M19-Pipework REV
M19-Pipework REV
M19-Pipework REV
M19
ZIRKU
MECHANICAL
PIPEWORK
TABLE OF CONTENTS
Paragraph Page
2.0 OBJECTIVES
2.1 INTRODUCTION
2.4.1 Flanges
2.7.1 Blinds
2.11 TUBING
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2.0 OBJECTIVES
2.1 INTRODUCTION
There are many different types of pipework used throughout a large plant.
It is important that mechanical technicians are familiar with different piping
specifications.
Refineries have large piping systems. All fluids and gases are moved
from place to place through piping systems. A piping system will include
the following:
Pipe fittings. Fittings are used to join sections of pipework and control
the direction of flow.
Valves. Valves control the amount and direction of flow, and shut off
the supply.
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The size and material used for the pipework and fittings depends on the
amount and type of fluid to be moved in the system. The piping system
can carry hot or cold water, crude oil, refined products, chemicals, gases
etc. These fluids can be at various temperatures, pressures, and flow
rates. All parts of the pipework system must be correctly maintained.
Although pipe is normally made of steel, it can also be found in may other
different materials. The material is selected because of the product it has
to carry and the conditions it will be used in.
Plastic and fibreglass pipe. This type of pipe is used for water or
other corrosive products. It can be joined together using various
methods, such as glue, welding, fusion or threading.
Brass and copper pipe. This type of pipe is used in some chemical
processes, but is mostly used for pneumatic instrumentation. It is
never used for processes where the temperature is higher than
232°C. It can be joined by threading, soldering, or with flanges or
compression fittings.
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Cast iron pipe. This type of pipe is used for water, sewers and some
chemical processes. It must not be used where temperatures go
above 232°C. It is very brittle and should not be used where there is
excessive vibration or shock loads. Cast iron can be joined by
threading, compression, bell and spigot, and flanged fittings.
Steel pipe. Steel is the most common type of pipe. It can be joined
by welding, threading, or by flanged joints. It has good resistance to
vibration, shock, low temperatures and fire.
Stainless steel pipe. This type of pipe is used in the same way as
normal steel pipe. The advantage of using stainless instead of normal
steel pipe is, it is stronger, lighter and more resistant to corrosion.
Figure 2-1.
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Figure 2-2
FLAT TYPE
ME-1 42 2
BACKING RING
Figure 2-3.
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ME-1 4 2 4
Figure 2-4
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Figure 2-5
Figure 2-6
Figure 2-7
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Figure 2-8
2.4.1 Flanges
Glued
Welded
Threaded
Flanged joints are required where pipelines and piping components need
to be disassembled for maintenance. No matter how the flanges are
attached to the pipe, the two flanges faces are bolted together. Gaskets
are placed between the flange faces to make sure there is no leakage.
For permanent joints, welding is used to join the two sections of pipe
together. If the pipework has to be separated it must be cut.
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Figure 2-9
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Figure 2-10
Figure 2-11
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Figure 2-12
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Figure 2-13
Figure 2-14
Flange faces are also different. The shape of the face depends on how it
is linked together. If the two faces do not match then the joint will leak.
Common flanged faces are as follows:
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Figure 2-15
Figure 2-16
Figure 2-17
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Figure 2-18
Figure 2-19
Figure 2-20
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There are four dimensions that are used to show the size of pipework,
they are:
Length.
Wall thickness.
Figure 2-21
The most common measurements on a piece of pipe are the outside and
inside diameters (OD and ID), and the nominal size.
Besides the OD, ID and wall thickness, the length of the pipe is also
important. A normal length of pipe is usually about 10 metres long.
The nominal size is a very important dimension. The nominal size is the
approximate size of the pipe.
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Under 300 mm (12") diameter the ID is used for the nominal size.
It is usually the nearest standard size. Normally the size of the pipe is
referred to using the nominal size and the schedule number.
The weight of a piece of pipe will vary according to the wall thickness and
material it is made from. Its weight is given for a 12" length.
Wrought pipe. This type of pipe is made from a single block of metal
which is heated and is either drilled or bored. The block is then rolled
and shaped to the final size. Pipe up to 65 mm (2 1/2") diameter can be
made this way. (see figure 2.22).
Figure 2-22
Forged pipe. This type of pipe is made from a block of metal that is
heated, lengthened and shaped, using forging hammers. This is done
to approximately 25 mm of its final size. Then it is machined to the
finished size. This method is used for large pipe with heavy wall
thickness.
Cast pipe. To make cast pipe, molten metal is poured into a mould
and allowed to cool. The pipe is then removed from the mould and
checked for faults. Its accuracy is limited to the quality of the mould.
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Welded pipe. Welded pipe is made from a flat strip of metal that is
rolled or shaped into a tube. The seam where the edges meet is then
welded. This is known as lap welding. Any size of pipe can be made
this way (see figure 2.23).
Figure 2-23
Figure 2-24
Pipe fittings are used to join sections of pipe together, or to change the
direction of flow. They can be made of the following materials:
Steel
Cast iron
Bronze
Copper
Plastic
Glass
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Most fittings are available in screw or welded types although the flanged
type is also common. Welded fittings are classed as permanent.
Figure 2-25
Figure 2-26
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Figure 2-27
Figure 2-28
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Figure 2-29
Figure 2-30
Figure 2-31
Figure 2-32
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Figure 2-33
Figure 2-34
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Figure 2-35
"Y" fitting. A "Y" fitting allows two branches to go off at 45° to each
other (see figure 2.36).
Figure 2.36
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Figure 2.37
2.7.1 Blinds
A blind is a circular metal plate that can be placed between two flanges to
stop the flow. It is used to isolate a section of the plant, usually for
maintenance work. A spacer is placed between the flanges to allow for
the thickness of the blind. It is removed when the blind is to be used.
Figure 2-38
Figure 2-39
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Figure 2-40
To insert a blind.
Remove the spacer from between the flanges. Place the blind between
the circle of the flange bolts, then insert the gasket. The flange bolts are
tightened to make a leakproof seal (see figure 2.41).
Figure 2-41
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Figure 2-42
Figure 2-43
Examples:
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1 1/4" 11
/16"
1 1/2" 11
/16"
3
2" /4"
Vibration.
Pipe stress.
Corrosion.
Explosions.
Fires.
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Repairing leaks
Temporary repair of leaks is often done without taking the pipeline out of
service. The most common piece of equipment used to repair leaks is
the pipe sleeve. A pipe sleeve must fit nicely over the outside diameter of
the pipe. If repairs are carried out whilst the line in still in operation, make
sure all safety precautions are taken. Wear all the proper safety
equipment.
Pressure must be taken off the line before the sleeve is installed. Then
the area around where the sleeve is to installed must be cleaned. A
chipping hammer and wire brush are used to clean the pipe. Assemble
the pipe sleeve a metre from the leak. When the bolts are in place, slide
the sleeve over the leak. Align the gasket correctly, then tighten the bolts.
Tighten, firstly by hand, and then with the correct size spanner (see figure
2.44).
Figure 2-44
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Any gasket material used must be suitable for the product in the line.
Figure 2-45
There are many different types of pipe support, each one is used for a
particular job. Some common ones are as follows:
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Figure 2-46
Adjustable swivel pipe roll. Roll type supports allow the pipe to
move as it expands and contracts due to heat (see figure 2.47).
Figure 2-47
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Figure 2-48
Figure 2-49
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Figure 2-50
Figure 2-52
The spacing of pipe hangers is very important. Although the space varies
according to the size and weight of the pipe, 3 metres is correct for simple
pipe hangers.
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2.11 TUBING.
It is small in diameter.
Steel and stainless steel. These pipes are used for high pressure
hydraulic systems, cooling units, evaporators, and process lines.
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Figure 2-53
Any rough edges are removed with a de-burring tool. When the tubing is
cut to length it can be joined to another piece.
Joining tubing.
Soldered fittings.
Compression fittings.
Flared fittings.
One of the main advantages of tube is that we can bend it. This reduces
the number of fittings that are required.
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Hand bender. This is used for small size tubing (see figure 2.54).
Figure 2-54
Figure 2-55
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The depth of the groove depends on the type of back guide or sleeve
used (see figure 2.56).
Figure 2-56
To set up the bender, firstly, lock the selected former in position. This is
done by passing a pin through the bending arm and the body of the
machine (see figure 2.57).
Figure 2.57
Fit the back stop to the stop bar of the machine, this holds the pipe in
position while it is being bent round the former (see figure 2.58).
Figure 2.58
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Place the pipe in the machine by passing it through the bending arm.
Make sure the pipe is sat in the groove of the former and against the back
stop (see figure 2.59).
Figure 2-59
Fit the back guide or sleeve over the back of the pipe. Then hand tighten
the bending arm adjusting screw until the bending arm roller contacts the
sleeve. This will hold it in position.
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Then tighten the bending arm lock nut using the correct size spanner (see
figure 2.60).
Figure 2-60
Take up a comfortable position with one foot in front of the other. This
will make sure the body is properly balanced. Then bend the pipe by
pulling the bending arm towards the body (see figure 2.61).
Figure 2-61
The sleeve bends the pipe round the former as the bending arm is pulled
forward.
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The back stop holds the tail of the pipe in position during the bending
operation (see figure 2.62).
Figure 2-62
To avoid faulty bends, always make sure to use the correct size former
and sleeve to suit the dimensions of the pipe (see figure 2.63).
Figure 2-63
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Figure 2-64
Place the machine on the ground. The forming head has holes that are
marked to show the nominal bore sizes of pipes (see figure 2.65).
Figure 2-65
Select the correct size former to suit the outside diameter of the pipe.
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Figure 2-66
Fit the former onto the cylinder ram (see figure 2.67).
Figure 2-67
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Place the pipe between the forming head plates and against the former
(see figure 2.68).
Figure 2-68
Support the pipe while fitting the dollies (or rollers) between the upper
and lower plates of the forming heads. Then secure them in position by
passing the pins through the plates and the dollies. The dollies
themselves fit into holes in the plates that suit the size of pipe (see figure
2.69).
Figure 2-69
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Close the pressure release valve on the pump body (see figure 2.70).
Figure 2-70
Start pumping to push the former against the pipe (see figure 2.71).
Figure 2-71
Stop pumping when the pipe has been bent to the required angle. Then
turn the pressure release valve anti-clockwise to release the pressure in
the hydraulic cylinder. When the ram has moved back about 6 mm ( 1/4")
to 10 mm (3/8") close the pressure release valve to hold the ram steady.
Check the accuracy of the bend. Then open the pressure release valve
to allow the ram to return to the start position. The machine can now be
disassembled and stored away in the correct place.
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A ratchet and die stock is a common tool used for cutting threads. It is
adjustable so that threads can be cut on pipe from 1/2" to 9" diameter (see
figure 2.72).
Figure 2-72
A ratchet diestock has a set of four dies for each size of standard pipe.
Each die is clearly marked with the thread type, the range of pipe it is
suitable for, and an identification number (see figure 2.73).
Figure 2-73
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These types of dies must always be stored as a set. If dies get mixed up
the thread will be ruined.
Slacken off the tightening nut and turn the face of the diestock anti-
clockwise until it is fully open. There are four slots inside the diestock that
are numbered 1 to 4. Fit each die into the slot with the corresponding
number, with the numbered face upwards (see figure 2.74).
Figure 2-74
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