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
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Piping Systems include:

Pipe Flanges Fittings Bolting Gaskets Valves Hangers and supports Insulations, coverings, coatings
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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

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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

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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

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Piping System Design Criteria 4 areas to consider:

Physical Attributes Loading and Service Conditions Environmental Factors Materials-Related Considerations

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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 Its the LAW

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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.

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

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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
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ASME B31.3 covers:

Materials and design Fabrication Erection and assembly Support Examination, inspection, and testing Web reference: www.piping-toolbox.com
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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

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Standard Tubing Sizes

Steel tubing

Diameters are Actual OD Wall thickness is specified Single wall thickness available for each size Actual OD Type K, L, M
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Refrigeration Tubing

Copper Tubing Nominal sizes

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Materials Metallic piping

Carbon and low alloy steel

Ductile Inexpensive and available Easy to machine, weld, cut Some drawbacks

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Materials Metallic piping

Alloy Steels including Stainless Steels

Good corrosion resistance More difficult to machine, weld, cut Some drawbacks

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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

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Materials Non-Metallic piping

Thermoplastics

Wide range of chemical compatibility Light weight Easily cut and joined Low temperature limits Need extra supports

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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

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Materials Others
Glass Concrete Lined or coated

Double Containment piping systems

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Glass Rubber Cement Teflon Zinc (galvanized pipe)

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

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Piping Systems Fiberglass Insulation w/ Asbestos plastered fitting coverings

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Metal Jacketed insulation covering

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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

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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

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Piping Systems Results of inadequate support

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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

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The Design Process a three step approach

Design for Flow

Find min. diameter to achieve desired flow velocity Find min. wall thickness for process and external conditions Find appropriate rating of in-line components

Design for Pressure Integrity

Re-check for Flow Criteria

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Design for Flow

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

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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.

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Next determine wall thickness:

Pressure Integrity Design method
ASME B31.3,

PD tm A 2SE Py
E=weld joint efficiency y=factor to adjust for temp A= addl thickness for corrosion, external loads, etc.
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tm=min. wall thickness P=design pressure, psig D=O.D. of pipe, in. S=allowable stress, psi

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Finally re-check ID
Select in-line components Determine insulation, coverings, coatings Design and locate supports and hangers
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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.
=thermal expansion coefficient for mild steel, =6.6x10-6 in/inoF
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Temp of pipe at amb. cond. =70oF Temp of 100 psig sat. steam =338oF T=268oF L=20=240 expansion due to temperature increase is *L* T =(6.6x10-6in/inoF)*(240in)*(268oF) =0.42 in per 20 of pipe
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What force is exerted on the end restraints of that 20 pipe if it is rigidly installed (end restraints cant move)?
=internal stress due to T, and = *(T)*E E is the material property called Modulus of Elasticity, relationship between stress and strain E=30x106 psi for low carbon steel
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= *(T)*E =(6.6x10-6 in/inoF)*(268oF)*(30x106lbf/in2) =53,000 lbf/in2 since =F/A, F=*A where: F=force on end restraints A=cross sec. area of 2, sched 40 pipe
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A=(OD2-ID2)/4 = (2.3752-2.0672)/4 =1.07 sq.in F= *A =(53,000 lbf/in2)*(1.07 in2) Force on the end restraints =57,000 lbf or 28.5 tons
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Pipe Joints

Threaded Welded Soldered/ Brazed Glued Compression Bell and spigot Upset or expanded

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Threaded joints

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Soldered joints

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Welded joints

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Piping Systems Mechanical joints shown on glass drain piping system

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Pipe Fittings

Forged Cast Malleable Iron 125, 250, or 2000, 3000, etc. Need a look-up table to determine max. allowable P for the design temperature

Pressure/Temperature Rated by Class

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Piping Systems Fittings for joining 2 sections of pipe: Coupling Reducing Coupling Union Flange
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Fittings for changing directions in pipe:

45o Ell 90o Ell

Street Ell

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Fittings for adding a branch in a run of piping: Tee

Cross

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Fittings for blocking the end of a run of piping: Pipe plug

Pipe cap Blind Flange
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Misc. pipe fittings:

Nipple

Reducing bushing

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

Sliding gate on knife-gate valve

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Globe Valve: Used to regulate flow

Cut-away shows stem seal plug and seat
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Piping Systems Ball Valve: Typically used as block valve

Quarter-turn valve
Cut-away shows ball and seat

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

Valve actuator/ positioner for accurate flow control

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Check Valves: Used to prevent backflow

Piston check
Swing check

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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.
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