GENERAL COMPOSITION OF
THE PIPING
2
GENERAL COMPOSITION OF THE PIPING
Piping system consists of the following components:
1 .The actual pipes
2 .The fittings: tees, elbows, reducers, etc….
3 .The range of connections: flanges, threaded fittings, weld
fittings, etc….
4 .The range of seals: gaskets, etc….
3
Piping and connections
COPPER PIPING
Copper tubes are best adapted for
cold/hot water and gas pipes .
It is sometimes necessary to anneal a tube
to improve its malleability.
Use a torch to heat the tube to redness
on the part which is to be annealed .
This work can be done with a
blowtorch (oxy-acetylene)
4
Annealing
COPPER PIPING
OLIVE COMPRESSION FITTINGS: These olive compression fittings
simplify the installation, but they cannot withstand several
disassemblies .
GRIP FITTING: For a beginner this principle is the easiest and has the
advantage of being indefinitely detachable.
5
Olive compression fitting Grip fitting
COPPER PIPING
FLARE FITTING
It consists of a female nut and a male union fitting.
This fitting requires the installation of a fibre or rubber
gasket for the sealing.
6
COPPER PIPING
PROGRESSIVE RING FITTINGS (ERMETO):
The Ermeto fitting is very popular due to its easy assembly which only needs two open spaners.
SPHERICAL SEAT UNION:
The tightening of the nut locally crushes the metal thus
procuring a tight seal.
7
Ermeto Spherical seat
COPPER PIPING
Weld fittings
There are several kinds of copper weld fittings .
With copper piping, the term “welding” is not used; we speak of
soldering or brazing .
Soldering and brazing consist of a lapped joint assembly of two
pieces of metal by capillarity, using a welding rod.
8
Brazing
COPPER PIPING
The difference between soldering and brazing:
1 .Soldering (melting point less than 450°C)
2 .Brazing (melting temperature higher than 450°C)
9Soldering Brazing
. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes
Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal . Soldering differs from welding in that soldering does not involve melting the work pieces
COPPER PIPING
Two things should be noted when speaking of soldering or brazing:
This is a capillary phenomenon (where a liquid spreads between
the cracks of two parts in contact and which slowly progresses
whatever the position of the parts)
Wetting (when the bond between the soldering or brazing and the
work piece is free of apparent defects and the coating of the
soldering or brazing appears even)
11Welding sleeves:
STEEL PIPING
The steel pipes are much larger than those made of copper but
steel pipes can also be found in small sizes.
Steel is divided into three categories :
1 .Non-alloy steels
2 .Alloy steels
3 .Stainless steels
12
STEEL PIPING
The choice of steel for the piping depends on the nature,
temperature and pressure of the fluid transported.
To connect steel pipes the electrical welding( with welding
electrodes) process is used for big diameters .
13
BUTT WELD FITTINGS
1 .Reducing T-pieces
2 .Reducers Concentric
3 .Reducers Eccentric
4 .Elbows 90°
5 .Collars
6 .Stub-ends
7 .T-pieces
8 .Caps
14
1
2 23
4
56 7
88
PIPE FITTINGS
Pipe fitting such as elbow, tees, reducers, etc. are used to:
1 .Change flow directions
2 .Change size and geometry of the line
3 .Fittings are manufactured from the same pipe materials.
4 .Fittings must have the same pressure rating of piping system and
corrosion resistance to the conveyed flow.
15
PIPE FITTINGS
Elbows
Elbows may be 180, 90 and 45 degrees. The radius of curvature is
generally equal to 1 or 1.5 times the nominal diameter .
They are used to change the direction by 45, 90, or 180.
TEE: used to connect three pipes together and branching a pipe
line at 90
CROSS: used to connect four pipes together
16
FITTINGS
Weld bend welding fittings are permanently identified by die
marking to designate:
1 .Manufacturer
2 .Size
3 .Wall Thickness
4 .Material Grade
5 .Heat Identification
17
WELDING FITTINGS (SHORT AND LONG RADIUS ELBOWS AND RETURN BENDS)
18
WELDING FITTINGS
19
WELDING FITTINGS (SHORT AND LONG RADIUS ELBOWS AND RETURN BENDS)
20
90 degrees elbows
180 degrees elbow (Return bends)
PIPE FITTINGS ( REDUCERRS)
21
To connect two pipes with two different diameters
PIPE FITTINGS (BUTT – WELDING TEES)
22
TEE: used to connect three pipes together and branching a pipe line at 90
Butt- welding Tees
Straight butt-welding Tee Reducing butt - welding Tee
PIPE FITTINGS (COUPLINGS)
23
Full coupling
Reducer: Join two different diameters of pipe
PIPE FITTINGS (CROSS CONNECTION)
24
CROSS: used to connect four pipes together
WELDING FITTINGS (REDUCING FITTINGS)
25
WELDING FITTINGS
26
Butt- welding cap
To close the end of the pipe
Flat closure
PIPE FITTINGS (SCREWED UNION)
27
TYPES OF FITTINGS
28
900 male elbows 450 male elbows
TeeUnion cross
NIPPLES, COUPLING AND UNION
Nipples and Couplings are used to connect pipes permanently.
Nipples have a male thread but couplings have a female one.
29
CAPS AND PLUGS
1 .Caps and plugs are used to plug (close) pipe ends
2 .Plugs are having external thread
3 .Caps are having internal thread
30
FLANGES
Flanges
When the tube diameters are larger than the diameters of the
largest fittings, steel pipes are joined by flanges .
The steel pipes with a small diameter can also be fit with flanges
depending on the nature and pressure of the transported fluid.
31
TYPES OF FLANGES
Connection to the pipe
1 .Welding-neck
2 .Slip on
3 .Screwed
4 .Blind
5 .Lap joint
6 .Socket-welding
32
1
2
4
6
3
1 .WELDING – NECK FLANGE
33
2 .SLIP ON FLANGE
34
3 .SCREWED FLANGE
35
5 .LAP – JOINT FLANGE (WITH STUB – END)
36
Stub end Lap joint flange
6 .SOCKET-WELDING
37
FLANGES
Flanges are permanently identified by die marking to designate:
1. Manufacturer
2. Size
3. Class
4. Material Specification
5. Heat Identification
6. Production Code (Optional)
38
TYPES OF FLANGE FACES
1 .Flat face flange
2 .Raised face flange
3 .Male & female flange
4 .Ring joint flange (RTJ)
39
TYPES OF FLANGE FACES
40
Flat face flange
Raised face flange
Metal ring joint face flange (RTJ)
FLANGE FACES1. FLAT FACE FLANGE
1 .The flange face is completely flat .
2 .Both flanges to be coupled are identical.
3 .The gasket must be of the disc type, entirely contained within the
diameter of the bolt holes or, more commonly, of the full-face
type and the bolt holes punched out.
4 .These require a very wide gasket, and are not suitable for high
pressures.
41
1 .FLANGE FACES - FLAT FACE FLANGE
42
Flat face flange (FF)
Gasket for flat face flange
FLANGE FACES1. FLAT FACE FLANGE
43
Flat face flange
Flat face flange gasket
FLANGE FACES 2. RAISED FACE FLANGE
1 .The two flange faces are identical.
2 .The gasket rests against the raised face.
3 .The purpose of the raised face is to ensure uniform distribution
of pressure over the gasket.
4 .Coupled flanges can easily be separated since the external part
is placed so as to permit the application of tools and wedges.
44
2. RAISED FACE FLANGE FACES
45
Raised face flange (RF)
3 .FLANGE FACES – MALE AND FEMALE FLANGE FACE
46
Large male and female flange
3 .FLANGE FACES – MALE AND FEMALE FLANGE
47
Large tongue and groove flange
4 .FLANGE FACES – RING JOINT FLANGE
48
Ring-joint flanges (RTJ)
SPECIAL FLANGES
1 .Blind flanges
2 .Spectacle blind flanges
3 .Orifice flanges
49
SPECIAL FLANGES 1. BLIND FLANGE OR END BLIND
These flanges are used only for closing lines and valves
50
SPECIAL FLANGES1. BLIND FLANGE
These flanges are used only for closing lines
It is inserted between two flanges
51
SPECIAL FLANGES2. SPECTACLE BLIND
1 .These flanges are used to keep the line open or close
2 .It gives indication if the line is open or closed
3 .It is inserted between two flanges
52
1. Spectacle blind
2. Flanges
3. Gaskets
4. Stud bolts
SPECIAL FLANGES2. SPECTACLE BLIND
53
SPECIAL FLANGES3. ORIFICE FLANGE
54
SPECIAL FLANGESTHE WORKING PRINCIPALE OF ORIFICE
55
For this kind of flanges:
1.The orifice disc must be installed in the correct direction
2.The holes in the flanges must be cleaned every time
3.The gaskets must be replaced
Orifice plate
SPECIAL FLANGES1. ORIFICE FLANGE
56
For this kind of flanges:
1.The orifice disc must be installed in the correct direction
2.The holes in the flanges must be cleaned every time
3.The gaskets must be replaced
1. Orifice disc2. The orifice disc hole3. Holes to connect the instrument system
FLANGE RATING
The ratings defined by the following:
150 pounds: corresponds to a maximum allowable pressure of 150
psig (pound per square inch gauge) at 500°F (260°C) for all
materials
300 pounds: max allowable pressure 300 psig at 850°F (454°C) for
carbon steel
600 pounds: max pressure (P=600psig) at the same temperature as
the 300 lbs rating
57
FLANGE RATING
The ratings defined by the following:
900 pounds: max pressure (P=900psig) at the same temperature as
the 300 lbs rating
1500 pounds: max pressure (P=1500psig) at the same temperature
as the 300 lbs rating
2500 pounds: max pressure (P=2500psig) at the same temperature
as the 300 lbs rating
58
FLANGE RATING CLASS 150
59
60
ORIFICE FLANGE UNIONS
61
GASKET SELECTION
The factors influencing the
choice of gasket are as follows:
1 .Nature of the fluid
2 .Pressure and temperature
3 .Forces acting on the junction
location
62
Gasket Softness
TYPES OF GASKET
Type of gasket Type of face System pressureC.A.F (Compressed Asbestos Fiber)
Flat face (full face)Raised face (Disc type)
Low
Spiral wound Raised face Moderate
Metal ring R.T.J (Ring tore joint) High
63
Spiral wound with and without Inner ring
Metal ring gasket (Reinforced) graphite gasket
Non-metallic gasket
TIGHTENING SEQUENCE
64
TIGHTENING SEQUENCE
65
66
PIPE EXPANSION &
EXPANSION JOINTS
EXPANSION JOINTS
What is the function of expansion joints?
It is used to provide some flexibility
1 .The flexibility could be in axial direction to accept the thermal
expansion
2 .Flexible rubber joint is used also to eliminate transmission of
vibration
67
PIPE EXPANSION
68
PIPE EXPANSION
69
EXPANSION LOOPS
70
The expansion loop can be fabricated from lengths of straight pipes and elbows welded at the joints
SLIDING JOINT
These are used because they take up little room, but it is essential
that the pipeline is rigidly anchored and guided in strict
accordance with the manufacturer’s instructions; otherwise
steam pressure acting on the cross sectional area of the sleeve
part of the joint tends to blow the joint apart in opposition to the
forces produced by the expanding pipe work (see the following
figures).
Misalignment will cause the sliding sleeve to bend, while regular
maintenance of the gland packing may also be needed.
71
SLIDING JOINT
72
EXPANSION JOINTSSLIDING JOINT
73
The draw back for this sliding joint
1.Misalignment will cause the sliding sleeve to bend,
2.Regular maintenance of the gland packing also needed.
OTHER DESIGNS TO OVERCOME PIPE EXPANSION
74
U - shape in horizontal plane
Z - shape + expansion joints
EXPANSION JOINTS
75
EXPANSION JOINTS
76
EXPANSION JOINTS
77
78
COLOUR CODING OF RIGID PIPES
COLOUR CODING OF RIGID PIPES
79
COLOUR CODING OF RIGID PIPES
Colour coding is used to indicate potential hazards associated with
the contents of a rigid pipe .
The goal of such marking is to make the task easier for the
technicians, to facilitate intervention by safety crews in event of
damage and to thus prevent any confusion.
80Example of colour codes
COLOR CODES
81
COLOUR CODING OF RIGID PIPES
Some fluids have a specific colour called the secondary identification
colour .
This colour is placed in several places, along the whole length of the
main identification colour .
This colour specifies some of the fluid’s properties :
–Pressure, Temperature, Purity
82
COLOUR CODING OF RIGID PIPES
83
COLOUR CODING OF RIGID PIPES
Indicating the direction of the flow can prove very useful to
quickly locate the block valves in case of an emergency .
A white or black arrow (so as to ensure a better contrast with the
background colour) is placed in the direction of the flow .
For two-way flows, a double arrow is used .
84Direction of the flow
COLOUR CODING OF RIGID PIPES
It is often recommended to explicitly attract the personnel’s
attention to the hazardous nature of certain fluids.
Therefore labels, plates, writings or icons are attached to the piping
close to the main background colour.
85
Examples of pictograms
General warning Explosive materialsSubstances under pressure