Piping

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The document discusses various piping codes, standards, components like pipes, flanges, fittings, valves, fasteners and gaskets. It also talks about piping manual, MARIAN database and Material Control System.

The different piping components discussed are pipes, flanges, pipe fittings, valves, fasteners and gaskets.

The different types of pipe classes mentioned are limit table, thickness table and branch table. The limit table specifies pressure and temperature limitations. The thickness table specifies schedule number and relevant pipe thickness. The branch table gives the types of branches to be taken from header pipes.

TABLE OF CONTENTS

1. PIPING CODES & STANDARDS-------------------------------------------------------------------------------2


2. INTRODUCTION TO PIPING COMPONENTS-------------------------------------------------------------4

2.1. Pipes-----------------------------------------------------------------------------------------------------------------4

2.2 Flanges--------------------------------------------------------------------------------------------------------------6

2.3. Pipe Fittings--------------------------------------------------------------------------------------------------------8

2.4. Valves--------------------------------------------------------------------------------------------------------------11

2.5 Fasteners----------------------------------------------------------------------------------------------------------17

2.6 Gaskets------------------------------------------------------------------------------------------------------------17
3. PIPING MANUAL :------------------------------------------------------------------------------------------------19

3.1 Standard / General Specifications---------------------------------------------------------------------------20

3.2 Pipe Class---------------------------------------------------------------------------------------------------------20

3.3 Instrument Nozzle Assemblies--------------------------------------------------------------------------------24

3.4 * Support Standard---------------------------------------------------------------------------------------------25

3.5 Special Parts------------------------------------------------------------------------------------------------------26


4. MARIAN-------------------------------------------------------------------------------------------------------------27

4.1 Main Database---------------------------------------------------------------------------------------------------27

4.2 MARIAN Modules----------------------------------------------------------------------------------------------27


5. TECHNICAL PROCUREMENT-------------------------------------------------------------------------------29

5.1 Piping Inquiry Specification----------------------------------------------------------------------------------29

5.2 Technical BID Evaluation-------------------------------------------------------------------------------------29

5.3 Technical Recommendation (TR)----------------------------------------------------------------------------29


6. *’S MATERIAL CONTROL SYSTEM (LMCS):-----------------------------------------------------------30

6.1 “MTO” Database------------------------------------------------------------------------------------------------30

6.2 “PROCUREMENT” Database-------------------------------------------------------------------------------30

6.3 “INSPECTION” Database------------------------------------------------------------------------------------31

6.4 “TRANSPORT” Database------------------------------------------------------------------------------------31

6.5 “RECEIPT” Database-----------------------------------------------------------------------------------------31

6.6 “ISSUE” Database----------------------------------------------------------------------------------------------31

Training Coordinator: D.H.Saraiya Page 1 of 21 Originator : SUS / HAS


1. PIPING CODES & STANDARDS
The following codes and standards shall be used together with this standard specification for
materials, design and dimensional requirements.

American National Standard Institute (ANSI)


American Society of Mechanical Engineers (ASME)

ASME B 31.1 Power piping


ASME B 31.3 Process Piping for Petroleum refineries, Chemical,
Pharmaceutical, Textile, Paper, Semiconductor & Cryogenic
plant
ASME B 31.4 Piping generally used for transporting & distributing liquid
Hydrocarbons & other liquids
ASME B 31.5 Refrigeration piping
ASME B 31.8 Piping generally used for transporting & distributing Gases.
ASME B 31.9 Building (Utility)services
ASME B 31.11 Slurry transportation piping system

ASME B 16.5 Pipe Flanges and Flanged Fittings NPS ½ Trough NPS 24
ASME B 16.9 Factory-Made Wrought Steel Buttwelding Fittings
ASME B 16.10 Face-to-Face and End-to-End Dimensions of Valves
ASME B 16.11 Forged Fittings, Socket- Welding and Threaded
ANSI B 16.14 Ferrous Pipe Plugs, Bushing and Locknuts with Pipe Threads
ASME B 16.20 Metallic Gaskets for Pipe Flanges- Ring-Joint, Spiral-Wound, and
Jacketed
ASME B 16.21 Nonmetallic Flat Gaskets for Pipe Flanges
ASME B 16.25 Buttwelding Ends
ASME B 16.28 Wrought Steel Buttwelding Short Radius Elbows
ASME B 16.34 Valves - Flanged, Threaded, and Welding End
ASME B 16.36 Orifice Flanges
ASME B 16.47a Large Diameter Steel Flanges NPS 26 Through NPS 60
ANSI B 18.2.1 Square and Hex Bolts and Screws (Inch Series)
ANSI B 18.2.2 Square and Hex nuts (Inch Series)
ASME B 36.10M Welded and Seamless Wrought Steel Pipe
ASME B 36.19M Stainless Steel Pipe

American Petroleum Institute (API)

API SPEC 5L Specification for Line Pipe


API STD 594 Check Valves: Wafer, Wafer-Lug, and Double Flanged Type
API STD 598 Valve Inspection and Testing
API STD 600 Steel Gate Valves- Flanged and Butt-welding Ends,
Bolted and Pressure Seal Bonnets
API STD 602 Compact Steel Gate Valves- Flanged, Threaded, Welding,
and Extended- Body Ends
API STD 609 Butterfly Valves: Double Flanged, Lug-and wafer Type

Training Coordinator: D.H.Saraiya Page 2 of 21 Originator : SUS / HAS


Manufacturers standardizations society-standard practice

MSS SP-6 Standard Finishes for Contact Faces of Pipe Flanges and
Connecting-End Flanges of Valves and Fittings
MSS SP-25 Standard Marking Systems for Valves, Fittings, Flanges &
Union
MSS SP-45 Bypass and Drain Connections
MSS SP-61 Pressure Testing of Steel Valves
MSS SP-67 Butterfly Valves
MSS SP-75 Specification for High Test Wrought Butt Welding Fittings
MSS SP-82 Valve Pressure Testing Methods
MSS SP-95 Swadged Nipples and Bull Plugs
MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings-
Socket welding, Threaded and Buttwelding Ends

American Society for Testing and Materials (ASTM)

ASTM Section II A Volume 1 & 2


ASTM Section V
ASTM Section VIII Division 1 & 2

British Standards (BS)

BS 5351 Steel ball valves for petroleum, petrochemical & allied industries
BS 5352 Specifications for steel wedge gate, globe & check valves 50
mm & smaller for petroleum, petrochemical & allied industries
BS 5353 Steel plug valves
BS 1873 Steel globe & globe stop & check valves (Flanged & butt-welded
ends) for petroleum, petrochemical & allied industries
BS 6755 (Part 1&2) Testing of Valves

Training Coordinator: D.H.Saraiya Page 3 of 21 Originator : SUS / HAS


2. INTRODUCTION TO PIPING COMPONENTS

2.1. PIPES

Piping in a particular plant can be compared with arteries & veins in our body. There are
mainly two types of pipes from manufacturing point of view. The first is Seamless pipes &
second is Welded pipes.

Various attributes of pipe are described below.

A) End Preparation:

There are three types of end preparation of pipes.


(a) Plain End (PE)
(b) Butt weld or Beveled End (BW/BE)
(c) Threaded End

B) Design & Dimension Standard:

This will provide the following information.


Nominal Bore (NB), Thickness, Outside Diameter (OD), Tolerance & Weight.

The Dimension Standard for pipe is as follows.


ANSI/ASME B 36.10 For Carbon Steel (CS), Low Temperature Carbon Steel
(LTCS), Low Alloy Steel (LAS) Pipes
ANSI/ASME B 36.19 For Stainless Steel (SS) Pipes

C) Material

I. CS: It is used for temperature range from (–) 290C to 4270C.


Most commonly used CS materials are as follows:

ASTM A 106 Gr. B (Seamless pipes)


API 5L Gr. B (Seamless & Welded)
ASTM A 53 Gr. B (Seamless & Welded)
IS 1239 (Upto 6” & ERW)
IS 3589 (Above 6”)

II. LTCS:It is used for low temperature i.e. from (–) 460C to 3430C.
The most commonly used LTCS materials are as follows:

ASTM A 333 Gr. 6 (Seamless pipes)


ASME A 671 (Welded pipes)

III. LAS: It is used for high temperature i.e. (-) 290C to C
The most commonly used LAS materials are as follows:

ASTM A 335 Gr. P11, P12, P9 (Seamless pipes)


ASTM A 691 Gr.C60, C65, C70 (Welded pipes)

Training Coordinator: D.H.Saraiya Page 4 of 21 Originator : SUS / HAS


IV. SS: It is used for cryogenic temperature range i.e. from (-) 1960C to 5380C.
Most commonly used SS materials are as follows:

ASTM A 312 TP 304 / ASTM A 312 TP 304L


ASTM A 312 TP 316 / ASTM A 312 TP 316L
ASTM A 312 TP 321

(Various shortforms:

IS Indian Standard
ERW Electric Resistance Welding
LS * Standard)

Training Coordinator: D.H.Saraiya Page 5 of 21 Originator : SUS / HAS


2.2 FLANGES

Flanges are used to make a joint that is required to be dismantled.


Various attributes of Flanges are described below:

A) Type: There are five types of Flanges.

I. Weld Neck Flange

It has Butt Weld End Connection.


Radiography Test (RT) is possible.

II. Socket Weld Flange

Here Fillet welding is done from outside only.


Die Penetration Test (DP) is possible.

III. Slip On Flange

Here Fillet welding is done from inside as well as from outside.


DP Test is possible.

IV. Threaded Flange

It is mainly used in Galvanized pipes.

V. Blind Flange

It is used for ending a line.

B) Facing: There are four types of facing.

I. Raised Face

It is specified up to 600 (psi) rating pipe class.

II. Ring Joint

It is specified from 900 rating (psi) & above pipe class.

III. Flat Face

It is only used for 150 (psi) rating pipe class.


It is specified for utility fluids like Cooling Water and Low Pressure Nitrogen.

IV. Tongue & Groove

Its use is mainly dependent upon the nature of fluid to be handled.


It is specified to handle extremely hazardous fluids like Liquid Ammonia.

C) Design and Dimension Standard: The dimensional standards generally used are

I. ANSI/ASME B16.5 for size upto 24’’

Training Coordinator: D.H.Saraiya Page 6 of 21 Originator : SUS / HAS


II. ANSI/ASME B16.47 series A & B for size above 24’’. Series B specifies compact
design & is used when space and cost are the main constraints.

D) Material: Flanges are manufactured from following forged materials.

I. Carbon Steel – ASTM A 105 (used most of the times)


ASTM A 181 (it is obsolete now)

II. Low Temperature Carbon Steel—ASTM A 350 Gr. LF 2


2
III. Low Alloy Steel – ASTM A 182 Gr. F 11 (generally used)
3 ASTM A 182 Gr. F 1/F22/F9

IV. Stainless Steel – ASTM A 182 Gr. F 304


ASTM A 182 Gr. F 304 L
ASTM A 182 Gr. F 316
ASTM A 182 Gr. F 316 L
ASTM A 182 Gr. F 321

ASTM Sec. II A defines ferrous material. It gives detail properties of Ferrous Material
- Chemical Analysis
- Physical Properties (tensile strength,
Yield strength, hardness, etc.)

E) Pressure Class (Rating)

Rating is maximum allowable non-shock working gauge pressure. There are 150, 300,
600, 900, 1500, 2500 ratings. To select a pressure class the following two steps are
followed.
I. Decide the group of material from Table 1A of ASME 16.5
II. Refer Table 2 of ASME 16.5 for design condition.

Spectacle Blind or Figure 8 Blind

It is not exactly a flange but it is kept between two flanges and is used for the temporary
isolation of a line.

Design & Dimension Standard----LS 423-06


Material----Same as Flange
Facing----Same as Flange

Generally it is used up to 10” & above 10” it is used in two separate pieces. One is
known as Slip Plate (Blind Part) & second is known as Slip Ring (Hollow Part).

Training Coordinator: D.H.Saraiya Page 7 of 21 Originator : SUS / HAS


2.3. PIPE FITTINGS

Pipe fittings are of different types.

2.3.1 Elbows: Used for change in direction of pipe routing.

(a) They are of 2 types


45 Elbow which can be
Short Radius Elbow, R = 1D
Long Radius Elbow, R = 1.5D

90 Elbow which can be


Short Radius Elbow, R = 1D
Long Radius Elbow, R = 1.5D

(b) According to End connection elbows can be classified as


4 Socket Weld : for size upto 1½’’
5 Butt Weld : for size greater than 1½’’ ( > 2’’ in *)
6 Threaded : for size upto 1½’’ in G.I. Pipes

(c) Dimensional Standard


For Socket Weld & Threaded Elbows: ANSI/ASME B16.11
For Bevelled end Elbows : ANSI/ASME B 16.9

Thickness for Beveled end fittings = Thickness of pipe


Thickness for 3000# Socket weld elbows = Schedule 80 of respective pipe size.
Thickness for 6000# Socket weld elbows = Schedule 160 of respective pipe size.
Thickness for 9000# Socket weld elbows = Schedule XXS of respective pipe size.

(d) Pressure class for Socket Weld & Threaded Pipe Fitting
It is as follows:
2000 psi or 2000 rating - used only for threaded pipe fittings
3000 psi - used only for Socket Weld Pipe fitting & threaded pipe fittings
6000psi - used only for Socket Weld Pipe fitting & threaded pipe fittings
9000psi - used only for Socket Weld Pipe fitting & threaded pipe fittings

(e) Material

Socket Weld and Threaded pipefitting are manufactured from following forged
materials
(1) Carbon Steel – ASTM A 105
(2) Low Temperature Carbon Steel- ASTM A 350 Gr. LF2
(3) Low Alloy Steel – ASTM A 182 Gr. F11(generally used), F1, F6, F9
(4) Stainless Steel – ASTM A 182 Gr. F 304, F304L, F316, F316L, F321

Butt Weld pipe fittings are manufactured from pipes


(1) Carbon Steel – ASTM A 234 Gr. WPB
(2) Low Temperature Carbon Steel – ASTM A 420 Gr. WPL6

Training Coordinator: D.H.Saraiya Page 8 of 21 Originator : SUS / HAS


(3) Low Alloy Steel – ASTM A 234 Gr. WP11/WP22/WP9
(4) Stainless Steel – ASTM A 403 WP/304, 304L, 316, 316L, 321

2.3.2 Tee: Used for taking a branch.

(a) Tee can be

7 Equal/Straight tee – All 3 sizes are equal


8 Unequal/Reduced tee – Branch size is always smaller

Points (b), (c), (d) and (e) are same as elbows

2.3.3 Half Coupling: Used to take a branch upto 1½’’ size.

9 End connections are Socket Weld & Threaded


10 Used in Pipe class upto 300 rating

Points (c), (d), (e) same as elbow

2.3.4 Reducer/Expander: Used when change in pipe size is there.

11 Type – Concentric Reducer – Butt Weld


Eccentric Reducer – Butt Weld
12 In case of Eccentric Reducer one side is tapered while the other side is straight. Here the
difference in elevation of the axis exists leading to eccentricity. Its construction is like a
trapezoid.
13 In case of Concentric Reducer both sides are tapered and the axis is also the same. Its
construction is like a cone.

Eccentricity

Eccentric Reducer Concentric Reducer

Thumb Rule for Reduction:

Higher Size Next Lower Size


2

For E.g. if the Header Side is 6’’ then 6/2 = 3 and hence the next lower size possible is
2½’’.
Hence it can be seen that reduction from 6’’ to 2½’’ is possible. Further reduction
beyond 2 ½’’ is not possible. Reducers can be manufactured in small size.

Dimension Standard: ANSI/ASME B16.9


Thickness is same as the pipe thickness.

Material: Same as BW Elbows


Training Coordinator: D.H.Saraiya Page 9 of 21 Originator : SUS / HAS
II.3.5 Full Coupling: Used for Pipe to Pipe joint of small bore (upto1½’’)

14 End connections are Socket Weld & Threaded


Dimensional Standard, Material and Pressure class same as Half coupling

II.3.6 Weldolet:

15 Used to take Butt Weld branch for which Reducing tee is not possible
16 Used in high pressure, high temperature pipe class from 900 rating

Dimension Standard:

17 MSS SP 97
18 Header and Branch size with thickness is to be specified

Material:

19 Forged same as elbow / half coupling

II.3.7 Sockolets:

20 Same as Weldolet except there is a Socket weld end at Branch side.

II.3.8 Caps: Used at the end of the line for the termination of the line.

End Connection: The end connections are

Socket weld }
Threaded end} Up to 1 ½”

Butt weld Above 2”

Dimension Standard:

ANSI/ASME B 16.11 For SW & Threaded End


ANSI/ASME B 16.9 For BW/BE
Thickness for BW caps same as thickness of pipe.

Material: Same as Elbow

Training Coordinator: D.H.Saraiya Page 10 of 21 Originator : SUS / HAS


2.4. VALVES

Valves are used for main three purposes listed below.

21 For Isolation of flow.


22 For Regulation of flow.
23 For avoiding the reversal of the flow.

The valves used for isolation cannot be used for regulation but other way round is possible.

Various types of valves.


(1) Gate valve
(2) Ball valve
(3) Plug valve
(4) Butterfly valve
(5) Globe valve
(6) Needle valve
(7) Check valve
(8) Control valve (Handled by Instrumentation Department)
(9) Pressure relief valve or Safety valve (Handled by Instrumentation Department)

First five valves are used for isolating the flow, 5th & 6th valves are used for regulating the flow
and 7th valve is used for avoiding the reversal of the flow.

2.4.1 GATE VALVE

It is the most commonly & very widely used valve in industrial piping for isolation of the flow.
It is manually operated and it is not recommended for regulation of the flow. Installation of
this valve is possible from both the ends. Hence it is bi-directional valve.

A) End Preparation:

(a) Cast Steel valves have Flanged or Butt weld end preparation.
(b) Forged Steel valves have Socket weld or Threaded end preparation.

B) Design & Dimension Standard:

The dimension Standard for gate valve is as follows.


API 600 For Cast Steel valves (Flanged/BW valves)
API 602 Forged Steel valves (SW/Threaded valves)
ANSI B 16.34 For Pressure & Temperature limitation & Rating
ANSI B 16.10 For face to face dimension of Flanged & BW end
API 598 For Testing of valve

C) Main parts: Gate valve has following main parts.

Training Coordinator: D.H.Saraiya Page 11 of 21 Originator : SUS / HAS


Body
Bonnet
Internals/Trim/Wetted parts: Parts that come in direct contact with the fluid. Gate
valve has following Internals/Trim/Wetted parts.
Wedge / Seat Ring / Stem / Gland Bush

D) Pressure Class:

There are 150,300,600,900,1500,2500 ratings for Flanged & BW valve.


There is 800 rating for SW or Threaded valve.

E) Material: Forged Steel Cast Steel

CS ASTM A 105 ASTM A 216 Gr WCB

LTCS ASTM A 350 Gr LF2 ASTM A 352 Gr LCB

LAS ASTM A 182 Gr F11 ASTM A 217 Gr WC6


ASTM A 182 Gr F22 ASTM A 217 Gr WC9
ASTM A 182 Gr F9

SS ASTM A 182 Gr F304 ASTM A 351 Gr CF8


ASTM A 182 Gr F304L ASTM A 351 Gr CF8M
ASTM A 182 Gr F316 ASTM A 351 Gr CF3M
ASTM A 182 Gr F316L ASTM A 351 Gr CF3C
ASTM A 182 Gr F321

2.4.2 GLOBE VALVE

The fluid while passing through this valve changes its flow direction and hence this valve
causes increased resistance to flow which result into considerable pressure drop. So this valve
is not suitable where pressure drop is critical. This valve is mainly used for regulation of the
flow.

Inlet and outlet of this valve are fixed. Hence installation of this valve is unidirectional. Flow
direction is marked on the valve body.

A) End Preparation: Same as Gate valve.

B) Design & Dimension Standard:

BS 5352 For SW/Threaded valves


BS 1873 For Flanged/BW valves
ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating
ANSI/ASTM B 16.10 For face to face dimension of Flanged/BW end valves
API 598 For Testing of valve

C) Main parts:

Globe valve has following main parts.


Body
Bonnet
Internals/Trim/Wetted parts: Globe valve has following Wetted parts.
Training Coordinator: D.H.Saraiya Page 12 of 21 Originator : SUS / HAS
Disc
Seat Ring
Stem
Gland Bush

D) Pressure Class: Same as Gate valve.

E) Material: Same as Gate valve.

2.4.3 CHECK VALVE

It is sometimes referred to as Non Return Valve.


It is self-operated valve and allows the flow to pass in one direction and will not allow reverse
flow.
Installation of this valve is unidirectional.
Flow direction is marked on the body.

A) Type and End Connection:

1) Lift Check Valve (up to 1 ½’’) : Socket Weld / Threaded / Butt Weld
2) Swing Check Valve ( >= 2’’) : Flanged / Butt Weld
3) Wafer type Check Valve: Wafer type / Wafer lug type. It is to be kept between two
flanges.

B) Design & Dimension Standard:

BS 5352 For Lift Check Valve


BS 1868 For Swing Check Valve
API 594 For Wafer Check Valve
ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating
ANSI/ASME B 16.10 For Face to Face dimension
API 598 For Testing of valve

C) Main Parts:

Lift Check Valve: Swing Check Valve: Wafer Check Valve:

Body Body Body


Cover Cover Plates
Spring Disc Spring Internals
Disc Internals Seat Internals Hinge pin
Seat Hinge Pin
Disc Carrier

D) Pressure Class: Same as Gate Valve

E) Material:

Lift Check Valve (up to 1.5” & SW / Threaded / BW): Same as forged Gate Valve
Swing Check Valve (>= 2’’& Flanged / BW): Same as cast steel Gate Valve
Wafer type Check Valve (Wafer type / Wafer lug type): Same as cast steel Gate Valve.
Training Coordinator: D.H.Saraiya Page 13 of 21 Originator : SUS / HAS
2.4.4 BALL VALVE

This valve is used for isolation & for quick on / off. It is mainly used in utility line i.e. cooling
water, instrument air etc. and in hazardous and combustible fluid. Rotating the lever by 900
opens or closes this valves fully. Hence this valve is called quarter turn valve. Fire safe design
as per API 607 is available for this valve. Installation of this valve is possible from both the
ends. Hence it is bi-directional valve.

3-way and 4-way construction is possible in ball valve by providing “T” or “L” port in the ball.

A) End Connection:

Socket Weld & Threaded End – up to 1.5’’, 3-piece design


Flanged / Butt Weld- 2 piece design

B) Design & Dimension Standard:

BS 5351 For Ball Valves


ANSI/ASME B 16.10 For Face to Face dimension
ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating
API 598 For Testing of Valves

C) Main Parts:

Ball valve has following main parts.


Body
Ball valve has following internals.
Ball
Seat
Stem

D) Pressure Class: Same as Gate Valve

E) Material: Same as Gate Valve


Here Seat material is PTFE (Poly Tetra Fluoro Ethylene)

Fire safe valves are available as per API 607 & has following seats
Primary Soft Seat of PTFE
Secondary Metal to Metal Seat

2.4.5 BUTTERFLY VALVE

It is mostly used for isolation and in specific case used for regulation.
Regulation is not as precise as Globe Valve

Training Coordinator: D.H.Saraiya Page 14 of 21 Originator : SUS / HAS


A) End Connection: Same as Wafer check valve

Wafer type / Wafer lug type / Flange end/Butt end

B) Design & Dimension Standard:

API 609 For Butterfly valve


ANSI/ASME B 16.10 For Face to Face dimension
ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating
API 598 For Testing of valve

C) Main parts:

Butterfly valve has following main parts.


Body
Butterfly valve has following internals.
Disc / Shaft / Seat

D) Pressure Class: Same as Gate Valve of cast steel type

E) Material: Same as cast steel Gate Valve


Seat Material: EPDM, Nitrile - These are one kind of Rubber, soft
material
EPDM- Ethylene Propylene Di Monomer

2.4.6 PLUG VALVE

This valve is used for regulation, isolation and quick on / off in combustible or Hazardous
fluid. 3-way and 4-way construction is possible in plug valve by providing “T” or “L” port in
the plug.

A) End Connection:

Socket Weld/Threaded
Flanged/Butt Weld

B) Design & Dimension Standard:

BS 5353 For Plug valve


ANSI/ASME B 16.10 For Face to Face dimension
ANSI/ASTM B 16.34 For Pressure & Temperature limitation and Rating
API 598 For Testing of valves

C) Main Parts:

Plug valve has following main parts.


Body
Cover
Plug valve has following internals.

Training Coordinator: D.H.Saraiya Page 15 of 21 Originator : SUS / HAS


Stem
Plug
Sealant

D) Pressure Class: Same as Gate Valve

E) Material: Same as Gate Valve

2.4.7 CONTROL VALVE ( handled by Instrumentation Department )

These valves are self operated type. They have actuators. Actuators operate on the signal
received from an instrument. They are used for very fine throttling and to have desired process
parameters (pressure, temperature, flow) of fluid.

Control Valves can be of the following types based on parameters to be controlled:

 Pressure control valve-Receives signal from Pressure Indicator / Pressure Transmitter.


 Temperature control valve-Receives signal from Temperature Indicator/Temperature
Transmitter
 Flow control valve-Receives signal from Flow Indicator/Flow Transmitter

There are two types of signal:

 Pneumatic – Valve has pneumatic actuator.(tubing is used)


 Electric – Valve has electrical (solenoid) actuator. (cables are used)

Based on construction, control valve has following types:

 Butterfly Valve
 Globe Valve
 Ball Valve

A) End Connection: Flanged End or BW. Flange end is always preferred


because of regular servicing & maintenance.

B) Material : Same as other cast steel valves.

C) Design & Dimension Standard: Same as other valves.

D) Pressure Class: Same as other valves.

2.4.8 SAFETY VALVE

This valve is also known as Pressure relief valve. It is used for safe operation of plant. This
valve releases excess pressure when it exceeds set pressure. Pressure is set by spring.

Inlet of this valve is one size lower or equal to the inlet pipe size. Outlet is at least one or more
size higher to outlet pipe size.

A) Material & Pressure Class: Same as Gate Valve

Training Coordinator: D.H.Saraiya Page 16 of 21 Originator : SUS / HAS


Outlet Pressure class <= Inlet Pressure class
B) Main Parts:

Pressure safety valve has following main parts.


Body / Bonnet
Safety valve internals: Spring / Disc / Stem

C) Design & Dimension Standard: API 526: For Pressure & Temperature limitation and
Rating and
for Center to Face Dimension.

2.5 FASTENERS

It consists of Bolts, Full threaded Stud Bolts and Nuts.


Bolts have Hexagonal or Round head while Studs are without heads.
One stud with two nuts forms a set of fastener.
Fasteners are used for flange joints in piping to retain flanges and gaskets.
Threading is done on the studs and bolts by two methods.

1. Cut threads using cutting tool on Lathe.


2. Thread Rolling using rollers on thread rolling machine.

A) Design & Dimension Standard:

ANSI/ASME B 16.5 For Studs (Length & Diameter)


ANSI/ASME B 18.2.1 For thread types with details of Studs & Bolts
ANSI/ASME B 18.2.2 For Nuts

B) Material:

(1) CS ASTM A 193 Gr B7 For Stud


ASTM A 194 Gr 24 For Nut

(2) LTCS ASTM A 320 Gr L7 For Stud


ASTM A 194 Gr 4 For Nut

(3) LAS ASTM A 193 Gr B16 For Stud


ASTM A 194 Gr 4 For Nut

(4) SS ASTM A 193 Gr B8 For Stud


ASTM A 194 Gr 8 For Nut

2.6 GASKETS

Gaskets are used to avoid Static leakage and metal to metal contact.
There are two types of gaskets from material point of view.

1. Metallic Gasket: Metal is used in the construction of Gasket either as main


material or as reinforcing material..
e.g.

Training Coordinator: D.H.Saraiya Page 17 of 21 Originator : SUS / HAS


Spiral wound gasket. Used with RF flanges up to 600
rating.
Thickness of spiral wound gasket is 4.5 mm.

Ring joint Gasket used with RJ flanges from 900 rating.

2. Non-metallic Gasket: Metal is not used in the construction of gaskets.


e.g. Flat Gasket
Thickness of this gasket is normally 2 to 3 mm.
It is used in FF and T&G type of flange.

A) Design & Dimension Standard:

ANSI/ASME B 16.20 For Metallic Gaskets


ANSI/ASME B 16.21 For Non-metallic Gaskets

B) Material:

For Metallic Gasket


(1) S.S. ring for ring joint gasket.
(2) Spiral wound Gasket

(a) S.S. (as reinforcement) & for inner and outer (centering) ring.

(b) Filler material as follows.

Graphite used for high temperature.


PTFE used for low temperature.
CAF – It is banned to use from health hazard point of view.

For Non-metallic Gasket

(1) Flat Gasket

(a) CAF (Compressed Asbestos Fiber)- It is banned to use from health


hazard
point of view.
(b) PTFE
(c) Graphite

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3. PIPING MANUAL :

ANSI/SME B 31.3 is used in Process Piping of following plants.

24 Petroleum Refineries.
25 Chemical Plants.
26 Pharmaceutical Plants.
27 Textile Industries.
28 Paper Industries.
29 Semiconductor Plants.
30 Cryogenic plants.

For piping components it specifies following details:

Design Material selection with Fabrication Testing requirements


Properties Details / Methods

31 Thickness of components considering internal and external pressure


32 Types of various Branch
33 Flexibility and Supports
34
Piping Manual is a basic document, prepared based on ASME B31.3, for

(1) Disciplines listed below of Piping Department.

35 Piping Design
36 Piping Material
37 Stress Analysis
38
39 (2) Instrumentation Dept.

Piping Manual has following documents.

 Standard / General Specifications for piping material

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 Pipe classes or Piping specifications
 Valve specification Sheets
 Technical purchase specifications
 Special part specifications(not covered in pipe class)
 Instrument nozzle assemblies
 Piping supports standard
40
Above documents are used in piping design and procurement.

3.1 Standard / General specifications: It consists of

 Applicable code & standards


 General specifications for fabrication
 General specifications for welding
 General specifications for procurement
 General specifications for certification
41
3.2 Pipe class: It is derived from

 Fluid to be handled
 Design pressure
 Design temperature
42
Above three points are obtained from the P&ID / Process.

Based on the above information, material group & rating are to be decided using table 2
of 16.5 and table 2 of 16.34. Then pipe class / pipe specifications are developed.

3.2.1 Pipe Class: Provides various components with its

 Size range
 End connection
 Design & dimension standard
 Valve Specification Sheet Number
 Material Grade
 Technical purchase specification
 Additional remark (if any)

3.2.2 Pipe class has 3 distinct tables:

 Limit table(Pressure and Temperature limitation)


 Thickness table(pipe thickness)
 Branch table(for selection of branch component)

Limit table:

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43 It specifies pressure and temperature limitation for the components listed in pipe class.
From this table, suitability of pipe class & its components for given design conditions is
decided.

Thickness table:

44 It specifies schedule no & relevant pipe thickness for all the sizes. Similar thickness to
pipe shall be used for Butt Weld pipefitting, Weld Neck Flange.
45
Pipe thickness is to be calculated for internal design pressure as per para 304.1.2 of
ASME B
31.3. Pipe thickness Calculation formula is available in MS EXCEL.

Branch Table:

It gives types of branch whenever it is required to be taken from header pipe. In


German language “Abzweig” is “Branch”. So in * pipe classes for all the branch types
“A” is specified as commodity code. Actual type is to be selected from the table. Branch
types are

Unreinforced Branch- here direct welding of branch pipe to header pipe is done.
Reinforced Branch- here branch pipe is welded to header pipe with reinforced pad or
ring.
(As per R-SP-1020 of * based on ASME B 31.3)
Equal / reduced tee
Weldolet
Sockolet
Half coupling
Based on calculation as per para 304.3 of ASME B 31.3, above branches are designed &
their dimensions are calculated. These branches are tabulated in branch table of a pipe
class. Appropriate branch is to be selected from this table.

Training Coordinator: D.H.Saraiya Page 21 of 21 Originator : SUS / HAS

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