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1
Course Contents
1. Pipe
2. Piping standard
- Nominal pipe diameter
- Schedule number
- Piping standards code
- Tubes
- Fittings and other piping auxiliaries
3. Method of joining sections
- Threaded
- Bell and spigot
- Flanged
- Welded connection
- Fitting
4. Types of flanged joints
5. Expansion joints
6. Blinds
7. Spaces
2
Course Contents
8. Valves
- Types of valves
9. Valves
- Gate valve
- Globe valve
- Diaphragm valve
- Plug valve
- Ball valve
- Butterfly valve
- Needle valve
- Check valve
- Safety valve
10. Function of valve
11. Basic control function of valves
3
Course Contents
10. Application of Valve types
11. Valve ratings
12. Valve operation and maintenance
13. Do’s and don’t for better valve service
14. Pressure relieving devices
- How high pressure develops
- Types of pressure relieving devices
15. Definition of pressure relief terms
4
Pipes
5
Piping Standards
6
Piping Standards
Schedule number
• Pipes were originally classified on the basis of wall thickness
as standard (extra strong, and double extra strong).
• Because of modern industrial demands for more exact spec,
pipes are now specified according to wall thickness by a
standard formula for schedule number designated by the
American Standards Association.
• Schedule number is defined by ASS as: = 1000 Ps/Ss
where Ps = safe working pressure
Ss = safe working fiber stress
7
Piping Standards
Schedule number
• Ten schedule numbers are in use at present.
• These are 10, 20, 40, 60, 80, 100, 120, 140, 160
• For pipe diameters up to 10 in, schedule 40 corresponds to the
former “standard” pipe and schedule 80 corresponds to the
former “extra strong” pipe.
8
Piping Standards
Schedule number
How they came up with the formula?
Bursting pressure of a thin walled cylinder may be estimated from
the following equation:
9
Piping Standards
Schedule number
A safe working pressure Ps can be evaluated from equation if the
tensile strength is replaced by a safe working fiber stress Ss
Ps = 2Sstm/Dm
10
Piping Standards
Piping standard codes
• ANSI B31
- List of those standards can be found in the ANSI B31 code
section
- Section also lists specifications for pipe and fitting materials
and testing methods of the American Society for Testing and
Materials (ASTM)
- American Welding Society (AWS) specification
- Standard of the manufacturers Standardization Society of the
Valve and Fitting Industry (MSS)
11
Piping Standards
Piping standard code (con’t)
12
Piping Standard
Tubing
Copper tubing, brass tubing are used extensively in industrial
operations. Other metals, such as nicklel and stainless steel, are also
available in the form of tubing.
Although pipe specifications are based on standard nominal sizes,
tubing specs are based on the actual outside diameter with a
designated wall thickness.
Conventional system, such as the Birmingham wire gauge (BWG) are
used to indicate the wall thickness.
13
Piping Standard
14
Method of Joining Sections
15
Threaded Joints
16
Bell and Spigot Joints
Bell and spigot connected pipe handle more fluid than any other
connection since it is the most practical type of joint in large pipe
sizes when pipes are made of materials other than steel. These
joints are usually calked with oakum and lead but the mechanical
joint is becoming more popular because of the tighter joint, simplicity
of installation, greater latitude of angular displacement and
expansion. These joints may be “locked” with a groove in the spigot
which prevents pulling apart the joint, “roll on” with a rubber gasket
tightened with a bolted ring or “screwed gland”, with a ring gland
drawn up against the gasket when screwed into threads in the bell.
Materials for pipe joined in this manner are usually cast iron, clay,
or concrete, although glass, plastic and cement asbestos are
sometimes employed.
17
Welded Connections
• The modern trend for pipe in sizes above 2 in. is toward more
welded connections. No threading, calking, or bolts is needed, and
no gaskets are required when the system is fused into an unknown
line of material.
• Pipe ends needs no treatment other than scarfing (beveling) and
very few fittings are required if the welder shapes the necessary
pieces from pipe sections.
• Fittings and valves are of steel and are of two types, butt weld and
socket weld. The butt weld fittings are of the same dimension as the
pipe, and the socket weld fittings have enlarged ends similar to
threaded fittings, but the pipe slips into place and is fillet welded.
18
Fittings
19
Fittings
20
Fittings
21
Fittings
Welded connections
Fittings are of steel and are of 2 types, butt weld and socket weld.
The butt weld fittings are of the same dimension as the pipe, and the
socket weld fittings have enlarged ends similar to threaded to
threaded fittings, but the pipe slips into place and is fillet welded.
Fittings are similar to equivalent threaded type.
22
Fittings
23
Fittings
Compression fittings
• Compression fittings are widely used for small sized tubing at both
low and high pressure. These are convenient and efficient,
particularly if the connection is to be broken.
24
Flanged Joints
Flanged joints are the most common method for joining pipe in sizes
2 inches and above. The use of flanges allows for making the piping
up in sections that are easy to handle and also allows access for
cleaning, draining, etc.
1. Socket welding flanges
2. Slip on welding flanges
3. Threaded flanges
4. Welding neck flanges
5. Lap joint flanges
25
Flanged Joints
26
Flanged Joints
27
Flanged Joints
Threaded Flanges
• Threaded flanges are widely used because no welding equipment is
required for assembly and both the pipe and flange can be
completely salvaged upon dismantling. Accurately cut, clean,
tapered pipe threads dimensioned to ANSI A2. 1 Pipe Threads,
assure strong, tight joints.
28
Flanged Joints
29
Flanged Joints
30
Flanged Joints
31
Flanged Joints
32
Expansion Joints
Expansion Joints
• All metals expand with increasing temperature. Steel pipe is no
exception to this rule. Expansion must be considered to
accommodate the change in length in the change from atmospheric
temperature to operating temperature. Expansion joints are used to
absorb the effect of the increased length with temperature. These
can be bends or corrugated expansion joints. The attached piping
must be properly anchored and guided to direct the expansion to
utilize the expansion to utilize the expansion joint most effectively.
33
Blinds
Blinds are a piping item used extensively in the plant. A blind is used
to provide positive isolation in between piping flanges and thus
insure that any leakage that takes place will be to the atmosphere
and not through the pipe.
• Normally, blinds are used to prepare vessels or tanks for entry
and to isolate equipment and piping in order to provide complete
safety in welding.
• Blinds are also used for hydrostatic testing but in this case they
must be of special design in order to handle the test pressures
that will be involved.
34
Spacers
35
Valves
• Valves are used for the control of volume and pressure of fluids
moving through piping or in enclosed vessels. They may be
operated automatically or by hand. Type of construction is as varied
as the operations within the plant; each is designed for the service to
be performed.
36
Valves
Types of valves
1. Gate valves
2. Globe valves
3. Diaphragm valves
4. Plug valves
5. Ball valves
6. Butterfly valves
7. Needle valves
8. Check valves
9. Safety valves
37
Valves
Gate valves
• The gate valve is probably the most widely used valve in plant
operations, particularly in the larger sizes of piping installations and
those of the most severe service.
• It consists of a main body and a stem which raises or lowers a “gate”
across the fluid flow. In high pressure installations the gates must be
of heavy construction and are sometimes difficult to open. Some are
motor operated and some have a small by-pass line for equalizing
the pressure on both sides of the gate before opening.
• The rising stem gate valve is used in both water and process piping.
It requires more overall space for installation, but is used to an
advantage in handling corrosive streams that tend to damage stem
threads in other type valves.
38
Valves
39
Valves
Gate valves
– used to minimize pressure drop in the open position and to
stop flow rather than to regulate it.
40
Valves
Globe valves
• The essential feature of this type valve is a globular body with an
internal, horizontal partition having a circular opening in which is
inserted a ring or seat. The globe or disc seats on this ring to effect
shut-off.
• The valve opening is so arranged that flow through it must make two
90-degree changes of direction. This results in a relatively high
pressure drop, or resistance to flow.
• The globe valve is generally used in small sized piping for throttling
or control. They are used principally in steam or air service where
throttling and a positive shut-off is desirable.
• Installation should be such that flow is up through the seat ring and
against the bottom of the disc or glove. This will prevent opening
difficulties caused by the accumulation of debris above the disc.
This should be avoided.
41
Valves
42
Valves
43
Valves
Diaphragm valves
44
Valve
Diaphragm valves
Diaphragm valves
– limited to 50psi, excellent for fluid containing suspended solids
45
Valves
Plug valves
• The plug valve, or cock, is a conical plug within a body. Its chief
advantage is in its tight shut off. A one quarter (90 degree) turn of
the plug changes it from a fully closed to a wide open position
• Since the plug tends to stick when used in high temperature and
high pressure service, some types of these valves have been
provided with a means of lubrication through the stem of the cock.
• A rotary life plug valve is non lubricated. In operation, as the stem is
turned, the plug lifts slightly from its seat, rotates to the opposite
position then lowers back into place. This operation can be
performed in about one-fourth to one-half a turn in the smaller sizes.
Large valves require more rotation of the stem.
• The quick opening principle of plug valves makes them impractical
as a means of controlling rate of flow.
46
Valves
47
Valves
Ball valves
• Ball valves are adaptations of plug valves using ball-shaped discs
instead of conical plugs located within the body. A hole through the
center of this disc provides the straight-through flow which is
characteristic of ball valves. Ball valves are used to shut off or permit
full flow of fluid through the valve.
• Ball valves have all the advantages of plug valves in terms of
excellent flow characteristics - quick opening, straight-through flow,
minimum turbulence, tight closure and compactness - plus the
additional advantage of not requiring any lubrication or sealant.
They achieve tight closure by establishing a controlled squeeze of
the ball against the sear rings which are made of plastic material
such as teflon.
48
Valve
Ball valves
49
Valves
Butterfly valves
• The butterfly valve derives its name from the wing-like action of the
disc which operates at right angles to the flow. Ordinarily, they are
not intended for tight shut off, but resilient seats have broadened
their possibilities and they are now frequently advertised as having
“bubble tight” closure.
50
Valves
Butterfly valve
51
Valves
Needle valves
• Needle valves are designed to give very fine control of flow in small
diameter piping systems. They get their name from their sharp-
pointed conical disc and matching seat. The stem threads are fine
so that more turns of the hand wheel are required to increase or
decrease the opening through the seat.
52
Valves
53
Valves
Check valves
• Check valves are automatic in operation. They prevent flow in one
direction, but allow it in the other. These valves should be carefully
checked for direction of flow in lines.
• Swing check valves are unsuitable for use in vertical lines. Note
importance of correct installation of a check valve in relation to the
stream flow. Usually the valve body has features that indicate
correct direction.
• Sometimes an arrow indicates the direction of flow permitted
through the valve. Do not rely upon a check valve to give full shut-off
against a back flow. Only on special occasions, [authorized] will the
check valve be depended upon to prevent back flow of liquid or
other hazardous material when opening lines into other systems or
to the atmosphere. Always use a block valve when possible.
54
Valves
Safety valves
• Safety valves are installed in strategic locations to provide pressure
relief for process equipment subjected to excessive pressure.
• A safety valve consists of six basic parts; spring, spindle or stem,
adjusting screw, disc, nozzle or seat, and body. Safety, or relief,
valves are intended for emergency protection only and should not be
used as an operating valve.
• Frequent “popping” of a relief valve contributes to their failure,
therefore, they should set at 25% above working pressure. For
example, relief valves on the discharge of reciprocating pumps will
relieve with each pump stroke if the set pressure is too low.
Continuous pounding of the disc upon the seat causes damage and
resultant leakage of the valve.
55
Valves
56
Pressure Relieving Devices
57
Functions Of Valves
58
Functions Of Valves
(cont)
• When valves are large size, difficult to operate due to flow
conditions, located in inaccessible positions, require rapid opening
and closing, or need to be operated remotely from a central control
area, mechanical or power actuated operators are frequently
installed on these valves. Gear operators, chain wheels, or electric
motor operators are some of the mechanical or power actuated
operators most often used.
• Each type of valve is designated for a specific purpose to meet
and/or satisfy the following basic control functions desired in a
piping system.
59
Basic Control Functions Of Valves
60
Basic Control Function Of Valves
(cont)
• Preventing backflow
Check valves perform the function of checking or preventing
reversal of flow in piping systems. Flow keeps these valves open if
the flow is in the right direction, while gravity and reversal of flow
closes them automatically. Check valves are available in two basic
types - swing and lift checks.
• Relieving Pressure
Relief and safety valves are installed on equipment such as boilers,
vessels, drums, piping systems, etc. which can be seriously
damaged if subject to pressures in excess of the equipment design.
They are usually spring loaded and automatically open to release
pressure which exceeds the limit for which the valve was set.
61
Application Of Valve Types
Gate valves
• The Principal characteristic of a gate valve is the fact that the
flow through the valve is stopped by sliding a relatively flat
surface, called a gate or disc, across the flow path of the fluid
and started by moving the disc into a chamber in the valve
bonnet out of the flow path. Gate valves are most effective fully
closed or fully opened. When fully opened the fluid flows
through the gate valve in a straight line with very little pressure
drop.
62
Application Of Valve Types
Globe valves
• Globe valves are named after the globular shape of their body.
They are most suitable for throttling fluid flows because of their type
of seating arrangements, however, they can also be used in fully
shut off and fully open service
• Globe valves seating is parallel to the line of flow with all contact
between seat and disc ending when flow begins.
• The fluid flow through a globe valve follows a changing course
which causes resistance to flow and considerable pressure drop.
However, in order to control the fluid flow we must sacrifice some
pressure drop.
63
Application Of Valve Types
Angle valves
• Angle valves are similar to the design of globe valve but have less
resistance which results in less pressure drop.
• The angle valve effectively utilizes globe valve seating principle
while providing for a 90 degree turn in piping. It is less resisting to
flow than the globe valve it displaces. Requires fewer joints; saves
make-up time and labor.
64
Application Of Valve Types
Needle valves
• Needle valves are designed to give very fine control of flow in small
diameter piping systems.
• Generally used in chemical injections to process and delivery lines
65
Application Of Valve Types
Plug valves
• The plug valve is often referred to as the oldest member of the valve
family, however, this is only true of the non-lubricated type which
may be considered a modification of the simple cock.
• The non-lubricated plug valve is an evolution of the simple plug
cock. All the advantages of the simple plug cock are maintained but
the tendency of the plug to seize or bind has been overcome by
changes in the design and construction of the plug valve. This has
been accomplished by the use of various plastics or other materials
with low friction values for contact or sealing surfaces. As a result of
these changes non-lubricated plug valves are now available for a
much greater range of service conditions.
• Teflon (tetrafluoroethylene) is one of the principle materials with low
friction value being used today for contact surfaces.
66
Application Of Valve Types
67
Application Of Valve Types
Ball valves
• Ball valves are adaptations of plug valves using ball-shaped discs
instead of conical plugs located within the body. A hole through the
center of this disc provides the straight-through flow which is
characteristic of ball valves. Ball valves are used to shut off or permit
full flow of fluid through the valve.
• Ball valves have all the advantages of plug valves in terms of
excellent flow characteristics - quick opening, straight-through flow,
minimum turbulence, tight closure and compactness - plus the
additional advantage of not requiring any lubrication or sealant.
They achieve tight closure by establishing a controlled squeeze of
the ball against the sear rings which are made of plastic material
such as teflon.
68
Application Of Valve Types
69
Application Of Valve Types
Butterfly valves
• They are widely used in the municipal field for the control of water
flow.
• Butterfly valves are excellent for handling large flow of gases and
liquid at relatively low pressure.
• The butterfly valve in full open position has relatively low pressure
drop and minimum turbulence since the disc position is parallel to
the fluid flow. Some of the advantages of butterfly valves are little
head room required, light in weight, durability, low initial cost and
ease of operation. However, they are limited in pressure and
temperature applications.
70
Application Of Valve Types
Check valves
• The principal function of a check valve is to automatically prevent
reversal of the direction of the fluid flow. Pressure of the fluid flowing
through the check valve keeps it open – reversal of the flow closes
it. Most manufacturers plainly mark check valves for direction of
flow. The design of check valves are relatively simple and are
available in three basically different types - swing check, lift check,
and ball check.
71
Application Of Valve Types
Check Valves
• Used to prevent reversal of flow
1. Swing check valve
- Normal design is for use only in horizontal lines
2. Lift check valves
- Vertical lift check valve – for installation in vertical line, where
the flow is normally upward
- Globe check valve – for use in horizontal lines
- Angle check valve – used for installation where a vertical line
with upward flow turn horizontal
3. Tilting disk check valve
- May be installed both horizontally and vertically. Less pressure
drop at low velocity but greater at high velocity. Arrests
slamming.
72
Application Of Valve Types
73
Application Of Valve Types
Check Valves
74
Application Of Valve Types
Check valves
75
Application Of Valve Types
76
Application Of Valve Types
Check valves
Check valves
79
Application Of Valve Types
80
Application Of Valve Types
81
Application Of Valve Types
82
Application Of Valve Types
83
Application Of Valve Types
Safety valves
• Applications of safety valves will be discussed separately later in
this module under pressure relieving devices.
84
Application Of Valve Types
Actuators
An actuator, [a transducer according to definition for instrumentation
final control element]) translates the control signal from one form or
level of energy or power to another, e.g. from a pneumatic signal into a
mechanical action which is used to manipulate a process variable.
85
Application Of Valve Types
86
Application Of Valve Types
87
Valve Ratings
S - Steam
O - Oil
G - Gas
W - Water
L - Liquid
88
Valves Ratings
• Steam Ratings
Steam ratings are used as a basis for determining the suitability of a
material for a given application. For lower temperatures the safe
working pressure of a material is usually greater that the steam
rating.
• Cold Ratings
Most valves have two service ratings. In addition to the steam
rating, explained above, cold service ratings are usually designated
by the mark WOG, which stands for cold water, oil, or gas, non-
shock.
89
Valve Ratings
90
Valve Ratings
91
Valve Operation And Maintenance
92
Valve Operation And Maintenance
(con’t)
2. Rising stem with inside screw. This is the simplest and most
common stem construction for gate, globe, and angle valves in the
smaller sizes. The position of the stem indicates the position of
the disc. The stem should be protected against damage when the
valve is open.
3. Non-rising stem with inside screw. Stem does not rise when
disc is raised, but merely turns with handwheel. Ideal where
headroom is limited. Since stem merely turns when operated,
wear on packing is minimized.
93
Do’s And Don’t For Better Valve Service
2. Don’t overlook leaks – big and small. A leak in a valve often can
be remedied simply and in a hurry, if caught in time. Stem leaks
normally can be fixed by slightly tightening the packing nut or gland.
94
Do’s And Don’t For Better Valve Service
(con’t)
2. Bonnet and flange leaks can be caused by bolts loosening under
service strain, If tightening the joints doesn’t stop the leak, the
gasket may be damaged and this repair should also be scheduled
for qualified maintenance mechanics.
3. Don’t spare the oil can. Wear on stem packing is due mainly to
the rising and turning motion of the valve stem, combined with
deteriorating effects of service conditions. A few drops of oil on the
stem, now and then, help to reduce friction - - and wear, Don’t
forget to lubricate exposed stem threads.
95
Do’s And Don’t For Better Valve Service
(con’t)
96
Pressure-Relieving Devices
How high pressure develops
97
Pressure Relieving Devices
98
Pressure Relieving Devices
Relief Valve
• A relief valve is an automatic pressure-relieving device actuated by
the static pressure upstream of the valve, and which opens further
with increase in pressure over the set pressure
• Opening of valve is proportional to the increase in pressure over the
opening pressure
• Used primarily for liquid services
• Rated capacity is usually attained at 25 percent over pressure
99
Pressure Relieving Devices
100
Pressure Relieving Devices
101
Pressure Relieving Devices
102
Pressure Relieving Devices
Safety Valves
• An automatic pressure relieving device actuated by the static
pressure upstream of the valve, and characterized by rapid full
opening or pop action upon opening.
• It is used for steam, gas or vapor service.
• Rated capacity is reached at 3, 10 or 20 percent overpressure,
depending upon applicable code.
103
Pressure Relieving Devices
Safety-relief valve
• Safety relief valve is an automatic pressure relieving device
actuated by the static pressure upstream of the valve and
characterized by an adjustment to allow either a “pop” or a “non
pop” action and a nozzle type entrance
• Suitable for use as either a safety or relief valve, depending on
application.
• Safety, relief and safety relief valves are installed in strategic
locations to provide pressure relief for process equipment subjected
to excessive pressures. These valves consist of six basic parts:
spring, stem, adjusting screw, disc, nozzle or seat, and body.
• Rated capacity is reached at 3 or 10 percent overpressure,
depending upon code and/or process conditions. Pressure relieving
valves are intended for emergency protection only and should not
be used as an operation valve. Frequent “popping” of a relief or
safety valve contributes to their failure and are therefore set at 25%
- 50% above the working pressure.
104
Pressure Relieving Devices
105
Pressure Relieving Devices
106
Pressure Relieving Devices
107
Pressure Relieving Devices
108
Definition of Pressure Relief Terms
1. Set pressure
• Is the inlet pressure at which the safety or relief valve is adjusted
to open
• This pressure is set regardless of any back pressure on the
discharge of the valve
109
Definition of Pressure Relief Terms
2. Overpressure
• Pressure increase over the set pressure of the primary relieving
device is over pressure
• It is the same as accumulation when the relieving device is set at
the maximum allowable working pressure of the vessel
110
Definition of Pressure Relief Terms
3. Accumulation
• Pressure increase over the maximum allowable working pressure
of the vessel during discharge through the safety or relief valve,
expressed as a percent of that pressure.
111
Definition of Pressure Relief Terms
112
Definition of Pressure Relief Terms
5. Operating pressure
• Pressure (gage), to which the vessel is subjected in service
• A processing vessel is usually designed for a maximum allowable
working pressure, which will provide a suitable margin above the
operating pressure to prevent undesirable operation of the relief
device
• Margin is approximately 10 % higher, or 25 psi – which ever is
higher.
113
Definition of Pressure Relief Terms
6. Blowdown
• The reduction in flowing pressure below the set point required for
a device to close
• Is the difference between the set pressure and the reseating
pressure of a safety or relief valve
• Expressed as percent of the set pressure or psi
114
Definition of Pressure Relief Terms
7. Back pressure
• Pressure developed on the discharge side of safety valves is back
pressure
• This pressure may be generated by the flowing fluid as it passes
through the relief discharge piping, or it may be an established
pressure as a part of a discharge vent system into which the valve
is discharging
• It may be combination of these two.
115
Vacuum Breaker
116
Electric Solenoid
117
Thermal Valve
118