select the suitable material for the pipeline and it is components

1. PIPING materials, specification &
fabrication [ CH 3]
1

2. Introduction
• Making a quality component is like baking a good pastry.
• To the base element (iron in one case; flour in the other), we add key
ingredients (alloys in one case; eggs, sugar, salt, water, etc. in the other).
Each alloying element, like each baking ingredient.
• brings a unique and valuable characteristic to the mix.
• The ingredients are mixed and poured (casting or forging in one case;
pouring in pots and pans in the other).
• The mixture is then placed in the oven (heat treatment in one case; baking
in the other).
• The difference between annealing, stress relieving, tempering, etc. can be
seen as the difference between broiling, baking, grilling

3. 3.1 material of PIPE
piping materials
Metallic None-Metallic
Ferrous
(iron-based)
Non-ferrous
(copper, aluminum)
Wrought-Iron Steel
Carbon-steel
Alloy steel
(stainless)‫خاصه‬ ‫معالجه‬
Cast-iron

4. Wrought Iron:
4
• In the Middle Ages, crushed iron was melted in stone furnaces, with the hot
charcoal serving as a source of carbon.
• Crushed limestone (rock of calcium carbonate) was added to facilitate the
removal of slag ‫الخبث‬
) ) and impurities. The nearly pure iron formed that way,
called wrought iron, was widely used for tools and weapons.
• Pure iron is soft and gains strength by alloying with carbon to form cast irons
or steels.

5. Cast Iron
• The term cast iron describes a series of iron and carbon alloys with a
carbon in excess of 1.7% (percent refer to weight).
• Other definitions of cast iron place the limit at 2% carbon and 1% silicon
[ASM].
• Cast irons have good flow properties when melted, and are therefore well
suited to pour into castings.
• They can be alloyed with Si, Ni or Cr to improve their abrasion or
corrosion resistance.
• Cast iron pipe (ASTM A 74) comes in 5 ft and 10 ft lengths, extra heavy
(marked XH) or service (marked SV) wall thickness.

6. Steel Pipe and Fittings
Engineering materials have four essential characteristics
that are closely interrelated:
1- Chemistry: the primary element (iron in the case of ferrous metals),
alloying elements (nickel, chromium, etc…),
2- Physical properties: density, coefficient of thermal
expansion, electrical and heat conduction.
3- Microstructure: atomic structure, metallurgical phase, type and size of
grains.
4- Mechanical Properties: through stress-strain curve, strength (yield,
ultimate, elongation at rupture) and toughness (Charpy test).

7. Carbon Steels
• Steel pipe and fittings are alloys of iron (Fe) and carbon, containing less
than 1.7% carbon. They can be classified in three groups: carbon steels,
and alloy steels.
• Carbon steels consist of iron, less than 1.7% carbon, less than 1.65%
manganese, incidental amounts of silicon (Si), aluminum (Al), and limits
on impurities such as sulfur (Su), Oxygen (O), Nitrogen (N).
• Carbon steel is the most common pipe material in the power, chemical,
process, hydrocarbon and pipeline industries.
• Carbon steel pipe specifications commonly used in steam, water or air
service include ASTM A106 and ASTM A53.

8. Alloy Steels
• Alloy steels are steels containing deliberate (
‫محسوبه‬
) amounts of
alloying elements, such as 0.3% chromium (Cr), 0.3% nickel (Ni),
0.08% molybdenum (Mo).
• Alloy steels are common used in high temperature service, such as
high-pressure steam lines in power plants, heat exchanger and furnace
tubes, and chemical reactor vessels.
• Each alloying element plays a unique role in improving the material’s
properties:
• Carbon (C) increases strength (yield and ultimate) and hardness, at
the cost of reduced ductility (elongation at rupture).
• Chromium (Cr) increases resistance to abrasion and wear (
‫بين‬ ‫احتكاك‬
‫سطحين‬
) . Above 11.5% Cr forms a stable oxide protective layer

9. Steel Line Pipe: In US, carbon steel line pipe used in
gas and oil pipelines is generally fabricated in
accordance with the American Petroleum Institute
specification API 5L.
NON-FERROUS PIPE: Non-ferrous pipe and fitting
materials are metallic materials with a matrix; for non-
iron example, aluminum and its alloys, and copper and
its alloys.

10. Aluminum Alloys
• Aluminum is obtained by mining aluminum ore (bauxite), which
contains aluminum oxide, iron, silicon and impurities.
• Aluminum is about one third the density of steel; it is easily machined or
formed and readily welded.
• It is reactive with oxygen and forms a tough protective oxide layer.
However, useful mechanical properties are typically limited to no more
than 300°F.

11. Copper Alloys in pipes
• Copper (containing over 90% Cu), bronze (Sn
and Cu alloys) and brass (Cu
with 20% to 40% Zn) have been used to make
pipes as early as 3000 BC.
• because they are soft, easy to form, and
corrosion resistant in water service.

12. Pipe Size
• Commercial steel pipe is fabricated either by piercing and extruding a hot billet
(seamless pipe) or by bending then welding steel plates.
• In either case, the fabricator produces a pipe with dimensions (diameter and
thickness) that comply with a standard, such as ASME B36.10 for carbon steel
pipe, ASME B36.19 for stainless steel pipe, API 5L for line pipe.
• Pipes are specified by their nominal size and schedule
• The schedule number of stainless steel pipe (ASME B36.19) is
followed by the letter S, and includes lower schedules with thinner walls than
carbon steel pipe (such as schedule 5S and 10S) for low-pressure corrosive
service.

13. Pipe Size
• The relationship between pipe size and schedule was
originally based on the following formula:
• where:
t=pipe wall thickness, in
sch=pipe schedule (ASME B36.10 or B36.19)
D=pipe outside diameter, “in”

14. Pipes are designated by schedule number .
Schedule number is represented by the pressure carrying capacity of the
pipe.
Schedule =1000P/S where
P =service pressure (psi) - (Internal pressure)
S =allowable stress (psi) - (Allowable tensile strength of material)
Irrespective of pipe dia., equal schedules have equal pressure carrying
capacity. For stainless steels schedule number are designated by suffix S i.e.
5S,10S,40S,80S etc.
For pipes of all dimensions the outside diameter (O.D.) remains relatively constant. The
variation in wall thickness affects only the inside diameters (I.D.). The higher the schedule
number is, the thicker the pipe is.
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SCHEDULE NUMBER

15. PIPING SCHEDULE
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16. FABRICATION OF STEEL PIPE
# Seamless Pipe :
• Seamless pipe is fabricated by piercing a hot cylindrical
billet and forming a seamless tube.

17. Watch video on Seamless Pipe

18. # Seam Welded Pipe:
FABRICATION OF STEEL PIPE

19. Watch video on Seam welded Pipe

20. PIPING SYSTEM
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o Itconvey the fluids, between the various equipment and end users.
o It consists of various components such as pipes, valves, fittings, online
measuring instruments, etc.
DIFFERENCE BETWEEN PIPE AND TUBE
PIPE
o It is a tubular product of circular cross section that has specific sizes and
thickness governed by particular dimensional standards.
TUBE
o It is a hollow product having circular
, elliptical or square cross section or cross
section of any closed perimeter
. Tubes are also used for heat transfer purpose.

21. LINE PIPE
o It is mainly used for conveying fluids over long distances and are subjected to
fluid pressure. Itis usually not subjected to high temperature. Oil pipelines
PRESSURE PIPE
o These are subjected to fluid pressure and /or temperature. Fluid pressure in
generally internal pressure or may be external pressure (e.g. Jacketed piping
)and are mainly used as plant piping.
STRUCTURAL PIPE
o These are not used for conveying fluids and not subjected to fluid pressures or
temperature. They are used as structural components (e.g. handrails, columns,
sleeves etc.) and are subjected to static loads only.
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CLASSIFICATION BASED ON END USE

22. 1. Pipe
2. Fittings (Elbows, T
ees,Reducers, Couplings, Unions, Olets)
3. Flanges
4. Gaskets
5. Fasteners
6. Valves
7. Special fittings
8. Specialty items (strainers, traps, bellows etc.)
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COMPONENTS OF PIPINGSYSTEM

23. o Pipe fittings are the components which tie together pipelines, valves, and
other parts of a piping system.
o Fittings may come in butt Welded, Socket welded, Screwed and flanged
connections.
o They are used to change the size of the line or its direction.
FITTINGS
23

24. 90° Elbow
Concentric
Reducer
Eccentric
Reducer
COMMON PIPEFITTINGS
Equal T
ee
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25. STRAIGHT TEE / EQUAL TEE
Itis used when the branch and header are the same.
REDUCING TEE
Itis used when the branch size is smaller than the header size.
POINT TO REMEMBER
It is expensive and requires three butt welds. Alternatively for low pressure services
,branching off is done by direct welding of pipe to pipe instead of standard T
ee.
TEES
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26. They are used to change direction of pipe.
1. LONG RADIUS (LR) AND
2. SHORT RADIUS (SR)ELBOWS.
90 degree elbow comes in LR and SR.
45 degree elbow comes in LR only.
The LR elbows radius is 1.5times the nominal size. The SRelbows radius is 1times the
nominal size.
Normally elbows are butt-welded, socket welded or sometimes bolted connections are also
available. Reducing elbows are available on 90 degree only and the radius is 1.5times of the
larger end
ELBOWS
26

27. FULL COUPLING
It is used to connect small bore pipes as
projection of welding inside the pipe bore
reduce the flow area
HALF COUPLING
Itis used for branch connection
UNIONS
It is used where dismantling of the pipe is
required more often. It can be with
threaded end or socket weld ends.
COUPLINGS & UNIONS
COUPLINGS
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28. It makes reduction in line size
ECCENTRIC REDUCER
It is used to pump suction to avoid cavitation with top
surface being flat.
REDUCERS
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29. SOCKET WELDING FLANGE
SLIPON FLANGES
BLINDFLANGES
LAP-JOINT FLANGE THREADED FLANGES
WELDINGNECK
FLANGES
FLANGES
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30. Types of Flanges

31. - Flange are also classified by pressure – temperature ratings as per ANSI (American
National standard Institute) B 16.5 .. It is available in seven ratings 150#,300#, 400#, 600#,
900#, 1500# and 2500#.These flange rating are called nominal rating. pressure –
temperaturecombines determinestheflangerating.
- The term “flange rating” (or class) refers to the maximum pressure (in psi or
bars) that a flange withstands at increasing temperatures. Flanges with a
higher rating (class) are stronger than flanges with lower ratings, as they bear
more pressure at increasing temperatures.
- Pressure (Flange) rating is the maximum pressure a pipe, fitting or valve
should be capable of withstanding at given temperature in normal conditions.
... The higher the pressure rating, the thicker the wall thickness must be so
that the pipe, fitting or valve body will not rupture
RATING OF FLANGE
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32. Flange Pressure Rating
- Flanges made in different materials show different pressure-temperature
performance at the same rating. In this context, you find the pressure rating
charts for carbon, alloy, and stainless steel flanges.
- According to the ANSI/ASME B16.5 specification, there are seven flange
pressure ratings: 150, 300, 400, 600, 900, 1500, and 2500.
- If two flanges have the same bore size (example 6 inches), the same material
(example A105-grade of carbon steel), but two different pressure
ratings (one flange is class 150, the other 300), the lower rated flange (class
150) will be smaller, lighter, and less healthy than the higher rated flange
(class 300).
- For example, a Class 150 flange is rated to approximately 270 PSIG at ambient
conditions, 180 PSIG at approximately 400°F, 150 PSIG at approximately
600°F, and 75 PSIG at approximately 800°F. In other words, when the pressure
goes down, the temperature goes up and vice versa.

33. - Now, let’s look at what this means in terms of pressure rating:
the class 150 flange withstands just 140 psi at a temperature of 600 degrees
F° (as per the rating chart below):
-The class 300 flange (bigger and stronger, but with the same bore size)
withstands 570 psi at the same temperature of 600 degrees F°.
so, how to select the proper flange rating?
-Find the rating table that applies to your flange scrolling below (this
depends on the material of the flange, as flanges with different material grades
have different pressure ratings).
- Determine the max working temperature in your piping system (i.e. select
one line in the table), Select a rating based on the maximum pressure you
expect at that temperature level (i.e. select one column in that line).
Flange Pressure Rating

34. - the class 150 flange withstands just 140 psi at a temperature of 600 degrees F°.
- the class 300 flange (bigger and stronger, but with the same bore size) withstands 570 psi at
the same temperature of 600 degrees F°

35. Difference between class 150, 300 & 600 Flange

36. Selection the required flange rating class ??

37. THERMAL EXPANSION OF PIPE
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Each material has its own coefficient of thermal expansion.
If the pipe is of carbon steel or low alloy steel, it will expand at the
rate of 6 to 7mm every meter length as the temperature raises to
500 degree C.
T
oaccommodate the thermal expansion, these joints are provided.

38. EXPANSION JOINTS
Expansion joints are used to accommodate certain degree of linear
expansion and torsional misalignments in the piping system
BELLOW TYPE
Metallic bellows of compatible materials (usually stainless steels) are
used to compensate the thermal expansion. Thickness of bellows
normally 1to 2mm.
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39. EXPANSION LOOPS
Expansion loops are widely used for high temperatures & high
pressures applications. Ideally suitable for longitudinal movements and
certain degree of torsional movement.
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40. VALVES
Velmurugan Sivaraman 40
to perform
valves are installed in between the pipes / equipment
following functions :
Isolation
Regulation
Non return
(gate valve, ball valve, butterfly valves etc.)
(globe valve etc.)
(check valve, SDNR etc.)
Special purpose (foot valve etc.)

41. Valves types used in piping

42. BALL VALVE
Ball valve is normally used for positive shut off. Operation by a quarter
turn of operating handle. The ball valve offers minimum resistance to
flow. Widely used on on-shore/off-shore and petrochemicals.
Velmurugan Sivaraman 42

43. GLOBE VALVE
Due to its globular body, it is called Globe Valve. There is higher
resistance and pressure drop in this valve. Most suitable for throttling
the flow.
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44. GATE VALVE
Flow is axial piping. Lower pressure drop. Itis not recommended for
throttling the flow.
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45. BUTTERFLY VALVE
Itis widely used on low pressure application .Itmay be used to
control and regulate the flow.
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46. CHECK VALVE / NON RETURN VALVE
Swing Check Valve
This valve allows flow in one direction only
. Return flow will
automatically close the valve, thus preventing flow in reverse direction.
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47. TESTING OF PIPING SYSTEM
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(AS PER ANSI B 31.3)
Piping system can be tested for leak tightness and pressure integrity
by hydro test / pneumatic test methods.

48. HYDROSTATIC TEST
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TEST PRESSURE =(1.5X Design Pressure X stress value at test temp) /
stress value at design temperature
TEST DURATION
A leak test shall be maintained for at least 10minutes, and all joints
may be examined for leaks.
TEST MEDIUM
Water at ambient temperature is the test medium. Incase of possibility
of freezing exists, other fluids may be used.

49. PNEUMATIC TEST
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TEST PRESSURE
(1.1x Design Pressure x stress value at test Temperature) / stress value
at design temperature
TEST DURATION
A leak test shall be maintained for at least 10minutes, and all joints
may be examined for leaks.
TEST MEDIUM
Air at ambient temperature is the test medium.

50. THANK YOU
50