Piping Design Piping, as a subject, is a vast field comprising of the following: Fluid Flow Heat Transfer Metallurg Materials

rg Materials of !onstruction !ode "e#uirements $elding %&T Fabrication ' (nstallation Thermal (nsulation !ommissioning The cost contributed b piping in a plant is substantial) The percentage cost can var between 1* and1 +*)

Piping Design

Piping is an assembl of piping components used to conve , distribute, mi,, separate, discharge, meter, control or snub fluid flows) Piping also includes pipe supporting elements but does not include support structures, such as building frames, bents, foundations, or an e#uipment)

Piping Design Pipes carr fluids such as water, steam, air, gas or an process fluid) Piping refers to pipes, fittings, flanges, in.line valves and specialities, pipe supports but does not include pipe supporting structures) Piping design, in general, includes the following: pipe si/ing, piping material selection, selection or design of pipe and fitting wall thic0ness or rating, selection of rating for flanges, valves and specialties, bolts, nuts and gas0ets) Material selection includes materials for all piping components, valves and specialities) Piping la outs and piping isometrics Pipe supports Thermal insulation and covering 1ills of materials for piping, thermal insulation, painting etc
-

Piping Design 3pecifications for procurement of pipes, fittings of all t pes, valves and specialities, thermal insulation 4suppl and application5, painting 4suppl and application5, piping fabrication and installation at site (nteraction with other groups 4civil, electrical, instrumentation, process etc5 for inter.disciplinar activities) Fig.1 shows pipes and some piping components)

Piping Design

Piping &esign

Pipe Flow (t is important that proper si/es of pipes and piping components are used so that the pressure drop in the s stem due to friction is minimum and the velocit of the fluid is as per generall accepted practice 4to 0eep the flow.generated noise minimum5) The pressure drop in the piping s stem becomes an input for the s stem designer) The t pe of fluid flow is determined b "e nolds number, "e) "e 7 48&95: ;, where 87 flow velocit , m:s &7 inside diameter of pipe, m 97 fluid densit , 0g:m- and ;7 absolute or d namic viscosit , %3:m+ "e is dimensionless)

Piping Design =,ample: if flow diameter is +*mm, absolute viscosit is >)-? %3:m+, specific gravit is >)@1 4densit , @1> 0g:m-5 and velocit is +)6 m:s, "e 7 4+)6A>)>+*A@1>5:>)-? B1*6) There are basicall three t pes of flow, namel , laminar, turbulent and transitional) Caminar flow occurs when "e is +>>> or less and turbulent when "e is over 2>>>) 1etween these two values, flow is transitional and erratic and it is difficult to predict the pressure drop) This region is avoided b proper design) Flow velocit is obtained b dividing the volumetric flow b the flow area) 1efore one calculates the pressure drop, one has to establish the pipe friction factor) This depends on the pipe diameter, pipe surface < character and "e nolds number and for, turbulent region, is obtained form

Piping Design
$hen the flow is in the laminar range, friction factor can be directl e,pressed as f762: "e) friction factor is independent of pipe surface roughness) For details refer to EFlow of Fluids FFF)G b !rane compan ) Hnce the friction factor is 0now, pressure drop due to friction is calculated using the &arc formula: IP7 4f ACA9A8+5: 4+AgAd5, where IP7 pressure drop due to friction, f7 &arc friction factor, C7 total piping length, including straight lengths of pipes and e#uivalent lengths for fittings, valve and other in.line components etc 9 7 fluid densit , 87 flow velocit , g7 gravitational constant and d7 pipe inside diameter, all in consistent units)
?

Piping Design
J piping s stem will normall consist of straight pipes, various t pes of fittings 4elbows, tees, reducers, bends5, valves and specialities, special items such as sudden enlargement or contraction etc5) To evaluate the pressure drop due to fittings etc, we use what are 0nown as e#uivalent lengths in the form of C:& ratios, where C gives the corresponding e#uivalent length of the valve or fitting and & is the inside pipe diameter) 3ee the C:& ratios listed below: Kate valve, full open, C:&71Klobe valve, full open, C:&7-2> !hec0 valve, conventional swing t pe, C:&71-* @>> elbow, C:&7-> Tee, flow along the run, C:&7+> Tee, flow through the branch, C:&76> For other items, refer !rane boo0) 1 e#uivalent length of a valve or fitting is meant the straight pipe length of the same diameter, which will give the same pressure drop as the valve or fitting)

Piping Design
=,ample for pressure drop calculation: 3uper heated steam at 2> barg pressure and 2*>> ! is passing through a commercial steel new pipe of 1*> mm %P3, schedule ?> at the rate of 21>>> 0g:h) The s stem contains 1>*m of straight pipe, - long radius elbows, a full . open gate valve, a tee with flow through the run) Find the pressure drop through the s stem) For the conditions given, the steam has the following properties, from steam tables: &ensit 71+)?+?> 0g:m3 Jbsolute viscosit 7+)6*-+*A1>-5 Pa:s Pipe flow diameter, for 1*>mm sch?> pipe7>)126-m Flow area7><?*2A>)126-+7 >)>16?1m2 8olumetric flow rate7 mass flow rate:densit 721>>>:1+)?+?>7-1@6 m 3 :h or >)??<? m3 :s) Flow velocit 7volumetric flow rate:flow area7>)??<?:>)>16?17*+)?1m:s) "e748&95: ;74*+)?1A>)126-A1+)?+?>5: +)6*-+*A1> -54%:m257+)6-A1>7 From Mood Ds chart, f7>)>1*)
1>

Piping Design
=#uivalent lengthsL - nos)@>> elbow, C:&7->, C7-A->A&7-A->A>)126-71-)1<m Full opened gate valve, 1 no) C71A1-A&71-A>)126-71)@>m Tee with flow through run, 1 no) C71A6>A>)126-7+)<<?m Total pipe length7 1>*M1-)1<M1)@>M+)<<?71++)?*m Pressure drop due to friction in the pipe, IP7 4f ACA9A8+5: 4+AgAd5, 7 4>)>1*A1++)?*A1+)?+?>A*+)?1+5:4+A@)?1A>)126-5 7 +)-0g:cm+) The calculated value shall be compared with the allowable value) $hen calculating pressure drop in the s stem for li#uids, the static head shall also be considered)
11

Piping Design For water pipes, a popular formula is used) This is the Ha/en.$illiams formula and is stated as followsL N7 0A!AJA"0.63 A30.54 where N7 flow in m3:s or ft3:s !7 constant depending on the pipe material and condition, 12> for steel J7flow area in m2:ft2 "7 h draulic radius, m:ft L e#ual to &:2 for circular pipes where & is inside diameter) 37 pressure drop in m:m or ft:ft O7 >)?* for 3( units and 1)-+ for inch units
1+

Piping Design Limitations of Darcys Form la &arc Ds formula is applicable for compressible fluids li0e water, oil etc) 1ut for compressible fluids li0e steam, the formula is accurate when the pressure drop is less than about 1>P of the upstream pressure and either upstream or downstream conditions of steam ma be used for the calculations) $hen the pressure drop is above 1>P and less than +>P of the upstream pressure, the calculation needs to be modified b ta0ing the conditions of steam at the mean pressure condition) For ver long lines, the line length ma be split into convenient stretches and pressure drop ma be calculated for each stretch) For gas piping 4natural gas etc in cross.countr pipes5, special formulas have been developed) "eference ma be made to !rane for details)
1-

Piping Design L!D "atios for #al$es an% Fittings The ratios have been developed b e,perimental means using certain pipe thic0ness and valve rating and are applicable for values of "e nolds number greater than 1>>> (n some cases a correction factor is to be used, when the actual conditions differ significantl from the test conditions) =,ample: $hen the calculated "e nolds number is less than 1>>>, the C:& ratio to be used in calculation is obtained b : 4C:&5s 7 Q"e:1>>>RA4C:&5t, where 4C:&5s refers to the ratio to be used when "e is less than 1>>> and 4C:&5t refers to the ratios for the test conditions as given in !rane Handboo0)

12

Piping &esign Pipe &all '(ic)ness *alc lations J pipe shall have ade#uate wall thic0ness to withstand the internal and or e,ternal pressure plus other loads) $all thic0ness is calculated according to applicable codes for the design of piping, such as J3M= 1 -1)1, J3M= 1-1)-, (1" etc) (1" or (ndian 1oiler "egulations applies to steam or feed water piping under the following conditions: when the internal pressure e,ceeds -)* 0g:cm+g or when the inside diameter of the pipe e,ceeds +*2mm) J3M= 1-1)1 applies to power plant piping and 1-1)- applies to chemical: process plant piping)

1*

Piping Design
The formula for wall thic0ness, for internal pressure, is as follows: (1": tm7 4PA&o5:4+A3A=MP5M !, where tm 7 minimum pipe wall thic0ness, P7 internal design pressure, &o 7 pipe outside diameter, 37 allowable stress for the pipe material, under the design temperature, =7weld joint efficienc factor71)> for seamless pipes, !7a factor e#ual to 1)>mm Jll the units shall be consistent)
16

Piping &esign Formula as per J3M= 1-1)-, tm7 4PA&o5:4+A3A=MPA 5M !, where ! is an allowance for corrosion, erosion, mechanical allowancesL is a coefficient given in the code) The minimum pipe wall thic0ness tm, as calculated above, shall be increased to provide for negative tolerances due to manufacturing methods) For e,ample, for pipes sa as per J3TM J 1>6, the negative tolerance is 1+)*P and the nominal thic0ness is obtained as tm : >)?<*) J standard thic0ness closest to the nominal thic0ness as calculated above 4on the higher side5 shall be selected) For pipes subject to e,ternal pressure 4jac0eted piping, piping under vacuum etc5, reference ma be made to J3M= 1-1)1) 1<

Piping Design
=,ample: &esign internal pressure76>A1>5 Pag &esign temperature7-*> deg)! Pipe material: carbon steel as per J3TM J 1>6 Kr) 1, pipe si/e:->>mm !orrosion allowance71)>mm Pipe code: J3M= 1-1)Jllowable stress at -*> deg)!7 116-A1>5 Pa =71 as J1>6 gr) 1 is seamless) Formula as per J3M= 1-1)- for pipe wall thic0ness: tm 74PA&o5:4+A3A=MPA 5M ! 7 46>A-+25:4+A116-A1)>M6>A>)25M1)* 7 41@?+@:+-@<5M1 7 @)+<+mm !onsidering manufacturing tolerance of 1+)*P for this t pe of pipe, %ominal thic0ness74@)+<+:>)?<*571>)6mm) The nearest standard wall thic0ness that is available as per J3M= 1-6)1>, is S3 4e,tra strong5, that is 1+)<mm) This thic0ness ma be specified) J3M= 1-6)1> is the dimensional standard for pipes as per1? Jmerican 3tandards) There are other standards such as (31+-@, (3 -*?@ etc)

Piping Design =,ternal Pressure &esign J3M= 3ec)8(((, &iv 1 gives an elegant method for calculating the thic0ness re#uired for e,ternal pressure applications) =,amples for e,ternal pressure applications are piping under vacuum, jac0eted piping where the pressure inside the jac0et is higher than the pressure inside the core pipe)

1@

Piping Design Dimensional +tan%ar%s for Pipes, (3 1+-@, (3 -*?@, J3TM J *-, J3TM J1>6, JP( *C, J3TM J --*, J3TM J -1+, J3TM J -*? are specifications for pipes) (31+-@ also specifies pipe wall thic0ness 4light, medium and heav classes5) J3M= standard 1-6)1> identifies wall thic0nesses of pipes in the form of schedules, for e,ample, sch+>, sch2>,sch?>, S3 4e,tra strong5, SS3 4double e,tra strong5, sch16> etc)These schedules have no direct correlation with the actual pipe wall thic0ness) J3M= 1-6)1@ covers some additional thic0nesses specificall for stainless steel pipes) These are sch *3,1>3,2>3 etc)
+>

Piping Design Pipe Fittings, Pipe fittings are of butt welding, soc0et welding and threaded t pe) The common dimensional standards for these fittings are: J3M= 116)@, for butt welding fittings, J3M= 116)11, for soc0et welding and threaded fittings, J3M= 116)*, for flanges) 1utt welding fittings have the same wall thic0ness as straight pipes) 3oc0et welding fittings have ratings as per J3M= 1 16)11, namel ->>>, 6>>> and @>>> classes) ->>> class fittings are suitable upto schedule ?> pipe) Threaded fittings are designated b classes +>>>, ->>> and 6>>>) 3ee 116)11 for details)
+1

Piping Design Pipe Fittings -cont%.. The commonl encountered fittings are elbows to effect a change in pipe direction, tees for having a branch connection, reducers for joining pipes of different si/es, stub ends for having cheaper carbon steel flanges on e,pensive stainless steel pipe, caps for pipe end closures) Flanges are used where removable connections are re#uired such as at connections to e#uipment, flanged valves etc) The commonl used standard for flanges is J3M= 1 16)*) (t covers man classes from 1*> to +*>>) The standard gives pressure. temperature ratings for flanges of various ratings and materials) The ma,imum si/e covered in this standard is 6>>mm)
++

Piping Design Flanges have different t pes of facings) The common facings are raised face and flat face) Flat faced flanges are used in conjunction with full.faced gas0ets in cast iron valves) This is to prevent brea0age of cast iron flanges b over.tightening) "aised face facings are used for steel flanges) Hther t pes of facings, small tongue and groove, and large tongue and groove, ring joint t pe etc are used in special applications and in some processes where the flange gas0ets +are contained within the groove)

Piping Design There are special fittings such as spectacle or figure.? blinds) These are used in process plants for positive closure of a pipe) T.fittings and laterals are used to minimi/e pressure drop in the lines) Hthers are reverse bends or elbows, stub ends for use with stainless pipes, reducing elbows, weldolet, soc0olet and threadolet t pe integrall reinforced fittings) (n tees, different t pes are seamless tees as per J3M= 116)@, soc0et welding and threaded tees as per J3M= 116)11 and fabricated tees) The fabricated tees are made from straight pipe b welding pipe to pipe) These have lower strength than the conventional tees and if full strength is re#uired, the branch connection is to be reinforced) The calculation of branch connections is dealt with in J3M= +2 codes)

Piping Design Flange "atings Flange ratings are decided in accordance with J3M= 116)*) Minimum rating class is 1*>) The pressure class depends on design pressure, design temperature and material) 1*> class flanges are suitable up to a pressure of 1@)6 barg at ambient temperature) The ratings given in the standard are non.shoc0 ratings) Flange Finis( Flanges have normall flat face smooth finish for use with cast iron components and raised face concentric serrated finish for steel components) The serrations shall be in accordance with J3M= 116)*)The serrations ma be concentric or spiral but concentric are preferred)

+*

Piping Design

+6

/l0ow

+<

Pipe Fittings

+?

Fa0ricate% Lateral

+@

Piping Design 3pectacle or Fig)? blind

->

Pipe 1iter /l0ows

-1

Flange% 2oint

-+

Flanges

--

Flange for stainless piping

-2

3se of +t 0 /n% in 2ac)ete% Piping

-*

'(ermal 4ns lation (nsulation is provided for piping to conserve heat 4hot piping5 or cold 4cold piping, such as chilled water5) Materials for hot insulation are loose mineral wool, preformed mineral wool pipe sections, resin.bonded mineral wool blan0ets, calcium silicate, ceramic fibre etc) The standards are (3.-6<<, @?2+, ?1?- etc) Materials for cold insulation are e,panded pol st rene 4thermocole5 and pol urethane foam 4PUF5) The standards are (326<1 and (31+2-6) Finishing over insulation is b galvani/ed or aluminum sheet or finishing cement) (nsulation is held b wires, clamps, bands etc) (nsulation calculations as per (3.12162) "efer T!=C standards for further details
-6