Pipe Material Specification Course
Table of Contents
Introduction Part 1 ................................................................................................... 6
Introduction part 2 ................................................................................................... 8
Codes, Standard and Specifications ...................................................................... 8
Schedule number part 1 ........................................................................................ 9
Schedule number part 2 ...................................................................................... 10
Schedule number part 3 ...................................................................................... 12
Types based on Manufacturing ................................................................................ 14
Materials:........................................................................................................... 16
Ends and Joints ...................................................................................................... 20
Sizing: Internal and External Pressure ...................................................................... 23
Problem Solving on Pipe Design Calculation - Part I .................................................. 27
Fitting Types: ......................................................................................................... 33
End connections: ............................................................................................... 36
Flanges and Connections: ...................................................................................... 38
Facing................................................................................................................ 41
Materials, Pressure and Temperature Rating of Flages: .......................................... 42
Gaskets and Bolting: .............................................................................................. 46
Boltings: ................................................................................................................ 52
Welding: ................................................................................................................ 54
Weldment: ......................................................................................................... 55
P, F and A Numbers in Welding:............................................................................ 60
WPS and PQR ..................................................................................................... 65
Isolation valves ...................................................................................................... 69
Gate Valve: Description and Functional - Part I...................................................... 69
Gate Valve: Description and Functional - Part II ..................................................... 73
Ball and Plug Valves: Description and Functional .................................................. 74
Piston and Diaphragm, Butterfly and Pinch Valves: Description and Functional ....... 78
REGULATING VALVES ............................................................................................. 82
Needle Valve: Description and Functional ............................................................ 85
NON-RETURN VALVES ............................................................................................ 87
Check Valves: Description and Functional - Part II................................................. 90
SPECIAL PURPOSE VALVES..................................................................................... 92
Manufacturing and Assembly of Valves .................................................................... 95
PIPING DRAWINGS ................................................................................................ 95
PFDs, P&IDs, Orthographic and Isometric Views - Part II ........................................ 99
PIPING COMPONENTS: DEMONSTRATION THROUGH GRAPHICS ........................... 104
Branching: Downward & Upward........................................................................ 108
Introduction Part 1
Introduction part 2
Codes, Standard and Specifications
Schedule number part 1
Schedule number part 2
Schedule number part 3
Types based on Manufacturing
Materials:
Ends and Joints
Sizing: Internal and External Pressure
BEND-Thickness
Problem Solving on Pipe Design Calculation - Part I
Solution:
The required thickness of straight section of pipe.
The thickness of straight pipe.
C = correction + erosion
For stainless steel the Corrosion factor is zero.
For a given material the C factor equals to zero.
The required pipe thickness under the pressure and
temperature with milltolerance :
B:
C:
D:
E:
Fitting Types:
End connections:
Flanges and Connections:
Facing
Materials, Pressure and Temperature Rating of Flages:
Gaskets and Bolting:
Semi metallic gaskets are used in higher pressure and
temperature applications.
Semi metallic gaskets are used in higher pressure and
temperature applications.
Boltings:
Welding:
Weldment:
Weldment is the assembly of pipe components or metal
plates that are connected by welding.
The welding process is performed based on these parameters.
P, F and A Numbers in Welding:
Two numbers are assigned to the ferrous base metal.
WPS and PQR
MODULE 2
Isolation valves
Gate Valve: Description and Functional - Part I
Hello learner, welcome to this module on description of valves, piping, drawings, piping
components, and their graphic representation. Let's start today's session with the
topic on gate wall description and functional. At the end of this topic, you'll be able to
understand the functions to be performed by walls in the process industry, understand
the classification of valves, understand the various parts of the gate valve and their
function, and know the advantages, limitations, and applications of gate walls. In a
process industry, a significant share of the fixed capital cost goes towards valve
procurement. It may be around 10% as of fixed capital cost. It is interesting to know that
the piping components and valve share is around 30-40% of the fixed capital cost of the
process plant. This means a major share goes against valves which are around 25%.
For example, the estimated fixed cost for establishing a process plant is 100
cross. Around 40 cross goes against piping, piping components and valves. Out of 40
cross, to procure valves, 10 cross is needed. Hence, one should be cautious while
choosing a valve. As you are aware that valves are mounted on equipment for relieving
the wall pressure, and placed in pipelines. Valves are used to meet a certain process
requirement. The requirement may be controlling the flow rate or just on and off
operation, or one way operation and regulating downstream process pressure.
Valves are classified as rotary motion and linear motion valves. One fourth turn is needed
to change the position from fully closed to fully open and vice versa in the case of rotary
valves. These are fast acting valves. The first acting valves are, ball valves, plug
valves, butterfly valves, and so on. In the case of linear motion valves, the disc or weights
will be raised or lowered to open or close the valve. Therefore, linear motion valves are
slower in operation compared to rotary motion valves. Gate and globe valves can
be considered linear motion valves.
The types of functions that need to be performed in the process industry are given
below. First is isolation. In an isolation function, the actuation mechanism of the valve
is completely isolated from the transported medium. In other words, these valves
are used only for on and off operation, not for regulating the fluid flow. Second is,
regulation or throttling. In a regulation or throttling function, the actuation mechanism of
the valve is not completely isolated from the transported medium. In other words, these
valves are used for regulating fluid flow.
Next is, unidirectional are non-return. In a unidirectional or non-return function, the
actuation mechanism of the valve allows the fluid to flow in one direction. The fluid flow
in opposite direction is not possible. Next is special purpose valves. Special purpose
valves are used for special purposes such as flow diversion, running the liquid material,
and so on. Gate valve, ball valve, plug valve, piston valve, butterfly valve, diaphragm
valve, and pinch valve fall under the category of isolation function. Hence, these are used
for on and off operation.
Globe valve, needle valve, butterfly valve, diaphragm valve, pinch valve, and piston
valve, fall under the category of regulation function. Multiport valve, flush bottom
valve, float valve, foot valve, line blind valve, and knife gate valve fall under the category
of special purpose function. Valves can be classified based on their operation. They are
operated valves and self operated valves. A check valve is a self operated valve, and all
other valves are operated valves. Four types of axiators will be used to operate the
valves. These are hydraulic, pneumatic, electrical, and mechanical.
Note that :: Isolation valve used for on and off function
Gate Valve: Description and Functional - Part II
Ball and Plug Valves: Description and Functional
learner. Welcome to this session with the topic on Ball and Plug Valves Description and
Function. At the end of this topic you will be able to: understand the major parts of the
ball and plug valves and their importance and function. Know the advantages,
limitations, and applications of ball and plug valves. Note that ball valves are positive
shut off valves. The positive shut off is possible due to its soft seats. To handle the high
temperature fluid surface, ball valves are also used.
However, a metal seat is used in this ball valve as shown in the figure here. Now, the
description and function of the ball valve is discussed here. The ball valve consists of the
body, bonnet, seat, ball, and stem as shown in the figure here. The disc is spherical like a
ball, hence the name ball valve. The ball has a through hole as shown in the figure
here. The spherical ball has a slot cut as shown here. The stem has a rectangular
extended portion as shown here.
It fits into the ball slot cut and the ball rotates when the torque is applied to the
stem. Therefore, the stem is not attached to the ball. The body of the ball valve is
connected to the bonnet. The bonnet holds the stem along with packing, gland, and ball
in the right position. The packing material may be a teflon. O-rings may be used in place
of packing. The diameter of the through hole in the ball is either the same diameter of the
pipe known as the full port ball valve, or a smaller than the pipe diameter known as the
reducer port ball valve.
The hand wheel is not used in the ball valves. A wrench handle is used to shut on or shut
off the valve. Ball valves can be operated manually or electrically or pneumatically, by the
quarter operation of the handle. The end connections of the ball valves are butt
welding, socket welding, flanged, and threaded or screwed. Now let us see the
functioning of the ball valve. A quarter rotational turn of the ball valve stem makes the
valve open fully or close fully. When the ball is rotated a quarter with the help of the stem
to allow the fluid to flow fully, the through hole of the ball is in line with the inlet and outlet
of the valve body as shown here.
If the ball is rotated to its initial position, the through hole in the ball valve
comes perpendicular to the valve body opening. This means the solid part of the ball
is faced the valve body openings as shown here. This is the closing position of the ball
valve. Note that the handle of the ball valve, which is connected to the stem, comes
parallel to the central axis of the pipe when the valve is opened. Handle perpendicular to
the axis of the pipe indicates the closing of the valve. Visual observation of the handle
position confirms the status of the valve, that is, whether the valve is open or closed. Let
us look at the advantages of the ball valve.
Ball valves offer low pressure drop, relatively smaller in size when compared to most of
the other valves, low torque is required to operate with a tight ceiling. The ball valve can
be quickly opened or closed since a quarter turn of the stem is required. Now let us look
at the limitations of ball valve. Quick opening or closing results in a fluid hammering.
Now let us discuss about plug valve. Description and function of plug valve is as
follows. Like the ball valve, quarter turn rotation is required to open or close the plug
valve.
The disc is a plug with the shape of either tapered or cylindrical as shown in the figure
here. The plug as the port as shown in the figure here. The plug valve consists of the
following components as shown in the figure here: body, stem, plug, and packing
gland. There is a possibility that the plug can jump in the body and therefore lubrication
is provided to overcome this practical issue. However, the lubrication contaminates the
conveyed fluid. Low friction seats like teflon can also be used. Now let us see the function
of the plug valve.
The port of the plug comes in line with the inlet and outlet ports of the body of the plug
valve, allowing the fluid to flow through it. The valve is closed if the stem is rotated quarter
rotation from its open position. In this scenario, the solid portion of the plug comes
against the body ports and blocks the ports. As a result, the fluid flow is stopped. The
types of plug valves are lubricating, non lubricating, eccentric, multi-port, and
expanding. Now let us see the applications of plug valve. Plug valves are good for
handling air, gas, and liquid fluids efficiently.
Plug valves are used in natural oil and gas piping systems. Plug valves are used to handle
at much lower pressure, that is vacuum, to higher pressure fluids. Plug valves are used to
handle the fluids at higher temperatures like condensate. Plug valves are used to handle
slurries and these valves perform well in handling slurries. Let us look into the
advantages of plug valves. Plug valves can be used for relatively high viscous
fluids. Available in a higher size compared to the ball valve, and plug valve construction
is simple as it needs a relatively less number of parts.
Let us see the limitations of the plug valve. The plug valve needs relatively large torque
required to open and close the valve. Big size valves DN100 and above need an actuator
or gearbox and size wise, plug valves are larger than ball valves. Now let us summarize all
that you have learned on this topic thus far. Discussed the parts of ball and plug valves
and their function, and discussed the advantages, limitations, and applications of ball
and plug valves. By this, we have come to the end of this topic. Let us meet in another
interesting session. Thank you, learner.
Piston and Diaphragm, Butterfly and Pinch Valves: Description and
Functional
REGULATING VALVES
Needle Valve: Description and Functional
NON-RETURN VALVES
Welcome to this session with the topic on Check valves, Description, and Functional. At
the end of this topic, you'll be able to realize the purpose of the check valve and its
functional requirement, understand specific applications, get acquainted with various
types of check valves, and understand the various parts of check valves and their
function. Note that the check valve is a non return valve, RNV, also known as a one-way
valve. This means the forward fluid flow opens the valve and the reverse flow closes the
valve. Check valve operates automatically. The pressure of the fluid assists in opening
the valve.
Note that, unlike isolation valves, check valves must dynamically respond to flow
conditions, and the durability of the check valve should be long term, and it needs to
provide trouble free performance. Check valves are mainly used to restrict the reversal
fluid flow in a piping system to protect the internals of the mechanical equipment such
as pumps and compressors. For example, a check valve is used in the discharge pipeline
of a pump to arrest the reversal fluid flow. The operation of the check valve is entirely
automatic. No operator or external control mechanism is needed for its operation. This
means it doesn't have the handle, or hand wheel, and stem. Now let us look into the
terminology, chattering.
Chattering is repeated opening and closing of the disc of a check valve, this may fail the
check valve. To prevent the failure due to chattering, a minimum of 5D straight pipe length
is to be maintained in upstream to ensure uniform flow without flow
disturbance. Similarly, at least a 10D straight pipe length is to be maintained in the
downstream side. Here D is the pipe diameter. Note that the presence of a bend can
causes back pressure, and the presence of bends control valve, and reduces at a shorter
distance to the check valve in upstream results in chartering due to fluid flow
disturbance. As shown in the figure here, a check valve is placed in a refinery
pipeline. There are upstream and downstream bends placed at a shorter distance
from the check valve on both sides due to space constraints.
In this scenario, the spilling streams in the upstream cause disc-chattering and creates
excessive noise. Next, let us see the types of check valves. Based on construction and
applications, different types of check valves existed. They are Number 1, swing check
valve, Number 2, lift check valve, Number 3, stop check valve, Number 4, Ball check
valve, Number 5, piston check valve, Number 6, tilting disc check valve, and Number 7,
wafer check wall. Note that cracking pressure, reseal pressure, and back pressure
are the terms used in the operation of the check valves. Let me explain in brief these
terms. First is the cracking pressure.
Cracking pressure is the minimum upstream pressure at which the valve operates. It is
also known as opening pressure. Second is the reseal pressure. Reseal pressure is
referred as closing pressure. This is the pressure gradient required between the inlet and
outlet of the valve to close the valve without a leak, and third is back pressure. Back
pressure is the pressure of the fluid in downstream which is higher compared to
upstream fluid pressure. Now, let us investigate the swing check valve first.
The swing check valve is the most popular among all check valves. The swing check valve
consists of a body and a circular disc. The circular disc is connected to the body by a
hinge. This circular disc swings over the hinge pin. When the disc opens fully, the swing
check valve offers low resistance to the fluid flow. The disc opens due to fluid
pressure. Disc returns to valve seat when the fluid flow in the upstream is stopped.
Closing of disc happens due to itself weight. The most preferred swing check
valve mounting position is horizontal.
Check Valves: Description and Functional - Part II
SPECIAL PURPOSE VALVES
Manufacturing and Assembly of Valves
PIPING DRAWINGS
PFDs, P&IDs, Orthographic and Isometric Views - Part II
PIPING COMPONENTS: DEMONSTRATION THROUGH
GRAPHICS
Branching: Downward & Upward