Pipe & Pipe Fitting Guide for Oil & Gas Career

Welcome!

How to be an Expert in Process Pipe & Pipe Fittings

By: Varun Patel, B.E- Mechanical, PMP®

I am Varun Patel…

• Mechanical Engineering

• Certified Project Management Professional- PMP®

My Experience…

• More than 10 years in Oil & Gas Industry- Mainly Refinery and Offshore Platforms

• Work from Project initiation to Project Closed out of mega projects

You will learn…

• What is Process piping & important

• What is Code, Standard & Specification

• Piping Components use in process piping such as Pipe, Pipe Fittings, Branch connection, Flanges, Gasket and Bolting.

You will learn…

• Materials (Metal, Non-Metal)

• Manufacturing methods

• Inspection and Testing requirements

• Dimensions & Markings requirements

• Code & Standard used

• Common terminology used in industry

• And much more….5

Best way to move forward….

• Watch Video tutorial

• Solve quizzed at the end of lecture

• If available − Check applicable Code & Standard − Check QA/QC & Inspection documents −Go and visit site and experience real materials

Ideal for….

• Student who want career in Oil & Gas or other process Industry

• Career changer in Oil & Gas or other process Industry

• Construction professional working such as Pipe fitter, welder, fabricator, piping supervisor etc.

Ideal for….

• Professional working in different discipline such as operation, maintenance, instrument, electrical, administrative or any other field

• This course does not covering Piping System Design, fabrication and site installation activities.

What we have learned?• About your tutor

• Overview of course & What is ahead in course

• Why this course is ideal choices for you

• How you will maximize you learning

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Process Piping

Source: Piping Component G_FORDHAM

Process Industries

Source: Pixabay.com2

What is Process Piping ?• Piping:

− Assembly of piping components used toconvey, distribute, mix, separate,discharge, meter, control, or stop fluidflows.

• Piping Systems:− Interconnected piping subject to the

same sets of design conditions.

What is Process Piping ?

• Process:− A series of activities performed in

particular ordered to convert rawmaterial into an useful product

• Process Piping is interconnectedpiping used in process industries toconvert raw material in to usefulproducts.

What is Process Piping ?• A Piping under the purview

of ASME Code - B31.3 is Process Piping

• A Process Piping Systems are design as per the guidelines given in ASME B31.3

ASME B31.3 Process Fluid Service

• Category D Fluid Service− The fluid is nonflammable, nontoxic, and not damaging to

human tissue.− The design pressure does not exceed 150 psig (1035 kPa).− The design temperature is between -29°C and 186°C.

• Category M Fluid Service− a fluid service in which the potential for personnel

exposure is judged to be significant and in which a singleexposure to a very small quantity of a toxic fluid, causedby leakage, can produce serious irreversible harm topersons on breathing or bodily contact, even when promptrestorative measures are taken

Types of ASME B31.3 Process Fluid

• High Pressure Fluid Service− High pressure fluids are those in which the Owner has

specified that the pressures will be in excess of thatallowed by the ASME B16.5 PN420 (Class 2500) rating forthe specified design temperature and material group.

• Normal Fluid Service− Everything else that does not cover under Category D,

Category M and High Pressure fluid service.− ASME B31.3 covers most of the process fluid in this

Category− Gauge

Types of Process Fluid in Oil & Gas

• Process fluid are mainlyclassified as following;− Mainly Hydrocarbons services,

starting from Crude oil to finaldistilled products

− Gas such as Hydrogen, Nitrogen,Oxygen and Instrument air etc..

− Chemicals for dosing such aschlorine, anti corrosion liquidetc..

Property of Process fluid use in Oil & Gas

•Flammable•Corrosive•Explosives•Volatile•Reactive •Hazardous to

human health13

Material for process fluids

• To handle different kind of process fluids indifferent physical and chemical environments weneed different kind of piping materials.

• Material that are able to withstand under variousdesign condition are chosen from based on manyprocess parameters.

• Lets learn about these types of material in nextlecture

What we have learned?

• Pipe

• Pipe fittings / components

• Piping / Piping System

• Process Piping

Code, Standard & Specification

What is Code, Standard & Specification ?

•Standard −A standard can be defined as a set of

technical definitions and guidelines-“how to" instructions for designers and manufacturers.

−They serve as a common language to defining quality and establishing safety criteria.

−Examples- ASTM standard, ISO standard.

•Why Standard is required ?−Standards are documents that establish

engineering or technical requirementsfor products, practices, methods oroperations.

−Build confidence about quality in users−Lower the cost of production as

requirements are standardize

•Code: A code is a standard that hasbeen adopted by one or moregovernmental bodies and has theforce of law, or when it has beenincorporated into a businesscontract

•Specification −Must meet requirements −Examples- Company Provided

specification, Product specification

Piping Code & Standard• Provide a set of requirements for a safe,

reliable and economical installation and operation throughout the life of process plant

• Provide consistent dimensions and ratings so that components will fit together

• Improve system reliability

• Cost saving

ASME B31.3 Process Piping Code•ASME B31.3 Code Covers−Requirements for materials−Components, −Design, −Fabrication, assembly, erection,−Examination, inspection, and

testing of piping.

Dimension standard•Dimension Standard cover−Different standard for different components gives

product specific requirements

• Pipe −Pipe sizes, inside and outside diameters, wall thickness,

schedules, end types, permissible variance, markings and weight of pipe•ASME B36.10 - Welded & Seamless wrought iron pipes•ASME B36.19 - Stainless steel pipes

Dimension standard• Pipe Fittings

− sizes, inside and outside diameters, wall thickness, ratings, end preparation, various tolerances and marking requirements

−Butt welded fittings;•ASME B16.9 - Factory-Made Wrought Butt welding Fittings•ASME B16.28 - Wrought Steel Butt Welding Short Radius Elbows

and Returns

−Socket & Threaded fittings•ASME B16.11- Forged Steel Fittings, Socket-Welding and Threaded

Dimension standard• Flange:

− Pressure-temperature ratings, materials, various flange dimensions, tolerances, marking. Flange bolting dimension and gasket requirements are also included

−NPS ½ through NPS 24•ASME B16.5 - Pipe Flanges and Flanged Fittings

−NPS 26 through NPS 60−ASME B16.47 - Large Diameter Steel Flanges

Dimension standard• Branch connection

−Pressure-temperature ratings, size and types, materials, dimensions, tolerances, marking and testing•MSS SP-97

• Bolting− Included in Flange dimension standard −ASME B16.5 /B16.47

Dimension standard• Gasket:

−Materials, dimensions, tolerances, and markings for metal ring-joint gaskets, spiral-wound metal gaskets, and metal jacketed gaskets and type of filler material used

−ASME B16.20 - Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Would, and Jacketed

−ASME B16.21- Nonmetallic Flat Gaskets for Pipe Flanges

•Code, Standard & Specification and why they are required

•Design standard

•Material standard

•Dimension standard

End of LectureGood Luck!

See you

in next lecture…

Piping MaterialsSelection

Wiki Common user: Alexander AlUS

Piping Material Selection Criteria

• Process condition will impact selection of material− Service Fluids

•Corrosive - Sea Water, H2S, Ammonia, Acids etc..•Non-Corrosive – Lube oil, Air, Nitrogen etc.

− Temperature•Cryogenic•Low temperature•Medium temperature•High temperature

• Process condition will impact selection of material− High or Low Pressure

• Others factor that also considered

−Cost−Availability−Weldability−Manufacturability

• Material property that considered before selection−Ultimate Tensile Strength− Yield Strength− Elasticity− % Elongation−Hardness− Toughness− Creep resistance− Fatigue Resistance

Classification of Piping MaterialPiping Material

Ferrous

Cast Iron

Carbon Steel

Alloy Steel

Stainless Steel

Non-Ferrous

Copper Alloy

Nickel Alloy

Aluminum Alloy

Other Alloy

Non-Metal

PVC / CPVC

GRP/GRE

Cement

Lined /Clad

Rubber Lined

PTFE Lined

FRP Lined

Glass Lined

Cement Lined5

• Pipe material selection criteria

• Design condition

• Property of material

• Classification of piping material

See you

in next lecture…

Ferrous Metal

• Metal which contains more iron than any other single element falls under ferrous metal.

• They are divided in following categories− Cast iron / Cast Steel− Carbon Steel− Stainless Steel− Alloy Steel

FeIron

Carbon Steel

• It can further classified as under− Law carbon steel: Carbon - 0.05% to 0.25%− Medium Carbon Steel: Carbon - 0.25% to 0.5%− High Carbon Steel: Carbon - 0.5% to less than 2%

Carbon Steel

• Commonly use carbon steel grade in Process piping

• Pipe: ASTM A53 Gr A/B, A106 Gr A/B/C, API 5L Gr B

• Wrought Fittings: ASTM A234 Gr.WPA/B, A420 Gr.WPL6

• Forged Fittings: ASTM A105, A350 Gr LF1/LF2, A181

What you have learned?

• Cast iron and Cast Steel

• Carbon Steel & its Alloying elements

• Classification of carbon Steel

• Common material grade for carbon steel

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in next lecture…

Alloy Steel

• Adding of alloying elements to improve the characteristics of the material is termed as Alloy Steel

• Low alloy steel :Alloying elements < 5%

• High alloy steel :Alloying elements > 5%

• Alloy Steel

• Alloying elements

• Purpose of Alloying elements

• Use of Alloy Steel & common grades

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in next lecture…

Stainless Steel

• A steel with a minimum chromium content of 10.5 % or more, and a maximum carbon content of less than 1.20%

• What is Stainless Steel

• Properties of Stainless Steel

• Types of Stainless steel

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in next lecture…

Stainless Steel Types

• Duplex stainless steel− Contain both Austenite & Ferrite in microstructure−Offer benefits of both Austenite & Ferrite stainless steel−Good resistance to pitting and crevice corrosion − high strength and high resistance to stress corrosion

cracking− EX- UNS S32205, S31803, S32760 −Used in sea water system, heat exchanger, structural

application etc.

Non-ferrous Metal

• Contains no iron or insignificant amount

• Metal such as Aluminum, Copper, Nickel, Titanium etc.

• Material used in Process Ind.− Copper and Copper Alloys−Nickel and Nickel Alloys− Aluminum and Aluminum Alloys− Titanium and Titanium Alloys− Zirconium and Zirconium Alloys

• Non-ferrous Metal

• Types of metal used in Process Piping

• Properties of these materials

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in next lecture…

Non- Metallic Material

Non Metallic Material

• Commonly used non-metallic piping materials − PVC / CPVC−HDPE−GRE/GRP− Cement

• These non metallic material offer some great advantage over metallic piping but also have some limitation.

PVC / CPVC

• PVC / CPVC− PVC – Polyvinyl Chloride− CPVC - Chlorinated Polyvinyl Chloride (higher strength at

elevated temperatures than PVC)

• Tough and exceptionally resistant to chemical attack

PVC / CPVC

• PVC , CPVC required protection form ultraviolet exposure if installed outdoor.

• Start softening when subjected to high temperature.

PVC / CPVC

• Pipe are manufactured by Extrusion process

• Fittings, flanges and valves are manufactured by injection moulding

• Has many application in industries and in home water piping.

• Types of Non Metallic Material and their uses

• Overview of properties and Manufacturing methods

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in next lecture…

Lined / Clad Material

Lined Pipe

• Mechanical bonding between pipe and line material

• To get the benefit of anti-corrosion property of lined material and strength of carbon steel

• Commonly used lined material are− PTFE− Rubber−Glass− FRP (Fiber reinforced plastic)

• What is lined pipe

• What is clad pipe

• Types of lining / cladding material

• Advantage and limitation

See you

in next lecture…

Varun Patel, B.E- Mechanical, PMP®

Pipe•A straight pressure tight cylindrical hallow,

used in piping system

•Different types of pipes used in different design conditions, considering technical and commercial parameters

•Pipes are mainly classified as follow ;

• Pipes are mainly classified as below;

Seamless

Welded

StraightSAW

Single Seam

Double SeamHelical/Spiral

SAWERW/EFW

Pipe Size

•Pipe size are mentioned as nominal pipe size (NPS),also mentioned as Diameter nominal (DN)

• It is in-between of outer and inner diameter of pipe

•For NPS 14” and above NPS is same as outer diameter

ID will changed with changed in Pipe Schedule number

Pipe Size

Pipe length

•Pipe are available in following lengths−Single random

•4.8 m to 6.7 m with 5% of lengths 3.7 to 4.8 m

−Double random•minimum average of 10.7 m and a minimum length of 4.8 m with 5 % 4.8 m to 10.7 m

−Fixed length as per purchase order

Pipe Thickness•Thickness are expressed in Schedule number

(5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160)

•Also in STD, extra strong-XS, double extra strong-XXS

•Higher the schedule higher the thickness

Pipe Thickness•What is Schedule No?

•A schedule number is the approximate value of the equation = 1000 P/S−P is the service pressure in (psi) −S is the allowable stress in (psi)

Pipe Thickness•The outside diameter of each pipe size is

standardized. Therefore, inside diameter depends upon the schedule number of pipe

•ASME B36.10 provides standard dimension requirements for Welded & Seamless wrought iron pipes.

Pipe Thickness for Stainless Steel

•Thickness are expressed in Schedule number (5S, 10S, 40S, 80S)

•Schedule no with S suffix are per ASME B36.19M, and it is use with stainless steel pipe only.

Pipe ends

•Pipe can be−Plain end−Beveled end−Threaded end−Special end such as socket & spigot

with o-ring type gaskets

•Basic of Pipe

•NPS & Schedule No.

•Types of Pipe End

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in next lecture…

Pipe Material

•Commonly used ASTM material Grade of pipe

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in next lecture…

Pipe Manufacturing-1

Seamless Pipe

•Strongest amongst all pipes.

•Homogenous structure throughout pipe length.

•Available in wide range of size.

•Restriction on large size

•Used in manufacturing of bends, elbow, tee.

Manufacturing of Seamless Pipe

• Seamless pipe are manufacture by following methods

• Mandrel

• Plug mill

• Extrusion

• Forging

Piercing Method

Manufacturing of Seamless Pipe

•Piercing Method

Billet

Heating in Furness Piercing

Extrusion

Force Pull

Hot Extrusion Hot / Cold Extrusion

Welded Pipe

•Pipe are manufactured from Plate or Coil

•Plate or coil rolled in circular section to weld

•Can be welded with or without filler material

•No restriction on large size

•Used in manufacturing of bends, elbow

•Weak in compare to seamless pipe due to joint12

Plat Bending / Forming for Welded Pipe

ERW or EFW Pipe

Induction Weld anodes

Weld Bead Trimmer Induction Heat

treatment

Water Cooling

Online NDT

•Manufacturing methods

•Seamless Pipe

•Welded Pipe

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in next lecture…

Pipe Manufacturing-2

Heat Treatment for pipe

•Hot finished Pipe−Temp. remain above heat treatment temperature

till final size and thickness achieved −No heat treatment required

•Cold finished Pipe−Pipe are clod drawn−Heat treatment as per applicable ASTM standard

Hydrostatic Test

• Ensure 100% leak proof pipe

• Ensure ability withstand under pressure

• Hydro test pressure is calculated based on equation given in ASTM A530

Marking •Following shall be marked on pipe−Manufacturer logo−ASTM material code−Material Grade−Size−Thickness−Length−Heat No−Special marking WR or NH,

VP 8” Sch 80 A106 XYZ123 10.2m

Marking•Marking can be by paint or by Hard punching

•For stainless steel stenciling can be used−For carbon steel no hard punching below 6 mm

thickness−For stainless steel no hard punching below 12 mm

thickness

•Heat Treatment

• Inspection and Testing

•Markings

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in next lecture…

Fittings

Fittings•Fittings are Piping component which helps in−Changes the direction of the flow

•elbows, tee

−Changes the size of the pipe•reducers, reducing tees, reducing couplings, reducing flanges

−Joins together pipe•flanges, couplings

Fittings ends•Socket weld & Threaded end−ASME B16.11 - Forged steel socket welding &

threaded fittings

• Basic of Pipe

• NPS / Schedule No.

• Types of Pipe End

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in next lecture…

Fittings Material

Material•Commonly used material for wrought fittings

•Carbon Steel :- ASTM A234Gr.WPA/B, ASTM A420 Gr.WPL6

•Alloy Steel :- ASTM A234 WP1 /WP5 /WP7 /WP9 /WP11 /WP12 /WP22

•Stainless Steel :- ASTM A403 WP304 /WP304L /WP304H /WP316 / WP316L/ WP321/ WP347

Material•Commonly used material for forge fittings

•Carbon Steel :- ASTM A181, ASTM A105, ASTM A350 LF1/2

•Alloy Steel :- ASTM A182F1 /F2 /F5 /F7 /F9/ F11 /F12 /F22

•Stainless Steel :- ASTM A182F6 /F304 /F304L /F304H /F316 /F316L/ F321/ F347/ F348

•Materials wrought & forged fittings

•Common ASTM material grades

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in next lecture…

Fittings Manufacturing-1

Wrought Fitting Manufacturing Methods•Hot forming or Extrusion Method

•Hydraulic Bulge method – Cold forming

•UO Method / Single weld seam

•Monaka Method / Double weld seam

•Deep Drawing Method

•Flare Method for Stub ends4

ELBOWS: Extrusion method (Cold Forming)

PushDie

Tees: Hydraulic Bulge method

Reducers: Outer Die method

CAPS: Deep Drawing method•Plate is cut out in a circle and formed by deep

drawing die

•Manufacturing methods

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in next lecture…

Fittings Manufacturing-2

Heat Treatment for Fittings•Heat treatment as per applicable ASTM standard

•Hot finished Fittings−Temp. remain within heat treatment temperature till

final size and thickness achieved −No heat treatment required

•Cold finished Fittings−Fittings are clod drawn−heat treatment required

Marking•Marking can be by paint or by Hard punching

•For stainless steel stenciling can be used

•For carbon steel no hard punching below 6 mm thickness

•For stainless steel no hard punching below 12 mm thickness

•Heat Treatment

•Markings

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in next lecture…

Flange

• Second most used joining method after welding

• Connect pipe with various equipment

• Provide flexibility in maintenance

• Cannot use in underground piping

• Most common source of leak

• Varity of flanges available to suit requirements

Flange Attachments Types

• Threaded Flanges

• Socket-Welded Flanges

• Slip-On Flanges

• Lapped Flanges

• Weld Neck Flanges

• Blind Flanges

Flange Facing Types

• Flat Faced (FF)

• Raised Face (RF)

• Ring Joint (RTJ)

• Tongue and groove (T&G)

• Male and Female

• These face can be smooth or serrated type

• Types Flange

• Flange End Connection

• Types of Flange Face

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in next lecture…

Flange Material

Material of construction

• Standard Flanges are made by forge materials

• Carbon steel

• Low alloy steel

• Stainless steel

• Combination of Exotic martials (Stub) and othermaterials

• Materials for Flanges

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in next lecture…

Flange Manufacturing

Manufacturing

• Flanges are manufactured by forging

• Large diameter flange are made by ring rolling methods

• Final dimension are achieved by machining

Hydrostatic Test

• Not required unless specifically requested by purchaser

• Code mandate that flange shall be able to withstand under pressure test of rating of finished

Marking

• Following shall be marked on pipe−Manufacturer logo− ASTM material code−Material Grade− Service rating (Pressure Class)− Size− Thickness (Schedule)−Heat No− Special marking QT (Quenched and tempered) or W

(Repair by welding)

VP 6” CL300 Sch80 A105 WNRF ABC12

Marking

• Marking can be by paint or by Hard punching

• For stainless steel stenciling can be used

• Flanged are marked in flange thickness area.

• Heat Treatment

• Markings

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in next lecture…

Branch Connection

• Reinforced branch Pipe to pipe− Site fabricated branch

connections

• Self reinforced branch − Specially design branch

connection which can be use without reinforcing pad

−Well-known as “Olets”

• Types of branch connection

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in next lecture…

Branch Connection Material

• Standard branch connection are made by forgematerials−Carbon steel− Low alloy steel− Stainless steel

• ASME B31.3 provides list of acceptable forge materialused in process piping

• Materials for Standard Branch connections

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in next lecture…

Branch Connection Manufacturing

Non Destructive testing

• Ultrasonic

• Magnetic particle test

• Liquid penetrant test

• Positive Material Identification

Distractive Testing

• Tensile test

• Hardness test

• Impact test / Charpy V-Notch Test

• Proof Test (Type Test) if specified

Marking

• Following shall be marked on Olets−Manufacturer logo− ASTM material code−Material Grade− Service rating (Pressure Class)− Size− Thickness (Schedule)−Heat No− Color code if specified

VP A105B CL3000 1” X Sch80 ABC12

Marking

• Marking by Hard punching

• For stainless steel stenciling can be used

• If ask by purchaser colour coding are also done

• Heat Treatment

• Markings

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in next lecture…

Gasket

• Gasket is sealing material placed between connecting Flanges

• create a static seal

• Maintain leakage proof sealing in all operating conditions

Spiral Wound GasketOuter Ring

Inner RingWinding Material

• Types of Gasket

• Various Construction

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in next lecture…

Gasket Material

Non-Metallic Gasket

• Resilient or pliable material

• Commonly used materials− Compressed Non-Asbestos fiber− PTFE− Rubber−Mica− Ceramic fiber

• Materials for Gasket

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in next lecture…

Gasket Manufacturing

Manufacturing of Gasket

• Non-metal gasket are manufactured as long sheet and cut as per requirements

• Spiral wound gasket are made by winding of metal and filler material on winding machine

• Winded material are tack welded to inner and outer ring of gasket

Manufacturing of Gasket

• Metallic gasket are made from forged ring or cut from the metal sheet and machined to achieve final surface finish and dimension

Dimension

• ASME B16.20-Metallic Gaskets for Pipe Flanges, Ring-Joint, Spiral Wound and Jacketed

• ASME B16.21-Nonmetallic Flat Gaskets for Pipe Flanges

Inspection and Testing

•Gasket Material shall be tested for−Hardness−Creep test−Thickness −Density −Compression −Recovery −Blowout resistance

Inspection and Testing •Following to be check for finished gasket

(Type test)−Tensile −Sealability−Flexibility −Corrosion resistance−Decomposition

Marking

• Manufacturer logo

• Manufacturing Code

• Size and Pressure Class

• Filler and winding material

• Inner and Outer ring material

Marking- Colour Code

• Spiral Wound Gasket are painted accordance with ASME B16.20.

• The solid colour on the centering ring indicates the metallic winding material

• The stripped colour indicates the non-metallic filler used between the metal winding.

Marking- Colour Code

Source: Flexitallic9

• Manufacturing method

• Dimension Standard

• Inspection & testing

• Marking & Colour Code

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in next lecture…

Bolting

Varun Patel, B.E- Mechanical, PMP®

Bolting

• Bolting is a term that includes stud, bolts, nuts, andwashers

• Also Known as fastener

Washers

• Conical or Belleville Springs washers−Keep bolted joints tight−High spring loads with small deflections−Used in area where vibration, differential thermal expansion,

and bolt creep present

• What is Stud, Bolt, Nut & washers

• Use of Stud, Bolt, Nut & washers

• Types of Stud, Bolt, Nut&washers

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in next lecture…

Bolting Material

• Carbon steel

• Low alloy steel

• Stainless steel

• Exotic material, such as Monel, Inconel, Nickel alloy

• These material further divide in −High Strength− Intermediate strength− Low Strength

• List of ASTM Material grade used for manufacturing stud are listed in ASME B16.5

Coating • Bolting are also coted with different materials to

improve its corrosion resistance and reducemaintenance− Chrome plated−Galvanized− Xylan coated− PTFE coated

• Materials for Stud, Bolt, Nut &washers

• Different type of coating

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in next lecture…

Bolting Manufacturing

Manufacturing of Stud & Bolt

• Rolling / Forming−Most common method for threading on stud and bolt− Cylindrical bar placed between two die and bar are rolled in

between the die−Used for stud and threaded portion of bolt

Wiki Common user: Wizard1913

• Machining− Threads are cut by lathe machine on blank−Hexagonal head of nut are also machine chamfered

• Forging / Die punching− Blank bar are placed between die and force applied to

produced threads in blank−Head of bolt are also made by die punching− Forging can be done by Hot & Cold forging methods

Wiki Common user: Wizard1915

• Manufacturing Methods

• Testing Requirements

• Types of Testing

• Visual & Dimension Inspection

• Product Marking

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in next lecture…

Pipe & Pipe Fitting Guide for Oil & Gas Career

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