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Venkateshwaran
Piping-Engineer
IDEA
PIPING ELEMENTS
PIPING ELEMENTS
PIPES
FITTINGS
FLANGES
GASKETS
BOLTING
VALVES
SPECIALITIES
PIPES
MANUFACTURING PROCESSES
MATERIAL SELECTION
MATERIALS
Classification Based on Manufacturing
Pipe
Seamless pipe Forged pipe Welded pipe Cast Steel Pipe Cast Iron Pipe
Ferrous pipe materials Forged and Bored PIpe Ferrous pipe materials Centrifugally Cast Pipe Vertical Pit Process
Extrusion Process
High Frequency Induction
Aluminium and its alloy materials
High Frequency Resistance
Extrusion Process
Cold Drawing
Extrusion Process
HOT ROTARY PIERCING
A. Strength
•Yield and Tensile Strength
•Creep Strength
•Fatigue Strength
B. Corrosion Resistance
C. Material Fracture Toughness
D. Fabricability
E. Availability And Cost
A. Strength
A material's strength is defined by its yield, tensile, creep, and fatigue strengths. Alloy content,
material grain size, and the steel production process are factors that affect material
1.0 Yield and Tensile Strength
A stress-strain diagram that is produced from a standard tensile test (Figure ) illustrates the yield and
tensile strengths. As the stress in a material increases, its deformation also increases. The yield
strength is the stress that is required to produce permanent deformation in the material (Point A in
Figure ).
If the stress is further increased, the permanent deformation continues to increase until the material fails. The
maximum stress that the material attains is the tensile strength (Point B in Figure ). If a large amount of strain
occurs in going from Point A to Point C, the rupture point, the material is said to be ductile. Steel is an
example of a ductile material. If the strain in going from Point A to Point C is small, the material is brittle.
Gray cast iron is an example of a brittle material.
SC
Below about 750°F for a given stress, the strain in most materials remains constant
with time. Above this temperature, even with constant stress, the strain in the material will
increase with time. This behavior is known as creep. The creep strength, like the yield and
tensile strengths, varies with temperature. For a particular temperature, the creep strength of a
material is the minimum stress that will rupture the material during a specified period of time.
The temperature at which creep strength begins to be a factor is a function of material chemistry.
For alloy materials (i.e., not carbon steel) creep strength becomes a consideration at
temperatures higher than 750°F.
3.0 Fatigue Strength
The term “fatigue” refers to the situation where a specimen breaks under a load that it
has previously withstood for a length of time, or breaks during a load cycle that it has previously
withstood several times. The first type of fatigue is called “static,” and the second type is called
“cyclic.”
One analogy to cyclic fatigue is the bending of a paper clip. The initial bending beyond a
certain point causes the paper clip to yield (i.e., permanently deform) but not break. The clip could be
bent back and forth several more times and still not break. However after a sufficient number of
bending (i.e., load) cycles, the paper clip will break under this repetitive loading. Purely elastic
deformation (i.e., without yielding) cannot cause a cyclic fatigue failure.
The fatigue strength of a material under cyclic loading can then be defined as the ability
to withstand repetitive loading without failure. The number of cycles to failure of a material decreases
as the stress resulting from the applied load increases
B. Corrosion Resistance
Galvanic Corrosion Occurs when two dissimilar metals contact each other in corrosive
electrolytic environment. The anodic metal develops deep pits or
grooves as a current flows from it to the cathode metal.
Graphitic Corrosion Occurs in cast iron exposed to salt water or weak acids. Reduces iron
in the cast iron and leaves the graphite in place. Result is extremely
soft material with no metal loss.
C. Material Fracture Toughness
One way to characterize the fracture behavior of a material is the amount of energy
necessary to initiate and propagate a crack at a given temperature. This is the material's fracture
toughness, which decreases as the temperature decreases. Tough materials require a relatively
large amount of energy to initiate and propagate a crack. The impact energy required to fracture a
material sample at a given temperature can be measured by standard V-notch tests.
Various factors other than temperature affect the fracture toughness of a material. These
include the following:
. •Chemical composition or alloying elements.
. • Heat treatment.
. • Grain size.
The major chemical elements that affect a material's fracture toughness are carbon,
manganese, nickel, oxygen, sulfur, and molybdenum. High carbon content, or excessive amounts of
oxygen, sulfur, or molybdenum, hurts fracture toughness. The addition of manganese or nickel
improves fracture toughness.
D. Fabricability
A material must be available in the shapes or forms that are required, and it typically must be
weldable. In piping systems, some common shapes and forms include the following:
. • Seamless pipe.
. •Plate that is used for welded pipe.
. •Wrought or forged elbows, tees, reducers, and crosses.
. •Forged flanges, couplings, and valves.
. • Cast valves.
The last factors that affect piping material selection are availability and cost. Where there is more than
one technically acceptable material, the final selection must consider what is readily available and
what are the relative costs of the acceptable options. For example, the use of carbon steel with a
large corrosion allowance could be more expensive than using a low-alloy material with a smaller
corrosion allowance.
PIPE FITTINGS
Fittings are used to make some change in the geometry of a piping system.
This change could include:
ELBOWS TEES CAPS COUPLINGS UNIONS SWAGE COUPLINGS STUB ENDS REDUCERS SPECIAL FITTINGS
END CONNECTION
REDUCERS
TEES
Pipe Fittings-Standards
ASA B16b1: Cast Iron Pipe Flanges and Flanged Fittings for 800
Psig Hydraulic Pressure
ASA B16.1: Cast Iron Pipe Flanges and Flanged Fittings, Class
125(standard Includes Also Bolt,nut and Gasket Data)
ASA B16.2: Cast Iron Pipe Flanges and Flanged Fittings, Class 250
(Bolt,nut and Gasket Data are also included)
SLIP – ON
SOCKET WELD
SCREWED
LAP JOINT
WELDING NECK
BLIND
INTEGRAL
BASED ON THE FACE OF THE FLANGE
FLANGE FACING
FLAT FACE
RAISED FACE
150#
300#
600#
900#
1500#
2500#
FACE FINISH
SMOOTH FINISH
SERRATED FINISH
FLANGE MATERIALS
ASTM A 105 - Forged Carbon steel
ASTM A 181 - Forged Carbon steel for general purpose
ASTM A 182 - Forged alloy steel and stainless steel
ASTM A 350 - Forged alloy steel for low temperature
services
ANSI B 16.47/API 605 – Higher sizes(above 3”)
IS 6392
SELECTION OF FLANGE
A flange type is specified by stating the type of attachment and the type
of face. The type of attachment defines how the flange is connected to a pipe
section or piece of equipment (e.g., welded). The type of flange face or facing
defines the geometry of the flange surface that contacts the gasket.
Flange Rating
ASME B16.5, Pipe Flanges and Flanged Fittings, provides steel flange
dimensional details for standard pipe sizes through NPS 24. Specification of an
ASME B16.5 flange involves selection of the correct material and flange "Class."
Flange Rating
Refer to ASME B16.5 for material specifications and corresponding Material Group
Numbers. –Table 1.1A
After the Material Group has been determined, the next step is to select the
appropriate Class. The Class is determined by using pressure/temperature rating
tables, the Material Group, design metal temperature, and design pressure.
Flange material specifications listed in Table 1A in ASME B16.5
SAMPLE PROBLEM 1 - DETERMINE FLANGE RATING
A new piping system will be installed at an existing plant. It is necessary to
determine the ASME class that is required for the flanges. The following design
information is provided:
. •Pipe Material: 1¼ Cr – ½ Mo.
. •Design Temperature: 700°F.
. •Design Pressure: 500 psig.
SOLUTION
Determine the Material Group Number for the flanges by referring to ASME
Table 1A. Find the 1¼ Cr – ½ Mo material in the Nominal Designation Steel column. The
material specification for forged flanges would be A182 Gr. F11, and the corresponding
material Group Number is 1.9.
Refer to Table 2 for Class 150. Read the allowable design pressure at the intersection of
the 700°F design temperature and Material Group 1.9. This is only 110 psig and is not
enough for this service.
Now check Class 300 and do the same thing. The allowable pressure in this case is 570
psig, which is acceptable.
The required flange Class is 300.
FLANGE LEAKAGES
Uneven bolt stress
Poor flange alignment
Off-center gasket installation
Dirty & damaged flange faces
Thermal shock
Incorrect gasket size
High vibration
BOLTING
MATERIAL FOR CONSTRUCTION OF BOLTING
DIMENENSINAL STANDRADS FOR BOLTS
MATERIALS
ASTM A 307 - Low carbon steel bolting material
ASTM A 320 - Alloy steel bolting material for low
temperature
ASTM A 193 - Alloy steel bolting material for
high temperature
ASTM A 194 - Alloy steel nut material for high
temperature service
IS 1367 - Threaded steel fasteners
STANDARDS
ANSI B 18.2.1 - Square & Hex. Head bolts
ANSI B 18.2.2 - Square & Hex. Nuts
BS 916 - Black bolts & nuts
IS 1367 - Threaded steel fasteners
GASKETS
SELECTION
1.
1. Compatibility of gasket
material with the fluid
2.
2. Ability to withstand pressure
and temperature of the
system
3.
3. Corrosion of fluids flowing
through the flanges
CLASSIFICATIONS
¾ Full face
¾ Inside bolt circle
¾ Ring type
¾ Metal jacketed
MATERIAL STANDARDS
Gate
Gate valves
valves Butterfly
Butterfly
valves
valves
ISOLATION VALVES
Diaphragm
Diaphragm
Plug
Plug valves
valves
valves
valves
Globe
Globe valves
valves
REGULATION Butterfly
Butterfly
Needle
Needle valves
valves
VALVES valves
valves
Diaphragm
Diaphragm
valves
valves
Non-return valve
Safety valve
Special purpose
OLETS
E XPANSION BELLOWS
STEAM STRAPS
STRAINER
OLETS
WELDOLET
THREDOLET
SOCKOLET
INSERT WELDOLET
FLEXOLET
BRAZOLET
NIPPOLET
COUPOLET
SWEEPOLET
ELBOLET & LATROLET
WELDOLET
For the piping system described below, determine the required flange rating (or Class) in
Pipe: 1¼ Cr – ½ Mo