Industrial Piping System BBF

INDUSTRIAL PIPING SYSTEM
Sl. No. Topics Page #
01. Pipe 03-10
02. Piping Tools 11-18
03. Pipe Joints 19-33
04. Supports and Hangers 34-37
05. Fitting 38-45
06. Pipe Bending 46-52
07. Symbol 54-57
08. Symbols 58-59
09. Useful Information 60-62
Prepared by: SURENDAR KUMAR Page 1 of 58

1.PIPE
INTRODUCTION
Pipe has been in use since prehistoric time, originally for irrigation purpose. First
pipe concept comes from canal as an open half pipe then it converted into close pipe
using bamboo and clay. Day by day society used the fire up clay to manufacture the clay
pipe. Most common example is the old well in the ancient villages. As well as the
knowledge and requirement of society changed, people started to manufacture the pipes
of various materials and made the scientific use first in society then in industries.
Parallel thought also gives the idea of pipe in society from blowpipe. It was made
of bamboo having circular cross section and having different control arrangement over
the blow as to produce the different nodes. This idea might have come from any corner
but society and industry is using the pipe network as the vein of human body. Pipe
network is also increasing in the same ratio at the automation jumps its level, thus it
makes the worth to study the pipe network to make the easy of process as well as the
qualitative maintenance of piping system.
It is more difficult to define the difference between pipe and tube. In regular
commercial use no clear distinction is made. In modern power plant application, the
distribution is generally made by custom. The boiler and heat exchanger are constructed
from tubes and steam and water are transported in pipes.
Generally tubing is an internal component and piping is an external component of
machinery. Generally tubes are having smaller diameter and size designates its outside
diameter while pipes are having comparatively greater diameter and size designates its
normal bore.
Some times confusion arises between nominal size and nominal bore. Let us
make it clear to understand. The term ‘Nominal size’ should be used in preference to
‘Nominal bore’. Since the nominal size for the larger tube is related more to the outside
diameter than the bore, but the term nominal bore (NB) may continuos to be used for
screwed and shocketed tubes and fitting.
It is common practice in standards to designate various forms of joints, fittings and
flanges by ‘nominal size’ which are the same as these for the tubes which they are to be
used. Internationally the symbol DN has been agreed to for ‘nominal size’ together with
the following definition.
NOMINAL SIZE (DN)
A numerical designation of size, which is common to all components, is a piping

system other than components designated by out side diameter. It is a convenient round
number for reference purpose and it is only loosely related to manufacturing dimension.
NOMINAL BORE (NB)
A numerical designation to specify the inner diameter is bore of the pipe.
PIPE NETWORK
The pipe networks are very essential in any industrialized society and their

contributions are for providing drinking water in streets. Irrigation water into farms and
cooling water to machinery. Piping network or piping system are the arteries of our
industrial processes, which convey different types of media in different location from one
end to another end.
TYPE OF PIPE NETWORK
Types of pipe network / pipe work system depend upon the types of media being
handled in any industry. There may be numerous media depend upon the types of
industries. Following are few common pipe networks in any steel industry.
• Drinking water network.
• Sewage network.
• Deminaralised water (DM) network.
• Compressed air network.
• Super heated steam network (HOT BLAST)
• Hydraulic pipe network.
• Nitrogen network.
• Oxygen network.
• Sulfuric acid network etc.
MEDIA
The material being transferred by the pipe from one point to another point is called
as media. As we know the type of media depend upon the type of industry. In any steel
plant common fluid flowing through the pipe i.e., media can be divided into following 10
groups.
1. Water
2. Air
3. Steam
4. Acids
5. Combustible gas
6. Non combustible gas
7. Combustible liquid
8. Non combustible liquid
9. Lays
10. Vacuums
PIPE MATERIAL
The development of various material and change in the engineering need causes
the used of different material to manufacturing the pipe. The various material widely used
to manufacture the pipes can be classified as:

Pipe Material
Metallic Non-Metallic Natural

(Not for pipe use)
Rubber
Synthetic
Ferrous Non-Ferrous
Mild Steel, Carbon steel Copper, Brass
Stainless steel, Alloy steel Lead Nitril Butyl Vinyl
Cast iron, malleable iron Aluminum
Wrought iron Ceramic
Glass, Clay ware, Concrete,
Asbestos Cement
Plastic Nylon Composite Materials

Glass reinforced plastic (GRP)
Thermosetting Plastic Pipe Thermoplastic Pipe

(Not for Pipe use) Unplasticized polyvinyl chloride (nPVC)
Chlorinated polyvinylchloride (cPVC)
Acryl nitrite Butadiene Styrene (ABS)
Polypropylene (PP)
Ploy butylenes (PB)
Medium Density polyethylene (MDPE)
Cross linked polyethylene (XLPE)
High density polyethylene
Low density polyethylene (LDPE)

Various pipe materials, its specific properties and uses can be seen is
the following table.
MATERIAL PROPERTIES USES
A. Cast Iron Pipe High compressive strength Water supply

Corrosion resistance Conveying ash slurry
Good cast ability
B. Mild Steel Pipe High workability Cooling water

More weld ability Gas network
Ease of fabrication Oil network
Compressed air network
C. G.I. Pipe Corrosion resistance Drinking water network
Anti rust
D. Brass Tube High thermal conductivity Coolers

Evaporators
Heaters
E. Copper Pipe High thermal conductivity Oil cooling system
Low co-efficient of friction Heating system
Vacuum system
Lubrication system
F. Alloy Steel Pipe High creep strength Super heater
Desired properties Reheater tube in thermal
power plant
G. PVC Pipe No rust and corrosion Acid and Alkali
Light weight Drinking water
Economical Sewage
H. Stainless Steel High corrosion resistance Chemical piping

High strength Milk and food product
High temperature resistance Industries
Alkali pipe work
I. Lead Pipe Resistance to corrosion Sanitary piping in old

days.
J. Rubber Pipe No rust and corrosion Water piping

Flexible Lubrication system
Hydraulic and pneumatic
pipe network
K. Clay Pipe Economical Drain piping
L. Glass Pipe No chemical reaction Lab work

Gauge glass tube
Medicine industries

M. Aluminums Pipe Light weight Decoration piping

Anti rusting Furniture pipes
N. Nylon Pipe Flexibility Pneumatic system

Light weight Food product
Anti rust Medicine industries
No corrosion
O. Asbestos No chemical reaction Sanitary pipe work

Cement Pipe Weather proof
P. ABS Pipe Tough, Ductile, Light weight Compressed air system

Resistance to chemical
Easy to fabricate, Economical
Q. UPVC Pipe Weather resistance Acid pipe work

Resistance to abrasion Water piping
Good chemical resistance L.P. Compressed air
R. Polypropylene Anti corrosion Chemical pipe network

Pipe Work Light weight Food product industries
S. Polyethylene Provide good flow ability Chemical plant

LDPE Resistance to rust Concentrated acid
MDPE Resistance to frost Food an breviaries
HDPE Anti abrasion & corrosion Abrasive material
SELECTION OF PIPE MATERIAL
The choice of material for different industrial piping problems is a demanding

subject and basically depends upon the following factors.
• Service Condition
Type of media
Temperature
Pressure
• Environmental Condition
• Ease to Fabricate
• Economy
PIPE MANUFACTURING METHODS

Pipes are manufactured under different methods as:

A. SEAMLESS
The pipes manufactured by the seamless are having no joint. The different
methods to manufacture the seamless pipes are:
a. Cold Drawn Seamless (CDS)

b. Hot Finish Seamless (HFS)
Cold drawn seamless is as the name implies, manufactured by cold drawing a

process of drawing the tube through a Die and over a plug at room temperature.
When tubes are drawn cold they become a work hardened on the surface which
has been in contact with the die and plug. The hardness increases the yield
strength and tensile strength of the metal. If the tubes are for pressure purpose it
is being annealed.
Hot finished is the term applied to a tube, which on completion of the
manufacturing process, is ready to be delivered from the mill. This is frequently
referred to the ‘Black’ tube and is normally coated on out side with the rust
preventive solution. This product is suitable for conveying the gas, air, steam, oil,
and water in addition to being used for structural purpose.
B. SEAMED
The pipe manufactured by this method are having welded joint on its
circumference lengthwise. The various welding processes to manufacture the
seamed pipes are:
a. Electric Resistance Welding (ERW)
b. Butt Welded (BW)
c. Hydraulic Lap Welded (HLW)
d. Electric Fusion Welded (EFW)
e. Spiral Seam Welded (SSW)
f. Submerged Arc Welded (SAW)
The term arc indicates that the tube has been made from strip, which is
longitudinally welded. The method of welding may be electric resistance high
frequency or induction welded. ERW tube can be drawn conventionally through
die controlling its out side diameter and over a plug which controls the inside
diameter. By this method all traces of welding flash are removed and bore finishes
can be provided. If need for pressure purpose it is necessary to use the annealed
product.
C. CASTING
The pipes are also manufactured by the method of casting. The materials having
less workability can be used to manufacture the pipe by the same process.
Basically there are two casting methods are being used to manufacture the pipe.
a. Continuous casting
b. Permanent mould casting
c. Centrifugal casting

Generally continues casting method is the fast manufacturing method specially to

manufacture the PVC Nylon and Plastic pipes. But we prefer the permanent
mould casting method for cast iron pipe.
D. FABRICATED PIPE
Practically it is very difficult to manufacture the pipe of large diameter by above

methods. To manufacture the pipe of such a large diameter and also the pipe of
uncommon diameters can be fabricated easily by very conventional means.
Fabrication of pipe comprises the gradual bending the plate or strip (width equal to
The circumference of pipe and thickness equal the pipe wall thickness) in the
shape of pipe and then welding the joint as ‘V’ butt welding. Small length of
fabricated files are joined together to get the desired length of pipe. Still fabricated
pipes are most practical and common in industrial application.
CLASSIFICATION OF PIPE
Basically classification is done to categories the pipe for the purpose of identification.
Classification has also importance to order or to purchase the pipe from market. Pipe can
be classified as following:
1. According to material
2. According to internal diameter
3. According to outside diameter
4. According to wall thickness
5. According to method of manufacturing

6. According to Group or Grade (Duty)
Class – 1 / Heavy
Class – 2 / Medium
Class – 3 / Light
7. According to the length
8. According to surface coating

PIPE SPECIFICATION
The piping specification is used for each specific job describes the cerecteria to be used
in the design and construction of the piping system required for the project. This
specification dictates requirement concerning applicable codes, piping materials,
fabrication techniques, preferred components and supports. Over all specification gives
all specific information required relater to pipes, pipe network laying and all accessories.
The following institution who prepare specification are:.
• BIS Bureau of Indian Standard.

• BS British Standard.
• ASME American Society of Mechanical Engineers.
• DIN Dutch Identification Number.

• AISI American Iron and Steel Institution.
• SAE Society of Automobile Engineers.
• IBR Indian Boiler Regulation.
• ISO International Standard Organization.
• ASTM American Society for testing and materials.
• API American Petroleum Institute.
• ANSI American National Standard Institution.
PROTECTION OF PIPES
Protections of pipes are having great importance to save it from atmospheric

attack. Pipes of wrought iron and steel are coated with primer and then with paint on the
inside. Steel pipes used for domestic water line are coated with Zinc, Brass and Copper
pipes are many times Chrome plated. Asbestos and cement pipes are coated with
distemper.

2. PIPING TOOLS
INTRODUCTION
The pipe fitters are expected to know how to use a greater verity of tools. Many
specialized tools are needed while executing the work. The tools listed and illustrated in
the chapter are few common tools. A pipe fitter should be capable to these tools and
tackles in correct manner.
MEASURING RULE
A measuring rule is very important tool to take the measurement related to pipe
work. The old practice was the wide use of wooden rule of different sizes. But for
accurate measurement and reliably of the measuring standard we are using steel rule of
different size as from 12” to 36”. The rule having graduation for metric and inch system in
the both the edge.
FLEXIBLE MEASURING TAPES
Measuring tapes are available in a verity of length and types, but flexible steel
measuring tape is the common one. The length of tape can be selected as per the use.

SCRIBER
It consists of small (4” to 6”) round steel wire pointed at one end and is fixed with
handle or rounded off for the purpose of better grip. It is being used by pipe fitter
specially to scribe out the lines. It is also useful for marking holes in companion flange.
DEVIDER
A marking tool, being used to scribe the circle or a round hole. Practically it has use
specially at the time of making a layout related to pipe work. A flange and gasket can be
marked very well by using divider.

SQUARE
It is also an important marking as well as checking tool. Basically at the time of

making a layout it has used to draw a perpendicular line. It has also application to check
the perpendicularity of pipe end along with the axis.
SPIRIT LEVEL
A level is used to check the horizontal orientation of pipe and other accessory
related to pipe work. As a converse of above, it is also having use to measure the
inclination of pipe with horizontal. Few spirit levels are having such a construction so that
it could be used to check the vertical also.
PLUMB BOB
The word plumb means perpendicular to the plane of the horizon and since the
plane of the horizon is perpendicular to the direction of gravity at any point, the force due
to gravity is utilized to obtain a vertical line in the device known as plumb bob. The plumb
bob is made of cast steel or brass as the shape given in the figure.

PIPE VICE
This is used for clamping pipes rigidly for threading, fitting and for other operations also.
It is fitted upon a bench or on special three-legged stand. It is clear by the figure that pipe
vice is having ‘V’ shape jaw one of which is fixed and another upper one is movable.
Compared with parallel jaw bench vice, the pipe vice is having four-point contact with the
pipe while only two points in the case of other. Due to this reason pipe vice facilitates the
distribution of load into four point. These results dent free and better hold upon circular
work. We are also having few of its types as yoke vice and chain vices.
TUBE CUTTER
It is a cutting tool basically being used to cut the pipes from 1/8” to 2” NB. It is mostly
suitable for the pipes of soft material like copper, aluminums, plastics and few thin wall
conduits also. Various types of pipe cutter have been shown in the figure.

PIPE REAMER
Pipe cut or threaded by any method should be reamed to remove inside burrs.
The special reamer is self-feeding and can be used by hand or with power equipment.
PIPE THREADING DIE & TAP
All pipe threads come with BSP or NPT threads irrespective to its size. The pipe
tapes come in a pair for cutting or cleaning internal threads. For cutting external threads
a two piece die is used. While threading, adjust the die cut for small amount to avoid the
die-digging deep in the pipe. Digging deep weakens the pipe. Guide bush helps to cut
thread straight and protects the teeth of die from breaking. It is also available in different
types as Flat, Bull dog, Retched and Die chaser types. To save time and labour both we
are using pipe-threading machines of different capacity and equipped with various
attachments.

PIPE BENDING TOOLD
There are verities of devices for bending pipes, both power and hand operated.
One of the most common pipe benders is illustrated in the figure. The lever type bender
is versatile, accurate and easy to use. There are six sizes for soft or hand copper, brass,
aluminums, steel and stainless steel tube.
FLARING TOOL
Several flaring tools are often needed by the pipe fitter. The type shown in figure is
called a flaring block and will flare several different of tubing.
PIPE WRENCHES
There is no such difference between wrench and spanner. In British system it is

the wrench, which same as spanner in metric system. The straight pattern pipe wrench,
available in different sizes from 4” to 36”. It the basic tool for pipe fitter. It is used to install
or remove pipe fittings. The jaw has serration to keep the work in grip.
The end pattern pipe wrench is used when working in close quarters or next to a wall or
corner. This is available in eight sizes from 6” to 36”.
The chain wrench or chain dog can be used with ratchet like action, makes it easier to
work in extra close quarters. Basically it is being used for pipe of large diameter. It is
made in four sizes from 14” to 36”.
OFFSET HEX WRENCH
The extra wide opening smooth wide jaw of the wrench shown in figure makes it
specially useful when working with chromium plated valve or fitting. The offset jaw gives
easy access to nuts and fitting in hard-to-get at place.


3. PIPE JOINTS
INTRODUCTION
Several types of connection / joints are used to joint pipes and components. The
types of pipe coupling or methods of joining used to give satisfactory service depend on
a verity of factors e.g.
• Pipe Diameter.
• Pipe Material.
• Pressure rating and other service requirements.
• Facility available.
• Operating temperature.
In many case specific types of joints or coupling may be specified for particular
class of pipes. The type of coupling or joint suitable is often dictated by the pressure
rating or the system, compression or expansion fitting normally being employed for high
pressure work. Some of the pipe materials, for example, can not be flared, thus
eliminating this type of coupling as a choice, thin wall pipes are not suitable for threading,
and so on.
JOINTING METHODS
The most common type of jointing methods used in any industries are:
1. WELDED JOINT
2. FLANGED JOINT
3. SCREWED JOINT
COMPARATIVE STUDY OF JOINTS
Each type of connection is used for different purpose. We can have comparative
study among all three are:

METHOD ADVANTAGE LIMITATION REMARKS
Threaded Need thick pipe Weakness pipe at

Joint No area joint low installation
Fast assembly connection for cost.
Practical for small diameters valve or fitting NO specification
Good pressure and temp. required
Resistance.
Minimum skill required to
install.
No welding slag in the system
Good for installing and Difficult to align

dismantling valve and fitting. Need space for
Accepts high temp and non installation
pressure reusable. expansive
Flanged
Joint
Welded Any diameter can be welded Not possible in Required special skill
Joint lighter in over all weight hazardous
Leak proof system.
Can not be
dismantled
Needs fanges
for waves
Expansive
No perfection
allowance
WELDED JOINT
Welding is the most common method of joining high pressure, high temperature
pipe in any piping system. A welded joint is the strongest type of joint. The advantages of
welded connection are no direct leakage path, less weight and less material used. It also
facilitates less maintenance and more flexibility in piping system.
Piping 2” and smaller is normally socket welded as shown in figure where as pipes
larger than 2” diameter are normally butt-welded together.

FLANGED JOINT
A flange is a flat ring attached to the end of a pipe that is bolted together face to
face with another flange on the end of another pipe. Normally a gasket is used to seal
this joint and prevent it from leakage due to the minor imperfection of the flange faces.

FLANGE FACE
The surface of contact for a flange is called the flange face. The flange face is
made in several ways. Five types of flange faces that you may encounter are:
a. Raised face.
b. Flat face.
c. Male female face.
d. Tongue and groove.
e. Ring joint.
These flange faces are shown in figure.

RECOMMENDED USE OF FLANGE FACES
These flange faces and their recommended uses are described in the table.
Face type Description and characteristics Recommendation

Most common both bar flanges Refereed for
a. Raised face are moderate service
Faces are 1/18 high for 150- condition.
800 and ¼ high for all others
Gasket is usually less in width
than the raised face.
b. Flat Face Often made by large manning

faces from Stan care raised
face flanges.
Made in large and small Used for special
C. Male & Female design metal gasket can be service requiring a
used with small design retained gasket (not
because of high gasket common)
compression
Made in large and small Used for service
d. Tongue & Groove design inside diameter does requiring a retained
not extend to flange bore. gasket and lack of
Thus eliminating contact of contact with
gasket by process fluid. Small process fluid (not
design gives higher joint common).
efficiency possible with flat
gasket by process fluid
Most expensive but most Preferred for high

e. Ring Joint efficient flange facing not temperature and
easily damaged in assembling pressure service
FLANGE MOUNTING METHODS
Flange can be attached to pipe ands by the following methods:
• Screwed / Threaded Flange – The flange is screwed / threaded and the pipe end is
also threaded. The flange is screwed onto the threaded pipe end. Some times pipe
end is machined off (refaced) along with the flange face.
• Weld Neck Flange – The flange is butt welded to the pipe.
• Slip-On Welded Flange – Flange is slipped over the pipe, and the end of pipe is
recessed with respect to the face of the flange. The flange is welded front and back.

• Slip-On Welded Refaced – Flange has special welding groove in its face. After it has
slipped over the pipe and welded front and back. The weld metal pipe and flange are
refaced until flush.
THREADED JOINT
Pipe fittings, couplings, elbows, tees, and other connections may be threaded and
screwed together. Screwed joints should not be used whether sever service condition
exists. For example, threaded connection should not be used where erosion, crevice
corrosion, shock, and excessive vibration are likely. Threaded connections are not
normally used in high temperature and high pressure application at power plants. In fact,
they are rarely found in power plant system because the threaded joint is not leak proof
at elevated temperature and pressure. Rather it has the application in low pressure and
low temperature.
SPECIAL JOINTS
Special connections are jointing method other than the welding, flanged or
threaded types. It serves the specific purpose at specific place. Few of the special joints
are:
1. Bonded joint.
2. Brazed and soldered joint.
3. Spigot and shocketed joint.
4. Tyton joint.
5. Viking Johnson joint.
6. Stan locks self-anchoring joint.
7. Compression joint.
8. Expansion joint.

BONDED JOINT
Adhesive bonded joint are a proposition only where the tube or pipe material is
suitable for such treatment e.g. certain types of plastic tube may be jointed by adhesive
bonding, but in general performance achieved will be inferior to that at given by
alternative methods.
In case of bonded glass plastic joints, pipe ends are formed so that the male end
of the pipe can be spigot into the female end and drawn up tight with clamps. An annular
clearance between the two overlapping section is then completely filled with resin which
is then set, resulting in a permanent, highly satisfactory joint with a good strength.
Special equipment is needed to make such bonded joints. Since the joint area must be
preheated and hot setting resin is employed.
Adhesive bonding on metallic pipe offers no advantage and many disadvantages

employed with conventional jointing method. Where as it is more popular in the case of
PVC and plastic pipes.

BRAZED AND SOLDERED JOINT
Brazing and soldering are applicable for low-pressure work, particularly for copper
and copper ally pipes. Soft soldering is not generally considered satisfactory, while
brazing is generally to be preferred to silver soldering on the score of strength, although
silver soldering is rather easier to apply. High frequency brazing is ideally suited to
stainless steel, while flame brazing or furnace brazing is also possible and easy to
perform.
SPIGOT AND SHOCKETED JOINT
There are various forms of spigot and shocketed joints, the most traditional being
the run lead joint. This type requires a fair amount of skill and may be considered difficult
in its making relative to its counter part. The same jointing method is also called as ‘Bell
and spigot joint.’

STAN LOCK SELF ANCHORING PIPE JOINT
The stan lock self anchoring pipe joint, (also called as bolted gland flexible joint)
can be utilized as such by merely inserting a split circlip in the specially formed chamber
in the socket and engaging it in a machined groove in the spigot. When a self anchoring
pipe line is to be install with this type of joint, the only additional requirement over the
formal design are for the pipe to have prepared for spigots and for the requisite number
of circlip is to be supplied. The method of sealing in the joint is virtually self-explanatory
in the figure.

TYTON JOINT
The Tyton anchor joint gasket is basically the same as the used in the
conventional tyton design is respect of dimensions and shape but serves as a carrier for
an integrally moulded toothed stainless steel insert, the teeth of which grip onto the
spigot surface to prevent joint separation.
VIKING JOHNSON COUPLING
There are many other types of joints in the market, non-being more successful
than the Viking Johnson coupling. The Viking Johnson coupling is designed for use with
plain ended pipes of steel, cat iron, ductile iron, concrete, asbestos cement, uPVC and
other similar materials. The joint comprises a center sleeve, two rubber wedge rings,
two-end flange and the necessary nut and bolts. The center sleeve can be supplied with
or without a center register. The register provides a locating stop to center of the
coupling and aids the laying of long pipe runs.
On the debit side the Viking Johnson Coupling doesn’t mechanically prevent separation
of pipe, so it is anchored by means of harness when pipe is laid above the ground.

FLARED JOINT
Flared joints are used to joint the pipes, which are well adapted to high-pressure
service and have exceptional resistance to mechanical pullout. They are used where a
joint is to be subjected to periodical disassembly, as they will giver repeated tight
connection. The nature of joint consists of the flair of the tube clamped between the nuts
and the body, which also have 45-degree flare on them. The flared types of fitting are
used on high, medium and low pressure lines where excessive vibration or tube
movement is not involved. These have proved on oil burners, refrigeration, air
conditioning, marine and LPG applications.
Single or double flair is made on tubing for maximum reliability. Double
flair ensures a positive sealing even if excessive tightening of joint is done.
COMPRESSION FITTINGS
The fittings which are widely used, known for their ease of assembly and efficiency for
high pressure connection. There are various types of compression fittings which can be
adapted to cater for different services and needs.

LOW – PRESSURE COMPRESSION FITTING

a) Olive type compression fitting:
Consists of the main body, nut and olive or sleeve. The sleeve compresses around the
tube when nut is tightened. These are useful for connecting copper, aluminums and
brass tubes. These are suitable for maximum working pressure of 20Kg/cm2.
b. Poly Flow Compression Fitting:
These are also similar to ‘olive type’ compression fittings. The body is similar to olive
type but has built in support for housing the plastic tube. An acetyl resin sleeve holds the
plastic tubing when the nut is tightened. These are mainly used where pressure does not
exceed 7 Kg/cm2. These fittings can be tightened by finger pressure rather no tools are
needed.
HIGH – PRESSURE COMPRESSION FITTING:
The joint mainly consists of main body, which has threads to suit the nut and a
cutting ring. Unlike other low-pressure fittings, the ring is not compressed on the surface
of tube. While tightening the nut, the cutting ring moves along the tube and at the same
time cuts into it, thus embedding into the ridge of the displaced material. The depth of cut
is controlled and there is no danger of cutting deeply that the tube is weakened. This
metallic interlock keeps this type of fitting absolutely leakproof even up to a pressure of
500Kg/cm2 and upper sever vibration condition.
These fittings require no special tools as such for installation. The tube is cut
square, debarred and assembled. The ring or sleeve gets permanently attached to the
tubing after the first assembly. These types of fittings are used in hydraulic control, high-
pressure lubrication systems and various pipe work system or process industries.

Expansion Joint
Expansion joints give system flexibility by permitting relative motion between pipe
sections. They compensate for change in dimension due to temperature variation or
permissible motion of concerned equipment. There are various type of expansion joints
which can be explained as following.
Slip Expansion Joint:
The slip expansion joint has a slip pipe welded to two flanges. Packing prevents
leakage between two pipes. The packing is placed around the outside of the slip pipe
and the slip pipe moves with the packing. The slip joint is lubricated to permit easy
movement. Slip joints are capable of handling a large amount of expansion. They are
typically used in low pressure applications.
Corrugated expansion joint:
The corrugated expansion joint has a flexible corrugated section of pipe that is
able to absorb pipe movement. A simple corrugated joint suitable for low pressure is
shown in figure.

Rubber expansion joint:
The rubber expansion joint is a flexible connector made of natural or synthetic

rubber, reinforced with fabric or metal or the both. It is design to allow the movement of
piping caused by temperature differences or the differing rate of expansion. This type of
expansion joints are made in the power plant system as:

• Condenser connection, circulating waterside.

• Extraction steam lines.
• Connection to air ejector.
• Condensate pump and low-pressure boiler feed pump suction lines.
A rectangular rubber expansion joint usually forms the flexible connection between the
turbine and condenser.
Duct type expansion joint:
The duct type of expansion joint is also made of rubber with reinforcing fabric.
Carbon or stainless steel retaining ring connects section of the power plant’s combustion
air ducting or components. The duct type expansion joint is used in the following power
plant system.
• Bughouses.
• Scrubbers.
• Precipitators.

On high pressure and high temperature pipes such as the main steam line reheat
system piping, expansion joints are not practical. In these systems, allowance for thermal
expansion must be made in the layout of the piping system. The layout includes a
number of bends and loops that allow room for thermal expansion or contraction.

4. SUPPORTS AND HANGERS
INTRODUCTION
Piping must be supported to prevent its weight from being transferred to attached
equipment. Pipe hangers prevent the sagging of pipe and allow for slight movement of
piping expansion and contraction caused omni directional piping movements.
Hangers must carry the weight of pipe, valves, fittings, and insulation, plus the
weight of the fluid inside the pipe. Pipe fitter should be familiar with the different types of
pipe hangers and be able to tell when undue stress is being exerted on the hanger.
The hangers and support most commonly used in any process industries are:
• Adjustable Hangers
• Variable Spring Hangers
• Constant Supports
• Roller Stand Supports
ADJUSTABLE HANGERS
Two common types of adjustable hangers, design to hang from overhead beams,
are shown in figure do not allow adjustable hanger for any vertical movement of the
system. A simple strap is used if horizontal pipe motion is not a factor a roller is used if
some horizontal movement is expected. These hangers are also commonly referred to
as rigid hangers.

VARIABLE SPRING HANGER
Variable spring hangers permit piping to move up or down without suddenly

distributing the load distribution. This type of hanger supports pipe runs, that may be
subjected to slight vertical movements. Variable spring hangers also support piping that
may be shifted horizontally due to movement of attached equipment or piping. An
example may be would thermal expansion of a vertical piping run followed by a 90
degree elbow and a horizontal run.
Variable hangers also provide a cushion for the piping system. Plant operators of pipe
fitters must observe these hangers closely to make sure the
load is balanced and the spring area not fully compressed or bottomed. Each hanger is
equipped with a load indicator and a load scale. The scale is normally marked with an
“H” or “C” to denote the correct load reading when hot and cold.

Variable hangers also provide a cushion for the piping system. Plant operators of pipe
fitters must observe these hangers closely to make sure the
load is balanced and the spring area not fully compressed or bottomed. Each hanger is
equipped with a load indicator and a load scale. The scale is normally marked with an
“H” or “C” to denote the correct load reading when hot and cold.
CONSTANT SUPPORT
Constant supports have a coiled helical spring that moves as the pipe moves to
provide constant support. This type of support is used when vertical movement is
substantial. Critical piping systems such as the main steam piping system usually have
constant support.
The constant support is adjusted to support a specified load. However spring
compression may be readjusted by tightening or loosening the spring tension. Constant
support are also fitted with the load indicator and marking on the scale. It should be
inspected to prevent spring from fully compressing.

ROLLER STAND SUPPORTS
The roller stand support may be bolted to beams or floors. Two general types of
roller stand support are adjustable and nonadjustable. The adjustable type can be raised
or lowered by flour adjusting screws to match pipe position. This type of support allows
for horizontal movement along the piping run. A typical application of roller stand
supports would be under a long horizontal piping system that is expected to undergo
extension and contraction as it warms and cools.

5. FITTINGS
INTRODUCTION
Since pipe cannot be obtained in unlimited lengths and practically in all pipe installations
there are numerous change in directions, branches, etc. By definition, the term fitting is
used to denote all fittings that may be attached to pipes. The very purposes of using
fittings are.
• To alter the directions of a pipe

• To draw out the branch with a main
• To connect two pipe of similar or different diameter
• To close the end
• To extend the length of pipe
Classification
There are different types of fittings. Thus various fittings may be classified as:
a) With respect to material:

1. Cast iron 2. Malleable iron 3. Brass 4. Copper
5. Steel 6. Plastic 7. Glass etc.
b) With respect to Design:

1. Plain 2. Beaded 3. Band
c) With respect to jointing method:

1. Screwed 2. Flanged 3. Hub and Spigot 4. Cement
5. Soldered 6. Glued 7. Welded 8. Compression
d) With respect to strength:

1. Gas 2. Steam 3. Hydraulic 4. Extra Heavy
e) With respect to surface:

1. Black 2. Galvanized
f) With respective to Finish:

1. Rough 2. Semi-finished 3. Finished 4. Polished
g) With respective to Service:

1. Gas 2. Steam 3. Hydraulic 4. Drain 5. Water etc

Types of Fittings:
Based on the classification, the fittings may be divided into several groups with respect of
their use:
a) Extension or joining
1. Nipple
2. Lock nut
3. Coupling
4. Off set
5. Joints
6. Union
b) Reducing or enlarging pipe diameter.

1. Bushing
2. Reducers
c) Changing in direction.
1. Off set
2. Elbow
3. Bends
d) Branching.
1. Side outlet elbows
2. Back outlet elbows
3. Tee
4. Branches
5. Crossers
e) Shutoff or closing purpose

1. Plug
2. Caps
3. Flanges
Common types of Fittings:

Nipple:
Nipple is short pieces of pipe threaded at both end and being used to extend the length
of pipe.
It is of three types:
• Close nipple
• Short nipple
• Long nipple
Uses:
Normally used to get extra length specially while using down cocks on a wall, valves in a
system.

Socket:
These are also known as couplings, have internal threads so that they may connect
together two length of pipes end to end
It is of three types:
• Plain socket
• Reducing socket
• Eccentric socket
Uses:
To connect two stock length of pipe reducing socket is used to connect a big dia pipe to
a small dia pipe face to face.
Elbow
It is used to changer the direction of pipe by 90 degree but with quick change.
It is of two types:
• Plain
• Male-Female elbow
Uses:
To connect angular connections.

Bend
It was slow bend which does not obstruct the flow and does not the flow of
Uses
In hydrageni line pump section line etc. Return bends s used where line is above to be
returned back upon its
Tee
It is in ‘T’ shape and being used to branch off line at 90 degree.
Uses
To take branch at right angle to the supply line
Branch
When a branch line is to be taken out from main line branch is used. It does not
resistance flow and pressure. Some times its called as 45 degree branch.
Crossers
Crossers have four opening which connects area pipelines are right angles to each one.
Union:
This connects two pipes and provides the facility to disconnect them in the middle of a
pipe run which other wise is not possible without cutting.
Uses:
The union is normally used in the middle of the pipe run the pipe therefore is easily
repaired in the event of a leak or blockage in the vicinity. Hence it provides additional
maintenance facility in the pipeline.

Cap
The cap has internal threads and is used to close the threaded end of the pipe.
Plug
It has external thread with a square flat spanner end.
It is of two types:
• Hollow plug
• Beaded plug
Uses:
Beaded plug is used for blanking off and hollow plug is used as drain plug.
Drain plug is used to take cut the collected foreign particles from the oil tank.
Forged Steel Fittings:
Forged steel foreign are made from solid forging, carbon steel or seamless pipe and are
thus insured of uniform wall thickness and high tensile strength. Wide ranges of fittings
obtained from 1/8” to 4”.
Use:
It is used in high-pressure lines as well as in high temperature also.

6.PIPE BENDING
INTRODUCTION:
When ever the pipe lines are installed it is not possible to install the line without providing
the bends. Different types of bend fittings are available for the purpose of directional
changes but the leakage points are increasing by using separate bent fittings. To avoid
the joint leakage, it is always better to use the technique to bend the pipes and tubes of
required angle and radius. Same time it reduces line friction, comparatively economical
and most suitable for viscous media which tend create blockages.
Bending Methods:
There are basically two bending methods:
• Hot bending
• Cold bending
Hot bending is prepared by heating the material up to its plastic state (650-Degree
Celsius) and then bending by suitable means. Whereas as cold bending are performed
at room temperature. The selection of whether hot or cold bending depends on.
• Size of pipe
• Wall thickness of pipe
• Bend radius
• Material of pipe
Care is to be taken that bend radius must be less than three times the NB of pipe.
Steps of Hot Bending
• Draw the layout sketch

• Prepare template to ensure accuracy
• Measure / calculate stock size
• Plug one end of pipe and fill the pipe with fine and dry sand.
• Plug the another end of pipe
• Heat the pipe suitably and bend it as per the prepared template.
• Clean the pipe properly
Care
• Thin layer of chalk is desirable upon layout sheet

• Select the straight wire to make template
• Use thin string to measure the stock size
• Plug should be provided with breathing hole
• Always use fine and dry sand
• Never over heat the pipe (Cherry Red)
• Be careful of possible defects


Bending Defect:
During the hot and cold bending preparation a number of defects can arise. The defects
and care to prevent are as detailed below.
• Flattening: Outer radius of pips becomes flat.

• Buckling: Inner radius of pipe acquires waviness or wrinkle.
• Thinning: Reduction of wall thickness of pipe at outer radius.
• Ovality: Cross section of pipe gets oval.
• Hot Spot: Caused by over heating which is identified as bright colour area contrast
with general colour of the heated pipe.
These defects can be minimized by taking care as:
• Take care with the packing of pipes for hot bending. Correct fitting of sand will
prevent few defects.
• Ensure that the heated area of the pipe is not in contact with bending pins.
• Ensure that the support plates are used with bending pins.
• Select and use correct radius or bend to suit the size of the pipe
• Select and use the correct components on bending machine e.g. Guide, formers and
stops.

Filler Material:
The importance of filler material is very high practically at the term of hot bending of large
pipe diameter as well as for cold bending of thin walled tubes at very close radius of
bends. Various types of filler material for hot and cold bending are:
• Sand
• Bending
• Wax
• Pitch
• Resin
• Lime
• Low melting point alloy (Lead)
Out of which sand and bending springs are suitable for hot bending. The sand having
properties of high refractoriness, cheaper and reusability is performed by piping
techniques.
Heating Source:
There are numbers of heating source available for pipe bending as:
• Oxyacetylene flame
• Blow lamp
• Hearth
• Burner
• Induction heater
• Furnaces
• Steam
• Electric element heater
• Hot air
• Boiling water
• Chemical pack (exothermic)
Pipe techniques selects the suitable method depending upon the size of pipe, design of
bend, pipe material, number of bend required, availability of heating source and cost
involved.
Common Bend:
Bends commonly used in any steel industry are:

• Offset Offset the path of pipe line
• Quarter (90 degree) bend Change in direction
• Return (180 degree) bend Change in direction, Heating & Cooling
• Expansion bend Take expansion and contraction
• Bent coil Heating & Cooling system
• Dead expansion bends Expansion and contraction to more extant.


Bending Machines:
In pipe bending shop there are various types of machines are used out of which few
commonly used are:
• Two pin bending fixture

• Hand operated pipe bender
• Hydraulic pipe bender
Two Pin Bending Fixture:
The bends are prepared by fixing the pipe within pair of pins and curvatures are
compared with accurate template. The two-pin fixture facilitates to bend the pipe at any
radius. Although the process requires much time and more skill but very suitable for
bends of complexity and less number of identical work is to be performed.
Hand Operated Pipe Bender
Here tubes are not filled and no heating is required. In this case a sharp bend cannot be
obtained. The bend radius is fixed which depends upon the radius of circular former.
Process has limitation that we can bend only smaller diameter pipe of thinner wall
thickness. But very much suitable for mass production.

Hydraulic Pipe Bender
A machine bender whether hand, hydraulic and power operated essentially consists of a
round former and roller which is separate for various pipe diameter. The radius becomes
progressively greater as the tube larger in hydraulic pipe bender the actuation of former
is obtained by the pressure of a O pressure is maintained by hand or motor driven pump.
The machines the laborer and having good compliance with mass production.
Bending Allowance
While using a three point bending machine for the pipe at 90 degree one NB must be
deducted from the required length. Always bend length must be calculated from the
center line of the pipe.
Example A 1 5” NB pipe bend is required. The length of 12” from the end of the pipe to
the center line of the bend leg is required. To mark this subtract the NB from the bend
length (i.e. 12”).
Mark the pipe and match with this mark in the middle of former. The result will be
desirable.


7. SYMBOLS
7.1 VALVE SYMBOL

Threaded Fitting Symbols

Welded Fittings

7.4 FLANGE SYMBOLS:

8. Colour Code
INTRODUCTION:
We know that numbers of process fluid is required for various industrial process and
hence the pipe network. To distinguish the media flowing through the pipe it is required
to have a wide range of colour code. The combination of ground, primary and secondary
colour serves the purpose to identify the number of media. Without knowing the colour
code, a piping technician or the operator can not work with a pipe network.
Colour Code for Pipe Line Conveying Fluids

(Tata Steel Standard):
Fuel Gases
CONTENTS GROUND FIRST SECOND
Blast furnace gas Light gray Venetian red
Coke oven gas Coal tar black
Mixed gas Coal tar black Venetian red
L.D. gas Light gray Golden yellow
Other Gases
Acetyline LP Canary yellow Dark violet
Hydrogen Canary yellow Signal red French blue
Nitrogen LP up to Canary yellow Black
5 bar
Nitrogen HP Canary yellow Signal red
Argon Canary yellow Brilliant green
Benzol Dark violet French blue
The word *________* in black shall be written on the pipe line at suitable location
Oxygen Aluminum with word “OXYGEN” in Red

Ammonia Dark violet
Ammonia liquor Dark violet Canary yellow
Sulpher di-oxide Dark violet Brilliant green
Carbon di-oxide Canary yellow Light gray

AIR LINES
CONTENTS GROUND FIRST SECOND
Compressed air Sky blue
up to 15 bar
Compressed air Sky blue Signal red
above 15 bar
Dry air or Sky blue White
instrument air
Vacuum air Sky blue Black
Furnace pressure French blue Aluminium
and draft impulse
Cold / Host blast Light gray
Acid and Alkali Lines
Hydrochloric acid Dark violet French blue Canary yellow
Sulphuric acid Dark violet
Castic soda Dark violet Aluminium
Lime Dark violet Light orange
Oil Lines
Furnace oil Canary yellow
Lubricating oil Canary yellow Light brown
Hydraulic oil Canary yellow French blue
Tar lines Black Aluminium
Water Lines
Demineralised Brilliant green Light orange
Boiler Feed Water
DM BF water Brilliant green with Light orange
return word “RETURN”
in Golden yellow
Cooling Brilliant green White
Cooling return Brilliant green with White
word “RETURN”
in Golden yellow
Drinking Brilliant green French blue
Service water Brilliant green
Fire hydrant water Post office red
Contaminated Brilliant green Signal red
water
Chilled water Brilliant green Light gray French blue
Chilled water Brilliant green with Light gray French blue
return word “RETURN”
in Golden yellow

9. USEFUL INFORMATION
9.1
Flow = Cross Section Area X Velocity of Flow
Q=AXV
Hence, The capacity of pipes is the square of their diameters. Thus doubling the
diameter of pipe increases its capacity four times.
9.2
Weight of pipe = Cross Section Area X Length X Specific Gravity
(Pipe Material)
9.3
Cross Section Area of Pipe = n/4 (OD x OD – ID X ID)
9.4
For pipe fabrication
Number of degree of turn

Angle of cut =
Number of weld x 2
DRILL SIZE FOR BSP TAPS
Tap size Thr. P. Inch Drill size Tap size Thr. P. Inch Drill size
1/8” 28 11/32” 2” 11 2-3/16”

¼” 19 7/16” 2 ½” 11 2-9/16”
3/8” 19 37/64” 3” 11 3-3/16”
½” 14 23/32” 3 ½” 11 3-11/16”
¾” 14 59/64” 4” 11 4-3/16”
1” 11 1-5/32” 4 ½” 11 4-3/4”
1 ¼” 11 1-1/2” 5” 11 5-5/16”
1 ½” 11 1-49/64” 6” 11 6-5/16”

BSP THREADS BASIC DIMENSION

NB of Tube O/S Dia Thr. P. Inch Depth of Pitch Dia Thr. Length
Thr
All dimensions are in inches
1/8 0.400 28 0.0229 0.3601 0.2345
¼ 0.538 19 0.0337 0.4843 0.2514
3/8 0.676 19 0.0337 0.6223 0.3947
½ 0.847 14 0.0457 0.7793 0.5178
¾ 1.063 14 0.0457 0.9953 0.5714
1 1.336 11 0.0582 1.2508 0.6591
1¼ 1.677 11 0.0582 1.5918 0.7500
1½ 1.909 11 0.0582 1.8238 0.7500
2 2.381 11 0.0582 2.2888 0.9204
2½ 2.996 11 0.0582 2.9018 1.0511
3 3.449 11 0.0582 3.4018 1.1761
3½ 3.991 11 0.0582 3.8918 1.2386
4 4.494 11 0.0582 4.3938 1.4091
5 5.498 11 0.0582 5.3918 1.5795
6 6.501 11 0.0582 6.3918 1.5795
STANDARD PIPE DATA

Pipe NB Actual ID Actual OD Inside area Weight per Length Volume in
Inch (Inch) (Inch) (Sq. Inch) Foot containing one linear
(Pounds) one cubic foot
foot (Feet) (Gallons
1/8 0.269 0.405 0.057 0.244 2526.0 0.0030
¼ 0.364 0.540 0.104 0.424 1383.8 0.0054
3/8 0.493 0.675 0.191 0.567 754.36 0.0099
½ 0.622 0.840 0.304 0.850 473.91 0.0158
¾ 0.824 1.050 0.533 1.130 270.03 0.0277
1 1.049 1.315 0.854 1.578 166.62 0.0449
1¼ 1.308 1.660 1.496 2.272 96.275 0.0777
1½ 1.610 1.900 2.036 2.717 70.733 0.1058
2 2.067 2.375 3.356 3.652 49.913 0.1743
2½ 2.496 2.875 4.788 5.793 30.077 0.2487
3 3.068 3.500 7.393 7.575 19.479 0.3840
3½ 3.648 4.000 9.887 9.109 14.565 0.5136
4 4.026 4.500 12.730 10.790 11.312 0.6613
4½ 4.660 5.000 15.470 12.954 9.030 0.8284
5 5.047 5.563 20.006 14.617 7.198 1.0393
6 6.065 6.625 28.890 18.974 4.984 1.5008

PIPE FLANGE
Pipe NB Thickness of Flange Bolt Circle Number of Bolt Diameter
Flange Diameter Diameter Bolt
½” ¼” 3 ¾” 2-5/8” 4 ½”
¾” ¼” 4” 2-7/8” 4 ½”
1” 9/32” 4 ½” 3-1/4” 4 ½”
1 ¼” 5/16” 4 ¾” 3-7/16” 4 ½”
1 ½” 11/32” 5 ¼” 3-7/8” 4 ½”
2” 3/8” 6” 4-1/2” 4 5/8”
2 ½” 13/32” 6 ½” 5” 4 5/8”
3” 7/16” 7 ¼” 5-3/4” 4 5/8”
3 ½” 15/32” 8” 6-1/2” 8 5/8”
4” ½” 8 ½” 7” 8 5/8”
5” 9/16” 10” 8-1/4” 8 5/8”
6” 11/16” 11” 9-1/4” 8 ¾”
7” ¾” 12” 10-1/4” 8 ¾”
8” ¾” 13 ¼” 11-1/2” 8 ¾”
9” 13/16” 14 ½” 12-3/4” 12 ¾”
10” 7/8” 16” 14” 12 ¾”
12” 1” 18” 16” 12 7/8”
9.6
Method of jointing used to give satisfactory service depends upon
• Pipe diameter
• Pipe material
• Pressure rating
• Service requirement
• Facility available
9.7
• Manufacturer provide + 12.5% on the wall thickness to avoid “Thinning”
• Radius of metred ELL = 2X NB
• Radius of Bend = 2.5 to OD

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INDUSTRIAL PIPING SYSTEM

Sl. No. Topics Page #

01. Pipe 03-10

02. Piping Tools 11-18

03. Pipe Joints 19-33

04. Supports and Hangers 34-37

05. Fitting 38-45

06. Pipe Bending 46-52

07. Symbol 54-57

08. Symbols 58-59

09. Useful Information 60-62

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NOMINAL SIZE (DN)

A numerical designation of size, which is common to all components, is a piping

NOMINAL BORE (NB)

A numerical designation to specify the inner diameter is bore of the pipe.

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TYPE OF PIPE NETWORK

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Metallic Non-Metallic Natural

Plastic Nylon Composite Materials

Thermosetting Plastic Pipe Thermoplastic Pipe

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MATERIAL PROPERTIES USES

A. Cast Iron Pipe High compressive strength Water supply

B. Mild Steel Pipe High workability Cooling water

D. Brass Tube High thermal conductivity Coolers

H. Stainless Steel High corrosion resistance Chemical piping

I. Lead Pipe Resistance to corrosion Sanitary piping in old

J. Rubber Pipe No rust and corrosion Water piping

K. Clay Pipe Economical Drain piping

L. Glass Pipe No chemical reaction Lab work

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M. Aluminums Pipe Light weight Decoration piping

N. Nylon Pipe Flexibility Pneumatic system

O. Asbestos No chemical reaction Sanitary pipe work

P. ABS Pipe Tough, Ductile, Light weight Compressed air system

Q. UPVC Pipe Weather resistance Acid pipe work

R. Polypropylene Anti corrosion Chemical pipe network

S. Polyethylene Provide good flow ability Chemical plant

SELECTION OF PIPE MATERIAL

The choice of material for different industrial piping problems is a demanding

PIPE MANUFACTURING METHODS

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a. Cold Drawn Seamless (CDS)

Cold drawn seamless is as the name implies, manufactured by cold drawing a

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Generally continues casting method is the fast manufacturing method specially to

Practically it is very difficult to manufacture the pipe of large diameter by above

5. According to method of manufacturing

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• BIS Bureau of Indian Standard.

• DIN Dutch Identification Number.

Protections of pipes are having great importance to save it from atmospheric

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FLEXIBLE MEASURING TAPES

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It is also an important marking as well as checking tool. Basically at the time of

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PIPE THREADING DIE & TAP

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PIPE BENDING TOOLD