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Jurandir Primo

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ASME – Power and Process Piping – Materials & Inspection Definitions

Jurandir Primo

Copyright @ 2012

1ª edição – junho de 2012

Capa:

Jurandir Primo

Primo, Jurandir

ASME – Power and Process Piping – Materials & Inspection Definitions

Indice para pesquisas: ASME, ANSI, API, Tubulação e Acessórios.

ISBN:

Livro no sistema de auto publicação cuja edição, revisão, diagramação e capa foram selecionados pelo

próprio autor, para não encarecer a obra e facilitar a compra, a todos os estudantes e interessados em

assuntos técnicos e engenharia de equipamentos.

Portanto, qualquer pessoa pode ter esse livro, sem necessidade de copiar, digitalizar ou utilizar outros

processos de reprodução, porque foi executado para custar menos que o valor de uma pizza.

No entanto, o autor permite que todas as partes do livro possam ser copiadas ou reproduzidas para

fundamentos educacionais, instrutivos e treinamento técnico.

Para adquirir esta ou outras publicações do autor, enviar solicitação para:

[email protected].

mailto:[email protected]

ASME-Power and Process Piping – Materials & Inspection Definitions

© Jurandir Primo 3 of 73

PREFACE:

The goal of this manual is to describe some of the most important functions of piping

application according to the ASME, ANSI and API codes, interrelated especially with

materials, allowable stress and the need to provide reasonable inspection requirements.

When writing a book for a particular population, it is necessary to make a choice as to the

treatment to be given to the matter. Technological development, currently is very fast, then,

it is necessary to establish and understand the concepts.

In developing each subject, the fundamental concepts were searched through examples of

didactic forms, not for specialists who already dominate the subject, but for students from

several classes interested in this matter.

Because of the existing communication facilities, future technicians and engineers, will

certainly be better than the past generations, but they should be, more than anything,

respected for their efforts to contribute to a new reality.

The author perfectly understands that is not an expert writer and is open to constructive

criticism and suggestions for improvement of this book.

This book is to everyone who, just like me, came from small to big cities, to study, to work,

to face all kinds of difficulties. However, even without the preparation of modern computer

programs, seeks to contribute to the needs of education and instruction for all social levels,

that should be the true values of democracy, development and progress in any country.

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Esse manual é parte de uma série de publicações para as diversas áreas de Engenharia:

Tecnologia de Soldagem;

Transportadores de Correia e Corrente;

Bombas Centrífugas;

Sêlos Mecânicos;

Compressores de Ar;

HVAC – Ar Condicionado;

Torres de Resfriamento;

Ventilação Industrial;

Vasos de Pressão – Normas ASME;

Trocadores de Calor;

Válvulas Industriais;

Tubulação Industrial;

Pavimentação Asfáltica;

Outros...



Contents

I. INTRODUCTION

II. PIPE – GENERAL REQUIREMENTS

III. PIPE MANUFACTURING PROCESSES

IV. PIPE CONNECTIONS

V. STEAM EXTRACTORS, SEPARATORS AND FILTERS

VI. CLASSIFICATION OF INDUSTRIAL PIPELINES

VII. MOUNTING, OPERATION AND MAINTENANCE

VIII. FLOWCHARTS AND SCHEMATIC DRAWINGS

IX. PIPING GENERAL INFORMATION

X. STANDARDS FOR PIPING APPLICATION

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To :

All teachers of my childhood , since my first letters , elementary, high

school and college ;

All who, with absolute sincerity, fights for social justice and life

environment;

Every one that has gone and everyone who came to this planet as

missionaries of :

Education.



ASME - POWER AND PROCESS PIPING Materials & Inspection Defintions

I. Introduction:

Pipe is a pressure tight cylinder used to convey a fluid or to transmit a fluid pressure in applicable material specifications. Tube or tubing in the specifications are treated as pipe when intended for pressure services, under ASME B31.1 - Power Piping and ASME-B31.3 - Process Piping.

Piping is an assembly of piping components used to convey, distribute, mix, separate, discharge, meter, control or stop fluid flows. Piping also includes pipe-supporting elements but does not include support structures, such as building frames, foundations, or any equipment excluded from Code definitions. Piping components are mechanical elements suitable for joining or assembly into pressure-tight fluid containing piping systems. Components include pipe, tubing, fittings, flanges, gaskets, bolting, valves and devices such as expansion joints, flexible joints, pressure hoses, traps, strainers, tie-ins, loops, unions, couplings, spools, in-line portions, instruments, separators, etc.

II. Pipe – General Considerations:

A vast array of materials for the manufacturing of pipes are employed today. Only A.S.T.M (American Society for Testing and Materials) specifies more than 500 different types of materials. Below is a summary of the main materials used:

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III. Pipe Manufacturing Processes: There are two types of industrial processes for the manufacture of pipes:

2) Welded Pipe – The welding process consists of two phases: In the first one the contact surface of two elements is heated using currents of high frequency. Next, the two welded elements are clenched. 1) Seamless pipe manufacturing: Seamless steel pipe is made from a solid round steel ‘billet’ which is heated and pushed or pulled over a form until the steel is shaped into a hollow tube. The seamless pipe is then finished to dimensional and wall thickness specifications in sizes from 1/8 inch to 26 inch OD. 1.1) Rolling Process:

The methods of manufacturing seamless steel pipe vary slightly from manufacturer to manufacturer, but these are the basic stages.

a) Cast Round Billets: High-quality steel round bars are required for seamless tubular products (Fig. 1/8).

Figure 1/8: Casting Process



b) Round Reheating: The rounds are cut to the required length and weighed prior to being reheated in a furnace (Fig. 2/8).

Figure 2/8: Round Reheating

c) Rotary Piercing Mill: The round billet is gripped by the rolls, which rotate and advance it into the piercer point, which creates a hole through its length (Fig. 3/8).

Figure 3/8: Rotary Piercing Mill (RPM)

d) Mandrel Pipe Mill: The pipe is rolled using several stands over a long, restrained mandrel (Fig. 4/8).

Figure 4/8: Mandrel Pipe Mill (MPM)

e) Shell Reheating: The MPM shell is transferred to a reheat facility, where it can be

cropped and weighed prior to reheating (see Fig 5/8).

Figure 5/8: Shell Reheated in a Furnace

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f) Stretch Reducing Mill: The reheated and descaled pipe is conveyed through a stretch reducing mill, which utilizes up to 24 stands to reduce the diameter to the required finished size (Fig. 6/8).

Figure 6/8: Stretch Reducing Mill

g) Cooling Bed: The pipe lengths are placed on cooling bed (Figure 7/8).

Figure 7/8: Pipe on a Cooling Bed

h) Batch Saws: After cooling, batches of the as-rolled mother pipe are roller conveyed in parallel to carbide tipped batch saws for cropping into specified lengths (Figure 8/8).

Figure 8/8: Batch Saws.

1.2) Extrusion Process: Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The main advantages of this process are the ability to create very complex cross-sections, work brittle materials, because the material only encounters compressive and shear stresses and form finished parts with an excellent surface finish.

a) Hot extrusion:

Hot extrusion is a hot working process, which means it is done above the material's recrystalli-zation temperature to keep the material from work hardening and to make it easier to push the material through the die. Most hot extrusions are done on horizontal hydraulic presses that range from 230 to 11,000 metric tons (250 to 12,000 short tons). Pressures range from 30 to 700 Mpa (4,400 to 100,000 psi), therefore lubrication is required, which can be oil or graphite for lower temperature extrusions, or glass powder for higher temperature extrusions. The biggest disadvantage of this process is its cost.



b) Cold extrusion: Cold extrusion is done at room temperature or near room temperature. The advantages of this over hot extrusion are the lack of oxidation, higher strength due to cold working, closer tolerances, good surface finish, and fast extrusion speeds if the material is subject to hot shortness. Materials that are commonly cold extruded include: lead, tin, aluminum copper, zirconium, titanium, molybdenum, beryllium, vanadium, niobium and steel. Examples of products produced by this process are: collapsible tubes, fire extinguisher cases, shock absorber cylinders and gear blanks.

c) Warm extrusion: Warm extrusion is done above room temperature, but below the recrystallization temperature of the material the temperatures ranges from 800 to 1800 °F (424 to 975 °C). It is usually used to achieve the proper balance of required forces, ductility and final extrusion properties. Metals that are commonly extruded include: Aluminum: is the most commonly extruded material. Aluminum can be hot or cold extruded. If it is hot extruded it is heated to 575° to 1100 °F (300° to 600 °C). Examples of products include profiles for tracks, frames, rails, mullions, and heat sinks. Brass: is used to extrude corrosion free rods, automobile parts, pipe fittings, engineering parts. Copper: (1100 to 1825 °F (600 to 1000 °C)) pipe, wire, rods, bars, tubes, and welding elec-trodes. Often more than 100 ksi (690 MPa) is required to extrude copper. Lead: and tin (maximum 575 °F (300 °C)) pipes, wire, tubes, and cable sheathing. Molten lead may also be used in place of billets on vertical extrusion presses. Magnesium: (575 to 1100 °F (300 to 600 °C)) aircraft parts and nuclear industry parts.

Magnesium is about as extrudable as aluminum. Zinc: (400 to 650 °F (200 to 350 °C)) rods, bar, tubes, components, fitting, and handrails. Steel: (1825 to 2375 °F (1000 to 1300 °C)) rods and tracks. Usually plain carbon steel is extruded, but alloy steel and stainless steel can also be extruded. Titanium: (1100 to 1825 °F (600 to 1000 °C)) aircraft components including seat tracks, engine

rings, and other structural parts. Obs.: Magnesium and aluminum alloys usually have a 0.75 µm (30 μ.in) RMS or better surface finish. Titanium and steel can achieve a 3 micrometres (120 μ.in) RMS.

d) Steel Pipe Extrusion: The manufacturing processes is also divided into hot-rolled (extrusion) and cold drawn seamless steel pipe. Cold-rolled seamless steel tubes tend to be small in diameter, hot-rolled seamless steel tubes are often large diameter. The dimension tolerance of the cold-rolled precision seamless steel tube is higher than hot-rolled seamless steel tubes, then, price is also higher than hot-rolled seamless steel tubes.

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e) Drawing:

Drawing simply involves pulling the hollow tube through a series of hardened steel dies to reduce its diameter. Before each step of the drawing process, the tube is pointed at one end to fit through the next die, whereupon it is gripped by automatic jaws attached to a rotating, 7 ft diameter drawing machine called a bull block.

1.3) Casting Steel Pipe: Centrifugal casting is a common casting steel process where molten metal is funneled into a rotating mold (commonly 700 to 1300 rpm). The rotation of the die creates centrifugal force which thrusts the metal towards the mold wall, as shown below.

The aspect ratio of the part to be cast is what determines which of the techniques can be used. When the diameter of the desired part is larger in comparison to the overall-length (ring shaped), vertical casting is most commonly used. Likewise, when the length is larger compared to the diameter (tube shaped), horizontal casting setups are used.



ASTM A660 - Standard Specification for Centrifugally Cast Carbon Steel Pipe: This specification

covers carbon steel pipe made by the centrifugal casting process intended for use in high-temperature, high-pressure service, suitable for fusion welding, bending, and other forming operations. Centrifugal castings use directional solidification and pressure from the centrifugal force to create castings with a denser sound structure, with superior physical properties in comparison to statically poured castings. It has been made clear that centrifugal casting is a versatile process with benefits in the areas of mechanical properties and overall process cost-effectiveness. The utilization of this process can be beneficial when producing a variety of products. Size Limitations of Centrifugal Castings: 2. Diameter: Up to 3 m (10 feet) 3. Length: 15 m (50 feet) length 4. Wall Thickness: 2.5 mm to 125 mm (0.1 - 5.0 in) 5. OD Tolerance: as fine as 2.5 mm (0.1 in) 6. ID Tolerance: can be 3.8 mm (0.15 in) 7. Surface Finish: from 2.5 mm to 12.5 mm (0.1 - 0.5 in) rms

2) Cast Iron Pipes: Historically are used as pressure pipes for transmission of water, gas and sewage, and as a water drainage pipe, during the 19th and 20th centuries. The material is predominantly gray cast iron, frequently used uncoated, although later developments did result in various coatings and linings to reduce corrosion and improve hydraulics. Gray cast iron pipes were gradually superseded by ductile iron pipes, which is a direct development, with most existing manufacturing plants transitioning to the new material during the 1970s and 1980s. There is currently almost no new manufacture of gray cast iron pipe. Iron is melted in the cupola furnace at approx. 1,550°C (~2820°F) using scrap steel and recycled materials. In order to obtain ductile cast iron, the iron is injected in the converter with a magnesium alloy. The pipes are manufactured from the “injected” iron using the centrifugal casting process. The centrifugal cast pipes are annealed at 960°C (1760°F) in a continuous furnace, so that the cementite can be broken down into ferrite and graphite. All pipes are then given a zinc or zinc-aluminium casing, cleaned in the sleeve area, spray-galvanised and pressure-tested at up to 50 bar (725 psi) , followed by a visual, dimensional and material check. The Cast Iron Soil Pipe Institute (CISPI), organized in 1949, is the leading American of cast iron soil pipe and fittings for most of manufacturers. The Institute is dedicated to aiding and improving the plumbing industry.

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3) Welded Pipe Manufacturing: The manufacturing process generally involves the following stages in a step by step procedure, as shown below.

a) Slitting: is a process in which a coil of material is cut down into a number of smaller coils of narrower measure, selectively thin (0.001 to 0.215 in.) and can be machined in sheet or roll form.

The illustration that follows provides a two-dimensional look at a typical coil slitting process. Note how the metal workpiece is drawn past the upper and lower slitting blades, leaving two coils the same length as the original wide coil.

b) Rolling: is a metal forming process in which metal stock is passed through a pair of rolls,

according to the temperature of the metal rolled. Hot rolling is when temperature of the metal is above recrystallization temperature. Cold rolling is when temperature of the metal is below its recrystallization temperature. Hot Rolled (HR) Coils are slitted to pre-determined widths for each and every size of pipes.



c) Uncoiling, End Shearing: The slitted coil is uncoiled at the entry of edge mill. The leading end of the coil is precisely cut to provide an edge that can be effectively joined with the trailing end of the previous coil being processed. This allows for a continuous pipe making operation.

d) Forming: The edge milled coil is introduced into the three roll edge pre-bending

assembly and then into the forming assembly, which consists of three forming roll banks and several outside cage rolls. This forming assembly combines the strength and precision to form the exact outside diameter and the other dimensional properties of the desired pipe for tack welding at a rate of up to 40 feet per minute.

e) ERW Welding: This operation provides a continuous weld seam, strong enough to keep the desired pipe OD end shape. In this stage, the future pipe open edges are heated to the forging temperature through a high-frequency, low-voltage welding system, and welded by forge rolls, making perfect and strong butt weld without filler materials.

f) Final Welding Station: The pipe is then taken to the final welding station, where the full

length of the tack welded seam is completed by a Submerge Arc Welding (SAW). Superior SAW quality is achieved first by precise tracking of the weld seam, in order to maintain the alignment of the pipe ID and OD.

g) De beading: In this stage, the weld flash on top and inside of the pipe, is trimmed out

using the carbide scarfing tools. Hydrostatic Testing: During this testing procedure, the pipe is filled with water and subjected to the specified pressure for a minimum of 10 seconds. The testing is accomplished by a 5,000 psi ultra-modern testing unit, performed to ensure the welding integrity of the pipe. Ultrasonic Testing: Non-destructive tests are performed to further ensure the integrity of the pipe weld and pipe body. An ultrasonic shear wave inspection of the full length of the weld zone and the heat affected zone is made. After ultrasonic evaluation is complete, pipe ends are inspected by X-Ray in a separate operation. Seam Normalising: When required, the welding portion and the heat affected zones, are put to normalizing treatment and then cooled down in a air cooling bed. Quenching and Tempering: When also required, the quenching and tempering of tubes include a number of variables that can have a big effect on the process and the finished product. The process of quenching and tempering carbon steel tubulars, is heated to about 1,600° F, cooled rapidly, and reheated to a temperature less than about 1,300° F. The exact temperatures and times are dictated by the steel chemistry and the desired mechanical properties.

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