ASME B31.3 Piping Design - part a

Piping Design & Applications Workshop

Rev 9-04-03


Part A


Part A

Don Frikken – Becht Engineering Company

A-2

ScopeScope

This workshop covers above ground industrial piping as practiced in the USA.I do not intend to cover:

PipelinesPlumbingNuclear plant piping


Rev 9-04-03

A-3

Topics CoveredTopics Covered

DefinitionsPiping StandardsClassifying ComponentsPipe & Fitting SelectionValve Selection

A-4

More Topics CoveredMore Topics Covered

Introduction to Piping Flexibility AnalysisDesigning with Expansion JointsWater HammerLiquid Thermal ExpansionFabrication, Examination and TestingIntroduction to Line Sizing and Pressure Drop


Rev 9-04-03

A-5

Definitions:Definitions:

piping: assemblies of piping components used…[for] fluid flows. Piping also includes pipe supporting elements, but does not include support structures…or equipment…

piping system: interconnected piping subject to the same design conditions

A-6

More Definitions:More Definitions:

piping components: mechanical elements suitable for joining or assembly into pressure-tight fluid-containing piping systems…pipe, tubing, fittings, flanges, gaskets, bolting, valves and devices such as expansion joints…


Rev 9-04-03

A-7

& More Definitions:& More Definitions:

design pressure: the pressure at the most severe condition of internal or external pressure and temperature expected during service

design temperature: the temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required

A-8

Piping StandardsPiping Standards

Provide a set of requirements for obtaining a safe, reliable and economical installation (system standards or codes)

Provide consistent dimensions and ratings so that components will fit together and can be used interchangeably (component standards)


Rev 9-04-03

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Piping System Standards - ASMEPiping System Standards - ASMEB31.1 Power PipingB31.3 Process PipingB31.4 Liquid Transportation PipelinesB31.5 Refrigeration PipingB31.8 Gas Transportation PipelinesB31.9 Building Services PipingB31.11 Slurry Transportation PipelinesBPE-1 Bioprocessing EquipmentPVHO-1 Pressure Vessels for Human OccupancyHPS High Pressure Systems

A-10

Piping System Standards - OtherPiping System Standards - OtherNFPA 13 – Installation of Sprinkler SystemsNFPA 24 – Installation of Private MainsNFPA 50 – Bulk Oxygen Systems NFPA 54 – National Fuel Gas Code CGA – Handling of Anhydrous Ammonia (K61.1)Chlorine Institute #6 – Piping Systems for Chlorine

See the longer list in the supplement.


Rev 9-04-03

A-11

Piping Component Standards - ASMEPiping Component Standards - ASME

B16.3 – Malleable Iron Threaded FittingsB16.5 – Pipe Flanges and Flanged FittingsB16.9 – Wrought Steel Buttweld FittingsB16.20 – Metallic GasketsB16.22 – Wrought Copper Solder Joint FittingsB16.33 – Metallic Gas ValvesB16.34 – Valves Flanged, Threaded and Welded


A-12

Piping Component Standards - OtherPiping Component Standards - OtherMSS SP-80 – Bronze ValvesMSS SP-97 – Branch Outlet FittingsAPI 602 – Compact Steel Gate ValvesAPI 608 – Metal Ball ValvesASTM A53 – Steel PipeASTM A312 – Stainless Steel PipeAWWA C110 – Ductile & Gray Iron FittingsAWWA C151 – Ductile Iron Pipe



Rev 9-04-03

A-13

Classifying ComponentsClassifying ComponentsBy Pressure-Temperature Ratings

By Reliability

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Classifying Componentsby Pressure-Temperature RatingsClassifying Componentsby Pressure-Temperature Ratings

Many piping systems, especially nonmetallic systems, are proprietary products and rated by the manufacturer.

Ratings for above ground metallic systems are generally governed by their joints. Frequently these are flanged joints manufactured in accordance with ASME B16.1 (iron flanges) and ASME B16.5 (other metallic flanges).


Rev 9-04-03

A-15

P-T Ratings for Flanges – Gray Iron P-T Ratings for Flanges – Gray Iron

0

10

20

30

40

0 50 100 150 200

Temperature (C)

Pres

sure

(bar

g)

Class 125,NPS 1-12

Class 125,NPS 14-24

Class 125,NPS 30-48

Class 250,NPS 1-12

Class 250,NPS 14-24

Class 250,NPS 30-48

A-16

P-T Ratings for Flanges – Carbon SteelP-T Ratings for Flanges – Carbon Steel

0

50

100

150

200

250

300

350

400

450

0 100 200 300 400 500

Temperature (C)

Pres

sure

(bar

g) Class 150Class 300Class 600Class 900Class 1500Class 2500


Rev 9-04-03

A-17

Class 300 Ratings for Flanges – Several MaterialsClass 300 Ratings for Flanges – Several Materials

0.0

10.0

20.0

30.0

40.0

50.0

60.0

0 100 200 300 400 500 600 700 800

Temperature (C)

Pres

sure

(bar

g)

Carbon Steel(B16.5)

316StainlessSteel (B16.5)Nickel Alloy400 (B16.5)

Coper AlloyB61 (B16.24)

AluminumAlloy 6061-T6 (B31.3)

A-18

Classifying Componentsby Reliability

Classifying Componentsby Reliability

RobustnessFire ResistanceBlow-out ResistanceTendencies to Leak


Rev 9-04-03

A-19

RobustnessRobustnessAble to withstand exposure to loads such as:

Being stepped onDropped toolDropped tool boxForklift trafficTruck trafficCrane booms

A-20

Fire ResistanceFire Resistance

Components able to maintain piping system integrity if subjected to approximately 1200 F (650 C) for 30 minutes. The intent is to

prevent the exposure of fire fighters to danger due to leaking fluids

prevent adding fuel to the fire


Rev 9-04-03

A-21

Blow-out ResistanceBlow-out ResistanceGaskets and seals able to withstand high pressure without failing by extrusion or fracture. A short-term leak could be resealed by tightening the bolting. The intent is to avoid large leaks

when a flanged joint is not tightened properlywhen the piping system is subjected topressures much higher than designwhen large bending moments areapplied to the flanges

A-22

Blow-out ResistanceBlow-out Resistance

Failure by Extrusion Failure by Fracture


Rev 9-04-03

A-23

Tendencies to LeakTendencies to LeakSome joints are more leak prone than others. These are usually a strong function of the construction and maintenance practices at a particular site. Examples:

Threaded jointsUnionsElastomeric seals such as o-rings

A-24

Pipe and Fitting SelectionPipe and Fitting SelectionWhat is a Fluid Service?What is a piping system failure?Bases for selectionIndividual components (metallic):

Pipe FittingsFlanges Branch ConstructionBolting Gaskets

Nonmetallic piping


Rev 9-04-03

A-25

Fluid ServiceFluid Service

What distinguishes one fluid service from another?

A-26

Piping System FailurePiping System Failure

How can you recognize a failure in a piping system?


Rev 9-04-03

A-27

Bases for SelectionBases for SelectionPressure ClassReliability

RobustnessFire ResistanceBlow-out ResistanceTendencies to leak

Corrosion ResistanceMaterial ToughnessCost

A-28

Corrosion ResistanceCorrosion ResistanceWhere corrosion is more or less uniform, extra pipe wall material can be provided in the form of a “corrosion allowance”.

Where material degradation is localized, either preventive measures must be used or a more resistant material must be provided. Examples of localized material problems:- Erosion - Pitting - Intergranular- Stress-Corrosion Cracking - Microbiological- Hydrogen Embrittlement


Rev 9-04-03

A-29

Material ToughnessMaterial Toughness

Measured by energy necessary to suddenly propagate a crack to failureMostly of concern for carbon steelsGenerally decreases as temperature decreasesFactors affecting fracture toughness include:

Chemical composition or alloying elementsHeat treatmentGrain size

A-30

Example of Brittle FractureExample of Brittle Fracture


Rev 9-04-03

A-31

Example of Ductile DeformationExample of Ductile Deformation

A-32

CostCost

0 2 4 6 8 10

Relative Installed Cost - NPS 4 Complex System

CPVC, Sch 80Carbon Steel, Sch 40

Stainless Steel, 304, Sch 10SStainless Steel, 316, Sch 10S

Aluminum, 6061 T6, Sch 40Fiberglass - Vinyl Ester

Polypropylene Lined SteelFluoropolymer Lined Steel

Alloy 20, Sch 10SAlloy 400, Sch 10SAlloy C276, Sch 10Zirconium, Sch 10


Rev 9-04-03

A-33

Pipe and Fitting Selection (Metallic)Pipe and Fitting Selection (Metallic)

PipeJoining MethodFittingsBranch ConnectionsFlangesGasketsBolting

A-34

Pipe - seamlessPipe - seamless

Strand Caster Billet Heating Rotary Piercing Mill

Elongator Reheat Pug Rolling Mill


Rev 9-04-03

A-35

Pipe - seamlessPipe - seamless

Reheat Sizing Mill Finishing

NDT Facing & Beveling Hydrotesting

A-36

Pipe – ERWPipe – ERW

Coil Feed First Forming Fin Pass

Welding NDT Seam Normalizer


Rev 9-04-03

A-37

Pipe - ERWPipe - ERW

Sizing Mill Flying Cut-Off Hydrotesting

Straightening NDT Facing & Beveling

A-38

Pipe Wall ThicknessPipe Wall Thickness

t =PD / [2 (SE + PY)]Where:

t = pressure design thicknessP = design pressureD = outside diameter of pipeS = allowable stress value from piping codeE = weld quality factorY = coefficient (function of material)

= 0.4 for ductile metals up to 900ºF (480ºC)= 0.0 for gray cast iron


Rev 9-04-03

A-39

Pipe Wall ThicknessPipe Wall Thickness

Total thickness required is the sum of1. Pressure design thickness2. Manufacturing tolerance (usually 12.5% of the

nominal wall thickness)3. Corrosion (or erosion) allowance4. Threading allowance

A-40

Pipe Wall ThicknessPipe Wall ThicknessWorkshop: What is the required nominal pipe wall thickness for the following case:

NPS 4 ERW carbon steel pipeDesign pressure = 150 psig (1035 kPa)Design temperature = 200°F (95°C)S = 20,000 psi (138 MPa)Corrosion allowance = 1/16” (1.6 mm)Buttwelded system (no threading allowance)

See Supplement starting on page 13.


Rev 9-04-03

A-41

FittingsFittingsFittings are selected primarily by the way they are joined to the pipe.

ThreadingSocket WeldingButtweldingOD Tubing (Compression fitting, Flare)Water Tubing (Solder, Braze)Others

A-42

Fittings: ThreadedFittings: ThreadedCommon materials

Gray iron (ASME B16.4)

Malleable iron (ASME B16.3)Steel (ASME B16.11)

Size frequently limited to ~NPS 2Potential injury for installersAbility to get a good seal

Generally not used where leaks cannot be tolerated


Rev 9-04-03

A-43

Fittings: Socket WeldingFittings: Socket Welding

Common materials (ASME B16.11)

Carbon SteelStainless Steel

Size frequently limited to ~NPS 1-1/2Not used in “severe cyclic conditions”Not use in services where corrosion is accelerated in crevices

A-44

Fittings: ButtweldingFittings: Buttwelding

Common materials (ASME B16.9)

Carbon SteelStainless SteelNickel alloys

Used in most piping systems ~NPS 2 and largerUse generally not restrictedDifficult in small sizes, especially for thin wall


Rev 9-04-03

A-45

Fittings: OD TubingFittings: OD TubingCommon materials

CopperCarbon steelStainless steelNickel alloys

Compression FittingsFlared Fittings (ASME B16.26)Generally not used in most severe services because of leak potential

A-46

Fittings: Water TubeFittings: Water TubeCommon material: copperSolder joint (ASME B16.18 & B16.22)Braze joint (ASME B16.50)Not fire resistant


Rev 9-04-03

A-47

Fittings: GroovedFittings: GroovedFittings that use grooves in pipe –elastomeric seal required

A-48

Fittings: Compression for PipeFittings: Compression for Pipe

Pressfit by Victaullic(B16.51 draft for copper)

Lokring(metal-to-metal seal)


Rev 9-04-03

A-49

Fittings: HygienicFittings: Hygienic

Clamp(Waukesha Cherry-Burrell)

Buttweld(HPS Products)

A-50

Fittings: Hygienic ClampFittings: Hygienic Clamp

(Waukesha Cherry-Burrell)

• Clamps, hubs and gaskets are not the same from manufacturer to manufacturer

• Gaskets are intended to be flush with the inside

• Those with metal-to-metal contact are more resistant to gasket over compression


Rev 9-04-03

A-51

Fittings: Hygienic ButtweldFittings: Hygienic Buttweld

(Arc Machines, Inc.)

Fittings have long tangents to allow space for automatic orbital welder.

(ASME BPE)

A-52

BranchesBranches

Generally many choices NPS 3 and largerChoices include:

TeeUnreinforced Fabricated TeeReinforced Fabricated TeeBranch Connection Fitting


Rev 9-04-03

A-53

BranchesBranchesTee

Unreinforced Fabricated Tee(Capable of less than full pressure)

Reinforced Fabricated Tee

A-54

BranchesBranches Branch Connection Fittings


Rev 9-04-03

A-55

BranchesBranchesBasis for selection:

Cost: depends on material, sizes & fabricatorResistance to external momentAbility to examine fabrication

See table in supplement.

A-56

Flanges (ASME B16.5)Flanges (ASME B16.5)Flange types designated by joining method

Threaded Socket welding Welding Neck (buttweld)

These flanges have the same advantages and restrictions as fittings with the same joining method


Rev 9-04-03

A-57

Flanges (ASME B16.5)Flanges (ASME B16.5)Other types of flanges - Slip-on

Has no crevice if installed with two weldsEasier to get good alignmentUnable to seat metal gaskets as well as WN & LJ

A-58

Flanges (ASME B16.5)Flanges (ASME B16.5)Other types of flanges - Lapped joint

Flange can be made from cheaper materialEasier to fabricate and install than WN


Rev 9-04-03

A-59

Flanges Facings (ASME B16.5)Flanges Facings (ASME B16.5)

Raised – normal choice

Flat

* Standard for gray iron flanges* More gasket has to be compressed, so

only “softer” gaskets can be used* Less likely to break flange when bolting

(applicable to brittle materials like grayiron)

A-60

GasketsGaskets

Important Gasket CharacteristicsResists deterioration in normal service

Chemical resistanceTemperature resistance

Low enough leak rateBlowout resistanceFire resistance


Rev 9-04-03

A-61

Gaskets – RubberGaskets – Rubber

LowBolt Strength

NoFire Resistant

NoBlowout Resistant

BestLeak Performance

200ºF (95ºC)

Approximate Max. Temp.

OK for mostChemical Resistant

(Thermoseal)

A-62

Gaskets – Reinforced RubberGaskets – Reinforced Rubber

LowBolt Strength

NoFire Resistant

NoBlowout Resistant

FairLeak Performance

325ºF (160ºC)

ApproximateMax. Temp.

OK for mostChemical Resistant

(Garlock)


Rev 9-04-03

A-63

Gaskets – FluoropolymerGaskets – Fluoropolymer

LowBolt StrengthNoFire Resistant

NoBlowout Resistant

GoodLeak Performance

350ºF (180ºC)


OK for almost all

Chemical Resistant

(Garlock)

(Gore) (Teadit)

A-64

Gaskets – Flexible GraphiteGaskets – Flexible Graphite

MediumBolt StrengthYesFire Resistant

Not without heavier insert

Blowout Resistant


900 or 625ºF (480 or 330ºC)


OK for almost all

Chemical Resistant

(SGL Carbon Group)

NaturalGraphite

Flake

ThermallyDecomposed

(Worms)

WormsCompressed

Into Foils


Rev 9-04-03

A-65

Gaskets – Flexible GraphiteGaskets – Flexible Graphite

(Teadit)

(Teadit)

Foil Inserted• Insert is usually 0.002”

(0.05 mm) type 316 stainless steel

• Adhesive bonded

Tang Inserted• Insert is usually 0.004”


• Mechanically bonded

A-66

Gaskets – Flexible GraphiteGaskets – Flexible GraphiteCorrugated Insert• Insert is usually 0.018”


• Adhesive bonded• Blowout resistant• Lower hand cutting

potential• Lower sealing stress• Cannot be cut from

sheet(Garlock)


Rev 9-04-03

A-67

Gaskets – Spiral WoundGaskets – Spiral Wound

HighBolt Strength

Depends on Filler

Fire Resistant

YesBlowout Resistant


1500ºF (820ºC)ApproximateMax. Temp.

Both metal winding & filler must be OK

Chemical Resistant

(Garlock)

(Flexitallic)

A-68

Gaskets – Spiral WoundGaskets – Spiral Wound (NE Seal)


Rev 9-04-03

A-69


OrangeAlloy 400BeigeAlloy C276RedNickel 200Green316L SSYellow304 SSRing Edge Color CodeWinding Material

A-70


YesNoNo

YesYes

Fire Resistant

1500 / 820No standardVermiculiteWhitePink

GrayNone

Ring Stripe Color Code

350 / 180325 / 160

900 / 4801500 / 820

Maximum Temp ºF/ ºC

PTFEMica Graphite

Flexible Graphite

Asbestos

Filler Material


Rev 9-04-03

A-71

Gaskets - KammprofileGaskets - Kammprofile

HighBolt Strength

Depends on sealing material

Fire Resistant



1500ºF (820ºC)ApproximateMax. Temp.

Both metal & sealing material

must be OK

Chemical Resistant

(Garlock)

A-72

Gaskets – Ring JointGaskets – Ring Joint

HighBolt StrengthYesFire Resistant


Very GoodLeak Performance

1500ºF (820ºC)


Metal must be OK

Chemical Resistant

(NE Seal)

Oval

Octagonal


Rev 9-04-03

A-73

BoltingBoltingHas to be strong enough to seat the gasketConsider need to be corrosion resistant to process fluidStuds versus bolts

A-74

Non-Metallic Pipe and FittingsNon-Metallic Pipe and Fittings

TypesThermoplasticReinforced Thermosetting Resin (RTR)

Fiberglass or carbon fiber reinforcementPolyester, vinylester or epoxy resin

Thermoplastic Lined Metals


Rev 9-04-03

A-75

Non-Metallic Pipe and FittingsNon-Metallic Pipe and Fittings

CharacteristicsLess expensive than metallic alternativesCannot be made fire resistantMore sensitive to abuseMore supports are generally requiredFlanged joint make-up requires more care

A-76

Thermoplastic Pipe and FittingsThermoplastic Pipe and Fittings

(Charlotte Pipe)

(Durapipe)

(Durapipe)

• Pipe is extruded• Fittings are usually injection

molded, but sometimes fabricated

• Valve parts are usually injection molded

• Requires warm, dry and clean environment for fabrication


Rev 9-04-03

A-77


(Asahi)

Butt fusion fittings are joined to the pipe using a butt fusion welding process.

(Asahi)

A-78


(Spears)

Socket fittings are joined to the pipe using a socket fusion welding process or solvent cement.

(Asahi)


Rev 9-04-03

A-79

RTR Pipe and FittingsRTR Pipe and Fittings• Pipe is filament wound

or centrifugally cast• Fittings are molded,

filament wound or fabricated

• Few RTR valves are available

• Requires warm, dry and clean environment for fabrication

(Smith Fibercast)

A-80

Butt fittings are joined to the pipe using a butt wrapping process.

RTR Pipe and FittingsRTR Pipe and Fittings

(Smith Fibercast)


Rev 9-04-03

A-81

Socket fittings are joined to the pipe using an adhesive.

RTR Pipe and FittingsRTR Pipe and Fittings

(Conley)

A-82

RTR Pipe and FittingsRTR Pipe and FittingsA leak at an elbow requires1. Cutting out the elbow

and adjacent pipe2. Fabricating a piece with

an elbow and two couplings

3. And installing it, hoping none of the six new joints leak


Rev 9-04-03

A-83

Lined Pipe and FittingsLined Pipe and Fittings• Common liners are

fluoropolymer, polypropylene, and PVDF

• Liners can be “locked-in” or loose

• PTFE and FEP lined systems require vent holes

• Pipe and fittings are usually ductile iron and steel

• Systems usually have many flanged joints

(Resistoflex)

A-84

Lined Pipe and FittingsLined Pipe and FittingsTypical Fittings


Rev 9-04-03

A-85

Lined Pipe and FittingsLined Pipe and Fittings

Untypical Fittings

A-86

Pipe & Fitting SelectionPipe & Fitting Selection

Workshop: What basic piping system characteristics would you provide for the following services:

Steam condensateSulfuric acidGasoline650 psig (45 bar) SteamHeat transfer oil

See Supplement page 21 for details.


Rev 9-04-03

A-87

B31.3 Fluid Service DefinitionsB31.3 Fluid Service Definitions

Category DCategory MHigh PressureNormal

A-88

B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsCategory D: The fluid handled is

nonflammable, nontoxic and not damaging to human tissue. The design pressure does not exceed 150 psig (1035 kPa). The design temperature is greater than -20°F (-29°C) and does not exceed 366 °F (186°C).

Often characterized as “utility”


Rev 9-04-03

A-89

B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsCategory M: A fluid service in which the potential

for personnel exposure is judged to be significant and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to persons upon breathing or on bodily contact, even when prompt restorative measures are taken.

Often characterized as “lethal”

A-90

B31.3 Fluid Service DefinitionsB31.3 Fluid Service DefinitionsHigh Pressure: A service for which the owner

specifies the use of Chapter IX [of B31.3] for piping design and construction… considered to be in excess of Class 2500 (PN 420).

Characterized as “high pressure”

Normal: Everything else.Often characterized as “process”

See Table in Supplement.


Rev 9-04-03

A-91

Fluid Service SelectionFluid Service Selection

Workshop: What B31.3 fluid service definition is most nearly applicable for the following services:

Steam condensateSulfuric acidGasoline650 psig ( ) SteamHeat transfer oil

See Supplement page 21 for details.

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ASME B31.3 Piping Design - part a

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