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What is a FLUID?
It can be any of the following
a GAS
a LIQUID
a mixture of GAS and LIQUID
a SUSPENSION of small SOLID PARTICLES
inside a LIQUID.
What is a PIPELINE?
A PIPELINE conveys a fluid from one given point of the plant usually called INLET
point of the line, to another part of the plant usually called OUTLET point of the line.
A PIPELINE can also connect one PIPELINE to another PIPELINE. PIPELINES can also
discharge the conveyed fluid into the environment (VENTS and DRAIN)
SUPPORTING SYSTEM
Every Pipeline must be supported. Not all Pipelines are supported in the same way
Cold Pipelines can be supported everywhere with FIXED POINTS Hot Pipelines cannot
be supported only with fixed points, butcertain points must be only GUIDED, meaning
that in those points the Pipeline retains a certain numbers of degree of
freedom in certain directions, while are constrained in certain other directions
PIPING DESIGN
Specification of Lines
It is a document that summarizes all the characteristics of a PIPELINE. Starting from
the PROPERTIES of the CONVEYED FLUID, the document specifies all the
CHARACTERISTICS of the PIPELINE FLUID TYPE Choice of material
Services where impurities are accepted industrial water lines (cooling water) steam
lube oil return / before filter lines air lines vents and drains
Carbon Steel, Low Alloy Steel (High T)
2. Corrosive fluids
Services where impurities are not accepted demineralized water lube oil after filters
fuel gas / oil sea water (water containing Chlorine) Stainless Steel No Iron (Fe)
Copper/ Nickel Alloys (Cu- Ni)
3. Aggressive Chemicals
FLUID TYPE
-Steel for High Temperature (Low Alloy Steel Creep Resistant) Calculation of wall
THICKNESS Routing Design and calculation of SUPPORTS (STRESS ANALYSIS)
-Hot Lines must be routed properly. Provisions shall be taken so that when
temperature rises from ambient to Operating Temperature the thermal expansion of
Pipelines does not generate stresses too high for the pipes to withstand. Application
of Thermal Insulation -T> 60° C Insulation for Personnel Protection is mandatory for
all pipeline parts that can be reached by hands.
PRESSURE :
- Non process Pipelines (For Example Vents and drain lines) may
even have no tests at all
- Low Pressure Pipelines can undergo only the Hydraulic Test
-For intermediate pressures a 10% to 50% of joints must be
examined with X- rays
-High Pressure Pipelines are usually 100% X- ray examined.
CARBON STEEL
Steel is basically a solution of carbon (C) into iron (Fe). The presence of carbon into
the crystal structure of the iron improve very much the mechanical characteristics of
the iron alone. Carbon steel is a conventional denomination for steel that has almost
no other metallic
elements added into it.
ASTM most employed carbon steel for pipes are ASTM A53 Grade A and B and ASTM
A106 Grade A and B. A53 used to be cheaper than A106 and Grade A cheaper than
Grade B. Today the difference is not so big, so that for small quantities ASTM A106
Gr. B is usually chosen. ASTM Specifications belonging to same family of Carbon Steel
SEAMLESS PIPES ASTM A53 (Gr. A / B) or A106 (Gr. A / B)
WELDED PIPES ASTM A134 / A135 / A139
WROUGHT FITTINGS ASTM A234 (WPA / WPB)
FORGED FITTINGS A105
CAST PARTS A216 (WCB)
API Standards
For Oil and Gas Industry, another American Standardization Institute is common and
important. This Institute is
API = AMERICAN PETROLEUM INSTITUTE
Rules, Practices and Standards for Oil and Gas Industry are issued by this Institute
and followed by almost all Oil and Gas Companies in the world. Among the many
Standards issued by the Institute there is also a Standard for design of Pipelines: API
STANDARD 5L Within this Standard Materials for Oil and Gas transportation pipelines
are specified, with denomination API 5L This is a family of Carbon Steels almost
equivalent to ASTM A53 /A106.
The introduction of other elements into steel can change very much its mechanical
characteristics. Steel is subject to a process called “creep” at high temperatures
(T > 540 °C) Creep is a reduction of strength over time due to high temperature. It
means that if today the steel can withstand a certain pressure, after a long time at
high temperature same steel can withstand much lower pressures, since its
resistance is decreasing with time due to the high temperature. Steel becomes also
particurarly fragile if submitted to sudden impacts at low temperatures (< - 20 °C).
The introduction of small percentages of chromium (Cr), nichel (Ni), magnesium
(Mg), manganese (Mn), molybdenum (Mo), proves to improve the strength of the
steel and its resistance to corrosion also at high temperatures (> 500 °C) or at low
temperaturea (< -20 °C). Low Alloy Steel is a conventional denomination for steels
where there are small percentages of elements, usually metallic, other than carbon
only. Alloy steels are usually identified with denominations that recall composition.
As for example following high temperature resistant steels: Denomination Alloy
percentage Grade Grade for Castings
5Cr-½ Mo (5% Cr – 0.5% Mo ) P5 C5
1¼ Cr-½ Mo- Si (1.25% Cr – 0.5% Mo – Si) P11 (WC5)
1Cr-½ Mo (1% Cr – 0.5 Mo) P12 (WC5)
2¼ Cr- 1Mo (2.25 Cr – 1% Mo) P22 WC9
ASTM Specifications belonging to same families of Low Alloy Steels
SEAMLESS PIPE A335 (P5 – P11 – P12 – P22)
WELDED PIPE ASTM A358
WROUGHT FITTINGS ASTM A234 (WP5 – WP11 – WP12 – WP22)
FORGED FITTINGS A182 (F5 – F11 – F12 – F 22)
CAST PARTS A217 (C5 – WC5 – WC9)
STAINLESS STEEL
One of most important problems with carbon and low alloy steels, is that the iron
exposed to air and water combines with oxygene (O 2 ) and generates rust (di- iron
tri- oxyde Fe 2 O 3 ) that peels out from the surface. High percentages of chromium
(Cr) and nichel (Ni) added into the steel stop this problem. Stainless Steel is
conventional generic denomination for steels with high percentages of chromium
(minimum 16%) and nichel (minimum 8 %). Traditional denomination for stainless
steel was given first from AISI (American Institute for Steel and Iron) and is still in
the tradition and retained in the Grade of ASTM Specifications. But as usual for alloy
steels, a more precise denomination can refer to composition. AISI Denomination
Alloy Percentage Grade for
Castings
304 / 304L 18Cr- 8Ni (18% Cr – 8% Ni) CF3 / CF8
316 / 316L 16Cr- 12Ni- 2Mo (16% Cr – 12% Ni – 2% Mo) CF3M / CF8M
321 18Cr- 10Ni- Ti (18% Cr – 10% Ni – Ti) Not Available
The “L” suffix stands for “Low Carbon”. In fact the presence of high percentages of Cr
and Ni improves the resistance of steel against rust, but at one cost: stainless steel is
very difficult to weld. Welding of stainless steel can be improved by reducing the
content of carbon in it. ASTM Specifications belonging to same family of Stainless
Steel
SEAMLESS PIPE A312 TP304 – 304L - 316 - 316L - 321
WELDED PIPE ASTM A249 TP304 - 304L - 316 - 316L - 321
WROUGHT FITTINGS ASTM A403 WP304 - 304L - 316 - 316L - 321
FORGED FITTINGS A182 F304 – 304L - 316 - 316L - 321
CAST PARTS A351 (CF3 – CF3M / CF8 – CF8M)
SIZE
NOMINAL PIPE SIZE : NPS It is a conventional size expressed solely in INCHES,
related to the cross section diameter of the pipeline. For smaller sizes the NPS is not
usually exactly equal to any real diameter, but bigger. This comes from the fact that
for uniformity, pipelines must have same Outside Diameter, and change Inside
Diameter with different thickness. But in fluid transportation the internal diameter is
more significant, so if the Outside Diameter is bigger of the NPS, taking away the
thickness, the NPS gives more an idea of the internal diameter. NOMINAL
DIAMETER : DN Same as NPS, but in mm. It is the usual denomination of Size in
Europe where S. I. is adopted. All external diameters pipes according
EUROPEAN Standards (DIN - Germany, UNI - Italy, AFNOR – France) are
exactly equal of the equivalent NPS Sizes according AMERICAN and
BRITISH Standars (BS) EXCEPT 5” (DN125)
WALL THICKNESS (1)1. For PIPES and WROUGHT BW FITTINGS, wall thickness is
given in INCHES or mm.
Some series of thicknesses are standardized. There are two series of systems of
standardized thicknesses. Carbon Steel
ANSI B16.10
5, 10, 20, 30, 40, 60, 80,
100, 120, 160. Schedule
Stainless Steel
ANSI B16.19
5S, 10S, 20S, 30S, 40S,
60S, 80S.
Std Standard
WALL THICKNESS (2)2. For FLANGES, VALVES and FORGED FITTINGS, a different
system of indicating the wall thickness is used. This is called PRESSURE RATING. It is
a NUMBER expressed in POUNDS per SQUARE INCH (PSI symbol #) that refers to the
maximum internal pressure acceptable for normal operation inside that part.
125# 150# 300# 400# 600# 800# Cast Iron Flanges & Valves (Not in NP Standards)
Fl. & Valves Forged Small Valves ( 2”) 900# 1500# 2500# 3000#
6000# 9000# F l a n g e s & V a l v e s Forged Fittings This conventional number is
not exactly the actual maximum pressure acceptable inside the part. The maximum
pressure allowed for a given rating is tabulated in the ANSI standards and depends
on þ Temperature þ ASTM Material
BUTT- WELDING ENDS The end is machined to allow head to head full penetrating
welding
FITTINGS
FLANGES
VALVES
GASKETS
BOLTS AND NUTS
2. Reducing Fittings
TYPE REDUCING TEE SIZE NPS 12” x8” (DIAMETER) (DN 300x200)
WALL THICKNESS Sch. 30x20 MATERIAL ASTM A234 WPB FORGED FITTINGS ANSI
B16.11
PIPE NIPPLES
They are standardized short pieces of pipe usually 50 mm or 100 mm long normally
used between two close fittings. They can come in straight size or in reducing size
and can have one end machined in a different way than the other. Such a variety of
combinations is summarized using abbreviations
B = Bevelled
P = Plain
T = Threaded
L = Large
S = Small E = End
1. Pipe Connection
Welding Neck
Slip On
Lap Joint
Socket Welding
Threaded
2. Mating
Flat Face
Raised Face
Ring Joint
WELDING NECK
Used for all sizes, they allow full penetration weld between pipe and flange. For this
eason they are used for severe applications where failure of welda cannot be
accepted. This does not come free of cost, since the shape of the flange obliges to
start from a heavy forging and waste a lot of material from machining.
SLIP ON
Used for all sizes, they are very much economical because they are flat and can be
obtained from sheets or plates with minimum waste of material from machining. But
they do not allow full penetration weld, so that they are use for low ratings (usually
150# only) and unsevere applications
THREADED
Can be used for all sized, but are preferably used for small sizes (< or equal to 2”).
Cheap manufacturing, cheap installation (no weld is required) but limited to threadel
lines, that means unsevere applications where leaks are not a major issue
LAP JOINT
A Stub End is welded on the pipe after the flange insertion of it. This solution is used
for Stainless Steel lines at low pressure, since the heavy flange does not come in
contact with the conveyed fluid and can be provided in much cheaper Carbon Steel
material. Moreover no weld is required, also a good thing for Stainless Steel lines.
SOCKET WELDING
Used for small sizes (< or equal to 2”) for unsevere services on Socket Welding lines.
Flat Face Gasket: Full Face Flat It covers the entire surface of the flange Raised Face
Gasket: Flat It covers the raised surface of the flange Spiral Wound Also known as
Spirometallic, or Spirotallic, its a wounded spiral of Stainless Steel and Graphite to
withstand high temperatures or severely aggressive fluids Ring Joint Gasket:
Metallic Ring It is normally made up of Steel. It deforms inside the ring joint grooves
assuring sealing at very high pressures. Surface Finishing of Flanges To improve the
sealing effect of plane gaskets, the surface of a flange can be machined. A set of
circular scares is machined in the surface. When the gasket is tightly squeezed
etween the flanges, it penetrates into the scares improving sealing.
ACTUATION OF VALVES
To open and close a valve, Hands, Electric Power, Compressed Air, High Pressure Oil
you can use in which case you need Handwheel, Electric Actuator, Pneumatic
ctuator, Hydraulic Actuator And is called Manual, Electric, Pneumatic, Hydraulic
CONTROL VALVES
These valves are used to CONTROL one or more of the PROPERTIES of the conveyed
fluid in order to mention the VALUES of the controlled property within a specific ange.
The internal parts of these valves are specially designed tu suit the particular control
task and are non subject to particular Standards. Anyway, the majority of Control
Valve Manufacturers try to respect at least the end to end dimensions given in
ANSIB16.25. Also connections follows the recognized international standards.
TUBING
1. FRACTIONAL TUBES
The INCH is the unit of measure, and since tubes for piping purpose (REMEMBER:
CONVEYING FLUIDS!) are small, usually less than 1”, FRACTIONS of inch are used,
hence the name
FRACTIONALMETRIC TUBES
Pneumatic Lines