CHAPTER
10
JACKETED PIPING ISSUES
General Info
The term “jacketed piping” refers to a pair of pressure pipes,
consisting of a smaller diameter pipe nested coaxially inside a
larger diameter pipe. The larger, outer pipe is called the
“jacket” and the smaller, inner pipe is called the “core” (see
Figure 10-1).
The “core fluid” is the hot material being transported in
the particular process. An example would be molten plastic or
polymer being pumped to extrusion dies to make fibers or
bulk chips.
The “jacket fluid” serves as thermal insulation, and typi-
cally is supplied to the jacket as saturated vapor of one of the
commercially produced heat transfer oils, such as one of the
DowTherms. A typical hot oil vapor jacket fluid temperature
would be 550°F (290°C.) Pressures are typically moderate,
depending on specific fluids used and the process temperature
requirements. Although the active jacket fluid is normally in
the vapor state, it may be pumped through as a liquid. A hot
oil boiler system generates the vapor from pumped conden-
sate return.
The jacket pipe OD is heavily covered with an appropriate
thermal insulation having a protective top cover of some sort.
Heat transfer oil is not the only jacket fluid you may
encounter. Sometimes moderate pressure steam may be used
in pipe (and heated mixing vessel) jackets. The normal steam
system rules must be followed, including startup blowdown
means, supervisory controls, and especially liquid condensate
trap system collection and return system design. Because of
the danger inherent in steam system design, actual design of
steam-jacketed piping should only be attempted by experienced
engineers, and requires careful analysis of pipe stress and hy-
draulics, especially to avoid accidental steam hammer. We will
look into this in more depth as a subtopic.
PHYSICAL DESCRIPTION
Both pipes maintain the same axial centerline. They are held
in position by rigid steel spacers, located periodically on centers
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along the common axial centerline. These spacers create an
annular ring of empty space between the ID of the Jacket Pipe
and the OD of the Core Pipe. This annular space carries the
jacket fluid under pressure when the system is in operation.
The core fluid is pumped through the inner pipe, of course.
The spacers are usually made by welding three-bladed steel
plate–fin arrangements equally spaced at 120° intervals around
the circumference of the core OD. Sometimes four plate fins,
located 90° apart, are used (see Figure 10-1). The plate fins
are oriented radially to the core OD, with the spacer plates
always oriented edge-on, to allow the jacket fluid to flow
through with minimal resistance.
The spacers may be welded to the jacket ID or to the core
OD; care is taken to make these welds clean, and the weldments
are designed to minimize local stress-raising effects. Although
not universal nomenclature, these spacers are often referred to
as “spiders.”
Jacketed piping construction, if done properly, is difficult
and demanding. Such pipeline elements as tees, branches, line
strainers, flowmeter elements, and feed-throughs for ther-
mowells and gauges present special design and fabrication
problems.
Typically, the core pipe will be designed with long radius
elbows and bends, sized for the process flow requirements. The
jacket is then welded in place in half-sections, using the “spi-
der” spacers to maintain axial alignment relative to the core.
The jacket pipe is sized so that the annulus can carry the desired
flowrate of heat transfer fluid, and it will be at least one, and
often two pipe sizes larger than the core. Typically the jacket
turns will be short radius elbows.
Note that each section of jacketed piping terminates with
a heavy ANSI Flange at each end of the spool piece. Special
flange configurations are used. For example, the flange may
be a slip-on type, double welded to the core as usual, and the
jacket may (or may not) be tapered at its ends to a somewhat
smaller OD/ID, and is then butt-welded to the back face of the
flange. Nipples are branch-welded onto the jackets near the
flanges, to act as jacket fluid inlet and outlet nozzles. The nipple
pipe sizes may be quite small relative to the jacket pipe size.
181
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FIGURE 10-1 Typical Cross Sections of Jacketed Pipe

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Finally, after the jacket sections are all welded into place
around the core, the actual pipe supports are installed and
hydrotesting is accomplished per Code (ASME B31.3). It is
not unusual to see a lot of variable spring hangers among the
supports, and directional guides are critical for displacement
and stress control.
It is important to note that the pipe supports that attach to
plant structure actually support the jacket directly, but the core
only indirectly. The actual core pipe support is provided by
the jacket pipe via direct contact through the spiders. This
is crucial to recognize for Code pipe stress purposes. If you,
as the piping engineer, do not demand that the specific quantity,
configuration and exact locations of each and every one of the
spiders be documented as-built, for the pipe stress analyst to
use in his modeling, then the pipe stress analysis will be at
best a guess, and as such will be essentially worthless.
Stress-wise, jacketed piping is somewhat crude, and pres-
ents a considerably more complex design problem for the me-
chanical piping engineer than single pipes.
• They are more rigid than congruent sections of jacket
pipe alone would be, due to the nature of their twin-
shell construction.
• They are quite heavy, which exacerbates gravity support
design difficulties.
• In addition to difficulty due to their constructional rigid-
ity, they are even more prone to severe thermal expansion
stress problems than single pipes, being usually very stiff
because of being composed of short runs of pipe. As
such they have little natural flexibility.
• They impose large loads, forces and moments, on anchors
and terminally connected equipment such as pumps, dies
and vessels. (It is not uncommon to mount the pumps
on guided slides, to allow them to move freely as the
jacketed piping expands and contracts thermally.)
The problems just described are pretty well known in the
process plant piping community. But there are a few other
problems, a bit more technical and insidious, that in real life
can create havoc with jacketed piping. Those are the problems
we want to discuss here.
The first of them concerns wall thickness of the core pipe.
THE CORE PIPE WALL THICKNESS PROBLEM
Normal single pipes are exposed to the atmosphere, and are
filled internally with a fluid under a gauge pressure, which
must be either positive (as when conducting a pumped liquid
or steam or compressed gas), negative (as when serving as a
vacuum line or air compressor inlet pipe), or zero (at atmo-
spheric pressure inside as well as outside.) Internal pressure
tends to cause tensile hoop stress in the pipe wall, causing it
to swell and burst.
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JACKETED PIPING ISSUES • 183
Of course, single pipes can be exposed to abnormal condi-
tions. They can be surrounded externally by matter at higher
than atmospheric pressure. Buried soil pipe, underwater oceanic
piping and pipe coils inside pressure vessels are examples of
externally pressurized piping. The external pressure creates
compressive stresses which tend to crush the pipe wall. So in
pipes such as these, you need to calculate the minimum wall
thickness required to withstand the maximum possible differen-
tial pressure, inside-out as well as outside-in. The thicker of the
two calculated wall schedules is then selected for construction.
Core pipes in jacketed pipe systems thus fall under this
“abnormal” condition.
• Core pipe minimum allowable wall thickness is first
calculated using the differential pressure based on maxi-
mum allowable working pressure applied internally,
while the pipe wall metal is held at the maximum working
fluid temperature, combined with full vacuum applied
externally to the core (maximum allowable fluid pressure
in core, full vacuum in jacket).
• Next, core pipe minimum allowable wall thickness is
calculated using the differential pressure based on maxi-
mum allowable working pressure applied externally, with
the pipe wall metal still held at the maximum working
fluid temperature, combined with full vacuum applied
internally to the core (full vacuum in core, maximum
allowable fluid pressure in jacket).
• This procedure yields two different values for minimum
required wall thickness. Select the larger of the two for
determining construction requirements of the core pipe.
Example Calculation of Core Pipe Wall Thickness:
To best illustrate the potential pitfalls of jacketed piping design,
we will use an example that magnifies the pitfalls. However,
this example is in no way unrealistic. Similar systems exist in
the real world this very day.
Core Pipe Details:
**Nominal core pipe size: 12-in. diameter.
O.D. = 12.75 in.
**Core pipe material: A-312 type TP 316-L stainless steel.
allowable working stress @ 420°F per ASME B31.3 Code
Table A-1 = 15.28 ksi.
**Core fluid: hot melt organic vapors.
**Core corrosion allowance: 0.06 in.
**Pipe service duty: off-gas vent to recovery vessel.
**Max core internal pressure: 10 psig.
**@ max core fluid working temp: 420°F.
Jacket Pipe Details:
**Nominal jacket pipe size: 16-in. diameter.
O.D. = 16.00 in.
**Jacket pipe material: A −106B carbon steel.
 184 • Chapter 10
allowable working stress @ 422°F per ASME B31.3 Code
Table A-1 = 19.76 ksi.
**Jacket fluid: 300 psig saturated steam.
**Jacket corrosion allowance: 0.06 in.
**Max jacket internal pressure: 315 psia.
**@ max jacket fluid working temp: 422°F.
• Find Core Pipe Wall Thickness “tm” based on Internal
Pressure acting on Core Pipe: use ASME B31.3 Code,
Equation 3(a) of Paragraph 304.1.2: {Also see pages
1–2 of this book.}
tm = [PD/(2)(SE + PY)] + c
before making allowance for mill undertolerance of wall
thickness, or
tm = [PD/(1.75)(SE+PY)] + c
if 12.5% undertolerance is assumed.
P = 10 psig max internal gauge pressure −
(− 14.7) psig full vacuum in jacket =
= 24.7 psi
D = 12.75 in.
S = 15.28 ksi × 1000 = 15,280 psi
E = 1.00 (seamless pipe)
Y = 0.4 (Table 304.1.1)
c = 0.06 in. corrosion allowance
Plug in these values, and obtain
tm ≡ 0.0103 + 0.06 ≡ 0.0703 in. after 12.5% mill undertoler-
ance is allowed. Schedule 5S pipe is the minimum available
commercial pipe thickness, and equals 0.156 inches in the 12
in. pipe size, according to the dimensional tables for commercial
steel pipe. Allowing for undertolerance of 12.5%, the Sch. 5S
pipe wall in new condition could be as thin as (1 − 0.125) ×
(0.156 in.) = 0.1365 in.; since 0.1365 in. ≥ 0.0703 in., pipe
wall thickness of Schedule 5S would be adequate for the core
pipe considering only the internal pressure.
• Find Core Pipe Wall Thickness “tm” based on External
Pressure acting on Core Pipe: use ASME B31.3
Code Requirements.
B31.3 Paragraph 304.1.3 tells us how to calculate for external
pressure. It refers us to two other ASME Codes, from which
we must dig out the appropriate data and equations: these are
**ASME Section VIII Div. 1, Paragraph UG-28(c)(1).
This is the unfired pressure vessel portion of the ASME
boiler code.
**ASME Section II Part D, Subpart 3, Figures G and
HA-4. This is from the Materials: Properties portion of the
ASME boiler code. {Note: in the July 1, 2003 Addendum
to Sect. II Part D, Figure G (generic, all materials) is found
on page 682 and Figure HA-4 (specific, type 316-L austenitic
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stainless steel) is found on Page 689. Reprints of these
two figures are included on pp. 185–186 herein for your
convenience; in this book they are named Figures 10-2 and
10-3.}
Step #1: make a first guess at the ratio of pipe outside diameter
“D0” to the finally selected wall thickness “t”. My guess would
be schedule 80S pipe, which has t = .50 inches for D0 = 12.75;
so D ÷ t ≅ 12.75/0.50 ≅ 25.5
Step #2: look at Figure G on the (D0/t) = 25 curve, and select
a minimum value of Pipe Length to Diameter ratio (L/D0) above
which the value of “Factor A” does not decrease (i.e., above
where the plot of (D0/τ) remains perpendicular to the plot axis
of “Factor A”.) Use this value of (L/D0) to read “Factor A”. I
read this point as (L/D0) ≥ 10.0, with a corresponding constant
value of “Factor A” = 0.0018.
{This procedure assures that a conservative value of wall thick-
ness will be selected.}
Step #3: enter Figure HA-4 @ “Factor A” = 0.0018, use
420°F as the metal temperature parameter and read “Factor
B” ≅ 6,900.
Step #4: Use equation Pa = 4B/[3(D0/t)] to calculate Pa, which is
the ASME Pressure Vessel Code-maximum-allowable external
pressure for all runs of pipe which are longer than (L/D0) ≥
10.0. {Note: the calculated max allowable external pressure
will thus be conservative for shorter runs of un-reinforced pipe.}
So Pa = (4)(6900) ÷ (3)(25) = 368 psig.
Step #5: Compare this result to the design requirement “Maxi-
mum design value of jacket pipe internal (differential) pressure
= 315 psig @ max jacket fluid working temp = 422°F.
Since the calculated value of 368 psig for the ASME Code
max allowable external pressure is > 315 psig design re-
quirement for the external differential pressure acting on
the Core in our example problem, we conclude that Sched-
ule 80S is acceptable for the Core pipe wall thickness.
Discussion of Results
In this example, the core pipe wall thickness must be selected
on the external pressure crushing criteria. Schedule 80S is the
proper selection. I will leave it as a practice exercise for you
to check my calculations in stating:
**If the core pipe wall thickness had been selected using
internal pressure (hoop stress) criteria, that is, Schedule 5S,
0.156 inches, the pipe would have been crushed by the steam
pressure in the jacket. The max allowable external steam jacket
pressure for Schedule 5S pipe would be about 23 psig.
**Schedule 40S (0.375 in.) wall thickness WOULD NOT
be acceptable, because its maximum allowable external pressure
 JACKETED PIPING ISSUES • 185

FIGURE 10-2 Figure G from ASME BOILER CODE Section II Part D, Subpart 3 (July 1, 2003 Addendum)

would be 245 psig steam, too much less than the required 300
psig saturated steam pressure.
THE JACKET STEAM HAMMER PROBLEM
The reason I selected a large diameter core pipe in conjunction
with relatively high pressure steam in the jacket annulus was
to illustrate the important fact, now to be revealed, that steam
hammer cannot be neglected in jacketed pipe design.
The effect of increased core pipe diameter is to magnify
the crushing force on the core cylinder (the P × A force) relative
to the resisting metal volume comprising the core pipe. The
ratios (L/D) and (D/τ) are analogous to “slenderness ratio” in
a compressed column problem: the higher the ratios, the more
susceptible to buckling is the column, and the more susceptible
to crushing is the core pipe cylinder under external fluid pres-
sure. Cylinder crushing is a stability phenomenon, just as is
buckling of a slender column. A threshold of elastic response
is passed in both cases, and drastic catastrophic plastic failure is
the result in both cases. (I strongly recommend to the interested
reader all of Chapter 8, “Buckling of Vessels Under External
Pressure,” in Prof. John E. Harvey’s terrific reference text,
Theory and Design of Pressure Vessels, Van Nostrand-Rein-
hold, Second Edition, 1991, New York. It is immensely valuable
to the design engineer.)
The effect of increased jacket pipe steam pressure is to
exacerbate the destructive effect of a steam hammer event, if

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FIGURE 10-3 Figure HA-4 from ASME BOILER CODE Section II Part D, Subpart 3 (July 1, 2003 Addendum)

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one is triggered in the jacket. I have personally examined
and testified to the results of such events. I can tell you with
absolute certainty that peak overpressures resulting from
steam hammer events in pipe jackets, carrying considerably
lower steam saturation pressure than we used in our previ-
ous example problem, can exceed and have exceeded
1,000 psig.
Yes. One thousand psig.
It should now be obvious to you that in our example prob-
lem, we could not expect our 12-inch core pipe to survive a
full-fledged steam hammer event. Our core pipe is constructed
of the greatest commercially available wall thickness for austen-
itic stainless steel pipe, Schedule 80S, t = 0.500 inches, and
we have already found that its maximum safe external pressure
differential is only 368 psig. How in the world could we expect
it to withstand 1000 psig or more?
The answer of course is that we could not expect survival.
Try plugging in about 1,300 psig for max required jacket op-
erating pressure into the Code Pa evaluation procedure above,
and see what you get for required core pipe wall thickness.
Then imagine trying to get seamless pipe fabricated in that
thickness to a 12.75 in. outside diameter, and paying the bill
for it. Not to mention the matching bends and fittings!
Clearly it is not feasible to design the core pipe wall to
survive jacket pipe steam hammer in anything approaching
normal circumstances! Submarine warfare, maybe, or nuclear
processes perhaps, but not in commercial manufacturing
plant duty.
Then what must you do if you are unfortunate enough to
become involved in engineering or constructing a steam jack-
eted pipeline in large diameters?
Well, I will tell you. You may wish to start with a thorough
review of chapter 1 in Volume One of this book, water hammer/
steam hammer dynamics. But, for sure, you will have to design
a failsafe supervised steam startup–timed condensate blowdown
system as well as failsafe steam condensate trap(s) and liquid
condensate return systems. You will have to design the piping
runs to slope a lot, always toward the drains, such that all points
in the jacket always drain completely, by gravity, with no
inverted P-traps or flat places in the line which can let conden-
sate build up.
You will have to catch the drained condensate in mud-leg
reservoirs of adequate volume such that steam trap selection
can approach normal sizing criteria. You will have to train all
hands involved in proper operation of these systems, and then
pray that they don’t skip, or skimp on, the “frequent steam trap
maintenance” programs that are necessary to keep those steam
jackets full of nothing but dry steam at all times.
So much for core pipe wall thickness calculations.
The next problem we should recognize concerns the high
temperatures, pipe stiffnesses, and effects of dissimilar metal
expansion rates, and the resulting thermal fatigue failures which
can happen.
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JACKETED PIPING ISSUES • 187
THE DISSIMILAR METAL THERMAL FATIGUE
STRESS PROBLEM
Usually, jacketed pipe systems feature jacket and core pipes
fabricated of the same material; both may be low-carbon steel
such as A106 or A53, or both may be stainless steel of the
same type, such as 304–316 austenitic. And this is good.
What is very bad is when the jacket and core pipes are
different metals. As in our previous example, in which we
stipulated an A106 carbon steel jacket with a 316-L stainless
steel core. Of course we picked the dissimilar pipe metals to
illustrate the pitfall. But, once again, such things actually get
built and indeed exist in operation this very day. So pay careful
attention to what we are about to study, please!
Here’s what happens. First, bear in mind that jacketed
piping sections are fabricated with stiff ANSI welded flanges
at both ends of each spool-piece. The core is welded to the
flanges, and so is the jacket. This means that the jacket pipe
end cannot move relative to the core pipe end, or vice-versa.
The two pipes are rigidly joined together by the flanges to
which the ends are welded. You may wish to refer to the
jacketed piping schematic once more to appreciate this fact.
When dissimilar pipe materials are used, they will have
different rates of thermal expansion. At room temperature, the
jacket and core will be of the same length. The pipe with the
greater coefficient of thermal expansion will try to grow to a
greater length, when the system is heated up to the operating
condition. But they will be forced to end up at the same hot
length, because of the rigid end restraint imposed by the
flange weldments.
This means that the pipe with the greater thermal coeffi-
cient will end up being compressed axially, while the other
pipe will be axially stretched. In other words, each pipe will
have a physical strain relative to the free length the pipe would
have attained if its thermal growth had not been restrained.
These strains are accompanied by stresses that may or may not
reach the materials’ yield points.
In our example problem, the 12-in. stainless core pipe tries
to grow at a rate of about 4 in. per 100 ft of room-temperature
length. But the 16-in. carbon steel jacket only wishes to grow
at a rate slightly less than 3 in. per hundred feet. So in our
example, growth of the system stretches the jacket pipe and
compresses the core.
Is this a problem? The answer often is “yes.” It depends
on the magnitudes of the stresses, upon the material’s fatigue
strength characteristics, and the number of thermal cycles to
which the system is exposed.
For each numerical range of stress magnitudes encountered
by the particular pipe material, there is a corresponding number
of thermal “cold-to-hot-back-to-cold” cycles, which will result
in formation of fatigue cracks, which will over time propagate
clean through the pipe wall. Thus containment is lost. The pipe
leaks under pressure; it is failed; it has broken.
 188 • Chapter 10
In general, the nearer the elastic stress to the tensile yield
point, the fewer cycles it takes to cause this failure. If the yield
stress is exceeded, what happens on any given cycle is that the
points of strain corresponding to tensile or compressive stress
above the material’s yield strength will relax locally, due to
plastic deformation at the maximum stress points after the
maximum temperature has been reached. When this occurs,
fatigue failure will occur rather quickly; only a relative few
thermal cycles will be needed to crack the pipe wall.
Remember, ASME B31.3 prohibits stressing pipe to the
yield point, and is normally intended to yield a leak-free
working lifetime of at least 7,000 full thermal cycles for the
piping system.
Now for the insidious part. The leaks will usually occur
at the flange weldment ends, where the local stress raisers
normally exist. The stress intensification factor for a slip-on
flange properly installed by a Code-worthy welder is at least
1.2, and sloppy welds will be worse than this. So we expect
the first leaks to occur at the flange-to-pipe welds.
Now if the jacket-to-flange weld cracks, in our example
problem, 300 psig steam will blow out into the room. This is
bad, of course, and very dangerous, but at least it is detectable.
But a crack in the core pipe weld will cause the 300 psig
steam to blow into the core pipe, and the leak at first will
be physically undetected. The condition will persist until
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something in the core system blows up, necessitating emer-
gency shutdown of the system, and hopefully not involving
death or personal injury. Once this has happened, if you
had a hand in it, you will no longer enjoy being an engineer.
So do your best to avoid letting one of these bastard systems
get built in the first place. Get your boss to read this chapter
before approving the project.
If you can’t do that, then be very careful in your participa-
tion and make absolutely no technical errors.
And if you can’t do that, then either beg off the project, or
go find another job where they are not bent on self-destruction.
• Illustrate Core Pipe Wall Cracking based on the condi-
tions of the previous example problem: Use the intent
of the ASME B31.3 Code to make these calculations:
You will next encounter an example of engineering analysis. It
is all typed out for your casual perusal and reading convenience,
except for the first page, which remains in the original hand-
drawn sketch format (for MY convenience, wise guy! See Fig-
ure 10-4a–j). You can use this example for guide purposes, but
remember, the complete pipe stress analysis includes multitudes
of additional task requirements, of which this is only one. I
have given it to you mainly to illustrate how bad the problem
of differential expansion of dissimilar materials can be.
 JACKETED PIPING ISSUES • 189

FIGURE 10-4 Example Problem Illustration (Core Fatigue Sheet “a”)

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