power Plant, etc.) where utility services are provided for the
use by Plant Operators and Maintenance.

• Location & service requirement for each Utility station shall be in accordance
with the Utility station section of the general piping design specification.

• The Utility stations shall generally be located adjacent to pipe-rack column.

• Shall be verified with Electrical & CSA group for not using the column used
for Utility station.

• provided on elevated structures like technological structure, operating

platforms of vertical equipment etc.

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• Branch connection from the header shall be preferably from the top of the
header for the stations located above & below the header.

• Shall be located so that the area being serviced can be reached with a 50’
hose.

• Routing shall be adjusted as necessary to clear obstructions.

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Configurations of US below Header( @ grade):

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Configuration of US @ elevated structure:

Utility stations shall be provided with standard access volume( if possible) for
various type to get clear idea of reserved space for any stations.

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 Steam control station, Steam Drip Leg details, steam traps & flatolet
requirement:

• Traps shall be installed so that they are accessible from Grade, Platform or
Portable Ladder.

• Traps shall be located as close to and below equipment being drained.

• Traps shall be provided at low points & dead ends of steam.

• up-stream of expansion loops and at dead ends via condensate drip legs.

• Traps shall not be insulated.

• Pay close attention to lines that could be bi-directional. Steam traps will be
required on both sides of the expansion loop.

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 Steam control station

Steam control station details

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• Drip Legs Details:

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 Steam traps & piping details:

Steam control station details

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Header @ Grade Elevated Header

Pre Fabricated Trap Modules

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 Safety Showers (standard detail/locations)
• Must be accessible within 10-seconds of hazard (~55-feet).
• Must be located on the same level as the hazard.

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 Level Instruments/level briddle:
• All level instruments must be accessible from grade, platform, or ladder.

• Their location is to be consistent with function and with convenience of

plant operation.

• Standpipes are used if more than one level gauge is required & there is
insufficient room to install instrumentation directly to valved connection on
vessel/Tank.

• Access to standpipe block valves ( generally 2” & above) shall be from fixed
platform.

• Instrument accessibility shall be taken into consideration while fixing the

taping on process pipe.

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.

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 Sample Connection systems:
• Sampling connection system means an assembly of equipment within a
process unit used during periods of representative operation to
take samples of the process or material fluid.

• Equipment used to take routine grab samples are only considered

a sampling connection system.

• Length of sample piping shall be kept to minimum.

• Taping for sample connection should not obstruct access way for valve
operations.

• Preferred taping orientation is along the length of access block or on back

side of it.

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.

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 SMALL BORE PIPINGS DESIGN TAKE AWAY
(OBSERVATIONS)
1. Use of full coupling ( as applicable)

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2. Utility station details :

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3. Drill of blind flange & use of Flatolet with vent:
Blind flange shall be shop material

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4. Call out on Isometrics:

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5. Proper end selection for fittings

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6. Use of Flange Pipet ( as applicable) :

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7. Use of nipples:

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8. Safety union or break out flange for threaded end SP items:

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9. Use of coupling :

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10. Use of coupling :

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11. Proper end connection of mating nozzle:

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12. Use of Union or flange for SP items for maintenance:

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13. 4” nipple in place of 3”

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 Q. & A.

Thank You

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