CM4120 Unit Operations Lab Piping SystemsSlide 2Slide 3Slide 4Slide 5Slide 6Slide 7Slide 8Slide 9Slide 10Slide 11Slide 12Slide 13Slide 14Slide 15Slide 16Slide 17Slide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24Slide 25Slide 26Slide 27Slide 28Slide 29Slide 30Slide 31Slide 32Slide 33Slide 34Slide 35Slide 36Slide 37Slide 38Slide 39Slide 40Slide 41Slide 42Slide 43Slide 44Slide 45Slide 46Slide 47Slide 48Slide 49Slide 50Slide 51Slide 52Slide 53Slide 541CM4120Unit Operations LabPiping SystemsPiping Systems in the Chemical Process IndustriesMarch, 2008IntroductionBasis for DesignPiping Codes and StandardsDesign of Process Piping SystemsJoints and FittingsValves2CM4120Unit Operations LabPiping SystemsPiping Systems include:PipeFlangesFittingsBoltingGasketsValvesHangers and supportsInsulations, coverings, coatings3CM4120Unit Operations LabPiping Systems“Piping systems are like arteries and veins. They carry the lifeblood of modern civilization.”Mohinder Nayyar, P.E.Piping Handbook, 7th ed.McGraw-Hill, 20004CM4120Unit Operations LabPiping SystemsPrimary Design Consideration is Saf e tyEvaluate Process ConditionsTemperaturePressureChemical compatibility/Corrosion allowancesVibration, flexing, bendingExpansion/Contraction due to temperature changeEnvironmental conditionsEvaluate the Effects of a LeakEvaluate Performance in a Fire Situation5CM4120Unit Operations LabPiping SystemsSecondary ConsiderationsEvaluate any Special RequirementsSanitary requirements – “Cleanability”Serviceability – ease of maintenance of equipmentPossible contamination of process fluid by piping materials, sealants, or gasketingEarthquake, Hurricane, Lightening, PermafrostLowest Cost over the Lifetime6CM4120Unit Operations LabPiping SystemsPiping System Design Criteria4 areas to consider:Physical AttributesLoading and Service ConditionsEnvironmental FactorsMaterials-Related Considerations7CM4120Unit Operations LabPiping SystemsCodes and Standards simplify design, manufacturing, installation processStandards – provide design criteria for componentsstandard sizes for pipedimensions for fittings or valvesCodes – specific design/fabrication methodologiesIncorporated into local/regional statute It’s the LAW8CM4120Unit Operations LabPiping SystemsASME Boiler and Pressure Vessel CodeASME B31: Code for Pressure PipingANSI Standards – dimensions for valves, piping, fittings, nuts/washers, etc.ASTM Standards for piping and tubeAPI – Specs for pipe and pipelinesAWS, ASHRAE, NFPA, PPI, UL, etc.9CM4120Unit Operations LabPiping SystemsASME B31 is the applicable standard for design of most piping systems in chemical plantsB31.1 – Power plant boilersB31.3 – Chemical plant and refinery pipingB31.4 – Liquid petroleum transportB31.7 – Nuclear power plant radioactive fluids10CM4120Unit Operations LabPiping SystemsASME B31.3 – Chemical Plant and Refinery Piping CodeIncludes:Process piping in chemical and refinery plantsProcess piping in pharmaceutical and food processingProcess piping in textile and paper plantsBoiler piping11CM4120Unit Operations LabPiping SystemsASME B31.3 covers:Materials and designFabricationErection and assemblySupportExamination, inspection, and testingWeb reference: www.piping-toolbox.com12CM4120Unit Operations LabPiping SystemsStandard Pipe SizesDiameters are “Nominal”Sizes 12” and less, nominal size < ODSizes 14” and over, nominal size = ODWall thickness inferred thru “Schedule”Schedule = P/S * 1000Defined Schedules:5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 16013CM4120Unit Operations LabPiping SystemsStandard Tubing SizesSteel tubingDiameters are Actual ODWall thickness is specifiedRefrigeration TubingSingle wall thickness available for each sizeActual ODCopper Tubing – Nominal sizesType K, L, M14CM4120Unit Operations LabPiping SystemsMaterials – Metallic pipingCarbon and low alloy steelDuctileInexpensive and availableEasy to machine, weld, cutSome drawbacks15CM4120Unit Operations LabPiping SystemsMaterials – Metallic pipingAlloy Steels including “Stainless Steels”Good corrosion resistanceMore difficult to machine, weld, cutSome drawbacks16CM4120Unit Operations LabPiping SystemsMaterials – Metallic pipingNickel, Titanium, Copper, etc.Copper is used in residential and commercial applications and is widely availableOther materials are expensive and difficult to machine, weld, joinSome incompatibilities with each17CM4120Unit Operations LabPiping SystemsMaterials – Non-Metallic pipingThermoplasticsWide range of chemical compatibilityLight weightEasily cut and joinedLow temperature limitsNeed extra supports18CM4120Unit Operations LabPiping SystemsMaterials – Non-Metallic pipingFiberglass Reinforced PipeWide range of chemical compatibilityEasily cut and joinedWider temperature limits than thermoplasticsThermal expansion similar to carbon steelSimilar structural performance as carbon steel19CM4120Unit Operations LabPiping SystemsMaterials – OthersGlassConcreteLined or coatedGlassRubberCementTeflonZinc (galvanized pipe)Double Containment piping systems20CM4120Unit Operations LabPiping SystemsPiping InsulationPrevent heat loss/ gainPrevent condensation – below ambientPersonnel protection – over 125oFFreeze protection – outdoor cold climatesFire protectionNoise control21CM4120Unit Operations LabPiping SystemsFiberglass Insulation w/ Asbestos plastered fitting coverings22CM4120Unit Operations LabPiping SystemsMetal Jacketedinsulation covering23CM4120Unit Operations LabPiping SystemsHeat TracingPrevents flow problems in cold climatesFreeze protectionLoss of flow due to viscosity increasePrevent condensation in vapor linesMethodsElectricHot Fluids24CM4120Unit Operations LabPiping SystemsPiping SupportsPrevent strain at connectionsPrevent sagMust allow for expansion/contractionDesign for wind/snow and ice/earthquakeClearance for plant traffic and equipment25CM4120Unit Operations LabPiping SystemsResults of inadequate support26CM4120Unit Operations LabPiping SystemsResults of inadequate support: Flixborough, EnglandMay, 1974 – Leaking reactor removed from train of reactors and temporarily replaced with a section of pipeJune, 1974 – Supports collapse, pipe breaks28 dead, 89 injured, 1800 houses damaged, 160 shops and factories damaged, large