ABOUT PIPING

WHAT IS PIPING ABOUT?

We can say PIPING is about designing, fabricating
and constructing lines conveying FLUIDS.

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.

Basic properties of conveyed FLUIDS

FLUID TYPE
with particular attention to
the CORROSION characteristics
the DANGER for HEALTH and the
ENVIRONMENT

FLOW RATE

PRESSURE

TEMPERATURE

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)

Basic characteristics of a PIPELINE

SIZE (or DIAMETER)

WALL THICKNESS

TYPE OF JOINTS BETWEEN PIECES

EXTERNAL FINISHING

QUALITY CHECKS

welded joints (butt welding / socket welding)

threaded joints
flanged joints

Painting
Insulation

Hydraulic Testing
Non Destructive Examination of Joints

Other characteristics of a PIPELINE

ROUTING

The routing is how the Pipeline is developed into the space.

Cold Pipelines connecting static objects (something that

does not move like Tanks, Vessels, other Pipelines, Headers)
can be straightly routed between the inlet and the outlet
point.

Cold Pipelines connecting MACHINES that vibrate or rotate

may need a flexible part between the inlet and the outlet
point.

Hot Pipelines must be flexible enough to adsorb the thermal

expansion of the Pipeline from cold to hot condition

There are rules and regulations to route a Pipeline according

the Good Engineering Practice

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, but

certain 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
Non corrosive fluids
Services where impurities are accepted
industrial water lines (cooling water)
steam
lube oil return / before filter lines
air lines
vents and drains
Corrosive fluids
Services where impurities are not accepted
demineralized water
lube oil after filters
fuel gas / oil
sea water (water containing Chlorine)
Agressive Chemicals
Strong Acids / Bases

Carbon Steel
Low Alloy Steel (High T)

Stainless Steel

No Iron (Fe)
Copper/Nikel Alloys (Cu-Ni)
Plastic:
PVC TEFLON PE
Rubber:
NBR, Viton
Composites:
RESIN GLASS

FLUID TYPE
Choice of CORROSION ALLOWANCE
Thickness increasing taking into account CORROSION
Typical corrosion allowance for water is 3 mm that affects THICKNESS

Choice of joints.
DANGEROUS fluids are conveyed in fully welded pipes, were leaks
cannot occur.

Choice of NDE
For Dangerous Fluids 100% of joints are likely to be X-Ray examined

FLOW RATE
Choice of Diameter
For a given flowrate
- SMALL DIAMETER means HIGHER VELOCITY of the conveyed fluid
- BIG DIAMETER means SLOWER VELOCITY of the conveyed fluid
Velocity of fluids in Pipelines affects
- Pressure Losses along the Pipeline
Pressure Losses are PROPORTIONAL to the square velocity (v2)
- Vibration of the Pipeline
Usual Velocity of Fluids inside pipelines are:
Gas:
20 m/s - max. 40 / 50 m/sec
Liquid:
2 to 4 m/s - max. 10 m/sec

TEMPERATURE
Choice of MATERIAL
- 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>60C Insulation for Personnel Protection is mandatory for all
pipeline parts that can be reached by hands.

PRESSURE
Calculation of Wall Thickness
Choice of the Joint
- Low pressure pipelines can be threaded or socket welded
- High Pressure pipelines are Butt Welded
Extension of NDE of the joints
-

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.

AMERICAN STANDARDS FOR PIPING DESIGN

ANSI =

AMERICAN
NATIONAL
STANDARDIZATION
INSTITUTE

ASME =

AMERICAN
SOCIETY of
MECHANICAL
ENGINEERS

ANSI/ASME B31.1: POWER PIPING

ANSI/ASME B31.3: PROCESS PIPING
THESE STANDARDS GIVE TECHNICAL RECOMMENDATIONS FOR
DESIGNING PIPING SYSTEM FOR POWER PLANTS AND CHEMICAL
PLANTS
THEY CONTAINS FORMULAS TO CALCULATE THE MINIMUM
THICKNESS OF PIPELINES
THEY CONTAINS FORMULAS TO CALCULATE THE EXTRA
THICKNESS THAT A PIPE MUST HAVE WHEN A BRANCH IS CUT
INTO IT.
THEY CONTAINS REGULATIONS FOR STRESS ANALYSIS
THEY CONTAINS TABLES THAT GIVE MAXIMUM ALLOWABLE
STRESS FOR METALLIC MATERIALS ACCEPTED BY ANSI FOR
PIPELINE CONSTRUCTION DEPENDING ON TEMPERATURES.

STANDARD MATERIALS FOR PIPING

ASTM =

AMERICAN SOCIETY for

TESTING MATERIALS

ASTM developed a collection of documents called MATERIAL

SPECIFICATIONS for standardising materials of large use in the
INDUSTRY. Specifications starting with A are for STEEL.
Specifications starting with B are for non-ferrous alloys (Bronze,
Brass, Copper Nickel alloys, Aluminium alloys and so on).
Specifications starting with D are for plastic material, as PVC.

An ASTM Specification does not only specify the basic CHEMICAL

COMPOSITION of material, but also the PROCESS through which the
material is shaped into the final product.

This is why for a given base material SEAMLESS PIPE have a

specification, WELDED PIPE have another specification WROUGHT
FITTINGS have another specification, FORGED FITTINGS have
another specification, large VALVE bodies (normally CAST) have
another specification

CARBON STEEL
Steel is basically a solution of carbon (C) into iron (Fe). The
presences of carbon into the crystal structure of the iron improve very
much the mechanical caracteristics 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 choosen.
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.

LOW ALLOY STEEL

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

5Cr-Mo
1Cr-Mo-Si
1Cr-Mo
2Cr-1Mo

(5% Cr 0.5% Mo )
(1.25%Cr 0.5% Mo Si)
(1% Cr 0.5 Mo)
(2.25 Cr 1% Mo)

P5
P11
P12
P22

Grade for
Castings
C5
(WC5)
(WC5)
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 (O2) and
generates rust (di-iron tri-oxyde Fe2O3) 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

304 / 304L
316 / 316L
321

18Cr-8Ni
16Cr-12Ni-2Mo
18Cr-10Ni-Ti

Alloy Percentage

Grade for
Castings
(18%Cr 8%Ni)
CF3 / CF8
(16%Cr 12%Ni 2%Mo) CF3M / CF8M
(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)

How Pipeline CHARACTERISTICS are

defined by the Standards.

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.

Schedule

Weight Series

Carbon Steel
ANSI B16.10

5, 10, 20, 30, 40, 60, 80,

100, 120, 160.

Stainless Steel
ANSI B16.19

5S, 10S, 20S, 30S, 40S,

60S, 80S.

Std

Standard

XS

Extra Strong

XXS

Extra Extra Strong

It happens that for a given diameter the thickess of one Schedule is equal
to the thickness of one Weight Series. For example for small diameters,
Sch. 40 is equal to Std Weight. THIS IS NOT A RULE, and this idea is one
of the most common mistakes in piping design.

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#

Cast Iron

900#

300#

400#

600#

Flanges & Valves

(Not in NP
Standards)

Fl. & Valves Forged Small

1500#

3000#

6000#

2500#

Flanges & Valves

800#
Valves (
2)

9000#

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
Temperature
ASTM Material

TYPE OF JOINTS BETWEEN PIECES (1)

1. BUTT-WELDING ENDS
The end is machined to allow head to head full penetrating welding

TYPE OF JOINTS BETWEEN PIECES (2)

2. SOCKET WELDING ENDS
A socket is provided where pipe can be inserted

TYPE OF JOINTS BETWEEN PIECES (3)

3. THREADED ENDS
Parts to be connected are threaded. For services where leaks are
strongly undesired, a light weld is carried out at the surface, this is called
Seal Weld.

Seal weld

STANDARDIZED PIPING OBJECTS

PIPES

FITTINGS
FLANGES

VALVES

GASKETS
BOLTS AND NUTS

PIPES: ANSI B36.10 CS / B36.19 SS

Seamless
Electric Resistance Welded
No material is added during welding
process

Electric Fusion Welded

Material (Filler Metal) is added during the
process of welding

HOW TO IDENTIFY A PIPE

SIZE

NPS 12

(DIAMETER)

(DN 300)

WALL THICKNESS

Sch. 40

MATERIAL

ASTM A106 Gr. B

BW FITTINGS : ANSI B16.9

Bends
30 - 45 - 60 - 90
Long Radius R=1.5 D
Short Radius R=D

Tees
Straight Full Tees
Reducing Tees

Reducers
Concentric Reducers
Eccentric Reducers

Caps

HOW TO IDENTIFY A BW FITTING

1. Straight Fittings
TYPE
BEND 90 LR
SIZE

NPS 12

(DIAMETER)

(DN 300)

WALL THICKNESS

Std

MATERIAL

ASTM A234 WPB

2. Reducing Fittings
TYPE

REDUCING TEE

SIZE

NPS 12x8

(DIAMETER)

(DN 300x200)

WALL THICKNESS

Sch. 30x20

MATERIAL

ASTM A234 WPB

FORGED FITTINGS ANSI B16.11

HOW TO IDENTIFY A FORGED FITTING

TYPE

ELBOW 90

SIZE

NPS 1

(DIAMETER)

(DN 25)

WALL THICKNESS

Rating 3000#

JOINT

NPT

MATERIAL

ASTM A105

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 L = Large
E = End
P = Plain
S = Small
T = Threaded

Pipe nipples can be used to change among

joint types.
For example a PExBE Pipe Nipple changes a
Socket Welding Line into a Buttwelding Line
Beveled End

Plain End

BW
SW

FLANGES ANSI B16.5

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 reason 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
tightenly squeezed between the
flanges, it penetrates into the scares
improving sealing.

HOW TO IDENTIFY A FLANGE

JOINT TYPE

SLIP ON

SIZE

NPS 6

(DIAMETER)

(DN 150)

WALL THICKNESS

Rating 300#

MATING - FINISH

RF R9

MATERIAL

ASTM A105

VALVES: CAST STEEL

Globe

Gate

Check

VALVES: FORGED STEEL

Globe

Gate

Check

Ball

Butterfly

ACTUATION OF VALVES
To open and close a
valve, you can use
Hands
Electric Power
Compressed Air
High Pressure Oil

in which case you need

a valve provided with
Handwheel
Electric Actuator
Pneumatic Actuator
Hydraulic Actuator

and the valve 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 mantain the VALUES of the controlled
property within a specific range.
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.

SAFETY AND RELIEF VALVES

These valves are installed on pipelines where pressure can exceed by
accident the DESIGN PRESSURE of the pipeline.
These valves are designed to open and discharge the conveyed fluid when
the pressure in the pipeline becomes greater than a specified value called
SET.
RELIEF

The valve opens when the pressure goes

over the SET, but close again when the
pressure returns under the SET

SAFETY

The valve opens when the pressure goes

over the SET, but never closes again.
Personnel intervention is required on the
pipeline to check the event and the
condition of the area, before re-arming the
valve and starting operation again

TUBING
A TUBE is a circular section of given
DIAMETER and THICKNESS.
It is normally specified giving the Ouside
Diameter (OD) and the thickness. But it
can also be specified giving the Inside
Diameter (ID) and the thickness.
The given numbers correspond exactly
to the geometrical dimension they refer.
So A 2 OD TUBE has exactly a 2
Outside Diameters.

Dimensionally, there are two big families

of 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
FRACTIONAL
2. METRIC TUBES

As per SI requirements, mm is the unit of

measure.
Again the value in mm is the actual
ouside diameter of the tube, so that a
DN15 pipe has a rather different OD then
a 15 mm tube.

TUBES in PIPING DESIGN.

Tubes are not usually used in PIPING
DESIGN except for some very particular
services.
In typical Oil and Gas Machinery
installations, like Nuovo Pignones,
TUBES are basically used for:
1. Parts of HP Hydraulic Lines
2. Instrument connecting Lines
3. Pneumatic Lines

These Lines are small size (usually less

than 1).
COMPRESSION FITTINGS
Tubing is usually BENT.
A large variety of fittings are available for
1. detachment of BRANCHES (Tees)
2. Passing through steel walls (Bulk
Unions)
3. Unite tube to tube (tubing is not
welded)

4. Connecting Tubing to PIPES

(Connectors)
5. Connecting Tubes to Flexible Hoses
Connection of TUBING with the fitting is
achieved through a particular locking
system where a RING (FERRULE) is
forced to COMPRESS the Tube walls for
sealing and joining.

These fittings are not STANDARDIZED,

but are branding based and patented.
Most popular manufacturers of
compression fittings are
PARKER
SWAGELOCK
GARILOCK