Overview of Process Plant Piping System Design Participant’s Guide CONTACT INFORMATION ASME Headquarters 1-800-THE-ASME ASME Professional Development 1-800-THE-ASME Eastern Regional Office Southern Regional Office 8996 Burke Lake Road – Suite L102 1950 Stemmons Freeway – Suite 5037C Burke, VA 22015-1607 Dallas, TX 75207-3109 703-978-5000 214-746-4900 800-221-5536 800-445-2388 703-978-1157 (FAX) 214-746-4902 (FAX) Midwest Regional Office Western Regional Office 17 North Elmhurst Avenue – Suite 108 119-C Paul Drive Mt. Prospect, IL 60056-2406 San Rafael, CA 94903-2022 847-392-8876 415-499-1148 800-628-6437 800-624-9002 847-392-8801 (FAX) 415-499-1338 (FAX) Northeast Regional Office 326 Clock Tower Commons Route 22 Brewster, NY 10509-9241 914-279-6200 800-628-5981 914-279-7765 (FAX) International Regional Office 1-800-THE-ASME Y ou can also find information on these courses and all of ASME, including ASME Professional Development, the Vice President of Professional Development, and other contacts at the ASME Web site…… http://www.asme.org Overview of Process Plant Piping System Design By: Vincent A. Carucci Carmagen Engineering, Inc. Copyright © 2000 by All Rights Reserved TABLE OF CONTENTS PART 1: PARTICIPANT NOTES 3 PART 2: BACKGROUND MATERIAL 73 I. Introduction 73 II. General 73 A. What is a piping system 73 B. Scope of ASME B31.3 73 III. Material selection considerations 75 A. Strength 75 B. Corrosion Resistance 77 C. Material Fracture Toughness 77 D. Fabricability 78 E. Availability and Cost 78 IV. Piping Components 79 A. Fittings, Flanges, and Gaskets 79 B. Flange Rating 85 Sample Problem 1 - Determine Flange Rating 88 Solution 88 V. Valves 89 A. Valve Functions 89 B. Primary Valve Types 90 C. Valve Selection Process 98 Exercise 1 – Determine Required Flange Rating 99 VI. Design 100 A. Design Conditions 100 B. Loads and Stresses 101 C. Pressure Design of Components 105 Sample Problem 2 - Determine Pipe wall thickness 110 Sample Problem 3 116 Exercise 2: Determine Required Pipe Wall Thickness 121 VII. System Design 122 A. Layout Considerations 122 B. Pipe Supports and Restraints 123 C. Piping Flexibility 129 D. Required Design Information for Piping Stress Analysis 132 E. Criteria for Allowable Equipment Nozzle Loads 132 F. When Should A Computer Analysis Be Used 134 G. Design Considerations for Piping System Stress Analysis 134 VIII. Fabrication, Assembly, and Erection 140 A. Welding and Heat Treatment 140 B. Assembly and Erection 144 IX. Quality Control 151 A. Inspection 151 B. Testing 154 X. Other Considerations 156 A. Nonmetallic Piping 156 B. Category M Fluid Service 157 C. High Pressure Piping 158 XI. Summary 160 3 Part 1: Participant Notes 4 1 OVERVIEW OF PROCESS PLANT PIPING SYSTEM DESIGN By: Vincent A. Carucci Carmagen Engineering, Inc. Notes: 2 Piping System Piping system: conveys fluid between locations Piping system includes: •Pipe • Fittings (e.g. elbows, reducers, branch connections, etc.) • Flanges, gaskets, bolting •Valves • Pipe supports Notes: 5 3 ASME B31.3 –Design – Materials –Fabrication – Petroleum refineries – Chemical plants – Pharmaceutical plants – Textile plants – Paper plants – Semiconductor plants – Cryogenic plants –Erection –Inspection – Testing • Provides requirements for: • For process plants including Notes: 4 Scope of ASME B31.3 • Piping and piping components, all fluid services: – Raw, intermediate, and finished chemicals – Petroleum products – Gas, steam, air, and water – Fluidized solids – Refrigerants – Cryogenic fluids • Interconnections within packaged equipment • Scope exclusions specified Notes: 6 5 Strength • Yield and Tensile Strength • Creep Strength • Fatigue Strength • Alloy Content • Material Grain size • Steel Production Process Notes: 6 Stress - Strain Diagram S A B C E Notes: 7 7 Corrosion Resistance • Deterioration of metal by chemical or electrochemical action • Most important factor to consider • Corrosion allowance added thickness • Alloying increases corrosion resistance Notes: 8 Piping System Corrosion General or Uniform Corrosion Uniform metal loss. M ay be combined with erosion if high-velocity fluids, or m oving fluids containing abrasives. Pittin g Corrosion Localized metal loss randomly located on material surface. Occurs most often in stagnant areas or areas of low-flow velocity. Galvanic Corrosion Occurs when two d issimilar metals contact each other in corrosive electrolytic environment. Anodic metal develops deep pits or grooves as current flows from it to cathodic metal. Crevice Corrosion Localized corrosion similar to pitting. Occurs at places such as gaskets, lap joints, and bolts where crevice exists. Concentration Cell Corrosion Occurs when different concentration of either a corrosive fluid or dissolved oxygen contacts areas of same metal. Usually associated with stagnant fluid. Graphitic Corrosion Occurs in cast iron exposed to salt water or weak acids. Reduces iron in cast iron, and leaves graphite in place. Result is extremely soft material with no metal loss. Notes: 8 9 Material Toughness • Energy necessary to initiate and propagate a crack • Decreases as temperature decreases • Factors affecting fracture toughness include: – Chemical composition or alloying elements – Heat treatment – Grain size Notes: 10 Fabricability • Ease of construction • Material must be weldable • Common shapes and forms include: – Seamless pipe – Plate welded pipe – Wrought or forged elbows, tees, reducers, crosses – Forged flanges, couplings, valves –Cast valves Notes: [...]... Notes: Sample Problem 1 Flange Rating New piping system to be installed at existing plant Determine required flange class • Pipe Material: • Design Temperature: • Design Pressure: 1 1 Cr − 1 Mo 4 2 700°F 500 psig 26 Notes: 16 Sample Problem 1 Solution • Determine Material Group Number (Fig 4.2) Group Number = 1.9 • Find allowable design pressure at intersection of design temperature and Group No Check... material specification of flange A-182 Gr, F11 2 Determine Material Group No (Table 4.2) Group 1.9 3 Determine class using Table 4.3 with design temperature and Material Group No – The lowest Class for design pressure of 375 psig is Class 300 – Class 300 has 450 psig maximum pressure at 900°F 41 Notes: Design Conditions • General – Normal operating conditions – Design conditions • Design pressure and... (i.e., design or service limitations) 4 Finalize valve selection Check factors to consider if two or more valves are suitable 5 Provide full technical description specifying type, material, flange rating, etc 39 Notes: Exercise 1 - Determine Required Flange Rating • Pipe: 1 1 Cr − 1 Mo 4 2 • Flanges: • Design Temperature: • Design Pressure: A-182 Gr F11 900°F 375 psig 40 Notes: 23 Exercise 1 - Solution... welded together – Often used in large diameter pipe – May require larger thickness • Function of number of welds, conditions, size 52 Notes: 29 Sample Problem 2 Determine Pipe Wall Thickness Design temperature: 650°F Design pressure: 1,380 psig Pipe outside diameter: 14 in Material: ASTM A335, Gr P11 ( 1 14 Cr − 12 Mo ), seamless Corrosion allowance: 0.0625 in 53 Notes: Sample Problem 2 - Solution t= PD... Bolts or Gland Eye-bolts and nuts Gland Lug Bolts and Nuts Stem Packing Plug Lantern Ring Backseat Bushing Bonnet Bonnet Gasket Bonnet Bolts and Nuts Gate Seat Ring Body One-Piece Gland (Alternate) Valve Port Figure 5.1 29 Notes: Globe Valve • • • • • Most economic for throttling flow Can be hand-controlled Provides “tight” shutoff Not suitable for scraping or rodding Too costly for on/off block operations... • Design pressure and temperature – Identify connected equipment and associated design conditions – Consider contingent conditions – Consider flow direction – Verify conditions with process engineer 42 Notes: 24 Loading Conditions Principal pipe load types • Sustained loads – Act on system all or most of time – Consist of pressure and total weight load • Thermal expansion loads – Caused by thermal... 20.0 20.0 20.0 20.0 18.9 17.3 16.5 10.8 6.5 2.5 1.0 C - ½Mo A 335 P1 18.3 18.3 17.5 16.9 16.3 15.7 15.1 13.5 12.7 4 2.4 P11 20.0 1¼ - ½Mo A 335 600 700 800 900 1000 1100 1200 1300 1400 1500 18.7 18.0 17.5 17.2 16.7 15.6 15.0 12.8 6.3 2.8 1.2 18Cr - 8Ni pipe A 312 TP304 20.0 20.0 20.0 18.7 17.5 16.4 16.0 15.2 14.6 13.8 9.7 6.0 3.7 2.3 1.4 16Cr - 12Ni-2Mo pipe A 312 TP316 20.0 20.0 20.0 19.3 17.9 17.0... 4.4 Notes: 11 Cap Figure 4.5 17 Notes: Lap-joint Stub End Note square corner R R Enlarged Section of Lap 18 Figure 4.6 Notes: 12 Typical Flange Assembly Flange Bolting Gasket Figure 4.7 19 Notes: Types of Flange Attachment and Facing Flange Attachment Types Flange Facing Types Threaded Flanges Flat Faced Socket-Welded Flanges Blind Flanges Raised Face Slip-On Flanges Lapped Flanges Ring Joint Weld... Molded-In Resilient Seal Sealing Slip Figure 5.7 37 Notes: Valve Selection Process General procedure for valve selection 1 Identify design information including pressure and temperature, valve function, material, etc 2 Identify potentially appropriate valve types and components based on application and function (i.e., block, throttle, or reverse flow prevention) 38 Notes: 22 Valve Selection Process, ... (150, 300, 400, 600, 900, 1,500, 2,500) • Flange strength increases with class number • Material and design temperature combinations without pressure indicated not acceptable 23 Notes: Material Specification List 24 Table 4.2 Notes: 15 Pressure - Temperature Ratings Material Group No Classes Temp., °F -2 0 to 100 200 300 400 500 600 650 700 750 800 850 900 950 1000 1.9 1.8 150 235 220 215 200 170 140 . TX 7520 7-3 109 70 3-9 7 8-5 000 21 4-7 4 6-4 900 80 0-2 2 1-5 536 80 0-4 4 5-2 388 70 3-9 7 8-1 157 (FAX) 21 4-7 4 6-4 902 (FAX) Midwest Regional Office Western Regional Office 17. 119-C Paul Drive Mt. Prospect, IL 6005 6-2 406 San Rafael, CA 9490 3-2 022 84 7-3 9 2-8 876 41 5-4 9 9-1 148 80 0-6 2 8-6 437 80 0-6 2 4-9 002 84 7-3 9 2-8 801 (FAX) 41 5-4 9 9-1 338