CM4120

Unit Operations Lab

Piping Systems
Piping Systems in the Chemical Process
Industries
March, 2008

 Introduction
 Basis for Design
 Piping Codes and Standards
 Design of Process Piping Systems
 Joints and Fittings
 Valves

1
CM4120
Unit Operations Lab

Piping Systems
Piping Systems include:
 Pipe
 Flanges
 Fittings
 Bolting
 Gaskets
 Valves
 Hangers and supports
 Insulations, coverings, coatings
2
CM4120
Unit Operations Lab

Piping Systems

“Piping systems are like arteries and

veins. They carry the lifeblood of
modern civilization.”

Mohinder Nayyar, P.E.

Piping Handbook, 7th ed.
McGraw-Hill, 2000

3
CM4120
Unit Operations Lab

Piping Systems

Primary Design Consideration is Safety

Evaluate Process Conditions
 Temperature
 Pressure
 Chemical compatibility/Corrosion allowances
 Vibration, flexing, bending
 Expansion/Contraction due to temperature change
 Environmental conditions
Evaluate the Effects of a Leak
Evaluate Performance in a Fire Situation
4
CM4120
Unit Operations Lab

Piping Systems
Secondary Considerations
Evaluate any Special Requirements
 Sanitary requirements – “Cleanability”
 Serviceability – ease of maintenance of equipment
 Possible contamination of process fluid by piping
materials, sealants, or gasketing
 Earthquake, Hurricane, Lightening, Permafrost
Lowest Cost over the Lifetime

5
CM4120
Unit Operations Lab
Piping Systems
Piping System Design Criteria
4 areas to consider:
 Physical Attributes
 Loading and Service Conditions
 Environmental Factors
 Materials-Related Considerations

6
CM4120
Unit Operations Lab

Piping Systems
Codes and Standards simplify design,
manufacturing, installation process
Standards – provide design criteria for
components
 standard sizes for pipe
 dimensions for fittings or valves
Codes – specific design/fabrication
methodologies
 Incorporated into local/regional statute
 It’s the LAW
7
CM4120
Unit Operations Lab
Piping Systems

ASME Boiler and Pressure Vessel Code

ASME B31: Code for Pressure Piping
ANSI Standards – dimensions for valves,
piping, fittings, nuts/washers, etc.
ASTM Standards for piping and tube
API – Specs for pipe and pipelines
AWS, ASHRAE, NFPA, PPI, UL, etc.

8
CM4120
Unit Operations Lab

Piping Systems
ASME B31 is the applicable standard for
design of most piping systems in
chemical plants
B31.1 – Power plant boilers
B31.3 – Chemical plant and refinery piping
B31.4 – Liquid petroleum transport
B31.7 – Nuclear power plant radioactive fluids

9
CM4120
Unit Operations Lab

Piping Systems
ASME B31.3 – Chemical Plant and
Refinery Piping Code
Includes:
Process piping in chemical and refinery plants
Process piping in pharmaceutical and food
processing
Process piping in textile and paper plants
Boiler piping

10
CM4120
Unit Operations Lab

Piping Systems
ASME B31.3 covers:
Materials and design
Fabrication
Erection and assembly
Support
Examination, inspection, and testing

Web reference: www.piping-toolbox.com

11
CM4120
Unit Operations Lab

Piping Systems
Standard Pipe Sizes
Diameters are “Nominal”
 Sizes 12” and less, nominal size < OD
 Sizes 14” and over, nominal size = OD

Wall thickness inferred thru “Schedule”

 Schedule = P/S * 1000

 Defined Schedules:

5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160

12
CM4120
Unit Operations Lab

Piping Systems
Standard Tubing Sizes
Steel tubing
 Diameters are Actual OD
 Wall thickness is specified
Refrigeration Tubing
 Single wall thickness available for each size
 Actual OD
Copper Tubing – Nominal sizes
 Type K, L, M

13
CM4120
Unit Operations Lab

Piping Systems
Materials – Metallic piping
Carbon and low alloy steel
 Ductile
 Inexpensive and available
 Easy to machine, weld, cut
 Some drawbacks

14
CM4120
Unit Operations Lab

Piping Systems
Materials – Metallic piping
Alloy Steels including “Stainless Steels”
 Good corrosion resistance
 More difficult to machine, weld, cut
 Some drawbacks

15
CM4120
Unit Operations Lab

Piping Systems
Materials – Metallic piping
Nickel, Titanium, Copper, etc.
 Copper is used in residential and commercial
applications and is widely available
 Other materials are expensive and difficult to
machine, weld, join
 Some incompatibilities with each

16
CM4120
Unit Operations Lab

Piping Systems
Materials – Non-Metallic piping
Thermoplastics
 Wide range of chemical compatibility
 Light weight
 Easily cut and joined
 Low temperature limits
 Need extra supports

17
CM4120
Unit Operations Lab

Piping Systems
Materials – Non-Metallic piping
Fiberglass Reinforced Pipe
 Wide range of chemical compatibility
 Easily cut and joined
 Wider temperature limits than thermoplastics
 Thermal expansion similar to carbon steel
 Similar structural performance as carbon steel

18
CM4120
Unit Operations Lab

Piping Systems
Materials – Others
Glass
Concrete
Lined or coated
 Glass
 Rubber
 Cement
 Teflon
 Zinc (galvanized pipe)
Double Containment piping systems

19
CM4120
Unit Operations Lab

Piping Systems
Piping Insulation
Prevent heat loss/ gain
Prevent condensation – below ambient
Personnel protection – over 125oF
Freeze protection – outdoor cold climates
Fire protection
Noise control

20
CM4120
Unit Operations Lab
Piping Systems
Fiberglass Insulation w/ Asbestos plastered
fitting coverings

21
CM4120
Unit Operations Lab
Piping Systems

Metal Jacketed
insulation covering

22
CM4120
Unit Operations Lab

Piping Systems
Heat Tracing
Prevents flow problems in cold climates
 Freeze protection
 Loss of flow due to viscosity increase
Prevent condensation in vapor lines
Methods
 Electric
 Hot Fluids

23
CM4120
Unit Operations Lab

Piping Systems
Piping Supports
Prevent strain at connections
Prevent sag
Must allow for expansion/contraction
Design for wind/snow and ice/earthquake
Clearance for plant traffic and equipment

24
CM4120
Unit Operations Lab
Piping Systems
Results of inadequate support

25
CM4120
Unit Operations Lab
Piping Systems
Results of inadequate support: Flixborough,
England
May, 1974 – Leaking reactor removed from train of
reactors and temporarily replaced with a section of
pipe

June, 1974 – Supports collapse, pipe breaks

28 dead, 89 injured, 1800 houses damaged, 160
shops and factories damaged, large crater where
plant stood

26
CM4120
Unit Operations Lab
Piping Systems

The Design Process – a three step

approach
Design for Flow
 Find min. diameter to achieve desired flow velocity
Design for Pressure Integrity
 Find min. wall thickness for process and external
conditions
 Find appropriate rating of in-line components
Re-check for Flow Criteria
27
CM4120
Unit Operations Lab

Piping Systems
Design for Flow
Determined by economics
Piping system must provide reliable service for
expected life
Smallest diameter usually is lowest cost

28
CM4120
Unit Operations Lab
Piping Systems
Typical design velocity Rules of Thumb
when sizing piping...
Water lines: 5-7 ft/sec
Pump discharge: (d/2 + 4 ft/sec)
Pump suction: (1/3 * discharge velocity)
Steam: d in 1000 ft/min
Slurries: > min. entrainment velocity

d = I.D. of pipe in inches

from Rase and Barrow, Project Engineering of Process Plants,
John Wiley, New York, 1957.
29
CM4120
Unit Operations Lab
Piping Systems
Next determine wall thickness:
Pressure Integrity Design method
ASME B31.3,
PD
tm  A
2SE  Py 
tm=min. wall thickness E=weld joint efficiency
P=design pressure, psig y=factor to adjust for temp
D=O.D. of pipe, in. A= add’l thickness for
S=allowable stress, psi corrosion, external loads,
etc.
30
CM4120
Unit Operations Lab
Piping Systems
Finally re-check ID

Select in-line components

Determine insulation, coverings, coatings

Design and locate supports and hangers

31
CM4120
Unit Operations Lab
Piping Systems
Effect of Thermal Expansion
Example:
Calculate the expansion per 20’ length of
2”, schedule 40 carbon steel steam line
at boiler startup for a 100 psig steam
service.
α=thermal expansion coefficient
for mild steel, α =6.6x10-6 in/inoF

32
CM4120
Unit Operations Lab
Piping Systems
Temp of pipe at amb. cond. =70oF
Temp of 100 psig sat. steam =338oF
ΔT=268oF
L=20’=240”
expansion due to temperature
increase is α *L* ΔT
=(6.6x10-6in/inoF)*(240in)*(268oF)
=0.42” in per 20’ of pipe
33
CM4120
Unit Operations Lab
Piping Systems
What force is exerted on the end
restraints of that 20’ pipe if it is rigidly
installed (end restraints can’t move)?
σ=internal stress due to ΔT, and
σ = α *(ΔT)*E
E is the material property called Modulus
of Elasticity, relationship between stress
and strain
E=30x106 psi for low carbon steel
34
CM4120
Unit Operations Lab
Piping Systems
σ= α *(ΔT)*E
=(6.6x10-6 in/inoF)*(268oF)*(30x106lbf/in2)
=53,000 lbf/in2
since σ=F/A, F=σ*A
where: F=force on end restraints
A=cross sec. area of 2”, sched 40
pipe

35
CM4120
Unit Operations Lab
Piping Systems
A=Π(OD2-ID2)/4
= Π(2.3752-2.0672)/4
=1.07 sq.in

F= σ*A
=(53,000 lbf/in2)*(1.07 in2)
Force on the end restraints =57,000 lbf
or 28.5 tons
36
CM4120
Unit Operations Lab

Piping Systems
Pipe Joints
 Threaded
 Welded
 Soldered/ Brazed
 Glued
 Compression
 Bell and spigot
 Upset or expanded

37
CM4120
Unit Operations Lab
Piping Systems

Threaded joints

38
CM4120
Unit Operations Lab
Piping Systems

Soldered joints

39
CM4120
Unit Operations Lab
Piping Systems

Welded joints

40
CM4120
Unit Operations Lab
Piping Systems
Compression joints

41
CM4120
Unit Operations Lab
Piping Systems
Mechanical joints
shown on glass drain piping system

42
CM4120
Unit Operations Lab

Piping Systems
Pipe Fittings
 Forged
 Cast
 Malleable Iron
Pressure/Temperature Rated by “Class”
 125, 250, or 2000, 3000, etc.
 Need a look-up table to determine max.
allowable P for the design temperature

43
CM4120
Unit Operations Lab
Piping Systems
Fittings for joining 2
sections of pipe:
Coupling

Reducing Coupling

Union

Flange
44
CM4120
Unit Operations Lab
Piping Systems

Fittings for changing

directions in pipe:
45o Ell

90o Ell

Street Ell

45
CM4120
Unit Operations Lab
Piping Systems

Fittings for adding

a branch in a run
of piping:
Tee

Cross

46
CM4120
Unit Operations Lab
Piping Systems

Fittings for blocking

the end of a run of
piping:
Pipe plug

Pipe cap

Blind Flange

47
CM4120
Unit Operations Lab
Piping Systems

Misc. pipe fittings:

Nipple

Reducing bushing

48
CM4120
Unit Operations Lab
Piping Systems

Gate Valve:
Used to block flow
(on/off service)

Sliding “gate”
on knife-gate
valve

49
CM4120
Unit Operations Lab
Piping Systems

Globe Valve:
Used to regulate
flow

Cut-away shows
stem seal
plug
and seat

50
CM4120
Unit Operations Lab
Piping Systems

Ball Valve:
Typically used as
block valve
“Quarter-turn” valve

Cut-away shows ball

and seat

51
CM4120
Unit Operations Lab
Piping Systems

Butterfly Valve:
Can be used for
flow control or
on/off
Valve actuator/
positioner for
accurate flow
control

52
CM4120
Unit Operations Lab
Piping Systems

Check Valves:
Used to prevent
backflow
Piston check

Swing check

53
CM4120
Unit Operations Lab
Piping Systems

References:
Piping Handbook, 7th ed., Nayyar, McGraw-Hill, New
York, 2000.
Piping Design for Process Plants, Rase, John Wiley,
New York, 1963.
Valve Handbook, Skousen, McGraw-Hill, New York,
1998
www.flowserve.com, Flowserve Corp., Sept. 2004.
www.engineeringtoolbox.com, The Engineering
Toolbox, Sept. 2004.

54